Graco 3A0260H- User Manual

Models 3A0260H 5 Remote Dispense Valves Fixed Dispense Valves Accessories Part Description 243694 Heated Dispense Valve 244951 Endure Valve ™ , Heated, 1/2 in. npt male outlet 244909 Endure Valve, Heated Part Description 244907 Endure Valve snuff-back Part Description 24D824 Automation I/O Cable 24E...

Warnings 6 3A0260H Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol aler ts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-s...

Overview 3A0260H 9 Overview System Configurations Typical Heated System Installation Key:AA *Control Center (User Interface)AB *Gear Meter AssemblyAC Applicator/Dispense Valve†AD Automation RobotAE Automation Interface Cable †AF *Gear Meter Cables AG Heated Fluid Supply SystemAH Fluid Supply HoseAJ ...

Overview 10 3A0260H Typical Ambient System Installation Key:A *Control Center (User Interface) B *Gear Meter Assembly C *Applicator/Dispense Valve D Automation Robot E Automation Interface Cable† F Gear Meter Cables G Fluid Supply System H Fluid Supply Hose J Automation Controller K Air Filter Assem...

Overview 3A0260H 11 Component Identification F IG . 3 Key: 1 Gear Meter 2 System Controls Box 3 User-Interface Touch Display 4 External Control Interface Connections 5 Power Input 6 Main Power Switch 7 Emergency Stop 8 Pump Fault Indicator Light 9 Control Power On/Off buttons 10 Pump Ready Light11 M...

Overview 12 3A0260H System Overview The PGM system provides positive displacement meter-ing for precision bead control. The control accepts auto-mation signals to provide accurate and consistent output flow. The gear meter can achieve high flow rates with high viscosity materials. Control Power On/O...

Installation 3A0260H 13 Installation Before Installation • Have all system and component documentation available during installation. • See component manuals for specific data on compo-nent requirements. Data presented here applies to the PGM assemblies only. • Be sure all accessories are adequately...

Installation 14 3A0260H Install Control Center Mount Ensure the following criteria are met before mounting the PGM control center: • Select a location for the control center that allows adequate space for installation, service, and use of the equipment. • For best viewing, the user interface should ...

Installation 3A0260H 15 Electrical Connections Install Gear Meter Assembly To install the PGM metering assembly: • Mount the gear meter assembly. • Ground gear meter assembly. • Connect the gear meter assembly to the control cen-ter. • Connect fluid lines and cables. Mount Before Mounting Assembly •...

Installation 3A0260H 17 Grounding Ground the gear meter assembly as instructed here and in the individual component manuals. Make sure the gear meter assembly and its components are installed correctly to ensure proper grounding. Air and Fluid Hoses For static dissipation, use only electrically cond...

Installation 18 3A0260H Install Cable Assemblies 1. Connect servo motor power and feedback cables. 2. Connect pressure transducer cable. 3. Connect dispense valve solenoid cable. 4. Connect heat cables, if equipped, to Therm-O-Flow controller. F IG . 9: Cable Installation Diagram ti22239a Remote mou...

System Setup 3A0260H 19 System Setup Overview The PGM system compensates for temperature, flow, or pressure fluctuations. However, if there is a hardware change on the supply system or the dispense material is changed, the PGM system must be setup again. After material is loaded into the supply syst...

System Setup 20 3A0260H Configure Control Settings Set the controls for the dispense source, how dispense commands are sent, and auto mode settings. 1. From the Home screen, select the Setup icon . NOTE: The Setup screens are password protected. Enter password “PGM10”to access the following screens....

System Setup 3A0260H 21 Configure Delay Settings Set on and off delays (in milliseconds) for the dispense valve. 1. With the system in setup mode, press to navi- gate to the Delay Settings screen. 2. Press the On Delay field and enter a desired delay value in milliseconds. Default is zero millisecon...

System Setup 22 3A0260H Configure Errors Set the error type (error or deviation) that will be issued if the pressure or drive torque goes outside the set high and/or low limits. See Appendix A - User Interface Display on page 81 for information on the purpose of each error type. NOTE: When an alarm ...

Operation 3A0260H 23 Operation Startup Initial Startup 1. Ensure the PGM control enclosure and all of the proper connections to and from the control enclo-sure have been made. Ensure fittings are tight. 2. Read and understand the Operation and User Inter-face sections of this manual. 3. Continue sta...

Operation 24 3A0260H Maintenance Mode Operation Operating from maintenance mode enables the pump to begin dispensing when the user presses . Dis- pense parameters and duration depend on the selected control. Verify System Operation Use maintenance mode to manually check the operation of the PGM syst...

Operation 3A0260H 25 Calibration 1. Perform Startup procedure, page 23. Verify all sys-tem components are at desired pressures and tem-peratures. Adjust as desired. 2. Navigate to the Calibrate screen. See Screen Navi-gation Diagram on page 81 in the Appendix A - User Interface Display section. 3. P...

Operation 3A0260H 27 Automation Control (Normal) Operation During automation control (normal operation) the PGM automatically dispenses when it receives a command from the automation unit. NOTE: See Appendix B - I/O on page 95. To enter Auto mode, select Auto (A) Control Mode . Typical Automation Cy...

Pressure Relief Procedure 28 3A0260H Pressure Relief Procedure 1. Shut off the fluid supply to the PGM inlet block. 2. If equipped, place a waste container beneath the fluid drain valve under the filter. 3. Place a waste container beneath the dispense valve. 4. Slowly open the drain valve at each fl...

Shutdown 30 3A0260H Shutdown 1. Press the Stop button. See F IG . 17. 2. Shut off the material supply to the gear meter/meter. 3. Shut off heat to PGM. See related manuals section for Therm-O-Flow manual and Accessory Heat Con-trol. 4. Shut off power and air to the fluid supply system. 5. Turn off t...

Troubleshooting 3A0260H 31 Troubleshooting NOTE: Check all possible solutions in the chart below before you disassemble the system. Refer to Supply Systems manual for additional trouble-shooting; refer to Related Manuals on page 3. Also refer to Error Codes and Troubleshooting, page 33. PGM Fluid As...

Troubleshooting 32 3A0260H Dispense Valves Measured flow does not match command Supply pressure too low Verify inlet pressure needed for flow rate Flow rate too high for application Perform dispense weight verification, see Calibration procedure on page 25; Lower flow rate and repeat Gear meter is n...

Errors 3A0260H 33 Errors View Errors Errors can be viewed from the Home screen or from the Alarm View screen. There are three levels or errors: alarms, deviations, and advisories. Alarms are critical and require immediate correction; therefore the system automatically shuts down. Deviations are impo...

Maintenance 36 3A0260H Maintenance Prior to performing any maintenance procedures, follow the Pressure Relief Procedure on page 28. Maintenance Schedule The following tables list the recommended maintenance procedures and frequencies to operate the equipment safely. The maintenance is divided betwee...

Repair 3A0260H 37 Repair NOTE: Refer to Parts section beginning on page 51 for part reference number identification. Gear Meter Assembly This section describes how to remove and replace com-ponents on the gear meter assembly. Prepare Gear Meter Assembly for Repair 1. Perform Pressure Relief Procedur...

Repair 38 3A0260H Install Servo Motor or Gearhead 1. Remove key from motor shaft. 2. Slide the gear head bushing into the drive coupling and align slots in drive coupling and bushing. See F IG . 19. 3. Rotate the drive coupling to align clamping bolts with access holes. 4. Place motor on work surfac...

Repair 3A0260H 39 5. Loosen clamping bolts on each side of coupling and remove coupling. NOTE: Pump shaft key may fall out during coupling removal. Secure pump shaft key until coupling is replaced. Install Coupling 1. Slide coupling onto gear head output shaft. Tighten coupling bolt just enough to h...

Repair 40 3A0260H Remove Dispense Valve 1. Prepare Gear Meter Assembly for Repair, page 37. 2. Manually actuate solenoid to ensure pressure has been removed. 3. Verify air supply is off. 4. Remove air lines from dispense valve. 5. Remove four dispense valve mounting bolts and remove dispense valve. ...

Repair 3A0260H 43 PGM-6 Pump Disassembly 1. Prepare Gear Meter Assembly for Repair, page 37. 2. Refer to Gear Pump Maintenance Guide on page 49 for special notes regarding gear pump repair. 3. Remove four pump block shoulder bolts (1102). 4. Remove drive assembly. See F IG . 23. 5. Remove seal retai...

Repair 3A0260H 47 PGM-20 Pump Disassembly 1. Prepare Gear Meter Assembly for Repair, page 37. 2. Refer to Gear Pump Maintenance Guide on page 49 for special notes regarding gear pump repair. 3. Remove six pump block shoulder bolts (4). 4. Remove drive assembly. See F IG . 23. 5. Remove seal retainer...

Repair 3A0260H 49 Gear Pump Maintenance Guide Review these guidelines prior to performing any mainte-nance on the pumps. • Do not run pump dry. • Do not pull from a vacuum or negative suction head. • Do not flush with water or other non-lubricating fluid. • Do not pump corrosives, abrasives and/or f...

Repair 50 3A0260H Installing new heater units and RTD sensors 1. Prepare Gear Meter Assembly for Repair, page 37. 2. Disconnect the power cables from the heaters. 3. Remove two M3 screws to remove the kit from the inlet block. 4. Remove two M6 screws to remove the kit from the pump block. 5. Remove ...

Parts 3A0260H 51 Parts PGM-20 Mounting Frame 12 11 10 9 3 8 1 4 2 5 ti21285a Ref Part Description Qty 1 124164 SCREW, shcs, M6-1.0 x 25 4 2 124165 SCREW, bhcs, M5-0.6 x 10 4 3 124166 SCREW, bhcs, M6-1.0 x 10 4 4 124167 SCREW, shoulder, 10x30, M8-1.25 6 5 124168 SCREW, shoulder, 8 x 6, M6-1.0 8 8 16D...

Parts 52 3A0260H PGM-20 Lower Assembly Block † Part included in o-ring kit 24E626. * For part breakdown and repair kits, refer to PGM-20 Pump Repair, page 46. 103 108 104 101 101 102 105 109 106 107 110 Ref Part Description Qty 101 101970 PLUG, pipe, headless 2 102 124173 SCREW, M6-1.0 x 90 4 103 12...

Parts 3A0260H 53 PGM-20 Pump Heat Kit  Replacement Danger and Warning labels, tags, and cards are available at no cost. 203 201 202 1 3 204 1 1 Ground location. 3 206 206 205 Ref Part Description Qty 201 117764 SENSOR, pressure 2 202 24E412 KIT, heat, pump, PGM-20 1 203 24E413 KIT, heat, PGM, inlet...

Parts 54 3A0260H PGM Drive - 20 cc Pump 301 302 303 302a Ref Part Description Qty 301 16D947 MOTOR, PGM drive, servo, 4 frame 1 302 16D946 GEAR REDUCER, PGM drive, 50:1, 80mm frame 1 302a COVER 1 303 16D945 COUPLING, PGM drive, 18x20mm, w/key 1

Parts 3A0260H 55 Endure Dispense Valve Fix Mounted 410 403 405 412 404 409 411 402 406 401 408 406 407 Ref Part Description Qty 401 597151 FITTING, elbow, 1/4 tube x 1/8 NPT, male 1 402 117820 SCREW, cap, socket head, M3 2 403 124200 SCREW, socket head cap screw, M6-1.0 x 30, stainless steel 4 404 1...

Parts 56 3A0260H Gear Meter Assembly Panel 651 603 617 614 614 616 614 615 615 616 617 622, 625 618 626, 612 609 608 606 604 605 602, 623 611, 612, 613 610 620 619 601 607 624 652

Parts 3A0260H 57  Replacement Danger and Warning labels, tags, and cards are available at no cost. Cables Ref Part Description Qty 601 ENCLOSURE, control, gear meter painted 1 602 24F386 MODULE, HMI, PGM 1 603 121148 HANDLE, disconnect, electric 1 604 81/2060-P/11 BUTTON, dual, grn/red, w/pl-wht 1 ...

Parts 58 3A0260H PGM Back Panel 718, 720 716, 720 718, 720 716 709 717 706 707 731 702, 707 701 704 729 705 728 719, 721 710, 725 715, 723, 724 727 718, 720 726, 728 717 714 722* 722* 712, 730 713 708 711 Ref Part Description Qty 701 PANEL, back, for30x24 encl, conduit 1 702 123361 SWITCH, disconnec...

Parts 3A0260H 59  Replacement Danger and Warning labels, tags, and cards are available at no cost. * Inline amplifiers are not mounted on panel controls with 15 m cables. Remote Mount Amplifiers Only for control centers with 15 m cables. Mount 1. Remove cover. 2. Insert #8 machine screws or equival...

Parts 60 3A0260H PGM Remote Dispense Valve 809 807 808 805 804 Ref Part Description Qty 804 FITTING 1 805 117820 SCREW, cap, socket head, M3 2 807 124200 SCREW, shsc, M6-1.0 x 30, stain- less steel 4 808 198446 VALVE, dispense, closer 1 809 16E055 BLOCK, outlet, PGM, 3/4 NPTF, stainless steel 1

Parts 3A0260H 61 PGM Transducer 901 901 901 20 cc Pump 6 cc Pump 901 Ref Part Description Qty 901 117764 SENSOR, pressure 2

Parts 64 3A0260H PGM-6 Lower Assembly Block † Parts are available in o-ring kit 24E677. * For part breakdown and repair kits, refer to PGM-6 Pump Repair, page 42. 1303 1309 1304 1308 1302 1307 1301 1305 1306 Ref Part Description Qty 1301 101970 PLUG, pipe, headless 2 1302 124173 SCREW, shcs, M6-1.0 ...

Schematics 66 3A0260H Schematics F IG . 29: Schematics, Page 1 of 10 140 149 147 145 142 110 138 136 134 132 130 128 126 124 122 120 118 114 116 112 108 106 104 102 100 141 148 144 146 143 111 139 137 135 133 131 129 127 125 123 121 119 115 117 113 109 107 105 103 101 50-60HZ 1PH/ 230V/ DISC-1 L2 1L...

Schematics 3A0260H 75 F IG . 38: Schematics, Page 10 of 10 585 595 593 591 587 555 583 581 579 577 575 573 571 569 567 565 563 559 561 557 553 551 586 594 589 592 588 556 584 582 580 578 576 574 572 570 568 566 564 560 562 558 554 552 550 598 596 599 597 590 GROUND DIST. BAR FIGURE 2 NTS PE GROUND S...

Accessory Parts 76 3A0260H Accessory Parts Automation Interface Cable Assembly The cable length of automation interface cable assembly 24D824 is 40 ft (12.2 m). This figure shows the cable and identifies the cable interface signals. See Appendix B - I/O on page 95 for wiring details. See Appendix C ...

Accessory Parts 3A0260H 77 Dynamic Regulators 1011 1004 1008 1006 1010 1013 1001 1005 1004 1004 1014 1016 1003 1002 1012 1007 1009 1018 1017 1021 1020 1019 Ref Part Description Qty 1001 112699 TUBE, 1/4 OD 2 1002 C20466 FITTING, nipple, hex 1 1003 112307 FITTING, elbow, street 1 1004 100139 PLUG, pi...

Accessory Parts 78 3A0260H Dynamic Regulator Setup and Installation 1. Remove air pressure from Therm-O-Flow supply system. See Pressure Relief Procedure in manual 311208. 2. Install dynamic regulator kit. See F IG . 39 on page 79. 3. Apply air to the Therm-O-Flow supply. Check for air leaks. 4. Set...

Accessory Parts 3A0260H 79 Dynamic Regulator Installation The dynamic regulator kit is used to control the static pressure of a Therm-O-Flow. The PGM has a maximum inlet pressure of 1500 psi. During dispense the dynamic regulator kit will activate the normal regulator located on the front panel of t...

Accessory Parts 80 3A0260H Endure Valve Nozzles Heater Nests Part Description 24E654 10 x 1.5 mm Ribbon Nozzle24E655 1/8 in. Bead Nozzle Part Description 24E678 Heater Nest with Blank Insert24E679 Heater Nest with Por ted Insert

Appendix A - User Interface Display 3A0260H 81 Appendix A - User Interface Display Screen Navigation Diagram Screen #1 Current Setup Screen Screen #2 Screen #3 Screen #4 Screen #5 Main START MACHINE Maintenance Home Calibrate Robot I/O Setup Screens Flow Supply Pump Setup Screens Alarm Screen Screen...

Appendix A - User Interface Display 82 3A0260H Main Screen Press the appropriate button to navigate to either the Home or Calibration screen. Enter password “PGM10”to access the Calibration screen. Key: A Navigate to the Home screen B Navigate to the Calibrate screen A B

Appendix A - User Interface Display 3A0260H 85 Home Screen Manual Mode In Manual Mode, the machine only accepts signals from the User Interface touch screen and the physical buttons on the machine. All signals from an External Control Interface to initiate a shot will be ignored. Automatic Mode In A...

Appendix A - User Interface Display 86 3A0260H Maintenance Screen Dispense Valve Control When Automatic Dispense Valve Control is enabled, the dispense valve will open and close as needed to dis-pense material. When Open the Dispense Valve is selected, the dis-pense valve will open and remain open u...

Appendix A - User Interface Display 88 3A0260H Setup #1 Screen #1 to #6 Buttons Press to navigate to the Setup Screen with that number. For example, press #3 to navigate to Setup Screen #3. Command Value Source Command Values can be controlled by the user-inter-face touch screen or by an external ma...

Appendix A - User Interface Display 90 3A0260H Setup #3 Screen #1 to #6 Buttons Press to navigate to the Setup Screen with that number. For example, press #3 to navigate to Setup Screen #3. Delay Settings The Delay Settings affect the timing of the Dispense Valve opening and closing when a shot is i...

Appendix A - User Interface Display 3A0260H 91 Setup #4 Screen #1 to #6 Buttons Press to navigate to the Setup Screen with that number. For example, press #3 to navigate to Setup Screen #3. Pump Settings Snuff Back: This enables the gear meter to rotate in reverse, immediately following dispensing, ...

Appendix A - User Interface Display 94 3A0260H Supply Pump Screen NOTE: This screen is used to control the optional dynamic regulator kit for a Therm-O-Flow. See Accessory Parts section on page 76 for additional information on the dynamic regulator kit option. Dynamic Regulator Primary Pump • Auto M...

Appendix B - I/O 3A0260H 95 Appendix B - I/O Using the PGM I/O The gear meter uses several I/O signals to communicate with plant automation controllers. There are two digital inputs, three digital outputs, and one analog input. All of these signals are routed to the I/O connector on the top of the c...

Appendix B - I/O 96 3A0260H Digital Outputs The three digital outputs are Dispenser Ready, Fault Present and In Cycle. These outputs perform high-side switching of 24 VDC and require a 24 VDC current sink-ing input at the automation controller. See F IG . 41. If the automation controller uses 24 VDC...

Appendix B - I/O 3A0260H 97 Analog Inputs The PGM receives a flow rate analog command from the automation. The 0 to 10 VDC analog input is refer-enced to analog common on the control. See F IG . 42. The reference for the automation controller analog out-put must be connected to the PGM analog refere...

Appendix C - Theory of Operation 98 3A0260H Appendix C - Theory of Operation Theory of Operation Input and Output Signals Terminology For the purpose of this document a digital signal is said to be SET when voltage is present (or above the mini-mum threshold). A signal is said to be RESET when the s...

Technical Data 3A0260H 99 Technical Data * Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expected to shear under pressure. New applications or fluids should always be tested to determine proper line sizes and equipment selections. See your Graco...

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/patents. Original instructions. This manual contains Eng...