Graco 3A2098H User Manual

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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

Installation

Discrete Gateway Module

Module Description

The Discrete Gateway Module (DGM) provides a control link between the PCF system and an automation controller through discrete input and output connections. 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.

Connect D-Sub Cable

The DGM provides all I/O through the D-Sub cable. Graco offers two options for connecting a D-Sub cable to the D-Sub connector (CG). Both options are accessories and must be ordered separately.

•

For single fluid plate systems only:

ing leads cable (123793). See Appendix B -

Discrete Gateway Module (DGM) Connection Details, page 115, for details and cable inter-

face signals.

D-Sub to fly-

DGM Rotary Switch Position

The Discrete Gateway Module (DGM) rotary switch must be in position 0 for Automation Gateway DGMs and positions 1-4 for Swirl Control DGMs in order for the DGM to operate. See Automation Gateway Module on page 18 and Swirl Control DGM on page 19.

•

For multiple fluid plate systems:

(123972) and 78-pin breakout board (123783). See Appendix B - Discrete Gateway Module (DGM) Connection Details, page 115, for details and pin assignments.

. 18: Connect D-Sub Cable

DGM Status LED Signals

D-Sub cable

r_24B681_2B9904_2b

See LED Diagnostic Information, page 65, for signal definitions.

3A2098H 31

System Setup

Overview

The PCF 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 PCF system must be set up again.

After material is loaded into the supply system, set up the PCF system using the Setup screens. The following procedure outlines the major system setup steps. The following subsections provide instructions to complete each setup step. Once these steps are complete the module is ready for operation.

NOTE: See the Advanced Display Module (ADM) section, page 17, and Appendix A - Advanced Display Module (ADM), page 99, for detailed operating instructions for the display keypad and each screen.

1. Configure System, page 32.

Configure System

Define the number of installed fluid plates (called “Dispenser” on this screen) and number of installed swirl dispensers. If a fluid plate is listed as “Uninstalled” the screens for that fluid plate will not appear in the run or setup screens.

1. With the system in setup mode, navigate to the System screen.

2. Press to access the fields to make changes.

3. Use the arrow keys to navigate to the desired field.

4. Press to open the drop-down list, and select

the desired setting. Press to accept the selection.

5. Repeat for the other Dispensers and Swirl Dispensers.

6. Press to exit edit mode.

2. Configure Control Settings, page 33.

3. Configure Mode Settings, page 34.

4. Configure Delay Settings, page 34.

5. Configure Flow Meter Settings, page 35.

6. Configure Pressure Loop Settings, page 35.

7. Adjust Pressure Sensors, page 36.

8. Configure Errors, page 36.

9. Setup Maintenance Schedule/Parameters, page 37.

10. For systems with swirl dispensers only:

a. Configure Swirl to valve association and error

type, page 37.

b. Configure Swirl settings, page 38.

11. Configure Gateway Settings, page 38.

12. Setup Styles, page 38.

. 19

13. Configure Advanced Settings, page 38.

32 3A2098H

System Setup

Configure Control Settings

Set the controls for the dispense source, how dispense commands are sent, and job settings.

1. With the system in setup mode, navigate to Fluid Plate x, screen 1 (Control Settings).

2. Press to access the fields to make changes.

7. Press to move to the Job End Delay field. Enter

the desired delay time (in seconds). Press to enter the value.

8. Press to move to the Run Mode Bead Adjust

field. Press to open the drop-down list, and

select Enable or Disable. Press to enter the value.

9. Press to move to the End Job on Alarm Check-

box. Press to enable or disable.

10. Press to move to the Display Control Password

field. Press to enter the value.

11. Press to exit edit mode.

If multiple fluid plates are installed,

12. cedure for the other Fluid Plates.

repeat this pro-

. 20

3. Press to open the Dispense Trigger Source drop-down list, and select Gateway, Command Cable, Command Cable 3x, or Combined. If Command Cable is selected, users can enable the

valves. Press to finalize the selection.

4. If the dispense trigger source is set to Command

Cable, press to move to the Enable Valves field.

Press and to enable valves.

5. Press to move to the Command Value Source

field. Press to open the drop-down list, and select Gateway, Command Cable, or Display. Press

to enter the value.

6. Press to move to the Job End Mode field. Press

to open the drop-down list, and select Timer or

Gateway. Press to enter the value.

3A2098H 33

System Setup

Configure Mode Settings

Set valve commands, including the dispense mode (pressure, bead, shot, or full open) and flow rate or pressure for each valve. The bead scale is also adjustable from this screen.

NOTE: For a description of each dispense mode, see Dispense Control Modes, page 112.

1. With the system in setup mode, navigate to the Fluid Plate x, screen 2 (Mode Settings).

2. Press to access the fields to make changes.

5. Press to move to the Bead Scale field. Enter a

scale value between 50% and 150%. Press to enter the value.

6. Press to exit edit mode.

Configure Delay Settings

Set on and off delays (in milliseconds) for each valve and the regulator. For an explanation of the on and off delays, refer to the On/Off Delays section on page 39.

1. With the system in setup mode, navigate to the Fluid Plate x, screen 3 (Delay Settings).

2. Press to access the fields to make changes.

. 21

3. Press and to set the mode for each

valve that will be used to Pressure, Bead, Shot, or Full Open. Press to enter each selection.

4. Use the four arrow buttons to navigate to each Fixed Command field. Enter the desired value for

each valve that will be used. Press to enter each value.

NOTE: The ability to dispense from multiple valves simultaneously is only allowed in either of the following scenarios.

• Each valve is set to Pressure mode and has

identical Fixed Command values.

• Each valve is set to Full Open mode.

Attempting to dispense from multiple valves simultaneously using any other combination will cause an Incompatible Valves Settings alarm.

FIG. 22

3. Use the four arrow buttons to navigate to each On and Off field. Enter a desired delay value (in milliseconds) for each valve that will be used and the

regulator. Press to enter each value.

4. Press to exit edit mode.

34 3A2098H

System Setup

Configure Flow Meter Settings

The accuracy of the PCF volume reporting depends on precise adjustment of the K-factor(s). The fluid plate uses the K-factor(s) to calculate the volume dispensed. If the set value is not correct, the system still delivers repeatable flow rates; however, the reported value may not be correct. See Verify Flow Meter Calibration, page 42, for additional K-factor information.

Table 5: Flow Meter K-Factors

Part Description K-Factor

246652 High Resolution Helical

Gear Meter

246340 Heated Helical Gear

Meter

16E993 Ultra High Flow Meter 33000

Set Flow Meter K-Factor

NOTE: In systems without a flow meter, the flow meter

settings will be grayed out.

1. With the system in setup mode, navigate to the Fluid Plate x, screen 4 (Pressure Loop and Flowmeter Settings).

2. Press to access the fields to make changes.

7000

3500

3. Press to open the Meter Type drop-down list, and select the meter type used by the system. Select Volume for volumetric flow meters or Mass

for mass flow meters. Press to enter the selection.

4. Press to move to the K-Factor field. Key in the

K-factor value. See Table 5: Flow Meter K-Factors for values. Press to enter the value.

5. Press to exit edit mode.

NOTE: If necessary, verify flow meter calibration. See Verify Flow Meter Calibration, page 42, for instruc-

tions.

Configure Pressure Loop Settings

The PCF system uses variables (Kp, Ki, and Kd) in the software calculations to accurately and precisely control the fluid pressure.

NOTE: It is recommended that these values are not changed from the factory defaults of 32.00 for Kp,

128.00 for Ki, and 0.00 for Kd. However, if the values

need to be adjusted, see Manually Adjust Control

Loop Parameters on page 43.

. 23

3A2098H 35

System Setup

Adjust Pressure Sensors

Set pressure offsets and pressure limits.

NOTE: Inlet sensor settings will be grayed out on this screen for systems with heated fluid plates.

1. With the system in setup mode, navigate to the Fluid Plate x, screen 5 (Pressure Sensors).

2. Press to access the fields to make changes.

. 24

Configure Errors

Set the error type (alarm, deviation, or none) that will be issued if the pressure, flow rate, volume, or computed target goes outside the tolerance settings of the active style. When an alarm occurs, the system stops dispensing. When a deviation occurs, the system will continue dispensing. See Fluid Plate x, Screen 6 (Error Type) on page 107 for more information.

NOTE: Only the low/high pressure errors will be enabled for systems without a flow meter.

1. With the system in setup mode, navigate to Fluid Plate x, screen 6 (Error Type).

2. Press to access the fields to make changes.

NOTE: For the following steps, press and

to navigate through each field, and to open

drop-down menus and enter changes or selections.

3. Set the desired offset for the inlet and outlet pressures between 0 and 100 psi (0.7 MPa, 7.0 bar). Remove all pressure on the sensors, and then adjust the offset so the measured value reads 0.

NOTE: It is recommended that offsets should not be changed from the factory defaults of 0.

4. Set the desired minimum and maximum pressure limits for the inlet, and the desired maximum pressure limit for the outlet.

5. Set the error type (alarm or deviation) that will be issued:

• If the minimum inlet pressure decreases below

the setting.

• If the maximum inlet pressure increases above

the setting.

• If the maximum outlet pressure increases above

the setting.

FIG. 25

3. Press to open the Low Pressure drop-down list, and select either Alarm or Deviation for the error

type. Press to enter the selection.

4. Press to move to the next field. Repeat Step 4

for each field.

5. Press to exit edit mode.

6. Press to exit edit mode.

36 3A2098H

System Setup

Setup Maintenance Schedule/Parameters

Set the volume (or hours) limit that will trigger a maintenance advisory for the fluid supply, Voltage to Pressure (V/P) Transducer, fluid regulator, flow meter, and all four valves.

NOTE: Hours is shown instead of Volume for fluid plates without a flow meter.

The Volume (or Hours) column displays the current totalizer value. If this value exceeds the set limit, the value will turn red and a maintenance advisory is issued. See Fluid Plate x, Screen 7 (Maintenance Advisory Limits), page 108, for more information about maintenance totalizers.

To set limits:

1. With the system in setup mode, navigate to the Fluid Plate x, screen 7 (Maintenance Advisory Limits).

2. Press to access the fields to make changes.

To reset a totalizer value:

1. Follow Steps 1-3 of To set limits: to make changes in

Fluid Plate x, screen 7 (Maintenance Advisory Lim-

its)

2. Press to scroll to the system component to

reset.

3. Press to reset the value.

Configure Valve to Swirl Association and Motor Error Type

Define which Swirl number is installed on which dispense valve.

Set the error type (alarm or deviation) that will be issued if a motor fault occurs. When an alarm occurs, the fluid plate stops dispensing. When a deviation occurs, the fluid plate will continue dispensing.

. 26

3. Enter the desired limit for the air supply and press to enter the selection.

4. Press to move to the next field. Repeat Step 4

for each field.

5. Press to exit edit mode.

3A2098H 37

FIG. 27

System Setup

Configure Swirl Settings

NOTE: This applies only to systems with swirl dispens-

ers.

Set the individual Swirl settings for each installed Swirl.

. 28

Configure Gateway Settings

Gateway settings differ for each system. See Automation Gateway Setup Screens, page 102, for guidelines

on configuring each type of Gateway interface.

Setup Styles

The PCF system can store up to 256 styles. See Styles, page 46, for more information about styles and instructions on setting up styles. Style 0 is always the purge style.

Configure Advanced Settings

Use the advanced settings to set or change the format and display units, such as the language, date format, and pressure units, for all PCF screens. See Setup Mode, page 101, for advanced setting guidelines.

38 3A2098H

On/Off Delays

The PCF fluid regulator can physically respond faster than the dispense device and its solenoid. As a result, the fluid regulator can supply material to the dispense device before the device has time to open. Supplying material to a closed device can create trapped-pressure.

At the end of a cycle, the dispense device can shut off before the pressure has dissipated. This can cause a dispense of an excess of material at the beginning of the next cycle.

To eliminate these two problems, change the delay time associated with the opening of the fluid regulator/dispense and/or the closing of the dispense device, see Table 5: On/Off Delay Variables. For instructions setting on/off delays, see Configure Delay Settings, page

34.

NOTE: On/Off delay can be set for each dispense device.

In general, delays should be adjusted so the outlet pressure during “no flow” is slightly below the outlet pressure during dispense.

System Setup

. 29 and Table 6: Delay On/Off Timing show delay

ON and OFF timing.

Table 6: Delay On/Off Timing

A Regulator ON

delay

The user sets the fluid regulator ON delay timing.

B Valve ON delay Usually set to zero. Can be

used to change the starting point of a bead.

C Valve OFF Delay Usually set to zero. Higher

values will lower the trapped pressure.

D Regulator OFF

delay

The user sets the regulator OFF delay timing. Zero or small values will lower the trapped pressure.

E Valve Open

Reaction Time

Time delay for valve to physically open. Delay varies based on pneumatic hose length and valve air volume.

F Valve Close

Reaction Time

Time delay for valve to physically close. Delay varies based on pneumatic hose length and valve air volume.

Table 5: On/Off Delay Variables

Variable: Sets the Amount of Time:

Valve ON Sets time from Dispense Valve High

to Valve Open command

Regulator ON

Sets time from Dispense Valve High to Regulator ON

Valve OFF Sets time from Dispense Valve Low

to Valve Close command

Regulator OFF

Sets time from Dispense Valve Low to Regulator OFF

Dispense Valve Signal

Fluid Regulator

Valve Open Command

Valve Actually Open

FIG. 29: Timing Delay

3A2098H 39

Operation

Pressure control may degrade at low output pressures. It is not recommended to dispense at outlet pressures less than 500 psi (3.4 MPa, 34 bar).

Startup

Initial Startup

1. Ensure the PCF control center is installed and all of the proper connections to and from the control center have been made. Ensure fittings are tight.

2. Read and understand the Operation (page 40) and Advanced Display Module (ADM) (page 17) sections of this manual.

3. Continue startup with step 2 in Standard Startup.

Standard Startup

1. Carefully inspect the entire system for signs of leakage or wear. Replace or repair any worn or leaking components before operating the system.

Load Material

Before using the system material must be loaded into the supply system.

1. If this is a new installation, follow the Initial Startup procedure. Otherwise, follow the Standard Startup procedure. See page 40.

2. Turn on the fluid supply pressure to the fluid plate assembly.

3. Place the valve(s) over a waste container.

4. Enter the maintenance screen. See Dispense From Maintenance Screen, page 43.

5. Select a control mode. See Dispense From Main- tenance Screen, page 43.

6. If the system status indicator LED (BB) is orange,

press to turn the system on.

2. Press the Stop button (BC). See F

3. Turn on air.

4. Turn on electrical power to the system.

5. Turn on the main power to supply power to the PCF.

6. Check Interface Signals: If this is a new installation, power on each system input and verify that each input is being received.

7. Turn on the material supply system.

. 8 on page 17.

7. Press and hold . Dispense fluid until clean,

air-free fluid flows from the valve.

8. Press to exit maintenance screen.

40 3A2098H

Operation

Maintenance Mode Operation

Fluid Plate

Maintenance Screen

Operating from maintenance mode enables manual

dispensing ( ) and manually starting the swirl dis-

penser ( ).

The system begins dispensing when the user presses

. Dispense parameters and duration depend on the

selected control. Dispensing continues for as long

as is pressed.

Maintenance Screen

Swirl

Follow steps in the supply system manual to set the inlet pressure.

NOTICE

Inlet pressure beyond the recommended range above will cause accelerated wear on the regulating valve and the pump feed system.

Feed System Pressure Drop

During material flow, the regulator inlet pressure decreases. The amount the pressure decreases is the amount of pressure lost between the feed pump and the regulator inlet.

With high viscosity fluids, long line lengths, or small diameter line sizes this pressure decrease can be thousands of psi (hundreds of bar). This means that the static pump pressure is set much higher than the regulator needs at its inlet. To prevent excessive control regulator wear or surging, a mastic fluid pressure regulator is recommended on the feed line close to the control regulator. The mastic regulator will suppress the static feed pressure at the control regulator inlet.

The system starts the swirl dispenser when the user

presses . The swirl dispenser continues to run until

is pressed again.

There is one maintenance screen for each installed fluid plate and each installed Swirl. The maintenance controls for the Swirl are shown on both the Swirl maintenance screen and on the Fluid Plate maintenance screen for the fluid plate where the swirl dispenser is installed.

Verify System Operation

Use maintenance mode to manually check the operation of the PCF system components before switching over to automation control (normal operation). See Dispense From Maintenance Screen, page 43, for instructions on operating from maintenance mode.

NOTE: Perform the following procedures while in maintenance mode.

Set Inlet Pressure

The inlet pressure reading should be in the range of 300 psi (2.1 MPa, 21 bar) to 500 psi (3.4 MPa, 34 bar) above the outlet pressure reading under your highest flow condition.

3A2098H 41

Operation

Dispense from Each Valve

Dispense from each valve that will be used in normal operation to confirm that the entire system is installed correctly and is capable of delivering desired results.

Follow the steps outlined in Dispense From Mainte- nance Screen, page 43, to perform each of the following applicable system verification checks.

NOTE: Each fluid plate controls only the dispense valves connected to it.

• For each valve that will be used during normal operation, dispense at each pressure or flow rate that will be used during normal operation. This verification check confirms that the system is capable of delivering material at your maximum desired operating point.

• For systems that will operate multiple valves in pressure mode at the same time, dispense from each valve at the same time. This verification check confirms that the system is capable of delivering material at your maximum desired operating point.

• For each valve operating in bead mode, perform an initial teaching process. Follow this procedure after significant system and/or material characteristic changes.

a. For each flow rate that will be used during nor-

mal operation, press until PCF achieves

the flow rate setpoint.

Verify Flow Meter Calibration

Most sealant and adhesive materials are compressible. Since the flow meter measures the material under high pressure, the actual volume of material dispensed may vary slightly from the measured volume, due to this compressibility. If the K-factor is not correct, the displayed volume will not be accurate.

Follow either of the following methods to calibrate the flow meter during initial setup and on a routine basis to check for flow meter wear.

Method 1. Using a gram scale

1. Record the flow meter k-factor shown on Fluid Plate x, screen 4 (Flowmeter Settings). See F

. 23 on

page 35.

2. Use a 500 cc or larger beaker. Measure the mass of the empty beaker.

3. Manually dispense material into the beaker. Hold the beaker so that the stream of material is submerged in the captured material to minimize air entrapment in the container.

4. Record the volume dispensed on Fluid Plate x, screen 1. See F

. 30 on page 43.

5. Calculate the actual volume dispensed:

fluid mass (g) density (g/cc)

measure volume (cc)

NOTE: During the initial system operation verification, it

6. Calculate the new flow meter K-factor:

may take four to five seconds for the system to learn system characteristics.

b. Continue to press for several seconds

K-Factor (new) =

7. Enter new K-factor.

displayed volume (cc) x K-Factor (old)

measured volume (cc)

after the desire flow rate is reached to confirm that the system is capable of maintaining the

8. Repeat the procedure to verify the new K-factor.

desired flow rate.

c. Repeat Steps a and b for a range of flow rates

to confirm that the system responds quickly to

achieve setpoint when is pressed.

Method 2. Without using a gram scale, visual measurement

1. Record the flow meter k-factor shown on Fluid Plate x, screen 4 (Flowmeter Settings). See F

. 23

on page 35.

2. Use a 500 cc or larger beaker.

42 3A2098H

Operation

3. Manually dispense material into the beaker. Hold the beaker so that the stream of material is submerged in the captured material to minimize air entrapment in the container.

4. Record the volume dispensed on Fluid Plate x, screen 1. See F

. 30 on page 43.

5. Settle the material into the beaker and view the actual volume dispensed.

6. Calculate the new flow meter K-factor:

K-Factor (new) =

displayed volume (cc) x K-Factor (old)

dispensed volume (cc)

7. Enter new K-factor.

8. Repeat the procedure to verify the new K-factor.

Manually Adjust Control Loop Parameters

Optional:

To fine tune the step response in pressure

mode, gradually increase the Kd value.

NOTE: Increasing Kd (pressure only) is typically not necessary but it may improve step response. However setting Kd too high may cause the system to oscillate.

7. Stop dispensing.

Dispense From Maintenance Screen

1. Navigate to Fluid Plate x, screen 1 for the desired fluid plate.

NOTE: It is recommended that these values not be changed from the factory defaults of 32.00 for Kp,

128.00 for Ki, and 0.00 for Kd.

If the system is not maintaining the desired setpoint while in pressure or bead control mode, manually change the Kp and Ki values:

NOTE: Pressure parameters should be adjusted first, even if you typically operate in bead control mode.

1. Begin dispensing material.

NOTE: Begin a new dispense each time control parameters are changed.

If the regulator outlet pressure does not closely follow the desired pressure,

set Ki to zero then increase Kp until the proper pressure control is achieved.

If the regulator outlet pressure oscillates rapidly above and below the commanded pressure,

decrease Kp by 10%. Continue to decrease the Kp value in 10% increments until the outlet pressure is stable.

4. Set Ki value to 2 then increase the Ki value until the system oscillates.

FIG. 30

2. Press to enter maintenance screen.

. 31

3. Press to open the Control Mode drop-down list, and select the preferred control mode. Press

again to exit the drop-down list.

5. Decrease Ki until oscillation stops.

3A2098H 43

Operation

4. Press to move to the target fields. Enter the tar-

get pressure, flow rate, or volume (dependent on control mode) and press to save.

5. Press to move to the valve check boxes. Press

to select the desired valves.

6. Follow step 2 - 4 of Manually Dispense Fluid, page

44.

Manually Dispense Fluid

1. From Fluid Plate x, screen 1, press to enter

maintenance screen.

2. Press and verify that the valve opens.

3. Continue to press as long as needed to load or

dispense material.

2. Press to enter maintenance screen.

FIG. 33

3. To change the RPM, use the arrow keys to navigate to the RPM box then enter the desired RPM.

4. Press again to exit maintenance screen.

Operate Swirl Dispenser From Maintenance Screen

1. Navigate to the Swirl x screen for the desired Swirl Dispenser. If the Swirl Dispenser is installed on Fluid Plate x, you may also navigate to Fluid Plate x, screen 1.

4. Press and verify that the Swirl Dispenser

begins rotating. Press again to stop the Swirl

Dispenser.

5. Press again to exit maintenance screen.

. 32

44 3A2098H

Operation

Automation Control (Normal Operation)

During automation control (normal operation), the system can dispense or change dispense parameters when it receives a command from the automation unit.

The automation control operates using the concept of jobs and styles. For a detailed explanation of jobs and how they work within the PCF system, see Jobs on page 45. For a detailed explanation of styles and how they work within the PCF system, see Styles on page 46.

Jobs

NOTE: See Appendix D - I/O Signal Descriptions,

page 138, for automation input and output signal descriptions.

A job is an automation sequence in which material can be dispensed. The amount of material specified for a job varies by application. In some applications, a job may be the amount of material dispensed on a part. Other applications may define a job to be the amount of material dispensed on a number of parts or dispensed over a period of time.

A job is initiated when the automation sends a Style Strobe signal to the PCF. Once the job is initiated, the PCF will start tracking the amount of volume requested by the automation and the amount of material that is actually dispensed. These volumes will be tracked until the job is completed. At the end of the job, error calculations are made and the volumes are stored on the PCF system (Job Log).

The PCF system monitors two things to determine when a job is complete. Either the Dispense Complete signal is sent by the automation or the job complete timer expires. The type of job end signal is configured to Timer or Gateway in Fluid Plate x, screen 1 (Control Settings). If the timer method is used, the timer begins counting every time the dispense valve is turned off. If the valve stays off for more than the preset timer value, the job is considered complete.

Actual (Measured) Volume - The amount of material measured by the flow meter during a job.

Requested Volume - The amount of material that the automation tries to dispense during a job. In Bead mode, the requested volume is calculated as the requested flow rate multiplied by the duration of the dispense. In all other modes, the requested volume is same as the target volume.

Target Volume - The amount of material a job should have. This is defined in the Style.

Jobs in Bead Mode

In Bead Mode, all of the previously mentioned volumes are monitored. The High Volume, Low Volume, and Computed Target errors are evaluated at the end of the job. The volume alarms compare the measured volume to the requested volume and the computed target alarm compares the requested volume to the target volume.

Jobs in Pressure Mode

In Pressure Mode, the requested volume is not measured. In this mode, the automation command voltage corresponds to a pressure instead of flow rate. For this reason the requested volume is not available (as well as the Computed Target error). The high and low volume alarms compare the measured volume to the target volume for pressure mode.

Continuously Running Applications

In some cases the target volume for a job is not known. An example of a case where the target volume is unknown is a continuously running system. This would be a system that does not run jobs, but runs continuously over a day or a shift. In this case, the flow rate becomes more important than the amount of volume dispensed in a job. The way to handle this situation is to set the target volume to a value of zero. This effectively disables the Computed Target error. The controls will still maintain the desired flow rate and report errors corresponding to the tolerance set for the running style.

Once the job is complete, the job information is stored to memory. The most recent jobs can be viewed on the Job screen. The information stored with each job is as follows. See Job Report Screens, page 114, for instructions on how to view job reports.

3A2098H 45

Operation

Styles

The PCF system has the ability to handle up to 256 styles, depending on the selected option.

NOTE: The number of available styles depends on the fluid plate configuration. See Models on page 4. Style 0 is specified for purging only.

For each style, an independent target volume and tolerance can be configured. This allows for job-related errors and logs to be evaluated for each style. The style is read at the beginning of a job and cannot be changed until the next job.

PCF reads in the styles via the Gateway interface. For detailed interface information, see Appendix B - Dis- crete Gateway Module (DGM) Connection Details on page 115, and Appendix C - Communications Gate- way Module (CGM) Connection Details on page 122, as applicable.

To setup a style:

3. Enter the style number in the Style field.

4. Enter Style Name:

a. Press while in the Style Name field to dis-

play the Keyboard screen.

FIG. 35

1. Navigate to Fluid Plate x, screen 8.

2. Press to access the style setup fields.

. 34

b. Use the arrow buttons on the ADM to scroll

through each letter. Press to enter a letter

in the style name field. See Keyboard Screen, page 109, for further details.

c. Press to accept the new value.

5. Enter the target volume in the Volume field, and the tolerance percentages in the Low and High Tolerance fields.

6. Enter precharge mode and parameters. See Pre- charge Modes beginning on page 47.

7. Press to exit edit mode.

46 3A2098H

Operation

Precharge Modes

NOTE: See the diagram on the following page.

Static Precharge Mode

Display

When Display precharge mode is selected, a static precharge pressure can be defined. When a job is active and all dispense valves are closed, the regulator will maintain the defined precharge pressure.

Gateway

NOTE: Gateway precharge mode is only available for systems containing CGMs.

When “Gateway” precharge mode is selected, the outlet pressure will be set according to the current pressure/flow command using the scaling set for dispense valve(s) selected through the gateway interface.

Dynamic Precharge Modes

Dynamic precharge control allows the system to better prepare for the upcoming dispense. The pressure/flow command is used to actively set the outlet pressure to the ideal pressure while all dispense valves are closed and provide a boost while the valve is opening to help accelerate material.

The “Closed” scaling will be applied when all dispense valves are closed and the “Opening” scaling will be applied immediately after a dispense valve starts to open and continue for the user-specified duration (in milliseconds). The precharge scaling values modify the control signals that are necessary to obtain the desired pressure/flow. The precharge pressure can be changed dynamically throughout the job by varying the pressure/flow command value.

Valve 1

When the “Valve 1” precharge mode is selected, the outlet pressure will be set according to the current pressure/flow command using Valve 1 scaling values.

3A2098H 47

Operation

Closed Precharge Scaling Value

Dispense Application Direction Dispense Application Direction Dispense Application Direction

Value Too Low Ideal Value Value Too High

-Controls outlet pressure based on desired command while valves are closed.

-Ideal value is typically less than 100% due to the minimal pressure losses within the system when fluid is not flowing.

Opening Precharge Scaling Value

Dispense Application Direction Dispense Application Direction Dispense Application Direction

Value Too Low Ideal Value

-Provides a boost upon valve opening to accelerate material.

-Ideal value is typically greater than 100%.

Value Too High

Opening Precharge Duration Value

Dispense Application Direction Dispense Application Direction Dispense Application Direction

Value Too Low Ideal Value Value Too High

-The duration for which the valve opening scaling is application before the command is no longer scaled.

Regulator On Delay Value

Dispense Application Direction Dispense Application Direction Dispense Application Direction

Value Too Low Ideal Value Value Too High

-Controls timing of transition from valve “closed” precharge to valve “opening” precharge and regular dispense.

-This delay should approximate the time it takes a dispense to open.

48 3A2098H

Operation

Typical Job Cycle

In order for the system to run it must be in the active

state (status LED next to on the ADM is green).

Before a job begins the automation controller outputs should have the following values:

• Style Strobe: 0

• Dispense Complete: 0

• Dispense Valve x On: all should be 0

• Style: Any value is acceptable

A typical job cycle consists of the following dispensing sequence. See Typical Job Cycle Chart, page 50.

NOTE: Each job cycle can apply to only one fluid plate.

1. The automation controller checks that Dispenser (Fluid Plate) Ready signal is set to 1. If it is set to 1, a job can begin.

2. The automation controller sets the Style to the next desired style value.

NOTE: Each fluid plate has a unique set of styles. For example, Style 2 for Fluid Plate 1 is different from Style 2 for Fluid Plate 2.

3. The automation controller sets the Style Strobe to 1.

7. PCF sets the following signals based on the results of the job.

• Dispenser (Fluid Plate) No Alarm

• Dispenser (Fluid Plate) No Error

• Dispense Volume OK

•Error

• Dispensed Volume

NOTE: The automation controller should not read the Dispense Volume OK or Dispense Volume signals until after the system clears the Dispense In Process signal.

8. PCF sets Dispense In Process to 0 to indicate the job is complete. At this time the signals from step 7 should be read.

9. The automation controller must clear Dispense Complete and Style Strobe (either can be cleared first) before the next job can start.

Jobs with Command Cable Dispense Trigger

With the Dispense Trigger Source configured to Command Cable or Command Cable 3x, users only need to trigger the dispense applicator to start a job. This configuration is useful for less demanding applications that do not require a full automation interface.

4. PCF reads the Style bits to select the new style. The system then starts a new job and sets Dispense In Process to 1.

5. The automation controller begins dispensing. The automation controller sets and clears Dispense Valve x On bits as desired throughout the course of the job.

6. When the dispense is complete the automation controller sets Dispense Complete to 1.

The following limitations apply when starting a job with this configuration:

• The selected style defaults to Style 1.

• There can be up to a 100 ms delay before dispensing while PCF prepares for the new job cycle.

• The job end mode timer must be used to end a job.

3A2098H 49

Operation

Typical Job Cycle Chart

NOTE: Swirl can be turned on at any point inside of or

outside of a job. Allow time for the swirl to reach desired RPM. If possible, verify Swirl speed through the automation interface prior to opening the dispense valve.

Automation Inputs (PCF Outputs)

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispenser (Fluid Plate) In Process

Volume OK

Automation Outputs (PCF Inputs)

Style Bits

Style Strobe

Dispense Valve X On

Dispense Complete

PCF State

Regulator Active (Precharge = 0)

Dispense Valve X Open

First Job

Second Job

50 3A2098H

Control Charts

Automation Inputs (PCF Outputs)

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Automation Outputs (PCF Inputs)

Operation

Purge Using Style 0

Dispense Ready

Dispense In Process

Purge In Process

Volume OK

Style Bits

Style Strobe

Dispense Valve X On

Dispense Complete

PCF State

Dispense Valve X Open

Automation Inputs (PCF Outputs)

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Purge In Process

Automation Outputs (PCF Inputs)

Remote Start / Purge

Purge Using Purge Bit

Dispense Valve X On

PCF State

Dispense Valve X Open

3A2098H 51

Operation

Control Charts (continued)

Automation Inputs (PCF Outputs)

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) Remote Start/Purge in Process

Automation Outputs (PCF Inputs)

Remote Start

Dispenser (Fluid Plate) Ready

Dispenser (Fluid Plate) No Error

Remote Start/Purge

Automation Inputs (PCF Outputs)

Dispenser (Fluid Plate) No Alarm / Dispenser (Fluid Plate) No Error

Automation Outputs (PCF Inputs)

Error Reset

Automation Inputs (PCF Outputs)

Dispense In Process

Automation Outputs (PCF Inputs)

Error Reset

Rising Edge Only

Cancel Job

52 3A2098H

Control Charts (continued)

Operation

Automation Inputs (PCF Outputs)

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Volume OK

Automation Outputs (PCF Inputs)

Style Bits

Style Strobe

Dispense Valve X On

Dispense Complete

PCF State

Regulator Active

Dispense Valve X Open

Automation Inputs (PCF Outputs)

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Volume OK

Precharge* - Display Mode

* Precharge: After starting a job and prior to opening the dispense valve, the fluid pres-

sure is increased to try to match the dispensing pressure. This helps the consistency of the dispense.

◆

Shaded areas indicate the precharge is active.

Precharge* - Gateway Mode

◆

Automation Outputs (PCF Inputs)

Style Bits

Style Strobe

Precharge Valve X On†

Command Signal Valid‡

Dispense Valve X On

Dispense Complete

PCF State

Regulator Active

Dispense Valve X Open

* Precharge: After starting a job and prior to opening the dispense valve, the fluid pres-

sure is increased to try to match the dispensing pressure. This helps the consistency of the dispense.

◆

Shaded areas indicate the precharge is active.

†

The “Precharge Valve X On” bits are only available through a fieldbus interface. This precharge method is not valid for DGM systems.

‡ Only applies to command signals when either “Command Cable” or “gateway” is

selected as “Command Value Source”.

3A2098H 53

Operation

Control Charts (continued)

Automation Inputs (PCF Outputs)

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Volume OK

Automation Outputs (PCF Inputs)

Style Bits

Style Strobe

Command Signal Valid†

Dispense Valve X On

Dispense Complete

PCF State

Regulator Active

Dispense Valve X Open

Precharge* - Valve 1 Mode

* Precharge: After starting a job and prior to opening the dispense valve, the fluid pressure is

increased to try to match the dispensing pressure. This helps the consistency of the dispense.

◆

Shaded areas indicate the precharge is active.

†

Only applies to command signals when either “Command Cable” or “gateway” is selected as “Command Value Source”. In systems containing an automation gateway DGM, when “Digital” is selected as the “Command Value Type”, the “Digital CMD 1” and “Digital CMD 2” inputs set the command.

◆

Trigger Using Command Cable 3x

Automation Inputs (PCF Outputs)

Dispense In Process

Automation Outputs (PCF Gateway Inputs)

Dispense Valve 1 Trigger

Dispense Valve 2 Trigger

Dispense Valve 3 Trigger

PCF State

Regulator Active (Precharge = 0)

Dispense Valve 1 Open

Dispense Valve 2 Open

Dispense Valve 3 Open

54 3A2098H

Control Charts (continued)

Automation Inputs (PCF Outputs)

Regulator Active (Precharge = 0)

Automation Inputs (PCF Outputs)

Automation Outputs (PCF Gateway Inputs)

Operation

Trigger Using Command Cable

Dispense In Process

Command Cable

Dispense Trigger

PCF State

Dispense Valve X Open*

* Dispense Valve X Open determined by Enable Valves check boxes

on Fluid Plate x, screen 1(Control Settings).

Trigger Using Gateway

Dispense In Process

Dispense Valve 1 On

Dispense Valve 2 On

Dispense Valve 3 On

Dispense Valve 4 On

PCF State

Regulator Active (Precharge = 0)

Dispense Valve 1 On

Dispense Valve 2 On

Dispense Valve 3 On

Dispense Valve 4 On

Trigger Using Command Cable and Gateway (Combined)

Automation Inputs (PCF Outputs)

Dispense In Process

Automation Outputs (PCF Gateway Inputs)

Dispense Valve X On

Dispense Valve Y On

Command Cable

Dispense Trigger

PCF State

Regulator Active (Precharge = 0)

Dispense Valve X On

Dispense Valve Y On

3A2098H 55

Operation

Control Charts (continued)

Automation Inputs (PCF Outputs)

Dispenser (Fluid Plate) Ready

Enable Swirl Dispenser

Swirl X Actual Speed - RPM (32 bits)

Automation Outputs (PCF Gateway Inputs)

Swirl X Speed Command (12 bits)

Swirl X Enable

PCF State

Swirl X On

NOTE:

Swirl orbiter may take a few seconds to reach full speed.

Actual Speed Value Valid

Command Value Set

Full Speed

Speeding Up

56 3A2098H

Pressure Relief Procedure

The equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking or servicing the equipment.

Pressure Relief Procedure

b. Continue actuating the plunger until all pressure

is purged from the system between the needle and the dispense valves attached to this fluid plate before proceeding to the next step.

For systems with multiple fluid plates,

ous steps for other fluid plates.

6. Shut off air to the fluid plate.

repeat previ-

1. Shut off the fluid supply to the fluid plate assembly.

2. Place a waste container beneath the dispense valve.

3. In maintenance mode, select Full Open Dispense Mode, which opens the regulator and dispense

valve. Press the manual dispense button until

the fluid flow stops.

4. If the dispense valve cannot be actuated from the control center, refer to F lowing steps to open the dispense valve and relieve fluid pressure:

a. Manually actuate the plunger on the solenoid to

open all dispense valves attached to this fluid plate and relieve fluid pressure. See F

Dispense Valve Air Solenoid

. 36 and perform the fol-

. 36.

7. Place a waste container below the air filter assembly then open drain valve on the air filter assembly. Close drain valve once air is relieved.

8. Turn main power switch on control panel to the OFF position.

9. If you have followed the previous steps and suspect that a valve, hose, or dispense nozzle is clogged or that pressure has not been fully relieved, very slowly remove the dispense tip, clean the orifice, and continue relieving pressure.

10. If this does not remove the clog, cover the hose end coupling with a rag then very slowly loosen the hose end coupling to relieve pressure gradually, then loosen the coupling completely. Clear the valves or hose. Do not pressurize the system until the blockage is cleared.

. 36: Dispense Valve Air Solenoid

3A2098H 57

Shutdown

1. Press the Stop button (BC).

FIG. 37: ADM - Stop Button

TI12362a

2. Shut off the material supply to the fluid plate/meter.

3. Follow the Pressure Relief Procedure on page 57.

4. Turn off the PCF system's compressed air supply.

5. Turn main power switch on control panel to the OFF position.

. 38: Control Center Main Power Switch

58 3A2098H

USB Data

All files downloaded from the USB are put in a DOWNLOAD folder on the drive. For example: “E:\GRACO\12345678\DOWNLOAD\”

The 8-digit numeric folder name matches the 8-digit ADM serial number. When downloading from multiple ADMs, there will be one sub-folder in the GRACO folder for each ADM.

USB Logs

. 39: ADM USB Port

During operation, PCF stores system and performance related information to memory in the form of log files. PCF maintains three types of log files: a job log, an event log, and dispense data logs. Follow the Down-

load Procedure, page 61, to retrieve log files.

Event Log

• Target volume (in the units shown in the volume units column)

• Requested volume (in the units shown in the volume units column)

• Actual dispensed volume (in the units shown in the volume units column)

• Volume units

• Error percentage between actual dispensed volume and requested volume (maximum of 100%)

• Minimum inlet pressure during job (measured in bar, heated systems will always read 0)

• Average inlet pressure during job (measured in bar, heated systems will always read 0)

• Maximum inlet pressure during job (measured in bar, heated systems will always read 0)

• Minimum outlet pressure during job (measured in bar)

• Average outlet pressure during job (measured in bar)

• Maximum outlet pressure during job (measured in bar)

• Minimum flow rate during job (measured in cc/min, systems with no flow meter will read 0)

• Average flow rate during job (measured in cc/min, systems with no flow meter will read 0)

• Maximum flow rate during job (measured in cc/min, systems with no flow meter will read 0)

• Elapsed time (mS)

The event log file name is 1-EVENT.CSV and is stored in the DOWNLOAD folder.

The event log maintains a record of the last 1,000 events. Each event record in the log file contains the date and time the event occurred, the event type, event code, and event description.

Job Log

The job log file name is 2-JOB.CSV and is stored in the DOWNLOAD folder.

The job log maintains a record of the last 10,000 jobs. At the completion of each job the following data is stored in the log file:

• Job completion date

• Job completion time

• Job number (sequential number)

• Dispenser (Fluid Plate) Number

• Style number

3A2098H 59

Dispense Data Log

The dispense data log file name is 3-DATAx.CSV and is stored in the DOWNLOAD folder. There is one dispense data log file for each installed fluid plate, so there can be up to four data logs.

The dispense data log maintains a record of system inlet pressure (heated systems will always read 0), system outlet pressure, system flow rate (systems without flow meters will always read 0), and active dispense valves. This data is recorded at one second intervals when a job cycle is in process. Each dispense data log is capable of storing up to two hours of data.

USB Data

System Configuration Settings File

The system configuration settings file name is SETTINGS.TXT and is stored in the DOWNLOAD folder.

A system configuration settings file automatically downloads each time a USB flash drive is inserted. Use this file to back up system settings for future recovery or to easily replicate settings across multiple PCF systems. Refer to the Upload Procedure, page 61, for instructions on how to use this file.

It is recommended to retrieve the SETTINGS.TXT file after all system settings are set as desired. Store the file for future use as a backup in case the settings are changed and need to be quickly changed back to the desired setup.

NOTE: System settings may not be compatible between different versions of the PCF software.

NOTE: Do not modify the contents of this file.

Custom Language File

The custom language file name is DISPTEXT.TXT and is stored in the DOWNLOAD folder.

A custom language file automatically downloads each time a USB flash drive is inserted. If desired, use this file to create a user-defined set of custom language strings to be displayed within the ADM.

The PCF system is able to display the following Unicode characters. For characters outside of this set, the system will display the Unicode replacement character, which appears as a white question mark inside of a black diamond.

• U+0020 - U+007E (Basic Latin)

• U+00A1 - U+00FF (Latin-1 Supplement)

• U+0100 - U+017F (Latin Extended-A)

• U+0386 - U+03CE (Greek)

• U+0400 - U+045F (Cyrillic)

Create Custom Language Strings

The custom language file is a tab-delimited text file that contains two columns. The first column consists of a list of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was previously installed, this column contains the custom strings. Otherwise the second column is blank.

Modify the second column of the custom language file as needed and then follow the Upload Procedure, page 61, to install the file.

The format of the custom language file is critical. The following rules must be followed in order for the installation process to succeed.

• The file name must be DISPTEXT.TXT.

• The file format must be a tab-delimited text file using Unicode (UTF-16) character representation.

• The file must contain only two columns, with columns separated by a single tab character.

• Do not add or remove rows to the file.

• Do not change the order of the rows.

• Define a custom string for each row in the second column.

60 3A2098H

USB Data

Download Procedure

1. Insert USB flash drive into USB port (BL). See FIG. 39 on page 59.

2. The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete. A pop-up will be present until the transfer is complete if it is not acknowledged.

3. Remove USB flash drive from USB port (BL).

4. Insert USB flash drive into USB port of computer.

5. The USB flash drive window automatically opens. If it does not, open USB flash drive from within Win-

dows

Explorer.

6. Open Graco folder.

7. Open system folder. If downloading data from more than one system, there will be more than one folder. Each folder is labeled with the corresponding serial number of the ADM (The serial number is on the back of the ADM.)

Upload Procedure

Use this procedure to install a system configuration file and/or a custom language file.

1. If necessary, follow the Download Procedure, page 61, to automatically generate the proper folder structure on the USB flash drive.

2. Insert USB flash drive into USB port of computer.

3. The USB flash drive window automatically opens. If it does not, open USB flash drive from within Windows Explorer.

4. Open Graco folder.

5. Open system folder. If working with more than one system, there will be more than one folder within the Graco folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial number is on the back of the module.)

6. If installing the system configuration settings file, place SETTINGS.TXT file into UPLOAD folder.

8. Open DOWNLOAD folder.

9. Open LOG FILES folder labeled with the highest number. The highest number indicates the most recent data download.

10. Open log file. Log files open in Microsoft default as long as the program is installed. However, they can also be opened in any text editor or

Microsoft

NOTE: All USB logs are saved in Unicode (UTF-16) format. If opening the log file in Microsoft Word, select Unicode encoding.

Word.

Excel® by

7. If installing the custom language file, place DISPTEXT.TXT file into UPLOAD folder.

8. Remove USB flash drive from computer.

9. Install USB flash drive into PCF system USB port.

10. The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete.

11. Remove USB flash drive from USB port.

NOTE: If the custom language file was installed, users can now select the new language from the Language drop-down menu in the Advanced Setup Screen 1.

3A2098H 61

Troubleshooting

NOTE: Check all possible solutions in the chart below

before you disassemble the system.

Troubleshooting for individual fluid regulators and flow meters is also discussed in their separate manuals; refer to Related Manuals on page 3. Also refer to Event and Error Codes and Troubleshooting, page 67, for detailed information on how error codes are communicated.

Fluid Plates

Problem Cause Solution

No outlet pressure Air pressure low Verify air pressure is above 60 psi

(410 kPa, 4.1 bar)

No “Valve On” signal from automation unit

No air signal to air diaphragm Check for loose/disconnected con-

False signal being sent to control Check outlet pressure sensor output;

High outlet pressure Fluid regulator needle/seat is worn Rebuild fluid regulator; replace nee-

Air leaks from fluid plate Loose air connections Check air connections; tighten if nec-

Worn gaskets Check/replace gaskets on Voltage to

Check output and wiring from automation unit

nector to Voltage to Pressure (V/P) Transducer; tighten

verify that it corresponds to zero pressure; replace sensor and/or amplifier

dle/ seat

essary

Pressure (V/P) Transducer and solenoid valve

62 3A2098H

Troubleshooting

Flow Meter

Problem Cause Solution

No flow measurement Flow meter pick-up sensor loose Tighten flow meter pick-up sensor

Flow too low Verify flow rate is above minimum

for the installed flow meter

Loose wiring Verify connection from flow meter to

FCM

Damaged flow meter pick-up sensor Replace pick-up sensor

False measurement Flow meter not calibrated Calibrate flow meter, page 42

System not grounded properly Verify system ground

Noisy power source Verify clean power supply power to

main enclosure

Flow reported is not correct or inconsistent

Flow meter not calibrated Calibrate flow meter, page 42

Flow meter is worn Replace flow meter

Fluid Regulator

Problem Cause Solution

No pressure regulation Damaged diaphragm Replace diaphragm

Leaking or dirty seat Replace cartridge, or clean seat

No fluid flow Damaged valve actuator Replace valve actuator

Pressure creeps above setting Metal chip or contamination

between ball and seat

Damaged diaphragm Replace diaphragm

Damaged o-ring or improper seal Replace the o-ring under the seat

Damaged or clogged air regulator or

line

Leaking or dirty seat Replace cartridge, or clean seat

Large change in inlet pressure Stabilize regulator inlet pressure

Pressure drops below setting Empty/clogged supply line Fill/flush supply line

Damaged or clogged air regulator or

line

Using valve beyond its rated flow

capacity

Large change in inlet air or fluid

pressure

Fluid leaks from spring housing Loose fluid housing Tighten the four cap screws

Damaged diaphragm Replace diaphragm

Chatter

Excessive pressure differential be tween pump and valve

Excessive flow rate

Replace cartridge, or clean seat

area

Clear obstruction in line. Service

regulator if necessary

Clear obstruction in line. Service

regulator if necessary

Install valve for each spray valve or

dispensing valve

Stabilize air and fluid regulator inlet

pressures

Reduce pump pressure to not more than 2000 psi (14 MPa, 138 bar) greater than required valve pressure.

Reduce fluid flow through regulator. Connect only one spray gun or dispense valve to each fluid regulator

3A2098H 63

Troubleshooting

Dispense Valves

Problem Cause Solution

Valve not opening Air not getting to the open port Verify air pressure to solenoid

No “Valve On” signal from automation unit

Valve not shutting off Air not getting to the close port

(except AutoPlus valve)

“Valve On” signal from automation unit is on

Sluggish open/close Air pressure low Verify air pressure is above 60 psi

Needle/seat worn Rebuild valve; replace needle/seat

Pressurized material past the valve shut-off is escaping

Faulty solenoid valve Replace solenoid valve

Solenoid valve muffler restricted Clean or replace muffler

Material leaks from back of valve Shaft seal is worn Rebuild valve; replace seals

Air leaks from dispense valve Loose air connections Check air connections; tighten if

Worn piston o-ring Rebuild valve; replace piston o-ring

Check input from automation unit

Verify air pressure to solenoid

Verify solenoid operation

Verify air line routing and connections

Check input from automation unit

(410 kPa, 4.1 bar)

Reduce running pressure

Reduce nozzle length

Increase nozzle orifice size

necessary

Swirl Dispenser

Problem Cause Solution

Motor not running (motor fault alarm active)

Motor not running (motor fault alarm not active)

Cable disconnected Verify cable connections to swirl

board, swirl motor cable, and swirl orbiter

CAN cable was re-connected with system power on (amber LED on swirl board will be on, this indicates circuit protection was triggered)

Shorted motor cable (amber LED on swirl board will be on, this indicates circuit protection was triggered)

Faulty swirl orbiter Replace swirl orbiter Cable disconnected

No “Swirl Enable” signal from automation unit

Swirl not installed

Cycle system power

Replace swirl motor cable (55 ft) then cycle power

Verify cable connections to swirl board, swirl board power cable, and swirl control DGM

Check input from automation unit

Verify that the proper swirl orbiter is installed in the system setup screen

64 3A2098H

Troubleshooting

Motor not responding to change in speed command

No “Swirl Speed Command” signal from automation unit

Swirl speed source incorrectly set Verify Speed Command Source in

Check input from automation unit

Swirl Setup screen

Gateway Module

Problem Cause Solution

No communication Incorrect wiring Check wiring per fieldbus standard. Refer to PCF Gateway

LED status indicators and Appendix C - Communications Gateway Module (CGM) Connection Details, page 122.

Incorrect fieldbus settings Confirm fieldbus settings at automation controller (fieldbus

master) and PCF Gateway (fieldbus slave). Refer to Appen- dix A - Advanced Display Module (ADM), page 99, for information on PCF Gateway configuration settings.

Incorrect data

Incorrect fieldbus configuration file installed on automation controller (fieldbus master)

Incorrect map installed on PCF Gateway

Download PCF fieldbus configuration file from www.graco.com, and install on automation controller (fieldbus master).

Confirm correct PCF data map is installed on PCF Gateway. Refer to Appendix A - Advanced Display Module (ADM), page 99, for information on how to determine installed data map. If necessary, install a new Gateway data map. Refer to Upgrade Gateway Module Fieldbus Map, page 78, for instructions, and Control Center and Expansion Swirl

Enclosure Parts, page 92, for map token part number.

LED Diagnostic Information

The following LED signals, diagnosis, and solutions apply to the Advanced Display Module, Fluid Control Module, and Gateway module.

Module Status LED Signal Diagnosis Solution

Green on System is powered up -

Yellow Internal communication in progress -

Red solid Hardware failure Replace module

Red flashing fast Uploading software -

Red flashing slow Token error Remove token and upload software

token again.

Red flashes three times, pauses, then repeats

Invalid rotary switch position (FCM and DGM only)

Change rotary switch position to a valid position then restart the system. See page 15.

3A2098H 65

Errors

View Errors

When an error occurs, an error pop-up is displayed that takes up the entire screen until the error is acknowl-

edged by pressing . Errors can also be acknowledged over the gateway. Active errors are displayed in the menu bar.

Error

. 40: Error Pop-Up

The previous 200 errors are displayed on the error report screens. See Run Mode, page 110, for instructions on navigating to and through the error report screens.

There are three levels of errors: alarms, deviations, and advisories. Alarms cause the system to shut down. Deviations and advisories do not shut down the system.

NOTE:

• Alarms set the dispenser (fluid plate) ready signal

LOW.

• Advisories and deviations do not set the dispenser (fluid plate) ready signal LOW.

Diagnose Errors

See Event and Error Codes and Troubleshooting on page 67 for error codes, possible causes, and solutions.

66 3A2098H

Errors

Event and Error Codes and Troubleshooting

Error codes are stored in the events log and are displayed on the error report screens. Gateway error numbers are reported over the Gateway interface.

Error codes shown as XYZ_ represent error codes XYZ1, XYZ2, XYZ3, XYZ4, where the last digit represents the number of the fluid plate to which the error applies. Error codes in the following table are sorted by gateway error number, then by event code.

System Events and Errors

Event

Code

--- 0 No Active Errors No errors --- --- No action necessary

EC0X --- Setup Values

EL0X --- Power Up Control box power up Record only --- No action necessary

EM0X --- Power Down Control box power

Gateway

Error No. Event Name

Changed

Event

Description Event Type Cause Solution

System Events and Errors

Setup change notification

down

Record only A setup value was

changed on the display

Record only --- ---

No action necessary if changes were desired

Control Center Events and Errors

Event

Code

EVUX --- USB Disabled USB download

MMUX --- USB Log 90%

V1G0 --- DGM Unpowered The Discrete Gateway

WSG0 --- Gateway Setup

EAUX --- Download to

Gateway

Error No. Event Name

Full

Error

USB in Process

Event

Description Event Type Cause Solution

Control Center Events and Errors

attempted, however, USB activity is disabled.

One or more USB log is 90% full.

Module does not have logic power supplied to it.

System settings are incompatible with Discrete Gateway Module.

Information is currently being downloaded to USB

Advisory (self-clearing)

Advisory Data in the jobs or

Advisory 24 Vdc has not been

Advisory Fluid plate 1 is not

Advisory (self-clearing)

Transfers are disabled in Advanced Setup screen 2.

events log has not been downloaded recently and logs are nearly full.

connected to the power pins.

installed. Or Fluid plate 3 or fluid plate 4 is installed.

Swirl 1 is not installed. Or Swirl 3 or Swirl 4 is installed.

--- No action necessary

Clears when drive is removed.

Download the data or disable USB errors.

Connect power according to Appendix B -

Discrete Gateway Module (DGM) Connection Details on

page 115.

Install fluid plate 1, uninstall fluid plates 3 and 4.

Install Swirl 1, uninstall swirls 3 and 4.

3A2098H 67

Errors

Event

Code

EBUX --- Download to

WSU0 --- USB configura-

WNC0 32 ADM Key Token

WNG0 --- Gateway Map

CBG0 --- Gateway Reset Gateway reset Advisory

WMG0 --- Gateway Error

CBD_ --- Fluid Plate Com-

CCG_ --- Fieldbus Com-

Gateway

Error No. Event Name

USB Complete

tion error

Error

Detected

munication Error

Event

Description Event Type Cause Solution

Control Center Events and Errors

Download to the USB is complete

USB configuration error Advisory USB configuration

Missing or invalid key token

Missing or invalid map Advisory Missing or invalid

Gateway error detected; includes any error not covered by another more specific error

Fluid Plate Communication Error with ADM

Fieldbus Communication Error

Advisory (self-clearing)

Alarm An ADM key token is

(self-clearing)

Alarm --- ---

Alarm The ADM lost commu-

Alarm The automation gate-

--- No action necessary

Reinstall system soft-

invalid or not present

required to run the system

Gateway map

Gateway setting(s) changed

nications with the FCM.

way lost communication with the automation controller.

ware on display

Verify the key token is installed

Verify the key token part number is correct for the PCF ADM

Install PCF map in Gateway

Wait for reset to complete before attempting automation control

Restore communication.

Restore communications.

Fluid Plate Events and Errors

Event

Code

CAC_ --- CGM Communi-

CAD_ --- Fluid Plate Com-

B7C_ 30 Style Out of

Gateway

Error No. Event Name

cation Error

munication Error

Range

Communication lost between CGM and Fluid Plate

FCM lost communication with the ADM

Style is out of range Alarm Style requested by

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Advisory Fluid Plate and CGM

are no longer communicating

CGM is not functioning Replace the CGM if the

Alarm ADM is not communi-

cating

ADM is not functioning Replace FCM if red

ADM does not contain appropriate key token

automation controller exceeds number of styles available on the fluid plate

Reconnect or replace CAN cable

red status LED is solid

Reconnect or replace CAN cable

status LED is solid

Verify intended ADM key token is properly inserted

Use a style number that is in range

Increase number of styles in PCF; purchase accessory key token

68 3A2098H

Errors

Event

Code

B30_ B40_

B10_ B20_

B1C_ B2C_

B3C_ B4C_

WND_ 51 Fluid Plate Key

Gateway

Error No. Event Name

31 High Material Material dispensed dur-

32 Low Material Material dispensed dur-

33 Low Computed

Target

34 High Computed

Target

Token Error

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

ing last dispense cycle was above amount requested plus the allowed tolerance

ing last dispense cycle below amount requested minus the allowed tolerance

Requested volume/ mass differs from entered process target by more than entered tolerance for style requested

Missing or invalid key token

Alarm or Deviation (user selectable)

Alarm FCM key token is

PCF regulator is not regulating correctly

Incorrect style target volume or tolerance

Partially plugged tip or supply system

Insufficient flow to PCF regulator inlet

PCF regulator is not regulating correctly

Check regulator; repair if necessary

Entered process target incorrectly

Entered tolerance incorrectly

Requested volume incorrectly

Automation problem Verify automation is

Entered process target incorrectly

Entered tolerance incorrectly

Requested volume incorrectly

Automation problem Verify automation is

required to run system

Check regulator and repair if necessary

Enter correct values or set tolerance to 0% to disable error

Clean tip and/or supply system

Increase flow rate to regulator inlet

Incorrect style target volume or tolerance setting

Enter correct process target

Enter correct tolerance

Check automation program

correct

Enter correct process target

Enter correct tolerance

Check automation program

correct

Verify FCM key token is installed

Verify FCM key token is correct part number

P6D_ 52 Outlet Pressure

Transducer Error

P6F_ 53 Inlet Pressure

Transducer Error

F6D_ 54 Flow Meter Error Flow Meter error Alarm Problem detected with

Outlet pressure transducer error

Inlet pressure transducer error

Alarm Problem detected with

outlet pressure transducer

Advisory Problem detected with

inlet pressure transducer

flow meter

Verify outlet pressure transducer is installed and/or connected correctly

Replace if necessary

Verify inlet pressure transducer is installed and/or connected correctly

Replace if necessary

Verify flow meter is installed and/or connected correctly

Replace if necessary

3A2098H 69

Errors

Event

Code

WED_ 55 V/P Error Voltage to Pressure

WJ1_ 56 Dispense Valve 1

WJ2_ 57 Dispense Valve 2

WJ3_ 58 Dispense Valve 3

WJ4_ 59 Dispense Valve 4

Gateway

Error No. Event Name

Error

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Transducer error

Dispense valve 1 error Alarm Problem detected with

Dispense valve 2 error Alarm Problem detected with

Dispense valve 3 error Alarm Problem detected with

Dispense valve 4 error Alarm Problem detected with

Alarm Problem detected with

V/P

dispense valve 1

dispense valve 2

dispense valve 3

dispense valve 4

Verify outlet pressure transducer is installed and/or connected correctly

Replace if necessary

Verify dispense valve 1 is installed and/or connected correctly

Replace if necessary

Verify dispense valve 2 is installed and/or connected correctly

Replace if necessary

Verify dispense valve 3 is installed and/or connected correctly

Replace if necessary

Verify dispense valve 4 is installed and/or connected correctly

WSD_ 60 Incompatible

Valve Settings

WSD5 60 Incompatible

Valve Settings

F7D_ 61 Closed Valve

Flow

Incompatible settings for multiple valve operation; attempted to dispense

System reading flow meter pulses with valve(s) closed

Replace if necessary

Alarm Attempted to dis-

pense simultaneously from multiple valves on the same fluid plate with different pressure settings

Alarm Attempted to dis-

pense simultaneously from multiple valves on the same fluid plate with different pressure settings

Alarm Dispense hose leak Check hose; replace if

Flow meter providing false pulses

Dispense valve not operating correctly

Check settings shown on Fluid Plate x, screen 2 (Mode Settings)

Verify automation programming

In the Discrete Gateway screens, change the settings of the simultaneously dispensing valves to the same pressure

Verify automation programming

needed

Replace flow meter sensor or calibrate meter

Repair dispense valve

70 3A2098H

Errors

Event

Code

V2D_ 62 Low Analog Command cable analog

WFD_ WFG_

EJD_ 64 Job Cycle Time

WXD_ 65 Fluid Plate Error

P3F_ P4F_

P3D_ P4D_

P1F_ P2F_

Gateway

Error No. Event Name

63 Flow Meter

Required

Out

Detected

66 Maximum Inlet

Pressure

67 Maximum Outlet

Pressure

68 Minimum Inlet

Pressure

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

command dropped below minimum value of 1 V while dispensing

Operating mode requires flow meter. Advisory is issued if fluid plate settings require a flow meter but meter is not present. Alarm is issued if dispense is attempted in mode that requires a flow meter but meter is not present.

Job cycle time out Alarm Automation signals did

Fluid plate error detected; includes any error not covered by another more specific error

Inlet pressure to regulator is above upper limit set for operation

Outlet pressure of regulator is above upper limit set for operation

Inlet pressure to regulator is below lower limit set for operation

Deviation Bad or loose com-

mand cable connection

Entered command mode incorrectly

Automation program error

Alarm or Advisory (self-clearing)

Alarm Analog voltage applied

Alarm or Deviation (user selectable)

Selected valve mode settings require flow meter

FCM key token missing or invalid

not properly end job cycle

to pin 1 of the command cable exceeds 10 Vdc.

Failed FCM Replace FCM if neces-

Incorrect set limit Verify limit is set cor-

Material supply pressure is too high

Failed transducer Check transducer;

Incorrect set limit Verify limit is set cor-

Material supply pressure is too high

Failed transducer Check transducer;

Incorrect set limit Verify limit is set cor-

Material supply pressure is too low

Failed transducer Check transducer;

Check command cable and connection

Enter correct command code

Verify correct automation program

Check valve mode settings

Purchase meter enabled token for FCM and install flow meter

Check for FCM key token error

Check automation programming per job operating instruction

Limit signal on pin 1 of command cable to the range of 0-10 Vdc.

sary

rectly

Decrease material supply pressure

replace if necessary

rectly

Decrease material supply pressure

replace if necessary

rectly

Increase crease material supply pressure

replace if necessary

3A2098H 71

Errors

Event

Code

P1C_ P2C_

P3C_ P4C_

F1D_ F2D_

F3D_ F4D_

EKD_ 73 Shot Terminated

EHD_ 74 Purge Timer

Gateway

Error No. Event Name

69 Low Pressure Measured outlet pres-

70 High Pressure Measured outlet pres-

71 Low Flow Rate Measured flow rate less

72 High Flow Rate Measured flow rate

by Job Timer

Expired

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Alarm or sure less than desired outlet pressure minus tolerance

sure greater than desired outlet pressure plus tolerance

than desired flow rate minus tolerance

greater than desired flow rate plus tolerance

Shot dispense cycle terminated by job timer

Purge timer expired Advisory PCF purge timer (style

Deviation

(user select-

able)

Alarm or

Deviation

(user select-

able)

Alarm or

Deviation

(user select-

able)

Alarm or

Deviation

(user select-

able)

Advisory Job end timer was

Incorrect limit set Verify limit is set cor-

rectly

No or insufficient material flow

Dispense valve needle is stuck closed

Dispense valve leaking

Regulator not operating correctly

Pump wink passed through outlet

Failed transducer Check transducer;

Incorrect limit set Verify limit is set cor-

Dispense hose/device plugged

Failed transducer Check transducer;

Regulator is not closing completely when it should

Fluid supply too low to achieve desired flow rate

Tip plugged Clean/replace tip

No air pressure to solenoid valves

No flow meter signal Check cable and sen-

No material supply Replace drum or turn

Incorrect flow tolerance of flow error time

Operating below minimum regulator operating pressure

Regulator worn or not operating correctly

Flow meter providing false pulses

Incorrect flow error tolerance or flow error time

used to stop shot dispense

0) has expired

Increase material flow rate

Dislodge and inspect needle

Repair dispense valve

Repair regulator

Increase pump pressure

replace if failed

rectly

Clean/replace hose/device

replace if failed

Repair regulator

Increase fluid supply pressure or check for clogged filter

Turn on air to solenoid valves

sor

on pumps

Enter correct tolerance or flow error time

Increase fluid pressure above regulator minimum

Repair regulator

Replace flow meter sensor

Enter correct tolerance or flow error time

No action required if timed shot is desired

Automation control requests purge

72 3A2098H

Errors

Event

Code

EAC_ 75 Maintenance

EBC_ 76 Maintenance

MHD_ 77 Maintenance

MFD_ 78 Maintenance

MED_ 79 Maintenance

MCD_ 80 Maintenance

MD1_ 81 Maintenance

MD2_ 82 Maintenance

MD3_ 83 Maintenance

MD4_ 84 Maintenance

CCD_

EAD_

WFC_

Gateway

Error No. Event Name

Mode Entered

Mode Exited

Due - Regulator

Due - Flow Meter

Due - V/P

Due - Supply

Due - Valve 1

Due - Valve 2

Due - Valve 3

Due - Valve 4

85 Duplicate Module Duplicate Fluid Control

86 Swirl Mainte-

nance Mode Entered

87 Shot No-Flow

Timeout

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Maintenance mode entered

Maintenance mode exited

Maintenance due for regulator

Maintenance due for flow meter

Maintenance due for Voltage to Pressure Transducer

Maintenance due for supply system

Maintenance due for valve 1

Maintenance due for valve 2

Maintenance due for valve 3

Maintenance due for valve 4

Module Detected

Swirl maintenance mode entered

No flow detected for five seconds on valve activated in shot mode

Advisory (self-clearing)

Advisory Totalizer exceeded

Alarm Two or more FCMs

Advisory (self-clearing)

Alarm Dispense valve not

Entered maintenance dispense mode

Exited maintenance dispense mode

limit setting

have the same rotary switch setting

Swirl zone that is associated with this fluid plate entered maintenance mode

operating properly

Fluid leak Check fluid connec-

No action required

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Verify that all FCMs have proper rotary switch settings. Reset module after changing rotary switch setting. Refer to Fluid Plate Assembly Overview section, page 14

No action required

Check dispense valve for correct operation and/or clogging

tions

3A2098H 73

Errors

Event

Code

CR1_ 88 Valve 1 Swirl

CR2_

CR3_

CR4_

WD1_ 92 Valve 1 Swirl

WD2_

WD3_

WD4_

MB1_

MB2_

Gateway

Error No. Event Name

Communication Error

89 Valve 2 Swirl

Communication Error

90 Valve 3 Swirl

Communication Error

91 Valve 4 Swirl

Communication Error

Fault

93 Valve 2 Swirl

Fault

94 Valve 3 Swirl

Fault

95 Valve 4 Swirl

Fault

96 Maintenance due

- V1 Orbiter

97 Maintenance due

- V2 Orbiter

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Fluid plate communication error with swirl

Swirl motor fault Alarm or

Maintenance due on valve 1 swirl orbiter

Maintenance due on valve 2 swirl orbiter

Alarm The fluid plate lost

communication with the swirl zone associated with this valve and fluid plate

Alarm The fluid plate lost

communication with the swirl zone associated with this valve and fluid plate

Alarm The fluid plate lost

communication with the swirl zone associated with this valve and fluid plate

Alarm The fluid plate lost

communication with the swirl zone associated with this valve and fluid plate

The swirl zone associDeviation (user-selectable)

Deviation (user-selectable)

Advisory The active time total-

ated with this valve

and fluid plate caused

a fault

The swirl zone associ-

ated with this valve

and fluid plate caused

a fault

The swirl zone associ-

ated with this valve

and fluid plate caused

a fault

The swirl zone associ-

ated with this valve

and fluid plate caused

a fault

izer for the swirl dis-

penser associated

with this valve and

fluid plate exceeded

limit setting

izer for the swirl dis-

penser associated

with this valve and

fluid plate exceeded

limit setting

Restore communications.

Resolve swirl motor fault (see error WBDX for possible solutions)

Service Component

If necessary, reset totalizer

Service Component

If necessary, reset totalizer

74 3A2098H

Errors

Event

Code

MB3_ 98 Maintenance due

MB4_

Gateway

Error No. Event Name

- V3 Orbiter

99 Maintenance due

- V4 Orbiter

Swirl Events and Errors

Event

Code

CBR_

CDR_

EAD_

EBD_

MBD_ --- Maintenance

WBD_

Gateway

Error No. Event Name

--- Swirl Communication Error

--- Duplicate Module Duplicate Swirl Control

--- Maintenance Mode Entered

--- Maintenance Mode Exited

Due - Orbiter

--- Swirl Motor Fault Motor speed is outside

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Maintenance due on valve 3 swirl orbiter

Maintenance due on valve 4 swirl orbiter

Event

Description Event Type Cause Solution

Swirl Events and Errors

Swirl communication error with ADM

DGM Detected

Maintenance mode entered

Maintenance mode exited

Maintenance due on swirl orbiter

the +/- 50% tolerance range for at least 5 seconds while operating

Advisory The active time total-

izer for the swirl dispenser associated with this valve and fluid plate exceeded limit setting

Advisory The active time total-

izer for the swirl dispenser associated with this valve and fluid plate exceeded limit setting

Alarm The ADM lost commu-

nication with the Swirl Control DGM

Alarm Two or more Swirl

Control DGMs have the same rotary switch setting

Advisory (self-clearing)

Advisory Swirl active time total-

Alarm Cable disconnected Verify cable connec-

Swirl maintenance mode entered

Swirl maintenance mode exited

izer exceeded limit setting

Shorted motor cable (amber LED on swirl board will be on)

Orbiter bearing failure Replace bearing

Motor defective Replace swirl orbiter

Service Component

If necessary, reset totalizer

Service Component

If necessary, reset totalizer

Restore communications

Verify that all Swirl Control DGMs have proper rotary switch settings. Reset module after changing rotary switch setting. Refer to Swirl Control DGM section, page 19.

No action required

Service Component

If necessary, reset totalizer

tions to swirl board, swirl motor cable, and swirl orbiter

Replace swirl motor cable (55 ft)

3A2098H 75

Maintenance

Prior to performing any maintenance procedures, follow the Pressure Relief Procedure on page 57.

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.

Mechanical

Operator Maintenance Person

Task Daily Weekly Monthly

Inspect system for leaks Depressurize fluid, after opera-

tion Remove heat from system,

after operation

Inspect filter (234967) bowls and drain

Check hoses for wear Check/tighten fluid connections ✓ Check/tighten air connections ✓

Lubricate dispense valves*

Rebuild regulator*

Rebuild dispense valve*

Replace air filter

Replace Solenoid

Replace Voltage to Pressure (V/P) Transducer

* Check component manual for more detailed maintenance information.

✓

3-6

months

125,000

cycles

✓

18-24

months

500,000

cycles

✓

36-48

months

1,000,000

cycles

✓

7000

hours

✓

Electrical

Task Weekly

Check cables for wear

Verify cable connections

Verify operation of “System Stop” button

* Check Component Manual for more detailed maintenance information.

76 3A2098H

✓

Maintenance

Advanced Display Module (ADM)

Upgrade Software

NOTE: Back up the custom language file (if installed)

before upgrading software. See USB Data, page 59, for more information.

1. Turn off power to the system.

2. Remove token access panel, and then remove the key token (do not discard token).

Access Panel

r_24E451_3B9900_3a

. 41: Remove Access Panel

Cleaning

Use any alcohol-based household cleaner, such as glass cleaner, to clean the display.

Upgrade Gateway Module Software

NOTE: The Gateway module connection to the system

is temporarily disabled during the use of upgrade tokens. The following instructions apply to all Gateway modules.

1. Turn off power to the system.

2. Remove the access cover.

Access Cover

3. Insert and press software token firmly into slot.

NOTE: There is no preferred orientation of token.

Token

r_24E451_3B9900_4a

. 42: Insert Token

4. Turn on power to the system. The red indicator light (BL) will flash until new software is completely loaded.

5. After the red indicator light shuts off, turn off power to the system.

6. Remove software token.

7. Reinstall key token, and replace token access panel.

TI12319A

FIG. 43: Remove Access Cover

3. Insert and press token firmly into slot.

NOTE: There is no preferred orientation of token.

4. Turn on power to the system. The red indicator light (CK) will flash until new software is completely

loaded.

Token

. 44: Insert Token

TI12320A

3A2098H 77

Maintenance

5. After the red indicator light shuts off, turn off power to the system.

6. Remove token.

7. Replace access cover.

Upgrade Gateway Module Fieldbus Map

NOTE: The fieldbus connection is temporarily disabled

during the use of a map token. The following instructions apply to all Gateway modules.

1. Perform Upgrade Gateway Module Software. Software must be upgraded before upgrading the fieldbus map.

2. Remove the access cover.

4. Press and hold the push button for three seconds and then release. The red indicator light (CK) will flash twice, pause, and then once after the data

map is uploaded.

TI12320A

Token

FIG. 46: Insert Token

5. Remove map token (CC) when software has successfully uploaded.

Push Button

Access Cover

TI12319A

. 45: Remove Access Cover

3. Insert and press map token firmly into slot.

NOTE: There is no preferred orientation of the token.

6. Replace access cover.

78 3A2098H

Maintenance

Upgrade Fluid Control Module (FCM) Software

NOTE: The FCM connection is temporarily disabled

during the use of the upgrade token.

1. Turn off power to the system.

2. Remove access cover then remove key token (do not discard token).

Access Cover

TI12334A

7. Reinstall key token, and replace access cover.

Air Filter Maintenance

To prevent filter element damage, replace air filter every two years or when pressure drop becomes 100 kPa (1.0 bar, 14.5 psi) or greater; which ever occurs first.

Replacement Air Filters for Dual Filter Assembly (234967)

Part Description

123091 5 micron air filter 123092 0.3 micron air filter

Swirl Dispensers

See manual 309403 for maintenance schedule.

. 47: Remove Access Cover

3. Insert and press software token firmly into slot.

NOTE: There is no preferred orientation of token.

4. Turn on power to the system. The red indicator light (CK) will flash until new software is completely loaded.

TI12335A

Token

. 48: Insert Token

5. After the red indicator light shuts off, turn off power to the system.

6. Remove software token.

3A2098H 79

Repair

Fluid Plate Assembly

This section describes how to remove and replace components on the fluid plate assembly.

Prepare Fluid Plate Assembly for Repair

1. Disconnect the CAN cable from the fluid plate.

2. Perform Pressure Relief Procedure on page 57.

3. Remove the fluid plate assembly shroud. See Fluid

Plate Assembly Parts, page 94.

Repair Flow Meter

For complete flow meter (129) repair instructions refer to the maintenance and repair section of manual 309834.

Remove Flow Meter from Mounting Plate

1. Prepare Fluid Plate Assembly for Repair, page

80.

2. Disconnect the flow meter cable (131) from the flow meter sensor. See F

3. Disconnect the material hose.

4. Disconnect the swivel fitting (109) from the regulator.

5. Loosen the four screws (127) and washers (125,

126); remove the bracket (124) and flow meter (129).

6. The flow meter weighs approximately 15 lbs. (6.75 kg). Carefully lift it off the mounting plate (101).

. 49.

103

124

129

125, 126, 127

FIG. 49: Fluid Plate Assembly

131

101

108

109

r_pf0000_313377_18a

80 3A2098H

Repair

Install Flow Meter on Mounting Plate

1. Rest the flow meter (129) and bracket (124) on the fluid plate while threading the swivel fitting (109) onto the regulator material inlet. See F

2. Tighten the swivel fitting to the regulator material inlet.

3. Tighten the four screws (127) and washers (125,

126) to hold the bracket and flow meter in place.

126

127

129

. 49.

4. Remove the dispense valve solenoid (132) and replace it with a new solenoid.

137

132

118

r_pf0000_313377_33a

. 51

5. Secure the new solenoid to the bracket with screws.

6. Reconnect the FCM cable and all three air tubes.

124

108

109

125

. 50

r_pf0000_313377_34a

4. Check that the flow meter and regulator (108) are still aligned.

5. Connect the material hose.

6. Connect the flow meter cable (131).

Replace Solenoid

1. Prepare Fluid Plate Assembly for Repair, page 80.

2. Disconnect FCM cable and all three air tubes.

3. Remove both screws (137) from transducer bracket (118).

Replace Voltage to Pressure (V/P) Transducer

1. Prepare Fluid Plate Assembly for Repair, page

80.

2. Disconnect the FCM cable and both air tubes.

3. Remove both transducer screws (122) from transducer bracket (118).

4. Remove the V/P transducer (121) and replace it with a new V/P transducer.

118

122

121

. 52

3A2098H 81

r_pf0000_313377_31a

Repair

5. Secure the new V/P transducer to the bracket with screws.

6. Reconnect the FCM cable and both air tubes.

Replace Fluid Control Module

1. Prepare Fluid Plate Assembly for Repair, page

80.

2. Remove the four screws (128) from the transducer bracket (118), and remove the bracket. (Leave the dispense valve solenoid (132) and V/P transducer (121) attached to the transducer bracket.)

102

103

118

132

Replace Fluid Control Module Base

1. Prepare Fluid Plate Assembly for Repair, page

80.

2. Remove the FCM (103); follow Replace Fluid Con- trol Module. (Leave the cables attached to the FCM.)

3. Remove the power supply cable from the base (102).

4. Remove the four screws (105) and ground screw (106) from the base and replace it with a new base.

128

121

. 53

r_pf0000_313377_30a

3. Remove the following cables from FCM:

• dispense valve solenoid cable

• meter sensor cable

• both V/P cables

• I/O cable

• inlet pressure transducer cable (ambient models only)

• outlet pressure transducer cable

4. Remove the two screws from FCM (103) and replace with a new FCM.

5. Secure the new FCM to the base (102) with screws.

6. Reconnect the cables listed in step 3.

102

105

106

103

. 54

5. Secure the base to the fluid plate (101) with screws.

6. Reconnect the power supply cable.

7. Reattach the FCM; follow Replace Fluid Control Module.

7. Reattach the transducer bracket using screws.

82 3A2098H

Replace Transducer O-Rings

1. Prepare Fluid Plate Assembly for Repair, page

80.

2. Remove the fluid outlet pressure sensor (117) from the regulator (108).

108

Repair

117

r_pf0000_313377_16a

. 55

3. Press the transducer (CG) out of the retainer nut (CH).

4. Remove the faulty o-ring (120) and replace with new.

. 56

5. Press the transducer back into the retainer nut.

120

6. Reconnect the fluid outlet pressure sensor to the regulator.

3A2098H 83

Repair

Repair Fluid Regulator

For complete cartridge fluid regulator repair refer to instruction manual 308647. For complete mastic fluid regulator repair refer to instruction manual 307517.

See F

. 57 and perform the following steps.

NOTICE

Carefully handle the hard carbide ball, valve actuator, and valve seat to avoid damaging them.

1. Prepare Fluid Plate Assembly for Repair, page 80.

2. Remove the cartridge assembly by loosening the valve housing (CE) with a 6 mm hex wrench and pulling the cartridge assembly out of the base housing (CD).

NOTE: The retaining nut (CC) often loosens when removing the cartridge assembly from the base housing. Be sure to re-torque as described in step 4.

3. Inspect and clean the internal walls of the base housing (CD).

NOTE: Be careful to not scrape or gouge the internal walls of the base housing. They are a sealing surface.

4. Re-torque the retaining nut (CC) to 140-160 in-lb (16-18 N•m).

NOTE: You must re-torque the retaining nut before you install it in the base housing during step 5.

5. Install the new cartridge assembly in the base housing (CD), and torque the valve housing (CE) to 30-35 ft-lb (41-48 N•m).

NOTE: The valve seat is double sided and may be reversed for extended life. The o-ring and ball must be replaced. See instruction manual 308647.

Cartridge Regulator 244734 Shown

diaphragm and valve actuator subassembly

FIG. 57: Replace Cartridge Assembly

cartridge assembly

Torque Sequence for Regulator

Base Housing Screws (CF)

84 3A2098H

Repair

Replace Amplifier

(Heated fluid plates only)

1. Prepare Fluid Plate Assembly for Repair, page

80.

2. Disconnect pressure sensor cable (117) and power output cable.

Screw

116

117

Power Output Cable

. 58: Replace Amplifier

Adjust Display Settings

3. With the system in setup mode, navigate to the Advanced screens.

4. Press to scroll to Advanced screen 2.

5. Press to access the fields to make changes.

6. Press to move the Pressure Units field. Press

to open the drop-down list, and select psi.

Press to enter the new units.

3. Loosen four screws on amplifier (116) cover, and then remove cover.

4. Remove four screws (105) securing amplifier to bracket.

5. Remove amplifier and replace with a new amplifier.

6. Secure new amplifier to bracket with four screws.

7. Replace amplifier cover and tighten screws.

8. Reconnect pressure sensor cable (117) and power output cable.

Calibrate Amplifier

(Heated fluid plates only)

1. Prepare Fluid Plate Assembly for Repair, page

80.

2. Remove outlet pressure sensor from outlet fitting to ensure there is no pressure applied to the sensor.

7. Press to exit edit mode.

8. With the system still in setup mode, navigate to Fluid Plate x, screen 5 (Pressure Sensors).

9. Press to access the fields to make changes.

10. Press to move the Outlet Offset field. Set the

psi to 0. Press to enter the new setting.

11. Press to exit edit mode.

3A2098H 85

Repair

Adjust Amplifier Settings

12. Remove cover from amplifier (116). See Replace Amplifier, page 85.

13. Ensure the EXCITATION SELECTOR jumper is in the middle position (5 Vdc). See F

. 59 on page 86.

14. Ensure the COARSE GAIN dipswitch 1 is set to ON. All others should be set to OFF.

15. Adjust the FINE ZERO potentiometer until the outlet pressure on the display reads 0.

16. Use a small piece of jumper wire or a paper clip to connect the SHUNT CAL and ENABLE terminals.

EXCITATION MODULE

To Readout

(+)SUPPLY

(-)OUTPUT

SUPPLY RETURN

(+)OUTPUT

SHUNT CAL

ENABLE

1 2

3 4 5 6

17. Use the data from the certificate of calibration for the pressure sensor (included with PCF documentation or the replacement pressure sensor) to calculate the Shunt Calibration Pressure using the following formula:

Shunt Calibration Pressure = (Shunt Cal Factor / Calibration Factor) * 5000 psi

18. Adjust the FINE GAIN potentiometer until the Outlet Pressure on Fluid Plate x, screen 5 (Pressure Sensors) matches the calculated Shunt Calibration Pressure.

19. Remove the jumper wire or paper clip from the SHUNT CAL and ENABLE terminals.

20. Repeat steps 15 - 19 at least one additional time to ensure proper calibration.

Panel mounting holes. Use #6 or #8 screws.

TRANSDUCERPOWER

A B

C D E F

(+)EXCITATION

(-)EXCITATION

(+)SIGNAL

(-)SIGNAL

SHUNT CAL

RESISTOR

To Transducer

EX SEL

10 VDC

5 VDC 3 VDC

ZERO

COARSE

FINE

Excitation Selector

Coarse Zero

Fine Zero

. 59: Amplifier Settings

21. Replace the amplifier cover. See Replace Amplifier, page 85.

22. Reconnect the outlet pressure sensor cable if it was removed.

23. If desired, change pressure units to desired setting on Advanced screen 2.

SPAN

12345678

COARSE

Fine Gain

Coarse Gain

86 3A2098H

Repair

Control Center Assembly

Prepare Control Center for Repair

1. Power off the display.

2. Disconnect main power to the control center assembly.

3. Remove the control center assembly front cover (20).

Replace Gateway Module

1. Prepare Control Center for Repair, page 87.

2. Remove the automation communications cable (AE).

3. Remove the two screws holding the Gateway module (5) to the base (3), and remove the module.

Replace Gateway Module Base

1. Prepare Control Center for Repair, page 87.

2. Remove the Gateway module (5); follow Replace Gateway Module. (Leave automation communications cable (AE) attached to Gateway module.)

3. Disconnect the CAN cable (19) and power supply cable (6) from the base (3).

4. Remove the four screws (16) and grounding screw (12) from the base and replace it with a new base.

FIG. 60

4. Attach a new Gateway module to the base using two screws.

. 61

5. Secure the new base to rear cover (1) using the five screws.

6. Reattach Gateway module; follow Replace Gate- way Module.

5. Reconnect the automation interface cable.

6. Upgrade software, page 77, then upgrade fieldbus map, page 78.

3A2098H 87

Repair

Replace Swirl Board 16K570:

1. Prepare Control Center for Repair, page 87.

2. Remove screw (a) from swirl board cover. Open swirl board cover.

3. Remove cable connectors (b) from swirl board.

4. Remove the four screws (c) from the swirl board. Replace with new board and secure using the four screws (c).

5. Insert cable connectors (b) into the new board.

6. Reassemble the swirl board cover using screw (a).

Replace Advanced Display Module

1. Prepare Control Center for Repair, page 87.

2. Disconnect the CAN cable (18) from the ADM (2).

FIG. 63

11, 14, 24

3. Remove the ADM by snapping it out of the mounting bracket.

4. On old ADM, remove token access panel then remove key token. Do not discard token.

. 62

5. Connect the CAN cable to the new ADM.

6. Upgrade new ADM software, page 77.

7. Insert key token into new ADM. Replace token access panel.

8. Install the new ADM by snapping it into the mounting bracket.

88 3A2098H

Repair

Replace Advanced Display Module Bracket

1. Prepare Control Center for Repair, page 87.

2. Remove the ADM (2); follow Replace Advanced Display Module. (Leave the CAN cable attached to the ADM.)

3. Remove the speed clips (25) and rivets (26) from the mounting bracket (21).

Replace DIN Rail Assembly

1. Prepare Control Center for Repair, page 87.

2. Remove both screws (22) and washers (28) from the line voltage assembly cover (7). Remove the cover.

. 64

4. Remove the mounting bracket from the front cover (20) and replace with a new bracket.

5. Secure the new bracket to the front cover with speed clips and rivets.

6. Reinstall the ADM.

. 65

3. Disconnect all wiring from the din rail module and filter.

4. Remove the four screws (40) from the din rail and filter.

5. Disconnect wires from rocker/rotary switch. Take note of wire positions for easy connection in Step 7.

3A2098H 89

Repair

6. Remove the din rail, filter, and rocker switch (snaps into place). Replace with new components. Secure din rail and filter to the rear control center assembly. cover (1) using the four screws (40). Snap

rocker/rotary switch into position.

. 66: 24 Vdc Din Rail Assembly

r_pf0000_313377_10a

7. Reconnect all wiring to the din rail module, filter, and rocker/rotary switch.

8. Reassemble the line voltage assembly cover using the screws and washers.

Replace Fuses

Replace fuses on the din rail assembly.

• For 24 Vdc control centers: see Technical Data

on page 140 for fuse specifications.

• For 100-240 Vac control centers: Order fuse

115805.

r_pf0000_313377_10a

Fuses

. 67: Fuse Location

90 3A2098H

Parts

Control Centers

Software Upgrade Tokens

Part Description

★

✠

16K743

★ * 16N601 PCF Gateway map token: Installs the CGM

★ 16K742 Historical PCF Gateway map token: Only for

Control Center Key Token Part Numbers

See Key Tokens on page 20 for more information about key tokens.

Includes PCF software for the ADM, FCM, CGM, and DGM

map starting on page 122.

users that used the original PCF with a Gateway, have purchased a new PCF, and do not wish to change their Gateway setup from the old Gateway map to the new Gateway map.

Parts

Part Description

★16M217 ADM Key Token, Standard PCF

Gateway Module Part Numbers

User

PCF

Model

Interface

Description

Gateway Part

Number To

Order

PFxx0x Discrete ★24B681

PFxx1x

DeviceNet

PFxx2x Ether-

Net/IP

PFxx3x

PFxx4x

PROFIBUS

PROFINET

™

★15V759

★15V760

™

★15V761

★15V762

3A2098H 91

Parts

Control Center and Expansion Swirl Enclosure Parts

3,4,12,16

6,10

5 or 43

241114

24 VDC units only:

100-240 VAC units only:

15,36

6,36

23,27

Add ferrite (36) to cable. Locate as close to cable connector as possible.

Included in swirl models only (both control centers and expansion swirl enclosures).

Ground/

Green

Control centers only. Not included in expansion swirl enclosures.

100-240 Vac models only.

Neutral/

Blue

Line/

Brown

92 3A2098H

Control Center Assembly Parts

Parts

Ref. Part Description Qty.

1 --- COVER, rear 1 2✠ 24E451 DISPLAY, with USB 1 3◆ 289697 BASE, cube 1 4◆ 277674 ENCLOSURE, cube door 1 5✠ --- MODULE, Gateway; see table on

page 91 for part number 6‡ --- SUPPLY, power 1 7‡❖ --- COVER, line voltage 1 8‡❖ --- GROMMET 1 9▲‡ 196548 LABEL, warning, electric shock 1 10‡ --- SCREW, cap, socket hd; m4 x 6 4 11✿ --- WASHER, lock 1 12◆ 121820 SCREW, mach, pan hd; m4 x 35 1 13 121807 CONNECTOR, splitter 1 14✿ 110755 WASHER, plain 1 15‡❖ --- MODULE, line voltage 1 16◆ 195875 SCREW, mach, pan hd 4 18 121001 CABLE, CAN, female / female 1.0m 1 19 121000 CABLE, CAN, female / female 0.5m 1 20 --- COVER, front 1 21✿ --- BRACKET, mounting 1 22‡❖ --- SCREW, mach, pan hd 2 23 120143 GUIDE, strain relief 2 24✿ 121253 KNOB, display 2 25✿ --- CLIP, speed, tubular 2 26✿ --- RIVET, aluminum 1 27 112925 SCREW, cap 2 28 100020 WASHER, lock 2 36 121901 SUPPRESSOR, box snap, ferrite 2 37 124654 CONNECTOR, splitter 1 38 --- LABEL 1 40 --- SCREW, mach, pan hd 4

Ref. Part Description Qty.

43✠ 24B681 MODULE, DGM 1 44 --- GUARD, edging 1 45 16K570 BOARD, circuit, swirl 1 46 --- BRACKET, display pivot 1 47 --- COVER, swirl, hinge side 1

48 --- COVER, swirl, latch side 1 49 --- COVER, swirl, lid 1 50 24K455 CABLE, swirl board, panel mount 1 51 24K458 CABLE, SWIRL-DGM 1 52 121597 CABLE, CAN, 90 female/90 female 1

▲

Replacement Danger and Warning labels, tags, and cards are available at no cost.

‡ Parts included with 100-240 Vac Module kit 24B928.

❖

Parts included with 24 Vdc Module kit 24B929.

✿

Parts included with Display Mounting Bracket kit 24B930.

✠

Base electronic components do not have PCF-specific software installed. Use software upgrade token (16K743) to install software before use.

* Fieldbus Gateway modules do not have a PCF-spe-

cific map installed. Use map token (16N601) to install map before use.

--- Not for sale.

3A2098H 93

Parts

Fluid Plate Assembly Parts

142

143

See page 95

199

153

See page 96

117, 120

135, 136

131

See page 95

151

152

94 3A2098H

101

Fluid Plate Assembly Parts (continued)

Parts

126

141

132

155

129

137

130

127

137

124

141

125

128

126

110

109

125

126

105

104

128

118

122

141

121

141

122

3A2098H 95

128

133

128

106

103

102

105

Parts

Fluid Plate Assembly Parts (continued)

119

127

Fluid Plate 24B962 Shown

114

108

127

113

112

111

112

113

141

ti19262a

105, 116

140, 141, 150

158

139

107

199

148

145

159

149

117

115

108

160

96 3A2098H

Parts

Fluid Plate Assembly Parts

Ref. Part Description Qty.

101 --- PLATE, fluid 1 102 289697 BASE, cube 1 103✠ 289696 FCM, cube 1 104 277674 ENCLOSURE, cube door 1 105✓ --- SCREW, mach, pan hd 106 121820 SCREW, machine, pan hd; m4 x 351

107 121228 CABLE, CAN, female/female;

15.0 m 108✓ --- REGULATOR, assy 109✓ --- UNION, adapter 110✓ --- NIPPLE, reducing, hex; 1/2 npt(f)

x 3/4 npt(f) 111 198269 BRACKET, flow meter, lower 1 112 110580 SCREW, cap, socket hd 2 113✓ --- SPACER 114 198268 BRACKET, flow meter 1 115✖ 624545 FITTING, tee; 3/4(m) x 1/4(f) 1 116✖ 258530 AMPLIFIER, signal conditioner 1 117✓ --- SENSOR, pressure, fluid outlet 2 118 --- BRACKET, valve 1 119✖ 16P819 BRACKET, signal conditioner 1 120✓ --- O-RING 121 120010 REGULATOR, I/P 1 122 111119 SCREW, valve 2 124✓ --- BRACKET, helical gear meter 125✓ --- WASHER, plain 126✓ --- WASHER, lock, spring; m6 127✓ --- SCREW, cap, socket hd 128✓ --- SCREW, cap, socket hd, hex 129✓ --- METER, assy 130✓ --- CABLE; m12-5p 131▲ 15X756 LABEL, warning, main 1 132 258334 VALVE, dispense, fluid plate 1 133 121806 CABLE, solenoid 1 135▲✖ 189285 LABEL, caution, hot surface 1 136 --- LABEL 1 137 117820 SCREW, cap, socket hd; m3 2 139 198179 FITTING, bulkhead, union 1 140 198175 FITTING, push 1 141 --- TUBE, nylon, round, black; 5.5 142 --- LABEL 1 143 --- SHROUD, fluid plate 1 145 121226 CABLE,CAN, male/female; 0.5 m1

146★ 234967 KIT, dual filter 1 147✓★ --- TOKEN, key 148 121612 CONNECTOR, thru; m12, m x f 1 149 121818 BULKHEAD, tube; 5/32 2 150 --- TAG, installation 1 151 114391 SCREW, grounding 1

Ref. Part Description Qty.

152 194337 WIRE, grounding, door 1 153▲ 186620 LABEL, ground 1 155✓ --- SUPPRESSOR, box snap, ferrite 158 122610 ELBOW 1 159▲ 290228 LABEL, caution, hot surface 1 160▲ 189930 LABEL, caution, electric shock 1 199* 124654 SPLITTER, CAN 1

▲

Replacement Danger and Warning labels, tags, and cards are available at no cost.

✓

See Parts Varying by Assembly table, page 98, for part number and quantity.

✖

Only included with fluid plates that use a heated mastic regulator.

✠

Base electronic components do not have PCF-specific software installed. Therefore, use software upgrade token (16K743) to install software before use.

★

Not shown.

--- Not for sale.

* CAN splitter is not included with the fluid plate

assembly included in the PFxxxx assembly. It is included only with the additional fluid plate kits.

Fluid Plate Key Token Part Numbers

See Key Tokens on page 20 for more information about key tokens.

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

3A2098H 97

Parts

Parts Varying by Assembly

The following table lists the varying part numbers by fluid plate assembly, and the quantity for each assembly.

Fluid Plate Assemblies

Heated

Mastic Cartridge Regulator

with High

Resolution

Ref. Part Description

105 195875 SCREW, mach, pan

108 244734 REGULATOR, assy 1 1

246642 11 246643 11

109 156684 UNION, adapter 1 1

157785 1

110 C20461 NIPPLE, reducing,

C20487 1 1

113 C34045 SPACER 2 2 117 15M669 SENSOR, pressure,

117764 11 120 111457 O-RING 2 2 2 2 124 117670 BRACKET, helical

125 C19197 WASHER, plain 4 4 4 126 --- WASHER, lock,

127 108328 SCREW, cap, socket

128 107530 SCREW, cap, socket

129 246652 METER, assy. 1

246340 1 130 122030 CABLE; m12-5p 1 1 1

16M100 TOKEN, key, 2 styles,

147

★

16M101 TOKEN, key, 2 styles,

16M102 TOKEN, key, 16

16M103 TOKEN, key, 16

16M104 TOKEN, key, 256

16M105 TOKEN, key, 256

155 121901 SUPPRESSOR, box

hex; 1/2 npt(f) x 3/4 npt(f)

fluid outlet

gear meter

spring; m6

hd, hex

meter enabled

meter disabled

styles, meter enabled

styles, meter disabled

styles, meter enabled

styles, meter disabled

snap, ferrite

Meter

444488

2222

1 1 1

6 6 6

626262

646464

1 1 1

Cartridge

Regulator

with

No Meter

1 1 1

Mastic

Regulator

with High

Resolution

Meter

1 1

Mastic

Regulator

with

No Meter

Regulator

with Heated

High

Resolution

Meter

Heated

Mastic

Regulator

with

No Meter

--- Not for sale.

98 3A2098H

Appendix A - Advanced Display Module (ADM)

Display Overview

The ADM display is divided into two main functions: Setup Mode and Run Mode.

Setup Mode Functions

The setup mode functions enable users to:

• configure installed system components

• set units, adjust values, set formats, and view software information for each component

• set or change information regarding the Gateway module

• view information regarding the particular Gateway module used

• set controls and valve commands

• set on and off delays for valves and the regulator

• set k-factor, pressure, and flow rate variables

• set offsets for inlet and outlet pressures

• set error types

• set variables for maintenance advisories

• set up to 256 styles for models with a CGM and set up to 16 styles for models with a DGM

Display Details

Power Up Screen

The following screen appears when the ADM is powered up. It remains on while the ADM runs through initialization and establishes communication with other modules in the system.

Run Mode Functions

The run mode functions enable users to:

• adjust the bead scale

• perform manual dispensing

• view a chronological list of system errors

• view a chronological list of jobs stored/performed in the system

• use a preventative maintenance schedule for the supply system, displacement pump, and air motor

Menu Bar

The menu bar appears at the top of each screen.

Date and Time

The date and time are always displayed in one of the following formats. The time is always displayed as a 24-hour clock.

• DD/MM/YY HH:MM

• MM/DD/YY HH:MM

• YY/MM/DD HH:MM

Arrows

The left and right arrows indicate screen navigation.

Screen Menu

The screen menu indicates the currently active screen, which is highlighted. It also indicates the associated screens that are available by scrolling left and right.

3A2098H 99

Appendix A - Advanced Display Module (ADM)

System Mode

There are five modes: Active, Job in Cycle, Display Control, Swirl Setup, and System Off. The current system mode is displayed at the left of the menu bar.

Alarm/Deviation

If there is an active system error, one of the following icons is displayed in the middle of the menu bar. There are four possibilities:

Icon Function Description

No information or

No Icon

no error has

occurred

Advisory Informational

Important but will

Deviation

Alarm

not shut down the

and will immedi-

the affected fluid

---

affected fluid

plate

Very important

ately shut down

plate

Navigation within Screens

Press to open drop-down menus on Setup

screens. Also, press to enter changes or make a selection.

Press to navigate to new screens and to navigate left and right within a screen.

Press to navigate to new screens and to navi-

gate up and down within a screen. Also press

to move between fields within a drop-down menu, and to increment or decrement numbers within a field.

Status

The current system status is displayed at the right of the menu bar.

Soft Keys

Icons next to the soft keys indicate which mode or action is associated with each soft key. Soft keys that do not have an icon next to them are not active in the current screen.

NOTICE

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

Jump In/Jump Out

In screens that have editable fields, press to access

the fields and make changes. When changes are com-

plete press again to exit edit mode.

100 3A2098H

Graco 3A2098H User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Models

Fluid Plate Kits

Expansion Swirl Enclosure Assemblies

PrecisionSwirl Orbital Dispenser Assemblies

Automation Gateway Assemblies

Swirl Control DGM

Warnings

System Configurations

Typical Installation - Single Swirl, Single Fluid Plate

Typical Installation - Multiple Fluid Plates, No Swirl Dispensers

Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers

Overview

System Overview

System Components

Fluid Plate Assembly Overview

Control Center Assembly Overview

Key Tokens

Installation

Before Installation

Overview

Install Control Center

Install Fluid Plate Assemblies

Install Cable Assemblies

Install Gateway Module Interface

System Setup

Overview

Configure System

Configure Control Settings

Configure Mode Settings

Configure Delay Settings

Configure Flow Meter Settings

Configure Pressure Loop Settings

Adjust Pressure Sensors

Configure Errors

Setup Maintenance Schedule/Parameters

Configure Valve to Swirl Association and Motor Error Type

Configure Swirl Settings

Configure Gateway Settings

Setup Styles

Configure Advanced Settings

On/Off Delays

Operation

Startup

Load Material

Maintenance Mode Operation

Automation Control (Normal Operation)

Jobs

Styles

Precharge Modes

Typical Job Cycle

Pressure Relief Procedure

Shutdown

USB Data

USB Logs

System Configuration Settings File

Custom Language File

Download Procedure

Upload Procedure

Troubleshooting

Fluid Plates

Flow Meter

Fluid Regulator

Dispense Valves

Gateway Module

LED Diagnostic Information

Errors

View Errors

Diagnose Errors

Event and Error Codes and Troubleshooting

Maintenance

Maintenance Schedule

Advanced Display Module (ADM)

Upgrade Gateway Module Software

Upgrade Gateway Module Fieldbus Map

Upgrade Fluid Control Module (FCM) Software