Graco PCF User manual

3A2098A
Instructions - Parts
PCF
Precision Dispense System
Electronically-controlled fluid metering system that provides precise continuous flow of up
to four single-component sealants and adhesives through closed-loop technology.
Not for use in explosive atmospheres or hazardous locations.
For professional use only.
See page 4 for model information. See page 5 for
maximum working pressure and approvals.
IMPORTANT:
This manual does not apply to some PCF sys-
tems. See note on page 3 to verify this is the
correct manual for your PCF system.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
EN

23A2098A
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fluid Plate Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gateway Assemblies . . . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Configurations . . . . . . . . . . . . . . . . . . . . . . 8
Typical Ambient System Installation . . . . . . . . . . 8
Typical Heated System Installation . . . . . . . . . . . 9
Typical Multiple Fluid Plate System Installation . 10
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Overview . . . . . . . . . . . . . . . . . . . . . . . 11
System Components . . . . . . . . . . . . . . . . . . . . . 11
Fluid Plate Assembly Overview . . . . . . . . . . . . . 12
Control Center Assembly Overview . . . . . . . . . 14
Key Tokens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Before Installation . . . . . . . . . . . . . . . . . . . . . . . 18
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install Control Center . . . . . . . . . . . . . . . . . . . . 19
Install Fluid Plate Assemblies . . . . . . . . . . . . . . 21
Install Cable Assemblies . . . . . . . . . . . . . . . . . . 25
Install Gateway Module Interface . . . . . . . . . . . 26
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Configure System . . . . . . . . . . . . . . . . . . . . . . . 29
Configure Control Settings . . . . . . . . . . . . . . . . 30
Configure Mode Settings . . . . . . . . . . . . . . . . . 31
Configure Delay Settings . . . . . . . . . . . . . . . . . 32
Configure Flow Meter Settings . . . . . . . . . . . . . 32
Configure Pressure Loop Settings . . . . . . . . . . 33
Adjust Pressure Sensors . . . . . . . . . . . . . . . . . 33
Configure Errors . . . . . . . . . . . . . . . . . . . . . . . . 34
Setup Maintenance Schedule/Parameters . . . . 34
Configure Gateway Settings . . . . . . . . . . . . . . . 35
Setup Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Configure Advanced Settings . . . . . . . . . . . . . . 35
On/Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Load Material . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Maintenance Mode Operation . . . . . . . . . . . . . . 38
Automation Control (Normal Operation) . . . . . . 41
Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Typical Job Cycle . . . . . . . . . . . . . . . . . . . . . . . 43
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 49
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
USB Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
System Configuration Settings File . . . . . . . . . . 52
Custom Language File . . . . . . . . . . . . . . . . . . . 52
Download Procedure . . . . . . . . . . . . . . . . . . . . . 53
Upload Procedure . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fluid Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fluid Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 55
Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . 56
Gateway Module . . . . . . . . . . . . . . . . . . . . . . . . 57
LED Diagnostic Information . . . . . . . . . . . . . . . . 57
Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
View Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Diagnose Errors . . . . . . . . . . . . . . . . . . . . . . . . . 58
Event and Error Codes and Troubleshooting . . . 59
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Maintenance Schedule . . . . . . . . . . . . . . . . . . . 66
Advanced Display Module (ADM) . . . . . . . . . . . 67
Upgrade Gateway Module Software . . . . . . . . . 67
Upgrade Gateway Module Fieldbus Map . . . . . . 68
Upgrade Fluid Control Module (FCM) Software 69
Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . 69
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fluid Plate Assembly . . . . . . . . . . . . . . . . . . . . . 70
Control Center Assembly . . . . . . . . . . . . . . . . . . 78
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Control Center Assembly Parts . . . . . . . . . . . . . 82
Fluid Plate Assembly Parts . . . . . . . . . . . . . . . . 84
Appendix A - Advanced Display Module (ADM) . 89
Display Overview . . . . . . . . . . . . . . . . . . . . . . . . 89
Display Details . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Appendix B - Discrete Gateway Module (DGM)
Connection Details . . . . . . . . . . . . . . . . . . . . 104
D-Sub Cable 123793 . . . . . . . . . . . . . . . . . . . . 104
D-Sub Cable 123792 and Breakout Board 123783
105
DGM Digital Input . . . . . . . . . . . . . . . . . . . . . . 108
DGM Digital Outputs . . . . . . . . . . . . . . . . . . . . 109
DGM Analog Inputs . . . . . . . . . . . . . . . . . . . . . 110
DGM Analog Outputs . . . . . . . . . . . . . . . . . . . 110

Related Manuals
3A2098A 3
Appendix C - Communications Gateway Module
(CGM) Connection Details . . . . . . . . . . . . . . 111
Install Fieldbus Connections . . . . . . . . . . . . . . 111
CGM I/O Data Map . . . . . . . . . . . . . . . . . . . . . 114
Appendix D - I/O Signal Descriptions . . . . . . . . 120
Automation Inputs . . . . . . . . . . . . . . . . . . . . . . 120
Automation Outputs . . . . . . . . . . . . . . . . . . . . . 121
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Fluid Plate Assembly Technical Data . . . . . . . 123
Control Center Assembly Technical Data . . . . 123
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 124
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 124
Related Manuals
The following is a list of component manuals written in
English. These manuals and any available translations
can be found at www.graco.com.
NOTE: In the Advanced screens on your system, if
the Advanced Display software part number shown
is 16F528 then this manual does not apply to your
system; refer to manual 313377 for your system.
Otherwise, the part number shown should be
16K405 and you should use this manual.
Manual Description
313377 Original PCF Instructions - Parts
(see the note below)
307517 Mastic Fluid Regulators Instruc-
tions-Parts
308647 Fluid Pressure Regulators Instruc-
tions-Parts
309834 Helical Gear Fluid Flow Meters Instruc-
tions-Parts
ADM Software Part No. 16F528
(see manual 313377)
ADM Software Part No. 16K405
(use this manual)
✓
✖

Models
43A2098A
Models
Check the identification (ID) plate for the 6-digit part number of the fluid metering system. Use the following matrix to
define the construction of the system, based on the six digits. For example, Part PF1110 represents a PCF fluid
metering system (PF), a two style system (1), a fluid plate with a cartridge regulator and no meter (1), a DeviceNet™
user interface (1) with a 100-240 Vac power supply (0).
NOTE: To order replacement parts, see Parts section in this manual. The digits in the matrix do not corre-
spond to the Ref. Nos. in the Parts drawings and lists.
◆Discrete Gateway systems do not include automation interface cables. The following Graco accessories are avail-
able for wiring to the automation system. Installers should follow Appendix B - Discrete Gateway Module (DGM)
Connection Details, page 104, for custom wiring.
For single fluid plate systems only: 50 ft (15 m) cable with flying leads (123793)
All systems: Breakout board (123783) and 50 ft (15 m) cable (123792)
❄These fluid metering systems have ETL certification.
NOTE: Fluid metering systems with heated mastic regulators are not ETL certified.
This product has been tested to the requirements of CAN/CSA-C22.2 No. 61010-1, second edition, including Amend-
ment 1, or a later version of the same standard incorporating the same level of testing requirements.
PF 1 110
First and
Second Digits
Third Digit Fourth Digit Fifth Digit Sixth Digit
Style/Size Fluid Plate User Interface Voltage
Description Regulator Meter Description Description
PF
(Precision
Continuous
Flow)
12 Styles 1❄Cartridge None 0◆Discrete 0100 - 240 Vac
216 Styles 2❄Mastic None 1DeviceNet™124 Vdc
3256 Styles 3❄Cartridge High
Resolution
2EtherNet/IP™
4❄Mastic High
Resolution
3PROFIBUS™
5Heated
Mastic
Heated
Standard
Resolution
4PROFINET™
6Heated
Mastic
None
7❄Cartridge Ultra High
Resolution
9902471
Certified to CAN/CSA C22.2 No. 61010-1
Conforms to
UL 61010-1
C
1

Models
3A2098A 5
Fluid Plate Kits
NOTE: The fluid plate kit numbers listed below include a CAN splitter. The fluid plate assembly included in
each PFxxxx assembly does not include a CAN splitter.
Fluid
Plate Kit
Used by
Model Maximum Working
Pressure Description
Includes:
Regula-
tor
Flow
Meter
FCM Key
Token
24B958 PF13xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, High Resolution Flow
Meter, 2 styles 244734 246652 16M100
24B959 PF11xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, No Flow Meter,
2styles 244734 --- 16M101
24B960 PF14xx 5000 psi
(35 MPa, 345 bar)
Mastic Regulator, High Resolution Flow
Meter, 2 styles 246642 246652 16M100
24B961 PF12xx 5000 psi
(35 MPa, 345 bar) Mastic Regulator, No Flow Meter, 2 styles 246642 --- 16M101
24B962 PF15xx 5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, Standard Resolu-
tion Heated Flow Meter, 2 styles 246643 246340 16M100
24C901 PF16xx 5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, No Flow Meter,
2styles 246643 --- 16M101
24J873 PF17xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, Ultra High Resolution
Flow Meter, 2 styles 244734 16E993 16M100
24K801 PF23xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, High Resolution Flow
Meter, 16 styles 244734 246652 16M102
24K802 PF21xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, No Flow Meter,
16 styles 244734 --- 16M103
24K803 PF24xx 5000 psi
(35 MPa, 345 bar)
Mastic Regulator, High Resolution Flow
Meter, 16 styles 246642 246652 16M102
24K804 PF22xx 5000 psi
(35 MPa, 345 bar) Mastic Regulator, No Flow Meter, 16 styles 246642 --- 16M103
24K805 PF25xx 5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, Standard Resolu-
tion Heated Flow Meter, 16 styles 246643 246340 16M102
24K806 PF26xx 5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, No Flow Meter,
16 styles 246643 --- 16M103
24K807 PF27xx 6000 psi
(41.4 MPa, 414 bar)
Cartridge Regulator, Ultra High Resolution
Flow Meter, 16 styles 244734 16E993 16M102
24K808 PF33xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, High Resolution Flow
Meter, 256 styles 244734 246652 16M104
24K809 PF31xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, No Flow Meter,
256 styles 244734 --- 16M105
24K810 PF34xx 5000 psi
(35 MPa, 345 bar)
Mastic Regulator, High Resolution Flow
Meter, 256 styles 246642 246652 16M104
24K811 PF32xx 5000 psi
(35 MPa, 345 bar)
Mastic Regulator, No Flow Meter,
256 styles 246642 --- 16M105
24K812 PF35xx 5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, Standard Resolu-
tion Heated Flow Meter, 256 styles 246643 246340 16M104
24K813 PF36xx 5000 psi
(35 MPa, 345 bar)
Heated Mastic Regulator, No Flow Meter,
256 styles 246643 --- 16M105
24K814 PF37xx 6000 psi
(41 MPa, 414 bar)
Cartridge Regulator, Ultra High Resolution
Flow Meter, 256 styles 244734 16E993 16M104

Warnings
63A2098A
Gateway Assemblies
Each user interface comes with a gateway assembly. If
you need to order a replacement gateway, see the fol-
lowing table.
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
PCF Model
User Interface
Description
Gateway Part Number To
Order
PFxx0x Discrete 24B681
PFxx1x DeviceNet™15V759
PFxx2x EtherNet/IP™15V760
PFxx3x PROFIBUS™15V761
PFxx4x PROFINET™15V762
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Engage trigger lock when not dispensing.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
•FollowthePressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately

Warnings
3A2098A 7
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhala-
tion of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
WARNING

System Configurations
83A2098A
System Configurations
Typical Ambient System Installation
Key:
A *Control Center (User Interface)
B *Fluid Plate Assembly
C Applicator/Dispense Valve
D Sealer Automation
E Automation Interface Cable
F *CAN Cable
G Fluid Supply System
H Fluid Supply Hose
J Automation Controller
K *Air Filter Assembly
* Included
FIG. 1: Typical Ambient System Installation
G
D
C
B*
F*
A*
E
H
J
K*
Power In
Air Supply
Drop Site

System Configurations
3A2098A 9
Typical Heated System Installation
Key:
AA *Control Center (User Interface)
AB *Fluid Plate Assembly
AC Applicator/Dispense Valve
AD Sealer Automation
AE Automation Interface Cable
AF *CAN Cable
AG Heated Fluid Supply System
AH Fluid Supply Hose
AJ Heat Control
AK Automation Controller
AL *Air Filter Assembly
AM RTD Cable
AN Power Supply to Heated Components
* Included
FIG. 2: Typical Heated System Installation
AD
AC
AB*
AJ
AF*
AA*
AE
AH
AK
AM
AG
AL*
AN
Power In
Air Supply
Drop Site
AN

System Configurations
10 3A2098A
Typical Multiple Fluid Plate System Installation
Key:
A *Control Center (User Interface)
B *Fluid Plate Assembly
C Applicator/Dispense Valve
D Sealer Automation
E Automation Interface Cable
F *CAN Cable
G Fluid Supply System
H Fluid Supply Hose
J Automation Controller
K *Air Filter Assembly
* Included
FIG. 3: Typical Multiple Fluid Plate System Installation
J
Air Supply
Drop Site
K*
HPower In
A
E
F*
F*
F*
F*
B*
B*
B*
B*
DC
DC
DC
DC
H
H
H
G
G
G
G
F*

Overview
3A2098A 11
Overview
System Overview
The PCF fluid metering system combines closed-loop
pressure control with the ability to change bead profiles
quickly. When used with an optional flow meter, the sys-
tem automatically adjusts for fluctuations in the operat-
ing environment, such as material viscosity,
temperature, tip wear, and automation speed, while
maintaining the desired dispense rate. The module
responds to automation signals to provide an accurate
and consistent output flow based on a comparison of
actual to desired flow rates.
Typical Applications
• Bead dispensing
•Gasketing
• Seam sealing
• Hem flange
• Sound deadening
• Anti-flutter
• Body panel reinforcement
• Profile wrapping
• Cable filling
System Components
The diagram in FIG. 4 shows an example of the PCF
module and cables.
Control Center (User Interface)
The control center communicates with the PCF fluid
plate assembly to control fluid pressure and dispense
valve operation.
The control center receives input from the automation
controller, and uses these inputs to determine communi-
cation to the fluid plate assembly.
Fluid Plate Assembly
The fluid plate assembly contains components that con-
trol and monitor fluid dispensing. A PCF fluid metering
system can have up to four fluid plates. Each fluid plate
can control up to four dispense valves. The system sup-
ports up to 16 dispense valves and can simultaneously
dispense from up to 10 dispense valves.
FIG. 4: PCF System Components
System shown with one fluid plate
Control Center
(User Interface)
Fluid Plate Assembly

Overview
12 3A2098A
Fluid Plate Assembly Overview
Fluid Plate Components
The fluid plate assembly in FIG. 5 can be attached to an
automation arm or mounted on a pedestal. The main
components of the fluid plate assembly include:
•Fluid regulator (cartridge, ambient mastic, or heated
mastic) (P).
•Flow meter (R) (optional) precisely measures the
flow rate of fluid dispensed.
•Solenoid air valve (S) controls the dispense valve.
•Voltage to Pressure Transducer (T), abbreviated V/P
transducer, adjusts the air pressure to the fluid regu-
lator (P).
•Fluid Control Module (FCM) (U) receives pulse read-
ings from the flow meter (R) and pressure readings
from the regulator. It also controls the fluid regulator
(P) and solenoid air valve (S).
The PCF fluid regulator is electrically controlled by the
PCF fluid control module. Consistent material flow is
assured by a closed-loop pressure or closed-loop flow
control design. The module responds to automa-
tion-supplied signals to provide an accurate and consis-
tent output flow based on a comparison of actual to
desired flow rates. The fluid 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.
The fluid plate assembly is available in two versions:
ambient and heated.
Ambient Fluid Plate Assembly
There are four ambient versions available:
• cartridge regulator without a flow meter;
• ambient mastic regulator without a flow meter;
• cartridge regulator with a high resolution meter;
• ambient mastic regulator with a high resolution
meter;
• cartridge regulator with an ultra high resolution
flow meter.
Heated Fluid Plate Assembly
There are two heated versions available:
• heated mastic fluid regulator with a heated flow
meter,
• and a heated mastic fluid regulator without a
flow meter.
FIG. 5: Fluid Plate Components
U
R
P
T
S

Overview
3A2098A 13
Fluid Regulator
There are three fluid regulator options:
•cartridge
• ambient mastic
• heated mastic
All of the fluid regulator options use air pressure to con-
trol fluid pressure, provide fast response to electronic
commands, and ensure a precisely controlled, continu-
ous flow of material.
Cartridge
The cartridge regulator (244734) is ideal for low to
medium viscosity sealants and adhesives.
Ambient Mastic
The ambient mastic regulator (246642) is ideal for
medium to high viscosity sealants and adhesives.
Heated Mastic
The heated mastic regulator (246643) is ideal for low to
high viscosity warm-melt and hot-melt sealants or adhe-
sives.
Fluid Control Module (FCM)
Rotary Switch on FCM
The rotary switch on the FCM, see FIG. 6, must be set to
a valid position and each FCM must have a unique
rotary switch position. The FCM rotary switch position
determines which number to assign to that fluid plate.
The settings, including defined styles, for each fluid
plate are stored in each FCM so changing the rotary
switch position causes the settings to be shown under
the new number on the ADM.
NOTE: See LED Diagnostic Information, page 57, for
signal definitions.
FIG. 6: FCM Sensor Connections
Table 1: FCM Sensor Connections
Connection Sensor Description
1 Dispense solenoid
2Flowmeter
3 Outlet pressure sensor (heated systems only)
4 Voltage to Pressure (V/P) Transducer
5 Command cable (optional accessory kit)
6 Inlet pressure sensor (non-heated systems
only)
7 Outlet pressure sensor (non-heated systems
only)
CAN
Connectors
---
Item
Rotary Switch
Position
Fluid Plate 1 0 or 1
Fluid Plate 2 2
Fluid Plate 3 3
Fluid Plate 4 4
3
4
5
CAN
Connectors
67
Status
LEDs
12
Key
token
Rotary
Switch

Overview
14 3A2098A
Control Center Assembly Overview
The control center includes the following components:
• Advanced Display Module (ADM) with USB; see
page 15 for details.
• USB enables users to download job, event, and data
logs; save and restore system settings; and custom-
ize the language.
• 24 Vdc and 100-240 Vac customer-wired options
available.
• Gateway Module, which can be one of the following
five types:
•Discrete
• DeviceNet
• EtherNet/IP
•PROFIBUS
•PROFINET
FIG. 7: Control Center Components
Front View Side View
Open View
ADM
Gateway Module
(24 Vdc Assembly) (100-240 Vac Assembly)

Overview
3A2098A 15
Advanced Display Module (ADM)
KEY:
FIG. 8: Advanced Display Module Component Identification
TI12362a
BA
BB
BC
BE
BH
BG
BF
BD
r_24E451_3B9900_1a
BJ
BR
BP
BN
BM
BL
BK
BS
Callout Function
BA Power On/Off Button
Enables/disables system.
BB System Status Indicator LED
Displays system status. Green LED indicates the
system is active. Orange LED indicates the sys-
tem is off. Solid LEDs indicate the system is in
Run mode. Flashing LEDs indicate the system is
in Setup mode.
BC Stop Button
Stops all system processes. However, it is not a
safety or emergency stop.
BD Soft Keys
Functions vary depending on the screen.
BE Cancel Button
Clears system errors and cancels a selection or
number entry while in the process of entering a
number or making a selection.
BF Enter Button
Acknowledge changing a value or making a selec-
tion.
BG Lock/Setup
Toggle between run and setup screens. If setup
screens are password protected, button toggles
between run and password entry screens.
Callout Function
BH Navigation Buttons
Navigate within a screen or to a new screen.
BJ Flat Panel Mount
Mounts to control center bracket (optional).
BK Model Number Tag
Model number.
BL USB Module Interface
USB port and USB indicator LEDs.
BM CAN Connector
Power connection.
BN Module Status LEDs
See LED Diagnostic Information, page 57, for
signal definitions.
BP Battery Cover
BR Token Access Cover
BS Digital I/O Port for Light Tower
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.

Overview
16 3A2098A
Gateway Module
The Discrete Gateway Module (DGM) rotary switch must be in position 0 in order the for the DGM to operate.The
Communications Gateway Module (DGM) rotary switch can be in any position.
Key:
CA Gateway Module
CB Base
CC Fieldbus Connector (see Appendix C - Communi-
cations Gateway Module (CGM) Connection
Details, page 111, for more information)
CD Module Connection Screws
CE Access Cover
CF Module Status LEDs (see LED Diagnostic Infor-
mation, page 57)
CG D-Subminiature (D-Sub) Connector (see Appendix
B - Discrete Gateway Module (DGM) Connection
Details, page 104, for pinout details)
CH CAN Connectors
FIG. 9: Gateway Module Components
TI11814A TI11815A
TI11816A
CA
CD
Gateway Module Connectors Table
CB
PROFINET or EtherNet/IP DeviceNet
PROFIBUS
CE CF CH
Front Back
Discrete
CC
CG
CC
CC
See Gateway Module
Connector Table
Rotary
Switch
Software
Token Slot
Front
(Access Cover Removed)

Overview
3A2098A 17
Key Tokens
The ADM and FCM must each have a key token
installed in order to operate. If the incorrect key token is
installed, the module will not operate. The DGM does
not require a key token.
NOTE: There is one FCM located on each fluid plate.
If a new ADM or FCM is installed, follow the instructions
on page 67 to upgrade the software in the new module
and to install the key token from the old module in the
new module.
The following is a list of key token part numbers. If you
lose your key token be sure to order the correct item to
ensure proper system operation.
NOTE: The key tokens for the ADM and FCM look
alike but only work in one module or the other. If the
key tokens for the ADM and FCM become mixed,
locate the part number on each token then refer to
the following table to determine which module each
token applies to.
FIG. 10
Part Description
16M100 FCM Key Token, 2 styles, Flow Meter
16M101 FCM Key Token, 2 styles, No Flow Meter
16M102 FCM Key Token, 16 styles, Flow Meter
16M103 FCM Key Token, 16 styles, No Flow Meter
16M104 FCM Key Token, 256 styles, Flow Meter
16M105 FCM Key Token, 256 styles, No Flow
Meter
16M217 ADM Key Token, Standard PCF
FCMADM

Installation
18 3A2098A
Installation
Before Installation
•Have all system and component documentation
available during installation.
•See component manuals for specific data on compo-
nent requirements. Data presented here applies to
the PCF assemblies only.
•Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.
•Use the PCF control center only with the PCF fluid
plate assembly.
Overview
The basic steps to install a PCF system are shown
below. See the separate component manuals for
detailed information.
Installation Steps
1. Mount control center, page 19.
2. Connect and ground control center, page 20.
3. Mount fluid plate assembly, page 21.
4. Ground fluid plate assembly, page 24.
5. Check ground continuity.
6. Connect fluid lines between fluid plate and applica-
tor. Connect fluid supply line and air supply to mod-
ule. See page 24.
7. Plumb air filter assembly near air supply drop site
that will be used for fluid plate assembly.
8. Connect other fluid and air lines to additional system
components as instructed in their manuals.
9. Install cable assemblies, page 25.
10. Install Gateway interface, page 26.
NOTICE
To avoid damaging the PCF system, use at least two
people to lift, move, or disconnect the system. The
system is too heavy for one person to lift or move.

Installation
3A2098A 19
Install Control Center
Mount
Ensure the following criteria are met before mounting
the PCF control center:
• Select a location for the control center that allows
adequate space for installation, service, and use of
the equipment.
• For best viewing, the ADM should be 60-64 in.
(152-163 cm) from the floor.
• Ensure there is sufficient clearance around the con-
trol unit to run cables to other components.
• Ensure there is safe and easy access to an appro-
priate electrical power source. The National Electric
Code requires 3 ft (0.91 m) of open space in front of
the control center.
• Ensure there is easy access to the power switch.
• Ensure the mounting surface can support the weight
of the control center and the cables attached to it.
Secure the control center with appropriate size bolts
through the 0.27 in. (7 mm) diameter holes in the mount-
ing tabs. See the mounting dimensions in Table 2 and
FIG. 11.
Table 2: Control Center Assembly Measurement
A10.50 in. (267 mm)
B5.75 in. (146 mm)
C17.00 in. (432 mm)
D16.25 in. (413 mm)
FIG. 11: Control Center Dimensions
A
B
CD

Installation
20 3A2098A
Electrical Connections
Connect Light Tower Accessory
1. Order the 255468 Light Tower Accessory as a diag-
nostic indicator for the PCF system.
2. Connect the cable from the light tower to the digital
I/O port (BS) on the ADM.
See Table 3 for a description of light tower signals.
NOTE: See Errors, page 58, for error definitions.
To reduce the risk of fire, explosion, or electric shock,
follow these precautions when grounding, connecting
cables, connecting to a power source or making other
electrical connections:
•The control center 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 min-
imum.
•A qualified electrician must complete all grounding
and wiring connections.
•For 24 Vdc wiring refer to FIG. 12.
•For 100-240 Vac wiring refer to FIG. 13.
•Incoming power wiring must be guarded from the
enclosure. Use a protective grommet where the
power wiring enters the enclosure to prevent wear.
•Refer to your local code for the requirements for a
“true earth ground” in your area.
NOTICE
If power and grounding connections are not done
properly, the equipment will be damaged and the
warranty voided.
FIG. 12: 24 Vdc Wiring
+
-
Ground
FIG. 13: 100-240 Vac Wiring
Table 3: Light Tower Signals
Signal Description
Green No errors.
Yellow An advisory exists.
Yellow flashing A deviation exists.
Red solid An alarm exists. One or more fluid
plates may be shutdown.
Ground
N
L