Graco 313877E User's Manual
Contents
1. Start Options Connection A Tank Level Controls Connection B Tank Level Controls Connection Dispense Valve I O Connection Motor Connection 313877E Component Identification PD44 Dispense Valve See PD44 Operation manual 313876 for detailed dis pense valve component identification and instructions Fic 3 PD44 Micrometer Dispense Valve 313877E Grounding B This product must be grounded In the event of an elec trical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric cur rent Grounding plug units this product is equipped with a cord having a grounding wire with an appropriate grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances Hard wired units the grounding wire must be used All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Air and fluid hoses use only electrically conductive hoses Fluid supply container follow local code Solvent pails used when flushing follow local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a non conductive sur face such as paper or cardboard which interrupts grounding continuity 313877E Grounding Setup Setup Micrometer and L2. In any mode operates in parallel to the footswitch Provide a dry contact clo sure between black and white wires on the customer signal cable to actuate machine Motor Driven PD44 Name Description Customer Start Input When a momentary contact closure is applied to this input the start device is activated Customer Purge Start Input When a momentary contact closure is applied to this input the purge shot is activated Customer SS FR Bit 1 2 3 Input When these inputs are activated in the proper sequence the machine acti vates the Shot Size and Flow Rate Combination seen on the Shot Sizes screen See the machine logic drawings for more information Customer Signal Done Output This output activates for 2 seconds after the dispense cycle is complete Customer Signal Dis pense Ready Output This output is active when the machine is in the Shot Mode and the dispense valve is retracted and loaded with material This output deactivates when the dispense valve is dispensing or if the machine is not in the shot mode Customer Signal Time to Purge Output If the Manual Reload W Customer Signal button under the Supervisor screen is selected this output is active when it is time for the machine to take a purge shot NOTE The dispense valve will not perform a purge shot until the start device is activated Customer Signal Open Auxiliary Dispense Valve Output Th
3. 21 Level 1 Control Screen 005 22 Level 2 Control Screen 00055 23 Purge Timer Screen 0000 25 Status Screen sea erare ea ia nir aeaieie 28 Motor Status Screen Motor Driven PD44 only 30 Motor Error Codes Screen Motor Driven PD44 Only 32 Supervisor Screen LRT PD44 Only 00 000 eee 33 Supervisor Screen Motor Driven PD44 Only 34 Supervisor Help Screen Motor Driven PD44 Only 35 Calibration Screen LRT PD44 Only 00 000 eee 36 Pressure Relief Procedure 38 Shutdown serere ees 38 Optional Customer Inputs 39 Maintenance lees 40 Troubleshooting lees 40 Technical Data 41 Graco Standard Warranty 42 Graco Information 42 313877E Related Manuals PD44 Manuals Part Description 313876 PD44 Dispense Valve Operation Parts Feed System Manuals 306565 Air Driven Stainless Steel Agitators 307043 Monark Air Motor Packed Stainless Steel Pumps 308116 Severe Duty UHMWPE PTFE or PTFE 308167 Low Volume Air Regulators 308168 High Volume Air Regulators 308169 Air Filters Lubricators and Kits 309306 Air Operated Husky Diaphragm Pumps 312376 Stainless Steel Agitator Ki
4. Select the Fill Timer button shown as 00000 A numeric keypad appears 2 Enter in the Fill Timer time in tenths of a second 24 NOTE For example if 15 is entered the Fill Timer set ting is 1 5 seconds 3 Press the m button The new Fill Timer setting appears in the Fill Timer field NOTE The current Fill Timer time is shown by lt 00000 This counts up to the preset time 313877E HMI Operation Purge Timer Screen NOTE The Error Code button is shown on every screen on the Motor Driven PD44 See the Main screen for def inition page 16 NOTE On the Micrometer PD44 the Purge Timer screen is named the Timer Counter Screen Purge Timer Screen 00000000000 ERROR CODE 000 Purge Timer Dwell Timer umber o sec sec Strokes During Purge onon lt 000 0 f 00000 00000 lt 000 0 MEHEEEEB lt 00000 Size Motor Driven PD44 Purge Timer Screen Shown Cycle Counter On Off button Micrometer PD44 Purge Timer On Off Only Not Shown The Cycle Counter switch is used to enable disable the cycle counter Always set the dwell alarm timer to a value that will OFF The Cycle Counter is disabled give the user adequate warning that the machine is about to dispense a purge shot See Dwell Alarm ON If Shot Mode is selected when the Cycle Counter is Timer section on page 26 enabled the number of cycles entered are dispensed To change the Cycle Counter
5. Flow Rate Level 1 Control lt gt Level 2 Control Purge Timer Status Supervisor Calibration S Calibration Help FIG 5 313877E Motor Driven PD44 FIG 6 HMI Operation Metering Valve Control B Shot Size Flow Rate Level 1 Control lt gt Level 2 Control Purge Timer Status lt gt Motor Status Motor Error Codes Supervisor lt gt Supervisor Help 313877E HMI Operation Main Screen NOTE The Error Code button is shown on every screen on the Motor Driven PD44 Liquid Control G GRACO Metering Valve Shot Size Level Control Flow Rate Control Timer 00000000000 ERROR CODE 000 Motor Driven PD44 Main Screen shown Screen Access Buttons All buttons on the main screen except for the Password and Error Code buttons open a new specified screen For example pressing the Status button opens the Status screen The Password and Error Code buttons are only on the Motor Driven PD44 screens Password Motor Driven PD44 only The password button enables the user to changes values in certain screens To access the password press the Password Access button shown as 0000 When the keyboard appears enter password 5810 then press the Enter key 16 Error Code Motor Driven PD44 only NOTE The Error Code button is shown on every screen on the Motor Driven PD44 On all screens that it is shown the Error Code button resets the error seen in the
6. disconnect power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords e Ensure ground prongs are intact on power and extension cords e Do not expose to rain Store indoors j 313877E Warnings PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury e Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals e Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use e 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 Route hoses and cabl
7. purge time appears in the Purge Timer button NOTE The current Purge Timer time is shown in the bottom text box below the Purge Timer button Calculating the Purge Timer Setting If the shot size is larger than the mixer volume set the timer for one half the gel time of the material If the shot size is smaller use the following formula to determine the Purge Timer setting Gel Time X Shot Size Timer Setting 2 X Mixer Volume For example with mixer volume 13 3cc shot size 10cc gel time 10 minutes use the following equation 100 cc min 3 76 min 26 6 cc 10 min X 10 cc 2X 13 3 cc 26 Dwell Alarm Timer Always set the dwell alarm timer to a value that will give the user adequate warning that the machine is about to dispense a purge shot This changes the duration that the audible alarm is active prior to the purge shot being initiated To change the Dwell Timer perform the following steps 1 Select the Dwell Timer button A numeric keypad appears 2 Enter the desired Dwell Timer time in seconds Use the button to enter tenths of seconds 3 Press the 1l button The new Dwell Timer time appears in the Dwell Timer field NOTE The current Dwell Timer time is shown by 000 0 Purge Shot Size button LRT and Motor Driven PD44 only This button shows the Shot Size volume in percent of stroke This volume is dispensed during the ratio check To change
8. shots because it cannot do another shot without going over 100 stroke If the selected shot size is greater than 50 of the metering rods stroke the metering rods will retract after every shot Manual Reload W Customer Signal button In this mode the customer must send a signal to reload the valve before the lower switch is activated Otherwise the dispense valve will initiate a shot using the selected shot size and flow rate combination NOTE This can be linked with a PLC input for system integration See the logic drawings for more information Reload Speed mm sec button This allows the operator to change the retract or reload speed in millimeters per second Feed Setup This allows the operator to choose the low level setting for the feed system with tanks or a feed system with car tridge or syringes This inverts the switch function in the PLC logic 313877E Supervisor Help Screen Motor Driven PD44 Only This screen describes the various reload and shot options in the Supervisor screen To get to the Setup Help screen press the Help button on the Supervisor screen al haere a can be spo 00 ly valve only when the uu 6 15 ready to retract Back 313877E HMI Operation 35 HMI Operation Calibration Screen LRT PD44 Only Calibration Screen Calibration Mode Pumps Retract Pumps Calibration Help Calibrate Mode button When this button is selected machine calibration sta
9. the Purge Shot Size volume perform the following steps 1 Select Purge Shot Size button A numeric keypad appears 2 Enter the desired material shot size volume 3 Press the 4 button The Purge Timer screen appears The new shot size percentage appears in the Purge Shot Size field Number of Strokes During Purge button indicator LRT and Motor Driven PD44 only This displays the number of strokes used during the purge shot For example if the purge shot size is set at 15096 Num ber of Strokes During Purge displays 2 and Amount Per Stroke displays 75 313877E HMI Operation Amount Per Stroke LRT and Motor Driven PD44 only This displays the percent of the stroke used during a shot For example if the shot size is set at 15096 Number of Strokes During Purge displays 2 and Amount Per Stroke displays 75 313877E 27 HMI Operation Status Screen NOTE A 1 indicates that the button is in the ON posi tion A 0 indicates that the button is in the OFF posi tion NOTE The Error Code button is shown on every screen on the Motor Driven PD44 See the Main screen for def inition page 16 Status Screen 0000000000 00000 Reset Maintenance Totalizer 0000000000 Totalizer cle Totalizer of Times Maintenance Totalizer has been Reset 000000000000 ERROR CODE 0000 0000000000 Micrometer PD44 and LRT PD44 Status Scre
10. 877E HMI Operation Supervisor Screen LRT PD44 Only NOTE This section describes the Supervisor screen for the LRT PD44 only See page 34 for the Motor Driven PD44 Supervisor screen Supervisor Screen Enter Password Pump Reload Position 000 00 000 00 Shot Size Offset n Calibration 000 00 rent lt 000 00 Main Pump Reload Shot Size Offset Button Pump Reload sets a transducer point where the The Shot Size Offset button sets the transducer point machine will reload The point is relative to the rod where the metering rods will retract The factory setting stroke mechanical limits is 1 Reload 3 Shot Size Offset 1 To change the Shot Size Offset setting perform the fol lowing steps Most Most 1 Press Enter Password button Retracted Extended Position Position 2 Enter password To change the Pump Reload setting perform the follow We Press Ihe enternuien ing steps 4 Press the Shot Size Offset button 1 Press Enter Password button 5 Enterthe desired Shot Size Offset 2 Enter password 6 Press the Enter button 3 Press the Enter button 7 Press the Enter Data button 4 Press the Pump Reload Position button 5 Enter the desired reload position 6 Press the Enter button 7 Press the Enter Data button 313877E 33 HMI Operation Supervisor Screen Motor Driven PD44 Only NOTE This section describes the Supervisor screen for the Motor Driven PD44 only See page 34 fo
11. RT PD44 Only 1 Connect air supply to main air inlet on control box Air supply must include a shut off bleed valve that bleeds pressure past the shut off bleed valve and an air water separator filter 2 Connectair lines from control box to dispense valve Match the number and color codes on the fittings and connections See the following table and illus tration Connection Connection Color Description Red Extend Blue Retract Yellow Dispense Green Reload 10 3 Connect Dispense Valve I O and Start Options logic cables If level controls are installed connect Level Controls logic cables Feed system and main logic control system must use separate air supplies Adjust air pressure regulator to 80 psi 0 6 MPa 6 bar Perform Setup procedure for dispense valve and feed system components See Related Manuals on page 3 313877E Setup Motor Driven PD44 Only 9 a 1 Connect Dispense Valve I O Start Options and Motor logic cables If level controls are installed connect Level Controls logic cables Feed system and main logic control system must use separate air supplies 4 gj 3 2 Adjust customer supplied air pressure regulator to 80 psi 0 6 MPa 6 bar 3 Perform Setup procedure for dispense valve and feed system components See Related Manual
12. Setup Operation G g GRACO P D44 313877E Control Box EN Meter mix and dispense system for precise two component micro dispensing of sealants and adhesives Not for use in explosive atmospheres Read all warnings and instructions in this e Important Safety Instructions manual Save these instructions See page 3 for model information including maximum working pressure and approvals Cay a j VA HN MZ pum Micrometer PD44 and LRT PD44 Control Box shown PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals eee eens 3 Models 1 llli ilie xci 3 WarningS 2 223 mc e I eee eae k 4 Component Identification 6 Control Boxes e c cee eee 6 PD44 Dispense Valve 000 8 Grounding eee eee 9 Ii ER 10 Micrometer and LRT PD44 Only 10 Motor Driven PD44 Only 11 Start p 24 tie Ae ak ian se a 12 Dispensing Operation 13 HMI Operation leere 14 Screen Navigation Diagrams 14 Main Screen 0 00 cece eee 16 Posidot Control Screen Micrometer PD44 and LRT PD44 only 0000 00 ee 17 Metering Valve Control Screen Motor Driven PD44 only 18 Shot Size Screen LRT PD44 only 00 0000 20 Shot Size Screen Motor Driven PD44 Only
13. are the 7 preset Shot Size percent and Flow Rate mm sec values Shot size is in percent of stroke The preset values can be selected using Select Shot Size Flow Rate Combination To edit the preset Shot Size or Flow Rate values log in as the supervisor See Main Screen page 16 Below is the minimum and maximum field allowance for this design Shot Size Minimum 2 596 Maximum 500 096 Flow Rate Minimum 0 50 mm second Maximum 25 00 mm second 21 HMI Operation Level 1 Control Screen NOTE The Error Code button is shown on every screen on the Motor Driven PD44 See the Main screen for def inition page 16 NOTE If A Tank Status and B Tank Status both dis play Levels Not Active then the level control feature is not installed on this machine Level1 Control Screen A Tank Status Alarm MATERIAL PRESENT B Tank Status MATERIAL PRESENT Start Fill Start Fill Stop Fill Micrometer PD44 and LRT PD44 Level 2 Control screen shown A Tank Status B Tank Status This displays information about each component tank filling process The following are the possible messages Message Description Material The tank level is at or above the high level sen High SOr Material The tank level is below the low level sensor Low Filling The tank is currently refilling in the tank refilling process Material The tank level is between the high and the low Present level s
14. bes the calibration procedure Calibration Screen Hel Calibration is used to establish the Calibration Procedure Refer to Machine Manual for detailed information 313877E HMI Operation 37 Pressure Relief Procedure Pressure Relief Procedure 1 Turn main air supply shut off bleed valve to the off position This will bleed air from the system 2 Perform feed system pressure relief procedure See Related Manuals on page 3 3 Perform dispense valve pressure relief procedure See Related Manuals on page 3 Shutdown 1 On Micrometer and LRT PD44s go to the Posidot Control screen On Motor Driven PD44s go to the Metering Valve Control screen 2 Press the Retract button 3 Press the Extend button 4 Press the Emergency Stop button Ensure every thing is off 5 Twist Emergency Stop to reset 6 Perform Pressure Relief Procedure 7 Perform feed system shutdown procedure See Related Manuals on page 3 8 Perform dispense valve shutdown procedure See Related Manuals on page 3 38 313877E Optional Customer Inputs Optional Customer Inputs Micrometer PD44 and LRT PD44 Name Description Ready to Dispense Signal Output In Shot Mode changes state when pump is retracted and LS EXT is tripped Cycle Complete Output In Shot Mode changes state for one second after the retract switch is tripped Customer Start Input
15. changes the delay before the Fill Timer Fault mes sage is displayed in the corresponding A Tank Status or B Tank Status field on the Level 1 Control screen If the material level is below the low level sensor for more than the duration of the Shutdown Timer setting the machine shuts down To change the Shutdown Timer setting perform the fol lowing steps 1 Select the Shutdown Timer button shown as 00000 A numeric keypad appears 2 Enterthe desired Shutdown Timer setting in tenths of a second NOTE For example if 15 is entered the shutdown time is 1 5 seconds 3 Pressthe button The new Shutdown Timer set ting is shown NOTE The current time of the Shutdown Timer is shown by lt 00000 This counts up to the preset time Fill Timer NOTE If the automatic refilling option has not been pur chased the Fill Timer function is disabled This changes the delay before the Fill Timer Fault mes sage is displayed to the corresponding A Tank Status or B Tank Status field in the Level 1 Control screen If the material level reaches the tank high level sensor before the preset fill time elapses the Tank High Level message is displayed in the Tank Status field and the Fill Timer is reset If the preset fill time expires before mate rial reaches the high level sensor Fill Timer Fault appears in the Level1 Control Screen To change the Fill Timer setting perform the following steps 1
16. ctive equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e Keep work area free of debris including solvent rags and gasoline e Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem e Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD AN This equipment must be grounded Improper grounding setup or usage of the system can cause elec e DE P e tric shock Wy e Turn off and
17. en Shown Maintenance Totalizer This counter increments each time the machine cycles Press the Reset Maintenance Totalizer button to reset This counter is used for maintenance purposes Of Times Maintenance Totalizer has been Reset This counter increments each time the Reset Mainte nance Totalizer button is pressed Reset Maintenance Totalizer button This button resets the Maintenance Totalizer Cycle Totalizer This counter increments each time the machine cycles Number of Strokes Motor Driven PD44 Only not shown This displays the number of strokes needed to perform the currently selected shot size If the selected shot size is 15096 Number of Strokes displays a 2 28 Amount per Stroke in Motor Driven PD44 Only not shown This displays the amount of stroke used to perform the currently selected shot If the shot size is 150 Amount per Stroke in 96 displays 75 Dispense Ready This displays 1 if the metering rods are loaded with material and ready to dispense It displays a 0 if the metering tube is reloading or at the end of the dispense cycle Customer Signal Integration Kit 80 2450 CS 50 which uses this output can be ordered separately The Customer Signal Integration Kit is standard on Motor Driven PD44s 313877E Dispense Complete This displays 1 if the metering rods are reloaded with material or at the end of the dispense cycle and dis plays a 0 if the metering tube i
18. ensors Level Sen The machine senses material at the high level sor Fault sensor but not at the low level sensor Levels Not Level sensors are not installed for the tank Active Fill Fault The tank began refilling and the fluid level did not reach the high level sensor within the preset time entered into the Fill Timer button seen in the Level2 Control screen Tank has stopped refilling Silence Alarm button This button silences the audible alarm when pressed 22 Start Fill A Start Fill B button W e When this button is pressed the transfer pump fills the tank until the material level reaches the high level sen sor on that tank NOTE The Start Fill A Start Fill B and the Stop Fill but tons are inoperable if the high level automatic tank refill ing feature was not purchased with this machine Stop Fill button This button stops the automatic tank refilling process for both the A and B component material tanks 313877E Level 2 Control Screen NOTE A 1 indicates that the button is in the ON posi tion A O indicates that the button is in the OFF posi tion NOTE The Error Code button is shown on every screen on the Motor Driven PD44 See the Main screen for def inition page 16 NOTE In the Level 1 Control Screen if A Tank Status and B Tank Status both display Levels Not Active then the level control feature is not installed on this machine Press the Main but
19. error string shown as lt 0000000000 and the error code number shown as lt 000 See the Motor Error Codes screen for more information page 32 313877E HMI Operation Posidot Control Screen Micrometer PD44 and LRT PD44 only NOTE A 1 indicates that the button is in the ON position A 0 indicates that the button is in the OFF position POSIDOT CONTROL Select Shot Size LN Purge Timer Amount per Stroke in 96 Shot Size Man LRT PD44 Posidot Control screen shown Start button When the Start button is pressed the machine starts the cycle for the selected Pump Mode Pump Mode NOTE The metering rods must be retracted prior to changing any setting under Pump Mode See Retract Piston page 13 Retract Mode The air cylinder and pumps immediately retract and remain in the retracted position This is used for mainte nance purposes only Extend Mode The air cylinder and pumps immediately extend and remain in the extended position This is the position that must be selected when the pump is idle for a long period of time Shot Mode The machine fully cycles the number of times displayed in the Cycle Counter field when the start device is pressed and released The machine cycles continuously when the start device is pressed and held 313877E Continuous Mode The machine continually cycles the pumps when the START DEVICE is pressed Purge Timer On Of
20. es 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 PLASTIC PARTS CLEANING SOLVENT HAZARD Use only compatible water based solvents to clean plastic structural or pressure containing parts Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturers warnings 313877E Component Identification Component Identification Control Boxes C H E L T S M Key A Emergency Stop K Main Air Inlet B Control Power Switch L Dispense Valve I O Connection C Touch Panel M Spool Valve Load Connection D Alarm Speaker N Spool Valve Dispense Connection E Power Input P Air Cylinder Extend Connection F Start Options Connection R Air Cylinder Retract Connection G Custom I O S Air Pressure Regulator H ATankLevel Controls Connection T Air Pressure Gauge J B Tank Level Controls Connection Fic 1 Micrometer and LRT PD44 Control Box 8 313877E oss Key A Emergency Stop B Control Power Switch C Touch Panel D Alarm Speaker E Power Input Fic 2 Motor Driven PD44 Control Box crcrm Component Identification AUDIO ALARM
21. f See Purge Timer screen for definition page 25 Dwell Timer LRT and Motor Driven Only See Purge Timer screen for definition page 25 Cycle Counter On Off Micrometer PD44 Only Cycle Counter not shown See Purge Timer screen for definition page 25 Select Shot Size LRT PD44 Only See Shot Size screen for definition page 20 Number of Strokes LRT PD44 Only See Shot Size screen for definition page 20 Amount per Stroke LRT PD44 Only See Shot Size screen for definition page 20 17 HMI Operation Metering Valve Control Screen Motor Driven PD44 only NOTE A 1 indicates that the button is in the ON posi tion A 0 indicates that the button is in the OFF posi tion NOTE The Error Code button is shown on every screen on the Motor Driven PD44 See the Main screen for def inition Start button Metering Valve Control e 9 AS 4 When the Start button is pressed the machine starts the cycle for the selected Pump Mode Pump Mode NOTE The metering rods must be retracted prior to changing any setting under Pump Mode See Retract Piston page 13 Retract Mode The air cylinder and pumps immediately retract and remain in the retracted position This is used for mainte nance purposes only 18 DOCE TOI OE JU 1 ERROR cope 04000 Extend Mode 9 AS 4 The air cylinder and pumps immediately extend and remain in the extended
22. he 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 manual contains English MM 313877 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised July 2013
23. hot button to select Shot Mode Press and release the start device to perform one shot Dispense Continuously The valve dispenses continuously until the end of the stroke is reached 1 On Micrometer and LRT PD44s navigate to the Posidot Control screen On Motor Driven PD44s navigate to the Metering Valve Control screen Under Posidot Mode press the Retract button Press the Continuous button On Micrometer and LRT PD44s press and release the start device Under Posidot Mode press the Retract button to stop dispensing and retract the metering rods On Motor Driven PD44s press and hold the start device to dispense continuously Release the start device to stop dispensing and retract the metering rods 313877E Dispensing Operation Retract Piston 1 On Micrometer and LRT PD44s navigate to the Posidot Control screen On Motor Driven PD44s navigate to the Metering Valve Control screen 2 Under Posidot Mode press the Retract button Extend Piston 1 On Micrometer and LRT PD44s navigate to the Posidot Control screen On Motor Driven PD44s navigate to the Metering Valve Control screen 2 Under Posidot Mode press the Extend button 13 HMI Operation HMI Operation Screen Navigation Diagrams Micrometer PD44 Main Screen Status Purge Timer Level 1 Control Level 2 Control Posidot Control Fic 4 LRT PD44 Main Screen Posidot Control mE Shot Size
24. ion describes the Shot Size screen for the Motor Driven PD44 only See page 20 for the LRT PD44 Shot Size screen 00000000000 ERROR CODE 000 Select Shot Size Flow Rate Combination HMI Operation fs 000 00 0 00 000 00 0 00 000 00 0 00 000 00 0 00 000 00 0 00 000 00 0 00 000 00 0 00 Strokes 00000 Stroke 96 000 Erratic operation results if the shot size value entered is not greater than the absolute value of the Shot Size Off set setting For example if the Shot Size Offset setting is 196 a shot size greater than 196 must be entered See Supervisor screen page 34 Select Shot Size Flow Rate Combination Use this to change the selected shot by entering a num ber between 1 and 7 The selected shot size and flow rate is shown in the Shot Size percent section and Flow Rate mm sec section Number of Strokes This displays the number of shots of material when the machine is dispensing For example if the purge shot size is set at 150 Num ber of Strokes displays a 2 and the Amount Per Stroke 96 displays 75 00 Amount Per Stroke This displays the stroke per shot in percent of stroke For example if the purge shot size is set at 34096 Amount Per Stroke 96 displays 85 00 and Number of Strokes During Purge displays a 4 313877E Metering Valve Control Shot Size percent Flow Rate mm sec These
25. is is to be used only when there is a metering valve feeding an on off type dispense valve This signal is used to open and close the dispense valve Customer Signal Reload Input When in customer reload mode after each shot the dispense Done signal is turned on for 2 seconds During this time the customer can toggle the cus tomer reload signal to reload the system If the timer expires the machines assumes the customer does not want to reload and finishes the sequence then turns on the ready signal and does not allow another reload until after the next shot 313877E 39 Maintenance Maintenance NOTE If material is leaking see Troubleshooting on page 40 See Related Manuals on page 3 for dispense valve and feed system maintenance schedule and procedures Air Water Separator Filter Drain water once a shift or as necessary Troubleshooting 2 Perform Pressure Relief Procedure before perform ing any troubleshooting procedure All Machines Problem Cause Solution Dispense valve stalling and no mate rial being dispensed despite ade quate input pressure Blocked mixer Check mixer for cured material replace mixer as required Flow control valve closed Open Dispense valve not discharging nor mal or full volume Low material level in reservoirs Fill material reservoirs and prime the machine Air in material tanks Fi
26. ll reservoirs and prime machine Material leaks past spool valves Spool valve worn or damaged Replace the spool valve and sleeve Improper material mixing Mixer not clean or free Remove and replace the mixer Material leaks around mixer while dispensing Cured material in mixer Check mixer for cured material replace mixer Motor Driven PD44 Only Problem Cause Solution The horn beeps after each shot Dispense is longer than the dispense limit timer Check mixer for cured material The horn beeps continuously If the low level sensors are on the system may be low on material Check level screen for low level con dition if low level condition is present fill tank with material 40 313877E Technical Data Maximum Ambient Temperature 04 Maximum Operating Temp llle Maximum Air Working Pressure 04 Supplied Air Requirements 000000 Electrical Requirements 0000 0 000s Fuses Required 313877E Technical Data 110 F 43 C 150 F 65 C 100 psi 0 7 MPa 7 bar 1 to 3 cfm at 80 psi to 100 psi 120 240V 50 60 Hz Micrometer and LRT PD44 Control Box 5 x 20 mm 2A time delay Graco part 81 1053 2 11 Qty 1 Motor Driven PD44 Control Box 5 x 20 mm 10A fast type F 250 VAC Graco part V 21610P Qty 2 Micrometer and LRT PD44 Control Box 2 amps Motor Driven PD44 Con
27. old but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la 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 Toll Free 1 800 746 1334 or Fax 330 966 3006 All written and visual data contained in this document reflects the latest product information available at t
28. position This position must be selected when the pump is idle for a long period of time e Shot Mode The machine cycles the number of times displayed in the Cycle Counter field when the start device is pressed and released The machine cycles continuously when the start device is pressed and held Continuous Operator Control Mode In this mode the machine to dispense while the start device is pressed When the start device is released the metering rods retract to the home position 313877E DV Valve Mode B 42 This mode actuates an optional dispense valve OPEN In this mode the dispense valve is held in the open posi tion allowing material to pass through AUTO In this mode the dispsense valve opens automatically whenever the pump is cycled CLOSE In this mode the dispense valve is held closed 313877E HMI Operation 19 HMI Operation Shot Size Screen LRT PD44 only NOTE This section describes the Shot Size screen for the LRT PD44 only See page 21 for the Motor Driven PD44 Shot Size screen Fior Sire Tortor suns Eo Screen Strokes 000 00 2000 00 Shot Size 4 Shot Size 8 mount per Stroke in 000 00 000 00 000 00 ETE Erratic operation results if the shot size value entered is not greater than the absolute value of the Shot Size Off set setting For example if the Shot Size Offset setting is 1 a shot
29. r the LRT PD44 Shot Size screen NOTE A 1 indicates that the button is in the ON position A O indicates that the button is in the OFF position Supervisor Screen Reload Setup Feed Setup i Cartridges Syringes NOTE To change the values on this screen log in as the supervisor See Main Screen page 16 Error Code button This button resets the error in the error string Shown as lt 0000000000 and the error code number Shown as lt 000 See the Motor Error Code screen for more information page 32 Reload Setup Only one of the three Reload Setup Options can be enabled at any given time Reload After Each Shot button In this mode the metering rods retract after every shot This is the default system setup Reload After Multiple Shots button In this mode the metering rods retract only when the metering rods are about to reach the end of the stroke This feature is only available when in Operator Control mode 34 00000 11111 Reload After qe EachShot f V EMME Reload After Mp Mutiple Shots WERE Manual Reload iei do Wi Cust Signal MESE ZEE r0D44 1003 EH e EE 0 Reload Speed mm sec J 0000 ERROR CODE 9000 Valve Type For example if the selected shot size is 30 of the metering rods stroke three shots will be taken 90 of the stroke then the metering rods will retract The rods retract after three
30. rts Extend Pumps button Teach HD e This extends the air cylinder for the calibration sequence The most extended position is recorded when the Teach button is then pressed Retract Pumps button This retracts the air cylinder for the calibration sequence The most retracted position is recorded when the Teach button is then pressed Teach button This teaches or stores various data collected during calibration mode Done button This button exits Calibration mode Transducer Position This shows the transducer position in transducer units 36 Transducer Postion 000000 Transducer Postion in 96 000 00 Shot Size Off 000 00 Reload Position 000 00 Supervisor Transducer Position in 96 This shows the transducer position in percent of stroke To calibrate the pumps perform the following steps 1 From the Calibration screen select Calibration Mode 2 Press the Extend Pumps button Pumps extend 3 Press the Teach button 4 Press the Retract Pumps button Pumps retract 5 Press the Teach button 6 Press the Done button Shot Size Offset The Shot Size Offset allows the operator to view the shot size offset percentage The factory default is 196 See the Supervisor screen page 33 Reload Position Reload Position allows the operator to view the reload position The factory setting is 3 313877E Calibration Screen Help This screen descri
31. s loaded with material and ready to dispense Customer Signal Integration Kit 80 2450 CS 50 which uses this output can be ordered separately The Customer Signal Integration Kit is stan dard on Motor Driven PD44s Contrast button This button increases the contrast of the screen Contrast button This button decreases the contrast of the screen PX CSV Reload This displays the status of the reload spool proximity switch If this displays a 1 the switch is activated and if this displays a 0 the switch is deactivated See Compo nent Identification section in dispense valve manual See Related Manuals on page 3 PX OSV Dispense This displays the status of the dispense spool proximity switch If this displays a 1 the switch is activated If this displays a 0 the switch is deactivated See component identification section in dispense valve manual See Related Manuals on page 3 PLC Program Micrometer and LRT PD44 only This gives the currently installed PLC program version and revision level HMI Program Micrometer and LRT PD44 only This gives the currently installed HMI program version and revision level 313877E HMI Operation 29 HMI Operation Motor Status Screen Motor Driven PD44 only NOTE A 1 indicates that the button is in the ON posi tion A 0 indicates that the button is in the OFF posi tion NOTE The Error Code button is shown on every screen on
32. s on page 3 313877E 11 Startup Startup NOTE See HMI Operation starting on page 14 for detailed HMI instructions 1 Press the Control Power On button 2 OnMicrometer and LRT PD44s navigate to the Posidot Control screen On Motor Driven PD44s navigate to the Metering Valve Control screen 3 Under Posidot Mode press the Retract button NOTE On LRT and Motor Driven PD44s when there is an Emergency Stop condition or the system power is lost the shot selection resets to 0 The operator must then select a shot NOTE On Micrometer PD44s skip steps 4 7 4 Navigate to the Shot Size screen 5 Select a shot number 6 Navigate to the Pump Mode screen 7 Press the Shot button to select Shot Mode 8 Verify air pressure is set to 80 psi 5 6 bar 9 Perform feed system startup procedure s See Related Manuals on page 3 10 Perform dispense valve startup procedure See Related Manuals on page 3 12 313877E Dispensing Operation NOTE See HMI Operation on page 14 for detailed HMI instructions The foot switch the Start button and the optional Cus tomer Start Signal can be used to initiate shots These are referred to as start devices Perform a Shot 1 On Micrometer and LRT PD44s navigate to the Posidot Control screen On Motor Driven PD44s navigate to the Metering Valve Control screen Under Posidot Mode press the Retract button Press the S
33. size greater than 196 must be entered See Supervisor screen page 33 Shot Size 1 10 The Shot Size 1 10 buttons allow the operator to pro gram 10 different shot sizes Shot size is percent of stroke Once the shot sizes are programmed the shot number can be selected using the Select Shot Size but ton To change the Shot Size 1 10 setting perform the fol lowing steps 1 Select one of the Shot Size 1 10 buttons A numeric keypad appears 2 Enter the desired material shot size volume in per cent of stroke For example enter 150 to dispense material volume equivalent to 1 5 strokes 3 Press the ya button The keypad disappears The new shot size percentage appears in the Shot Size field 20 Select Shot Size button The Select Shot Size button allows the operator to choose one of the ten preset shot sizes seen in the Shot Size 1 10 section Number of Strokes This displays the number of strokes needed to perform the selected shot If the Shot Size selected is 150 then Number of Strokes displays a 2 because the machine performs two strokes at 75 of the full stroke Amount per Stroke in This displays the percent of stroke used to perform the selected shot If the Shot Size selected is 150 then the Amount per Stroke in displays 75 because the machine performs 2 strokes using 75 of the full stroke length 313877E Shot Size Screen Motor Driven PD44 Only NOTE This sect
34. t 313526 Check Mate Pump Packages 406088 Check Mate Ram Packages Models Max Air Working PD44 Control Box Pressure Model psi MPa bar Voltage CE Approved Linear Resistive 100 0 7 7 120 240V v Transducer LRT 50 60Hz 100 0 7 7 120 240V v Micrometer 50 60Hz 100 0 7 7 120 240V v Motor Driven 50 60Hz Ifa custom PD44 is ordered it will not be CE approved unless otherwise noted 313877E Related Manuals 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 3 TOXIC FLUID OR FUMES HAZARD Qu Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying or cleaning equipment e If this equipment is used with isocyanate material see additional information on isocyanates in Iso cyanate Conditions Section of this manual PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate prote
35. the Motor Driven PD44 See the Main screen for def inition page 16 Motor Status li 00000000000 ERROR CODE 000 ot Mode Step lt 0 EN lt OSV i ENS lt Switch Upper ower To navigate to the Motor Status screen press the Motor Status button on the Status screen CSV Switch Closed Spool Valve Switch This displays 1 when the spool valve is in the closed or reload position OSV Switch Open Spool Valve Switch This displays 1 when the spool valve is in the open or dispense position Home Switch Home Limit Switch This displays 1 when the metering valve rod home switch is activated Upper Switch Upper Over Limit Switch Extend This displays 1 when the metering valve rod upper over travel limit switch is activated The dispense valve is in the most retracted position 30 Step lt O Step lt 0 lt 000000000 ETE lt 000000 00 Motor Error Codes lt 000000 00 Main Lower Switch Lower Over Limit Switch Retract This displays 1 when the metering valve rod lower over travel limit switch is activated The dispense valve is in the most extended position Put the dispense valve in this position when it is idle for a long period of time Motor Position Steps This gives the motor step position in terms of transducer steps Shot Size This shows the Shot Size volume in percent of stroke Flow Rate mm sec This allows the operator to view
36. the current flow rate in millimeters per second 313877E Shot Mode Step This gives the current step in the shot mode program This is used for troubleshooting Reload Mode Step This gives the current step in the reload mode program This is used for troubleshooting Oper Mode Step This gives the current step in the operator mode pro gram This is used for troubleshooting 313877E HMI Operation 31 HMI Operation Motor Error Codes Screen Motor Driven PD44 Only These screens give descriptions of the motor error codes Error Codes Description No error Aborted by user Configuration error Call LCC For Technical Help Illegal command Call LCC For Technical Help Aborted due to no valid configuration Aborted due to no user power Aborted due to no defined reference point Aborted due to STOP input active Aborted due to UPPER LIMIT input active Aborted due to LOWER INPUT input active Aborted due to problem executing motion No profile block configured For specified profile IOo amp oh OO 7 p p q C Error Codes Description Illegal operation mode Operation mode not supported for this command Illegal number of steps in profile block Illegal direction change Illegal distance RPS trigger occurred before target speed reached Insufficient RPS active region width Speed out of range Insufficient distance to perform desired speed change urs at Power Up Back a 313
37. ton to exit from this screen Level2 Control Screen 000 0 000 0 Micrometer PD44 and LRT PD44 Level 1 Control screen shown Clear Fill Fault Silence Alarm Low Level Shutdown button When this button displays 1 and the material level of either the A component tank or the B component tank goes below the low level sensor the machine shuts down To recover refill the component tank with material to above the low level sensor When 0 is displayed the low level shutdown feature is disabled Alarm Engage button When this button displays 1 and the material level of either the A component tank or the B component tank goes below the low level sensor the audible alarm is activated Auto Fill Engage button When this button displays 1 the automatic filling func tion is activated 313877E HMI Operation Low Level Shutdown Alarm Engage Auto Fill Engage Clear Fill Fault button This button clears the Fill Timer Fault message dis played in the corresponding A Tank Status or B Tank Status field in the Level 1 Control screen Silence Alarm button Press this button to silence the low fluid level audible alarm The audible alarm will be activated again when the low level condition reoccurs 23 HMI Operation Shutdown Timer button indicator NOTE If the level control option has not been pur chased the Shutdown Timer button is disabled This
38. trol Box 10 amps Micrometer and LRT PD44 Control Box 13 in x 12 in x 15 in 330 mm x 305 mm x 381 mm Motor Driven PD44 Control Box 20 in x 8 in x 20 in 508 mm x 203 mm x 508 mm Micrometer and LRT PD44 Control Box 30 Ib 13 6 kg Motor Driven PD44 Control Box 60 Ib 27 2 kg 41 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 struc
39. tures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items s
40. value perform the follow The Purge Timer On Off switch is used to enable dis ing steps able the Purge Timer 1 Select the Cycle Counter button A numeric keypad OFF The Purge Timer is disabled appears ON The Purge Timer is enabled The machine initiates 2 Enter in the desired number of counts for the Cycle a purge shot when the purge timer expires provided the Counter fluid ball valves are open Shot Mode is selected and no errors exist 3 Press the Enter button The current number of cycles appears in the Cycle Counter field 313877E 25 HMI Operation Enter Purge Time Button The Enter Purge Time button is shown as 2000 0 below the Purge Timer On Off button The Enter Purge Time button allows the operator to set the required time between cycles When the Purge Timer switch is in the ON position and the Pump Mode switch is in the Shot or Operator Control position the purge timer unit counts up to the preset time When it reaches the preset time a purge shot is initiated The timer then automatically resets and continues with the sequence of cycling and resetting It continues until the Purge Timer is turned to the OFF position To change the Purge Timer setting perform the follow ing steps 1 Select Purge Timer button A numeric keypad appears GEJ 2 Enter the desired purge time in seconds Use the button to enter tenths of a second 3 Press the l button The Purge Timer screen appears The new
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