Graco PCF Instructions - Parts Manual
Instructions - Parts
PCF
313377L
Precision Dispense System
Electronically-controlled fluid metering system that provides precise continuous flow of
single-component sealants and adhesives through closed-loop technology.
Not for use in explosive atmospheres.
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.
EN
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.
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fluid Plate Assemblies . . . . . . . . . . . . . . . . . . . . 5
Control Center Assemblies . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Configurations . . . . . . . . . . . . . . . . . . . . . . 8
Typical Ambient System Installation . . . . . . . . . . 8
Typical Heated System Installation . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System Overview . . . . . . . . . . . . . . . . . . . . . . . 10
System Components . . . . . . . . . . . . . . . . . . . . . 10
Fluid Plate Assembly Overview . . . . . . . . . . . . 11
Control Center Assembly Overview . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Before Installation . . . . . . . . . . . . . . . . . . . . . . . 16
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install Control Center . . . . . . . . . . . . . . . . . . . . 17
Install Fluid Plate Assembly . . . . . . . . . . . . . . . 19
Install Cable Assemblies . . . . . . . . . . . . . . . . . . 22
Install Gateway Module Interface . . . . . . . . . . . 23
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Configure Control Settings . . . . . . . . . . . . . . . . 26
Configure Mode Settings . . . . . . . . . . . . . . . . . 27
Configure Delay Settings . . . . . . . . . . . . . . . . . 28
Configure Flow Meter Settings . . . . . . . . . . . . . 28
Configure Control Loop Settings . . . . . . . . . . . . 29
Adjust Pressure Sensors . . . . . . . . . . . . . . . . . 29
Configure Errors . . . . . . . . . . . . . . . . . . . . . . . . 30
Setup Maintenance Schedule/Parameters . . . . 31
Configure Gateway Settings . . . . . . . . . . . . . . . 31
Setup Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Configure Advanced Settings . . . . . . . . . . . . . . 31
On/Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Maintenance Mode Operation . . . . . . . . . . . . . . 34
Automation Control (Normal) Operation . . . . . . 37
Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Precharge Modes . . . . . . . . . . . . . . . . . . . . . . . 39
Typical Job Cycle . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 46
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
USB Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
System Configuration Settings File . . . . . . . . . . 48
Custom Language File . . . . . . . . . . . . . . . . . . . 49
Download Procedure . . . . . . . . . . . . . . . . . . . . . 49
Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . 50
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fluid Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fluid Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fluid Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 52
Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 53
Gateway Module . . . . . . . . . . . . . . . . . . . . . . . . 54
LED Diagnostic Information . . . . . . . . . . . . . . . . 54
Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Diagnose Errors . . . . . . . . . . . . . . . . . . . . . . . . . 55
Clear Errors and Reset Control Unit . . . . . . . . . 55
Error Codes and Troubleshooting . . . . . . . . . . . 55
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Maintenance Schedule . . . . . . . . . . . . . . . . . . . 62
Advanced Display Module (ADM) . . . . . . . . . . . 63
Upgrade Gateway Module Software . . . . . . . . . 63
Upgrade Gateway Module Fieldbus Map . . . . . 64
Upgrade Fluid Control Module (FCM) Software 65
Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . 65
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fluid Plate Assembly . . . . . . . . . . . . . . . . . . . . . 66
Control Center Assembly . . . . . . . . . . . . . . . . . . 74
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Control Center Assembly Parts . . . . . . . . . . . . . 78
Fluid Plate Assembly Parts . . . . . . . . . . . . . . . . 80
Appendix A - Advanced Display Module (ADM) . 85
Display Overview . . . . . . . . . . . . . . . . . . . . . . . . 85
Display Details . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Appendix B - Discrete Gateway Module (DGM)
Connection Details . . . . . . . . . . . . . . . . . . . . . 98
D-Sub Cable 123793 . . . . . . . . . . . . . . . . . . . . . 98
D-Sub Cable 123792 and Breakout Board 123783
99
DGM Digital Input . . . . . . . . . . . . . . . . . . . . . . 102
DGM Digital Outputs . . . . . . . . . . . . . . . . . . . . 103
DGM Analog Inputs . . . . . . . . . . . . . . . . . . . . . 104
DGM Analog Outputs . . . . . . . . . . . . . . . . . . . 104
2 313377L
Related Manuals
ADM Software Part No. 16K405
(see manual 3A2098)
ADM Software Part No. 16F528 or 15V769
(use this manual)
Appendix C - Communications Gateway Module
(CGM) Connection Details . . . . . . . . . . . . . . 105
Install Fieldbus Connections . . . . . . . . . . . . . . 105
CGM I/O Data Map . . . . . . . . . . . . . . . . . . . . . 108
Appendix D - I/O Signal Descriptions . . . . . . . . 111
Automation Inputs . . . . . . . . . . . . . . . . . . . . . . 111
Automation Outputs . . . . . . . . . . . . . . . . . . . . . 112
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Fluid Plate Assembly Technical Data . . . . . . . 115
Control Center Assembly Technical Data . . . . 115
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 116
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 116
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
3A2098
307517
308647
309834
NOTE: In the Advanced screens on your system, if
the Advanced Display software part number shown
is 16K405 then this manual does not apply to your
system; refer to manual 3A2098 for your system.
Otherwise, the part number shown should be
16F528 or 15V769 and you should use this manual.
New PCF Instructions - Parts
(see the note below)
Mastic Fluid Regulators Instructions-Parts
Fluid Pressure Regulators Instructions-Parts
Helical Gear Fluid Flow Meters Instructions-Parts
313377L 3
Models
Models
Check the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to
define the construction of the system, based on the six digits. For example, Part 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
First and
Second Digits
1 2 Styles 1 Cartridge None 0 Discrete 0 100 - 240 Vac
2
3 256 Styles 3 Cartridge High
PF
(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 98, for custom wiring.
50 ft (15 m) cable with flying leads (123793)
Breakout board (123783) and 50 ft (15 m) cable (123792)
1
Third Digit
Style/Size
Description Regulator Meter Description Description
16 Styles 2 Mastic None 1
4 Mastic High
5 Heated
Mastic
6 Heated
Mastic
1
Fourth Digit
Fluid Plate
Resolution
Resolution
Standard
Resolution
Heated
None
Fifth Digit
User Interface
DeviceNet
2
EtherNet/IP
3
PROFIBUS
4
PROFINET
1
0
Sixth Digit
Voltage
™
1 24 Vdc
™
™
™
Fluid metering systems with ETL certification and Canadian approval.
NOTE: Fluid metering systems with heated mastic regulators are not ETL certified.
1
C
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 313377L
9902471
Conforms to
UL 61010-1
Fluid Plate Assemblies
Models
Maximum Working
Pressure
Part
24B958 6000 psi (41.4 MPa, 414 bar) Cartridge Regulator,
24B959 6000 psi (41.4 MPa, 414 bar) Cartridge Regulator, No Flow Meter 244734 --
24B960 5000 psi (34.4 MPa, 344 bar) Mastic Regulator,
24B961 5000 psi (34.4 MPa, 344 bar) Mastic Regulator, No Flow Meter 246642 --
24B962 5000 psi (34.4 MPa, 344 bar) Heated Mastic Regulator,
24C901 5000 psi (34.4 MPa, 344 bar) Heated Mastic Regulator, No Flow Meter 246643 --
psi (MPa, bar) Description
High Resolution Flow Meter
High Resolution Flow Meter
Standard Resolution Heated Flow Meter
Includes:
Regulator
244734 246652
246642 246652
246643 246340
Control Center Assemblies
Description Bus Module Bus Module Part
100 - 240 Vac DeviceNet 15V759
100 - 240 Vac EtherNet/IP 15V760
100 - 240 Vac PROFIBUS 15V761
100 - 240 Vac PROFINET 15V762
100 - 240 Vac Discrete 24B681
24 Vdc DeviceNet 15V759
24 Vdc EtherNet/IP 15V760
24 Vdc PROFIBUS 15V761
24 Vdc PROFINET 15V762
24 Vdc Discrete 24B681
Flow
Meter
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 98, for custom wiring.
50 ft (15 m) cable with flying leads (123793)
Breakout board (123783) and 50 ft (15 m) cable (123792)
313377L 5
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
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
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.
• Engage trigger lock when not dispensing.
• 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.
6 313377L
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. Wait until equipment/fluid has cooled completely.
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
313377L 7
System Configurations
G
D
C
B*
F*
A*
E
H
J
Air Supply
Drop Site
K*
Power
System Configurations
Typical Ambient System Installation
F
IG. 1: Typical Ambient System Installation
Key:
A *Control Center (User Interface)
B *Fluid Plate Assembly
C Applicator/Dispense Valve
DSealer Automation
E Automation Interface Cable
F *CAN Cable
G Fluid Supply System
H Fluid Supply Hose
J Automation Controller
K *Air Filter Assembly
* Included
8 313377L
Typical Heated System Installation
AD
AC
AB*
AJ
AF*
AA*
AE
AH
AK
AM
AG
Air Supply
Drop Site
AL*
AN
Power
System Configurations
F
IG. 2: Typical Heated System Installation
Key:
AA *Control Center (User Interface)
AB *Fluid Plate Assembly
AC Applicator/Dispense Valve
AD Sealer Automation
AE Automation Interface Cable
AF *CAN Cable
AG Heated Fluid Supply System
AH Fluid Supply Hose
AJ Heat Control
AK Automation Controller
AL *Air Filter Assembly
AM RTD Cable
* Included
313377L 9
Overview
Control Center
Fluid Plate
Assembly
Automation
Controller
Power
(User Interface)
Overview
System Overview
The PCF fluid metering system combines closed-loop
pressure control with the ability to change bead profiles
quickly. When used with the optional flow meter, the
module automatically adjusts for fluctuations in the operating environment, such as material viscosity, temperature, tip wear, and automation speed, while maintaining
the desired dispense rate. 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.
Typical Applications
• Bead dispensing
• Gasketing
• Seam sealing
• Hem flange
• Sound deadening
• Anti-flutter
• Body panel reinforcement
• Profile wrapping
• Cable filling
System Components
The diagram in FIG. 3 shows an example of the PCF
module and cables.
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.
F
IG. 3: PCF System Components
10 313377L
Overview
U
R
P
T
S
Fluid Plate Assembly Overview
Fluid Plate Components
The fluid plate assembly in FIG. 4 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.
• V/P regulator (T) 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.
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.
F
IG. 4: Fluid Plate Components
313377L 11
Overview
3
4
5
CAN
Connectors
TI12337A
TI12336A
6
7
Status LEDs
1
2
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)
NOTE: See LED Diagnostic Information, page 54, for
signal definitions.
Table 1: FCM Sensor Connections
Connection Sensor Description
1 Dispense solenoid
2Flow meter
3 Outlet pressure sensor (heated systems only)
4V/P
5 Command cable (optional accessory kit)
6 Inlet pressure sensor (non-heated systems
only)
7 Outlet pressure sensor (non-heated systems
only)
CAN
Connectors
FIG. 5: FCM Sensor Connections
12 313377L
Control Center Assembly Overview
Front View
Side View
Open View
ADM
Gateway Module
(24 Vdc Assembly)
(100-240 Vac Assembly)
Overview
F
IG. 6: Control Center Components
The control center includes the following components:
• Advanced Display Module (ADM) with USB; see
page 14 for details.
• USB enables users to download job, error, and data
logs; save and restore system settings; and customize the language.
• 24 Vdc and 100-240 Vac customer-wired options
available.
• Gateway Module, which includes the following five
options:
• Discrete
• DeviceNet
• EtherNet/IP
•PROFIBUS
• PROFINET
313377L 13
Overview
TI12362a
BA
BB
BC
BE
BH
BG
BF
BD
r_24E451_3B9900_1a
BJ
BR
BP
BN
BM
BL
BK
BS
Advanced Display Module (ADM)
F
IG. 7: Advanced Display Module Component Identification
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 indicate the system is in
Run mode. Flashing LEDs 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
BP Battery Cover
BR Token Access Cover
BS Digital I/O Port for Light Tower
See LED Diagnostic Information, page 54, for
signal definitions.
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
14 313377L
Gateway Module
TI11985A
TI11814A
TI11815A
TI11816A
CA
CD
See Gateway Module Connector Table
Gateway Module Connectors Table
CB
PROFINET or EtherNet/IP
DeviceNet
PROFIBUS
CE
TI11972A
CF
CH
Front Back
Discrete
CC
CG
CC
CC
Overview
F
IG. 8: Gateway Module Components
Key:
CA Gateway Module
CB Base
CC Fieldbus Connector (see Appendix C - Communi-
cations Gateway Module (CGM) Connection
Details, page 105, for more information)
CD Module Connection Screws
CF Module Status LEDs (see LED Diagnostic Infor-
mation, page 54)
CG D-Subminiature (D-Sub) Connector (see Appendix
CH CAN Connectors
B - Discrete Gateway Module (DGM) Connection
Details, page 98, for pinout details)
CE Access Cover
313377L 15
Installation
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.
NOTICE
To avoid damaging the PCF system, use at least two
people to lift, move, or disconnect the system. The
system is too heavy for one person to lift or move.
Installation Steps
1. Mount control center.
2. Connect and ground control center.
3. Mount fluid plate assembly.
4. Ground fluid plate assembly.
5. Check ground continuity.
6. Connect fluid lines between fluid module and applicator. Connect fluid supply line and air supply to
module.
7. Plumb filter assembly near air drop site that will be
used for fluid plate assembly.
8. Connect other fluid and air lines to additional system
components as instructed in their manuals.
9. Install cable assemblies.
10. Install Gateway interface.
16 313377L
Installation
A
B
C
D
Install Control Center
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 mounting dimensions in Table 2 and
F
IG. 9.
Table 2: Control Center Assembly Measurement
A
B
C
D
10.50 in. (267 mm)
5.75 in. (146 mm)
17.00 in. (432 mm)
16.25 in. (413 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.
F
IG. 9: Control Center Dimensions
313377L 17
Installation
+
-
Ground
Ground
N
L
Electrical Connections
Follow these precautions when grounding, connecting
cables, connecting to a power source or making other
electrical connections.
To reduce the risk of fire, explosion, or electric shock:
• The control center must be electrically connected to
a true earth ground; the ground in the electrical system may not be sufficient.
• 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
• Refer to your local code for the requirements for a
“true earth ground” in your area.
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
IG. 10.
IG. 11.
FIG. 11: 100-240 Vac Wiring
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.
Red flashing A deviation exists.
Red solid An alarm exists and the system is
shut down.
NOTE: See Errors, page 55, for error definitions.
F
IG. 10: 24 Vdc Wiring
18 313377L
Installation
A
B
C
D
Install Fluid Plate Assembly
To install the PCF fluid plate assembly:
• Mount the fluid plate assembly.
• Ground fluid plate assembly.
• Connect the fluid plate assembly to the control cen-
ter.
• Connect fluid lines and cables.
Mount
Before Mounting Assembly
• See component manuals for specific information on
component requirements. Information presented
here pertains to the PCF fluid plate assembly only.
• Have all system and subassembly documentation
available during installation.
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
A
B
C
D
IG. 12.
16.5 in. (419 mm)
14.0 in. (356 mm)
14.4 in. (366 mm)
13.4 in. (340 mm)
• 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.
IG. 12: Fluid Plate Assembly Dimensions
F
313377L 19
Installation
GCA Cable
Splitter Assembly
Hole for bulkhead fitting
Connection 1
Mount Four-Valve Breakout Kit 24B693
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.
NOTE: Up to three additional dispense valves can
be connected to the dispense valve splitter assembly. For each additional dispense valve required
order one dispense valve (258334) and one solenoid
cable (121806).
6. Mount splitter assembly and dispense valves, and
connect air lines as necessary for application.
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
IG. 13.
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.
FCM
Port
Pin #
1 White Command voltage (0-10 Vdc)
2 Brown No connection
3 Green Dispense trigger (*sourcing input)
4 Yellow No connection
5 Gray Dispense trigger ground
6 Pink No connection
7 Blue Command signal ground
8 Red No connection
Command
Cable Wire
Color Function
F
IG. 13: Mount Breakout Kit
3. Connect one end of the extension cable (included in
4. Connect the splitter assembly to the bulkhead fit-
5. Connect the dispense valve cable(s) to the connec-
20 313377L
the kit) to connection 1 on the FCM and the other
end of the cable to the bulkhead fitting.
ting.
tions on the splitter assembly.
NOTE: Command cable inputs are not isolated from
PCF 24 Vdc power.
* To turn on the dispense trigger, connect pin 3 (dis-
pense trigger) to pin 5 (dispense trigger ground).
Installation
Ground
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
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.
• 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.
• Connect an air supply line to the 1/4 npt inlet port on
the fluid module(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.
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.
313377L 21
Installation
From Control Center
Power to FCM
Power to ADM
Install Cable Assemblies
NOTE: To prevent system errors, only connect
cables with the power off.
1. Connect the CAN cable from the control center to
the fluid plate assembly.
2. Connect the Gateway module to the automation
controller.
3. Connect power cable from power source to control
center.
F
IG. 14: Cable Installation Diagram
22 313377L
Install Gateway Module Interface
Installation
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
37, 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 111, 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 PFC 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 105, for details.
2. Turn on system power. Navigate to the Gateway
setup screens, and ensure the PCF standard data
map is installed. Refer to Appendix A - Advanced
Display Module (ADM), page 85, 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 85, 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 control center run screen for troubleshooting fieldbus data communication problems.
Refer to Appendix A - Advanced Display Module
(ADM), page 85, for details. Also, use the status indicators on the PCF Gateway module for fieldbus status information. Refer to Appendix C Communications Gateway Module (CGM) Connection Details, page 105, for details.
313377L 23
Installation
r_24B681_2B9904_2b
CG
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
37, 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.
• D-Sub to flying leads cable (123793). See
Appendix B - Discrete Gateway Module
(DGM) Connection Details, page 98, for
details and cable interface signals.
• D-Sub cable (123972) and 78-pin breakout
board (123783). See Appendix B - Discrete
Gateway Module (DGM) Connection Details,
page 98, for details and pin assignments.
F
IG. 15: Connect D-Sub Cable
DGM Status LED Signals
See LED Diagnostic Information, page 54, for signal
definitions.
24 313377L
System Setup
System Setup
Configure Control Settings (
page 26)
Configure Mode Settings (
page 27)
Configure Delay Settings (
page 28)
Configure Flow Meter
Settings (
page 28)
Configure Pressure Loop
Settings (
page 29)
Adjust Pressure Sensors (
page 29)
Configure Errors (
page 30)
Setup Styles (
page 31)
Setup Maintenance
Schedule/Parameters (
page 31)
Configure Gateway
Settings (
page 31)
Configure Advanced
Settings (
page 31)
End 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 setup again.
After material is loaded into the supply system, set up
the PCF system using the Setup screens. F
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 14, and Appendix A - Advanced Display Module (ADM), page 85, for detailed operating
instructions for the display keypad and each screen.
IG. 16 shows
System Setup
F
IG. 16
313377L 25
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 the Fluid
Plate set of screens.
2. Press to scroll to the Control Settings
screen (screen 1).
3. Press to access the fields to make changes.
6. 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.
7. 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.
8. Press to move to the Job End Delay field.
Enter the desired delay time (in seconds). Press
to enter the value.
9. Press to move to the Run Mode Bead Adjust
F
IG. 17
4. Press to open the Dispense Trigger Source
drop-down list, and select Gateway, Command
Cable, or Combined. If Command Cable is selected,
users can enable the guns. Press to finalize
the selection.
5. If the dispense trigger source is set to Command
Cable, press to move to the Enable Guns
field. Press and to enable guns.
field. Press to open the drop-down list, and
select Enable or Disable. Press to enter the
value.
10. Press to move to the Display Control Pass-
word field. Press to open the drop-down list,
and select Enable or Disable. Press to enter
the value.
11. Press to exit edit mode.
26 313377L
System Setup
Configure Mode Settings
Set gun commands, including the dispense mode (pressure, bead, shot, or full open) and flow rate or pressure
for each gun. The bead scale is also adjustable from the
Mode Settings screen.
NOTE: For a description of each dispense mode,
see Home Screen 1 - Fluid Plate, page 95.
1. With the system in setup mode, navigate to the Fluid
Plate set of screens.
2. Press to scroll to the Mode Settings
screen (screen 2).
3. Press to access the fields to make changes.
NOTE: The ability to dispense from multiple guns
simultaneously is only allowed in either of the following scenarios.
• Each gun is set to Pressure mode and has
identical Fixed Command values.
• Each gun is set to Full Open mode.
Attempting to dispense from multiple guns simultaneously using any other combination will cause an
Incompatible Guns Settings alarm.
6. Press to move to the Bead Scale field. Enter a
scale value between 50% and 150%. Press to
enter the value.
7. Press to exit edit mode.
F
IG. 18
4. Press and to set the mode for
each gun that will be used to Pressure, Bead, Shot,
or Full Open. Press to enter each selection.
5. Use the four arrow buttons to navigate to each
Fixed Command field. Enter the desired value for
each gun that will be used. Press to enter
each value.
313377L 27
System Setup
Configure Delay Settings
Set on and off delays (in milliseconds) for each gun and
the regulator. For an explanation of the on and off
delays, refer to the On/Off Delays section on page 32.
1. With the system in setup mode, navigate to the Fluid
Plate set of screens.
2. Press to scroll to the Delay Settings
screen (screen 3).
3. Press to access the fields to make changes.
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 35, 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
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 set of screens.
7000
3500
F
IG. 19
4. Use the four arrow buttons to navigate to each On
and Off field. Enter a desired delay value (in milliseconds) for each gun that will be used and the reg-
ulator. Press to enter each value.
5. Press to exit edit mode.
2. Press to scroll to the Flowmeter Set-
tings screen (screen 4).
3. Press to access the fields to make changes.
F
IG. 20
28 313377L
System Setup
4. 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.
5. 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.
6. Press to exit edit mode.
NOTE: If necessary, verify flow meter calibration.
See Verify Flow Meter Calibration, page 35, for
instructions.
Configure Control Loop Settings
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 set of screens.
2. Press to scroll to the Pressure Sensors
screen (screen 5).
3. Press to access the fields to make changes.
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 not be
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 Verify Flow Meter Calibration on page 35.
FIG. 21
NOTE: For the following steps, press
and to navigate through each field, and
to open drop-down menus and enter changes
or selections.
4. 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.
313377L 29
System Setup
5. Set the desired minimum and maximum pressure
limits for the inlet, and the desired maximum pressure limit for the outlet.
6. 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.
7. Press to exit edit mode.
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 set high and/or low limits. See
Jobs, page 37, for information on the purpose of each
error type.
NOTE: Only the first two error types (low pressure
and high pressure) will be enabled for systems without a flow meter.
1. With the system in setup mode, navigate to the Fluid
Plate set of screens.
2. Press to scroll to the Error Type
screen (screen 6).
3. Press to access the fields to make changes.
FIG. 22
4. Press to open the Low Pressure drop-down
list, and select either Alarm or Deviation for the error
type. Press to enter the selection.
5. Press to move to the next field. Repeat Step 4
for each field.
6. Press to exit edit mode.
30 313377L
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