Graco PCF Instructions - Parts Manual

Page 1

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.

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.

Page 2

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

DGM Digital Input . . . . . . . . . . . . . . . . . . . . . . 102

DGM Digital Outputs . . . . . . . . . . . . . . . . . . . . 103

DGM Analog Inputs . . . . . . . . . . . . . . . . . . . . . 104

DGM Analog Outputs . . . . . . . . . . . . . . . . . . . 104

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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

Page 4

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.

™

First and

Second Digits

1 2 Styles 1 Cartridge None 0 Discrete 0 100 - 240 Vac

2 3 256 Styles 3 Cartridge High

(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)

Third Digit

Style/Size

Description Regulator Meter Description Description

16 Styles 2 Mastic None 1

4 Mastic High

5 Heated

Mastic

6 Heated

Mastic

Fourth Digit

Fluid Plate

Resolution

Standard

Resolution

Heated

None

Fifth Digit

User Interface

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

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.

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

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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

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)

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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.

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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

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System Configurations

Air Supply Drop Site

Power

System Configurations

Typical Ambient System Installation

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

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Typical Heated System Installation

AB*

AF*

AA*

Air Supply Drop Site

AL*

Power

System Configurations

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

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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.

IG. 3: PCF System Components

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Overview

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.

IG. 4: Fluid Plate Components

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Page 12

Overview

CAN Connectors

TI12337A

TI12336A

Status LEDs

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

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Control Center Assembly Overview

Front View

Side View

Open View

ADM

Gateway Module

(24 Vdc Assembly)

(100-240 Vac Assembly)

Overview

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

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Page 14

Overview

TI12362a

r_24E451_3B9900_1a

Advanced Display Module (ADM)

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.

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Gateway Module

TI11985A

TI11814A

TI11815A

TI11816A

See Gateway Module Connector Table

Gateway Module Connectors Table

PROFINET or EtherNet/IP

DeviceNet

PROFIBUS

TI11972A

Front Back

Discrete

Overview

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

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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.

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Installation

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

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.

IG. 9: Control Center Dimensions

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Page 18

Installation

Ground

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.

IG. 10: 24 Vdc Wiring

18 313377L

Page 19

Installation

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

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

313377L 19

Page 20

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

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).

Page 21

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

Page 22

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.

IG. 14: Cable Installation Diagram

22 313377L

Page 23

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

Page 24

Installation

r_24B681_2B9904_2b

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.

IG. 15: Connect D-Sub Cable

DGM Status LED Signals

See LED Diagnostic Information, page 54, for signal definitions.

24 313377L

Page 25

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

IG. 16

313377L 25

Page 26

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

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

Page 27

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.

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

Page 28

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

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.

IG. 20

28 313377L

Page 29

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

Page 30

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

Page 31

System Setup

Setup Maintenance Schedule/Parameters

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

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 Maintenance Screen, page 97, for more information about maintenance totalizers.

To set limits:

1. With the system in setup mode, navigate to the Fluid Plate set of screens.

2. Press to scroll to the Maintenance

Advisory Limits screen (screen 7).

3. Press to access the fields to make changes.

6. Press to exit edit mode.

To reset a totalizer value:

1. Follow Steps 1-3 of To set limits: to make changes in the Maintenance Advisory Limits screen.

2. Press to scroll to the system compo-

nent to reset.

3. Press to reset the value.

Configure Gateway Settings

Gateway settings differ for each system. See Gateway Setup Screens, page 88, for guidelines on configuring

each type of Gateway interface.

Setup Styles

The PCF system can store up to 255 styles. See Styles, page 38, for more information about styles and instructions on setting up styles.

IG. 23

4. Enter the desired limit for the air supply and press

to enter the selection.

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

for each field.

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 87, for advanced setting guidelines.

313377L 31

Page 32

System Setup

Dispense Gun Signal

Fluid Regulator

Gun Open Command

Gun Actually Open

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

28.

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.

IG. 24 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 Gun ON delay Usually set to zero. Can be

used to change the starting point of a bead.

C Gun 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.

EGun Open

Reaction Time

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

F Gun Close

Reaction Time

Time delay for gun 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:

Gun ON Sets time from Dispense Gun High to

Gun Open command

Regulator ON

Sets time from Dispense Gun High to Regulator ON

Gun OFF Sets time from Dispense Gun Low to

Gun Close command

Regulator OFF

Sets time from Dispense Gun Low to Regulator OFF

FIG. 24: Timing Delay

32 313377L

Page 33

Operation

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 33) and Advanced Display Module (ADM) (page 14) 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.

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

3. Turn on air and electrical power to the system.

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

IG. 7.

Load Material

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

1. If this is a new installation, follow the Initial Start up procedure. Otherwise, follow the Standard Startup procedure. See page 33.

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

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

4. Enter the maintenance screen. See Dispense From Maintenance Screen, page 36.

5. Select a control mode. See Dispense From Main- tenance Screen, page 36.

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

press to turn the system on.

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

6. Turn on the material supply system.

7. Press and hold . Dispense fluid until clean,

air-free fluid flows from the gun.

8. Press again to exit maintenance screen.

313377L 33

Page 34

Operation

Maintenance Mode Operation

Operating from maintenance mode enables the module

to begin dispensing when the user presses . Dis-

pense parameters and duration depend on the selected

control. Dispensing continues for as long as is

pressed.

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 36, for instructions on operating from maintenance mode.

NOTE: Perform any of 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.

Dispense from Each Gun

Dispense from each gun 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 36, to perform each of the following applicable system verification checks.

• For each gun 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 a maximum desired operating point.

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

• For each gun 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-

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

NOTICE

Excessive inlet pressure 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.

mal operation, press until PCF achieves

the flow rate setpoint.

NOTE: During the initial system operation verification, it may take four to five seconds for the system to learn system characteristics.

b. Continue to press for several seconds

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

34 313377L

Page 35

Operation

fluid mass (g) density (g/cc)

= measure volume (cc)

K-Factor (new) =

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

measured volume (cc)

K-Factor (new) =

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

dispensed volume (cc)

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 the Flowmeter Settings screen (Fluid Plate - screen 4). See F

IG. 20 on page 28.

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 the Home screen

1. See F

IG. 25 on page 36.

5. Calculate the actual volume dispensed:

6. Calculate the new flow meter K-factor:

7. Enter new K-factor.

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

Method 2. Without using a gram scale, visual measurement

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

IG. 20 on page 28.

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 the Home screen

1. See F

IG. 25 on page 36.

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

6. Calculate the new flow meter K-factor:

7. Enter new K-factor.

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

Manually Adjust Control Loop Parameters

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.

2. If the regulator outlet pressure does not closely fol- low the desired pressure, set Ki to zero then increase Kp until the proper pressure control is achieved.

3. 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.

5. Decrease Ki until oscillation stops.

6. 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.

313377L 35

Page 36

Operation

Dispense From Maintenance Screen

1. Navigate to Home screen 1.

IG. 25

2. Press to enter maintenance screen.

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

target pressure, flow rate, and volume (dependent

on control mode) and press to save.

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

to select the desired guns.

6. Follow Step 2 of Manually Dispense Fluid, page

36.

Manually Dispense Fluid

1. From Home screen 1 press to enter mainte-

nance screen.

2. Press and verify that the gun opens.

IG. 26

3. Press to open the Control Mode drop-down

list, and select the preferred control mode. Press

again to exit the drop-down list.

3. Continue to press as long as needed to load

or dispense material.

4. Press again to exit maintenance screen.

36 313377L

Page 37

Operation

Automation Control (Normal) Operation

During automation control (normal operation) the module automatically dispenses 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 37. For a detailed explanation of styles and how they work within the PCF system, see Styles on page

38.

Jobs

NOTE: See Appendix D - I/O Signal Descriptions, page 111, for automation input and output signal descriptions.

A job is a specified amount of material that is dispensed by the system. The amount of material specified for a job varies, depending on the 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, fault calculations are made and the volumes are stored to non-volatile memory 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 in the Fluid Plate Control Settings screen to Timer or Gateway. If the timer method is used, the timer begins counting every time the dispense gun is turned off. If the gun 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. This volume is calculated by measuring how long the dispense gun is on, taking in effect the command voltage from the automation over time.

Target Volume - The theoretical amount of material that a job should have. This value is usually calculated or found using trial and error when the application is first set up.

Jobs in Bead Mode

In Bead Mode, all of these volumes are monitored. The High Volume, Low Volume, and Computed Target faults 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 fault). 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 fault. The controls will still maintain the desired flow rate and report faults 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 97, for instructions on how to view job reports.

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Page 38

Operation

Styles

The PCF system has the ability to handle up to 255 styles, depending on the selected option. Styles typically correspond to different components of a specific system.

NOTE: The number of available styles depends on the system 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 faults 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 has been initiated.

To setup a style:

1. Press to access the style setup fields.

2. Enter the style number in the Style field.

a. Press while in the Style Name field to

enter the Keyboard screen.

FIG. 28

IG. 27

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 94, for further details.

c. Press to accept the new value.

3. Enter the target volume in the Volume field, and the tolerance percentage in the Tolerance field.

4. Enter precharge mode and parameters. See Pre- charge Modes on page 39.

5. Press to exit edit mode.

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Page 39

Precharge Modes

Operation

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.

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.

Dynamic Precharge Mode

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.

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Page 40

Operation

Dispense Application Direction Dispense Application Direction Dispense Application Direction

-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.

-Provides a boost upon valve opening to accelerate material.

-Ideal value is typically greater than 100%.

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

-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.

Closed Precharge Scaling Value

Opening Precharge Scaling Value

Opening Precharge Duration Value

Regulator On Delay Value

Value Too Low Ideal Value Value Too High

Value Too Low Ideal Value

Value Too High

Value Too Low Ideal Value Value Too High

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Page 41

Operation

Typical Job Cycle

In order for the system to run it must be in the active state (status light on ADM is green). Before a job begins the robot outputs should have the following values:

• Style Strobe: 0

• Dispense Complete: 0

• Dispense Gun x On: all should be 0

• Style: Any value is acceptable

A typical job cycle consists of the following dispensing sequence. See Control Charts, page 43.

1. The robot checks that Dispenser Ready signal is set to 1. If it is set to 1, a job can begin.

2. The robot sets the Style to the next desired style value.

3. The robot sets the Style Strobe to 1.

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 robot begins dispensing. The robot sets and clears Dispense Gun x On bits as desired throughout the course of the job.

7. PCF sets the following signals based on the results of the job. The robot should not read these signals until after the system clears the Dispense In Process signal.

• Dispenser No Alarm

• Dispenser No Error

• Dispense Volume OK

•Error

• Dispensed Volume

8. PCF clears Dispense In Process to 0 to indicate the job is complete and all signals from step 7 are valid.

9. The robot 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, 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.

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

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

• The style must always be set 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.

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Page 42

Operation

Typical Job Cycle Chart

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Page 43

Control Charts

Precharge* - Display Mode

Dispense Trigger Source = Command Cable

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 “Com-

mand 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.

Automation Inputs (PCF Outputs)

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Volume OK

Style Bits

Style Strobe

Command Signal Valid†

Regulator Active

Dispense Valve X Open

Automation Outputs (PCF Inputs)

PCF State

Dispense Valve X On

Dispense Complete

* Dispense Gun X Open determined by Enable Guns check boxes on Fluid Plate Control Settings screen.

Operation

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Page 44

Operation

Dispense Trigger Source = Gateway

Control Charts (continued)

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Page 45

Control Charts (continued)

Dispense Trigger Source = Combined

Operation

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Page 46

Pressure Relief Procedure

Dispense Valve Air Solenoid

Pressure Relief Procedure

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

2. Place a waste container beneath the fluid drain valve under the filter. Place a waste container beneath the dispense valve.

3. Slowly open the drain valve at each fluid filter to relieve fluid pressure. Close valve when pressure gauge reads zero.

4. 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.

5. If the dispense device 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,

that opens the dispense valve to relieve fluid pressure. Refer to F

b. Continue actuating the plunger until all pressure

is purged from the system between the needle and the dispense valve before proceeding to the next step.

6. Shut off power and air to the fluid supply system.

IG. 29 and perform the fol-

IG. 29.

FIG. 29: Dispense Valve Air Solenoid

If you have followed the previous and still 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.

If this does not remove the obstruction, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen the coupling completely. Clear the valves or hose. Do not pressurize the system until the blockage is cleared.

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Page 47

Shutdown

TI12362a

1. Press the Stop button (BC).

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

3. Follow the Pressure Relief Procedure on page 46.

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

5. Turn off the main power supply.

Shutdown

FIG. 30: ADM - Stop Button

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Page 48

USB Data

USB Logs

During operation, PCF stores system and performance related information to memory in the form of log files. PCF maintains three log files: job logs, error logs, and dispense data logs. Follow the Download Procedure, page 49, to retrieve log files.

Job Log

The job log file name is 1-JOB.CSV and is stored in the DOWNLOAD folder.

The job log maintains a record of the last 1,000 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)

• Style number

• Target volume (in units set in the volume units

field)

• Requested volume (in units set in the volume

units field)

• Actual dispensed volume (in units set in the vol-

ume units field)

• Volume units

• Error percentage between actual dispensed vol-

ume and requested volume

• Minimum inlet pressure during job in units of bar

(heated systems will always read 0)

• Average Inlet pressure during job in units of bar

(heated systems will always read 0)

• Maximum inlet pressure during job in units of

bar (heated systems will always read 0)

• Minimum outlet pressure during job in units of

bar

• Average outlet pressure during job in units of

bar

• Maximum outlet pressure during job in units of

bar

• Minimum flow rate during job in units of cc/min

(systems with no flow meter will read 0)

• Average flow rate during job in units of cc/min

(systems with no flow meter will read 0)

• Maximum flow rate during job in units of cc/min

(systems with no flow meter will read 0)

• Elapsed time

Error Log

The error log file name is 2-ERROR.CSV and is stored in the DOWNLOAD folder.

The error log maintains a record of the last 1,000 errors. Each error record in the log file contains: the date and time the error occurred, the error code, and the error description.

Dispense Data Log

The dispense data log file name is 3-DATA.CSV and is stored in the DOWNLOAD folder.

The dispense data log maintains a record of system inlet pressure (heated systems will always read 0), system outlet pressure, and system flow rate (systems without flow meters will always read 0). This data is recorded at one second intervals when a job cycle is in process. The dispense data log is capable of storing up to two hours of 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 50, for instructions on how to use this file.

NOTE: Do not modify the contents of this file.

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USB Data

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 50, 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.

Download Procedure

1. Insert USB flash drive into USB port (BL).

NOTE: System configuration setting files and custom language files can be modified if the files are in the UPLOAD folder of the USB flash drive. See System Configuration Settings File, Custom Language File, and Upload Procedure sections.

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

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.)

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

Word.

Excel® by

• 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.

313377L 49

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

Page 50

USB Data

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 49, 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.

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.

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Troubleshooting

NOTE: Check all possible solutions in the chart below before you disassemble the system.

Troubleshooting for individual regulators and flow meters is discussed in their separate manuals; refer to

Related Manuals on page 3. Also refer to Error Codes and Troubleshooting, page 55, for detailed information

on how error codes are communicated.

Fluid Modules

Problem Cause Solution

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

(0.4 MPa, 4 bar)

No “Gun 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 Needle/seat is worn Rebuild regulator; replace needle/

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

Worn gaskets Check/replace gaskets on V/P and

Check output and wiring from automation unit

nector to V/P valve; tighten

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

seat

essary

solenoid valve

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Page 52

Troubleshooting

Fluid 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 flow meter selected

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

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

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 pressure Stabilize regulator inlet 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 gun

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 gun or

dispensing valve

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

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

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Troubleshooting

Dispense Valves

Problem Cause Solution

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

No “Gun On” signal from automation unit

Valve not shutting off Air not getting to close port (except

AutoPlus valve)

“Gun 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

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

(0.4 MPa, 4 bar)

Reduce running pressure

Reduce nozzle length

Increase nozzle orifice size

necessary

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Page 54

Troubleshooting

Gateway Module

Problem Cause Solution

No communication Incorrect wiring Check wiring per fieldbus standard.

Refer to PCF Gateway status indicators and Appendix C - Commu-

nications Gateway Module (CGM) Connection Details, page 105.

Incorrect fieldbus settings Confirm fieldbus settings at automa-

tion controller (fieldbus master) and PCF Gateway (fieldbus slave). Refer to Appendix A - Advanced Display Module (ADM), page 85, 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 85, for infor-

mation on how to determine installed data map. If necessary, install a new Gateway data map. Refer to Upgrade Gateway Mod- ule Fieldbus Map, page 64, for instructions, and to Control Center Assembly Parts, page 78, for map token part number.

LED Diagnostic Information

The following LED signals, diagnosis, and solutions are the same for the display module, fluid control module, an Gateway module.

Module Status LED Signal Diagnosis Solution

Green on System is powered up -

Yellow Internal communication in progress -

Red solid Hardware failure Replace display module, fluid control

module, or Gateway module

Red flashing fast Uploading software -

Red flashing slow Token error Remove token and upload software

token again.

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Page 55

Errors

Error Code

Errors

View Errors

When errors occur the highest priority active error is displayed in the menu bar. The previous 140 errors are displayed on the error report screens. See Run Mode, page 95, for instructions on navigating to and through the error report screens.

There are three levels of errors: alarms, deviations, and advisories. Alarms are critical and require immediate correction; therefore, the system automatically shuts down. Deviations are critical and require attention but not immediately. Advisories are not critical but still require attention.

NOTE:

• Alarms set the dispenser ready signal LOW.

• Advisories and deviations do not set the dispenser

ready signal LOW.

Diagnose Errors

See Error Codes and Troubleshooting for valid error codes, possible causes, and solutions.

Clear Errors and Reset Control Unit

Press to clear an error before restarting the control

unit.

Error Codes and Troubleshooting

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

Error

Code

0000 0 No Active Errors No errors n/a n/a No action necessary

EP0X 1 Power Up Control box power up Record only n/a No action necessary

EC0X 2 Setup Values

Gateway Error No. Error Name

Changed

Error

Description Error Type Cause Solution

System Errors

Setup change notification

Record only A setup value was

changed on the display

No action necessary if changes were desired

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Page 56

Errors

Error Code

EAU0 3 Download to

EBU0 4 Download to

WSU0 5 USB configura-

WNC0 10 ADM Key Token

WMC0 19 Display Error

CAC0 20 CGM Communi-

WMG0 21 Gateway Map

CBG0 22 Gateway Reset Gateway reset Advisory

WMG0 29 Gateway Error

B7C0 30 Style Out of

B40X B30X

Gateway

Error No. Error Name

USB in Process

USB Complete

tion error

Error

Detected

cation Error

Error

Detected

Range

31 High Volume or

High Mass

Error

Description Error Type Cause Solution

Control Center Errors

Information is currently being downloaded to USB

Download to the USB is complete

USB configuration error Advisory USB configuration

Missing or invalid key token

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

Communication lost between CGM and ADM

Missing or invalid map Advisory Missing or invalid

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

Style is out of range Alarm Style requested by

Material dispensed during last dispense cycle was above amount requested plus the allowed tolerance

Advisory (self-clearing)

Alarm An ADM key token is

Alarm

Advisory ADM and CGM are no

(self-clearing)

Alarm

Alarm or Deviation (user selectable)

n/a No action necessary

Reinstall system soft-

invalid or not present

required to run the system

longer communicating

CGM is not functioning Replace the CGM if the

Gateway map

Gateway setting(s) changed

automation controller exceeds number of styles in system

PCF regulator is not regulating correctly

Incorrect style target volume or tolerance

ware on display

Verify the key token is installed

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

Reconnect or replace CAN cable

red status LED is solid

Install PCF map in Gateway

Wait for reset to complete before attempting automation control

Use a style number that is in range

Increase number of styles in PCF; purchase accessory key token

Check regulator and repair if necessary

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

56 313377L

Page 57

Errors

Error

Code

B10X B20X

B1CX B2CX

B3CX B4CX

CAD1 50 Fluid Plate Com-

WND1 51 Fluid Plate Key

Gateway Error No. Error Name

32 Low Volume or

Low Mass

33 Low Computed

Target

34 High Computed

Target

munication Error

Token Error

Error

Description Error Type Cause Solution

Control Center Errors (continued)

Material dispensed during last dispense cycle below amount requested minus the allowed tolerance

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

Fluid Plate Errors

Communication lost between fluid plate and ADM

Missing or invalid key token

Alarm or Deviation (user selectable)

Alarm FCM is not

Alarm FCM key token is

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

communicating

FCM is not functioning Replace FCM if red

required to run system

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

Reconnect or replace CAN cable

status LED is solid

Verify FCM key token is installed

Verify FCM key token is correct part number

P6D1 52 Outlet Pressure

Transducer Error

P6F1 53 Inlet Pressure

Transducer Error

313377L 57

Outlet pressure transducer error

Inlet pressure transducer error

Alarm Problem detected with

outlet pressure transducer

Advisory Problem detected with

inlet pressure transducer

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

Page 58

Errors

Error Code

F6D1 54 Flow Meter Error Flow Meter error Alarm Problem detected with

WED1 55 V/P Error V/P error Alarm Problem detected with

WJD1 56 Dispense Valve 1

WJD2 57 Dispense Valve 2

WJD3 58 Dispense Valve 3

Gateway

Error No. Error Name

Error

Description Error Type Cause Solution

Fluid Plate Errors (continued)

flow meter

V/P

Dispense valve 1 error Alarm Problem detected with

dispense valve 1

Dispense valve 2 error Alarm Problem detected with

dispense valve 2

Dispense valve 3 error Alarm Problem detected with

dispense valve 3

Verify flow meter is installed and/or connected correctly

Replace if necessary

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

WJD4 59 Dispense Valve 4

Error

WSD1 60 Incompatible

Gun Settings

F7D1 61 Closed Gun Flow System reading flow

V2D1 62 Low Analog Analog command

Dispense valve 4 error Alarm Problem detected with

Incompatible settings for multiple gun operation; attempted to dispense

meter pulses with gun(s) closed

dropped below minimum value (user defined) while dispensing

Replace if necessary

Verify dispense valve 4

dispense valve 4

Alarm Attempted to dis-

pense from multiple guns with incompatible settings

Alarm Dispense hose leak Check hose; replace if

Flow meter providing false pulses

Dispense valve not operating correctly

Deviation Bad or loose com-

mand cable connection

Entered command mode incorrectly

Automation program error

is installed and/or connected correctly

Replace if necessary

Check gun mode settings (on fluid plate setup screen)

Verify automation programming

needed

Replace flow meter sensor or calibrate meter

Repair dispense valve

Check command cable and connection

Enter correct command code

Verify correct automation program

58 313377L

Page 59

Errors

Error

Code

WFD1 63 Flow Meter

EJD1 64 Job Cycle Time

WXD1 65 Fluid Plate Error

P3F1 P4F1

P3D1 P4D1

P1F1 P2F1

P1D1 P2D1

Gateway

Error No. Error Name

Required

Out

Detected

66 Maximum Inlet

Pressure

67 Maximum Outlet

Pressure

68 Minimum Inlet

Pressure

69 Low Pressure Measured outlet pres-

Error

Description Error Type Cause Solution

Fluid Plate Errors (continued)

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

sure less than desired outlet pressure minus tolerance

Alarm or Advisory (self-clearing)

Alarm

Alarm or Deviation (user selectable)

Selected gun mode settings require flow meter

FCM key token missing or invalid

not properly end job cycle

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;

Incorrect limit set Verify limit is set cor-

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;

Check gun 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

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

rectly

Increase material flow rate

Dislodge and inspect needle

Repair dispense valve

Repair regulator

Increase pump pressure

replace if failed

313377L 59

Page 60

Errors

Error Code

P3D1 P4D1

F1D1 F2D1

F3D1 F4D1

Gateway

Error No. Error Name

70 High Pressure Measured outlet pres-

sure greater than desired outlet pressure plus tolerance

71 Low Flow Rate Measured flow rate less

than desired flow rate minus tolerance

72 High Flow Rate Measured flow rate

greater than desired flow rate plus tolerance

Error

Description Error Type Cause Solution

Fluid Plate Errors (continued)

Alarm or Deviation (user selectable)

Incorrect limit set Verify limit is set cor-

rectly

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 fault time

Operating below minimum regulator operating pressure

Regulator worn or not operating correctly

Flow meter providing false pulses

Incorrect flow fault tolerance or flow fault time

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 fault time

Increase fluid pressure above regulator minimum

Repair regulator

Replace flow meter sensor

Enter correct tolerance or flow fault time

60 313377L

Page 61

Errors

Error

Code

EKD1 73 Shot Terminated

EHD1 74 Purge Timer

EAC1 75 Maintenance

EBC1 76 Maintenance

MHD1 77 Maintenance

MFD1 78 Maintenance

MED1 79 Maintenance

MCD1 80 Maintenance

MDD1 81 Maintenance

MDD2 82 Maintenance

MDD3 83 Maintenance

MDD4 84 Maintenance

Gateway

Error No. Error Name

by Job Timer

Expired

Mode Entered

Mode Exited

Due - Regulator

Due - Flow Meter

Due - V/P

Due - Supply

Due - Gun 1

Due - Gun 2

Due - Gun 3

Due - Gun 4

Error

Description Error Type Cause Solution

Fluid Plate Errors (continued)

Shot dispense cycle terminated by job timer

Purge timer expired Advisory PCF purge timer (style

Maintenance mode entered

Maintenance mode exited

Maintenance due for regulator

Maintenance due for flow meter

Maintenance due for V/P regulator

Maintenance due for supply system

Maintenance due for gun 1

Maintenance due for gun 2

Maintenance due for gun 3

Maintenance due for gun 4

Advisory Job end timer was

used to stop shot dispense

0) has expired

Advisory (self-clearing)

Advisory Totalizer exceeded

Entered maintenance dispense mode

Exited maintenance dispense mode

limit setting

No action required if timed shot is desired

Automation control requests purge

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

313377L 61

Page 62

Maintenance

Prior to performing any maintenance procedures, follow the Pressure Relief Procedure on page 46.

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 V/P valve

* 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.

62 313377L



Page 63

Maintenance

r_24E451_3B9900_3a

Access Panel

Token

r_24E451_3B9900_4a

TI12319A

Access Cover

TI12320A

Token

Advanced Display Module (ADM)

Upgrade Software

NOTE: Back up the custom language file (if installed) before upgrading software. See USB Data, page 48, 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).

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 installation of upgrade tokens. The following instructions apply to all Gateway module connectors.

1. Turn off power to the system.

2. Remove the access cover.

IG. 31: Remove Access Panel

3. Insert and press token firmly into slot.

NOTE: There is no preferred orientation of token.

IG. 32: 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 token.

FIG. 33: 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.

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

313377L 63

IG. 34: Insert Token

Page 64

Maintenance

Access Cover

TI12319A

Token

TI12320A

Push Button

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 upgrade of a map token. The following instructions apply to all Gateway module connectors.

1. Remove the access cover.

3. 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.

FIG. 36: Insert Token

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

IG. 35: Remove Access Cover

2. Insert and press map token firmly into slot.

NOTE: There is no preferred orientation of token.

5. Replace access cover.

64 313377L

Page 65

Maintenance

TI12334A

Access Cover

Token

TI12335A

Upgrade Fluid Control Module (FCM) Software

NOTE: The FCM connection is temporarily disabled during the installation of the upgrade a key token.

1. Turn off power to the system.

2. Remove access cover.

IG. 37: Remove Access Cover

Air Filter Maintenance

To prevent filter element damage, replace air filter every two years or when pressure drop becomes 0.1 MPa (1.0 bar, 14.5 psi); which ever occurs first.

Replacement Air Filters

Part Description

123091 5 micron air filter 123092 0.3 micron air filter

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.

IG. 38: Insert Token

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

6. Remove token.

7. Replace access cover.

313377L 65

Page 66

Repair

129

108

101

124

125, 126, 127

109

131

103

r_pf0000_313377_18a

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 46.

3. Remove the fluid plate assembly shroud. See Fluid

Plate Assembly Parts, page 80.

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

66.

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).

IG. 39.

FIG. 39: Fluid Plate Assembly

66 313377L

Page 67

Repair

r_pf0000_313377_34a

129

108

125

124

126

127

109

137

118

132

r_pf0000_313377_33a

122

121

118

r_pf0000_313377_31a

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.

IG. 39.

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

FIG. 41

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

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

IG. 40

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

66.

2. Disconnect FCM cable and all three air tubes.

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

Replace V/P Valve

1. Prepare Fluid Plate Assembly for Repair, page

66.

2. Disconnect the FCM cable and both air tubes.

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

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

IG. 42

313377L 67

Page 68

Repair

128

121

118

132

r_pf0000_313377_30a

102

103

106

105

103

102

5. Secure the new V/P valve 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

66.

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

Replace Fluid Control Module Base

1. Prepare Fluid Plate Assembly for Repair, page

66.

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.

IG. 43

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.

7. Reattach the valve bracket using screws.

FIG. 44

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.

68 313377L

Page 69

Replace Transducer O-Rings

117

108

r_pf0000_313377_16a

120

1. Prepare Fluid Plate Assembly for Repair, page

66.

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

Repair

IG. 45

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

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

IG. 46

5. Press the transducer back into the retainer nut.

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

313377L 69

Page 70

Repair

diaphragm and valve actuator subassembly

cartridge assembly

Torque Sequence for Regulator

Base Housing Screws (CF)

Cartridge Regulator 244734 Shown

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

IG. 47 and perform the following steps.

NOTICE

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

1. Prepare Fluid Plate Assembly for Repair, page

66.

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.

FIG. 47: Replace Cartridge Assembly

70 313377L

Page 71

Repair

117

116

Screw

Power Output Cable

Replace Amplifier

(Heated fluid plates only)

1. Prepare Fluid Plate Assembly for Repair, page

66.

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

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.

IG. 48: Replace Amplifier

313377L 71

Page 72

Repair

Calibrate Amplifier

(Heated fluid plates only)

1. Prepare Fluid Plate Assembly for Repair, page

66.

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

Adjust Display Settings

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

4. Press to scroll to Advanced Setup

Screen 2.

9. Press to scroll to the Pressure Sensors

screen (screen 5).

10. Press to access the fields to make changes.

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

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.

7. Press to exit edit mode.

8. With the system still in setup mode, navigate to the Fluid Plate set of screens.

psi to 0. Press to enter the new setting.

12. Press to exit edit mode.

Adjust Amplifier Settings

13. Remove cover from amplifier (116). See Replace Amplifier, page 71.

14. Ensure the EXCITATION SELECTOR jumper is in the middle position (5 Vdc).

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

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

NOTE: The display is not capable of displaying negative pressures. Therefore, increase the FINE ZERO potentiometer clockwise until the display reads greater than 0. Then, decrease the potentiometer counter clockwise until the display reads 0.

72 313377L

Page 73

Repair

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

17. Insert a small piece of jumper wire or a paper clip across the SHUNT CAL and ENABLE terminals.

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

19. Adjust the FINE GAIN potentiometer until the Outlet Pressure on the Pressure Sensors screen (screen

5) matches the calculated Shunt Calibration Pressure.

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

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

FIG. 49: Amplifier Settings

22. Replace the amplifier cover. See Replace Amplifier, page 71.

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

24. If desired, change pressure units to desired setting on the Advanced Setup screen 2.

313377L 73

Page 74

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 74.

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 74.

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. 51

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

6. Reattach Gateway module; follow Replace Gate-

way Module.

FIG. 50

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

5. Reconnect the automation interface cable.

74 313377L

Page 75

Repair

11, 14, 24

Replace Advanced Display Module

1. Prepare Control Center for Repair, page 74.

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

IG. 52

Replace Advanced Display Module Bracket

1. Prepare Control Center for Repair, page 74.

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).

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

FIG. 53

4. Insert the new ADM by snapping it into the mounting bracket.

5. Reconnect the CAN cable to the new ADM.

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.

313377L 75

Page 76

Repair

r_pf0000_313377_10a

Fuses

r_pf0000_313377_10a

Replace DIN Rail Assembly

1. Prepare Control Center for Repair, page 74.

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

IG. 54

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. Both fuses are 5 x 20 mm.

• For 24 Vdc control centers: see Technical Data

on page 114 for fuse specifications.

• For 100-240 Vac control centers: Order fuse

115805.

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.

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.

FIG. 56: Fuse Location

IG. 55: 24 Vdc Din Rail Assembly

76 313377L

Page 77

Repair

313377L 77

Page 78

Parts

24 Vdc Din Rail Assembly Shown

r_pf0000_313377_10a

r_pf0000_313377_11a

Components of 24 Vdc Module Kit (24B929) and 100-240 Vac Line Voltage Module Kit (24B928)

Parts

Control Center Assembly Parts

78 313377L

Page 79

Parts

Control Center Assembly Parts

Qty

Ref. Part Description

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 for

part number

6†‡ SUPPLY, power; 24vdc, 4A, 100W 1 7‡ COVER, line voltage 1 8‡ GROMMET 1 9‡ 196548 LABEL, caution 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, assy 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 LABEL 1 40 SCREW, mach, pan hd 4

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

† Parts included with 100-240 Vac models only.

 Parts included with 24 Vdc models only.

‡ 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-spe-

cific software installed. Therefore, use software upgrade token (16C958) to install software before use.

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

cific map installed. Therefore, use map token (16C959) to install map before use.

 Not shown.

Gateway Module Part Numbers

Gateway Module Part Number

*DeviceNet 15V759 *EtherNet/IP 15V760 *PROFIBUS 15V761 *PROFINET 15V762

Discrete 24B681

Control Center Key Token Part Numbers

PCF Model Part Description

PF1xxx 24B948 TOKEN, key, 2 styles PF2xxx 24B949 TOKEN, key, 16 styles PF3xxx 24B950 TOKEN, key, 256 styles

313377L 79

Page 80

Parts

See page 82

See page 81

101

143

142

152

131

153

151

See page 81

135, 136

Fluid Plate Assembly Parts

80 313377L

Page 81

Fluid Plate Assembly Parts (continued)

105

103

106

105

102

104

141

118

122

141

122

141

128

133

128

137

141

132

128

121

137

125

126

129

124

127

126

125

109

110

126

130

155

127

128

Parts

313377L 81

Page 82

Parts

111

117, 120

141

113

112

113

112

127

114

108

154

119

115

117

108

105, 116

Fluid Plate 24B962

149

140, 141, 150

158

139

107

148

145

Shown

159

160

Fluid Plate Assembly Parts (continued)

82 313377L

Page 83

Parts

Fluid Plate Assembly Parts

Qty

Ref. Part Description

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 1 132 258334 VALVE, dispense, fluid plate 1 133 121806 CABLE, solenoid 1 135 189285 LABEL, caution 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

m 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

152 194337 WIRE, grounding, door 1

153 186620 LABEL, ground 1 154 107257 SCREW, hex, washer hd 2 155 SUPPRESSOR, box snap, fer-

rite

158 122610 ELBOW 1 159 189930 LABEL, caution, electric shock 1 160 290228 LABEL, caution, hot surface 1

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

 See Parts Varying by Assembly table, page 84, for

part number and quantity.

 Only included with 24B962 (heated mastic regulator

with a high resolution meter) and 24C901 (heated mastic regulator without a meter).

 Base electronic components do not have PCF-spe-

cific software installed. Therefore, use software upgrade token (16C958) to install software before use.

 Not shown.

Qty

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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 hd

108 244734 REGULATOR,

assy 246642 1 1 246643 11

109 156684 UNION, adapter 1 1

157785 1

110 C20461 NIPPLE, reducing,

hex; 1/2 npt(f) x

3/4 npt(f) C20487 1 1

113 C34045 SPACER 2 2 117 15M669 SENSOR, pres-

sure, fluid outlet 117764 1 1

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

gear meter

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

spring; m6

127 108328 SCREW, cap,

socket hd

128 107530 SCREW, cap,

socket hd, hex

129 246652 METER, assy. 1

246340 1

130 122030 CABLE; m12-5p 1 1 1

24B946 TOKEN, key,

147

meter enabled 24B947 TOKEN, key,

meter disabled

155 121901 SUPPRESSOR,

box snap, ferrite

Meter

4 4 4 4 8 8

2222

1 1 1

6 6 6

626262

6 4 6 4 6 4

1 1 1

Cartridge

Regulator

with

No Meter

1 1 1

Mastic Regulator with High

Resolution

Meter

Mastic

Regulator

with

No Meter

Regulator

with Heated

High

Resolution

Meter

Heated Mastic

Regulator

with

No Meter

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Appendix A - Advanced Display Module (ADM)





ADM Software Part No. 16K405

(see manual 3A2098)

ADM Software Part No. 16F528 or 15V769

(use this manual)

Appendix A - Advanced Display Module (ADM)

• set controls and gun commands;

• set on and off delays for guns 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;

• and set up to 255 styles.

Run Mode Functions

The run mode functions enable users to:

• adjust the bead scale;

• change the control mode;

• change the volume to be dispensed;

• change the target pressure;

• change the number of dispense valves used;

• view a chronological list of system errors;

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

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

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:

• 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;

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 PCF.

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Appendix A - Advanced Display Module (ADM)

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.

System Mode

The current system mode is displayed at the left of the menu bar.

Alarm/Deviation

The current system error is displayed in the middle of the menu bar. There are four possibilities:

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 complete press again to exit edit mode.

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. Also press

select digits within a field to change.

Icon Function

No Icon No information or no error has occurred

Advisory

Deviation

Alarm

Status

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

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Press to navigate to new screens and to

navigate up and down within a screen. Also press

to move bet ween fields within a drop-down

menu, and to increment or decrement numbers within a field.

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Appendix A - Advanced Display Module (ADM)

Setup Mode

Setup mode screens are divided into four sections: Advanced setup, Gateway setup, Fluid plate setup, and

Style setup. While in Run mode, press to enter

Setup mode. Press to navigate through the

Setup mode screens.

Advanced Setup Screens

There are three Advanced setup screens, which enable users to set units, adjust values, set formats, and view software information for each component. Press

to scroll through the Advanced setup

screens. Once in the desired Advanced setup screen,

press to access the fields to make changes. Press

to exit edit mode.

NOTE: Users must be out of edit mode to scroll through the Advanced setup screens.

Advanced Setup Screen 2

This screen enables users to setup the maintenance units, and flow rate.

Advanced Setup Screen 3

This screen displays the software part number and version for the ADM, fluid plate, and Gateway module, and USB configuration.

Advanced Setup Screen 1

This screen enables users to set the language, date format, current date and time, password, and number of minutes before the screen saver comes on. This screen does not automatically update for daylight savings time.

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Appendix A - Advanced Display Module (ADM)

Gateway Setup Screens

NOTE: The Gateway Setup screens are not available if a Discrete Gateway Module is attached to the system.

There are up to three Gateway Setup screens (depending on fieldbus), which enable users to set or change information regarding the Gateway module used on the PCF system. These screens also enable users to view information regarding the particular Gateway module used.

Press to scroll through the Gateway Setup

screens. Once in the desired Advanced Setup screen,

press to access the fields to make changes. Press

to exit edit mode.

NOTE: Users must be out of edit mode to scroll through the Gateway Setup screens.

Gateway Setup Screen 1 - DeviceNet

This screen enables users to set the device address and the baud rate. The DeviceNet screen displays the hardware revision number, system serial number, map ID, name, revision number, and install date.

Gateway Setup Screen 1 - EtherNet/IP

This screen enables users to set the IP address, subnet mask, Gateway, DNS 1, DNS 2, and if a DHCP is used.

Gateway Setup Screen 2 - EtherNet/IP

This screen is the same for EtherNet/IP and PROFIBUS. It enables users to view the following information regarding the Gateway module used on the PCF system:

• hardware revision number

• system serial number

• map ID number

• map name

• map revision number

• date the map was created

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Appendix A - Advanced Display Module (ADM)

Gateway Setup Screen 1 - PROFIBUS

This screen enables users to set the device address, install date, location tag, function tag, and system description.

Gateway Setup Screen 2 - PROFIBUS

This screen is the same for EtherNet/IP and PROFIBUS. See Gateway Setup Screen 2 - EtherNet/IP, page 88, for details.

Gateway Setup Screen 2 - PROFINET

This screen enables users to set the device address, install date, location tag, function tag, and system description.

Gateway Setup Screen 3 - PROFINET

This screen enables users to view the following information regarding the Gateway module used on the PCF system:

Gateway Setup Screen 1 - PROFINET

This screen enables users to set the IP address, subnet mask, Gateway, DNS 1, DNS 2, and if a DHCP is used

• hardware revision number

• system serial number

• map ID number

• map name

• map revision number

• date the map was created

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Appendix A - Advanced Display Module (ADM)

Discrete Gateway Setup Screen

NOTE: The Discrete Gateway Setup screen is not available if a Discrete Gateway Module (DGM) is not attached to the system.

This screen enables users to select the Command Value Type signal (Analog or Digital) the automation system will provide to PCF. If Analog control is selected, the user must provide an analog voltage to the proper input on the DGM. See Appendix B - Discrete Gate- way Module (DGM) Connection Details, page 98, for connection details.

If Digital control is selected, the user can define three digital settings for each dispense gun. The user must provide two digital signals to the proper inputs on the DGM. See Appendix B - Discrete Gateway Module

(DGM) Connection Details, page 98, and the Digital Command Logic Table for connection details.

NOTE: The control mode for each dispense gun is set in the Mode Settings Screen, page 91. For example, if Gun 1 is set to Pressure mode on the Mode Settings Screen, then the digital commands for Gun 1 are pressure values.

Press to access the fields to make changes. Press

to exit edit mode.

The Digital Command Logic Table indicates which value each input must be set to in order to select a particular setting.

Digital Command Logic Table

Resulting Digital Command Value Input 1

Low

High

Don’t Care

Digital Command Value Input 2

Low Setting #1

Low Setting #2

High Setting #3

Digital

Command

Selection

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Appendix A - Advanced Display Module (ADM)

Fluid Plate Setup Screens

There are seven fluid plate setup screens, which enable users to:

• set controls and gun commands;

• set on and off delays for guns and the regulator;

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

• set offsets for inlet and outlet pressures;

• set error types;

• and set variables for maintenance advisories.

Press to scroll through the Fluid Plate

Setup screens. Once in the desired screen, press

to access the fields to make changes. Press to exit

edit mode.

NOTE: Users must be out of edit mode to scroll through the fluid plate setup screens.

Control Settings Screen

Mode Settings Screen

This screen enables users to set gun commands. Use this screen to select a mode (pressure, bead, shot, or full open) for each gun. Users can also set the flow rate or pressure for each gun, and adjust the bead scale.

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 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.

This screen enables users to:

• Set the dispense trigger source to Gateway, Command Cable, or Combined. If it is set to Command Cable, users can enable the guns.

• Set the command value source to Gateway, Command Cable, or Display.

• Set the Job End Timer to Timer or Gateway. If this field is set to Timer, users can set Job End Delay.

• Set the Run Mode Bead Adjust to Enable or Disable.

• Set Display Control Password to Enable or Disable. When entering maintenance mode, a password prompt will appear if Display Control Password is set to Enable and a password is set in the Advanced screens.

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Appendix A - Advanced Display Module (ADM)

Delay Settings Screen

This screen enables users to set on and off delays (in milliseconds) for each gun and the regulator explanation of the on and off delays, refer to the On/Off

Delays section on page 32.

Flowmeter and Control Loop Settings Screen

. For an

Pressure Sensors Screen

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

This screen enables users to:

• Set the offset for the inlet and outlet pressures.

NOTE: The offset value must be set to a non-zero value before ‘-’ can be selected from the +/- drop-down menu.

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

• Set the error type (alarm or deviation) that will be issued if the inlet and/or outlet pressure go outside

of the set limits.

This screen enables users to set the meter type (volume or mass) and the K-Factor for the flowmeter. Users can also set the Kp, Ki, and Kd for the pressure control loop as well as Kp and Ki for bead control loop.

NOTE: In systems without a flow meter, the flow meter settings will be grayed out.

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.

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Appendix A - Advanced Display Module (ADM)

Error Type Settings Screen

This screen enables users to 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. For more information on the purpose of each error, see Jobs, page 37.

Maintenance Advisory Limits Screen

This screen enables users to set volume (or hours) limit that will trigger a maintenance advisory for the air supply, V/P regulator, fluid regulator, flow meter, and all four guns.

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

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Appendix A - Advanced Display Module (ADM)

Style Setup Screen

This screen enables users to set up to 256 styles. Press

to access the style setup fields. Enter the style

number in the Style field, the target volume in the Volume field, and the tolerance percentage in the Tolerance field. Enter the precharge mode and parameters.

NOTE: The number of possible styles is dependent on the model type.

To enter the style name, press while in the Style

Name field. See Keyboard Screen, page 94, for instructions on using the keyboard screen to enter the style name.

Keyboard Screen

Use all four arrow buttons to select each letter; press

to enter the letter. To back space, press . To

delete the entire style name entered, press . To

enter the style name, press . To cancel the entry

and exit the keyboard screen, press .

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Appendix A - Advanced Display Module (ADM)

Current Dispense Control Mode

Outlet Pressure

Current Command Value

Flow Rate

(systems with flow meters)

Inlet Pressure (non-heated systems)

Command Voltage

(Displays only when Command Cable or Gateway is selected as the Command Value Source; see Fluid Plate Setup Screens, page

91.)

Run Mode

Run mode screens are divided into four sections: home, error reports, job reports, and preventative mainte-

nance. While in Setup mode press to enter Run

mode. Press to navigate through the Run

mode screens.

Home Screens

There are two home screens: one for the fluid plate and

one for the control center. Press to scroll

through the home screens.

Home Screen 1 - Fluid Plate

This screen displays the current dispense control mode used, the current pressure, and the current style being dispensed. It also displays the target dispense volume, the actual dispense volume, and the requested dispense volume.

From this screen users can adjust the bead scale and

enter maintenance mode. Press and to

change the bead scale. Press to enter mainte-

nance mode.

The PCF system has two operating modes:

• Dispense mode – enables the module to begin dispensing when it receives a command from the automation unit.

• Maintenance mode – enables the module to begin dispensing when the user presses the manual dispense button. Dispense parameters and duration depend on the selected control.

Dispensing continues for as long as the manual dis-

pense button is pressed.

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Appendix A - Advanced Display Module (ADM)

Dispense Control Modes

The PCF system has four fluid dispensing control modes.

• Bead Control – the control unit measures the flow rate of the material being dispensed. The regulator outlet pressure is varied to control the fluid flow rate to the requested value. Use the bead control when a consistent bead size is required.

• Shot Control – the regulator outlet pressure is controlled to the requested value. The dispense valve is closed when the target volume is reached or when the automation controller provides a signal.

• Pressure Control – the regulator outlet pressure is controlled to the requested value. Use the pressure control mode if the system does not include a flow meter.

• Full Open Control – the PCF system does not control fluid pressure or flow. Instead the regulator opens to allow for recirculation applications.

Maintenance Mode

Home Screen 2 - Control Center

NOTE: Users must be out of maintenance mode in home screen 1 to scroll to home screen 2.

This screen enables users to view and monitor the current status of the robot outputs and inputs. An X is displayed in the check boxes if the robot is using a style strobe, when the dispense completes, for each dispense trigger used, when the dispenser is ready, when the dispense is in process, if there are no alarms or errors, and when the dispense volume is correct.

This screen also displays the current dispense style, command voltage, current number of errors or error number, and the amount of volume dispensed.

Press from the dispense control mode screen to

enter maintenance mode. Maintenance mode enables users to change the control mode, volume to be dispensed, target pressure, and number of dispense valves used in the system.

NOTE: Volume, pressure, and dispense valve options change according to mode.

See Maintenance Mode Operation, page 34, for instructions on changing the control mode, target pressure, and number of dispense valves used.

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Appendix A - Advanced Display Module (ADM)

Error Report Screens

There are nine error report screens that display a chronological list of system errors. These screens display the last 140 errors. Each error report screen displays the date, time, error code, and description for each error. See Errors, page 55, for more information on errors, a list of error codes, and information on error troubleshooting.

Press to scroll through each error report

screen.

Maintenance Screen

This screen enables users to view the maintenance totalizers for each system component and the limits set that will trigger a maintenance advisory.

Maintenance totalizers keep track of the total volume (or hours) that each system component has been running. If the totalizer value exceeds the set limit, the totalizer value will turn red and a maintenance advisory is issued.

The limits are set in the Maintenance Advisory Limits Screen, page 93, for the air supply, V/P regulator, fluid regulator, flow meter, and all four guns.

NOTE: If a flow meter is not included in the system, this screen shows hours instead of volume and the flow meter entry is grayed out.

Job Report Screens

There are 21 job report screens that store and display a chronological list of jobs performed by the system. Each job record includes the date and time the job was completed; the style dispensed; the error percentage; and the target, requested, and actual dispense volumes.

Press to scroll through each job report

screen.

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Appendix B - Discrete Gateway Module (DGM) Connection Details

D-Sub Cable 123793

The cable length of the interface cable assembly 123793 is 50 ft (15.2 m). The following table identifies the cable interface signals.

NOTE: See Appendix D - I/O Signal Descriptions, page 111, for I/O signal descriptions.

Wire Color Description Pin Type

Green/Yellow Isolated Logic Power Supply Supply 51 + 27

Gray Isolated Logic GND Supply 70

Blue/Green Dispense Ready Digital Output 9

Brown/Green Dispense No Error Digital Output 11

Blue/Orange Dispense In Process Digital Output 12

White Dispense Purge Digital Output 15

Blue Dispense Remote Start Digital Output 16

White/Yellow Style Bit 1 Digital Input 52

Blue/Yellow Style Bit 2 Digital Input 53

Brown/Yellow Style Bit 3 Digital Input 54

Black/Red Style Bit 4 Digital Input 55

White/Red Style Strobe Digital Input 56

Blue/Red Dispense Complete Digital Input 57

Brown/Red Error Reset Digital Input 58

Black Remote Start/Purge Digital Input 59

D-Sub Pin No.

Black/Gray Dispense Gun 1 Digital Input 73

Brown/Orange Dispense Gun 2 Digital Input 74

Brown Command Value Analog Input 1

Black/Yellow Command Value GND Analog Input 2

White/Gray N/C 3

Blue/Gray N/C 21

Brown/Gray N/C 23

White/Orange Dispense Gun 3 Digital Input 75

Black/Orange Dispense Gun 4 Digital Input 76

Black/Green Digital CMD 1 Digital Input 77

White/Green Digital CMD 2 Digital Input 78

Orange N/C N/C

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Appendix B - Discrete Gateway Module (DGM) Connection Details

D-Sub Cable 123792 and Breakout Board 123783

The cable length of the interface cable assembly 123792 is 50 ft (15.2 m). The following table identifies the pin assignments for the 78-pin breakout board.

NOTE: See Appendix D - I/O Signal Descriptions, page 111, for I/O signal descriptions.

D-Sub Pin No. Description Pin Type Voltage (Vdc)

1 Command Value Analog In 0-10

2 Command Value GND Analog In GND 0

9 Dispense Ready Digital Out - Bank 1 0 - voltage connected to Pin 27

10 Dispense Alarm/Error on Data Digital Out - Bank 1 0 - voltage connected to Pin 27

11 Dispense Error Digital Out - Bank 1 0 - voltage connected to Pin 27

12 Dispense In Process Digital Out - Bank 1 0 - voltage connected to Pin 27

13 Dispense Volume OK Digital Out - Bank 1 0 - voltage connected to Pin 27

15 Dispense Purge Digital Out - Bank 1 0 - voltage connected to Pin 27

16 Dispense Remote Start Digital Out - Bank 1 0 - voltage connected to Pin 27

17 Data 1* Digital Out - Bank 2 0 - voltage connected to Pin 68

18 Data 2* Digital Out - Bank 2 0 - voltage connected to Pin 68

19 Data 4* Digital Out - Bank 2 0 - voltage connected to Pin 68

20 Data 8* Digital Out - Bank 2 0 - voltage connected to Pin 68

27 Digital Out Supply - Bank 1 Isolated Logic Supply V+ 10-30

28 Data 16* Digital Out - Bank 2 0 - voltage connected to Pin 68

29 Data 32* Digital Out - Bank 2 0 - voltage connected to Pin 68

30 Data 64* Digital Out - Bank 2 0 - voltage connected to Pin 68

31 Data 128* Digital Out - Bank 2 0 - voltage connected to Pin 68

32 Data 256* Digital Out - Bank 3 0 - voltage connected to Pin 69

33 Data 512* Digital Out - Bank 3 0 - voltage connected to Pin 69

34 Data 1024* Digital Out - Bank 3 0 - voltage connected to Pin 69

35 Data 2048* Digital Out - Bank 3 0 - voltage connected to Pin 69

36 Data 4096* Digital Out - Bank 3 0 - voltage connected to Pin 69

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Appendix B - Discrete Gateway Module (DGM) Connection Details

D-Sub Pin No. Description Pin Type Voltage (Vdc)

37 Data 8192* Digital Out - Bank 3 0 - voltage connected to Pin 69

38 Data 16384* Digital Out - Bank 3 0 - voltage connected to Pin 69

39 Data 32768* Digital Out - Bank 3 0 - voltage connected to Pin 69

51 Isolated Logic Power Supply Isolated Logic Supply V+ 10-30

52 Style Bit 1 Digital In 0-30

53 Style Bit 2 Digital In 0-30

54 Style Bit 3 Digital In 0-30

55 Style Bit 4 Digital In 0-30

56 Style Strobe Digital In 0-30

57 Dispense Complete Digital In 0-30

58 Error Reset Digital In 0-30

59 Remote Start/Purge Digital In 0-30

68 Digital Out Supply - Bank 2 Isolated Logic Supply V+ 10-30

69 Digital Out Supply - Bank 3 Isolated Logic Supply V+ 10-30

70 Isolated Logic GND Isolated Ground 0

73 Dispense Gun 1 Digital In 0-30

74 Dispense Gun 2 Digital In 0-30

75 Dispense Gun 3 Digital In 0-30

76 Dispense Gun 4 Digital In 0-30

77 Digital CMD 1 Digital In 0-30

78 Digital CMD 2 Digital In 0-30

* 16-bit data outputs contain either volume or error information depending on state of dispense alarm/error on data.

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