Graco Dispensit 1052 Troubleshooting guide

Cycle Detection and Luer Lock Outlet Shown

3A0231E

Operation - Maintenance

Dispensit

1052

Patented meter and dispense system for precise one-component micro-dispensing. Not for

use in explosive atmospheres.

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.

23A0231E

Contents

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

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . 5

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . 5

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 5

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Optional Cycle Detection Spool Sensors . . . . . . . 6

Component Identification . . . . . . . . . . . . . . . . . . . . 7

Typical System Configurations . . . . . . . . . . . . . . 7

Typical Feed System Components . . . . . . . . . . . 8

Typical Feed System Components (continued) . . 9

Metering Valve . . . . . . . . . . . . . . . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 11

Valve Mounting Diagram . . . . . . . . . . . . . . . . . . 12

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Adjusting the Shot Size . . . . . . . . . . . . . . . . . . . . 14

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Sequence of Operation . . . . . . . . . . . . . . . . . . . 15

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 16

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Graco Ohio Standard Warranty . . . . . . . . . . . . . . 22

Graco Ohio Information . . . . . . . . . . . . . . . . . . . . 22

Warnings

3A0231E 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back

to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where

applicable.

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 Iso-

cyanate 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.

Warnings

43A0231E

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-

tric 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 manu-

facturer’s replacement parts only.

• Do not alter or modify equipment.

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

• Route hoses and 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.

WARNING

Isocyanate Conditions

3A0231E 5

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of

Isocyanates

ISO will react with moisture (such as humidity) to form

small, hard, abrasive crystals, which become sus-

pended in the fluid. Eventually a film will form on the sur-

face 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 crystal-

lization varies depending on the blend of ISO, the

humidity, and the temperature.

To prevent exposing ISO to moisture:

• 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.

• Always lubricate threaded parts with ISO pump oil

or grease when reassembling.

Changing Materials

• When changing materials, flush the equipment mul-

tiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical

compatibility.

Spraying or dispensing materials containing isocya-

nates 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 ventila-

tion 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 per-

sonal protective equipment, including chemically

impermeable gloves, boots, aprons, and goggles, is

also required for everyone in the work area.

Some materials may become self-igniting if applied

too thickly. Read material manufacturer’s warnings

and material MSDS.

Grounding

63A0231E

Grounding

This product must be grounded. In the event of an elec-

trical short circuit, grounding reduces the risk of electric

shock by providing an escape wire for the electric cur-

rent.

Metering valve: attach ground wire from grounding lug

to true earth ground. See Component Identification

starting on page 7.

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 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 needle

with a flow rate suitable for production requirements.

The complete system is enclosed. See Sequence of

Operation on page 15.

Optional Cycle Detection

Spool Sensors

The spool sensors are magnetic reed switches and must

be connected to an electrical control. An LED on the

switch illuminates to indicate the shifting of the spool.

Component Identification

3A0231E 7

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

Component Identification

83A0231E

Typical Feed System Components

FIG. 2

DO NOT SERVICE WITHOUT

REMOVING AIR PRESSURE AND

WEARING SAFETY GLASSES.

WARNING

200

psi

20 oz Cartridge Feed

with Mounting Post

5 Gallon Pail Cover

with Diaphragm Pump

1 Gallon Ram

and Pump

5 Gallon Pail Cover

with Diaphragm

Pump and Agitator

5 Gallon Ram and

11:1 Transfer Pump

5 Gallon Pail Cover

with Diaphragm

Pump

5 Gallon Pail Cover

with 5:1 Transfer

Pump

Component Identification

3A0231E 9

Typical Feed System Components (continued)

FIG. 3

psi

5 Gallon Tank with Diaphragm Pump and Stand 5 Gallon Tank with 5:1 Pump and Stand

10 Gallon Tank with Diaphragm Pump, Agitator,

Vacuum, and Stand

10 Gallon Tank with 5:1 Pump, Agitator, Vacuum,

and Stand

Component Identification

10 3A0231E

Metering Valve

FIG. 4

GREEN

YELLOW

0 43218765 21095634 987

YELLOW

Key:

A Material Inlet

C Grounding Lug

D Spool

E Metering Rod

F Oil Cup Retaining Block

G Extend Air Inlet

H Retract Air Inlet

J Dispense Air Inlet

K Reload Air Inlet

L Extend Air Flow Adjustment

Knob

M Retract Air Flow Adjustment

Knob

S Shot Size Locking Ring

T Shot Size Adjuster

Z Needle

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