Graco 334784D - InvisiPac Pattern Controller Owner's Manual

Operation, Repair, and Parts
InvisiPac® Pattern
334784D
Controller
EN
To control fluid dispense valves of adhesive supply equipment. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions. Read all warnings and instructions in
this manual and related manuals. Save these instructions.
See page 3 for model information and
Agency approvals.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Models............................................................... 3
Agency Approvals............................................... 3
Related Manuals ................................................ 3
Warnings ........................................................... 4
Overview............................................................ 7
Component Identification (Internal Models) ........... 8
Component Identification (External
Models) ................................................ 9
Installation — Internal Models.............................. 10
Connect Pattern Control Board ..................... 10
Connect Power Supply and Advanced
Display Module............................... 11
Install Control Board into InvisiPac
System .......................................... 12
Installation — External Models ............................ 13
Mounting ..................................................... 13
Connect Advanced Display Module
(ADM) ............................................ 13
Connect Pattern Control Board ..................... 14
Connect Electrical Cord................................ 14
Wire Pattern Control Board ................................. 15
Valve Installation.......................................... 15
Trigger Installation ....................................... 15
PLC Inputs and Outputs Installation
(optional)........................................ 16
Encoder Installation (PC-8e only) .................. 17
Run Up Installation (PC-8e only) ................... 17
Initial Startup ...................................................... 18
Software Update .......................................... 18
Key Token ................................................... 18
Screens ............................................................. 19
Screen Maps ............................................... 19
HMI Interface............................................... 20
PC Screens ................................................. 21
Advanced Screens ....................................... 32
Calibration.......................................................... 37
Gun Compensation (optional) ....................... 37
Line Speed .................................................. 38
Run Up Control (PC-8e Only) ....................... 39
Modulated Bead (PC-8e Only) ...................... 40
Verification ......................................................... 41
Valves......................................................... 41
Triggers....................................................... 41
Encoder ...................................................... 41
Run Up Control ............................................ 41
PLC Inputs .................................................. 41
Troubleshooting.................................................. 42
Error Codes ................................................. 42
Display ........................................................ 43
Pattern ........................................................ 43
Valve .......................................................... 44
Trigger ........................................................ 44
Encoder ...................................................... 44
Run Up........................................................ 45
PLC Inputs and Outputs ............................... 45
Software Update Procedure ................................ 46
USB Download ................................................... 47
Download Procedure.................................... 47
Accessing Files............................................ 47
USB Logs.................................................... 47
Parts.................................................................. 48
External Models ........................................... 48
Internal Models ............................................ 50
Kits ............................................................. 51
Wiring Diagrams ................................................. 54
Internal Pattern Controller (Generation 2
Systems with AWB) ........................ 54
Internal Pattern Controller (Generation 1
Systems with DIN Rail) ................... 55
External Models ........................................... 56
Stitching............................................................. 34
Dimensioned Drawings ....................................... 57
Random Length Bead Mode................................ 35
Technical Data ................................................... 60
Mirror Mode........................................................ 36
Notes................................................................. 61
Material Tracking ................................................ 36
Graco Standard Warranty.................................... 62
2
334784D
Models
Models
Usage
Part
With
InvisiPac
(internal
model)
24X640
PC-8
Time or distance mode, no encoder Internal Pattern Controller
24X641
PC-8e
With
InvisiPac
(external
model)
24X523
PC-8
24X524
PC-8e
24X525
PC-8
Time of distance mode, with or
Internal Pattern Controller
without encoder. Run up control
Key Token for Encoder and Run Up
(optional)
Time or distance mode, no encoder Pattern Controller
Time or distance mode, with or
Pattern Controller
without encoder
Run up control (optional)
Key Token for Encoder and Run up
Time or distance mode, no encoder Pattern Controller
Advanced Display Module
24X526
PC-8e
Without
InvisiPac
(external
model)
Type
Description
Contents
Time or distance mode, with or
without encoder
Run up control (optional)
Pattern Controller
Advanced Display Module
Key Token for Encoder and Run up
Agency Approvals
Type
Description
External Pattern 127971
Controller
Internal Pattern
24X521
Controller
Advanced Display 24E451
Module
334784D
Related Manuals
Contents
CE, ETL, cETL
CE, ETL, cETL
Manual
Number
333347
Product
InvisiPac HM25 and HM50 Tank-Free™
Hot Melt Delivery System
CE, ETL, cETL
3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
4
334784D
Warnings
WARNING
SKIN INJECTION HAZARD
000000
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get
immediate surgical treatment.
000000
000000
000000
000000
000000
•
•
•
•
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the fluid outlet.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Do not use solvent-based adhesives that can create an explosive atmosphere when
processed.
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Stop operation immediately if static sparking occurs or you feel a shock.. Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
TOXIC FLUID FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
334784D
5
Warnings
WARNING
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death,
serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon
solvents or fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
6
334784D
Overview
Overview
InvisiPac Pattern Control systems can be integrated with InvisiPac systems or stand alone with any other
equipment. For all installations, the Advanced Display Module (ADM) is used to make programming easy.
PC-8 controllers operate in time or distance mode without an encoder. Up to 8 guns and 4 independent
triggers are supported.
PC-8e controllers include the same features as PC-8 with the addition of distance based control using an
encoder, and run up control using an I/P or V/P pressure regulator.
Features of the PC-8 and PC-8e:
Feature
Details
Gun Outputs
Trigger Inputs
8
4
Encoder
2 (PC-8e only)
Run Up Control
Program Storage
2 (PC-8e only)
50
PLC Enable / Disable
Yes
PLC Alarm Output
Yes
PLC Program Select
Password Protection
Yes
Yes
Yes
Integrated Power Supply
For more information, see Technical Data, page 60.
334784D
7
Component Identification (Internal Models)
Component Identification (Internal Models)
Installed onto InvisiPac System
Key
C
H
Communication Cable
Valve
J
K
Trigger
Encoder
L
Run Up
8
Key
M
N
P
Power Supply
Power Supply Bracket
Power Harness
S
T
Control Board
Cord Grip
334784D
Component Identification (External Models)
Component Identification (External Models)
Key
A
Pattern Controller
B
Power Switch
C
D
Communication Cable
ADM
E
H
USB Port
Valve
J
Trigger
334784D
Key
K
Encoder
L
M
N
Inside View of Pattern Controller
Customer Power Cord (not included)
P
Ground Terminal
S
T
Control Board
Cord Grips (I/O x2, power)
Run Up
9
Installation — Internal Models
Installation — Internal Models
Connect Pattern Control Board
1. Set Pattern Control system type selector switch
to 0. NOTE: The system must be powered off for
a change in system type to have an effect.
2. Remove cord grip assembly (T) from Pattern
Control board (S) and remove inserts. Inserts will
grip tightly on most M8 and M12 cables and will
expand and compress to accept cables larger
than the apparent hole size.
3. Install valve signal wires, trigger signal
wires, PLC wires (optional) and Encoder
and Run Up wires (PC-8e only). See
Wire Pattern Control Board, page 15.
4. Route cables through the opening in the pattern
control board back panel as shown.
5. Apply cord grip inserts over cables and replace
into frame. Replace frame onto Pattern Control
panel.
6. Remove excess slack from cables but do not
pull tight. Tighten cord grip frame on inserts to
secure.
10
334784D
Installation — Internal Models
Connect Power Supply and Advanced Display Module
NOTE: If the Internal Pattern Controller is being
installed into a first generation HM25 with DIN
rail wiring, additional connections must be made.
Install Kit 24Y171 has the necessary components
and instructions to perform this installation. See
Kits, page 51.
4. Connect communication cable (C) to open J3
connector (or J6, if J3 is used) on MZLP board. If
connecting to MZLP #2, loop extra cable length
along back edge of electrical enclosure.
1. Turn main power switch OFF.
2. Remove panel door, then remove blanking plate
from left-hand side of system electrical enclosure.
3. Remove connector from AWB terminal pins J1
and remove the power supply and harness from
mounting bracket. Unscrew mounting bracket
from AWB.
334784D
5. Remove blue connectors from terminals of power
supply W and discard or set aside.Install new
power supply bracket (N) onto AWB and clip new
power supply (M) into place.
11
Installation — Internal Models
6. Connect power harness (P) to AWB terminal pins
J1 and the input and output terminals of power
supply. See .
Install Control Board into InvisiPac
System
1. Mount board into open space on left-hand side of
electrical enclosure. Use serrated-flange screws.
2. Connect power harness to Pattern Control Board
terminal P1, and connect communication cable
to Pattern control Board terminal P4.
3. Replace system electrical enclosure door.
12
334784D
Installation — External Models
Installation — External Models
Mounting
Connect Advanced Display Module
(ADM)
The Pattern Controller and ADM can be mounted
using the included VESA-compatible bracket and
mounting hardware.
Integrate with InvisiPac
1. Unscrew the two lower screws to uncouple the
“wall” portion of the bracket.
1. Set Pattern Control system type selector switch
to 0. NOTE: The system must be powered off for
a change in system type to have an effect.
2. Securely mount the bracket in the desired
location.
3. Slide the controller onto the bracket and tighten
the two screws for permanent fastening.
ALTERNATIVE METHOD: remove mounting
hardware and mount directly to any surface.
NOTE: Make sure at least 13 in. of clearance is
available above the top of the mounting bracket in
order to slide the enclosure in and out of the wall
mount.
NOTE: To make repairing the system easier, locate
the system so that it is easily accessible and has
sufficient lighting.
2. Disconnect the CAN cable from the ADM (D),
push the cable through the plastic shroud (B),
then remove the shroud from the system.
3. Connect the CAN cable from the ADM (D) to one
of the male ends of the splitter (2).
4. Connect the CAN cable from the Pattern
Controller (A) to the other male end of the splitter
(2).
5. Connect the male end of the short CAN cable
contained in Pattern Controller kit (3) to the
female end of the splitter (2).
6. Push the free end of the short CAN cable (3)
through the shroud and connect the female end
to the ADM.
7. Use zip ties (4) to attach the CAN cable bundle
to the other vertical bundle of cables.
334784D
13
Installation — External Models
Stand Alone
Connect Electrical Cord
1. Set the Pattern Control system type selector
switch to 1. NOTE: The system must be powered
off for a change in system type to have an effect.
Improper wiring may cause electric shock or other
serious injury if work is not performed properly.
Have a qualified electrician perform any electrical
work. Be sure your installation complies with all
National, State, and Local safety and fire codes.
2. Mount the ADM using the provided bracket.
3. Connect the CAN cable (C) between the Pattern
Controller and the ADM.
The equipment must be grounded to reduce the
risk of electric shock. Improper grounding can
cause electric shock. Grounding provides an
escape wire for the electric current.
The pattern controller system is equipped with a
ground terminal. Have a qualified electrician ground
the system using this terminal.
Electrical power enters through the smaller cord
grip on the right side of the enclosure (see figure).
The power cord can be further secured inside the
enclosure with the provided zip-tie and tie mount.
1. Install power wires (L1/L2 or L/N) into terminals
2 and 4 on the disconnect switch. The switch
accepts solid or stranded 12 AWG and 14 AWG
wire. For ratings, see Technical Data, page 60.
Connect Pattern Control Board
See Wire Pattern Control Board, page 15.
NOTE: The power switch housing can be
removed for easy wiring using the red tab on top
of the switch.
1. Install triggers and valves.
2. Connect earth ground to the grounding terminal.
2. Install PLC inputs and outputs (optional).
3. Verify that the cord grip securely tightens around
the power cord. Use a wrench to tighten, if
necessary.
3. Install encoder (PC-8e only).
4. Install Run Up (optional, PC-8e only).
14
334784D
Wire Pattern Control Board
Wire Pattern Control Board
Valve Installation
Trigger Installation
1. Connect up to 4 NPN, PNP, or dry contact
triggers.
1. Connect up to 8 valves.
NOTE: Supplied voltage (+) is 24 VDC.
NOTE: Control voltage is 24 VDC with a limit of 1
amp per output and 6 amps total.
NOTE: Green LEDs indicate the status of each
valve.
Terminal
Cable
Plus (+)
Minus ( - )
Standard Wiring Colors
Function
M8 Cable
2. Connect the two wires between TR and minus (-)
to install a dry contact.
NOTE: Yellow LEDs indicate the status of each
trigger. Polarity can be inverted if needed (see
Trigger Setup, page 28).
DIN Cable
Terminal
24V Supply Brown
Return
Blue
Black
Black
Plus (+)
TR
Minus (-)
334784D
Standard Wiring Colors
Function
M8 or M12 Cable
Brown
24V Supply
NPN, PNP, or Black or White
Dry Contact
Return (or Dry Blue
Contact)
15
Wire Pattern Control Board
PLC Inputs and Outputs Installation (optional)
Functions:
Type
Input
Output
Function
ENABLE
Description
DISABLE
Turns the controller on and off (rising edge enables, falling edge
disables).
Integrated Systems: Turn the heat on/off using the InvisiPac PLC input
(instead of this input). The pattern controller will be turned on by the
InvisiPac system once the InvisiPac goes inactive.
Disables the pattern controller (pull high to disable).
PROGRAM
SELECT
ALARM 1
Bits select a program to run (1–15) i.e. 1010 selects program #10
NOTE: 0000 disables PLC selection (local program selection on ADM)
Relay opens for active alarm(s) on Line 1
ALARM 2
Relay opens for active alarm(s) on Line 2
Specifications
Inputs
Outputs
• Bipolar Input
• Dry Contact Output
• Electrically Isolated
• 0–24 VDC or 0–240 VAC
• 0–30 VDC
• 2A max
• Min. 10 VDC to assert
• Sinks 10 mA at 24 VDC
NOTE: To connect a dry contact signal, route GND to
one terminal and connect 24 VDC signal through the dry
contact to the other terminal (see image below).
16
Alarms indicated by output relays (see
Troubleshooting Error Codes, page 42 for more details).
Description
Code
A40P
Overcurrent on accessory power supply output
A4XP
Overcurrent on communication cable output
A4_P
Overcurrent on valve output “_”
K4_P
Encoder “_” pulse rate exceeds maximum limit
334784D
Wire Pattern Control Board
(PC--8e only)
Encoder Installation (PC
(PC--8e only)
Run Up Installation (PC
1. Connect up to two “I/P” or “V/P” run-up air
pressure regulators to vary pump pressure based
on line speed. Hardware automatically detects
whether an I2P or V2P is connected.
NOTE: Pressure vs. line speed settings are
entered on the run-up setup screen (see
Run Up Control, page 31).
1. Connect up to two encoders to monitor line
speed. NOTE: Line 1 and Line 2 on the ADM.
NOTE: Encoder type must be quadrature
differential line driver (RS422). Scaling is entered
in the encoder setup screen using the live
calibration feature.
NOTE: Some encoders have Z and Z’
connections. These are not used and do not
need to be connected.
Terminal
Plus (+)
Standard Wire Colors
Function
M12 Cable
Brown
24V Supply
Minus ( - )
Output to run-up Black
Return
Blue
Minus ( - )
Return
%
White
NOTE: Encoder direction can be reversed by
swapping A and A’ with B and B’. Do this if line
speed reads negative on the ADM.
Graco Encoder Wiring Diagram
Terminal
Function
Wire Color
Red
Plus (+)
15V Supply
A
A’
B
B’
Minus ( - )
PE
334784D
Phase A
(RS422)
Phase A
return
Phase B
(RS422)
Phase B
return
Return
Shield
signal Brown
signal White
signal Yellow
signal Green
Blue
Bare
17
Initial Startup
Initial Startup
Software Update
Key Token
When integrating into an InvisiPac System, the
system may require a software update in order to
be compatible with the pattern controller. Follow
Software Update Procedure, page 46.
For PC-8e models only, a key token is required to
enable encoder and run up use.
1. Remove token access panel on back of ADM.
2. Insert blue Key Token 24X626 and press firmly
into slot.
3. Replace cover, leaving Key Token inside.
18
334784D
Screens
Screens
Navigate through each screen to set up the Pattern
Controller interface.
• Run screens include the home page and pattern
definition.
• Setup screens contain configurable settings for
each accessory.
Screen Maps
NOTE: On integrated InvisiPac system, additional
chapters are present for hot melt HMI.
Run Screens
PC Control
PC Home
Events
Errors
1. Program Storage
– Purge
2. Pattern Definition
– Pattern
Preview
Press to switch between Run and Setup
Setup Screens
PC Setup
Advanced
1. Event Map
1. Display
2. Line Mode
2. Units
3. Trigger Setup
3. USB Settings
4. General
4. Software
5. Gun Setup
6. Run Up 1
7. Run Up 2
334784D
19
Screens
HMI Interface
Key
BA
Controller Enable/Disable
BC
BD
Stop all system processes
Defined by icon next to soft key
Abort current operation
Accept change, acknowledge error,
select item, toggle selected item
Toggle between Run and Setup screens
Navigate within a screen or to a new
screen
BE
BF
BG
BH
20
Function
334784D
Screens
PC Screens
Home
Read-only view of pattern controller inputs and outputs:
1. Status of guns
, triggers , and PLC signals.
2. Production rate
, and units completed
3. Material dispensed per product
.
.
A — Gun States
B — Trigger States
C — Line Information
D — PLC Signals
Icon
Name
Description
Gun
Gun status: Active (green), Enabled (gray), Disabled (crossed out).
Trigger
Trigger Status: Active (bright yellow), Inactive (dark yellow).
Line Number
Line number for other display values in row.
Line Speed
Current line speed (or fixed line speed setting).
Run Up Output
Percentage of run up pressure range being output (PC-8e only).
Production Rate
Number of product per minute.
Product Count
PLC Enable
Total products completed. To configure and reset, see
Trigger Setup (Screen 3), page 28.
Amount of glue per product (integrated InvisiPac systems only). NOTE: For
best results, enter the appropriate specific gravity value for the adhesive
material in use (see the InvisiPac system manual).
State of enable signal from PLC.
PLC Disable
State of disable signal from PLC.
Active Program
Displays the active program chosen by the PLC (displays dashes if the PLC
is not selecting a program).
Alarm status to the PLC (on line 1 or 2).
%
Glue Rate
PLC Alarm
334784D
21
Screens
Program Storage (Screen 1)
1. Select program to load.
2. Copy program
3. Purge guns
, erase program
, or rename program
.
.
.
4. Lock/unlock controller for maintenance
NOTE: Copy, erase, and rename capabilities are disabled if “Lock Pattern Definition” is enabled (see
General Setup, page 29).
A — Enter Screen
B — Maintenance Lock / Unlock
C — To Purge Screen
D — Active Program
P — Screen Number (Screen 1)
Icon
Name
Description
Maintenance Lock
Press to disable Pattern Controller
(without disabling the InvisiPac pump and heaters)
Maintenance Unlock
Press to enable Pattern Controller
E — Exit Screen
F — Copy Selected
G — Erase Selected
H — Rename Selected
to Select Active Program
J — Press
22
334784D
Screens
Gun Purge
1. Purge individual guns
.
2. Purge all guns by pressing enter
.
NOTE: Only guns with assigned triggers will purge.
NOTE: Guns may only be purged when the system is active or within 5 minutes of the system being active.
A — Press to Purge
B — Disabled Guns will not Purge
Icon
Name
Description
Purge
Purge specific gun
Enter
Purge all enabled guns
Return / Cancel
Exit screen
334784D
23
Screens
Pattern Definition (Screen 2)
1. Enter start point and length of beads.
2. Enable or disable stitching for each bead.
3. Preview this pattern.
NOTE: To clone the pattern from gun A to gun B, navigate to any bead on gun B and press/hold the
number key for gun A.
NOTE: Enter the screen and scroll down to see valves 5–8. Add beads and continue to scroll right to access
beads 6–24.
A — Enter Screen
B — Pattern Preview
Dots = Stitched
C—
Solid = Solid Bead
D — Current Program*
Start of Bead
E—
Bead Length
P—
Screen Number
(Screen 2)
F — Exit Screen
G — Confirm Changes
H — Cancel Changes
J — Stitch Bead
Icon
Name
Description
Bead Offset
Distance from the edge of the product to the start of the bead
Bead Length
Length of the Bead
Stitch Bead
Enable or disable stitching of this bead.
* Current program indicator signifies that changes to the settings on this page will only affect the current
program.
24
334784D
Screens
Pattern Preview
Read-only display of bead pattern.
A — Endpoint of Last Bead
B — Exit Preview
— Gun Number
— Trigger Number
NOTE: Dotted pattern shows stitching. The actual number of stitched beads is not represented.
NOTE: A red pattern indicates that the gun does not have a trigger selected (see Event Map, page 26).
334784D
25
Screens
Event Map (Screen 1)
Enter configuration settings for this pattern:
1. Assign trigger to each gun.
2. Enter gun trigger offset.
3. Enter minimum product length (if false trigger pickup is a concern).
4. Enable pattern mirroring.
5. Enter stitch percentage and interval.
A — Enter Screen
B — Gun Number
C — Trigger for Gun
D — Gun Trigger Offset
E — Minimum Product Length
F — Current Program*
G — Stitch Interval
H — Stitch Savings
J — Mirror Mode
P — Screen Number (Screen 1)
Icon
Name
Description
Trigger
Trigger associated with this gun
Gun Trigger Offset
The physical distance or time between the trigger and the gun.
Minimum Product
Length
Mirror Mode
Blocks triggers from activating a second pattern within the minimum product
length
Mirrors beads from the leading edge of the box to the trailing edge of the box.
NOTE: If mirror mode is selected, the Gun-to-Trigger Offset must be at least
half the length of the box (see Mirror Mode, page 36).
Percentage of glue saved by stitching. Set to 0 to disable stitching.
NOTE: Stitching must also be enabled/disabled for each bead (see
Stitching, page 34).
The distance between the start of each stitch.
Stitch Savings
Stitch Interval
* Current program indicator signifies that changes to the settings on this page will only affect the current
program.
26
334784D
Screens
Line Mode (Screen 2)
1. Select mode:
last product
a. Time based.
b. Distance mode without encoder (uses fixed
line speed).
c.
until length of
b. Adjust line speed setting
Distance mode with encoder.
2. For time mode, there are no additional settings.
3. For distance mode without encoder:
a. Pass one product by the trigger at normal
speed.
NOTE: See trigger setup section if product is
not tripping the trigger properly.
is correct.
4. For distance mode with encoder:
a. Verify positive line speed when line is moving
forward. If speed is negative, swap A and A’
with B and B’ wires at the encoder connector
on the Pattern Controller.
b. Pass one product by the trigger.
c.
Adjust encoder pulses per mm
length of last product
until
is correct.
A — Enter Screen
B — Last Box Length
P — Screen Number (Screen 2)
Icon
Name
Time Time Mode Select
Based
Line Number
Description
In time mode, programs settings are in units of milliseconds
Line number for other settings/values in a row
Length of Last Product Length of the last product seen by a trigger on the line.
NOTE: Value adjusts for changes in encoder/speed settings.
Encoder
Select if encoder is to be used
Encoder Pulses per
mm
Pulses encoder generates per mm of line travel.
NOTE: 1000 ppr encoder, 300 mm wheel = 3.333 pulses/min.
Low Line Speed Alarm Outputs will not fire when the line is below this speed.
NOTE: A value of 0 disables this alarm.
Read-only: Maximum line speed allowed.
High Line Speed
NOTE: The value is calculated from encoder pulses per mm.
Alarm
Line Speed
• If encoder enabled: view current line speed
• If encoder disabled: enter fixed line speed
334784D
27
Screens
Trigger Setup (Screen 3)
1. Select Trigger Polarity
:
a. Trigger should show bright yellow when
product is present and dark yellow for no
product.
b. If polarity is backwards, use the drop-down
b. Where two line speed settings are required,
select line 1 for triggers sensing from the first
line speed and line 2 for the second.
3. Trigger Cycle Counters:
a. View current and lifetime cycle counts of
each trigger.
to invert the detection.
2. Select Trigger Line Number
(PC-8e only):
b. Press soft key
to reset current cycle
count of selected trigger.
a. If product runs past all triggers at the same
speed, select line 1.
A — Enter Screen
B — Trigger Polarity
C — Line 1 or 2
D — Reset Selected Counter
E — Lifetime Trigger Count
F — Resettable Trigger Count
G — Include in Product Count
P — Screen Number (Screen 3)
Icon
Name
Description
Trigger Polarity
Toggle polarity to invert state of trigger signal
Select Line
Select which line the trigger is sensing on (PC-8e only)
Reset Counter
Reset trigger cycle count. NOTE: Resetting the first trigger on a given line will
reset the product counter on the PC home screen for the given line.
Include in Product Checked – Include trigger cycles in product counter
Count
Unchecked – Do not include trigger cycles in product counter (see table below)
Line Configuration
Single Line
Diagram
Trigger Setup
PC Home
Multi--unit Line
Multi
Multi--line
Multi
NOTE: To reset the PC Home product for each line, reset the current trigger count for the trigger with the
disabled (gray) check box.
28
334784D
Screens
General Setup (Screen 4)
1. Lock Pattern Definition (optional) — Protects
pattern from accidental changes. Operator must
enter a password to change patterns, and copy,
delete, or rename programs.
NOTE: This setting will only take effect
if Run Screens are also locked (see
Advanced Screens, page 32).
2. Enable Pressure Compensation (optional, PC-8e
only):
• Used to maintain consistent glue output with
variable line speed.
• With run-up kit installed, this feature adjusts
pump pressure according to the output
vs. speed curve. For run-up settings, see
Run Up Control, page 31.
3. Enable Modulated Bead (optional, PC-8e only):
• Used to maintain consistent glue output with
variable line speed.
• Adjusts output by stitching beads according to
the output vs. speed curve.
• When Pressure Compensation is enabled,
modulated bead becomes active below the
minimum output percentage.
• When Pressure Compensation is disabled,
modulated bead follows the output vs.
speed curve. For run-up settings, see
Run Up Control, page 31.
4. Clear queue On Stop (PC-8e only):
• If selected, products queued between the
trigger and gun will be cleared when the line
stops.
• If not selected, products queued between the
trigger and gun will be kept when the line
stops. Products can still be manually cleared
from the queue by turning the system off and
back on via the power button.
A — Enter Screen
P — Screen Number (Screen 4)
334784D
29
Screens
Gun Setup (Screen 5)
1. Gun Compensation (see
Calibration – Gun Compensation, page 37):
• Enter gun open compensation
.
• Enter gun close compensation
.
• View current and lifetime cycle counts of each
gun.
to reset current cycle
• Press soft key
counter of selected gun.
2. Gun Cycle Counters:
A — Enter Screen
B — Gun Open Compensation
C — Gun Close Compensation
D — Lifetime Gun Cycles x 1000
E — Resettable Gun Cycles x1000
P — Screen Number (Screen 5)
Icon
Name
Description
Open Compensation
Mechanical delay between electrical signal to gun and physical opening of gun
Close Compensation Mechanical delay between electrical signal to gun and physical closing of gun
Reset Counter
30
Reset gun cycle count
334784D
Screens
Run Up Control (Screens 6–7, PC–8e only)
Enter run up output settings (see
Calibration – Run Up Control, page 37).
A — Enter Screen
B — Minimum Output
C — Maximum Output
D — High Calibration Point
E — Low Calibration Point
P — Screen Number (Screen 6)
Icon
Name
Description
Output Pressure
Percentage
Line Speed
Enter minimum and maximum pressure for run up control.
Enter corresponding pressure points for entered line speed points to set run
up curve.
Upper and Lower line speed points
Run Up Pressure to
Line Speed Curve
Curve is set by two points which are defined by the user. Upper and lower
limits define bounds over which run-up will function linearly.
NOTE: % output refers to the percentage of the run
controller full scale setting, not the percentage of the
inlet high pressure.
334784D
31
Screens
Advanced Screens
Advanced — Display
Advanced — Units
General display settings including language, time,
and password protection.
Select the system units to be used on the display.
Name
Name
Language
Date Format
Description
Date
Select the display language
Select the display date format
Enter the display date
Time
Enter the display time
Password
Enter the password to restrict
access to Setup screens. NOTE:
A value of “0000” does not require
a password for access to setup
screens.
Enter the time-out for the display
screen saver. NOTE: A value of “0”
disables the screen saver.
If selected, disables the display
beep functionality.
If selected, operators will not be
able to change most run screen
settings.
NOTE: In order for this setting
to have any effect, a password
other than “0000” must be entered
above.
NOTE: When returning to the
run set of screens from the setup
screens, the operator will have two
minutes to make changes before
the screens lock.
Screen Saver
Silent Mode
Lock Run
Screens
32
Description
Temperature
Select the system temperature
units (integrated systems only)
Mass Units
Select the system mass units
(integrated systems only)
Distance Units Select the system distance units.
NOTE: This setting applies to all
pattern control distance values
except when time based mode is
selected on PC Setup – Line Mode
(distance units become time units
of milliseconds).
334784D
Screens
Advanced — USB Downloads Settings
Advanced — System Software
Select USB download settings.
Read only display of system software.
Name
Description
Disable USB
Downloads /
Uploads
Disable USB Log
Errors
Download Depth
Disables USB port from
transmitting data to/from a USB
drive
Disables USB log advisory
334784D
Sets the length of the data logs
to be downloaded (affects the
download time)
Name
Description
Module
Name of module in system
Software Part # Part number of software installed
on module
Software Version Version of software installed on
module
NOTE: If software versions or part numbers
do not match the expected values, see
Software Update Procedure, page 46.
33
Stitching
Stitching
Stitching is used to reduce adhesive consumption while maintaining bond strength.
Definitions
Sub-Bead —
One dispense cycle of a stitched bead.
Stitch Interval —
The distance between the starts of two adjacent sub-beads.
Stitch Savings —
The percentage of adhesive saved.
Anchor Beads
An anchor bead is a sub-bead placed at the end of the stitched bead that guarantees the stitched bead ends at
the same location as the original (non-stitched) bead.
Setup
In order to stitch any bead, perform the following
steps:
1. Navigate to Event Map, page 26.
2. Enter the desired Stitch Interval
and Stitch
4. Stitch individual beads by selecting the Stitch
option within each bead entry box.
Bead
NOTE: Not all beads for a specific gun must be
stitched (some can be stitched while others are
solid).
for the desired gun. NOTE:
Savings
Stitching can be disabled by setting Stitch
Savings to “0”.
3. Navigate to Pattern Definition, page 24.
34
334784D
Random Length Bead Mode
Random Length Bead Mode
For handling products of various lengths with one pattern
To use random length bead mode, perform the following steps:
1. Navigate to Event Map, page 26.
2. Verify the appropriate Gun-Trigger Offset
for the selected gun.
6. Enter the length of the longest random bead
(LRB) that may be needed in the bead 1 length
box.
7. Enable or disable stitching for bead 1.
NOTE: Gun-Trigger Offset must be greater than
or equal to the leading margin.
3. Enable Mirror Mode
for the desired gun.
4. Navigate to Pattern Definition, page 24.
5. Enter the leading margin (LM) in the bead 1
offset box. NOTE: The leading margin is equal to
the trailing margin.
334784D
35
Mirror Mode
Mirror Mode
For symmetrical patterns, including products with
varying lengths.
To use mirror mode, perform the following steps:
1. Navigate to Event Map, page 26.
2. Verify Gun-Trigger Offset
(final bead offset + length).
3. Enable Mirror Mode
for the selected gun is greater than or equal to the end of the final bead
for the desired gun.
4. Navigate to Pattern Definition, page 24.
5. Enter bead information for the first half of the product.
6. Enable or disable stitching for each bead.
Material Tracking
The Material Tracking feature can be used on pattern controllers that are connected to an InvisiPac (internal
and integrated systems). See the Material Tracking section in manual 333347 for more details.
36
334784D
Calibration
Calibration
Recommended Values
GM-100: 5-10 ms
GS-35: 10–20 ms
Unknown, other: 10 ms
Gun Compensation (optional)
Calibration Routine
For high speed lines and precision applications.
1. Navigate to Gun Setup, page 30.
NOTE: Before entering gun compensation values,
make sure the gun-trigger offset has been entered
on Event Map, page 26.
2. Dispense desired pattern (program contained
within the Pattern Controller).
Gun compensation ensures higher accuracy of bead
placement. Begin with Recommended Values below
and adjust according to Calibration Routine.
3. Measure the error distance between the
dispensed pattern on the product and the desired
pattern.
4. Adjust Open/Close compensation values
according to the following Gun Compensation
Table and Gun Compensation Formula below.
5. Repeat steps 2-3 until desired pattern achieved.
Gun Compensation Adjustment Guide:
Edge
Relative Position
Desired:
Leading Edge
Trailing Edge
Lagging
Leading
Lagging
Leading
Increase
Decrease
Increase
Decrease
vs.
Dispensed:
Adjustment
Gun Compensation Formula:
Determine the gun compensation adjustment amount in milliseconds.
Standard units:
Adjustment (ms) =
Metric units:
Adjustment (ms) =
5000 x Measured Offset Distance (in.)
Line Speed (ft/min.)
60 x Measured Offset Distance (mm)
Line Speed (m/min.)
Bead offset distances in inches (mm) as a function of Gun Compensation and Line Speed
Gun
Compensation
(ms)
5
10
20
334784D
50 ft/min
15.24 (m/min)
0.05 in.
1.27 (mm)
0.1 in.
2.54 (mm)
0.2 in.
5.08 (mm)
100 ft/min
30.48 (m/min)
0.1 in.
2.54 (mm)
0.2 in.
5.08 (mm)
0.4 in.
10.16 (mm)
Line Speed
200 ft/min
60.96 (m/min)
0.2 in.
5.08 (mm)
0.4 in.
10.16 (mm)
0.8 in.
20.32 (mm)
500 ft/min
152.4 (m/min)
0.5 in,
12.7 (mm)
1.0 in.
25.4 (mm)
2.0 in.
50.8 (mm)
1000 ft/min
304.8 (m/min)
1.0 in.
25.4 (mm)
2.0 in.
50.8 (mm)
4.0 in.
101.6 (mm)
37
Calibration
Line Speed
1. Make sure the pattern controller is “inactive” or
“locked”. Press the power button to toggle the
status (if necessary).
4. Adjust settings:
NOTE: Last Product Length indicator will update
according to the changes made in settings above
(step 2 only needs to be performed once).
a. On encoder systems (PC-8e only), adjust
Encoder Pulses per mm
until the Last
Product Length value matches the expected
length.
Actual Pulses per mm = Current Pulses
per mm x Distance Observed (On ADM) /
Distance Measured
NOTE: A minimum of 0.25 pulse/mm is
required to achieve 1 mm distance precision.
2. Pass a product of known length past the trigger
in use.
3. Once the product has passed the trigger, note
the value displayed in the Last Product Length
indicator.
NOTE: This value is the length of the part of the
product that passes below the trigger in use, not
necessarily the overall length of the product.
Encoder pulses per mm box.
b. On fixed line speed systems (both versions),
until the Last
adjust Fixed Line Speed
Product Length value matches the expected
length.
Actual Speed = Current Speed x Distance
Measured / Distance Observed (on ADM)
Last Product Length displayed for trigger is 18.00
inches long.
Fixed Line Speed box.
38
334784D
Calibration
(PC--8e Only)
Run Up Control (PC
Run Up Control is used to adjust fluid pressure
according to line speed.
4. Use the dial and gauge at the base of the
InvisiPac system to adjust the pump pressure
until the desired glue output is achieved.
NOTE: The Graco Run Up Controller is calibrated for
the procedure below. When using a non-Graco Run
Up Controller, make sure the controller settings are
set to 0 psi offset and 100 psi span.
1. Change units on regulator from Bar to PSI (using
buttons on front of regulator):
5. Enter the pressure displayed on the run up
controller in the highlighted boxes below.
6. Reduce the line speed to the minimum speed and
enter the line speed in the highlighted box below.
2. Disable the Pressure Compensation.
NOTE: This is required to determine the settings.
7. Reduce the pump pressure, then use the dial
and gauge at the base of the InvisiPac system to
adjust the pump pressure until the desired glue
output is achieved.
NOTE: InvisiPac pump pressure must be at least
20 psi.
3. Turn the system ON at maximum speed and
enter the line speed into the highlighted box
below.
8. Enter the pressure displayed on the regulator in
the highlighted boxes below.
334784D
39
Calibration
9. Return the pressure on the InvisiPac pump
pressure gauge to the position from step 3.
2. Enter “100” for both high output values.
NOTE: A value of “100” will ensure that a solid
bead is dispensed at speeds above the maximum
line speed.
10. Enable the Pressure Compensation.
3. Enter the minimum and maximum line speed.
NOTE: The maximum line speed is the speed at
which beads will go from solid to stitched.
(PC--8e Only)
Modulated Bead (PC
Modulated Bead is used to adjust fluid output
according to line speed without a pressure regulator
(using stitching).
NOTE: Modulated beads use the same stitch interval
as a normal stitched bead (see Event Map, page 26).
1. Enable modulated bead.
4. Enter the low output values.
Low Output =
40
Minimum Speed
Maximum Speed
* 100
334784D
Verification
Run Up Control
Verification
1. Navigate to Home, page 21.
This section verifies proper installation of the
InvisiPac Pattern Control System. For further
assistance, see Troubleshooting, page 42.
2. Turn the system ON and wait for the Pattern
Controller to become ACTIVE.
Valves
3. Run the line at various speeds and verify the
appropriate Run Up Output is displayed on the
ADM. Verify the run-up output pressure correctly
follows.
1. To verify glue can be dispensed, turn system
ON and attempt a purge on each installed valve,
then verify the valve is actuated (glue has been
dispensed from the appropriate valve).
4. If the percentage/pressure displayed
does not match the expected value, see
Run Up Control, page 31.
2. To verify the electrical signal, disconnect the
cable from the solenoid and attempt a purge
on each installed valve and verify the signal is
actuated (via the LED on the valve connector).
PLC Inputs
1. Navigate to Home, page 21.
Triggers
2. Actuate the PLC input remotely and verify the
expected result is indicated in the PLC IO section
in the upper right corner of the display.
1. Navigate to Home, page 21.
Action
2. Without product in front of the trigger, verify the
trigger indicator LED is OFF.
3. With product in front of the trigger, verify the
trigger indicator LED is ON.
Encoder
Icon
Expected
Outcome
Turn on line from PLC.
NOTE: on integrated
systems, use InvisiPac PLC
IO to turn on/off InvisiPac.
Pattern controller will be
in standby until InvisiPac
becomes active.
Turn off line from PLC.
1. Navigate to Home, page 21.
2. Verify the line speed displayed in the Current
Line Speed indicator
for different line speeds.
is positive and varies
3. If the line speed shown does not match the
known/expected value, see Calibration, page 37.
334784D
Create safety fault (open
door).
Remove safety fault (close
door).
Select program from PLC.
De-select program from
PLC.
Create an alarm.
NOTE: on integrated
systems, turn off pattern
control box (will generate
CAXP alarm).
Clear the alarm.
NOTE: on integrated
systems, turn on pattern
control box.
Program #
– – –
PLC detects
alarm
PLC alarm
clears
41
Troubleshooting
Troubleshooting
Error Codes
When error occur, press
to acknowledge each error. After being acknowledged, the error will clear
automatically when the condition that caused it is corrected. Active errors scroll on the menu bar
Alarms shut down the Pattern Controller and activate the dry contact PLC output. Advisories and deviations
are informational only and do not shut the system down.
Code
Description
CAXP
Communication
Error
A40P
Overcurrent
A4XP
Overcurrent
A4_P
Overcurrent
K4_P
High Pulse Rate
Code
V1_P
V4_P
K1_P
EBTX
42
Alarms (shut the system down)
Cause
Solution
ADM unable to
Check for green power light on the Pattern
communicate with Pattern Controller
Controller
Check communication cabling
Overcurrent on accessory Check accessory cabling for short circuit
power supply output
Check ADM CAN cabling for short circuit
Overcurrent on
communication cable
Replace display (ADM)
output
Overcurrent on valve
Check wiring for short circuit
output “_”
Verify valve resistance is higher than 24 ohms
Encoder “_” pulse rate
exceeds maximum limit
Select encoder with lower pulse rate
Reduce line speed or gearing ratio
Advisories and Deviations (do not shut the system down)
Description
Cause
Solution
Low Voltage
Power supply voltage
To check for overloaded power supply, measure
below 18 VDC
the voltage with all valves off, and then with all
valves on (purging).
To check for overheated power supply, allow the
unit to cool and recheck voltage.
Adjust voltage to 24 V if possible, or replace the
power supply.
High Voltage
Power supply voltage
Adjust voltage to 24 V if possible or replace the
above 28 VDC
power supply.
Low Line Speed
Poor Encoder Coupling
Check to ensure proper coupling between line
on line “_”
and encoder. Verify Pattern controller is reading
appropriate line speed (see Line Mode, page 27).
Line Speed is less than Increase line speed or decrease low line speed
low line speed alarm level alarm level (see Line Mode, page 27).
on line “_”
PC-8e Token
Missing or loose PC-8e
If missing, re-insert PC-8e token. If present,
Removed
token
check for loose connection.
334784D
Troubleshooting
Display
Problem
Display does not turn on
Cause
Selector dial on Pattern Control
board set to wrong position
Solution
Integrated Systems: set to 0
Stand-Alone Systems: set to 1
Check for green light on Pattern Control
board and Display
Communication cable disconnected Verify Pattern Control board is connected
to Display
Selector dial on Pattern Control
Integrated Systems: set to 0
board set to wrong position
Stand-Alone Systems: set to 1
Software version mismatch
Perform software update process
with latest version of software (see
Software Update Procedure, page 46).
PC-8e key token not inserted in ADM Obtain PC-8e key token (comes with
PC-8e versions of InvisiPac Pattern Control
System)
Power not turned on
Pattern Control Screens
not present
Run Up Control Screens
not present
Encoder settings not
present
Pattern
Problem
No pattern dispensed
Cause
Valve not associated with correct
trigger (or not assigned to any
trigger)
Physical problem with valve
Improper stitch settings
Wrong/empty program selected
Pattern Controller not ACTIVE
Pattern dispenses too
early/late
Improper gun-trigger offset entered
Improper valve Open/Close
Compensation
/
entered
Pattern measurement
units are in distance/time
334784D
Improper line mode selected
Solution
Ensure valve has appropriate trigger
selected
See “No Glue Dispensed” troubleshooting
help within Valve section
Stitch Interval
too short or Stitch
Savings
too high
Ensure proper program is selected
on PC Control – Program Storage
(see Program Storage, page 22) and
PC Control – Pattern Preview (see
Pattern Preview, page 25) contains a pattern
Turn on pattern controller. Stand-Alone
systems will go ACTIVE immediately,
whereas Integrated systems will go ACTIVE
once the InvisiPac system has gone ACTIVE
Ensure appropriate Gun-Trigger Offset
is entered on PC Setup – Event Map
(see Event Map, page 26)
Perform calibration routine found in
Calibration – Gun Compensation (see
Calibration, page 37)
Select appropriate line mode setting on PC
Setup – Line Mode (see ##)
43
Troubleshooting
Valve
Problem
System reset when guns
fire
No glue dispensed
Cause
Solution
Current draw from combined Ensure current draw is below 6A total between all
valves exceeds power supply simultaneously firing valves.
rating (150 W)
Ensure proper wiring between solenoid and
Solenoid shorted
pattern controller. If no shorts found, consider
replacing solenoid.
Wrong type of valve in use
Pattern controller is only compatible with 24 VDC
solenoids (no electric valves or AC solenoids)
Trigger
Problem
Trigger always on/off
Trigger detects multiple
times on one box
Trigger sensor turned off
(no 24 VDC present)
Cause
Solution
Sensor is covered/misaligned Clear any sensor obstructions and verify sensor
changes states with object present/absent
Polarity is backwards
Change Trigger Polarity +/- in PC Setup – Trigger
Setup (see Trigger Setup, page 28).
Improper sensor
See Installation – Trigger Installation for proper
type/installation
sensor selection/installation
Trigger not adjusted properly
in PC Setup –
or artifacts on the object being Set Minimum Product Length
Event
Map
(see
Event
Map,
page
26).
sensed cause false detection
Excessive current drawn from Perform power cycle to reset power to 24 VDC pins
24 VDC supply on
If error persists, remove components and power
cycle until component with excessive current draw
is discovered
Encoder
Problem
Cause
Encoder speed is negative Encoder travel direction is
reversed
Encoder speed varies
significantly
Encoder reads wrong
speed
Solution
Exchange A and A’ wires with B and B’ wires
Flip encoder to spin the opposite direction
Encoder coupling is slipping
Improve encoder coupling to line by using different
bracket, mounting, coupling, etc.
Encoder is improperly scaled Perform calibration routine found in Calibration –
Line Speed (see Calibration, page 37).
Encoder movement not
Remount encoder to ensure ratio between encoder
proportionately scaled to path movement and product movement is always a
of product
fixed proportion
Encoder does not read line Improper sensor
See Installation – Encoder Installation for proper
speed
type/installation
sensor selection/installation
Wrong line mode selected
Select encoder line mode setting on PC Setup –
Line Mode (see Line Mode, page 27).
Fixed line speed mode
Line speed is fixed
Select Encoder
line mode setting on PC Setup
selected
– Line Mode (see Line Mode, page 27).
44
334784D
Troubleshooting
Run Up
Problem
Cause
Run Up Controller reads 0 Integrated systems: InvisiPac
system is INACTIVE
psi
Run Up Controller
produces undesired
results
Solution
Integrated systems: Turn system ON, run
up will be active once system is ACTIVE
(pump will turn on)
Stand-Alone systems: PC system is
INACTIVE
Stand-Alone systems: Turn system ON, run
up controller will
Ensure pressure is being supplied to the
No pressure to inlet of run up
inlet of run up controller (check for valves
controller
and shutoffs upstream of controller)
Improper user settings entered
Perform calibration routine found in
Calibration – Run Up Control (see
Calibration, page 37).
Output pressure desired is greater Ensure enough pressure is being supplied
to the inlet of the run up controller (standard
than inlet pressure
calibration routine calls for 100 psi)
PLC Inputs and Outputs
Problem
Input from PLC not read
by Pattern Controller
Cause
Improper input signal from PLC
Broken wire
Output from Pattern
Improper interface to PLC
Controller not read by PLC
Broken wire
334784D
Solution
See PLC Inputs and Outputs Installation
(optional), page 16 for proper sensor
selection/installation
Check wiring between Pattern Controller
and PLC
See PLC Inputs and Outputs Installation
(optional), page 16 for specifications and
proper installation
Check wiring between Pattern Controller
and PLC
45
Software Update Procedure
Software Update Procedure
When software is updated on the ADM the software
is then automatically updated on all connected
GCA components. A status screen is shown while
software is updating to indicate progress.
1. Turn system main power switch OFF.
2. Remove ADM from bracket.
3. Remove token access panel.
NOTE: When the screen turns on, you will see
the following screens:
First:
Software is checking
which GCA modules
will take the
available updates.
Second:
Status of the
update with
approximate time
until completion.
Third:
4. Insert and press InvisiPac software upgrade
token (part no. 24R324) firmly into slot.
NOTE: There is no preferred orientation of token.
Updates are
complete. Icon
indicates update
success/failure.
See the following
Icon table.
Icon
Description
Update successful.
5. Install ADM into bracket.
6. Turn system main power switch ON.
Update unsuccessful.
NOTICE
A status is shown while software is updating to
indicate progress. To prevent corrupting the
software load, do not remove token until the
status screen disappears.
Update complete, no changes
necessary.
Update was successful/complete but
one or more GCA modules did not have
a CAN boot-loader so software was not
updated on that module.
7. Remove token (T).
8. Replace token access panel.
9. Press
screens.
46
to continue to the InvisiPac operation
334784D
USB Download
USB Download
Accessing Files
The system can store 250,000 entries in its logs
and adds a new entry 15 seconds. This means the
system stores 655 hours of system operation data, or
27 days of around-the-clock operation. Once full, the
system will overwrite the oldest data.
All files downloaded from the USB are put in a
DOWNLOAD folder on the stick drive. For example:
“E:\GRACO\12345678\DOWNLOAD\”. The 8-digit
numeric folder name matches the 8-digit ADM serial
number, which is located on the back of the ADM.
When downloading from multiple ADMs, there will be
one sub-folder in the GRACO folder for each ADM.
NOTE: To prevent losing any data, never go more
than 27 days without downloading the logs.
The log files should be opened in a spreadsheet
program.
NOTE: If emailing the files, zip (compress) them to
minimize file size.
Download Procedure
NOTICE
Uploading an edited system configuration file
can damage the system. Never put a modified
SETTINGS.TXT file in the UPLOAD folder on the
flash drive.
1. Insert USB flash drive into USB port.
NOTE: Flash drive must be 8 GB or smaller.
USB
USB Logs
During operation, InvisiPac stores system and
performance related information to memory in the
form of log files. InvisiPac maintains the events, data,
GCA, Black Box, and Diagnostics logs. Follow the
Download Procedure to retrieve log files.
Events Log
The event log (1-EVENT.CSV) maintains a record of
the last 175,000 events. Each event record in the log
file contains the date and time the event occurred,
the event type, event code, and event description.
Data Log
2. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete. A pop-up will be present until
the transfer is complete if it is not acknowledged.
NOTE: If the pop-up screen does not appear, the
flash drive is not compatible with the ADM. Try a
different flash drive.
NOTE: The system can log up to 45 mb of additional
data per week, depending on system operation.
The data log (2-DATA.CSV) tracks the setpoint and
actual temperatures every 15 seconds. This log can
store up to 250,000 lines of data. The system stores
1041 hours of system operation data, or 43 days of
around-the-clock operation. Once full, the system will
overwrite the oldest data.
NOTE: To prevent losing any data, never go more
than 43 days without downloading the logs.
GCA Log
This log (3-GCA.CSV) lists the installed GCA
modules and their respective software versions.
Black Box, Diagnostic Logs
These logs (4-BLACKB.CSV, 5-DIAGN.CSV) are
designed to provide useful information to Graco when
calling for technical assistance.
334784D
47
Parts
Parts
External Models
48
334784D
Parts
Parts List
Part
Description
▲4
186620
5
127886
6
7
126881
126891
ENCLOSURE, PC,
painted
FOAM, gasket
LABEL, pattern
controller
LABEL, symbol,
ground
GROMMET, pattern
controller
BUSHING, strain relief
NUT, bushing
8
114421
BUSHING, strain relief
1
FASTENER, hex,
standoff
TOOL, screwdriver
4
1
BLOCK, ground
1
Ref.
1
2
3
11
12
13
127939
Qty.
1
Ref.
30
Part
Description
119162
2
+31
128156
*32
128147
33
128117
35
127768
CONNECTOR, plug, 6
position
BRACKET, mounting,
slide-on
CONNECTOR, plug,
3.81 mm, 8 position
CONNECTOR, plug,
3.81 mm, 12 position
CABLE, can, female
1.5 m
TIE, cable, 7.5 in.
1
1
2
2
2
15
WASHER, lock, ext
2
16
NUT, #8–32 hex
2
1
21
MODULE, GCA,
pattern control
SCREW, machine, ph,
8 x 3/8 in.
WASHER, lock
NUT, hex
22
23
WASHER, lock
LATCH, tool, secured
4
1
24
LATCH, cam
1
25
26
SCREW, cap, hex hd
BLANK, label kit
4
1
CONNECTOR, plug,
3.81 mm, 4 position
1
17
17E019
19
20
29
116772
334784D
37
38
128116
40
24X626
41
124654
42
121226
43
24P860
4
1
1
CONNECTOR, plug,
3.81 mm, 7–position
(PC-8e only)
KIT, token, GCA, key,
PC-8e (PC-8e only)
CONNECTOR, splitter
(externally integrated
models only)
CABLE, can,
male/female, 0.4 m
(externally integrated
models only)
KIT, replacement, ADM
(stand-alone models
only)
Qty.
2
1
2
1
1
1
2
1
1
1
1
+ Qty 2 for Stand Alone models
* Qty 4 for PC-8e
▲ Replacement Danger and Warning labels are
available at no cost.
49
Parts
Internal Models
Parts List
Ref.
Part
101
24X521
101b
128176
101c
128177
101d
-----
101e
128178
101f
Description
MODULE, GCA, PC-8,
internal
FRAME, cable grip,
5–position
INSERT, rubber, cable
grip, 4 x 6 mm
PIN, .250 in.
Ref.
1
129
116772
1
130
119162
1
132+
128147
4
133
128117
138*
128116
140*
24X626
4
-----
INSERT, rubber, cable
grip, 4 x 3 mm
PIN, .125 in.
16
101g
-----
SCREW, #10–32 x .750
2
102
128180
POWER SUPPLY, 120 W
1
103
128443
1
104
128183
105
128182
106
125856
BRACKET, power supply,
PC-8 internal
HARNESS, power, PC-8
internal, AWB
CABLE, CAN,
female/male
SCREW, 8–32, serrated
flange
50
Part
Qty.
1
1
4
Description
Qty.
CONNECTOR, plug, 3.81
mm, 4–position
CONNECTOR, plug, 3.81
mm, 6–position
CONNECTOR, plug, 3.81
mm, 8–position
CONNECTOR, plug, 3.81
mm, 12–position
CONNECTOR, plug, 3.81
mm, 7–position
KIT, token, GCA, key,
PC-8e
FUSE, automotive, 4A,
32V, mini (not shown)
TOOL, screwdriver (not
shown)
TIE, cable, 7.5 in. (not
shown)
1
2
2
1
2
1
1
1
8
+Qty 4 for PC-8e
*PC-8e only
334784D
Parts
Kits
Sensors/Mounting
Part
24X446
Description
KIT, photoeye,
diffuse, 18 mm
Contents
128073 - SENSOR, photoelectric diffuse
Image
128071 - BRACKET, sensor mount, straight
128070 - BRACKET, sensor mount, angled
24X447
KIT, photoeye,
pol ret ref, 18
mm
24X449 - CABLE, M12, 4-pin, 5.0 m
128072 - SENSOR, photoelectric, polarized
128071 - BRACKET, sensor mount, straight
128070 - BRACKET, sensor mount, angled
128069 - SENSOR, reflector
24X448
24X607
KIT, encoder,
1000 PPR, 10
mm
24X449 - CABLE, M12, 4-pin, 5.0 m
128074 - ENCODER, incremental
24X455 - CABLE, M12, 8-pin, 10.0 m
17E037 - BRACKET, mounting, encoder
SCREWS (qty 3)
KIT, encoder
brackets
17E018 - BRACKET, encoder
128586
KIT, encoder,
standoff bracket
BRACKET, mounting, standoff, encoder
17F656
KIT, encoder,
friction wheel,
300 mm
KIT, coupler,
encoder
BRACKET, encoder, right hand
17F540
17F541
17E017 - BRACKET, 90 degree, encoder
10 mm x 6 mm
10 mm x 8 mm
17F542
10 mm x 10 mm
17F543
10 mm x 12 mm
17F544
10 mm x 1/8 in.
17F545
10 mm x 3/16 in.
17F546
10 mm x 1/4 in.
17F547
10 mm x 3/8 in.
17F548
17F549
10 mm x 1/2 in.
10 mm x 15 mm
17F550
10 mm x 5/8 in.
10 mm x 3/4 in.
17F551
17E020
334784D
KIT, run up
127787 – REGULATOR, pressure, V2P
24X449 – CABLE, M12, 4–pin, 5.0 m
FITTINGS
51
Parts
Cables
Part
24X449
Description
KIT, cable, M12,
4-pin, F-L, 5 m
24X453
KIT, cable, M12,
4-pin, F-L, 10 m
KIT, cable, M12,
8-pin, F-L, 5 m
KIT, cable, M12,
8-pin, F-L, 10 m
KIT, cable, M8,
3-pin, F-L, 5 m
KIT, cable, M8,
3–pin, F-L, 10 m
KIT, cable, M8,
4-pin, F-L, 5 m
KIT, cable, M8,
4-pin, F-L, 10 m
KIT, cordset,
solenoid, 5 m
KIT, cordset,
solenoid, 10 m
KIT, cable, CAN
5m
KIT, cable, CAN,
15 m
KIT, cable, CAN
50 m
24X454
24X455
24X456
24X457
24X458
24X459
17F443
17F444
24R710
24R711
24R712
Use with
Triggers with M12 connection (12mm nut)
Run-up controller
Image
Encoder
Mini solenoid valve (i.e. GM-100)
Triggers with M8 connection (8 mm nut)
Standard solenoid valve (i.e. GS-35)
Remote mounting of pattern controller
enclosure or ADM
Repair Parts
Part
17E019
Description
KIT, pattern
control board
Use with
External Models
24X521
KIT, internal
pattern control
board
Internal models
52
Image
334784D
Parts
Upgrades
Part
24R324
Description
KIT, software
Contents
TOKEN, GCA, upgrade
17F712
KIT, PC-8 to PC-8e
upgrade
KIT, token, GCA, key, PC-8e
CONNECTOR, plug, 3.81 mm, 7 position (x2)
CONNECTOR, plug, 3.81 mm, 8 position (x2)
24Y171
KIT, install, internal
pattern control
HARNESS, secondary power and fuse
Image
Connector, splitter
Generation 1 systems
CABLE, communications, female/female, 1.0 m
CABLE, communications, female/female, 0.5 m
334784D
53
Wiring Diagrams
Wiring Diagrams
Internal Pattern Controller (Generation 2 Systems with AWB)
Ref.
1
Part
128180
2
128183
3
128182
54
Description
POWER SUPPLY, 120
W
HARNESS, power,
PC-8, AWB
CABLE,
communication
Qty.
1
Ref.
Part
Description
Qty.
1
1
334784D
Wiring Diagrams
Internal Pattern Controller (Generation 1 Systems with DIN Rail)
Ref.
1
Part
128180
2a
128265
2b
3
121807
4
128182
5
125789
6
127068
334784D
Description
POWER SUPPLY, 120
W
HARNESS, power,
PC-8, DIN
HARNESS, fuse, PC-8,
DIN
CONNECTOR, splitter
CABLE,
communication
CABLE,
communication
CABLE,
communication
Qty.
1
Ref.
Part
Description
Qty.
1
1
1
1
1
1
55
Wiring Diagrams
External Models
Ref.
9
Part
Description
15U423
SWITCH, 2P, 25 A
10
127887
38
POWER SUPPLY, 24
VDC, 6.3 A, 150 W
HARNESS, ground
CONNECTOR, plug, 3
position
TERMINAL, fork, #8
2
39
TERMINAL, fork, #4
1
14
28
56
Qty.
1
Ref.
Part
Description
Qty.
1
1
1
334784D
Dimensioned Drawings
Dimensioned Drawings
System Enclosure
Triggers
128072 – Polarized Retro-Reflective Sensor
128071 – Mounting Bracket, Straight
128073 – Diffuse Sensor
128069 – Reflector
128070 – Mounting Bracket, Right Angle
334784D
57
Dimensioned Drawings
Encoders
128074 – Encoder, Incremental
17E018 – Universal Bracket
Right Hand Bracket
17E037 – Mounting Bracket
128586 – Standoff Bracket
17E017 – Angle Bracket, 90 degree
58
334784D
Dimensioned Drawings
Couplers
Part
L
L1
L2
D
Graco
Encoder
Shaft
17F540
Customer
Shaft (Bore)
6 mm
17F541
8 mm
17F542
10 mm
17F543
17F544
17F545
1 in.
(25.4 mm)
0.374 in.
(9.5 mm)
0.25 in
(6.4 mm)
12 mm
0.984 in.
(25.0 mm)
1/8 in.
10 mm
17F546
17F547
3/16 in.
1/4 in.
3/8 in.
17F548
1/2 in.
17F549
15 mm
17F550
17F551
1.17 in.
(29.7 mm)
0.394 in.
(10.0 mm)
0.38 in.
(9.7 mm)
1.457 in.
(37.0 mm)
5/8 in.
3/4 in.
Run Up Controller
334784D
59
Technical Data
Technical Data
InvisiPac Pattern Controller
Description
Input Power
Value
Details
External models only
8
90 W (internal models)
150 W (external models)
4
Gun Outputs
Total Gun Wattage
Trigger Inputs
Trigger Excitation
100–240 VAC, 50/60 Hz, 2A max
24 VDC, 1A each, 6A max total
NPN or PNP or Dry Contact
24 VDC
Encoder
Encoder Excitation
2 (PC-8e only)
Run Up Control
Run Up Excitation
PLC Enable/Disable
2 (PC-8e only)
24 VDC
Quadrature differential line driver
15 VDC
I/P (4–20mA) or V/P (0–10V)
PLC Program Select Bit
PLC Alarm Output
YES
4
0–30 VDC, min 10V to assert
Select up to 15 unique programs
YES
Integrated Power Supply
YES
0–250 VAC (dry contact output)
24 VDC, 120 W (internal models)
24 VDC, 150 W (external models)
Program Storage
50
Beads Per Output
24
Distance Accuracy
Time Accuracy
1mm, 0.1 in.
1ms
Enclosure Environmental Rating
Ambient Temperature
IP54
Sensor Type
Excitation
Sensing range
Run Up Specifications:
Kit Part
24X446
Diffuse
24X447
Retro-reflective
10 – 30 VDC
200 mm
5.0 m
Output type
Resistant to dust and splashing water
32˚ – 120˚ F, 0˚ – 50˚ C
Trigger Specifications:
Description
Each bead can be stitched, allowing many
more than 24 dots
Description
Excitation
Control Voltage
Kit Part
17E020
21.6 – 26.4 VDC
0 – 10 VDC
NPN/PNP
Encoder Specifications:
Description
Excitation
Pulses per revolution
Output type
60
Kit Part
24X448
10 – 30 VDC
1000
5 VDC (TTL/RS422)
Differential Line Driver
334784D
Notes
Notes
334784D
61
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name
to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With
the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve
months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s
written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage
or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance,
negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for
malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories,
equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid.
If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a
reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer
agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost
sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for
breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS
OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by
Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto,
whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en
rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original Instructions. This manual contains English. MM 334784
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision D, June 2015

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