Graco 333347F User Manual

Instructions - Parts

™

InvisiPac

™

HM25 and HM50 Tank-Free

333347F

Hot Melt Delivery System

For delivering and dispensing hot melt adhesive pellets. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

1200 psi (8.3 MPa, 83 bar) Maximum Working Pressure 400°F (204°C) Maximum Fluid Operating Temperature 100 psi (0.7 MPa,7 bar) Maximum Air Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this manual and in the applicator and hose manuals. Save all instructions.

WLD

9902471

Certified to

CAN/CSA C22.2 No. 88

Conforms to ANSI/UL 499

Contents

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

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

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

200-230 VAC, 350-415 VAC HM50 Models . . . . . . . . . . . 4

200-230 VAC, 350-415 VAC HM25 Models . . . . . . . . . . . 5

400 VAC Transformer HM25 Models . . . . . . . . . . . . . . . . 6

480 VAC Transformer HM25 Models . . . . . . . . . . . . . . . . 7

480 VAC Transformer HM50 Models . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Heated Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Advanced Display Module (ADM) . . . . . . . . . . . . . . . . . . 14

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Attach Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Recommended Air Setup . . . . . . . . . . . . . . . . . . . . . . . . 22

Connect Electrical Cord . . . . . . . . . . . . . . . . . . . . . . . . . . 23

208V Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Select ADM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Initial Startup and Prime . . . . . . . . . . . . . . . . . . . . . . . . . 29

Manual Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Automatic Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dispense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . 33

Drain the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Operation Tips to Minimize Charring . . . . . . . . . . . . . . . . 36

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Replace Outlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Replace Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Replace Funnel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Filter Maintenance Guidelines* . . . . . . . . . . . . . . . . . . . . 39

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

ADM Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Mechanical and Electrical Troubleshooting . . . . . . . . . . 46

MZLP Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Melter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Multi-Zone Low Power Temperature Control Module (MZLP)

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Transformer Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Software Update Procedure . . . . . . . . . . . . . . . . . . . . . . 77

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Cable Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

480VAC Transformer Option . . . . . . . . . . . . . . . . . . . . . . 80

Typical Hose / Applicator Wiring . . . . . . . . . . . . . . . . . . . 80

2nd and 3rd MZLP Options . . . . . . . . . . . . . . . . . . . . . . . 81

Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

InvisiPac Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Transformer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 92

Melter and Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 93

Air Motor, 24V558 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Feed System Shaker and Tube, 24V507 . . . . . . . . . . . . 96

Air Controls Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Pressure Relief Valve, 24P856 . . . . . . . . . . . . . . . . . . . . 98

Feed Inlet Funnel, 24V505 . . . . . . . . . . . . . . . . . . . . . . . 99

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Non-Graco Applicator Adapter Cables . . . . . . . . . . . . . 101

Air Adjustment Lock, 24R084 . . . . . . . . . . . . . . . . . . . . 101

System Stand, 24R088 . . . . . . . . . . . . . . . . . . . . . . . . . 102

Caster for Stand, 120302 . . . . . . . . . . . . . . . . . . . . . . . 102

Adapter Plate, 24R083 . . . . . . . . . . . . . . . . . . . . . . . . . 102

30 Gallon Vibrating Hopper, 24R136 . . . . . . . . . . . . . . 104

Light Tower Kit, 24R226 . . . . . . . . . . . . . . . . . . . . . . . . 106

Air Reservoir Kit, 16W366 . . . . . . . . . . . . . . . . . . . . . . . 107

4 Channel Upgrade Kit, 24V528 . . . . . . . . . . . . . . . . . . 108

6 Channel Upgrade Kit, 24V529 . . . . . . . . . . . . . . . . . . 110

InvisiPac ADM Simulator Kit, 24R323 . . . . . . . . . . . . . . 112

ADM Extension Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

ADM Remote Mount Bracket, 24A326 . . . . . . . . . . . . . 112

Overtemperature Jumper, 16Y727 . . . . . . . . . . . . . . . . 113

Air Metric Fitting Kit, 24W637 . . . . . . . . . . . . . . . . . . . . 113

Strain Relief Bushing Kit, 24X190 . . . . . . . . . . . . . . . . . 113

Hose Straps (4 Pack), 24R0294 . . . . . . . . . . . . . . . . . . 113

Pressure Gauge Replacement Kit, 24R635 . . . . . . . . . 113

Appendix A - ADM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Icon Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Operation Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Appendix B - USB Downloading, Uploading . . . . . . . . . . 120

Download Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Accessing Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

System Settings File . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

System Language File . . . . . . . . . . . . . . . . . . . . . . . . . 122

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Startup Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Graco Extended Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 130

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

2 333347F

Related Manuals

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

Part Description

3A2805 InvisiPac GS35 Hot Melt Applicator Instruc-

tions - Parts 332072 InvisiPac Heated Hose Instructions - Parts 333348 HM50 Fuse Kit, Instructions-Parts 333349 InvisiPac 480V Transformer Upgrade Kit,

Instructions-Parts 333348 MZLP Fuse Kit, Instructions

Required Tools

• Standard allen wrench set

• Metric allen wrench set

• Various sizes of crescent wrenches

• 11/16 in. wrench

• 3/8 in. ratchet

• 3/8 in. socket

• 5/16 in. driver

• 7/16 in. socket

• 7/8 in. deep well socket

• 1 in. socket

• 13 mm socket

• 10 mm socket

• 1/2 in. ratchet

• Side cutter

• Phillips head screwdriver

• Flat head screwdriver

• Multimeter

• Tubing cutter

Related Manuals

333347F 3

Models

200-240 VAC, 350-415 VAC HM50 Models

See 400 VAC Transformer models on page 6.

See 480 VAC Transformer models on page 7.

Model Channels Voltage

200-240 VAC

24T918 2

24T919 4

24T920 6

200-240 VAC

350-415 VAC Y

200-240 VAC

350-415 VAC Y

200-240 VAC

350-415 VAC Y

Type Description Frequency

/ PE

3Φ / PE

/ Neutral / PE

/ PE

3Φ / PE

3Φ / Neutral / PE

/ PE

3Φ / PE

/ Neutral / PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

•

1-Phase

•

200-240 VAC

•

2 wire and PE

•

3-Phase without Neutral

•

200-240 VAC Line to Line

•

3 wire and PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

•

1-Phase

•

200-240 VAC

•

2 wire and PE

•

3-Phase without Neutral

•

200-240 VAC Line to Line

•

3 wire and PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

Max

Amps

50/60 Hz 32A

50/60 Hz 27A

50/60 Hz 16A

50/60 Hz 40A

50/60 Hz 27A

50/60 Hz 16A

50/60 Hz 40A

50/60 Hz 30A

4 333347F

200-240 VAC, 350-415 VAC HM25 Models

See 400 VAC Transformer models on page 6.

See 480 VAC Transformer models on page 7.

Model Channels Voltage

200-240 VAC

24V423 2

24V424 4

24V425 6

200-240 VAC

350-415 VAC Y

200-240 VAC

350-415 VAC Y

200-240 VAC

350-415 VAC Y

Type Description Frequency

/ PE

3Φ / PE

/ Neutral / PE

/ PE

3Φ / PE

/ Neutral / PE

/ PE

3Φ / PE

/ Neutral / PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

•

1-Phase

•

200-240VAC

•

2 wire and PE

•

3-Phase without Neutral

•

200-240VAC

•

3 wire and PE

•

3-Phase with Neutral

•

350-415 VAC Line to Line

•

200-240 VAC Line to Neutral

•

3 wire, Neutral, and PE

Models

Max

Amps

50/60 Hz 32A

50/60 Hz 27A

50/60 Hz 16A

50/60 Hz 40A

50/60 Hz 27A

50/60 Hz 16A

50/60 Hz 40A

50/60 Hz 30A

333347F 5

Models

400 VAC Transformer HM25 Models

Model Channels Voltage

24V426 2 335-400 VAC

24V427 4 335-400 VAC

24V428 6 335-400 VAC

Type Description Frequency

/ PE

400 VAC Transformer HM50 Models

Model Channels Voltage

24V198 2 335-400 VAC

24V199 4 335-400 VAC

24V200 6 335-400 VAC

Type Description Frequency

/ PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

335-400 VAC Line to Line

•

3 wire and PE

Max

Amps

50/60 Hz 17A

Max

Amps

50/60 Hz 17A

6 333347F

480 VAC Transformer HM25 Models

Model Channels Voltage

24V429 2

24V430 4

24V431 6

400-480 VAC

Type Description Frequency

/ PE

3Φ / PE

480 VAC Transformer HM50 Models

Model Channels Voltage

24V201 2 400-480 VAC

24V202 4 400-480 VAC

24V203 6 400-480 VAC

Type Description Frequency

/ PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

•

3-Phase without Neutral

•

400-480 VAC Line to Line

•

3 wire and PE

Models

Max

Amps

50/60 Hz 14A

Max

Amps

50/60 Hz 14A

333347F 7

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

•Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

8 333347F

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Do not use solvent-based adhesives that can create an explosive atmosphere when processed.

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

333347F 9

Warnings

WARNING

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

10 333347F

Component Identification

Key:

A Advanced Display Module (ADM) B Electrical Enclosure C Pump Air Pressure Regulator D Pump Air Pressure Gauge E Vacuum Transfer Air Pressure Regulator F Vacuum Transfer Air Pressure Gauge GShaker Tube G1 Shaker Head G2 Vacuum Transfer Tube G3 Vacuum Transfer Inlet Funnel G4 Vacuum Transfer 3/8 in. OD Air Supply H Main Power Switch J System Air Inlet K Vacuum Transfer (Shaker) Inlet L Air Motor and Pump M Incoming Power Strain Relief N Heated Fluid Manifold (Melter) P Multi-Zone Low Power Temperature Control Module (MZLP) R Fluid Outlets for connection to Heated Hoses (numbered 1-6) S Customer I/O Cable (optional) AC Drain Port AD Transformer (optional)

FIG. 1

WLD

WLD

333347F 11

Component Identification

Heated Fluid Manifold

NOTE: System shown with plastic and metal shrouds removed.

FIG. 2

Key:

T Electrical Enclosure Front Access Door UMelter W1 Drain Port W2 Drain Tray X Inlet Filter (Low Pressure - Before Pump) Y Outlet Filter (High Pressure - After Pump) Z Adhesive Pellets Level Sensor (not shown; inside funnel) AA Power and RTD Harness Connection to Heated Hose and

Applicator (harness connects from system to heated hose then from heated hose to applicator)

AB Inlet Funnel Screen

WLD

12 333347F

Electrical Enclosure

Component Identification

FIG. 3

Key:

P Multi-Zone Low Power Temperature Control Module

(MZLP) AC Incoming Power Connection AF Chassis Ground AG Automatic Wiring Board (AWB)

WLD

333347F 13

Component Identification

Advanced Display Module (ADM)

User Interface

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

NOTE: See Appendix A - ADM on page 114 for complete ADM operation details.

FIG. 5

Key:

BK Part Number Identification Label BL USB Interface BM CAN Cable Connection (Power Supply and Communica-

tion) BN Module Status LEDs BP (Not used) BR Software Token Access Panel

TI12362a1

FIG. 4

Key Function

BA Heating system and pump enable/disable

BB System status indicator (LED)

BC Stop all system processes

BD Defined by icon next to softkey

BE Abort current operation

BF Accept change, acknowledge error, select item,

toggle selected item

BG Toggle between Operation and Setup screens

BH Navigate within a screen or to a new screen

14 333347F

Screen Components

Component Identification

Current date and time

Operating Mode

Hose and Applicator

Heating Status

Hose Actual Temperature

FIG. 6: Main Screen Components

Operating Mode Description Component Status

System Off

Inactive

Warm Up

Active

The system doesn’t have power.

The heating system and pumps are disabled.

The system is heating the material to the set temperature.

The system is ready to dispense material.

Screens Order

Applicator Actual Temperature

• No System Status Indicator LED on the ADM

• No heat

• Pump is off

• Yellow system status indicator LED on the ADM

• No heat

• Pump is off

• Flashing green system status indicator LED on the ADM

• Heat is increasing to setpoint temperature

• Pump is off

• Solid green system status indicator LED on the ADM

• Heat is at setpoint temperature

• Pump is on

Faults, Status

Melter Heating Status

Melter Actual Temperature

333347F 15

Component Identification

16 333347F

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 is equipped with a ground terminal. A qualified electrician must ground the system using this terminal. See Connect Electrical Cord on page 23.

NOTICE

To prevent excessive static buildup on shaker or adhesive bin, install optional grounding kit 24R708.

The applicator(s) must be located no more than 25 ft (7.6 m) from the melter.

Place the base system on a surface that is eye-level for easiest operation. Use System Stand, 24R088, to install system at eye-level. See page 102.

If installing the system in place of a non-Graco hot melt system, purchase Adapter Plate, 24R083. See page 102.

Optional 30 Gallon Vibrating Hopper, 24R136, available (purchase separately). See page 104.

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

Attach Components

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

WLD

FIG. 7: Grounding Kit 24R708

Location

Ambient temperature must be 32-120°F (0-49°C).

The supplied vacuum transfer hose length is 10 ft (3 m). The maximum vacuum transfer hose length available is 30 ft (9.1 m). The adhesive pellets container must be located within reach of the vacuum transfer hose and no more than 30 ft (9.1 m) away.

NOTE: Only systems with transformers are supplied with a lifting strap.

NOTICE

To prevent strain on electrical or mechanical connections around the pump assembly, loop the strap around the tie rods as shown.

1. Use supplied lifting strap 127735, to transport systems with transformers. Wrap strap around all three pump tie rods and loop the strap back through itself in the Choker Configuration. See strap for details. See F

. 8, page 18.

333347F 17

Setup

3. Adjust the funnel inlet:

WLD

FIG. 8: Lifting Strap

2. Place the base system in the desired operating

location and orientation. See Location, page 17.

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

WLD

a. Remove plug (23) and insert the provided 5/16

in. nut driver (92) through the access hole in the back of the system. Loosen the band clamp (81) two turns.

b. Rotate the funnel inlet (G3) and re-tighten the

band clamp (81).

• To install the InvisiPac system in place of a

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

page 102.

• To raise the system to eye-level, purchase System Stand, 24R088. See installation instructions on page 102.

FIG. 9

WLD

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

4. Insert 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) into vacuum transfer funnel (G3) inlet and secure with supplied hose clamp. The hose clamp should be placed over the cutouts in the funnel inlet where it can firmly hold the transfer hose. See F

5. Connect the long supplied 3/8 in. OD air line (G4) to the 3/8 in. push-to-connect fitting on the air line from the system. See F

18 333347F

. 9.

Setup

NOTE: In the following steps, when routing the vacuum transfer hose, ensure there are no tight coils, turns, or dips in the vacuum hose. These will inhibit optimal functioning of the vacuum transfer system.

NOTE: Maximum vacuum hose length is 30 ft (9.1 m). Use horizontal hose routing as much as possible. The vacuum hose must not rise more than 10 ft (3.0 m), measured from the vacuum inlet. Any vertical rise will lower the maximum flow rate of the vacuum transfer system.

6. Route the 1.3 in. (33 mm) OD clear vacuum transfer hose (G2) from the system to the adhesive pellets container location.

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

. 10.

NOTICE

To prevent shaker head (G1) galling to the shaker tube (G), do not overtighten shaker head onto shaker tube. These should be hand-tightened.

ties (G5). See F

. 10.

10. If desired, secure the 1.3 in. (33 mm) clear vacuum transfer tube (G2) and 3/8 in. OD air line (G4) with zip ties to a supporting structure at various points in the routing.

11. Attach the other end of the long 3/8 in. OD air line (G4) to the 3/8 in. push-to-connect fitting on the shaker head (G1).

12. Ensure the adhesive pellets container is in the desired operating location. The location should be chosen to make it easy to fill the container with pellets.

13. Place shaker assembly in an empty adhesive pellets container then fill the container with adhesive pellets.

NOTE: To promote optimal system performance, purchase 30 Gallon Vibrating Hopper, 24R136. See installation instructions on page 104.

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

. 7.

ti21131a

FIG. 10

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

. 10.

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

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

333347F 19

Setup

14. Install heated hoses, see FIG. 11:

To reduce the risk of fire and explosion, only use Graco heated hoses with the InvisiPac system. Use of non-Graco hoses will void agency approvals.

Applicator

247

FIG. 11

ti23298a

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

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

. 11.

f. Install hose onto hydraulic fitting (68) with male

electrical connector side toward the system. Use 11/16 in. wrench to tighten hose onto hydraulic fitting (68).

g. Locate MZLP (AA) connector marked with same

number as the hose fluid outlet port. Remove that connector cover then install connector from heated hose. See F

. 11.

h. Repeat the procedure for the remaining chan-

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

i. Install cap on any unused MZLP electrical con-

nectors.

NOTE: Fluid outlet port 1 must be used and electrical connector from that hose must be connected to MZLP connector 1. The system will not operate unless a hose is connected to MZLP connector 1. If a hose is not connected to connector 1, “Invalid Sensor - hose/gun” faults will result. If the melter must be run without a hose/applicator electrically attached to MZLP connector, use Overtemperature Jumper, 16Y727, page 113.

15. Install applicator(s), see F

. 11:

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

port plug (W1). See F

. 11.

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

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

plug (W1) then remove rag. See F

. 11.

d. Remove plug (247) from the lowest numbered

outlet on the melter. Do not use the drain

plug (W1). See F

. 11.

NOTE: In the following step, the o-ring side of the

hydraulic fitting (68) faces the system. See F

. 11.

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

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

NOTE: Use of a Graco applicator is not required with this system. However, all applicators attached to the system must be rated for 1200 psi (8.3 MPa, 83 bar), 400°F (204°C), have an RTD type sensor, and use no more than 400W at 240 VAC.

a. Connect heated hose fluid outlet to applicator

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

. 11.

b. For Graco applicators, attach applicator electri-

cal connector to heated hose electrical connec-

tor. See F

. 11.

c. For non-Graco applicators, attach applicator

electrical connector to adapter harness 16T916, 16T917, or 16Y828 then attach adapter harness connector to heated hose connector. See Non-Graco Applicator Adapter Cables on page 101 to determine which adapter cable to use with your applicator.

20 333347F

Setup

d. Repeat for any additional applicators.

16. If necessary, set up the pattern controller (not included) to control opening and closing of the applicator. See pattern controller manual.

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

17. Install the supplied air inlet bleeding ball valve and air filter kit (Graco Part No. 24R707) at the 1/4 NPT female system air inlet (J). See F

. 12.

NOTE: Elbows and riser tube provided with inlet air kit are optional and may be used as desired.

19. Close the ball valve.

WLE

FIG. 13

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

. 13.

NOTE: Air supply pressure must be between 80 psi (550 kPa, 5.5 bar) and 100 psi (690 kPa, 6.9 bar). Recommended pressure is 100 psi (690 kPa, 6.9 bar). If air pressure is expected to drop below 80 psi (0.5 MPa, 5 bar), there is an air reservoir kit that allows the system to operate down to 60 psi (0.4 MPa, 4 bar). See Air Reservoir Kit, 16W366, on page 107.

WLE

FIG. 12

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

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

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

18. If using the same air for the applicator(s), make sure

to install the tee in the air line before the ball valve. There should not be anything between the ball valve and the system. See applicator manual for applica- tor air pressure requirements, and use a regulator before the gun to decrease the air pressure, if necessary.

21. To lock access to the air pressure adjustments, purchase Air Adjustment Lock, 24R084. See installation instructions on page 101.

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

system error occurs, purchase Light Tower Kit, 24R226. See installation instructions on page 106.

23. To upgrade a 2 channel system to a 4 channel system, purchase 4 Channel Upgrade Kit, 24V528.

See installation instructions on page 108.

24. To upgrade a 4 channel system to a 6 channel sys- tem, purchase 6 Channel Upgrade Kit, 24V529. See installation instructions on page 110.

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

333347F 21

Setup

Recommended Air Setup

Main Air Line

Air In: Less than 50 ft (15.2 m): 3/8 in. More than 50 ft (15.2 m): 1/2 in. 80-100 psi (5.5-6.8 bar, 0.55-6.8 MPa) 30 scfm capacity.

Ensure funnel air is connected

Air Filter/Ball Valve at

System Air Inlet

(Graco Kit 24R707,

included)

Vacuum Pump

No dips in vacuum transfer hose

Vacuum:

40 - 80 psi (2.8-5.5 bar,

0.28-0.55 MPa);

and at least 65% of hopper

shaker air pressure, if used

Air In:

3/8 in.,

100 psi

(6.8 bar, 0.68 MPa),

30 scfm capacity

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

0.14-0.68 MPa)

WLE

Regulator set to

Air to applicators

70 psi

(4.8 bar, 0.48 MPa)

FIG. 14

22 333347F

Setup

Connect Electrical Cord

NOTE: See Grounding section on page 17.

Improper wiring may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform any electrical work. Be sure your installation complies with all National, State and Local safety and fire codes.

To reduce the risk of electric shock, perform the entire Attach Components procedure beginning on page 17 prior to connecting electrical cord.

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

0.708-1.260 in. (18-32 mm) OD electrical cord. See F

15. If needed, use a wrench to tighten the strain relief bushing until it is snug on the cable.

The accessory strain relief bushing kit 24X190 is available for smaller (0.512-1.024 in, 13-26 mm) OD electrical cords. See Accessories, page 100.

5. Attach insulated ferrules to the end of each wire.

106

FIG. 15

6. Connect ground wire to chassis ground (AF). See F

. 15.

7. Connect L1, L2, L3, and N as shown in F all models use all 4 wires.

WLD

. 16. Not

For 208V Electrical Circuits, see page 24.

1. Turn main power switch OFF.

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

3. Remove electrical enclosure access door (T). See F

. 2 on page 12.

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

. 15.

a. Alternate electrical cord routing: using conduit,

run electrical cord from access port (X) through hole (Y). Conduit is required when routing wires near compressed air components.

FIG. 16

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

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

10. Install electrical enclosure door.

11. Perform Select ADM Settings on page 24 prior to turning on heat.

333347F 23

Setup

208V Electrical Circuits

For 208V electrical supply, a qualified electrician can install a 208V to 240V step-up transformer to improve startup times.

Transformer Sizing

Minimum transformer rating can be calculated by taking transformer output voltage times the ADM breaker setting.

Single Phase, 20A ADM Breaker Setting Example:

240 volts x 20 amps = 4800 watts

Three Phase, 20A ADM Breaker Setting Example:

240 volts x 20 amps x SQRT(3) = 8315 watts

Select ADM Settings

NOTE: See Appendix A - ADM on page 114 for

detailed ADM information, including general operation.

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

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

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

4. On the System 3 screen:

1. Turn main power switch ON .

2. When the ADM is finished starting up, press

to switch from the Operation screens to the Setup

screens. Use , , , and to navigate

between screens.

3. On the System 2 screen:

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

channel that has a heated hose and applicator installed.

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

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

NOTE: The InvisiPac system limits the amount of power it pulls based on the input circuit breaker size. This impacts the startup times because it affects the heating energy used to warm up the materials.

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

b. Select the RTD type used on each installed

applicator. See applicator manual.

24 333347F

Setup

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

7. To setup the optional Schedule function, see

Schedule on page 33.

NOTE: The Schedule function enables the system to

automatically enable and disable heating at specified times so that the system is already up to temperature when a shift begins.

8. If desired, set any remaining settings in the Setup screens before going on to the next steps that use the Operation screens. These are not required for system operation but include useful functions. See Appendix A - ADM, beginning on page 114, for detailed information about each setup item.

9. Press to switch from the Setup screens to the

Operation screens. Use , , , and to

navigate between screens.

10. On the Targets screen, use and , shown

next to , to adjust system melter setting.

Also, the desired temperature setting can be typed in using the numeric keypad.

333347F 25

Setup

11. On the Targets screen, adjust heated hose and applicator temperature settings:

NOTE: InvisiPac is a high powered tank-free system that delivers heat faster than traditional tank systems. Tanks are often run at a lower temperature than the application temperature to avoid excessive adhesive degradation since a large volume of adhesive sits at temperature.

a. Press to select the channel.

b. Use and , shown next to , to

adjust applicator temperature setting to the desired setting for that channel.

NOTE: If a higher applicator temperature is desired, adjust all zones to the higher temperature or adjust only the applicator in small increments.

NOTE: Alternatively, use the physical up and down

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

numeric keypad to enter the desired temperature.

NOTICE

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

ring, page 36.

See Operation Tips to Minimize Char-

Applicators

Applicator heating is controlled by the system, but the system does not control opening and closing the applicators. Setup a separate pattern controller to open and close the applicators.

NOTE: Alternatively, use the physical up and down

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

c. Use and , shown next to ,

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

26 333347F

Setup

PLC Connection

A PLC can control and monitor all items shown in the dropdown menus on the System 1 screen in the Setup screens.

Customer Input Dropdown Options

Option Description

Disable Not used.

Heater On/Off Turn on or off the heating system and

pump.

Channel 1, 2, 3, 4, 5, or 6 Enable/Disable

Customer Output Dropdown Options

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

NOTE: The InvisiPac system ships with two screw-terminal connectors that plug into MZLP connectors H1 and H2. Connectors are located in a bag on the inside of the electrical enclosure front access door. To replace the connectors, order kit 24P176.

1. On the System 1 screen (in the Setup screens) select the function of each input on MZLP connector H1 and each output on MZLP connector H2.

2. Turn main power switch OFF.

3. Remove electrical enclosure front access door.

4. Route I/O cable through strain relief in electrical enclosure. See Customer I/O Cable (S) in F

. 1 on

page 11.

5. Remove power from PLC.

6. Connect the PLC to connectors H1 and H2.

NOTE: Each connector has four signals. The MZLP board specifies the input range for each signal. See the following table for pin assignments.

F10

Option Description

Disable Not used.

System Ready Indicates when the system is up to tem-

perature and the pump is stalled at pressure.

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

An active alarm will disable the heating system and pump.

Error (Deviation/Advisory)

Maintenance Due Indicates when the maintenance total

Indicates when there is an active deviation or advisory. An active deviation or advisory will NOT disable the heating system and pump.

has reached the preset notification value.

NOTE: All outputs are normally open when power is OFF. For Error (Alarm) output, the contacts open when an alarm occurs. For all others, contacts close.

WLD

FIG. 17: MZLP Board

H1 - Customer Input H2 - Customer Output

Signal Pin Signal Pin

1 1, 2 1 1, 2

2 3, 4 2 3, 4

3 5, 6 3 5, 6

4 7, 8 4 7, 8

Inputs: High: 10-30 Vdc, Low: 0-5 Vdc. Inputs function without concern for polarity. Applying “high” voltage will turn the heaters on and enable channels. Removing voltage will turn the heaters off and disable channels.

Outputs: 0-250 Vac, 0-30 Vdc, 2A Maximum.

333347F 27

Setup

PLC Connection Block Diagrams

The following block diagrams show how to connect customer inputs and outputs to the InvisiPac MZLP. For convenience, each InvisiPac ships with connector kit 24P176. If a connector is lost or damaged, order kit 24P176 for replacements.

FIG. 18: Customer Input

MZLP Customer In

Customer Output

Vin (no polarity) 30 VDC Max

MZLP Customer Out

Customer In

250 VAC, 0-30 VDC, 2A Max

To Customer Input

FIG. 19: Customer Output

28 333347F

Operation

Heating and dispensing hot melt adhesive may create potentially harmful vapors. Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions. Ventilation of the work area may be required.

Operation

Initial Startup and Prime

NOTE: All setup procedures must be completed prior to initial startup. See Setup on page 17.

NOTE: See Appendix A - ADM on page 114 for

detailed ADM information.

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

NOTE: See Appendix B - USB Downloading, Uploading on page 120 for detailed USB information.

Overview

The system includes a vacuum transfer system that pulls the adhesive pellets into the system as needed. Once melted, the adhesive enters the pump where it is pumped into the heated hoses then to the heated applicators. The applicator then briefly opens to dispense the desired quantity of adhesive.

Even though the system rises to operating temperature quickly, there is a Schedule function in the ADM that eliminates waiting for the system to heat up. The Schedule function automatically enables the heating system at the user-specified times so the system is ready to dispense when a shift begins. The Schedule function also disables the heating system at user-specified times to ensure the heating system is disabled when not being used.

NOTE: Only 1/4 in. (6 mm) round hot melt adhesive pellets can be used in the InvisiPac system. PSA-type adhesive pellets will not work in the InvisiPac system.

1. Direct the applicator into an appropriate waste container.

2. Verify the shaker inlet is at the bottom of the empty adhesive pellets container. Optional vibrating adhesive pellets container, part 24R136, is available. See Accessories on page 100.

NOTE: The shaker inlet must be completely covered in adhesive pellets to effectively pull pellets into the tube.

3. Fill adhesive pellets container with hot melt adhesive pellets.

4. Turn main power switch ON .

5. Open system air inlet ball valve.

WLE

333347F 29

Operation

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

FIG. 20

7. Use vacuum transfer air pressure regulator (E) to adjust vacuum transfer air pressure setting to 40-100 psi (280-690 kPa, 2.8-6.9 bar). Recommended setting is 60 psi (414 kPa, 4.1 bar). See F

. 20.

NOTE: If using shaker accessory, regulator should be set to at least 65% of air pressure connected to shaker.

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

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

250°F (121°C) and the funnel is filled with pellets, set the melter temperature back to the desired operating temperature. See Select ADM Settings on page 24 for instructions.

11. Use separate pattern controller to open the applicators and keep them open.

NOTICE

In the following step, to prevent damage to the pump due to pump cavitation, do not supply more than 20 psi (140 kPa, 1.4 bar) air pressure to the pump until the system is fully primed.

12. With the applicators open and the system up to temperature, slowly increase pump air pressure until the pump begins to run very slowly. Approximately 20 psi (140 kPa, 1.4 bar) should be sufficient.

NOTE: Operation may be erratic below 20 psi (140 kPa,

1.4 bar).

13. Continue running the pump until clean, air-free material is dispensed from each applicator.

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

To prevent fire and explosion, never exceed the cleaning fluid’s rated temperature. If the system was just flushed, residual cleaning fluid is still in the system until the system is primed with adhesive. Do not raise temperature above cleaning fluid rated temperature until system is primed with adhesive.

NOTE: A new system may have residual oil due to testing at the factory prior to shipping. To prevent smoking, make sure to perform the following step.

8. On new systems only: temporarily adjust the melter

temperature to 250°F (121°C). See Select ADM Settings on page 24 for instructions.

9. Press to enable the heaters and pump.

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

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

a. Adjust pump pressure to between 20-100 psi

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

b. Use separate pattern controller to repeatedly

open and close each applicator while inspecting the dispense pattern.

c. Repeat until desired dispense pattern is

achieved.

Manual Refill

NOTE: Use Automatic Refill whenever possible. The

system uses Automatic Refill by default and must be manually changed to Manual Refill. Only use Manual Refill if the Automatic Refill system is not functioning properly and cannot be fixed in a timely manner. Perform service to automatic feed system as soon as possible to limit debris buildup on feed funnel.

30 333347F

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