Graco PD44 User manual

313904B
Instructions
Pneumatic PD44
Patented meter, mix and dispense valve for precise two-component micro-dispensing.
SN8048, SN8049, SN8051,
SN8052, SN8053, SN8054
2200 psi (15 MPa, 152 bar) Maximum Outlet Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Working Pressure
Metal Sleeves: 1200 psi (8 MPa, 83 bar) Maximum Inlet Working Pressure
Plastic Sleeves: 400 psi (2.8 MPa, 28 bar) Maximum Inlet Working Pressure
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
2313904B
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Identification . . . . . . . . . . . . . . . . . . . . 9
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Other Features . . . . . . . . . . . . . . . . . . . . . . . . . 10
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjusting the Shot Size . . . . . . . . . . . . . . . . . . . . 12
Ratio Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sequence of Operation . . . . . . . . . . . . . . . . . . . 14
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Metering Rod Alignment . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wetted Section Disassembly . . . . . . . . . . . . . . . 19
Wetted Section Reassembly . . . . . . . . . . . . . . . 20
Spool Valve Rebuild . . . . . . . . . . . . . . . . . . . . . . 22
Wetted Section Rebuild . . . . . . . . . . . . . . . . . . . 23
Micrometer Drive Rebuild
(Micrometer PD44 Only) . . . . . . . . . . . . . . . 25
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Graco Ohio Standard Warranty . . . . . . . . . . . . . . 30
Graco Ohio Information . . . . . . . . . . . . . . . . . . . . . 30
Related Manuals
Pneumatic PR70 Manual
Part Description
313937 Pneumatic PR70 Instructions
MD2 Dispense Valve Manual
Part Description
312185 MD2 Dispense Valve Instructions and Parts Manual

Warnings
313904B 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
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.
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.

Warnings
4313904B
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.
WARNING

Warnings
313904B 5

Grounding
6313904B
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
313904B 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
8313904B
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
313904B 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.
Dispense Valve
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
FIG. 3

Component Identification
10 313904B
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.

Initial Startup
313904B 11
Initial Startup
NOTE: Some on-site assembly may be required prior to
initial startup. See assembly drawings for more informa-
tion.
2.
1. Go through the Pre-Operation Checklist in the fol-
lowing table.
2. Close all ball valves and all other valves within the
feed systems.
3. Place an in-line regulator and shut-off valve
between the machine and the air supply.
4. Connect a 3/8 in. or larger diameter air supply line to
the air inlet.
5. Connect the required electrical power to the
machine as indicated on the identification name-
plate and logic drawings.
6. Check the tightness of all fittings.
✔Checklist
System Grounded
Verify all grounding connections were made. See
Grounding, page 6.
All connections are tight and correct
Verify all fluid, air, and system connections are
tight and installed according to the supplied sche-
matics.
Air supply valves are open
Verify all Incoming Air Ball Valves are open.
Fluid supply valves are open
Verify all Fluid Line Ball Valves are open.

Adjusting the Shot Size
12 313904B
Adjusting the Shot Size
Follow these instructions to adjust the shot size of your
machine. Repeat this procedure every time an adjust-
ment is required.
1. Set Pump Mode switch to EXTEND. The metering
rods will extend down and stop.
2. Turn counterclockwise the shot size locking ring to
loosen.
3. Turn the shot size adjuster to the desired shot size.
4. Turn the Pump Mode switch to SHOT. The drive pis-
ton and metering rods will retract.
5. Turn clockwise the shot size locking ring to tighten.
NOTE: If the LED on the Extend Proximity switch is illu-
minated, skip the following step. See the following image
for Extend Proximity switch location.
6. If LED on the Extend Proximity switch is not illu-
minated, slide the proximity switch until the LED on
the proximity switch is illuminated.
NOTE: The lower proximity switch (RETRACT proximity
switch (PX-RET) is factory preset and does not need to
be adjusted. If the lower proximity switch is changed
from the factory setting, see the assembly drawings for
more information on readjustment. This switch is
marked with a RET tag on the wire.
Extend Proximity
Switch

Ratio Check
313904B 13
Ratio Check
The Ratio Check is a simple procedure where individual
samples of material are collected from each valve,
weighed, and compared to the manufacturer’s desired
outputs. It is recommended that you do a ratio check at
startup and rebuild.
1. Initiate shot.
2. Remove Posimixer then cycle machine several
times into waste container to clear and prime.
3. Weigh six small cups and label as indicated. Record
weights.
4. Install the ratio check nozzle.
5. Prime the ratio check nozzle.
6. Place cups as indicated under ratio check nozzle
and cycle machine once.
7. Repeat until all three sets of cups have been used.
8. Re-weigh all six cups and record weights.
9. Subtract weight of empty cups from weight of filled
cups to get material weights.
10. Complete ratio calculations.

Operation
14 313904B
Operation
Always add compatible lubricant such as mesamoll or
silicone oil to the dispensing rod wet cups prior to opera-
tion.
Sequence of Operation
Step 1: Reload
• Spools shift to the right.
• Material feed inlets are opened
• Materials are transferred into the metering cham-
bers by a pressurized feed system
• Outlet ports are blocked
• Metering rods are retracted to a precise position
determining the volume of each material
Step 2: Shift
• The balanced spool assemblies shift to the dis-
pense position
• Material path to the mixer inlet is opened
• Material feed inlet ports are blocked
• Metering rods remain in the retracted position
Step 3: Dispense
• Metering rods extend
• A and B materials are simultaneously dispensed
from the metering chamber into the disposable
mixer.
• A and B materials are dispensed at the predeter-
mined volume ratio.
Upon completion of the dispense stroke, the metering
rod and spool assemblies shift back to the reload posi-
tion.

Startup
313904B 15
Startup
1. Go through the Pre-Operation Checklist in the fol-
lowing table.
2. Perform material loading and ratio check proce-
dures.
3. Install Posimixer and shroud.
4. Cycle machine several times to prime the mixer.
Shutdown
1. Bleed air from machine.
NOTE: Water contamination will dramatically shorten, if
not end, pneumatic valve life.
2. Inspect the valve shafts for material buildup. Clean
and lubricate.
3. Install night cap (storage cap).
See startup instructions and related warnings in sup-
plied manuals. See Related Manuals on page 2.
✔Checklist
System Grounded
Verify all grounding connections were made. See
Grounding, page 6.
All connections are tight and correct
Verify all fluid, air, and system connections are
tight and installed according to the supplied sche-
matics.
Air supply valves are open
Verify all Incoming Air Ball Valves are open.
Fluid supply valves are open
Verify all Fluid Line Ball Valves are open.

Maintenance
16 313904B
Maintenance
Perform the following procedures once a shift or as
required.
NOTE: If material is leaking, see Troubleshooting on
page 18.
Material Reservoirs
Check material levels and refill as necessary. Ensure
that the material reservoirs are vented properly. (Dry Air,
Nitrogen, etc.)
Air Dryer
Check the condition of the desiccant air dryer.
Wetcups
Refill wetcups with compatible lubricant such as mesa-
moll or silicone oil.

Metering Rod Alignment
313904B 17
Metering Rod Alignment
Metering rod alignment must be completed whenever
the metering rods are removed from the valve.
1. Disconnect the main air supply and bleed air from
the machine by pushing the tube on the bottom of
regulator.
2. Place the oil cup-retaining block on the valve and
evenly tighten the screws.
3. Manually extend the metering rods fully.
4. Slide the metering rod retainer on the connecting
block.
5. Manually retract the metering rods. Ensure that they
are firmly in place by physically checking.
6. Turn the valve sideways and use the guide rods to
ensure that the metering rod assemblies are in line
with the guide rod.

Troubleshooting
18 313904B
Troubleshooting
Problem Cause Solution
PosiDot stalling and no material
being PosiDoted despite adequate
input pressure.
Blocked mixer. Check mixer for cured material,
replace mixer as required.
Flow control valve closed. Open.
PosiDots not discharging normal or
full volume.
Low material level in reservoirs. Fill material reservoirs and prime the
machine
Air in material tanks. Fill reservoirs and prime machine.
Motionless Mixer (after satisfactory startup)
Partially unmixed material through
cycle.
Mixer not clean or free. Remove and replace the mixer.
Material leaks past spool valves. Spool valve worn or damaged. Replace the spool valve and sleeve.
Material leaks around mixer while
dispensing
Cured material in mixer. Check mixer for cured material,
replace mixer.

Rebuild
313904B 19
Rebuild
NOTE: See assembly drawings for more information.
Wetted Section Disassembly
1. Mark and disconnect all material feed lines, pneu-
matic lines, and proximity switch wiring. Remove the
dispense valve from mounts.
2. Remove the four cap screws to remove the rear tie
plate.
NOTE: The rear tie plate is tie plate with the proximity
switches.
3. Slide the material rod retaining plate until the larger
hole position matches the material rod.
4. Once the material rod plate is in position, slide the
material rod away from the retaining plate.
5. Once the pneumatic material rods are disconnected
from the retaining plate, remove the four cap screws
from the front tie plate.
6. Separate the pneumatic drive cylinder and the valve
guides from the metering block.
7. Disassemble the pneumatic spool drives.
8. Remove the two cap screws located at the top of the
upper metering rod block.
Cap Screws
Retaining Plate
Material Rod
Cap Screws
Cap Screws
Upper Metering Block

Rebuild
20 313904B
9. Remove the material rods and upper metering rod
block.
10. Remove the eight cap screws attaching the material
inlet blocks. Remove the material inlet blocks.
11. Remove the two material rods and sleeves.
NOTE: Always keep rods and sleeves together as they
are a matched set.
12. Remove the protruding cap screws on the each
spool block.
13. Remove the two pneumatic spools.
Wetted Section Reassembly
1. Install the pneumatic spool rod drive.
2. Repeat for other side.
Material Rod
Upper Metering Rod Block
Material Inlet Blocks
Sleeve
Cap Screws
Spool Block