INSTRUCTIONS-PARTS LIST
309280
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
First choice when
quality counts.t
Rev. A
Ultra–Flo Shot Metering Dispenser
2500 psi (17.2 MPa, 172.4 bar) Maximum Fluid Working Pressure
The Ultra–Flo Shot Metering Dispensers listed below
are described in this manual. These units are specifically designed to be used with robotic equipment. Use
of the Graco Ultra–Flo Shot Metering Dispenser with
non–robotic equipment can result in personnel injury or
damage to equipment.
List of Models
Part No. 243348, Series A
Without board for Precision Swirl
Part No. 243349, Series A
With board for Precision Swirl
Part No. 244816, Series A
Without board for Precision Swirl and
without temperature conditioning jacket
Part No. 244817, Series A
With board for Precision Swirl and
without temperature conditioning jacket
TI0853
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 2001, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Motor Drive
provided by other
manufactures.
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Uncrating the System 5. . . . . . . . . . . . . . . . . . . . . . . . .
Overview 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metering and Application System 5. . . . . . . . . . . . .
Metering assembly operation 5. . . . . . . . . . . . . . . . .
Refill System operation 5. . . . . . . . . . . . . . . . . . . . . .
Junction Box Panel 5. . . . . . . . . . . . . . . . . . . . . . . . .
Required Air Supply 5. . . . . . . . . . . . . . . . . . . . . . . . .
Required Electrical Supply 5. . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing the Site 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing to Install the System 6. . . . . . . . . . . . . . .
Initial Checkup and Startup 6. . . . . . . . . . . . . . . . . . .
Grounding the System 7. . . . . . . . . . . . . . . . . . . . . . .
Flushing the System Before Initial Use 7. . . . . . . . .
Initial Material Loading and Filling 8. . . . . . . . . . . . .
Supply Pump Adjustment 8. . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 8. . . . . . . . . . . . . . . . . . .
Connecting Power to the Junction Box 9. . . . . . . . .
Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare the Operator 11. . . . . . . . . . . . . . . . . . . . . . .
Initial System Startup Procedure 11. . . . . . . . . . . . .
Loading and Filling 11. . . . . . . . . . . . . . . . . . . . . . . . .
System Shut Down 11. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultra–Flo Assembly 12. . . . . . . . . . . . . . . . . . . . . . .
Junction Box Panel 12. . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Schedule 13. . . . . . . . . . .
Flushing the System 13. . . . . . . . . . . . . . . . . . . . . . .
Service 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Junction Box Panel 14. . . . . . . . . . . . . . . . . . . . . . . .
Fuse Removal 14. . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement 14. . . . . . . . . . . . . . . . . . . . . .
Surge Suppressor Removal 14. . . . . . . . . . . . . .
Surge Suppressor Replacement 14. . . . . . . . . .
Connecting Power to the Junction Box 15. . . . . . . .
Electrical Diagram
Shot Meter Assembly Piston Rod Seal 17. . . . . . .
Ball Screw Repair and Bearing Replacement 18. . . .
System Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Spare Parts 23. . . . . . . . . . . . . . . . . . .
Integration Data 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Vacuum Curve 25. . . . . . . . . . . . . . . . . . . . . .
Dimensions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 28. . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 28. . . . . . . . . . . . . . . . . . . . . . . .
16. . . . . . . . . . . . . . . . . . . . . . . . .
2 309280
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
D Wear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the pump.
D Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
309280 3
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the guards in place when spraying.
D Follow the Pressure Relief Procedure on page 8 whenever you are instructed to relieve pressure;
stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
D Use only Graco approved hoses. Do not remove any spring guard that is used to help protect the
hose from rupture caused by kinks or bends near the couplings.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
D Ground the equipment and the container where the material is deposited. Refer to Grounding the
System on page 7.
D If there is any static sparking or you feel an electric shock while using this equipment, stop the
pumps immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not operate a gasoline engine in the spray area.
4 309280
Uncrating the System
The Ultra–Flo Shot Metering Dispenser was carefully
packaged for shipment by Graco. When the system
arrives, perform the following procedure to uncrate the
system.
WARNING
EQUIPMENT MOVING HAZARD
Removing the unit off the pallet without following
the uncrating procedure could cause personal
injury and possible damage to the equipment.
To uncrate the system, do the following:
1. Inspect the crate carefully for shipping damage.
Contact the carrier promptly if damage is discovered.
2. Remove the sides and top of the crate.
3. Inspect the contents carefully. There should not be
any loose or damaged parts.
4. Compare the packing slip against all items included in the crate. Report any shortages or other
inspection problems immediately.
5. Remove the band straps that hold the Ultra–Flo to
the pallet.
NOTE: The Ultra–Flo is ready for installation. Before
installing the system, read the “Overview” section on
page 5 to become familiar with the system components.
Overview
Metering and application system
The complete Ultra–Flo Shot Metering Dispenser (SMD) is comprised of three components; shot meter and drive
unit (with pressure and over travel sensing), inlet valve with air solenoid, and junction box, all assembled together
as a single package. The SMD can be mounted on top of a stand or nearly anywhere else. It’s connected by hoses
to a pneumatically operated dispensing assembly (not included), which can be adapted to mount on almost any robot arm. The remaining two dispensing and control components and corresponding installation and operation
instructions are provided by other manufactures.
A typical robotic metering assembly consists of an Ultra–Flo 50 cu. in. Shot Metering Dispenser, and automatic dispense valve. The materials are dispensed from the meter through an automatic dispense gun. The location of the
Ultra–Flo should be as close to the dispensing area as possible or mounted directly to the robot frame.
Metering assembly operation
A user supplied servo motor transmits power to the
ball screw. A push block is attached to one end of the
ball screw. The push block presses against the piston
moving it into the cylinder and forcing the sealant or
mastic out.
Refill System operation
When the lead screw reaches its pre–determined extension and the material is expended from the cylinder,
the motor reverses which retracts the ball screw and
push block. A fill valve which is threaded into the cylinder wall is opened and the sealant or mastic is forced
into the cylinder through an annular passage between
the outside of the displacement rod and the inside of
the cylinder. With the refill cycle complete, the fill valve
is closed, and the system is ready to resume dispensing. Two proximity switches act as safety backups for
both fill and dispensing to shut the system down in the
event of displacement rod overtravel. End of travel,
and end stroke marks are provided on the tie rods for
reference.
Junction Box Panel
The junction box panel includes the necessary termination points for communication back to the controller.
Required Air Supply
The system requires a 1/8” NPT(m) air line to the
Ultra–Flo meter. The air supply should be filtered, and
capable of maintaining a minimum of 60 PSI under all
operating conditions.
Required Electrical Supply
The electrical controls for the system are provided by
the Robot Manufacturer’s Control System.
Over Pressure Protection
A 5000 psi rupture disc is provided for over pressure
protection.
Temperature Conditioning
This unit includes a water jacket that encloses the fluid
cylinder. For temperature conditioning, 1/2 NPT(F) inlet
and outlet ports are provided to connect to a conditioned water supply and return. Maximum water pressure of this jacket is 100 psi.
309280 5
Installation
Preparing the Site
Ensure that you have an adequate compressed air
supply. Keep the site clear of any obstacles or debris
that could interfere with the installer’s and operator’s
movement.
Preparing to Install the System
Before installing the system:
D See component manuals for specific data on com-
ponent requirements. Data presented here pertains
to the system only.
D Have all system and subassembly documentation
available during installation.
D Be sure that all non-Graco supplied hoses are
adequately sized and pressure-rated to meet the
system requirements.
D Have all robot manufacturer’s instructions and
system documentation available for reference.
Initial Checkup and Startup
WARNING
PRESSURIZED EQUIPMENT HAZARD
To prevent the the risk of injury or equipment damage, do not pressurize the system until you have verified the system is
ready and it is safe to operate.
1. Check all material hoses and fittings to ensure
tightness to prevent any material leakage. Ensure
that Input and Output hoses are correctly connected (See Fig.1).
1/4” O.D. tube
fitting air inlet
solenoid valve
TI0853
Servo Drive provided
by other manufactures
Fig. 1
2. Check all system air lines and automatic gun
plumbing. Make sure that routing of all lines and
cables will not interfere with any moving components with the fixture.
Fluid Outlet
3/4” npt (female)
1/2” NPT Ports
for Temperature
Conditioning
Fluid Inlet
(on valve
body) 1/2 npt
(female)
6 309280
WARNING
PRESSURIZED FLUID HAZARD
To reduce risk of injury or equipment
damage:
D Make sure all material hose con-
nections are secure.
D Check that all routing of air lines
will not interfere with any moving
components within the fixture.
D Do not pressurize the system until
you have verified the system is
ready and it is safe to do so.
3. Connect temperature conditioning water supply
line.
a. Connect water supply line to either of the two
1/2” temperature conditioning ports.
b. Connect water return line to second 1/2” port.
4. Follow system instructions of supply equipment.
5. Perform initial material loading and filling per
system instructions.
Installation
Grounding the System
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 4.
1. Fluid Pump (not provided): use a ground wire and
clamp. See Fig. 2. Loosen the grounding lug
locknut (W) and washer (X). Insert one end of a 12
ga (1.5 mm@) minimum ground wire (Y) into the
slot in lug (Z) and tighten the locknut securely.
Connect the other end of the wire to a true earth
ground. For a ground wire and clamp, order Part
No. 237569.
Z
Y
Flushing the System Before Initial Use
Flushing the system before its initial use can prevent
material contamination, which may cause the material
to fail or perform poorly.
CAUTION
Flush the system before performing the initial
material loading procedure. The system was facto-
ry tested using a light soluble oil, a soybean oil, or
some other oil as tagged. Flush the system to avoid
contaminating the material that has been designated
for initial material loading.
To flush the system, perform the following procedure:
1. Select the material for the initial material load.
2. Verify whether the factory-test oil and the initial
material load are compatible:
a. If the two substances are compatible, omit the
remaining steps in this procedure and perform
the Initial System Startup Procedure on
page 11.
b. If the two substances are incompatible, per-
form the remaining steps in this procedure to
flush the system.
X
W
Fig. 2
2. Air and fluid hoses: Use only electrically conductive hoses.
3. Air compressor: follow manufacturer’s recommendations.
4. Spray gun or dispensing valve: ground through
connection to a properly grounded fluid hose and
pump.
5. Object being sprayed: follow your local code.
6. Fluid supply drum: follow your local code.
7. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive
and placed on a grounded surface. Do not place
the pail on a nonconductive surface, such as paper
or cardboard which interrupts the grounding continuity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray /
dispensing gun firmly to the side of a grounded
metal pail, then trigger the gun.
0720
WARNING
Use fluids and solvents that are chemically compatible with the equipment wetted parts. See the
Technical Data sections of all the equipment
manuals. Always read the material manufacturer’s
literature before using fluid or solvent in this equipment.
To avoid damaging the unit do not use fluids containing halogenated hydrocarbons (HHC) to flush or
clean the system as HHC is not compatible with
aluminum. See technical data on page 24 for a list
of wetted parts.
3. Select a drum containing a compatible material
that can dissolve, clean, and eliminate the factorytest oil from the system. If necessary, check with
the material supplier for a recommended flush material.
4. Before flushing, be sure the entire system and
flushing drums are properly grounded. Refer to
Ground the System, on page 7.
5. Perform the Initial System Startup Procedure
steps on page 11 to load the drum containing the
solvent.
6. Run the flush material through the system for
approximately 1 to 2 minutes.
7. Remove the drum containing the flush material.
309280 7
Installation
Initial Material Loading and Filling
WARNING
MOVING PARTS HAZARD
To reduce risk of injury or damage to
equipment, make sure all material hose
connections are secure.
WARNING
PRESSURIZED FLUID HAZARD
To reduce the risk of serious bodily injury,
such as fluid injection or splashing fluid in
the eyes or on the skin, always wear eye
protection and protective clothing when installing,
operating, or servicing this dispensing system.
1. Verify that supply lines to the meter are filled (see
Loading and Filling on pg 11).
NOTE: Remove or open the dispense valve. Place the
valve or hose end over an appropriate material waste
container, and open the material inlet valve to the
meter. This will allow the system to fill without restriction.
2. Turn on Ultra–Flo unit per Start–up control instructions supplied by Robot Manufacturer.
NOTE: During initial system fill, use a relatively low
speed, 20–30% of full speed.
3. Turn on the air supply to the pumps and ram.
4. Dispense and reload the meter until air–free material is dispensed.
Supply Pump Adjustment
Adjust the air pressure to each supply unit pump until
the desired flow rate/bead characteristics are
achieved, and the mastic regulator has been adjusted.
For the Ultra–Flo meter do not exceed 2500 psi material pressure on the meter. Pressures between 500 and
2000 psi are ideal.
WARNING
PRESSURE RELIEF PROCEDURE
To reduce the risk of serious bodily
injury, including fluid injection, splash-
ing in the eyes or on the skin, or injury
from moving parts, always follow this procedure
whenever you shut off the pump, such as before
checking and servicing system components.
1. Engage the dispensing valve safety latch (if
applicable).
2. Shut off air supply to the pump and ram.
3. Open the drain valve and/or pump bleeder
valve. Have a container ready to catch the
material drainage.
4. Release the dispensing valve latch and trigger
the dispensing valve to relieve any additional
pressure.
5. Leave the drain valve open until you are ready
to dispense again.
NOTE: While dispensing, verify that the dispense valve
is open during a dispense cycle, and closed otherwise.
5. Set the desired flow rate per Robot Manufacturer’s
Control Instructions.
CAUTION
The inlet pressure to the meter should never exceed
2500 psi.
NOTE: Adjust the inlet valve stroke so that the cylinder
rod retracts at approximately 1/2” per second.
NOTE: You will notice pressure faults (Robot Dispensing Controls) and bleed interruptions until the meter is
full, and until the required flow rate is established.
8 309280
If you suspect the dispenser nozzle or hose has
become completely clogged, or that pressure has
not been fully relieved after following the steps
above, VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve the pressure gradually, then loosen completely. Clear the
tip or hose at this point.
Installation
Connecting to the Junction Box
Refer to Robot Manufacturer’s supplied Control and
System Instructions for connecting power to the junction box. All power to the junction box is provided by
multi wired cables with matching pin connectors that
connect to mating connector that is attached to the
junction box (see connector information on page 24).
WARNING
ELECTRIC SHOCK HAZARD
Do not connect the junction box panel to
a power source unless you are a trained
electrician. Failure to follow standard
procedures or to observe the necessary precautions could result in serious bodily injury or equipment damage.
CAUTION
If power and grounding connections are not done
properly, the equipment may be damaged and the
warranty will be voided.
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury. Have only qualified electricians access the
control assembly.
309280 9
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