PVA PVA2000, System Manual

Page 1: ...ation for schematics custom equipment documentation etc To view these documents click the link to the specified topic If the topic is located on an external document there will be a button to access these documents When you click the button Adobe may display a confirmation message asking if you want to launch the application used to view the document Select All and a list of available documents on...

Page 2: ...se this media whether claimed under this agreement or otherwise Nondisclosure The documents in this media terms pricing and all information identified as confidential under this Agreement are considered confidential information Confidential Information Confidential Information shall not include information that a becomes part of the public domain without breach of this Agreement by Customer b has ...

Page 3: ...684 15 SOLAR DRIVE HALFMOON NY 12065 PHONE 518 371 2684 FAX 518 371 2684 All Rights Reserved Copyright c 2003 Precision Valve Automation Inc Coating and Dispensing System Manual PVA2000 PVA3000 PVA2000C PVA750 PVA550 PVA250 ...

Page 4: ...Automated Dispensing System 15 Solar Drive Halfmoon NY 12065 PVA250 P N SNGT1133 S N W1948 Singletec Inc TM Operating Guide ...

Page 5: ...Configuration Operation and Maintenance Manual PathMaster Manual Cut Sheets Schematics Software Table Of Contents 1 2 3 4 5 6 ...

Page 6: ...Configuration Operation and Maintenance Manual PathMaster Manual Cut Sheets Schematics Software Configuration 1 ...

Page 7: ...cifics Serial Number Program Revision PathMaster Version Date of Ship Power Requirements Electrical Rating Interrupting Capacity Pressure Settings Table 1 Pressure Settings Regulator Description Setting Valve Nomenclature Table 2 Valve Nomenclature Head Name Description Z slide Rotary W1948 3 04 2 3 49 3 05 120 Vac 60 Hz 5 Amps 10 kA REG 1 Main air pressure 90 P S I 10 P S I REG 2 Pump Air Motor P...

Page 8: ...Optional Equipment Documentation on non Standard equipment installed on the workcell is included with this manual To view these documents click the button below Select Optional Equipment ...

Page 9: ...Notes ...

Page 10: ...Configuration Operation and Maintenance Manual PathMaster Manual Cut Sheets Schematics Software Operation and Maintenance 2 ...

Page 11: ...he workcell 6040 In situations where inattention could cause either personal injury or damage to equipment a warning notice is used 6014 Do not smoke near the workcell Always have a fire extinguisher available for emergency use 6019 Before operating the system read and understand the manuals provided with the unit 6017 Before performing any repairs or maintenance to the system turn off power and l...

Page 12: ...he unit Service should only be performed by a qualified individual 6018 Exercise caution when pressurized vessels are present Identify and repair any leaks immediately Always wear appropriate safety equipment when working with pressurized vessels or vessels containing chemicals 6054 Laser light source present Do not stare directly into the beam Do not use in the presence of highly reflective surfa...

Page 13: ...es subsequently made Precision Valve Automation Inc makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply This document including the information contained herein is the property of...

Page 14: ... or may have additions If the manual refers to an option that was not purchased ignore that section If options exist on the machine not mentioned in this manual please consult the Optional Equipment section of the Operating Guide for more information on these additions Revisions to This Manual The following list describes the major revisions in this manual Rev M ii 4 03 as compared to the previous...

Page 15: ...n sequences and modes of operation Troubleshooting Provides a guide to troubleshooting the workcell A fault diagnosis table is used to lead the operator through common problems and solutions Several troubleshooting procedures are described Maintenance Provides a preventive maintenance schedule and replacement procedures Appendix A Definitions Definitions for commonly used terms Appendix B Serial C...

Page 16: ...dling Transportation and Storage 11 Handling and Transportation 11 Storage 11 Installation and Setup 12 Unpacking and Inspection 12 Installation 12 Operating Environment 13 Location 13 Temperature and Humidity 13 Dip Switch Settings 13 Operator Interface Dip Switch Settings 14 Software 14 Main program file 14 PathMaster 14 Project File 14 Machine Communications 14 SMEMA 14 Operating Safety 16 Noti...

Page 17: ...Needle Calibration 24 Standard 25 Operator Defined 25 Sensor Defined 25 Manual Mode 26 Valve Selection 27 Automatic Mode 27 Status Mode 28 Status Sequence 28 Setup Mode 29 Conveyor Control 29 Trackball Control 30 Teach Pendant 31 OIT Jog Control 31 Fault Recovery 33 Recovering from Emergency Stop and Other Machine Errors 33 Pneumatic Error Recovery Procedure 34 Run Time Error Recovery Procedure 35...

Page 18: ... Fan Setup 51 Pressure Differential Switch Setup 51 Appendix A Definitions 52 Appendix B Serial Communication 54 Serial Communication 54 Overview 54 9 Pin Serial Connector 54 25 Pin Serial Connector 54 Computer 9 Pin to workcell Programming Port 55 Computer 25 Pin to workcell Programming Port 55 Appendix C Error Codes 56 DMC Error Codes 56 Appendix D Open Loop Velocity Settings 58 Maximum Velocity...

Page 19: ...000 and PVA3000 systems Fault Diagnosis 38 Table 7 PVA250 PVA750 and PVA2000C Fault Diagnosis 41 Table 8 Preventive Maintenance Schedule 48 Table 9 DTE 9 Pin Serial Connector 54 Table 10 DTE 25 Pin Serial Connector 54 Table 11 Cable for Computer DB9 to workcell 55 Table 12 Cable for Computer DB25 to workcell 55 Table 13 DMC Error Codes 56 Table 14 PVA250 Velocity Limits 58 Table 15 PVA750 PVA2000C...

Page 20: ...rding The operator interface permits the operator complete control of the machine This includes machine setup manual operation program selection and automatic operation Machine status and error messages are displayed on the LCD screen and via the optional light tower It is necessary that operator s have read or by training understand the operation of this machine Any uses other than listed above c...

Page 21: ...ransportation should be done in such a fashion as to minimize the vibration and shock introduced to the system An air ride truck is recommended for roadway transport Although the machine is designed and built to perform in an industrial environment excessive abuse will greatly impact the performance of the machine Storage Dust and Debris All enclosures and connector covers should be closed tightly...

Page 22: ...models Installation 1 Plug the machine into an appropriate power source as determined by the Machine Specific Information section of the Operating Guide or the legend plate on the rear of the machine The electrical service should be properly grounded and the power source clean If there is high power equipment operating off the same source a line conditioner may be necessary Errors in machine opera...

Page 23: ...s to communicate with the host computer Table 1 DMC 1500 Dip Switch Settings Switch Position Description MRST OFF Master Reset 1200 OFF Baud rate selection 9600 OFF Baud rate selection 19 2K ON Baud rate selection HSHK ON Hardware Handshaking PVA550 PVA1000 PVA2000 and PVA3000 models Table 2 DMC 2100 Dip Switch Settings Switch Position Description MRST OFF Master Reset XON OFF Software Handshaking...

Page 24: ...ed with any text editor such as Microsoft Notepad or Word The Main program file is downloaded via a drop down menu in PathMaster but it should NEVER be opened within the PathMaster software PathMaster Precision Valve Automation s Windows based programming software It is used to create maintain and download project files for the workcell The Operating Guide has a separate section on using PathMaste...

Page 25: ...ctors The cables are straight through so orientation does not matter On each module the wire to the J1 Previous plug must connect to the J2 Next plug on the machine upstream Similarly the J2 plug on each machine must connect to the J1 plug on the machine downstream as shown in the following diagram ...

Page 26: ...uit The safety circuit contains two relays under voltage protection and one or more safety devices The relays are wired in a redundant manner Redundancy consists of two parallel relay circuits which work together electrically with the safety devices The tripping contacts of the relays are connected in series to insure that the safety circuit will disconnect power even if one of the relays has fail...

Page 27: ...ine power up the light curtain must be reset by turning the key switch to Reset for at least second Exhaust Fan Some machines are equipped with an exhaust fan The exhaust fan is provided to exhaust fumes from the work area The exhaust flange should be connected to an appropriate ducting system that is capable of receiving 150 CFM cubic feet per minute Insufficient air flow through the exhaust syst...

Page 28: ...t an amber light o The red indicator is on steady when the machine is not in Auto Cycle due to operator intervention It will flash when the machine is in cycle but cycle is halted due to a machine problem It is off at all other times o The buzzer cycles with the red indicator during machine errors Table 4 Light Tower Buzzer Status State Red Amber Green Buzzer Cycle Stop ON OFF OFF OFF Auto Cycle O...

Page 29: ...ecified time the machine interprets this as a failure and displays an error screen such as this EStop button failed Press F1 to repeat test F1 F2 F3 F4 F5 F6 F7 F8 By pressing F1 the operator can repeat the test one time If a second failure occurs a screen such as this appears EStop button failed Repair and restart the machine F1 F2 F3 F4 F5 F6 F7 F8 After the second failure the program ceases fun...

Page 30: ...e solvent cups In Manual mode the heads are removed from the cups and remain out until exiting this mode In Auto Cycle the heads lift and run the auto purge routine They return to the solvent cups after a pre programmed period of inactivity To change the time delay before the heads enter the solvent cups in Auto Cycle change the variable SLP_TM in the Machine Specific Information section of the Ma...

Page 31: ...ue F1 F2 F3 F4 F5 F6 F7 F8 The Mat value is the amount of material dispensed The operator should go to the Flow Control mode and change the flow set point to the Mat value that appeared on the flow data screen then return to the singular cycle option to run more cycles and verify the consistency of the path program NOTE The above screen does not display if the material target level is set to zero ...

Page 32: ...more precise calibration determine volume by weight The specific gravity or density of the material must be known to do this Flow Control Mode Flow control mode is typically accessed through the Cycle Stop menu using the F2 function key If access to Flow Control mode is not achieved through Cycle Stop or if more than one flow monitor is installed on the workcell documentation in the Optional Equip...

Page 33: ...ason during operation Sensor Defined Needle Calibration This method focuses around the NCU Needle Calibration Unit The calibration sequence redefines the coordinate system according to the positioning of a specific needle or dispense head Limitations may arise with a multiple head workcell utilizing two or more dispense heads in the same path program The NCU is referenced from the home position on...

Page 34: ... Auto Cycle see page 27 F6 STAT Check the status of certain machine items F8 SETUP View or change the setup functions of the machine see page 29 Program Selection Select Program Program 1 EXIT PREV NEXT F1 F2 F3 F4 F5 F6 F7 F8 The workcell is capable of storing up to 30 different programs The program selection menu allows the operator to choose which program is used during the Auto Cycle mode F1 E...

Page 35: ...librates the system The operator can use the trackball to move the end effector F1 EXIT Leave needle calibration and return to Cycle Stop F2 RECAL Execute re calibration F3 HOME Home the system The workcell returns to the pre set point F4 X Y Operate the X and Y axes simultaneously F5 X Operate only the X axis F6 Y Operate only the Y axis F7 Z Operate only the Z axis F8 W Operate only the W axis S...

Page 36: ...shed in concert with a PC compatible computer by using Precision Valve Automation s PathMaster software The operator must be in Manual mode or a sub level of Manual mode for PathMaster to function properly For more information on programming please consult the separate PathMaster Manual in the Operating Guide F1 EXIT Leave Manual mode and return to Cycle Stop F2 TEACH Program the current point F3 ...

Page 37: ...is mode handles the automatic cycling of the machine There are three machine setups that may be encountered o Conveyor equipped o Stand alone without a light curtain o Stand alone with a light curtain For a workcell with a conveyor the part is placed for process on the conveyor either by an operator or mechanically via an upstream process SMEMA signals are provided with the machine to be used in c...

Page 38: ... to the workcell and change the Up Ready and Down Board Available output signals F1 EXIT Leave Status mode and return to Cycle Stop F3 STAT Switch to the Status Sequence see page 28 F4 SMEMA INP Check the status of the SMEMA inputs momentary Displays the following screen Up Board Available OFF Down Ready OFF F1 F2 F3 F4 F5 F6 F7 F8 F5 Up Ready ON Turn the Up Ready signal on F6 Up Ready OFF Turn th...

Page 39: ...rge default setting is dependent upon the type of material used in the workcell The workcell only auto purges when in Auto Cycle or Cycle Stop If the workcell is in any other state it does not auto purge However it immediately auto purges if necessary once returning to Cycle Stop or Auto Cycle NOTE If the workcell is equipped with solvent cups the auto purge feature is overridden by the solvent cu...

Page 40: ...except PVA250 PVA750 PVA2000C Trackball Control Current X Y EXIT TEACH PURG X Y X Y Z W F1 F2 F3 F4 F5 F6 F7 F8 Trackball Control allows the operator to switch the active axis on the trackball F1 EXIT Leave Trackball Control and return to the previous mode F2 TEACH Program the current point F3 PURG Actuate the current valve F4 X Y Operate the X and Y axes simultaneously F5 X Operate only the X axi...

Page 41: ...from the active valve Axis The axis button allows the operator to toggle through the available axis configurations Typical configurations are X only Y only Z only W only and X Y together LED s The X Y Z and W LED s represent the selected axis configuration The teach LED indicates a successful response from PathMaster when a position is taught The teach LED is accompanied by a beep from the light t...

Page 42: ...is in the negative direction F7 X Jog the X axis in the positive direction F8 Y Jog the Y axis in the positive direction To jog an axis press and hold the function key that corresponds to the axis and direction of motion desired Once the axis is in motion for approx 1 sec the speed will increase by a factor of 15 ...

Page 43: ... Press F1 to return head to standby OK F1 F2 F3 F4 F5 F6 F7 F8 2 Correct the fault which prompted the operator to emergency stop the machine open the door etc 3 Open the access door 4 Remove all parts from the work area Determine which parts can be re worked and put them in the input queue 5 Close the access door 6 Follow the Startup Procedure Recovery from a door error resulting from a door being...

Page 44: ...or the air pressure alarm Consult the separate are pressure sensor manual for information on setting the air pressure set point 4 Adjust the set point for approximately 65 75 P S I 5 Restart the machine If the error persists the air pressure sensor may be damaged Low Material Level The workcell only checks the material level s when running cycles If there is a material level error the machine can ...

Page 45: ...lecting F5 Error 000 on line 0000 Press F1 to restart F5 for status F1 F2 F3 F4 F5 F6 F7 F8 Position Error Recovery Procedure All models except PVA250 PVA750 PVA2000C A position error is caused when the difference between the commanded position and the current position exceeds the maximum allowable error for an axis The error limit is defined to be approximately 1 5 For most cases this is 1000 cou...

Page 46: ...A250 PVA750 PVA2000C For Position and Limit Errors the error screen displays the stop codes for all the motors This information tells the operator which axis or axes caused the machine to go to fault Table 5 Stop Code Definitions Code Meaning 0 Motors are running independent mode 1 Motors stopped at commanded independent position 2 Decelerating or stopped by FWD limit switch or software limit FL 3...

Page 47: ...ll cases this occurs when a program s length exceeds the maximum available space in RAM or a defective function key The solution for this problem is to shorten the active program or replace the function key membrane panel Consult the separate PathMaster Manual in the Operating Guide for more information on altering a program Subroutine Error A Subroutine error occurs if the path programs have not ...

Page 48: ... was it doing etc 3 If the error was not serious attempt to repeat the error If the error does not repeat the problem may have been operator generated 4 Use a terminal screen to communicate with the controller Most troubleshooting necessitates issuing commands directly to the controller 5 If the problem is programming related a hard copy or email of the program in question may be requested by PVA ...

Page 49: ... axis drive is enabled The Z axis brake is not disengaging when the drive is enabled Check the SSR 1 wiring It should be on when the Z axis drive is enabled SSR 1 is ON when the Z axis drive is enabled The fuse for SSR 1 is blown or SSR 1 is damaged Check the fuse using an OHM meter Replace component if necessary Axis does not move Encoder works according to the Encoder Feedback Test on page 46 Th...

Page 50: ...Operating Guide for particular pressure settings Restricted air line Correct any tight bends or restrictions in the air lines Loose Fitting or Tubing Connection Tighten connection Frayed or damaged air line Replace the damaged air line s Sensor is not positioned correctly Adjust the sensor location Part in place sensor failure Cable is loose or not connected Check the cable connections Correct any...

Page 51: ... The electrical enclosure is open so the electrical enclosure safety switch is in the open position Close the electrical enclosure The secondary disconnect if off PVA750 PVA2000C only Check the secondary power disconnect located on the left side of the electrical enclosure in the rear of the machine Blown fuse Check FU 2 FU 3 FU 4 which is located inside the electrical enclosure Replace if necessa...

Page 52: ...interface board Motor Cable s are loose or disconnected Verify CPC connections at motor and terminal connections on amp Axis Looses position The axis speed or acceleration has been set to too high Check speed acceleration and deceleration settings Refer to Appendix D for speed acceleration deceleration charts Coupling is slipping Check coupling connection at motor and ball screw Tighten if needed ...

Page 53: ... GPIO interface board Motor Cable s are loose or disconnected Verify CPC connections at motor and terminal connections on amp Exhaust fan does not run No air flow The motor overload relay OL 1 is in the tripped state Reset the exhaust fan overload relay The exhaust fan overload relay trips frequently Excessive motor heating Insufficient air flow Blocked exhaust filter leads to excessive motor heat...

Page 54: ...lay on the operator terminal 11 Open a terminal screen and enter the LS List command The controller should return 000 after pressing ENTER This verifies that the controller is now at factory default and the memory is clear The controller is ready to accept the main program and a project Request Controller Version Perform the following procedure to request the controller firmware version using the ...

Page 55: ...E MACHINE OFF IMMEDIATELY Permanent damage to the components may occur 1 Remove all of the fuses in the enclosure except for FU 1 2 Disable the enclosure power safety switch 3 Turn the machine ON 4 Use a DMM Digital Multi Meter to check the AC power in the machine There should be 110 120 VAC between the 100 and 101 terminals If not turn off the power and check that FU 1 is installed and operationa...

Page 56: ...there may be a failure in the coil of CRM 2 or a short in its associated diode D 2 Encoder Feedback Test All models except PVA250 PVA750 PVA2000C Use this procedure to test the encoder feedback for all of the axes If a problem is found with any of the encoders repair and report the error to the production supervisor Most encoders used with the workcell generate 5080 counts inch Check to make sure ...

Page 57: ...table error and power available to the amplifiers This protects personnel and equipment OE 1 Off on error enabled for all axes ER 1000 Error limit for all axes TL 1 Torque limit of 1 for all axes SP 5000 Set the speed AC 10000 Set the acceleration DP 0 Define the current position as 0 0 0 0 SB5 Enable power only on machines without a POWER ON button SH Apply power to the servo motors 5 Release the...

Page 58: ...smooth operation Check for any chaffing of wires pneumatic lines or material lines Inspect enclosure air filter clean with warm soapy water as needed Air dry before reinstalling PVA250 PVA750 models only Grease the ball screw slides with Lithium Grease JIS Type 2 Inspect all moving cables for excessive wear Conveyor System Clean conveyor belts Check for material and dust buildup on the sensors Che...

Page 59: ...peration and Maintenance Manual Rev M ii 4 03 49 Type Of Service Service Area Every Shift Weekly Monthly Quarterly Dispensing Spraying Equipment Lubricate packing as per the manufacturers recommendations ...

Page 60: ...ley wheels farthest from the motor NOTE Make sure that there are no twists in the belt 6 Place the belt around the large pulley wheel then around the remaining wheels 7 Rotate the pulley wheels several turns by hand This ensures that the belt is correctly seated 8 Replace the cover plate Valves Refer to the Cut Sheets section of the Operating Guide for information about the dispensing spraying equ...

Page 61: ...N If it is not turn the adjustment screw counterclockwise until the input just turns ON 6 Turn off the exhaust Make sure the pressure switch turns OFF 7 Turn on the exhaust Make sure the pressure switch input turns ON If not turn the adjustment screw counterclockwise again until the input turns ON Verify that the input turns OFF when the exhaust is turned off 8 Restrict the outlet of the exhaust u...

Page 62: ...on of the home sensors It is NOT the same as the Standby Position Jog Moving any combination of axes continuously at a set rate of speed until commanded to stop Light Tower The light tower consists of three stacked lights red amber and green top to bottom It is used to indicate the status of the machine Main program file Text file containing the code that runs the workcell during normal operations...

Page 63: ...nd effector The machine moves here after homing and after each cycle This position is usually located near the start point for the program s It is NOT the same as the Home Position Terminal A program used as a communication link between the controller and operator Teach A process by which the workcell registers its current gantry location with PathMaster to create a motion sequence Workcell A mode...

Page 64: ... the workcell service outlet for computer power if provided 9 Pin Serial Connector Table 9 describes the pinout for standard serial ports found on most portable computers Table 9 DTE 9 Pin Serial Connector Pin Description 1 Carrier Detect CD 2 Received Data RD 3 Transmitted Data TD 4 Data Terminal Ready DTR 5 Signal Ground 6 Data Set Ready DSR 7 Request to Send RTS 8 Clear to Send CTS 9 Ring Indic...

Page 65: ...a Signal Rate Selector 24 DTE Transmitter Clock 25 Unused Computer 9 Pin to workcell Programming Port For standard communication between a computer and a workcell Table 11 Cable for Computer DB9 to workcell Comp DTE DB9 workcell DCE DM9F 1 1 2 2 3 3 4 4 5 5 Computer 25 Pin to workcell Programming Port For standard communication between a computer and a workcell Table 12 Cable for Computer DB25 to ...

Page 66: ... and DL not valid while program running 18 Command not valid when contouring 19 Application strand already executing 20 Begin not valid with motor off 21 Begin not valid while running 22 Begin not possible due to Limit Switch 24 Begin not valid because no sequence defined 25 Variable not given in IN command 28 S operand not valid 29 Not valid during coordinated move 30 Sequence segment too short 3...

Page 67: ...alid in task 0 80 Record mode already running 81 No array or source specified 82 Undefined array 83 Not a valid number 84 Too many elements 90 Only X Y Z W valid operand 95 TM too large for stepper pulse 96 SM jumper needs to be installed for stepper motor operation 100 Not valid when running ECAM 101 Improper index into ET must be 0 256 102 No master axis defined for ECAM 103 Master axis modulus ...

Page 68: ...ystem are listed below Table 14 PVA250 Velocity Limits PVA250 Axis Max User Speed Max Burn in speed Max Acceleration Max Deceleration X Axis 60000 cnts sec 66000 cnts sec 300000 cnts sec2 300000 cnts sec2 Y Axis 60000 cnts sec 66000 cnts sec 300000 cnts sec2 300000 cnts sec2 Z Axis 6000 cnts sec 6500 cnts sec 30000 cnts sec2 30000 cnts sec2 Table 15 PVA750 PVA2000C Velocity Limits PVA750 PVA2000C ...

Page 69: ...se 2 Ground GND GND Neutral NEU NEU AC or DC Motor nTm 1T2 Motor 1 phase 2 Inputs n1mm 1101 Module 1 Input 01 Outputs n0mm 2001 Module 2 Output 02 Connector Jnnn mm J100 5 Connector 100 pin 5 Wire Color Code Table 17 Wire Color Code NOTE This color code does not apply to multi conductor cables Type Color Example DC 150 V BLUE 0 Vdc 80 Vdc DC 150 V BLACK 200 Vdc AC 150 V RED 120 Vac AC 150 V BLACK ...

Page 70: ...Configuration Operation and Maintenance Manual PathMaster Manual Cut Sheets Schematics Software PathMaster 3 ...

Page 71: ...g System 6040 In situations where inattention could cause either personal injury or damage to equipment a warning notice is used 6014 Do not smoke near the Dispensing System Always have a fire extinguisher available for emergency use 6019 Before operating the system read and understand the manuals provided with the unit 6017 Before performing any repairs or maintenance to the system turn off power...

Page 72: ...he unit Service should only be performed by a qualified individual 6018 Exercise caution when pressurized vessels are present Identify and repair any leaks immediately Always wear appropriate safety equipment when working with pressurized vessels or vessels containing chemicals 6054 Laser light source present Do not stare directly into the beam Do not use in the presence of highly reflective surfa...

Page 73: ...es subsequently made Precision Valve Automation Inc makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply This document including the information contained herein is the property of...

Page 74: ... Operating Guide for more information on these additions Revisions to This Manual The following list describes the major revisions in this manual Rev H 6 03 as compared to previous manuals Rewrite for PathMaster version 2 05 including subroutine information Update for PathMaster version 2 3 6 23 03 TMB Content of This Manual Definitions Definitions for commonly used terms Notices and Warning Basic...

Page 75: ...uter Settings 13 Uninstalling PathMaster 13 Multiple Dispensing System Issues 13 Year 2000 Compliance 13 If Something Goes Wrong 14 Calling Technical Support 14 Working with Materials 15 Overview 15 System Components 15 Material Feed 15 Dispense Needle Valve 15 Spray Valve 15 Programming 16 Beginning Programming 17 Overview 17 Planning Path Programs 17 Incorrect Valve Usage 17 Inserting Valve Comm...

Page 76: ...ing PathMaster 25 Starting PathMaster 25 Configuring PathMaster 25 Machine Parameters 25 Database Backup and Restoration 29 Automatic Backup 29 Manual Backup 29 Database Restoration 30 Important Reminders 30 Machine Selection 30 Project Selection 31 Reading a Program 31 Playback 32 Edit Windows 32 Interacting With the Dispensing System 33 Manual Jog Teach Mode 33 Trackball Control 33 Teach Pendant...

Page 77: ... FastMask 58 Dot 59 Editing the commands 59 Password Protection 59 Download Password 59 Save Password 59 Changing Password 59 Resetting Password 59 Importing Files 60 CAD Files 60 PathMaster 1 5 Pre 1 5 Projects 64 Text File 64 DMC File 64 Subroutine 64 Exporting Files 64 Text File 64 DMC File 64 Subroutine 65 Utilities 65 View FastPath 65 Measure Distance 65 Machine Debugger 65 Refresh Communicat...

Page 78: ...DMC 1500 Dip Switch Settings for PathMaster 12 Table 2 Communication Program Settings 13 Table 3 Coordinate System Locations 19 Table 4 Variable Explanations 19 Table 5 Required CAD File Elements 60 Table 6 Important DMC Commands 67 Table 7 DMC Error Codes 74 ...

Page 79: ...ommanded to stop Light Tower The light tower consists of three stacked lights red amber and green top to bottom It is used to indicate the status of the machine Main program file Text file containing the code that runs the Dispensing System during normal operations Motion Sequence A continuous motion profile The valve is on dispensing during the entire motion profile Also known as a Dispense Path ...

Page 80: ...ion for the end effector The machine moves here after homing and after each cycle This position is usually located near the start point for the program s It is NOT the same as the Home Position Terminal A program used as a communication link between the controller and operator WSDK 1500 Windows Servo Design Kit 1500 This software is used to setup and tune the servo system ...

Page 81: ...uipment Do not disable the safety features of the machine Lock out and tag the air and power supplies before servicing or cleaning any part of this equipment Do not remove any hose either air or fluid without relieving the pressure Do not replace any hose with a hose of inadequate pressure rating Use only replacement parts recommended or supplied by the manufacturer Always remain clear of all movi...

Page 82: ... tutorials directory of the PathMaster CD ROM are a number of audio visual tutorials These can be accessed via the Help Contents option in PathMaster or the pathmaster hlp file NOTE If the computer in use does not have a sound card or the card is not installed properly the audio portion of the tutorials will not function Communications The Dispensing System communicates with a computer using the E...

Page 83: ...NOT deleting any shared files Precision Valve Automation Inc assumes no responsibility for any difficulties arising from the deletion of shared files during the uninstall procedure of PathMaster NOTE This process completely eliminates the PathMaster software and all its components including registry entries Multiple Dispensing System Issues Unless a multiple machine cross programming system was pu...

Page 84: ...t if as many of the following items are addressed before calling for help 1 Note the serial number of the Dispensing System The serial number can be found on the legend plate located on the front of the electrical enclosure 2 Record all the information on the OIT or PC when the error occurred 3 If the error was not serious attempt to repeat the error If the error does not repeat the problem may ha...

Page 85: ...Turning the knurled knob on the top of the valve counter clockwise increases flow through the valve A fine steady stream of material is all that is needed Once a satisfactory setting is found secure the stroke position with the locking nut Once the locking nut is secure verify the valve flow rate before continuing Needle Selection Experiment with different needle sizes to determine the best size f...

Page 86: ...s cap is rectangular oval in shape It is identified by the protruding atomizing air ports It works best with non solvent based materials and provides a wider spray path for increased coverage Programming Once the physical parameters are successfully established for the delivery system they should never be altered The best method for changing the material output is to alter the program In most case...

Page 87: ...oken into two paths or entirely reprogrammed Incorrect Valve Usage When programming or operating the Dispensing System the valves should NEVER be used for moving components or boards Precision Valve Automation is not responsible for damages incurred from using the valves in an inappropriate manner Inserting Valve Commands into Programs Pneumatic positions head up down rotary selection are not auto...

Page 88: ... the main program that runs the Dispensing System Usually it involves setting up points for the machine to use If the operator must do this it is imperative to download the corrected main file properly to avoid any problems Open the Main program using a text editor such as Windows Notepad or Winpad Common Main Program Changes There are a few sets of points that commonly need changing Standby posit...

Page 89: ... PT_CAL 1 PT_CAL 2 PT_CAL 3 Standby Location PT_SBY 0 PT_SBY 1 PT_SBY 2 PT_SBY 3 Table 4 Variable Explanations Variable Explanation AP_EN Default value for auto purge 1 on 0 off AP_LEN Length of auto purge in milliseconds AP_TIME Time between auto purges in millesends SLP_TM Sleep timer value for solvent rest in millesends SO_EN Solvent rest enable disable 1 enable 0 disable Once Main program modi...

Page 90: ...per Status Bar The upper status bar displays the active machine configuration current project file and current path program The current path program can be changed via the drop down list box Lower Status Bar The lower status bar shows the current status of the Dispensing System Whether or not the PC is communicating with the Dispensing System is reflected in the Connected display The Manual displa...

Page 91: ...egment s from the clipboard and insert it into the program Delete Delete highlighted path segment s Select All Select all path segments from the displayed program Teach Menu Move Code a move to a specific location 3D Path Teach a 3D path segment and specify valve activity 2D Path Teach a 2D path segment and specify valve activity Dot Dispense at a defined point for a length of time and specify val...

Page 92: ...meters Setup machine parameters for the current machine profile Passwords Set password for downloading and saving projects Help Menu Contents PathMaster online help Commands Online help manual for the Galil DMC 1500 controller About Information about PathMaster including release version Right Click Menu Using the right mouse button while highlighting a function accesses this menu Teach Move Code a...

Page 93: ...ng Toolbar The programming toolbar provides quick access to the most frequently used programming tools Programming Tools Programming tools are used to create path segments which make up a path program PathMaster contains a variety of useful programming tools which can be used to create 2 dimensional and 3 dimensional path motion Many of the most commonly used tools are located on the toolbar while...

Page 94: ...ltiple Dispensing Systems The database structure employs a system which will allow as many Dispensing System configurations as needed In a production environment where multiple machines with varying configurations are utilized a single PathMaster database can use and maintain the configurations for each of these machines Machine Configuration Pathmaster will utilize the default machine configurati...

Page 95: ...oller This is normal for the initial startup Click the OK button to continue Configuring PathMaster Before PathMaster can be used it must be configured to suit the machine and machine application Communication parameters must also be configured to allow PathMaster to interact with the Dispensing System Machine Parameters The machine parameter form is used to set attributes specific to the software...

Page 96: ...e The names are located in the Configuration section of the Operating Guide along with the options present for each valve The Enabled box should be checked for all the valves present on the machine Z Slide and Rotary should be checked if they are installed Valve Parameters On Delay Wait The pause after turning the valve on but before starting the path Off Delay Wait The pause after finishing the p...

Page 97: ...t a time To configure communications click the Edit Controller button on the Machine Parameters form If a message appears indicating that PathMaster could not find any controllers in the Windows Registry click OK This simply means that no control handles have been configured yet When the Edit Registry window appears click New Controller Select the controller model installed in the Dispensing Syste...

Page 98: ...ng that the controller has been added Control handle properties can be modified by highlighting the controller and clicking Properties Multiple control handles can be added Control handles can be deleted by clicking the Delete button Click Close Once one or more control handles have been created you must select the control handle that PathMaster will use to communicate with the Dispensing System T...

Page 99: ...therefore backup file will be stored for the last ten days that PathMaster was executed All automatic backups are stored in the Db Daily sub folder of the PathMaster application folder The default location of these files is c program files pva pathmaster db daily Manual Backup A manual database backup is by far the safest method This method requires a conscious effort by the user and therefore sho...

Page 100: ...tion on the screen It is the operator s responsibility to ensure the proper area is highlighted to accommodate the new path Inserting Valve Commands Commands to move the heads or valves are NOT automatically inserted into PathMaster the path programs If the operator needs a head to change position up down rotary the appropriate command must be inserted manually via the Head programming tool Please...

Page 101: ... is arranged in a table format Use the chart below to determine the purpose of the text that appears in each field COLUMN USE EXAMPLE EXPLANATION Command Programmed command DOT Dot program NOTE A command uses all the lines below it until another command reference appears in the command column LINE 3D 3D Line Position Coordinates 4555 3000 760 Cartesian coordinates for current point On Valve or I O...

Page 102: ...Run Program from the drop down menu or the right click menu Before playback begins the user will be prompted to select a Wet or Dry playback Wet playback activates the valve s while running the path Dry playback does not activate the valve s Edit Windows Path tools with editing capability allow the operator to change a path segment once it has been created Examples of edit windows appear in each p...

Page 103: ... Manual Jog Teach Mode F1 EXIT Leave Manual Jog Teach mode and return to Cycle Stop F2 TEACH Program the current point F3 VLV Switch to Valve Selection F4 RUN Run singular cycles of the current program F5 PURG Actuate the current valve F6 TP Momentary switch that displays the current position of the head F7 CONV Switch to Conveyor Control F8 AXIS Switch to Trackball Control NOTE Playback of a path...

Page 104: ...unction TRACKBALL The trackball allows the operator to jog each axis independently or X and Y together Teach The teach button mimics the teach button found on the Dispensing System OIT in that it will register the gantry position back to PathMaster when teaching a motion profile Purge The purge button mimics the purge button found on the Dispensing System OIT in that it will purge material from th...

Page 105: ... the current valve F4 AXIS Toggle axis control between X Y and Z F5 Y Jog the Y axis in the negative direction F6 X Jog the X axis in the negative direction F7 X Jog the X axis in the positive direction F8 Y Jog the Y axis in the positive direction To jog an axis press and hold the function key that corresponds to the axis and direction of motion desired Once the axis is in motion for approx 1 sec...

Page 106: ...nd corner of the activation pad Double click on the TracPad to teach a point while the TracMouse is active Pneumatic Commands Pneumatic positions head up down rotary selection are not automatically programmed by PathMaster and there is no communication between the Dispensing System and PathMaster concerning the valves pneumatic position Therefore it is the responsibility of the operator to select ...

Page 107: ...XYW Y only XYW then Z Z only W only XY then Z XY then W then Z Current Position If there is communication established with the controller the current position appears in the text box Use the trackball on the Dispensing System to change the position Input Coordinates Manual entry of target position Teach Record current position and add to the program Equivalent to the F2 key on the Dispensing Syste...

Page 108: ...g Parameters Select appropriate parameters for the current dispense including the active valve Valve On Time The pause after turning the valve on but before starting the dispense path Valve Off Time The pause after finishing the path and turning the valve off but before moving to the next point Valve On Distance Distance the path traveled before turning the valve on Valve Off Distance Distance the...

Page 109: ...t position Dispensing Parameters Select appropriate parameters for the current dispense including the active valve Valve On Time The pause after turning the valve on but before starting the dispense path Valve Off Time The pause after finishing the path and turning the valve off but before moving to the next point Valve On Distance Distance the path traveled before turning the valve on Valve Off D...

Page 110: ...space them evenly around the arc Current Position If there is communication established with the controller the current position appears in the text box Use the trackball on the Dispensing System to change the position Input Coordinates Manual entry of target position Dispensing Parameters Select appropriate parameters for the current dispense including the active valve Valve On Wait The pause aft...

Page 111: ...sing System is currently in Manual Jog Teach mode Only three points can be plotted for the arc function Circle Programmed Teach Screen Edit Screen This tool teaches a circle The operator must select three 3 points on the circumference of the circle including the start point moving clockwise or counter clockwise in the direction the axes must move The Z axis does not alter its position during the p...

Page 112: ...ing the dispense path Valve Off Wait The pause after finishing the path and turning the valve off but before moving to the next point Valve On Distance Distance the path traveled before turning the valve on Valve Off Distance Distance the path traveled when turning the valve off before the path finishes Teach Record current position Equivalent to the F2 key on the Dispensing System Done Add to the...

Page 113: ...pense path Valve Off Wait The pause after finishing the path and turning the valve off but before moving to the next point Valve On Distance Distance the path traveled before turning the valve on Valve Off Distance Distance the path traveled when turning the valve off before the path finishes Area or Path Spacing Distance between runs Teach Record the current point Equivalent to the F2 key on the ...

Page 114: ...e the width is along the Y axis 3 Point 3 defines the width The width is the difference in Y between points 1 and 3 This is divided by the Area Spacing or Path Spacing parameter resulting in the number of paths the machine needs to run to fill the given area Area 2 1 Point 1 defines the start 2 Point 2 is along the Y axis so that is the direction of the path The length of the path is the distance ...

Page 115: ...s selected a wizard will open Select the appropriate valve parameters then teach the opposing corners of the area to be coated point 1 and point 2 Click Next to continue Teach the opposing corners of the first keep out area Click Add to add the keep out to the FastMask list Keep adding keep out areas up to 99 keep outs until all non coat areas have been included in the FastMask list Click Next to ...

Page 116: ... changes at higher speeds Combining lines with arcs and circles will smooth the motion and create uniform corners and circles A polyline can be created using two different methods Multiple path segments can be created using the conventional method and then converted to a polyline or the polyline can be created using the PolyLine tool New Polyline To create a new polyline open the PolyLine tool and...

Page 117: ...reate a polyline from existing path segments simply select the path segments to include in the polyline access the Teach menu and select PolyLine From Selected Lines If the endpoints of the path segments do not match up exactly PathMaster will ask you if you would like to match up the endpoints If you choose not to match up the points the polyline will not be created If you choose to match up the ...

Page 118: ... entry of target position Dispensing Parameters Select appropriate parameters for the current dispense including the active valve Valve On Wait The length of time the valve remains on Valve Off Wait The pause after turning the valve off but before moving to the next point Z Retract Relative Distance to raise the Z axis after completing certain moves Teach Record current position and add to the pro...

Page 119: ... between the Dispensing System and PathMaster with regard to the active valve or its pneumatic position Therefore it is the responsibility of the operator to select the appropriate valve within PathMaster and to insert the necessary pneumatic commands into the program after a path has been completed See Inserting Valve Commands into Programs on page 17 for further information about head function p...

Page 120: ...set a delay in program execution in between path segments Subroutine Creating Highlight the commands to be included in the subroutine Select the Teach Subroutine Create option from the main menu This function allows the operator to use an existing command line element excluding DMC commands in an array sequence or in random placement You also have the option to insert existing subroutines in your ...

Page 121: ...rrayed or random placed will be referenced from this point of origin Choose to create an array or select random placement of the subroutine This screen corresponds to random program placement By selecting the Teach button PathMaster utilizes the current location of the end effector as an execution point Select the direction of the array The arrows assist in determining the direction in relation to...

Page 122: ...e list The stored subroutine code appears Edit it like normal Save the subroutine and reopen the current project I O Teach Screen This function allows the operator to control outputs or wait for an input to be in a particular state The I O for this Dispensing System is located in the Machine Specific Information section of the Operating Guide Operators who understand discrete I O and its usage sho...

Page 123: ... pointing device could be another valve a laser pointer or a camera Open the Machine parameters window by selecting the Setup Machine Parameters option from the main menu Click the Valve Offsets button The valve offsets form will display PathMaster must measure the offset for each valve relative to the pointing device To measure this distance the offset wizard will step through a series of instruc...

Page 124: ...e and valve one can reach Click the Teach button when valve one is over the fiducial making sure that the Z height is considered in the taught position Next move the pointing device over the fiducial Click the Teach button The distance between the pointing device and the fiducial has now been taught ...

Page 125: ... Rev H 6 03 55 The next offset must be taught Move valve two over the fiducial and click the Teach button Move the pointing device to the same location and press the Teach button The valve distances have now been taught ...

Page 126: ...ence point could be the lower right of your image and the valve one coordinates for the intersection of the front rail and the board stop of your machine Choose the reference point type and then find the machine coordinates for the same location Type the valve one coordinates into the robot reference point edit boxes You have successfully setup your machine to use offline programming Repeat these ...

Page 127: ...nd will be added to the program table in succession until another object or path segment is selected Once another object or path segment is selected the insertion point for the next path segment will be above the highlighted or selected path segment in the program table Press CNTRL F to close the FastPath window and return to the normal PathMaster editing window Most PathMaster programming tools a...

Page 128: ...e circle The playback of the arc will be the number of degrees between the points Circle The Circle tool is similar to the Arc tool except that a full circle is created with three points Click the Circle button to select the tool Each time a point is taught the cursor will briefly become a crosshair indicating that the point was registered The circle will display on the board image You may edit th...

Page 129: ...hMaster Download Password To add password protection to the download function in PathMaster select the Setup Password Set Download Password option from the main menu If no password exists you will be asked if you would like to create one If a previous password exists you must enter it correctly to continue Next enter the new password click OK Then re enter the password for verification and click O...

Page 130: ...tion of the CAD File Below is the original drawing Figure 1 and the required elements Table 5 NOTE The CAD X and CAD Y arrows are for reference only These are not required Figure 1 Original CAD Layout Required Element Description BEGIN1 BEGIN2 etc Defines the start of the segment The valve will turn ON at this point END1 END2 etc Defines the end of the segment The valve will turn OFF at this point...

Page 131: ... H 6 03 61 Figure 2 CAD drawing Mirrored on Y axis The drawing must be Rotated Clockwise 90 degrees 90deg for standard AutoCAD Setup Figure 3 Figure 3 CAD Drawing rotated 90deg The final step is to export the file to a dxf ...

Page 132: ...s to recognize the proper associations between drawing segments in the CAD file A minimum of 0 015 is recommended NOTE This does not affect the accuracy of the path It only allows for proper translation of the drawing entities Choose the method of importation Figure 5 Paths from Begin to End will import the file as drawn with proper segment ordering BEGIN1 END1 etc observed All Entities ignores co...

Page 133: ...mport Figure 7 Figure 7 PathMaster import screen 4 After a successful import the path will be displayed in a path preview window Figure 8 PathMaster import screen 4 The file will be imported as individual paths Line Arc etc The paths are ready for playback or may be converted to a polyline ...

Page 134: ...ile dialog box opens select the location and the file name of the project to import Click Open NOTE You may need to change the file filter type to dmc to see the project file in the dialog box Subroutine A properly formated subroutine can be imported into PathMaster using the import subroutine option Select the File Import Subrotuine Text File option from the main PathMaster menu or the File Impor...

Page 135: ...option from the main menu NOTE The FastPath window can also be accessed using the FastPath button on the programming toolbar Measure Distance The distance measurement tool is used to measure the distance between two point using current measurement units To open the tool click the Utilities Measure Distance option from the main menu To measure distance move the head to the first point click Teach P...

Page 136: ... A semicolon is used as a carriage return This allows for multiple commands on the same line and can be used to save space in the program Labels Sections of a program subroutines are defined by labels Labels start with the pound sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are never permitted PathMaster generates its ow...

Page 137: ...d move The units are in counts AV1000 wait until the axes have moved 1000 counts The AV command resets to zero after every use It can be calculated by summing the distances between each point on the coordinated move BG Begin BG starts a motion on an axis or a sequence BGX begin motion on the X axis BGS begin motion sequence BG begin motion on all axes A second BG command cannot be given until the ...

Page 138: ...g JP Jump to a program location Locations are marked by labels This command can be used in a conditional statement and the jump occurs if the conditional is true JP NOOP jump to location NOOP JP NOOP COUNT 10 jump to location NOOP if the value of COUNT exceeds 10 It is important not to confuse JP with JS Using a JP when a JS is required results in the thread being halted once the EN command is rea...

Page 139: ...osition without reference to the origin RS Reset Resets the controller to its power on state All the information in the controller s RAM is erased RS If PathMaster fails to download a file properly the program may be halted in the controller Executing an RS command from the terminal screen restarts the program SB Set bit Sets a bit on the output port SB40 sets the bit for the buzzer Setting a bit ...

Page 140: ...sk VA Acceleration for coordinated moves The units are in counts per second VA 100000 Make sure the value of the acceleration is high enough to get the motion to speed within a reasonable amount of time VD Deceleration for coordinated moves The units are in counts per second VA 100000 Make sure the value of the acceleration is high enough to get the motion to speed within a reasonable amount of ti...

Page 141: ...e I O point you wish to toggle and click it The button will change colors when the I O point changes state The refresh interval is the frequency of the tool display refresh in milliseconds Analog Input The analog input tool will monitor the value of analog input feedback The refresh interval is the frequency of the tool display refresh in milliseconds ...

Page 142: ...ing on the model of controller being used Variable Watch The variable watch tool will monitor a list of program variables entered by the user Type a valid program variable name into the watch list on the left click Start Watch and the value of the variable will be displayed on the right Multiple variables can be monitored simultaneously The refresh interval is the frequency of the tool display ref...

Page 143: ...ts Highlight all path segments to be displayed in the preview Select the Utilites Path Preview option from the main menu The path preview window will display Right click the path preview window to reveal a zoom pan rotate coordinate info menu Click the Reset button to return the preview to its default display Show Code The show code option will display the compiled machine code for the selected se...

Page 144: ...en contouring 19 Application strand already executing 20 Begin not valid with motor off 21 Begin not valid while running 22 Begin not possible due to Limit Switch 24 Begin not valid because no sequence defined 25 Variable not given in IN command 28 S operand not valid 29 Not valid during coordinated move 30 Sequence segment too short 31 Total move distance in a sequence 2 billion 32 More than 511 ...

Page 145: ... array or source specified 82 Undefined array 83 Not a valid number 84 Too many elements 90 Only X Y Z W valid operand 95 TM too large for stepper pulse 96 SM jumper needs to be installed for stepper motor operation 100 Not valid when running ECAM 101 Improper index into ET must be 0 256 102 No master axis defined for ECAM 103 Master axis modulus greater than 256 EP value 104 Not valid when axis p...

Page 146: ...Configuration Operation and Maintenance Manual PathMaster Manual Cut Sheets Schematics Software Cut Sheets 4 ...

Page 147: ...Cut Sheets Included on this cd are technical data sheets for componants installed on the Workcell To view these documents click the button below Select Cut Sheet ...

Page 148: ...Configuration Operation and Maintenance Manual PathMaster Manual Cut Sheets Schematics Software Schematics 5 ...

Page 149: ...hematics for this unit To view these schematics online click the button below NOTE Before you can view the schematics you must have an AutoCAD compatible viewer installed The AutoCAD viewer Volo View Express is provided on this cd Select Schematic ...

Page 150: ...Configuration Operation and Maintenance Manual PathMaster Manual Cut Sheets Schematics Software Software 6 ...

Page 151: ... On this CD you will find a directory labeled 144MB Simply copy the files from each disk directory to individual floppies for a complete set of installation floppy disks Floppy Disk s One 1 floppy disk is included with this manual It contains a backup copy of the main program xxxx_m01 txt where xxxx is the serial number of the machine and m01 is the main program revision The machine was shipped fr...