Graco PCF Instructions - Parts Manual
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Graco PCF Instructions - Parts Manual

Precision dispense system
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Instructions - Parts
PCF
Precision Dispense System
Electronically-controlled fluid metering system that provides precise continuous flow of
single-component sealants and adhesives through closed-loop technology.
Not for use in explosive atmospheres.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 4 for model information. See page 5 for
maximum working pressure and approvals.
IMPORTANT:
This manual does not apply to some PCF sys-
tems. See note on page 3 to verify this is the
correct manual for your PCF system.
313377L
EN

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Summary of Contents for Graco PCF

  • Page 1 See page 4 for model information. See page 5 for maximum working pressure and approvals. IMPORTANT: This manual does not apply to some PCF sys- tems. See note on page 3 to verify this is the correct manual for your PCF system.

  • Page 2: Table Of Contents

    Contents Related Manuals ......3 USB Data ....... . . 48 Models .

  • Page 3: Related Manuals

    Graco Standard Warranty ....116 Fluid Pressure Regulators Instruc- 308647 Graco Information ......116 tions-Parts Helical Gear Fluid Flow Meters Instruc-...

  • Page 4: 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 ™...

  • Page 5: Fluid Plate Assemblies

    24B681 Discrete  Discrete Gateway systems do not include automation interface cables. The following Graco accessories are avail- able for wiring to the automation system. Installers should follow Appendix B - Discrete Gateway Module (DGM) Connection Details, page 98, for custom wiring.

  • Page 6: Warnings

    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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
  • Page 7 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.

  • Page 8: System Configurations

    System Configurations System Configurations Typical Ambient System Installation Power Air Supply Drop Site . 1: Typical Ambient System Installation Key: *Control Center (User Interface) *CAN Cable *Fluid Plate Assembly G Fluid Supply System Applicator/Dispense Valve Fluid Supply Hose Sealer Automation Automation Controller Automation Interface Cable *Air Filter Assembly...

  • Page 9: Typical Heated System Installation

    System Configurations Typical Heated System Installation Power Air Supply Drop Site . 2: Typical Heated System Installation Key: AA *Control Center (User Interface) AG Heated Fluid Supply System AB *Fluid Plate Assembly AH Fluid Supply Hose AC Applicator/Dispense Valve AJ Heat Control AD Sealer Automation AK Automation Controller AE Automation Interface Cable...

  • Page 10: Overview

    System Components The PCF fluid metering system combines closed-loop The diagram in F . 3 shows an example of the PCF pressure control with the ability to change bead profiles module and cables. quickly. When used with the optional flow meter, the...

  • Page 11: Fluid Plate Assembly Overview

    Overview Fluid Plate Assembly 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 Fluid Plate Components control design. The module responds to automa-...
  • Page 12 Overview Fluid Regulator Fluid Control Module (FCM) There are three fluid regulator options: NOTE: See LED Diagnostic Information, page 54, for • cartridge signal definitions. • ambient mastic Table 1: FCM Sensor Connections • heated mastic Connection Sensor Description All of the fluid regulator options use air pressure to con- Dispense solenoid trol fluid pressure, provide fast response to electronic Flow meter...

  • Page 13: Control Center Assembly Overview

    Overview Control Center Assembly Overview Front View Side View Open View Gateway Module (100-240 Vac Assembly) (24 Vdc Assembly) . 6: Control Center Components The control center includes the following components: • Advanced Display Module (ADM) with USB; see • Gateway Module, which includes the following five page 14 for details.
  • Page 14 Overview Advanced Display Module (ADM) TI12362a r_24E451_3B9900_1a . 7: Advanced Display Module Component Identification KEY: Callout Function Navigation Buttons Callout Function Navigate within a screen or to a new screen. Power On/Off Button Flat Panel Mount Enables/disables system. Mounts to control center bracket (optional). System Status Indicator LED Model Number Tag Displays system status.
  • Page 15 Overview Gateway Module Front Back See Gateway Module Connector Table TI11972A TI11985A Gateway Module Connectors Table PROFINET or EtherNet/IP DeviceNet TI11814A TI11815A Discrete PROFIBUS TI11816A . 8: Gateway Module Components Key: CA Gateway Module CF Module Status LEDs (see LED Diagnostic Infor- CB Base mation, page 54) CC Fieldbus Connector (see Appendix C - Communi-...

  • Page 16: Installation

    Installation Before Installation Overview • Have all system and component documentation The basic steps to install a PCF system are shown available during installation. below. See the separate component manuals for detailed information. • See component manuals for specific data on compo- nent requirements.

  • Page 17: Install Control Center

    10.50 in. (267 mm) 5.75 in. (146 mm) Ensure the following criteria are met before mounting 17.00 in. (432 mm) the PCF control center: 16.25 in. (413 mm) • Select a location for the control center that allows adequate space for installation, service, and use of the equipment.

  • Page 18: Electrical Connections

    1. Order the 255468 Light Tower Accessory as a diag- • Refer to your local code for the requirements for a nostic indicator for the PCF system. “true earth ground” in your area. 2. Connect the cable from the light tower to the digital NOTICE I/O port (BS) on the ADM.

  • Page 19: Install Fluid Plate Assembly

    13.4 in. (340 mm) Before Mounting Assembly • See component manuals for specific information on component requirements. Information presented here pertains to the PCF fluid plate assembly only. • Have all system and subassembly documentation available during installation. • Be sure all accessories are adequately sized and pressure-rated to meet the system's requirements.
  • Page 20 No connection . 13: Mount Breakout Kit NOTE: Command cable inputs are not isolated from PCF 24 Vdc power. 3. Connect one end of the extension cable (included in the kit) to connection 1 on the FCM and the other To turn on the dispense trigger, connect pin 3 (dis- end of the cable to the bulkhead fitting.
  • Page 21 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. •...

  • Page 22: Install Cable Assemblies

    Installation Install Cable Assemblies NOTE: To prevent system errors, only connect 2. Connect the Gateway module to the automation cables with the power off. controller. 3. Connect power cable from power source to control 1. Connect the CAN cable from the control center to center.

  • Page 23: Install Gateway Module Interface

    The Communications Gateway Module (CGM) provides used. Ensure the installer understands the automa- a control link between the PCF system and a selected tion controller communication architecture and the fieldbus. This provides the means for remote monitoring fieldbus being used.
  • Page 24 This provides the means for remote monitoring and con- trol by external automation systems. See Automation Control (Normal) Operation, page 37, 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.

  • Page 25: System Setup

    System Setup System Setup Overview System Setup The PCF system compensates for temperature, flow, or pressure fluctuations. However, if there is a hardware Configure Control Settings (page 26) change on the supply system or the dispense material is changed, the PCF system must be setup again.

  • Page 26: Configure Control Settings

    System Setup Configure Control Settings 6. Press to move to the Command Value Source Set the controls for the dispense source, how dispense field. Press to open the drop-down list, and commands are sent, and job settings. select Gateway, Command Cable, or Display. Press 1.

  • Page 27: Configure Mode Settings

    System Setup Configure Mode Settings NOTE: The ability to dispense from multiple guns simultaneously is only allowed in either of the fol- lowing scenarios. Set gun commands, including the dispense mode (pres- sure, bead, shot, or full open) and flow rate or pressure •...

  • Page 28: Configure Delay Settings

    Configure Flow Meter Settings Set on and off delays (in milliseconds) for each gun and The accuracy of the PCF volume reporting depends on the regulator. For an explanation of the on and off precise adjustment of the K-factor(s). The fluid plate delays, refer to the On/Off Delays section on page 32.

  • Page 29: Configure Control Loop Settings

    See Verify Flow Meter Calibration, page 35, for instructions. Configure Control Loop Settings The PCF system uses variables (Kp, Ki, and Kd) in the software calculations to accurately and precisely control the fluid pressure. NOTE: It is recommended that these values not be changed from the factory defaults of 32.00 for Kp,...

  • Page 30: Configure Errors

    System Setup Configure Errors 5. Set the desired minimum and maximum pressure limits for the inlet, and the desired maximum pres- sure limit for the outlet. Set the error type (alarm, deviation, or none) that will be issued if the pressure, flow rate, volume, or computed 6.

  • Page 31: Setup Maintenance Schedule/Parameters

    Maintenance Setup Styles Advisory Limits screen (screen 7). The PCF system can store up to 255 styles. See Styles, page 38, for more information about styles and instruc- 3. Press to access the fields to make changes.

  • Page 32: On/Off Delays

    On/Off Delays . 24 and Table 6: Delay On/Off Timing show delay ON and OFF timing. The PCF fluid regulator can physically respond faster Table 6: Delay On/Off Timing than the dispense device and its solenoid. As a result, A Regulator ON...

  • Page 33: Operation

    3. Turn on air and electrical power to the system. 4. Turn on the main power to supply power to the PCF. 7. Press and hold . Dispense fluid until clean, 5. Check Interface Signals: If this is a new installa- tion, power on each system input and verify that air-free fluid flows from the gun.

  • Page 34: Maintenance Mode Operation

    Use maintenance mode to manually check the operation ing material at a maximum desired operating point. of the PCF system components before switching over to automation control (normal operation). See Dispense •...
  • Page 35 Operation Verify Flow Meter Calibration 3. Manually dispense material into the beaker. Hold the beaker so that the stream of material is sub- Most sealant and adhesive materials are compressible. merged in the captured material to minimize air Since the flow meter measures the material under high entrapment in the container.
  • Page 36 Operation Dispense From Maintenance Screen 4. Press to move to the target fields. Enter the 1. Navigate to Home screen 1. target pressure, flow rate, and volume (dependent on control mode) and press to save. 5. Press to move to the gun check boxes. Press to select the desired guns.

  • Page 37: Automation Control (Normal) Operation

    A job is initiated when the automation sends a Style alarms compare the measured volume to the target vol- Strobe signal to the PCF. Once the job is initiated, the ume for pressure mode. PCF will start tracking the amount of volume requested...

  • Page 38: Styles

    Operation Styles 2. Enter the style number in the Style field. The PCF system has the ability to handle up to 255 a. Press while in the Style Name field to styles, depending on the selected option. Styles typically correspond to different components of a specific sys- enter the Keyboard screen.

  • Page 39: Precharge Modes

    Operation Precharge Modes NOTE: See the diagram on the following page. Valve 1 When the “Valve 1” precharge mode is selected, the Static Precharge Mode outlet pressure will be set according to the current pres- sure/flow command using Valve 1 scaling values. Display When Display precharge mode is selected, a static pre- charge pressure can be defined.
  • Page 40 Operation Closed Precharge Scaling Value Dispense Application Direction Dispense Application Direction Dispense Application Direction Value Too Low Ideal Value Value Too High -Controls outlet pressure based on desired command while valves are closed. -Ideal value is typically less than 100% due to the minimal pressure losses within the system when fluid is not flowing.

  • Page 41: Typical Job Cycle

    3. The robot sets the Style Strobe to 1. With the Dispense Trigger Source configured to Com- 4. PCF reads the Style bits to select the new style. The mand Cable, users only need to trigger the dispense system then starts a new job and sets Dispense In applicator to start a job.
  • Page 42 Operation Typical Job Cycle Chart 313377L...
  • Page 43 Operation Control Charts Precharge* - Display Mode  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†...
  • Page 44 Operation Control Charts (continued) Dispense Trigger Source = Gateway 313377L...
  • Page 45 Operation Control Charts (continued) Dispense Trigger Source = Combined 313377L...

  • Page 46: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 1. Shut off the fluid supply to the fluid plate assembly. Dispense Valve Air Solenoid 2. Place a waste container beneath the fluid drain valve under the filter. Place a waste container beneath the dispense valve. 3.

  • Page 47: Shutdown

    1. Press the Stop button (BC). 2. Shut off the material supply to the fluid plate/meter. 3. Follow the Pressure Relief Procedure on page 46. 4. Turn off the PCF system's compressed air supply. 5. Turn off the main power supply. TI12362a .

  • Page 48: Usb Data

    DOWNLOAD folder. related information to memory in the form of log files. PCF maintains three log files: job logs, error logs, and The error log maintains a record of the last 1,000 errors. dispense data logs. Follow the Download Procedure, Each error record in the log file contains: the date and page 49, to retrieve log files.

  • Page 49: Custom Language File

    ADM. 2. The menu bar and USB indicator lights indicate that The PCF system is able to display the following Unicode the USB is downloading files. Wait for USB activity characters. For characters outside of this set, the sys- to complete.

  • Page 50: Upload Procedure

    49, to automatically generate the proper folder structure on the USB flash drive. 9. Install USB flash drive into PCF system USB port. 2. Insert USB flash drive into USB port of computer. 10. The menu bar and USB indicator lights indicate that the USB is downloading files.

  • Page 51: Troubleshooting

    Troubleshooting Troubleshooting NOTE: Check all possible solutions in the chart Troubleshooting for individual regulators and flow below before you disassemble the system. meters is discussed in their separate manuals; refer to Related Manuals on page 3. Also refer to Error Codes and Troubleshooting, page 55, for detailed information on how error codes are communicated.

  • Page 52: Fluid Meter

    Troubleshooting Fluid Meter Problem Cause Solution No flow measurement Flow meter pick-up sensor loose Tighten flow meter pick-up sensor Flow too low Verify flow rate is above minimum for the flow meter selected Loose wiring Verify connection from flow meter to Damaged flow meter pick-up sensor Replace pick-up sensor False measurement...

  • Page 53: Dispense Valves

    Troubleshooting Dispense Valves Problem Cause Solution Valve not opening Air not getting to open port Verify air pressure solenoid No “Gun On” signal from automa- Check input from automation unit tion unit Valve not shutting off Air not getting to close port (except Verify air pressure to solenoid AutoPlus valve) Verify solenoid operation...

  • Page 54: Gateway Module

    Problem Cause Solution No communication Incorrect wiring Check wiring per fieldbus standard. Refer to PCF Gateway status indi- cators and Appendix C - Commu- nications Gateway Module (CGM) Connection Details, page 105. Incorrect fieldbus settings Confirm fieldbus settings at automa- tion controller (fieldbus master) and PCF Gateway (fieldbus slave).

  • Page 55: Errors

    Errors Errors View Errors There are three levels of errors: alarms, deviations, and advisories. Alarms are critical and require immediate correction; therefore, the system automatically shuts When errors occur the highest priority active error is dis- down. Deviations are critical and require attention but played in the menu bar.
  • Page 56 Verify the key token is Error token required to run the installed system Verify the key token part number is correct for the PCF ADM WMC0 19 Display Error ADM error detected; Alarm Detected includes any error not covered by another...
  • Page 57 (user select- Insufficient flow to Increase flow rate to requested minus the able) PCF regulator inlet regulator inlet allowed tolerance PCF regulator is not Incorrect style target regulating correctly volume or tolerance setting Check regulator; repair if necessary B1CX Low Computed...
  • Page 58 Errors Error Gateway Error Code Error No. Error Name Description Error Type Cause Solution Fluid Plate Errors (continued) F6D1 Flow Meter Error Flow Meter error Alarm Problem detected with Verify flow meter is flow meter installed and/or con- nected correctly Replace if necessary WED1 V/P Error...
  • Page 59 Errors Error Gateway Error Code Error No. Error Name Description Error Type Cause Solution Fluid Plate Errors (continued) WFD1 Flow Meter Operating mode Alarm or Selected gun mode Check gun mode set- Required requires flow meter. Advisory settings require flow tings Advisory is issued if (self-clearing)
  • Page 60 Errors Error Gateway Error Code Error No. Error Name Description Error Type Cause Solution Fluid Plate Errors (continued) P3D1 High Pressure Measured outlet pres- Alarm or Incorrect limit set Verify limit is set cor- P4D1 sure greater than Deviation rectly desired outlet pressure (user select- Dispense hose/device...
  • Page 61 Job Timer terminated by job timer used to stop shot dis- timed shot is desired pense EHD1 Purge Timer Purge timer expired Advisory PCF purge timer (style Automation control Expired 0) has expired requests purge EAC1 Maintenance Maintenance mode Advisory...

  • Page 62: Maintenance

    Maintenance Maintenance Prior to performing any maintenance procedures, follow the Pressure Relief Procedure on page 46. 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.

  • Page 63: Advanced Display Module (Adm)

    Maintenance Advanced Display Module Cleaning (ADM) Use any alcohol-based household cleaner, such as glass cleaner, to clean the display. Upgrade Software Upgrade Gateway Module NOTE: Back up the custom language file (if Software installed) before upgrading software. See USB Data, page 48, for more information.

  • Page 64: Upgrade Gateway Module Fieldbus Map

    Maintenance 5. After the red indicator light shuts off, turn off power 3. Press and hold the push button for three seconds to the system. and then release. The red indicator light (CK) will flash twice, pause, and then once after the data 6.

  • Page 65: Upgrade Fluid Control Module (Fcm) Software

    Maintenance Upgrade Fluid Control Module Air Filter Maintenance (FCM) Software To prevent filter element damage, replace air filter every two years or when pressure drop becomes 0.1 MPa (1.0 NOTE: The FCM connection is temporarily disabled bar, 14.5 psi); which ever occurs first. during the installation of the upgrade a key token.

  • Page 66: Repair

    Repair Repair Fluid Plate Assembly Repair Flow Meter For complete flow meter (129) repair instructions refer to the maintenance and repair section of manual 309834. Remove Flow Meter from Mounting Plate This section describes how to remove and replace com- 1.
  • Page 67 Repair Install Flow Meter on Mounting Plate 4. Remove the dispense valve solenoid (132) and 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.
  • Page 68 Repair 5. Secure the new V/P valve to the bracket with Replace Fluid Control Module Base screws. 1. Prepare Fluid Plate Assembly for Repair, page 6. Reconnect the FCM cable and both air tubes. 2. Remove the FCM (103); follow Replace Fluid Con- Replace Fluid Control Module trol Module.
  • Page 69 Repair Replace Transducer O-Rings 1. Prepare Fluid Plate Assembly for Repair, page 2. Remove the fluid outlet pressure sensor (117) from the regulator (108). r_pf0000_313377_16a . 45 3. Press the transducer (CG) out of the retainer nut (CH). 4. Remove the faulty o-ring (120) and replace with new.
  • Page 70 Repair Repair Fluid Regulator NOTE: The retaining nut (CC) often loosens when removing the cartridge assembly from the base For complete cartridge fluid regulator repair refer to housing. Be sure to re-torque as described in step 4. instruction manual 308647. For complete mastic fluid regulator repair refer to instruction manual 307517.
  • Page 71 Repair Replace Amplifier 3. Loosen four screws on amplifier (116) cover, and then remove cover. (Heated fluid plates only) 4. Remove four screws (105) securing amplifier to 1. Prepare Fluid Plate Assembly for Repair, page bracket. 5. Remove amplifier and replace with a new amplifier. 2.
  • Page 72 Repair Calibrate Amplifier 9. Press to scroll to the Pressure Sensors (Heated fluid plates only) screen (screen 5). 1. Prepare Fluid Plate Assembly for Repair, page 2. Remove outlet pressure sensor from outlet fitting to ensure there is no pressure applied to the sensor. Adjust Display Settings 3.
  • Page 73 5) matches the calculated Shunt Calibration Pres- 18. Using the data from the certificate of calibration for sure. the pressure sensor (included with PCF documenta- tion or the replacement pressure sensor), calculate 20. Remove the jumper wire or paper clip from the the Shunt Calibration Pressure using the following SHUNT CAL and ENABLE terminals.

  • Page 74: Control Center Assembly

    Repair Control Center Assembly Replace Gateway Module Base 1. Prepare Control Center for Repair, page 74. 2. Remove the Gateway module (5); follow Replace Gateway Module. (Leave automation communica- tions cable (AE) attached to Gateway module.) Prepare Control Center for Repair 3.
  • Page 75 Repair Replace Advanced Display Module Replace Advanced Display Module Bracket 1. Prepare Control Center for Repair, page 74. 1. Prepare Control Center for Repair, page 74. 2. Remove the ADM (2); follow Replace Advanced 2. Disconnect the CAN cable (18) from the ADM (2). Display Module.
  • Page 76 Repair Replace DIN Rail Assembly 7. Reconnect all wiring to the din rail module, filter, and rocker/rotary switch. 1. Prepare Control Center for Repair, page 74. 8. Reassemble the line voltage assembly cover using 2. Remove both screws (22) and washers (28) from the screws and washers.
  • Page 77 Repair 313377L...

  • Page 78: Parts

    Parts Parts Control Center Assembly Parts r_pf0000_313377_11a 24 Vdc Din Rail Assembly Shown Components of 24 Vdc Module Kit (24B929) and 100-240 Vac Line Voltage Module Kit r_pf0000_313377_10a (24B928) 313377L...
  • Page 79  Parts included with Display Mounting Bracket kit 6†‡ SUPPLY, power; 24vdc, 4A, 100W 24B930. 7‡ COVER, line voltage  Base electronic components do not have PCF-spe- 8‡ GROMMET cific software installed. Therefore, use software 9‡ 196548 LABEL, caution 10†‡...

  • Page 80: Fluid Plate Assembly Parts

    Parts Fluid Plate Assembly Parts See page 82 135, 136 See page 81 See page 81 313377L...
  • Page 81 Parts Fluid Plate Assembly Parts (continued) 313377L...
  • Page 82 Parts Fluid Plate Assembly Parts (continued) 117, 120 Fluid Plate 24B962 Shown 105, 116 140, 141, 150 313377L...
  • Page 83 110580 SCREW, cap, socket hd mastic regulator without a meter). 113 SPACER 198268 BRACKET, flow meter  Base electronic components do not have PCF-spe- 115 624545 FITTING, tee; 3/4(m) x 1/4(f) cific software installed. Therefore, use software 116 258530 AMPLIFIER, signal conditioner upgrade token (16C958) to install software before 117...
  • Page 84 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 Mastic Regulator Heated Regulator Cartridge Regulator Mastic with Heated Mastic with High Regulator with High Regulator...

  • Page 85: Appendix A - Advanced Display Module (Adm)

    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 PCF. Display Overview The ADM display is divided into two main functions: Setup Mode and Run Mode.
  • Page 86 Appendix A - Advanced Display Module (ADM) Menu Bar Soft Keys The menu bar appears at the top of each screen. 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.

  • Page 87: Setup Mode

    Appendix A - Advanced Display Module (ADM) Setup Mode Advanced Setup Screen 2 This screen enables users to setup the maintenance Setup mode screens are divided into four sections: units, and flow rate. Advanced setup, Gateway setup, Fluid plate setup, and Style setup.
  • Page 88 There are up to three Gateway Setup screens (depend- ing on fieldbus), which enable users to set or change information regarding the Gateway module used on the PCF system. These screens also enable users to view information regarding the particular Gateway module used.
  • Page 89 This screen is the same for EtherNet/IP and PROFI- BUS. See Gateway Setup Screen 2 - EtherNet/IP, This screen enables users to view the following informa- page 88, for details. tion regarding the Gateway module used on the PCF system: Gateway Setup Screen 1 - PROFINET •...
  • Page 90 This screen enables users to select the Command Value Type signal (Analog or Digital) the automation system will provide to PCF. If Analog control is selected, the user must provide an analog voltage to the proper input on the DGM. See Appendix B - Discrete Gate- way Module (DGM) Connection Details, page 98, for connection details.
  • Page 91 Appendix A - Advanced Display Module (ADM) Fluid Plate Setup Screens Mode Settings Screen This screen enables users to set gun commands. Use There are seven fluid plate setup screens, which enable this screen to select a mode (pressure, bead, shot, or users to: full open) for each gun.
  • Page 92 Appendix A - Advanced Display Module (ADM) Delay Settings Screen Pressure Sensors Screen This screen enables users to set on and off delays (in NOTE: Inlet sensor settings will be grayed out on this screen for systems with heated fluid plates. milliseconds) for each gun and the regulator For an explanation of the on and off delays, refer to the On/Off...
  • Page 93 Appendix A - Advanced Display Module (ADM) Error Type Settings Screen Maintenance Advisory Limits Screen This screen enables users to set the error type (alarm, This screen enables users to set volume (or hours) limit deviation, or none) that will be issued if the pressure, that will trigger a maintenance advisory for the air sup- flow rate, volume, or computed target goes outside the ply, V/P regulator, fluid regulator, flow meter, and all four...
  • Page 94 Appendix A - Advanced Display Module (ADM) Style Setup Screen Keyboard Screen Use all four arrow buttons to select each letter; press This screen enables users to set up to 256 styles. Press to access the style setup fields. Enter the style to enter the letter.

  • Page 95: Run Mode

    Press to navigate through the Run mode screens. The PCF system has two operating modes: Home Screens • Dispense mode – enables the module to begin dis- There are two home screens: one for the fluid plate and pensing when it receives a command from the auto- mation unit.
  • Page 96 Use the pressure control mode if the system does not include a flow meter. • Full Open Control – the PCF system does not con- trol fluid pressure or flow. Instead the regulator opens to allow for recirculation applications. Maintenance Mode...
  • Page 97 Appendix A - Advanced Display Module (ADM) Error Report Screens Maintenance Screen There are nine error report screens that display a This screen enables users to view the maintenance chronological list of system errors. These screens dis- totalizers for each system component and the limits set play the last 140 errors.

  • Page 98: Appendix B - Discrete Gateway Module (Dgm) Connection Details

    Appendix B - Discrete Gateway Module (DGM) Connection Details Appendix B - Discrete Gateway Module (DGM) Connection Details D-Sub Cable 123793 The cable length of the interface cable assembly 123793 is 50 ft (15.2 m). The following table identifies the cable interface signals.

  • Page 99: D-Sub Cable 123792 And Breakout Board 123783

    Appendix B - Discrete Gateway Module (DGM) Connection Details D-Sub Cable 123792 and Breakout Board 123783 The cable length of the interface cable assembly 123792 is 50 ft (15.2 m). The following table identifies the pin assignments for the 78-pin breakout board. NOTE: See Appendix D - I/O Signal Descriptions, page 111, for I/O signal descriptions.
  • Page 100 Appendix B - Discrete Gateway Module (DGM) Connection Details D-Sub Pin No. Description Pin Type Voltage (Vdc) Data 8192* Digital Out - Bank 3 0 - voltage connected to Pin 69 Data 16384* Digital Out - Bank 3 0 - voltage connected to Pin 69 Data 32768* Digital Out - Bank 3 0 - voltage connected to Pin 69...
  • Page 101 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-subminia- ture connector cable; it is already grounded through the mounting screw on the base of the DGM. .

  • Page 102: Dgm Digital Input

    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 101, for details. The digital input is rated at 0-30 Vdc, and requires an NEC Class 2 power supply connected to pin 51.

  • Page 103: Dgm Digital Outputs

    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 101, 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.

  • Page 104: Dgm Analog Inputs

    Appendix B - Discrete Gateway Module (DGM) Connection Details DGM Analog Inputs The analog inputs function only when the DGM is connected to a power supply through the CAN connection. Each analog input has a corresponding reference (ground) pin. See Pin References, page 101, for details. •...

  • Page 105: Appendix C - Communications Gateway Module (Cgm) Connection Details

    Appendix C - Communications Gateway Module (CGM) Connection Details Appendix C - Communications Gateway Module (CGM) Connection Details Install Fieldbus Connections Module Status (MS) Connect cables to fieldbus per fieldbus standards. State Description Comments Not initial- No power or module in PROFINET ized “SETUP”...
  • Page 106 Appendix C - Communications Gateway Module (CGM) Connection Details EtherNet/IP DeviceNet Link 3 4 5 TI11814A TI11815A . 59: EtherNet/IP Fieldbus Connections . 60: DeviceNet Fieldbus Connections The Ethernet interface operates at 100Mbit, full duplex, as required by PROFINET. The Ethernet interface is Network Status (NS) auto polarity sensing and auto-crossover capable.
  • Page 107 Appendix C - Communications Gateway Module (CGM) Connection Details PROFIBUS PROFIBUS Connector (DC) Signal Description B Line Positive RxD/TxD, RS485 level Request to send 9 8 7 6 GND Bus Ground (isolated) TI11816A +5V Bus +5V termination power (isolated) . 61: PROFIBUS Fieldbus Connections Output Operation Mode (OP) A Line...

  • Page 108: Cgm I/O Data Map

    Appendix C - Communications Gateway Module (CGM) Connection Details CGM I/O Data Map Byte Input Bit Description Dispensed Volume - 256 Automation Inputs (signals from PCF) Dispensed Volume - 512 Dispensed Volume - 1024 Byte Input Bit Description Dispensed Volume - 2048...
  • Page 109 Appendix C - Communications Gateway Module (CGM) Connection Details Byte Input Bit Description Byte Input Bit Description I168 Outlet Pressure - 256 I256 Actual Flow Rate - 1 I169 Outlet Pressure - 512 I257 Actual Flow Rate - 2 I170 Outlet Pressure - 1024 I258 Actual Flow Rate - 4...
  • Page 110 Appendix C - Communications Gateway Module (CGM) Connection Details Automation Outputs (signals to PCF) Byte Output Bit Description O48-O55 Byte Output Bit Description O56-O63 Style - 1 Style - 2 O64-O71 Style - 4 O72-O79 Style - 8 O80-O87 Style - 16...

  • Page 111: Appendix D - I/O Signal Descriptions

    Appendix D - I/O Signal Descriptions Appendix D - I/O Signal Descriptions Automation Inputs Dispenser Remote Start / Purge in Process This signal is 0 on power up. This signal will be 1 under the following conditions: Dispenser Ready This signal is 0 on power up. This signal will be 1 under •...

  • Page 112: Automation Outputs

    Appendix D - I/O Signal Descriptions Automation Outputs Inlet Pressure A 16 bit number indicates the current inlet pressure of the fluid plate. Applicable in all control modes. Units of Style this number are dependent on the pressure units. The desired style of the next job. These 8 bits are read at the start of a job to determine the selected style.
  • Page 113 Appendix D - I/O Signal Descriptions 313377L...

  • Page 114: Technical Data

    * Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expected to shear under pressure. New applications or fluids should always be tested to determine proper line sizes and equip- ment selections. See your Graco Authorized distributor for other capabilities. 313377L...

  • Page 115: Fluid Plate Assembly Technical Data

    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 Mastic Regulator Regulator Manual 308647 307517 Weight - No Flow Meter 25.5 lbs (11.6 kg) 33 lbs (15 kg) Weight - Helical 40 lbs (18 kg)

  • Page 116: Graco Standard Warranty

    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.

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