For proportional mixing of plural component coatings (44 pages)
Summary of Contents for Graco PrecisionFlo 918463
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ASTM Standard D4206 Sustained Burn Test. Control Assembly with Pendant Control Assembly with Keypad Part No. 918463 8646A Part No. 918644 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 http://www.graco.com COPYRIGHT 1996, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
Warnings Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the instructions.
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Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180 F (82 C) or below –40 F (–40 C). Do not use the hoses to pull the equipment.
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WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in fire or explosion and serious injury. Ground the equipment and the object being sprayed. The PrecisionFlo metering valve is grounded through proper connection of the two electrical cables.
PrecisionFlo Module Overview What This Manual Includes This manual provides detailed information on the Pre- cisionFlo control assembly and operation of the Preci- sionFlo module only. Specific information on metering valves or material conditioning systems, for example, is contained in other instruction forms supplied with each component, as part of the PrecisionFlo system.
PrecisionFlo Module Overview Fluid Metering Assembly The PrecisionFlo metering valve is electrically con- trolled by the PrecisionFlo module, and consistent ma- The fluid metering assembly (Fig. 2) can be attached terial flow is assured by a closed-loop pressure control to a robot’s arm, or mounted on a pedestal. Main design.
PrecisionFlo Module Overview PrecisionFlo Options Flow Monitor: Allows precise control of material volumes and accumulation of accurate SPC data. Material Conditioning: Allows precise regulation of material temperature. Dispensing Accessories: A variety of hoses, cables, dispense devices, manifolds, and other components are available to meet the requirements of customer applications and material types.
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PrecisionFlo Module Overview Fig. 4 The following list describes the numbered components in the typical installation drawing. Description Control Assembly Metering Valve Dispense Gun Control Pendant Sealer Robot Flow Meter Robot Controller Robot Interface Cable Temperature Conditioning System Temperature Conditioning Hoses Fluid Supply System Fluid Supply Header Filter Module (not shown)
Some of the software settings are password protected. configuring the software for operation To obtain the password, contact your Graco service representative. Fig. 5 shows the tasks that make up each procedure. Configure software...
Fig. 7. available during installation. Be sure all accessories are adequately sized and pressure-rated to meet the system’s requirements. Use only the Graco PrecisionFlo control assembly with the PrecisionFlo metering valve. WARNING EQUIPMENT MISUSE HAZARD The PrecisionFlo control assembly...
Current / Temperature Board using cables provided with the metering valve. Grounding Stud An 8 AWG, 25 foot long ground wire with clamp, part Main Electrical Switch no. 222011, is available from Graco. Master Control Relay I/O Board1 –– Service Control Board Assy .
Description provided with the metering valve. Current / Temperature Board An 8 AWG, 25 foot long ground wire with clamp, part Grounding Stud no. 222011, is available from Graco. Main Electrical Switch Master Control Relay I/O Board1 –– Service Control Board Assy .
Installing Control Assembly Hardware Verifying Ground Continuity To connect the control assembly to the electrical source: Verify ground continuity between: true earth ground and the panel ground lug 1. Create an opening in the enclosure. the application device and the robot the metering valve and the robot 2.
Installing Control Assembly Hardware Connecting Fluid Lines, Air Lines, and 5. Connect the following cables from the PrecisionFlo metering valve (2) to the mating receptacles on the Cables control assembly (1). Follow these steps to assemble the PrecisionFlo a. Operations cable to the OP receptacle (6). module and incorporate it into a complete fluid dis- Then, connect the operations cable to the pensing system.
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Installing Control Assembly Hardware Compressed Air Inlet 3/8 NPT(f) Fluid Outlet 3/8 NPT(f) Operations Cable – OP Robot I/O Cable – I/O Robot Analog Cable – RAR Motor Cable – MP Sensor Cable – MS Flow Meter Cable – FM Fluid Supply Inlet 3/4 NPSM(f) 8805A...
Never exceed the maximum air or fluid working pressure rating of the lowest NOTE: Some of the software settings are password rated component in the system. Over- protected. To obtain the password, contact your Graco pressurization can cause component service representative. rupture and serious bodily injury.
Loading Material into PrecisionFlo Module Configuring Pressure Sensors Before you set the scale factor, determine which type of sensor you have and what settings you have to This section describes how to set maximum and enter into the software. minimum limits for these pressure sensors: 1.
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Loading Material into PrecisionFlo Module Setting the Scale Factor for Pressure Sensors Setting the Outlet Pressure Limit (continued) Enter 3500 for the high pressure limit and 0 for the low 5. Enter the information: pressure limit. a. Key in the 4-digit maximum Vdc, (the Preci- 1.
Loading Material into PrecisionFlo Module Entering Nominal Values for Kp and Kd Calibrating PrecisionFlo Module in Pressure Mode The values you enter for Kp and Kd depend on the viscosity of the material and type of application in For more information about flow calibration, or for which you are using the PrecisionFlo module.
Loading Material into PrecisionFlo Module Dispensing in Manual Mode 4. Press [F2] on the pendant to begin dispensing. For more information about manual dispense mode, Dispensing continues as long as you continue to see page 46. press [F2] and stops when you release the [F2] key.
Configuring the PrecisionFlo Module After you have loaded material into the dispensing NOTE: You have the option of using a dual channel system, configure the software for PrecisionFlo module storage oscilloscope to run tests for determining: operation. To configure the PrecisionFlo software, Kp and Kd parameters perform the following procedures.
Configuring the PrecisionFlo Module You will be entering Kp and Kd values more than once Make sure that: while you are starting up the PrecisionFlo module. 1. Material has been loaded into the dispense sys- The first time you enter values is to simply load materi- tem.
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Configuring the PrecisionFlo Module Setting Up to Dispense Test Material c. At the prompt, key in 0, then press [ENTER]. You see: To set up for dispensing test material, perform the following tasks: ––WARNING!!!–– Material Will Be 1. Supply material pressure to the PrecisionFlo Dispensed, Press module.
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Configuring the PrecisionFlo Module Evaluating Beads In order to set Kp and Kd, dispense material and check it to see if the bead or outlet pressure is even and stable (Fig. 18). A properly adjusted bead has equal segments and a smooth appearance. An even bead segment 1 segment 2 segment 3...
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Configuring the PrecisionFlo Module Adjust Kp and Kd Values Visually Set Kp Dispense material Bead Bead even? maintains Kp < 5000? Kp + 100 stability Bead maintains Kp –100 stability Bead Fine maintains Kp + 20 Bead even? Kp – 20 Tuning stability Set Kd...
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Configuring the PrecisionFlo Module Adjust Kp and Kd Values Visually 4. Add 100 to Kd and rerun the test. If this does not stabilize bead performance, repeatedly increase Refer to the chart in Fig. 21 on page 27 for more Kd by 100 and retest until stability is achieved.
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Configuring the PrecisionFlo Module Adjust Kp and Kd Values Visually (continued) From Set Kd Adjust Bead unstable? Kd + 100 Kd –100 Kd +20 Bead unstable? Kd – 20 Done Fig. 22 Set Kd (Visually) 4. Decrease Kd to the last previous setting. Refer to the chart in Fig.
Configuring the PrecisionFlo Module Adjust Kp and Kd Values Using an Oscilloscope 5. Add 100 to Kd and rerun the test. If this does not equalize the pressures, repeatedly increase Kd by Connecting The Oscilloscope 100 and retest until equality is achieved. Then If you are using an oscilloscope, follow this procedure return to step 4.
Configuring the PrecisionFlo Module Adjust Kp and Kd Values Using an Oscilloscope (continued) From Set Kd Adjust Bead unstable? Kd + 100 Kd –100 Kd +20 Bead unstable? Kd – 20 Done Fig. 24 Set Kd (with an Oscilloscope) Using the Control Pendant to Modify Kp and Kd Parameters Refer to the chart in Fig.
Configuring the PrecisionFlo Module Setting the Flow-Meter K-Factor Calibrating Flow Rate and Setting Module Operation Mode If your PrecisionFlo unit has a flow meter, you need to set the K-factor. When you calibrate the flow rate you are performing 2 functions: The flow meter sends an electrical pulse to indicate the passage of a specific amount of material.
Configuring the PrecisionFlo Module Using Flow Mode 3. If your PrecisionFlo configuration does not include a flow meter, determine the maximum outlet In flow mode, you enter the maximum flow rate re- pressure for your application. quired by the application. The PrecisionFlo module: Setting Flow Calibration 1.
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Configuring the PrecisionFlo Module Calibration for Systems that have a Flow Meter Calibration for Systems with a Disconnected Flow Meter or Without a Flow Meter Connected to the Control Assembly (continued) To calibrate the material flow: 4. Key in the maximum operating flow rate, in cubic centimeters/minute, then press [ENTER].
Configuring the PrecisionFlo Module Setting PrecisionFlo On and Off Delays Table 4 — Delay On/Off Variables The PrecisionFlo metering valve can physically re- Variable: Sets the Amount of Time: spond faster than the dispense device and dispense Gun ON the device delays opening after gun solenoid.
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Configuring the PrecisionFlo Module Test Procedure A Test Procedure B To use an oscilloscope to determine ON and OFF To determine ON and OFF delays: delays: 1. Set the GUN ON and REGULATION ON delays 1. Connect one input channel of an oscilloscope to to 0.
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Configuring the PrecisionFlo Module Modifying PrecisionFlo ON Delays Modifying PrecisionFlo OFF Delays 1. On the control pendant: 1. On the control pendant: HOME SETUP Protected Setup HOME SETUP Protected Setup 2. Key in the password, then press [ENTER]. 2. Key in the password, then press [ENTER]. 3.
Configuring the PrecisionFlo Module Controlling Volume Compensation 4. You see: ––MODIFY PD/VOL COMP–– If the PrecisionFlo module is operating in flow mode, Kp xxxx Kd xxxx you should turn on volume compensation. When Vol Comp= xxx xx cts volume compensation is on, the PrecisionFlo module Press F1 To Toggle measures the volume of material dispensed and then adjusts the actual material flow rate to match the...
Fine Tuning The procedures in this section are for fine tuning the 2. You see: PrecisionFlo system when there are minor or tempo- ––SCALE ANALOG IN–– rary changes to the material characteristics. Analog Input Scale Setting Scale Analog In Factor=xxx% Previous=xxx% The Scale Analog In allows the operator to uniformly increase or decrease the dispense rate throughout the...
PrecisionFlo Module Operation Pressure Relief Procedure 5. Refer to Fig. 29. and perform the following steps to open the dispense device and relieve fluid This procedure describes how to relieve pressure for pressure: the PrecisionFlo unit. Use this procedure whenever you shut off the dispenser/sprayer and before checking a.
PrecisionFlo Module Operation Starting the Module Restarting the Module To start the module, you (Fig. 30): If the module is on, but the CONTROL ON indicator on the control assembly is not lit: 1. Carefully inspect the entire system for signs of leakage or wear.
PrecisionFlo Module Operation Reading the PrecisionFlo Control Panel Indicators Use the tables below and Fig. 30 to read the indicators on the PrecisionFlo control panel. Part No. 918463 Part No. 918644 Fig. 30 Button/Switch What it Does Master Start / Stop Reset Button Turns on power to PrecisionFlo’s metering valve drive after power is applied to the module.
PrecisionFlo Module Operation Setting Operation Mod 3. You see: The PrecisionFlo module has 3 operating states: –AUTOMATIC DISPENSE– >Monitor Pressure Automatic dispense mode — enables the Volume Dispensed PrecisionFlo module so that when it receives a Last Fault command from the robot, PrecisionFlo can begin dispensing material.
PrecisionFlo Module Operation Using Manual Dispense Mode Shutting Down the PrecisionFlo Module 1. Make sure the CONTROL ON indicator, (26) in Fig. 30, is lit. If it is not, push the MASTER START button (24) to turn on power to the Preci- sionFlo metering valve drive circuitry.
Maintenance Maintaining the PrecisionFlo Module 1. Perform the Pressure Relief Procedure on page 42 to ensure the module is depressurized. See Fig. 4 on page 9 for a description of the basic components in a typical system equipped with a Preci- WARNING sionFlo module.
Troubleshooting and Fault Recovery The following table describes the valid fault codes Restarting the Module After a Fault used by the PrecisionFlo module, possible causes, and If a fault has occurred, you must clear the fault before solutions. See Theory of Operation – Fault Han- restarting the PrecisionFlo module.
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Troubleshooting and Fault Recovery Warnings (continued) Table 6 — Fault Code Table Fault Fault Name Fault Causes Solutions Code Description Inlet Pressure Input pressure to Precision- Incorrect limit set Check limit setting and correct High Flo metering valve is above if necessary.
Troubleshooting and Fault Recovery Alarms Table 7 — Alarm Code Table Alarm Alarm Alarm Description Causes Solutions Code Name Servo Drive Servo circuit condition at Servo drive failure Replace servo drive Fault servo drive’s output, or hard- ’ Motor short Check that motor coil resistance is ware failure occurred on the 10–13 Ohms.
PrecisionFlo Module I/O PrecisionFlo Control Board FLOW METER MATERIAL INPUT ’ Fig. 32 PrecisionFlo Module I/O Schematic Figure 32 shows the internal and external signals used by the PrecisionFlo module. Inputs to the opto-isolators are digital signals from external sources such as a robotic system or temperature conditioning system. Outputs from the opto-isolators are digital signals either sent to an external robotic system and used to control the solenoid air valve which opens and closes the dispense gun.
PrecisionFlo Module I/O Fig. 33 I/O Rack Layout Figure 33 shows the layout of input/output (I/O) modules in the PrecisionFlo control enclosure. Table 8 describes these I/O modules on page 54. For wiring information, see the wiring diagram in your system documentation. 310531...
PrecisionFlo Module I/O Table 8 — I/O Module Description Module Description Input/Output Active State Normal Number (no fault) LED State Watch Dog Signal Output Fault Strobe Output High Dispenser Stop Output Closer Solenoid Output High Gun Solenoid Output High Dispense Input High Temperature Conditioning Fault...
Theory of Operation Manual Mode Automatic Mode When in Manual mode, the PrecisionFlo module When in Automatic mode, the PrecisionFlo module remains in a ready state, and reacts only to operator remains in a ready state, indicated by the DISPENSER input to the control pendant.
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Theory of Operation Typical Dispense Cycle DISPENSER READY Robot In Cycle Style Data Valid Style Data MEASURE VOLUME DISPENSE Gun Open PrecisionFlo Metering Valve Regulating Table 9 — Dispensing Operation Timing 65 msec Time between MEASURE VOLUME and DISPENSE Gun on delay The user sets either the gun on delay or regulation on delay timing.
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Theory of Operation Typical Dispense Cycle 16. At the end of the cycle, PrecisionFlo module (continued) checks if a GUN OFF DELAY has been set by the 7. Robotic system controller requests material to be user. dispensed by setting the DISPENSE signal HIGH. If the delay has been set, the PrecisionFlo module 8.
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Theory of Operation Fault Handling For example, if bits 2 and 3 are HIGH, the fault code > value is equal to 4 + 8, or 12, and a Volume Fault is indicated. Fault Strobe Typical Fault Handling Procedure 1. A problem occurs in the PrecisionFlo module. >1 msec 2.
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Theory of Operation Volume Reporting To determine the amount of material dispensed, con- vert the 10 bits from binary to decimal. The accuracy The volume dispensed during the last job is available depends on the accuracy of the flow meter. on the data bus at the end of a cycle.
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Theory of Operation Volume Reporting 9. Robotic controller sets the VOLUME REQUEST (continued) signal HIGH. 1. Robotic controller sets MEASURE VOLUME to LOW after the cycle is complete. 10. PrecisionFlo module places the second 5 bits (B5–B9) on the data bus . 2.
Theory of Operation Volume Compensation Volume Compensation Algorithm The algorithm for controlling flow: The PrecisionFlo module compensates for changes in material viscosity by: 1. Find the pressure from commanded flow and flow calibration curve. 1. Comparing actual flow rate with the flow rate commanded by the robot.
Parts Model 918644, PrecisionFlo Control Assembly Part Description Qty. Part Description Qty. 114617 Pendant, door 918583 Board assy., service, control, PrecisionFlo 617508 Label, PrecisionFlo, Includes items 8 and 9 15.2 x 30.5 mm (6 x 12”) 918494 . EPROM set, programmed 238093 Board assy., current/temp 237955...
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Parts Model 918644, PrecisionFlo Control Assembly (continued) Fig. 42 310531...
PrecisionFlo Control Interface Signals The PrecisionFlo module is designed to be controlled by a robotic workcell or line control computer. This section describes the interface between the line or cell control system and the PrecisionFlo module, and provides cable/pin level information for the connections. For information about the connector pin-outs, see page 71 . Digital Input Signals sent from an external controller to the PrecisionFlo module.
PrecisionFlo Control Interface Signals Digital Output Signals sent to an external controller from the PrecisionFlo module. Signal Name Connector / Signal Description Fault Strobe I/O–D16 Signal is HIGH when the PrecisionFlo module has detected a fault, and valid data representing the current fault condition is available to be read from the data bus.
Module Internal Interface Signals Digital Input Signal Name Connector / Signal Description Temperature Fault WIRE 1561 A temperature conditioning system can raise this signal to indicate an over- or under-temperature condition to the PrecisionFlo module. The activation of this signal will cause the PrecisionFlo module to place fault code 24 on the data bus for transmission to the external controller (unless volume data is currently being reported).
Module Internal Interface Signals Analog Input Signal Name Connector / Pin Signal Description PrecisionFlo SIG = MS–C Provides an input from the pressure transducer at the PrecisionFlo Outlet Pressure COM = MS–B metering valve outlet to the PrecisionFlo control assembly. This signal is necessary for the module to control outlet pressure, and allows the operator to monitor fluid pressure from the control pendant.
Control Panel Operator Interface PrecisionFlo Module Control Panel The control panel has these indicators and switches: Control / Indicator Device ID Control / Indicator Description Name POWER ON / LT113 Light is ON when both electric power and a proper ground are connected GROUND CON- to the PrecisionFlo control assembly.
Connector Pin-outs These pin-outs are for the connectors on the side of the PrecisionFlo Control Assembly cabinet. For descriptions of the signals, see the tables beginning on page 66. Motor Power (MP) Pendant (TP) Contacts Connects to Contacts Connects to + motor –...
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Connector Pin-outs Operations (OP) Contacts Connects to + 24 V 24 V common gun solenoid – closer solenoid command + servo pressure servo ressure valve command – +12 V 12 V common signal auxiliary pressure transducer common ground shield 310531...
Appendix A. Hand Pendant Operation Do this: Select from the menu ––––––––HOME–––––––– >Automatic 1. Use the UP and DOWN Manual arrow keys to move the Setup cursor to your choice. Press [ENTER]. Signal that you have completed entering information into a field or screen Press the [ENTER] key.
Appendix B. Configuring the Hand Pendant You must set three parameters on the pendant: the 1. Make sure the pendant and pendant cable are display contrast, baud rate, and data format. connected to the control assembly. During the set-up procedure, the pendant automatically 2.
NOTE: Have the system binder (a collection of manu- Make sure all the pins are in the holes als and diagrams in a three-ring binder, supplied by Graco) available to refer to. Note direction of chip Installing the New Software Fig.
Appendix C. Changing the Software Chips Control Component Identification Checking for Control Panel DC Voltage Problems There are four major control components: Power Supply WARNING Service Control Board Current/Temperature Board ELECTRIC SHOCK HAZARD Pendant High voltage is present when performing the following voltage checks, which Before you troubleshoot the PrecisionFlo Control, it is could cause an electric shock injury if...
Appendix D. Door Pendant Operation Do this: Select from the menu 1. Use the UP and DOWN arrow keys to move the cursor to your choice. Press [ENTER]. Signal that you have completed entering information into a field or screen Press the [ENTER] key.
Appendix E. Configuring the Door Pendant You must set three parameters on the pendant: the 5. Adjust the display contrast. display contrast, baud rate, and data format. a. Step through the selections, until the display is During the set-up procedure, the pendant automatically at the desired contrast.
12–30 Volts D.C. Control Assembly Storage Temperature –25 to +55 C (–13 F to + 131 F) * 4–20 mA. current mode flow control is available as a factory configuration of the control board. Contact Graco Technical Assistance for information. Related Publications...
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 sub- stitution of non–Graco component parts.
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