Graco InvisiPac HM25 Instructions Manual
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Graco InvisiPac HM25 Instructions Manual

Graco InvisiPac HM25 Instructions Manual

Hot melt delivery system
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Instructions - Parts
InvisiPac
HM25 and HM50 Tank-Free
Hot Melt Delivery System
For delivering and dispensing hot melt adhesive pellets. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure
400°F (204°C) Maximum Fluid Operating Temperature
100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this manual
before using the equipment. Be familiar with the proper
control and usage of the equipment. Save these
instructions.
™
™
333347ZAC
ti22732
9902471
Certified to
CAN/CSA C22.2 No. 88
Conforms to
ANSI/UL 499
EN

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Summary of Contents for Graco InvisiPac HM25

  • Page 1 Instructions - Parts ™ InvisiPac ™ HM25 and HM50 Tank-Free Hot Melt Delivery System 333347ZAC For delivering and dispensing hot melt adhesive pellets. For professional use only. Not approved for use in explosive atmospheres or hazardous locations. 1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure 400°F (204°C) Maximum Fluid Operating Temperature 100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure Important Safety Instructions...

  • Page 2: Table Of Contents

    Material Tracking ......29 Non-Graco Applicator Adapter Cables ..112 Calibration ......31 Air Adjustment Lock, 24R084.

  • Page 3: Related Manuals

    Graco Extended Warranty ....142 Graco Information ......142 Related Manuals Manuals are available at www.graco.com.

  • Page 4: Models

    Models Models Feed Systems Part Usage 25C193 For use in standard pellet feed applications 17D749 For use in chicklet feed applications 24N957 For use in standard pellet feed applications with separate feed bin or bulk container 333347ZAC...
  • Page 5 Models 200-240 VAC, 350-415 VAC HM50 Models System Channels Voltage Description Max Amps Φ Type • 1-Phase 200-240 • 1Φ / PE 2 wire and PE • 50/60 Hz • 3-Phase without Neutral 200-240 • 3Φ / PE 3 wire and PE 24T918 VAC Δ...
  • Page 6 Models 200-240 VAC, 350-415 VAC HM25 Models System Channels Voltage Description Max Amps Φ Type • 1-Phase 200-240 • 1Φ / PE 2 wire and PE • 50/60 Hz • 3-Phase without Neutral 200-240 • 3Φ / PE 3 wire and PE 24V423 VAC Δ...
  • Page 7 Models 400 VAC Transformer HM25 Models System Channels Voltage Description Max Amps Φ Type • 3-Phase without Neutral 24V246 335-400 • 3Φ / PE 3wire and PE 24Y104* • 50/60 Hz • 3-Phase without Neutral 24V427 335-400 • 3Φ / PE 3 wire and PE 24Y105* •...
  • Page 8 Models 480 VAC Transformer HM25 Models System Channels Voltage Description Max Amps Φ Type • 3-Phase without Neutral 24V429 400-480 • 3Φ / PE 3wire and PE 24Y106* • 50/60 Hz • 3-Phase without Neutral 24V430 400-480 • 3Φ / PE 3 wire and PE 24Y107* •...

  • Page 9: Safety Symbols

    Safety Symbols Safety Symbols The following safety symbols appear throughout this manual and on warning labels. Read the table below to understand what each symbol means. Symbol Meaning Follow Pressure Relief Procedure Burn Hazard Ventilate Work Area Cleaning Solvent Hazard Wear Personal Protective Equipment Electric Shock Hazard...

  • Page 10: Warnings

    Warnings Warnings The following warnings apply throughout this manual. Read, understand, and follow the warnings before using this equipment. Failure to follow these warnings can result in serious injury. DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment is powered by more than 240 V. Contact with this voltage will cause death or serious injury.
  • Page 11 Warnings WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
  • Page 12 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 MSDSs to know the specific hazards of the fluids you are using. •...

  • Page 13: Component Identification

    Component Identification Component Identification ti23594 Key: Advanced Display Module (ADM) Electrical Enclosure Pump Air Pressure Regulator Pump Air Pressure Gauge Vacuum Transfer Air Pressure Regulator Vacuum Transfer Air Pressure Gauge Main Power Switch System Air Inlet Air Motor and Pump Incoming Power Strain Relief Heated Fluid Manifold (Melter) Multi-Zone Low Power Temperature Control Module (MZLP)
  • Page 14 Component Identification Heated Fluid Manifold NOTE: System shown with plastic and metal shrouds removed. Key: Electrical Enclosure Front Access Door Melter W1 Drain Port W2 Drain Tray Inlet Filter (Low Pressure - Before Pump) Outlet Filter (High Pressure - After Pump) Adhesive Pellets Level Sensor (not shown;...

  • Page 15: Electrical Enclosure

    Component Identification Electrical Enclosure Key: Multi-Zone Low Power Temperature Control Module AF Chassis Ground (MZLP) AG Automatic Wiring Board (AWB) AC Incoming Power Connection 333347ZAC...

  • Page 16: Advanced Display Module (Adm)

    Component Identification Advanced Display Module (ADM) User Interface NOTICE To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. NOTE: See 400VAC and 480VAC Transformer Kits on page 125 for complete ADM operation details. Key: BK Part Number Identification Label BL USB Interface...

  • Page 17: Screen Components

    Component Identification Screen Components . 6: Main Screen Components Operating Mode Description Component Status • No System Status Indicator LED on the System Off The system doesn’t have power. • No heat • Pump is off • Yellow system status indicator LED on the The heating system and pumps are Inactive disabled.

  • Page 18: Setup

    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 114. If installing the system in place of a non-Graco hot melt system, purchase Adapter Plate, 24R083. See page 114.
  • Page 19 (81) two turns. system. 6. Install heated hoses, see F . 9: To reduce the risk of fire and explosion, only use Graco heated hoses with the InvisiPac system. Use of non-Graco hoses will void agency approvals. 333347ZAC...
  • Page 20 When fluid stops draining, re-install drain port plug (W1) then remove rag. See F . 9. Use of a Graco applicator is not required with this system. However, all applicators attached to the d. Remove plug (247) from the lowest numbered system must be rated for 1200 psi (8.3 MPa, 83 bar),...
  • Page 21 9. Install the supplied air inlet bleeding ball valve and air filter kit (Graco Part No. 24R707) at the 1/4 NPT female system air inlet (J). See F . 10.

  • Page 22: Recommended Air Setup

    More than 50 ft (15.2 m): 1/2 in. 80-100 psi (5.5-6.8 bar, 0.55-0.68 MPa) 30 scfm capacity Ensure funneled air is connected Air Filter / Ball Valve at System Air Inlet (Graco Kit 24R707 included) Vacuum Pump Vacuum: Pump 40-80 psi 20-100 psi (2.8-5.5 bar,...

  • Page 23: Connect Electrical Cord

    Setup Connect Electrical Cord 5. Attach insulated ferrules to the end of each wire. NOTE: See Grounding section on page 18. 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.

  • Page 24: 208V Electrical Circuits

    Setup 208V Electrical Circuits An incorrect RTD setting will cause the system to be incapable of maintaining the temperature setting. For 208V electrical supply, a qualified electrician can The supported RTD types are Ni, 100 ohm; Ni, install a 208V to 240V step-up transformer to improve 120 ohm;...
  • Page 25 Setup 6. On the Advanced 2 screen, set the temperature and 9. Press to switch from the Setup screens to mass units. the Operation screens. Use to navigate between screens. 10. On the Targets screen, use , shown next to , to adjust system melter setting.

  • Page 26: Applicators

    Setup 11. On the Targets screen, adjust heated hose and applicator temperature settings: c. Use , shown next to InvisiPac is a high powered tank-free system that to adjust heated hose temperature setting to delivers heat faster than traditional tank systems. Tanks the desired setting for that channel.

  • Page 27: Plc Connection

    Setup PLC Connection The InvisiPac system ships with two screw-terminal connectors that plug into MZLP connectors H1 and H2. Connectors are located in a bag on the inside of the electrical enclosure front access door. To replace the connectors, order kit 24P176. 1.
  • Page 28 Setup PLC Connection Block Diagrams The following block diagrams show how to connect customer inputs and outputs to the InvisiPac MZLP. For convenience, each InvisiPac ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for replacements.

  • Page 29: Material Tracking

    Setup Material Tracking The material tracking function allows the user to track product counts and material usage for long term data collection. Viewing the Log In order to view the log, navigate to the Home screen and press the material log softkey (see below).
  • Page 30 Setup Material Tracking Coverage for Pattern Controller Systems Material per Products per Line Material Used Product Line Configuration Diagram Single Line Multi-Unit Line Multi-Line * Products on both parts of the line must be the same ** Accurate material per product data cannot be in order to generate accurate material per product generated for multi-line configurations (assumes data.

  • Page 31: Calibration

    Setup Calibration Perform the following steps to calibrate the material tracking function: 1. Navigate to the Material Tracking Screen (Screen 4 of the System chapter). 2. To calibrate using the tape and scrape method: a. Obtain a scale. b. Place tape on a product(s) in locations where material is dispensed.
  • Page 32 Setup Material Alerts This feature can be used to monitor material usage based on a target material per unit value. If material alerts are enabled the system will record an event every time the system deviates over 20% from the target. The material alert information can be seen in the bottom left corner of the material log (see image below).

  • Page 33: Operation

    Operation Operation function also disables the heating system at user-specified times to ensure the heating system is disabled when not being used. Heating and dispensing hot melt adhesive may Initial Startup and Prime create potentially harmful vapors. Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions.
  • Page 34 Operation 5. Use pump air pressure regulator (C) to adjust pump When system is up to temperature, the pump will be activated automatically, but will not start because there air pressure to 0. is no air pressure supplied to the pump. When the melter is up to temperature, the auto-fill function will initiate to fill the funnel with pellets.

  • Page 35: Manual Refill

    Operation Manual Refill 3. Disconnect the sensor cable and sensor cooling air. 4. Fill the funnel with adhesive pellets. 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.

  • Page 36: Automatic Refill

    Operation Automatic Refill Dispense The system uses automatic refill by default. If the automatic refill system is malfunctioning and cannot immediately be fixed, Manual Refill can be used. To use automatic refill: Only hot melt adhesive pellets can be used in the InvisiPac system.

  • Page 37: Shutdown

    Operation Schedule 5. When the system is up to temperature, use separate pattern controller to open and close the The Schedule function allows the user to specify times applicators as desired to dispense material. when the system will automatically turn ON and OFF the heaters and pump.

  • Page 38: Pressure Relief Procedure

    Operation Pressure Relief Procedure 2. If the heating system is disabled, press enable the heaters and pump. Follow the Pressure Relief Procedure whenever you see this symbol. 3. Decrease pump air pressure to 0. 4. Close system air inlet ball valve. 5.

  • Page 39: Flush

    Operation Flush To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. 6. Change the melter, heated hoses, and applicators temperature settings to the high temperature hot melt cleaning fluid manufacturer’s recommended To prevent fire and explosion, use the adhesive temperature.

  • Page 40: Operation Tips To Minimize Charring

    Operation temperature for the duration specified by the hot 27. On the System 3 screen (in the Setup screens), set melt cleaning fluid manufacturer. the Refill Setting to “Auto”. “Soaking” is important to ensure the best possible cleaning. 15. After the hot melt cleaning fluid has “soaked” for the specified amount of time, open the system air inlet ball valve.

  • Page 41: Maintenance

    Maintenance Maintenance 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 8. Place o-rings (232, 237) provided with new outlet The outlet filter is designed to prevent small filter onto new outlet filter (236).

  • Page 42: Replace Funnel Filter

    Maintenance 4. When the melter temperature is the desired d. Once ADM software finishes starting up, temperature, turn main power switch OFF. press to enable the heaters. 5. Disconnect cable from ADM, push cable through plastic shroud, then remove plastic shroud from e.

  • Page 43: Filter Maintenance Guidelines

    To establish a preventative maintenance cycle tailored to your environment, Graco recommends inspecting filters every 4 weeks after installation and replacing when necessary. Document replacement intervals and use this as your preventative maintenance schedule moving forward.

  • Page 44: Troubleshooting

    Troubleshooting Troubleshooting DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury. Turn off and disconnect all power before disconnecting any cables and before servicing equipment To avoid injury due to unexpected machine operation initiated by a remote controller, disconnect the...
  • Page 45 Troubleshooting An alarm will disable the heating system and pump. A deviation or advisory will not disable the heating system and pump. Code Description Type Cause Solution A1D0 Low Current Advisor Melter current is less than 500mA. Check heater resistance and resistance to Melter ground.
  • Page 46 Troubleshooting Code Description Type Cause Solution A8D_ No Current Gun Alarm Power not getting to applicator. Check fuses F3 and F4 (channels 1, 3, 5) or F7 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.
  • Page 47 Troubleshooting Code Description Type Cause Solution DDDX Pump Diving Deviati Pump is trying to feed adhesive, no Storage bin out of adhesive pellets. Refill adhesive to feed. with pellets. Level sensor may be over heating. Verify air is being delivered from tube (35). Melter at incorrect temperature, too low.
  • Page 48 Troubleshooting Code Description Type Cause Solution T2D0 Deviati Melter temperature dropped to Verify system is operating within meltrate Temperature, 15°F(-9°C) below setpoint. specifications. Consider incoming voltage Melter 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.
  • Page 49 Troubleshooting Code Description Type Cause Solution T4D_ High Temp Gun Alarm Applicator assembly continues to raise Turn on system without dispensing. Check above the setpoint. if applicator can maintain setpoint temperature. If the applicator’s RTD readings are unstable, replace the applicator RTD.
  • Page 50 Troubleshooting Code Description Type Cause Solution T8D0 No Temp Rise in Alarm Temperature reading does not change. Check fuses F1 and F2 on MZLP with Melter (all zones) daughter board. Check that RTD is installed in the melter. Check J1 is properly plugged into the MZLP with daughter board and in J3 on AWB.
  • Page 51 Troubleshooting Mechanical and Electrical Troubleshooting Problem Cause Solution Refill Timeout The system was unable Check hopper for adequate material and material blocking. Error to refill in less than 30 Verify the vacuum transfer system air pressure is 40-80 psi (60 psi seconds.
  • Page 52 Troubleshooting Problem Cause Solution Level Sensor Failure of the level Check sensor cable J14 to level sensor (20). Error sensor (20) or sensor Enable Diagnostic screen on ADM then check sensor readings on the cable 16T108 (J14 to Diagnostic screen. Sensor readings should be about 4.3V if melter is level sensor (20)).
  • Page 53 Troubleshooting Problem Cause Solution USB Log Full The InvisiPac system To prevent data loss, download system data. See Appendix B - USB will display this Downloading, Uploading on page 133. notification when the USB data logs reach 90% full. The InvisiPac This error generally This can occur if the melt rate for the system is exceeded, resulting in system is...
  • Page 54 Troubleshooting Problem Cause Solution 1. If the cycle rate is below (11 cpm - HM25, 22 cpm - HM50) and the Unable to The InvisiPac system system is still running away increase the InvisiPac system achieve monitors temperature temperature in small increments over the current set point, leave published melt within aluminum mass hoses and applicators at desired set point.
  • Page 55 Troubleshooting Problem Cause Solution Slow start-up Wrong setting in ADM Wrong 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 10 400 VAC for a 400 volt unit.
  • Page 56 Troubleshooting Problem Cause Solution No adhesive or Plugged applicator Replace applicator manifold filter. Graco applicator manifold filter in incorrect manifold filter. bottom of manifold or inline filter on other applicators. amount of Clogged hose. Flush or replace hose. adhesive output when all Solenoid valve.
  • Page 57 Troubleshooting Problem Cause Solution Adhesive Failed valve in the open Replace dispense module. flowing out of position. one/some Adhesive pressure too Reduce air pressure to air motor. applicators high. when not triggered Applicator will Heat rod failure in Check resistance on heater rods. Repair applicator manifold if heater rods not heat.
  • Page 58 Troubleshooting Problem Cause Solution Static shock Ground wire not in place Attach a ground wire from the shaft of the shaker unit to a true earth ground. when touching on shaker assembly. Order shaker grounding kit 24R708. shaker or Some adhesives, flow adhesive bin.
  • Page 59 Troubleshooting Flush Pressure Relief Valve Check the Pump Air Solenoid Operation Perform this procedure when directed in the Perform this procedure when directed in the Troubleshooting table. Troubleshooting table. 1. With the system active at the required adhesive System must be up to operating temperature for pump temperature, set the air motor air pressure to 20 psi solenoid to trigger on.

  • Page 60: Mzlp Troubleshooting

    Troubleshooting MZLP Troubleshooting Signal Description Green On MZLP is powered up and input voltage is within operating conditions. Yellow On Internal communication in process Red Solid MZLP failure. See troubleshooting table. Red Flashing Software update in process or missing software. MZLP .

  • Page 61: Repair

    Repair Repair Some procedures require special tools. Read through Disassembly (see F . 29): each procedure prior to beginning it to ensure you have 1. Flush the system. See page 39. the required tools to complete the entire procedure. Order any required tools and have them on hand prior 2.
  • Page 62 Repair 3. Grease the throat u-cup (234) and slide the u-cup over the piston rod (223) with the lips facing down. Reassembly (see F . 29): 4. Place a 7/8 in. deep-well socket (3/8 in. drive) over 1. To protect the seals from the sharp threads, place the piston rod (223) then use a rubber mallet to seal installation tool 15B661 into the throat bore.
  • Page 63 Repair 5. Slide throat bearing (233) over the piston rod (223). Replace Pump Inlet Housing Checks Use socket and tap with a rubber mallet to press throat Remove seal installation tool. 270 269 . 32 6. Remove seal installation tool. 7.
  • Page 64 Repair Replace Pup Reassembly (see F . 33): 1. Install new o-ring (231), o-ring (229), seat (228), and Replace Pump Cylinder Seals and Piston ball (227) then use a 1/2 in. drive ratchet without a Seals socket to install and tighten foot valve (230) onto melter.
  • Page 65 Repair 6. Remove nuts (3) securing melter shield (27) in place Reassembly: then remove melter shield. See F . 29 on page 61. 1. Apply grease to seals (217) then install new cylinder seals (217) onto cylinder (216). See F .

  • Page 66: Melter

    Repair Melter 4. Disconnect all heated hoses from the melter outlet manifold. 5. Remove cable from ADM (30) then slide forward the shroud (29) and remove it from the system. DANGER 6. Remove screws (8) then remove electrical enclosure front access door (10). SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V.
  • Page 67 Repair 20. Remove electrical enclosure front access door (10). 3. Use 4 bolts (259) to secure washers (268) and melter assembly to melter base (257). 21. Remove all heater wires from the following terminals. Pull wires up through the rubber 4.
  • Page 68 Repair 20. Open system air inlet ball valve. 3. Disconnect cable from ADM (30) then remove shroud (29). Replace Band Heater 4. Remove front access door (10) from electrical enclosure (1). 5. Remove fabric melter insulators (53). DANGER 6. While system is still near operating temperature, SEVERE ELECTRIC SHOCK HAZARD loosen clamp (80) and then remove screws (8) and This equipment can be powered by more than 240 V.
  • Page 69 Repair refilling may occur. Tighten band clamps to 25 3. Disconnect cable from ADM then remove shroud. in-lbs. 4. Remove air tube (36) from relief valve. Pull the air 8. Install fabric melter insulator (53). tube through the metal shroud (27). 9.
  • Page 70 Repair 11. Turn main power switch ON. Re-assembly (see F . 41): 1. Use the two screws (255) to secure the new 12. Open system air inlet ball valve. over-temperature switch (251) to the melter. Replace Heater Over-Temperature Switch 2. Connect wire connectors to new over-temperature switch.
  • Page 71 Repair 3. Disconnect cable from ADM then remove Replace Heater Rod shroud (29). 4. If removing the pump heater rod (271): a. Remove the air tube (36) from the relief valve (245). Pull the air tube through the metal DANGER shroud (27).
  • Page 72 Repair c. Pull the air tube through the metal shroud (27) 2. Close the system air inlet ball valve. then connect the air tube (36) to the relief 3. Turn main power switch OFF. valve (245). 4. Remove the air tube (36) from the relief valve (245). 7.

  • Page 73: Multi-Zone Low Power Temperature Control Module (Mzlp)

    Repair Multi-Zone Low Power Temperature Control Module (MZLP) Replace MZLP Fuse NOTICE To prevent system damage, always use fast acting fuses. Fast acting fuses are required for short-circuit protection. DANGER SEVERE ELECTRIC SHOCK HAZARD Fuse Part This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious 24V510 MZLP Fuses injury.
  • Page 74 Repair a. To replace MZLP #1, remove the daughter card Replace MZLP and standoffs, and re-install them on the new MZLP #1. b. To replace MZLP #3, remove the jumper (135) from MZLP #3 J5 connector and reinstall it on DANGER the new MZLP #3 J5 connector.
  • Page 75 Repair 4. Remove four mounting screws (112b) from Replace MZLP Daughter Card daughter card (112a) and set aside. 112b DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. 112a Contact with this voltage will cause death or serious ti20342a injury.

  • Page 76: System

    Repair System Reassembly (see F . 47): 1. Thread new fill sensor (20) into sensor housing (73). Bottom out the sensor in the sensor housing then Replace Fill Sensor back out 1/2 turn. 2. Tighten jam nut on fill sensor (20). 3.
  • Page 77 Repair 5. Remove two screws (144) securing power supply Replace AWB bracket (145) to AWB (143) and remove power supply bracket. See F . 49. Reassembly: DANGER 1. Use two screws (144) to secure power supply SEVERE ELECTRIC SHOCK HAZARD bracket (145) to new AWB (143).

  • Page 78: Power Supply Connection

    Repair 4. Disconnect screw terminal connections between Replace Power Supply Harness power supply (146) and power supply harness (147) according to the following table. See F . 49. Power Supply Harness Label DANGER Connection SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

  • Page 79: Air Controls

    Repair Air Controls 9. Disconnect air control solenoids cable from MZLP daughter board connector J13. Pull wire out of the electrical enclosure. 10. Remove two screws (405) securing solenoids (402) to air control assembly (9) then remove air control DANGER solenoids.

  • Page 80: Air Motor

    Repair 5. For 480V systems, install transformer assembly NOTICE (140) with screws (142) and reconnect transformer In the following step, do not overtighten the two wires to J2 connector on AWB board and the main nuts (403a). Overtightening may cause the gauge to power switch.
  • Page 81 Repair 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.
  • Page 82 Repair Remove Air Motor 7. If replacing a damaged air motor with a new fully assembled air motor: a. Remove three screws (211) securing air motor tie rods (220) to base plate (219). b. Remove tie rods (220) from air motor (218). Install Air Motor See F .

  • Page 83: Transformer Fan

    Repair Transformer Fan 4. Remove connector from J7 connector on AWB board. Remove red (+) and black (-) wires from connector. DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

  • Page 84: Software Update Procedure

    Repair 4. Reinstall corrugated tube (167) on fan and 5. Install ADM into bracket. transformer wires. See F . 57. 6. Turn system main power switch ON. To prevent fan errors on ADM, remove excess slack and ensure cabling and zip ties do not contact fan NOTICE blades.

  • Page 85: Electrical Schematics

    Repair 10. Navigate to System screen. Verify the following b. System Screen Page 2, Channel and RTD pages. Reference screens on page 130. types are set correctly. a. System Screen Page 1, Customer I/O is set c. System Screen Page 3, System Type, Pump correctly.
  • Page 86 Repair Systems Without Internal Pattern Controller Review Connect Electrical Cord section, Figure 16 TRANSFORMER TEMP TEMP OPTION TEMP TEMP TO MZTCM #2, FAN - FAN - FAN + FAN + 4 and 6 CHANNEL OPTION BAND PUMP MELTER BASE GROUND STUD DC OK DC OK...
  • Page 87 Repair Systems With Internal Pattern Controller Review Connect Electrical Cord section, Figure 16 TRANSFORMER TEMP TEMP OPTION TEMP TEMP TO MZTCM #2, FAN - FAN - FAN + FAN + 4 and 6 CHANNEL OPTION BAND PUMP MELTER BASE GROUND STUD PC-8 MZLP 1...
  • Page 88 Repair 400 VAC Transformer Option 480 VAC Transformer Option 333347ZAC...
  • Page 89 Repair Typical Hose / Applicator Wiring 333347ZAC...
  • Page 90 Repair 2nd and 3rd MZLP Options MZLP3 MZLP 2 MZLP 1 Internal PC-8 Options One MZLP 333347ZAC...

  • Page 91: Air Schematic

    Air Schematic Air Schematic Install an optional ramp up/down controller to limit air to the air motor and slow down the system dispense rate. 333347ZAC...

  • Page 92: Parts

    Parts Parts InvisiPac Systems System Parts, Page 1 of 3 Apply door gaskets (11) to door (10) per layout diagram. Apply pipe sealant to all non-swiveling pipe threads. Bottom sensor (20) out then back off 1/2 turn. Lubricate all seals and o-rings with water resistant grease. Torque to 5-11 ft-lb (7-15 N•m).
  • Page 93 Parts System Parts, Page 2 of 3 333347ZAC...
  • Page 94 Parts System Parts, Page 3 of 3 48 in. (1219 mm) 48 in. (1219 mm) 16 in. (406.4 mm) 48 in. 48 in. (1219 mm) (1219 mm) 8 in. (203 mm) 2 in. (50.8 mm) 13 in. 330.2 mm) 333347ZAC...
  • Page 95 Parts System Parts Quantities HM50 HM25 2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel Part Description ENCLOSURE, electrical 115942 NUT, hex, flange head 167002 INSULATOR, heat 24V169 SYSTEM, melter, HM25 24V542 SYSTEM, melter/pump, HM50 6✓ GUARD, insulated 6✚...
  • Page 96 Parts Quantities HM50 HM25 2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel Part Description BUSHING, strain relief GROMMET, tube GROMMET, tube 43▲ 16Y781 LABEL, safety 16U007 LABEL, InvisiPac, HM25 LABEL, InvisiPac HM50 LABEL 47✖ 24P859 KIT, fuses, board, temp control 48✖...
  • Page 97 Parts Quantities HM50 HM25 2 Channel 4 Channel 6 Channel 2 Channel 4 Channel 6 Channel Part Description BRACKET, funnel, HM25 BRACKET, HM50, funnel, mounting 123986 FITTING, elbow, 3/8 OD tube 1 GROMMET 127666 CABLE, gca, m12-5p WIRE, ground 116343 SCREW, ground WASHER, 1/4 external tooth lock...
  • Page 98 Parts Electrical Enclosure, Systems without Internal Pattern Controller MZLP 3 MZLP 112a 106, 107 MZLP 2 Apply sealant to all non-swiveling pipe threads. Set rotary switch to “1” on MZLP with daughter card. Set rotary switch to “2” on MZLP 2. Set rotary switch to “3”...
  • Page 99 Parts Electrical Enclosure, Systems with Internal Pattern Controller MZLP 112a 106, 107 MZLP2 Apply sealant to all non-swiveling pipe threads. Set rotary switch to "1" on MZLP with daughter card. Set rotary switch to "2" on MZLP 2. 333347ZAC...
  • Page 100 Parts Electrical Enclosure Parts Quantity Part Description 1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP No Transformer 400/480 V Transformer CABINET, controls 127666 CABLE, gca, m12-5p HARNESS, MZLP1, AWB 123970 SWITCH, disconnect, 40a 126839 CONTACT, n-pole 120858 BUSHING, strain relief, m40 thread 120859...
  • Page 101 Parts Quantity Part Description 1 MZLP 2 MZLP 3 MZLP 1 MZLP 2 MZLP 3 MZLP No Transformer 400/480 V Transformer 16T108 CABLE, ultrasonic, m12-4p, 1m HARNESS, MZLP 2, awb HARNESS, MZLP 2/3, awb 114958 STRAP, tie SCREW, flange, serrated, 10-24 x 0.5 123967 KNOB, operator disconnect 16W035 CONNECTOR, jumper...
  • Page 102 Parts Transformer Assemblies Mount fan with arrow pointing towards grill. Use nut to lock down the ground wire from transformer. Tie down cabling from transformer and fan using cable tie onto Connect black fan wire labeled (-) from transformer (153) in the tie down locations.
  • Page 103 Parts Melter and Pump Assembly HM25, 24V169 HM50, 24V542 Lubricate all seals and o-rings with grease. Torque to 27-33 in.-lb (3-3.8 N•m). Orient melter (202) sensor hole in line with band heater (208) Apply anaerobic thread sealant on threads. clamp. Torque to 12-18 ft-lb (16-24 N•m).
  • Page 104 Parts Ref. Part Description Qty. 252• INSERT, helical 253✖ PLATE, melter; HM50 only PLATE, melter; HM25 only O-RING, -910 HM25 Meter and Pump, 17F830 255✿• 107388 SCREW, mach, pnh; #4 x 3/8 in. HM50 Melter and Pump, 24V542 BRACKET, shelf; HM50 only Ref.
  • Page 105 Parts Air Motor, 24V558 Apply water-resistant grease. Torque to 95-105 in-lb (10.7-11.9 N•m). -- Not for sale. Ref. Part Description 24A579 MANIFOLD, medium, short † Included in Air Motor Valve Kit 24R026. GASKET, cover, small 507† SEAL, air valve, manifold 509†...
  • Page 106 Parts Air Controls Assembly Apply sealant to all non-swiveling pipe threads. Air Controls Assembly Parts Part Description PANEL, air, controls 24V520 CONTROL, air, vacuum transfer and pump 128260 GAUGE, pressure, air, panel mount, 1/8 in. npt 15T498 FITTING, 90 degree, swivel, 5/32 in.

  • Page 107: Part Description

    Parts Pressure Relief Valve, 24P856 611 608 Apply sealant to all non-swiveling pipe threads. Apply grease. Torque to 4-6 in-lb (0.5-0.7 N•m). ti20926a Part Description 609† 110073 PACKING, o-ring Part Description 111841 WASHER, plain 5/8 in. BODY, fluid 611† BEARING, valve BODY, air 612†...
  • Page 108 Parts Feed Inlet Funnel, 24V505 HM25 Ref. Part Description BAFFLE, pellet O-RING, fluoroelastomer, 160 FUNNEL, insert 24V506 FILTER, feed FUNNEL, filter cover 126901 SCREW, #10-16, thread forming 110932 FITTING, connector, air HOUSING, sensor FUNNEL, large mouth ADAPTER, HM25 gen2 CLAMP, hose --- Not for sale.Not included in 24V505: Part Description...
  • Page 109 Parts Feed Inlet Funnel, 25T368 HM50 Ref. Part Description BAFFLE, pellet O-RING, fluoroelastomer, 160 FUNNEL, insert 24V506 FILTER, feed FUNNEL, filter cover 126901 SCREW, #10-16, thread forming 110932 FITTING, connector, air HOUSING, sensor FUNNEL, large mouth ADAPTER, melter HM50 CLAMP, hose spacer CLAMP, hose spacer --- Not for sale.

  • Page 110: Accessories

    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. ** Parts included in Rod Tools Kit 24R228 (purchase Part Purpose separately) 1301* Remove Cylinder Part Purpose 1302*...

  • Page 111: Preventative Maintenance Kits

    Accessories Preventative Maintenance Kits 24R041 Kit, Level Sensor 24P852 Kit, Repair, Pump These kits contain components which are commonly used in maintenance. 24V816 Kit, Repair, AWB 24R042 Kit, Board, Daught. HM25 Generation 1 Preventative Maintenance Kit, 24R885 Kit, Cycle Switch 24X865 24V510 Kit, MZLP w/ fuses...

  • Page 112: Non-Graco Applicator Adapter Cables

    Accessories Non-Graco Applicator Adapter Adapter Cable Cables 128621: Adapter cable allows non-Graco NI120 RTD Hoses to be used on InvisiPac. 16T916: For connecting to non-Graco applicators that use a rectangular, 6-pin connector. ti21128a 128372: For connecting to non-Graco applicators that use a rectangular 8-pin connector.

  • Page 113: Air Adjustment Lock, 24R084

    Accessories Air Adjustment Lock, 24R084 Feed Sensor Dedicated Air Kit, 17F699 Panel enables locking access to the air adjustment screws. For connecting a dedicated air source to the feed ™ sensor on InvisiPac systems. Part Description 106148 FILTER, air, 3/8 npt 110224 VALVE, vented 2-way 198177 FITTING, push, straight 128264 BRACKET...

  • Page 114: System Stand, 24R088

    Accessories System Stand, 24R088 Adapter Plate, 24R083 Use the stand to mount the system at eye level. When Use this adapter plate to install InvisiPac in place of an the system is mounted on the stand, the ADM is 45 in. existing hot melt applicator system.
  • Page 115 Accessories Light Tower Kit, 24R226 The light tower enables someone away from the system to quickly see whether the system is inactive or OFF (no lights), warming up (flashing green), at temperature (solid green), or has an active error (red). 1201 1201a 1203...

  • Page 116: Air Reservoir Kit, 16W366

    Accessories Air Reservoir Kit, 16W366 Light Tower Kit Installation This kit allows the system to operate as low as 60 psi (0.4 MPa, 4 bar). DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.
  • Page 117 Accessories 4 Channel Upgrade Kit, 24V528 Use this kit to upgrade a 2 channel system to a 4 channel system. 1307 1306 1301 1308 1304 1308 1302 1305 ◆ Not shown. Part Description 1301 MODULE, GCA, MZLP 1302 16T087 CABLE, jumper, male/male, 21 in. 1303 HARNESS, 2nd MZLP power 1304...
  • Page 118 Accessories 4 Channel Upgrade Kit Installation included with the InvisiPac system. Use the fittings that meet your hose routing needs. 10. To ensure your InvisiPac system has the latest software, insert token (1306) into ADM. Follow Software Update Procedure, page 84. DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V.
  • Page 119 Accessories Step 7: Install Jumper Cable (1302). MZLP 2 MZLP 1 ti23596a 333347ZAC...
  • Page 120 Accessories 6 Channel Upgrade Kit, 24V529 Use this kit to upgrade a 4 channel system to a 6 channel system. 1304 1308 1302 1307 1306 1303 1305 1301 Part Description 1305 16T440 CAP, jam nut, sealing Part Description 1306 HARNESS, MZLP #3 1301 MODULE, GCA, MZLP 1307...
  • Page 121 Accessories 6 Channel Upgrade Kit Installation DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury. Turn off and disconnect all power before disconnecting any cables and before servicing equipment.
  • Page 122 Accessories Step 7: Install jumper cable (1302). 333347ZAC...
  • Page 123 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. 1401 1402 1404 1403 ti20990a Part Description...

  • Page 124: Adm Extension Kits

    Accessories Simulator Instructions 1. Remove ADM access panel and install InvisiPac Simulator Token (1404). r_24P860_3B9900_3a . 3: Remove Access Panel Installation 2. Connect power supply (1402) to ADM (1401). 1. In the ADM setup screens, uninstall Channel 1. All 3. Connect cord (1403) to power supply (1402). other Channels can be installed or uninstalled as needed.

  • Page 125: Strain Relief Bushing Kit, 24X190

    127567 KIT, 400VAC Transformer 127568 KIT, 480VAC Transformer Hose Straps (4 Pack), 240296 Adapter Cable Use these straps to secure hoses without excessive pinching. Part Description 128621 Adapter cable allows non-Graco Ni120 RTD Hoses to be used on InvisPac 333347ZAC...

  • Page 126: Appendix A - Adm

    Appendix A - ADM Appendix A - ADM General Operation Icon Description Use the physical numeric keypad on ADM to enter temperature ADM Power setting. The ADM automatically turns on when the main power Select channel to view and/or edit the switch is turned ON.
  • Page 127 Appendix A - ADM Icon Description Schedule Screen Only Edit schedule value Erase schedule value Accept schedule change Cancel schedule change 333347ZAC...

  • Page 128: Operation Screens

    Appendix A - ADM Operation Screens Home See Appendix B - USB Downloading, Uploading on page 133. Tracked Events Code Custom Language Downloaded EQU3 Custom Language Uploaded EQU4 Fill Valve Closed EBFX Fill Valve Open EAFX Heat Off EBDX Heat On EADX High Material Usage ECAH...
  • Page 129 Appendix A - ADM Diagnostic Fill Sol: Current draw of fill solenoid • (0 mA - off) • (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 system.

  • Page 130: Setup Screens

    Appendix A - ADM Setup Screens NOTE: It is important to set all settings in the System System 3 screens correctly to ensure optimal system performance. Password System Type: Choose the model of the system. Enable Diagnostic Screen: Choose whether to hide the Diagnostic screen.
  • Page 131 Appendix A - ADM Enable ADM Unit Counter: Select to enable ADM Advanced 1 counting of units using an external sensor. Enable Material Alerts: Select to enable record only events indicating low/high material usage. Specific Gravity: Required to convert the volume dispensed to mass dispensed for tracking the total weight and flow rate.
  • Page 132 Appendix A - ADM Advanced 3 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 Disable USB Downloads/Uploads: Disables use of the USB for downloading and uploading.

  • Page 133: Appendix B - Usb Downloading, Uploading

    NOTE: To prevent losing any data, never go more than When downloading from multiple ADMs, there will be 27 days without downloading the logs. one sub-folder in the GRACO folder for each ADM. The log files should be opened in a spreadsheet Download Procedure program.

  • Page 134: Usb Logs

    USB is uploading files. Wait for USB activity to complete. These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are designed to provide useful information to Graco when 11. Remove USB flash drive from USB port. calling for technical assistance. If a custom language file was installed, users can now...

  • Page 135: System Language File

    Appendix B - USB Downloading, Uploading System Language File list of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was The system language file name is DISPTEXT.TXT and is previously installed, this column contains the custom stored in the DOWNLOAD folder.

  • Page 136: Technical Data

    Technical Data Technical Data InvisiPac Hot Melt Delivery System Metric Incoming Power. 200-240 VAC, 1-ph, 50/60 Hz, 32A HM25: 24V423, 24Y102 200-240 VAC, 3-ph, Δ, 50/60 Hz, 27A HM50: 24T918, 24Y114 350-415 VAC, 3-ph, Y, 50/60 Hz, 16A HM25: 24V429, 24Y106 400-480 VAC, 3-ph, Δ, 50/60 Hz, 14A HM50: 24V201, 24Y118 200-240 VAC, 1-ph, 50/60 Hz, 40A...
  • Page 137 Technical Data InvisiPac Hot Melt Delivery System Metric System Dimensions (Width x Height x Depth) 19.0 x 42 x 16.5 in. 483 x 1067 x 419 mm Pressure and Temperature Ranges Main System Air Supply Pressure Range (set 80-100 psi 0.55-0.69 MPa (5.5-7 bar) with regulator on front of system) Pump Operating Air Pressure Range...

  • Page 138: Startup Time

    Technical Data Startup Time Single Phase Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration. Start Time in Minutes Hose Channels 20 Amp 30 Amp 40 Amp 50 Amp 20 Amp 30 Amp 40 Amp 50 Amp System Length...
  • Page 139 Technical Data Three Phase Times are approximate and may vary with ambient conditions, voltage configuration, and machine configuration. Start Time in Minutes Hose Channels 20 Amp 30 Amp 40 Amp 50 Amp 20 Amp 30 Amp 40 Amp 50 Amp System Length Breaker...

  • Page 140: System Dimensions

    Dimensions Dimensions 240V System Dimensions System With 480V Transformer HM25 HM50 HM25 HM50 35.5 in. (901.7 mm) 35.8 in. (909.3 mm) 41.6 in. (1056.6 mm) 41.9 in. (1064.3 mm) 20.8 in. (528.3 mm) 22.3 in. (566.4 mm) 20.9 in. (530.9 mm) 22.3 in.

  • Page 141: California Proposition

    Dimensions California Proposition 65 CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov. 333347ZAC...

  • Page 142: Graco Extended Warranty

    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 determined by Graco to be defective.

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