Graco 313877E User Manual

Setup - Operation

PD44

Control Box

Meter, mix and dispense system for precise two-component micro-dispensing of sealants and adhesives. Not for use in explosive atmospheres.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 3 for model information, including maximum working pressure and approvals.

313877E

Micrometer PD44 and LRT PD44 Control Box shown

Contents

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

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Component Identification . . . . . . . . . . . . . . . . . . . . 6

Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PD44 Dispense Valve . . . . . . . . . . . . . . . . . . . . . 8

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Micrometer and LRT PD44 Only . . . . . . . . . . . . 10

Motor Driven PD44 Only . . . . . . . . . . . . . . . . . . 11

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Dispensing Operation . . . . . . . . . . . . . . . . . . . . . . 13

HMI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Screen Navigation Diagrams . . . . . . . . . . . . . . 14

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Posidot Control Screen

(Micrometer PD44 and

LRT PD44 only) . . . . . . . . . . . . . . . . . . . . . 17

Metering Valve Control Screen

(Motor Driven PD44 only) . . . . . . . . . . . . . . 18

Shot Size Screen

(LRT PD44 only) . . . . . . . . . . . . . . . . . . . . . 20

Shot Size Screen

(Motor Driven PD44 Only) . . . . . . . . . . . . . 21

Level 1 Control Screen . . . . . . . . . . . . . . . . . . . 22

Level 2 Control Screen . . . . . . . . . . . . . . . . . . . 23

Purge Timer Screen . . . . . . . . . . . . . . . . . . . . . 25

Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Motor Status Screen

(Motor Driven PD44 only) . . . . . . . . . . . . . . 30

Motor Error Codes Screen

(Motor Driven PD44 Only) . . . . . . . . . . . . . 32

Supervisor Screen

(LRT PD44 Only) . . . . . . . . . . . . . . . . . . . . 33

Supervisor Screen

(Motor Driven PD44 Only) . . . . . . . . . . . . . 34

Supervisor Help Screen

(Motor Driven PD44 Only) . . . . . . . . . . . . . 35

Calibration Screen

(LRT PD44 Only) . . . . . . . . . . . . . . . . . . . . 36

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 38

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Optional Customer Inputs . . . . . . . . . . . . . . . . . . . 39

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42

2 313877E

Related Manuals

PD44 Manuals

Part Description

313876 PD44 Dispense Valve Operation - Parts

Feed System Manuals

306565 Air-Driven, Stainless Steel Agitators

307043

308116 Severe-Duty, UHMWPE/PTFE or PTFE

308167 Low Volume Air Regulators

308168 High Volume Air Regulators

308169 Air Filters, Lubricators and Kits

309306

312376 Stainless Steel Agitator Kit

313526

406088

Monark

Packed Stainless Steel Pumps

Air-Operated Husky

Check-Mate

Air Motor

Pump Packages

Ram Packages

™

Diaphragm Pumps

Related Manuals

Models

Max Air Working

PD44 Control Box

Model

Linear Resistive

Transducer (LRT)

Micrometer

Motor Driven

* If a custom PD44 is ordered, it will not be CE

approved unless otherwise noted.

Pressure

psi (MPa, bar) Voltage CE Approved*

100 (0.7, 7) 120/240V,

✔

50/60Hz

✔

50/60Hz

✔

50/60Hz

313877E 3

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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

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 MSDS’s 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.

• Always wear impervious gloves when spraying or cleaning equipment.

• If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate Conditions Section of this manual.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

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:

• 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.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

4 313877E

Warnings

WARNING

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

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.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual 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.

• 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.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage. See Technica l Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s warnings.

313877E 5

Component Identification

Control Boxes

AB C

Key:

A Emergency Stop B Control Power Switch C Touch Panel D Alarm Speaker E Power Input F Start Options Connection GCustom I/O H A Tank Level Controls Connection J B Tank Level Controls Connection

HJGFE

A TANK

B TANK

CUSTOMER I/O

START

5 34

617

PG-3

LEVEL CONTROLS

5 34

PG-4

SPOOL VALVE

108 107

LOAD

SIGNAL CONNECTION

5 34

PG-2

PG-8

AIR

CYLINDER

106

105

RET

DISP

EXT

LEVEL CONTROLS

KMain Air Inlet L Dispense Valve I/O Connection M Spool Valve Load Connection N Spool Valve Dispense Connection P Air Cylinder Extend Connection R Air Cylinder Retract Connection S Air Pressure Regulator T Air Pressure Gauge

100V TO 250V AC

MACHINE I/O

12563

11 8

129131014

PG-1

KM NPR

FIG. 1: Micrometer and LRT PD44 Control Box

6 313877E

BAC

CONTROL POWER

Component Identification

AUDIO ALARM

START OPTIONS

MOTOR

VALVE I/O

VERIFY INCOMING VOLTAGE

WITH VOLTAGE SWITCH SETTING

BEFORE CONNECTING POWER

Key:

A Emergency Stop B Control Power Switch C Touch Panel D Alarm Speaker E Power Input

FIG. 2: Motor Driven PD44 Control Box

F Start Options Connection H A Tank Level Controls Connection J B Tank Level Controls Connection L Dispense Valve I/O Connection U Motor Connection

313877E 7

Component Identification

PD44 Dispense Valve

See PD44 Operation manual 313876 for detailed dispense valve component identification and instructions.

IG. 3: PD44 Micrometer Dispense Valve

8 313877E

Grounding

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.

Grounding plug units: this product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Hard-wired units: the grounding wire must be used. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Grounding

Air and fluid hoses: use only electrically conductive hoses.

Fluid supply container: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts grounding continuity.

313877E 9

Setup

Micrometer and LRT PD44 Only

1. Connect air supply to main air inlet on control box. Air supply must include a shut-off/bleed valve that bleeds pressure past the shut-off/bleed valve and an air-water separator/filter.

A TANK

B TANK

CUSTOMER I/O

START

CYLINDER

100V TO 250V AC

PG-8

MACHINE I/O

12563

11 8

129131014

PG-1

AIR

105

RET

5 34

617

PG-3

LEVEL CONTROLS

5 34

PG-4

SPOOL VALVE

108 107

LOAD

SIGNAL CONNECTION

5 34

PG-2

106

DISP

EXT

LEVEL CONTROLS

2. Connect air lines from control box to dispense valve. Match the number and color codes on the fittings and connections. See the following table and illustration.

3. Connect Dispense Valve I/O, and Start Options logic cables. If level controls are installed, connect Level Controls logic cables.

NOTICE

Feed system and main logic control system must use separate air supplies.

A TANK

B TANK

CUSTOMER I/O

START

106

EXT

CYLINDER

100V TO 250V AC

PG-8

MACHINE I/O

12563

11 8

129131014

PG-1

AIR

105

RET

LEVEL CONTROLS

5 34

617

PG-3

LEVEL CONTROLS

5 34

PG-4

SPOOL VALVE

108 107

LOAD

SIGNAL CONNECTION

5 34 7

PG-2

DISP

4. Adjust air pressure regulator to 80 psi (0.6 MPa, 6bar).

5. Perform Setup procedure for dispense valve and feed system components. See Related Manuals on page 3.

Connection Color

Connection Description

Red Extend Blue Retract Yellow Dispense Green Reload

A TANK

B TANK

CUSTOMER I/O

START

CYLINDER

100V TO 250V AC

PG-8

MACHINE I/O

12563

11 8

129131014

PG-1

AIR

105

RET

5 34

617

PG-3

LEVEL CONTROLS

5 34

PG-4

SPOOL VALVE

108 107

LOAD

SIGNAL CONNECTION

5 34

PG-2

106

DISP

EXT

LEVEL CONTROLS

10 313877E

Motor Driven PD44 Only

1. Connect Dispense Valve I/O, Start Options, and Motor logic cables. If level controls are installed, connect Level Controls logic cables.

NOTICE

Feed system and main logic control system must use separate air supplies.

AUDIO ALARM

START OPTIONS

MOTOR

VALVE I/O

VERIFY INCOMING VOLTAGE

WITH VOLTAGE SWITCH SETTING

BEFORE CONNECTING POWER

Setup

2. Adjust customer supplied air pressure regulator to 80 psi (0.6 MPa, 6 bar).

3. Perform Setup procedure for dispense valve and feed system components. See Related Manuals on page 3.

313877E 11

Startup

NOTE: See HMI Operation starting on page 14 for

detailed HMI instructions.

1. Press the Control Power On button.

2. On Micrometer and LRT PD44s, navigate to the Posidot

On Motor Driven PD44s, navigate to the Metering Valve Control screen.

3. Under Posidot Mode, press the Retract button.

NOTE: On LRT and Motor Driven PD44s, when there is an Emergency Stop condition or the system power is lost, the shot selection resets to “0”. The operator must then select a shot.

Control screen.

NOTE: On Micrometer PD44s, skip steps 4-7.

4. Navigate to the Shot Size screen.

5. Select a shot number.

6. Navigate to the Pump Mode screen.

7. Press the Shot button to select Shot Mode.

8. Verify air pressure is set to 80 psi (5.6 bar).

9. Perform feed system startup procedure(s). See Related Manuals on page 3.

10. Perform dispense valve startup procedure. See Related Manuals on page 3.

12 313877E

Dispensing Operation

NOTE: See HMI Operation on page 14 for detailed HMI instructions.

The foot switch, the “Start” button, and the optional Customer Start Signal can be used to initiate shots. These are referred to as start devices.

Perform a Shot

1. On Micrometer and LRT PD44s, navigate to the Posidot Control screen. On Motor Driven PD44s, navigate to the Metering Valve Control screen.

2. Under Posidot Mode, press the Retract button.

3. Press the Shot button to select Shot Mode.

4. Press and release the start device to perform one shot.

Retract Piston

1. On Micrometer and LRT PD44s, navigate to the Posidot Control screen. On Motor Driven PD44s, navigate to the Metering Valve Control screen.

2. Under Posidot Mode, press the Retract button.

Extend Piston

1. On Micrometer and LRT PD44s, navigate to the Posidot Control screen. On Motor Driven PD44s, navigate to the Metering Valve Control screen.

2. Under Posidot Mode, press the Extend button.

Dispense Continuously

The valve dispenses continuously until the end of the stroke is reached.

1. On Micrometer and LRT PD44s, navigate to the Posidot Control screen. On Motor Driven PD44s, navigate to the Metering Valve Control screen.

2. Under Posidot Mode, press the Retract button.

3. Press the Continuous button.

4. On Micrometer and LRT PD44s, press and release the start device. Under Posidot Mode, press the Retract button to stop dispensing and retract the metering rods. On Motor Driven PD44s, press and hold the start device to dispense continuously. Release the start device to stop dispensing and retract the metering rods.

313877E 13

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