Graco PrecisionFlo 918463 Instructions-Parts List Manual Download Page 2

Page: 2 / 80

2 310531

Table of Contents

Warnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PrecisionFlo Module Overview

. . . . . . . . . . . . . . . . .

What This Manual Includes

. . . . . . . . . . . . . . . . . .

PrecisionFlo Module Description

. . . . . . . . . . . . . .

PrecisionFlo Module Capabilities

. . . . . . . . . . . . . .

Typical Fluid Applications

. . . . . . . . . . . . . . . . . . . .

PrecisionFlo Features

. . . . . . . . . . . . . . . . . . . . . . .

PrecisionFlo Options

. . . . . . . . . . . . . . . . . . . . . . . .

Instruction Manual Conventions

. . . . . . . . . . . . . . .

PrecisionFlo Definitions

. . . . . . . . . . . . . . . . . . . . . .

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Control Assembly Hardware

. . . . . . . . .

Installing the Control Assembly Enclosure

. . . . .

Grounding Control Assembly 918463

. . . . . . . . .

Grounding Control Assembly 918644

. . . . . . . . .

Verifying Ground Continuity

. . . . . . . . . . . . . . . . .

Connect PrecisionFlo Control Assembly
to Power Source

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Resistance Between the
Control Assembly and the
True Earth Ground

. . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Fluid Lines, Air Lines, and Cables

Loading Material into PrecisionFlo Module

. . . . .

Material Loading Procedure

. . . . . . . . . . . . . . . . .

Configuring Pressure Sensors

. . . . . . . . . . . . . . .

Entering Nominal Values for Kp and Kd

. . . . . . .

Calibrating PrecisionFlo Module

. . . . . . . . . . . . .

Dispensing in Manual Mode

. . . . . . . . . . . . . . . . .

Configuring the PrecisionFlo Module

. . . . . . . . . .

Adjusting the Kp and Kd to Ensure
Accuracy and Repeatability of
Metering Valve Operation

. . . . . . . . . . . . . . . . . . .

Using the Control Pendant to Modify
Kp and Kd Parameters

. . . . . . . . . . . . . . . . . . . . .

Setting the Flow-Meter K-Factor

. . . . . . . . . . . . .

Calibrating Flow Rate and Setting
Module Operation Mode

. . . . . . . . . . . . . . . . . . . .

Setting the Flow-Meter K-Factor

. . . . . . . . . . . . .

Calibrating Flow Rate and Setting
Module Operation Mode

. . . . . . . . . . . . . . . . . . . .

Setting Flow Calibration

. . . . . . . . . . . . . . . . . . . .

Setting PrecisionFlo On and Off Delays

. . . . . . .

Controlling Volume Compensation

. . . . . . . . . . .

Fine Tuning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Scale Analog In

. . . . . . . . . . . . . . . . . . . . .

PrecisionFlo Module Operation

. . . . . . . . . . . . . . .

Pressure Relief Procedure

. . . . . . . . . . . . . . . . . .

Starting the Module

. . . . . . . . . . . . . . . . . . . . . . . .

Restarting the Module

. . . . . . . . . . . . . . . . . . . . . .

Reading the PrecisionFlo
Control Panel Indicators

. . . . . . . . . . . . . . . . . . . .

Setting Operation Modes

. . . . . . . . . . . . . . . . . . .

Shutting Down the PrecisionFlo Module

. . . . . . .

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the PrecisionFlo Module

. . . . . . . . .

Testing the Metering Valve’s Motor

. . . . . . . . . . .

Troubleshooting and Fault Recovery

. . . . . . . . . .

Restarting the Module After a Fault

. . . . . . . . . . .

Warnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alarms

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Selection Map

. . . . . . . . . . . . . . . . . . . . . . . . . .

PrecisionFlo Module I/O

. . . . . . . . . . . . . . . . . . . . . .

PrecisionFlo Module I/O Schematic

. . . . . . . . . .

I/O Rack Layout

. . . . . . . . . . . . . . . . . . . . . . . . . . .

I/O Module Description

. . . . . . . . . . . . . . . . . . . . .

Theory of Operation

. . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Volume Compensation

. . . . . . . . . . . . . . . . . . . . .

Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 918463 Control Assembly

. . . . . . . . . . . . .

Model 918644 Control Assembly

. . . . . . . . . . . . .

PrecisionFlo Control Interface Signals

. . . . . . . . .

Digital Input

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Output

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Input

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module Internal Interface Signals

. . . . . . . . . . . . . .

Digital Input

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Output

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Input

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Operator Interface

. . . . . . . . . . . . . .

PrecisionFlo Module Control Panel

. . . . . . . . . . .

Connector Pin-outs

. . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A. Hand Pendant Operation

. . . . . . . . .

Appendix B. Configuring the Hand Pendant

. . . .

Appendix C. Changing the Software Chips

. . . . .

Installing the New Software

. . . . . . . . . . . . . . . . .

Checking for Control Panel
DC Voltage Problems

. . . . . . . . . . . . . . . . . . . . . .

Appendix D. Door Pendant Operation

. . . . . . . . . .

Appendix E. Configuring the Door Pendant

. . . .

Technical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Publications

. . . . . . . . . . . . . . . . . . . . . . . . .

Graco Standard Warranty

. . . . . . . . . . . . . . . . . . . . .

Graco Phone Number

. . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for PrecisionFlo 918463

Page 1: ...conditions for non flammability D The fluid has a flash point above 140_F 60_C and a maximum organic solvent concentration of 20 by weight per ASTM Standard D93 D The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test Part No 918463 Control Assembly with Pendant Part No 918644 Control Assembly with Keypad 8646A GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 ht...

Page 2: ...ow Calibration 35 Setting PrecisionFlo On and Off Delays 37 Controlling Volume Compensation 40 Fine Tuning 41 Setting Scale Analog In 41 PrecisionFlo Module Operation 42 Pressure Relief Procedure 42 Starting the Module 43 Restarting the Module 43 Reading the PrecisionFlo Control Panel Indicators 44 Setting Operation Modes 45 Shutting Down the PrecisionFlo Module 46 Maintenance 47 Maintaining the P...

Page 3: ...ressure Relief Procedure on page 42 whenever you are instructed to relieve pres sure stop dispensing clean check or service the equipment or install or clean a spray tip or nozzle Tighten all the fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn damaged or loose parts immediately Permanently coupled hoses cannot be repaired replace the entire h...

Page 4: ... representative for motor service Do not exceed the maximum working pressure of the lowest rated system component The maximum working pressure of the PrecisionFlo metering valve is shown on the fluid head Other components may have lower working pressure ratings 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 o...

Page 5: ...cal equipment performed by a qualified electrician only Make sure all electrical equipment is installed and operated in compliance with applicable codes Do not install the PrecisionFlo module in a hazardous area as defined in Article 500 of the National Electrical Code USA Make sure power is disconnected when servicing and repairing equipment Keep the dispensing area free of debris including solve...

Page 6: ...ly 3 cables and hoses PrecisionFlo options include inlet and dispense device pressure sensors to monitor inlet and dispense device pressures and also to report faults air spray package to provide shaping air to the fluid spray a variety of dispense devices to handle specific fluid characteristics and application requirements PrecisionFlo Control Assembly The PrecisionFlo control assembly includes ...

Page 7: ...s assured by a closed loop pressure control design The module responds to robot supplied sig nals to provide an accurate and consistent output flow based on a comparison of actual with desired flow rates Fluid temperature conditioning is also available as an option Typical Fluid Applications PVC Sealer Plastisols Low Viscosity Mastics Adhesives Silicone Materials PrecisionFlo Features Sophisticate...

Page 8: ...u enter data look like this MODIFY PD VOL COMP Kp xxxx Kd xxxx Vol Comp xxx xx cts Press F1 To Toggle Abb Stands For msec milliseconds SPC Statistical Process Control PVC Poly Vinyl Chloride psi pounds per square inch gnd ground com common V volts Vac volts ac Vdc volts dc PrecisionFlo Definitions Control Assembly The pendant 2 and the enclosure 1 containing the electronics used to control the met...

Page 9: ...n the typical installation drawing No Description 4 Control Assembly 5 Metering Valve 6 Dispense Gun 7 Control Pendant 8 Sealer Robot 9 Flow Meter 10 Robot Controller 11 Robot Interface Cable 12 Temperature Conditioning System 13 Temperature Conditioning Hoses 14 Fluid Supply System 15 Fluid Supply Header Filter Module not shown ...

Page 10: ...eaterobot test program End Software Config Set volume compensation ifapplicable Fig 5 Turn on electrical power to control assembly Set pressure sensor characteristics Setnominal values for Kp and Turn on fluid supply pressure Place dispense device over waste container Disconnect flow meter Calibrate PrecisionFlo module in pressure mode Place module in manualdispense mode Bleed air from materialdis...

Page 11: ...tely 50 kg 110 lbs and should never be moved or lifted by one person Use adequate personnel and support devices when mounting moving or handling the control assembly to prevent equipment damage or personal injury Installing the Enclosure 1 Select a location for the PrecisionFlo control assembly enclosure Keep the following in mind Allow sufficient space for installing and using the equipment Make ...

Page 12: ...310531 12 Installing Control Assembly Hardware 30 31 24 18 24 Fig 6 457 mm 762 mm 794 mm Part No 918463 610 mm Fig 7 30 31 24 19 25 635 mm 483 mm 762 mm 794 mm 8646A Part No 918644 ...

Page 13: ... connections are not done properly the equipment will be damaged and the warranty will be voided Connect a ground wire from the ground point in the PrecisionFlo control assembly enclosure shown in Figs 8 and 9 to a true earth ground The PrecisionFlo metering valve is grounded to the control assembly using cables provided with the metering valve An 8 AWG 25 foot long ground wire with clamp part no ...

Page 14: ...d grounding connections are not done properly the equipment will be damaged and the warranty will be voided Connect a ground wire from the ground point in the PrecisionFlo control assembly enclosure shown in Fig 10 to a true earth ground The PrecisionFlo metering valve is grounded to the control assembly using cables provided with the metering valve An 8 AWG 25 foot long ground wire with clamp par...

Page 15: ... 918463 PrecisionFlo 918463 with optional 617474 with optional 617497 Vac 120 220 100 Hz 60 50 50 Phase 1 1 1 Full Load Amps 13 8 16 Circuit Breaker 20 10 20 Power Requirements for Control Assembly 918644 918644 VAC Hz Phase Full Load Amps 120 60 1 13 3 To connect the control assembly to the electrical source 1 Create an opening in the enclosure 2 For 918463 or 918644 connect electrical power to L...

Page 16: ...mation 3 Connect the fluid line to the 3 4 NPSM f fluid supply inlet port on the flow meter 3 4 Install a fluid filter 5 Connect the following cables from the PrecisionFlo metering valve 2 to the mating receptacles on the control assembly 1 a Operations cable to the OP receptacle 6 Then connect the operations cable to the PrecisionFlo junction box connector 4 b Robot I O cable to the I O receptacl...

Page 18: ...us bodily injury To help reduce the risk of injury or equipment damage do not pressurize the system until you have verified the system is ready and it is safe to do so To reduce risk of injury or damage to equipment make sure all material hose connections are secure NOTE Read this procedure before powering up the module 1 Make sure you have installed and made all the proper connections to and from...

Page 19: ...he maximum and minimum limits of the pressure sensors correspond to the maximum and minimum voltages produced by the sensors For example If the sensor has a pressure range of 0 to 1500 psi and an output range of 1 to 5 volts the PrecisionFlo control assembly correlates a 1 volt signal with a pressure of 0 psi and a 5 volt signal with a pressure of 1500 psi Fig 14 0 1 5 1500 Pounds per Square Inch ...

Page 20: ...lo module with a pressure above the maximum psi could result in damage to the equipment Setting the Outlet Pressure Limit Enter 3500 for the high pressure limit and 0 for the low pressure limit 1 On the control pendant HOME SETUP Outlet Pressure Limit 2 Key in the High Pressure Limit then press ENTER 3 Move the cursor to the next line Key in the Low Pressure Limit and press ENTER 4 Press BACK to r...

Page 21: ...s tics of your material and dispensing system 5 Key in the Kp parameter then press ENTER Move the cursor to the Kd field Key in Kd and press ENTER 6 Press either BACK to return to the SETUP menu or HOME to return to the HOME screen Calibrating PrecisionFlo Module in Pressure Mode For more information about flow calibration or for instructions on how to calibrate a system with a con nected flow met...

Page 22: ...s F2 to Dispense 3 Key in 80 the software automatically adds the percent then press ENTER WARNING The system is now ready to dispense Make sure dispensing will not endanger people or equipment before proceeding 4 Press F2 on the pendant to begin dispensing Dispensing continues as long as you continue to press F2 and stops when you release the F2 key 5 Press HOME to exit Manual dispense mode and re...

Page 23: ...hannel storage oscilloscope to run tests for determining Kp and Kd parameters On and Off delays 1 Create a robot test program to dispense material on a flat surface in a straight line for 36 inches The robot must provide the PrecisionFlo module with Command Voltage Portion of Path 4 volts first 12 inches 8 volts second 12 inches 4 volts third 12 inches 2 Set the Kp and Kd parameters using the proc...

Page 24: ...llation and instability in module output For example if the module receives a command to output a pressure of 1000 psi higher values of Kp will result in output pressures closer to 1000 psi Low values of Kd will soften or slow module responses to changes in the command input voltage while higher values of Kd will tighten or speed up module re sponses If either Kp or Kd is set too high the module m...

Page 25: ...ate the material flow in pressure mode a On the control pendant HOME SETUP FLOW CALIBRATION You see FLOW CALIBRATION Enter Maximum Operating Flow Rate 00cc min b Make sure the flow meter has been discon nected c At the prompt key in 0 then press ENTER You see WARNING Material Will Be Dispensed Press F2 To Continue d Place the dispensing device over a waste container then press F2 You see FLOW CALI...

Page 26: ...ad Kd affects the stability of the bead You must first adjust Kp and then adjust Kd Fig 19 shows uneven beads where Kp needs to be adjusted Fig 20 shows beads where Kp has been adjusted and now Kd needs to be adjusted Fig 19 segment 1 segment 2 segment 3 Example Uneven Bead Patterns Fig 20 Example Unstable Bead Patterns segment 1 segment 2 segment 3 segment 1 segment 2 segment 3 NOTE Some material...

Page 27: ...es Kp 100 Kp 5000 Bead Yes No No No Yes Dispensematerial Set Kp Set Kd A Kp 20 Yes No Yes No A B 2 5 3 1 Kd 100 Beadunstable Set Kd Minus B A No Fig 22 Page 29 4 4 4 Adjust Kp and Kd Values Visually 6 Yes 7 Fine Tuning maintains stability Bead maintains stability Bead maintains stability Yes ...

Page 28: ... bead again Continue to increase Kp in incre ments of 100 until either the beadwidths become equal as in Fig 18 or until you reach 5000 Kp When the beadwidths become equal go to step 5 If you reach 5000 Kp and the bead still is not even go to step 4 4 Add 100 to Kd and rerun the test If this does not stabilize bead performance repeatedly increase Kd by 100 and retest until stability is achieved Th...

Page 29: ...s any waves in it after a change in bead width 2 If no waves exist increase Kd by 100 and dis pense another test bead Repeatedly increase Kd and retest until a wave appears after a width change to indicate unstable performance Fig 20 3 Reduce Kd by 100 and resume adjusting upward by increments of 20 and retesting until the wavi ness or instability appears again 4 Decrease Kd to the last previous s...

Page 30: ...30 310531 Notes ...

Page 31: ...let Yes No No No Yes Dispense Set Kp Set Kd A Kp 20 Yes No Yes No A B 2 5 3 1 Set Kd Fig 24 Page 33 4 4 Adjust Kp and Kd Values Using an Oscilloscope equal equal material Start oscilloscope 5 5 6 7 9 Yes pressure stable Outlet pressure stable Outlet pressure stable Fine Tuning Kd 100 B A No Yes Outlet pressure unstable Minus ...

Page 32: ... equal the bead is even If the pressures are equal go to step 6 4 If the1st and 3rd pressures are not the same increase Kp by 100 and examine the pressures again Continue to increase Kp in increments of 100 until either the pressures become equal or you reach 5000 Kp When the pressures become equal go to step 6 If Kp reaches 5000 and the pressures are still not equal go to step 5 5 Add 100 to Kd a...

Page 33: ...20 and retesting until the wavi ness or instability appears again 4 Decrease Kd to the last previous setting 5 Disconnect the oscilloscope 6 Reconnect the electrical cable to the flow meter The adjustment procedure is complete and the module is set for optimum performance with the current materi al and module configuration Using the Control Pendant to Modify Kp and Kd Parameters NOTE Kp and Kd are...

Page 34: ...return to the HOME screen Calibrating Flow Rate and Setting Module Operation Mode When you calibrate the flow rate you are performing 2 functions selecting whether the PrecisionFlo module will be operating in pressure mode or flow mode calibrating flow rate The PrecisionFlo module has two modes of operation pressure mode and flow mode You can only use flow mode if your PrecisionFlo configuration i...

Page 35: ...a flow meter A determine the maximum flow rate required by the application Fig 27 A 3 If your PrecisionFlo configuration does not include a flow meter determine the maximum outlet pressure for your application Setting Flow Calibration COMPONENT RUPTURE HAZARD Never exceed the maximum air or fluid working pressure rating of the lowest rated component in the system Over pressurization can cause comp...

Page 36: ... BACK key 2 Adjust either the system components or the soft ware configuration settings 3 Run the calibration procedure again Calibration for Systems with a Disconnected Flow Meter or Without a Flow Meter To calibrate the material flow 1 Make sure the CONTROL ON indicator is lit on the control assembly If not press MASTER START STOP RESET on the control assembly 24 in Fig 30 2 On the control penda...

Page 37: ...N the device delays opening after regulation begins Regulation ON regulation delays starting after the gun solenoid is activated Gun OFF the device delays closing after regulation ends Regulation OFF regulation delays stopping after the gun solenoid is activated Fig 28 and Table 5 show delay ON and OFF timing Fig 28 DISPENSE Gun Open PrecisionFlo Metering Valve Regulating A B C D E MEASURE VOLUME ...

Page 38: ...orm on the oscilloscope There should be no pressure overshoot visible in the pressure sensor output when the GUN ON signal rises If the Do This Initial psi spikes then drops to regular psi Increase the REGULATION ON delay in 10 msec intervals until the problem is eliminated Initial psi drops then builds to regular psi Increase the GUN ON delay in 10 msec intervals until the problem is eliminated T...

Page 39: ... is automatically set to 0 6 Press either BACK to return to the PROTECTED SETUP menu or HOME to return to the HOME screen Modifying PrecisionFlo OFF Delays 1 On the control pendant HOME SETUP Protected Setup 2 Key in the password then press ENTER 3 Then go to PROTECTED SETUP Set Off Delay 4 You see SET OFF DELAY Gun xxx msec Reg xxx msec 5 Key in a value for either the gun or regulation OFF delay ...

Page 40: ...an attempt to match the required flow rate Refer to the Volume Compensation section in the theory of operation section page 61 before using manual mode 1 On the control pendant HOME SETUP Protected Setup 2 Key in the password then press ENTER 3 Then go to PROTECTED SETUP Modify PD VOL COMP 4 You see MODIFY PD VOL COMP Kp xxxx Kd xxxx Vol Comp xxx xx cts Press F1 To Toggle 5 Press F1 to step the vo...

Page 41: ...g to reprogram the robot To change the dispense rate you must first determine the percentage by which to increase or decrease the material amount The maximum adjustment permitted is 10 of the initial value Only values between 90 and 110 will be accepted Larger changes must be made in the robot controller 1 On the control pendant HOME SETUP Scale Analog In 2 You see SCALE ANALOG IN Analog Input Sca...

Page 42: ...he fluid stops flowing from them 3 Shut off power to the fluid supply system 4 Place waste containers beneath the fluid drain valve and the dispense device 5 Refer to Fig 29 and perform the following steps to open the dispense device and relieve fluid pressure a Manually actuate the plunger on the solenoid B which opens the dispense device to relieve fluid pressure b Continue actuating the plunger...

Page 43: ...n on material pump 6 Push the MASTER START button 24 to turn on power to the PrecisionFlo metering valve drive circuitry This lights the CONTROL ON indicator 7 If this is the first time the module has been started or you want to configure the software go to Con figuring the PrecisionFlo Module on page 23 Restarting the Module If the module is on but the CONTROL ON indicator on the control assembly...

Page 44: ...t 28 Dispenser System Stop Button Disengages the Master Control Relay Signals the external controller that a DISPENSER SYSTEM STOP condition is in effect Shuts down PrecisionFlo Assembly Turns off Control On light De energizes the drive for the PrecisionFlo metering valve 46 Hand Door Pendant Selector Selects the hand held pendant or door pendant Ref Indicator Indicator Light is Meaning 25 Power O...

Page 45: ...nto Automatic dispense mode WARNING You are about to place the system under robot ic control Make sure dispensing will not endan ger people or equipment before proceeding 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 2 On the control pendant HOME Automatic 3 You see AUTOMATI...

Page 46: ...e proceeding 5 Press F2 on the pendant to begin dispensing Dispensing continues as long as you continue to press F2 and stops when you release the F2 key 6 Press HOME to exit Manual dispense mode and return to the HOME screen Shutting Down the PrecisionFlo Module Fig 31 24 25 26 27 28 Part No 918463 Part No 918644 24 25 28 26 27 1 Shut OFF the material supply to the module 2 Follow the Pressure Re...

Page 47: ... only energized for 5 seconds at a time so position yourself where you can watch the needle and seat on the metering valve when performing this procedure CAUTION This procedure should be conducted only by trained personnel since incorrect use of this procedure can overheat and damage the motor 1 Perform the Pressure Relief Procedure on page 42 to ensure the module is depressurized WARNING To reduc...

Page 48: ...metering valve is be low the lower limit set for op Material supply shut off Check pumps and valves low the lower limit set for o eration Material supply not connected Check supply connections Incorrect limit set Check limit setting and correct if necessary Failed transducer Check transducer replace if failed 17 Outlet Pressure Low Output pressure of the Pre cisionFlo metering valve is Incorrect l...

Page 49: ... expected for that job Partially plugged tip or supply sys tem Error is outside volume com pensation window Clean tip and or supply sys tem Insufficient flow to PrecisionFlo me tering valve inlet Error is outside vol ume compensation window Increase flow rate to Preci sionFlo metering valve inlet Material viscosity is outside volume compensation window Verify material characteristics PrecisionFlo ...

Page 50: ...ASTER START STOP RESET Control assembly not reacti vated after fault SEALER STOP push button pressed CONTROL ON light not lit control assembly is off Apply power to PrecisionFlo module then press MASTER START STOP RESET 5 Motor Over Temperature PrecisionFlo metering valve linear motor temperature h d d 85 C Servo drive short Check for continuity between and outputs of servo drive sensor has exceed...

Page 51: ...i Low xxxx psi SCALE ANALOG IN Analog Input Scale Factor xxx Previous xxx FLOW CALIBRATION Enter Maximum Operating Flow Rate xxxcc min ENTER PASSWORD 00 MODIFY PD VOL COMP Kp xxxx Kd xxxx Volume Comp Auto xx cts Press F1 to Toggle SET ON DELAY Gun xxx msec Reg xxx msec TEST MOTOR Setpoint Moves Shaft Current xxx SCALE PRESS SENSOR Enter Max and Min x xxxVdc xxxxpsi Max x xxxVdc xxxxpsi Min FLOWMET...

Page 52: ...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 Analog inputs from pressure sensors the optional flow meter and the external robotic system go to the PrecisionFlo control board Other internal signals control the linear motor in t...

Page 53: ... 12 13 14 15 16 17 18 19 20 21 22 23 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 ...

Page 55: ...he PrecisionFlo module in this state is taken in response to the detection of a fault When a fault is detected the PrecisionFlo module sets the FAULT STROBE signal HIGH and disables dis pensing by disengaging the Master Control Relay MCR which shuts off power to the PrecisionFlo metering valve and sets the DISPENSER READY signal LOW Fault detection can also occur during dispensing See Fault Handli...

Page 56: ...y timing The other delay is set to 0 E Regulation off The other delay is set to 0 Fig 34 1 Robotic system controller verifies that the DIS PENSER READY signal is HIGH 2 Robotic system goes into cycle 3 Robotic system controller places the style informa tion on the style data bus 4 Robot sets the MEASURE VOLUME signal HIGH 5 PrecisionFlo module reads the style bits from the data bus Style Bits 0 5 ...

Page 57: ...ENSE line LOW indicating that no material is required during this portion of the program Robot can cycle the DISPENSE signal HIGH and LOW throughout a cycle if re quired Volume measurement will still occur 16 At the end of the cycle PrecisionFlo module checks if a GUN OFF DELAY has been set by the user If the delay has been set the PrecisionFlo module waits until the delay has expired then closes ...

Page 58: ...e value is equal to 4 8 or 12 and a Volume Fault is indicated Typical Fault Handling Procedure 1 A problem occurs in the PrecisionFlo module 2 The PrecisionFlo module analyzes the problem indication and determines if the fault is an alarm or a warning 3 If the fault is an alarm a The PrecisionFlo module disables the MCR which sets the DISPENSER READY signal LOW and shuts down the module b Then the...

Page 59: ...on the accuracy of the flow meter The last volume dispensed is overwritten when the MEASURE VOLUME line is changed from LOW to HIGH by the robot Fig 37 B A C E F D Least Significant Data Most Significant Data Measure Volume Volume Request Volume Valid Volume Data C D Table 10 Volume Data Timing Limits Minimum Time msec Maximum Time msec A MEASURE VOLUME drops to VOLUME REQUEST rises 1 B MEASURE VO...

Page 60: ... the VOLUME VALID signal LOW 9 Robotic controller sets the VOLUME REQUEST signal HIGH 10 PrecisionFlo module places the second 5 bits B5 B9 on the data bus 11 PrecisionFlo module sets the VOLUME VALID signal HIGH 12 Robotic controller reads the data 13 Robotic controller sets the VOLUME REQUEST signal LOW to indicate volume data has been read 14 PrecisionFlo module sets the VOLUME VALID signal to ...

Page 61: ...flow rate 3 Compensates for changes in flow rate Off N A Turns off volume com pensation Volume Compensation Algorithm The algorithm for controlling flow 1 Find the pressure from commanded flow and flow calibration curve 2 Multiply the pressure by the flow correction gain Send the corrected pressure as a command to the metering valve 3 If the flow meter has registered the correct number of pulses i...

Page 62: ...5 2 x 30 5 mm 6 x 12 1 50 617472 Label danger electric shock 1 60 238093 Board assy current temp 1 Ref No Part No Description Qty 70 918583 Board assy service control PrecisionFlo Includes items 80 and 90 1 80 918494 EPROM set programmed 1 90 237955 Board assy flow control 1 Replacement Danger and Warning labels tags and cards are available at no cost Keep these spare parts on hand to reduce down ...

Page 63: ...310531 63 Parts Model 918463 PrecisionFlo Control Assembly continued Fig 40 90 80 60 70 ...

Page 64: ...ard assy current temp 1 Ref No Part No Description Qty 4 918583 Board assy service control PrecisionFlo Includes items 8 and 9 1 5 918494 EPROM set programmed 1 6 237955 Board assy flow control 1 7 617472 Label danger electric shock not shown 1 Replacement Danger and Warning labels tags and cards are available at no cost Hole cover not shown provided inside cabinet Fig 41 2 1 ...

Page 65: ...310531 65 Parts Model 918644 PrecisionFlo Control Assembly continued MP FM TP MS RAR OP I O Fig 42 3 6 5 4 ...

Page 66: ...Style Bit 2 Style Bit 3 Style Bit 4 Style Bit 5 I O D3 I O D7 I O D13 I O D5 I O A1 I O D8 Make the appropriate style bits HIGH to indicate the style bit code for the current job before raising DISPENSE ENABLE The style bits are used by the PrecisionFlo module for SPC data collection No compensation is done based on this input Refer to figure 35 on page 56 Volume Request I O A8 Make this signal HI...

Page 67: ...nd should be HIGH before a dispense cycle is initiated Data Bus 0 Data Bus 1 Data Bus 2 Data Bus 3 Data Bus 4 I O A2 I O D14 I O D9 I O D15 I O A5 These output bits are used to signal volume and fault data Refer to the timing diagrams and descriptions on pages 58 through 59 Volume Valid I O D10 Signal is made HIGH to indicate that the data bus is presenting valid volume information Refer to figure...

Page 68: ...nsation AVC Digital Output Signal Name Connector Pin Signal Description Gun On SIG OP E COM OP B This signal is raised by the PrecisionFlo module to actuate the solenoid valve that opens the dispense gun The PrecisionFlo module turns this signal ON in response to a manual or external dispense request This signal is turned OFF to shut off the dispense gun MCR Enable WIRE 1801 CR180 This signal is t...

Page 69: ...nitor inlet pressure and the user to view inlet pressure by using the control pendant to enter AUTOMATIC mode and display pressures Tip Pressure Optional Provides an input from a pressure transducer at the tip of the dispense gun Tip pressure can be used to detect bead skips in extru sion applications The operator can view tip pressure by using the control pendant to enter AUTOMATIC mode and displ...

Page 70: ...ified electrician check the power wiring to the module CONTROL ON LT127 Light is ON when the MASTER CONTROL RELAY MCR is engaged DISPENSER SYS TEM STOP PB1252 Push this button to disengage the MCR and signal the external controller that an Dispenser System Stop condition is in effect The MCR will remain disengaged until the MASTER START button is pressed MASTER START STOP RESET PB1251 Push this bu...

Page 71: ... Contacts Connects to A 12 Vdc 200 ohms resistance B dc common C outlet pressure sensor signal D inlet pressure sensor signal E shield Pendant TP Contacts Connects to A in B out C 5 Vdc common D 5 Vdc E shield I O Con tacts Connects to Con tacts Connects to A1 style bit 4 input D1 fault acknowledge input A2 data bit 0 output D2 dispense input A3 measure volume input D3 style bit 0 input A4 24 Vdc ...

Page 72: ...ations OP Contacts Connects to A 24 V B 24 V common C gun solenoid D E closer solenoid F command servo pressure G command servo ressure valve H 12 V J 12 V common K signal auxiliary pressure d L g common y transducer M ground S shield ...

Page 73: ...eted entering information into a field or screen Press the ENTER key Move to the next field or previous field UP arrow key Use either the UP arrow key DOWN arrow key Return to the previous menu Press the BACK key Return directly to the HOME menu Press the HOME key Enter data in response to screen prompts 1 Key in numbers 2 Press ENTER PrecisionFlo accepts the data Resume operation after an alarm h...

Page 74: ...e control assembly 2 Remove power from the control assembly 3 Hold in the ENTER key and turn on power to the Control Assy The pendant displays the software version number 4 Release the ENTER key and you see CONTRAST 5 Adjust the display contrast a Step through the selections until the display is at the desired contrast b Save your selection The pendant displays BR XXXX 6 Adjust the baud rate a Ste...

Page 75: ...l the new software do the following 1 Turn off the power to the PrecisionFlo Control 2 Locate the control board 32 in the control box assembly See Fig 45 Fig 45 05499 32 U9 U4 U7 U1 U6 3 Locate the software chips U6 and U7 on the con trol board 32 Note the direction of the chips 4 Use an I C extraction tool 33 to remove the old software chips Pull the chips directly up See Fig 46 Fig 46 33 To remo...

Page 76: ... with it through RS 232 communication The function of the pendant is similar to the function of a computer keyboard and monitor The pendant allows the operator to see information about the PrecisionFlo operation and to make changes to the operation Checking for Control Panel DC Voltage Problems WARNING ELECTRIC SHOCK HAZARD High voltage is present when performing the following voltage checks which...

Page 77: ...g information into a field or screen Press the ENTER key Move to the next field or previous field UP arrow key Use either the UP arrow key DOWN arrow key Return to the previous menu Press the BACK key Return directly to the HOME menu Press the HOME key Enter data in response to screen prompts 1 Key in numbers 2 Press ENTER PrecisionFlo accepts the data Resume operation after an alarm has been trig...

Page 78: ... Remove power from the control assembly 3 Hold in the ENTER key and turn on power to the Control Assy The pendant displays the software version number 4 Release the ENTER key and you see CONTRAST 5 Adjust the display contrast a Step through the selections until the display is at the desired contrast b Save your selection The pendant displays BR XXXX 6 Adjust the baud rate a Step through the select...

Page 79: ...sure to be opened for servicing Electrical Input Requirement 120 VAC 10 Single Phase 60 Hz 13 3 Ampere maximum current Circuit Breaker Rating 15 Amperes Flow Command Input Signal Voltage 0 10 Volts D C minimum impedance 44 KW Flow Meter Option Output Signal Voltage 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 fact...

Page 80: ...nty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARR...

Search results

Summary of Contents for PrecisionFlo 918463

Reviews:

Related manuals for PrecisionFlo 918463

Brands by name

Popular brands

Graco PrecisionFlo 918463, Instructions-Parts List Manual

Search results

Summary of Contents for PrecisionFlo 918463

Reviews:

Related manuals for PrecisionFlo 918463

Brands by name

Popular brands