Graco PD44 User manual
313904D
EN
Instructions
Pneumatic PD44
Meter, mix and dispense valve for precise two-component micro-dispensing of sealants
and adhesives. For professional use only.
See page 3 for model information includ-
ing maximum working pressures.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
PUMP AIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMP MODE
SHOT
CONT.
Pump and Tank not shown
Related Manuals
2313904D
Contents
Related Manuals ...........................2
Model ....................................3
Warnings .................................3
Isocyanate Conditions ......................5
Material Self-ignition .......................5
Moisture Sensitivity of Isocyanates ............5
Keep Components A and B Separate ..........5
Foam Resins with 245 fa Blowing Agents ....... 5
Changing Materials .........................5
Grounding ................................6
Overview ..................................8
Component Identification ....................9
Controls................................9
Other Features ..........................9
Typical Feed System Components .........10
Micrometer PD44 Metering Valve ...........12
Setup....................................13
Typical Installation ......................13
Valve Mounting Diagram ..................14
Adjusting the Shot Size ....................15
Ratio Check ..............................16
Operation ................................17
Sequence of Operation ...................17
Startup ..................................18
Pressure Relief Procedure ..................19
Shutdown ................................19
Maintenance ..............................20
Metering Rod Alignment ....................21
Troubleshooting ...........................22
Schematics ...............................22
Rebuild ..................................23
Wetted Section Disassembly ...............23
Wetted Section Reassembly ...............25
Spool Valve Rebuild .....................26
Wetted Section Rebuild ...................27
Micrometer Drive Rebuild .................30
Accessories ..............................32
Technical Data ............................35
Graco Ohio Standard Warranty ..............36
GracoOhioInformation.....................36
Related Manuals
Components manuals in English. Manuals are available
at www.graco.com.
Feed System Manuals
Manual No. Description
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
Model
313904D 3
Model
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.
Metering Valve
Model
Max Outlet
Fluid Working
Pressure
psi (MPa, bar)
Max Air
Working
Pressure
psi (MPa, bar)
Max Inlet Working Pressure
psi (MPa, bar)
Metal Sleeves Plastic Sleeves
Micrometer 2000 (14, 138) 100 (0.7, 7) 1200 (8, 83) 400 (2.8, 28)
WARNING
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.
• Hold gun firmly to side of grounded pail when triggering into pail.
• 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.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
materials and gases. To help prevent fire and explosion:
• Clean plastic parts in a well ventilated area.
• Do not clean with a dry cloth.
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.
Warnings
4313904D
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.
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
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
313904D 5
Isocyanate Conditions
Material Self-ignition
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 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.
• Never use solvent on one side if it has been con-
taminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Keep Components A and
B Separate
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
• 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.
• Most materials use ISO on the A side, but some use
ISOontheBside.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
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.
NOTICE
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocy-
anate) and component B (resin) parts.
Grounding
6313904D
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
Agitator: agitators are grounded to pump through tank
and stand. No ground wire is necessary. Regularly
check continuity between agitator and pump grounding
lug.
Tanks: tanks are grounded to pump through stand. No
ground wire is necessary. Regularly check continuity
between tank and pump grounding lug.
Pumps: connect a ground wire from the grounding lug
on the pump to a true earth ground.
Footswitch: use a ground wire to ground the footswitch
to the PosiDot Controls.
PosiDot Controls: use a ground wire to ground to a
true earth ground.
Dispense Valve: connect ground wire from grounding
post on right side of dispense valve to a true earth
ground.
Air and fluid hoses: use only electrically conductive
hoses.
Air compressor: follow manufacturer's recommenda-
tions.
Fluid supply container: follow your local code.
Object being dispensed into: follow your 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 non-conductive sur-
face, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the valve.
See Grounding illustration, FIG. 1 on page 7.
Grounding
313904D 7
FIG. 1: Grounding Illustration
PosiDot Controls and Footswitches PosiDot Dispense Valves
PosiDot Pumps and Tanks
NOTE: Assemblies
not shown to scale
PUMPAIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMPMODE
SHOT
CONT.
PUMPAIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMPMODE
SHOT
CONT.
PUMPAIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMPMODE
SHOT
CONT.
PUMPAIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMPMODE
SHOT
CONT.
PUMPAIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMPMODE
SHOT
CONT.
PUMPAIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMPMODE
SHOT
CONT.
R
R
R
R
Overview
8313904D
Overview
This plural component meter, mix, and dispense device
accurately meters liquid and semi-paste materials
throughout a wide range of viscosities.
The machine is ideal for a two-component application of
very small and precisely mixed shots.
The ratio of pneumatic cylinder to pump shaft area, pro-
vides the adjustable pressure intensification needed to
move the separate liquids through the mixer with a flow
rate quite suitable for production requirements.
The complete system is completely enclosed; mixing of
the liquids takes place only in the mixing chamber at the
final stage of the machine operation. The motionless
mixer keeps the volume of material to a minimum while
ensuring adequate mixing.
All personnel charged with operating, maintaining, or
cleaning the equipment should read this manual in its
entirety.
CAUTION: Due to the precise nature of the machine,
we recommend you contact Graco before making major
adjustments.
Throughout this manual, references to the A side and B
side are used. The A and B sides correspond to the par-
ticular material originally specified for use in the
machine and relate to the corresponding label on the
material supply and to the hoses. Any change of mate-
rial supplier may require relabelling the supply, pumps,
and hoses accordingly.
Component Identification
313904D 9
Component Identification
Controls
Pump Mode Switch
EXTEND: The air cylinder and PosiDot rods will immedi-
ately extend and remain in the extended position. This is
the position that the valve should be in if idle for an
extended period of time.
SHOT: The PosiDot will complete one full cycle when
the start device is pressed and released. The PosiDot
will cycle continuously when the start device is pressed
and held.
CONTINUOUS: The PosiDot will continually cycle when
CONTINUOUS is selected. The PosiDot will continue to
cycle until the Pump Mode switch is placed in the SHOT
or the EXTEND position.
Other Features
Foot Switch
The foot switch is used to initiate a PosiDot cycle when
operating in SHOT Mode. The foot switch is referred to
as a Start device in this manual. When the SHOT Mode
is selected and the start device is pressed and released,
the PosiDot will cycle.
Customer Signal
This allows the controller to operate the PosiDot from a
remote device. The Customer Signal air ports are
located on the left side of the PosiDot Controls box.
START Port: When air is applied, the PosiDot will oper-
ate as if the foot switch is pressed and held.
DONE Port: When the PosiDot has completed the
cycle, the DONE Port will discharge a pulse of air.
FIG.2
PUMP AIR PRESSURE
psi
160
80
20
40
60
0
140
120
100
EXTEND
PUMP MODE
SHOT
CONT.
Air Pressure Regulator
Air Pressure Gauge
Emergency Stop
Pump Mode Switch
Component Identification
10 313904D
Typical Feed System Components
FIG.3
DO NOT SERVICE WITHOUT
REMOVING AIR PRESSURE AND
WEARING SAFETY GLASSES.
WARNING
F
200
psi
0
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
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