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
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