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

Troubleshooting

Troubleshooting

NOTE: Check all possible solutions in the chart
below before you disassemble the system.

Refer to Supply Systems manual for additional trouble­shooting; refer to Related Manuals on page 3. Also
refer to Error Codes and Troubleshooting, page 33.

PGM Fluid Assembly

Problem Cause Solution

No Inlet Pressure No air pressure on supply system Verify supply system pressure

Leak in supply system Check supply lines and connections
False signal being sent to control Check inlet pressure sensor output;

verify that it corresponds to zero
pressure; replace sensor and/or
amplifier

Leak at PGM drive shaft Replace drive shaft seals

No Outlet Pressure Dispense motor not rotating Refer to Error code section of the

manual; Cycle power and perform
startup

Dispense Off delay set too long Verify Dispense valve delays in

setup screens

Dispense valve solenoid stuck
open

Verify function of dispense valve

False signal being sent to control Check outlet pressure sensor out-

put; verify that it corresponds to zero
pressure; replace sensor and/or
amplifier

High Outlet Pressure Blocked dispense tip Replace dispense tip

Flow rate too high for application decrease flow rate
Dispense valve On delay set too

long
Dispense valve solenoid stuck

closed

Dispense pattern too light Supply pressure too low Verify inlet pressure needed for flow

Flow rate too high for application Perform dispense weight verification,

3A0260H 31

Verify Dispense valve delays in
setup screens

Verify function of dispense valve

rate

see Calibration procedure on
page 25; Lower flow rate and repeat

Troubleshooting

Measured flow does not match
command

Supply pressure too low Verify inlet pressure needed for flow

rate

Flow rate too high for application Perform dispense weight verification,

see Calibration procedure on
page 25; Lower flow rate and repeat

Gear meter is not calibrated Perform calibration; Perform weight

verification, see Calibration proce-
dure on page 25

Gear meter is worn or damaged Perform weight verification, see Cal-

ibration procedure on page 25; if
weights are not repeatable repair or
replace gear meter

Dispense Valves

Problem Cause Solution

Valve not opening Air not getting to open port Verify air pressure solenoid

No Dispense Trigger signal from
automation unit

Valve not shutting off Air not getting to close port (except

AutoPlus valve)

Dispense Trigger signal from auto­mation unit is on

Sluggish open/close Air pressure low Verify air pressure is above 60 psi

Needle/seat worn Rebuild valve; replace needle/seat
Pressurized material past the valve

shut-off is escaping

Material leaks from back of valve Shaft seal is worn Rebuild valve; replace seals
Air leaks from dispense valve Loose air connections Check air connections; tighten if

Worn piston o-ring Rebuild valve; replace piston o-ring

Check input from automation unit

Verify air pressure to solenoid
Verify solenoid operation
Verify air line routing and connec-

tions
Check input from automation unit

(0.4 MPa, 4 bar)

Reduce running pressure
Reduce nozzle length
Increase nozzle orifice size

necessary

32 3A0260H

Errors

Errors

View Errors

Errors can be viewed from the Home screen or from the
Alarm View screen.

Access the Alarm
View screen

Error Message

There are three levels or errors: alarms, deviations, and
advisories. Alarms are critical and require immediate
correction; therefore the system automatically shuts
down. Deviations are important and require attention but
not immediately. Advisories are not critical but still
require attention.

NOTE:

• Errors set the dispenser ready signal LOW.

• Advisories and deviations do not set the dispenser

ready signal LOW.

Diagnose Errors

See Error Codes and Troubleshooting for valid error
codes, possible causes, and solutions.

Clear Errors and Reset Control Unit

From the Alarm View screen, press to clear an

Error Codes and Troubleshooting

Error
No.

1 Control Power Off Control power has

2 Inlet Pressure Devia-

3 Inlet High Pressure

Error Name Error Description

PGM Control Errors

been removed
Inlet material pres-

tion

Error

sure outside limits

Inlet material pres­sure above max limit

error before restarting the control unit.

NOTE: See the Configure Errors section on page 22.

Error
Type

Advisory Stop button or

Deviation Feed pressure set

Alarm Feed pressure too

Cause Solution

Press Control Power

E-stop

too high or too low.
Limits are not set
correctly

high. Limits are
not set correctly.

button
Verify pressure limits

in Setup Screen 5.
Verify supply pres­sures during dis­pense.

Verify pressure limits
in Setup Screen 5.
Verify supply pres­sures during dis­pense.

3A0260H 33

Errors

Error
No.

Error Name Error Description

4 Inlet Low Pressure

Error

5 Outlet Pressure Devi-

ation

6 Outlet High Pressure

Error

7 Outlet Low Pressure

Error

8 Inlet Max Pressure

Fault - Relieve Pres­sure and Cycle Power

Inlet material pres­sure below min limit

Outlet material pres­sure outside limits

Outlet material pres­sure above max limit

Outlet material pres­sure below min limit

Inlet material pres­sure exceeds max
rated pressure

Error
Type

Cause Solution

Alarm Feed pressure too

low. Limits are not
set correctly.

Deviation Back pressure is

too high or too low.
Limits are not set
correctly

Alarm Back pressure is

too high. Limits
are not set cor­rectly

Alarm Outlet pressure

too low. Limits are
not set correctly.

Alarm Feed system pres-

sure is set too
high. Pressure
sensor damaged.

Verify pressure limits
in Setup Screen 5.
Verify supply pres­sures during dis­pense.

Verify pressure limits
in Setup Screen 5.
Verify outlet pressures
during dispense.

Verify pressure limits
in Setup Screen 5.
Verify outlet pressures
during dispense.

Verify pressure limits
in Setup Screen 5.
Verify outlet pressures
during dispense.

Perform pressure
relief procedure.
Change inlet supply
pressure. Cycle
power; Verify Pres­sure sensor is work­ing properly.

9 Outlet Max Pressure

Fault - Relieve Pres­sure and Cycle Power

10 Drive Torque Devia-

tion

Outlet material pres­sure exceeds max
rated pressure

Motor exceeds con­tinuous rated torque

11 Drive Torque Error Motor exceeds con-

tinuous rated torque

12 Drive Peak Torque

Error - Drive disabled,

Motor exceeds peek
torque rating

Cycle Power

Alarm Dispense valve

not opening. Flow
rate too high.
Material not at
temperature

Deviation Flow rate too high.

Dispense Valve
not opening.
Material not at
temperature

Alarm Flow rate too high.

Dispense Valve
not opening.
Material not at
temperature

Alarm Flow rate too high.

Dispense Valve
not opening.
Material not at
temperature

Perform pressure
relief procedure;
Cycle Power; Verify
Dispense valve func­tion; Perform weight
check verification;
Reduce flow rate

Lower flow rate;
reduce outlet pres­sure drop; Verify
material temperature

Lower flow rate;
reduce outlet pres­sure drop; Verify
material temperature

Cycle Power Lower
flow rate; reduce out­let pressure drop; Ver­ify material
temperature

34 3A0260H

Errors

Error
No.

Error Name Error Description

13 Pre-Charge Timeout Pre-Charge Pressure

was not reached
after dispense

14 High Pressure Inter-

lock OFF

15 Dispense Valve Open

(Auto Default)

16 Calibration is enabled

complete calibration

Pressure limit is
bypassed

Dispense valve is
open

Calibration mode
enabled

procedure

17 Drive Fault, Cycle

Power

18 Calibration out of

range

Motor drive is dis­abled

Calibration values
are out of range or
flow rate is too low
for current K factor

Error
Type

Advisory Pre-Charge value

Cause Solution

Set Pre-Charge to

not set correctly

zero. Monitor outlet
pressure; Adjust
Pre-Charge pressure

Advisory Pressure sensors

are disabled

Advisory Dispense valve

open button has
been selected

Advisory Calibration

enabled selected

Contact Graco cus­tomer service

From the Mainte­nance screen select
Dispense valve Auto

Complete calibration

procedure
from the calibrate
screen

Alarm Various conditions Cycle Power verify

motor torque during

dispense

Advisory Improper calibra-

tion, flow rate too

Perform calibration

procedure
low, or pump wear

3A0260H 35

Maintenance

Maintenance

Prior to performing any maintenance procedures, follow
the Pressure Relief Procedure on page 28.

Maintenance Schedule

The following tables list the recommended maintenance procedures and frequencies to operate the equipment safely.
The maintenance is divided between mechanical and electrical tasks. Maintenance must be performed by trained
personnel per this schedule to assure safety and reliability of the equipment.

Mechanical

Operator Maintenance Person

Task Daily Weekly Monthly

Inspect system for leaks
Depressurize fluid, after opera-

tion
Remove heat from system,

after operation
Inspect filter (234967) bowls

and drain
Check hoses for wear

Check/tighten fluid connections 
Check/tighten air connections 

Lubricate dispense valves*
Replace gear meter seals
Rebuild dispense valve*
Replace air filter
Replace Solenoid
Replace gear meter drive shaft
Replace gear head
* Check component manual for more detailed maintenance information.













3-6

months

or

125,000

cycles



18-24

months

or

500,000

cycles



36-48

months

or

1,000,000

cycles





As

Required





Electrical

Task Weekly

Check cables for wear
Verify cable connections
Verify operation of “System Stop” button

* Check Component Manual for more detailed maintenance information.

36 3A0260H







Repair

Repair

NOTE: Refer to Parts section beginning on page 51
for part reference number identification.

Gear Meter Assembly

This section describes how to remove and replace com­ponents on the gear meter assembly.

Prepare Gear Meter Assembly for Repair

Replace Servo Motor or Gear Head

Replacing either the Servo Motor or Gear Head requires
the following procedure.

Remove Servo Motor and Gearhead

1. Prepare Gear Meter Assembly for Repair,

page 37.

2. Remove support gussets (9, 1106).

3. Remove bolts (1, 1103) connecting top mounting
plate (8, 1105) to vertical mounting plate (10, 1107).

4. Remove servo motor, gear head, and top plate.
Coupling (303, 1203) will separate.

5. Remove coupling half

6. Remove 4 screws (3, 1110) that mount to plate to
gear head.

7. Remove gear head coupling covers (302a, 1202a).

8. Loosen gearhead coupling on gearhead shaft.

FIG. 18

1. Perform Pressure Relief Procedure, page 28.

2. Disconnect main power at the control box.

3. If present, remove power from the heat control.

4. Remove servo power cable and servo feed back

cable. See gear meter assembly parts; see Parts
section starting on page 51.

5. Remove heat cables.

6. Remove pressure transducer cables and dispense
valve cable.

7. Remove supply air pressure from solenoid.

8. Remove front guard.

9. Remove material hoses if necessary.

9. Remove 4 bolts connecting servo motor to gear­head.

10. Remove servo motor from gear head.

3A0260H 37

Repair

Install Servo Motor or Gearhead

1. Remove key from motor shaft.

NOTICE

Use caution when handling servo motor to prevent
damage. Do not use tools that could cause dam­age.

2. Slide the gear head bushing into the drive coupling
and align slots in drive coupling and bushing. See

F

IG. 19.

SEE DETAIL

A

FIG. 19

3. Rotate the drive coupling to align clamping bolts
with access holes.

4. Place motor on work surface with motor shaft facing
straight up then mount the gear head. Mounting the
gear head in any other orientation will usually lead
to misalignment and excessive noise.

5. Pre-torque drive coupling to 0.4 N•m (4 in-lb).

6. Bolt gear head to the motor with fasteners provided.

7. Final toque drive coupling to 8.5 N•m (76 in-lb) in
three steps increasing torque each time.

8. Do not tighten coupling to gear head output shaft
until drive assembly is mounted in frame.

DETAIL

A

SCALE

3/2

NOTE: Orient servo motor so that the motor connec­tions do not interfere with material inlet hose.

9. Install gussets with shoulder bolts (5, 1104).

Remove Coupling

1. Prepare Gear Meter Assembly for Repair,

page 37.

2. Remove support gussets (9, 1106).

3. Remove bolts (1, 1103) connecting top mounting
plate (8, 1105) to vertical mounting plate (10, 1107).

4. Remove servo motor, gear head, and top plate.

38 3A0260H

Repair

5. Loosen clamping bolts on each side of coupling and
remove coupling.

NOTE: Pump shaft key may fall out during coupling
removal. Secure pump shaft key until coupling is
replaced.

Install Coupling

5. Separate coupling until proper gap is created. F

21. See the following table.

Pump Size

cc / revolution Gap (mm)

618

20 20

Gap

FIG. 21

IG.

FIG. 20

1. Slide coupling onto gear head output shaft. Tighten
coupling bolt just enough to hold it’s position.

2. Align pump shaft key and slide coupling onto pump
shaft. Tighten coupling bolt just enough to hold it’s
position.

3. Attach servo motor, gear head, and top plate to
pump assembly. See F

IG. 20.

4. Slide drive coupling so it is evenly spaced between
pump and gearhead. Both sides of coupling should
slide easily on each shaft. If coupling does not slide
freely loosen pump bolts (103, 1303) and align
pump until coupling moves freely. Tighten pump to
pump block to 430-480 in-lb (48.58-54.23 N•m)

6. Tighten coupling bolts to the following torques:

Pump Size

cc / revolution

Torque,

in-lb (N•m)

6 132 (15)

20 309 (35)

7. Install gussets with shoulder bolts (5, 1104).

3A0260H 39

Repair

Remove Dispense Valve

1. Prepare Gear Meter Assembly for Repair,

page 37.

2. Manually actuate solenoid to ensure pressure has
been removed.

Dispense Valve
Air Solenoid

4. Connect air lines.

5. Apply air to the solenoid.

6. Manually shuttle solenoid, see F
pense valve is open when solenoid is depressed.

IG. 22. Verify dis-

Replace Solenoid

1. Prepare Gear Meter Assembly for Repair,
page 37.

2. Disconnect solenoid cable. Remove mating
screws (405) from gusset.

3. Remove the dispense valve solenoid (410) and
replace it with a new solenoid.

4. Reconnect solenoid cable.

Gear Meter O-Ring Replacement

Refer to Parts section starting on page 51 for o-ring kits.

1. Prepare Gear Meter Assembly for Repair,
page 37.

FIG. 22: Dispense Valve Air Solenoid

3. Verify air supply is off.

4. Remove air lines from dispense valve.

5. Remove four dispense valve mounting bolts and
remove dispense valve.

NOTE: For remote mount dispense valves, remove
supply hose at inlet block of dispense valve.

6. Refer to dispense valve manual for complete dis­pense valve repair instructions; refer to Related

Manuals on page 3.

Install Dispense Valve

1. For direct mounted dispense valves, replace
o-ring (409) if necessary.

2. Align dispense valve with mounting pins on front
block.

2. Remove pump block shoulder bolts (4, 1102). See
F

IG. 23.

NOTICE

Pump section should be fully supported to prevent
damage being dropped. It is recommended that the
gear meter assembly be located on a work bench
for service.

3. Install four mounting bolts (408) torque to
50-60 in-lb (5.6-6.7 N•m).

40 3A0260H

Repair

3. Remove drive assembly. See FIG. 23.

4, 1102

FIG. 23

4. Perform Remove Dispense Valve procedure.

5. Loosen 4 bolts (407) and remove front block (412).

6. Loosen 4 bolts and remove inlet block (110, 1302).

7. Loosen pump bolts (3, 1303) and remove
pump (108, 1309).

8. Replace front block o-ring (105, 1305).

9. Install front block (412) onto pump block (109,

1308).

10. Replace inlet block o-ring (107, 1306).

11. Install inlet block (102, 1302) onto pump block.

12. Replace pump block o-rings (106, 104; 1304). See
F

IG. 24.

103,

1303

104, 1304

108,
1309

102, 1302

106,
1304

109,
1308

*107, 1306

105,

1305*

412

407

* Provided in o-ring kit 24E626.

FIG. 24

13. Place pump (109, 1308) onto pump block. Install
bolts (103, 1303) hand tight.

14. Locate drive assembly on top of pump assembly.

15. Tighten pump block mounting shoulder bolts to
frame (4, 1102).

16. Loosen pump bolts (103, 1303) as needed to
ensure couplings are aligned.

17. Tighten pump bolts to 430 in-lb (48.58 N•m).

18. Replace all electrical connections and fluid connec­tions before applying fluid pressure and power.

3A0260H 41

Repair

PGM-6 Pump Repair

1614

1607

1608

1615
(P/N: 125656)

1605

1611

1612†

1611

1612†

1613

1609
(P/N: 125657)

1606

1604

1603

1610

1601

1602

FIG. 25: PGM-6

42 3A0260H

† Parts included in kit 24E607.

 Parts included in kit 24E827.
 Parts included in kit 24E826.

Repair

PGM-6 Pump Disassembly

1. Prepare Gear Meter Assembly for Repair,

page 37.

2. Refer to Gear Pump Maintenance Guide on

page 49 for special notes regarding gear pump
repair.

3. Remove four pump block shoulder bolts (1102).

NOTICE

Pump section should be fully supported to prevent
damage being dropped. It is recommended that the
gear meter assembly be located on a work bench
for service.

4. Remove drive assembly. See F

NOTICE

IG. 23.

allow the shaft to be pressed through the gear from
the top or coupling end. Make sure to leave clear­ance for the drive key.

11. The stud (1606) for the driven gear (1608) is press
fit into the back plate (1603) and need not be
removed if not worn.

NOTICE

The PGM pump design relies on a lap fit between
components for performance and sealing. Be care­ful not to drop the gears (1607, 1608) or damage
the mating surfaces of the pump plates (1601,

1603) and gear case (1602). To prevent damage, do
not use pliers or screwdrivers to remove the gears.

12. Clean all components thoroughly before reassem­bly. The use of an ultrasonic cleaner is recom­mended.

Thicker materials may pump heating prior to disas­sembly. Do not expose the pump to thermal shock.
Raise temperature at a maximum rate of 180°F
(100°C) per hour. Do not exceed 400°F (204°C).
Gradually cool the pump to room temperature.

5. Remove seal retainer fasteners (1614) and seal
retainers (1611).

6. Remove pump dowel pins (1610) using an arbor
press.

NOTICE

Do not use a hammer to remove dowel pins as this
will damage the pump.

7. Remove the pump plate screws (1613).

8. Separate the pump front plate (1601), gear case
(1602) and back plate (1603).

NOTE: Notches on the pump plates can be used to
separate the plates.

9. To remove the drive shaft (1605) from the bottom
plate (1603) press the shaft and gear from the bot­tom pump plate towards the coupling end.

10. To remove the drive gear (1607) from the drive shaft
(1605) Support the drive gear at the lower end to

3A0260H 43

Repair

PGM-6 Pump Assembly

NOTICE

Do not hammer or force components together or
damage may occur. Parts will drop into place if
properly cleaned and aligned. Use of a compatible
oil is recommended during assembly.

1. Place the back plate (1603) on a table inside facing
up.

2. Place the driven gear (1608) on its stud (1606).

3. Place gear case (1602) onto back plate (1603).
Check orientation of dowel pin holes to assure they
align with the ones in the back plate.

4. Slide drive gear (1607) onto drive shaft (1605). Ver­ify shaft key (1609) is installed properly.

5. Install drive gear (1607) and drive shaft (1605) into
back plate (1603).

6. Position top plate (1601) over drive shaft (1605) and
place onto gear case (1602).

12. Install new seals (1612). See F

1515,

1614

1512,

1611

*1513,

1612

FIG. 26: Seal Locations

IG. 26 and FIG. 27.

7. Rotate the gears several times to ensure free rota­tion.

8. Insert the dowel pins (1610) and rotate the gears
several times to ensure free rotation.

NOTE: Dowel pins are not a press fit and may be
installed using a plastic hammer if necessary.

9. Install pump plate screws (1613) and tighten to
85-105 in-lb (9.6-11.8 N•m).

10. Rotate the gears several times to ensure free rota­tion.

11. Apply a heat resistant, non-evaporating lubricant to
the seal area of the drive shaft (1605).

Pump Body

FIG. 27: Seal Orientation

13. Install seal retainers (1611) and seal retainer screws
(1614). Tighten screws to 85-105 in-lb
(9.6-11.8 N•m).

14. Align pump shaft key and slide coupling onto pump
shaft. Tighten coupling bolt just enough to hold it’s
position.

15. Attach servo motor, gear head, and top plate to
pump assembly. See F

IG. 20.

16. Separate coupling until proper gap is created. See
F

IG. 21.

17. Tighten pump block mounting shoulder bolts to
frame (1102).

18. Replace all electrical connections and fluid connec­tions before applying fluid pressure and power.

44 3A0260H

Repair

3A0260H 45

Repair

PGM-20 Pump Repair

1515

1512

1513

†

1512

1514

1509

1501

1513

†

1511



1510

1516



(P/N: 125654)

1504



1508



(P/N: 125655)

1507



1505



† Parts included in kit 24E619.

1502

1506

1503



 Parts included in kit 24E825.
 Parts included in kit 24E824.

FIG. 28: PGM-20

46 3A0260H

Repair

PGM-20 Pump Disassembly

1. Prepare Gear Meter Assembly for Repair,

page 37.

2. Refer to Gear Pump Maintenance Guide on

page 49 for special notes regarding gear pump
repair.

3. Remove six pump block shoulder bolts (4).

NOTICE

Pump section should be fully supported to prevent
damage being dropped. It is recommended that the
gear meter assembly be located on a work bench
for service.

4. Remove drive assembly. See F

NOTICE

IG. 23.

is enough clearance between the drive gear (1506)
and top plate (1501) to insert one spacer. Be sure to
allow clearance for drive key (1508).

11. Continue pressing the drive shaft (1504) and insert­ing spacers until the shaft is free from the drive gear
(1506).

12. The stud (1505) for the driven gear (1507) is press
fit into the back plate (1503) and need not be

removed if not worn.

NOTICE

The PGM pump design relies on a lap fit between
components for performance and sealing. Be care­ful not to drop the gears (1607, 1608) or damage
the mating surfaces of the pump plates (1601,

1603) and gear case (1602). To prevent damage, do
not use pliers or screwdrivers to remove the gears.

13. Clean all components thoroughly before reassem­bly. The use of an ultrasonic cleaner is recom­mended.

Thicker materials may pump heating prior to disas­sembly. Do not expose the pump to thermal shock.
Raise temperature at a maximum rate of 180°F
(100°C) per hour. Do not exceed 400°F (204°C).
Gradually cool the pump to room temperature.

5. Remove seal retainer fasteners (1515) seal retain­ers (1512), spacers (1510) and (1511).

6. Remove pump dowels (1509) using an arbor press.

NOTICE

Do not use a hammer to remove dowel pins as this
will damage the pump.

7. Remove the pump plate screws (1514).

8. Separate the pump front plate (1501), gear case
(1502) and back plate (1503).

NOTE: Notches on the pump plates can be used to
separate the plates.

9. To remove drive shaft (1504) from the drive gear
(1506) several flat spacers 1/8 in. (3 mm) thick will
be needed. These will provide clearance for the
drive shaft key (1508) and the top plate (1501).

10. Support pump top plate (1501) and press drive shaft
(1504) through drive gear (1506). Stop when there

3A0260H 47

Repair

PGM-20 Pump Assembly

NOTICE

Do not hammer or force components together or
damage may occur. Parts will drop into place if
properly cleaned and aligned. Use of a compatible
oil is recommended during assembly.

1. Place back plate (1503) on a table inside face up.

2. Install the driven gear (1507) on stud (1505).

3. Place gear case (1502) onto back plate (1503).
Check orientation of dowel pin holes to assure they
align with the ones in the back plate.

4. Place the top plate (1501) on its edge on a table.
Pass the drive shaft (1504) through the top plate
from the seal side so that the boss on the shaft rests
on the top plate.

5. Rotate the drive shaft (1504) to position the drive
key slot at the top. Insert the drive key (1508) and
driven gear (1506)

6. Grasp the top plate (1501), drive shaft (1504) and
driven gear (1506) to prevent them from separating
and carefully lower them into position onto the gear
case (1502).

14. Align pump shaft key and slide coupling onto pump
shaft. Tighten coupling bolt just enough to hold it’s
position.

15. Attach servo motor, gear head, and top plate to
pump assembly. See F

IG. 20.

16. Separate coupling until proper gap is created. See
F

IG. 21.

17. Tighten pump block mounting shoulder bolts to
frame (4).

18. Replace all electrical connections and fluid connec­tions before applying fluid pressure and power.

7. Rotate the gears several times to ensure free rota­tion.

8. Insert the dowel pins (1509) and check again for
free rotation.

NOTE: Dowel pins are not a press fit and may be
installed using a plastic hammer if necessary.

9. Install pump plate screws (1514) and tighten to
85-105 in-lb (9.6-11.8 N•m).

10. Rotate the gears several times to ensure free rota­tion.

11. Apply a heat resistant, non-evaporating lubricant to
the seal area of the drive shaft (1504).

12. Install new seals (1513). See F

IG. 26 and FIG. 27.

13. Install spacers (1510, 1511), seal retainers, (1512)
and seal retainer screws (1515). Tighten screws to
85-105 in-lb (9.6-11.8 N•m).

48 3A0260H

Gear Pump Maintenance Guide

Review these guidelines prior to performing any mainte­nance on the pumps.

• Do not run pump dry.

• Do not pull from a vacuum or negative suction head.

• Do not flush with water or other non-lubricating fluid.

• Do not pump corrosives, abrasives and/or fluids car­rying particles that may harm the pump.

• Do not heat or cool pump faster than 180°F (100°C)
per hour

• Do not drop disassembled parts on a hard surfaces
and do not let parts knock together.

• Never strike the pump parts with an iron hammer.
The parts are designed to drop in place if properly
aligned. Use arbor press to insert or remove press
fit components.

Repair

• Do not use pliers to lift the gears.

• Never use a screwdriver to pry the gears upward.

• Apply clean oil or compatible fluid during assembly.

3A0260H 49

Repair

Installing new heater units and RTD sensors

1. Prepare Gear Meter Assembly for Repair,

page 37.

2. Disconnect the power cables from the heaters.

3. Remove two M3 screws to remove the kit from the
inlet block.

6. Remove the heaters and sensor from the block.

NOTICE

The heaters may be difficult to remove and removal
depends on the system type. To ensure proper heat
transfer and to avoid premature heater failure,

System with through hole:

Press out the heater element using an 0.125”
(3 mm) diameter pin.

System without through hole:
Drill out the heater element using a 5mm (0.203 in.)
drill bit. Do not increase the hole dia mt er.

7. Clean any residue from both heater and sensor
ports.

8. Installation is the reverse of removal.

4. Remove two M6 screws to remove the kit from the
pump block.

5. Remove the two M8 heater nuts and M6 sensor nut.

50 3A0260H

Parts

PGM-20 Mounting Frame

Parts

1

8

10

3

9

4

ti21285a

5

2

12

11

Ref Part Description Qty

1 124164 SCREW, shcs, M6-1.0 x 25 4
2 124165 SCREW, bhcs, M5-0.6 x 10 4
3 124166 SCREW, bhcs, M6-1.0 x 10 4
4 124167 SCREW, shoulder, 10x30, M8-1.25 6
5 124168 SCREW, shoulder, 8 x 6, M6-1.0 8
8 16D840 PLATE, mounting 1
9 16D841 GUSSET 2
10 16D842 PLATE 1
11 16D843 INSULATOR 1
12 16V444 GUARD, drive 1

3A0260H 51

Parts

PGM-20 Lower Assembly Block

108

104

103

101

101

102

Ref Part Description Qty

101 101970 PLUG, pipe, headless 2
102 124173 SCREW, M6-1.0 x 90 4
103 124174 SCREW, M10-1.5 x 75 6
104† O-RING 1
105† PACKING, o-ring 1
106† PACKING, o-ring 1
107† PACKING, o-ring 1
108* 16D827 METER, gear, precision, 20cc/rev 1
109 16D915 BLOCK, pump, mounting 1
110 16D916 BLOCK, inlet, PGM 1

106

109

105

107

110

† Part included in o-ring kit 24E626.
* For part breakdown and repair kits, refer to PGM-20

Pump Repair, page 46.

52 3A0260H

PGM-20 Pump Heat Kit

3

Parts

1

204

202

1

203

1

206

3

Ground location.

Ref Part Description Qty

201 117764 SENSOR, pressure 2
202 24E412 KIT, heat, pump, PGM-20 1
203 24E413 KIT, heat, PGM, inlet 1
204 125363 LABEL, heat/burn, warning 2
205 16D923 INSULATOR 1
206 124175 SCREW 3

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

201

205

206

3A0260H 53

Parts

PGM Drive - 20 cc Pump

301

302

302a

303

Ref Part Description Qty

301 16D947 MOTOR, PGM drive, servo, 4

frame

302 16D946 GEAR REDUCER, PGM drive,

50:1, 80mm frame
302a COVER 1
303 16D945 COUPLING, PGM drive, 18x20mm,

w/key

1

1

1

54 3A0260H

Endure Dispense Valve Fix Mounted

Parts

410

401

403

408

406

407

406

405

402

411

409

404

412

Ref Part Description Qty

401 597151 FITTING, elbow, 1/4 tube x 1/8 NPT, male 1
402 117820 SCREW, cap, socket head, M3 2
403 124200 SCREW, socket head cap screw, M6-1.0 x 30,

stainless steel

404 124201 SCREW, socket head cap screw, M5-0.8 x 60,

stainless steel
405 116768 PACKING, o-ring 1
406 124403 FITTING, adapter, 1/8 NPTM x 03 JICM, mild steel 4
407 124405 SWIVEL, elbow, 90 deg, 03 JICF x 03 JICM, mild

steel
408 198446 VALVE, dispense, closer 1
409 244907 VALVE, endure 1
410 16D943 BLOCK, mounting 1
411 16E899 HOSE, assembly, stainless steel braid, 3/16 x 12 2
412 C32089 RETAINER, seat 1

4

4

2

3A0260H 55

Parts

Gear Meter Assembly Panel

601

611, 612, 613

610

617

614

616

615

617

616

614

624

614

615

602, 623

622, 625

618

626, 612

609

606

608

607

604

605

603

620

651

619

652

56 3A0260H

Parts

Ref Part Description Qty

601 ENCLOSURE, control, gear meter

painted
602 24F386 MODULE, HMI, PGM 1
603 121148 HANDLE, disconnect, electric 1
604 81/2060-

P/11

605 81/2065-

R/11

606 81/2065-

G/11
607 LABEL, legend, panel, PGM 1
608 16D363 BUTTON, operator, pb, flush, black1
609 FITTING, bulkhead, gland, 9wire 1
610 GRIP, cord, .35-.63, 3/4 1
611 81/1060-

14/25
612 96/0360/99FASTENER, shc, 4-40x0.25, ms, e 12

613 COVER, dust, amp17 conn w/chain1
614 81/2070/11LATCH, operator 4

615 81/2080-

1/11

BUTTON, dual, grn/red, w/pl-wht 1

BUTTON, operator, pl, red 1

BUTTON, operator, pl, green 1

CONNECTOR, sq, 14pw/key, 7a,
panel m

CONTACT, block, no 2

1

1

Ref Part Description Qty

616 81/2072-

2/11

617 81/2081-

1/11

06 81/1096-

IC2/25

619 81/2060-

E/11

620 81/2060-

EL/11

622 81/1096-

IC1/11

623 81/1097-

CV6/11

624 84/0130-

23/11
625 STRAP, wrap, spiral, 1/2'', nylon 4
626 81/1060-

4/25
651 196548 LABEL, caution 1
652 15M511 LABEL, warning,

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

LIGHT, led, white, 24vdc, latch 3

CONTACT, block, nc 2

ADAPTER, db9, hmi to plc, s7200,
mxm

BUTTON, mush, maint, twist, red 1

LABEL, legend, e-stop, 60mm 1

CABLE, ribbon, db9, m-f, 6ft 1

COVER, PET, 6", operator inter 1

LABEL, prot earth(grnd).375x.375 1

CONNECTOR, sq, 4p w/key, 7a,
panel m

english/spanish/french

1

2

1

Cables

Description 3 Meter 6 Meter 9 Meter 15 Meter

Servo Power Cable 124251 124252 124253 127280
Feedback Cable 124254 124255 124256 127281
Dispense Valve 24E571 24E572 24E573 24U020

3A0260H 57

Parts

PGM Back Panel

716

718, 720

711

716, 720

718, 720

712, 730

726, 728

718, 720

709 717 706 707 731 702, 707 701

708

704

729

705

728

719, 721

710, 725

717

715, 723, 724

713

Ref Part Description Qty

701 PANEL, back, for30x24 encl,

conduit
702 123361 SWITCH, disconnect, 32a 1
703 124228 EXTENSION, disconnect,

230-350mm
704 117666 TERMINAL, ground 1
705 U70077 TERMINAL, lug, ground, bus type 1
706 123298 CIRCUIT, breaker, 2p, 20a, ul489 1
707 123296 CIRCUIT, breaker, 2p, 1a, ul489 1
708 123359 RELAY, contactor, 30a, 3p, 24vdc co1

709 124064 FILTER 1
710 121808 POWER SUPPLY, 24vdc, 4.0a,

100w
711 123718 FILTER, emi, 6a, spade con 1
712 24F323 MODULE, plc, s7-200, 14di/10do,

24dc

1

1

1

1

727

714722*722*

Ref Part Description Qty

713 124223 MODULE, analog in, s7-200, 4ai,

10dc

714 124224 MODULE, ana-out, s7-200, 2aq,

10dc

715 24F324 DRIVE, indexer (PGM-06 only) 1

24F325 DRIVE, indexer (PGM-20 only) 1

716 STRIP, terminal, PGM, control 1
717 RAIL, din 1
718 WIREWAY, panduit, 1.5""x3.0""x6' 6
719 WIREWAY, panduit, 1"x3"x6' 6
720 COVER, panduit, 1.5""x6' 6
721 WIREWAY, cover, panduit, 1"x6' 6

1

1

58 3A0260H

Parts

Ref Part Description Qty

722 124265 AMPLIFIER, signal conditioner,

PGM (3, 6, or 9 m cables)

*127279 AMPLIFIER, signal conditioner,

PGM (15 m cable)

723 124292 HARNESS, PGM, 26pin dsub, 24

awg

724 24D853 HARNESS, wire, power, motor

control
725 120997 CABLE, turck, rs 4t-4 1
726 DOCUMENT, schematic, PGM 1
727 CLAMP, wire, harness, 1/4,

galvaniz

2

2

1

1

1

Remote Mount Amplifiers

Only for control centers with 15 m cables.

Mount

1. Remove cover.

Ref Part Description Qty

728 84/0130-

23/11

729 84/0130-

26/11

730 81/1096-

B/11

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

* Inline amplifiers are not mounted on panel controls

with 15 m cables.

LABEL, prot earth (grnd).375x.375 1

LABEL, pe 1

BATTERY, backup, 200 day, s7200
plc

1

2. Insert #8 machine screws or equivalent (not pro-

vided) into cover mounting holes.

2.2 in.
(56.5 mm)

3.7 in.
(94 mm)

3.1 in.
(79 mm)

2.5 in.
(65 mm)

1.9 in.
(50 mm)

3A0260H 59

Parts

PGM Remote Dispense Valve

804

808

805

807

Ref Part Description Qty

804 FITTING 1
805 117820 SCREW, cap, socket head, M3 2
807 124200 SCREW, shsc, M6-1.0 x 30, stain-

less steel
808 198446 VALVE, dispense, closer 1
809 16E055 BLOCK, outlet, PGM, 3/4 NPTF,

stainless steel

809

4

1

60 3A0260H

PGM Transducer

Parts

20 cc Pump 6 cc Pump

Ref Part Description Qty

901 117764 SENSOR, pressure 2

901

901901901

3A0260H 61

Parts

PGM-6 Mounting Frame

1101

1103

1105

1101

1107

1106

1104

1109

Ref Part Description Qty

1101 124165 SCREW, bhcs, M5-0.8 x 10, stain-

less steel
1102 124167 SCREW, shoulder, 10 x 30,

M8-1.25, stainless steel
1103 124313 SCREW, shcs, M6-1 x 16 mm,

stainless steel
1104 124314 SCREW, shoulder, 6 x 8, M5 - 0.8,

carbon steel
1105 16E327 PLATE, mounting, drive, PGM-6 1
1106 16E328 GUSSET, drive, PGM-6 2
1107 16E329 PLATE, mounting, pump, PGM-6 1
1108 16E330 INSULATOR, pump, PGM-6 1
1109 16E331 GUARD, drive, PGM-6 1

1102

1108

7

4

3

8

62 3A0260H

PGM-6 Drive Kit

Parts

1203a

1203b

1203

1202

1202a

1201

Ref Part Description Qty

1201 16E367 COUPLING, PGM drive, 12 mm x

14 mm, with key

1202 16E368 GEAR REDUCER, PGM drive,

50:1, 60 mm frame
1202a COVER 1
1203 16E369 MOTOR, PGM drive, frame 1
1203a SCREW 4
1203b WASHER 4

1

1

3A0260H 63

Parts

PGM-6 Lower Assembly Block

1305

1303

1309

1304

1308

1307

1302

1306

1301

Ref Part Description Qty

1301 101970 PLUG, pipe, headless 2
1302 124173 SCREW, shcs, M6-1.0 x 90, stain-

less steel

1303 124174 SCREW, shcs, M10- 1.5 x 75,

stainless steel
1304† PACKING, o-ring 2
1305† O-RING 1
1306† PACKING, o-ring 1
1307 16D916 BLOCK, inlet, PGM 1
1308 16E340 BLOCK, pump mounting, PGM-6 1
1309* 24E832 METER, gear, precision, 6cc/rev 1

† Parts are available in o-ring kit 24E677.
* For part breakdown and repair kits, refer to PGM-6

Pump Repair, page 42.

4

4

64 3A0260H

PGM-6 Pump Heat Kit

1402

1

Parts

1401

3

1

1404

1405

3

Ground location.

Ref Part Description Qty

1401 117764 SENSOR, pressure 2
1402 24E732 KIT, heat, pump, PGM-6 1
1403 24E413 KIT, heat, PGM, inlet 1
1404125363 LABEL, heat, warning 2
1405 16E366 INSULATOR 1
1406 124166 SCREW 2

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

1406

1403

3A0260H 65

Schematics

Schematics

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149

L11L1

1L1

1L1

230V/

1PH/

50-60HZ

L21L2

1L2

GND

DISC-1

1L1

1L21L2

10 AWG

1L1

1L2

10 AWG

FIG. 29: Schematics, Page 1 of 10

CB1A

20A

CB5
5A

100

101

110

111

12 AWG

16 AWG

J1

AC

POWER

GND

FIL-1

P

N

FIL-2

P

N

LINE

LINE

GND

GND

P

LOAD

N

P

LOAD

N

102

103

112

113

12

CRM

34

CRM

12 AWG

104

105

BRN

BLU

CABLE FROM PS-1

HARNESS 24D853

PS-1

125

V+

130

V-

FG

L

N

2

PG-PS1

3

PG-PS1

1

PG-PS1

PE

1

REGEN

2

-BUS

3

+BUS

4

C2 CNTRL VAC

5

C1 CNTRL VAC

6

L3

7

L2 240/120 VAC HOT

8

L1 240/120 VAC N

9

CASE GROUND

WHT

BLU

BRN

24V DC

DC COM

HARNESS 120997

66 3A0260H

Schematics

24

VDC

150

125 130

151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199

CONTROL POWER

I

PB-1

CRM

140

0X

125

56

125

125

125 130

0

PB-1A

PROGRAMMING

E-STOP

141

XO

142

XO

PB-2

PLC-1

L+

HMI-1

IF2 IF1B

+24V

REMOTE STOP

G

IF1A

G

143

DC/DC/DC

M

CAB-1

NOTE: SET SWITCHES

0V

A1 A2

CONTROL_PWR

143

PL-3

PORT 0 OF PLC-1

FOR DP/MPI

CRM

ON

W

DC COM

130

130

130

130

FIG. 30: Schematics, Page 2 of 10

3A0260H 67

Schematics

200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249

24

VDC

125 130

PLC-1

INPUTS

1M

200

I0.0

202

125

125

204

206

208

210

212

310

I0.1

I0.2

I0.3

I0.4

I0.5

I0.6

I0.7

125

125

MANL-PURGE

PB-3

0X

14

26 PIN MALE
HIGH DENSITY

D-SUB

6

7

8

9

1

PG-IO

2

PG-IO

5

PG-IO

PG-IO

ORG

ORG

ORG

ORG

358

DRIVE-1 I/O

HARNESS
124292

24VDC+

24VDC+

125

125

310

DC COM

130

SPARE

SPARE

DRIVE-1
FAULT

DRIVE-1
FAULT

AUTOMATION
START

AUTOMATION
JOB COMPLETE

MANUAL START

CONTROL POWER

XXX XXX

FIG. 31: Schematics, Page 3 of 10

68 3A0260H

Schematics

250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299

24

VDC

125 130

PLC-1

INPUTS

2M

I1.0

I1.1

I1.2

I1.3

I1.4

I1.5

COM

130

DC

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE

125 130

FIG. 32: Schematics, Page 4 of 10

3A0260H 69

Schematics

300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349

24VDC

125

125

PLC-1

OUTPUTS

1M

1L+

Q0.0

Q0.1

Q0.2

Q0.3

Q0.4

300

302

304

306

308

PG-IO

PG-IO

PG-IO

PG-IO

BLK

11

10

12

6

USE ORANGE WIRE

WHT

+

-

1

2

SOL-DV

FAULT

R

PL-2

RED

130

130

130

130

COM

130

DC

GEARMETER
FAULT

GEARMETER
READY TO
DISPENSE

GEARMETER
IN CYCLE

24VDC
COMMON

OPEN
DISPENSE
VALV E

GEARMETER FAULT

125

130

FIG. 33: Schematics, Page 5 of 10

70 3A0260H

Schematics

350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399

24VDC

125 130

130

125

13 14

CRM

310

2L+

2M

Q0.5

312

130

DRIVE-1 I/O

HARNESS

124292

26 PIN MALE

HIGH DENSITY

D-SUB

130

312

1

2

285

314

Q0.6

WHT

3

Q0.7

316

1

PG-A

BLK

+

1

SOL-A

-

2

RED

PG-A

2

130

WHT

3

Q1.0

Q1.1

318

320

1

BLK

PG-B

+

1

SOL-B

-

2

READY

G

RED

PG-B

2

130

130

PL-1

DC

COM

DC COM

DRIVE-1
ENABLE

SPARE

PRIMARY A
DYNAMIC REGULATOR

TANDEM B
DYNAMIC REGULATOR

GEARMETER READY

125 130

FIG. 34: Schematics, Page 6 of 10

3A0260H 71

Schematics

400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449

24VDC

125 130

125

125 130

COM

DC

EXP-1

ANALOG INPUT

130

24VDC

GND

M

L+

24VDC

125

USE CABLE P/N 81/0055-MC3/11

INLET AMP

POWER TRANSDUCER

130

RA

IN A+

IN A-

130

400

24VDC

125

RED

BLACK

+POWER

-OUTPUT

/RETURN

+OUTPUT

SHUNTCAL

ENABLE

OUTLET AMP

1

2
3

4

5
6

+EXCITATION

A

-EXCITATION

B

+SIGNAL

C

-SIGNAL

D
E
F

SHUNT
CAL
RESISTOR

REDWHITE
BLACK
WHITE
GREEN

INLET
PRESURE
TRANSDUCER

POWER TRANSDUCER

130

130

130

RB

IN B+

IN B-

IN C+

IN C-

RB

IN D+

IN D-

+POWER

-OUTPUT

402

130

RC

404

130

408

130

RED

BLACK

ORG

ORG

7

PG-IO

8

PG-IO

DRIVE-1 I/O

CONFIGURE DIP SWITCHES ON EXP-1 FOR 0-10V AS SHOWN BELOW

DIP SWITCHES LOCATED INSIDE ANALOG MODULE

/RETURN

+OUTPUT

SHUNTCAL

ENABLE

0-10 VDC
ANALOG FLOW COMMAND
FROM AUTOMATION

ANALOG COM

HARNESS

124292

21 3 54 6

1

2
3

4

5
6

A
B
C
D
E
F

26 PIN MALE

HIGH DENSITY

D-SUB

15

16

ON

OFF

+EXCITATION

-EXCITATION

+SIGNAL

-SIGNAL

SHUNT
CAL
RESISTOR

DAC MON-2

REDWHITE
BLACK
WHITE
GREEN

OUTLET
PRESURE
TRANSDUCER

FIG. 35: Schematics, Page 7 of 10

72 3A0260H

Schematics

450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499

24VDC

125 130

125

24VDC

EXP-2

ANALOG OUTPUT

M

L+

GND

26 PIN MALE
HIGH DENSITY

D-SUB

130

130

26

410

M0

412

V0

DRIVE-1 I/O

HARNESS

I0

M1

V1

I1

124292

25

24

DC

COM

ANALOG OUT

+/- 10 VDC
COMMANDED

FLOW TO DRIVE

125 130

FIG. 36: Schematics, Page 8 of 10

3A0260H 73

Schematics

500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549

474

358446

HARNESS

124292

209

DRIVE-1

26 PIN MALE
HIGH DENSITY

D-SUB

J5 SERIAL

PORT

J4

COMMAND I/O

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

PE

J3

FEEDBACK

1
2
3
4
5
6

J2
MOTOR
POWER

1
2
3
4

J1

AC
POWER

1
2
3
4
5
6
7
8
9

DRIVE CABLE CHART

CONTROL P/N

24E630 124254 124251
24E633 124255 124252
24E634 124256 124253

FEEDBACK CABLE POWER CABLE

FEEDBACK CABLE
SEE CHART

102

HARNESS
124292

MOTOR POWER CABLE
SEE CHART

FIG. 37: Schematics, Page 9 of 10

74 3A0260H

550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599

GROUNDING NOTES:

1. GROUND ALL DISTRIBUTION BARS F/N

2. GROUND ALL DOORS

3. DO NOT JUMPER GROUND WIRES.

PLACE NEAR
GROUND LUG

PE

PE GROUND STUD GRN/YEL

SUBPLATE

DRIVE-1 PE

DRIVE-1 J1-1

GROUND DIST. BAR

TO GROUND

DIST. BAR #1

FIGURE 1

NTS

AMP-2

AMP-1

FIL-1

FIGURE 2

NTS

FIL-2

TERMINAL STRIP

STAR WASHER

GROUND LUG

INCOMING GROUND
PROTECTIVE EARTH

PLACE NEAR
GROUND DIST BAR

Schematics

FIG. 38: Schematics, Page 10 of 10

3A0260H 75

Accessory Parts

Accessory Parts

Automation Interface Cable Assembly

The cable length of automation interface cable assembly 24D824 is 40 ft (12.2 m). This figure shows the cable and
identifies the cable interface signals. See Appendix B - I/O on page 95 for wiring details. See Appendix C - Theory

of Operation on page 98.

Pin # Wire # Color Description

1 208 Black Dispense Start
2 210 Red Job Complete
3 SPARE White N/C
4 SPARE White/Black N/C
5 125 Orange 24 VDC from PGM
6 130 Blue 24 VDC common
7 404 Red/Black Analog flow command
8 406 Green Analog common

9 SPARE Green/Black N/C
10 302 Blue/Black Dispenser ready
11 300 Red/White Fault present
12 304 Orange/Black In cycle
13 SPARE Green/White Minimum volume dispensed
14 310 Blue/White 24 VDC thru E-stop

76 3A0260H

Dynamic Regulators

1010

1004

1018

1017

1001

1006

1005

Accessory Parts

1011

1004

1009

1008

1007

1012

1002

1003

1004

1021

1020

1013

Ref Part Description Qty

1001 112699 TUBE, 1/4 OD 2
1002 C20466 FITTING, nipple, hex 1
1003 112307 FITTING, elbow, street 1
1004 100139 PLUG, pipe 2
1005 112781 FITTING, elbow, swivel 1
1006 054776 TUBE, nylon, round, 5/16 in/ 8 mm 2
1007 110321 BRACKET, mounting 1
1008 297612 SCREW, cap, button head 2
1009 110318 REGULATOR, air, 1/4 in. npt 1
1010 110319 GAUGE, pressure, air, 1/8 npt 1
1011 115948 FITTING, elbow, 1/4 nptM, 5/16T OD 1
1012 107110 NUT, lock 2
1013 121022 FITTING, elbow, male, 1/4 npt 1
1014 198171 FITTING, elbow 1
1015 198446 VALVE, dispense, closer 1
1016 24E574 CABLE, feed regulator, PGM, 9 meter 1
1017 080226 VALVE, quick exhaust, 3/4 in. nptf 1
1018 C20461 FITTING, nipple, reducing, hex 1
1019 125466 FITTING, swivel, elbow, 1/2 nptf 1
1020 100896 FITTING, bushing, pipe 1
1021 111530 MUFFLER 1

1019

1014

1016

3A0260H 77

Accessory Parts

Dynamic Regulator Setup and Installation

1. Remove air pressure from Therm-O-Flow supply
system. See Pressure Relief Procedure in manual

311208.

2. Install dynamic regulator kit. See F

IG. 39 on

page 79.

3. Apply air to the Therm-O-Flow supply. Check for air
leaks.

4. Set the secondary regulator for a low operating
pressure, for example 20-25 psi.

5. Adjust the panel mount Therm-O-Flow regulator to
zero psi.

6. Connect the dynamic regulator cable from the
Therm-O-Flow to the PGM control box.

7. Navigate to the Supply Pump screen. See Appen-
dix A - User Interface Display starting on page 81
for Supply Pump screen information.

8. Select ON mode for the Primary or Tandem Pump
drop-down menu.

9. Set the appropriate press for the panel mount regu­lator on the Therm-O-Flow. For example, 30-40 psi.

10. Select AUTO mode for the Primary or Tandem
Pump drop-down menu.

11. Verify operation of the new regulator and adjust
pressure as needed to achieve a maximum static
pressure of 1500 psi (103 bar) when the system is
not dispensing.

78 3A0260H

Dynamic Regulator Installation

.

Accessory Parts

5/16 in.

7/32 in.

diameter

11/16 in

6

2

Detail A

4

1

3

7

8

1

Remove plug and attach supplied tubing to
regulator inlet.

2

Holes required for mounting. See detail A.

3

5/32 in. tubing removed from Therm-O-Flow
regulator to be attached here.

4

Regulator pilot port will have an existing 5/32 in.
air line. This air line and its fitting are to be
removed from the regulator and replaced with
the fitting supplied with dynamic regulator.

The existing pilot tube will be connected to the
5/32 fitting on the diverting valve supplied with
24E575.

F

IG. 39

The dynamic regulator kit is used to control the static
pressure of a Therm-O-Flow. The PGM has a maximum
inlet pressure of 1500 psi. During dispense the dynamic
regulator kit will activate the normal regulator located on
the front panel of the Therm-O-Flow. When the system
is idle the secondary regulator will control static pres­sure.

5

5

To Therm-O-Flow regulator pilot port.

6

Regulator inlet.

7

Thread existing air line with 1/2 in. npt coupling
to 90° swivel fitting.

8

Attach to PGM control panel.

3A0260H 79

Accessory Parts

Endure Valve Nozzles Heater Nests

Part Description

24E654 10 x 1.5 mm Ribbon Nozzle
24E655 1/8 in. Bead Nozzle

Part Description

24E678 Heater Nest with Blank Insert
24E679 Heater Nest with Ported Insert

80 3A0260H

Appendix A - User Interface Display

Screen Navigation Diagram

START MACHINE

Appendix A - User Interface Display

Main

Calibrate

Home

Maintenance

Robot I/O

Setup Screens

Supply Pump

Alarm Screen

Setup Screens Flow

Screen #1

Current Setup

Screen

3A0260H 81

Screen #2

Screen #3

Screen #4

Screen #5

Screen #6

Appendix A - User Interface Display

Main Screen

Press the appropriate button to navigate to either the Home or Calibration screen. Enter password “PGM10”to
access the Calibration screen.

A

Key:

A Navigate to the Home screen
B Navigate to the Calibrate screen

B

82 3A0260H

Calibrate Screen #1

NOTE: See Calibration procedure on page 25.

Appendix A - User Interface Display

G

J

L

Key:

C Enable Calibration button (Begin

Calibration)
D Done button (Finish Calibration)\
E Calibration Shot Time Input Box
F Calibration K Factor (Automatically

Calculated)
G Start Low Speed Calibration button

H

C

D

E

F

M

K

H Low Speed Calibration Shot Volume Input

Box
J Start High Speed Calibration button
K High Speed Calibration Shot Volume Input

Box
L Navigate to Main Screen
M Enter Calibration Screen

3A0260H 83

Appendix A - User Interface Display

Calibrate Screen #2

NOTE: See Calibration procedure on page 25.

A1

A2

Key:

A1 Pump RPM during low speed calibration
A2 Pump RPM during high speed calibration

84 3A0260H

Home Screen

Appendix A - User Interface Display

N

R

T

S

Y

P

V

W

U

N Enable Manual mode
P Enable Automatic mode
R Increase Bead Scale
S Decrease Bead Scale
T Current Bead Scale setting

Manual Mode

In Manual Mode, the machine only accepts signals from
the User Interface touch screen and the physical buttons
on the machine. All signals from an External Control
Interface to initiate a shot will be ignored.

Automatic Mode

In Automatic Mode, the machine only accepts initiate
shot signals from an external machine. All signals to ini­tiate a shot using the User Interface touch screen or the
physical buttons on the machine will be ignored.

Bead Scale

X

Key:

U Navigate to Maintenance Screen
V Navigate to Robot I/O Screen
W Navigate to Setup Screens
X Navigate to Main Screen
Y Navigate to Alarm Screen

Screens Navigation

Access to the Setup screens requires the Supervisor
password.

Flow Rate Display

The Home screen will display the commanded Flow
Rate from 1 of 3 sources:

• 1 - Maintenance Flow Rate (see Maintenance
Screen on page 86)

• 2 - Auto Mode Display Flow (see Setup #2 Screen
on page 89)

The bead scale function adjusts the quantity dispensed
by the scale percent value shown. For example, if the
system is setup to dispense 100 cc/min and the bead
scale setting is 110 then the machine will dispense
100 cc/min x 110% scale =110 cc/min.

The primary purpose of the bead scale is to be able to
quickly adjust volume dispensed to be able to find that
actual desired volume. Once the correct volume is
found, the flow rate should be adjusted accordingly.

3A0260H 85

• 3 - Remote 0-10 VDC Command Flow (see Appen­dix B - I/O on page 95)

Appendix A - User Interface Display

Maintenance Screen

Z

N

P

AB

AC

AA

A

Key:

Z Enable Automatic Dispense Valve

Control

AA Open the Dispense Valve, Disable

Automatic Dispense Valve Control

AB Dispense Mode Selection

drop-down menu

Dispense Valve Control

When Automatic Dispense Valve Control is enabled, the
dispense valve will open and close as needed to dis­pense material.

When Open the Dispense Valve is selected, the dis­pense valve will open and remain open until Automatic
Dispense Valve Control is enabled.

Dispense Settings

AE

AD

AC Dispense Duration Input Box
AD Flow Rate Input Box
AE Manual Start Dispense

Flow Rate: This is the rate at which the machine will
dispense for the given dispense duration.

Manual Start Dispense

After adjusting the settings, the user can press the Man­ual Start Dispense button (AE) to dispense material
using the current settings.

NOTE: This button performs the same function as the
manual purge button located on the control panel.

Dispense Mode: Options include Bead and Shot.

• In Bead mode, dispensing begins when the initiate
shot button is pressed and dispensing ends when
the initiate shot button is released.

• In Shot mode, dispensing begins when the initiate
shot button is pressed and released. Dispensing
ends when the Dispense Duration (AC) elapses.

Dispense Duration: This is the amount of time the
machine will dispense at the given flow rate. This value
is only used in Shot Mode.

86 3A0260H

Robot I/O Screen

A

Overview

This screen is for settings related to an external
machine setup to control the dispense operation of this
system. See Appendix B - I/O on page 95 for more
information.

Appendix A - User Interface Display

Robot Outputs

These are signals sent by the external machine when
the related action should occur. The Job Complete sig­nal is sent to stop the In Cycle signal. The Dispense
Trigger is sent to begin dispensing. The Command Volt­age is a display of the voltage of the command cable
and is for troubleshooting only. See Appendix B - I/O on
page 95 for more information.

Robot Inputs

These are signals sent to the external machine to notify
it of system conditions. The Dispense Ready signal tells
the external machine that the system is ready to dis­pense and a dispense can be initiated. The No Alarm
signal tells the machine that there are currently no active
alarms. The In Cycle signal tells the external machine
that the system is currently busy so dispensing cannot
be initiated.

NOTE: Dispense Ready remains on while in Auto Mode.
If a deviation alarm occurs the Dispense Ready and
Alarm signal will remain ON. If an error alarm occurs the
Dispense Ready will be removed.

3A0260H 87

Appendix A - User Interface Display

Setup #1 Screen

A

#1 to #6 Buttons

Press to navigate to the Setup Screen with that number.
For example, press #3 to navigate to Setup Screen #3.

Command Value Source

Command Values can be controlled by the user-inter­face touch screen or by an external machine connected
to the system via the External Control Interface.

Run Mode Bead Adjust

When this option is enabled the Bead Scale function
appears on the Home Screen. See the Home Screen
on page 85 for more information.

Job End Mode

The In Cycle signal can be dropped when the dispense
trigger is removed when Display is selected.

If Remote is selected the Job Complete signal is
required to remove the In Cycle signal.

Job End Delay (sec)

When Job End mode is set to Display the In Cycle signal
is removed after the time in this field.

88 3A0260H

Setup #2 Screen

A

Appendix A - User Interface Display

Overview

The Dispense Mode, Flow Rate, and Dispense Duration

settings apply to Automatic Control Mode (A)
only. Values changed on this screen independent of

changes made on the Maintenance screen.

The Bead Scale value is a duplicate to the Bead Scale
setting on the Home Screen, which can be enabled or
disabled from the Setup #1 screen. See Setup #1

Screen on page 88 for more information.

Fixed Command cc/min

Flow rate can be entered here. This field is only used
when command value source is set to Display on Setup
Screen 1. See Setup #1 Screen on page 88 for more
information.

#1 to #6 Buttons

Press to navigate to the Setup Screen with that number.
For example, press #3 to navigate to Setup Screen #3.

Pre-Charge

This is the pressure between the meter and the dis­pense valve when the dispense valve is closed. If the
pre-charge setting is non-zero then, immediately after
dispensing, the gear meter will continue to rotate after
the dispense valve closes until the pre-charge pressure
value is achieved. The maximum Pre-Charge value is

2500 psi (17.2 MPa, 172 bar).

Larger values for the On Delay setting lead to larger
pressures in the system. If a value too large is input,
the machine could over-pressurize leading to rup­tured components and serious injury.

3A0260H 89

Appendix A - User Interface Display

Setup #3 Screen

A

#1 to #6 Buttons

Press to navigate to the Setup Screen with that number.
For example, press #3 to navigate to Setup Screen #3.

Delay Settings

Larger values for the On Delay setting lead to larger
pressures in the system. If a value too large is input,
the machine could over-pressurize leading to rup­tured components and serious injury.

The Delay Settings affect the timing of the Dispense
Valve opening and closing when a shot is initiated.

The On Delay is the amount of time, in milliseconds,
between a shot being initiated and the dispense valve
opening. If the On Delay is set to 100 the machine will
wait 100 milliseconds after a shot is initiated before
opening the dispense valve. This will lead to a pressure
build up between the meter and dispense valve until the
dispense valve opens.

Drive Information

Motor Torque

Display motor torque during dispense. If motor torque
climbs above continuous torque an alarm is issued. See

Errors on page 33.

Cont. Torque

Continuous torque rating of the motor.

NOTE: The motor torque display is a good way to deter­mine the maximum flow rate with a given viscosity.

The Off Delay is the amount of time, in milliseconds,
between a shot completing and the dispense valve clos­ing. If the Off Delay is set to 100 the machine will wait
100 milliseconds after a shot is complete before closing
the dispense valve.

90 3A0260H

Setup #4 Screen

#1 to #6 Buttons

Appendix A - User Interface Display

A

Press to navigate to the Setup Screen with that number.
For example, press #3 to navigate to Setup Screen #3.

Pump Settings

Snuff Back: This enables the gear meter to rotate in

reverse, immediately following dispensing, to pull mate­rial back from the dispense valve to minimize or elimi­nate material drooling. The Snuff Back Time and Snuff
Back Pump RPM are the settings used when Snuff Back
is enabled. These settings should be adjusted to work
best for your material.

NOTE: Not recommended for very viscous materials.

Pump Hour Totalizer: This field will record the total dis-

pense time on the machine in hours. This field is
non-resettable.

Pump Hour Meter: This field displays total dispense
time in hours. This field is resettable.

3A0260H 91

Appendix A - User Interface Display

Setup #5 Screen

A

Overview

This screen controls settings for the pressure sensors.
These values are used for triggering errors.

#1 to #6 Buttons

Press to navigate to the Setup Screen with that number.
For example, press #3 to navigate to Setup Screen #3.

Inlet, Outlet Offset

The inlet, outlet offset values are used to tune the pres­sure transducer. If the pressure transducers do not reg­ister zero pressure when there is no material in the
system, enter a value to shift the pressure value to zero.
For example, if 15 psi is shown, enter -15 psi to shift the
value to 0.

Min/Max Inlet/Outlet Limits

These limit values are used to set the acceptable range
of values for dispensing. If values are outside of this
range during dispensing the machine will issue an
alarm. See Errors on page 33.

PSI, BAR

Set the unit of measure for pressure system-wide.

92 3A0260H

Setup #6 Screen

A

Errors

Appendix A - User Interface Display

Error Reset: If set to Disable, errors cannot be reset. If
set to Enable, errors can be reset.

Inlet/Outlet Pressure, Drive Torque: If set to Error, an
error will be generated when the out-of-limit condition
occurs. The machine will be disabled until the error is
reset. If set to deviation, an error will be generated when
the out-of-limit condition occurs. The machine will not be
disabled until the error is reset.

If set to Deviation, an error will be generated when the
out-of-limit condition occurs. The machine will not be
disabled. See Errors on page 33.

3A0260H 93

Appendix A - User Interface Display

Supply Pump Screen

A

NOTE: This screen is used to control the optional
dynamic regulator kit for a Therm-O-Flow. See
Accessory Parts section on page 76 for additional
information on the dynamic regulator kit option.

Dynamic Regulator

Primary Pump

• Auto Mode: During normal operation this mode will
activate the dynamic regulator solenoid when the
dispense valve solenoid is activated

• ON Mode: This will activate the dynamic regulator
solenoid

• OFF Mode: The dynamic regulator option is dis-
abled

Tandem Pump

• Same control features as primary pump

94 3A0260H

Appendix B - I/O

Appendix B - I/O

Using the PGM I/O

The gear meter uses several I/O signals to communicate with plant automation controllers. There are two digital
inputs, three digital outputs, and one analog input. All of these signals are routed to the I/O connector on the top of
the controller.

Other pins on the I/O connector include 24 VDC power, 24 VDC common, analog common, and a signal which is 24
VDC power only when the controller E-Stop switch is latched in. None of the signals are isolated; all are referenced to
the ground plane of the control box. The following paragraphs describe typical connection methods for the automa­tion controller signals.

Digital Inputs

The two digital inputs are Dispense Start and Job Com­plete. These inputs require a 24 VDC current sourcing
output from the automation controller. See F

IG. 40.

If the automation controller uses relay contacts to acti­vate I/O signals, the 24 VDC available at the gear meter
I/O connector (pin 5) should be used to drive the inputs.
If the automation controller uses high-side switching of
24 VDC, the automation outputs can be directly con­nected to the inputs as long as the 24 VDC common
(pin 6) of the gear meter is able to be connected to the
automation controller common. If the automation con­troller outputs are low-side switching (open collector) or
a voltage other than 24 VDC, relays must be used as
shown in F

IG. 40.

Automation PGM Control

5

24VDC

Relay
Contact

Input

Pin 1 or 2

Input Circuit

FIG. 40

3A0260H 95

Appendix B - I/O

Digital Outputs

The three digital outputs are Dispenser Ready, Fault
Present and In Cycle. These outputs perform high-side
switching of 24 VDC and require a 24 VDC current sink­ing input at the automation controller. See F
automation controller uses 24 VDC relay coils to receive
I/O signals, the signals should be connected as shown
in F

IG. 41.

If the automation controller inputs are current sourcing
or use a voltage other than 24 VDC, relays with 24 VDC
coils must be used as shown in F

Pins 10, 11, 12

IG. 41.

AutomationPGM Control

IG. 41. If the

Load
(750 mA max)

DC Common

IG. 41

F

6

Output Circuit

96 3A0260H

Appendix B - I/O

Analog Inputs

The PGM receives a flow rate analog command from
the automation. The 0 to 10 VDC analog input is refer­enced to analog common on the control. See F
The reference for the automation controller analog out­put must be connected to the PGM analog reference
(pin 8) for this signal to function properly.

AutomationPGM Control

0 to 10 VDC

Pin 7

Pin 8

Analog Input

F

IG. 42

_

+

-

IG. 42.

Voltage

Relays

If the use of relays is required to condition the digital I/O
signals, these are some examples of part numbers that
could be used.

For 24 VDC Coils:

• Relay: Phoenix Contact Part Number: 2966171

For 120 VAC Coils:

• Relay: Phoenix Contact Part Number: 2966197

24 VDC From E-Stop

The PGM provides a signal that can be used by the
automation controller to monitor the emergency stop
switch position of the PGM controller. See F

IG. 43.

+24 VDC

Pin 14

E-Stop Switch

IG. 43

F

3A0260H 97

Appendix C - Theory of Operation

Appendix C - Theory of Operation

Theory of Operation

Input and Output Signals

Terminology

For the purpose of this document a digital signal is said
to be SET when voltage is present (or above the mini­mum threshold). A signal is said to be RESET when the
signal voltage is not present (below minimum threshold).
Devices are referred to as SET when they are in their
energized or active state.

Digital Inputs

Dispense Start - This is the Dispense Signal. The PGM

unit will attempt to dispense at either the commanded
flowrate while this signal is SET, dependent on mode.

Control On - This input is reset when the E-stop button
is pressed.

Job Complete - This input can be used to signal a job
end.

Fault Present - This bit is RESET under the following
conditions:

1. No Faults (alarms or warnings) are active.

In Cycle - In Cycle signal is set at the beginning of a dis­pense cycle. It is reset at the end of the dispense cycle.
The dispense cycle can end in two ways, depending on
how the Job End mode is set:

• If the Job End mode is set to remote, dispense cycle

ends when the job complete signal is received from
the automation I/O.

• If the Job End mode is set to Display, dispense cycle

ends when the Job End delay timer expires. See

Appendix A - User Interface Display on page 81.

Analog Input

Flow Command - The flow command signal input rep-

resents flow requests. The voltage must be between 0
and 10 volts DC. The 0-10 volt signal is interpreted as a
relative 0-100% flow command signal. The system must
be in Remote Mode for this input to be used.

NOTE: The dispenser ready signal is an important sig­nal for the automation to monitor. When the dispenser
ready output is not on, the LT may not be responding to
requests from the automation. This could create the sit­uation where the automation is running production, but
the PGM is not dispensing any material.

Dispense Valve Solenoid - This signal will be set to
energize the dispense valve solenoid at the beginning of
a dispense cycle.

See the Accessory Parts on page 76.

98 3A0260H

Technical Data

Technical Data

Volume repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 1%

Minimum Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev model: 30 cc/min

20 cc/rev model: 40 cc/min

Maximum Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev model: 480 cc/min

20 cc/rev model: 1600 cc/min

Minimum Dispensed Shot Size . . . . . . . . . . . . . . . . . . . 6 cc/rev model: 8 cc

20 cc/rev model: 10 cc

Maximum Fluid Working Inlet Pressure . . . . . . . . . . . . . 1500 psi (10.3 MPa, 103 bar)

Maximum Fluid Working Outlet Pressure . . . . . . . . . . . 2500 psi (17.2 MPa, 172 bar)

Air Supply Pressure Range . . . . . . . . . . . . . . . . . . . . . . 60-100 psi (filtration required)

Fluid Filtration Recommended. . . . . . . . . . . . . . . . . . . . Up to 200 mesh, depending on viscosity

Viscosity Range of Fluids . . . . . . . . . . . . . . . . . . . . . . . 1,000-1,000,000 Centipoise

Wetted Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless Steel, Tool Steel, Chrome, Carbide, Acetal

Plastic, PTFE, Chemical Resistant O-Rings

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Load: 18.5A, Fuse Rating: 21A

Power Supply Voltage Range . . . . . . . . . . . . . . . . . . . . 240VAC, 50-60 Hz, single phase

Sound Pressure Level at Maximum Flow Rate . . . . . . . 6 cc/rev model: 58 dB(A)

20 cc/rev model: 72 dB(A)

Sound Power Level at Maximum Flow Rate . . . . . . . . . 6 cc/rev model: 68 dB(A)

20 cc/rev model: 79 dB(A)

Operating Temperature Range . . . . . . . . . . . . . . . . . . . Control: 40-104°F (4-40°C)

Heated Pump: 40-400°F (4-204°C)

Ambient Pump: 40-120°F (4-49°C)

Operating Humidity Range . . . . . . . . . . . . . . . . . . . . . . 10-90% non-condensing

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev model: 30 lb (13.61 kg)

20 cc/rev model: 60 lb (27.22 kg)

Controls: 100 lb (45.36 kg)

Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev model: 19.75 H x 9.38 W x 6.6 D in.

(50.17 H x 23.83 W x 16.76 D mm)

20 cc/rev model: 21.75 H x 9.5 W x 8.9 D in.

(55.25 H x 24.13 W x 22.6 D mm)

Control: 30 H x 24 W x 12D in.

(76.2 H x 60.96 W x 30.48 D mm)

* Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expected to

shear under pressure. New applications or fluids should always be tested to determine proper line sizes and
equipment selections. See your Graco Authorized distributor for other capabilities.

3A0260H 99

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: [phone] or Toll Free: 1-800-328-0211 Fax: [phone]

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 3A0260

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised September 2013