309738L - PrecisionFlo LT Standard, Instructions, English - Graco Inc.

Instructions 

PrecisionFlo LT 

Standard, Series B 

309738L 

ENG 

Electronically controlled fluid dispensing packages. For professional use 

only. 

• Pneumatically operated fluid regulators 

• EasyKey keypad interface 

Not for use in explosive atmospheres. 

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

See page 4 for Table of Contents. 

Important Safety Instructions 

Read all warnings and instructions in this manual. 

Save these instructions. 

9902471 

Certified to CAN/CSA C22.2 No. 1010 

Conforms to 

UL 3121-1

List of Models 


Control Modules 

PrecisionFlo LT 

Control Module 

Number 

Description Power Supply Voltage Power Requirement 

234129, Series B Standard PrecisionFlo LT Control Unit 93 - 264 VAC, 50-60 HZ Full Load Amps - 1 

Fused Amps - 2 

Fluid Modules 

Precision- 

Flo LT Fluid 

Module 

Number 

Description 

Maximum Fluid 

Inlet Pressure 

Regulated Fluid 

Pressure 

Maximum Inbound 

Air Pressure 

234168 Ambient cartridge style regulator 

with no flow meter 

6000 psi 

(41 MPa, 414 bar) 

100 - 4500 psi 

(0.7-31 MPa, 7-310 bar) 

100 psi 

(0.7 MPa, 7 bar) 


with a G3000 flow meter 

4000 psi 

(28 MPa, 276 bar) 

100 - 4000 psi 

(0.7-28 MPa, 7-276 bar) 

100 psi 

(0.7 MPa, 7 bar) 


with a G3000HR flow meter 

4000 psi 

(28 MPa, 276 bar) 

100 - 4000 psi 

(0.7-28 MPa, 7-276 bar) 

100 psi 

(0.7 MPa, 7 bar) 


with a Graco helical flow meter 

6000 psi 

(41 MPa, 414 bar) 

100 - 4500 psi 

(0.7-31 MPa, 7-310 bar) 

100 psi 

(0.7 MPa, 7 bar) 


with a Graco high resolution helical 

flow meter 

6000 psi 

(41 MPa, 414 bar) 

100 - 4500 psi 

(0.7-31 MPa, 7-310 bar) 

100 psi 

(0.7 MPa, 7 bar) 

234170 Ambient mastic style regulator 

with no flow meter 

5000 psi 

(34.4 MPa, 344 bar) 

100 - 4500 psi 

(0.7-31 MPa, 7-310 bar) 

100 psi 

(0.7 MPa, 7 bar) 


with a Graco helical flow meter 

5000 psi 

(34.4 MPa, 344 bar) 

100 - 4500 psi 

(0.7-31 MPa, 7-310 bar) 

100 psi 

(0.7 MPa, 7 bar) 


with a Graco high resolution helical 

flow meter 

5000 psi 

(34.4 MPa, 344 bar) 

100 - 4500 psi 

(0.7-31 MPa, 7-310 bar) 

100 psi 

(0.7 MPa, 7 bar) 

234193 Heated mastic style regulator with 

no flow meter 

5000 psi 

(34.4 MPa, 344 bar) 

100 - 3500 psi 

(0.7-24.1 MPa, 7-241 bar) 

65 psi 

(0.45 MPa, 4.5 bar) 

234194 Heated mastic style regulator with 

a heated Graco helical flow meter 

5000 psi 

(34.4 MPa, 344 bar) 

100 - 3500 psi 

(0.7-24.1 MPa, 7-241 bar) 

65 psi 

(0.45 MPa, 4.5 bar) 

Standard Systems 


System Number 

Description 

Configurator 

Code 

Control 

Module 

Fluid 

Module 

Cables 

234284 Advanced PFlo LT Control with Ambient Cartridge 

Regulator and Helical Gear Meter 

234285 Advanced PFlo LT Control with a Heated Mastic 

Regulator and Heated Helical Flow Meter 

PFlo 

LT-A-2-5-04-1 

PFlo 

LT-A-2-5-10-1 

234190 234167 I/O-117752 

234190 234194 Automation- 

117774 

2 309738L


309738L 3

Contents 

Contents 

ManualConventions ........................5 

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

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ConfiguringSoftware ......................32 

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

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

FlowRateCalibration ....................34 

VerifyingFlowMeterCalibration ............35 

OtherSoftwareSettings ..................35 

On/OffDelays ..........................37 

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

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

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

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

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

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

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

FlowMeter.............................44 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TechnicalData ............................73 

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


Contents 

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

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

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

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

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

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

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

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

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

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

Bead Control / Vol. Monitor / Pressure Control . 99 

Typical Bead Control / Vol. Monitor / Pressure 

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

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

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

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

FlowRateCalculation ...................104 

FlowCalibration........................104 

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

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

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

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

GracoInformation ......................108 


Manual Conventions 

Manual Conventions 

Warning 

WARNING 

A warning alerts you to possible serious injury or 

death if you do not follow instructions. 

Symbols, such as fire and explosion (shown), alert you 

to a specific hazard and direct you to read the indicated 

hazard warnings beginning on page 6. 

Caution 

CAUTION 

A caution alerts you to possible equipment damage or 

destruction if you do not follow instructions. 

Note 

A note indicates additional helpful information. 

WARNINGS 

EQUIPMENT MISUSE HAZARD 

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

• This equipment is for professional use only. 

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

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

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

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

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

• Be sure that all spray/dispensing equipment and accessories are rated to withstand the maximum 

working pressure of the pump. Do not exceed the maximum working pressure of any component 

or accessory used in the system. 

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

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

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

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

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

and solvent manufacturer. 

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


Warning 

WARNING 

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD 

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and 

result in fire or explosion and serious injury. 

• Ground the equipment and the object being dispensed. 

• Do not use this equipment with flammable liquids. 

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

• If there is any static sparking or you feel an electric shock while using the equipment, stop dispensing 

immediately. Do not use the equipment until you have identified and corrected the problem. 

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

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

only. 

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

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

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

• Do not smoke in the dispensing area. 

• Keep liquids away from the electrical components. 

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

TOXIC FLUID OR FUMES HAZARD 

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

swallowed, or inhaled. 

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

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

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

state and national guidelines. 

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

solvent manufacturer. 

• Avoid exposure to heated material fumes. 


Warning 

WARNING 

SKIN INJECTION HAZARD 

Spray from the gun, leaks, or ruptured components can inject fluid into your body and cause extremely 

serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also 

cause serious injury. 

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

treatment. 

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

• Follow the Pressure Relief Procedure on page 30 and in your separate equipment manuals whenever 

you are instructed to: relieve pressure, stop dispensing, clean, check, or service the equipment; 

or install or clean a nozzle. 

• Tighten all the fluid connections before operating the equipment. 

• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. 

Permanently coupled hoses cannot be repaired; replace the entire hose. 

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

equipment. 

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

MOVING PARTS HAZARD 

Moving parts can pinch fingers. 

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

HEAVY EQUIPMENT 

Use adequate personnel and support devices when mounting, moving, or handling the control unit to 

prevent equipment damage or personal injury. 

HOT SURFACE AND FLUID HAZARD 

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

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

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

• Allow the equipment to cool thoroughly before servicing. 

• Some heated systems are designed to dispense Polyurethane (PUR) heated materials. PUR Systems 

are supplied with ventilation hoods, and require proper ventilation and specifically designed 

system components. 


Model Identification 

Model Identification 


Graco’s PrecisionFlo LT is an electronically controlled 

fluid regulating package designed to meter and dispense 

adhesives and sealants. Your equipment was 

likely ordered as a configured package to fit your applicator. 

Model Number Identification 

On your control unit, there is an ID plate with a model 

number on it. Use the table on this page for explanations 

of each code letter and to define what equipment was 

ordered as part of the configured package from Graco. 

Typical Model Number 

LT-A -___ - ___ - ___ - ___ 

Code A B C D 

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

Code A: Control Unit 

Code B: Operations Cable 

Options 1-3 Options 1-N 

1. Standard 1. High Flex 25’ 

2. Advanced 2. High Flex 60’ 

3. Automation Integrated 3. High Flex 125’ 

4. Standard Flex 25’ 

Code C: Fluid Regulator 5. Standard Flex 60’ 

Options 01-10 6. Standard Flex 125’ 

01. Ambient Cartridge Regulator / No Flow Meter 7. Low Flex 25’ 

02. Ambient Cartridge Regulator / G3000 Flow Meter 8. Low Flex 60’ 

03. Ambient Cartridge Regulator / G3000 HR Flow Meter 9. Low Flex 125’ 

04. Ambient Cartridge Regulator / Helical Flow Meter N. None 

05. Ambient Cartridge Regulator / HR Helical Flow Meter 

06. Ambient Mastic Regulator / No Flow Meter Code D: Language 

07. Ambient Mastic Regulator / Helical Flow Meter Options 1-8 

08. Ambient Mastic Regulator / HR Helical Flow Meter 1. English 

09. Heated Mastic Regulator / No Flow Meter 2. French 

10. Heated Mastic Regulator / Helical Flow Meter 3. German 

4. Italian 

5. Japanese 

6. Korean 

7. Portuguese 

8. Spanish 


Overview 

Overview 

What This Manual Includes 

This manual provides detailed information about the 

PrecisionFlo LT control unit and operation of the PrecisionFlo 

LT system. Specific information on the fluid 

module for example is contained in other instruction 

forms supplied with each component as part of the PrecisionFlo 

LT system. 

Instruction Manual Conventions 

Reference numbers (10) and letters (A) in parentheses 

in this manual refer to the numbers and letters in the 

illustrations. 

Unless otherwise specified, the step-by-step procedures 

in this manual must be performed in numerical order. 

Procedures that contain a list preceded by bullets can 

be performed in any order. 

Abbreviations and Acronyms 

Abbreviation: 

COM 

FM 

GND 

msec 

OP 

psi 

PVC 

V 

VAC 

VDC 

Stands For: 

common 

flow meter 

ground 

milliseconds 

operations cable 

pounds per square inch 

poly vinyl chloride 

volts 

volts AC 

volts DC 

PrecisionFlo LT Definitions 

Component 

Control Unit 

Description 

The PrecisionFlo LT control unit contains 

the electronics used to control 

the fluid module. 

PrecisionFlo LT The control unit, fluid module, and all 

System cables and sensors used to measure 

and control the fluid application. 

Automation 

Controller 

EasyKey 

Fluid Module 

An external electronic (automation) 

system having some control interaction 

via electronic signals with the 

PrecisionFlo LT system. 

EasyKey is the type of interface used 

to set up, display, operate and monitor 

the PrecisionFlo LT system. 

The fluid module includes components 

that control and monitor fluid 

dispensing, such as a flow meter and 

regulator. 


PrecisionFlo LT Module Overview 

PrecisionFlo LT Module Overview 

The block diagram in FIG. 1 shows an example of the 

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

numbers. 

The fluid metering assembly contains the components 

that control and monitor fluid dispensing. It can be 

attached to an automation arm or mounted on a pedestal. 

The control assembly sends continuous voltage signals 

to the PrecisionFlo LT fluid assembly regulator to control 

fluid pressure and the opening and closing of the dispense 

valve. 

The control assembly receives input from the automation 

controller. The control assembly uses these inputs 

to determine the signals it should send to the fluid 

metering assembly. 

The PrecisionFlo LT fluid regulator is electrically controlled 

by the PrecisionFlo LT module, and consistent 

material flow is assured by a closed-loop pressure or 

closed-loop flow control design. The module responds 

to automation-supplied signals to provide an accurate 

and consistent output flow based on a comparison of 

actual to desired flow rates. The pneumatic regulator 

uses air pressure to control fluid pressure and to provide 

fast response to electronic commands and ensure 

a precisely controlled, continuous flow of material. 

Job Complete (3310) 

Dispense (3290) 

Flow Command (3150) 


Control Assembly 

Fault Present (2710) 

Dispenser Ready (2680) 

Min Volume Dispensed (2770) 

In Cycle (2740) 

Flow Rate (3210) 

Automation Controller 

 

 

Gun On 

V/P 

FIG. 1 


Fluid Metering Assembly 

D 

Flow Meter 

Outlet Pressure 


Typical PrecisionFlo LT Configurations 


Major components in a typical PrecisionFlo LT installation. 

5* 

10 

4 

8 

9 

1* 

6* 

11* 

2* 

3 

Air Supply 

Drop Site 

4 

7 

Note: For proper operation of filter assembly, filter orientation must be such that the bowls are orientated so the 

bowls are always perpendicular to the ground (i.e. do not attach to robotic arms, as the filters may not remain in the 

proper orientation.) 

FIG. 2 

No. Description 

1* PFlo Control Assembly 

2* PFlo Fluid Metering Assembly 

3 Applicator/Dispense Valve 

4 User Interface 

5* PFlo LT Automation Control Cable Interface 

6* PFlo LT Operations (OP) Cable 

7 Fluid Supply System 

8 Fluid Supply Header 

9 Filter Module 

10 Automation Controller 

11* Filter Assembly 

* included 




Optional Temperature Conditioned System 

6* 

4 

1* 

11 

Air Supply 

Drop Site 

9 

7* 

14* 

8 

2* 

13 

12 

3 

5 

13 

FIG. 3 


1* PFlo LT Control Assembly 

2* PFlo LT Fluid Metering Assembly 

3 Water Conditioned Applicator / Dispense 

Valve 


5 Sealer Automation 

6* PFlo LT Automation Control Cable 

Interface 

7* PFlo LT Operations (OP) cable 

8 Fluid Supply System 

9 Water Jacketed Supply Hose 

10 Water Jacketed Dispense Hose 

11 Temperature Control Unit 

12 RTD Cable 

13 Water Hose 

14* Filter Assembly 

* included 




Major components in a typical heated PrecisionFlo LT installation. 

5* 

4 

Air Supply 

Drop Site 

9 

1* 

8 

6* 

11* 

10 

2* 

3 

4 

7 

FIG. 4 


1* PFlo LT Control Assembly 

2* PFlo LT Fluid Metering Assembly 

3 Applicator/Dispense Valve 

4 Sealer automation 

5* PFlo LT Automation Control Cable Interface 

6* PFlo LT Operations (OP) Cable 

7 Heated Fluid Supply System 

8 Fluid Supply Hose 

9 2 - Zone Accessory Heat Control 


* included 


Fluid Metering Assembly Overview 

Fluid Metering Assembly Overview 

Pneumatic Fluid Metering Assembly 

The fluid metering assembly in FIG. 5 can be attached to 

an automation arm, or mounted on a pedestal. Main 

components of the fluid metering assembly are: 

• PrecisionFlo LT pneumatic fluid regulator (A) 

• Optional flow meter (B) to precisely measure the 

amount of fluid dispensed 

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

• Voltage to pressure (V/P) controller (D) for adjusting 

the air pressure to the fluid regulator (A) 

B 

A 

The PrecisionFlo LT module combines continuous pressure 

control with the ability to change bead profiles 

quickly. When used with one of the optional flow meters, 

the PrecisionFlo LT module automatically adjusts for 

fluctuations in the operating environment, such as material 

viscosity, temperature, tip wear, and automation 

speed, while maintaining the desired dispense rate. The 

module responds to automation-supplied signals to provide 

an accurate and consistent output flow based on a 

comparison of actual to desired flow rates. 

Typical Fluid Applications 

• PVC sealer 

• Plastisols 

• Sound deadening materials 

• Body panel reinforcement 

• Silicones 

• Hot melt 

 

 

C 

FIG. 5 

D 

PrecisionFlo LT Pneumatic Fluid 

Regulator 

The PrecisionFlo LT pneumatic fluid regulator is a precision 

fluid pressure regulator that uses air pressure to 

control fluid pressure and to provide fast response to 

electronic commands and ensure a precisely controlled, 

continuous flow of material. 


Installation 

Installation 

Overview 

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

for detailed information. 

Installation Steps 

1. Mount LT control unit 

2. Ground LT control unit 

3. Mount fluid plate 

4. Connect cables between the LT control unit and: 

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

b. Automation or cell controller (automation I/O cable) 

5. Check ground continuity 

6. Connect air and fluid lines 

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

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

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

7. Connect control unit to power source 

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

Before Beginning Installation 

• Have all system and component documentation 

available during installation. 

• See component manuals for specific data on component 

requirements. Data presented here applies to 

the PrecisionFlo LT assemblies only. 

• Electrical schematics are included in this manual. 

Refer to the schematics as required when connecting 

power and I/O signals. 

• Be sure all accessories are adequately sized and 

pressure-rated to meet system requirements. 

• Use the Graco PrecisionFlo LT control unit only with 

the PrecisionFlo LT fluid module. 


Installing the Control Unit 


Mounting the Control Unit 

WARNING 

Read Warnings, page 6. 

• Select a location for the PrecisionFlo LT control unit 

that allows adequate space for installation, service, 

and use of the equipment. See FIG. 6. 

• Mount the control unit so that the disconnect is readily 

accessible and located 54-67 in. (137-170 cm) 

above the floor. 

• For best viewing, the control display should be 60-64 

in. (152-163 cm) from the floor. 

• Ensure all fluid lines, cables, and hoses easily reach 

the components to which they will be connected. 

• Ensure there is sufficient clearance around the control 

unit to run cables to other components. 

• Ensure there is safe and easy access to an appropriate 

electrical power source. The National Electric 

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

the assembly enclosure. 

• Ensure the mounting surface can support the weight 

of the control unit and the cables attached to it. 

8. Secure the PrecisionFlo LT control unit with appropriate 

size bolts through the 0.31 in. (8 mm) diameter 

holes in the mounting tabs. 

14” 

356 mm 

12” 

305 mm 

Control Unit 

Back View 

12” 

305 mm 

12.75” 

324 mm 

13.5” 

343 mm 

FIG. 6 



Electrical Connections 

Follow these precautions when grounding, connecting 

cables, connecting to a power source or making other 

electrical connections. 

WARNING 

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

• The PrecisionFlo LT control unit must be electrically 

connected to a true earth ground; the ground 

in the electrical system may not be sufficient. 

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

• A qualified electrician must complete all grounding 

and wiring connections. 

• Refer to your local code for the requirements for a 

“true earth ground” in your area. 


Grounding Control Unit 

CAUTION 

To avoid control voltage differences, ensure that the 

automation and PrecisionFlo LT equipment are 

grounded to the same point. 

Connect a ground wire from the ground point in the PrecisionFlo 

LT control enclosure to a true earth ground. 

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

with clamp, Part No. 222011, is supplied. 

The PrecisionFlo LT fluid module is grounded to the 

control unit, using cables provided with the module. 

Ground Terminal 

L2 

L1 

CAUTION 

If power and grounding connections are not done properly, 

the equipment will be damaged and the warranty 

voided. 

FIG. 7 



Connecting to Power Source 

WARNING 

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

the resistance between the supply unit components 

and true earth ground must be less than 0.25 ohms. 


Have a qualified electrician connect the PrecisionFlo LT 

control assembly to a grounded electrical source that 

has the required service ratings, as shown in the Power 

Requirement table. 

To connect the control unit to the power source: 

1. Remove a hole plug to use one of the pre-cut enclosure 

holes or, if necessary for your installation, create 

an opening in the control assembly enclosure. 

Protect interior components from metal chips when 

cutting or drilling. 

2. Using the appropriate gauge wire, connect electrical 

power L1 and L2 to the top of the fuse terminal 

blocks, see FIG. 7, page 18. 

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

enter the enclosure. 

Power Requirements: 

VAC: 93 - 264 

Phase: 1 

Hz: 50/60 

Full Load Amps. 1 

Fused Amps 2 


Installing Fluid Metering Assembly 


To install the fluid metering assembly hardware: 

• Install the PrecisionFlo LT fluid metering assembly. 

• Connect the PrecisionFlo LT fluid metering assembly 

to the control assembly. 

• Connect fluid lines and cables. 

Installing the Fluid Metering Assembly 

WARNING 


Preparing to Install the Assembly 

Before installing the fluid metering assembly: 

• See component manuals for specific data on component 

requirements. Data presented here pertains to 

the PrecisionFlo LT fluid metering assembly only. 

• Have all system and subassembly documentation 

available during installation. 

• Be sure all accessories are adequately sized and 

pressure-rated to meet the system's requirements. 

• Use only the Graco PrecisionFlo LT fluid metering 

assembly with the PrecisionFlo LT control assembly. 

• Make sure the fluid metering assembly allows the 

automation unit to move freely along all axis. 

• Make sure the fluid metering assembly provides 

easy access for servicing its components. 

2. Locate and secure the PrecisionFlo LT fluid metering 

assembly to the automation unit (or other mounting 

surface) with appropriate size bolts through the 

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

See the mounting dimensions in Table 1 - Measurement, 

inches (mm) and FIG. 8. 

Table 1 - Measurement, inches (mm) 

A 16.0 (407) 

B 15.0 (381) 

C 11.0 (280) 

D 8.0 (204) 

A 

B 

Installing the Assembly 

C 

 

 

WARNING 

D 


1. Select a location for the PrecisionFlo LT fluid metering 

assembly. Keep the following in mind: 

• Allow sufficient space for installing the equipment. 

• Make sure all fluid lines, cables and hoses easily 

reach the components to which they will be connected. 

FIG. 8 



Connecting Fluid and Air 

Lines 

CAUTION 

Route all fluid and air lines carefully. Avoid pinching 

and premature wear due to excessive flexing or rubbing. 

Hose life is directly related to how well they are 

supported. 

Follow the instructions in your separate component 

manuals to connect air and fluid lines. General guide 

lines are provided below. 

• The PrecisionFlo LT fluid module should be installed 

on the automation unit or in another appropriate 

place, as close as practical to the dispense valve. 

• Connect a fluid line between the fluid module outlet 

and the dispense device. Smaller diameter and 

shorter fluid lines (hoses) will provide better fluid system 

response. 

• Connect a fluid line to the flow meter fluid inlet or regulator 

inlet if your system does not have a flow meter. 

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

MPa - 4.14 bar). Flush air line before plumbing in air 

filter assembly (234967). Plumb in air filter assembly 

near air drop site (upstream of fluid plate module). 

Adding an air regulator to this line will provide more 

consistent dispense valve response times. 

• Connect an air supply line to the 1/4 npt inlet port on 

the fluid module(s) air supply inlet. 

• Connect 5/32 in. or 4 mm OD air lines from the applicator's 

solenoid valve to the applicator. Plug any 

unused solenoid ports. 

To maximize system performance keep the dispense 

hose length and ID as small as the application 

will allow. 

Grounding the Metering Assembly 

Grounding the Fluid Metering Assembly 

WARNING 


CAUTION 

If power and grounding connections are not done 

properly, the equipment will be damaged and the warranty 

voided. 

Air and Fluid Hoses 

For static dissipation, use only electrically conductive 

hoses or ground the applicator / dispense valves. 

Metering Module 

The PrecisionFlo LT fluid metering assembly is 

grounded to the control assembly through proper connection 

of the electrical cable provided with the metering 

module. 

Dispense Device 

Follow the grounding instructions in the dispense device 

documentation. 

Ground the fluid metering assembly as instructed here 

and in the individual component manuals. Make sure the 

fluid metering assembly and its components are 

installed correctly to ensure proper grounding. 


Installing Cable Assemblies 

Installing Cable Assemblies 

B 

B 

*Operations Cable 

Automation I/O 


Control Unit 

FIG. 9 

*Available in 

lengths of: 

25’, 60’, or 125’ 

Automation I/O 

Controller 

Fluid Module Cables 

Operations Cable (13) - This cable carries signals 

between the fluid module and the control unit. The 

applicator solenoid, V/P valve, pressure transducer and 

flow meter signals are carried through this cable. 

Automation I/O Cable (17) - This cable carries signals 

between the automation controller and the PrecisionFlo 

LT control unit. 

Maximum recommended length of both the operations 

and automation cable is 125 ft. (38.1 m). 

FIG. 10 

13 17 

Control Unit - Top View 

CAUTION 

Always make connections to the control assembly with 

the power off. 

Connecting the Operations Cable 

Operation cables are offered in three lengths (25, 60, 

and 125 ft.) and three flexibilities (see page 6 for cable 

options.) 

To connect the operation cable between the control unit 

and fluid module do the following: 

1. Locate the receptacle on the top of the control unit. 

See Fig. 8. 

2. Connect the operation cable to the control unit revceptable. 

3. Locate the receptacle on the fluid module junction 

box. 

4. Route the operation cable and conform to the following 

cable routing requirements: 

• Avoid small bend radii. 

• Avoid pinch points. 

• Avoid cable pulling or stretching. 

• Keep cables from rubbing against other components 

or machinery. 

• If a lot of robot wrist motion is required, leave 

sufficient cable length to allow for the motion, 

avoiding any cable droops that may interfere 

with the machinery or substrate. 

• Cable ties should only be used to loosely bundle 

hoses together. Do not tighten cable ties to the 

point where cable movement is restricted. 

5. Connect the operation cable to the fluid module 

junction box. 

6. Check the connections to ensure the cable is connected 

correctly. 


Installing the Cable Assemblies 


CAUTION 

Always make connections to the control assembly with 

the power off. 

Connecting the Automation Control 

Cable 

The PrecisionFlo LT control assembly is provided with 

an 18-pin receptacle for the automation I/O cable. 

Any wiring from an external source such as an 

automation controller, must follow the automation manufacturer’s 

instructions and must comply with the appropriate 

codes and standards. 

The automation cable has terminated individual 

leads. The installer will need to configure the proper 

connector for the automation/cell controller being used. 

Refer to Appendix C Theory of Operation on page 95 

and Appendix A PrecisionFlo LT User Interface on 

page 84. 

To connect the automaton control cable between the 

control assembly and the automation perform the following 

steps: 

Signal Wire No 

Dispense Gun / 3290 

Job Complete / 3310 

Dispenser Ready / 2680 

Fault Present / 2710 

In Cycle / 2740 

Minimum Volume Dispensed 

/ 2770 

PFlo LT E-Stop / 2170 

Analog Flow Command / 

3150 

Description 

Digital Input 

This signal is used to control the opening of the dispense 

valve. 

This signal can be used to signal the end of a job. 

Digital Output 

This signal indicates to the automation controller that 

the PrecisionFlo LT unit is ready to dispense. 

This signal indicates to the automation control when a 

fault is present. 

This signal indicates to the automation control that the 

PrecisionFlo LT unit is currently in a job cycle. 

This signal indicates when the minimum amount of 

material is dispensed. 

This signal indicates to the automation control when 

the emergency stop is depressed on the PrecisionFlo 

LT unit. 

Analog Input 

This signal represents the flow or pressure requests 

from the automation control. 

Analog Output 

Actual Flow Rate Signal Analog output signal of the current system flow rate. 

3210 

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

24 VDC Common / 2121 Digital reference point. 

Analog Common / 3170 Analog reference point. 

GND 

Shield connection. 

1. Locate the receptacle on the top of the control 

assembly. See FIG. 10. 

2. Connect the cable assembly to the automation I/O 

receptacle in FIG. 10. 

3. Connect the opposite end of the cable assembly to 

the applicable terminals or receptacle on the robot 

controller. 

For information about specific control assembly circuitry 

and connections, read the chart on this page and see 

the Wiring Diagrams beginning on page 69 and FIG. 10. 

4. Check the connections to ensure the cable is connected 

correctly. 



Checking Ground Continuity 

WARNING 

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

the resistance between the supply unit components 

and true earth grounding must be less than 0.25 

ohms. 


Have a qualified electrician check the resistance 

between: 

• true earth ground and the panel ground lug 

• the application device and the automation unit 

• the fluid module and the automation unit 

• the regulator and the automation unit 

• each supply system component and true earth 

ground 

The resistance must be less than 0.25 ohms. If the 

resistance is greater than 0.25 ohms, a different ground 

site may be required. Do not operate the system until 

the problem is corrected. 


PrecisionFlo LT Module Operation 


Reading PrecisionFLo LT Control / Indicators 

1 

7 

FIG. 11 

2 

3 

4 

6 

Table2-PrecisionFlo Buttons/Switches 

Ref Button/Switch What it Does 

4 Sealer Stop Button • Disables all air solenoids and V/P regulators. 

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

6 Run/Setup Mode Key 

Switch 

7 Main Electrical Power 

(Disconnect) Switch 

Table3-PrecisionFlo LT Indicators 

• Turn key switch counter-clockwise to set control unit to Run Mode. When the 

key is in Run Mode or removed, you can operate and monitor the system. 

• Turn key switch clockwise to set control unit to Setup Mode (for software configuration). 

The key cannot be removed while turned to Setup Mode. 

• Turns on power to system. 

• Lights Condition Light(s). 

Ref Indicator Indicator Meaning 

light 

1 User Display On Display is on when power is applied to the control assembly. 

Off Display is off when power is removed from the control assembly or 

the screen saver is active. Press any key to activate the screen. 

Table4-PrecisionFlo Indicator Lights 

Dispenser Ready Fault Present Light 

Light (Ref 2) Status (Ref 3) Status 

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

present. 

On Off System is in auto mode with no fault present. 

On On System is in auto mode with a minor fault present. 

Off On System is in auto or manual mode with a major fault present or 

the system is in manual mode with a minor fault present. 




PrecisionFlo LT User Interface 


The EasyKey User Interface is available with the PrecisionFlo 

LT control unit. 

For screen-captures of the screens and your selection 

options, see page 84 for the EasyKey interface. 

EasyKey User Interface Overview 

Screen 

Navigation Keys 

Data Field 

Navigation Keys 

Bead Size Decrease 

Bead Size Increase 

Help Key 

Manual 

Dispense Gun 

Enter Key 

Fault Reset 

Auto / Manual 

FIG. 12 

Key Groups 

There are three groups of keys on the PrecisionFlo LT 

user interface. 

• Action Keys – perform an action when they are 

pressed. Manual Dispense Gun, Fault Reset, Bead 

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

Manual. See Action Keys at right. 

• Numeric Entry Keys – are used to enter variable 

data into the controller. 

• Navigation Keys – are used to navigate between 

and within the different user screens. 

Action Keys 

• Manual Dispense Gun – is used for functions 

related to the regulator and dispense gun, including 

manual dispense, and calibration. 

• Bead Size – is used to increase or decrease the 

bead size during unit operation. This feature is 

enabled / disabled in the setup screens. 

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

• Fault Reset – is used to reset a fault generated on 

the control once the fault has been corrected. 

• Auto / Manual – is used to change the mode of 

operation between Automatic and Manual. 



Operation Modes 

The PrecisionFlo LT system has two operating modes: 

• Automatic dispense mode – enables the Precision- 

Flo LT module to begin dispensing when it receives a 

command from the automation unit. 

• Manual dispense mode – enables the Precision Flo 

LT module to begin dispensing when you press Manual 

Dispense Gun on the EasyKey interface. Dispensing 

continues for as long as the Manual 

Dispense Gun button is pressed. Manual mode is 

also used for system tuning or calibration. 

To select the Operation Mode and to operate in manual 

dispense mode, see the following specific instructions. 

Refer to Appendix C, Theory of Operation, page 95 

for more information on Operation Modes. 

locations. 

Refer to Keypad Overview on page 27 for key 

Setting Operation Mode 

On the keypad, perform the following steps: 

1. The dispense mode is indicated on the run screen, 

either Auto or Manual. 

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

Control Modes 

The PrecisionFlo LT module has four fluid dispensing 

control modes: 

• Bead Control – the control unit measures the flow 

rate of material being dispensed. The regulator outlet 

pressure is varied to control the fluid flow rate to the 

requested value. Use Bead Control Mode when a 

consistent bead size is required. 

• Volume Monitor – regulator outlet pressure is controlled 

to the requested value. Use Volume Monitor 

Mode when a constant pressure is required for a 

spray application. 

• Batch Dispense – regulator outlet pressure is controlled 

to the requested value. Dispense valve is 

closed when target volume is reached or the automation 

provides a signal. 

• Pressure Control – regulator outlet pressure is controlled 

to the requested value. Use pressure control 

mode if the system does not include a flow meter. 


for more information on Control Modes. 

Setting the Control Mode 

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

2. The control mode is indicated on the dispense 

screen. 

Manually Dispensing Fluid 


1. Place the system in manual dispense mode. Refer 

to Setting Operation Mode, above. 

3. To change the mode, press the down arrow key 

until the cursor is over the mode cell. 

4. Press Enter and use the up and down arrow keys, 

or to change values. 

2. Press the Manual Dispense Gun key . 

5. Press Enter. 

a. Press the key and verify that the dispense 

device opens. 

b. Continue to press the key as long as needed to 

load material or dispense. 


Automation Modes 

The PrecisionFlo LT system has two automation command 

modes: 

• Fixed mode – enables the PrecisionFlo LT system to 

dispense at preset rate in the control unit. 

• Analog mode – enables the PrecisionFlo LT system 

to dispense at a rate proportional to a 0-10 VDC analog 

input signal from the automation unit. 


for more information on Automation Command Modes. 


Setting Automation Mode 


1. With the system in setup mode (key switch clock 

wise), press the right arrow key until the 

OTHER screen appears. The command mode is 

indicated on this screen, either Fixed or Analog. 

2. To change the mode, press the down arrow key 

until the cursor is over the desired mode cell. 

3. Press Enter and use the up and down arrow keys, 

or to change values. 

4. Press Enter. 


Operation 

Operation 

Pressure Relief Procedure 

Dispense Valve 

Air Solenoid 

WARNING 


This procedure describes how to relieve pressure for the 

PrecisionFlo LT system. 

1. Shut off the fluid supply to the fluid module. 

 

To Dispense 

Valve 

2. Place a waste container beneath the fluid drain 

valve, which is located at the filter. Place a waste 

container beneath the dispense device. 

3. Slowly open the drain valve, located at each filter, to 

relieve fluid pressure. Close valve when pressure 

gauge reads zero. 

4. In manual dispense mode, touch and hold the Manual 

Dispense Gun key , which will open the regulator 

and the dispensing device, until the fluid stops 

flowing from them. 

5. If the dispense device cannot be actuated from the 

control unit, refer to FIG. 13 and perform the following 

steps to open the dispense device and relieve 

fluid pressure: 

a. Manually actuate the plunger on the solenoid, 

that opens the dispense device, to relieve fluid 

pressure. Refer to FIG. 13. 

b. Continue actuating the plunger until all pressure 

is purged from the system between the needle 

and the dispense device before proceeding to 

thenextstep. 

FIG. 13 

If you have followed the steps above and still suspect 

that a valve, hose, or dispense nozzle is clogged or 

pressure has not been fully relieved, very slowly remove 

the dispense tip, clean the orifice, and continue relieving 

pressure. 

If this does not remove the obstruction, very slowly 

loosen the hose end coupling and relieve pressure gradually, 

then loosen the coupling completely. Clear the 

valves or hose. Do not pressurize the system until the 

blockage is cleared. 

Safety Reminder 

Follow the precautions below and the warnings that 

begin on page 6. 

WARNING 


Manual 

Actuator 

6. Shut off power and air to the fluid supply systems. 


Operation 

FIG. 14 

Initial Startup 

Read and understand Operation 

section of this manual 

Startup system 

Check interface 

signals 

Load Material 

Verify flow meter 

K-factors 

Configure software 

End Initial Startup 

Be sure to set the max outlet pressure range 

switch in the fluid module junction box to the appropriate 

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

pressure) must match the junction box setting. See page 

92. 

See Table2-PrecisionFlo Buttons/Switches 

and PrecisionFlo LT User Interface, page 32 for information 

on the PrecisionFlo LT control unit buttons, 

switches, and indicator lights. 

1. Carefully inspect the entire system for signs of leakage 

or wear. Replace or repair any worn or leaking 

components before operating the system. 

2. Press the E-stop button (4). See FIG. 15. 

3. Turn on air and electrical power to the system. 

4. Turn on the main electrical disconnect (7) to supply 

power to the PrecisionFlo LT module. 

The user interface becomes active, showing first a 

diagnostic message and then the first screen. The 

dispenser ready (2) and / or the fault present indicator 

light (3) turns on. 

5. Check Interface Signals: If this is a new installation, 

power each of the system inputs and verify that 

the input is being received. 

6. Turn on material supply system. 

Starting the System 

7 

Initial Startup 

1. Make sure you have installed and made all the 

proper connections to and from the PrecisionFlo LT 

control assembly enclosure. Make sure fittings are 

tight. 

2. Read and understand the Operation and Software 

Configuration sections of this manual. 

3. Continue startup with step 2 in Standard Startup. 

1 

FIG. 15 

2 3 

4 6 


Operation 

Loading Material 

Before you can configure the software, you must load 

material into the supply system. 

1. If this is a new installation, follow the Initial Start up 

procedure. Otherwise, follow the Standard Startup 

procedure. See page 31. 

2. Turn on fluid supply pressure to the fluid module. 

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

4. Set the control unit to Manual mode. See Operation 

Modes, below. 

5. Select a control mode other than bead control. Dispensing 

in bead control mode is not possible until a 

flow calibration has been performed. See Control 

Modes on page 28. 

6. Disengage the E-stop button (4). See FIG. 15. 

7. Press and hold the Manual Dispense Gun key 

. Manually dispense fluid until clean, air-free 

fluid flows from the Dispense Gun. 


Configuring Software 


After you have loaded material into the dispensing system, 

configure the PrecisionFlo LT software. FIG. 16 

shows the major configuration steps. 

Configure Software 

Select Control 

Mode. Ref Page 27 

Calibrate 

system 

Verify flow 

meter K-factor 

Calibrate 

system 

Set user and 

system variables 

Set dispense 

on/off delays 

The PrecisionFlo LT system compensates for temperature, 

flow, or pressure fluctuations. However, if you 

change hardware on the dispensing system or change 

the type of material being dispensed, you must reconfigure 

the PrecisionFlo LT software. 

To configure the PrecisionFlo LT software, perform the 

following procedure. When you have completed this procedure, 

the module is ready for operation. 

1. Select the desired control mode. See page 28. 

2. Calibrate the system. See page 34. 

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

4. Verify other controller preset values. See page 37 

for more information. 

5. The PrecisionFlo LT User Interface section on 

page 27 gives detailed operating instructions for the 

display keypad and each screen. 

For more information regarding applications that 

run continuously see Appendix C, Theory of Operation, 

page 95. 

End Software 

Configuration 

FIG. 16 



Setting Flow Meter K-Factors 

The accuracy of the PrecisionFlo LT volume reporting 

depends on precise adjustment of the K-factor(s). The 

control unit uses the K-factor(s) to calculate the volume 

dispensed. If the set value is not correct, the system still 

delivers accurate and repeatable flow rates; however, 

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

additional K-factor information. 

Table4-FlowMeterK-Factors 

Part No. Description K-Factor 

239716 G3000 Gear Meters 8400 

244292 G3000 HR Gear Meter 16400 

246190 Helical Gear Meter 3500 

246652 High Resolution Helical Gear 7000 

Meter 

246340 Heated Helical Gear Meter 3500 

Set Flow Meter K-Factor 


1. With the system in setup mode, press the screen navigation 

key until the OTHER screen appears. 

2. Press the down data field navigation key until the 

flow meter K factor value is highlighted. 

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

4 - Flow Meter K-Factors for values. 

System Calibration 

Pressure Calibration 

The PrecisionFlo LT system uses variables (Kp and Ki) 

in the software calculations to accurately and precisely 

control the fluid pressure and flow rate. The control unit 

calculates Kp and Ki automatically during pressure calibration. 

These values are different with every material. 

3. Verify that the fluid module air supply is on. 

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

value. 

Calibrate 


1. Press the right screen navigation key until the 

Calibrate screen appears. 

2. Enter the desired 100% command Flow/Pressure. 

3. Press the Manual Dispense Gun key . The system 

will dispense material for 15-30 seconds and 

gather the required information. 

Manually Adjusting Kp and Ki 

If automatic pressure calibration does not result in 

proper system pressure control, you can change the Kp 

and Ki values manually: 

• If the regulator outlet pressure does not closely follow 

the desired pressure increase Kp with the Ki 

value set to zero. Continue to increase the Kp value 

by 10% increments until the proper pressure control 

is achieved. 

• Decrease Kp if the regulator outlet pressure oscillates 

rapidly above and below the commanded pressure. 

Continue to decrease the Kp value by 10% 

increments until the outlet pressure is stable. 

• Set Ki volume to 2 and continue to increase the Ki 

value by 2 until the system oscillates. 

• Decrease Ki until oscillation stops. 

The system must be loaded with material before 

calibrating pressure. The nozzle or tip should be 

installed on the dispense device. 

Before Calibrating 

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

dispense mode. 

2. Verify that dispense device is placed over a material 

waste container. 



Flow Rate Calibration 

The system only calibrates flow rate if you are operating 

in Bead Control Mode. Flow rate calibration takes place 

immediately after the pressure calibration in bead control 

mode. 

How Flow Rate Calibration Works 

Each application may have different flow rate requirements. 

Flow rate calibration verifies the maximum flow 

rate of the system and determines the regulator outlet 

pressure required to achieve the required flow rate. 

At the start of the flow rate calibration procedure, you 

need to enter the maximum flow rate required by the 

application. When you actuate the dispensing device 

during calibration, the control unit: 

1. Measures the maximum system flow rate. If the 

maximum system flow rate is less than the required 

maximum flow rate a fault is generated. 

2. Determines the outlet pressure required to obtain 

the flow rate value you entered. 

3. Calculates a linear ratio of the automation analog 

input voltage to the desired flow rate. Refer to FIG. 

17. 

FIG. 17 

Flow mode: Analog voltage to flow rate ratio 

Max. 

Flow 

Rate 

Flow Rate 

(cc/minute) 

0 

0 Automation Flow Command 10 

Volts (Vdc) 

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

Round Equivalent Bead Diameter (mm) 

Max. Automation 

Speed 

(mm/sec) 

2 3 5 7 9 

50 10 21 59 115 191 

100 19 42 118 231 382 

200 38 85 236 462 763 

300 57 127 353 693 1145 

400 75 170 471 924 1527 

500 94 212 589 1155 1909 

600 113 254 707 1385 2290 

700 132 297 825 1616 2672 

800 151 340 943 1847 3054 

900 170 382 160 2078 3435 

1000 189 424 1178 2309 3817 

Setting Inlet Pressure 

The inlet pressure reading should be in the range of 300 

psi (2.1 MPa, 21 bar) to 500 psi (3.4 MPa, 34 bar) above 

the outlet pressure reading under your highest flow condition. 

Excessive inlet pressure will cause accelerated wear on 

the regulating valve and the pump feed system. 

Feed System Pressure Drop 

During material flow, the regulator inlet pressure 

decreases. The amount the pressure decreases is the 

amount of pressure lost between the feed pump and the 

regulator inlet. With high viscosity fluids, long line 

lengths, or small diameter line sizes this pressure 

decrease can be thousands of psi (hundreds of bar). 

This means that the static pump pressure is set much 

higher than the regulator needs at its inlet. To prevent 

excessive control regulator wear or surging, a mastic 

fluid pressure regulator is recommended on the feed line 

close to the control regulator. The mastic regulator will 

suppress the static feed pressure at the control regulator 

inlet. 

Flow Rate Guide 

Use the values in Table 5 - Maximum Flow Rate Values 

(cc/min) as a guide to determine the maximum flow 

rate to enter during flow rate calibration. 



Verifying Flow Meter 

Calibration 

Most sealant and adhesive materials are compressible. 

Since the flow meter is measuring the material under 

high pressure, the actual volume of material dispensed 

may vary slightly from the measured volume, due to this 

compressibility. If the K-factor is not correct, the displayed 

volume will not be accurate. 

Follow this procedure to calibrate the flow meter during 

initial setup and on a routine basis to check for flow 

meter wear. 

Method 1. Using a gram scale 

1. Obtain a beaker, 500 cc or larger, and measure the 

mass of the empty beaker. 

2. Manually dispense material into the beaker. Hold 

the beaker so that the stream of material is submerged 

in the captured material. This is to minimize 

air entrapment in the container. 

3. Record the volume dispensed on the Run screen 

and the flow meter K-factor from the Setup Other 

screen. 

4. Calculate the actual volume dispensed: 

fluid mass (g) 

density (g/cc) 

5. Calculate the new flow meter K-factor: 

K-Factor (new) = 

6. Enter new K-factor. 

= measure volume (cc) 

displayed volume (cc) x K-Factor (old) 

measured volume (cc) 

Method 2. Without using a gram scale, visual measurement 

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

increments. 

2. Manually dispense material into the beaker. Hold 

the beaker so that the stream of material is submerged 

in the captured material. This is to minimize 

air entrapment in the container. 

3. Record the volume dispensed on the Run screen 

and the flow meter K-factor from the Setup screen. 

4. Settle the material into the beaker and view the 

actual volume dispensed. 

5. Calculate the new flow meter K-factor: 

K-Factor (new) = 

6. Enter new K-factor. 

displayed volume (cc) x K-Factor (old) 

dispensed volume (cc) 

7. Repeat the procedure to verify the new K-factor. 

Other Software Settings 

There are various software settings that are preset at 

the factory, based on the system configuration that was 

ordered. A quick check of these variables is recommended. 

See Table5-PrecisionFlo LT User Variables 

and Presets and Table6-PrecisionFlo LT 

System Variables. 

The PrecisionFlo LT User Interface screens are listed 

in Appendix B beginning on page 84 to guide you 

through the process. 

7. Repeat the procedure to verify the new K-factor. 



Setting User Variables 

The following variables and presets should be verified prior to calibration and path programming and/or operation in 

automatic mode. All of the screens as well as additional screen information can be viewed in Appendix B, PrecisionFlo 

LT User Interface, starting on page 84. 

There are additional variables that should be set after the path programming is completed, they include; High/Low 

pressure settings and Style (volume) information. 

Table 5 - PrecisionFlo LT User Variables and Presets 

Values in italics are factory defaults. 

Screen Variable / Preset Values Comments 

Dispense Control Mode Bead Control, Volume Monitor, 

Batch Dispense, or pressure 

control 

Only bead control mode controls flow. 

Other Command Mode Analog or Fixed 

Job End Mode Timer or Digital I/O 

Language Many Set the desired language. 

Pressure Units psi or bar Set the desired pressure units. 

Manual Gun Flow 

Rate 

Other System Variables 

After the calibration and automation path programming is complete and the desired bead profiles have been 

achieved, verify that the following variables are set. 

Table 6 - PrecisionFlo LT System Variables 

0 - 100%, 50% Flow rate or pressure setting for Manual 

Dispense. 

Job End Delay 0 - 999 sec, 4 sec Delay time after dispensing for job complete 

if Job End Mode is set to Timer. 

Year, Month, Day, 

Hour, Minute 

Set the Time and Date. 

Default / Fixed 

Command 

0-100%, 50% Set value for fixed command mode. If the 

command signal falls below 1 VDC in analog 

mode, this value will be used as the 

command. 

Screen Variable / Preset Values Comments 

Dispense Volume 0 - 9999 cc, 25 cc Set the volume set point for each of the styles being used. 

Tolerance 0 - 99.9%, 10% Set the volume tolerance for each of the styles being used. 

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

Appendix B, PrecisionFlo LT User Interface. 

An Alarm will cause the fault present signal to activate and the dispenser ready signal to drop out. This 

is something considered by the user to be a major fault, one which should cause the system to stop 

dispensing. 

A Warning will cause the fault present signal to activate and the dispense ready signal to stay on. This 

is something considered by the user to be a minor fault, one which will warn the user but will continue 

dispensing even if the bead profile is degraded. 



On/Off Delays 

The PrecisionFlo LT regulator can physically respond 

faster than the dispense device and its solenoid. As a 

result, the regulator can supply material to the dispense 

device before the device has time to open. Supplying 

material to a closed device can create trapped-pressure. 

At the end of a cycle, the dispense device can shut off 

before the pressure has dissipated. This can cause a 

dispense of an excess of material at the beginning of the 

next cycle. 

To eliminate these two problems, you can change the 

delay time associated with the opening of the regulator/dispense 

and/or the closing of the dispense device, 

see Table 7 - On/Off Delay Variables. 

In general, your outlet pressure on the screen during “no 

flow” should be slightly below the outlet pressure during 

dispense. If your dispense hose to the gun is creating 

too much pressure drop during flow, you may want the 

no flow reading to be lower. High trapped pressures 

shorten the dispense device life. 

Table 7 - On/Off Delay Variables 

Variable: 

Gun ON 

Regulator ON 

Gun OFF 

Regulator 

OFF 

Sets the Amount of Time: 

Sets time from Dispense Gun High to 

Gun Open command 

Sets time from Dispense Gun High to 

Regulator ON 

Sets time from Dispense Gun Low to 

Gun Close command 

Sets time from Dispense Gun Low to 

Regulator OFF 

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

ON and OFF timing. 

Dispense Gun 

Signal 


Regulator 

A 

C 

D 

Gun Open 

Command 

B 

Gun Actually 

Open 

FIG. 18 

E 

F 

Table 8 - Delay On/Off Timing 

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

B Gun ON delay Usually set to zero. Can be used to change the starting point of a bead. 

C Gun OFF Delay Usually set to zero. Higher values will lower the trapped pressure. 

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

trapped pressure. 

E Gun Open Reaction Time delay for gun to physically open. Delay varies based on pneumatic hose length 

Time 

and valve air volume. 

F Gun Close Reaction Time delay for gun to physically close. Delay varies based on pneumatic hose length 

Time 

and valve air volume. 

Regulator Pre-Charge 

Another method which can be used to increase the dispense hose pressure while the dispense valve is closed is to 

use a regulator pre-charge. Setting this value to a range of 1.00 to 5.00 VDC causes the V/P to apply 0 to 100 psi (.60 

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



Shutting Down the System 

1. Shut off the material supply to the fluid module. 

2. Follow the Pressure Relief Procedure on page 30. 

WARNING 

2 


3. Turn off the PrecisionFlo LT system's compressed 

air supply. 

4. Press the sealer stop button (7). See FIG. 19. 

5. Turn off the main electrical disconnect (2). 

FIG. 19 

7 


Communicating with PrecisionFlo LT 


Communication with the PrecisionFlo LT is carried out 

through the Graco Shell program (included). This is a 

text based menu program that you can use to perform 

the following tasks: 

• Upgrade software 

• Display software versions 

• Download job and alarm logs 

• Backup and restore setup parameters 

• Restore the factory defaults 

You can access the Graco Shell program via the programming 

port on the side of the control box. Plug one 

end of the programming cable into the RJ12 (phone jack 

style) on the control box and the other end of the cable 

into the serial (COM port) of a computer. 

For more information on the use of Ethernet and 

Ethernet Kit 118329 see Appendix D, Ethernet Kit 

118329, page 106. 

The laptop computer used to interface to the Graco 

Shell must be running some type of terminal emulation 

software. Some examples are Hyper Terminal or Tera 

Term. Graco recommends using Tera Term which can 

be downloaded from http://hp.vector.co.jp/authors/ 

VA002416/teraterm.html. The following communications 

parameters must be used (these are the default 

parameters in Tera Term). 

Setting 

Value 

Port COM 1 or COM 2 

Baud Rate 57600 

Data 

8 Bit 

Parity 

None 

Stop 

1 bit 

Flow Control 

None 

Once the programming cable is connected and the communications 

software is running, the user can activate 

the Graco Shell by pressing the Enter key on the keyboard. 

The main menu will be displayed. 

The main menu will look as follows: 

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

Build date: Mar 05 2003 14:23:23 

a. Software Update and Version Information 

b. Data Transfer 

c. Restore settings to factory defaults 

Enter Selection [a-c]: 

Upgrading Control Board Software 

To upgrade the controller software, you must first obtain 

the latest version of Ltcontrol.rec. Contact your Graco 

distributor for details. 

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

Setup mode. The following text will be displayed. 

Are you sure? 

Enter yes to continue: 

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

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

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

Warning: you are about to erase your application 

software. 

Type ‘yes’ to continue upgrading software 

(reboot to cancel). 


Sector 1 erased. 



Hyperterminal: Go to (Menu Transfer XXX Send 

Text File) and select *.rec file. 

Tera Term: Go to (File XXX Send File) and 

select *.rec file. 

Select Send File from the File menu in Tera Term. Then 

select the Ltcontrol.rec from the selection box window 

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

The file will begin to download to the controller, which 

will take approximately one to two minutes. When the 

download is complete, a new menu will appear on the 

screen. The software upgrade is now complete. Cycling 

power to the controller is recommended after a software 

upgrade. 



Upgrading Display Board Software 

To upgrade the display software, you must first obtain 

the latest version of Ltdisplay.rec. Contact your Graco 

distributor for details. 

To upgrade the Display Software the jumpers 

between terminals 2540 and 2541and terminals 2550 

and 2551 should be moved to connect terminals 2541 

and 3720 and terminals 2551 and 3740. 

Once the programming cable is connected and the communications 

software is running, the user can activate 

the Graco Shell by pressing the Enter key on the keyboard. 

The main menu will be displayed. 

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

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

a. Install Display Application Software 

b. Display Software Versions 

Enter Selection (a-b) 

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

Setup mode. The following text will be displayed. 

Are you sure? 

Enter yes to continue: 


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

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

Warning: you are about to erase your application 

software. 

Type ‘yes’ to continue upgrading software 

(reboot to cancel). 





Hyperterminal: Go to (Menu Transfer XXX Send 

Text File) and select *.rec file. 

Tera Term: Go to (File XXX Send File) and 

select *.rec file. 

Select Send File from the File menu in Tera Term. Then 

select the Ltdisplay.rec from the selection box window 

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

The file will begin to download to the controller, which 

will take approximately one to two minutes. When the 

download is complete, a new menu will appear on the 

screen. The software upgrade is now complete. Cycling 

power to the controller is recommended after a software 

upgrade. 

Displaying Versions 

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

Boot Code version: 1.01.001, checksum=52c2f6, 

built:Mar 10 2003 14:47:49 

Application: 1.01.001, checksum=cc5bd, 

built:Mar 05 2003 14:47:49 

Return to Main Menu 

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

Welcome to the Graco Control Application Menu 

Build date: Jul 06 2001 15:45:38 (debug build) 

a. Software Update and Version Information 

b. Data Transfer 

c. Restore settings to factory defaults 

Enter Selection [a-c]: 

Restoring Defaults 

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

Are you sure? Enter yes to continue: 

Type “yes”. 

When the operation is complete, the main menu will 


Maintenance 

Maintenance 

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

The maintenance is divided between mechanical and electrical tasks. Maintenance must be performed by trained 

personnel per this schedule to assure safety and reliability of the equipment. 

Mechanical 

Operator 

Maintenance Person 

Task Daily Weekly Monthly 3-6 

months 

or 

125,000 

cycles 

Inspect system for leaks 

✓ 

Depressurize fluid, after operation 

✓ 

Remove heat from system, after ✓ 

operation 

Inspect filter (234967) bowls 

✓ 

and drain 

Check hoses for wear 

✓ 

Check/tighten fluid connections 

✓ 

Check/tighten air connections 

✓ 

Lubricate dispense valves* 

✓ 

Rebuild regulator* 

✓ 

Rebuild dispense valve* 

✓ 

Replace air filter (234967) 

assembly 

Replace Solenoid 

Replace V/P valve 

* Check component manual for more detailed maintenance information. 

6-12 

months 

or 

250,000 

cycles 

18-24 

months 

or 

500,000 

cycles 

✓ 

36-48 

months 

or 

1,000,000 

cycles 

✓ 

✓ 

Electrical 

Task Daily Weekly Monthly 6 months 12 months 

Calibrate flow meter** 

✓ 

Check cables for wear 

✓ 

Verify cable connections 

✓ 

Verify resistance of electric heaters* 

✓ 

Verify operation of “System Stop” button 

✓ 

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

* Check Component Manual for more detailed maintenance information. 


Troubleshooting 


WARNING 


Troubleshooting for individual regulators and flow 

meters is discussed in their separate manuals. These 

manuals are called out in the parts lists later in this manual. 

Also refer to the section on Troubleshooting and 

Fault Recovery for detailed information on how fault 

codes are communicated. 

Check all possible solutions in the chart below 

before you disassemble the regulator. 

Fluid Modules 

Problem Cause(s) Possible Solution(s) 

No outlet pressure Air pressure low Verify air pressure is above 60 psi 

(0.4 MPa, 4 bar) 

No “Gun On” signal from automation 

unit 

Check input from automation unit 

No output signal from system I/O 

board 

No air signal to air diaphragm 

False signal being sent to control 

Check signal from system I/O 

board, verify that a signal is being 

sent (1-5 VDC) 

Check for loose/disconnected/worn 

operations cable; tighten/replace as 

required 

Check for loose/disconnected DIN 

connector to V/P valve; tighten 

Check outlet pressure sensor out 

put; verify that it corresponds to 

zero pressure; replace sensor 

and/or amplifier 

High outlet pressure Needle/seat is worn Rebuild regulator; replace needle/ 

seat 

Air leaks from fluid module Loose air connections Check air connections; tighten if 

necessary 

Worn gaskets 

Check/replace gaskets on V/P and 

solenoid valve 

Fluid module heater does not heat Temperature controller turned off Verify Zone is properly adjusted. 

Loose electrical connections Verify connection between inlet 

hose and fluid module connector 

Verify connections between inlet 

hose and main enclosure 

Blown fuse 

Check/verify fuse in heater control 

box 

Broken heater element 

Check/verify heater resistance 

Broken sensor 

Check/verify sensor resistance 



Flow Meter 


No flow measurement Flow meter pick-up sensor loose Tighten flow meter pick-up sensor 

Flow too low 

Verify flow rate is above minimum 

for the flow meter selected 

Loose wiring 

Verify wiring connections from flow 

meter to junction box 

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

False measurement Flow meter not calibrated Calibrate flow meter 

Flow meter cable shield wire not Verify shielding to ground 

connected 

System not grounded properly Verify system ground 

Noisy power source 

Verify clean power supply power to 

main enclosure 

Flow reported is not correct or Flow meter not calibrated 

Calibrate flow meter 

inconsistent 

Flow meter is worn 

Replace flow meter 

Regulator 


No pressure regulation Damaged diaphragm Replace diaphragm 

Leaking or dirty seat 

Replace cartridge, or clean seat 

No fluid flow Damaged valve actuator Replace valve actuator 

Pressure creeps above setting 

Metal chip or contamination 

between ball and seat 

Damaged diaphragm 

Damaged o-ring or improper seal 

Damaged or clogged air regulator or 

line (air-operated regulator only) 

Leaking or dirty seat 

Large change in inlet pressure 


area 

Replace diaphragm 

Replace the o-ring under the seat 

Clear obstruction in line. Service 

regulator if necessary 


Stabilize regulator inlet pressure 

Pressure drops below setting Empty/clogged supply line Fill/flush supply line 

Damaged or clogged air regulator or Clear obstruction in line. Service 

line (air-operated regulator only) regulator if necessary 

Using valve beyond its rated flow Install valve for each spray gun or 

capacity 

dispensing valve 

Large change in inlet pressure Stabilize regulator inlet pressure 

Fluid leaks from spring housing Loose fluid housing Tighten the four cap screws 

Damaged diaphragm 

Replace diaphragm 

Chatter 

Excessive pressure differential be Reduce pump pressure to not more 

tween pump and gun 

than 2000 psi (14 MPa, 138 bar) 

Excessive flow rate 

greater than required gun pressure. 

Reduce fluid flow through regulator. 

Connect only one spray gun or dispensing 

valve to each fluid regulator 



Dispense Valves 


Valve not opening Air not getting to open port Verify air pressure solenoid 

No “Gun On” signal from automation 


unit 

No output from system I/O board Check output from system I/O 

board; verify that it is on 

Valve not shutting off 

Air not getting to close port (except 

AutoPlus valve) 

Verify air pressure to solenoid 

Verify solenoid operation 

Verify air line routing and connections 

“Gun On” signal from automation 

unitison 


Check output from system I/O 

board; verify that it is on 

Sluggish open/close Air pressure low Verify air pressure is above 60 psi 

(0.4 MPa, 4 bar) 

Needle/seat worn 

Rebuild valve; replace needle/seat 

Pressurized material past the valve 

shut-off is escaping 

Reduce running pressure 

Reduce nozzle length 

Increase nozzle orifice size 

Material leaks from back of valve Shaft seal is worn Rebuild valve; replace seals 

Air leaks from dispense valve Loose air connections Check air connections; tighten if 

necessary 

Worn piston o-ring 

Rebuild valve; replace piston o-ring 

Dispense valve does not heat Temperature controller turned off Verify zone #4 is on through the 

user interface 

Loose electrical connections Verify connection between outlet 

hose and valve connector 

Verify connection between outlet 

hose and main enclosure through 

extension cord 

Blown fuse 

Check/verify fuse in Electric Heat 

box 

Broken heat cartridge 

Check/verify heater resistance 

Broken sensor 

Check/verify sensor resistance 



Electrical Component Paths 

Use the following table to troubleshoot wiring to the automation: 

Component Description Cable / 

Pin 

KEY 

Enclosure 

Wire 

Board / Connector 

Wire Color 

Dispense Gun +24 VDC Input 1 3290 J8-4 WHT 

Job Complete +24 VDC Input 2 3310 J8-5 BLU 

24 VDC From IFC +24 VDC Input 5 2120 +24 VDC RED 

24 VDC Common COM 6 2121 Common BLK 

Analog Flow Command 0-10 VDC Input 7 3150 J7-3 GRN/BLK 

Analog Common COM 8 3170 J7-4 GRN 

Actual FLow Rate Signal 0-5 VDC Output 9 3210 J7-6 ORN/BLK 

Dispenser Ready +24 VDC Output 10 2680 J5-5, Green Light BLU/BLK 

Fault Present +24 VDC Output 11 2710 J5-7, Red Light BLK/WHT 

In Cycle +24 VDC Output 12 2740 J5-9 RED/WHT 

Minimum Volume Dispensed 

+24 VDC Output 13 2770 J5-11 GRN/WHT 

24 VDC Thru E-Stop +24 VDC Output 14 2170 E-Stop Switch ORN 

GND Shield GND 15 Shield Chassis GND N/A 

Component – External component wired into module's 

junction box. 

Description – Type of signal. 

Component ID – Where it originates from on the component. 

J-Box Wire – Wire number or terminal location in the 

module's junction box. 

Cable/Pin – Pin number on the operations cable. The 

operations cable connects the module's junction box to 

the main electrical enclosure. 

Enclosure Wire – The wire number inside of the main 

electrical enclosure. 

Board/Connector – Where the wire terminates inside of 

the main electrical enclosure. 


Troubleshooting and Fault Recovery 


The following table describes the valid fault codes used 

by the PrecisionFlo LT module, possible causes, and 

solutions. PrecisionFlo LT module displays warnings 

and alarms on the user interface and alarms via the control 

unit fault light. 

• Alarms set the dispenser ready signal LOW. 

• Warnings do not set the dispenser ready signal 

LOW. 

Resetting Control Unit After a Fault 

If a fault has occurred, you should clear (reset) the fault 

before restarting the PrecisionFlo LT control unit. Press 

the fault reset key to clear the fault, or press the ? 

key for additional information. 

Table9–FaultPriority Table 

Fault 

Priority 

Fault Name 

2 Dispenser 

Stop 

5 Closed Gun 

Flow 

1 Communication 

Error 

Fault 

Description 

There is no electrical 

power 

System reading flow 

meter pulses from Flow 

Meter with Gun closed. 

These meter pulses correspond 

to a flow rate 

that is greater than 1000 

cc/min 

Causes 

The following faults are always Alarms 

E-Stop has been pressed 

Green and/or red light not lit, control 

assembly is off 

Dispense hose leak 

Flow meter providing false pulses 

Dispense valve not operating 

properly 


The following faults are always Warnings 

Communication has 

been lost between the 

control board nd the display 

board 

3 Power Up Control box power up 

4 Calibration 

Error 

System was not able to 

complete a flow calibration 

The display board and the control 

board are no longer communicating 

Flow setpoint higher than the flow 

rate the system can deliver 

Regulator worn or not operating 

properly 

A dispense command in flow 

mode was received without a 

valid flow calibration being performed 

Solutions 

Turn E-Stop switch to release 

Apply power to PrecisionFlo LT 

module 

Check hose; replace if needed 

Replace flow meter sensor or calibrate 

meter (corilis) 

Repair dispense valve 

Replace flow meter sensor 

Repair any loose or disconnected 

wires in the connectors between 

the two circuit boards 

Replace one or both of the circuit 

boards if their “heartbeat” LEDs 

are no longer blinking 

Replace the wiring harness 

between the two circuit boards 

Lower calibration flow setpoint 

Increase dispense valve tip size or 

dispense hose diameter 

Increase supply pressure 

Repair regulator 

Perform a flow calibration 



Table9-FaultPriority Table (continued) 

Fault Fault Name Fault Description Causes Solutions 

Priority 

The following faults are always Warnings (con't) 

6 Volume 

Comp Limit 

Peak value of flow compensation 

for regulator 

has reached the 25% or 

400% limit 

7 Low Analog Analog command 

dropped below 1 VDC 

while dispensing 

15 Default Kp/Ki Default Values for Kp & 

Ki have been loaded 

16 Setup Values 

Changed 

Setup change notification 

Fluid supply too low to achieve 

desired flow rate 

Regulator is not able to close 

completely 

Major change to fluid or fluid system 

downstream of the regulator 

Operating below the minimum 

regulator operating pressure 

Bad or loose I/O cable connection 

Entered command mode incorrectly 

Automation program error 

The autotune portion of the calibration 

has failed to find new Kp 

and Ki values. Default values for 

these parameters are being used. 

When the Key Switch was turned 

from Setup to Run mode, the control 

detected a change from previous 

setup data value(s) 

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

8 High Outlet 

Pressure 

Output pressure to the 

PrecisionFlo LT regulator 

is above the upper limit 

set for operation. If this 

fault occurred while 

doing a pressure calibration, 

pressure calibration 

could not determine optimum 

values and default 

values were used 

Incorrect limit set 

Dispense hose/device plugged 

Failed transducer 

Regulator is not closing completely. 

Incorrect pressure amplification 

switch setting 

Increase fluid supply pressure or 

check for clogged filter 


Check fluid viscosity 

Check hoses and tips for problems 

Perform a new calibration if necessary 

Increase fluid pressure above regulator 

minimum 

Check cable and connection 

Enter correct command mode 

Verify correct automation program 

or set the default flow rate to 3500 

or disable this fault 

Decrease the volume of the dispense 

hose (length and / or diameter) 

Choose a smaller tip size for the 

dispense valve 

Increase the fluid supply pressure 

Manually adjust Kp and Ki (see 

page 34) 

No action necessary if changes 

were desired 

Alarms/Warnings screen) 

Verify limit is set correctly 

Clean/replace hose/device 

CHeck transducer, replace if failed 


Verify switch is set correctly 



Table9-FaultPriority Table (continued) 

Fault 

Priority 

Fault Name Fault Description Causes Solutions 

9 Low Outlet 

Pressure 

Output pressure of the 

PrecisionFlo LT regulator 

is below the limit set for 

operation. If this fault 

occurred while doing a 

pressure calibration, system 

pressure was too 

low (


Fault 

Priority 

13 High Flow 

Rate 

14 Computed 

Target 

Fault Name Fault Description Causes 

Measured Flow rate 

more than desired flow 

rate plus tolerance 

The requested volume 

differs from the entered 

process target by more 

than the entered tolerance 

for style requested 

Operating below the minimum 

regulator operating pressure 

Regulator worn or not operating 

properly 


Incorrect flow fault tolerance or 

flow fault time 

Entered process target incorrectly 

Entered tolerance incorrectly 

Requested volume incorrect 

Automation problem 

Increase fluid pressure above regulator 

minimum 


Replace flow meter sensor 

Enter correct tolerance or flow fault 

time 

Enter correct process target 

Enter correct tolerance 

Check automation program 

Verify automation is correct 


Control Assembly Service 

Control Assembly Service 

Servicing the Panel Assembly 

This part of the manual provides information about the 

following panel assembly component: 

• Main Control Board 

• Software Upgrade 

• Fuse 

• Display Backlight 

Display Backlight Easy Key Interface Main Control Board 

Fuses 

FIG. 20 

Door Side 

Enclosure Side 

Main Control Board Removal 

Remove the control board as follows: 

WARNING 

Control Board Replacement 

Replace the control board as follows: 

1. Snap the main control board onto the din rail. 

2. Plug the connectors into the control board. 


1. Shut off system power at the main circuit breaker. 

2. At the control assembly, move the MAIN power 

switch to the OFF position. 

3. Open the hinged cover of the control assembly. 

4. Unplug the connectors from the control board. 

5. Pry the plastic cups off the board with a screwdriver 

to release the board from the din rail. 

3. Close and lock the hinged cover on the control 

assembly. 

4. Apply system power at the main circuit breaker. 

5. Move the MAIN power switch to the ON position, 

applying power to the control assembly. 

6. Verify that the control board operates correctly. 

7. Restore the system parameters to return the control 

assembly to normal operating condition. 


Software Upgrade 


There are two ways to upgrade the software in the PrecisionFlo 

LT system. 

• Use the Graco Shell Serial menu System (see Communicating 

with PrecisionFlo LT, page 40). 

• Replace the flash memory in the two circuit boards. 

The software upgrade kit (253614 Standard) can also be 

used to upgrade software. This kit contains flash memory 

chips for the display board (see FIG. 21) and control 

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

tool. 

To replace a flash memory chip on either the display 

board or the control board, perform the following steps. 

1. Attach the grounding strap included with the kit to 

your wrist and ground appropriately. 

2. Turn off the power to the LT system. 

3. Press the two feet of the chip extraction tool into the 

open holes in the corners of the flash chip socket on 

the circuit board. See Display Board FIG. 21or 

Control Board FIG. 22. 

4. Position the chip extraction tool so that the feet of 

the tool are underneath the flash chip. Squeeze the 

tool to grip the chip. 

5. Continue squeezing the tool while pulling the chip 

out of the socket. 

6. Orient the new flash chip such that the beveled corner 

on the chip aligns with the beveled corner of the 

socket. 

7. Press the new chip into the open socket. Make sure 

that the pins are not bent or touching. 

8. Repeat this procedure for both circuit boards. 

9. Turn the power on the LT back on. 

Display Board 

253612 Standard 

flash memory chip 

Beveled 

Edge 

FIG. 21 


Control Board 


Beveled 

edge 

253613 flash 

memory chip 

FIG. 22 


Panel Assembly Service 


Fuse Removal 

Remove the fuse as follows: 

WARNING 



2. At the control assembly, move the MAIN power 

switch to the off position. 

3. Unlock and open the hinged cover of the control 

assembly. 

4. Lift to unlock the top of the fuse holder, which is 

hinged at the bottom, from its clamp. 

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

inside. 

6. Carefully remove the fuse from the fuse holder. 

Fuse Replacement 

Replace the fuse as follows: 

Check the new fuse to ensure that it matches the 

amp rating of the failed fuse. 

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

the fuse holder. 

2. Close and lock the fuse holder into place. 

3. Close and lock the hinged cover on the control 

assembly. 

4. Apply system power at the main circuit breaker. 

5. Move the MAIN power switch to the ON position 

applying power to the control assembly. 

6. Verify that the fuse operates correctly. 

7. Return the control assembly to the normal operating 

condition. 

Lift the top of the 

fuse holder to unlock 

Fuse location 

(two places) 

FIG. 23 



Replacing the Backlighting 

WARNING 

A qualified electrician must complete all grounding 

and wiring connections. 


A Backlighting Replacement Kit is available. Order part 

no. 118337. 

Before replacing the backlighting, check the inverter (9) 

for proper voltage by unplugging the backlighting connector 

(1), turning on the PFlo LT and carefully measuring 

the AC voltage across the two pins of the inverter. 

Voltage should read approximately 700 VAC. If not 

replace the inverter. 


2. At the control assembly, move the main power 

switch to the off position. 

3. Unlock and open the hinged cover of the control 

assembly. 

4. Unplug the ribbon cable from the board (4) by sliding 

it out of the connector. Note the position of the 

cable in the connector. The arrow indicates pin #1, 

reconnect later with pin #1 engaged. 

5. Unplug the remaining connectors on the board and 

note their location. Unplug the connector (1) coming 

from the backlighting bulb. 

6. Remove the four screws from the board. 

7. Disconnect the ground wire. 

8. Remove the two small screws holding the backlighting 

(3) to the display (2), and slide the backlighting 

out the side of the display. 

9. Install the parts in reverse order of disassembly 

10. Return the control assembly to normal operating 

conditions. 

2 

4 

3 

1 

9 

FIG. 24 


Fluid Module Service 


This section describes how to remove and replace these 

components on the fluid metering assembly: 

• flow meter (20) (FIG. 25) 

• regulator (14) (FIG. 25) 

The numbers in parentheses in the text refer to reference 

numbers in the parts drawings and parts lists. 

Prepare the System for Service 

Relieve the system pressure. Follow procedure on 

page 30. 

WARNING 


Servicing the Flow Meter 

For complete flow meter service instructions refer to the 

maintenance and service sections of the following manuals: 

308778 for all G3000 meters, and 309834 for all 

Graco Helical flow meters. 

Remove the Flow Meter from the Mounting Plate 

1. Prepare the system for service as instructed above. 

2. Disconnect the flow meter cable (J) from the flow 

meter sensor. See FIG. 25. 

3. Disconnect the material hose. 

4. Disconnect the swivel fitting (18) from the regulator. 

5. Loosen the four screws (12), and remove the 

bracket (22) and flow meter. 

6. The flow meter (20) weighs approximately 15 lbs. 

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

20 22 12 J 

18 

14 

10 

FIG. 25 



Install the Flow Meter on the Mounting Plate 

1. Rest the flow meter and bracket (20) on the fluid 

plate while threading the swivel fitting (18) onto the 

regulator material inlet. See FIG. 25. 

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

inlet. 

3. Tighten the four screws (12) to hold the bracket and 

flow meter in place. 

4. Check that the flow meter (20) and regulator (14) 

are still aligned. 

5. Connect the material hose. 

6. Connect the flow meter cable (J). 

Servicing the Fluid Regulator 

For complete cartridge fluid regulator service refer 

to instruction manual 308647. For Mastic Fluid Regulators 

refer to instruction manual 307517. 

Replacing the Cartridge 

See FIG. 26 and perform the following steps. 

CAUTION 

Handle the hard carbide parts ball, valve actuator, and 

valve seat, carefully to avoid damaging them. 

1. Relieve the pressure. 

WARNING 

2. Remove the cartridge assembly by loosening the 

valve housing (5) with a6mmhexwrench and pulling 

the cartridge assembly out of the base housing 

(4). 

The retaining nut (3) often loosens when removing 

the cartridge assembly from the base housing. Be sure 

to re-torque as described in step 4. 

3. Inspect and clean the internal walls of the base 

housing (4). 

Be careful to not scrape or gouge the internal walls 

of the base housing. They are a sealing surface. 

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

(16to18N•m). 

You must re-torque the retaining nut before you 

install it in the base housing in step 5. 

5. Install the new cartridge assembly in the base housing 

(4), and torque the valve housing (5) to 30 to 35 

ft-lb (41 to 48 N•m). 

The valve seat is double sided and may be 

reversed for extended life. The o-ring and ball must be 

replaced. See instruction manual 308647. 

Service Kits for Regulator 244734 

For the Fluid Diaphragm Repair Kit, order Part No. 

238747. 

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




Torque Sequence for Regulator 

Base Housing Screws (9) 

4 

4 

1 

3 

2 3 

diaphragm 

and valve 

actuator 

subassembly 

cartridge 

assembly 

5 

FIG. 26 


Frequently Asked Questions 


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

A: In Volume Monitor the control will maintain a specific pressure at the fluid regulator outlet. If the viscosity of the 

fluid changes or the nozzle becomes restricted, that pressure will result in a different flow rate. If you have a flow 

meter installed it can still monitor the job volume for faults. Volume monitor is sometimes desirable for spray 

applications to maintain a specific spray pattern. 

In Bead Control the fluid regulator is still reacting to the fluid pressure for quick adjustment, but the control also 

monitors the flow meter. If the flow rate does not agree with the flow command, the pressure target is adjusted. 

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

flow meter. 

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

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

Screen. This can be set from 50-150% of command flow. To change the Bead Scale turn the key switch to the 

right to enter Setup mode. The Setup mode screen allows you to change the Bead Scale percentage. To change 

to the new setting press the Enter key on the EasyKey interface. The new value will be stored when you turn the 

key switch back to Run mode. In Run mode the Bead Scale can be changed using the bead adjust keys. 

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

A: Something has changed since you calibrated the regulator. The control has changed the regulator pressure set 

point too far away from the calibration point. This happens in Bead Control when the control is monitoring the 

flow meter and trying to maintain the proper flow rate. The cause is some factor that has changed the pressure, 

downstream of the regulator, at the desired flow rate. This might be a plugged nozzle or a fluid viscosity change. 

The viscosity difference could be caused by a change in temperature or a new batch of material. If the pressure 

needs to increase to maintain the desired flow rate, but the fluid regulator is already fully open, the volume compensation 

continues to increase the desired pressure target until the limit is reached. The fluid feed pressure at 

the regulator inlet needs to be increased. If the fluid and equipment are all right you need to recalibrate to your 

flow target. 

Q: How is a fluid control regulator calibration performed? 

A: There are three steps: (1) determine system maximums (2) pressure calibration (3) flow calibration. These steps 

are performed sequentially during the calibration process. If you are not using a flow meter and will run in pressure 

control mode, only the pressure calibration and system maximums will be performed. To calibrate pressure 

and flow, see page 104. 

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

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

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

A: You may not have enough fluid pressure downstream of the regulator. Raising the downstream pressure 

becomes more important if the pressure is below 500 psi (3.5 MPa, 34.5 bar). Try a smaller nozzle on the dispense 

valve. 



Q: Why is my calibration failing after only a few seconds? 

A: You may not have been able to reach the maximum flow rate or maximum pressure you entered. To reach a 

higher flow rate or pressure, you can increase the feed pressure or increase the dispense valve nozzle size. 

Q: Why will my dispense valve not operate? 

A: The valve will not dispense in Bead Control Mode until a valid calibration has been performed. Try switching to 

volume monitor or pressure control mode or calibrate again. 

Q: Does Volume Monitor Mode use a flow meter? 

A: Running in Volume Monitor Mode requires a flow meter to monitor the job volume limits or job log volumes. If 

you do not have a flow meter set the system to the pressure control mode. 

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

A: Calibrate the flow meter as instructed on page 104. This is strongly recommended as many sealants are compressible, 

and the flow meter measures the fluid while it is under pressure. Calibrating the meter makes it accurate 

for your fluid at ambient pressure. Periodic calibration is also important to monitor your meter for wear. 

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

A: If a fluid regulator fails it can no longer hold back fluid pressure. If the outlet pressure climbs up to equalize with 

the inlet pressure when you stop dispensing, the regulator has lost the ability to shutoff or fully regulate flow. If 

you have pressure limits set you will get a High Outlet Pressure alarm. If you have job volume limits set you will 

get a High Volume On Last Job alarm. 

Q: Is there a way to put the fluid plate control regulator in a bypass mode to still operate the dispense 

valve when I have a problem? 

A: With the air operated regulators you can move the air tube that feeds the V/P valve directly to the fluid regulator 

air inlet. Turn off the air supply before moving tubes. 

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

A: There is an external phone-style connection on the right side of the control enclosure. You need a PC or laptop 

computer with terminal emulation software and part number 233657 accessory cable kit. See Communicating 

with PrecisionFlo LT, page 40. 

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

A: No. All setup parameters, job logs, and alarm logs are saved to flash memory and do not need any power. This 

is non-volatile memory similar to the cards used with digital cameras. There also is no battery to replace. The 

setup parameters are stored to flash memory when the key switch is moved from the setup to the run position. 

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

A: If the key switch is turned counter clockwise or removed, which means the system is in Run mode, you can view 

the run screen but you cannot change any parameters except Bead Scale when enabled. You can still select 

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



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

A: Yes. If you turn the key switch to Setup mode, you have complete control of the system. Changes to control 

modes, pressure values, time delays, alarms, etc. become effective when you press Enter and the changes are 

saved to memory when the key switch is turned back to Run mode. 

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

A: You can turn the power off before turning the key switch back to Run mode. When you turn the power back on, 

the changes will not be there. 

Q: How do I set my pressures? 

A: First, set the dispense pressure. A dispense valve hose and nozzle should be used, which will maintain at least 

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

Second, set the feed pressure. Once you are running, back down the feed pressure to a point where the regulator 

inlet pressure stays at least 500 psi (3.5 MPa, 34.5 bar) greater than the regulator outlet pressure, when dispensing 

at your maximum flow rate. If you will have multiple valves open at the same time, being fed by the 

same feed pump, do this check with all of those valves open. Excessive feed pressure will cause excessive 

wear. 


Fault Reporting 

Fault Reporting 

• Alarms, which cause the PrecisionFlo LT DIS- 

PENSER READY signal to go LOW or, 

• Warnings, which keep the PrecisionFlo LT DIS- 

PENSER READY signal HIGH. 

Fault On Data 

Fault Code Data 

>1 msec 

Both volume and fault data are available on the I/O 

interface. Volume and fault data share I/O points, Data 1 

- Data 32768. If the VOLUME ON DATA output is on, the 

outputs contain volume data. If the FAULT ON DATA output 

is on, the outputs contain fault data. 

FIG. 27 

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

FAULT ON DATA goes HIGH. Fault code data remains 

valid, and the FAULT ON DATA remains HIGH, until a 

FAULT RESET is received from the automation controller, 

or the fault is cleared using the display. 

Fault codes are reported using the FAULT ON DATA signal 

and the data bus. Fault codes can be either: 

The automation unit can read a fault code any time during 

the cycle, If several faults are present at the same 

time, the highest priority fault code is sent to the data 

bus. At the end of the dispense cycle the data bus is 

used for volume reporting, If requested by the automation 

controller. Once volume reporting has been competed, 

the fault code is placed back on the data bus. 

Each fault is recorded on the user interface. The fault 

data is also available on the I/O interface until the fault is 

cleared. 

Refer to the Troubleshooting and Fault Recover section 

for fault code causes, descriptions, and solutions for the 

various faults. 


Control Assembly Parts 

Control Assembly Parts 

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

Ref 

No Part No Description Qty. 

1 ENCLOSURE 1 

2 112546 SCREW, machine 8 

3◆ 118334 LABEL, warning 1 

4 PLUG, conduit 2 

5 CONNECTOR 1 

6 HARNESS, key switch wire 1 

7 SWITCH, power rotary 1 

8 PANEL, control assembly 1 

9 116653 SWITCH, key 1 

10 LABEL, identification switch 1 

11 117689 SWITCH, emergency stop 1 

12 C19208 WASHER, lock 8 

13 117788 KIT, accessory 1 

14 117762 LAMP, led red snap in 1 

15 117763 LAMP, led green snap in 1 

16 LABEL, identification control box 1 

17 CONNECTOR 1 

18 LATCH, quarter turn 1 

20† 223547 WIRE, assy 25 ft. 1 

21 NUT, hex 4 

22 WASHER, lock 2 

23 WIRE, grounding 1 

Ref 

No Part No Description Qty. 

24 TERMINAL 1 


26 NUT, hex 6 

27 CONNECTOR, RJ12 1 

28 253620 BOARD, control circuit 1 

29 117782 POWER supply 1 

30 115216 FUSE, 1 amp 2 

31 BLOCK, clamp end 1 


33 TERMINAL, ground 1 

34 TERMINAL, block 4 

35 FUSE, holder 2 

36 SCREW, machine 1 

37 TERMINAL, block 5 

38 117790 POWER, supply 5V inverter 1 

39 118337 DISPLAY, backlight 1 

† These parts are not shown on the parts drawing. 

◆ Replacement Danger and Warning labels, tags and 

cards are available at no cost. 

2, 5, 12 2,12,17 7 

1 

3 

18 

9 

13 

15 

4 

14 

11 

27 


Control Assembly Parts (continued) 

Control Assembly Parts (continued) 

24 

25, 26 

6 

29 32, 33, 36 

8 

31 

38 

30, 35 

39 

23 

28 


Fluid Module Parts 

For additional parts see page 66. 

31 4 

Fluid Inlet 

22 

21 

Fluid Outlet 

8 

16 

Fluid Module Parts 

Air Inlet 

13 

35 

7 

16 

To Dispense 

Valve 

8 

11 

26 

38,39 

8 

16 

32 

13 

35 

40 

1 43,44 

19 

18 

35 

17 

23 

23 

3 

8 

38,39 33 

12 2 

26 30,34 

12 

28 

37 

36 

27 

41 

20 

29 

Ref 

Qty. 

No Part No Description 

1 117669 PLATE, blank fluid 1 

2 195942 REGULATOR, I/P 1 

6 198179 FITTING, bulkhead 1 

7 551348 VALVE, sol 4-W 1 

8 C06061 MUFFLER, sinter 2 

10 234967 FILTER, inline (not shown) 1 

11 198175 FITTING, push 1 

12 111119 SCREW, valve 4 

13 117820 SCREW, cap skt 2 

16 198177 FITTING, push 3 

20 198269 BRACKET, flowmeter 1 


24 070269 SEALANT, anaero 1 

25 070408 SEALANT, pipe s 1 

Ref 

Qty. 

No Part No Description 

26 054753 TUBE, nylon rd 2.3 

29 110580 SCREW, cap sock 2 

30 198315 BLANK, label 1 

32 196108 PLUG, assy 100V 1 

33 198683 WIRE, 3 cond 2 2 

34 291487 ARTWORK, identification 1 

35 198708 LABEL, rectangular 3 

36 198268 BRACKET, flowmeter 1 


39 112906 WASHER, lock sp 2 

42 804500 LABEL, warning 1 

43 112513 FERRULE, wire, white 5 

44 112515 FERRULE, wire, red 4 


Fluid Module Parts (continued) 

Fluid Module Parts (continued) 

Code C Option-01 Model No 234168 1 

3 234171 Junction box 1 

4 198082 Transducer, pressure 1 

21 244734 Regulator, assembly 1 

27 108328 Screw, cap, skt 2 

40 C34045 Spacer 

Code C Option-02 Model No 234165 



17 198327 Bracket, flowmeter 1 

18 110501 Screw, cap, skt 4 


22 162449 Fitting, nipple 1 

27 108328 Screw, cap, skt 2 

28 239716 Meter, gear, G3000 1 

31 156684 Union, adapter 1 

37 198578 Harness, cable 1 

40 C34045 Spacer 2 



4 198082 Transducer, pre 1 


18 110501 Screw, cap, skt 4 


22 162449 Fitting, nipple 1 

27 108328 Screw, cap, skt 2 

28 244292 Meter, gear, G3000 HR 1 



40 C34045 Spacer 2 





19 115226 Washer, lock sp 6 


22 C20461 Fitting, nipple 1 

27 108328 Screw, cap, skt 6 

28 246190 Meter, helical gear 1 



40 C34045 Spacer 2 

44 C19197 Washer, plain 4 





19 115226 Washer, lock sp 6 



27 108328 Screw, cap, skt 6 

28 246652 Meter, helical gear, HR 1 



40 C34045 Spacer 2 


Code C Option - 06 Model No 234170 

3 234171 Junction Box 1 

4 198082 Transducer, Pressure 1 

21 246642 Regulator, mastic 1 

27 108328 Screw, cap skt 2 





19 115226 Washer, lock, sp 6 



27 108328 Screw, cap, skt 6 

28 246190 Meter, helical gear 1 

31 157785 Union, swivel 1 






17 117670 Bracket, flow meter 1 

19 115226 Washer, lock 6 



27 108328 Screw, cap, skt 6 

28 246652 Meter, helical gear, HR 1 






4 234191 Cable, pressure 1 

5 117764 Sensor, pressure 1 


27 108328 Screw, cap, skt 2 

41 118331 Label, warning 1 

45 624545 Fitting, tee 3/4 x 1/4 1 


3 234209 Junction, box 1 

4 234191 Cable, pressure 1 

5 117764 Sensor, pressure 1 


19 115226 Washer, lock, sp 6 


22 175013 Nipple, pipe 1 

27 108328 Screw, cap, skt 6 

28 246340 Meter, helical gear, HTD 1 



41 118331 Label, warning 1 


45 624545 Fitting, tee, 3/4 x 1/4 1 


Accessory Parts 

Accessory Parts 

Automation Interface Cable Assembly 

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

identifies the cable interface signals. 

6 

2 1 

5 4 3 

11 

10 

9 

8 

7 

15 

14 

13 

12 

18 

17 

16 

Pin # Wire # Color Description 

1 3290 Blk Dispense Gun 

2 3310 Red Job Complete 

3 3350 Wht Style Bit 1 

4 3370 Grn Style Bit 2 

5 2120 Orn 24 VDC from IFC 

6 2121 Blu 24 VDC common 

7 3150 Brn Analog flow command 

8 3170 Yel Analog common 

9 3210 Vlt Actual Flow rate signal 

10 2680 Gry Dispenser ready 

11 2710 Pnk Fault present 

12 2740 Tan In cycle 

13 2770 Red / Grn Minimum volume dispensed 

14 2170 Red / Orn 24 VDC thru E-stop 

15 Ground 

16 3390 Red / Blk Style Bit 3 

17 3410 Wht / Blk Style Bit 4 

18 Spare Wht / Red N/C 

N/A Spare Wht / Grn N/C 

N/A Spare Wht / Yel N/C 

N/A Spare Wht / Blu N/C 


Operations Cable Assembly 

Operations Cable Assembly 

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

cable options. 

A 1 A 24 VDC thru E-stop 

B 2 B 24 VDC common 

C 3 C Gun solenoid 

D 4 D Ground 

E 5 E V/P + 

F 6 F V/P - 

G - G 

H - H 

J 7 J Pressure Sensor + 

K 8 K Pressure sensor - 

L - L 

M - M 

N 9 N Flow meter signal 

P 10 P Flow meter common 

R 11 R 

S 12 S 

L 

A 

K 

B 

M 

S N 

J 

C 

R P 

D 

H 

E 

G F 


DISPENSER READY 

Electrical Schematics 

PrecisionFlo LT Control Box 

Electrical Schematics 

DATA DOWNLOAD/ 

PROGRAMMING 

PORT 

+24 

COM 

2120 

2121 

Rx 

Tx 

CONTROL BOARD 

#20 PUR 12 

WHT 

2541 

1 

BLK 

2551 

2 

RJ12 

JACK 

RED 

2560 

380 

3 

378 

RS-232 TO 

DISPLAY BOARD 

15 

#20 BLU/WHT 11 

2541 

2551 

2560 

Optional Ethernet 

Kit 118329 

220 

403 

COMMON 

405 

222 

DISPENSE GUN 

#20 pur 12 

DISPENSER FEADY 

469 

221 

FAULT PRESENT 

471 

473 

IN CYCLE 

475 

MIN VOL DISPENSED 

2540 

2550 

2560 

2570 

2580 

2170 

2650 

2660 

2680 

2681 

2680 

222 

469 

2710 

2740 

2770 

SERIAL (RS-232) 

VCC 

1 

TX1 

2 

RX1 

3 

4 

TX2 

5 

RX2 

6 

7 

DIGITAL OUT 

+24 IN 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

J2 

J5 

250 

251 

252 

253 

254 

255 

256 

257 

258 

259 

260 

261 

262 

263 

264 

265 

266 

267 

268 

269 

270 

271 

272 

273 

274 

275 

276 

277 

278 

279 

280 

WIRING FOR ROCKER SWITCH WIRING FOR ROTARY SWITCH 

1A 1 

G 

1 2 

2A 2 

5 6 

13 

#20 BLK 

2060 2061 

#20 BLK 

13 

#18 GRN/YEL 

PS210 

POWER SUPPLY 

#18 GRN/YEL 

10 

+24V COM 

2120 

2121 

#20 BLU/WHT 

11 

301 459 358 

264 

2710 

2121 

271 R 

2680 

2121 

333 

268 G 

401 

307 

2121 

477 

461 

2121 

360 

2121 

10 

13 

#20 BLK 

FU2051 

2 AMP 

L1 

93-264 VAC 

50/60 Hz 

L2 

FU2052 

2 AMP 

9 

#20 BLU 

PB215 

E-STOP 

SWITCH 

2170 

200 

201 

202 

203 

204 

205 

206 

207 

208 

209 

210 

211 

212 

213 

214 

215 

216 

217 

218 

219 

220 

221 

222 

223 

224 

225 

226 

227 

228 

229 

230 

231 

232 

233 

234 

235 

236 

237 

238 

FIG. 28 


Black 

Red 

White 

Green 

258 



BACKLIGHT 

DISPLAY BOARD 

KS353 

OPEN = RUN 

CLOSED = SETUP 

2120 

215 

2121 

226 

3620 

3660 

+5 RED 

WHT 

INVERTER 

3680 

COM GRN 

WHT 

3720 

RS-232 PROGRAMMING PORT 

3740 

2580 

2570 

RS-232 TO CONTROL BOARD 

257 

DIGITAL INPUTS 

1 

2 

3 

POWER/BACKLIGHT 

+24V 

1 

2 

V5 

3 

+5 

4 

+5 

5 

B2 

6 

SERIAL (RS232) 

TX1 

1 

RX1 

2 

3 

TX2 

4 

RX2 

5 

6 

J1 

J5 

J6 

350 

351 

352 

353 

354 

355 

356 

357 

358 

359 

360 

361 

362 

363 

364 

365 

366 

367 

368 

369 

370 

371 

372 

373 

374 

375 

376 

377 

378 

379 

380 

381 

382 

COMMAND (0-10VDC) 

6 

G 

FLOW RATE (0-5VDC) 

463 

465 

467 

CONTROL BOARD 

2120 

215 

2121 

222 

3130 

417 

PRESSURE SENSOR (0-5VDC) 

White 

3150 

3170 

417 

411 ANALOG COMMON 

Red 

3190 

409 

V/P COMMAND (0-5VDC) 

Black 

3210 

3230 

425 

FLOW METER 

3250 

427 

COMMON 

3290 

451 

DISPENSE GUN 

3310 

453 

JOB COMPLETE 

2170 

222 

CONTROL ON 

3350 

455 

STYLE BIT 1 

3370 

457 

STYLE BIT 2 

1 

2 

3 

1 

2 

3 

4 

5 

6 

1 

2 

3 

4 

5 

6 

7 

8 

POWER 

+24V 

+24V 

ANALOG 

VDDA 

IN 

IN 

A 

OUT 

OUT 

DIGITAL IN 

+24V 

J6 

J7 

J8 

300 

301 

302 

303 

304 

305 

306 

307 

308 

309 

310 

311 

312 

313 

314 

315 

316 

317 

318 

319 

320 

321 

322 

323 

324 

325 

326 

327 

328 

329 

330 

331 

332 

334 

335 

336 

337 

338 

FIG. 29 




#24 17 

I/O CONNECTOR 

329 

DISPENSE GUN 

331 

JOB COMPLETE 

335 

STYLE BIT 1 

Spare 

337 

STYLE BIT 2 

Spare 

215 

24VDC 

224 

24VDC COMMON 

315 

COMMAND 

ANALOG COMMON 

321 

FLOW RATE 

268 

DISPENSE READY 

272 

FAULT PRESENT 

274 

IN CYCLE 

277 

MIN VOL DISPENSED 

226 

24V FROM E-STOP 

#18 GRN/YEL 10 

SHIELD 

SPARE 

SPARE 

SPARE 

3290 

3310 

3350 

3370 

2120 

2121 

3150 

3170 

3210 

2680 

2710 

2740 

2770 

2170 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

450 

451 

452 

453 

454 

455 

456 

457 

458 

459 

460 

461 

462 

463 

464 

465 

466 

467 

468 

469 

470 

471 

472 

473 

474 

475 

476 

477 

478 

479 

480 

481 

482 

483 

484 

485 

OPERATIONS CONNECTOR 

2170 

A 

224 

24V FROM E-STOP 

2650 

B 265 

COMMON 

2660 

C 266 

DISPENSE GUN 

#18 GRN/YEL 10 

D 

SHIELD 

3190 

E 319 

V/P + 

3170 

F 317 

V/P - 

G 

SPARE 

H 

SPARE 

3130 

J 313 

PRESSURE SENSOR + 

3170 

K 316 

PRESSURE SENSOR - 

L 

SPARE 

#24 16 

M 

SPARE 

3230 

N 323 

FLOW METER SIGNAL 

3250 

P 325 

FLOW METER COMMON 

R 

SPARE 

S 

SPARE 

G 

400 

401 

402 

403 

404 

405 

406 

407 

408 

409 

410 

411 

412 

413 

414 

415 

416 

417 

418 

419 

420 

421 

422 

423 

424 

425 

426 

427 

428 

429 

430 

431 

432 

433 

434 

435 

436 

437 

438 

FIG. 30 



Fluid Module Junction Box 

A -2170 

B A-2650 

-2170 

C B-2660 

D C-GND 

E D-3190 

F E-3170 

G F 

H G 

J H-3130 

K J-3170 

L K 

M L 

N M-3230 

P N-3250 

-3230 

R P -3250 

S R 

S 

Connections for: 

Pressure sensor 

V/P 

Gun Solenoid 

Flow Meter 

Orange tab 

on housing 

Max outlet pressure 

range switch: 

set appropriate fluid 

working pressure 

(1500, 3500, 

or 5000 psi) See page 

95 for software update 

Approximate 

Approximate 

LED location 

LED location 

2170 

2170 

2170 

2170 

3170 

3170 3170 

3170 

3130 

GND 3130 

GND 

2660 

2650 2660 

3190 2650 

3190 

2650 

3230 2650 

3250 3230 

3250 

J2-A 

J2-B J2-A 

J2-C J2-B 

J2-D J2-C 

J2-E J2-D 

J2-F J2-E 

J2-G J2-F 

J2-H J2-G 

J2-H 

GND 

GND GND 

+ - GND + 

- 

+ - 

+ 

- 

J1-H 

J1-G J1-H 

J1-F J1-G 

J1-E J1-F 

J1-D J1-E 

J1-C J1-D 

J1-B J1-C 

J1-A J1-B 

J1-A 

2170 

2170 

3190 

2650 

3190 

2650 

GND 

GND 

2660 

2660 

2650 

2650 

GND 

GND 

GND 

GND 

RED 

RED 

WHT 

BLK 

WHT 

BLK 

RED 

RED 

WHT 

WHT 

BLK 

BLK 

1 

1 

2 

2 

3 

3 

24V 

24V 

SIG 1 

COM 

SIG 1 

COM 

1 

1 SOL 

2 SOL 

RTN 

GND 

2 

GND GND 

RTN 

GND 

OP cable 

connector 

V/P 

V/P 

SOL. 1 

SOL. 1 

2170 

2170 

3230 

3230 

3250 

3250 

GND 

GND 

RED 

RED 

CLR 

CLR 

BLK 

BLK 

24V 

24V 

SIG 1 

COM 

SIG 1 

COM 

Flow 

Meter Flow 

Meter 

J1-D 

J1-C 

J1-D 

J1-B J1-C 

J1-A J1-B 

J1-A 

GND 

GND 

5 

5 

BLK 

RED BLK 

GRN RED 

WHT 

GRN 

WHT 

EXE - 

EXE 

EXE 

+ 

- 

SIG EXE + + 

SIG SIG - + 

SIG - 

Pressure 

Sensor Pressure 

Sensor 

FIG. 31 


Technical Data 


*Minimum Flow Rates 

*Maximum Flow Rates 

Maximum Fluid 

Working Pressure 

Minimum Fluid 

Working Pressure 

Minimum Back 

Pressure 

Air Supply Pressure 

Range 

Fluid Filtration 

Required 

*Viscosity Range 

of Fluids 

*Minimum Dispensed 

Shot Size 

V/P Output 

Wetted Parts 

38 cc/minute with G3000HR meter 

75 cc/minute with G3000 meter 

50 cc/minute with High Resolution Helical flow meter 

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

1900 cc/minute with G3000HR meter 

3800 cc/minute with G3000 meter 

3750 cc/minute with High Resolution Helical flow meter 

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

See List of Models on page 2 

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

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

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

30 mesh (500 micron) minimum 

50 to 50000 cps with G3000 meter 

10000 to 1000000 cps with Helical meter 

3 cc with G3000HR meter 

6 cc with G3000 meter 

4 cc with High Resolution Helical meter 

7 cc with Helical meter 

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

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

PTFE, steel, Fluoroelastomer 

Power Requirements Full Load Amps - 1, Fused Amps - 2 

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

Range 

Operating Temperature 

Range 

Operating Humidity 

Range 

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

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

0 - 90% non-condensing 

*Flow rates and viscosities are general estimates. Flow rates drop as viscosity increases. Fluids are expected to 

shear under pressure. New applications or fluids should always be tested to determine proper line sizes and equipment 

selections. 

See your Graco Authorized distributor for other capabilities. 



Regulator Plates 

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

of this manual. 

Cartridge Regulator 

Mastic Regulator 

Regulator Manual 308647 307517 

Weight - No Flow Meter 25.5 lbs (11.6 kg) 33 lbs (15 kg) 

Weight - W/G3000 30 lbs (13.6 kg) N/A 

Weight - Helical 40 lbs (18 kg) 48 lbs (22 kg) 

Fluid Port Inlet 

G3000 1/4” NPT (f) 

3/4” npt(f) 

Helical 3/4” NPT(f) 

Fluid Port Outlet 1/2” npt(f) 3/4” npt(f) 

Maximum Inlet Pressure See List of Models on page 2 5000 psi (34 MPa, 340 bar) 

Maximum Working Pressure* 4500 psi (31 MPa, 310 bar) Ambient 4500 psi (31 MPa, 310 bar) 

Heated 3500 psi (24 MPa, 241 bar) 

Air Supply 1/4” npt(f) 1/4” npt(f) 

Maximum Air Pressure 100 psi (0.7 MPa, 7.0 bar) 100 psi (0.7 MPa, 7.0 bar) 

Minimum Air Pressure 60 psi (0.4 MPa, 4.1 bar) 60 psi (0.4 MPa, 4.1 bar) 

Range Operating Temperature Ambient 40° - 120°F (4° - 50°C)) Heated 40° - 400°F (4° - 204°C) 

Ambient 40° - 120°F (4° - 60°C) 

Minimum Flow Rate - G3000 50 cc/min N/A 

Minimum Flow Rate - Helical 100 cc/min 100 cc/min 

*Maximum system pressure depends on dispense valve. 

Air outlets, open and close to dispense valve 5/32” or 4 mm tube fittings 

Electric Power Requirements 

24 VDC, from PrecisionFlo LT control 

Height 

8” (203 mm) (varies with model) 

Fluid Specifications 

For use when dispensing fluids that meet at least one 

of the following conditions for non-flammability: 

• The fluid has a flash point above 140° F (60° C) and 

a maximum organic solvent concentration of 20% 

by weight, per ASTM Standard D93. 

• The fluid does not sustain burning when tested per 

ASTM Standard D4206 Sustained Burn Test. 

Ambient Air Temperature Range 40° to 120° (5°to50° C) 

Noise Data 

70 dBA 

Continuous operator (full current) 

Dispensing device exhaust (with muffler, peakhold) 

84 dBA 


Kits and Accessories 


PrecisionFlo LT Recommended Spare Parts 

Part Number 

Description 

234282 Advanced control manual set in binder 

244283 Standard control manual set in binder 

117782 Power Supply 

246496 Board, Circuit Assy, HI-Temp Press Sensor 

246517 Board, Circuit Assy, Ambient Press Sensor 

115216 Fuse, 2 Amp 

117764 Sensor, Pressure, Assembly, High Temp. 

246786 Sensor, High Temp., Helical 

198082 Sensor, Pressure, Ambient 

118342 Kit, Accessory, Communications Cable 

195942 V/P 

234967 Filter 

Control Parts and Accessories 

253620 PFlo LT Control Board Assy 

117788 Kit, Accessory, Interface & Board, Std 

117790 Power Supply, 5V Inverter 

117818 Key, Panel Access 

116728 Key, Set-Up 

118329 Ethernet Kit 

118337 Kit, Backlight Repair 

117762 LED, Red 

117763 LED, Green 

117689 E-Stop 

116320 Power Switch Rocker 

116653 Rotary Disconnect 

253614 Chip Set, CNTRL & Display Std 

Fluid Plates 

234168 Fluid plate, Ambient Cartridge Regulator with no flow meter 

234165 Fluid plate, Ambient Cartridge Regulator with G3000 flow meter 

234166 Fluid plate, Ambient Cartridge Regulator with a G3000HR flow meter 

234167 Fluid Plate, Ambient Cartridge with helical flow meter 

234195 Fluid plate, Ambient Cartridge Regulator with high resolution helical flow meter 

234170 Fluid plate, Ambient Mastic Regulator with no flow meter 

234169 Fluid plate, Ambient Mastic Regulator with helical flow meter 

234196 Fluid plate, Ambient Mastic Regulator with high resolution helical flow meter 

234193 Fluid plate, Heated Mastic Regulator with no flow meter 

234194 Fluid plate, Heated Mastic Regulator with helical flow meter 



Fluid Plate Parts and Accessories 

246687 Mastic regulator, 3/4” air operated (no transducer ports) 

246642 Mastic regulator, 3/4” air operated, with transducer ports for ambient fluid plates 

246643 Mastic regulator, 3/4” air operated, for heated fluid plates 

246688 Mastic regulator, 3/4” air operated for heated applications (no transducer ports) 

244734 Cartridge regulator with transducer ports for fluid plates 

238748 Repair kit, cartridge regulator 

238747 Fluid diaphragm repair kit, cartridge regulator 

233131 Fluid section repair kit, mastic fluid regulator 

246190 Flow meter, ambient helical, w/sensor 

234134 Flow meter, ambient helical, w/o sensor 

246652 Flow meter, high resolution helical, w/sensor 

246650 Flow meter, high resolution helical, w/o sensor 

246340 Flow meter, heated helical, w/sensor 

246191 Flow meter, heated helical, w/o sensor 

246786 Kit, sensor and cable for HG6000 (all models) 

239716 Flow meter assembly, G3000 spur gear, meter and sensor 

239719 Flow meter, G3000 spur gear, does not include sensor 

244292 Flow meter assembly, G3000 HR spur gear, meter and sensor 

244291 Flow meter, G3000HR spur gear, does not include sensor 

239717 Sensor, flow meter, G3000 & G3000HR 

198082 Pressure sensor, outlet for ambient regulators 

117764 Pressure sensor, outlet for heated regulators 

198579 Kit, cable, for adding SRZ40 meter 

198578 Kit, cable, for adding G3000 meter 

244343 Mass flow meter kit, non-intrusive 

246596 Kit, Helical gear set repair (standard and heated) 

246949 Kit, Helical gear set repair (high resolution) 

123409 Kit, cable for adding HG6000 (Helical) meter 

Cables 

118342 Cable kit, PrecisionFlo LT to personal computer 

117774 Cable, automation analog, 40 ft. (12.9 m) 

198731 Cable, High Flex Operation, 20 ft. (6.11 m) 



117751 Cable, Standard Flex Operation 20 ft. (6.11 m) 



117747 Cable, Low Flex Operation, 20 ft. (6.11 m) 



234191 Cable, Heated Pressure Sensor 



Filters and Accessories 

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

MPa) 1-1/4” NPT Inlet 1” NPT Outlet 

C59547 Single filter kit, gauges, ball and drain valves, 30 mesh element, 5000 psi, (345 bar, 34.5 MPa) 1” 

NPT 

C58997 Fluid filter, polyethylene support, 30 mesh element, 5000 psi (345 bar, 34.5 MPa) 1” NPT 

515222 Fluid filter, polyethylene support, no element from above kits 

157630 Spring, filter 

521477 Fluid shutoff valve, 1” NPT(F), 5000 psi (345 bar, 34.5 MPa) CS, Fluoroelastomer 

210657 Ball valve, high pressure, 1/2” NPT(M), 5000 psi, (345 bar, 34.5 MPa) CS, Fluoroelastomer 

210658 Ball valve, high pressure, 3/8” NPT(M), 5000 psi, (345 bar, 34.5 MPa) CS, Fluoroelastomer 

210659 Ball valve, high pressure, 3/8” x 1/4” NPT(M), 5000 psi, (345 bar, 34.5 MPa) CS, Fluoroelastomer 

Applicators and Repair Kits 

918533 Dispense Valve, Extrusion, Ambient, Ball Seat 

918535 Dispense Valve, Extrusion, Ambient, Snuff Back 

918537 Dispense Valve, High Viscosity 

918539 Dispense Valve, Extrusion, High Flow, High Viscosity 

918623 Compact Dispense Valve, Extrusion 

918625 Compact Dispense Valve, Spray 

233670 AutoPlus SAE valve 

244930 Manifold, Fluid Inlet, AutoPlus SAE valve 

243482 1K Ultra-Lite valve 45° outlet for orbiter 

244535 EnDure Valve replacement, no manifold 

244910 EnDure Valve with ambient or temperature conditioning manifold 

244961 EnDure Valve with 120 volt electric heat (200°F) (93.3°C) 

244962 EnDure Valve with 230 volt electric heat (200°F) (93.3°C) 

239807 Needle assembly, AutoPlus SAE valve 

233671 Seat, AutoPlus SAE valve 

189970 Gasket, AutoPlus SAE valve, seat 

192443 Gasket, AutoPlus SAE valve, inlet 

114134 Gasket, AutoPlus SAE valve, inlet air 

570267 Fluid Section Seal kit, 1K Ultra-Lite valve 

570268 Rebuild kit, 1K Ultra-Lite valve 

15E012 Standard seal kit, EnDure valve 

15E011 High temperature seal kit, EnDure valve 

104661 Quick exhaust valve, 1/8” NPT(F) 

244021 Cable kit, 8 pin connector and 10 ft. cable for 240 VAC valves 

PrecisionSwirl 

234029 PrecisionSwirl Module, Narrow Pattern 

241658 PrecisionSwirl Module, Wide Pattern 

243402 Swirl orbiter, narrow pattern 

243403 Swirl orbiter, wide pattern 

243437 Tube/bearing repair kit, narrow pattern 



918620 Tube/bearing repair kit, wide pattern 

617870 Cable, PrecisionSwirl, 55’ 

617829 Cable, PrecisionSwirl, automation, 40’ 

233125 Extension cable, 6’ 

233124 Extension cable 9’ 

233123 Extension cable 15’ 

241479 Motor kit 

196008 Bellows (12-pack) 

241569 Bearing Repair Tool Kit 

Tips, Nozzles and Adapters 

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
















198316 Nozzle nut, 1/8” NPT for AutoPlus SAE valve, extruding applications 

198391 Tip nut, AutoPlus SAE valve, fan or stream 

617585 Nozzle nut for streaming tips, EnDure valve 

197504 Straight 3/4-16 JIC outlet for swirl, EnDure valve 

197842 Nozzle, 45° nose piece, orbiter to EnDure valve 

198323 Adapter, 45° orbiter to EnDure 

198324 Fitting, 45° orbiter to EnDure 

607665 Dispense nozzle, steel, 1/8” NPT(M), 0.125”, (3.18 mm), 2’ (0.6 m) long 



C17009 Dispense nozzle, steel, 1/8” NPT(M), 0.125”, (3.18 mm), 1.22’ (0.36 m) long 

C01025 Dispense nozzle, steel, 1/8” NPT(M), 0.9” x 0.37 (22.86 mm x 9.40 mm) ribbon hardened tip, 2.43” 

(61.72 mm) long 

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

270025 Streaming tip, 0.025 (0.64 mm) orifice 











C08224 Shower tip, 6 orifices, 0.021” (0.53 mm) orifice size 

Hoses 

116760 Dispense, 0.50” (1.27 mm) ID x 6’, (1.83 m), Neoprene core, 4000 psi, (276 bar, 27.6 MPa) high 

flex, abrasion resistant for automation units 

116762 Dispense, 0.62” (1.57 mm) ID x 6’, (1.83 m), Neoprene core, 3625, (250 bar, 25.0 MPa) high flex, 

abrasion resistant for automation units 

116761 Dispense 0.50” (1.27 mm) ID x 10’, (3.05 m), Neoprene core, 4000 psi, (276 bar, 27.6 MPa) high 


116763 Dispense, 0.62” (1.57 mm) ID x 10’, (3.05 m) Neoprene core, 3625 psi, 250 bar, 25.0 MPa) high 


C12383 Feed, 1.0” (25.4 mm) ID x 10’, (3.05 mm), Neoprene core 5000 psi (345 bar, 34.5 MPa) 

C12218 Feed, 1.0” (25.4 mm) ID x 20’, (3.03 m), Neoprene core, 5000 psi (345 bar, 34.5 MPa) 

116749 Co-axial feed, 1.0” (25.4 mm) ID x 10’ (3.05 mm), synthetic rubber, 5000 psi (345 bar 24.5 MPa) 

116748 Co-axial feed, 1.0” (25.4 mm) ID x 20’ (3.03 m), synthetic rubber, 5000 psi (345 bar 24.5 MPa) 

115875 Dispense, 240 volt electric heat, 0.5” (1.27 mm) x 6’, (1.83 m) PTFE core 




115885 Feed, 240 volt electric heat, 0.87” (22.10 mm) x 10’, (3.05 m) PTFE core 

115887 Feed, 240 volt electric heat, 0.87” (22.10 mm) x 20’, (6.1 m) PTFE core 

116770 Jacket, 6’ (1.83 m) dispense hose, temperature conditioning 

116769 Jacket, 10’ (3.05 m) dispense hose, temperature conditioning 

C50239 Hose swivel, 1/2” NPT(F), 5000 psi (345 bar, 34.5 MPa) 

512028 PTFE hose, SS braid, 0.187 (4.75 mm) ID, 10’ (3.05 m) long, 3000 psi (207 bar, 20.7 MPa) 


205099 PTFE hose, SS braid, 0.25 (6.35 mm) ID, 2.5’ (0.76 m) long, 3000 psi (207 bar, 20.7 MPa) 

205058 PTFE hose, SS braid, 0.25 (6.35 m) ID, 6’ (1.83 m) long, 3000 psi (207 bar, 20.7 MPa) 

205349 PTFE hose, SS braid, 0.25 (6.35 m) ID, 15’ (4.57 m) long, 3000 psi (207 bar, 20.7 MPa) 



235905 PTFE hose, SS braid, 0.308 (7.82 mm) ID, 2.5’ (0.76 m) long, 4000 psi (276 bar, 27.6 MPa) 





685606 PTFE hose, SS braid, 0.617 (15.67 mm) ID, 10’ (3.05 mm) long, 4000 psi (276 bar, 27.6 MPa) 





C12288 PTFE hose, SS braid, 0.51 (12.95 mm) ID, 10’ (3.05 m) long, 1500 psi (103 bar, 10.3 MPa) 

514428 PTFE hose, SS braid, 0.25 (6.35 m) ID, 10’ (3.05 mm) long, 3000 psi (207 bar, 20.7 MPa) 

511385 PTFE feed 3/4”, (19.05 mm) 10’ (3.05 m) long, SS braid, PTFE feed, 4000 psi (276 bar, 27.6 MPa) 

511387 PTFE feed 3/4”, (19.05 mm) 25’ (7.62 m) long, SS braid, PTFE feed, 4000 psi (276 bar, 27.6 MPa) 

511390 PTFE feed 1”, (25.4 mm) 10’ (3.05 m) long, SS braid, PTFE feed, 4000 psi (276 bar, 27.6 MPa) 

109161 Hose Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/8” (9.52 mm) ID, 2’ (0.61 m) long 







215241 Hose Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 6’ (1.83 m) long 




626721 Dried hose, Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 10’ (3.05 m) 

long, dried, capped with desiccant 

626722 Dried hose, Buna-N core and cover, 5000 psi, (345 bar, 34.5 MPa) 1/2” (12.7 mm) ID, 25’ (7.62 mm) 




626723 Dried hose, Neoprene core and cover, 5000 psi, (345 bar, 34.5 MPa) 3/4” (19.05 mm) ID, 6’ (1.83 

m) long, dried, capped with desiccant 







Temperature Conditioning and Electric Heat 

198457 RTD Sensor, 100 ohm, 3 pin picofast connector 

198458 Sensor cable, 6 ft., (1.83 m) 198457 sensor to temperature conditioning unit 

116824 Heat zone controller module, temperature conditioning (spare parts) 

116503 Heat zone controller module, electric heat (spare parts) 

116201 Control relay 12v coil, electric heat box (spare parts) 

116204 Zone relay, qty. 4, electric heat box (spare parts) 


Appendix A 

Appendix A 

Using the PrecisionFlo LT I/O 

The PrecisionFlo LT uses several I/O signals to communicate with plant automation controllers. There are four digital 

inputs, four digital outputs, one analog input, and one analog output. All of these signals are routed to the I/O connector 

on the top of the controller. 

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

VDC power only when the controller E-Stop switch is not latched in. None of the signals are isolated; all are referenced 

to the ground plane of the control board. The following paragraphs describe typical connection methods for the 

automation controller signals. 

Digital Inputs 

The two digital inputs are Dispense Gun and Job Complete. 

These inputs require a 24 VDC current sourcing 

output from the automation controller. See FIG. 32. 

If the automation controller uses relay contacts to activate 

I/O signals, the 24 VDC available at the Precision- 

Flo LT I/O connector (pin 5) should be used to drive the 

inputs. If the automation controller uses high-side 

switching of 24 VDC, the automation outputs can be 

directly connected to the inputs as long as the 24 VDC 

common (pin 6) of the PrecisionFlo LT is able to be connected 

to the automation controller common. If the automation 

controller outputs are low-side switching (open 

collector) or a voltage other than 24 VDC, relays must 

be used as shown in FIG. 32. 

Pin1or2 

FIG. 32 


Appendix A 

Digital Outputs 

The four digital outputs are Dispenser Ready, Fault 

Present, In Cycle, and Minimum Volume Dispensed. 

These outputs perform high-side switching of 24 VDC 

and require a 24 VDC current sinking input at the automation 

controller. See FIG. 33. If the automation controller 

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

signals should be connected as shown in FIG. 33. 

If the automation controller uses optocouplers to receive 

digital I/O signals, the inputs must be designed for 24 

VDC and the optocoupler emitter cathode must be connected 

to the PrecisionFlo LT 24 VDC common (pin 6). 

See FIG. 34. 

If the automation controller inputs are current sourcing 

or use a voltage other than 24 VDC, relays with 24 VDC 

coils must be used as shown in FIG. 33. 

FIG. 34 

FIG. 33 


Appendix A 

Analog Inputs 

The PrecisionFlo LT receives a flow rate or pressure 

analog command from the automation. The 0 to 10 VDC 

analog input is referenced to analog common on the 

control board. See FIG. 35. The reference for the automation 

controller analog output must be connected to 

the PrecisionFlo LT analog reference (pin 8) for this signal 

to function properly. If this reference connection is 

not possible an analog isolator must be used. 

24 VDC From E-Stop 

The PrecisionFlo LT provides a signal that can be used 

by the automation controller to monitor the emergency 

stop switch position of the PrecisionFlo LT controller. 

See FIG. 37. 

FIG. 37 

Relays 

FIG. 35 

Analog Outputs 

The PrecisionFlo LT provides a flow rate (tach) signal for 

use in the automation. The 0 to 5 VDC analog output is 

referenced to analog common on the control board. See 

FIG. 36. The reference for the automation controller analog 

output must be connected to the PrecisionFlo LT 

analog reference (pin 8) for this signal to function properly. 

If this reference connection is not possible an analog 

isolator must be used. 

If the use of relays is required to condition the digital I/O 

signals, these are some examples of part numbers that 

could be used. 

For 24 VDC Coils: 

• Relay: IDEC Part # RH1B-UDC24V 

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

• Spring: IDEC Part # SY2S-02F1 

For 120 VAC Coils: 

• Relay: IDEC Part # RH1B-UAC120V 

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

• Spring: IDEC Part # SY2S-02F1 

FIG. 36 


Appendix B 

Appendix B 


Screen Overview - Run Screen (Bead Control Mode) 

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

Description Possible Values Default Value 

Hour 0-23 N/A 

Minute 0-59 N/A 

Day 1-31 N/A 

Month 1-12 N/A 

Year 2000-2099 N/A 

Date Format mm/dd/yy-dd/mm/yy mm/dd/yy 

Pressure 0-9999 N/A 

Pressure Units psi or bar psi 

Actual Flow Rate 0-9999 cc/min N/A 

Command 0-100% N/A 

Bead Scale note 1 50-150% 100% 

Dispense Mode Auto or Manual N/A 

Control Mode 

Bead Control, Volume Monitor, Batch 

Dispense, or Pressure Control 

Bead Control 

Style (not shown in low end) 1 to 4 1 

Target Volume note 2 0 to 9,999.9 cc 25.0 cc 

Requested Volume 0 to 9,999,999.9 cc N/A 

Actual Volume 0 to 9,999,999.9 cc N/A 

Volume Error note 3 -100.0 to 999.9% N/A 

Active Fault Numerous text strings N/A 

Notes: 

1. Reverse image indicates Run Mode Bead scale is enabled in the setup other screen. 

2. Target Volume should change based on style. 

3. Error values reflect the last completed job’s data. 

Output: 345 psi 213 cc/min 

Command: 100% 112 % Bead Scale 

Mode: Auto Bead Control 

VOLUME: 

Target: 414 cc 

Requested: 415 + 0.2% 

Measured: 412 - 0.5% 

No Active Faults 09/06/02 10:00 


Appendix B 

Run Screen (Volume Control Mode) 



Hour 0-23 N/A 


Day 1-31 N/A 


Year 2000-2099 N/A 








Control Mode 

Bead Control, Volume Monitor, 

Batch Dispense, or Pressure 

Bead Control 

Control 

Style 1 to 4 1 

Target Volume note 2 0 to 9999.9 cc 25.0 cc 




Notes: 

1. Reverse image indicates Run Mode Bead Scale is enabled in the setup other screen. 

2. Target Volume should change based on style. 

3. Error Values reflect the completed last job's data. 



Mode: Auto Volume Monitor 

VOLUME: 


Measured: 412 - 0.5% 



Appendix B 

Run Screen (Batch Dispense Mode) 



Hour 0-23 N/A 


Day 1-31 N/A 


Year 2000-2099 N/A 








Control Mode 



Bead Control 

Control 


Target Volume note 2 0 to 9999.9 cc 25.0 cc 




Notes: 


2. Target volume should change based on style. 

3. Error values reflect the last completed job’s data. 



Mode: Auto Batch Dispense 

VOLUME: 


Measured 412 - 0.5% 



Appendix B 

Run Screen (Pressure Control Mode) 



Hour 0-23 N/A 


Day 1-31 N/A 


Year 2000-2099 N/A 







Control Mode 



Bead Control 

Control 



Notes: 


Output: 345 psi 


Mode: Auto Pressure Control 



Appendix B 

Setup Screen 1 Dispense Screen 


Notes: 

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

Bead Scale 100 % 

Control Mode Bead Control 

Target Volume 25.0 cc +/- 10.0% 

Dispense Calibrate Other 



Hour 0-23 N/A 


Day 1-31 N/A 


Year 2000-2099 N/A 


Bead Scale 50-150% 100% 

Control Mode 


Batch Dispense, or Pressure Control 

Bead Control 

Target Volume 0 to 9999.9 N/A 

Volume Tolerance 1 to 4 0 to 99.9% 10.0% 


Notes: 

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


Appendix B 

Setup Screen 2: Calibrate Screen (Bead Control Mode) 

100% Command Flow 2548 cc/min 

In Manual Mode, press to begin calibration 

Calibration required (valid) 

Press to see details 

Output 345 psi 2134 cc/min 

Desired Output 333 psi 2115 cc/min 

Kp 105 Ki 4 346 psi 

Max System Output 3405 cc/min 622 psi 

Volume Compensation -2% 112% 



Notes: 


Hour 0-23 N/A 


Day 1-31 N/A 


Year 2000-2099 N/A 


100% commanded flow rate 50-150% 100% 

Pressure tuning status In process, complete N/A 

Flow calibration status In process, complete N/A 

Flow calibration result Required, Valid Required 


Pressure units psi or bar psi 

Actual flow rate 0-9999cc/min N/A 

Desired outlet pressure 0-9999 N/A 

Desired flow rate 0-9999 N/A 

Calculated optimal KP note 1 0 to 9999 100 

Calculated optimal Ki note 1 0 to 9999 6 

Pressure for 100% flow 0 to 9999 N/A 

System maximum flow with completely open 0 to 9999 N/A 

reg 

Compensation zero offset -50 to 399% 0% 

Compensation peak 25 to 400 100% 


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

screen. 


Appendix B 

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

100% Command Flow 2500 psi 




Output 1254 psi 

Desired Output 1250 psi 

Result Kp 105 Ki 4 

Max System Output 3250 psi 3405 cc/min 




Hour 0-23 N/A 


Day 1-31 N/A 


Year 2000-2099 N/A 


100% commanded pressure 1 to 9999 1000 

Calibration status In process, complete N/A 



Desired Outlet Pressure 0 - 9999 N/A 

Calculated optimal Kp note 1 0 to 9999 100 


System maximum pressure with completely 0 to 9999 N/A 

open reg 

System maximum flow with completely open 0 to 9999 N/A 

reg 


Notes: 

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

setup screen. 


Appendix B 

Setup Screen 2: Calibrate Screen (Pressure Control Mode) 

100% Command Pressure 2500 psi 




Output 1254 psi 

Desired Output 1250 psi 

Result Kp 105 Ki 4 

Max System Output 3250 psi 




Hour 0-23 N/A 


Day 1-31 N/A 


Year 2000-2099 N/A 


100% commanded pressure 1 to 9999 1000 

Calibration status In process, complete N/A 



Desired Outlet Pressure 0 - 9999 N/A 

Calculated optimal Kp note 1 0 to 9999 100 


System maximum pressure with completely 

0 to 9999 N/A 

open reg 


Notes: 

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

setup screen. 


Appendix B 

Setup Screen 3: Other Screens 

Language 

Control Mode 

Command Mode 

Pressure Loop Kp 

English 

Bead Control 

Analog 

107 

1 

Pressure Loop Ki 

Job End Mode 

9 

Timer 

Job End Delay 

4 seconds 

Run Mode Bead Scale? 

Regulator Pre-Charge 

No 

.00 VDC 

Gun On Delay 

0 ms 

Gun Off Delay 0 ms 2 

Reg On Delay 

0 ms 

Reg. Off Delay 

Pulses per Flow Reading 

Flow Comp Pivot 

0 

6 

50 % 

Flow Fault Time 

2 seconds 

Screen Saver Timeout 

0 minutes 

Pressure Units psi 

3 

Flow Meter K Factor 

3500 pulses/L 

Default/Fixed Command 50 % 

Manual Command 50 % 

Zero Pressure Signal 

1.00 VDC 

5 VDC Pressure 3500 psi 

Minimum Pressure 

0 psi 

Maximum Pressure 5000 psi 4 

5 VDC Output Flow Rate 1000 cc/min 

mm/dd/yy 

Date Format 

Year 20 03 

Month 

Day 

09 

06 

5 

Hour 

Minute 

18 

00 


Appendix B 

. 

Low Volume 

Alarm 

High Volume 

Warning 

Low Flow Rate 

Alarm 

High Flow Rate Alarm 6 

Low Pressure 

Warning 

High Pressure 

Warning 

Computed Target 

Warning 


Language 

English, Spanish, English 

French, German, Italian, 

Portuguese, Japanese, 

or Korean 

Date Format dd/mm/yy or mm/dd/yy mm/dd/yy 

Year 00 to 99 (2000 to 2099) N/A 

Month 1 to 12 N/A 

Day 1 to 31 N/A 

Hour 0 to 23 N/A 

Minute 0to59 N/A 

Pressure Units PSI or BAR PSI 

Command Mode Fixed or Analog Analog 

Default Command note 1 0 to 100% 50% 

Manual Command 0 to 100% 50% 

Job End Mode Timer or Digital I/O Digital I/O 

Job End Delay 1 to 99 seconds 4 sec 

Flow Meter K-Factor 1 to 99,999 pulses/L 3500 

Regulator Pre-Charge 0.00 to 5.00 VDC 0.00 VDC 

Gun On Delay 0 to 999 msec 0 msec 

Gun Off Delay 0 to 999 msec 0 msec 

Reg On Delay 0 to 999 msec 0 msec 

Reg Off Delay 0 to 999 msec 0 msec 

Zero Pressure Sensor Signal 0.00 to 5.00 VDC 1.00 VDC 

5 VDC Sensor Pressure 0 to 5000 PSI 3500 PSI 

Minimum Outlet Pressure for 0 to 5000 PSI 0 PSI 

Fault 

Maximum Outlet Pressure for 0 to 5000 PSI 5000 PSI 

Fault 

Pressure Loop Kp note 2 0 to 9999 100 

Pressure Loop Ki note 2 0 to 9999 6 


Appendix B 

Pulses per Flow Reading 2 to 99 pulses 4 pulses 

note 3 

Flow Compensation Pivot 0 to 100% 50% 

Point note 4 

Flow Fault Time 1 to 99 seconds 2 seconds 

Enable Run Mode Bead YesorNo 

No 

Adjust? 

Screen Saver Timeout 0to99minutes note 5 0 minutes 

5 VDC Output Flow Rate 1 to 9999 cc/min 5000 cc/min 

(scale analog “tach” out) 

Low Volume Fault Alarm or Warning Alarm 

High Volume Fault Alarm or Warning Warning 

Low Flow Rate Fault Alarm or Warning Alarm 

High Flow Rate Fault Alarm or Warning Warning 

Low Pressure Fault Alarm or Warning Warning 

High Pressure Fault Alarm or Warning Warning 

Computed Target Fault Alarm or Warning Warning 


Notes: 

1. The default flow rate command would be used if there is no analog signal (fixed) or the analog signal is lost. Setting 

this value to zero disables the low analog fault. 

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

and can be manually changed here. See page 104. 

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

can be manually changed here. See page 34. 

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

volume compensation. See page 104. 

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

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

keeping the light on continuously. 


Appendix C 

Appendix C 

Theory of Operation 

Input and Output Signals 

Terminology 

For the purpose of this document a digital signal is said 

to be SET when voltage is present (or above the minimum 

threshold). A signal is said to be RESET when the 

signal voltage is not present (below minimum threshold). 

Devices are referred to as SET when they are in their 

energized or active state. 

Digital Inputs 

Dispense Gun - This is the Dispense Signal. The PrecisionFlo 

LT unit will attempt to dispense at either the 

commanded flowrate or commanded pressure while this 

signal is SET, dependent on mode. 

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

is pressed. 

Job Complete - This input can be used to signal a job 

end. 

The dispenser ready signal is an important signal 

for the automation to monitor. When the dispenser ready 

output is not on, the LT may not be responding to 

requests form the automation. This could create the situation 

where the automation is running production, but 

the LT is not dispensing any material. 

Gun Solenoid - This signal will be set to energize the 

gun solenoid at the beginning of a dispense cycle. 

Minimum Volume Dispensed - This signal will be set 

when the minimum volume (target volume - tolerance) 

has been dispensed for the job. 

Fault Present - This bit is RESET under the following 

conditions: 

1. No Faults (alarms or warnings) are active. 

In Cycle - In Cycle signal is set at the beginning of a dispense 

cycle. It is reset at the end of the dispense cycle. 

The dispense cycle can end in two ways, depending on 

how the Job End mode is set: 

• If the Job End mode is set to automation I/O, dispense 

cycle ends when the job complete signal is 

received from the automation I/O. 

• If the Job End mode is set to Timer, dispense cycle 

ends when the Job End delay timer expires. 

Analog Input 

Flow Command - The flow command signal input represents 

flow or pressure requests. The voltage must be 

between 0 and 10 volts DC. The 0-10 volt signal is interpreted 

as a relative 0-100% flow or pressure command 

signal. The system must be in Analog Mode for this 

input to be used. 

Outlet Pressure- The outlet pressure input represents 

the fluid pressure at the regulator outlet. The default 

voltage ranges from 1 to 5 VDC for 0 to 3500 psi (23.8 

MPa, 238 bar). 

Analog Output 

V/P Command - The V/P command output corresponds 

to an air pressure driving the regulator. The voltage 

ranges from 1-5VDCtoadjustflowand/or pressure in 

the fluid system. 

Flow Rate - The flow rate output relates to the fluid flow 

through the meter. The voltage ranges from 0-5VDC 

corresponding to a0-5000 cc/min. 




Dispense Modes: 

Manual Mode 

When in Manual mode, the PrecisionFlo LT control 

reacts only to input from the user interface. The PrecisionFlo 

LT control ignores automation controller signals 

when in Manual mode. 

Automatic Mode 

When in Automatic mode, the PrecisionFlo LT control 

remains in a ready state, indicated by the DISPENSER 

READY signal, and reacts to inputs such as DISPENSE 

and VOLUME REQUEST signals from the automation 

unit. 

When a fault is detected, the PrecisionFlo LT control 

sets the FAULT present signal HIGH, and may set the 

DISPENSER READY signal LOW. Fault detection can 

also occur during manual dispensing. 

Control Modes: 

Volume Monitor 

The automation I/O or Manual dispense command and 

the 100% pressure setting are used to set a pressure 

target. The regulator adjusts to maintain this pressure. 

In automatic mode the controller compares the dispensed 

volume to the target volume and sets volume 

faults if needed. 

Batch Dispense: 

The automation I/O command and the 100% pressure 

settings are used to set the pressure target. The regulator 

adjusts to maintain this pressure. In automatic mode 

the dispense valve is closed when the target volume is 

reached, a job complete signal is received by the control, 

or the job timer expires. 

Automation I/O Modes: 

Analog 

0-10 VDC signal from the automation unit is used to 

determine the pressure or flow command. A 10 volt 

command will establish a pressure or flow rate command 

equal to the 100% value entered during the calibration 

procedure. If an analog signal < 1vdc is given 

the pressure or flow command is determined by the 

value entered in the default/fixed command parameter. 

During dispensing, the PrecisionFlo LT control performs 

a variety of functions in the background. These functions 

include fault monitoring, real-time volume compensation, 

measuring volume (per job), and continuous 

calculations to maintain the pressure and flow control 

loops. 

Bead Control 

The automation I/O command for manual dispense 

establishes a Flow Rate target. A pressure setpoint is 

determined from the calibration results and the volume 

compensation values. The regulator adjusts to maintain 

the pressure setpoint, volume compensation will adjust 

the pressure setpoint to achieve the desired flow rate. 

Pressure Control 

The automation I/O or manual dispense command and 

the 100% pressure setting are used to set a pressure 

target. The regulator adjusts to maintain this pressure. 

Fixed 

The default/fixed value entered in the setup is used to 

determine the pressure or flow command. 


Jobs 

Jobs 

The PrecisionFlo LT system operates using the concept 

of jobs. A job is a specified amount of material that is 

dispensed by the system. The amount of material specified 

for a job varies, depending on the application. In 

some applications, a job may be the amount of material 

dispensed on a part. Other applications may define a 

job to be the amount of material dispensed on a number 

of parts or dispensed over a period of time. 

A job is initiated when the automation sends a “Dispense 

Gun” signal to the LT. Once the job is initiated, the 

LT will start tracking the amount of volume requested by 

the automation and the amount of material that is actually 

dispensed. These volumes will be tracked until the 

job is completed. At the end of the job, fault calculations 

are made and the volumes are stored to non-volatile 

memory on the LT system (Job Log). 

The LT system watches two things to decide when a job 

is complete. Either the “Job Complete” signal is sent by 

the automation, or the job complete timer expires. The 

type of job end signal is configured in the “Other” screen 

to be of type “Timer” or “Digital I/O”. If the timer method 

is used, the timer begins counting every time the dispense 

gun is turned off. If the gun stays off for more than 

the preset timer value, then the job is considered complete. 

Once the job is complete, the job information is stored to 

memory. The most recent jobs can then be viewed on 

the “Job” screen or by using the Graco Shell Menu System. 

The information stored with each job is as follows. 

Measured Volume - The amount of material measured 

by the flow meter during a job. 

Requested Volume - The amount of material that the 

automation tries to dispense during a job. This volume is 

calculated by measuring how long the dispense gun is 

on, taking in effect the command voltage from the automation 

over time. 

Target Volume - The theoretical amount of material that 

a job should have. This value is usually calculated or 

found using trial and error when the application is first 

set up. 

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

High Volume, Low Volume, and Computed Target faults 

are evaluated at the end of the job. The volume alarms 

compare the measured volume to the requested volume 

and the computed target alarm compares the requested 

volume to the target volume. 

In Volume Monitor Mode and Batch Mode, the 

requested volume is not measured. In these two modes, 

the automation command voltage corresponds to a 

pressure instead of flow rate. For this reason the 

requested volume is not available (as well as the Computed 

Target fault). The high and low volume alarms 

compare the measured volume to the target volume for 

Volume Monitor and Batch modes. 

In Pressure Mode, there are no flow meters available 

and the controls are all performed based on pressure. 

For this reason the LT does not monitor measured, 

requested, or target volume. The High Volume, Low Volume, 

and Computed Target faults are all inactive when 

using Pressure mode. 


Typical Job Cycle 

Typical Job Cycle 

1. Automation system controller verifies that the DIS- 

PENSER READY signal is HIGH. 

2. Automation system goes into cycle. 

3. PrecisionFlo LT control waits for DISPENSE gun 

signal from the automation system to start dispensing. 

4. Automation system controller requests material to 

be dispensed by setting the DISPENSE gun signal 

HIGH. 

In Batch Dispense Mode the dispense gun signal 

must remain valid for a minimum of 20 msec. 

5. Dispense gun opens after the GUN ON DELAY, 

immediately if the delay is set to zero. 

6. PrecisionFlo LT control checks if a REGULATOR 

ON DELAY has been set by the user. 

If the delay has been set, the PrecisionFlo LT control 

waits until the delay has expired, then begins regulating 

material to the gun. 

If the delay has not been set, the PrecisionFlo LT 

control immediately begins regulating material to 

the gun. 

7. PrecisionFlo LT control regulates output based on 

the COMMAND input signal from the automation 

unit in analog mode or the set value in Default/Fixed 

mode. 

8. PrecisionFlo LT control measures the volume dispensed 

continuously in all modes except pressure 

control. 

9. PrecisionFlo LT control continuously monitors the 

outlet fluid pressure and the flow rate, as measured 

by the flow meter, and makes adjustments for 

changes in operating conditions. 

10. PrecisionFlo LT control monitors operating parameters 

to detect and report any faults that may occur. 

11. Automation unit sets the DISPENSE gun signal 

LOW, indicating that no material is required during 

this portion of the program. (automation unit can 

cycle the DISPENSE gun signal HIGH and LOW 

throughout a cycle if required. Volume measurement 

will still occur.) 

12. The regulator closes after the REGULATOR OFF 

DELAY expires. 

13. The PrecisionFlo LT control checks if a GUN OFF 

DELAY has been set by the user. 

If the delay has been set, the PrecisionFlo LT control 

waits until the delay has expired, then closes the 

dispense gun solenoid, which closes the gun. 

If the delay has not been set, the PrecisionFlo LT 

control immediately closes the dispense gun solenoid, 

which closes the gun. 

14. PrecisionFlo LT control stops measuring volume 

after the DISPENSE DONE DELAY timer expires or 

the JOB COMPLETE automation I/O signal is 

received, depending on the job end mode selected. 

The job complete signal must remain valid for a minimum 

of 20 msec. 

15. PrecisionFlo LT control updates the Status screen 

and the Data table. 

16. The PrecisionFlo LT waits for the next cycle to 

begin. 


Typical Dispense Cycle 

Typical Dispense Cycle 

The In Cycle signal is set at the beginning of a dispense cycle, which starts with a Dispense Gun signal from the 

automation unit. 

Bead Control / Vol. Monitor / Pressure Control 

Using I/O for Job End 

Dispense Gun 

Input Signal 

Regulator 

On 

A 

B 

Valve 

On 

C 

D 

E 

Job Complete 

Input Signal 

F 

In Cycle 

Output Signal 

FIG. 38 

A = Regulator On Delay 

B = Regulator Off Delay 

C = Gun On Delay 

D = Gun Off Delay 

E = Minimum delay between regulator / valve closing is 10 msec 

F = The minimum pulse width for the Job Complete signal is 20 msec 


Typical Bead Control / Vol. Monitor / Pressure Control 

Typical Bead Control / Vol. Monitor / Pressure Control 

Using Timer for Job End 

Dispense Gun 

Input Signal 

Regulator 

On 

A 

B 

Valve 

On 

C 

D 

In Cycle 

Output Signal 

E 

FIG. 39 

A = Regulator On Delay 

B = Regulator Off Delay 

C = Gun On Delay 

D = Gun Off Delay 

E = Job end delay time, default value is 4 seconds 


Typical Batch Dispense Cycle (I/O) 


Using I/O for Job End 

Dispense Gun 

Input Signal 

A 

Regulator 

On 

B 

C 

Valve 

On 

D 

E 

Volume Not Reached, Job Aborted by I/O 

Job Complete 

Input Signal 

F 

In Cycle 

Output Signal 

Min Volume 

Output Signal 

Volume Reached, Job Ended Automatically 

Job Complete 

Input Signal 

In Cycle 

Output Signal 

Min Volume 

Output Signal 

FIG. 40 

A = The minimum pulse width for the Dispense Gun input signal is 20 msec. 

B = Regulator On Delay 

C = Regulator Off Delay 

D = Gun On Delay 

E = Gun Off Delay 

F = The minimum pulse width for the Job Complete signal is 20 msec 



Typical Batch Dispense Cycle (Timer) 

Using Timer for Job End 

Dispense Gun 

Input Signal 

A 

Regulator 

On 

B 

C 

Valve 

On 

D 

E 

Volume not reached, job aborted by timer 

In Cycle 

Output Signal 

F 

Min Volume 

Output Signal 

Volume reached, job ended automatically 

In Cycle 

Output Signal 

Min. Volume 

Output Signal 

Target Volume Reached 

Minimum Volume Reached 

FIG. 41 

(Minimum Volume = Target Volume - Volume Tolerance) 

A = The minimum pulse width for the Dispense Gun input signal is 20 msec. 

B = Regulator On Delay 

C = Regulator Off Delay 

D = Gun On Delay 

E = Gun Off Delay 

F = The Job End Delay time, default is 4 seconds. 


Continuously Running Applications 

Continuously Running Applications 

In some cases the target volume for a job is not known. 

An example of a case where the target volume is 

unknown is a continuously running system. This would 

be a system that does not run jobs, but runs continuously 

over a day or a shift. In this case, the flow rate 

becomes more important than the amount of volume 

dispensed in a job. The way to handle this situation is to 

set the target volume to a value of zero. This effectively 

disables the computed target fault. The controls will still 

maintain the desired flow rate and report faults corresponding 

to the tolerance set for the running style. 

Another situation where it may be desirable to set the 

target volume to be zero is when there are too many 

styles for the LT to keep track of. For the standard configuration, 

the LT only maintains one style and for the 

advanced configuration there are four styles. If the target 

volume is set to zero, then the LT will be able to handle 

running jobs with varied volumes with out generating 

faults. The flow rate faults will still be active and the high 

and low volume faults will also still be active. The computed 

target faults will not be active and the job logs will 

always show a value of 0 in the Target Volume column. 


Flow Rate Calculation 


The pulses per flow reading value is calculated by the 

system based on the K-factor and the flow rate entered 

during flow calibration. 

Example: pulses per reading = 4 pulses 

Flow Rate = 400 cc/min 

K-factor = 3500 pulses/liter = 3.5 pulses/cc 

4 pulses 

(pulses per reading) 

The time is measured for the number of flow meter 

pulses in the flow average variable to occur and the flow 

rate is calculated. 

This gives a pulse rate of 23.3 pulses/second or 43 milliseconds/pulse. 

A new flow rate is measured approximately 

every 171 milli-seconds. 

If the time measured with the same parameters (3500 

pulses/liter, 4 pulses flow average) is 180 milliseconds, 

the flow rate calculation would be 380 cc/minute. 

Flow Calibration 

In order to control the flow rate of a material, the system must determine the pressure required at the regulator outlet 

to achieve a desired flow rate (Fig. 20).The flow calibration procedure provides the pressure required to obtain the 

maximum desired flow rate (10 VDC flow command.) 

1000 

800 

100% 

80% 

The flow calibration procedure 

determines this point. This is the 

initial pressure/flow peak setting 

(100%). 

Pressure (psi) 

600 

400 

60% 

40% 

This is the 

initial pressure 

flow offset setting 

(0%) 

200 

0 

20% 

Default flow comp pivot 

point (50%). See Control 

0% 

Assembly Parts on page 

-10% 

0 2 4 6 8 10 

Flow Command (VDC) 

10 VDC = flow rate entered on flow calibration screen for 100% flow command 

FIG. 42 



Volume Compensation 

Volume compensation is used when the PrecisionFlo LT 

system is operated in bead control mode. The system 

measures the actual flow rate and adjusts the pressure/flow 

relationship (as determined during flow calibration) 

to achieve the desired flow. 

When flow calibration is completed, the resulting pressure 

value is divided by 100 to obtain a 1% value. The 

initial offset is set to 0%, the initial peak is set to 100% 

(see Flow Calibration on page 104). 

Endpoint 

Adjustment 

Flow rate < 

desired 

flow rate 

Flow rate > 

desired 

flow rate 

Flow Command < 

Flow comp Pivot 

Point 

Increase offset 

Decrease offset 

FlowCommand> 

Flow comp Pivot 

Point 

Increase peak 

Decrease peak 

Each time a new flow rate measurement has been completed, 

the actual flow rate is compared to the requested 

flow rate. The flow rate command from the automation 

unit (analog or fixed) is also compared to the flow rate 

defined by the flow comp pivot point value. The pivot 

point should be set to the average value of the minimum 

and maximum automation commands when using Analog 

for automation mode. 

The volume compensation routine moves the end points 

of a straight line which defines the pressure/flow relationship 

of the system. 

The end point of the pressure/flow line (offset or peak) is 

moved the 1% value determined at the end of the flow 

calibration routine. The magnitude of the flow rate error 

does not affect the size of the adjustment. 

The maximum adjustment range of the peak point is 

25% to 400% of the original value from calibration. If the 

25% or 400% limits are reached, a Volume Comp Limit 

fault is generated. 


Appendix D 

Appendix D 

Ethernet Kit 118329 

The Ethernet kit for PrecisionFlo LT provides for a way to 

communicate with the LT via an industrial or office network. 

This kit converts the serial (RS232) information 

provided in the Graco Shell menu system into Ethernet 

packets that can be accessed using TCP/IP networking. 

A DIN rail mounted module that has terminal screws for 

the RS232 wires as well as a RJ45 port for Ethernet performs 

the conversion. 

The kit comes from the factory pre-wired with the wires 

needed to connect to the LT system. The five wires are 

labeled with wire numbers that indicate where they 

should be located inside of the LT control box. The wiring 

for the converter module is as follows. 

Wire function Wire Number 

+24 V 2120 

Common 2121 

RS232 Transmit 2551 

RS232 Receive 2541 

RS232 Ground 2560 

The kit ships with a User’s Guide that provides detailed 

instructions on how to configure the conversion module. 

The module can be configured using a graphical web 

based configuration connection or by using a serial connection 

to the module. In general, the default settings of 

the unit may be used with the following exceptions. 

• The Baud Rate needs to be changed to 57600 

• The “End Char” setting needs to be “0x0D” 

• The dip switches on the outside the box should 

be set to “Terminal”. This would be switch #4 on 

and all of the other switches are off. 

Once the conversion module has been configured, the 

Graco Shell menu system (see page 40) for the LT can 

be accessed by any computer that exists on the same 

network as the LT. The LT will be uniquely identified by 

its IP Address. This IP address could be an internal IP 

address assigned by your IS department or it could be a 

public IP address that will make the system accessible 

on the Internet. The module can also be configured to 

obtain its IP address automatically from the network that 

it is attached to using DHCP. Due to the security implications 

and the complexity of setting up a new IP 

addresses, the IP address selection and configuration 

should be done with the help of an IS professional. 

2551 

2541 

It is important to note that Xmodem and Ymodem do not 

work reliably through the Ethernet conversion module. 

These protocols are used when selecting the menu 

options that “Transfer” or “Restore” files to and from the 

LT. The alternative is to use the options that “Dump” the 

file to the screen. The data can then be copied to the 

clipboard. 

2120 

2560 

2121 

FIG. 43 


Appendix D 


Graco Standard Warranty 

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in 

material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty 

published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by 

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written 

recommendations. 

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty 

installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of 

non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with 

structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or 

maintenance of structures, accessories, equipment or materials not supplied by Graco. 

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of 

the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned 

to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs 

will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. 

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED 

TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. 

Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy 

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or 

consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. 

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A 

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT 

MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to 

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these 

warranties. 

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or 

the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the 

negligence of Graco, or otherwise. 

FOR GRACO CANADA CUSTOMERS 

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, 

given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la 

rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite 

de ou en rapport, directement ou indirectement, avec les procedures concernées. 

Graco Information 

For the latest information about Graco products, visit www.graco.com. 

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. 

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505 

All written and visual data contained in this document reflects the latest product information available at the time of publication. 

Graco reserves the right to make changes at any time without notice. 

This manual contains English. MM 309738 

Graco Headquarters: Minneapolis 

International Offices: Belgium, China, Japan, Korea 

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 

Copyright 2003, Graco Inc. is registered to ISO 9001 

www.graco.com 

Revised 01/2010

309738L - PrecisionFlo LT Standard, Instructions, English - Graco Inc.

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