Setup - Operation PD44 Control Box 313877E EN Meter, mix and dispense system for precise two-component micro-dispensing of sealants and adhesives. Not for use in explosive atmospheres. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information, including maximum working pressure and approvals.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Identification . . . . . . . . . . . . . . . . . . . . 6 Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PD44 Dispense Valve . . . . . . . . . . . . . . . . . . . . . 8 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Manuals 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 308116 Severe-Duty, UHMWPE/PTFE or PTFE Packed Stainless Steel Pumps 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 Kit 313526 Check-Mate® Pump Packages 406
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
Warnings WARNING 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. • Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Component Identification Component Identification Control Boxes A B D C H J A TANK LEVEL CONTROLS G B TANK LEVEL CONTROLS F CUSTOMER I/O SIGNAL CONNECTION 2 1 5 4 3 7 6 2 1 5 4 3 7 6 2 1 5 4 3 7 6 PG-3 PG-4 PG-2 START E L 100V TO 250V AC 1 3 2 4 PG-8 MACHINE I/O 3 2 7 6 11 1 5 10 14 4 9 13 8 12 PG-1 SPOOL VALVE T S M N AIR CYLINDER 108 107 106 105 LOAD DISP EXT RET P R K Key: A B C D E F G H J Emergency Stop Control Power Switch Touch Panel Alarm Speake
Component Identification B A C CONTROL POWER D AUDIO ALARM START OPTIONS 4 1 3 2 MOTOR VALVE I/O F VERIFY INCOMING VOLTAGE WITH VOLTAGE SWITCH SETTING BEFORE CONNECTING POWER L U E J H Key: A B C D E Emergency Stop Control Power Switch Touch Panel Alarm Speaker Power Input F H J L U Start Options Connection A Tank Level Controls Connection B Tank Level Controls Connection Dispense Valve I/O Connection Motor Connection FIG.
Component Identification PD44 Dispense Valve See PD44 Operation manual 313876 for detailed dispense valve component identification and instructions. FIG.
Grounding Grounding This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. 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.
Setup Setup Micrometer and LRT PD44 Only 3. Connect Dispense Valve I/O, and Start Options logic cables. If level controls are installed, connect Level Controls logic cables. NOTICE Feed system and main logic control system must use separate air supplies. 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.
Setup Motor Driven PD44 Only 1. Connect Dispense Valve I/O, Start Options, and Motor logic cables. If level controls are installed, connect Level Controls logic cables. NOTICE Feed system and main logic control system must use separate air supplies. AUDIO ALARM START OPTIONS 4 1 3 2 VALVE I/O MOTOR VERIFY INCOMING VOLTAGE WITH VOLTAGE SWITCH SETTING BEFORE CONNECTING POWER 2. Adjust customer supplied air pressure regulator to 80 psi (0.6 MPa, 6 bar). 3.
Startup Startup NOTE: See HMI Operation starting on page 14 for detailed HMI instructions. 1. Press the Control Power On button. 2. On Micrometer 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.
Dispensing Operation Dispensing Operation NOTE: See HMI Operation on page 14 for detailed HMI instructions. The foot switch, the “Start” button, and the optional Customer Start Signal can be used to initiate shots. These are referred to as start devices. 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 Perform a Shot 1.
HMI Operation HMI Operation Screen Navigation Diagrams Micrometer PD44 Main Screen Status Purge Timer Level 1 Control Level 2 Control Posidot Control FIG. 4 LRT PD44 Main Screen Posidot Control Shot Size/Flow Rate Level 1 Control Level 2 Control Purge Timer Status Supervisor Calibration Calibration Help FIG.
HMI Operation Motor Driven PD44 Main Screen Metering Valve Control Shot Size/Flow Rate Level 1 Control Level 2 Control Purge Timer Status Supervisor Motor Status Motor Error Codes Supervisor Help FIG.
HMI Operation Main Screen NOTE: The Error Code button is shown on every screen on the Motor Driven PD44. Motor Driven PD44 Main Screen shown Screen Access Buttons Error Code (Motor Driven PD44 only) 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.
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. LRT PD44 Posidot Control screen shown Start button Continuous Mode When the Start button is pressed, the machine starts the cycle for the selected Pump Mode. The machine continually cycles the pumps when the START DEVICE is pressed.
HMI Operation Metering Valve Control Screen (Motor Driven 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. NOTE: The Error Code button is shown on every screen on the Motor Driven PD44. See the Main screen for definition. Start button Extend Mode When the Start button is pressed, the machine starts the cycle for the selected Pump Mode. The air cylinder and pumps immediately extend and remain in the extended position.
HMI Operation DV Valve Mode This mode actuates an optional dispense valve. OPEN In this mode, the dispense valve is held in the open position, 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.
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. NOTICE Erratic operation results if the shot size value entered is not greater than the absolute value of the Shot Size Offset setting. For example, if the Shot Size Offset setting is -1%, a shot size greater than 1% must be entered. See Supervisor screen, page 33.
HMI Operation Shot Size Screen (Motor Driven PD44 Only) NOTE: This section describes the Shot Size screen for the Motor Driven PD44 only. See page 20 for the LRT PD44 Shot Size screen. NOTICE Erratic operation results if the shot size value entered is not greater than the absolute value of the Shot Size Offset setting. For example, if the Shot Size Offset setting is -1%, a shot size greater than 1% must be entered. See Supervisor screen, page 34.
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 definition, page 16. NOTE: If ‘A Tank Status’ and ‘B Tank Status’ both display 'Levels Not Active' then the level control feature is not installed on this machine. Micrometer PD44 and LRT PD44 Level 2 Control screen shown A Tank Status, B Tank Status Start Fill A, Start Fill B button This displays information about each component tank filling process.
HMI Operation Level 2 Control Screen NOTE: A “1” indicates that the button is in the “ON” position. A “0” indicates that the button is in the “OFF” position. NOTE: The Error Code button is shown on every screen on the Motor Driven PD44. See the Main screen for definition, 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 button to exit from this screen.
HMI Operation Shutdown Timer button/indicator NOTE: If the level control option has not been purchased the Shutdown Timer button is disabled. This changes the delay before the Fill Timer Fault message 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. NOTE: For example, if 15 is entered, the Fill Timer setting is 1.
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 definition, page 16. NOTE: On the Micrometer PD44, the “Purge Timer screen” is named the “Timer/Counter Screen.” Motor Driven PD44 Purge Timer Screen Shown Cycle Counter On/Off button (Micrometer PD44 Only, Not Shown) Purge Timer On /Off The Cycle Counter switch is used to enable/disable the cycle counter. OFF: The Cycle Counter is disabled.
HMI Operation Dwell / Alarm Timer Enter Purge Time Button The Enter Purge Time button is shown as “=000.0” 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.
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 150%, Number of Strokes During Purge displays “2” and Amount Per Stroke % displays “75”.
HMI Operation Status Screen NOTE: A “1” indicates that the button is in the “ON” position. A “0” indicates that the button is in the “OFF” position. NOTE: The Error Code button is shown on every screen on the Motor Driven PD44. See the Main screen for definition, page 16. Micrometer PD44 and LRT PD44 Status Screen 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.
HMI Operation Dispense Complete This displays “1” if the metering rods are reloaded with material or at the end of the dispense cycle, and displays a “0” if the metering tube is 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 standard on Motor Driven PD44s. Contrast + button This button increases the contrast of the screen.
HMI Operation Motor Status Screen (Motor Driven 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. NOTE: The Error Code button is shown on every screen on the Motor Driven PD44. See the Main screen for definition, page 16. To navigate to the Motor Status screen, press the “Motor Status” button on the Status screen.
HMI Operation 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 program. This is used for troubleshooting.
HMI Operation Motor Error Codes Screen (Motor Driven PD44 Only) These screens give descriptions of the motor error codes.
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. Pump Reload Shot Size Offset Button Pump Reload sets a transducer point where the machine will reload. The point is relative to the rod stroke mechanical limits. Reload 3% Shot Size Offset -1% The Shot Size Offset button sets the transducer point where the metering rods will retract. The factory setting is -1.
HMI Operation Supervisor Screen (Motor Driven PD44 Only) NOTE: This section describes the Supervisor screen for the Motor Driven PD44 only. See page 34 for the LRT PD44 Shot Size screen. NOTE: A “1” indicates that the button is in the “ON” position. A “0” indicates that the button is in the “OFF” position. NOTE: To change the values on this screen, log-in as the supervisor. See Main Screen, page 16.
HMI Operation 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.
HMI Operation Calibration Screen (LRT PD44 Only) Calibrate Mode button Transducer Position in % When this button is selected machine calibration starts. This shows the transducer position in percent of stroke. Extend Pumps button To calibrate the pumps, perform the following steps. 1. From the Calibration screen, select Calibration Mode. 2. Press the Extend Pumps button. Pumps extend. This extends the air cylinder for the calibration sequence.
HMI Operation Calibration Screen Help This screen describes the calibration procedure.
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.
Optional Customer Inputs Optional Customer Inputs Micrometer PD44 and LRT PD44 Name Description Ready to Dispense Signal (Output) Cycle-Complete (Output) Customer Start (Input) In Shot Mode, changes state when pump is retracted and LS-EXT is tripped. In Shot Mode, changes state for one second after the retract switch is tripped. In any mode, operates in parallel to the footswitch. Provide a dry contact closure between black and white wires on the customer signal cable to actuate machine.
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 Perform Pressure Relief Procedure before performing any troubleshooting procedure.
Technical Data Technical Data Maximum Ambient Temperature. . . . . . . . . . . . . . . . . . . . Maximum Operating Temp . . . . . . . . . . . . . . . . . . . . . . . . Maximum Air Working Pressure . . . . . . . . . . . . . . . . . . . . Supplied Air Requirements. . . . . . . . . . . . . . . . . . . . . . . . Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110°F (43°C) 150°F (65°C) 100 psi (0.
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.
