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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3A2098H
Instructions - Parts
PCF™ with
PrecisionSwirl™
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.
See page 4 for model information. See page 5 for
maximum working pressure and approvals.
IMPORTANT:
This manual does not apply to some PCF sys-
tems. See note on page 3 to verify this is the
correct manual for your PCF system.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Optional PrecisionSwirl Orbital
Dispenser (sold separately)
PCF Control Center
PCF Fluid Plate
EN
23A2098H
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
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
Related Manuals
3A2098H 3
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.
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.
Manual Description
313377 Original PCF Instructions - Parts
(see the note below)
309403 PrecisionSwirl Orbital Dispenser
307517 Mastic Fluid Regulators Instruc-
tions-Parts
308647 Fluid Pressure Regulators Instruc-
tions-Parts
309834 Helical Gear Fluid Flow Meters Instruc-
tions-Parts
ADM Software Part No. 16F528 or 15V769
(see manual 313377)
ADM Software Part No. 16K405
(use this manual)
✓
✖
Models
43A2098H
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.
◆
Discrete Gateway systems do not include automation interface cables. The following Graco accessories are avail-
able for wiring to the automation system. Installers should follow Appendix B - Discrete Gateway Module
(DGM) Connection Details, page 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.
This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition, including
Amendment 1, or a later version of the same standard incorporating the same level of testing requirements.
PF 1 110
First and
Second Digits
Third Digit Fourth Digit Fifth Digit Sixth Digit
Style/Size Fluid Plate User Interface Voltage
Description Regulator Meter Description Description
PF
(Precision
Continuous
Flow)
12 Styles 1❄Cartridge None 0◆Discrete 0100 - 240 Vac
216 Styles 2❄Mastic None 1DeviceNet
™
124 Vdc
3256 Styles 3❄Cartridge High
Resolution
2EtherNet/IP
™
2100 - 240 Vac with
Integrated Swirl
4❄Mastic High
Resolution
3PROFIBUS
™
324 Vdc with
Integrated Swirl
5Heated
Mastic
Heated
Standard
Resolution
4PROFINET
™
6 Heated
Mastic
None
7❄Cartridge Ultra High
Resolution
9902471
Certified to CAN/CSA C22.2 No. 61010-1
Conforms to
UL 61010-1
C
1
Models
3A2098H 5
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.
Fluid
Plate Kit
Used by
Model
Maximum Working
Pressure Description
Includes:
Regula-
tor
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 Resolu-
tion 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 Resolu-
tion 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 Resolu-
tion 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
Models
63A2098H
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.
PrecisionSwirl Orbital Dispenser Assemblies
See manual 309403.
PrecisionSwirl Orbital Dispenser Cable
Assemblies
Part Description
16M350 100 - 240 Vac
16M351 24 Vdc
Version Part, Series Coupler Offset Typical Application
Maximum
Working
Pressure
Standard 243402, B 0.012 in. for narrow bead
widths
Hem flange and after hem
3500 psi
(24.1 MPa,
241 bar)
Standard 243403, B 0.028 in. for wide bead
widths
Seam sealing
Compact 289262, A 0.012 in. for narrow bead
widths
Hem flange and after hem
Compact 289261, A 0.018 in. for medium bead
widths
Seam sealing
Part Description
233125 6 ft (1.8 m) motor extension cable assembly
233124 9 ft (2.7 m) motor extension cable assembly
233123 15 ft (4.6 m) motor extension cable assembly
617870 55 ft (16.8 m) motor extension cable assembly
Models
3A2098H 7
Automation Gateway Assemblies
Each control center comes with one automation gateway
assembly. The automation gateway module is either a Dis-
crete Gateway Module (DGM) or one of the Communications
Gateway Modules (CGM).To order a replacement, see the
following table. You will also need to order software upgrade
token (16K743).
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).
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
Assembly
Part Number
To Order
Rotary Switch
Position
PFxxx2,
PFxxx3,
16M350,
16M351
24B681
1, 2, 3, or 4;
see Swirl Control
DGM on page 19
Automation Gateway
(DGM or CGM)
Swirl Control DGM
Warnings
83A2098H
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
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.
Warnings
3A2098H 9
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 manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
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, inhala-
tion 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
WARNING
System Configurations
10 3A2098H
System Configurations
Typical Installation - Single Swirl, Single Fluid Plate
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
* Included
◆ Optional
F
IG
. 1: Typical Ambient System Installation
G
D
C
B*
F*
A*
E
H
J
K*
Power In
Air Supply
Drop Site
L
M
NOTE: Shown with one fluid plate and one swirl dispenser.
F*
System Configurations
3A2098H 11
Typical Installation - Multiple Fluid Plates, No Swirl Dispensers
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
* Included
F
IG
. 2: Typical Multiple Fluid Plate System Installation
J
Air Supply
Drop Site
K*
H
Power In
A
E
F*
F*
F*
F*
B*
B*
B*
B*
D
C
D
C
D
C
D
C
H
H
H
G
G
G
G
F*
System Configurations
12 3A2098H
Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers
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
F
IG
. 3: Typical Multiple Fluid Plate System Installation
J
Air
Supply
Drop Site
K* H
Power In
A
E
M
F*
F*
B*
B*
D
C
D
C
H
G
G
F*
N
L
L
M
Overview
3A2098H 13
Overview
System Overview
The PCF fluid metering system combines closed-loop
pressure control with the ability to change bead profiles
quickly. When used with an optional flow meter, the sys-
tem automatically adjusts for fluctuations in the operat-
ing environment, such as material viscosity,
temperature and tip wear, in order to maintain the
desired dispense rate. The module responds to automa-
tion signals to provide an accurate and consistent output
flow based on a comparison of actual to desired flow
rates.
Typical Applications
• Bead dispensing
• Gasketing
• Seam sealing
• Hem flange
• Sound deadening
• Anti-flutter
• Body panel reinforcement
• Profile wrapping
• Cable filling
System Components
The diagram in F
IG
. 4 shows an example of the PCF
module and cables.
Control Center (User Interface)
The control center communicates with the PCF fluid
plate assembly to control fluid pressure and dispense
valve operation.
The control center receives input from the automation
controller, and uses these inputs to determine communi-
cation to the fluid plate assembly.
Fluid Plate Assembly
The fluid plate assembly contains components that con-
trol and monitor fluid dispensing. A PCF fluid metering
system can have up to four fluid plates. Each fluid plate
can control up to four dispense valves. The system sup-
ports up to 16 dispense valves and can simultaneously
dispense from up to 10 dispense valves.
PrecisionSwirl Orbital Dispenser
(Swirl Dispenser), Sold Separately
The swirl dispenser dispenses material in a circular pat-
tern at speeds from 6600 to 24000 rpm. A PCF fluid
metering system can have up to four swirl dispensers.
See manual 309403 for detailed information.
F
IG
. 4: PCF System Components
System shown with one fluid plate and one swirl dispenser
Control Center
(User Interface)
Fluid Plate Assembly
Overview
14 3A2098H
Fluid Plate Assembly Overview
Fluid Plate Components
The fluid plate assembly in F
IG
. 5 can be attached to an
automation arm or mounted on a pedestal. The main
components of the fluid plate assembly include:
•Fluid regulator (cartridge, ambient mastic, or heated
mastic) (P).
•Flow meter (R) (optional) precisely measures the
flow rate of fluid dispensed.
•Solenoid air valve (S) controls the dispense valve.
•Voltage to Pressure Transducer (T), abbreviated V/P
transducer, adjusts the air pressure to the fluid regu-
lator (P).
•Fluid Control Module (FCM) (U) receives pulse read-
ings from the flow meter (R) and pressure readings
from the regulator. It also controls the fluid regulator
(P) and solenoid air valve (S).
The PCF fluid regulator is electrically controlled by the
PCF fluid control module. Consistent material flow is
assured by a closed-loop pressure or closed-loop flow
control design. The module responds to automa-
tion-supplied signals to provide an accurate and consis-
tent output flow based on a comparison of actual to
desired flow rates. The fluid regulator uses air pressure
to control fluid pressure and to provide fast response to
electronic commands and ensure a precisely controlled,
continuous flow of material.
The fluid plate assembly is available in two versions:
ambient and heated.
Ambient Fluid Plate Assembly
There are four ambient versions available:
• cartridge regulator without a flow meter;
• ambient mastic regulator without a flow meter;
• cartridge regulator with a high resolution meter;
• ambient mastic regulator with a high resolution
meter;
• cartridge regulator with an ultra high resolution
flow meter.
Heated Fluid Plate Assembly
There are two heated versions available:
• heated mastic fluid regulator with a heated flow
meter,
• and a heated mastic fluid regulator without a
flow meter.
F
IG
. 5: Fluid Plate Components
U
R
P
T
S
Overview
3A2098H 15
Fluid Regulator
There are three fluid regulator options:
• cartridge
• ambient mastic
• heated mastic
All of the fluid regulator options use air pressure to con-
trol fluid pressure, provide fast response to electronic
commands, and ensure a precisely controlled, continu-
ous flow of material.
Cartridge
The cartridge regulator (244734) is ideal for low to
medium viscosity sealants and adhesives.
Ambient Mastic
The ambient mastic regulator (246642) is ideal for
medium to high viscosity sealants and adhesives.
Heated Mastic
The heated mastic regulator (246643) is ideal for low to
high viscosity warm-melt and hot-melt sealants or adhe-
sives.
Fluid Control Module (FCM)
Rotary Switch on FCM
The rotary switch on the FCM, see F
IG
. 6, must be set to
a valid position and each FCM must have a unique
rotary switch position. The FCM rotary switch position
determines which number to assign to that fluid plate.
The settings, including defined styles, for each fluid
plate are stored in each FCM so changing the rotary
switch position causes the settings to be shown under
the new number on the ADM.
NOTE: See LED Diagnostic Information, page 65, for
signal definitions.
F
IG
. 6: FCM Sensor Connections
Table 1: FCM Sensor Connections
Connection Sensor Description
1 Dispense solenoid
2Flow meter
3 Outlet pressure sensor (heated systems only)
4 Voltage to Pressure (V/P) Transducer
5 Command cable (optional accessory kit)
6 Inlet pressure sensor (non-heated systems
only)
7 Outlet pressure sensor (non-heated systems
only)
CAN
Connectors
---
Item
Rotary Switch
Position
Fluid Plate 1 0 or 1
Fluid Plate 2 2
Fluid Plate 3 3
Fluid Plate 4 4
3
4
5
CAN
Connectors
67
Status
LEDs
12
Key
token
Rotary
Switch
Overview
16 3A2098H
Control Center Assembly Overview
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.
F
IG
. 7: Control Center Components
Front View Side View
ADM
Gateway
Module
Front View
Swirl Board
Swirl Control
DGM
100-240 Vac Assembly
Overview
3A2098H 17
Advanced Display Module (ADM)
KEY:
F
IG
. 8: Advanced Display Module Component Identification
TI12362a
BA
BB
BC
BE
BH
BG
BF
BD
r_24E451_3B9900_1a
BJ
BR
BP
BN
BM
BL
BK
BS
Callout Function
BA Power On/Off Button
Enables/disables system.
BB System Status Indicator LED
Displays system status. Green LED indicates the
system is active. Orange LED indicates the sys-
tem is off. Solid LEDs (green or orange) indicate
the system is in Run mode. Flashing LEDs (green
or orange) indicate the system is in Setup mode.
BC Stop Button
Stops all system processes. However, it is not a
safety or emergency stop.
BD Soft Keys
Functions vary depending on the screen.
BE Cancel Button
Clears system errors and cancels a selection or
number entry while in the process of entering a
number or making a selection.
BF Enter Button
Acknowledge changing a value or making a selec-
tion.
BG Lock/Setup
Toggle between run and setup screens. If setup
screens are password protected, button toggles
between run and password entry screens.
Callout Function
BH Navigation Buttons
Navigate within a screen or to a new screen.
BJ Flat Panel Mount
Mounts to control center bracket (optional).
BK Model Number Tag
Model number.
BL USB Module Interface
USB port and USB indicator LEDs.
BM CAN Connector
Power connection.
BN Module Status LEDs
See LED Diagnostic Information, page 65, for
signal definitions.
BP Battery Cover
BR Token Access Cover
BS 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.
Overview
18 3A2098H
Automation Gateway Module
See the following table for the appropriate rotary switch position for your automation gateway module.
NOTE: See Control Center Assembly Overview on page 16 for automation and swirl control DGM identification.
Key:
CA Gateway Module
CB Base
CC Fieldbus Connector (see Appendix C - Communi-
cations Gateway Module (CGM) Connection
Details, page 122, for more information)
CD Module Connection Screws
CE Access Cover
CF Module Status LEDs (see LED Diagnostic Infor-
mation, page 65)
CG D-Subminiature (D-Sub) Connector (see Appendix
B - Discrete Gateway Module (DGM) Connection
Details, page 115, for pinout details)
CH CAN Connectors
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
F
IG
. 9: Automation Gateway Module Components
TI11816A
PROFIBUS Discrete
CG
CC
TI11814A TI11815A
CA CD
Gateway Module Connectors
CB
PROFINET or EtherNet/IP DeviceNet
CE CF CH
Front Back
CC CC
Rotary
Switch
Software
Token Slot
Front
(Access Cover Removed)
Overview
3A2098H 19
Swirl Control DGM
One swirl control DGM is included in the integrated Swirl
control center, and in each expansion swirl enclosure.
Each Swirl control DGM controls one swirl orbiter.
Each swirl control DGM must have a unique rotary
switch position. The rotary switch position determines
the number assigned to the swirl dispenser attached to
that DGM. If the rotary switch position must be changed,
do so with the power off.
Each integrated swirl control center and swirl enclosure
comes with a pre-installed cable between the swirl con-
trol DGM and the swirl board. The customer does not
need to make any external connections with the swirl
control DGM.
DGM Function Rotary Switch
Position
Swirl Control 1 1
Swirl Control 2 2
Swirl Control 3 3
Swirl Control 4 4
F
IG
. 10: Swirl Control DGM
CA
CD
CB
CE CF CH
Front Back
Rotary
Switch
Software
Token Slot
Front
(Access Cover Removed)
Overview
20 3A2098H
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.
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.
F
IG
. 11
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
FCMADM
Installation
3A2098H 21
Installation
Before Installation
•Have all system and component documentation
available during installation.
•See component manuals for specific data on compo-
nent requirements. Data presented here applies to
the PCF assemblies only.
•Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.
•Use the PCF control center only with the PCF fluid
plate assembly.
Overview
The basic steps to install a PCF system are shown
below. See the separate component manuals for
detailed information.
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.
10. Connect other fluid and air lines to additional system
components as instructed in their manuals.
11. Install fluid plate, swirl, and gateway cable assem-
blies, page 28.
12. Install Gateway interface, page 30.
To avoid injury and damage to equipment, use at
least two people to lift, move, or disconnect the sys-
tem. The system is too heavy for one person to lift or
move.
Installation
22 3A2098H
Install Control Center
NOTE: This section applies to both the primary control
center and the expansion Swirl enclosures.
Mount
Ensure the following criteria are met before mounting
the PCF control center:
• Select a location for the control center that allows
adequate space for installation, service, and use of
the equipment.
• For best viewing, the ADM should be 60-64 in.
(152-163 cm) from the floor.
• Ensure there is sufficient clearance around the con-
trol unit to run cables to other components.
• Ensure there is safe and easy access to an appro-
priate electrical power source. The National Electric
Code requires 3 ft (0.91 m) of open space in front of
the control center.
• Ensure there is easy access to the power switch.
• Ensure the mounting surface can support the weight
of the control center and the cables attached to it.
Secure the control center with appropriate size bolts
through the 0.27 in. (7 mm) diameter holes in the mount-
ing tabs. See the following mounting dimensions.
Table 2: Control Center Assembly Measurement
A10.50 in. (267 mm)
B 5.75 in. (146 mm)
C22.00 in. (559 mm)
D21.25 in. (540 mm)
F
IG
. 12: Control Center Dimensions
A
B
CD
Installation
3A2098H 23
Electrical Connections
Connect Light Tower Accessory
1. Order the 255468 Light Tower Accessory as a diag-
nostic indicator for the PCF system.
2. Connect the cable from the light tower to the digital
I/O port (BS) on the ADM.
See Table 3 for a description of light tower signals.
NOTE: See Errors, page 66, for error definitions.
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 min-
imum.
•A qualified electrician must complete all grounding
and wiring connections.
•For 24 Vdc wiring refer to F
IG
. 13.
•For 100-240 Vac wiring refer to F
IG
. 14.
•Incoming power wiring must be guarded from the
enclosure. Use a protective grommet where the
power wiring enters the enclosure to prevent wear.
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
F
IG
. 13: 24 Vdc Wiring
+
-
Ground
F
IG
. 14: 100-240 Vac Wiring
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.
Ground
N
L
Installation
24 3A2098H
Install Fluid Plate Assemblies
To install the PCF fluid plate assemblies:
•Mount the fluid plate assemblies, page 24
•Ground fluid plate assemblies, page 27
•Connect one fluid plate assembly to the control cen-
ter. See Install Cable Assemblies on page 28.
•
If multiple fluid plates,
connect the fluid plates
together. See Install Cable Assemblies on
page 28.
•Connect fluid lines, air lines, and cables; page 27
Mount
Before Mounting Assembly
•See component manuals for specific information on
component requirements. Information presented
here pertains to the PCF fluid plate assembly only.
•Have all system and subassembly documentation
available during installation.
•Be sure all accessories are adequately sized and
pressure-rated to meet the system's requirements.
•Use only the Graco PCF fluid plate assembly with
the Graco PCF control center.
Mount Assembly
1. Select a location for the fluid plate assembly. Keep
the following in mind:
• Allow sufficient space for installing the equip-
ment.
• Make sure all fluid lines, cables and hoses eas-
ily 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.
2. Mount and secure the fluid plate assembly to the
automation unit (or other mounting surface) with
appropriate size bolts through the 0.397 in. (10 mm)
diameter holes in the base plate. See the mounting
dimensions in Table 4 and F
IG
. 15.
Table 4: Fluid Plate Assembly Measurement
A16.5 in. (419 mm)
B14.0 in. (356 mm)
C14.4 in. (366 mm)
D13.4 in. (340 mm)
F
IG
. 15: Fluid Plate Assembly Dimensions
A
B
C
D
Installation
3A2098H 25
Mount Four-Valve Breakout Kit 24B693
PCF is capable of controlling up to four separate dis-
pense valves from port 1 on the FCM. A four-valve
breakout kit (24B693) is available to split the dispense
solenoid connector (port 1 on the FCM) into four sepa-
rate dispense solenoid connectors. For each additional
dispense valve, order one dispense valve
solenoid (258334) and one solenoid cable (121806).
Follow this procedure if using the four-valve breakout
kit.
1. Remove the existing dispense solenoid and cable
from the fluid plate.
2. Install bulkhead fitting (included in the kit) into the
empty hole on the fluid plate.
3. Connect one end of the extension cables (included
in the kit) to connection 1 on the FCM and the other
end of the cable to the bulkhead fitting.
4. Connect the splitter assembly to the bulkhead fit-
ting.
5. Connect the dispense valve cable(s) to the connec-
tions on the splitter assembly.
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 sole-
noid outputs are capable of sourcing up to 0.5A each
(maximum 12W coil).
F
IG
. 16: Mount Breakout Kit
GCA Cable
Splitter Assembly
Hole for bulk-
head fitting
Connection 1
J1 J3
J2 J4
Cable for:
Connects to Splitter
Connection Labeled:
Dispense Valve 1 J1
Dispense Valve 2 J2
Dispense Valve 3 J3
Dispense Valve 4 J4
Installation
26 3A2098H
Install Command Cable Kit 24B694
Follow this procedure if using the command cable kit.
1. Install bulkhead fitting (included in the kit) into the
empty hole on the fluid plate. See F
IG
. 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.
NOTE: Command cable inputs are not isolated from
PCF 24 Vdc power.
* To turn on the dispense trigger, connect the dis-
pense trigger pin to the dispense trigger ground pin
(pin 5).
FCM
Port
Pin #
Command
Cable Wire
Color
Function
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
Installation
3A2098H 27
Ground
Ground the fluid plate assembly as instructed here and
in the individual component manuals. Make sure the
fluid plate assembly and its components are installed
correctly to ensure proper grounding.
Air and Fluid Hoses
For static dissipation, use only electrically conductive
hoses or ground the applicator / dispense valves.
Dispense Valve
Follow the grounding instructions in the dispense valve
manual.
Connect Fluid and Air Lines
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 appli-
cator's solenoid valve to the applicator. Plug any
unused solenoid ports.
NOTE: To maximize system performance keep the dis-
pense hose length and ID as small as the application
will allow.
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 min-
imum.
•A qualified electrician must complete all grounding
and wiring connections.
•For 24 Vdc wiring refer to F
IG
. 13.
•For 100-240 Vac wiring refer to F
IG
. 14.
•Incoming power wiring must be guarded from the
enclosure. Use a protective grommet where the
power wiring enters the enclosure to prevent wear.
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
NOTICE
Route all fluid and air lines carefully. Avoid pinching
and premature wear due to excessive flexing or rub-
bing. Hose life is directly related to how well they are
supported.
Installation
28 3A2098H
Install Cable Assemblies
NOTE: To prevent system errors, only connect cables
with the power off.
NOTE: See F
IG
. 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 F
IG
. 17 on
page 29.
5. Use the automation interface cable (not provided) to
connect the Gateway module to the automation
controller.
Installation
3A2098H 29
F
IG
. 17: Cable Installation Diagram
Multiple Fluid Plate and Multiple Swirl System shown
4
5
4
4
3
1
1
2
2
2
2
1
Installation
30 3A2098H
Install Gateway Module Interface
NOTE: Systems with swirl dispensers will have two gateway modules in the control center. The gateway module on
the left is the swirl control DGM module, and does not need any setup or modification. The gateway module on the
right is the automation Gateway module. This section covers the automation Gateway module.
Fieldbus Communications Gateway Module
Module Description
The Communications Gateway Module (CGM) provides
a control link between the PCF system and a selected
fieldbus. This provides the means for remote monitoring
and control by external automation systems.
See Automation Control (Normal Operation), page
45, for details on controlling the PCF system through the
Gateway module.
Data Exchange
Data is available by block transfer, cyclic transfer,
change of state triggered, and explicit access to individ-
ual attributes as 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 net-
works
• GSD file: PROFIBUS fieldbus networks
• SDML: PROFINET fieldbus networks
CGM Status LED Signals
*The red LED (CF) will flash a code, pause, then repeat.
Installation
NOTE: The following installation instructions assume
the person implementing the PCF fieldbus connection
fully comprehends the fieldbus being used. Ensure the
installer understands the automation controller commu-
nication architecture and the fieldbus being used.
1. Install interface cables between the PCF system
and the automation controller per the fieldbus stan-
dards. Refer to Appendix C - Communications
Gateway Module (CGM) Connection Details,
page 122, for details.
2. Turn on system power. Navigate to the Gateway
setup screens and ensure the data map name is:
PCF 4FP. Refer to Appendix A - Advanced Dis-
play Module (ADM), page 99, for details about the
data map.
3. Set the PCF Gateway configuration values as
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 con-
troller (fieldbus master). Configure it for communica-
tion with the PCF Gateway (fieldbus slave).
6. Establish communication between the automation
controller and the PCF Gateway to confirm the suc-
cessful configuration of the hardware and data.
NOTE: Use the ADM screens for troubleshooting field-
bus data communication problems. Refer to Appendix
A - Advanced Display Module (ADM), page 99, for
details. Also, use the LED status indicators on the PCF
Gateway module for fieldbus status information. Refer to
Appendix C - Communications Gateway Module
(CGM) Connection Details, page 122, for details.
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
Installation
3A2098H 31
Discrete Gateway Module
Module Description
The Discrete Gateway Module (DGM) provides a control
link between the PCF system and an automation con-
troller through discrete input and output connections.
This provides the means for remote monitoring and con-
trol by external automation systems.
See Automation Control (Normal Operation), page
45, for details on controlling the PCF system through the
Gateway module.
Connect D-Sub Cable
The DGM provides all I/O through the D-Sub cable.
Graco offers two options for connecting a D-Sub cable
to the D-Sub connector (CG). Both options are accesso-
ries and must be ordered separately.
•
For single fluid plate systems only:
D-Sub to fly-
ing leads cable (123793). See Appendix B -
Discrete Gateway Module (DGM) Connection
Details, page 115, for details and cable inter-
face signals.
•
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.
DGM Status LED Signals
See LED Diagnostic Information, page 65, for signal
definitions.
DGM Rotary Switch Position
The Discrete Gateway Module (DGM) rotary switch
must be in position 0 for Automation Gateway DGMs
and positions 1-4 for Swirl Control DGMs in order for the
DGM to operate. See Automation Gateway Module on
page 18 and Swirl Control DGM on page 19.
F
IG
. 18: Connect D-Sub Cable
r_24B681_2B9904_2b
CG
System Setup
32 3A2098H
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) sec-
tion, page 17, and Appendix A - Advanced Display
Module (ADM), page 99, for detailed operating instruc-
tions for the display keypad and each screen.
1. Configure System, page 32.
2. Configure Control Settings, page 33.
3. Configure Mode Settings, page 34.
4. Configure Delay Settings, page 34.
5. Configure Flow Meter Settings, page 35.
6. Configure Pressure Loop Settings, page 35.
7. Adjust Pressure Sensors, page 36.
8. Configure Errors, page 36.
9. Setup Maintenance Schedule/Parameters, page 37.
10. For systems with swirl dispensers only:
a. Configure Swirl to valve association and error
type, page 37.
b. Configure Swirl settings, page 38.
11. Configure Gateway Settings, page 38.
12. Setup Styles, page 38.
13. Configure Advanced Settings, page 38.
Configure System
Define the number of installed fluid plates (called “Dis-
penser” on this screen) and number of installed swirl
dispensers. If a fluid plate is listed as “Uninstalled” the
screens for that fluid plate will not appear in the run or
setup screens.
1. With the system in setup mode, navigate to the Sys-
tem screen.
2. Press to access the fields to make changes.
3. Use the arrow keys to navigate to the desired field.
4. Press to open the drop-down list, and select
the desired setting. Press to accept the selec-
tion.
5. Repeat for the other Dispensers and Swirl Dispens-
ers.
6. Press to exit edit mode.
F
IG
. 19
System Setup
3A2098H 33
Configure Control Settings
Set the controls for the dispense source, how dispense
commands are sent, and job settings.
1. With the system in setup mode, navigate to Fluid
Plate x, screen 1 (Control Settings).
2. Press to access the fields to make changes.
3. Press to open the Dispense Trigger Source
drop-down list, and select Gateway, Command
Cable, Command Cable 3x, or Combined. If Com-
mand Cable is selected, users can enable the
valves. Press to finalize the selection.
4. If the dispense trigger source is set to Command
Cable, press to move to the Enable Valves field.
Press and to enable valves.
5. Press to move to the Command Value Source
field. Press to open the drop-down list, and
select Gateway, Command Cable, or Display. Press
to enter the value.
6. Press to move to the Job End Mode field. Press
to open the drop-down list, and select Timer or
Gateway. Press to enter the value.
7. Press to move to the Job End Delay field. Enter
the desired delay time (in seconds). Press to
enter the value.
8. Press to move to the Run Mode Bead Adjust
field. Press to open the drop-down list, and
select Enable or Disable. Press to enter the
value.
9. Press to move to the End Job on Alarm Check-
box. Press to enable or disable.
10. Press to move to the Display Control Password
field. Press to enter the value.
11. Press to exit edit mode.
12.
If multiple fluid plates are installed,
repeat this pro-
cedure for the other Fluid Plates.
F
IG
. 20
System Setup
34 3A2098H
Configure Mode Settings
Set valve commands, including the dispense mode
(pressure, bead, shot, or full open) and flow rate or pres-
sure for each valve. The bead scale is also adjustable
from this screen.
NOTE: For a description of each dispense mode, see
Dispense Control Modes, page 112.
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 2 (Mode Settings).
2. Press to access the fields to make changes.
3. Press and to set the mode for each
valve that will be used to Pressure, Bead, Shot, or
Full Open. Press to enter each selection.
4. Use the four arrow buttons to navigate to each
Fixed Command field. Enter the desired value for
each valve that will be used. Press to enter
each value.
NOTE: The ability to dispense from multiple valves
simultaneously is only allowed in either of the following
scenarios.
• Each valve is set to Pressure mode and has
identical Fixed Command values.
• Each valve is set to Full Open mode.
Attempting to dispense from multiple valves simultane-
ously using any other combination will cause an Incom-
patible Valves Settings alarm.
5. Press to move to the Bead Scale field. Enter a
scale value between 50% and 150%. Press to
enter the value.
6. Press to exit edit mode.
Configure Delay Settings
Set on and off delays (in milliseconds) for each valve
and the regulator. For an explanation of the on and off
delays, refer to the On/Off Delays section on page 39.
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 3 (Delay Settings).
2. Press to access the fields to make changes.
3. Use the four arrow buttons to navigate to each On
and Off field. Enter a desired delay value (in milli-
seconds) for each valve that will be used and the
regulator. Press to enter each value.
4. Press to exit edit mode.
F
IG
. 21
F
IG
. 22
System Setup
3A2098H 35
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
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 Set-
tings).
2. Press to access the fields to make changes.
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 selec-
tion.
4. Press to move to the K-Factor field. Key in the
K-factor value. See Table 5: Flow Meter K-Factors
for values. Press to enter the value.
5. Press to exit edit mode.
NOTE: If necessary, verify flow meter calibration. See
Verify Flow Meter Calibration, page 42, for instruc-
tions.
Configure Pressure Loop
Settings
The PCF system uses variables (Kp, Ki, and Kd) in the
software calculations to accurately and precisely control
the fluid pressure.
NOTE: It is recommended that these values are not
changed from the factory defaults of 32.00 for Kp,
128.00 for Ki, and 0.00 for Kd. However, if the values
need to be adjusted, see Manually Adjust Control
Loop Parameters on page 43.
Part Description K-Factor
246652 High Resolution Helical
Gear Meter
7000
246340 Heated Helical Gear
Meter
3500
16E993 Ultra High Flow Meter 33000
F
IG
. 23
System Setup
36 3A2098H
Adjust Pressure Sensors
Set pressure offsets and pressure limits.
NOTE: Inlet sensor settings will be grayed out on this
screen for systems with heated fluid plates.
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 5 (Pressure Sensors).
2. Press to access the fields to make changes.
NOTE: For the following steps, press and
to navigate through each field, and to open
drop-down menus and enter changes or selections.
3. Set the desired offset for the inlet and outlet pres-
sures between 0 and 100 psi (0.7 MPa, 7.0 bar).
Remove all pressure on the sensors, and then
adjust the offset so the measured value reads 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 pres-
sure limit for the outlet.
5. Set the error type (alarm or deviation) that will be
issued:
• If the minimum inlet pressure decreases below
the setting.
• If the maximum inlet pressure increases above
the setting.
• If the maximum outlet pressure increases above
the setting.
6. Press to exit edit mode.
Configure Errors
Set the error type (alarm, deviation, or none) that will be
issued if the pressure, flow rate, volume, or computed
target goes outside the tolerance settings of the active
style. When an alarm occurs, the system stops dispens-
ing. When a deviation occurs, the system will continue
dispensing. See Fluid Plate x, Screen 6 (Error Type)
on page 107 for more information.
NOTE: Only the low/high pressure errors will be
enabled for systems without a flow meter.
1. With the system in setup mode, navigate to Fluid
Plate x, screen 6 (Error Type).
2. Press to access the fields to make changes.
3. Press to open the Low Pressure drop-down
list, and select either Alarm or Deviation for the error
type. Press to enter the selection.
4. Press to move to the next field. Repeat Step 4
for each field.
5. Press to exit edit mode.
F
IG
. 24
F
IG
. 25
System Setup
3A2098H 37
Setup Maintenance
Schedule/Parameters
Set the volume (or hours) limit that will trigger a mainte-
nance advisory for the fluid supply, Voltage to Pressure
(V/P) Transducer, fluid regulator, flow meter, and all four
valves.
NOTE: Hours is shown instead of Volume for fluid plates
without a flow meter.
The Volume (or Hours) column displays the current
totalizer value. If this value exceeds the set limit, the
value will turn red and a maintenance advisory is issued.
See Fluid Plate x, Screen 7 (Maintenance Advisory
Limits), page 108, for more information about mainte-
nance totalizers.
To set limits:
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 7 (Maintenance Advisory Limits).
2. Press to access the fields to make changes.
3. Enter the desired limit for the air supply and press
to enter the selection.
4. Press to move to the next field. Repeat Step 4
for each field.
5. Press to exit edit mode.
To reset a totalizer value:
1. Follow Steps 1-3 of To set limits: to make changes
in
Fluid Plate x, screen 7 (Maintenance Advisory Lim-
its)
.
2. Press to scroll to the system component to
reset.
3. Press to reset the value.
Configure Valve to Swirl
Association and Motor Error
Type
Define which Swirl number is installed on which dis-
pense valve.
Set the error type (alarm or deviation) that will be issued
if a motor fault occurs. When an alarm occurs, the fluid
plate stops dispensing. When a deviation occurs, the
fluid plate will continue dispensing.
F
IG
. 26 F
IG
. 27
System Setup
38 3A2098H
Configure Swirl Settings
NOTE: This applies only to systems with swirl dispens-
ers.
Set the individual Swirl settings for each installed Swirl.
Configure Gateway Settings
Gateway settings differ for each system. See Automa-
tion Gateway Setup Screens, page 102, for guidelines
on configuring each type of Gateway interface.
Setup Styles
The PCF system can store up to 256 styles. See Styles,
page 46, for more information about styles and instruc-
tions on setting up styles. Style 0 is always the purge
style.
Configure Advanced Settings
Use the advanced settings to set or change the format
and display units, such as the language, date format,
and pressure units, for all PCF screens. See Setup
Mode, page 101, for advanced setting guidelines.
F
IG
. 28
System Setup
3A2098H 39
On/Off Delays
The PCF fluid regulator can physically respond faster
than the dispense device and its solenoid. As a result,
the fluid regulator can supply material to the dispense
device before the device has time to open. Supplying
material to a closed device can create trapped-pressure.
At the end of a cycle, the dispense device can shut off
before the pressure has dissipated. This can cause a
dispense of an excess of material at the beginning of the
next cycle.
To eliminate these two problems, change the delay time
associated with the opening of the fluid regulator/dis-
pense and/or the closing of the dispense device, see
Table 5: On/Off Delay Variables. For instructions set-
ting on/off delays, see Configure Delay Settings, page
34.
NOTE: On/Off delay can be set for each dispense
device.
In general, delays should be adjusted so the outlet pres-
sure during “no flow” is slightly below the outlet pressure
during dispense.
Table 5: On/Off Delay Variables
F
IG
. 29 and Table 6: Delay On/Off Timing show delay
ON and OFF timing.
Table 6: Delay On/Off Timing
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
A Regulator ON
delay
The user sets the fluid regu-
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
delay
The user sets the regulator
OFF delay timing. Zero or
small values will lower the
trapped pressure.
E Valve Open
Reaction Time
Time delay for valve to phys-
ically open. Delay varies
based on pneumatic hose
length and valve air volume.
F Valve Close
Reaction Time
Time delay for valve to phys-
ically close. Delay varies
based on pneumatic hose
length and valve air volume.
F
IG
. 29: Timing Delay
D
C
A
B
Dispense Valve
Signal
Fluid
Regulator
Valve Open
Command
Valve Actually
Open
EF
Operation
40 3A2098H
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 cen-
ter have been made. Ensure fittings are tight.
2. Read and understand the Operation (page 40) and
Advanced Display Module (ADM) (page 17) sec-
tions of this manual.
3. Continue startup with step 2 in Standard Startup.
Standard Startup
1. Carefully inspect the entire system for signs of leak-
age or wear. Replace or repair any worn or leaking
components before operating the system.
2. Press the Stop button (BC). See F
IG
. 8 on page 17.
3. Turn on air.
4. Turn on electrical power to the system.
5. Turn on the main power to supply power to the PCF.
6. Check Interface Signals: If this is a new installa-
tion, power on each system input and verify that
each input is being received.
7. Turn on the material supply system.
Load Material
Before using the system material must be loaded into
the supply system.
1. If this is a new installation, follow the Initial Startup
procedure. Otherwise, follow the Standard Startup
procedure. See page 40.
2. Turn on the fluid supply pressure to the fluid plate
assembly.
3. Place the valve(s) over a waste container.
4. Enter the maintenance screen. See Dispense
From Maintenance Screen, page 43.
5. Select a control mode. See Dispense From Main-
tenance Screen, page 43.
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.
Operation
3A2098H 41
Maintenance Mode Operation
Operating from maintenance mode enables manual
dispensing ( ) and manually starting the swirl dis-
penser ( ).
The system begins dispensing when the user presses
. Dispense parameters and duration depend on the
selected control. Dispensing continues for as long
as is pressed.
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 con-
trols for the Swirl are shown on both the Swirl mainte-
nance screen and on the Fluid Plate maintenance
screen for the fluid plate where the swirl dispenser is
installed.
Verify System Operation
Use maintenance mode to manually check the operation
of the PCF system components before switching over to
automation control (normal operation). See Dispense
From Maintenance Screen, page 43, for instructions
on operating from maintenance mode.
NOTE: Perform the following procedures while in main-
tenance mode.
Set Inlet Pressure
The inlet pressure reading should be in the range of
300 psi (2.1 MPa, 21 bar) to 500 psi (3.4 MPa, 34 bar)
above the outlet pressure reading under your highest
flow condition.
Follow steps in the supply system manual to set the inlet
pressure.
Feed System Pressure Drop
During material flow, the regulator inlet pressure
decreases. The amount the pressure decreases is the
amount of pressure lost between the feed pump and the
regulator inlet.
With high viscosity fluids, long line lengths, or small
diameter line sizes this pressure decrease can be thou-
sands of psi (hundreds of bar). This means that the
static pump pressure is set much higher than the regula-
tor needs at its inlet. To prevent excessive control regu-
lator wear or surging, a mastic fluid pressure regulator is
recommended on the feed line close to the control regu-
lator. The mastic regulator will suppress the static feed
pressure at the control regulator inlet.
Fluid Plate
Maintenance Screen
Swirl
Maintenance Screen
NOTICE
Inlet pressure beyond the recommended range
above will cause accelerated wear on the regulating
valve and the pump feed system.
Operation
42 3A2098H
Dispense from Each Valve
Dispense from each valve that will be used in normal
operation to confirm that the entire system is installed
correctly and is capable of delivering desired results.
Follow the steps outlined in Dispense From Mainte-
nance Screen, page 43, to perform each of the follow-
ing applicable system verification checks.
NOTE: Each fluid plate controls only the dispense
valves connected to it.
• For each valve that will be used during normal oper-
ation, dispense at each pressure or flow rate that
will be used during normal operation. This verifica-
tion check confirms that the system is capable of
delivering material at your maximum desired operat-
ing point.
• For systems that will operate multiple valves in pres-
sure mode at the same time, dispense from each
valve at the same time. This verification check con-
firms that the system is capable of delivering mate-
rial at your maximum desired operating point.
• For each valve operating in bead mode, perform an
initial teaching process. Follow this procedure after
significant system and/or material characteristic
changes.
a. For each flow rate that will be used during nor-
mal operation, press until PCF achieves
the flow rate setpoint.
NOTE: During the initial system operation verification, it
may take four to five seconds for the system to learn
system characteristics.
b. Continue to press for several seconds
after the desire flow rate is reached to confirm
that the system is capable of maintaining the
desired flow rate.
c. Repeat Steps a and b for a range of flow rates
to confirm that the system responds quickly to
achieve setpoint when is pressed.
Verify Flow Meter Calibration
Most sealant and adhesive materials are compressible.
Since the flow meter measures the material under high
pressure, the actual volume of material dispensed may
vary slightly from the measured volume, due to this
compressibility. If the K-factor is not correct, the dis-
played volume will not be accurate.
Follow either of the following methods to calibrate the
flow meter during initial setup and on a routine basis to
check for flow meter wear.
Method 1. Using a gram scale
1. Record the flow meter k-factor shown on Fluid Plate
x, screen 4 (Flowmeter Settings). See F
IG
. 23 on
page 35.
2. Use a 500 cc or larger beaker. Measure the mass of
the empty beaker.
3. Manually dispense material into the beaker. Hold
the beaker so that the stream of material is sub-
merged in the captured material to minimize air
entrapment in the container.
4. Record the volume dispensed on Fluid Plate x,
screen 1. See F
IG
. 30 on page 43.
5. Calculate the actual volume dispensed:
6. Calculate the new flow meter K-factor:
7. Enter new K-factor.
8. Repeat the procedure to verify the new K-factor.
Method 2. Without using a gram scale, visual measure-
ment
1. Record the flow meter k-factor shown on Fluid
Plate x, screen 4 (Flowmeter Settings). See F
IG
. 23
on page 35.
2. Use a 500 cc or larger beaker.
fluid mass (g)
density (g/cc)
=
measure volume (cc)
K-Factor (new) = displayed volume (cc) x K-Factor (old)
measured volume (cc)
Operation
3A2098H 43
3. Manually dispense material into the beaker. Hold
the beaker so that the stream of material is sub-
merged in the captured material to minimize air
entrapment in the container.
4. Record the volume dispensed on Fluid Plate x,
screen 1. See F
IG
. 30 on page 43.
5. Settle the material into the beaker and view the
actual volume dispensed.
6. Calculate the new flow meter K-factor:
7. Enter new K-factor.
8. Repeat the procedure to verify the new K-factor.
Manually Adjust Control Loop Parameters
NOTE: It is recommended that these values not be
changed from the factory defaults of 32.00 for Kp,
128.00 for Ki, and 0.00 for Kd.
If the system is not maintaining the desired setpoint
while in pressure or bead control mode, manually
change the Kp and Ki values:
NOTE: Pressure parameters should be adjusted first,
even if you typically operate in bead control mode.
1. Begin dispensing material.
NOTE: Begin a new dispense each time control param-
eters are changed.
2.
If the regulator outlet pressure does not closely fol-
low the desired pressure,
set Ki to zero then
increase Kp until the proper pressure control is
achieved.
3.
If the regulator outlet pressure oscillates rapidly
above and below the commanded pressure,
decrease Kp by 10%. Continue to decrease the Kp
value in 10% increments until the outlet pressure is
stable.
4. Set Ki value to 2 then increase the Ki value until the
system oscillates.
5. Decrease Ki until oscillation stops.
6.
Optional:
To fine tune the step response in pressure
mode, gradually increase the Kd value.
NOTE: Increasing Kd (pressure only) is typically not
necessary but it may improve step response. However
setting Kd too high may cause the system to oscillate.
7. Stop dispensing.
Dispense From Maintenance Screen
1. Navigate to Fluid Plate x, screen 1 for the desired
fluid plate.
2. Press to enter maintenance screen.
3. Press to open the Control Mode drop-down
list, and select the preferred control mode. Press
again to exit the drop-down list.
K-Factor (new) = displayed volume (cc) x K-Factor (old)
dispensed volume (cc)
F
IG
. 30
F
IG
. 31
Operation
44 3A2098H
4. Press to move to the target fields. Enter the tar-
get pressure, flow rate, or volume (dependent on
control mode) and press to save.
5. Press to move to the valve check boxes. Press
to select the desired valves.
6. Follow step 2 - 4 of Manually Dispense Fluid, page
44.
Manually Dispense Fluid
1. From Fluid Plate x, screen 1, press to enter
maintenance screen.
2. Press and verify that the valve opens.
3. Continue to press as long as needed to load or
dispense material.
4. Press again to exit maintenance screen.
Operate Swirl Dispenser From Maintenance
Screen
1. Navigate to the Swirl x screen for the desired Swirl
Dispenser. If the Swirl Dispenser is installed on
Fluid Plate x, you may also navigate to Fluid Plate x,
screen 1.
2. Press to enter maintenance screen.
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.
F
IG
. 32
F
IG
. 33
Operation
3A2098H 45
Automation Control (Normal
Operation)
During automation control (normal operation), the sys-
tem can dispense or change dispense parameters when
it receives a command from the automation unit.
The automation control operates using the concept of
jobs and styles. For a detailed explanation of jobs and
how they work within the PCF system, see Jobs on
page 45. For a detailed explanation of styles and how
they work within the PCF system, see Styles on
page 46.
Jobs
NOTE: See Appendix D - I/O Signal Descriptions,
page 138, for automation input and output signal
descriptions.
A job is an automation sequence in which material can
be dispensed. The amount of material specified for a job
varies by application. In some applications, a job may be
the amount of material dispensed on a part. Other appli-
cations may define a job to be the amount of material
dispensed on a number of parts or dispensed over a
period of 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 calcula-
tions are made and the volumes are stored on the PCF
system (Job Log).
The PCF system monitors two things to determine when
a job is complete. Either the Dispense Complete signal
is sent by the automation or the job complete timer
expires. The type of job end signal is configured to
Timer or Gateway in Fluid Plate x, screen 1 (Control
Settings). If the timer method is used, the timer begins
counting every time the dispense valve is turned off. If
the valve stays off for more than the preset timer value,
the job is considered complete.
Once the job is complete, the job information is stored to
memory. The most recent jobs can be viewed on the
Job screen. The information stored with each job is as
follows. See Job Report Screens, page 114, for
instructions on how to view job reports.
Actual (Measured) Volume - The amount of material
measured by the flow meter during a job.
Requested Volume - The amount of material that the
automation tries to dispense during a job. In Bead
mode, the requested volume is calculated as the
requested flow rate multiplied by the duration of the dis-
pense. In all other modes, the requested volume is
same as the target volume.
Target Volume - The amount of material a job should
have. This is defined in the Style.
Jobs in Bead Mode
In Bead Mode, all of the previously mentioned volumes
are monitored. The High Volume, Low Volume, and
Computed Target errors are evaluated at the end of the
job. The volume alarms compare the measured volume
to the requested volume and the computed target alarm
compares the requested volume to the target volume.
Jobs in Pressure Mode
In Pressure Mode, the requested volume is not mea-
sured. In this mode, the automation command voltage
corresponds to a pressure instead of flow rate. For this
reason the requested volume is not available (as well as
the Computed Target error). The high and low volume
alarms compare the measured volume to the target vol-
ume for pressure mode.
Continuously Running Applications
In some cases the target volume for a job is not known.
An example of a case where the target volume is
unknown is a continuously running system. This would
be a system that does not run jobs, but runs continu-
ously over a day or a shift. In this case, the flow rate
becomes more important than the amount of volume
dispensed in a job. The way to handle this situation is to
set the target volume to a value of zero. This effectively
disables the Computed Target error. The controls will
still maintain the desired flow rate and report errors cor-
responding to the tolerance set for the running style.
Operation
46 3A2098H
Styles
The PCF system has the ability to handle up to 256
styles, depending on the selected option.
NOTE: The number of available styles depends on the
fluid plate configuration. See Models on page 4. Style 0
is specified for purging only.
For each style, an independent target volume and toler-
ance can be configured. This allows for job-related
errors and logs to be evaluated for each style. The style
is read at the beginning of a job and cannot be changed
until the next job.
PCF reads in the styles via the Gateway interface. For
detailed interface information, see Appendix B - Dis-
crete Gateway Module (DGM) Connection Details on
page 115, and Appendix C - Communications Gate-
way Module (CGM) Connection Details on page 122,
as applicable.
To setup a style:
1. Navigate to Fluid Plate x, screen 8.
2. Press to access the style setup fields.
3. Enter the style number in the Style field.
4. Enter Style Name:
a. Press while in the Style Name field to dis-
play the Keyboard screen.
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.
c. Press to accept the new value.
5. Enter the target volume in the Volume field, and the
tolerance percentages in the Low and High Toler-
ance fields.
6. Enter precharge mode and parameters. See Pre-
charge Modes beginning on page 47.
7. Press to exit edit mode.
F
IG
. 34
F
IG
. 35
Operation
3A2098H 47
Precharge Modes
NOTE: See the diagram on the following page.
Static Precharge Mode
Display
When Display precharge mode is selected, a static pre-
charge pressure can be defined. When a job is active
and all dispense valves are closed, the regulator will
maintain the defined precharge pressure.
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 pres-
sure/flow command value.
Valve 1
When the “Valve 1” precharge mode is selected, the
outlet pressure will be set according to the current pres-
sure/flow command using Valve 1 scaling values.
Gateway
NOTE: Gateway precharge mode is only available for
systems containing CGMs.
When “Gateway” precharge mode is selected, the outlet
pressure will be set according to the current pres-
sure/flow command using the scaling set for dispense
valve(s) selected through the gateway interface.
Operation
48 3A2098H
Dispense Application Direction Dispense Application Direction Dispense Application Direction
Dispense Application Direction Dispense Application Direction Dispense Application Direction
Dispense Application Direction Dispense Application Direction Dispense Application Direction
Dispense Application Direction Dispense Application Direction Dispense Application Direction
-Controls outlet pressure based on desired command while valves are closed.
-Ideal value is typically less than 100% due to the minimal pressure losses within the system when fluid is not
flowing.
-Provides a boost upon valve opening to accelerate material.
-Ideal value is typically greater than 100%.
-The duration for which the valve opening scaling is application before the command is no longer scaled.
-Controls timing of transition from valve “closed” precharge to valve “opening” precharge and regular dispense.
-This delay should approximate the time it takes a dispense to open.
Closed Precharge Scaling Value
Opening Precharge Scaling Value
Opening Precharge Duration Value
Regulator On Delay Value
Value Too Low Ideal Value Value Too High
Value Too Low Ideal Value
Value Too High
Value Too Low Ideal Value Value Too High
Value Too Low Ideal Value Value Too High
Operation
3A2098H 49
Typical Job Cycle
In order for the system to run it must be in the active
state (status LED next to on the ADM is green).
Before a job begins the automation controller outputs
should have the following values:
• Style Strobe: 0
• Dispense Complete: 0
• Dispense Valve x On: all should be 0
• Style: Any value is acceptable
A typical job cycle consists of the following dispensing
sequence. See Typical Job Cycle Chart, page 50.
NOTE: Each job cycle can apply to only one fluid plate.
1. The automation controller checks that Dispenser
(Fluid Plate) Ready signal is set to 1. If it is 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.
6. When the dispense is complete the automation con-
troller sets Dispense Complete to 1.
7. PCF sets the following signals based on the results
of the job.
• Dispenser (Fluid Plate) No Alarm
• Dispenser (Fluid Plate) No Error
• Dispense Volume OK
•Error
• Dispensed Volume
NOTE: The automation controller should not read the
Dispense Volume OK or Dispense Volume signals until
after the system clears the Dispense In Process signal.
8. PCF sets Dispense In Process to 0 to indicate the
job is complete. At this time the signals from step 7
should be read.
9. The automation controller must clear Dispense
Complete and Style Strobe (either can be cleared
first) before the next job can start.
Jobs with Command Cable Dispense
Trigger
With the Dispense Trigger Source configured to Com-
mand Cable or Command Cable 3x, users only need to
trigger the dispense applicator to start a job. This config-
uration is useful for less demanding applications that do
not require a full automation interface.
The following limitations apply when starting a job with
this configuration:
• The selected style defaults to Style 1.
• There can be up to a 100 ms delay before dis-
pensing while PCF prepares for the new job
cycle.
• The job end mode timer must be used to end a
job.
Operation
50 3A2098H
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 automa-
tion interface prior to opening the dispense valve.
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispenser (Fluid Plate) In Process
Volume OK
Style Bits
Style Strobe
Automation Outputs (PCF Inputs)
Dispense Valve X On
Dispense Complete
Regulator Active (Precharge = 0)
PCF State
Dispense Valve X Open
Dispense Ready
Automation Inputs (PCF Outputs)
First Job Second Job
Operation
3A2098H 51
Control Charts
Automation Inputs (PCF Outputs)
Volume OK
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Purge In Process
Automation Outputs (PCF Inputs)
Style Bits
Style Strobe
Dispense Valve X On
Dispense Complete
Dispense Valve X Open
PCF State
Purge Using Style 0
Purge Using Purge Bit
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Purge In Process
Automation Outputs (PCF Inputs)
Remote Start / Purge
Dispense Valve X On
PCF State
Dispense Valve X Open
Operation
52 3A2098H
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
Remote Start/Purge
Automation Outputs (PCF Inputs)
Automation Inputs (PCF Outputs)
Dispenser (Fluid Plate) No Alarm / Dispenser (Fluid Plate) No Error
Automation Outputs (PCF Inputs)
Error Reset
Error Reset
Rising Edge Only
Cancel Job
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Inputs)
Error Reset
Operation
3A2098H 53
Control Charts (continued)
Precharge* - Gateway Mode
◆
Precharge* - Display Mode
◆
Automation Inputs (PCF Outputs)
Dispense Ready
* Precharge: After starting a job and prior to opening the dispense valve, the fluid pres-
sure is increased to try to match the dispensing pressure. This helps the consistency
of the dispense.
◆
Shaded areas indicate the precharge is active.
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Volume OK
Style Bits
Style Strobe
Dispense Valve X On
Dispense Complete
Regulator Active
Dispense Valve X Open
Automation Outputs (PCF Inputs)
PCF State
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Volume OK
Style Bits
Style Strobe
Precharge Valve X On†
Command Signal Valid‡
Regulator Active
Dispense Valve X Open
Automation Outputs (PCF Inputs)
PCF State
Dispense Valve X On
Dispense Complete
* Precharge: After starting a job and prior to opening the dispense valve, the fluid pres-
sure is increased to try to match the dispensing pressure. This helps the consistency of
the dispense.
◆
Shaded areas indicate the precharge is active.
†
The “Precharge Valve X On” bits are only available through a fieldbus interface. This
precharge method is not valid for DGM systems.
‡ Only applies to command signals when either “Command Cable” or “gateway” is
selected as “Command Value Source”.
Operation
54 3A2098H
Control Charts (continued)
Precharge* - Valve 1 Mode
◆
* Precharge: After starting a job and prior to opening the dispense valve, the fluid pressure is
increased to try to match the dispensing pressure. This helps the consistency of the dispense.
◆
Shaded areas indicate the precharge is active.
†
Only applies to command signals when either “Command Cable” or “gateway” is selected as “Com-
mand Value Source”. In systems containing an automation gateway DGM, when “Digital” is
selected as the “Command Value Type”, the “Digital CMD 1” and “Digital CMD 2” inputs set the
command.
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Volume OK
Style Bits
Style Strobe
Command Signal Valid†
Regulator Active
Dispense Valve X Open
Automation Outputs (PCF Inputs)
PCF State
Dispense Valve X On
Dispense Complete
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Gateway Inputs)
Dispense Valve 1 Trigger
PCF State
Regulator Active (Precharge = 0)
Dispense Valve 2 Trigger
Dispense Valve 3 Trigger
Dispense Valve 1 Open
Dispense Valve 2 Open
Dispense Valve 3 Open
Trigger Using Command Cable 3x
Operation
3A2098H 55
Control Charts (continued)
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Gateway Inputs)
Dispense Valve X On
PCF State
Regulator Active (Precharge = 0)
Trigger Using Command Cable and Gateway (Combined)
Dispense Valve Y On
Dispense Valve X On
Dispense Valve Y On
Command Cable
Dispense Trigger
Trigger Using Command Cable
* Dispense Valve X Open determined by Enable Valves check boxes
on Fluid Plate x, screen 1(Control Settings).
Automation Inputs (PCF Outputs)
Dispense In Process
Command Cable
Dispense Trigger
PCF State
Regulator Active (Precharge = 0)
Dispense Valve X Open*
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Gateway Inputs)
Dispense Valve 1 On
PCF State
Regulator Active (Precharge = 0)
Trigger Using Gateway
Dispense Valve 2 On
Dispense Valve 3 On
Dispense Valve 4 On
Dispense Valve 1 On
Dispense Valve 2 On
Dispense Valve 3 On
Dispense Valve 4 On
Operation
56 3A2098H
Control Charts (continued)
Automation Inputs (PCF Outputs)
Dispenser (Fluid Plate) Ready
Automation Outputs (PCF Gateway Inputs)
Swirl X Actual Speed - RPM (32 bits)
PCF State
Swirl X On
Enable Swirl Dispenser
Swirl X Speed Command (12 bits)
NOTE:
Swirl orbiter may take a few seconds to reach full speed.
Swirl X Enable
Speeding Up
Command Value Set
Actual Speed Value Valid
Full Speed
Pressure Relief Procedure
3A2098H 57
Pressure Relief Procedure
1. Shut off the fluid supply to the fluid plate assembly.
2. Place a waste container beneath the dispense
valve.
3. In maintenance mode, select Full Open Dispense
Mode, which opens the regulator and dispense
valve. Press the manual dispense button until
the fluid flow stops.
4. If the dispense valve cannot be actuated from the
control center, refer to F
IG
. 36 and perform the fol-
lowing steps to open the dispense valve and relieve
fluid pressure:
a. Manually actuate the plunger on the solenoid to
open all dispense valves attached to this fluid
plate and relieve fluid pressure. See F
IG
. 36.
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 previ-
ous steps for other fluid plates.
6. Shut off air to the fluid plate.
7. Place a waste container below the air filter assem-
bly then open drain valve on the air filter assembly.
Close drain valve once air is relieved.
8. Turn main power switch on control panel to the OFF
position.
9. If you have followed the previous steps and suspect
that a valve, hose, or dispense nozzle is clogged or
that pressure has not been fully relieved, very slowly
remove the dispense tip, clean the orifice, and con-
tinue 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 block-
age is cleared.
The equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief Pro-
cedure when you stop dispensing and before clean-
ing, checking or servicing the equipment.
F
IG
. 36: Dispense Valve Air Solenoid
Dispense Valve Air Solenoid
Shutdown
58 3A2098H
Shutdown
1. Press the Stop button (BC).
2. Shut off the material supply to the fluid plate/meter.
3. Follow the Pressure Relief Procedure on page 57.
4. Turn off the PCF system's compressed air supply.
5. Turn main power switch on control panel to the OFF
position.
F
IG
. 37: ADM - Stop Button
F
IG
. 38: Control Center Main Power Switch
BC
TI12362a
USB Data
3A2098H 59
USB Data
All files downloaded from the USB are put in a DOWN-
LOAD folder on the drive. For example:
“E:\GRACO\12345678\DOWNLOAD\”
The 8-digit numeric folder name matches the 8-digit
ADM serial number. When downloading from multiple
ADMs, there will be one sub-folder in the GRACO folder
for each ADM.
USB Logs
During operation, PCF stores system and performance
related information to memory in the form of log files.
PCF maintains three types of log files: a job log, an
event log, and dispense data logs. Follow the Down-
load Procedure, page 61, to retrieve log files.
Event Log
The event log file name is 1-EVENT.CSV and is stored
in the DOWNLOAD folder.
The event log maintains a record of the last 1,000
events. Each event record in the log file contains the
date and time the event occurred, the event type, event
code, and event description.
Job Log
The job log file name is 2-JOB.CSV and is stored in the
DOWNLOAD folder.
The job log maintains a record of the last 10,000 jobs. At
the completion of each job the following data is stored in
the log file:
• Job completion date
• Job completion time
• Job number (sequential number)
• Dispenser (Fluid Plate) Number
• Style number
• Target volume (in the units shown in the volume
units column)
• Requested volume (in the units shown in the
volume units column)
• Actual dispensed volume (in the units shown in
the volume units column)
• Volume units
• Error percentage between actual dispensed vol-
ume 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.
F
IG
. 39: ADM USB Port
USB Data
60 3A2098H
System Configuration Settings
File
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
A system configuration settings file automatically down-
loads each time a USB flash drive is inserted. Use this
file to back up system settings for future recovery or to
easily replicate settings across multiple PCF systems.
Refer to the Upload Procedure, page 61, for instruc-
tions on how to use this file.
It is recommended to retrieve the SETTINGS.TXT file
after all system settings are set as desired. Store the file
for future use as a backup in case the settings are
changed and need to be quickly changed 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 sys-
tem will display the Unicode replacement character,
which appears as a white question mark inside of a
black diamond.
• U+0020 - U+007E (Basic Latin)
• U+00A1 - U+00FF (Latin-1 Supplement)
• U+0100 - U+017F (Latin Extended-A)
• U+0386 - U+03CE (Greek)
• U+0400 - U+045F (Cyrillic)
Create Custom Language Strings
The custom language file is a tab-delimited text file that
contains two columns. The first column consists of a list
of strings in the language selected at the time of down-
load. The second column can be used to enter the cus-
tom language strings. If a custom language was
previously installed, this column contains the custom
strings. Otherwise the second column is blank.
Modify the second column of the custom language file
as needed and then follow the Upload Procedure,
page 61, to install the file.
The format of the custom language file is critical. The
following rules must be followed in order for the installa-
tion process to succeed.
• The file name must be DISPTEXT.TXT.
• The file format must be a tab-delimited text file
using Unicode (UTF-16) character representa-
tion.
• 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 sec-
ond column.
USB Data
3A2098H 61
Download Procedure
1. Insert USB flash drive into USB port (BL). See F
IG
.
39 on page 59.
2. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete. A pop-up will be present until the trans-
fer is complete if it is not acknowledged.
3. Remove USB flash drive from USB port (BL).
4. Insert USB flash drive into USB port of computer.
5. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Win-
dows
®
Explorer.
6. Open Graco folder.
7. Open system folder. If downloading data from more
than one system, there will be more than one folder.
Each folder is labeled with the corresponding serial
number of the ADM (The serial number is on the
back of the ADM.)
8. Open DOWNLOAD folder.
9. Open LOG FILES folder labeled with the highest
number. The highest number indicates the most
recent data download.
10. Open log file. Log files open in Microsoft
®
Excel
®
by
default as long as the program is installed. How-
ever, they can also be opened in any text editor or
Microsoft
®
Word.
NOTE: All USB logs are saved in Unicode (UTF-16) for-
mat. If opening the log file in Microsoft Word, select Uni-
code encoding.
Upload Procedure
Use this procedure to install a system configuration file
and/or a custom language file.
1. If necessary, follow the Download Procedure,
page 61, to automatically generate the proper folder
structure on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Win-
dows Explorer.
4. Open Graco folder.
5. Open system folder. If working with more than one
system, there will be more than one folder within the
Graco folder. Each folder is labeled with the corre-
sponding serial number of the ADM. (The serial
number is on the back of the module.)
6. If installing the system configuration settings file,
place SETTINGS.TXT file into UPLOAD folder.
7. If installing the custom language file, place
DISPTEXT.TXT file into UPLOAD folder.
8. Remove USB flash drive from computer.
9. Install USB flash drive into PCF system USB port.
10. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete.
11. Remove USB flash drive from USB port.
NOTE: If the custom language file was installed, users
can now select the new language from the Language
drop-down menu in the Advanced Setup Screen 1.
Troubleshooting
62 3A2098H
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 communi-
cated.
Fluid Plates
Problem Cause Solution
No outlet pressure Air pressure low Verify air pressure is above 60 psi
(410 kPa, 4.1 bar)
No “Valve On” signal from automation
unit
Check output and wiring from auto-
mation unit
No air signal to air diaphragm Check for loose/disconnected con-
nector to Voltage to Pressure (V/P)
Transducer; tighten
False signal being sent to control Check outlet pressure sensor output;
verify that it corresponds to zero
pressure; replace sensor and/or
amplifier
High outlet pressure Fluid regulator needle/seat is worn Rebuild fluid regulator; replace nee-
dle/ seat
Air leaks from fluid plate Loose air connections Check air connections; tighten if nec-
essary
Worn gaskets Check/replace gaskets on Voltage to
Pressure (V/P) Transducer and sole-
noid valve
Troubleshooting
3A2098H 63
Flow Meter
Fluid Regulator
Problem Cause Solution
No flow measurement Flow meter pick-up sensor loose Tighten flow meter pick-up sensor
Flow too low Verify flow rate is above minimum
for the installed flow meter
Loose wiring Verify connection from flow meter to
FCM
Damaged flow meter pick-up sensor Replace pick-up sensor
False measurement Flow meter not calibrated Calibrate flow meter, page 42
System not grounded properly Verify system ground
Noisy power source Verify clean power supply power to
main enclosure
Flow reported is not correct or
inconsistent
Flow meter not calibrated Calibrate flow meter, page 42
Flow meter is worn Replace flow meter
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
Pressure drops below setting 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
Damaged diaphragm Replace diaphragm
Chatter Excessive pressure differential be
tween pump and valve
Reduce pump pressure to not more
than 2000 psi (14 MPa, 138 bar)
greater than required valve pres-
sure.
Excessive flow rate Reduce fluid flow through regulator.
Connect only one spray gun or dis-
pense valve to each fluid regulator
Troubleshooting
64 3A2098H
Dispense Valves
Swirl Dispenser
Problem Cause Solution
Valve not opening Air not getting to the open port Verify air pressure to solenoid
No “Valve On” signal from automa-
tion unit
Check input from automation unit
Valve not shutting off Air not getting to the close port
(except AutoPlus valve)
Verify air pressure to solenoid
Verify solenoid operation
Verify air line routing and connec-
tions
“Valve On” signal from automation
unit is on Check input from automation unit
Sluggish open/close Air pressure low Verify air pressure is above 60 psi
(410 kPa, 4.1 bar)
Needle/seat worn Rebuild valve; replace needle/seat
Pressurized material past the valve
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
Problem Cause Solution
Motor not running (motor fault alarm
active)
Cable disconnected Verify cable connections to swirl
board, swirl motor cable, and swirl
orbiter
CAN cable was re-connected with
system power on (amber LED on
swirl board will be on, this indicates
circuit protection was triggered)
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 Replace swirl orbiter
Motor not running (motor fault alarm
not active)
Cable disconnected Verify cable connections to swirl
board, swirl board power cable, and
swirl control DGM
No “Swirl Enable” signal from auto-
mation unit Check input from automation unit
Swirl not installed Verify that the proper swirl orbiter is
installed in the system setup screen
Troubleshooting
3A2098H 65
Gateway Module
LED Diagnostic Information
The following LED signals, diagnosis, and solutions apply to the Advanced Display Module, Fluid Control Module,
and Gateway module.
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
Problem Cause Solution
No communication Incorrect wiring Check wiring per fieldbus standard. Refer to PCF Gateway
LED status indicators and Appendix C - Communications
Gateway Module (CGM) Connection Details, page 122.
Incorrect fieldbus settings Confirm fieldbus settings at automation controller (fieldbus
master) and PCF Gateway (fieldbus slave). Refer to Appen-
dix A - Advanced Display Module (ADM), page 99, for infor-
mation on PCF Gateway configuration settings.
Incorrect data Incorrect fieldbus configu-
ration 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.
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.
Errors
66 3A2098H
Errors
View Errors
When an error occurs, an error pop-up is displayed that
takes up the entire screen until the error is acknowl-
edged by pressing . Errors can also be acknowl-
edged over the gateway. Active errors are displayed in
the menu bar.
The previous 200 errors are displayed on the error
report screens. See Run Mode, page 110, for instruc-
tions on navigating to and through the error report
screens.
There are three levels of errors: alarms, deviations, and
advisories. Alarms cause the system to shut down.
Deviations and advisories do not shut down the system.
NOTE:
•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.
F
IG
. 40: Error Pop-Up
Error
Errors
3A2098H 67
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
Control Center 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 notifica-
tion
Record only A setup value was
changed on the dis-
play
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 --- ---
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Control Center Events and Errors
EVUX --- USB Disabled USB download
attempted, however,
USB activity is dis-
abled.
Advisory
(self-clearing)
Transfers are disabled
in Advanced Setup
screen 2.
Clears when drive is
removed.
MMUX --- USB Log 90%
Full
One or more USB log is
90% full.
Advisory 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
Module does not have
logic power supplied to
it.
Advisory 24 Vdc has not been
connected to the
power pins.
Connect power accord-
ing to Appendix B -
Discrete Gateway
Module (DGM) Con-
nection Details on
page 115.
WSG0 --- Gateway Setup
Error
System settings are
incompatible with Dis-
crete Gateway Module.
Advisory 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.
Swirl 1 is not installed.
Or Swirl 3 or Swirl 4 is
installed.
Install Swirl 1, unin-
stall swirls 3 and 4.
EAUX --- Download to
USB in Process
Information is currently
being downloaded to
USB
Advisory
(self-clearing)
--- No action necessary
Errors
68 3A2098H
Fluid Plate Events and Errors
EBUX --- Download to
USB Complete
Download to the USB is
complete
Advisory
(self-clearing)
--- No action necessary
WSU0 --- USB configura-
tion error
USB configuration error Advisory USB configuration
invalid or not present
Reinstall system soft-
ware on display
WNC0 32 ADM Key Token
Error
Missing or invalid key
token
Alarm An ADM key token is
required to run the
system
Verify the key token is
installed
Verify the key token
part number is correct
for the PCF ADM
WNG0 --- Gateway Map
Error
Missing or invalid map Advisory Missing or invalid
Gateway map
Install PCF map in
Gateway
CBG0 --- Gateway Reset Gateway reset Advisory
(self-clearing)
Gateway setting(s)
changed
Wait for reset to com-
plete before attempt-
ing automation control
WMG0 --- Gateway Error
Detected
Gateway error
detected; includes any
error not covered by
another more specific
error
Alarm --- ---
CBD_ --- Fluid Plate Com-
munication Error
Fluid Plate Communi-
cation Error with ADM
Alarm The ADM lost commu-
nications with the
FCM.
Restore communica-
tion.
CCG_ --- Fieldbus Com-
munication Error
Fieldbus Communica-
tion Error
Alarm The automation gate-
way lost communica-
tion with the
automation controller.
Restore communica-
tions.
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Control Center Events and Errors
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
CAC_ --- CGM Communi-
cation Error
Communication lost
between CGM and
Fluid Plate
Advisory Fluid Plate and CGM
are no longer commu-
nicating
Reconnect or replace
CAN cable
CGM is not functioning Replace the CGM if the
red status LED is solid
CAD_ --- Fluid Plate Com-
munication Error
FCM lost communica-
tion with the ADM
Alarm ADM is not communi-
cating
Reconnect or replace
CAN cable
ADM is not functioning Replace FCM if red
status LED is solid
ADM does not contain
appropriate key token
Verify intended ADM
key token is properly
inserted
B7C_ 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; pur-
chase accessory key
token
Errors
3A2098H 69
B30_
B40_
31 High Material Material dispensed dur-
ing last dispense cycle
was above amount
requested plus the
allowed tolerance
Alarm or
Deviation
(user select-
able)
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
B10_
B20_
32 Low Material Material dispensed dur-
ing last dispense cycle
below amount
requested minus the
allowed tolerance
Alarm or
Deviation
(user select-
able)
Partially plugged tip or
supply system
Clean tip and/or supply
system
Insufficient flow to
PCF regulator inlet
Increase flow rate to
regulator inlet
PCF regulator is not
regulating correctly
Check regulator;
repair if necessary
Incorrect style target
volume or tolerance
setting
B1C_
B2C_
33 Low Computed
Target
Requested volume/
mass differs from
entered process target
by more than entered
tolerance for style
requested
Alarm or
Deviation
(user select-
able)
Entered process target
incorrectly
Enter correct process
target
Entered tolerance
incorrectly
Enter correct tolerance
Requested volume
incorrectly
Check automation pro-
gram
Automation problem Verify automation is
correct
B3C_
B4C_
34 High Computed
Target
Requested volume/
mass differs from
entered process target
by more than entered
tolerance for style
requested
Alarm or
Deviation
(user select-
able)
Entered process target
incorrectly
Enter correct process
target
Entered tolerance
incorrectly
Enter correct tolerance
Requested volume
incorrectly
Check automation pro-
gram
Automation problem Verify automation is
correct
WND_ 51 Fluid Plate Key
Token Error
Missing or invalid key
token
Alarm FCM key token is
required to run system
Verify FCM key token
is installed
Verify FCM key token
is correct part number
P6D_ 52 Outlet Pressure
Transducer Error
Outlet pressure trans-
ducer error
Alarm Problem detected with
outlet pressure trans-
ducer
Verify outlet pressure
transducer is installed
and/or connected cor-
rectly
Replace if necessary
P6F_ 53 Inlet Pressure
Transducer Error
Inlet pressure trans-
ducer error
Advisory Problem detected with
inlet pressure trans-
ducer
Verify inlet pressure
transducer is installed
and/or connected cor-
rectly
Replace if necessary
F6D_ 54 Flow Meter Error Flow Meter error Alarm Problem detected with
flow meter
Verify flow meter is
installed and/or con-
nected correctly
Replace if necessary
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
Errors
70 3A2098H
WED_ 55 V/P Error Voltage to Pressure
Transducer error
Alarm Problem detected with
V/P
Verify outlet pressure
transducer is installed
and/or connected cor-
rectly
Replace if necessary
WJ1_ 56 Dispense Valve 1
Error
Dispense valve 1 error Alarm Problem detected with
dispense valve 1
Verify dispense valve 1
is installed and/or con-
nected correctly
Replace if necessary
WJ2_ 57 Dispense Valve 2
Error
Dispense valve 2 error Alarm Problem detected with
dispense valve 2
Verify dispense valve 2
is installed and/or con-
nected correctly
Replace if necessary
WJ3_ 58 Dispense Valve 3
Error
Dispense valve 3 error Alarm Problem detected with
dispense valve 3
Verify dispense valve 3
is installed and/or con-
nected correctly
Replace if necessary
WJ4_ 59 Dispense Valve 4
Error
Dispense valve 4 error Alarm Problem detected with
dispense valve 4
Verify dispense valve 4
is installed and/or con-
nected correctly
Replace if necessary
WSD_ 60 Incompatible
Valve Settings
Incompatible settings
for multiple valve opera-
tion; attempted to dis-
pense
Alarm Attempted to dis-
pense simultaneously
from multiple valves
on the same fluid plate
with different pressure
settings
Check settings shown
on Fluid Plate x,
screen 2 (Mode Set-
tings)
Verify automation pro-
gramming
WSD5 60 Incompatible
Valve Settings
Incompatible settings
for multiple valve opera-
tion; attempted to dis-
pense
Alarm Attempted to dis-
pense simultaneously
from multiple valves
on the same fluid plate
with different pressure
settings
In the Discrete Gate-
way screens, change
the settings of the
simultaneously dis-
pensing valves to the
same pressure
Verify automation pro-
gramming
F7D_ 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
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
Errors
3A2098H 71
V2D_ 62 Low Analog Command cable analog
command dropped
below minimum value
of 1 V while dispensing
Deviation Bad or loose com-
mand cable connec-
tion
Check command cable
and connection
Entered command
mode incorrectly
Enter correct com-
mand code
Automation program
error
Verify correct automa-
tion program
WFD_
WFG_
63 Flow Meter
Required
Operating mode
requires flow meter.
Advisory is issued if
fluid plate settings
require a flow meter but
meter is not present.
Alarm is issued if dis-
pense is attempted in
mode that requires a
flow meter but meter is
not present.
Alarm or
Advisory
(self-clearing)
Selected valve mode
settings require flow
meter
Check valve mode set-
tings
Purchase meter
enabled token for FCM
and install flow meter
FCM key token miss-
ing or invalid
Check for FCM key
token error
EJD_ 64 Job Cycle Time
Out
Job cycle time out Alarm Automation signals did
not properly end job
cycle
Check automation pro-
gramming per job oper-
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
to pin 1 of the com-
mand cable exceeds
10 Vdc.
Limit signal on pin 1 of
command cable to the
range of 0-10 Vdc.
Failed FCM Replace FCM if neces-
sary
P3F_
P4F_
66 Maximum Inlet
Pressure
Inlet pressure to regula-
tor is above upper limit
set for operation
Alarm or
Deviation
(user select-
able)
Incorrect set limit Verify limit is set cor-
rectly
Material supply pres-
sure is too high
Decrease material
supply pressure
Failed transducer Check transducer;
replace if necessary
P3D_
P4D_
67 Maximum Outlet
Pressure
Outlet pressure of regu-
lator is above upper
limit set for operation
Alarm or
Deviation
(user select-
able)
Incorrect set limit Verify limit is set cor-
rectly
Material supply pres-
sure is too high
Decrease material
supply pressure
Failed transducer Check transducer;
replace if necessary
P1F_
P2F_
68 Minimum Inlet
Pressure
Inlet pressure to regula-
tor is below lower limit
set for operation
Alarm or
Deviation
(user select-
able)
Incorrect set limit Verify limit is set cor-
rectly
Material supply pres-
sure is too low
Increase crease mate-
rial supply pressure
Failed transducer Check transducer;
replace if necessary
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
Errors
72 3A2098H
P1C_
P2C_
69 Low Pressure Measured outlet pres-
sure less than desired
outlet pressure minus
tolerance
Alarm or
Deviation
(user select-
able)
Incorrect limit set Verify limit is set cor-
rectly
No or insufficient
material flow
Increase material flow
rate
Dispense valve nee-
dle is stuck closed
Dislodge and inspect
needle
Dispense valve leak-
ing
Repair dispense valve
Regulator not operat-
ing correctly
Repair regulator
Pump wink passed
through outlet
Increase pump pres-
sure
Failed transducer Check transducer;
replace if failed
P3C_
P4C_
70 High Pressure Measured outlet pres-
sure greater than
desired outlet pressure
plus tolerance
Alarm or
Deviation
(user select-
able)
Incorrect limit set Verify limit is set cor-
rectly
Dispense hose/device
plugged
Clean/replace
hose/device
Failed transducer Check transducer;
replace if failed
Regulator is not clos-
ing completely when it
should
Repair regulator
F1D_
F2D_
71 Low Flow Rate Measured flow rate less
than desired flow rate
minus tolerance
Alarm or
Deviation
(user select-
able)
Fluid supply too low to
achieve desired flow
rate
Increase fluid supply
pressure or check for
clogged filter
Tip plugged Clean/replace tip
No air pressure to
solenoid valves
Turn on air to solenoid
valves
No flow meter signal Check cable and sen-
sor
No material supply Replace drum or turn
on pumps
Incorrect flow toler-
ance of flow error time
Enter correct toler-
ance or flow error time
F3D_
F4D_
72 High Flow Rate Measured flow rate
greater than desired
flow rate plus tolerance
Alarm or
Deviation
(user select-
able)
Operating below mini-
mum regulator operat-
ing pressure
Increase fluid pres-
sure above regulator
minimum
Regulator worn or not
operating correctly
Repair regulator
Flow meter providing
false pulses
Replace flow meter
sensor
Incorrect flow error tol-
erance or flow error
time
Enter correct toler-
ance or flow error time
EKD_ 73 Shot Terminated
by Job Timer
Shot dispense cycle
terminated by job timer
Advisory Job end timer was
used to stop shot dis-
pense
No action required if
timed shot is desired
EHD_ 74 Purge Timer
Expired
Purge timer expired Advisory PCF purge timer (style
0) has expired
Automation control
requests purge
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
Errors
3A2098H 73
EAC_ 75 Maintenance
Mode Entered
Maintenance mode
entered
Advisory
(self-clearing)
Entered maintenance
dispense mode
No action required
EBC_ 76 Maintenance
Mode Exited
Maintenance mode
exited
Advisory
(self-clearing)
Exited maintenance
dispense mode
No action required
MHD_ 77 Maintenance
Due - Regulator
Maintenance due for
regulator
Advisory Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
MFD_ 78 Maintenance
Due - Flow Meter
Maintenance due for
flow meter
Advisory Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
MED_ 79 Maintenance
Due - V/P
Maintenance due for
Voltage to Pressure
Transducer
Advisory Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
MCD_ 80 Maintenance
Due - Supply
Maintenance due for
supply system
Advisory 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 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
EAD_ 86 Swirl Mainte-
nance Mode
Entered
Swirl maintenance
mode entered
Advisory
(self-clearing)
Swirl zone that is
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 connec-
tions
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
Errors
74 3A2098H
CR1_ 88 Valve 1 Swirl
Communication
Error
Fluid plate communica-
tion error with swirl
Alarm The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
CR2_ 89 Valve 2 Swirl
Communication
Error
Fluid plate communica-
tion error with swirl
Alarm The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
CR3_ 90 Valve 3 Swirl
Communication
Error
Fluid plate communica-
tion error with swirl
Alarm The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
CR4_ 91 Valve 4 Swirl
Communication
Error
Fluid plate communica-
tion error with swirl
Alarm The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
WD1_ 92 Valve 1 Swirl
Fault
Swirl motor fault Alarm or
Deviation
(user-select-
able)
The swirl zone associ-
ated with this valve
and fluid plate caused
a fault
Resolve swirl motor
fault (see error WBDX
for possible solutions)
WD2_ 93 Valve 2 Swirl
Fault
Swirl motor fault Alarm or
Deviation
(user-select-
able)
The swirl zone associ-
ated with this valve
and fluid plate caused
a fault
Resolve swirl motor
fault (see error WBDX
for possible solutions)
WD3_ 94 Valve 3 Swirl
Fault
Swirl motor fault Alarm or
Deviation
(user-select-
able)
The swirl zone associ-
ated with this valve
and fluid plate caused
a fault
Resolve swirl motor
fault (see error WBDX
for possible solutions)
WD4_ 95 Valve 4 Swirl
Fault
Swirl motor fault Alarm or
Deviation
(user-select-
able)
The swirl zone associ-
ated with this valve
and fluid plate caused
a fault
Resolve swirl motor
fault (see error WBDX
for possible solutions)
MB1_ 96 Maintenance due
- V1 Orbiter
Maintenance due on
valve 1 swirl orbiter
Advisory The active time total-
izer for the swirl dis-
penser associated
with this valve and
fluid plate exceeded
limit setting
Service Component
If necessary, reset
totalizer
MB2_ 97 Maintenance due
- V2 Orbiter
Maintenance due on
valve 2 swirl orbiter
Advisory The active time total-
izer for the swirl dis-
penser associated
with this valve and
fluid plate exceeded
limit setting
Service Component
If necessary, reset
totalizer
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
Errors
3A2098H 75
Swirl Events and Errors
MB3_ 98 Maintenance due
- V3 Orbiter
Maintenance due on
valve 3 swirl orbiter
Advisory The active time total-
izer for the swirl dis-
penser associated
with this valve and
fluid plate exceeded
limit setting
Service Component
If necessary, reset
totalizer
MB4_ 99 Maintenance due
- V4 Orbiter
Maintenance due on
valve 4 swirl orbiter
Advisory The active time total-
izer for the swirl dis-
penser associated
with this valve and
fluid plate exceeded
limit setting
Service Component
If necessary, reset
totalizer
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Fluid Plate Events and Errors
Event
Code
Gateway
Error No. Event Name
Event
Description Event Type Cause Solution
Swirl Events and Errors
CBR_ --- Swirl Communi-
cation Error
Swirl communication
error with ADM
Alarm The ADM lost commu-
nication with the Swirl
Control DGM
Restore communica-
tions
CDR_ --- 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 mod-
ule after changing
rotary switch setting.
Refer to Swirl Control
DGM section, page 19.
EAD_ --- Maintenance
Mode Entered
Maintenance mode
entered
Advisory
(self-clear-
ing)
Swirl maintenance
mode entered
No action required
EBD_ --- Maintenance
Mode Exited
Maintenance mode
exited
Advisory
(self-clear-
ing)
Swirl maintenance
mode exited
No action required
MBD_ --- Maintenance
Due - Orbiter
Maintenance due on
swirl orbiter
Advisory Swirl active time total-
izer exceeded limit set-
ting
Service Component
If necessary, reset
totalizer
WBD_ --- Swirl Motor Fault Motor speed is outside
the +/- 50% tolerance
range for at least 5 sec-
onds while operating
Alarm Cable disconnected Verify cable connec-
tions 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
Maintenance
76 3A2098H
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
Electrical
* Check Component Manual for more detailed maintenance information.
Operator Maintenance Person
Task Daily 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 system for leaks ✓
Depressurize fluid, after opera-
tion ✓
Remove heat from system,
after operation ✓
Inspect filter (234967) bowls
and drain
✓
Check hoses for wear ✓
Check/tighten fluid connections ✓
Check/tighten air connections ✓
Lubricate dispense valves* ✓
Rebuild regulator* ✓
Rebuild dispense valve* ✓
Replace air filter ✓
Replace Solenoid ✓
Replace Voltage to Pressure
(V/P) Transducer
✓
* Check component manual for more detailed maintenance information.
Task Weekly
Check cables for wear ✓
Verify cable connections ✓
Verify operation of “System Stop” button ✓
Maintenance
3A2098H 77
Advanced Display Module
(ADM)
Upgrade Software
NOTE: Back up the custom language file (if installed)
before upgrading software. See USB Data, page 59, for
more information.
1. Turn off power to the system.
2. Remove token access panel, and then remove the
key token (do not discard token).
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
(BL) will flash until new software is completely
loaded.
5. After the red indicator light shuts off, turn off power
to the system.
6. Remove software token.
7. Reinstall key token, and replace token access
panel.
Cleaning
Use any alcohol-based household cleaner, such as
glass cleaner, to clean the display.
Upgrade Gateway Module
Software
NOTE: The Gateway module connection to the system
is temporarily disabled during the use of upgrade
tokens. The following instructions apply to all Gateway
modules.
1. Turn off power to the system.
2. Remove the access cover.
3. Insert and press token firmly into slot.
NOTE: There is no preferred orientation of token.
4. Turn on power to the system. The red indicator light
(CK) will flash until new software is completely
loaded.
F
IG
. 41: Remove Access Panel
F
IG
. 42: Insert Token
r_24E451_3B9900_3a
Access Panel
Token
BL
r_24E451_3B9900_4a
F
IG
. 43: Remove Access Cover
F
IG
. 44: Insert Token
TI12319A
Access
Cover
TI12320A
CK
Token
Maintenance
78 3A2098H
5. After the red indicator light shuts off, turn off power
to the system.
6. Remove token.
7. Replace access cover.
Upgrade Gateway Module
Fieldbus Map
NOTE: The fieldbus connection is temporarily disabled
during the 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.
2. Remove the access cover.
3. Insert and press map token firmly into slot.
NOTE: There is no preferred orientation of the 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.
5. Remove map token (CC) when software has suc-
cessfully uploaded.
6. Replace access cover.
F
IG
. 45: Remove Access Cover
Access
Cover
TI12319A
F
IG
. 46: Insert Token
Token
TI12320A
Push Button
CK
Maintenance
3A2098H 79
Upgrade Fluid Control Module
(FCM) Software
NOTE: The FCM connection is temporarily disabled
during the use of the upgrade token.
1. Turn off power to the system.
2. Remove access cover then remove key token (do
not discard token).
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.
5. After the red indicator light shuts off, turn off power
to the system.
6. Remove software token.
7. Reinstall key token, and replace access cover.
Air Filter Maintenance
To prevent filter element damage, replace air filter every
two years or when pressure drop becomes 100 kPa
(1.0 bar, 14.5 psi) or greater; which ever occurs first.
Replacement Air Filters for Dual Filter
Assembly (234967)
Swirl Dispensers
See manual 309403 for maintenance schedule.
F
IG
. 47: Remove Access Cover
F
IG
. 48: Insert Token
TI12334A
Access
Cover
CK
Token
TI12335A
Part Description
123091 5 micron air filter
123092 0.3 micron air filter
Repair
80 3A2098H
Repair
Fluid Plate Assembly
This section describes how to remove and replace com-
ponents on the fluid plate assembly.
Prepare Fluid Plate Assembly for
Repair
1. Disconnect the CAN cable from the fluid plate.
2. Perform Pressure Relief Procedure on page 57.
3. Remove the fluid plate assembly shroud. See Fluid
Plate Assembly Parts, page 94.
Repair Flow Meter
For complete flow meter (129) repair instructions refer to
the maintenance and repair section of manual 309834.
Remove Flow Meter from Mounting Plate
1. Prepare Fluid Plate Assembly for Repair, page
80.
2. Disconnect the flow meter cable (131) from the flow
meter sensor. See F
IG
. 49.
3. Disconnect the material hose.
4. Disconnect the swivel fitting (109) from the regula-
tor.
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).
F
IG
. 49: Fluid Plate Assembly
129
108
101
124
125, 126, 127
109
131
103
r_pf0000_313377_18a
Repair
3A2098H 81
Install Flow Meter on Mounting Plate
1. Rest the flow meter (129) and bracket (124) on the
fluid plate while threading the swivel fitting (109)
onto the regulator material inlet. See F
IG
. 49.
2. Tighten the swivel fitting to the regulator material
inlet.
3. Tighten the four screws (127) and washers (125,
126) to hold the bracket and flow meter in place.
4. Check that the flow meter and regulator (108) are
still aligned.
5. Connect the material hose.
6. Connect the flow meter cable (131).
Replace Solenoid
1. Prepare Fluid Plate Assembly for Repair,
page 80.
2. Disconnect FCM cable and all three air tubes.
3. Remove both screws (137) from transducer
bracket (118).
4. Remove the dispense valve solenoid (132) and
replace it with a new solenoid.
5. Secure the new solenoid to the bracket with screws.
6. Reconnect the FCM cable and all three air tubes.
Replace Voltage to Pressure (V/P)
Transducer
1. Prepare Fluid Plate Assembly for Repair, page
80.
2. Disconnect the FCM cable and both air tubes.
3. Remove both transducer screws (122) from trans-
ducer bracket (118).
4. Remove the V/P transducer (121) and replace it
with a new V/P transducer.
F
IG
. 50
r_pf0000_313377_34a
129
108
125
124
126
127
109
F
IG
. 51
F
IG
. 52
137
132
118
r_pf0000_313377_33a
122
121
118
r_pf0000_313377_31a
Repair
82 3A2098H
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.)
3. Remove the following cables from FCM:
• dispense valve solenoid cable
• meter sensor cable
• both V/P cables
• I/O cable
• inlet pressure transducer cable (ambient mod-
els only)
• outlet pressure transducer cable
4. Remove the two screws from FCM (103) and
replace with a new FCM.
5. Secure the new FCM to the base (102) with screws.
6. Reconnect the cables listed in step 3.
7. Reattach the transducer bracket using screws.
Replace Fluid Control Module Base
1. Prepare Fluid Plate Assembly for Repair, page
80.
2. Remove the FCM (103); follow Replace Fluid Con-
trol Module. (Leave the cables attached to the
FCM.)
3. Remove the power supply cable from the base
(102).
4. Remove the four screws (105) and ground screw
(106) from the base and replace it with a new base.
5. Secure the base to the fluid plate (101) with screws.
6. Reconnect the power supply cable.
7. Reattach the FCM; follow Replace Fluid Control
Module.
F
IG
. 53
128
121
118
132
r_pf0000_313377_30a
102
103
F
IG
. 54
106
105
103
102
Repair
3A2098H 83
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).
3. Press the transducer (CG) out of the retainer nut
(CH).
4. Remove the faulty o-ring (120) and replace with
new.
5. Press the transducer back into the retainer nut.
6. Reconnect the fluid outlet pressure sensor to the
regulator.
F
IG
. 55
F
IG
. 56
117
108
r_pf0000_313377_16a
120
CH CG
Repair
84 3A2098H
Repair Fluid Regulator
For complete cartridge fluid regulator repair refer to
instruction manual 308647. For complete mastic fluid
regulator repair refer to instruction manual 307517.
See F
IG
. 57 and perform the following steps.
1. Prepare Fluid Plate Assembly for Repair,
page 80.
2. Remove the cartridge assembly by loosening the
valve housing (CE) with a 6 mm hex wrench and
pulling the cartridge assembly out of the base hous-
ing (CD).
NOTE: The retaining nut (CC) often loosens when
removing the cartridge assembly from the base housing.
Be sure to re-torque as described in step 4.
3. Inspect and clean the internal walls of the base
housing (CD).
NOTE: Be careful to not scrape or gouge the internal
walls of the base housing. They are a sealing surface.
4. Re-torque the retaining nut (CC) to 140-160 in-lb
(16-18 N•m).
NOTE: You must re-torque the retaining nut before you
install it in the base housing during step 5.
5. Install the new cartridge assembly in the base hous-
ing (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.
NOTICE
Carefully handle the hard carbide ball, valve actua-
tor, and valve seat to avoid damaging them.
F
IG
. 57: Replace Cartridge Assembly
diaphragm
and valve
actuator
subassembly
cartridge
assembly
Torque Sequence for Regulator
Base Housing Screws (CF)
4
23
1
CD
CE
CC
Cartridge Regulator 244734 Shown
CF
Repair
3A2098H 85
Replace Amplifier
(Heated fluid plates only)
1. Prepare Fluid Plate Assembly for Repair, page
80.
2. Disconnect pressure sensor cable (117) and power
output cable.
3. Loosen four screws on amplifier (116) cover, and
then remove cover.
4. Remove four screws (105) securing amplifier to
bracket.
5. Remove amplifier and replace with a new amplifier.
6. Secure new amplifier to bracket with four screws.
7. Replace amplifier cover and tighten screws.
8. Reconnect pressure sensor cable (117) and power
output cable.
Calibrate Amplifier
(Heated fluid plates only)
1. Prepare Fluid Plate Assembly for Repair, page
80.
2. Remove outlet pressure sensor from outlet fitting to
ensure there is no pressure applied to the sensor.
Adjust Display Settings
3. With the system in setup mode, navigate to the
Advanced screens.
4. Press to scroll to Advanced screen 2.
5. Press to access the fields to make changes.
6. Press to move the Pressure Units field. Press
to open the drop-down list, and select psi.
Press to enter the new units.
7. Press to exit edit mode.
8. With the system still in setup mode, navigate to
Fluid Plate x, screen 5 (Pressure Sensors).
9. Press to access the fields to make changes.
10. Press to move the Outlet Offset field. Set the
psi to 0. Press to enter the new setting.
11. Press to exit edit mode.
F
IG
. 58: Replace Amplifier
117
116
Screw
Power Output Cable
Repair
86 3A2098H
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 F
IG
. 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 documenta-
tion or the replacement pressure sensor) to calcu-
late the Shunt Calibration Pressure using the
following formula:
18. Adjust the FINE GAIN potentiometer until the Outlet
Pressure on Fluid Plate x, screen 5 (Pressure Sen-
sors) matches the calculated Shunt Calibration
Pressure.
19. Remove the jumper wire or paper clip from the
SHUNT CAL and ENABLE terminals.
20. Repeat steps 15 - 19 at least one additional time to
ensure proper calibration.
21. Replace the amplifier cover. See Replace Ampli-
fier, page 85.
22. Reconnect the outlet pressure sensor cable if it was
removed.
23. If desired, change pressure units to desired setting
on Advanced screen 2.
Shunt Calibration Pressure = (Shunt Cal Factor /
Calibration Factor) * 5000 psi
F
IG
. 59: Amplifier Settings
1
2
3
4
5
6
A
B
C
D
E
F
EXCITATION MODULE
TRANSDUCERPOWER
(+)SUPPLY
(+)SIGNAL
(-)SIGNAL
(+)EXCITATION
(-)EXCITATION
(-)OUTPUT
(+)OUTPUT
SHUNT CAL SHUNT CAL
RESISTOR
ENABLE
EX SEL
10 VDC
5 VDC
3 VDC
ZERO
COARSE
FINE
FINE
SPAN
COARSE
12345678
ON
SUPPLY RETURN
Excitation Selector
Coarse Zero
Fine Zero Fine Gain
Coarse Gain
Panel mounting holes.
Use #6 or #8 screws.
To Transducer
To Readout
Repair
3A2098H 87
Control Center Assembly
Prepare Control Center for Repair
1. Power off the display.
2. Disconnect main power to the control center assem-
bly.
3. Remove the control center assembly front cover
(20).
Replace Gateway Module
1. Prepare Control Center for Repair, page 87.
2. Remove the automation communications cable
(AE).
3. Remove the two screws holding the Gateway mod-
ule (5) to the base (3), and remove the module.
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.
Replace Gateway Module Base
1. Prepare Control Center for Repair, page 87.
2. Remove the Gateway module (5); follow Replace
Gateway Module. (Leave automation communica-
tions cable (AE) attached to Gateway module.)
3. Disconnect the CAN cable (19) and power supply
cable (6) from the base (3).
4. Remove the four screws (16) and grounding
screw (12) from the base and replace it with a new
base.
5. Secure the new base to rear cover (1) using the five
screws.
6. Reattach Gateway module; follow Replace Gate-
way Module.
F
IG
. 60
5
3
F
IG
. 61
1
16
19
3
12
5
4
6
Repair
88 3A2098H
Replace Swirl Board 16K570:
1. Prepare Control Center for Repair, page 87.
2. Remove screw (a) from swirl board cover. Open
swirl board cover.
3. Remove cable connectors (b) from swirl board.
4. Remove the four screws (c) from the swirl board.
Replace with new board and secure using the four
screws (c).
5. Insert cable connectors (b) into the new board.
6. Reassemble the swirl board cover using screw (a).
Replace Advanced Display Module
1. Prepare Control Center for Repair, page 87.
2. Disconnect the CAN cable (18) from the ADM (2).
3. Remove the ADM by snapping it out of the mounting
bracket.
4. On old ADM, remove token access panel then
remove key token. Do not discard token.
5. Connect the CAN cable to the new ADM.
6. Upgrade new ADM software, page 77.
7. Insert key token into new ADM. Replace token
access panel.
8. Install the new ADM by snapping it into the mount-
ing bracket.
F
IG
. 62
a
b
c
F
IG
. 63
18 11, 14, 24
2
21
Repair
3A2098H 89
Replace Advanced Display Module Bracket
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.)
3. Remove the speed clips (25) and rivets (26) from
the mounting bracket (21).
4. Remove the mounting bracket from the front cover
(20) and replace with a new bracket.
5. Secure the new bracket to the front cover with
speed clips and rivets.
6. Reinstall the ADM.
Replace DIN Rail Assembly
1. Prepare Control Center for Repair, page 87.
2. Remove both screws (22) and washers (28) from
the line voltage assembly cover (7). Remove the
cover.
3. Disconnect all wiring from the din rail module and fil-
ter.
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.
F
IG
. 64
2
26
20
21
25
F
IG
. 65
22 28
7
Repair
90 3A2098H
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.
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.
F
IG
. 66: 24 Vdc Din Rail Assembly
F
IG
. 67: Fuse Location
40
40 40
r_pf0000_313377_10a
1
Fuses
r_pf0000_313377_10a
Parts
3A2098H 91
Parts
Control Centers
Software Upgrade Tokens
Control Center Key Token Part Numbers
See Key Tokens on page 20 for more information about
key tokens.
Gateway Module Part Numbers
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 Gate-
way, have purchased a new PCF, and do not
wish to change their Gateway setup from the
old Gateway map to the new Gateway map.
Part Description
★16M217 ADM Key Token, Standard PCF
PCF
Model
User
Interface
Description
Gateway Part
Number To
Order
PFxx0x Discrete ★24B681
PFxx1x DeviceNet
™
★15V759
PFxx2x Ether-
Net/IP
™
★15V760
PFxx3x PROFIBUS
™
★15V761
PFxx4x PROFINET
™
★15V762
Parts
92 3A2098H
Control Center and Expansion Swirl Enclosure Parts
50
13
15
22
40
28
7
9
44
24
1
3
16
12
4
5 or 43
20
26
241114
21
25
2
6,10
38
23,27
18
13
19
24 VDC units only:
15,36
100-240 VAC units only:
6,36
43
3,4,12,16
6;
Ground/
Green
6;
Neutral/
Blue
6;
Line/
Brown
37
1
Add ferrite (36) to cable. Locate
as close to cable connector as
possible.
Included in swirl models only
(both control centers and
expansion swirl enclosures).
Control centers only. Not included
in expansion swirl enclosures.
100-240 Vac models only.
1
13
14
15
26
49
22
28
45
25
22
25
47
22
48
44
13
13
13
13
13
13
13
13
13
13
50
13
13
13
14
14
14
14 14 14
14
14 14
14
14
14
15
Parts
3A2098H 93
Control Center Assembly Parts
▲
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-spe-
cific software installed. Use software upgrade token
(16K743) to install software before use.
* Fieldbus Gateway modules do not have a PCF-spe-
cific map installed. Use map token (16N601) to
install map before use.
--- Not for sale.
Ref. Part Description Qty.
1 --- COVER, rear 1
2✠24E451 DISPLAY, with USB 1
3◆289697 BASE, cube 1
4◆277674 ENCLOSURE, cube door 1
5✠--- MODULE, Gateway; see table on
page 91 for part number
1
6‡ --- SUPPLY, power 1
7‡❖--- COVER, line voltage 1
8‡❖--- GROMMET 1
9▲‡ 196548 LABEL, warning, electric shock 1
10‡ --- SCREW, cap, socket hd; m4 x 6 4
11✿--- WASHER, lock 1
12◆121820 SCREW, mach, pan hd; m4 x 35 1
13 121807 CONNECTOR, splitter 1
14✿110755 WASHER, plain 1
15‡❖--- MODULE, line voltage 1
16◆195875 SCREW, mach, pan hd 4
18 121001 CABLE, CAN, female / female 1.0m 1
19 121000 CABLE, CAN, female / female 0.5m 1
20 --- COVER, front 1
21✿--- BRACKET, mounting 1
22‡❖--- SCREW, mach, pan hd 2
23 120143 GUIDE, strain relief 2
24✿121253 KNOB, display 2
25✿--- CLIP, speed, tubular 2
26✿--- RIVET, aluminum 1
27 112925 SCREW, cap 2
28 100020 WASHER, lock 2
36 121901 SUPPRESSOR, box snap, ferrite 2
37 124654 CONNECTOR, splitter 1
38 --- LABEL 1
40 --- SCREW, mach, pan hd 4
43✠24B681 MODULE, DGM 1
44 --- GUARD, edging 1
45 16K570 BOARD, circuit, swirl 1
46 --- BRACKET, display pivot 1
47 --- COVER, swirl, hinge side 1
48 --- COVER, swirl, latch side 1
49 --- COVER, swirl, lid 1
50 24K455 CABLE, swirl board, panel mount 1
51 24K458 CABLE, SWIRL-DGM 1
52 121597 CABLE, CAN, 90 female/90 female 1
Ref. Part Description Qty.
Parts
94 3A2098H
Fluid Plate Assembly Parts
See page 96
See page 95
101
143
142
152
131
153
151
See page 95
135, 136
199
117, 120
Parts
3A2098H 95
Fluid Plate Assembly Parts (continued)
105
103
106
105
102
104
141
141
118
122
141
122
141
128
133
128
137
141
132
128
121
137
125
126
129 124
127
126
125
109
110
126
130
155 127
128
Parts
96 3A2098H
Fluid Plate Assembly Parts (continued)
111
141
113
112
113
112
127
127
114
108
115
117
108
105, 116
Fluid Plate 24B962
149
140, 141, 150
158
139
107
148
145
Shown
159
160
199
ti19262a
119
Parts
3A2098H 97
Fluid Plate Assembly Parts
▲
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-spe-
cific software installed. Therefore, use software
upgrade token (16K743) to install software before
use.
★
Not shown.
--- Not for sale.
* CAN splitter is not included with the fluid plate
assembly included in the PFxxxx assembly. It is
included only with the additional fluid plate kits.
Fluid Plate Key Token Part Numbers
See Key Tokens on page 20 for more information about
key tokens.
Ref. Part Description Qty.
101 --- PLATE, fluid 1
102 289697 BASE, cube 1
103✠289696 FCM, cube 1
104 277674 ENCLOSURE, cube door 1
105✓--- SCREW, mach, pan hd
106 121820 SCREW, machine, pan hd; m4 x
35
1
107 121228 CABLE, CAN, female/female;
15.0 m
1
108✓--- REGULATOR, assy
109✓--- UNION, adapter
110✓--- NIPPLE, reducing, hex; 1/2 npt(f)
x 3/4 npt(f)
111 198269 BRACKET, flow meter, lower 1
112 110580 SCREW, cap, socket hd 2
113✓--- SPACER
114 198268 BRACKET, flow meter 1
115✖624545 FITTING, tee; 3/4(m) x 1/4(f) 1
116✖258530 AMPLIFIER, signal conditioner 1
117✓--- SENSOR, pressure, fluid outlet 2
118 --- BRACKET, valve 1
119✖16P819 BRACKET, signal conditioner 1
120✓--- O-RING
121 120010 REGULATOR, I/P 1
122 111119 SCREW, valve 2
124✓--- BRACKET, helical gear meter
125✓--- WASHER, plain
126✓--- WASHER, lock, spring; m6
127✓--- SCREW, cap, socket hd
128✓--- SCREW, cap, socket hd, hex
129✓--- METER, assy
130✓--- CABLE; m12-5p
131▲15X756 LABEL, warning, main 1
132 258334 VALVE, dispense, fluid plate 1
133 121806 CABLE, solenoid 1
135▲✖ 189285 LABEL, caution, hot surface 1
136 --- LABEL 1
137 117820 SCREW, cap, socket hd; m3 2
139 198179 FITTING, bulkhead, union 1
140 198175 FITTING, push 1
141 --- TUBE, nylon, round, black; 5.5
142 --- LABEL 1
143 --- SHROUD, fluid plate 1
145 121226 CABLE,CAN, male/female; 0.5
m
1
146★234967 KIT, dual filter 1
147✓★ --- TOKEN, key
148 121612 CONNECTOR, thru; m12, m x f 1
149 121818 BULKHEAD, tube; 5/32 2
150 --- TAG, installation 1
151 114391 SCREW, grounding 1
152 194337 WIRE, grounding, door 1
153▲186620 LABEL, ground 1
155✓--- SUPPRESSOR, box snap, ferrite
158 122610 ELBOW 1
159▲290228 LABEL, caution, hot surface 1
160▲189930 LABEL, caution, electric shock 1
199* 124654 SPLITTER, CAN 1
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
Ref. Part Description Qty.
Parts
98 3A2098H
Parts Varying by Assembly
The following table lists the varying part numbers by fluid plate assembly, and the quantity for each assembly.
--- Not for sale.
Ref. Part Description
Fluid Plate Assemblies
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
Heated
Mastic
Regulator
with
No Meter
105 195875 SCREW, mach, pan
hd
444488
108 244734 REGULATOR, assy 1 1
246642 11
246643 11
109 156684 UNION, adapter 1 1
157785 1
110 C20461 NIPPLE, reducing,
hex; 1/2 npt(f) x 3/4
npt(f)
1
C20487 1 1
113 C34045 SPACER 2 2
117 15M669 SENSOR, pressure,
fluid outlet
2222
117764 11
120 111457 O-RING 2 2 2 2
124 117670 BRACKET, helical
gear meter
1 1 1
125 C19197 WASHER, plain 4 4 4
126 --- WASHER, lock,
spring; m6
6 6 6
127 108328 SCREW, cap, socket
hd
626262
128 107530 SCREW, cap, socket
hd, hex
646464
129 246652 METER, assy. 1 1
246340 1
130 122030 CABLE; m12-5p 1 1 1
147
★
16M100 TOKEN, key, 2 styles,
meter enabled
1 1 1
16M101 TOKEN, key, 2 styles,
meter disabled
1 1 1
16M102 TOKEN, key, 16
styles, meter enabled
11 1
16M103 TOKEN, key, 16
styles, meter disabled
1 1 1
16M104 TOKEN, key, 256
styles, meter enabled
11 1
16M105 TOKEN, key, 256
styles, meter disabled
1 1 1
155 121901 SUPPRESSOR, box
snap, ferrite
11 1
Appendix A - Advanced Display Module (ADM)
3A2098H 99
Appendix A - Advanced Display Module (ADM)
Display Overview
The ADM display is divided into two main functions:
Setup Mode and Run Mode.
Setup Mode Functions
The setup mode functions enable users to:
• configure installed system components
• set units, adjust values, set formats, and view
software information for each component
• set or change information regarding the Gate-
way module
• view information regarding the particular Gate-
way module used
• set controls and valve commands
• set on and off delays for valves and the regula-
tor
• set k-factor, pressure, and flow rate variables
• set offsets for inlet and outlet pressures
• set error types
• set variables for maintenance advisories
• set up to 256 styles for models with a CGM and
set up to 16 styles for models with a DGM
Run Mode Functions
The run mode functions enable users to:
• adjust the bead scale
• perform manual dispensing
• view a chronological list of system errors
• view a chronological list of jobs stored/per-
formed in the system
• use a preventative maintenance schedule for
the supply system, displacement pump, and air
motor
Display Details
Power Up Screen
The following screen appears when the ADM is pow-
ered up. It remains on while the ADM runs through ini-
tialization and establishes communication with other
modules in the system.
Menu Bar
The menu bar appears at the top of each screen.
Date and Time
The date and time are always displayed in one of the fol-
lowing formats. The time is always displayed as a
24-hour clock.
• 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.
Appendix A - Advanced Display Module (ADM)
100 3A2098H
System Mode
There are five modes: Active, Job in Cycle, Display Con-
trol, Swirl Setup, and System Off. The current system
mode is displayed at the left of the menu bar.
Alarm/Deviation
If there is an active system error, one of the following
icons is displayed in the middle of the menu bar. There
are four possibilities:
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.
Jump In/Jump Out
In screens that have editable fields, press to access
the fields and make changes. When changes are com-
plete press again to exit edit mode.
Navigation within Screens
Press to open drop-down menus on Setup
screens. Also, press to enter changes or make a
selection.
Press to navigate to new screens and to nav-
igate left and right within a screen.
Press to navigate to new screens and to navi-
gate up and down within a screen. Also press
to move between fields within a drop-down menu, and to
increment or decrement numbers within a field.
Icon Function Description
No Icon
No information or
no error has
occurred
---
Advisory Informational
Deviation
Important but will
not shut down the
affected fluid
plate
Alarm
Very important
and will immedi-
ately shut down
the affected fluid
plate
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Appendix A - Advanced Display Module (ADM)
3A2098H 101
Setup Mode
Setup mode screens are divided into five sections: Sys-
tem setup, Advanced setup, Gateway setup, Fluid Plate
setup, and Swirl setup. While in Run mode, press
to enter Setup mode. Press to navigate
through the Setup mode screens.
If the setup screens are password protected, a pass-
word 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 screens. Once in the desired Advanced
setup screen, press to access the fields to make
changes. Press to exit edit mode.
NOTE: Users must be out of edit mode to scroll through
the Advanced setup screens.
Advanced Setup Screen 1
This screen enables users to set the language, date for-
mat, current date and time, password, and number of
minutes before the screen saver comes on. The time
does not automatically update for daylight savings time.
Advanced Setup Screen 2
This screen enables users to set the units of measure
for maintenance volume, maintenance mass, pressure,
and flow rate.
Advanced Setup Screen 3
This screen enables users to setup USB-related set-
tings. The Disable USB Log Errors option disables
recording events when the logs are at least 90% full.
Advanced Setup Screen 4
This screen displays the software part number and ver-
sion for the ADM, USB configuration, Gateway module,
and fluid plates.
Appendix A - Advanced Display Module (ADM)
102 3A2098H
Automation Gateway Setup Screens
There are up to three automation Gateway Setup
screens (depending on fieldbus), which enable users to
set or change information regarding the automation
Gateway module used on the PCF system. These
screens also enable users to view information regarding
the particular automation Gateway module used.
Press to scroll through the Gateway Setup
screens. Once in the desired Advanced Setup screen,
press 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 hard-
ware revision number, system serial number, map ID,
name, revision number, and install date.
Gateway Setup Screen 1 - EtherNet/IP
This screen enables users to set the IP address, subnet
mask, Gateway, DNS 1, DNS 2, and if a DHCP is used.
Gateway Setup Screen 2 - EtherNet/IP
This screen is the same for EtherNet/IP and PROFI-
BUS. It enables users to view the following information
regarding the Gateway module used on the PCF sys-
tem:
• hardware revision number
• system serial number
• map ID number
• map name
• map revision number
• date the map was created
Appendix A - Advanced Display Module (ADM)
3A2098H 103
Gateway Setup Screen 1 - PROFIBUS
This screen enables users to set the device address,
install date, location tag, function tag, and system
description.
Gateway Setup Screen 2 - PROFIBUS
This screen is the same for EtherNet/IP and PROFI-
BUS. See Gateway Setup Screen 2 - EtherNet/IP,
page 102, for details.
Gateway Setup Screen 1 - PROFINET
This screen enables users to set the IP address, subnet
mask, Gateway, DNS 1, DNS 2, and if a DHCP is used.
Gateway Setup Screen 2 - PROFINET
This screen enables users to set the device address,
install date, location tag, function tag, and system
description.
Gateway Setup Screen 3 - PROFINET
This screen enables users to view the following informa-
tion regarding the Gateway module used on the PCF
system:
• hardware revision number
• system serial number
• map ID number
• map name
• map revision number
• date the map was created
Appendix A - Advanced Display Module (ADM)
104 3A2098H
Discrete Gateway (Automation) Setup Screen
NOTE: The Discrete Gateway Setup screen is not avail-
able if an automation Discrete Gateway Module (DGM)
is not attached to the system.
NOTE: If Swirl Dispensers are installed, a Swirl Discrete
Gateway Module will be installed. This section is not
related to that module. See Control Center Assembly
Overview on page 16 for gateway identification.
This screen enables users to set Active Errors to High
(default) or Low. If High is selected, alarm and error sig-
nals are low during normal operation and high if an
alarm or error exists. If Low is selected, alarm and error
signals are high under normal operation and low if an
alarm or error exists.
This screen also enables users to select the Command
Value Type signal (Analog or Digital) the automation
system will provide to PCF. If Analog control is selected,
the user must provide an analog voltage to the proper
input on the DGM. See Appendix B - Discrete Gate-
way Module (DGM) Connection Details, page 115, for
connection details.
If Digital control is selected and one fluid plate is
installed, the user can define three digital settings for
each dispense valve. If Digital control is selected and
two fluid plates are installed, the user can define two
digital settings for each dispense valve. The user must
provide two digital signals to the proper inputs on the
DGM. See Appendix B - Discrete Gateway Module
(DGM) Connection Details, page 115, and the Digital
Command Logic Table for connection details.
NOTE: The control mode for each dispense valve is set
in the Fluid Plate x, Screen 2 (Mode Settings), page
105. For example, if Valve 1 is set to Pressure mode on
the Fluid Plate x, Screen 2 (Mode Settings), then the
digital commands for Valve 1 are pressure values.
The Digital Command Logic Table indicates which value
each input must be set to in order to select a particular
setting.
Digital Command Logic Table
(Single Fluid Plate Systems)
Digital Command Logic Table
(2-Fluid Plate Systems)
Press to access the fields to make changes. Press
to exit edit mode.
Digital
Command
Input 1
Digital
Command
Input 2
Resulting Digital
Command Selection
Low Low Setting #1
High Low Setting #2
--- High Setting #3
Digital
Command
Input 1
Digital
Command
Input 2
Resulting Digital
Command Selection
Low
--- Fluid Plate 1,
Setting #1
High
--- Fluid Plate 1,
Setting #2
--- Low
Fluid Plate 2,
Setting #1
--- High
Fluid Plate 2,
Setting #2
Single fluid plate system
2-fluid plate system
Appendix A - Advanced Display Module (ADM)
3A2098H 105
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 regula-
tor
• Set k-factor, pressure, and flow rate variables
• Set offsets for inlet and outlet pressures
• Set error types
• Set variables for maintenance advisories
• Define styles
• Associate swirl dispenser with fluid plate
Press to scroll through the fluid plate setup
screens. Once in the desired screen, press to
access the fields to make changes. Press to exit
edit mode.
NOTE: Users must be out of edit mode to scroll through
the fluid plate setup screens.
Fluid Plate x, Screen 1 (Control Settings)
This screen enables users to:
• Set the dispense trigger source to Gateway, Com-
mand Cable, Command Cable 3x, or Combined. If it
is set to Command Cable, users can enable the
valves.
• Set the command value source to Gateway, Com-
mand 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 Dis-
able. When entering maintenance mode, a pass-
word prompt will appear if the Display Control
Password is set to Enable and a password is set in
the Advanced setup screens.
• Set the Run Mode Bead Adjust to Enable or Dis-
able.
NOTE: Run mode bead adjust allows a user to quickly
adjust flow rate or pressure from the run screen.
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.
Appendix A - Advanced Display Module (ADM)
106 3A2098H
Attempting to dispense from multiple valves simultane-
ously using any other combination will cause an Incom-
patible 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.
Appendix A - Advanced Display Module (ADM)
3A2098H 107
Fluid Plate x, Screen 5 (Pressure Sensors)
NOTE: Inlet sensor settings will be grayed out on this
screen for systems with heated fluid plates.
This screen enables users to:
• 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.
Fluid Plate x, Screen 6 (Error Type)
This screen enables users to set the error type (none,
alarm, or deviation) that will be issued if the pressure,
flow rate, volume, or computed target goes outside the
tolerance settings of the active style. See Configure
Errors on page 36.
NOTE: Only the low/high pressure errors will be
enabled for systems without a flow meter.
• 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 vol-
ume defined in the style
Appendix A - Advanced Display Module (ADM)
108 3A2098H
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 sup-
ply, voltage to pressure (V/P) transducer, fluid regulator,
flow meter, and all four valves.
NOTE: Hours is shown instead of Volume for fluid plates
without a flow meter.
The Volume (or Hours) column displays the current
totalizer value. If this value exceeds the set limit, the
value will turn red and a maintenance advisory is issued.
See Fluid Plate x, Screen 3 (Maintenance Totalizers),
page 113, for more information about maintenance total-
izers.
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.
Appendix A - Advanced Display Module (ADM)
3A2098H 109
Fluid Plate x, Screen 9 (Swirl Association)
This screen enables users to set the swirl to fluid plate
association. This allows the system to apply errors to
the correct fluid plate when a swirl error occurs, and to
stop the correct fluid plate from dispensing when certain
swirl errors occur.
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 .
Swirl Setup Screen
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 Dis-
able
• Set the speed scale from 50-150%
• Set the Swirl Orbiter Maintenance Advisory Limit
Appendix A - Advanced Display Module (ADM)
110 3A2098H
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:
• 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).
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
Appendix A - Advanced Display Module (ADM)
3A2098H 111
Fluid Plate x, Screen 1
This screen displays the current dispense control mode
used, the current pressure, and the current style being
dispensed. It also displays the target dispense volume,
the actual dispense volume, and the requested dis-
pense volume.
From this screen users can adjust the bead scale and
enter maintenance mode. Press and to
change the bead scale. Press to enter mainte-
nance mode.
The PCF system has two operating modes:
• Dispense mode – enables the module to begin dis-
pensing when it receives a command from the auto-
mation unit.
• Maintenance mode – enables the module to begin
dispensing when the user presses the manual dis-
pense button. Dispense parameters and duration
depend on the selected control.
Dispensing continues for as long as the manual dis-
pense button is pressed.
Current Dispense
Control Mode Outlet Pres-
sure
Current Command
Value
Flow Rate
(systems with flow
meters)
Inlet Pressure
(non-heated systems)
Command Voltage
(Displays only when
Command Cable or Gate-
way is selected as the
Command Value Source;
see Fluid Plate Setup
Screens, page 105.)
Active Style Progress Bar Volumes
Active Dispense
Valves
Associated Swirl
Dispensers
Bead Scale
Quickly adjust pres-
sure/flowrate from this
screen
Appendix A - Advanced Display Module (ADM)
112 3A2098H
Maintenance Mode
Press 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.
See Maintenance Mode Operation, page 41, for
instructions on changing the control mode, target pres-
sure, and number of dispense valves used.
Dispense Control Modes
The PCF system has four fluid dispensing control
modes.
• 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 con-
sistent bead size is required.
• Shot Control – the regulator outlet pressure is con-
trolled to the requested value. The dispense valve is
closed when the target volume is reached or when
the automation controller provides a signal.
• Pressure Control – the regulator outlet pressure is
controlled to the requested value.
• Full Open Control – the PCF system does not con-
trol fluid pressure or flow. Instead the regulator
opens to allow for recirculation applications.
Appendix A - Advanced Display Module (ADM)
3A2098H 113
Fluid Plate x, Screen 2 (Control Center)
NOTE: Users must be out of maintenance mode in Fluid
Plate x, screen 1 in order to scroll to this screen.
NOTE: The term “Robot” on this screen refers to the
automation controller.
This screen enables users to view and monitor the cur-
rent status of the “robot” outputs and inputs. An X is dis-
played in the applicable check box when:
• 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
This screen also displays the current dispense style,
command voltage, Gateway error number/code, and the
volume dispensed.
Fluid Plate x, Screen 3 (Maintenance Totalizers)
This screen enables users to view the maintenance
totalizers for each system component and the limits set
that will trigger a maintenance advisory.
Maintenance totalizers keep track of the total volume (or
hours) that each system component has been running.
If the totalizer value exceeds the set limit, the totalizer
value will turn red and a maintenance advisory is issued.
The limits are set in the Fluid Plate x, Screen 7 (Main-
tenance Advisory Limits), page 108, for the air supply,
voltage to pressure (V/P) transducer, fluid regulator,
flow meter, and all four valves.
NOTE: If a flow meter is not included in the system, this
screen shows hours instead of volume and the flow
meter entry is grayed out.
Appendix A - Advanced Display Module (ADM)
114 3A2098H
Swirl X Screen
There is one Swirl X screen for each installed swirl dis-
penser. This screen displays the following items:
• Swirl Enable signal from the automation interface
• Speed command voltage from automation interface
• Actual and requested speed
• Active time and maintenance advisory limit
Job Report Screens
The job report screens store and display a chronological
list of 180 jobs performed by the system. Each job
record includes the date and time the job was com-
pleted; the style dispensed; the error percentage; and
the target, requested, and actual dispense volumes.
Press to scroll through each job report screen.
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.
Press to scroll through each event report
screen.
Error Report Screens
The error report screens display a chronological list of
system errors. These screens display the last 200
errors. Each error report screen displays the date, time,
error code, and description for each 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.
Appendix B - Discrete Gateway Module (DGM) Connection Details
3A2098H 115
Appendix B - Discrete Gateway Module (DGM) Connection Details
D-Sub Cable 123793
The D-sub cable 123793 is only compatible with single fluid plate systems. Systems with 2 fluid plates must use
cable 123792 and breakout board 123783.
The cable length of interface cable assembly 123793 is 50 ft (15.2 m). The following table identifies the cable inter-
face signals.
NOTE: See Appendix D - I/O Signal Descriptions, page 138, for I/O signal descriptions.
◆
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.
Wire Color Description Pin Type D-Sub
Pin No.
Green/Yellow Isolated Logic Power Supply Supply 51 and 27
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 --- 3
Blue/Gray Swirl 1 Speed Command ◆Analog Input 21
Brown/Gray Swirl 2 Speed Command ◆Analog Input 23
White/Orange Dispense Valve 3/
Swirl 1 Enable◆Digital Input 75
Black/Orange Dispense Valve 4/
Swirl 2 Enable◆Digital Input 76
Black/Green Digital CMD 1 Digital Input 77
White/Green Digital CMD 2 Digital Input 78
Orange --- N/C
Appendix B - Discrete Gateway Module (DGM) Connection Details
116 3A2098H
D-Sub Cable 123792 and Breakout Board 123783
The cable length of the interface cable assembly 123792 is 50 ft (15.2 m). The following table identifies the pin
assignments for the 78-pin breakout board
.
NOTE: See Appendix D - I/O Signal Descriptions on page 138.
D-Sub
Pin No. Description Pin Type Voltage (Vdc)
1 Command Value (Fluid Plate 1) Analog In 0 - 10
2 Command Value Ground (Fluid Plate 1) Analog In Ground 0
3 Command Value (Fluid Plate 2) Analog In 0 - 10
4 Command Value Ground (Fluid Plate 2) Analog In Ground 0
5
6
7
8
9 ◆ Dispense Ready Digital Out - Bank 1 0 - voltage connected to Pin 27
10 ◆† Dispense Alarm/Error on Data Digital Out - Bank 1 0 - voltage connected to Pin 27
11 ◆† Dispense Error Digital Out - Bank 1 0 - voltage connected to Pin 27
12 ◆ Dispense In Process Digital Out - Bank 1 0 - voltage connected to Pin 27
13 ◆ Dispense Volume OK Digital Out - Bank 1 0 - voltage connected to Pin 27
14 Fluid Plate Selected Fluid Plate Selected Fluid Plate Selected
15 ◆ Dispense Purge Digital Out - Bank 1 0 - voltage connected to Pin 27
16 ◆ Dispense Remote Start Digital Out - Bank 1 0 - voltage connected to Pin 27
17 ◆ * Data 1 Digital Out - Bank 2 0 - voltage connected to Pin 68
18 ◆ * Data 2 Digital Out - Bank 2 0 - voltage connected to Pin 68
19 ◆ * Data 4 Digital Out - Bank 2 0 - voltage connected to Pin 68
20 ◆ * Data 8 Digital Out - Bank 2 0 - voltage connected to Pin 68
21 Swirl 1 Speed Command Analog In 0 - 10
22 Swirl 1 Speed Command Ground Analog In Ground 0
23 Swirl 2 Speed Command Analog In 0 - 10
24 Swirl 2 Speed Command Ground Analog In Ground 0
25
26
27 Digital Out Supply - Bank 1 Isolated Logic Supply V+ 10-30
28 ◆ * Data 16 Digital Out - Bank 2 0 - voltage connected to Pin 68
29 ◆ * Data 32 Digital Out - Bank 2 0 - voltage connected to Pin 68
30 ◆ * Data 64 Digital Out - Bank 2 0 - voltage connected to Pin 68
31 ◆ * Data 128 Digital Out - Bank 2 0 - voltage connected to Pin 68
32 ◆ * Data 256 Digital Out - Bank 3 0 - voltage connected to Pin 69
33 ◆ * Data 512 Digital Out - Bank 3 0 - voltage connected to Pin 69
34 ◆ * Data 1024 Digital Out - Bank 3 0 - voltage connected to Pin 69
35 ◆ * Data 2048 Digital Out - Bank 3 0 - voltage connected to Pin 69
36 ◆ * Data 4096 Digital Out - Bank 3 0 - voltage connected to Pin 69
37 ◆ * Data 8192 Digital Out - Bank 3 0 - voltage connected to Pin 69
38 ◆ * Data 16384 Digital Out - Bank 3 0 - voltage connected to Pin 69
39 ◆ * Data 32768 Digital Out - Bank 3 0 - voltage connected to Pin 69
40 Swirl 1 Actual Speed Analog Out 0 - 10
41 Swirl 1 Actual Speed Ground Analog Out Ground 0
42 Swirl 2 Actual Speed Analog Out 0 - 10
43 Swirl 2 Actual Speed Ground Analog Out Ground 0
44 - 50
51 Isolated Logic Power Supply Isolated Logic Supply V+ 10-30
52 Style Bit 1 Digital In 0-30
53 Style Bit 2 Digital In 0-30
54 Style Bit 3 Digital In 0-30
55 Style Bit 4 Digital In 0-30
56 Style Strobe Fluid Plate 1 Digital In 0-30
Appendix B - Discrete Gateway Module (DGM) Connection Details
3A2098H 117
* 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.
57 ◆ Dispense Complete Digital In 0-30
58 ◆ Error Reset Digital In 0-30
59 ◆ Remote Start/Purge Digital In 0-30
60 -67
68 Digital Out Supply - Bank 2 Isolated Logic Supply V+ 10-30
69 Digital Out Supply - Bank 3 Isolated Logic Supply V+ 10-30
70 Isolated Logic GND Isolated Ground 0
71 Style Strobe Fluid Plate 2 Digital In 0-30
72 ◆ Fluid Plate Selector Digital In 0-30
73
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
Digital In 0-30
74
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
Digital In 0-30
75
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
Digital In 0-30
76
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 In 0-30
77 Digital CMD 1 Digital In 0-30
78 Digital CMD 2 Digital In 0-30
D-Sub
Pin No. Description Pin Type Voltage (Vdc)
Appendix B - Discrete Gateway Module (DGM) Connection Details
118 3A2098H
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.
F
IG
. 68: D-Subminiature Connector - Pin References
1
20
21
40
60
78
59
39
Appendix B - Discrete Gateway Module (DGM) Connection Details
3A2098H 119
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
• Maximum current draw: 3.6 mA
Microcontroller
Discrete Gateway Customer Automation
Optical
Isolator
Digital Input
Isolated Logic ICs
24VDC
D-Sub Pin 51 (Isolated
Logic Supply)
D-Sub Pin 70
(Isolated Ground)
Microcontroller
Discrete Gateway Customer Automation
Optical
Isolator
Isolated Logic ICs
24VDC
D-Sub Pin 51 (Isolated
Logic Supply), 10-30 VDC
D-Sub Pin 70
(Isolated Ground)
Appendix B - Discrete Gateway Module (DGM) Connection Details
120 3A2098H
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
Microcontroller
Discrete Gateway
Optical
Isolator
Isolated Logic ICs
24VDC24VDC
D-Sub Pin 51 (Isolated
Logic Supply)
D-Sub Pin 70
(Isolated Ground)
Customer Automation
24VDC24VDC
LOADLOAD
LOADLOAD
LOADLOAD
Digital Output
Supply Bank 1
Digital Output
Supply Bank 2
Digital Output
Supply Bank 3
D-Sub
Pin 27
D-Sub
Pin 69
D-Sub
Pin 68
Digital
Output 1-8
Digital
Output 9-16
Digital
Output 17-24
Appendix B - Discrete Gateway Module (DGM) Connection Details
3A2098H 121
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
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
Ω
+
-
20kΩ
Discrete Gateway
Microcontroller Analog Input +
Analog Input -
+
-
Discrete Gateway
Microcontroller
Analog Output +
Analog Output -
0-10VDC @10mA
Appendix C - Communications Gateway Module (CGM) Connection Details
122 3A2098H
Appendix C - Communications Gateway Module
(CGM) Connection Details
Install Fieldbus Connections
Connect cables to fieldbus per fieldbus standards.
PROFINET
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)
Module Status (MS)
Link/Activity (Link)
F
IG
. 69: PROFINET Fieldbus Connections
State Description Comments
Off Offline
•
No power
•
No connection with IO
Controller
Green On-line,
(RUN)
•
Connection with IO Con-
troller established
•
IO Controller with RUN
state
Flashing
Green
On-line,
(STOP)
•
Connection with IO Con-
troller established
•
IO Controller in STOP
state
TI11814A
NS
MS
Link
State Description Comments
Off Not initial-
ized
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)
Configura-
tion 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 Inter-
nal Error
Cycle system power; replace
module
State Description
Off No Link, no communication present
Green Link established, no communication present
Green,
flashing
Link established, communication present
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 123
EtherNet/IP
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)
Module Status (MS)
LINK/Activity (Link)
DeviceNet
Network Status (NS)
Module Status (MS)
DeviceNet Connector (DC)
F
IG
. 70: EtherNet/IP Fieldbus Connections
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)
State Description
Off No power
Green Controlled by a Scanner in Run state
Flashing
Green
Not configured, or Scanner in Idle state
Red Major fault (EXCEPTION-state, FATAL error
etc.)
Flashing
Red
Recoverable fault(s)
State Description
Off No link, no activity
Green Link established
Flashing
Green
Activity
TI11814A
NS
MS
Link
F
IG
. 71: DeviceNet Fieldbus Connections
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
State Description
Off No power or not initialized
Green Initialized
Flashing
Green (1 Hz)
Missing or incomplete configuration, device
needs commissioning
Red Unrecoverable Fault(s)
Flashing
Red (1 Hz)
Recoverable Fault(s)
Alternating
Red/Green
Self test
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
TI11815A
NS MS
DC
23451
Appendix C - Communications Gateway Module (CGM) Connection Details
124 3A2098H
PROFIBUS
Operation Mode (OP)
Status Mode (ST)
PROFIBUS Connector (DC)
F
IG
. 72: PROFIBUS Fieldbus Connections
State Description
Off 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
State Description
Off No power or not initialized
Green Initialized
Flashing
Green
Initialized, diagnostic event(s) present
Red Exception error
TI11816A
ST
OP
DC
12345
9876
Pin Signal Description
1- -
2- -
3 B Line Positive RxD/TxD, RS485 level
4 RTS Request to send
5 GND Bus Ground (isolated)
6+5V Bus
Output
+5V termination power (isolated)
7- -
8 A Line Negative RxD/TxD, RS485 level
9- -
Housing Cable
Shield
Internally connected to the Anybus
protective earth via cable shield filters
according to the PROFIBUS stan-
dard.
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 125
CGM I/O Data Map
See Appendix D - I/O Signal Descriptions on page
138.
Automation Inputs (signals from PCF)
Byte
Input
Bit Description Zone
0
I00 Dispenser (Fluid Plate) Ready
Fluid
Plate 1
I01 Dispenser (Fluid Plate) No Alarm
I02 Dispense No Error
I03 Dispense in Process
I04 Dispense Volume OK
I05 ---
I06 Dispenser (Fluid Plate) Purge
Request
I07 Dispenser (Fluid Plate) Remote
Start / Purge In Process
1
I08 Pressure Units - Bit 0
Fluid
Plate 1
I09 Pressure Units - Bit 1
I10 ---
I11 ---
I12 ---
I13 ---
I14 ---
I15 ---
2
I16 ---
Fluid
Plate 1
I17 ---
I18 ---
I19 ---
I20 ---
I21 ---
I22 ---
I23 ---
3
I24 Error - 1
Fluid
Plate 1
I25 Error - 2
I26 Error - 4
I27 Error - 8
I28 Error - 16
I29 Error - 32
I30 Error - 64
I31 Error - 128
4
I32 Dispenser (Fluid Plate) Ready
Fluid
Plate 2
I33 Dispenser (Fluid Plate) No Alarm
I34 Dispense No Error
I35 Dispense in Process
I36 Dispense Volume OK
I37 ---
I38 Dispenser (Fluid Plate) Purge
Request
I39 Dispenser (Fluid Plate) Remote
Start / Purge In Process
5
I40 Pressure Units - Bit 0
Fluid
Plate 2
I41 Pressure Units - Bit 1
I42 ---
I43 ---
I44 ---
I45 ---
I46 ---
I47 ---
6
I48 ---
Fluid
Plate 2
I49 ---
I50 ---
I51 ---
I52 ---
I53 ---
I54 ---
I55 ---
7
I56 Error - 1
Fluid
Plate 2
I57 Error - 2
I58 Error - 4
I59 Error - 8
I60 Error - 16
I61 Error - 32
I62 Error - 64
I63 Error - 128
8
I64 Dispenser (Fluid Plate) Ready
Fluid
Plate 3
I65 Dispenser (Fluid Plate) No Alarm
I66 Dispense No Error
I67 Dispense in Process
I68 Dispense Volume OK
I69 ---
I70 Dispenser (Fluid Plate) Purge
Request
I71 Dispenser (Fluid Plate) Remote
Start / Purge In Process
9
I72 Pressure Units - Bit 0
Fluid
Plate 3
I73 Pressure Units - Bit 1
I74 ---
I75 ---
I76 ---
I77 ---
I78 ---
I79 ---
10
I80 ---
Fluid
Plate 3
I81 ---
I82 ---
I83 ---
I84 ---
I85 ---
I86 ---
I87 ---
Byte
Input
Bit Description Zone
Appendix C - Communications Gateway Module (CGM) Connection Details
126 3A2098H
11
I88 Error - 1
Fluid
Plate 3
I89 Error - 2
I90 Error - 4
I91 Error - 8
I92 Error - 16
I93 Error - 32
I94 Error - 64
I95 Error - 128
12
I96 Dispenser (Fluid Plate) Ready
Fluid
Plate 4
I97 Dispenser (Fluid Plate) No Alarm
I98 Dispense No Error
I99 Dispense in Process
I100 Dispense Volume OK
I101 ---
I102 Dispenser (Fluid Plate) Purge
Request
I103 Dispenser (Fluid Plate) Remote
Start / Purge In Process
13
I104 Pressure Units - Bit 0
Fluid
Plate 4
I105 Pressure Units - Bit 1
I106 ---
I107 ---
I108 ---
I109 ---
I110 ---
I111 ---
14
I112 ---
Fluid
Plate 4
I113 ---
I114 ---
I115 ---
I116 ---
I117 ---
I118 ---
I119 ---
15
I120 Error - 1
Fluid
Plate 4
I121 Error - 2
I122 Error - 4
I123 Error - 8
I124 Error - 16
I125 Error - 32
I126 Error - 64
I127 Error - 128
16
I128 Command Interface - Value - Bit 0
See CGM Command Interface on
page 131 for command interface
details.
All Fluid
Plates/Swi
rls
I129 Command Interface - Value - Bit 1
I130 Command Interface - Value - Bit 2
I131 Command Interface - Value - Bit 3
I132 Command Interface - Value - Bit 4
I133 Command Interface - Value - Bit 5
I134 Command Interface - Value - Bit 6
I135 Command Interface - Value - Bit 7
Byte
Input
Bit Description Zone
17
I136 Command Interface - Value - Bit 8
All Fluid
Plates/Swi
rls
I137 Command Interface - Value - Bit 9
I138 Command Interface - Value - Bit 10
I139 Command Interface - Value - Bit 11
I140 Command Interface - Value - Bit 12
I141 Command Interface - Value - Bit 13
I142 Command Interface - Value - Bit 14
I143 Command Interface - Value - Bit 15
18
I144 Command Interface - Value - Bit 16
All Fluid
Plates/Swi
rls
I145 Command Interface - Value - Bit 17
I146 Command Interface - Value - Bit 18
I147 Command Interface - Value - Bit 19
I148 Command Interface - Value - Bit 20
I149 Command Interface - Value - Bit 21
I150 Command Interface - Value - Bit 22
I151 Command Interface - Value - Bit 23
19
I152 Command Interface - Value - Bit 24
All Fluid
Plates/Swi
rls
I153 Command Interface - Value - Bit 25
I154 Command Interface - Value - Bit 26
I155 Command Interface - Value - Bit 27
I156 Command Interface - Value - Bit 28
I157 Command Interface - Value - Bit 29
I158 Command Interface - Value - Bit 30
I159 Command Interface - Value - Bit 31
20
I160 Command Interface Status - Com-
mand Active
All Fluid
Plates/Swi
rls
I161 Command Interface Status - Com-
mand Success
I162 Command Interface Status - Com-
mand Failure
I163 Command Interface Status - Value
Coerced
I164 ---
I165 ---
I166 ---
I167 ---
21-
25
I168-
I207 --- ---
Byte
Input
Bit Description Zone
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 127
Automation Outputs (signals to PCF)
Byte
Output
Bit Description Zone
0
O00 Style Strobe
Fluid
Plate 1
O01 Dispense Complete
O02 Dispense Valve 1 On
O03 Dispense Valve 2 On
O04 Dispense Valve 3 On
O05 Dispense Valve 4 On
O06 Error Reset / Cancel Job
O07 Remote Start / Purge
1
O08 Swirl Enable
Swirl 1
O09 ---
O10 ---
O11 ---
O12 ---
O13 ---
O14 ---
O15 ---
2
O16 Style - 1
Fluid
Plate 1
O17 Style - 2
O18 Style - 4
O19 Style - 8
O20 Style - 16
O21 Style - 32
O22 Style - 64
O23 Style - 128
3
O24 Dispense Valve 1 Precharge On
Fluid
Plate 1
O25 Dispense Valve 2 Precharge On
O26 Dispense Valve 3 Precharge On
O27 Dispense Valve 4 Precharge On
O28 ---
O29 ---
O30 ---
O31 ---
4
O32 Command Value - 1
Fluid
Plate 1
O33 Command Value - 2
O34 Command Value - 4
O35 Command Value - 8
O36 Command Value - 16
O37 Command Value - 32
O38 Command Value - 64
O39 Command Value - 128
5
O40 Command Value - 256
Fluid
Plate 1
O41 Command Value - 512
O42 Command Value - 1024
O43 Command Value - 2048
O44 ---
O45 ---
O46 ---
O47 ---
6
O48 Swirl Command Value - 1
Swirl 1
O49 Swirl Command Value - 2
O50 Swirl Command Value - 4
O51 Swirl Command Value - 8
O52 Swirl Command Value - 16
O53 Swirl Command Value - 32
O54 Swirl Command Value - 64
O55 Swirl Command Value - 128
7
O56 Swirl Command Value - 256
Swirl 1
O57 Swirl Command Value - 512
O58 Swirl Command Value - 1024
O59 Swirl Command Value - 2048
O60 ---
O61 ---
O62 ---
O63 ---
8
O64 Style Strobe
Fluid
Plate 2
O65 Dispense Complete
O66 Dispense Valve 1 On
O67 Dispense Valve 2 On
O68 Dispense Valve 3 On
O69 Dispense Valve 4 On
O70 Error Reset / Cancel Job
O71 Remote Start / Purge
9
O72 Swirl Enable
Swirl 2
O73 ---
O74 ---
O75 ---
O76 ---
O77 ---
O78 ---
O79 ---
10
O80 Style - 1
Fluid
Plate 2
O81 Style - 2
O82 Style - 4
O83 Style - 8
O84 Style - 16
O85 Style - 32
O86 Style - 64
O87 Style - 128
11
O88 Dispense Valve 1 Precharge On
Fluid
Plate 2
O89 Dispense Valve 2 Precharge On
O90 Dispense Valve 3 Precharge On
O91 Dispense Valve 4 Precharge On
O92 ---
O93 ---
O94 ---
O95 ---
Byte
Output
Bit Description Zone
Appendix C - Communications Gateway Module (CGM) Connection Details
128 3A2098H
12
O96 Command Value - 1
Fluid
Plate 2
O97 Command Value - 2
O98 Command Value - 4
O99 Command Value - 8
O100 Command Value - 16
O101 Command Value - 32
O102 Command Value - 64
O103 Command Value - 128
13
O104 Command Value - 256
Fluid
Plate 2
O105 Command Value - 512
O106 Command Value - 1024
O107 Command Value - 2048
O108 ---
O109 ---
O110 ---
O111 ---
14
O112 Swirl Command Value - 1
Swirl 2
O113 Swirl Command Value - 2
O114 Swirl Command Value - 4
O115 Swirl Command Value - 8
O116 Swirl Command Value - 16
O117 Swirl Command Value - 32
O118 Swirl Command Value - 64
O119 Swirl Command Value - 128
15
O120 Swirl Command Value - 256
Swirl 2
O121 Swirl Command Value - 512
O122 Swirl Command Value - 1024
O123 Swirl Command Value - 2048
O124 ---
O125 ---
O126 ---
O127 ---
16
O128 Style Strobe
Fluid
Plate 3
O129 Dispense Complete
O130 Dispense Valve 1 On
O131 Dispense Valve 2 On
O132 Dispense Valve 3 On
O133 Dispense Valve 4 On
O134 Error Reset / Cancel Job
O135 Remote Start / Purge
17
O136 Swirl Enable
Swirl 3
O137 ---
O138 ---
O139 ---
O140 ---
O141 ---
O142 ---
O143 ---
18
O144 Style - 1
Fluid
Plate 3
O145 Style - 2
O146 Style - 4
O147 Style - 8
O148 Style - 16
O149 Style - 32
O150 Style - 64
O151 Style - 128
Byte
Output
Bit Description Zone
19
O152 Dispense Valve 1 Precharge On
Fluid
Plate 3
O153 Dispense Valve 2 Precharge On
O154 Dispense Valve 3 Precharge On
O155 Dispense Valve 4 Precharge On
O156 ---
O157 ---
O158 ---
O159 ---
20
O160 Command Value - 1
Fluid
Plate 3
O161 Command Value - 2
O162 Command Value - 4
O163 Command Value - 8
O164 Command Value - 16
O165 Command Value - 32
O166 Command Value - 64
O167 Command Value - 128
21
O168 Command Value - 256
Fluid
Plate 3
O169 Command Value - 512
O170 Command Value - 1024
O171 Command Value - 2048
O172 ---
O173 ---
O174 ---
O175 ---
22
O176 Swirl Command Value - 1
Swirl 3
O177 Swirl Command Value - 2
O178 Swirl Command Value - 4
O179 Swirl Command Value - 8
O180 Swirl Command Value - 16
O181 Swirl Command Value - 32
O182 Swirl Command Value - 64
O183 Swirl Command Value - 128
23
O184 Swirl Command Value - 256
Swirl 3
O185 Swirl Command Value - 512
O186 Swirl Command Value - 1024
O187 Swirl Command Value - 2048
O188 ---
O189 ---
O190 ---
O191 ---
24
O192 Style Strobe
Fluid
Plate 4
O193 Dispense Complete
O194 Dispense Valve 1 On
O195 Dispense Valve 2 On
O196 Dispense Valve 3 On
O197 Dispense Valve 4 On
O198 Error Reset / Cancel Job
O199 Remote Start / Purge
25
O200 Swirl Enable
Swirl 4
O201 ---
O202 ---
O203 ---
O204 ---
O205 ---
O206 ---
O207 ---
Byte
Output
Bit Description Zone
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 129
26
O208 Style - 1
Fluid
Plate 4
O209 Style - 2
O210 Style - 4
O211 Style - 8
O212 Style - 16
O213 Style - 32
O214 Style - 64
O215 Style - 128
27
O216 Dispense Valve 1 Precharge On
Fluid
Plate 4
O217 Dispense Valve 2 Precharge On
O218 Dispense Valve 3 Precharge On
O219 Dispense Valve 4 Precharge On
O220 ---
O221 ---
O222 ---
O223 ---
28
O224 Command Value - 1
Fluid
Plate 4
O225 Command Value - 2
O226 Command Value - 4
O227 Command Value - 8
O228 Command Value - 16
O229 Command Value - 32
O230 Command Value - 64
O231 Command Value - 128
29
O232 Command Value - 256
Fluid
Plate 4
O233 Command Value - 512
O234 Command Value - 1024
O235 Command Value - 2048
O236 ---
O237 ---
O238 ---
O239 ---
30
O240 Swirl Command Value - 1
Swirl 4
O241 Swirl Command Value - 2
O242 Swirl Command Value - 4
O243 Swirl Command Value - 8
O244 Swirl Command Value - 16
O245 Swirl Command Value - 32
O246 Swirl Command Value - 64
O247 Swirl Command Value - 128
31
O248 Swirl Command Value - 256
Swirl 4
O249 Swirl Command Value - 512
O250 Swirl Command Value - 1024
O251 Swirl Command Value - 2048
O252 ---
O253 ---
O254 ---
O255 ---
Byte
Output
Bit Description Zone
32
O256
Command Interface - Command -
Bit 0
See CGM Command Interface on
page 131 for command interface
details.
All Fluid
Plates/S
wirls
O257 Command Interface - Command -
Bit 1
O258 Command Interface - Command -
Bit 2
O259 Command Interface - Command -
Bit 3
O260 Command Interface - Command -
Bit 4
O261 Command Interface - Command -
Bit 5
O262 Command Interface - Command -
Bit 6
O263 Command Interface - Command -
Bit 7
33
O264 Command Interface - Command -
Bit 8
All Fluid
Plates/S
wirls
O265 Command Interface - Command -
Bit 9
O266 Command Interface - Command -
Bit 10
O267 Command Interface - Command -
Bit 11
O268 Command Interface - Command -
Bit 12
O269 Command Interface - Command -
Bit 13
O270 Command Interface - Command -
Bit 14
O271 Command Interface - Command -
Bit 15
34
O272 Command Interface - Command -
Bit 16
All Fluid
Plates/S
wirls
O273 Command Interface - Command -
Bit 17
O274 Command Interface - Command -
Bit 18
O275 Command Interface - Command -
Bit 19
O276 ---
O277 ---
O278 ---
O279 ---
35 O280-
O287 --- ---
Byte
Output
Bit Description Zone
Appendix C - Communications Gateway Module (CGM) Connection Details
130 3A2098H
36
O288
Command Interface - Value - Bit 0
See CGM Command Interface on
page 131 for command interface
details.
All Fluid
Plates/S
wirls
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
37
O296 Command Interface - Value - Bit 8
All Fluid
Plates/S
wirls
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
38
O304 Command Interface - Value - Bit 16
All Fluid
Plates/S
wirls
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
39
O312 Command Interface - Value - Bit 24
All Fluid
Plates/S
wirls
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
40
O320 Command Interface - Control Bits -
Read
All Fluid
Plates/S
wirls
O321 Command Interface - Control Bits -
Write
O322 ---
O323 ---
O324 ---
O325 ---
O326 ---
O327 ---
41 O328-
O335 --- ---
Byte
Output
Bit Description Zone
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 131
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 sys-
tem setting (write).
• Output bits 256-267 are used to identify the individ-
ual command. Each bit will have a single binary
value to create the hex code listed in the commands
table.
• Output bits 268-275 are used to identify the individ-
ual Fluid Plate or Swirl dispenser to which the com-
mands 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.
The CGM command interface uses automation input
bits 128-159 to read the current system values. It also
uses input bits 160-163 to identify the status of com-
mands:
• Bit 160: Command Active
• Bit 161: Command Success
• Bit 162: Command Failure
• Bit 163: Value Coerced
NOTE: If both output bits 320 (read) and 321 (write) are
high during a command the result will be a command
failure identified by input bit 162 (command failure)
going high.
Examples
NOTE: See the timing diagram and tables starting on
page 132 for detailed descriptions of the input and out-
put bits.
Example 1: if output bits 256-275 are 0xB0203, output
bits 288-319 are 0x0004, and output bit 321 is high, this
means:
• 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 com-
mand as a whole:
Change the purge period setting on
fluid plate 1 to 4 minutes.
Example 2: if output bits 256-275 are 0xB3212, input
bits 288-319 are 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 dis-
abled.
Appendix C - Communications Gateway Module (CGM) Connection Details
132 3A2098H
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 Fail-
ure 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 opera-
tion.
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.
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 opera-
tion.
Fluid Plate/Swirl Identification Commands
Fluid Plate Commands
F
IG
. 73: CGM Command Interface Timing Diagram
Automation Inputs (PCF Outputs)
Automation Outputs (PCF Inputs)
Command Bits 256-275
Value Bits 288-319
Write Bit 321
Read Bit 320
Value Bits 128-159
Command Active Bit 160
Command Success Bit 161
Command Failure Bit 162
Command Value Coerced Bit 163
Bits Set Bits Set
Bits Set
Bits Set Bits Set
Write Command Read Command
Output Bits 268-275 Description
0xB0 Fluid Plate 1
0xB1 Fluid Plate 2
0xB2 Fluid Plate 3
0xB3 Fluid Plate 4
0xE1 Swirl 1
0xE2 Swirl 2
0xE3 Swirl 3
0xE4 Swirl 4
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
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
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 133
0x007 Software Part
Number
STR_15_12 Read Only
0x008 Software Ver-
sion
Version Read Only
0x0DD Maintenance
Units Type
Maintenance Units
Enumeration
Read Only
0x0DF Enabled Styles ### Read Only
0x203 Purge Period #### (minutes) Read /
Write
0x204 Dispense Trig-
ger Source
Dispense Trigger
Source Enumeration
Read /
Write
0x208 Command
Value Source
Command Value
Source Enumeration
Read /
Write
0x20F Bead Scale ### (percent) Read /
Write
0x210 Job End Mode Job End Mode Enu-
meration
Read /
Write
0x211 Job End Delay
Time
Integer (Seconds) Read /
Write
0x2B5 End Job On
Alarm
Boolean
0x212 Valve 1 Enable Boolean Read /
Write
0x213 Valve 2 Enable Boolean Read /
Write
0x214 Valve 3 Enable Boolean Read /
Write
0x215 Valve 4 Enable Boolean Read /
Write
0x216 Regulator On
Delay
### (mS) Read /
Write
0x217 Regulator Off
Delay
### (mS) Read /
Write
0x218 Valve 1 On
Delay
### (mS) Read /
Write
0x219 Valve 2 On
Delay
### (mS) Read /
Write
0x21A Valve 3 On
Delay
### (mS) Read /
Write
0x21B Valve 4 On
Delay
### (mS) Read /
Write
0x21C Valve 1 Off
Delay
### (mS) Read /
Write
0x21D Valve 2 Off
Delay
### (mS) Read /
Write
0x21E Valve 3 Off
Delay
### (mS) Read /
Write
0x21F Valve 4 Off
Delay
### (mS) Read /
Write
0x230 Flow Meter
Type
Flow Meter Type Enu-
meration
Read /
Write
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
0x231 Flow Meter
K-Factor
##### (pulses/Liter,
pulses/kg)
Read /
Write
0x23C Outlet Pres-
sure Sensor
User Offset
sint32; #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x23D Inlet Pressure
Sensor User
Offset
sint32; #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x241 Maximum Out-
let Pressure
uint32; #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x244 Minimum Inlet
Pressure
uint32; #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x245 Maximum Inlet
Pressure
uint32; #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x248 Pressure Kp ####.## Read /
Write
0x249 Pressure Ki ####.## Read /
Write
0x247 Pressure Kd ####.## Read /
Write
0x254 Bead Kp ####.## Read /
Write
0x255 Bead Ki ####.## Read /
Write
0x260 Regulator Time
Advisory Limit
###### (hours) Read /
Write
0x262 Regulator Vol-
ume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x264 Flow meter
Time Advisory
Limit
###### (hours) Read /
Write
0x266 Flow meter
Volume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x268 Supply Time
Advisory Limit
###### (hours) Read /
Write
0x26A Supply Vol-
ume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x26C V/P Time Advi-
sory Limit
###### (hours) Read /
Write
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
Appendix C - Communications Gateway Module (CGM) Connection Details
134 3A2098H
0x26E V/P Vol-
ume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x270 Valve 1 Time
Advisory Limit
###### (hours) Read /
Write
0x271 Valve 2 Time
Advisory Limit
###### (hours) Read /
Write
0x272 Valve 3 Time
Advisory Limit
###### (hours) Read /
Write
0x273 Valve 4 Time
Advisory Limit
###### (hours) Read /
Write
0x278 Valve 1 Vol-
ume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x279 Valve 2 Vol-
ume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x27A Valve 3 Vol-
ume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x27B Valve 4 Vol-
ume/Mass
Advisory Limit
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x283 Swirl Fault
Error Type
Error Type Enumera-
tion 2
0x284 Low Flow Rate
Error Type
Error Type Enumera-
tion 1
Read /
Write
0x285 High Flow Rate
Error Type
Error Type Enumera-
tion 1
Read /
Write
0x286 Low Pressure
Error Type
Error Type Enumera-
tion 1
Read /
Write
0x287 High Pressure
Error Type
Error Type Enumera-
tion 1
Read /
Write
0x289 High Outlet
Pressure Error
Type
Error Type Enumera-
tion 2
Read /
Write
0x28A Low Volume
Error Type
Error Type Enumera-
tion 1
Read /
Write
0x28B High Volume
Error Type
Error Type Enumera-
tion 1
Read /
Write
0x28C Low Com-
puted Target
Error Type
Error Type Enumera-
tion 1
Read /
Write
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
0x28D High Com-
puted Target
Error Type
Error Type Enumera-
tion 1
Read /
Write
0x28E Low Inlet Pres-
sure Error Type
Error Type Enumera-
tion 2
Read /
Write
0x28F High Inlet
Pressure Error
Type
Error Type Enumera-
tion 2
Read /
Write
0x292 Valve 1 Mode Valve Mode Enumera-
tion
Read /
Write
0x293 Valve 2 Mode Valve Mode Enumera-
tion
Read /
Write
0x294 Valve 3 Mode Valve Mode Enumera-
tion
Read /
Write
0x295 Valve 4 Mode Valve Mode Enumera-
tion
Read /
Write
0x296 Valve 1 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
0x297 Valve 2 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
0x298 Valve 3 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
0x299 Valve 4 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
0x29A Valve 1 10
VDC Analog
Scale Pressure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x29B Valve 2 10
VDC Analog
Scale Pressure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x29C Valve 3 10
VDC Analog
Scale Pressure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x29D Valve 4 10
VDC Analog
Scale Pressure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x302 Regulator
Maintenance -
Dispensed Vol-
ume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x303 Flow meter
Maintenance -
Dispensed Vol-
ume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 135
0x304 Supply Mainte-
nance - Dis-
pensed
Volume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x305 V/P Mainte-
nance - Dis-
pensed
Volume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x308 Valve 1 Mainte-
nance - Dis-
pensed
Volume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x309 Valve 2 Mainte-
nance - Dis-
pensed
Volume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x30A Valve 3 Mainte-
nance - Dis-
pensed
Volume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x30B Valve 4 Mainte-
nance - Dis-
pensed
Volume*
Volume: ######
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
0x312 Regulator
Maintenance -
Dispense
Time*
###### (hours) Read /
Write
0x313 Flow meter
Maintenance -
Dispense
Time*
###### (hours) Read /
Write
0x314 Supply Mainte-
nance - Dis-
pense Time*
###### (hours) Read /
Write
0x315 V/P Mainte-
nance - Dis-
pense Time*
###### (hours) Read /
Write
0x318 Valve 1 Mainte-
nance - Dis-
pense Time*
###### (hours) Read /
Write
0x319 Valve 2 Mainte-
nance - Dis-
pense Time*
###### (hours) Read /
Write
0x31A Valve 3 Mainte-
nance - Dis-
pense Time*
###### (hours) Read /
Write
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
0x31B Valve 4 Mainte-
nance - Dis-
pense Time*
###### (hours) Read /
Write
0x800 Purge Defini-
tion - Volume
#####.# (cc) Read /
Write
0x801 Purge Defini-
tion - Pressure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x802 Purge Defini-
tion - Toler-
ances
Tolerances Type Read /
Write
0x803 Purge Defini-
tion - Duration
#### (seconds) Read /
Write
0x804 Style 1 Defini-
tion - Volume
#####.# (cc) Read /
Write
0x805 Style 1 Defini-
tion - Pressure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0x806 Style 1 Defini-
tion - Toler-
ances
Tolerances Type Read /
Write
0x807 Style 1 Defini-
tion - Pre-
charge
Settings
Precharge Settings
Type
Read /
Write
0xBFC Style 255 Defi-
nition - Volume
#####.# (cc) Read /
Write
0xBFD Style 255 Defi-
nition - Pres-
sure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
0xBFE Style 255 Defi-
nition - Toler-
ances
Tolerances Type Read /
Write
0xBFF Style 255 Defi-
nition - Pre-
charge
Settings
Precharge Settings
Type
---
0xC04 Style 1 Defini-
tion - Name
STR_3_0 Read /
Write
0xC05 Style 1 Defini-
tion - Name
STR_7_4 Read /
Write
0xC06 Style 1 Defini-
tion - Name
STR_11_8 Read /
Write
0xC07 Style 1 Defini-
tion - Name
STR_15_12 Read /
Write
0xC3C Style 15 Defini-
tion - Name
STR_3_0 Read /
Write
0xC3D Style 15 Defini-
tion - Name
STR_7_4 Read /
Write
0xC3E Style 15 Defini-
tion - Name
STR_11_8 Read /
Write
0xC3F Style 15 Defini-
tion - Name
STR_15_12 Read /
Write
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
Appendix C - Communications Gateway Module (CGM) Connection Details
136 3A2098H
* Maintenance dispensed volume/time can only be set
to 0.
Swirl Commands
0x29E Pressure Units Pressure Units Enu-
meration
Read /
Write
0x29F Rate Units Rate Units Enumera-
tion
Read /
Write
0x2A0 Maintenance
Volume Units
Volume Units Enumer-
ation
Read /
Write
0x2A1 Maintenance
Mass Units
Mass Units Enumera-
tion
Read /
Write
0x2A2 Maintenance
Time Units
Mass Units Enumera-
tion
Read /
Write
0x2AD Valve 1 Swirl
Association
(Swirl Zone)
Swirl Enumeration Read /
Write
0x2AE Valve 2 Swirl
Association
(Swirl Zone)
Swirl Enumeration Read /
Write
0x2AF Valve 3 Swirl
Association
(Swirl Zone)
Swirl Enumeration Read /
Write
0x2B0 Valve 4 Swirl
Association
(Swirl Zone)
Swirl Enumeration Read /
Write
0x2B5 End Job On
Alarm
Boolean Read /
Write
0x3FB Style Bits ### Read /
Write
0x115 Command
Value
uint12 Read /
Write
0x116 Error Reset /
Remote Start
Dispense Control 2 Bit-
field
Read /
Write
0x118 Disable Dis-
pensing
Boolean Read /
Write
0x3FF Dispense Con-
trol
Dispense Control 1 Bit-
field
Read /
Write
0x0FB Inlet Pressure Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read Only
0x0FC Outlet Pres-
sure
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read Only
0x0DC Pressure Com-
mand
Pressure: #### (psi);
###.# (bar); ##.##
(Mpa)
Read Only
0x403 Flowrate Com-
mand
##### cc/min Read Only
0x404 Flowrate
Actual
##### cc/min Read Only
0x406 Fluid Plate Sta-
tus 0
Fluid Plate Status 0
bitfield
Read Only
0x409 Fluid Plate
Faults
Gateway Error Number Read Only
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
0x0FF Fluid Plate Dis-
pensed Vol-
ume
#####.# (cc) Read Only
0x0DB Active Fault
Error Code
Fault Error Code Read Only
0x0F8 Fluid Plate Sta-
tus Bits
Fluid Plate Status bit-
field
Read Only
0x0FE Requested Vol-
ume
#####.# (cc) Read Only
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 Scal-
ing
### (percent) Read /
Write
0x404 Swirl Maintenance
Time Advisory
Limit
###### (hours) Read /
Write
0x3FF Swirl - Actual Run
Time
###### (hours) Read /
Write
0x2FC Swirl Status Bits 1 Swirl Status Bit-
field 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
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137
Read or
Write
Appendix C - Communications Gateway Module (CGM) Connection Details
3A2098H 137
Units Definitions
Unit s String Definition
Command Value Source Enu-
meration
0 - Display, 1 - Command Cable, 2 - Gateway
Dispense Control 1 Bitfield
Dispense Control 2 Bitfield Bit 14 - Error Reset, Bit 15 - Remote Start
Dispense Trigger Source Enu-
meration
0 - Command Cable, 1 - Gateway, 2 - Combined, 3 - Command Cable 3x
Error Type Enumeration 1 0 - None, 1 - Alarm, 2 - Deviation
Error Type Enumeration 2 1 - Alarm, 2 - Deviation
Fault Error Code A 32-bit string in the format of 0xDDCCBBAA where 0xAA represents the most significant char-
acter in the string and 0xDD represents the least significant character in the string.
Flow Meter Type Enumeration 1 - Volume, 2 - Mass
Fluid Plate Status 0 Bitfield
Fluid Plate Status Bitfield
Job End Mode Enumeration 0 - Timer, 1 - Gateway
Maintenance Units Enumeration 0 - Volume, 1 - Mass, 2 - Time
Mass Units Enumeration 0 - lb, 1 - kg
Precharge Settings Type A 32 bit value in the format of 0xDDCCBBA:
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 (%)
Pressure Units Enumeration 0 - psi, 1 - bar, 2 - MPa
Rate Units Enumeration 0 - x/min, 1 - x/sec
sint32 A 32 bit positive or negative value
Speed Source Enumeration 0 - Display, 1 - Gateway
STR_X_Y A 32 bit value where X signifies which character in the string that the most significant byte rep-
resents and Y signifies which character in the string that the least significant byte represents.
Swirl Control Enumeration 0 - Swirl Enable
Swirl Enumeration 0 - None, 1 - Swirl 1, 2 - Swirl 2, 3 - Swirl 3, 4 - Swirl 4
Swirl Status Bitfield 1 0 - Swirl Active, 1 - Swirl Ready, 2 - Swirl Enabled
Tolerances Type 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.
Valve Mode Enumeration 0 - Pressure, 1 - Bead, 2 - Shot, 3 - Full Open
uint12 A 12 bit positive value
uint32 A 32 bit positive value
Version 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.
Volume Units Enumeration 0 - gal(US), 1 - gal(UK), 2 - Liters
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
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
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
Appendix D - I/O Signal Descriptions
138 3A2098H
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:
• The system is in an active state, and
• The dispenser (fluid plate) does not have an
active Alarm (Deviations have no effect).
Dispenser (Fluid Plate) No Alarm
For systems with a CGM, this signal will be 1 under the
following condition:
• 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, devi-
ation, 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.
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
This signal will be 1 under the following conditions:
• The system has completed a job, and
• the volume of the job is within the tolerance
specified, and
• the style strobe is 1.
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.
Dispenser (Fluid Plate) Remote Start / Purge in
Process
This signal is 0 on power up. This signal will be 1 under
the following conditions:
• A remote start sequence is in process. This sig-
nal shall remain asserted until the dispense
equipment has achieved Dispense Ready sta-
tus.
• A purge sequence is in process. This signal
shall remain asserted until the purge sequence
is complete.
Units
All units settings are set in the Advanced Display Mod-
ule. The following signals are used to communicate this
information to the automation controller.
Pressure Units
Errors
Error numbers are formed by 8 bits. This is the error
number in the system.
Value Units
0psi
1bar
2MPa
3reserve
Appendix D - I/O Signal Descriptions
3A2098H 139
Automation Outputs
Style
The desired style of the next job. These 8 bits are read
at the start of a job to determine the selected style.
Style Strobe
This bit is used to start a new job. A new job is started
when the style strobe changes from 0 to 1.
Dispense Complete
This bit is used to signal the end of a job. A job is ended
when this signal changes from 0 to 1.
Dispense Valve x On
These 4 bits are used to signal the turn on and turn off
of each of the 4 dispense valves on the applicable fluid
plate.
Command Value
This 12 bit value indicates the analog command value
from 0-10Volts (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 config-
ured 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 sta-
tus.
Remote Start / Purge
This bit is used to restart the dispense system from any
“not-ready” state. If the system is already in a Dispense
Ready state, this signal shall initiate a purge based on
the configured purge parameters.
Swirl X Enable
This bit is used to signal the on and off status of each
swirl dispenser motor.
Swirl Command Value
This 12-bit value indicates a swirl speed command from
0-10 volts. 0 volts (0x000) represents a speed of
6,600 rpm and 10 volts (0xFFF) represents 24,000 rpm.
Dispense Valve X Precharge On
These 4 bits are used to turn on precharge for each of
the 4 dispense valves when the precharge mode is set
to Gateway.
Technical Data
140 3A2098H
Technical Data
* Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expected to
shear under pressure. New applications or fluids should always be tested to determine proper line sizes and equip-
ment selections. See your Graco authorized distributor for other capabilities.
Control Center Assembly Technical Data
*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) . . . .
feed pressure to fluid plate (mastic regulator) . . . . . .
at regulator outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . .
at regulator outlet with electric heat components . . .
6000 psi (41 MPa, 414 bar)
5000 psi (35 MPa, 345 bar)
4500 psi (31 MPa, 310 bar)
3500 psi (24 MPa, 241 bar)
Minimum Fluid Working Pressure (at regulator outlet). . . 100 psi (0.7 MPa, 7.0 bar)
Air Supply Pressure Range . . . . . . . . . . . . . . . . . . . . . . . 60-120 psi (0.4 - 0.8 MPa, 4.1- 8.3 bar) - 10 Micron filtra-
tion required
Fluid Filtration Required . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mesh (500 micron) minimum
*Viscosity Range of Fluids . . . . . . . . . . . . . . . . . . . . . . . . 10,000 to 1,000,000 cps with helical flow meter
*Minimum Dispensed Shot Size. . . . . . . . . . . . . . . . . . . . 3 cc with high-resolution (ambient) helical flow meter
6 cc with heated helical flow meter
Wetted Parts (meters and fluid plates). . . . . . . . . . . . . . . 303, 304, 321, 17- 4 stainless steel; tungsten carbide,
PTFE, steel, fluoroelastomer
Power Requirements
100-240 Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 Vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full load-1.4A, fuse rating-2.5A
full load-4A, fuse rating-4A
Power Supply Voltage Range . . . . . . . . . . . . . . . . . . . . . 100-240 Vac, 50-60 Hz, single phase
Operating Temperature Range
control center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
heated fluid plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ambient fluid plate . . . . . . . . . . . . . . . . . . . . . . . . . . .
40°F (4°C) - 120°F (49°C)
40°F (4°C) - 400°F (204°C)
40°F (4°C) - 120°F (49°C)
Operating Humidity Range. . . . . . . . . . . . . . . . . . . . . . . . 0 - 90% non-condensing
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
Technical Data
3A2098H 141
Fluid Plate Assembly Technical Data
Mounting dimensions and parts breakdowns for the fluid plate assemblies are in the installation section of this man-
ual.
*Maximum system pressure depends on dispense valve.
Swirl Dispenser Technical Data
Refer to manual 309403.
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
Air outlets, open and close to dispense valve 5/32 in. (4 mm) tube fittings
Electric Power Requirements 24 Vdc or 100-240 Vac
Power Supplied to Dispense Valve Solenoid(s) 24 Vdc
Fluid Specifications For use when dispensing fluids that meet at least one of
the following conditions for non-flammability:
•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.
Ambient Air Temperature Range 40° to 120° (4° to 50° C)
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
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.
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