Instructions - Parts PGM Precision Gear Metering For metering and dispensing ambient or high-temperature, high-viscosity single-component materials. Not approved for use in European explosive atmosphere locations. For professional use only. 2500 psi (17.2 MPa, 172 bar) Maximum Working Outlet Pressure 1500 psi (10.3 MPa, 103 bar) Maximum Working Inlet Pressure See Technical Data on page 99 for temperature ranges Important Safety Instructions Read all warnings and instructions in this manual.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bulk Melt (Therm-O-Flow 20 + Therm-O-Flow 200) and Ambient Hoses . . . . . . . . . . . . . . . . . . . 4 Remote Dispense Valves . . . . . . . . . . . . . . . . . . 5 Fixed Dispense Valves . . . . . . . . . . . . . . . . . . . . 5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Warnings . . . . . . . . . . . . . . . . . . . . .
Related Manuals Appendix A - User Interface Display . . . . . . . . . . 81 Screen Navigation Diagram . . . . . . . . . . . . . . . . 81 Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Calibrate Screen #1 . . . . . . . . . . . . . . . . . . . . . . 83 Calibrate Screen #2 . . . . . . . . . . . . . . . . . . . . . . 84 Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Maintenance Screen . . . . . . . . . . . . . . . . . . . . . 86 Robot I/O Screen . . . . . . . . . . . .
Models Models Check the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to define the construction of the system, based on the six digits. For example, Part PG0111 represents a PGM fluid metering system (PG), with a 6cc system (0), unheated (1), with controls/3m (1), and an Endure snuff-back (1). NOTE: To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the Ref. Nos.
Models Remote Dispense Valves Part Description 243694 Heated Dispense Valve 244951 Part Description 124238 Adapter Fitting, 3/4 in. Tube x 16 SAE 124239 Adapter Fitting, 1 in. Tube x 16 SAE 124240 Adapter Fitting, 1-1/4 in. Tube x 16 SAE 124241 Adapter Fitting, 16 SAE x 1 in. NPTF 124242 Swivel, 16 SAE x 1 in. NPTF 124243 Swivel, 16 SAE x 1 in.
Warnings 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 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 ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
Warnings 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.
Warnings WARNING 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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to: • • 8 Protective eyewear, and hearing protection. Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
Overview Overview System Configurations Typical Heated System Installation Air Supply Drop Site Power AE AA* AK AL AF* AH AB* AN AH AM AG AJ AH AC AD AO AO FIG.
Overview Typical Ambient System Installation E Air Supply Drop Site Power A* J F* K B* C* H G D FIG.
Overview Component Identification 4 2 5 3 6 7 1 10 8 9 11 12 Key: 1 2 3 4 5 6 Gear Meter System Controls Box User-Interface Touch Display External Control Interface Connections Power Input Main Power Switch 7 8 9 10 11 12 Emergency Stop Pump Fault Indicator Light Control Power On/Off buttons Pump Ready Light Manual Purge Button Dispense Valve FIG.
Overview System Overview Typical Applications • Solar Panel • Perimeter Seal • Desiccant • Edge Seal • Automotive Manufacturing • Window and Door General Assembly FIG. 4: Control Center Dimensions The PGM system provides positive displacement metering for precision bead control. The control accepts automation signals to provide accurate and consistent output flow. The gear meter can achieve high flow rates with high viscosity materials.
Installation Installation Before Installation Overview • Have all system and component documentation available during installation. • See component manuals for specific data on component requirements. Data presented here applies to the PGM assemblies only. The basic steps to install a PGM system are shown below. See the separate component manuals for detailed information on supply systems and dispense valves.
Installation Install Control Center Mount Secure the control center with appropriate size bolts through the 0.50 in. (13 mm) diameter holes. See the mounting dimensions in the following table and FIG. 5. Control Center Assembly Measurement 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 be 60-64 in.
Installation Install Gear Meter Assembly Electrical Connections To install the PGM metering assembly: Follow these precautions when grounding, connecting cables, connecting to a power source or making other electrical connections. • Mount the gear meter assembly. • Ground gear meter assembly. • Connect the gear meter assembly to the control center. • Connect fluid lines and cables.
Installation 2. Mount and secure the gear meter assembly to the automation unit (or other mounting surface) with mounting plate. The mounting plate is tapped with M10 x 1.5 bolts. Maximum bolt length through plate is 0.75 in. (19 mm). See the mounting dimensions in Table 4 and FIG. 7. Table 4: Gear Meter Assembly Measurement 6 cc Pump 20 cc Pump A 2.00 in. (50.8 mm) 3.00 in. (76.2 mm) B 5.00 in. (127 mm) 3.875 in. (98.43 mm) C 2.375 in. (60.33 mm) 2.313 in. (58.75 mm) D NA 1.063 in. (27.
Installation Grounding • See page 4 for list of inlet fittings. NOTICE If power and grounding connections are not done properly, the equipment will be damaged and the warranty voided. 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 conductive hoses or ground the applicator / dispense valves.
Installation Install Cable Assemblies 1. Connect servo motor power and feedback cables. 3. Connect dispense valve solenoid cable. 2. Connect pressure transducer cable. 4. Connect heat cables, if equipped, to Therm-O-Flow controller. Remote mount amplifier on units with 15 meter cables only. ti22239a FIG.
System Setup System Setup Overview System Setup 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. Configure Control Settings (page 20) Configure Mode Settings (page 20) After material is loaded into the supply system, set up the PGM system using the Setup screens. FIG. 10 shows the major system setup steps.
System Setup Configure Control Settings Configure Mode Settings Set the controls for the dispense source, how dispense commands are sent, and auto mode settings. Set the dispense mode (bead or shot). The bead scale and pre-charge are also adjustable from the Mode Settings screen. 1. From the Home screen, select the Setup icon NOTE: See Appendix A - User Interface Display on page 81 for a description of each feature. . NOTE: The Setup screens are password protected.
System Setup Configure Delay Settings Adjust Pressure Sensors Set on and off delays (in milliseconds) for the dispense valve. Set pressure offsets and pressure limits. 1. With the system in setup mode, press 1. With the system in setup mode, press to navi- to navi- gate to the Pressure Sensor screen. gate to the Delay Settings screen. FIG. 14 FIG. 13 2. Press the On Delay field and enter a desired delay value in milliseconds. Default is zero milliseconds. 2.
System Setup 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 is set to Error the machine will be disabled when the alarm occurs. 1. With the system in setup mode, press to navi- gate to the Errors screen. FIG. 15 2.
Operation Operation Startup Load Material Before using the system material must be loaded into the supply system. Initial Startup 1. If this is a new installation, follow the Initial Startup procedure. Otherwise, follow the Standard Startup procedure. 1. Ensure the PGM control enclosure and all of the proper connections to and from the control enclosure have been made. Ensure fittings are tight. 2. Turn on the fluid supply pressure to the fluid inlet block for the PGM. 2.
Operation Maintenance Mode Operation 4. Record a minimum of 5 shot weights. Operating from maintenance mode enables the pump to 5. If shot weights are inconsistent check feed pressure or reduce flow rate and repeat shot test. begin dispensing when the user presses . Dis- pense parameters and duration depend on the selected control. NOTE: Regular weight checks are recommended to ensure system is performing properly.
Operation Calibration 10. Weigh a second disposable container and tare the scale. 11. Place container below dispense nozzle. 1. Perform Startup procedure, page 23. Verify all system components are at desired pressures and temperatures. Adjust as desired. 12. Press the Start High Speed Calibration button 2. Navigate to the Calibrate screen. See Screen Navigation Diagram on page 81 in the Appendix A User Interface Display section. 3. Press the Enable Calibration button . 4.
Operation Dispense from Maintenance Screen 1. Navigate to the Maintenance screen. See Screen Navigation Diagram on page 81 in the Appendix A - User Interface Display section. 2. Select Manual (M) Control Mode . 3. From the Mode drop-down menu, select Bead or Shot Mode. Manually Dispense Fluid 1. Press and verify the dispense valve opens. 2. Continue to press as long as needed to load or dispense material. Release to stop dispensing. 3. If desired, press to navigate to the Home screen.
Operation 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 Cycle In order for the system to run it must be in Auto mode.
Pressure Relief Procedure Pressure Relief Procedure d. Continue to dispense until the inlet pressure on the PGM is near zero. 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. e. Visually locate the plug installed at the back of the inlet block. f. Place a container under the plug and slowly remove the plug to relieve remaining inlet pressure. 7.
Pressure Relief Procedure 8. If the dispense device cannot be actuated from the control center, refer to FIG. 16 and perform the following steps to open the dispense valve and relieve fluid pressure: a. Manually actuate the plunger on the solenoid, that opens the dispense valve to relieve fluid pressure. Refer to FIG. 16. b. Continue actuating the plunger until all pressure is purged from the system between the needle and dispense valve before proceeding to the next step.
Shutdown Shutdown 1. Press the Stop button. See FIG. 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 Control. 4. Shut off power and air to the fluid supply system. 5. Turn off the main power supply. FIG.
Troubleshooting Troubleshooting NOTE: Check all possible solutions in the chart below before you disassemble the system. Refer to Supply Systems manual for additional troubleshooting; refer to Related Manuals on page 3. Also refer to Error Codes and Troubleshooting, page 33.
Troubleshooting 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 not calibrated Perform calibration; Perform weight verification, see Calibration procedure on page 25 Gear meter is worn or damaged Perform weight verification, see Calibration procedure on page 25; if weights are not repeatable re
Errors 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 important and require attention but not immediately. Advisories are not critical but still require attention. NOTE: • Errors set the dispenser ready signal LOW.
Errors Error No. Error Name Error Description Error Type Cause Solution 4 Inlet Low Pressure Error Inlet material pressure below min limit Alarm Feed pressure too low. Limits are not set correctly. Verify pressure limits in Setup Screen 5. Verify supply pressures during dispense. 5 Outlet Pressure Deviation Outlet material pressure outside limits Deviation Back pressure is too high or too low. Limits are not set correctly Verify pressure limits in Setup Screen 5.
Errors Error No. Error Name Error Description Error Type Cause Solution 13 Pre-Charge Timeout Pre-Charge Pressure was not reached after dispense Advisory Pre-Charge value not set correctly Set Pre-Charge to zero.
Maintenance 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 between mechanical and electrical tasks. Maintenance must be performed by trained personnel per this schedule to assure safety and reliability of the equipment.
Repair Repair NOTE: Refer to Parts section beginning on page 51 for part reference number identification. Replace Servo Motor or Gear Head Replacing either the Servo Motor or Gear Head requires the following procedure. Gear Meter Assembly Remove Servo Motor and Gearhead 1. Prepare Gear Meter Assembly for Repair, page 37. 2. Remove support gussets (9, 1106). This section describes how to remove and replace components on the gear meter assembly. Prepare Gear Meter Assembly for Repair 3.
Repair Install Servo Motor or Gearhead 1. Remove key from motor shaft. NOTICE Use caution when handling servo motor to prevent damage. Do not use tools that could cause damage. 2. Slide the gear head bushing into the drive coupling and align slots in drive coupling and bushing. See FIG. 19. SEE DETAILA DETAIL A SCALE 3/2 FIG. 19 3. Rotate the drive coupling to align clamping bolts with access holes. NOTE: Orient servo motor so that the motor connections do not interfere with material inlet hose. 4.
Repair 5. Loosen clamping bolts on each side of coupling and remove coupling. 5. Separate coupling until proper gap is created. FIG. 21. See the following table. NOTE: Pump shaft key may fall out during coupling removal. Secure pump shaft key until coupling is replaced. Pump Size cc / revolution 6 20 Gap (mm) 18 20 Install Coupling Gap FIG. 21 6. Tighten coupling bolts to the following torques: FIG. 20 1. Slide coupling onto gear head output shaft.
Repair Remove Dispense Valve 4. Connect air lines. 1. Prepare Gear Meter Assembly for Repair, page 37. 5. Apply air to the solenoid. 2. Manually actuate solenoid to ensure pressure has been removed. 6. Manually shuttle solenoid, see FIG. 22. Verify dispense valve is open when solenoid is depressed. Replace Solenoid Dispense Valve Air Solenoid 1. Prepare Gear Meter Assembly for Repair, page 37. 2. Disconnect solenoid cable. Remove mating screws (405) from gusset. 3.
Repair 3. Remove drive assembly. See FIG. 23. 12. Replace pump block o-rings (106, 104; 1304). See FIG. 24. 103, 1303 104, 1304 4, 1102 108, 1309 102, 1302 106, 1304 109, 1308 *107, 1306 105, 1305* FIG. 23 412 4. Perform Remove Dispense Valve procedure. 5. Loosen 4 bolts (407) and remove front block (412). 6. Loosen 4 bolts and remove inlet block (110, 1302). 7. Loosen pump bolts (3, 1303) and remove pump (108, 1309). 407 * Provided in o-ring kit 24E626. FIG. 24 13.
Repair PGM-6 Pump Repair 1607 1608 1615 (P/N: 125656) 1614 1605 1611 1609 (P/N: 125657) 1612† 1606 1611 1604 1603 1612† 1610 1613 1601 1602 † Parts included in kit 24E607. Parts included in kit 24E827. Parts included in kit 24E826. FIG.
Repair 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). NOTICE Pump section should be fully supported to prevent damage being dropped. It is recommended that the gear meter assembly be located on a work bench for service. 4. Remove drive assembly. See FIG. 23. allow the shaft to be pressed through the gear from the top or coupling end.
Repair PGM-6 Pump Assembly NOTICE Do not hammer or force components together or damage may occur. Parts will drop into place if properly cleaned and aligned. Use of a compatible oil is recommended during assembly. 1. Place the back plate (1603) on a table inside facing up. 2. Place the driven gear (1608) on its stud (1606). 12. Install new seals (1612). See FIG. 26 and FIG. 27. 1515, 1614 1512, 1611 *1513, 1612 3. Place gear case (1602) onto back plate (1603).
Repair 3A0260H 45
Repair PGM-20 Pump Repair 1514 1515 1509 1512 1513† 1501 1512 1513† 1502 1511 1506 1510 1516 (P/N: 125654) 1507 1503 1504 1505 1508 (P/N: 125655) † Parts included in kit 24E619. Parts included in kit 24E825. Parts included in kit 24E824. FIG.
Repair 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). NOTICE Pump section should be fully supported to prevent damage being dropped. It is recommended that the gear meter assembly be located on a work bench for service. 4. Remove drive assembly. See FIG. 23.
Repair PGM-20 Pump Assembly NOTICE Do not hammer or force components together or damage may occur. Parts will drop into place if properly cleaned and aligned. Use of a compatible oil is recommended during assembly. 1. Place back plate (1503) on a table inside face up. 14. Align pump shaft key and slide coupling onto pump shaft. Tighten coupling bolt just enough to hold it’s position. 15. Attach servo motor, gear head, and top plate to pump assembly. See FIG. 20. 16.
Repair Gear Pump Maintenance Guide Review these guidelines prior to performing any maintenance 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 fluids carrying particles that may harm the pump. • Do not heat or cool pump faster than 180°F (100°C) per hour • Do not drop disassembled parts on a hard surfaces and do not let parts knock together.
Repair Installing new heater units and RTD sensors 1. Prepare Gear Meter Assembly for Repair, page 37. 2. Disconnect the power cables from the heaters. 6. Remove the heaters and sensor from the block. NOTICE The heaters may be difficult to remove and removal depends on the system type. To ensure proper heat transfer and to avoid premature heater failure, System with through hole: Press out the heater element using an 0.125” (3 mm) diameter pin.
Parts Parts PGM-20 Mounting Frame 1 8 3 5 9 2 4 12 10 11 Ref 1 2 3 4 5 8 9 10 11 12 Part 124164 124165 124166 124167 124168 16D840 16D841 16D842 16D843 16V444 3A0260H ti21285a Description Qty SCREW, shcs, M6-1.0 x 25 4 SCREW, bhcs, M5-0.6 x 10 4 SCREW, bhcs, M6-1.0 x 10 4 SCREW, shoulder, 10x30, M8-1.25 6 SCREW, shoulder, 8 x 6, M6-1.
Parts PGM-20 Lower Assembly Block 103 108 104 106 101 101 109 102 105 107 110 Ref 101 102 103 104† 105† 106† 107† 108* 109 110 Part 101970 124173 124174 Description PLUG, pipe, headless SCREW, M6-1.0 x 90 SCREW, M10-1.5 x 75 O-RING PACKING, o-ring PACKING, o-ring PACKING, o-ring 16D827 METER, gear, precision, 20cc/rev 16D915 BLOCK, pump, mounting 16D916 BLOCK, inlet, PGM Qty 2 4 6 1 1 1 1 1 1 1 † Part included in o-ring kit 24E626.
Parts PGM-20 Pump Heat Kit 1 204 3 202 1 203 201 1 205 206 206 3 Ref 201 202 203 204 205 206 Part 117764 24E412 24E413 125363 16D923 124175 Ground location. Description SENSOR, pressure KIT, heat, pump, PGM-20 KIT, heat, PGM, inlet LABEL, heat/burn, warning INSULATOR SCREW Qty 2 1 1 2 1 3 Replacement Danger and Warning labels, tags, and cards are available at no cost.
Parts PGM Drive - 20 cc Pump 301 302 302a 303 Ref Part Description Qty 301 16D947 MOTOR, PGM drive, servo, 4 1 frame 302 16D946 GEAR REDUCER, PGM drive, 1 50:1, 80mm frame 302a COVER 1 303 16D945 COUPLING, PGM drive, 18x20mm, 1 w/key 54 3A0260H
Parts Endure Dispense Valve Fix Mounted 408 402 411 401 406 407 406 409 410 404 403 405 412 Ref Part 401 402 403 597151 FITTING, elbow, 1/4 tube x 1/8 NPT, male 117820 SCREW, cap, socket head, M3 124200 SCREW, socket head cap screw, M6-1.0 x 30, stainless steel 124201 SCREW, socket head cap screw, M5-0.
Parts Gear Meter Assembly Panel 610 611, 612, 613 601 602, 623 651 603 616 617 605 617 616 615 606 614 614 620 615 608 607 614 619 604 622, 625 618 626, 612 624 609 652 56 3A0260H
Parts Ref Part 601 ENCLOSURE, control, gear meter 1 painted 24F386 MODULE, HMI, PGM 1 121148 HANDLE, disconnect, electric 1 81/2060- BUTTON, dual, grn/red, w/pl-wht 1 P/11 81/2065- BUTTON, operator, pl, red 1 R/11 81/2065- BUTTON, operator, pl, green 1 G/11 LABEL, legend, panel, PGM 1 16D363 BUTTON, operator, pb, flush, black 1 FITTING, bulkhead, gland, 9wire 1 GRIP, cord, .35-.63, 3/4 1 81/1060- CONNECTOR, sq, 14pw/key, 7a, 1 14/25 panel m 96/0360/ FASTENER, shc, 4-40x0.
Parts PGM Back Panel 718, 720 709 717 708 706 707 731 702, 707 701 704 716 729 718, 720 705 711 716, 720 728 718, 720 719, 721 712, 730 710, 725 717 726, 728 715, 723, 724 727 722* Ref Part 701 702 703 123361 124228 704 705 706 707 708 117666 U70077 123298 123296 123359 709 710 124064 121808 711 712 123718 24F323 58 713 722* 714 Description Qty Ref Part PANEL, back, for30x24 encl, conduit SWITCH, disconnect, 32a EXTENSION, disconnect, 230-350mm TERMINAL, ground TERMINAL, lug, g
Parts Ref 722 723 724 725 726 727 Part Description 124265 AMPLIFIER, signal conditioner, PGM (3, 6, or 9 m cables) *127279 AMPLIFIER, signal conditioner, PGM (15 m cable) 124292 HARNESS, PGM, 26pin dsub, 24 awg 24D853 HARNESS, wire, power, motor control 120997 CABLE, turck, rs 4t-4 DOCUMENT, schematic, PGM CLAMP, wire, harness, 1/4, galvaniz Qty Ref 2 728 84/0130- LABEL, prot earth (grnd).375x.
Parts PGM Remote Dispense Valve 804 808 805 809 807 Ref 804 805 807 Part 808 809 198446 16E055 60 117820 124200 Description Qty FITTING 1 SCREW, cap, socket head, M3 2 SCREW, shsc, M6-1.
Parts PGM Transducer 20 cc Pump 901 Ref 901 Part Description 117764 SENSOR, pressure 3A0260H 6 cc Pump 901 901 901 Qty 2 61
Parts PGM-6 Mounting Frame 1103 1105 1101 1107 1106 1104 1101 1102 1109 1108 Ref Part Description Qty 7 1101 124165 SCREW, bhcs, M5-0.8 x 10, stainless steel 1102 124167 SCREW, shoulder, 10 x 30, 4 M8-1.25, stainless steel 1103 124313 SCREW, shcs, M6-1 x 16 mm, 3 stainless steel 1104 124314 SCREW, shoulder, 6 x 8, M5 - 0.
Parts PGM-6 Drive Kit 1203a 1203b 1203 1202 1202a 1201 Ref Part Description 1201 16E367 COUPLING, PGM drive, 12 mm x 14 mm, with key 1202 16E368 GEAR REDUCER, PGM drive, 50:1, 60 mm frame 1202a COVER 1203 16E369 MOTOR, PGM drive, frame 1203a SCREW 1203b WASHER 3A0260H Qty 1 1 1 1 4 4 63
Parts PGM-6 Lower Assembly Block 1303 1309 1304 1308 1307 1302 1305 1306 1301 Ref Part Description Qty 1301 101970 PLUG, pipe, headless 2 1302 124173 SCREW, shcs, M6-1.0 x 90, stain4 less steel 1303 124174 SCREW, shcs, M10- 1.5 x 75, 4 stainless steel 1304† PACKING, o-ring 2 1305† O-RING 1 1306† PACKING, o-ring 1 1307 16D916 BLOCK, inlet, PGM 1 1308 16E340 BLOCK, pump mounting, PGM-6 1 1309* 24E832 METER, gear, precision, 6cc/rev 1 † Parts are available in o-ring kit 24E677.
Parts PGM-6 Pump Heat Kit 1401 3 1 1402 1 1404 1405 1406 3 Ref Part 1401 117764 1402 24E732 1403 24E413 1404 125363 1405 16E366 1406 124166 1403 Ground location. Description SENSOR, pressure KIT, heat, pump, PGM-6 KIT, heat, PGM, inlet LABEL, heat, warning INSULATOR SCREW Qty 2 1 1 2 1 2 Replacement Danger and Warning labels, tags, and cards are available at no cost.
Schematics Schematics GND J1 AC POWER 1 2 3 4 5 6 7 8 9 1L2 DISC-1 GND L2 L1 1L1 1L2 100 1L2 P 101 N CB1A 20A P 103 2 104 3 4 V+ VFG 1L2 1L2 111 CB5 5A 10 AWG 16 AWG P N LOAD FIL-2 110 P N -BUS +BUS C2 CNTRL VAC C1 CNTRL VAC L3 L2 240/120 VAC HOT L1 240/120 VAC N HARNESS 24D853 2 1L1 REGEN CASE GROUND 12 AWG PS-1 1L1 PE 105 CRM GND 12 AWG 1 CRM N 10 AWG 102 LOAD 1L1 LINE FIL-1 LINE 1L1 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116
Schematics 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 24 VDC 125 DC COM 130 CONTROL POWER E-STOP 0 I 140 125 PB-1 5 142 141 XO 0X PB-1A A1 143 A2 130 XO PB-2 CRM REMOTE STOP 6 143 CRM CONTROL_PWR ON W 130 PL-3 PLC-1 125 L+ DC/DC/DC G 130 M PORT 0 OF PLC-1 CAB-1 PROGRAMMING IF2 125 125 +24V HMI-1 IF1A G IF1B 0V N
Schematics 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 24 VDC 125 DC COM 130 PLC-1 INPUTS 1M 200 202 DRIVE-1 I/O HARNESS 124292 26 PIN MALE HIGH DENSITY D-SUB 204 6 24VDC+ 7 125 24VDC+ 9 1 125 I0.0 SPARE I0.1 SPARE I0.2 DRIVE-1 FAULT I0.3 DRIVE-1 FAULT I0.4 AUTOMATION START 125 206 8 125 ORG 208 ORG 210 PG-IO 2 I0.
Schematics 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 24 VDC 125 DC COM 130 PLC-1 INPUTS 2M 125 130 I1.0 SPARE I1.1 SPARE I1.2 SPARE I1.3 SPARE I1.4 SPARE I1.5 SPARE 130 FIG.
Schematics 24VDC 125 DC COM PLC-1 130 OUTPUTS 130 1M 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 125 1L+ Q0.0 11 300 GEARMETER FAULT PG-IO Q0.1 10 302 GEARMETER READY TO DISPENSE PG-IO USE ORANGE WIRE Q0.2 12 304 GEARMETER IN CYCLE PG-IO 6 PG-IO 24VDC COMMON 130 WHT Q0.3 306 BLK + 1 2 RED 130 SOL-DV 308 Q0.
Schematics DC COM 24VDC 125 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 130 130 2M DRIVE-1 I/O HARNESS 124292 125 13 14 310 2L+ 26 PIN MALE HIGH DENSITY D-SUB 130 CRM Q0.5 312 130 1 312 2 DC COM DRIVE-1 ENABLE 285 Q0.6 314 SPARE WHT 3 Q0.
Schematics 24VDC DC COM 125 130 EXP-1 ANALOG INPUT 130 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 M 24VDC 125 USE CABLE P/N 81/0055-MC3/11 L+ GND 24VDC 125 INLET AMP POWER +POWER WHITE RA 400 /RETURN +OUTPUT SHUNTCAL IN A+ ENABLE 130 130 1 2 3 4 5 6 -OUTPUT RED BLACK TRANSDUCER +EXCITATION A B C D E F -EXCITATION +SIGNAL -SIGNAL
Schematics 24VDC DC COM 125 130 EXP-2 ANALOG OUTPUT 130 M 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 125 24VDC L+ 130 GND 26 PIN MALE HIGH DENSITY D-SUB 26 410 25 ANALOG OUT +/- 10 VDC COMMANDED FLOW TO DRIVE M0 412 24 V0 DRIVE-1 I/O HARNESS 124292 I0 M1 V1 I1 125 130 FIG.
Schematics 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 DRIVE-1 J5 SERIAL PORT 26 PIN MALE HIGH DENSITY D-SUB 474 446 358 J3 FEEDBACK 1 2 3 4 5 6 J4 COMMAND I/O 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 209 HARNESS 124292 FEEDBACK CABLE SEE CHART J2 MOTOR POWER 1 2 3 4 MOTOR POWER CABLE SEE CHART J1 AC POWER 1
Schematics GROUNDING NOTES: 1. GROUND ALL DISTRIBUTION BARS F/N 2. GROUND ALL DOORS 3. DO NOT JUMPER GROUND WIRES. TO GROUND DIST.
Accessory Parts 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 - Theory of Operation on page 98.
Accessory Parts Dynamic Regulators 1011 1004 1006 1009 1008 1010 1004 1007 1018 1012 1005 1001 1002 1017 1003 1004 1014 1021 1019 1020 1013 1016 Ref 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 Part 112699 C20466 112307 100139 112781 054776 110321 297612 110318 110319 115948 107110 121022 198171 198446 24E574 080226 C20461 125466 100896 111530 3A0260H Description TUBE, 1/4 OD FITTING, nipple, hex FITTING, elbow, street PLUG, pipe FIT
Accessory Parts 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 FIG. 39 on page 79. 3. Apply air to the Therm-O-Flow supply. Check for air leaks. 4. Set the secondary regulator for a low operating pressure, for example 20-25 psi. 5. Adjust the panel mount Therm-O-Flow regulator to zero psi. 6.
Accessory Parts Dynamic Regulator Installation 5/16 in. 7/32 in. diameter 11/16 in. 6 Detail A 2 4 1 7 3 8 5 1 Remove plug and attach supplied tubing to regulator inlet. 2 Holes required for mounting. See detail A. 3 5/32 in. tubing removed from Therm-O-Flow regulator to be attached here. 4 Regulator pilot port will have an existing 5/32 in. air line. This air line and its fitting are to be removed from the regulator and replaced with the fitting supplied with dynamic regulator.
Accessory Parts Endure Valve Nozzles Heater Nests Part Description 24E654 10 x 1.5 mm Ribbon Nozzle 24E655 1/8 in.
Appendix A - User Interface Display Appendix A - User Interface Display Screen Navigation Diagram START MACHINE Main Calibrate Home Maintenance Robot I/O Setup Screens Supply Pump Alarm Screen Setup Screens Flow Screen #1 Current Setup Screen Screen #2 Screen #3 Screen #4 Screen #5 Screen #6 3A0260H 81
Appendix A - User Interface Display Main Screen Press the appropriate button to navigate to either the Home or Calibration screen. Enter password “PGM10”to access the Calibration screen.
Appendix A - User Interface Display Calibrate Screen #1 NOTE: See Calibration procedure on page 25.
Appendix A - User Interface Display Calibrate Screen #2 NOTE: See Calibration procedure on page 25.
Appendix A - User Interface Display Home Screen N P R V T S W Y X U Key: N P R S T Enable Manual mode Enable Automatic mode Increase Bead Scale Decrease Bead Scale Current Bead Scale setting U V W X Y Navigate to Maintenance Screen Navigate to Robot I/O Screen Navigate to Setup Screens Navigate to Main Screen Navigate to Alarm Screen Manual Mode Screens Navigation In Manual Mode, the machine only accepts signals from the User Interface touch screen and the physical buttons on the machine.
Appendix A - User Interface Display Maintenance Screen P N AB AC Z AE AA A AD Key: Z Enable Automatic Dispense Valve Control AA Open the Dispense Valve, Disable Automatic Dispense Valve Control AB Dispense Mode Selection drop-down menu Dispense Valve Control When Automatic Dispense Valve Control is enabled, the dispense valve will open and close as needed to dispense material.
Appendix A - User Interface Display Robot I/O Screen A Overview This screen is for settings related to an external machine setup to control the dispense operation of this system. See Appendix B - I/O on page 95 for more information. Robot Outputs These are signals sent by the external machine when the related action should occur. The Job Complete signal is sent to stop the In Cycle signal. The Dispense Trigger is sent to begin dispensing.
Appendix A - User Interface Display Setup #1 Screen A #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-interface touch screen or by an external machine connected to the system via the External Control Interface. Run Mode Bead Adjust When this option is enabled the Bead Scale function appears on the Home Screen.
Appendix A - User Interface Display Setup #2 Screen A Overview Pre-Charge The Dispense Mode, Flow Rate, and Dispense Duration This is the pressure between the meter and the dispense valve when the dispense valve is closed. If the pre-charge setting is non-zero then, immediately after dispensing, the gear meter will continue to rotate after the dispense valve closes until the pre-charge pressure value is achieved. The maximum Pre-Charge value is 2500 psi (17.2 MPa, 172 bar).
Appendix A - User Interface Display Setup #3 Screen A #1 to #6 Buttons Drive Information Press to navigate to the Setup Screen with that number. For example, press #3 to navigate to Setup Screen #3. Motor Torque Delay Settings Display motor torque during dispense. If motor torque climbs above continuous torque an alarm is issued. See Errors on page 33. Cont. Torque Continuous torque rating of the motor. Larger values for the On Delay setting lead to larger pressures in the system.
Appendix A - User Interface Display Setup #4 Screen A #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, to pull material back from the dispense valve to minimize or eliminate material drooling. The Snuff Back Time and Snuff Back Pump RPM are the settings used when Snuff Back is enabled.
Appendix A - User Interface Display Setup #5 Screen A Overview This screen controls settings for the pressure sensors. These values are used for triggering errors. #1 to #6 Buttons Press to navigate to the Setup Screen with that number. For example, press #3 to navigate to Setup Screen #3. Inlet, Outlet Offset The inlet, outlet offset values are used to tune the pressure transducer.
Appendix A - User Interface Display Setup #6 Screen A Errors Error Reset: If set to Disable, errors cannot be reset. If set to Enable, errors can be reset. Inlet/Outlet Pressure, Drive Torque: If set to Error, an error will be generated when the out-of-limit condition occurs. The machine will be disabled until the error is reset. If set to deviation, an error will be generated when the out-of-limit condition occurs. The machine will not be disabled until the error is reset.
Appendix A - User Interface Display Supply Pump Screen A 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.
Appendix B - I/O 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 controller. Other pins on the I/O connector include 24 VDC power, 24 VDC common, analog common, and a signal which is 24 VDC power only when the controller E-Stop switch is latched in.
Appendix B - I/O 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 sinking input at the automation controller. See FIG. 41. If the automation controller uses 24 VDC relay coils to receive I/O signals, the signals should be connected as shown in FIG. 41.
Appendix B - I/O Analog Inputs Relays The PGM receives a flow rate analog command from the automation. The 0 to 10 VDC analog input is referenced to analog common on the control. See FIG. 42. The reference for the automation controller analog output must be connected to the PGM analog reference (pin 8) for this signal to function properly. If the use of relays is required to condition the digital I/O signals, these are some examples of part numbers that could be used.
Appendix C - Theory of Operation Appendix C - Theory of Operation Theory of Operation Fault Present - This bit is RESET under the following conditions: Input and Output Signals 1. No Faults (alarms or warnings) are active. Terminology In Cycle - In Cycle signal is set at the beginning of a dispense cycle. It is reset at the end of the dispense cycle.
Technical Data Technical Data Volume repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 1% Minimum Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev model: 20 cc/rev model: 30 cc/min 40 cc/min Maximum Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cc/rev model: 20 cc/rev model: 480 cc/min 1600 cc/min Minimum Dispensed Shot Size . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
