Graco 3A2098H PCF Manual de usuario

3A2098HInstructions - PartsPCF™ with PrecisionSwirl™Precision Dispense SystemElectronically-controlled fluid metering system that provides precise con

System Configurations 10 3A2098HSystem ConfigurationsTypical Installation - Single Swirl, Single Fluid PlateKey:A *Control Center (User Interface)B *F

Appendix A - Advanced Display Module (ADM) 100 3A2098HSystem ModeThere are five modes: Active, Job in Cycle, Display Con-trol, Swirl Setup, and System

Appendix A - Advanced Display Module (ADM)3A2098H 101Setup ModeSetup mode screens are divided into five sections: Sys-tem setup, Advanced setup, Gatew

Appendix A - Advanced Display Module (ADM) 102 3A2098HAutomation Gateway Setup ScreensThere are up to three automation Gateway Setup screens (dependin

Appendix A - Advanced Display Module (ADM)3A2098H 103Gateway Setup Screen 1 - PROFIBUSThis screen enables users to set the device address, install dat

Appendix A - Advanced Display Module (ADM) 104 3A2098HDiscrete Gateway (Automation) Setup ScreenNOTE: The Discrete Gateway Setup screen is not avail-a

Appendix A - Advanced Display Module (ADM)3A2098H 105Fluid Plate Setup ScreensThere are nine fluid plate setup screens, which enable users to:• Set co

Appendix A - Advanced Display Module (ADM) 106 3A2098HAttempting to dispense from multiple valves simultane-ously using any other combination will cau

Appendix A - Advanced Display Module (ADM)3A2098H 107Fluid Plate x, Screen 5 (Pressure Sensors)NOTE: Inlet sensor settings will be grayed out on this

Appendix A - Advanced Display Module (ADM) 108 3A2098HFluid Plate x, Screen 7 (Maintenance Advisory Limits)This screen enables users to set volume (or

Appendix A - Advanced Display Module (ADM)3A2098H 109Fluid Plate x, Screen 9 (Swirl Association)This screen enables users to set the swirl to fluid pl

System Configurations3A2098H 11Typical Installation - Multiple Fluid Plates, No Swirl Dispensers Key:A *Control Center (User Interface)B *Fluid Plate

Appendix A - Advanced Display Module (ADM) 110 3A2098HRun ModeRun mode screens are divided into six sections: home, fluid plates, swirls, events, erro

Appendix A - Advanced Display Module (ADM)3A2098H 111Fluid Plate x, Screen 1This screen displays the current dispense control mode used, the current p

Appendix A - Advanced Display Module (ADM) 112 3A2098HMaintenance ModePress from Fluid Plate x, screen 1 (Control Center) to enter maintenance mode.

Appendix A - Advanced Display Module (ADM)3A2098H 113Fluid Plate x, Screen 2 (Control Center)NOTE: Users must be out of maintenance mode in Fluid Plat

Appendix A - Advanced Display Module (ADM) 114 3A2098HSwirl X ScreenThere is one Swirl X screen for each installed swirl dis-penser. This screen displ

Appendix B - Discrete Gateway Module (DGM) Connection Details3A2098H 115Appendix B - Discrete Gateway Module (DGM) Connection DetailsD-Sub Cable 12379

Appendix B - Discrete Gateway Module (DGM) Connection Details 116 3A2098HD-Sub Cable 123792 and Breakout Board 123783The cable length of the interface

Appendix B - Discrete Gateway Module (DGM) Connection Details3A2098H 117* 16-bit data outputs contain either volume or error information depending on

Appendix B - Discrete Gateway Module (DGM) Connection Details 118 3A2098HPin ReferencesNOTE: To avoid ground loops and noise immunity issues, do not g

Appendix B - Discrete Gateway Module (DGM) Connection Details3A2098H 119DGM Digital InputThe digital inputs function only when power is supplied to pi

System Configurations 12 3A2098HTypical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers Key:A *Control Center (User Interface)B *Fluid

Appendix B - Discrete Gateway Module (DGM) Connection Details 120 3A2098HDGM Digital OutputsThe digital outputs function only when power is supplied t

Appendix B - Discrete Gateway Module (DGM) Connection Details3A2098H 121DGM Analog InputsThe analog inputs function only when the DGM is connected to

Appendix C - Communications Gateway Module (CGM) Connection Details 122 3A2098HAppendix C - Communications Gateway Module (CGM) Connection DetailsInst

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 123EtherNet/IPThe Ethernet interface operates at 100Mbit, full duplex, as r

Appendix C - Communications Gateway Module (CGM) Connection Details 124 3A2098HPROFIBUSOperation Mode (OP)Status Mode (ST)PROFIBUS Connector (DC)FIG.

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 125CGM I/O Data MapSee Appendix D - I/O Signal Descriptions on page 138.Aut

Appendix C - Communications Gateway Module (CGM) Connection Details 126 3A2098H11I88 Error - 1Fluid Plate 3I89 Error - 2I90 Error - 4I91 Error - 8I92

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 127Automation Outputs (signals to PCF) ByteOutput Bit Description Zone0O00

Appendix C - Communications Gateway Module (CGM) Connection Details 128 3A2098H12O96 Command Value - 1Fluid Plate 2O97 Command Value - 2O98 Command Va

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 12926O208 Style - 1Fluid Plate 4O209 Style - 2O210 Style - 4O211 Style - 8O

Overview3A2098H 13OverviewSystem OverviewThe PCF fluid metering system combines closed-loop pressure control with the ability to change bead profiles

Appendix C - Communications Gateway Module (CGM) Connection Details 130 3A2098H36O288Command Interface - Value - Bit 0See CGM Command Interface on pag

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 131CGM Command InterfaceNOTE: The CGM command interface is only available f

Appendix C - Communications Gateway Module (CGM) Connection Details 132 3A2098HCommand Interface Timing Diagram Command Interface Write Operation1. Se

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 1330x007 Software Part NumberSTR_15_12 Read Only0x008 Software Ver-sionVers

Appendix C - Communications Gateway Module (CGM) Connection Details 134 3A2098H0x26E V/P Vol-ume/Mass Advisory LimitVolume: ###### (gal(US)); ###### (

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 1350x304 Supply Mainte-nance - Dis-pensed Volume*Volume: ###### (gal(US));

Appendix C - Communications Gateway Module (CGM) Connection Details 136 3A2098H* Maintenance dispensed volume/time can only be set to 0.Swirl Commands

Appendix C - Communications Gateway Module (CGM) Connection Details3A2098H 137Units Definitions Unit s String DefinitionCommand Value Source Enu-merat

Appendix D - I/O Signal Descriptions 138 3A2098HAppendix D - I/O Signal DescriptionsThis section provides details about the CGM and DGM Automation Inp

Appendix D - I/O Signal Descriptions3A2098H 139Automation OutputsStyleThe desired style of the next job. These 8 bits are read at the start of a job t

Overview 14 3A2098HFluid Plate Assembly OverviewFluid Plate ComponentsThe fluid plate assembly in FIG. 5 can be attached to an automation arm or mount

Technical Data 140 3A2098HTechnical Data* Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expecte

Technical Data3A2098H 141Fluid Plate Assembly Technical DataMounting dimensions and parts breakdowns for the fluid plate assemblies are in the install

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves th

Overview3A2098H 15Fluid RegulatorThere are three fluid regulator options:• cartridge• ambient mastic • heated masticAll of the fluid regulator options

Overview 16 3A2098HControl Center Assembly OverviewThe control center includes the following components:• Advanced Display Module (ADM) with USB; see

Overview3A2098H 17Advanced Display Module (ADM)KEY:FIG. 8: Advanced Display Module Component IdentificationTI12362aBABBBCBEBHBGBFBDr_24E451_3B9900_1aB

Overview 18 3A2098HAutomation Gateway ModuleSee the following table for the appropriate rotary switch position for your automation gateway module. NOT

Overview3A2098H 19Swirl Control DGMOne swirl control DGM is included in the integrated Swirl control center, and in each expansion swirl enclosure. Ea

2 3A2098HContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Models . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 20 3A2098HKey TokensThe ADM and FCM must each have a key token installed in order to operate. If the incorrect key token is installed, the mo

Installation3A2098H 21InstallationBefore Installation• Have all system and component documentation available during installation.• See component manua

Installation 22 3A2098HInstall Control CenterNOTE: This section applies to both the primary control center and the expansion Swirl enclosures.MountEns

Installation3A2098H 23Electrical Connections Connect Light Tower Accessory1. Order the 255468 Light Tower Accessory as a diag-nostic indicator for th

Installation 24 3A2098HInstall Fluid Plate AssembliesTo install the PCF fluid plate assemblies:• Mount the fluid plate assemblies, page 24• Ground flu

Installation3A2098H 25Mount Four-Valve Breakout Kit 24B693PCF is capable of controlling up to four separate dis-pense valves from port 1 on the FCM. A

Installation 26 3A2098HInstall Command Cable Kit 24B694Follow this procedure if using the command cable kit.1. Install bulkhead fitting (included in t

Installation3A2098H 27GroundGround the fluid plate assembly as instructed here and in the individual component manuals. Make sure the fluid plate asse

Installation 28 3A2098HInstall Cable AssembliesNOTE: To prevent system errors, only connect cables with the power off.NOTE: See FIG. 17 on page 29.1.

Installation3A2098H 29FIG. 17: Cable Installation DiagramMultiple Fluid Plate and Multiple Swirl System shown454431122221

Related Manuals3A2098H 3Appendix A - Advanced Display Module (ADM) . 99Display Overview . . . . . . . . . . . . . . . . . . . . . . . . 99Display Det

Installation 30 3A2098HInstall Gateway Module InterfaceNOTE: Systems with swirl dispensers will have two gateway modules in the control center. The ga

Installation3A2098H 31Discrete Gateway ModuleModule DescriptionThe Discrete Gateway Module (DGM) provides a control link between the PCF system and an

System Setup 32 3A2098HSystem SetupOverview The PCF system compensates for temperature, flow, or pressure fluctuations. However, if there is a hardwar

System Setup3A2098H 33Configure Control SettingsSet the controls for the dispense source, how dispense commands are sent, and job settings. 1. With th

System Setup 34 3A2098HConfigure Mode SettingsSet valve commands, including the dispense mode (pressure, bead, shot, or full open) and flow rate or pr

System Setup3A2098H 35Configure Flow Meter SettingsThe accuracy of the PCF volume reporting depends on precise adjustment of the K-factor(s). The flui

System Setup 36 3A2098HAdjust Pressure SensorsSet pressure offsets and pressure limits.NOTE: Inlet sensor settings will be grayed out on this screen f

System Setup3A2098H 37Setup Maintenance Schedule/ParametersSet the volume (or hours) limit that will trigger a mainte-nance advisory for the fluid sup

System Setup 38 3A2098HConfigure Swirl SettingsNOTE: This applies only to systems with swirl dispens-ers.Set the individual Swirl settings for each in

System Setup3A2098H 39On/Off DelaysThe PCF fluid regulator can physically respond faster than the dispense device and its solenoid. As a result, the f

Models 4 3A2098HModelsCheck the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to define

Operation 40 3A2098HOperationPressure control may degrade at low output pressures. It is not recommended to dispense at outlet pressures less than 500

Operation3A2098H 41Maintenance Mode OperationOperating from maintenance mode enables manual dispensing ( ) and manually starting the swirl dis-penser

Operation 42 3A2098HDispense from Each ValveDispense from each valve that will be used in normal operation to confirm that the entire system is instal

Operation3A2098H 433. Manually dispense material into the beaker. Hold the beaker so that the stream of material is sub-merged in the captured materia

Operation 44 3A2098H4. Press to move to the target fields. Enter the tar-get pressure, flow rate, or volume (dependent on control mode) and press

Operation3A2098H 45Automation Control (Normal Operation)During automation control (normal operation), the sys-tem can dispense or change dispense para

Operation 46 3A2098HStylesThe PCF system has the ability to handle up to 256 styles, depending on the selected option.NOTE: The number of available st

Operation3A2098H 47Precharge Modes NOTE: See the diagram on the following page.Static Precharge ModeDisplayWhen Display precharge mode is selected, a

Operation 48 3A2098HDispense Application Direction Dispense Application Direction Dispense Application DirectionDispense Application Direction Dispens

Operation3A2098H 49Typical Job CycleIn order for the system to run it must be in the active state (status LED next to on the ADM is green). Before a

Models3A2098H 5Fluid Plate KitsNOTE: The fluid plate kit numbers listed below include a CAN splitter. The fluid plate assembly included in each PFxxxx

Operation 50 3A2098HTypical Job Cycle ChartNOTE: Swirl can be turned on at any point inside of or outside of a job. Allow time for the swirl to reach

Operation3A2098H 51Control ChartsAutomation Inputs (PCF Outputs)Volume OKDispense ReadyDispenser (Fluid Plate) No AlarmDispenser (Fluid Plate) No Erro

Operation 52 3A2098HControl Charts (continued)Remote StartAutomation Inputs (PCF Outputs)Dispenser (Fluid Plate) ReadyDispenser (Fluid Plate) No Alarm

Operation3A2098H 53Control Charts (continued)Precharge* - Gateway Mode◆Precharge* - Display Mode◆Automation Inputs (PCF Outputs)Dispense Ready* Precha

Operation 54 3A2098HControl Charts (continued)Precharge* - Valve 1 Mode◆* Precharge: After starting a job and prior to opening the dispense valve, the

Operation3A2098H 55Control Charts (continued)Automation Inputs (PCF Outputs)Dispense In ProcessAutomation Outputs (PCF Gateway Inputs)Dispense Valve X

Operation 56 3A2098HControl Charts (continued)Automation Inputs (PCF Outputs)Dispenser (Fluid Plate) ReadyAutomation Outputs (PCF Gateway Inputs)Swirl

Pressure Relief Procedure3A2098H 57Pressure Relief Procedure 1. Shut off the fluid supply to the fluid plate assembly.2. Place a waste container benea

Shutdown 58 3A2098HShutdown1. Press the Stop button (BC).2. Shut off the material supply to the fluid plate/meter.3. Follow the Pressure Relief Proced

USB Data3A2098H 59USB DataAll files downloaded from the USB are put in a DOWN-LOAD folder on the drive. For example:“E:\GRACO\12345678\DOWNLOAD\”The 8

Models 6 3A2098HExpansion Swirl Enclosure AssembliesThe following enclosures are ETL approved. Assemblies PFxxx2, and PFxxx3 are setup for one Precisi

USB Data 60 3A2098HSystem Configuration Settings FileThe system configuration settings file name is SETTINGS.TXT and is stored in the DOWNLOAD folder.

USB Data3A2098H 61Download Procedure1. Insert USB flash drive into USB port (BL). See FIG. 39 on page 59.2. The menu bar and USB indicator lights indi

Troubleshooting 62 3A2098HTroubleshootingNOTE: Check all possible solutions in the chart below before you disassemble the system.Troubleshooting for i

Troubleshooting3A2098H 63Flow MeterFluid RegulatorProblem Cause SolutionNo flow measurement Flow meter pick-up sensor loose Tighten flow meter pick-u

Troubleshooting 64 3A2098HDispense ValvesSwirl Dispenser Problem Cause SolutionValve not opening Air not getting to the open port Verify air pressure

Troubleshooting3A2098H 65Gateway ModuleLED Diagnostic InformationThe following LED signals, diagnosis, and solutions apply to the Advanced Display Mod

Errors 66 3A2098HErrorsView Errors When an error occurs, an error pop-up is displayed that takes up the entire screen until the error is acknowl-edged

Errors3A2098H 67Event and Error Codes and TroubleshootingError codes are stored in the events log and are displayed on the error report screens. Gatew

Errors 68 3A2098HFluid Plate Events and Errors EBUX --- Download to USB CompleteDownload to the USB is completeAdvisory (self-clearing)--- No action n

Errors3A2098H 69B30_B40_31 High Material Material dispensed dur-ing last dispense cycle was above amount requested plus the allowed toleranceAlarm or

Models3A2098H 7Automation Gateway Assemblies Each control center comes with one automation gateway assembly. The automation gateway module is either a

Errors 70 3A2098HWED_ 55 V/P Error Voltage to Pressure Transducer errorAlarm Problem detected with V/PVerify outlet pressure transducer is installed a

Errors3A2098H 71V2D_ 62 Low Analog Command cable analog command dropped below minimum value of 1 V while dispensingDeviation Bad or loose com-mand cab

Errors 72 3A2098HP1C_P2C_69 Low Pressure Measured outlet pres-sure less than desired outlet pressure minus toleranceAlarm or Deviation (user select-ab

Errors3A2098H 73EAC_ 75 Maintenance Mode EnteredMaintenance mode enteredAdvisory (self-clearing)Entered maintenance dispense modeNo action requiredEBC

Errors 74 3A2098HCR1_ 88 Valve 1 Swirl Communication ErrorFluid plate communica-tion error with swirlAlarm The fluid plate lost communication with the

Errors3A2098H 75Swirl Events and ErrorsMB3_ 98 Maintenance due - V3 OrbiterMaintenance due on valve 3 swirl orbiterAdvisory The active time total-izer

Maintenance 76 3A2098HMaintenancePrior to performing any maintenance procedures, follow the Pressure Relief Procedure on page 57.Maintenance ScheduleT

Maintenance3A2098H 77Advanced Display Module (ADM)Upgrade SoftwareNOTE: Back up the custom language file (if installed) before upgrading software. See

Maintenance 78 3A2098H5. After the red indicator light shuts off, turn off power to the system.6. Remove token.7. Replace access cover.Upgrade Gateway

Maintenance3A2098H 79Upgrade Fluid Control Module (FCM) SoftwareNOTE: The FCM connection is temporarily disabled during the use of the upgrade token.1

Warnings 8 3A2098HWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point

Repair 80 3A2098HRepairFluid Plate AssemblyThis section describes how to remove and replace com-ponents on the fluid plate assembly.Prepare Fluid Plat

Repair3A2098H 81Install Flow Meter on Mounting Plate1. Rest the flow meter (129) and bracket (124) on the fluid plate while threading the swivel fitti

Repair 82 3A2098H5. Secure the new V/P transducer to the bracket with screws.6. Reconnect the FCM cable and both air tubes.Replace Fluid Control Modul

Repair3A2098H 83Replace Transducer O-Rings1. Prepare Fluid Plate Assembly for Repair, page 80.2. Remove the fluid outlet pressure sensor (117) from th

Repair 84 3A2098HRepair Fluid RegulatorFor complete cartridge fluid regulator repair refer to instruction manual 308647. For complete mastic fluid reg

Repair3A2098H 85Replace Amplifier(Heated fluid plates only)1. Prepare Fluid Plate Assembly for Repair, page 80.2. Disconnect pressure sensor cable (11

Repair 86 3A2098HAdjust Amplifier Settings12. Remove cover from amplifier (116). See Replace Amplifier, page 85.13. Ensure the EXCITATION SELECTOR jum

Repair3A2098H 87Control Center Assembly Prepare Control Center for Repair1. Power off the display.2. Disconnect main power to the control center assem

Repair 88 3A2098HReplace Swirl Board 16K570:1. Prepare Control Center for Repair, page 87.2. Remove screw (a) from swirl board cover. Open swirl board

Repair3A2098H 89Replace Advanced Display Module Bracket1. Prepare Control Center for Repair, page 87.2. Remove the ADM (2); follow Replace Advanced Di

Warnings3A2098H 9EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.• Do not operate the unit when fatigued or under the influence of dr

Repair 90 3A2098H6. Remove the din rail, filter, and rocker switch (snaps into place). Replace with new components. Secure din rail and filter to the

Parts3A2098H 91Parts Control CentersSoftware Upgrade Tokens Control Center Key Token Part NumbersSee Key Tokens on page 20 for more information about

Parts 92 3A2098HControl Center and Expansion Swirl Enclosure Parts50131522402879442413161245 or 432026241114212526,103823,2718131924 VDC units only: 1

Parts3A2098H 93Control Center Assembly Parts▲Replacement Danger and Warning labels, tags, and cards are available at no cost.‡ Parts included with 100

Parts 94 3A2098HFluid Plate Assembly PartsSee page 96See page 95101143142152131153151See page 95135, 136199117, 120

Parts3A2098H 95Fluid Plate Assembly Parts (continued)1051031061051021041411411181221411221411281331281371411321281211371251261291241271261251091101261

Parts 96 3A2098HFluid Plate Assembly Parts (continued)111141113112113112127127114108115117108105, 116Fluid Plate 24B962149140, 141, 150158139107148145

Parts3A2098H 97Fluid Plate Assembly Parts ▲Replacement Danger and Warning labels, tags, and cards are available at no cost.✓See Parts Varying by Assem

Parts 98 3A2098HParts Varying by AssemblyThe following table lists the varying part numbers by fluid plate assembly, and the quantity for each assembl

Appendix A - Advanced Display Module (ADM)3A2098H 99Appendix A - Advanced Display Module (ADM)Display OverviewThe ADM display is divided into two main