Graco 3A2098H Pcf Users Manual 3A2098H, PCF, Instructions Parts, (English)
3A2098H to the manual b17f154f-8a4d-41d7-bd89-21ffed7fb84e
2015-04-02
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Instructions - Parts PCF™ with ™ PrecisionSwirl 3A2098H EN Precision Dispense System Electronically-controlled fluid metering system that provides precise continuous flow of up to four single-component sealants and adhesives through closed-loop technology. Not for use in explosive atmospheres or hazardous locations. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 4 for model information. See page 5 for maximum working pressure and approvals. Optional PrecisionSwirl Orbital Dispenser (sold separately) IMPORTANT: PCF Control Center This manual does not apply to some PCF systems. See note on page 3 to verify this is the correct manual for your PCF system. PCF Fluid Plate Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fluid Plate Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Expansion Swirl Enclosure Assemblies . . . . . . . 6 PrecisionSwirl Orbital Dispenser Assemblies . . . 6 Automation Gateway Assemblies . . . . . . . . . . . 7 Swirl Control DGM . . . . . . . . . . . . . . . . . . . . . . . 7 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 System Configurations . . . . . . . . . . . . . . . . . . . . . 10 Typical Installation - Single Swirl, Single Fluid Plate 10 Typical Installation - Multiple Fluid Plates, No Swirl Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . 11 Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers . . . . . . . . . . . . . . . . . . . . 12 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 System Overview . . . . . . . . . . . . . . . . . . . . . . . 13 System Components . . . . . . . . . . . . . . . . . . . . . 13 Fluid Plate Assembly Overview . . . . . . . . . . . . 14 Control Center Assembly Overview . . . . . . . . . 16 Key Tokens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Error Type . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Configure Swirl Settings . . . . . . . . . . . . . . . . . . 38 Configure Gateway Settings . . . . . . . . . . . . . . . 38 Setup Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Configure Advanced Settings . . . . . . . . . . . . . . 38 On/Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Maintenance Mode Operation . . . . . . . . . . . . . . 41 Automation Control (Normal Operation) . . . . . . 45 Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Precharge Modes . . . . . . . . . . . . . . . . . . . . . . . 47 Typical Job Cycle . . . . . . . . . . . . . . . . . . . . . . . 49 Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 57 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 USB Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 System Configuration Settings File . . . . . . . . . . 60 Custom Language File . . . . . . . . . . . . . . . . . . . 60 Download Procedure . . . . . . . . . . . . . . . . . . . . . 61 Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . 61 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Fluid Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fluid Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 63 Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 64 Gateway Module . . . . . . . . . . . . . . . . . . . . . . . . 65 LED Diagnostic Information . . . . . . . . . . . . . . . . 65 Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Diagnose Errors . . . . . . . . . . . . . . . . . . . . . . . . . 66 Event and Error Codes and Troubleshooting . . 67 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Maintenance Schedule . . . . . . . . . . . . . . . . . . . 76 Advanced Display Module (ADM) . . . . . . . . . . . 77 Upgrade Gateway Module Software . . . . . . . . . 77 Upgrade Gateway Module Fieldbus Map . . . . . 78 Upgrade Fluid Control Module (FCM) Software 79 Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . 79 Swirl Dispensers . . . . . . . . . . . . . . . . . . . . . . . . 79 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Fluid Plate Assembly . . . . . . . . . . . . . . . . . . . . . 80 Control Center Assembly . . . . . . . . . . . . . . . . . 87 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Control Centers . . . . . . . . . . . . . . . . . . . . . . . . . 91 Control Center and Expansion Swirl Enclosure Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Fluid Plate Assembly Parts . . . . . . . . . . . . . . . . 94 3A2098H Related Manuals 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 . . . . . . . . . . . . . . . . . . . . . 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 Related Manuals The following is a list of component manuals written in English. These manuals and any available translations can be found at www.graco.com. Manual Description 313377 Original PCF Instructions - Parts (see the note below) 309403 PrecisionSwirl Orbital Dispenser 307517 308647 309834 Mastic Fluid Regulators Instructions-Parts Fluid Pressure Regulators Instructions-Parts Helical Gear Fluid Flow Meters Instructions-Parts NOTE: In the Advanced screens on your system, if the Advanced Display software part number shown is 16F528 or 15V769 then this manual does not apply to your system; refer to manual 313377 for your system. Otherwise, the part number shown should be 16K405 and you should use this manual. ADM Software Part No. 16F528 or 15V769 (see manual 313377) ✖ ADM Software Part No. 16K405 (use this manual) ✓ 3A2098H 3 Models Models Check the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to define the construction of the system, based on the six digits. For example, Part PF1110 represents a PCF fluid metering system (PF), a two style system (1), a fluid plate with a cartridge regulator and no meter (1), a DeviceNet™ user interface (1) with a 100-240 Vac power supply (0). NOTE: To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the Ref. Nos. in the Parts drawings and lists. PF First and Second Digits PF (Precision Continuous Flow) 1 1 1 0 Third Digit Fourth Digit Fifth Digit Sixth Digit Fluid Plate User Interface Description Voltage Style/Size Description 1 2 3 Regulator Meter 2 Styles 16 Styles 1 2 ❄Cartridge ❄Mastic None None 0 1 DeviceNet™ 256 Styles 3 ❄Cartridge High Resolution 2 EtherNet/IP™ 2 100 - 240 Vac with Integrated Swirl 4 ❄Mastic 3 PROFIBUS™ 3 5 Heated Mastic 4 PROFINET™ 6 Heated Mastic ❄Cartridge High Resolution Heated Standard Resolution None 7 ◆Discrete Description 0 1 100 - 240 Vac 24 Vdc 24 Vdc with Integrated Swirl Ultra High Resolution ◆ Discrete Gateway systems do not include automation interface cables. The following Graco accessories are available for wiring to the automation system. Installers should follow Appendix B - Discrete Gateway Module (DGM) Connection Details, page 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. 9902471 Certified to CAN/CSA C22.2 No. 61010-1 Conforms to UL 61010-1 1 This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition, including C 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. Includes: Fluid Plate Kit Used by Model Maximum Working Pressure Description Regulator Flow Meter FCM Key Token 24B958 PF13xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, High Resolution Flow Meter, 2 styles 244734 246652 16M100 24B959 PF11xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, No Flow Meter, 2 styles 244734 --- 16M101 24B960 PF14xx 5000 psi (35 MPa, 345 bar) Mastic Regulator, High Resolution Flow Meter, 2 styles 246642 246652 16M100 24B961 PF12xx 5000 psi (35 MPa, 345 bar) Mastic Regulator, No Flow Meter, 2 styles 246642 --- 16M101 24B962 PF15xx 5000 psi (35 MPa, 345 bar) Heated Mastic Regulator, Standard Resolution Heated Flow Meter, 2 styles 246643 246340 16M100 24C901 PF16xx 5000 psi (35 MPa, 345 bar) Heated Mastic Regulator, No Flow Meter, 2 styles 246643 --- 16M101 24J873 PF17xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, Ultra High Resolution Flow Meter, 2 styles 244734 16E993 16M100 24K801 PF23xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, High Resolution Flow Meter, 16 styles 244734 246652 16M102 24K802 PF21xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, No Flow Meter, 16 styles 244734 --- 16M103 24K803 PF24xx 5000 psi (35 MPa, 345 bar) Mastic Regulator, High Resolution Flow Meter, 16 styles 246642 246652 16M102 24K804 PF22xx 5000 psi (35 MPa, 345 bar) Mastic Regulator, No Flow Meter, 16 styles 246642 --- 16M103 24K805 PF25xx 5000 psi (35 MPa, 345 bar) Heated Mastic Regulator, Standard Resolution Heated Flow Meter, 16 styles 246643 246340 16M102 24K806 PF26xx 5000 psi (35 MPa, 345 bar) Heated Mastic Regulator, No Flow Meter, 16 styles 246643 --- 16M103 24K807 PF27xx 6000 psi (41.4 MPa, 414 bar) Cartridge Regulator, Ultra High Resolution Flow Meter, 16 styles 244734 16E993 16M102 24K808 PF33xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, High Resolution Flow Meter, 256 styles 244734 246652 16M104 24K809 PF31xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, No Flow Meter, 256 styles 244734 --- 16M105 24K810 PF34xx 5000 psi (35 MPa, 345 bar) Mastic Regulator, High Resolution Flow Meter, 256 styles 246642 246652 16M104 24K811 PF32xx 5000 psi (35 MPa, 345 bar) Mastic Regulator, No Flow Meter, 256 styles 246642 --- 16M105 24K812 PF35xx 5000 psi (35 MPa, 345 bar) Heated Mastic Regulator, Standard Resolution Heated Flow Meter, 256 styles 246643 246340 16M104 24K813 PF36xx 5000 psi (35 MPa, 345 bar) Heated Mastic Regulator, No Flow Meter, 256 styles 246643 --- 16M105 24K814 PF37xx 6000 psi (41 MPa, 414 bar) Cartridge Regulator, Ultra High Resolution Flow Meter, 256 styles 244734 16E993 16M104 3A2098H 5 Models Expansion Swirl Enclosure Assemblies The following enclosures are ETL approved. Assemblies PFxxx2, and PFxxx3 are setup for one PrecisionSwirl Orbital Dispenser. If you wish to have additional swirl dispensers, order one expansion PrecisionSwirl assembly below for each. Systems with a DGM as the automation gateway can have up to two swirl dispensers total. Systems with a CGM as the automation gateway can have up to four swirl dispensers total. Part Description 16M350 16M351 100 - 240 Vac 24 Vdc PrecisionSwirl Orbital Dispenser Assemblies See manual 309403. Version Part, Series Standard 243402, B Standard 243403, B Compact 289262, A Compact 289261, A Coupler Offset 0.012 in. for narrow bead widths 0.028 in. for wide bead widths 0.012 in. for narrow bead widths 0.018 in. for medium bead widths Typical Application Maximum Working Pressure Hem flange and after hem Seam sealing Hem flange and after hem 3500 psi (24.1 MPa, 241 bar) Seam sealing PrecisionSwirl Orbital Dispenser Cable Assemblies Part 233125 233124 233123 617870 6 Description 6 ft (1.8 m) motor extension cable assembly 9 ft (2.7 m) motor extension cable assembly 15 ft (4.6 m) motor extension cable assembly 55 ft (16.8 m) motor extension cable assembly 3A2098H Models Automation Gateway Assemblies Each control center comes with one automation gateway assembly. The automation gateway module is either a Discrete Gateway Module (DGM) or one of the Communications Gateway Modules (CGM).To order a replacement, see the following table. You will also need to order software upgrade token (16K743). PCF Model User Interface Description Gateway Part Number To Order Rotary Switch Position PFxx0x Discrete (DGM) 24B681 0 PFxx1x DeviceNet™ (CGM) 15V759 Any PFxx2x EtherNet/IP™ (CGM) 15V760 Any PFxx3x PROFIBUS™ (CGM) 15V761 Any PFxx4x PROFINET™ (CGM) 15V762 Any Swirl Control DGM The assemblies below each contain one swirl control DGM used to control one Swirl Dispenser. To order a replacement, see the following table. You will also need to order software upgrade token (16K743). Assembly PFxxx2, PFxxx3, 16M350, 16M351 3A2098H Part Number To Order Rotary Switch Position 24B681 1, 2, 3, or 4; see Swirl Control DGM on page 19 Automation Gateway (DGM or CGM) Swirl Control DGM 7 Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment. • Connect only to grounded power source. • All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Do not point dispensing device at anyone or at any part of the body. • Do not put your hand over the fluid outlet. • Do not stop or deflect leaks with your hand, body, glove, or rag. • Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses and couplings daily. Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline. • Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. • Ground all equipment in the work area. See Grounding instructions. • Use only grounded hoses. • Hold gun firmly to side of grounded pail when triggering into pail. • If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. • Keep a working fire extinguisher in the work area. 8 3A2098H Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. • Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only. • Do not alter or modify equipment. • Use equipment only for its intended purpose. Call your distributor for information. • Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. • Do not kink or over bend hoses or use hoses to pull equipment. • Keep children and animals away from work area. • Comply with all applicable safety regulations. BURN HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns: • Do not touch hot fluid or equipment. TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDS’s to know the specific hazards of the fluids you are using. • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to: • Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer 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 E A* J F* Air Supply Drop Site K* F* M C H B* L D G FIG. 1: Typical Ambient System Installation Key: A *Control Center (User Interface) B *Fluid Plate Assembly C Applicator/Dispense Valve D Sealer Automation E Automation Interface Cable F *CAN Cable G Fluid Supply System 10 H J K L M Fluid Supply Hose Automation Controller *Air Filter Assembly ◆PrecisionSwirl Orbital Dispenser (Swirl Dispenser) ◆PrecisionSwirl Cable * Included ◆ Optional 3A2098H System Configurations Typical Installation - Multiple Fluid Plates, No Swirl Dispensers B* F* H Power In D C G B* A F* K* Air Supply Drop Site H D C F* G F* E B* F* J D H C G B* H D C G FIG. 2: Typical Multiple Fluid Plate System Installation Key: A *Control Center (User Interface) B *Fluid Plate Assembly C Applicator/Dispense Valve D Sealer Automation E Automation Interface Cable F G H J K *CAN Cable Fluid Supply System Fluid Supply Hose Automation Controller *Air Filter Assembly * Included 3A2098H 11 System Configurations Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers F* B* K* Power In A M D H C E L Air Supply Drop Site G F* B* D H C F* N J L M G FIG. 3: Typical Multiple Fluid Plate System Installation Key: A *Control Center (User Interface) B *Fluid Plate Assembly C Applicator/Dispense Valve D Sealer Automation E Automation Interface Cable F *CAN Cable G Fluid Supply System H Fluid Supply Hose J Automation Controller K *Air Filter Assembly L ◆PrecisionSwirl Orbital Dispenser (Swirl Dispenser) M ◆PrecisionSwirl Cable N ◆Expansion Swirl Enclosure * Included ◆ Optional 12 3A2098H Overview Overview System Overview The PCF fluid metering system combines closed-loop pressure control with the ability to change bead profiles quickly. When used with an optional flow meter, the system automatically adjusts for fluctuations in the operating environment, such as material viscosity, temperature and tip wear, in order to maintain the desired dispense rate. The module responds to automation signals to provide an accurate and consistent output flow based on a comparison of actual to desired flow rates. Typical Applications • • • • • • • • • Bead dispensing Gasketing Seam sealing Hem flange Sound deadening Anti-flutter Body panel reinforcement Profile wrapping Cable filling Control Center (User Interface) The control center communicates with the PCF fluid plate assembly to control fluid pressure and dispense valve operation. The control center receives input from the automation controller, and uses these inputs to determine communication to the fluid plate assembly. Fluid Plate Assembly The fluid plate assembly contains components that control and monitor fluid dispensing. A PCF fluid metering system can have up to four fluid plates. Each fluid plate can control up to four dispense valves. The system supports up to 16 dispense valves and can simultaneously dispense from up to 10 dispense valves. PrecisionSwirl Orbital Dispenser (Swirl Dispenser), Sold Separately The swirl dispenser dispenses material in a circular pattern at speeds from 6600 to 24000 rpm. A PCF fluid metering system can have up to four swirl dispensers. See manual 309403 for detailed information. System Components The diagram in FIG. 4 shows an example of the PCF module and cables. 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: The PCF fluid regulator is electrically controlled by the PCF fluid control module. Consistent material flow is assured by a closed-loop pressure or closed-loop flow control design. The module responds to automation-supplied signals to provide an accurate and consistent output flow based on a comparison of actual to desired flow rates. The fluid regulator uses air pressure to control fluid pressure and to provide fast response to electronic commands and ensure a precisely controlled, continuous flow of material. • Fluid regulator (cartridge, ambient mastic, or heated mastic) (P). • Flow meter (R) (optional) precisely measures the flow rate of fluid dispensed. • Solenoid air valve (S) controls the dispense valve. Ambient Fluid Plate Assembly • Voltage to Pressure Transducer (T), abbreviated V/P transducer, adjusts the air pressure to the fluid regulator (P). There are four ambient versions available: • The fluid plate assembly is available in two versions: ambient and heated. Fluid Control Module (FCM) (U) receives pulse readings from the flow meter (R) and pressure readings from the regulator. It also controls the fluid regulator (P) and solenoid air valve (S). S T • • • • • cartridge regulator without a flow meter; ambient mastic regulator without a flow meter; cartridge regulator with a high resolution meter; ambient mastic regulator with a high resolution meter; cartridge regulator with an ultra high resolution flow meter. Heated Fluid Plate Assembly There are two heated versions available: U • • heated mastic fluid regulator with a heated flow meter, and a heated mastic fluid regulator without a flow meter. P R FIG. 5: Fluid Plate Components 14 3A2098H Overview Fluid Regulator Fluid Control Module (FCM) There are three fluid regulator options: • cartridge • ambient mastic • heated mastic 1 All of the fluid regulator options use air pressure to control fluid pressure, provide fast response to electronic commands, and ensure a precisely controlled, continuous flow of material. Cartridge The ambient mastic regulator (246642) is ideal for medium to high viscosity sealants and adhesives. Heated Mastic The heated mastic regulator (246643) is ideal for low to high viscosity warm-melt and hot-melt sealants or adhesives. 3 4 CAN Connectors Status LEDs 5 Key token 6 7 Rotary Switch FIG. 6: FCM Sensor Connections The cartridge regulator (244734) is ideal for low to medium viscosity sealants and adhesives. Ambient Mastic 2 Table 1: FCM Sensor Connections Connection Sensor Description 1 Dispense solenoid 2 Flow meter 3 Outlet pressure sensor (heated systems only) 4 Voltage to Pressure (V/P) Transducer 5 Command cable (optional accessory kit) 6 Inlet pressure sensor (non-heated systems only) 7 Outlet pressure sensor (non-heated systems only) CAN Connectors --- 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 position causes the settings to be shown under the new number on the ADM. Item Rotary Switch Position Fluid Plate 1 0 or 1 Fluid Plate 2 2 Fluid Plate 3 3 Fluid Plate 4 4 NOTE: See LED Diagnostic Information, page 65, for signal definitions. 3A2098H 15 Overview Control Center Assembly Overview Front View Front View 100-240 Vac Assembly Side View Swirl Board Gateway Module ADM Swirl Control DGM FIG. 7: Control Center Components The control center includes the following components: • Advanced Display Module (ADM) with USB; see page 17 for details. • USB enables users to download job, event, and data logs; save and restore system settings; and customize the language. See USB Data on page 59. • 24 Vdc and 100-240 Vac customer-wired options available. • • If system has a swirl dispenser: Swirl Control DGM (the module on the left) and Swirl Board. Automation Gateway Module (the module on the right), which can be one of the following five types: • Discrete • DeviceNet • EtherNet/IP • PROFIBUS • PROFINET 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) BB BJ BC BP BD BA BK BL BE BF BH BM BR BG BS TI12362a BN r_24E451_3B9900_1a FIG. 8: Advanced Display Module Component Identification KEY: Callout Callout Function BA Power On/Off Button Enables/disables system. System Status Indicator LED Displays system status. Green LED indicates the system is active. Orange LED indicates the system is off. Solid LEDs (green or orange) indicate the system is in Run mode. Flashing LEDs (green or orange) indicate the system is in Setup mode. Stop Button Stops all system processes. However, it is not a safety or emergency stop. Soft Keys Functions vary depending on the screen. Cancel Button Clears system errors and cancels a selection or number entry while in the process of entering a number or making a selection. Enter Button Acknowledge changing a value or making a selection. Lock/Setup Toggle between run and setup screens. If setup screens are password protected, button toggles between run and password entry screens. BB BC BD BE BF BG 3A2098H BH BJ BK BL BM BN BP BR BS Function Navigation Buttons Navigate within a screen or to a new screen. Flat Panel Mount Mounts to control center bracket (optional). Model Number Tag Model number. USB Module Interface USB port and USB indicator LEDs. CAN Connector Power connection. Module Status LEDs See LED Diagnostic Information, page 65, for signal definitions. Battery Cover Token Access Cover Digital I/O Port for Light Tower NOTICE To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. 17 Overview Automation Gateway Module See the following table for the appropriate rotary switch position for your automation gateway module. PCF Model User Interface Description Gateway Part Number To Order Rotary Switch Position PFxx0x Discrete (DGM) 24B681 0 PFxx1x DeviceNet™ (CGM) 15V759 Any PFxx2x EtherNet/IP™ (CGM) 15V760 Any PFxx3x PROFIBUS™ (CGM) 15V761 Any PFxx4x PROFINET™ (CGM) 15V762 Any NOTE: See Control Center Assembly Overview on page 16 for automation and swirl control DGM identification. Front CA Front (Access Cover Removed) Back CD CB CF CE Rotary Switch CH Software Token Slot Gateway Module Connectors PROFINET or EtherNet/IP CC TI11814A DeviceNet CC TI11815A Discrete PROFIBUS CC CG TI11816A FIG. 9: Automation Gateway Module Components Key: CA Gateway Module CB Base CC Fieldbus Connector (see Appendix C - Communications Gateway Module (CGM) Connection Details, page 122, for more information) CD Module Connection Screws CE Access Cover CF Module Status LEDs (see LED Diagnostic Information, page 65) 18 CG D-Subminiature (D-Sub) Connector (see Appendix B - Discrete Gateway Module (DGM) Connection Details, page 115, for pinout details) CH CAN Connectors 3A2098H Overview Swirl Control DGM One swirl control DGM is included in the integrated Swirl control center, and in each expansion swirl enclosure. Each Swirl control DGM controls one swirl orbiter. Each swirl control DGM must have a unique rotary switch position. The rotary switch position determines the number assigned to the swirl dispenser attached to that DGM. If the rotary switch position must be changed, do so with the power off. DGM Function Rotary Switch Position Swirl Control 1 1 Swirl Control 2 2 Swirl Control 3 3 Swirl Control 4 4 Each integrated swirl control center and swirl enclosure comes with a pre-installed cable between the swirl control DGM and the swirl board. The customer does not need to make any external connections with the swirl control DGM. Front Back Front (Access Cover Removed) CD CA CB CE CF CH Rotary Switch Software Token Slot FIG. 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 FCM FIG. 11 NOTE: There is one FCM located on each fluid plate. If a 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. Part 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 16M217 ADM Key Token, Standard PCF 20 3A2098H Installation Installation Before Installation • • Have all system and component documentation available during installation. See component manuals for specific data on component requirements. Data presented here applies to the PCF assemblies only. • Be sure all accessories are adequately sized and pressure-rated to meet system requirements. • Use the PCF control center only with the PCF fluid plate assembly. 10. Connect other fluid and air lines to additional system components as instructed in their manuals. 11. Install fluid plate, swirl, and gateway cable assemblies, page 28. 12. Install Gateway interface, page 30. Overview The basic steps to install a PCF system are shown below. See the separate component manuals for detailed information. To avoid injury and damage to equipment, use at least two people to lift, move, or disconnect the system. The system is too heavy for one person to lift or move. 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 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 21 Installation Install Control Center NOTE: This section applies to both the primary control center and the expansion Swirl enclosures. Secure the control center with appropriate size bolts through the 0.27 in. (7 mm) diameter holes in the mounting tabs. See the following mounting dimensions. Table 2: Control Center Assembly Measurement Mount Ensure the following criteria are met before mounting the PCF control center: A B 10.50 in. (267 mm) 5.75 in. (146 mm) C 22.00 in. (559 mm) D 21.25 in. (540 mm) • 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. A • Ensure there is sufficient clearance around the control unit to run cables to other components. B • Ensure there is safe and easy access to an appropriate electrical power source. The National Electric Code requires 3 ft (0.91 m) of open space in front of the control center. • 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. C D FIG. 12: Control Center Dimensions 22 3A2098H Installation Electrical Connections To reduce the risk of fire, explosion, or electric shock, when grounding, connecting cables, connecting to a power source or making other electrical connections: • Ground The control center must be electrically connected to a true earth ground; the ground in the electrical system may not be sufficient. Refer to your local code for the requirements for a “true earth ground” in your area. • All wires used for grounding must be 18 AWG minimum. • A qualified electrician must complete all grounding and wiring connections. • For 24 Vdc wiring refer to FIG. 13. • For 100-240 Vac wiring refer to FIG. 14. • Incoming power wiring must be guarded from the enclosure. Use a protective grommet where the power wiring enters the enclosure to prevent wear. N L FIG. 14: 100-240 Vac Wiring Connect Light Tower Accessory NOTICE If power and grounding connections are not done properly, the equipment will be damaged and the warranty voided. 1. Order the 255468 Light Tower Accessory as a diagnostic indicator for the PCF system. 2. Connect the cable from the light tower to the digital I/O port (BS) on the ADM. See Table 3 for a description of light tower signals. Table 3: Light Tower Signals Signal Description Green No errors. Yellow An advisory exists. 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. Ground + FIG. 13: 24 Vdc Wiring 3A2098H 23 Installation Install Fluid Plate Assemblies To install the PCF fluid plate assemblies: 2. Mount and secure the fluid plate assembly to the automation unit (or other mounting surface) with appropriate size bolts through the 0.397 in. (10 mm) diameter holes in the base plate. See the mounting dimensions in Table 4 and FIG. 15. • Mount the fluid plate assemblies, page 24 • Ground fluid plate assemblies, page 27 • Connect one fluid plate assembly to the control center. See Install Cable Assemblies on page 28. A 16.5 in. (419 mm) • If multiple fluid plates, connect the fluid plates together. See Install Cable Assemblies on page 28. B 14.0 in. (356 mm) C 14.4 in. (366 mm) Connect fluid lines, air lines, and cables; page 27 D 13.4 in. (340 mm) • Table 4: Fluid Plate Assembly Measurement Mount A 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. D C B FIG. 15: Fluid Plate Assembly Dimensions Mount Assembly 1. Select a location for the fluid plate assembly. Keep the following in mind: 24 • Allow sufficient space for installing the equipment. • Make sure all fluid lines, cables and hoses easily reach the components to which they will be connected. • Make sure the fluid plate assembly allows the automation unit to move freely along all axis. • Make sure the fluid plate assembly provides easy access for servicing its components. 3A2098H Installation Mount Four-Valve Breakout Kit 24B693 PCF is capable of controlling up to four separate dispense valves from port 1 on the FCM. A four-valve breakout kit (24B693) is available to split the dispense solenoid connector (port 1 on the FCM) into four separate dispense solenoid connectors. For each additional dispense valve, order one dispense valve solenoid (258334) and one solenoid cable (121806). Follow this procedure if using the four-valve breakout kit. 1. Remove the existing dispense solenoid and cable from the fluid plate. 2. Install bulkhead fitting (included in the kit) into the empty hole on the fluid plate. GCA Cable 5. Connect the dispense valve cable(s) to the connections on the splitter assembly. Cable for: Connects to Splitter Connection Labeled: Dispense Valve 1 J1 Dispense Valve 2 J2 Dispense Valve 3 J3 Dispense Valve 4 J4 6. Mount splitter assembly and dispense valves, and connect air lines as necessary for application. Custom Breakout Cable If desired, the following connector pinout information may be used to build a custom breakout cable: Pinout of FCM Port 1 Pin 1: Dispense Solenoid 4 Pin 2: Dispense Solenoid 2 Pin 3: Voltage - (common for all solenoids) Pin 4: Dispense Solenoid 1 Pin 5: Dispense Solenoid 3 Dispense solenoid outputs are 24 Vdc. Dispense solenoid outputs are capable of sourcing up to 0.5A each (maximum 12W coil). Connection 1 Hole for bulkhead fitting Splitter Assembly J1 J3 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 fitting. 3A2098H 25 Installation Install Command Cable Kit 24B694 Follow this procedure if using the command cable kit. 1. Install bulkhead fitting (included in the kit) into the empty hole on the fluid plate. See 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. Function FCM Port Pin # Command Cable Wire Color Dispense Trigger Source: ‘Command Cable’ or ‘Combined’ Dispense Trigger Source: ‘Command Cable 3x’ 1 White Command voltage (0-10 Vdc) Command voltage (0-10 Vdc) 2 Brown No connection Valve 3 dispense trigger (*sourcing input) 3 Green Dispense trigger (*sourcing input) Valve 1 dispense trigger (*sourcing input) 4 Yellow No connection Valve 2 dispense trigger (*sourcing input) 5 Gray Dispense trigger ground Dispense trigger ground 6 Pink No connection No connection 7 Blue Command signal ground Command signal ground 8 Red No connection No connection NOTE: Command cable inputs are not isolated from PCF 24 Vdc power. * 26 To turn on the dispense trigger, connect the dispense trigger pin to the dispense trigger ground pin (pin 5). 3A2098H Installation Ground To reduce the risk of fire, explosion, or electric shock, when grounding, connecting cables, connecting to a power source or making other electrical connections: • The control center must be electrically connected to a true earth ground; the ground in the electrical system may not be sufficient. Refer to your local code for the requirements for a “true earth ground” in your area. • All wires used for grounding must be 18 AWG minimum. • A qualified electrician must complete all grounding and wiring connections. • For 24 Vdc wiring refer to FIG. 13. • For 100-240 Vac wiring refer to FIG. 14. • Incoming power wiring must be guarded from the enclosure. Use a protective grommet where the power wiring enters the enclosure to prevent wear. Connect Fluid and Air Lines NOTICE Route all fluid and air lines carefully. Avoid pinching and premature wear due to excessive flexing or rubbing. Hose life is directly related to how well they are supported. Follow the instructions in your separate component manuals to connect air and fluid lines. The following are only general guidelines. • The PCF fluid plate assembly should be installed on the automation unit or in another appropriate place, as close as practical to the dispense valve. • Connect a fluid line between the fluid plate outlet and the dispense valve. Smaller diameter and shorter fluid lines (hoses) will provide better fluid system response. • Connect a fluid line to the flow meter fluid inlet or to the regulator inlet if your system does not have a flow meter. • Air must be clean and dry, between 60-120 psi (0.41-0.82 MPa, 4.14-8.27 bar). Flush air line before plumbing in air filter assembly (234967). Plumb in air filter assembly near air drop site (upstream of fluid plate module). Adding an air regulator to this line will provide more consistent dispense valve response times. • Connect an air supply line to the 1/4 npt inlet port on the fluid plate(s) air supply inlet. • Connect 5/32 in. or 4 mm OD air lines from the applicator's solenoid valve to the applicator. Plug any unused solenoid ports. 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. NOTE: To maximize system performance keep the dispense hose length and ID as small as the application will allow. Dispense Valve Follow the grounding instructions in the dispense valve manual. 3A2098H 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. 2. For systems with one or more swirl dispensers, use motor cable to connect each swirl dispenser to an expansion swirl enclosure or to the control center. 3. Connect a CAN cable from the control center to one fluid plate assembly. 4. For multiple fluid plate systems, use CAN cables to connect each fluid plate to one other fluid plate Repeat until all fluid plates are connected to one other fluid plate. NOTE: Use the connections on the CAN splitter on the left side of each fluid plate to connect the fluid plates together. There will be a CAN splitter on all but one fluid plate. 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 connect the Gateway module to the automation controller. 28 3A2098H Installation 2 4 5 1 2 4 1 2 4 1 3 2 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 individual attributes as 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 • EDS file: DeviceNet or EtherNet/IP fieldbus networks GSD file: PROFIBUS fieldbus networks SDML: PROFINET fieldbus networks • • CGM Status LED Signals Signal Description Green on System is powered up Yellow Internal communication in progress Red Solid CGM hardware failure *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 communication architecture and the fieldbus being used. 1. Install interface cables between the PCF system and the automation controller per the fieldbus standards. Refer to Appendix C - Communications Gateway Module (CGM) Connection Details, page 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 Display Module (ADM), page 99, for details about the data map. 3. Set the PCF Gateway configuration values as required to interface with automation controller. Refer to Appendix A - Advanced Display Module (ADM), page 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 controller (fieldbus master). Configure it for communication with the PCF Gateway (fieldbus slave). 6. Establish communication between the automation controller and the PCF Gateway to confirm the successful configuration of the hardware and data. NOTE: Use the ADM screens for troubleshooting fieldbus data communication problems. Refer to Appendix A - Advanced Display Module (ADM), page 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 Installation Discrete Gateway Module DGM Rotary Switch Position Module Description The Discrete Gateway Module (DGM) provides a control link between the PCF system and an automation controller through discrete input and output connections. This provides the means for remote monitoring and control by external automation systems. 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. 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 connecting a D-Sub cable to the D-Sub connector (CG). Both options are accessories and must be ordered separately. • For single fluid plate systems only: D-Sub to flying leads cable (123793). See Appendix B Discrete Gateway Module (DGM) Connection Details, page 115, for details and cable interface signals. • 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. 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 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 instructions to complete each setup step. Once these steps are complete the module is ready for operation. NOTE: See the Advanced Display Module (ADM) section, page 17, and Appendix A - Advanced Display Module (ADM), page 99, for detailed operating instructions for the display keypad and each screen. 1. Configure System, page 32. Configure System Define the number of installed fluid plates (called “Dispenser” on this screen) and number of installed swirl dispensers. If a fluid plate is listed as “Uninstalled” the screens for that fluid plate will not appear in the run or setup screens. 1. With the system in setup mode, navigate to the System screen. 2. Press to access the fields to make changes. 3. Use the arrow keys to navigate to the desired field. 4. Press to open the drop-down list, and select the desired setting. Press tion. to accept the selec- 5. Repeat for the other Dispensers and Swirl Dispensers. 6. Press to exit edit mode. 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. FIG. 19 b. Configure Swirl settings, page 38. 11. Configure Gateway Settings, page 38. 12. Setup Styles, page 38. 13. Configure Advanced Settings, page 38. 32 3A2098H System Setup Configure Control Settings Set the controls for the dispense source, how dispense commands are sent, and job settings. 1. With the system in setup mode, navigate to Fluid Plate x, screen 1 (Control Settings). 7. Press to move to the Job End Delay field. Enter the desired delay time (in seconds). Press enter the value. 8. Press to move to the Run Mode Bead Adjust field. Press 2. Press to access the fields to make changes. to open the drop-down list, and select Enable or Disable. Press value. 9. Press to enable or disable. to move to the Display Control Password field. Press 11. Press to enter the to move to the End Job on Alarm Check- box. Press 10. Press to to enter the value. to exit edit mode. 12. If multiple fluid plates are installed, repeat this procedure for the other Fluid Plates. FIG. 20 3. Press to open the Dispense Trigger Source drop-down list, and select Gateway, Command Cable, Command Cable 3x, or Combined. If Command Cable is selected, users can enable the valves. Press to finalize the selection. 4. If the dispense trigger source is set to Command Cable, press to move to the Enable Valves field. Press and 5. Press to enable valves. to move to the Command Value Source field. Press to open the drop-down list, and select Gateway, Command Cable, or Display. Press to enter the value. 6. Press to move to the Job End Mode field. Press to open the drop-down list, and select Timer or Gateway. Press 3A2098H to enter the value. 33 System Setup Configure Mode Settings Set valve commands, including the dispense mode (pressure, bead, shot, or full open) and flow rate or pressure for each valve. The bead scale is also adjustable from this screen. NOTE: For a description of each dispense mode, see Dispense Control Modes, page 112. 1. With the system in setup mode, navigate to the Fluid Plate x, screen 2 (Mode Settings). 2. Press to access the fields to make changes. 5. Press to move to the Bead Scale field. Enter a scale value between 50% and 150%. Press enter the value. 6. Press to 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 to access the fields to make changes. 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. FIG. 22 4. Use the four arrow buttons to navigate to each Fixed Command field. Enter the desired value for each valve that will be used. Press to enter each value. NOTE: The ability to dispense from multiple valves simultaneously is only allowed in either of the following scenarios. • • Each valve is set to Pressure mode and has identical Fixed Command values. Each valve is set to Full Open mode. 3. Use the four arrow buttons to navigate to each On and Off field. Enter a desired delay value (in milliseconds) for each valve that will be used and the regulator. Press to enter each value. 4. Press to exit edit mode. Attempting to dispense from multiple valves simultaneously using any other combination will cause an Incompatible Valves Settings alarm. 34 3A2098H System Setup Configure Flow Meter Settings The accuracy of the PCF volume reporting depends on precise adjustment of the K-factor(s). The fluid plate uses the K-factor(s) to calculate the volume dispensed. If the set value is not correct, the system still delivers repeatable flow rates; however, the reported value may not be correct. See Verify Flow Meter Calibration, page 42, for additional K-factor information. Table 5: Flow Meter K-Factors Part Description K-Factor 246652 High Resolution Helical Gear Meter Heated Helical Gear Meter Ultra High Flow Meter 7000 246340 16E993 3500 4. Press to move to the K-Factor field. Key in the K-factor value. See Table 5: Flow Meter K-Factors for values. Press to enter the value. 5. Press to exit edit mode. NOTE: If necessary, verify flow meter calibration. See Verify Flow Meter Calibration, page 42, for instructions. 33000 Set Flow Meter K-Factor NOTE: In systems without a flow meter, the flow meter settings will be grayed out. 1. With the system in setup mode, navigate to the Fluid Plate x, screen 4 (Pressure Loop and Flowmeter Settings). 2. Press 3. Press to open the Meter Type drop-down list, and select the meter type used by the system. Select Volume for volumetric flow meters or Mass for mass flow meters. Press to enter the selection. to access the fields to make changes. 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. FIG. 23 3A2098H 35 System Setup Adjust Pressure Sensors Configure Errors Set pressure offsets and pressure limits. Set the error type (alarm, deviation, or none) that will be issued if the pressure, flow rate, volume, or computed target goes outside the tolerance settings of the active style. When an alarm occurs, the system stops dispensing. When a deviation occurs, the system will continue dispensing. See Fluid Plate x, Screen 6 (Error Type) on page 107 for more information. NOTE: Inlet sensor settings will be grayed out on this screen for systems with heated fluid plates. 1. With the system in setup mode, navigate to the Fluid Plate x, screen 5 (Pressure Sensors). 2. Press to access the fields to make changes. NOTE: Only the low/high pressure errors will be enabled for systems without a flow meter. 1. With the system in setup mode, navigate to Fluid Plate x, screen 6 (Error Type). 2. Press to access the fields to make changes. 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 pressures between 0 and 100 psi (0.7 MPa, 7.0 bar). Remove all pressure on the sensors, and then adjust the offset so the measured value reads 0. NOTE: It is recommended that offsets should not be changed from the factory defaults of 0. 4. Set the desired minimum and maximum pressure limits for the inlet, and the desired maximum pressure limit for the outlet. FIG. 25 3. Press to open the Low Pressure drop-down list, and select either Alarm or Deviation for the error type. Press to enter the selection. 4. Press 5. Set the error type (alarm or deviation) that will be issued: • • • If the minimum inlet pressure decreases below the setting. If the maximum inlet pressure increases above the setting. If the maximum outlet pressure increases above the setting. 6. Press 36 to move to the next field. Repeat Step 4 for each field. 5. Press to exit edit mode. to exit edit mode. 3A2098H System Setup Setup Maintenance Schedule/Parameters Set the volume (or hours) limit that will trigger a maintenance advisory for the fluid supply, Voltage to Pressure (V/P) Transducer, fluid regulator, flow meter, and all four valves. To reset a totalizer value: 1. Follow Steps 1-3 of To set limits: to make changes in Fluid Plate x, screen 7 (Maintenance Advisory Limits). 2. Press to scroll to the system component to reset. NOTE: Hours is shown instead of Volume for fluid plates without a flow meter. 3. Press 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 maintenance totalizers. Configure Valve to Swirl Association and Motor Error Type Define which Swirl number is installed on which dispense valve. To set limits: 1. With the system in setup mode, navigate to the Fluid Plate x, screen 7 (Maintenance Advisory Limits). 2. Press to reset the value. to access the fields to make changes. FIG. 26 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. FIG. 27 3. Enter the desired limit for the air supply and press to enter the selection. 4. Press to move to the next field. Repeat Step 4 for each field. 5. Press 3A2098H to exit edit mode. 37 System Setup Configure Swirl Settings NOTE: This applies only to systems with swirl dispensers. Set the individual Swirl settings for each installed Swirl. FIG. 28 Configure Gateway Settings Gateway settings differ for each system. See Automation Gateway Setup Screens, page 102, for guidelines on configuring each type of Gateway interface. Setup Styles The PCF system can store up to 256 styles. See Styles, page 46, for more information about styles and instructions on setting up styles. Style 0 is always the purge style. Configure Advanced Settings Use the advanced settings to set or change the format and display units, such as the language, date format, and pressure units, for all PCF screens. See Setup Mode, page 101, for advanced setting guidelines. 38 3A2098H System Setup On/Off Delays FIG. 29 and Table 6: Delay On/Off Timing show delay ON and OFF timing. The PCF fluid regulator can physically respond faster than the dispense device and its solenoid. As a result, the fluid regulator can supply material to the dispense device before the device has time to open. Supplying material to a closed device can create trapped-pressure. At the end of a cycle, the dispense device can shut off before the pressure has dissipated. This can cause a dispense of an excess of material at the beginning of the next cycle. To eliminate these two problems, change the delay time associated with the opening of the fluid regulator/dispense and/or the closing of the dispense device, see Table 5: On/Off Delay Variables. For instructions setting on/off delays, see Configure Delay Settings, page 34. NOTE: On/Off delay can be set for each dispense device. In general, delays should be adjusted so the outlet pressure during “no flow” is slightly below the outlet pressure during dispense. Table 6: Delay On/Off Timing A Regulator ON The user sets the fluid regudelay lator ON delay timing. B Valve ON delay Usually set to zero. Can be used to change the starting point of a bead. C Valve OFF Delay Usually set to zero. Higher values will lower the trapped pressure. D Regulator OFF The user sets the regulator delay OFF delay timing. Zero or small values will lower the trapped pressure. E Valve Open Time delay for valve to physReaction Time ically open. Delay varies based on pneumatic hose length and valve air volume. F Valve Close Time delay for valve to physReaction Time ically close. Delay varies based on pneumatic hose length and valve air volume. Table 5: On/Off Delay Variables Variable: Sets the Amount of Time: Valve ON Sets time from Dispense Valve High to Valve Open command Regulator ON Sets time from Dispense Valve High to Regulator ON Valve OFF Sets time from Dispense Valve Low to Valve Close command Regulator OFF Sets time from Dispense Valve Low to Regulator OFF C Dispense Valve Signal A Fluid Regulator D B Valve Open Command Valve Actually Open E F 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 Initial Startup 1. Ensure the PCF control center is installed and all of the proper connections to and from the control center have been made. Ensure fittings are tight. 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. 2. Turn on the fluid supply pressure to the fluid plate assembly. 3. Place the valve(s) over a waste container. 2. Read and understand the Operation (page 40) and Advanced Display Module (ADM) (page 17) sections of this manual. 3. Continue startup with step 2 in Standard Startup. 4. Enter the maintenance screen. See Dispense From Maintenance Screen, page 43. 5. Select a control mode. See Dispense From Maintenance Screen, page 43. Standard Startup 1. Carefully inspect the entire system for signs of leakage or wear. Replace or repair any worn or leaking components before operating the system. 2. Press the Stop button (BC). See FIG. 8 on page 17. 3. Turn on air. 4. Turn on electrical power to the system. 6. If the system status indicator LED (BB) is orange, press to turn the system on. 7. Press and hold . Dispense fluid until clean, air-free fluid flows from the valve. 8. Press to exit maintenance screen. 5. Turn on the main power to supply power to the PCF. 6. Check Interface Signals: If this is a new installation, power on each system input and verify that each input is being received. 7. Turn on the material supply system. 40 3A2098H Operation Maintenance Mode Operation Fluid Plate Maintenance Screen Swirl Maintenance Screen 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 Operating from maintenance mode enables manual dispensing ( penser ( ) and manually starting the swirl dis). The system begins dispensing when the user presses . Dispense parameters and duration depend on the selected control. Dispensing continues for as long as 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. is pressed. With high viscosity fluids, long line lengths, or small diameter line sizes this pressure decrease can be thousands of psi (hundreds of bar). This means that the static pump pressure is set much higher than the regulator needs at its inlet. To prevent excessive control regulator wear or surging, a mastic fluid pressure regulator is recommended on the feed line close to the control regulator. The mastic regulator will suppress the static feed pressure at the control regulator inlet. The system starts the swirl dispenser when the user presses . The swirl dispenser continues to run until is pressed again. There is one maintenance screen for each installed fluid plate and each installed Swirl. The maintenance controls for the Swirl are shown on both the Swirl maintenance screen and on the Fluid Plate maintenance screen for the fluid plate where the swirl dispenser is installed. Verify System Operation Use maintenance mode to manually check the operation of the PCF system components before switching over to automation control (normal operation). See Dispense From Maintenance Screen, page 43, for instructions on operating from maintenance mode. NOTE: Perform the following procedures while in maintenance mode. Set Inlet Pressure The inlet pressure reading should be in the range of 300 psi (2.1 MPa, 21 bar) to 500 psi (3.4 MPa, 34 bar) above the outlet pressure reading under your highest flow condition. 3A2098H 41 Operation Dispense from Each Valve Verify Flow Meter Calibration 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. Most sealant and adhesive materials are compressible. Since the flow meter measures the material under high pressure, the actual volume of material dispensed may vary slightly from the measured volume, due to this compressibility. If the K-factor is not correct, the displayed volume will not be accurate. Follow the steps outlined in Dispense From Maintenance Screen, page 43, to perform each of the following applicable system verification checks. NOTE: Each fluid plate controls only the dispense valves connected to it. • • • For each valve that will be used during normal operation, dispense at each pressure or flow rate that will be used during normal operation. This verification check confirms that the system is capable of delivering material at your maximum desired operating point. For systems that will operate multiple valves in pressure mode at the same time, dispense from each valve at the same time. This verification check confirms that the system is capable of delivering material at your maximum desired operating point. For each valve operating in bead mode, perform an initial teaching process. Follow this procedure after significant system and/or material characteristic changes. a. For each flow rate that will be used during normal operation, press until PCF achieves 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 submerged 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) 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 c. for several seconds 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. after the desire flow rate is reached to confirm that the system is capable of maintaining the desired flow rate. 8. Repeat the procedure to verify the new K-factor. Repeat Steps a and b for a range of flow rates to confirm that the system responds quickly to Method 2. Without using a gram scale, visual measurement achieve setpoint when is pressed. 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. 42 3A2098H Operation 3. Manually dispense material into the beaker. Hold the beaker so that the stream of material is submerged in the captured material to minimize air entrapment in the container. 4. Record the volume dispensed on Fluid Plate x, screen 1. See FIG. 30 on page 43. 6. Optional: To fine tune the step response in pressure mode, gradually increase the Kd value. NOTE: Increasing Kd (pressure only) is typically not necessary but it may improve step response. However setting Kd too high may cause the system to oscillate. 7. Stop dispensing. 5. Settle the material into the beaker and view the actual volume dispensed. 6. Calculate the new flow meter K-factor: K-Factor (new) = Dispense From Maintenance Screen 1. Navigate to Fluid Plate x, screen 1 for the desired fluid plate. displayed volume (cc) x K-Factor (old) 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: FIG. 30 2. Press to enter maintenance screen. NOTE: Pressure parameters should be adjusted first, even if you typically operate in bead control mode. 1. Begin dispensing material. NOTE: Begin a new dispense each time control parameters are changed. 2. If the regulator outlet pressure does not closely follow the desired pressure, set Ki to zero then increase Kp until the proper pressure control is achieved. 3. If the regulator outlet pressure oscillates rapidly above and below the commanded pressure, decrease Kp by 10%. Continue to decrease the Kp value in 10% increments until the outlet pressure is stable. 4. Set Ki value to 2 then increase the Ki value until the system oscillates. 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. 5. Decrease Ki until oscillation stops. 3A2098H 43 Operation 4. Press to move to the target fields. Enter the tar- 2. Press to enter maintenance screen. 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 maintenance screen. 2. Press and verify that the valve opens. 3. Continue to press dispense material. 4. Press to enter as long as needed to load or 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. FIG. 33 3. To change the RPM, use the arrow keys to navigate to the RPM box then enter the desired RPM. 4. Press and verify that the Swirl Dispenser begins rotating. Press again to stop the Swirl Dispenser. 5. Press again to exit maintenance screen. FIG. 32 44 3A2098H Operation Automation Control (Normal Operation) During automation control (normal operation), the system can dispense or change dispense parameters when it receives a command from the automation unit. The automation control operates using the concept of jobs and styles. For a detailed explanation of jobs and how they work within the PCF system, see Jobs on page 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 applications may define a job to be the amount of material dispensed on a number of parts or dispensed over a period of time. A job is initiated when the automation sends a Style Strobe signal to the PCF. Once the job is initiated, the PCF will start tracking the amount of volume requested by the automation and the amount of material that is actually dispensed. These volumes will be tracked until the job is completed. At the end of the job, error calculations are made and the volumes are stored on the PCF system (Job Log). The PCF system monitors two things to determine when a job is complete. Either the Dispense Complete signal is sent by the automation or the job complete timer expires. The type of job end signal is configured to Timer or Gateway in Fluid Plate x, screen 1 (Control Settings). If the timer method is used, the timer begins counting every time the dispense valve is turned off. If the valve stays off for more than the preset timer value, the job is considered complete. Actual (Measured) Volume - The amount of material measured by the flow meter during a job. Requested Volume - The amount of material that the automation tries to dispense during a job. In Bead mode, the requested volume is calculated as the requested flow rate multiplied by the duration of the dispense. In all other modes, the requested volume is same as the target volume. Target Volume - The amount of material a job should have. This is defined in the Style. Jobs in Bead Mode In Bead Mode, all of the previously mentioned volumes are monitored. The High Volume, Low Volume, and Computed Target errors are evaluated at the end of the job. The volume alarms compare the measured volume to the requested volume and the computed target alarm compares the requested volume to the target volume. Jobs in Pressure Mode In Pressure Mode, the requested volume is not measured. In this mode, the automation command voltage corresponds to a pressure instead of flow rate. For this reason the requested volume is not available (as well as the Computed Target error). The high and low volume alarms compare the measured volume to the target volume for pressure mode. Continuously Running Applications In some cases the target volume for a job is not known. An example of a case where the target volume is unknown is a continuously running system. This would be a system that does not run jobs, but runs continuously over a day or a shift. In this case, the flow rate becomes more important than the amount of volume dispensed in a job. The way to handle this situation is to set the target volume to a value of zero. This effectively disables the Computed Target error. The controls will still maintain the desired flow rate and report errors corresponding to the tolerance set for the running style. 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 45 Operation Styles 3. Enter the style number in the Style field. The PCF system has the ability to handle up to 256 styles, depending on the selected option. 4. Enter Style Name: a. Press NOTE: The number of available styles depends on the fluid plate configuration. See Models on page 4. Style 0 is specified for purging only. while in the Style Name field to dis- play the Keyboard screen. For each style, an independent target volume and tolerance can be configured. This allows for job-related errors and logs to be evaluated for each style. The style is read at the beginning of a job and cannot be changed until the next job. PCF reads in the styles via the Gateway interface. For detailed interface information, see Appendix B - Discrete Gateway Module (DGM) Connection Details on page 115, and Appendix C - Communications Gateway Module (CGM) Connection Details on page 122, as applicable. FIG. 35 To setup a style: 1. Navigate to Fluid Plate x, screen 8. 2. Press b. Use the arrow buttons on the ADM to scroll through each letter. Press to enter a letter in the style name field. See Keyboard Screen, page 109, for further details. to access the style setup fields. c. Press to accept the new value. 5. Enter the target volume in the Volume field, and the tolerance percentages in the Low and High Tolerance fields. 6. Enter precharge mode and parameters. See Precharge Modes beginning on page 47. 7. Press to exit edit mode. FIG. 34 46 3A2098H Operation Precharge Modes Gateway NOTE: See the diagram on the following page. NOTE: Gateway precharge mode is only available for systems containing CGMs. Static Precharge Mode Display When Display precharge mode is selected, a static precharge pressure can be defined. When a job is active and all dispense valves are closed, the regulator will maintain the defined precharge pressure. When “Gateway” precharge mode is selected, the outlet pressure will be set according to the current pressure/flow command using the scaling set for dispense valve(s) selected through the gateway interface. Dynamic Precharge Modes Dynamic precharge control allows the system to better prepare for the upcoming dispense. The pressure/flow command is used to actively set the outlet pressure to the ideal pressure while all dispense valves are closed and provide a boost while the valve is opening to help accelerate material. The “Closed” scaling will be applied when all dispense valves are closed and the “Opening” scaling will be applied immediately after a dispense valve starts to open and continue for the user-specified duration (in milliseconds). The precharge scaling values modify the control signals that are necessary to obtain the desired pressure/flow. The precharge pressure can be changed dynamically throughout the job by varying the pressure/flow command value. Valve 1 When the “Valve 1” precharge mode is selected, the outlet pressure will be set according to the current pressure/flow command using Valve 1 scaling values. 3A2098H 47 Operation Closed Precharge Scaling Value Dispense Application Direction Value Too Low Dispense Application Direction Ideal Value Dispense Application Direction 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 Value Too Low Dispense Application Direction Dispense Application Direction Ideal Value -Provides a boost upon valve opening to accelerate material. -Ideal value is typically greater than 100%. Value Too High Opening Precharge Duration Value Dispense Application Direction Value Too Low Dispense Application Direction Ideal Value Dispense Application Direction 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 Value Too Low Dispense Application Direction Ideal Value Dispense Application Direction 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 Operation Typical Job Cycle In order for the system to run it must be in the active state (status LED next to on the ADM is green). Before a job begins the automation controller outputs should have the following values: • • • • 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 Style Strobe: 0 Dispense Complete: 0 Dispense Valve x On: all should be 0 Style: Any value is acceptable 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. A typical job cycle consists of the following dispensing sequence. See Typical Job Cycle Chart, page 50. 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. NOTE: Each job cycle can apply to only one fluid plate. 1. The automation controller checks that Dispenser (Fluid Plate) Ready signal is set to 1. If it is set to 1, a job can begin. 2. The automation controller sets the Style to the next desired style value. NOTE: Each fluid plate has a unique set of styles. For example, Style 2 for Fluid Plate 1 is different from Style 2 for Fluid Plate 2. 3. The automation controller sets the Style Strobe to 1. 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. 9. The automation controller must clear Dispense Complete and Style Strobe (either can be cleared first) before the next job can start. Jobs with Command Cable Dispense Trigger With the Dispense Trigger Source configured to Command Cable or Command Cable 3x, users only need to trigger the dispense applicator to start a job. This configuration is useful for less demanding applications that do not require a full automation interface. The following limitations apply when starting a job with this configuration: • • • The selected style defaults to Style 1. There can be up to a 100 ms delay before dispensing while PCF prepares for the new job cycle. The job end mode timer must be used to end a job. 6. When the dispense is complete the automation controller sets Dispense Complete to 1. 3A2098H 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 speed through the automation 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 Operation Control Charts Purge Using Style 0 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 Purge Using Purge Bit Automation Inputs (PCF Outputs) Dispense Ready Dispenser (Fluid Plate) No Alarm Dispenser (Fluid Plate) No Error Dispense In Process Purge In Process Automation Outputs (PCF Inputs) Remote Start / Purge Dispense Valve X On PCF State Dispense Valve X Open 3A2098H 51 Operation Control Charts (continued) Remote Start Automation Inputs (PCF Outputs) Dispenser (Fluid Plate) Ready Dispenser (Fluid Plate) No Alarm Dispenser (Fluid Plate) No Error Dispenser (Fluid Plate) Remote Start/Purge in Process Automation Outputs (PCF Inputs) Remote Start/Purge 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 Operation Control Charts (continued) Precharge* - Display Mode◆ 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 * 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. Precharge* - Gateway Mode◆ 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 Precharge Valve X On† Command Signal Valid‡ Dispense Valve X On Dispense Complete PCF State Regulator Active Dispense Valve X Open 3A2098H * 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. † 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) Precharge* - Valve 1 Mode◆ 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 Valid† Dispense Valve X On Dispense Complete PCF State Regulator Active Dispense Valve X Open * 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 “Command 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) Dispense Valve 1 Open Dispense Valve 2 Open Dispense Valve 3 Open 54 3A2098H Operation Control Charts (continued) Trigger Using Command Cable Automation Inputs (PCF Outputs) Dispense In Process Command Cable Dispense Trigger PCF State Regulator Active (Precharge = 0) Dispense Valve X Open* * 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 Valve 2 On Dispense Valve 3 On Dispense Valve 4 On PCF State Regulator Active (Precharge = 0) 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 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 Pressure Relief Procedure The equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking or servicing the equipment. 1. Shut off the fluid supply to the fluid plate assembly. 2. Place a waste container beneath the dispense valve. 3. In maintenance mode, select Full Open Dispense Mode, which opens the regulator and dispense valve. Press the manual dispense button b. Continue actuating the plunger until all pressure is purged from the system between the needle and the dispense valves attached to this fluid plate before proceeding to the next step. 5. For systems with multiple fluid plates, repeat previous steps for other fluid plates. 6. Shut off air to the fluid plate. 7. Place a waste container below the air filter assembly then open drain valve on the air filter assembly. Close drain valve once air is relieved. 8. Turn main power switch on control panel to the OFF position. until the fluid flow stops. 4. If the dispense valve cannot be actuated from the control center, refer to FIG. 36 and perform the following steps to open the dispense valve and relieve fluid pressure: a. Manually actuate the plunger on the solenoid to open all dispense valves attached to this fluid plate and relieve fluid pressure. See FIG. 36. 9. If you have followed the previous steps and suspect that a valve, hose, or dispense nozzle is clogged or that pressure has not been fully relieved, very slowly remove the dispense tip, clean the orifice, and continue relieving pressure. 10. If this does not remove the clog, cover the hose end coupling with a rag then very slowly loosen the hose end coupling to relieve pressure gradually, then loosen the coupling completely. Clear the valves or hose. Do not pressurize the system until the blockage is cleared. Dispense Valve Air Solenoid FIG. 36: Dispense Valve Air Solenoid 3A2098H 57 Shutdown Shutdown 1. Press the Stop button (BC). BC TI12362a 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. FIG. 38: Control Center Main Power Switch 58 3A2098H USB Data USB Data All files downloaded from the USB are put in a DOWNLOAD folder on the drive. For example: “E:\GRACO\12345678\DOWNLOAD\” • The 8-digit numeric folder name matches the 8-digit ADM serial number. When downloading from multiple ADMs, there will be one sub-folder in the GRACO folder for each ADM. • USB Logs • • • • • • • • FIG. 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 Download Procedure, page 61, to retrieve log files. • Event Log The event log file name is 1-EVENT.CSV and is stored in the DOWNLOAD folder. The event log maintains a record of the last 1,000 events. Each event record in the log file contains the date and time the event occurred, the event type, event code, and event description. Job Log The job log file name is 2-JOB.CSV and is stored in the DOWNLOAD folder. The job log maintains a record of the last 10,000 jobs. At the completion of each job the following data is stored in the log file: • • • • • • • • Target volume (in the units shown in the volume units column) Requested volume (in the units shown in the volume units column) Actual dispensed volume (in the units shown in the volume units column) Volume units Error percentage between actual dispensed volume and requested volume (maximum of 100%) Minimum inlet pressure during job (measured in bar, heated systems will always read 0) Average inlet pressure during job (measured in bar, heated systems will always read 0) Maximum inlet pressure during job (measured in bar, heated systems will always read 0) Minimum outlet pressure during job (measured in bar) Average outlet pressure during job (measured in bar) Maximum outlet pressure during job (measured in bar) Minimum flow rate during job (measured in cc/min, systems with no flow meter will read 0) Average flow rate during job (measured in cc/min, systems with no flow meter will read 0) Maximum flow rate during job (measured in cc/min, systems with no flow meter will read 0) Elapsed time (mS) 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. Job completion date Job completion time Job number (sequential number) Dispenser (Fluid Plate) Number Style number 3A2098H 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 downloads each time a USB flash drive is inserted. Use this file to back up system settings for future recovery or to easily replicate settings across multiple PCF systems. Refer to the Upload Procedure, page 61, for instructions on how to use this file. It is recommended to retrieve the SETTINGS.TXT file after all system settings are set as desired. Store the file for future use as a backup in case the settings are changed and need to be quickly changed back to the desired setup. NOTE: System settings may not be compatible between different versions of the PCF software. NOTE: Do not modify the contents of this file. Custom Language File The custom language file name is DISPTEXT.TXT and is stored in the DOWNLOAD folder. A custom language file automatically downloads each time a USB flash drive is inserted. If desired, use this file to create a user-defined set of custom language strings to be displayed within the ADM. The PCF system is able to display the following Unicode characters. For characters outside of this set, the system will display the Unicode replacement character, which appears as a white question mark inside of a black diamond. • • • • • U+0020 - U+007E (Basic Latin) U+00A1 - U+00FF (Latin-1 Supplement) U+0100 - U+017F (Latin Extended-A) U+0386 - U+03CE (Greek) U+0400 - U+045F (Cyrillic) Create Custom Language Strings The custom language file is a tab-delimited text file that contains two columns. The first column consists of a list of strings in the language selected at the time of download. The second column can be used to enter the custom language strings. If a custom language was previously installed, this column contains the custom strings. Otherwise the second column is blank. Modify the second column of the custom language file as needed and then follow the Upload Procedure, page 61, to install the file. The format of the custom language file is critical. The following rules must be followed in order for the installation process to succeed. • • • • • • 60 The file name must be DISPTEXT.TXT. The file format must be a tab-delimited text file using Unicode (UTF-16) character representation. The file must contain only two columns, with columns separated by a single tab character. Do not add or remove rows to the file. Do not change the order of the rows. Define a custom string for each row in the second column. 3A2098H USB Data Download Procedure Upload Procedure 1. Insert USB flash drive into USB port (BL). See FIG. 39 on page 59. Use this procedure to install a system configuration file and/or a custom language file. 2. The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete. A pop-up will be present until the transfer is complete if it is not acknowledged. 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. Remove USB flash drive from USB port (BL). 4. Insert USB flash drive into USB port of computer. 5. The USB flash drive window automatically opens. If it does not, open USB flash drive from within Windows® 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.) 3. The USB flash drive window automatically opens. If it does not, open USB flash drive from within Windows Explorer. 4. Open Graco folder. 5. Open system folder. If working with more than one system, there will be more than one folder within the Graco folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial number is on the back of the module.) 6. If installing the system configuration settings file, place SETTINGS.TXT file into UPLOAD folder. 7. If installing the custom language file, place DISPTEXT.TXT file into UPLOAD folder. 8. Open DOWNLOAD folder. 9. Open LOG FILES folder labeled with the highest number. The highest number indicates the most recent data download. 8. Remove USB flash drive from computer. 9. Install USB flash drive into PCF system USB port. Microsoft® Excel® 10. Open log file. Log files open in by default as long as the program is installed. However, they can also be opened in any text editor or Microsoft® Word. NOTE: All USB logs are saved in Unicode (UTF-16) format. If opening the log file in Microsoft Word, select Unicode encoding. 3A2098H 10. The menu bar and USB indicator lights indicate that the USB is downloading files. Wait for USB activity to complete. 11. Remove USB flash drive from USB port. NOTE: If the custom language file was installed, users can now select the new language from the Language drop-down menu in the Advanced Setup Screen 1. 61 Troubleshooting Troubleshooting NOTE: Check all possible solutions in the chart below before you disassemble the system. Troubleshooting for individual fluid regulators and flow meters is also discussed in their separate manuals; refer to Related Manuals on page 3. Also refer to Event and Error Codes and Troubleshooting, page 67, for detailed information on how error codes are communicated. Fluid Plates Problem No outlet pressure Cause Air pressure low Solution Verify air pressure is above 60 psi (410 kPa, 4.1 bar) No “Valve On” signal from automation Check output and wiring from autounit mation unit No air signal to air diaphragm Check for loose/disconnected connector 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 needle/ seat Air leaks from fluid plate Loose air connections Check air connections; tighten if necessary Worn gaskets Check/replace gaskets on Voltage to Pressure (V/P) Transducer and solenoid valve 62 3A2098H Troubleshooting Flow Meter Problem No flow measurement False measurement Flow reported is not correct or inconsistent Cause Solution Flow meter pick-up sensor loose Tighten flow meter pick-up sensor Flow too low Verify flow rate is above minimum for the installed flow meter Loose wiring Verify connection from flow meter to FCM Damaged flow meter pick-up sensor Replace pick-up sensor 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 meter not calibrated Calibrate flow meter, page 42 Flow meter is worn Replace flow meter Fluid Regulator Problem Cause Solution No pressure regulation Damaged diaphragm Replace diaphragm Leaking or dirty seat Replace cartridge, or clean seat No fluid flow Damaged valve actuator Replace valve actuator Pressure creeps above setting Metal chip or contamination between ball and seat Replace cartridge, or clean 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 line Clear obstruction in line. Service regulator if necessary Leaking or dirty seat Replace cartridge, or clean seat Large change in inlet pressure Stabilize regulator inlet pressure Empty/clogged supply line Fill/flush supply line Damaged or clogged air regulator or line Clear obstruction in line. Service regulator if necessary Using valve beyond its rated flow capacity Install valve for each spray valve or dispensing valve Large change in inlet air or fluid pressure Stabilize air and fluid regulator inlet pressures Fluid leaks from spring housing Loose fluid housing Tighten the four cap screws Chatter Damaged diaphragm Excessive pressure differential be tween pump and valve Replace diaphragm Reduce pump pressure to not more than 2000 psi (14 MPa, 138 bar) greater than required valve pressure. Reduce fluid flow through regulator. Connect only one spray gun or dispense valve to each fluid regulator Pressure drops below setting Excessive flow rate 3A2098H 63 Troubleshooting Dispense Valves Problem Valve not opening Valve not shutting off Cause Solution Air not getting to the open port Verify air pressure to solenoid No “Valve On” signal from automation unit Check input from automation unit Air not getting to the close port (except AutoPlus valve) Verify air pressure to solenoid Verify solenoid operation Verify air line routing and connections Sluggish open/close “Valve On” signal from automation unit is on Check input from automation unit 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 shut-off is escaping Reduce running pressure 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 Problem Motor not running (motor fault alarm active) Motor not running (motor fault alarm not active) Cause Cable disconnected Verify cable connections to swirl board, swirl motor cable, and swirl orbiter CAN cable was re-connected with system power on (amber LED on swirl board will be on, this indicates circuit protection was triggered) Cycle system power Shorted motor cable (amber LED on swirl board will be on, this indicates circuit protection was triggered) Replace swirl motor cable (55 ft) then cycle power Faulty swirl orbiter Cable disconnected Replace swirl orbiter No “Swirl Enable” signal from automation unit Swirl not installed 64 Solution Verify cable connections to swirl board, swirl board power cable, and swirl control DGM Check input from automation unit Verify that the proper swirl orbiter is installed in the system setup screen 3A2098H Troubleshooting Motor not responding to change in speed command No “Swirl Speed Command” signal from automation unit Check input from automation unit Swirl speed source incorrectly set Verify Speed Command Source in Swirl Setup screen Gateway Module Problem No communication Incorrect data Cause Solution 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 Appendix A - Advanced Display Module (ADM), page 99, for information on PCF Gateway configuration settings. Incorrect fieldbus configuration file installed on automation controller (fieldbus master) Download PCF fieldbus configuration file from www.graco.com, and install on automation controller (fieldbus master). Incorrect map installed on PCF Gateway Confirm correct PCF data map is installed on 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 Solution Green on System is powered up - Yellow Internal communication in progress - Red solid Hardware failure Replace module Red flashing fast Uploading software - Red flashing slow Token error Remove token and upload software token again. Red flashes three times, pauses, then repeats Invalid rotary switch position (FCM and DGM only) Change rotary switch position to a valid position then restart the system. See page 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 acknowledged by pressing . Errors can also be acknowledged over the gateway. Active errors are displayed in the menu bar. Error FIG. 40: Error Pop-Up The previous 200 errors are displayed on the error report screens. See Run Mode, page 110, for instructions 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: • Alarms set the dispenser (fluid plate) ready signal LOW. • 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 Code Gateway Error No. Event Name Event Description Event Type Cause Solution System Events and Errors --- 0 No Active Errors No errors --- --- No action necessary EC0X --- Setup Values Changed Setup change notification Record only A setup value was changed on the display No action necessary if changes were desired EL0X --- Power Up Control box power up Record only --- No action necessary EM0X --- Power Down Control box power down Record only --- --- Control Center Events and Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Control Center Events and Errors Transfers are disabled Clears when drive is Advisory (self-clearing) in Advanced Setup removed. screen 2. EVUX --- USB Disabled USB download attempted, however, USB activity is disabled. MMUX --- USB Log 90% Full One or more USB log is Advisory 90% full. Data in the jobs or events log has not been downloaded recently and logs are nearly full. Download the data or disable USB errors. V1G0 --- DGM Unpowered The Discrete Gateway Advisory Module does not have logic power supplied to it. 24 Vdc has not been connected to the power pins. Connect power according to Appendix B Discrete Gateway Module (DGM) Connection Details on page 115. WSG0 --- Gateway Setup Error Fluid plate 1 is not installed. Or Fluid plate 3 or fluid plate 4 is installed. Install fluid plate 1, uninstall fluid plates 3 and 4. System settings are Advisory incompatible with Discrete Gateway Module. Swirl 1 is not installed. Install Swirl 1, uninOr Swirl 3 or Swirl 4 is stall swirls 3 and 4. installed. EAUX 3A2098H --- Download to USB in Process Information is currently being downloaded to USB Advisory --(self-clearing) No action necessary 67 Errors Event Code Gateway Error No. Event Description Event Name Event Type Cause Solution Control Center Events and Errors EBUX --- Download to USB Complete Download to the USB is Advisory --complete (self-clearing) No action necessary WSU0 --- USB configuration error USB configuration error Advisory USB configuration invalid or not present Reinstall system software on display WNC0 32 ADM Key Token Error Missing or invalid key token An ADM key token is required to run the system Verify the key token is installed Missing or invalid Gateway map Install PCF map in Gateway Alarm Verify the key token part number is correct for the PCF ADM WNG0 --- Gateway Map Error Missing or invalid map Advisory CBG0 --- Gateway Reset Gateway reset Advisory Gateway setting(s) (self-clearing) changed Wait for reset to complete before attempting automation control WMG0 --- Gateway Error Detected Gateway error detected; includes any error not covered by another more specific error Alarm --- --- CBD_ --- Fluid Plate Com- Fluid Plate Communimunication Error cation Error with ADM Alarm The ADM lost commu- Restore communicanications with the tion. FCM. CCG_ --- Fieldbus Communication Error Alarm The automation gateway lost communication with the automation controller. Fieldbus Communication Error Restore communications. Fluid Plate Events and Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors CAC_ --- CGM Communication Error Communication lost between CGM and Fluid Plate Advisory Fluid Plate and CGM Reconnect or replace are no longer commu- CAN cable nicating CGM is not functioning Replace the CGM if the red status LED is solid CAD_ --- Fluid Plate Com- FCM lost communicamunication Error tion with the ADM Alarm ADM is not communicating Reconnect or replace CAN cable ADM is not functioning Replace FCM if red status LED is solid ADM does not contain Verify intended ADM appropriate key token key token is properly inserted B7C_ 68 30 Style Out of Range Style is out of range Alarm Style requested by automation controller exceeds number of styles available on the fluid plate Use a style number that is in range Increase number of styles in PCF; purchase accessory key token 3A2098H Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors B30_ B40_ B10_ B20_ 31 32 High Material Low Material Material dispensed during last dispense cycle was above amount requested plus the allowed tolerance Alarm or Deviation (user selectable) PCF regulator is not regulating correctly Check regulator and repair if necessary Incorrect style target volume or tolerance Enter correct values or set tolerance to 0% to disable error Material dispensed during last dispense cycle below amount requested minus the allowed tolerance Alarm or Deviation (user selectable) Partially plugged tip or Clean tip and/or supply supply system system Insufficient flow to PCF regulator inlet Increase flow rate to regulator inlet PCF regulator is not regulating correctly Incorrect style target volume or tolerance setting Check regulator; repair if necessary B1C_ B2C_ B3C_ B4C_ WND_ 33 34 51 Low Computed Target High Computed Target Fluid Plate Key Token Error Requested volume/ mass differs from entered process target by more than entered tolerance for style requested Requested volume/ mass differs from entered process target by more than entered tolerance for style requested Missing or invalid key token Alarm or Deviation (user selectable) Alarm or Deviation (user selectable) Alarm Entered process target Enter correct process incorrectly target Entered tolerance incorrectly Enter correct tolerance Requested volume incorrectly Check automation program Automation problem Verify automation is correct Entered process target Enter correct process incorrectly target Entered tolerance incorrectly Enter correct tolerance Requested volume incorrectly Check automation program Automation problem Verify automation is correct FCM key token is Verify FCM key token required to run system is installed Verify FCM key token is correct part number P6D_ 52 Outlet Pressure Outlet pressure transTransducer Error ducer error Alarm Problem detected with Verify outlet pressure outlet pressure trans- transducer is installed ducer and/or connected correctly P6F_ 53 Inlet Pressure Inlet pressure transTransducer Error ducer error Advisory Problem detected with Verify inlet pressure inlet pressure transtransducer is installed ducer and/or connected correctly F6D_ 54 Flow Meter Error Flow Meter error Alarm Problem detected with Verify flow meter is flow meter installed and/or connected correctly Replace if necessary Replace if necessary Replace if necessary 3A2098H 69 Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors WED_ 55 V/P Error Voltage to Pressure Transducer error WJ1_ 56 Dispense Valve 1 Dispense valve 1 error Error Alarm Problem detected with Verify outlet pressure V/P transducer is installed and/or connected correctly Alarm Problem detected with Verify dispense valve 1 dispense valve 1 is installed and/or connected correctly Replace if necessary Replace if necessary WJ2_ 57 Dispense Valve 2 Dispense valve 2 error Error Alarm Problem detected with Verify dispense valve 2 dispense valve 2 is installed and/or connected correctly WJ3_ 58 Dispense Valve 3 Dispense valve 3 error Error Alarm Problem detected with Verify dispense valve 3 dispense valve 3 is installed and/or connected correctly Replace if necessary Replace if necessary WJ4_ 59 Dispense Valve 4 Dispense valve 4 error Error Alarm Problem detected with Verify dispense valve 4 dispense valve 4 is installed and/or connected correctly Replace if necessary WSD_ WSD5 60 60 Incompatible Valve Settings Incompatible Valve Settings Incompatible settings Alarm for multiple valve operation; attempted to dispense Incompatible settings Alarm for multiple valve operation; attempted to dispense Attempted to dispense simultaneously from multiple valves on the same fluid plate with different pressure settings Check settings shown on Fluid Plate x, screen 2 (Mode Settings) Attempted to dispense simultaneously from multiple valves on the same fluid plate with different pressure settings In the Discrete Gateway screens, change the settings of the simultaneously dispensing valves to the same pressure Verify automation programming Verify automation programming F7D_ 70 61 Closed Valve Flow System reading flow meter pulses with valve(s) closed Alarm Dispense hose leak Check hose; replace if needed Flow meter providing false pulses Replace flow meter sensor or calibrate meter Dispense valve not operating correctly Repair dispense valve 3A2098H Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors V2D_ WFD_ WFG_ 62 63 Low Analog Flow Meter Required Command cable analog Deviation command dropped below minimum value of 1 V while dispensing Bad or loose command cable connection Check command cable and connection Entered command mode incorrectly Enter correct command code Automation program error Verify correct automation program Operating mode Alarm or requires flow meter. Advisory Advisory is issued if (self-clearing) fluid plate settings require a flow meter but meter is not present. Alarm is issued if dispense is attempted in mode that requires a flow meter but meter is not present. Selected valve mode settings require flow meter Check valve mode settings Purchase meter enabled token for FCM and install flow meter FCM key token missing or invalid Check for FCM key token error EJD_ 64 Job Cycle Time Out Job cycle time out Alarm Automation signals did Check automation pronot properly end job gramming per job opercycle ating instruction WXD_ 65 Fluid Plate Error Detected Fluid plate error detected; includes any error not covered by another more specific error Alarm Analog voltage applied Limit signal on pin 1 of to pin 1 of the comcommand cable to the mand cable exceeds range of 0-10 Vdc. 10 Vdc. P3F_ P4F_ P3D_ P4D_ P1F_ P2F_ 3A2098H 66 67 68 Maximum Inlet Pressure Maximum Outlet Pressure Minimum Inlet Pressure Inlet pressure to regula- Alarm or tor is above upper limit Deviation set for operation (user selectable) Outlet pressure of regu- Alarm or lator is above upper Deviation limit set for operation (user selectable) Inlet pressure to regula- Alarm or tor is below lower limit Deviation set for operation (user selectable) Failed FCM Replace FCM if necessary Incorrect set limit Verify limit is set correctly Material supply pressure is too high Decrease material supply pressure Failed transducer Check transducer; replace if necessary Incorrect set limit Verify limit is set correctly Material supply pressure is too high Decrease material supply pressure Failed transducer Check transducer; replace if necessary Incorrect set limit Verify limit is set correctly Material supply pressure is too low Increase crease material supply pressure Failed transducer Check transducer; replace if necessary 71 Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors P1C_ P2C_ P3C_ P4C_ 69 70 Low Pressure High Pressure Measured outlet pressure less than desired outlet pressure minus tolerance Measured outlet pressure greater than desired outlet pressure plus tolerance Alarm or Deviation (user selectable) Alarm or Deviation (user selectable) Incorrect limit set Verify limit is set correctly No or insufficient material flow Increase material flow rate Dispense valve needle is stuck closed Dislodge and inspect needle Dispense valve leaking Repair dispense valve Regulator not operating correctly Repair regulator Pump wink passed through outlet Increase pump pressure Failed transducer Check transducer; replace if failed Incorrect limit set Verify limit is set correctly Dispense hose/device Clean/replace plugged hose/device Failed transducer Check transducer; replace if failed Regulator is not clos- Repair regulator ing completely when it should F1D_ F2D_ 71 Low Flow Rate Measured flow rate less Alarm or Deviation than desired flow rate (user selectminus tolerance able) Fluid supply too low to Increase fluid supply pressure or check for achieve desired flow clogged filter rate Tip plugged Clean/replace tip No air pressure to solenoid valves Turn on air to solenoid valves No flow meter signal Check cable and sensor No material supply Replace drum or turn on pumps Incorrect flow tolerEnter correct tolerance of flow error time ance or flow error time F3D_ F4D_ 72 High Flow Rate Measured flow rate Alarm or greater than desired Deviation flow rate plus tolerance (user selectable) Operating below mini- Increase fluid presmum regulator operat- sure above regulator ing pressure minimum Regulator worn or not operating correctly Repair regulator Flow meter providing false pulses Replace flow meter sensor Incorrect flow error tol- Enter correct tolererance or flow error ance or flow error time time EKD_ 73 Shot Terminated by Job Timer Shot dispense cycle Advisory terminated by job timer Job end timer was used to stop shot dispense EHD_ 74 Purge Timer Expired Purge timer expired PCF purge timer (style Automation control 0) has expired requests purge 72 Advisory No action required if timed shot is desired 3A2098H Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors EAC_ 75 Maintenance Mode Entered Maintenance mode entered Advisory Entered maintenance (self-clearing) dispense mode No action required EBC_ 76 Maintenance Mode Exited Maintenance mode exited Advisory Exited maintenance (self-clearing) dispense mode No action required MHD_ 77 Maintenance Due - Regulator Maintenance due for regulator Advisory Service component Totalizer exceeded limit setting If necessary, reset totalizer MFD_ 78 Maintenance Maintenance due for Due - Flow Meter flow meter Advisory Totalizer exceeded limit setting Service component If necessary, reset totalizer MED_ MCD_ 79 80 Maintenance Due - V/P Maintenance Due - Supply Maintenance due for Voltage to Pressure Transducer Advisory Maintenance due for supply system Advisory Totalizer exceeded limit setting Service component If necessary, reset totalizer Totalizer exceeded limit setting Service component If necessary, reset totalizer MD1_ 81 Maintenance Due - Valve 1 Maintenance due for valve 1 Advisory Totalizer exceeded limit setting Service component If necessary, reset totalizer MD2_ 82 Maintenance Due - Valve 2 Maintenance due for valve 2 Advisory Totalizer exceeded limit setting Service component If necessary, reset totalizer MD3_ 83 Maintenance Due - Valve 3 Maintenance due for valve 3 Advisory Totalizer exceeded limit setting Service component If necessary, reset totalizer MD4_ 84 Maintenance Due - Valve 4 Maintenance due for valve 4 Advisory Totalizer exceeded limit setting Service component If necessary, reset totalizer CCD_ 85 Duplicate Module Duplicate Fluid Control Module Detected Alarm EAD_ 86 Swirl Maintenance Mode Entered Swirl maintenance mode entered Advisory Swirl zone that is (self-clearing) associated with this fluid plate entered maintenance mode No action required WFC_ 87 Shot No-Flow Timeout No flow detected for five seconds on valve activated in shot mode Alarm Dispense valve not operating properly Check dispense valve for correct operation and/or clogging Fluid leak Check fluid connections 3A2098H Two or more FCMs have the same rotary switch setting 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 73 Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors CR1_ 88 Valve 1 Swirl Communication Error Fluid plate communica- Alarm tion error with swirl The fluid plate lost communication with the swirl zone associated with this valve and fluid plate Restore communications. CR2_ 89 Valve 2 Swirl Communication Error Fluid plate communica- Alarm tion error with swirl The fluid plate lost communication with the swirl zone associated with this valve and fluid plate Restore communications. CR3_ 90 Valve 3 Swirl Communication Error Fluid plate communica- Alarm tion error with swirl The fluid plate lost communication with the swirl zone associated with this valve and fluid plate Restore communications. CR4_ 91 Valve 4 Swirl Communication Error Fluid plate communica- Alarm tion error with swirl The fluid plate lost communication with the swirl zone associated with this valve and fluid plate Restore communications. WD1_ 92 Valve 1 Swirl Fault Swirl motor fault Alarm or Deviation (user-selectable) The swirl zone associ- Resolve swirl motor ated with this valve fault (see error WBDX and fluid plate caused for possible solutions) a fault WD2_ 93 Valve 2 Swirl Fault Swirl motor fault Alarm or Deviation (user-selectable) The swirl zone associ- Resolve swirl motor ated with this valve fault (see error WBDX and fluid plate caused for possible solutions) a fault WD3_ 94 Valve 3 Swirl Fault Swirl motor fault Alarm or Deviation (user-selectable) The swirl zone associ- Resolve swirl motor ated with this valve fault (see error WBDX and fluid plate caused for possible solutions) a fault WD4_ 95 Valve 4 Swirl Fault Swirl motor fault Alarm or Deviation (user-selectable) The swirl zone associ- Resolve swirl motor ated with this valve fault (see error WBDX and fluid plate caused for possible solutions) a fault MB1_ 96 Maintenance due Maintenance due on - V1 Orbiter valve 1 swirl orbiter Advisory The active time totalizer for the swirl dispenser associated with this valve and fluid plate exceeded limit setting Service Component The active time totalizer for the swirl dispenser associated with this valve and fluid plate exceeded limit setting Service Component MB2_ 74 97 Maintenance due Maintenance due on - V2 Orbiter valve 2 swirl orbiter Advisory If necessary, reset totalizer If necessary, reset totalizer 3A2098H Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Fluid Plate Events and Errors MB3_ MB4_ 98 99 Maintenance due Maintenance due on - V3 Orbiter valve 3 swirl orbiter Maintenance due Maintenance due on - V4 Orbiter valve 4 swirl orbiter Advisory Advisory The active time totalizer for the swirl dispenser associated with this valve and fluid plate exceeded limit setting Service Component The active time totalizer for the swirl dispenser associated with this valve and fluid plate exceeded limit setting Service Component If necessary, reset totalizer If necessary, reset totalizer Swirl Events and Errors Event Code Gateway Error No. Event Name Event Description Event Type Cause Solution Swirl Events and Errors CBR_ --- Swirl Communication Error CDR_ --- EAD_ Alarm The ADM lost commu- Restore communicanication with the Swirl tions Control DGM Duplicate Module Duplicate Swirl Control DGM Detected Alarm Two or more Swirl Control DGMs have the same rotary switch setting Verify that all Swirl Control DGMs have proper rotary switch settings. Reset module after changing rotary switch setting. Refer to Swirl Control DGM section, page 19. --- Maintenance Mode Entered Maintenance mode entered Advisory (self-clearing) Swirl maintenance mode entered No action required EBD_ --- Maintenance Mode Exited Maintenance mode exited Advisory (self-clearing) Swirl maintenance mode exited No action required MBD_ --- Maintenance Due - Orbiter Maintenance due on swirl orbiter Advisory Swirl active time total- Service Component izer exceeded limit setting If necessary, reset totalizer WBD_ --- Swirl Motor Fault Motor speed is outside Alarm the +/- 50% tolerance range for at least 5 seconds while operating 3A2098H Swirl communication error with ADM Cable disconnected Verify cable connections to swirl board, swirl motor cable, and swirl orbiter Shorted motor cable (amber LED on swirl board will be on) Replace swirl motor cable (55 ft) Orbiter bearing failure Replace bearing Motor defective Replace swirl orbiter 75 Maintenance Maintenance 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 Task Inspect system for leaks Depressurize fluid, after operation Remove heat from system, after operation Daily Maintenance Person Weekly Monthly 3-6 months or 125,000 cycles 18-24 months or 500,000 cycles 36-48 months or 1,000,000 cycles 7000 hours ✓ ✓ ✓ Inspect filter (234967) bowls and drain ✓ Check hoses for wear Check/tighten fluid connections Check/tighten air connections ✓ ✓ ✓ ✓ Lubricate dispense valves* Rebuild regulator* ✓ Rebuild dispense valve* ✓ ✓ Replace air filter ✓ Replace Solenoid ✓ Replace Voltage to Pressure (V/P) Transducer * Check component manual for more detailed maintenance information. Electrical Task Weekly Check cables for wear ✓ Verify cable connections ✓ Verify operation of “System Stop” button ✓ * Check Component Manual for more detailed maintenance information. 76 3A2098H Maintenance Advanced Display Module (ADM) Cleaning Use any alcohol-based household cleaner, such as glass cleaner, to clean the display. 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). 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 Panel r_24E451_3B9900_3a Access Cover FIG. 41: Remove Access Panel 3. Insert and press software token firmly into slot. TI12319A NOTE: There is no preferred orientation of token. BL Token FIG. 43: Remove Access Cover 3. Insert and press token firmly into slot. NOTE: There is no preferred orientation of token. r_24E451_3B9900_4a FIG. 42: Insert Token 4. Turn on power to the system. The red indicator light (CK) will flash until new software is completely loaded. 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. CK 6. Remove software token. 7. Reinstall key token, and replace token access panel. 3A2098H Token TI12320A FIG. 44: Insert Token 77 Maintenance 5. After the red indicator light shuts off, turn off power to the system. 6. Remove token. 4. Press and hold the push button for three seconds and then release. The red indicator light (CK) will flash twice, pause, and then once after the data map is uploaded. 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 fieldbus map. CK TI12320A Token Push Button FIG. 46: Insert Token 2. Remove the access cover. 5. Remove map token (CC) when software has successfully uploaded. 6. Replace access cover. Access Cover TI12319A FIG. 45: Remove Access Cover 3. Insert and press map token firmly into slot. NOTE: There is no preferred orientation of the token. 78 3A2098H Maintenance Upgrade Fluid Control Module (FCM) Software NOTE: The FCM connection is temporarily disabled during the use of the upgrade token. 7. Reinstall key token, and replace access cover. Air Filter Maintenance 1. Turn off power to the system. 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. 2. Remove access cover then remove key token (do not discard token). Replacement Air Filters for Dual Filter Assembly (234967) Part Description 123091 123092 5 micron air filter 0.3 micron air filter Swirl Dispensers Access Cover See manual 309403 for maintenance schedule. TI12334A FIG. 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 flash until new software is completely loaded. CK TI12335A Token FIG. 48: Insert Token 5. After the red indicator light shuts off, turn off power to the system. 6. Remove software token. 3A2098H 79 Repair Repair Fluid Plate Assembly 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 This section describes how to remove and replace components on the fluid plate assembly. Prepare Fluid Plate Assembly for Repair 1. Prepare Fluid Plate Assembly for Repair, page 80. 2. Disconnect the flow meter cable (131) from the flow meter sensor. See FIG. 49. 3. Disconnect the material hose. 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. 4. Disconnect the swivel fitting (109) from the regulator. 5. Loosen the four screws (127) and washers (125, 126); remove the bracket (124) and flow meter (129). 6. The flow meter weighs approximately 15 lbs. (6.75 kg). Carefully lift it off the mounting plate (101). 101 103 108 124 129 125, 126, 127 131 109 r_pf0000_313377_18a FIG. 49: Fluid Plate Assembly 80 3A2098H Repair Install Flow Meter on Mounting Plate 1. Rest the flow meter (129) and bracket (124) on the fluid plate while threading the swivel fitting (109) onto the regulator material inlet. See FIG. 49. 4. Remove the dispense valve solenoid (132) and replace it with a new solenoid. 137 2. Tighten the swivel fitting to the regulator material inlet. 132 3. Tighten the four screws (127) and washers (125, 126) to hold the bracket and flow meter in place. 118 r_pf0000_313377_33a FIG. 51 126 127 5. Secure the new solenoid to the bracket with screws. 6. Reconnect the FCM cable and all three air tubes. 129 124 108 109 125 Replace Voltage to Pressure (V/P) Transducer 1. Prepare Fluid Plate Assembly for Repair, page 80. r_pf0000_313377_34a FIG. 50 4. Check that the flow meter and regulator (108) are still aligned. 5. Connect the material hose. 2. Disconnect the FCM cable and both air tubes. 3. Remove both transducer screws (122) from transducer bracket (118). 4. Remove the V/P transducer (121) and replace it with a new V/P transducer. 6. Connect the flow meter cable (131). Replace Solenoid 1. Prepare Fluid Plate Assembly for Repair, page 80. 2. Disconnect FCM cable and all three air tubes. 118 3. Remove both screws (137) from transducer bracket (118). 121 122 r_pf0000_313377_31a FIG. 52 3A2098H 81 Repair 5. Secure the new V/P transducer to the bracket with screws. 6. Reconnect the FCM cable and both air tubes. Replace Fluid Control Module 1. Prepare Fluid Plate Assembly for Repair, page 80. 2. Remove the four screws (128) from the transducer bracket (118), and remove the bracket. (Leave the dispense valve solenoid (132) and V/P transducer (121) attached to the transducer bracket.) Replace Fluid Control Module Base 1. Prepare Fluid Plate Assembly for Repair, page 80. 2. Remove the FCM (103); follow Replace Fluid Control Module. (Leave the cables attached to the FCM.) 3. Remove the power supply cable from the base (102). 4. Remove the four screws (105) and ground screw (106) from the base and replace it with a new base. 102 103 118 132 102 105 106 128 121 103 r_pf0000_313377_30a FIG. 53 FIG. 54 3. Remove the following cables from FCM: 5. Secure the base to the fluid plate (101) with screws. • • • • • • dispense valve solenoid cable meter sensor cable both V/P cables I/O cable inlet pressure transducer cable (ambient models only) outlet pressure transducer cable 6. Reconnect the power supply cable. 7. Reattach the FCM; follow Replace Fluid Control Module. 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 3A2098H Repair 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). 108 117 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 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. 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). See FIG. 57 and perform the following steps. NOTICE Carefully handle the hard carbide ball, valve actuator, and valve seat to avoid damaging them. NOTE: Be careful to not scrape or gouge the internal walls of the base housing. They are a sealing surface. 4. Re-torque the retaining nut (CC) to 140-160 in-lb (16-18 N•m). 1. Prepare Fluid Plate Assembly for Repair, page 80. NOTE: You must re-torque the retaining nut before you install it in the base housing during step 5. 2. Remove the cartridge assembly by loosening the valve housing (CE) with a 6 mm hex wrench and pulling the cartridge assembly out of the base housing (CD). 5. Install the new cartridge assembly in the base housing (CD), and torque the valve housing (CE) to 30-35 ft-lb (41-48 N•m). NOTE: The valve seat is double sided and may be reversed for extended life. The o-ring and ball must be replaced. See instruction manual 308647. Cartridge Regulator 244734 Shown CD Torque Sequence for Regulator Base Housing Screws (CF) 4 1 CF CC CE 2 3 cartridge assembly diaphragm and valve actuator subassembly FIG. 57: Replace Cartridge Assembly 84 3A2098H Repair Replace Amplifier Adjust Display Settings (Heated fluid plates only) 3. With the system in setup mode, navigate to the Advanced screens. 1. Prepare Fluid Plate Assembly for Repair, page 80. 4. Press to scroll to Advanced screen 2. 2. Disconnect pressure sensor cable (117) and power output cable. Screw 116 117 Power Output Cable FIG. 58: Replace Amplifier 5. Press to access the fields to make changes. 6. Press to move the Pressure Units field. Press to open the drop-down list, and select psi. Press to enter the new units. 3. Loosen four screws on amplifier (116) cover, and then remove cover. 7. Press 4. Remove four screws (105) securing amplifier to bracket. 8. With the system still in setup mode, navigate to Fluid Plate x, screen 5 (Pressure Sensors). to exit edit mode. 5. Remove amplifier and replace with a new amplifier. 6. Secure new amplifier to bracket with four screws. 7. Replace amplifier cover and tighten screws. 8. Reconnect pressure sensor cable (117) and power output cable. Calibrate Amplifier (Heated fluid plates only) 1. Prepare Fluid Plate Assembly for Repair, page 80. 9. Press to access the fields to make changes. 2. Remove outlet pressure sensor from outlet fitting to ensure there is no pressure applied to the sensor. 10. Press to move the Outlet Offset field. Set the psi to 0. Press 11. Press 3A2098H to enter the new setting. 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 the 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. 17. Use the data from the certificate of calibration for the pressure sensor (included with PCF documentation or the replacement pressure sensor) to calculate the Shunt Calibration Pressure using the following formula: 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 Sensors) matches the calculated Shunt Calibration Pressure. 19. Remove the jumper wire or paper clip from the SHUNT CAL and ENABLE terminals. 20. Repeat steps 15 - 19 at least one additional time to ensure proper calibration. Panel mounting holes. Use #6 or #8 screws. EXCITATION MODULE POWER (+)EXCITATION (-)EXCITATION (+)SIGNAL (-)SIGNAL A B C D E F 1 2 3 4 5 6 7 8 ON COARSE Excitation Selector Coarse Zero Fine Zero To Transducer SHUNT CAL RESISTOR SPAN FINE 10 VDC 5 VDC 3 VDC ZERO FINE EX SEL COARSE To Readout TRANSDUCER 1 2 3 4 5 6 (+)SUPPLY (-)OUTPUT SUPPLY RETURN (+)OUTPUT SHUNT CAL ENABLE Coarse Gain Fine Gain FIG. 59: Amplifier Settings 21. Replace the amplifier cover. See Replace Amplifier, 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 3A2098H Repair Control Center Assembly Replace Gateway Module Base 1. Prepare Control Center for Repair, page 87. 2. Remove the Gateway module (5); follow Replace Gateway Module. (Leave automation communications cable (AE) attached to Gateway module.) Prepare Control Center for Repair 3. Disconnect the CAN cable (19) and power supply cable (6) from the base (3). 1. Power off the display. 2. Disconnect main power to the control center assembly. 3. Remove the control center assembly front cover (20). 4. Remove the four screws (16) and grounding screw (12) from the base and replace it with a new base. 1 Replace Gateway Module 1. Prepare Control Center for Repair, page 87. 2. Remove the automation communications cable (AE). 19 6 3. Remove the two screws holding the Gateway module (5) to the base (3), and remove the module. 3 12 5 16 4 FIG. 61 3 5. Secure the new base to rear cover (1) using the five screws. 6. Reattach Gateway module; follow Replace Gateway Module. 5 FIG. 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 87 Repair Replace Swirl Board 16K570: Replace Advanced Display Module 1. Prepare Control Center for Repair, page 87. 1. Prepare Control Center for Repair, page 87. 2. Remove screw (a) from swirl board cover. Open swirl board cover. 2. Disconnect the CAN cable (18) from the ADM (2). 21 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). 2 5. Insert cable connectors (b) into the new board. 6. Reassemble the swirl board cover using screw (a). a b 18 11, 14, 24 FIG. 63 3. Remove the ADM by snapping it out of the mounting bracket. 4. On old ADM, remove token access panel then remove key token. Do not discard token. c 5. Connect the CAN cable to the new ADM. FIG. 62 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 mounting bracket. 88 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 Display Module. (Leave the CAN cable attached to the ADM.) 2. Remove both screws (22) and washers (28) from the line voltage assembly cover (7). Remove the cover. 3. Remove the speed clips (25) and rivets (26) from the mounting bracket (21). 22 26 28 20 21 2 25 7 FIG. 65 FIG. 64 3. Disconnect all wiring from the din rail module and filter. 4. Remove the mounting bracket from the front cover (20) and replace with a new bracket. 5. Secure the new bracket to the front cover with speed clips and rivets. 4. Remove the four screws (40) from the din rail and filter. 5. Disconnect wires from rocker/rotary switch. Take note of wire positions for easy connection in Step 7. 6. 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. 1 40 40 40 FIG. 66: 24 Vdc Din Rail Assembly r_pf0000_313377_10a 7. Reconnect all wiring to the din rail module, filter, and rocker/rotary switch. 8. Reassemble the line voltage assembly cover using the screws and washers. Replace Fuses Replace fuses on the din rail assembly. • • For 24 Vdc control centers: see Technical Data on page 140 for fuse specifications. For 100-240 Vac control centers: Order fuse 115805. r_pf0000_313377_10a Fuses FIG. 67: Fuse Location 90 3A2098H Parts Parts Control Centers Software Upgrade Tokens Part Description ★ ✠ 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 Gateway, have purchased a new PCF, and do not wish to change their Gateway setup from the old Gateway map to the new Gateway map. Control Center Key Token Part Numbers See Key Tokens on page 20 for more information about key tokens. Part Description ★16M217 ADM Key Token, Standard PCF Gateway Module Part Numbers PCF Model User Interface Description Gateway Part Number To Order PFxx0x Discrete ★24B681 PFxx1x DeviceNet™ ★15V759 PFxx2x EtherNet/IP™ ★15V760 PFxx3x PROFIBUS™ ★15V761 PFxx4x PROFINET™ ★15V762 3A2098H 91 Parts Control Center and Expansion Swirl Enclosure Parts 24 15 40 7 44 28 22 50 38 13 22 9 13 13 13 13 13 13 13 48 25 45 15 28 6,10 22 49 26 1 44 20 13 25 14 14 22 26 3,4,12,16 13 43 13 13 13 47 3 14 21 14 25 16 14 4 14 5 or 43 14 11 24 14 14 14 12 14 50 13 24 VDC units only: 15,36 100-240 VAC units only: 6,36 2 14 14 1 19 37 13 18 23,27 1 Add ferrite (36) to cable. Locate 6; Ground/ Green 14 Control centers only. Not included in expansion swirl enclosures. 15 100-240 Vac models only. as close to cable connector as possible. 13 92 6; Neutral/ Blue 6; Line/ Brown Included in swirl models only (both control centers and expansion swirl enclosures). 3A2098H Parts Control Center Assembly Parts Ref. 1 2✠ 3◆ 4◆ 5✠ Part --24E451 289697 277674 --- 6‡ 7‡❖ 8‡❖ 9▲‡ 10‡ 11✿ 12◆ 13 14✿ 15‡❖ 16◆ 18 19 20 21✿ 22‡❖ 23 24✿ 25✿ 26✿ 27 28 36 37 38 40 ------196548 ----121820 121807 110755 --195875 121001 121000 ------120143 121253 ----112925 100020 121901 124654 ----- 3A2098H Description Qty. COVER, rear 1 DISPLAY, with USB 1 BASE, cube 1 ENCLOSURE, cube door 1 MODULE, Gateway; see table on 1 page 91 for part number SUPPLY, power 1 COVER, line voltage 1 GROMMET 1 LABEL, warning, electric shock 1 SCREW, cap, socket hd; m4 x 6 4 WASHER, lock 1 SCREW, mach, pan hd; m4 x 35 1 CONNECTOR, splitter 1 WASHER, plain 1 MODULE, line voltage 1 SCREW, mach, pan hd 4 CABLE, CAN, female / female 1.0m 1 CABLE, CAN, female / female 0.5m 1 COVER, front 1 BRACKET, mounting 1 SCREW, mach, pan hd 2 GUIDE, strain relief 2 KNOB, display 2 CLIP, speed, tubular 2 RIVET, aluminum 1 SCREW, cap 2 WASHER, lock 2 SUPPRESSOR, box snap, ferrite 2 CONNECTOR, splitter 1 LABEL 1 SCREW, mach, pan hd 4 Ref. 43✠ 44 45 46 47 48 49 50 51 52 Part 24B681 --16K570 --------24K455 24K458 121597 Description Qty. MODULE, DGM 1 GUARD, edging 1 BOARD, circuit, swirl 1 BRACKET, display pivot 1 COVER, swirl, hinge side 1 COVER, swirl, latch side 1 COVER, swirl, lid 1 CABLE, swirl board, panel mount 1 CABLE, SWIRL-DGM 1 CABLE, CAN, 90 female/90 female 1 ▲ Replacement Danger and Warning labels, tags, and cards are available at no cost. ‡ Parts included with 100-240 Vac Module kit 24B928. ❖ Parts included with 24 Vdc Module kit 24B929. ✿ Parts included with Display Mounting Bracket kit 24B930. ✠ Base electronic components do not have PCF-specific software installed. Use software upgrade token (16K743) to install software before use. * Fieldbus Gateway modules do not have a PCF-specific map installed. Use map token (16N601) to install map before use. --- Not for sale. 93 Parts Fluid Plate Assembly Parts 142 143 See page 96 See page 95 117, 120 135, 136 131 199 See page 95 153 101 151 152 94 3A2098H Parts Fluid Plate Assembly Parts (continued) 126 127 125 124 129 128 126 110 130 109 127 155 125 126 105 137 137 141 104 141 132 141 128 133 118 102 105 128 106 122 103 141 121 128 141 122 3A2098H 95 Parts Fluid Plate Assembly Parts (continued) 111 112 113 108 112 114 113 141 119 127 ti19262a 127 Fluid Plate 24B962 Shown 105, 116 140, 141, 150 158 139 149 117 107 199 115 148 108 145 159 160 96 3A2098H Parts Fluid Plate Assembly Parts Ref. 101 102 103✠ 104 105✓ 106 Part --289697 289696 277674 --121820 107 121228 108✓ 109✓ 110✓ ------- 111 112 113✓ 114 115✖ 116✖ 117✓ 118 119✖ 120✓ 121 122 124✓ 125✓ 126✓ 127✓ 128✓ 129✓ 130✓ 131▲ 132 133 135▲✖ 136 137 139 140 141 142 143 145 198269 110580 --198268 624545 258530 ----16P819 --120010 111119 --------------15X756 258334 121806 189285 --117820 198179 198175 ------121226 146★ 147✓★ 148 149 150 151 234967 --121612 121818 --114391 3A2098H Description Qty. PLATE, fluid 1 BASE, cube 1 FCM, cube 1 ENCLOSURE, cube door 1 SCREW, mach, pan hd SCREW, machine, pan hd; m4 x 1 35 CABLE, CAN, female/female; 1 15.0 m REGULATOR, assy UNION, adapter NIPPLE, reducing, hex; 1/2 npt(f) x 3/4 npt(f) BRACKET, flow meter, lower 1 SCREW, cap, socket hd 2 SPACER BRACKET, flow meter 1 FITTING, tee; 3/4(m) x 1/4(f) 1 AMPLIFIER, signal conditioner 1 SENSOR, pressure, fluid outlet 2 BRACKET, valve 1 BRACKET, signal conditioner 1 O-RING REGULATOR, I/P 1 SCREW, valve 2 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 1 VALVE, dispense, fluid plate 1 CABLE, solenoid 1 LABEL, caution, hot surface 1 LABEL 1 SCREW, cap, socket hd; m3 2 FITTING, bulkhead, union 1 FITTING, push 1 TUBE, nylon, round, black; 5.5 LABEL 1 SHROUD, fluid plate 1 CABLE,CAN, male/female; 0.5 1 m KIT, dual filter 1 TOKEN, key CONNECTOR, thru; m12, m x f 1 BULKHEAD, tube; 5/32 2 TAG, installation 1 SCREW, grounding 1 Ref. 152 153▲ 155✓ 158 159▲ 160▲ 199* Part 194337 186620 --122610 290228 189930 124654 Description Qty. WIRE, grounding, door 1 LABEL, ground 1 SUPPRESSOR, box snap, ferrite ELBOW 1 LABEL, caution, hot surface 1 LABEL, caution, electric shock 1 SPLITTER, CAN 1 ▲ 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. ✠ Base electronic components do not have PCF-specific 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. Part 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 The following table lists the varying part numbers by fluid plate assembly, and the quantity for each assembly. Fluid Plate Assemblies Ref. Part Description 105 195875 SCREW, mach, pan hd 108 244734 REGULATOR, assy 246642 246643 109 156684 UNION, adapter 157785 110 C20461 NIPPLE, reducing, C20487 hex; 1/2 npt(f) x 3/4 npt(f) 113 C34045 SPACER 117 15M669 SENSOR, pressure, 117764 fluid outlet 120 111457 O-RING 124 117670 BRACKET, helical gear meter 125 C19197 WASHER, plain 126 --WASHER, lock, spring; m6 127 108328 SCREW, cap, socket hd 128 107530 SCREW, cap, socket hd, hex 129 246652 METER, assy. 246340 130 122030 CABLE; m12-5p 147★ 16M100 TOKEN, key, 2 styles, meter enabled 16M101 TOKEN, key, 2 styles, meter disabled 16M102 TOKEN, key, 16 styles, meter enabled 16M103 TOKEN, key, 16 styles, meter disabled 16M104 TOKEN, key, 256 styles, meter enabled 16M105 TOKEN, key, 256 styles, meter disabled 155 121901 SUPPRESSOR, box snap, ferrite Cartridge Regulator with High Resolution Meter Cartridge Regulator with No Meter Mastic Regulator with High Resolution Meter Mastic Regulator with No Meter Heated Mastic Regulator with Heated High Resolution Meter 4 4 4 4 8 8 1 1 1 1 1 1 1 Heated Mastic Regulator with No Meter 1 1 1 1 2 2 2 2 2 1 2 1 2 2 2 1 2 1 4 6 1 1 4 6 4 6 6 2 6 2 6 2 6 4 6 4 6 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 --- Not for sale. 98 3A2098H Appendix A - Advanced Display Module (ADM) Appendix A - Advanced Display Module (ADM) Display Overview Display Details The ADM display is divided into two main functions: Setup Mode and Run Mode. Power Up Screen Setup Mode Functions The setup mode functions enable users to: • • • • • • • • • • • The following screen appears when the ADM is powered up. It remains on while the ADM runs through initialization and establishes communication with other modules in the system. configure installed system components set units, adjust values, set formats, and view software information for each component set or change information regarding the Gateway module view information regarding the particular Gateway module used set controls and valve commands set on and off delays for valves and the regulator set k-factor, pressure, and flow rate variables set offsets for inlet and outlet pressures set error types set variables for maintenance advisories set up to 256 styles for models with a CGM and set up to 16 styles for models with a DGM Run Mode Functions Menu Bar The menu bar appears at the top of each screen. The run mode functions enable users to: • • • • • adjust the bead scale perform manual dispensing view a chronological list of system errors view a chronological list of jobs stored/performed in the system use a preventative maintenance schedule for the supply system, displacement pump, and air motor Date and Time The date and time are always displayed in one of the following formats. The time is always displayed as a 24-hour clock. • • • DD/MM/YY HH:MM MM/DD/YY HH:MM YY/MM/DD HH:MM Arrows The left and right arrows indicate screen navigation. Screen Menu The screen menu indicates the currently active screen, which is highlighted. It also indicates the associated screens that are available by scrolling left and right. 3A2098H 99 Appendix A - Advanced Display Module (ADM) System Mode Navigation within Screens There are five modes: Active, Job in Cycle, Display Control, Swirl Setup, and System Off. The current system mode is displayed at the left of the menu bar. Press to open drop-down menus on Setup screens. Also, press selection. to enter changes or make a 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 No Icon Function No information or no error has occurred Description Advisory Informational Deviation Alarm Press to navigate to new screens and to navigate left and right within a screen. --Press Important but will not shut down the affected fluid plate Very important and will immediately shut down the affected fluid plate 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. Status The current system status is displayed at the right of the menu bar. Soft Keys Icons next to the soft keys indicate which mode or action is associated with each soft key. Soft keys that do not have an icon next to them are not active in the current screen. NOTICE To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. Jump In/Jump Out In screens that have editable fields, press to access the fields and make changes. When changes are complete press 100 again to exit edit mode. 3A2098H Appendix A - Advanced Display Module (ADM) Setup Mode Advanced Setup Screen 2 Setup mode screens are divided into five sections: System setup, Advanced setup, Gateway setup, Fluid Plate This screen enables users to set the units of measure for maintenance volume, maintenance mass, pressure, and flow rate. setup, and Swirl setup. While in Run mode, press to enter Setup mode. Press through the Setup mode screens. to navigate If the setup screens are password protected, a password entry screen will appear after pressing . 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 Screen 3 This screen enables users to setup USB-related settings. The Disable USB Log Errors option disables recording events when the logs are at least 90% full. Advanced setup screens. Once in the desired Advanced setup screen, press changes. Press to access the fields to make 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 format, 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. 3A2098H Advanced Setup Screen 4 This screen displays the software part number and version for the ADM, USB configuration, Gateway module, and fluid plates. 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 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. to scroll through the Gateway Setup screens. Once in the desired Advanced Setup screen, press to access the fields to make changes. Press to exit edit mode. NOTE: Users must be out of edit mode to scroll through the Gateway Setup screens. Gateway Setup Screen 1 - DeviceNet This screen enables users to set the device address and the baud rate. The DeviceNet screen displays the hardware revision number, system serial number, map ID, name, revision number, and install date. Gateway Setup Screen 2 - EtherNet/IP This screen is the same for EtherNet/IP and PROFIBUS. It enables users to view the following information regarding the Gateway module used on the PCF system: • • • • • • 102 hardware revision number system serial number map ID number map name map revision number date the map was created 3A2098H Appendix A - Advanced Display Module (ADM) Gateway Setup Screen 1 - PROFIBUS Gateway Setup Screen 2 - PROFINET This screen enables users to set the device address, install date, location tag, function tag, and system description. This screen enables users to set the device address, install date, location tag, function tag, and system description. Gateway Setup Screen 2 - PROFIBUS This screen is the same for EtherNet/IP and PROFIBUS. See Gateway Setup Screen 2 - EtherNet/IP, page 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. 3A2098H Gateway Setup Screen 3 - PROFINET This screen enables users to view the following information regarding the Gateway module used on the PCF system: • • • • • • hardware revision number system serial number map ID number map name map revision number date the map was created 103 Appendix A - Advanced Display Module (ADM) Discrete Gateway (Automation) Setup Screen NOTE: The Discrete Gateway Setup screen is not available if an automation Discrete Gateway Module (DGM) is not attached to the system. Digital Command Logic Table (2-Fluid Plate Systems) 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. Digital Command Input 1 This screen enables users to set Active Errors to High (default) or Low. If High is selected, alarm and error signals 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. Low --- Low Fluid Plate 2, Setting #1 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 Gateway Module (DGM) Connection Details, page 115, for connection details. --- High Fluid Plate 2, Setting #2 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 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. Digital Command Input 2 --- Fluid Plate 1, Setting #1 --- Fluid Plate 1, Setting #2 High Press Resulting Digital Command Selection to access the fields to make changes. Press to exit edit mode. Single fluid plate system 2-fluid plate system 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 Low Digital Command Input 2 Low Resulting Digital Command Selection Setting #1 High Low Setting #2 --- High Setting #3 104 3A2098H Appendix A - Advanced Display Module (ADM) Fluid Plate Setup Screens There are nine fluid plate setup screens, which enable users to: • • • • • • • • Set controls and valve commands Set on and off delays for valves and the regulator Set k-factor, pressure, and flow rate variables Set offsets for inlet and outlet pressures Set error types Set variables for maintenance advisories Define styles Associate swirl dispenser with fluid plate Press • Set the Run Mode Bead Adjust to Enable or Disable. NOTE: Run mode bead adjust allows a user to quickly adjust flow rate or pressure from the run screen. to scroll through the fluid plate setup screens. Once in the desired screen, press access the fields to make changes. Press to 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: • • • • Set the dispense trigger source to Gateway, Command Cable, Command Cable 3x, or Combined. If it is set to Command Cable, users can enable the valves. Set the command value source to Gateway, Command Cable, or Display. Set the Job End Timer to Timer or Gateway. If this field is set to Timer, users can set Job End Delay. Set the Display Control Password to Enable or Disable. When entering maintenance mode, a password prompt will appear if the Display Control Password is set to Enable and a password is set in the Advanced setup screens. 3A2098H 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. • • Each valve is set to Pressure mode and has identical command values. Each valve is set to Full Open mode. 105 Appendix A - Advanced Display Module (ADM) Attempting to dispense from multiple valves simultaneously using any other combination will cause an Incompatible Valves Settings alarm. 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 explanation of the on and off delays, refer to the On/Off Delays section on page 39. 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. 106 3A2098H Appendix A - Advanced Display Module (ADM) Fluid Plate x, Screen 5 (Pressure Sensors) Fluid Plate x, Screen 6 (Error Type) NOTE: Inlet sensor settings will be grayed out on this screen for systems with heated fluid plates. 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. This screen enables users to: • • • Set the offset for the inlet and outlet pressures. NOTE: The offset value must be set to a non-zero value before ‘-’ can be selected from the +/drop-down menu. Set the minimum and maximum pressure limits for the inlet, and the maximum pressure limit for the outlet. Set the error type (alarm or deviation) that will be issued if the inlet and/or outlet pressure go outside of the set limits. 3A2098H NOTE: Only the low/high pressure errors will be enabled for systems without a flow meter. • • The pressure and flow rate errors are relative to the value commanded (through the command cable, gateway or display) The volume is relative to the requested volume and computed target errors are relative to the target volume defined in the style 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 that will trigger a maintenance advisory for the air 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 3 (Maintenance Totalizers), page 113, for more information about maintenance totalizers. 108 Fluid Plate x, Screen 8 (Style) This screen enables users to set up to 256 styles, depending on system configuration. Press to access the style setup fields. Enter the style number in the Style field, the target volume in the Volume field, and the tolerance percentage in the Tolerance field. 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. 3A2098H Appendix A - Advanced Display Module (ADM) Fluid Plate x, Screen 9 (Swirl Association) Swirl Setup Screen 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. This screen enables users to: • • • • Set the Speed Command Source to Display or Gateway. If it is set to Display, users can set the fixed speed Set the Run Mode Speed Adjust to Enable or Disable Set the speed scale from 50-150% Set the Swirl Orbiter Maintenance Advisory Limit 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 the entire style name entered, press . To enter the style name, press . To cancel the entry and exit the keyboard screen, press 3A2098H . 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 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: • • • • • 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: • • • Requested motor speed Actual motor speed Progress bar indicating requested and actual motor speed 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). 3A2098H Appendix A - Advanced Display Module (ADM) The PCF system has two operating modes: 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 dispense volume. From this screen users can adjust the bead scale and enter maintenance mode. Press and • Dispense mode – enables the module to begin dispensing when it receives a command from the automation unit. • Maintenance mode – enables the module to begin dispensing when the user presses the manual dispense button. Dispense parameters and duration depend on the selected control. to Dispensing continues for as long as the manual dis- change the bead scale. Press to enter mainte- pense button is pressed. nance mode. Current Dispense Control Mode Inlet Pressure (non-heated systems) Outlet Pressure Command Voltage (Displays only when Command Cable or Gateway is selected as the Command Value Source; see Fluid Plate Setup Screens, page 105.) Flow Rate (systems with flow meters) Current Command Value Active Dispense Valves Bead Scale Quickly adjust pressure/flowrate from this screen Active Style 3A2098H Progress Bar Volumes Associated Swirl Dispensers 111 Appendix A - Advanced Display Module (ADM) Maintenance Mode Dispense Control Modes Press The PCF system has four fluid dispensing control modes. from Fluid Plate x, screen 1 (Control Center) to enter maintenance mode. Maintenance mode enables users to change the control mode, volume to be dispensed, target pressure, and number of dispense valves used in the system. NOTE: Volume, pressure, and dispense valve options change according to mode. • Bead Control – the system controls the flow rate of the material being dispensed. The regulator outlet pressure is varied to control the fluid flow rate to the requested value. Use the bead control when a consistent bead size is required. • Shot Control – the regulator outlet pressure is controlled to the requested value. The dispense valve is closed when the target volume is reached or when the automation controller provides a signal. • Pressure Control – the regulator outlet pressure is controlled to the requested value. • Full Open Control – the PCF system does not control fluid pressure or flow. Instead the regulator opens to allow for recirculation applications. See Maintenance Mode Operation, page 41, for instructions on changing the control mode, target pressure, and number of dispense valves used. 112 3A2098H Appendix A - Advanced Display Module (ADM) Fluid Plate x, Screen 2 (Control Center) Fluid Plate x, Screen 3 (Maintenance Totalizers) NOTE: Users must be out of maintenance mode in Fluid Plate x, screen 1 in order to scroll to this screen. This screen enables users to view the maintenance totalizers for each system component and the limits set that will trigger a maintenance advisory. NOTE: The term “Robot” on this screen refers to the automation controller. This screen enables users to view and monitor the current status of the “robot” outputs and inputs. An X is displayed in the applicable check box when: • • • • • • • Using a style strobe The dispense is complete A dispense trigger occurs The dispenser (fluid plate) is ready The dispense is in process There are no alarms or errors The dispense volume is correct 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 (Maintenance 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. This screen also displays the current dispense style, command voltage, Gateway error number/code, and the volume dispensed. 3A2098H 113 Appendix A - Advanced Display Module (ADM) Swirl X Screen There is one Swirl X screen for each installed swirl dispenser. This screen displays the following items: • • • • Press to scroll through each event report screen. Swirl Enable signal from the automation interface Speed command voltage from automation interface Actual and requested speed Active time and maintenance advisory limit Error Report Screens 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 completed; the style dispensed; the error percentage; and the target, requested, and actual dispense volumes. Press 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 error. 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. to scroll through each job report screen. 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 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 interface signals. NOTE: See Appendix D - I/O Signal Descriptions, page 138, for I/O signal descriptions. D-Sub Pin No. 51 and 27 Wire Color Description Pin Type Green/Yellow Isolated Logic Power Supply Supply Gray Isolated Logic GND Supply 70 Blue/Green Dispense Ready Digital Output 9 Brown/Green Dispense Error* Digital Output 11 Blue/Orange Dispense In Process Digital Output 12 White Dispense Purge Digital Output 15 Blue Dispense Remote Start Digital Output 16 White/Yellow Style Bit 1 Digital Input 52 Blue/Yellow Style Bit 2 Digital Input 53 Brown/Yellow Style Bit 3 Digital Input 54 Black/Red Style Bit 4 Digital Input 55 White/Red Style Strobe Digital Input 56 Blue/Red Dispense Complete Digital Input 57 Brown/Red Error Reset Digital Input 58 Black Remote Start/Purge Digital Input 59 Black/Gray Dispense Valve 1 Digital Input 73 Brown/Orange Dispense Valve 2 Digital Input 74 Brown Command Value Analog Input 1 Black/Yellow Analog GND Analog Input 2 White/Gray --- Blue/Gray Swirl 1 Speed Command ◆ Analog Input 21 Brown/Gray Analog Input 23 Digital Input 75 Digital Input 76 Black/Green Swirl 2 Speed Command ◆ Dispense Valve 3/ Swirl 1 Enable◆ Dispense Valve 4/ Swirl 2 Enable◆ Digital CMD 1 Digital Input 77 White/Green Digital CMD 2 Digital Input 78 Orange --- White/Orange Black/Orange 3 N/C ◆ Swirl-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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 - 50 51 52 53 54 55 56 116 Description Command Value (Fluid Plate 1) Command Value Ground (Fluid Plate 1) Command Value (Fluid Plate 2) Command Value Ground (Fluid Plate 2) Pin Type Analog In Analog In Ground Analog In Analog In Ground Voltage (Vdc) 0 - 10 0 0 - 10 0 ◆ Dispense Ready ◆† Dispense Alarm/Error on Data ◆† Dispense Error ◆ Dispense In Process ◆ Dispense Volume OK Fluid Plate Selected ◆ Dispense Purge ◆ Dispense Remote Start ◆ * Data 1 ◆ * Data 2 ◆ * Data 4 ◆ * Data 8 Swirl 1 Speed Command Swirl 1 Speed Command Ground Swirl 2 Speed Command Swirl 2 Speed Command Ground Digital Out - Bank 1 Digital Out - Bank 1 Digital Out - Bank 1 Digital Out - Bank 1 Digital Out - Bank 1 Fluid Plate Selected Digital Out - Bank 1 Digital Out - Bank 1 Digital Out - Bank 2 Digital Out - Bank 2 Digital Out - Bank 2 Digital Out - Bank 2 Analog In Analog In Ground Analog In Analog In Ground 0 - voltage connected to Pin 27 0 - voltage connected to Pin 27 0 - voltage connected to Pin 27 0 - voltage connected to Pin 27 0 - voltage connected to Pin 27 Fluid Plate Selected 0 - voltage connected to Pin 27 0 - voltage connected to Pin 27 0 - voltage connected to Pin 68 0 - voltage connected to Pin 68 0 - voltage connected to Pin 68 0 - voltage connected to Pin 68 0 - 10 0 0 - 10 0 Digital Out Supply - Bank 1 ◆ * Data 16 ◆ * Data 32 ◆ * Data 64 ◆ * Data 128 ◆ * Data 256 ◆ * Data 512 ◆ * Data 1024 ◆ * Data 2048 ◆ * Data 4096 ◆ * Data 8192 ◆ * Data 16384 ◆ * Data 32768 Swirl 1 Actual Speed Swirl 1 Actual Speed Ground Swirl 2 Actual Speed Swirl 2 Actual Speed Ground Isolated Logic Supply V+ Digital Out - Bank 2 Digital Out - Bank 2 Digital Out - Bank 2 Digital Out - Bank 2 Digital Out - Bank 3 Digital Out - Bank 3 Digital Out - Bank 3 Digital Out - Bank 3 Digital Out - Bank 3 Digital Out - Bank 3 Digital Out - Bank 3 Digital Out - Bank 3 Analog Out Analog Out Ground Analog Out Analog Out Ground 10-30 0 - voltage connected to Pin 68 0 - voltage connected to Pin 68 0 - voltage connected to Pin 68 0 - voltage connected to Pin 68 0 - voltage connected to Pin 69 0 - voltage connected to Pin 69 0 - voltage connected to Pin 69 0 - voltage connected to Pin 69 0 - voltage connected to Pin 69 0 - voltage connected to Pin 69 0 - voltage connected to Pin 69 0 - voltage connected to Pin 69 0 - 10 0 0 - 10 0 Isolated Logic Power Supply Style Bit 1 Style Bit 2 Style Bit 3 Style Bit 4 Style Strobe Fluid Plate 1 Isolated Logic Supply V+ Digital In Digital In Digital In Digital In Digital In 10-30 0-30 0-30 0-30 0-30 0-30 3A2098H Appendix B - Discrete Gateway Module (DGM) Connection Details D-Sub Pin No. 57 58 59 60 -67 68 69 70 71 72 73 74 75 76 77 78 * Description ◆ Dispense Complete ◆ Error Reset ◆ Remote Start/Purge Pin Type Digital In Digital In Digital In Voltage (Vdc) 0-30 0-30 0-30 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 Digital CMD 1 Digital CMD 2 Isolated Logic Supply V+ Isolated Logic Supply V+ Isolated Ground Digital In Digital In Digital In 10-30 10-30 0 0-30 0-30 0-30 Digital In 0-30 Digital In 0-30 Digital In 0-30 Digital In Digital In 0-30 0-30 16-bit data outputs contain either volume or error information depending on state of dispense alarm/error on data. ◆ 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. † 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. 3A2098H 117 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. 1 21 20 40 39 60 59 78 FIG. 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. • • Pins: 52 – 59, 71-78 Type: Sinking • Discrete Gateway Maximum current draw: 3.6 mA Customer Automation D-Sub Pin 51 (Isolated Logic Supply), Supply) 10-30 VDC Isolated Logic ICs Digital Input Microcontroller Optical 24VDC Isolator D-Sub Pin 70 (Isolated Ground) 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. • • Pins: 9-20, 28-39 Type: Sourcing • Maximum continuous current output: 350 mA (sourced from customer supply) Recommended continuous current: 100 mA • Discrete Gateway Customer Automation D-Sub Pin 51 (Isolated Logic Supply) Isolated Logic ICs Digital Output Supply Bank 1 D-Sub Pin 27 Microcontroller Optical Isolator Digital Output 1-8 D-Sub Pin 69 LOAD Digital Output Supply Bank 2 24VDC Digital Output 9-16 LOAD D-Sub Pin 68 Digital Output Supply Bank 3 Digital Output 17-24 LOAD 24VDC D-Sub Pin 70 (Isolated Ground) 120 3A2098H Appendix B - Discrete Gateway Module (DGM) Connection Details DGM Analog Inputs The analog inputs function only when the DGM is connected to a power supply through the CAN connection. Each analog input has a corresponding reference (ground) pin. See Pin References, page 118, for details. • • Type: Sinking Voltage Rating: 0-10 Vdc • Input Impedance: 20 k Ω Discrete Gateway Analog Input + Microcontroller + 20kΩ Analog Input - DGM Analog Outputs 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. • Type: Sourcing • Voltage Rating: 0-10 Vdc, 10 mA at 10 Vdc Discrete Gateway Analog Output + Microcontroller 0-10VDC @10mA + Analog Output - 3A2098H 121 Appendix C - Communications Gateway Module (CGM) Connection Details Appendix C - Communications Gateway Module (CGM) Connection Details Install Fieldbus Connections Connect cables to fieldbus per fieldbus standards. PROFINET Module Status (MS) State Link Not initialized No power or module in “SETUP” or “NW_INIT” state Green Normal operation Diagnostic event(s) present Flashing Green Initialized, diagnostic event(s) present Used by engineering tools to identify node on network Red Exception error Module in state “EXCEPTION” Red (1 flash) Configuration error Expected Identification differs from Real Identification Red (2 flashes) IP Address not set Set IP address via system monitor or DNS server Red (3 flashes) Station Name not set Set Station Name via system monitor Red (4 flashes) Major Internal Error Cycle system power; replace module TI11814A FIG. 69: PROFINET 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) State Description Comments Off Offline • • No power No connection with IO Controller Green On-line, (RUN) • Connection with IO Controller established IO Controller with RUN state • Flashing Green On-line, (STOP) • • 122 Connection with IO Controller established IO Controller in STOP state Comments Off MS NS Description Link/Activity (Link) State Description Off No Link, no communication present Green Link established, no communication present Green, flashing Link established, communication present 3A2098H Appendix C - Communications Gateway Module (CGM) Connection Details EtherNet/IP DeviceNet MS NS MS Link NS 1 2 TI11814A 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. TI11815A Network Status (NS) State Description Off No power or no IP address Green On-line, one or more connections established (CIP Class 1 or 3) Flashing Green On-line, no connections established Red Duplicate IP address, FATAL error Flashing Red One or more connections timed out (CIP Class 1 or 3) Module Status (MS) State Description Off Not online / No power Green On-line, one or more connections are established Flashing Green (1 Hz) On-line, no connections established Red Critical link failure Flashing Red (1 Hz) One or more connections timed-out Alternating Red/Green Self test Module Status (MS) Description Off No power Green Controlled by a Scanner in Run state Flashing Green Not configured, or Scanner in Idle state Red Flashing Red State Description Off No power or not initialized Green Initialized Flashing Green (1 Hz) Missing or incomplete configuration, device needs commissioning Major fault (EXCEPTION-state, FATAL error etc.) Red Unrecoverable Fault(s) Recoverable fault(s) Flashing Red (1 Hz) Recoverable Fault(s) Alternating Red/Green Self test LINK/Activity (Link) State Description Off No link, no activity Green Link established Flashing Green Activity 3A2098H 4 5 DC FIG. 71: DeviceNet Fieldbus Connections Network Status (NS) State 3 DeviceNet Connector (DC) Pin Signal Description 1 V- Negative bus supply voltage 2 CAN_L CAN low bus line 3 SHIELD Cable shield 4 CAN_H CAN high bus line 5 V+ Positive bus supply voltage 123 Appendix C - Communications Gateway Module (CGM) Connection Details PROFIBUS Connector (DC) PROFIBUS OP ST 5 4 3 2 1 DC 9 8 7 6 TI11816A FIG. 72: PROFIBUS Fieldbus Connections Operation Mode (OP) State Off Description Not online / No power Green On-line, data exchange Flashing Green On-line, clear Flashing Red (1 flash) Parameterization error Flashing Red (2 flashes) PROFIBUS Configuration error Pin 1 2 3 4 5 6 Signal B Line RTS GND Bus +5V Bus Output 7 8 A Line 9 Housing Cable Shield Description Positive RxD/TxD, RS485 level Request to send Ground (isolated) +5V termination power (isolated) Negative RxD/TxD, RS485 level Internally connected to the Anybus protective earth via cable shield filters according to the PROFIBUS standard. Status Mode (ST) State Description Off No power or not initialized Green Initialized Flashing Green Initialized, diagnostic event(s) present Red Exception error 124 3A2098H Appendix C - Communications Gateway Module (CGM) Connection Details CGM I/O Data Map Byte See Appendix D - I/O Signal Descriptions on page 138. 5 Automation Inputs (signals from PCF) Byte 0 Input Bit I00 I01 I02 I03 I04 I05 I06 I07 1 2 3 4 I08 I09 I10 I11 I12 I13 I14 I15 I16 I17 I18 I19 I20 I21 I22 I23 I24 I25 I26 I27 I28 I29 I30 I31 I32 I33 I34 I35 I36 I37 I38 I39 3A2098H Description Dispenser (Fluid Plate) Ready Dispenser (Fluid Plate) No Alarm Dispense No Error Dispense in Process Dispense Volume OK --Dispenser (Fluid Plate) Purge Request Dispenser (Fluid Plate) Remote Start / Purge In Process Pressure Units - Bit 0 Pressure Units - Bit 1 ----------------------------Error - 1 Error - 2 Error - 4 Error - 8 Error - 16 Error - 32 Error - 64 Error - 128 Dispenser (Fluid Plate) Ready Dispenser (Fluid Plate) No Alarm Dispense No Error Dispense in Process Dispense Volume OK --Dispenser (Fluid Plate) Purge Request Dispenser (Fluid Plate) Remote Start / Purge In Process Zone Fluid Plate 1 6 7 Fluid Plate 1 Fluid Plate 1 8 Input Bit I40 I41 I42 I43 I44 I45 I46 I47 I48 I49 I50 I51 I52 I53 I54 I55 I56 I57 I58 I59 I60 I61 I62 I63 I64 I65 I66 I67 I68 I69 I70 I71 Fluid Plate 1 Fluid Plate 2 9 10 I72 I73 I74 I75 I76 I77 I78 I79 I80 I81 I82 I83 I84 I85 I86 I87 Description Pressure Units - Bit 0 Pressure Units - Bit 1 ----------------------------Error - 1 Error - 2 Error - 4 Error - 8 Error - 16 Error - 32 Error - 64 Error - 128 Dispenser (Fluid Plate) Ready Dispenser (Fluid Plate) No Alarm Dispense No Error Dispense in Process Dispense Volume OK --Dispenser (Fluid Plate) Purge Request Dispenser (Fluid Plate) Remote Start / Purge In Process Pressure Units - Bit 0 Pressure Units - Bit 1 ----------------------------- Zone Fluid Plate 2 Fluid Plate 2 Fluid Plate 2 Fluid Plate 3 Fluid Plate 3 Fluid Plate 3 125 Appendix C - Communications Gateway Module (CGM) Connection Details Byte 11 12 Input Bit I88 I89 I90 I91 I92 I93 I94 I95 I96 I97 I98 I99 I100 I101 I102 I103 13 14 15 16 126 I104 I105 I106 I107 I108 I109 I110 I111 I112 I113 I114 I115 I116 I117 I118 I119 I120 I121 I122 I123 I124 I125 I126 I127 I128 I129 I130 I131 I132 I133 I134 I135 Description Zone Error - 1 Error - 2 Error - 4 Error - 8 Fluid Error - 16 Plate 3 Error - 32 Error - 64 Error - 128 Dispenser (Fluid Plate) Ready Dispenser (Fluid Plate) No Alarm Dispense No Error Dispense in Process Dispense Volume OK Fluid --Plate 4 Dispenser (Fluid Plate) Purge Request Dispenser (Fluid Plate) Remote Start / Purge In Process Pressure Units - Bit 0 Pressure Units - Bit 1 --Fluid --Plate 4 ----------------Fluid --Plate 4 ------Error - 1 Error - 2 Error - 4 Error - 8 Fluid Error - 16 Plate 4 Error - 32 Error - 64 Error - 128 Command Interface - Value - Bit 0 See CGM Command Interface on page 131 for command interface details. All Fluid Command Interface - Value - Bit 1 Command Interface - Value - Bit 2 Plates/Swi rls Command Interface - Value - Bit 3 Command Interface - Value - Bit 4 Command Interface - Value - Bit 5 Command Interface - Value - Bit 6 Command Interface - Value - Bit 7 Byte 17 18 19 Input Bit I136 I137 I138 I139 I140 I141 I142 I143 I144 I145 I146 I147 I148 I149 I150 I151 I152 I153 I154 I155 I156 I157 I158 I159 I160 I161 I162 20 2125 I163 Description Command Interface - Value - Bit 8 Command Interface - Value - Bit 9 Command Interface - Value - Bit 10 Command Interface - Value - Bit 11 Command Interface - Value - Bit 12 Command Interface - Value - Bit 13 Command Interface - Value - Bit 14 Command Interface - Value - Bit 15 Command Interface - Value - Bit 16 Command Interface - Value - Bit 17 Command Interface - Value - Bit 18 Command Interface - Value - Bit 19 Command Interface - Value - Bit 20 Command Interface - Value - Bit 21 Command Interface - Value - Bit 22 Command Interface - Value - Bit 23 Command Interface - Value - Bit 24 Command Interface - Value - Bit 25 Command Interface - Value - Bit 26 Command Interface - Value - Bit 27 Command Interface - Value - Bit 28 Command Interface - Value - Bit 29 Command Interface - Value - Bit 30 Command Interface - Value - Bit 31 Command Interface Status - Command Active Command Interface Status - Command Success Command Interface Status - Command Failure Command Interface Status - Value Coerced --------- I164 I165 I166 I167 I168--I207 Zone All Fluid Plates/Swi rls All Fluid Plates/Swi rls All Fluid Plates/Swi rls All Fluid Plates/Swi rls --- 3A2098H Appendix C - Communications Gateway Module (CGM) Connection Details Automation Outputs (signals to PCF) Output Byte Bit O00 O01 O02 O03 0 O04 O05 O06 O07 O08 O09 O10 O11 1 O12 O13 O14 O15 O16 O17 O18 O19 2 O20 O21 O22 O23 O24 O25 O26 O27 3 O28 O29 O30 O31 O32 O33 O34 O35 4 O36 O37 O38 O39 O40 O41 O42 O43 5 O44 O45 O46 O47 3A2098H Byte Description Style Strobe Dispense Complete Dispense Valve 1 On Dispense Valve 2 On Dispense Valve 3 On Dispense Valve 4 On Error Reset / Cancel Job Remote Start / Purge Swirl Enable --------------Style - 1 Style - 2 Style - 4 Style - 8 Style - 16 Style - 32 Style - 64 Style - 128 Dispense Valve 1 Precharge On Dispense Valve 2 Precharge On Dispense Valve 3 Precharge On Dispense Valve 4 Precharge On --------Command Value - 1 Command Value - 2 Command Value - 4 Command Value - 8 Command Value - 16 Command Value - 32 Command Value - 64 Command Value - 128 Command Value - 256 Command Value - 512 Command Value - 1024 Command Value - 2048 --------- Zone 6 Fluid Plate 1 7 Swirl 1 8 Fluid Plate 1 9 Fluid Plate 1 10 Fluid Plate 1 11 Fluid Plate 1 Output Bit O48 O49 O50 O51 O52 O53 O54 O55 O56 O57 O58 O59 O60 O61 O62 O63 O64 O65 O66 O67 O68 O69 O70 O71 O72 O73 O74 O75 O76 O77 O78 O79 O80 O81 O82 O83 O84 O85 O86 O87 O88 O89 O90 O91 O92 O93 O94 O95 Description Swirl Command Value - 1 Swirl Command Value - 2 Swirl Command Value - 4 Swirl Command Value - 8 Swirl Command Value - 16 Swirl Command Value - 32 Swirl Command Value - 64 Swirl Command Value - 128 Swirl Command Value - 256 Swirl Command Value - 512 Swirl Command Value - 1024 Swirl Command Value - 2048 --------Style Strobe Dispense Complete Dispense Valve 1 On Dispense Valve 2 On Dispense Valve 3 On Dispense Valve 4 On Error Reset / Cancel Job Remote Start / Purge Swirl Enable --------------Style - 1 Style - 2 Style - 4 Style - 8 Style - 16 Style - 32 Style - 64 Style - 128 Dispense Valve 1 Precharge On Dispense Valve 2 Precharge On Dispense Valve 3 Precharge On Dispense Valve 4 Precharge On --------- Zone Swirl 1 Swirl 1 Fluid Plate 2 Swirl 2 Fluid Plate 2 Fluid Plate 2 127 Appendix C - Communications Gateway Module (CGM) Connection Details Byte 12 13 14 15 16 17 18 128 Output Bit O96 O97 O98 O99 O100 O101 O102 O103 O104 O105 O106 O107 O108 O109 O110 O111 O112 O113 O114 O115 O116 O117 O118 O119 O120 O121 O122 O123 O124 O125 O126 O127 O128 O129 O130 O131 O132 O133 O134 O135 O136 O137 O138 O139 O140 O141 O142 O143 O144 O145 O146 O147 O148 O149 O150 O151 Description Command Value - 1 Command Value - 2 Command Value - 4 Command Value - 8 Command Value - 16 Command Value - 32 Command Value - 64 Command Value - 128 Command Value - 256 Command Value - 512 Command Value - 1024 Command Value - 2048 --------Swirl Command Value - 1 Swirl Command Value - 2 Swirl Command Value - 4 Swirl Command Value - 8 Swirl Command Value - 16 Swirl Command Value - 32 Swirl Command Value - 64 Swirl Command Value - 128 Swirl Command Value - 256 Swirl Command Value - 512 Swirl Command Value - 1024 Swirl Command Value - 2048 --------Style Strobe Dispense Complete Dispense Valve 1 On Dispense Valve 2 On Dispense Valve 3 On Dispense Valve 4 On Error Reset / Cancel Job Remote Start / Purge Swirl Enable --------------Style - 1 Style - 2 Style - 4 Style - 8 Style - 16 Style - 32 Style - 64 Style - 128 Zone Byte Fluid Plate 2 19 Fluid Plate 2 20 Swirl 2 21 Swirl 2 22 Fluid Plate 3 23 Swirl 3 24 Fluid Plate 3 25 Output Bit O152 O153 O154 O155 O156 O157 O158 O159 O160 O161 O162 O163 O164 O165 O166 O167 O168 O169 O170 O171 O172 O173 O174 O175 O176 O177 O178 O179 O180 O181 O182 O183 O184 O185 O186 O187 O188 O189 O190 O191 O192 O193 O194 O195 O196 O197 O198 O199 O200 O201 O202 O203 O204 O205 O206 O207 Description Dispense Valve 1 Precharge On Dispense Valve 2 Precharge On Dispense Valve 3 Precharge On Dispense Valve 4 Precharge On --------Command Value - 1 Command Value - 2 Command Value - 4 Command Value - 8 Command Value - 16 Command Value - 32 Command Value - 64 Command Value - 128 Command Value - 256 Command Value - 512 Command Value - 1024 Command Value - 2048 --------Swirl Command Value - 1 Swirl Command Value - 2 Swirl Command Value - 4 Swirl Command Value - 8 Swirl Command Value - 16 Swirl Command Value - 32 Swirl Command Value - 64 Swirl Command Value - 128 Swirl Command Value - 256 Swirl Command Value - 512 Swirl Command Value - 1024 Swirl Command Value - 2048 --------Style Strobe Dispense Complete Dispense Valve 1 On Dispense Valve 2 On Dispense Valve 3 On Dispense Valve 4 On Error Reset / Cancel Job Remote Start / Purge Swirl Enable --------------- Zone Fluid Plate 3 Fluid Plate 3 Fluid Plate 3 Swirl 3 Swirl 3 Fluid Plate 4 Swirl 4 3A2098H Appendix C - Communications Gateway Module (CGM) Connection Details Byte 26 27 28 29 30 31 Output Bit O208 O209 O210 O211 O212 O213 O214 O215 O216 O217 O218 O219 O220 O221 O222 O223 O224 O225 O226 O227 O228 O229 O230 O231 O232 O233 O234 O235 O236 O237 O238 O239 O240 O241 O242 O243 O244 O245 O246 O247 O248 O249 O250 O251 O252 O253 O254 O255 3A2098H Description Style - 1 Style - 2 Style - 4 Style - 8 Style - 16 Style - 32 Style - 64 Style - 128 Dispense Valve 1 Precharge On Dispense Valve 2 Precharge On Dispense Valve 3 Precharge On Dispense Valve 4 Precharge On --------Command Value - 1 Command Value - 2 Command Value - 4 Command Value - 8 Command Value - 16 Command Value - 32 Command Value - 64 Command Value - 128 Command Value - 256 Command Value - 512 Command Value - 1024 Command Value - 2048 --------Swirl Command Value - 1 Swirl Command Value - 2 Swirl Command Value - 4 Swirl Command Value - 8 Swirl Command Value - 16 Swirl Command Value - 32 Swirl Command Value - 64 Swirl Command Value - 128 Swirl Command Value - 256 Swirl Command Value - 512 Swirl Command Value - 1024 Swirl Command Value - 2048 --------- Zone Byte Fluid Plate 4 32 Fluid Plate 4 Fluid Plate 4 Fluid Plate 4 33 Swirl 4 34 Swirl 4 35 Output Bit Description Command Interface - Command Bit 0 O256 See CGM Command Interface on page 131 for command interface details. Command Interface - Command O257 Bit 1 Command Interface - Command O258 Bit 2 Command Interface - Command O259 Bit 3 Command Interface - Command O260 Bit 4 Command Interface - Command O261 Bit 5 Command Interface - Command O262 Bit 6 Command Interface - Command O263 Bit 7 Command Interface - Command O264 Bit 8 Command Interface - Command O265 Bit 9 Command Interface - Command O266 Bit 10 Command Interface - Command O267 Bit 11 Command Interface - Command O268 Bit 12 Command Interface - Command O269 Bit 13 Command Interface - Command O270 Bit 14 Command Interface - Command O271 Bit 15 Command Interface - Command O272 Bit 16 Command Interface - Command O273 Bit 17 Command Interface - Command O274 Bit 18 Command Interface - Command O275 Bit 19 O276 --O277 --O278 --O279 --O280--O287 Zone All Fluid Plates/S wirls All Fluid Plates/S wirls All Fluid Plates/S wirls --- 129 Appendix C - Communications Gateway Module (CGM) Connection Details Byte 36 37 38 39 40 41 130 Output Bit Description Command Interface - Value - Bit 0 See CGM Command Interface on O288 page 131 for command interface details. O289 Command Interface - Value - Bit 1 O290 Command Interface - Value - Bit 2 O291 Command Interface - Value - Bit 3 O292 Command Interface - Value - Bit 4 O293 Command Interface - Value - Bit 5 O294 Command Interface - Value - Bit 6 O295 Command Interface - Value - Bit 7 O296 Command Interface - Value - Bit 8 O297 Command Interface - Value - Bit 9 O298 Command Interface - Value - Bit 10 O299 Command Interface - Value - Bit 11 O300 Command Interface - Value - Bit 12 O301 Command Interface - Value - Bit 13 O302 Command Interface - Value - Bit 14 O303 Command Interface - Value - Bit 15 O304 Command Interface - Value - Bit 16 O305 Command Interface - Value - Bit 17 O306 Command Interface - Value - Bit 18 O307 Command Interface - Value - Bit 19 O308 Command Interface - Value - Bit 20 O309 Command Interface - Value - Bit 21 O310 Command Interface - Value - Bit 22 O311 Command Interface - Value - Bit 23 O312 Command Interface - Value - Bit 24 O313 Command Interface - Value - Bit 25 O314 Command Interface - Value - Bit 26 O315 Command Interface - Value - Bit 27 O316 Command Interface - Value - Bit 28 O317 Command Interface - Value - Bit 29 O318 Command Interface - Value - Bit 30 O319 Command Interface - Value - Bit 31 Command Interface - Control Bits O320 Read Command Interface - Control Bits O321 Write O322 --O323 --O324 --O325 --O326 --O327 --O328--O335 Zone All Fluid Plates/S wirls All Fluid Plates/S wirls All Fluid Plates/S wirls All Fluid Plates/S wirls All Fluid Plates/S wirls --- 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 I/O 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 system setting (write). • • • • • Output bits 256-267 are used to identify the individual command. Each bit will have a single binary value to create the hex code listed in the commands table. Output bits 268-275 are used to identify the individual Fluid Plate or Swirl dispenser to which the commands will apply. Output bits 288-319 are used to identify the value of the command specified by bits 256-267 and 268-275. Output bit 321 identifies the command as a write command. Output bit 320 identifies the command as a read command. Examples NOTE: See the timing diagram and tables starting on page 132 for detailed descriptions of the input and output bits. Example 1: if output bits 256-275 are 0xB0203, output bits 288-319 are 0x0004, and output bit 321 is high, this means: • • • • The command relates to the purge period in minutes (0x__203) The command relates to fluid plate 1 (0xB0___) The command is a write command (bit 321 high) The value of the command is 4 (0x0004) Combine these individual pieces to understand the command 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 0x0000, and output bit 320 is high, this means: • • • • The command relates to whether valve 1 is enabled (0x__212) The command relates to fluid plate 4 (0xB3___) The command is a read command (bit 320 high) The value of the command is 0 (0x0000) Combined, this means: Valve 1 on fluid plate 4 is disabled. 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 commands: • • • • 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 131 Appendix C - Communications Gateway Module (CGM) Connection Details Command Interface Timing Diagram Read Command Write Command Automation Outputs (PCF Inputs) Command Bits 256-275 Bits Set Value Bits 288-319 Bits Set Bits Set Write Bit 321 Read Bit 320 Automation Inputs (PCF Outputs) Value Bits 128-159 Bits Set Bits Set Command Active Bit 160 Command Success Bit 161 Command Failure Bit 162 Command Value Coerced Bit 163 FIG. 73: CGM Command Interface Timing Diagram Command Interface Write Operation 1. Set Command Identification Bits and Fluid Plate/Swirl Identification Bits to the desired values. 2. Set Value Bits (Output) with the value that is desired to be written. 3. Set Write Bit. 4. Wait for the Command Active Bit to become set. This indicates that an operation is in process. 5. Wait for the Command Success Bit, Command Failure Bit, or Command Value Coerced Bit to become set. NOTE: The Value Bits (Input) now contain the value that was actually written. 6. Clear the Write Bit to end the write command operation. Command Interface Read Operation 1. Set Command Identification Bits and Fluid Plate/Swirl Identification Bits to the desired values. 2. Set Read Bit. 3. Wait for the Command Active Bit to become set. This indicates that an operation is in process. 132 4. Wait for the Command Success Bit or Command Failure Bit to become set. NOTE: If Command Success Bit has been set, valid data will be present within the Value Bits (Input). 5. Clear the Read Bit to end the read command operation. Fluid Plate/Swirl Identification Commands Output Bits 268-275 0xB0 0xB1 0xB2 0xB3 0xE1 0xE2 0xE3 0xE4 Description Fluid Plate 1 Fluid Plate 2 Fluid Plate 3 Fluid Plate 4 Swirl 1 Swirl 2 Swirl 3 Swirl 4 Fluid Plate Commands Output Bits 256-267 Description 0x004 Software Part Number 0x005 Software Part Number 0x006 Software Part Number Units *See Units Read or Definitions, page 137 Write STR_3_0 Read Only STR_7_4 Read Only STR_11_8 Read Only 3A2098H Appendix C - Communications Gateway Module (CGM) Connection Details Output Bits 256-267 Description 0x007 Software Part Number 0x008 Software Version 0x0DD Maintenance Units Type 0x0DF Enabled Styles 0x203 Purge Period 0x204 0x208 0x20F 0x210 0x211 0x2B5 0x212 0x213 0x214 0x215 0x216 0x217 0x218 0x219 0x21A 0x21B 0x21C 0x21D 0x21E 0x21F 0x230 3A2098H Dispense Trigger Source Command Value Source Bead Scale Units *See Units Read or Definitions, page 137 Write STR_15_12 Read Only Version Read Only Maintenance Units Enumeration ### #### (minutes) Read Only Dispense Trigger Source Enumeration Command Value Source Enumeration ### (percent) Job End Mode Job End Mode Enumeration Job End Delay Integer (Seconds) Time End Job On Boolean Alarm Valve 1 Enable Boolean Read Only Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Valve 2 Enable Boolean Read / Write Valve 3 Enable Boolean Read / Write Valve 4 Enable Boolean Read / Write Regulator On ### (mS) Read / Delay Write Regulator Off ### (mS) Read / Delay Write Valve 1 On ### (mS) Read / Delay Write Valve 2 On ### (mS) Read / Delay Write Valve 3 On ### (mS) Read / Delay Write Valve 4 On ### (mS) Read / Delay Write Valve 1 Off ### (mS) Read / Delay Write Valve 2 Off ### (mS) Read / Delay Write Valve 3 Off ### (mS) Read / Delay Write Valve 4 Off ### (mS) Read / Delay Write Flow Meter Flow Meter Type Enu- Read / Type meration Write Output Bits 256-267 Description 0x231 Flow Meter K-Factor 0x23C Outlet Pressure Sensor User Offset 0x23D Inlet Pressure Sensor User Offset 0x241 Maximum Outlet Pressure 0x248 Units *See Units Definitions, page 137 ##### (pulses/Liter, pulses/kg) sint32; #### (psi); ###.# (bar); ##.## (Mpa) sint32; #### (psi); ###.# (bar); ##.## (Mpa) uint32; #### (psi); ###.# (bar); ##.## (Mpa) Minimum Inlet uint32; #### (psi); Pressure ###.# (bar); ##.## (Mpa) Maximum Inlet uint32; #### (psi); Pressure ###.# (bar); ##.## (Mpa) Pressure Kp ####.## 0x249 Pressure Ki ####.## 0x247 Pressure Kd ####.## 0x254 Bead Kp ####.## 0x255 Bead Ki ####.## 0x260 Regulator Time Advisory Limit Regulator Volume/Mass Advisory Limit ###### (hours) 0x244 0x245 0x262 0x264 0x266 0x268 0x26A 0x26C Read or 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 Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Flow meter ###### (hours) Read / Time Advisory Write Limit Flow meter Volume: ###### Read / Volume/Mass (gal(US)); ###### Write Advisory Limit (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Supply Time ###### (hours) Read / Advisory Limit Write Supply VolVolume: ###### Read / ume/Mass (gal(US)); ###### Write Advisory Limit (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) V/P Time Advi- ###### (hours) Read / sory Limit Write 133 Appendix C - Communications Gateway Module (CGM) Connection Details Output Bits 256-267 Description 0x26E V/P Volume/Mass Advisory Limit 0x270 0x271 0x272 0x273 0x278 0x279 0x27A Valve 1 Time Advisory Limit Valve 2 Time Advisory Limit Valve 3 Time Advisory Limit Valve 4 Time Advisory Limit Valve 1 Volume/Mass Advisory Limit Valve 2 Volume/Mass Advisory Limit Valve 3 Volume/Mass Advisory Limit 0x27B Valve 4 Volume/Mass Advisory Limit 0x283 Swirl Fault Error Type Low Flow Rate Error Type High Flow Rate Error Type Low Pressure Error Type High Pressure Error Type High Outlet Pressure Error Type Low Volume Error Type High Volume Error Type Low Computed Target Error Type 0x284 0x285 0x286 0x287 0x289 0x28A 0x28B 0x28C 134 Units *See Units Definitions, page 137 Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) ###### (hours) ###### (hours) ###### (hours) ###### (hours) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Error Type Enumeration 2 Error Type Enumeration 1 Error Type Enumeration 1 Error Type Enumeration 1 Error Type Enumeration 1 Error Type Enumeration 2 Error Type Enumeration 1 Error Type Enumeration 1 Error Type Enumeration 1 Read or Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Output Bits 256-267 Description 0x28D High Computed Target Error Type 0x28E Low Inlet Pressure Error Type 0x28F High Inlet Pressure Error Type 0x292 Valve 1 Mode 0x293 Valve 2 Mode 0x294 Valve 3 Mode 0x295 Valve 4 Mode 0x296 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 Valve 1 10 VDC Analog Scale Pressure Valve 2 10 VDC Analog Scale Pressure Valve 3 10 VDC Analog Scale Pressure Valve 4 10 VDC Analog Scale Pressure Regulator Maintenance Dispensed Volume* Read / Write 0x297 Read / Write Read / Write 0x298 0x299 0x29A Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write 0x29B 0x29C 0x29D 0x302 0x303 Flow meter Maintenance Dispensed Volume* Units *See Units Definitions, page 137 Error Type Enumeration 1 Read or Write Read / Write Error Type Enumeration 2 Error Type Enumeration 2 Read / Write Read / Write Valve Mode Enumeration Valve Mode Enumeration Valve Mode Enumeration Valve Mode Enumeration 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) Pressure: #### (psi); ###.# (bar); ##.## (Mpa) Pressure: #### (psi); ###.# (bar); ##.## (Mpa) Pressure: #### (psi); ###.# (bar); ##.## (Mpa) Pressure: #### (psi); ###.# (bar); ##.## (Mpa) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) 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 3A2098H Appendix C - Communications Gateway Module (CGM) Connection Details Output Bits 256-267 Description 0x304 Supply Maintenance - Dispensed Volume* 0x305 0x308 0x309 0x30A 0x30B 0x312 0x313 0x314 0x315 0x318 0x319 0x31A 3A2098H V/P Maintenance - Dispensed Volume* Valve 1 Maintenance - Dispensed Volume* Valve 2 Maintenance - Dispensed Volume* Valve 3 Maintenance - Dispensed Volume* Valve 4 Maintenance - Dispensed Volume* Regulator Maintenance Dispense Time* Flow meter Maintenance Dispense Time* Supply Maintenance - Dispense Time* V/P Maintenance - Dispense Time* Valve 1 Maintenance - Dispense Time* Valve 2 Maintenance - Dispense Time* Valve 3 Maintenance - Dispense Time* Units *See Units Definitions, page 137 Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) Volume: ###### (gal(US)); ###### (gal(Uk)); ###### (Liters); Mass: ###### (lb), ###### (kg) ###### (hours) Read or Write Read / Write Read / Write Output Bits 256-267 Description 0x31B Valve 4 Maintenance - Dispense Time* 0x800 Purge Definition - Volume 0x801 Purge Definition - Pressure 0x802 Read / Write 0x803 0x804 Read / Write 0x805 0x806 Read / Write Read / Write 0x807 0xBFC 0xBFD Read / Write 0xBFE ###### (hours) Read / Write 0xBFF ###### (hours) Read / Write 0xC04 ###### (hours) Read / Write 0xC05 ###### (hours) Read / Write ###### (hours) Read / Write 0xC06 0xC07 0xC3C ###### (hours) Read / Write 0xC3D 0xC3E 0xC3F Purge Definition - Tolerances Purge Definition - Duration Style 1 Definition - Volume Style 1 Definition - Pressure Style 1 Definition - Tolerances Style 1 Definition - Precharge Settings Style 255 Definition - Volume Style 255 Definition - Pressure Style 255 Definition - Tolerances Style 255 Definition - Precharge Settings Style 1 Definition - Name Style 1 Definition - Name Style 1 Definition - Name Style 1 Definition - Name Style 15 Definition - Name Style 15 Definition - Name Style 15 Definition - Name Style 15 Definition - Name Units *See Units Read or Definitions, page 137 Write ###### (hours) Read / Write #####.# (cc) Pressure: #### (psi); ###.# (bar); ##.## (Mpa) Tolerances Type #### (seconds) #####.# (cc) Pressure: #### (psi); ###.# (bar); ##.## (Mpa) Tolerances Type Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Precharge Settings Type Read / Write #####.# (cc) Read / Write Read / Write Pressure: #### (psi); ###.# (bar); ##.## (Mpa) Tolerances Type Read / Write Precharge Settings Type --- STR_3_0 Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write STR_7_4 STR_11_8 STR_15_12 STR_3_0 STR_7_4 STR_11_8 STR_15_12 135 Appendix C - Communications Gateway Module (CGM) Connection Details Output Bits 256-267 Description 0x29E Pressure Units 0x29F Rate Units 0x2A0 Maintenance Volume Units Maintenance Mass Units Maintenance Time Units Valve 1 Swirl Association (Swirl Zone) Valve 2 Swirl Association (Swirl Zone) Valve 3 Swirl Association (Swirl Zone) Valve 4 Swirl Association (Swirl Zone) End Job On Alarm Style Bits 0x2A1 0x2A2 0x2AD 0x2AE 0x2AF 0x2B0 0x2B5 0x3FB 0x115 0x116 0x118 0x3FF 0x0FB 0x0FC 0x0DC 0x403 0x404 0x406 0x409 136 Units *See Units Definitions, page 137 Pressure Units Enumeration Rate Units Enumeration Volume Units Enumeration Mass Units Enumeration Mass Units Enumeration Swirl Enumeration Swirl Enumeration Read or Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Read / Write Swirl Enumeration Read / Write Swirl Enumeration Read / Write Boolean Read / Write ### Read / Write Command uint12 Read / Value Write Error Reset / Dispense Control 2 Bit- Read / Remote Start field Write Disable DisBoolean Read / pensing Write Dispense Con- Dispense Control 1 Bit- Read / trol field Write Inlet Pressure Pressure: #### (psi); Read Only ###.# (bar); ##.## (Mpa) Outlet PresPressure: #### (psi); Read Only sure ###.# (bar); ##.## (Mpa) Pressure Com- Pressure: #### (psi); Read Only mand ###.# (bar); ##.## (Mpa) Flowrate Com- ##### cc/min Read Only mand Flowrate ##### cc/min Read Only Actual Fluid Plate Sta- Fluid Plate Status 0 Read Only tus 0 bitfield Fluid Plate Gateway Error Number Read Only Faults Output Bits 256-267 Description 0x0FF Fluid Plate Dispensed Volume 0x0DB Active Fault Error Code 0x0F8 Fluid Plate Status Bits 0x0FE Requested Volume * Units *See Units Read or Definitions, page 137 Write #####.# (cc) Read Only Fault Error Code Read Only Fluid Plate Status bitfield #####.# (cc) Read Only Read Only Maintenance dispensed volume/time can only be set to 0. Swirl Commands Output Bits 264-275 Description Gateway Units Read or Write 0x004 Software Part Number STR_3_0 Read Only 0x005 Software Part Number STR_7_4 Read Only 0x006 Software Part Number STR_11_8 Read Only 0x007 Software Part Number STR_15_12 Read Only 0x00B Software Version Version Read Only 0x400 Swirl Speed Source Speed Source Enumeration Read / Write 0x401 Swirl Fixed Speed ##### (RPM) Read / Write 0x403 Swirl Speed Scaling ### (percent) Read / Write 0x404 Swirl Maintenance ###### (hours) Time Advisory Limit Read / Write 0x3FF Swirl - Actual Run Time ###### (hours) Read / Write 0x2FC Swirl Status Bits 1 Swirl Status Bitfield 1 Read Only 0x4FE Swirl Actual Speed ##### (RPM) Read Only 0x500 Swirl Control Swirl Control Enumeration Read / Write 0x501 Swirl Requested Speed uint12 Read / Write 3A2098H Appendix C - Communications Gateway Module (CGM) Connection Details Units Definitions Unit s String Command Value Source Enumeration Dispense Control 1 Bitfield Definition 0 - Display, 1 - Command Cable, 2 - Gateway Dispense Control 2 Bitfield Dispense Trigger Source Enumeration Error Type Enumeration 1 Error Type Enumeration 2 Fault Error Code Bit 14 - Error Reset, Bit 15 - Remote Start 0 - Command Cable, 1 - Gateway, 2 - Combined, 3 - Command Cable 3x Flow Meter Type Enumeration Fluid Plate Status 0 Bitfield Bit .........Function 0 ............Style Strobe 1 ............Dispense Complete 2 ............Valve 1 On 3 ............Valve 2 On 4 ............Valve 3 On 5 ............Valve 4 On 6 ............Error Reset 7 ............Remote Start/Purge 0 - None, 1 - Alarm, 2 - Deviation 1 - Alarm, 2 - Deviation A 32-bit string in the format of 0xDDCCBBAA where 0xAA represents the most significant character in the string and 0xDD represents the least significant character in the string. 1 - Volume, 2 - Mass Bit .........Function 0 ............Dispenser Ready 1 ............Dispense No Alarm 2 ............Dispense No Error 3 ............Dispense In Process 4 ............Dispensed Volume OK 5 ............--6 ............Dispenser Purge Request 7 ............Purge in Process/Remote Start in Process Fluid Plate Status Bitfield Bit .........Function 0-2 .........Operation Mode (see Valve Mode Enumeration) 3 ............Precharge Active 4 ............Valve 1 State 5 ............Valve 2 State 6 ............Valve 3 State 7 ............Valve 4 State 8 ............Ready to Dispense 9 ............In Job Cycle 10 ..........Job Cycle Complete 11 ......... Alarm Active 12 ......... Deviation Active 13 ......... Advisory Active 14 ......... Dispensing Disabled 15 ......... Fluid Plate Enabled 16 ......... Flowmeter Enabled 17 ......... Inlet Sensor Enabled 18 ......... Heated Plate 19 ......... Integrator Enabled 22 ......... Valve 1 Swirl Installed 23 ......... Valve 2 Swirl Installed 24 ......... Valve 3 Swirl Installed 25 ......... Valve 4 Swirl Installed 26 ......... Valve 1 Swirl Active 27 ......... Valve 2 Swirl Active 28 ......... Valve 3 Swirl Active 29 ......... Valve 4 Swirl Active 30 ......... Fault Reset 31 ......... Remote Start/Purge Job End Mode Enumeration Maintenance Units Enumeration Mass Units Enumeration Precharge Settings Type 0 - Timer, 1 - Gateway 0 - Volume, 1 - Mass, 2 - Time 0 - lb, 1 - kg A 32 bit value in the format of 0xDDCCBBA: Pressure Units Enumeration Rate Units Enumeration sint32 Speed Source Enumeration STR_X_Y Swirl Control Enumeration Swirl Enumeration Swirl Status Bitfield 1 Tolerances Type Valve Mode Enumeration uint12 uint32 Version Volume Units Enumeration 3A2098H 0xA........Precharge mode enumeration: 0 - Display, 1 - Gateway, 2 - Valve 1 0xBBB...Precharge valve opening duration (ms) 0xCC.....Precharge scale - valve closed (%) 0xDD.....Precharge scale - valve opening (%) 0 - psi, 1 - bar, 2 - MPa 0 - x/min, 1 - x/sec A 32 bit positive or negative value 0 - Display, 1 - Gateway A 32 bit value where X signifies which character in the string that the most significant byte represents and Y signifies which character in the string that the least significant byte represents. 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 0x0000BBAA where 0xAA represents the low tolerance (%) and 0xBB represents the high tolerance (%). A value of 0 means that tolerance is disabled. 0 - Pressure, 1 - Bead, 2 - Shot, 3 - Full Open A 12 bit positive value A 32 bit positive value A 32 bit value in the format of 0x00CCBBAA where 0xAA represents the major version, 0xBB represents the minor version and 0xCC 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 the CGM and DGM Automation Input and Output signals. Automation Inputs Dispenser (Fluid Plate) Ready This signal is 0 on power up. This signal will be 1 under in the following conditions: Dispenser (Fluid Plate) Purge Request This signal is 1 on power up if a purge interval has been defined, 0 on power up otherwise. Any dispensing will turn off this bit and reset the purge timer. This signal will be 1 under the following condition: • The system purge interval timer has expired. • The system is in an active state, and Dispenser (Fluid Plate) Remote Start / Purge in Process • The dispenser (fluid plate) does not have an active Alarm (Deviations have no effect). This signal is 0 on power up. This signal will be 1 under the following conditions: Dispenser (Fluid Plate) No Alarm • A remote start sequence is in process. This signal shall remain asserted until the dispense equipment has achieved Dispense Ready status. • A purge sequence is in process. This signal shall remain asserted until the purge sequence is complete. For systems with a CGM, this signal will be 1 under the following condition: • The system does not have an alarm. • 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: • The system does not have an error (alarm, deviation, or advisory). • 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. Units All units settings are set in the Advanced Display Module. The following signals are used to communicate this information to the automation controller. Pressure Units Value Units 0 psi 1 bar 2 MPa 3 reserve Dispense in Process This signal is 0 on power up. This signal will be 1 under the following condition: • The system is in the middle of a job. Dispense Volume OK Errors Error numbers are formed by 8 bits. This is the error number in the system. This signal will be 1 under the following conditions: • • • 138 The system has completed a job, and the volume of the job is within the tolerance specified, and the style strobe is 1. 3A2098H Appendix D - I/O Signal Descriptions Automation Outputs Style Remote Start / Purge The desired style of the next job. These 8 bits are read at the start of a job to determine the selected style. 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. 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. Swirl X Enable This bit is used to signal the on and off status of each swirl dispenser motor. 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. Swirl Command Value This 12-bit value indicates a swirl speed command from 0-10 volts. 0 volts (0x000) represents a speed of 6,600 rpm and 10 volts (0xFFF) represents 24,000 rpm. 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. 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. Command Value This 12 bit value indicates the analog command value from 0-10Volts (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 configured scale factor. Error Reset / Cancel Job If the “End Job On Alarm” setting is enabled: • • If in a job, setting this bit will cancel the current job. If not in a job, setting this will reset errors. If the “End Job On Alarm” setting is disabled: • Setting this bit will reset errors regardless of job status. 3A2098H 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-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 filtration 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 Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full load-1.4A, fuse rating-2.5A 24 Vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full load-4A, fuse rating-4A Power Supply Voltage Range . . . . . . . . . . . . . . . . . . . . . 100-240 Vac, 50-60 Hz, single phase Operating Temperature Range control center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 equipment selections. See your Graco authorized distributor for other capabilities. Control Center Assembly Technical Data 100 - 240 Vac Assemblies 24 Vdc Assembly Voltage 100-240 Vac 24 Vdc Phase 1 --- Frequency 50-60 Hz --- Full Load Current 1.4 A 4.0 A 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 manual. Cartridge Regulator Mastic Regulator Regulator Manual 308647 307517 Weight - No Flow Meter 25.5 lb (11.6 kg) 33 lb (15 kg) Weight - Helical 40 lb (18 kg) 48 lb (22 kg) Fluid Port Inlet Helical: 3/4 in. npt(f) 3/4 in. npt(f) Fluid Port Outlet 1/2 in. npt(f) 3/4 in. npt(f) Maximum Fluid Working Pressure* See Models on page 4 See Models on page 4 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. 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 For use when dispensing fluids that meet at least one of the following conditions for non-flammability: Fluid Specifications Ambient Air Temperature Range • The fluid has a flash point above 140° F (60° C) and a 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. 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, 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, 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. 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
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File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : Yes Page Mode : UseOutlines XMP Toolkit : 3.1-701 Marked : True Producer : Acrobat Distiller 7.0.5 (Windows) Copyright : 2011, Revision H, August 2014 Job Ref : Z088732 Web Statement : 3A2098H, PCF, Instructions-Parts, (English) MM 3A2098 Keywords : "MM 3A2098, 3A2098H, 3A2098-H, 3A2098EN, 3A2098EN-H, PCF, Instructions-Parts, PF1100, PF1101, PF1110, PF1111, PF1120, PF1121, PF1130, PF1131, PF1140, PF1141, PF1200, PF1201, PF1210, PF1211, PF1220, PF1221, PF1230, PF1231, PF1240, PF1241, PF1300, PF1301, PF1310, PF1311, PF1320, PF1321, PF1330, PF1331, PF1340, PF1341, PF1400, PF1401, PF1410, PF1411, PF1420, PF1421, PF1430, PF1431, PF1440, PF1441, PF1500, PF1501, PF1510, PF1511, PF1520, PF1521, PF1530, PF1531, PF1540, PF1541, PF1600, PF1601, PF1610, PF1611, PF1620, PF1621, PF1630, PF1631, PF1640, PF1641, PF1700, PF1701, PF1710, PF1711, PF1720, PF1721, PF1730, PF1731, PF1740, PF1741, PF2100, PF2101, PF2110, PF2111, PF2120, PF2121, PF2130, PF2131, PF2140, PF2141, PF2200, PF2201, PF2210, PF2211, PF2220, PF2221, PF2230, PF2231, PF2240, PF2241, PF2300, PF2301, PF2310, PF2311, PF2320, PF2321, PF2330, PF2331, PF2340, PF2341, PF2400, PF2401, PF2410, PF2411, PF2420, PF2421, PF2430, PF2431, PF2440, PF2441, PF2500, PF2501, PF2510, PF2511, PF2520, PF2521, PF2530, PF2531, PF2540, PF2541, PF2600, PF2601, PF2610, PF2611, PF2620, PF2621, PF2630, PF2631, PF2640, PF2641, PF2700, PF2701, PF2710, PF2711, PF2720, PF2721, PF2730, PF2731, PF2740, PF2741, PF3100, PF3101, PF3110, PF3111, PF3120, PF3121, PF3130, PF3131, PF3140, PF3141, PF3200, PF3201, PF3210, PF3211, PF3220, PF3221, PF3230, PF3231, PF3240, PF3241, PF3300, PF3301, PF3310, PF3311, PF3320, PF3321, PF3330, PF3331, PF3340, PF3341, PF3400, PF3401, PF3410, PF3411, PF3420, PF3421, PF3430, PF3431, PF3440, PF3441, PF3500, PF3501, PF3510, PF3511, PF3520, PF3521, PF3530, PF3531, PF3540, PF3541, PF3600, PF3601, PF3610, PF3611, PF3620, PF3621, PF3630, PF3631, PF3640, PF3641, PF3700, PF3701, PF3710, PF3711, PF3720, PF3721, PF3730, PF3731, PF3740, PF3741" Creator Tool : FrameMaker 11.0 Create Date : 2011:09:14 14:56:38Z Modify Date : 2014:08:21 09:30:49-05:00 Metadata Date : 2014:08:21 09:30:49-05:00 Document ID : uuid:3c9c37ba-ef02-4c9b-ac5a-e64941da9f66 Instance ID : uuid:480cb85e-8dc1-4a60-a91c-fa0daab88136 Format : application/pdf Title : 3A2098H, PCF, Instructions-Parts, (English) Description : 3A2098, PCF, Instructions-Parts, (English) Creator : Mike Jueneman Subject : MM 3A2098, 3A2098H, 3A2098-H, 3A2098EN, 3A2098EN-H, PCF, Instructions-Parts, PF1100, PF1101, PF1110, PF1111, PF1120, PF1121, PF1130, PF1131, PF1140, PF1141, PF1200, PF1201, PF1210, PF1211, PF1220, PF1221, PF1230, PF1231, PF1240, PF1241, PF1300, PF1301, PF1310, PF1311, PF1320, PF1321, PF1330, PF1331, PF1340, PF1341, PF1400, PF1401, PF1410, PF1411, PF1420, PF1421, PF1430, PF1431, PF1440, PF1441, PF1500, PF1501, PF1510, PF1511, PF1520, PF1521, PF1530, PF1531, PF1540, PF1541, PF1600, PF1601, PF1610, PF1611, PF1620, PF1621, PF1630, PF1631, PF1640, PF1641, PF1700, PF1701, PF1710, PF1711, PF1720, PF1721, PF1730, PF1731, PF1740, PF1741, PF2100, PF2101, PF2110, PF2111, PF2120, PF2121, PF2130, PF2131, PF2140, PF2141, PF2200, PF2201, PF2210, PF2211, PF2220, PF2221, PF2230, PF2231, PF2240, PF2241, PF2300, PF2301, PF2310, PF2311, PF2320, PF2321, PF2330, PF2331, PF2340, PF2341, PF2400, PF2401, PF2410, PF2411, PF2420, PF2421, PF2430, PF2431, PF2440, PF2441, PF2500, PF2501, PF2510, PF2511, PF2520, PF2521, PF2530, PF2531, PF2540, PF2541, PF2600, PF2601, PF2610, PF2611, PF2620, PF2621, PF2630, PF2631, PF2640, PF2641, PF2700, PF2701, PF2710, PF2711, PF2720, PF2721, PF2730, PF2731, PF2740, PF2741, PF3100, PF3101, PF3110, PF3111, PF3120, PF3121, PF3130, PF3131, PF3140, PF3141, PF3200, PF3201, PF3210, PF3211, PF3220, PF3221, PF3230, PF3231, PF3240, PF3241, PF3300, PF3301, PF3310, PF3311, PF3320, PF3321, PF3330, PF3331, PF3340, PF3341, PF3400, PF3401, PF3410, PF3411, PF3420, PF3421, PF3430, PF3431, PF3440, PF3441, PF3500, PF3501, PF3510, PF3511, PF3520, PF3521, PF3530, PF3531, PF3540, PF3541, PF3600, PF3601, PF3610, PF3611, PF3620, PF3621, PF3630, PF3631, PF3640, PF3641, PF3700, PF3701, PF3710, PF3711, PF3720, PF3721, PF3730, PF3731, PF3740, PF3741 Page Count : 142 Author : Mike JuenemanEXIF Metadata provided by EXIF.tools