Graco 3A2098H User Manual

Instructions - Parts

™

PCF

with

™

PrecisionSwirl

3A2098H

Precision Dispense System

Electronically-controlled fluid metering system that provides precise continuous flow of up to four single-component sealants and adhesives through closed-loop technology.

Not for use in explosive atmospheres or hazardous locations. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 4 for model information. See page 5 for maximum working pressure and approvals.

IMPORTANT:

This manual does not apply to some PCF systems. See note on page 3 to verify this is the correct manual for your PCF system.

Optional PrecisionSwirl Orbital

Dispenser (sold separately)

PCF Control Center

PCF Fluid Plate

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fluid Plate Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Expansion Swirl Enclosure Assemblies . . . . . . . 6

PrecisionSwirl Orbital Dispenser Assemblies . . . 6

Automation Gateway Assemblies . . . . . . . . . . . 7

Swirl Control DGM . . . . . . . . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

System Configurations . . . . . . . . . . . . . . . . . . . . . 10

Typical Installation - Single Swirl, Single Fluid Plate

Typical Installation - Multiple Fluid Plates, No Swirl

Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . 11

Typical Installation - Multiple Fluid Plates, Multiple

Swirl Dispensers . . . . . . . . . . . . . . . . . . . . 12

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

System Overview . . . . . . . . . . . . . . . . . . . . . . . 13

System Components . . . . . . . . . . . . . . . . . . . . . 13

Fluid Plate Assembly Overview . . . . . . . . . . . . 14

Control Center Assembly Overview . . . . . . . . . 16

Key Tokens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Before Installation . . . . . . . . . . . . . . . . . . . . . . . 21

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Install Control Center . . . . . . . . . . . . . . . . . . . . 22

Install Fluid Plate Assemblies . . . . . . . . . . . . . . 24

Install Cable Assemblies . . . . . . . . . . . . . . . . . . 28

Install Gateway Module Interface . . . . . . . . . . . 30

System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Configure System . . . . . . . . . . . . . . . . . . . . . . . 32

Configure Control Settings . . . . . . . . . . . . . . . . 33

Configure Mode Settings . . . . . . . . . . . . . . . . . 34

Configure Delay Settings . . . . . . . . . . . . . . . . . 34

Configure Flow Meter Settings . . . . . . . . . . . . . 35

Configure Pressure Loop Settings . . . . . . . . . . 35

Adjust Pressure Sensors . . . . . . . . . . . . . . . . . 36

Configure Errors . . . . . . . . . . . . . . . . . . . . . . . . 36

Setup Maintenance Schedule/Parameters . . . . 37

Configure Valve to Swirl Association and Motor

Error Type . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Configure Swirl Settings . . . . . . . . . . . . . . . . . . 38

Configure Gateway Settings . . . . . . . . . . . . . . . 38

Setup Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Configure Advanced Settings . . . . . . . . . . . . . . 38

On/Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Maintenance Mode Operation . . . . . . . . . . . . . . 41

Automation Control (Normal Operation) . . . . . . 45

Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Precharge Modes . . . . . . . . . . . . . . . . . . . . . . . 47

Typical Job Cycle . . . . . . . . . . . . . . . . . . . . . . . 49

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 57

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

USB Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

System Configuration Settings File . . . . . . . . . . 60

Custom Language File . . . . . . . . . . . . . . . . . . . 60

Download Procedure . . . . . . . . . . . . . . . . . . . . . 61

Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . 61

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Fluid Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fluid Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 63

Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 64

Gateway Module . . . . . . . . . . . . . . . . . . . . . . . . 65

LED Diagnostic Information . . . . . . . . . . . . . . . . 65

Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Diagnose Errors . . . . . . . . . . . . . . . . . . . . . . . . . 66

Event and Error Codes and Troubleshooting . . 67

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Maintenance Schedule . . . . . . . . . . . . . . . . . . . 76

Advanced Display Module (ADM) . . . . . . . . . . . 77

Upgrade Gateway Module Software . . . . . . . . . 77

Upgrade Gateway Module Fieldbus Map . . . . . 78

Upgrade Fluid Control Module (FCM) Software 79

Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . 79

Swirl Dispensers . . . . . . . . . . . . . . . . . . . . . . . . 79

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Fluid Plate Assembly . . . . . . . . . . . . . . . . . . . . . 80

Control Center Assembly . . . . . . . . . . . . . . . . . 87

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Control Centers . . . . . . . . . . . . . . . . . . . . . . . . . 91

Control Center and Expansion Swirl Enclosure

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Fluid Plate Assembly Parts . . . . . . . . . . . . . . . . 94

2 3A2098H

Related Manuals

Appendix A - Advanced Display Module (ADM) . 99

Display Overview . . . . . . . . . . . . . . . . . . . . . . . . 99

Display Details . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Appendix B - Discrete Gateway Module (DGM)

Connection Details . . . . . . . . . . . . . . . . . . . . 115

D-Sub Cable 123793 . . . . . . . . . . . . . . . . . . . . 115

D-Sub Cable 123792 and Breakout Board 123783

116

DGM Digital Input . . . . . . . . . . . . . . . . . . . . . . 119

DGM Digital Outputs . . . . . . . . . . . . . . . . . . . . 120

DGM Analog Inputs . . . . . . . . . . . . . . . . . . . . . 121

DGM Analog Outputs . . . . . . . . . . . . . . . . . . . 121

Appendix C - Communications Gateway Module

(CGM) Connection Details . . . . . . . . . . . . . . 122

Install Fieldbus Connections . . . . . . . . . . . . . . 122

CGM I/O Data Map . . . . . . . . . . . . . . . . . . . . . 125

Appendix D - I/O Signal Descriptions . . . . . . . . 138

Automation Inputs . . . . . . . . . . . . . . . . . . . . . . 138

Automation Outputs . . . . . . . . . . . . . . . . . . . . . 139

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Control Center Assembly Technical Data . . . . 140

Fluid Plate Assembly Technical Data . . . . . . . 141

Swirl Dispenser Technical Data . . . . . . . . . . . 141

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 142

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 142

Related Manuals

The following is a list of component manuals written in English. These manuals and any available translations can be found at www.graco.com.

Manual Description

313377

309403 PrecisionSwirl Orbital Dispenser

307517

308647

309834

NOTE: In the Advanced screens on your system, if the Advanced Display software part number shown is 16F528 or 15V769 then this manual does not apply to your system; refer to manual 313377 for your system. Otherwise, the part number shown should be 16K405 and you should use this manual.

ADM Software Part No. 16F528 or 15V769

Original PCF Instructions - Parts (see the note below)

Mastic Fluid Regulators Instructions-Parts

Fluid Pressure Regulators Instructions-Parts

Helical Gear Fluid Flow Meters Instructions-Parts

(see manual 313377)

✖

✓

ADM Software Part No. 16K405

(use this manual)

3A2098H 3

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 PF1110 represents a PCF fluid

metering system (PF), a two style system (1), a fluid plate with a cartridge regulator and no meter (1), a DeviceNet user interface (1) with a 100-240 Vac power supply (0).

NOTE: To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the Ref. Nos. in the Parts drawings and lists.

™

PF 1

First and

Second Digits

(Precision

Continuous

Flow)

Discrete Gateway systems do not include automation interface cables. The following Graco accessories are avail-

◆

able for wiring to the automation system. Installers should follow Appendix B - Discrete Gateway Module (DGM) Connection Details, page 115, for custom wiring.

For single fluid plate systems only: 50 ft (15 m) cable with flying leads (123793) All systems: Breakout board (123783) and 50 ft (15 m) cable (123792)

NOTE: 256 styles option is not available with Discrete Gateway systems.

Third Digit

Style/Size

Description Regulator Meter Description Description

1 2 Styles 1 ❄Cartridge None 0 ◆Discrete 0 100 - 240 Vac

16 Styles 2 ❄Mastic None 1

2 3 256 Styles 3 ❄Cartridge High

4 ❄Mastic High

5 Heated

Mastic

6 Heated

Mastic

7 ❄Cartridge Ultra High

Fourth Digit

Fluid Plate

Resolution

Standard

Resolution

Heated

None

Fifth Digit

User Interface

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

™

1 24 Vdc

™

2 100 - 240 Vac with

™

3 24 Vdc with

™

Sixth Digit

Voltage

Integrated Swirl

❄

These fluid metering systems have ETL certification.

NOTE: Fluid metering systems with heated mastic regulators are not ETL certified.

Certified to CAN/CSA C22.2 No. 61010-1

This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition, including

Amendment 1, or a later version of the same standard incorporating the same level of testing requirements.

4 3A2098H

9902471

Conforms to

UL 61010-1

Models

Fluid Plate Kits

NOTE: The fluid plate kit numbers listed below include a CAN splitter. The fluid plate assembly included in each

PFxxxx assembly does not include a CAN splitter.

Includes:

Fluid

Plate Kit

24B958 PF13xx

24B959 PF11xx

24B960 PF14xx

24B961 PF12xx

24B962 PF15xx

24C901 PF16xx

24J873 PF17xx

24K801 PF23xx

24K802 PF21xx

24K803 PF24xx

24K804 PF22xx

24K805 PF25xx

24K806 PF26xx

24K807 PF27xx

24K808 PF33xx

24K809 PF31xx

24K810 PF34xx

24K811 PF32xx

24K812 PF35xx

24K813 PF36xx

24K814 PF37xx

Used by

Model

Maximum Working

Pressure

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

6000 psi

(41.4 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

6000 psi

(41 MPa, 414 bar)

Regula-

Description

Cartridge Regulator, High Resolution Flow

Meter, 2 styles

Cartridge Regulator, No Flow Meter,

2 styles

Mastic Regulator, High Resolution Flow

Meter, 2 styles

Mastic Regulator, No Flow Meter, 2 styles 246642 --- 16M101

Heated Mastic Regulator, Standard Resolu-

tion Heated Flow Meter, 2 styles

Heated Mastic Regulator, No Flow Meter,

2 styles

Cartridge Regulator, Ultra High Resolution

Flow Meter, 2 styles

Cartridge Regulator, High Resolution Flow

Meter, 16 styles

Cartridge Regulator, No Flow Meter,

16 styles

Mastic Regulator, High Resolution Flow

Meter, 16 styles

Mastic Regulator, No Flow Meter, 16 styles 246642 --- 16M103

Heated Mastic Regulator, Standard Resolu-

tion Heated Flow Meter, 16 styles

Heated Mastic Regulator, No Flow Meter,

16 styles

Cartridge Regulator, Ultra High Resolution

Flow Meter, 16 styles

Cartridge Regulator, High Resolution Flow

Meter, 256 styles

Cartridge Regulator, No Flow Meter,

256 styles

Mastic Regulator, High Resolution Flow

Meter, 256 styles

Mastic Regulator, No Flow Meter,

256 styles

Heated Mastic Regulator, Standard Resolu-

tion Heated Flow Meter, 256 styles

Heated Mastic Regulator, No Flow Meter,

256 styles

Cartridge Regulator, Ultra High Resolution

Flow Meter, 256 styles

tor

244734 246652 16M100

244734 --- 16M101

246642 246652 16M100

246643 246340 16M100

246643 --- 16M101

244734 16E993 16M100

244734 246652 16M102

244734 --- 16M103

246642 246652 16M102

246643 246340 16M102

246643 --- 16M103

244734 16E993 16M102

244734 246652 16M104

244734 --- 16M105

246642 246652 16M104

246642 --- 16M105

246643 246340 16M104

246643 --- 16M105

244734 16E993 16M104

Flow

Meter

FCM Key

Token

3A2098H 5

Models

Expansion Swirl Enclosure Assemblies

The following enclosures are ETL approved. Assemblies PFxxx2, and PFxxx3 are setup for one PrecisionSwirl Orbital Dispenser. If you wish to have additional swirl dispensers, order one expansion PrecisionSwirl assembly below for each. Systems with a DGM as the automation gateway can have up to two swirl dispensers total. Systems with a CGM as the automation gateway can have up to four swirl dispensers total.

Part Description

16M350 100 - 240 Vac 16M351 24 Vdc

PrecisionSwirl Orbital Dispenser Assemblies

See manual 309403.

Maximum

Working

Version Part, Series Coupler Offset Typical Application

Standard 243402, B 0.012 in. for narrow bead

widths

Standard 243403, B 0.028 in. for wide bead

widths

Compact 289262, A 0.012 in. for narrow bead

widths

Compact 289261, A 0.018 in. for medium bead

widths

Hem flange and after hem

Seam sealing

Hem flange and after hem

Seam sealing

Pressure

3500 psi

(24.1 MPa,

241 bar)

PrecisionSwirl Orbital Dispenser Cable Assemblies

Part Description

233125 6 ft (1.8 m) motor extension cable assembly 233124 9 ft (2.7 m) motor extension cable assembly 233123 15 ft (4.6 m) motor extension cable assembly 617870 55 ft (16.8 m) motor extension cable assembly

6 3A2098H

Models

Automation Gateway Assemblies

Each control center comes with one automation gateway assembly. The automation gateway module is either a Discrete Gateway Module (DGM) or one of the Communications Gateway Modules (CGM).To order a replacement, see the following table. You will also need to order software upgrade token (16K743).

Gateway

User Interface

PCF Model

PFxx0x Discrete

PFxx1x

PFxx2x

PFxx3x

PFxx4x

Description

(DGM)

DeviceNet

(CGM)

EtherNet/IP

(CGM)

PROFIBUS

(CGM)

PROFINET

(CGM)

™

Part Number

To Order

24B681 0

15V759 Any

15V760 Any

15V761 Any

15V762 Any

Rotary Switch

Position

Swirl Control DGM

The assemblies below each contain one swirl control DGM used to control one Swirl Dispenser. To order a replacement, see the following table. You will also need to order software upgrade token (16K743).

Assembly

PFxxx2,

PFxxx3,

16M350,

16M351

Part Number

To Order

24B681

Rotary Switch

Position

1, 2, 3, or 4;

see Swirl Control

DGM on page 19

Automation Gateway (DGM or CGM)

Swirl Control DGM

3A2098H 7

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, 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

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 at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, 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 dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately

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.

8 3A2098H

Warnings

WARNING

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.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’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.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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.

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:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

3A2098H 9

System Configurations

Typical Installation - Single Swirl, Single Fluid Plate

NOTE: Shown with one fluid plate and one swirl dispenser.

Power In

Air Supply Drop Site

. 1: Typical Ambient System Installation

Key:

A *Control Center (User Interface) B *Fluid Plate Assembly C Applicator/Dispense Valve D Sealer Automation E Automation Interface Cable F *CAN Cable G Fluid Supply System

10 3A2098H

H Fluid Supply Hose J Automation Controller K *Air Filter Assembly L ◆PrecisionSwirl Orbital Dispenser (Swirl Dispenser) M ◆PrecisionSwirl Cable

* Included

◆ Optional

System Configurations

Typical Installation - Multiple Fluid Plates, No Swirl Dispensers

Power In

Air Supply Drop Site

. 2: Typical Multiple Fluid Plate System Installation

Key:

A *Control Center (User Interface) B *Fluid Plate Assembly C Applicator/Dispense Valve D Sealer Automation E Automation Interface Cable

3A2098H 11

F *CAN Cable G Fluid Supply System H Fluid Supply Hose J Automation Controller K *Air Filter Assembly

* Included

System Configurations

Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers

Air Supply Drop Site

Power In

. 3: Typical Multiple Fluid Plate System Installation

Key:

A *Control Center (User Interface) B *Fluid Plate Assembly C Applicator/Dispense Valve D Sealer Automation E Automation Interface Cable F *CAN Cable G Fluid Supply System H Fluid Supply Hose J Automation Controller K *Air Filter Assembly L ◆PrecisionSwirl Orbital Dispenser (Swirl Dispenser) M ◆PrecisionSwirl Cable N ◆Expansion Swirl Enclosure

* Included

◆ Optional

12 3A2098H

Overview

System Overview

The PCF fluid metering system combines closed-loop pressure control with the ability to change bead profiles quickly. When used with an optional flow meter, the system automatically adjusts for fluctuations in the operating environment, such as material viscosity, temperature and tip wear, in order to maintain the desired dispense rate. The module responds to automation signals to provide an accurate and consistent output flow based on a comparison of actual to desired flow rates.

Typical Applications

• Bead dispensing

• Gasketing

• Seam sealing

• Hem flange

• Sound deadening

• Anti-flutter

• Body panel reinforcement

• Profile wrapping

• Cable filling

Control Center (User Interface)

The control center communicates with the PCF fluid plate assembly to control fluid pressure and dispense valve operation.

The control center receives input from the automation controller, and uses these inputs to determine communication to the fluid plate assembly.

Fluid Plate Assembly

The fluid plate assembly contains components that control and monitor fluid dispensing. A PCF fluid metering system can have up to four fluid plates. Each fluid plate can control up to four dispense valves. The system supports up to 16 dispense valves and can simultaneously dispense from up to 10 dispense valves.

PrecisionSwirl Orbital Dispenser (Swirl Dispenser), Sold Separately

The swirl dispenser dispenses material in a circular pattern at speeds from 6600 to 24000 rpm. A PCF fluid metering system can have up to four swirl dispensers. See manual 309403 for detailed information.

System Components

The diagram in FIG. 4 shows an example of the PCF module and cables.

System shown with one fluid plate and one swirl dispenser

. 4: PCF System Components

Control Center (User Interface)

Fluid Plate Assembly

3A2098H 13

Overview

Fluid Plate Assembly Overview

Fluid Plate Components

The fluid plate assembly in FIG. 5 can be attached to an automation arm or mounted on a pedestal. The main components of the fluid plate assembly include:

• Fluid regulator (cartridge, ambient mastic, or heated mastic) (P).

• Flow meter (R) (optional) precisely measures the flow rate of fluid dispensed.

• Solenoid air valve (S) controls the dispense valve.

• Voltage to Pressure Transducer (T), abbreviated V/P

transducer, adjusts the air pressure to the fluid regulator (P).

• Fluid Control Module (FCM) (U) receives pulse readings from the flow meter (R) and pressure readings from the regulator. It also controls the fluid regulator (P) and solenoid air valve (S).

The PCF fluid regulator is electrically controlled by the PCF fluid control module. Consistent material flow is assured by a closed-loop pressure or closed-loop flow control design. The module responds to automation-supplied signals to provide an accurate and consistent output flow based on a comparison of actual to desired flow rates. The fluid regulator uses air pressure to control fluid pressure and to provide fast response to electronic commands and ensure a precisely controlled, continuous flow of material.

The fluid plate assembly is available in two versions: ambient and heated.

Ambient Fluid Plate Assembly

There are four ambient versions available:

• cartridge regulator without a flow meter;

• ambient mastic regulator without a flow meter;

• cartridge regulator with a high resolution meter;

• ambient mastic regulator with a high resolution meter;

• cartridge regulator with an ultra high resolution flow meter.

. 5: Fluid Plate Components

Heated Fluid Plate Assembly

There are two heated versions available:

• heated mastic fluid regulator with a heated flow meter,

• and a heated mastic fluid regulator without a flow meter.

14 3A2098H

Overview

Fluid Regulator

There are three fluid regulator options:

• cartridge

• ambient mastic

• heated mastic

All of the fluid regulator options use air pressure to control fluid pressure, provide fast response to electronic commands, and ensure a precisely controlled, continuous flow of material.

Cartridge

The cartridge regulator (244734) is ideal for low to medium viscosity sealants and adhesives.

Ambient Mastic

The ambient mastic regulator (246642) is ideal for medium to high viscosity sealants and adhesives.

Heated Mastic

The heated mastic regulator (246643) is ideal for low to high viscosity warm-melt and hot-melt sealants or adhesives.

Fluid Control Module (FCM)

Status LEDs

. 6: FCM Sensor Connections

Connection Sensor Description

1 Dispense solenoid

2Flow meter

3 Outlet pressure sensor (heated systems only)

4 Voltage to Pressure (V/P) Transducer

5 Command cable (optional accessory kit)

6 Inlet pressure sensor (non-heated systems

7 Outlet pressure sensor (non-heated systems

CAN Connectors

Key

token

Table 1: FCM Sensor Connections

only)

---

Rotary Switch

Rotary Switch on FCM

The rotary switch on the FCM, see FIG. 6, must be set to a valid position and each FCM must have a unique rotary switch position. The FCM rotary switch position determines which number to assign to that fluid plate. The settings, including defined styles, for each fluid plate are stored in each FCM so changing the rotary switch position causes the settings to be shown under the new number on the ADM.

Rotary Switch

Item

Fluid Plate 1 0 or 1

Fluid Plate 2 2

Fluid Plate 3 3

Fluid Plate 4 4

Position

NOTE: See LED Diagnostic Information, page 65, for

signal definitions.

3A2098H 15

Overview

Control Center Assembly Overview

Front View Side View

Front View

100-240 Vac Assembly

Swirl Board

ADM

. 7: Control Center Components

The control center includes the following components:

• Advanced Display Module (ADM) with USB; see page 17 for details.

• USB enables users to download job, event, and data logs; save and restore system settings; and customize the language. See USB Data on page 59.

• 24 Vdc and 100-240 Vac customer-wired options available.

Gateway Module

Swirl Control DGM

•

If system has a swirl dispenser:

(the module on the left) and Swirl Board.

• Automation Gateway Module (the module on the right), which can be one of the following five types:

•Discrete

• DeviceNet

• EtherNet/IP

•PROFIBUS

• PROFINET

Swirl Control DGM

Expansion Swirl Enclosure

If more than one swirl dispenser is installed, the system will have one Expansion Swirl Enclosure for each additional swirl dispenser. The Expansion Swirl Enclosure is similar to the primary control center, but it does not include the ADM or the Automation Gateway module.

16 3A2098H

Advanced Display Module (ADM)

Overview

. 8: Advanced Display Module Component Identification

TI12362a

KEY:

Callout Function

BA Power On/Off Button

Enables/disables system.

BB System Status Indicator LED

Displays system status. Green LED indicates the system is active. Orange LED indicates the system is off. Solid LEDs (green or orange) indicate the system is in Run mode. Flashing LEDs (green or orange) indicate the system is in Setup mode.

BC Stop Button

Stops all system processes. However, it is not a safety or emergency stop.

BD Soft Keys

Functions vary depending on the screen.

BE Cancel Button

Clears system errors and cancels a selection or number entry while in the process of entering a number or making a selection.

BF Enter Button

Acknowledge changing a value or making a selection.

BG Lock/Setup

Toggle between run and setup screens. If setup screens are password protected, button toggles between run and password entry screens.

Callout Function

BH Navigation Buttons

Navigate within a screen or to a new screen.

BJ Flat Panel Mount

Mounts to control center bracket (optional).

BK Model Number Tag

Model number.

BL USB Module Interface

USB port and USB indicator LEDs.

BM CAN Connector

Power connection.

BN Module Status LEDs

See LED Diagnostic Information, page 65, for

signal definitions. BP Battery Cover BR Token Access Cover BS Digital I/O Port for Light Tower

r_24E451_3B9900_1a

NOTICE

To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

3A2098H 17

Overview

Automation Gateway Module

See the following table for the appropriate rotary switch position for your automation gateway module.

Gateway Part Number To

PCF Model User Interface Description

PFxx0x Discrete (DGM) 24B681 0

PFxx1x

PFxx2x

PFxx3x

PFxx4x

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

™

(CGM)

™

(CGM)

™

(CGM)

™

(CGM)

NOTE: See Control Center Assembly Overview on page 16 for automation and swirl control DGM identification.

Front Back

Order Rotary Switch Position

15V759 Any

15V760 Any

15V761 Any

15V762 Any

Front

(Access Cover Removed)

Gateway Module Connectors

PROFINET or EtherNet/IP

TI11814A

. 9: Automation Gateway Module Components

DeviceNet

TI11815A

Key:

CA Gateway Module CB Base CC Fieldbus Connector (see Appendix C - Communi-

cations Gateway Module (CGM) Connection Details, page 122, for more information)

CD Module Connection Screws CE Access Cover CF Module Status LEDs (see LED Diagnostic Infor-

mation, page 65)

PROFIBUS

Rotary Switch

TI11816A

Software Token Slot

Discrete

CG D-Subminiature (D-Sub) Connector (see Appendix

B - Discrete Gateway Module (DGM) Connection Details, page 115, for pinout details)

CH CAN Connectors

18 3A2098H

Swirl Control DGM

Overview

One swirl control DGM is included in the integrated Swirl control center, and in each expansion swirl enclosure. Each Swirl control DGM controls one swirl orbiter.

Each swirl control DGM must have a unique rotary switch position. The rotary switch position determines the number assigned to the swirl dispenser attached to that DGM. If the rotary switch position must be changed, do so with the power off.

Each integrated swirl control center and swirl enclosure comes with a pre-installed cable between the swirl control DGM and the swirl board. The customer does not need to make any external connections with the swirl control DGM.

Front

Back

DGM Function

Swirl Control 1 1

Swirl Control 2 2

Swirl Control 3 3

Swirl Control 4 4

(Access Cover Removed)

Rotary Switch

Position

Front

FIG. 10: Swirl Control DGM

3A2098H 19

Rotary Switch

Software Token Slot

Overview

Key Tokens

The ADM and FCM must each have a key token installed in order to operate. If the incorrect key token is installed, the module will not operate. The DGM does not require a key token.

FCMADM

. 11

NOTE: There is one FCM located on each fluid plate.

If a new ADM or FCM is installed, follow the instructions on page 77 to upgrade the software in the new module and to install the key token from the old module in the new module.

The following is a list of key token part numbers. If you lose your key token be sure to order the correct item to ensure proper system operation.

NOTE: The key tokens for the ADM and FCM look alike but only work in one module or the other. If the key tokens for the ADM and FCM become mixed, locate the part number on each token then refer to the following table to determine which module each token applies to.

Part Description

16M100 FCM Key Token, 2 styles, Flow Meter

16M101 FCM Key Token, 2 styles, No Flow Meter

16M102 FCM Key Token, 16 styles, Flow Meter

16M103 FCM Key Token, 16 styles, No Flow Meter

16M104 FCM Key Token, 256 styles, Flow Meter

16M105 FCM Key Token, 256 styles, No Flow

Meter

16M217 ADM Key Token, Standard PCF

20 3A2098H

Installation

Before Installation

• Have all system and component documentation

available during installation.

• See component manuals for specific data on component requirements. Data presented here applies to the PCF assemblies only.

• Be sure all accessories are adequately sized and pressure-rated to meet system requirements.

• Use the PCF control center only with the PCF fluid plate assembly.

Overview

The basic steps to install a PCF system are shown below. See the separate component manuals for

detailed information.

To avoid injury and damage to equipment, use at least two people to lift, move, or disconnect the system. The system is too heavy for one person to lift or move.

10. Connect other fluid and air lines to additional system components as instructed in their manuals.

11. Install fluid plate, swirl, and gateway cable assemblies, page 28.

12. Install Gateway interface, page 30.

Installation Steps

1. Mount control center, page 22.

For systems with multiple swirl dispensers,

2. expansion Swirl enclosures, page 22.

3. Connect and ground control center and expansion Swirl enclosures, page 23.

4. Mount each fluid plate assembly, page 24.

5. Ground each fluid plate assembly, page 27.

6. Check ground continuity.

7. Connect fluid lines between each fluid plate and applicator. Connect fluid supply line and air supply to module. See page 27.

8. Plumb air filter assembly near air supply drop site that will be used for fluid plate assembly.

9. For systems with swirl dispensers,

dispenser onto outlet of a dispense valve.

install each swirl

mount

3A2098H 21

Installation

Install Control Center

NOTE: This section applies to both the primary control

center and the expansion Swirl enclosures.

Mount

Ensure the following criteria are met before mounting the PCF 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 ADM should be 60-64 in. (152-163 cm) from the floor.

• Ensure there is sufficient clearance around the control unit to run cables to other components.

• Ensure there is safe and easy access to an appropriate electrical power source. The National Electric Code requires 3 ft (0.91 m) of open space in front of the control center.

Secure the control center with appropriate size bolts through the 0.27 in. (7 mm) diameter holes in the mounting tabs. See the following mounting dimensions.

Table 2: Control Center Assembly Measurement

A B

10.50 in. (267 mm)

5.75 in. (146 mm)

22.00 in. (559 mm)

21.25 in. (540 mm)

• Ensure there is easy access to the power switch.

• Ensure the mounting surface can support the weight of the control center and the cables attached to it.

. 12: Control Center Dimensions

22 3A2098H

Electrical Connections

To reduce the risk of fire, explosion, or electric shock, when grounding, connecting cables, connecting to a power source or making other electrical connections:

• The control center must be electrically connected to a true earth ground; the ground in the electrical system may not be sufficient. Refer to your local code for the requirements for a “true earth ground” in your area.

• All wires used for grounding must be 18 AWG minimum.

• A qualified electrician must complete all grounding and wiring connections.

• For 24 Vdc wiring refer to F

. 13.

. 14: 100-240 Vac Wiring

Installation

Ground

• For 100-240 Vac wiring refer to F

. 14.

• Incoming power wiring must be guarded from the enclosure. Use a protective grommet where the power wiring enters the enclosure to prevent wear.

NOTICE

If power and grounding connections are not done properly, the equipment will be damaged and the warranty voided.

Ground

Connect Light Tower Accessory

1. Order the 255468 Light Tower Accessory as a diagnostic indicator for the PCF system.

2. Connect the cable from the light tower to the digital I/O port (BS) on the ADM.

See Table 3 for a description of light tower signals.

Table 3: Light Tower Signals

Signal Description

Green No errors.

Yellow An advisory exists.

Yellow flashing A deviation exists.

Red solid An alarm exists. One or more fluid

plates may be shutdown.

NOTE: See Errors, page 66, for error definitions.

. 13: 24 Vdc Wiring

3A2098H 23

Installation

Install Fluid Plate Assemblies

To install the PCF fluid plate assemblies:

• Mount the fluid plate assemblies, page 24

• Ground fluid plate assemblies, page 27

• Connect one fluid plate assembly to the control cen- ter. See Install Cable Assemblies on page 28.

•

If multiple fluid plates,

together. See Install Cable Assemblies on page 28.

• Connect fluid lines, air lines, and cables; page 27

Mount

Before Mounting Assembly

• See component manuals for specific information on

component requirements. Information presented here pertains to the PCF fluid plate assembly only.

connect the fluid plates

2. Mount and secure the fluid plate assembly to the automation unit (or other mounting surface) with appropriate size bolts through the 0.397 in. (10 mm) diameter holes in the base plate. See the mounting dimensions in Table 4 and F

Table 4: Fluid Plate Assembly Measurement

. 15.

16.5 in. (419 mm)

14.0 in. (356 mm)

14.4 in. (366 mm)

13.4 in. (340 mm)

• Have all system and subassembly documentation

available during installation.

• Be sure all accessories are adequately sized and pressure-rated to meet the system's requirements.

• Use only the Graco PCF fluid plate assembly with the Graco PCF control center.

Mount Assembly

1. Select a location for the fluid plate assembly. Keep

the following in mind:

• Allow sufficient space for installing the equipment.

• Make sure all fluid lines, cables and hoses easily reach the components to which they will be connected.

• Make sure the fluid plate assembly allows the automation unit to move freely along all axis.

• Make sure the fluid plate assembly provides easy access for servicing its components.

. 15: Fluid Plate Assembly Dimensions

24 3A2098H

Installation

Mount Four-Valve Breakout Kit 24B693

PCF is capable of controlling up to four separate dispense valves from port 1 on the FCM. A four-valve breakout kit (24B693) is available to split the dispense solenoid connector (port 1 on the FCM) into four separate dispense solenoid connectors. For each additional dispense valve, order one dispense valve solenoid (258334) and one solenoid cable (121806).

Follow this procedure if using the four-valve breakout kit.

1. Remove the existing dispense solenoid and cable from the fluid plate.

2. Install bulkhead fitting (included in the kit) into the empty hole on the fluid plate.

GCA Cable

5. Connect the dispense valve cable(s) to the connections on the splitter assembly.

Connects to Splitter

Cable for:

Dispense Valve 1 J1

Dispense Valve 2 J2

Dispense Valve 3 J3

Dispense Valve 4 J4

Connection Labeled:

6. Mount splitter assembly and dispense valves, and connect air lines as necessary for application.

Custom Breakout Cable

If desired, the following connector pinout information may be used to build a custom breakout cable:

Pinout of FCM Port 1

Pin 1: Dispense Solenoid 4 Pin 2: Dispense Solenoid 2 Pin 3: Voltage - (common for all solenoids) Pin 4: Dispense Solenoid 1 Pin 5: Dispense Solenoid 3

Connection 1

Hole for bulkhead fitting

Splitter Assembly

J1 J3

J2 J4

. 16: Mount Breakout Kit

3. Connect one end of the extension cables (included in the kit) to connection 1 on the FCM and the other end of the cable to the bulkhead fitting.

Dispense solenoid outputs are 24 Vdc. Dispense solenoid outputs are capable of sourcing up to 0.5A each (maximum 12W coil).

4. Connect the splitter assembly to the bulkhead fitting.

3A2098H 25

Installation

Install Command Cable Kit 24B694

Follow this procedure if using the command cable kit.

1. Install bulkhead fitting (included in the kit) into the empty hole on the fluid plate. See F

. 16 on

page 25.

2. Connect one end of the extension cable (included in the kit) to connection 5 on the FCM and the other end of the cable to the bulkhead fitting.

3. Connect command cable to bulkhead fitting and wire to automation controller per the following pinout table.

Function

FCM Port Pin #

Command Cable Wire Color

1 White Command voltage (0-10 Vdc) Command voltage (0-10 Vdc)

2 Brown No connection Valve 3 dispense trigger (*sourcing

3 Green Dispense trigger (*sourcing input) Valve 1 dispense trigger (*sourcing

4 Yellow No connection Valve 2 dispense trigger (*sourcing

5 Gray Dispense trigger ground Dispense trigger ground

6 Pink No connection No connection

7 Blue Command signal ground Command signal ground

8 Red No connection No connection

Dispense Trigger Source:

‘Command Cable’ or

‘Combined’

Dispense Trigger Source:

‘Command Cable 3x’

input)

NOTE: Command cable inputs are not isolated from PCF 24 Vdc power.

* To turn on the dispense trigger, connect the dis-

pense trigger pin to the dispense trigger ground pin (pin 5).

26 3A2098H

Installation

Ground

To reduce the risk of fire, explosion, or electric shock, when grounding, connecting cables, connecting to a power source or making other electrical connections:

• All wires used for grounding must be 18 AWG minimum.

• A qualified electrician must complete all grounding and wiring connections.

• For 24 Vdc wiring refer to F

• For 100-240 Vac wiring refer to F

• Incoming power wiring must be guarded from the

enclosure. Use a protective grommet where the power wiring enters the enclosure to prevent wear.

NOTICE

If power and grounding connections are not done properly, the equipment will be damaged and the warranty voided.

. 13.

. 14.

Connect Fluid and Air Lines

NOTICE

Route all fluid and air lines carefully. Avoid pinching and premature wear due to excessive flexing or rubbing. Hose life is directly related to how well they are supported.

Follow the instructions in your separate component manuals to connect air and fluid lines. The following are only general guidelines.

• The PCF fluid plate assembly should be installed on the automation unit or in another appropriate place, as close as practical to the dispense valve.

• Connect a fluid line between the fluid plate outlet and the dispense valve. Smaller diameter and shorter fluid lines (hoses) will provide better fluid system response.

• Connect a fluid line to the flow meter fluid inlet or to the regulator inlet if your system does not have a flow meter.

• Air must be clean and dry, between 60-120 psi (0.41-0.82 MPa, 4.14-8.27 bar). Flush air line before plumbing in air filter assembly (234967). Plumb in air filter assembly near air drop site (upstream of fluid plate module). Adding an air regulator to this line will provide more consistent dispense valve response times.

Ground the fluid plate assembly as instructed here and in the individual component manuals. Make sure the fluid plate 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.

Dispense Valve

Follow the grounding instructions in the dispense valve manual.

• Connect an air supply line to the 1/4 npt inlet port on the fluid plate(s) air supply inlet.

• Connect 5/32 in. or 4 mm OD air lines from the applicator's solenoid valve to the applicator. Plug any unused solenoid ports.

NOTE: To maximize system performance keep the dispense hose length and ID as small as the application will allow.

3A2098H 27

Installation

Install Cable Assemblies

NOTE: To prevent system errors, only connect cables

with the power off.

NOTE: See F

. 17 on page 29.

1. For systems with more than one swirl dispenser:

Use a CAN cable to connect the control center to one swirl expansion enclosure. Use additional CAN cables to connect any remaining expansion swirl enclosures together in sequence.

2. For systems with one or more swirl dispensers,

motor cable to connect each swirl dispenser to an expansion swirl enclosure or to the control center.

Connect a CAN cable from the control center to one fluid plate assembly.

For multiple fluid plate systems,

connect each fluid plate to one other fluid plate Repeat until all fluid plates are connected to one other fluid plate.

NOTE: Use the connections on the CAN splitter on the left side of each fluid plate to connect the fluid plates together. There will be a CAN splitter on all but one fluid plate.

use CAN cables to

use

NOTE: The control center, expansion swirl enclosures, and fluid plates may be connected in any order as long as each is connected to another system component with a CAN cable. See the example shown in F page 29.

5. Use the automation interface cable (not provided) to connect the Gateway module to the automation controller.

. 17 on

28 3A2098H

Installation

Multiple Fluid Plate and Multiple Swirl System shown

FIG. 17: Cable Installation Diagram

3A2098H 29

Installation

Install Gateway Module Interface

NOTE: Systems with swirl dispensers will have two gateway modules in the control center. The gateway module on

the left is the swirl control DGM module, and does not need any setup or modification. The gateway module on the right is the automation Gateway module. This section covers the automation Gateway module.

Fieldbus Communications Gateway Module

Module Description

The Communications Gateway Module (CGM) provides a control link between the PCF system and a selected fieldbus. This provides the means for remote monitoring and control by external automation systems.

See Automation Control (Normal Operation), page 45, for details on controlling the PCF system through the Gateway module.

Data Exchange

Data is available by block transfer, cyclic transfer, change of state triggered, and explicit access to individual attributes as defined by the fieldbus specification. Refer to Appendix C - Communications Gateway Module (CGM) Connection Details, page 138, for details about PCF/fieldbus data map.

NOTE: The following system network configuration files are available at www.graco.com

• EDS file: DeviceNet or EtherNet/IP fieldbus networks

• GSD file: PROFIBUS fieldbus networks

• SDML: PROFINET fieldbus networks

CGM Status LED Signals

Signal Description

Green on System is powered up

Yellow Internal communication in progress

Red Solid

*Red (7 flashes)

*The red LED (CF) will flash a code, pause, then repeat.

CGM hardware failure

Data map load failure

Incorrect data map for fieldbus type

No data map loaded

Installation

NOTE: The following installation instructions assume

the person implementing the PCF fieldbus connection fully comprehends the fieldbus being used. Ensure the installer understands the automation controller communication architecture and the fieldbus being used.

1. Install interface cables between the PCF system and the automation controller per the fieldbus standards. Refer to Appendix C - Communications Gateway Module (CGM) Connection Details, page 122, for details.

2. Turn on system power. Navigate to the Gateway setup screens and ensure the data map name is: PCF 4FP. Refer to Appendix A - Advanced Dis- play Module (ADM), page 99, for details about the data map.

3. Set the PCF Gateway configuration values as required to interface with automation controller. Refer to Appendix A - Advanced Display Module (ADM), page 99, for details about the configuration settings.

4. Retrieve the appropriate fieldbus configuration file for the fieldbus being used from www.graco.com.

5. Install the configuration file on the automation controller (fieldbus master). Configure it for communication with the PCF Gateway (fieldbus slave).

6. Establish communication between the automation controller and the PCF Gateway to confirm the successful configuration of the hardware and data.

NOTE: Use the ADM screens for troubleshooting fieldbus data communication problems. Refer to Appendix A - Advanced Display Module (ADM), page 99, for details. Also, use the LED status indicators on the PCF Gateway module for fieldbus status information. Refer to

Appendix C - Communications Gateway Module (CGM) Connection Details, page 122, for details.

30 3A2098H

+ 112 hidden pages