Instructions - Parts
PCF™ with
PrecisionSwirl™
3A2098H
EN
Precision Dispense System
Electronically-controlled fluid metering system that provides precise continuous flow of up
to four single-component sealants and adhesives through closed-loop technology.
Not for use in explosive atmospheres or hazardous locations.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
maximum working pressure and approvals.
Optional PrecisionSwirl Orbital
Dispenser (sold separately)
IMPORTANT:
PCF Control Center
This manual does not apply to some PCF sys-
correct manual for your PCF system.
PCF Fluid Plate
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Related Manuals
Related Manuals
The following is a list of component manuals written in
English. These manuals and any available translations
can be found at www.graco.com.
Appendix B - Discrete Gateway Module (DGM)
Manual
313377
309403
307517
Description
Original PCF Instructions - Parts
(see the note below)
D-Sub Cable 123792 and Breakout Board 123783
PrecisionSwirl Orbital Dispenser
Mastic Fluid Regulators Instruc-
tions-Parts
Fluid Pressure Regulators Instruc-
tions-Parts
Helical Gear Fluid Flow Meters Instruc-
tions-Parts
308647
309834
Appendix C - Communications Gateway Module
NOTE: In the Advanced screens on your system, if the
Advanced Display software part number shown is
16F528 or 15V769 then this manual does not apply to
your system; refer to manual 313377 for your system.
Otherwise, the part number shown should be 16K405
and you should use this manual.
ADM Software Part No. 16F528 or 15V769
(see manual 313377)
✖
ADM Software Part No. 16K405
(use this manual)
✓
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Models
Models
Check the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to
define the construction of the system, based on the six digits. For example, Part PF1110 represents a PCF fluid
metering system (PF), a two style system (1), a fluid plate with a cartridge regulator and no meter (1), a DeviceNet™
user interface (1) with a 100-240 Vac power supply (0).
NOTE: To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the
Ref. Nos. in the Parts drawings and lists.
1
0
PF
1
1
Fourth Digit
Sixth Digit
Third Digit
Fifth Digit
First and
Second Digits
Fluid Plate
Voltage
Style/Size
Description
2 Styles
User Interface
Description
◆Discrete
DeviceNet™
EtherNet/IP™
Regulator
Meter
None
None
Description
100 - 240 Vac
24 Vdc
PF
1
1
2
❄Cartridge
❄Mastic
0
1
0
1
(Precision
Continuous
Flow)
16 Styles
2
3
256 Styles
3
❄Cartridge
High
Resolution
2
2 100 - 240 Vac with
Integrated Swirl
PROFIBUS™
PROFINET™
4
5
❄Mastic
High
Resolution
Heated
Standard
Resolution
None
3
4
3
24 Vdc with
Integrated Swirl
Heated
Mastic
6
7
Heated
Mastic
❄Cartridge
Ultra High
Resolution
◆ 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
For single fluid plate systems only: 50 ft (15 m) cable with flying leads (123793)
All systems: Breakout board (123783) and 50 ft (15 m) cable (123792)
NOTE: 256 styles option is not available with Discrete Gateway systems.
❄ These fluid metering systems have ETL certification.
NOTE: Fluid metering systems with heated mastic regulators are not ETL certified.
9902471
Certified to CAN/CSA C22.2 No. 61010-1
Conforms to
UL 61010-1
1
This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition, including
C
Amendment 1, or a later version of the same standard incorporating the same level of testing requirements.
4
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Models
Fluid Plate Kits
NOTE: The fluid plate kit numbers listed below include a CAN splitter. The fluid plate assembly included in each
PFxxxx assembly does not include a CAN splitter.
Includes:
Fluid
Plate Kit
Used by
Model
Regula-
tor
Flow
Meter
FCM Key
Token
Maximum Working
Pressure
Description
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, High Resolution Flow
Meter, 2 styles
24B958
24B959
24B960
24B961
24B962
24C901
24J873
24K801
24K802
24K803
24K804
24K805
24K806
24K807
24K808
24K809
24K810
24K811
24K812
24K813
24K814
PF13xx
PF11xx
PF14xx
PF12xx
PF15xx
PF16xx
PF17xx
PF23xx
PF21xx
PF24xx
PF22xx
PF25xx
PF26xx
PF27xx
PF33xx
PF31xx
PF34xx
PF32xx
PF35xx
PF36xx
PF37xx
244734
244734
246642
246642
246643
246643
244734
244734
244734
246642
246652
---
16M100
16M101
16M100
16M101
16M100
16M101
16M100
16M102
16M103
16M102
16M103
16M102
16M103
16M102
16M104
16M105
16M104
16M105
16M104
16M105
16M104
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, No Flow Meter,
2 styles
5000 psi
(35 MPa, 345 bar)
Mastic Regulator, High Resolution Flow
Meter, 2 styles
246652
---
5000 psi
(35 MPa, 345 bar)
Mastic Regulator, No Flow Meter, 2 styles
5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, Standard Resolu-
tion Heated Flow Meter, 2 styles
246340
---
5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, No Flow Meter,
2 styles
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, Ultra High Resolution
Flow Meter, 2 styles
16E993
246652
---
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, High Resolution Flow
Meter, 16 styles
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, No Flow Meter,
16 styles
5000 psi
(35 MPa, 345 bar)
Mastic Regulator, High Resolution Flow
Meter, 16 styles
246652
---
5000 psi
(35 MPa, 345 bar)
Mastic Regulator, No Flow Meter, 16 styles 246642
5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, Standard Resolu-
246643
246340
---
tion Heated Flow Meter, 16 styles
5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, No Flow Meter,
246643
16 styles
6000 psi
(41.4 MPa, 414 bar)
Cartridge Regulator, Ultra High Resolution
244734
16E993
246652
---
Flow Meter, 16 styles
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, High Resolution Flow
244734
Meter, 256 styles
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, No Flow Meter,
244734
256 styles
5000 psi
(35 MPa, 345 bar)
Mastic Regulator, High Resolution Flow
246642
246652
---
Meter, 256 styles
5000 psi
(35 MPa, 345 bar)
Mastic Regulator, No Flow Meter,
246642
256 styles
5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, Standard Resolu-
246643
246340
---
tion Heated Flow Meter, 256 styles
5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, No Flow Meter,
246643
256 styles
6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, Ultra High Resolution
244734
16E993
Flow Meter, 256 styles
3A2098H
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Models
Expansion Swirl Enclosure Assemblies
The following enclosures are ETL approved. Assemblies PFxxx2, and PFxxx3 are setup for one PrecisionSwirl
Orbital Dispenser. If you wish to have additional swirl dispensers, order one expansion PrecisionSwirl assembly
below for each. Systems with a DGM as the automation gateway can have up to two swirl dispensers total. Systems
with a CGM as the automation gateway can have up to four swirl dispensers total.
Part
Description
16M350
16M351
100 - 240 Vac
24 Vdc
PrecisionSwirl Orbital Dispenser Assemblies
See manual 309403.
Maximum
Working
Pressure
Version
Part, Series
Coupler Offset
Typical Application
Standard
243402, B
0.012 in. for narrow bead
widths
Hem flange and after hem
Standard
Compact
Compact
243403, B
289262, A
289261, A
0.028 in. for wide bead
widths
Seam sealing
3500 psi
(24.1 MPa,
241 bar)
0.012 in. for narrow bead
widths
Hem flange and after hem
Seam sealing
0.018 in. for medium bead
widths
PrecisionSwirl Orbital Dispenser Cable
Assemblies
Part
Description
233125
233124
233123
617870
6 ft (1.8 m) motor extension cable assembly
9 ft (2.7 m) motor extension cable assembly
15 ft (4.6 m) motor extension cable assembly
55 ft (16.8 m) motor extension cable assembly
6
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Models
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).
Gateway
UserInterface PartNumber
Rotary
Switch
PCF Model
Description
To Order
Position
PFxx0x
Discrete
(DGM)
24B681
0
DeviceNet™
(CGM)
PFxx1x
PFxx2x
PFxx3x
PFxx4x
15V759
15V760
15V761
15V762
Any
EtherNet/IP™
(CGM)
Any
Any
Any
PROFIBUS™
(CGM)
PROFINET™
(CGM)
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).
Part Number
To Order
Rotary Switch
Position
Assembly
PFxxx2,
PFxxx3,
16M350,
16M351
1, 2, 3, or 4;
see Swirl Control
Automation Gateway
(DGM or CGM)
24B681
Swirl Control DGM
3A2098H
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Warnings
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.
8
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Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
•
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•
•
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine 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
3A2098H
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System Configurations
System Configurations
Typical Installation - Single Swirl, Single Fluid Plate
NOTE: Shown with one fluid plate and one swirl dispenser.
Power In
E
A*
J
F*
Air Supply
Drop Site
K*
F*
M
C
H
B*
L
D
G
FIG. 1: Typical Ambient System Installation
Key:
A
B
C
D
E
F
*Control Center (User Interface)
*Fluid Plate Assembly
Applicator/Dispense Valve
Sealer Automation
Automation Interface Cable
*CAN Cable
H
J
K
L
Fluid Supply Hose
Automation Controller
*Air Filter Assembly
◆PrecisionSwirl Orbital Dispenser (Swirl Dispenser)
◆PrecisionSwirl Cable
M
* Included
◆ Optional
G
Fluid Supply System
10
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System Configurations
Typical Installation - Multiple Fluid Plates, No Swirl Dispensers
B*
F*
Power In
H
D
D
D
C
C
C
G
B*
A
F*
K*
H
Air Supply
Drop Site
F*
F*
E
G
B*
F*
J
H
G
B*
H
D
C
G
FIG. 2: Typical Multiple Fluid Plate System Installation
Key:
A
B
C
D
E
*Control Center (User Interface)
*Fluid Plate Assembly
Applicator/Dispense Valve
Sealer Automation
F
G
H
J
*CAN Cable
Fluid Supply System
Fluid Supply Hose
Automation Controller
*Air Filter Assembly
Automation Interface Cable
K
* Included
3A2098H
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System Configurations
Typical Installation - Multiple Fluid Plates, Multiple Swirl Dispensers
F*
A
Power In
B*
M
K*
D
H
C
E
L
Air
Supply
Drop Site
F*
F*
G
B*
D
J
H
N
C
L
M
G
FIG. 3: Typical Multiple Fluid Plate System Installation
Key:
A
B
C
D
E
F
*Control Center (User Interface)
*Fluid Plate Assembly
Applicator/Dispense Valve
Sealer Automation
Automation Interface Cable
*CAN Cable
G
H
J
Fluid Supply System
Fluid Supply Hose
Automation Controller
K
L
M
N
*Air Filter Assembly
◆PrecisionSwirl Orbital Dispenser (Swirl Dispenser)
◆PrecisionSwirl Cable
◆Expansion Swirl Enclosure
* Included
◆ Optional
12
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Overview
Overview
Control Center (User Interface)
System Overview
The control center communicates with the PCF fluid
plate assembly to control fluid pressure and dispense
valve operation.
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.
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.
Typical Applications
•
•
•
•
•
•
•
•
•
Bead dispensing
Gasketing
Seam sealing
Hem flange
Sound deadening
Anti-flutter
Body panel reinforcement
Profile wrapping
Cable filling
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.
System Components
The diagram in FIG. 4 shows an example of the PCF
module and cables.
Control Center
(User Interface)
Fluid Plate Assembly
System shown with one fluid plate and one swirl dispenser
FIG. 4: PCF System Components
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Overview
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.
Fluid Plate Assembly Overview
Fluid Plate Components
The fluid plate assembly in FIG. 5 can be attached to an
automation arm or mounted on a pedestal. The main
components of the fluid plate assembly include:
•
•
Fluid regulator (cartridge, ambient mastic, or heated
mastic) (P).
The fluid plate assembly is available in two versions:
ambient and heated.
Flow meter (R) (optional) precisely measures the
flow rate of fluid dispensed.
•
•
Solenoid air valve (S) controls the dispense valve.
Ambient Fluid Plate Assembly
Voltage to Pressure Transducer (T), abbreviated V/P
transducer, adjusts the air pressure to the fluid regu-
lator (P).
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;
•
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).
•
cartridge regulator with an ultra high resolution
flow meter.
S
T
Heated Fluid Plate Assembly
There are two heated versions available:
U
•
•
heated mastic fluid regulator with a heated flow
meter,
and a heated mastic fluid regulator without a
flow meter.
P
R
FIG. 5: Fluid Plate Components
14
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Overview
Fluid Regulator
Fluid Control Module (FCM)
There are three fluid regulator options:
1
2
5
6
7
3
4
•
•
•
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.
CAN
Connectors
Status
LEDs
Rotary
Switch
Key
token
Cartridge
FIG. 6: FCM Sensor Connections
The cartridge regulator (244734) is ideal for low to
medium viscosity sealants and adhesives.
Table 1: FCM Sensor Connections
Connection Sensor Description
Ambient Mastic
1
2
3
4
5
6
Dispense solenoid
Flow meter
The ambient mastic regulator (246642) is ideal for
medium to high viscosity sealants and adhesives.
Outlet pressure sensor (heated systems only)
Voltage to Pressure (V/P) Transducer
Command cable (optional accessory kit)
Heated Mastic
The heated mastic regulator (246643) is ideal for low to
high viscosity warm-melt and hot-melt sealants or adhe-
sives.
Inlet pressure sensor (non-heated systems
only)
7
Outlet pressure sensor (non-heated systems
only)
CAN
---
Connectors
Rotary Switch on FCM
The rotary switch on the FCM, see FIG. 6, must be set to
a valid position and each FCM must have a unique
rotary switch position. The FCM rotary switch position
determines which number to assign to that fluid plate.
The settings, including defined styles, for each fluid
plate are stored in each FCM so changing the rotary
switch position causes the settings to be shown under
the new number on the ADM.
Rotary Switch
Item
Position
Fluid Plate 1
Fluid Plate 2
Fluid Plate 3
Fluid Plate 4
0 or 1
2
3
4
signal definitions.
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Overview
Control Center Assembly Overview
Front View
100-240 Vac Assembly
Front View
Side View
Swirl Board
Gateway
Module
ADM
Swirl Control
DGM
FIG. 7: Control Center Components
The control center includes the following components:
•
Advanced Display Module (ADM) with USB; see
page 17 for details.
•
•
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:
•
USB enables users to download job, event, and
data logs; save and restore system settings; and
•
•
•
•
•
Discrete
DeviceNet
EtherNet/IP
PROFIBUS
PROFINET
•
24 Vdc and 100-240 Vac customer-wired options
available.
Expansion Swirl Enclosure
If more than one swirl dispenser is installed, the system will have one Expansion Swirl Enclosure for each additional
swirl dispenser. The Expansion Swirl Enclosure is similar to the primary control center, but it does not include the
ADM or the Automation Gateway module.
16
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Overview
Advanced Display Module (ADM)
BB
BJ
BC
BD
BP
BA
BK
BL
BE
BF
BH
BM
BN
BR
BS
BG
TI12362a
r_24E451_3B9900_1a
FIG. 8: Advanced Display Module Component Identification
KEY:
Callout Function
BH
Navigation Buttons
Navigate within a screen or to a new screen.
Callout Function
BA
Power On/Off Button
BJ
Flat Panel Mount
Mounts to control center bracket (optional).
Enables/disables system.
BB
System Status Indicator LED
BK
BL
BM
BN
Model Number Tag
Model number.
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.
USB Module Interface
USB port and USB indicator LEDs.
CAN Connector
Power connection.
BC
Stop Button
Module Status LEDs
signal definitions.
Stops all system processes. However, it is not a
safety or emergency stop.
BD
BE
Soft Keys
BP
BR
BS
Battery Cover
Functions vary depending on the screen.
Token Access Cover
Digital I/O Port for Light Tower
Cancel Button
Clears system errors and cancels a selection or
number entry while in the process of entering a
number or making a selection.
NOTICE
BF
Enter Button
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
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.
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Overview
Automation Gateway Module
See the following table for the appropriate rotary switch position for your automation gateway module.
Gateway Part Number To
PCF Model
User Interface Description
Discrete (DGM)
Order
Rotary Switch Position
PFxx0x
PFxx1x
24B681
15V759
0
DeviceNet™ (CGM)
EtherNet/IP™ (CGM)
PROFIBUS™ (CGM)
PROFINET™ (CGM)
Any
PFxx2x
PFxx3x
PFxx4x
15V760
15V761
15V762
Any
Any
Any
NOTE: See Control Center Assembly Overview on page 16 for automation and swirl control DGM identification.
Front
Front
Back
(Access Cover Removed)
CD
CA
CB
Rotary
Switch
Software
Token Slot
CF
CE
CH
Gateway Module Connectors
DeviceNet
PROFINET or EtherNet/IP
CC
Discrete
CG
PROFIBUS
CC
CC
TI11816A
TI11815A
TI11814A
FIG. 9: Automation Gateway Module Components
Key:
CA Gateway Module
CB Base
CD Module Connection Screws
CH CAN Connectors
CE Access Cover
18
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Overview
Swirl Control DGM
One swirl control DGM is included in the integrated Swirl
control center, and in each expansion swirl enclosure.
Each Swirl control DGM controls one swirl orbiter.
Rotary Switch
DGM Function
Position
Swirl Control 1
Swirl Control 2
Swirl Control 3
Swirl Control 4
1
2
3
4
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.
Front
Back
Front
(Access Cover Removed)
CD
CA
CB
Rotary
Switch
Software
Token Slot
CF
CE
CH
FIG. 10: Swirl Control DGM
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Overview
Key Tokens
The ADM and FCM must each have a key token
installed in order to operate. If the incorrect key token is
installed, the module will not operate. The DGM does
not require a key token.
ADM
FCM
FIG. 11
NOTE: There is one FCM located on each fluid plate.
If a new ADM or FCM is installed, follow the instructions
and to install the key token from the old module in the
new module.
The following is a list of key token part numbers. If you
lose your key token be sure to order the correct item to
ensure proper system operation.
NOTE: The key tokens for the ADM and FCM look alike
but only work in one module or the other. If the key
tokens for the ADM and FCM become mixed, locate the
part number on each token then refer to the following
table to determine which module each token applies to.
Part
Description
16M100
FCM Key Token, 2 styles, Flow Meter
16M101
16M102
16M103
16M104
16M105
FCM Key Token, 2 styles, No Flow Meter
FCM Key Token, 16 styles, Flow Meter
FCM Key Token, 16 styles, No Flow Meter
FCM Key Token, 256 styles, Flow Meter
FCM Key Token, 256 styles, No Flow
Meter
16M217
ADM Key Token, Standard PCF
20
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Installation
Installation
10. Connect other fluid and air lines to additional system
components as instructed in their manuals.
Before Installation
•
Have all system and component documentation
available during installation.
11. Install fluid plate, swirl, and gateway cable assem-
•
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.
To avoid injury and damage to equipment, use at
least two people to lift, move, or disconnect the sys-
tem. The system is too heavy for one person to lift or
move.
Installation Steps
2. For systems with multiple swirl dispensers, mount
expansion Swirl enclosures, page 22.
3. Connect and ground control center and expansion
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.
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Installation
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.
Install Control Center
NOTE: This section applies to both the primary control
center and the expansion Swirl enclosures.
Table 2: Control Center Assembly Measurement
Mount
10.50 in. (267 mm)
5.75 in. (146 mm)
A
B
Ensure the following criteria are met before mounting
the PCF control center:
22.00 in. (559 mm)
21.25 in. (540 mm)
C
D
•
Select a location for the control center that allows
adequate space for installation, service, and use of
the equipment.
•
•
•
For best viewing, the ADM should be 60-64 in.
(152-163 cm) from the floor.
A
Ensure there is sufficient clearance around the con-
trol unit to run cables to other components.
B
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.
C
D
FIG. 12: Control Center Dimensions
22
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Installation
Electrical Connections
To reduce the risk of fire, explosion, or electric shock,
when grounding, connecting cables, connecting to a
power source or making other electrical connections:
Ground
•
The control center must be electrically connected
to a true earth ground; the ground in the electrical
system may not be sufficient. Refer to your local
code for the requirements for a “true earth ground”
in your area.
N
•
•
All wires used for grounding must be 18 AWG min-
imum.
L
A qualified electrician must complete all grounding
and wiring connections.
FIG. 14: 100-240 Vac Wiring
•
•
•
Connect Light Tower Accessory
Incoming power wiring must be guarded from the
enclosure. Use a protective grommet where the
power wiring enters the enclosure to prevent wear.
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.
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
See Table 3 for a description of light tower signals.
Table 3: Light Tower Signals
Signal
Description
Green
No errors.
Yellow
An advisory exists.
A deviation exists.
Yellow flashing
Red solid
An alarm exists. One or more fluid
plates may be shutdown.
Ground
+
-
FIG. 13: 24 Vdc Wiring
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Installation
2. Mount and secure the fluid plate assembly to the
automation unit (or other mounting surface) with
appropriate size bolts through the 0.397 in. (10 mm)
diameter holes in the base plate. See the mounting
dimensions in Table 4 and FIG. 15.
Install Fluid Plate Assemblies
To install the PCF fluid plate assemblies:
•
•
•
Mount the fluid plate assemblies, page 24
Ground fluid plate assemblies, page 27
Table 4: Fluid Plate Assembly Measurement
Connect one fluid plate assembly to the control cen-
16.5 in. (419 mm)
14.0 in. (356 mm)
14.4 in. (366 mm)
13.4 in. (340 mm)
A
B
C
D
•
If multiple fluid plates, connect the fluid plates
•
Connect fluid lines, air lines, and cables; page 27
Mount
A
Before Mounting Assembly
•
See component manuals for specific information on
component requirements. Information presented
here pertains to the PCF fluid plate assembly only.
D
C
•
•
•
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.
B
FIG. 15: Fluid Plate Assembly Dimensions
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.
24
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Installation
Mount Four-Valve Breakout Kit 24B693
5. Connect the dispense valve cable(s) to the connec-
tions on the splitter assembly.
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
Connects to Splitter
Cable for:
Connection Labeled:
Dispense Valve 1
Dispense Valve 2
Dispense Valve 3
Dispense Valve 4
J1
J2
J3
J4
solenoid (258334) and one solenoid cable (121806).
Follow this procedure if using the four-valve breakout
kit.
6. Mount splitter assembly and dispense valves, and
connect air lines as necessary for application.
1. Remove the existing dispense solenoid and cable
from the fluid plate.
Custom Breakout Cable
2. Install bulkhead fitting (included in the kit) into the
empty hole on the fluid plate.
If desired, the following connector pinout information
may be used to build a custom breakout cable:
Pinout of FCM Port 1
GCA Cable
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).
Connection 1
Hole for bulk-
head fitting
Splitter Assembly
J1
J2
J3
J4
FIG. 16: Mount Breakout Kit
3. Connect one end of the extension cables (included
in the kit) to connection 1 on the FCM and the other
end of the cable to the bulkhead fitting.
4. Connect the splitter assembly to the bulkhead fit-
ting.
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Installation
Install Command Cable Kit 24B694
Follow this procedure if using the command cable kit.
1. Install bulkhead fitting (included in the kit) into the
2. Connect one end of the extension cable (included in
the kit) to connection 5 on the FCM and the other
end of the cable to the bulkhead fitting.
3. Connect command cable to bulkhead fitting and
wire to automation controller per the following pinout
table.
Function
FCM
Port
Pin # Color
Command
Cable Wire
Dispense Trigger Source:
‘Command Cable’ or
‘Combined’
Dispense Trigger Source:
‘Command Cable 3x’
1
2
White
Command voltage (0-10 Vdc)
No connection
Command voltage (0-10 Vdc)
Brown
Green
Yellow
Valve 3 dispense trigger (*sourcing
input)
3
4
Dispense trigger (*sourcing input) Valve 1 dispense trigger (*sourcing
input)
No connection
Valve 2 dispense trigger (*sourcing
input)
5
6
7
8
Gray
Pink
Blue
Red
Dispense trigger ground
No connection
Dispense trigger ground
No connection
Command signal ground
No connection
Command signal ground
No connection
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).
26
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Installation
Ground
Connect Fluid and Air Lines
NOTICE
Route all fluid and air lines carefully. Avoid pinching
and premature wear due to excessive flexing or rub-
bing. Hose life is directly related to how well they are
supported.
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.
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.
•
•
All wires used for grounding must be 18 AWG min-
imum.
A qualified electrician must complete all grounding
and wiring connections.
•
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.
Incoming power wiring must be guarded from the
enclosure. Use a protective grommet where the
power wiring enters the enclosure to prevent wear.
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.
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
•
•
Connect an air supply line to the 1/4 npt inlet port on
the fluid plate(s) air supply inlet.
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.
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.
Air and Fluid Hoses
NOTE: To maximize system performance keep the dis-
pense hose length and ID as small as the application
will allow.
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.
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Installation
Install Cable Assemblies
NOTE: To prevent system errors, only connect cables
with the power off.
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
5. Use the automation interface cable (not provided) to
connect the Gateway module to the automation
controller.
28
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Installation
Install Gateway Module Interface
NOTE: Systems with swirl dispensers will have two gateway modules in the control center. The gateway module on
the left is the swirl control DGM module, and does not need any setup or modification. The gateway module on the
right is the automation Gateway module. This section covers the automation Gateway module.
Installation
Fieldbus Communications Gateway Module
NOTE: The following installation instructions assume
the person implementing the PCF fieldbus connection
Module Description
fully comprehends the fieldbus being used. Ensure the
installer understands the automation controller commu-
nication architecture and the fieldbus being used.
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.
45, for details on controlling the PCF system through the
Gateway module.
1. Install interface cables between the PCF system
and the automation controller per the fieldbus stan-
dards. Refer to Appendix C - Communications
page 122, for details.
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
details about PCF/fieldbus data map.
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-
data map.
3. Set the PCF Gateway configuration values as
required to interface with automation controller.
Refer to Appendix A - Advanced Display Module
settings.
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
4. Retrieve the appropriate fieldbus configuration file
for the fieldbus being used from www.graco.com.
CGM Status LED Signals
5. Install the configuration file on the automation con-
troller (fieldbus master). Configure it for communica-
tion with the PCF Gateway (fieldbus slave).
Signal
Description
Green on
Yellow
System is powered up
6. Establish communication between the automation
controller and the PCF Gateway to confirm the suc-
cessful configuration of the hardware and data.
Internal communication in progress
CGM hardware failure
Red
Solid
NOTE: Use the ADM screens for troubleshooting field-
bus data communication problems. Refer to Appendix
details. Also, use the LED status indicators on the PCF
Gateway module for fieldbus status information. Refer to
*Red
(7 flashes)
Data map load failure
Incorrect data map for fieldbus type
No data map loaded
*The red LED (CF) will flash a code, pause, then repeat.
30
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Installation
DGM Rotary Switch Position
Discrete Gateway Module
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
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.
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 -
face signals.
•
For multiple fluid plate systems: D-Sub cable
(123972) and 78-pin breakout board (123783).
details and pin assignments.
r_24B681_2B9904_2b
CG
FIG. 18: Connect D-Sub Cable
DGM Status LED Signals
definitions.
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System Setup
Configure System
System Setup
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.
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.
1. With the system in setup mode, navigate to the Sys-
tem screen.
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.
2. Press
to access the fields to make changes.
3. Use the arrow keys to navigate to the desired field.
4. Press
tion.
to open the drop-down list, and select
to accept the selec-
the desired setting. Press
tions for the display keypad and each screen.
5. Repeat for the other Dispensers and Swirl Dispens-
ers.
6. Press
to exit edit mode.
10. For systems with swirl dispensers only:
a. Configure Swirl to valve association and error
FIG. 19
32
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System Setup
Configure Control Settings
7. Press
to move to the Job End Delay field. Enter
Set the controls for the dispense source, how dispense
commands are sent, and job settings.
the desired delay time (in seconds). Press
enter the value.
to
1. With the system in setup mode, navigate to Fluid
Plate x, screen 1 (Control Settings).
8. Press
to move to the Run Mode Bead Adjust
to open the drop-down list, and
field. Press
2. Press
to access the fields to make changes.
select Enable or Disable. Press
value.
to enter the
9. Press
box. Press
to move to the End Job on Alarm Check-
to enable or disable.
10. Press
to move to the Display Control Password
to enter the value.
field. Press
11. Press
to exit edit mode.
12. If multiple fluid plates are installed, repeat this pro-
cedure for the other Fluid Plates.
FIG. 20
3. Press
to open the Dispense Trigger Source
drop-down list, and select Gateway, Command
Cable, Command Cable 3x, or Combined. If 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
Press
to move to the Enable Valves field.
and to enable valves.
5. Press
to move to the Command Value Source
to open the drop-down list, and
field. Press
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.
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System Setup
Configure Mode Settings
5. Press
to move to the Bead Scale field. Enter a
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.
scale value between 50% and 150%. Press
enter the value.
to
6. Press
to exit edit mode.
NOTE: For a description of each dispense mode, see
Configure Delay Settings
Set on and off delays (in milliseconds) for each valve
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 2 (Mode Settings).
and the regulator. For an explanation of the on and off
2. Press
to access the fields to make changes.
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 3 (Delay Settings).
2. Press
to access the fields to make changes.
FIG. 21
3. Press
and
to set the mode for each
valve that will be used to Pressure, Bead, Shot, or
Full Open. Press to enter each selection.
FIG. 22
4. Use the four arrow buttons to navigate to each
Fixed Command field. Enter the desired value for
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
each valve that will be used. Press
each value.
to enter
NOTE: The ability to dispense from multiple valves
simultaneously is only allowed in either of the following
scenarios.
regulator. Press
to enter each value.
4. Press to exit edit mode.
•
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.
34
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System Setup
3. Press
to open the Meter Type drop-down list,
Configure Flow Meter Settings
and select the meter type used by the system.
Select Volume for volumetric flow meters or Mass
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
page 42, for additional K-factor information.
for mass flow meters. Press
tion.
to enter the selec-
4. Press
K-factor value. See Table 5: Flow Meter K-Factors
for values. Press to enter the value.
to move to the K-Factor field. Key in the
Table 5: Flow Meter K-Factors
Part
Description
K-Factor
5. Press
to exit edit mode.
246652
High Resolution Helical
Gear Meter
7000
NOTE: If necessary, verify flow meter calibration. See
tions.
246340
16E993
Heated Helical Gear
Meter
Ultra High Flow Meter
3500
33000
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.
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).
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
2. Press
to access the fields to make changes.
FIG. 23
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System Setup
Adjust Pressure Sensors
Configure Errors
Set pressure offsets and pressure limits.
Set the error type (alarm, deviation, or none) that will be
issued if the pressure, flow rate, volume, or computed
target goes outside the tolerance settings of the active
style. When an alarm occurs, the system stops dispens-
ing. When a deviation occurs, the system will continue
dispensing. See Fluid Plate x, Screen 6 (Error Type)
NOTE: Inlet sensor settings will be grayed out on this
screen for systems with heated fluid plates.
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 5 (Pressure Sensors).
2. Press
to access the fields to make changes.
NOTE: Only the low/high pressure errors will be
enabled for systems without a flow meter.
1. With the system in setup mode, navigate to Fluid
Plate x, screen 6 (Error Type).
2. Press
to access the fields to make changes.
FIG. 24
NOTE: For the following steps, press
and
to navigate through each field, and
to open
drop-down menus and enter changes or selections.
3. Set the desired offset for the inlet and outlet 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.
FIG. 25
NOTE: It is recommended that offsets should not be
changed from the factory defaults of 0.
3. Press
to open the Low Pressure drop-down
list, and select either Alarm or Deviation for the error
4. Set the desired minimum and maximum pressure
limits for the inlet, and the desired maximum pres-
sure limit for the outlet.
type. Press
to enter the selection.
4. Press
to move to the next field. Repeat Step 4
5. Set the error type (alarm or deviation) that will be
issued:
for each field.
5. Press to exit edit mode.
•
•
•
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.
36
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System Setup
To reset a totalizer value:
Setup Maintenance
Schedule/Parameters
in Fluid Plate x, screen 7 (Maintenance Advisory Lim-
its)
.
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.
2. Press
reset.
to scroll to the system component to
to reset the value.
NOTE: Hours is shown instead of Volume for fluid plates
without a flow meter.
3. Press
The Volume (or Hours) column displays the current
totalizer value. If this value exceeds the set limit, the
value will turn red and a maintenance advisory is issued.
nance totalizers.
Configure Valve to Swirl
Association and Motor Error
Type
Define which Swirl number is installed on which dis-
pense valve.
To set limits:
1. With the system in setup mode, navigate to the Fluid
Plate x, screen 7 (Maintenance Advisory Limits).
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.
2. Press
to access the fields to make changes.
FIG. 26
FIG. 27
3. Enter the desired limit for the air supply and press
to enter the selection.
4. Press
to move to the next field. Repeat Step 4
to exit edit mode.
for each field.
5. Press
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System Setup
Configure Swirl Settings
NOTE: This applies only to systems with swirl dispens-
ers.
Set the individual Swirl settings for each installed Swirl.
FIG. 28
Configure Gateway Settings
Gateway settings differ for each system. See Automa-
on configuring each type of Gateway interface.
Setup 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
38
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System Setup
FIG. 29 and Table 6: Delay On/Off Timing show delay
ON and OFF timing.
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.
Table 6: Delay On/Off Timing
A Regulator ON
The user sets the fluid regu-
delay
lator ON delay timing.
B Valve ON delay
C Valve OFF Delay
Usually set to zero. Can be
used to change the starting
point of a bead.
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.
Usually set to zero. Higher
values will lower the trapped
pressure.
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-
34.
D Regulator OFF
delay
The user sets the regulator
OFF delay timing. Zero or
small values will lower the
trapped pressure.
Time delay for valve to phys-
ically open. Delay varies
based on pneumatic hose
length and valve air volume.
E Valve Open
Reaction Time
NOTE: On/Off delay can be set for each dispense
device.
F Valve Close
Reaction Time
Time delay for valve to phys-
ically close. Delay varies
based on pneumatic hose
length and valve air volume.
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
Variable:
Sets the Amount of Time:
Valve ON
Sets time from Dispense Valve High
to Valve Open command
Regulator
ON
Sets time from Dispense Valve High
to Regulator ON
Valve OFF
Sets time from Dispense Valve Low
to Valve Close command
Regulator
OFF
Sets time from Dispense Valve Low
to Regulator OFF
C
D
Dispense Valve
Signal
A
Fluid
Regulator
B
Valve Open
Command
Valve Actually
Open
E
F
FIG. 29: Timing Delay
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Operation
Operation
Pressure control may degrade at low output pressures.
It is not recommended to dispense at outlet pressures
less than 500 psi (3.4 MPa, 34 bar).
Load Material
Before using the system material must be loaded into
the supply system.
Startup
1. If this is a new installation, follow the Initial Startup
procedure. Otherwise, follow the Standard Startup
Initial Startup
2. Turn on the fluid supply pressure to the fluid plate
assembly.
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.
3. Place the valve(s) over a waste container.
tions of this manual.
Standard Startup
6. If the system status indicator LED (BB) is orange,
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.
press
to turn the system on.
3. Turn on air.
7. Press and hold
. Dispense fluid until clean,
air-free fluid flows from the valve.
4. Turn on electrical power to the system.
5. Turn on the main power to supply power to the PCF.
8. Press
to exit maintenance screen.
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.
40
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Operation
Follow steps in the supply system manual to set the inlet
pressure.
Maintenance Mode Operation
Fluid Plate
Maintenance Screen
Swirl
NOTICE
Maintenance Screen
Inlet pressure beyond the recommended range
above will cause accelerated wear on the regulating
valve and the pump feed system.
Feed System Pressure Drop
During material flow, the regulator inlet pressure
decreases. The amount the pressure decreases is the
amount of pressure lost between the feed pump and the
regulator inlet.
Operating from maintenance mode enables manual
dispensing (
penser (
) and manually starting the swirl dis-
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.
).
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
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.
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Operation
Dispense from Each Valve
Verify Flow Meter Calibration
Dispense from each valve that will be used in normal
operation to confirm that the entire system is installed
correctly and is capable of delivering desired results.
Most sealant and adhesive materials are compressible.
Since the flow meter measures the material under high
pressure, the actual volume of material dispensed may
vary slightly from the measured volume, due to this
compressibility. If the K-factor is not correct, the dis-
played volume will not be accurate.
Follow the steps outlined in Dispense From Mainte-
ing applicable system verification checks.
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.
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.
Method 1. Using a gram scale
1. Record the flow meter k-factor shown on Fluid Plate
2. Use a 500 cc or larger beaker. Measure the mass of
the empty beaker.
•
•
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.
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.
For each valve operating in bead mode, perform an
initial teaching process. Follow this procedure after
significant system and/or material characteristic
changes.
4. Record the volume dispensed on Fluid Plate x,
5. Calculate the actual volume dispensed:
fluid mass (g)
a. For each flow rate that will be used during nor-
=
measure volume (cc)
mal operation, press
the flow rate setpoint.
until PCF achieves
density (g/cc)
6. Calculate the new flow meter K-factor:
NOTE: During the initial system operation verification, it
may take four to five seconds for the system to learn
system characteristics.
displayed volume (cc) x K-Factor (old)
measured volume (cc)
K-Factor (new) =
b. Continue to press
for several seconds
7. Enter new K-factor.
after the desire flow rate is reached to confirm
that the system is capable of maintaining the
desired flow rate.
8. Repeat the procedure to verify the new K-factor.
c. Repeat Steps a and b for a range of flow rates
to confirm that the system responds quickly to
Method 2. Without using a gram scale, visual measure-
ment
achieve setpoint when
is pressed.
1. Record the flow meter k-factor shown on Fluid
on page 35.
2. Use a 500 cc or larger beaker.
42
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Operation
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.
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.
4. Record the volume dispensed on Fluid Plate x,
7. Stop dispensing.
5. Settle the material into the beaker and view the
actual volume dispensed.
Dispense From Maintenance Screen
1. Navigate to Fluid Plate x, screen 1 for the desired
fluid plate.
6. Calculate the new flow meter K-factor:
displayed volume (cc) x K-Factor (old)
K-Factor (new) =
dispensed volume (cc)
7. Enter new K-factor.
8. Repeat the procedure to verify the new K-factor.
Manually Adjust Control Loop Parameters
NOTE: It is recommended that these values not be
changed from the factory defaults of 32.00 for Kp,
128.00 for Ki, and 0.00 for Kd.
FIG. 30
If the system is not maintaining the desired setpoint
while in pressure or bead control mode, manually
change the Kp and Ki values:
2. Press
to enter maintenance screen.
NOTE: Pressure parameters should be adjusted first,
even if you typically operate in bead control mode.
1. Begin dispensing material.
NOTE: Begin a new dispense each time control 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.
FIG. 31
3. Press
to open the Control Mode drop-down
list, and select the preferred control mode. Press
4. Set Ki value to 2 then increase the Ki value until the
system oscillates.
again to exit the drop-down list.
5. Decrease Ki until oscillation stops.
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Operation
4. Press
to move to the target fields. Enter the tar-
2. Press
to enter maintenance screen.
get pressure, flow rate, or volume (dependent on
control mode) and press to save.
5. Press
to move to the valve check boxes. Press
to select the desired valves.
44.
Manually Dispense Fluid
1. From Fluid Plate x, screen 1, press
maintenance screen.
to enter
2. Press
and verify that the valve opens.
FIG. 33
3. Continue to press
dispense material.
as long as needed to load or
3. To change the RPM, use the arrow keys to navigate
to the RPM box then enter the desired RPM.
4. Press
again to exit maintenance screen.
4. Press
and verify that the Swirl Dispenser
begins rotating. Press
Dispenser.
again to stop the Swirl
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.
5. Press
again to exit maintenance screen.
FIG. 32
44
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Operation
Actual (Measured) Volume - The amount of material
measured by the flow meter during a job.
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.
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.
The automation control operates using the concept of
jobs and styles. For a detailed explanation of jobs and
page 45. For a detailed explanation of styles and how
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
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.
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.
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).
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.
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
instructions on how to view job reports.
3A2098H
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Operation
3. Enter the style number in the Style field.
4. Enter Style Name:
Styles
The PCF system has the ability to handle up to 256
styles, depending on the selected option.
a. Press
while in the Style Name field to dis-
NOTE: The number of available styles depends on the
is specified for purging only.
play the Keyboard screen.
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-
as applicable.
FIG. 35
To setup a style:
1. Navigate to Fluid Plate x, screen 8.
b. Use the arrow buttons on the ADM to scroll
through each letter. Press
to enter a letter
2. Press
to access the style setup fields.
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.
7. Press
to exit edit mode.
FIG. 34
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Operation
Gateway
Precharge Modes
NOTE: See the diagram on the following page.
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.
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.
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Operation
Closed Precharge Scaling Value
Dispense Application Direction
Value Too Low
Dispense Application Direction
Dispense Application Direction
Value Too High
Ideal Value
-Controls outlet pressure based on desired command while valves are closed.
-Ideal value is typically less than 100% due to the minimal pressure losses within the system when fluid is not
flowing.
Opening Precharge Scaling Value
Dispense Application Direction
Value Too Low
Dispense Application Direction
Dispense Application Direction
Ideal Value
Value Too High
-Provides a boost upon valve opening to accelerate material.
-Ideal value is typically greater than 100%.
Opening Precharge Duration Value
Dispense Application Direction
Dispense Application Direction
Dispense Application Direction
Value Too High
Value Too Low
Ideal Value
-The duration for which the valve opening scaling is application before the command is no longer scaled.
Regulator On Delay Value
Dispense Application Direction
Dispense Application Direction
Dispense Application Direction
Value Too Low
Ideal Value
Value Too High
-Controls timing of transition from valve “closed” precharge to valve “opening” precharge and regular dispense.
-This delay should approximate the time it takes a dispense to open.
48
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Operation
7. PCF sets the following signals based on the results
of the job.
Typical Job Cycle
In order for the system to run it must be in the active
•
•
•
•
•
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense Volume OK
Error
state (status LED next to
on the ADM is green).
Before a job begins the automation controller outputs
should have the following values:
Dispensed Volume
•
•
•
•
Style Strobe: 0
Dispense Complete: 0
Dispense Valve x On: all should be 0
Style: Any value is acceptable
NOTE: The automation controller should not read the
Dispense Volume OK or Dispense Volume signals until
after the system clears the Dispense In Process signal.
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.
A typical job cycle consists of the following dispensing
9. The automation controller must clear Dispense
Complete and Style Strobe (either can be cleared
first) before the next job can start.
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.
Jobs with Command Cable Dispense
Trigger
2. The automation controller sets the Style to the next
desired style value.
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.
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.
The following limitations apply when starting a job with
this configuration:
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.
•
•
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.
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.
•
The job end mode timer must be used to end a
job.
6. When the dispense is complete the automation con-
troller sets Dispense Complete to 1.
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Operation
Typical Job Cycle Chart
NOTE: Swirl can be turned on at any point inside of or
outside of a job. Allow time for the swirl to reach desired
RPM. If possible, verify Swirl speed through the automa-
tion interface prior to opening the dispense valve.
First Job
Second Job
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispenser (Fluid Plate) In Process
Volume OK
Automation Outputs (PCF Inputs)
Style Bits
Style Strobe
Dispense Valve X On
Dispense Complete
PCF State
Regulator Active (Precharge = 0)
Dispense Valve X Open
50
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Operation
Control Charts
Purge Using Style 0
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Purge In Process
Volume OK
Automation Outputs (PCF Inputs)
Style Bits
Style Strobe
Dispense Valve X On
Dispense Complete
PCF State
Dispense Valve X Open
Purge Using Purge Bit
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Purge In Process
Automation Outputs (PCF Inputs)
Remote Start / Purge
Dispense Valve X On
PCF State
Dispense Valve X Open
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Operation
Control Charts (continued)
Remote Start
Automation Inputs (PCF Outputs)
Dispenser (Fluid Plate) Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispenser (Fluid Plate) Remote Start/Purge in Process
Automation Outputs (PCF Inputs)
Remote Start/Purge
Error Reset
Automation Inputs (PCF Outputs)
Dispenser (Fluid Plate) No Alarm / Dispenser (Fluid Plate) No Error
Automation Outputs (PCF Inputs)
Error Reset
Rising Edge Only
Cancel Job
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Inputs)
Error Reset
52
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Operation
Control Charts (continued)
Precharge* - Display Mode◆
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Volume OK
Automation Outputs (PCF Inputs)
Style Bits
Style Strobe
Dispense Valve X On
Dispense Complete
PCF State
Regulator Active
Dispense Valve X Open
*
Precharge: After starting a job and prior to opening the dispense valve, the fluid pres-
sure is increased to try to match the dispensing pressure. This helps the consistency
of the dispense.
◆
Shaded areas indicate the precharge is active.
Precharge* - Gateway Mode◆
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Volume OK
Automation Outputs (PCF Inputs)
Style Bits
Style Strobe
Precharge Valve X On†
Command Signal Valid‡
Dispense Valve X On
Dispense Complete
PCF State
Regulator Active
Dispense Valve X Open
*
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”.
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Operation
Control Charts (continued)
Precharge* - Valve 1 Mode◆
Automation Inputs (PCF Outputs)
Dispense Ready
Dispenser (Fluid Plate) No Alarm
Dispenser (Fluid Plate) No Error
Dispense In Process
Volume OK
Automation Outputs (PCF Inputs)
Style Bits
Style Strobe
Command Signal Valid†
Dispense Valve X On
Dispense Complete
PCF State
Regulator Active
Dispense Valve X Open
*
Precharge: After starting a job and prior to opening the dispense valve, the fluid pressure is
increased to try to match the dispensing pressure. This helps the consistency of the dispense.
◆
Shaded areas indicate the precharge is active.
†
Only applies to command signals when either “Command Cable” or “gateway” is selected as “Com-
mand Value Source”. In systems containing an automation gateway DGM, when “Digital” is
selected as the “Command Value Type”, the “Digital CMD 1” and “Digital CMD 2” inputs set the
command.
Trigger Using Command Cable 3x
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Gateway Inputs)
Dispense Valve 1 Trigger
Dispense Valve 2 Trigger
Dispense Valve 3 Trigger
PCF State
Regulator Active (Precharge = 0)
Dispense Valve 1 Open
Dispense Valve 2 Open
Dispense Valve 3 Open
54
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Operation
Control Charts (continued)
Trigger Using Command Cable
Automation Inputs (PCF Outputs)
Dispense In Process
Command Cable
Dispense Trigger
PCF State
Regulator Active (Precharge = 0)
Dispense Valve X Open*
*
Dispense Valve X Open determined by Enable Valves check boxes
on Fluid Plate x, screen 1(Control Settings).
Trigger Using Gateway
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Gateway Inputs)
Dispense Valve 1 On
Dispense Valve 2 On
Dispense Valve 3 On
Dispense Valve 4 On
PCF State
Regulator Active (Precharge = 0)
Dispense Valve 1 On
Dispense Valve 2 On
Dispense Valve 3 On
Dispense Valve 4 On
Trigger Using Command Cable and Gateway (Combined)
Automation Inputs (PCF Outputs)
Dispense In Process
Automation Outputs (PCF Gateway Inputs)
Dispense Valve X On
Dispense Valve Y On
Command Cable
Dispense Trigger
PCF State
Regulator Active (Precharge = 0)
Dispense Valve X On
Dispense Valve Y On
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Operation
Control Charts (continued)
Enable Swirl Dispenser
Automation Inputs (PCF Outputs)
Dispenser (Fluid Plate) Ready
Swirl X Actual Speed - RPM (32 bits)
Actual Speed Value Valid
Command Value Set
Automation Outputs (PCF Gateway Inputs)
Swirl X Speed Command (12 bits)
Swirl X Enable
PCF State
Swirl X On
Full Speed
Speeding Up
NOTE: Swirl orbiter may take a few seconds to reach full speed.
56
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Pressure Relief Procedure
Pressure Relief Procedure
b. Continue actuating the plunger until all pressure
is purged from the system between the needle
and the dispense valves attached to this fluid
plate before proceeding to the next step.
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.
5. For systems with multiple fluid plates, repeat previ-
ous steps for other fluid plates.
6. Shut off air to the fluid plate.
1. Shut off the fluid supply to the fluid plate assembly.
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.
2. Place a waste container beneath the dispense
valve.
8. Turn main power switch on control panel to the OFF
position.
3. In maintenance mode, select Full Open Dispense
Mode, which opens the regulator and dispense
valve. Press the manual dispense button
the fluid flow stops.
until
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.
4. If the dispense valve cannot be actuated from the
control center, refer to FIG. 36 and perform the fol-
lowing steps to open the dispense valve and relieve
fluid pressure:
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.
a. Manually actuate the plunger on the solenoid to
open all dispense valves attached to this fluid
plate and relieve fluid pressure. See FIG. 36.
Dispense Valve Air Solenoid
FIG. 36: Dispense Valve Air Solenoid
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Shutdown
Shutdown
1. Press the Stop button (BC).
BC
TI12362a
FIG. 37: ADM - Stop Button
2. Shut off the material supply to the fluid plate/meter.
4. Turn off the PCF system's compressed air supply.
5. Turn main power switch on control panel to the OFF
position.
FIG. 38: Control Center Main Power Switch
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USB Data
USB Data
All files downloaded from the USB are put in a DOWN-
LOAD folder on the drive. For example:
“E:\GRACO\12345678\DOWNLOAD\”
•
•
•
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%)
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
•
•
•
•
•
•
•
•
•
•
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)
FIG. 39: ADM USB Port
During operation, PCF stores system and performance
related information to memory in the form of log files.
PCF maintains three types of log files: a job log, an
event log, and dispense data logs. Follow the Down-
Event Log
The event log file name is 1-EVENT.CSV and is stored
in the DOWNLOAD folder.
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 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.
The dispense data log maintains a record of system inlet
pressure (heated systems will always read 0), system
outlet pressure, system flow rate (systems without flow
meters will always read 0), and active dispense valves.
This data is recorded at one second intervals when a job
cycle is in process. Each dispense data log is capable of
storing up to two hours of data.
Job 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
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USB Data
System Configuration Settings
File
The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
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.
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.
tions on how to use this file.
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.
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.
•
•
•
•
•
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)
NOTE: System settings may not be compatible between
different versions of the PCF software.
Create Custom Language Strings
NOTE: Do not modify the contents of this file.
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
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.
•
•
•
60
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USB Data
Download Procedure
Upload Procedure
Use this procedure to install a system configuration file
and/or a custom language file.
2. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete. A pop-up will be present until the trans-
fer is complete if it is not acknowledged.
page 61, to automatically generate the proper folder
structure on the USB flash drive.
2. Insert USB flash drive into USB port of computer.
3. Remove USB flash drive from USB port (BL).
4. Insert USB flash drive into USB port of computer.
3. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Win-
dows Explorer.
5. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Win-
4. Open Graco folder.
dows® Explorer.
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. 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.)
6. If installing the system configuration settings file,
place SETTINGS.TXT file into UPLOAD folder.
7. If installing the custom language file, place
DISPTEXT.TXT file into UPLOAD folder.
8. Open DOWNLOAD folder.
9. Open LOG FILES folder labeled with the highest
number. The highest number indicates the most
recent data download.
8. Remove USB flash drive from computer.
9. Install USB flash drive into PCF system USB port.
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
10. The menu bar and USB indicator lights indicate that
the USB is downloading files. Wait for USB activity
to complete.
Microsoft® Word.
11. Remove USB flash drive from USB port.
NOTE: All USB logs are saved in Unicode (UTF-16) for-
mat. If opening the log file in Microsoft Word, select Uni-
code encoding.
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.
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Troubleshooting
Troubleshooting
NOTE: Check all possible solutions in the chart below
before you disassemble the system.
Troubleshooting for individual fluid regulators and flow
meters is also discussed in their separate manuals;
detailed information on how error codes are communi-
cated.
Fluid Plates
Problem
Cause
Air pressure low
Solution
No outlet pressure
Verify air pressure is above 60 psi
(410 kPa, 4.1 bar)
No “Valve On” signal from automation Check output and wiring from auto-
unit
mation unit
No air signal to air diaphragm
Check for loose/disconnected con-
nector to Voltage to Pressure (V/P)
Transducer; tighten
False signal being sent to control
Check outlet pressure sensor output;
verify that it corresponds to zero
pressure; replace sensor and/or
amplifier
High outlet pressure
Fluid regulator needle/seat is worn
Loose air connections
Worn gaskets
Rebuild fluid regulator; replace nee-
dle/ seat
Air leaks from fluid plate
Check air connections; tighten if nec-
essary
Check/replace gaskets on Voltage to
Pressure (V/P) Transducer and sole-
noid valve
62
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Troubleshooting
Flow Meter
Problem
Cause
Solution
No flow measurement
Flow meter pick-up sensor loose
Flow too low
Tighten flow meter pick-up sensor
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
System not grounded properly
Noisy power source
Calibrate flow meter, page 42
Verify system ground
Verify clean power supply power to
main enclosure
Flow reported is not correct or
inconsistent
Flow meter not calibrated
Flow meter is worn
Calibrate flow meter, page 42
Replace flow meter
Fluid Regulator
Problem
Cause
Solution
No pressure regulation
Damaged diaphragm
Replace diaphragm
Leaking or dirty seat
Replace cartridge, or clean seat
Replace valve actuator
Replace cartridge, or clean seat
area
No fluid flow
Damaged valve actuator
Metal chip or contamination
between ball and seat
Pressure creeps above setting
Damaged diaphragm
Replace diaphragm
Damaged o-ring or improper seal
Replace the o-ring under the seat
Damaged or clogged air regulator or Clear obstruction in line. Service
line
regulator if necessary
Leaking or dirty seat
Large change in inlet pressure
Empty/clogged supply line
Replace cartridge, or clean seat
Stabilize regulator inlet pressure
Fill/flush supply line
Pressure drops below setting
Damaged or clogged air regulator or Clear obstruction in line. Service
line
regulator if necessary
Install valve for each spray valve or
dispensing valve
Using valve beyond its rated flow
capacity
Large change in inlet air or fluid
pressure
Stabilize air and fluid regulator inlet
pressures
Fluid leaks from spring housing
Chatter
Loose fluid housing
Damaged diaphragm
Excessive pressure differential be
tween pump and valve
Tighten the four cap screws
Replace diaphragm
Reduce pump pressure to not more
than 2000 psi (14 MPa, 138 bar)
greater than required valve pres-
sure.
Reduce fluid flow through regulator.
Connect only one spray gun or dis-
pense valve to each fluid regulator
Excessive flow rate
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Troubleshooting
Dispense Valves
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
Sluggish open/close
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
Air pressure low
Verify air pressure is above 60 psi
(410 kPa, 4.1 bar)
Needle/seat worn
Rebuild valve; replace needle/seat
Reduce running pressure
Reduce nozzle length
Pressurized material past the valve
shut-off is escaping
Increase nozzle orifice size
Replace solenoid valve
Faulty solenoid valve
Solenoid valve muffler restricted
Shaft seal is worn
Clean or replace muffler
Rebuild valve; replace seals
Material leaks from back of valve
Air leaks from dispense valve
Loose air connections
Check air connections; tighten if
necessary
Worn piston o-ring
Rebuild valve; replace piston o-ring
Swirl Dispenser
Problem
Cause
Solution
Motor not running (motor fault alarm Cable disconnected
active)
Verify cable connections to swirl
board, swirl motor cable, and swirl
orbiter
CAN cable was re-connected with
Cycle system power
system power on (amber LED on
swirl board will be on, this indicates
circuit protection was triggered)
Shorted motor cable (amber LED on Replace swirl motor cable (55 ft)
swirl board will be on, this indicates
circuit protection was triggered)
then cycle power
Faulty swirl orbiter
Replace swirl orbiter
Motor not running (motor fault alarm Cable disconnected
not active)
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
64
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Troubleshooting
Motor not responding to change in
speed command
No “Swirl Speed Command” signal
from automation unit
Check input from automation unit
Swirl speed source incorrectly set
Verify Speed Command Source in
Swirl Setup screen
Gateway Module
Problem
Cause
Solution
No communication
Incorrect wiring
Check wiring per fieldbus standard. Refer to PCF Gateway
LED status indicators and Appendix C - Communications
Incorrect fieldbus settings Confirm fieldbus settings at automation controller (fieldbus
master) and PCF Gateway (fieldbus slave). Refer to Appen-
mation on PCF Gateway configuration settings.
Incorrect data
Incorrect fieldbus configu- Download PCF fieldbus configuration file from
ration file installed on
automation controller
(fieldbus master)
www.graco.com, and install on automation controller (fieldbus
master).
Incorrect map installed on Confirm correct PCF data map is installed on PCF Gateway.
PCF Gateway
page 99, for information on how to determine installed data
map. If necessary, install a new Gateway data map. Refer to
instructions, and Control Center and Expansion Swirl
LED Diagnostic Information
The following LED signals, diagnosis, and solutions apply to the Advanced Display Module, Fluid Control Module,
and Gateway module.
Module Status LED Signal
Green on
Diagnosis
Solution
System is powered up
Internal communication in progress
Hardware failure
-
-
Yellow
Red solid
Replace module
-
Red flashing fast
Red flashing slow
Uploading software
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.
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Errors
Errors
View Errors
When an error occurs, an error pop-up is displayed that
takes up the entire screen until the error is acknowl-
edged by pressing
. Errors can also be acknowl-
edged over the gateway. Active errors are displayed in
the menu bar.
Error
FIG. 40: Error Pop-Up
The previous 200 errors are displayed on the error
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
66
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Errors
Event and Error Codes and Troubleshooting
Error codes are stored in the events log and are displayed on the error report screens. Gateway error numbers are
reported over the Gateway interface.
Error codes shown as XYZ_ represent error codes XYZ1, XYZ2, XYZ3, XYZ4, where the last digit represents the
number of the fluid plate to which the error applies. Error codes in the following table are sorted by gateway error
number, then by event code.
System Events and Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
System Events and Errors
---
0
No Active Errors No errors
---
---
No action necessary
EC0X ---
Setup Values
Changed
Setup change notifica- Record only A setup value was
No action necessary if
changes were desired
tion
changed on the dis-
play
EL0X
---
Power Up
Control box power up
Record only ---
No action necessary
---
EM0X ---
Power Down
Control box power
down
Record only ---
Control Center Events and Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Control Center Events and Errors
USB download Advisory Transfers are disabled Clears when drive is
EVUX ---
USB Disabled
attempted, however,
USB activity is dis-
abled.
(self-clearing) in Advanced Setup
screen 2.
removed.
MMUX ---
USB Log 90%
Full
One or more USB log is Advisory
90% full.
Data in the jobs or
events log has not
been downloaded
recently and logs are
nearly full.
Download the data or
disable USB errors.
V1G0
---
DGM Unpowered The Discrete Gateway Advisory
24 Vdc has not been
connected to the
power pins.
Connect power accord-
ing to Appendix B -
Discrete Gateway
page 115.
Module does not have
logic power supplied to
it.
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 and 4.
is installed.
Install fluid plate 1,
uninstall fluid plates 3
Swirl 1 is not installed. Install Swirl 1, unin-
Or Swirl 3 or Swirl 4 is stall swirls 3 and 4.
installed.
EAUX ---
Download to
Information is currently Advisory
---
No action necessary
USB in Process being downloaded to
USB
(self-clearing)
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Control Center Events and Errors
Download to the USB is Advisory ---
EBUX ---
WSU0 ---
WNC0 32
Download to
USB Complete
No action necessary
Reinstall system soft-
complete
(self-clearing)
USB configura-
tion error
USB configuration error Advisory
USB configuration
invalid or not present ware on display
ADM Key Token Missing or invalid key
Alarm
An ADM key token is Verify the key token is
Error
token
required to run the
system
installed
Verify the key token
part number is correct
for the PCF ADM
WNG0 ---
CBG0 ---
Gateway Map
Error
Missing or invalid map Advisory
Missing or invalid
Gateway map
Install PCF map in
Gateway
Gateway Reset
Gateway reset
Advisory
Gateway setting(s)
Wait for reset to com-
plete before attempt-
ing automation control
(self-clearing) changed
WMG0 ---
Gateway Error
Detected
Gateway error
Alarm
---
---
detected; includes any
error not covered by
another more specific
error
CBD_ ---
CCG_ ---
Fluid Plate Com- Fluid Plate Communi-
munication Error cation Error with ADM
Alarm
The ADM lost commu- Restore communica-
nications with the
FCM.
tion.
Fieldbus Com-
Fieldbus Communica- Alarm
The automation gate- Restore communica-
way lost communica- tions.
tion with the
munication Error tion Error
automation controller.
Fluid Plate Events and Errors
Event Gateway
Event
Code Error No.
Event Name
Description
Event Type
Cause
Solution
Fluid Plate Events and Errors
CGM Communi- Communication lost Advisory
CAC_ ---
Fluid Plate and CGM Reconnect or replace
are no longer commu- CAN cable
nicating
cation Error
between CGM and
Fluid Plate
CGM is not functioning Replace the CGM if the
red status LED is solid
CAD_ ---
Fluid Plate Com- FCM lost communica- Alarm
munication Error tion with the ADM
ADM is not communi- Reconnect or replace
cating
CAN cable
ADM is not functioning Replace FCM if red
status LED is solid
ADM does not contain Verify intended ADM
appropriate key token key token is properly
inserted
B7C_
30
Style Out of
Range
Style is out of range
Alarm
Style requested by
automation controller that is in range
Use a style number
exceeds number of
Increase number of
styles available on the
styles in PCF; pur-
fluid plate
chase accessory key
token
68
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Fluid Plate Events and Errors
B30_
B40_
31
High Material
Material dispensed dur- Alarm or
ing last dispense cycle Deviation
PCF regulator is not
regulating correctly
Check regulator and
repair if necessary
was above amount
requested plus the
allowed tolerance
(user select-
able)
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- Alarm or
ing last dispense cycle Deviation
Partially plugged tip or Clean tip and/or supply
supply system
system
below amount
requested minus the
allowed tolerance
(user select-
able)
Insufficient flow to
PCF regulator inlet
Increase flow rate to
regulator inlet
PCF regulator is not
regulating correctly
Incorrect style target
volume or tolerance
setting
Check regulator;
repair if necessary
B1C_
B2C_
33
Low Computed
Target
Requested volume/
mass differs from
Alarm or
Deviation
Entered process target Enter correct process
incorrectly
target
entered process target (user select-
Entered tolerance
incorrectly
Enter correct tolerance
by more than entered
tolerance for style
requested
able)
Requested volume
incorrectly
Check automation pro-
gram
Automation problem
Verify automation is
correct
B3C_
B4C_
34
High Computed Requested volume/
Alarm or
Deviation
Entered process target Enter correct process
Target
mass differs from
incorrectly
target
entered process target (user select-
Entered tolerance
incorrectly
Enter correct tolerance
by more than entered
tolerance for style
requested
able)
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 is installed
Verify FCM key token
Verify FCM key token
is correct part number
P6D_
P6F_
F6D_
52
53
54
Outlet Pressure Outlet pressure trans- Alarm
Transducer Error ducer error
Problem detected with Verify outlet pressure
outlet pressure trans- transducer is installed
ducer
and/or connected cor-
rectly
Replace if necessary
Inlet Pressure
Inlet pressure trans-
Advisory
Alarm
Problem detected with Verify inlet pressure
Transducer Error ducer error
inlet pressure trans-
ducer
transducer is installed
and/or connected cor-
rectly
Replace if necessary
Flow Meter Error Flow Meter error
Problem detected with Verify flow meter is
flow meter
installed and/or con-
nected correctly
Replace if necessary
3A2098H
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Fluid Plate Events and Errors
Voltage to Pressure Alarm
Transducer error
WED_ 55
V/P Error
Problem detected with Verify outlet pressure
V/P
transducer is installed
and/or connected cor-
rectly
Replace if necessary
WJ1_
WJ2_
WJ3_
WJ4_
56
57
58
59
Dispense Valve 1 Dispense valve 1 error Alarm
Error
Problem detected with Verify dispense valve 1
dispense valve 1
is installed and/or con-
nected correctly
Replace if necessary
Dispense Valve 2 Dispense valve 2 error Alarm
Error
Problem detected with Verify dispense valve 2
dispense valve 2
is installed and/or con-
nected correctly
Replace if necessary
Dispense Valve 3 Dispense valve 3 error Alarm
Error
Problem detected with Verify dispense valve 3
dispense valve 3
is installed and/or con-
nected correctly
Replace if necessary
Dispense Valve 4 Dispense valve 4 error Alarm
Error
Problem detected with Verify dispense valve 4
dispense valve 4
is installed and/or con-
nected correctly
Replace if necessary
Check settings shown
pense simultaneously on Fluid Plate x,
from multiple valves screen 2 (Mode Set-
WSD_ 60
Incompatible
Valve Settings
Incompatible settings
for multiple valve opera-
tion; attempted to dis-
pense
Alarm
Alarm
Attempted to dis-
on the same fluid plate tings)
with different pressure
Verify automation pro-
gramming
settings
WSD5 60
Incompatible
Valve Settings
Incompatible settings
for multiple valve opera-
tion; attempted to dis-
pense
Attempted to dis-
In the Discrete Gate-
pense simultaneously way screens, change
from multiple valves the settings of the
on the same fluid plate simultaneously dis-
with different pressure pensing valves to the
settings
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 Replace flow meter
false pulses
sensor or calibrate
meter
Dispense valve not
operating correctly
Repair dispense valve
70
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Fluid Plate Events and Errors
V2D_
62
Low Analog
Commandcableanalog Deviation
command dropped
below minimum value
Bad or loose com-
mand cable connec-
tion
Check command cable
and connection
of 1 V while dispensing
Entered command
mode incorrectly
Enter correct com-
mand code
Automation program
error
Verify correct automa-
tion program
WFD_ 63
WFG_
Flow Meter
Required
Operating mode
Alarm or
Advisory
(self-clearing) meter
Selected valve mode Check valve mode set-
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.
settings require flow
tings
Purchase meter
enabled token for FCM
and install flow meter
FCM key token miss- Check for FCM key
ing or invalid token error
EJD_
64
Job Cycle Time
Out
Job cycle time out
Alarm
Alarm
Automation signals did Check automation pro-
not properly end job
cycle
gramming per job oper-
ating instruction
WXD_ 65
Fluid Plate Error Fluid plate error
Analog voltageapplied Limit signal on pin 1 of
Detected
detected; includes any
to pin 1 of the com-
mand cable exceeds
10 Vdc.
command cable to the
range of 0-10 Vdc.
error not covered by
another more specific
error
Failed FCM
Replace FCM if neces-
sary
P3F_
P4F_
66
67
68
Maximum Inlet
Pressure
Inlet pressure to regula- Alarm or
tor is above upper limit Deviation
Incorrect set limit
Verify limit is set cor-
rectly
set for operation
(user select-
able)
Material supply pres- Decrease material
sure is too high
supply pressure
Failed transducer
Check transducer;
replace if necessary
P3D_
P4D_
Maximum Outlet Outlet pressure of regu- Alarm or
Pressure
Incorrect set limit
Verify limit is set cor-
rectly
lator is above upper
limit set for operation
Deviation
(user select-
able)
Material supply pres- Decrease material
sure is too high
supply pressure
Failed transducer
Check transducer;
replace if necessary
P1F_
P2F_
Minimum Inlet
Pressure
Inlet pressure to regula- Alarm or
tor is below lower limit Deviation
Incorrect set limit
Verify limit is set cor-
rectly
set for operation
(user select-
able)
Material supply pres- Increase crease mate-
sure is too low
rial supply pressure
Failed transducer
Check transducer;
replace if necessary
3A2098H
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Fluid Plate Events and Errors
P1C_
P2C_
69
Low Pressure
Measured outlet pres- Alarm or
sure less than desired Deviation
Incorrect limit set
Verify limit is set cor-
rectly
outlet pressure minus
tolerance
(user select-
able)
No or insufficient
material flow
Increase material flow
rate
Dispense valve nee-
dle is stuck closed
Dislodge and inspect
needle
Dispense valve leak- Repair dispense valve
ing
Regulator not operat- Repair regulator
ing correctly
Pump wink passed
through outlet
Increase pump pres-
sure
Failed transducer
Check transducer;
replace if failed
P3C_
P4C_
70
High Pressure
Measured outlet pres- Alarm or
sure greater than Deviation
desired outlet pressure (user select-
plus tolerance able)
Incorrect limit set
Verify limit is set cor-
rectly
Dispense hose/device Clean/replace
plugged
hose/device
Failed transducer
Check transducer;
replace if failed
Regulator is not clos- Repair regulator
ing completely when it
should
F1D_
F2D_
71
Low Flow Rate
Measured flow rate less Alarm or
Fluid supply too low to Increase fluid supply
than desired flow rate
minus tolerance
Deviation
(user select- rate
able)
achieve desired flow
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
No material supply
Incorrect flow toler-
Check cable and sen-
sor
Replace drum or turn
on pumps
Enter correct toler-
ance of flow error time ance or flow error time
F3D_
F4D_
72
High Flow Rate
Measured flow rate
greater than desired
Alarm or
Deviation
Operating below mini- Increase fluid pres-
mum regulator operat- sure above regulator
flow rate plus tolerance (user select- ing pressure
able)
minimum
Regulator worn or not Repair regulator
operating correctly
Flow meter providing Replace flow meter
false pulses
sensor
Incorrect flow error tol- Enter correct toler-
erance or flow error
time
ance or flow error time
EKD_ 73
EHD_ 74
Shot Terminated Shot dispense cycle
Advisory
Advisory
Job end timer was
used to stop shot dis- timed shot is desired
pense
No action required if
by Job Timer
terminated by job timer
Purge Timer
Expired
Purge timer expired
PCF purge timer (style Automation control
0) has expired
requests purge
72
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Fluid Plate Events and Errors
Maintenance mode Advisory
(self-clearing) dispense mode
Advisory Exited maintenance
(self-clearing) dispense mode
EAC_ 75
EBC_ 76
MHD_ 77
Maintenance
Mode Entered
Entered maintenance No action required
entered
Maintenance
Mode Exited
Maintenance mode
exited
No action required
Service component
Maintenance
Maintenance due for
Due - Regulator regulator
Advisory
Advisory
Advisory
Advisory
Advisory
Advisory
Advisory
Advisory
Totalizer exceeded
limit setting
If necessary, reset
totalizer
MFD_ 78
MED_ 79
MCD_ 80
MD1_ 81
MD2_ 82
MD3_ 83
MD4_ 84
CCD_ 85
Maintenance
Maintenance due for
Due - Flow Meter flow meter
Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
Maintenance
Due - V/P
Maintenance due for
Voltage to Pressure
Transducer
Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
Maintenance
Due - Supply
Maintenance due for
supply system
Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
Maintenance
Due - Valve 1
Maintenance due for
valve 1
Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
Maintenance
Due - Valve 2
Maintenance due for
valve 2
Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
Maintenance
Due - Valve 3
Maintenance due for
valve 3
Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
Maintenance
Due - Valve 4
Maintenance due for
valve 4
Totalizer exceeded
limit setting
Service component
If necessary, reset
totalizer
Duplicate Module Duplicate Fluid Control Alarm
Module Detected
Two or more FCMs
have the same rotary have proper rotary
Verify that all FCMs
switch setting
switch settings. Reset
module after changing
rotary switch setting.
Refer to Fluid Plate
section, page 14
EAD_ 86
WFC_ 87
Swirl Mainte-
nance Mode
Entered
Swirl maintenance
mode entered
Advisory
Swirl zone that is
No action required
(self-clearing) associated with this
fluid plate entered
maintenance mode
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
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Fluid Plate Events and Errors
Fluid plate communica- Alarm
Communication tion error with swirl
Error
CR1_
CR2_
CR3_
CR4_
88
89
90
91
Valve 1 Swirl
The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
Valve 2 Swirl
Fluid plate communica- Alarm
Communication tion error with swirl
Error
The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
Valve 3 Swirl
Fluid plate communica- Alarm
Communication tion error with swirl
Error
The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
Valve 4 Swirl
Fluid plate communica- Alarm
Communication tion error with swirl
Error
The fluid plate lost
communication with
the swirl zone associ-
ated with this valve
and fluid plate
Restore communica-
tions.
WD1_ 92
WD2_ 93
WD3_ 94
WD4_ 95
MB1_ 96
Valve 1 Swirl
Fault
Swirl motor fault
Swirl motor fault
Swirl motor fault
Swirl motor fault
Alarm or
Deviation
The swirl zone associ- Resolve swirl motor
ated with this valve fault (see error WBDX
(user-select- and fluid plate caused for possible solutions)
able)
a fault
Valve 2 Swirl
Fault
Alarm or
Deviation
The swirl zone associ- Resolve swirl motor
ated with this valve
fault (see error WBDX
(user-select- and fluid plate caused for possible solutions)
able)
a fault
Valve 3 Swirl
Fault
Alarm or
Deviation
The swirl zone associ- Resolve swirl motor
ated with this valve
fault (see error WBDX
(user-select- and fluid plate caused for possible solutions)
able)
a fault
Valve 4 Swirl
Fault
Alarm or
Deviation
The swirl zone associ- Resolve swirl motor
ated with this valve
fault (see error WBDX
(user-select- and fluid plate caused for possible solutions)
able)
a fault
Maintenance due Maintenance due on
- V1 Orbiter valve 1 swirl orbiter
Advisory
The active time total- Service Component
izer for the swirl dis-
penser associated
with this valve and
fluid plate exceeded
limit setting
If necessary, reset
totalizer
MB2_ 97
Maintenance due Maintenance due on
- V2 Orbiter valve 2 swirl orbiter
Advisory
The active time total- Service Component
izer for the swirl dis-
penser associated
with this valve and
fluid plate exceeded
limit setting
If necessary, reset
totalizer
74
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Errors
Event Gateway
Code Error No.
Event
Description
Event Name
Event Type
Cause
Solution
Fluid Plate Events and Errors
MB3_ 98
Maintenance due Maintenance due on
- V3 Orbiter valve 3 swirl orbiter
Advisory
The active time total- Service Component
izer for the swirl dis-
penser associated
with this valve and
fluid plate exceeded
limit setting
If necessary, reset
totalizer
MB4_ 99
Maintenance due Maintenance due on
Advisory
The active time total- Service Component
izer for the swirl dis-
- V4 Orbiter
valve 4 swirl orbiter
penser associated
with this valve and
fluid plate exceeded
limit setting
If necessary, reset
totalizer
Swirl Events and Errors
Event Gateway
Event
Code Error No.
Event Name
Description
Event Type
Cause
Solution
Swirl Events and Errors
Swirl Communi- Swirl communication Alarm
cation Error error with ADM
CBR_ ---
The ADM lost commu- Restore communica-
nication with the Swirl tions
Control DGM
CDR_ ---
Duplicate Module Duplicate Swirl Control Alarm
DGM Detected
Two or more Swirl
Control DGMs have
Verify that all Swirl
Control DGMs have
the same rotary switch proper rotary switch
setting
settings. Reset mod-
ule after changing
rotary switch setting.
Refer to Swirl Control
EAD_ ---
EBD_ ---
MBD_ ---
Maintenance
Mode Entered
Maintenance mode
entered
Advisory
(self-clear-
ing)
Swirl maintenance
mode entered
No action required
Maintenance
Mode Exited
Maintenance mode
exited
Advisory
(self-clear-
ing)
Swirl maintenance
mode exited
No action required
Maintenance
Due - Orbiter
Maintenance due on
swirl orbiter
Advisory
Swirl active time total- Service Component
izer exceeded limit set-
ting
If necessary, reset
totalizer
WBD_ ---
Swirl Motor Fault Motor speed is outside Alarm
the +/- 50% tolerance
Cable disconnected
Verify cable connec-
tions to swirl board,
swirl motor cable, and
swirl orbiter
range for at least 5 sec-
onds while operating
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
3A2098H
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Maintenance
Maintenance
Prior to performing any maintenance procedures, follow
Maintenance Schedule
The following tables list the recommended maintenance procedures and frequencies to operate the equipment
safely. The maintenance is divided between mechanical and electrical tasks. Maintenance must be performed by
trained personnel per this schedule to assure safety and reliability of the equipment.
Mechanical
Operator
Daily
Maintenance Person
3-6
months
or
18-24
months
or
500,000
cycles
36-48
months
or
1,000,000
cycles
7000
hours
Task
Weekly
Monthly
125,000
cycles
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.
Electrical
Task
Weekly
Check cables for wear
Verify cable connections
Verify operation of “System Stop” button
✓
✓
✓
* Check Component Manual for more detailed maintenance information.
76
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Maintenance
Cleaning
Advanced Display Module
(ADM)
Use any alcohol-based household cleaner, such as
glass cleaner, to clean the display.
Upgrade Software
Upgrade Gateway Module
Software
NOTE: Back up the custom language file (if installed)
more information.
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 token access panel, and then remove the
key token (do not discard token).
1. Turn off power to the system.
2. Remove the access cover.
Access Panel
r_24E451_3B9900_3a
Access
Cover
FIG. 41: Remove Access Panel
3. Insert and press software token firmly into slot.
TI12319A
NOTE: There is no preferred orientation of token.
FIG. 43: Remove Access Cover
3. Insert and press token firmly into slot.
BL
Token
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.
r_24E451_3B9900_4a
FIG. 42: Insert Token
4. Turn on power to the system. The red indicator light
(BL) will flash until new software is completely
loaded.
5. After the red indicator light shuts off, turn off power
to the system.
CK
6. Remove software token.
Token
7. Reinstall key token, and replace token access
panel.
TI12320A
FIG. 44: Insert Token
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Maintenance
5. After the red indicator light shuts off, turn off power
to the system.
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.
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.
CK
Software must be upgraded before upgrading the
fieldbus map.
TI12320A
Token
Push Button
FIG. 46: Insert Token
2. Remove the access cover.
5. Remove map token (CC) when software has suc-
cessfully uploaded.
6. Replace access cover.
Access
Cover
TI12319A
FIG. 45: Remove Access Cover
3. Insert and press map token firmly into slot.
NOTE: There is no preferred orientation of the token.
78
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Maintenance
7. Reinstall key token, and replace access cover.
Upgrade Fluid Control Module
(FCM) Software
Air Filter Maintenance
NOTE: The FCM connection is temporarily disabled
during the use of the upgrade token.
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.
1. Turn off power to the system.
2. Remove access cover then remove key token (do
not discard token).
Replacement Air Filters for Dual Filter
Assembly (234967)
Part
Description
123091
123092
5 micron air filter
0.3 micron air filter
Swirl Dispensers
See manual 309403 for maintenance schedule.
Access
Cover
TI12334A
FIG. 47: Remove Access Cover
3. Insert and press software token firmly into slot.
NOTE: There is no preferred orientation of token.
4. Turn on power to the system. The red indicator light
(CK) will flash until new software is completely
loaded.
CK
TI12335A
Token
FIG. 48: Insert Token
5. After the red indicator light shuts off, turn off power
to the system.
6. Remove software token.
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Repair
Repair
Repair Flow Meter
Fluid Plate Assembly
For complete flow meter (129) repair instructions refer to
the maintenance and repair section of manual 309834.
Remove Flow Meter from Mounting Plate
This section describes how to remove and replace com-
ponents on the fluid plate assembly.
80.
2. Disconnect the flow meter cable (131) from the flow
meter sensor. See FIG. 49.
Prepare Fluid Plate Assembly for
Repair
3. Disconnect the material hose.
1. Disconnect the CAN cable from the fluid plate.
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).
101
108
103
124
129
125, 126, 127
131
109
r_pf0000_313377_18a
FIG. 49: Fluid Plate Assembly
80
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Repair
4. Remove the dispense valve solenoid (132) and
Install Flow Meter on Mounting Plate
replace it with a new solenoid.
1. Rest the flow meter (129) and bracket (124) on the
fluid plate while threading the swivel fitting (109)
onto the regulator material inlet. See FIG. 49.
137
2. Tighten the swivel fitting to the regulator material
inlet.
132
3. Tighten the four screws (127) and washers (125,
126) to hold the bracket and flow meter in place.
118
r_pf0000_313377_33a
FIG. 51
126
127
5. Secure the new solenoid to the bracket with screws.
6. Reconnect the FCM cable and all three air tubes.
129
Replace Voltage to Pressure (V/P)
Transducer
124
108
109
80.
r_pf0000_313377_34a
125
2. Disconnect the FCM cable and both air tubes.
FIG. 50
3. Remove both transducer screws (122) from trans-
ducer bracket (118).
4. Check that the flow meter and regulator (108) are
still aligned.
4. Remove the V/P transducer (121) and replace it
with a new V/P transducer.
5. Connect the material hose.
6. Connect the flow meter cable (131).
Replace Solenoid
118
2. Disconnect FCM cable and all three air tubes.
3. Remove both screws (137) from transducer
bracket (118).
122
r_pf0000_313377_31a
121
FIG. 52
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Repair
5. Secure the new V/P transducer to the bracket with
screws.
Replace Fluid Control Module Base
80.
6. Reconnect the FCM cable and both air tubes.
trol Module. (Leave the cables attached to the
FCM.)
Replace Fluid Control Module
80.
3. Remove the power supply cable from the base
(102).
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.)
4. Remove the four screws (105) and ground screw
(106) from the base and replace it with a new base.
102
103
118
132
102
105
106
128
103
r_pf0000_313377_30a
121
FIG. 54
FIG. 53
5. Secure the base to the fluid plate (101) with screws.
6. Reconnect the power supply cable.
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.
82
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Repair
Replace Transducer O-Rings
80.
2. Remove the fluid outlet pressure sensor (117) from
the regulator (108).
108
117
r_pf0000_313377_16a
FIG. 55
3. Press the transducer (CG) out of the retainer nut
(CH).
4. Remove the faulty o-ring (120) and replace with
new.
CH
CG
120
FIG. 56
5. Press the transducer back into the retainer nut.
6. Reconnect the fluid outlet pressure sensor to the
regulator.
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Repair
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.
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.
3. Inspect and clean the internal walls of the base
housing (CD).
See FIG. 57 and perform the following steps.
NOTE: Be careful to not scrape or gouge the internal
NOTICE
walls of the base housing. They are a sealing surface.
Carefully handle the hard carbide ball, valve actua-
tor, and valve seat to avoid damaging them.
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.
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).
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.
Cartridge Regulator 244734 Shown
CD
Torque Sequence for Regulator
Base Housing Screws (CF)
4
1
CF
CC
CE
3
2
cartridge
assembly
diaphragm
and valve
actuator
subassembly
FIG. 57: Replace Cartridge Assembly
84
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Repair
Adjust Display Settings
Replace Amplifier
3. With the system in setup mode, navigate to the
Advanced screens.
(Heated fluid plates only)
80.
4. Press
to scroll to Advanced screen 2.
2. Disconnect pressure sensor cable (117) and power
output cable.
Screw
116
117
5. Press
6. Press
to access the fields to make changes.
to move the Pressure Units field. Press
to open the drop-down list, and select psi.
to enter the new units.
Power Output Cable
Press
FIG. 58: Replace Amplifier
3. Loosen four screws on amplifier (116) cover, and
then remove cover.
7. Press
to exit edit mode.
8. With the system still in setup mode, navigate to
Fluid Plate x, screen 5 (Pressure Sensors).
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)
9. Press
10. Press
to access the fields to make changes.
to move the Outlet Offset field. Set the
80.
2. Remove outlet pressure sensor from outlet fitting to
ensure there is no pressure applied to the sensor.
psi to 0. Press
to enter the new setting.
11. Press
to exit edit mode.
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Repair
Adjust Amplifier Settings
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:
12. Remove cover from amplifier (116). See Replace
13. Ensure the EXCITATION SELECTOR jumper is in
Shunt Calibration Pressure = (Shunt Cal Factor /
Calibration Factor) * 5000 psi
14. Ensure the COARSE GAIN dipswitch 1 is set to ON.
All others should be set to OFF.
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.
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.
19. Remove the jumper wire or paper clip from the
SHUNT CAL and ENABLE terminals.
ensure proper calibration.
Panel mounting holes.
Use #6 or #8 screws.
EXCITATION MODULE
POWER
TRANSDUCER
(+)EXCITATION
A
(+)SUPPLY
1
2
3
4
5
6
(-)EXCITATION
(+)SIGNAL
B
C
D
E
F
(-)OUTPUT
SUPPLY RETURN
(+)OUTPUT
To Transducer
To Readout
(-)SIGNAL
SHUNT CAL
ENABLE
SHUNT CAL
RESISTOR
ZERO
SPAN
1 2 3 4 5 6 7 8 ON
EX SEL
10 VDC
5 VDC
3 VDC
COARSE
Excitation Selector
Coarse Zero
Fine Zero
Coarse Gain
Fine Gain
FIG. 59: Amplifier Settings
21. Replace the amplifier cover. See Replace Ampli-
22. Reconnect the outlet pressure sensor cable if it was
removed.
23. If desired, change pressure units to desired setting
on Advanced screen 2.
86
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Repair
Replace Gateway Module Base
Control Center Assembly
Gateway Module. (Leave automation communica-
tions cable (AE) attached to Gateway module.)
Prepare Control Center for Repair
3. Disconnect the CAN cable (19) and power supply
cable (6) from the base (3).
1. Power off the display.
2. Disconnect main power to the control center assem-
bly.
4. Remove the four screws (16) and grounding
screw (12) from the base and replace it with a new
base.
3. Remove the control center assembly front cover
(20).
1
Replace Gateway Module
2. Remove the automation communications cable
(AE).
19
6
3. Remove the two screws holding the Gateway mod-
ule (5) to the base (3), and remove the module.
3
12
5
16
4
FIG. 61
5. Secure the new base to rear cover (1) using the five
screws.
3
5
FIG. 60
4. Attach a new Gateway module to the base using
two screws.
5. Reconnect the automation interface cable.
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Repair
Replace Swirl Board 16K570:
Replace Advanced Display Module
2. Remove screw (a) from swirl board cover. Open
swirl board cover.
2. Disconnect the CAN cable (18) from the ADM (2).
21
3. Remove cable connectors (b) from swirl board.
4. Remove the four screws (c) from the swirl board.
Replace with new board and secure using the four
screws (c).
2
5. Insert cable connectors (b) into the new board.
6. Reassemble the swirl board cover using screw (a).
a
b
18
11, 14, 24
FIG. 63
3. Remove the ADM by snapping it out of the mounting
bracket.
4. On old ADM, remove token access panel then
remove key token. Do not discard token.
c
5. Connect the CAN cable to the new ADM.
FIG. 62
7. Insert key token into new ADM. Replace token
access panel.
8. Install the new ADM by snapping it into the mount-
ing bracket.
88
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Repair
Replace Advanced Display Module Bracket
Replace DIN Rail Assembly
Display Module. (Leave the CAN cable attached to
the ADM.)
2. Remove both screws (22) and washers (28) from
the line voltage assembly cover (7). Remove the
cover.
3. Remove the speed clips (25) and rivets (26) from
the mounting bracket (21).
22
28
26
20
21
25
2
7
FIG. 65
FIG. 64
3. Disconnect all wiring from the din rail module and fil-
ter.
4. Remove the mounting bracket from the front cover
(20) and replace with a new bracket.
4. Remove the four screws (40) from the din rail and
filter.
5. Secure the new bracket to the front cover with
speed clips and rivets.
5. Disconnect wires from rocker/rotary switch. Take
note of wire positions for easy connection in Step 7.
6. Reinstall the ADM.
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Repair
6. Remove the din rail, filter, and rocker switch (snaps
into place). Replace with new components. Secure
din rail and filter to the rear control center assembly.
cover (1) using the four screws (40). Snap
rocker/rotary switch into position.
1
40
40
r_pf0000_313377_10a
40
FIG. 66: 24 Vdc Din Rail Assembly
7. Reconnect all wiring to the din rail module, filter, and
rocker/rotary switch.
8. Reassemble the line voltage assembly cover using
the screws and washers.
Replace Fuses
Replace fuses on the din rail assembly.
•
•
For 24 Vdc control centers: see Technical Data
For 100-240 Vac control centers: Order fuse
115805.
r_pf0000_313377_10a
Fuses
FIG. 67: Fuse Location
90
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Parts
Parts
Control Centers
Software Upgrade Tokens
Part
Description
Includes PCF software for the ADM, FCM,
CGM, and DGM
★
✠
16K743
★ * 16N601 PCF Gateway map token: Installs the CGM
★ 16K742
Historical PCF Gateway map token: Only for
users that used the original PCF with a Gate-
way, have purchased a new PCF, and do not
wish to change their Gateway setup from the
old Gateway map to the new Gateway map.
Control Center Key Token Part Numbers
key tokens.
Part
Description
★16M217 ADM Key Token, Standard PCF
Gateway Module Part Numbers
User
Interface
Description
Gateway Part
Number To
Order
PCF
Model
PFxx0x
PFxx1x
Discrete
★24B681
★15V759
DeviceNet™
PFxx2x
Ether-
Net/IP™
★15V760
PROFIBUS™
PROFINET™
PFxx3x
PFxx4x
★15V761
★15V762
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Parts
Control Center and Expansion Swirl Enclosure Parts
24
15
40
7
44
28
22
50
13
13 22
1348
38
9
13 25
13 45
13 28
13 22
49
15
6,10
13 26
20
1
44
13
25
3,4,12,16
13
22
14
26
13
4313
1347
314
14 21
14 25
1614
4
14
1214
14
5 or 43
14 11 24
14
14
14
50 13
24 VDC units only: 15,36
100-240 VAC units only: 6,36
214
1
19
37
13
18
6;
Line/
Brown
23,27
6;
6;
Neutral/
Blue
Ground/
Green
1
14
15
Add ferrite (36) to cable. Locate
as close to cable connector as
possible.
Control centers only. Not included
in expansion swirl enclosures.
100-240 Vac models only.
13
Included in swirl models only
(both control centers and
expansion swirl enclosures).
92
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Parts
Control Center Assembly Parts
Ref. Part
43✠ 24B681 MODULE, DGM
Description
Qty.
Ref. Part
Description
COVER, rear
Qty.
1
1
1
1
1
1
1
1
1
1
---
1
1
1
1
1
44
45
46
47
48
49
50
51
52
---
GUARD, edging
2✠
3◆
4◆
5✠
24E451 DISPLAY, with USB
289697 BASE, cube
16K570 BOARD, circuit, swirl
---
---
---
---
BRACKET, display pivot
COVER, swirl, hinge side
COVER, swirl, latch side
COVER, swirl, lid
277674 ENCLOSURE, cube door
---
MODULE, Gateway; see table on
SUPPLY, power
COVER, line voltage
GROMMET
6‡
---
1
1
1
1
4
1
1
1
1
1
4
1
1
1
1
2
2
2
2
1
2
2
2
1
1
4
24K455 CABLE, swirl board, panel mount
24K458 CABLE, SWIRL-DGM
121597 CABLE, CAN, 90 female/90 female
7‡❖ ---
8‡❖ ---
1
9▲‡ 196548 LABEL, warning, electric shock
10‡ ---
11✿ ---
12◆ 121820 SCREW, mach, pan hd; m4 x 35
13 121807 CONNECTOR, splitter
14✿ 110755 WASHER, plain
15‡❖ ---
SCREW, cap, socket hd; m4 x 6
WASHER, lock
▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
‡ Parts included with 100-240 Vac Module kit 24B928.
MODULE, line voltage
❖ Parts included with 24 Vdc Module kit 24B929.
16◆ 195875 SCREW, mach, pan hd
✿ Parts included with Display Mounting Bracket kit
18
19
20
121001 CABLE, CAN, female / female 1.0m
121000 CABLE, CAN, female / female 0.5m
---
24B930.
COVER, front
BRACKET, mounting
SCREW, mach, pan hd
✠ Base electronic components do not have PCF-spe-
cific software installed. Use software upgrade token
(16K743) to install software before use.
21✿ ---
22‡❖ ---
23
120143 GUIDE, strain relief
24✿ 121253 KNOB, display
25✿ ---
26✿ ---
*
Fieldbus Gateway modules do not have a PCF-spe-
cific map installed. Use map token (16N601) to
install map before use.
CLIP, speed, tubular
RIVET, aluminum
27
28
36
37
38
40
112925 SCREW, cap
100020 WASHER, lock
--- Not for sale.
121901 SUPPRESSOR, box snap, ferrite
124654 CONNECTOR, splitter
---
---
LABEL
SCREW, mach, pan hd
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Parts
Fluid Plate Assembly Parts
Ref.
152
Part
Description
Qty.
194337 WIRE, grounding, door
186620 LABEL, ground
1
1
Ref.
Part
Description
Qty.
153▲
155✓
158
159▲
160▲
199*
101
102
---
PLATE, fluid
1
1
1
1
---
SUPPRESSOR, box snap, ferrite
289697 BASE, cube
122610 ELBOW
1
1
1
1
103✠
104
105✓
106
289696 FCM, cube
290228 LABEL, caution, hot surface
189930 LABEL, caution, electric shock
124654 SPLITTER, CAN
277674 ENCLOSURE, cube door
---
SCREW, mach, pan hd
121820 SCREW, machine, pan hd; m4 x
1
1
35
▲ Replacement Danger and Warning labels, tags, and
107
121228 CABLE, CAN, female/female;
15.0 m
cards are available at no cost.
108✓
109✓
110✓
---
---
---
REGULATOR, assy
UNION, adapter
NIPPLE, reducing, hex; 1/2 npt(f)
x 3/4 npt(f)
part number and quantity.
✖ Only included with fluid plates that use a heated
mastic regulator.
111
112
198269 BRACKET, flow meter, lower
110580 SCREW, cap, socket hd
1
2
✠ Base electronic components do not have PCF-spe-
cific software installed. Therefore, use software
upgrade token (16K743) to install software before
use.
113✓
114
115✖
116✖
117✓
118
119✖
120✓
121
---
SPACER
198268 BRACKET, flow meter
1
1
1
2
1
1
624545 FITTING, tee; 3/4(m) x 1/4(f)
258530 AMPLIFIER, signal conditioner
---
---
16P819 BRACKET, signal conditioner
--- O-RING
120010 REGULATOR, I/P
111119 SCREW, valve
---
---
---
---
---
---
---
SENSOR, pressure, fluid outlet
BRACKET, valve
★ 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.
1
2
122
124✓
125✓
126✓
127✓
128✓
129✓
130✓
131▲
132
BRACKET, helical gear meter
WASHER, plain
WASHER, lock, spring; m6
SCREW, cap, socket hd
SCREW, cap, socket hd, hex
METER, assy
Fluid Plate Key Token Part Numbers
CABLE; m12-5p
key tokens.
15X756 LABEL, warning, main
258334 VALVE, dispense, fluid plate
121806 CABLE, solenoid
1
1
1
1
1
2
1
1
133
135▲✖ 189285 LABEL, caution, hot surface
Part
Description
136
137
139
140
141
142
143
145
---
LABEL
★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
117820 SCREW, cap, socket hd; m3
198179 FITTING, bulkhead, union
198175 FITTING, push
---
---
---
TUBE, nylon, round, black; 5.5
LABEL
SHROUD, fluid plate
1
1
1
121226 CABLE,CAN, male/female; 0.5
m
146★
234967 KIT, dual filter
1
147✓★ ---
TOKEN, key
★16M105 FCM Key Token, 256 styles, No Flow
148
149
150
151
121612 CONNECTOR, thru; m12, m x f
121818 BULKHEAD, tube; 5/32
1
2
1
1
Meter
---
TAG, installation
114391 SCREW, grounding
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Parts
Parts Varying by Assembly
The following table lists the varying part numbers by fluid plate assembly, and the quantity for each assembly.
Fluid Plate Assemblies
Heated
Mastic
Cartridge
Regulator
with High
Resolution
Meter
Mastic
Regulator
with High
Resolution
Meter
Regulator
with Heated
High
Resolution
Meter
Heated
Mastic
Regulator
with
Cartridge
Regulator
with
Mastic
Regulator
with
Ref. Part
Description
No Meter
No Meter
No Meter
105 195875 SCREW, mach, pan
hd
4
4
4
4
8
8
108 244734 REGULATOR, assy
246642
1
1
1
1
246643
1
1
1
1
109 156684 UNION, adapter
157785
1
1
1
110 C20461 NIPPLE, reducing,
hex; 1/2 npt(f) x 3/4
npt(f)
C20487
1
2
113 C34045 SPACER
2
2
2
2
117 15M669 SENSOR, pressure,
2
2
fluid outlet
117764
1
1
1
120 111457 O-RING
2
1
2
2
1
124 117670 BRACKET, helical
gear meter
125 C19197 WASHER, plain
4
6
4
6
4
6
126 ---
WASHER, lock,
spring; m6
127 108328 SCREW, cap, socket
hd
6
6
1
2
4
6
6
1
2
4
6
6
2
4
128 107530 SCREW, cap, socket
hd, hex
129 246652 METER, assy.
246340
1
1
1
130 122030 CABLE; m12-5p
1
1
1
1
16M100 TOKEN, key, 2 styles,
meter enabled
147★
16M101 TOKEN, key, 2 styles,
meter disabled
1
1
1
1
1
1
1
1
1
16M102 TOKEN, key, 16
styles, meter enabled
1
1
1
1
1
1
1
1
1
16M103 TOKEN, key, 16
styles, meter disabled
16M104 TOKEN, key, 256
styles, meter enabled
16M105 TOKEN, key, 256
styles, meter disabled
155 121901 SUPPRESSOR, box
snap, ferrite
--- Not for sale.
98
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Appendix A - Advanced Display Module (ADM)
Appendix A - Advanced Display Module (ADM)
Display Overview
Display Details
The ADM display is divided into two main functions:
Setup Mode and Run Mode.
Power Up Screen
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.
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
Menu Bar
Run Mode Functions
The menu bar appears at the top of each screen.
The run mode functions enable users to:
•
•
•
•
adjust the bead scale
perform manual dispensing
view a chronological list of system errors
view a chronological list of jobs stored/per-
formed in the system
use a preventative maintenance schedule for
the supply system, displacement pump, and air
motor
Date and Time
The date and time are always displayed in one of the 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.
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Appendix A - Advanced Display Module (ADM)
System Mode
Navigation within Screens
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.
Press
to open drop-down menus on Setup
screens. Also, press
selection.
to enter changes or make a
Alarm/Deviation
If there is an active system error, one of the following
icons is displayed in the middle of the menu bar. There
are four possibilities:
Press
to navigate to new screens and to nav-
igate left and right within a screen.
Icon
Function
Description
No information or
no error has
occurred
No Icon
---
Press
to navigate to new screens and to navi-
gate up and down within a screen. Also press
Advisory
Informational
to move between fields within a drop-down menu, and to
increment or decrement numbers within a field.
Important but will
not shut down the
affected fluid
plate
Deviation
Very important
and will immedi-
ately shut down
the affected fluid
plate
Alarm
Status
The current system status is displayed at the right of the
menu bar.
Soft Keys
Icons next to the soft keys indicate which mode or action
is associated with each soft key. Soft keys that do not
have an icon next to them are not active in the current
screen.
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Jump In/Jump Out
In screens that have editable fields, press
the fields and make changes. When changes are com-
plete press again to exit edit mode.
to access
100
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Appendix A - Advanced Display Module (ADM)
Advanced Setup Screen 2
Setup Mode
Setup mode screens are divided into five sections: Sys-
tem setup, Advanced setup, Gateway setup, Fluid Plate
This screen enables users to set the units of measure
for maintenance volume, maintenance mass, pressure,
and flow rate.
setup, and Swirl setup. While in Run mode, press
to enter Setup mode. Press
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
Advanced Setup Screen 3
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
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.
component. Press
to scroll through the
Advanced setup screens. Once in the desired Advanced
setup screen, press
changes. Press
to access the fields to make
to exit edit mode.
NOTE: Users must be out of edit mode to scroll through
the Advanced setup screens.
Advanced Setup Screen 1
This screen enables users to set the language, date 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 4
This screen displays the software part number and ver-
sion for the ADM, USB configuration, Gateway module,
and fluid plates.
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Appendix A - Advanced Display Module (ADM)
Automation Gateway Setup Screens
There are up to three automation Gateway Setup
screens (depending on fieldbus), which enable users to
set or change information regarding the automation
Gateway module used on the PCF system. These
screens also enable users to view information regarding
the particular automation Gateway module used.
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.
Press
screens. Once in the desired Advanced Setup screen,
press to access the fields to make changes. Press
to scroll through the Gateway Setup
to exit edit mode.
NOTE: Users must be out of edit mode to scroll through
the Gateway Setup screens.
Gateway Setup Screen 1 - DeviceNet
Gateway Setup Screen 2 - EtherNet/IP
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.
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
102
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Appendix A - Advanced Display Module (ADM)
Gateway Setup Screen 1 - PROFIBUS
Gateway Setup Screen 2 - PROFINET
This screen enables users to set the device address,
install date, location tag, function tag, and system
description.
This screen enables users to set the device address,
install date, location tag, function tag, and system
description.
Gateway Setup Screen 2 - PROFIBUS
This screen is the same for EtherNet/IP and PROFI-
page 102, for details.
Gateway Setup Screen 3 - PROFINET
This screen enables users to view the following informa-
tion regarding the Gateway module used on the PCF
system:
Gateway Setup Screen 1 - PROFINET
•
•
•
•
•
•
hardware revision number
system serial number
map ID number
map name
map revision number
date the map was created
This screen enables users to set the IP address, subnet
mask, Gateway, DNS 1, DNS 2, and if a DHCP is used.
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Appendix A - Advanced Display Module (ADM)
Discrete Gateway (Automation) Setup Screen
NOTE: The Discrete Gateway Setup screen is not avail-
able if an automation Discrete Gateway Module (DGM)
is not attached to the system.
Digital Command Logic Table
(2-Fluid Plate Systems)
NOTE: If Swirl Dispensers are installed, a Swirl Discrete
Gateway Module will be installed. This section is not
related to that module. See Control Center Assembly
Digital
Command
Input 1
Digital
Command
Input 2
Resulting Digital
Command Selection
---
Fluid Plate 1,
Setting #1
Low
High
---
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.
---
Fluid Plate 1,
Setting #2
Fluid Plate 2,
Setting #1
Low
Fluid Plate 2,
Setting #2
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-
connection details.
---
High
Press
to exit edit mode.
Single fluid plate system
to access the fields to make changes. Press
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
Command Logic Table for connection details.
NOTE: The control mode for each dispense valve is set
105. For example, if Valve 1 is set to Pressure mode on
digital commands for Valve 1 are pressure values.
2-fluid plate system
The Digital Command Logic Table indicates which value
each input must be set to in order to select a particular
setting.
Digital Command Logic Table
(Single Fluid Plate Systems)
Digital
Digital
Command
Input 1
Command
Input 2
Resulting Digital
Command Selection
Low
Low
High
Setting #1
Setting #2
Setting #3
Low
High
---
104
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Appendix A - Advanced Display Module (ADM)
Fluid Plate Setup Screens
There are nine fluid plate setup screens, which enable
users to:
•
Set the Run Mode Bead Adjust to Enable or Dis-
able.
NOTE: Run mode bead adjust allows a user to quickly
•
•
Set controls and valve commands
Set on and off delays for valves and the regula-
tor
adjust flow rate or pressure from the run screen.
•
•
•
•
•
•
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
edit mode.
to exit
NOTE: Users must be out of edit mode to scroll through
Fluid Plate x, Screen 2 (Mode Settings)
the fluid plate setup screens.
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.
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.
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.
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Appendix A - Advanced Display Module (ADM)
Attempting to dispense from multiple valves simultane-
ously using any other combination will cause an Incom-
patible Valves Settings alarm.
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
Fluid Plate x, Screen 4 (Control Loop and Flowmeter
Settings)
This screen enables users to set the meter type (volume
or mass) and the K-Factor for the flowmeter. Users can
also set the Kp, Ki, and Kd for the pressure control loop
as well as Kp and Ki for bead control loop.
NOTE: In systems without a flow meter, the flow meter
settings will be grayed out.
NOTE: It is recommended that these values not be
changed from the factory defaults of 32.00 for Kp,
128.00 for Ki, and 0.00 for Kd.
106
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Appendix A - Advanced Display Module (ADM)
Fluid Plate x, Screen 5 (Pressure Sensors)
Fluid Plate x, Screen 6 (Error Type)
NOTE: Inlet sensor settings will be grayed out on this
screen for systems with heated fluid plates.
This screen enables users to set the error type (none,
alarm, or deviation) that will be issued if the pressure,
flow rate, volume, or computed target goes outside the
tolerance settings of the active style. See Configure
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.
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)
•
•
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.
•
The volume is relative to the requested volume and
computed target errors are relative to the target vol-
ume defined in the style
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Appendix A - Advanced Display Module (ADM)
Fluid Plate x, Screen 7 (Maintenance Advisory
Limits)
Fluid Plate x, Screen 8 (Style)
This screen enables users to set up to 256 styles,
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.
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: Hours is shown instead of Volume for fluid plates
without a flow meter.
NOTE: The number of possible styles is dependent on
the model type.
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.
page 113, for more information about maintenance total-
izers.
To enter the style name, press
while in the Style
instructions on using the keyboard screen to enter the
style name.
108
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Appendix A - Advanced Display Module (ADM)
Fluid Plate x, Screen 9 (Swirl Association)
Swirl Setup Screen
This screen enables users to set the swirl to fluid plate
association. This allows the system to apply errors to
the correct fluid plate when a swirl error occurs, and to
stop the correct fluid plate from dispensing when certain
swirl errors occur.
This screen enables users to:
•
•
Set the Speed Command Source to Display or
Gateway. If it is set to Display, users can set the
fixed speed
Set the Run Mode Speed Adjust to Enable or Dis-
able
•
•
Set the speed scale from 50-150%
Set the Swirl Orbiter Maintenance Advisory Limit
Keyboard Screen
The keyboard screen appears when text is edited. Use
all four arrow buttons to select each letter; press
to
enter the letter. To back space, press
the entire style name entered, press
. To delete
. To enter the
style name, press
. To cancel the entry and exit the
.
keyboard screen, press
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Appendix A - Advanced Display Module (ADM)
Run Mode
Run mode screens are divided into six sections: home,
fluid plates, swirls, events, errors, and jobs. While in
Swirl Home Screen
NOTE: This screen only appears if more than one Swirl
Dispenser is installed.
Setup mode press
to enter Run mode. Press
to navigate through the Run mode screens.
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:
Fluid Plate Home Screen
NOTE: This screen only appears if more than one fluid
plate is installed.
•
•
•
Requested motor speed
Actual motor speed
Progress bar indicating requested and actual motor
speed
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).
110
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Appendix A - Advanced Display Module (ADM)
Fluid Plate x, Screen 1
The PCF system has two operating modes:
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.
•
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.
From this screen users can adjust the bead scale and
enter maintenance mode. Press
and
to
Dispensing continues for as long as the manual dis-
change the bead scale. Press
nance mode.
to enter mainte-
pense button
is pressed.
Current Dispense
Control Mode
Inlet Pressure
(non-heated systems)
Outlet Pres-
sure
Command Voltage
(Displays only when
Command Cable or Gate-
way is selected as the
Command Value Source;
Flow Rate
(systems with flow
meters)
Current Command
Value
Active Dispense
Valves
Bead Scale
Quickly adjust pres-
sure/flowrate from this
screen
Associated Swirl
Dispensers
Active Style
Volumes
Progress Bar
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Appendix A - Advanced Display Module (ADM)
Maintenance Mode
Dispense Control Modes
The PCF system has four fluid dispensing control
modes.
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.
•
•
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.
NOTE: Volume, pressure, and dispense valve options
change according to mode.
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.
instructions on changing the control mode, target pres-
sure, and number of dispense valves used.
•
•
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.
112
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Appendix A - Advanced Display Module (ADM)
Fluid Plate x, Screen 2 (Control Center)
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.
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.
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.
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:
The limits are set in the Fluid Plate x, Screen 7 (Main-
voltage to pressure (V/P) transducer, fluid regulator,
flow meter, and all four valves.
•
•
•
•
•
•
•
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
NOTE: If a flow meter is not included in the system, this
screen shows hours instead of volume and the flow
meter entry is grayed out.
This screen also displays the current dispense style,
command voltage, Gateway error number/code, and the
volume dispensed.
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Appendix A - Advanced Display Module (ADM)
Swirl X Screen
Press
to scroll through each event report
There is one Swirl X screen for each installed swirl dis-
penser. This screen displays the following items:
screen.
•
•
•
•
Swirl Enable signal from the automation interface
Speed command voltage from automation interface
Actual and requested speed
Active time and maintenance advisory limit
Error Report Screens
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,
page 66, for more information on errors, a list of error
codes, and information on error troubleshooting.
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 error report
screen.
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.
114
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Appendix B - Discrete Gateway Module (DGM) Connection Details
Appendix B - Discrete Gateway Module (DGM) Connection Details
D-Sub Cable 123793
The D-sub cable 123793 is only compatible with single fluid plate systems. Systems with 2 fluid plates must use
cable 123792 and breakout board 123783.
The cable length of interface cable assembly 123793 is 50 ft (15.2 m). The following table identifies the cable inter-
face signals.
D-Sub
Pin No.
Wire Color
Description
Pin Type
Green/Yellow
Gray
Isolated Logic Power Supply
Isolated Logic GND
Dispense Ready
Dispense Error*
Dispense In Process
Dispense Purge
Dispense Remote Start
Style Bit 1
Supply
51 and 27
Supply
70
9
Blue/Green
Brown/Green
Blue/Orange
White
Digital Output
Digital Output
Digital Output
Digital Output
Digital Output
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Analog Input
Analog Input
11
12
15
16
52
53
54
55
56
57
58
59
73
74
1
Blue
White/Yellow
Blue/Yellow
Brown/Yellow
Black/Red
White/Red
Blue/Red
Style Bit 2
Style Bit 3
Style Bit 4
Style Strobe
Dispense Complete
Error Reset
Brown/Red
Black
Remote Start/Purge
Dispense Valve 1
Dispense Valve 2
Command Value
Analog GND
Black/Gray
Brown/Orange
Brown
Black/Yellow
White/Gray
Blue/Gray
Brown/Gray
2
---
3
Swirl 1 Speed Command ◆
Analog Input
Analog Input
21
23
Swirl 2 Speed Command ◆
Dispense Valve 3/
Swirl 1 Enable◆
Dispense Valve 4/
Swirl 2 Enable◆
White/Orange
Black/Orange
Digital Input
Digital Input
75
76
Black/Green
White/Green
Orange
Digital CMD 1
Digital CMD 2
---
Digital Input
Digital Input
77
78
N/C
◆ Swirl-related inputs apply only to systems with Swirl Dispensers.
* Dispense Error may be active high or low, depending on the setting on the Gateway setup screen. See Discrete
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Appendix B - Discrete Gateway Module (DGM) Connection Details
D-Sub Cable 123792 and Breakout Board 123783
The cable length of the interface cable assembly 123792 is 50 ft (15.2 m). The following table identifies the pin
assignments for the 78-pin breakout board.
D-Sub
Pin No.
1
2
3
4
Description
Pin Type
Analog In
Analog In Ground
Analog In
Analog In Ground
Voltage (Vdc)
0 - 10
0
0 - 10
0
Command Value (Fluid Plate 1)
Command Value Ground (Fluid Plate 1)
Command Value (Fluid Plate 2)
Command Value Ground (Fluid Plate 2)
5
6
7
8
9
◆ Dispense Ready
◆† Dispense Alarm/Error on Data
◆† Dispense Error
◆ Dispense In Process
◆ Dispense Volume OK
Fluid Plate Selected
◆ Dispense Purge
◆ Dispense Remote Start
◆ * Data 1
◆ * Data 2
◆ * Data 4
◆ * Data 8
Swirl 1 Speed Command
Swirl 1 Speed Command Ground
Swirl 2 Speed Command
Swirl 2 Speed Command Ground
Digital Out - Bank 1
Digital Out - Bank 1
Digital Out - Bank 1
Digital Out - Bank 1
Digital Out - Bank 1
Fluid Plate Selected
Digital Out - Bank 1
Digital Out - Bank 1
Digital Out - Bank 2
Digital Out - Bank 2
Digital Out - Bank 2
Digital Out - Bank 2
Analog In
0 - voltage connected to Pin 27
0 - voltage connected to Pin 27
0 - voltage connected to Pin 27
0 - voltage connected to Pin 27
0 - voltage connected to Pin 27
Fluid Plate Selected
0 - voltage connected to Pin 27
0 - voltage connected to Pin 27
0 - voltage connected to Pin 68
0 - voltage connected to Pin 68
0 - voltage connected to Pin 68
0 - voltage connected to Pin 68
0 - 10
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44 - 50
51
52
53
54
55
56
Analog In Ground
Analog In
Analog In Ground
0
0 - 10
0
Digital Out Supply - Bank 1
◆ * Data 16
◆ * Data 32
◆ * Data 64
◆ * Data 128
◆ * Data 256
◆ * Data 512
◆ * Data 1024
◆ * Data 2048
Isolated Logic Supply V+
Digital Out - Bank 2
Digital Out - Bank 2
Digital Out - Bank 2
Digital Out - Bank 2
Digital Out - Bank 3
Digital Out - Bank 3
Digital Out - Bank 3
Digital Out - Bank 3
Digital Out - Bank 3
Digital Out - Bank 3
Digital Out - Bank 3
Digital Out - Bank 3
Analog Out
10-30
0 - voltage connected to Pin 68
0 - voltage connected to Pin 68
0 - voltage connected to Pin 68
0 - voltage connected to Pin 68
0 - voltage connected to Pin 69
0 - voltage connected to Pin 69
0 - voltage connected to Pin 69
0 - voltage connected to Pin 69
0 - voltage connected to Pin 69
0 - voltage connected to Pin 69
0 - voltage connected to Pin 69
0 - voltage connected to Pin 69
0 - 10
◆ * Data 4096
◆ * Data 8192
◆ * Data 16384
◆ * Data 32768
Swirl 1 Actual Speed
Swirl 1 Actual Speed Ground
Swirl 2 Actual Speed
Swirl 2 Actual Speed Ground
Analog Out Ground
Analog Out
Analog Out Ground
0
0 - 10
0
Isolated Logic Power Supply
Style Bit 1
Style Bit 2
Style Bit 3
Style Bit 4
Isolated Logic Supply V+
Digital In
Digital In
Digital In
Digital In
10-30
0-30
0-30
0-30
0-30
0-30
Style Strobe Fluid Plate 1
Digital In
116
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Appendix B - Discrete Gateway Module (DGM) Connection Details
D-Sub
Pin No.
57
58
59
Description
◆ Dispense Complete
◆ Error Reset
Pin Type
Voltage (Vdc)
0-30
0-30
Digital In
Digital In
Digital In
◆ Remote Start/Purge
0-30
60 -67
68
69
70
71
Digital Out Supply - Bank 2
Digital Out Supply - Bank 3
Isolated Logic GND
Style Strobe Fluid Plate 2
◆ Fluid Plate Selector
Isolated Logic Supply V+
Isolated Logic Supply V+
Isolated Ground
Digital In
Digital In
Digital In
10-30
10-30
0
0-30
0-30
0-30
72
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
1 installed fluid plate, no swirl:
Fluid Plate 1, Dispense Valve 2
2 installed fluid plates, no swirl:
Fluid Plate 1, Dispense Valve 2
1 installed fluid plate, one or more swirl:
Fluid Plate 1, Dispense Valve 2
2 installed fluid plates, one or more swirl:
Fluid Plate 2, Dispense Valve 1
1 installed fluid plate, no swirl:
Fluid Plate 1, Dispense Valve 3
2 installed fluid plates, no swirl:
Fluid Plate 2, Dispense Valve 1
1 installed fluid plate, one or more swirl:
Swirl 1 Enable
74
75
76
Digital In
Digital In
Digital In
0-30
0-30
0-30
2 installed fluid plates, one or more swirl:
Swirl 1 Enable
1 installed fluid plate, no swirl:
Fluid Plate 1, Dispense Valve 4
2 installed fluid plates, no swirl:
Fluid Plate 2, Dispense Valve 2
1 installed fluid plate, one or more swirl:
Swirl 2 Enable
2 installed fluid plates, one or more swirl:
Swirl 2 Enable
77
78
Digital CMD 1
Digital CMD 2
Digital In
Digital In
0-30
0-30
*
16-bit data outputs contain either volume or error information depending on state of dispense alarm/error on data.
◆ Fluid plate selector input (pin 72) toggles the plate to which these inputs and outputs will apply:
Pin 72 = 0: Inputs and outputs apply to fluid plate 1.
Pin 72 = 1: Inputs and outputs apply to fluid plate 2.
† Alarm and Error signals may be active high or low, depending on the setting on the Gateway setup screen. See
3A2098H
117
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Appendix B - Discrete Gateway Module (DGM) Connection Details
Pin References
NOTE: To avoid ground loops and noise immunity
issues, do not ground the shield of the D-subminiature
connector cable; it is already grounded through the
mounting screw on the base of the DGM.
1
21
20
39
40
60
59
78
FIG. 68: D-Subminiature Connector - Pin References
118
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Appendix B - Discrete Gateway Module (DGM) Connection Details
DGM Digital Input
The digital inputs function only when power is supplied to pin 51 and there is a ground connection to pin 70. See Pin
References, page 118, for details. The digital input is rated at 0-30 Vdc, and requires an NEC Class 2 power supply
connected to pin 51. The DGM provides optical isolation as shown in the following illustration.
•
•
Pins: 52 – 59, 71-78
Type: Sinking
•
Maximum current draw: 3.6 mA
Discrete Gateway
Customer Automation
D-Sub Pin 51 (Isolated
Logic Supply), 10-30 VDC
Isolated Logic ICs
Digital Input
Optical
Isolator
Microcontroller
24VDC
D-Sub Pin 70
(Isolated Ground)
3A2098H
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Appendix B - Discrete Gateway Module (DGM) Connection Details
DGM Digital Outputs
The digital outputs function only when power is supplied to pins 27, 68, and 69 and there is a ground connection to
pin 70. See Pin References, page 118, for details. The digital output is rated at 0-30 Vdc, and requires an NEC
Class 2 power supply connected to pin 27 for supply bank 1, pin 69 for supply bank 2, and pin 68 for supply bank 3.
The DGM provides optical isolation as shown in the following illustration.
•
•
Pins: 9-20, 28-39
Type: Sourcing
•
•
Maximum continuous current output: 350 mA
(sourced from customer supply)
Recommended continuous current: 100 mA
Discrete Gateway
Isolated Logic ICs
Customer Automation
D-Sub Pin 51 (Isolated
Logic Supply)
Digital Output
Supply Bank 1
D-Sub
Pin 27
Optical
Isolator
Microcontroller
Digital
Output 1-8
LOAD
D-Sub
Pin 69
Digital Output
Supply Bank 2
24VDC
Digital
Output 9-16
LOAD
Digital Output
Supply Bank 3
D-Sub
Pin 68
Digital
Output 17-24
LOAD
24VDC
D-Sub Pin 70
(Isolated Ground)
120
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Appendix B - Discrete Gateway Module (DGM) Connection Details
DGM Analog Inputs
The analog inputs function only when the DGM is connected to a power supply through the CAN connection. Each
•
•
Type: Sinking
Voltage Rating: 0-10 Vdc
•
Input Impedance: 20 k
Ω
Discrete Gateway
Analog Input +
Microcontroller
+
20kΩ
-
Analog Input -
DGM Analog Outputs
The analog outputs function only when the DGM is connected to a power supply through the CAN connection. Each
analog output has a corresponding reference (ground) pin. See Pin References, page 118, for details.
•
Type: Sourcing
•
Voltage Rating: 0-10 Vdc, 10 mA at 10 Vdc
Discrete Gateway
Analog Output +
0-10VDC @10mA
Microcontroller
+
-
-
Analog Output
3A2098H
121
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Appendix C - Communications Gateway Module (CGM) Connection Details
Appendix C - Communications Gateway Module
(CGM) Connection Details
Module Status (MS)
Install Fieldbus Connections
Connect cables to fieldbus per fieldbus standards.
State
Off
Description
Comments
Not initial-
ized
No power or module in
“SETUP” or “NW_INIT” state
PROFINET
Green
Normal
Diagnostic event(s) present
MS
Link
operation
Flashing
Green
Initialized,
diagnostic
event(s)
present
Used by engineering tools to
identify node on network
NS
TI11814A
Red
Exception
error
Module in state “EXCEPTION”
FIG. 69: PROFINET Fieldbus Connections
Red (1
flash)
Configura-
tion error
Expected Identification differs
from Real Identification
The Ethernet interface operates at 100Mbit, full duplex,
as required by PROFINET. The Ethernet interface is
auto-polarity sensing and auto-crossover capable.
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
Network Status (NS)
State
Off
Description
Comments
No power
No connection with IO
Controller
Red (4
flashes)
Major Inter-
nal Error
Cycle system power; replace
module
Offline
•
•
Link/Activity (Link)
State
Green
On-line,
(RUN)
•
•
Connection with IO Con-
troller established
IO Controller with RUN
state
Description
Off
No Link, no communication present
Green
Link established, no communication present
Link established, communication present
Flashing
Green
On-line,
(STOP)
•
•
Connection with IO Con-
troller established
IO Controller in STOP
state
Green,
flashing
122
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Appendix C - Communications Gateway Module (CGM) Connection Details
EtherNet/IP
DeviceNet
NS
MS
MS
Link
NS
1 2
3
4 5
TI11814A
TI11815A
FIG. 70: EtherNet/IP Fieldbus Connections
DC
FIG. 71: DeviceNet Fieldbus Connections
The Ethernet interface operates at 100Mbit, full duplex,
as required by PROFINET. The Ethernet interface is
auto-polarity sensing and auto-crossover capable.
Network Status (NS)
State
Description
Not online / No power
Network Status (NS)
Off
State
Off
Description
Green
On-line, one or more connections are
established
No power or no IP address
Flashing
Green
(1 Hz)
On-line, no connections established
Green
On-line, one or more connections established
(CIP Class 1 or 3)
Flashing
Green
On-line, no connections established
Red
Critical link failure
Flashing
Red (1 Hz)
One or more connections timed-out
Red
Duplicate IP address, FATAL error
Flashing
Red
One or more connections timed out (CIP Class
1 or 3)
Alternating
Red/Green
Self test
Module Status (MS)
State
Module Status (MS)
State
Description
Description
Off
No power
Off
No power or not initialized
Initialized
Green
Controlled by a Scanner in Run state
Not configured, or Scanner in Idle state
Green
Flashing
Flashing
Green
Missing or incomplete configuration, device
Green (1 Hz) needs commissioning
Red
Major fault (EXCEPTION-state, FATAL error
etc.)
Red
Unrecoverable Fault(s)
Recoverable Fault(s)
Flashing
Red (1 Hz)
Flashing
Red
Recoverable fault(s)
Alternating
Red/Green
Self test
LINK/Activity (Link)
State
DeviceNet Connector (DC)
Description
Off
No link, no activity
Pin
Signal
V-
Description
Green
Link established
Activity
1
2
3
4
5
Negative bus supply voltage
CAN low bus line
Flashing
Green
CAN_L
SHIELD
CAN_H
V+
Cable shield
CAN high bus line
Positive bus supply voltage
3A2098H
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Appendix C - Communications Gateway Module (CGM) Connection Details
PROFIBUS
PROFIBUS Connector (DC)
Pin Signal
Description
OP
DC
ST
5 4 3 2 1
1
2
3
4
5
6
-
-
-
-
B Line
RTS
Positive RxD/TxD, RS485 level
Request to send
9 8 7 6
GND Bus
Ground (isolated)
TI11816A
+5V Bus
Output
+5V termination power (isolated)
FIG. 72: PROFIBUS Fieldbus Connections
Operation Mode (OP)
7
8
9
-
-
A Line
-
Negative RxD/TxD, RS485 level
-
State
Description
Not online / No power
Housing Cable
Shield
Internally connected to the Anybus
protective earth via cable shield filters
according to the PROFIBUS stan-
dard.
Off
Green
On-line, data exchange
On-line, clear
Flashing
Green
Flashing Red
(1 flash)
Parameterization error
Flashing Red PROFIBUS Configuration error
(2 flashes)
Status Mode (ST)
State
Description
Off
No power or not initialized
Initialized
Green
Flashing
Green
Initialized, diagnostic event(s) present
Red
Exception error
124
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Appendix C - Communications Gateway Module (CGM) Connection Details
Input
CGM I/O Data Map
Byte Bit Description
I40 Pressure Units - Bit 0
Zone
I41 Pressure Units - Bit 1
I42 ---
138.
I43 ---
I44 ---
I45 ---
I46 ---
I47 ---
I48 ---
I49 ---
I50 ---
I51 ---
I52 ---
I53 ---
I54 ---
Fluid
Plate 2
5
6
7
Automation Inputs (signals from PCF)
Input
Byte Bit Description
I00 Dispenser (Fluid Plate) Ready
Zone
I01 Dispenser (Fluid Plate) No Alarm
I02 Dispense No Error
I03 Dispense in Process
I04 Dispense Volume OK
I05 ---
Fluid
Plate 2
Fluid
0
Plate 1
I06 Dispenser (Fluid Plate) Purge
Request
I55 ---
I07 Dispenser (Fluid Plate) Remote
Start / Purge In Process
I08 Pressure Units - Bit 0
I09 Pressure Units - Bit 1
I10 ---
I56 Error - 1
I57 Error - 2
I58 Error - 4
I59 Error - 8
I60 Error - 16
I61 Error - 32
I62 Error - 64
I63 Error - 128
I64 Dispenser (Fluid Plate) Ready
I65 Dispenser (Fluid Plate) No Alarm
I66 Dispense No Error
I67 Dispense in Process
I68 Dispense Volume OK
I69 ---
Fluid
Plate 2
I11 ---
I12 ---
I13 ---
I14 ---
I15 ---
I16 ---
I17 ---
I18 ---
I19 ---
I20 ---
I21 ---
I22 ---
I23 ---
I24 Error - 1
I25 Error - 2
I26 Error - 4
Fluid
1
2
3
Plate 1
Fluid
Plate 3
Fluid
8
Plate 1
I70 Dispenser (Fluid Plate) Purge
Request
I71 Dispenser (Fluid Plate) Remote
Start / Purge In Process
I72 Pressure Units - Bit 0
I73 Pressure Units - Bit 1
I74 ---
I75 ---
I76 ---
I77 ---
I78 ---
I79 ---
I80 ---
I81 ---
I82 ---
I83 ---
I84 ---
I85 ---
I86 ---
I27 Error - 8
I28 Error - 16
Fluid
Fluid
Plate 3
Plate 1
9
I29 Error - 32
I30 Error - 64
I31 Error - 128
I32 Dispenser (Fluid Plate) Ready
I33 Dispenser (Fluid Plate) No Alarm
I34 Dispense No Error
I35 Dispense in Process
I36 Dispense Volume OK
I37 ---
Fluid
Plate 3
Fluid
10
4
Plate 2
I38 Dispenser (Fluid Plate) Purge
Request
I39 Dispenser (Fluid Plate) Remote
Start / Purge In Process
I87 ---
3A2098H
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Appendix C - Communications Gateway Module (CGM) Connection Details
Input
Input
Byte Bit Description
I136 Command Interface - Value - Bit 8
Byte Bit Description
I88 Error - 1
Zone
Zone
I89 Error - 2
I90 Error - 4
I91 Error - 8
I92 Error - 16
I93 Error - 32
I94 Error - 64
I95 Error - 128
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
I144 Command Interface - Value - Bit 16
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
I152 Command Interface - Value - Bit 24
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
I160 Command Interface Status - Com-
mand Active
All Fluid
Plates/Swi
rls
Fluid
Plate 3
11
17
18
19
I96 Dispenser (Fluid Plate) Ready
I97 Dispenser (Fluid Plate) No Alarm
I98 Dispense No Error
I99 Dispense in Process
I100 Dispense Volume OK
I101 ---
All Fluid
Plates/Swi
rls
Fluid
Plate 4
12
I102 Dispenser (Fluid Plate) Purge
Request
I103 Dispenser (Fluid Plate) Remote
Start / Purge In Process
I104 Pressure Units - Bit 0
I105 Pressure Units - Bit 1
I106 ---
I107 ---
I108 ---
I109 ---
I110 ---
All Fluid
Plates/Swi
rls
Fluid
Plate 4
13
14
15
I111 ---
I112 ---
I113 ---
I114 ---
I115 ---
I116 ---
I117 ---
I118 ---
I119 ---
I120 Error - 1
I121 Error - 2
I122 Error - 4
I123 Error - 8
I161 Command Interface Status - Com-
mand Success
I162 Command Interface Status - Com-
mand Failure
I163 Command Interface Status - Value
Coerced
I164 ---
I165 ---
I166 ---
I167 ---
All Fluid
Plates/Swi
rls
Fluid
Plate 4
20
21- I168-
---
---
Fluid
Plate 4
25
I207
I124 Error - 16
I125 Error - 32
I126 Error - 64
I127 Error - 128
I128 Command Interface - Value - Bit 0
details.
I129 Command Interface - Value - Bit 1
All Fluid
16
I130 Command Interface - Value - Bit 2 Plates/Swi
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
rls
126
3A2098H
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Bit
Automation Outputs (signals to PCF)
Byte
Description
Zone
Output
O48
O49
O50
O51
O52
O53
O54
O55
O56
O57
O58
O59
O60
O61
O62
O63
O64
O65
O66
O67
O68
O69
O70
O71
O72
O73
O74
O75
O76
O77
O78
O79
O80
O81
O82
O83
O84
O85
O86
O87
O88
O89
O90
O91
O92
O93
O94
O95
Swirl Command Value - 1
Swirl Command Value - 2
Swirl Command Value - 4
Swirl Command Value - 8
Swirl Command Value - 16
Swirl Command Value - 32
Swirl Command Value - 64
Swirl Command Value - 128
Swirl Command Value - 256
Swirl Command Value - 512
Swirl Command Value - 1024
Swirl Command Value - 2048
---
---
---
---
Style Strobe
Dispense Complete
Dispense Valve 1 On
Dispense Valve 2 On
Dispense Valve 3 On
Dispense Valve 4 On
Error Reset / Cancel Job
Remote Start / Purge
Swirl Enable
---
---
---
---
---
---
---
Style - 1
Style - 2
Style - 4
Style - 8
Style - 16
Style - 32
Style - 64
Style - 128
Dispense Valve 1 Precharge On
Dispense Valve 2 Precharge On
Dispense Valve 3 Precharge On
Dispense Valve 4 Precharge On
---
---
---
---
Byte
Bit
Description
Style Strobe
Dispense Complete
Dispense Valve 1 On
Dispense Valve 2 On
Dispense Valve 3 On
Dispense Valve 4 On
Error Reset / Cancel Job
Remote Start / Purge
Swirl Enable
---
---
---
---
---
---
---
Style - 1
Style - 2
Style - 4
Style - 8
Style - 16
Style - 32
Style - 64
Style - 128
Dispense Valve 1 Precharge On
Dispense Valve 2 Precharge On
Dispense Valve 3 Precharge On
Dispense Valve 4 Precharge On
---
---
---
Zone
O00
O01
O02
O03
O04
O05
O06
O07
O08
O09
O10
O11
O12
O13
O14
O15
O16
O17
O18
O19
O20
O21
O22
O23
O24
O25
O26
O27
O28
O29
O30
O31
O32
O33
O34
O35
O36
O37
O38
O39
O40
O41
O42
O43
O44
O45
O46
O47
6
Swirl 1
Fluid
Plate 1
0
7
8
Swirl 1
1
2
3
4
5
Swirl 1
Fluid
Plate 2
Fluid
Plate 1
9
Swirl 2
Fluid
Plate 1
---
Command Value - 1
Command Value - 2
Command Value - 4
Command Value - 8
Command Value - 16
Command Value - 32
Command Value - 64
Command Value - 128
Command Value - 256
Command Value - 512
Command Value - 1024
Command Value - 2048
---
Fluid
Plate 2
10
11
Fluid
Plate 1
Fluid
Plate 2
Fluid
Plate 1
---
---
---
3A2098H
127
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Bit
Output
Bit
Byte
Description
Zone
Byte
Description
Zone
O96
O97
O98
O99
Command Value - 1
Command Value - 2
Command Value - 4
Command Value - 8
O152 Dispense Valve 1 Precharge On
O153 Dispense Valve 2 Precharge On
O154 Dispense Valve 3 Precharge On
O155 Dispense Valve 4 Precharge On
O156 ---
O157 ---
O158 ---
O159 ---
O160 Command Value - 1
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
O168 Command Value - 256
O169 Command Value - 512
O170 Command Value - 1024
O171 Command Value - 2048
O172 ---
Fluid
Plate 2
Fluid
Plate 3
12
19
O100 Command Value - 16
O101 Command Value - 32
O102 Command Value - 64
O103 Command Value - 128
O104 Command Value - 256
O105 Command Value - 512
O106 Command Value - 1024
O107 Command Value - 2048
O108 ---
Fluid
Plate 2
Fluid
Plate 3
13
14
15
16
17
18
20
21
22
23
24
25
O109 ---
O110 ---
O111 ---
O112 Swirl Command Value - 1
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
O120 Swirl Command Value - 256
O121 Swirl Command Value - 512
O122 Swirl Command Value - 1024
O123 Swirl Command Value - 2048
O124 ---
O125 ---
O126 ---
O127 ---
O128 Style Strobe
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
O136 Swirl Enable
O137 ---
O138 ---
O139 ---
O140 ---
O141 ---
O142 ---
O143 ---
O144 Style - 1
O145 Style - 2
O146 Style - 4
O147 Style - 8
O148 Style - 16
Fluid
Plate 3
Swirl 2
O173 ---
O174 ---
O175 ---
O176 Swirl Command Value - 1
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
O184 Swirl Command Value - 256
O185 Swirl Command Value - 512
O186 Swirl Command Value - 1024
O187 Swirl Command Value - 2048
O188 ---
O189 ---
O190 ---
O191 ---
O192 Style Strobe
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
O200 Swirl Enable
Swirl 2
Swirl 3
Fluid
Plate 3
Swirl 3
Fluid
Plate 4
Swirl 3
O201 ---
O202 ---
O203 ---
O204 ---
Fluid
Plate 3
Swirl 4
O149 Style - 32
O205 ---
O150 Style - 64
O206 ---
O151 Style - 128
O207 ---
128
3A2098H
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Bit
Output
Bit
Byte
Description
Zone
Byte
Description
Zone
O208 Style - 1
O209 Style - 2
Command Interface - Command -
Bit 0
O210 Style - 4
O211 Style - 8
O212 Style - 16
details.
Fluid
Plate 4
26
O213 Style - 32
O214 Style - 64
Command Interface - Command -
O257
Bit 1
O215 Style - 128
Command Interface - Command -
O258
Bit 2
O216 Dispense Valve 1 Precharge On
O217 Dispense Valve 2 Precharge On
O218 Dispense Valve 3 Precharge On
O219 Dispense Valve 4 Precharge On
O220 ---
O221 ---
O222 ---
O223 ---
O224 Command Value - 1
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
O232 Command Value - 256
O233 Command Value - 512
O234 Command Value - 1024
O235 Command Value - 2048
O236 ---
All Fluid
32
Command Interface - Command - Plates/S
Bit 3
Command Interface - Command -
Bit 4
Command Interface - Command -
Bit 5
Command Interface - Command -
Bit 6
Command Interface - Command -
Bit 7
Command Interface - Command -
Bit 8
Command Interface - Command -
Bit 9
Command Interface - Command -
Bit 10
Command Interface - Command -
Bit 11
Command Interface - Command -
Bit 12
Command Interface - Command -
Bit 13
Command Interface - Command -
Bit 14
Command Interface - Command -
Bit 15
Command Interface - Command -
Bit 16
Command Interface - Command -
Bit 17
Command Interface - Command -
Bit 18
O259
O260
O261
O262
O263
O264
O265
O266
O267
O268
O269
O270
O271
O272
O273
O274
O275
wirls
Fluid
Plate 4
27
28
29
30
31
Fluid
Plate 4
All Fluid
Plates/S
wirls
33
Fluid
Plate 4
O237 ---
O238 ---
O239 ---
O240 Swirl Command Value - 1
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
O248 Swirl Command Value - 256
O249 Swirl Command Value - 512
O250 Swirl Command Value - 1024
O251 Swirl Command Value - 2048
O252 ---
Swirl 4
All Fluid
Plates/S
wirls
34
35
Command Interface - Command -
Bit 19
O276 ---
O277 ---
O278 ---
O279 ---
Swirl 4
O253 ---
O254 ---
O255 ---
O280-
O287
---
---
3A2098H
129
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Byte
Bit
Description
Zone
Command Interface - Value - Bit 0
details.
O288
O289 Command Interface - Value - Bit 1 All Fluid
O290 Command Interface - Value - Bit 2 Plates/S
36
O291 Command Interface - Value - Bit 3
O292 Command Interface - Value - Bit 4
O293 Command Interface - Value - Bit 5
O294 Command Interface - Value - Bit 6
O295 Command Interface - Value - Bit 7
O296 Command Interface - Value - Bit 8
O297 Command Interface - Value - Bit 9
O298 Command Interface - Value - Bit 10
O299 Command Interface - Value - Bit 11
O300 Command Interface - Value - Bit 12
O301 Command Interface - Value - Bit 13
O302 Command Interface - Value - Bit 14
O303 Command Interface - Value - Bit 15
O304 Command Interface - Value - Bit 16
O305 Command Interface - Value - Bit 17
O306 Command Interface - Value - Bit 18
O307 Command Interface - Value - Bit 19
O308 Command Interface - Value - Bit 20
O309 Command Interface - Value - Bit 21
O310 Command Interface - Value - Bit 22
O311 Command Interface - Value - Bit 23
O312 Command Interface - Value - Bit 24
O313 Command Interface - Value - Bit 25
O314 Command Interface - Value - Bit 26
O315 Command Interface - Value - Bit 27
O316 Command Interface - Value - Bit 28
O317 Command Interface - Value - Bit 29
O318 Command Interface - Value - Bit 30
O319 Command Interface - Value - Bit 31
wirls
All Fluid
Plates/S
wirls
37
38
39
All Fluid
Plates/S
wirls
All Fluid
Plates/S
wirls
Command Interface - Control Bits -
O320
Read
Command Interface - Control Bits -
O321
Write
All Fluid
Plates/S
wirls
O322 ---
O323 ---
O324 ---
O325 ---
O326 ---
O327 ---
40
41
O328-
O335
---
---
130
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Appendix C - Communications Gateway Module (CGM) Connection Details
CGM Command Interface
NOTE: The CGM command interface is only available
Examples
for fluid plates with 16 or 256 styles.
NOTE: See the timing diagram and tables starting on
page 132 for detailed descriptions of the input and out-
put bits.
The CGM command interface utilizes bits in the CGM
functions that are not available in the other CGM I/O
bits.
Example 1: if output bits 256-275 are 0xB0203, output
bits 288-319 are 0x0004, and output bit 321 is high, this
means:
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 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)
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).
Combine these individual pieces to understand the com-
mand as a whole: Change the purge period setting on
fluid plate 1 to 4 minutes.
•
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.
Example 2: if output bits 256-275 are 0xB3212, input
bits 288-319 are 0x0000, and output bit 320 is high, this
means:
•
•
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.
•
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)
•
•
Output bit 321 identifies the command as a write
command.
Output bit 320 identifies the command as a read
command.
Combined, this means: Valve 1 on fluid plate 4 is dis-
abled.
The CGM command interface uses automation input
bits 128-159 to read the current system values. It also
uses input bits 160-163 to identify the status of com-
mands:
•
•
•
•
Bit 160: Command Active
Bit 161: Command Success
Bit 162: Command Failure
Bit 163: Value Coerced
NOTE: If both output bits 320 (read) and 321 (write) are
high during a command the result will be a command
failure identified by input bit 162 (command failure)
going high.
3A2098H
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Appendix C - Communications Gateway Module (CGM) Connection Details
Command Interface Timing Diagram
Read Command
Write Command
Automation Outputs (PCF Inputs)
Command Bits 256-275
Value Bits 288-319
Write Bit 321
Bits Set
Bits Set
Bits Set
Read Bit 320
Automation Inputs (PCF Outputs)
Value Bits 128-159
Bits Set
Bits Set
Command Active Bit 160
Command Success Bit 161
Command Failure Bit 162
Command Value Coerced Bit 163
FIG. 73: CGM Command Interface Timing Diagram
Command Interface Write Operation
4. Wait for the Command Success Bit or Command
Failure Bit to become set.
1. Set Command Identification Bits and Fluid
Plate/Swirl Identification Bits to the desired values.
NOTE: If Command Success Bit has been set, valid
data will be present within the Value Bits (Input).
2. Set Value Bits (Output) with the value that is desired
to be written.
5. Clear the Read Bit to end the read command opera-
tion.
3. Set Write Bit.
Fluid Plate/Swirl Identification Commands
4. Wait for the Command Active Bit to become set.
This indicates that an operation is in process.
Output Bits 268-275
Description
Fluid Plate 1
Fluid Plate 2
Fluid Plate 3
Fluid Plate 4
Swirl 1
0xB0
0xB1
0xB2
0xB3
0xE1
0xE2
0xE3
0xE4
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.
Swirl 2
Swirl 3
6. Clear the Write Bit to end the write command opera-
tion.
Swirl 4
Fluid Plate Commands
Command Interface Read Operation
Output
Bits
256-267 Description
Units
*See Units
Definitions, page 137 Write
Software Part STR_3_0 Read Only
1. Set Command Identification Bits and Fluid
Plate/Swirl Identification Bits to the desired values.
Read or
0x004
0x005
0x006
2. Set Read Bit.
Number
Software Part STR_7_4
Number
Read Only
Read Only
3. Wait for the Command Active Bit to become set.
This indicates that an operation is in process.
Software Part STR_11_8
Number
132
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Units
Output
Units
Bits
*See Units
Read or
Bits
*See Units
Read or
256-267 Description
Definitions, page 137 Write
256-267 Description
Definitions, page 137 Write
0x007
0x008
Software Part STR_15_12
Number
Read Only
0x231
Flow Meter
K-Factor
##### (pulses/Liter,
pulses/kg)
Read /
Write
Software Ver- Version
sion
Read Only
Read Only
Read Only
0x23C Outlet Pres-
sure Sensor
sint32; #### (psi);
###.# (bar); ##.##
(Mpa)
Read /
Write
User Offset
0x0DD Maintenance
Units Type
Maintenance Units
Enumeration
0x23D Inlet Pressure sint32; #### (psi);
Read /
Write
Sensor User
Offset
###.# (bar); ##.##
(Mpa)
0x0DF Enabled Styles ###
0x203
0x204
0x208
Purge Period #### (minutes)
Read /
Write
0x241
0x244
0x245
Maximum Out- uint32; #### (psi);
let Pressure
Read /
Write
###.# (bar); ##.##
(Mpa)
Dispense Trig- Dispense Trigger
Read /
Write
ger Source
Command
Source Enumeration
Command Value
Minimum Inlet uint32; #### (psi);
Pressure
Read /
Write
Read /
Write
###.# (bar); ##.##
(Mpa)
Value Source Source Enumeration
0x20F Bead Scale ### (percent)
Read /
Write
Maximum Inlet uint32; #### (psi);
Pressure
Read /
Write
###.# (bar); ##.##
(Mpa)
0x210
0x211
Job End Mode Job End Mode Enu-
meration
Read /
Write
0x248
0x249
0x247
0x254
0x255
0x260
0x262
Pressure Kp
Pressure Ki
Pressure Kd
Bead Kp
####.##
####.##
####.##
####.##
####.##
Read /
Write
Job End Delay Integer (Seconds)
Time
Read /
Write
Read /
Write
0x2B5 End Job On
Alarm
Boolean
Read /
Write
0x212
0x213
0x214
0x215
0x216
0x217
0x218
0x219
Valve 1 Enable Boolean
Valve 2 Enable Boolean
Valve 3 Enable Boolean
Valve 4 Enable Boolean
Read /
Write
Read /
Write
Read /
Write
Bead Ki
Read /
Write
Read /
Write
RegulatorTime ###### (hours)
Advisory Limit
Read /
Write
Read /
Write
Regulator Vol- Volume: ######
ume/Mass
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Read /
Write
Regulator On ### (mS)
Delay
Read /
Write
(gal(US)); ######
Regulator Off ### (mS)
Delay
Read /
Write
Valve 1 On
Delay
### (mS)
### (mS)
### (mS)
### (mS)
### (mS)
### (mS)
### (mS)
### (mS)
Read /
Write
0x264
0x266
Flow meter
Time Advisory
Limit
###### (hours)
Read /
Write
Valve 2 On
Delay
Read /
Write
Flow meter
Volume: ######
Read /
Write
0x21A Valve 3 On
Delay
Read /
Write
Volume/Mass (gal(US)); ######
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
0x21B Valve 4 On
Delay
Read /
Write
(lb), ###### (kg)
0x268
Supply Time
Advisory Limit
###### (hours)
Read /
Write
0x21C Valve 1 Off
Delay
Read /
Write
0x26A Supply Vol-
ume/Mass
Volume: ######
(gal(US)); ######
Read /
Write
0x21D Valve 2 Off
Delay
Read /
Write
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
0x21E Valve 3 Off
Delay
Read /
Write
0x21F Valve 4 Off
Delay
Read /
Write
0x26C V/P Time Advi- ###### (hours)
sory Limit
Read /
Write
0x230
Flow Meter
Type
Flow Meter Type Enu- Read /
meration Write
3A2098H
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Units
Output
Units
Bits
*See Units
Read or
Bits
*See Units
Read or
256-267 Description
Definitions, page 137 Write
256-267 Description
Definitions, page 137 Write
0x26E V/P Vol-
ume/Mass
Volume: ######
(gal(US)); ######
Read /
Write
0x28D High Com-
puted Target
Error Type Enumera- Read /
tion 1
Write
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Error Type
0x28E Low Inlet Pres- Error Type Enumera- Read /
sure Error Type tion 2 Write
High Inlet Error Type Enumera- Read /
0x270
0x271
0x272
0x273
0x278
Valve 1 Time ###### (hours)
Advisory Limit
Read /
Write
0x28F
Pressure Error tion 2
Type
Write
Valve 2 Time ###### (hours)
Advisory Limit
Read /
Write
0x292
0x293
0x294
0x295
0x296
Valve 1 Mode Valve Mode Enumera- Read /
tion Write
Valve 2 Mode Valve Mode Enumera- Read /
tion Write
Valve 3 Mode Valve Mode Enumera- Read /
tion Write
Valve 4 Mode Valve Mode Enumera- Read /
Valve 3 Time ###### (hours)
Advisory Limit
Read /
Write
Valve 4 Time ###### (hours)
Advisory Limit
Read /
Write
Valve 1 Vol-
ume/Mass
Volume: ######
(gal(US)); ######
Read /
Write
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
tion
Write
Valve 1 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
0x279
Valve 2 Vol-
ume/Mass
Volume: ######
(gal(US)); ######
Read /
Write
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
0x297
0x298
0x299
Valve 2 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
0x27A Valve 3 Vol-
ume/Mass
Volume: ######
(gal(US)); ######
Read /
Write
Valve 3 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
0x27B Valve 4 Vol-
ume/Mass
Volume: ######
(gal(US)); ######
Read /
Write
Valve 4 10
VDC Analog
Scale Flow
rate
Volume: #####
(cc/sec); #####
(cc/min); Mass: #####
(g/sec); ##### (g/min)
Read /
Write
Advisory Limit (gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
0x29A Valve 1 10
VDC Analog
Pressure: #### (psi); Read /
###.# (bar); ##.## Write
0x283
0x284
0x285
0x286
0x287
0x289
Swirl Fault
Error Type
Error Type Enumera-
tion 2
Scale Pressure (Mpa)
Low Flow Rate Error Type Enumera- Read /
Error Type tion 1 Write
High Flow Rate Error Type Enumera- Read /
Error Type tion 1 Write
Low Pressure Error Type Enumera- Read /
Error Type tion 1 Write
High Pressure Error Type Enumera- Read /
0x29B Valve 2 10
VDC Analog
Pressure: #### (psi); Read /
###.# (bar); ##.## Write
Scale Pressure (Mpa)
0x29C Valve 3 10
VDC Analog
Pressure: #### (psi); Read /
###.# (bar); ##.## Write
Scale Pressure (Mpa)
0x29D Valve 4 10
VDC Analog
Pressure: #### (psi); Read /
###.# (bar); ##.##
Error Type
tion 1
Write
Write
High Outlet
Error Type Enumera- Read /
Scale Pressure (Mpa)
Pressure Error tion 2
Type
Write
0x302
Regulator Volume: ######
Maintenance - (gal(US)); ######
Dispensed Vol- (gal(Uk)); ######
Read /
Write
0x28A Low Volume
Error Type
Error Type Enumera- Read /
tion 1
Error Type Enumera- Read /
tion 1 Write
Error Type Enumera- Read /
tion 1 Write
Write
ume*
(Liters); Mass: ######
(lb), ###### (kg)
0x28B High Volume
Error Type
0x303
Flow meter
Volume: ######
Read /
Write
Maintenance - (gal(US)); ######
Dispensed Vol- (gal(Uk)); ######
0x28C Low Com-
puted Target
ume*
(Liters); Mass: ######
(lb), ###### (kg)
Error Type
134
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Units
Output
Units
Bits
*See Units
Read or
Bits
*See Units
Read or
256-267 Description
Definitions, page 137 Write
256-267 Description
Definitions, page 137 Write
0x304
0x305
0x308
0x309
Supply Mainte- Volume: ######
Read /
Write
0x31B Valve 4 Mainte- ###### (hours)
nance - Dis-
Read /
Write
nance - Dis-
pensed
Volume*
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
pense Time*
0x800
0x801
Purge Defini- #####.# (cc)
tion - Volume
Read /
Write
V/P Mainte-
nance - Dis-
pensed
Volume: ######
Read /
Write
Purge Defini- Pressure: #### (psi); Read /
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
tion - Pressure ###.# (bar); ##.##
(Mpa)
Write
Volume*
0x802
Purge Defini- Tolerances Type
Read /
Write
tion - Toler-
ances
Valve 1 Mainte- Volume: ######
Read /
Write
nance - Dis-
pensed
Volume*
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
0x803
0x804
0x805
Purge Defini- #### (seconds)
tion - Duration
Read /
Write
Style 1 Defini- #####.# (cc)
tion - Volume
Read /
Write
Valve 2 Mainte- Volume: ######
Read /
Write
Style 1 Defini- Pressure: #### (psi); Read /
nance - Dis-
pensed
Volume*
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
tion - Pressure ###.# (bar); ##.##
(Mpa)
Write
0x806
0x807
Style 1 Defini- Tolerances Type
tion - Toler-
ances
Read /
Write
0x30A Valve 3 Mainte- Volume: ######
Read /
Write
nance - Dis-
pensed
Volume*
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
Style 1 Defini- Precharge Settings
Read /
Write
tion - Pre-
charge
Type
Settings
0x30B Valve 4 Mainte- Volume: ######
Read /
Write
0xBFC Style 255 Defi- #####.# (cc)
nition - Volume
Read /
Write
nance - Dis-
pensed
Volume*
(gal(US)); ######
(gal(Uk)); ######
(Liters); Mass: ######
(lb), ###### (kg)
0xBFD Style 255 Defi- Pressure: #### (psi); Read /
nition - Pres-
sure
###.# (bar); ##.##
(Mpa)
Write
0x312
0x313
Regulator
Maintenance -
Dispense
Time*
###### (hours)
Read /
Write
0xBFE Style 255 Defi- Tolerances Type
Read /
Write
nition - Toler-
ances
0xBFF Style 255 Defi- Precharge Settings
---
Flow meter
Maintenance -
Dispense
Time*
###### (hours)
Read /
Write
nition - Pre-
charge
Type
Settings
0xC04 Style 1 Defini- STR_3_0
tion - Name
Read /
Write
0x314
0x315
0x318
0x319
Supply Mainte- ###### (hours)
nance - Dis-
pense Time*
Read /
Write
0xC05 Style 1 Defini- STR_7_4
tion - Name
Read /
Write
V/P Mainte-
nance - Dis-
pense Time*
###### (hours)
Read /
Write
0xC06 Style 1 Defini- STR_11_8
tion - Name
Read /
Write
Valve 1 Mainte- ###### (hours)
nance - Dis-
pense Time*
Read /
Write
0xC07 Style 1 Defini- STR_15_12
tion - Name
Read /
Write
0xC3C Style 15 Defini- STR_3_0
tion - Name
Read /
Write
Valve 2 Mainte- ###### (hours)
nance - Dis-
pense Time*
Read /
Write
0xC3D Style 15 Defini- STR_7_4
tion - Name
Read /
Write
0x31A Valve 3 Mainte- ###### (hours)
nance - Dis-
Read /
Write
0xC3E Style 15 Defini- STR_11_8
tion - Name
Read /
Write
pense Time*
0xC3F Style 15 Defini- STR_15_12
tion - Name
Read /
Write
3A2098H
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Appendix C - Communications Gateway Module (CGM) Connection Details
Output
Units
Output
Units
Bits
*See Units
Read or
Bits
*See Units
Read or
256-267 Description
Definitions, page 137 Write
256-267 Description
Definitions, page 137 Write
0x29E Pressure Units Pressure Units Enu-
meration
Read /
Write
0x0FF Fluid Plate Dis- #####.# (cc)
Read Only
pensed Vol-
ume
0x29F Rate Units
Rate Units Enumera- Read /
tion Write
Volume Units Enumer- Read /
0x0DB Active Fault
Error Code
Fault Error Code
Read Only
0x2A0 Maintenance
Volume Units ation
Write
0x0F8
Fluid Plate Sta- Fluid Plate Status bit- Read Only
tus Bits field
0x2A1 Maintenance
Mass Units
Mass Units Enumera- Read /
tion
Write
0x0FE Requested Vol- #####.# (cc)
ume
Read Only
0x2A2 Maintenance
Time Units
Mass Units Enumera- Read /
tion
Write
*
Maintenance dispensed volume/time can only be set
to 0.
0x2AD Valve 1 Swirl Swirl Enumeration
Read /
Write
Association
(Swirl Zone)
Swirl Commands
0x2AE Valve 2 Swirl Swirl Enumeration
Read /
Write
Association
(Swirl Zone)
Output
Bits
264-275 Description
Read or
Write
0x2AF Valve 3 Swirl Swirl Enumeration
Read /
Write
Gateway Units
Association
(Swirl Zone)
0x004
0x005
0x006
0x007
Software Part
Number
STR_3_0
Read Only
Read Only
Read Only
Read Only
Read Only
0x2B0 Valve 4 Swirl Swirl Enumeration
Read /
Write
Association
(Swirl Zone)
Software Part
Number
STR_7_4
0x2B5 End Job On
Alarm
Boolean
###
Read /
Write
Software Part
Number
STR_11_8
STR_15_12
0x3FB Style Bits
Read /
Write
Software Part
Number
0x115
0x116
0x118
Command
Value
uint12
Read /
Write
0x00B
0x400
Software Version Version
Swirl Speed
Source
Speed Source
Enumeration
Read /
Write
Error Reset /
Remote Start field
Dispense Control 2 Bit- Read /
Write
0x401
0x403
0x404
Swirl Fixed Speed ##### (RPM)
Read /
Write
Disable Dis-
pensing
Boolean
Read /
Write
Swirl Speed Scal- ### (percent)
ing
Read /
Write
0x3FF Dispense Con- Dispense Control 1 Bit- Read /
trol field Write
Swirl Maintenance ###### (hours)
Read /
Write
0x0FB Inlet Pressure Pressure: #### (psi); Read Only
Time Advisory
Limit
###.# (bar); ##.##
(Mpa)
0x3FF
Swirl - Actual Run ###### (hours)
Time
Read /
Write
0x0FC Outlet Pres-
sure
Pressure: #### (psi); Read Only
###.# (bar); ##.##
(Mpa)
0x2FC Swirl Status Bits 1 Swirl Status Bit-
field 1
Read Only
0x0DC Pressure Com- Pressure: #### (psi); Read Only
mand
###.# (bar); ##.##
(Mpa)
0x4FE
0x500
Swirl Actual Speed ##### (RPM)
Read Only
Swirl Control
Swirl Control
Enumeration
Read /
Write
0x403
0x404
0x406
0x409
Flowrate Com- ##### cc/min
mand
Read Only
Read Only
Read Only
0x501
Swirl Requested
Speed
uint12
Read /
Write
Flowrate
Actual
##### cc/min
Fluid Plate Sta- Fluid Plate Status 0
tus 0
bitfield
Fluid Plate
Faults
Gateway Error Number Read Only
136
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Appendix C - Communications Gateway Module (CGM) Connection Details
Units Definitions
Unit s String
Definition
Command Value Source Enu- 0 - Display, 1 - Command Cable, 2 - Gateway
meration
Bit .........Function
3 ............Valve 2 On
4 ............Valve 3 On
5 ............Valve 4 On
6 ............Error Reset
7 ............Remote Start/Purge
Dispense Control 1 Bitfield
Dispense Control 2 Bitfield
0 ............Style Strobe
1 ............Dispense Complete
2 ............Valve 1 On
Bit 14 - Error Reset, Bit 15 - Remote Start
Dispense Trigger Source Enu- 0 - Command Cable, 1 - Gateway, 2 - Combined, 3 - Command Cable 3x
meration
Error Type Enumeration 1
Error Type Enumeration 2
Fault Error Code
0 - None, 1 - Alarm, 2 - Deviation
1 - Alarm, 2 - Deviation
A 32-bit string in the format of 0xDDCCBBAA where 0xAA represents the most significant char-
acter in the string and 0xDD represents the least significant character in the string.
Flow Meter Type Enumeration 1 - Volume, 2 - Mass
Bit .........Function
3 ............Dispense In Process
4 ............Dispensed Volume OK
5 ............---
7 ............Purge in Process/Remote
Start in Process
Fluid Plate Status 0 Bitfield
0 ............Dispenser Ready
1 ............Dispense No Alarm
2 ............Dispense No Error
6 ............Dispenser Purge Request
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
11 ......... Alarm Active
12 ......... Deviation Active
13 ......... Advisory Active
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
Fluid Plate Status Bitfield
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
31 ......... Remote Start/Purge
10 ..........Job Cycle Complete
Job End Mode Enumeration
0 - Timer, 1 - Gateway
Maintenance Units Enumeration 0 - Volume, 1 - Mass, 2 - Time
Mass Units Enumeration
Precharge Settings Type
0 - lb, 1 - kg
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
Rate Units Enumeration
sint32
0 - psi, 1 - bar, 2 - MPa
0 - x/min, 1 - x/sec
A 32 bit positive or negative value
0 - Display, 1 - Gateway
Speed Source Enumeration
STR_X_Y
A 32 bit value where X signifies which character in the string that the most significant byte rep-
resents and Y signifies which character in the string that the least significant byte represents.
Swirl Control Enumeration
Swirl Enumeration
0 - Swirl Enable
0 - None, 1 - Swirl 1, 2 - Swirl 2, 3 - Swirl 3, 4 - Swirl 4
0 - Swirl Active, 1 - Swirl Ready, 2 - Swirl Enabled
Swirl Status Bitfield 1
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
A 12 bit positive value
uint12
uint32
Version
A 32 bit positive value
A 32 bit value in the format of 0x00CCBBAA where 0xAA represents the major version, 0xBB
represents the minor version and 0xCC represents the build version.
Volume Units Enumeration
0 - gal(US), 1 - gal(UK), 2 - Liters
3A2098H
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Appendix D - I/O Signal Descriptions
Appendix D - I/O Signal Descriptions
This section provides details about the CGM and DGM
Automation Input and Output signals.
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:
Automation Inputs
•
The system purge interval timer has expired.
Dispenser (Fluid Plate) Ready
This signal is 0 on power up. This signal will be 1 under
in the following conditions:
Dispenser (Fluid Plate) Remote Start / Purge in
Process
•
•
The system is in an active state, and
The dispenser (fluid plate) does not have an
active Alarm (Deviations have no effect).
This signal is 0 on power up. This signal will be 1 under
the following conditions:
•
A remote start sequence is in process. This sig-
nal shall remain asserted until the dispense
equipment has achieved Dispense Ready sta-
tus.
Dispenser (Fluid Plate) No Alarm
For systems with a CGM, this signal will be 1 under the
following condition:
•
A purge sequence is in process. This signal
shall remain asserted until the purge sequence
is complete.
•
•
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
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.
Dispenser (Fluid Plate) No Error
For systems with a CGM, this signal will be 1 under the
following condition:
Pressure Units
•
The system does not have an error (alarm, devi-
ation, or advisory).
Value
Units
•
For systems with a DGM, this signal can be
configured to be active high or active low. See
Discrete Gateway (Automation) Setup
psi
0
1
2
3
bar
MPa
Dispense in Process
reserve
This signal is 0 on power up. This signal will be 1 under
the following condition:
Errors
•
The system is in the middle of a job.
Error numbers are formed by 8 bits. This is the error
number in the system.
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.
138
3A2098H
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Appendix D - I/O Signal Descriptions
Automation Outputs
Style
Remote Start / Purge
The desired style of the next job. These 8 bits are read
at the start of a job to determine the selected style.
This bit is used to restart the dispense system from any
“not-ready” state. If the system is already in a Dispense
Ready state, this signal shall initiate a purge based on
the configured purge parameters.
Style Strobe
This bit is used to start a new job. A new job is started
when the style strobe changes from 0 to 1.
Swirl X Enable
This bit is used to signal the on and off status of each
swirl dispenser motor.
Dispense Complete
This bit is used to signal the end of a job. A job is ended
when this signal changes from 0 to 1.
Swirl Command Value
This 12-bit value indicates a swirl speed command from
0-10 volts. 0 volts (0x000) represents a speed of
6,600 rpm and 10 volts (0xFFF) represents 24,000 rpm.
Dispense Valve x On
These 4 bits are used to signal the turn on and turn off
of each of the 4 dispense valves on the applicable fluid
plate.
Dispense Valve X Precharge On
These 4 bits are used to turn on precharge for each of
the 4 dispense valves when the precharge mode is set
to Gateway.
Command Value
This 12 bit value indicates the analog command value
from 0-10Volts (0x000-0xFFF). This analog value is
scaled to a flow rate (in bead mode) or pressure (in
pressure or shot mode) command based on the 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.
3A2098H
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Technical Data
Technical Data
*Minimum Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 cc/minute with high-resolution (ambient) helical flow
meter
50 cc/minute with heated helical flow meter
*Maximum Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . 7500 cc/minute with high-resolution (ambient) helical flow
meter
22,500 cc/minute with heated helical flow meter
37,500 cc/minute with separate flow meter
Maximum Fluid Working Pressure
feed pressure to fluid plate (cartridge regulator) . . . . 6000 psi (41 MPa, 414 bar)
feed pressure to fluid plate (mastic regulator) . . . . . . 5000 psi (35 MPa, 345 bar)
at regulator outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 psi (31 MPa, 310 bar)
at regulator outlet with electric heat components . . . 3500 psi (24 MPa, 241 bar)
Minimum Fluid Working Pressure (at regulator outlet). . . 100 psi (0.7 MPa, 7.0 bar)
Air Supply Pressure Range . . . . . . . . . . . . . . . . . . . . . . . 60-120 psi (0.4 - 0.8 MPa, 4.1- 8.3 bar) - 10 Micron 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full load-1.4A, fuse rating-2.5A
24 Vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full load-4A, fuse rating-4A
Power Supply Voltage Range . . . . . . . . . . . . . . . . . . . . . 100-240 Vac, 50-60 Hz, single phase
Operating Temperature Range
control center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°F (4°C) - 120°F (49°C)
heated fluid plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°F (4°C) - 400°F (204°C)
ambient fluid plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°F (4°C) - 120°F (49°C)
Operating Humidity Range. . . . . . . . . . . . . . . . . . . . . . . . 0 - 90% non-condensing
* Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expected to
shear under pressure. New applications or fluids should always be tested to determine proper line sizes and equip-
ment selections. See your Graco authorized distributor for other capabilities.
Control Center Assembly Technical Data
100 - 240 Vac Assemblies
24 Vdc Assembly
Voltage
100-240 Vac
1
24 Vdc
Phase
---
Frequency
Full Load Current
Fuse Rating
50-60 Hz
1.4 A
---
4.0 A
250 Vac, 2.5A T
125 Vac, 4A F
140
3A2098H
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Technical Data
Fluid Plate Assembly Technical Data
Mounting dimensions and parts breakdowns for the fluid plate assemblies are in the installation section of this man-
ual.
Cartridge Regulator
308647
Mastic Regulator
307517
Regulator Manual
Weight - No Flow Meter
Weight - Helical
25.5 lb (11.6 kg)
33 lb (15 kg)
40 lb (18 kg)
48 lb (22 kg)
Fluid Port Inlet
Helical: 3/4 in. npt(f)
1/2 in. npt(f)
3/4 in. npt(f)
Fluid Port Outlet
3/4 in. npt(f)
Maximum Fluid Working Pressure*
Air Supply
1/4 in. npt(f)
1/4 in. npt(f)
Maximum Air Working Pressure
Minimum Air Working Pressure
Fluid Operating Temperature
100 psi (0.7 MPa, 7.0 bar)
60 psi (410 kPa, 4.1 bar)
Ambient 40° - 120°F (4° - 50°C)
100 psi (0.7 MPa, 7.0 bar)
60 psi (410 kPa, 4.1 bar)
Heated 40° - 400°F (4° - 204°C)
Ambient 40° - 120°F (4° - 50°C)
Minimum Flow Rate - Helical
Ambient 25 cc/min
Heated 50 cc/min
Ambient 25 cc/min
*Maximum system pressure depends on dispense valve.
Air outlets, open and close to dispense valve
Electric Power Requirements
5/32 in. (4 mm) tube fittings
24 Vdc or 100-240 Vac
24 Vdc
For use when dispensing fluids that meet at least one of
the following conditions for non-flammability:
Power Supplied to Dispense Valve Solenoid(s)
Fluid Specifications
•
•
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)
Swirl Dispenser Technical Data
Refer to manual 309403.
3A2098H
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Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 3A2098
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2011, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised August 2014
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