Graco Dispensit 1092 Troubleshooting guide

Cycle Detection and Luer Lock Outlet Show
n
332089C
EN
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
R
GREEN
GREEN
YELLOW
YELLOW
0
TIMER
DISPENSE
Liquid Control
R
PRESSURE
SYSTEM
REG-1 REG-2
AUXILIARY
PRESSURE
G-1 G-2
OFF
ON
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
332089C 11
Typical Feed System Components
FIG.2
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

Component Identification
12 332089C
Typical Feed System Components (continued)
FIG.3
R
0
12
8
4
psi
30
22
19
15
26
R
0
12
8
4
psi
30
22
19
15
26
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
332089C 13
Metering Valve
FIG.4
GREEN
GREEN
YELLOW
YELLOW
0432187210965 9873564
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 Luer Lock Outlet
T
S
H
G
E
M
KJ
F
D
A
L
C
Z

Setup
14 332089C
Setup
NOTE: See Typical Installation diagram.
2.
3. Perform Setup procedure for feed system compo-
nents. See feed system manual(s).
4. Place an in-line air pressure regulator, air-water
separator/filter, and shut-off/bleed valve between
the air supply and the control solenoids.
5. Connect each 1/4 in. outside diameter supplied air
line to the corresponding control solenoid. See
Component Identification starting on page 10.
6. Connect chemical lines from feed system to meter-
ing valve material inlets. See Component Identifi-
cation starting on page 10.
Typical Installation
FIG.5
Metering Valve
Pump
Material Tank (optional)
Fluid Shut-Off Valve
Air Supply Air Shut-off and Bleed Valve
Air Pressure Regulator
User Supplied
Air-Water Separator/Filter
Control Solenoids

Setup
332089C 15
Valve Mounting Diagram
As desired, use the following diagram to mount the
metering valve.
FIG.6
GREEN
GREEN
GREEN
MODEL 1092-10A
YELLOW
YELLOW
GREEN
GREEN
YELLOW
YELLOW
2 = 1" METERING STROKE
4 = 2" METERING STROKE
6 = 3" METERING STROKE
1
4
NPT FEMALE
MATERIAL INLET
SHOT SIZE
ADJUSTMENT
WITH LOCK
RETRACT/CLOSE
DISPENSE VALVE
EXTEND/OPEN
DISPENSE VALVE
EXTEND
ADJUSTABLE
FLOW CONTROL
WITH LOCK
RETRACT
ADJUSTABLE
FLOW CONTROL
WITH LOCK
GROUND STUD
LUER LOCK
NEEDLE MOUNT
MATERIAL OUTLET
0432187210965 9873564
USA
SN XXXXXX
0.56
E
D
B
A
0.88
0.59
1.53
1.75
C
(2) #F (.257 DIA.) DRILL THRU
(2) .189/.191DIA. DRILL THRU
0.688
0.688
CYCLE DETECTION
8.38
4.19
B
A
NON CYCLE DETECTIONDIMENSION
9.13
4.56
6
11.00
1.750
D
C
2
DIMENSION
18.75
1.750
2.500
E2.500
1092-10A-_
4
15.63
3.250
2.250
Dispensit
R
R

Startup
16 332089C
Startup
1. Lubricate the metering rod port in the oil cup retain-
ing block and fill the spool valve ports with compati-
ble lubricant such as mesamoll or silicone oil.
2. Pressurize the feed systems connected to the
metering valve to prime the system. See Technical
Data on page 37 for maximum inlet feed pressure.
3. Dispense several full stroke shots until material is
air-free and has good shut-off at the nose.
NOTE: Very viscous, compressible materials may con-
tinue 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 pro-
ceeding.
FIG. 7: Top View of Metering Valve with Top Section
Removed
Metering Rod Port
Spool Valve Ports

Adjusting the Shot Size
332089C 17
Adjusting the Shot Size
1. Rotate the shot size locking ring counterclockwise
to loosen.
2. Rotate the shot size adjuster to adjust shot size.
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.

Operation
18 332089C
Operation
The operation of the 1092 metering valve is controlled
by an external source. If a 4104A Control Box was pur-
chased, see the 4104A Control Box manual for opera-
tion instructions.
Sequence of Operation
Step 1: Reload
• Spool shifts to the right
• Material feed inlet is opened
• Material is transferred into the metering chambers
by a pressurized feed system
• Outlet port is blocked
• Metering rod is retracted to a precise position deter-
mining the volume of each material
Step 2: Shift
• The balanced spool shifts to the dispense position
• Material path to the needle is opened
• Material feed inlet port is blocked
• Metering rod remains in the retracted position
Step 3: Dispense
• Metering rod extends
• Material is dispensed from the metering chamber
into the needle
Upon completion of the dispense stroke, the metering
rod and spool shifts back to the reload position.

Pressure Relief Procedure
332089C 19
Pressure Relief
Procedure
1. Retract the metering rods. See the 4104A Control
Box manual.
2. Close the fluid shut-off valve.
3. Remove needle.
4. Dispense 5 shots. Shots should be at least 75% of
the full stroke.
5. Extend the metering rod into the tubes. If Graco
controls are provided with the system, see the
4104A Controls manual.
6. Close the incoming air shut-off/bleed valve that sup-
plies air to the metering valve.
7. Close the incoming air shut-off/bleed valve that sup-
plies the feed system. Refer to feed system manual
for pressure relief procedure.
Shutdown
1. Perform Pressure Relief Procedure.
2. Inspect the metering rod for material buildup. Clean
as necessary.
3. Lubricate the metering rod with compatible lubricant
such as mesamoll or silicone oil.
4. Remove needle and replace with an airtight cap.
Maintenance
Perform the following procedures once a shift.
NOTE: If material is leaking, see Troubleshooting on
page 20.
Material Reservoirs
Check material levels and refill as necessary. Ensure
that the material reservoirs are properly vented.
Air Dryer
Check the condition of the desiccant air dryer. Replace
as necessary.
Metering Rod Port
Lubricate with compatible lubricant such as mesamoll or
silicone oil. See FIG. 7 on page 16.
Spool Valve Port
Fill with compatible lubricant such as mesamoll or sili-
cone oil. See FIG. 7 on page 16.

Troubleshooting
20 332089C
Troubleshooting
Schematics
For standard machines, the schematics will be
included in the 4104A Parts manual.
For custom machines, the schematics will be included
in the assembly drawings manual.
Perform Pressure Relief Procedure before perform-
ing any troubleshooting procedure.
Problem Cause Solution
Metering valve stalling and no mate-
rial being dispensed despite ade-
quate input pressure
Blocked needle Check needle for cured material,
replace as required
Flow control valve closed Open needle
Metering valve not discharging nor-
mal or full volume
Low material level in reservoirs Fill material reservoirs and prime the
machine
Air in material tank Fill reservoir and prime machine
Material leaks past spool valve Spool valve worn or damaged Replace the spool valve
Spool will not actuate Low air pressure Increase air pressure to approxi-
mately 20-30 psi
Cured material on spool Check spool for cured material,
replace as required
Seals are worn Replace seals