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Graco 3A2098H PCF User's Manual

1. I Ih iad WwW aS Ww G FIG 2 Typical Multiple Fluid Plate System Installation Key Control Center User Interface B Fluid Plate Assembly C Applicator Dispense Valve D Sealer Automation E Automation Interface Cable 3A2098H CAN Cable Fluid Supply System Fluid Supply Hose Automation Controller Air Filter Assembly AIO TN Included 11 System Configurations Typical Installation Multiple Fluid Plates Multiple Swirl Dispensers K Air Supply Drop Site Fic 3 Typical Multiple Fluid Plate System Installation A D Control Center User Interface Fluid Plate Assembly Applicator Dispense Valve Sealer Automation Automation Interface Cable CAN Cable Fluid Supply System Fluid Supply Hose Automation Controller Air Filter
2. 139 Technical Data 140 Control Center Assembly Technical Data 140 Fluid Plate Assembly Technical Data 141 Swirl Dispenser Technical Data 141 Graco Standard Warranty 142 Graco Information 142 3A2098H Related Manuals 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 Description Original PCF Instructions Parts aaa see the note below PrecisionSwirl Orbital Dispenser Mastic Fluid Regulators Instruc Fluid Pressure Regulators Instruc Helical Gear Fluid Flow Meters Instruc NOTE In the Advanced screens on your system if the Advanced Display software part number shown is 16F528 or 15V769 then this manual does not apply to your system refer to manual 313377 for your system Otherwise the part number shown should be 16K405 and you should use this manual ADM Software Part No 16F528 or 15V769 see manual 313377 12 17 10 14 54 Style System OFF No Ac vous Sage fume Advanced Display 16F 320 1 017 001 Fluid Plate fiv Ed 103 001 Gateway 1BA626 103 006 USB Configuration 160954 102 001 309403 ADM Software Part No 16K405 use this manual Gateway Mo Active Errors software software Module Part Version Advanced Display 16k405 TO OT LISE Configuration 874 101 002 Gateway 16J 57
3. P A sal Multiple Fluid Plate and Multiple Swirl System shown FIG 17 Cable Installation Diagram 3A2098H 29 Installation Install Gateway Module Interface NOTE Systems with swirl dispensers will have two gateway modules in the control center The gateway module on the left is the swirl control DGM module and does not need any setup or modification The gateway module on the right is the automation Gateway module This section covers the automation Gateway module Fieldbus Communications Gateway Module Module Description The Communications Gateway Module CGM provides a control link between the PCF system and a selected fieldbus This provides the means for remote monitoring and control by external automation systems See Automation Control Normal Operation page 45 for details on controlling the PCF system through the Gateway module Data Exchange Data is available by block transfer cyclic transfer change of state triggered and explicit access to individ ual attributes as
4. 38 Setup SIVIGS esarri dT ONENE ronen 38 Configure Advanced Settings 38 On Off Delays 23 murs eus desserts 39 Operation ie is sd cals Eee 40 RO ES ALES D ER ET 40 LOad Material she mien tata 40 Maintenance Mode Operation 41 Automation Control Normal Operation 45 JOBS samedis sas amine ssn diseases 45 SV 2 ed Ne er pate im nn 46 Precharge Modes 47 Typical Job Cycle 49 Pressure Relief Procedure 57 SMUTCOOW MN 5 83 gos oh we es ete ee amsn 58 USB Dalal en sind tee etn oh cet dete 59 USB LOGS orere he bee ou nee eed 59 System Configuration Settings File 60 Custom Language File 60 Download Procedure 61 Upload Procedure 61 Troubleshooting 62 Rud Plates 222 hein HER die 8 Ble es 62 FIOW Meter 23 Dans ds et a tan 63 Fluid Regulator 63 Dispense Valves 64 Gateway Module 65 LED Diagnostic Information 65 EVlOrs nes deteste in sise eae ee 66 VIEW EMOS 2254 4 vase tenant 66 Diagnose Errors 66 Event and Error Codes and Troubleshooting 67 Maintenance 76 Maintenance Schedule 76 Advanced Display Module ADM 77 Upgrade Gateway Modul
5. T112320A FIG 44 Insert Token 77 Maintenance 5 After the red indicator light shuts off turn off power 4 Press and hold the push button for three seconds to the system and then release The red indicator light CK will flash twice pause and then once after the data 6 Remove token map is uploaded 7 Replace access cover Upgrade Gateway Module Fieldbus Map NOTE The fieldbus connection is temporarily disabled during the use of a map token The following instructions apply to all Gateway modules 1 Perform Upgrade Gateway Module Software Software must be upgraded before upgrading the Meson fieldbus map Token Push Button 2 Remove the access cover FIG 46 Insert Token 5 Remove map token CC when software has suc cessfully uploaded 6 Replace access cover Access Pe Cover T112319A Fic 45 Remove Access Cover 3 Insert and press map token firmly into slot NOTE There is no preferred orientation of the token 78 3A2098H Upgrade Fluid Control Module FCM Software NOTE The FCM connection is temporarily disabled during the use of the upgrade token 1 Turn off power to the system 2 Remove access cover then remove key token do not discard token T112334A Fic 47 Remove Access Cover 3 Insert and press software token firmly into slot NOTE There is no preferred orientation of token 4 Turn on power to the system The red indicator light CK will f
6. Important but will Deviation not shut down the affected fluid plate Very important and will immedi Alarm ately shut down the affected fluid plate The current system status is displayed at the right of the menu bar Status Soft Keys Icons next to the soft keys indicate which mode or action is associated with each soft key Soft keys that do not have an icon next to them are not active in the current screen NOTICE To prevent damage to the soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails Jump In Jump Out In screens that have editable fields press rgato access the fields and make changes When changes are com plete press A again to exit edit mode CN 100 Navigation within Screens Press to open drop down menus on Setup screens Also press to enter changes or make a selection Press to navigate to new screens and to nav igate left and right within a screen Press to navigate to new screens and to navi gate up and down within a screen Also press to move between fields within a drop down menu and to increment or decrement numbers within a field 3A2098H Setup Mode Setup mode screens are divided into five sections Sys tem setup Advanced setup Gateway setup Fluid Plate setup and Swirl setup While in Run mode press La to enter Setup mode Press to navigate through the Setup mode screens If the setup screens
7. 3A2098H Appendix A Advanced Display Module ADM Fluid Plate x Screen 3 Maintenance Totalizers This screen enables users to view the maintenance totalizers for each system component and the limits set that will trigger a maintenance advisory Maintenance totalizers keep track of the total volume or hours that each system component has been running If the totalizer value exceeds the set limit the totalizer value will turn red and a maintenance advisory is issued The limits are set in the Fluid Plate x Screen 7 Main tenance Advisory Limits page 108 for the air supply voltage to pressure V P transducer fluid regulator flow meter and all four valves NOTE If a flow meter is not included in the system this screen shows hours instead of volume and the flow meter entry is grayed out ARTE Peete Co EN Fluid Plate 1 Mo Active Errors system Off Supply WIP Regulator Flowmeter Valve T Valve 2 Valve 3 Valve 4 113 Appendix A Advanced Display Module ADM Swirl X Screen There is one Swirl X screen for each installed swirl dis penser This screen displays the following items Swirl Enable signal from the automation interface Speed command voltage from automation interface Actual and requested speed Active time and maintenance advisory limit 11 17 11 13 50 Fluid Plate 2 Swirl 2 C Mo Active Errors 0 FPM O RPh Actual Requestect Enabled Hours Lirnit
8. Advanced Catewau Fluid Plate gt system Uff No Active Errors tai PROFIBUS Device Address 146 Install Date Location Tag Function Tag Description Gateway Setup Screen 2 PROFIBUS This screen is the same for EtherNet IP and PROFI BUS See Gateway Setup Screen 2 EtherNet IP page 102 for details Gateway Setup Screen 1 PROFINET This screen enables users to set the IP address subnet mask Gateway DNS 1 DNS 2 and if a DHCP is used LER ea eee Catewau Fluid Plate system Uff C Mo Active Errors tai PROFINET IP Address 194 166 00 1 004 DHCP subnet Mask Gateway DNS 1 DNS 2 3A2098H Appendix A Advanced Display Module ADM Gateway Setup Screen 2 PROFINET This screen enables users to set the device address install date location tag function tag and system description EE Ce heed Gateway QE A0 system Uff C No Active Errors PROFINET Station Name Install Date Location Tag Function Tag Description Gateway Setup Screen 3 PROFINET This screen enables users to view the following informa tion regarding the Gateway module used on the PCF system hardware revision number system serial number map ID number map name map revision number date the map was created 09 10 01 12 56 Advanced Catewau RERA system Uff No Active Errors PROFINET Hardware Revision 0002 System Serial 10000008 Wap ID 00001 Map Name POF Standard Hap Rev
9. Air outlets open and close to dispense valve 5 32 in 4 mm tube fittings Electric Power Requirements 24 Vdc or 100 240 Vac Power Supplied to Dispense Valve Solenoid s 24 Vdc Fluid Specifications For use when dispensing fluids that meet at least one of the following conditions for non flammability e The fluid has a flash point above 140 F 60 C anda maximum organic solvent concentration of 20 by weight per ASTM Standard D93 The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test Ambient Air Temperature Range 40 to 120 4 to 50 C Swirl Dispenser Technical Data Refer to manual 309403 3A2098H 141 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion
10. WFD WFG EJD_ WXD_ P3F_ P4F_ P3D_ P4D_ P1F_ D NO I 62 63 O D 65 67 3A2098H T E Flow Meter Required Job Cycle Time Out Fluid Plate Error Detected Maximum Inlet Pressure Maximum Outlet Pressure Minimum Inlet Pressure Fluid Plate Events and Errors Command cable analog Deviation Bad or loose com Check command cable command dropped mand cable connec and connection below minimum value tion of 1 V while dispensing Entered command Enter correct com mode incorrectly mand code Automation program Verify correct automa error tion program Operating mode Alarm or Selected valve mode Check valve mode set requires flow meter Advisory settings require flow tings Advisory is issued if self clearing meter fluid plate settings Purchase meter require a flow meter but enabled token for FCM meter is not present and install flow meter Alarm is issued if dis FCM key token miss Check for FCM key pense is attempted in ing or invalid token error mode that requires a flow meter but meter is not present Job cycle time out Automation signals did Check automation pro not properly end job gramming per job oper cycle ating instruction Fluid plate error Analog voltage applied Limit signal on pin 1 of detected includes any to pin 1 of the com command cable to the error not covered by mand cable exceeds __ range of 0 10 Vdc another more specific 1
11. for each field 5 Press to exit edit mode 3A2098H System Setup To reset a totalizer value 1 Follow Steps 1 3 of To set limits to make changes in Fluid Plate x screen 7 Maintenance Advisory Lim its 2 Press to scroll to the system component to reset to reset the value Configure Valve to Swirl Association and Motor Error Type Define which Swirl number is installed on which dis pense 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 Fluid Plate 2 SE Fluic Plate 1 E Mo Active Errors Swirl Association Valve 1 Swirl 1 rl Valve 2 Valve 3 Valve 4 Error Type Motor Fault Deviation FIG 27 37 System Setup Configure Swirl Settings NOTE This applies only to systems with swirl dispens ers Set the individual Swirl settings for each installed Swirl 12 13 11 14 26 Fluid Plate 2 C Mo Active Errors Control Settings Speed Command Source Gateway gt Run Mode Speed Adjust Enable Speed Scale 100 Maintenance Acwisory Limits Lirnit Hours Swirl Orbiter 0 293 FIG 28 Configure Gateway Settings Gateway settings differ for each system See Automa tion Gateway Setup Screens page 102 for guidelines on configuring each type of Gateway interface Setup Styles The PC
12. o WNGO Download to USB Complete USB configura tion error ADM Key Token Error CBGO WMGO Gateway Error Detected Fluid Plate Com munication Error Fieldbus Com munication Error Event Description Cause Control Center Events and Errors Missing or invalid key token An ADM key token is required to run the system Advisory self clearing Gateway setting s changed Gateway error detected includes any error not covered by another more specific error The ADM lost commu nications with the FCM The automation gate way lost communica tion with the automation controller Fluid Plate Communi cation Error with ADM Fieldbus Communica tion Error Fluid Plate Events and Errors Event Gateway Code Error No Event Name CGM Communi cation Error Fluid Plate Com munication Error Style Out of Range ia Il 68 Event Description Fluid Plate Events and Errors Fluid Plate and CGM are no longer commu Communication lost between CGM and Fluid Plate FCM lost communica tion with the ADM ES Event Type RES Download to the USB is Advisory No action necessary complete self clearing USB configuration error Advisory USB configuration Reinstall system soft invalid or not present ware on display Verify the key token is installed Verify the key token part number is correct for the PCF ADM Gateway Map Missing or invalid map Advisory Missin
13. 0102 Command Value 64 0158 e o Me a 0104 Command Value 256 Command Value T 0105 Command Value 512 Fluid Plate 2 0160 Command Value 1 0167 0106 0162 0107 0163 Fluid 0708 O164 Plate 3 0165 Command Value 32 O166 Command Value 64 0110 OTe Ont f 0167 Command Value 128 OTT2 i OT68 OTTS OT69 OTA 0170 0115 Swirl 2 0171 Command Value 2048 Fluid OTTO Oe SSCS Plates OTT7 Os SOS OTIB CALC ES OTTO os SS OT20 0176 0121 O17 OT22 0178 0723 Sa OT7S OT80 0181 0182 Swirl Command Value 64 0183 Swirl Command Value 128 0184 Swirl Command Value 256 0185 Swirl Command Value 512 Swirl 3 oTa e os p oo OT OT pe o 07128 07129 0730 0186 Fluid 07187 Plate 3 0188 O73 0132 0133 0134 0135 Oo f SSS O10 f SSCS OTT f O72 Style Stobe Style Strobe 0193 0194 Fluid Plate 4 0136 CAE A Oe SSCS i Oa SSS git 0195 OO f SSCS 0796 om f 0197 0798 syer ooo 0199 Remote Start Purge Style 1 0144 0200 Swirl Enable 0145 Siye 2 OT O146_ Siyie 4 CC EE 0147 Siye 8 Fluid CEE Cg on Siye 16 Plate 3 poop Ee 0142 0143 12 13 14 15 16 17 8 19 20 21 22 23 24 5 O149 Style 32 O205 O150 Style 64 O206 O151 Siyie 128 O207 128 3A2098H Appendix C Communications Gateway Module CGM Connection Details Output Byte Bit Description Description 0208 Command Inte
14. 3 4 MPa 34 bar above the outlet pressure reading under your highest flow condition 3A2098H Operation 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 thou sands of psi hundreds of bar This means that the static pump pressure is set much higher than the regula tor needs at its inlet To prevent excessive control regu lator wear or surging a mastic fluid pressure regulator is recommended on the feed line close to the control regu lator The mastic regulator will suppress the static feed pressure at the control regulator inlet 41 Operation Dispense from Each Valve Dispense from each valve that will be used in normal operation to confirm that the entire system is installed correctly and is capable of delivering desired results Follow the steps outlined in Dispense From Mainte nance Screen page 43 to perform each of the follow ing applicable system verification checks NOTE Each fluid plate controls only the dispense valves connected to it e
15. BG TI12362a r 24E451 3B9900 1a FIG 8 Advanced Display Module Component Identification Navigation Buttons Navigate within a screen or to a new screen Power On Off Button Enables disables system J Flat Panel Mount Mounts to control center bracket optional BB System Status Indicator LED E BK Model Number Tag Displays system status Green LED indicates the Model b system is active Orange LED indicates the sys aL eee wees tem is off Solid LEDs green or orange indicate USB Module Interface USB port and USB indicator LEDs the system is in Run mode Flashing LEDs green or orange indicate the system is in Setup mode CAN Connector Stop Button Power connection Functions vary depending on the screen Battery Cover BE Cancel Button BR Token Access Cover Clears system errors and cancels a selection or Digital I O Port for Light Tower number entry while in the process of entering a number or making a selection Enter Button NOTICE Acknowledge changing a value or making a selec To prevent damage to the soft key buttons do not tion press the buttons with sharp objects such as pens Lock Setup plastic cards or fingernails Toggle between run and setup screens If setup screens are password protected button toggles Stops all system processes However it is not a BN Module Status LEDs safety or emergency stop See LED Diagnostic Information page 65 for Soft Keys signal definitions BA BC BF BG between ru
16. DGM See Appendix B Discrete Gateway Module DGM Connection Details page 115 and the Digital Command Logic Table for connection details NOTE The control mode for each dispense valve is set in the Fluid Plate x Screen 2 Mode Settings page 105 For example if Valve 1 is set to Pressure mode on the Fluid Plate x Screen 2 Mode Settings then the digital commands for Valve 1 are pressure values The Digital Command Logic Table indicates which value each input must be set to in order to select a particular setting Digital Command Logic Table Single Fluid Plate Systems Digital Command Input 1 Digital Command Input 2 Low Resulting Digital Command Selection Low etting 1 High Low etting 2 104 Digital Command Logic Table 2 Fluid Plate Systems Digital Command Input 1 Digital Command Input 2 Resulting Digital Command Selection Fluid Plate 1 Setting 1 Fluid Plate 1 Setting 2 Fluid Plate 2 Setting 1 Fluid Plate 2 Setting 2 Press pZlto access the fields to make changes Press to exit edit mode Single fluid plate system 080814 13 30 System Achy system Off C Mo Active Errors tai Discrete Active Errors High rl Command Value Type Digital J setting Dispenser Valve 2 3 1 1 psi 1 2 psi 1 3 A0 a00 psi ill S00 psi 2 fluid plate system Discrete Active Errors High Command Value Type Digital gt setting Dis
17. O O D a D a O O lt lt O O Flow meter Time Advisory Limit Flow meter Volume Mass Advisory Limit Volume gal US 4 gal Uk HHHH Liters Mass lb kg Supply Time hours Advisory Limit Volume gal US H 4 gal Uk HHHH Liters Mass Ib kg VIP Time Advi hours Read sory Limit i O O O O O O O O O O O O O O O O O lt x lt x lt x lt gt x lt x lt x lt x lt x lt x lt x lt x lt x lt x lt NO NO NO NO NO NO NO NO NO NO NO NO NO NO O O O O O O1 O1 A gt gt A A gt CO O gt NO O O1 gt N O O1 gt g O x N O gt ep Cc D 2 lt lt 2 I ume Mass Advisory Limit E O Ox26C O 133 Appendix C Communications Gateway Module CGM Connection Details Units See Units Definitions page 137 Volume gal US HHHHH 256 267 Description gal Uk HHHHH Liters Mass Ox26E V P Vol ume Mass Advisory Limit Ib kg 0x270 Valve 1 Time hours Advisory Limit Units See Units Read or Definitions page 137 Write Error Type Enumera Read puted Target ltion 1 Write Error Type Read Write Read Write 0x271 Valve 2 Time hours Advisory Limit Valve 1 Mode Valve Mode Enumera Read 0x272 Valve 3 Time hours tion Write Advisory Lim
18. and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 3A2098H 9 System Configurations System Configurations Typical Installation Single Swirl Single Fluid Plate NOTE Shown with one fluid plate and one swirl dispenser Power In EZ DO Air Supply Drop Site Cy LEE t 44 oo TELL A LL JE T IL UJ FIG 1 Typical Ambient System Installation onmo A 10 Control Center User Interface H Fluid Supply Hose Fluid Plate Assembly J Automation Controller Applicator Dispense Valve K Air Filter Assembly Sealer Automation L PrecisionSwirl Orbital Dispenser Swirl Dispenser Automation Interface Cable M PrecisionSwirl Cable CAN Cable Fluid Supply System Included Optional 3A2098H System Configurations Typical Installation Multiple Fluid Plates No Swirl Dispensers s Power In K Air Supply Drop Site
19. orbiter CAN cable was re connected with Cycle system power system power on amber LED on swirl board will be on this indicates circuit protection was triggered Shorted motor cable amber LED on Replace swirl motor cable 55 ft swirl board will be on this indicates then cycle power circuit protection was triggered Faulty swirl orbiter Replace swirl orbiter Motor not running motor fault alarm Cable disconnected Verify cable connections to swirl not active board swirl board power cable and swirl control DGM No Swirl Enable signal from auto Check input from automation unit mation unit Swirl not installed Verify that the proper swirl orbiter is installed in the system setup screen 64 3A2098H Troubleshooting Motor not responding to change in No Swirl Speed Command signal Check input from automation unit speed command from automation unit Swirl speed source incorrectly set Verify Soeed Command Source in Swirl Setup screen Gateway Module Problem ase Soon No communication Incorrect wiring Check wiring per fieldbus standard Refer to PCF Gateway LED status indicators and Appendix C Communications Gateway Module CGM Connection Details page 122 Incorrect fieldbus settings Confirm fieldbus settings at automation controller fieldbus master and PCF Gateway fieldbus slave Refer to Appen dix A Advanced Display Module ADM page 99 for infor mation on PCF Gateway configurat
20. r_pf0000_313377_30a Fic 53 FIG 54 3 Remove the following cables from FCM 5 Secure the base to the fluid plate 101 with screws e dispense valve solenoid cable 6 Reconnect the power supply cable daat a da n 7 Reattach the FCM follow Replace Fluid Control e 1 0 cable MOQUE e inlet pressure transducer cable ambient mod els only 3A2098H Replace Transducer O Rings 1 Prepare Fluid Plate Assembly for Repair page 80 2 Remove the fluid outlet pressure sensor 117 from the regulator 108 r_pf0000_313377_16a FIG 55 3 Press the transducer CG out of the retainer nut CH 4 Remove the faulty o ring 120 and replace with new CH CG 120 FIG 56 5 Press the transducer back into the retainer nut 6 Reconnect the fluid outlet pressure sensor to the regulator 3A2098H Repair 83 Repair Repair Fluid Regulator For complete cartridge fluid regulator repair refer to instruction manual 308647 For complete mastic fluid regulator repair refer to instruction manual 307517 See FIG 57 and perform the following steps NOTICE Carefully handle the hard carbide ball valve actua tor and valve seat to avoid damaging them 1 Prepare Fluid Plate Assembly for Repair page 80 2 Remove the cartridge assembly by loosening the valve housing CE with a 6 mm hex wrench and pulling the cartridge assembly out of the base hous ing CD Cartridge Regulator 244734 Shown cartridg
21. 0 020 Job Report Screens The job report screens store and display a chronological list of 180 jobs performed by the system Each job record includes the date and time the job was com pleted the style dispensed the error percentage and the target requested and actual dispense volumes Press to scroll through each job report screen Style Requested Error 18 g 1 A 1 lal lal 12 14 10 Occ 10 0 cc 12 12 10 0 cc 10 0 cc Event Report Screens The event report screens display a chronological list of system events These screens display the last 200 events Each event report screen displays the date time event code and description for each event 114 Press to scroll through each event report screen 11 1 11 1351 ef los Events Errors Horne gt Activ No Acti fe Errors Time Code Description 13 51 EBD2 R Maint Mode Exited SW2 Jeo EADZ R Maint Mode Entered 542 1350 EDF Maint Mode Exited SW1 1250 EADT R Maint Mode Entered 54 1250 EBC2 R Maint Mode Exited FP2 Jac0 EACZ R Maint Mode Enterec FP 13 49 EBDI R Maint Mode Exited SW1 1249 EBCI R Maint Mode Exited FP1 1549 EADT R Maint Mode Entered 5141 1549 EACT Maint Mode Entered FP1 Error Report Screens The error report screens display a chronological list of system errors These screens display the last 200 errors Each error report screen displays the date time error code and description for each err
22. 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 e Job completion date e Job completion time e Job number sequential number e Dispenser Fluid Plate Number e Style number 3A2098H USB Data e Target volume in the units shown in the volume units column e Requested volume in the units shown in the volume units column e Actual dispensed volume in the units shown in the volume units column e Volume units e Error percentage between actual dispensed vol ume and requested volume maximum of 100 e Minimum inlet pressure during job measured in bar heated systems will always read 0 e Average inlet pressure during job measured in bar heated systems will always read 0 e Maximum inlet pressure during job measured in bar heated systems will always read 0 e Minimum outlet pressure during job measured in bar e Average outlet pressure during job measured in bar e Maximum outlet pressure during job measured in bar e Minimum flow rate during job measured in cc min systems with no flow meter will r
23. Application Direction p p p Value Too Low Ideal Value Value Too High Provides a boost upon valve opening to accelerate material Ideal value is typically greater than 100 Opening Precharge Duration Value Dispense Application Direction Dispense Application Direction Dispense Application Direction a p y Value Too Low Ideal Value Value Too High The duration for which the valve opening scaling is application before the command is no longer scaled Regulator On Delay Value Dispense Application Direction Dispense Application Direction Dispense Application Direction p p p Value Too Low Ideal Value Value Too High Controls timing of transition from valve closed precharge to valve opening precharge and regular dispense This delay should approximate the time it takes a dispense to open 48 3A2098H Typical Job Cycle In order for the system to run it must be in the active state status LED next to on the ADM is green Before a job begins the automation controller outputs should have the following values Style Strobe 0 Dispense Complete 0 Dispense Valve x On all should be 0 Style Any value is acceptable A typical job cycle consists of the following dispensing sequence See Typical Job Cycle Chart page 50 NOTE Each job cycle can apply to only one fluid plate 1 The automation controller checks that Dispenser Fluid Plate Ready signal is set to 1 If it is se
24. Bit 25 1104 1105 1106 1107 1108 1109 1110 1111 112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1158 Command Interface Value Bit 30 1159 Command Interface Value Bit 31 1160 Command Interface Status Com 2 mangao o 1161 Command Interface Status Com 7 mand Success 1162 Command Interface Status Com All Fluid 1163 Command Interface Status Value oa Pressure Units Bit 0 1154 Command Interface Value Bit 26 Pressure Units Bit 1 1155 Command Interface Value Bit 27 Aar ug E A en Fluid Plate 4 Fluid Plate 4 1164 1165 de EEE Error 7 TC CE Error 2 BC EE LE cu 168 ETor 1 Plate 4 Error 126 Error 127 Error 28 1128 Value See CGM Command Interface on page 131 for command interface details All Fluid Plates Swi ris O 3 3 D J 2 D D D O D lt Cc D W 126 3A2098H Appendix C Communications Gateway Module CGM Connection Details gr Bite Bk Description zone m Byte Bit Description 048 Swirl Command Value 1 Style Strobe oe O50 Swirl Command Value 4 O01 Dispense Complete E D Val O51 Swirl Command Value 8 02 Dispense Valve 1 On O52 _ Swirl Command Value 16 O03 Dispense Valve 2 On Fluid O04 Dispense Valve 3 On Plate 1 ee spel vawe ON T T E O54 Swirl Command Value 64 O05 Dispense Valve 4 On RS Swirl Command Value 128 5 au Reset Sl Job Swirl
25. 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 FIG 16 on page 25 2 Connect one end of the extension cable included in the kit to connection 5 on the FCM and the other end of the cable to the bulkhead fitting 3 Connect command cable to bulkhead fitting and wire to automation controller per the following pinout table FCM Command Dispense Trigger Source Port Cable Wire Command Cable or Dispense Trigger Source Pin Color Combined Command Cable 3x Command voltage 0 10 Vdc Command voltage 0 10 Vdc A Brown No connection Valve 3 dispense trigger sourcing input Dispense trigger sourcing input Valve 1 dispense trigger sourcing input NOTE Command cable inputs are not isolated from PCF 24 Vdc power 4 Yellow No connection Valve 2 dispense trigger sourcing input To turn on the dispense trigger connect the dis pense trigger pin to the dispense trigger ground pin pin 5 26 3A2098H Ground Av Ac To reduce the risk of fire explosion or electric shock when grounding connecting cables connecting to a power source or making other electrical connections e 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 requir
26. Command Value 256 07 emote Start Purge Swirl Command Value 512 _ Swirl 1 008 Swirl Enable O58 Swirl Command Value 1024 EE O59 Swirl Command Value 2048 OO 7 o SE a a E CAE S ee LE CE EE CCR RE Style 1 O17 OT8 O79 Fluid Plate 1 ea lt mh O Swirl 1 Dispense Valve 2 On Dispense Valve 3 On O69 Dispense Valve 4 On Error Reset Cancel Job Remote Start Purge BCE CE Or O61 082 O63 020 O21 022 023 O24 025 026 027 Fluid Plate 1 Style Strobe O66 Dispense Valve TON Fluid D e OT f SSS Command Value Tt O32 Command Value 1 O82 083 Fluid 084 Plate 2 085 Style 32 Style 64 Style 128 Dispense Valve 1 Precharge On 11 033 034 10 035 Fluid 036 Plate 1 037 038 039 040 Zi 042 043 Fluid 044 Plate 1 045 O6 Dispense Valve 2 Precharge On Dispense Valve 3 Precharge On O90 DI Dispense Valve 4 Precharge On Fluid Plate 2 O47 aoc Lae ee ROLE BEL BOL Ea Bae ao Eee Led ee ee aoe RCE aa Ee ee ER CCE 023 RCE Es Eee i bee eee mae ae aos Leet Pa aed more EE RCE oo Ee RSR CL RCE MCE CE ee RC RCE 3A2098H 127 Appendix C Communications Gateway Module CGM Connection Details Output Output Byte Bit Description Byte Bit Description 0152 097 OT53 0754 Fluid OT55 Fluid 0100 Plate 2 0156 Plate 3 O70 0157 0103 ommand Value 128 0159 E Pe
27. Excel by default as long as the program is installed How ever they can also be opened in any text editor or Microsoft Word NOTE All USB logs are saved in Unicode UTF 16 for mat If opening the log file in Microsoft Word select Uni code encoding 3A2098H USB Data Upload Procedure Use this procedure to install a system configuration file and or a custom language file 1 If necessary follow the Download Procedure page 61 to automatically generate the proper folder structure on the USB flash drive 2 Insert USB flash drive into USB port of computer 3 The USB flash drive window automatically opens If it does not open USB flash drive from within Win dows 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 corre sponding serial number of the ADM The serial number is on the back of the module 6 If installing the system configuration settings file place SETTINGS TXT file into UPLOAD folder 7 If installing the custom language file place DISPTEXT TXT file into UPLOAD folder 8 Remove USB flash drive from computer 9 Install USB flash drive into PCF system USB port 10 The menu bar and USB indicator lights indicate that the USB is downloading files Wait for USB activity to complete 11 Remove USB flash drive from USB port NOTE If the custom languag
28. Flashing Recoverable fault s Red LINK Activity Link De Omer No link no activity Green Link established Activity Flashing Green 3A2098H DeviceNet NS MS TI11815A DC FIG 71 DeviceNet Fieldbus Connections Network Status NS Sete ES Not online No power Green On line one or more connections are established Flashing On line no connections established Green 1 Hz Red o Critical link failure Flashing One or more connections timed out Red 1 Hz Alternating Self test Red Green Module Status MS a a No power or not initialized Green Initialized Flashing Missing or incomplete configuration device Green 1 Hz needs commissioning Red Unrecoverable Fault s Flashing Recoverable Fault s Red 1 Hz Alternating Self test Red Green DeviceNet Connector DC Pin sona Besson Negative bus supply voltage CAN_L CAN low bus line CAN_H CAN high bus line Positive bus supply voltage gh bust 123 Appendix C Communications Gateway Module CGM Connection Details PROFIBUS T111816A Fic 72 PROFIBUS Fieldbus Connections Operation Mode OP State Description Not online No power On line data exchange Flashing Green Flashing Red Parameterization error 1 flash Flashing Red PROFIBUS Configuration error 2 flashes Status Mode ST sme Desenmten No power or not initialized Flashing Initialized diagnostic even
29. Fluid Plate Setup Reo TES Flow Rate lt 2488 ps ola Screens page 105 150 ps H systems with flow meters _ en are 1 1 Current Command Value Bead Scale Quickly adjust pres sure flowrate from this screen Active Style 3A2098H Progress Bar Active Dispense Valves Target 10 0 cc Actual 47 5 cc Requestect 100 0 cc Associated Swirl Dispensers Volumes 111 Appendix A Advanced Display Module ADM Maintenance Mode Dispense Control Modes l The PCF system has four fluid dispensing control from Fluid Plate x screen 1 Control Center modes to enter maintenance mode Maintenance mode enables users to change the control mode volume to be e Bead Control the system controls the flow rate of dispensed target pressure and number of dispense the material being dispensed The regulator outlet valves used in the system pressure is varied to control the fluid flow rate to the requested value Use the bead control when a con NOTE Volume pressure and dispense valve options sistent bead size is required change according to mode e Shot Control the regulator outlet pressure is con trolled to the requested value The dispense valve is closed when the target volume is reached or when the automation controller provides a signal See Maintenance Mode Operation page 41 for instructions on changing the control mode target pres sure and number of dispense valve
30. For each valve that will be used during normal oper ation dispense at each pressure or flow rate that will be used during normal operation This verifica tion check confirms that the system is capable of delivering material at your maximum desired operat ing point e For systems that will operate multiple valves in pres sure mode at the same time dispense from each valve at the same time This verification check con firms that the system is capable of delivering mate rial at your maximum desired operating point e For each valve operating in bead mode perform an initial teaching process Follow this procedure after significant system and or material characteristic changes a For each flow rate that will be used during nor mal operation press Ld 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 kd 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 kd is pressed 42 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 s
31. Light Tower Accessory 1 Order the 255468 Light Tower Accessory as a diag nostic indicator for the PCF system 2 Connect the cable from the light tower to the digital I O port BS on the ADM See Table 3 for a description of light tower signals Table 3 Light Tower Signals Green No errors Yellow An advisory exists Yellow flashing A deviation exists Red solid An alarm exists One or more fluid plates may be shutdown NOTE See Errors page 66 for error definitions 23 Installation Install Fluid Plate Assemblies To install the PCF fluid plate assemblies Mount the fluid plate assemblies page 24 Ground fluid plate assemblies page 27 Connect one fluid plate assembly to the control cen ter See Install Cable Assemblies on page 28 If multiple fluid plates connect the fluid plates together See Install Cable Assemblies on page 28 Connect fluid lines air lines and cables page 27 Mount Aw LS Before Mounting Assembly See component manuals for specific information on component requirements Information presented here pertains to the PCF fluid plate assembly only Have all system and subassembly documentation available during installation Be sure all accessories are adequately sized and pressure rated to meet the system s requirements Use only the Graco PCF fluid plate assembly with the Graco PCF control center Mount Assembly 1 24 Select a
32. Part STR_11_8 Read Only Alarm Write Number Ox3FB Style Bits Read 0x007 Software Part STR_15 12 Read Only Write Number Fra 0x116 Error Reset Dispense Control 2 Bit Read oe oe ee Write Source Enumeration Write 0x118 Disable Dis Boolean Read Ox3FF Dispense Con Dispense Control 1 Bit Read 0x408 Swirl Speed Scal percent Read trol field Write Ing Write Read Only Read Write Pressure psi Read Only H hours Read bar 4 Write Mpa psi Ox2FC Swirl Status Bits 1 Swirl Status Bit Read Only field 1 Ox4FE Swirl Actual Speed RPM Read Only Nipa _ 0x500 Swirl Control Swirl Control Read 0x403 Flowrate Com cc min Read Only Enumeration Write mand Ox Flowrate HH HH CC min Read Only ees ee dace mS ee l Atia Speed Write 404 0x406 Fluid Plate Sta Fluid Plate Status 0 Read Only tus 0 bitfield x409 0 Fluid Plate Gateway Error Number Read Only Faults lt a E 33 De aal zal 60 lt lt 136 3A2098H Appendix C Communications Gateway Module CGM Connection Details Units Definitions Units String Definition OO O Command Value Source Enu O Display 1 Command Cable 2 Gateway meration Valve 2 On Valve 3 On Valve 4 On Error Reset Remote Start Purge Function Style Strobe Dispense Complete Valve 1 On Dispense Control 2 Bitfield Bit 14 Error Reset Bit 15 Remote Start Dispense
33. Verify FCM key token is correct part number Problem detected with outlet pressure trans ducer Verify outlet pressure transducer is installed and or connected cor rectly Replace if necessary Problem detected with Verify inlet pressure P6F_ Inlet Pressure Inlet pressure trans Transducer Error ducer error F6D _ Flow Meter Error Flow Meter error 3A2098H E Token Error inlet pressure trans ducer Problem detected with flow meter transducer is installed and or connected cor rectly Replace if necessary Verify flow meter is installed and or con nected correctly Replace if necessary 69 Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause 7 WJ1_ 56 Dispense Valve 1 Error WJ2_ 57 Dispense Valve 2 Error WJ3_ 58 Dispense Valve 3 Error WJ4_ 59 Dispense Valve 4 Error WSD_ Incompatible Valve Settings WSD5 Incompatible Valve Settings O Closed Valve Flow F7D_ Fluid Plate Events and Errors Alarm Problem detected with Voltage to Pressure Transducer error Problem detected with dispense valve 1 Dispense valve 1 error Alarm Problem detected with dispense valve 2 Dispense valve 2 error Alarm Problem detected with dispense valve 3 Dispense valve 3 error Alarm Problem detected with dispense valve 4 Alarm Alarm Dispense valve 4 error Incompatible settings for multiple valve opera tion attemp
34. able NOTE Run mode bead adjust allows a user to quickly adjust flow rate or pressure from the run screen RENE Fluid Plate 1 Acti Mo Active Errors Control Settings Fluid Plate 2 Command Value Source 2 Job End Mode 2 Run Mode Bead Adjust Enables J I End Job On Alarm 4 Display Control Password Disable F g Fluid Plate x Screen 2 Mode Settings This screen enables users to set valve commands Use this screen to select a mode pressure bead shot or full open for each valve Users can also set the flow rate or pressure for each valve and adjust the bead scale NOTE The ability to dispense from multiple valves simultaneously is only allowed in either of the following scenarios e Each valve is set to Pressure mode and has identical command values e Each valve is set to Full Open mode 105 Appendix A Advanced Display Module ADM Attempting to dispense from multiple valves simultane ously using any other combination will cause an Incom patible Valves Settings alarm 11 1 11 1532 e Fluid Plate 1 Activ Mo Active Errors a hlode Fluid Plate 2 Mode Settings YOC Command Valve 1 1000 psi Valve 2 Pressure 1000 psi Valve 3 Pressure gt 2000 psi Valve 4 Pressure 1000 psi Bead Scale 106 Fluid Plate x Screen 3 Delay Settings This screen enables users to set on and off delays in milliseconds for each valve and the regulator For an ex
35. address and the baud rate The DeviceNet screen displays the hard ware revision number system serial number map ID name revision number and install date EMEA Gateway RERA System Off A C No Active Errors DeviceNet Device Address Baud Rate 500 Hardware Revision TOQI System Serial 20000008 Wap ID 00001 Map Name POF Standard Mas Revision 001 002 Wap Date 09 09 74 102 Gateway Setup Screen 1 EtherNet IP This screen enables users to set the IP address subnet mask Gateway DNS 1 DNS 2 and if a DHCP is used Ce El Gateway REA System Off tal C No Active Errors Etherbet IP IP Address 001 002 003 004 DHCP subnet Mask Gateway DNS 1 DNS 2 Gateway Setup Screen 2 EtherNet IP This screen is the same for EtherNet IP and PROFI BUS It enables users to view the following information regarding the Gateway module used on the PCF sys tem hardware revision number system serial number map ID number map name map revision number e date the map was created 090903 12 57 e Advanced Gateway Fluid Plate system Uff C No Active Errors EtherNet IP Hardware Revision 0000 System Serial 00000000 Wap ID 00001 Map Name POF Standard Mas Revision 001 001 Wap Date 09 0223 3A2098H Gateway Setup Screen 1 PROFIBUS This screen enables users to set the device address install date location tag function tag and system description 09 10 05 08 26
36. analog input has a corresponding reference ground pin See Pin References page 118 for details e Type Sinking e Voltage Rating 0 10 Vdc Microcontroller DGM Analog Outputs e Input Impedance 20 kQ Discrete Gateway Analog Input Analog Input The analog outputs function only when the DGM is connected to a power supply through the CAN connection Each analog output has a corresponding reference ground pin See Pin References page 118 for details e Type Sourcing 3A2098H Microcontroller e Voltage Rating 0 10 Vdc 10 mA at 10 Vdc Discrete Gateway 0 10VDC 10mA Analog Output LR gt Analog Output 121 Appendix C Communications Gateway Module CGM Connection Details Appendix C Communications Gateway Module CGM Connection Details Install Fieldbus Connections Module Status MS Connect cables to fieldbus per fieldbus standards State Description Comments Off Not initial No power or module in PROFINET ized SETUP or NW_INIT state Green Normal Diagnostic event s present MS operation hank Flashing Initialized Used by engineering tools to NS Green diagnostic identify node on network event s TI11814A present Fic 69 PROFINET Fieldbus Connections ae ORD RS een ee Red 1 Configura Expected Identification differs The Ethernet interface operates at 100Mbit full duplex flash tion error from Real Identification as require
37. 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 60 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 sys tem 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 down load The second column can be used to enter the cus tom language strings If a custom language was previously installed this column contains the custom strings Otherwise the second column is blank Modify the second column of the custom language file as needed and then follow the Upload Procedure page 61 to install the file The format of the custom language file is
38. container 4 Record the volume dispensed on Fluid Plate x screen 1 See FIG 30 on page 43 5 Settle the material into the beaker and view the actual volume dispensed 6 Calculate the new flow meter K factor KE actor ten Pia oe WIS Ce er Ecler ale dispensed volume cc 7 Enter new K factor 8 Repeat the procedure to verify the new K factor Manually Adjust Control Loop Parameters NOTE It is recommended that these values not be changed from the factory defaults of 32 00 for Kp 128 00 for Ki and 0 00 for Kd If the system is not maintaining the desired setpoint while in pressure or bead control mode manually change the Kp and Ki values NOTE Pressure parameters should be adjusted first even if you typically operate in bead control mode 1 Begin dispensing material NOTE Begin a new dispense each time control param eters are changed 2 Ifthe regulator outlet pressure does not closely fol low the desired pressure set Ki to zero then increase Kp until the proper pressure control is achieved 3 Ifthe 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 3A2098H Operation 6 Optional To fine tune the step response in pressure
39. corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property
40. critical The following rules must be followed in order for the installa tion process to succeed e The file name must be DISPTEXT TXT e The file format must be a tab delimited text file using Unicode UTF 16 character representa tion e The file must contain only two columns with columns separated by a single tab character e Do not add or remove rows to the file e Do not change the order of the rows e Define a custom string for each row in the sec ond column 3A2098H Download Procedure 1 Insert USB flash drive into USB port BL See FIG 39 on page 59 2 The menu bar and USB indicator lights indicate that the USB is downloading files Wait for USB activity to complete A pop up will be present until the trans fer is complete if it is not acknowledged 3 Remove USB flash drive from USB port BL 4 Insert USB flash drive into USB port of computer 5 The USB flash drive window automatically opens If it does not open USB flash drive from within Win dows Explorer 6 Open Graco folder 7 Open system folder If downloading data from more than one system there will be more than one folder Each folder is labeled with the corresponding serial number of the ADM The serial number is on the back of the ADM 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
41. defined by the fieldbus specification Refer to Appendix C Communications Gateway Module CGM Connection Details page 138 for details about PCF fieldbus data map NOTE The following system network configuration files are available at www graco com e EDS file DeviceNet or EtherNet IP fieldbus net works e GSD file PROFIBUS fieldbus networks e SDML PROFINET fieldbus networks CGM Status LED Signals Description Green on System is powered up Yellow Internal communication in progress Red CGM hardware failure Solid Red 7 flashes Data map load failure Incorrect data map for fieldbus type No data map loaded The red LED CF will flash a code pause then repeat 30 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 commu nication architecture and the fieldbus being used 1 Install interface cables between the PCF system and the automation controller per the fieldbus stan dards Refer to Appendix C Communications Gateway Module CGM Connection Details page 122 for details 2 Turn on system power Navigate to the Gateway setup screens and ensure the data map name is PCF 4FP Refer to Appendix A Advanced Dis play Module ADM page 99 for details about the data map 3 Set the PCF Gateway configuration values as requir
42. el 0x21D Valve 2 Off HHH A r S Ox21E Valve 3 Of HHH pe loom S Ox21F Valve 4 Off HHH m ee fom a 0x230 Flow Meter Flow Meter Type Enu 3A2098H Appendix C Communications Gateway Module CGM Connection Details Read or Read Only Read Only Read Only Read Only Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write Read Write D Units See Units 256 267 Description Definitions page 137 0x231 Flow Meter pulses Liter sint32 psi sure Sensor bar User Offset Mpa Inlet Pressure sint82 psi Sensor User bar 4 Offset Mpa Maximum Out uint32 psi let Pressure H bar 4 Mpa uint32 psi HHHH bar Mpa Maximum Inlet uint32 psi Pressure H bar 4 Mpa HHHH HH Read Write Write Write Write egulator Time Read Advisory Limit Regulator Vol Volume Read ume Mass gal US Advisory Limit gal Uk Liters Mass lb kg HHH hours Read or Write Read O x D U O O Cc D 5 a D Read Minimum Inlet Pressure om om om mn om om gt
43. 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 kd until the fluid flow stops 4 Ifthe dispense valve cannot be actuated from the control center refer to FIG 36 and perform the fol lowing steps to open the dispense valve and relieve fluid pressure a Manually actuate the plunger on the solenoid to open all dispense valves attached to this fluid plate and relieve fluid pressure See FIG 36 Dispense Valve Air Solenoid 3A2098H Mo 2 10 Pressure Relief Procedure b Continue actuating the plunger until all pressure is purged from the system between the needle and the dispense valves attached to this fluid plate before proceeding to the next step For systems with multiple fluid plates repeat previ ous steps for other fluid plates Shut off air to the fluid plate Place a waste container below the air filter assem bly then open drain valve on the air filter assembly Close drain valve once air is relieved Turn main power switch on control panel to the OFF position SI 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 con tinue relieving pressure If
44. 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 111511 1345 Horne Fluid Plate 1 Rte Re e gt C Mo Active Errors a 1 g psi 263 psi Beag Scale 1151 11 13 49 Horne Fluid Plate 1 Display Control No Active Errors FIG 31 3 Press to open the Control Mode drop down list and select the preferred control mode Press again to exit the drop down list 43 Operation 4 Press to move to the target fields Enter the tar get pressure flow rate or volume dependent on control mode and press to save 5 Press to move to the valve check boxes Press to select the desired valves 6 Follow step 2 4 of Manually Dispense Fluid page 44 Manually Dispense Fluid 1 From Fluid Plate x screen 1 press Bi to enter maintenance screen 2 Press kd and verify that the valve opens 3 Continue to press kd as long as needed to load or dispense material 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 1
45. or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou i
46. reducing hex 1 2 npt f x 3 4 npt f BRACKET flow meter lower SCREW cap socket hd SPACER BRACKET flow meter FITTING tee 3 4 m x 1 4 f AMPLIFIER signal conditioner SENSOR pressure fluid outlet BRACKET valve BRACKET signal conditioner O RING REGULATOR I P SCREW valve BRACKET helical gear meter WASHER plain WASHER lock spring m6 SCREW cap socket hd SCREW cap socket hd hex METER assy CABLE m12 5p LABEL warning main VALVE dispense fluid plate CABLE solenoid LABEL caution hot surface LABEL SCREW cap socket hd m3 FITTING bulkhead union FITTING push TUBE nylon round black 5 5 LABEL SHROUD fluid plate CABLE CAN male female 0 5 m KIT dual filter TOKEN key CONNECTOR thru m12 m xf BULKHEAD tube 5 32 TAG installation SCREW grounding N e ND N Ref 152 1534 1557 158 1594 1604 199 Part 194337 186620 122610 290228 189930 124654 Parts Description WIRE grounding door LABEL ground SUPPRESSOR box snap ferrite ELBOW LABEL caution hot surface LABEL caution electric shock SPLITTER CAN Qty A Replacement Danger and Warning labels tags and cards are available at no cost See Parts Varying by Assembly table page 98 for part number and quantity Only included with fluid plates that use a heated mastic regulator x Base electronic compo
47. resolution ambient helical flow meter 22 500 cc minute with heated helical flow meter 37 500 cc minute with separate flow meter Maximum Fluid Working Pressure feed pressure to fluid plate cartridge regulator 6000 psi 41 MPa 414 bar feed pressure to fluid plate mastic regulator 5000 psi 35 MPa 345 bar at regulator outlet 4500 psi 31 MPa 310 bar at regulator outlet with electric heat components 3500 psi 24 MPa 241 bar Minimum Fluid Working Pressure at regulator outlet 100 psi 0 7 MPa 7 0 bar Air Supply Pressure Range 60 120 psi 0 4 0 8 MPa 4 1 8 3 bar 10 Micron filtra tion required Fluid Filtration Required 30 mesh 500 micron minimum Viscosity Range of Fluids 10 000 to 1 000 000 cps with helical flow meter Minimum Dispensed Shot Size 3 cc with high resolution ambient helical flow meter 6 cc with heated helical flow meter Wetted Parts meters and fluid plates 303 304 321 17 4 stainless steel tungsten carbide PTFE steel fluoroelastomer Power Requirements 100 240 VAG 2 025 580 5240 Rell SORE eee eek full load 1 4A fuse rating 2 5A ZA OG on Sanh ys asarga Bad BD Sees ane eiditos full load 4A fuse rating 4A Power Supply Voltage Range 100 240 Vac 50 60 Hz single phase Operating Temperature Range control cente sis Gets ohne
48. that will trigger a maintenance advisory for the air sup ply 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 3 Maintenance Totalizers page 113 for more information about maintenance total izers RRB CS Co Fluid Plate 1 acti C Mo Active Errors Maintenance Advisory Limits Fluid Flate 2 Lirnit Volume Supply To O25 gal Us 26416 galt 152 gal Us 0475 galls TESTS galls PAYS gal Us 0 006 galls 0 001 galis wP ol Regulator Ol Flowmeter O0 Valve T D Valve 2 Ol Valve oO Valve 0 108 Fluid Plate x Screen 8 Style This screen enables users to set up to 256 styles depending on system configuration Press cal to access the style setup fields Enter the style number in the Style field the target volume in the Volume field and the tolerance percentage in the Tolerance field NOTE The number of possible styles is dependent on the model type To enter the style name press while in the Style Name field See Keyboard Screen page 109 for instructions on using the keyboard screen to enter the style name TEMEN Fid Plate 1 System Ott Mo Active Errors Style
49. 0 Vdc error Failed FCM Replace FCM if neces sary Inlet pressure to regula Alarm or Incorrect set limit Verify limit is set cor tor is above upper limit Deviation rectly set for operation user select Material supply pres Decrease material able sure is too high supply pressure Failed transducer Check transducer replace if necessary Incorrect set limit Verify limit is set cor rectly Outlet pressure of regu Alarm or lator is above upper Deviation limit set for operation _ user select Material supply pres Decrease material able sure is too high supply pressure Failed transducer Check transducer replace if necessary Incorrect set limit Verify limit is set cor rectly Material supply pres Increase crease mate sure is too low rial supply pressure Failed transducer Check transducer replace if necessary Inlet pressure to regula Alarm or tor is below lower limit Deviation set for operation user select able Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause ps Fluid Plate Events andErrors ss s sSSSCs Plate Events and Errors BGS TT RIE EM E EN ES Low Pressure Measured outlet pres Alarm or Incorrect limit set Verify limit is set cor P2C_ sure less than desired Deviation rectly outlet pressure minus user select No or insufficient Increase material flow tolerance able material flow rate P3C_ P4C_ Dispense valve nee Dislod
50. 03 0x804 0x805 0x806 0x807 w a n OxC04 OxC05 OxC06 OxCO7 D 135 Appendix C Communications Gateway Module CGM Connection Details Units Units See Units See Units Read or JJ D Q Q O 256 267 Description Definitions page 137 Write 256 267 Description Definitions page 137 Write Ox29E Pressure Units Pressure Units Enu Read OxOFF Fluid Plate Dis Cc Read Only meration Write pensed Vol ume Ox29F Rate Units Rate Units Enumera Read ee at Write OxODB Active Fault Fault Error Code Read Only Ox2A0 Maintenance Volume Units Enumer Read Wa fo Lee Pe emis ee Write OxOF8 Fluid Plate Sta Fluid Plate Status bit Read Only Ox2A1 Maintenance Mass Units Enumera Read Mi tus Bits ee este de Write OxOFE Requested Vol cc Read Only Ox2A2 Maintenance Mass Units Enumera Read er ume ere Ox2AD Valve 1 Swirl Swirl Enumeration i Association ma Swirl Zone Ox2AE Valve 2 Swirl Swirl Enumeration Association mt Swirl Zone Ox2AF Valve 3 Swirl Swirl Enumeration Association ak Swirl Zone 0x2B0 Valve 4 Swirl Swirl Enumeration Association Swirl Zone Maintenance dispensed volume time can only be set to 0 Swirl Commands Read or 264 275 Description Gateway Units Write 0x004 Software Part STR_3_0 Read Only Number 0x005 Software Part STR_7_4 Read Only Number Ox2B5 End Job On Boolean Read 0x006 Software
51. 115 for custom wiring For single fluid plate systems only 50 ft 15 m cable with flying leads 123793 All systems Breakout board 123783 and 50 ft 15 m cable 123792 NOTE 256 styles option is not available with Discrete Gateway systems These fluid metering systems have ETL certification NOTE Fluid metering systems with heated mastic regulators are not ETL certified C US LISTED Intertek 9902471 Certified to CAN CSA C22 2 No 61010 1 Conforms to UL 61010 1 C This product has been tested to the requirements of CAN CSA C22 2 No 61010 1 second edition including Amendment 1 or a later version of the same standard incorporating the same level of testing requirements 4 3A2098H 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 Used by RE Maximum Working he aah FCM Key Model Pressure Description tor Token eee r Re a Cartridge oe Flow ere es n Ra a Cartridge E Flow Meter ama re an og i Mastic age ru Flow sina PF12xx N00 psl Mastic Regulator No Flow Meter 2 styles zaa 16M101 35 MPa 345 bar moo aia RE Bi Sse Rt am See z o a Heated Mastic esr No Flow Meter EIRE MEN PF17xx a o sa Cartridge ene ae Resolution 16M100 PE P hig oy 7 Cartridge de Flow re PFO1 xx a nay ip sai Cartridge ees Flow Meter aa 16M103 EEE a sgh a Mastic E a Flow SEO PF22xx 2000 pa Mas
52. 136 131 117 120 See page 96 See page 95 V aw V CARS A 7 x D ff Y tm Nr a ve CA ee YA J v A EX fo IWA EN W Wa Vv N z p O K 0 FZ 7 Ll See page 95 3A2098H 94 Parts Fluid Plate Assembly Parts continued LO N 129 126 110 109 26 105 128 Ss 141 122 ok N g Ve DS A Tr lt T 121 95 3A2098H Parts Fluid Plate Assembly Parts continued 108 114 119 1 27 a P P Pi T ao lA gy ti19262a Fluid Plate 24B962 Shown 140 141 150 158 ET 107 199 148 145 96 3A2098H Fluid Plate Assembly Parts Ref 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 1177 118 119 1207 121 122 1247 1257 1267 1277 1287 1297 1307 131A 132 133 1354 136 137 139 140 141 143 145 146 1477 148 149 150 151 3A2098H Part 289697 289696 27 674 121820 121228 198269 110580 198268 624545 258530 16P819 120010 111119 15X756 258334 121806 189285 117820 198179 198175 121226 234967 121612 121818 114391 Description PLATE fluid BASE cube FCM cube ENCLOSURE cube door SCREW mach pan hd SCREW machine pan hd m4 x 35 CABLE CAN female female 15 0 m REGULATOR assy UNION adapter NIPPLE
53. 14 MPa 138 bar greater than required valve pres sure Excessive flow rate Reduce fluid flow through regulator Connect only one spray gun or dis pense valve to each fluid regulator 3A2098H 63 Troubleshooting Dispense Valves Valve not opening Air not getting to the open port Verify air pressure to solenoid No Valve On signal from automa Check input from automation unit tion unit Valve not shutting off Air not getting to the close port Verify air pressure to solenoid except AutoPlus valve Verify solenoid operation Verify air line routing and connec tions Ria On signal from automation Check input from automation unit unit is on Sluggish open close Air pressure low Verify air pressure is above 60 psi 410 kPa 4 1 bar Needle seat worn Rebuild valve replace needle seat Pressurized material past the valve Reduce running pressure shut off is escaping Reduce nozzle length Increase nozzle orifice size 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 necessary Worn piston o ring Rebuild valve replace piston o ring Swirl Dispenser Motor not running motor fault alarm Cable disconnected Verify cable connections to swirl active board swirl motor cable and swirl
54. 1C19197 WASHER WASHER plain Pr NS DS spring m6 RS PS RS RS RS RE hd EC ER A ER RES RE hd hex 129 246652 METER assy r ee mo p pees PP o 16 meter L a styles meter eee styles meter es 147 16M100 TOKEN key 2 styles meter enabled 16M104 TOKEN key 256 styles meter enabled M101 TOKEN key 2 styles 16M105 TOKEN key 256 iad Oe meter disabled 15 121901 SUPPRESSOR box ia t snap ferrite Not for sale 98 3A2098H Appendix A Advanced Display Module ADM Appendix A Advanced Display Module ADM Display Overview The ADM display is divided into two main functions Setup Mode and Run Mode Setup Mode Functions The setup mode functions enable users to e configure installed system components e set units adjust values set formats and view software information for each component e set or change information regarding the Gate way module e view information regarding the particular Gate way module used e set controls and valve commands e set on and off delays for valves and the regula tor set k factor pressure and flow rate variables set offsets for inlet and outlet pressures set error types set variables for maintenance advisories set up to 256 styles for models with a CGM and set up to 16 styles for models with a DGM Run Mode Functions The run mode functions enable users to adjust the bead scale perform manual dispens
55. 2 101 006 Fluid Plate 1 LITE 101 012 Fluid Flate 2 LITE 101009 Swirl Control 1 TEE 2 101 006 Swirl Control 2 LITE 101 006 Models Models Check the identification ID plate for the 6 digit part number of the fluid metering system Use the following matrix to define the construction of the system based on the six digits For example Part PF1110 represents a PCF fluid metering system PF a two style system 1 a fluid plate with a cartridge regulator and no meter 1 a DeviceNet user interface 1 with a 100 240 Vac power supply 0 NOTE To order replacement parts see Parts section in this manual The digits in the matrix do not correspond to the Ref Nos in the Parts drawings and lists First and Third Digit Fourth Digit Fifth Digit SithDigit LI Description Regulator Meter Description Description PFT 25yes HET FCarridge None O Discrete 0 100 240 Vac onimucus 2 1OSVes 2 Mastic None 1 DeviceNet 1 24 Vdc a ae se PT oser flans Resolution Integrated Swirl Mastic High PROFIBUS 24 Vde with I nesouion PROFPUST gag Swn Heated Heated PROFINET Mastic Standard Resolution Es None Mate JM ANS Cartridge Ultra High un 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
56. 24 1 MPa Compact 289262 A 0 012 in for narrow bead Hem flange and after hem i 241 bar widths widths PrecisionSwirl Orbital Dispenser Cable Assemblies Description 233125 6 ft 1 8 m motor extension cable assembly 233124 9 ft 2 7 m motor extension cable assembly 233123 15 ft 4 6 m motor extension cable assembly 617870 55 ft 16 8 m motor extension cable assembly 6 3A2098H Automation Gateway Assemblies Each control center comes with one automation gateway assembly The automation gateway module is either a Dis crete 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 PCF Model Gateway Part Number To Order Rotary Switch Position User Interface Description PFxx0x Discrete 24B681 DGM PFxx1 X DeviceNet 1 5V759 CGM PFxx3x PROFIBUS 15V761 CGM PROFINET Swirl Control DGM PFXx2x EtherNet IP 15V760 Any CGM ny CGM 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 Part Number Rotary Switch Assembly To Order Position PFxxx2 1 2 3 or4 PFXxx3 see Swirl Control 16M350 16M351 DGM on page 19 24B681 3A2098H Models Automation Gateway DGM or CGM Swirl Control DGM Warn
57. 914 psi 263 psi Scale Bead 44 2 Press B f4 to enter maintenance screen 11 17 11 1349 Home Fid Pate IEEE 2 gt Display Control Mo Active Errors Control Mode MIRE LA 265 psi P n e RPM 1814 psi E FIG 33 3 To change the RPM use the arrow keys to navigate to the RPM box then enter the desired RPM 4 Press Bi and verify that the Swirl Dispenser begins rotating Press a again to stop the Swirl Dispenser again to exit maintenance screen 3A2098H Automation Control Normal Operation During automation control normal operation the sys tem can dispense or change dispense parameters when it receives a command from the automation unit The automation control operates using the concept of jobs and styles For a detailed explanation of jobs and how they work within the PCF system see Jobs on page 45 For a detailed explanation of styles and how they work within the PCF system see Styles on page 46 Jobs NOTE See Appendix D I O Signal Descriptions page 138 for automation input and output signal descriptions A job is an automation sequence in which material can be dispensed The amount of material specified for a job varies by application In some applications a job may be the amount of material dispensed on a part Other appli cations may define a job to be the amount of material dispensed on a number of parts or dispensed over a period of tim
58. Assembly PrecisionSwirl Orbital Dispenser Swirl Dispenser PrecisionSwirl Cable Expansion Swirl Enclosure ZITASTTONMOOWX gt Included Optional 12 ai Power In 3A2098H Overview System Overview The PCF fluid metering system combines closed loop pressure control with the ability to change bead profiles quickly When used with an optional flow meter the sys tem automatically adjusts for fluctuations in the operat ing environment such as material viscosity temperature and tip wear in order to maintain the desired dispense rate The module responds to automa tion signals to provide an accurate and consistent output flow based on a comparison of actual to desired flow rates Typical Applications Bead dispensing Gasketing Seam sealing Hem flange Sound deadening Anti flutter Body panel reinforcement Profile wrapping Cable filling System Components The diagram in FiG 4 shows an example of the PCF module and cables Overview Control Center User Interface The control center communicates with the PCF fluid plate assembly to control fluid pressure and dispense valve operation The control center receives input from the automation controller and uses these inputs to determine communi cation to the fluid plate assembly Fluid Plate Assembly The fluid plate assembly contains components that con trol and monitor fluid dispensing A PCF fluid metering system can have u
59. Dispense No Error Fluid Plate 2 78 79 EE y y y w S si o o o o wo il 2 B Fluid n o i Pates 4 164 Dispenser Fluid Plate Ready 65 67 Fluid Plate 3 7 3B 136 Dispense Volume OK BT 138 Dispenser Fluid Plate Purge Request 139 Dispenser Fluid Plate Remote Start Purge In Process 184 85 O O1 A N 187 3A2098H 125 Appendix C Communications Gateway Module CGM Connection Details GE ka mr rs Command Interface Value Bit 10 Interface Value Bit 10 EL Fluid 2 Plate 3 93 94 95 All Fluid n a ee E E Interface Value Bit 11 Plates Swi a Command Interface Value Bit 12 Interface Value Bit 12 ae iat Command Interface Value BIL 13 Interface Value Bit 13 ae COMMAS V Bi Te Interface Value Bit 14 HA RARE e a Interface Value Bit 15 DE Command interface Value Bit 16 Dispenser Fluid Plate Ready 197 Dispenser Fluid Plate No Alarm RE Dispense No Error a8 Command Interface Value Bit 18 Interface Values Bit 18 All Fluid Dispense in Process nar Plates Swi 1100 Dispense Volume OK Fluid Te Command Interface Value Bit 20 interfaces clue Bit 20 LE 107 Plate 4 1102 Dispenser Fluid Plate Purge ommand Interface STANCE Bit 22 Request Command Interface Value Bit 23 1103 Dispenser Fluid Plate Remote ommand Interface Value Bit 24 Start Purge In Process 4 Command Interface Value
60. F system can store up to 256 styles See Styles page 46 for more information about styles and instruc tions on setting up styles Style 0 is always the purge style Configure Advanced Settings Use the advanced settings to set or change the format and display units such as the language date format and pressure units for all PCF screens See Setup Mode page 101 for advanced setting guidelines 38 3A2098H On Off Delays The PCF fluid regulator can physically respond faster than the dispense device and its solenoid As a result the fluid regulator can supply material to the dispense device before the device has time to open Supplying material to a closed device can create trapped pressure At the end of a cycle the dispense device can shut off before the pressure has dissipated This can cause a dispense of an excess of material at the beginning of the next cycle To eliminate these two problems change the delay time associated with the opening of the fluid regulator dis pense and or the closing of the dispense device see Table 5 On Off Delay Variables For instructions set ting on off delays see Configure Delay Settings page 34 NOTE On Off delay can be set for each dispense device In general delays should be adjusted so the outlet pres sure during no flow is slightly below the outlet pressure during dispense Table 5 On Off Delay Variables Sets the Amount of Time Sets time from Dispense Va
61. 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 3A2098H Purge Using Style 0 Purge Using Purge Bit Operation 51 Operation Control Charts continued 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 Automation Outputs PCF Inputs Remote Start Purge Remote Start PP PTT TT TT a ee a a ee ee ee ee ee ee ee fa CE a S E S E S e 3 Error Reset 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 52 3A2098H Control Charts continued Automation Inputs PCF Outputs Dispense Ready Dispenser Fluid Plate No Alarm Dispenser Fluid Plate No Error Dispense In Process Volume OK Automation Outputs PCF Inputs Style Bits Style Strobe Dispense Valve X On Dispense Complete PCF State Regulator Active Dispense Valve X Open Automation Inputs PCF Outputs Dispense Ready Dispenser Fluid Plate No Alarm Dispenser Fluid Plate No Error Dispe
62. Gateway Press to enter the value 3A2098H System Setup Press to move to the Job End Delay field Enter the desired delay time in seconds Press to enter the value 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 Press to move to the End Job on Alarm Check box Press to enable or disable Press to move to the Display Control Password field Press to enter the value Press to exit edit mode If multiple fluid plates are installed repeat this pro cedure for the other Fluid Plates 33 System Setup Configure Mode Settings Set valve command s including the dispense mode pressure bead shot or full open and flow rate or pres sure for each valve The bead scale is also adjustable from this screen NOTE For a description of each dispense mode see Dispense Control Modes page 112 1 With the system in setup mode navigate to the Fluid Plate x screen 2 Mode Settings 2 Press m to access the fields to make changes Pd 137 Fluid Plate 1 Fluid Plate 2 No Active Errors Mode Settings Mode WYOC Command Valve t Pressure 1000 psi Valve 2 1000 psi Valve 3 Pressure 1000 psi Valve 4 Pressure gt 1000 psi Bead Scale FIG 21 3 Press and to set the mode for each valve that will be used to Pressure Bead Shot or Full Open Press to enter each selection 4 U
63. 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 mea sured 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 vol ume for pressure mode Continuously Running Applications In some cases the target volume for a job is not known An example of a case where the target volume is unknown is a continuously running system This would be a system that does not run jobs but runs continu ously 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 cor responding to
64. Instructions Parts gt 7 PCF with PrecisionSwirl noce Precision Dispense System EN GRACO 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 Optional PrecisionSwirl Orbital Dispenser sold separately GRAGO IMPORTANT This manual does not apply to some PCF sys tems See note on page 3 to verify this is the correct manual for your PCF system PCF Control Center PCF Fluid Plate CE PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 MOGGIS jie dace meee hci aes OS coos at a Se 4 Fluid Plate ANS 224 5 sen ain banni 5 Expansion Swirl Enclosure Assemblies 6 PrecisionSwirl Orbital Dispenser Assemblies 6 Automation Gateway Assemblies 7 Swirl Control DGM 7 WaIMINGS 6 444 i56 is iris seen sos 8 System Configurations 10 Typical Installation Single Swirl Singl
65. La Style Style Names Volurne O O cc Tolerances O ols Pre Charge Mode Display Pressure O ps Fluid Plate 2 3A2098H Fluid Plate x Screen 9 Swirl Association This screen enables users to set the swirl to fluid plate association This allows the system to apply errors to the correct fluid plate when a swirl error occurs and to stop the correct fluid plate from dispensing when certain swirl errors occur Fluid Plate 2 Sell Fluid Plate 1 Mo Active Errors url Association Valve T Swirl Je Valve 2 Valve 3 Valve 4 Error Type Motor Fault Deviation Keyboard Screen The keyboard screen appears when text is edited Use all four arrow buttons to select each letter press to enter the letter To back space press To delete To enter the the entire style name entered press 4 style name press S To cancel the entry and exit the keyboard screen press fi RRGMECC TIM Fluic Plate 1 acti Mo Active Errors Style Mame 15 characters max C Miele istel tel ol Fluid Plate 2 Active falwife Ir Telly be BAGG unaua Pe feb It fee Im Te 3A2098H Appendix A Advanced Display Module ADM Swirl Setup Screen This screen enables users to e Set the Speed Command Source to Display or Gateway If it is set to Display users can set the fixed speed e Set the Run Mode Speed Adjust to Enable or Dis able e Set the speed scale from 50 150 e S
66. Logic Supply V solated Logic Supply V solated Ground Digital In Digital In Digital In 0 30 0 30 0 30 71 72 Digital In 0 30 N O1 Digital In 0 30 N O N N N N Digital In 0 30 0 30 io O Fluid plate selector input pin 72 toggles the plate to which these inputs and outputs will apply Pin 72 0 Inputs and outputs apply to fluid plate 1 Pin 72 1 Inputs and outputs apply to fluid plate 2 t Alarm and Error signals may be active high or low depending on the setting on the Gateway setup screen See Discrete Gateway Automation Setup Screen page 104 N 3A2098H 11 Appendix B Discrete Gateway Module DGM Connection Details Pin References NOTE To avoid ground loops and noise immunity issues do not ground the shield of the D subminiature connector cable it is already grounded through the mounting screw on the base of the DGM Fic 68 D Subminiature Connector Pin References 118 3A2098H Appendix B Discrete Gateway Module DGM Connection Details DGM Digital Input The digital inputs function only when power is supplied to pin 51 and there is a ground connection to pin 70 See Pin References page 118 for details The digital input is rated at 0 30 Vdc and requires an NEC Class 2 power supply connected to pin 51 The DGM provides optical isolation as shown in the following illustration e Pins 52 59 71 78 e Maximum current draw 3 6 mA e Type Sinking Discret
67. 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 con trol DGM and the swirl board The customer does not need to make any external connections with the swirl control DGM Front Back Front Access Cover Removed LU Software CF CH Switch Token Slot Fic 10 Swirl Control DGM 3A2098H 19 Overview Key Tokens The ADM and FCM must each have a key token installed in order to operate If the incorrect key token is installed the module will not operate The DGM does not require a key token ADM FIG 11 NOTE There is one FCM located on each fluid plate Ifa new ADM or FCM is installed follow the instructions on page 77 to upgrade the software in the new module and to install the key token from the old module in the new module The following is a list of key token part numbers If you lose your key token be sure to order the correct item to ensure proper system operation NOTE The key tokens for the ADM and FCM look alike but only work in one module or the other If the key tokens for the ADM and FCM become mixed locate the part number on each token then refer to the following table to determine which module each token applies to Des
68. Trigger Source Enu O Command Cable 1 Gateway 2 Combined 3 Command Cable 3x meration Error Type Enumeration 1 0 None 1 Alarm 2 Deviation Error Type Enumeration 2 1 Alarm 2 Deviation Fault Error Code A 32 bit string in the format of OXxDDCCBBAA where OxAA represents the most significant char acter in the string and OxDD represents the least significant character in the string Flow Meter Type Enumeration 1 Volume 2 Mass Fluid Plate Status 0 Bitfield Function Dispense In Process Purge in Process Remote Dispenser Ready Dispensed Volume OK Start in Process Dispense No Alarm Dispense No Error Dispense Control 1 Bitfield Dispenser Purge Request Fluid Plate Status Bitfield Valve 3 Swirl Installed Valve 4 Swirl Installed Valve 1 Swirl Active Valve 2 Swirl Active Valve 3 Swirl Active Valve 4 Swirl Active Fault Reset Remote Start Purge Alarm Active Deviation Active Advisory Active Dispensing Disabled Fluid Plate Enabled Flowmeter Enabled Inlet Sensor Enabled Heated Plate Integrator Enabled Function Operation Mode see Valve Mode Enumeration Precharge Active Valve 1 State Valve 2 State Valve 3 State Valve 4 State Ready to Dispense In Job Cycle Valve 1 Swirl Installed Job Cycle Complete Valve 2 Swirl Installed Job End Mode Enumeration 0 Timer 1 Gateway Maintenance Units Enumeration 0 Volume 1 Mass 2 Time Mass Units Enumeration 0 lb 1 kg Precharge Settin
69. accept the selec tion 5 Repeat for the other Dispensers and Swirl Dispens ers 6 Press aye to exit edit mode N Mo Active Errors stem Configuration Swirl Orbiter Fluid Plate Installed T a ninstallec 3 Uninstalled Lninstalled Uninstalled FIG 19 3A2098H 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 LA to access the fields to make changes Fluid Plate 2 SEA Fluid Plate 1 Mo Active Errors Control Settings Fr Dispense Trigger Source 5 Command Value Source 1 Job End Mode 2 Run Mode Bead Adjust Enables I End Job On Alarm 4 Display Control Password Disable F FIG 20 3 Press to open the Dispense Trigger Source drop down list and select Gateway Command Cable Command Cable 3x or Combined If Com mand 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
70. alog _ bar Scale Pressure Mpa Valve 4 10 Pressure psi VDC Analog _ bar Scale Pressure Mpa Regulator Volume Maintenance gal US Dispensed Vol gal Uk ume Liters Mass HH lb kg Volume Maintenance gal US Dispensed Vol gal Uk ume Liters Mass lb H H HH kg 0x27B Valve 4 Vol Volume ume Mass gal US H Advisory Limit gal Uk Liters Mass Ib HHH kg Ox283 Swirl Fault Error Type Enumera Error Type tion 2 0x284 Low Flow Rate Error Type Enumera Read Error Type tion 1 Write 0x285 High Flow Rate Error Type Enumera Read Error Type tion 1 Write x287 x28A Read Write Read Read Write Write Read Write Read 0x286 Low Pressure Error Type Enumera 0 High Pressure Error Type Enumera Error Type tion 1 Read Write D O NS Read Write 0x289 High Outlet Error Type Enumera Pressure Error tion 2 Type 0 Low Volume Error Type 0x28B High Volume Error Type 0x28C Low Com puted Target mn Error Type 134 Error Type Enumera Read tion 1 Write Error Type Enumera Read tion 1 Write Error Type Enumera Read tion 1 Read Write Flow meter O es O 3A2098H Units See Units 256 267 Description Definitions page 137 Supply Mai
71. are password protected a pass word entry screen will appear after pressing La The password is defined in the Advanced setup screen If the password is set to 0000 the password is disabled Advanced Setup Screens There are four Advanced setup screens which enable users to set units adjust values set formats define USB settings and view software information for each component Press to scroll through the Advanced setup screens Once in the desired Advanced setup screen press alto access the fields to make changes Press to exit edit mode NOTE Users must be out of edit mode to scroll through the Advanced setup screens Advanced Setup Screen 1 This screen enables users to set the language date for mat current date and time password and number of minutes before the screen saver comes on The time does not automatically update for daylight savings time Mo Active Errors 11 17 11 13 59 Language English Date Format rornfcel Date ley Time 13 Password 0000 Screen Saver O rninutes 3A2098H Appendix A Advanced Display Module ADM Advanced Setup Screen 2 This screen enables users to set the units of measure for maintenance volume maintenance mass pressure and flow rate 111711 13 59 Gateway Fluid Plate E Mo Active Errors Maintenance Units galde fw Maintenance Units Pressure Units Rate Advanced Setup Screen 3 This screen enables users to se
72. arm Cable disconnected Verify cable connec the 50 tolerance tions to swirl board range for at least 5 sec swirl motor cable and onds while operating swirl orbiter Shorted motor cable Replace swirl motor amber LED on swirl cable 55 ft board will be on Orbiter bearing failure Replace bearing Motor defective Replace swirl orbiter 3A2098H 75 Maintenance Maintenance AOA Prior to performing any maintenance procedures follow the Pressure Relief Procedure on page 57 Maintenance Schedule The following tables list the recommended maintenance procedures and frequencies to operate the equipment safely The maintenance is divided between mechanical and electrical tasks Maintenance must be performed by trained personnel per this schedule to assure safety and reliability of the equipment Mechanical Operator Maintenance Person Task Daily Weekly Monthly Bsr 7000 or 1 000 000 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 La Check tighten fluid connections Check tighten air connections Replace Voltage to Pressure V P Transducer Electrical Task Check cables for wear Verify cable connections Verify operation of System Stop button Check Component Manual for more detailed maintenance information 76 3A2098H Advanced Displ
73. ass differs from entered process target by more than entered tolerance for style requested WND_ Fluid Plate Key Missing or invalid key token Outlet Pressure Transducer Error Outlet pressure trans ducer error Alarm Alarm Alarm or Deviation user select able PCF regulator is not Check regulator and regulating correctly repair if necessary Incorrect style target Enter correct values or set tolerance to 0 to disable error Partially plugged tip or Clean tip and or supply supply system system Insufficient flow to Increase flow rate to PCF regulator inlet regulator inlet PCF regulator is not Incorrect style target regulating correctly volume or tolerance setting volume or tolerance Alarm or Deviation user select able Check regulator repair if necessary Entered process target Enter correct process incorrectly target Entered tolerance Enter correct tolerance incorrectly Requested volume Check automation pro incorrectly gram Automation problem Verify automation is correct Entered process target Enter correct process incorrectly target Entered tolerance Enter correct tolerance incorrectly Requested volume Check automation pro incorrectly gram Automation problem Verify automation is correct FCM key token is Verify FCM key token required to run system is installed Alarm or Deviation user select able Alarm or Deviation user select able
74. ay Module ADM Upgrade Software NOTE Back up the custom language file if installed before upgrading software See USB Data page 59 for more information 1 Turn off power to the system 2 Remove token access panel and then remove the key token do not discard token Access Panel t 24E451 2B9900_ 3a FIG 41 Remove Access Panel 3 Insert and press software token firmly into slot NOTE There is no preferred orientation of token BL r 24E451_ 3B9900 4a FIG 42 Insert Token 4 Turn on power to the system The red indicator light BL will flash until new software is completely loaded 5 After the red indicator light shuts off turn off power to the system 6 Remove software token 7 Reinstall key token and replace token access panel 3A2098H Maintenance Cleaning Use any alcohol based household cleaner such as glass cleaner to clean the display Upgrade Gateway Module Software NOTE The Gateway module connection to the system is temporarily disabled during the use of upgrade tokens The following instructions apply to all Gateway modules 1 Turn off power to the system 2 Remove the access cover Access Aa Cover T112319A FIG 43 Remove Access Cover 3 Insert and press token firmly into slot NOTE There is no preferred orientation of token 4 Turn on power to the system The red indicator light CK will flash until new software is completely loaded
75. between each fluid plate and applicator Connect fluid supply line and air supply to module See page 27 8 Plumb air filter assembly near air supply drop site that will be used for fluid plate assembly 9 For systems with swirl dispensers install each swirl dispenser onto outlet of a dispense valve 3A2098H Installation 10 Connect other fluid and air lines to additional system components as instructed in their manuals 11 Install fluid plate swirl and gateway cable assem blies page 28 12 Install Gateway interface page 30 21 Installation Install Control Center NOTE This section applies to both the primary control center and the expansion Swirl enclosures Mount Ensure the following criteria are met before mounting the PCF control center 22 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 con trol unit to run cables to other components Ensure there is safe and easy access to an appro priate electrical power source The National Electric Code requires 3 ft 0 91 m of open space in front of the control center 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 Secure the control center wi
76. ble e heated mastic fluid regulator with a heated flow meter e anda heated mastic fluid regulator without a flow meter 3A2098H Fluid Regulator There are three fluid regulator options e cartridge e ambient mastic e heated mastic All of the fluid regulator options use air pressure to con trol fluid pressure provide fast response to electronic commands and ensure a precisely controlled continu ous 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 adhe Ssives 3A2098H Overview Fluid Control Module FCM LEDS Connectors FIG 6 FCM Sensor Connections Table 1 FCM Sensor Connections Sensor Description Command cable optional accessory kit Inlet pressure sensor non heated systems only Outlet pressure sensor non heated systems only Rotary Switch on FCM The rotary switch on the FCM see FIG 6 must be set to a valid position and each FCM must have a unique rotary switch position The FCM rotary switch position determines which number to assign to that fluid plate The settings including defined styles for each fluid plate are stored in each FCM so changing the rotary switch
77. connect each swirl dispenser to an expansion swirl enclosure or to the control center Connect a CAN cable from the control center to one fluid plate assembly For multiple fluid plate systems 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 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 FIG 17 on page 29 5 Use the automation interface cable not provided to 28 connect the Gateway module to the automation controller 3A2098H Installation a i paii i J J
78. cription 16M100 FCM Key Token 2 styles Flow Meter 16M101 FCM Key Token 2 styles No Flow Meter 16M102 FCM Key Token 16 styles Flow Meter 16M103 FCM Key Token 16 styles No Flow Meter 16M104 FCM Key Token 256 styles Flow Meter 16M105 FCM Key Token 256 styles No Flow Meter 16M217 ADM Key Token Standard PCF 20 3A2098H Installation Before Installation e Have all system and component documentation available during installation e See component manuals for specific data on compo nent requirements Data presented here applies to the PCF assemblies only e Be sure all accessories are adequately sized and pressure rated to meet system requirements e 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 sys tem The system is too heavy for one person to lift or move Installation Steps 1 Mount control center page 22 2 For systems with multiple swirl dispensers mount expansion Swirl enclosures page 22 3 Connect and ground control center and expansion Swirl enclosures page 23 4 Mount each fluid plate assembly page 24 5 Ground each fluid plate assembly page 27 6 Check ground continuity 7 Connect fluid lines
79. cting a D Sub cable to the D Sub connector CG Both options are accesso ries and must be ordered separately e For single fluid plate systems only D Sub to fly ing leads cable 123793 See Appendix B Discrete Gateway Module DGM Connection Details page 115 for details and cable inter face signals e 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 115 for details and pin assignments KID W N fr 2 J r_24B681_2B9904_2b CG FIG 18 Connect D Sub Cable DGM Status LED Signals See LED Diagnostic Information page 65 for signal definitions 3A2098H Installation DGM Rotary Switch Position The Discrete Gateway Module DGM rotary switch must be in position 0 for Automation Gateway DGMs and positions 1 4 for Swirl Control DGMs in order for the DGM to operate See Automation Gateway Module on page 18 and Swirl Control DGM on page 19 31 System Setup 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 instruction
80. d by PROFINET The Ethernet interface is Red 2 IP Address Set IP address via system auto polarity sensing and auto crossover capable Network Status NS Red 3 Station Set Station Name via system a ee not monitor Red 4 o Inter Cycle system power replace n No power tenes nal Error module No connection with lO Controller Link Activity Link Green au ahs Connection with IO Con lO Controller with RUN state cc a No Link no communication present Flashing Connection with IO Con Link established no communication present Green troller established Green Link established communication present IO Controller in STOP flashing state 122 3A2098H Appendix C Communications Gateway Module CGM Connection Details EtherNet IP MS NS Link 1111814A FIG 70 EtherNet IP Fieldbus Connections The Ethernet interface operates at 100Mbit full duplex as required by PROFINET The Ethernet interface is auto polarity sensing and auto crossover capable Network Status NS sate esere No power or no IP address Green On line one or more connections established CIP Class 1 or 3 Flashing On line no connections established Green Red Duplicate IP address FATAL error Flashing One or more connections timed out CIP Class Red 1 or 3 Module Status MS sme een Controlled by a Scanner in Run state Flashing Not configured or Scanner in Idle state Green Major fault EXCEPTION state FATAL error etc
81. dee 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 Trigger Using Command Cable 3x Automation Inputs PCF Outputs Dispense In Process Automation Outputs PCF Gateway Inputs Dispense Valve 1 Trigger Dispense Valve 2 Trigger Dispense Valve 3 Trigger PCF State Regulator Active Precharge 0 LOL LL Dispense Valve 1 Open Dispense Valve 2 Open i Dispense Valve 3 Open CL 54 3A2098H Control Charts continued Trigger Using Command Cable Automation Inputs PCF Outputs Dispense In Process Command Cable Dispense Trigger COLLE PCF State Regulator Active Precharge 0 COOL Dispense Valve X Open LOTO Dispense Valve X Open determined by Enable Valves check boxes on Fluid Plate x screen 1 Control Settings Trigger Using Gateway Automation Inputs PCF Outputs Dispense In Process Automation Outputs PCF Gateway Inputs Dispense Valve 1 On Dispense Valv
82. deviation that will be issued if the inlet and or outlet pressure go outside of the set limits LUT AIT Lae e Fluid Flate 1 Fluid Flate 2 Activ E Mo Active Errors Pressure Sensors Offset Pressure Inlet LT psi 1914 psi Outlet psi 23 psl Lirnit rror Type Min Inlet C O psi Max Inlet 5000 psi Max Outlet 5000 psi 3A2098H Appendix A Advanced Display Module ADM Fluid Plate x Screen 6 Error Type This screen enables users to set the error type none alarm or deviation that will be issued if the pressure flow rate volume or computed target goes outside the tolerance settings of the active style See Configure Errors on page 36 NOTE Only the low high pressure errors will be enabled for systems without a flow meter e The pressure and flow rate errors are relative to the value commanded through the command cable gateway or display e The volume is relative to the requested volume and computed target errors are relative to the target vol ume defined in the style RRREBEC Co Fluid Plate 1 ERTE Active Mo Active Errors tai Error Type La Low Pressure Deviation High Pressure Deviation Low Flow Rate Deviation M High Flow Rate Deviation V Low Material High Material Low Computed Target High Computed Target 107 Appendix A Advanced Display Module ADM Fluid Plate x Screen 7 Maintenance Advisory Limits This screen enables users to set volume or hours limit
83. dged over the gateway Active errors are displayed in the menu bar CPE Fid Plate 1 IRL CT WNCO Key Token Error 4DM WACO A Key Token Error ADM Fic 40 Error Pop Up The previous 200 errors are displayed on the error report screens See Run Mode page 110 for instruc tions on navigating to and through the error report screens There are three levels of errors alarms deviations and advisories Alarms cause the system to shut down Deviations and advisories do not shut down the system NOTE e Alarms set the dispenser fluid plate ready signal LOW e Advisories and deviations do not set the dispenser fluid plate ready signal LOW Diagnose Errors See Event and Error Codes and Troubleshooting on page 67 for error codes possible causes and solutions 66 3A2098H Errors Event and Error Codes and Troubleshooting Error codes are stored in the events log and are displayed on the error report screens Gateway error numbers are reported over the Gateway interface Error codes shown as XYZ_ represent error codes XYZ1 XYZ2 XYZ3 XYZ4 where the last digit represents the number of the fluid plate to which the error applies Error codes in the following table are sorted by gateway error number then by event code System Events and Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause System Events and Errors ECOX Setup Values Setup change notifica Record only A se
84. ducer 1 Prepare Fluid Plate Assembly for Repair page 80 Disconnect the FCM cable and both air tubes Remove both transducer screws 122 from trans ducer bracket 118 Remove the V P transducer 121 and replace it with a new V P transducer r_pf0000_313377_31a 81 Repair 5 Secure the new V P transducer to the bracket with Replace Fluid Control Module Base SCrews 1 6 Reconnect the FCM cable and both air tubes e 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 82 Prepare Fluid Plate Assembly for Repair page 80 2 Remove the FCM 103 follow Replace Fluid Con Replace Fluid Control Module trol Module Leave the cables attached to the 1 Prepare Fluid Plate Assembly for Repair page FCM 99 3 Remove the power supply cable from the base 2 Remove the four screws 128 from the transducer 102 a a ane eae Ie AG eye ule 4 Remove the four screws 105 and ground screw dispense valve solenoid 132 and V P transducer Le 121 attached to the transducer bracket 106 from the base and replace it with a new base RA
85. 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 pres sure flow command value Valve 1 When the Valve 1 precharge mode is selected the outlet pressure will be set according to the current pres sure flow command using Valve 1 scaling values 3A2098H Operation 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 pres sure flow command using the scaling set for dispense valve s selected through the gateway interface OLUJI 1 24 en KPE Fuc Plate 2 RU system Off Mo Active Errors Style ca Style Style Marne L o Volume Tolerances Low Ols High ol Pre Charge hlode Closed A Opening 50 rns 47 Operation Closed Precharge Scaling Value Dispense Application Direction Dispense Application Direction Dispense Application Direction eo eo TS a Value Too Low Ideal Value Value Too High Controls outlet pressure based on desired command while valves are closed Ideal value is typically less than 100 due to the minimal pressure losses within the system when fluid is not flowing Opening Precharge Scaling Value Dispense Application Direction Dispense Application Direction Dispense
86. e 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 calcula tions 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 114 for instructions on how to view job reports 3A2098H Operation 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 dis pense
87. e assembly diaphragm and valve actuator subassembly FIG 57 Replace Cartridge Assembly 84 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 Nem 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 hous ing CD and torque the valve housing CE to 30 35 ft lb 41 48 Nem 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 Torque Sequence for Regulator Base Housing Screws CF 3A2098H Replace Amplifier Heated fluid plates only 1 3 Prepare Fluid Plate Assembly for Repair page 80 Disconnect pressure sensor cable 117 and power output cable Power Output Cable FIG 58 Replace Amplifier Loosen four screws on amplifier 116 cover and then remove cover Remove four screws 105 securing amplifier to bracket Remove amplifier and replace with a new amplifier Secure new amplifier to bracket with four screws Replace amplifier cover and tighten screws Reconnect
88. e 2 Maintenance due for valve 3 Maintenance due for valve 4 Duplicate Fluid Control Module Detected Swirl maintenance mode entered No flow detected for five seconds on valve activated in shot mode Advisory Alarm Advisory self clearing Alarm Totalizer exceeded limit setting Totalizer exceeded limit setting Totalizer exceeded limit setting Totalizer exceeded limit setting Totalizer exceeded limit setting Totalizer exceeded limit setting Totalizer exceeded limit setting Totalizer exceeded limit setting Two or more FCMs have the same rotary switch setting Swirl zone that is associated with this fluid plate entered maintenance mode Dispense valve not operating properly Service component If necessary reset totalizer Service component If necessary reset totalizer Service component If necessary reset totalizer Service component If necessary reset totalizer Service component If necessary reset totalizer Service component If necessary reset totalizer Service component If necessary reset totalizer Service component If necessary reset totalizer Verify that all FCMs have proper rotary switch settings Reset module after changing rotary switch setting Refer to Fluid Plate Assembly Overview section page 14 No action required Check dispense valve for correct operation and or clogging Fluid leak Check fluid conn
89. e 2 On Dispense Valve 3 On Dispense Valve 4 On PCF State Regulator Active Precharge 0 3 Dispense Valve 1 On Dispense Valve 2 On Dispense Valve 3 On Dispense Valve 4 On Trigger Using Command Cable and Gateway Combined Automation Inputs PCF Outputs Dispense In Process Automation Outputs PCF Gateway Inputs Dispense Valve X On Dispense Valve Y On Command Cable Dispense Trigger PCF State Regulator Active Precharge 0 Dispense Valve X On Dispense Valve Y On 3A2098H Operation 55 Operation Control Charts continued Enable Swirl Dispenser Automation Inputs PCF Outputs Dispenser Fluid Plate Ready Swirl X Actual Speed RPM 32 bits Actual Speed Value Valid Automation Outputs PCF Gateway Inputs Swirl X Speed Command 12 bits Command Value Set Swirl X Enable PCF State Swirl X On Full Speed Speeding Up NOTE Swirl orbiter may take a few seconds to reach full speed 56 3A2098H Pressure Relief Procedure Ao 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 Pro cedure when you stop dispensing and before clean ing checking or servicing the equipment 1 Shut off the fluid supply to the
90. e CGM Command Interface on 0288 page 131 for command interface details 36 0289 All Fluid Plates S wiris Command Interface Value Bit 8 E J E ia Command Interface Value Bit 16 ieee n o oa Aiea 7 E ac 0319 Command Interface Value Bit 31 0320 Command interface Control Bits Read 0321 oo Interface Control Bits All Fluid TA lates wiris Ose ES O87 O328 130 3A2098H Appendix C Communications Gateway Module CGM Connection Details CGM Command Interface NOTE The CGM command interface is only available for fluid plates with 16 or 256 styles The CGM command interface utilizes bits in the CGM 1 0 Data Map page 125 to support many additional functions that are not available in the other CGM I O bits NOTE When changes are made over the command interface the ADM screen may not update immediately it may be necessary to navigate away from the screen then back to it The CGM command interface uses automation output bits 256 to 327 These bits can be used to request the value of a current system setting read or change a sys tem setting write e Output bits 256 267 are used to identify the individ ual command Each bit will have a single binary value to create the hex code listed in the commands table e Output bits 268 275 are used to identify the individ ual Fluid Plate or Swirl dispenser to which the com mands will apply e Output bits 288 319 are used to iden
91. e CGM and DGM Automation Input and Output signals Automation Inputs Dispenser Fluid Plate Ready This signal is O on power up This signal will be 1 under in the following conditions e The system is in an active state and e The dispenser fluid plate does not have an active Alarm Deviations have no effect Dispenser Fluid Plate No Alarm For systems with a CGM this signal will be 1 under the following condition e The system does not have an alarm e For systems with a DGM this signal can be configured to be active high or active low See Discrete Gateway Automation Setup Screen page 104 Dispenser Fluid Plate No Error For systems with a CGM this signal will be 1 under the following condition e The system does not have an error alarm devi ation or advisory e For systems with a DGM this signal can be configured to be active high or active low See Discrete Gateway Automation Setup Screen page 104 Dispense in Process This signal is O on power up This signal will be 1 under the following condition e The system is in the middle of a job Dispense Volume OK This signal will be 1 under the following conditions e The system has completed a job and e the volume of the job is within the tolerance specified and e the style strobe is 1 138 Dispenser Fluid Plate Purge Request This signal is 1 on power up if a purge interval has been defined O on power up otherwise An
92. e Fluid Plate 10 Typical Installation Multiple Fluid Plates No Swirl Dispensers si s nisa mianvessentssine 11 Typical Installation Multiple Fluid Plates Multiple Swirl Dispensers 12 OMBFVICW En ete Seat ate eee eue 13 System Overview 13 System Components 13 Fluid Plate Assembly Overview 14 Control Center Assembly Overview 16 Key Tokens 20 stala hoN users sine benuedit sense 21 Before Installation 21 Overview 21 Install Control Center 22 Install Fluid Plate Assemblies 24 Install Cable Assemblies 28 Install Gateway Module Interface 30 System Setup 2 4 304 520 245055 25 o305406 2e52 32 Overview 32 Configure System 32 Configure Control Settings 33 Configure Mode Settings 34 Configure Delay Settings 34 Configure Flow Meter Settings 35 Configure Pressure Loop Settings 35 Adjust Pressure Sensors 36 Configure Errors 36 Setup Maintenance Schedule Parameters 37 Configure Valve to Swirl Association and Motor ENO TYDE o mnics othe eed desert 37 Configure Swirl Settings 38 Configure Gateway Settings
93. e Gateway Customer Automation D Sub Pin 51 Isolated Logic Supply 10 30 VDC Isolated Logic ICs Isolated Ground Digital Input Microcontroller Optical lt Isolator i i D Sub Pin 70 3A2098H 119 Appendix B Discrete Gateway Module DGM Connection Details DGM Digital Outputs The digital outputs function only when power is supplied to pins 27 68 and 69 and there is a ground connection to pin 70 See Pin References page 118 for details The digital output is rated at 0 30 Vdc and requires an NEC Class 2 power supply connected to pin 27 for supply bank 1 pin 69 for supply bank 2 and pin 68 for supply bank 3 The DGM provides optical isolation as shown in the following illustration e Pins 9 20 28 39 e Maximum continuous current output 350 mA e Type Sourcing sourced from customer supply e Recommended continuous current 100 mA Customer Automation Discrete Gateway D Sub Pin 51 Isolated Logic Supply Isolated Logic ICs D Sub Digital Output Pin 27 Supply Bank 1 i Optical Microcontroller p igital Isolator utput 1 8 Digital Output Supply Bank 2 D Sub Pin 70 Isolated Ground 120 3A2098H DGM Analog Inputs Appendix B Discrete Gateway Module DGM Connection Details The analog inputs function only when the DGM is connected to a power supply through the CAN connection Each
94. e Software 77 Upgrade Gateway Module Fieldbus Map 78 Upgrade Fluid Control Module FCM Software 79 Air Filter Maintenance 79 Swirl Dispensers 79 PROD ONE oeiia th Un dir mca ate al keds ee 80 Fluid Plate Assembly 80 Control Center Assembly 87 PAWS 22 lie eet ee he die eee ee 91 Control Centers 91 Control Center and Expansion Swirl Enclosure PUIG ys caters et axle a on en Slaven tee lates de 92 Fluid Plate Assembly Parts 94 3A2098H Appendix A Advanced Display Module ADM 99 Display Overview 99 Display Details 99 Setup Mode 101 Run Mode 110 Appendix B Discrete Gateway Module DGM Connection Details 115 D Sub Cable 123793 115 D Sub Cable 123792 and Breakout Board 123783 116 DGM Digital Input 119 DGM Digital Outputs 120 DGM Analog Inputs 121 DGM Analog Outputs 121 Appendix C Communications Gateway Module CGM Connection Details 122 Install Fieldbus Connections 122 CGM I O Data Map 125 Appendix D I O Signal Descriptions 138 Automation Inputs 138 Automation Outputs
95. e accuracy of the PCF volume reporting depends on precise adjustment of the K factor s The fluid plate uses the K factor s to calculate the volume dispensed If the set value is not correct the system still delivers repeatable flow rates however the reported value may not be correct See Verify Flow Meter Calibration page 42 for additional K factor information Table 5 Flow Meter K Factors Description 246652 High Resolution Helical 7000 Gear Meter Heated Helical Gear Meter 16E993 Ultra High Flow Meter 33000 Set Flow Meter K Factor 246340 3500 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 Set tings 2 Press LA to access the fields to make changes Fluid Plate 2 DEAN Fluid Plate 1 system OTT C Mo Active Errors Control Loop Settings Pressure Bead 32 0 32 00 125 00 126 00 Flowmeter Settings Meter Type Volume Factor t000 pulses Liter a r 5 E M Gg FIG 23 3A2098H System Setup p 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 selec tion 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 Pr
96. e arrow buttons on the ADM to scroll through each letter Press to enter a letter in the style name field See Keyboard Screen page 109 for further details c Press to accept the new value 5 Enter the target volume in the Volume field and the tolerance percentages in the Low and High Toler ance fields 6 Enter precharge mode and parameters See Pre charge Modes beginning on page 47 7 Press to exit edit mode 3A2098H Precharge Modes NOTE See the diagram on the following page Static Precharge Mode Display When Display precharge mode is selected a static pre charge pressure can be defined When a job is active and all dispense valves are closed the regulator will maintain the defined precharge pressure Ske Fluid Plate 1 No Active Errors Style Fluid Plate 2 Style Style Mame o Volume cc Tolerances O O Pre Charge Mode Display Te Pressure O psi 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
97. e file was installed users can now Select the new language from the Language drop down menu in the Advanced Setup Screen 1 61 Troubleshooting Troubleshooting A AN H M 77 1 NOTE Check all possible solutions in the chart below before you disassemble the system Troubleshooting for individual fluid regulators and flow meters is also discussed in their separate manuals refer to Related Manuals on page 3 Also refer to Event and Error Codes and Troubleshooting page 67 for detailed information on how error codes are communi cated Fluid Plates No outlet pressure Air pressure low Verify air pressure is above 60 psi 410 kPa 4 1 bar No Valve On signal from automation Check output and wiring from auto unit mation unit No air signal to air diaphragm Check for loose disconnected con nector to Voltage to Pressure V P Transducer tighten False signal being sent to control Check outlet pressure sensor output verify that it corresponds to zero pressure replace sensor and or amplifier High outlet pressure Fluid regulator needle seat is worn Rebuild fluid regulator replace nee dle seat Air leaks from fluid plate Check air connections tighten if nec essary Worn gaskets Check replace gaskets on Voltage to Pressure V P Transducer and sole noid valve 62 3A2098H Troubleshooting Flow Meter No flow measurement Flow meter pick up sensor loose Tighten flow meter pick up s
98. e value that was actually written 6 Clear the Write Bit to end the write command opera tion Fluid Plat d Command Interface Read Operation uid Plate Commands Units 1 Set Command Identification Bits and Fluid Gee Units Read or Plate Swirl Identification Bits to the desired values 256 267 Description Definitions page 137 Write 0x004 Software Part STR_3_0 Read Only 3 Wait for the Command Active Bit to become set 0x005 Software Part STR_7_4 Read Only bcs ee i Number This indicates that an operation is in process Software Part STR_11_8 Read Only Number 132 3A2098H Units See Units 256 267 Description Definitions page 137 0x007 Software Part STR_15 12 Number i Maintenance Units Units Type Enumeration x0ODF Enabled Styles 0x203 Purge Period minutes 0x204 Dispense Trig Dispense Trigger ger Source Source Enumeration 0x208 Command Command Value Value Source Source Enumeration 0x20F Bead Scale percent 0x210 Job End Mode Job End Mode Enu meration 0x211 Job End Delay Integer Seconds Time 0x2B5 End Job On Boolean Alarm 0x212 Valve 1 Enable 0x213 Valve 2 Enable 0x214 Valve 3 Enable 0x215 Valve 4 Enable 0x216 Regulator On mS Delay 0x217 Regulator Off mS Delay 0x218 Valve 1 On MS Delay 0x219 Valve 2 On MS Delay Ox21A_ Valve 3 On MS Delay 0x21B Valve 4 On MS Delay Ox21C_ Valve 1 Off MS Delay mS mS S
99. ead 0 e Average flow rate during job measured in cc min systems with no flow meter will read 0 e Maximum flow rate during job measured in cc min systems with no flow meter will read 0 e Elapsed time mS 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 59 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 down loads each time a USB flash drive is inserted Use this file to back up system settings for future recovery or to easily replicate settings across multiple PCF systems Refer to the Upload Procedure page 61 for instruc tions 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
100. ec tions 73 Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause Valve 1 Swirl Communication Error Valve 2 Swirl Communication Error CR3_ Valve 3 Swirl Communication Error CR4 91 Valve 4 Swirl Communication Error WD1_ 92 Valve 1 Swirl Fault WD2_ 93 Valve 2 Swirl Fault WD3_ 194 Valve 3 Swirl Fault WD4 95 Valve 4 Swirl Fault MB1_ Maintenance due V1 Orbiter MB2_ 97 Maintenance due V2 Orbiter 74 Fluid Plate Events and Errors Fluid plate communica Alarm tion error with swirl Fluid plate communica tion error with swirl Alarm Alarm Alarm Alarm or Deviation user select able Alarm or Deviation user select able Alarm or Deviation user select able Alarm or Deviation user select able Advisory Fluid plate communica tion error with swirl Fluid plate communica tion error with swirl Swirl motor fault Swirl motor fault Swirl motor fault Swirl motor fault Maintenance due on valve 1 swirl orbiter Maintenance due on valve 2 swirl orbiter Advisory The fluid plate lost communication with the swirl zone associ ated with this valve and fluid plate The fluid plate lost communication with the swirl zone associ ated with this valve and fluid plate The fluid plate lost communication with the swirl zone associ ated with this valve and fluid plate The fluid plate lost communication with
101. ed to interface with automation controller Refer to Appendix A Advanced Display Module ADM page 99 for details about the configuration settings 4 Retrieve the appropriate fieldbus configuration file for the fieldbus being used from www graco com 5 Install the configuration file on the automation con troller fieldbus master Configure it for communica tion with the PCF Gateway fieldbus slave 6 Establish communication between the automation controller and the PCF Gateway to confirm the suc cessful configuration of the hardware and data NOTE Use the ADM screens for troubleshooting field bus data communication problems Refer to Appendix A Advanced Display Module ADM page 99 for details Also use the LED status indicators on the PCF Gateway module for fieldbus status information Refer to Appendix C Communications Gateway Module CGM Connection Details page 122 for details 3A2098H Discrete Gateway Module Module Description The Discrete Gateway Module DGM provides a control link between the PCF system and an automation con troller through discrete input and output connections This provides the means for remote monitoring and con trol by external automation systems See Automation Control Normal Operation page 45 for details on controlling the PCF system through the Gateway module Connect D Sub Cable The DGM provides all I O through the D Sub cable Graco offers two options for conne
102. ee Technical Data on page 140 for fuse specifications e For 100 240 Vac control centers Order fuse 115805 CD CD Ne ET 7 2 TEn e i _ AS OOO L _ j IL z QI D TES COOL O n ET sr a a pe P r_pf0000_313377_10a Fuses FIG 67 Fuse Location 90 3A2098H Parts Control Centers Software Upgrade Tokens Pat Description 4 16K743 Includes PCF software for the ADM FCM CGM and DGM 16N601 PCF Gateway map token Installs the CGM map starting on page 122 16K742 Historical PCF Gateway map token Only for users that used the original PCF with a Gate way have purchased a new PCF and do not wish to change their Gateway setup from the old Gateway map to the new Gateway map Control Center Key Token Part Numbers See Key T
103. eed e Actual motor speed e Progress bar indicating requested and actual motor speed 12 13 11 14 18 Errors Fluid Plate Mo Active Errors x bs SD n 2 nm 0 RPM 0 RFM 0 RPM 0 RFM Active Actual Actual Requestect Requestect 3A2098H Fluid Plate x Screen 1 This screen displays the current dispense control mode used the current pressure and the current style being dispensed It also displays the target dispense volume the actual dispense volume and the requested dis pense volume From this screen users can adjust the bead scale and enter maintenance mode Press t and to change the bead scale Press W to enter mainte nance mode Appendix A Advanced Display Module ADM The PCF system has two operating modes e Dispense mode enables the module to begin dis pensing when it receives a command from the auto mation unit e Maintenance mode enables the module to begin dispensing when the user presses the manual dis pense button Dispense parameters and duration depend on the selected control Dispensing continues for as long as the manual dis pense button Ld IS pressed Current Dispense Inlet Pressure Outlet Pres Control Mode non heated systems sure Command Voltage Displays only when Command Cable or Gate agzi leit 14 0 M j 4 Ho me Flic Plate 1 Fluid ME fe way is selected as the Jobin Cycle In Cycle Wo Active iwefrrore rs Command Value Source eS see
104. eee ie awe ees eek 40 F 4 C 120 F 49 C heated fluid plate 40 F 4 C 400 F 204 C ambient fluid plate 40 F 4 C 120 F 49 C Operating Humidity Range 0 90 non condensing Flow rates and viscosities are general estimates Flow rates drop as viscosity increases Fluids are expected to shear under pressure New applications or fluids should always be tested to determine proper line sizes and equip ment selections See your Graco authorized distributor for other capabilities Control Center Assembly Technical Data Cn 100 240 Vac Assemblies 24 Vdc Assembly Voltage 100 240 Vac 24 Vdc Phase Fuse Rating 250 Vac 2 5A T 125 Vac 4A F 140 3A2098H Technical Data Fluid Plate Assembly Technical Data Mounting dimensions and parts breakdowns for the fluid plate assemblies are in the installation section of this man ual D anridge Regulator Mastic Regulator Air Supply 1 4 in npt f 1 4 in npt f Maximum Air Working Pressure 100 psi 0 7 MPa 7 0 bar 100 psi 0 7 MPa 7 0 bar Minimum Air Working Pressure 60 psi 410 kPa 4 1 bar 60 psi 410 kPa 4 1 bar Fluid Operating Temperature Ambient 40 120 F 4 50 C Heated 40 400 F 4 204 C Ambient 40 120 F 4 50 C Minimum Flow Rate Helical Ambient 25 cc min Heated 50 cc min Ambient 25 cc min Maximum system pressure depends on dispense valve
105. ely measures the flow rate of fluid dispensed e Solenoid air valve S controls the dispense valve e Voltage to Pressure Transducer T abbreviated V P transducer adjusts the air pressure to the fluid regu lator P e Fluid Control Module FCM U receives pulse read ings from the flow meter R and pressure readings from the regulator It also controls the fluid regulator P and solenoid air valve S Fic 5 Fluid Plate Components 14 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 automa tion supplied signals to provide an accurate and consis tent output flow based on a comparison of actual to desired flow rates The fluid regulator uses air pressure to control fluid pressure and to provide fast response to electronic commands and ensure a precisely controlled continuous flow of material The fluid plate assembly is available in two versions ambient and heated Ambient Fluid Plate Assembly There are four ambient versions available cartridge regulator without a flow meter ambient mastic regulator without a flow meter cartridge regulator with a high resolution meter ambient mastic regulator with a high resolution meter e cartridge regulator with an ultra high resolution flow meter Heated Fluid Plate Assembly There are two heated versions availa
106. ements for a true earth ground in your area e All wires used for grounding must be 18 AWG min imum e A qualified electrician must complete all grounding and wiring connections e For 24 Vdc wiring refer to FIG 13 e For 100 240 Vac wiring refer to FIG 14 e Incoming power wiring must be guarded from the enclosure Use a protective grommet where the power wiring enters the enclosure to prevent wear NOTICE If power and grounding connections are not done properly the equipment will be damaged and the warranty voided Ground 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 3A2098H Installation Connect Fluid and Air Lines NOTICE Route all fluid and air lines carefully Avoid pinching and premature wear due to excessive flexing or rub bing 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 e The PCF fluid plate assembly should be installed on the automation unit or in another appropriate place as cl
107. empty hole on the fluid plate GCA Cable O W 2 0 R oq 2 e UMA XV 7 L OSEE D O Connection 1 Hole for bulk head fitting Splitter Assembly J4 J3 ol D gt Ilo Of J2 J4 FIG 16 Mount Breakout Kit 3 Connect one end of the extension cables included in the kit to connection 1 on the FCM and the other end of the cable to the bulkhead fitting 4 Connect the splitter assembly to the bulkhead fit ting 3A2098H Installation 5 Connect the dispense valve cable s to the connec tions on the splitter assembly caieto Connection abet Cable for Connection Labeled Dispense Valve 3 6 Mount splitter assembly and dispense valves and connect air lines as necessary for application Dispense Valve 1 Dispense Valve 2 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 sole noid outputs are capable of sourcing up to 0 5A each maximum 12W coil 25 Installation Install Command
108. ensor Flow too low Verify flow rate is above minimum for the installed flow meter Verify connection from flow meter to FCM Damaged flow meter pick up sensor Replace pick up sensor False measurement Flow meter not calibrated Calibrate flow meter page 42 System not grounded properly Verify system ground Noisy power source Verify clean power supply power to main enclosure Flow reported is not correct or Flow meter not calibrated Calibrate flow meter page 42 Fluid Regulator Pressure creeps above setting Metal chip or contamination Replace cartridge or clean seat between ball and seat area Damaged diaphragm Replace diaphragm Damaged o ring or improper seal Replace the o ring under the seat Damaged or clogged air regulator or Clear obstruction in line Service line regulator if necessary 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 Clear obstruction in line Service Using valve beyond its rated flow Install valve for each spray valve or Large change in inlet air or fluid Stabilize air and fluid regulator inlet Fluid leaks from spring housing Loose fluid housing Tighten the four cap screws Damaged diaphragm Replace diaphragm Chatter Excessive pressure differential be Reduce pump pressure to not more tween pump and valve than 2000 psi
109. ess to exit edit mode NOTE If necessary verify flow meter calibration See Verify Flow Meter Calibration page 42 for instruc tions Configure Pressure Loop Settings The PCF system uses variables Kp Ki and Kd in the software calculations to accurately and precisely control the fluid pressure NOTE It is recommended that these values are not changed from the factory defaults of 32 00 for Kp 128 00 for Ki and 0 00 for Kd However if the values need to be adjusted see Manually Adjust Control Loop Parameters on page 43 35 System Setup Adjust Pressure Sensors Set pressure offsets and pressure limits NOTE Inlet sensor settings will be grayed out on this screen for systems with heated fluid plates 1 With the system in setup mode navigate to the Fluid Plate x screen 5 Pressure Sensors 2 Press LA to access the fields to make changes Pressure Sensors Offset Pressure Inlet Hf psi 1914 psi Outlet psi 263 psi Lirit Min Inlet 0 pri Max Inlet psi Max Outlet S000 psi Deviation IE Deviation S Deviation e FIG 24 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 pres sures 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 O NOTE It is recom
110. et the Swirl Orbiter Maintenance Advisory Limit 12 13 11 14 26 Fluid Plate 2 Swirl 2 C Mo Active Errors Control Settings Speed Command Source Gateway sw Run Mode Speed Adjust Enable Speed Scale 100 Maintenance Advisory Limits Lirnit Hours Swirl Orbiter 0 293 109 Appendix A Advanced Display Module ADM Run Mode Run mode screens are divided into six sections home fluid plates swirls events errors and jobs While in Setup mode press La to enter Run mode Press to navigate through the Run mode screens Fluid Plate Home Screen NOTE This screen only appears if more than one fluid plate is installed The Fluid Plate Home screen shows an overview for each of the individual fluid plates The screen displays the following items Open dispense valves Active style number and name Flow rate Inlet and outlet pressures Progress bar indicating actual amount dispensed blue shaded portion requested volume upper and lower arrows and target volume end of white bar Style Purge psl 1914 psi 203 psl P n oe OOccimn F 110 Swirl Home Screen NOTE This screen only appears if more than one Swirl Dispenser is installed To access the Swirl Home screen press the down arrow key from the Fluid Plate Home screen The Swirl Home screen shows an overview for each of the individual Swirl Dispensers The screen displays the following items e Requested motor sp
111. g or invalid Install PCF map in Error Gateway map Gateway Gateway Reset Gateway reset Wait for reset to com plete before attempt ing automation control Restore communica tion Restore communica tions oe Event Type ee Reconnect or replace CAN cable red status LED is solid Advisory nicating CGM is not functioning Replace the CGM if the ADM is not functioning Replace FCM if red ADM does not contain appropriate key token Style is out of range Style requested by automation controller exceeds number of styles available on the fluid plate Alarm status LED is solid Verify intended ADM key token is properly inserted Alarm ADM is not communi Reconnect or replace cating CAN cable Use a style number that is in range Increase number of styles in PCF pur chase accessory key token 3A2098H Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause Fluid Plate Events and Errors B30_ 31 High Material Material dispensed dur B40_ ing last dispense cycle was above amount requested plus the allowed tolerance B10_ Material dispensed dur B20_ ing last dispense cycle below amount requested minus the allowed tolerance Low Material Low Computed Target B1C B2C Requested volume mass differs from entered process target by more than entered tolerance for style requested B3C B4C High Computed Target Requested volume m
112. ge and inspect dle is stuck closed needle F1D_ F2D_ Pump wink passed Increase pump pres through outlet sure Failed transducer Check transducer replace if failed High Pressure Measured outlet pres Alarm or Incorrect limit set Verify limit is set cor sure greater than Deviation rectly desired outlet pressure user select Dispense hose device Clean replace plus tolerance able plugged hose device Failed transducer Check transducer ET Regulator is not clos Repair regulator ing completely when it should Fluid supply too low to Increase fluid supply Low Flow Rate Measured flow rate less Alarm or than desired flow rate Deviation achieve desired flow pressure or check for minus tolerance user select rate clogged filter able Tip plugged Clean replace tip No air pressure to Turn on air to solenoid solenoid valves valves No flow meter signal ee cable and sen No material supply ae drum or turn on pumps Incorrect flow toler Enter correct toler ance of flow error time ance or flow error time Operating below mini Increase fluid pres mum regulator operat sure above regulator ing pressure minimum eer valve leak Repair dispense valve F3D_ High Flow Rate Measured flow rate Alarm or greater than desired Deviation flow rate plus tolerance user select able Regulator worn or not Repair regulator operating correctly Flow meter providing Replace flow meter false pulses sensor ere n
113. gs Type A 32 bit value in the format of OxDDCCBBA OxA Precharge mode enumeration 0 Display 1 Gateway 2 Valve 1 OxBBB Precharge valve opening duration ms OxCC Precharge scale valve closed OxDD Precharge scale valve opening Pressure Units Enumeration 0 psi 1 bar 2 MPa Rate Units Enumeration STR_X_Y A 32 bit value where X signifies which character in the string that the most significant byte rep resents and Y signifies which character in the string that the least significant byte represents Swirl Control Enumeration Swirl Enumeration Swirl Status Bitfield 1 Tolerances Type uint12 0 Swirl Enable 0 None 1 Swirl 1 2 Swirl 2 3 Swirl 3 4 Swirl 4 0 Swirl Active 1 Swirl Ready 2 Swirl Enabled A 32 bit value in the format of OXOOOOBBAA where OxAA represents the low tolerance and OxBB represents the high tolerance A value of 0 means that tolerance is disabled Valve Mode Enumeration 0 Pressure 1 Bead 2 Shot 3 Full Open uint32 Version Volume Units Enumeration 3A2098H 12 bit positive value 32 bit positive value A 32 bit value in the format of Ox00CCBBAA where OxAA represents the major version OxBB represents the minor version and OxCC represents the build version 0 gal US 1 gal UK 2 Liters 137 Appendix D I O Signal Descriptions Appendix D I O Signal Descriptions This section provides details about th
114. h pan hd m4 x 35 CONNECTOR splitter WASHER plain MODULE line voltage SCREW mach pan hd CABLE CAN female female 1 0m CABLE CAN female female 0 5m COVER front BRACKET mounting SCREW mach pan hd GUIDE strain relief KNOB display CLIP speed tubular RIVET aluminum SCREW cap WASHER lock SUPPRESSOR box snap ferrite CONNECTOR splitter LABEL SCREW mach pan hd 2 lt LL ee ee ee DB PO PVP PN PN um S S A HSH HSH HSH HSH ARH BS HS Part 24B681 16K570 24K455 24K458 121597 Parts Description MODULE DGM GUARD edging BOARD circuit swirl BRACKET display pivot COVER swirl hinge side COVER swirl latch side COVER swirl lid CABLE swirl board panel mount CABLE SWIRL DGM CABLE CAN 90 female 90 female Qty i i i A Replacement Danger and Warning labels tags and cards are available at no cost se 24B930 Parts included with 100 240 Vac Module kit 24B928 Parts included with 24 Vdc Module kit 24B929 Parts included with Display Mounting Bracket kit x Base electronic components do not have PCF spe cific software installed Use software upgrade token 16K743 to install software before use Fieldbus Gateway modules do not have a PCF spe cific map installed Use map token 16N601 to install map before use Not for sale 93 Parts Fluid Plate Assembly Parts 143 135
115. he middle position 5 Vdc See FIG 59 on page 86 14 Ensure the COARSE GAIN dipswitch 1 is set to ON All others should be set to OFF 15 Adjust the FINE ZERO potentiometer until the outlet pressure on the display reads 0 16 Use a small piece of jumper wire or a paper clip to connect the SHUNT CAL and ENABLE terminals POWER SUPPLY OUTPUT SUPPLY RETURN OUTPUT SHUNT CAL ENABLE To Readout SKE NE a O Nn El Z H fu Excitation Selector Coarse Zero Fine Zero Fic 59 Amplifier Settings 21 Replace the amplifier cover See Replace Ampli fier page 85 22 Reconnect the outlet pressure sensor cable if it was removed 23 If desired change pressure units to desired setting on Advanced screen 2 86 EXCITATION MODULE gr ZERO SPAN 12345678 e H dOBdUE 17 Use the data from the certificate of calibration for the pressure sensor included with PCF documenta tion or the replacement pressure sensor to calcu late the Shunt Calibration Pressure using the following formula Shunt Calibration Pressure Shunt Cal Factor Calibration Factor 5000 psi 18 Adjust the FINE GAIN potentiometer until the Outlet Pressure on Fluid Plate x screen 5 Pressure Sen sors 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 additio
116. ial Startup 1 3 Ensure the PCF control center is installed and all of the proper connections to and from the control cen ter have been made Ensure fittings are tight Read and understand the Operation page 40 and Advanced Display Module ADM page 17 sec tions of this manual Continue startup with step 2 in Standard Startup Standard Startup 1 40 Carefully inspect the entire system for signs of leak age or wear Replace or repair any worn or leaking components before operating the system Press the Stop button BC See FIG 8 on page 17 Turn on air Turn on electrical power to the system Turn on the main power to supply power to the PCF Check Interface Signals If this is a new installa tion power on each system input and verify that each input is being received Turn on the material supply system Load Material Before using the system material must be loaded into the supply system 1 If this is a new installation follow the Initial Startup procedure Otherwise follow the Standard Startup procedure See page 40 Turn on the fluid supply pressure to the fluid plate assembly Place the valve s over a waste container Enter the maintenance screen See Dispense From Maintenance Screen page 43 Select a control mode See Dispense From Main tenance Screen page 43 If the system status indicator LED BB is orange press to turn the system on Press and hold kd Dispense flu
117. id until clean air free fluid flows from the valve to exit maintenance screen 3A2098H Maintenance Mode Operation Fluid Plate Swirl Maintenance Screen Maintenance Screen UIQ FLE lt Display Control m No Active Errors Actual 0 RPM Requestect RSS RPM Operating from maintenance mode enables manual dispensing hd and manually starting the swirl dis penser PA The system begins dispensing when the user presses Ld Dispense parameters and duration depend on the selected control Dispensing continues for as long as kd is pressed The system starts the swirl dispenser when the user presses A 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 con trols for the Swirl are shown on both the Swirl mainte nance screen and on the Fluid Plate maintenance screen for the fluid plate where the swirl dispenser is installed Verify System Operation Use maintenance mode to manually check the operation of the PCF system components before switching over to automation control normal operation See Dispense From Maintenance Screen page 43 for instructions on operating from maintenance mode NOTE Perform the following procedures while in main tenance mode Set Inlet Pressure The inlet pressure reading should be in the range of 300 psi 2 1 MPa 21 bar to 500 psi
118. ing view a chronological list of system errors view a chronological list of jobs stored per formed in the system e use a preventative maintenance schedule for the supply system displacement pump and air motor 3A2098H Display Details Power Up Screen The following screen appears when the ADM is pow ered up It remains on while the ADM runs through ini tialization and establishes communication with other modules in the system D Cr Menu Bar The menu bar appears at the top of each screen Date and Time The date and time are always displayed in one of the fol lowing formats The time is always displayed as a 24 hour clock e DD MM YY HH MM e MM DD YY HH MM e YY MM DD HH MM Arrows The left and right arrows indicate screen navigation Screen Menu The screen menu indicates the currently active screen which is highlighted It also indicates the associated screens that are available by scrolling left and right 99 Appendix A Advanced Display Module ADM System Mode There are five modes Active Job in Cycle Display Con trol Swirl Setup and System Off The current system mode is displayed at the left of the menu bar Alarm Deviation If there is an active system error one of the following icons is displayed in the middle of the menu bar There are four possibilities Icon Function Description _ No information or no error has occurred Advisory Informational No Icon
119. ings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 PIN ELECTRIC SHOCK HAZARD A N This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock D 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 e 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 opera
120. ion settings Incorrect data Incorrect fieldbus configu Download PCF fieldbus configuration file from ration file installed on www graco com and install on automation controller fieldbus automation controller master fieldbus master Incorrect map installed on Confirm correct PCF data map is installed on PCF Gateway PCF Gateway Refer to Appendix A Advanced Display Module ADM page 99 for information on how to determine installed data map If necessary install a new Gateway data map Refer to Upgrade Gateway Module Fieldbus Map page 78 for instructions and Control Center and Expansion Swirl Enclosure Parts page 92 for map token part number LED Diagnostic Information The following LED signals diagnosis and solutions apply to the Advanced Display Module Fluid Control Module and Gateway module Module Status LED Signal Diagnosis sowon Greenon eme pop Yelow intera communication in progress 7 oO Red ashingfast Uploadngsoftwa re Red flashing slow Token error Remove token and upload software token again Red flashes three times pauses Invalid rotary switch position FCM Change rotary switch position to a then repeats and DGM only valid position then restart the system See page 15 3A2098H 65 Errors Errors View Errors When an error occurs an error pop up is displayed that takes up the entire screen until the error is acknowl edged by pressing Fes Errors can also be acknowl e
121. ision 001 002 Wap Date 09 09 74 103 Appendix A Advanced Display Module ADM Discrete Gateway Automation Setup Screen NOTE The Discrete Gateway Setup screen is not avail able if an automation Discrete Gateway Module DGM is not attached to the system NOTE If Swirl Dispensers are installed a Swirl Discrete Gateway Module will be installed This section is not related to that module See Control Center Assembly Overview on page 16 for gateway identification This screen enables users to set Active Errors to High default or Low If High is selected alarm and error sig nals are low during normal operation and high if an alarm or error exists If Low is selected alarm and error signals are high under normal operation and low if an alarm or error exists This screen also enables users to select the Command Value Type signal Analog or Digital the automation system will provide to PCF If Analog control is selected the user must provide an analog voltage to the proper input on the DGM See Appendix B Discrete Gate way Module DGM Connection Details page 115 for connection details If Digital control is selected and one fluid plate is installed the user can define three digital settings for each dispense valve If Digital control is selected and two fluid plates are installed the user can define two digital settings for each dispense valve The user must provide two digital signals to the proper inputs on the
122. it V V alve 2 Mode Valve Mode Enumera Read 0x273 Valve4 Time hours tion Write Advisory Limit alve 3 Mode Valve Mode Enumera Volume tion Read gal US Valve 4 Mode Valve Mode Enumera tion Read Write gal Uk Write Liters Mass 0x278 Valve 1 Vol ume Mass Advisory Limit 0x279 Ox27A Valve 2 Vol ume Mass Advisory Limit Valve 3 Vol ume Mass Advisory Limit Ib kg Volume gal US gal Uk HHHEHH Liters Mass Ib kg Volume gal US gal Uk HHHEHH Liters Mass Ib kg Valve 1 10 VDC Analog Scale Flow rate Valve 2 10 VDC Analog Scale Flow rate Valve 3 10 VDC Analog Scale Flow rate Valve 4 10 VDC Analog Scale Flow rate Volume cc sec cc min Mass g sec g min Volume cc sec cc min Mass g sec g min Volume cc sec cc min Mass g sec g min Volume cc sec cc min Mass g sec g min Read Write Read Write Read Write Read Write Read Write Valve 1 10 Pressure psi VDC Analog _ bar Scale Pressure Mpa Valve 2 10 Pressure psi VDC Analog _ bar Scale Pressure Mpa Valve 3 10 Pressure psi VDC An
123. lash until new software is completely loaded T112335A FIG 48 Insert Token 5 After the red indicator light shuts off turn off power to the system 6 Remove software token 3A2098H Maintenance 7 Reinstall key token and replace access cover Air Filter Maintenance To prevent filter element damage replace air filter every two years or when pressure drop becomes 100 kPa 1 0 bar 14 5 psi or greater which ever occurs first Replacement Air Filters for Dual Filter Assembly 234967 Description 123091 5 micron air filter 123092 0 3 micron air filter Swirl Dispensers See manual 309403 for maintenance schedule 79 Repair Repair Fluid Plate Assembly A 7 i M M This section describes how to remove and replace com ponents on the fluid plate assembly Prepare Fluid Plate Assembly for Repair 1 Disconnect the CAN cable from the fluid plate 2 Perform Pressure Relief Procedure on page 57 3 Remove the fluid plate assembly shroud See Fluid Plate Assembly Parts page 94 103 124 129 125 126 127 Fic 49 Fluid Plate Assembly 80 Repair Flow Meter For complete flow meter 129 repair instructions refer to the maintenance and repair section of manual 309834 Remove Flow Meter from Mounting Plate 1 Prepare Fluid Plate Assembly for Repair page 80 Disconnect the flow meter cable 131 fr
124. lightly from the measured volume due to this compressibility If the K factor is not correct the dis played 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 FIG 23 on page 35 2 Use a 500 cc or larger beaker Measure the mass of the empty beaker 3 Manually dispense material into the beaker Hold the beaker so that the stream of material is sub merged in the captured material to minimize air entrapment in the container 4 Record the volume dispensed on Fluid Plate x screen 1 See FIG 30 on page 43 5 Calculate the actual volume dispensed fluid mass g density g cc measure volume cc 6 Calculate the new flow meter K factor K Factor new displayed volume cc x K Factor old measured volume cc 7 Enter new K factor 8 Repeat the procedure to verify the new K factor Method 2 Without using a gram scale visual measure ment 1 Record the flow meter k factor shown on Fluid Plate x screen 4 Flowmeter Settings See FIG 23 on page 35 2 Use a 500 cc or larger beaker 3A2098H 3 Manually dispense material into the beaker Hold the beaker so that the stream of material is sub merged in the captured material to minimize air entrapment in the
125. location for the fluid plate assembly Keep the following in mind e Allow sufficient space for installing the equip ment e Make sure all fluid lines cables and hoses eas ily reach the components to which they will be connected e Make sure the fluid plate assembly allows the automation unit to move freely along all axis e Make sure the fluid plate assembly provides easy access for servicing its components N 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 FIG 15 Table 4 Fluid Plate Assembly Measurement 16 5 in 419 mm 14 0 in 856 mm 14 4 in 366 mm 13 4 in 340 mm FIG 15 Fluid Plate Assembly Dimensions 3A2098H Mount Four Valve Breakout Kit 24B693 PCF is capable of controlling up to four separate dis pense 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 sepa rate dispense solenoid connectors For each additional dispense valve order one dispense valve solenoid 258334 and one solenoid cable 121806 Follow this procedure if using the four valve breakout kit 1 Remove the existing dispense solenoid and cable from the fluid plate 2 Install bulkhead fitting included in the kit into the
126. lve High to Valve Open command Regulator Sets time from Dispense Valve High ON to Regulator ON Valve OFF Variable Valve ON Sets time from Dispense Valve Low to Valve Close command Sets time from Dispense Valve Low to Regulator OFF Dispense Valve Signal Regulator OFF r A Fluid Regulator System Setup FIG 29 and Table 6 Delay On Off Timing show delay ON and OFF timing Table 6 Delay On Off Timing A Regulator ON The user sets the fluid regu dar iator ON delay tring Valve ON delay Usually set to zero Can be used to change the starting ied point of a bead C Valve OFF Delay Usually set to zero Higher values will lower the trapped pressure The user sets the regulator OFF delay timing Zero or small values will lower the trapped pressure Time delay for valve to phys ically open Delay varies based on pneumatic hose length and valve air volume Time delay for valve to phys ically close Delay varies based on pneumatic hose length and valve air volume Regulator OFF delay Reaction Time Valve Close Reaction Time Valve Open C l D gt lt _J Valve Open B s Command Valve Actually E gt a Open FR o FIG 29 Timing Delay 3A2098H 39 Operation 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 Init
127. mended that offsets should not be changed from the factory defaults of O 4 Set the desired minimum and maximum pressure limits for the inlet and the desired maximum pres sure limit for the outlet 5 Set the error type alarm or deviation that will be issued e lf the minimum inlet pressure decreases below the setting e If the maximum inlet pressure increases above the setting e Ifthe maximum outlet pressure increases above the setting 6 Press oe to exit edit mode N 36 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 dispens ing When a deviation occurs the system will continue dispensing See Fluid Plate x Screen 6 Error Type on page 107 for more information NOTE Only the low high pressure errors will be enabled for systems without a flow meter 1 With the system in setup mode navigate to Fluid Plate x screen 6 Error Type 2 Press LA to access the fields to make changes Fluid Plate 2 REECE CA Fluid Plate 1 Acti C No Active Errors Error Type Low Pressure Deviation Vw High Pressure Deviation Low Flow Rate Deviation High Flow Rate Deviation Low Material High Matertal Low Computed Target High Computed Target FIG 25 3 Press to open the Low Pressure drop down lis
128. n and password entry screens 3A2098H 17 Overview Automation Gateway Module See the following table for the appropriate rotary switch position for your automation gateway module Gateway Part Number To PCF Model User Interface Description Order Rotary Switch Position Discrete DGM 24B681 DeviceNet CGN 15V750 CGM PROFIBUS CON NOTE See Control Center Assembly Overview on page 16 for automation and swirl control DGM identification Front Access Cover Removed LIT LL LU Rotary Software Switch Token Slot Gateway Module Connectors PROFIBUS Discrete T111814A T111815A T111816A FIG 9 Automation Gateway Module Components Key CA Gateway Module CG D Subminiature D Sub Connector see Appendix CB Base B Discrete Gateway Module DGM Connection CC Fieldbus Connector see Appendix C Communi Details page 115 for pinout details cations Gateway Module CGM Connection CH CAN Connectors Details page 122 for more information CD Module Connection Screws CE Access Cover CF Module Status LEDs see LED Diagnostic Infor mation page 65 18 3A2098H Overview Swirl Control DGM One swirl control DGM is included in the integrated Swirl Rotary Switch control center and in each expansion swirl enclosure Position Each Swirl control DGM controls one swirl orbiter Each swirl control DGM must have a unique rotary switch position
129. nal time to ensure proper calibration Panel mounting holes Use 6 or 8 screws TRANSDUCER EXCITATION EXCITATION SIGNAL SIGNAL To Transducer Hh el lel bel SHUNT CAL RESISTOR Coarse Gain Fine Gain 3A2098H Control Center Assembly A Prepare Control Center for Repair 1 2 Power off the display Disconnect main power to the control center assem bly Remove the control center assembly front cover 20 Replace Gateway Module 1 Prepare Control Center for Repair page 87 2 Remove the automation communications cable AE 3 Remove the two screws holding the Gateway mod ule 5 to the base 3 and remove the module Fic 60 4 Attach a new Gateway module to the base using two screws 5 Reconnect the automation interface cable 6 Upgrade software page 77 then upgrade fieldbus map page 78 3A2098H Repair Replace Gateway Module Base ls Prepare Control Center for Repair page 87 2 Remove the Gateway module 5 follow Replace Gateway Module Leave automation communica tions 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 5 FIG 61 5 Secure the new base to rear cover 1 using the five Screws 6 Reattach Ga
130. ndirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original instructions This manual contains English MM 3A2098 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2011 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised August 2014
131. nents do not have PCF spe cific software installed Therefore use software upgrade token 16K743 to install software before use Not shown Not for sale CAN splitter is not included with the fluid plate assembly included in the PFxxxx assembly It is included only with the additional fluid plate kits Fluid Plate Key Token Part Numbers See Key Tokens on page 20 for more information about key tokens Description 16M100 FCM Key Token 2 styles Flow Meter 16M101 FCM Key Token 2 styles No Flow Meter 16M102 FCM Key Token 16 styles Flow Meter 16M103 FCM Key Token 16 styles No Flow Meter 16M104 FCM Key Token 256 styles Flow Meter 16M105 FCM Key Token 256 styles No Flow Meter 97 Parts Parts Varying by Assembly Fluid Plate Assemblies 4 Heated Mastic Cartridge Mastic Regulator Heated Regulator Cartridge Regulator Mastic with Heated Mastic The following table lists the varying part numbers by fluid plate assembly and the quantity for each assembly with High Regulator with High Regulator High Regulator Resolution with Resolution with Resolution with 3 Description No Meter No Meter No Meter hd bel 244734 REGULATOR assy us 246643 109 156684 UNION adapter A D o on 157785 Ge 110 C20461 NIPPLE reducing C20487 hex 1 2 npt f x 3 4 113 037075 SPACER o gt D mr mmeo SENSOR essre e TTT eouel OM eo sr O RING a SE DE mu gear meter 125
132. nse In Process Volume OK Automation Outputs PCF Inputs Style Bits Style Strobe Precharge Valve X Ont Command Signal Valid Dispense Valve X On Dispense Complete PCF State Regulator Active Dispense Valve X Open 3A2098H Operation Precharge Display Modee Precharge After starting a job and prior to opening the dispense valve the fluid pres sure is increased to try to match the dispensing pressure This helps the consistency of the dispense Shaded areas indicate the precharge is active Precharge Gateway Mode 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 53 Operation Control Charts continued Automation Inputs PCF Outputs Dispense Ready Dispenser Fluid Plate No Alarm Dispenser Fluid Plate No Error Dispense In Process Volume OK Automation Outputs PCF Inputs Style Bits Style Strobe Command Signal Validf Dispense Valve X On Dispense Complete PCF State Regulator Active Dispense Valve X Open Precharge Valve 1 Mo
133. nte Volume nance Dis gal US pensed gal Uk 4 Volume Liters Mass Ib H kg V P Mainte Volume nance Dis gal US H pensed gal Uk Volume Liters Mass Ib HH H kg Valve 1 Mainte Volume nance Dis gal US pensed gal Uk Volume Liters Mass lb H HHH kg Valve 2 Mainte Volume nance Dis gal US pensed gal Uk Volume Liters Mass lb H HH HH kg Valve 3 Mainte Volume nance Dis gal US H pensed gal Uk Volume Liters Mass lb H HHH kg Valve 4 Mainte Volume nance Dis gal US HHHH pensed gal Uk Volume Liters Mass lb HHHHH Kg Regulator HHHHHH hours Maintenance Flow meter H HH hours Maintenance Supply Mainte hours nance Dis pense Time V P Mainte H hours nance Dis pense Time Valve 1 Mainte hours nance Dis pense Time Valve 2 Mainte hours nance Dis pense Time Valve 3 Mainte hours nance Dis pense Time 3A2098H Appendix C Communications Gateway Module CGM Connection Details Units See Units 256 267 Description Definitions page 137 0x31B Valve 4 Mainte hours nance Dis pense Time Purge Defini CC ti
134. okens on page 20 for more information about key tokens Part Description 16M217 ADM Key Token Standard PCF Gateway Module Part Numbers User Gateway Part PCF Interface Number To Model Description Order PFxx2x Ether 15V760 Net IP 3A2098H Parts 91 Parts Control Center and Expansion Swirl Enclosure Parts 15 24 VDC units only 15 36 100 240 VAC units only 6 36 6 Ground Green A Add ferrite 36 to cable Locate as close to cable connector as possible AS 100 240 Vac models only Ad Included in swirl models only both control centers and expansion swirl enclosures 92 Dam LAT a D 4 QO LT XB1 AN yN 4 f A e 6 Neutral Blue AA Control centers only Not included in expansion swirl enclosures Control Center Assembly Parts Ref 4 2 3 4 5H 6 74 8t Oat 10 11 12 Part 24E451 289697 27 674 196548 121820 121807 110755 195875 121001 121000 120143 121253 112925 100020 121901 124654 3A2098H Description COVER rear DISPLAY with USB BASE cube ENCLOSURE cube door MODULE Gateway see table on page 91 for part number SUPPLY power COVER line voltage GROMMET LABEL warning electric shock SCREW cap socket hd m4 x 6 WASHER lock SCREW mac
135. om the flow meter sensor See FIG 49 Disconnect the material hose Disconnect the swivel fitting 109 from the regula tor Loosen the four screws 127 and washers 125 126 remove the bracket 124 and flow meter 129 The flow meter weighs approximately 15 Ibs 6 75 kg Carefully lift it off the mounting plate 101 O a 101 108 131 109 r_pf0000_313377_18a 3A2098H Install Flow Meter on Mounting Plate Th Rest the flow meter 129 and bracket 124 on the fluid plate while threading the swivel fitting 109 onto the regulator material inlet See FIG 49 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 108 r_pf0000_313377_34a FIG 50 4 Check that the flow meter and regulator 108 are still aligned 5 Connect the material hose 6 Connect the flow meter cable 131 Replace Solenoid 1 Prepare Fluid Plate Assembly for Repair page 80 Disconnect FCM cable and all three air tubes Remove both screws 137 from transducer bracket 118 3A2098H 4 Repair Remove the dispense valve solenoid 132 and replace it with a new solenoid r_pf0000_313377_33a Fic 51 9 6 Secure the new solenoid to the bracket with screws Reconnect the FCM cable and all three air tubes Replace Voltage to Pressure V P Trans
136. on Volume Purge Defini Pressure psi tion Pressure bar Mpa Purge Defini Tolerances Type tion Toler ances Purge Defini seconds ton Duraton Style 1 Defini cc ton voune w Style 1 Defini Pressure psi Read tion Pressure bar Mpa Style 1 Defini Tolerances Type tion Toler ances Style 1 Defini Precharge Settings tion Pre Type charge Settings xBFC Style 255 Defi cc Pin Vome S i Pressure psi Read nition Pres bar sure Mpa Tolerances Type W TI U ct D MO O1 O1 U D U TI m 9 lt D M O1 O1 U D nition Toler ances WU TI TI 2 D N O1 O1 O D I Precharge Settings nition Pre Type charge Settings Style 1 Defini STR_3_0 Read ton name O Ma Style 1 Defini STR_7_4 inname O Style 1 Defini STR_11_8 Read ton Name Li Style 1 Defini STR_15_12 Read ton Name OxC3C Style 15 Defini STR_3_0 Read ioncam OxC3D Style 15 Defini STR_7_4 Read ioncam TT a OxC3E Style 15 Defini STR_11_8 Read ioncam OxC3F Style 15 Defini STR_15_12 Read TE oO D gt Q D D Qa O DO DO D a O D ajo a O O O lt lt lt lt lt O D O O 0x800 0x801 0x802 0x8
137. or See Errors page 66 for more information on errors a list of error codes and information on error troubleshooting Press to scroll through each error report screen 11 17 11 13 51 Events Eor Horne gt C Mo Active Errors Time Code Description 1542 CACZ2 A Gateway Comm Error FP2 1542 CACTA Gateway Comm Error FP1 T340 WED2 A Swirl Motor Fault SW2 13 40 CR42 A Valve 4 Swirl Comm Error FP2l 40 CR A Valve 1 Swirl Comm Error FP2 1540 WND2 A Key Token Error FP2 W339 F6Dl A Outlet Pressure Sensor FP 1330 CER2 A Comm Error Sli 1330 CBD 2 4 Comm Error FP2 W336 POA Outlet Pressure Sensor FP 3A2098H Appendix B Discrete Gateway Module DGM Connection Details Appendix B Discrete Gateway Module DGM Connection Details D Sub Cable 123793 The D sub cable 123793 is only compatible with single fluid plate systems Systems with 2 fluid plates must use cable 123792 and breakout board 123783 The cable length of interface cable assembly 123793 is 50 ft 15 2 m The following table identifies the cable inter face signals NOTE See Appendix D I O Signal Descriptions page 138 for I O signal descriptions mereen _ Dispense Ready Doom me lt Dispense Remote Sia poao w RO sem O CL meran foen CE ES Bomam swem oam s mees e O O ET O E ee RE SC e Et ama Black Green lt Digital CMD 1 Digital Input 77 White Green Digital CMD 2 Digital Input Orange p ES ES Swirl
138. ose as practical to the dispense valve e 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 e Connect a fluid line to the flow meter fluid inlet or to the regulator inlet if your system does not have a flow meter e 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 e Connect an air supply line to the 1 4 npt inlet port on the fluid plate s air supply inlet e Connect 5 32 in or 4 mm OD air lines from the appli cator s solenoid valve to the applicator Plug any unused solenoid ports NOTE To maximize system performance keep the dis pense hose length and ID as small as the application will allow 27 Installation Install Cable Assemblies NOTE To prevent system errors only connect cables with the power off NOTE See FIG 17 on page 29 1 For systems with more than one swirl dispenser Use a CAN cable to connect the control center to one swirl expansion enclosure Use additional CAN cables to connect any remaining expansion swirl enclosures together in sequence For systems with one or more swirl dispensers use motor cable to
139. ot operat Repair regulator ing correctly F4D Incorrect flow error tol Enter correct toler erance or flow error ance or flow error time time Advisory Job end timer was No action required if used to stop shot dis timed shot is desired pense Purge Timer Purge timer expired Advisory oe purge timer style Automation control Expired 0 has expired requests purge 72 3A2098H Shot Terminated Shot dispense cycle by Job Timer terminated by job timer Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause Fluid Plate Events and Errors EAC_ 75 Maintenance Maintenance mode Advisory Entered maintenance No action required Mode Entered entered self clearing dispense mode Maintenance Maintenance mode Advisory Exited maintenance No action required Mode Exited exited self clearing dispense mode Maintenance Due Regulator MFD_ 78 Maintenance Due Flow Meter MED_ 79 Maintenance Due V P MCD __ Maintenance Due Supply MD1 81 Maintenance Due Valve 1 MD2 82 Maintenance Due Valve 2 MD3_ 183 Maintenance Due Valve 3 MD4 84 Maintenance Due Valve 4 CCD_ Duplicate Module EAD _ Swirl Mainte nance Mode Entered WFC 87 Shot No Flow Timeout 3A2098H Maintenance due for regulator Maintenance due for flow meter Maintenance due for Voltage to Pressure Transducer Maintenance due for supply system Maintenance due for valve 1 Maintenance due for valv
140. p to four fluid plates Each fluid plate can control up to four dispense valves The system sup ports up to 16 dispense valves and can simultaneously dispense from up to 10 dispense valves PrecisionSwirl Orbital Dispenser Swirl Dispenser Sold Separately The swirl dispenser dispenses material in a circular pat tern 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 Control Center User Interface Fluid Plate Assembly System shown with one fluid plate and one swirl dispenser FIG 4 PCF System Components 3A2098H 13 Overview Fluid Plate Assembly Overview Fluid Plate Components The fluid plate assembly in FIG 5 can be attached to an automation arm or mounted on a pedestal The main components of the fluid plate assembly include e Fluid regulator cartridge ambient mastic or heated mastic P e Flow meter R optional precis
141. penser Valve 1 3 1 1 psi 2 psi 2 1 psi 2 2 230 Fa psi 3A2098H Fluid Plate Setup Screens There are nine fluid plate setup screens which enable users to e Set controls and valve commands e Seton and off delays for valves and the regula tor Set k factor pressure and flow rate variables Set offsets for inlet and outlet pressures Set error types Set variables for maintenance advisories Define styles Associate swirl dispenser with fluid plate Press to scroll through the fluid plate setup screens Once in the desired screen press cal to access the fields to make changes Press to exit edit mode NOTE Users must be out of edit mode to scroll through the fluid plate setup screens Fluid Plate x Screen 1 Control Settings This screen enables users to e Set the dispense trigger source to Gateway Com mand Cable Command Cable 3x or Combined If it is set to Command Cable users can enable the valves e Set the command value source to Gateway Com mand Cable or Display e Set the Job End Timer to Timer or Gateway If this field is set to Timer users can set Job End Delay e Set the Display Control Password to Enable or Dis able When entering maintenance mode a pass word prompt will appear if the Display Control Password is set to Enable and a password is set in the Advanced setup screens 3A2098H Appendix A Advanced Display Module ADM e Set the Run Mode Bead Adjust to Enable or Dis
142. planation of the on and off delays refer to the On Off Delays section on page 39 Lid 1332 e Fluid Plate 1 Activ C Mo Active Errors Fluid Flate 2 Delay Settings Valve I Valve 4 Valve 3 Valve Regulator Fluid Plate x Screen 4 Control Loop and Flowmeter Settings This screen enables users to set the meter type volume or mass and the K Factor for the flowmeter Users can also set the Kp Ki and Kd for the pressure control loop as well as Kp and Ki for bead control loop NOTE In systems without a flow meter the flow meter settings will be grayed out NOTE It is recommended that these values not be changed from the factory defaults of 32 00 for Kp 128 00 for Ki and 0 00 for Kd DEER Ep Fluid Plate 1 system Off C Mo Active Errors tal Control Loop Settings Fluid Plate 2 Pressure Bead kp 32 00 32 00 ki 126 00 126 00 Kot Flowmeter Settings Meter Type Volume k Factor r000 pulsesLiter 3A2098H Fluid Plate x Screen 5 Pressure Sensors NOTE Inlet sensor settings will be grayed out on this screen for systems with heated fluid plates This screen enables users to e Set the offset for the inlet and outlet pressures NOTE The offset value must be set to a non zero value before can be selected from the drop down menu e Set the minimum and maximum pressure limits for the inlet and the maximum pressure limit for the outlet e Set the error type alarm or
143. position causes the settings to be shown under the new number on the ADM Rotary Switch Position Fluid Plate 2 Fluid Plate 3 NOTE See LED Diagnostic Information page 65 for signal definitions 15 Overview Control Center Assembly Overview Front View Front View Side View 100 240 Vac Assembly pee Swirl Board aol Gateway ADM Module Swirl Control DGM FIG 7 Control Center Components The control center includes the following components e Advanced Display Module ADM with USB see e If system has a swirl dispenser Swirl Control DGM page 17 for details the module on the left and Swirl Board e Automation Gateway Module the module on the e USB enables users to download job event and right which can be one of the following five types data logs save and restore system settings and e Discrete customize the language See USB Data on e DeviceNet page 59 e EtherNet IP e PROFIBUS e 24 Vdc and 100 240 Vac customer wired options e PROFINET available Expansion Swirl Enclosure If more than one swirl dispenser is installed the system will have one Expansion Swirl Enclosure for each additional swirl dispenser The Expansion Swirl Enclosure is similar to the primary control center but it does not include the ADM or the Automation Gateway module 16 3A2098H Overview Advanced Display Module ADM BJ
144. pressure sensor cable 117 and power output cable Calibrate Amplifier Heated fluid plates only 1 Prepare Fluid Plate Assembly for Repair page 80 Remove outlet pressure sensor from outlet fitting to ensure there is no pressure applied to the sensor 3A2098H Repair Adjust Display Settings 3 With the system in setup mode navigate to the Advanced screens 4 Press to scroll to Advanced screen 2 11 1711 13 59 Gateway Fluid F Mo Active Errors Maintenance Units gals Maintenance Units Pressure Units ipsi Rate 5 Press p to access the fields to make changes 6 Press to move the Pressure Units field Press to open the drop down list and select psi Press to enter the new units 7 Press to exit edit mode 8 With the system still in setup mode navigate to Fluid Plate x screen 5 Pressure Sensors HSE e Fluid Plate 1 Fuig Plate 2 Acti No Active Errors Pressure Sensors Offset Pressure Inlet Hf psi 1914 psi Outlet psi 253 psi Lirnit Error Type Min Inlet 0 psi Max Inlet psi Max Outlet 5000 psi a1 1 l 9 Press pZlto access the fields to make changes 10 Press to move the Outlet Offset field Set the psi to 0 Press to enter the new setting 11 Press to exit edit mode 85 Repair Adjust Amplifier Settings 12 Remove cover from amplifier 116 See Replace Amplifier page 85 13 Ensure the EXCITATION SELECTOR jumper is in t
145. r the dispense applicator to start a job This config uration is useful for less demanding applications that do not require a full automation interface The following limitations apply when starting a job with this configuration e The selected style defaults to Style 1 e There can be up to a 100 ms delay before dis pensing while PCF prepares for the new job cycle e The job end mode timer must be used to end a job 49 Operation Typical Job Cycle Chart NOTE Swirl can be turned on at any point inside of or outside of a job Allow time for the swirl to reach desired RPM If possible verify Swirl soeed through the automa tion interface prior to opening the dispense valve First Job Second Job Automation Inputs PCF Outputs Dispense Ready Dispenser Fluid Plate No Alarm Dispenser Fluid Plate No Error Dispenser Fluid Plate In Process Volume OK Automation Outputs PCF Inputs Style Bits Style Strobe Dispense Valve X On Dispense Complete PCF State Regulator Active Precharge 0 Dispense Valve X Open 50 3A2098H Control Charts Automation Inputs PCF Outputs Dispense Ready Dispenser Fluid Plate No Alarm Dispenser Fluid Plate No Error Dispense In Process Purge In Process Volume OK Automation Outputs PCF Inputs Style Bits Style Strobe Dispense Valve X On Dispense Complete PCF State Dispense Valve X Open Automation Inputs PCF Outputs Dispense Ready Dispenser
146. related inputs apply only to systems with Swirl Dispensers Dispense Error may be active high or low depending on the setting on the Gateway setup screen See Discrete Gateway Automation Setup Screen page 104 3A2098H 115 Appendix B Discrete Gateway Module DGM Connection Details D Sub Cable 123792 and Breakout Board 123783 The cable length of the interface cable assembly 123792 is 50 ft 15 2 m The following table identifies the pin assignments for the 78 pin breakout board NOTE See Appendix D I O Signal Descriptions on page 138 D Sub Pin No Description Pin Type Voltage Vdc PO Command Value Fluid Plate 1 Analog In 0 10 2 Command Value Ground Fluid Plate 1 Analog In Ground FO 3 Command Value Fluid Plate 2 Analog In Command Value Ground Fluid Plate 2 Analog In Ground oa nn a Digital Out Bank 1 O N 7 EEE Digital Out Bank 1 22 Swirl Speed Command Ground Analog in Ground 0 o 24 Swirl Speed Command Ground Analog In Ground 0 O o BE E E bon CE G oo 4 Swt Actual Speed Ground Analog Out Ground Jo O O 43 Swirl Actual Speed Ground Analog Out Ground Jo o mo l O o o 10 11 12 13 14 116 3A2098H Appendix B Discrete Gateway Module DGM Connection Details D Sub Pin No 57 58 59 60 67 Description Dispense Complete Error Reset Remote Start Purge Pin Type Digital In Digital In Digi
147. rer s warnings For complete information about your material request MSDS forms from distributor or retailer e Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer 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 74 BURN HAZARD AE ee Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if solashed in the eyes or on skin inhaled or swallowed e Read MSD9 s to know the specific hazards of the fluids you are using e 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 inhala tion of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear
148. rface Command 0209 Bit 0 0210 See CGM Command Interface on 2 O211 page 131 for command interface 0212 Plate 4 details 0213 tyle 32 Command Interface Command 0214 Style 64 Bit 1 0215 tyle 128 Command Interface Command 0216 Dispense Valve 1 Precharge On Bit 2 All Fluid 2 Fluid Plate 4 6 O217 Command Interface Command Plates S 0219 Command Interface Command 0221 Command interface Command EE Command Interface Command O225 Command Interface Command 28 7 0223 O227 Fluid Command interface Command O229 Command Interface Command 0231 Command Interface Command 0234 Bit 11 aye og O23 Fluid 0236 Plate 4 Bit 12 Poo 0237 ee Command Interface Command ORB SSCS Bit 13 E Swirl Command Value 1 7 0239 Command Interface Command 0240 Swirl Command Value 1 0241 Command Interface Command 0244 Bit 16 Command Interface Command 0246 Swirl Command Value 64 O247 Swirl Command Value 128 Command Interface Command All Fluid 0248 Swirl Command Value 256 Bit 18 gt Plates S 31 Swirl 4 Command Interface Command 0249 Swirl Command Value 512 0250 Swirl Command Value 1024 0251 Swirl Command Value 2048 0252 wirls 0245 Swirl Command Value 32 os Oma 0255 3A2098H 129 Appendix C Communications Gateway Module CGM Connection Details Output Byte Bit Description Command Interface Value Bit 0 Se
149. s to complete each setup step Once these steps are complete the module is ready for operation NOTE See the Advanced Display Module ADM sec tion page 17 and Appendix A Advanced Display Module ADM page 99 for detailed operating instruc tions for the display keypad and each screen 1 Configure System page 32 2 Configure Control Settings page 33 3 Configure Mode Settings page 34 4 Configure Delay Settings page 34 5 Configure Flow Meter Settings page 35 6 Configure Pressure Loop Settings page 35 7 Adjust Pressure Sensors page 36 8 Configure Errors page 36 9 Setup Maintenance Schedule Parameters page 37 10 For systems with swirl dispensers only a Configure Swirl to valve association and error type page 37 b Configure Swirl settings page 38 11 Configure Gateway Settings page 38 12 Setup Styles page 38 13 Configure Advanced Settings page 38 32 Configure System Define the number of installed fluid plates called Dis penser 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 Sys tem screen 2 Press LA 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
150. s used TIT CITE RE TETE e Pressure Control the regulator outlet pressure is LUT 7 11 13 49 4 Home Fluid Plate 1 EEEE do des Aie Display Control CL Mo Active Errors Control Mode ET e Full Open Control the PCF system does not con 263 psi trol fluid pressure or flow Instead the regulator 1914 ps i ae opens to allow for recirculation applications A A 112 3A2098H Fluid Plate x Screen 2 Control Center NOTE Users must be out of maintenance mode in Fluid Plate x screen 1 in order to scroll to this screen NOTE The term Robot on this screen refers to the automation controller This screen enables users to view and monitor the cur rent status of the robot outputs and inputs An X is dis played in the applicable check box when e Using a style strobe e The dispense is complete e A dispense trigger occurs e The dispenser fluid plate is ready e The dispense is in process e There are no alarms or errors e The dispense volume is correct This screen also displays the current dispense style command voltage Gateway error number code and the volume dispensed LUT AIT 1345 ae Horne Fluid Plate 1 RER Active C Mo Active Errors Style 0 Robot Outputs Style Strobe Dispense Complete Dispense Trigger I 2 Jal Jal Command Digital 1 Robot Inputs Dispenser Ready x No Alarm x No Error D Vol OK Error U Dispensed Volurne O cc In Process
151. se 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 e Each valve is set to Pressure mode and has identical Fixed Command values e Each valve is set to Full Open mode Attempting to dispense from multiple valves simultane ously using any other combination will cause an Incom patible Valves Settings alarm 34 5 Press to move to the Bead Scale field Enter a scale value between 50 and 150 Press to enter the value 6 Press to exit edit mode Configure Delay Settings Set on and off delays in milliseconds for each valve and the regulator For an explanation of the on and off delays refer to the On Off Delays section on page 39 1 With the system in setup mode navigate to the Fluid Plate x screen 3 Delay Settings 2 Press LA to access the fields to make changes 11 1111 1352 e Fluid Plate 1 Fluid Plate 2 Active C Mo Active Errors tai Delay Settings Valve 1 Valve 4 Valve 3 Valve Regulator FIG 22 3 Use the four arrow buttons to navigate to each On and Off field Enter a desired delay value in milli seconds for each valve that will be used and the regulator Press to enter each value 4 Press to exit edit mode 3A2098H Configure Flow Meter Settings Th
152. sory The active time total izer for the swirl dis penser associated with this valve and fluid plate exceeded limit setting The active time total izer for the swirl dis penser associated with this valve and fluid plate exceeded limit setting Service Component lf necessary reset totalizer Service Component lf necessary reset totalizer Event Gateway Event Code Error No Event Name Description Event Type Cause Swirl Communi cation Error Duplicate Module Maintenance Mode Entered Maintenance Mode Exited Maintenance Due Orbiter Swirl Events and Errors Swirl communication error with ADM Duplicate Swirl Control DGM Detected Maintenance mode entered Maintenance mode exited Maintenance due on swirl orbiter Advisory self clear ing Advisory self clear ing Advisory The ADM lost commu nication with the Swirl Control DGM Two or more Swirl Control DGMs have the same rotary switch setting Swirl maintenance mode entered Swirl maintenance mode exited Swirl active time total izer exceeded limit set ting Restore communica tions Verify that all Swirl Control DGMs have proper rotary switch settings Reset mod ule after changing rotary switch setting Refer to Swirl Control DGM section page 19 No action required No action required Service Component If necessary reset totalizer Swirl Motor Fault Motor speed is outside Al
153. t 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 3A2098H Setup Maintenance Schedule Parameters Set the volume or hours limit that will trigger a mainte nance advisory for the fluid supply Voltage to Pressure V P Transducer fluid regulator flow meter and all four valves NOTE Hours is shown instead of Volume for fluid plates without a flow meter The Volume or Hours column displays the current totalizer value If this value exceeds the set limit the value will turn red and a maintenance advisory is issued See Fluid Plate x Screen 7 Maintenance Advisory Limits page 108 for more information about mainte nance totalizers To set limits 1 With the system in setup mode navigate to the Fluid Plate x screen 7 Maintenance Advisory Limits 2 Press LA to access the fields to make changes Fluid Plate 2 RRM CE Co Fluid Plate 1 C Mo Active Errors fa Maintenance Advisory Limits ca Linit Volume Supply 0 79 251 galls we ol 26 416 galls 0 132 galis 0475 galus 17 313 gal Us 7473 galus 0 006 gallus 0 001 gal Ls Active Regulator Ol Flowmeter 0 Valve F D Valve 2 Ol Valve Oo Valve oO FIG 26 3 Enter the desired limit for the air supply and press to enter the selection 4 Press to move to the next field Repeat Step 4
154. t s present Green 124 PROFIBUS Connector DC Pn so Besson 3 Bline Positive RxD TxD R5485 level Request to send 5 GND Bus Ground isolated E Bus 5V termination power isolated s Negative a xD RS485 level Housing Cable Shield Internally connected to the Anybus protective earth via cable shield filters according to the PROFIBUS stan dard 3A2098H Appendix C Communications Gateway Module CGM Connection Details CGM I O Data Map an pri Byte Description See Appendix D I O Signal Descriptions on page 140 138 Gi 5 Fluid Plate 2 153 154 I55 Automation Inputs signals from PCF Description Zone 01 Dispenser Fluid Plate No Alarm 02 03 04 Fluid o5 p Plate Dispenser Fluid Plate Purge Request 07 Dispenser Fluid Plate Remote Start Purge In Process 22 110 11 Fluid 12 Plate 1 123 144 145 146 147 148 Fluid Plate 2 i56 Error E E ES ee S fe es EE E E 57 5B 59 Fluid 16 Plate 2 2 4 7 G 62 63 O1 O1 ON A A N O w PO 18 19 20 21 Dispenser Fluid Plate Purge Request Dispenser Fluid Plate Remote Start Purge In Process 72 73 174 75 Fluid 176 Plate 3 0 J 7 CE Fluid Plate 1 24 Error J 25 26 27 Fluid 16 Plate 1 32 64 28 29 30 aT 32 Dispenser Fluid Plate Ready 133 Dispenser Fluid Plate No Alarm 34
155. t 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 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 con troller sets Dispense Complete to 1 3A2098H Operation 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 Com mand Cable or Command Cable 3x users only need to trigge
156. tal In Voltage Vdc 0 30 0 30 0 30 10 30 10 30 Digital Out Supply Bank 2 Digital Out Supply Bank 3 Isolated Logic GND Style Strobe Fluid Plate 2 Fluid Plate Selector 1 installed fluid plate no swirl Fluid Plate 1 Dispense Valve 1 2 installed fluid plates no swirl Fluid Plate 1 Dispense Valve 1 1 installed fluid plate one or more swirl Fluid Plate 1 Dispense Valve 1 2 installed fluid plates one or more swirl Fluid Plate 1 Dispense Valve 1 1 installed fluid plate no swirl Fluid Plate 1 Dispense Valve 2 2 installed fluid plates no swirl Fluid Plate 1 Dispense Valve 2 1 installed fluid plate one or more swirl Fluid Plate 1 Dispense Valve 2 2 installed fluid plates one or more swirl Fluid Plate 2 Dispense Valve 1 1 installed fluid plate no swirl Fluid Plate 1 Dispense Valve 3 2 installed fluid plates no swirl Fluid Plate 2 Dispense Valve 1 1 installed fluid plate one or more swirl Swirl 1 Enable 2 installed fluid plates one or more swirl Swirl 1 Enable 1 installed fluid plate no swirl Fluid Plate 1 Dispense Valve 4 2 installed fluid plates no swirl Fluid Plate 2 Dispense Valve 2 1 installed fluid plate one or more swirl Swirl 2 Enable 2 installed fluid plates one or more swirl Swirl 2 Enable 77 Digital I Digital In 16 bit data outputs contain either volume or error information depending on state of dispense alarm error on data solated
157. te 4 OxB3___ e The command is a read command bit 320 high e The value of the command is 0 0x0000 Combined this means Valve 7 on fluid plate 4 is dis abled 131 Appendix C Communications Gateway Module CGM Connection Details Command Interface Timing Diagram Write Command Read Command Automation Outputs PCF Inputs Command Bits 256 275 l l Value Bits 288 319 l l l Write Bit 321 i l Read Bit 320 Automation Inputs PCF Outputs Value Bits 128 159 Command Active Bit 160 Command Success Bit 161 Command Failure Bit 162 l I l Command Value Coerced Bit 163 l l l FIG 73 CGM Command Interface Timing Diagram Command Interface Write Operation 4 Wait for the Command Success Bit or Command 1 Set Command Identification Bits and Fluid Failure Bit to become set Plate Swirl Identification Bits to the desired values NOTE If Command Success Bit has been set valid 2 Set Value Bits Output with the value that is desired CAA V LE Dissent LS CCS S to be written 5 Clear the Read Bit to end the read command opera 3 Set Write Bit tion 4 Wait for the Command Active Bit to become set Fluid Plate Swirl Identification Commands This indicates that an operation is in process Output Bits 268 275 5 Wait for the Command Success Bit Command Fail Fluid Plate 1 ure Bit or Command Value Coerced Bit to become Fluid Plate 2 set Fluid Plate 3 Fluid Plate 4 NOTE The Value Bits Input now contain th
158. ted to dis pense Attempted to dis pense simultaneously from multiple valves on the same fluid plate with different pressure settings Incompatible settings Alarm for multiple valve opera tion attempted to dis pense Attempted to dis pense simultaneously from multiple valves on the same fluid plate with different pressure settings Alarm System reading flow meter pulses with valve s closed Flow meter providing false pulses Verify outlet pressure transducer is installed and or connected cor rectly Replace if necessary Verify dispense valve 1 is installed and or con nected correctly Replace if necessary Verify dispense valve 2 is installed and or con nected correctly Replace if necessary Verify dispense valve 3 is installed and or con nected correctly Replace if necessary Verify dispense valve 4 is installed and or con nected correctly Replace if necessary Check settings shown on Fluid Plate x screen 2 Mode Set tings Verify automation pro gramming In the Discrete Gate way screens change the settings of the simultaneously dis pensing valves to the same pressure Verify automation pro gramming Dispense hose leak Check hose replace if needed Replace flow meter sensor or calibrate meter Dispense valve not Repair dispense valve operating correctly 3A2098H Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause
159. teway module follow Replace Gate way Module 87 Repair Replace Swirl Board 16K570 1 Prepare Control Center for Repair page 87 2 Remove screw a from swirl board cover Open swirl board cover 3 Remove cable connectors b from swirl board 4 Remove the four screws c from the swirl board Replace with new board and secure using the four screws C 5 Insert cable connectors b into the new board 6 Reassemble the swirl board cover using screw a FIG 62 88 Replace Advanced Display Module 1 Prepare Control Center for Repair page 87 2 Disconnect the CAN cable 18 from the ADM 2 11 14 24 FIG 63 3 Remove the ADM by snapping it out of the mounting bracket 4 Onold ADM remove token access panel then remove key token Do not discard token 5 Connect the CAN cable to the new ADM 6 Upgrade new ADM software page 77 7 Insert key token into new ADM Replace token access panel 8 Install the new ADM by snapping it into the mount ing bracket 3A2098H Repair Replace Advanced Display Module Bracket Replace DIN Rail Assembly 1 Prepare Control Center for Repair page 87 1 Prepare Control Center for Repair page 87 2 Remove the ADM 2 follow Replace Advanced 2 Remove both screws 22 and washers 28 from Display Module Leave the CAN cable attached to the line voltage assembly cover 7 Remove the the ADM co
160. th appropriate size bolts through the 0 27 in 7 mm diameter holes in the mount ing tabs See the following mounting dimensions Table 2 Control Center Assembly Measurement 10 50 in 267 mm 5 75 in 146 mm C 22 00 in 559 mm 21 25 in 540 mm Rs GRAGO FIG 12 Control Center Dimensions 3A2098H Electrical Connections Av Ac To reduce the risk of fire explosion or electric shock when grounding connecting cables connecting to a power source or making other electrical connections e 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 e All wires used for grounding must be 18 AWG min imum e A qualified electrician must complete all grounding and wiring connections e For 24 Vdc wiring refer to FIG 13 e For 100 240 Vac wiring refer to FIG 14 e 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 Stiles CE tit Ground FIG 13 24 Vdc Wiring 3A2098H Installation O Ground LT N FIG 14 100 240 Vac Wiring Connect
161. the swirl zone associ ated with this valve and fluid plate 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 The swirl zone associ ated with this valve and fluid plate caused a fault The active time total izer for the swirl dis penser associated with this valve and fluid plate exceeded limit setting The active time total izer for the swirl dis penser associated with this valve and fluid plate exceeded limit setting Restore communica tions Restore communica tions Restore communica tions Restore communica tions Resolve swirl motor fault see error WBDX for possible solutions Resolve swirl motor fault see error WBDX for possible solutions Resolve swirl motor fault see error WBDX for possible solutions Resolve swirl motor fault see error WBDX for possible solutions Service Component lf necessary reset totalizer Service Component lf necessary reset totalizer 3A2098H Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause Fluid Plate Events and Errors Maintenance due V3 Orbiter Maintenance due V4 Orbiter Swirl Events and Errors Maintenance due on valve 3 swirl orbiter Maintenance due on valve 4 swirl orbiter Advisory Advi
162. the tolerance set for the running style 45 Operation Styles The PCF system has the ability to handle up to 256 styles depending on the selected option NOTE The number of available styles depends on the fluid plate configuration See Models on page 4 Style O is specified for purging only For each style an independent target volume and toler ance can be configured This allows for job related errors and logs to be evaluated for each style The style is read at the beginning of a job and cannot be changed until the next job PCF reads in the styles via the Gateway interface For detailed interface information see Appendix B Dis crete Gateway Module DGM Connection Details on page 115 and Appendix C Communications Gate way Module CGM Connection Details on page 122 as applicable To setup a style 1 Navigate to Fluid Plate x screen 8 2 Press LA to access the style setup fields Fluid Plate 2 DEEE Fluid Plate 1 E Mo Active Errors Style c l Style Style Marne Volume cc system Off Tolerances Ols ols Pre Charge Mode Display rl Pressure ___ O ps FIG 34 46 3 Enter the style number in the Style field 4 Enter Style Name a Press while in the Style Name field to dis play the Keyboard screen ERNSEGN Fluid Plate 1 IRC Mo Active Errors Style Mame 1 characters max O e E fallwife Iie felt be eiim IE a FIG 35 b Use th
163. 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 block age is cleared 57 Shutdown Shutdown A 1 Press the Stop button BC BC T112362a FIG 37 ADM Stop Button 2 Shut off the material supply to the fluid plate meter 3 Follow the Pressure Relief Procedure on page 57 4 Turn off the PCF system s compressed air supply 5 Turn main power switch on control panel to the OFF position O _ i Gee PCF RACO FIG 38 Control Center Main Power Switch 58 3A2098H USB Data All files downloaded from the USB are put in a DOWN LOAD 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 MSs SES a Fic 39 ADM USB Port During operation PCF stores system and performance related information to memory in the form of log files PCF maintains three types of log files a job log an event log and dispense data logs Follow the Down load Procedure page 61 to retrieve log files Event Log The event log file name is
164. tic Regulator No Flow Meter 16 styles aaea 16M103 35 MPa 345 bar rate i aay O Reg al one N z nr m Heated Mastic ree No Flow Meter 2a o EERO cae ea je bar Di res es RONDE eee P 2 sal Cartridge ee Flow Maio Seas a De a Cartridge i pe Flow Meter ama nies rats eg ay Na Reni Hah exon Fm one ae m hoa or i Mastic er Meter EIRE pinion Ua one EE z oi Heated Mastic 2 No Flow Meter EIRE NE PS Ue Rs mo Fluid Plate Kit 24B958 24B959 24B960 24B961 24B962 24C901 24J873 24K801 24K802 24K803 24K804 24K805 24K806 24K807 24K808 24K809 24K810 24K811 24K812 24K813 24K814 3A2098H 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 Description 16M350 100 240 Vac 16M351 24 Vdc PrecisionSwirl Orbital Dispenser Assemblies See manual 309403 Maximum Working Version Part Series Coupler Offset Typical Application Pressure 243402 B 0 012 in for narrow bead Hem flange and after hem widths Bal 243403 B 0 028 in for wide bead Seam sealing widths 3500 psi
165. tify the value of the command specified by bits 256 267 and 268 275 e Output bit 321 identifies the command as a write command e Output bit 320 identifies the command as a read command The CGM command interface uses automation input bits 128 159 to read the current system values It also uses input bits 160 163 to identify the status of com mands Bit 160 Command Active Bit 161 Command Success Bit 162 Command Failure Bit 163 Value Coerced NOTE If both output bits 320 read and 321 write are high during a command the result will be a command failure identified by input bit 162 command failure going high 3A2098H Examples NOTE See the timing diagram and tables starting on page 132 for detailed descriptions of the input and out put bits Example 1 if output bits 256 275 are 0xB0203 output bits 288 319 are 0x0004 and output bit 321 is high this means e The command relates to the purge period in minutes Ox__ 203 e The command relates to fluid plate 1 OxBO___ e The command is a write command bit 321 high e The value of the command is 4 0x0004 Combine these individual pieces to understand the com mand as a whole Change the purge period setting on fluid plate 1 to 4 minutes Example 2 if output bits 256 275 are 0xB3212 input bits 288 319 are Ox0000 and output bit 320 is high this means e The command relates to whether valve 1 is enabled Ox__ 212 e The command relates to fluid pla
166. ting 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 e Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area 8 3A2098H Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals e Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufactu
167. ts 0x000 0xFFF This analog value is scaled to a flow rate in bead mode or pressure in pressure or shot mode command based on the config ured scale factor Error Reset Cancel Job If the End Job On Alarm setting is enabled e If ina job setting this bit will cancel the current job e If not in a job setting this will reset errors If the End Job On Alarm setting is disabled e Setting this bit will reset errors regardless of job sta tus 3A2098H Appendix D I O Signal Descriptions Remote Start Purge This bit is used to restart the dispense system from any not ready state If the system is already in a Dispense Ready state this signal shall initiate a purge based on the configured purge parameters Swirl X Enable This bit is used to signal the on and off status of each swirl dispenser motor Swirl Command Value This 12 bit value indicates a swirl speed command from 0 10 volts O volts 0x000 represents a speed of 6 600 rpm and 10 volts OxFFF represents 24 000 rpm Dispense Valve X Precharge On These 4 bits are used to turn on precharge for each of the 4 dispense valves when the precharge mode is set to Gateway 139 Technical Data Technical Data Minimum Flow Rates 25 cc minute with high resolution ambient helical flow meter 50 cc minute with heated helical flow meter Maximum Flow Rates 7500 cc minute with high
168. tup USB related set tings The Disable USB Log Errors option disables recording events when the logs are at least 90 full 11 17 11 14 00 es Gateway ER E Mo Active Errors Disable USB Downloads Uploacts Disable USB Log Errors Download Depth Last Days Advanced Setup Screen 4 This screen displays the software part number and ver sion for the ADM USB configuration Gateway module and fluid plates 11 17 11 14 00 e Gateway nase C Mo Active Errors Software Software Part Version 16k 405 10207 16874 101002 LITE 101 006 LIRE 101072 16873 101 009 1872 101 006 161972 101 006 Module Advanced Display LISE Configuration Gateway Fluid Plate 1 Fluid Plate 2 Swirl Control 1 Swirl Control 2 101 Appendix A Advanced Display Module ADM Automation Gateway Setup Screens There are up to three automation Gateway Setup screens depending on fieldbus which enable users to set or change information regarding the automation Gateway module used on the PCF system These screens also enable users to view information regarding the particular automation Gateway module used Press to scroll through the Gateway Setup screens Once in the desired Advanced Setup screen press Elto access the fields to make changes Press to exit edit mode NOTE Users must be out of edit mode to scroll through the Gateway Setup screens Gateway Setup Screen 1 DeviceNet This screen enables users to set the device
169. tup value was No action necessary if Changed tion changed on the dis changes were desired play down Control Center Events and Errors Event Gateway Event Code ErrorNo Event Name Description Event Type Cause Control Center Events and Errors EVUX USB Disabled USB download Advisory Transfers are disabled Clears when drive is attempted however self clearing in Advanced Setup removed USB activity is dis screen 2 abled USB Log 90 One or more USB log is Advisory Data in the jobs or Download the data or Full 90 full events log has not disable USB errors been downloaded recently and logs are nearly full DGM Unpowered The Discrete Gateway Advisory 24 Vdc has not been Connect power accord Module does not have connected to the ing to Appendix B logic power supplied to power pins Discrete Gateway it Module DGM Con nection Details on page 115 Gateway Setup System settings are Advisory Fluid plate 1 is not Install fluid plate 1 Error incompatible with Dis installed Or Fluid uninstall fluid plates 3 crete Gateway Module plate 3 or fluid plate 4 and 4 is installed Swirl 1 is not installed Install Swirl 1 unin Or Swirl 3 or Swirl 4 is stall swirls 3 and 4 installed Download to Information is currently Advisory No action necessary USB in Process being downloaded to self clearing USB 3A2098H 67 Errors Event Gateway Event Name Code Error No EBUX WSUO
170. ver 3 Remove the speed clips 25 and rivets 26 from the mounting bracket 21 u WN ARE et peer nt a FIG 65 FIG 64 3 Disconnect all wiring from the din rail module and fil ter 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 3A2098H 89 Repair 6 Remove the din rail filter and rocker switch Snaps into place Replace with new components Secure din rail and filter to the rear control center assembly cover 1 using the four screws 40 Snap rocker rotary switch into position d ny lel tl C3 Oo W ge i hy i fe r_pf0000_313377_10a 40 FIG 66 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 e For 24 Vdc control centers s
171. y dispensing will turn off this bit and reset the purge timer This signal will be 1 under the following condition e The system purge interval timer has expired Dispenser Fluid Plate Remote Start Purge in Process This signal is O on power up This signal will be 1 under the following conditions e Aremote start sequence is in process This sig nal shall remain asserted until the dispense equipment has achieved Dispense Ready sta tus e A purge sequence is in process This signal shall remain asserted until the purge sequence is complete Units All units settings are set in the Advanced Display Mod ule The following signals are used to communicate this information to the automation controller Pressure Units reserve Errors Error numbers are formed by 8 bits This is the error number in the system 3A2098H Automation Outputs Style The desired style of the next job These 8 bits are read at the start of a job to determine the selected style Style Strobe This bit is used to start a new job A new job is started when the style strobe changes from 0 to 1 Dispense Complete This bit is used to signal the end of a job A job is ended when this signal changes from 0 to 1 Dispense Valve x On These 4 bits are used to signal the turn on and turn off of each of the 4 dispense valves on the applicable fluid plate Command Value This 12 bit value indicates the analog command value from 0 10Vol

Graco 3A2098H PCF User's Manual

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