Graco PD44 Manual instruction

313877G
Setup - Operation
PD44
Control Box
Meter, mix and dispense system for precise two-component micro-dispensing of sealants
and adhesives. Not for use in explosive atmospheres.
See page 3 for model information, including maximum
working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Micrometer PD44 and LRT PD44 Control Box shown
EN

2313877G
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PD44 Dispense Valve . . . . . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Micrometer and LRT PD44 Only . . . . . . . . . . . . 10
Motor Driven PD44 Only . . . . . . . . . . . . . . . . . . 11
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dispensing Operation . . . . . . . . . . . . . . . . . . . . . . 13
HMI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Screen Navigation Diagrams . . . . . . . . . . . . . . 14
Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Posidot Control Screen
(Micrometer PD44 and
LRT PD44 only) . . . . . . . . . . . . . . . . . . . . . 17
Metering Valve Control Screen
(Motor Driven PD44 only) . . . . . . . . . . . . . . 18
Shot Size Screen
(LRT PD44 only) . . . . . . . . . . . . . . . . . . . . . 20
Shot Size Screen
(Motor Driven PD44 Only) . . . . . . . . . . . . . 21
Level 1 Control Screen . . . . . . . . . . . . . . . . . . . 22
Level 2 Control Screen . . . . . . . . . . . . . . . . . . . 23
Purge Timer Screen . . . . . . . . . . . . . . . . . . . . . 25
Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor Status Screen
(Motor Driven PD44 only) . . . . . . . . . . . . . . 30
Motor Error Codes Screen
(Motor Driven PD44 Only) . . . . . . . . . . . . . 32
Supervisor Screen
(LRT PD44 Only) . . . . . . . . . . . . . . . . . . . . 33
Supervisor Screen
(Motor Driven PD44 Only) . . . . . . . . . . . . . 34
Supervisor Help Screen
(Motor Driven PD44 Only) . . . . . . . . . . . . . 35
Calibration Screen
(LRT PD44 Only) . . . . . . . . . . . . . . . . . . . . 36
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 38
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Customer Inputs/Outputs . . . . . . . . . . . . . . . . . . . 39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Linear Resistive Transducer (LRT) . . . . . . . . . . 42
Motor Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

Related Manuals
313877G 3
Related Manuals
Models
PD44 Manuals
Part Description
313876 PD44 Dispense Valve Operation - Parts
Feed System Manuals
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
406088 Check-Mate®Ram Packages
PD44 Control Box
Model
Max Air Working
Pressure
psi (MPa, bar) Voltage
Linear Resistive
Transducer (LRT)
100 (0.7, 7) 120/240V,
50/60Hz
Micrometer
100 (0.7, 7) 120/240V,
50/60Hz
Motor Driven
100 (0.7, 7) 120/240V,
50/60Hz

Warnings
4313877G
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
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.
• 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.
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.

Warnings
313877G 5
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying 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.
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.
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

Component Identification
6313877G
Component Identification
Control Boxes
FIG. 1: Micrometer and LRT PD44 Control Box
7
2
5 34
6
1
7
2
5 34
6
1
7
2
5 34
6
1
12
56
3
7
12
9
13
10
14
11 8
4
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
1
3
4
2
EXT
LOAD DISP RET
106
VALV E
108 107
SPOOL
105
CYLINDER
AIR
D
Key:
A Emergency Stop
B Control Power Switch
C Touch Panel
D Alarm Speaker
E Power Input
F Start Options Connection
GCustomI/O
H A Tank Level Controls Connection
J B Tank Level Controls Connection
KMainAirInlet
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
ST
AB C HJGFE
KM NPR
L

Component Identification
313877G 7
FIG. 2: Motor Driven PD44 Control Box
CONTROL POWER
VERIFYINCOMINGVOLTAGE
BEFORE CONNECTING POWER
WITHVOLTAGE SWITCH SETTING
VALVE I/O MOTOR
3
24
1
AUDIO ALARM
START OPTIONS
Key:
A Emergency Stop
B Control Power Switch
C Touch Panel
D Alarm Speaker
E Power Input
F Start Options Connection
H A Tank Level Controls Connection
J B Tank Level Controls Connection
L Dispense Valve I/O Connection
U Motor Connection
BAC
D
H
J
E
F
L
U

Component Identification
8313877G
PD44 Dispense Valve
See PD44 Operation manual 313876 for detailed dis-
pense valve component identification and instructions.
FIG. 3: PD44 Micrometer Dispense Valve

Grounding
313877G 9
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.
Grounding plug units: 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.
Hard-wired units: the grounding wire must be used. All
electrical wiring must be done by a qualified electrician
and comply with all local codes and regulations.
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 non-conductive sur-
face, such as paper or cardboard, which interrupts
grounding continuity.

Setup
10 313877G
Setup
Micrometer and LRT PD44 Only
1. Connect air supply to main air inlet on 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 control box to dispense valve.
Match the number and color codes on the fittings
and connections. See the following table and illus-
tration.
3. Connect Dispense Valve I/O, and Start Options
logic cables. If level controls are installed, connect
Level Controls logic cables.
4. Adjust air pressure regulator to 80 psi (0.6 MPa,
6bar).
5. Perform Setup procedure for dispense valve and
feed system components. See Related Manuals on
page 3.
Connection
Color
Connection
Description
Red Extend
Blue Retract
Yellow Dispense
Green Reload
7
2
5 34
6
1
7
2
5 34
6
1
7
2
5 34
6
1
12
56
3
7
12
9
13
10
14
11 8
4
SIGNAL CONNECTION
PG-3
ATANK
LEVEL CONTROLS
PG-4
BTANK
LEVEL CONTROLS
PG-2
CUSTOMERI/O 100V TO 250V AC
PG-8
START
MACHINE I/O
PG-1
1
3
4
2
EXT
LOAD DISP RET
106
VALV E
108 107
SPOOL
105
CYLINDER
AIR
7
2
5 34
6
1
7
2
5 34
6
1
7
2
5 34
6
1
12
56
3
7
12
9
13
10
14
11 8
4
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
1
3
4
2
EXT
LOAD DISP RET
106
VALV E
108 107
SPOOL
105
CYLINDER
AIR
NOTICE
Feed system and main logic control system must
use separate air supplies.
7
2
5 34
6
1
7
2
5 34
6
1
7
2
5 34
6
1
12
56
3
7
12
9
13
10
14
11 8
4
SIGNAL CONNECTION
PG-3
ATANK
LEVEL CONTROLS
PG-4
BTANK
LEVEL CONTROLS
PG-2
CUSTOMERI/O 100V TO 250V AC
PG-8
START
MACHINE I/O
PG-1
1
3
4
2
EXT
LOAD DISP RET
106
VALV E
108 107
SPOOL
105
CYLINDER
AIR