Graco PD44 Manual instruction

313877J

Setup - Operation - Parts

PD44

Control Box

Meter, mix and dispense system for two-component micro-dispensing of sealants and

adhesives. For professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

26C940

Micrometer PD44 Control Box

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

See page 2 for model information.

Important Safety Instructions

Read all warnings and instructions in this

manual before using the equipment.

Save these instructions.

2 313877J

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

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

Component Identification . . . . . . . . . . . . . . . . . . . . 8

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PD44 Dispense Valve . . . . . . . . . . . . . . . . . . . . . 9

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Dispensing Operation . . . . . . . . . . . . . . . . . . . . . . 11

HMI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Screen Navigation Diagram . . . . . . . . . . . . . . . . 12

Main Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Posidot Control Screen . . . . . . . . . . . . . . . . . . . 13

Timer/Counter Control Screen . . . . . . . . . . . . . . 15

Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Level 1 Control Screen . . . . . . . . . . . . . . . . . . . 19

Level 2 Control Screen . . . . . . . . . . . . . . . . . . . 21

Pressure Relief Procedure. . . . . . . . . . . . . . . . . . . 23

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 24

End of Product Life . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Air-Water Separator/Filter . . . . . . . . . . . . . . . . . 24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Customer Inputs/Outputs . . . . . . . . . . . . . . . . . . . 26

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical Schematics. . . . . . . . . . . . . . . . . . . . . 27

Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . 30

Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . 31

Lower Pneumatic Enclosure . . . . . . . . . . . . . . . 32

Technical Specifications . . . . . . . . . . . . . . . . . . . . 33

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 33

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34

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Manual in

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308167 Low Volume Air Regulators

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308169 Air Filters, Lubricators and Kits

309306 Air-Operated Husky™ Diaphragm Pumps

312376 Stainless Steel Agitator Kit

313526 Check-Mate® Pump Packages

406088 Check-Mate® Ram Packages

PD44 Control

Box Model

Maximum Air Working

Pressure

psi (MPa, bar) Voltage

Micrometer 100 (0.7, 7) 120/240V,

50/60Hz

Warnings

313877J 3

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 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

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.

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.

Warnings

4 313877J

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.

• Connect only to grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause

serious injury.

• Follow the Pressure Relief Procedure when you stop spraying/dispensing 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.

WARNING

Warnings

313877J 5

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

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information 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

manufacturer’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.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious

injury or property damage.

• Use only compatible solvents to clean plastic structural or pressure-containing parts.

• See Technical Specifications in all equipment manuals for materials of construction. Consult the

solvent manufacturer for information and recommendations about compatibility.

WARNING

Important Isocyanate (ISO) Information

6 313877J

Important Isocyanate (ISO) Information

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

crystallization 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 Sheets (SDSs) to know

specific hazards and precautions related to

isocyanates.

•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 SDSs.

•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 SDSs.

•Avoid all skin contact with isocyanates. Everyone

in the work area must wear chemically

impermeable gloves, protective clothing and foot

coverings as recommended by the fluid

manufacturer and local regulatory authority.

Follow all fluid manufacturer recommendations,

including those regarding handling of

contaminated clothing. After spraying, wash

hands and face before eating or drinking.

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

contaminated 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

313877J 7

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.

Component Identification

8 313877J

Component Identification

Control Box

Key:

A Emergency Stop

B Control Power Switch

C Touch Panel

D Alarm Speaker

E Power Input

F Start Options Connection

G Custom I/O

H A Tank Level Controls Connection

J B Tank Level Controls Connection

K Main Air Inlet

L Dispense Valve I/O Connection

M Spool Valve Load Connection

N Spool Valve Dispense Connection

P Air Cylinder Extend Connection

R Air Cylinder Retract Connection

S Air Pressure Regulator

T Air Pressure Gauge

FIG. 1: Micrometer PD44 Control Box

5 34

11 8

SIGNAL CONNECTION

PG-3

ATANK

LEVEL CONTROLS

PG-4

BTANK

LEVEL CONTROLS

PG-2

CUSTOMER I/O 100V TO250V AC

PG-8

START

MACHINE I/O

PG-1

EXT

LOAD DISP RET

106

VALV E

108 107

SPOOL

105

CYLINDER

AIR

A B C H J G F E

KM N P R

Grounding

313877J 9

PD44 Dispense Valve

See the PD44 Dispense Valve Operation-Parts manual

for detailed dispense valve component identification and

instructions. See Related Manuals on page 2.

Grounding

Control box: 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.

Air and fluid hoses: use only electrically conductive

hoses.

Fluid supply container: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded

surface. Do not place the pail on a nonconductive

surface, such as paper or cardboard, which interrupts

grounding continuity.

FIG. 2: PD44 Micrometer Dispense Valve

The equipment must be grounded to reduce the risk

of static sparking and electric shock. Electric or static

sparking can cause fumes to ignite or explode.

Improper grounding can cause electric shock.

Grounding provides an escape wire for the electric

current.

Setup

10 313877J

Setup

1. Connect the air supply to the main air inlet (K) on

the control box. Air supply must include a

shut-off/bleed valve that bleeds pressure past the

shut-off/bleed valve and an air-water

separator/filter.

2. Connect air lines from the control box to the

dispense valve. Match the number and color codes

on the fittings and connections. See the following

table and illustration.

3. Connect the Dispense Valve I/O and Start Options

logic cables. If level controls are installed, connect

the Level Controls logic cables.

4. Adjust the air pressure regulator to 80 psi (0.6 MPa,

6 bar).

5. Perform the Setup procedure for the dispense valve

and feed system components. See Related

Manuals on page 2.

FIG. 3

Connection Color Connection Description

Red Extend

Blue Retract

Yellow Dispense

Green Reload

FIG. 4

5 34

11 8

SIGNAL CONNECTION

PG-3

ATANK

LEVEL CONTROLS

PG-4

BTANK

LEVEL CONTROLS

PG-2

CUSTOMERI/O 100V TO250V AC

PG-8

START

MACHINE I/O

PG-1

EXT

LOAD DISP RET

106

VALV E

108 107

SPOOL

105

CYLINDER

AIR

5 34

11 8

SIGNAL CONNECTION

PG-3

ATANK

LEVEL CONTROLS

PG-4

BTANK

LEVEL CONTROLS

PG-2

CUSTOMERI/O 100V TO250V AC

PG-8

START

MACHINE I/O

PG-1

EXT

LOAD DISP RET

106

VALV E

108 107

SPOOL

105

CYLINDER

AIR

NOTICE

The feed system and main logic control system must

use separate air supplies. Failure to use separate air

supplies could cause material to enter the control

lines and result in damage to the system.

FIG. 5

5 34

11 8

SIGNAL CONNECTION

PG-3

ATANK

LEVEL CONTROLS

PG-4

BTANK

LEVEL CONTROLS

PG-2

CUSTOMERI/O 100V TO250V AC

PG-8

START

MACHINE I/O

PG-1

EXT

LOAD DISP RET

106

VALV E

108 107

SPOOL

105

CYLINDER

AIR

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