PVA PVA2000, PVA3000, PVA2000C, PVA250, PVA750 System Manual
...
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Coating and Dispensing
System Manual
- PVA2000
- PVA3000
- PVA2000C
- PVA750
- PVA550
- PVA250
info@pva.net
(518) 371-2684
15 SOLAR DRIVE - HALFMOON, NY 12065
PHONE: (518) 371-2684 - FAX: (518) 371-2684
All Rights Reserved, Copyright (c) 2003 Precision Valve & Automation, Inc.
PVA250
P/N: SNGT1133 S/N: W1948
Singletec, Inc.
TM
Operating Guide
Automated Dispensing System
15 Solar Drive – Halfmoon, NY 12065
Table Of Contents
Configuration
1
Operation and Maintenance Manual
2
PathMaster® Manual
3
4
5
6
Cut Sheets
Schematics
Software
Configuration
Configuration
1
Operation and Maintenance Manual
PathMaster® Manual
Cut Sheets
Schematics
Software
Configuration
W1948
3.04
2.3.49
3/05
120 Vac, 60 Hz, 5 Amps
10 kA
REG-1
Main air pressure
90 P.S.I. +/- 10 P.S.I
REG-2
Pump Air Motor Pressure
60 P.S.I. +/- 10 P.S.I
REG-3
Material Regulator Pressure
Customer Determined
REG-4
Regulator Output Pressure
Customer Determined
REG-5
Pail Pump Elevation Press.
15 P.S.I. +/- 5 P.S.I.
1
FC100
Dispense Valve
No
No
Notice
This document, including the information contained herein, is the property of Precision Valve &
Automation, Inc. and is considered confidential and proprietary information. It is delivered on the
express condition that it not be used, disclosed, or reproduced in whole or in part, for any reason without
prior written consent of Precision Valve & Automation, Inc.
Machine Specifics
Serial Number:
Program Revision:
PathMaster® Version:
Date of Ship:
Power Requirements
Electrical Rating:
Interrupting Capacity:
Pressure Settings
Regulator Description Setting
Valve Nomenclature
Head # Name Description Z-slide Rotary
Table 1 – Pressure Settings
Table 2 – Valve Nomenclature
Workcell Configuration
- 1 -
Optional Equipment
Select Optional Equipment
Documentation on non-Standard equipment installed on the workcell is included with this
manual. To view these documents click the button below.
Notes
Operation and Maintenance
Configuration
Operation and Maintenance Manual
2
PathMaster® Manual
Cut Sheets
Schematics
Software
Operation and Maintenance Manual
Warnings, Cautions, and Notes
Certain warning symbols are affixed to the machine and correspond to notations in this manual. Before
operating the workcell, identify these warning labels and read the notices described below. Not all labels
may be used on any specific system.
Always wear approved safety glasses when operating or working near the
workcell.
6040
In situations where inattention could cause either personal injury or
damage to equipment a warning notice is used.
6014
Do not smoke near the workcell. Always have a fire extinguisher
available for emergency use.
6019
Before operating the system, read and understand the manuals provided
with the unit.
6017
Before performing any repairs or maintenance to the system, turn off
power and lock out the power disconnect switch.
6011
Never place hands or tools in areas designated by this symbol when the
machine is in operation. A dangerous condition may exist.
6008
Warning notices are used to emphasize that hazardous voltages, current,
temperatures, or other conditions that could case personal injury exist in
this equipment or may be associated with its use. Only qualified
personnel should enter areas designated with this symbol.
6010
Before performing any repairs or maintenance to the system, read and
understand the manuals provided with the unit. Service should only be
performed by a qualified individual.
6018
Exercise caution when pressurized vessels are present. Identify and
repair any leaks immediately. Always wear appropriate safety equipment
when working with pressurized vessels or vessels containing chemicals.
6054
Laser light source present. Do not stare directly into the beam. Do not
use in the presence of highly reflective surfaces.
6003
Pinch hazard from moving parts. Avoid contact.
1012
Shear hazard from moving parts. Avoid contact.
1099
Hot surface. Avoid contact.
6043
Do not remove protective guarding.
6060
This document is based on information available at the time of its publication. While efforts have been
made to be accurate, the information contained herein does not purport to cover all details or variations in
hardware or software, nor to provide for every possible contingency in connection with installation,
operation, or maintenance. Features may be described herein which are not present in all hardware and
software systems. Precision Valve & Automation, Inc. assumes no obligation of notice to holders of this
document with respect to changes subsequently made.
Precision Valve & Automation, Inc. makes no representation or warranty, expressed, implied, or statutory
with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of
the information contained herein. No warranties of merchantability or fitness for purpose shall apply.
This document, including the inform ation contained herein, is the property of Precision Valve &
Automation, Inc. and is considered co nfidential and proprietary information. It is delivered on the
express condition that it not be used, disclosed , or reproduced in whole or in part, for any reason without
prior written consent of Precision Valve & Automation, Inc.
Copyright © 2003 Precision Valve & Automation, Inc.
All Rights Reserved.
Preface
Notice & Disclaimer
This manual applies to one of the following automated workcells produced by Precision Valve &
Automation, Inc.:
o PVA250™
o PVA550™
o PVA750™
o PVA1000™
o PVA2000™
o PVA200C™
o PVA3000™
All machines are refere nced t hroughout the manual as the workce ll. T his manual pr ovide s informat ion and
functionality descriptions covering all the common options and configurations for a workcell. The
particular machine associated with this manual may not contain all items or may have additions. If the
manual refers to an option that was not purchased, ignore that section. If options exist on the machine not
mentioned in this manual, please consult the Optional Equipment section of the Operating Guide for more
information on these additions.
Revisions to This Manual
The following list describes the major revisions in this manual (Rev M (ii) (4/03)) as compared to the
previous versi on:
o Rewrite for latest program revisions (3.01 & 3.02 & 3.03 & 3.04).
o Altered Power Check procedure and added Door Interlock Check procedure.
o Added compatibility for the PVA250™, PVA2000C™, solvent cups, flow monitor, and teach pendant.
2/10/03 TMB
o Updated Power Check procedure. 2/10/03 TMB
o Added PVA750™ references. 8/1/03 TMB
Operation and Maintenance Manual Rev M(ii) 4/03
- iv -
Content of This Manual
Introduction. Provides an overview of the workcell functionality and physical characteristics.
Installation and Setup. Describes the procedures for installing the workcell and preparing the system for
use. Included in this chapter are instructions for unpacking, inspecting, and installing the workcell.
Operating Safety. Basic safety practices are reviewed. The safety devices and guarding for the workcell
are described.
Operation. Describes system operations of the workcell. It includes a discussion of the system power-up
and power-down sequences and modes of operation.
Troubleshooting. Provides a guide to troubleshooting the workcell. A fault diagnosis table is used to lead
the operator through common problems and sol ut i ons. Several troublesho oting procedures are described.
Maintenance. Provides a preventive maintenance schedule and replacement procedures.
Appendix A – Definitions. Definitions for commonly used terms.
Appendix B – Serial Communication. A brief overview of establishing communication with the workcell.
Appendix C – Error Codes. A list of error codes that may be encountered while using the workcell.
Appendix D – Open Loop Velocity Settings. A list of maximum velocity settings for an open loop drive
system.
Appendix E – Wiring Schema tic Legend. A l egend for t he number ing and c olo r c odi ng used i n the co ntro l
enclosure for the workcell.
Operation and Maintenance Manual Rev M(ii) 4/03
- v -
Contents
Table Of Contents
Preface ......................................................................................................................................... iv
Notice & Disclaimer............................................................................................................................. iv
Revisions to This Manual .....................................................................................................................iv
Content of This Manual......................................................................................................................... v
Contents....................................................................................................................................... vi
Table Of Contents................................................................................................................................. vi
List of Tables........................................................................................................................................ix
Introduction................................................................................................................................10
System Description..............................................................................................................................10
Year 2000 Compliance................................................................................................................. 10
Environmental......................................................................................................................................11
Noise Levels................................................................................................................................. 11
Materials/Chemicals..................................................................................................................... 11
Hazards Due to Contact................................................................................................................11
Handling, Transportation and Storage................................................................................................. 11
Handling and Transportation........................................................................................................ 11
Storage..........................................................................................................................................11
Installation and Setup................................................................................................................ 12
Unpacking and Inspection....................................................................................................................12
Installation...........................................................................................................................................12
Operating Environment........................................................................................................................ 13
Location........................................................................................................................................13
Temperature and Humidity........................................................................................................... 13
Dip Switch Settings..............................................................................................................................13
Operator Interface Dip Switch Settings ............................................................................................... 14
Software............................................................................................................................................... 14
Main program file.........................................................................................................................14
PathMaster®.................................................................................................................................14
Project File ................................................................................................................................... 14
Machine Communications ................................................................................................................... 14
SMEMA ....................................................................................................................................... 14
Operating Safety ........................................................................................................................ 16
Notices and Warnings.......................................................................................................................... 16
Safety Devices and Guarding............................................................................................................... 16
Safety Circuit................................................................................................................................ 16
Lexan Guarding............................................................................................................................ 16
Doors............................................................................................................................................16
Light Curtain.................................................................................................................................17
Exhaust Fan.................................................................................................................... .............. 17
Operation .................................................................................................................................... 18
Startup Procedure.................................................................................................................................18
Operation and Maintenance Manual Rev M(ii) 4/03
- vi -
Light Tower Operation........................................................................................................................ 18
Exhaust Verification............................................................................................................................ 18
Machine Safety Check.........................................................................................................................19
Homing the Axes ................................................................................................................................. 19
Standby Position.................................................................................................................................. 20
Solvent Cups ........................................................................................................................................20
Flow Monitor System...........................................................................................................................20
Priming the Flow Monitor ............................................................................................................ 20
Determining the Correct Material Volume...................................................................................21
Setting the Material Volume Check..............................................................................................21
Auto Cycle Flow Error ................................................................................................................. 21
Flow Monitor Calibration.............................................................................................................22
Flow Control Mode.......................................................................................................................22
Calibration Procedures......................................................................................................................... 23
Standard Needle Calibration......................................................................................................... 23
Operator Defined Needle Calibration...........................................................................................23
Sensor Defined Needle Calibration.............................................................................................. 23
Shutdown Procedure............................................................................................................................23
Cycle Stop............................................................................................................................................ 24
Program Selection................................................................................................................................ 24
Needle Calibration............................................................................................................................... 24
Standard........................................................................................................................................25
Operator Defined.......................................................................................................................... 25
Sensor Defined .............................................................................................................................25
Manual Mode....................................................................................................................................... 26
Valve Selection....................................................................................................................................27
Automatic Mode.................................................................................................................................. 27
Status Mode......................................................................................................................................... 28
Status Sequence................................................................................................................................... 28
Setup Mode.......................................................................................................................................... 29
Conveyor Control................................................................................................................................29
Trackball Control................................................................................................................................. 30
Teach Pendant...................................................................................................................................... 31
OIT Jog Control................................................................................................................ ................... 31
Fault Recovery..................................................................................................................................... 33
Recovering from Emergency Stop and Other Machine Errors......................................................33
Pneumatic Error Recovery Procedure........................................................................................... 34
Run-Time Error Recovery Procedure........................................................................................... 35
Position Error Recovery Procedure.............................................................................................. 35
Limit Error Recovery Procedure................................................................................................... 36
Stop Codes.................................................................................................................................... 36
Startup Errors................................................................................................................................36
Subroutine Error........................................................................................................................... 37
Troubleshooting......................................................................................................................... 38
If Something Goes Wrong . . . .............................................................................................................38
Calling Technical Support............................................................................................................38
Fault Diagnostic...................................................................................................................................38
Closed Loop Servo Systems......................................................................................................... 38
Open Loop Stepper Systems...................................................................................................... ... 41
Controller Master Reset.......................................................................................................................44
Request Controller Version..................................................................................................................44
EEPROM Upgrade Procedure............................................................................................................. 44
Power Check........................................................................................................................................ 45
Operation and Maintenance Manual Rev M(ii) 4/03
- vii -
Door Interlock Check...........................................................................................................................46
Encoder Feedback Test........................................................................................................................ 46
Motor Feedback Test........................................................................................................................... 47
Maintenance ............................................................................................................................... 48
Schedule............................................................................................................................................... 48
Procedures ........................................................................................................................................... 50
Ball Screw Slides.......................................................................................................................... 50
Inspection .....................................................................................................................................50
Conveyor Belt Replacement......................................................................................................... 50
Valves...........................................................................................................................................50
Servicing the Inline Material Filter............................................................................................... 50
Exhaust Fan Setup........................................................................................................................ 51
Pressure Differential Switch Setup ...............................................................................................51
Appendix A – Definitions........................................................................................................... 52
Appendix B – Serial Communication....................................................................................... 54
Serial Communication..........................................................................................................................54
Overview ......................................................................................................................................54
9 Pin Serial Connector..................................................................................................................54
25 Pin Serial Connector................................................................................................................54
Computer 9 Pin to workcell Programming Port............................................................................55
Computer 25 Pin to workcell Programming Port..........................................................................55
Appendix C – Error Codes......................................................................................................... 56
DMC Error Codes................................................................................................................................ 56
Appendix D – Open Loop Velocity Settings............................................................................ 58
Maximum Velocity settings................................................................................................................. 58
Appendix E – Wiring Schematic Legend ................................................................................. 59
Wire Numbering.................................................................................................................................. 59
Wire Color Code.................................................................................................................................. 59
Operation and Maintenance Manual Rev M(ii) 4/03
- viii -
List of Tables
Table 1 – DMC-1500 Dip Switch Settings................................................................................................. 13
Table 2 – DMC-2100 Dip Switch Settings................................................................................................. 13
Table 3 – OIT Jumper Settings................................................................................................................... 14
Table 4 – Light Tower & Buzzer Status..................................................................................................... 18
Table 5 – Stop Code Definitions................................................................................................................. 36
Table 6 – PVA550™, PVA1000™, PVA2000™ and PVA3000™ systems Fault Diagnosis.................... 38
Table 7 – PVA250™, PVA750, and PVA2000C Fault Diagnosis............................................................. 41
Table 8 – Preventive Maintenance Schedule.............................................................................................. 48
Table 9 – DTE 9 Pin Serial Connector .......................................................................................................54
Table 10 – DTE 25 Pin Serial Connector ...................................................................................................54
Table 11 – Cable for Computer DB9 to workcell....................................................................................... 55
Table 12 – Cable for Computer DB25 to workcell..................................................................................... 55
Table 13 – DMC Error Codes..................................................................................................................... 56
Table 14 – PVA250™ Velocity Limits........................................................................................................58
Table 15 – PVA750™, PVA2000C™ Velocity Limits.............................................................................. 58
Table 16 – Wire Numbering....................................................................................................................... 59
Table 17 – Wire Color Code....................................................................................................................... 59
Operation and Maintenance Manual Rev M(ii) 4/03
- ix -
Introduction
System Description
The workcell has been designed specifically for applications involving industrial dispensing and conformal
coating. The flexibility of the machine allows it to be used effectively for a wide range of applications.
The valves are mounted to the end effector of a two, three or four axis Cartesian robot. All dispensing /
spraying is performed within the lexan enclosed work area. Limits have been imposed on the axes to
prevent damage to the machine. The dispense / spray path and active heads are controlled by a program
stored in the motion controller. The controller can store and retrieve up to 30 programs.
NOTE: Not all models are equipped with lexan guarding.
The operator interface permits the operator complete control of the machine. This includes machine setup,
manual operation, program selection and automatic operation. Machine status and error messages are
displayed on the LCD screen and via the optional light tower. It is necessary that operator(s) have read or
by training understand the operation of this machine.
Any uses other than listed above could result in a dangerous condition and cannot be protected against by
the safety features installed on the system.
Figure 1 – workcell Functional Block Diagram
Year 2000 Compliance
The workcell is compliant with and comprehends the year 2000 century date change. The workcell will not
have any operational impediments, malfunction, cease to perform, generate incorrect or ambiguous data
and/or produce incorrect or ambiguous results with respect to same-century and multi-century formulas,
functions, date values and date-data interfaces.
Operation and Maintenance Manual Rev M(ii) 4/03
- 10 -
Environmental
Noise Levels
The audible noise level of the workcell is below 65 dBA.
Materials/Chemicals
There are no dangerous materials or chemicals used in the operation of the machine except for the required
application material. The application material should include a Material Safety Data Sheet (MSDS) which
specifies known dange rs and toxicity.
Hazards Due to Contact
The workcell is designed in such a way as to minimize injury from contact with any accessible portion of
the machine. However, under certain modes of operation, it is possible to enter the work area while the
motion platform is under power. Only a qualified person should do this. All hot surfaces are indicated with
a warning label.
Handling, Transportation and Storage
Handling and Transportation
Handling and transportation should be done in such a fashion as to minimize the vibration and shock
introduced to the system. An air-ride tr uck is reco mmended for ro adway transpor t. Although the machi ne
is designed and built to perform in an industrial environment, excessive abuse will greatly impact the
performance of the machine.
Storage
Dust and Debris
All enclosures and connector covers should be closed tightly. It is recommended that a cover be place over
the system if dust or other airborne debris is present in the storage area.
Temperature and Humidity
Storage should be done in an area at 40°F - 105°F (4°C – 41°C) and low humidity. Condensation should
not be allowed to collect on the machine.
Dispensing / Spraying Equipment
Whenever the machine is to be stored for extended periods of time, the workcell should be flushed using a
solvent compatible with the application material. This includes the following systems, if applicable:
o Dispensing valves, spray valves and servo valves.
o Material lines and hoses.
o Pressure vessels.
o Pumping systems.
Operation and Maintenance Manual Rev M(ii) 4/03
- 11 -
Installation and Setup
WARNING The following procedures should be performed by qualified persons in
accordance with this manual and applicable safety regulations. A “ qualified person” is defined as “a
person or persons who, by possession of a recognized degree or certificate or professional training, or
who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to
solve problems relating to the subject matter and work.” (ref. ANSI/ASME B30.2-1983.)
Unpacking and Inspection
1) Remove all packing materials and strapping. Thoroughly inspect the exterior of the machine for
damage, loose fasteners, etc. Gently move the X & Y axis slides to the center of the work area.
2) At the rear of the machine, inspect all tubing connections, gauges, and regulators.
3) Open the electrical enclosure and visually inspect connectors and components for vibration during
shipping. Close the door, as the machine should not operate with the doors open (All accept .
4) Reinstall the Light tower.
5) Reinstall flow monitor. The flow monitor is typically mounted on the rear of the workcell.
6) Reinstall the main air regulator assembly.
NOTE: Step 3 does not apply to PVA250™ models.
Installation
1) Plug the machine into an appropriate power source as determined by the Machine Specific Information
section of the Operating Guide or the legend plate on the rear of the machine. The electrical service
should be properly grounded, and the power source “clean”. If there is high power equipment
operating off the same source, a line conditioner may be necessary. Errors in machine operation could
indicate poor quality power.
WARNING Failure to comply with electrical specifications can result in damage to the
machine as well as injury to installa tion personnel. Electrical hookup must be made by a qualified
electrician and must comply with any applicable local standards.
2) A ¼” NPT female fitting is provided at the rear of the machine (PVA250™ models have a ¼” quick
disconnect fitting). Connect to a source of clean, dry air. A hose of ¼” inside diameter is sufficient.
3) Ground any pressure vessel to earth or the machine. NOTE: Precision Valve & Automation
STRONGLY recommends the machine not be powered on or material added to the pressure vessels
until they are properly grounded.
4) Close any access doors and push in the EMERGENCY STOP button. At the rear of the machine, turn
on the red air lockout valve (PVA250™ models are not equipped with an air lockout).
5) T urn on power at the red handled switch on the front or rear of the machine (PVA250™ models have a
black “rocker” switch on the rear next to the power cord).
Operation and Maintenance Manual Rev M(ii) 4/03
- 12 -
Operating Environment
Location
The machine should be installed on a level surface away from standing water, possible overspray and
overhead leaks.
Temperature and Humidity
The machine should be operated in an area at 40°F - 105°F (4°C – 41°C) and low humidity. Condensation
should not be allowed to collect on the machine.
Dip Switch Settings
NOTE: During normal operatio n there is no need to adjust the dip switch setting s. If communicatio ns
between the computer and the controller are not reliable, lower the baud rate on both until
communications are satisfactory.
The main RS-232 port on the motion controller must be configured as follows to communicate with the host
computer:
Table 1 – DMC-1500 Dip Switch Settings
Switch Position Description
MRST OFF Master Reset
1200 OFF Baud rate selection
9600 OFF Baud rate selection
19.2K ON Baud rate selection
HSHK ON Hardware Handshaking
(PVA550™, PVA1000™, PVA2000™, and PVA3000™ models)
Table 2 – DMC-2100 Dip Switch Settings
Switch Position Description
MRST OFF Master Reset
XON OFF Software Handshaking
HSHK ON Hardware Handshaking
9600 OFF Baud rate selection
19.2K ON Baud rate selection
38.4K OFF Baud rate selection
OPT OFF Hardware Option
ENET OFF Use Ethernet port as default for
Unsolicited messages.
(PVA250™, PVA750™, PVA2000C models)
CAUTION If hardware handshaking is enabled, the program uses the message command
and a computer is not attached to the Main RS-232 port, the controller eventually halts.
program included with this machine does not contain any message statements.
The
Operation and Maintenance Manual Rev M(ii) 4/03
- 13 -
Operator Interface Dip Switch Settings
NOTE: During normal operation there is no need to adjust the dip switch settings.
The operator interface must be configured to communicate with the controller. The correct settings are
given in the table below. These setting enables 9600 baud, 7 data bits, 1 stop bit and 1 start bit.
Table 3 – OIT Jumper Settings
Jumper Setting
E1 A
E2 A
E3 B
E4 B
E5 A
E6 B
Software
The complete workcell software package consists of several items. To avoid problems and
miscommunication, it is imperative every operator understand what each piece of software is and its
purpose. For more information about PathMaster® and its features, please consult the separate
PathMaster® Manual in the Operating Guide.
Main program file
A text file containing the code that runs the workcell. Under normal circumstances it is not necessary to
change this file, but if needed it can be opened and edited with any text editor, such as Microsoft® Notepad
or Word. The Main program file is downloaded via a drop-down menu in PathMaster® but it should
NEVER be opened within the PathMaster® software.
PathMaster®
Precision Valve & Automation’s Windows®-based programming software. It is used to create, maintain
and download project files for the workcell. The Operating Guide has a separate section on using
PathMaster® to program the workcell.
Project File
A text file containing the code for one or more programs. In almost all cases this file is created within
PathMaster®. This file is downloaded using PathMaster®.
Machine Communications
For manufacturing lines (multiple machines utilizing conveyor systems) it is necessary for the individual
modules to communicate reliably. Therefore, the SMEMA cables must be connected in the correct manner.
NOTE: On the diagrams the J# refers to the label on the machine, not the label on the cable.
SMEMA
The Surface Mount Equipment Manufacturers Association (SMEMA) Electrical Equipment Interface
Standard is used to insure proper sequencing of boards. If these connections are not in place, boards can
not move from one machine to another.
Operation and Maintenance Manual Rev M(ii) 4/03
- 14 -
SMEMA cables have male 14-pin amp-type CPC connectors. The cables are straight-through, so
orientation does not matter. On each module, the wire to the J1 (Previous) plug must connect to the J2
(Next) plug on the machine upstream. Similarly, the J2 plug on each machine must connect to the J1 plug
on the machine downstream, as shown in the following diagram:
Operation and Maintenance Manual Rev M(ii) 4/03
- 15 -
Operating Safety
Notices and Warnings
o Safety glasses, gloves, and long sleeved clothing are necessary precautions when working with
automated industrial equipment.
o Read and understand all operating manua l s before using this equipment.
o Do not disable the safety features of the machine.
o Lock-out and tag the air and power supplies before servicing or cleaning any part of this equipment.
o Do not remove any hose, either air or fluid, without relieving the pressure.
o Do not replace any hose with a hose of inadequate pressure rating.
o Use only replacement parts recommended or supplied by the manufacturer.
o Always remain clear of all moving parts when the system is in operation.
Safety Devices and Guarding
The workcell has several safety features that protect the operator from hazards during normal operation of
the machine.
NOTE: The safety fe atures should NEVER be byp assed, disable d or tampered with. Precision Valve &
Automation, Inc. is not responsible for any damages incurred, mechanical or human, because of
alteration or destruction of any safety features.
Safety Circuit
The main power to the machine is monitored and controlled by the safety circuit. The safety circuit
contains two relays, under-voltage protection, and one or more safety devices. The relays are wired in a
redundant manner. Redundancy consists of two parallel relay circuits which work together electrically with
the safety devices. The tripping contacts of the relays are connected in series to insure that the safety circuit
will disconnect power even if one of the relays has failed. Self-checking consists of positive guided
contacts which are mechanically forced to operate together. If one of the redundant relays fails, the power
contacts are opened. The safety devices monitor the state of the EMERGENCY STOP push button and other
safety mechanisms. When the safety relay detects that the one or more of the safety devices has opened, the
power to the motors and pneumatics is cut.
Lexan Guarding
The work area is enclosed with Lexan guarding. The front of the machine is either open, to allow for
manual part loading and unloading, or guarded by doors.
Doors
For machines with an automatic load/unload cycle the front of the machine is protected by two doors. Each
door is monitored by a non-defeatable limit switch. When the door is opened power to the motors and
pneumatics is disconnected. The DOOR BYPASS key switch is provided to allow maintenance personnel
access to the work area without disconnecting power. This bypass switch only allows access during Manual
and Calibration modes.
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Light Curtain
Some machines are equipped with an optional light curtain. The light curtain is redundant and self
checking. The control signals from the light curtain are included as safety devices in the safety circuit. On
machine power up, the light curtain must be reset by turning the key switch to ‘Reset’ for at least ½ second.
Exhaust Fan
Some machines are equipped with an exhaust fan. The exhaust fan is provided to exhaust fumes from the
work area. The exhaust flange should be connected to an appropriate ducting system that is capable of
receiving 150 CFM (cubic feet per minute). Insufficient air flow through the exhaust system generates an
error.
NOTE: Installed safety devices vary from model to model.
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Operation
Startup Procedure
1) Check the fluid and air pressures.
2) Close all doors and turn the DOOR BYPASS key switch to the OFF position (If applicable).
3) Engage the EMERGENCY STOP button.
4) Turn on main power using the red rotary switch at the front or rear of the machine (Black “rocker”
switch on PVA250™ models).
Light Tower Operation
Three stacked indicator lights and a buzzer are used to indicate the status of the machine. The lights are
green, amber, and red with green on the bottom, amber in the middle and red on top. The buzzer is located
below the green light. The lights are visible from all sides of the machine. The indicators operate as
follows.
o The green indicator is on when the machine is in cycle and producing parts. It is off at all other times.
o The amber indicator is on when the machine is in Auto Cycle and ready to produce parts, but can not
cycle due to an external material handling problem (no incoming parts or no room to unload parts).
PVA750™ and PVA2000C™ models are equipped with a light tower but not an amber light.
o The red indicator is on stead y when the machine is not in Auto Cycle due to operator intervention. It
will flash when the machine is in cycle, but cycle is halted due to a machine problem. It is off at all
other times.
o The buzzer cycles with the red indicator during machine errors.
Table 4 – Light Tower & Buzzer Status
State Red Amber Green Buzzer
Cycle Stop ON OFF OFF OFF
Auto Cycle OFF ON OFF OFF
In Cycle OFF OFF ON OFF
Machine Error FLASH OFF OFF FLASH
Exhaust Verification
Once the workcell has initialized, most models will perform an exhaust flow verification process. If
initialization fails, consult the section Startup Errors on page 36. During this process, and whenever the
workcell is in operation the exhaust flow rate is monitored via the on board pressure differential switch.
The workcell must exhaust at a rate no less than 150 cubic feet per minute, otherwise a critical fault will
occur shutting the motors down. The verification process will also attempt to evacuate any potential vapors
that may already exist in the work area of the workcell. The time this process takes will vary from model to
model, but the remaining time for the process will be displayed as in the screen below:
Verifying exhaust. Please wait ...
060
F1 F2 F3 F4 F5 F6 F7 F8
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Machine Safety Check
Once initialize and exhaust verification is complete, the operator interface displays the following message:
Machine Safety Check
Press F1 to initiate.
F1 F2 F3 F4 F5 F6 F7 F8
The machine safety check ensures the workcell safety devices (emergency stop, door interlocks, light
curtain, etc.) are operating properly. During startup, the operator must enter the safety check and complete
it successfully. Otherwise, the machine halts all operations. After pressing F1 the operator is prompted by
the operator interface to activate and deactivate the safety devices and the POWER ON button, if present.
Certain events in this procedure are timed and if an action is not performed within a specified time the
machine interprets this as a failure and displays an error screen such as this:
EStop button failed.
Press F1 to repeat test.
F1 F2 F3 F4 F5 F6 F7 F8
By pressing F1 the operator can repeat the test one time. If a second failure occurs, a screen such as this
appears:
EStop button failed.
Repair and restart the machine.
F1 F2 F3 F4 F5 F6 F7 F8
After the second failure the program ceases functioning and the machine must be restarted. The second
failure need not be for the same device. An emergency stop failure followed by a door interlock failure
halts the program.
If the safety check fails, the entire system should be thoroughly examined by qualified maintenance
personnel before the machine is returned to operation.
Homing the Axes
Press F1 to home the system.
F1 F2 F3 F4 F5 F6 F7 F8
After successfully completing the safety check, the operator is shown the above screen. Pressing F1 homes
the system and displays the following screen:
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Homing axes. Please wait...
F1 F2 F3 F4 F5 F6 F7 F8
The axes home in the following order: Z, W, then X & Y simultaneously.
Standby Position
Once the machine has completed the homing sequence or finishes a required calibration procedure (if so
equipped), it moves to the standby position. Standby is a defined location, DISTINCT from the home
position, although in some circ umstances it may be defined as the same position as home. In most cases,
the standby position is placed near the board stop to minimize travel during Auto Cycle. The workcell
always returns to the standby position in Cycle Stop. If the standby position needs to be changed, please
consult the Main Program Modifications section of the PathMaster® Manual.
Solvent Cups
Some workcells have solvent cups installed as an option. The need for solvent cups is dictated by the
process by which the workcell will be used for. When solvent cusp are installed, the Auto Purge feature is
overridden by the solvent cup routines regardless of the Setup mode settings.
The solvent cup location varies from model to model, however, the location will be somewhere in the
workspace of the workcell. Solvent cups are used as a means of maintaining clean dispense / spray heads.
In Cycle Stop the heads are situated in the solvent cups. In Manual mode, the heads are removed from the
cups and remain out until exiting this mode. In Auto Cycle the heads lift and run the auto purge routine.
They return to the solvent cups after a pre-programmed period of inactivity.
To change the time delay before the heads enter the solvent cups in Auto Cycle, change the variable
SLP_TM in the Machine-Specific Information section of the Main program. A value of 1000 equals 1000
milliseconds or 1 second.
Flow Monitor System
Some workcells have a flow monitor installed as an option. The flow monitor on the workcell measures the
amount of material moving thr o ugh the mater ia l sup p ly line before it is split to supply the individual valves.
It is used as a verification of the dispensing process, not a control of that process, and reports excessive
deviations from desired values. Both the desired material volume and allowable deviation are determined
by the operator.
Priming the Flow Monitor
The flow monitor must be primed prior to use to prevent damage to the unit. Priming the flow
monitor minimizes the amount of air that will pass through the unit during initial startup. Follow the
procedure below to prime the flow monitor.
o Fill the pressure vessel with material and seal.
o Set the material pressure regulator to 0 P.S.I.
o Turn the inlet air and outlet material valve to the closed position.
o Disconnect the material line from the inlet port of the flow monitor.
o Turn the air inlet and material outlet valves to the open position.
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