Graco Dispensit 1092 Troubleshooting guide

Cycle Detection and Luer Lock Outlet Show

332089C

Operation - Maintenance

Dispensit

1092

Patented meter and dispense system for precise one-component micro-dispensing.

Dispense Valve

2000 psi (14 MPa, 138 bar) Maximum Outlet Fluid Working Pressure

Metal Sleeves: 1200 psi (8 MPa, 83 bar) Maximum Material Inlet Pressure

Plastic Sleeves: 400 psi (2.8 MPa, 28 bar) Maximum Material Inlet Pressure

100 psi (0.7 MPa, 7 bar) Maximum Air Working Pressure

110°F (43°C) Maximum Ambient Temperature

150°F (65°C) Maximum Operating Temperature

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

2 332089C

Contents

1092 Valve Models ..........................3

Warnings .................................4

Important Isocyanate (ISO) Information ........6

Isocyanate Conditions .....................6

Material Self-ignition ......................6

Keep Components A and B Separate .........6

Moisture Sensitivity of Isocyanates ...........6

Changing Materials .......................7

Grounding ................................8

Overview ..................................8

Optional Cycle Detection Sensors .............9

Component Identification ...................10

Typical System Configurations .............10

Typical Feed System Components ..........11

Typical Feed System Components (continued) . 12

Metering Valve ..........................13

Setup ....................................14

Typical Installation .......................14

Valve Mounting Diagram ..................15

Startup .................................. 16

Adjusting the Shot Size ....................17

Operation ................................18

Sequence of Operation ...................18

Pressure Relief Procedure .................. 19

Shutdown ................................19

Maintenance ..............................19

Troubleshooting ...........................20

Schematics ...............................20

Parts ....................................21

1092 Valve 1” CD ....................... 21

1092 Valve 1” Without CD .................23

1092 Valve 2” CD ....................... 25

1092 Valve 2” Without CD .................27

1092 Valve 3” CD ....................... 29

1092 Valve 3” Without CD .................31

Rebuild ..................................33

Disassembly ...........................33

Assembly ..............................34

Electrical Requirements (Cycle Detection Option) 36

Technical Data ............................37

Graco Standard Warranty ...................38

Graco Information .........................38

1092 Valve Models

332089C 3

1092 Valve Models

1092 Valves

Part No. Configuration Description

A2A05051 VALVE, 1092-10A-2RS1-250-V-CD 1 inch stroke, 0.250 diameter rod, nitrided tool steel wetted

components, cycle detect

A2A05054 VALVE, 1092-10A-2RS1-375-V-CD 1 inch stroke, 0.375 diameter rod, nitrided tool steel wetted

components, cycle detect

A2A05057 VALVE, 1092-10A-2S1-MR.500-CD 1 inch stroke, 0.500 diameter rod, nitrided tool steel wetted

components, cycle detect

A2A05011 VALVE, 1092-10A-2RS1-MR.250-V 1 inch stroke, 0.250 diameter rod, nitrided tool steel wetted

components

A2A05014 VALVE, 1092-10A-2RS1-375-V, #HWG 1 inch stroke, 0.375 diameter rod, nitrided tool steel wetted

components

A2A05017 VALVE, 1092-10A-2RS1-500-V-V, DISPE 1 inch stroke, 0.500 diameter rod, nitrided tool steel wetted

components

A2A05069 VALVE, 1092-10A-2TT1-250-V, DISP 1 inch stroke, 0.250 diameter rod, stainless steel wetted com-

ponents, cycle detect

A2A05075 VALVE, 1092-10A-2TT1-500-V-CD 1 inch stroke, 0.500 diameter rod, stainless steel wetted com-

ponents, cycle detect

A2A05029 VALVE, 1092-10A-2TT1-250-V, DISP 1 inch stroke, 0.250 diameter rod, stainless steel wetted com-

ponents

A2A05035 VALVE, 1092-10A-2TT1-500-V, DISP 1 inch stroke, 0.500 diameter rod, stainless steel wetted com-

ponents

A2A05083 VALVE, 1092-10A-4RS1-375-V-CD 2 inch stroke, 0.375 diameter rod, nitrided tool steel wetted

components, cycle detect

A2A05079 VALVE, 1092-10A-4RS1-500-V-CD 2 inch stroke, 0.500 diameter rod, nitrided tool steel wetted

components, cycle detect

A2A05093 VALVE, 1092-10A-4RS1-375-V-DISP 2 inch stroke, 0.375 diameter rod, nitrided tool steel wetted

components

A2A05039 VALVE, 1092-10A-4RS1-500-V-DISP 2 inch stroke, 0.500 diameter rod, nitrided tool steel wetted

components

A2A05080 VALVE, 1092-10A-6RS1-500-V-CD 3 inch stroke, 0.500 diameter rod, nitrided tool steel wetted

components, cycle detect

A2A05040 VALVE, 1092-10A-6RS1-500-V, DISP 3 inch stroke, 0.250 diameter rod, nitrided tool steel wetted

components

Warnings

4 332089C

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 symbols refer to procedure-specific risks. When

these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific

hazard symbols and warnings not covered in this section may appear throughout the body of this manual where

applicable.

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This

may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the

fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keep work area

well-ventilated and always wear appropriate personal protective equipment. See Personal

Protective Equipment warnings in this manual.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing

equipment, or when in the work area. Protective equipment helps prevent serious injury, including

long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and

hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable

gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local

regulatory authority.

• Protective eyewear and hearing protection.

Warnings

332089C 5

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent

flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well-ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static sparking).

• Ground all equipment in the work area. See Grounding instructions.

• Never spray or flush solvent at high pressure.

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they

are anti-static or conductive.

•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-

tions in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete infor-

mation about your material, request Safety Data Sheets (SDSs) from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-

facturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut 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 and disconnect all power sources.

WARNING

Important Isocyanate (ISO) Information

6 332089C

Important Isocyanate (ISO) Information

Isocyanate Conditions

Material Self-ignition

Keep Components A and B

Separate

Moisture Sensitivity of

Isocyanates

Exposure to moisture (such as humidity) will cause ISO

to partially cure, forming small, hard, abrasive crystal

that become suspended in the fluid. Eventually a film will

form on the surface and the ISO will begin to gel,

increasing in viscosity.

NOTE: The amount of film formation and rate of crystal-

lization varies depending on the blend of ISO, the

humidity, and the temperature.

Spraying or dispensing fluids that contain isocyanates

creates potentially harmful mists, vapors, and

atomized particulates.

• Read and understand the fluid manufacturer’s

warnings and Safety Data Sheet (SDS) to know

specific hazards and precautions related to isocy-

anates.

• Use of isocyanates involves potentially hazardous

procedures. Do not spray with this equipment

unless you are trained, qualified, and have read

and understood the information in this manual and

in the fluid manufacturer’s application instructions

and SDS.

• Use of incorrectly maintained or mis-adjusted

equipment may result in improperly cured material.

Equipment must be carefully maintained and

adjusted according to instructions in the manual.

• To prevent inhalation of isocyanate mists, vapors,

and atomized particulates, everyone in the work

area must wear appropriate respiratory protection.

Always wear a properly fitting respirator, which

may include a supplied-air respirator. Ventilate the

work area according to instructions in the fluid

manufacturer’s SDS.

• Avoid all skin contact with isocyanates. Everyone

in the work area must wear chemically imperme-

able gloves, protective clothing and foot coverings

as recommended by the fluid manufacturer and

local regulatory authority. Follow all fluid manufac-

turer recommendations, including those regarding

handling of contaminated clothing. After spraying,

wash hands and face before eating or drinking.

Some materials may become self-igniting if applied

too thick. Read material manufacturer’s warnings and

material Safety Data Sheet (SDS).

Cross-contamination can result in cured material in

fluid lines which could cause serious injury or damage

equipment. To prevent cross-contamination:

• Never interchange component A and component

B wetted parts.

• Never use solvent on one side if it has been con-

taminated from the other side.

NOTICE

Partially cured ISO will reduce performance and the life

of all wetted parts.

• 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 pump wet cup or reservoir (if

installed) filled with appropriate lubricant. The

lubricant creates a barrier between the ISO and

the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

• Never use reclaimed solvents, which may contain

moisture. Always keep solvent containers closed

when not in use.

• Always lubricate threaded parts with an

appropriate lubricant when reassembling.

Important Isocyanate (ISO) Information

332089C 7

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

NOTICE

Changing the material types used in your equipment

requires special attention to avoid equipment damage

and downtime.

• 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.

• When changing between epoxies and urethanes

or polyureas, disassemble and clean all fluid

components and change hoses. Epoxies often

have amines on the B (hardener) side. Polyureas

often have amines on the B (resin) side.

Grounding

8 332089C

Grounding

Metering valve: attach ground wire from grounding lug

to true earth ground. See Component Identification

starting on page 10.

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.

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 sur-

face, such as paper or cardboard, which interrupts

grounding continuity.

Overview

This single-component meter and dispense device

accurately meters liquid and semi-paste materials.

The machine is ideal for a single-component application

requiring very small and precise shots.

The ratio of the pneumatic cylinder area to pump shaft

area provides the adjustable pressure intensification

needed to move the liquids through the needle with a

flow rate suitable for production requirements.

The complete system is enclosed. See Sequence of

Operation on page 18.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes to

ignite or explode. Grounding provides an escape wire

for the electric current.

Optional Cycle Detection Sensors

332089C 9

Optional Cycle Detection

Sensors

The sensors are magnetic reed switches and must be

connected to an electrical control package. The sensors

wires are #24 awg and have 9 foot (2.7 meters) flying

leads. An LED on the sensor illuminates to indicate a

change in state.

Suggested Sequence of Operation (See

page 18).

• The Valve Inputs are listed in FIG. 8, page 36.

• The Valve Outputs (supplied by others) consisting

of two power valves or one dual power valve [Sole-

noid-Close Spool Valve/RETract (Green Tube 1/4

in. OD) and Solenoid-Open Spool Valve/EXTend

(Yellow Tube 1/4 in.OD)]. Connect each Quick Dis-

connect (5/16-24 fitting) to respective power valve

port.

• Other needed Input would include some type of

Start device (Foot Switch or Control Box) (supplied

by others)

1. Home (Reload) Position

a. Solenoid-Close Spool Valve/RETract is acti-

vated.

b. Solenoid-Open Spool Valve/EXTend is deacti-

vated.

c. PX-EXT and PX-CSV signal have been made.

d. PX-RET and PX-OSV signal is not made.

e. Metering Rod is Retracted.

2. Shot Procedure

a. Start device signal is made.

b. Solenoid-Close Spool Valve/RETract is deacti-

vated.

c. Solenoid-Open Spool Valve/EXTend is acti-

vated.

d. PX-EXT and PX-CSV signal drops off.

e. Spool shifts from the Reload Position to the Dis-

pense Position.

f. PX-OSV signal is made.

g. Metering Rod Extends downward (Dispensing

Material).

h. PX-RET signal is made and Metering Rod is

down (Dispense Material Complete).

i. Solenoid-Open Spool Valve/EXTend is deacti-

vated.

j. Solenoid-Close Spool Valve/RETract is acti-

vated.

k. PX-OSV signal drops Spool shifts from the Dis-

pense Position to the Reload Position and

Metering Rod Retracts upward (Reloading

Material).

l. PX-CSV signal is made.

m. PX-EXT signal is made.

n. Dispense Valve is ready for next Start device

signal.

Component Identification

10 332089C

Component Identification

Typical System Configurations

FIG.1

GREEN

YELLOW

TIMER

DISPENSE

Liquid Control

PRESSURE

SYSTEM

REG-1 REG-2

AUXILIARY

PRESSURE

G-1 G-2

OFF

PB-1

SW-1/PL-1

TR-1

HAND

OFF

SW-2

POWER

AUTO START

Valve

Controls

Top View of Controls

System shown with optional 4104A controls

This manual suits for next models

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