Graco 313876F Pd44 Metering Valves And Feed Systems Users Manual Systems, Operation Maintenance, English
2015-04-02
: Graco Graco-313876F-Pd44-Metering-Valves-And-Feed-Systems-Users-Manual-686577 graco-313876f-pd44-metering-valves-and-feed-systems-users-manual-686577 graco pdf
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Operation - Maintenance PD44 313876F ENG Metering Valves and Feed Systems Meter, mix, and dispense system for precise two-component micro-dispensing of sealants and adhesives. Not approved for use in European explosive atmosphere locations. 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. See page 6 for product configuration information. Linear Resistive Transducer PD44 Metering Valve shown, Feed Systems not shown Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product Configurator . . . . . . . . . . . . . . . . . . . . . . . 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 13 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 13 Moisture Sensitivity of Isocyanates . . . . . . . . . . . 13 Keep Components A and B Separate . . . . . . . . . 13 Foam Resins with 245 fa Blowing Agents . . . . . . 13 Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . 13 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Component Identification . . . . . . . . . . . . . . . . . . . 15 Typical System Configurations . . . . . . . . . . . . . 15 Typical Feed System Components . . . . . . . . . . 16 Micrometer PD44 Metering Valve . . . . . . . . . . . 18 LRT PD44 Metering Valve . . . . . . . . . . . . . . . . . 19 Motor Driven PD44 Metering Valve . . . . . . . . . . 20 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 21 Tank Level Sensor Wiring Schematic . . . . . . . . 22 Valve Mounting Diagram . . . . . . . . . . . . . . . . . . 22 Motor Mounting Diagram . . . . . . . . . . . . . . . . . . 23 Custom Drive Mounting Diagram . . . . . . . . . . . 23 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjusting the Shot Size . . . . . . . . . . . . . . . . . . . . 25 Micrometer PD44 Only . . . . . . . . . . . . . . . . . . . 25 LRT and Motor Driven PD44 . . . . . . . . . . . . . . . 25 Ratio Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Sequence of Operation . . . . . . . . . . . . . . . . . . . 27 Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 28 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wetted Section Disassembly . . . . . . . . . . . . . . 30 Wetted Section Reassembly . . . . . . . . . . . . . . . 32 Spool Valve Rebuild . . . . . . . . . . . . . . . . . . . . . 33 Wetted Section Rebuild . . . . . . . . . . . . . . . . . . . 34 Micrometer Drive Rebuild (Micrometer PD44 Only) . . . . . . . . . . . . . . . 37 Electrical Requirements . . . . . . . . . . . . . . . . . . . . 39 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2 Graco Ohio Standard Warranty . . . . . . . . . . . . . . 44 Graco Ohio Information . . . . . . . . . . . . . . . . . . . . . 44 313876F Related Manuals Related Manuals Manuals are available at www.graco.com Component manuals in U.S. English. PD44 Manuals Part Description 313877 PD44 Control Box Setup - Operation 3A0987 PD44 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 3A1452 20 oz Cartridge Models Max Air Working Pressure psi (MPa, bar) Metal Sleeves Plastic Sleeves CE Approved* Linear Resistive Transducer (LRT) 2000 (14, 138) 100 (0.7, 7) 1200 (8, 83) 400 (2.8, 28) ✔ Micrometer 2000 (14, 138) 100 (0.7, 7) 1200 (8, 83) 400 (2.8, 28) ✔ Motor Driven 2000 (14, 138) 100 (0.7, 7) 1200 (8, 83) 400 (2.8, 28) ✔ Metering Valve Model * Max Inlet Working Pressure psi (MPa, bar) Max Outlet Fluid Working Pressure psi (MPa, bar) If a custom PD44 is ordered, it will not be CE approved unless otherwise noted. 313876F 3 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. WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, 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. • Do not point gun at anyone or at any part of the body. • Do not put your hand over the dispense outlet. • Do not stop or deflect leaks with your hand, body, glove, or rag. • Follow Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning, checking, or servicing equipment. TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDS’s to know the specific hazards of the fluids you are using. • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. • Always wear impervious gloves when spraying or cleaning equipment. • If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate Conditions Section of this manual. PERSONAL PROTECTIVE EQUIPMENT 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, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to: • Protective eyewear • Clothing and respirator as recommended by the fluid and solvent manufacturer • Gloves • 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. • 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. • If 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. 4 313876F Warnings WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power cord before servicing equipment. • Use only grounded electrical outlets. • Use only 3-wire extension cords. • Ensure ground prongs are intact on power and extension cords. • Do not expose to rain. Store indoors. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. • 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. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’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 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. MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply. 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 manufacturer’s warnings. 313876F 5 Product Configurator Product Configurator This system can be ordered with many different options as shown in the configurator below. PD44 C - A - BCD -EFG- H - I - J - K - L - M - NO - P - Q - RS - T - U - V - W - X Seal Lubricant Bench Stand Vacuum Pump(s) Low Volume Feed Options Low Volume Feed Hose Low Volume Feed High Volume Feed Options High Volume Feed Hose High Volume Feed Power Cord Controls Mixer Outlet Nose Low Volume Spool High Volume Spool Low Volume Rod Material, Size High Volume Rod Material, Size Base Unit Configurator Series Level The following table applies to the PD44 configurations and indicates all of the options available for each letter shown above. Code A A B C Code B Part Base Unit 964000 Micrometer PD44 964001 Linear Resistive Transducer PD44 964002 Motor Driven PD44 Part High Volume Rod Material NOTE: See code CD for last two digits of part number A 9641__ Hardened Steel B 9642__ Stainless Steel, UHMW C 9643__ Tungsten Carbide, UHMW Code CD Part High Volume Rod Size NOTE: See code B for first four digits of part number 01 ____01 1.25 mm rod diameter 02 ____02 1.38 mm rod diameter 03 ____03 1.50 mm rod diameter 04 ____04 1.63 mm rod diameter 05 ____05 1.75 mm rod diameter 06 ____06 2.00 mm rod diameter 07 ____07 2.13 mm rod diameter 08 ____08 2.25 mm rod diameter 09 ____09 2.38 mm rod diameter 10 ____10 2.50 mm rod diameter 11 ____11 2.63 mm rod diameter 12 ____12 2.75 mm rod diameter 13 ____13 3.00 mm rod diameter 14 ____14 3.13 mm rod diameter 15 ____15 3.25 mm rod diameter 16 ____16 3.38 mm rod diameter 17 ____17 3.50 mm rod diameter 18 ____18 3.63 mm rod diameter 6 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 ____19 ____20 ____21 ____22 ____23 ____24 ____25 ____26 ____27 ____28 ____29 ____30 ____31 ____32 ____33 ____34 ____35 ____36 ____37 ____38 ____39 ____40 ____41 ____42 ____43 ____44 3.75 mm rod diameter 4.00 mm rod diameter 4.25 mm rod diameter 4.50 mm rod diameter 4.63 mm rod diameter 4.75 mm rod diameter 4.88 mm rod diameter 5.00 mm rod diameter 5.13 mm rod diameter 5.25 mm rod diameter 5.50 mm rod diameter 5.75 mm rod diameter 6.00 mm rod diameter 6.13 mm rod diameter 6.25 mm rod diameter 6.38 mm rod diameter 6.50 mm rod diameter 6.63 mm rod diameter 6.75 mm rod diameter 7.00 mm rod diameter 7.25 mm rod diameter 7.50 mm rod diameter 7.63 mm rod diameter 7.75 mm rod diameter 7.88 mm rod diameter 8.00 mm rod diameter 313876F Product Configurator Code E Part Low Volume Rod Material NOTE: See code FG for last two digits of part number A 9641__ Hardened Steel B 9642__ Stainless Steel, UHMW C 9643__ Tungsten Carbide, UHMW Code FG Part Low Volume Rod Size NOTE: See code E for first four digits of part number 01 ____01 1.25 mm rod diameter 02 ____02 1.38 mm rod diameter 03 ____03 1.50 mm rod diameter 04 ____04 1.63 mm rod diameter 05 ____05 1.75 mm rod diameter 06 ____06 2.00 mm rod diameter 07 ____07 2.13 mm rod diameter 08 ____08 2.25 mm rod diameter 09 ____09 2.38 mm rod diameter 10 ____10 2.50 mm rod diameter 11 ____11 2.63 mm rod diameter 12 ____12 2.75 mm rod diameter 13 ____13 3.00 mm rod diameter 14 ____14 3.13 mm rod diameter 15 ____15 3.25 mm rod diameter 16 ____16 3.38 mm rod diameter 17 ____17 3.50 mm rod diameter 18 ____18 3.63 mm rod diameter 19 ____19 3.75 mm rod diameter 20 ____20 4.00 mm rod diameter 21 ____21 4.25 mm rod diameter 22 ____22 4.50 mm rod diameter 23 ____23 4.63 mm rod diameter 24 ____24 4.75 mm rod diameter 25 ____25 4.88 mm rod diameter 26 ____26 5.00 mm rod diameter 27 ____27 5.13 mm rod diameter 28 ____28 5.25 mm rod diameter 29 ____29 5.50 mm rod diameter 30 ____30 5.75 mm rod diameter 31 ____31 6.00 mm rod diameter 32 ____32 6.13 mm rod diameter 33 ____33 6.25 mm rod diameter 34 ____34 6.38 mm rod diameter 35 ____35 6.50 mm rod diameter 36 ____36 6.63 mm rod diameter 37 ____37 6.75 mm rod diameter 38 ____38 7.00 mm rod diameter 39 ____39 7.25 mm rod diameter 40 ____40 7.50 mm rod diameter 41 ____41 7.63 mm rod diameter 42 ____42 7.75 mm rod diameter 43 ____43 7.88 mm rod diameter 44 ____44 8.00 mm rod diameter 313876F Code H Part High Volume Spool 1 2 3 4 964003 964004 964005 964006 High viscosity, HS High viscosity, Stainless Steel/UHMWPE High viscosity, TC/UHMWPE Low viscosity, Stainless Steel Code I Part Low Volume Spool 1 2 3 4 964011 964012 964013 964014 High viscosity, HS High viscosity, Stainless Steel/UHMWPE High viscosity, TC/UHMWPE Low viscosity, Stainless Steel Code J Part Outlet Nose 1 2 3 4 964020 964021 964022 964023 5 6 7 Code K 1 2 3 4 5 6 7 8 Luer lock, equal ports, no check valves Luer lock, equal ports, dual check valves Equal ports, 7/8-9, no check valves Large and small ports, 7/8-9, no check valves 964024 Large and small ports, 7/8-9, single check valve 964025 Dual small ports, 7/8-9, no check valves 964026 Dual small ports, 7/8-9 dual check valves Part Mixer 964027 1/8-24 Luer Lock inlet and outlet, 0.5 cc 964028 3/16-32 bell mouth inlet, luer lock outlet, 2.0 cc 964029 1/4-24 bell mouth inlet, luer lock outlet, 4.0 cc 964030 1/4-32 bell mouth inlet, luer lock outlet, 5.5 cc 964031 1/4-48 bell mouth inlet, luer lock outlet, 8.0 cc 964032 3/16-32 bell mouth inlet, tapered outlet, 1.5 cc 964033 1/4-24 bell mouth inlet, tapered outlet, 3.5 cc 964034 3/16-24 bell mouth inlet, tapered outlet, 1.0 cc 7 Product Configurator Code L 1 2 3 4 5 6 7 8 9 A B C 8 Part Controls 964035 Pneumatic, micrometer, wire harness only 964036 Pneumatic, micrometer, HMI controls, low level 964037 Pneumatic, micrometer, HMI controls, low level, I/O package 964038 Pneumatic, micrometer, HMI controls, low level, high level 964039 Pneumatic, micrometer, HMI controls, low level, high level, I/O package 964040 Pneumatic, linear resistive transducer, wire harness only 964041 Pneumatic, linear resistive transducer, HMI controls, low level 964042 Pneumatic, linear resistive transducer, HMI controls, low level, I/O package 964043 Pneumatic, linear resistive transducer, HMI controls, low level, high level 964044 Pneumatic, linear resistive transducer, HMI controls, low level, high level, I/O package 964045 Motor driven, I/O, wire harness only 964046 Stepper motor, HMI control, low level, high level, I/O package Code M Part 1 2 3 4 121055 121054 121056 121057 5 6 7 8 9 A N 121058 124864 124861 124863 124862 121060 -- Code NO Part High Volume Feed 01 02 03 04 964050 964051 964052 964053 05 06 964054 964055 07 964056 08 964057 09 964058 10 964059 11 964060 12 964061 13 964062 14 964063 15 964064 16 964065 17 964066 18 964067 20 oz cartridge feed with mounting post 1 gallon pail Ram and transfer pump 5 gallon pail cover with diaphragm pump 5 gallon pail cover diaphragm pump and agitator 5 gallon pail cover and 5:1 transfer pump 5 gallon pail cover, 1:1 pump with dip tube for moisture sensitive materials 5 gallon single post Ram with 11:1 pump, mild steel 5 gallon single post Ram with 11:1 pump, stainless steel 5 gallon tank, support and diaphragm pump, mild steel 5 gallon tank, support, diaphragm pump and agitator, mild steel 5 gallon tank, support, diaphragm pump, agitator and vacuum fill, mild steel 5 gallon tank, support, diaphragm pump, stainless steel 5 gallon tank, support, diaphragm pump, agitator, stainless steel 5 gallon tank, support, diaphragm pump, agitator, vacuum fill, stainless steel 5 gallon tank, support and 5:1 pump, mild steel 5 gallon tank, support, 5:1 pump, agitator, mild steel 5 gallon tank, support, 5:1 pump, agitator, vacuum fill, mild steel 5 gallon tank, support, 5:1 pump, stainless steel Power Cord 120 VAC, North American cord set 250 VAC, 1 phase, no plug 10 amp, 250 volt, continental Europe 10 amp, 250 volt, United Kingdom and Ireland 10 amp, 250 volt, Israel 10 amp, 250 volt, Australia 10 amp, 250 volt, Italy 10 amp, 250 volt, Switzerland 10 amp, 250 volt, Denmark 10 amp, 250 volt, India None 313876F Product Configurator 19 20 21 22 23 24 25 26 27 28 29 30 31 32 NN Code P 1 3 5 N 964068 5 gallon tank, support, 5:1 pump, agitator, stainless steel 964069 5 gallon tank, support, 5:1 pump, agitator, vacuum fill, stainless steel 964070 10 gallon tank, support, diaphragm pump, mild steel 964071 10 gallon tank, support, diaphragm pump, agitator, mild steel 964072 10 gallon tank, support, diaphragm pump, agitator, vacuum fill, mild steel 964073 10 gallon tank, support, diaphragm pump, stainless steel 964074 10 gallon tank, support, diaphragm pump, agitator, stainless steel 964075 10 gallon tank, support, diaphragm pump, agitator, vacuum fill, stainless steel 964076 10 gallon tank, support, 5:1 pump, mild steel 964077 10 gallon tank, support, 5:1 pump, agitator, mild steel 964078 10 gallon tank, support, 5:1 pump, agitator, vacuum fill, mild steel 964079 10 gallon tank, support, 5:1 pump, stainless steel 964080 10 gallon, tank, support, 4:1 pump, agitator, stainless steel 964081 10 gallon tank, support, 5:1 pump, agitator, vacuum fill, stainless steel -None Part 964082 1/2 in. x 8 ft PTFE and stainless steel hose, stainless steel fittings 964084 1/2 in. x 10 ft PTFE and stainless steel hose, stainless steel fittings 964086 1/2 in. x 15 ft PTFE and stainless steel hose, stainless steel fittings -None Code Q Part A B C N 964088 964089 964090 -- 313876F High Volume Feed Hose Code RS Part Low Volume Feed 01 02 03 04 964050 964051 964052 964053 05 06 964054 964055 07 964056 08 964057 09 964058 10 964059 11 964060 12 964061 13 964062 14 964063 15 964064 16 964065 17 964066 18 964067 20 oz cartridge feed with mounting post 1 gallon pail Ram and transfer pump 5 gallon pail cover with diaphragm pump 5 gallon pail cover diaphragm pump and agitator 5 gallon pail cover and 5:1 transfer pump 5 gallon pail cover, 1:1 pump with dip tube for moisture sensitive materials 5 gallon single post Ram with 11:1 pump, mild steel 5 gallon single post Ram with 11:1 pump, stainless steel 5 gallon tank, support and diaphragm pump, mild steel 5 gallon tank, support, diaphragm pump and agitator, mild steel 5 gallon tank, support, diaphragm pump, agitator and vacuum fill, mild steel 5 gallon tank, support, diaphragm pump, stainless steel 5 gallon tank, support, diaphragm pump, agitator, stainless steel 5 gallon tank, support, diaphragm pump, agitator, vacuum fill, stainless steel 5 gallon tank, support and 5:1 pump, mild steel 5 gallon tank, support, 5:1 pump, agitator, mild steel 5 gallon tank, support, 5:1 pump, agitator, vacuum fill, mild steel 5 gallon tank, support, 5:1 pump, stainless steel High Volume Feed Dessicant dryers for tank lids Nitrogen harness assembly for tank lids Low level sensor 11:1 Ram only None 9 Product Configurator 19 20 21 22 23 24 25 26 27 28 29 30 31 32 NN Code T 1 3 5 7 964068 5 gallon tank, support, 5:11 pump, agitator, stainless steel 964069 5 gallon tank, support, 5:1 pump, agitator, vacuum fill, stainless steel 964070 10 gallon tank, support, diaphragm pump, mild steel 964071 10 gallon tank, support, diaphragm pump, agitator, mild steel 964072 10 gallon tank, support, diaphragm pump, agitator, vacuum fill, mild steel 964073 10 gallon tank, support, diaphragm pump, stainless steel 964074 10 gallon tank, support, diaphragm pump, agitator, stainless steel 964075 10 gallon tank, support, diaphragm pump, agitator, vacuum fill, stainless steel 964076 10 gallon tank, support, 5:1 pump, mild steel 964077 10 gallon tank, support, 5:1 pump, agitator, mild steel 964078 10 gallon tank, support, 5:1 pump, agitator, vacuum fill, mild steel 964079 10 gallon tank, support, 5:1 pump, stainless steel 964080 10 gallon, tank, support, 4:1 pump, agitator, stainless steel 964081 10 gallon tank, support, 5:1 pump, agitator, vacuum fill, stainless steel -None Part Part A B C N 964088 964089 964090 -- 1 2 3 4 N 10 A N Code X A B Part Bench Stand 964095 Adjustable height bench stand -None Part Seal Lubricant 964096 Non-silicone seal lubricant 964097 Silicone seal lubricant Low Volume Feed Hose 964082 1/2 in. x 8 ft PTFE and stainless steel hose, stainless steel fittings 964084 1/2 in. x 10 ft PTFE and stainless steel hose, stainless steel fittings 964086 1/2 in. x 15 ft PTFE and stainless steel hose, stainless steel fittings -None Code U Code V Code W Part Low Volume Feed Dessicant dryers for tank lids Nitrogen harness assembly for tank lids Low level sensor 11:1 Ram only None Vacuum Pump(s) 964091 1-115V, 1 phase, 6.9 cfm, inlet and outlet filter, 1 in. hose to single tank 964092 1-115V, 1 phase, 6.9 cfm, inlet and outlet filter, 1 in. hose to two tanks 964093 1-230V, 1 phase, 6.9 cfm, inlet and outlet filter, 1 in. hose to single tank 964094 1-230V, 1 phase, 6.9 cfm, inlet and outlet filter, 1 in. hose to two tanks -None 313876F Accessories Accessories Mixer Kits with Shroud Part Description 964034 Mixer, Kit, 3/16 in. (4.8mm) x 24, 10 taper tip mixers with shroud 964032 Mixer, Kit, 3/16 in. (4.8mm) x 32, 10 taper tip mixers with shroud 964028 Mixer, Kit, 3/16 in. (4.8mm) x 32, 10 Luer Lock tip mixers with shroud/sleeve 964033 Mixer, Kit, 1/4 in. (6.5mm) x 24, 10 taper tip mixers with shroud 964029 Mixer, Kit, 1/4 in. (6.5mm) x 24, 10 Luer Lock tip mixers with shroud/sleeve 964030 Mixer, Kit, 1/4 in. (6.5mm) x 32, 10 Luer Lock tip mixers with shroud/sleeve 964031 Mixer, Kit, 1/4 in. (6.5mm) x 48, 10 Luer Lock tip mixers with shroud/sleeve Mixer Packs Part Description Part Description 964027 Mixer, 1/8 in. (3.2mm) x 24 Luer Lock inlet/tip, 10 Pack LC0089 Mixer, 1/4 in. (6.5mm) x 24 Luer Lock tip, 250 Pack 16D962 Mixer, 1/8 in. (3.2mm) x 24 Luer Lock inlet/tip, 50 Pack 16D968 Mixer, 1/4 in. (6.5mm) x 32 Luer Lock tip, 50 Pack 16D963 Mixer, 1/8 in. (3.2mm) x 24 Luer Lock inlet/tip, 250 Pack 16D969 Mixer, 1/4 in. (6.5mm) x 32 Luer Lock tip, 250 Pack 16D978 Mixer, 3/16 in. (4.8mm) x 24 taper tip, 50 Pack 16D970 Mixer, 1/4 in. (6.5mm) x 48 Luer Lock tip, 50 Pack 16D979 Mixer, 3/16 in. (4.8mm) x 24 taper tip, 250 Pack 16D973 Mixer, 1/4 in. (6.5mm) x 48 Luer Lock tip, 250 Pack LC0077 Mixer, 3/16 in. (4.8mm) x 32 taper tip, 50 Pack LC0084 Mixer, 3/16 in. (4.8mm) x 32 taper tip, 250 Pack LC0082 Mixer, 3/16 in. (4.8mm) x 32 Luer Lock tip, 50 Pack LC0090 Mixer, 3/16 in. (4.8mm) x 32 Luer Lock tip, 250 Pack LC0078 Mixer, 1/4 in. (6.5mm) x 24 taper tip mixer, 50 Pack LC0085 Mixer, 1/4 in. (6.5mm) x 24 taper tip mixer, 250 Pack LC0083 Mixer, 1/4 in. (6.5mm) x 24 Luer Lock tip, 50 Pack 313876F 11 Accessories O-Rings and Seals Part Description Part Description 24E247 Kit, O-ring, chemical resistant, PD44 16B286 Seal, Posipack, 4.50, ZAP 24E248 Kit, Seal, Spool, H.V., PD44 16B287 Seal, Posipack, 4.63, ZAP 24E249 Kit, Seal, Spool, L.V., PD44 16B288 Seal, Posipack, 4.75, ZAP 16B265 Seal, Posipack, 1.25, ZAP 16B289 Seal, Posipack, 4.88, ZAP 16B266 Seal, Posipack, 1.38, ZAP 16B290 Seal, Posipack, 5.00, ZAP 16B267 Seal, Posipack, 1.50, ZAP 16B291 Seal, Posipack, 5.13, ZAP 16B268 Seal, Posipack, 1.63, ZAP 16B292 Seal, Posipack, 5.25, ZAP 16B269 Seal, Posipack, 1.75, ZAP 16B293 Seal, Posipack, 5.50, ZAP 16B270 Seal, Posipack, 2.00, ZAP 16B294 Seal, Posipack, 5.75, ZAP 16B271 Seal, Posipack, 2.13, ZAP 16B295 Seal, Posipack, 6.00, ZAP 16B272 Seal, Posipack, 2.25, ZAP 16B296 Seal, Posipack, 6.13, ZAP 16B273 Seal, Posipack, 2.38, ZAP 16B297 Seal, Posipack, 6.25, ZAP 16B274 Seal, Posipack, 2.50, ZAP 16B298 Seal, Posipack, 6.38, ZAP 16B275 Seal, Posipack, 2.63, ZAP 16B299 Seal, Posipack, 6.50, ZAP 16B276 Seal, Posipack, 2.75, ZAP 16B300 Seal, Posipack, 6.63, ZAP 16B277 Seal, Posipack, 3.00, ZAP 16B301 Seal, Posipack, 6.75, ZAP 16B278 Seal, Posipack, 3.13, ZAP 16B302 Seal, Posipack, 7.00, ZAP 16B279 Seal, Posipack, 3.25, ZAP 16B303 Seal, Posipack, 7.25, ZAP 16B280 Seal, Posipack, 3.38, ZAP 16B304 Seal, Posipack, 7.50, ZAP 16B281 Seal, Posipack, 3.50, ZAP 16B305 Seal, Posipack, 7.63, ZAP 16B282 Seal, Posipack, 3.63, ZAP 16B306 Seal, Posipack, 7.75, ZAP 16B283 Seal, Posipack, 3.75, ZAP 16B307 Seal, Posipack, 7.88, ZAP 16B284 Seal, Posipack, 4.00, ZAP 16B450 Seal, Posipack, 8.00, ZAP 16B285 Seal, Posipack, 4.25, ZAP Needles Part Description Part Description E4000025-50 Needle, Luer Lock, Sampler Package (10 each 14 ga x 1/2 in., 16 ga x 1/2 in., 18 ga x 1/2 in., 20 ga x 1/2 in., 22 ga x 1/2 in.) E4000006-50 Needle, Luer Lock, 18 Gauge x 1 in., 50 Pack E4000011-50 Needle, Luer Lock, 22 Gauge x 1/2 in., 50 Pack E4000001-50 Needle, Luer Lock, 14 Gauge x 1/2 in., 50 Pack E4000014-50 Needle, Luer Lock, 14 Gauge x 1 in., 50 Pack E4000004-50 Needle, Luer Lock, 15 Gauge x 1/2 in., 50 Pack E4000024-50 Needle, Luer Lock, 23 Gauge x 1/2 in., 50 Pack E4000005-50 Needle, Luer Lock, 16 Gauge x 1 in., 50 Pack E4000088-50 Needle, Luer Lock, 16 Gauge x 1/2 in., 50 Pack 12 313876F Isocyanate Conditions Isocyanate Conditions To prevent exposing ISO to moisture: • Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. • Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates. • Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area. • • • To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area. Material Self-ignition Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS. Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. Keep Components A and B Separate NOTICE To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system. Changing Materials • • • • • 313876F Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container. Keep the ISO lube pump reservoir (if installed) filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere. Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system. Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use. Never use solvent on one side if it has been contaminated from the other side. Always lubricate threaded parts with ISO pump oil or grease when reassembling. When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. Always clean the fluid inlet strainers after flushing. Check with your material manufacturer for chemical compatibility. Most materials use ISO on the A side, but some use ISO on the B side. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side. 13 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. Metering valve: attach ground wire from grounding lug to true earth ground. See Component Identification starting on page 15. Fluid hoses: use only electrically conductive hoses. Feed system components: attach ground wire from grounding lug to true earth ground. See feed system manual for grounding points. See Related Manuals on page 3. 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 nonconductive surface, such as paper or cardboard, which interrupts grounding continuity. Overview This plural component meter, mix, and dispense device accurately meters liquid and semi-paste materials. The machine is ideal for a two-component application requiring very small and precisely mixed shots. The ratio of the pneumatic cylinder area to pump shaft area provides the adjustable pressure intensification needed to move the separate liquids through the mixer with a flow rate suitable for production requirements. The complete system is enclosed. Mixing of the two materials takes place only in the mixer at the final stage of metering valve operation. See Sequence of Operation on page 27. 14 313876F Component Identification Component Identification Typical System Configurations Base Unit 0 1 2 3 4 5 6 7 8 9 0 B Side Feed 1 A Side Feed Controls WARNING Do Not service without removing air pressure and waring saftey glasses. Liquid Control Corp. 8400 PORT JACKSON AVE. N.W. NORTH CANTON, OH 44720 USA SERIAL NUMBER MODEL NUMBER TO SH CK TO E PU LO LL AS PU LE RE B Side Feed A Side Feed Base Unit Controls CONTROL POWER Liquid Control Corp. 8400 PORT JACKSON AVE. N.W. NORTH CANTON, OH 44720 USA SERIAL NUMBER MODEL NUMBER FIG. 1 313876F 15 Component Identification Typical Feed System Components 5 Gallon Pail Cover with Diaphragm Pump 5 Gallon Pail Cover with Diaphragm Pump and Agitator 20 oz Cartridge Feed with Mounting Post 1 Gallon Ram and Pump F WARNING 0 psi 20 0 DO NOT SERVICE WITHOUT REMOVING AIR PRESSURE AND WEARING SAFETY GLASSES. 5 Gallon Pail Cover with 5:1 Transfer Pump 5 Gallon Pail Cover with Diaphragm Pump 5 Gallon Ram and 11:1 Transfer Pump FIG. 2 16 313876F Component Identification Typical Feed System Components (continued) R 5 Gallon Tank with Diaphragm Pump and Stand 5 Gallon Tank with 5:1 Pump and Stand 15 12 8 4 0 8 4 30 0 19 26 26 psi 30 19 22 psi 22 15 12 R 10 Gallon Tank with Diaphragm Pump, Agitator, Vacuum, and Stand 10 Gallon Tank with 5:1 Pump, Agitator, Vacuum, and Stand FIG. 3 313876F 17 Component Identification Micrometer PD44 Metering Valve T G S L H P M N E C F R R K J A D B D Side View Front View Key: A B C D E F G H J K A Material Inlet B Material Inlet Grounding Lug Spool Assemblies Metering Rods Oil Cup Retaining Block Extend Air Inlet Retract Air Inlet Dispense Air Inlet Reload Air Inlet L M N P R S T Extend Air Flow Adjustment Knob Retract Air Flow Adjustment Knob Retract Proximity Switch Extend Proximity Switch Spool Valve Proximity Switch Shot Size Locking Ring Shot Size Adjuster FIG. 4 18 313876F Component Identification LRT PD44 Metering Valve U L G H M E F C R R K J D B A D Front View Side View Key: A B C D E F G H J A Material Inlet B Material Inlet Grounding Lug Spool Assemblies Metering Rods Oil Cup Retaining Block Extend Air Inlet Retract Air Inlet Dispense Air Inlet K L M R U Reload Air Inlet Extend Air Flow Adjustment Knob Retract Air Flow Adjustment Knob Spool Valve Proximity Switch Transducer Connection FIG. 5 313876F 19 Component Identification Motor Driven PD44 Metering Valve W V X W E C P F N R R K J D B A D Side View Front View Key: A B C D E F J K L A Material Inlet B Material Inlet Grounding Lug Spool Assemblies Metering Rods Oil Cup Retaining Block Dispense Air Inlet Reload Air Inlet Extend Air Flow Adjustment Knob M N P R V W X Retract Air Flow Adjustment Knob Over-travel Proximity Switch Home Proximity Switch Spool Valve Proximity Switch Optional Motor (provided with configured controls) Over-travel Proximity Switch Main Air Inlet (on far side of valve as shown) FIG. 6 20 313876F Setup Setup NOTE: See Typical Installation diagram. 1. Perform Setup procedure for feed system components. See feed system manuals. See Related Manuals on page 3. 2. 4. On the Motor Driven PD44, if a non-Graco motor is used, install the motor onto the metering valve. See Motor Mounting Diagram, page 23. 2. Place an in-line air pressure regulator, air-water separator/filter, and shut-off/bleed valve between the air supply and the control solenoids. 3. Connect each 1/4 in. outside diameter supplied air line to the corresponding control solenoid. See Component Identification starting on page 15. 5. On the Motor Driven PD44, connect the required electrical power to the metering valve. See Motor Specifications, page 43. 6. Connect chemical lines from feed system to metering valve material inlets. See Component Identification starting on page 15. Typical Installation Air Supply User Supplied Air Shut-off and Bleed Valve Air-Water Separator/Filter Air Pressure Regulator A Side Material Tank (optional) A Side Pump B Side Pump A Side Fluid Shut-Off Valve Control Solenoids Metering Valve B Side Fluid Shut-Off Valve B Side Material Tank FIG. 7 313876F 21 Setup Tank Level Sensor Wiring Schematic TANK LEVEL 2 5 1 4 7 3 6 PIN NUMBER PIN USAGE USAGE 1 2 3 4 5 6 7 BROWN BLACK BLUE BROWN BLACK BLUE BLUE HIGH HIGH HIGH LOW LOW LOW LOW JUMPER PIN 6 AND 7 24 VDC+ BRN BLK BLU SIGNAL COM TYPICAL LEVEL SENSOR WIRING Valve Mounting Diagram As desired, use the following diagram to mount the metering valve. Front of Metering Valve 1.75 0.563 4X 10-24 X 0.5 DP 0.38 0.862 0.75 C L 4X Ø 0.188 DOWEL PINS 1.06 1.50 0.190 1.63 3.25 3.75 Bottom View (Spool Assembly Not Shown) FIG. 8 22 313876F Setup Motor Mounting Diagram If using a non-Graco motor with the Motor Driven PD44, use the following diagram to install the non-Graco motor onto the Motor Driven PD44 metering valve. See Motor Specifications, page 43. 2.22 2.039 0.182 0.182 Ø 0.251 STANDARD 2.22 2.039 4X 10-32 Top View of Drive Assembly FIG. 9 Custom Drive Mounting Diagram If using a non-Graco lead screw or housing, use the following diagram to ensure that the guide rods will align properly with the custom housing. 2X #30 (0.129Ø) FLAT BTTM DRILL X .25 DP 1.56 1.75 1.31 .44 .19 1.75 Bottom View of Lead Screw Housing FIG. 10 313876F 23 Startup Startup 1. Lubricate the metering rod ports in the oil cup retaining block and fill the spool valve ports with compatible lubricant. Consult with your material supplier to select an acceptable lubricant. Regularly verify that lubricant is present. NOTICE Testing has shown that failure to lubricate the valve will significantly reduce seal life. Metering Rod Ports 5. Dispense several full stroke shots until material is air-free and has good shut-off at the nose. NOTE: Very viscous, compressible materials may continue to droll after system is primed. Reduce flow rate as required to produce air-free dispense. NOTE: Very thin materials may require tilting the valve greater than 45 degrees and dispensing shots until material is air-free. Remove oil from cups before proceeding. Spool Valve Ports FIG. 11: Top View of Metering Valve with Top Section Removed 2. Perform Ratio Check, page 26. 3. Install mixer and shroud. 4. Pressurize the A and B material feed systems connected to the metering valve to prime the system. See page 3 for maximum inlet feed pressures. 24 313876F Adjusting the Shot Size Adjusting the Shot Size Micrometer PD44 Only 1. Rotate the shot size locking ring counterclockwise to loosen. 2. Rotate the shot size adjuster to adjust shot size. 6. If LED on the extend proximity switch is not illuminated, slide the proximity switch until the LED on the proximity switch is illuminated. Extend Proximity Switch Retract Proximity Switch NOTE: The retract proximity switch (PX-RET) is factory preset and does not need to be adjusted. If the lower proximity switch is changed from the factory setting, see the assembly drawings for more information on readjustment. This switch is marked with a RET tag on the wire. LRT and Motor Driven PD44 On LRT and Motor Driven PD44s, shot size is controlled by the PD44 Control Box. See the PD44 Control Box manual. See Related Manuals on page 3. 3. Rotate the shot size locking ring clockwise to tighten. 4. Dispense into waste container to test shot size. 5. Repeat until desired shot size is achieved. 313876F 25 Ratio Check Ratio Check Perform ratio check procedure at startup and after rebuild. 8. Subtract weight of empty cups from weight of filled cups to get material weights. 1. Weigh six small cups and label as indicated. Record weights. 9. Complete ratio calculations. 2. Remove mixer. 3. Install the ratio check nozzle. 4. Dispense into a waste container to prime the ratio check nozzle. 5. Place cups as indicated under ratio check nozzle and cycle machine once. 6. Repeat until all three sets of cups have been used. 7. Re-weigh all six cups and record weights. 26 313876F Operation Operation The operation of the PD44 metering valve is controlled by an external source. If a PD44 Control Box was purchased, see the PD44 Control Box manual for operation instructions. See Related Manuals on page 3. Step 3: Dispense Sequence of Operation Step 1: Reload • • • • • • • • Spools shift to the right Material feed inlets are opened Materials are transferred into the metering chambers by a pressurized feed system Outlet ports are blocked Metering rods are retracted to a precise position determining the volume of each material Metering rods extend A and B materials are simultaneously dispensed from the metering chamber into the disposable mixer A and B materials are dispensed at the predetermined volume ratio. Upon completion of the dispense stroke, the metering rod and spool assemblies shift back to the reload position. Step 2: Shift • • • • The balanced spool assemblies shift to the dispense position Material path to the mixer inlet is opened Material feed inlet ports are blocked Metering rods remain in the retracted position 313876F 27 Pressure Relief Procedure Pressure Relief Procedure Maintenance Perform the following procedures once a shift. 1. Retract the metering rods. See the PD44 Control Box manual. See Related Manuals on page 3. NOTE: If material is leaking, see Troubleshooting on page 29. 2. Close both the A side and B side fluid shut-off valves. Material Reservoirs 3. Remove static mixer. Check material levels and refill as necessary. Ensure that the material reservoirs are properly vented. 4. Dispense 5 shots. Shots should be at least 75% of the full stroke. Air Dryer 5. Extend the metering rods into the tubes. If Graco controls are provided with the system, see the PD44 Controls manual. See Related Manuals on page 3. 6. Close the incoming air shut-off/bleed valve that supplies air to the metering valve. 7. Close the incoming air shut-off/bleed valve that supplies the A feed system. Repeat for the B side feed system. Refer to feed system manual for pressure relief procedure. See Related Manuals on page 3. Shutdown Check the condition of the desiccant air dryer. Replace as necessary. Metering Rod Ports Lubricate with compatible lubricant such as mesamoll or silicone oil. See FIG. 11 on page 24. Spool Valve Ports Fill with compatible lubricant such as mesamoll or silicone oil. See FIG. 11 on page 24. Ratio Check See Ratio Check on page 26. 1. Perform Pressure Relief Procedure. 2. Inspect the metering rods for material buildup. Clean as necessary. 3. Lubricate the metering rods with compatible lubricant such as mesamoll or silicone oil. 4. Install storage cap on outlet nose. 28 313876F Troubleshooting Troubleshooting Perform Pressure Relief Procedure before performing any troubleshooting procedure. Problem Cause Solution Metering valve stalling and no material being dispensed despite adequate input pressure Blocked mixer Check mixer for cured material, replace mixer as required Flow control valve closed Open Metering valve not discharging normal or full volume Low material level in reservoirs Fill material reservoirs and prime the machine Air in material tanks Fill 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 Schematics For standard machines, the schematics will be included in the PD44 Parts manual. See Related Manuals on page 3. For custom machines, the schematics will be included in the assembly drawings manual. 313876F 29 Rebuild Rebuild Wetted Section Disassembly 6. Loosen set screws on top of the connecting block. 7. Slide the metering rod retaining plate until the larger hole position is in-line with the metering rod. See FIG. 12 in the following step. 1. Perform Pressure Relief Procedure, page 28. 8. Once the metering rod plate is in position, manually move connecting block up. Rods will remain in position and connecting block is separated from rods. 2. On Motor Driven PD44s, remove electrical power. 3. Mark and disconnect all material feed lines, pneumatic lines, and proximity switch wiring. Remove the metering valve from mounts. NOTE: On Micrometer and Motor Driven PD44s, the rear tie plate is the tie plate with the proximity switches. NOTE: On LRT PD44s, the rear tie plate is the tie plate on the same side of the metering valve as the main air inlets. 4. Remove the four cap screws to remove the rear tie plate. Connecting Block Metering Rod Retaining Plate Metering Rod FIG. 12 9. Once the metering rods are disconnected from the retaining plate, remove the four cap screws from the front tie plate. Cap Screws 5. Manually move the connecting block down so that rods are in the extended position. Cap Screws 10. Separate the drive cylinder and the valve guides from the oil cup retaining block. 30 313876F Rebuild 11. Remove the four cap screws located at the top of the oil cup retaining block. Oil Cup Retaining Block 14. Remove the two metering rods and tubes. Always keep rods and tubes together as they are a matched set. Tube 15. Remove the protruding cap screws on the each spool block. Cap Screws 12. Remove the metering rods and oil cup retaining block. Oil Cup Retaining Block Spool Block Cap Screws 16. Remove the two pneumatic spools. Metering Rod 13. Remove the eight cap screws attaching the material inlet blocks. Remove the material inlet blocks. Material Inlet Blocks 313876F 31 Rebuild Wetted Section Reassembly 4. Install drive assembly to the guides. 1. Install the pneumatic spool rod drive. Torque fasteners to 67-70 in-lb (7.5-7.9 N•m). Micrometer PD44 shown 5. Attach the front plate to the serial number side of the metering body. 6. On Micrometer and LRT PD44s, ensure the air inlet ports are pointed towards the front plate. 7. Install the cap head screws to the back plate. 2. Repeat for other side. Cap Screws 3. Install guide rods. Refer to Wetted Section Rebuild on page 34 for details on spool valve and metering rod assembly. Guide Rods 8. Slide connecting block down until rod heads are inserted into retaining plate keyway. 9. Slide the metering rod retaining plate to the locked position. Retaining Plate 10. Tighten set screw located on top of connecting block until it contacts the top of the metering rod head. Evenly torque the A and B set screws to 4-8 in-lb (0.45-0.9 N•m). 32 313876F Rebuild 11. Manually move connecting block up and down to insure rods are properly installed. Spool Valve Rebuild 12. Install the back plate and cap screws. Back Plate 1. Perform Wetted Section Disassembly, page 30. 2. Remove the two cap screws. Cap Screws Cap Screws 13. Install material inlet blocks with new o-rings. Material Inlet Block O-Ring 3. Disassemble the spool cylinder. 14. Install material nose assembly with new o-rings. 4. Remove the piston from the cylinder. O-Rings Nose 15. Attach material line, pneumatic line, and electrical harness. 5. Install new u-cup seal on piston. 16. Perform Startup procedure, page 24. 313876F 33 Rebuild 6. Insert new o-ring into spool air cylinder end cap. 2. Remove spool rods and sleeves from the metering block. 7. Install proximity switch. 8. Apply Krytox or compatible lubricant to cylinder. 9. Insert piston into cylinder with the u-cup lip pointed in the direction of the tapered end of the cylinder. The “U” points toward the air inlet. Air Inlet O-ring NOTE: The spool sleeve can be removed by sliding the sleeve in the direction of the identification marking. 3. Remove the pneumatic drive spool bearing, seals, and seal retainer for both spools. 10. Careful not to cut the o-ring, install pneumatic spool blocks. 11. Install the two cap screws. 4. Inspect the metering rod and sleeve assemblies and the spool rod and sleeve assemblies for excessive wear. If there are any scratches on the rod that can be felt by a fingernail, replace the rod and sleeve assembly. Cap Screws 5. Clean all wetted components thoroughly with compatible solvent. 12. Repeat for opposite side pneumatic spool rod drive. Wetted Section Rebuild 1. Perform Wetted Section Disassembly, page 30. 34 313876F Rebuild 6. For each pneumatic drive spool block, install new zap seals and o-rings onto o-ring retainer. NOTE: Correct orientation of seals shown. Low Viscosity Spool Sleeve Seals Low Viscosity Spool High Viscosity Spool Sleeve Cutout View High Viscosity Spool 11. Carefully install the spool sleeves into the metering block. Make sure the notched edge will align with the pin in the metering block and not cut the spool sleeve o-rings. Metering Block 7. Lubricate o-rings and bearing surfaces with Krytox or compatible lubricant. 8. Re-install the rod bearings, zap seals, and o-rings retainers into each spool block. Spool Sleeve NOTE: Typically, the spring in the zap seal and the o-rings in the retainers point toward the metering block which is in the direction of the material. 9. On each spool sleeve, install new zap seal (on low viscosity spool), and o-rings on the outside of the sleeves. 10. Lubricate o-rings and bearing surfaces with Krytox or compatible lubricant. 313876F Spool Sleeve Notch 35 Rebuild 12. Apply Krytox to spool rod then carefully install the spool rod into the spool sleeve (inside the metering block). Make sure not to cut the spool sleeve zap seals (on low viscosity spools). 17. Install the wetcup sleeve onto the metering sleeve. Wetcup Sleeve 18. Install the oil cup retaining block. Torque to 77 in-lb (8.7 N•m). 13. Torque bolts 67-70 in-lb (7.6-7.9 N•m) Oil Cup Retaining Block 14. Install new zap seal in the metering tube sleeve with the spring facing down or toward the material pressure side of the sleeve. 19. Apply Krytox grease to chamfer of metering rod. NOTE: Seals are individually packaged with part number and size. Verify rod nominal size matches seal prior to installation. 20. Carefully insert metering rod through bearing, seal, and metering tube. Make sure not to cut the metering sleeve zap seals. 21. Move connecting block to extended position. 22. Move slide plate to capture the metering rods. Metering Sleeve PTFE Seal 15. Install the metering sleeve PTFE seal in the metering block. Replace the metering sleeve PTFE seal with a new one every rebuild. 23. Install the set screw until it contacts the top of the metering rod. Torque set screw to 4-8 in-lb (0.45-0.90 N•m). Set Screw 16. Install metering tube sleeve into the metering block. Metering Block "A" Side Front Metering Tube Sleeve 36 313876F Rebuild Micrometer Drive Rebuild 5. Slide the pneumatic drive piston off the drive rod. (Micrometer PD44 Only) 1. Perform Wetted Section Disassembly, page 30. 2. Remove the four cap screws located at the top of the pneumatic drive assembly. Cap Screws 6. Slide the air cylinder mounting block off the drive rod. 3. Remove the drive top cap. Drive Top Cap 7. Install new seals on the drive piston. Make sure the lip of the seal points toward the pressure side of the drive. See the following illustration and the assembly drawings for more information. 4. Slide the drive rod into the open slot. 8. Remove retaining ring, washer, and posipak seal from the air cylinder mounting block. Retaining Ring Washer Posipak Seal 313876F 37 Rebuild 9. Install new posipak seal with the o-ring pointed towards the drive piston, then install washer and retaining ring. 13. Slide the drive rod into the closed slot in the piston. 14. Install the cylinder o-ring then, careful not to cut the piston seal, install the drive rod into the block. Retaining Ring Washer Posipak Seal 10. Apply Krytox or compatible lubricant to drive rod. 11. Careful not to cut the posipak seal, install drive rod into the block. 15. Install the upper cylinder o-ring. 16. Install top cap block to cylinder. 12. Install the drive rod into the piston. 17. Install drive housing bolts to the cylinder mounting block. 38 313876F 313876F BRN (24VDC+) BLK (SIG) BLU (DC COM) GND LABEL PX-OSV BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-EXT BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-RET BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-CSV RED EXTEND BLUE RETRACT YELLOW DISPENSE GREEN RELOAD 2 2 25 30 2 DETAIL 1 2 GREEN (39") SOL-CSV PX-CSV (39.5") PX-RET (41.5") PX-EXT (42") SEE DETAIL 1 PX-EXT METERING RODS AT HOME OR RELOAD POSITION (ADJUSTABLE). PX-RET METERING RODS COMPLETED DISPENSE STROKE (FIXED MOUNT). PX-CSV SPOOL VALVE IN THE RELOAD POSITION ALWAYS ON WHEN VALVE IS NOT DISPENSING. PX-OSV SPOOL VALVE IN THE DISPENSE POSITION ON ONLY DURING DISPENSE STROKE. SOL-EXT AIR SIGNAL TO DRIVE METERING RODS DOWN (DISPENSE) RED TUBE. SOL-RET AIR SIGNAL TO RETRACT METERING RODS (RELOAD) BLUE TUBE. SOL-CSV AIR SIGNAL TO CLOSE SPOOL VALVE (RELOAD POSITION) GREEN TUBE. SOL-OSV AIR SIGNAL TO OPEN SPOOL VALVE (DISPENSE READY POSITION) YELLOW TUBE. I/O DEFINITION: A A FRONT YELLOW (44") SOL-OSV PX-OSV (42.5") PX-RET USE SENSOR HARDWARE 1-7/16 BLUE (45") SOL-RET VIEW A-A WIRE LABEL TYP SERIAL LEGEND METERING RODS RED (48") SOL-EXT 3-7/8 PX-EXT Electrical requirements for pneumatically driven and stepper driven control boxes can be found in the PD44 Control Box manual. See Related Manuals, page 3. 6 SEQUENCE OF OPERATION: 1. SPOOLS IN RELOAD POSITION (SOL-CSV 'ON', PX-CSV 'ON') 2. METERING RODS IN HOME/RELOAD POSITION (SOL-RET 'ON', PX-EXT 'ON') 3. START SIGNAL INITIATED 4. SPOOL SHIFT DISPENSE (SOL-CSV 'OFF', SOL-OSV 'ON', PX-OSV 'ON', PX-CSV 'OFF') 5. METERING RODS DISPENSE (SOL-RET 'OFF', SOL-EXT 'ON') 6. METERING ROD REACH PX-RET SWITCH. 7. SPOOLS SHIFT RELOAD POSITION (SOL-OSV 'OFF', SOL-CSV 'ON', PX-OSV 'OFF', PX-CSV 'ON') 8. METERING RODS RETRACT (SOL-EXT 'OFF', SOL-RET 'ON' PX-OSV 'OFF', PX-CSV 'ON', PX-EXT 'ON', PX-RET 'OFF') Electrical Requirements Electrical Requirements PD44 metering valve only: Wiring harness sensors are 24 VDC normally open PNP. See FIG. 13, FIG. 14, or FIG. 15 as appropriate. FIG. 13: Micrometer PD44 Metering Valve Electrical Requirements 39 40 BRN (24VDC+) BLK (SIG) BLU (DC COM) GND LABEL PX-HOME BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-OSV BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-CSV BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-DOWN BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-UP GREEN RELOAD YELLOW DISPENSE 6" 2" 2" 1 5/16 PX-DOWN (45") USE SENSOR HARDWARE 3 15/16 PX-UP (47") USE SENSOR HARDWARE 30" 25" VIEW A-A 3 7/8 2" PX-HOME (47") USE SENSOR HARDWARE TYP 2" GREEN (39") PX-CSV (39.5") GROUND STUD A A WIRE LABEL TYP YELLOW (44") PX-OSV (42.5") FRONT NOTES: 1) SENSORS ARE PNP NORMALLY OPEN 2) FOR PX-UP AND PX-DOWN, USE SCREW PROVIDED WITH SENSORS 3) PX-UP AND DOWN TO BE USED FOR OVER TRAVELS Electrical Requirements FIG. 14: Motor Driven PD44 Metering Valve Electrical Requirements 313876F 313876F BRN (24VDC+) BLK (SIG) BLU (DC COM) GND LABEL PX-OSV BRN (24VDC+) BLK (SIG) BLU (DC COM) LABEL PX-CSV RED (OUTPUT) BLK (-10VDC) WHT (+10VDC) LABEL LRT RED EXTEND BLUE RETRACT YELLOW DISPENSE GREEN DISPENSE 6 2 2 25 LRT SIGNAL INPUT: 10 VDC TYPICAL 1 MOhm INPUT IMPEDANCE REQ: SPEED: 25 INCHES/SECOND >0 TO SLIGHTLY LESS SIGNAL OUTPUT: THAN FS SIGNAL INPUT NOTES: 30 2 RED 1 BLK 2 RED 3 WHT 2 DETAIL 1 FEMALE MALE 2 GREEN (39") 3 WHT 1 BLK PX-CSV (39.5") SEE DETAIL 1 SEE 02/2980-4/25 (48") M F PG-7 PG-7 LOOKING FROM SOLDER SIDE WIRE LABEL TYP RED (48") YELLOW (44") PX-OSV (42.5") FRONT BLUE (45") Electrical Requirements FIG. 15: LRT PD44 Metering Valve Electrical Requirements 41 Technical Data Technical Data NOTE: See feed system manuals for dimensions, weights, and wetted parts lists for those components. Dimensions, weights, and wetted parts for components not covered in component feed system manuals and for combined assemblies are listed below. Maximum Ambient Temperature . . . . . . . . . . . . . . . . . . . Maximum Operating Temp . . . . . . . . . . . . . . . . . . . . . . . . Maximum Outlet Fluid Working Pressure. . . . . . . . . . . . . Maximum Air Working Pressure. . . . . . . . . . . . . . . . . . . . Maximum Material Inlet Pressure. . . . . . . . . . . . . . . . . . . Supplied Air Requirements . . . . . . . . . . . . . . . . . . . . . . . Ratio Range (depending on metering rods selected). . . . Shot Size Range (depending on metering rods selected) Maximum Cycle Rate (application dependent) . . . . . . . . 110°F (43°C) 150°F (65°C) 2000 psi (14 MPa, 138 bar) 100 psi (0.7 MPa, 7 bar) Metal Sleeves: 1200 psi (8 MPa, 83 bar) Plastic Sleeves: 400 psi (2.8 MPa, 28 bar) 1 to 3 cfm at 80 psi to 100 psi 1:1 to 25:1 0.005 cc to 5.0 cc Micrometer PD44: Up to 60 cycles per minute LRT PD44: Up to 60 cycles per minute Motor Driven PD44: Up to 15 cycles per minute (with standard Graco motor) Dimensions (H x L x W), height to end of material inlet block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Micrometer PD44: 17.5 x 4.13 x 7.57 in. (445 x 105 x 192 mm) LRT PD44: 14.5 x 4.13 x 7.57 in. (368 x 105 x 192 mm) Motor Driven PD44 (with Graco motor): 17.5 x 4.13 x 7.57 in. (445 x 105 x 192 mm) Mixer: 4 - 14.75 in. (102 - 375 mm) Graco-supplied Feed System Assemblies (depends on selected options): Smallest: 22.5 x 10 x 4 in. (572 x 254 x 102 mm) Largest: 60 x 28 x 19 in. (1524 x 711 x 483 mm) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PD44 Metering Valve: 14 - 15 lb (6.35 - 6.80 kg) Valve stand only: 8 lb (3.6 kg) Feed Systems: 4 - 175 lb (1.8 - 79.4 kg) Sound Data*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PD44 Metering Valve: 76.5 dBA Sound Power Level 92.8 dB Max Sound Pressure Graco-supplied Feed Systems: See Related Manuals, page 3. Wetted Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PD44 Metering Valve: Hardened steel, 303/304, 404, UHMWPE, Tungsten, carbide, fluoroelastomer, EPDM, PTFE Graco-supplied Feed System Hoses and Fittings: Mild steel, 303/304, PTFE, buna, polyethylene, polypropylene Graco-supplied Tanks: Polyethylene, 303/304, mild steel * 42 Sound data measured per standard ISO 11202 (1993) & ISO3746 (1995). 313876F Technical Data Motor Specifications If a non-Graco motor is used with the Motor Driven PD44 Metering Valve, it must meet the following specifications. Frame: NEMA 23 Torque at Typical Dispense Speed: 180 oz-in. (11.25 in-lb) at 10 revolutions per second (1/2 in. rod travel per second) or less. Above 10 revolutions per second, the power declines. Torque at Maximum Speed: 117 oz-in (7.3 in-lb) at 20 revolutions per second (1 in. of rod travel per second). Motor Face Pilot Boss: 1.5 in. diameter by 0.0625 in. projection from motor face flange. Shaft Size: 0.25 diameter by 0.75 in. projection from motor face pilot boss to end of shaft. 313876F 43 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 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 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 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. 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 the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 313876 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO OHIO INC. 8400 PORT JACKSON AVE NW, NORTH CANTON, OH 44720 Copyright 2009, Graco Ohio Inc. is registered to ISO 9001 www.graco.com Revised 07/2011
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