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Summary of Contents for PVA PVA2000
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Page 1: Troubleshooting
Using The Electronic Manual Requirements The following is a list of system requirements for the electronic manual: Pentium Processor 64 MB of RAM 50 MB of Available Hard Drive Space ® Windows 98 SE, Millenium, NT, 2000, or XP Operating System CD-ROM Drive 800 x 600 Screen Resolution ®... - Page 2 Disclaimer CAREFULLY READ ALL OF THE TERMS AND CONDITIONS OF THIS DOCUMENT BEFORE INSTALLING THIS MEDIA. OPENING OF THIS MEDIA CONSTITUTES ACCEPTANCE OF ALL OF THE TERMS AND CONDITIONS OF THIS AGREEMENT. If you do not agree to these terms and conditions, you may return this media and the other components of this product.
- Page 3 Coating and Dispensing System Manual - PVA2000 - PVA3000 - PVA2000C - PVA750 - PVA550 - PVA250 info@pva.net (518) 371-2684 15 SOLAR DRIVE - HALFMOON, NY 12065 PHONE: (518) 371-2684 - FAX: (518) 371-2684 All Rights Reserved, Copyright (c) 2003 Precision Valve & Automation, Inc.
- Page 4 PVA250 Automated Dispensing System P/N: SNGT1133 S/N: W1948 Singletec, Inc. Operating Guide 15 Solar Drive – Halfmoon, NY 12065...
- Page 5 Table Of Contents Configuration Operation and Maintenance Manual ® PathMaster Manual Cut Sheets Schematics Software...
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Page 6: Configuration
Configuration Configuration Operation and Maintenance Manual ® PathMaster Manual Cut Sheets Schematics Software... -
Page 7: Power Requirements
Configuration Notice This document, including the information contained herein, is the property of Precision Valve & Automation, Inc. and is considered confidential and proprietary information. It is delivered on the express condition that it not be used, disclosed, or reproduced in whole or in part, for any reason without prior written consent of Precision Valve &... - Page 8 Optional Equipment Documentation on non-Standard equipment installed on the workcell is included with this manual. To view these documents click the button below. Select Optional Equipment...
- Page 9 Notes...
- Page 10 Operation and Maintenance Configuration Operation and Maintenance Manual ® PathMaster Manual Cut Sheets Schematics Software...
- Page 11 Operation and Maintenance Manual Warnings, Cautions, and Notes Certain warning symbols are affixed to the machine and correspond to notations in this manual. Before operating the workcell, identify these warning labels and read the notices described below. Not all labels may be used on any specific system.
- Page 12 Warning notices are used to emphasize that hazardous voltages, current, temperatures, or other conditions that could case personal injury exist in this equipment or may be associated with its use. Only qualified personnel should enter areas designated with this symbol. 6010 Before performing any repairs or maintenance to the system, read and understand the manuals provided with the unit.
- Page 13 This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance.
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Page 14: Preface
PVA250™ o PVA550™ o PVA750™ o PVA1000™ o PVA2000™ o PVA200C™ o PVA3000™ All machines are referenced throughout the manual as the workcell. This manual provides information and functionality descriptions covering all the common options and configurations for a workcell. -
Page 15: Content Of This Manual
Content of This Manual Introduction. Provides an overview of the workcell functionality and physical characteristics. Installation and Setup. Describes the procedures for installing the workcell and preparing the system for use. Included in this chapter are instructions for unpacking, inspecting, and installing the workcell. Operating Safety. -
Page 16: Table Of Contents
Contents Table Of Contents Preface ............................iv Notice & Disclaimer ..........................iv Revisions to This Manual ........................iv Content of This Manual ......................... v Contents............................vi Table Of Contents..........................vi List of Tables ............................ix Introduction ..........................10 System Description ..........................10 Year 2000 Compliance ......................... - Page 17 Light Tower Operation ........................18 Exhaust Verification ..........................18 Machine Safety Check ......................... 19 Homing the Axes ..........................19 Standby Position ..........................20 Solvent Cups ............................20 Flow Monitor System........................... 20 Priming the Flow Monitor ......................20 Determining the Correct Material Volume ................... 21 Setting the Material Volume Check....................
- Page 18 Door Interlock Check........................... 46 Encoder Feedback Test........................46 Motor Feedback Test ........................... 47 Maintenance ..........................48 Schedule............................... 48 Procedures ............................50 Ball Screw Slides.......................... 50 Inspection ............................. 50 Conveyor Belt Replacement ......................50 Valves ............................50 Servicing the Inline Material Filter....................50 Exhaust Fan Setup ........................
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Page 19: List Of Tables
Table 4 – Light Tower & Buzzer Status ..................... 18 Table 5 – Stop Code Definitions......................... 36 Table 6 – PVA550™, PVA1000™, PVA2000™ and PVA3000™ systems Fault Diagnosis ....38 Table 7 – PVA250™, PVA750, and PVA2000C Fault Diagnosis ............. 41 Table 8 –... -
Page 20: Introduction
Introduction System Description The workcell has been designed specifically for applications involving industrial dispensing and conformal coating. The flexibility of the machine allows it to be used effectively for a wide range of applications. The valves are mounted to the end effector of a two, three or four axis Cartesian robot. All dispensing / spraying is performed within the lexan enclosed work area. -
Page 21: Environmental
Environmental Noise Levels The audible noise level of the workcell is below 65 dBA. Materials/Chemicals There are no dangerous materials or chemicals used in the operation of the machine except for the required application material. The application material should include a Material Safety Data Sheet (MSDS) which specifies known dangers and toxicity. -
Page 22: Installation And Setup
Installation and Setup WARNING The following procedures should be performed by qualified persons in accordance with this manual and applicable safety regulations. A “qualified person” is defined as “a person or persons who, by possession of a recognized degree or certificate or professional training, or who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work.”... -
Page 23: Operating Environment
Master Reset 1200 Baud rate selection 9600 Baud rate selection 19.2K Baud rate selection HSHK Hardware Handshaking (PVA550™, PVA1000™, PVA2000™, and PVA3000™ models) Table 2 – DMC-2100 Dip Switch Settings Switch Position Description MRST Master Reset Software Handshaking HSHK Hardware Handshaking... -
Page 24: Operator Interface Dip Switch Settings
Operator Interface Dip Switch Settings NOTE: During normal operation there is no need to adjust the dip switch settings. The operator interface must be configured to communicate with the controller. The correct settings are given in the table below. These setting enables 9600 baud, 7 data bits, 1 stop bit and 1 start bit. Table 3 –... - Page 25 SMEMA cables have male 14-pin amp-type CPC connectors. The cables are straight-through, so orientation does not matter. On each module, the wire to the J1 (Previous) plug must connect to the J2 (Next) plug on the machine upstream. Similarly, the J2 plug on each machine must connect to the J1 plug on the machine downstream, as shown in the following diagram: Operation and Maintenance Manual Rev M(ii) 4/03 - 15 -...
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Page 26: Operating Safety
Operating Safety Notices and Warnings Safety glasses, gloves, and long sleeved clothing are necessary precautions when working with automated industrial equipment. Read and understand all operating manuals before using this equipment. Do not disable the safety features of the machine. Lock-out and tag the air and power supplies before servicing or cleaning any part of this equipment. -
Page 27: Light Curtain
Light Curtain Some machines are equipped with an optional light curtain. The light curtain is redundant and self checking. The control signals from the light curtain are included as safety devices in the safety circuit. On machine power up, the light curtain must be reset by turning the key switch to ‘Reset’ for at least ½ second. Exhaust Fan Some machines are equipped with an exhaust fan. -
Page 28: Operation
Operation Startup Procedure 1) Check the fluid and air pressures. 2) Close all doors and turn the DOOR BYPASS key switch to the OFF position (If applicable). 3) Engage the EMERGENCY STOP button. 4) Turn on main power using the red rotary switch at the front or rear of the machine (Black “rocker” switch on PVA250™... -
Page 29: Machine Safety Check
Machine Safety Check Once initialize and exhaust verification is complete, the operator interface displays the following message: Machine Safety Check Press F1 to initiate. The machine safety check ensures the workcell safety devices (emergency stop, door interlocks, light curtain, etc.) are operating properly. During startup, the operator must enter the safety check and complete it successfully. -
Page 30: Standby Position
Homing axes. Please wait... The axes home in the following order: Z, W, then X & Y simultaneously. Standby Position Once the machine has completed the homing sequence or finishes a required calibration procedure (if so equipped), it moves to the standby position. Standby is a defined location, DISTINCT from the home position, although in some circumstances it may be defined as the same position as home. -
Page 31: Determining The Correct Material Volume
Slowly increase the material pressure regulator until material flows from the disconnected material line. Turn the outlet material valve to the closed position. Bleed pressure for pressure vessel and adjust the material pressure regulator to 0 P.S.I Reconnect the material line to the inlet port of the flow monitor. Open the valve (dispense or spray) using the manual purge procedure outlined in the operations and maintenance manual. -
Page 32: Flow Monitor Calibration
volume was outside acceptable parameters, the flow error screen appears. This screen is similar to the flow data screen shown above. The board should be removed before returning the machine to operation. NOTE: Any changes made to settings in the material delivery system (material pressure, stroke adjustment, etc.) may affect the data from the flow monitor. -
Page 33: Calibration Procedures
Calibration Procedures The workcell has one of three calibration methods: Standard, Operator Defined and Sensor Defined. If a Sensor Defined or Operator Defined method is installed on the workcell, the machine may or may not automatically enter its particular calibration mode following the homing sequence depending on the application the workcell was set up for. -
Page 34: Cycle Stop
CAUTION If maintenance is to be performed during the shutdown, be sure to lockout and tag the machine. Cycle Stop Cycle Stop PROG AUTO STAT SETUP The Cycle Stop state is the default state for the workcell. All other modes and capabilities can be accessed from this state through the function key buttons listed below. -
Page 35: Standard
Standard Calibration EXIT HOME Once at the preset point, the operator must physically reposition the dispense needle to ensure proper calibration. [F1] EXIT – Leave needle calibration and return to Cycle Stop. [F3] HOME – Home the system. Operator Defined Calibration AXIS: X&Y EXIT... -
Page 36: Manual Mode
[F3] HOME – Home the system. This automatically runs the calibration routine afterward. Manual Mode PVA550™, PVA1000™, PVA2000™, PVA250™, PVA000C™ models PVA3000™ models. Jog Mode Head: FC100 Axis: X&Y Manual Mode Head: FC100 EXIT TEACH PURG CONV AXIS EXIT TEACH PURG Manual mode allows manual control of all devices on the workcell. -
Page 37: Valve Selection
Valve Selection Valve Functions Head: FC100 EXIT PURG DOWN ROTA ROTB Units equipped with multiple valves have this mode. The active head or valve can be selected from the Valve sublevel menu. The pneumatics Z-slide(s) and rotary(s) (if equipped) can be actuated from the Valve submenu. -
Page 38: Status Mode
If the workcell possesses a light curtain, it operates in a similar manner as a stand-alone model without a light curtain. However, the light curtain may be used to initiate cycles (bypassing the hand switches). Screen during cycle. Screen with valves deactivated. In Cycle... -
Page 39: Setup Mode
Encoder Status Motor Status (all except PVA250™) X-axis Motors On/Off Torque Tor.Lim. X-axis Enc.Pos. Com.Pos. Pos.Err. 000000 000000 000000 0.0000 0.0000 Sensor Status Tuning Status X-axis Sensors Home For.Lim. Rev.Lim. X-axis Tuning 000.00 000.00 000.00 Setup Mode Setup Counter Auto Purge Run Mode EXIT *OFF... -
Page 40: Trackball Control
[F1] EXIT – Leave Conveyor Control and return to the previous mode. [F5] Conveyor ON – Turn the conveyor on. [F6] Conveyor OFF – Turn the conveyor off. [F7] Stop ON – Turn the board stop on. [F8] Stop OFF – Turn the board stop off. Trackball Control (All models except PVA250™, PVA750™, PVA2000C™) Trackball Control... -
Page 41: Teach Pendant
Teach Pendant PVA550™, PVA2000™, and PVA3000™ are equipped with a teach pendant which has a trackball, teach button, purge button, axis selection button, and LED indicators for selected axes and teach function. TRACKBALL – The trackball allows the operator to jog each axis independently or X and Y together. - Page 42 [F5] -Y – Jog the Y axis in the negative direction. [F6] -X – Jog the X axis in the negative direction. [F7] +X– Jog the X axis in the positive direction. [F8] +Y – Jog the Y axis in the positive direction. To jog an axis, press and hold the function key that corresponds to the axis and direction of motion desired.
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Page 43: Fault Recovery
Fault Recovery Recovering from Emergency Stop and Other Machine Errors If the operator uses one of the EMERGENCY STOP push buttons or the machine encounters a system error, this procedure should be followed to return the machine to the Cycle Stop state. NOTE: The PVA250™, PVA750™, and PVA2000C models will require the workcell to rehome after recovering from and EMERGENCY STOP, or any other error. -
Page 44: Pneumatic Error Recovery Procedure
Low Material Level Low Exhaust Flow Material A Level low. Exhaust Flow low. Press F1 to continue. Repair and press F1. Low Air Pressure There is an air pressure gauge mounted on the main regulator at the rear of the machine, which may include a low pressure sensor. -
Page 45: Run-Time Error Recovery Procedure
FC100 Z-slide down failed. Repair and press F1. The operator should determine the cause of the problem before pressing F1 and continuing. Refer to the pneumatic actuator failure section of Troubleshooting (page 38) for more information about diagnosing the problem. Run-Time Error Recovery Procedure A run-time error is generated during the execution of the program. -
Page 46: Limit Error Recovery Procedure
Limit Error Recovery Procedure The machine encounters a limit error in the following cases. First, if the path program attempts to move the dispense / spray head past one of the software limits. If a software limit caused the error, then either the path or the software limits must be changed. -
Page 47: Subroutine Error
Variable error. Initializing... If the error occurs more than one time during the startup of the machine, the following message is displayed. This indicates a bug in the main program. The original program should be downloaded to the controller. Unrecoverable variable error during startup. -
Page 48: Troubleshooting
5) If the problem is programming related, a hard copy or email of the program in question may be requested by PVA. Please be prepared to send it. The PVA fax number is (518) 371-2688, or the customer service representative will provide an email address, if all parties are email capable. - Page 49 Operation Other Symptoms Possible Cause Corrective Action • Blown fuse. Check FU-1 which is located inside the electrical enclosure. Replace if necessary. • Homing the axes. Home sensor is out of Depress the EMERGENCY The end effector position or too far away STOP push button.
- Page 50 Operation Other Symptoms Possible Cause Corrective Action • Axis runs away. Motor power connections Check the phasing using the are wired incorrectly. electrical drawings. • Z axis encoder Z axis encoder/brake cable Check the cable does not work. is loose or not connected. connections.
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Page 51: Open Loop Stepper Systems
Operation Other Symptoms Possible Cause Corrective Action • Reset the exhaust fan overload relay. • The filter and The overload relay current Verify the current setting on ducting are fine. setting has been changed. the overload relay. Please The motor refer to exhaust fan setup. - Page 52 Operation Other Symptoms Possible Cause Corrective Action on GPIO interface board. • Amp cables are loose or Check J9 and J11 disconnected connections on GPIO interface board. • Motor Cable(s) are loose or Verify CPC connections at disconnected motor and terminal connections on amp.
- Page 53 Operation Other Symptoms Possible Cause Corrective Action particular pressure settings. • Restricted air line. Correct any tight bends or restrictions in the air lines. • Loose Fitting or Tubing Tighten connection. Connection. • Frayed or damaged air line. Replace the damaged air line(s).
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Page 54: Controller Master Reset
Operation Other Symptoms Possible Cause Corrective Action relay. Controller Master Reset Performing a controller master reset returns the Galil controller to factory defaults. All memory, variables and settings stored in the controller are lost. DO NOT perform this operation unless the operator understands how to download the main program and dispense / spray programs. -
Page 55: Power Check
6) Perform a Master Reset so that the controller recognizes the new EEPROM firmware. Please refer to the Controller Master Reset procedure on page 44. 7) Return the old EEPROMs to Precision Valve & Automation. PVA must have the old EEPROMs back in order to continue service in the future. -
Page 56: Door Interlock Check
Door Interlock Check (All models except PVA250™, PVA750™, PVA2000C) If you experience a failure at step 14 of the Power Check, follow this procedure: 1) Engage the Door Bypass switch. If CRM-1 engages when the Door Bypass switch is engaged, there may be a failure in the left door interlock switch, the right door interlock switch, or their wiring. -
Page 57: Motor Feedback Test
13) Move the W axis in the positive direction and display the current position. 14) Move the W axis in the negative direction and display the current position. 15) Turn the machine OFF. 16) Reconnect the motor power cables. 17) Turn the machine ON. Motor Feedback Test (All models except PVA250™, PVA750™, PVA2000C) Use this procedure to verify that the motor power and hall effect sensors are wired correctly. -
Page 58: Maintenance
Maintenance Schedule Table 8 – Preventive Maintenance Schedule Type Of Service Service Area Every Shift Weekly Monthly Quarterly Dispensing Check all fluid Check for material Inspect the fluid Check the inline Equipment pressures and buildup on fixtures delivery lines for material filter for dispense weights. - Page 59 Type Of Service Service Area Every Shift Weekly Monthly Quarterly Dispensing / Lubricate packing Spraying as per the Equipment manufacturers recommendations. Operation and Maintenance Manual Rev M(ii) 4/03 - 49 -...
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Page 60: Procedures
Procedures Ball Screw Slides The slides should be greased via the fitting on the carriage every 100KM or approximately once a month. Clean any buildup on the ballscrew and seals. The manufacturer recommends using a lithium type soap base grease (JIS Type 2). Not all models have slide with grease fitting. If a slide does not have a grease fitting, simply apply a small amount of grease to the slide, then work the slide back and forth. -
Page 61: Exhaust Fan Setup
Exhaust Fan Setup 1) Turn power OFF. 2) Open the electrical enclosure. 3) Set the overload relay current for 1.0 * FLA for the motor. The FLA is shown on the motor nameplate. 4) Set the reset button to Manual. 5) Restart the machine. -
Page 62: Appendix A - Definitions
Purge Position – The location in the workspace where the head moves to perform all auto purge operations. PVA – Precision Valve & Automation, Inc. Solvent Cups – Reservoirs containing a compatible solvent used to maintain the dispense / spray valves when the workcell is not processing product. - Page 63 Teach – A process by which the workcell registers its current gantry location with PathMaster® to create a motion sequence. Workcell – A model PVA250™, PVA550™, PVA750™, PVA1000™, PVA2000™, PVA2000C™ or PVA3000™ automated system. Operation and Maintenance Manual Rev M(ii) 4/03...
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Page 64: Appendix B - Serial Communication
Appendix B – Serial Communication Serial Communication Overview The workcell communicates with a computer using the EIA RS-232C standard. The computer is the Data Terminal Equipment (DTE Device) and the controller is the Data Communications Equipment (DCE Device). The tables below give a brief overview of the connections required to communicate between DTE and DCE devices. -
Page 65: Computer 9 Pin To Workcell Programming Port
Secondary CTS Secondary TD DCE Transmitter Clock Secondary RD Receiver Signal Clock Unused Secondary RTS Data Terminal Ready (DTR) Signal Quality Detector Ring Indicator (RI) Data Signal Rate Selector DTE Transmitter Clock Unused Computer 9 Pin to workcell Programming Port For standard communication between a computer and a workcell. -
Page 66: Appendix C - Error Codes
Appendix C – Error Codes DMC Error Codes Table 13 – DMC Error Codes ID Description Unrecognized command Command only valid from program Command not valid in program Operand error Input buffer full Number out of range Command not valid while running Command not valid while not running Variable error 10 Empty program line or undefined label... - Page 67 ID Description 58 Unrecognized command in a command response (i.e._GNX) 59 Mismatched parentheses 60 Download error - line too long or too many lines 61 Duplicate or bad label 62 Too many labels 65 IN command must have a comma 66 Array space full 67 Too many arrays or variables 71 IN only valid in task #0...
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Page 68: Appendix D - Open Loop Velocity Settings
Appendix D – Open Loop Velocity Settings Maximum Velocity settings Due to the “open loop” nature of the stepper driven systems, we must set a maximum speed for each axis that must not be exceeded. Unlike our “closed loop” servo systems which generate a position error if the user attempts to run the motors faster than they are capable of moving, an “open loop”... -
Page 69: Appendix E - Wiring Schematic Legend
Appendix E – Wiring Schematic Legend Wire Numbering Table 16 – Wire Numbering Type Example Description DC Control 400 - 599 DC Supply 300 - 399 AC Control 200 - 299 AC Control Power 100 - 199 AC Supply Power Segment 1 of AC Supply Phase 2 Ground Neutral... - Page 70 PathMaster® Configuration Operation and Maintenance Manual ® PathMaster Manual Cut Sheets Schematics Software...
- Page 71 PathMaster® Manual Warnings, Cautions, and Notes Certain warning symbols are affixed to the machine and correspond to notations in this manual. Before operating the Dispensing System, identify these warning labels and read the notices described below. Not all labels may be used on any specific system. Always wear approved safety glasses when operating or working near the Dispensing System.
- Page 72 Warning notices are used to emphasize that hazardous voltages, current, temperatures, or other conditions that could case personal injury exist in this equipment or may be associated with its use. Only qualified personnel should enter areas designated with this symbol. 6010 Before performing any repairs or maintenance to the system, read and understand the manuals provided with the unit.
- Page 73 This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance.
- Page 74 • PVA250™ • PVA550™ • PVA750™ • PVA1000™ • PVA2000™ • PVA200C™ • PVA3000™ All machines are referenced throughout the manual as the Dispensing System or Workcell. This manual provides information and functionality descriptions covering all the common options and configurations for a Dispensing System.
- Page 75 Contents Table of Contents Preface ................................iv Notice & Disclaimer ..........................iv Revisions to This Manual .......................... iv Content of This Manual ..........................iv Contents ................................. v Table of Contents............................v List of Tables ............................viii Definitions..............................9 Notices and Warnings..........................11 Getting Started............................
- Page 76 Main Menu..............................21 File Menu.............................. 21 Edit Menu ............................. 21 Teach Menu ............................21 Modify Menu ............................21 Run Menu ............................. 22 Download Menu ........................... 22 Utilities Menu ............................22 Setup Menu ............................22 Help Menu ............................22 Right-Click Menu ............................. 22 Teach..............................
- Page 77 Quick Play ............................50 Dwell..............................50 Subroutine............................. 50 I/O ................................. 52 DMC Command............................ 53 Valve Offsets ............................53 Offline Programming (FastPath™)......................56 Setting Up the Image ..........................56 Valve Selection ............................. 56 Drawing a Program ..........................57 Commands ............................58 Move ..............................
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Page 78: List Of Tables
List of Tables ® Table 1 – DMC-1500 Dip Switch Settings for PathMaster ................. 12 Table 2 – Communication Program Settings ....................13 Table 3 – Coordinate System Locations ....................... 19 Table 4 – Variable Explanations........................19 Table 5 - Required CAD File Elements ......................60 Table 6 –... -
Page 79: Definitions
Purge Position – The location in the workspace where the head moves to perform all auto purge operations. PVA – Precision Valve & Automation, Inc. Precision Valve & Automation. Solvent Cups – A container filled with an agent designed to prevent the spray and dispensing valves from clogging when idle for a specified period of time. - Page 80 Solvent Purge – An Auto Purge performed after the valves move from the solvent cups prior to processing product. Standby Position – The rest position for the end effector. The machine moves here after homing and after each cycle. This position is usually located near the start point for the program(s). It is NOT the same as the Home Position.
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Page 81: Notices And Warnings
Notices and Warnings • Safety glasses, gloves, and long sleeved clothing are necessary precautions when working with automated industrial equipment. • Read and understand all operating manuals before using this equipment. • Do not disable the safety features of the machine. •... -
Page 82: Getting Started
Run setup.exe and follow the instructions on the screen. For CD-ROM installations, insert the CD into the CD drive. Run setup.exe on the CD drive and follow the instructions on the screen. NOTE: PVA recommends installing the software in its default directory (c:\Program Files\PVA). Tutorials ®... -
Page 83: Computer Settings
9600 Baud rate 19200 Baud rate HSHK Hardware Handshaking Switch NOTE: If hardware handshaking is enabled, and the program uses the message command and a computer is not attached to the Main RS-232 port, the controller eventually halts. A computer must be attached to the controller when handshaking is enabled and message commands are used. -
Page 84: If Something Goes Wrong
5) A hard copy or email of the program in question may be requested by PVA. Please be prepared to send it. The PVA fax number is (518) 371-2688, or the customer service representative will provide an email address, if all parties are email capable. -
Page 85: Working With Materials
Working with Materials Overview The Dispensing System workcell is designed to operate with many different materials in a variety of applications. Learning to use and program with these materials is both an art and a science. There are no concrete rules for an operator to follow; the best method for establishing settings for the system is trial-and- error. -
Page 86: Programming
5) Replace the spray cap. 6) While purging, adjust the atomizing air until the spray is satisfactory. Test the spray pattern on scrap. If the atomizing air is too high, the spray will be misty. If it is too low, there will be splatter. Thin, solvent based materials usually require as little as 0.5 P.S.I., while some silicones require as much as 15 P.S.I. -
Page 87: Beginning Programming
Beginning Programming Overview This section provides important information every operator must know before programming the Dispensing System. A thorough understanding is recommended. Planning Path Programs It is best to plan the path program on paper before starting on the machine. Break the planned program into individual paths and number each path and the points within it, along with which valve is active and what pneumatic operations must be performed. -
Page 88: Inter-Path Movement
Inter-Path Movement ® When programming the Dispensing System via PathMaster it is easy to determine the movement, point- to-point, within a path program via the playback feature. However, it is more difficult to gauge movement between segments. After completing a segment, the Dispensing System immediately moves the axes to the start point of the next segment. - Page 89 The following tables display the command variables that an operator may wish to change. Table 3 – Coordinate System Locations Axis Locations Auto Purge Location PT_APG[0] PT_APG[1] PT_APG[2] PT_APG[3] Solvent Cup Location PT_SOL[0] PT_SOL[1] PT_SOL[2] PT_SOL[3] Calibration Location PT_CAL[0] PT_CAL[1] PT_CAL[2] PT_CAL[3] Standby Location...
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Page 90: Pathmaster® Overview
PathMaster® Overview General ® Precision Valve & Automation, Inc. has developed a Windows application to facilitate the development, ® maintenance and execution of programs for the Dispensing System. PathMaster combines the ease of use ® in typical Windows applications with the specific functionality necessary for programming the Dispensing System. -
Page 91: Main Menu
state of error. The ‘Units’ field is the measurement system in use when programming, and can be altered in ® the Setup section of PathMaster NOTE: In order to teach path programs online, PathMaster® must be connected, in Manual mode, and not in a state of error. -
Page 92: Run Menu
• Valve Parameters – Modify parameters for selected path segments, or the entire program. • Subroutine Call – Change a subroutine call for the selected path segments. Run Menu • Selection – Run (playback) the highlighted path segment on the Dispensing System. •... -
Page 93: Modify
Modify Properties – Modify properties of selected path segment. Offset – Apply an offset to any axis for selected path segments, or the entire program. Speed – Modify speed for selected path segments, or the entire program. Valve Parameters – Modify parameters for selected path segments, or the entire program. Selection –... -
Page 94: Pathmaster® Database
Head – Insert valve functions (up/down, rotary, etc.). Step Over Program – Step to the previous, or next path segment. Play – Play back the selected path segments. FastPath – Open the FastPath™ window for offline programming. PathMaster® Database General The PathMaster®... -
Page 95: Using Pathmaster
® Using PathMaster Starting PathMaster® The first time you run PathMaster® it will need to be configured to run properly with the Dispensing System. To start the PathMaster® application, locate and double-click the PathMaster® icon. The Select Project dialog box will display. Click the Create a New Project radio button and select OK. An information box will appear indicating that no communication settings were found for your controller. - Page 96 Select the preferred measurement system (encoder counts, millimeters, inches). Machine Type Configure PathMaster for a two, three, or four axis gantry. Check the Stepper Motors box if you are running PathMaster® on a PVA250™, PVA750™, PVA2000C™, or any other open loop stepper PVA Dispensing System. Valves Name and configure valve heads as they are used throughout the software.
- Page 97 OK. This simply means that no control handles have been configured yet. When the Edit Registry window appears, click New Controller. Select the controller model installed in the Dispensing System from the table below: PVA Workcell Controller Model PVA250...
- Page 98 Select the communication port that your PC is using: The Comm. Speed should match the comm. speed set on the controller. This is set to 9600 by Precision Valve & Automation prior to shipping. Select hardware handshaking. - Click Finish - Acknowledge the dialog box stating that the controller has been added.
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Page 99: Database Backup And Restoration
PathMaster® was executed. All automatic backups are stored in the Db\Daily sub folder of the PathMaster® application folder. The default location of these files is “c:\program files\pva\pathmaster\db\daily”. Manual Backup A manual database backup is by far the safest method. This method requires a conscious effort by the user, and therefore, should be part of a their programming procedure. -
Page 100: Database Restoration
Database Restoration To restore the PathMaster® database, select the File -> Database -> Restore option from the main menu. You can restore a *.bck (standard backup) or *.abck (automatic backup) file using this option. WARNING: Restoring a PathMaster® database will completely overwrite all existing data prior to the restore operation. -
Page 101: Project Selection
Project Selection It is necessary to select the appropriate project before programming. This option presents itself on startup, ® whenever PathMaster changes the current machine setting or the operator wishes to open a different project. • OK – Select the highlighted project as current. •... -
Page 102: Playback
head 1, valve off time of .75 seconds. D500 Deactivate the path’s head, valve off distance of 500 counts. Wait for input 51 to be off. Turn off output 35. Speed Path speed. 2000 Path speed of 2000 counts/second. Other Varies according to Z=250 Z axis relative move of... -
Page 103: Interacting With The Dispensing System
Next Point – Move to the next point in the path (if one exists). Insert Point – Insert a new point BEFORE the current highlighted point. Delete Point – Delete the highlighted point. Append Point – Add a point to the end of the path. Interacting With the Dispensing System ®... -
Page 104: Teach Pendant
[F8] W – Operate only the W axis. Teach Pendant PVA550™, PVA2000™, and PVA3000™ are equipped with a teach pendant which has a trackball, teach button, purge button, axis selection button, and LED indicators for selected axes and teach function. -
Page 105: Oit Jog Control
OIT Jog Control (PVA250™, PVA750™, PVA2000C™ models only) Jog Mode EXIT Teach AXIS OIT Jog Control allows the operator to jog the gantry via the OIT function keys to perform teach functions. [F1] EXIT – Leave OIT Jog Control and return to the previous mode. [F2] TEACH –... -
Page 106: Tracmouse
TracMouse™ PathMaster® is equipped with the capability to jog the workcell gantry using a pointing device with your computer, such as a mouse or trackball. This feature is especially useful on PVA250™, PVA750™, and PVA2000C™ machines that are not equipped with a teach pendant or built in trackball. The TracMouse™... -
Page 107: Move
Move Programmed Teach Screen Edit Screen This tool allows the operator to program an absolute move. This is a non dispense move. • Approach Type – Select the order of movement for the function. “XY Only” means the controller moves along the X and Y axes simultaneously. “XY then Z” means the controller first moves X &Y and once that motion is complete it moves Z. -
Page 108: 2D Path
2D Path Programmed Teach Screen Edit Screen This tool teaches 2D path segments. The Z axis does not alter its position during the path. • Current Position – If there is communication established with the controller, the current position appears in the text box. Use the trackball on the Dispensing System to change the position. •... - Page 109 NOTES: Playback is only allowed if the Dispensing System is currently in Manual/Jog/Teach mode. 3D Path Programmed Teach Screen Edit Screen This tool teaches 3D path segments. • Current Position – If there is communication established with the controller, the current position appears in the text box.
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Page 110: Arc
NOTES: Playback is only allowed if the Dispensing System is currently in Manual/Jog/Teach mode. Programmed Teach Screen Edit Screen This tool teaches an arc. The operator must select three (3) points on the arc length, including the beginning and end points, moving (clockwise or counter-clockwise) in the direction the axes must move. The Z axis does not alter its position during the path. -
Page 111: Circle
Valve Off Distance – Distance the path traveled when turning the valve off, before the path finishes. • Teach – Record current position. Equivalent to the F2 key on the Dispensing System. • Done – Add to the program. • Cancel –... -
Page 112: Area
• Current Position – If there is communication established with the controller, the current position appears in the text box. Use the trackball on the Dispensing System to change the position. • Input Coordinates – Manual entry of target position. •... - Page 113 This tool teaches rectangular paths. The Z axis does not alter its position during the path. • Current Position – If there is communication established with the controller, the current position appears in the text box. Use the trackball on the Dispensing System to change the position. •...
- Page 114 By using only three points ‘Area’ path segments are calculated in the following manner: Point 1 defines the start of the pattern. Point 2 defines the direction and length of the pattern. After the direction of the pattern is determined, the distance from point 1 to point 3 determines the width of the pattern.
- Page 115 FastMask™ The FastMask™ tool will create an area to be coated as well as keep outs of within that area. There can be up to 99 keep out areas defined within the coating area. Sample PCB Keepouts Once the Fastmask™ tool is selected, a wizard will open: Select the appropriate valve parameters, then teach the opposing corners of the area to be coated, point 1 and point 2.
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Page 116: Polyline
Select the direction of the brush stroke. This is the direction the coating valve will travel when completing the FastMask™ pattern. Click Next to continue: The FastMask™ wizard is complete. Click Finish. The FastMask™ pattern will always begin at the point taught closest to the origin of the gantry (the smallest coordinate in the pattern). -
Page 117: Dot
NOTE: When teaching each segment in a polyline, the last point of the last segment will be used as the first point of the new segment. For example, a polyline arc (assuming it is not the first segment of the polyline) will only require teaching two points since the first point will be taken from the last point of the previous segment. - Page 118 Edit Screen This function teaches a timed dispense. • Current Position – If there is communication established with the controller, the current position appears in the text box. Use the trackball on the Dispensing System to change the position. • Input Coordinates –...
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Page 119: Head
Head Programmed Entry Screen This function allows the operator to enter head (valve) commands into the edit window. The command is placed at the active field location. A head function only appears in the head tool once it has been configured in the machine parameter setup. -
Page 120: Quick Play
Quick Play The quick play tool will play back the selected path segments in wet or dry mode. This is the equivalent of using the Run Selection option on the menu. Dwell The Dwell tool will set a delay in program execution in between path segments. Subroutine Creating •... - Page 121 • • Choose an abbreviated name and brief Choose a reference point on the part to description for the subroutine. The description group the command line sequences. Each serves to assist the operator when selecting execution of the subroutine to be arrayed from multiple saved subroutines.
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Page 122: I/O
• • Assign the first and last points of execution. This screen confirms the final step. By ® The coordinates to be entered are relative to the selecting finish, PathMaster saves your point of origin assigned in the previous steps. created array or random placement and ®... -
Page 123: Dmc Command
DMC Command Programmed Teach Screen Edit Screen This function allows the operator to enter DMC code into the program. Operators who thoroughly understand the DMC language and its usage should only use this. • Done – Accept the current code and add to the program. •... - Page 124 Move valve one (spray) over a fiducial which both the pointing device and valve one can reach. Click the Teach button when valve one is over the fiducial, making sure that the Z height is considered in the taught position. Next move the pointing device over the fiducial.
- Page 125 The next offset must be taught. Move valve two over the fiducial and click the Teach button. Move the pointing device to the same location and press the Teach button. The valve distances have now been taught. PathMaster® Manual Rev. H 6/03 - 55 -...
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Page 126: Offline Programming (Fastpath™)
The offsets have been taught. Click the Done button to save the valve offsets. Click the Save and Close button to exit Machine Parameters. Offline Programming (FastPath™) Before using FastPath™, valve offsets must be configured. For more information on configuring valve offsets, refer to the Valve Offsets section of this manual. -
Page 127: Drawing A Program
Drawing a Program You have setup you machine and program for FastPath™ and now it is time to draw your program on your image. Press CNTRL+F (or click the FastPath™ icon on the programming toolbar) to open the FastPath™ window. The window opens. Press the Zoom-In and Zoom-Out buttons to get the image to a working size. Next choose which command you would like to use to generate a path segment. -
Page 128: Commands
Commands NOTE: All programming tool procedures listed below are for FastPath™ only. Each path segment taught corresponds to the valve selected in the FastPath™ toolbar. Move Click the Move Icon on the FastPath™ toolbar. Next click the location within the image where you would like to move. -
Page 129: Dot
The Dot tool creates a dot at the specified location on the board image. Click the Dot button to select the tool. The default dot on and off parameters for the selected valve are used for each dot. Editing the commands Objects taught on the board image may be modified once created. -
Page 130: Importing Files
Importing Files The PathMaster® import function can import programs, projects, subroutines, and CAD files. CAD Files A 2-dimensional drawing generated in CAD can be imported into PathMaster® as a path program. There are several steps required for a successful import. These include: •... - Page 131 Figure 2: CAD drawing Mirrored on Y axis The drawing must be Rotated Clockwise 90 degrees (-90deg for standard AutoCAD Setup). (Figure 3) Figure 3: CAD Drawing rotated 90deg. The final step is to export the file to a *.dxf. PathMaster®...
- Page 132 In AutoCAD: • Click the File->Export menu. • When the Export Data window comes up, select Save As Type AutoCAD R12/LT2DXF. • Under the Options button ensure that the Export Format is ASCII. • Give the file a name and save it. Importing the file into PathMaster The path will be imported to a new program.
- Page 133 Figure 6: PathMaster import screen #3 Select the file to import. (Figure 7) Figure 7: PathMaster import screen #4 After a successful import the path will be displayed in a path preview window. Figure 8: PathMaster import screen #4 The file will be imported as individual paths. (Line, Arc, etc.) The paths are ready for playback or may be converted to a polyline.
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Page 134: Pathmaster® 1.5 & Pre 1.5 Projects
PathMaster® 1.5 & Pre 1.5 Projects To import a PathMaster® 1.5 or pre 1.5 project, select the File -> Import -> Project -> PathMaster 1.5 or Pre PathMaster 1.5 option from the main menu. When the file dialog box opens, select the location and the file name of the project to import. -
Page 135: Subroutine
Subroutine To export a PathMaster® subroutine to a tab delimited text file, select the File -> Export -> Subroutine -> Text File option from the main PathMaster® menu or the File -> Export Subroutine option from the subroutine edit window menu. Select the location and name of the subroutine and click the Save button. Utilities PathMaster®... - Page 136 Terminal The terminal lets the operator send commands directly to the controller. To send a command to the controller, ensure the keyboard caps lock is on, type the command in the terminal window, and press the Enter key. A response from the controller will display under the command that was issued. If the controller does not understand what it received, it will respond with a “?”.
- Page 137 Labels must appear at the start of a line. An operator manually entering code must ensure that no labels exist in the middle of a line. This generates an error when running the program. Important Commands The DMC programming language contains over 135 commands. For programming the Dispensing System the majority of these commands are not used and even fewer are used for creating dispense paths.
- Page 138 machine. Specifying a positive X circle and a half positive, negative traverse angle yields half negative Y. Similarly, 90° is an clockwise motion in the entirely negative Y circle, 180° Cartesian coordinate system. entirely positive Y, with both having X half positive, half negative. Clear Sequence Clears Memory of prior coordinated sequences.
- Page 139 buffer is full. Motor off. Shuts off motor control. MO (turn all motors off), MOX MO shuts off the motor(s).The (turn off only the X axis motors are reactivated with the motor). SH (servo here) command. Reverse Motion to Position Motor Type No operation.
- Page 140 Tell error code. Displays the number and a text description for a command error. Tell Dual Encoder Tell error. This returns the current Use this command in the position error of the motors. Units terminal screen if a motor are in counts. appears to be working incorrectly.
- Page 141 Digital I/O The digital I/O tool allows for toggling of most digital IO points on the controller. Find the button for the I/O point you wish to toggle, and click it. The button will change colors when the I/O point changes state. The refresh interval is the frequency of the tool display refresh in milliseconds.
- Page 142 Resources The resources tool allows monitoring of controller resources such as available program labels, and program variables. The type of resources displayed on this form will vary depending on the model of controller being used. Variable Watch The variable watch tool will monitor a list of program variables entered by the user. Type a valid program variable name into the watch list on the left, click Start Watch and the value of the variable will be displayed on the right.
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Page 143: Refresh Communication
Refresh Communication If PathMaster® looses communication with the Dispensing System, select the Utilities -> Refresh Communications option from the main menu. If communication is not reestablished, check cables and communication setting. Jog Toolbar The jog tools bar can be used to jog the X or Y axis a specified distance. Select the Utilites -> Jog Toolbar option from the main menu. -
Page 144: Dmc Error Codes
DMC Error Codes Table 7 – DMC Error Codes Description Unrecognized command Command only valid from program Command not valid in program Operand error Input buffer full Number out of range Command not valid while running Command not valid while not running Variable error 10 Empty program line or undefined label 11 Invalid label or line number... - Page 145 Description 60 Download error - line too long or too many lines 61 Duplicate or bad label 62 Too many labels 65 IN command must have a comma 66 Array space full 67 Too many arrays or variables 71 IN only valid in task #0 80 Record mode already running 81 No array or source specified 82 Undefined array...
- Page 146 Cut Sheets Configuration Operation and Maintenance Manual ® PathMaster Manual Cut Sheets Schematics Software...
- Page 147 Cut Sheets Included on this cd are technical data sheets for componants installed on the Workcell. To view these documents click the button below. Select Cut Sheet...
- Page 148 Schematics Configuration Operation and Maintenance Manual ® PathMaster Manual Cut Sheets Schematics Software...
- Page 149 Schematics Included on this cd is a set of schematics for this unit. To view these schematics online, click the button below. ® NOTE: Before you can view the schematics, you must have an AutoCAD compatible ® ™ viewer installed. The AutoCAD viewer, Volo View Express, is provided on this cd.
- Page 150 Software Configuration Operation and Maintenance Manual ® PathMaster Manual Cut Sheets Schematics Software...
- Page 151 Software CD ROM ® • One (1) CD ROM is included with this manual. It contains the PathMaster software used to program the Dispensing System via a Windows interface. To install, insert CD ROM, and click “Install PathMaster® “ NOTE: If you have previously installed PathMaster®, be sure to uninstall the old version before installing the new version.
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