Graco PD44 Manual instruction

313877J
EN
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
Related Manuals
Models
Manual in
English Description
PD44 Manuals
313876 PD44 Dispense Valve Operation - Parts
3A5656 HMI Replacement Kit for PD44
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
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
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
ST
A B C H J G F E
KM N P R
L

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
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
K
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
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
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