Graco PrecisionSwirl, PCF Instructions-parts List Manual

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Instructions - Parts

Optional PrecisionSwirl Orbital

Dispenser (sold separately)

PCF Control Center

PCF Fluid Plate

™

PCF

with

™

PrecisionSwirl

3A2098S

Precision Dispense System

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

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

Important Safety Instructions

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

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

IMPORTANT:

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

Contents

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

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

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

Control Panel Kits . . . . . . . . . . . . . . . . . . . . . . . . 7

Expansion Swirl Enclosure Assemblies . . . . . . . 8

PrecisionSwirl Orbital Dispenser Assemblies . . . 8

Automation Gateway Assemblies . . . . . . . . . . . . 9

Swirl Control DGM . . . . . . . . . . . . . . . . . . . . . . . 9

Integration Upgrade with Advanced Map . . . . . 10

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

System Configurations . . . . . . . . . . . . . . . . . . . . . 13

Typical Installation - Single Swirl, Single Fluid Plate

Typical Installation - Multiple Fluid Plates, No Swirl

Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . 14

Typical Installation - Multiple Fluid Plates, Multiple

Swirl Dispensers . . . . . . . . . . . . . . . . . . . . . 15

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

System Overview . . . . . . . . . . . . . . . . . . . . . . . 16

System Components . . . . . . . . . . . . . . . . . . . . . 16

Fluid Plate Assembly Overview . . . . . . . . . . . . 17

Control Center Assembly Overview . . . . . . . . . 19

Key Tokens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Before Installation . . . . . . . . . . . . . . . . . . . . . . . 24

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Install Control Center . . . . . . . . . . . . . . . . . . . . 25

Install Fluid Plate Assemblies . . . . . . . . . . . . . . 27

Install Cable Assemblies . . . . . . . . . . . . . . . . . . 32

Install Gateway Module Interface . . . . . . . . . . . 34

System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Configure System . . . . . . . . . . . . . . . . . . . . . . . 36

Configure Control Settings . . . . . . . . . . . . . . . . 37

Configure Mode Settings . . . . . . . . . . . . . . . . . 38

Configure Delay Settings . . . . . . . . . . . . . . . . . 38

Configure Flow Meter Settings . . . . . . . . . . . . . 39

Configure Pressure Loop Settings . . . . . . . . . . 39

Adjust Pressure Sensors . . . . . . . . . . . . . . . . . 40

Configure Errors . . . . . . . . . . . . . . . . . . . . . . . . 40

Setup Maintenance Schedule/Parameters . . . . 41

Configure Valve to Swirl Association and Motor

Error Type . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Configure Swirl Settings . . . . . . . . . . . . . . . . . . 42

Configure Gateway Settings . . . . . . . . . . . . . . . 42

Setup Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Configure Advanced Settings . . . . . . . . . . . . . . 42

On/Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Maintenance Mode Operation . . . . . . . . . . . . . . 45

Automation Control (Normal Operation) . . . . . . 49

Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Precharge Modes . . . . . . . . . . . . . . . . . . . . . . . 51

Typical Job Cycle . . . . . . . . . . . . . . . . . . . . . . . 53

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 61

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

USB Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

System Configuration Settings File . . . . . . . . . . 64

Custom Language File . . . . . . . . . . . . . . . . . . . 64

Download Procedure . . . . . . . . . . . . . . . . . . . . . 65

Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . 65

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Fluid Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Fluid Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 67

Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 68

Gateway Module . . . . . . . . . . . . . . . . . . . . . . . . 69

LED Diagnostic Information . . . . . . . . . . . . . . . . 69

Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Diagnose Errors . . . . . . . . . . . . . . . . . . . . . . . . . 70

Event and Error Codes and Troubleshooting . . 71

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Maintenance Schedule . . . . . . . . . . . . . . . . . . . 80

Advanced Display Module (ADM) . . . . . . . . . . . 81

Upgrade Gateway Module Software (16K743) . 81 Upgrade Gateway Module Fieldbus Map (16N601

or 17P799) . . . . . . . . . . . . . . . . . . . . . . . . . 82

Upgrade Fluid Control Module (FCM) Software

(16K743) . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . 83

Swirl Dispensers . . . . . . . . . . . . . . . . . . . . . . . . 83

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Fluid Plate Assembly . . . . . . . . . . . . . . . . . . . . . 84

Control Center Assembly . . . . . . . . . . . . . . . . . . 91

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Control Centers . . . . . . . . . . . . . . . . . . . . . . . . . 95

Control Center and Expansion Swirl Enclosure

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Fluid Plate Assembly Parts . . . . . . . . . . . . . . . . 98

2 3A2098S

Related Manuals

ADM Software Part No. 16F528 or 15V769

(see manual 313377)

ADM Software Part No. 16K405

(use this manual)





Appendix A - Advanced Display Module (ADM) 104

Display Overview . . . . . . . . . . . . . . . . . . . . . . . 104

Display Details . . . . . . . . . . . . . . . . . . . . . . . . . 104

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Appendix B - Discrete Gateway Module (DGM)

Connection Details . . . . . . . . . . . . . . . . . . . . 121

D-Sub Cable 123793 . . . . . . . . . . . . . . . . . . . . 121

D-Sub Cable 123792 and Breakout Board 123783

122

DGM Digital Input . . . . . . . . . . . . . . . . . . . . . . 125

DGM Digital Outputs . . . . . . . . . . . . . . . . . . . . 126

DGM Analog Inputs . . . . . . . . . . . . . . . . . . . . . 127

DGM Analog Outputs . . . . . . . . . . . . . . . . . . . 127

Appendix C - Communications Gateway Module

(CGM) Connection Details . . . . . . . . . . . . . . 128

Install Fieldbus Connections . . . . . . . . . . . . . . 128

CGM I/O Data Map . . . . . . . . . . . . . . . . . . . . . 131

Appendix D - I/O Signal Descriptions . . . . . . . . 146

Automation Inputs . . . . . . . . . . . . . . . . . . . . . . 146

Automation Outputs . . . . . . . . . . . . . . . . . . . . . 147

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Swirl Dispenser Technical Data . . . . . . . . . . . 148

Fluid Plate Assembly Technical Data . . . . . . . 149

Control Center Assembly Technical Data . . . . 149

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 150

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 150

Related Manuals

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

Manual Description

313377

309403 PrecisionSwirl Orbital Dispenser

307517

308647

309834

3A4649 Integrated PCF Instructions

3A5295 Coriolis Flow Meter Instructions - Parts

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

Original PCF Instructions - Parts (see the note below)

Mastic Fluid Regulators Instructions-Parts

Fluid Pressure Regulators Instructions-Parts

Helical Gear Fluid Flow Meters Instructions-Parts

3A2098S 3

Models

9902471

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

Conforms to

UL 61010-1

Models

Check the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to define the construction of the system, based on the six digits. For example, Part PF1110 represents a PCF fluid

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

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

™

PF 1

First and

Second Digits

(Precision

Continuous

Flow)

Third Digit

Style/Size

Description Regulator Meter Description Description

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

16 Styles 2 Mastic None 1

2 3 256 Styles 3 Cartridge High

4 Mastic High

5 Heated

6 Heated Mas-

7 Cartridge Ultra High

8 Cartridge High

9 Mastic High

C Cartridge Coriolis

Fourth Digit

Fluid Plate

Mastic

tic

Resolution

Heated

Standard Res-

olution

None 5 Not Used.

Resolution

Resolution /GB

6 DeviceNet

7 EtherNet I/P

Fifth Digit

User Interface

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

No ADM

™

1 24 Vdc

™

2 100 - 240 Vac with

™

3 24 Vdc with

™

Sixth Digit

Voltage

Integrated Swirl

 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 121, for custom wiring.

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

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

 These fluid metering systems have ETL certification.

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

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 3A2098S

Models

Fluid Plate Kits

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

PFxxxx assembly does not include a CAN splitter.

Includes:

Fluid

Plate Kit

24B958 PF13xx

24B959 PF11xx

24B960 PF14xx

24B961 PF12xx

24B962 PF15xx

24C901 PF16xx

24J873 PF17xx

24K801 PF23xx

24K802 PF21xx

24K803 PF24xx

24K804 PF22xx

24K805 PF25xx

24K806 PF26xx

24K807 PF27xx

24K808 PF33xx

24K809 PF31xx

24K810 PF34xx

24K811 PF32xx

24K812 PF35xx

24K813 PF36xx

24K814 PF37xx

24V592 PF18xx

Used by

Model

Maximum Working

Pressure

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

6000 psi

(41.4 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

Regula-

Description

Cartridge Regulator, High Resolution Flow

Meter, 2 styles

Cartridge Regulator, No Flow Meter,

2styles

Mastic Regulator, High Resolution Flow

Meter, 2 styles

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

Heated Mastic Regulator, Standard Resolu-

tion Heated Flow Meter, 2 styles

Heated Mastic Regulator, No Flow Meter,

2styles

Cartridge Regulator, Ultra High Resolution

Flow Meter, 2 styles

Cartridge Regulator, High Resolution Flow

Meter, 16 styles

Cartridge Regulator, No Flow Meter,

16 styles

Mastic Regulator, High Resolution Flow

Meter, 16 styles

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

Heated Mastic Regulator, Standard Resolu-

tion Heated Flow Meter, 16 styles

Heated Mastic Regulator, No Flow Meter,

16 styles

Cartridge Regulator, Ultra High Resolution

Flow Meter, 16 styles

Cartridge Regulator, High Resolution Flow

Meter, 256 styles

Cartridge Regulator, No Flow Meter,

256 styles

Mastic Regulator, High Resolution Flow

Meter, 256 styles

Mastic Regulator, No Flow Meter,

256 styles

Heated Mastic Regulator, Standard

Resolution Heated Flow Meter, 256 styles

Heated Mastic Regulator, No Flow Meter,

256 styles

Cartridge Regulator, Ultra High Resolution

Flow Meter, 256 styles

Cartridge Regulator, Glass Bead High

Resolution Flow Meter, 2 styles

tor

244734 246652 16M100

244734 --- 16M101

246642 246652 16M100

246643 246340 16M100

246643 --- 16M101

244734 16E993 16M100

244734 246652 16M102

244734 --- 16M103

246642 246652 16M102

246643 246340 16M102

246643 --- 16M103

244734 16E993 16M102

244734 246652 16M104

244734 --- 16M105

246642 246652 16M104

246642 --- 16M105

246643 246340 16M104

246643 --- 16M105

244734 16E993 16M104

244734 24P688 16M100

Flow

Meter

FCM Key

Token

3A2098S 5

Models

Fluid

Plate Kit

24V593 PF28xx

24V594 PF38xx

24V595 PF19xx

24V596 PF29xx

24V597 PF39xx

24W201 PF15xx

24W202 PF25xx

24W203 PF35xx

25C783 PF1Cxx

25C784 PF2Cxx

25C785 PF3Cxx

Used by

Model

Maximum Working

Pressure

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

5000 psi

(35 MPa, 345 bar)

Description

Cartridge Regulator, Glass Bead High

Resolution Flow Meter, 16 styles

Cartridge Regulator, Glass Bead High

Resolution Flow Meter, 256 styles

Mastic Regulator, Glass Bead High

Resolution Flow Meter, 2 styles

Mastic Regulator, Glass Bead High

Resolution Flow Meter, 16 styles

Mastic Regulator, Glass Bead High

Resolution Flow Meter, 256 styles

Heated Mastic Regulator, Standard

Resolution Heated Flow Meter, 2 styles

Heated Mastic Regulator, Standard

Resolution Heated Flow Meter, 16 styles

Heated Mastic Regulator, Standard

Resolution Heated Flow Meter, 256 styles

Cartridge Regulator, Coriolis Flow Meter, 2

styles

Cartridge Regulator, Coriolis Flow Meter,

16 styles

Cartridge Regulator, Coriolis Flow Meter,

256 styles

Includes:

Regula-

tor

244734 24P688 16M102

244734 24P688 16M104

246642 24P688 16M100

246642 24P688 16M102

246642 24P688 16M104

246643 246340 16M100

246643 246340 16M102

246643 246340 16M104

244734 25D026 16M100

244734 25D026 16M102

244734 25D026 16M104

Flow

Meter

FCM Key

Token

6 3A2098S

Models

Control Panel Kits

NOTE: The control kit numbers listed below are replacement control enclosures with their voltage and automation

interface listed.

Automation

Part No.

16K601 ACCESSORY SWIRL VAC

16K602 ACCESSORY SWIRL VAC

16K603 ACCESSORY SWIRL VAC

16K604 ACCESSORY SWIRL VAC

16K605 ACCESSORY SWIRL VAC IO

16K606 ACCESSORY SWIRL VDC

16K607 ACCESSORY SWIRL VDC

16K608 ACCESSORY SWIRL VDC

16K609 ACCESSORY SWIRL VDC

16K610 ACCESSORY SWIRL VDC IO

16M350 SWIRL EXPANSION VAC N/A

16M351 SWIRL EXPANSION VDC N/A

24S023 STANDARD VAC

25C590 STANDARD VAC

25C591 STANDARD VAC

25C592 STANDARD VAC

25C593 STANDARD VAC IO

24S024 STANDARD VDC

25C594 STANDARD VDC

25C595 STANDARD VDC

25C596 STANDARD VDC

25C597 STANDARD VDC IO

25C582 INTEGRATED (No ADM) VAC

25C583 INTEGRATED (No ADM) VAC

25C584 INTEGRATED (No ADM) VAC

25C585 INTEGRATED (No ADM) VAC

25C586 INTEGRATED (No ADM) VDC

25C587 INTEGRATED (No ADM) VDC

25C588 INTEGRATED (No ADM) VDC

25C589 INTEGRATED (No ADM) VDC

System Type

Voltage

Interface

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

DeviceNet

EtherNet/IP

DeviceNet

EtherNet/IP

DeviceNet

EtherNet/IP

DeviceNet

EtherNet/IP

3A2098S 7

Models

Expansion Swirl Enclosure Assemblies

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

Part Description

16M350 100 - 240 Vac 16M351 24 Vdc

PrecisionSwirl Orbital Dispenser Assemblies

See manual 309403.

Maximum

Working

Version Part, Series Coupler Offset Typical Application

Standard 243402, B 0.012 in. for narrow bead

widths

Standard 243403, B 0.028 in. for wide bead

widths

Compact 289262, A 0.012 in. for narrow bead

widths

Compact 289261, A 0.018 in. for medium bead

widths

Hem flange and after hem

Seam sealing

Hem flange and after hem

Seam sealing

Pressure

3500 psi

(24.1 MPa,

241 bar)

PrecisionSwirl Orbital Dispenser Cable Assemblies

Part Description

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

8 3A2098S

Automation Gateway Assemblies

Automation Gateway (DGM or CGM)

Swirl Control DGM

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

NOTE: Base and cable are not included.

Gateway

Compatible

with

Advanced

CGM Map

PCF

Model

User

Interface

Description

Part

Number

Order

Rotary Switch

Position

Models

PFxx0x Discrete

(DGM)

PFxx1x

PFxx6x

PFxx2x

PFxx7x

PFxx3x

PFxx4x

DeviceNet

(CGM)

EtherNet/IP

(CGM)

PROFIBUS

(CGM)

PROFINET

(CGM)

24B681 0 No

™

15V759 Any Yes

™

15V760 Any Yes

™

15V761 Any No

™

15V762 Any No

Swirl Control DGM

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

Assembly

Part Number

To Order

Rotary Switch

Position

PFxxx2,

PFxxx3,

16M350,

16M351

3A2098S 9

24B681

see Swirl Control

DGM on page 22

1, 2, 3, or 4;

Models

Integration Upgrade with Advanced Map

NOTE: See manual 3A4649 for more information.

Graco provides an upgraded software solution for PCF systems that came with automation communication gateway modules (CGM). The table below shows which systems have the ability to upgrade their system with the update kit (25C527). This kit includes new CGM software, as well as a larger data map.

Benefits of Upgrading:

1. Direct access to important information such as flowrates and pressures of the system (all four fluid plates).

2. Allows for a complete integration of a Graco PCF system, meaning an ADM is no longer necessary.

3. Much easier set up and integrate.

4. Much more supporting documentation to identify what is important.

NOTE: Only systems with Ethernet I/P and Device Net are capable of upgrading to use the Advanced Map.

Table 1: Software Upgrade Tokens

Part Description Contents

  16K743

 * 16N601 PCF Gateway map token: Installs

16T061 PCF Gateway map token: Installs

 16K742 Historical PCF Gateway map

25C527 Advanced integration software kit.

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

the CGM map starting on page 128.

the CGM map starting on page

128.

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

Includes the latest PCF software for the ADM, FCM, CGM, and DGM (16K743). It also includes the larger Map (17P799). Both of these must be installed for the CGM to run, and have advanced integration features.

System Software

Standard Gateway Map

Basic Gateway Map (2 fluid plate), No Swirl

Historical Map

System Software and Advanced Map

Table 2: Fieldbus Setup Options

PCF

Model

User Interface

Description

Able to

Upgrade

Kit

PFxx0x Discrete (DGM) No N/A

PFxx1x Device Net

Yes 25C527

(CGM)

PFxx2x Ethernet I/P

Yes 25C527

(CGM)

PFxx3x ProfiBus (CGM) No N/A

PFxx4x ProfiNet (CGM) No N/A

PFxx6x Device Net

(CGM)

PFxx7x Ethernet I/P

(CGM)

Already

has upgrade installed

Already

has upgrade installed

Already

has upgrade installed

Already

has upgrade installed

Basic Gateway Map: 16T061

System Software: 16K743

Comm. Format: Data - SINT

Input Assembly Instance: 100

Input Instance Size: 10

Output Assembly Instance: 150

Output Instance Size: 6

Standard Gateway Map: 16N601

System Software: 16K743

Comm. Format: Data - SINT

Input Assembly Instance: 100

Input Instance Size: 26

Output Assembly Instance: 150

Output Instance Size: 42

Advanced Gateway Map: 17P799

System Software: 16K743 (newest version)

Comm. Format Data - SINT

Input Assembly Instance: 100

Input Instance Size 126

Output Assembly Instance: 150

Output Instance Size: 44

10 3A2098S

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

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

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

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

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

• Tighten all fluid connections before operating the equipment.

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

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

3A2098S 11

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

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

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

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

BURN HAZARD

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

• Do not touch hot fluid or equipment.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

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

12 3A2098S

System Configurations

Power In

Air Supply Drop Site

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

Typical Installation - Single Swirl, Single Fluid Plate

System Configurations

IG. 1: Typical Ambient System Installation

Key:

3A2098S 13

K *Air Filter Assembly L PrecisionSwirl Orbital Dispenser (Swirl Dispenser) M PrecisionSwirl Cable N Sealer Automation Control Cable

* Included  Optional

System Configurations

Air Supply Drop Site

Power In

Typical Installation - Multiple Fluid Plates, No Swirl Dispensers

IG. 2: Typical Multiple Fluid Plate 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 L Sealer Automation Control Cable

* Included

14 3A2098S

System Configurations

Air Supply Drop Site

Power In

Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers

IG. 3: Typical Multiple Fluid Plate 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 L PrecisionSwirl Orbital Dispenser (Swirl Dispenser) M PrecisionSwirl Cable N Expansion Swirl Enclosure O Sealer Automation Control Cable

* Included  Optional

3A2098S 15

Overview

System shown with one fluid plate and one swirl dispenser

Control Center (User Interface)

Fluid Plate Assembly

Overview

System Overview

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

Typical Applications

• Bead dispensing

• Gasketing

• Seam sealing

• Hem flange

• Sound deadening

• Anti-flutter

• Body panel reinforcement

• Profile wrapping

• Cable filling

Control Center (User Interface)

NOTE: The control center is available with or without an

ADM, depending on the model you are using. See Models on page 4.

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

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

Fluid Plate Assembly

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

PrecisionSwirl Orbital Dispenser (Swirl Dispenser), Sold Separately

System Components

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

IG. 4: PCF System Components

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

16 3A2098S

Overview

Fluid Plate Assembly Overview

Fluid Plate Components

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

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

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

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

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

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

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

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

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

Ambient Fluid Plate Assembly

There are five ambient versions available:

• cartridge regulator without a flow meter

• ambient mastic regulator without a flow meter

• cartridge regulator with a high resolution meter

• ambient mastic regulator with a high resolution meter

• cartridge regulator with an ultra high resolution flow meter

• cartridge regulator with Coriolis flow meter

Heated Fluid Plate Assembly

There are two heated versions available:

• heated mastic fluid regulator with a heated flow meter

• heated mastic fluid regulator without a flow meter

IG. 5: Fluid Plate Components

3A2098S 17

Overview

CAN Connectors

Status LEDs

Key

token

Rotary Switch

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)

IG. 6: FCM Sensor Connections

Connection Sensor Description

1 Dispense solenoid

2Flow meter

3 Outlet pressure sensor (heated systems only)

4 Voltage to Pressure (V/P) Transducer

5 Command cable (optional accessory kit)

6 Inlet pressure sensor (non-heated systems

7 Outlet pressure sensor (non-heated systems

CAN Connectors

Table 3: FCM Sensor Connections

only)

---

Rotary Switch on FCM

The rotary switch on the FCM, see F

IG. 6, must be set to

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

Rotary Switch

Item

Fluid Plate 1 0 or 1

Fluid Plate 2 2

Fluid Plate 3 3

Fluid Plate 4 4

Position

NOTE: See LED Diagnostic Information, page 69, for

signal definitions.

18 3A2098S

Control Center Assembly Overview

Front View Side View

ADM

Gateway Module

Front View

Swirl Board

Swirl Control DGM

100-240 Vac Assembly

CAN Splitter

- To Fluid Plate

- To ADM

Overview

IG. 7: Control Center Components

The control center includes the following components:

• Advanced Display Module (ADM) with USB; see page 20 for details.

• USB enables users to download job, event, and data logs; save and restore system settings; and customize the language. See USB Data on page 63.

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

• If system has a swirl dispenser: Swirl Control DGM

(the module on the left) and Swirl Board.

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

• Discrete (supports up to 2 Fluid Plates)

• DeviceNet (supports up to 4 Fluid Plates)

• EtherNet/IP (supports up to 4 Fluid Plates)

• PROFIBUS (supports up to 4 Fluid Plates)

• PROFINET (supports up to 4 Fluid Plates)

Expansion Swirl Enclosure

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

3A2098S 19

Overview

TI12362a

r_24E451_3B9900_1a

Advanced Display Module (ADM)

IG. 8: 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 (green or orange) indicate the system is in Run mode. Flashing LEDs (green or orange) indicate the system is in Setup mode.

BC Stop Button

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

BD Soft Keys

Functions vary depending on the screen.

BE Cancel Button

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

BF Enter Button

Acknowledge changing a value or making a selection.

BG Lock/Setup

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

Callout Function

BH Navigation Buttons

Navigate within a screen or to a new screen.

BJ Flat Panel Mount

Mounts to control center bracket (optional).

BK Model Number Tag

Model number.

BL USB Module Interface

USB port and USB indicator LEDs.

BM CAN Connector

Power connection.

BN Module Status LEDs

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

See LED Diagnostic Information, page 69, 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.

20 3A2098S

Automation Gateway Module

TI11816A

PROFIBUS

Discrete

TI11814A

TI11815A

Gateway Module Connectors

PROFINET or EtherNet/IP

DeviceNet

Front Back

Rotary Switch

Software Token Slot

Front

(Access Cover Removed)

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

Overview

PCF

Model User Interface Description

Gateway Part Number

To Order

Rotary Switch

Position

Max Number of

Fluid Plates

PFxx0x Discrete (DGM) 24B681 0 2

PFxx1x

PFxx2x

PFxx3x

PFxx4x

DeviceNet

EtherNet/IP

PROFIBUS

PROFINET

™

(CGM)

™

(CGM)

™

(CGM)

™

(CGM)

15V759 Any 4

15V760 Any 4

15V761 Any 4

15V762 Any 4

NOTE: See Control Center Assembly Overview on page 19 for automation and swirl control DGM identification.

IG. 9: Automation Gateway Module Components

Key:

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

cations Gateway Module (CGM) Connection Details, page 128, for more information)

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

mation, page 69)

3A2098S 21

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

CH CAN Connectors

B - Discrete Gateway Module (DGM) Connection Details, page 121, for pinout details)

Overview

Front

Back

Rotary Switch

Software Token Slot

Front

(Access Cover Removed)

Swirl Control DGM

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

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

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

DGM Function

Swirl Control 1 1

Swirl Control 2 2

Swirl Control 3 3

Swirl Control 4 4

Rotary Switch

Position

FIG. 10: Swirl Control DGM

22 3A2098S

Overview

FCMADM

Key Tokens

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

IG. 11

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

If a new ADM or FCM is installed, follow the instructions on page 81 to upgrade the software in the new module and to install the key token from the old module in the new module.

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

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

Part Description

16M100 FCM Key Token, 2 styles, Flow Meter,

ADM required

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

ADM required

16M102 FCM Key Token, 16 styles, Flow Meter,

Integrator Mode Enabled, ADM not required

16M103 FCM Key Token, 16 styles, No Flow

Meter, Integrator Mode Enabled, ADM not required

16M104 FCM Key Token, 256 styles, Flow Meter,

Integrator Mode Enabled, ADM not required

16M105 FCM Key Token, 256 styles, No Flow

Meter, Integrator Mode Enabled, ADM not required

16M217 ADM Key Token, Standard PCF

3A2098S 23

Installation

Before Installation

• Have all system and component documentation

available during installation.

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

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

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

Overview

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

detailed information.

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

10. For systems with swirl dispensers, install each swirl

dispenser onto outlet of a dispense valve.

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

12. Install fluid plate, swirl, and gateway cable assemblies, page 32.

13. Install Gateway interface, page 34.

Installation Steps

1. Mount control center, page 25.

2. For systems with multiple swirl dispensers, mount

expansion Swirl enclosures, page 25.

3. Connect and ground control center and expansion Swirl enclosures, page 26.

4. Mount each fluid plate assembly, page 27.

5. If using a Coriolis flow meter system, mount the flow meter, page 149.

6. Ground each fluid plate assembly, page 31.

7. Check ground continuity.

8. Connect fluid lines between each fluid plate and applicator. Connect fluid supply line and air supply to module. See page 31.

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

24 3A2098S

Installation

Install Control Center

NOTE: This section applies to both the primary control

center and the expansion Swirl enclosures.

Mount

Ensure the following criteria are met before mounting the PCF control center:

• Select a location for the control center that allows adequate space for installation, service, and use of the equipment.

• For best viewing, the ADM should be 60-64 in. (152-163 cm) from the floor.

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

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

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

Table 4: Control Center Assembly Measurement

A B

10.50 in. (267 mm)

5.75 in. (146 mm)

22.00 in. (559 mm)

21.25 in. (540 mm)

• Ensure there is easy access to the power switch.

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

IG. 12: Control Center Dimensions

3A2098S 25

Installation

Ground

Electrical Connections

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.

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

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

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

FIG. 14: 100-240 Vac Wiring

• For 24 Vdc wiring refer to F

• For 100-240 Vac wiring refer to F

• Incoming power wiring must be guarded from the

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

NOTICE

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

IG. 13.

IG. 14.

Connect Light Tower Accessory

NOTE: A light tower is not included on models that do

not have an ADM. See Models on page 4.

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 5: Light Tower Signals

Signal Description

Green No errors.

Yellow An advisory exists.

Yellow flashing A deviation exists.

Red solid An alarm exists. One or more fluid

plates may be shutdown.

NOTE: See Errors, page 70, for error definitions.

IG. 13: 24 Vdc Wiring

26 3A2098S

Installation

Inlet

Outlet

CAN Connector

Dispense Valve to Gun Open

Dispense Valve to Gun Close

Install Fluid Plate Assemblies

To install the PCF fluid plate assemblies:

• Mount the fluid plate assemblies, page 27

• Ground fluid plate assemblies, page 31

• Connect one fluid plate assembly to the control center. See Install Cable Assemblies on page 32.

• If multiple fluid plates, connect the fluid plates

together. See Install Cable Assemblies on page 32.

• Connect fluid lines, air lines, and cables; page 31

Mount

Before Mounting Assembly

• See component manuals for specific information on

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

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

IG. 15.

Table 4: Fluid Plate Assembly Measurement

16.5 in. (419 mm)

14.0 in. (356 mm)

14.4 in. (366 mm)

13.4 in. (340 mm)

• Have all system and subassembly documentation available during installation.

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

• Use only the Graco PCF fluid plate assembly with

IG. 15: Fluid Plate Assembly Dimensions

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.

3A2098S 27

Installation

check valve

Mount Coriolis Flow Meter

NOTE: A Coriolis flow meter only comes with PFxCxx

assemblies.

NOTICE

See Fluid Plate Assembly Technical Data on page 149 for the weight of your meter. The meter is heavy and must be properly supported to avoid stress on the fluid connections.

Fluid Flow Upward

Mounting so fluid flow is upward through the meter is preferred as this allows solids to settle out and air to rise away from metering tube. See F

IG. 16.

Horizontal Installation

The horizontal installation is the recommended installation.

If the medium might contain solid particles, mount the meter as shown in position A, in all other cases as

shown in position B.

IG. 16. Fluid Flow Upward

FIG. 17.

28 3A2098S

Installation

GCA Cable

Splitter Assembly

Hole for bulkhead fitting

Connection 1

J1 J3

J2 J4

Critical Installations

The meters must be mounted at the highest point of the tubing (A), if gas bubbles are to be expected, or at the lowest point (B), if solid particles are to be expected, as

in both cases also the right orientation might not help.

IG. 18.

Mount Four-Valve Breakout Kit 24B693

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

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

FIG. 19: Mount Breakout Kit

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

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

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

4. Connect the splitter assembly to the bulkhead fitting.

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

Connects to Splitter

Cable for:

Dispense Valve 1 J1

Dispense Valve 2 J2

Dispense Valve 3 J3

Dispense Valve 4 J4

Connection Labeled:

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

3A2098S 29

Installation

Custom Breakout Cable

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

Pinout of FCM Port 1

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

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

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. 19 on

page 29.

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

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

Function

FCM Port Pin #

Command Cable Wire Color

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

2 Brown No connection Valve 3 dispense trigger (*sourc-

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

4 Yellow No connection Valve 2 dispense trigger (*sourc-

5 Gray Dispense trigger ground Dispense trigger ground

6 Pink No connection No connection

7 Blue Command signal ground Command signal ground

8 Red No connection No connection

Dispense Trigger Source:

‘Command Cable’ or

‘Combined’

Dispense Trigger Source:

‘Command Cable 3x’

ing input)

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

* To turn on the dispense trigger, connect the

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

30 3A2098S

Installation

Ground

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current.

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

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

• For 24 Vdc wiring refer to F

• For 100-240 Vac wiring refer to F

• Incoming power wiring must be guarded from the

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

IG. 13.

IG. 14.

Solvent Pails Used When Flushing

Follow local code. Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts grounding continuity.

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.

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.

Fluid Supply Container

Follow local code.

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

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

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

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

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

3A2098S 31

Installation

Install Cable Assemblies

NOTE: To prevent system errors, only connect cables

with the power off.

NOTE: See F

1. For systems with more than one swirl dispenser:

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

2. For systems with one or more swirl dispensers, use

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

3. Connect a CAN cable from the control center to one

fluid plate assembly.

4. For multiple fluid plate systems, use CAN cables to

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

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

IG. 20 on page 33.

NOTE: The control center, expansion swirl enclosures, and fluid plates may be connected in any order as long as each is connected to another system component with a CAN cable. See the example shown in F page 33.

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

IG. 20 on

32 3A2098S

Installation

ti30855a

Multiple Fluid Plate and Multiple Swirl System shown

FIG. 20: Cable Installation Diagram

3A2098S 33

Installation

Install Gateway Module Interface

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

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

Fieldbus Communications Gateway Module

Module Description

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

See Automation Control (Normal Operation), page 49, 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 146, 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

Installation

NOTE: The following installation instructions assume

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

NOTE: An Integrated PCF (without ADM) has a CGM that must be configured through an ADM. A single ADM may be used to set up multiple machines.

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 128, for details.

2. Turn on system power. Navigate to the Gateway setup screens and ensure the data map name is: PCF 4FP. Refer to Appendix A - Advanced Display Module (ADM), page 104, 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 104, for details about the configuration settings.

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.

34 3A2098S

CGM hardware failure

Data map load failure

Incorrect data map for fieldbus type

No data map loaded

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

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

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

NOTE: Use the ADM screens for troubleshooting fieldbus data communication problems. Refer to Appendix A - Advanced Display Module (ADM), page 104, for details. Also, use the LED status indicators on the PCF Gateway module for fieldbus status information. Refer to

Appendix C - Communications Gateway Module (CGM) Connection Details, page 128, for details.

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 49, for details on controlling the PCF system through the Gateway module.

Connect D-Sub Cable

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

• For single fluid plate systems only: D-Sub to

flying leads cable (123793). See Appendix B -

Discrete Gateway Module (DGM) Connection Details, page 121, for details and cable

interface signals.

DGM Rotary Switch Position

The Discrete Gateway Module (DGM) rotary switch must be in position 0 for Automation Gateway DGMs and positions 1-4 for Swirl Control DGMs in order for the DGM to operate. See Automation Gateway Module on page 21 and Swirl Control DGM on page 22.

• For multiple fluid plate systems: D-Sub cable

(123972) and 78-pin breakout board (123783). See Appendix B - Discrete Gateway Module (DGM) Connection Details, page 121, for details and pin assignments.

IG. 21: Connect D-Sub Cable

DGM Status LED Signals

See LED Diagnostic Information, page 69, for signal definitions.

3A2098S 35

System Setup

Overview

The PCF system compensates for temperature, flow, or pressure fluctuations. However, if there is a hardware change on the supply system or the dispense material is changed, the PCF system must be set up again.

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

NOTE: See the Advanced Display Module (ADM) section, page 20, and Appendix A - Advanced Display Module (ADM), page 104, for detailed operating instructions for the display keypad and each screen.

NOTE: If configuring an Integrated PCF (without ADM), at least one ADM must be purchased to allow for setup and troubleshooting.

1. Configure System, page 36.

Configure System

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

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

2. Press to access the fields to make changes.

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

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

the desired setting. Press to accept the selection.

5. Repeat for the other Dispensers and Swirl Dispensers.

6. Press to exit edit mode.

2. Configure Control Settings, page 37.

3. Configure Mode Settings, page 38.

4. Configure Delay Settings, page 38.

5. Configure Flow Meter Settings, page 39.

6. Configure Pressure Loop Settings, page 39.

7. Adjust Pressure Sensors, page 40.

8. Configure Errors, page 40.

9. Setup Maintenance Schedule/Parameters, page 41.

10. For systems with swirl dispensers only:

a. Configure Swirl to valve association and error

type, page 41.

b. Configure Swirl settings, page 42.

11. Configure Gateway Settings, page 42.

12. Setup Styles, page 42.

IG. 22

13. Configure Advanced Settings, page 42.

36 3A2098S

System Setup

Configure Control Settings

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

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

2. Press to access the fields to make changes.

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

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

8. Press to move to the Run Mode Bead Adjust

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

select Enable or Disable. Press to enter the value.

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

Box. Press to enable or disable.

10. Press to move to the Display Control Password

field. Press to enter the value.

11. Press to exit edit mode.

12. If multiple fluid plates are installed, repeat this

procedure for the other Fluid Plates.

IG. 23

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

valves. Press to finalize the selection.

4. If the dispense trigger source is set to Command

Cable, press to move to the Enable Valves field.

Press and to enable valves.

5. Press to move to the Command Value Source

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

to enter the value.

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

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

Gateway. Press to enter the value.

3A2098S 37

System Setup

Configure Mode Settings

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

NOTE: For a description of each dispense mode, see Dispense Control Modes, page 118.

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

2. Press to access the fields to make changes.

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

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

6. Press to exit edit mode.

Configure Delay Settings

Set on and off delays (in milliseconds) for each valve and the regulator. For an explanation of the on and off delays, refer to the On/Off Delays section on page 43.

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

2. Press to access the fields to make changes.

IG. 24

3. Press and to set the mode for each

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

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

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

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

• Each valve is set to Pressure mode and has

identical Fixed Command values.

• Each valve is set to Full Open mode.

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

FIG. 25

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

the regulator. Press to enter each value.

4. Press to exit edit mode.

38 3A2098S

System Setup

Configure Flow Meter Settings

The accuracy of the PCF volume reporting depends on precise adjustment of the K-factor(s). The fluid plate uses the K-factor(s) to calculate the volume dispensed. If the set value is not correct, the system still delivers repeatable flow rates; however, the reported value may not be correct. See Verify Flow Meter Calibration, page 46, for additional K-factor information.

Table 5: Flow Meter K-Factors

Part Description K-Factor

246652 High Resolution Helical

Gear Meter

246340 Heated Helical Gear

Meter 16E993 Ultra High Flow Meter 33000 25D026 Coriolis Flow Meter 1176

Set Flow Meter K-Factor

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

settings will be grayed out.

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

2. Press to access the fields to make changes.

7000

3500

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

for mass flow meters. Press to enter the selection.

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

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

5. Press to exit edit mode.

NOTE: If necessary, verify flow meter calibration. See Verify Flow Meter Calibration, page 46, for

instructions.

Configure Pressure Loop Settings

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

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

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

need to be adjusted, see Manually Adjust Control

Loop Parameters on page 47.

IG. 26

3A2098S 39

System Setup

Adjust Pressure Sensors

Set pressure offsets and pressure limits.

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

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

2. Press to access the fields to make changes.

IG. 27

Configure Errors

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

(Error Type) on page 113 for more information.

NOTE: Only the low/high pressure errors will be

enabled for systems without a flow meter.

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

2. Press to access the fields to make changes.

NOTE: For the following steps, press and

to navigate through each field, and to open

drop-down menus and enter changes or selections.

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

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

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

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

• If the minimum inlet pressure decreases below

the setting.

• If the maximum inlet pressure increases above

the setting.

• If the maximum outlet pressure increases above

the setting.

FIG. 28

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

type. Press to enter the selection.

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

for each field.

5. Press to exit edit mode.

6. Press to exit edit mode.

40 3A2098S

System Setup

Setup Maintenance Schedule/Parameters

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

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

The Volume (or Hours) column displays the current totalizer value. If this value exceeds the set limit, the value will turn red and a maintenance advisory is issued. See Fluid Plate x, Screen 7 (Maintenance Advisory Limits), page 113, for more information about maintenance totalizers.

To set limits:

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

2. Press to access the fields to make changes.

To reset a totalizer value:

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

Fluid Plate x, screen 7 (Maintenance Advisory

Limits)

2. Press to scroll to the system component to

reset.

3. Press to reset the value.

Configure Valve to Swirl Association and Motor Error Type

Define which Swirl number is installed on which dispense valve.

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

IG. 29

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

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

for each field.

5. Press to exit edit mode.

3A2098S 41

FIG. 30

System Setup

Configure Swirl Settings

NOTE: This applies only to systems with swirl

dispensers.

Set the individual Swirl settings for each installed Swirl.

IG. 31

Configure Gateway Settings

Gateway settings differ for each system. See Automation Gateway Setup Screens, page 107, for guidelines on configuring each type of Gateway interface.

Setup Styles

The PCF system can store up to 256 styles. See Styles, page 50, for more information about styles and instructions on setting up styles. Style 0 is always the purge style.

Configure Advanced Settings

Use the advanced settings to set or change the format and display units, such as the language, date format, and pressure units, for all PCF screens. See Setup Mode, page 106, for advanced setting guidelines.

42 3A2098S

On/Off Delays

Dispense Valve Signal

Fluid Regulator

Valve Open Command

Valve Actually Open

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 38.

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.

Table 5: On/Off Delay Variables

Variable: Sets the Amount of Time:

System Setup

IG. 32 and Table 6: Delay On/Off Timing show delay

ON and OFF timing.

Table 6: Delay On/Off Timing

A Regulator ON

delay

The user sets the fluid regulator ON delay timing.

B Valve ON delay Usually set to zero. Can be

used to change the starting point of a bead.

C Valve OFF Delay Usually set to zero. Higher

values will lower the trapped pressure.

D Regulator OFF

delay

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

E Valve Open

Reaction Time

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

F Valve Close

Reaction Time

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

Valve ON Sets time from Dispense Valve High

Regulator ON

Valve OFF Sets time from Dispense Valve Low

Regulator OFF

FIG. 32: Timing Delay

to Valve Open command

Sets time from Dispense Valve High to Regulator ON

to Valve Close command

Sets time from Dispense Valve Low to Regulator OFF

3A2098S 43

Operation

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

Startup

Initial Startup

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

2. Read and understand the Operation (page 44) and Advanced Display Module (ADM) (page 20) sections of this manual.

3. Continue startup with step 2 in Standard Startup.

Standard Startup

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

Load Material

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

1. If this is a new installation, follow the Initial Startup procedure. Otherwise, follow the Standard Startup procedure. See page 44.

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

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

4. Enter the maintenance screen. See Dispense From Maintenance Screen, page 47.

5. Select a control mode. See Dispense From Main- tenance Screen, page 47.

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

press to turn the system on.

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

3. Turn on air.

4. Turn on electrical power to the system.

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

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

7. Turn on the material supply system.

IG. 8 on page 20.

7. Press and hold . Dispense fluid until clean,

air-free fluid flows from the valve.

8. Press to exit maintenance screen.

44 3A2098S

Operation

Fluid Plate

Maintenance Screen

Swirl

Maintenance Screen

Maintenance Mode Operation

Operating from maintenance mode enables manual

dispensing ( ) and manually starting the swirl

dispenser ( ).

The system begins dispensing when the user presses

. Dispense parameters and duration depend on the

selected control. Dispensing continues for as long

as is pressed.

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

NOTICE

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

Feed System Pressure Drop

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

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

The system starts the swirl dispenser when the user

presses . The swirl dispenser continues to run until

is pressed again.

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

Verify System Operation

Use maintenance mode to manually check the operation of the PCF system components before switching over to automation control (normal operation). See Dispense From Maintenance Screen, page 47, for instructions on operating from maintenance mode.

NOTE: Perform the following procedures while in maintenance mode.

Set Inlet Pressure

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

3A2098S 45

Operation

fluid mass (g) density (g/cc)

= measure volume (cc)

K-Factor (new) =

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

measured volume (cc)

Dispense from Each Valve

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

Follow the steps outlined in Dispense From Maintenance Screen, page 47, to perform each of the following applicable system verification checks.

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

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

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

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

a. For each flow rate that will be used during

Verify Flow Meter Calibration

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

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

Method 1. Using a gram scale

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

IG. 26 on

page 39.

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

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

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

IG. 33 on page 47.

5. Calculate the actual volume dispensed:

normal 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.

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 Fluid Plate x, screen 4 (Flowmeter Settings). See F

IG. 26

on page 39.

2. Use a 500 cc or larger beaker.

46 3A2098S

Operation

K-Factor (new) =

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

dispensed volume (cc)

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

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

IG. 33 on page 47.

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.

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.

Dispense From Maintenance Screen

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

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 follow 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.

FIG. 33

2. Press to enter maintenance screen.

IG. 34

3. Press to open the Control Mode drop-down list,

and select the preferred control mode. Press again to exit the drop-down list.

3A2098S 47

Operation

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

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

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

to select the desired valves.

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

48.

Manually Dispense Fluid

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

maintenance screen.

2. Press and verify that the valve opens.

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

dispense material.

2. Press to enter maintenance screen.

FIG. 36

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

4. Press again to exit maintenance screen.

Operate Swirl Dispenser From Maintenance Screen

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

4. Press and verify that the Swirl Dispenser

begins rotating. Press again to stop the Swirl

Dispenser.

5. Press again to exit maintenance screen.

IG. 35

48 3A2098S

Operation

Automation Control (Normal Operation)

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

The automation control operates using the concept of jobs and styles. For a detailed explanation of jobs and how they work within the PCF system, see Jobs on page 49. For a detailed explanation of styles and how they work within the PCF system, see Styles on page 50.

Jobs

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

page 146, for automation input and output signal descriptions.

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

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

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

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 120, for instructions on how to view job reports.

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

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

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

Jobs in Bead Mode

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

Jobs in Pressure Mode

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

Jobs in Shot Mode

In Shot Mode, the job is started the same as a normal job, but when the gun is triggered it dispenses until the target volume is reached. After the shot is done, the Dispense in Process bit goes low and you can check the Volume OK bit to see if the shot was within tolerance. If the Job End Mode is set to Timer, the shot times out after the specified amount of time and sends an advisory, even if target volume is not reached.

Continuously Running Applications

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

3A2098S 49

Operation

Styles

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

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

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

PCF reads in the styles via the Gateway interface. For detailed interface information, see Appendix B - Dis- crete Gateway Module (DGM) Connection Details on page 121, and Appendix C - Communications Gate- way Module (CGM) Connection Details on page 128, as applicable.

To setup a style:

1. Navigate to Fluid Plate x, screen 8.

3. Enter the style number in the Style field.

4. Enter Style Name:

a. Press while in the Style Name field to

display the Keyboard screen.

FIG. 38

2. Press to access the style setup fields.

IG. 37

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 114, for further details.

c. Press to accept the new value.

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

6. Enter precharge mode and parameters. See Precharge Modes beginning on page 51.

7. Press to exit edit mode.

50 3A2098S

Operation

Precharge Modes

NOTE: See the diagram on the following page.

Static Precharge Mode

Display

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

Gateway

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

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

Dynamic Precharge Modes

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

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

Valve 1

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

3A2098S 51

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

52 3A2098S

Operation

Typical Job Cycle

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

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

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

• Style Strobe: 0

• Dispense Complete: 0

• Dispense Valve x On: all should be 0

• Style: Any value is acceptable

A typical job cycle consists of the following dispensing sequence. See Typical Job Cycle Chart, page 54.

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

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

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

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

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

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

• Dispenser (Fluid Plate) No Alarm

• Dispenser (Fluid Plate) No Error

• Dispense Volume OK

•Error

• Dispensed Volume

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

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

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

Jobs with Command Cable Dispense Trigger

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

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

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

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

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

• The selected style defaults to Style 1.

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

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

3A2098S 53

Operation

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispenser (Fluid Plate) In Process

Volume OK

Style Bits

Style Strobe

Automation Outputs (PCF Inputs)

Dispense Valve X On

Dispense Complete

Regulator Active (Precharge = 0)

PCF State

Dispense Valve X Open

Dispense Ready

Automation Inputs (PCF Outputs)

First Job

Second Job

Typical Job Cycle Chart

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

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

NOTE: A 50ms delay is suggested between each signal.

NOTE: Dispense Complete must be strobed, not held high in order to avoid an advisory.

54 3A2098S

Control Charts

Automation Inputs (PCF Outputs)

Volume OK

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Purge In Process

Automation Outputs (PCF Inputs)

Style Bits

Style Strobe

Dispense Valve X On

Dispense Complete

Dispense Valve X Open

PCF State

Purge Using Style 0

Purge Using Purge Bit

Automation Inputs (PCF Outputs)

Dispense Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Purge In Process

Automation Outputs (PCF Inputs)

Remote Start / Purge

Dispense Valve X On

PCF State

Dispense Valve X Open

Operation

3A2098S 55

Operation

Remote Start

Automation Inputs (PCF Outputs)

Dispenser (Fluid Plate) Ready

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispenser (Fluid Plate) Remote Start/Purge in Process

Remote Start/Purge

Automation Outputs (PCF Inputs)

Automation Inputs (PCF Outputs)

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

Automation Outputs (PCF Inputs)

Error Reset

Rising Edge Only

Cancel Job

Automation Inputs (PCF Outputs)

Dispense In Process

Automation Outputs (PCF Inputs)

Error Reset

Control Charts (continued)

56 3A2098S

Control Charts (continued)

Precharge* - Gateway Mode

Precharge* - Display Mode

Automation Inputs (PCF Outputs)

Dispense Ready

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

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

 Shaded areas indicate the precharge is active.

Dispenser (Fluid Plate) No Alarm

Dispenser (Fluid Plate) No Error

Dispense In Process

Volume OK

Style Bits

Style Strobe

Dispense Valve X On

Dispense Complete

Regulator Active

Dispense Valve X Open

Automation Outputs (PCF Inputs)

PCF State

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

Precharge Valve X On†

Command Signal Valid‡

Regulator Active

Dispense Valve X Open

Automation Outputs (PCF Inputs)

PCF State

Dispense Valve X On

Dispense Complete

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

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

 Shaded areas indicate the precharge is active.

† The “Precharge Valve X On” bits are only available through a fieldbus interface. This

precharge method is not valid for DGM systems.

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

selected as “Command Value Source”.

Operation

3A2098S 57

Operation

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

Automation Inputs (PCF Outputs)

Dispense In Process

Automation Outputs (PCF Gateway Inputs)

Dispense Valve 1 Trigger

PCF State

Regulator Active (Precharge = 0)

Dispense Valve 2 Trigger

Dispense Valve 3 Trigger

Dispense Valve 1 Open

Dispense Valve 2 Open

Dispense Valve 3 Open

Trigger Using Command Cable 3x

Control Charts (continued)

58 3A2098S

Control Charts (continued)

Automation Inputs (PCF Outputs)

Dispense In Process

Automation Outputs (PCF Gateway Inputs)

Dispense Valve X On

PCF State

Regulator Active (Precharge = 0)

Trigger Using Command Cable and Gateway (Combined)

Dispense Valve Y On

Dispense Valve X On

Dispense Valve Y On

Command Cable

Dispense Trigger

Trigger Using Command Cable

* Dispense Valve X Open determined by Enable Valves check

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

Automation Inputs (PCF Outputs)

Dispense In Process

Command Cable

Dispense Trigger

PCF State

Regulator Active (Precharge = 0)

Dispense Valve X Open*

Automation Inputs (PCF Outputs)

Dispense In Process

Automation Outputs (PCF Gateway Inputs)

Dispense Valve 1 On

PCF State

Regulator Active (Precharge = 0)

Trigger Using Gateway

Dispense Valve 2 On

Dispense Valve 3 On

Dispense Valve 4 On

Dispense Valve 1 On

Dispense Valve 2 On

Dispense Valve 3 On

Dispense Valve 4 On

Operation

3A2098S 59

Operation

Automation Inputs (PCF Outputs)

Dispenser (Fluid Plate) Ready

Automation Outputs (PCF Gateway Inputs)

Swirl X Actual Speed - RPM (32 bits)

PCF State

Swirl X On

Enable Swirl Dispenser

Swirl X Speed Command (12 bits)

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

Swirl X Enable

Speeding Up

Command Value Set

Actual Speed Value Valid

Full Speed

Control Charts (continued)

60 3A2098S

Pressure Relief Procedure

Dispense Valve Air Solenoid

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

Pressure Relief Procedure

b. Continue actuating the plunger until all pressure

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

5. For systems with multiple fluid plates, repeat

previous steps for other fluid plates.

6. Shut off air to the fluid plate.

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

2. Place a waste container beneath the dispense valve.

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

valve. Press the manual dispense button until

the fluid flow stops.

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

a. Manually actuate the plunger on the solenoid to

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

IG. 39 and perform the

IG. 39.

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

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

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

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

IG. 39: Dispense Valve Air Solenoid

3A2098S 61

Shutdown

TI12362a

Shutdown

1. Press the Stop button (BC).

FIG. 40: ADM - Stop Button

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

3. Follow the Pressure Relief Procedure on page 61.

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

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

IG. 41: Control Center Main Power Switch

62 3A2098S

USB Data

NOTE: USB data is not available on models that do not have an ADM. See Models on page 4.

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

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

USB Logs

IG. 42: ADM USB Port

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

load Procedure, page 65, to retrieve log files.

Event Log

• Job number (sequential number)

• Dispenser (Fluid Plate) Number

•Style number

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

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

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

• Volume units

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

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

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

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

• Minimum outlet pressure during job (measured in bar)

• Average outlet pressure during job (measured in bar)

• Maximum outlet pressure during job (measured in bar)

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

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

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

• Elapsed time (mS)

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

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

Job Log

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

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

• Job completion date

• Job completion time

3A2098S 63

Dispense Data Log

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

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

USB Data

System Configuration Settings File

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

A system configuration settings file automatically downloads each time a USB flash drive is inserted. Use this file to back up system settings for future recovery or to easily replicate settings across multiple PCF systems. Refer to the Upload Procedure, page 65, for instructions on how to use this file.

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

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

NOTE: Do not modify the contents of this file.

Custom Language File

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

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

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

• U+0020 - U+007E (Basic Latin)

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

• U+0100 - U+017F (Latin Extended-A)

• U+0386 - U+03CE (Greek)

• U+0400 - U+045F (Cyrillic)

Create Custom Language Strings

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

Modify the second column of the custom language file as needed and then follow the Upload Procedure, page 65, to install the file.

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

• The file name must be DISPTEXT.TXT.

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

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

• Do not add or remove rows to the file.

• Do not change the order of the rows.

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

64 3A2098S

USB Data

Download Procedure

1. Insert USB flash drive into USB port (BL). See FIG. 42 on page 63.

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

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

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

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

Windows

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.)

Explorer.

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 65, to automatically generate the proper folder structure on the USB flash drive.

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

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

4. Open Graco folder.

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

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

8. Open DOWNLOAD folder.

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

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

Microsoft

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

Word.

Excel® by

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

8. Remove USB flash drive from computer.

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

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

11. Remove USB flash drive from USB port.

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

3A2098S 65

Troubleshooting

NOTE: Check all possible solutions in the chart below

before you disassemble the system.

Troubleshooting for individual fluid regulators and flow meters is also discussed in their separate manuals; refer to Related Manuals on page 3. Also refer to Event and Error Codes and Troubleshooting, page 71, for detailed information on how error codes are communicated.

Fluid Plates

Problem Cause Solution

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

(410 kPa, 4.1 bar)

No “Valve On” signal from automation unit

No air signal to air diaphragm Check for loose/disconnected

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

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

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

Worn gaskets Check/replace gaskets on Voltage to

Check output and wiring from automation unit

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

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

needle/ seat

necessary

Pressure (V/P) Transducer and solenoid valve

66 3A2098S

Troubleshooting

Flow Meter

Problem Cause Solution

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

Flow too low Verify flow rate is above minimum

for the installed flow meter

Loose wiring Verify connection from flow meter to

FCM

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

False measurement Flow meter not calibrated Calibrate flow meter, page 46

System not grounded properly Verify system ground

Noisy power source Verify clean power supply power to

main enclosure

Flow reported is not correct or inconsistent

Flow meter not calibrated Calibrate flow meter, page 46

Flow meter is worn Replace flow meter

Fluid Regulator

Problem Cause Solution

No pressure regulation Damaged diaphragm Replace diaphragm

Leaking or dirty seat Replace cartridge, or clean seat

No fluid flow Damaged valve actuator Replace valve actuator

Pressure creeps above setting Metal chip or contamination

between ball and seat

Damaged diaphragm Replace diaphragm

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

Damaged or clogged air regulator or

line

Leaking or dirty seat Replace cartridge, or clean seat

Large change in inlet pressure Stabilize regulator inlet pressure

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

Damaged or clogged air regulator or

line

Using valve beyond its rated flow

capacity

Large change in inlet air or fluid

pressure

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

Damaged diaphragm Replace diaphragm

Chatter

Excessive pressure differential be tween pump and valve

Excessive flow rate

Replace cartridge, or clean seat

area

Clear obstruction in line. Service

regulator if necessary

Clear obstruction in line. Service

regulator if necessary

Install valve for each spray valve or

dispensing valve

Stabilize air and fluid regulator inlet

pressures

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

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

3A2098S 67

Troubleshooting

Dispense Valves

Problem Cause Solution

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

No “Valve On” signal from automation unit

Valve not shutting off Air not getting to the close port

(except AutoPlus valve)

“Valve On” signal from automation unit is on

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

Needle/seat worn Rebuild valve; replace needle/seat

Pressurized material past the valve shut-off is escaping

Faulty solenoid valve Replace solenoid valve

Solenoid valve muffler restricted Clean or replace muffler

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

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

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

Check input from automation unit

Verify air pressure to solenoid

Verify solenoid operation

Verify air line routing and connections

Check input from automation unit

(410 kPa, 4.1 bar)

Reduce running pressure

Reduce nozzle length

Increase nozzle orifice size

necessary

Swirl Dispenser

Problem Cause Solution

Motor not running (motor fault alarm active)

Motor not running (motor fault alarm not active)

Cable disconnected Verify cable connections to swirl

board, swirl motor cable, and swirl orbiter

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

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

Faulty swirl orbiter Replace swirl orbiter Cable disconnected

No “Swirl Enable” signal from automation unit

Swirl not installed

Cycle system power

Replace swirl motor cable (55 ft) then cycle power

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

Check input from automation unit

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

68 3A2098S

Troubleshooting

Motor not responding to change in speed command

No “Swirl Speed Command” signal from automation unit

Swirl speed source incorrectly set Verify Speed Command Source in

Check input from automation unit

Swirl Setup screen

Gateway Module

Problem Cause Solution

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

LED status indicators and Appendix C - Communications Gateway Module (CGM) Connection Details, page 128.

Incorrect fieldbus settings Confirm fieldbus settings at automation controller (fieldbus

master) and PCF Gateway (fieldbus slave). Refer to Appen- dix A - Advanced Display Module (ADM), page 104, 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 104, for information on how to determine installed data map. If necessary, install a new Gateway data map. Refer to

Upgrade Gateway Module Fieldbus Map (16N601 or 17P799), page 82, for instructions, and Control Center and Expansion Swirl Enclosure Parts, page 96, for map token

part number.

LED Diagnostic Information

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

Module Status LED Signal Diagnosis Solution

Green on System is powered up -

Yellow Internal communication in progress -

Red solid Hardware failure Replace module

Red flashing fast Uploading software -

Red flashing slow Token error Remove token and upload software

token again.

Red flashes three times, pauses, then repeats

Invalid rotary switch position (FCM and DGM only)

Change rotary switch position to a valid position then restart the system. See page 18.

3A2098S 69

Errors

Error

Errors

View Errors

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

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

IG. 43: Error Pop-Up

The previous 200 errors are displayed on the error report screens. See Run Mode, page 116, for instructions on navigating to and through the error report screens.

Diagnose Errors

See Event and Error Codes and Troubleshooting on page 71 for error codes, possible causes, and solutions.

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

NOTE:

• Alarms set the dispenser (fluid plate) ready signal

LOW.

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

Errors can be viewed through a CGM on models that do not have an ADM. See Appendix C, page 128, Output bits 0x0DB. The Error codes are described by a 4 digit ASCII string. For example: the first event code in the manual is EC0X and is represented using an ASCII table:

E = 0x45 C = 0x43 0 = 0x00 X = 0x58

70 3A2098S

Errors

Event and Error Codes and Troubleshooting

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

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

NOTE: The following error list is available in the PCF Integration package at www.graco.com.

System Events and Errors

Event

Code

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

EC0X --- Setup Values

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

EM0X --- Power Down Control box power

Gateway

Error No. Event Name

Changed

Event

Description Event Type Cause Solution

System Events and Errors

Setup change notification

down

Record only A setup value was

changed on the display

Record only --- ---

No action necessary if changes were desired

Control Center Events and Errors

Event

Code

EVUX --- USB Disabled USB download

MMUX --- USB Log 90%

V1G0 --- DGM Unpowered The Discrete Gateway

WSG0 --- Gateway Setup

EAUX --- Download to

Gateway

Error No. Event Name

Full

Error

USB in Process

Event

Description Event Type Cause Solution

Control Center Events and Errors

attempted, however, USB activity is disabled.

One or more USB log is 90% full.

Module does not have logic power supplied to it.

System settings are incompatible with Discrete Gateway Module.

Information is currently being downloaded to USB

Advisory (self-clearing)

Advisory Data in the jobs or

Advisory 24 Vdc has not been

Advisory Fluid plate 1 is not

Advisory (self-clearing)

Transfers are disabled in Advanced Setup screen 2.

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

connected to the power pins.

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

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

--- No action necessary

Clears when drive is removed.

Download the data or disable USB errors.

Connect power according to Appendix B -

Discrete Gateway Module (DGM) Connection Details on

page 121.

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

Install Swirl 1, uninstall swirls 3 and 4.

3A2098S 71

Errors

Event

Code

EBUX --- Download to

WSU0 --- USB configura-

WNC0 32 ADM Key Token

WNG0 --- Gateway Map

CBG0 --- Gateway Reset Gateway reset Advisory

WMG0 --- Gateway Error

CBD_ --- Fluid Plate Com-

CCG_ --- Fieldbus Com-

Gateway

Error No. Event Name

USB Complete

tion error

Error

Detected

munication Error

Event

Description Event Type Cause Solution

Control Center Events and Errors

Download to the USB is complete

USB configuration error Advisory USB configuration

Missing or invalid key token

Missing or invalid map Advisory Missing or invalid

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

Fluid Plate Communication Error with ADM

Fieldbus Communication Error

Advisory (self-clearing)

Alarm An ADM key token is

(self-clearing)

Alarm --- ---

Alarm The ADM lost commu-

Alarm The automation gate-

--- No action necessary

Reinstall system soft-

invalid or not present

required to run the system

Gateway map

Gateway setting(s) changed

nications with the FCM.

way lost communication with the automation controller.

ware on display

Verify the key token is installed

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

Install PCF map in Gateway

Wait for reset to complete before attempting automation control

Restore communication.

Restore communications.

Fluid Plate Events and Errors

Event

Code

CAC_ --- CGM Communi-

CAD_ --- Fluid Plate Com-

B7C_ 30 Style Out of

Gateway

Error No. Event Name

cation Error

munication Error

Range

Communication lost between CGM and Fluid Plate

FCM lost communication with the ADM

Style is out of range Alarm Style requested by

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Advisory Fluid Plate and CGM

are no longer communicating

CGM is not functioning Replace the CGM if the

Alarm ADM is not communi-

cating

ADM is not functioning Replace FCM if red

ADM does not contain appropriate key token

automation controller exceeds number of styles available on the fluid plate

Reconnect or replace CAN cable

red status LED is solid

Reconnect or replace CAN cable

status LED is solid

Verify intended ADM key token is properly inserted

Use a style number that is in range

Increase number of styles in PCF; purchase accessory key token

72 3A2098S

Errors

Event

Code

B30_ B40_

B10_ B20_

B1C_ B2C_

B3C_ B4C_

WND_ 51 Fluid Plate Key

Gateway

Error No. Event Name

31 High Material Material dispensed

32 Low Material Material dispensed

33 Low Computed

Target

34 High Computed

Target

Token Error

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

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

during last dispense cycle below amount requested minus the allowed tolerance

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

Missing or invalid key token

Alarm or Deviation (user selectable)

Alarm FCM key token is

PCF regulator is not regulating correctly

Incorrect style target volume or tolerance

Partially plugged tip or supply system

Insufficient flow to PCF regulator inlet

PCF regulator is not regulating correctly

Check regulator; repair if necessary

Entered process target incorrectly

Entered tolerance incorrectly

Requested volume incorrectly

Automation problem Verify automation is

Entered process target incorrectly

Entered tolerance incorrectly

Requested volume incorrectly

Automation problem Verify automation is

required to run system

Check regulator and repair if necessary

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

Clean tip and/or supply system

Increase flow rate to regulator inlet

Incorrect style target volume or tolerance setting

Enter correct process target

Enter correct tolerance

Check automation program

correct

Enter correct process target

Enter correct tolerance

Check automation program

correct

Verify FCM key token is installed

Verify FCM key token is correct part number

P6D_ 52 Outlet Pressure

Transducer Error

P6F_ 53 Inlet Pressure

Transducer Error

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

3A2098S 73

Outlet pressure transducer error

Inlet pressure transducer error

Alarm Problem detected with

outlet pressure transducer

Advisory Problem detected with

inlet pressure transducer

flow meter

Verify outlet pressure transducer is installed and/or connected correctly

Replace if necessary

Verify inlet pressure transducer is installed and/or connected correctly

Replace if necessary

Verify flow meter is installed and/or connected correctly

Replace if necessary

Errors

Event

Code

WED_ 55 V/P Error Voltage to Pressure

WJ1_ 56 Dispense Valve 1

WJ2_ 57 Dispense Valve 2

WJ3_ 58 Dispense Valve 3

WJ4_ 59 Dispense Valve 4

Gateway

Error No. Event Name

Error

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Transducer error

Dispense valve 1 error Alarm Problem detected with

Dispense valve 2 error Alarm Problem detected with

Dispense valve 3 error Alarm Problem detected with

Dispense valve 4 error Alarm Problem detected with

Alarm Problem detected with

V/P

dispense valve 1

dispense valve 2

dispense valve 3

dispense valve 4

Verify outlet pressure transducer is installed and/or connected correctly

Replace if necessary

Verify dispense valve 1 is installed and/or connected correctly

Replace if necessary

Verify dispense valve 2 is installed and/or connected correctly

Replace if necessary

Verify dispense valve 3 is installed and/or connected correctly

Replace if necessary

Verify dispense valve 4 is installed and/or connected correctly

WSD_ 60 Incompatible

Valve Settings

WSD5 60 Incompatible

Valve Settings

F7D_ 61 Closed Valve

Flow

V2D_ 62 Low Analog Command cable ana-

Incompatible settings for multiple valve operation; attempted to dispense

System reading flow meter pulses with valve(s) closed

log command dropped below minimum value of 1 V while dispensing

Replace if necessary

Alarm Attempted to dis-

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

Alarm Attempted to dis-

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

Alarm Dispense hose leak Check hose; replace if

Flow meter providing false pulses

Dispense valve not operating correctly

Deviation Bad or loose com-

mand cable connection

Entered command mode incorrectly

Automation program error

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

Verify automation programming

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

Verify automation programming

needed

Replace flow meter sensor or calibrate meter

Repair dispense valve

Check command cable and connection

Enter correct command code

Verify correct automation program

74 3A2098S

Errors

Event

Code

WFD_ WFG_

EJD_ 64 Job Cycle Time

WXD_ 65 Fluid Plate Error

P3F_ P4F_

P3D_ P4D_

P1F_ P2F_

P1C_ P2C_

Gateway

Error No. Event Name

63 Flow Meter

Required

Out

Detected

66 Maximum Inlet

Pressure

67 Maximum Outlet

Pressure

68 Minimum Inlet

Pressure

69 Low Pressure Measured outlet pres-

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

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 Analog voltage applied

Alarm or Deviation (user selectable)

Selected valve mode settings require flow meter

FCM key token missing or invalid

not properly end job cycle

to pin 1 of the command cable exceeds 10 Vdc.

Failed FCM Replace FCM if neces-

Incorrect set limit Verify limit is set cor-

Material supply pressure is too high

Failed transducer Check transducer;

Incorrect set limit Verify limit is set cor-

Material supply pressure is too high

Failed transducer Check transducer;

Incorrect set limit Verify limit is set cor-

Material supply pressure is too low

Failed transducer Check transducer;

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 valve mode settings

Purchase meter enabled token for FCM and install flow meter

Check for FCM key token error

Check automation programming per job operating instruction

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

sary

rectly

Decrease material supply pressure

replace if necessary

rectly

Decrease material supply pressure

replace if necessary

rectly

Increase crease material supply pressure

replace if necessary

rectly

Increase material flow rate

Dislodge and inspect needle

Repair dispense valve

Repair regulator

Increase pump pressure

replace if failed

3A2098S 75

Errors

Event

Code

P3C_ P4C_

F1D_ F2D_

F3D_ F4D_

EKD_ 73 Shot Terminated

EHD_ 74 Purge Timer

EAC_ 75 Maintenance

EBC_ 76 Maintenance

MHD_ 77 Maintenance

MFD_ 78 Maintenance

Gateway

Error No. Event Name

70 High Pressure Measured outlet pres-

71 Low Flow Rate Measured flow rate less

72 High Flow Rate Measured flow rate

by Job Timer

Expired

Mode Entered

Mode Exited

Due - Regulator

Due - Flow Meter

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Alarm or sure greater than desired outlet pressure plus tolerance

than desired flow rate minus tolerance

greater than desired flow rate plus tolerance

Shot dispense cycle terminated by job timer

Purge timer expired Advisory PCF purge timer (style

Maintenance mode entered

Maintenance mode exited

Maintenance due for regulator

Maintenance due for flow meter

Deviation

(user select-

able)

Alarm or

Deviation

(user select-

able)

Alarm or

Deviation

(user select-

able)

Advisory Job end timer was

Advisory

(self-clearing)

Advisory

(self-clearing)

Advisory Totalizer exceeded

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 error time

Operating below minimum regulator operating pressure

Regulator worn or not operating correctly

Flow meter providing false pulses

Incorrect flow error tolerance or flow error time

used to stop shot dispense

0) has expired

Entered maintenance dispense mode

Exited maintenance dispense mode

limit setting

Clean/replace hose/device

replace if failed

Repair regulator

Increase fluid supply pressure or check for clogged filter

Turn on air to solenoid valves

sor

on pumps

Enter correct tolerance or flow error time

Increase fluid pressure above regulator minimum

Repair regulator

Replace flow meter sensor

Enter correct tolerance or flow error time

No action required if timed shot is desired

Automation control requests purge

No action required

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

76 3A2098S

Errors

Event

Code

MED_ 79 Maintenance

MCD_ 80 Maintenance

MD1_ 81 Maintenance

MD2_ 82 Maintenance

MD3_ 83 Maintenance

MD4_ 84 Maintenance

CCD_ 85 Duplicate Module Duplicate Fluid Control

EAD_

WFC_

CR1_

CR2_

Gateway

Error No. Event Name

Due - V/P

Due - Supply

Due - Valve 1

Due - Valve 2

Due - Valve 3

Due - Valve 4

86 Swirl Mainte-

nance Mode Entered

87 Shot No-Flow

Timeout

88 Valve 1 Swirl

Communication Error

89 Valve 2 Swirl

Communication Error

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Maintenance due for Voltage to Pressure Transducer

Maintenance due for supply system

Maintenance due for valve 1

Maintenance due for valve 2

Maintenance due for valve 3

Maintenance due for valve 4

Module Detected

Swirl maintenance mode entered

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

Fluid plate communication error with swirl

Advisory Totalizer exceeded

limit setting

Advisory Totalizer exceeded

limit setting

Advisory Totalizer exceeded

limit setting

Advisory Totalizer exceeded

limit setting

Advisory Totalizer exceeded

limit setting

Advisory Totalizer exceeded

limit setting

Alarm Two or more FCMs

have the same rotary switch setting

Advisory (self-clearing)

Alarm Dispense valve not

Alarm The fluid plate lost

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

operating properly

Fluid leak Check fluid connec-

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

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Service component

If necessary, reset totalizer

Verify that all FCMs have proper rotary switch settings. Reset module after changing rotary switch setting. Refer to Fluid Plate Assembly Overview section, page 17

No action required

Check dispense valve for correct operation and/or clogging

tions

Restore communications.

3A2098S 77

Errors

Event

Code

CR3_ 90 Valve 3 Swirl

CR4_

WD1_

WD2_ 93 Valve 2 Swirl

WD3_ 94 Valve 3 Swirl

WD4_

MB1_ 96 Maintenance due

MB2_

MB3_

MB4_

Gateway

Error No. Event Name

Communication Error

91 Valve 4 Swirl

Communication Error

92 Valve 1 Swirl

Fault

95 Valve 4 Swirl

Fault

- V1 Orbiter

97 Maintenance due

- V2 Orbiter

98 Maintenance due

- V3 Orbiter

99 Maintenance due

- V4 Orbiter

Event

Description Event Type Cause Solution

Fluid Plate Events and Errors

Fluid plate communication error with swirl

Swirl motor fault Alarm or

Maintenance due on valve 1 swirl orbiter

Maintenance due on valve 2 swirl orbiter

Maintenance due on valve 3 swirl orbiter

Maintenance due on valve 4 swirl orbiter

Alarm The fluid plate lost

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

Alarm The fluid plate lost

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

The swirl zone associDeviation (user-selectable)

Deviation (user-selectable)

Advisory The active time total-

ated with this valve

and fluid plate caused

a fault

The swirl zone associ-

ated with this valve

and fluid plate caused

a fault

The swirl zone associ-

ated with this valve

and fluid plate caused

a fault

The swirl zone associ-

ated with this valve

and fluid plate caused

a fault

izer for the swirl dis-

penser associated

with this valve and

fluid plate exceeded

limit setting

izer for the swirl dis-

penser associated

with this valve and

fluid plate exceeded

limit setting

izer for the swirl dis-

penser associated

with this valve and

fluid plate exceeded

limit setting

izer for the swirl dis-

penser associated

with this valve and

fluid plate exceeded

limit setting

Restore communications.

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

Service Component

If necessary, reset totalizer

Service Component

If necessary, reset totalizer

Service Component

If necessary, reset totalizer

Service Component

If necessary, reset totalizer

78 3A2098S

Swirl Events and Errors

Errors

Event

Code

CBR_

CDR_

EAD_

EBD_ --- Maintenance

MBD_ --- Maintenance

WBD_

Gateway

Error No. Event Name

--- Swirl Communication Error

--- Duplicate Module Duplicate Swirl Control

--- Maintenance Mode Entered

Mode Exited

Due - Orbiter

--- Swirl Motor Fault Motor speed is outside

Event

Description Event Type Cause Solution

Swirl Events and Errors

Swirl communication error with ADM

DGM Detected

Maintenance mode entered

Maintenance mode exited

Maintenance due on swirl orbiter

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

Alarm The ADM lost commu-

nication with the Swirl Control DGM

Alarm Two or more Swirl

Control DGMs have the same rotary switch setting

Advisory (self-clearing)

Advisory Swirl active time total-

Alarm Cable disconnected Verify cable connec-

Swirl maintenance mode entered

Swirl maintenance mode exited

izer exceeded limit setting

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

Orbiter bearing failure Replace bearing

Motor defective Replace swirl orbiter

Restore communications

Verify that all Swirl Control DGMs have proper rotary switch settings. Reset module after changing rotary switch setting. Refer to Swirl Control DGM section, page 22.

No action required

Service Component

If necessary, reset totalizer

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

Replace swirl motor cable (55 ft)

3A2098S 79

Maintenance

Prior to performing any maintenance procedures, follow the Pressure Relief Procedure on page 61.

Maintenance Schedule

The following tables list the recommended maintenance procedures and frequencies to operate the equipment safely. The maintenance is divided between mechanical and electrical tasks. Maintenance must be performed by trained personnel per this schedule to assure safety and reliability of the equipment.

Mechanical

Operator Maintenance Person

Task Daily Weekly Monthly

Inspect system for leaks Depressurize fluid, after opera-

tion Remove heat from system,

after operation

Inspect filter (234967) bowls and drain

Check hoses for wear Check/tighten fluid connections 

Check/tighten air connections 

Lubricate dispense valves*

Rebuild regulator*

Rebuild dispense valve*

Replace air filter

Replace Solenoid

Replace Voltage to Pressure (V/P) Transducer

* Check component manual for more detailed maintenance information.



3-6

months

125,000

cycles



18-24

months

500,000

cycles



36-48

months

1,000,000

cycles



7000

hours



Electrical

Task Weekly

Check cables for wear

Verify cable connections

Verify operation of “System Stop” button

* Check Component Manual for more detailed maintenance information.

80 3A2098S



Maintenance

r_24E451_3B9900_3a

Access Panel

Token

r_24E451_3B9900_4a

TI12319A

Access Cover

TI12320A

Token

Press Button

Advanced Display Module (ADM)

Upgrade Software (16K743)

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

before upgrading software. See USB Data, page 63, 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).

Upgrade Gateway Module Software (16K743)

NOTE: The Gateway module connection to the system

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

1. Turn off power to the system.

2. Remove the access cover.

IG. 44: Remove Access Panel

3. Insert and press software token firmly into slot.

NOTE: There is no preferred orientation of token.

IG. 45: Insert Token

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

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

6. Remove software token.

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

FIG. 46: Remove Access Cover

3. Insert and press token firmly into slot.

NOTE: There is no preferred orientation of token.

4. Press and hold the button shown in F second, then release. The red indicator light (CK)

will flash until new software is completely loaded.

IG. 47: Insert Token

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

6. Remove token.

IG. 47 for ~1

Cleaning

7. Replace access cover.

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

3A2098S 81

Maintenance

Access Cover

TI12319A

Token

TI12320A

Push Button

Upgrade Gateway Module Fieldbus Map (16N601 or 17P799)

NOTE: The fieldbus connection is temporarily disabled

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

1. Perform Upgrade Gateway Module Software (16K743). Software must be upgraded before upgrading the fieldbus map.

2. Remove the access cover.

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

map is uploaded.

FIG. 49: Insert Token

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

IG. 48: Remove Access Cover

3. Insert and press map token firmly into slot.

NOTE: There is no preferred orientation of the token.

6. Replace access cover.

82 3A2098S

Maintenance

TI12334A

Access Cover

Token

TI12335A

Press Button

Upgrade Fluid Control Module (FCM) Software (16K743)

NOTE: The FCM connection is temporarily disabled

during the use of the upgrade token.

1. Turn off power to the system.

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

7. Reinstall blue key token, and replace access cover.

Air Filter Maintenance

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

Replacement Air Filters for Dual Filter Assembly (234967)

Part Description

123091 5 micron air filter 123092 0.3 micron air filter

Swirl Dispensers

See manual 309403 for maintenance schedule.

IG. 50: Remove Access Cover

3. Insert and press software token firmly into slot.

NOTE: There is no preferred orientation of token.

4. Press and hold the button shown in F second, then release. The red indicator light (CK) will flash until new software is completely loaded.

IG. 51: Insert Token

IG. 51 for ~1

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

6. Remove software token.

3A2098S 83

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 61.

3. Remove the fluid plate assembly shroud. See Fluid

Plate Assembly Parts, page 98.

Repair Flow Meter

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

NOTE: The Coriolis flow meter is not field repairable.

Remove Flow Meter from Mounting Plate

1. Prepare Fluid Plate Assembly for Repair, page

84.

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. 52.

FIG. 52: Fluid Plate Assembly

84 3A2098S

Repair

r_pf0000_313377_34a

129

108

125

124

126

127

109

137

132

118

r_pf0000_313377_33a

122

121

118

r_pf0000_313377_31a

Install Flow Meter on Mounting Plate

NOTE: The Coriolis flow meter does not mount to the

fluid 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. 52.

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

FIG. 54

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

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

IG. 53

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 84.

2. Disconnect FCM cable and all three air tubes.

Replace Voltage to Pressure (V/P) Transducer

1. Prepare Fluid Plate Assembly for Repair, page

84.

2. Disconnect the FCM cable and both air tubes.

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

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

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

IG. 55

3A2098S 85

Repair

128

121

118

132

r_pf0000_313377_30a

102

103

106

105

103

102

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

6. Reconnect the FCM cable and both air tubes.

Replace Fluid Control Module

1. Prepare Fluid Plate Assembly for Repair, page

84.

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

Replace Fluid Control Module Base

1. Prepare Fluid Plate Assembly for Repair, page

84.

2. Remove the FCM (103); follow Replace Fluid Control 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. 56

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 transducer bracket using screws.

FIG. 57

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.

86 3A2098S

Replace Transducer O-Rings

117

108

r_pf0000_313377_16a

120

1. Prepare Fluid Plate Assembly for Repair, page

84.

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

Repair

IG. 58

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

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

IG. 59

5. Press the transducer back into the retainer nut.

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

3A2098S 87

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. 60 and perform the following steps.

NOTICE

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

1. Prepare Fluid Plate Assembly for Repair, page 84.

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. 60: Replace Cartridge Assembly

88 3A2098S

Repair

117

116

Screw

Power Output Cable

Replace Amplifier

(Heated fluid plates only)

1. Prepare Fluid Plate Assembly for Repair, page

84.

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

IG. 61: Replace Amplifier

Adjust Display Settings

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

4. Press to scroll to Advanced screen 2.

5. Press to access the fields to make changes.

6. Press to move the Pressure Units field. Press

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

Press to enter the new units.

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

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

5. Remove amplifier and replace with a new amplifier.

6. Secure new amplifier to bracket with four screws.

7. Replace amplifier cover and tighten screws.

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

Calibrate Amplifier

(Heated fluid plates only)

1. Prepare Fluid Plate Assembly for Repair, page

84.

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

7. Press to exit edit mode.

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

9. Press to access the fields to make changes.

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

psi to 0. Press to enter the new setting.

3A2098S 89

11. Press to exit edit mode.

Repair

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

Excitation Selector

Coarse Zero

Fine Zero

Fine Gain

Coarse Gain

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

To Transducer

To Readout

Adjust Amplifier Settings

12. Remove cover from amplifier (116). See Replace Amplifier, page 89.

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

IG. 62 on page 90.

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

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

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

EXCITATION MODULE

(+)SUPPLY

(-)OUTPUT

SUPPLY RETURN

(+)OUTPUT

SHUNT CAL

ENABLE

1 2

3 4 5 6

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

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

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

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

TRANSDUCERPOWER

A B

C D E F

(+)EXCITATION

(-)EXCITATION

(+)SIGNAL

(-)SIGNAL

SHUNT CAL

RESISTOR

EX SEL

10 VDC

5 VDC 3 VDC

FIG. 62: Amplifier Settings

21. Replace the amplifier cover. See Replace Amplifier, page 89.

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

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

ZERO

COARSE

SPAN

12345678

FINE

COARSE

90 3A2098S

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 91.

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 91.

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. 64

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

6. Reattach Gateway module; follow Replace Gate-

FIG. 63

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

5. Reconnect the automation interface cable.

6. Upgrade software, page 81, then upgrade fieldbus map, page 82.

3A2098S 91

way Module.

Repair

11, 14, 24

Replace Swirl Board 16K570:

1. Prepare Control Center for Repair, page 91.

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

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

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

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

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

Replace Advanced Display Module

1. Prepare Control Center for Repair, page 91.

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

FIG. 66

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

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

5. Connect the CAN cable to the new ADM.

IG. 65

6. Upgrade new ADM software, page 81.

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

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

92 3A2098S

Repair

Replace Advanced Display Module Bracket

1. Prepare Control Center for Repair, page 91.

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

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

Replace DIN Rail Assembly

1. Prepare Control Center for Repair, page 91.

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

FIG. 68

IG. 67

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

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

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

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

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

6. Reinstall the ADM.

3A2098S 93

Repair

r_pf0000_313377_10a

Fuses

r_pf0000_313377_10a

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.

IG. 69: 24 Vdc Din Rail Assembly

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

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

Replace Fuses

Replace fuses on the din rail assembly.

• For 24 Vdc control centers: see Technical Data

on page 148 for fuse specifications.

• For 100-240 Vac control centers: Order fuse

115805.

IG. 70: Fuse Location

94 3A2098S

Parts

Control Centers

Software Upgrade Tokens

Refer to the Software Upgrade Tokens table on page

10.

Control Center Key Token Part Numbers

See Key Tokens on page 23 for more information about key tokens.

Part Description

16M217 ADM Key Token, Standard PCF

Gateway Module Part Numbers

Parts

User

PCF

Model

PFxx0x Discrete 24B681

PFxx1x

PFxx2x Ether-

PFxx3x PROFI-

PFxx4x



Parts included with 24 Vdc Module kit 24B929.

* Fieldbus Gateway modules do not have a PCF-specific map installed. Use map token (16N601) to install map before use.

Interface

Description

DeviceNet

™

Net/IP

™

BUS

PROFINET

Gateway Part

™

Number To

Order

15V759

15V760

15V761

15V762

3A2098S 95

Parts

5 or 43

241114

6,10

23,27

24 VDC units only: 15,36

100-240 VAC units only: 6,36

3,4,12,16

Ground/

Green

Neutral/

Blue

Line/

Brown

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

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

Control centers only. Not included in expansion swirl enclosures.

100-240 Vac models only.

Control Center and Expansion Swirl Enclosure Parts

96 3A2098S

Control Center Assembly Parts

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 on

page 95 for part number

6‡ --- SUPPLY, power 1 7‡ --- COVER, line voltage 1 8‡ --- GROMMET 1 9‡ 196548 LABEL, warning, electric shock 1 10‡ --- SCREW, cap, socket hd; m4 x 6 4 11 --- WASHER, lock 1 12 121820 SCREW, mach, pan hd; m4 x 35 1 13 121807 CONNECTOR, splitter 1 14 110755 WASHER, plain 1 15‡ --- MODULE, line voltage 1 16 195875 SCREW, mach, pan hd 4 18 121001 CABLE, CAN, female / female 1.0m 1 19 125789 CABLE, CAN, female / female 0.5m 1 20 --- COVER, front 1 21 --- BRACKET, mounting 1 22‡ --- SCREW, mach, pan hd 2 23 120143 GUIDE, strain relief 2 24 121253 KNOB, display 2 25 --- CLIP, speed, tubular 2 26 --- RIVET, aluminum 1 27 112925 SCREW, cap 2 28 100020 WASHER, lock 2 36 121901 SUPPRESSOR, box snap, ferrite 2 37 124654 CONNECTOR, splitter 1

Ref. Part Description

38 --- LABEL 1 40 110637 SCREW, mach, pan hd 4 43 24B681 MODULE, DGM 1 44 --- GUARD, edging 1 45 16K570 BOARD, circuit, swirl 1

46 --- BRACKET, display pivot 1 47 --- COVER, swirl, hinge side 1 48 --- COVER, swirl, latch side 1 49 --- COVER, swirl, lid 1 50 24K455 CABLE, swirl board, panel mount 1 51 24K458 CABLE, SWIRL-DGM 1 52 121597 CABLE, CAN, 90 female/90 female 1

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

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

 Parts included with 24 Vdc Module kit 24B929.

 Parts included with Display Mounting Bracket kit

24B930.

 Base electronic components do not have

PCF-specific software installed. Use software upgrade token (16K743) to install software before use.

* Fieldbus Gateway modules do not have a

PCF-specific map installed. Use map token (16N601) to install map before use.

--- Not for sale.

Qty

3A2098S 97

Parts

101

143

142

152

131

153

151

135, 136

199

117, 120

Fluid Plate Assembly Parts

98 3A2098S

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

3A2098S 99

Parts

111

141

113

112

113

112

127

114

108

115

117

108

105, 116

Fluid Plate 24B962

149

140, 141, 150

158

139

107

148

145

Shown

159

160

199

ti19262a

119

Fluid Plate Assembly Parts (continued)

100 3A2098S

Graco PrecisionSwirl, PCF Instructions-parts List Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Models

Fluid Plate Kits

Control Panel Kits

Expansion Swirl Enclosure Assemblies

PrecisionSwirl Orbital Dispenser Assemblies

Automation Gateway Assemblies

Swirl Control DGM

Integration Upgrade with Advanced Map

Warnings

System Configurations

Typical Installation - Single Swirl, Single Fluid Plate

Typical Installation - Multiple Fluid Plates, No Swirl Dispensers

Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers

Overview

System Overview

System Components

Fluid Plate Assembly Overview

Control Center Assembly Overview

Key Tokens

Installation

Before Installation

Overview

Install Control Center

Install Fluid Plate Assemblies

Install Cable Assemblies

Install Gateway Module Interface

System Setup

Overview

Configure System

Configure Control Settings

Configure Mode Settings

Configure Delay Settings

Configure Flow Meter Settings

Configure Pressure Loop Settings

Adjust Pressure Sensors

Configure Errors

Setup Maintenance Schedule/Parameters

Configure Valve to Swirl Association and Motor Error Type

Configure Swirl Settings

Configure Gateway Settings

Setup Styles

Configure Advanced Settings

On/Off Delays

Operation

Startup

Load Material

Maintenance Mode Operation

Automation Control (Normal Operation)

Jobs

Styles

Precharge Modes

Typical Job Cycle

Pressure Relief Procedure

Shutdown

USB Data

USB Logs

System Configuration Settings File

Custom Language File

Download Procedure

Upload Procedure

Troubleshooting

Fluid Plates

Flow Meter

Fluid Regulator

Dispense Valves

Gateway Module

LED Diagnostic Information

Errors

View Errors

Diagnose Errors

Event and Error Codes and Troubleshooting

Maintenance

Maintenance Schedule

Advanced Display Module (ADM)

Upgrade Gateway Module Software (16K743)