Graco 309738K - PrecisionFlo LT Standard, U.S. Owner's Manual

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Graco 309738K - PrecisionFlo LT Standard, U.S. Owner's Manual | Manualzz

Instructions

PrecisionFlo LT

Standard, Series B

Electronically controlled fluid dispensing packages

• Pneumatically operated fluid regulators

• EasyKey keypad interface

See page 2 for a list of models and maximum working pressures.

See page 4 for Table of Contents.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

309738K

9902471

Certified to CAN/CSA C22.2 No. 1010

Conforms to

UL 3121-1

2

List of Models

List of Models

Control Modules

PrecisionFlo LT

Control Module

Number

Description

234129, Series B Standard PrecisionFlo LT Control Unit

Power Supply Voltage Power Requirement

93 - 264 VAC, 50-60 HZ Full Load Amps - 1

Fused Amps - 2

Fluid Modules

Precision-

Flo LT Fluid

Module

Number

234168

234165

234166

234167

234195

234170

234169

234196

234193

234194

Description

Ambient cartridge style regulator with no flow meter

Ambient cartridge style regulator with a G3000 flow meter

Ambient cartridge style regulator with a G3000HR flow meter

Ambient cartridge style regulator with a Graco helical flow meter

Ambient cartridge style regulator with a Graco high resolution helical flow meter

Ambient mastic style regulator with no flow meter

Ambient mastic style regulator with a Graco helical flow meter

Ambient mastic style regulator with a Graco high resolution helical flow meter

Heated mastic style regulator with no flow meter

Heated mastic style regulator with a heated Graco helical flow meter

Maximum Fluid

Inlet Pressure

6000 psi

(41 MPa, 414 bar)

4000 psi

(28 MPa, 276 bar)

4000 psi

(28 MPa, 276 bar)

6000 psi

(41 MPa, 414 bar)

6000 psi

(41 MPa, 414 bar)

Regulated Fluid

Pressure

100 - 4500 psi

(0.7-31 MPa, 7-310 bar)

100 - 4000 psi

(0.7-28 MPa, 7-276 bar)

100 - 4000 psi

(0.7-28 MPa, 7-276 bar)

100 - 4500 psi

(0.7-31 MPa, 7-310 bar)

100 - 4500 psi

(0.7-31 MPa, 7-310 bar)

5000 psi

(34.4 MPa, 344 bar)

5000 psi

(34.4 MPa, 344 bar)

5000 psi

(34.4 MPa, 344 bar)

100 - 4500 psi

(0.7-31 MPa, 7-310 bar)

100 - 4500 psi

(0.7-31 MPa, 7-310 bar)

100 - 4500 psi

(0.7-31 MPa, 7-310 bar)

Maximum Inbound

Air Pressure

100 psi

(0.7 MPa, 7 bar)

100 psi

(0.7 MPa, 7 bar)

100 psi

(0.7 MPa, 7 bar)

100 psi

(0.7 MPa, 7 bar)

100 psi

(0.7 MPa, 7 bar)

100 psi

(0.7 MPa, 7 bar)

100 psi

(0.7 MPa, 7 bar)

100 psi

(0.7 MPa, 7 bar)

5000 psi

(34.4 MPa, 344 bar)

5000 psi

(34.4 MPa, 344 bar)

100 - 3500 psi

(0.7-24.1 MPa, 7-241 bar)

100 - 3500 psi

(0.7-24.1 MPa, 7-241 bar)

65 psi

(0.45 MPa, 4.5 bar)

65 psi

(0.45 MPa, 4.5 bar)

Standard Systems

PrecisionFlo LT

System Number

234284

234285

Description

Advanced PFlo LT Control with Ambient Cartridge Regulator and Helical Gear Meter

Advanced PFlo LT Control with a Heated Mastic Regulator and Heated Helical Flow Meter

Configurator Code

PFlo

LT-A-2-5-04-1

PFlo

LT-A-2-5-10-1

Control

Module

234190

234190

Fluid

Module

234167

234194

Cables

I/O-117752

Automation-

117774

309738K

List of Models

309738K 3

4

Contents

Contents

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 5

Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . 8

PrecisionFlo LT . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Model Number Identification . . . . . . . . . . . . . . . . 8

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PrecisionFlo LT Module Overview . . . . . . . . . . . . 10

Typical PrecisionFlo LT Configurations . . . . . . . 11

Typical PrecisionFlo LT Configurations . . . . . . . 12

Typical PrecisionFlo LT Configurations . . . . . . . 13

Fluid Metering Assembly Overview . . . . . . . . . . . 14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Before Beginning Installation . . . . . . . . . . . . . . 15

Installing the Control Unit . . . . . . . . . . . . . . . . . . . 16

Mounting the Control Unit . . . . . . . . . . . . . . . . . 16

Electrical Connections . . . . . . . . . . . . . . . . . . . 17

Grounding Control Unit . . . . . . . . . . . . . . . . . . . 17

Connecting to Power Source . . . . . . . . . . . . . . 18

Installing Fluid Metering Assembly . . . . . . . . . . . 19

Connecting Fluid and Air Lines . . . . . . . . . . . . . 20

Grounding the Metering Assembly . . . . . . . . . . 20

Installing Cable Assemblies . . . . . . . . . . . . . . . . . 21

Installing the Cable Assemblies . . . . . . . . . . . . . . 22

Checking Ground Continuity . . . . . . . . . . . . . . . 23

PrecisionFlo LT Module Operation . . . . . . . . . . . 24

PrecisionFlo LT User Interface . . . . . . . . . . . . . . . 26

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . 26

Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Automation Modes . . . . . . . . . . . . . . . . . . . . . . 28

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Pressure Relief Procedure . . . . . . . . . . . . . . . . 29

Safety Reminder . . . . . . . . . . . . . . . . . . . . . . . . 29

Starting the System . . . . . . . . . . . . . . . . . . . . . . 30

Loading Material . . . . . . . . . . . . . . . . . . . . . . . . 31

Configuring Software . . . . . . . . . . . . . . . . . . . . . . 32

Setting Flow Meter K-Factors . . . . . . . . . . . . . . 33

System Calibration . . . . . . . . . . . . . . . . . . . . . . 33

Flow Rate Calibration . . . . . . . . . . . . . . . . . . . . 34

Verifying Flow Meter Calibration . . . . . . . . . . . . 35

Other Software Settings . . . . . . . . . . . . . . . . . . 35

On/Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Shutting Down the System . . . . . . . . . . . . . . . . 39

Communicating with PrecisionFlo LT . . . . . . . . . 40

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fluid Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 45

Electrical Component Paths . . . . . . . . . . . . . . . 46

Troubleshooting and Fault Recovery . . . . . . . . . 47

Control Assembly Service . . . . . . . . . . . . . . . . . . 51

Servicing the Panel Assembly . . . . . . . . . . . . . . 51

Software Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . 52

Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Panel Assembly Service . . . . . . . . . . . . . . . . . . . . 54

Fuse Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . 54

Replacing the Backlighting . . . . . . . . . . . . . . . . 55

Fluid Module Service . . . . . . . . . . . . . . . . . . . . . . . 56

Frequently Asked Questions . . . . . . . . . . . . . . . . 59

Fault Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Control Assembly Parts . . . . . . . . . . . . . . . . . . . . 63

Control Assembly Parts (continued) . . . . . . . . . . 64

Fluid Module Parts . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fluid Module Parts (continued) . . . . . . . . . . . . . . 66

Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Automation Interface Cable Assembly . . . . . . . 67

Operations Cable Assembly . . . . . . . . . . . . . . . . . 68

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 69

PrecisionFlo LT Control Box . . . . . . . . . . . . . . . . 69

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 75

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Using the PrecisionFlo LT I/O . . . . . . . . . . . . . . 81

Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

PrecisionFlo LT User Interface . . . . . . . . . . . . . 84

Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 95

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

309738K

Typical Job Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 98

Typical Dispense Cycle . . . . . . . . . . . . . . . . . . . . . 99

Bead Control / Vol. Monitor / Pressure Control . 99

Typical Bead Control / Vol. Monitor / Pressure

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Typical Batch Dispense Cycle (I/O) . . . . . . . . . . 101

Typical Batch Dispense Cycle (Timer) . . . . . . 102

Continuously Running Applications . . . . . . . . . 103

Flow Rate Calculation . . . . . . . . . . . . . . . . . . . . . 104

Flow Calibration . . . . . . . . . . . . . . . . . . . . . . . . 104

Volume Compensation . . . . . . . . . . . . . . . . . . 105

Appendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Ethernet Kit 118329 . . . . . . . . . . . . . . . . . . . . . 106

Graco Standard Warranty . . . . . . . . . . . . . . . . . 108

Graco Information . . . . . . . . . . . . . . . . . . . . . . 108

Contents

309738K 5

6

Manual Conventions

Manual Conventions

Warning

WARNING

Caution

A warning alerts you to possible serious injury or death if you do not follow instructions.

Symbols, such as fire and explosion (shown), alert you to a specific hazard and direct you to read the indi-

cated hazard warnings beginning on page 6.

CAUTION

A caution alerts you to possible equipment damage or destruction if you do not follow instructions.

Note

A note indicates additional helpful information.

WARNINGS

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

• This equipment is for professional use only.

• Use the equipment only for its intended purpose. Call your Graco distributor for information.

• Read all instruction manuals, tags, and labels before operating equipment.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify this equipment. Use only Graco parts and accessories.

• Do not exceed the maximum working pressure of the lowest rated system component.

• Be sure that all spray/dispensing equipment and accessories are rated to withstand the maximum working pressure of the pump. Do not exceed the maximum working pressure of any component or accessory used in the system.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not exceed the maximum working temperature of the lowest rated system hose.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Configuring Software

in all equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Always wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer.

• Comply with all applicable local, state, and national fire, electrical, and safety regulations.

309738K

309738K

Warning

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in fire or explosion and serious injury.

• Ground the equipment and the object being dispensed.

• Do not use this equipment with flammable liquids.

• Keep the dispense area free of debris, including solvent, rags, and gasoline.

• If there is any static sparking or you feel an electric shock while using the equipment, stop dispensing immediately . Do not use the equipment until you have identified and corrected the problem.

• Be sure all electrical work is performed by a qualified electrician only.

• Have any checks, installation, or service to electrical equipment performed by a qualified electrician only.

• Be sure all electrical equipment is installed and operated in compliance with applicable codes.

• Be sure power is disconnected when servicing and repairing equipment.

• Before operating the equipment, extinguish all open flames or pilot lights in the dispense area.

• Do not smoke in the dispensing area.

• Keep liquids away from the electrical components.

• Disconnect electrical power at the main switch before servicing the equipment.

TOXIC FLUID OR FUMES HAZARD

Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

• Provide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed.

• Know the specific hazards of the fluid you are using.

• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

• Avoid exposure to heated material fumes .

7

Warning

WARNING

SKIN INJECTION HAZARD

Spray from the gun, leaks, or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury.

• Fluid injected into the skin might look like just a cut, but it is a serious injury.

Get immediate surgical treatment.

• Do not stop or deflect fluid leaks with you hand, body, glove, or rag.

• Follow the

Pressure Relief Procedure on page 30 and in your separate equipment manuals when-

ever you are instructed to: relieve pressure, stop dispensing, clean, check, or service the equipment; or install or clean a 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 hose.

• Always wear eye protection and protective clothing when installing, operating, or servicing this dispensing equipment.

• Never wipe off build-up around the nozzle or inlet cap until pressure is fully relieved.

MOVING PARTS HAZARD

Moving parts can pinch fingers.

• Keep clear of any moving parts when starting or operating the equipment.

HEAVY EQUIPMENT

Use adequate personnel and support devices when mounting, moving, or handling the control unit to prevent equipment damage or personal injury.

HOT SURFACE AND FLUID HAZARD

Heated fluid can cause severe burns and can cause equipment surfaces to become very hot.

• Wear protective gloves and clothing when operating this equipment in a heated system.

• Do not touch the metal heat sink when the surface is hot.

• Allow the equipment to cool thoroughly before servicing.

• Some heated systems are designed to dispense Polyurethane (PUR) heated materials. PUR Systems are supplied with ventilation hoods, and require proper ventilation and specifically designed system components.

8 309738K

Model Identification

Model Identification

PrecisionFlo LT

Graco’s PrecisionFlo LT is an electronically controlled fluid regulating package designed to meter and dispense adhesives and sealants. Your equipment was likely ordered as a configured package to fit your applicator.

Model Number Identification

On your control unit, there is an ID plate with a model number on it. Use the table on this page for explanations of each code letter and to define what equipment was ordered as part of the configured package from Graco.

Typical Model Number

LT-A -___ - ___ - ___ - ___

Code A B C D

Example: LT-A-1-2-04-5

Code A: Control Unit

Options 1-3

1. Standard

2. Advanced

3. Automation Integrated

Code C: Fluid Regulator

Options 01-10

01. Ambient Cartridge Regulator / No Flow Meter

02. Ambient Cartridge Regulator / G3000 Flow Meter

03. Ambient Cartridge Regulator / G3000 HR Flow Meter

04. Ambient Cartridge Regulator / Helical Flow Meter

05. Ambient Cartridge Regulator / HR Helical Flow Meter

06. Ambient Mastic Regulator / No Flow Meter

07. Ambient Mastic Regulator / Helical Flow Meter

08. Ambient Mastic Regulator / HR Helical Flow Meter

09. Heated Mastic Regulator / No Flow Meter

10. Heated Mastic Regulator / Helical Flow Meter

Code B: Operations Cable

Options 1-N

1. High Flex 25’

2. High Flex 60’

3. High Flex 125’

4. Standard Flex 25’

5. Standard Flex 60’

6. Standard Flex 125’

7. Low Flex 25’

8. Low Flex 60’

9. Low Flex 125’

N. None

Code D: Language

Options 1-8

1. English

2. French

3. German

4. Italian

5. Japanese

6. Korean

7. Portuguese

8. Spanish

309738K 9

Overview

Overview

What This Manual Includes

This manual provides detailed information about the

PrecisionFlo LT control unit and operation of the PrecisionFlo LT system. Specific information on the fluid module for example is contained in other instruction forms supplied with each component as part of the PrecisionFlo LT system.

Instruction Manual Conventions

Reference numbers (10) and letters (A) in parentheses in this manual refer to the numbers and letters in the illustrations.

Unless otherwise specified, the step-by-step procedures in this manual must be performed in numerical order.

Procedures that contain a list preceded by bullets can be performed in any order.

Abbreviations and Acronyms

Abbreviation: Stands For:

COM common

FM

GND flow meter ground msec

OP psi

PVC milliseconds operations cable pounds per square inch poly vinyl chloride

V

VAC

VDC volts volts AC volts DC

PrecisionFlo LT Definitions

Component Description

Control Unit The PrecisionFlo LT control unit contains the electronics used to control the fluid module.

PrecisionFlo LT The control unit, fluid module, and all

System cables and sensors used to measure and control the fluid application.

Automation

Controller

An external electronic (automation) system having some control interaction via electronic signals with the

PrecisionFlo LT system.

EasyKey EasyKey is the type of interface used to set up, display, operate and monitor the PrecisionFlo LT system.

Fluid Module The fluid module includes components that control and monitor fluid dispensing, such as a flow meter and regulator.

10 309738K

PrecisionFlo LT Module Overview

PrecisionFlo LT Module Overview

The block diagram in F IG . 1 shows an example of the

PrecisionFlo LT module, robot I/O signals, and wire numbers.

The fluid metering assembly contains the components that control and monitor fluid dispensing. It can be attached to an automation arm or mounted on a pedestal.

The control assembly sends continuous voltage signals to the PrecisionFlo LT fluid assembly regulator to control fluid pressure and the opening and closing of the dispense valve.

The control assembly receives input from the automation controller. The control assembly uses these inputs to determine the signals it should send to the fluid metering assembly.

The PrecisionFlo LT fluid regulator is electrically controlled by the PrecisionFlo LT module, and consistent material flow is assured by a closed-loop pressure or closed-loop flow control design. The module responds to automation-supplied signals to provide an accurate and consistent output flow based on a comparison of actual to desired flow rates. The pneumatic regulator uses air pressure to control fluid pressure and to provide fast response to electronic commands and ensure a precisely controlled, continuous flow of material.

PrecisionFlo LT

Control Assembly

Job Complete (3310)

Dispense (3290)

Flow Command (3150)

Fault Present (2710)

Dispenser Ready (2680)

Min Volume Dispensed (2770)

In Cycle (2740)

Flow Rate (3210)

Automation Controller

"

"

Gun On

V/P

Flow Meter

Outlet Pressure

F IG . 1

PrecisionFlo LT

Fluid Metering Assembly

D

309738K 11

Typical PrecisionFlo LT Configurations

Typical PrecisionFlo LT Configurations

Major components in a typical PrecisionFlo LT installation.

4

5*

10

9

8

6*

1*

11*

2*

3

Air Supply

Drop Site

4

7

12

Note: For proper operation of filter assembly, filter orientation must be such that the bowls are orientated so the bowls are always perpendicular to the ground (i.e. do not attach to robotic arms, as the filters may not remain in the proper orientation.)

F IG . 2

4

5*

6*

7

No.

1*

2*

3

8

9

10

11*

* included

Description

PFlo Control Assembly

PFlo Fluid Metering Assembly

Applicator/Dispense Valve

User Interface

PFlo LT Automation Control Cable Interface

PFlo LT Operations (OP) Cable

Fluid Supply System

Fluid Supply Header

Filter Module

Automation Controller

Filter Assembly

309738K

Typical PrecisionFlo LT Configurations

Typical PrecisionFlo LT Configurations

Optional Temperature Conditioned System

6*

11 Air Supply

Drop Site

9

4

1*

7*

14*

8

2*

13

12

3

5

13

F

IG

. 3

No.

Description

1* PFlo LT Control Assembly

2* PFlo LT Fluid Metering Assembly

3 Water Conditioned Applicator / Dispense Valve

4

5

Automation Controller

Sealer Automation

6* PFlo LT Automation Control Cable

Interface

7* PFlo LT Operations (OP) cable

309738K

8

9

Fluid Supply System

Water Jacketed Supply Hose

10 Water Jacketed Dispense Hose

11 Temperature Control Unit

12 RTD Cable

13 Water Hose

14* Filter Assembly

* included

13

Typical PrecisionFlo LT Configurations

Typical PrecisionFlo LT Configurations

Major components in a typical heated PrecisionFlo LT installation.

1*

6*

4

5*

8

2*

11*

Air Supply

Drop Site

9

10

3

4

7

F IG . 4

No.

Description

1* PFlo LT Control Assembly

2* PFlo LT Fluid Metering Assembly

3 Applicator/Dispense Valve

4 Sealer automation

5* PFlo LT Automation Control Cable Interface

6* PFlo LT Operations (OP) Cable

7 Heated Fluid Supply System

14

8

9

Fluid Supply Hose

2 - Zone Accessory Heat Control

10 Automation Controller

* included

309738K

Fluid Metering Assembly Overview

Fluid Metering Assembly Overview

Pneumatic Fluid Metering Assembly

The fluid metering assembly in F IG . 5 can be attached to

an automation arm, or mounted on a pedestal. Main components of the fluid metering assembly are:

• PrecisionFlo LT pneumatic fluid regulator (A)

• Optional flow meter (B) to precisely measure the amount of fluid dispensed

• Solenoid air valve (C) that controls a dispense valve

• Voltage to pressure (V/P) controller (D) for adjusting the air pressure to the fluid regulator (A)

B A

The PrecisionFlo LT module combines continuous pressure control with the ability to change bead profiles quickly. When used with one of the optional flow meters, the PrecisionFlo LT module automatically adjusts for fluctuations in the operating environment, such as material viscosity, temperature, tip wear, and automation speed, while maintaining the desired dispense rate. The module responds to automation-supplied signals to provide an accurate and consistent output flow based on a comparison of actual to desired flow rates.

Typical Fluid Applications

• PVC sealer

• Plastisols

• Sound deadening materials

• Body panel reinforcement

• Silicones

• Hot melt

"

"

C

D

F IG . 5

PrecisionFlo LT Pneumatic Fluid

Regulator

The PrecisionFlo LT pneumatic fluid regulator is a precision fluid pressure regulator that uses air pressure to control fluid pressure and to provide fast response to electronic commands and ensure a precisely controlled, continuous flow of material.

309738K 15

Installation

Installation

Overview

The basic steps to install a Graco PrecisionFlo LT system are shown below. See the separate component manuals for detailed information.

Installation Steps

1.

Mount LT control unit

2.

Ground LT control unit

3.

Mount fluid plate

4.

Connect cables between the LT control unit and: a.

Junction box of the fluid module (OP cable) b.

Automation or cell controller (automation I/O cable)

5.

Check ground continuity

6.

Connect air and fluid lines a.

Connect fluid lines between fluid module and applicator. Connect fluid supply line and air supply to module b.

Plumb filter assembly near air drop site that will be used for fluid metering assembly c.

Connect other fluid and air lines to additional system components as instructed in their manuals

7.

Connect control unit to power source

A number of different types of applicators can be used with the system. Refer to the manual for your applicator.

Before Beginning Installation

• Have all system and component documentation available during installation.

• See component manuals for specific data on component requirements. Data presented here applies to the PrecisionFlo LT assemblies only.

• Electrical schematics are included in this manual.

Refer to the schematics as required when connecting power and I/O signals.

• Be sure all accessories are adequately sized and pressure-rated to meet system requirements.

• Use the Graco PrecisionFlo LT control unit only with the PrecisionFlo LT fluid module.

16 309738K

Installing the Control Unit

Mounting the Control Unit

WARNING

Read Warnings, page 6.

• Select a location for the PrecisionFlo LT control unit that allows adequate space for installation, service,

and use of the equipment. See F

IG

. 6.

• Mount the control unit so that the disconnect is readily accessible and located 54-67 in. (137-170 cm) above the floor.

• For best viewing, the control display should be 60-64 in. (152-163 cm) from the floor.

• Ensure all fluid lines, cables, and hoses easily reach the components to which they will be connected.

• Ensure there is sufficient clearance around the control unit to run cables to other components.

• Ensure there is safe and easy access to an appropriate electrical power source. The National Electric

Code requires 3 ft. (0.91 m) of open space in front of the assembly enclosure.

• Ensure the mounting surface can support the weight of the control unit and the cables attached to it.

8.

Secure the PrecisionFlo LT control unit with appropriate size bolts through the 0.31 in. (8 mm) diameter holes in the mounting tabs.

14”

356 mm

12”

305 mm

Control Unit

Back View

12”

305 mm

12.75”

324 mm

13.5”

343 mm

F IG . 6

309738K

Installing the Control Unit

17

Installing the Control Unit

Electrical Connections

Follow these precautions when grounding, connecting cables, connecting to a power source or making other electrical connections.

WARNING

Grounding Control Unit

CAUTION

To avoid control voltage differences, ensure that the automation and PrecisionFlo LT equipment are grounded to the same point.

To reduce the risk of fire, explosion or electric shock:

• The PrecisionFlo LT control unit must be electrically connected to a true earth ground; the ground in the electrical system may not be sufficient.

• All wires used for grounding must be 18 AWG minimum.

• A qualified electrician must complete all grounding and wiring connections.

• Refer to your local code for the requirements for a

“true earth ground” in your area.

Read Warnings, page 6.

Connect a ground wire from the ground point in the PrecisionFlo LT control enclosure to a true earth ground.

See F IG . 7. A 10 AWG, 25 ft. (7.6 m) long ground wire

with clamp, Part No. 222011, is supplied.

The PrecisionFlo LT fluid module is grounded to the control unit, using cables provided with the module.

Ground Terminal

L2

L1

CAUTION

If power and grounding connections are not done properly, the equipment will be damaged and the warranty voided.

F IG . 7

18 309738K

Connecting to Power Source

WARNING

To reduce the risk of fire, explosion, or electric shock, the resistance between the supply unit components and true earth ground must be less than 0.25 ohms.

Read Warnings, page 6.

Have a qualified electrician connect the PrecisionFlo LT control assembly to a grounded electrical source that has the required service ratings, as shown in the Power

Requirement table.

To connect the control unit to the power source:

1.

Remove a hole plug to use one of the pre-cut enclosure holes or, if necessary for your installation, create an opening in the control assembly enclosure.

Protect interior components from metal chips when cutting or drilling.

2.

Using the appropriate gauge wire, connect electrical power L1 and L2 to the top of the fuse terminal

blocks, see F IG . 7, page 18.

3.

Use NEMA 4 cord grip to seal the area where wires enter the enclosure.

Power Requirements:

VAC:

Phase:

Hz:

Full Load Amps.

Fused Amps

93 - 264

1

50/60

1

2

Installing the Control Unit

309738K 19

Installing Fluid Metering Assembly

Installing Fluid Metering Assembly

To install the fluid metering assembly hardware:

• Install the PrecisionFlo LT fluid metering assembly.

• Connect the PrecisionFlo LT fluid metering assembly to the control assembly.

• Connect fluid lines and cables.

Installing the Fluid Metering Assembly

WARNING

Read Warnings, page 6.

Preparing to Install the Assembly

Before installing the fluid metering assembly:

• See component manuals for specific data on component requirements. Data presented here pertains to the PrecisionFlo LT fluid metering assembly only.

• Have all system and subassembly documentation available during installation.

• Be sure all accessories are adequately sized and pressure-rated to meet the system's requirements.

• Use only the Graco PrecisionFlo LT fluid metering assembly with the PrecisionFlo LT control assembly.

• Make sure the fluid metering assembly allows the automation unit to move freely along all axis.

• Make sure the fluid metering assembly provides easy access for servicing its components.

2.

Locate and secure the PrecisionFlo LT fluid metering assembly to the automation unit (or other mounting surface) with appropriate size bolts through the

0.42 in. (10.7 mm) diameter holes in the base plate.

See the mounting dimensions in

Table 1 - Measurement, inches (mm) and F IG . 8.

Table 1 - Measurement, inches (mm)

A 16.0 (407)

B

C

D

15.0 (381)

11.0 (280)

8.0 (204)

A

B

"

Installing the Assembly

WARNING

C

D

"

Read Warnings, page 6.

1.

Select a location for the PrecisionFlo LT fluid metering assembly. Keep the following in mind:

• Allow sufficient space for installing the equipment.

• Make sure all fluid lines, cables and hoses easily reach the components to which they will be connected.

F IG . 8

20 309738K

Connecting Fluid and Air

Lines

CAUTION

Route all fluid and air lines carefully. Avoid pinching and premature wear due to excessive flexing or rubbing. Hose life is directly related to how well they are supported.

Installing Fluid Metering Assembly

• Connect a fluid line to the flow meter fluid inlet or regulator inlet if your system does not have a flow meter.

• Air must be clean and dry, between 60-120 psi (0.41

MPa - 4.14 bar). Flush air line before plumbing in air filter assembly (234967). Plumb in air filter assembly near air drop site (upstream of fluid plate module).

Adding an air regulator to this line will provide more consistent dispense valve response times.

• Connect an air supply line to the 1/4 npt inlet port on the fluid module(s) air supply inlet.

• Connect 5/32 in. or 4 mm OD air lines from the applicator's solenoid valve to the applicator. Plug any unused solenoid ports.

Follow the instructions in your separate component manuals to connect air and fluid lines. General guide lines are provided below.

• The PrecisionFlo LT fluid module should be installed on the automation unit or in another appropriate place, as close as practical to the dispense valve.

• Connect a fluid line between the fluid module outlet and the dispense device. Smaller diameter and shorter fluid lines (hoses) will provide better fluid system response.

To maximize system performance keep the dispense hose length and ID as small as the application will allow.

Grounding the Metering Assembly

Grounding the Fluid Metering Assembly

WARNING

Air and Fluid Hoses

For static dissipation, use only electrically conductive hoses or ground the applicator / dispense valves.

Read Warnings, page 6.

CAUTION

If power and grounding connections are not done properly, the equipment will be damaged and the warranty voided.

Metering Module

The PrecisionFlo LT fluid metering assembly is grounded to the control assembly through proper connection of the electrical cable provided with the metering module.

Dispense Device

Follow the grounding instructions in the dispense device documentation.

Ground the fluid metering assembly as instructed here and in the individual component manuals. Make sure the fluid metering assembly and its components are installed correctly to ensure proper grounding.

309738K 21

Installing Cable Assemblies

Installing Cable Assemblies

Automation I/O

B

B

*Operations Cable

22

PrecisionFlo LT

Control Unit

*Available in lengths of:

25’, 60’, or 125’

Automation I/O

Controller

F

IG

. 9

Fluid Module Cables

Operations Cable (13) This cable carries signals between the fluid module and the control unit. The applicator solenoid, V/P valve, pressure transducer and flow meter signals are carried through this cable.

Automation I/O Cable (17) This cable carries signals between the automation controller and the PrecisionFlo

LT control unit.

Maximum recommended length of both the operations and automation cable is 125 ft. (38.1 m).

F IG . 10

13

Control Unit - Top View

17

CAUTION

Always make connections to the control assembly with the power off.

Connecting the Operations Cable

Operation cables are offered in three lengths (25, 60, and 125 ft.) and three flexibilities (see page 6 for cable options.)

To connect the operation cable between the control unit and fluid module do the following:

1.

Locate the receptacle on the top of the control unit.

See Fig. 8.

2.

Connect the operation cable to the control unit revceptable.

3.

Locate the receptacle on the fluid module junction box.

4.

Route the operation cable and conform to the following cable routing requirements:

• Avoid small bend radii.

• Avoid pinch points.

• Avoid cable pulling or stretching.

• Keep cables from rubbing against other components or machinery.

• If a lot of robot wrist motion is required, leave sufficient cable length to allow for the motion, avoiding any cable droops that may interfere with the machinery or substrate.

• Cable ties should only be used to loosely bundle hoses together. Do not tighten cable ties to the point where cable movement is restricted.

5.

Connect the operation cable to the fluid module junction box.

6.

Check the connections to ensure the cable is connected correctly.

309738K

Installing the Cable Assemblies

Installing the Cable Assemblies

CAUTION

Always make connections to the control assembly with the power off.

Connecting the Automation Control

Cable

The PrecisionFlo LT control assembly is provided with an 18-pin receptacle for the automation I/O cable.

Any wiring from an external source such as an automation controller, must follow the automation manufacturer’s instructions and must comply with the appropriate codes and standards.

The automation cable has terminated individual leads. The installer will need to configure the proper connector for the automation/cell controller being used.

Refer to

Appendix C Theory of Operation on page 95

and

Appendix A PrecisionFlo LT User Interface

on

page 84.

Signal Wire No

Dispense Gun / 3290

Description

Digital Input

This signal is used to control the opening of the dispense valve.

Job Complete / 3310 This signal can be used to signal the end of a job.

Digital Output

Dispenser Ready / 2680 This signal indicates to the automation controller that the PrecisionFlo LT unit is ready to dispense.

Fault Present / 2710

In Cycle / 2740

This signal indicates to the automation control when a fault is present.

This signal indicates to the automation control that the

PrecisionFlo LT unit is currently in a job cycle.

Minimum Volume Dispensed / 2770

PFlo LT E-Stop / 2170

This signal indicates when the minimum amount of material is dispensed.

This signal indicates to the automation control when the emergency stop is depressed on the PrecisionFlo

LT unit.

Analog Flow Command /

3150

Analog Input

This signal represents the flow or pressure requests from the automation control.

Analog Output

Actual Flow Rate Signal

3210

Analog output signal of the current system flow rate.

24 VDC / 2120 24 VDC from the PrecisionFlo LT control box.

24 VDC Common / 2121 Digital reference point.

Analog Common / 3170 Analog reference point.

GND Shield connection.

To connect the automaton control cable between the control assembly and the automation perform the following steps:

1.

Locate the receptacle on the top of the control

assembly. See F IG . 10.

2.

Connect the cable assembly to the automation I/O

receptacle in F IG . 10.

3.

Connect the opposite end of the cable assembly to the applicable terminals or receptacle on the robot controller.

For information about specific control assembly circuitry and connections, read the chart on this page and see

the Wiring Diagrams beginning on page 69 and F IG . 10.

4.

Check the connections to ensure the cable is connected correctly.

309738K 23

Installing the Cable Assemblies

Checking Ground Continuity

Have a qualified electrician check the resistance between:

WARNING

• true earth ground and the panel ground lug

To reduce the risk of fire, explosion, or electric shock, the resistance between the supply unit components and true earth grounding must be less than 0.25

ohms.

Read Warnings, page 6.

• the application device and the automation unit

• the fluid module and the automation unit

• the regulator and the automation unit

• each supply system component and true earth ground

The resistance must be less than 0.25 ohms. If the resistance is greater than 0.25 ohms, a different ground site may be required. Do not operate the system until the problem is corrected.

24 309738K

PrecisionFlo LT Module Operation

Reading PrecisionFLo LT Control / Indicators

7

1

PrecisionFlo LT Module Operation

4

2

3

6

F IG . 11

Table 2 - PrecisionFlo Buttons/Switches

Ref

4

Button/Switch

Sealer Stop Button •

What it Does

Disables all air solenoids and V/P regulators.

6

7

Run/Setup Mode Key

Switch

Main Electrical Power

(Disconnect) Switch

• Signals the external controller that a SEALER STOP condition is in effect.

• Turn key switch counter-clockwise to set control unit to Run Mode. When the key is in Run Mode or removed, you can operate and monitor the system.

• Turn key switch clockwise to set control unit to Setup Mode (for software configuration). The key cannot be removed while turned to Setup Mode.

• Turns on power to system.

• Lights Condition Light(s).

Table 3 - PrecisionFlo LT Indicators

1

Ref Indicator

User Display

Indicator light

On

Off

Meaning

Display is on when power is applied to the control assembly.

Display is off when power is removed from the control assembly or the screen saver is active. Press any key to activate the screen.

Table 4 - PrecisionFlo Indicator Lights

Dispenser Ready

Light (Ref 2) Status

Off

Fault Present Light

(Ref 3) Status

Off

On

On

Off

Off

On

On

No System Power or the system is in manual mode with no fault present.

System is in auto mode with no fault present.

System is in auto mode with a minor fault present.

System is in auto or manual mode with a major fault present or the system is in manual mode with a minor fault present.

309738K 25

PrecisionFlo LT Module Operation

26 309738K

PrecisionFlo LT User Interface

PrecisionFlo LT User Interface

The EasyKey User Interface is available with the PrecisionFlo LT control unit.

EasyKey User Interface Overview

For screen-captures of the screens and your selection

options, see page 84 for the EasyKey interface.

Screen

Navigation Keys

Data Field

Navigation Keys

Bead Size Decrease

Bead Size Increase

Help Key

F IG . 12

Key Groups

There are three groups of keys on the PrecisionFlo LT user interface.

• Action Keys – perform an action when they are pressed. Manual Dispense Gun, Fault Reset, Bead

Size Increase, Bead Size Decrease, Help, and Auto/

Manual. See Action Keys at right.

• Numeric Entry Keys – are used to enter variable data into the controller.

• Navigation Keys – are used to navigate between and within the different user screens.

Manual

Dispense Gun

Fault Reset

Enter Key

Auto / Manual

Action Keys

• Manual Dispense Gun – is used for functions related to the regulator and dispense gun, including manual dispense, and calibration.

• Bead Size – is used to increase or decrease the bead size during unit operation. This feature is enabled / disabled in the setup screens.

• Help Key – is used to display the help screen.

• Fault Reset – is used to reset a fault generated on the control once the fault has been corrected.

• Auto / Manual – is used to change the mode of operation between Automatic and Manual.

309738K 27

PrecisionFlo LT User Interface

Operation Modes

The PrecisionFlo LT system has two operating modes:

• Automatic dispense mode – enables the Precision-

Flo LT module to begin dispensing when it receives a command from the automation unit.

• Manual dispense mode – enables the Precision Flo

LT module to begin dispensing when you press Manual Dispense Gun on the EasyKey interface. Dispensing continues for as long as the Manual

Dispense Gun button is pressed. Manual mode is also used for system tuning or calibration.

To select the Operation Mode and to operate in manual dispense mode, see the following specific instructions.

Refer to

Appendix C , Theory of Operation , page 95

for more information on Operation Modes.

Refer to Keypad Overview

on page 27 for key

locations.

Setting Operation Mode

On the keypad, perform the following steps:

1.

The dispense mode is indicated on the run screen, either Auto or Manual.

2.

To change the mode, press the Auto/Manual key.

Manually Dispensing Fluid

On the keypad, perform the following steps:

1.

Place the system in manual dispense mode. Refer to Setting Operation Mode , above.

Control Modes

The PrecisionFlo LT module has four fluid dispensing control modes:

• Bead Control – the control unit measures the flow rate of material being dispensed. The regulator outlet pressure is varied to control the fluid flow rate to the requested value. Use Bead Control Mode when a consistent bead size is required.

• Volume Monitor – regulator outlet pressure is controlled to the requested value. Use Volume Monitor

Mode when a constant pressure is required for a spray application.

• Batch Dispense – regulator outlet pressure is controlled to the requested value. Dispense valve is closed when target volume is reached or the automation provides a signal.

• Pressure Control – regulator outlet pressure is controlled to the requested value. Use pressure control mode if the system does not include a flow meter.

Refer to

Appendix C

,

Theory of Operation , page 95

for more information on Control Modes.

Setting the Control Mode

1.

Place the system in setup mode (key switch clockwise).

2.

The control mode is indicated on the dispense screen.

3.

To change the mode, press the down arrow key until the cursor is over the mode cell.

4.

Press Enter and use the up and down arrow keys, or to change values.

2.

Press the Manual Dispense Gun key .

a.

Press the key and verify that the dispense device opens.

b.

Continue to press the key as long as needed to load material or dispense.

5.

Press Enter.

28 309738K

Automation Modes

The PrecisionFlo LT system has two automation command modes:

• Fixed mode – enables the PrecisionFlo LT system to dispense at preset rate in the control unit.

• Analog mode – enables the PrecisionFlo LT system to dispense at a rate proportional to a 0-10 VDC analog input signal from the automation unit.

Refer to

Appendix C , Theory of Operation , page 95

for more information on Automation Command Modes.

PrecisionFlo LT User Interface

Setting Automation Mode

On the keypad, perform the following steps:

1.

2.

With the system in setup mode (key switch clock wise), press the right arrow key until the

OTHER screen appears. The command mode is indicated on this screen, either Fixed or Analog.

To change the mode, press the down arrow key until the cursor is over the desired mode cell.

3.

Press Enter and use the up and down arrow keys, or to change values.

4.

Press Enter.

309738K 29

Operation

Operation

Pressure Relief Procedure

WARNING

Dispense Valve

Air Solenoid

Read Warnings, page 6.

This procedure describes how to relieve pressure for the

PrecisionFlo LT system.

1.

Shut off the fluid supply to the fluid module.

2.

Place a waste container beneath the fluid drain valve, which is located at the filter. Place a waste container beneath the dispense device.

3.

Slowly open the drain valve, located at each filter, to relieve fluid pressure. Close valve when pressure gauge reads zero.

4.

In manual dispense mode, touch and hold the Manual Dispense Gun key , which will open the reg-

F IG . 13

"

To Dispense

Valve

Manual

Actuator

If you have followed the steps above and still suspect that a valve, hose, or dispense nozzle is clogged or pressure has not been fully relieved, very slowly remove the dispense tip, clean the orifice, and continue relieving pressure.

If this does not remove the obstruction, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen the coupling completely. Clear the valves or hose. Do not pressurize the system until the blockage is cleared.

ulator and the dispensing device, until the fluid stops flowing from them.

5.

If the dispense device cannot be actuated from the control unit, refer to F IG . 13 and perform the following steps to open the dispense device and relieve fluid pressure: a.

Manually actuate the plunger on the solenoid, that opens the dispense device, to relieve fluid pressure. Refer to F IG . 13.

b.

Continue actuating the plunger until all pressure is purged from the system between the needle and the dispense device before proceeding to the next step.

6.

Shut off power and air to the fluid supply systems.

Safety Reminder

Follow the precautions below and the warnings that

begin on page 6.

WARNING

Read Warnings, page 6.

30 309738K

Operation

F IG . 14

Initial Startup

Read and understand Operation section of this manual

Startup system

Check interface signals

Load Material

Verify flow meter

K-factors

Configure software

End Initial Startup

Starting the System

Initial Startup

1.

Make sure you have installed and made all the proper connections to and from the PrecisionFlo LT control assembly enclosure. Make sure fittings are tight.

2.

Read and understand the Operation and Software

Configuration sections of this manual.

3.

Continue startup with step 2 in Standard Startup.

Be sure to set the max outlet pressure range switch in the fluid module junction box to the appropriate

value. See page 72. The pressure range (5 VDC sensor

pressure) must match the junction box setting. See page

92.

See

Table 2 - PrecisionFlo Buttons/Switches

and

PrecisionFlo LT User Interface

, page 32 for infor-

mation on the PrecisionFlo LT control unit buttons, switches, and indicator lights.

1.

Carefully inspect the entire system for signs of leakage or wear. Replace or repair any worn or leaking components before operating the system.

2.

Press the E-stop button (4). See F

IG

. 15.

3.

Turn on air and electrical power to the system.

4.

Turn on the main electrical disconnect (7) to supply power to the PrecisionFlo LT module.

The user interface becomes active, showing first a diagnostic message and then the first screen. The dispenser ready (2) and / or the fault present indicator light (3) turns on.

5.

Check Interface Signals: If this is a new installation, power each of the system inputs and verify that the input is being received.

6.

Turn on material supply system.

7

1

4

F IG . 15

2 3

6

309738K 31

Operation

Loading Material

Before you can configure the software, you must load material into the supply system.

1.

If this is a new installation, follow the Initial Start up procedure. Otherwise, follow the Standard Startup

procedure. See page 31.

2.

Turn on fluid supply pressure to the fluid module.

3.

Place the dispense device(s) over a waste container.

4.

Set the control unit to Manual mode. See Operation

Modes , below.

5.

Select a control mode other than bead control. Dispensing in bead control mode is not possible until a flow calibration has been performed. See

Control

Modes on page 28.

6.

Disengage the E-stop button (4). See F IG . 15.

7.

Press and hold the Manual Dispense Gun key

. Manually dispense fluid until clean, air-free fluid flows from the Dispense Gun.

32 309738K

Configuring Software

Configuring Software

After you have loaded material into the dispensing sys-

tem, configure the PrecisionFlo LT software. F IG . 16

shows the major configuration steps.

Configure Software

Select Control

Mode. Ref Page 27

Calibrate system

Verify flow meter K-factor

Calibrate system

Set user and system variables

The PrecisionFlo LT system compensates for temperature, flow, or pressure fluctuations. However, if you change hardware on the dispensing system or change the type of material being dispensed, you must reconfigure the PrecisionFlo LT software.

To configure the PrecisionFlo LT software, perform the following procedure. When you have completed this procedure, the module is ready for operation.

1.

Select the desired control mode. See page 28.

2.

Calibrate the system. See page 34.

3.

Verify the flow meter K-Factor. See page 34.

4.

Verify other controller preset values. See page 37

for more information.

5.

The

PrecisionFlo LT User Interface

section on

page 27 gives detailed operating instructions for the

display keypad and each screen.

Set dispense on/off delays

For more information regarding applications that run continuously see

Appendix C , Theory of Operation , page 95.

End Software

Configuration

F

IG

. 16

309738K 33

Configuring Software

Setting Flow Meter K-Factors

The accuracy of the PrecisionFlo LT volume reporting depends on precise adjustment of the K-factor(s). The control unit uses the K-factor(s) to calculate the volume dispensed. If the set value is not correct, the system still delivers accurate and repeatable flow rates; however,

the reported value may not be correct. See page 36 for

additional K-factor information.

Table 4 - Flow Meter K-Factors

Part No.

Description

239716 G3000 Gear Meters

244292

246190

246652

246340

G3000 HR Gear Meter

Helical Gear Meter

High Resolution Helical Gear

Meter

Heated Helical Gear Meter

K-Factor

8400

16400

3500

7000

3500

Set Flow Meter K-Factor

On the keypad, perform the following steps:

1.

With the system in setup mode, press the screen navigation key until the OTHER screen appears.

2.

Press the down data field navigation key until the flow meter K factor value is highlighted.

3.

Key in the K-factor value and press Enter. See

Table

4 - Flow Meter K-Factors

for values.

System Calibration

Pressure Calibration

The PrecisionFlo LT system uses variables (Kp and Ki) in the software calculations to accurately and precisely control the fluid pressure and flow rate. The control unit calculates Kp and Ki automatically during pressure calibration. These values are different with every material.

3.

Verify that the fluid module air supply is on.

4.

Verify that the control mode is set to the desired value.

Calibrate

On the keypad, perform the following steps:

1.

Press the right screen navigation key until the

Calibrate screen appears.

2.

Enter the desired 100% command Flow/Pressure.

3.

Press the Manual Dispense Gun key . The system will dispense material for 15-30 seconds and gather the required information.

Manually Adjusting Kp and Ki

If automatic pressure calibration does not result in proper system pressure control, you can change the Kp and Ki values manually:

• If the regulator outlet pressure does not closely follow the desired pressure increase Kp with the Ki value set to zero. Continue to increase the Kp value by 10% increments until the proper pressure control is achieved.

• Decrease Kp if the regulator outlet pressure oscillates rapidly above and below the commanded pressure. Continue to decrease the Kp value by 10% increments until the outlet pressure is stable.

• Set Ki volume to 2 and continue to increase the Ki value by 2 until the system oscillates.

• Decrease Ki until oscillation stops.

The system must be loaded with material before calibrating pressure. The nozzle or tip should be installed on the dispense device.

Before Calibrating

1.

Verify that the system is in setup mode and manual dispense mode.

2.

Verify that dispense device is placed over a material waste container.

34 309738K

Configuring Software

Flow Rate Calibration

The system only calibrates flow rate if you are operating in Bead Control Mode. Flow rate calibration takes place immediately after the pressure calibration in bead control mode.

How Flow Rate Calibration Works

Each application may have different flow rate requirements. Flow rate calibration verifies the maximum flow rate of the system and determines the regulator outlet pressure required to achieve the required flow rate.

At the start of the flow rate calibration procedure, you need to enter the maximum flow rate required by the application. When you actuate the dispensing device during calibration, the control unit:

1.

Measures the maximum system flow rate. If the maximum system flow rate is less than the required maximum flow rate a fault is generated.

2.

Determines the outlet pressure required to obtain the flow rate value you entered.

3.

Calculates a linear ratio of the automation analog

input voltage to the desired flow rate. Refer to F IG .

17.

Flow mode: Analog voltage to flow rate ratio

Max.

Flow

Rate

Flow Rate

(cc/minute)

F IG . 17

0

0 Automation Flow Command

Volts (Vdc)

10

Table 5 - Maximum Flow Rate Values (cc/min)

Round Equivalent Bead Diameter (mm)

Max. Automation Speed

(mm/sec)

50

100

200

300

400

500

600

700

800

900

1000

2 3

10 21 59

5 7 9

19 42 118 231 382

38 85 236 462 763

57 127 353 693 1145

75 170 471 924 1527

94 212 589 1155 1909

113 254 707 1385 2290

132 297 825 1616 2672

151

170

189

340

382

424

943

160

1178

115 191

1847

2078

2309

3054

3435

3817

Setting Inlet Pressure

The inlet pressure reading should be in the range of 300 psi (2.1 MPa, 21 bar) to 500 psi (3.4 MPa, 34 bar) above the outlet pressure reading under your highest flow condition.

Excessive inlet pressure will cause accelerated wear on the regulating valve and the pump feed system.

Feed System Pressure Drop

During material flow, the regulator inlet pressure decreases. The amount the pressure decreases is the amount of pressure lost between the feed pump and the regulator inlet. With high viscosity fluids, long line lengths, or small diameter line sizes this pressure decrease can be thousands of psi (hundreds of bar).

This means that the static pump pressure is set much higher than the regulator needs at its inlet. To prevent excessive control regulator wear or surging, a mastic fluid pressure regulator is recommended on the feed line close to the control regulator. The mastic regulator will suppress the static feed pressure at the control regulator inlet.

Flow Rate Guide

Use the values in

Table 5 - Maximum Flow Rate Values (cc/min)

as a guide to determine the maximum flow rate to enter during flow rate calibration.

309738K 35

Configuring Software

Verifying Flow Meter

Calibration

Most sealant and adhesive materials are compressible.

Since the flow meter is measuring the material under high pressure, the actual volume of material dispensed may vary slightly from the measured volume, due to this compressibility. If the K-factor is not correct, the displayed volume will not be accurate.

Follow this procedure to calibrate the flow meter during initial setup and on a routine basis to check for flow meter wear.

Method 1. Using a gram scale

1.

Obtain a beaker, 500 cc or larger, and measure the mass of the empty beaker.

2.

Manually dispense material into the beaker. Hold the beaker so that the stream of material is submerged in the captured material. This is to minimize air entrapment in the container.

3.

Record the volume dispensed on the Run screen and the flow meter K-factor from the Setup Other screen.

4.

Calculate the actual volume dispensed: fluid mass (g) density (g/cc)

= measure volume (cc)

5.

Calculate the new flow meter K-factor:

K-Factor (new) = displayed volume (cc) x K-Factor (old) measured volume (cc)

Method 2. Without using a gram scale, visual measurement

1.

Obtain a beaker, 500 cc or larger with measurement increments.

2.

Manually dispense material into the beaker. Hold the beaker so that the stream of material is submerged in the captured material. This is to minimize air entrapment in the container.

3.

Record the volume dispensed on the Run screen and the flow meter K-factor from the Setup screen.

4.

Settle the material into the beaker and view the actual volume dispensed.

5.

Calculate the new flow meter K-factor:

K-Factor (new) = displayed volume (cc) x K-Factor (old) dispensed volume (cc)

6.

Enter new K-factor.

7.

Repeat the procedure to verify the new K-factor.

Other Software Settings

There are various software settings that are preset at the factory, based on the system configuration that was ordered. A quick check of these variables is recommended. See

Table 5 - PrecisionFlo LT User Variables and Presets

and

Table 6 - PrecisionFlo LT

System Variables

.

The

PrecisionFlo LT User Interface

screens are listed in

Appendix B beginning on page 84 to guide you

through the process.

6.

Enter new K-factor.

7.

Repeat the procedure to verify the new K-factor.

36 309738K

Configuring Software

Setting User Variables

The following variables and presets should be verified prior to calibration and path programming and/or operation in automatic mode. All of the screens as well as additional screen information can be viewed in

Appendix B

,

PrecisionFlo LT User Interface , starting on page 84.

There are additional variables that should be set after the path programming is completed, they include; High/Low pressure settings and Style (volume) information.

Table 5 - PrecisionFlo LT User Variables and Presets

Values in italics are factory defaults.

Screen

Dispense

Other

Variable / Preset Values

Control Mode Bead Control

Batch Dispense, or pressure control

, Volume Monitor,

Command Mode Analog or Fixed

Job End Mode

Language

Pressure Units

Manual Gun Flow

Rate

Job End Delay

Timer or

Many psi or bar

0 - 100%,

Digital

50%

0 - 999 sec,

I/O

4 sec

Comments

Only bead control mode controls flow.

Set the desired language.

Set the desired pressure units.

Flow rate or pressure setting for Manual

Dispense.

Delay time after dispensing for job complete if Job End Mode is set to Timer.

Set the Time and Date.

Year, Month, Day,

Hour, Minute

Default / Fixed

Command

0-100%, 50%

Set value for fixed command mode. If the command signal falls below 1 VDC in analog mode, this value will be used as the command.

Other System Variables

After the calibration and automation path programming is complete and the desired bead profiles have been achieved, verify that the following variables are set.

Table 6 - PrecisionFlo LT System Variables

Screen Variable / Preset Values

Dispense Volume 0 - 9999 cc, 25 cc

Tolerance 0 - 99.9%, 10%

Other

Comments

Set the volume set point for each of the styles being used.

Set the volume tolerance for each of the styles being used.

Set the User configurable faults to Alarms or Warnings. More information on the faults can be found in

Appendix B , PrecisionFlo LT User Interface .

An Alarm will cause the fault present signal to activate and the dispenser ready signal to drop out. This is something considered by the user to be a major fault, one which should cause the system to stop dispensing.

A Warning will cause the fault present signal to activate and the dispense ready signal to stay on. This is something considered by the user to be a minor fault, one which will warn the user but will continue dispensing even if the bead profile is degraded.

309738K 37

Configuring Software

On/Off Delays

The PrecisionFlo LT regulator can physically respond faster than the dispense device and its solenoid. As a result, the regulator can supply material to the dispense device before the device has time to open. Supplying material to a closed device can create trapped-pressure.

At the end of a cycle, the dispense device can shut off before the pressure has dissipated. This can cause a dispense of an excess of material at the beginning of the next cycle.

To eliminate these two problems, you can change the delay time associated with the opening of the regulator/dispense and/or the closing of the dispense device, see

Table 7 - On/Off Delay Variables .

In general, your outlet pressure on the screen during “no flow” should be slightly below the outlet pressure during dispense. If your dispense hose to the gun is creating too much pressure drop during flow, you may want the no flow reading to be lower. High trapped pressures shorten the dispense device life.

Table 7 - On/Off Delay Variables

Variable:

Gun ON

Sets the Amount of Time:

Sets time from Dispense Gun High to

Gun Open command

Regulator ON Sets time from Dispense Gun High to

Regulator ON

Gun OFF Sets time from Dispense Gun Low to

Gun Close command

Regulator

OFF

Sets time from Dispense Gun Low to

Regulator OFF

F IG . 18 and Table 8 - Delay On/Off Timing show delay

ON and OFF timing.

38

A

C

Dispense Gun

Signal

PrecisionFlo LT

Regulator

D

Gun Open

Command

F IG . 18

Gun Actually

Open

E

B

F

Table 8 - Delay On/Off Timing

A Regulator ON delay The user sets the regulator ON delay timing.

B Gun ON delay

C Gun OFF Delay

Usually set to zero. Can be used to change the starting point of a bead.

Usually set to zero. Higher values will lower the trapped pressure.

D Regulator OFF delay The user sets the regulator OFF delay timing. Zero or small values will lower the trapped pressure.

E Gun Open Reaction

Time

Time delay for gun to physically open. Delay varies based on pneumatic hose length and valve air volume.

F Gun Close Reaction

Time

Time delay for gun to physically close. Delay varies based on pneumatic hose length and valve air volume.

Regulator Pre-Charge

Another method which can be used to increase the dispense hose pressure while the dispense valve is closed is to use a regulator pre-charge. Setting this value to a range of 1.00 to 5.00 VDC causes the V/P to apply 0 to 100 psi (.60

MPa, 68 bar) air pressure to the fluid regulator. Typical values entered would be about 1.2 VDC.

309738K

Shutting Down the System

1.

Shut off the material supply to the fluid module.

2.

Follow the

Pressure Relief Procedure on page 30.

WARNING

Read Warnings, page 6.

3.

Turn off the PrecisionFlo LT system's compressed air supply.

4.

Press the sealer stop button (7). See F IG . 19.

5.

Turn off the main electrical disconnect (2).

F IG . 19

Configuring Software

7

2

309738K 39

Communicating with PrecisionFlo LT

Communicating with PrecisionFlo LT

Communication with the PrecisionFlo LT is carried out through the Graco Shell program (included). This is a text based menu program that you can use to perform the following tasks:

Upgrade software

• Display software versions

• Download job and alarm logs

Backup and restore setup parameters

Restore the factory defaults

You can access the Graco Shell program via the programming port on the side of the control box. Plug one end of the programming cable into the RJ12 (phone jack style) on the control box and the other end of the cable into the serial (COM port) of a computer.

For more information on the use of Ethernet and

Ethernet Kit 118329 see

Appendix D , Ethernet Kit

118329 , page 106.

The laptop computer used to interface to the Graco

Shell must be running some type of terminal emulation software. Some examples are Hyper Terminal or Tera

Term. Graco recommends using Tera Term which can be downloaded from http://hp.vector.co.jp/authors/

VA002416/teraterm.html

. The following communications parameters must be used (these are the default parameters in Tera Term).

Setting

Port

Baud Rate

Data

Parity

Stop

Flow Control

Value

COM 1 or COM 2

57600

8 Bit

None

1 bit

None

Once the programming cable is connected and the communications software is running, the user can activate the Graco Shell by pressing the Enter key on the keyboard. The main menu will be displayed.

The main menu will look as follows:

****Welcome to the Graco Control Application Menu****

Build date: Mar 05 2003 14:23:23 a. Software Update and Version Information b. Data Transfer c. Restore settings to factory defaults

Enter Selection [a-c]:

Upgrading Control Board Software

To upgrade the controller software, you must first obtain the latest version of Ltcontrol.rec

. Contact your Graco distributor for details.

Select option “a”. Make sure the key switch is turned to

Setup mode. The following text will be displayed.

Are you sure?

Enter yes to continue:

Type “yes”. The following text will be shown.

****Welcome to the Graco Control Boot Software.****

Version: 1.01.001 Built: Mar 10 2003 14:39:33.

Warning: you are about to erase your application software.

Type ‘yes’ to continue upgrading software

(reboot to cancel).

Type “yes”. The following text will be shown.

Sector 1 erased.

Sector 2 erased.

Sector 3 erased.

Hyperterminal: Go to (Menu Transfer XXX Send

Text File) and select *.rec file.

Tera Term: Go to (File XXX Send File) and select *.rec file.

Select Send File from the File menu in Tera Term. Then select the Ltcontrol.rec

from the selection box window

(you will need to browse to the appropriate directory).

The file will begin to download to the controller, which will take approximately one to two minutes. When the download is complete, a new menu will appear on the screen. The software upgrade is now complete. Cycling power to the controller is recommended after a software upgrade.

40 309738K

Communicating with PrecisionFlo LT

Upgrading Display Board Software

To upgrade the display software, you must first obtain the latest version of Ltdisplay.rec

. Contact your Graco distributor for details.

To upgrade the Display Software the jumpers between terminals 2540 and 2541and terminals 2550 and 2551 should be moved to connect terminals 2541 and 3720 and terminals 2551 and 3740.

Once the programming cable is connected and the communications software is running, the user can activate the Graco Shell by pressing the Enter key on the keyboard. The main menu will be displayed.

****Welcome to the Graco EasyKey Display****

Build date: Mar 10 2003 14:23:23.

a. Install Display Application Software b. Display Software Versions

Enter Selection (a-b)

Select option “a”. Make sure the key switch is turned to

Setup mode. The following text will be displayed.

Are you sure?

Enter yes to continue:

Type “yes”. The following text will be shown.

****Welcome to the Graco Control Boot Software.****

Version: 1.01.001 Built: Mar 10 2003 14:39:33.

Warning: you are about to erase your application software.

Type ‘yes’ to continue upgrading software

(reboot to cancel).

Type “yes”. The following text will be shown.

Sector 1 erased.

Sector 2 erased.

Sector 3 erased.

Hyperterminal: Go to (Menu Transfer XXX Send

Text File) and select *.rec file.

Tera Term: Go to (File XXX Send File) and select *.rec file.

Select Send File from the File menu in Tera Term. Then select the Ltdisplay.rec

from the selection box window

(you will need to browse to the appropriate directory).

The file will begin to download to the controller, which will take approximately one to two minutes. When the download is complete, a new menu will appear on the screen. The software upgrade is now complete. Cycling power to the controller is recommended after a software upgrade.

Displaying Versions

Select option “b”. Text similar to this will be shown.

Boot Code version: 1.01.001, checksum=52c2f6, built:Mar 10 2003 14:47:49

Application: 1.01.001, checksum=cc5bd, built:Mar 05 2003 14:47:49

Return to Main Menu

Select option “h”. The main menu will be shown.

Welcome to the Graco Control Application Menu

Build date: Jul 06 2001 15:45:38 (debug build) a. Software Update and Version Information b. Data Transfer c. Restore settings to factory defaults

Enter Selection [a-c]:

Restoring Defaults

Select option “c” and the following message will appear.

Are you sure?

Enter yes to continue:

Type “yes”.

When the operation is complete, the main menu will

309738K 41

Maintenance

Maintenance

The following is a list of recommended maintenance procedures and frequencies to operate your equipment safely.

The maintenance is divided between mechanical and electrical tasks. Maintenance must be performed by trained personnel per this schedule to assure safety and reliability of the equipment.

Mechanical

Operator Maintenance Person

Task Daily Weekly Monthly 3-6 months or

125,000 cycles

Inspect system for leaks

Depressurize fluid, after operation

Remove heat from system, after operation

Inspect filter (234967) bowls and drain

Check hoses for wear

Check/tighten fluid connections

Check/tighten air connections

Lubricate dispense valves*

Rebuild regulator*

Rebuild dispense valve*

Replace air filter (234967) assembly

Replace Solenoid

Replace V/P valve

* Check component manual for more detailed maintenance information.

6-12 months or

250,000 cycles

18-24 months or

500,000 cycles

36-48 months or

1,000,000 cycles

Electrical

Task

Calibrate flow meter**

Check cables for wear

Verify cable connections

Daily Weekly Monthly 6 months 12 months

Verify resistance of electric heaters*

Verify operation of “System Stop” button

** Weekly calibration is recommended for applications using abrasive materials.

* Check Component Manual for more detailed maintenance information.

42 309738K

Troubleshooting

Troubleshooting

WARNING

Read Warnings, page 6.

High outlet pressure

Air leaks from fluid module

Needle/seat is worn

Loose air connections

Worn gaskets

Fluid module heater does not heat Temperature controller turned off

Loose electrical connections

Blown fuse

Broken heater element

Broken sensor

Troubleshooting for individual regulators and flow meters is discussed in their separate manuals. These manuals are called out in the parts lists later in this manual. Also refer to the section on Troubleshooting and

Fault Recovery for detailed information on how fault codes are communicated.

Check all possible solutions in the chart below before you disassemble the regulator.

Fluid Modules

Problem

No outlet pressure

Cause(s)

Air pressure low

No “Gun On” signal from automation unit

No output signal from system I/O board

No air signal to air diaphragm

False signal being sent to control

Possible Solution(s)

Verify air pressure is above 60 psi

(0.4 MPa, 4 bar)

Check input from automation unit

Check signal from system I/O board, verify that a signal is being sent (1-5 VDC)

Check for loose/disconnected/worn operations cable; tighten/replace as required

Check for loose/disconnected DIN connector to V/P valve; tighten

Check outlet pressure sensor out put; verify that it corresponds to zero pressure; replace sensor and/or amplifier

Rebuild regulator; replace needle/ seat

Check air connections; tighten if necessary

Check/replace gaskets on V/P and solenoid valve

Verify Zone is properly adjusted.

Verify connection between inlet hose and fluid module connector

Verify connections between inlet hose and main enclosure

Check/verify fuse in heater control box

Check/verify heater resistance

Check/verify sensor resistance

309738K 43

Troubleshooting

Flow Meter

Problem

No flow measurement

False measurement

Flow reported is not correct or inconsistent

Regulator

Problem

No pressure regulation

No fluid flow

Pressure creeps above setting

Pressure drops below setting

Fluid leaks from spring housing

Chatter

Cause(s)

Flow meter pick-up sensor loose

Flow too low

Loose wiring

Possible Solution(s)

Tighten flow meter pick-up sensor

Verify flow rate is above minimum for the flow meter selected

Verify wiring connections from flow meter to junction box

Damaged flow meter pick-up sensor Replace pick-up sensor

Flow meter not calibrated Calibrate flow meter

Flow meter cable shield wire not connected

Verify shielding to ground

System not grounded properly

Noisy power source

Flow meter not calibrated

Verify system ground

Verify clean power supply power to main enclosure

Calibrate flow meter

Flow meter is worn Replace flow meter

Cause(s)

Damaged diaphragm

Leaking or dirty seat

Damaged valve actuator

Metal chip or contamination between ball and seat

Damaged diaphragm

Damaged o-ring or improper seal

Damaged or clogged air regulator or line (air-operated regulator only)

Leaking or dirty seat

Large change in inlet pressure

Empty/clogged supply line

Damaged or clogged air regulator or line (air-operated regulator only)

Using valve beyond its rated flow capacity

Large change in inlet pressure

Loose fluid housing

Damaged diaphragm

Excessive pressure differential be tween pump and gun

Excessive flow rate

Possible Solution(s)

Replace diaphragm

Replace cartridge, or clean seat

Replace valve actuator

Replace cartridge, or clean seat area

Replace diaphragm

Replace the o-ring under the seat

Clear obstruction in line. Service regulator if necessary

Replace cartridge, or clean seat

Stabilize regulator inlet pressure

Fill/flush supply line

Clear obstruction in line. Service regulator if necessary

Install valve for each spray gun or dispensing valve

Stabilize regulator inlet pressure

Tighten the four cap screws

Replace diaphragm

Reduce pump pressure to not more than 2000 psi (14 MPa, 138 bar) greater than required gun pressure.

Reduce fluid flow through regulator.

Connect only one spray gun or dispensing valve to each fluid regulator

44 309738K

Troubleshooting

Dispense Valves

Problem

Valve not opening

Valve not shutting off

Sluggish open/close

Material leaks from back of valve

Air leaks from dispense valve

Dispense valve does not heat

Cause(s)

Air not getting to open port

No “Gun On” signal from automation unit

No output from system I/O board

Air not getting to close port (except

AutoPlus valve)

“Gun On” signal from automation unit is on

Air pressure low

Needle/seat worn

Pressurized material past the valve shut-off is escaping

Shaft seal is worn

Loose air connections

Worn piston o-ring

Temperature controller turned off

Loose electrical connections

Blown fuse

Broken heat cartridge

Broken sensor

Possible Solution(s)

Verify air pressure solenoid

Check input from automation unit

Check output from system I/O board; verify that it is on

Verify air pressure to solenoid

Verify solenoid operation

Verify air line routing and connections

Check input from automation unit

Check output from system I/O board; verify that it is on

Verify air pressure is above 60 psi

(0.4 MPa, 4 bar)

Rebuild valve; replace needle/seat

Reduce running pressure

Reduce nozzle length

Increase nozzle orifice size

Rebuild valve; replace seals

Check air connections; tighten if necessary

Rebuild valve; replace piston o-ring

Verify zone #4 is on through the user interface

Verify connection between outlet hose and valve connector

Verify connection between outlet hose and main enclosure through extension cord

Check/verify fuse in Electric Heat box

Check/verify heater resistance

Check/verify sensor resistance

309738K 45

Troubleshooting

Electrical Component Paths

Use the following table to troubleshoot wiring to the automation:

Component

Dispense Gun

Job Complete

24 VDC From IFC

24 VDC Common

Analog Flow Command

Analog Common

Actual FLow Rate Signal

Dispenser Ready

Fault Present

In Cycle

Minimum Volume Dispensed

24 VDC Thru E-Stop

GND

Description

+24 VDC Input

+24 VDC Input

+24 VDC Input

COM

0-10 VDC Input

COM

0-5 VDC Output 9

7

8

+24 VDC Output 10

+24 VDC Output

11

+24 VDC Output

12

+24 VDC Output

13

2

5

6

Cable /

Pin

1

3150

3170

3210

2680

2710

2740

2770

Enclosure

Wire

3290

3310

2120

2121

+24 VDC Output

Shield GND

14

15

2170

Shield

Board / Connector Wire Color

J8-4

J8-5

+24 VDC

Common

J7-3

J7-4

J7-6

J5-5, Green Light

J5-7, Red Light

J5-9

J5-11

E-Stop Switch

Chassis GND

WHT

BLU

RED

BLK

GRN/BLK

GRN

ORN/BLK

BLU/BLK

BLK/WHT

RED/WHT

GRN/WHT

ORN

N/A

KEY

Component – External component wired into module's junction box.

Description – Type of signal.

Component ID – Where it originates from on the component.

J-Box Wire – Wire number or terminal location in the module's junction box.

Cable/Pin – Pin number on the operations cable. The operations cable connects the module's junction box to the main electrical enclosure.

Enclosure Wire – The wire number inside of the main electrical enclosure.

Board/Connector – Where the wire terminates inside of the main electrical enclosure.

46 309738K

Troubleshooting and Fault Recovery

Troubleshooting and Fault Recovery

The following table describes the valid fault codes used by the PrecisionFlo LT module, possible causes, and solutions. PrecisionFlo LT module displays warnings and alarms on the user interface and alarms via the control unit fault light.

Resetting Control Unit After a Fault

If a fault has occurred, you should clear (reset) the fault before restarting the PrecisionFlo LT control unit. Press the fault reset key to clear the fault, or press the ?

key for additional information.

• Alarms set the dispenser ready signal LOW.

• Warnings do not set the dispenser ready signal

LOW.

3

4

Table 9 – Fault Priority Table

Fault

Priority

Fault Name Fault

Description

2

5

Dispenser

Stop

Closed Gun

Flow

The following faults are always Alarms

There is no electrical power

System reading flow meter pulses from Flow

Meter with Gun closed.

These meter pulses correspond to a flow rate that is greater than 1000 cc/min

Causes

E-Stop has been pressed

Green and/or red light not lit, control assembly is off

Solutions

Turn E-Stop switch to release

Apply power to PrecisionFlo LT module

Dispense hose leak

Dispense valve not operating properly

Check hose; replace if needed

Flow meter providing false pulses Replace flow meter sensor or calibrate meter (corilis)

Repair dispense valve

Flow meter providing false pulses Replace flow meter sensor

1 Communication Error

The following faults are always Warnings

Communication has been lost between the control board nd the display board

The display board and the control board are no longer communicating

Repair any loose or disconnected wires in the connectors between the two circuit boards

Replace one or both of the circuit boards if their “heartbeat” LEDs are no longer blinking

Replace the wiring harness between the two circuit boards

Power Up

Calibration

Error

Control box power up

System was not able to complete a flow calibration

Flow setpoint higher than the flow rate the system can deliver

Lower calibration flow setpoint

Increase dispense valve tip size or dispense hose diameter

Increase supply pressure

Repair regulator Regulator worn or not operating properly

A dispense command in flow mode was received without a valid flow calibration being performed

Perform a flow calibration

309738K 47

Troubleshooting and Fault Recovery

Table 9 - Fault Priority Table (continued)

Fault

Priority

Fault Name Fault Description

6 Volume

Comp Limit

Causes

The following faults are always Warnings (con't)

Peak value of flow compensation for regulator has reached the 25% or

400% limit

Fluid supply too low to achieve desired flow rate

Regulator is not able to close completely

Major change to fluid or fluid system downstream of the regulator

7

15

Low Analog

Default Kp/Ki

Analog command dropped below 1 VDC while dispensing

Default Values for Kp &

Ki have been loaded

Operating below the minimum regulator operating pressure

The autotune portion of the calibration has failed to find new Kp and Ki values. Default values for these parameters are being used.

Solutions

Increase fluid supply pressure or check for clogged filter

Repair regulator

Check fluid viscosity

Check hoses and tips for problems

Perform a new calibration if necessary

Increase fluid pressure above regulator minimum

Bad or loose I/O cable connection Check cable and connection

Entered command mode incorrectly

Enter correct command mode

Automation program error Verify correct automation program or set the default flow rate to 3500 or disable this fault

Decrease the volume of the dispense hose (length and / or diameter)

Choose a smaller tip size for the dispense valve

Increase the fluid supply pressure

Manually adjust Kp and Ki (see

page 34)

No action necessary if changes were desired

16 Setup Values Changed

Setup change notification

When the Key Switch was turned from Setup to Run mode, the control detected a change from previous setup data value(s)

Remaining faults are selectable by the user as Alarms or Warnings (Setup

8 High Outlet

Pressure

Output pressure to the

PrecisionFlo LT regulator is above the upper limit set for operation. If this fault occurred while doing a pressure calibration, pressure calibration could not determine optimum values and default values were used

Incorrect limit set

Dispense hose/device plugged

Failed transducer

Regulator is not closing completely.

Incorrect pressure amplification switch setting

Alarms/Warnings screen)

Verify limit is set correctly

Clean/replace hose/device

CHeck transducer, replace if failed

Repair regulator

Verify switch is set correctly

48 309738K

Troubleshooting and Fault Recovery

Table 9 - Fault Priority Table (continued)

Fault

Priority

Fault Name Fault Description

9 Low Outlet

Pressure

Output pressure of the

PrecisionFlo LT regulator is below the limit set for operation. If this fault occurred while doing a pressure calibration, system pressure was too low (<500 psi [3.4MPa,

34 bar] at the regulator outlet) to complete the calibration

Causes

10

11

12

High Volume

Low Volume

Low Flow

Rate

Material dispensed during the last dispense cycle was above the amount established by request and above the allowable (entered) tolerance

Material dispensed during the last dispense cycle was below the amount established by request and below the allowable (entered) tolerance

Measured flow rate less than desired flow rate minus tolerance

Solutions

Incorrect limit set

No or insufficient material flow

Dispense valve needle is stuck closed

Verify limit is set correctly

Increase material flow rate

Dislodge and inspect needle

Dispense valve leaking

Regulator not operating properly

Repair dispense valve

Repair regulator

Pump wink passed through outlet Recalibrate PrecisionFlo LT or increase pump pressure

Failed transducer

Incorrect pressure amplification switch setting

Material viscosity is outside flow compensation window

Check transducer, replace if failed

Verify switch is set correctly

PrecisionFlo LT regulator is not regulating properly

Verify material characteristics, recalibrate if necessary. Increase

Bead scale

Check regulator, repair if necessary. Increase pressure to regulator above.

Enter correct values or minimum operating pressure

Incorrect volume or tolerance when using Volume Monitor or

Batch Dispense

Partially plugged tip or supply system. Error is outside flow compensation window

Insufficient flow to PrecisionFlo LT regulator inlet. Error is outside flow compensation window

Material viscosity is outside flow compensation window

Clean tip and/or supply system.

Increase flow rate to PrecisionFlo

LT regulator inlet

Material viscosity increased

PrecisionFlo LT regulator is not regulating properly

Fluid supply too low to achieve desired flow rate

Tip plugged

Verify material characteristics, recalibrate if necessary

Increase bead scale

Enter correct values or set the tolerance to 0% to disable this fault

Increase fluid supply pressure or check for clogged filter

Clean/replace tip

No air pressure to solenoid valves Turn on air to solenoid valves

No flow meter signal Check cable and sensor

No material supply

Incorrect flow tolerance or flow fault time

Replace drum or turn on pumps

Enter correct tolerance or flow fault time

309738K 49

Troubleshooting and Fault Recovery

Fault

Priority

13

Fault Name

High Flow

Rate

14 Computed

Target

Fault Description

Measured Flow rate more than desired flow rate plus tolerance

The requested volume differs from the entered process target by more than the entered tolerance for style requested

Causes

Operating below the minimum regulator operating pressure

Regulator worn or not operating properly

Increase fluid pressure above regulator minimum

Repair regulator

Flow meter providing false pulses Replace flow meter sensor

Incorrect flow fault tolerance or flow fault time

Enter correct tolerance or flow fault time

Entered process target incorrectly Enter correct process target

Entered tolerance incorrectly

Requested volume incorrect

Automation problem

Enter correct tolerance

Check automation program

Verify automation is correct

50 309738K

Control Assembly Service

Servicing the Panel Assembly

This part of the manual provides information about the following panel assembly component:

• Main Control Board

• Software Upgrade

• Fuse

• Display Backlight

Main Control Board

Display Backlight

Easy Key Interface

Control Assembly Service

Fuses

Door Side

Enclosure Side

F IG . 20

Main Control Board Removal

Remove the control board as follows:

WARNING

Read Warnings, page 6.

1.

Shut off system power at the main circuit breaker.

2.

At the control assembly, move the MAIN power switch to the OFF position.

3.

Open the hinged cover of the control assembly.

4.

Unplug the connectors from the control board.

5.

Pry the plastic cups off the board with a screwdriver to release the board from the din rail.

309738K

Control Board Replacement

Replace the control board as follows:

1.

Snap the main control board onto the din rail.

2.

Plug the connectors into the control board.

3.

Close and lock the hinged cover on the control assembly.

4.

Apply system power at the main circuit breaker.

5.

Move the MAIN power switch to the ON position, applying power to the control assembly.

6.

Verify that the control board operates correctly.

7.

Restore the system parameters to return the control assembly to normal operating condition.

51

Software Upgrade

Software Upgrade

There are two ways to upgrade the software in the PrecisionFlo LT system.

• Use the Graco Shell Serial menu System (see

Communicating with PrecisionFlo LT , page 40).

• Replace the flash memory in the two circuit boards.

The software upgrade kit (253614 Standard) can also be used to upgrade software. This kit contains flash memory chips for the display board (see F IG . 21) and control

board (see F IG . 22). The kit also includes a chip pulling

tool.

To replace a flash memory chip on either the display board or the control board, perform the following steps.

1.

Attach the grounding strap included with the kit to your wrist and ground appropriately.

2.

Turn off the power to the LT system.

3.

Press the two feet of the chip extraction tool into the open holes in the corners of the flash chip socket on the circuit board. See

Display Board

F IG . 21 or

Control Board F IG . 22.

4.

Position the chip extraction tool so that the feet of the tool are underneath the flash chip. Squeeze the tool to grip the chip.

5.

Continue squeezing the tool while pulling the chip out of the socket.

6.

Orient the new flash chip such that the beveled corner on the chip aligns with the beveled corner of the socket.

7.

Press the new chip into the open socket. Make sure that the pins are not bent or touching.

8.

Repeat this procedure for both circuit boards.

9.

Turn the power on the LT back on.

Display Board

253612 Standard flash memory chip

Beveled

Edge

F IG . 21

52 309738K

F IG . 22

309738K

Control Board

Software Upgrade

Beveled edge

253613 flash memory chip

53

Panel Assembly Service

Panel Assembly Service

Fuse Removal

Remove the fuse as follows:

WARNING

Fuse Replacement

Replace the fuse as follows:

Read Warnings, page 6.

1.

Shut off system power at the main circuit breaker.

2.

At the control assembly, move the MAIN power switch to the off position.

3.

Unlock and open the hinged cover of the control assembly.

4.

Lift to unlock the top of the fuse holder, which is hinged at the bottom, from its clamp.

5.

Open the fuse holder fully. Locate the failed fuse inside.

6.

Carefully remove the fuse from the fuse holder.

Check the new fuse to ensure that it matches the amp rating of the failed fuse.

1.

Press both ends of the new fuse evenly into place in the fuse holder.

2.

Close and lock the fuse holder into place.

3.

Close and lock the hinged cover on the control assembly.

4.

Apply system power at the main circuit breaker.

5.

Move the MAIN power switch to the ON position applying power to the control assembly.

6.

Verify that the fuse operates correctly.

7.

Return the control assembly to the normal operating condition.

Lift the top of the fuse holder to unlock

Fuse location

(two places)

F IG . 23

54 309738K

Replacing the Backlighting

WARNING

A qualified electrician must complete all grounding and wiring connections.

Read Warnings, page 6.

A Backlighting Replacement Kit is available. Order part no. 118337.

Before replacing the backlighting, check the inverter (9) for proper voltage by unplugging the backlighting connector (1), turning on the PFlo LT and carefully measuring the AC voltage across the two pins of the inverter.

Voltage should read approximately 700 VAC. If not replace the inverter.

1.

Shut off system power at the main circuit breaker.

2.

At the control assembly, move the main power switch to the off position.

Panel Assembly Service

3.

Unlock and open the hinged cover of the control assembly.

4.

Unplug the ribbon cable from the board (4) by sliding it out of the connector. Note the position of the cable in the connector. The arrow indicates pin #1, reconnect later with pin #1 engaged.

5.

Unplug the remaining connectors on the board and note their location. Unplug the connector (1) coming from the backlighting bulb.

6.

Remove the four screws from the board.

7.

Disconnect the ground wire.

8.

Remove the two small screws holding the backlighting (3) to the display (2), and slide the backlighting out the side of the display.

9.

Install the parts in reverse order of disassembly

10. Return the control assembly to normal operating conditions.

4

2

1

3

9

F IG . 24

309738K 55

Fluid Module Service

Fluid Module Service

This section describes how to remove and replace these components on the fluid metering assembly:

flow meter (20) (F IG . 25)

regulator (14) (F IG . 25)

The numbers in parentheses in the text refer to reference numbers in the parts drawings and parts lists.

Prepare the System for Service

Relieve the system pressure. Follow procedure on

page 30

.

WARNING

Read Warnings, page 6.

Servicing the Flow Meter

For complete flow meter service instructions refer to the maintenance and service sections of the following manuals: 308778 for all G3000 meters, and 309834 for all

Graco Helical flow meters.

Remove the Flow Meter from the Mounting Plate

1.

Prepare the system for service as instructed above.

2.

Disconnect the flow meter cable (J) from the flow

meter sensor. See F IG . 25.

3.

Disconnect the material hose.

4.

Disconnect the swivel fitting (18) from the regulator.

5.

Loosen the four screws (12), and remove the bracket (22) and flow meter.

6.

The flow meter (20) weighs approximately 15 lbs.

(6.75 kg). Carefully lift it off the mounting plate (10).

20

22

12

J

18

14

10

56

F IG . 25

309738K

Install the Flow Meter on the Mounting Plate

1.

Rest the flow meter and bracket (20) on the fluid plate while threading the swivel fitting (18) onto the

regulator material inlet. See F IG . 25.

2.

Tighten the swivel fitting (18) to the regulator material inlet.

3.

Tighten the four screws (12) to hold the bracket and flow meter in place.

4.

Check that the flow meter (20) and regulator (14) are still aligned.

5.

Connect the material hose.

6.

Connect the flow meter cable (J).

Servicing the Fluid Regulator

Fluid Module Service

2.

Remove the cartridge assembly by loosening the valve housing (5) with a 6 mm hex wrench and pulling the cartridge assembly out of the base housing

(4).

The retaining nut (3) often loosens when removing the cartridge assembly from the base housing. Be sure

to re-torque as described in step 4.

3.

Inspect and clean the internal walls of the base housing (4).

Be careful to not scrape or gouge the internal walls of the base housing. They are a sealing surface.

4.

Re-torque the retaining nut (3) to 140 to 160 in-lb

(16 to 18 N•m).

For complete cartridge fluid regulator service refer to instruction manual 308647. For Mastic Fluid Regulators refer to instruction manual 307517.

Replacing the Cartridge

See F IG . 26 and perform the following steps.

You must re-torque the retaining nut before you install it in the base housing in step 5.

5.

Install the new cartridge assembly in the base housing (4), and torque the valve housing (5) to 30 to 35 ft-lb (41 to 48 N•m).

Handle the hard carbide parts ball, valve actuator, and valve seat, carefully to avoid damaging them.

1.

CAUTION

Relieve the pressure.

WARNING

The valve seat is double sided and may be reversed for extended life. The o-ring and ball must be replaced. See instruction manual 308647.

Service Kits for Regulator 244734

For the Fluid Diaphragm Repair Kit, order Part No.

238747.

For the Cartridge Repair Kit, order Part No. 238748.

Read Warnings, page 6.

309738K 57

Fluid Module Service diaphragm and valve actuator subassembly

F

IG

. 26 cartridge assembly

3

5

4

Torque Sequence for Regulator

Base Housing Screws (9)

4 1

2

3

58 309738K

Frequently Asked Questions

Frequently Asked Questions

Q:

What is the difference between running in Volume Monitor versus Bead Control?

A: In Volume Monitor the control will maintain a specific pressure at the fluid regulator outlet. If the viscosity of the fluid changes or the nozzle becomes restricted, that pressure will result in a different flow rate. If you have a flow meter installed it can still monitor the job volume for faults. Volume monitor is sometimes desirable for spray applications to maintain a specific spray pattern.

In Bead Control the fluid regulator is still reacting to the fluid pressure for quick adjustment, but the control also monitors the flow meter. If the flow rate does not agree with the flow command, the pressure target is adjusted.

This method gives you the quick response of a pressure transducer, while maintaining the rate accuracy of a flow meter.

Q:

How do I adjust the flow rate up or down without changing my automation commands?

A: There is an adjustment called Bead Scale which appears on the EasyKey Run screen or on the Dispense Setup

Screen. This can be set from 50-150% of command flow. To change the Bead Scale turn the key switch to the right to enter Setup mode. The Setup mode screen allows you to change the Bead Scale percentage. To change to the new setting press the Enter key on the EasyKey interface. The new value will be stored when you turn the key switch back to Run mode. In Run mode the Bead Scale can be changed using the bead adjust keys.

Q:

Why do I get a warning for “Volume Compensation Limit”?

A: Something has changed since you calibrated the regulator. The control has changed the regulator pressure set point too far away from the calibration point. This happens in Bead Control when the control is monitoring the flow meter and trying to maintain the proper flow rate. The cause is some factor that has changed the pressure, downstream of the regulator, at the desired flow rate. This might be a plugged nozzle or a fluid viscosity change.

The viscosity difference could be caused by a change in temperature or a new batch of material. If the pressure needs to increase to maintain the desired flow rate, but the fluid regulator is already fully open, the volume compensation continues to increase the desired pressure target until the limit is reached. The fluid feed pressure at the regulator inlet needs to be increased. If the fluid and equipment are all right you need to recalibrate to your flow target.

Q:

How is a fluid control regulator calibration performed?

A: There are three steps: (1) determine system maximums (2) pressure calibration (3) flow calibration. These steps are performed sequentially during the calibration process. If you are not using a flow meter and will run in pressure control mode, only the pressure calibration and system maximums will be performed. To calibrate pressure

and flow, see page 104.

Q:

How do I know if the fluid control regulator calibration was successful?

A: On the EasyKey display, calibration was successful if the calibrate setup screen indicates “Calibration Valid”.

Q:

Why will my fluid control regulator not calibrate in the calibration screen?

A: You may not have enough fluid pressure downstream of the regulator. Raising the downstream pressure becomes more important if the pressure is below 500 psi (3.5 MPa, 34.5 bar). Try a smaller nozzle on the dispense valve.

309738K 59

Frequently Asked Questions

Q:

Why is my calibration failing after only a few seconds?

A: You may not have been able to reach the maximum flow rate or maximum pressure you entered. To reach a higher flow rate or pressure, you can increase the feed pressure or increase the dispense valve nozzle size.

Q:

Why will my dispense valve not operate?

A: The valve will not dispense in Bead Control Mode until a valid calibration has been performed. Try switching to volume monitor or pressure control mode or calibrate again.

Q:

Does Volume Monitor Mode use a flow meter?

A: Running in Volume Monitor Mode requires a flow meter to monitor the job volume limits or job log volumes. If you do not have a flow meter set the system to the pressure control mode.

Q:

How do I know my flow and volume measurements are accurate?

A:

Calibrate the flow meter as instructed on page 104. This is strongly recommended as many sealants are com-

pressible, and the flow meter measures the fluid while it is under pressure. Calibrating the meter makes it accurate for your fluid at ambient pressure. Periodic calibration is also important to monitor your meter for wear.

Q:

I have flow, but how do I know if my fluid regulator is working?

A: If a fluid regulator fails it can no longer hold back fluid pressure. If the outlet pressure climbs up to equalize with the inlet pressure when you stop dispensing, the regulator has lost the ability to shutoff or fully regulate flow. If you have pressure limits set you will get a High Outlet Pressure alarm. If you have job volume limits set you will get a High Volume On Last Job alarm .

Q:

Is there a way to put the fluid plate control regulator in a bypass mode to still operate the dispense valve when I have a problem?

A: With the air operated regulators you can move the air tube that feeds the V/P valve directly to the fluid regulator air inlet. Turn off the air supply before moving tubes.

Q:

How do I download job logs or alarm logs from the PrecisionFlo LT control?

A: There is an external phone-style connection on the right side of the control enclosure. You need a PC or laptop computer with terminal emulation software and part number 233657 accessory cable kit. See

Communicating with PrecisionFlo LT , page 40.

Q:

Will I lose any of my Setup parameters or logged information if power is lost?

A: No. All setup parameters, job logs, and alarm logs are saved to flash memory and do not need any power. This is non-volatile memory similar to the cards used with digital cameras. There also is no battery to replace. The setup parameters are stored to flash memory when the key switch is moved from the setup to the run position.

Q:

Can I cause an error or system problem while looking at screens when production is running?

A: If the key switch is turned counter clockwise or removed, which means the system is in Run mode, you can view the run screen but you cannot change any parameters except Bead Scale when enabled. You can still select

Manual or Automatic mode on the user interface which would stop the automation initiated dispensing.

60 309738K

Frequently Asked Questions

Q:

Can I change my Setup values while the machine is running?

A: Yes. If you turn the key switch to Setup mode, you have complete control of the system. Changes to control modes, pressure values, time delays, alarms, etc. become effective when you press Enter and the changes are saved to memory when the key switch is turned back to Run mode.

Q:

How can I get out of Setup without saving the changes I have entered?

A: You can turn the power off before turning the key switch back to Run mode. When you turn the power back on, the changes will not be there.

Q:

How do I set my pressures?

A: First, set the dispense pressure.

A dispense valve hose and nozzle should be used, which will maintain at least

500 psi (3.5 MPa, 34.5 bar) back pressure at the fluid control regulator outlet at your lowest flow rate setting.

Second, set the feed pressure.

Once you are running, back down the feed pressure to a point where the regulator inlet pressure stays at least 500 psi (3.5 MPa, 34.5 bar) greater than the regulator outlet pressure, when dispensing at your maximum flow rate. If you will have multiple valves open at the same time, being fed by the same feed pump, do this check with all of those valves open. Excessive feed pressure will cause excessive wear.

309738K 61

Fault Reporting

Fault Reporting

F IG

Fault On Data

Fault Code Data

. 27

>1 msec

Fault code data is valid for a minimum of 1 msec before

FAULT ON DATA goes HIGH. Fault code data remains valid, and the FAULT ON DATA remains HIGH, until a

FAULT RESET is received from the automation controller, or the fault is cleared using the display.

Fault codes are reported using the FAULT ON DATA signal and the data bus. Fault codes can be either:

• Alarms , which cause the PrecisionFlo LT DIS-

PENSER READY signal to go LOW or,

• Warnings , which keep the PrecisionFlo LT DIS-

PENSER READY signal HIGH.

Both volume and fault data are available on the I/O interface. Volume and fault data share I/O points, Data 1

- Data 32768. If the VOLUME ON DATA output is on, the outputs contain volume data. If the FAULT ON DATA output is on, the outputs contain fault data.

The automation unit can read a fault code any time during the cycle, If several faults are present at the same time, the highest priority fault code is sent to the data bus. At the end of the dispense cycle the data bus is used for volume reporting, If requested by the automation controller. Once volume reporting has been competed, the fault code is placed back on the data bus.

Each fault is recorded on the user interface. The fault data is also available on the I/O interface until the fault is cleared.

Refer to the Troubleshooting and Fault Recover section for fault code causes, descriptions, and solutions for the various faults.

62 309738K

13

15

Control Assembly Parts

Control Assembly Parts

Part No. 234129, Series B, PrecisionFlo LT Standard Control Assembly

Ref

No Part No Description

7

8

5

6

1 ENCLOSURE

2 112546 SCREW, machine

3 ◆ 118334 LABEL, warning

4 PLUG, conduit

CONNECTOR

HARNESS, key switch wire

SWITCH, power rotary

PANEL, control assembly

9

10

116653 SWITCH, key

LABEL, identification switch

11 117689 SWITCH, emergency stop

12 C19208 WASHER, lock

13 117788 KIT, accessory

14 117762 LAMP, led red snap in

15 117763 LAMP, led green snap in

16 LABEL, identification control box

17

18

CONNECTOR

LATCH, quarter turn

20† 223547 WIRE, assy 25 ft.

21 NUT, hex

22

23

WASHER, lock

WIRE, grounding

Qty.

1

1

1

1

1

8

1

1

1

1

1

1

1

2

1

8

1

4

1

1

2

1

Ref

No Part No Description

24

25

26

27

TERMINAL

WASHER, lock

NUT, hex

CONNECTOR, RJ12

28 253620 BOARD, control circuit

29 117782 POWER supply

30 115216 FUSE, 1 amp

31 BLOCK, clamp end

32

33

34

35

WASHER, lock

TERMINAL, ground

TERMINAL, block

FUSE, holder

36

37

SCREW, machine

TERMINAL, block

38 117790 POWER, supply 5V inverter

39 118337 DISPLAY, backlight

† These parts are not shown on the parts drawing.

◆ Replacement Danger and Warning labels, tags and cards are available at no cost.

Qty.

1

1

1

5

4

2

1

1

2

1

1

1

6

1

1

6

2,12,17 7 2, 5, 12

1

3

18

9

4

11

14

309738K

27

63

Control Assembly Parts (continued)

Control Assembly Parts

(continued)

25, 26 6

24

29 32, 33, 36

8

31

30, 35

38

39

23

28

64 309738K

Fluid Module Parts

11

8

26

38,39

Fluid Module Parts

For additional parts see page 66.

Fluid Inlet

22

31

4

Air Inlet

28

23

3

37

8

38,39 33

12

21

Fluid Outlet

8

16

2

26 30,34 12

36

27

41

20

29

13

35

16

7

1

16

13

35

8

32

40

35

To Dispense

Valve

43,44

19

18

17

23

Ref

No Part No Description

1 117669 PLATE, blank fluid

2 195942 REGULATOR, I/P

6 198179 FITTING, bulkhead

7 551348 VALVE, sol 4-W

8 C06061 MUFFLER, sinter

10 234967 FILTER, inline (not shown)

11 198175 FITTING, push

12 111119 SCREW, valve

13 117820 SCREW, cap skt

16 198177 FITTING, push

20 198269 BRACKET, flowmeter

23 107530 SCREW, cap skt

24 070269 SEALANT, anaero

25 070408 SEALANT, pipe s

309738K

Qty.

1

4

2

3

1

1

1

4

2

1

1

1

1

1

Ref

No Part No Description

26 054753 TUBE, nylon rd

29 110580 SCREW, cap sock

30 198315 BLANK, label

32 196108 PLUG, assy 100V

33 198683 WIRE, 3 cond 2

34 291487 ARTWORK, identification

35 198708 LABEL, rectangular

36 198268 BRACKET, flowmeter

38 107100 SCREW, cap skt

39 112906 WASHER, lock sp

42 804500 LABEL, warning

43 112513 FERRULE, wire, white

44 112515 FERRULE, wire, red

Qty.

3

1

2

1

2.3

2

1

1

1

5

2

2

4

65

Fluid Module Parts (continued)

Fluid Module Parts

(continued)

Code C

3

4

17

19

21

22

27

28

31

37

40

44

Code C

3

4

17

18

21

22

27

28

31

37

40

Code C

3

4

17

19

21

22

27

28

31

37

40

44

Code C

3

4

21

27

40

Code C

3

4

17

18

21

22

27

28

31

37

40

Option-03

234171

198082

198327

110501

244734

162449

108328

244292

156684

198578

C34045

Option-04

234171

198082

117670

115226

244734

C20461

108328

246190

156684

198578

C34045

C19197

Option-01

234171

198082

244734

108328

C34045

Option-02

234171

198082

198327

110501

244734

162449

108328

239716

156684

198578

C34045

Option-05

234171

198082

117670

115226

244734

C20461

108328

246652

156684

198578

C34045

C19197

Model No 234168

Junction box

Transducer, pressure

Regulator, assembly

Screw, cap, skt

Spacer

Model No 234165

Junction box

Transducer, pressure

Bracket, flowmeter

Screw, cap, skt

Regulator, assembly

Fitting, nipple

Screw, cap, skt

Meter, gear, G3000

Union, adapter

Harness, cable

Spacer

Model No 234166

Junction box

Transducer, pre

Bracket, flowmeter

Screw, cap, skt

Regulator, assembly

Fitting, nipple

Screw, cap, skt

Meter, gear, G3000 HR

Union, adapter

Harness, cable

Spacer

Model No 234167

Junction box

Transducer, pressure

Bracket, flowmeter

Washer, lock sp

Regulator, assembly

Fitting, nipple

Screw, cap, skt

Meter, helical gear

Union, adapter

Harness, cable

Spacer

Washer, plain

Model No 234195

Junction box

Transducer, pressure

Bracket, flowmeter

Washer, lock sp

Regulator, assembly

Fitting, nipple

Screw, cap, skt

Meter, helical gear, HR

Union, adapter

Harness, cable

Spacer

Washer, plain

6

1

1

1

1

6

1

1

2

4

1

1

6

1

1

1

1

6

1

1

2

4

1

1

2

1

1

1

1

4

1

1

1

1

2

2

1

1

1

1

4

1

1

1

1

2

1

1

1

1

2

Code C

3

4

17

19

21

22

27

28

31

37

44

Code C

3

4

5

21

27

41

45

Code C

3

4

5

17

19

21

22

27

28

31

37

41

44

45

Code C

3

4

21

27

Code C

3

4

17

19

21

22

27

28

31

37

44

Option-08

234171

198082

117670

115226

246642

C20487

108328

246652

157785

198578

C19197

Option-09

234209

234191

117764

246643

108328

118331

624545

Option-10

234209

234191

117764

117670

115226

246643

175013

108328

246340

157785

198578

118331

C19197

624545

Option - 06 Model No 234170

234171 Junction Box

198082

246642

108328

Transducer, Pressure

Regulator, mastic

Screw, cap skt

Option-07

234171

198082

117670

115226

246642

C20487

108328

246190

157785

198578

C19197

Model No 234169

Junction box

Transducer, pressure

Bracket, flowmeter

Washer, lock, sp

Regulator, mastic

Fitting, nipple

Screw, cap, skt

Meter, helical gear

Union, swivel

Harness, cable

Washer, plain

Model No 234196

Junction box

Transducer, pressure

Bracket, flow meter

Washer, lock

Regulator, mastic

Fitting, nipple

Screw, cap, skt

Meter, helical gear, HR

Union, swivel

Harness, cable

Washer, plain

Model No 234193

Junction box

Cable, pressure

Sensor, pressure

Regulator, mastic

Screw, cap, skt

Label, warning

Fitting, tee 3/4 x 1/4

Model No 234194

Junction, box

Cable, pressure

Sensor, pressure

Bracket, flowmeter

Washer, lock, sp

Regulator, mastic

Nipple, pipe

Screw, cap, skt

Meter, helical gear, HTD

Union, swivel

Harness, cable

Label, warning

Washer, plain

Fitting, tee, 3/4 x 1/4

6

1

1

1

1

6

1

1

1

4

4

2

1

1

1

1

1

1

1

1

1

1

4

1

1

6

6

1

1

1

1

1

6

1

1

1

1

6

1

1

1

1

4

1

2

1

1

66 309738K

Accessory Parts

Accessory Parts

Automation Interface Cable Assembly

The cable length of automation interface cable assembly 117774 is 40 ft (12.2 m). This figure shows the cable and identifies the cable interface signals.

6

2

5 4

1

3

11

15

10

14

9

13

8

12

7

18 17 16

6

7

4

5

Pin # Wire #

1 3290

2

3

3310

3350

3370

2120

2121

3150

8

9

3170

3210

10 2680

11 2710

12 2740

13 2770

14 2170

15

16 3390

17 3410

18 Spare

N/A Spare

N/A Spare

N/A Spare

309738K

Color

Blk

Red

Wht

Grn

Orn

Blu

Brn

Yel

Vlt

Gry

Pnk

Tan

Red / Grn

Red / Orn

Red / Blk

Wht / Blk

Wht / Red

Wht / Grn

Wht / Yel

Wht / Blu

Description

Dispense Gun

Job Complete

Style Bit 1

Style Bit 2

24 VDC from IFC

24 VDC common

Analog flow command

Analog common

Actual Flow rate signal

Dispenser ready

Fault present

In cycle

Minimum volume dispensed

24 VDC thru E-stop

Ground

Style Bit 3

Style Bit 4

N/C

N/C

N/C

N/C

67

Operations Cable Assembly

Operations Cable Assembly

The operations cable is offered in these lengths (25 ft, 60 ft, and 125 ft.) and three different flexibilities. See page 9 for

cable options.

R

S

N

P

L

M

J

K

G

H

E

F

A

B

C

D

9

10

11

12

-

-

7

8

-

-

5

6

1

2

3

4

R

S

N

P

L

M

J

K

G

H

E

F

A

B

C

D

24 VDC thru E-stop

24 VDC common

Gun solenoid

Ground

V/P +

V/P -

Pressure Sensor +

Pressure sensor -

Flow meter signal

Flow meter common

L

J

K

H

G

S

R

M

N

P

F

A

E

B

C

D

68 309738K

Electrical Schematics

PrecisionFlo LT Control Box

Electrical Schematics

F IG . 28

309738K 69

PrecisionFlo LT Control Box

PrecisionFlo LT Control Box

70

F IG . 29

309738K

PrecisionFlo LT Control Box

PrecisionFlo LT Control Box

F

IG

. 30

309738K 71

PrecisionFlo LT Control Box

Fluid Module Junction Box

72

F

IG

. 31

2170

2170

2170

2170

3170

3170

3130

GND

2660

3190

2650

3250

J2-A

A

B

C

L

M

N

D

E

F

G

H

J

K

F

G

-2170

-2170

-2650

-2660

-GND

-3190

-3170

J -3130

K

L

-3170

P

R

S

P

R

S

-3250

Connections for:

Pressure sensor

V/P

Gun Solenoid

Flow Meter

Orange tab on housing

Approximate

Approximate

LED location

J1-H

J2-H

GND

+

-

+

-

-

-

+

J1-A

Max outlet pressure range switch: set appropriate fluid working pressure

(1500, 3500, or 5000 psi) See page

95 for software update

2170

2170

3190

2650

2650

GND

GND

2660

2650

GND

GND

GND

GND

RED

RED

WHT

BLK

BLK

RED

RED

WHT

BLK

BLK

2170

2170

3230

3250

3250

GND

GND

J1-D

J1-C

J1-B

J1-A

J1-A

GND

GND

5

5

RED

RED

CLR

CLR

BLK

BLK

BLK

RED

GRN

WHT

WHT

1

2

1

3

2

3

24V

24V

SIG 1

COM

OP cable connector

V/P

V/P

1

2

1 SOL

SOL

RTN

GND

GND

RTN

GND

SOL. 1

SOL. 1

24V

24V

SIG 1

COM

COM

EXE -

EXE +

SIG +

SIG -

SIG -

Flow

Meter

Meter

Pressure

Sensor

309738K

Technical Data

Technical Data

*Minimum Flow Rates 38 cc/minute with G3000HR meter

75 cc/minute with G3000 meter

50 cc/minute with High Resolution Helical flow meter

100 cc/minute with Helical flow meter (ambient/heated)

*Maximum Flow Rates 1900 cc/minute with G3000HR meter

3800 cc/minute with G3000 meter

3750 cc/minute with High Resolution Helical flow meter

7500 cc/minute with Helical flow meter (ambient/heated)

See

List of Models on page 2

Maximum Fluid

Working Pressure

Minimum Fluid

Working Pressure

Minimum Back

Pressure

Air Supply Pressure

Range

At Regulator Outlet ......... 500 psi (3.5 MPa, 34.5 bar)

Between Regulator Outlet and Dispense Nozzle ...... 500 psi (3.5 MPa, 34.5 bar)

60-120 psi (.4 - .8 MPa, 4.1- 8.3 bar) - 10 Micron filtration recommended

Fluid Filtration

Required

*Viscosity Range of Fluids

*Minimum Dispensed

Shot Size

V/P Output

Wetted Parts

30 mesh (500 micron) minimum

50 to 50000 cps with G3000 meter

10000 to 1000000 cps with Helical meter

3 cc with G3000HR meter

6 cc with G3000 meter

4 cc with High Resolution Helical meter

7 cc with Helical meter

1 to 5 VDC provide 0 to 100 psi (.68 MPa, 6.8 bar)

Meters and Fluid Panels ..... 303, 304, 321, 17- 4 stainless steel; tungsten carbide,

PTFE, steel, Fluoroelastomer

Full Load Amps - 1, Fused Amps - 2

120 VAC nominal ..... 93 - 264 VAC, 50-60 Hz., single phase

Power Requirements

Power Supply Voltage

Range

Operating Temperature Range

Operating Humidity

Range

Controller ..... 40° - 122° F (4° - 50° C)

Fluid Panel ..... see regulator rate technical data, page 74.

0 - 90% non-condensing

*Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expected to shear under pressure. New applications or fluids should always be tested to determine proper line sizes and equipment selections.

See your Graco Authorized distributor for other capabilities.

309738K 73

Technical Data

Regulator Plates

Mounting dimensions and parts breakdowns for the Air-Operated Regulator Fluid Plates are in the installation section of this manual.

Regulator Manual

Weight - No Flow Meter

Weight - W/G3000

Weight - Helical

Fluid Port Inlet

Fluid Port Outlet

Maximum Inlet Pressure

Maximum Working Pressure*

Cartridge Regulator

308647

25.5 lbs (11.6 kg)

30 lbs (13.6 kg)

40 lbs (18 kg)

G3000 1/4” NPT (f)

Helical 3/4” NPT(f)

1/2” npt(f)

See

List of Models on page 2

4500 psi (31 MPa, 310 bar)

Mastic Regulator

307517

33 lbs (15 kg)

N/A

48 lbs (22 kg)

3/4” npt(f)

Air Supply

Maximum Air Pressure

Minimum Air Pressure

Range Operating Temperature

1/4” npt(f)

100 psi (0.7 MPa, 7.0 bar)

60 psi (0.4 MPa, 4.1 bar)

Ambient 40° - 120°F (4° - 50°C))

Minimum Flow Rate - G3000

Minimum Flow Rate - Helical

50 cc/min

100 cc/min

*Maximum system pressure depends on dispense valve.

3/4” npt(f)

5000 psi (34 MPa, 340 bar)

Ambient 4500 psi (31 MPa, 310 bar)

Heated 3500 psi (24 MPa, 241 bar)

1/4” npt(f)

100 psi (0.7 MPa, 7.0 bar)

60 psi (0.4 MPa, 4.1 bar)

Heated 40° - 400°F (4° - 204°C)

Ambient 40° - 120°F (4° - 60°C)

N/A

100 cc/min

Air outlets, open and close to dispense valve

Electric Power Requirements

Height

Fluid Specifications

Ambient Air Temperature Range

Noise Data

Continuous operator (full current)

Dispensing device exhaust (with muffler, peakhold)

5/32” or 4 mm tube fittings

24 VDC, from PrecisionFlo LT control

8” (203 mm) (varies with model)

For use when dispensing fluids that meet at least one of the following conditions for non-flammability:

• 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.

• The fluid does not sustain burning when tested per

ASTM Standard D4206 Sustained Burn Test.

40° to 120° (5° to 50° C)

70 dBA

84 dBA

74 309738K

Kits and Accessories

PrecisionFlo LT Recommended Spare Parts

Part Number

234282

244283

117782

246496

246517

115216

117764

246786

198082

118342

195942

234967

Description

Advanced control manual set in binder

Standard control manual set in binder

Power Supply

Board, Circuit Assy, HI-Temp Press Sensor

Board, Circuit Assy, Ambient Press Sensor

Fuse, 2 Amp

Sensor, Pressure, Assembly, High Temp.

Sensor, High Temp., Helical

Sensor, Pressure, Ambient

Kit, Accessory, Communications Cable

V/P

Filter

Control Parts and Accessories

253620 PFlo LT Control Board Assy

117788

117790

Kit, Accessory, Interface & Board, Std

Power Supply, 5V Inverter

117818

116728

118329

118337

Key, Panel Access

Key, Set-Up

Ethernet Kit

Kit, Backlight Repair

117762

117763

117689

116320

116653

253614

LED, Red

LED, Green

E-Stop

Power Switch Rocker

Rotary Disconnect

Chip Set, CNTRL & Display Std

Fluid Plates

234168

234165

234166

234167

234195

234170

234169

234196

234193

234194

Fluid plate, Ambient Cartridge Regulator with no flow meter

Fluid plate, Ambient Cartridge Regulator with G3000 flow meter

Fluid plate, Ambient Cartridge Regulator with a G3000HR flow meter

Fluid Plate, Ambient Cartridge with helical flow meter

Fluid plate, Ambient Cartridge Regulator with high resolution helical flow meter

Fluid plate, Ambient Mastic Regulator with no flow meter

Fluid plate, Ambient Mastic Regulator with helical flow meter

Fluid plate, Ambient Mastic Regulator with high resolution helical flow meter

Fluid plate, Heated Mastic Regulator with no flow meter

Fluid plate, Heated Mastic Regulator with helical flow meter

Kits and Accessories

309738K 75

Kits and Accessories

Cables

118342

117774

198731

198296

198732

117751

117752

117753

117747

117748

117749

234191

246786

239716

239719

244292

244291

239717

198082

117764

198579

198578

244343

246596

246949

Fluid Plate Parts and Accessories

246687

246642

Mastic regulator, 3/4” air operated (no transducer ports)

Mastic regulator, 3/4” air operated, with transducer ports for ambient fluid plates

246643

246688

244734

238748

Mastic regulator, 3/4” air operated, for heated fluid plates

Mastic regulator, 3/4” air operated for heated applications (no transducer ports)

Cartridge regulator with transducer ports for fluid plates

Repair kit, cartridge regulator

238747

233131

246190

234134

246652

246650

246340

246191

Fluid diaphragm repair kit, cartridge regulator

Fluid section repair kit, mastic fluid regulator

Flow meter, ambient helical, w/sensor

Flow meter, ambient helical, w/o sensor

Flow meter, high resolution helical, w/sensor

Flow meter, high resolution helical, w/o sensor

Flow meter, heated helical, w/sensor

Flow meter, heated helical, w/o sensor

Sensor, HG6000 (all models)

Flow meter assembly, G3000 spur gear, meter and sensor

Flow meter, G3000 spur gear, does not include sensor

Flow meter assembly, G3000 HR spur gear, meter and sensor

Flow meter, G3000HR spur gear, does not include sensor

Sensor, flow meter, G3000 & G3000HR

Pressure sensor, outlet for ambient regulators

Pressure sensor, outlet for heated regulators

Kit, cable, for adding SRZ40 meter

Kit, cable, for adding G3000 meter

Mass flow meter kit, non-intrusive

Kit, Helical gear set repair (standard and heated)

Kit, Helical gear set repair (high resolution)

Cable kit, PrecisionFlo LT to personal computer

Cable, automation analog, 40 ft. (12.9 m)

Cable, High Flex Operation, 20 ft. (6.11 m)

Cable, High Flex Operation, 60 ft. (18.29 m)

Cable, High Flex Operation, 125 ft. (38.1 m)

Cable, Standard Flex Operation 20 ft. (6.11 m)

Cable, Standard Flex Operation 60 ft. (18.29 m)

Cable, Standard Flex Operation 125 ft. (38.1 m)

Cable, Low Flex Operation, 20 ft. (6.11 m)

Cable, Low Flex Operation, 60 ft. (18.29 m)

Cable, Low Flex Operation, 125 ft. (38.1 m)

Cable, Heated Pressure Sensor

76 309738K

Kits and Accessories

Filters and Accessories

C59725 Dual filter bank with gauges, ball and drain valves, 30 mesh element, 5000 psi, (345 bar, 34.5

MPa) 1-1/4” NPT Inlet 1” NPT Outlet

C59547

C58997

Single filter kit, gauges, ball and drain valves, 30 mesh element, 5000 psi, (345 bar, 34.5 MPa) 1”

NPT

Fluid filter, polyethylene support, 30 mesh element, 5000 psi (345 bar, 34.5 MPa) 1” NPT

515222

157630

521477

210657

210658

210659

Fluid filter, polyethylene support, no element from above kits

Spring, filter

Fluid shutoff valve, 1” NPT(F), 5000 psi (345 bar, 34.5 MPa) CS, Fluoroelastomer

Ball valve, high pressure, 1/2” NPT(M), 5000 psi, (345 bar, 34.5 MPa) CS, Fluoroelastomer

Ball valve, high pressure, 3/8” NPT(M), 5000 psi, (345 bar, 34.5 MPa) CS, Fluoroelastomer

Ball valve, high pressure, 3/8” x 1/4” NPT(M), 5000 psi, (345 bar, 34.5 MPa) CS, Fluoroelastomer

189970

192443

114134

570267

570268

15E012

15E011

104661

244021

244930

243482

244535

244910

244961

244962

239807

233671

Applicators and Repair Kits

918533 Dispense Valve, Extrusion, Ambient, Ball Seat

918535

918537

Dispense Valve, Extrusion, Ambient, Snuff Back

Dispense Valve, High Viscosity

918539

918623

918625

233670

Dispense Valve, Extrusion, High Flow, High Viscosity

Compact Dispense Valve, Extrusion

Compact Dispense Valve, Spray

AutoPlus SAE valve

Manifold, Fluid Inlet, AutoPlus SAE valve

1K Ultra-Lite valve 45° outlet for orbiter

EnDure Valve replacement, no manifold

EnDure Valve with ambient or temperature conditioning manifold

EnDure Valve with 120 volt electric heat (200°F) (93.3°C)

EnDure Valve with 230 volt electric heat (200°F) (93.3°C)

Needle assembly, AutoPlus SAE valve

Seat, AutoPlus SAE valve

Gasket, AutoPlus SAE valve, seat

Gasket, AutoPlus SAE valve, inlet

Gasket, AutoPlus SAE valve, inlet air

Fluid Section Seal kit, 1K Ultra-Lite valve

Rebuild kit, 1K Ultra-Lite valve

Standard seal kit, EnDure valve

High temperature seal kit, EnDure valve

Quick exhaust valve, 1/8” NPT(F)

Cable kit, 8 pin connector and 10 ft. cable for 240 VAC valves

PrecisionSwirl

234029 PrecisionSwirl Module, Narrow Pattern

241658

243402

PrecisionSwirl Module, Wide Pattern

Swirl orbiter, narrow pattern

243403

243437

Swirl orbiter, wide pattern

Tube/bearing repair kit, narrow pattern

309738K 77

Kits and Accessories

918620

617870

617829

233125

233124

233123

241479

196008

241569

Tube/bearing repair kit, wide pattern

Cable, PrecisionSwirl, 55’

Cable, PrecisionSwirl, automation, 40’

Extension cable, 6’

Extension cable 9’

Extension cable 15’

Motor kit

Bellows (12-pack)

Bearing Repair Tool Kit

241816

198316

198391

617585

197504

197842

198323

198324

607665

161505

164799

C17009

C01025

918607

918608

918611

918612

918613

918614

241813

241814

Tips, Nozzles and Adapters

918610 Swirl dispense tip 0.012”, (0.31 mm) carbide

918601

918602

Swirl dispense tip 0.015”, (0.38 mm) carbide

Swirl dispense tip 0.017”, (0.43 mm) carbide

918603

918604

918605

918606

Swirl dispense tip 0.019”, (0.48 mm) carbide

Swirl dispense tip 0.021”, (0.53 mm) carbide

Swirl dispense tip 0.023”, (0.58 mm) carbide

Swirl dispense tip 0.025”, (0.64 mm) carbide

Swirl dispense tip 0.027”, (0.69 mm) carbide

Swirl dispense tip 0.031”, (0.79 mm) carbide

Swirl dispense tip 0.035”, (0.90 mm) carbide

Swirl dispense tip 0.039”, (0.99 mm) carbide

Swirl dispense tip 0.043”, (1.09 mm) carbide

Swirl dispense tip 0.047”, (1.19 mm) carbide

Swirl dispense tip 0.051”, (1.30 mm) carbide

Swirl dispense tip 0.055”, (1.40 mm) carbide

182XXX

270025

270027

270029

Swirl dispense tip 0.070”, (1.78 mm) carbide

Nozzle nut, 1/8” NPT for AutoPlus SAE valve, extruding applications

Tip nut, AutoPlus SAE valve, fan or stream

Nozzle nut for streaming tips, EnDure valve

Straight 3/4-16 JIC outlet for swirl, EnDure valve

Nozzle, 45° nose piece, orbiter to EnDure valve

Adapter, 45° orbiter to EnDure

Fitting, 45° orbiter to EnDure

Dispense nozzle, steel, 1/8” NPT(M), 0.125”, (3.18 mm), 2’ (0.6 m) long

Dispense nozzle, steel, 1/8” NPT(M), 0.094”, (2.39 mm), 2’ (0.6 m) long

Dispense nozzle, steel, 1/8” NPT(M), 0.055”, (1.4 mm), 2’ (0.6 m) long

Dispense nozzle, steel, 1/8” NPT(M), 0.125”, (3.18 mm), 1.22’ (0.36 m) long

Dispense nozzle, steel, 1/8” NPT(M), 0.9” x 0.37 (22.86 mm x 9.40 mm) ribbon hardened tip, 2.43”

(61.72 mm) long

Airless 182xxx fan tips for AutoPlus SAE valve, ref. 308813 manual

Streaming tip, 0.025 (0.64 mm) orifice

Streaming tip, 0.027 (0.69 mm) orifice

Streaming tip, 0.029 (0.74 mm) orifice

78 309738K

Kits and Accessories

270035

270037

270039

270041

270043

270059

C08224

Hoses

116760

116762

116761

116763

205058

205349

204938

206024

235905

685602

685603

511381

685605

685606

685607

C12383

C12218

116749

116748

115875

115903

115876

115880

115885

115887

116770

116769

C50239

512028

685612

205099

Streaming tip, 0.035 (0.89 mm) orifice

Streaming tip, 0.037 (0.94 mm) orifice

Streaming tip, 0.039 (0.99 mm) orifice

Streaming tip, 0.041 (1.04 mm) orifice

Streaming tip, 0.043 (1.09 mm) orifice

Streaming tip, 0.059 (1.50 mm) orifice

Shower tip, 6 orifices, 0.021” (0.53 mm) orifice size

Dispense, 0.50” (1.27 mm) ID x 6’, (1.83 m), Neoprene core, 4000 psi, (276 bar, 27.6 MPa) high flex, abrasion resistant for automation units

Dispense, 0.62” (1.57 mm) ID x 6’, (1.83 m), Neoprene core, 3625, (250 bar, 25.0 MPa) high flex, abrasion resistant for automation units

Dispense 0.50” (1.27 mm) ID x 10’, (3.05 m), Neoprene core, 4000 psi, (276 bar, 27.6 MPa) high flex, abrasion resistant for automation units

Dispense, 0.62” (1.57 mm) ID x 10’, (3.05 m) Neoprene core, 3625 psi, 250 bar, 25.0 MPa) high flex, abrasion resistant for automation units

Feed, 1.0” (25.4 mm) ID x 10’, (3.05 mm), Neoprene core 5000 psi (345 bar, 34.5 MPa)

Feed, 1.0” (25.4 mm) ID x 20’, (3.03 m), Neoprene core, 5000 psi (345 bar, 34.5 MPa)

Co-axial feed, 1.0” (25.4 mm) ID x 10’ (3.05 mm), synthetic rubber, 5000 psi (345 bar 24.5 MPa)

Co-axial feed, 1.0” (25.4 mm) ID x 20’ (3.03 m), synthetic rubber, 5000 psi (345 bar 24.5 MPa)

Dispense, 240 volt electric heat, 0.5” (1.27 mm) x 6’, (1.83 m) PTFE core

Dispense, 240 volt electric heat, 0.62” (15.75 mm) x 6’, (1.83 m) PTFE core

Dispense, 240 volt electric heat, 0.5” (1.27 mm) x 10’, (3.05 m) PTFE core

Dispense, 240 volt electric heat, 0.62” (15.75 mm) x 10’, (3.05 m) PTFE core

Feed, 240 volt electric heat, 0.87” (22.10 mm) x 10’, (3.05 m) PTFE core

Feed, 240 volt electric heat, 0.87” (22.10 mm) x 20’, (6.1 m) PTFE core

Jacket, 6’ (1.83 m) dispense hose, temperature conditioning

Jacket, 10’ (3.05 m) dispense hose, temperature conditioning

Hose swivel, 1/2” NPT(F), 5000 psi (345 bar, 34.5 MPa)

PTFE hose, SS braid, 0.187 (4.75 mm) ID, 10’ (3.05 m) long, 3000 psi (207 bar, 20.7 MPa)

PTFE hose, SS braid, 0.22 (5.59 mm) ID, 6’ (1.83 m) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.25 (6.35 mm) ID, 2.5’ (0.76 m) long, 3000 psi (207 bar, 20.7 MPa)

PTFE hose, SS braid, 0.25 (6.35 m) ID, 6’ (1.83 m) long, 3000 psi (207 bar, 20.7 MPa)

PTFE hose, SS braid, 0.25 (6.35 m) ID, 15’ (4.57 m) long, 3000 psi (207 bar, 20.7 MPa)

PTFE hose, SS braid, 0.25 (6.35 mm) ID, 25’ (7.62 m) long, 3000 psi (207 bar, 20.7 MPa)

PTFE hose, SS braid, 0.25 (6.35 mm) ID, 50’ (15.35 m) long, 3000 psi (207 bar, 20.7 MPa)

PTFE hose, SS braid, 0.308 (7.82 mm) ID, 2.5’ (0.76 m) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.308 (7.82 mm) ID, 15’ (4.57 m) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.308 (7.82 mm) ID, 25’ (7.62 m) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.401 (10.19 mm) ID, 10’ (3.05 m) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.617 (15.67 mm) ID, 6’ (1.85 m) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.617 (15.67 mm) ID, 10’ (3.05 mm) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.617 (15.67 mm) ID, 15’ (4.57 m) long, 4000 psi (276 bar, 27.6 MPa)

309738K 79

626720

626723

626724

626725

626726

686608

C12288

514428

511385

511387

511390

109161

109162

109163

215441

215443

215444

215445

215241

215238

215239

215240

626721

626722

Kits and Accessories

PTFE hose, SS braid, 0.617 (15.67 mm) ID, 25’ (7.62 m) long, 4000 psi (276 bar, 27.6 MPa)

PTFE hose, SS braid, 0.51 (12.95 mm) ID, 10’ (3.05 m) long, 1500 psi (103 bar, 10.3 MPa)

PTFE hose, SS braid, 0.25 (6.35 m) ID, 10’ (3.05 mm) long, 3000 psi (207 bar, 20.7 MPa)

PTFE feed 3/4”, (19.05 mm) 10’ (3.05 m) long, SS braid, PTFE feed, 4000 psi (276 bar, 27.6 MPa)

PTFE feed 3/4”, (19.05 mm) 25’ (7.62 m) long, SS braid, PTFE feed, 4000 psi (276 bar, 27.6 MPa)

PTFE feed 1”, (25.4 mm) 10’ (3.05 m) long, SS braid, PTFE feed, 4000 psi (276 bar, 27.6 MPa)

Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/8” (9.52 mm) ID, 2’ (0.61 m) long

Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/8” (9.52 mm) ID, 4’ (1.22 m) long

Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/8” (9.52 mm) ID, 6’ (1.83 m) long

Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/8” (9.52 mm) ID, 10’ (3.05 m) long

Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 25’ (7.62 m) long

Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 50’ (15.24 m) long

Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 5’ (1.52 m) long

Hose Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 6’ (1.83 m) long

Hose Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 10’ (3.05 m) long

Hose Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 15’ (4.57 m) long

Hose Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 25’ (7.62 m) long

Dried hose, Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 10’ (3.05 m) long, dried, capped with desiccant

Dried hose, Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 25’ (7.62 mm) long, dried, capped with desiccant

Dried hose, Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 5’ (1.52 m) long, dried, capped with desiccant

Dried hose, Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 6’ (1.83

m) long, dried, capped with desiccant

Dried hose, Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 10’ (12.7

m) long, dried, capped with desiccant

Dried hose, Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 15’ (4.57

m) long, dried, capped with desiccant

Dried hose, Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 25’ (7.62 m) long, dried, capped with desiccant

Temperature Conditioning and Electric Heat

198457

198458

RTD Sensor, 100 ohm, 3 pin picofast connector

Sensor cable, 6 ft., (1.83 m) 198457 sensor to temperature conditioning unit

116824

116503

116201

116204

Heat zone controller module, temperature conditioning (spare parts)

Heat zone controller module, electric heat (spare parts)

Control relay 12v coil, electric heat box (spare parts)

Zone relay, qty. 4, electric heat box (spare parts)

80 309738K

Appendix A

Appendix A

Using the PrecisionFlo LT I/O

The PrecisionFlo LT uses several I/O signals to communicate with plant automation controllers. There are four digital inputs, four digital outputs, one analog input, and one analog output. All of these signals are routed to the I/O connector on the top of the controller.

Other pins on the I/O connector include 24 VDC power, 24 VDC common, analog common, and a signal which is 24

VDC power only when the controller E-Stop switch is not latched in. None of the signals are isolated; all are referenced to the ground plane of the control board. The following paragraphs describe typical connection methods for the automation controller signals.

Digital Inputs

The two digital inputs are Dispense Gun and Job Complete. These inputs require a 24 VDC current sourcing

output from the automation controller. See F IG . 32.

If the automation controller uses relay contacts to activate I/O signals, the 24 VDC available at the Precision-

Flo LT I/O connector (pin 5) should be used to drive the inputs. If the automation controller uses high-side switching of 24 VDC, the automation outputs can be directly connected to the inputs as long as the 24 VDC common (pin 6) of the PrecisionFlo LT is able to be connected to the automation controller common. If the automation controller outputs are low-side switching (open collector) or a voltage other than 24 VDC, relays must

be used as shown in F IG . 32.

F IG . 32

Pin 1 or 2

309738K 81

Appendix A

Digital Outputs

The four digital outputs are Dispenser Ready, Fault

Present, In Cycle, and Minimum Volume Dispensed.

These outputs perform high-side switching of 24 VDC and require a 24 VDC current sinking input at the auto-

mation controller. See F IG . 33. If the automation control-

ler uses 24 VDC relay coils to receive I/O signals, the

signals should be connected as shown in F IG . 33.

If the automation controller uses optocouplers to receive digital I/O signals, the inputs must be designed for 24

VDC and the optocoupler emitter cathode must be connected to the PrecisionFlo LT 24 VDC common (pin 6).

See F IG . 34.

If the automation controller inputs are current sourcing or use a voltage other than 24 VDC, relays with 24 VDC

coils must be used as shown in F IG . 33.

F IG . 34

F IG . 33

82 309738K

Appendix A

Analog Inputs

The PrecisionFlo LT receives a flow rate or pressure analog command from the automation. The 0 to 10 VDC analog input is referenced to analog common on the

control board. See F

IG

. 35. The reference for the auto-

mation controller analog output must be connected to the PrecisionFlo LT analog reference (pin 8) for this signal to function properly. If this reference connection is not possible an analog isolator must be used.

24 VDC From E-Stop

The PrecisionFlo LT provides a signal that can be used by the automation controller to monitor the emergency stop switch position of the PrecisionFlo LT controller.

See F

IG

. 37.

F IG . 37

F

IG

. 35

Analog Outputs

The PrecisionFlo LT provides a flow rate (tach) signal for use in the automation. The 0 to 5 VDC analog output is referenced to analog common on the control board. See

F

IG

. 36. The reference for the automation controller ana-

log output must be connected to the PrecisionFlo LT analog reference (pin 8) for this signal to function properly. If this reference connection is not possible an analog isolator must be used.

Relays

If the use of relays is required to condition the digital I/O signals, these are some examples of part numbers that could be used.

For 24 VDC Coils:

• Relay: IDEC Part # RH1B-UDC24V

• Socket (DIN Rail): IDEC Part # SH1B-05

• Spring: IDEC Part # SY2S-02F1

For 120 VAC Coils:

• Relay: IDEC Part # RH1B-UAC120V

• Socket (DIN Rail): IDEC Part # SH1B-05

• Spring: IDEC Part # SY2S-02F1

F

IG

. 36

309738K 83

Appendix B

Appendix B

PrecisionFlo LT User Interface

Screen Overview - Run Screen (Bead Control Mode)

The purpose of this screen is to display the required run parameters.

Description

Hour

Minute

Day

Month

Year

Date Format

Pressure

Pressure Units

Actual Flow Rate

Command

Bead Scale note 1

Dispense Mode

Control Mode

Style (not shown in low end)

Target Volume note 2

Requested Volume

Actual Volume

Volume Error note 3

Active Fault

Possible Values

0-23

0-59

1-31

1-12

2000-2099 mm/dd/yy-dd/mm/yy

0-9999 psi or bar

0-9999 cc/min

0-100%

50-150%

Auto or Manual

Bead Control, Volume Monitor, Batch

Dispense, or Pressure Control

1 to 4

0 to 9,999.9 cc

0 to 9,999,999.9 cc

0 to 9,999,999.9 cc

-100.0 to 999.9%

Numerous text strings

Notes:

1.

Reverse image indicates Run Mode Bead scale is enabled in the setup

2.

Target Volume should change based on style.

3.

Error values reflect the last completed job’s data.

other screen.

Default Value

N/A

N/A

N/A

N/A

N/A mm/dd/yy

N/A psi

N/A

N/A

100%

N/A

Bead Control

1

25.0 cc

N/A

N/A

N/A

N/A

Output: 345 psi

Command: 100%

Mode: Auto

213 cc/min

112 % Bead Scale

Bead Control

VOLUME:

Target:

Requested:

Measured:

No Active Faults

414 cc

415

412

+ 0.2%

- 0.5%

09/06/02 10:00

84 309738K

Run Screen (Volume Control Mode)

The purpose of this screen is to display the required run parameters.

Description

Hour

Minute

Day

Month

Year

Date Format

Pressure

Pressure Units

Actual Flow Rate

Command

Bead Scale note 1

Dispense Mode

Control Mode

Style

Target Volume note 2

Actual Volume

Volume Error note 3

Active Fault

Possible Values

0-23

0-59

1-31

1-12

2000-2099 mm/dd/yy-dd/mm/yy

0-9999 psi or bar

0-9999 cc/min

0-100%

50-150%

Auto or Manual

Bead Control, Volume Monitor,

Batch Dispense, or Pressure

Control

1 to 4

0 to 9999.9 cc

0 to 9,999,999.9 cc

-100.0 to 999.9%

Numerous text strings

Notes:

1.

Reverse image indicates Run Mode Bead Scale is enabled in the setup

2.

Target Volume should change based on style.

3.

Error Values reflect the completed last job's data .

other screen.

Default Value

N/A

N/A

N/A

N/A

N/A mm/dd/yy

N/A psi

N/A

N/A

100%

N/A

Bead Control

1

25.0 cc

N/A

N/A

N/A

Output: 345 psi

Command: 100%

Mode: Auto

213 cc/min

112 % Bead Scale

Volume Monitor

VOLUME:

Target:

Measured:

414 cc

412 - 0.5%

No Active Faults 02/25/03 10:00

Appendix B

309738K 85

Appendix B

Run Screen (Batch Dispense Mode)

The purpose of this screen is to display the required run parameters.

Description

Hour

Minute

Day

Month

Year

Date Format

Pressure

Pressure Units

Actual Flow Rate

Command

Bead Scale note 1

Dispense Mode

Control Mode

Style

Target Volume note 2

Actual Volume

Volume Error note 3

Active Fault

Possible Values

0-23

0-59

1-31

1-12

2000-2099 mm/dd/yy-dd/mm/yy

0-9999 psi or bar

0-9999 cc/min

0-100%

50-150%

Auto or Manual

Bead Control, Volume Monitor,

Batch Dispense, or Pressure

Control

1 to 4

0 to 9999.9 cc

0 to 9,999,999.9 cc

-100.0 to 999.9%

Numerous text strings

1

25.0 cc

N/A

N/A

N/A

Notes:

1.

Reverse image indicates Run Mode Bead scale is enabled in the setup

2.

Target volume should change based on style.

3.

Error values reflect the last completed job’s data.

Output:

Mode:

345 psi

Command: 100%

Auto

213 cc/min

112 % Bead Scale

Batch Dispense other screen.

Default Value

N/A

N/A

N/A

N/A

N/A mm/dd/yy

N/A psi

N/A

N/A

100%

N/A

Bead Control

VOLUME:

Target: 414 cc

Measured 412 - 0.5%

No Active Faults 09/06/02 10:00

86 309738K

Run Screen (Pressure Control Mode)

The purpose of this screen is to display the required run parameters.

Description

Hour

Minute

Day

Month

Year

Date Format

Pressure

Pressure Units

Command

Bead Scale note 1

Dispense Mode

Control Mode

Style

Active Fault

Possible Values

0-23

0-59

1-31

1-12

2000-2099 mm/dd/yy-dd/mm/yy

0-9999 psi or bar

0-100%

50-150%

Auto or Manual

Bead Control, Volume Monitor, Batch Dispense, or Pressure Control

1 to 4

Numerous text strings

Default Value

N/A

N/A

N/A

N/A

N/A mm/dd/yy

N/A psi

N/A

100%

N/A

Bead Control

1

N/A

Notes:

1.

Reverse image indicates Run Mode Bead scale is enabled in the setup

Output: 345 psi

Command: 100%

Mode: Auto

112 % Bead Scale

Pressure Control other screen.

Appendix B

No Active Faults 09/06/02 10:00

309738K 87

Appendix B

Setup Screen 1 Dispense Screen

The purpose of this screen is to display the required run parameters.

Notes:

1.

Reverse image to indicate an input cell only if Run Mode Bead Adjust is enabled.

Bead Scale

Control Mode

100 %

Bead Control

Target Volume 25.0

cc +/10.0

%

Dispense

No Active Faults

Calibrate Other

02/24/06 09:34

Description

Hour

Minute

Day

Month

Year

Date Format

Bead Scale

Control Mode

Target Volume

Volume Tolerance 1 to 4

Active Fault

Possible Values

0-23

0-59

1-31

1-12

2000-2099 mm/dd/yy-dd/mm/yy

50-150%

Bead Control, Volume Monitor,

Batch Dispense, or Pressure Control

0 to 9999.9

0 to 99.9%

Numerous text strings

Default Value

N/A

N/A

N/A

N/A

N/A mm/dd/yy

100%

Bead Control

N/A

10.0%

N/A

Notes:

Bead Scale cannot be changed with the membrane buttons in Setup mode, only with the number keys.

88 309738K

Setup Screen 2: Calibrate Screen (Bead Control Mode)

100% Command Flow 2548 cc/min

In Manual Mode, press to begin calibration

Calibration required (valid)

Output

Press to see details

345 psi 2134 cc/min

Desired Output

Kp 105

333 psi

Ki 4

2115 cc/min

346 psi

Max System Output 3405 cc/min 622 psi

Volume Compensation -2%

Dispense

Calibrate

112%

Other

No Active Faults 09/06/02 10:00

Description

Hour

Minute

Day

Month

Year

Date Format

100% commanded flow rate

Pressure tuning status

Flow calibration status

Flow calibration result

Pressure

Pressure units

Actual flow rate

Desired outlet pressure

Desired flow rate

Calculated optimal KP note 1

Calculated optimal Ki note 1

Pressure for 100% flow

System maximum flow with completely open reg

Compensation zero offset

Compensation peak

Active Fault

Possible Values

0-23

0-59

1-31

Default Value

N/A

N/A

N/A

1-12

2000-2099

N/A

N/A mm/dd/yy-dd/mm/yy mm/dd/yy

50-150% 100%

In process, complete N/A

In process, complete N/A

Required, Valid

0-9999

Required

N/A psi or bar

0-9999cc/min

0-9999

0-9999

0 to 9999 psi

N/A

N/A

N/A

100

0 to 9999

0 to 9999

0 to 9999

6

N/A

N/A

-50 to 399%

25 to 400

0%

100%

Numerous text strings N/A

Notes:

The values for the pressure loop constants Kp and Ki can also be directly entered by the user in the OTHER setup screen.

Appendix B

309738K 89

Appendix B

Setup Screen 2: Calibrate Screen (Batch Dispense and Volume Monitor Modes)

100% Command Flow 2500 psi

In Manual Mode, press to begin calibration

Calibration required (valid)

Press to see details

Output

Desired Output

Result

Max System Output

1254 psi

1250 psi

Kp 105

3250 psi

Ki 4

3405 cc/min

Dispense

No Active Faults

Calibrate

Other

09/06/02 10:00

Description

Hour

Minute

Day

Month

Year

Date Format

100% commanded pressure

Calibration status

Pressure

Pressure Units

Desired Outlet Pressure

Calculated optimal Kp note 1

Calculated optimal Ki note 1

System maximum pressure with completely open reg

System maximum flow with completely open reg

Active Fault

Possible Values

0-23

0-59

1-31

Default Value

N/A

N/A

N/A

1-12

2000-2099

N/A

N/A mm/dd/yy-dd/mm/yy mm/dd/yy

1 to 9999 1000

In process, complete N/A

0-9999 N/A psi or bar

0 - 9999

0 to 9999 psi

N/A

100

0 to 9999

0 to 9999

0 to 9999

6

N/A

N/A

Numerous text strings N/A

Notes:

1.

The values for the pressure loop constants Kp and Ki can also be directly entered by the user in the OTHER setup screen.

90 309738K

Appendix B

Setup Screen 2: Calibrate Screen (Pressure Control Mode)

100% Command Pressure 2500 psi

In Manual Mode, press to begin calibration

Calibration required (valid)

Press to see details

Output 1254 psi

Desired Output 1250 psi

Result Kp 105 Ki 4

Max System Output 3250 psi

Dispense

Calibrate

No Active Faults

Other

09/06/02 10:00

Description

Hour

Minute

Day

Month

Year

Date Format

100% commanded pressure

Calibration status

Pressure

Pressure Units

Desired Outlet Pressure

Calculated optimal Kp note 1

Calculated optimal Ki note 1

System maximum pressure with completely open reg

Active Fault

Possible Values

0-23

0-59

1-31

Default Value

N/A

N/A

N/A

1-12

2000-2099

N/A

N/A mm/dd/yy-dd/mm/yy mm/dd/yy

1 to 9999 1000

In process, complete N/A

0-9999 N/A psi or bar

0 - 9999

0 to 9999 psi

N/A

100

0 to 9999

0 to 9999

6

N/A

Numerous text strings N/A

Notes:

1.

The values for the pressure loop constants Kp and Ki can also be directly entered by the user in the OTHER setup screen.

309738K 91

Appendix B

Setup Screen 3: Other Screens

Language

Control Mode

Command Mode

Pressure Loop Kp

Pressure Loop Ki

Job End Mode

Job End Delay

Run Mode Bead Scale?

Regulator Pre-Charge

Gun On Delay

Gun Off Delay

Reg On Delay

Reg. Off Delay

Pulses per Flow Reading

Flow Comp Pivot

Flow Fault Time

Screen Saver Timeout

Pressure Units

Flow Meter K Factor

Default/Fixed Command

Manual Command

Zero Pressure Signal

5 VDC Pressure

Minimum Pressure

Maximum Pressure

5 VDC Output Flow Rate

English

Bead Control

Analog

107

9

Timer

4

No seconds

.00

0

0

VDC ms ms

0 ms

0

6

50 %

2 seconds

0 psi minutes pulses/L 3500

50 %

50 %

1.00

3500

0

5000

1000

VDC psi psi psi cc/min

Date Format

Year

Month

Day

Hour

Minute

mm/dd/yy

20 03

09

06

18

00

1

2

3

4

5

92 309738K

.

Low Volume

High Volume

Low Flow Rate

High Flow Rate

Low Pressure

High Pressure

Computed Target

Alarm

Warning

Alarm

Alarm

Warning

Warning

Warning

6

Description

Language

Date Format

Year

Month

Day

5 VDC Sensor Pressure

Minimum Outlet Pressure for

Fault

Maximum Outlet Pressure for

Fault

Possible Values

English, Spanish,

French, German, Italian,

Portuguese, Japanese, or Korean dd/mm/yy or mm/dd/yy

00 to 99 (2000 to 2099)

1 to 12

1 to 31

Hour

Minute

Pressure Units

Command Mode

0 to 23

0 to 59

PSI or BAR

Fixed or Analog

0 to 100%

Default Command note 1

Manual Command

Job End Mode

Job End Delay

Flow Meter K-Factor

Regulator Pre-Charge

Gun On Delay

Gun Off Delay

Reg On Delay

0 to 100%

Timer or Digital I/O

1 to 99 seconds

1 to 99,999 pulses/L

0.00 to 5.00 VDC

0 to 999 msec

0 to 999 msec

0 to 999 msec

Reg Off Delay 0 to 999 msec

Zero Pressure Sensor Signal 0.00 to 5.00 VDC

0 to 5000 PSI

0 to 5000 PSI

0 to 5000 PSI

Default Value

English mm/dd/yy

N/A

N/A

N/A

N/A

N/A

PSI

Analog

50%

50%

Digital I/O

4 sec

3500

0.00 VDC

0 msec

0 msec

0 msec

0 msec

1.00 VDC

3500 PSI

0 PSI

5000 PSI

Pressure Loop Kp note 2 0 to 9999 100

Pressure Loop Ki note 2 0 to 9999 6

309738K

Appendix B

93

Appendix B

Pulses per Flow Reading note 3

Flow Compensation Pivot

Point note 4

Flow Fault Time

Enable Run Mode Bead

Adjust?

Screen Saver Timeout

5 VDC Output Flow Rate

(scale analog “tach” out)

Low Volume Fault

High Volume Fault

Low Flow Rate Fault

High Flow Rate Fault

Low Pressure Fault

High Pressure Fault

Computed Target Fault

Active Fault

2 to 99 pulses

0 to 100%

1 to 99 seconds

Yes or No

0 to 99 minutes note 5

1 to 9999 cc/min

Alarm or Warning

Alarm or Warning

Alarm or Warning

Alarm or Warning

Alarm or Warning

Alarm or Warning

Alarm or Warning

Numerous text strings

4 pulses

50%

2 seconds

No

0 minutes

5000 cc/min

Alarm

Warning

Alarm

Warning

Warning

Warning

Warning

N/A

Notes:

1.

The default flow rate command would be used if there is no analog signal (fixed) or the analog signal is lost. Setting this value to zero disables the low analog fault.

2.

The values for the pressure loop constant Kp and Ki are automatically calculated during the calibration process

and can be manually changed here. See page 104.

3.

The value for the number of pulses per flow reading is automatically calculated during the calibration process and

can be manually changed here. See page 34.

4.

The Flow Comp Pivot is the command level that determines whether the zero offset or peak is adjusted during

volume compensation. See page 104.

5.

This variable sets the number of minutes without button press activity before the screen backlight will turn off.

This function increases the life of the backlight. Setting this value to zero disables the screen saver function, keeping the light on continuously.

94 309738K

Appendix C

Appendix C

Theory of Operation

Input and Output Signals

Terminology

For the purpose of this document a digital signal is said to be SET when voltage is present (or above the minimum threshold). A signal is said to be RESET when the signal voltage is not present (below minimum threshold).

Devices are referred to as SET when they are in their energized or active state.

Digital Inputs

Dispense Gun This is the Dispense Signal. The PrecisionFlo LT unit will attempt to dispense at either the commanded flowrate or commanded pressure while this signal is SET, dependent on mode.

Control On This input is reset when the E-stop button is pressed.

Job Complete This input can be used to signal a job end.

The dispenser ready signal is an important signal for the automation to monitor. When the dispenser ready output is not on, the LT may not be responding to requests form the automation. This could create the situation where the automation is running production, but the LT is not dispensing any material.

Gun Solenoid This signal will be set to energize the gun solenoid at the beginning of a dispense cycle.

Minimum Volume Dispensed This signal will be set when the minimum volume (target volume - tolerance) has been dispensed for the job.

Fault Present This bit is RESET under the following conditions:

1.

No Faults (alarms or warnings) are active.

In Cycle In Cycle signal is set at the beginning of a dispense cycle. It is reset at the end of the dispense cycle.

The dispense cycle can end in two ways, depending on how the Job End mode is set:

• If the Job End mode is set to automation I/O, dispense cycle ends when the job complete signal is received from the automation I/O.

• If the Job End mode is set to Timer, dispense cycle ends when the Job End delay timer expires.

Analog Input

Flow Command The flow command signal input represents flow or pressure requests. The voltage must be between 0 and 10 volts DC. The 0-10 volt signal is interpreted as a relative 0-100% flow or pressure command signal. The system must be in Analog Mode for this input to be used.

Outlet PressureThe outlet pressure input represents the fluid pressure at the regulator outlet. The default voltage ranges from 1 to 5 VDC for 0 to 3500 psi (23.8

MPa, 238 bar).

Analog Output

V/P Command The V/P command output corresponds to an air pressure driving the regulator. The voltage ranges from 1 - 5 VDC to adjust flow and/or pressure in the fluid system.

Flow Rate The flow rate output relates to the fluid flow through the meter. The voltage ranges from 0 - 5 VDC corresponding to a 0 - 5000 cc/min.

309738K 95

Operation Modes

Operation Modes

Dispense Modes:

Manual Mode

When in Manual mode, the PrecisionFlo LT control reacts only to input from the user interface. The PrecisionFlo LT control ignores automation controller signals when in Manual mode.

Automatic Mode

When in Automatic mode, the PrecisionFlo LT control remains in a ready state, indicated by the DISPENSER

READY signal, and reacts to inputs such as DISPENSE and VOLUME REQUEST signals from the automation unit.

When a fault is detected, the PrecisionFlo LT control sets the FAULT present signal HIGH, and may set the

DISPENSER READY signal LOW. Fault detection can also occur during manual dispensing.

During dispensing, the PrecisionFlo LT control performs a variety of functions in the background. These functions include fault monitoring, real-time volume compensation, measuring volume (per job), and continuous calculations to maintain the pressure and flow control loops.

Control Modes:

Volume Monitor

The automation I/O or Manual dispense command and the 100% pressure setting are used to set a pressure target. The regulator adjusts to maintain this pressure.

In automatic mode the controller compares the dispensed volume to the target volume and sets volume faults if needed.

Batch Dispense:

The automation I/O command and the 100% pressure settings are used to set the pressure target. The regulator adjusts to maintain this pressure. In automatic mode the dispense valve is closed when the target volume is reached, a job complete signal is received by the control, or the job timer expires.

Automation I/O Modes:

Bead Control

The automation I/O command for manual dispense establishes a Flow Rate target. A pressure setpoint is determined from the calibration results and the volume compensation values. The regulator adjusts to maintain the pressure setpoint, volume compensation will adjust the pressure setpoint to achieve the desired flow rate.

Pressure Control

The automation I/O or manual dispense command and the 100% pressure setting are used to set a pressure target. The regulator adjusts to maintain this pressure.

Analog

0-10 VDC signal from the automation unit is used to determine the pressure or flow command. A 10 volt command will establish a pressure or flow rate command equal to the 100% value entered during the calibration procedure. If an analog signal < 1vdc is given the pressure or flow command is determined by the value entered in the default/fixed command parameter.

Fixed

The default/fixed value entered in the setup is used to determine the pressure or flow command.

96 309738K

Jobs

Jobs

The PrecisionFlo LT system operates using the concept of jobs. A job is a specified amount of material that is dispensed by the system. The amount of material specified for a job varies, depending on the application. In some applications, a job may be the amount of material dispensed on a part. Other applications may define a job to be the amount of material dispensed on a number of parts or dispensed over a period of time.

A job is initiated when the automation sends a “Dispense Gun” signal to the LT. Once the job is initiated, the

LT will start tracking the amount of volume requested by the automation and the amount of material that is actually dispensed. These volumes will be tracked until the job is completed. At the end of the job, fault calculations are made and the volumes are stored to non-volatile memory on the LT system (Job Log).

The LT system watches two things to decide when a job is complete. Either the “Job Complete” signal is sent by the automation, or the job complete timer expires. The type of job end signal is configured in the “Other” screen to be of type “Timer” or “Digital I/O”. If the timer method is used, the timer begins counting every time the dispense gun is turned off. If the gun stays off for more than the preset timer value, then the job is considered complete.

Once the job is complete, the job information is stored to memory. The most recent jobs can then be viewed on the “Job” screen or by using the Graco Shell Menu System. The information stored with each job is as follows.

Measured Volume The amount of material measured by the flow meter during a job.

Requested Volume The amount of material that the automation tries to dispense during a job. This volume is calculated by measuring how long the dispense gun is on, taking in effect the command voltage from the automation over time.

Target Volume The theoretical amount of material that a job should have. This value is usually calculated or found using trial and error when the application is first set up.

In Bead Mode, all of these volumes are monitored. The

High Volume, Low Volume, and Computed Target faults are evaluated at the end of the job. The volume alarms compare the measured volume to the requested volume and the computed target alarm compares the requested volume to the target volume.

In Volume Monitor Mode and Batch Mode, the requested volume is not measured. In these two modes, the automation command voltage corresponds to a pressure instead of flow rate. For this reason the requested volume is not available (as well as the Computed Target fault). The high and low volume alarms compare the measured volume to the target volume for

Volume Monitor and Batch modes.

In Pressure Mode, there are no flow meters available and the controls are all performed based on pressure.

For this reason the LT does not monitor measured, requested, or target volume. The High Volume, Low Volume, and Computed Target faults are all inactive when using Pressure mode.

309738K 97

Typical Job Cycle

Typical Job Cycle

1.

Automation system controller verifies that the DIS-

PENSER READY signal is HIGH.

2.

Automation system goes into cycle.

3.

PrecisionFlo LT control waits for DISPENSE gun signal from the automation system to start dispensing.

4.

Automation system controller requests material to be dispensed by setting the DISPENSE gun signal

HIGH.

In Batch Dispense Mode the dispense gun signal must remain valid for a minimum of 20 msec.

5.

Dispense gun opens after the GUN ON DELAY, immediately if the delay is set to zero.

6.

PrecisionFlo LT control checks if a REGULATOR

ON DELAY has been set by the user.

If the delay has been set, the PrecisionFlo LT control waits until the delay has expired, then begins regulating material to the gun.

If the delay has not been set, the PrecisionFlo LT control immediately begins regulating material to the gun.

7.

PrecisionFlo LT control regulates output based on the COMMAND input signal from the automation unit in analog mode or the set value in Default/Fixed mode.

8.

PrecisionFlo LT control measures the volume dispensed continuously in all modes except pressure control.

9.

PrecisionFlo LT control continuously monitors the outlet fluid pressure and the flow rate, as measured by the flow meter, and makes adjustments for changes in operating conditions.

10. PrecisionFlo LT control monitors operating parameters to detect and report any faults that may occur.

11. Automation unit sets the DISPENSE gun signal

LOW, indicating that no material is required during this portion of the program. (automation unit can cycle the DISPENSE gun signal HIGH and LOW throughout a cycle if required. Volume measurement will still occur.)

12. The regulator closes after the REGULATOR OFF

DELAY expires.

13. The PrecisionFlo LT control checks if a GUN OFF

DELAY has been set by the user.

If the delay has been set, the PrecisionFlo LT control waits until the delay has expired, then closes the dispense gun solenoid, which closes the gun.

If the delay has not been set, the PrecisionFlo LT control immediately closes the dispense gun solenoid, which closes the gun.

14. PrecisionFlo LT control stops measuring volume after the DISPENSE DONE DELAY timer expires or the JOB COMPLETE automation I/O signal is received, depending on the job end mode selected.

The job complete signal must remain valid for a minimum of 20 msec.

15. PrecisionFlo LT control updates the Status screen and the Data table.

16. The PrecisionFlo LT waits for the next cycle to begin.

98 309738K

Typical Dispense Cycle

Typical Dispense Cycle

The In Cycle signal is set at the beginning of a dispense cycle, which starts with a Dispense Gun signal from the automation unit.

Bead Control / Vol. Monitor / Pressure Control

Using I/O for Job End

Dispense Gun

Input Signal

Regulator

On

A

Valve

On

C

Job Complete

Input Signal

In Cycle

Output Signal

F IG . 38

A = Regulator On Delay

B = Regulator Off Delay

C = Gun On Delay

D = Gun Off Delay

E = Minimum delay between regulator / valve closing is 10 msec

F = The minimum pulse width for the Job Complete signal is 20 msec

B

D

E

F

309738K 99

Typical Bead Control / Vol. Monitor / Pressure Control

Typical Bead Control / Vol. Monitor / Pressure Control

Using Timer for Job End

Dispense Gun

Input Signal

Regulator

On

A

Valve

On

C

In Cycle

Output Signal

F IG . 39

A = Regulator On Delay

B = Regulator Off Delay

C = Gun On Delay

D = Gun Off Delay

E = Job end delay time, default value is 4 seconds

B

D

E

100 309738K

Typical Batch Dispense Cycle (I/O)

Using I/O for Job End

Dispense Gun

Input Signal

A

Regulator

On

B

Valve

On

D

Volume Not Reached, Job Aborted by I/O

Job Complete

Input Signal

In Cycle

Output Signal

Min Volume

Output Signal

F

C

E

Volume Reached, Job Ended Automatically

Job Complete

Input Signal

In Cycle

Output Signal

Min Volume

Output Signal

F IG . 40

A = The minimum pulse width for the Dispense Gun input signal is 20 msec.

B = Regulator On Delay

C = Regulator Off Delay

D = Gun On Delay

E = Gun Off Delay

F = The minimum pulse width for the Job Complete signal is 20 msec

Typical Batch Dispense Cycle (I/O)

309738K 101

Typical Batch Dispense Cycle (I/O)

Typical Batch Dispense Cycle (Timer)

Using Timer for Job End

Dispense Gun

Input Signal

A

Regulator

On

B

Valve

On

D

Volume not reached, job aborted by timer

In Cycle

Output Signal

F

C

E

Min Volume

Output Signal

Volume reached, job ended automatically

In Cycle

Output Signal

Min. Volume

Output Signal

Target Volume Reached

Minimum Volume Reached

F IG . 41

(Minimum Volume = Target Volume - Volume Tolerance)

A = The minimum pulse width for the Dispense Gun input signal is 20 msec.

B = Regulator On Delay

C = Regulator Off Delay

D = Gun On Delay

E = Gun Off Delay

F = The Job End Delay time, default is 4 seconds.

102 309738K

Continuously Running Applications

Continuously Running Applications

In some cases the target volume for a job is not known.

An example of a case where the target volume is unknown is a continuously running system. This would be a system that does not run jobs, but runs continuously over a day or a shift. In this case, the flow rate becomes more important than the amount of volume dispensed in a job. The way to handle this situation is to set the target volume to a value of zero. This effectively disables the computed target fault. The controls will still maintain the desired flow rate and report faults corresponding to the tolerance set for the running style.

Another situation where it may be desirable to set the target volume to be zero is when there are too many styles for the LT to keep track of. For the standard configuration, the LT only maintains one style and for the advanced configuration there are four styles. If the target volume is set to zero, then the LT will be able to handle running jobs with varied volumes with out generating faults. The flow rate faults will still be active and the high and low volume faults will also still be active. The computed target faults will not be active and the job logs will always show a value of 0 in the Target Volume column.

309738K 103

Flow Rate Calculation

Flow Rate Calculation

The pulses per flow reading value is calculated by the system based on the K-factor and the flow rate entered during flow calibration.

4 pulses

(pulses per reading)

The time is measured for the number of flow meter pulses in the flow average variable to occur and the flow rate is calculated.

Example: pulses per reading = 4 pulses

Flow Rate = 400 cc/min

K-factor = 3500 pulses/liter = 3.5 pulses/cc

This gives a pulse rate of 23.3 pulses/second or 43 milliseconds/pulse. A new flow rate is measured approximately every 171 milli-seconds.

If the time measured with the same parameters (3500 pulses/liter, 4 pulses flow average) is 180 milliseconds, the flow rate calculation would be 380 cc/minute.

Flow Calibration

In order to control the flow rate of a material, the system must determine the pressure required at the regulator outlet to achieve a desired flow rate (Fig. 20).The flow calibration procedure provides the pressure required to obtain the maximum desired flow rate (10 VDC flow command.)

1000

800

100%

80%

The flow calibration procedure determines this point. This is the initial pressure/flow peak setting

(100%).

60% 600

Pressure (psi)

400 40%

104

This is the initial pressure flow offset setting

(0%)

200

0

20%

0%

Default flow comp pivot point (50%). See

Control

Assembly Parts

on page

-10%

0

2 4

6

Flow Command (VDC)

8 10

10 VDC = flow rate entered on flow calibration screen for 100% flow command

F IG . 42

309738K

Flow Rate Calculation

Volume Compensation

Volume compensation is used when the PrecisionFlo LT system is operated in bead control mode. The system measures the actual flow rate and adjusts the pressure/flow relationship (as determined during flow calibration) to achieve the desired flow.

When flow calibration is completed, the resulting pressure value is divided by 100 to obtain a 1% value. The initial offset is set to 0%, the initial peak is set to 100%

(see Flow Calibration on page 104).

Each time a new flow rate measurement has been completed, the actual flow rate is compared to the requested flow rate. The flow rate command from the automation unit (analog or fixed) is also compared to the flow rate defined by the flow comp pivot point value. The pivot point should be set to the average value of the minimum and maximum automation commands when using Analog for automation mode.

Endpoint

Adjustment

Flow Command <

Flow comp Pivot

Point

Increase offset Flow rate < desired flow rate

Flow rate > desired flow rate

Decrease offset

Flow Command >

Flow comp Pivot

Point

Increase peak

Decrease peak

The volume compensation routine moves the end points of a straight line which defines the pressure/flow relationship of the system.

The end point of the pressure/flow line (offset or peak) is moved the 1% value determined at the end of the flow calibration routine. The magnitude of the flow rate error does not affect the size of the adjustment.

The maximum adjustment range of the peak point is

25% to 400% of the original value from calibration. If the

25% or 400% limits are reached, a Volume Comp Limit fault is generated.

309738K 105

Appendix D

Appendix D

Ethernet Kit 118329

The Ethernet kit for PrecisionFlo LT provides for a way to communicate with the LT via an industrial or office network. This kit converts the serial (RS232) information provided in the Graco Shell menu system into Ethernet packets that can be accessed using TCP/IP networking.

A DIN rail mounted module that has terminal screws for the RS232 wires as well as a RJ45 port for Ethernet performs the conversion.

The kit comes from the factory pre-wired with the wires needed to connect to the LT system. The five wires are labeled with wire numbers that indicate where they should be located inside of the LT control box. The wiring for the converter module is as follows.

Wire function

+24 V

Common

RS232 Transmit

RS232 Receive

RS232 Ground

Wire Number

2120

2121

2551

2541

2560

2551

2541

The kit ships with a User’s Guide that provides detailed instructions on how to configure the conversion module.

The module can be configured using a graphical web based configuration connection or by using a serial connection to the module. In general, the default settings of the unit may be used with the following exceptions.

• The Baud Rate needs to be changed to 57600

• The “End Char” setting needs to be “0x0D”

• The dip switches on the outside the box should be set to “Terminal”. This would be switch #4 on and all of the other switches are off.

Once the conversion module has been configured, the

Graco Shell menu system (see page 40) for the LT can

be accessed by any computer that exists on the same network as the LT. The LT will be uniquely identified by its IP Address. This IP address could be an internal IP address assigned by your IS department or it could be a public IP address that will make the system accessible on the Internet. The module can also be configured to obtain its IP address automatically from the network that it is attached to using DHCP. Due to the security implications and the complexity of setting up a new IP addresses, the IP address selection and configuration should be done with the help of an IS professional.

It is important to note that Xmodem and Ymodem do not work reliably through the Ethernet conversion module.

These protocols are used when selecting the menu options that “Transfer” or “Restore” files to and from the

LT. The alternative is to use the options that “Dump” the file to the screen. The data can then be copied to the clipboard.

2560

2120

2121

F IG . 43

106 309738K

Appendix D

309738K 107

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 procedures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

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.

This manual contains English. MM 309738

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2003, Graco Inc. is registered to ISO 9001 www.graco.com

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