Graco PrecisionFlo XL User manual

Instructions
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2001, Graco Inc. is registered to I.S. EN ISO 9001
309374E
Read warnings and instructions.
Certified to
CAN/CSA C22.2
Conforms to
UL 3121–1
PrecisionFlo XL
Electronically controlled fluid dispensing packages
SPneumatically or electrically operated fluid regulators
SEasyKeyRKeypad or TouchScreen interface.
Maximum Working Pressures of packages ordered through the PrecisionFlo XL configurator:
Maximum Fluid Feed Pressure
5000 psi (34.5 MPs, 345 bar) Ambient and Temperature Conditioned
3000 psi (20.7 MPa, 207 bar) Electrically Heated (hoses)
Maximum Working Air Pressure
120 psi (.83 MPs, 8.3 bar) All Pneumatic Components
Parts

Warnings
2 309374
Table of Contents
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Identification 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical PrecisionFlo XL Configuration 9. . . . . . . . . .
Sound Deadener Package 10. . . . . . . . . . . . . . . . . .
Pneumatic Regulator Package 11. . . . . . . . . . . . . . .
Installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Beginning Installation 12. . . . . . . . . . . . . . . .
Mounting Control Unit 13. . . . . . . . . . . . . . . . . . . . . .
Electrical Connections 15. . . . . . . . . . . . . . . . . . . . . .
Grounding Control Unit 15. . . . . . . . . . . . . . . . . . . . .
Connecting Cables 16. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Ground Continuity 17. . . . . . . . . . . . . . . . .
Connecting Fluid and Air Lines 18. . . . . . . . . . . . . .
Connecting to Power Source 19. . . . . . . . . . . . . . . .
Pressure Relief Procedure 20. . . . . . . . . . . . . . . . . .
Safety Reminder 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 20. . . . . . . . . . . . . . . . . .
PrecisionFlo XL User Interface 21. . . . . . . . . . . . . .
Starting the System 23. . . . . . . . . . . . . . . . . . . . . . . .
Control Unit Buttons, Switches and Indicators 24.
Loading Material 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation Modes 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Robot Modes 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Modes 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting Down the System 29. . . . . . . . . . . . . . . . . .
Configuring Software 30. . . . . . . . . . . . . . . . . . . . . . . . .
Setting Flow Meter K–Factors 31. . . . . . . . . . . . . . .
Calibrating Pressure 32. . . . . . . . . . . . . . . . . . . . . . .
Flow Rate Calibration 33. . . . . . . . . . . . . . . . . . . . . .
Other Software Settings 34. . . . . . . . . . . . . . . . . . . .
On/Off Delays 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verifying FLow Meter Calibration 38. . . . . . . . . . . . . .
Verification and Calibration 38. . . . . . . . . . . . . . . . . .
Communicating with PrecisionFlo XL 39. . . . . . . . .
PrecisionFlo XL Module Operation 40. . . . . . . . . . . .
PrecisionFlo XL EasyKey Interface 41. . . . . . . . . . . .
PrecisionFlo XL TouchScreen Interface 57. . . . . . . .
PrecisionFlo XL Remote Screen Interface 86. . . . . .
Robot I/O Interface 89. . . . . . . . . . . . . . . . . . . . . . . . . . .
Discrete Signals 94. . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation 97. . . . . . . . . . . . . . . . . . . . . . . . . .
Input and Output Signals 97. . . . . . . . . . . . . . . . . . . .
Operation Modes 99. . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Dispense Cycle 101. . . . . . . . . . . . . . . . . . . .
Typical Job Cycle 102. . . . . . . . . . . . . . . . . . . . . . . . .
Fault Reporting 103. . . . . . . . . . . . . . . . . . . . . . . . . . .
Volume Reporting 105. . . . . . . . . . . . . . . . . . . . . . . . .
Flow Rate Calculation 107. . . . . . . . . . . . . . . . . . . . .
Flow Calibration 107. . . . . . . . . . . . . . . . . . . . . . . . . .
Volume Compensation 108. . . . . . . . . . . . . . . . . . . .
Maintenance 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 110. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Modules 110. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Meter 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dispense Valves 112. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Component Paths 113. . . . . . . . . . . . . . .
Fluid Module #1 113. . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Module #2 114. . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting and Fault Recovery 116. . . . . . . . .
Frequently Asked Questions 121. . . . . . . . . . . . . . . . .
Technical Data 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Unit. 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Hoses 130. . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Module Components 130. . . . . . . . . . . . . . . . .
Dispensing Devices 131. . . . . . . . . . . . . . . . . . . . . . .
Filtering Accessories 131. . . . . . . . . . . . . . . . . . . . . .
PrecisionFLo XL Remote Control Box 132. . . . . . . .
Adding Local Stations to a Remote Box 133. . . . . .
Adding Swirl Capability to an
Existing Control Box 134. . . . . . . . . . . . . . . . . . . . . . . .
Temperature Control 136. . . . . . . . . . . . . . . . . . . . . . . .
Temperature-Conditioned Package
(St. Clair Systems) 136. . . . . . . . . . . . . . . . . . . . . . . .
Electric Heat Package 137. . . . . . . . . . . . . . . . . . . . .
Fluid Plate Electric Heat Kits 139. . . . . . . . . . . . . . .
Coriolis Flow Meter Kit 141. . . . . . . . . . . . . . . . . . . . . .
Coriolis Flow Meter Settings 144. . . . . . . . . . . . . . . . .
Appendix A
Ethernet and FTP –TouchScreen Only 145. . . . . . . .
Overview 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Start 145. . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TCP/IP 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FTP 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B
TouchScreen and Remote Screen
Configuration and Calibration 151. . . . . . . . . . . . . . . .
Before You Start 151. . . . . . . . . . . . . . . . . . . . . . . . . .
PC/104 Board Configurations 152. . . . . . . . . . . . . . .
Configuration Mode 153. . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 156. . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 156. . . . . . . . . . . . . . . . . . . . . .

Warnings
309374 3
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INJECTION HAZARD
Spray from the dispensing device, hose 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 medi-
cal attention.
Do not point the dispensing device at anyone or at any part of the body.
Do not put hand or fingers over the front of the dispensing device.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure on page 20 whenever you are instructed to: relieve pres-
sure; stop dispensing; clean, check, or service the equipment; or install or clean a spray tip or
nozzle.
Tighten all the fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
Always wear eye protection and protective clothing when installing, operating, or servicing this
dispensing equipment.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Follow the fluid manufacturer’s recommendations.
Provide fresh air ventilation to avoid the buildup of vapors from the fluid being dispensed.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Wear the appropriate protective clothing, gloves, eyewear, and respirator.

Warnings
4 309374
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, warnings, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call the
distributor closest to you. See the Graco Phone Number on page 156 for information.
Only use the PrecisionFlo XL fluid modules with the PrecisionFlo XL control unit.
Only use a dispensing device appropriate for the fluid and application method, and capable of
operating at the highest possible fluid supply pressure the module may experience.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not disassemble the PrecisionFlo XL metering valve motor. The motor contains powerful
magnets, which could attract metal objects and create a hazardous condition if the motor end
plates are removed. Contact your Graco distributor for motor service.
Do not exceed the maximum working pressure of the lowest rated system component.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco ambient hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull the equipment.
Use only fluids that are compatible with the equipment wetted parts. See the Technical Data
sections of all the equipment manuals. Read the fluid manufacturer’s warnings.
Comply with all applicable local, state and national fire, electrical and other safety regulations.
Do not touch the metal heat sink on the metering valve when the surface is hot.
Do not cover the PrecisionFlo XL linear metering valve; the motor needs air ventilation for
cooling.
Do not attempt to modify the programming of the module. Any modification of the programming
could result in serious injury or damage to the module.
MOVING PARTS HAZARD
Moving parts, such as the fluid needle, can pinch fingers.
Do not operate the equipment with the guard removed.
Keep clear of any moving parts when starting or operating the equipment.

Warnings
309374 5
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
Ground the equipment and the object being sprayed. See Grounding the Control Assembly on
page 15.
If there is any static sparking or you feel an electric shock while using the equipment, stop dis-
pensing immediately. Do not use the equipment until you have identified and corrected the prob-
lem.
Make 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.
Make sure all electrical equipment is installed and operated in compliance with applicable codes.
Do not install the PrecisionFlo XL module in a hazardous area, as defined in Article 500 of the
National Electrical Code (USA).
Turn off power to the PrecisionFlo XL module before disconnecting any cables connected to the
control unit or other components.
Disconnect electrical power at the main switch before servicing the equipment.
Keep the dispensing area free of debris, including solvent, rags, and gasoline.
Before operating the equipment, extinguish all open flames or pilot lights in the dispense area.
Do not smoke in the dispensing area.
Disconnect the electrical cables from the PrecisionFlo XL metering valve before servicing the
valve.
Keep liquids away from the electrical components

Model Identification
6 309374
Model Identification
PrecisionFlo XL
Graco’s PrecisionFlo XL is an electronically controlled
fluid regulating package designed to meter and dis-
pense adhesives and sealants. Your equipment was
likely ordered as a configured package to fit your
application. The configuration was picked from the
categories in the table on page 7.
Model Number Identification
On your control unit, there is an ID plate with a model
number on it. Use the table on page 7 for explana-
tions of each code letter and to define what equipment
was ordered as part of the configured package from
Graco. Where applicable, reference is given to other
instruction forms in your package binder.
XL-D- --------------
Code A B C D E F G H J K LA LB M N P
Typical Model Number
Example: XL–D–1–2–1–2–2–4–2–3–2–1–N–N–2–1–E

Model Identification
309374 7
Table 1: Model Code Information
Model Product Description Form Number
XL–EPrecisionFlo Fluid Module N/A
Code A Configuration
1PrecisionFlo XL Package 309374
2Electrical Enclosure Only 309374
Code B Enclosure
NBack plane Only 309374/309364
1Rotary switch power disconnect 309374/309364
2Knife switch power disconnect 309374/309364
Code C Cables
1All cables included 309374/309364
2No cables included N/A
Code D User Interface
NNone –To be linked to another N/A
1Standard User Interface 309374
2Advanced User Interface 309374
3Remote Mounted Advanced User In-
terface
309374
Code E Primary Voltage (single phase) 309374/309364
1110–120 Volts 309374/309364
2220–240 Volts 309374/309364
3400–480 Volts 309374/309364
Code F Robot I/O Interface Options
124 VDC 309374/309364
2120 V 309374/309364
3 DeviceNet 309374/309364
4 InterBus 309374/309364
5 ProfiBus 309374/309364
6 ControlNet 309374/309364
Code G Temperature Control
NNone –Ambient N/A
1Temperature Conditioned (50 Hz)
Heat and Cool
St. Clair Manual
2Temperature Conditioned (50 Hz)
Heat Only
St. Clair Manual
3Temperature Conditioned (60 Hz)
Heat and Cool
St. Clair Manual
4Temperature Conditioned (60 Hz)
Heat Only
St. Clair Manual
5Electrically Heated (50/60 Hz) 309374/309364
Code H Fluid Module
Electric Regulator / Linear Motor
1Low Viscosity (PVC) 308601
2Med/High Viscosity (Hem) 308601
3Med/High Viscosity–Integrated Regu-
lator (Hem)
308601
Pneumatic Regulator
4Low Viscosity (1/2”reg) 308647
5Med/High Viscosity (3/4”reg) 307517
Model Product Description Form Number
Dual Pneumatic Regulators
(2 Fluid Plates)
6Low Viscosity (1/2”reg) 308647
7Med/High Viscosity (3/4”reg) 307517
Code J Flow Meter
NNone –pressure regulation only N/A
1Spur: G3000 308778
2Helical: SRZ–40 308968
3Non-intrusive Mass Flow –mounted
remotely
309374
Code K Dispense Valve / Applicator
N None N/A
1AutoPlus SAE (compact) –
stream/spray
308813
2Endure (snuff back) –
stream/extrude/swirl
309376
31K Valve –45 degree outlet 308876
Code LA PrecisionSwirl Options (tool mount
only)
N None N/A
1Narrow Pattern (widths from
0.187–0.5”)
310554
2Wide Pattern (widths from 0.5–2.5”) 310554
Code LB Orbiter Extension Cable Options
N None N/A
1Extension Cable, 6’(233125) 309374 Accy.
2Extension Cable, 9’(233124) 309374 Accy.
3Extension Cable, 15’(233123) 309374 Accy.
Code M Supply Hose
N None
110’(1”ID) 309374 Accy.
220’(1”ID) 309374 Accy.
Code N Dispense Hose
N None
1 6’x 1/2”ID 309374 Accy.
2 6’x 5/8”ID 309374 Accy.
310’x 1/2”ID 309374 Accy.
410’x 5/8”ID 309374 Accy.
Code P Language
E English
F French
G German
I Italian
J Japanese
K Korean
P Portuguese
S Spanish
N/A – Not applicable
Accy. – Listed in Accessories section of manual.

Overview
8 309374
Overview
What This Manual Includes
This manual provides detailed information on the
PrecisionFlo XL control unit and operation of the
PrecisionFlo XL system only. Specific information on
the fluid module or material conditioning systems, for
example, is contained in other instruction forms sup-
plied with each component, as part of the PrecisionFlo
XL 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 proce-
dures 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
Abb.: Stands For:
COM common
FM flow meter
GND ground
MP motor power
msec milliseconds
MS motor signal (pressure sensor)
OP operations cable
psi pounds per square inch
PVC Poly Vinyl Chloride
PWM pulse width modulation
SPC Statistical Process Control
V volts
VAC volts AC
VDC volts DC
PrecisionFlo XL Definitions
Refer to pages 9–11.
Component Description
Control Unit The PrecisionFlo XL control unit
contains the electronics used to con-
trol the fluid module and Precision-
Swirl Orbiter if used.
PrecisionFlo
XL System
The control unit, fluid module, and all
cables and sensors used to measure
and control the fluid application.
Controller An external electronic (robotic) sys-
tem having some control interaction
via electronic signals with the Preci-
sionFlo XL system.
TouchScreen
and EasyKey
TouchScreen and EasyKey are the
two types of interfaces used to set
up, display, operate and monitor the
PrecisionFlo XL system.
Fluid Module The fluid module includes
components that control and monitor
fluid dispensing, such as a fluid
metering valve, flow meter, and
regulator.

Typical PrecisionFlo XL Configuration
309374 9
Typical PrecisionFlo XL Configuration
Fig. 1 shows the major components in a typical PrecisionFlo XL installation.
Fig. 1
9
2
8
7
1
4
5
3
6
No. Description
1 Control Unit
2 Fluid Module
3 Applicator/Dispense Gun
4 User Interface
5 Sealer Robot
6 Robot Digital Interface Cable (RDR)
7 Fluid Supply System
8 Fluid Supply Header
9 Robot Analog Cable (RAR)
–– Filter Module (not shown)
Sound Deadener Package with Dual Flow Meters and Swirl Orbiters

Typical PrecisionFlo XL Configuration
10 309374
Sound Deadener Package with Dual Flow Meters and Swirl Orbiters
TI1415A
Robot Analog
Robot Digital
Power
Process Fluid Suppl
y
Pumps
Dual Non-Intrusive Flow Meters
Air Inlet
Regulator-type Fluid Module
Tool Mount Swirl Orbiters
Operation Cables
Swirl Cable
Swirl Cable
Air signals to gun
Air inlet
In
Out In
Air signals
to gun
Out
Control Unit with EasyKey Interface (rotary disconnect switch shown)

Typical PrecisionFlo XL Configuration
309374 11
Pneumatic Regulator Package for Extrusion or Streaming
Dispense Hose
233670 Compact Valve with 244930 Manifold for streaming
244910 EnDureValve for extruding/streaming higher flow/higher viscosity sealants
Regulator-type Fluid Module
AIR
Power
Control Unit with TouchScreen Interface (knife disconnect switch shown)
Process Fluid from Feed Pumps
Feed Hose
Robot Analog
Robot Digital
Operation Cable
Gun
TI1416A
Air Signals

Installation
12 309374
Installation
Overview
The basic steps to install a Graco PrecisionFlo XL system are shown below. See the separate component manuals
listed for detailed information.
Installation Steps Manual
1. Mount XL control unit
2. Ground XL control unit.
309374, pg. 13
pg. 15
3. Mount fluid plate. 309375
4. Mount applicator.
5. Ground applicator.
*
6. Connect cables between the XL control unit and: 309364
–plus –
a. Junction box of the fluid module(s). 309375
b. Robot or cell controller. 309374, pg. 16
309364
c. Swirl Orbiters (if installed). 310558
d. Metering valve with linear motor (if installed). 309384
7. Check ground continuity. 309374, pg. 17
8. Connect air and fluid lines. 309374, pg. 18
a. Connect fluid lines between fluid module(s) and applicator(s). Connect fluid supply
line (and air if needed) to module.
309375
*
b. Connect other fluid and air lines to additional system components as instructed in
their manuals.
*
9. Connect control unit to power source. 309374, pg. 19
* A number 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 com-
ponent requirements.
Electrical schematics are in manual 309364. A copy
of control schematics is inside the control enclo-
sure.
Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.
Use the Graco PrecisionFlo XL control unit only
with the PrecisionFlo XL fluid module.

Installation
309374 13
Mounting Control Unit
WARNING
ELECTROCUTION HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury. Have only qualified electricians access the
control unit enclosure.
WARNING
EQUIPMENT MISUSE HAZARD
The PrecisionFlo XL control unit weighs
approximately 110 lbs (50 kg) and
should never be moved or lifted by one
person. Use adequate personnel and support
devices when mounting, moving, or handling the
control unit to prevent equipment damage or per-
sonal injury.
If your PrecisionFlo XL is equipped with integrated
temperature-conditioning, it is on a floor stand
frame. Bolt this stand securely to the floor to avoid
tipping.
1. Select a location for the PrecisionFlo XL control
unit that allows adequate space for installation,
service, and use of the equipment. See Fig. 2. If
you are using the remote display and the
Precision-Flo XL control unit witll be mounted
away from the operator, the robot controller must
be wired to the “Remote Start”and “Remote Stop”
functions. These are normally controlled by the
push buttons on the PrecisionFlo XL control unit.
See pages 89 and 94.
Mount the control unit so that the disconnect
handle is readily accessible and located
54–67 in. (1.4–1.7 m) above the floor.
For best viewing, the control display should be
60–64 in. (1.5–1.6 m) from the floor.
Ensure all fluid lines, cables, and hoses easily
reach the components they will be connected
to.
Ensure there is sufficient clearance around the
control unit to run fluid lines and cables to other
components.
Ensure there is safe and easy access to an
appropriate electrical power source. The Na-
tional 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 at-
tached to it.
2. Secure the PrecisionFlo XL control unit with four
3/8 in. bolts through the 0.44 in. (11 mm) diameter
holes in the mounting tabs.
Fi
g
. 2
28.5”
724 mm
31.5”
800 mm
24”
610 mm
22.5”
572 mm
Control Unit
Back View
20”
508 mm
18.5”
470 mm
16”
406 mm
17.5”
445 mm
Remote Display
Back View

Installation
14 309374
Temperature Control Packages
See page 136 for additional information on the optional Temperature Control Package.
Temperature-Conditioned Package
Fig. 3 TI1484A
72”
1.83 m
24”
610 mm
36”
914 mm
Heat Only
26”
660 mm
Heat/Cool
Temperature conditioned units are free-standing but
must be bolted to the floor.
Electric Heat Package
Fig. 4 TI1484A
60.5”
1.54 m
24.5”
622 mm
12.8”
325 mm
Electric heat units have the two control boxes inte-
grated onto a subframe. The frame assembly must be
mounted with the electrical disconnect 54-67”(1.4-1.7
m) from the floor.

Installation
309374 15
Electrical Connections
Follow these precautions when grounding, connecting
cables, connecting to a power source or making other
electrical connections.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of fire, explosion, or
electric shock:
The PrecisionFlo XL control unit must
be electrically connected to a true
earth ground; the ground in the electri-
cal system may not be sufficient.
All wires used for grounding must be
12 AWG minimum.
A qualified electrician must complete all ground-
ing and wiring connections.
Refer to your local code for the requirements for
a “true earth ground”in your area.
Also read and follow the warnings on pages
3–5.
CAUTION
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
Grounding Control Unit
CAUTION
To avoid control voltage differences, ensure that the
robot and PrecisionFlo XL equipment are grounded
to the same point.
Connect a ground wire from the ground point in the
PrecisionFlo XL control enclosure to a true earth
ground. See Fig. 5. A 10 AWG, 25 ft. (7.6 m) long
ground wire with clamp, Part No. 222011, is supplied.
NOTE: The PrecisionFlo XL fluid module is grounded
to the control unit, using cables provided with the mod-
ule.
Fig. 5
Ground
Terminal

Installation
16 309374
Connecting Cables
Fig. 6
Robot I/O
(digital & analog cables
or network cable)
Robot
Controller
PrecisionFlo XL
Control Unit
Swirl Cable(s)
(optional)
Motor Power
(linear motor only)
Operations Cable(s)
CAUTION
Route cables carefully. Avoid pinching and premature
wear due to excessive flexing or rubbing. Cable life is
directly related to how well they are supported.
NOTE: See page 128 for cable part numbers and
lengths. Descriptions of the cables follow steps 1–3,
below.
Connect the cables as instructed below.
1. Connect digital and analog cables or a network
cable from the robot/cell controller to the Precision-
Flo XL control unit.
2. Connect the operation cable(s) from the fluid
module(s) to the mating connectors on the Preci-
sionFlo XL.
3. Connect cables from any installed options to the
appropriate connectors on the PrecisionFlo XL.
(See the instruction forms associated with those
options for detailed information.)
NOTE: Digital and analog cables are not terminated
on the robot end. The installer will need to configure
the proper connectors for the robot/cell controller being
used. Refer to PrecisionFlo XL I/O Interface on page
89 and also on form 309364 for schematics.
Interface Cables
Digital and Analog Cables —If your model is config-
ured with discrete I/O, digital and analog robot I/O
cables were likely supplied as part of your package.
The Digital cable is larger than the analog cable and it
communicates I/O commands between the Precision-
Flo XL and a robot or cell controller. The Analog cable
communicates speed commands between the control-
lers.
Network Cable —If Network I/O is used, one network
cable communicates both the robot digital I/O and
analog speed commands between the PrecisionFlo XL
and a robot or cell controller. This cable is not supplied
by Graco.

Installation
309374 17
Fluid Module Cables
Operations Cable —This cable carries signals be-
tween the fluid module(s) and PrecisionFlo XL. The
applicator solenoid, V/P valve, pressure transducer
and flow meter signals are carried through this cable.
There is one cable per fluid module.
Motor Power Cable —This cable supplies power to
the linear motor (when used) from the PrecisionFlo XL.
The motor requires a higher DC voltage signal that
cannot be combined with signals in the Operations
Cable.
Swirl Cable —This cable connects between the
PrecisionFlo XL and the PrecisionSwirl extension cable
if a PrecisionSwirl Orbiter is installed. The cable pro-
vides power to the orbiter and carries orbiter speed
information back to the PrecisionFlo XL.
Fig. 7
5
4
13 17
18
Control Unit –Top View TI1555A
Ref No. Description
ÁÁÁÁ
ÁÁÁÁ
4
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
External Interface Cable (Robot Digital)
ÁÁÁÁ
ÁÁÁÁ
5
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
External Interface Cable (Robot Analog)
ÁÁÁÁ
13
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Operations Cable Connector
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
–
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Motor Power Cable Connector (not on this
configuration)
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
17
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Remote Display Connector/Ethernet
Connection (TouchScreen option only)
ÁÁÁÁ
18
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Swirl Cable Connector (optional)
Checking Ground
Continuity
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
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.
Have a qualified electrician check the resistance
between:
true earth ground and the panel ground lug
the application device and the robot
the fluid module and the robot
the metering valve and the robot
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.

Installation
18 309374
Connecting Fluid and
Air Lines
CAUTION
Route all fluid and air lines carefully. Avoid pinching
and premature wear due to excessive flexing or rub-
bing. Hose life is directly related to how well they are
supported.
Follow the instructions in your separate component
manuals to connect air and fluid lines. General guide-
lines are provided below.
The PrecisionFlo XL fluid module should be
installed on the robot 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.
If you are using two fluid control plates and two
guns, be sure each device is clearly labeled 1 or 2.
Connect a fluid line to the flow meter fluid inlet or
regulator inlet if your system does not have a flow
meter.
If using a remote mount coriolis-type flow meter:
–The flow meter must be mounted stationary. It
cannot move on the robot.
–Connect a fluid line from the flow meter to the
regulator inlet. The hose should be as short as
practical.
–Connect 120 VAC power to the flow meter.
–Connect the meter signal to the fluid module.
Connect an air supply line to the 1/4 npt inlet port
on the fluid module(s) air supply inlet.
Connect 4 mm or 5/32 in. OD air lines from the
applicator’s solenoid valve to the applicator.

Installation
309374 19
Connecting to Power
Source
WARNING
ELECTRIC SHOCK HAZARD
Do not connect the PrecisionFlo XL con-
trol unit to a power source unless you
are a trained electrician.
Have a qualified electrician connect the PrecisionFlo
XL control assembly to a grounded electrical source
that has the required service ratings, as shown in the
Power Requirement tables below.
To connect control unit to power source:
1. Remove a hole plug to use one of the pre-cut
enclosure holes or, if necessary for your installa-
tion, 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 electri-
cal power to the disconnect inside the control
enclosure.
3. Use NEMA 4 cord grip to seal the area where
wires enter the enclosure.
Power Requirements:
Without Heat or Temp. Conditioning
Option G–N
VAC: 90 –120 200 –240* 400 –480*
Phase: 1 1 1
Hz: 50/60 50/60 50/60
Full Load
Amps.
8 4.2 2.1
* When ordered with transformer
With Temperature Conditioning
Option G–1 (50 Hz) Heat/Cool
VAC: N/A 200 –240 400 –480
Phase: N/A 1 1
Hz: N/A 50 50
Full Load
Amps.
N/A 25.1 12.6
With Temperature Conditioning
Option G–2 (50 Hz) Heat Only
VAC: N/A 200 –240 400 –480
Phase: N/A 1 1
Hz: N/A 50 50
Full Load
Amps.
N/A 18.8 9.5
With Temperature Conditioning
Option G–3 (60 Hz) Heat/Cool
VAC: N/A 200 –240 400 –480
Phase: N/A 1 1
Hz: N/A 60 60
Full Load
Amps.
N/A 25.1 12.6
With Temperature Conditioning
Option G–4 (60 Hz) Heat Only
VAC: N/A 200 –240 400 –480
Phase: N/A 1 1
Hz: N/A 60 60
Full Load
Amps.
N/A 18.8 9.5
With Electric Heat
Option G–5
VAC: N/A 200 –240 400 –480
Phase: N/A 1 1
Hz: N/A 50/60 50/60
Full Load
Amps.
N/A 18.8 9.5

Operation
20 309374
Operation
Pressure Relief Procedure
WARNING
The PrecisionFlo XL module pressure
must be manually relieved to prevent the
module from starting or spraying acciden-
tally. To reduce the risk of serious injury,
including fluid injection, splashing in the eyes or on
the skin, or injury from moving parts, always follow
the Pressure Relief Procedure whenever you:
are instructed to relieve the pressure
check, adjust, or service any of the system
equipment
shut off the pump or dispense device
or install or clean the spray tip
This procedure describes how to relieve pressure for
the PrecisionFlo XL system.
1. Shut off the fluid supply to the fluid module.
2. Shut off power and air to the fluid supply systems.
3. Place a waste container beneath the fluid drain
valve, which is located at the filter. Place a waste
container beneath the dispense device.
4. Slowly open the drain valve, located at each filter,
to relieve fluid pressure. Close valve when pres-
sure gauge reads zero.
5. In manual dispense mode, touch and hold the Dis-
pense Gun 1 key , which will open the regulator
and the dispensing device, until the fluid stops
flowing from them. Repeat for Gun 2 if installed.
Refer to page 25 for procedures on dispensing in
manual mode.
6. If the dispense device cannot be actuated from the
control unit, refer to Fig. 8 and perform the follow-
ing 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.
b. Continue actuating the plunger until all pres-
sure is purged from the system between the
needle and the dispense device before pro-
ceeding to the next step.
Fi
g
. 8
Dispense Valve
Air Solenoid
To Dispense
Valve
Manual
Actuator
TI1422A
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 re-
move 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.
Safety Reminder
Follow the precautions below and the warnings that
begin on page 3.
WARNING
FLUID INJECTION HAZARD
Wear eye protection and protective
clothing when installing, operating, or
servicing the system.
COMPONENT RUPTURE HAZARD
Never exceed the maximum air or fluid
working pressure rating of the lowest
rated component in the system.
Do not pressurize the system or dispense until you
have verified the system is ready and it is safe to
do so.
Ensure all hose connections are secure.
MOVING PARTS HAZARD
Ensure all personnel are clear of moving
parts before operating equipment.