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Graco 3A0260H User's Manual

1. Up to 200 mesh depending on viscosity Viscosity Range of Fluids 1 000 1 000 000 Centipoise Wetted Parts Stainless Steel Tool Steel Chrome Carbide Acetal Plastic PTFE Chemical Resistant O Rings Power Requirements Full Load 18 5A Fuse Rating 21A Power Supply Voltage Range 240VAC 50 60 Hz single phase Sound Pressure Level at Maximum Flow Rate 6 cc rev model 58 dB A 20 cc rev model 72 dB A Sound Power Level at Maximum Flow Rate 6 cc rev model 68 dB A 20 cc rev model 79 dB A Operating Temperature Range Control 40 104 4 40 C Heated Pump 40 400 F 4 204 C Ambient Pump 40 120 4 49 C Operating Humidity Range 10 90 non condensing WIG be emer m ee eate 6 cc rev model 30 Ib 13 61 kg 20 cc rev model 60 Ib 27 22 kg Controls 100 Ib 45 36 kg Overall Dimensions 6 cc rev model 19 75 H x 9 38 W x 6 6 D in 50 17 H x 23 83 W x 16 76 D mm 20 cc rev model 21 75 Hx9 5W x 8 9 D in 55 25 H x 24 13 W x 22 6 D mm Control 30 H x 24 W x 12D in 76 2 H x 60 96 W x 30 48 D mm Flow rates and viscosities are general estimates Flow rates drop as viscosity increases Fluids are expected to shear under pressure New applications or fluids should always be tested to determine proper line s
2. 42 PGM 20 Pump Repair 46 Gear Pump Maintenance Guide 49 Installing new heater units and RTD sensors 50 Paris olm 51 PGM 20 Mounting Frame 51 PGM 20 Lower Assembly Block 52 PGM 20 Pump Heat Kit 53 PGM Drive 20 Pump 54 Endure Dispense Valve Fix Mounted 55 Gear Meter Assembly Panel 56 PGM Back Panel 58 Remote Mount Amplifiers 59 PGM Remote Dispense Valve 60 PGM Transducer 61 PGM 6 Mounting Frame 62 PGM 6 Drive Kit 63 PGM 6 Lower Assembly Block 64 PGM 6 Pump Heat Kit 65 Schematics a eli Ee sise 66 Accessory Parts 76 Automation Interface Cable Assembly 76 Dynamic Regulators 77 Endure Valve Nozzles 80 Heater Nests 80 3A0260H Appendix A User Interface Display 81 Screen Navigation Diagram 81 Main Sereen suae exa m x Reb sa 82 Calibrate Screen 1 83 Calibrate Screen 2 84 Home Screen 85 Maintenance Screen 86 Robot I O Screen 87 Setup 1 Screen
3. TIT IN INCOMING GROUND GROUND LUG PROTECTIVE EARTH FIGURE 1 NTS PLACE NEAR GROUND DIST BAR a E 5 gt of 2 cdi PE GROUND STUD GRN YEL 2 2 2 2 2 2 2 2 2 2 GROUND DIST BAR FIGURE 2 NTS Fic 38 Schematics Page 10 of 10 Schematics 0260 75 Accessory Parts Accessory Parts Automation Interface Cable Assembly The cable length of automation interface cable assembly 24D824 is 40 ft 12 2 m This figure shows the cable and identifies the cable interface signals See Appendix B I O on page 95 for wiring details See Appendix C Theory of Operation on page 98 Pin Wire Color Description 1 208 Black Dispense Start 2 210 Red Job Complete 3 SPARE White N C 4 SPARE White Black N C 5 125 Orange 24 VDC from PGM 6 130 Blue 24 VDC common 7 404 Red Black Analog flow command 8 406 Green Analog common 9 SPARE Green Black N C 10 302 Blue Black Dispenser ready 11 300 Red White Fault present 12 304 Orange Black In cycle 13 SPARE Green White Minimum volume dispensed 14 310 Blue White 24 VDC thru E stop 76 3A0260H Dynamic Regulators Ref 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 Part 112699 C20466 112307 100139 112
4. obo A A F Fic 2 Typical Ambient System Installation Key A Control Center User Interface F Gear Meter Cables B Gear Meter Assembly G Fluid Supply System C Applicator Dispense Valve H Fluid Supply Hose D Automation Robot J Automation Controller E Automation Interface Cablet K Air Filter Assembly ncluded T Accessory 10 3A0260H Overview Component Identification 3 5 2 UT 6 1 O O 8 9 o Key 1 Gear Meter 7 Emergency Stop 2 System Controls Box 8 Pump Fault Indicator Light 3 User Interface Touch Display 9 Control Power On Off buttons 4 External Control Interface 10 Pump Ready Light Connections 11 Manual Purge Button 5 Power Input 12 Dispense Valve 6 Main Power Switch Fic 3 3A0260H 11 Overview System Overview pay O I i L Tt 2 Fic 4 Control Center Dimensions The PGM system provides positive displacement meter ing for precision bead control The control accepts auto mation signals to provide accurate and consistent output flow The gear meter can achieve high flow rates with high viscosity materials Control Power On Off 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 Rea
5. 1104 0260 Parts PGM 6 Drive Kit 1201 Ref Part Description Qty 1201 16E367 COUPLING PGM drive 12 mm x 1 14 mm with key 1202 16E368 GEAR REDUCER PGM drive 1 50 1 60 mm frame 1202a COVER 1 1203 16E369 MOTOR PGM drive frame 1 1203a SCREW 4 1203b WASHER 4 3A0260H 63 Parts PGM 6 Lower Assembly Block 1302 Ref Part Description Qty 1301 101970 PLUG pipe headless 2 1302 124173 SCREW shcs M6 1 0 x 90 stain 4 less steel 1303 124174 SCREW shcs M10 1 5 x 75 4 stainless steel 13041 PACKING o ring 13051 O RING 13061 PACKING o ring 1307 16D916 BLOCK inlet PGM 1308 16E340 BLOCK pump mounting PGM 6 1309 24E832 METER gear precision 6cc rev NN T Parts are available in o ring kit 24E677 For part breakdown and repair kits refer to PGM 6 Pump Repair page 42 64 3A0260H PGM 6 Pump Heat Kit 1404 1405 A Ground location Ref Part Description Qt 1401 117764 SENSOR pressure 1402 24 732 KIT heat pump PGM 6 1403 24E413 KIT heat PGM inlet 1404 125363 LABEL heat warning 1405 16E366 INSULATOR 1406 124166 SCREW Replacement Danger and Warning labels tags and cards are available at no cost 0260 y N ND D 1406 1401 1403 Parts 65 Schematics Schematics 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125
6. Error Reset Inlet Pressure Outlet Pressure Error Error Reset If set to Disable errors cannot be reset If set to Enable errors can be reset Inlet Outlet Pressure Drive Torque If set to Error an error will be generated when the out of limit condition occurs The machine will be disabled until the error is reset If set to deviation an error will be generated when the out of limit condition occurs The machine will not be disabled until the error is reset If set to Deviation an error will be generated when the out of limit condition occurs The machine will not be disabled See Errors on page 33 0260 93 Appendix A User Interface Display Supply Pump Screen Pinay une m vl Tarden eune aao v NOTE This screen is used to control the optional dynamic regulator kit for a Therm O Flow See Accessory Parts section on page 76 for additional information on the dynamic regulator kit option Dynamic Regulator Primary Pump Auto Mode During normal operation this mode will activate the dynamic regulator solenoid when the dispense valve solenoid is activated ON Mode This will activate the dynamic regulator solenoid e OFF Mode The dynamic regulator option is dis abled Tandem Pump e Same control features as primary pump 94 3A0260H Appendix B I O Appendix B I O Using the PGM I O The gear meter uses several I O signals to communicate with plant automation con
7. For 24 VDC Coils Relay Phoenix Contact Part Number 2966171 For 120 VAC Coils Relay Phoenix Contact Part Number 2966197 97 Appendix C Theory of Operation Appendix C Theory of Operation Theory of Operation Input and Output Signals Terminology For the purpose of this document a digital signal is said to be SET when voltage is present or above the mini mum threshold A signal is said to be RESET when the signal voltage is not present below minimum threshold Devices are referred to as SET when they are in their energized or active state Digital Inputs Dispense Start This is the Dispense Signal The PGM unit will attempt to dispense at either the commanded flowrate while this signal is SET dependent on mode Control On This input is reset when the E stop button is pressed Job Complete This input can be used to signal a job end NOTE The dispenser ready signal is an important sig nal for the automation to monitor When the dispenser ready output is not on the LT may not be responding to requests from the automation This could create the sit uation where the automation is running production but the PGM is not dispensing any material Dispense Valve Solenoid This signal will be set to energize the dispense valve solenoid at the beginning of a dispense cycle 98 Fault Present This bit is RESET under the following conditions 1 No Faults alarms or warnings are active I
8. PG A BLK 318 130 DC COM DRIVE 1 ENABLE SPARE PRIMARY A 130 DYNAMIC REGULATOR TANDEM B lt K PG B READY 320 yoy Q 130 DYNAMIC REGULATOR GEARMETER READY 399 125 Fic 34 Schematics Page 6 of 10 130 0260 71 Schematics 24VDC 125 400 125 DC COM 130 130 24VDC EXP 1 ANALOG INPUT 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 125 130 uH 400 24VDC 125 PO INLET AMP WER USE CABLE P N 81 0055 MC3 11 TRANSDUCER POWER FEXCITATION WHITE OUTPUT EXCITATION SIGNAL RED BLACK RETURN OUTPUT SIGNAL 130 24VDC 130 402 125 WHITE SHUNTCAL ENABLE OU Tnm gt TRANSDUCER POWER EXCITATION OUTPUT EXCITATION RED RETURN SIGNAL 130 BLACK 130 404 i 130 ORG ORG 130 408 OUTPUT SHUNTCAL
9. 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 sink ing input at the automation controller See Fic 41 If the automation controller uses 24 VDC relay coils to receive signals the signals should be connected as shown in FIG 41 If the automation controller inputs are current sourcing or use a voltage other than 24 VDC relays with 24 VDC coils must be used as shown in FIG 41 PGM Control Automation Pins 10 11 12 Load 750 mA max DC Common Output Circuit FiG 41 96 0260 Analog Inputs The PGM receives a flow rate analog command from the automation The 0 to 10 VDC analog input is refer enced to analog common on the control See FIG 42 The reference for the automation controller analog out put must be connected to the PGM analog reference pin 8 for this signal to function properly PGM Control Automation 0to 10 VDC lt Pin 7 Voltage Pin 8 Analog Input Fic 42 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 FIG 43 24 VDC Pin 14 E Stop Switch Fic 43 0260 Appendix B I O 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
10. Y aq a B Fic 5 Control Center Dimensions 14 3A0260H Electrical Connections w N Follow these precautions when grounding connect ing 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 e A qualified electrician must complete all grounding and wiring connections For wiring refer to FIG 6 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 6 240 Vac Wiring 0260 Installation 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 MW w A 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
11. 88 Setup 2 Screen 89 Setup 3 Screen 90 Setup 4 Screen 91 Setup 5 Screen 92 Setup 46 Screen 93 Supply Pump Screen 94 95 Using the PGM I O 95 Appendix C Theory of Operation 98 Theory of Operation 98 Technical Data 99 Graco Standard Warranty 100 Graco Information 100 3A0260H Related Manuals Related Manuals Part Description 309376 Endure Dispense Valve 310538 Heated Automatic Dispense Valve 311208 Therm O Flow 200 313296 Warm Melt Supply System 309213 Accessory Heat Zone Controls 313526 Ambient Supply Systems Models Models Check the identification ID plate for the 6 digit part number of the fluid metering system Use the following matrix to define the construction of the system based on the six digits For example Part PG0111 represents a PGM fluid metering system PG with a 6cc system 0 unheated 1 with controls 3m 1 and an Endure snuff back 1 NOTE To order replacement parts see Parts section in this manual The digits in the matrix do not corre spond to the Ref Nos in the Parts drawings and lists PG 0 1 1 2 G
12. ENABLE SHUNT A B HSIGNAL D E F CAL T RESISTOR 0 10 VDC ANALOG FLOW COMMAND FROM AUTOMATION ANALOG COM 26 PIN MALE HIGH DENSITY D SUB DAC MON 2 z Y 130 15 130 Fic 35 Schematics Page 7 of 10 DRIVE 1 I O HARNESS 124292 V 16 RP CONFIGURE DIP SWITCHES ON EXP 1 FOR 0 10V AS SHOWN BELOW ON OFF DIP SWITCHES LOCATED INSIDE ANALOG MODULE INLET PRESURE TRANSDUCER OUTLET PRESURE TRANSDUCER 72 0260 Fic 36 Schematics Page 8 of 10 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 24VDC 125 125 24VDC 125 DC COM 130 EXP 2 ANALOG OUTPUT 26 PIN MALE HIGH DENSITY fA D SUB D SUB gt 26 410 O z 412 O vo L___ DRIVE 1 1 0 C HARNESS 124292 10 M1 O O 130 Schematics ANALOG OUT 10 VDC COMMANDED FLOW TO DRIVE 3A0260H 73 Schematics 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529
13. I O on page 95 for more information Robot Outputs These are signals sent by the external machine when the related action should occur The Job Complete sig nal is sent to stop the In Cycle signal The Dispense Trigger is sent to begin dispensing The Command Volt age is a display of the voltage of the command cable and is for troubleshooting only See Appendix B I O on page 95 for more information Robot Inputs These are signals sent to the external machine to notify it of system conditions The Dispense Ready signal tells the external machine that the system is ready to dis pense 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 0260 Robot Inputs Dispense Ready O In Cycle E Alarm m Appendix A User Interface Display 87 Appendix A User Interface Display Setup 1 Screen ear Meter Cont Setti Command Value Source Remote Max Flow cc min Run Mode Bead Adjust Enable Job End Mode Display Job End Delay sec 1 to 6 Buttons Press to navigate to the Setup Screen with that number
14. For example press 3 to navigate to Setup Screen 3 Command Value Source Command Values can be controlled by the user inter face 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 0260 Setup 42 Screen Overview The Dispense Mode Flow Rate and Dispense Duration settings apply to Automatic Control Mode A only Values changed on this screen independent of changes made on the Maintenance screen The Bead Scale value is a duplicate to the Bead Scale setting on the Home Screen which can be enabled or disabled from the Setup 1 screen See Setup 1 Screen on page 88 for more information Fixed Command cc min Flow rate can be entered here This field is only used when command value source is set to Display on Setup Screen 1 See Setup 1 Screen on page 88 for more information 1 to 6 Buttons Press to navigate to the Setup Screen with that number For example press 3 t
15. 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 CUSTOMER MUST SUPPLY BRANCH CIRCUIT PROTECTION 230V 1PH 50 60HZ Gr SEE N z 112 1L1 4 5 lo lo 2 GND DISC 1 FIL 1 1L1 112 10 AWG LINE LOAD i A GND gt ics POWER 1 REGEN BUS BUS C2 CNTRL VAC C1 CNTRL VAC L3 RM C 1 L2 240 120 VAC HOT 12 AWG 110 FIL 2 GND 1L2 111 LINE LOAD 112 CRM 12 AWG HARNESS 24D853 v 82 V 125 130 FG f BRN 113 BLU 10 AWG FIG 29 Schematics Page 1 of 10 16 AWG GND CABLE FROM PS 1 L1 240 120 VAC N e om Re CASE GROUND 24V DC DC COM HARNESS 120997 66 3A0260H 24 VDC 150 125 151 152 153 154 155 156 157 158 159 125 160 0X 161 PB 1 162 163 CRM CONTROL POWER 140 164 165 166 167 168 169 125 E STOP 141 142 143 Schematics DC COM 130 i 130 1 O Og PB 2 REMOTE STOP DC DC DC 170 171 172 173 174 175 176 177 178 179 180 181 125 PROGRAMMING SZ CRM CONTROL_PWR ON 143 WE 130 IF2 IFIA IF1B 182
16. Install Control Center 14 Install Gear Meter Assembly 15 Install Cable Assemblies 18 System 19 Overview icu eludere y ER EAT 19 Configure Control Settings 20 Configure Mode Settings 20 Configure Delay Settings 21 Adjust Pressure Sensors 21 Configure Errors 22 Operation 25 2 lv Ie 23 Startup benne eto ane MR ee NE 23 Load Material 23 Maintenance Mode Operation 24 Calibration 25 Dispense from Maintenance Screen 26 Automation Control Normal Operation 27 Typical Automation Cycle 27 Pressure Relief Procedure 28 ShiutdoWn ENS 30 Troubleshooting 31 PGM Fluid Assembly 31 Dispense Valves 32 ETO d UA lhe ute dide 33 View Errors 33 Diagnose Errors 33 Clear Errors and Reset Control Unit 33 Error Codes and Troubleshooting 33 2 Maintenance 36 Maintenance Schedule 36 va fetes Oe Li nr E 37 Gear Meter Assembly 37 PGM 6 Pump Repair
17. PLC 1 INPUTS DC COM Schematics 130 130 130 SPARE SPARE SPARE SPARE SPARE SPARE 3A0260H 69 Schematics Fic 33 Schematics Page 5 of 10 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 24VDC 125 125 125 PLC 1 OUTPUTS DC COM 130 130 ae 300 A X7 PG IO 302 Q0 1 PG IO MM 304 PG IO V PG IO 130 BLK 306 Q 130 308 FAULT aha R 130 Q0 4 R 22 E 8 PL 2 130 GEARMETER FAULT GEARMETER READY TO DISPENSE GEARMETER IN CYCLE 24VDC COMMON OPEN DISPENSE VALVE GEARMETER FAULT 70 0260 24VDC 125 350 351 352 353 354 355 356 357 358 310 2M 125 3 9 M CRM EN 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 130 Schematics DC COM 130 DRIVE 1 1 0 HARNESS 124292 7 26 PIN MALE HIGH DENSITY D SUB 130 130 99 312 312 314 BLK 316 lt
18. Prepare Gear Meter Assembly for Repair page 37 2 Remove pump block shoulder bolts 4 1102 See 23 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 0260 3 Remove drive assembly See FIG 23 No 4 1102 Fic 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 0260 12 102 1302 FiG 13 14 15 16 17 18 Repair Replace pump block o rings 106 104 1304 See FIG 24 103 PN tT 1303 M 104 1304 107 1306 105 1305 Provided in o ring kit 24E626 24 Place pump 109 1308 onto pump block Install bolts 103 1303 hand tight Locate drive assembly on top of pump assembly Tighten pump block mounting shoulder bolts to frame 4 1102 Loosen pump bolts 103 1303 as needed to ensure couplings are aligned Tighten pump bolts to 430 in lb 48 58 Nem Replace all electrical connections and fluid connec tions before applying fluid press
19. degree 16 SAE x 20 JIC 3A0260H 5 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and reg ulations SKIN INJECTION HAZARD High pressure fluid from hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Inspect hose before each use for cuts bulges kinks or any other damage Replace hoses proactively at regular intervals based on your operating conditions A Replace damaged hose immediately Tighten all fluid connections before operating the equipment Keep clear of leaks Do not stop or deflect leaks with your hand body glove or rag Never exceed hose Maximum Pressure or Temperature rati
20. for very viscous materials Pump Hour Totalizer This field will record the total dis pense time on the machine in hours This field is non resettable Pump Hour Meter This field displays total dispense time in hours This field is resettable 3A0260H Appendix A User Interface Display 2 91 Appendix A User Interface Display Setup 5 Screen Offset Pressure Inlet 0 00 psi Outlet 0 00 psi Limit Limit Min Inlet oo psi Min Outlet oo Max Inlet psi Outlet psi 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 pres sure transducer If the pressure transducers do not reg ister zero pressure when there is no material in the System enter a value to shift the pressure value to zero For example if 15 psi is shown enter 15 psi to shift the value to 0 Min Max Inlet Outlet Limits These limit values are used to set the acceptable range of values for dispensing If values are outside of this range during dispensing the machine will issue an alarm See Errors on page 33 PSI BAR Set the unit of measure for pressure system wide 92 0260 Setup 6 Screen Errors Appendix A User Interface Display
21. heaters may be difficult to remove and removal depends on the system type To ensure proper heat transfer and to avoid premature heater failure System with through hole Press out the heater element using an 0 125 3 mm diameter pin System without through hole Drill out the heater element using a 5mm 0 203 in drill bit Do not increase the hole dia mt er 7 Clean any residue from both heater and sensor 3 Remove two M3 screws to remove the kit from the ports inlet block 3 8 Installation is the reverse of removal LE K 4 Remove two M6 screws to remove the kit from the pump block 50 3A0260H Parts PGM 20 Mounting Frame Ref Part 1 124164 2 124165 3 124166 4 124167 5 124168 8 16D840 9 16D841 10 16D842 11 16D843 12 16V444 0260 Description SCREW shcs M6 1 0 x 25 SCREW bhcs M5 0 6 x 10 SCREW bhcs M6 1 0 x 10 SCREW shoulder 10x30 M8 1 25 SCREW shoulder 8 x 6 M6 1 0 PLATE mounting GUSSET PLATE INSULATOR GUARD drive 10 ti21285a 11 9 lt D 0 O gt Parts 51 Parts PGM 20 Lower Assembly Block 103 108 ES 107 Qty Ref Part Description 101 101970 PLUG pipe headless 102 124173 SCREW M6 1 0 x 90 103 124174 SCREW M10 1 5 x 75 1041 O RING 1051 PACKING o ring 1061 PACKING o ring 1071 PACKING o ring 108 16D827 METER gear precision 20cc rev 109 160915 BLOCK pum
22. manual contains English MM 3A0260 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised September 2013
23. properly the equipment will be damaged and the warranty voided Ground the gear meter assembly as instructed here and in the individual component manuals Make sure the gear meter assembly and its components are installed correctly to ensure proper grounding Air and Fluid Hoses For static dissipation use only electrically conductive hoses or ground the applicator dispense valves Dispense Valve Follow the grounding instructions in the dispense valve manual Connect Fluid and Air Lines Route all fluid and air lines carefully Avoid pinching and premature wear due to excessive flexing or rub bing 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 Foraremote mount dispense valve connect a fluid line between the gear meter outlet and the dis pense valve Shorter fluid lines hoses will provide better fluid system response 0260 Installation See page 4 for list of inlet fittings Fic 8 Inlet Fitting e 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
24. the shaft and gear from the bot tom 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 0260 Repair allow the shaft to be pressed through the gear from the top or coupling end Make sure to leave clear ance 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 PGM pump design relies on a lap fit between components for performance and sealing Be care ful not to drop the gears 1607 1608 or damage the mating surfaces of the pump plates 1601 1603 and gear case 1602 To prevent damage do not use pliers or screwdrivers to remove the gears 12 Clean all components thoroughly before reassem bly The use of an ultrasonic cleaner is recom mended 43 Repair PGM 6 Pump Assembly 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 Ver ify shaft key 1609 is inst
25. 124224 24F324 24F325 709 717 708 706 707 731 702 707 701 728 mM 719 721 710 725 717 PL 715 723 724 NICE 714 Description MODULE analog in 57 200 4ai 10dc MODULE ana out s7 200 2aq 10dc DRIVE indexer PGM 06 only DRIVE indexer PGM 20 only STRIP terminal PGM control RAIL din WIREWAY panduit 1 5 x3 0 x6 WIREWAY panduit 1 x3 x6 COVER panduit 1 5 x6 WIREWAY cover panduit 1 x6 0260 Qty 1 1 O O Ref Part 722 124265 127279 723 124292 724 24D853 725 120997 726 727 Description PGM 3 6 or 9 m cables Qty AMPLIFIER signal conditioner 2 AMPLIFIER signal conditioner 2 PGM 15 m cable HARNESS PGM 26pin dsub 24 1 awg HARNESS wire power motor 1 control CABLE turck rs 4t 4 DOCUMENT schematic PGM 1 CLAMP wire harness 1 4 galvaniz Remote Mount Amplifiers Only for control centers with 15 m cables Mount 1 Remove cover 2 8 machine screws or equivalent not pro vided into cover mounting holes 0260 Parts Ref Part Description Qty 728A 84 0130 LABEL prot earth grnd 375x 375 1 231 729A 84 0130 LABEL pe 1 26 11 730 81 1096 BATTERY backup 200 day s7200 1 11 plc Replacement Danger and Warning labels tags and cards are available at no cost Inline amplifiers are not mounted on panel controls with 15 m
26. 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 125 Fic 30 Schematics Page 2 of 10 PORT 0 OF PLC 1 NOTE SET SWITCHES FOR DP MPI 130 e 090 2 130 0260 67 Schematics 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 Fic 31 Schematics Page 3 of 10 24 VDC 125 D RJ Q c un XXX 130 200 DRIVE 1 1 0 329 26 PIN MALE HIGH DENSITY HARNESS D SUB 124292 D SUB 204 6 10 2 j 2VDC 1 e 206 8 10 3 24VDC 125 9 lt Z Q 125 9 ORG 208 10 4 PG IO ORG 210 10 5 PG IO ORG PG IO 125 MANL PURGE 125 L 212 310 358 9 ORG 310 PG IO DC COM 130 SPARE SPARE DRIVE 1 FAULT DRIVE 1 FAULT AUTOMATION START AUTOMATION JOB COMPLETE MANUAL START CONTROL POWER XXX 68 3A0260H Fic 32 Schematics Page 4 of 10 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 24 VDC 125 125
27. 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 qwe c HARNESS 124292 MOTOR POWER CABLE SEE CHART DRIVE 1 J5 SERIAL PORT FEEDBACK 4 26 PIN MALE 2 HIGH DENSITY m 3 ___ FEEDBACK CABLE D SUB COMMAND 1 0 4 gt SEE CHART 1 tae gt 1 5 gt gt 2 6 gt gt 3 gt 4 J2 5 MOTOR POWER gt 6 gt 7 A gt gt 8 2 gt gt 9 3 gt 2 gt 10 1 2 gt 1 gt B gt AG 15 POWER r gt 16 1 gt gt 17 2 gt 18 des 19 4 gt gt a a gt 21 S 5 2 HARNESS I D 124292 gt 8 gt gt 9 gt 5 L gt PE Q Q DRIVE CABLE CHART CONTROL P N FEEDBACK CABLE POWER CABLE 24E630 124254 124251 24E633 124255 124252 24E634 124256 124253 FIG 37 Schematics Page 9 of 10 74 0260 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 GROUNDING NOTES 1 GROUND ALL DISTRIBUTION BARS F N 2 GROUND ALL DOORS 3 DO NOT JUMPER GROUND WIRES PE TO GROUND PLACE NEAR DIST BAR 1 GROUND LUG SUBPLATE EM S STAR WASHER
28. 781 054776 110321 297612 110318 110319 115948 107110 121022 198171 198446 24E574 080226 C20461 125466 100896 111530 0260 gt 1019 Description TUBE 1 4 OD FITTING nipple hex FITTING elbow street PLUG pipe FITTING elbow swivel TUBE nylon round 5 16 in 8 mm BRACKET mounting SCREW cap button head REGULATOR air 1 4 in npt GAUGE pressure air 1 8 npt FITTING elbow 1 4 nptM 5 16T OD NUT lock FITTING elbow male 1 4 npt FITTING elbow VALVE dispense closer CABLE feed regulator PGM 9 meter VALVE quick exhaust 3 4 in nptf FITTING nipple reducing hex FITTING swivel elbow 1 2 nptf FITTING bushing pipe MUFFLER lt Mu 5 N N N N N Accessory Parts 77 Accessory Parts Dynamic Regulator Setup and Installation 10 11 78 A 2 Remove air pressure from Therm O Flow supply system See Pressure Relief Procedure in manual 311208 Install dynamic regulator kit See FIG 39 on page 79 Apply air to the Therm O Flow supply Check for air leaks Set the secondary regulator for a low operating pressure for example 20 25 psi Adjust the panel mount Therm O Flow regulator to Zero psi Connect the dynamic regulator cable from the Therm O Flow to the PGM control box Navigate to the Supply Pump screen See Appen dix A User Interface Display starting on page 81 for Supply Pump sc
29. Dispense Mode is set to Shot 0260 Configure Delay Settings Set on and off delays in milliseconds for the dispense valve 1 With the system in setup mode press 3 to navi gate to the Delay Settings screen Gear Meter mm Fic 13 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 0260 System Setup Adjust Pressure Sensors Set pressure offsets and pressure limits 1 With the system in setup mode press 5 t navi gate to the Pressure Sensor screen ear Meter Inlet Outlet Min Inlet Max Inlet PSI FIG 14 2 Setthe desired offset for the inlet and outlet pres sures 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 Setthe 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 21 System Setup Configure Errors Set the error type error or deviation that will be issued if the pressure or drive torque goes outside the set high and or low limits See Appendix A User Interface Display on page 81 for information on the purpose of each error type NOTE When an alarm is set to Error th
30. Instructions Parts G GRACO PG M 3A0260H Precision Gear Metering EN For metering and dispensing ambient or high temperature high viscosity single component materials Not approved for use in European explosive atmosphere locations For professional use only 2500 psi 17 2 MPa 172 bar Maximum Working Outlet Pressure 1500 psi 10 3 MPa 103 bar Maximum Working Inlet Pressure See Technical Data on page 99 for temperature ranges Read all warnings and instructions in this manual Save these instructions e Important Safety Instructions See page 4 for model information CE PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Models 1 22 ilxe enims 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 2 1 13 9 DR IRI x seen 6 OvervigW 22 eR tee URS 9 System Configurations 9 Component Identification 11 System Overview 12 Typical Applications 12 Installation 13 Before Installation 13 x oss doa twm pue 13
31. M control panel The dynamic regulator kit is used to control the static pressure of a Therm O Flow The PGM has a maximum inlet pressure of 1500 psi During dispense the dynamic regulator kit will activate the normal regulator located on the front panel of the Therm O Flow When the system is idle the secondary regulator will control static pres sure 0260 79 Accessory Parts Endure Valve Nozzles Part Description 24E654 10 x 1 5 mm Ribbon Nozzle 24E655 1 8 in Bead Nozzle 80 Heater Nests Part Description 24E678 Heater Nest with Blank Insert 24E679 Heater Nest with Ported Insert 0260 Appendix A User Interface Display Appendix A User Interface Display Screen Navigation Diagram START MACHINE N Main Calibrate MAIN fib Home Maintenance Robot 1 0 Go gt Setup Screens gt Supply Pump e Alarm Screen Setup Screens Flow Current Setup Screen 3A0260H 81 Appendix A User Interface Display Main Screen Press the appropriate button to navigate to either the Home or Calibration screen Enter password PGM10 to access the Calibration screen 82 Key A Navigate to the Home screen B Navigate to the Calibrate screen 0260 Calibrate Screen 1 NOTE See Calibration procedure on page 25 0260 Low Speed Calibration Gtart Calculated High Speed i Calibration 0 000 0 000 C Enabl
32. STENER shc 4 40x0 25 ms e12 625 STRAP wrap spiral 1 2 nylon 4 99 626 81 1060 CONNECTOR sq 4p w key 7a 2 613 COVER dust amp17 conn w chain1 4 25 panelm 614 81 2070 LATCH operator 4 DAT A cannon 11 652A 15M511 LABEL warning 1 615 81 2080 CONTACT block no 2 english spanish french 1 11 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 124251 124252 124253 127280 Feedback Cable 124254 124255 124256 127281 Dispense Valve 24E571 24E572 24E573 24U020 3A0260H 57 Parts PGM Back Panel 718 720 716 718 720 711 716 720 718 720 712 730 722 Ref Part Description 701 PANEL back for30x24 encl conduit 702 123361 SWITCH disconnect 32a 703 124228 EXTENSION disconnect 230 350mm 704 117666 TERMINAL ground 705 U70077 TERMINAL lug ground bus type 706 123298 CIRCUIT breaker 2p 20a ul489 707 123296 CIRCUIT breaker 2p 1a ul489 708 123359 RELAY contactor 30a 3p 24vdc 709 124064 FILTER 710 121808 POWER SUPPLY 24vdc 4 0a 100w 711 123718 FILTER emi 6a spade con 712 24F323 MODULE 57 200 14di 10do 24dc 58 B k lc Tm Ref 713 714 715 716 717 718 719 720 721 722 Part 124223
33. abled the dispense valve will open and close as needed to dis pense material When Open the Dispense Valve is selected the dis pense valve will open and remain open until Automatic Dispense Valve Control is enabled Dispense Settings Dispense Mode Options include Bead and Shot Bead mode dispensing begins when the initiate shot button is pressed and dispensing ends when the initiate shot button is released In Shot mode dispensing begins when the initiate shot button is pressed and released Dispensing ends when the Dispense Duration AC elapses Dispense Duration This is the amount of time the machine will dispense at the given flow rate This value is only used in Shot Mode 86 AE AD AC Dispense Duration Input Box AD Flow Rate Input Box AE Manual Start Dispense Flow Rate This is the rate at which the machine will dispense for the given dispense duration Manual Start Dispense After adjusting the settings the user can press the Man ual Start Dispense button AE to dispense material using the current settings NOTE This button performs the same function as the manual purge button located on the control panel 0260 Robot I O Screen Control Center Robot Outputs Dispense Trigger o Job Complete Command Voltage 0 00 wdc Overview This screen is for settings related to an external machine setup to control the dispense operation of this system See Appendix B
34. age 95 Turn on the material supply system 0260 Load Material Before using the system material must be loaded into the supply system 1 Ifthis is a new installation follow the Initial Startup procedure Otherwise follow the Standard Startup procedure 2 Turn on the fluid supply pressure to the fluid inlet block for the PGM 3 Place the dispense valve over a waste container 4 Navigate to the Maintenance screen See Screen Navigation Diagram on page 81 in the Appendix A User Interface Display section 5 Select Manual M Control Mode 6 Enter the minimum flow rate to prime the system See the following table Pump Size Min Flow Rate cc revolution cc minute 6 12 20 40 7 Press and hold the dispense valve icon d Dis pense fluid until clean air free fluid flows from the dispense valve NOTE The manual purge button on the user inter face panel can be used to prime the system 8 If desired press to navigate to the Home Screen 23 Operation Maintenance Mode Operation Operating from maintenance mode enables the pump to begin dispensing when the user presses y Dis L pense parameters and duration depend on the selected control Verify System Operation Use maintenance mode to manually check the operation of the PGM system components before switching over to automation control normal operation NOTE Perform any of the following proced
35. alled 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 7 Rotate the gears several times to ensure free rota tion 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 Ib 9 6 11 8 Nem 10 Rotate the gears several times to ensure free rota tion 11 Apply a heat resistant non evaporating lubricant to the seal area of the drive shaft 1605 44 12 Install new seals 1612 See FIG 26 and FIG 27 1515 1614 1512 1611 1513 1612 Fic 26 Seal Locations 27 1 Pump Body Fic 27 Seal Orientation 13 Install seal retainers 1611 and seal retainer screws 1614 Tighten screws to 85 105 9 6 11 8 Nem 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 FIG 20 16 Separate coupling until proper gap is created See FiG 21 17 Tighten pump block mounting shoulder bolts to frame 1102 18 Replace all electrical connections and fluid connec tions before applying fluid pressure and power 0260 Repa
36. ance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original instructions This
37. b Complete before starting the next cycle NOTE In the event of a deviation alarm the Dis pense Ready signal will remain on along with the alarm signal In the event of an error alarm the Dis pense Ready signal will turn off and the alarm signal will remain on 0260 27 Pressure Relief Procedure Pressure Relief Procedure 28 Shut off the fluid supply to the PGM inlet block If equipped place a waste container beneath the fluid drain valve under the filter Place a waste container beneath the dispense valve Slowly open the drain valve at each fluid filter to relieve fluid pressure Close valve when pressure gauge reads zero Navigate to the Maintenance screen See Screen Navigation Diagram on page 81 in the Appendix A User Interface Display section 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 y or the Purge button on the control L 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 pres sure In maintenance mode s
38. cables 2 2 in 56 5 mm 3 7 in 94 mm lt 3 1 in 79 mm Y 2 5 in 4 I 65 mm gt Y 50 Y 59 Parts PGM Remote Dispense Valve Ref 804 805 807 808 809 60 Part 117820 124200 198446 16E055 804 808 805 809 807 Description Qty FITTING 1 SCREW cap socket head M3 2 SCREW shsc M6 1 0 x 30 stain 4 less steel VALVE dispense closer 1 BLOCK outlet PGM 3 4 NPTF 1 stainless steel 0260 PGM Transducer 20 cc Pump 901 901 Ref Part Description 901 117764 SENSOR pressure 0260 Qty 6 cc Pump 901 901 Parts 61 Parts PGM 6 Mounting Frame Ref 1101 1102 1103 1104 1105 1106 1107 1108 1109 62 Part 124165 124167 124313 124314 16E327 16E328 16E329 16E330 16E331 Description SCREW bhcs M5 0 8 x 10 stain less steel SCREW shoulder 10 x 30 M8 1 25 stainless steel SCREW shcs M6 1 x 16 mm stainless steel SCREW shoulder 6 x 8 M5 0 8 carbon steel PLATE mounting drive PGM 6 GUSSET drive PGM 6 PLATE mounting pump PGM 6 INSULATOR pump PGM 6 GUARD drive PGM 6 Qty 1103 1105 1101 1107 1106 um 1108
39. ce gear head Check component manual for more detailed maintenance information Electrical Task Weekly Check cables for wear A Verify cable connections 4 Verify operation of System Stop button J Check Component Manual for more detailed maintenance information 36 3A0260H Repair NOTE Refer to Parts section beginning on page 51 for part reference number identification Gear Meter Assembly This section describes how to remove and replace com ponents on the gear meter assembly Prepare Gear Meter Assembly for Repair i i i TE 3 O Fic 18 1 Perform Pressure Relief Procedure page 28 2 Disconnect main power at the control box 3 If present remove power from the heat control 4 Remove servo power cable and servo feed back cable See gear meter assembly parts see Parts section starting on page 51 5 Remove heat cables 6 Remove pressure transducer cables and dispense valve cable 7 Remove supply air pressure from solenoid 8 Remove front guard 9 Remove material hoses if necessary 0260 Repair Replace Servo Motor or Gear Head Replacing either the Servo Motor or Gear Head requires the following procedure Remove Servo Motor and Gearhead 1 Prepare Gear Meter Assembly for Repair page 37 2 Remove support gussets 9 1106 3 Remove bolts 1 1103 connect
40. d 2 steel VALVE dispense closer VALVE endure BLOCK mounting HOSE assembly stainless steel braid 3 16 x 12 RETAINER seat a po 404 409 Parts 55 Parts Gear Meter Assembly Panel 610 601 611 612 613 602 623 m e 603 B 516 ETS 617 Z 617 5 616 NS 615 x 606 A Si Sie A N Eu 620 619 V 604 614 607 622 625 618 st LAT I 2 626 612 4 97 i 624 T Ses 3A0260H 56 Parts Ref Part Description SY bn hite 24vde latch 601 ENCLOSURE control gear meter 1 2 11 i M CLE painted z 617 81 2081 2 1 11 603 121148 HANDLE disconnect electric 1 06 81 1096 ADAPTER db9 hmi to plc 57200 1 604 81 2060 BUTTON dual grn red w pl wht 1 11 2 25 605 81 2065 BUTTON operator red 1 619 81 2060 BUTTON mush maint twist red 1 i MES E 11 RA 1 606 81 2065 BUTTON operator pl green 1 Bed 517 LABEL legendse step Bomm G 11 607 LABEL legend panel PGM 1 622 81 1096 CABLE ribbon db9 m f 6ft 1 608 160363 BUTTON operator pb flush black 1 11 609 FITTING bulkhead gland 9wire 1 623 81 1097 COVER PET 6 operator inter 1 610 GRIP cord 35 63 3 4 1 CV6 11 611 81 1060 CONNECTOR sq 14pw key 7a 1 624A 84 0130 LABEL prot earth grnd 375x 375 1 14 25 panel m 23 11 I 612 96 0360 FA
41. dy Light The Pump Ready light displays when the pump is ready for Automatic Mode dispensing When Manual mode is enabled this light will not turn on Pump Fault Light The Pump Fault light is illuminated whenever a pump fault is active Manual Purge Button The Manual Purge button initiates a shot 12 Typical Applications Solar Panel Perimeter Seal Desiccant e Edge Seal Automotive Manufacturing Window and Door General Assembly 3A0260H Installation Before Installation Have all system and component documentation available during installation See component manuals for specific data on compo nent requirements Data presented here applies to the PGM assemblies only Be sure all accessories are adequately sized and pressure rated to meet system requirements e Use the PGM control center only with the PGM metering assembly 0260 Installation 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 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 me
42. e 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 Calibration Shot time Seconds Actual Calibration Volume fcc Volume cc K Factor Appendix A User Interface Display H Low Speed Calibration Shot Volume Input Box J Start High Speed Calibration button K High Speed Calibration Shot Volume Input Box L Navigate to Main Screen M Enter Calibration Screen 83 Appendix A User Interface Display Calibrate Screen 2 NOTE See Calibration procedure on page 25 A2 Calibration Settings Low Pump High Pump RPM RPM Low Flow High Flow A1 ccjmin ccjmin 0 00 0 00 Technician Password Key A1 Pump RPM during low speed calibration A2 Pump RPM during high speed calibration 84 0260 Home Screen Inlet psi Enable Manual mode Enable Automatic mode Increase Bead Scale Decrease Bead Scale Current Bead Scale setting domJmuz Manual Mode In Manual Mode the machine only accepts signals from the User Interface touch screen and the physical buttons on the machine 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 ini tiate a shot using the User Interface touch screen or the phys
43. e Devi Outlet material pres Deviation Back pressure is Verify pressure limits ation sure outside limits too high or too low in Setup Screen 5 Limits are not set Verify outlet pressures correctly during dispense 6 Outlet High Pressure Outlet material pres Alarm Back pressure is Verify pressure limits Error sure above max limit too high Limits in Setup Screen 5 are not set cor Verify outlet pressures rectly during dispense 7 Outlet Low Pressure Outlet material pres Alarm Outlet pressure Verify pressure limits Error sure below min limit too low Limits are in Setup Screen 5 not set correctly Verify outlet pressures during dispense 8 Inlet Max Pressure Inlet material pres Alarm Feed system pres Perform pressure Fault Relieve Pres sure exceeds max sure is set too relief procedure sure and Cycle Power rated pressure high Pressure Change inlet supply sensor damaged pressure Cycle power Verify Pres sure sensor is work ing properly 9 Outlet Max Pressure Outlet material pres Alarm Dispense valve Perform pressure Fault Relieve Pres sure exceeds max not opening Flow relief procedure sure and Cycle Power rated pressure rate too high Cycle Power Verify Material not at Dispense valve func temperature tion Perform weight check verification Reduce flow rate 10 Drive Torque Devia Motor exceeds con Deviation Flow rate too high Lower flow rate tion tinuous rated torque Dispense Valve reduce out
44. e dispenser ready signal LOW Diagnose Errors See Error Codes and Troubleshooting for valid error codes possible causes and solutions Clear Errors and Reset Control Unit From the Alarm View screen press 22 to clear Error Codes and Troubleshooting error before restarting the control unit NOTE See the Configure Errors section on page 22 Error Error No Error Name Error Description Type Cause Solution PGM Control Errors 1 Control Power Off Control power has Advisory Stop button or Press Control Power been removed E stop button 2 Inlet Pressure Devia Inlet material pres Deviation Feed pressure set Verify pressure limits tion sure outside limits too high or too low in Setup Screen 5 Limits are not set Verify supply pres correctly sures during dis pense 3 Inlet High Pressure Inlet material pres Alarm Feed pressure too Verify pressure limits Error sure above max limit high Limits are in Setup Screen 5 not set correctly Verify supply pres sures during dis pense 0260 33 Errors Error Error No Error Name Error Description Type Cause Solution 4 Inlet Low Pressure Inlet material pres Alarm Feed pressure too Verify pressure limits Error sure below min limit low Limits are not in Setup Screen 5 set correctly Verify supply pres sures during dis pense 5 Outlet Pressur
45. e machine will be disabled when the alarm occurs 1 With the system in setup mode press 6 to navi gate to the Errors screen Gear Meter Error Reset Disable Inlet Pressure Error Outlet Pressure Error 5 6 Drive Torque Error Fic 15 2 Press the Error Reset drop down list and select Enable or Disable 3 Press the Inlet Pressure drop down list and select Error or Deviation 4 Press the Outlet Pressure drop down list and select Error or Deviation 5 Press the Drive Torque drop down list and select Error or Deviation 22 0260 Operation Startup AO Initial Startup 1 3 Ensure the PGM control enclosure and all of the proper connections to and from the control enclo sure have been made Ensure fittings are tight Read and understand the Operation and User Inter face sections of this manual Continue startup with Step 2 in Standard Startup Standard Startup 1 Carefully inspect the entire system for signs of leak age or wear Replace or repair any worn or leaking components before operating the system Press the Stop button on the control enclosure Turn on air and electrical power to the system Turn on the main power to supply power to the PGM Check Interface Signals If this is a new installa tion power on each system input and verify that each input is being received See Appendix B 1 0 on p
46. ear Meter First and Third Digit Fourth Digit Fifth Digit Sixth Digit Second Digits Size Heat Controls Valve Description Description Description Description PG 0 1 Unheated No controls 1 Endure snuff back Precision 5 20cc 2 Heated Controls 3m 6 Remote mount Controls 6m Controls 9m 0 1 2 3 4 Controls 15m Controllers Bulk Melt Therm O Flow 20 Therm O Flow 200 and Ambient Hoses PGM Control Center does not include heat controls Heat loads are configured to be controlled by Therm O Flow 12 8 10 1 1 16 in 12 16 3 4 in 16 JIC 7 8 in 14 JIC JIC 1 5 16 in 12 JIC 3 8 in 1 2 in P 6 ft None 115875 None 115884 109163 626720 D 1 2 in x 5 ft E 10 ft 115873 115876 115880 115885 None 215441 8 15 ft Non None None None 109165 511381 685602 Fittings PGM Inlet None None 124238 124239 None None 16 SAE 124235 90 124243 T 124236 90 PGM Outlet 124286 C20595 15M863 107127 124290 T 124289 T 3 4 in npt Valve Inlet 124287 C20768 107052 124288 158256 T 190451 T T Indicates swivel Indicates PTFE hose all others Buna N 0260 Remote Dispense Valves Models Part Description 124238 Adapter Fitting 3 4 i
47. ed the PGM system must be setup again After material is loaded into the supply system set up the PGM system using the Setup screens FiG 10 shows the major system setup steps The following sub sections provide instructions to complete each setup step Once these steps are complete the module is ready for operation NOTE See Appendix A User Interface Display on page 81 for detailed operating instructions for each user interface screen Fic 10 0260 6 System Setup Configure Control Settings page 20 Configure Mode Settings page 20 Configure Delay Settings page 21 Adjust Pressure Sensors page 21 System Setup Configure Errors page 22 C End System Setup 19 System Setup Configure Control Settings Set the controls for the dispense source how dispense commands are sent and auto mode settings 1 From the Home screen select the Setup icon b NOTE Setup screens password protected Enter password PGM10 to access the following screens ear Meter Cont Setti Command Value Source a Ey Remote Max Flow cc min Run Mode Bead Adjust Enable Job End Mode Display Job End Delay sec Ew 4 n FIG 11 2 Press the drop down list for Command Value Source and select Display or Remote Press Enter 4 to confirm selection 3 If Command Value Source is set to R
48. elect Open Dispense Valve Control mode Which opens the dis pense valve Press the manual dispense button y until fluid flow stops L 3A0260H 8 Ifthe dispense device cannot be actuated from the control center refer to FiG 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 FIG 16 b Continue actuating the plunger until all pressure is purged from the system between the needle and dispense valve before proceeding to the next step Dispense Valve Air Solenoid Fic 16 Dispense Valve Air Solenoid Pressure Relief Procedure OA If you have followed the previous steps and still sus pect that a valve hose or dispense nozzle is clogged or that pressure has not been fully relieved very slowly remove the dispense tip clean the orifice and con tinue relieving pressure If this does not remove the obstruction very slowly loosen the hose end coupling and relieve pressure gradually then loosen the coupling completely Clear the valves or hose Do not pressurize the system until the blockage is cleared 9 Shut off power and air to the fluid supply system 0260 29 Shutdown Shutdown 1 Press the Stop button See FIG 17 2 Shutoff the material supply to the gear meter me
49. emote enter the Remote Max Flow cc min for the 10 VDC com mand source 4 Press the drop down list for Run Mode Bead Adjust and select Enable or Disable Press Enter 4 to confirm selection 5 Press the drop down list for Job End Mode and select Display or Remote Press Enter 4 to confirm selection 6 If Job End Mode is set to Display press Job End Delay Display field and enter desired delay time in seconds Press Enter 4 to confirm 20 Configure Mode Settings Set the dispense mode bead or shot The bead scale and pre charge are also adjustable from the Mode Set tings screen NOTE See Appendix A User Interface Display on page 81 for a description of each feature 1 With the system in setup mode press 2 to navi gate to the Mode Settings screen Gear Meter Mode Settings Made Eixed Command Bead Scale o 96 Pre Charge o psi Fic 12 2 Press the drop down list for Mode Select Bead or Shot Press Enter 4 to confirm selection 3 If Command Value Source is set to Display press the drop down list for Fixed Command Flow Rate then enter the flow rate in cc min Press Enter to confirm See Configure Control Settings for instructions to set the Command Value Source value 4 f Shot Time is displayed press the drop down list for Shot Time in Seconds Press Enter 4 to confirm NOTE Shot Time is only displayed if
50. et 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 clos ing If the Off Delay is set to 100 the machine will wait 100 milliseconds after a shot is complete before closing the dispense valve 90 0 00 Drive Information Motor Torque Display motor torque during dispense If motor torque climbs above continuous torque an alarm is issued See Errors on page 33 Cont Torque Continuous torque rating of the motor NOTE The motor torque display is a good way to deter mine the maximum flow rate with a given viscosity 0260 Setup 4 Screen Snuffback Time ms Snuffback Pump RPM Pump Hour A Totalizer Pump Hour Meter 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 mate rial back from the dispense valve to minimize or elimi nate 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
51. fere with material inlet hose 9 Install gussets with shoulder bolts 5 1104 Remove Coupling 1 Prepare Gear Meter Assembly for Repair page 37 Remove support gussets 9 1106 Remove bolts 1 1103 connecting top mounting plate 8 1105 to vertical mounting plate 10 1107 Remove servo motor gear head and top plate 0260 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 FiG 20 Repair 5 Separate coupling until proper gap is created FIG 21 See the following table Pump Size cc revolution Gap mm 6 18 20 20 Gap p Fic 21 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 FIG 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 48 58 54 23 Nem 0260 6 Tighten coupling bolts to the following torques Pump Size Torque cc
52. ical buttons on the machine will be ignored 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 2110 cc min The primary purpose of the bead scale is to be able to quickly adjust volume dispensed to be able to find that actual desired volume Once the correct volume is found the flow rate should be adjusted accordingly 0260 Appendix User Interface Display V W Outlet psi 0 X cc min 0 0 Key Navigate to Maintenance Screen Navigate to Robot I O Screen Navigate to Setup Screens Navigate to Main Screen Navigate to Alarm Screen lt xs lt c Screens Navigation Access to the Setup screens requires the Supervisor password Flow Rate Display The Home screen will display the commanded Flow Rate from 1 of 3 sources 1 Maintenance Flow Rate see Maintenance Screen on page 86 2 Auto Mode Display Flow see Setup 2 Screen on page 89 3 Remote 0 10 VDC Command Flow see Appen dix B I O on page 95 85 Appendix A User Interface Display Maintenance Screen Key Z Enable Automatic Dispense Valve Control AA Open the Dispense Valve Disable Automatic Dispense Valve Control AB Dispense Mode Selection drop down menu Dispense Valve Control When Automatic Dispense Valve Control is en
53. ify air pressure to solenoid Verify solenoid operation Verify air line routing and connec tions Dispense Trigger signal from auto mation unit is on Check input from automation unit Sluggish open close Air pressure low Verify air pressure is above 60 psi 0 4 MPa 4 bar Needle seat worn Rebuild valve replace needle seat Pressurized material past the valve shut off is escaping Reduce running pressure Reduce nozzle length Increase nozzle orifice size 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 necessary Worn piston o ring Rebuild valve replace piston o ring 32 0260 Errors View Errors Errors can be viewed from the Home screen or from the Alarm View screen Errors There are three levels or errors alarms deviations and advisories Alarms are critical and require immediate correction therefore the system automatically shuts down Deviations are important and require attention but Home Inlet psi Access the Alarm View screen E y Outlet psi A 0 cc min 0 0 Error Message not immediately Advisories are not critical but still require attention NOTE e Errors set the dispenser ready signal LOW e Advisories and deviations do not set th
54. ing 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 12022 8 Loosen gearhead coupling on gearhead shaft 9 Remove 4 bolts connecting servo motor to gear head 10 Remove servo motor from gear head 37 Repair Install Servo Motor or Gearhead 1 Remove key from motor shaft Use caution when handling servo motor to prevent damage Do not use tools that could cause dam age 2 Slide the gear head bushing into the drive coupling and align slots in drive coupling and bushing See FiG 19 SEE DETAILA Fic 19 DETAIL A SCALE 3 2 3 38 Rotate the drive coupling to align clamping bolts with access holes Place motor on work surface with motor shaft facing straight up then mount the gear head Mounting the gear head in any other orientation will usually lead to misalignment and excessive noise Pre torque drive coupling to 0 4 Nem 4 in lb Bolt gear head to the motor with fasteners provided Final toque drive coupling to 8 5 Nem 76 in Ib in three steps increasing torque each time Do not tighten coupling to gear head output shaft until drive assembly is mounted in frame NOTE Orient servo motor so that the motor connec tions do not inter
55. ir 3A0260H 45 Repair PGM 20 Pump Repair 1515 af 1509 1512 7 258 2 kn MN En 1512 151319 gt lt T 1511O 1510 e 2 LAN WA 15160 2 e LE 125654 1 15040 503 1508 O P N 125655 T Parts included in kit 24E619 Parts included in kit 24E825 Parts included in kit 24E824 Fic 28 PGM 20 46 3A0260H PGM 20 Pump Disassembly 1 Prepare Gear Meter Assembly for Repair page 37 2 Referto Gear Pump Maintenance Guide on page 49 for special notes regarding gear pump repair 3 Remove six pump block shoulder bolts 4 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 FIG 23 AlS Thicker materials may pump heating prior to disas sembly Do not expose the pump to thermal shock Raise temperature at a maximum rate of 180 F 100 C per hour Do not exceed 400 F 204 C Gradually cool the pump to room temperature 5 Remove seal retainer fasteners 1515 seal retain ers 1512 spacers 1510 and 1511 6 Remove pump dowels 1509 using an arbor press 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 pu
56. izes and equipment selections See your Graco Authorized distributor for other capabilities 3A0260H 99 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with Structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributo
57. let pres not opening sure drop Verify Material not at material temperature temperature 11 Drive Torque Error Motor exceeds con Alarm Flow rate too high Lower flow rate tinuous rated torque Dispense Valve reduce outlet pres not opening sure drop Verify Material not at material temperature temperature 12 Drive Peak Torque Motor exceeds peek Alarm Flow rate too high Cycle Power Lower Error Drive disabled torque rating Dispense Valve flow rate reduce out Cycle Power not opening let pressure drop Ver Material not at ify material temperature temperature 34 3A0260H Errors Error Error No Error Name Error Description Type Cause Solution 13 Pre Charge Timeout Pre Charge Pressure Advisory Pre Charge value Set Pre Charge to was not reached not set correctly zero Monitor outlet after dispense pressure Adjust Pre Charge pressure 14 High Pressure Inter Pressure limit is Advisory Pressure sensors Contact Graco cus lock OFF bypassed are disabled tomer service 15 Dispense Valve Open Dispense valve is Advisory Dispense valve From the Mainte Auto Default open open button has nance screen select been selected Dispense valve Auto 16 Calibration is enabled Calibration mode Advisory Calibration Complete calibration complete calibration enabled enabled selected procedure procedure from the calibrate screen 17 Drive Fault Cycle Motor drive is dis Alarm Various conditions Cycle Power ve
58. luid in approved containers and dispose of it according to applicable guidelines 3A0260H 7 Warnings D PERSONAL PROTECTIVE EQUIPMENT om You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhala tion of toxic fumes and burns This equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufac turer 3A0260H Overview System Configurations Typical Heated System Installation Overview Air Supply AE Power Drop Site o P AL EN dud AN AH AJ RE 2 F4 y A 1 ri i HE 1 Typical Heated System Installation AH Key AA Control Center User Interface AB Gear Meter Assembly AC Applicator Dispense Valvet AD Automation Robot AE Automation Interface Cable T AF Gear Meter Cables 0260 AG Heated Fluid Supply System AH Fluid Supply Hose AJ Heat Control AK Automation Controller AL Air Filter Assembly AM Remote Dispense Hose T AN Heated Manifold AO Dynamic Regulator T Included T Accessory Overview Typical Ambient System Installation 4 Air Supply Power Drop Site x e
59. mp front plate 1501 gear case 1502 and back plate 1503 NOTE Notches on the pump plates can be used to separate the plates 9 To remove drive shaft 1504 from the drive gear 1506 several flat spacers 1 8 in 3 mm thick will be needed These will provide clearance for the drive shaft key 1508 and the top plate 1501 10 Support pump top plate 1501 and press drive shaft 1504 through drive gear 1506 Stop when there 0260 Repair 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 insert ing 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 The PGM pump design relies on a lap fit between components for performance and sealing Be care ful not to drop the gears 1607 1608 or damage the mating surfaces of the pump plates 1601 1603 and gear case 1602 To prevent damage do not use pliers or screwdrivers to remove the gears 13 Clean all components thoroughly before reassem bly The use of an ultrasonic cleaner is recom mended 47 Repair PGM 20 Pump Assembly 14 Align pump shaft key and slide coupling onto pump shaft Tighten coupling bolt just enough to hold it s position Do not hamme
60. n Navigation Diagram on page 81 in the Appendix A User Interface Display section 2 Select Manual M Control Mode 5E 3 From the Mode drop down menu select Bead or Shot Mode Manually Dispense Fluid 1 Press y and verify the dispense valve opens L 2 Continue to press y as long as needed to load L or dispense material Release to stop dispensing 3 If desired press to navigate to the Screen 26 0260 Automation Control Normal Operation During automation control normal operation the PGM automatically dispenses when it receives a command from the automation unit NOTE See Appendix B I O on page 95 To enter Auto mode select Auto A Control 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 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 begin ning on page 81 3 Robot turns on dispense trigger 4 PGM turns on In Cycle 5 Robot removes dispense trigger 6 IfJob Complete is set to Remote robot turns on Job Complete 7 Robot removes Jo
61. n Tube x Part Description 16 SAE 243694 Heated Dispense Valve 124239 Adapter Fitting 1 in Tube x 244951 Endure Valve Heated 1e PAE 1 2 in npt male outlet 124240 Adapter Fitting 1 1 4 in Tube x 244909 Endure Valve Heated I9 OAE 124241 Adapter Fitting 16 SAE x 1 Fixed Dispense Valves 124242 Swivel 16 SAE x 1 in NPTF 124243 Swivel 16 SAE x 1 in tube DRE 124244 Swivel 1 2 NPTM x 10 JIC 252407 Endure valve snuf hack 124245 Swivel 1 2 NPTM x 1 2 NPTF 124286 Adapter Fitting 3 4 NPTM x 8 Accessories 124287 Adapter Fitting 1 2 NPTM x 8 JICM 124288 Adapter Fitting 1 2 NPTM x 16 Part Description JICM 24D824 Automation Cable 124289 Swivel Fitting 3 4 NPTM x 1 2 NPS 24E654 Ribbon Nozzle Kit 10 x 1 5 mm 124290 Swivel Fitting 3 4 NPTM x 3 8 NPS 24E655 Bead Nozzle Kit 3 mm dia 24E575 Dynamic Air Regulator for Therm O Flow 24E607 Gear Pump Seals 6 cc 24E619 Gear Pump Seals 20 cc 24E677 O ring Kit 6 cc 24E626 O ring Kit 20 cc 24E678 Heated Nest Pilot 24E679 Heated Nest Ribbon or Bead 16E242 Nozzle Heater Insert 16E256 Ported Nozzle Heater Insert 124267 Seal Housing 6 cc 24E826 Gear Shaft Repair Kit 6 cc 24E827 Seal Shaft Repair Kit 6 cc 124266 Pump Seal Housing 20 cc 24E824 Gear Shaft Repair Kit 20 cc 24E825 Seal Shaft Repair Kit 20 cc 124235 Elbow Fitting 90 degree 3 4 in tube x 16 SAE 124236 Elbow Fitting 90 degree 1 in tube x 16 SAE 124237 Elbow Fitting 90
62. n Cycle In Cycle signal is set at the beginning of a dis pense cycle It is reset at the end of the dispense cycle The dispense cycle can end in two ways depending on how the Job End mode is set fthe Job End mode is set to remote dispense cycle ends when the job complete signal is received from the automation I O e fthe Job End mode is set to Display dispense cycle ends when the Job End delay timer expires See Appendix A User Interface Display on page 81 Analog Input Flow Command The flow command signal input rep resents flow requests The voltage must be between 0 and 10 volts DC The 0 10 volt signal is interpreted as a relative 0 100 flow command signal The system must be in Remote Mode for this input to be used See the Accessory Parts on page 76 0260 Technical Data Technical Data Volume repeatability 1 Minimum Flow 6 cc rev model 30 cc min 20 cc rev model 40 cc min Maximum Flow Rate 6 cc rev model 480 cc min 20 cc rev model 1600 cc min Minimum Dispensed Shot Size 6 cc rev model 8 cc 20 cc rev model 10 cc Maximum Fluid Working Inlet Pressure 1500 psi 10 3 MPa 103 bar Maximum Fluid Working Outlet Pressure 2500 psi 17 2 MPa 172 bar Air Supply Pressure Range 60 100 psi filtration required Fluid Filtration Recommended
63. ngs Only use chemicals that are compatible with wetted parts See Technical Data in this manual Read MSDSs and fluid and solvent manufacturer s recommendations Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment AN BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns Do not touch hot fluid or equipment 6 3A0260H Warnings FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help pre vent fire and explosion gt lt d t Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail lf there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area 9 EQUIPMENT MISUSE HAZARD Misuse can cause death o
64. o navigate to Setup Screen 3 0260 Made Eixed Command Bead Scale o 96 Pre Charge o psi Appendix A User Interface Display B Ls Ls B mn Pre Charge This is the pressure between the meter and the dis pense 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 rup tured components and serious injury 89 Appendix A User Interface Display Setup 3 Screen 0 00 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 rup tured 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 s
65. p mounting 110 160916 BLOCK inlet PGM OO NO f Partincluded in o ring kit 24E626 For part breakdown and repair kits refer to PGM 20 Pump Repair page 46 52 3A0260H PGM 20 Pump Heat Kit N 5 LT 204 206 A Ground location Ref Part Description Qty 201 117764 SENSOR pressure 202 24 412 KIT heat pump PGM 20 203 24E413 KIT heat PGM inlet 2044 125363 LABEL heat burn warning 205 160923 INSULATOR 206 124175 SCREW ND D Replacement Danger and Warning labels tags and cards are available at no cost 0260 206 205 201 202 Parts 53 Parts PGM Drive 20 cc Pump Ref Part Description Qty 301 16D947 MOTOR PGM drive servo 4 1 frame 302 160946 GEAR REDUCER PGM drive 1 50 1 80mm frame 302a COVER 1 303 16D945 COUPLING PGM drive 18x20mm 1 w key 54 0260 Endure Dispense Valve Fix Mounted Ref Part 401 597151 402 117820 403 124200 404 124201 405 116768 406 124403 407 124405 408 198446 409 244907 410 160943 411 16E899 412 C32089 3A0260H 410 403 405 412 Description Qty FITTING elbow 1 4 tube x 1 8 NPT male 1 SCREW cap socket head M3 2 SCREW socket head cap screw M6 1 0 x 30 4 stainless steel SCREW socket head cap screw M5 0 8 x 60 4 stainless steel PACKING o ring 1 FITTING adapter 1 8 NPTM x 03 JICM mild steel 4 SWIVEL elbow 90 deg 03 JICF x 03 JICM mil
66. r for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assist
67. r or force components together or damage may occur Parts will drop into place if properly cleaned and aligned Use of a compatible 15 Attach servo motor gear head and top plate to pump assembly See FIG 20 oil is recommended during assembly 18 coupling uni proper cape created 666 1 Place back plate 1503 on a table inside face up FIG 21 2 Install the driven gear 1507 on stud 1505 17 block mounting shoulder bolts to ram 1 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 18 Replace all electrical connections and fluid connec tions before applying fluid pressure and power 4 Place the top plate 1501 on its edge on a table Pass the drive shaft 1504 through the top plate from the seal side so that the boss on the shaft rests on the top plate 5 Rotate the drive shaft 1504 to position the drive key slot at the top Insert the drive key 1508 and driven gear 1506 6 Grasp the top plate 1501 drive shaft 1504 and driven gear 1506 to prevent them from separating and carefully lower them into position onto the gear case 1502 7 Rotate the gears several times to ensure free rota tion 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
68. r serious injury 2 Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information e 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 9 TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed the eyes or skin inhaled or swallowed Read MSDSs to know the specific hazards of the fluids you are using Store hazardous f
69. reen information Select ON mode for the Primary or Tandem Pump drop down menu Set the appropriate press for the panel mount regu lator on the Therm O Flow For example 30 40 psi Select AUTO mode for the Primary or Tandem Pump drop down menu 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 0260 Dynamic Regulator Installation A Remove plug and attach supplied tubing to regulator inlet Holes required for mounting See detail A A 5 32 in tubing removed from Therm O Flow regulator to be attached here A 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 FIG 39 LL Cb um Bi v 9 L ZZ BS 27 SE 1 Ay V 222221 H Accessory Parts 5 16 in 7 32 in diameter 11 16 in Detail A A 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 PG
70. revolution in Ib Nem 6 132 15 20 309 35 7 Install gussets with shoulder bolts 5 1104 39 Repair Remove Dispense Valve 1 Prepare Gear Meter Assembly for Repair page 37 2 Manually actuate solenoid to ensure pressure has been removed Dispense Valve Air Solenoid Fic 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 Referto dispense valve manual for complete dis pense 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 3 Install four mounting bolts 408 torque to 50 60 in lb 5 6 6 7 Nem 40 4 Connect air lines 5 Apply air to the solenoid 6 Manually shuttle solenoid see FIG 22 Verify dis pense valve is open when solenoid is depressed Replace Solenoid 1 Prepare Gear Meter Assembly for Repair page 37 2 Disconnect solenoid cable Remove mating screws 405 from gusset 3 Remove the dispense valve solenoid 410 and replace it with a new solenoid 4 Reconnect solenoid cable Gear Meter O Ring Replacement Refer to Parts section starting on page 51 for o ring kits 1
71. rify Power abled motor torque during dispense 18 Calibration out of Calibration values Advisory Improper calibra Perform calibration range are out of range or flow rate is too low for current K factor tion flow rate too low or pump wear procedure 0260 35 Maintenance Maintenance Prior to performing any maintenance procedures follow the Pressure Relief Procedure on page 28 Maintenance Schedule The following tables list the recommended maintenance procedures and frequencies to operate the equipment safely The maintenance is divided between mechanical and electrical tasks Maintenance must be performed by trained personnel per this schedule to assure safety and reliability of the equipment Mechanical Operator Maintenance Person Task Daily Weekly Monthly 3 6 months or 125 000 cycles 18 24 months or 500 000 cycles 36 48 months or 1 000 000 cycles As Required 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 lt Check tighten air connections Lubricate dispense valves Replace gear meter seals Rebuild dispense valve Replace air filter Replace Solenoid Replace gear meter drive shaft Repla
72. 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 Select a location for the gear meter assembly Keep the following in mind e Allow sufficient space for installing the equip ment sure all fluid lines cables and hoses eas ily reach the components to which they will be connected sure the gear meter assembly allows the automation unit to move freely along all axis e sure the gear meter assembly provides easy access for servicing its components 15 Installation 2 Mount and secure the gear meter assembly to the automation unit or other mounting surface with mounting plate The mounting plate is tapped with M10 x 1 5 bolts Maximum bolt length through plate is 0 75 in 19 mm See the mounting dimensions in Table 4 and FIG 7 Table 4 Gear Meter Assembly Measurement 6 cc Pump 20 cc Pump A 2 00 in 50 8 mm 3 00 in 76 2 mm B 5 00 in 127 mm 3 875 in 98 43 mm C 2 375 in 60 33 mm 2 313 in 58 75 mm D NA 1 063 in 27 00 mm T 0 238 in 6 0 mm 0 238 in 6 0 mm diameter diameter A e FRA EM ET 20 Pump 6 cc Pump Fic 7 Gear Meter Assembly Dimensions 16 3A0260H Grounding ME w A If power and grounding connections are not done
73. ssure Blocked dispense tip Replace dispense tip Flow rate too high for application decrease flow rate Dispense valve On delay set too Verify Dispense valve delays in long setup screens Dispense valve solenoid stuck Verify function of dispense valve closed Dispense pattern too light Supply pressure too low Verify inlet pressure needed for flow rate Flow rate too high for application Perform dispense weight verification see Calibration procedure on page 25 Lower flow rate and repeat 0260 31 Troubleshooting Measured flow does not match command Supply pressure too low Verify inlet pressure needed for flow rate Flow rate too high for application Perform dispense weight verification see Calibration procedure on page 25 Lower flow rate and repeat Gear meter is not calibrated Perform calibration Perform weight verification see Calibration proce dure on page 25 Gear meter is worn or damaged Perform weight verification see Cal ibration procedure on page 25 if weights are not repeatable repair or replace gear meter Dispense Valves Problem Cause Solution Valve not opening Air not getting to open port Verify air pressure solenoid No Dispense Trigger signal from automation unit Check input from automation unit Valve not shutting off Air not getting to close port except AutoPlus valve Ver
74. ter 3 Shut off heat to PGM See related manuals section for Therm O Flow manual and Accessory Heat Con trol 4 Shutoff power and air to the fluid supply system 5 Turn off the main power supply 1 17 Stop Button 30 3A0260H Troubleshooting WI S A w Troubleshooting NOTE Check all possible solutions in the chart Refer to Supply Systems manual for additional trouble below before you disassemble the system shooting refer to Related Manuals on page 3 Also refer to Error Codes and Troubleshooting page 33 PGM Fluid Assembly Problem Cause Solution No Inlet Pressure No air pressure on supply system Verify supply system pressure Leak in supply system Check supply lines and connections False signal being sent to control Check inlet pressure sensor output verify that it corresponds to zero pressure replace sensor and or amplifier Leak at PGM drive shaft Replace drive shaft seals No Outlet Pressure Dispense motor not rotating Refer to Error code section of the manual Cycle power and perform startup Dispense Off delay set too long Verify Dispense valve delays in setup screens Dispense valve solenoid stuck open Verify function of dispense valve False signal being sent to control Check outlet pressure sensor out put verify that it corresponds to zero pressure replace sensor and or amplifier High Outlet Pre
75. ter and dispense valve For remote mount dispense valves con nect 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 13 Installation Install Control Center Secure the control center with appropriate size bolts through the 0 50 in 13 mm diameter holes See the mounting dimensions in the following table and FIG 5 Mount Control Center Assembly Measurement M A 24 0 in 610 mm B 22 5 in 572 mm Ensure the following criteria are met before mounting 30 0 in 762 mm the PGM control center D 28 5 in 724 mm e 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 e Ensure there is sufficient clearance around the con trol unit to run cables to other components e Ensure there is easy access to an appropriate elec trical power source The National Electric Code requires 3 ft 0 91 m of open space in front of the control center e Ensure there is easy access to the power switch Ensure the mounting surface can support the weight of the control center and the cables attached to it
76. tighten to 85 105 in Ib 9 6 11 8 Nem 10 Rotate the gears several times to ensure free rota tion 11 Apply a heat resistant non evaporating lubricant to the seal area of the drive shaft 1504 12 Install new seals 1513 See 26 and FIG 27 13 Install spacers 1510 1511 seal retainers 1512 and seal retainer screws 1515 Tighten screws to 85 105 in Ib 9 6 11 8 Nem 48 3A0260H Gear Pump Maintenance Guide Review these guidelines prior to performing any mainte nance 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 car rying 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 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 0260 Repair 49 Repair Installing new heater units and RTD sensors 1 Prepare Gear Meter Assembly for Repair 6 Remove the heaters and sensor from the block page 37 NOTICE 2 Disconnect the power cables from the heaters The
77. trollers 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 automa tion controller signals Digital Inputs The two digital inputs are Dispense Start and Job Com plete These inputs require a 24 VDC current sourcing output from the automation controller See FIG 40 If the automation controller uses relay contacts to acti vate 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 con nected 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 con troller outputs are low side switching open collector or a voltage other than 24 VDC relays must be used as shown in FIG 40 Automation PGM Control 8 24VDC Relay Contact gt Pin 1 2 Input Circuit 40 3A0260H 95 Appendix B I O Digital Outputs
78. upstream of PGM Adding an air regulator to this line will provide more consistent dispense valve response times e 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 17 Installation Install Cable Assemblies 1 Connect servo motor power and feedback cables 3 Connect dispense valve solenoid cable 2 Connect pressure transducer cable 4 Connect heat cables if equipped to Therm O Flow controller Remote mount amplifier on units with 15 meter cables only M IN LINE AMPLIFIER ti22239a FIG 9 Cable Installation Diagram 18 3A0260H 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 chang
79. ure and power 41 Repair PGM 6 Pump Repair 1607 1608 16159 P N 125656 16059 16099 x P N 125657 161219 x 1610 1613 j T Parts included in kit 24E607 Parts included in kit 24E827 Parts included in kit 24 826 FIG 25 PGM 6 42 3A0260H PGM 6 Pump Disassembly 1 Prepare Gear Meter Assembly for Repair page 37 2 Referto Gear Pump Maintenance Guide on page 49 for special notes regarding gear pump repair 3 Remove four pump block shoulder bolts 1102 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 FIG 23 AlS Thicker materials may pump heating prior to disas sembly Do not expose the pump to thermal shock Raise temperature at a maximum rate of 180 F 100 C per hour Do not exceed 400 F 204 C Gradually cool the pump to room temperature 5 Remove seal retainer fasteners 1614 and seal retainers 1611 6 Remove pump dowel pins 1610 using an arbor press Do not use a hammer to remove dowel pins as this will damage the pump 7 Remove the pump plate screws 1613 8 Separate the pump front plate 1601 gear case 1602 and back plate 1603 NOTE Notches on the pump plates can be used to separate the plates 9 To remove the drive shaft 1605 from the bottom plate 1603 press
80. ure system is performing properly 0260 Calibration 5526 Perform Startup procedure page 23 Verify all sys tem components are at desired pressures and tem peratures Adjust as desired Navigate to the Calibrate screen See Screen Navi gation Diagram on page 81 in the Appendix A User Interface Display section Press the Enable Calibration button Weigh one disposable container and tare the scale Place container below dispense tip Press the Start Low Speed Calibration Start L button tew seed Weigh the container Divide the weight of the dispensed material by the specific gravity to determine the volume Enter the volume into the Low Speed Calibration Actual l Actual Volume input box 0000 000 0260 10 11 12 13 14 17 Weigh second disposable container and tare the scale Place container below dispense nozzle Press the Start High Speed Calibration Start button a 2591 Weigh the container Divide the weight of the dispensed material by the specific gravity to determine the volume Enter the volume into the High Speed Calibration Actual Actual Volume input box E 0000 000 Press the Done button Done If desired press to navigate to the Main Screen 25 Operation Dispense from Maintenance Screen 1 Navigate to the Maintenance screen See Scree
81. ures while in maintenance mode Set Inlet Pressure The inlet pressure reading should be in the range of 300 psi 2 1 MPa 21 bar to 1500 psi 10 3 MPa 103 bar The recommended inlet pressure should be 500 psi 3 4 MPa 34 bar lower than the outlet pressure Follow steps in the supply system manual to set the inlet pressure 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 thou sands 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 recom mended on air motor supply air During dispense the normal pump regulator is active During a stalled condi tion the dynamic regulator is active Dispense Weight Verification 1 From maintenance screen select Shot mode 2 Enter a 10 second shot time 3 Enter the desired flow rate 24 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 ens

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