Graco 3A0260H User Manual
Instructions - Parts
PGM
Precision Gear Metering
For metering and dispensing ambient or high-temperature, high-viscosity
single-component materials.
Not approved for use in European explosive atmosphere locations.
For professional use only.
2500 psi (17.2 MPa, 172 bar) Maximum Working Outlet Pressure
1500 psi (10.3 MPa, 103 bar) Maximum Working Inlet Pressure
See Technical Data on page 99 for temperature ranges
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 4 for model information.
3A0260H
EN
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bulk Melt (Therm-O-Flow 20 + Therm-O-Flow 200)
and Ambient Hoses . . . . . . . . . . . . . . . . . . . 4
Remote Dispense Valves . . . . . . . . . . . . . . . . . . 5
Fixed Dispense Valves . . . . . . . . . . . . . . . . . . . . 5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Configurations . . . . . . . . . . . . . . . . . . . . 9
Component Identification . . . . . . . . . . . . . . . . . 11
System Overview . . . . . . . . . . . . . . . . . . . . . . . 12
Typical Applications . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Before Installation . . . . . . . . . . . . . . . . . . . . . . . 13
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install Control Center . . . . . . . . . . . . . . . . . . . . 14
Install Gear Meter Assembly . . . . . . . . . . . . . . . 15
Install Cable Assemblies . . . . . . . . . . . . . . . . . . 18
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Configure Control Settings . . . . . . . . . . . . . . . . 20
Configure Mode Settings . . . . . . . . . . . . . . . . . 20
Configure Delay Settings . . . . . . . . . . . . . . . . . 21
Adjust Pressure Sensors . . . . . . . . . . . . . . . . . 21
Configure Errors . . . . . . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance Mode Operation . . . . . . . . . . . . . . 24
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Dispense from Maintenance Screen . . . . . . . . . 26
Automation Control (Normal) Operation . . . . . . 27
Typical Automation Cycle . . . . . . . . . . . . . . . . . 27
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 28
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PGM Fluid Assembly . . . . . . . . . . . . . . . . . . . . . 31
Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 32
Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Diagnose Errors . . . . . . . . . . . . . . . . . . . . . . . . 33
Clear Errors and Reset Control Unit . . . . . . . . . 33
Error Codes and Troubleshooting . . . . . . . . . . . 33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Maintenance Schedule . . . . . . . . . . . . . . . . . . . 36
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Gear Meter Assembly . . . . . . . . . . . . . . . . . . . . 37
PGM-6 Pump Repair . . . . . . . . . . . . . . . . . . . . . 42
PGM-20 Pump Repair . . . . . . . . . . . . . . . . . . . . 46
Gear Pump Maintenance Guide . . . . . . . . . . . . 49
Installing new heater units and RTD sensors . . 50
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
PGM-20 Mounting Frame . . . . . . . . . . . . . . . . . 51
PGM-20 Lower Assembly Block . . . . . . . . . . . . 52
PGM-20 Pump Heat Kit . . . . . . . . . . . . . . . . . . 53
PGM Drive - 20 cc Pump . . . . . . . . . . . . . . . . . . 54
Endure Dispense Valve Fix Mounted . . . . . . . . 55
Gear Meter Assembly Panel . . . . . . . . . . . . . . . 56
PGM Back Panel . . . . . . . . . . . . . . . . . . . . . . . 58
Remote Mount Amplifiers . . . . . . . . . . . . . . . . . 59
PGM Remote Dispense Valve . . . . . . . . . . . . . 60
PGM Transducer . . . . . . . . . . . . . . . . . . . . . . . . 61
PGM-6 Mounting Frame . . . . . . . . . . . . . . . . . . 62
PGM-6 Drive Kit . . . . . . . . . . . . . . . . . . . . . . . . 63
PGM-6 Lower Assembly Block . . . . . . . . . . . . . 64
PGM-6 Pump Heat Kit . . . . . . . . . . . . . . . . . . . 65
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Automation Interface Cable Assembly . . . . . . . . 76
Dynamic Regulators . . . . . . . . . . . . . . . . . . . . . 77
Endure Valve Nozzles . . . . . . . . . . . . . . . . . . . . 80
Heater Nests . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2 3A0260H
Related Manuals
Appendix A - User Interface Display . . . . . . . . . . 81
Screen Navigation Diagram . . . . . . . . . . . . . . . . 81
Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Calibrate Screen #1 . . . . . . . . . . . . . . . . . . . . . . 83
Calibrate Screen #2 . . . . . . . . . . . . . . . . . . . . . . 84
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Maintenance Screen . . . . . . . . . . . . . . . . . . . . . 86
Robot I/O Screen . . . . . . . . . . . . . . . . . . . . . . . . 87
Setup #1 Screen . . . . . . . . . . . . . . . . . . . . . . . . 88
Setup #2 Screen . . . . . . . . . . . . . . . . . . . . . . . . 89
Setup #3 Screen . . . . . . . . . . . . . . . . . . . . . . . . 90
Setup #4 Screen . . . . . . . . . . . . . . . . . . . . . . . . 91
Setup #5 Screen . . . . . . . . . . . . . . . . . . . . . . . . 92
Setup #6 Screen . . . . . . . . . . . . . . . . . . . . . . . . 93
Supply Pump Screen . . . . . . . . . . . . . . . . . . . . . 94
Appendix B - I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Using the PGM I/O . . . . . . . . . . . . . . . . . . . . . . 95
Appendix C - Theory of Operation . . . . . . . . . . . . 98
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 98
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 100
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 100
Related Manuals
Part Description
309376 Endure Dispense Valve
310538 Heated Automatic Dispense Valve
311208 Therm-O-Flow 200
313296 Warm Melt Supply System
309213 Accessory Heat Zone Controls
313526 Ambient Supply Systems
3A0260H 3
Models
Models
Check the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to
define the construction of the system, based on the six digits. For example, Part PG0111 represents a PGM fluid
metering system (PG), with a 6cc system (0), unheated (1), with controls/3m (1), and an Endure snuff-back (1).
NOTE: To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the Ref. Nos. in the Parts drawings and lists.
PG 0
First and
Second Digits
PG
(Precision
Gear Meter)
1
Third Digit
Size
Description Description Description Description
Fourth Digit
Heat
1
Fifth Digit
Controls *
0 6cc 1 Unheated 0 No controls 1 Endure snuff-back
2 20cc 2 Heated 1 Controls / 3m 6 Remote mount
2
Sixth Digit
Valve
2 Controls / 6m
3 Controls / 9m
4 Controls / 15m
* PGM Control Center does not include heat controls. Heat loads are configured to be controlled by Therm-O-Flow
Controllers.
Bulk Melt (Therm-O-Flow 20 + Therm-O-Flow 200) and Ambient Hoses
Hose Diameter
- 8
3/4 in. - 16 JIC
6 ft None 115875 None 115884 109163 626720
10 ft 115873 115876 115880 115885 None 215441
15 ft Non None None None 109165/
Hose Length
PGM Inlet
(-16 SAE)
PGM Outlet
(3/4 in. npt)
Valve Inlet 124287 C20768 107052 124288 158256 † 190451 †
None None 124238
124286 C20595 15M863 107127 124290 † 124289 †
- 10
7/8 in. - 14 JIC
- 12
1-1/16 in. - 12
JIC
Fittings
124235 (90°)
- 16
1-5/16 in. - 12 JIC 3/8 in. 1/2 in.
(1/2 in. x 5 ft)
511381*
124239
124243 †
124236 (90°)
685602*
None None
* Indicates PTFE hose, all others Buna-N.
† Indicates swivel.
4 3A0260H
Models
Remote Dispense Valves
Part Description
243694 Heated Dispense Valve
244951
244909 Endure Valve, Heated
Endure Valve
1/2 in. npt male outlet
™
, Heated,
Fixed Dispense Valves
Part Description
244907 Endure Valve snuff-back
Accessories
Part Description
24D824 Automation I/O Cable
24E654 Ribbon Nozzle Kit, 10 x 1.5 mm
24E655 Bead Nozzle Kit, 3 mm dia.
24E575 Dynamic Air Regulator for
Therm-O-Flow
24E607 Gear Pump Seals, 6 cc
24E619 Gear Pump Seals, 20 cc
24E677 O-ring Kit, 6 cc
24E626 O-ring Kit, 20 cc
24E678 Heated Nest, Pilot
24E679 Heated Nest, Ribbon or Bead
16E242 Nozzle Heater Insert
16E256 Ported Nozzle Heater Insert
124267 Seal Housing, 6 cc
24E826 Gear Shaft Repair Kit, 6 cc
24E827 Seal Shaft Repair Kit, 6 cc
124266 Pump Seal Housing, 20 cc
24E824 Gear Shaft Repair Kit, 20 cc
24E825 Seal Shaft Repair Kit, 20 cc
124235 Elbow Fitting, 90 degree, 3/4 in.
tube x 16 SAE
124236 Elbow Fitting, 90 degree, 1 in. tube
x 16 SAE
124237 Elbow Fitting, 90 degree, 16 SAE x
20 JIC
Part Description
124238 Adapter Fitting, 3/4 in. Tube x
16 SAE
124239 Adapter Fitting, 1 in. Tube x
16 SAE
124240 Adapter Fitting, 1-1/4 in. Tube x
16 SAE
124241 Adapter Fitting, 16 SAE x
1in.NPTF
124242 Swivel, 16 SAE x 1 in. NPTF
124243 Swivel, 16 SAE x 1 in. tube
124244 Swivel, 1/2 NPTM x 10 JIC
124245 Swivel, 1/2 NPTM x 1/2 NPTF
124286 Adapter Fitting, 3/4 NPTM x 8 JICM
124287 Adapter Fitting, 1/2 NPTM x 8 JICM
124288 Adapter Fitting, 1/2 NPTM x 16
JICM
124289 Swivel Fitting, 3/4 NPTM x 1/2 NPS
124290 Swivel Fitting, 3/4 NPTM x 3/8 NPS
3A0260H 5
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 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
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
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.
SKIN INJECTION HAZARD
High-pressure fluid from 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.
• Inspect hose before each use for cuts, bulges, kinks or any other damage.
• Replace hoses proactively at regular intervals based on your operating conditions.
• Replace damaged hose immediately.
• Tighten all fluid connections before operating the equipment.
• Keep clear of leaks.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Never exceed hose Maximum Pressure or Temperature ratings.
• Only use chemicals that are compatible with wetted parts. See Technical Data in this manual.
Read MSDSs and fluid and solvent manufacturer’s recommendations.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
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.
6 3A0260H
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:
• 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.
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.
• 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.
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.
3A0260H 7
Warnings
WARNING
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, hearing loss, inhalation of toxic fumes, and burns. This 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.
8 3A0260H
Overview
System Configurations
Typical Heated System Installation
Overview
Air Supply
Drop Site
AL
AG
AJ
AK
AH
AF*
AN
AA*
AE
Power
AB*
AH
AM
AH
AC
AD
AO
F
IG. 1: Typical Heated System Installation
AO
Key:
AA *Control Center (User Interface)
AB *Gear Meter Assembly
AC Applicator/Dispense Valve†
AD Automation Robot
AE Automation Interface Cable †
AF *Gear Meter Cables
AG Heated Fluid Supply System
AH Fluid Supply Hose
AJ Heat Control
AK Automation Controller
AL Air Filter Assembly
AM Remote Dispense Hose †
AN Heated Manifold
AO Dynamic Regulator †
*Included
† Accessory
3A0260H 9
Overview
Typical Ambient System Installation
Air Supply
Drop Site
K
H
E
Power
A*
J
F*
B*
C*
G
F
IG. 2: Typical Ambient System Installation
Key:
A *Control Center (User Interface)
B *Gear Meter Assembly
C *Applicator/Dispense Valve
D Automation Robot
E Automation Interface Cable†
D
F Gear Meter Cables
G Fluid Supply System
H Fluid Supply Hose
J Automation Controller
K Air Filter Assembly
* Included
† Accessory
10 3A0260H
Component Identification
Overview
3
4
2
5
6
7
1
10
11
8
9
FIG. 3
12
Key:
1 Gear Meter
2 System Controls Box
3 User-Interface Touch Display
4 External Control Interface
Connections
5 Power Input
6 Main Power Switch
7 Emergency Stop
8 Pump Fault Indicator Light
9 Control Power On/Off buttons
10 Pump Ready Light
11 Manual Purge Button
12 Dispense Valve
3A0260H 11
Overview
System Overview
F
IG. 4: Control Center Dimensions
The PGM system provides positive displacement metering for precision bead control. The control accepts automation signals to provide accurate and consistent output
flow. The gear meter can achieve high flow rates with
high viscosity materials.
Control Power On/Off
Typical Applications
• Solar Panel
• Perimeter Seal
• Desiccant
• Edge Seal
• Automotive Manufacturing
• Window and Door General Assembly
Control Power is the power for the signals to the gear
meter which control gear meter rotation. When Control
Power is off, the gear meter cannot rotate.
Pump Ready Light
The Pump Ready light displays when the pump is ready
for Automatic Mode dispensing. When Manual mode is
enabled, this light will not turn on.
Pump Fault Light
The Pump Fault light is illuminated whenever a pump
fault is active.
Manual Purge Button
The Manual Purge button initiates a shot.
12 3A0260H
Installation
Installation
Before Installation
• Have all system and component documentation
available during installation.
• See component manuals for specific data on compo-
nent requirements. Data presented here applies to
the PGM assemblies only.
• Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.
• Use the PGM control center only with the PGM
metering assembly.
Overview
The basic steps to install a PGM system are shown
below. See the separate component manuals for
detailed information on supply systems and dispense
valves.
NOTICE
To avoid damaging the PGM system, use at least
two people to lift, move, or disconnect the system.
The system is too heavy for one person to lift or
move.
Installation Steps
1. Mount control center.
2. Connect and ground control center.
3. Mount gear meter assembly.
4. Ground gear meter assembly.
5. Check ground continuity.
6. Connect fluid line between gear meter and dispense
valve. For remote mount dispense valves, connect fluid supply line and air supply to gear meter.
7. Plumb filter assembly near air drop site that will be
used for gear meter assembly.
8. Connect other fluid and air lines to additional system
components as instructed in their manuals.
9. Install cable assemblies.
3A0260H 13
Installation
Install Control Center
Mount
Ensure the following criteria are met before mounting
the PGM control center:
• Select a location for the control center that allows
adequate space for installation, service, and use of
the equipment.
• For best viewing, the user interface should be
60-64 in. (152-163 cm) from the floor.
• Ensure there is sufficient clearance around the control unit to run cables to other components.
• Ensure there is easy access to an appropriate electrical power source. The National Electric Code
requires 3 ft. (0.91 m) of open space in front of the
control center.
Secure the control center with appropriate size bolts
through the 0.50 in. (13 mm) diameter holes. See the
mounting dimensions in the following table and F
Control Center Assembly Measurement
A
B
C
D
C
24.0 in. (610 mm)
22.5 in. (572 mm)
30.0 in. (762 mm)
28.5 in. (724 mm)
IG. 5.
D
• Ensure there is easy access to the power switch.
• Ensure the mounting surface can support the weight
of the control center and the cables attached to it.
B
A
F
IG. 5: Control Center Dimensions
14 3A0260H
Installation
Electrical Connections
Follow these precautions when grounding, connecting cables, connecting to a power source or making
other electrical connections.
To reduce the risk of fire, explosion, or electric shock:
• The control center must be electrically connected
to a true earth ground; the ground in the electrical
system may not be sufficient.
• A qualified electrician must complete all grounding
and wiring connections.
• For wiring, refer to F
Refer to your local code for the requirements for a
“true earth ground” in your area.
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
IG. 6.
NOTICE
Install Gear Meter Assembly
To install the PGM metering assembly:
• Mount the gear meter assembly.
• Ground gear meter assembly.
• Connect the gear meter assembly to the control cen-
ter.
• Connect fluid lines and cables.
Mount
Before Mounting Assembly
• See component manuals for specific information on
component requirements. Information presented
here pertains to the PGM gear meter assembly only.
• Have all system and subassembly documentation
available during installation.
• Be sure all accessories are adequately sized and
pressure-rated to meet the system's requirements.
F
IG. 6: 240 Vac Wiring
L1
L2
Ground
• Use only the Graco PGM gear meter assembly with
the Graco PGM control center.
Mount Assembly
1. Select a location for the gear meter assembly. Keep
the following in mind:
• Allow sufficient space for installing the equip-
ment.
• Make sure all fluid lines, cables and hoses eas-
ily reach the components to which they will be
connected.
• Make sure the gear meter assembly allows the
automation unit to move freely along all axis.
• Make sure the gear meter assembly provides
easy access for servicing its components.
3A0260H 15
Installation
2. Mount and secure the gear meter assembly to the
automation unit (or other mounting surface) with
mounting plate. The mounting plate is tapped with
M10 x 1.5 bolts. Maximum bolt length through plate
is 0.75 in. (19 mm). See the mounting dimensions in
Table 4 and F
IG. 7.
Table 4: Gear Meter Assembly Measurement
6 cc Pump 20 cc Pump
A
B
C
D
2.00 in. (50.8 mm) 3.00 in. (76.2 mm)
5.00 in. (127 mm) 3.875 in. (98.43 mm)
2.375 in. (60.33 mm) 2.313 in. (58.75 mm)
NA 1.063 in. (27.00 mm)
0.238 in. (6.0 mm)
0.238 in. (6.0 mm)
diameter
diameter
A
C
B
A
B
D
C
6 cc Pump
F
IG. 7: Gear Meter Assembly Dimensions
16 3A0260H
20 cc Pump
Installation
Grounding
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
Ground the gear meter assembly as instructed here and
in the individual component manuals. Make sure the
gear meter assembly and its components are installed
correctly to ensure proper grounding.
Air and Fluid Hoses
For static dissipation, use only electrically conductive
hoses or ground the applicator / dispense valves.
Dispense Valve
Follow the grounding instructions in the dispense valve
manual.
Connect Fluid and Air Lines
NOTICE
Route all fluid and air lines carefully. Avoid pinching
and premature wear due to excessive flexing or rubbing. Hose life is directly related to how well they are
supported.
• See page 4 for list of inlet fittings.
FIG. 8: Inlet Fitting
• Air must be clean and dry, between 60-100 psi
(0.41-0.68 MPa, 4.14-6.89 bar). Flush air line before
plumbing in air filter assembly (234967). Plumb in air
filter assembly near air drop site (upstream of PGM).
Adding an air regulator to this line will provide more
consistent dispense valve response times.
• Connect a 1/4 in. OD air supply line to the inlet port
on the PGM air supply inlet.
NOTE: To maximize system performance keep the
dispense hose length as short as the application
will allow.
Follow the instructions in your separate component
manuals to connect air and fluid lines. The following are
only general guidelines.
• The PGM gear meter assembly should be installed
on the automation unit or in another appropriate
place, as close as practical to the dispense valve.
• For a remote mount dispense valve, connect a
fluid line between the gear meter outlet and the dispense valve. Shorter fluid lines (hoses) will provide
better fluid system response.
3A0260H 17
Installation
Install Cable Assemblies
1. Connect servo motor power and feedback cables.
2. Connect pressure transducer cable.
3. Connect dispense valve solenoid cable.
4. Connect heat cables, if equipped, to Therm-O-Flow
controller.
Remote mount amplifier on units
with 15 meter cables only.
IG. 9: Cable Installation Diagram
F
ti22239a
18 3A0260H
System Setup
System Setup
Overview
The PGM system compensates for temperature, flow, or
pressure fluctuations. However, if there is a hardware
change on the supply system or the dispense material is
changed, the PGM system must be setup again.
After material is loaded into the supply system, set up
the PGM system using the Setup screens. F
shows the major system setup steps. The following subsections provide instructions to complete each setup
step. Once these steps are complete the module is
ready for operation.
NOTE: See Appendix A - User Interface Display on
page 81 for detailed operating instructions for each
user interface screen.
IG. 10
F
IG. 10
System Setup
Configure Control Settings (
Configure Mode Settings (
Configure Delay Settings (
Adjust Pressure Sensors (
Configure Errors (
End System Setup
page 22)
page 20)
page 20)
page 21)
page 21)
3A0260H 19
System Setup
Configure Control Settings
Set the controls for the dispense source, how dispense
commands are sent, and auto mode settings.
1. From the Home screen, select the Setup icon
NOTE: The Setup screens are password protected.
Enter password “PGM10
screens.
”to access the following
.
Configure Mode Settings
Set the dispense mode (bead or shot). The bead scale
and pre-charge are also adjustable from the Mode Settings screen.
NOTE: See Appendix A - User Interface Display on
page 81 for a description of each feature.
1. With the system in setup mode,
gate to the Mode Settings screen.
press
to navi-
IG. 11
F
2. Press the drop-down list for Command Value
Source and select Display or Remote. Press
Enter to confirm selection.
3. If Command Value Source is set to Remote, enter
the Remote Max Flow (cc/min) for the 10 VDC command source.
4. Press the drop-down list for Run Mode Bead Adjust
and select Enable or Disable. Press Enter
to confirm selection.
5. Press the drop-down list for Job End Mode and
select Display or Remote. Press Enter to
confirm selection.
6. If Job End Mode is set to Display, press Job End
Delay Display field and enter desired delay time in
seconds. Press Enter to confirm.
FIG. 12
2. Press the drop-down list for Mode. Select Bead or
Shot. Press Enter to confirm selection.
3. If Command Value Source is set to Display, press
the drop-down list for Fixed Command Flow Rate
then enter the flow rate in cc/min. Press
Enter to confirm. See Configure Control
Settings for instructions to set the Command Value
Source value.
4. If Shot Time is displayed, press the drop-down list
for Shot Time in Seconds. Press Enter to
confirm.
NOTE: Shot Time is only displayed if Dispense Mode
is set to Shot.
20 3A0260H
System Setup
Configure Delay Settings
Set on and off delays (in milliseconds) for the dispense
valve.
1. With the system in setup mode,
gate to the Delay Settings screen.
F
IG. 13
press
to navi-
Adjust Pressure Sensors
Set pressure offsets and pressure limits.
1. With the system in setup mode,
gate to the Pressure Sensor screen.
FIG. 14
press
to navi-
2. Press the On Delay field and enter a desired delay
value in milliseconds. Default is zero milliseconds.
3. Press the Off Delay field and enter e desired value
in milliseconds. Default is zero milliseconds.
2. Set the desired offset for the inlet and outlet pressures. Remove all pressure on the sensors, and
then adjust the offset so the measured value
reads 0.
NOTE: Offsets are set at the factory.
3. Set the desired minimum and maximum pressure
limits for the inlet and outlet.
NOTE: These values may need changed after the
system has gone through the Startup procedure.
3A0260H 21
System Setup
Configure Errors
Set the error type (error or deviation) that will be issued
if the pressure or drive torque goes outside the set high
and/or low limits. See Appendix A - User Interface
Display on page 81 for information on the purpose of
each error type.
NOTE: When an alarm is set to Error the machine
will be disabled when the alarm occurs.
1. With the system in setup mode,
gate to the Errors screen.
F
IG. 15
2. Press the Error Reset drop-down list and select
Enable or Disable.
press
to navi-
3. Press the Inlet Pressure drop-down list and select
Error or Deviation.
4. Press the Outlet Pressure drop-down list and select
Error or Deviation.
5. Press the Drive Torque drop-down list and select
Error or Deviation.
22 3A0260H
Operation
Operation
Startup
Initial Startup
1. Ensure the PGM control enclosure and all of the
proper connections to and from the control enclosure have been made. Ensure fittings are tight.
2. Read and understand the Operation and User Interface sections of this manual.
3. Continue startup with Step 2 in Standard Startup.
Standard Startup
1. Carefully inspect the entire system for signs of leakage or wear. Replace or repair any worn or leaking
components before operating the system.
2. Press the Stop button on the control enclosure.
3. Turn on air and electrical power to the system.
4. Turn on the main power to supply power to the
PGM.
Load Material
Before using the system material must be loaded into
the supply system.
1. If this is a new installation, follow the Initial Startup
procedure. Otherwise, follow the Standard Startup
procedure.
2. Turn on the fluid supply pressure to the fluid inlet
block for the PGM.
3. Place the dispense valve over a waste container.
4. Navigate to the Maintenance screen. See Screen
Navigation Diagram on page 81 in the Appendix
A - User Interface Display section.
5. Select Manual (M) Control Mode .
6. Enter the minimum flow rate to prime the system.
See the following table.
Pump Size
cc / revolution
612
20 40
Min Flow Rate
cc / minute
5. Check Interface Signals: If this is a new installa-
tion, power on each system input and verify that
each input is being received. See Appendix B - I/O
on page 95.
6. Turn on the material supply system.
3A0260H 23
7. Press and hold the dispense valve icon . Dispense fluid until clean, air-free fluid flows from the
dispense valve.
NOTE: The manual purge button on the user-interface panel can be used to prime the system.
8. If desired, press to navigate to the Home
screen.
Operation
Maintenance Mode Operation
Operating from maintenance mode enables the pump to
begin dispensing when the user presses . Dis-
pense parameters and duration depend on the selected
control.
Verify System Operation
Use maintenance mode to manually check the operation
of the PGM system components before switching over to
automation control (normal operation).
NOTE: Perform any of the following procedures
while in maintenance mode.
Set Inlet Pressure
The inlet pressure reading should be in the range of
300 psi (2.1 MPa, 21 bar) to 1500 psi (10.3 MPa,
103 bar). The recommended inlet pressure should be
500 psi (3.4 MPa, 34 bar) lower than the outlet pressure.
Follow steps in the supply system manual to set the inlet
pressure.
4. Record a minimum of 5 shot weights.
5. If shot weights are inconsistent check feed pressure
or reduce flow rate and repeat shot test.
NOTE: Regular weight checks are recommended to
ensure system is performing properly.
NOTICE
Excessive inlet pressure will cause accelerated
wear on the gear meter seals and the pump feed
system.
Feed System Pressure Drop
During material flow, the PGM inlet pressure decreases.
The amount the pressure decreases is the amount of
pressure lost between the feed pump and the PGM inlet.
With high viscosity fluids, long line lengths, or small
diameter line sizes this pressure decrease can be thousands of psi (hundreds of bar). This means that the
static pump pressure is set much higher than the PGM
needs at its inlet. To prevent excessive static pressure at
the inlet of the PGM, a dynamic regulator is recommended on air motor supply air. During dispense the
normal pump regulator is active. During a stalled condition the dynamic regulator is active.
Dispense Weight Verification
1. From maintenance screen, select Shot mode.
2. Enter a 10 second shot time.
3. Enter the desired flow rate.
24 3A0260H
Calibration
Operation
10. Weigh a second disposable container and tare the
scale.
1. Perform Startup procedure, page 23. Verify all sys-
tem components are at desired pressures and temperatures. Adjust as desired.
2. Navigate to the Calibrate screen. See Screen Navi-
gation Diagram on page 81 in the Appendix A User Interface Display section.
3. Press the Enable Calibration button .
4. Weigh one disposable container and tare the scale.
5. Place container below dispense tip.
6. Press the Start Low Speed Calibration
button .
7. Weigh the container.
8. Divide the weight of the dispensed material by the
specific gravity to determine the volume.
9. Enter the volume into the Low Speed Calibration
11. Place container below dispense nozzle.
12. Press the Start High Speed Calibration
button .
13. Weigh the container.
14. Divide the weight of the dispensed material by the
specific gravity to determine the volume.
15. Enter the volume into the High Speed Calibration
Actual Volume input box .
16. Press the Done button .
17. If desired, press to navigate to the Main
screen.
Actual Volume input box .
3A0260H 25
Operation
Dispense from Maintenance Screen
1. Navigate to the Maintenance screen. See Screen
Navigation Diagram on page 81 in the Appendix
A - User Interface Display section.
2. Select Manual (M) Control Mode .
3. From the Mode drop-down menu, select Bead or
Shot Mode.
Manually Dispense Fluid
1. Press and verify the dispense valve opens.
2. Continue to press as long as needed to load
or dispense material. Release to stop dispensing.
3. If desired, press to navigate to the Home
screen.
26 3A0260H
Automation Control (Normal) Operation
During automation control (normal operation) the PGM
automatically dispenses when it receives a command
from the automation unit.
NOTE: See Appendix B - I/O on page 95.
To enter Auto mode, select Auto (A) Control
Mode .
Typical Automation Cycle
In order for the system to run it must be in Auto mode.
Before a cycle begins the robot outputs should have the
following values:
Operation
• Job Complete: 0
• Dispense Trigger: 0
A typical cycle consists of the following dispensing
sequence.
1. The robot checks that Dispenser Ready signal is set
to On (High). If On, a cycle can begin.
2. If command source is set to Remote, robot sends
0-10 VDC Flow Rate signal.
NOTE: See Setup Screen 1 information in the
Appendix A - User Interface Display section beginning on page 81.
3. Robot turns on dispense trigger.
4. PGM turns on In Cycle.
5. Robot removes dispense trigger.
6. If Job Complete is set to Remote, robot turns on Job
Complete.
7. Robot removes Job Complete before starting the
next cycle.
NOTE: In the event of a deviation alarm, the Dispense Ready signal will remain on along with the
alarm signal. In the event of an error alarm, the Dispense Ready signal will turn off and the alarm signal
will remain on.
3A0260H 27
Pressure Relief Procedure
Pressure Relief Procedure
1. Shut off the fluid supply to the PGM inlet block.
d. Continue to dispense until the inlet pressure on
the PGM is near zero.
e. Visually locate the plug installed at the back of
the inlet block.
2. If equipped, place a waste container beneath the
fluid drain valve under the filter.
3. Place a waste container beneath the dispense
valve.
4. Slowly open the drain valve at each fluid filter to
relieve fluid pressure. Close valve when pressure
gauge reads zero.
5. Navigate to the Maintenance screen. See Screen
Navigation Diagram on page 81 in the Appendix
A - User Interface Display section.
6. Perform the following steps to perform a low flow
dispense:
a. From the Mode drop-down menu, select Bead
mode.
b. Enter the minimum flow rate for your system.
For example, 12 cc/min or 40 cc/min depending
on the size of the gear meter.
f. Place a container under the plug and slowly
remove the plug to relieve remaining inlet pressure.
7. In maintenance mode, select Open Dispense Valve
Control mode , which opens the dis-
pense valve. Press the manual dispense button
until fluid flow stops.
c. Press or the Purge button on the control
enclosure to begin the low flow dispense.
28 3A0260H
8. If the dispense device cannot be actuated from the
control center, refer to F
IG. 16 and perform the fol-
lowing steps to open the dispense valve and relieve
fluid pressure:
Pressure Relief Procedure
a. Manually actuate the plunger on the solenoid,
that opens the dispense valve to relieve fluid
pressure. Refer to F
IG. 16.
b. Continue actuating the plunger until all pressure
is purged from the system between the needle
and dispense valve before proceeding to the
next step.
Dispense Valve
Air Solenoid
If you have followed the previous steps and still suspect that a valve, hose, or dispense nozzle is clogged
or that pressure has not been fully relieved, very slowly
remove the dispense tip, clean the orifice, and continue relieving pressure.
If this does not remove the obstruction, very slowly
loosen the hose end coupling and relieve pressure
gradually, then loosen the coupling completely. Clear
the valves or hose. Do not pressurize the system until
the blockage is cleared.
FIG. 16: Dispense Valve Air Solenoid
9. Shut off power and air to the fluid supply system.
3A0260H 29
Shutdown
Shutdown
1. Press the Stop button. See FIG. 17.
2. Shut off the material supply to the gear meter/meter.
3. Shut off heat to PGM. See related manuals section
for Therm-O-Flow manual and Accessory Heat Control.
4. Shut off power and air to the fluid supply system.
5. Turn off the main power supply.
FIG. 17: Stop Button
30 3A0260H
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