Graco PGM Instructions - Parts Manual

Instructions - Parts

™

PGM

Precision Gear Metering

For metering and dispensing ambient or high-temperature, high-viscosity
single-component materials. For professional use only.

Not approved for use in European explosive atmosphere locations.

2500 psi (17.2 MPa, 172 bar) Maximum Working Outlet Pressure
1500 psi (10.3 MPa, 103 bar) Maximum Working Inlet Pressure
See Technical Specifications on page 102 for temperature ranges

3A5185B

EN

See page 4 for model information.

Important Safety Instructions

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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

System Configurations . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . 10

System Overview . . . . . . . . . . . . . . . . . . . . . . . 11

Typical Applications . . . . . . . . . . . . . . . . . . . . . 11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Before Installation . . . . . . . . . . . . . . . . . . . . . . . 12

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Install Control Center . . . . . . . . . . . . . . . . . . . . 13

Install Gear Meter Assembly . . . . . . . . . . . . . . . 14

Install Cable Assemblies . . . . . . . . . . . . . . . . . . 17

System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Configure Control Settings . . . . . . . . . . . . . . . . 19

Configure Mode Settings . . . . . . . . . . . . . . . . . 19

Configure Delay Settings . . . . . . . . . . . . . . . . . 20

Adjust Pressure Sensors . . . . . . . . . . . . . . . . . 20

Configure Errors . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Maintenance Mode Operation . . . . . . . . . . . . . . 23

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Dispense from Maintenance Screen . . . . . . . . . 25

Automation Control (Normal) Operation . . . . . . 25

Typical Automation Cycle . . . . . . . . . . . . . . . . . 25

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 26

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 30

Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Diagnose Errors . . . . . . . . . . . . . . . . . . . . . . . . 31

Clear Errors and Reset Control Unit . . . . . . . . . 31

Error Codes and Troubleshooting . . . . . . . . . . . 32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Maintenance Schedule . . . . . . . . . . . . . . . . . . . 34

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Gear Meter Assembly . . . . . . . . . . . . . . . . . . . . 35

PGM-6 Pump Repair . . . . . . . . . . . . . . . . . . . . . 40

PGM-20 Pump Repair . . . . . . . . . . . . . . . . . . . . 44

Gear Pump Maintenance Guide . . . . . . . . . . . . 47

Installing new heater units and RTD sensors . . 48

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

PGM-20 Mounting Frame . . . . . . . . . . . . . . . . . 49

PGM-20 Lower Assembly Block . . . . . . . . . . . . 50

PGM-20 Pump Heat Kit . . . . . . . . . . . . . . . . . . . 51

PGM Drive - 20 cc Pump . . . . . . . . . . . . . . . . . . 52

EnDure Dispense Valve Fix Mounted . . . . . . . . 53

Gear Meter Assembly Panel . . . . . . . . . . . . . . . 54

PGM Back Panel . . . . . . . . . . . . . . . . . . . . . . . . 56

Remote Mount Amplifiers . . . . . . . . . . . . . . . . . 57

PGM Remote Dispense Valve . . . . . . . . . . . . . . 58

PGM Ambient Transducer . . . . . . . . . . . . . . . . . 59

PGM-6 Mounting Frame . . . . . . . . . . . . . . . . . . 60

PGM-6 Drive Kit . . . . . . . . . . . . . . . . . . . . . . . . . 61

PGM-6 Lower Assembly Block . . . . . . . . . . . . . 62

PGM-6 Pump Heat Kit . . . . . . . . . . . . . . . . . . . . 63

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Automation Interface Cable Assembly . . . . . . . 74

Dynamic Regulators (98****) . . . . . . . . . . . . . . . 75

EnDure Valve Nozzles . . . . . . . . . . . . . . . . . . . . 81

Heater Nests . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Appendix A - User Interface Display . . . . . . . . . . 82

Screen Navigation Diagram . . . . . . . . . . . . . . . . 82

Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Calibrate Screen . . . . . . . . . . . . . . . . . . . . . . . . 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

Pressure Trend Screen . . . . . . . . . . . . . . . . . . . 95

Torque Trend Screen . . . . . . . . . . . . . . . . . . . . 96

Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2 3A5185B

Appendix B - I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Using the PGM I/O . . . . . . . . . . . . . . . . . . . . . . 98

Appendix C - Theory of Operation . . . . . . . . . . . 101

Theory of Operation . . . . . . . . . . . . . . . . . . . . 101

Technical Specifications . . . . . . . . . . . . . . . . . . . 102

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 104

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 104

Related Manuals

Part Description

309376

310538

334130 Therm-O-Flow 200 (P/N UH****)

311208 Therm-O-Flow 200 (P/N 98****)

313296 Warm Melt Supply Systems

309213 Therm-O-Flow Accessory Heat Zone

EnDure
Instructions-Parts List

Therm-O-Flow
Valves Instructions-Parts List

Instructions-Parts

Instructions

Instructions-Parts

Controls Instructions-Parts List

®

Automatic Dispense Valves

®

Automatic Dispense

313526 Ambient Supply Systems Operation

3A5185B 3

Models

Models

NOTE: This manual covers a series change to the PGM system. For systems built prior to 2016, refer to manual

3A0260.

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

Third Digit

Size

1

Fourth Digit

Heat

1

Fifth Digit

Controls *

2

Sixth Digit

Valve

Description Description Description Description

PG

(Precision

Gear Meter)

0
2 20cc 2 Heated 1 Controls / 3m 6 Remote mount

6cc 1 Unheated 0 No controls 1 EnDure

snuff-back

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 19M404

10 ft 19M402

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 †

17J652

None None 124238

124286 C20595 15M863 107127 124290 † 124289 †

- 10

7/8 in. - 14 JIC

17J654

19M405

17J655

- 12

1-1/16 in. - 12

JIC

None 19M416

19M412

17J662

Fittings

124235 (90°)

1-5/16 in. - 12 JIC

- 16

17J666

19M417

17J667

124239

124243 †

124236 (90°)

Non-Heated Hoses

3/8 in. 1/2 in.

109163 626720

None 215441

685602*

None None

(1/2 in. x 5 ft)

511381*

* Indicates PTFE hose, all others Buna-N.

† Indicates swivel.
 Therm-O-Flow part number 98xxxx models.

4 3A5185B

Models

Remote Dispense Valves

Part Description

243694 Heated Dispense Valve

244951 EnDure Valve, Heated,

1/2 in. npt male outlet

244909 EnDure Valve, 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.

25A055 Dynamic Air Regulator for

Therm-O-Flow (P/N UH****)

24E575 Dynamic Air Regulator for

Therm-O-Flow (P/N 98****)

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

Part Description

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

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

3A5185B 5

Warnings

WARNING

Warnings

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

ELECTRIC SHOCK HAZARD

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

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

• Connect only to grounded power source.

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

SKIN INJECTION HAZARD

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

treatment.

• Engage trigger lock when not dispensing.

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

• Do not put your hand over the fluid outlet.

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

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

• Tighten all fluid connections before operating the equipment.

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

BURN HAZARD

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

• Do not touch hot fluid or equipment.

6 3A5185B

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
flowing through the equipment can cause static sparking. 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 sparking).

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

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are
anti-static or conductive.

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

• Keep a working fire extinguisher in the work area.

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 Specifications in all equipment manuals.

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

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

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

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

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

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

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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 Safety Data Sheets (SDSs) 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.

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eyewear, and hearing protection.

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

3A5185B 7

Overview

AD

AC

AH

AB*

AF*

AA*

AE

AK

AM

AG

Air Supply
Drop Site

AN

Power

AL

AJ

AH

AH

AO

AO

Overview

System Configurations

Typical Heated System Installation

F

IG. 1: Typical Heated System Installation

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

8 3A5185B

Typical Ambient System Installation

G

D

C*

F*

A*

E

H

J

Air Supply
Drop Site

K

Power

B*

Overview

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†

F *Gear Meter Cables
G Fluid Supply System
H Fluid Supply Hose
J Automation Controller
K Air Filter Assembly

* Included
† Accessory

3A5185B 9

Overview

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

1

2

3

4

5

12

6

7

8

9

10

11

Component Identification

FIG. 3

10 3A5185B

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.

3A5185B 11

Installation

Installation

Before Installation

• Have all system and component documentation

available during installation.

• See component manuals for specific data on compo­nent 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.

12 3A5185B

Installation

A

B

C

D

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.

• Ensure there is easy access to the power switch.

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

24.0 in. (610 mm)

22.5 in. (572 mm)

30.0 in. (762 mm)

28.5 in. (724 mm)

IG. 5.

• Ensure the mounting surface can support the weight
of the control center and the cables attached to it.

F

IG. 5: Control Center Dimensions

3A5185B 13

Installation

L2

L1

Ground

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.

• Use only the Graco PGM gear meter assembly with
the Graco PGM control center.

Mount Assembly

F

IG. 6: 240 Vac Wiring

1. Select a location for the gear meter assembly. Keep

the following in mind:

• Allow sufficient space for installing the equip­ment.

• Make sure all fluid lines, cables and hoses eas­ily 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.

14 3A5185B

2. Mount and secure the gear meter assembly to the

C

B

6 cc Pump

20 cc Pump

A

A

D

C

B

0.238 in. (6.0 mm)
diameter

0.238 in. (6.0 mm)
diameter

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

Installation

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)

F

IG. 7: Gear Meter Assembly Dimensions

3A5185B 15

Installation

Grounding

The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.

NOTICE

If power and grounding connections are not done prop­erly, the equipment will be damaged and the warranty
voided.

Gear Meter

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.

• 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.

• See page 4 for list of inlet fittings.

FIG. 8: Inlet Fitting

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.

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.

• 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.

16 3A5185B

Install Cable Assemblies

NOTE: Models with
15 meter cables
include a remote
junction box to be
mounted in the field.

Installation

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.

F

IG. 9: Cable Installation Diagram

3A5185B 17

System Setup

System Setup

Configure Control Settings (page 19)

Configure Mode Settings (page 19)

Configure Delay Settings (page 20)

Adjust Pressure Sensors (page 20)

Configure Errors (page 21)

End 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 82 for detailed operating instructions for each
user interface screen.

IG. 10

F

IG. 10

18 3A5185B

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 “PGM17
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 82 for a description of each feature.

1. With the system in setup mode,

igate to the Mode Settings screen.

press

to nav-

F

IG. 11

2. Select Display or Remote from the Command Value
Source Options.

3. If Command Value Source is set to Remote,
enter the Remote Max Flow (cc/min) for the 10 VDC
command source.

4. Select Enable or Disable for Run Mode Bead Adjust
Options. Default is Disable.

5. Select Display or Remote for Job End Mode
Options.

6. If Job End Mode is set to Display, press Job End
Delay Display field and enter desired delay time in
seconds.

FIG. 12

2. Select Bead or Shot for the Dispense Mode.

3. If Command Value Source is set to Display, enter
the flow rate in cc/min in the Fixed Command Flow
Rate. See Configure Control Settings for instruc­tions to set the Command Value Source value.

4. If Shot Time is displayed, enter the Shot Time in
Seconds.

NOTE: Shot Time is only displayed if Dispense
Mode is set to Shot.

3A5185B 19

System Setup

Configure Delay Settings

Set on and off delays (in milliseconds) for the dispense
valve.

1. With the system in setup mode,

igate to the Delay Settings screen.

F

IG. 13

press

to nav-

Adjust Pressure Sensors

Set pressure offsets and pressure limits.

1. With the system in setup mode,

igate to the Pressure Sensor screen.

FIG. 14

press

to nav-

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.

20 3A5185B

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 82 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.

System Setup

1. With the system in setup mode,

igate to the Errors screen.

F

IG. 15

2. Select Enable or Disable for the Error Reset.

3. Select Error or Deviation for the Inlet Pressure.

4. Select Error or Deviation for the Outlet Pressure.

press

to nav-

5. Select Error or Deviation for the Drive Torque.

3A5185B 21

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 along with the
related manuals.

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 82 in the Appendix
A - User Interface Display section.

5. Select Manual 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 installa­tion, power on each system input and verify that
each input is being received. See Appendix B - I/O
on page 98.

6. For heated systems, open the dispense valve over a
waste container while the system is heating up. This
will prevent a pressure build-up caused by fluids or
gases expanding from the heat.

7. Turn on the material supply system.

22 3A5185B

7. Press and hold the manual start button .

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 .

Dispense 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.

Dispense Weight Verification

1. From maintenance screen, select Shot mode.

2. Enter a 10 second shot time.

3. Enter the desired flow rate.

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.

Follow steps in the supply system manual to set the inlet
pressure.

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.

3A5185B 23

Operation

Calibration

1. Perform Startup procedure, page 22. Verify all sys­tem components are at desired pressures and tem­peratures. Adjust as desired.

2. Navigate to the Calibrate screen. See Screen Navi-

gation Diagram on page 82 in the Appendix A ­User Interface Display section.

NOTE: PGM systems are calibrated at the factory. Per-

form calibration after pump maintenance or during trou­bleshooting (see page 29 for troubleshooting matrix).

3. Press the Enable Calibration button .

4. Weigh one disposable container and tare the scale.

5. Place container below dispense tip.

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.

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

Actual Volume input box .

10. Weigh a second disposable container and tare the
scale.

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.

24 3A5185B

Operation

Dispense from Maintenance Screen

1. Navigate to the Maintenance screen. See Screen
Navigation Diagram on page 82 in the Appendix
A - User Interface Display section.

2. Select Manual Control Mode .

3. Select Bead or Shot from the Manual Mode Option.

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.

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 98.

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:

• Job Complete: 0

• Dispense Trigger: 0

A typical cycle consists of the following dispensing
sequence.

3. If desired, press to navigate to the Home

screen.

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 82.

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.

3A5185B 25

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever
you see this symbol.

This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, follow the
Pressure Relief Procedure when you stop dispens­ing and before cleaning, checking, or servicing the
equipment.

1. Shut off the fluid supply to the PGM 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 82 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.

c. Press or the Purge button on the

control enclosure to begin the low flow dis­pense.

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.

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 dispense valve. Press the manual dispense but-

ton until fluid flow stops.

26 3A5185B

Pressure Relief Procedure

Dispense Valve
Air Solenoid

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:

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.

9. If you suspect that a valve, hose, or dispense nozzle
is clogged or that pressure has not been fully
relieved:

a. Very slowly remove the dispense tip, clean the

orifice, and continue relieving pressure as
described in steps 6-8.

b. If this does not remove the obstruction, very

slowly loosen the hose end coupling to relieve
pressure gradually, then loosen the coupling
completely. Clear the valves or hose. Do not
pressurize the system until the blockage is
cleared.

10. Shut off power and air to the fluid supply system.

FIG. 16: Dispense Valve Air Solenoid

3A5185B 27

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. For heated systems, open the dispense valve over a
waste container while the system is cooling down.
This will prevent a pressure build-up caused by flu­ids or gases expanding from the heat.

5. Shut off power and air to the fluid supply system.

6. Turn off the main power supply.

FIG. 17: Stop Button

28 3A5185B

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 32.

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

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

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

3A5185B 29

Verify function of dispense valve

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

Verify Dispense valve delays in
setup screens

Verify function of dispense valve

Troubleshooting

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

rate

Flow rate too high for application Perform dispense weight verifica-

tion, see Calibration procedure on
page 24; Lower flow rate and repeat

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 verifica-

tion, see Calibration procedure on
page 24; Lower flow rate and repeat

Gear meter is not calibrated Perform calibration; Perform weight

verification, see Calibration proce­dure on page 24

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

ibration procedure on page 24; 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 connec­tions

Check input from automation unit

(0.4 MPa, 4 bar)

Reduce running pressure

Reduce nozzle length

Increase nozzle orifice size

necessary

30 3A5185B

Errors

Access the Alarm
View screen

Errors

View Errors

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

There are three levels of 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.

Clear Errors and Reset Control Unit

From the Alarm View screen, perform the following
steps to clear an error before restarting the control unit:

1. Press Acknowledge All List

2. Press Clear All Alarms

NOTE: Acknowledging alarms does not clear them.

NOTE: See the Configure Errors section on page 21.

• 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.

3A5185B 31

Errors

Error Codes and Troubleshooting

Error
No.

1 Control Power Off Control power has

2 Inlet Pressure Devia-

3 Inlet High Pressure

4 Inlet Low Pressure

5 Outlet Pressure Devi-

Error Name Error Description

PGM Control Errors

been removed

Inlet material pres-

tion

Error

Error

ation

sure outside limits

Inlet material pres­sure above max limit

Inlet material pres­sure below min limit

Outlet material pres­sure outside limits

Error
Type

Advisory Stop button or

Deviation Feed pressure set

Alarm Feed pressure too

Alarm Feed pressure too

Deviation Back pressure is

Cause Solution

E-stop

too high or too
low. Limits are not
set correctly

high. Limits are
not set correctly.

low. Limits are not
set correctly.

too high or too
low. Limits are not
set correctly.

Press Control Power
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.

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

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

6 Outlet High Pressure

Error

7 Outlet Low Pressure

Error

8 Inlet Max Pressure

Fault - Relieve Pres­sure and Cycle Power

Outlet material pres­sure above max limit

Outlet material pres­sure below min limit

Inlet material pres­sure exceeds max
rated pressure

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 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.

32 3A5185B

Errors

Error
No.

9 Outlet Max Pressure

10 Drive Torque Devia-

Error Name Error Description

Outlet material pres­Fault - Relieve Pres­sure and Cycle Power

sure exceeds max

rated pressure

Motor exceeds con­tion

tinuous 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

Error
Type

Cause Solution

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.

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 dis-

abled

Calibration values

are out of range or

flow rate is too low

for current K factor

Advisory Pre-Charge value

not set correctly.

Advisory Pressure sensors

are disabled.

Advisory Dispense valve

open button has
been selected.

Advisory Calibration

enabled selected
from the calibrate
screen.

Alarm Various condi-

tions.

Advisory Improper calibra-

tion, flow rate too
low, or pump
wear.

Set Pre-Charge to
zero. Monitor outlet
pressure; Adjust
Pre-Charge pressure.

Contact Graco cus­tomer service.

From the Mainte­nance screen select
Dispense valve Auto.

Complete calibration
procedure.

Cycle Power verify
motor torque during
dispense.

Perform calibration
procedure.

3A5185B 33

Maintenance

Maintenance

Prior to performing any maintenance procedures, follow
the Pressure Relief Procedure on page 26.

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.

34 3A5185B







Repair

Repair

NOTE: Refer to Parts section beginning on page 49
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 35.

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 26.

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 49.

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.

3A5185B 35

Repair

SEE DETAIL

A

DETAIL

A

SCALE

3/2

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

IG. 19.

F

FIG. 19

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

4. Place motor on work surface with motor shaft facing

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

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

straight up then mount the gear head. Mounting the
gear head in any other orientation will usually lead
to misalignment and excessive noise.

Remove Coupling

1. Prepare Gear Meter Assembly for Repair,

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

page 35.

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.

until drive assembly is mounted in frame.

36 3A5185B

Repair

Gap

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

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).

3A5185B 37

Repair

Dispense Valve
Air Solenoid

Remove Dispense Valve

1. Prepare Gear Meter Assembly for Repair,
page 35.

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

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 35.

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 49 for o-ring kits.

1. Prepare Gear Meter Assembly for Repair,
page 35.

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).

38 3A5185B

Repair

4, 1102

*107, 1306

105,

1305*

102, 1302

104, 1304

* Provided in o-ring kit 24E626.

103,

1303

106,
1304

109,
1308

412

407

108,
1309

3. Remove drive assembly. See FIG. 23.

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

IG. 24.

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.

FIG. 24

13. Place pump (109, 1308) onto pump block. Install
bolts (103, 1303) and tighten to 430 in-lb (48.58
N•m).

14. Locate drive assembly on top of pump assembly.

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

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

3A5185B 39

1614

1611

1612†

1611

1612†

1613

1601

1602

1607

1608

1615

1605

1609

1604

1606

1603

1610

† Parts included in kit 24E607.

 Parts included in kit 24E827.

 Parts included in kit 24E826.

(P/N: 125657)

(P/N: 125656)

Repair

PGM-6 Pump Repair

FIG. 25: PGM-6

40 3A5185B

Repair

PGM-6 Pump Disassembly

1. Prepare Gear Meter Assembly for Repair,
page 35.

2. Refer to Gear Pump Maintenance Guide on
page 47 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.

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
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.

Thicker materials may require 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).
Exceeding this temperature could promote leakage in
the pump. 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).

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

3A5185B 41

Repair

1515,

1614

1512,

1611

*1513,

1612

Pump Body

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

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).

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.

42 3A5185B

Repair

3A5185B 43

Repair

1515

1512

1513†

1512

1513†

1511

1510

1504

1508

1516

1514

1509

1501

1502

1506

1503

1507

1505

† Parts included in kit 24E619.

 Parts included in kit 24E825.

 Parts included in kit 24E824.

(P/N: 125655)

(P/N: 125654)

PGM-20 Pump Repair

FIG. 28: PGM-20

44 3A5185B

Repair

PGM-20 Pump Disassembly

1. Prepare Gear Meter Assembly for Repair,
page 35.

2. Refer to Gear Pump Maintenance Guide on
page 47 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.

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
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.

Thicker materials may require 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).
Exceeding this temperature could promote leakage in
the pump. 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.

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

9. To remove drive shaft (1504) from the drive gear
(1506) several flat spacers 1/8 in. (3 mm) thick will

3A5185B 45

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).

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.

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).

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).

46 3A5185B

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.

3A5185B 47

Repair

Installing new heater units and RTD sensors

1.Prepare Gear Meter Assembly for Repair, page 35.

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 diameter.

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.

48 3A5185B

Parts

12

11

10

9

3

8

1

4

2

5

ti21285a

PGM-20 Mounting Frame

Parts

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

3A5185B 49

Parts

103

108

104

101

101

102

105

109

106

107

110

PGM-20 Lower Assembly Block

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

† Part included in o-ring kit 24E626.

* For part breakdown and repair kits, refer to PGM-20

Pump Repair, page 44.

50 3A5185B

PGM-20 Pump Heat Kit

203

201

202

1

3

204

1

1

Ground location.

3

206

206

205

Parts

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.

3A5185B 51

Parts

301

302

303

302a

PGM Drive - 20 cc Pump

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

52 3A5185B

EnDure Dispense Valve Fix Mounted

410

403

405

412

404

409

411

402

406

401

408

406

407

Parts

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

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

steel

4

4

2

3A5185B 53

Parts

652

624

609

626, 612

618

622, 625

601

614

614

614

616

616

617

615

615

614

617

611, 612, 613

606

608

607

604

605

610

651

603

620

619

602

Gear Meter Assembly Panel

54 3A5185B

Parts

Part

Ref

601

---

Description Qty

ENCLOSURE, control, gear meter

1

painted
602 25C836 MODULE, HMI, PGM 1
603 121148 HANDLE, disconnect, electric 1
604 81/2060-

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

P/11

605 81/2065-

BUTTON, operator, pl, red 1

R/11

606 81/2065-

BUTTON, operator, pl, green 1

G/11

607

---

LABEL, legend, panel, PGM 1

608 16D363 BUTTON, operator, pb, flush, black 1
609

---

610

---

611 81/1060-

14/25

FITTING, bulkhead, gland, 9wire 1

GRIP, cord, .35-.63, 3/4 1

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

panel m

1

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

613

---

COVER, dust, amp17 conn w/chain1

614 81/2070/11LATCH, operator 4

Part

Ref

615 81/2080-

Description Qty

CONTACT, block, no 2

1/11

616 81/2072-

LIGHT, led, white, 24vdc, latch 3

2/11

617 81/2081-

CONTACT, block, nc 2

1/11

619 81/2060-

BUTTON, mush, maint, twist, red 1

E/11

620 81/2060-

LABEL, legend, e-stop, 60mm 1

EL/11

622 126987 CABLE, communication 1
624 84/0130-

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

23/11

625

---

626 81/1060-

4/25

STRAP, wrap, spiral, 1/2'', nylon 4

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

2

651 196548 LABEL, caution 1
652 15M511 LABEL, warning,

1

english/spanish/french

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Cables

Description 3 Meter 6 Meter 9 Meter 15 Meter

Servo Power Cable 17R673 17R674 17R675 17R676

Feedback Cable 17R677 17R678 17R679 17R680

Dispense Valve 24E571 24E572 24E573 24U020

3A5185B 55

Parts

718, 720

718, 720

718, 720

716

701

704

729

728

719, 721

710, 725

727

726, 728

717

714

722*

746 713

711

705

708

709

717

706

707

731

702, 707

712

715

PGM Back Panel

Ref Part Description Qty

701

---

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

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 130185 FILTER 1
710 121808 POWER SUPPLY, 24vdc, 4.0a,

PANEL, back, for30x24 encl,
conduit

230-350mm

100w

1

1

1

Ref Part Description Qty

711 123718 FILTER, emi, 6a, spade con 1
712 25C833 MODULE, plc, 14di/10do, 24dc 1
713 129709 MODULE, analog in 1
714 U70899 MODULE, ana-out 1
715 25C834 DRIVE, indexer (PGM-06 only) 1

716

717

718

719

720

721

25C835 DRIVE, indexer (PGM-20 only) 1

---

---

---

---

---

---

STRIP, terminal, PGM, control 1

RAIL, din 1

WIREWAY, panduit, 1.5""x3.0""x6' 6

WIREWAY, panduit, 1"x3"x6' 6

COVER, panduit, 1.5""x6' 6

WIREWAY, cover, panduit, 1"x6' 6

56 3A5185B

Parts

8.77 in.

(222.76 mm)

Ø .31 in.

(7.87 mm)

4.0 in.

(101.6 mm)

Ref Part Description Qty

722 129710 AMPLIFIER, signal conditioner,

PGM (3, 6, or 9 m cables)
725 120997 CABLE, turck, rs 4t-4 1
727

---

CLAMP, wire, harness, 1/4,

galvaniz

2

1

Remote Mount Amplifiers

Only for control centers with 15 m cables.

Ref Part Description Qty

728 84/0130-

23/11

729 84/0130-

26/11

746 --- MODULE, varistor 1

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

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

LABEL, pe 1

3A5185B 57

Parts

809

807

808

805

804

PGM Remote Dispense Valve

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-

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

less steel

stainless steel

4

1

58 3A5185B

PGM Ambient Transducer

901901901

20 cc Pump 6 cc Pump

901

Parts

Ref Part Description Qty

901 124517 SENSOR, pressure 2

NOTE: Ambient sensors are used on models PGx1xx
(unheated). See technical page for ambient operating
temperature range.

3A5185B 59

Parts

1107

1103

1105

1106

1104

1102

1108

1109

1101

1101

PGM-6 Mounting Frame

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

7

4

3

8

60 3A5185B

PGM-6 Drive Kit

1203a

1203b

1203

1202

1201

1202a

Parts

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

3A5185B 61

Parts

1303

1309

1304

1308

1302

1307

1310

1305

1306

1301

PGM-6 Lower Assembly Block

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
1310 16K738 WASHER, split, lock, M10, sst 4

† Parts are available in o-ring kit 24E677.

* For part breakdown and repair kits, refer to PGM-6

Pump Repair, page 40.

62 3A5185B

4

4

PGM-6 Pump Heat Kit

1

3

1401

1405

1402

Ground location.

3

1406

1403

1

1404

Parts

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

3A5185B 63

cards are available at no cost.

Schematics

CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION

50-60HZ

1PH/

230V/

DISC-1

L21L2

L11L1

GND

1L1

CB5

1L1

1L21L2

1L1

CB1A

1L1

1L21L2

20A

5A

110

111

100

101

GND

FIL-1

LOAD

LINE

102

103

GND

FIL-2

LOAD

LINE

112

113

X3

AC

POWER

GND

-RB

-DC

+RB

L1

L2

L3

PE

PS-1

N

24V DC

L

FG

V-

V+

130

125

104

105

HARNESS

10 AWG

10 AWG

12 AWG

16 AWG

DC COM

2

PG-PS1

3

PG-PS1

HARNESS 120997

1

PG-PS1

12 AWG

CABLE FROM PS-1

P

N

P

N

P

N

P

N

17S930

104

105

HARNESS
17S895

DVS-1

DVS-2

14 AWG

14 AWG

105

104

140

149

147

145

142

110

138

136

134

132

130

128

126

124

122

120

118

114

116

112

108

106

104

102

100

141

148

144

146

143

111

139

137

135

133

131

129

127

125

123

121

119

115

117

113

109

107

105

103

101

CRM

12

CRM

34

4

3

2

1

7

6

5

BRN

BLU

WHT

BLU

BRN

Schematics

FIG. 29: Schematics, Page 1 of 10

64 3A5185B

Schematics

CRM

A1 A2

5

9

3

8

7

4

1

6

2

0X

I

PB-1

125

CONTROL POWER

140

CONTROL_PWR

ON

PL-3

130

0

PB-1A

XO

24

VDC

REMOTE STOP

125

125

130

130

130

141

142

143

143

DC COM

PB-2

XO

E-STOP

HMI1

PE

+

_

RS232
PORT

125

130

CAB-1

126987

PLC1

FG

+24 COM

RS232

PORT

125

130

USB PORTPROGRAMMING

ETHERNET
PORT

190

199

197

195

192

160

188

186

184

182

180

178

176

174

172

170

168

164

166

162

158

156

154

152

150

191

198

194

196

193

161

189

187

185

183

181

179

177

175

173

171

169

165

167

163

159

157

155

153

151

W

125 130

125 130

CRM

56

FIG. 30: Schematics, Page 2 of 10

3A5185B 65

Schematics

0X

PB-3

MANL-PURGE

24

VDC

130

CONTROL POWER

1

2

5

125

DC COM

PG-IO

PG-IO

PG-IO

125

320

14

PG-IO

310

ONBOARD DIGITAL

INPUTS

I-04

I-05

I-06

I-07

COM

0

PLC-1

AUTOMATION
START

AUTOMATION
JOB COMPLETE

MANUAL START

X8

125

DRIVE-1
FAULT

24VDC+

12524VDC+

DRIVE-1
RUN

CONNECTOR

SPARE

I-00

I-01

I-02

I-03

SPARE
HARNESS
17R672

DRIVE-1 I/O

X7

CONNECTOR

HARNESS

17R671

DRIVE-1 I/O

125 130

XXX XXX

240

249

247

245

242

210

238

236

234

232

230

228

226

224

222

220

218

214

216

212

208

206

204

202

200

241

248

244

246

243

211

239

237

235

233

231

229

227

225

223

221

219

215

217

213

209

207

205

203

201

125

125

1

2

5

6

ORG

ORG

ORG

310

212

210

208

206

204

202

200

FIG. 31: Schematics, Page 3 of 10

66 3A5185B

Schematics

24

VDC

130

DC

COM

DRIVE-1

I-08

COM

01

ONBOARD DIGITAL

INPUTS

PLC-1

HARNESS
17R671

X7

12524VDC+

CONNECTOR

DRIVE-1 I/O

DIGITAL-OUT1

I-09

I-10

I-11

I-12

I-13

RESERVED

SPARE

SPARE

SPARE

SPARE

125 130

125 130

258

265

263

260

256

254

252

250

259

266

262

264

261

257

255

253

251

267
268

279

298

296

294

292

290

287

283

285

281

277

275

273

271

269

280

299

297

295

293

291

289

284

286

282

278

276

274

272

270

288

125

7

8

214

.

.

.

.

.

FIG. 32: Schematics, Page 4 of 10

3A5185B 67

Schematics

125

24VDC

130

130

DC

COM

R

FAULT

PL-2

DISPENSE
VALVE

OPEN

130

SOL-DV

+

1

RED

-

2

WHT

BLK

DC

ONBOARD DIGITAL

OUTPUTS

+24

+

CM0

+

CM1

DC

-24

O

00

O

01

-

CM0

0

02

PLC-1

125

130

125

310

GEARMETER
FAULT

GEARMETER
FAULT

IN CYCLE

GEARMETER

11

12

6

130

24VDC
COMMON

PG-IO

PG-IO

PG-IO

0

03

0

04

249

508

READY TO
DISPENSE

GEARMETER

10

PG-IO

G

READY

PL-1

130

125 130

125 130

310

319

317

315

312

308

306

304

302

300

311

318

314

316

313

309

307

305

303

301

329

336

334

331

326

324

322

320

330

337

333

335

332

328

325

323

321

327

348

346

344

342

340

338

349

347

345

343

341

339

CRM

13 14

306

308

300

304

302

302

FIG. 33: Schematics, Page 5 of 10

68 3A5185B

Schematics

RESERVED

24VDC

DC

COM

X8

CONNECTOR

130

312

DC COM

HARNESS

17R672

DRIVE-1 I/O

DRIVE-1
ENABLE

PRIMARY A
DYNAMIC REGULATOR

130

130

SOL-B

BLK

+

1

RED

-

2

WHT

PG-B

2

PG-B

1

3

TANDEM B

130

SOL-A

BLK

+

1

RED

-

2

WHT

PG-A

2

PG-A

1

3

130

DYNAMIC REGULATOR

0

05

0

06

0

07

0

08

ONBOARD DIGITAL

OUTPUTS

PLC-1

0

09

-

CM1

X7

CONNECTOR

130

314

DC COM

HARNESS

17R671

DRIVE-1 I/O

DRIVE-1
DIGITAL-IN3

130

125 130

125 130

378

387

385

383

380

376

374

372

370

368

366

364

362

360

358

356

352

354

350

379

386

382

384

381

377

375

373

371

369

367

365

363

361

359

357

353

355

351

391

398

396

393

389

392

399

395

397

394

390

388

130

4

3

4

1

318

314

316

312

320

130

FIG. 34: Schematics, Page 6 of 10

3A5185B 69

Schematics

+EXCITATION

-EXCITATION

-SIGNAL

+SIGNAL

POWER TRANSDUCER

WHITE

GREEN

BLACK

RED

WHITE

RED

BLACK

.
.
.
.
.
.

.
.
.
.
.
.

-SHUNT

+SUPPLY

-SUPPLY

+OUTPUT

-OUTPUT

+SHUNT

+EXCITATION

-EXCITATION

.

POWER TRANSDUCER

BLACK

RED

WHITE

RED

BLACK

RES A

RES B

.
.
.
.
.
.

-SHUNT

+SUPPLY

-SUPPLY

+OUTPUT

-OUTPUT

+SHUNT

.
.
.
.
.
.

.

RES A

RES B

A
B
C
D
E
F

-SIGNAL

+SIGNAL

WHITE

GREEN

A
B
C
D
E
F

400

130

24VDC

COM

DC

INLET
PRESURE
TRANSDUCER

402

130

24VDC

OUTLET
PRESURE
TRANSDUCER

404

7

130

8

0-10 VDC
ANALOG FLOW COMMAND

ANALOG COM

FROM AUTOMATION

PG-IO

PG-IO

X8

CONNECTOR

408

HARNESS

17R672

DRIVE-1 I/O

ANALOG-OUT +

PLC ANALOG IN MODULE

DRIVE-1

A GND

DRIVE-1

24VDC

130

406

404

402

405

403

400
401

442

449

447

444

411

440

438

436

434

432

430

428

426

424

422

419

415

417

413

409

407

443

446

448

445

412

441

439

437

435

433

431

429

427

425

423

421

416

418

414

410

408

420

125 130

125

125 130

125

7

8

ORG

ORG

COM

VI-0

CI-2

COM

COM

VI-1

VI-3

CI-1

CI-3

COM

VI-2

CI-0

B3 B4 B6B1 B2 B5

A1 A2 A3 A4 A5 A6

INLET AMP

OUTLET AMP

FIG. 35: Schematics, Page 7 of 10

70 3A5185B

Schematics

24VDC

COM

DC

HARNESS

17R672

DRIVE-1 I/O

ANALOG OUT

0-10 VDC
COMMANDED

FLOW TO DRIVE

PLC ANALOG OUT MODULE #1

412

410

DRIVE-1

ANALOG-IN COM

ANALOG-IN +

X8

CONNECTOR

410

412

RESERVED

451

450

461

468

466

463

458

456

454

452

462

469

465

467

464

460

457

455

453

459

474

471

470

473

472

475

486

498

496

494

490

492

488

484

482

480

478

476

487

499

497

495

491

493

489

485

483

481

479

477

125 130

125 130

10

9

B1

VO-0

COM

CO-0

COM

VO-1

COM

CO-1

COM

B2 B3 B4

A1 A2 A3 A4

FIG. 36: Schematics, Page 8 of 10

3A5185B 71

Schematics

6

POWER
CABLE

FEEDBACK
CABLE

MOTOR

X10

X2

X3

X7

223

HARNESS
17R671

X8

215

HARNESS
17R672

DRIVE

I/0

DRIVE

I/0

DRIVE

PWR

259

355 440

X1

24VDC

PWR

320

HARNESS
17S161

130

125

24VSTO

-24V

+24V

310

130

125

X7
PIN DESCRIPTION

1 DC COM

2 IN 7
3 IN 4
4 IN 3
5 OUT 2­6 OUT 2+
7 OUT 1­8 OUT 1+
9 IN 2

10 IN 1

X8
PIN DESCRIPTION
1FAULT
2FAULT
3 DC COM
4 ENABLE
5 IN 6
6 IN 5
7 A GND
8 ANALOG OUT +
9 ANALOG IN ­10 ANALOG IN +

365 458

110

HARNESS
17S930

516

525

523

521

518

514

512

510

508

506

504

502

500

517

524

520

522

519

515

513

511

509

507

505

503

501

534

541

539

536

532

530

528

526

535

542

538

540

537

533

531

529

527

543
544

549

547

545

548

546

DRIVE-1

FIG. 37: Schematics, Page 9 of 10

72 3A5185B

Schematics

TO GROUND

DIST. BAR #1

STAR WASHER

GROUND LUG

INCOMING GROUND
PROTECTIVE EARTH

SUBPLATE

PE GROUND STUD GRN/YEL

DRIVE-1 PE

DRIVE-1 X3-1

PLACE NEAR
GROUND DIST BAR

GROUNDING NOTES:

1. GROUND ALL DISTRIBUTION BARS.

2. GROUND ALL DOORS.

3. DO NOT JUMPER GROUND WIRES.

PE

PLACE NEAR
GROUND LUG

FIL-2

FIL-1

585

595

593

591

587

555

583

581

579

577

575

573

571

569

567

565

563

559

561

557

553

551

586

594

589

592

588

556

584

582

580

578

576

574

572

570

568

566

564

560

562

558

554

552

550

598

596

599

597

590

GROUND DIST. BAR

FIGURE 2

NTS

FIGURE 1

NTS

FIG. 38: Schematics, Page 10 of 10

3A5185B 73

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 98 for wiring details. See Appendix C - Theory

of Operation on page 101.

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
8 130 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 N/C
14 310 Blue/White 24 VDC thru E-stop

74 3A5185B

Dynamic Regulators (98****)

1011

1004

1008

1006

1010

1013

1001

1005

1004

1004

1014

1016

1003

1002

1012

1007

1009

1018

1017

1021

1020

1019

NOTE: This kit is intended for Therm-O-Flow units built prior to 2016, which includes part numbers
that start with 98xxxx. See Accessories on page 5 for the latest version of the Therm-O-Flow
which includes part number UHxxxx.

Kit 24E575

Accessory Parts

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

3A5185B 75

Accessory Parts

Dynamic Regulator Setup and Installation
(P/N 98****) 24E575

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

311208.

2. Install dynamic regulator kit. See F
page 77.

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 82
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.

IG. 39 on

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.

76 3A5185B

Dynamic Regulator Installation 24E575

Detail A

3

1

6

2

4

11/16 in.

7/32 in.

5

diameter

7

8

Remove plug and attach supplied tubing to
regulator inlet.

Holes required for mounting. See detail A.

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

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.

To Therm-O-Flow regulator pilot port.

Regulator inlet.

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

Attach to PGM control panel.

1234567

8

5/16 in.

Accessory Parts

F

IG. 39

The dynamic regulator kit is used to control the static
pressure of a Therm-O-Flow (98****). 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.

3A5185B 77

Accessory Parts

1001

1002

1003

1004

1005

1006

1018

1007

1016

1017

1009

1012

1014

1014

1015

1003

1013

1012

1011

1010

1009

1018

1008

NOTE: This kit is for the current series of Therm-O-Flow which contains part number UHxxxx.

Kit 25A055

Dynamic Regulators (UH****)

Ref Part Description Qty

1001 158491 FITTING, nipple 1
1002 120435 REGULATOR, remote piloted 1
1003 121022 FITTING, elbow, male, 1/4 npt 2
1004 C20461 FITTING, nipple, reducing, hex 1
1005 080226 VALVE, quick exhaust, 3/4” nptf 1
1006 111530 MUFFLER 1
1007 121282 FITTING, swivel, straight, 1/2 fx3/4 m 1
1008 24E574 CABLE, feed regulator, pgm, 9 mtr 1
1009 112781 ELBOW, swivel, 90 deg 2
1010 112307 FITTING, street elbow 1
1011 C20466 FITTING, nipple, hex 1
1012 100139 PLUG, pipe 2
1013 110318 REGULATOR, air, 1/4” npt 1
1014 123257 FITTING, nipple, hex, 1/4 npt, brs 2
1015 113264 CROSS, pipe 1
1016 110319 GUAGE, press, air, 1/8” npt 1
1017 198446 VALVE, dispense, closer 1
1018 054130 TUBE, plyeth .250 od 3

78 3A5185B

Dynamic Regulator Setup and Installation
(P/N UH****) 25A055

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

334130.

Accessory Parts

2. Install dynamic regulator kit. See F
page 80.

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 air motor regulator at the top of the air
tree 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 82
for Supply Pump screen information.

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

9. Set the appropriate pressure for the air motor regu­lator at the top of the air tree on the Therm-O-Flow.
For example, 30-40 psi.

IG. 40 on

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.

3A5185B 79

Accessory Parts

5

7

1

4

3

6

2

Disconnect red airline from air tree.

Remove pressure relief safety valve from air
tree.

Screw in the cross with adjustable air pressure
regulator into the pressure relief safety valve
hole.

Attach the dynamic regulator assembly to the
hose connection on the air tree.

Attach the red air hose to the dynamic regulator
assembly.

Attach the pressure relief safety valve to open
port on the cross fitting.

Attach to PGM control panel.

12345

6

7

Dynamic Regulator Installation

F

IG. 40

The dynamic regulator kit is used to control the static
pressure of a Therm-O-Flow (UH****). 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.

80 3A5185B

EnDure Valve Nozzles Heater Nests

Accessory Parts

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

3A5185B 81

Appendix A - User Interface Display

Screen #1

Current Setup

Screen

Screen #2

Screen #3

Screen #4

Screen #5

Main

START MACHINE

Maintenance

Home

Calibrate

Robot I/O

Setup Screens Flow

Supply Pump

Setup Screens

Alarm Screen

Screen #6

Appendix A - User Interface Display

Screen Navigation Diagram

82 3A5185B

Appendix A - User Interface Display

Key:

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

A

B

Main Screen

Press the appropriate button to navigate to either the Home or Calibration screen. To access the Calibration screen,
select the login button and enter user “setup

.

” and password “PGM17”.

3A5185B 83

Appendix A - User Interface Display

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 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 Pump RPM during low speed calibration
N Pump RPM during high speed calibration

K

F

E

L

J

G

H

C

D

N

M

Calibrate Screen

NOTE: See Calibration procedure on page 24.

84 3A5185B

Home Screen

Key:

O Enable Manual mode
P Enable Automatic mode
R Increase Bead Scale
S Decrease Bead Scale
T Current Bead Scale setting
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
Z Navigate to Supply Pump Screen
AA Navigate to Trend Screen

R

T

S

Y

U

X

W

AA

V

Z

O

P

Appendix A - User Interface Display

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.

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.

Screens Navigation

Access to the Setup screens requires the setup pass­word.

Flow Rate Display

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

Bead Scale

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.

3A5185B 85

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

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

• 3 - Remote 0-10 VDC Command Flow (see Appen-
dix B - I/O on page 98)

Appendix A - User Interface Display

Key:

AB Enable Automatic Dispense Valve

Control

AC Open the Dispense Valve, Disable

Automatic Dispense Valve Control

AD Enable Bead Manual Mode

AE Enable Shot Manual Mode
AF Dispense Duration Input Box
AG Flow Rate Input Box
AH Manual Start Dispense

A

AC

AB

AG

AD

AF

AH

Q

AE

P

Maintenance Screen

Dispense Valve Control

Dispense Duration: This is the amount of time the

machine will dispense at the given flow rate. This value

When Automatic Dispense Valve Control is enabled, the

is only used in Shot Mode.

dispense valve will open and close as needed to dis­pense material.

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

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

Manual Start Dispense

After adjusting the settings, the user can press the Man-

Dispense Settings

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.

ual Start Dispense button (AH) to dispense material
using the current settings.

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

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

86 3A5185B

Robot I/O Screen

A

Appendix A - User Interface Display

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 98 for more
information.

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 98 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.

3A5185B 87

Appendix A - User Interface Display

A

Setup #1 Screen

#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 3A5185B

Setup #2 Screen

A

Appendix A - User Interface Display

Overview

The Dispense Mode, Flow Rate, and Dispense Duration
settings apply to Automatic Control Mode

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.

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.

#1 to #6 Buttons

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

3A5185B 89

Appendix A - User Interface Display

A

Setup #3 Screen

#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.

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.

Drive Information

Motor Torque

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

Errors on page 31.

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.

90 3A5185B

Setup #4 Screen

A

Appendix A - User Interface Display

#1 to #6 Buttons

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.

3A5185B 91

Appendix A - User Interface Display

A

Setup #5 Screen

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 31.

PSI, BAR

Set the unit of measure for pressure system-wide.

92 3A5185B

Setup #6 Screen

A

Appendix A - User Interface Display

Fault Settings

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 31.

3A5185B 93

Appendix A - User Interface Display

A

Supply Pump Screen

NOTE: This screen is used to control the optional
dynamic regulator kit for a Therm-O-Flow. See
Accessory Parts section on page 74 for additional
information on the dynamic regulator kit option.

Supply Pumps (Dynamic Analog Regulator)

Primary Supply Pump Mode

• 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 dis­abled.

Secondary Supply Pump Mode

• Same control features as primary pump.

94 3A5185B

Pressure Trend Screen

Key:

AI Navigate to the Torque Trend

screen.

A

AI

Appendix A - User Interface Display

Overview

The Pressure Trend screen allows the user to view both
inlet and outlet pressures in real time. The pressures
displayed on this screen are the same values shown on
the Home and Maintenance screens.

3A5185B 95

Appendix A - User Interface Display

Key:

AJ Navigate to the Pressure Trend

screen.

A

AJ

Torque Trend Screen

Overview

The Torque Trend screen allows the user to view the
pump torque and motor torque in real time.

Pump Torque

The Pump Torque shows the effective torque on the
pump during operation.

Motor Torque

The Motor Torque shows the torque on the motor during
operation and is measured in in/lbs.

96 3A5185B

Appendix A - User Interface Display

A

Alarm Screen

Refer to Error Codes and Troubleshooting on page 32 for information on possible errors.

Acknowledge All List

When pressed, the Acknowledge All List button
acknowledges all errors listed on the Alarm Screen and
adds to the screen the time when the errors were
acknowledged. This button must be pressed prior to
pressing the Clear All Alarms button.

NOTE: Acknowledging alarms does not clear them.

Clear All Alarms

When pressed, the Clear All Alarms button will remove
all errors listed on the Alarm Screen. Before pressing
the Clear All Alarms button, all alarms must be acknowl­edged.

NOTE: The Clear All Alarms button can only be pressed
if Error Reset is Enabled (see Configure Errors on
page 21).

3A5185B 97

Appendix B - I/O

Automation PGM Control

Input Circuit

24VDC

Relay
Contact

Input

Pin 1 or 2

5

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. 41.

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. 41.

FIG. 41

98 3A5185B

Digital Outputs

AutomationPGM Control

Output Circuit

Load
(750 mA max)

Pins 10, 11, 12

DC Common

6

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. 42.

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

IG. 42.

IG. 42. If the

Appendix B - I/O

IG. 42

F

3A5185B 99

Appendix B - I/O

+24 VDC

E-Stop Switch

Pin 14

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. 43

_

+

-

IG. 43.

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

F

IG. 44

IG. 44.

100 3A5185B