Graco 3A4938H, InvisiPac HM25c Hot Melt Delivery System Owner's Manual

Instructions - Parts
InvisiPac® HM25c
Hot Melt Delivery System
3A4938H
EN
For delivering and dispensing hot melt adhesive pellets. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
See page 4 for Models information.
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
Important Safety Instructions
Read all warnings and instructions in this manual and in
the applicator and hose manuals. Save all instructions.
WLD
9902471
Certified to
CAN/CSA C22.2 No. 88
Conforms to
ANSI/UL 499
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification (typical installation) . . . . . 8
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connect Feed System . . . . . . . . . . . . . . . . . . . . . . 10
Connect Heated Hoses . . . . . . . . . . . . . . . . . . . . . 11
Connect Applicators . . . . . . . . . . . . . . . . . . . . . . . . 12
Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . . . 13
Connect PLC Inputs . . . . . . . . . . . . . . . . . . . . . . . . 15
Connect PLC Outputs . . . . . . . . . . . . . . . . . . . . . . 17
Connect Material Tracking Input . . . . . . . . . . . . . . 18
Connect Accessories . . . . . . . . . . . . . . . . . . . . . . . 19
Connect Electrical Cord . . . . . . . . . . . . . . . . . . . . . 19
Select ADM Settings . . . . . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Initial Startup and Prime . . . . . . . . . . . . . . . . . . . . . 22
Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 25
Operation Tips to Maximize Adhesive Life . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspect Funnel and Filter . . . . . . . . . . . . . . . . . . . . 26
Replace Pump Outlet Filter . . . . . . . . . . . . . . . . . . 26
Replace Pump Inlet Filter . . . . . . . . . . . . . . . . . . . . 27
Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Alarms (shuts system down) . . . . . . . . . . . . . . . . . 31
Fill System Verification . . . . . . . . . . . . . . . . . . . . . . 36
Input Power Verification . . . . . . . . . . . . . . . . . . . . . 36
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Replace the Pump Inlet Housing Check and Cylinder
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replace Electrical Component(s) . . . . . . . . . . . . . 50
2
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . 52
Common Schematic (all systems) . . . . . . . . . . . . . 52
Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8 Channel Systems (25C702, 25C703, 25C722,
25C723) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pattern Controller . . . . . . . . . . . . . . . . . . . . . . . . . 55
Typical Hose/Applicator Wiring . . . . . . . . . . . . . . . 55
Air Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . 56
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Common System Parts . . . . . . . . . . . . . . . . . . . . . 57
Common System Parts (continued) . . . . . . . . . . . . 59
8-Channel, Pattern Controller, and 480V System Parts
61
Safety and Identification Labels . . . . . . . . . . . . . . . 64
Air Control Assembly 25C468 Parts . . . . . . . . . . . 65
Melter Assembly 17S257 Parts . . . . . . . . . . . . . . . 67
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Adapter Plate Kit, 25M528 . . . . . . . . . . . . . . . . . . . 69
System Stand Kit, 17S264 . . . . . . . . . . . . . . . . . . . 69
Light Tower Kit, 25C662 . . . . . . . . . . . . . . . . . . . . 70
ADM Remote Mount Extension Cables . . . . . . . . . 71
Material Tracking Kit . . . . . . . . . . . . . . . . . . . . . . . 71
Hose Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Applicator Adapters . . . . . . . . . . . . . . . . . . . . . . . . 72
Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . . . . 77
Appendix A - ADM (Advanced Display Module) . . . 78
ADM Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Screen Navigation . . . . . . . . . . . . . . . . . . . . . . . . . 78
ADM Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Appendix B - USB Downloading, Uploading . . . . . . 91
Download Procedure . . . . . . . . . . . . . . . . . . . . . . . 91
Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 91
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
System Settings File . . . . . . . . . . . . . . . . . . . . . . . 92
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
System Language File . . . . . . . . . . . . . . . . . . . . . . 93
Appendix C - Software Update . . . . . . . . . . . . . . . . . 94
Software Update Procedure . . . . . . . . . . . . . . . . . 94
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
240V System Dimensions . . . . . . . . . . . . . . . . . . . 95
System with 480V Transformer . . . . . . . . . . . . . . . 95
Mounting Hole Dimensions . . . . . . . . . . . . . . . . . . 96
System with Stand and Feed Hose Dimensions . . 97
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . 98
California Proposition 65 . . . . . . . . . . . . . . . . . . 99
Startup Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . 102
3A4938H
Related Manuals
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
Part
Description
334627
3A2805
332072
3A4937
334629
334784
334610
InvisiPac GM100 Plug-Free Hot Melt Applicator
InvisiPac GS35 Hot Melt Applicator
InvisiPac Heated Hose
InvisiPac Standard Feed System
InvisiPac Advanced Feed System
InvisiPac Pattern Controller
LineSite® Remote Monitoring Solution
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
3A4938H
•
•
•
•
•
•
•
•
•
1 in. socket
13 mm socket
10 mm socket
1/2 in. ratchet
Side cutter
Phillips head screwdriver
Flat head screwdriver
Multimeter
Tubing cutter
3
Models
Models
InvisiPac HM25c System Models
NOTE: InvisiPac HM25c system part numbers listed below do not include a feed system. Refer to the Feed Systems
table below to select the appropriate feed system for use with selected InvisiPac HM25c system.
Part
Pattern Controller
Channels
25C700
25C701
25C702
25C703
25C720
25C721
Not included
PC-8*
Not included
PC-8*
Not included
PC-8*
8
25C722
25C723
Not included
PC-8*
8
Voltage (VAC, 50/60 Hz)
Max Amps
200-240 1˓/3˓, 350-415 3˓ + N
32 A
400-480 3˓
16 A
4
4
* Order kit 17F712 to upgrade to PC-8e (includes Key Token for Encoder).
Refer to manual 334784 - InvisiPac Pattern Controller for details.
Feed Systems
Part
Usage
25C193
For use in standard pellet feed applications
17D749
For use in chiclet feed applications
WLD
24N957
For use in standard pellet feed applications
with separate feed bin or bulk container
WLD
4
3A4938H
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
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 power at main switch before disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
WARNING
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
\
3A4938H
5
Warnings
WARNING
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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush at high pressure
• 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.
• Use only grounded hoses.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request Safety Data Sheets (SDSs) from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
6
3A4938H
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.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes
but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury,
or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Do not use chlorine bleach.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.
3A4938H
7
Component Identification (typical installation)
Component Identification (typical installation)
*
$*
$.
*
$)
*
$+
*
*
/
6
.
3
3
$0
$
(
0
+
$'
Ref.
A
AD
AF
AG
AH*
AK*
AM*
AN*
B
C
D
G*
G1*
G2*
%
'
&
$1
5
)
Description
Advanced Display Module (ADM)
Transformer Base
System Inlet Air Filter
System Inlet Air Ball Valve
Applicator Air Regulator
Feed Bin
Heated Hose
Applicator
Electrical Enclosure
Pump Air Pressure Regulator
Pump Air Pressure Gauge
Shaker Tube
Shaker Head
Feed Tube
N
Ref.
G3
G4*
H
J
K
L
M
N
P
P1
P2
R
S
WLD
Description
Feed Inlet Funnel
3/8 in. OD Air Supply Feed Hose
Main Power Switch
System Air Inlet
Vacuum Transfer (Shaker) Inlet
Air Motor and Pump
Incoming Power Strain Relief
Heated Fluid Manifold (Melter)
Automatic Multi-Zone (AMZ)
Automatic Multi-Zone 1 (AMZ 1)
Automatic Multi-Zone 2 (AMZ 2)
Fluid Outlets for connection to Heated Hoses
Customer I/O Cable Gland
* Not supplied with InvisiPac HM25c (sold separately).
8
3A4938H
Setup
Setup
Grounding
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
•
The InvisiPac system must be located to allow the
feed hose to reach the feed bin (AK). The length of
feed hose supplied with each feed system is 10 ft (3
m). The maximum recommended feed hose length
is 30 ft (9.1 m). Use 30 ft Feed Hose, 24R043 to
achieve the maximum feed hose length.
•
The InvisiPac system must be located to allow the
heated hoses (AM) to reach from the melter (N) to
the applicators. The maximum length of an InvisiPac hose is 25 ft (7.6 m).
•
For ease of operation, place the InvisiPac system
with the display slightly below eye-level. Use System
Stand Kit, 17S264 to locate the InvisiPac system at
the appropriate height. See page 69 for details.
•
Use Adapter Plate Kit, 25M528 (page 69) to locate
the InvisiPac system in place of a non-Graco system.
•
For ease of operation and maintenance, position the
InvisiPac system so that all sides are easily accessible and have sufficient lighting.
•
Permanently fasten the system base in the location
selected using the mounting holes provided. See
Mounting Hole Dimensions on page 96.
The InvisiPac system is equipped with a ground terminal. A qualified electrician must ground the system using
this terminal. See Connect Electrical Cord on page 19.
Location
When setting up the InvisiPac system, make sure it
meets the following criteria:
•
Ambient temperature must be 32°-120° F (0°-49° C).
3A4938H
9
Setup
Connect Feed System
1. Refer to the instruction manual supplied with the
feed system for any assembly steps required prior
to connecting the feed system to the InvisiPac system.
3. Insert 1.3 in. (33 mm) OD clear feed hose (G2) into
the funnel inlet (79). Tighten the hose clamp over
the cutouts in the funnel inlet to secure the feed
hose.
2. Adjust the funnel inlet (79) on the InvisiPac system
(optional):
a. Loosen all three tie bolts (87).
87
G2
79
WLD
WLD
b. Rotate the funnel inlet (79) to the desired position and re-tighten all three tie bolts (87).
10
4. Connect the 3/8 in. (9.525 cm) OD air supply feed
hose (G4) to the empty 3/8 in. (9.525 cm)
push-to-connect the fitting on the back of the InvisiPac system.
3A4938H
Setup
Connect Heated Hoses
c.
When fluid stops draining, reinstall the drain
port plug (640) and remove the rag from the
melter drain tray (650).
2. Make a fluid connection between the melter (N) and
heated hose(s) (AM). Remove the melter outlet
manifold cap (640).
Use of a Graco heated hose is not required with this
system. However, all heated hoses 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 1250W at 240 VAC. Non-Graco heated hoses
require an electrical adapter cable.
NOTE: For ease of installation, use the bottom
melter ports first.
NOTE: Do not use the top port (PT) for hose fluid
connections.
If connecting hoses to a system already in service:
perform Pressure Relief Procedure on page 25, and
ensure system is at a safe temperature to perform work,
then proceed to step 2.
3. Repeat the previous step for all remaining hoses.
4. Make electrical connection between heated hose(s)
and AMZ(s):
If connecting hoses to a new system: begin with step 1.
1. Drain any residual oil from factory testing:
a. Place a rag on the melter drain tray (650).
Residual oil may remain in the system from factory testing.
b. Use a 1/4 in. Allen wrench to remove the drain
port plug (640).
NOTE: For ease of installation, make connections
between the rightmost melter ports and the rightmost AMZ electrical connectors first.
a. Remove the cap (CP) from the AMZ electrical
connector and install the hose electrical connector (HC).
5. Repeat the previous step for all remaining hoses.
AMZ
HC
CP
RG
640
N
WLD
PT
3A4938H
650
HF
AM
11
Setup
Connect Applicators
fluid connection between the heated hose (AM) and
applicator (AN).
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. Non-Graco applicators require
an electrical adapter cable.
2. Make an electrical connection between the heated
hose (AM) and the applicator (AN):
a. For connecting Graco heated hoses to Graco
applicators, attach the heated hose electrical
connector (HHE) to the applicator electrical connector (AEC).
b. For connecting Graco heated hoses to
non-Graco applicators, attach a heated hose
electrical connector (HHE) to the non-Graco
applicator adapter cable and connect the other
end to the applicator electrical connector (AEC).
If connecting applicators to a system already in
service: perform Pressure Relief Procedure on page
25, and ensure system is at a safe temperature to
perform work.
1. Use a 11/16 in. wrench to tighten the heated hose
fluid outlet (FD) to applicator fluid inlet to make a
3.
Repeat the previous steps for all remaining applicators.
AN
FD
WLD
AEC
HHE
AM
12
3A4938H
Setup
Connect Air Supply
See Connecting the Air Supply on page 14 for recommended air setup guidelines before continuing the
remaining steps.
NOTE: The system must use a bleed-type ball valve
that bleeds pressure downstream when closed.
NOTE: The system must use an air filter with a minimum flow rate of 30 scfm.
2. Close the ball valve (366).
NOTE: If using the same air for actuating the applicator(s), install the tee in the air supply line before
the ball valve. See the applicator manual for applicator air pressure requirements. If necessary, use a
regulator before the applicator to decrease air pressure.
NOTE: The system air gauge lenses are plastic to allow
for use in food and beverage industries.
366
NOTICE
Oiling the air supply can reduce the life of the air controls components. Do not install an oiler on the air supply to the system.
1. Install the supplied air inlet bleeding ball valve (366)
and air filter (AF) at the 1/4 NPT female system air
inlet.
NOTE: Additional fittings provided with the inlet air
kit are optional and may be used as required.
WLD
3. Connect a 3/8 in. (9.525 cm) minimum air supply
line to the ball valve (366).
366
NOTE: For best performance, supply pressure
should be between 80 psi (550 MPa, 5.5 bar) and
100 psi (690 MPa, 6.9 bar). If air supply is not able
to sustain pressure at the flow rate required by the
InvisiPac system, or if pressure is expected to drop
due to other equipment sharing the supply, an Air
Reservoir Kit 16W366 is available that allows the
system to operate on lower pressure or restricted air
supply lines.
AF
WLD
3A4938H
13
Setup
Connecting the Air Supply (typical installation)
No dips in feed hose
Main Air Line
Air in:
Less than 50 ft (15.2 m): 3/8 in.
More than 50 ft (15.2 m): 1/2 in.
80-100 psi (5.5 - 6.8 bar, 0.55 - 6.8 MPa)
30 scfm capacity.
Bleed-type
Ball Valve
110224
Air Filter
106148
Pump:
20-100 psi
(2.7-5.5 bar,
0.27-0.55 MPa)
Regulator set to 70 psi
(4.8 bar, 0.48 MPa)
Air to applicators
WLD
14
3A4938H
Setup
Connect PLC Inputs
Wire the PLC Inputs
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 power at main switch
before disconnecting any cables and before servicing equipment.
1. Route a multi-conductor cable through one of the
cable grommets (CG) on the back of the InvisiPac
system enclosure.
CG
Each InvisiPac system is equipped with six PLC inputs.
Each input can be configured in software to perform one
of the following options:
•
Turn the InvisiPac system on/off
•
Disable the InvisiPac system (turn off the pump)
•
Enable/Disable individual channels (1 - 8)
P1
WLD
NOTE: See Appendix A - ADM on page 78 for
detailed information regarding software configuration of the options above.
2. Refer to the following sections (Digital Inputs and
Dry Contact Inputs, depending on the input type
needed) to wire the PLC inputs to the System I/O
Board on AMZ #1 (P1).
NOTE: Additional PLC inputs are available on InvisiPac systems containing an internal pattern controller. Refer to the Pattern Control System manual
334784 for more detail.
NOTE: On 8-channel InvisiPac systems, an additional
System I/O board is included on AMZ #2 (P2). Do not
wire PLC inputs to the System I/O Board on AMZ #2.
The InvisiPac PLC inputs accept the input types below:
Input Type
Digital Input
Dry Contact
3A4938H
Specifications
0-30 VDC
Signal Low: 0-2.5 V
Signal High: 10-30 V
Open/Closed Circuit
Signal Low: Open Circuit
Signal High: Closed Circuit
15
Setup
Digital Inputs (0 - 30 VDC)
NOTICE
1. Connect the PLC GND wire (16-28 AWG) to the
“ISO GND” terminal on J9.
The system I/O board and/or the PLC could become
damaged if connections are made to J8. Do not connect any wires to J8 while using Digital Input type PLC
inputs. Signals on J8 are provided for Dry Contact type
inputs only.
2. Connect the input signal wire to the desired input
terminal on J9 (labeled by input number).
3. Repeat step 2 for remaining inputs.
J8
24V
+
+
J9
ISO
GND
PLC GND
PLC #1
1
PLC #2
2
PLC #3
3
PLC #4
4
PLC #5
5
PLC #6
6
ti31248a
Dry Contact Inputs (Open/Closed Circuit)
2. Connect one side of the input to one of the “+” terminals on J8.
3. Connect the other side of the input to the desired
input terminal on J9 (labeled by input number).
4. Repeat steps 2 and 3 for remaining inputs.
1. Connect a jumper wire (16-28 AWG) between “-”
terminal on J8 and “ISO GND” terminal on J9.
J8
6
1
(5, 4, 3, 2)
24V
+
+
J9
ISO
GND
1
2
3
4
5
6
ti31249a
16
3A4938H
Setup
Connect PLC Outputs
The InvisiPac PLC outputs have the following
specifications:
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 power at main switch
before disconnecting any cables and before servicing equipment.
Item
Output Type
Max Voltage
Max Current
Specification
Dry Contact (Open/Close Circuit)
24 VDC / 240 VAC
2A
Wire the PLC Outputs
1. Route a multi-conductor cable through one of the
cable grommets (CG) on the back of the InvisiPac
system enclosure.
Each InvisiPac system is equipped with two PLC outputs. Each output can be configured separately in software to indicate the following states:
•
InvisiPac System Ready
•
Error Present
•
Maintenance Due
CG
NOTE: See Appendix A - ADM on page 78 for
detailed information regarding software configuration of the options above.
NOTE: Additional PLC outputs are available on InvisiPac systems containing an internal pattern controller. Refer to the Pattern Control System manual
334784 for more detail.
P1
WLD
2. Refer to the image below to wire PLC outputs to the
system I/O Board on AMZ #1 (P1).
NOTE: On 8-channel InvisiPac systems, an additional
System I/O board is included on AMZ #2 (P2). Do not
wire PLC outputs to the System I/O Board on AMZ #2.
J11
PLC #1
1
2
3
PLC #2
4
ti31252a
3A4938H
17
Setup
Connect Material Tracking Input
3. Route the flying lead end of cable through one of the
cable grommets (CG) on the back of the InvisiPac
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 power at main switch
before disconnecting any cables and before servicing equipment.
CG
A trigger sensor or dry contact input can be used to add
material tracking to InvisiPac HM25c systems that do
not contain a pattern controller. See Accessories (starting on page 69) for additional details.
NOTE: InvisiPac HM25c systems with an integrated pattern controller track material usage per unit automatically and do not require an additional trigger sensor or
dry contact input.
NOTE: See System Screen 4 - Material Tracking
Setup on page 88 for detailed information regarding
how to view setup and material tracking information in
the software.
P1
WLD
4. Refer to the table and image below to connect flying
leads to the System I/O Board on AMZ #1 (P1).
NOTE: On 8-channel InvisiPac systems, an additional System I/O board is included on AMZ #2 (P2).
Do not wire the trigger sensor to the System I/O
board on AMZ #2.
Perform the following steps to connect a trigger sensor
to the InvisiPac system:
1. Mount the trigger sensor according to the guidelines
in the table below:
Kit
24X446
Sensor
Type
Diffuse
Notes
•
•
•
24X447
Retro
Reflective
•
•
•
•
•
18
(do not connect both)
GND
Align sensor perpendicular
to line.
Adjust sensitivity for
proper operation.
Ensure sensor trips once
per unit.
Range: 200 mm
2. Connect the M12 end of the supplied cable to the
trigger sensor.
VCC
NPN or PNP
Image
Align sensor perpendicular
to line.
Align reflector and sensor.
Ensure sensor trips once
per unit.
Range: 3.5 mm
J10
+
TR
-
ti31250a
Flying Lead Signal (color)
J10 Pin
VCC (brown)
+
PNP (black)
NPN (white)
GND (blue)
ti31255a
TR*
-
*NOTE: Only connect one wire (trim and terminate the
other wire).
3A4938H
Setup
Perform the following steps to connect a dry contact to
the InvisiPac system:
NOTE: The installed strain relief bushing (SR) fits a
0.71-0.98 in. (18-25 mm) OD electrical cord.
1. Route cable through one of the cable grommets
(CG) in back of the InvisiPac electrical enclosure.
1. Turn the main power switch (H) OFF.
ON
2. Refer to the table and image below to connect flying
leads to the System I/O Board on AMZ #1.
H
OFF
NOTE: On 8-channel InvisiPac systems, an additional
System I/O board is included on AMZ #2. Do not wire the
dry contact input to the System I/O board on AMZ #2.
SR
CD
J10
WLD
+
2. Remove the electrical enclosure door (CD).
TR
3. Insert the electrical cord through the electrical
enclosure strain relief bushing (SR).
-
ti31251a
4. Attach insulated ferrules to the end of each wire.
Connect Accessories
5. Connect ground wire to the chassis ground.
See Accessories (starting on page 69) for additional
kits and installation instructions.
6. Connect power wires to the main power switch as
shown below.
Connect Electrical Cord
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 power at main switch
before disconnecting any cables and before
servicing equipment.
• This equipment must be grounded. Connect only
to grounded power source.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
• To reduce the risk of electric shock, perform the
previous Setup sections (beginning on page 9)
prior to connecting the electrical cord.
3A4938H
ti31214a
NOTE: Use a flat-head or Pozidriv screwdriver to
tighten terminals to at 7-10 in-lb (0.8-1.1 N•m).
7.
Tighten strain relief bushing (SR) around electrical cord.
8. Install the electrical enclosure door (CD).
19
Setup
Select ADM Settings
NOTE: The following steps involve the minimum ADM
settings required to startup the system. See Appendix
A - ADM on page 78 for detailed information.
1. Turn main power switch (H) on
.
To prevent fire and explosion, a qualified electrician
must determine the proper circuit breaker size to use
for the power supplied to the system.
4. On System Screen 2 - General Setup:
2. Once the ADM has finished starting up, press
to switch from the Operation screens to the Setup
screens. Use
,
between screens.
,
, and
to navigate
3. On System Screen 1 - Gun Setup:
a. Enter the main circuit breaker size used. This is
the circuit breaker in-line with main power supplied to the system (external to the system, provided by the end user).
a. Check the box in the “Installed” column for each
channel that has a heated hose and gun (applicator) installed.
b. Select the RTD type used on each installed gun
(applicator). Refer to the applicator manual for
details on RTD type selection.
NOTE: The system limits current draw on incoming
power lines based on the circuit breaker size
entered. The minimum value for the setting is 15 A,
and a larger circuit breaker will allow the system to
draw more power and reduce startup time (see
Startup Time on page 100). See Models on page
4for maximum system current draw.
5. On Advanced Screen 1 - Display Settings:
a. Set the display language, date and time.
20
3A4938H
Setup
6. On Advanced Screen 2 - Display Units:
8. Press
to switch from the Setup screens to the
Operation screens. Use
,
navigate between screens.
,
, and
to
9. On Targets Screen(s):
a. Set the temperature and mass units.
NOTE: Distance units are used by systems with
integrated pattern controller only.
7. If desired, set any remaining settings in the Setup
screens before returning to the Operations screens
in the following steps. These additional settings are
not required for basic system operation, but include
some useful functions. See Appendix A - ADM on
page 78 for detailed information about each setting.
3A4938H
10. Use
and
, or the number pad to enter the
melter, hose and applicator temperature setpoints.
21
Operation
Operation
6. Use pump air pressure regulator (PP) to adjust
pump air pressure to 0.
PP
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.
NOTE: See Appendix A – ADM on page 78 for detailed
ADM information.
WLD
NOTE: See Appendix B - USB Downloading on page
91 for detailed USB information.
NOTE: Feed system will not begin to feed pellets until
the system reaches operating temperature.
Overview
The system uses a vacuum transfer system (feed 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 and finally the
heated applicators. The applicator then briefly opens to
dispense the desired amount of adhesive.
Initial Startup and Prime
NOTE: All setup procedures must be completed prior to
initial startup. See Setup on page 9.
1. Direct the applicator into an appropriate waste container.
2. Verify the shaker inlet (K) is at the bottom of the
feed bin (AK).
3. Fill feed bin (AK) with hot melt adhesive pellets.
4. Turn main power switch (H) on
.
5. Open system air inlet ball valve (366).
366
WLD
22
To prevent fire and explosion, never exceed the
cleaning fluid’s rated temperature. If the system was
just flushed, residual cleaning fluid is still in the system until the system is primed with adhesive. Do not
raise temperature above cleaning fluid rated temperature until system is primed with adhesive.
7. On new systems only: A new system may have
residual oil in the melter from factory testing prior to
shipping. To prevent smoking, temporarily adjust
the melter temperature to 250°F (121°C). See
Appendix A – ADM on page 78 for details.
8. Press
to begin system warm-up.
NOTE: Once the system is up to temperature, the
pump will be activated automatically. However, the
pump will not start since there is no air pressure
supplied to the pump.
NOTE: Once the system is up to temperature, the
feed system will fill the melter will pellets.
9. On new systems only: After the system has reached
temperature and the melter is filled with pellets, set
the melter temperature to the desired temperature.
See Appendix A – ADM on page 78 for details.
10. Use pattern controller or manual triggering method
to open the applicators and keep them open. If system includes an InvisiPac pattern controller, see the
InvisiPac Pattern Controller manual for details on
purging using the ADM.
3A4938H
Operation
11. With the applicators open and the system up to temperature, slowly increase the pump air pressure
(PP) until the pump begins to run very slowly.
Approximately 20 psi (140 MPa, 1.4 bar) should be
sufficient.
NOTICE
To prevent damage to the pump due to pump cavitation, do not supply more than 20 psi (140 MPa, 1.4 bar)
air pressure to the pump until the system is fully
primed.
NOTE: Pump operation may be erratic below 20 psi
(140 MPa, 1.4 bar).
12. Continue running the pump until clean, air-free
material is dispensed from each applicator.
13. Once each applicator is fully primed, adjust pump to
desired pressure setting.
a. Adjust pump pressure to 20-100 psi (140-690
MPa, 1.4-6.9 bar).
b. Use pattern controller to repeatedly open and
close each applicator while inspecting the dispense pattern.
c.
Manual Refill
NOTE: Only use Manual Refill if the Automatic Refill
system is not functioning properly and cannot be fixed in
a timely manner. Perform service to the automatic feed
system as soon as possible to limit debris buildup on the
feed funnel.
It is recommended to maintain a minimum flow rate of
1.5 lb/hour to prevent material from melting within the
feed cap and funnel. If production rate is below 1.5
lb/hour or system sits at temperature without dispensing
for extended periods of time, use manual refilling with
caution. System flow rate can be monitored on the Diagnostic Screen (see Appendix A - ADM on page 78 for
details).
1. Navigate to System Screen 2 - General Setup and
select “Manual” from the “Refill Setting” dropdown
(see Appendix A – ADM on page 78 for details).
2. Remove the three bolts (87) shown below. Then
remove the top portion of the funnel (81).
87
81
Repeat until desired dispense pattern is
achieved.
Automatic Refill
3. Fill the funnel with adhesive pellets.
The system uses automatic refill by default. If the automatic refill system is unable to feed pellets to the system
and cannot be fixed immediately, Manual Refill can be
used.
STOP
To use automatic refill:
1. Verify feed system is connected (see Connect
Feed System, page 10).
2. Navigate to System Screen 2 - General Setup and
select “Auto” from the “Refill Setting” dropdown (see
Appendix A – ADM on page 78 for details).
3. System will automatically refill pellets into the melter
when adhesive level drops below the refill threshold.
NOTE: During the refill process, the feed solenoid is
turned on and off repeatedly to regulate the flow of
pellets. For each subsequent refill, the system
adjusts length of these air pulses to refill at an exact
rate each time.
4. Refill the funnel as needed to maintain the required
flow rate.
5. Prior to shutting off the system, dispense into a
waste container until the material level is down into
the melter core. This will ensure all melted pellets
re-melt when the system is re-heated.
4. A refill timeout alarm will appear on the ADM screen
if refill is unable to complete.
WLE
3A4938H
23
Operation
Dispense
NOTE: Only hot melt adhesive pellets can be used in
the InvisiPac system.
NOTE: While operating the system, the actual temperatures of the hose, applicator, and system melter are displayed on the Home screen.
1. If the system is empty or has air in the lines, perform
Initial Startup and Prime procedure on page 22.
2. If main power switch (H) is OFF, turn main power
switch ON
.
NOTE: The main power switch (H) should be left ON at
all times when using the Schedule function.
3. Prepare for dispensing:
a. Verify air inlet ball (AG) is open.
b. Check pump air pressure gauge (D) to verify
pressure is set as desired.
c.
If using Automatic Refill, see page 23.
Shutdown
d. If using Manual Refill, see page 23.
Press
e. Verify applicators are closed.
screen will say “Inactive”. If using the Schedule function,
the heaters and pump will be disabled automatically at
4. Press
to enable the heaters and pump.
NOTE: If using the Schedule function, the heaters and
pump will be enabled automatically at the set time. You
will not need to press
if using the Schedule func-
to disable the heaters and pump. The
the set time. You will not need to press
if using the
Schedule function unless you wish to disable the heating system before the set time. If the heaters were manually disabled, the Schedule function will automatically
enable them at the next set time.
tion unless you wish to enable the heating system
before the set time.
NOTE: When the 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 pattern
controller to open and close the applicators as
desired to dispense material.
Do not turn the main power switch (H) OFF if using the
Schedule function.
24
3A4938H
Operation
Schedule
The Schedule function allows the user to specify times
when the system will automatically turn the heaters and
pump ON and OFF.
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
Set Schedule Times
NOTE: Times are set using a 24-hour clock. Several on
and off times can be set each day.
1. On the Schedule screen (in the Setup screens), set
the ON times for each day of the week.
2. Set the OFF times for each day of the week.
Enable Schedule Function
The Schedule function is automatically enabled when
values are entered in the Schedule screen. To disable a
scheduled event, navigate to the event and press
The event will appear gray on the screen when it is disabled. To re-enable an event, navigate to the event and
press
. The event will appear red (system off) or
green (system on). If no events are needed, turn the
main power switch (H) OFF to prevent system from
automatically enabling and disabling the heaters.
How to Use the Schedule Function
1. Turn main power switch (H) OFF
.
2. Close the inlet air supply ball valve (AG).
Operation Tips to Maximize
Adhesive Life
Set Pump Idle Time to System Inactive to the lowest
value that will not interfere with normal operation (see
System Screen 2 – General Setup, page 84). This feature will automatically disable the heating system after
pump is idle for longer than the prescribed time. Disabling the heating system minimizes adhesive degradation.
Set melter, hose, and applicator 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 and
could lead to adhesive degradation in the hose.
At the end of the work day leave main power switch (H)
ON
. The Schedule function will automatically
enable and disable the heaters and pump at the specified times.
3A4938H
25
Maintenance
Maintenance
Replace Pump Outlet Filter
Task
Maintenance Interval
Inspect Funnel Filter
Replace Pump Outlet Filter
6-12 months
50,000 lb (25,000 kg) of
adhesive pumped
Rarely
Replace Pump Inlet Filter
To avoid severe burns, wear protective gloves and
clothing that will insulate your hands and body from
the hot surfaces and material.
The pump outlet filter prevents small contaminants from
entering hoses and applicators.
Inspect Funnel and Filter
1. Warm system to operating temperature.
The funnel (81) and filter (77) should be inspected periodically to ensure air exhaust and flow of pellets into the
melter is clear.
The filter (77) and upper portion of the funnel (81) can
be inspected without interrupting production. Replace or
clean the filter as needed. Use a flat blade screwdriver
to remove stray glue or pellets or buildup.
2. Perform Pressure Relief Procedure procedure,
page 25, but replace the pump outlet filter before
the system cools. Adhesive must be fluid to perform
this procedure.
3. Verify that the main power switch (H) to OFF.
4. Use a 1 in. socket to unscrew outlet filter (TF).
TF
81
77
WLD
Infrequently, buildup in the lower portion of the funnel
may need to be cleared. To do this, remove the three
screws (72), separating the top of the funnel (79, 80)
from the base (78). Use a flat blade screwdriver to
remove built up adhesive.
80
72
5. Insert an Allen wrench through the outlet filter cap to
lift the outlet filter (TF) out.
6. Place o-rings (provided with new filter) onto new
outlet filter (TF).
7. Place new outlet filter into melter housing and
tighten with a 1 in. socket.
79
78
26
3A4938H
Maintenance
Replace Pump Inlet Filter
2. Perform Pressure Relief Procedure procedure,
page 25.
The inlet filter is designed to prevent large items from
entering the systems.
3. Remove ADM and shrouding (331) from around the
melter.
4. Remove the thermal insulation (651) from the
melter.
To avoid severe burns, wear protective gloves and
clothing that will insulate your hands and body from
the hot surfaces and material.
1. Increase temperature gradually until adhesive softens to a gel-like state.
5. Use a 9/16 in. socket to remove the inlet filter plug
(FP).
6. Use o-ring pick or a small Allen wrench to remove
filter screen (FS). Repeat step 2 if adhesive is not
thin enough to remove.
7. Slide a new filter screen into melter manifold. Install
filter plug (FP) using a 9/16 in. socket.
651
WLD
FS
(17N323)
3A4938H
FP
(15H305)
331
27
Maintenance
Drain System
Flush
NOTE: The system must be drained prior to flushing
and prior to some maintenance and repair procedures.
1. Navigate to System Screen 2 - General Setup and
select “Manual” from the “Refill Setting” dropdown
menu (see Appendix A - ADM on page 78 for
details).
2. If the system is inactive, press
to enable the
heaters and pump.
3. Decrease pump air pressure (C) to 0.
4. Close system air inlet ball valve (AG).
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 (C) until fluid begins
flowing into the waste container.
NOTE: It may take several minutes to empty the system. When there is no melter fluid at the pump, the
pump will begin to cycle faster.
To prevent fire and explosion, use the adhesive
manufacturer’s recommended cleaning fluid.
• Never exceed the cleaning fluid’s rated temperature.
• Never flush your system or clean any aluminum
components with halogenated hydrocarbon
cleaning solution.
• To prevent severe burns, wear protective clothing.
See the hot melt adhesive technical data sheet or SDS
for the recommended cleaning fluid.
1. Perform Pressure Relief Procedure procedure,
page 25.
2. Perform Drain the System procedure, page 28.
3. Enter Manual Refill mode, page 23.
4. Remove the three bolts (87) shown below, then
remove the top portion of the funnel (81).
81
87
8. When the pump begins to cycle faster, close the
system air inlet ball valve (AG).
9. Press
to disable the heaters and pump.
10. Remove melter drain plug (640).
11. Disconnect hose from melter outlet.
12. Wait until system stops draining or at most 10 minutes.
NOTE: There will be some residual adhesive in the system.
13. When done draining the system, navigate to System Screen 2 - General Setup and set Refill Setting back to “Auto” (see Appendix A - ADM on page
78 for details).
28
WLE
3A4938H
Maintenance
8. Allow hot melt cleaning fluid to soak in the melter for
the duration specified by the cleaning fluid manufacturer.
To prevent fire and explosion, never exceed the
cleaning fluid’s rated temperature.
9. Disconnect hose(s) from the applicator manifold(s)
and route into a waste container.
5. Change temperature setpoints to the manufacturer’s recommended temperature for the cleaning
fluid. Allow all system zones to heat or cool to the
recommended setpoint.
10. Open air inlet ball valve (AG) and slowly increase
pressure to purge into the waste container.
6. Verify the system air inlet ball valve (AG) is closed
and pump air pressure is set to 0.
11. After flushing, set system back to Automatic Refill
mode (see page 23). Then perform Initial Startup
and Prime on page 22.
7. Fill melter with hot melt cleaning fluid. To avoid
overfill and spilling, do not fill above the metal portion of the melter.
WLE
3A4938H
29
Troubleshooting
Troubleshooting
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 power at main switch before disconnecting any cables and before servicing equipment.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
To avoid injury due to unexpected machine operation initiated by a remote controller, disconnect the customer I/O
cable from the system prior to troubleshooting.
NOTE: For the latest troubleshooting guidance, visit help.graco.com.
Error Codes
When an error occurs, press
to acknowledge the error. If a Maintenance error occurs, navigate to the
Maintenance screen (see Appendix A - ADM, page 78) and press the reset counter softkey
to clear the error.
NOTE: Some of the error codes listed can apply to multiple items and contain a lookup letter (denoted by a bold letter
in parentheses “()”). Use the following error code lookup tables to determine the specific source of an error.
InvisiPac System Error Code Lookup Tables
1
2
3
4
5
6
7
8
9
A
(Z)one
Channel 1 Gun (Applicator)
Channel 1 Hose
Channel 2 Gun (Applicator)
Channel 2 Hose
Channel 3 Gun (Applicator)
Channel 3 Hose
Channel 4 Gun (Applicator)
Channel 4 Hose
Channel 5 Gun (Applicator)
Channel 5 Hose
B
C
D
E
F
G
1
2
(Z)one
Channel 6 Gun (Applicator)
Channel 6 Hose
Channel 7 Gun (Applicator)
Channel 7 Hose
Channel 8 Gun (Applicator)
Channel 8 Hose
(M)odule
AMZ 1
AMZ 2
InvisiPac Pattern Controller Error Code Lookup Tables
1
2
3
4
5
6
7
8
30
(G)un
Pattern Control Gun 1 (Solenoid Valve)
Pattern Control Gun 2 (Solenoid Valve)
Pattern Control Gun 3 (Solenoid Valve)
Pattern Control Gun 4 (Solenoid Valve)
Pattern Control Gun 5 (Solenoid Valve)
Pattern Control Gun 6 (Solenoid Valve)
Pattern Control Gun 7 (Solenoid Valve)
Pattern Control Gun 8 (Solenoid Valve)
1
2
(L)ine
Pattern Control Line 1
Pattern Control Line 2
3A4938H
Troubleshooting
Alarms (shuts system down)
Code
Description
Cause
Solution
A2D0
Low Current Melter
Current through the melter heating One or more of the fuses in the fuse harness assembly
(does not shut down
rods is less than expected.
is blown. Remove short with corresponding melter heatsystem or melter zone)
ing rod and replace the fuse.
A40P*
High Current VPCM
Overcurrent on PCM circuit board
accessory power supply output
Check accessory cabling for short circuit. Unplug one
connection at a time.
A4(G)P*
High Current Gun
(PCM)
Overcurrent on valve output
Check valve wiring for short circuit.
High Current Melter
Melter heater rods
A4D0
Verify valve resistance is greater than 24 ohms.
Check resistance of melter heat rods.
Check for excessively high system line voltage.
A4D(Z)
High Current Gun
(AMZ)
Heater rods in gun manifold
High Current hose
Heater wires in hose
Swap with known good gun.
Refer to gun manual for nominal heater wire resistance.
Check resistance and replace hose if necessary.
Swap with known good hose.
Refer to hose manual for nominal heater wire resistance. Check resistance and replace hose if necessary.
A4FX
High current Fill Solenoid
Wiring shorted or fill solenoid draw- Check for damaged wiring.
ing excessive current
Verify fill solenoid connection to J6-FILL of AMZ circuit
board.
A4PX
High Current Pump
Solenoid
Wiring shorted or pump solenoid
drawing excessive current
Replace fill solenoid.
Check for damaged wiring.
Verify pump solenoid connection to J6-PUMP of AMZ
circuit board.
Verify solenoid resistance is 97 to 115 ohms.
Replace pump solenoid.
A4SX
High Current 24 VDC
Supply
Short in PLC I/O wiring
Unplug PLC I/O wiring from J8 of AMZ circuit board.
Check resistance from power to ground.
Short in Unit Counter wiring
Unplug unit counter from J10 of AMZ circuit board.
Check resistance from power to ground.
Verify solenoid resistance is 97 to 115 ohms.
Short in Level Sensor wiring
Unplug level sensor from J4 of AMZ circuit board.
Verify level sensor connection to J4 of AMZ circuit
board.
A4XP
High Current VCAN
Overcurrent on communication
cable output
Check CAN connection to P4 of PCM circuit board.
A7D0
Unexpected
Current Melter
Unexpected current to melter
Check for damaged wiring.
Check heater resistance to ground.
Replace faulty heater(s).
Replace AMZ circuit board.
3A4938H
31
Troubleshooting
Code
A7D(Z)
Description
Unexpected Current
Gun
Cause
Unexpected Current to gun
Solution
Swap in known good gun.
Swap in known good hose.
Check heater resistance to ground.
Replace AMZ circuit board.
Unexpected
Current Hose
Unexpected current to hose
Swap in known good hose.
Check for damaged wiring.
Check heater resistance to ground.
Replace AMZ circuit board.
A8D0
No Current Melter
No current melter
Check J24 is plugged into AMZ.
Check fuses FHA and FHB on AMZ.
A8D(Z)
No Current Gun
No current to gun
Swap in known good gun.
Swap in known good hose.
Check fuses on AMZ (F1 through F4).
Check for damaged wiring.
Check fro heater resistance.
No Current Hose
No current to hose
Swap in known good hose.
Check fuses on AMZ (F1 through F4).
Check for damaged wiring.
Check heater resistance.
CAC(M)
Comm. Error AMZ
System is unable to
communicate with AMZ
Check dial positions. Set AMZ 1 to position “1” and AMZ
2 to position “2”.
Verify CAN cable is plugged in. Remove and reconnect,
taking care not to cross-thread the connector nut.
Verify solid green LED and blinking yellow LED on
AMZ.
Perform Software Update procedure on page 94.
CACP*
Comm. Error PCM
System is unable to communicate
with PCM
Check dial position of PCM. Set to “0”.
Verify CAN cable is plugged in. Remove and reconnect,
taking care not to cross-thread the connector nut.
Verify solid green LED and blinking yellow LED on
AMZ.
Perform Software Update procedure on page 94.
CACX
Comm. Error SIOB
(System I/O Board)
System is unable to communicate
with SIOB
Verify solid green LED and blinking yellow LED on AMZ
System I/O board.
DADX*
Pump Runaway
Melter ran out of adhesive
Refill feed bin.
Reduce Adhesive flow rate.
Verify adhesive temperature setting.
See Fill System Verification on page 36.
K4(L)P
L6FX
32
High Pulse Rate Line
Level Sensor Error
Worn or damaged pump seals.
Inspect pump seals. Replace if necessary.
Encoder pulse rate exceeds maximum limit
Select encoder with lower pulse rate.
Level sensor is not reading within
expected range
Check connection to level sensor.
Reduce line speed or gearing ratio.
See Fill System Verification on page 36.
3A4938H
Troubleshooting
Code
L8FX*
Description
Refill Error
Cause
Adhesive refill timed out before
completing
Solution
Refill feed bin and inspect for bridging or blocking.
Check feed hose and wand for plugged material.
Verify sufficient air supply and pressure.
See Fill System Verification on page 36.
T4D0
High Temp. Melter
Melter temperature deviated above Check that RTD is fully seated in melter.
setpoint.
Verify overtemperature switch connection to J1-OT of
AMZ circuit board. Check continuity.
Replace RTD if fully seated and temperature on screen
is not stable.
T4D(Z)
High Temp. Gun
Gun temperature deviated above
setpoint
Turn on system without dispensing. Check if hose maintains stable setpoint temperature.
Check gun RTD.
Swap with known good gun.
High Temp. Hose
Hose temperature deviated above
setpoint
Turn on system without dispensing. Check if hose maintains stable setpoint temperature.
Verify melter temperature setting is not set above hose.
Swap with known good hose.
T4MX
T6D0
High Temp.
Transformer
Transformer thermistor reading
above 212° F (100° C)
Verify transformer fan is free of obstructions.
Sensor Error Melter
No reading from melter RTD
Verify RTD connection to J1-RTD1 on AMZ circuit
board.
Fan only spins when transformer is warm, and for a 5
second check each time electrical power is cycled.
Check RTD for continuity.
Replace RTD.
T6D(Z)
Sensor Error Gun
No reading from gun RTD
Verify hose and gun connections.
Swap with known good gun.
Sensor Error Hose
No reading from hose RTD
Verify hose connection.
Swap with known good hose.
T6MX
Sensor Error
Transformer
No reading from transformer therm- Verify sensor connection to J2 on AMZ circuit board.
istor
Check wiring for damage.
T8D0
No Temp. Rise Melter
Melter temperature reading does
not increase toward setpoint.
Check that RTD is installed in melter.
Compare temperature displayed on screen vs
temperature of melter.
Replace RTD.
T8D(Z)
No Temp. Rise Gun
Applicator temperature reading
Verify gun is not wet.
does not increase toward setpoint.
Swap with known good gun.
Check heater rod(s) in gun for proper resistance.
No Temp. Rise Hose
Hose temperature reading does not Verify hose is not wet.
increase toward setpoint.
Swap with known good hose.
V4M(M)
High Line Voltage AMZ Refer to AMZ Input Power Verification section on page 36.
V6M(M)
Invalid Power Type
AMZ
Refer to AMZ Input Power Verification section on page 36.
* Alarm turns off the pump, but system will remain at temperature.
3A4938H
33
Troubleshooting
Advisories and Deviations (does not shut the system down)
Problem
A4MF
Description
High Current
Transformer Fan
A8FX
No Current
Fill Solenoid
Cause
Excessive current draw above
600mA
Solution
Check for pinched or shorted fan
wiring.
Replace fan.
Refer to Fill System Verification section on page 36.
Check for damaged wiring.
Verify connection from fill solenoid to J6-FILL on AMZ circuit board.
A8MF
A8PX
No Current
Transformer Fan
Verify solenoid resistance is 97 to 115 ohms.
Fan is not connected or is
Verify fan power cable is connected to J2 on
blocked from spinning
AMZ circuit board.
No Current Pump
Solenoid
Verify fan is free of obstructions and can spin
freely.
Pump solenoid is connected to Check for damaged wiring.
AMZ
Verify connection from pump solenoid to
J6-PUMP on AMZ circuit board.
B2AX
Low Glue per Unit
Adhesive pressure is too low
Glue per until target needs to
be reset
B3AX
High Glue per Unit
Gun module filter may be
restricting flow
Adhesive pressure too high
Glue per unit target needs to
be reset
DDDX
Pump Diving
Nozzle size was increased
Melter ran out of adhesive
Verify solenoid resistance is 97 to 115 ohms.
Check if pump pressure has been reduced
from desired level.
Navigate to material tracking page from
home screen and press the gauge softkey to
reset target setting.
Replace gun module filter.
Check if pump pressure as been increased
from desired level.
Navigate to material tracking page from
home screen and press the gauge softkey to
reset target setting.
Check if desired nozzle size is installed.
Refill feed bin.
Reduce adhesive flow rate.
Verify adhesive temperature setting.
DE0X
Cycle Switch Error
EVUX
USB Disabled
K1(L)P
Low Line Speed
L0FX
Manual Fill Mode
34
See Fill System Verification on page 36.
Worn or damaged pump seals Inspect pump seals. Replace if necessary.
No signal from cycle switch
Verify connection from cycle switch to J5 on
AMZ.
Replace cycle switch.
Enable USB logging. See Appendix A ADM, page 78.
Poor encoder coupling on line Check to ensure proper coupling between
line and encoder.
Line speed is less than low line Increase line speed or decrease low line
speed advisory level
speed advisory level.
System is operating in manual Change to auto fill mode in System Setup
fill mode
screen 2.
USB logging disabled
3A4938H
Troubleshooting
Problem
L3FX
Description
Slow Refill
MMUX
USB Logs Full
MND(X)
Pump maintenance
due
T2D(Z)
Low Temp Gun
V20P
V30P
V2M(M)
V2XP
V3XP
3A4938H
Cause
Refills are taking longer than
expected and may soon result
in failure to fill
USB logs full - data loss will
occur if data is no downloaded
Pump maintenance is due
according to the user-defined
settings for pump cycles, material dispensed, or time while
hot.
Gun deviated below setpoint.
Solution
See Fill System Verification on page 36.
Download USB data. See Appendix B USB Downloading, Uploading on page 91.
Perform maintenance and reset “Due”
counter to 0 at the Setup Maintenance
screen.
Turn on system without dispensing. Check if
gun maintains stable setpoint temperature.
Check gun RTD. Swap with a known properly functioning gun.
Low Temp Hose
Hose deviated below setpoint. Turn on system without dispensing. Verify
melter temperature setting is not higher than
hose setting. Check if hose maintains stable
setpoint temperature. Swap with a known
properly functioning hose.
Low Temp Melter
Melter deviated below setpoint. Check that RTD us fully seated in melter.
Replace RTD if fully seated and temperature
on screen is not stable.
Low Voltage VPCM
PCM supply voltage below 18 Check connection and supplied voltage to
VDC
P1 of PCM circuit board.
High Voltage VPCM
PCM supply voltage above 28 Check connection and supplied voltage to
VDC
P1 of PCM circuit board.
Low Line Voltage AMZ Refer to verification section AMZ Input Power Verification
section on page 36.
Low Voltage
System power supply voltage Check power supply voltage to J3 of AMZ
24 VDC PCM
below 18 VDC
circuit board.
High Voltage
System power supply voltage Check power supply voltage to J3 of AMZ
24 VDC PCM
above 28 VDC
circuit board
35
Troubleshooting
Fill System Verification
Input Power Verification
1. Check air filter by removing quick turn cap on top of
funnel. Clean or replace if needed.
1. Verify that the wires are tightly secured into the
electrical disconnect.
2. Remove top section of funnel and inspect. Remove
stuck debris if needed. Ensure level sensor sight
tube is clear of debris.
2. Confirm wiring matches label on electrical disconnect.
3. Verify air supply to system is strong and between 50
and 100 psi (80 to 100 psi preferred).
4. Verify level sensor readings on diagnostic screen
are consistent and slowly increase as material is
dispensed.
5. Inspect air line and vacuum tubing to feed bin. Dips
or kinks in the vacuum tubing can lead to a blocked
flow path.
3. Measure incoming line voltage. For a transformer
system, also measure transformer output voltage at
the terminal block.
4. Verify power connections to J22 on the AMZ circuit
board are fully seated.
5. Check internal wiring against Electrical Schematics, starting on page 50.
6. Check number of pump cycles in between refills (8
to 10 cycles is desired). Short fills of 3 or fewer
cycles can be caused by clogged funnel filter or
debris in funnel.
7. Monitor pellet flow and time to refill. Refills in excess
of 15 seconds can be caused by low adhesive level
in feed bin, insufficient air pressure, restricted feed
hose, or clogged funnel filter.
8. Verify size and shape of adhesive being fed is compatible with feed system and that melt rate ability is
not exceeded.
9. Check if glue is excessively dusty or releases oily
vapor when heated. Fill system maintenance will be
minimal given typical glue selection.
36
3A4938H
Repair
Repair
NOTE: Some procedures require special tools. Read
through each procedure prior to beginning it to ensure
that you have the required tools to complete the entire
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.
3. Disconnect the cable on fill sensor (20) from the
machine and pull the cable through the top of the
sensor housing (73).
4. Unscrew the fill sensor (20) and remove it from the
housing (73).
5. Thread the new fill sensor (20) into the housing (73).
6. Reconnect the fill sensor cable, filter and filter cover
(68).
Replace the Cycle Switch
1. Turn the main power switch OFF.
System
2. Disconnect the cable from the cycle switch (59a).
3. Use a screwdriver to remove screw (59c).
4. Remove cycle switch (59a) from the motor.
Replace the Fill Sensor
5. Replace new cycle switch and tighten screw (59c).
Torque to 7-10 in-lb (0.7-1.0 N•m).
6. Reconnect the cycle switch cable.
68
5
20
59b
59a
59c
73
WLD
WLD
1. Turn the main power switch (H) OFF.
2. Remove the filter cover (68) and filter element.
3A4938H
37
Repair
Air Controls
c.
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 power at main switch
before disconnecting any cables and before servicing equipment.
To install a new regulator, perform steps 1 and
2 in reverse.
515
507
525
515
Replace the Air Control Solenoid and Pump
Regulator
507
1. Perform the Pressure Relief Procedure on page 25.
524
WLD
2. Close the bleed-type ball valve installed at the system air inlet to relieve all air pressure in the system.
3. Use a 3/8 in. socket to remove six screws (336)
from the air control cover and electrical enclosure
front access panel.
4. Remove the air control cover (330) to access the air
control panel. Remove the electrical enclosure front
access panel (EFP) (only required if replacing the
solenoid).
502
6. Replace the Solenoid:
a. Disconnect the air tubing from the solenoid
(507) to be replaced.
b. Inside the electrical enclosure, disconnect the
air control electrical connector from the AMZ
daughter board and remove the leads for the
solenoid to be replaced.
c.
Use a 5/16 in. socket to remove two nuts (515)
and remove solenoid (507).
d. Pull the solenoid leads out through the grommet
in the top of the air control panel.
336
e. To install the new solenoid, perform steps 1
through 4 in reverse.
330
EFP
Air
WLD
5. Replace the Pump Air Regulator and Gauge:
a. Disconnect the air tubing from regulator (502)
and remove panel nut (524).
b. Remove the regulator from the panel.
38
3A4938H
Repair
Melter
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 power at main switch
before disconnecting any cables and before servicing equipment.
BURN HAZARD
Equipment surfaces and fluid that is heated can
become very hot during operation. To avoid severe
burns, wear protective equipment and do not touch hot
fluid or equipment.
Replace the Temperature Sensor
1. Turn the main power switch OFF.
2. Remove the electrical enclosure door (332) and
remove the melter control connector from AMZ #1
daughter board.
3. Remove the temperature sensor (RTD) leads from
the connector as shown. See Electrical Schematics on page 50.
4. Use a 3/8 in. socket to remove four screws (336)
from melter shroud (331) and remove shroud.
5. Remove screw (RS) retaining the temperature sensor (RTD) and remove the sensor from the melter
manifold.
6. Pull the leads through grommet (13) in the side of
the electrical enclosure.
7. Replace the new temperature sensor (RTD) and
thread in retaining screw (RS). Torque to 7-10 in-lb
(0.7-1.0 N•m).
8. Insert sensor leads into the side of the electrical
enclosure through grommet (13).
9. Tighten the temperature sensor leads into the connector as shown. Reconnect the connector back into
AMZ #1. See Electrical Schematics on page 50.
13
RTD
332
RS
331
336
WLD
19
20
3A4938H
39
Repair
Replace the Overtemperature Switch
Remove the Melter from the System
1. Turn the main power switch (H) OFF.
2. Use a 3/8 in. socket to remove four screws (336)
from melter shroud (331), then remove the shroud.
3. Remove the spade connectors from the over-temperature switch (20).
4. Use a screwdriver to remove two screws (19) retaining the over-temperature switch (20).
5. Replace the spade connectors from the over-temperature switch cable onto the new switch (20).
6. Replace the over-temperature switch (20) and
retaining screws (19). Torque to 7-10 in-lb (0.7-1.0
N•m).
7. Replace melter shroud (331) and screws (336).
1. Perform the Pressure Relief Procedure on page 25.
2. Use a 3/8 in. socket to remove four screws (336)
from the melter shroud (331), then remove the
shroud.
3. Use a 7/16 socket to remove two nuts (30) and a 3/8
in. socket to remove screw (31) from the melter rear
cover (21).
4. Disconnect the pump supply air tube (95a) from the
air motor air inlet fitting (659).
5. Disconnect the cycle switch cable from cycle switch
(59).
6. Disconnect the level sensor cable from level sensor
(54).
59
54
659
74
95a
336
31
WLD
21
30
40
3A4938H
Repair
7. Disconnect the level sensor cooling air tube from
5/32 in. push-to-connect fitting (74).
12. Pull the temperature sensor, over-temperature
switch, and heater leads through grommet (13) in
the side of the electrical enclosure.
13. Use a 7/16 in. socket to remove four nuts (30) from
the melter base plate.
14. Grasp the air motor to lift and rotate the melter
assembly off from the system base.
74
54
59
659
8. Remove the electrical enclosure door (332) and
remove the melter control connector from AMZ #1
daughter board.
9. Remove the temperature sensor (RTD) and
over-temperature switch leads from the connector
as shown. See Electrical Schematics on page 50.
10. Remove the melter and pump heater connector
from AMZ #1 as shown.
11. Remove the melt heater leads from the connector.
See Electrical Schematics on page 50.
3A4938H
WLD
41
Repair
Reassemble the Melter Onto the System
5. Replace electrical enclosure door (332).
6. Reconnect the level sensor cooling air tube from
5/32 in. push-to-connect fitting (74).
1. Perform the Pressure Relief Procedure on page 25.
2. Locate the melter on the system base and fasten
four nuts (30). See Parts on page 57.
3. Insert the temperature sensor, over-temperature
switch, and heater leads through grommet (13) in
the side of the electrical enclosure.
4. Reconnect the temperature sensor (RTD),
over-temperature switch (OT), and heater leads into
the connectors for AMZ #1 as shown. See Electrical Schematics on page 50.
Item
42
7. Reconnect the cable from the enclosure to the level
sensor (54).
8. Reconnect the cable from the enclosure to the cycle
switch (59).
9. Reconnect pump supply air tube (95a) to the air
motor air inlet fitting (659).
10. Fasten melter rear cover (21) with two nuts (30) and
screw (31).
11. Reattach melter shroud (331) with four screws
(336).
Heater Rod Wire Marking
AMZ Connector Marking
Pump Heater Rod 1
J24-1 (2 wires)
J24-1 (2 terminals)
Pump Heater Rod 2
J24-2 (2 wires)
J24-2 (2 terminals)
Melter Heater Rod 1
J24-3 (2 wires)
J24-3 (2 terminals)
Melter Heater Rod 2
J24-4 (2 wires)
J24-4 (2 terminals)
3A4938H
Repair
Pump
6. Use a 5/32 Allen wrench to remove the two insulation fasteners (652) closest to the relief valve.
Replace the Fluid Pressure Relief Valve
7. Roll the meter insulation (651) back past the relief
valve. This will prevent fluid from soaking it during
repair.
2. Perform the Pressure Relief Procedure on page 25.
8. Place a rag or cloth between the melter and melter
base plate beneath the relief valve to catch any
fluid.
3. Remove the melter shroud and rear cover. Follow
steps 1-9 of Remove the Air Motor, page 44.
9. Use a 1-7/16 in. socket or box wrench to remove
relief valve (642) from the melter.
1. Flush the system, see page 28.
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.
4. Use a 7/16 socket to remove four nuts (30) from the
melter base plate. Rotate the melter to gain clear
access to the pressure relief valve.
5. Disconnect air tube (95b) leading from the air motor
inlet fitting to the pressure relief valve (642).
10. Replace the pressure relief valve and wipe away
any fluid from the side of the melter.
11. Roll the melter insulation (651) back around the
melter and secure with insulation fasteners (652).
12. Reconnect air tube (95b) to relief valve and air
motor inlet fitting.
13. Rotate the melter back into place on mounting
studs. Secure the melter base plate with nuts (30).
14. Replace the melter rear cover and shroud.
651
84
331
95b
336
642
30
3A4938H
WLD
652
WL[[[[D
43
Repair
Remove the Air Motor
1. Perform the Pressure Relief Procedure on page 25.
2. Use a 3/8 in. socket to remove four screws (336)
from melter shroud (331), then remove the shroud.
3. Use a screwdriver to remove screw (84) from the
funnel motor support bracket. This will allow
removal of the funnel from the melter.
4. Use a 7/16 in. socket to remove two nuts (30) and a
3/8 in. socket to remove screw (31) from the melter
rear cover (21).
5. Use a 7/16 in. socket to remove two nuts (30) from
the funnel standoffs and remove funnel from the
melter.
6. Disconnect air tubes (95a, 95b) from the air motor
air inlet fitting (659).
7. Slide retaining ring (604) up the shaft of the air
motor and slide pump connecting pin (603) from the
motor and pump shafts.
8. Use a 1/4 Allen wrench to remove three screws
(605) from the air motor mounting plate (606) and lift
air motor (601) off of the melter.
601
59
95b
30
659
82
604
602
603
95a
605 606
607
336
21
WLD
31
30
44
3A4938H
Repair
Replace the Air Motor
1. Use a 1/4 in. Allen wrench to remove three screws
(607) from the bottom of the air motor mounting
plate (606), then remove the mounting plate.
2. Remove tie rods (602) from air motor (601).
3. Use a 13 mm socket to remove screw (83) holding
the funnel motor support bracket (82) from the air
motor.
4. Remove cycle switch (59). Perform Remove the
Cycle Switch procedure, page 37.
5. Slide retaining o-ring (604) off of old motor shaft and
onto new air motor.
Remove the Pump Rod, Throat Seal, and
Bearing
1. Perform the Flush procedure on page 28.
2. Perform Remove the Air Motor on page 44.
3. Use a screwdriver and rubber mallet to break loose
retaining nut (608).
4. Remove retaining nut (608) from the pump throat.
5. Insert an Allen wrench through the hole in the top of
piston rod (PR) to lift the pump rod assembly, throat
seal, and bearing out of the pump.
608
6. Reinstall cycle switch (59) and the funnel motor support bracket (82) on the new air motor.
609
610
7. Reinstall tie rods (602) into the motor mounting
plate (606) and tighten screws (607).
8. Place the air motor back onto the melter.
PR
9. Slide pump connecting pin (603) through the motor
and pump shaft. The motor shaft may need to be
manually raised, lowered, or rotated to the correct
position.
10. Slide retaining o-ring (604) into place over the connecting pin.
11. Reinstall screws (605) to secure the air motor onto
the melter.
12. Replace the funnel assembly, melter rear panel,
and melter shroud.
3A4938H
WLD
45
Repair
Replace the Pump Rod, Throat Seal, and Bearing
1. To protect seals from threads, place seal installation
tool 15B661 into the throat bore.
2. Push the piston rod assembly (PR) into the pump.
3. Grease throat seal (610) and slide over the piston
rod with the lips facing down.
4. Place a 7/8 in. deep-well socket (3/8 in. drive) over
the piston rod and use a rubber mallet to gently tap
throat seal (610) into place.
15B661
5. Slide throat bearing (609) over piston rod. Use a
socket and mallet to press the throat bearing into
place.
6. Remove the seal installation tool 15B661.
7. Install retaining nut (608).
8. To reassemble the air motor onto the pump. See
Replace the Air Motor on page 45.
610
WLD
46
3A4938H
Repair
Replace the Pump Inlet Housing Check and Cylinder Seals
6. Use a 1/2 in. square-drive ratchet (without socket) to
remove pump inlet housing (625) from the melter.
7. Remove and discard inlet seat (622) and o-ring
(623) and inlet check ball (621).
Replace the Pump Inlet Housing Check
8. Install new o-rings (626) and (624) onto the inlet
housing.
1. Flush the system, see page 28.
2. Perform the Pressure Relief Procedure on page 25.
3. Remove the melter by following the Remove the
Melter from the System procedure on page 40.
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.
4. Turn the melter onto its side. NOTE: Do not rest the
melter on its over-temperature switch.
5. Use a 3/8 in. socket to remove four screws (627)
and lift the melter base plate from the melter. Retain
thermal insulators (628) for reassembly.
9. Install new o-ring (623) in the housing underneath
new seat (622) and ball (621).
10. Remove and discard inlet housing o-rings (626,
624).
11. Apply grease to all seals before reassembling.
12. Reinstall the new pump inlet housing and checks.
13. Apply a small amount o f grease to insulators (628)
and place into holes in the melter base plate. The
grease will hold them in place during assembly.
Take care not to grease the heater leads.
14. Line up the melter base plate and tighten screws
(627).
15. Reassemble the melter onto the system by following
the Reassemble the Melter Onto the System on
page 42.
628
WLD
627
617
621
618
620
623
626
625
622
624
3A4938H
47
Repair
Replace the Pump Cylinder Seals
1. Perform Flush procedure on page 28.
2. Perform the Pressure Relief Procedure on page 25.
3. Perform the Remove the Melter from the System
procedure on page 40.
7. Install new o-rings (617) onto cylinder and apply
grease.
8. Place the cylinder female installation tool (1302) into
the pump inlet bore to protect the seals.
9. Use the male installation tool (1303) to gently press
the cylinder into the melter.
4. Remove the pump rod (see on page 45).
5. Insert the cylinder removal tool (1301) into the pump
throat.
6. Gently tap the cylinder removal tool with a rubber
mallet to remove cylinder (618). Discard o-rings
(617).
10. Reinstall the pump inlet housing following steps
11-16 of the Replace the Pump Inlet Housing
Check procedure on page 47.
1301
617
618
617
1303
1302
48
WLD
3A4938H
Repair
Heaters
Replace the Melter and Pump Heaters
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 power at main switch
before disconnecting any cables and before servicing equipment.
1. Perform the Pressure Relief Procedure on page 25.
2. Use a 3/8 in. socket to remove four screws (336)
from melter shroud (331), then remove the shroud.
3. Perform the Remove the Melter from the System
procedure on page 40.
4. Verify the resistance of the heater. Each heater
should have a resistance of 52-64 ohms.
NOTE: The heater connector must be removed
from AMZ #1 when verifying resistance. If checking
resistance with the connector plugged in, the heaters should have a parallel resistance value of 26-32
ohms.
7. Use a 3/8 in. socket to remove four screws (627)
and lift the melter base plate from the melter. Retain
the thermal insulators (628) for reassembly.
8. Remove retaining rings (631) and slide the heater
(632) out of the housing bore. NOTE: The heater
may become seized into the housing due to thermal
cycling. The heater may be removed more easily
with the system at a safe warm temperature below
the melting point of the glue. If removal is not possible, melter manifold kit 17S258 includes the two
pump heaters pre-installed.
9. After installing the new heater rod(s), replace retaining ring(s) (631) and thread the leads through grommets (639) in the melter base plate.
10. Apply a small amount of grease to insulators (628)
and place into holes in the melter base plate. The
grease will hold them in place during assembly. Do
NOT grease the heater leads.
11. Line up the melter base plate and tighten screws
(627).
12. Perform the Reassemble the Melter onto the
System procedure on page 42.
Item
Heater Rod Wire
Marking
AMZ Connector
Marking
Pump Heater
Rod 1
J24-1 (2 wires)
J24-1 (2 terminals)
5. If the heater needs to be replaced, follow steps 6-8,
otherwise proceed to step 9. Repair kit 17P347
includes four heaters with identification labels
attached.
Pump Heater
Rod 2
J24-2 (2 wires)
J24-2 (2 terminals)
Melter Heater
Rod 1
J24-3 (2 wires)
J24-3 (2 terminals)
6. Turn the melter onto its side. NOTE: Do not rest the
melter on its over-temperature switch.
Melter Heater
Rod 2
J24-4 (2 wires)
J24-4 (2 terminals)
632
631
628
627
WLD
639
3A4938H
49
Repair
Replace Electrical Component(s)
2. Remove electrical enclosure door (332)
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 power at main switch
before disconnecting any cables and before servicing equipment.
3. Use a non-conductive fuse puller tool to remove the
blown fuse.
NOTICE
Using an improper tool, such as a screwdriver or pliers
may break fuse or cause damage to board.
NOTE: Fuses FHA and FHB are not replaceable. If
FHA or FHB fuses are blown, order AMZ Replacement Kit, 25M525.
4. Install a new fuse into the empty fuse holder.
Replace Auto Multi-Zone (AMZ) Fuse(s)
5. Install electrical enclosure door (332).
Replace Auto Multi-Zone (AMZ)
(('
++
+
WLD
%
06
$0=
06
1. Turn the main power switch (H) OFF.
NOTICE
To prevent system damage, always use fast acting
fuses. Fast acting fuses are required for short-circuit
protection.
Fuse
Part
Identification
F1A-F4B
129346
250VAC, 12.5A, fast acting
FHA-FHB
-----
250VAC, 25A
2. Remove electrical enclosure door (EED).
3. Remove AMZ:
a. Disconnect heated hose electrical connections
(HH) from the back of the AMZ.
b. Disconnect cables from the AMZ on the inside
of the electrical enclosure (B).
c.
1. Turn main power switch (H) OFF.
50
$0=
Remove the four screws (MS) used to mount
the AMZ to the back of the electrical enclosure
(B) and remove the AMZ.
3A4938H
Repair
Replace the Pattern Control Module (PCM)
4. Insert the new AMZ:
a. Set the AMZ dial position according to the
image below.
1. Turn the main power switch (H) OFF.
2. Remove the electrical enclosure door (332). See
Parts on page 57.
3. Disconnect cables from PCM (309).
AMZ 1
(Channels 1-4)
4. Remove four mounting screws (304) and remove
PCM (309).
5. Install the new PCM (309) on the bottom of electrical enclosure (B) using four mounting screws (304)
removed in the previous step.
6. Connect the cables removed previously to the new
PCM (309).
AMZ 2
(Channels 5-8)
b. Mount the AMZ to the back of the electrical
enclosure (B) using the four screws (MS)
removed from the original AMZ.
c.
Reconnect the cables on the inside of the electrical enclosure (B) to the AMZ. See Electrical
Schematics on page 52 for connections.
d. Reconnect the heated hose electrical connections (HH) to the back AMZ.
5. Replace the electrical enclosure door (EED).
Replace Advanced Display Module (ADM)
NOTICE
The ADM stores useful lifetime and diagnostic data that
will be lost when it is replaced. To keep this data, perform a USB download prior to replacing the ADM.
1. Turn the main power switch (H) OFF.
7. Install electrical enclosure door (332).
Replace the Power Supply
1. Turn the main power switch (H) OFF.
2. Remove electrical enclosure door (332). See Parts
on page 57.
3. Disconnect power supply cables from AMZ 1 (headers J3 and J21).
4. Remove the power supply (5) from electrical enclosure (B) by removing the four mounting nuts (29)
used to mount the power supply (5) to the top of the
electrical enclosure (B).
5. Disconnect power supply cables from J3 and J21
plugs.
6. Make connections between new power supply
cables and J3 and J21 plugs. See Electrical Schematics on page 52 for connections.
2. Disconnect cable (103) from the bottom of the ADM.
7. Mount the new power supply (5) to the top of the
electrical enclosure (B) using the previously
removed four mounting nuts (29).
3. Remove ADM (335) from bracket (334). See Parts
on page 57.
8. Connect power supply cables AMZ 1 (headers J3
and J21).
4. Install new ADM (335) into bracket (334).
9. Install electrical enclosure door (332).
5. Connect cable (103) to the bottom of new ADM
(335).
3A4938H
51
Electrical Schematics
Electrical Schematics
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 power at main switch before disconnecting any cables and before servicing equipment.
• This equipment must be grounded. Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
Common Schematic (all systems)
1
H1
H2
129197
W1
W2
W3
W4
GND
H3
H4
FAN+
FANTEMP
TEMP
AMZ #1
J22
GND
RTD
17M295
θ
17M487
129537
1
2
3
4
5
6
7
8
HEATER
RODS
POWER
SUPPLY
127887
128116
J24
18B072
1
2
3
4
5
6
7
8
J1
OT
OT
RTD1
RTD1
RTD2
RTD2
PE
7
6
5
4
3
2
1
PUMP 1
PUMP 1
PUMP 2
PUMP 2
MELTER 3
MELTER 3
MELTER 4
MELTER 4
1
2
3
4
5
6
7
8
MELTER FUSE
HARNESS ASSEMBLY
L
N
GND
129192
J21
3
2
1
L
N
GND
129542
VCAN
GND
3
J3
24V IN +
24V IN 24V OUT +
24V OUT -
1
2
3
4
+
AI 1
AI 2
LEVEL SENSOR
+
AI 1
AI 2
AI 3
+
AI 4
CYCLE SWITCH
AI 3
+
AI 4
24R885
17M274
AIR CONTROLS
J6
FILL
FILL
PUMP
PUMP
129869
17R646
J5
W1
W2
W3
W4
GND
117666
OVERTEMP
126780
SWITCH
J4
4
3
2
1
CH1
25C468
A-M
CH2
A-M
4
CH3
A-M
25C450
ADM
CH4
A-M
VCAN +
VCAN CAN H
CAN L
GND
J2
FAN+
FANTEMP
TEMP
J12
VCAN +
VCAN CAN H
CAN L
GND
VCAN +
VCAN CAN H
CAN L
GND
2
5
1
1 2 3 4 5
6
J23
VCAN +
VCAN CAN H
CAN L
GND
VCAN +
VCAN CAN H
CAN L
GND
CAN
CABLE
121000
ti31241a
25M525
1
2
3
52
See Incoming Power, page 53.
4
See Typical Hose/Applicator Wiring, page 55.
Fan connector not present on all systems.
5
See Pattern Controller, page 55 and 8-Channel Systems, page 54.
6
Optional light tower accessory.
See Pattern Controller, page 55.
3A4938H
Electrical Schematics
Incoming Power
25C700, 25C701
25C702, 25C703
(240V, 8 CHANNEL SYSTEMS)
(240V, 4 CHANNEL SYSTEMS)
17M491
17M280
H1
H1
W1
W2
W3
W4
GND
H2
H3
H4
W1
W2
W3
W4
GND
H2
H3
2
H4
GND
W1
W2
W3
W4
GND
GND
2
3
ti31242a
25C722, 25C723
25C720, 25C721
(480V, 4 CHANNEL SYSTEMS)
(480V, 8 CHANNEL SYSTEMS)
FAN+
FAN+
FAN+
FANTEMP
TEMP
FANTEMP
1
TEMP
TEMP
H1
H2
H3
H4
H1
X1
H2
X2
H3
X3
TEMP
129337
17M280
H1
W1
W2
W3
W4
GND
H2
H3
H4
H1
X1
H2
X2
H3
X3
2
GND
FAN+
FANTEMP
TEMP
FAN-
GND
129337
17M491
1
2
W1
W2
W3
W4
GND
W1
W2
W3
W4
GND
3
1
2
3
Connects to AMZ #1 - J2.
Connects to AMZ #1 - J22.
Connects to AMZ #2 - J22.
3A4938H
53
Electrical Schematics
8 Channel Systems (25C702, 25C703, 25C722, 25C723)
AMZ #2
CH5
A-M
CH6
A-M
2
CH7
A-M
CH8
A-M
J12
VCAN +
VCAN CAN H
CAN L
GND
1
J22
W1
W2
W3
W4
GND
W1
W2
W3
W4
GND
2
3
4
54
CAN
CABLE
121000
VCAN +
VCAN CAN H
CAN L
GND
3
J23
VCAN +
VCAN CAN H
CAN L
GND
25M525
1
VCAN +
VCAN CAN H
CAN L
GND
4
ti31241a
See Incoming Power, page 53.
See Typical Hose/Applicator Wiring, page 55.
Connected to AMZ #1 - J12.
See Pattern Controller, page 55.
3A4938H
Electrical Schematics
Pattern Controller
PCM
P1
1
24V OUT +
24V OUT -
+24VDC
- GND
PE
+24VDC
- GND
PE
ti31244a
P4
VCAN +
VCAN CAN H
CAN L
GND
CAN
CABLE
VCAN +
VCAN CAN H
CAN L
GND
121000
VCAN +
VCAN CAN H
CAN L
GND
2
17E019
1
Connects to “24V Out+” and “24V Out -” on AMZ #1 - J3.
2
4 Channel systems (25C701, 25C721): Connects to AMZ #1 - J12.
8 channel system (25C703, 25C723): Connects to AMZ #2 - J23.
Typical Hose/Applicator Wiring
A
APPLICATOR HEATER & OVERTEMP
θ
B
HOSE HEATER
C
D
1
E
F
GND
HOSE OVERTEMP
θ
APPLICATOR RTD
G
H
J
K
L
M
1
HOSE RTD
ti31245a
Connects to Ch1-4 on AMZ #1 and Ch5-8 on AMZ #2.
3A4938H
55
Air Control Schematic
Air Control Schematic
Feed
Solenoid
Line Air
Ball Valve
Air Filter
ti31247a
56
Feed System
Pump Air
Pressure
Gauge
Safety Valve,
Blow Off
Air
Regulator
Pump
Solenoid
Air
Restrictor
Pump Fluid
Pressure
Relief Valve
Pump
Level
Sensor Air
3A4938H
Parts
Parts
Common System Parts
1
WLE
D
E
F
E
D
3A4938H
57
Parts
Common System Parts List
Ref.
1
2
3
4
5
Part
25C364
26A262
25C468
25A989
127887
7
10
11
12
13
19
20
21
117666
126881
126891
114421
121487
126780
107388
17R874
27
29
30
31
35
36
38
40
41
125856
109466
115942
113161
17M487
17M295
17M274
121000
129192
49
54
56
57
58
59
60
129598
129869
127138
102360
127110
24X220
129542
62
128116
63
129539
64
129541
65
129537
67
129538
71
72
58
123967
15A834
Description
Qty.
ENCLOSURE, electrical, painted
1
PUMP, melter /w motor, gen 3
1
CONTROL, air, assembly
1
MODULE, GCA, mzlp4 w db
1
POWER SUPPLY, 24DC, 6.3a,
1
151.2 W
TERMINAL, ground
1
BUSHING, strain relief
1
NUT, bushing
1
BUSHING, strain relief
2
GROMMET, sheet metal, 3/4 in.
4
SWITCH, over temperature
1
SCREW, mach, pnh
2
BRACKET, shroud, mltr, HM25c,
1
painted
SCREW, 8-32, serrated flange
4
NUT, lock, hex
4
NUT, hex, flange head
13
SCREW, flange, hex hd
1
SENSOR, 1000 ohm rtd
1
HARNESS, ot
1
CABLE, M12, Molex
2
CABLE, can, female / female 0.5 M
1
CONNECTOR, plug, 5.08 mm, 3
1
position
GRIP, cord, snap-in
2
SENSOR, ultrasonic, m8
1
PIN, dowel
2
WASHER, flat
1
SCREW, pan head, #8-32 x 1.5 in.
1
SWITCH, reed, assy
1
CONNECTOR, plug, 5.08 mm 4
1
position
CONNECTOR, plug, 3.81 mm, 7
2
position
CONNECTOR, plug, 3.81 mm 3
2
position
CONNECTOR, plug, 5.08 mm 4
1
position
CONNECTOR, plug, 5.08 mm 8
1
position
CONNECTOR, plug, 3.81 mm 4
1
position
KNOB, operator disconnect
1
ROD, tie
2
Ref.
73
74*
75
76
77*
78*
79*
80*
81*
82
83
84
85
86
87*
92*
94
95
96
Part
16D984
110932
129197
129657
129908
278870
278871
----278873
17R610
129746
126901
129658
116610
130165
129813
17R646
054986
598095
99
100
17S421
17M487
101
102
103
17M295
17M274
121000
104 17R646
105** - - - - -
Description
Qty.
WASHER, g3, ll
2
CONNECTOR, male
1
SWITCH, disconnect, 40A
1
ADAPTER, funnel/melter, gen 3
1
FILTER, air, funnel, coarse
1
FUNNEL, base
1
FUNNEL, inlet, HM25c
1
HOUSING, sensor, HM25c
1
CAP, filter, funnel, HM25c
1
BRACKET, funnel, painted
1
BOLT, flange hd, serrated, m8
1
SCREW, #10-16, thread forming
1
CLAMP, hose, worm drive
2
SCREW, mach, phil, pan, #10
2
SCREW, mach, pnh, 10-32 x 2.5 in. 3
O-RING, Viton, 043
2
CABLE, M8, Molex
1
TUBE, ptfe, 1/4 in. OD
2
TUBE, 5/32 OD, nylon
1.34
in.
WASHER, funnel
2
SENSOR, 1000 ohm rtd
1
(not shown)
HARNESS, ot (not shown)
1
CABLE, M12 (not shown)
1
CABLE, can, female/female
1
0.5 mm (not shown)
CABLE, M8 (not shown)
1
HARNESS, assembly, fuse holder,
1
8 leads
* Included in funnel kit 17S259
** Included in fuse harness kit 25P567
4
Bottom out sensor (54) then back off 1/2 turn.
Tighten the jam nut to secure.
Punch inside holes and install using screws supplied
with (71).
Torque to 100 +/- 10 in-lb (11 +/- 1 N•m).
5
Torque to 7-10 in-lb (0.7-1 N•m).
8
Rotary switch is to be set to “1” ON.
9
Lubricate o-rings.
1
3
3A4938H
Parts
Common System Parts (continued)
WLE
3A4938H
59
Parts
Common System Parts List (continued)
Ref.
301
302
303
304
305
306
307
Part
25C259
24P175
126801
125856
17N362
17N360
128233
308
328
330
331
332
333
334
335
336
338
342
343
344
345
346
17M280
16T440
17R967
17R912
25C370
17N827
17R887
24E451
113161
114606
403210
129346
129189
116793
120663
Description
Qty.
SYSTEM, base, HM25c
1
PLATE, blank, sgl mztcm, painted
1
GASKET, foam, mztcm
1
SCREW, 8-32, serrated flange
4
PLATE, block off, pc, painted
1
GASKET, foam, block off, pc
1
SCREW, cap, socket hd, #10-32 x
2
.75
HARNESS, disconnect
1
CAP, souriau, uts14
4
COVER, air control, painted
1
COVER, melter, hm25c, painted
1
DOOR, front, painted
1
FOAM, gasket, door
1
BRACKET, adm, HM25c, painted
1
MODULE, gca, adm
1
SCREW, flange, hex hd
12
PLUG, hole
2
BAG, mailer
1
FUSE, 250V, 12.5 A
10
TOOL, puller, fuse
1
FITTING
4
FITTING, straight, hydraulic
4
 Not shown.
 Replacement Danger and Warning labels are
available at no cost.
60
3A4938H
Parts
8-Channel, Pattern Controller, and 480V System Parts
346
347
363
345
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
WLE
3A4938H
61
Parts
8-Channel, Pattern Controller, and 240V System Parts List
240V Systems
4-channel
no PC
Ref.
Description
304
305
307
308
309
310
311
312
313
314
315
316
317
318
319
320
322
323
324
325
326
327
328
329
345
346
347
348
353
363
364
SCREW, 8-32, serrated flange
FRAME, cord grip, 4-position
SCREW, cap, socket hd, #10-32 x .75
HARNESS, disconnect (not shown)
KIT, pattern control board
HARNESS, PC-8 internal (not shown)
CONNECTOR, plug, 8 position
CONNECTOR, plug, 6 position
CONNECTOR, plug, 4 position
CONNECTOR, plug, 12 position
MODULE, GCA, AMZ w DB
SCREW, cap, flange head
NUT, hex, flange head
GROMMET, 1/4 ID
NUT, KEPS, hex
FAN, 24VDC, 120 mm x 120 mm
GUARD, fan, 120 mm
BLOCK, terminal
PLATE, fan, transformer
BASE, transformer enclosure
TRANSFORMER, 480V
SCREW
CAP, Souriau
GROMMET
FITTING
FITTING, straight, hydraulic
FITTING, 45 elbow, hydraulic
FITTING, tee
LABEL, safety, multiple
STRAP, retaining
CABLE, CAN, female/female 0.5 m
8-Channel
with PC
no PC
with PC
Part
Qty.
Part
Qty.
Part
Qty.
Part
Qty.
125856
--------17M280
------------------------25M525
--------------------------------------------16T440
--------------------17P381
114271
-----
4
1
2
1
1
4
125856
129594
----17M280
17E019
17M504
128147
129540
129538
128117
25M525
--------------------------------------------16T440
--------------------17P381
114271
121000
8
1
2
1
1
1
2
2
1
1
1
4
125856
--------17M491
------------------------25M525
--------------------------------------------16T440
----------------127208
17P381
114271
121000
4
1
2
1
2
8
125856
129594
----17M491
17E019
17M504
128147
129540
129538
128117
25M525
--------------------------------------------16T440
----------------127208
17P381
114271
121000
8
1
2
1
1
1
2
2
1
1
2
8
4
4
4
1
20
-
4
4
4
1
20
1
8
8
8
2
1
30
1
8
8
8
2
1
30
2
 Included in fittings kit 24V504, 6 each.
Replacement Danger and Warning labels are available at no cost.
62
3A4938H
Parts
8-Channel, Pattern Controller, and 480V System Parts List
480V Systems
4-channel
no PC
Ref.
Description
304
305
307
308
309
310
311
312
313
314
315
316
317
318
319
320
322
323
324
325
326
327
328
329
345
346
347
348
353
363
364
SCREW, 8-32, serrated flange
FRAME, cord grip, 4-position
SCREW, cap, socket hd, #10-32 x .75
HARNESS, disconnect (not shown)
KIT, pattern control board
HARNESS, PC-8 internal (not shown)
CONNECTOR, plug, 8 position
CONNECTOR, plug, 6 position
CONNECTOR, plug, 4 position
CONNECTOR, plug, 12 position
MODULE, GCA, AMZ w DB
SCREW, cap, flange head
NUT, hex, flange head
GROMMET, 1/4 ID
NUT, KEPS, hex
FAN, 24VDC, 120 mm x 120 mm
GUARD, fan, 120 mm
BLOCK, terminal
PLATE, fan, transformer
BASE, transformer enclosure
TRANSFORMER, 480V
SCREW
CAP, Souriau
GROMMET
FITTING
FITTING, straight, hydraulic
FITTING, 45 elbow, hydraulic
FITTING, tee
LABEL, safety, multiple
STRAP, retaining
CABLE, CAN, female/female 0.5 m
8-Channel
with PC
no PC
with PC
Part
Qty.
Part
Qty.
Part
Qty.
Part
Qty.
125856
--------17M280
------------------------25M525
112395
115942
----127278
127421
----129337
17P309
25C365
25C577
113964
16T440
16C252
----------------17P381
114271
-----
4
1
2
1
1
4
4
1
4
1
1
1
1
1
1
2
4
1
4
4
4
1
20
-
125856
129594
----17M280
17E019
17M504
128147
129540
129538
128117
25M525
112395
115942
----127278
127421
----129337
17P309
25C365
25C577
113964
16T440
16C252
----------------17P381
114271
121000
8
1
2
1
1
1
2
2
1
1
1
4
4
1
4
1
1
1
1
1
1
2
4
1
4
4
4
1
20
1
125856
--------17M491
------------------------25M525
112395
115942
----127278
127421
----129337
17P309
25C365
25C577
113964
16T440
16C252
------------127208
17P381
114271
121000
4
1
2
1
2
4
4
1
4
1
1
1
1
1
1
2
8
1
8
8
8
2
1
30
1
125856
129594
----17M491
17E019
17M504
128147
129540
129538
128117
25M525
112395
115942
----127278
127421
----129337
17P309
25C365
25C577
113964
16T440
16C252
------------127208
17P381
114271
121000
8
1
2
1
1
1
2
2
1
1
2
4
4
1
4
1
1
1
1
1
1
2
8
1
8
8
8
2
1
30
2
 Included in fittings kit 24V504, 6 each.
Replacement Danger and Warning labels are available at no cost.
3A4938H
63
Parts
Safety and Identification Labels
WLD
Safety and Identification Labels
Ref.
Part
353 17P381
Description
LABEL, safety, danger, multiple
Qty.
1
Replacement Danger and Warning labels are available
at no cost.
64
3A4938H
Parts
Air Control Assembly 25C468 Parts
LQ
PP
LQ
PP
LQ
PP
LQ
PP
LQ
PP
LQ
PP
LQ
PP
WLD
3A4938H
LQ
PP
65
Parts
Air Control Assembly 25C468 Parts List
Ref.
501
502
503
504
505
506
507
508
509
Part
----129805
129899
104641
110937
C12509
129477
121021
114320
510
512
513
111162
113498
15T937
514
515
516
517
519
106228
128672
17P080
129900
129902
522
524
525
129898
116514
128260
66
Description
BRACKET, top, air controls
REGULATOR, air
FITTING, triple union, 1/4 tube
FITTING, bulkhead
FITTING, elbow
TUBE, nylon, rnd
VALVE, solenoid, 3 way
VENT, breather, muffler
FITTING, connector, female, 1/8
NPT
FITTING, elbow
VALVE, safety, 110 psi
FITTING, elbow, swivel 1/4 npt x
5/32 t
FITTING, tee, street
NUT, serrated flange, #6-32, sst
FITTING, elbow, PTC, 3/8
BULKHEAD, 1/4 NPT x 1/4 tube
RESTRICTOR, .023,
1/4 tube x 1/4 tube
FITTING, 3/8 x 1/4 elbow
NUT, regulator mnt
GAUGE, panel mount
4
Apply sealant to external threads.
5
Torque to 25 +/- 5 in-lb (2.8 +/- 0.5 N•m).
Qty.
1
1
1
1
7
6
2
2
1
1
1
1
1
4
1
2
1
1
1
1
3A4938H
Parts
Melter Assembly 17S257 Parts
WLD
3A4938H
67
Parts
Melter Assembly 17S257 Parts List
Ref.
601
602
603
604
605
606
607
608
609
610
611
612
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
631
632
635
68
Part
Description
Qty.
25C160 MOTOR, air, 2.5 in., hi temp, 1.5
1
strk
16W387 ROD, tie, 1.5 in. stroke
3
196762 PIN, straight
1
514129 PACKING, o-ring
1
- - - - - SCREW, cap, socket head,
3
5/16-18
17M475 PLATE, tie rod
1
- - - - - SCREW, cap, sh, 5/16-18
3
193046 NUT, packing
1
17L996 BEARING, throat
1
17L995 SEAL, throat
1
- - - - - ROD, displacement
1
- - - - - BALL, .31250
1
- - - - - SEAL, u-cup, piston
1
- - - - - BEARING, piston
1
- - - - - VALVE, piston
1
108526 PACKING, o-ring, ptfe
2
- - - - - SLEEVE, cylinder
1
556431 PLUG, sae, 5/16-24
1
192624 GUIDE, ball
1
105445 BALL, .5000
1
192642 SEAT, carbide
1
107079 PACKING, o-ring
1
105802 O-RING
1
17M477 HOUSING, valve, foot
1
113944 PACKING, o-ring
1
113161 SCREW, flange, hex hd
5
167002 INSULATOR, heat
4
17N255 BRACKET, melter, HM25c,
1
painted
111317 RING, retaining, int.
4
- - - - - HEATER, fire rod, 1000 watts,
4
240V
102867 PACKING, o-ring
Ref.
636
637
638
639
640
641
Part
17M474
17M476
24P855
----15H304
15H305
642
643
644
Description
Qty.
HOUSING, firerod
2
HEAT SINK, melter
2
FILTER, assy, 100 mesh, welded
1
GROMMET, 1/4 ID
4
FITTING, plug 9/16 sae
7
FITTING, plug hollow hex 1-3/16
1
sae
26A242 VALVE, relief
1
295607 PLUG, hex
2
- - - - - MANIFOLD, melter, HM25c
1
648
650
651
652
659
17N323
17P898
129178
111831
129810
SCREEN, wire
TRAY, drip, HM25c
INSULATOR, heat jacket
SCREW, cap, skt, button hd
FITTING, double union, 1/4 tube
1
1
1
4
1
 Included in displacement rod repair kit 25C513.
 Available in Melter Manifold Kit 17S258 which includes
two heaters (632).
 Heater repair kit 17P347 includes four heaters (632)
with electrical leads labeled.
3
Torque to 27 +/- 3 ft-lb (36.6 +/- 4 N•m).
9
Lubricate o-rings.
2
3A4938H
Accessories
Accessories
NOTE: For pattern controller accessories, see manual 334784.
Adapter Plate Kit, 25M528
System Stand Kit, 17S264
1203
1101
1102
1201
1202
A
B
C
1103
WLD
WLD
Ref.
1101
1102
1103
Part
----112395
112958
3A4938H
Description
Qty.
PLATE, adapter, HM25c, painted
1
SCREW, cap, flanged hd
4
NUT, hex, flanged
8
Ref. Part
1201 - - - - 1202 112958
1203 112395
Description
STAND, InvisiPac, HM25c,
painted
NUT, hex, flanged
SCREW, cap, flanged hd
Qty.
1
4
4
69
Accessories
Light Tower Kit, 25C662
WLD
Ref.
801
802
803
804
70
Part
127087
17R703
---------
Description
Qty.
LIGHT, tower, 30 mm, red/green
1
CABLE, GCA, M12-5P, m/f, 0.3 m
1
BRACKET, light tower, painted
1
SCREW, shcs M5 x 12
2
3A4938H
Accessories
ADM Remote Mount Extension Cables
Used to connect a remote mounted ADM to an InvisiPac system.
Part
Description
24R710
5M CAN Extension Cable
24R711
15M CAN Extension Cable
Image
ti31234a
Material Tracking Kit
Used to track material consumption per product without a pattern controller.
Installation
1. See Connect Material Tracking Input (page 18) for details on hardware installation.
2. Navigate to the Material Tracking Setup screen (see System Screen 4 - Material Tracking Setup, page 86) and
check “Enable AUX Counter” setting.
3. Navigate to the Material Log screen using the softkey on the Home screen (see page 80). Verify sensor counts
once per product.
Part
24X446
Description
KIT, photoeye,
diffuse, 18 mm
Contents
Image
128073 - SENSOR, photoelectric diffuse
128071 - BRACKET, sensor mount, straight
128070 - BRACKET, sensor mount, angled
24X449 - CABLE, M12, 4-pin, 5.0 m
ti31235a
24X447
3A4938H
KIT, photoeye,
pol ret ref, 18
mm
128072 - SENSOR, photoelectric, polarized
128071 - BRACKET, sensor mount, straight
128070 - BRACKET, sensor mount, angled
128069 - SENSOR, reflector
24X449 - CABLE, M12, 4-pin, 5.0 m
ti31259a
71
Accessories
Hose Adapters
Used to connect non-Graco hoses to an InvisiPac system.
Part
128621
Description
Image
For connecting to non-Graco hoses that
use a NI 120 RTD.
WLD
Applicator Adapters
Used to connect non-Graco applicators to Graco heated hoses.
Part
Description
16T916
For connecting to non-Graco applicators
that use a rectangular, 6-pin connector.
16Y828
For connecting to non-Graco applicators
that use a circular, 6-pin connector. IPx6
rated.
Image
WLD
16T917
For connecting to non-Graco applicators
that use a circular, 9-pin connector.
128372
For connecting to non-Graco applicators
that use a rectangular, 8-pin connector.
WLD
72
3A4938H
Accessories
Upgrade Kits
4. Install caps (1405) on connectors.
5. Set AMZ #2 (1409) rotary switch to “2”.
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 power at main switch before
disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to
grounded power source.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
6. Connect CAN cable (1403) between AMZ 1 and
AMZ 2.
AA
8 Channel Upgrade Kit, 25M527
WLD
Installation
1. Turn main power switch (H) OFF and disconnect
power from the system.
2. Remove blank plate (AA) and replace with AMZ #2
(1409)
3. Replace 4-channel AMZ power harness with
8-channel harness (1402).
Ref.
1402
1403
1405
1409
Part
17M491
121000
16T440
25M525
Description
Qty.
HARNESS, disconnect, 8 ch
1
CABLE, can, female/female 0.5 m
1
CAP, souriau, UTS14
4
KIT, repair, AMZ
1
AMZ #1
AMZ #2
WLD
(240V)
(480V)
X4
3A4938H
X3
X2
X1
73
Accessories
PC-8 Upgrade Kit, 25M526
Used to upgrade a system and add pattern control
(PC-8).
NOTE: To upgrade to PC-8e, order kit 17F712 in addition to the kit listed above.
5. 4-channel systems: Connect CAN cable between
AMZ 1 - J12 and PCM - P3.
8-channel systems: Connect CAN cable between
AMZ 2 - J23 and PCM - P3.
Black Disconnect Handle Kit, 17S164
Used to replace a red disconnect handle with a black
disconnect handle.
WLD
Installation
1. Turn main power switch (H) OFF and disconnect
power from the system.
2. Set PCM rotary switch to “0”.
3. Mount pattern controller board to bottom of electrical enclosure.
4. Connect power supply harness from AMZ 1 - J3 to
PCM - P1.
74
6
WLD
3A4938H
Accessories
480V Transformer Upgrade Kit, 17S265
Installation
Used to upgrade to a 240 VAC system for 480 VAC
incoming power.
1. Turn the main power switch (H) OFF and disconnect
power from the system.
2. Remove the electrical enclosure door (332).
3. Remove the knockout (KO) on the bottom of electrical enclosure (B).
4. Insert grommet (329) into the knockout hole.
5. Mount terminal block (323) to the bottom of the electrical enclosure using the terminal block mounting
screws (327).
6. Disconnect wire harness (308) from disconnect
switch (75).
7. Connect wire harness (308) to the back side of terminal block (323). See Electrical Schematics on
page 52 for details.
8. Route wires from transformer base (325) through
the knockout hole.
Transformer
9. Connect the fan connector to AMZ #1 - J2.
10. Connect free wires labeled H1-H3 to the disconnect
switch (75). See Electrical Schematics on page 52
for details.
11. Connect free wires labeled X1-X3 to the terminal
block (323). See Electrical Schematics on page 52
for details.
WLD
12. Replace electrical enclosure door (332).
+
%
WLD
.2
3A4938H
75
Accessories
Special Tools
These special tools are designed to make system repairs as easy as possible while ensuring that parts do not get
damaged.
Part
129804
1301*
1302*
1303*
*
Purpose
Spanner wrench to remove melter heater rod housing
Remove Cylinder
Install Cylinder - Female
Install Cylinder - Male
Parts included in Cylinder Tools Kit 24R227 (purchase separately).
Part
1304**
1305**
1306**
Purpose
Install Rod - Female
Install Rod - Male
Install Rod - Bullet
**Parts included in Rod Tools Kit 24R228 (purchase separately).
WLD
Spanning Wrench - 129804
76
3A4938H
Accessories
Air Reservoir Kit, 16W366
Allows the system to operate on lower pressure or
restricted air supply lines.
16W366 Parts
Ref.
1501
1502
1503
1504
1505
1506
Part
----100081
113777
114485
155665
-----
Description
HOSE, nylon (6 ft)
BUSHING, pipe
TEE, pipe
CONNECTOR, male, 3/8 npt
UNION, adapter
TANK, air, accumulator
Qty.
1
1
1
2
1
1
- - - - - Not for sale separately.
WLD
3A4938H
77
Appendix A - ADM (Advanced Display Module)
Appendix A - ADM (Advanced Display Module)
ADM Interface
Key
BA
BC
BD
BE
BF
BG
BH
Function
System Enable/Disable
Stop all system processes
Defined by icon next to soft key
Abort current operation
Accept change, acknowledge error, select
item, toggle selected item
Toggle between Run and Setup screens
Navigate within a screen or to a new screen
Screen Navigation
Navigate through each screen to set up and operate the InvisiPac HM25c.
NOTE: additional screens are present for the pattern controller on InvisiPac systems with an integrated pattern controller. Refer to InvisiPac Pattern Controller manual for details.
Run Screens
Home
Targets
Targets
Material log
(Channels 1-4)
(Channels 5-8)
Press the unlock key
Events
Errors
Diagnostic
to switch between Run and Setup screens.
Setup Screens
78
3A4938H
Appendix A - ADM (Advanced Display Module)
ADM Screens
Home
Read-only view of system heat states and temperatures.
A - Material Log
A
Icon
Name
Description
Channel heat state:
Channel Heat state
Active
Warmup
Inactive
Not Installed
Hose Temperature
Current temperature of the hose
Gun (Applicator)
Temperature
Current temperature of the gun
Current temperature of the melter and melter heat state:
Melter Heat State
and Temperature
Material Log Softkey
3A4938H
Active
Warmup
Inactive
Not Installed
NOTE: Melter heat state is not ACTIVE until all installed channels
and the melter have reached setpoint.
Use to navigate to the Material Log screen.
79
Appendix A - ADM (Advanced Display Module)
Material Log
View of material log.
A
A - Exit Screen
Icon
Name
Reset Material
Target
Date
Cycles
lb
Description
Press to reset the target material per unit to the current value. An hourglass will
appear in place of the material usage scale in the bottom left corner until a new
target value is learned.
Material Usage Indicates current material per unit relative to the learned target value. The curScale
rent material per unit is denoted by the arrow indicator and black blinking bar.
The top of the scale indicates high usage of 20% deviation above target. The
bottom of the scale indicates low usage of 20% deviation below the target. If
material alerts are enabled, an alert will be generated each time the current
value goes outside the range shown (see System Screen 4 - Material Tracking
for details).
Date
Date of the material log entry.
Total pump cycles.
Cycles
Material Used
Program
Total material used.
Pattern controller program.
Total products produced.
Products on pattern controller line 1.
Product Count
Products on pattern controller line 2.
Products on non-pattern controller systems.
Material Per
Product
Average material per product.
NOTE: Not all material log columns are present on all systems.
80
3A4938H
Appendix A - ADM (Advanced Display Module)
Targets
View and adjust system temperature setpoints.
B
A - Channel Select
B - Increase Setpoint
C - Decrease Setpoint
Icon
C
A
Name
Number Pad
Indicator
Description
Indicates which setting will be changed when using the ADM number keypad.
Channel Select Press softkey to select channel and enter setpoints for gun and hose.
NOTE: a second Targets screen is available for eight channel systems. Press
the right arrow key to navigate to the second screen.
NOTE: press and hold softkey to copy the melter temperature setpoint to the
channel temperature setpoint (for faster setup).
Increase Setpoint Press softkey to increase temperature setpoint.
Decrease
Setpoint
3A4938H
Press softkey to decrease temperature setpoint.
81
Appendix A - ADM (Advanced Display Module)
Errors
Events
Read-only view of logged errors. Press the up and down
arrows to scroll through the log.
Read-only view of logged events. Press the up and
down arrows to scroll through the log.
82
3A4938H
Appendix A - ADM (Advanced Display Module)
Diagnostic
Read-only view of the important system diagnostic information.
A - Heat Zones
B - Pump
C - Fill (Feed System)
D - AUX Unit Counter
E - PLC Inputs
F - PLC Outputs
G - USB Download %
H - Transformer
J - Line Voltage
NOTE: Use the up and down arrow keys to scroll up and down within the screen.
System Screen 1 - Gun Setup
Install heat channels and select gun RTD type.
A
A - Enter/Exit Screen
B - Screen Number
Icon
B
Name
Gun (Applicator) Number
Installed
Gun Current
Temperature
Gun RTD Type
3A4938H
Description
Number of each gun that the row applies to.
Check to install a channel (gun and hose pair).
Current temperature of the gun (according to the RTD type selected).
Drop-down selection of gun RTD type. Select gun RTD type according to
documentation supplied with each gun.
83
Appendix A - ADM (Advanced Display Module)
System Screen 2 - General Setup
Install heat channels and select gun RTD type.
A
A - Enter/Exit Screen
B - Screen Number
Icon
B
Name
Description
Enable Diagnostic Check to enable Diagnostic screen in Run screens. See Diagnostic screen for
Screen
details.
Pump Idle Time to Set to allow the system to automatically go to the Inactive state after the
System Inactive desired duration of pump inactivity.
Circuit Breaker
Size
Select the circuit breaker size used. Use the size of the circuit breaker used to
supply power to the system (circuit breaker is external to the system).
Enable Slow Refill Check to enable the slow refill alert (Error code “L3FX”). See Troubleshooting
Alert
section for details.
Drop-down selection with the following options:
• Auto: use automatic feed system. See Automatic Refill section for details.
Refill Setting
• Manual: do not use automatic feed system. See Manual Refill section for
details.
Refill Setting
Softkey
84
Press softkey to toggle Refill Setting between Auto and Manual.
3A4938H
Appendix A - ADM (Advanced Display Module)
System Screen 3 - PLC I/O Setup
Configure and view the current state of the system PLC inputs and outputs.
A
A - Enter/Exit Screen
B - Screen Number
Icon
B
Name
Description
Indicates the current state of the input/output signal (see tables below)
Signal State
Indicator
Drop-down selection of the desired input option. Available options are outlined
in the table below. All input options except Pump Enable/Disable are transition-based.
Input Option
Drop-down selection of the desired output option. Available options are outlined
in the table below. All output options are normally open when power is OFF.
Output Option
NOTE: See the Setup section for details on PLC I/O wiring.
3A4938H
85
Appendix A - ADM (Advanced Display Module)
System Screen 4 - Material Tracking Setup
Setup material tracking settings.
A
A - Enter/Exit Screen
B - Screen Number
Icon
B
Name
Description
Calibration Weight
Resettable totalizer that can be used for determining Specific Gravity.
Totalizer
Material per Unit
Current material per unit.
Reset Weight TotalPress softkey to reset the calibration weight totalizer.
izer
Enable AUX Unit
Counter
Enable Material
Alerts
Specific Gravity
86
Check to enable the AUX unit counter on the System IO Board.
See Setup section for AUX Unit Counter wiring details.
NOTE: this box does not need to be checked for systems with an integrated
pattern controller.
Check to enable material alerts when the current material unit deviates 20%
from the established target.
See Material Log screen for details on setting a target material per unit.
Specific Gravity of the material in use. See Calibration section for methods to
determine the appropriate value.
3A4938H
Appendix A - ADM (Advanced Display Module)
Advanced Screen 1 - Display Settings
Advanced Screen 2 - Units
General display settings including language, time and
password protection.
Select the system units to be used on the display.
Name
Name
Language
Date Format
Description
Select the display language.
Select the display date format.
Date
Enter the display date.
Time
Enter the display time.
Password
Screen Saver
Silent Mode
Lock Run Screens
Enter the password to restrict
access to the Setup screens.
Description
Temperature Select the system temperature units.
Units
Mass Units
Select the system mass units.
Distance Units Select the system distance units.
NOTE: this setting only applies to pattern controller values.
NOTE: a value of “0000” does
not require a password for
access to Setup screens.
Enter the timeout for the display
screen saver.
NOTE: a value of “0” disables
the screen saver.
Check to disable display beep
functionality.
If checked, operators will not be
able to change most run screen
settings.
NOTE: in order for this setting
to take effect, a password other
than “0000” must be entered
above.
NOTE: when returning to the
Run screens from the setup
screens, the operator will have
two minutes to make changes
before the screens lock.
3A4938H
87
Appendix A - ADM (Advanced Display Module)
Advanced Screen 3 - USB Settings
Advanced Screen 4 - System Software
Select USB download settings.
Read only display of system software.
Name
Description
Disables USB port from transDisable USB
Downloads/Uploads mitting data to/from a USB
drive.
Disables USB log advisories.
Disable USB
Log Errors
Sets the length of the data logs
Download Depth
to be downloaded (affects the
download time).
Name
System
Software
Part #
System
Software
Version
Description
Part number of the software on the most
recently loaded system software token.
NOTE: this part number is not the part
number of the system software token (PN
17R827).
Version of the software on the most
recently loaded system software token.
NOTE: A red X next to the software means that one or
more system components have software that is not the
current version. This will not prevent the system from
running. All components can be updated to run the current software version by performing the Software
Update Procedure on page 94.
88
3A4938H
Appendix A - ADM (Advanced Display Module)
Maintenance
Setup material tracking settings.
A
A - Enter/Exit Screen
Name
Current
Description
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 in the bottom left corner.
Maintenance interval period for variable in the row.
Interval
Lifetime
Pump Cycles
Pump Weight
Heat On Time
Pump Idle Time
3A4938H
NOTE: set to a non-zero value to generate advisories when the current counter
reaches this value.
Lifetime counter of the variable in the row.
Pump cycle totalizers.
Pump weight totalizers.
Heat on time totalizers (time spent with heat on).
Pump idle time totalizer (time spent with system at temperature, but no pump activity).
89
Appendix A - ADM (Advanced Display Module)
Schedule
Set daily system ON and OFF commands following a weekly schedule.
A
A - Enter/Exit Screen
Icon
90
Name
Description
The time value (24-hour clock) of the schedule entry indicates the time that the
desired action will take place for a given day (indicated by the column).
Schedule Entry
The color or the schedule entry indicates the desired action. The colors represent the following actions:
Create Schedule
Entry
Press softkey to create a new schedule entry. Once pressed, a pop-up box will
appear allowing the user to set the time of the schedule entry (24-hour clock) as
well as the desired action (Heat On/Off).
Delete Schedule
Entry
Press softkey to delete selected schedule entry.
Enable / Disable
Schedule Entry
Press softkey to toggle the state (enabled or disabled) of the selected schedule
entry.
3A4938H
Appendix B - USB Downloading, Uploading
Appendix B - USB Downloading, Uploading
The system can store 50,000 entries in its logs and the
system adds a new entry to the logs every 60 seconds.
This means the system stores 800 hours of system
operation data, or 34 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
34 days without downloading the logs.
Download Procedure
Accessing Files
All files downloaded from the USB are put in a DOWNLOAD 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 program.
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 procedure. See USB Logs, System Settings File, and System Language File starting on page 92.
1. Insert USB flash drive into USB port (PT).
NOTE: Flash drive must be 8 GB or smaller.
NOTE: If emailing the files, zip (compress) them to minimize 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 92.
PT
1. If necessary, follow the System Language File,
page 93, to automatically generate the proper folder
structure on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
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 transfer 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.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Windows 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 corresponding serial number of the ADM. (The serial
number is on the back of the module.)
6. If installing the system settings file, place SETTINGS.TXT file into UPLOAD folder.
7. If installing the custom language file, place DISPTEXT.TXT file into UPLOAD folder.
3A4938H
91
Appendix B - USB Downloading, Uploading
8. Remove USB flash drive from computer.
Black Box, Diagnostics Logs
9. Install USB flash drive into InvisiPac system USB
port.
These logs (4-BLACKB.CSV, 5-DIAGNO.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
10. The menu bar and USB indicator lights indicate that
the USB is uploading files. Wait for USB activity to
complete.
Material Log
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 corresponding ADM. To avoid unintentionally overwriting system settings, delete the files from the UPLOAD folders
on the USB drive after the upload is complete.
USB Logs
During operation, InvisiPac stores system and performance related information to memory in the form of log
files. InvisiPac maintains the events, data, GCA, Black
Box, and Diagnostics logs. Follow the System Language File, page 93, to retrieve log files.
Events Log
The event log (1-EVENT.CSV) maintains a record of the
last 75,000 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
This log (6-MATERI.CSV) lists up to 500 material log
entries.
Fill Log
This log (7-FILL.CSV) is 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 configuration settings file automatically downloads 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 systems. Refer to the Upload Procedure, page 91, for
instructions on how to use this file.
The data log (2-DATA.CSV) tracks the setpoint and
actual temperatures every 60 seconds. This log can
store up to 50,000 lines of data.
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.
The system stores 800 hours of system operation data,
or 34 days of around-the-clock operation. Once full, the
system will overwrite the oldest data.
NOTE: System settings may not be compatible between
different versions of the InvisiPac software.
NOTE: To prevent losing any data, never go more than
34 days without downloading the logs.
GCA Log
This log (3-GCA.CSV) lists the installed GCA modules
and their respective software versions.
92
3A4938H
Appendix B - USB Downloading, Uploading
System Language File
Create Custom Language Strings
The system language file name is DISPTEXT.TXT and
is stored in the DOWNLOAD folder.
The custom language file is a tab-delimited text file that
contains two columns. The first column consists of a 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
previously installed, this column contains the custom
strings. Otherwise the second column is blank.
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 system 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)
Modify the second column of the custom language file
as needed and then follow the Upload Procedure,
page 91, to install the file.
The format of the custom language file is critical. The
following rules must be followed in order for the installation process to succeed.
•
•
•
•
•
•
3A4938H
The file name must be DISPTEXT.TXT.
The file format must be a tab-delimited text file
using Unicode (UTF-16) character representation.
The file must contain only two columns, with
columns separated by a single tab character.
Do not add or remove rows to the file.
Do not change the order of the rows.
Define a custom string for each row in the second column.
93
Appendix C - Software Update
Appendix C - Software Update
Software Update Procedure
When software is updated on the ADM the software is
then automatically updated on all connected GCA components. A status screen is shown while software is
updating to indicate progress.
1. Turn system main power switch (H) OFF.
NOTE: When the screen turns on, the following screens
appear:
First:
Software is checking
which GCA modules
will take the available
updates.
Second:
Status of the update
with approximate time
until completion.
2. Remove ADM from bracket (BK).
3. Remove token access panel.
BK
Third:
Updates are complete.
Icon indicates update
success/failure. See
the following Icon
table.
ADM
Icon
Description
r_24P860_3B9900_3a
4. Insert and press InvisiPac software upgrade token
(TK, part no. 17R827) firmly into slot.
Update successful.
NOTE: There is no preferred orientation of token.
Update unsuccessful.
Update complete, no changes necessary.
Update was successful/complete but one or
more GCA modules did not have a CAN boot
loader so software was not updated on that
module.
TK
r_24P860_3B9900_4a
5. Install ADM into bracket (BK).
6. Turn system main power switch (H) 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.
94
7. Remove token (TK).
8. Replace token access panel.
9. Press
to continue to InvisiPac operation
screens.
3A4938H
Dimensions
Dimensions
240V System Dimensions
System with 480V Transformer
A
A
B
B
C
C
WLD
A
B
C
23.1 in. (58.7 cm)
25.4 in. (64.5 cm)
16.5 in. (41.9 cm)
3A4938H
WLD
A
B
C
26.3 in. (66.8 cm)
25.4 in. (64.5 cm)
16.5 in. (41.9 cm)
95
Dimensions
Mounting Hole Dimensions
240V Systems
9.8 in.
(24.89 cm)
ti31272a
9.8 in.
(1.11 cm)
1.495 in.
(3.79 cm)
9.8 in.
(1.11 cm)
2X 15.0 in.
38.1 cm
0.5 in.
(1.27 cm)
2X 17.16 in.
(43.58 cm)
20.25 in.
(51.43 cm)
480V Systems
18.925 in.
(48.06 cm)
9.8 in.
(1.11 cm)
0.5 in.
(1.27 cm)
.386 in.
(0.98 cm)
9.8 in.
(1.11 cm)
8.5 in.
(21.59 cm)
.65 in.
(1.65 cm)
2X 15.0 in.
38.1 cm
ti31273a
9.8 in.
(1.11 cm)
2X 17.16 in.
(43.58 cm)
20.25 in.
(51.43 cm)
96
3A4938H
Dimensions
System with Stand and Feed Hose Dimensions
%
&
'
$
(
WLD
A
B
C
D
E
3A4938H
240V Systems
49.3 in. (125.2 cm)
25.4 in. (64.5 cm)
16.5 in. (41.9 cm)
26.0 in. (66.0 cm)
28.0 in. (71.1 cm)
480V Systems
52.5 in. (133.4 cm)
25.4 in. (64.5 cm)
16.5 in. (41.9 cm)
26. in. (66.0 cm)
28.0 in. (71.1 cm)
97
Technical Specifications
Technical Specifications
InvisiPac HM25c Hot Melt Delivery System
US
Incoming Power
HM25c: 25C700, 25C701, 25C702, 25C703
HM25c: 25C720, 25C721, 25C722, 25C723
Electrical
Minimum Applicator Wattage Per Channel
Maximum Applicator Wattage Per Channel
Minimum Hose Wattage Per Channel
Maximum Hose Wattage Per Channel
PLC Inputs
PLC Outputs
Pump Flow Rate
HM25c
Melt Rate / Constant Throughout
HM25c
Weight
HM25c: 25C700, 25C701, 25C702, 25C703
HM25c: 25C720, 25C721, 25C722, 25C723
General
Pump Output
Time to Temperature*
Pump
Channels
Pressure and Temperature Ranges
System Air Supply Inlet
Pump Operating Air Pressure Range
(set with regulator on front of system)
Pump Operating Fluid Pressure Range
Control Temperature Range
Ambient Temperature Range
Air Consumption Specifications
Average air use at 5 lb/hour**
Average air use at 25 lb/hour**
Feed Hose Specifications
Maximum Feed Hose Length
Maximum Feed Hose Vertical Rise
Required Air Tubing Size
Minimum Air Tubing Inner Diameter
Minimum Air Tubing Inner Diameter
(50 ft, 15.2 m or longer tubing)
98
Metric
200-240 VAC, 1-ph, 50/60 Hz, 32 A
200-240 VAC, 3-ph, ˂, 50/60 Hz, 32 A
350-415 VAC, 3-ph, Y, 50/60 Hz, 32 A
400-480 VAC, 3-ph, ˂, 50/60 Hz, 14A
90 W (@ 240 VAC)
400 W (@ 240 VAC)
90 W (@ 240 VAC)
1250 W (@240 VAC)
6 inputs (0-30 VDC)
2 outputs (240 VAC / 24 VDC, 2 A max)
96 lb/hr
43.5 kg/hr
25 lb/hr
11.3kg/hr
86 lb
160 lb
39 kg
73 kg
19.3 cc/cycle
Less than 10 minutes
Pneumatic Piston, 12:1
0-8 channels
80-100 psi
20-100 psi
0.55-0.69 MPa (5.5-7 bar)
0.14-0.69 MPa (0.7-7 bar)
240-1200 psi
100°-400° F
32°-120° F
1.7-8 MPa (17-80 bar)
38°-204° C
0°-49° C
1.9 scfm
5.4 scfm
3.3 scmh
9.2 scmh
30 ft
10 ft
9.1 m
3.0 m
3/8 in.
1/2 in.
9.5 mm
12.7 mm
3A4938H
Technical Specifications
InvisiPac HM25c Hot Melt Delivery System
US
Sound
Sound Pressure Level***
IP Code
HM25c
Wetted Parts
Wetted Parts
Metric
77 db(A)
IP54
PTFE, chemically resistant o-rings, aluminum, stainless steel, zinc
plating, carbon steel, brass, carbide, chrome
* From 70°F to 350° F (21° C to 177° C), dependent upon power supply and machine configuration.
** Includes intermittent air use up to 13 scfm (22 scmh) when vacuum system is feeding.
*** Sound pressure level measured 3.1 ft (1 meter) from equipment.
California Proposition 65
CALIFORNIA RESIDENTS
WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.
3A4938H
99
Technical Specifications
Startup Time
45
A
A
B
40
B
35
C
C
Time
(minutes)
D
D
30
E
25
E
F
F
20
15
10
0 (0)
25 (7.62)
50 (15.24)
75 (22.86)
Hose Length
(ft (m)
A
B
C
D
E
F
100
100 (30.48)
150 (45.72)
200 (60.96)
ti31246a
20 Amp 208V Heatup Time
20 Amp 240V Heatup Time
30 Amp 208V Heatup Time
30 Amp 240V Heatup Time
40 Amp 208V Heatup Time
40 Amp 240V Heatup Time
3A4938H
Notes
Notes
3A4938H
101
Graco Standard 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 determined 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 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 entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For more information about InvisiPac, visit www.InvisiPac.com or email [email protected].
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
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.
This manual contains English. MM 3A4938
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2008, Graco Inc. is registered to I.S. EN ISO 9001
www.graco.com
Revision H, July 2020

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