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Coating and Dispensing
Installation and Service
Manual
Models:
- PVA650 FT
[email protected]
(518) 371-2684
15 SOLAR DRIVE - HALFMOON, NY 12065
PHONE: (518) 371-2684 - FAX: (518) 371-2684
All Rights Reserved, Copyright (c) 2003 Precision Valve & Automation, Inc.
Operation and Maintenance Manual
Warnings, Cautions, and Notes

Certain warning symbols are affixed to the machine and correspond to notations in this manual.
Before operating the workcell, identify these warning labels and read the notices described
below. Not all labels may be used on any specific system.
Always wear-approved safety glasses when operating or working

near the workcell.
6040
In situations where inattention could cause either personal injury

or damage to equipment a warning notice is used.
6014
Do not smoke near the workcell. Always have a fire extinguisher

available for emergency use.
6019
Before operating the system, read and understand the manuals

provided with the unit.
6017
Before performing any repairs or maintenance to the system, turn

off power and lock out the power disconnect switch.
6011
Never place hands or tools in areas designated by this symbol

when the machine is in operation. A dangerous condition may
exist.
6008
Warning notices are used to emphasize that hazardous voltages,
current, temperatures, or other conditions that could case
personal injury exist in this equipment or may be associated with
its use. Only qualified personnel should enter areas designated
with this symbol.
6010
Before performing any repairs or maintenance to the system, read

and understand the manuals provided with the unit. A qualified
individual should only perform Service.
6018
Exercise caution when pressurized vessels are present. Identify

and repair any leaks immediately. Always wear appropriate safety
equipment when working with pressurized vessels or vessels
containing chemicals.
6054
Laser light source present. Do not stare directly into the beam. Do
not use in the presence of highly reflective surfaces.
6003
Pinch hazard from moving parts. Avoid contact.
1012
Shear hazard from moving parts. Avoid contact.
1099
Hot surface. Avoid contact.
6043
Do not remove protective guarding.
6060
This document is based on information available at the time of its publication. While efforts have
been made to be accurate, the information contained herein does not purport to cover all details
or variations in hardware or software, or to provide for every possible contingency in connection
with installation, operation, or maintenance. Features may be described herein, which are not
present in all hardware and software systems. Precision Valve & Automation, Inc. assumes no
obligation of notice to holders of this document with respect to changes subsequently made.
Precision Valve & Automation, Inc. makes no representation or warranty, expressed, implied, or
statutory with respect to, and assumes no responsibility for the accuracy, completeness,
sufficiency, or usefulness of the information contained herein. No warranties of merchantability
or fitness for purpose shall apply.
This docum ent, including the inform ation contained herein, is the property of
P recision Valve & Autom ation, I nc. and is considered confidential and proprietary
inform ation. I t is delivered on the ex press condition that it not be used, disclosed, or
reproduced in w hole or in part, for any reason w ithout prior w ritten consent of
P recision Valve & Autom ation, I nc.
Copyright © 2008 Precision Valve & Automation, Inc.

Preface
Notice & Disclaimer
o This manual applies ONLY to the PVA650-FT™ automated workcell.
All equipment is referenced throughout the manual as the workcell. This manual
provides information and functionality descriptions covering all the common options and
configurations for a workcell. The particular machine associated with this manual may not
contain all items or may have additions. If the manual refers to an option that was not
purchased, ignore that section. If options exist on the machine not mentioned in this manual,
please consult the Optional Equipment section of the Operating Guide for more information on
these additions.
CAUTION! If the equipment is used in a manner not specified by PVA, the protection
provided by the equipment may be impaired.
Contact
Main Office PVA
15 Solar Drive
Halfmoon NY 12065
Tel (518) 371-2684
Fax (518) 371-2688
Website http://www.pva.net/
Email mailto:[email protected]
Technical Support Tel (518) 371-2684
Operation and Maintenance Manual Rev A 9/07

- iv -
Revisions to This Manual
The following list describes the major revisions in this manual (Rev A 9/07) as compared to the
previous version:
o First Edition for 650 Flip Top Workcell

-v-
Content of This Manual
Introduction: Provides an overview of the workcell functionality and physical characteristics.
Installation and Setup: Describes the procedures for installing the workcell and preparing the
system for use. Included in this chapter are instructions for unpacking, inspecting, and installing
the workcell.
Operating Safety: Basic safety practices are reviewed. The safety devices and guarding for the
workcell are described.
Operation: Describes system operations of the workcell. It includes a discussion of the system
power-up and power-down sequences and modes of operation.
Troubleshooting: Provides a guide to troubleshooting the workcell. A fault diagnosis table is

used to lead the operator through common problems and solutions. Several troubleshooting
procedures are described.
Maintenance: Provides a preventive maintenance schedule and replacement procedures.
Appendix A – Definitions: Definitions for commonly used terms.
Appendix B – Serial Communication: A brief overview of establishing communication with the

workcell.
Appendix C – Error Codes : A list of error codes that may be encountered while using the
workcell.
Appendix D – Wiring Schematic Legend: A legend for the numbering and color coding used
in the control enclosure for the workcell.

- vi -
Contents
Table of Contents
Warnings, Cautions, and Notes .............................................................................................................i
Preface ........................................................................................................................................... iv
Notice & Disclaimer ...............................................................................................................................iv
Contact ...................................................................................................................................................iv
Revisions to This Manual....................................................................................................................... v
Content of This Manual ........................................................................................................................vi
Contents ........................................................................................................................................ vii

Table of Contents .................................................................................................................................vii
Table of Figures...................................................................................................................................... x
List of Tables........................................................................................................................................... x
Introduction ................................................................................................................................. 11
System Description .............................................................................................................................. 11
Safety Precautions ........................................................................................................................ 12
Basic Practices ............................................................................................................................... 12
Year 2000 Compliance.................................................................................................................. 12
Intended of Use.................................................................................................................................... 12
Emergency Shutdowns ........................................................................................................................ 12
Emergency Stop Recovery .................................................................................................................. 13
Environmental ....................................................................................................................................... 13
Noise Levels ................................................................................................................................... 13
Materials/Chemicals ...................................................................................................................... 13
Hazards Due to Contact ............................................................................................................... 13
Handling, Transportation and Storage .............................................................................................. 13
Handling and Transportation ....................................................................................................... 13
Storage ........................................................................................................................................... 13
Installation and Setup................................................................................................................ 15

Tools and Material needed ................................................................................................................. 15
Uncrating and Inspection .................................................................................................................... 15
To place the dispense system ..................................................................................................... 15
Inspection.............................................................................................................................................. 16
Leveling the Workcell .......................................................................................................................... 16
Tools needed ................................................................................................................................. 16
To level the workcell..................................................................................................................... 16
Installing the Teach Pendant and Light Tower ................................................................................ 17
Power Up ............................................................................................................................................... 17
Overview ........................................................................................................................................ 17
Operating Environment ....................................................................................................................... 18
Board Sensor Sensitivity Adjustment procedures ..................................................................... 18
Tools needed ................................................................................................................................. 18
Location .......................................................................................................................................... 18
Temperature and Humidity.......................................................................................................... 18

- vii -
Dip Switch Settings .............................................................................................................................. 19
Software ................................................................................................................................................ 19
Main program file .......................................................................................................................... 19
PathMaster® ................................................................................................................................. 19
Project File ..................................................................................................................................... 19
Machine Communications ................................................................................................................... 20
SMEMA............................................................................................................................................ 20
Operating Safety ......................................................................................................................... 21

Notices and Warnings .......................................................................................................................... 21
Safety Devices and Guarding ............................................................................................................. 21
Safety Circuit ................................................................................................................................. 21
Lexan Guarding ............................................................................................................................. 21
Doors .............................................................................................................................................. 21
Light Curtain .................................................................................................................................. 21
Exhaust Fan ................................................................................................................................... 22
Operation ...................................................................................................................................... 23
Startup Procedure ................................................................................................................................ 23
Light Tower Operation......................................................................................................................... 23
Exhaust Verification ............................................................................................................................. 23
Machine Safety Check.......................................................................................................................... 24
Homing the Axes .................................................................................................................................. 26
Standby Position ................................................................................................................................... 27
Solvent Cups ......................................................................................................................................... 27
Flow Monitor System ........................................................................................................................... 27
Priming the Flow Monitor ............................................................................................................. 27
Determining the Correct Material Volume ................................................................................. 28
Setting the Material Volume Check ............................................................................................ 28
Auto Cycle Flow Error ................................................................................................................... 28
Flow Monitor Calibration .............................................................................................................. 28
Flow Monitor Setup ....................................................................................................................... 29
Calibration Procedures......................................................................................................................... 29
Standard Needle Calibration ........................................................................................................ 30
Operator Defined Needle Calibration ......................................................................................... 30
Sensor Defined Needle Calibration ............................................................................................. 30
Shutdown Procedure .................................................................................................................... 31
Cycle Stop ...................................................................................................................................... 32
Program Selection ................................................................................................................................ 33
Manual Mode ................................................................................................................................. 33
Valve Selection .............................................................................................................................. 34
Conveyor Control .......................................................................................................................... 35
Board Locators .............................................................................................................................. 36
Run Mode ....................................................................................................................................... 36
Launch PathMaster®.................................................................................................................... 37
SMEMA Status ............................................................................................................................... 37
Automatic Mode ............................................................................................................................ 38
Setup Mode .................................................................................................................................... 39
Auto Purge/Solvent Setup............................................................................................................ 40
Needle Calibration ......................................................................................................................... 41

- viii -
Teach Pendant ...................................................................................................................................... 42
Fault Recovery ...................................................................................................................................... 43
Recovering from Emergency Stop and Other Machine Errors ................................................ 43
Pneumatic Error Recovery Procedure ........................................................................................ 45
Run-Time Error Recovery Procedure .......................................................................................... 45
Position Error Recovery Procedure ............................................................................................. 45
Limit Error Recovery Procedure .................................................................................................. 46
Stop Codes ..................................................................................................................................... 47
Troubleshooting .......................................................................................................................... 48
If Something Goes Wrong . . . ........................................................................................................... 48
Calling Technical Support............................................................................................................. 48
Records........................................................................................................................................... 48
Fault Diagnostic .................................................................................................................................... 49
Closed Loop Servo Systems ......................................................................................................... 49
Controller Master Reset ....................................................................................................................... 52
IP Configuration ................................................................................................................................... 52
Request Controller Version ................................................................................................................. 54
Flexible coupling ................................................................................................................................... 54
Power Check ......................................................................................................................................... 55
Door Interlock Check ........................................................................................................................... 55
Encoder Feedback Test ....................................................................................................................... 56
Motor Feedback Test ........................................................................................................................... 56
Maintenance ................................................................................................................................. 58
Schedule ................................................................................................................................................ 58
Procedures ............................................................................................................................................ 60
Ball Screw Slides ........................................................................................................................... 60
Inspection ...................................................................................................................................... 60
Conveyor Belt Replacement ........................................................................................................ 60
Valves ............................................................................................................................................. 60
Servicing the Inline Material Filter .............................................................................................. 60
Exhaust Fan Setup ........................................................................................................................ 61
Pressure Differential Switch Setup ............................................................................................. 61
Part Replacement........................................................................................................................ 62
Ordering Parts ............................................................................................................................... 62
Return Material Authorization (RMA) ......................................................................................... 62
Training .......................................................................................................................................... 62
Warranty ........................................................................................................................................ 62
Shipping.......................................................................................................................................... 62
Appendix A – Definitions ........................................................................................................... 63
Appendix B – Serial Communication ....................................................................................... 65

Serial Communication .......................................................................................................................... 65
Overview ........................................................................................................................................ 65
9 Pin Serial Connector .................................................................................................................. 65
25 Pin Serial Connector ................................................................................................................ 65

- ix -
Computer 9 Pin to workcell Programming Port… ..................................................................... 66
Computer 25 Pin to workcell Programming Port… ................................................................... 66
Appendix C – Error Codes .......................................................................................................... 67

DMC Error Codes .................................................................................................................................. 67
Appendix D – Wiring Schematic Legend ................................................................................. 69

Wire Numbering ................................................................................................................................... 69
Wire Color Code ................................................................................................................................... 69
Table of Figures
Figure 1 – workcell Functional Block Diagram .......................................................................... 11

Figure 2 –SMEMA Diagram .................................................................................................... 20
Figure 3 - Needle Sensor Calibration Block .............................................................................. 30
Figure 4 - Teach Pendant ...................................................................................................... 42
Figure 6 - Flexible Coupling.................................................................................................... 54
List of Tables
Table 1 – DMC-2200 Dip Switch Settings ................................................................................ 19
Table 2 – Light Tower & Buzzer Status ................................................................................... 23
Table 3 – Stop Code Definitions ............................................................................................. 47
Table 4 – PVA650™ systems Fault Diagnosis........................................................................... 49
Table 5 – Preventive Maintenance Schedule ............................................................................ 58
Table 6 – DTE 9 Pin Serial Connector ..................................................................................... 65
Table 7 – DTE 25-Pin Serial Connector ................................................................................... 65
Table 8 – Cable for Computer DB9 to workcell ........................................................................ 66
Table 9 – Cable for Computer DB25 to workcell ...................................................................... 66
Table 10 – DMC Error Codes .................................................................................................. 67
Table 11 – Wire Numbering ................................................................................................... 69
Table 12 – Wire Color Code ................................................................................................... 69

-x-
Introduction
System Description
This manual is intended primarily as a reference for production and operator. However, technical personal
that is not familiar with PVA equipment find this manual useful for introduction and training.
The workcell has been designed specifically for applications involving high precision industrial dispensing
and spray conformal coating. The flexibility of the machine allows it to be used effectively for a wide
range of applications.
The valves are mounted to the end effecter of a two, three or four axis Cartesian robot. All
dispensing/spraying is performed within the lexan enclosed work area. Limits have been imposed on the
axes to prevent damage to the machine. The dispense/spray path and active heads are controlled by a
program stored in the motion controller. The controller can store and retrieve up to 30 programs.
NOTE: Not all m odels are equipped w ith lex an guarding.

The PVA Portal software permits the operator the complete control of the machine. This includes
machine setup, manual operation, program selection and automatic operation. Machine status and error
messages are displayed in the program window and via the optional light tower. It is necessary that
operator(s) have read or by training understand the operation of this machine.
Any uses other than listed above could result in a dangerous condition and cannot be protected against
by the safety features installed on the system.
PC INTERFACE
SENSORS
X-Y-Z-W
ACTUATORS MOTION ELECTRO-
CONTROLLER MECHANICAL
COMPONENTS
CONVEYOR
CONTROL
CONVEYOR
Figure 1 – workcell Functional Block Diagram

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Safety Precautions
Operation of your workcell involves air pressure, electrical power and mechanical devices and the use of
Hazardous materials. Is very important that qualify technicians operating and servicing the system fully
understand the systems and safety precautions.
Basic Practices
• Only trained personnel should be permitted perform maintenance and service
• Do not wear loose clothes or jewelry while operating the system
• Do not touch the dispense head while is moving
• Learn and know the MSDS recommendations on the material intended to use
• Make sure cables or pneumatics hoses are secure and to cross walkways
• Immediately press Emergency Stop if personnel is in danger
• Locate and define all safety label around the equipment before power up
• There should be always two people while performing maintenance to the equipment
Year 2000 Compliance

The workcell is compliant with and comprehends the year 2000-century date change. The workcell will
not have any operational impediments, malfunction, cease to perform, generate incorrect or ambiguous
data and/or produce incorrect or ambiguous results with respect to same-century and multi-century
formulas, functions, date values and date-data interfaces.
Intended of Use
Safety is considered a joint responsibility in between the OEM and the end-user. All precautions and
practices should be in accordance with local regulations.
Using the workcell in other ways than is described in this documentation supplied with the equipment
may result in injury or damage of the equipment. Example of this:
• Using incompatibles tools
• Removing doors interlocks or bypassing safety devices
• Making custom mechanics or fluid delivery modifications
• Change material from original design
Emergency Shutdowns
As a minimum push the EMERGENCY STOP if someone is in immediate danger, or electric shock
• Unexpected head movement

- 12 -
• If any PCB are in danger or being damage
Emergency Stop Recovery

Do not restart operation until the condition that caused the failure is being alleviated.
• Open the front doors and remove all PCB from the work area
• Close the doors and pull the stop button out
• Press Continue to recover power and restart your program by pressing AUTO
Environmental
Noise Levels
The audible noise level of the workcell is below 65 dBA.
Materials/Chemicals
There are no dangerous materials or chemicals used in the operation of the machine except for the
required application material. The application material should include a Material Safety Data Sheet
(MSDS), which specifies known dangers and toxicity.
Hazards Due to Contact

The workcell is designed in such a way as to minimize injury from contact with any accessible portion of
the machine. However, under certain modes of operation, it is possible to enter the work area while the
motion platform is under power. Only a qualified person should do this. All hot surfaces are indicated
with a warning label.
Handling, Transportation and Storage
Handling and Transportation

Handling and transportation should be done in such a fashion as to minimize the vibration and shock
introduced to the system. An air-ride truck is recommended for roadway transport. Although the
machine is designed and built to perform in an industrial environment, excessive abuse will greatly impact
the performance of the machine.
Storage
Dust and Debris

All enclosures and connector covers should be closed tightly. It is recommended that a cover be place
over the system if dust or other airborne debris is present in the storage area.
Temperature and Humidity

Storage should be done in an area at 40°F - 105°F (4°C – 41°C) and low humidity. Condensation should
not be allowed to collect on the machine.

- 13 -
Dispensing/Spraying Equipment
Whenever the machine is to be stored for extended periods of time, the workcell should be flushed using
a solvent compatible with the application material. This includes the following systems, if applicable:
o Dispense valves, spray valves, and servo valves.
o Material lines and hoses.
o Pressure vessels.
o Pumping systems.
o Diaphragm pumps

- 14 -
Installation and Setup
WARNING! The following procedures should be performed by qualified persons in
accordance with this manual and all applicable safety regulations. A “qualified person” is
defined as “a person or persons who, by possession of a recognized degree or certificate or
professional training, or who, by extensive knowledge, training, and experience, has
successfully demonstrated the ability to solve problems relating to the subject matter and
work.” (Ref. ANSI/ASME B30.2-1983.)
Tools and Material needed

The following tools and material will be need for this procedure
• ½ - Inch Wrench
• Forklift
• Work Gloves
• Tie Wrap cutters
• Safety Glasses
• 3 mm hex Key
• 4 mm hex Key
• 5 mm hex key
• Flat Bar
Uncrating and Inspection
1) Use the flat bar and hammer to remove the top and sides of all four sides of the crate
2) Remove all packing materials and strapping.
3) Use the 9/16-inch wrench to remove the following bolts and anchoring the dispensing system to the
floor of the crate.
• Two (2) Bolts in each of the foot (8 Total)
4) Use a forklift to gentle remove the dispense equipment off the pallet; lift the equipment either from
the back or the front. Place forks all the way in and making sure that blade reach from front to back.
To place the dispense system

1. Move the dispense system to the location where it will be operated
2. Adjust the forklift height until the dispense equipment is approximately at the required height. If
any foot touches the floor before the forklift reaches the required height.
3. Loosen the locking nuts, if necessary.
4. Once the workcell has reached the approximate required height; make sure that all four levelers
(feet) are touching the ground. If any feet are not touching the ground, use the crescent wrench
to lower the feet by turning the feet clockwise.

- 15 -
5. Gentle lower the workcell and remove the forklift.
NOTE: I t is not necessary to tighten the locking nut at this tim e.
Inspection
1. Open the front doors, and remove all straps, tie wraps, and sponges around the dispense heads.
2. Thoroughly inspect the exterior of the machine for damage, loose fasteners, etc. Gently move
the X & Y axis slide to the center of the work area. At the rear of the machine, inspect all tubing
connections, gauges, and regulators.
3. Open the electrical enclosure and visually inspect connectors and components for vibration during
shipping. Close the door, as the machine should not operate with the doors open.
4. Reinstall the Light tower.
5. Reinstall flow monitor. The flow monitor is typically mounted on the rear of the workcell.
6. Reinstall the main air regulator assembly.
Leveling the Workcell

This section describes the procedures for leveling the Workcell. If the workcell is going to use as an in-line
system, it needs to be leveled and aligned in relation to upstream and downstream systems. This
document does not include procedures for upstream and downstream systems. Alignment procedures
should be developed and followed by your facility.
Tools needed
The following tools will be needed to level the workcell
• Level
• Crescent wrench
To level the workcell

1. Place the level in the center of the front conveyor.
2. Observe the position of the bubble within the level window. Determine if the workcell is level
from side to side. The bubble should be centered between the two lines.
TIP: If the position of the bubble is positioned to the closer to the right line, the left side of the
workcell needs to be raised. If the bubble is outside or positioned closer to the left line, the
workcell needs to be raised to the right side.
3. If necessary, loosen the locking nut on each foot using a crescent wrench.
4. Using a crescent wrench, adjust the feet of the workcell by placing the wrench on the flat
(unthreaded) part of the pedestal and turning in the desired direction until the workcell is level
from side to side.
TIP: Turning the pedestal clockwise raises the workcell. Turning the pedestal counterclockwise
lowers the workcell.
5. Check for level at both ends of the conveyors rail by placing the level along the length of the rail
6. Put the level across the center of the conveyors rails, with one end on the front conveyors and
the second end in the back rail.

- 16 -
7. Look at the position of the bubble within the level window. Determine if the workcell is level from
front to back
8. Check the workcell for all corner stability by putting your hands on top of the workcell in one
corner and pressing down. If one of the feet is not touching the ground the workcell will rock
back and forth. Adjust the feet so that they are all bearing the weight equally.
9. After checking the corner, re-level the workcell from side to side and front to back if necessary
10. Once the workcell is level from front to back and side to side and is stable with all four feet
bearing the weight equally, finger tighten the locking nuts by turning them counterclockwise.
Installing the Teach Pendant and Light Tower

1. Locate the light tower on the top rear of the workcell
2. Remove all packaging and material from the light tower including wrapping paper, bubble pack and
tape.
3. Locate the existing light tower connection on the top rear of the workcell
4. Align the mast to the extrusion and tighten using a 5mm hex wrench.
5. Connect the two ends of the light tower cables.
6. Locate the Teach Pendant and connect the end into the 15 pin connector located on the front of the
workcell.
7. Using a small flat head screwdriver tight the two screws form the Teach Pendant into the threads.
Power Up
Overview
Once you have performed the preliminary installation of the accessories, you are ready to power up the
workcell. This section describes the connection of the system to air and power supplies, system power up,
and subsequence testing procedures that ensure that all system components are functioning and
communicating properly.
WARNING Failure to comply with electrical specifications can result in damage to the
machine as well as injury to installation personnel. Electrical hookup must be made by a
qualified electrician and must comply with any applicable local standards.
1) Plug the machine into an appropriate power source as determined by the Machine Specific
Information section of the Operating Guide or the legend plate on the rear of the machine. The
electrical service should be properly grounded, and the power source “cleans”. If there is high power
equipment operating off the same source, a line conditioner may be necessary. Errors in machine
operation could indicate poor quality power.
WARNING Make sure that the Main Power switch is off before connecting the workcell to the
facility power source.
• All workcells shipped from: P recision Valve & Autom ation factory is already equipped to
handle the voltage being used at the installation site per engineering design.

- 17 -
2) Locate the main air regulator
3) Attach the quick-disconnect air hose to the facility air supply, slowly open the facility air valve
4) Close any access doors and push in the EMERGENCY STOP button. At the rear of the machine, turn
on the red air lockout valve.
5) A ¼” NPT female fitting is provided at the rear of the machine. Connect to a source of clean, dry air.
A hose of ¼” inside diameter is sufficient.
6) Ground any pressure vessel to earth or the machine. NOTE: P recision Valve & Autom ation
STRONGLY recom m ends the m achine not be pow ered on or m aterial added to the
pressure vessels until they are properly grounded.
7) Turn on power at the red handled switch on the front or rear of the machine.
8) Perform Safety check and homing routine, press Manual mode and manually move the head around
the entire work area, making sure that it does not encounter any obstacles during travel. Make sure
that pneumatic and electrical cables do not impede the heads from travel and are not in danger of
being cut or snagged. Please contact P recision Valve & Autom ation if there are any problems.
9) Check the valve brackets and make sure that the valve and brackets are tight and that the valve does
not rock or wiggle in the bracket.
10) Close Doors.
Operating Environment
Board Sensor Sensitivity Adjustment procedures

Board sensors are optic sensors located along the length of the front of the conveyors. They are facing
upward. They detect the presence of a board or part and send the signal to the motion controller. You
should adjust board sensor sensitivity after initial installation and if the sensors are failing the presence of
a board.
Depending upon your system configuration, your workcell may have as many as three board sensors, one
for each zone (Initial cycle, Spray area, and exit).
Tools needed
• Small flat screw driver
• Production board or sample board that is going to be processed.
To adjust the board sensors
1. Place a board on the conveyors rail and check for the sensor sensitivity, then with the flat
head turn it clockwise to set the gain higher or counterclockwise for less sensitivity.
2. Run boards both sides (Top and Bottom).
Location
The machine should be installed on a level surface away from standing water, possible over spray and
overhead leaks.

The machine should be operated in an area at 40°F - 105°F (4°C – 41°C) and low humidity. Condensation
should not be allowed to collect on the machine.

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Dip Sw itch Settings
NOTE: During norm al operation there is no need to adjust the dip sw itch settings. I f
com m unications betw een the com puter and the controller are not reliable, low er the baud
rate on both until com m unication is satisfactory.
The main RS-232 port on the motion controller must be configured as follows to communicate with the
host computer:
Table 1 – DMC-2200 Dip Switch Settings
Switch Position Description

MRST OFF Master Reset
XON OFF Software Handshaking
HSHK ON Hardware Handshaking
9600 OFF Baud rate selection
19.2K ON Baud rate selection
38.4K OFF Baud rate selection
OPT OFF Hardware Option
ENET OFF Use Ethernet port as default
for Unsolicited messages.
CAUTION! If hardware handshaking is enabled, the program uses the message

command and a computer is not attached to the Main RS-232 port, the controller eventually
halts. The program included with this machine does not contain any message statements.
Software
The complete workcell software package consists of several items. To avoid problems and
miscommunication, it is imperative every operator understand what each piece of software is and its
purpose. For more information about PathMaster® and its features, please consult the separate
PathMaster® Manual in the Operating Guide.
Main program file

A text file contains the commands that run the workcell. Under normal circumstances it is not necessary
to change this file, but if needed it can be opened and edited with any text editor, such as Microsoft®
Notepad or Word. The Main program file is downloaded via a drop-down menu in PathMaster® but it
should NEVER be opened within the Pathmaster® software.
PathMaster®
Precision Valve & Automation’s Windows®-based programming software. It is used to create, maintain
and download project files for the workcell. The Operating Guide has a separate section on using
PathMaster® to program the workcell.
Project File
A text file contains the code for one or more programs. In almost all cases this file is created within
PathMaster®. This file is downloaded using PathMaster®.

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Machine Communications
For manufacturing lines (multiple machines utilizing conveyor systems) it is necessary for the individual
modules to communicate reliably. Therefore, the SMEMA cables must be connected in the correct
manner.
NOTE: On the diagram s the J# refers to the label on the m achine, not the label on the cable.
SMEMA
The Surface Mount Equipment Manufacturers Association (SMEMA) Electrical Equipment Interface
Standard is used to insure proper sequencing of boards. If these connections are not in place, boards
cannot move from one machine to another.
SMEMA cables have male 14-pin amp-type CPC connectors. The cables are straight through, so
orientation does not matter. Each machine must have the same transport conveyor height from the floor
to the bottom of the PC board. For equipment with an adjustable conveyor width, the front rail is fixed
and the rear rail is adjustable. The range of adjustment will vary with the equipment. To sequence the
boards properly from machine to machine, one or two signal lines will be used: Board not available and
Board Available. On each module, the wire to the J1 (Previous) plug must connect to the J2 (Next) plug
on the machine upstream. Similarly, the J2 plug on each machine must connect to the J1 plug on the
machine downstream, as shown in the following diagram:
Figure 2 –SMEMA Diagram

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Operating Safety
Notices and Warnings
o Safety glasses, gloves, and long sleeved clothing are necessary precautions when working with
automated industrial equipment.
o Read and understand all operating manuals before using this equipment.
o Do not disable the safety features of the machine.
o Lock-out and tag the air and power supplies before servicing or cleaning any part of this equipment.
o Do not remove any hose, either air or fluid, without relieving the pressure.
o Do not replace any hose with a hose of inadequate pressure rating.
o Use only replacement parts recommended or supplied by the manufacturer.
o Always remain clear of all moving parts when the system is in operation.
Safety Devices and Guarding

The workcell has several safety features that protect the operator from hazards during normal operation
of the machine.
NOTE: The safety features should NEVER be bypassed, disabled or tam pered w ith. P recision
Valve & Autom ation is not responsible for any dam ages incurred, m echanical or hum an,
because of alteration or destruction of any safety features.
Safety Circuit
The main power to the machine is monitored and controlled by the safety circuit. The safety circuit
contains two relays, under-voltage protection, and one or more safety devices. The relays are wired in a
redundant manner. Redundancy consists of two parallel relay circuits which work together electrically
with the safety devices. The tripping contacts of the relays are connected in series to insure that the
safety circuit will disconnect power even if one of the relays has failed. Self-checking consists of positive
guided contacts which are mechanically forced to operate together. If one of the redundant relays fails,
the power contacts are opened. The safety devices monitor the state of the EMERGENCY STOP push
button and other safety mechanisms. When the safety relay detects that the one or more of the safety
devices has opened, the power to the motors and pneumatics is cut.
Lexan Guarding
The work area is enclosed with Lexan guarding. The front of the machine is either open, to allow for
manual part loading and unloading, or guarded by doors.
Doors
For machines with an automatic load/unload cycle the front of the machine is protected by two doors.
Each door is monitored by a non-defeatable limit switch. When the door is opened power to the motors
and pneumatics is disconnected. The DOOR BYPASS key switch is provided to allow maintenance
personnel access to the work area without disconnecting power. This bypass switch only allows access
during Manual and Calibration modes.
Light Curtain
Some machines are equipped with an optional light curtain. The light curtain is redundant and self-
checking. The control signals from the light curtain are included as safety devices in the safety circuit. On

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machine power up, the light curtain must be reset by turning the key switch to ‘Reset’ for at least ½
second.
Exhaust Fan
Some machines are equipped with an exhaust fan. The exhaust fan is provided to exhaust fumes from
the work area. The exhaust flange should be connected to an appropriate ducting system that is capable
of receiving 300 CFM (cubic feet per minute). Insufficient airflow through the exhaust system generates
an error.
NOTE: I nstalled safety devices vary from m odel to m odel.

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Operation
Startup Procedure
1) Check the fluid and air pressures.
2) Close all doors and turn the DOOR BYPASS key switch to the OFF position (If applicable).
3) Engage the EMERGENCY STOP button.
4) Turn on main power using the red rotary switch at the front or rear of the machine.
Light Tower Operation

Three stacked indicator lights and a buzzer are used to indicate the status of the machine. The lights are
green, amber, and red with green on the bottom, amber in the middle and red on top. The buzzer is
located below the green light. The lights are visible from all sides of the machine. The indicators operate
as follows. The light tower may help you be your first clue for solving a problem.
o The green indicator is on when the machine is in cycle and producing parts. It is off at all other
times.
o The amber indicator is on when the machine is in Auto Cycle and ready to produce parts, but can
not cycle due to an external material handling problem (no incoming parts or no room to unload
parts).
o The red indicator is on steady when the machine is not in Auto Cycle due to operator intervention. It
will flash when the machine is in cycle, but cycle is halted due to a machine problem. It is off at all
other times.
o The buzzer cycles with the red indicator during machine errors.
Table 2 – Light Tower & Buzzer Status
State Red Am be Gree Buzzer

r n
Cycle Stop ON OFF OFF OFF
Auto Cycle OFF ON OFF OFF
In Cycle OFF OFF ON OFF
Machine Error FLASH OFF OFF FLASH
Exhaust Verification
Once the workcell has initialized, it will perform an exhaust flow verification process. If initialization fails,
consult the section Error! Reference source not found. On page 47. During this process, and whenever
the workcell is in operation the exhaust flow rate is monitored via the on board pressure differential
switch. The workcell must exhaust at a rate no less than 300 cubic feet per minute, otherwise a critical
fault will occur shutting the motors down. The verification process will also attempt to evacuate any
potential vapors that may already exist in the work area of the workcell. The time this process takes will
vary from model to model, but the remaining time for the process will be displayed as in the screen on
the next page:

- 23 -
Machine Safety Check
Once initialize and exhaust verification is complete, the operator interface displays the following message:
The machine safety check ensures the workcell safety devices (emergency stop, door interlocks, light
curtain, etc.) are operating properly. During startup, the operator must enter the safety check and
complete it successfully. Otherwise, the machine halts all operations. After pressing [Continue] the

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operator is prompted by the operator interface to activate and deactivate the safety devices and the
POWER ON button, if present. Certain events in this procedure are timed and if an action is not
performed within a specified time the machine interprets this as a failure and displays an error screen
such as this:
By pressing [Continue] the operator can repeat the test. If the safety check continues to fail, the entire
system should be thoroughly examined by qualified maintenance personnel before the machine is
returned to operation.

- 25 -
Homing the Axes
After successfully completing the safety check, the operator is shown the above screen. Pressing
[Continue] homes the system and displays the following screen:
The axes home in the following order: Z, W, then X & Y simultaneously.

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Standby Position
Once the machine has completed the homing sequence or finishes a required calibration procedure (if so
equipped), it moves to the standby position. Standby is a defined location, DISTINCT from the home
position, although in some circumstances it may be defined as the same position as home. In most
cases, the standby position is placed near the board stop to minimize travel during Auto Cycle. The
workcell always returns to the standby position in Cycle Stop. If the standby position needs to be
changed, please consult the Main Program Modifications section of the PathMaster® Manual.
Solvent Cups
Some workcells have solvent cups installed as an option. The need for solvent cups is dictated by the
process by which the workcell will be used for. When solvent cups are installed, the Auto Purge feature is
overridden by the solvent cup routines regardless of the Setup mode settings.
The solvent cup location varies from model to model, however, the location will be somewhere in the
workspace of the workcell. Solvent cups are used as a means of maintaining clean dispense/spray heads.
In Cycle Stop the heads are situated in the solvent cups. In Manual mode, the heads are removed from
the cups and remain out until exiting this mode. In Auto Cycle the heads lift and run the auto purge
routine. They return to the solvent cups after a pre-programmed period of inactivity.
To change the time delay before the heads enter the solvent cups in Auto Cycle, change the value in the
“Sleep” field under the Cups tab in Setup mode (see page 40).
Flow Monitor System

Some workcells can have up to four (4) flow monitors installed as an option. The flow monitor on the
workcell measures the amount of material moving through the material supply line before it is split to
supply the individual valves. It is used as a verification of the dispensing process, not a control of that
process, and reports excessive deviations from desired values. The operator determines both the desired
material volume and allowable deviation.
Priming the Flow Monitor

The flow monitor must be primed prior to use to prevent damage to the unit. Priming the flow
monitor minimizes the amount of air that will pass through the unit during initial startup. Follow the
procedure below to prime the flow monitor.
o Fill the pressure vessel with material and seal.
o Set the material pressure regulator to 0 P.S.I.
o Turn the inlet air and outlet material valve to the closed position.
o Disconnect the material line from the inlet port of the flow monitor.
o Turn the air inlet and material outlet valves to the open position.
o Slowly increase the material pressure regulator until material flows from the disconnected material
line.
o Turn the outlet material valve to the closed position.
o Bleed pressure for pressure vessel and adjust the material pressure regulator to 0 P.S.I
o Reconnect the material line to the inlet port of the flow monitor.
o Open the valves (dispense or spray) using the manual purge procedure outlined in the operations and
maintenance manual.
o Turn the material outlet valve to the open position.
o Slowly increase the material pressure to the target operating pressure.

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o Continue the manual purge procedure for each valve until the material flows free of air.
Determining the Correct Material Volume

Before attempting to determine the appropriate material volume, the operator should have a completed
path program, since any changes to a program alters the flow data results. With the completed program
loaded into memory, the operator should enter the Manual mode, position the board correctly with
respect to the board stops and run a singular cycle. For more information on the Manual mode, please
consult page 33 of the Operation and Maintenance Manual.
After the singular cycle finishes, the dispensed volume is displayed in the System Messages window. The
operator should go to the Flow Monitor tab in Setup mode and change the flow set point to the value that
appeared on the System Messages window, then return to the singular cycle option to run more cycles
and verify the consistency of the path program.
Setting the Material Volume Check

There are two methods of setting the material volume check parameters.
1) Go to the Flow Monitor tab in Setup and adjust the material volume and deviation parameters.
2) Program the settings into the path program. Two variables are used: FCx_SET and FCx_DEV, where
‘x’ is the letter of the appropriate flow monitor (A, B, C, or D). FCx_SET is the set point for the
material flow, which can range from 0 to 99. FCx_DEV is the percent deviation allowed, which can be
anywhere from 0 to 99. As an example, entering the following line into a path program:
FCA_SET=0.500; FCA_DEV=5 would put the volume setting for monitor ‘A’ at 0.5 cc and the
allowable deviation at 5%.
If the settings are programmed into the path program, they are used instead of the settings from Flow
Monitor setup. If no settings are programmed in the path, the machine defaults to the Flow Monitor
setup settings.
Auto Cycle Flow Error

The Auto Cycle checks the material flow after every cycle if the error is turned ON in the Flow Control
mode. If the volume was within parameters, no indication is given to the operator. In cases where the
volume was outside acceptable parameters, the flow error screen appears. This screen is similar to the
flow data screen shown above. The board should be removed before returning the machine to operation.
NOTE: Any changes m ade to settings in the m aterial delivery system (m aterial pressure,
stroke adjustm ent, etc.) m ay affect the data from the flow m onitor. I f this happens, the
operator m ay need to determ ine the correct m aterial volum e again.
Flow Monitor Calibration

Periodically, the flow monitor calibration should be checked. Start by connecting a PC to the Dispensing
System, open a terminal screen and enter DEZ=0. This resets the flow monitor encoder to zero. Then
dispense 10 cubic centimeters of material through any valve, by means of a manual purge. When
finished, enter MG _DEZ on the terminal screen. This returns a value representing the number of
encoder counts read by the flow monitor. Calculate the flow monitor calibration value: (Encoder Counts /
10) = FC_CAL. Change the value of the FC_CAL variable in the Machine-Specific Information section of
the Main program to the result of the calculation.
NOTE: For a m ore precise calibration, determ ine volum e by w eight. The specific gravity or
density of the m aterial m ust be know n to do this.

- 28 -
Flow Monitor Setup
The settings for flow monitors are accessed through the Flow Monitor tab under Setup mode. If the
machine has multiple monitors installed, a tab for each one will be displayed on the right-hand side of the
box.
This option allows control over the flow monitor data that is used as a process check only during Auto
Cycle. These settings are used to determine the material volume and whether or not it is excessive
unless superseded by commands in a path program. The error selection turns the process verification
check on and off. The error ON/OFF selection cannot be overridden by commands in a path program.
Target Volume: Increase or decrease the material target level. Range is 0 to 99 cc.
Deviation: Increase or decrease the allowable deviation. Range is 0 to 99%.
Check Flow: Toggle the material flow error checking on or off. (Default is off)
Calibration Procedures
The workcell has one of three calibration methods: Standard, Operator Defined and Sensor Defined. If a
Sensor Defined or Operator Defined method is installed on the workcell, the machine may or may not
automatically enter its particular calibration mode following the homing sequence depending on the
application the workcell was set up for. See page 32 for particulars on operating the workcell during a
calibration sequence.

- 29 -
Standard Needle Calibration
The simplest calibration procedure requires the operator to visually inspect the position of a needle with
respect to a calibration point (such as cross-hairs). If the needle is not directly above the point, the
operator must physically reposition the needle so it is above the calibration point.
Operator Defined Needle Calibration

This method is dependent upon the operator utilizing the trackball to redefine the coordinate system
according to the positioning of a specific needle or dispense head. This process is optional. If the specific
needle is located in the desired position this process can be skipped.
The calibration routine automatically runs when the machine is powered on or if the controller is reset.
The head moves to a calibration point (specified in the main program). When at the calibration position
the operator has control of the axes. Using the trackball, the position of the needle tip can be redefined
in reference to a calibration point (such as cross-hairs). This process can also be run manually through
the CAL function key if a needle needs to be replaced for any reason during operation.
Sensor Defined Needle Calibration

The NCU is referenced from the home position on the gantry. The start positions for each head to enter
the NCU are referenced from the cross-hair mark on the top of the NCU. The coordinates are defined for
each head using reflective sensors in the NCU. Z is always calibrated first in a downward motion into the
Z sensor. The X and Y coordinates are then calibrated from this position in reference to the positioning of
the NCU in the work area. The needle moves into the next sensor (X or Y) finding the first coordinate,
then moves to the opposite side of the sensor and finds a second coordinate. The calibration routine
then calculates the average of the first and second coordinates and redefines the new position
accordingly. This sequence is repeated for the remaining axis.
Figure 3 - Needle Sensor Calibration Block

- 30 -
Shutdown Procedure
If the machine is in cycle, wait for the cycle to finish and then return to the Cycle Stop mode. If the
machine is in any other mode, the operator should return to Cycle Stop.
1) Press the EMERGENCY STOP button.
2) Press [Quit] on the HMI program. The operator will be prompted for confirmation. A blue window will
appear, indicating the machine is shutting down.
3) Shutdown the attached PC. The operator MUST ensure that the PC has been properly shut
down BEFORE turning off power to the workcell!!
4) Turn off power to the system. Rotate the main disconnect switch to the “0” position.
5) Clean any excess material from the tips of the needles.
6) Remove spray cap(s), wipe tip of needle/seat as well, clean cap thoroughly.
7) If the system will be down for an extended period of time, it is recommended to turn off the air to
the machine. The red lockout valve at the rear of the machine can be used for this.
CAUTION! If maintenance is to be performed during the shutdown, be sure to lockout

and tag the machine.

- 31 -
Cycle Stop
The Cycle Stop state is the default state for the workcell. All other modes and capabilities can be
accessed from this state through the function key buttons listed below.
Manual: Manually operate the machine (see page 33). Also known as Jog or Teach mode.
Auto: Run the machine in Auto Cycle (see page 35).
Setup: View or change the setup functions of the machine (see page 39).
Linked: Displays the machine “heartbeat.” This indicator will blink while the
PC is connected to the workcell, but NOT while the machine is in an error
state.

- 32 -
Program Selection
The current active program can be changed at any time by using the Program Selection drop-
down menu (seen below). Path programs are downloaded to the controller using the included
PathMaster® software.
NOTE: The selected program is not loaded into the controller memory until it is called from either
auto cycle or the Run option in manual mode.
Manual Mode
Manual mode allows manual control of all devices on the workcell. There are tabs within Manual mode
that are used to access different workcell functions. A trackball can be used to manipulate the axes,
operate the valves, and teach positions to PathMaster®.

- 33 -
Programming the workcell is accomplished in concert with a PC-compatible computer by using Precision
Valve & Automation’s PathMaster® software. The operator must be in Manual mode for PathMaster® to
function properly. For more information on programming, please consult the separate PathMaster®
Manual in the Operating Guide.
Stop: Leave Manual mode and return to Cycle Stop.
Valves: Switch to Valve Selection (see page 34).
Conveyor: Switch to Conveyor Control (see page 35).
Run: Run singular cycles of the current program. Press either “WET” or “DRY” to run one cycle.
PathMaster: Contains a button for launching PathMaster®.
SMEMA: Test communications with upstream and/or downstream machines.
Valve Selection
Units equipped with multiple valves have this mode. The active head or valve can be selected from the
drop-down menu. The pneumatics Z-slide(s) and rotary(s) (if equipped) can be actuated using the
appropriate buttons.
NOTE: W hen program m ing or operating the w orkcell, the valves should NEVER be used for
m oving com ponents or boards. P recision Valve & Autom ation is not responsible for dam ages
incurred from using the valves in an inappropriate m anner.
Purge Valve: Actuate the current valve.
Z-Slide: Raise or lower the active head’s Z-slide.
Rotary: Put the rotary in the home position (Default, A) or the auxiliary position (B).

- 34 -
Conveyor Control
The conveyor and stop are controlled under this tab so the operator can position boards in the workcell.
Conveyor: Turn the conveyor on or off.
Reverse (Bi-directional systems ONLY): Check to reverse conveyor direction
Board Stop - UP: Turn the board stops off.
Board Stop - DOWN: Turn the board stops on.
Board Stop 2: For bi-directional systems, operates the upstream board stops.

- 35 -
Board Locators
Some machines are equipped with pneumatic-powered board locators. This tab allows the operator to
engage and disengage the locators.
Locate – UP: Return the locators into the up position.
Locate – DOWN: Engage the locators in the down position.
Run Mode
This option allows the operator to test a downloaded path program without engaging the auto cycle
process. The path can be run with or without the valves active by selecting “WET” or “DRY.” The operator
should verify that the part has been positioned properly inside the workcell before running the path in
order to ensure accuracy.
WET: Run the selected program with the valves on.
DRY: Run the selected program without any valve activity.

- 36 -
Launch PathMaster®
This tab contains a button that launches the included PathMaster® software.
SMEMA Status
The SMEMA tab allows the operator to check the communication between machines. When the workcell
is placed in-line, SMEMA signals ensure communication with the upstream and downstream machines.
The operator can check the inputs to the workcell and change the Upstream Ready and Downstream
Board Available output signals.
Upstream – Board Available: Turns on only when the upstream machine is sending a Board Available
signal.

- 37 -
Upstream – Ready: Toggle the Ready output to the upstream machine on or off.
Downstream – Ready: Turns on only when the downstream machine is sending a Ready signal.
Downstream – Board Available: Toggle the Board Available output to the downstream machine on or
off.
Automatic Mode
This mode handles the automatic cycling of the machine. There are three machine setups that may be
encountered:
o Conveyor equipped.
o Stand-alone without a light curtain.
o Stand-alone with a light curtain.
For a workcell with a conveyor, the part is placed for process on the conveyor either by an operator or
mechanically via an upstream process. SMEMA signals are provided with the machine to be used in
conjunction with an upstream process. The part is recognized at the entrance to the machine and is
shuttled to the stop for cycling. Once against the stop the part is registered and dispensed/sprayed on.
Once the program finishes, the board is released and shuttled to the downstream end of the conveyor to
await any process that may follow. Once released or removed, the process is set to repeat itself.
For machines without a conveyor, all parts must be placed in the workcell manually. Part-in-place
sensors detect if a board is present or not. If a board is misplaced in the cell, the operator is alerted of
the fact. Once a machine is ready for cycling, the operator must activate the hand switches to process
parts. All parts must be removed after cycling before a new cycle may begin.

- 38 -
If the workcell possesses a light curtain, it operates in a similar manner as a stand-alone model without a
light curtain. However, the light curtain may be used to initiate cycles (bypassing the hand switches).
Setup Mode
Setup mode allows the operator to control basic functions of the machine. The valves can be turned off
during Auto Cycle by setting the run mode to dry. This option does NOT affect the run option in the
Manual mode, which is user selected as a wet or dry run.
The auto purge feature dispenses/sprays material from all valves at specific intervals to prevent valves
from clogging. The auto purge default setting is dependent upon the type of material used in the
workcell. The workcell only auto purges when in Auto Cycle or Cycle Stop. If the workcell is in any other
state, it does not auto purge. However, it immediately auto purges, if necessary, once returning to Cycle
Stop or Auto Cycle.
NOTE: I f the w orkcell is equipped w ith solvent cups, the auto purge feature is overridden by
the solvent cup routines. The system w ill purge only w hen needed according to the solvent
cup sequence, regardless of the auto purge setting in Setup m ode.
Stop: Leave Setup mode and return to Cycle Stop.
Run Wet: Toggle on or off
Bi-Directional: On equipped machines, toggles auto cycle behavior between single and bi-directional.
RESET: Reset the cycle count to zero.

- 39 -
Auto Purge/Solvent Setup
The cups tab allows the operator to configure the purge and/or solvent cup features.
Auto Purge: Enables ONLY auto-purging. Solvent cups cannot be enabled while this is toggled.
Frequency: Set how often the valves will purge.
Duration: The length of time the valves will purge for (applies to both auto purge and solvent options).
Solvent Cups: Enables solvent cups. Overrides auto purging, but heads will purge any time they are
moved out of the solvent position.
Sleep: The duration of inactivity during auto cycle before the heads move to the solvent cups.

- 40 -
Needle Calibration
The end effecter may contain dispense (as opposed to spray) heads, each of which has a needle.
Whenever a needle is replaced or the machine is started the needles should be calibrated. When the
machine enters this mode it automatically moves to a pre-set calibration point.
Each head on the gantry will have a predetermined reference position. The operator can select the
appropriate head and order the gantry to move to its corresponding position. Once at the preset point,
the operator must physically reposition the dispense needle to ensure proper calibration.
Select Valve: Change the active valve.
Reference Position - GO: Move to the assigned reference position for the active valve. This feature is
useful when any maintenance is performed that might alter the alignment of the gantry (i.e. replacing a
valve after a head collision).
Home: Home the system. The machine will NOT return to the standby point after homing is completed,
but will do so after the operator exits setup mode.
Needle Calibration: Begins a needle calibration procedure. The operator will follow a series of screen
prompts as the machine is calibrated.

- 41 -
Teach Pendant
The PVA650™ is equipped with a teach pendant which has a trackball, teach button, purge
button, axis selection button, and LED indicators for selected axes and teach function.
Trackball: The trackball allows the operator

to jog each axis independently or X and Y
together.
Teach: The teach button will register the

gantry position back to PathMaster® when
teaching a motion profile.
Purge: The purge button purges material

from the active valve.
Axis: The axis button allows the operator to

toggle through the available axis
configurations. Typical configurations are X
only, Y only, Z only, W only, and X & Y
together.
LED’s: The X, Y, Z and W LED’s represent

the selected axis configuration. The teach
LED indicates a successful response from Figure 4 - Teach Pendant
PathMaster® when a position is taught.
The teach LED is accompanied by a ‘beep’
from the light tower buzzer.

- 42 -
Fault Recovery
Recovering from Emergency Stop and Other Machine Errors

If the operator uses one of the EMERGENCY STOP push buttons or the machine encounters a system
error, this procedure should be followed to return the machine to the Cycle Stop state.
WARNING! If the EM ERGENCY STOP was activated because of system failure, DO NOT
release the EM ERGENCY STOP . Shutdown the system and have qualified personnel repair the
machine.
1) After resetting the button, press Continue to return the head to the standby position. The screen
returns to Cycle Stop. Note that all functions are disabled until the button is reset.
2) Correct the fault which prompted the operator to emergency stop the machine (open the door, etc).
3) Open the access door.
4) Remove all parts from the work area. Determine which parts can be re-worked and put them in the
input queue.
5) Close the access door.
6) Follow the Startup Procedure.
Recovery from a door error, resulting from a door being open while the DOOR BYPASS switch is in the
OFF position, is handled in a similar manner as an emergency stop. Depending upon the machine setup,
other errors could occur, such as low air pressure, low material flow or insufficient exhaust air flow. As
with an emergency stop, these errors should be corrected first, then the operator should follow the
startup procedure to continue.
Examples of the other possible error screens:

- 43 -
Door Error
Low Material Level Low Exhaust Flow
Low Material Level

The workcell only checks the material level(s) when running cycles. If there is a material level error, the
machine can operate in all its modes (except for cycles) until the material level is reestablished.
Resetting the Exhaust Fan Overload Relay

Machines with exhaust fans may encounter errors when the overload relays trips. Follow these steps to
return the machine to normal operation:
1) Turn machine power OFF.
2) Open the electrical enclosure.
3) Check the tripped flag on the overload relay.
4) Verify that the current set point is set properly on the overload relay. Check the rating on the
exhaust fan housing for current draw.
5) If necessary, push the reset button to reset the relay.
6) Restart the machine. If the problem persists, consult the Troubleshooting section on page 48 for
more information.

- 44 -
Pneumatic Error Recovery Procedure
The system pneumatics is checked for errors any time they operate. In addition, any movements to
home or the standby position require the pneumatics to be in their “home” position before proceeding. If
a pneumatic fails, it generates an error such as the one below.
The operator should determine the cause of the problem before pressing Continue. Refer to the
pneumatic actuator failure section of Troubleshooting (page 48) for more information about diagnosing
the problem.
Run-Time Error Recovery Procedure

A run-time error is generated during the execution of the program. For more information about
programming, please refer to the separate PathMaster® Manual. This type of failure should not be
encountered during normal operation of the machine. The most common cause for this type of failure is
when using PathMaster® version 2.1 or higher and attempting to playback an area function without first
downloading a properly formatted project file to the workcell. The error type and program line number
will be displayed in the System Messages window. For m ore on error codes please refer to
Appendix C.
Position Error Recovery Procedure

A position error is caused when the difference between the commanded position and the current position
exceeds the maximum allowable error for an axis. The error limit is defined to be approximately 1/5”.
For most cases this is 1000 counts. The error limit can be reached if the dispense/spray head reaches a
hard stop, in Manual mode, if the speed or acceleration is set too high or if the axes drives are not

- 45 -
powered. Check the EMERGENCY STOP button. The motor stop codes are displayed in the System
Messages window. See page 46 for m ore on stop codes.
2) Move the dispense/spray head to the center of the work area. The Z-axis is equipped with a brake.
The motor coupling can be turned by hand to move the head towards the center of the work area.
4) Press Continue to clear the error.
5) Follow the startup procedure.
Limit Error Recovery Procedure

The machine encounters a limit error in the following cases. First, if the path program attempts to move
the dispense/spray head past one of the software limits. If a software limit caused the error, then either
the path or the software limits must be changed. The stop codes will be displayed in the System
Messages window.
2) Move the dispense/spray head to the center of the work area. The Z axis is equipped with a brake.

- 46 -
Stop Codes
For Position and Limit Errors, the error screen displays the stop codes for all the motors. This information
tells the operator which axis (or axes) caused the machine to go to fault.
Table 3 – Stop Code Definitions
Code Meaning
0 Motors are running, independent mode.
1 Motors stopped at commanded independent position.
2 Decelerating or stopped by FWD limit switch or software limit,
3 Decelerating or stopped by REV limit switch or software limit,
4 Decelerating or stopped by Stop Command (ST).
6 Stopped by Abort input.
7 Stopped by Abort command (AB).
8 Decelerating or stopped by Off-on-Error (OE1).
9 Stopped after Finding Edge (FE).
10 Stopped after Homing (HM).
50 Contour running.
51 Contour Stop.
99 MC timeout.
100 Motors are running, vector sequence.
101 Motors stopped at commanded vector.

- 47 -
Troubleshooting
If Something Goes Wrong . . .
Some problems encountered when using the workcell are easy to identify and solve. Others require more
extensive help. This troubleshooting section is designed to assist an operator in solving problems before
seeking additional help. It is strongly recommended the operator check this section first if a mechanical
or electrical problem occurs. If you experience problems that are not listed in this section, or continue
after trying different methods, please contact PVA Customer Service. Remember, not every problem can
be described in this section, but this should be a good place to start.
NOTE: I f a problem occurs w hile running a particular path program , consult the separate
P athM aster® M anual for inform ation on debugging code problem s.
Calling Technical Support

The technical support staff is always available to help solve any problems. The phone number is (518)
371-2684. To assist in the troubleshooting process, it is best if as many of the following items are
addressed before calling for help:
1) Record all the information from the HMI when the error occurred.
2) Take note of the operation in progress when the machine developed trouble (when did it have
problems, what was it doing, etc.).
3) If the error was not serious, attempt to repeat the error. If the error does not repeat, the problem
may have been operator generated.
4) Use a terminal screen to communicate with the controller. Most troubleshooting necessitates issuing
commands directly to the controller.
5) If the problem is programming related, a hard copy or email of the program in question may be
requested by PVA. Please be prepared to send it. The PVA fax number is (518) 371-2688, or the
customer service representative will provide an email address, if all parties are email capable.
Records
Any service or replaced components should be recorded in maintenance records and any other pertinent
data for future reference.

- 48 -
Fault Diagnostic
The PVA650™ uses a closed loop servo drive system. Listed below are general fault diagnostic table for
each type of system.
Closed Loop Servo Systems
Table 4 – PVA650™ systems Fault Diagnosis
Operation Other Symptoms Possible Cause Corrective Action

Turn the Cables are loose or not • Check the cable
machine ON. connected. connections. Correct any
The operator loose connections.
interface does
not have power.
The electrical The electrical enclosure is • Close the electrical

enclosure does open, so the electrical enclosure.
not have power. enclosure safety switch is
in the open position.
Blown fuse. • Check FU-1 which is

located inside the
electrical enclosure.
Replace if necessary.
Home the axes. Home sensor is out of • Depress the EMERGENCY

The end effecter position or too far away STOP push button. Move
moves past the from the homing tab. the axis by hand until the
home sensor homing tab moves into
and hits the the home sensor. The
hard stop. sensor should be on.
Loosen the lock nut on
the sensor and readjust
to .020” gap.
Sensor cable is loose or • Check the cable

not connected. connections. Correct any
loose connections.
Home the axes. End effecter can The EMERGENCY STOP • Release the EMERGENCY
The Z axis does be moved freely push button is depressed. STOP push button.
not move. when the power
is on.
SSR-1 is not ON The Z axis brake is not • Check the SSR-1 wiring.
when the Z axis disengaging when the It should be on when the
drive is enabled. drive is enabled. Z axis drive is enabled.
SSR-1 is ON The fuse for SSR-1 is • Check the fuse using an

when the Z axis blown or SSR-1 is OHM meter. Replace
drive is enabled. damaged. component if necessary.
Axis does not Encoder works The axis speed or • Set the speed and
according to the acceleration has been set acceleration to a positive,
- 49 -
have any Motion Encoder to zero. non-zero value using the
Feedback Test on SP and AC commands.
page 56.
Axis drive light is Axis drive is not enabled. • Enable the drive using
RED. the SH command.
The axis cables are loose • Check the cable

or not connected. connections. Correct any
loose connections.
The EMERGENCY STOP • Release the EMERGENCY

push button is depressed. STOP push button.
Hall effect sensors are not • Check the cable
correctly connected. connections for the axis.
Correct any loose
connections.
• Check the Hall Effect

sensor phasing using the
electrical drawings.
The axis amplifier is bad. • Replace the amplifier.
Doors are open • Close doors firmly
Axis runs away. Motor power connections • Check the phasing using
are wired incorrectly. the electrical drawings.
Z axis encoder Z axis encoder/brake • Check the cable

does not work. cable is loose or not connections. Correct any
connected. loose connections.
Pneumatic Pneumatics work Air lockout valve on the • Turn the lockout valve to
actuator failure. slowly. rear of the machine is in the ON position.
the OFF position.
Insufficient air pressure. • Check and adjust the

system pressures to the
correct values. Please
refer to the Machine
Specific Information
section of the Operating
Guide for particular
pressure settings.
Restricted air line. • Correct any tight bends

or restrictions in the air
lines.
Loose Fitting or Tubing • Tighten connection.

Connection.
Frayed or damaged air • Replace the damaged air

- 50 -
line. line(s).
Sensor is not positioned • Adjust the sensor

correctly. location.
Part in place Cable is loose or not • Check the cable

sensor failure. connected. connections. Correct any
loose connections.
Conveyor does Conveyor belt stuck to • Clean or replace belt.

not run. rails.
No power to Control relay not • Check voltages and

conveyor motor. energized or Power On connections.
light not illuminated
(Certain Models).
• Check conveyor power

fuse.
Exhaust fan No air flow. The motor overload relay, • Reset the exhaust fan
does not run. OL-1, is in the tripped overload relay.
state.
• Check FU-5 in the

Insufficient air flow • Upgrade the duct to

capacity in the factory allow for more air flow.
ducting.
• Reset the exhaust fan
overload relay.
The filter and The overload relay • Verify the current setting
ducting are fine. current setting has been on the overload relay.
The motor changed. Please refer to exhaust
temperature is fan setup.
normal.
• Checked the tripped flag
on the overload relay.
Push the reset button to
reset the relay.

- 51 -
Controller Master Reset
Performing a controller master reset returns the Galil controller to factory defaults. All memory, variables
and settings stored in the controller are lost. DO NOT perform this operation unless the operator
understands how to download the main program and dispense/spray programs. This operation cannot be
undone.
1) Turn the machine OFF.
3) Locate the DIP switches on the Galil controller.
4) Move the MRST (master reset) switch to the ON position.
5) Turn the machine ON.
6) Wait for 20 seconds.
8) Move the MRST (master reset) switch to the OFF position.
9) Close the electrical enclosure.
10) Turn the machine ON. There should be no display on the operator terminal.
11) Open a terminal screen and enter the LS (List) command. The controller should return 000 after
pressing ENTER. This verifies that the controller is now at factory default and the memory is clear.
The controller is ready to accept the main program and a project.
IP Configuration
When performing a master reset to the Galil controller on a machine with PVA Portal it is
necessary to reassign the IP address of the controller before any communication can be established.
After resetting the machine PVA Portal will not be able to establish communication with the Galil
controller and will automatically shut down.
From the Windows START menu on the desktop got to Programs PathMaster® to run
PathMaster® THIS IS THE ONLY TIME IT IS ACCEPTABLE TO RUN PathMaster® OUTSIDE OF
PORTAL.
Any other time you must execute PathMaster® through the PVA Portal interface to ensure all the
communication settings remain configured correctly. After Starting PathMaster® selects the machine you
are currently using and any project you would like.
Because there is no communication after you select the project to open, PathMaster® will try to
communicate.
This will take anywhere from 30 seconds to a minute during which time PathMaster® will be
unresponsive.
After the main screen loads, at the top of your screen click on Setup Machine Parameters. In
the dialog box that opens in the bottom left click on Edit Controller. In the box that opens there, click on
the Edit Controller Properties button. The will bring up the following window

- 52 -
The IP address that is highlighted blue is the address
that will need to be reset.
It would be a good idea to write this address down for later.
Now click on the Set IP Address button. In the box that

opens just click close in the lower right hand corner.
This will bring the same box shown at the right back up
except the IP address will be 0.0.0.0.
Now click Set IP Address again which will bring up the box
shown below.
In the window labeled Possible

Controller Address enter the IP address you
recorded earlier.
After entering this address click the Test
Address button to ensure the address is not in use
anywhere else on the network.
If the address appears to be available, as
shown at right, then click Assign Address.
Finally before closing the window check
that the NIC IP Address matches the IP address
of the computer, and that the NIC Subnet Mask
is 255.255.255.0, then close the window.
PathMaster® will then acknowledge the

changes that were made, click okay, now close the edit controller window, and click save and close in the
Machine Parameters window. Now you should have communication with your machine in PathMaster®.
If that is not the case then repeat the previous steps making sure that you are assigning the
correct IP address for your controller as well as for the NIC card.
If you have communication then you are ready to download your main file. In PathMaster®
select the Download menu from the top of your screen and select Main. Now select the main file from
your computer and click ok or save to download. When that is complete exit completely out of
PathMaster®. Next Power the machine down. If you do not cycle power to the machine you will not have
any system messages displayed in Portal.

- 53 -
Be sure to shut down the PC first if it is powered by the workcell or if there is no UPS on the
machine to avoid losing any work not saved. Next turn the machine back on and if necessary start the
Portal software on the PC. You will see a System Initialization message followed by a Variable Error.
The machine will the restart and display the System Initialization message again and will continue on
to the exhaust and safety check. You are now ready to run.
Request Controller Version

Perform the following procedure to request the controller firmware version using the PathMaster®
terminal.
1) Establish communication with the controller. Please refer to the PathMaster® Manual.
2) Open the PathMaster® terminal.
3) Type ‘^R^V’
4) Press Enter.
The controller version is displayed in the terminal window.
Flexible coupling
Servo couplings are compensating couplings with a backlash free and conformal torque transfer providing
high torsional stiffness and a low moment of inertia. Check periodically if a shifting is suspected.
Figure 5 - Flexible Coupling
Flexible
Coupling

- 54 -
Power Check
If the expected voltages are not present in the following tests TURN THE MACHINE OFF
IMMEDIATELY. Permanent damage to the components may occur.
1) Remove all of the fuses in the enclosure, except for FU-1.
2) Disable the enclosure power safety switch.
4) Use a DMM (Digital Multi Meter) to check the AC power in the machine. There should be 110-120VAC
between the 100 and 101 terminals. If not, turn off the power and check that FU-1 is installed and
operational.
6) Install all of the fuses in the enclosure.
7) Push the EMERGENCY STOP push button in.
9) CRM-1 and CRM-2 should be DISENGAGED.
10) Check for 5 VDC between 304 (+) and 303 (-).
13) Pull the EMERGENCY STOP push button out.
14) Put a jumper wire between terminal 4 on the 5 V Monitor relay SSR-5 relay and any 304 terminal
block (this will engage the SSR-5 relay). If the SSR-5 relay LED is not on, there may be a problem
with the SSR-5 relay or the wiring on the coil side.
15) CRM-1 and CRM-2 should be ENGAGED. If not, check the next section (Door Interlock Check) for
machines equipped with doors.
Door Interlock Check

1) Engage the Door Bypass switch. If CRM-1 engages when the Door Bypass switch is engaged, there
may be a failure in the left door interlock switch, the right door interlock switch, or their wiring.
2) Check for a red indicator light on the 5 V Monitor relay SSR-5. If the indicator is not lit, there may be
a failure in the 5 V monitor relay or its wiring.
3) Check for 24 VDC between 504 (+) and 302 (-). If 24 VDC is not present, there may be a failure in
the 5 V Monitor relay, the EMERGENCY STOP push button PB-1, or their wiring.
the left door interlock switch or its wiring.
the right door interlock switch or its wiring.
6) If 24 VDC is present between 506 (+) and 302 (-), there may be a failure in the coil of CRM-1 or a
short in its associated diode D-1, or there may be a failure in the coil of CRM-2 or a short in its
associated diode D-2.
- 55 -
Encoder Feedback Test
Use this procedure to test the encoder feedback for all of the axes. If a problem is found with any of the
encoders repair and report the error to the production supervisor.
Most encoders used with the workcell generate 5080 counts/inch. Check to make sure that the position
feedback is reasonable.
(500*4 counts/rev)*(1 rev/cm)*(2.54 cm/in) = 5080 counts/inch.
1) Open a terminal program and establish communication with the DMC-1500 controller.
2) Turn the machine OFF. Disconnect the black motor power cables. Leave the orange encoder
feedback cables attached.
3) Move all of the axes to the center of travel position.
5) Enter HX.
6) Define the current position as (0, 0, 0, 0). Enter DP*=0.
7) Move the X-axis in the positive direction and display the current position. Enter TP.
8) Move the X-axis in the negative direction and display the current position.
9) Move the Y-axis in the positive direction and display the current position.
10) Move the Y-axis in the negative direction and display the current position.
11) Move the Z-axis in the positive direction and display the current position.
12) Move the Z-axis in the negative direction and display the current position.
13) Move the W axis in the positive direction and display the current position.
14) Move the W axis in the negative direction and display the current position.
16) Reconnect the motor power cables.
Motor Feedback Test

Use this procedure to verify that the motor power and Hall Effect sensors are wired correctly. If a
problem is found with any of the axes, repair and report them to the production supervisor.
2) Enable the EMERGENCY STOP button. This cuts the power to the amplifiers.
3) Open a terminal program and establish communication with the DMC-2200 controller. This can be
accomplished via the ‘terminal’ option in PathMaster®.
4) Enter the following commands via the terminal screen. The motors may be wired incorrectly. The
following program limits the acceptable error and power available to the amplifiers. This protects
personnel and equipment.
OE*=1 Off-on-error enabled for all axes.

ER*=1000 Error limit for all axes.
- 56 -
TL*=1 Torque limit of 1 for all axes.
SP*=5000 Set the speed.
AC*=10000 Set the acceleration.
DP*=0 Define the current position as (0, 0, 0, 0).
SB5 Enable power (only on machines without a POWER ON
button).
SH Apply power to the servo motors.
5) Release the EMERGENCY STOP push button. Push the POWER ON button (if present) so it lights up.
This restores power to the amplifiers. Care must be taken because any of the axes can move at this
time.
6) Command the X-axis to make a positive move. If the axis runs away debug and repeat the
procedure.
PRX=2000
BGX
WARNING! Make sure that the workspace is clear of any obstacles. In the event of a
run-away condition, the machine may be irreversibly damaged.
7) Display the current position and position error. TP; TE.
8) Command the X-axis to make a negative move. If the axis runs away debug and repeat the
procedure.
PRX=-2000
BGX
10) Repeat step 6 through 9 for the Y, Z and W axes.

- 57 -
Maintenance
Schedule
Table 5 – Preventive Maintenance Schedule
Type Of Service
Service
Area Every Shift W eekly M onthly Quarterly
Dispensing Check all fluid Check for Inspect the Check the
Equipment pressures and material buildup fluid delivery inline material
dispense on fixtures and lines for filter for
weights. locating excessive clogging.
surfaces. wear.
Check for any

leaks around
compression
fittings.
Retighten or
replace if
needed.
Electro- Check motors Grease the Inspect all

mechanical for overheating ball screw moving cables
components and smooth slides with for excessive
operation. Lithium wear.
Grease (JIS
Check for any Type 2).
chaffing of
wires,
pneumatic lines
or material lines.
Inspect
enclosure air
filter, clean with
warm soapy
water as
needed. Air dry
before
reinstalling.
(PVA250™,
PVA750™
models only.)
Conveyor Clean conveyor Check for Check the

System belts. material and conveyor belts
dust buildup on for wear.
the sensors.
Part-in-Place Clean with

warm water, a

- 58 -
Type Of Service
Service
Sensors mild solvent
(like dish soap)
and a soft
cloth. DO NOT
use moderate
or harsh
solvents, such
as Isopropyl
Alcohol,
Acetone,
OS120, etc.
Pneumatics Check for proper Check the

operation. slides for wear
Drain any and smooth
accumulated operation.
water from the
main
Filter/Regulator.
Dispensing / Lubricate
Spraying packing as per
Equipment the
manufacturer’s
recommendation
s.
Clean Purge Daily

Cups
Clean Valve Daily

Tips

- 59 -
Procedures
Ball Screw Slides
The slides should be greased via the fitting on the carriage every 100KM or approximately once a month.
Clean any buildup on the ball screw and seals. The manufacturer recommends using lithium-type soap
base grease (JIS Type 2). Not all models have slide with grease fitting. If a slide does not have a grease
fitting, simply apply a small amount of grease to the slide, and then work the slide back and forth.
Inspection
The cables in the flexible cable carrier should be checked for excessive wear. Any worn cables should be
replaced. Check for loose screws in the top frame and end effecter.
Conveyor Belt Replacement

1) Lockout the power and air supplies.
2) Remove the dust cover plate. The dust cover plate is located near the conveyor motor on the inside
of the conveyor.
3) Remove the old conveyor belt from the pulley wheels.
4) Clean the conveyor rails where the belt rides.
5) Install the new conveyor belt. Start by placing the belt on the pulley wheels farthest from the motor.
NOTE: M ake sure that there are no tw ists in the belt.
6) Place the belt around the large pulley wheel, then around the remaining wheels.
7) Rotate the pulley wheels several turns by hand. This ensures that the belt is correctly seated.
8) Replace the cover plate.
Valves
Refer to the Cut Sheets section of the Operating Guide for information about the dispensing / spraying
equipment.
Servicing the Inline Material Filter

Machines dispensing or spraying low viscosity materials (such as conformal coating) may have an inline
stainless steel filter on the pressure vessel. If material flow appears restricted, the filter element could be
clogged. All parts of the filter are stainless steel and can be cleaned several times before replacing.
Follow these steps to clean or replace the filter:
1) Turn off air supply pressure to the pressure vessel.
2) Turn off the material valve on the vessel.
3) Using two large adjustable wrenches, separate the two sections of the filter.
4) Remove the stainless steel filter element, noting the proper orientation.
5) Clean or replace the filter as necessary.
6) Reassemble the filter and pressurize the system. It may be necessary to purge any trapped air from
the system.

- 60 -
Exhaust Fan Setup
1) Turn power OFF.
3) Set the overload relay current for 1.0 * FLA for the motor. The FLA is shown on the motor
nameplate.
4) Set the reset button to Manual.
5) Restart the machine.
Pressure Differential Switch Setup

NOTE: The flow velocities referred to be only valid for a 5” duct diam eter!!!!
1) Turn on the exhaust at 100% speed.
2) Check operation of the pressure switch input. The input should be ON with the exhaust at 100%
speed.
3) Turn off the exhaust. Make sure the pressure switch input turns OFF.
4) Restrict the outlet of the exhaust until the airflow velocity is between 2200-2350 ft/min (300-320
CFM) at the exhaust flange screen.
5) Verify that the exhaust pressure switch input is still ON. If it is not, turn the adjustment screw
counterclockwise until the input just turns ON.
6) Turn off the exhaust. Make sure the pressure switch turns OFF.
7) Turn on the exhaust. Make sure the pressure switch input turns ON. If not, turn the adjustment
screw counterclockwise again until the input turns ON. Verify that the input turns OFF when the
exhaust is turned off.
9) Verify that the pressure switch input stays OFF at this airflow velocity. If the input stays ON, turn
the adjustment screw clockwise SLOWLY until the input turns OFF. If an adjustment is made, re-
check the input at the airflow velocity used in step 4. The input should still turn ON at an airflow
velocity within the range used in step 4.
10) Cycle the exhaust off and back on again. Verify that the pressure switch input stays OFF for an
airflow velocity within the range used in step 8.

- 61 -
Part Replacement
Ordering Parts
All customers can order parts by contacting Customer Service Support. Your customer service
representative can help take your order. When ordering spare parts, be prepare to provide the following
information:
• Your Company Name

• Billing Address
• Shipping Address
• Serial Number of the Workcell (found on the back of the equipment)
• Part number or description
• Quantity
• Purchase Order or Credit card information
• Shipping Instructions
TIP: Keeping an extra set of frequently used spare parts can help reduce down time.
Return Material Authorization (RMA)

Obtain a Return Material Authorization (RMA) from Precision Valve & Automation by calling PVA Tech
Support.
Training
Because the replacement parts it requires safety and familiarity with the equipment, Precision Valve &
Automation offers Training Certificates to Customer technicians. Contact PVA for more information.
Warranty
Contact Precision Valve & Automation for any warranty issue related with spare parts.
Shipping
When you ordering parts, specify which carrier you prefer to use. Precision Valve & Automation will
determine the best shipping if no instructions are received.

- 62 -
Appendix A – Definitions
Auto Cycle: Machine state where cycles are running.
Auto Purge: A machine function that automatically purges material after a predefined period of time or
during solvent cups procedures.
Calibration Position: The location in the workspace where the X, Y, Z and W locations for the needle(s)
is normalized.
Cycle Stop: Machine state where no action is occurring and the machine is at the standby position.
Depress: Press and hold for the duration of the operation.
Dispense/Spray Path: A continuous motion profile. The valve is on (dispense/spray) during the entire
motion profile. This is also known as a Path or Motion Sequence.
DMC: Language used to program the motion controller in the workcell.
End Effector: The dispense/spray head assembly. The end effector is moved by the axes.
Head: Dispensing / spraying valve.
Home Position: The (0, 0, 0, 0) location of the workspace. This position is determined by the location
of the home sensors. It is NOT the same as the Standby Position.
Jog: Moving any combination of axes continuously at a set rate of speed until commanded to stop.
Light Tower: The light tower consists of three stacked lights, red, amber and green (top to bottom). It
is used to indicate the status of the machine.
Main program file: A text file containing the code that runs the workcell during normal operations.
Motion Sequence: A continuous motion profile. The valve is on (dispensing) during the entire motion
profile. This is also known as a Dispense/Spray Path or Path.
Path: A continuous motion profile. The valve is on (dispense/spray) during the entire motion profile.
This is also known as a Dispense/Spray Path or Motion Sequence.
PathMaster®: Windows® programming software. Used to create, maintain and download program
files for the workcell.
Press: Press and release.
Program: A collection (or series) of motion sequences.
Project: File containing the code for one or more programs (typically 30 programs).
Purge Position: The location in the workspace where the head moves to perform all auto purge
operations.
PVA: Precision Valve & Automation
Solvent Cups: Reservoirs containing a compatible solvent used to maintain the dispense/spray valves
when the workcell is not processing product.

- 63 -
Solvent Position: The location in the workspace where the head moves to rest in a solvent solution to
maintain the dispense/spray valves when the workcell is not processing product.
Standby Position: The rest position for the end effector. The machine moves here after homing and
after each cycle. This position is usually located near the start point for the program(s). It is NOT the
same as the Home Position.
Terminal: A program used as a communication link between the controller and operator.
Teach: A process by which the workcell registers its current gantry location with PathMaster® to create a
motion sequence.
Workcell: A model PVA250™, PVA250E™, PVA350™, PVA550™, PVA650™, PVA650-FT™, PVA750™,

PVA1000™, PVA2000™, PVA2000C™ or PVA3000™ automated system.

- 64 -
Appendix B – Serial Communication
Serial Communication
Overview
The workcell communicates with a computer using the EIA RS-232C standard. The computer is
the Data Terminal Equipment (DTE Device) and the controller is the Data Communications
Equipment (DCE Device). The tables below give a brief overview of the connections required to
communicate between DTE and DCE devices.
WARNING! The computer must be at the same ground potential as the machine.
Damage to the machine or computer may result if the ground potentials are different.
Use the workcell service outlet for computer power if provided.
9 Pin Serial Connector

Table 6 describes the pin-out for standard serial ports found on most portable computers.
Table 6 – DTE 9 Pin Serial Connector
Pin Description
1 Carrier Detect (CD)
2 Received Data (RD)
3 Transmitted Data (TD)
4 Data Terminal Ready
(DTR)
5 Signal Ground
6 Data Set Ready (DSR)
7 Request to Send (RTS)
8 Clear to Send (CTS)
9 Ring Indicator (RI)

Table 7 describes the pin-out for standard serial ports found on most desktop computers.
Table 7 – DTE 25-Pin Serial Connector
Pin Description
1 Protective Ground
7 Signal Ground
9 +Voltage
10 -Voltage
11 Unused

- 65 -
12 Secondary CD
13 Secondary CTS
14 Secondary TD
15 DCE Transmitter Clock
16 Secondary RD
17 Receiver Signal Clock
18 Unused
19 Secondary RTS
(DTR)
21 Signal Quality Detector
23 Data Signal Rate Selector
24 DTE Transmitter Clock
25 Unused
Computer 9 Pin to workcell Programming Port…

…For standard communication between a computer and a workcell.
Table 8 – Cable for Computer DB9 to workcell
Comp workcell
DTE DCE
DB9 DM9F
1 1
2 2
3 3
4 4
5 5

Comp workcell
DTE DCE
DB9 DM9F
1 5
2 3
3 2
4 1
5 4

- 66 -
Appendix C – Error Codes
DMC Error Codes
Table 10 – DMC Error Codes
ID Description
1 Unrecognized command
2 Command only valid from program
3 Command not valid in program
4 Operand error
5 Input buffer full
6 Number out of range
7 Command not valid while running
8 Command not valid while not running
9 Variable error
10 Empty program line or undefined label
11 Invalid label or line number
12 Subroutine more than 8 deep
13 JG only valid when running in jog mode
14 EEPROM check sum error
15 EEPROM check write error
16 IP incorrect sign during position move or IP given during forced
deceleration
17 ED, BN and DL not valid while program running
18 Command not valid when contouring
19 Application strand already executing
20 Begin not valid with motor off
21 Begin not valid while running
22 Begin not possible due to Limit Switch
24 Begin not valid because no sequence defined
25 Variable not given in “IN” command
28 S operand not valid
29 Not valid during coordinated move
30 Sequence segment too short
31 Total move distance in a sequence > 2 billion
32 More than 511 segments in a sequence
41 Contouring record range error
42 Contour data being sent too slowly
46 Gear axis both master and follower
47 Gearing and coordinated moves cannot run simultaneously
50 Not enough fields
51 Question mark not valid
52 Missing " or string too long
53 Error in {}
54 Question mark part of string
55 Missing [ or []
56 Array index invalid or out of range

- 67 -
ID Description
57 Bad function or array
58 Unrecognized command in a command response (i.e. _GNX)
59 Mismatched parentheses
60 Download error - line too long or too many lines
61 Duplicate or bad label
62 Too many labels
65 IN command must have a comma
66 Array space full
67 Too many arrays or variables
71 IN only valid in task #0
80 Record mode already running
81 No array or source specified
82 Undefined array
83 Not a valid number
84 Too many elements
90 Only X Y Z W valid operand
95 TM too large for stepper pulse
96 SM jumper needs to be installed for stepper motor operation
100 Not valid when running ECAM
101 Improper index into ET (must be 0-256)
102 No master axis defined for ECAM
103 Master axis modulus greater than 256*EP value
104 Not valid when axis performing ECAM
105 EB1 command must be given first
118 Controller has GL1600 not GL1800

- 68 -
Appendix D – Wiring Schematic Legend
Wire Numbering
Table 11 – Wire Numbering
Type ID Example Description

DC Control 400 - 599 400
DC Supply 300 - 399 300
AC Control 200 - 299 200
AC Control Power 100 - 199 100
AC Supply Power nLm 1L2 Segment 1 of AC Supply Phase
2
Ground GND GND
Neutral NEU NEU
AC or DC Motor nTm 1T2 Motor 1, phase 2
Inputs n1mm 1101 Module 1, Input 01
Outputs n0mm 2001 Module 2, Output 02
Connector Jnnn/mm J100/5 Connector 100, pin 5
Wire Color Code
Table 12 – Wire Color Code
NOTE: This color code does not apply to m ulti-conductor cables.
Type Color Example

DC (<150 V) BLUE 0 VDC, 80 VDC
DC (>150 V) BLACK 200 VDC
AC (<150 V) RED 120 VAC
AC (>150 V) BLACK 208 VAC, 480 VAC
Neutral WHITE
Ground GREEN or GREEN with YELLOW
Remote YELLOW Remote control
circuit

- 69 -
PVA650-FTTM
Automated Dispensing System
P/N: CIRT2000 S/N: W3175
CIRCUITRONICS
Operating Guide
15 Solar Drive – Halfmoon, NY 12065

Table Of Contents
1 Configuration
2 Operation and Maintenance Manual
PathMaster® Manual
3
4 Cut Sheets
5 Schematics
6 Software
Configuration
1 Configuration
PathMaster® Manual
Cut Sheets
Schematics
Software
Configuration
Notice
This document, including the information contained herein, is the property of Precision Valve &
Automation, Inc. and is considered confidential and proprietary information. It is delivered on the
express condition that it not be used, disclosed, or reproduced in whole or in part, for any reason without
prior written consent of Precision Valve & Automation, Inc.
Machine Specifics
Serial Number: W3175
Program Revision: 3.04
PathMaster® Version: 2.3.49
Date of Ship: 12/2008
Power Requirements
Electrical Rating: 120 Vac, 60 Hz, 12 Amps 1Phase
Interrupting Capacity: 200 kA
Pressure Settings
Table 1 – Pressure Settings
Regulator Description Setting

REG-1 Main air pressure 90 P.S.I. +/- 10 P.S.I
REG-2 Material air pressure TANK 20 PSI
REG-3 Atomizing Air Pressure H1 1P.S.I.
REG-4 Material air pressure syringe Customer Preference
Valve Nomenclature
Table 2 – Valve Nomenclature
Head # Name Description Z-slide Rotary

1 FCS300-ES Extended Spray Valve YES NO
2 FC100-MC Dispense Needle valve YES NO
3 30cc SYRINGE Syringe Dispense System YES NO
KALREZ O-Ring Materials
1B73 Material Used (Humiseal)
Syringe Material Techspray Wondermask 2218
Workcell Configuration
-1-
Optional Equipment
Documentation on non-Standard equipment installed on the workcell is included with this
manual. To view these documents click the button below.
Select Optional Equipment

Notes
See PMaster's folder for back up and dispensing setting parameters.

Operation and Maintenance
Configuration
2 Operation and Maintenance Manual
PathMaster® Manual
Cut Sheets
Schematics
Software

Certain warning symbols are affixed to the machine and correspond to notations in this manual.
Before operating the workcell, identify these warning labels and read the notices described
below. Not all labels may be used on any specific system.
Always wear-approved safety glasses when operating or working

near the workcell.
6040
In situations where inattention could cause either personal injury

or damage to equipment a warning notice is used.
6014
Do not smoke near the workcell. Always have a fire extinguisher

available for emergency use.
6019
Before operating the system, read and understand the manuals

provided with the unit.
6017
Before performing any repairs or maintenance to the system, turn

off power and lock out the power disconnect switch.
6011
Never place hands or tools in areas designated by this symbol

when the machine is in operation. A dangerous condition may
exist.
6008
Warning notices are used to emphasize that hazardous voltages,
current, temperatures, or other conditions that could case
personal injury exist in this equipment or may be associated with
its use. Only qualified personnel should enter areas designated
with this symbol.
6010
Before performing any repairs or maintenance to the system, read

and understand the manuals provided with the unit. A qualified
individual should only perform Service.
6018
Exercise caution when pressurized vessels are present. Identify

and repair any leaks immediately. Always wear appropriate safety
equipment when working with pressurized vessels or vessels
containing chemicals.
6054
Laser light source present. Do not stare directly into the beam. Do
not use in the presence of highly reflective surfaces.
6003
1012
1099
6043
6060
This document is based on information available at the time of its publication. While efforts have
been made to be accurate, the information contained herein does not purport to cover all details
or variations in hardware or software, or to provide for every possible contingency in connection
with installation, operation, or maintenance. Features may be described herein, which are not
present in all hardware and software systems. Precision Valve & Automation, Inc. assumes no
obligation of notice to holders of this document with respect to changes subsequently made.
Precision Valve & Automation, Inc. makes no representation or warranty, expressed, implied, or
statutory with respect to, and assumes no responsibility for the accuracy, completeness,
sufficiency, or usefulness of the information contained herein. No warranties of merchantability
or fitness for purpose shall apply.
This docum ent, including the inform ation contained herein, is the property of
P recision Valve & Autom ation, I nc. and is considered confidential and proprietary
inform ation. I t is delivered on the ex press condition that it not be used, disclosed, or
reproduced in w hole or in part, for any reason w ithout prior w ritten consent of
P recision Valve & Autom ation, I nc.

Preface
Notice & Disclaimer
o This manual applies ONLY to the PVA650-FT™ automated workcell.
All equipment is referenced throughout the manual as the workcell. This manual
provides information and functionality descriptions covering all the common options and
configurations for a workcell. The particular machine associated with this manual may not
contain all items or may have additions. If the manual refers to an option that was not
purchased, ignore that section. If options exist on the machine not mentioned in this manual,
please consult the Optional Equipment section of the Operating Guide for more information on
these additions.
CAUTION! If the equipment is used in a manner not specified by PVA, the protection
provided by the equipment may be impaired.
Contact
Main Office PVA
15 Solar Drive
Halfmoon NY 12065
Tel (518) 371-2684
Fax (518) 371-2688
Website http://www.pva.net/
Technical Support Tel (518) 371-2684

- iv -
The following list describes the major revisions in this manual (Rev A 9/07) as compared to the
previous version:
o First Edition for 650 Flip Top Workcell

-v-
Introduction: Provides an overview of the workcell functionality and physical characteristics.
Installation and Setup: Describes the procedures for installing the workcell and preparing the
system for use. Included in this chapter are instructions for unpacking, inspecting, and installing
the workcell.
Operating Safety: Basic safety practices are reviewed. The safety devices and guarding for the
workcell are described.
Operation: Describes system operations of the workcell. It includes a discussion of the system
power-up and power-down sequences and modes of operation.
Troubleshooting: Provides a guide to troubleshooting the workcell. A fault diagnosis table is

used to lead the operator through common problems and solutions. Several troubleshooting
procedures are described.
Maintenance: Provides a preventive maintenance schedule and replacement procedures.
Appendix A – Definitions: Definitions for commonly used terms.
Appendix B – Serial Communication: A brief overview of establishing communication with the

workcell.
Appendix C – Error Codes : A list of error codes that may be encountered while using the
workcell.
Appendix D – Wiring Schematic Legend: A legend for the numbering and color coding used
in the control enclosure for the workcell.

- vi -
Contents
Table of Contents
Warnings, Cautions, and Notes .............................................................................................................i
Preface ........................................................................................................................................... iv
Notice & Disclaimer ...............................................................................................................................iv
Contact ...................................................................................................................................................iv
Revisions to This Manual....................................................................................................................... v
Content of This Manual ........................................................................................................................vi
Contents ........................................................................................................................................ vii

Table of Contents .................................................................................................................................vii
Table of Figures...................................................................................................................................... x
List of Tables........................................................................................................................................... x
Introduction ................................................................................................................................. 11
System Description .............................................................................................................................. 11
Safety Precautions ........................................................................................................................ 12
Basic Practices ............................................................................................................................... 12
Year 2000 Compliance.................................................................................................................. 12
Intended of Use.................................................................................................................................... 12
Emergency Shutdowns ........................................................................................................................ 12
Emergency Stop Recovery .................................................................................................................. 13
Environmental ....................................................................................................................................... 13
Noise Levels ................................................................................................................................... 13
Materials/Chemicals ...................................................................................................................... 13
Hazards Due to Contact ............................................................................................................... 13
Handling, Transportation and Storage .............................................................................................. 13
Handling and Transportation ....................................................................................................... 13
Storage ........................................................................................................................................... 13
Installation and Setup................................................................................................................ 15

Tools and Material needed ................................................................................................................. 15
Uncrating and Inspection .................................................................................................................... 15
To place the dispense system ..................................................................................................... 15
Inspection.............................................................................................................................................. 16
Leveling the Workcell .......................................................................................................................... 16
Tools needed ................................................................................................................................. 16
To level the workcell..................................................................................................................... 16
Installing the Teach Pendant and Light Tower ................................................................................ 17
Power Up ............................................................................................................................................... 17
Overview ........................................................................................................................................ 17
Operating Environment ....................................................................................................................... 18
Board Sensor Sensitivity Adjustment procedures ..................................................................... 18
Tools needed ................................................................................................................................. 18
Location .......................................................................................................................................... 18
Temperature and Humidity.......................................................................................................... 18

- vii -
Dip Switch Settings .............................................................................................................................. 19
Software ................................................................................................................................................ 19
Main program file .......................................................................................................................... 19
PathMaster® ................................................................................................................................. 19
Project File ..................................................................................................................................... 19
Machine Communications ................................................................................................................... 20
SMEMA............................................................................................................................................ 20
Operating Safety ......................................................................................................................... 21

Notices and Warnings .......................................................................................................................... 21
Safety Devices and Guarding ............................................................................................................. 21
Safety Circuit ................................................................................................................................. 21
Lexan Guarding ............................................................................................................................. 21
Doors .............................................................................................................................................. 21
Light Curtain .................................................................................................................................. 21
Exhaust Fan ................................................................................................................................... 22
Operation ...................................................................................................................................... 23
Startup Procedure ................................................................................................................................ 23
Light Tower Operation......................................................................................................................... 23
Exhaust Verification ............................................................................................................................. 23
Machine Safety Check.......................................................................................................................... 24
Homing the Axes .................................................................................................................................. 26
Standby Position ................................................................................................................................... 27
Solvent Cups ......................................................................................................................................... 27
Flow Monitor System ........................................................................................................................... 27
Priming the Flow Monitor ............................................................................................................. 27
Determining the Correct Material Volume ................................................................................. 28
Setting the Material Volume Check ............................................................................................ 28
Auto Cycle Flow Error ................................................................................................................... 28
Flow Monitor Calibration .............................................................................................................. 28
Flow Monitor Setup ....................................................................................................................... 29
Calibration Procedures......................................................................................................................... 29
Standard Needle Calibration ........................................................................................................ 30
Operator Defined Needle Calibration ......................................................................................... 30
Sensor Defined Needle Calibration ............................................................................................. 30
Shutdown Procedure .................................................................................................................... 31
Cycle Stop ...................................................................................................................................... 32
Program Selection ................................................................................................................................ 33
Manual Mode ................................................................................................................................. 33
Valve Selection .............................................................................................................................. 34
Conveyor Control .......................................................................................................................... 35
Board Locators .............................................................................................................................. 36
Run Mode ....................................................................................................................................... 36
Launch PathMaster®.................................................................................................................... 37
SMEMA Status ............................................................................................................................... 37
Automatic Mode ............................................................................................................................ 38
Setup Mode .................................................................................................................................... 39
Auto Purge/Solvent Setup............................................................................................................ 40
Needle Calibration ......................................................................................................................... 41

- viii -
Teach Pendant ...................................................................................................................................... 42
Fault Recovery ...................................................................................................................................... 43
Recovering from Emergency Stop and Other Machine Errors ................................................ 43
Pneumatic Error Recovery Procedure ........................................................................................ 45
Run-Time Error Recovery Procedure .......................................................................................... 45
Position Error Recovery Procedure ............................................................................................. 45
Limit Error Recovery Procedure .................................................................................................. 46
Stop Codes ..................................................................................................................................... 47
Troubleshooting .......................................................................................................................... 48
If Something Goes Wrong . . . ........................................................................................................... 48
Calling Technical Support............................................................................................................. 48
Records........................................................................................................................................... 48
Fault Diagnostic .................................................................................................................................... 49
Closed Loop Servo Systems ......................................................................................................... 49
Controller Master Reset ....................................................................................................................... 52
IP Configuration ................................................................................................................................... 52
Request Controller Version ................................................................................................................. 54
Flexible coupling ................................................................................................................................... 54
Power Check ......................................................................................................................................... 55
Door Interlock Check ........................................................................................................................... 55
Encoder Feedback Test ....................................................................................................................... 56
Motor Feedback Test ........................................................................................................................... 56
Maintenance ................................................................................................................................. 58
Schedule ................................................................................................................................................ 58
Procedures ............................................................................................................................................ 60
Ball Screw Slides ........................................................................................................................... 60
Inspection ...................................................................................................................................... 60
Conveyor Belt Replacement ........................................................................................................ 60
Valves ............................................................................................................................................. 60
Servicing the Inline Material Filter .............................................................................................. 60
Exhaust Fan Setup ........................................................................................................................ 61
Pressure Differential Switch Setup ............................................................................................. 61
Part Replacement........................................................................................................................ 62
Ordering Parts ............................................................................................................................... 62
Return Material Authorization (RMA) ......................................................................................... 62
Training .......................................................................................................................................... 62
Warranty ........................................................................................................................................ 62
Shipping.......................................................................................................................................... 62
Appendix A – Definitions ........................................................................................................... 63
Appendix B – Serial Communication ....................................................................................... 65

Serial Communication .......................................................................................................................... 65
Overview ........................................................................................................................................ 65
9 Pin Serial Connector .................................................................................................................. 65
25 Pin Serial Connector ................................................................................................................ 65

- ix -
Computer 9 Pin to workcell Programming Port… ..................................................................... 66
Computer 25 Pin to workcell Programming Port… ................................................................... 66
Appendix C – Error Codes .......................................................................................................... 67

DMC Error Codes .................................................................................................................................. 67
Appendix D – Wiring Schematic Legend ................................................................................. 69

Wire Numbering ................................................................................................................................... 69
Wire Color Code ................................................................................................................................... 69
Table of Figures
Figure 1 – workcell Functional Block Diagram .......................................................................... 11

Figure 2 –SMEMA Diagram .................................................................................................... 20
Figure 3 - Needle Sensor Calibration Block .............................................................................. 30
Figure 4 - Teach Pendant ...................................................................................................... 42
Figure 6 - Flexible Coupling.................................................................................................... 54
List of Tables
Table 1 – DMC-2200 Dip Switch Settings ................................................................................ 19
Table 2 – Light Tower & Buzzer Status ................................................................................... 23
Table 3 – Stop Code Definitions ............................................................................................. 47
Table 4 – PVA650™ systems Fault Diagnosis........................................................................... 49
Table 5 – Preventive Maintenance Schedule ............................................................................ 58
Table 6 – DTE 9 Pin Serial Connector ..................................................................................... 65
Table 7 – DTE 25-Pin Serial Connector ................................................................................... 65
Table 8 – Cable for Computer DB9 to workcell ........................................................................ 66
Table 9 – Cable for Computer DB25 to workcell ...................................................................... 66
Table 10 – DMC Error Codes .................................................................................................. 67
Table 11 – Wire Numbering ................................................................................................... 69
Table 12 – Wire Color Code ................................................................................................... 69

-x-
Introduction
System Description
This manual is intended primarily as a reference for production and operator. However, technical personal
that is not familiar with PVA equipment find this manual useful for introduction and training.
The workcell has been designed specifically for applications involving high precision industrial dispensing
and spray conformal coating. The flexibility of the machine allows it to be used effectively for a wide
range of applications.
The valves are mounted to the end effecter of a two, three or four axis Cartesian robot. All
dispensing/spraying is performed within the lexan enclosed work area. Limits have been imposed on the
axes to prevent damage to the machine. The dispense/spray path and active heads are controlled by a
program stored in the motion controller. The controller can store and retrieve up to 30 programs.
NOTE: Not all m odels are equipped w ith lex an guarding.

The PVA Portal software permits the operator the complete control of the machine. This includes
machine setup, manual operation, program selection and automatic operation. Machine status and error
messages are displayed in the program window and via the optional light tower. It is necessary that
operator(s) have read or by training understand the operation of this machine.
Any uses other than listed above could result in a dangerous condition and cannot be protected against
by the safety features installed on the system.
PC INTERFACE
SENSORS
X-Y-Z-W
ACTUATORS MOTION ELECTRO-
CONTROLLER MECHANICAL
COMPONENTS
CONVEYOR
CONTROL
CONVEYOR
Figure 1 – workcell Functional Block Diagram

- 11 -
Safety Precautions
Operation of your workcell involves air pressure, electrical power and mechanical devices and the use of
Hazardous materials. Is very important that qualify technicians operating and servicing the system fully
understand the systems and safety precautions.
Basic Practices
• Only trained personnel should be permitted perform maintenance and service
• Do not wear loose clothes or jewelry while operating the system
• Do not touch the dispense head while is moving
• Learn and know the MSDS recommendations on the material intended to use
• Make sure cables or pneumatics hoses are secure and to cross walkways
• Immediately press Emergency Stop if personnel is in danger
• Locate and define all safety label around the equipment before power up
• There should be always two people while performing maintenance to the equipment

The workcell is compliant with and comprehends the year 2000-century date change. The workcell will
not have any operational impediments, malfunction, cease to perform, generate incorrect or ambiguous
data and/or produce incorrect or ambiguous results with respect to same-century and multi-century
formulas, functions, date values and date-data interfaces.
Intended of Use
Safety is considered a joint responsibility in between the OEM and the end-user. All precautions and
practices should be in accordance with local regulations.
Using the workcell in other ways than is described in this documentation supplied with the equipment
may result in injury or damage of the equipment. Example of this:
• Using incompatibles tools
• Removing doors interlocks or bypassing safety devices
• Making custom mechanics or fluid delivery modifications
• Change material from original design
Emergency Shutdowns
As a minimum push the EMERGENCY STOP if someone is in immediate danger, or electric shock
• Unexpected head movement

- 12 -
• If any PCB are in danger or being damage
Emergency Stop Recovery

Do not restart operation until the condition that caused the failure is being alleviated.
• Open the front doors and remove all PCB from the work area
• Close the doors and pull the stop button out
• Press Continue to recover power and restart your program by pressing AUTO
Environmental
Noise Levels
The audible noise level of the workcell is below 65 dBA.
Materials/Chemicals
There are no dangerous materials or chemicals used in the operation of the machine except for the
required application material. The application material should include a Material Safety Data Sheet
(MSDS), which specifies known dangers and toxicity.
Hazards Due to Contact

The workcell is designed in such a way as to minimize injury from contact with any accessible portion of
the machine. However, under certain modes of operation, it is possible to enter the work area while the
motion platform is under power. Only a qualified person should do this. All hot surfaces are indicated
with a warning label.
Handling, Transportation and Storage
Handling and Transportation

Handling and transportation should be done in such a fashion as to minimize the vibration and shock
introduced to the system. An air-ride truck is recommended for roadway transport. Although the
machine is designed and built to perform in an industrial environment, excessive abuse will greatly impact
the performance of the machine.
Storage
Dust and Debris

All enclosures and connector covers should be closed tightly. It is recommended that a cover be place
over the system if dust or other airborne debris is present in the storage area.

Storage should be done in an area at 40°F - 105°F (4°C – 41°C) and low humidity. Condensation should
not be allowed to collect on the machine.

- 13 -
Dispensing/Spraying Equipment
Whenever the machine is to be stored for extended periods of time, the workcell should be flushed using
a solvent compatible with the application material. This includes the following systems, if applicable:
o Dispense valves, spray valves, and servo valves.
o Material lines and hoses.
o Pressure vessels.
o Pumping systems.
o Diaphragm pumps

- 14 -
Installation and Setup
WARNING! The following procedures should be performed by qualified persons in
accordance with this manual and all applicable safety regulations. A “qualified person” is
defined as “a person or persons who, by possession of a recognized degree or certificate or
professional training, or who, by extensive knowledge, training, and experience, has
successfully demonstrated the ability to solve problems relating to the subject matter and
work.” (Ref. ANSI/ASME B30.2-1983.)
Tools and Material needed

The following tools and material will be need for this procedure
• ½ - Inch Wrench
• Forklift
• Work Gloves
• Tie Wrap cutters
• Safety Glasses
• 3 mm hex Key
• 4 mm hex Key
• 5 mm hex key
• Flat Bar
Uncrating and Inspection
1) Use the flat bar and hammer to remove the top and sides of all four sides of the crate
2) Remove all packing materials and strapping.
3) Use the 9/16-inch wrench to remove the following bolts and anchoring the dispensing system to the
floor of the crate.
• Two (2) Bolts in each of the foot (8 Total)
4) Use a forklift to gentle remove the dispense equipment off the pallet; lift the equipment either from
the back or the front. Place forks all the way in and making sure that blade reach from front to back.
To place the dispense system

1. Move the dispense system to the location where it will be operated
2. Adjust the forklift height until the dispense equipment is approximately at the required height. If
any foot touches the floor before the forklift reaches the required height.
3. Loosen the locking nuts, if necessary.
4. Once the workcell has reached the approximate required height; make sure that all four levelers
(feet) are touching the ground. If any feet are not touching the ground, use the crescent wrench
to lower the feet by turning the feet clockwise.

- 15 -
5. Gentle lower the workcell and remove the forklift.
NOTE: I t is not necessary to tighten the locking nut at this tim e.
Inspection
1. Open the front doors, and remove all straps, tie wraps, and sponges around the dispense heads.
2. Thoroughly inspect the exterior of the machine for damage, loose fasteners, etc. Gently move
the X & Y axis slide to the center of the work area. At the rear of the machine, inspect all tubing
connections, gauges, and regulators.
3. Open the electrical enclosure and visually inspect connectors and components for vibration during
shipping. Close the door, as the machine should not operate with the doors open.
4. Reinstall the Light tower.
5. Reinstall flow monitor. The flow monitor is typically mounted on the rear of the workcell.
6. Reinstall the main air regulator assembly.
Leveling the Workcell

This section describes the procedures for leveling the Workcell. If the workcell is going to use as an in-line
system, it needs to be leveled and aligned in relation to upstream and downstream systems. This
document does not include procedures for upstream and downstream systems. Alignment procedures
should be developed and followed by your facility.
Tools needed
The following tools will be needed to level the workcell
• Level
• Crescent wrench
To level the workcell

1. Place the level in the center of the front conveyor.
2. Observe the position of the bubble within the level window. Determine if the workcell is level
from side to side. The bubble should be centered between the two lines.
TIP: If the position of the bubble is positioned to the closer to the right line, the left side of the
workcell needs to be raised. If the bubble is outside or positioned closer to the left line, the
workcell needs to be raised to the right side.
3. If necessary, loosen the locking nut on each foot using a crescent wrench.
4. Using a crescent wrench, adjust the feet of the workcell by placing the wrench on the flat
(unthreaded) part of the pedestal and turning in the desired direction until the workcell is level
from side to side.
TIP: Turning the pedestal clockwise raises the workcell. Turning the pedestal counterclockwise
lowers the workcell.
5. Check for level at both ends of the conveyors rail by placing the level along the length of the rail
6. Put the level across the center of the conveyors rails, with one end on the front conveyors and
the second end in the back rail.

- 16 -
7. Look at the position of the bubble within the level window. Determine if the workcell is level from
front to back
8. Check the workcell for all corner stability by putting your hands on top of the workcell in one
corner and pressing down. If one of the feet is not touching the ground the workcell will rock
back and forth. Adjust the feet so that they are all bearing the weight equally.
9. After checking the corner, re-level the workcell from side to side and front to back if necessary
10. Once the workcell is level from front to back and side to side and is stable with all four feet
bearing the weight equally, finger tighten the locking nuts by turning them counterclockwise.
Installing the Teach Pendant and Light Tower

1. Locate the light tower on the top rear of the workcell
2. Remove all packaging and material from the light tower including wrapping paper, bubble pack and
tape.
3. Locate the existing light tower connection on the top rear of the workcell
4. Align the mast to the extrusion and tighten using a 5mm hex wrench.
5. Connect the two ends of the light tower cables.
6. Locate the Teach Pendant and connect the end into the 15 pin connector located on the front of the
workcell.
7. Using a small flat head screwdriver tight the two screws form the Teach Pendant into the threads.
Power Up
Overview
Once you have performed the preliminary installation of the accessories, you are ready to power up the
workcell. This section describes the connection of the system to air and power supplies, system power up,
and subsequence testing procedures that ensure that all system components are functioning and
communicating properly.
WARNING Failure to comply with electrical specifications can result in damage to the
machine as well as injury to installation personnel. Electrical hookup must be made by a
qualified electrician and must comply with any applicable local standards.
1) Plug the machine into an appropriate power source as determined by the Machine Specific
Information section of the Operating Guide or the legend plate on the rear of the machine. The
electrical service should be properly grounded, and the power source “cleans”. If there is high power
equipment operating off the same source, a line conditioner may be necessary. Errors in machine
operation could indicate poor quality power.
WARNING Make sure that the Main Power switch is off before connecting the workcell to the
facility power source.
• All workcells shipped from: P recision Valve & Autom ation factory is already equipped to
handle the voltage being used at the installation site per engineering design.

- 17 -
2) Locate the main air regulator
3) Attach the quick-disconnect air hose to the facility air supply, slowly open the facility air valve
4) Close any access doors and push in the EMERGENCY STOP button. At the rear of the machine, turn
on the red air lockout valve.
5) A ¼” NPT female fitting is provided at the rear of the machine. Connect to a source of clean, dry air.
A hose of ¼” inside diameter is sufficient.
6) Ground any pressure vessel to earth or the machine. NOTE: P recision Valve & Autom ation
STRONGLY recom m ends the m achine not be pow ered on or m aterial added to the
pressure vessels until they are properly grounded.
7) Turn on power at the red handled switch on the front or rear of the machine.
8) Perform Safety check and homing routine, press Manual mode and manually move the head around
the entire work area, making sure that it does not encounter any obstacles during travel. Make sure
that pneumatic and electrical cables do not impede the heads from travel and are not in danger of
being cut or snagged. Please contact P recision Valve & Autom ation if there are any problems.
9) Check the valve brackets and make sure that the valve and brackets are tight and that the valve does
not rock or wiggle in the bracket.
10) Close Doors.
Operating Environment
Board Sensor Sensitivity Adjustment procedures

Board sensors are optic sensors located along the length of the front of the conveyors. They are facing
upward. They detect the presence of a board or part and send the signal to the motion controller. You
should adjust board sensor sensitivity after initial installation and if the sensors are failing the presence of
a board.
Depending upon your system configuration, your workcell may have as many as three board sensors, one
for each zone (Initial cycle, Spray area, and exit).
Tools needed
• Small flat screw driver
• Production board or sample board that is going to be processed.
To adjust the board sensors
1. Place a board on the conveyors rail and check for the sensor sensitivity, then with the flat
head turn it clockwise to set the gain higher or counterclockwise for less sensitivity.
2. Run boards both sides (Top and Bottom).
Location
The machine should be installed on a level surface away from standing water, possible over spray and
overhead leaks.

The machine should be operated in an area at 40°F - 105°F (4°C – 41°C) and low humidity. Condensation
should not be allowed to collect on the machine.

- 18 -
Dip Sw itch Settings
NOTE: During norm al operation there is no need to adjust the dip sw itch settings. I f
com m unications betw een the com puter and the controller are not reliable, low er the baud
rate on both until com m unication is satisfactory.
The main RS-232 port on the motion controller must be configured as follows to communicate with the
host computer:
Table 1 – DMC-2200 Dip Switch Settings

MRST OFF Master Reset
XON OFF Software Handshaking
HSHK ON Hardware Handshaking
9600 OFF Baud rate selection
19.2K ON Baud rate selection
38.4K OFF Baud rate selection
OPT OFF Hardware Option
ENET OFF Use Ethernet port as default
for Unsolicited messages.
CAUTION! If hardware handshaking is enabled, the program uses the message

command and a computer is not attached to the Main RS-232 port, the controller eventually
halts. The program included with this machine does not contain any message statements.
Software
The complete workcell software package consists of several items. To avoid problems and
miscommunication, it is imperative every operator understand what each piece of software is and its
purpose. For more information about PathMaster® and its features, please consult the separate
PathMaster® Manual in the Operating Guide.
Main program file

A text file contains the commands that run the workcell. Under normal circumstances it is not necessary
to change this file, but if needed it can be opened and edited with any text editor, such as Microsoft®
Notepad or Word. The Main program file is downloaded via a drop-down menu in PathMaster® but it
should NEVER be opened within the Pathmaster® software.
PathMaster®
Precision Valve & Automation’s Windows®-based programming software. It is used to create, maintain
and download project files for the workcell. The Operating Guide has a separate section on using
PathMaster® to program the workcell.
Project File
A text file contains the code for one or more programs. In almost all cases this file is created within
PathMaster®. This file is downloaded using PathMaster®.

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Machine Communications
For manufacturing lines (multiple machines utilizing conveyor systems) it is necessary for the individual
modules to communicate reliably. Therefore, the SMEMA cables must be connected in the correct
manner.
NOTE: On the diagram s the J# refers to the label on the m achine, not the label on the cable.
SMEMA
The Surface Mount Equipment Manufacturers Association (SMEMA) Electrical Equipment Interface
Standard is used to insure proper sequencing of boards. If these connections are not in place, boards
cannot move from one machine to another.
SMEMA cables have male 14-pin amp-type CPC connectors. The cables are straight through, so
orientation does not matter. Each machine must have the same transport conveyor height from the floor
to the bottom of the PC board. For equipment with an adjustable conveyor width, the front rail is fixed
and the rear rail is adjustable. The range of adjustment will vary with the equipment. To sequence the
boards properly from machine to machine, one or two signal lines will be used: Board not available and
Board Available. On each module, the wire to the J1 (Previous) plug must connect to the J2 (Next) plug
on the machine upstream. Similarly, the J2 plug on each machine must connect to the J1 plug on the
machine downstream, as shown in the following diagram:
Figure 2 –SMEMA Diagram

- 20 -
Operating Safety
o Safety glasses, gloves, and long sleeved clothing are necessary precautions when working with
o Read and understand all operating manuals before using this equipment.
o Do not disable the safety features of the machine.
o Lock-out and tag the air and power supplies before servicing or cleaning any part of this equipment.
o Do not remove any hose, either air or fluid, without relieving the pressure.
o Do not replace any hose with a hose of inadequate pressure rating.
o Use only replacement parts recommended or supplied by the manufacturer.
o Always remain clear of all moving parts when the system is in operation.
Safety Devices and Guarding

The workcell has several safety features that protect the operator from hazards during normal operation
of the machine.
NOTE: The safety features should NEVER be bypassed, disabled or tam pered w ith. P recision
Valve & Autom ation is not responsible for any dam ages incurred, m echanical or hum an,
because of alteration or destruction of any safety features.
Safety Circuit
The main power to the machine is monitored and controlled by the safety circuit. The safety circuit
contains two relays, under-voltage protection, and one or more safety devices. The relays are wired in a
redundant manner. Redundancy consists of two parallel relay circuits which work together electrically
with the safety devices. The tripping contacts of the relays are connected in series to insure that the
safety circuit will disconnect power even if one of the relays has failed. Self-checking consists of positive
guided contacts which are mechanically forced to operate together. If one of the redundant relays fails,
the power contacts are opened. The safety devices monitor the state of the EMERGENCY STOP push
button and other safety mechanisms. When the safety relay detects that the one or more of the safety
devices has opened, the power to the motors and pneumatics is cut.
Lexan Guarding
The work area is enclosed with Lexan guarding. The front of the machine is either open, to allow for
manual part loading and unloading, or guarded by doors.
Doors
For machines with an automatic load/unload cycle the front of the machine is protected by two doors.
Each door is monitored by a non-defeatable limit switch. When the door is opened power to the motors
and pneumatics is disconnected. The DOOR BYPASS key switch is provided to allow maintenance
personnel access to the work area without disconnecting power. This bypass switch only allows access
during Manual and Calibration modes.
Light Curtain
Some machines are equipped with an optional light curtain. The light curtain is redundant and self-
checking. The control signals from the light curtain are included as safety devices in the safety circuit. On

- 21 -
machine power up, the light curtain must be reset by turning the key switch to ‘Reset’ for at least ½
second.
Exhaust Fan
Some machines are equipped with an exhaust fan. The exhaust fan is provided to exhaust fumes from
the work area. The exhaust flange should be connected to an appropriate ducting system that is capable
of receiving 300 CFM (cubic feet per minute). Insufficient airflow through the exhaust system generates
an error.
NOTE: I nstalled safety devices vary from m odel to m odel.

- 22 -
Operation
Startup Procedure
1) Check the fluid and air pressures.
2) Close all doors and turn the DOOR BYPASS key switch to the OFF position (If applicable).
3) Engage the EMERGENCY STOP button.
4) Turn on main power using the red rotary switch at the front or rear of the machine.
Light Tower Operation

Three stacked indicator lights and a buzzer are used to indicate the status of the machine. The lights are
green, amber, and red with green on the bottom, amber in the middle and red on top. The buzzer is
located below the green light. The lights are visible from all sides of the machine. The indicators operate
as follows. The light tower may help you be your first clue for solving a problem.
o The green indicator is on when the machine is in cycle and producing parts. It is off at all other
times.
o The amber indicator is on when the machine is in Auto Cycle and ready to produce parts, but can
not cycle due to an external material handling problem (no incoming parts or no room to unload
parts).
o The red indicator is on steady when the machine is not in Auto Cycle due to operator intervention. It
will flash when the machine is in cycle, but cycle is halted due to a machine problem. It is off at all
other times.
o The buzzer cycles with the red indicator during machine errors.
Table 2 – Light Tower & Buzzer Status
State Red Am be Gree Buzzer

r n
Cycle Stop ON OFF OFF OFF
Auto Cycle OFF ON OFF OFF
In Cycle OFF OFF ON OFF
Machine Error FLASH OFF OFF FLASH
Exhaust Verification
Once the workcell has initialized, it will perform an exhaust flow verification process. If initialization fails,
consult the section Error! Reference source not found. On page 47. During this process, and whenever
the workcell is in operation the exhaust flow rate is monitored via the on board pressure differential
switch. The workcell must exhaust at a rate no less than 300 cubic feet per minute, otherwise a critical
fault will occur shutting the motors down. The verification process will also attempt to evacuate any
potential vapors that may already exist in the work area of the workcell. The time this process takes will
vary from model to model, but the remaining time for the process will be displayed as in the screen on
the next page:

- 23 -
Machine Safety Check
Once initialize and exhaust verification is complete, the operator interface displays the following message:
The machine safety check ensures the workcell safety devices (emergency stop, door interlocks, light
curtain, etc.) are operating properly. During startup, the operator must enter the safety check and
complete it successfully. Otherwise, the machine halts all operations. After pressing [Continue] the

- 24 -
operator is prompted by the operator interface to activate and deactivate the safety devices and the
POWER ON button, if present. Certain events in this procedure are timed and if an action is not
performed within a specified time the machine interprets this as a failure and displays an error screen
such as this:
By pressing [Continue] the operator can repeat the test. If the safety check continues to fail, the entire
system should be thoroughly examined by qualified maintenance personnel before the machine is
returned to operation.

- 25 -
Homing the Axes
After successfully completing the safety check, the operator is shown the above screen. Pressing
[Continue] homes the system and displays the following screen:
The axes home in the following order: Z, W, then X & Y simultaneously.

- 26 -
Standby Position
Once the machine has completed the homing sequence or finishes a required calibration procedure (if so
equipped), it moves to the standby position. Standby is a defined location, DISTINCT from the home
position, although in some circumstances it may be defined as the same position as home. In most
cases, the standby position is placed near the board stop to minimize travel during Auto Cycle. The
workcell always returns to the standby position in Cycle Stop. If the standby position needs to be
changed, please consult the Main Program Modifications section of the PathMaster® Manual.
Solvent Cups
Some workcells have solvent cups installed as an option. The need for solvent cups is dictated by the
process by which the workcell will be used for. When solvent cups are installed, the Auto Purge feature is
overridden by the solvent cup routines regardless of the Setup mode settings.
The solvent cup location varies from model to model, however, the location will be somewhere in the
workspace of the workcell. Solvent cups are used as a means of maintaining clean dispense/spray heads.
In Cycle Stop the heads are situated in the solvent cups. In Manual mode, the heads are removed from
the cups and remain out until exiting this mode. In Auto Cycle the heads lift and run the auto purge
routine. They return to the solvent cups after a pre-programmed period of inactivity.
To change the time delay before the heads enter the solvent cups in Auto Cycle, change the value in the
“Sleep” field under the Cups tab in Setup mode (see page 40).
Flow Monitor System

Some workcells can have up to four (4) flow monitors installed as an option. The flow monitor on the
workcell measures the amount of material moving through the material supply line before it is split to
supply the individual valves. It is used as a verification of the dispensing process, not a control of that
process, and reports excessive deviations from desired values. The operator determines both the desired
material volume and allowable deviation.
Priming the Flow Monitor

The flow monitor must be primed prior to use to prevent damage to the unit. Priming the flow
monitor minimizes the amount of air that will pass through the unit during initial startup. Follow the
procedure below to prime the flow monitor.
o Fill the pressure vessel with material and seal.
o Set the material pressure regulator to 0 P.S.I.
o Turn the inlet air and outlet material valve to the closed position.
o Disconnect the material line from the inlet port of the flow monitor.
o Turn the air inlet and material outlet valves to the open position.
o Slowly increase the material pressure regulator until material flows from the disconnected material
line.
o Turn the outlet material valve to the closed position.
o Bleed pressure for pressure vessel and adjust the material pressure regulator to 0 P.S.I
o Reconnect the material line to the inlet port of the flow monitor.
o Open the valves (dispense or spray) using the manual purge procedure outlined in the operations and
maintenance manual.
o Turn the material outlet valve to the open position.
o Slowly increase the material pressure to the target operating pressure.

- 27 -
o Continue the manual purge procedure for each valve until the material flows free of air.
Determining the Correct Material Volume

Before attempting to determine the appropriate material volume, the operator should have a completed
path program, since any changes to a program alters the flow data results. With the completed program
loaded into memory, the operator should enter the Manual mode, position the board correctly with
respect to the board stops and run a singular cycle. For more information on the Manual mode, please
consult page 33 of the Operation and Maintenance Manual.
After the singular cycle finishes, the dispensed volume is displayed in the System Messages window. The
operator should go to the Flow Monitor tab in Setup mode and change the flow set point to the value that
appeared on the System Messages window, then return to the singular cycle option to run more cycles
and verify the consistency of the path program.
Setting the Material Volume Check

There are two methods of setting the material volume check parameters.
1) Go to the Flow Monitor tab in Setup and adjust the material volume and deviation parameters.
2) Program the settings into the path program. Two variables are used: FCx_SET and FCx_DEV, where
‘x’ is the letter of the appropriate flow monitor (A, B, C, or D). FCx_SET is the set point for the
material flow, which can range from 0 to 99. FCx_DEV is the percent deviation allowed, which can be
anywhere from 0 to 99. As an example, entering the following line into a path program:
FCA_SET=0.500; FCA_DEV=5 would put the volume setting for monitor ‘A’ at 0.5 cc and the
allowable deviation at 5%.
If the settings are programmed into the path program, they are used instead of the settings from Flow
Monitor setup. If no settings are programmed in the path, the machine defaults to the Flow Monitor
setup settings.
Auto Cycle Flow Error

The Auto Cycle checks the material flow after every cycle if the error is turned ON in the Flow Control
mode. If the volume was within parameters, no indication is given to the operator. In cases where the
volume was outside acceptable parameters, the flow error screen appears. This screen is similar to the
flow data screen shown above. The board should be removed before returning the machine to operation.
NOTE: Any changes m ade to settings in the m aterial delivery system (m aterial pressure,
stroke adjustm ent, etc.) m ay affect the data from the flow m onitor. I f this happens, the
operator m ay need to determ ine the correct m aterial volum e again.
Flow Monitor Calibration

Periodically, the flow monitor calibration should be checked. Start by connecting a PC to the Dispensing
System, open a terminal screen and enter DEZ=0. This resets the flow monitor encoder to zero. Then
dispense 10 cubic centimeters of material through any valve, by means of a manual purge. When
finished, enter MG _DEZ on the terminal screen. This returns a value representing the number of
encoder counts read by the flow monitor. Calculate the flow monitor calibration value: (Encoder Counts /
10) = FC_CAL. Change the value of the FC_CAL variable in the Machine-Specific Information section of
the Main program to the result of the calculation.
NOTE: For a m ore precise calibration, determ ine volum e by w eight. The specific gravity or
density of the m aterial m ust be know n to do this.

- 28 -
Flow Monitor Setup
The settings for flow monitors are accessed through the Flow Monitor tab under Setup mode. If the
machine has multiple monitors installed, a tab for each one will be displayed on the right-hand side of the
box.
This option allows control over the flow monitor data that is used as a process check only during Auto
Cycle. These settings are used to determine the material volume and whether or not it is excessive
unless superseded by commands in a path program. The error selection turns the process verification
check on and off. The error ON/OFF selection cannot be overridden by commands in a path program.
Target Volume: Increase or decrease the material target level. Range is 0 to 99 cc.
Deviation: Increase or decrease the allowable deviation. Range is 0 to 99%.
Check Flow: Toggle the material flow error checking on or off. (Default is off)
Calibration Procedures
The workcell has one of three calibration methods: Standard, Operator Defined and Sensor Defined. If a
Sensor Defined or Operator Defined method is installed on the workcell, the machine may or may not
automatically enter its particular calibration mode following the homing sequence depending on the
application the workcell was set up for. See page 32 for particulars on operating the workcell during a
calibration sequence.

- 29 -
Standard Needle Calibration
The simplest calibration procedure requires the operator to visually inspect the position of a needle with
respect to a calibration point (such as cross-hairs). If the needle is not directly above the point, the
operator must physically reposition the needle so it is above the calibration point.
Operator Defined Needle Calibration

This method is dependent upon the operator utilizing the trackball to redefine the coordinate system
according to the positioning of a specific needle or dispense head. This process is optional. If the specific
needle is located in the desired position this process can be skipped.
The calibration routine automatically runs when the machine is powered on or if the controller is reset.
The head moves to a calibration point (specified in the main program). When at the calibration position
the operator has control of the axes. Using the trackball, the position of the needle tip can be redefined
in reference to a calibration point (such as cross-hairs). This process can also be run manually through
the CAL function key if a needle needs to be replaced for any reason during operation.
Sensor Defined Needle Calibration

The NCU is referenced from the home position on the gantry. The start positions for each head to enter
the NCU are referenced from the cross-hair mark on the top of the NCU. The coordinates are defined for
each head using reflective sensors in the NCU. Z is always calibrated first in a downward motion into the
Z sensor. The X and Y coordinates are then calibrated from this position in reference to the positioning of
the NCU in the work area. The needle moves into the next sensor (X or Y) finding the first coordinate,
then moves to the opposite side of the sensor and finds a second coordinate. The calibration routine
then calculates the average of the first and second coordinates and redefines the new position
accordingly. This sequence is repeated for the remaining axis.
Figure 3 - Needle Sensor Calibration Block

- 30 -
Shutdown Procedure
If the machine is in cycle, wait for the cycle to finish and then return to the Cycle Stop mode. If the
machine is in any other mode, the operator should return to Cycle Stop.
1) Press the EMERGENCY STOP button.
2) Press [Quit] on the HMI program. The operator will be prompted for confirmation. A blue window will
appear, indicating the machine is shutting down.
3) Shutdown the attached PC. The operator MUST ensure that the PC has been properly shut
down BEFORE turning off power to the workcell!!
4) Turn off power to the system. Rotate the main disconnect switch to the “0” position.
5) Clean any excess material from the tips of the needles.
6) Remove spray cap(s), wipe tip of needle/seat as well, clean cap thoroughly.
7) If the system will be down for an extended period of time, it is recommended to turn off the air to
the machine. The red lockout valve at the rear of the machine can be used for this.
CAUTION! If maintenance is to be performed during the shutdown, be sure to lockout

and tag the machine.

- 31 -
Cycle Stop
The Cycle Stop state is the default state for the workcell. All other modes and capabilities can be
accessed from this state through the function key buttons listed below.
Manual: Manually operate the machine (see page 33). Also known as Jog or Teach mode.
Auto: Run the machine in Auto Cycle (see page 35).
Setup: View or change the setup functions of the machine (see page 39).
Linked: Displays the machine “heartbeat.” This indicator will blink while the
PC is connected to the workcell, but NOT while the machine is in an error
state.

- 32 -
Program Selection
The current active program can be changed at any time by using the Program Selection drop-
down menu (seen below). Path programs are downloaded to the controller using the included
NOTE: The selected program is not loaded into the controller memory until it is called from either
auto cycle or the Run option in manual mode.
Manual Mode
Manual mode allows manual control of all devices on the workcell. There are tabs within Manual mode
that are used to access different workcell functions. A trackball can be used to manipulate the axes,
operate the valves, and teach positions to PathMaster®.

- 33 -
Programming the workcell is accomplished in concert with a PC-compatible computer by using Precision
Valve & Automation’s PathMaster® software. The operator must be in Manual mode for PathMaster® to
function properly. For more information on programming, please consult the separate PathMaster®
Manual in the Operating Guide.
Stop: Leave Manual mode and return to Cycle Stop.
Valves: Switch to Valve Selection (see page 34).
Conveyor: Switch to Conveyor Control (see page 35).
Run: Run singular cycles of the current program. Press either “WET” or “DRY” to run one cycle.
PathMaster: Contains a button for launching PathMaster®.
SMEMA: Test communications with upstream and/or downstream machines.
Valve Selection
Units equipped with multiple valves have this mode. The active head or valve can be selected from the
drop-down menu. The pneumatics Z-slide(s) and rotary(s) (if equipped) can be actuated using the
appropriate buttons.
NOTE: W hen program m ing or operating the w orkcell, the valves should NEVER be used for
m oving com ponents or boards. P recision Valve & Autom ation is not responsible for dam ages
incurred from using the valves in an inappropriate m anner.
Purge Valve: Actuate the current valve.
Z-Slide: Raise or lower the active head’s Z-slide.
Rotary: Put the rotary in the home position (Default, A) or the auxiliary position (B).

- 34 -
Conveyor Control
The conveyor and stop are controlled under this tab so the operator can position boards in the workcell.
Conveyor: Turn the conveyor on or off.
Reverse (Bi-directional systems ONLY): Check to reverse conveyor direction
Board Stop - UP: Turn the board stops off.
Board Stop - DOWN: Turn the board stops on.
Board Stop 2: For bi-directional systems, operates the upstream board stops.

- 35 -
Board Locators
Some machines are equipped with pneumatic-powered board locators. This tab allows the operator to
engage and disengage the locators.
Locate – UP: Return the locators into the up position.
Locate – DOWN: Engage the locators in the down position.
Run Mode
This option allows the operator to test a downloaded path program without engaging the auto cycle
process. The path can be run with or without the valves active by selecting “WET” or “DRY.” The operator
should verify that the part has been positioned properly inside the workcell before running the path in
order to ensure accuracy.
WET: Run the selected program with the valves on.
DRY: Run the selected program without any valve activity.

- 36 -
Launch PathMaster®
This tab contains a button that launches the included PathMaster® software.
SMEMA Status
The SMEMA tab allows the operator to check the communication between machines. When the workcell
is placed in-line, SMEMA signals ensure communication with the upstream and downstream machines.
The operator can check the inputs to the workcell and change the Upstream Ready and Downstream
Board Available output signals.
Upstream – Board Available: Turns on only when the upstream machine is sending a Board Available
signal.

- 37 -
Upstream – Ready: Toggle the Ready output to the upstream machine on or off.
Downstream – Ready: Turns on only when the downstream machine is sending a Ready signal.
Downstream – Board Available: Toggle the Board Available output to the downstream machine on or
off.
Automatic Mode
This mode handles the automatic cycling of the machine. There are three machine setups that may be
encountered:
o Conveyor equipped.
o Stand-alone without a light curtain.
o Stand-alone with a light curtain.
For a workcell with a conveyor, the part is placed for process on the conveyor either by an operator or
mechanically via an upstream process. SMEMA signals are provided with the machine to be used in
conjunction with an upstream process. The part is recognized at the entrance to the machine and is
shuttled to the stop for cycling. Once against the stop the part is registered and dispensed/sprayed on.
Once the program finishes, the board is released and shuttled to the downstream end of the conveyor to
await any process that may follow. Once released or removed, the process is set to repeat itself.
For machines without a conveyor, all parts must be placed in the workcell manually. Part-in-place
sensors detect if a board is present or not. If a board is misplaced in the cell, the operator is alerted of
the fact. Once a machine is ready for cycling, the operator must activate the hand switches to process
parts. All parts must be removed after cycling before a new cycle may begin.

- 38 -
If the workcell possesses a light curtain, it operates in a similar manner as a stand-alone model without a
light curtain. However, the light curtain may be used to initiate cycles (bypassing the hand switches).
Setup Mode
Setup mode allows the operator to control basic functions of the machine. The valves can be turned off
during Auto Cycle by setting the run mode to dry. This option does NOT affect the run option in the
Manual mode, which is user selected as a wet or dry run.
The auto purge feature dispenses/sprays material from all valves at specific intervals to prevent valves
from clogging. The auto purge default setting is dependent upon the type of material used in the
workcell. The workcell only auto purges when in Auto Cycle or Cycle Stop. If the workcell is in any other
state, it does not auto purge. However, it immediately auto purges, if necessary, once returning to Cycle
Stop or Auto Cycle.
NOTE: I f the w orkcell is equipped w ith solvent cups, the auto purge feature is overridden by
the solvent cup routines. The system w ill purge only w hen needed according to the solvent
cup sequence, regardless of the auto purge setting in Setup m ode.
Stop: Leave Setup mode and return to Cycle Stop.
Run Wet: Toggle on or off
Bi-Directional: On equipped machines, toggles auto cycle behavior between single and bi-directional.
RESET: Reset the cycle count to zero.

- 39 -
Auto Purge/Solvent Setup
The cups tab allows the operator to configure the purge and/or solvent cup features.
Auto Purge: Enables ONLY auto-purging. Solvent cups cannot be enabled while this is toggled.
Frequency: Set how often the valves will purge.
Duration: The length of time the valves will purge for (applies to both auto purge and solvent options).
Solvent Cups: Enables solvent cups. Overrides auto purging, but heads will purge any time they are
moved out of the solvent position.
Sleep: The duration of inactivity during auto cycle before the heads move to the solvent cups.

- 40 -
Needle Calibration
The end effecter may contain dispense (as opposed to spray) heads, each of which has a needle.
Whenever a needle is replaced or the machine is started the needles should be calibrated. When the
machine enters this mode it automatically moves to a pre-set calibration point.
Each head on the gantry will have a predetermined reference position. The operator can select the
appropriate head and order the gantry to move to its corresponding position. Once at the preset point,
the operator must physically reposition the dispense needle to ensure proper calibration.
Select Valve: Change the active valve.
Reference Position - GO: Move to the assigned reference position for the active valve. This feature is
useful when any maintenance is performed that might alter the alignment of the gantry (i.e. replacing a
valve after a head collision).
Home: Home the system. The machine will NOT return to the standby point after homing is completed,
but will do so after the operator exits setup mode.
Needle Calibration: Begins a needle calibration procedure. The operator will follow a series of screen
prompts as the machine is calibrated.

- 41 -
Teach Pendant
The PVA650™ is equipped with a teach pendant which has a trackball, teach button, purge
button, axis selection button, and LED indicators for selected axes and teach function.
Trackball: The trackball allows the operator

to jog each axis independently or X and Y
together.
Teach: The teach button will register the

gantry position back to PathMaster® when
teaching a motion profile.
Purge: The purge button purges material

from the active valve.
Axis: The axis button allows the operator to

toggle through the available axis
configurations. Typical configurations are X
only, Y only, Z only, W only, and X & Y
together.
LED’s: The X, Y, Z and W LED’s represent

the selected axis configuration. The teach
LED indicates a successful response from Figure 4 - Teach Pendant
PathMaster® when a position is taught.
The teach LED is accompanied by a ‘beep’
from the light tower buzzer.

- 42 -
Fault Recovery
Recovering from Emergency Stop and Other Machine Errors

If the operator uses one of the EMERGENCY STOP push buttons or the machine encounters a system
error, this procedure should be followed to return the machine to the Cycle Stop state.
WARNING! If the EM ERGENCY STOP was activated because of system failure, DO NOT
release the EM ERGENCY STOP . Shutdown the system and have qualified personnel repair the
machine.
1) After resetting the button, press Continue to return the head to the standby position. The screen
returns to Cycle Stop. Note that all functions are disabled until the button is reset.
2) Correct the fault which prompted the operator to emergency stop the machine (open the door, etc).
4) Remove all parts from the work area. Determine which parts can be re-worked and put them in the
input queue.
6) Follow the Startup Procedure.
Recovery from a door error, resulting from a door being open while the DOOR BYPASS switch is in the
OFF position, is handled in a similar manner as an emergency stop. Depending upon the machine setup,
other errors could occur, such as low air pressure, low material flow or insufficient exhaust air flow. As
with an emergency stop, these errors should be corrected first, then the operator should follow the
startup procedure to continue.
Examples of the other possible error screens:

- 43 -
Door Error
Low Material Level Low Exhaust Flow
Low Material Level

The workcell only checks the material level(s) when running cycles. If there is a material level error, the
machine can operate in all its modes (except for cycles) until the material level is reestablished.
Resetting the Exhaust Fan Overload Relay

Machines with exhaust fans may encounter errors when the overload relays trips. Follow these steps to
return the machine to normal operation:
1) Turn machine power OFF.
3) Check the tripped flag on the overload relay.
4) Verify that the current set point is set properly on the overload relay. Check the rating on the
exhaust fan housing for current draw.
5) If necessary, push the reset button to reset the relay.
6) Restart the machine. If the problem persists, consult the Troubleshooting section on page 48 for
more information.

- 44 -
Pneumatic Error Recovery Procedure
The system pneumatics is checked for errors any time they operate. In addition, any movements to
home or the standby position require the pneumatics to be in their “home” position before proceeding. If
a pneumatic fails, it generates an error such as the one below.
The operator should determine the cause of the problem before pressing Continue. Refer to the
pneumatic actuator failure section of Troubleshooting (page 48) for more information about diagnosing
the problem.
Run-Time Error Recovery Procedure

A run-time error is generated during the execution of the program. For more information about
programming, please refer to the separate PathMaster® Manual. This type of failure should not be
encountered during normal operation of the machine. The most common cause for this type of failure is
when using PathMaster® version 2.1 or higher and attempting to playback an area function without first
downloading a properly formatted project file to the workcell. The error type and program line number
will be displayed in the System Messages window. For m ore on error codes please refer to
Appendix C.
Position Error Recovery Procedure

A position error is caused when the difference between the commanded position and the current position
exceeds the maximum allowable error for an axis. The error limit is defined to be approximately 1/5”.
For most cases this is 1000 counts. The error limit can be reached if the dispense/spray head reaches a
hard stop, in Manual mode, if the speed or acceleration is set too high or if the axes drives are not

- 45 -
powered. Check the EMERGENCY STOP button. The motor stop codes are displayed in the System
Messages window. See page 46 for m ore on stop codes.
2) Move the dispense/spray head to the center of the work area. The Z-axis is equipped with a brake.
Limit Error Recovery Procedure

The machine encounters a limit error in the following cases. First, if the path program attempts to move
the dispense/spray head past one of the software limits. If a software limit caused the error, then either
the path or the software limits must be changed. The stop codes will be displayed in the System
Messages window.
2) Move the dispense/spray head to the center of the work area. The Z axis is equipped with a brake.

- 46 -
Stop Codes
For Position and Limit Errors, the error screen displays the stop codes for all the motors. This information
tells the operator which axis (or axes) caused the machine to go to fault.
Table 3 – Stop Code Definitions
Code Meaning
0 Motors are running, independent mode.
1 Motors stopped at commanded independent position.
2 Decelerating or stopped by FWD limit switch or software limit,
3 Decelerating or stopped by REV limit switch or software limit,
4 Decelerating or stopped by Stop Command (ST).
6 Stopped by Abort input.
7 Stopped by Abort command (AB).
8 Decelerating or stopped by Off-on-Error (OE1).
9 Stopped after Finding Edge (FE).
10 Stopped after Homing (HM).
50 Contour running.
51 Contour Stop.
99 MC timeout.
100 Motors are running, vector sequence.
101 Motors stopped at commanded vector.

- 47 -
Troubleshooting
Some problems encountered when using the workcell are easy to identify and solve. Others require more
extensive help. This troubleshooting section is designed to assist an operator in solving problems before
seeking additional help. It is strongly recommended the operator check this section first if a mechanical
or electrical problem occurs. If you experience problems that are not listed in this section, or continue
after trying different methods, please contact PVA Customer Service. Remember, not every problem can
be described in this section, but this should be a good place to start.
NOTE: I f a problem occurs w hile running a particular path program , consult the separate
P athM aster® M anual for inform ation on debugging code problem s.

The technical support staff is always available to help solve any problems. The phone number is (518)
371-2684. To assist in the troubleshooting process, it is best if as many of the following items are
1) Record all the information from the HMI when the error occurred.
2) Take note of the operation in progress when the machine developed trouble (when did it have
problems, what was it doing, etc.).
3) If the error was not serious, attempt to repeat the error. If the error does not repeat, the problem
may have been operator generated.
4) Use a terminal screen to communicate with the controller. Most troubleshooting necessitates issuing
5) If the problem is programming related, a hard copy or email of the program in question may be
requested by PVA. Please be prepared to send it. The PVA fax number is (518) 371-2688, or the
customer service representative will provide an email address, if all parties are email capable.
Records
Any service or replaced components should be recorded in maintenance records and any other pertinent
data for future reference.

- 48 -
Fault Diagnostic
The PVA650™ uses a closed loop servo drive system. Listed below are general fault diagnostic table for
each type of system.
Closed Loop Servo Systems
Table 4 – PVA650™ systems Fault Diagnosis

Turn the Cables are loose or not • Check the cable
machine ON. connected. connections. Correct any
The operator loose connections.
interface does
not have power.
The electrical The electrical enclosure is • Close the electrical

enclosure does open, so the electrical enclosure.
not have power. enclosure safety switch is
in the open position.
Blown fuse. • Check FU-1 which is

located inside the
Replace if necessary.
Home the axes. Home sensor is out of • Depress the EMERGENCY

The end effecter position or too far away STOP push button. Move
moves past the from the homing tab. the axis by hand until the
home sensor homing tab moves into
and hits the the home sensor. The
hard stop. sensor should be on.
Loosen the lock nut on
the sensor and readjust
to .020” gap.
Sensor cable is loose or • Check the cable

not connected. connections. Correct any
loose connections.
Home the axes. End effecter can The EMERGENCY STOP • Release the EMERGENCY
The Z axis does be moved freely push button is depressed. STOP push button.
not move. when the power
is on.
SSR-1 is not ON The Z axis brake is not • Check the SSR-1 wiring.
when the Z axis disengaging when the It should be on when the
drive is enabled. drive is enabled. Z axis drive is enabled.
SSR-1 is ON The fuse for SSR-1 is • Check the fuse using an

when the Z axis blown or SSR-1 is OHM meter. Replace
drive is enabled. damaged. component if necessary.
Axis does not Encoder works The axis speed or • Set the speed and
according to the acceleration has been set acceleration to a positive,
- 49 -
have any Motion Encoder to zero. non-zero value using the
Feedback Test on SP and AC commands.
page 56.
Axis drive light is Axis drive is not enabled. • Enable the drive using
RED. the SH command.
The axis cables are loose • Check the cable

or not connected. connections. Correct any
loose connections.
The EMERGENCY STOP • Release the EMERGENCY

push button is depressed. STOP push button.
Hall effect sensors are not • Check the cable
correctly connected. connections for the axis.
Correct any loose
connections.
• Check the Hall Effect

sensor phasing using the
electrical drawings.
Doors are open • Close doors firmly
Axis runs away. Motor power connections • Check the phasing using
are wired incorrectly. the electrical drawings.
Z axis encoder Z axis encoder/brake • Check the cable

does not work. cable is loose or not connections. Correct any
connected. loose connections.
Pneumatic Pneumatics work Air lockout valve on the • Turn the lockout valve to
actuator failure. slowly. rear of the machine is in the ON position.
the OFF position.
Insufficient air pressure. • Check and adjust the

system pressures to the
correct values. Please
refer to the Machine
Specific Information
section of the Operating
Guide for particular
pressure settings.
Restricted air line. • Correct any tight bends

or restrictions in the air
lines.
Loose Fitting or Tubing • Tighten connection.

Connection.
Frayed or damaged air • Replace the damaged air

- 50 -
line. line(s).
Sensor is not positioned • Adjust the sensor

correctly. location.
Part in place Cable is loose or not • Check the cable

sensor failure. connected. connections. Correct any
loose connections.
Conveyor does Conveyor belt stuck to • Clean or replace belt.

not run. rails.
No power to Control relay not • Check voltages and

conveyor motor. energized or Power On connections.
light not illuminated
(Certain Models).
• Check conveyor power

fuse.
Exhaust fan No air flow. The motor overload relay, • Reset the exhaust fan
does not run. OL-1, is in the tripped overload relay.
state.
• Check FU-5 in the

Insufficient air flow • Upgrade the duct to

capacity in the factory allow for more air flow.
ducting.
• Reset the exhaust fan
overload relay.
The filter and The overload relay • Verify the current setting
ducting are fine. current setting has been on the overload relay.
The motor changed. Please refer to exhaust
temperature is fan setup.
normal.
• Checked the tripped flag
on the overload relay.
Push the reset button to
reset the relay.

- 51 -
Controller Master Reset
Performing a controller master reset returns the Galil controller to factory defaults. All memory, variables
and settings stored in the controller are lost. DO NOT perform this operation unless the operator
understands how to download the main program and dispense/spray programs. This operation cannot be
undone.
3) Locate the DIP switches on the Galil controller.
4) Move the MRST (master reset) switch to the ON position.
6) Wait for 20 seconds.
8) Move the MRST (master reset) switch to the OFF position.
9) Close the electrical enclosure.
10) Turn the machine ON. There should be no display on the operator terminal.
11) Open a terminal screen and enter the LS (List) command. The controller should return 000 after
pressing ENTER. This verifies that the controller is now at factory default and the memory is clear.
The controller is ready to accept the main program and a project.
IP Configuration
When performing a master reset to the Galil controller on a machine with PVA Portal it is
necessary to reassign the IP address of the controller before any communication can be established.
After resetting the machine PVA Portal will not be able to establish communication with the Galil
controller and will automatically shut down.
From the Windows START menu on the desktop got to Programs PathMaster® to run
PathMaster® THIS IS THE ONLY TIME IT IS ACCEPTABLE TO RUN PathMaster® OUTSIDE OF
PORTAL.
Any other time you must execute PathMaster® through the PVA Portal interface to ensure all the
communication settings remain configured correctly. After Starting PathMaster® selects the machine you
are currently using and any project you would like.
Because there is no communication after you select the project to open, PathMaster® will try to
communicate.
This will take anywhere from 30 seconds to a minute during which time PathMaster® will be
unresponsive.
After the main screen loads, at the top of your screen click on Setup Machine Parameters. In
the dialog box that opens in the bottom left click on Edit Controller. In the box that opens there, click on
the Edit Controller Properties button. The will bring up the following window

- 52 -
The IP address that is highlighted blue is the address
that will need to be reset.
It would be a good idea to write this address down for later.
Now click on the Set IP Address button. In the box that

opens just click close in the lower right hand corner.
This will bring the same box shown at the right back up
except the IP address will be 0.0.0.0.
Now click Set IP Address again which will bring up the box
shown below.
In the window labeled Possible

Controller Address enter the IP address you
recorded earlier.
After entering this address click the Test
Address button to ensure the address is not in use
anywhere else on the network.
If the address appears to be available, as
shown at right, then click Assign Address.
Finally before closing the window check
that the NIC IP Address matches the IP address
of the computer, and that the NIC Subnet Mask
is 255.255.255.0, then close the window.
PathMaster® will then acknowledge the

changes that were made, click okay, now close the edit controller window, and click save and close in the
Machine Parameters window. Now you should have communication with your machine in PathMaster®.
If that is not the case then repeat the previous steps making sure that you are assigning the
correct IP address for your controller as well as for the NIC card.
If you have communication then you are ready to download your main file. In PathMaster®
select the Download menu from the top of your screen and select Main. Now select the main file from
your computer and click ok or save to download. When that is complete exit completely out of
PathMaster®. Next Power the machine down. If you do not cycle power to the machine you will not have
any system messages displayed in Portal.

- 53 -
Be sure to shut down the PC first if it is powered by the workcell or if there is no UPS on the
machine to avoid losing any work not saved. Next turn the machine back on and if necessary start the
Portal software on the PC. You will see a System Initialization message followed by a Variable Error.
The machine will the restart and display the System Initialization message again and will continue on
to the exhaust and safety check. You are now ready to run.
Request Controller Version

Perform the following procedure to request the controller firmware version using the PathMaster®
terminal.
1) Establish communication with the controller. Please refer to the PathMaster® Manual.
2) Open the PathMaster® terminal.
3) Type ‘^R^V’
4) Press Enter.
The controller version is displayed in the terminal window.
Flexible coupling
Servo couplings are compensating couplings with a backlash free and conformal torque transfer providing
high torsional stiffness and a low moment of inertia. Check periodically if a shifting is suspected.
Figure 5 - Flexible Coupling
Flexible
Coupling

- 54 -
Power Check
If the expected voltages are not present in the following tests TURN THE MACHINE OFF
IMMEDIATELY. Permanent damage to the components may occur.
1) Remove all of the fuses in the enclosure, except for FU-1.
2) Disable the enclosure power safety switch.
4) Use a DMM (Digital Multi Meter) to check the AC power in the machine. There should be 110-120VAC
between the 100 and 101 terminals. If not, turn off the power and check that FU-1 is installed and
operational.
6) Install all of the fuses in the enclosure.
7) Push the EMERGENCY STOP push button in.
9) CRM-1 and CRM-2 should be DISENGAGED.
13) Pull the EMERGENCY STOP push button out.
14) Put a jumper wire between terminal 4 on the 5 V Monitor relay SSR-5 relay and any 304 terminal
block (this will engage the SSR-5 relay). If the SSR-5 relay LED is not on, there may be a problem
with the SSR-5 relay or the wiring on the coil side.
15) CRM-1 and CRM-2 should be ENGAGED. If not, check the next section (Door Interlock Check) for
machines equipped with doors.
Door Interlock Check

1) Engage the Door Bypass switch. If CRM-1 engages when the Door Bypass switch is engaged, there
may be a failure in the left door interlock switch, the right door interlock switch, or their wiring.
2) Check for a red indicator light on the 5 V Monitor relay SSR-5. If the indicator is not lit, there may be
a failure in the 5 V monitor relay or its wiring.
the 5 V Monitor relay, the EMERGENCY STOP push button PB-1, or their wiring.
the left door interlock switch or its wiring.
the right door interlock switch or its wiring.
6) If 24 VDC is present between 506 (+) and 302 (-), there may be a failure in the coil of CRM-1 or a
short in its associated diode D-1, or there may be a failure in the coil of CRM-2 or a short in its
associated diode D-2.
- 55 -
Encoder Feedback Test
Use this procedure to test the encoder feedback for all of the axes. If a problem is found with any of the
encoders repair and report the error to the production supervisor.
Most encoders used with the workcell generate 5080 counts/inch. Check to make sure that the position
feedback is reasonable.
(500*4 counts/rev)*(1 rev/cm)*(2.54 cm/in) = 5080 counts/inch.
1) Open a terminal program and establish communication with the DMC-1500 controller.
2) Turn the machine OFF. Disconnect the black motor power cables. Leave the orange encoder
feedback cables attached.
3) Move all of the axes to the center of travel position.
5) Enter HX.
6) Define the current position as (0, 0, 0, 0). Enter DP*=0.
7) Move the X-axis in the positive direction and display the current position. Enter TP.
8) Move the X-axis in the negative direction and display the current position.
9) Move the Y-axis in the positive direction and display the current position.
10) Move the Y-axis in the negative direction and display the current position.
11) Move the Z-axis in the positive direction and display the current position.
12) Move the Z-axis in the negative direction and display the current position.
13) Move the W axis in the positive direction and display the current position.
14) Move the W axis in the negative direction and display the current position.
16) Reconnect the motor power cables.
Motor Feedback Test

Use this procedure to verify that the motor power and Hall Effect sensors are wired correctly. If a
problem is found with any of the axes, repair and report them to the production supervisor.
2) Enable the EMERGENCY STOP button. This cuts the power to the amplifiers.
3) Open a terminal program and establish communication with the DMC-2200 controller. This can be
accomplished via the ‘terminal’ option in PathMaster®.
4) Enter the following commands via the terminal screen. The motors may be wired incorrectly. The
following program limits the acceptable error and power available to the amplifiers. This protects
personnel and equipment.
OE*=1 Off-on-error enabled for all axes.

ER*=1000 Error limit for all axes.
- 56 -
TL*=1 Torque limit of 1 for all axes.
SP*=5000 Set the speed.
AC*=10000 Set the acceleration.
DP*=0 Define the current position as (0, 0, 0, 0).
SB5 Enable power (only on machines without a POWER ON
button).
SH Apply power to the servo motors.
5) Release the EMERGENCY STOP push button. Push the POWER ON button (if present) so it lights up.
This restores power to the amplifiers. Care must be taken because any of the axes can move at this
time.
6) Command the X-axis to make a positive move. If the axis runs away debug and repeat the
procedure.
PRX=2000
BGX
WARNING! Make sure that the workspace is clear of any obstacles. In the event of a
run-away condition, the machine may be irreversibly damaged.
8) Command the X-axis to make a negative move. If the axis runs away debug and repeat the
procedure.
PRX=-2000
BGX
10) Repeat step 6 through 9 for the Y, Z and W axes.

- 57 -
Maintenance
Schedule
Table 5 – Preventive Maintenance Schedule
Type Of Service
Service
Dispensing Check all fluid Check for Inspect the Check the
Equipment pressures and material buildup fluid delivery inline material
dispense on fixtures and lines for filter for
weights. locating excessive clogging.
surfaces. wear.
Check for any

leaks around
compression
fittings.
Retighten or
replace if
needed.
Electro- Check motors Grease the Inspect all

mechanical for overheating ball screw moving cables
components and smooth slides with for excessive
operation. Lithium wear.
Grease (JIS
Check for any Type 2).
chaffing of
wires,
pneumatic lines
or material lines.
Inspect
enclosure air
filter, clean with
warm soapy
water as
needed. Air dry
before
reinstalling.
(PVA250™,
PVA750™
models only.)
Conveyor Clean conveyor Check for Check the

System belts. material and conveyor belts
dust buildup on for wear.
the sensors.
Part-in-Place Clean with

warm water, a

- 58 -
Type Of Service
Service
Sensors mild solvent
(like dish soap)
and a soft
cloth. DO NOT
use moderate
or harsh
solvents, such
as Isopropyl
Alcohol,
Acetone,
OS120, etc.
Pneumatics Check for proper Check the

operation. slides for wear
Drain any and smooth
accumulated operation.
water from the
main
Filter/Regulator.
Dispensing / Lubricate
Spraying packing as per
Equipment the
manufacturer’s
recommendation
s.
Clean Purge Daily

Cups
Clean Valve Daily

Tips

- 59 -
Procedures
Ball Screw Slides
The slides should be greased via the fitting on the carriage every 100KM or approximately once a month.
Clean any buildup on the ball screw and seals. The manufacturer recommends using lithium-type soap
base grease (JIS Type 2). Not all models have slide with grease fitting. If a slide does not have a grease
fitting, simply apply a small amount of grease to the slide, and then work the slide back and forth.
Inspection
The cables in the flexible cable carrier should be checked for excessive wear. Any worn cables should be
replaced. Check for loose screws in the top frame and end effecter.
Conveyor Belt Replacement

1) Lockout the power and air supplies.
2) Remove the dust cover plate. The dust cover plate is located near the conveyor motor on the inside
of the conveyor.
3) Remove the old conveyor belt from the pulley wheels.
4) Clean the conveyor rails where the belt rides.
5) Install the new conveyor belt. Start by placing the belt on the pulley wheels farthest from the motor.
NOTE: M ake sure that there are no tw ists in the belt.
6) Place the belt around the large pulley wheel, then around the remaining wheels.
7) Rotate the pulley wheels several turns by hand. This ensures that the belt is correctly seated.
8) Replace the cover plate.
Valves
Refer to the Cut Sheets section of the Operating Guide for information about the dispensing / spraying
equipment.
Servicing the Inline Material Filter

Machines dispensing or spraying low viscosity materials (such as conformal coating) may have an inline
stainless steel filter on the pressure vessel. If material flow appears restricted, the filter element could be
clogged. All parts of the filter are stainless steel and can be cleaned several times before replacing.
Follow these steps to clean or replace the filter:
1) Turn off air supply pressure to the pressure vessel.
2) Turn off the material valve on the vessel.
3) Using two large adjustable wrenches, separate the two sections of the filter.
4) Remove the stainless steel filter element, noting the proper orientation.
5) Clean or replace the filter as necessary.
6) Reassemble the filter and pressurize the system. It may be necessary to purge any trapped air from
the system.

- 60 -
Exhaust Fan Setup
1) Turn power OFF.
3) Set the overload relay current for 1.0 * FLA for the motor. The FLA is shown on the motor
nameplate.
4) Set the reset button to Manual.
5) Restart the machine.
Pressure Differential Switch Setup

NOTE: The flow velocities referred to be only valid for a 5” duct diam eter!!!!
1) Turn on the exhaust at 100% speed.
2) Check operation of the pressure switch input. The input should be ON with the exhaust at 100%
speed.
3) Turn off the exhaust. Make sure the pressure switch input turns OFF.
5) Verify that the exhaust pressure switch input is still ON. If it is not, turn the adjustment screw
counterclockwise until the input just turns ON.
6) Turn off the exhaust. Make sure the pressure switch turns OFF.
7) Turn on the exhaust. Make sure the pressure switch input turns ON. If not, turn the adjustment
screw counterclockwise again until the input turns ON. Verify that the input turns OFF when the
exhaust is turned off.
9) Verify that the pressure switch input stays OFF at this airflow velocity. If the input stays ON, turn
the adjustment screw clockwise SLOWLY until the input turns OFF. If an adjustment is made, re-
check the input at the airflow velocity used in step 4. The input should still turn ON at an airflow
velocity within the range used in step 4.
10) Cycle the exhaust off and back on again. Verify that the pressure switch input stays OFF for an
airflow velocity within the range used in step 8.

- 61 -
Part Replacement
Ordering Parts
All customers can order parts by contacting Customer Service Support. Your customer service
representative can help take your order. When ordering spare parts, be prepare to provide the following
information:
• Your Company Name

• Billing Address
• Shipping Address
• Serial Number of the Workcell (found on the back of the equipment)
• Part number or description
• Quantity
• Purchase Order or Credit card information
• Shipping Instructions
TIP: Keeping an extra set of frequently used spare parts can help reduce down time.
Return Material Authorization (RMA)

Obtain a Return Material Authorization (RMA) from Precision Valve & Automation by calling PVA Tech
Support.
Training
Because the replacement parts it requires safety and familiarity with the equipment, Precision Valve &
Automation offers Training Certificates to Customer technicians. Contact PVA for more information.
Warranty
Contact Precision Valve & Automation for any warranty issue related with spare parts.
Shipping
When you ordering parts, specify which carrier you prefer to use. Precision Valve & Automation will
determine the best shipping if no instructions are received.

- 62 -
Appendix A – Definitions
Auto Cycle: Machine state where cycles are running.
Auto Purge: A machine function that automatically purges material after a predefined period of time or
during solvent cups procedures.
Calibration Position: The location in the workspace where the X, Y, Z and W locations for the needle(s)
is normalized.
Cycle Stop: Machine state where no action is occurring and the machine is at the standby position.
Depress: Press and hold for the duration of the operation.
Dispense/Spray Path: A continuous motion profile. The valve is on (dispense/spray) during the entire
motion profile. This is also known as a Path or Motion Sequence.
DMC: Language used to program the motion controller in the workcell.
End Effector: The dispense/spray head assembly. The end effector is moved by the axes.
Head: Dispensing / spraying valve.
Home Position: The (0, 0, 0, 0) location of the workspace. This position is determined by the location
of the home sensors. It is NOT the same as the Standby Position.
Jog: Moving any combination of axes continuously at a set rate of speed until commanded to stop.
Light Tower: The light tower consists of three stacked lights, red, amber and green (top to bottom). It
is used to indicate the status of the machine.
Main program file: A text file containing the code that runs the workcell during normal operations.
Motion Sequence: A continuous motion profile. The valve is on (dispensing) during the entire motion
profile. This is also known as a Dispense/Spray Path or Path.
Path: A continuous motion profile. The valve is on (dispense/spray) during the entire motion profile.
This is also known as a Dispense/Spray Path or Motion Sequence.
PathMaster®: Windows® programming software. Used to create, maintain and download program
files for the workcell.
Press: Press and release.
Program: A collection (or series) of motion sequences.
Project: File containing the code for one or more programs (typically 30 programs).
Purge Position: The location in the workspace where the head moves to perform all auto purge
operations.
PVA: Precision Valve & Automation
Solvent Cups: Reservoirs containing a compatible solvent used to maintain the dispense/spray valves
when the workcell is not processing product.

- 63 -
Solvent Position: The location in the workspace where the head moves to rest in a solvent solution to
maintain the dispense/spray valves when the workcell is not processing product.
Standby Position: The rest position for the end effector. The machine moves here after homing and
after each cycle. This position is usually located near the start point for the program(s). It is NOT the
same as the Home Position.
Terminal: A program used as a communication link between the controller and operator.
Teach: A process by which the workcell registers its current gantry location with PathMaster® to create a
motion sequence.
Workcell: A model PVA250™, PVA250E™, PVA350™, PVA550™, PVA650™, PVA650-FT™, PVA750™,

PVA1000™, PVA2000™, PVA2000C™ or PVA3000™ automated system.

- 64 -
Appendix B – Serial Communication
Serial Communication
Overview
The workcell communicates with a computer using the EIA RS-232C standard. The computer is
the Data Terminal Equipment (DTE Device) and the controller is the Data Communications
Equipment (DCE Device). The tables below give a brief overview of the connections required to
communicate between DTE and DCE devices.
WARNING! The computer must be at the same ground potential as the machine.
Damage to the machine or computer may result if the ground potentials are different.
Use the workcell service outlet for computer power if provided.

Table 6 describes the pin-out for standard serial ports found on most portable computers.
Table 6 – DTE 9 Pin Serial Connector
Pin Description
(DTR)
5 Signal Ground

Table 7 describes the pin-out for standard serial ports found on most desktop computers.
Table 7 – DTE 25-Pin Serial Connector
Pin Description
1 Protective Ground
7 Signal Ground
9 +Voltage
10 -Voltage
11 Unused

- 65 -
12 Secondary CD
13 Secondary CTS
14 Secondary TD
15 DCE Transmitter Clock
16 Secondary RD
17 Receiver Signal Clock
18 Unused
19 Secondary RTS
(DTR)
21 Signal Quality Detector
23 Data Signal Rate Selector
24 DTE Transmitter Clock
25 Unused

Comp workcell
DTE DCE
DB9 DM9F
1 1
2 2
3 3
4 4
5 5

Comp workcell
DTE DCE
DB9 DM9F
1 5
2 3
3 2
4 1
5 4

- 66 -
Appendix C – Error Codes
DMC Error Codes
ID Description
1 Unrecognized command
4 Operand error
5 Input buffer full
9 Variable error
15 EEPROM check write error
16 IP incorrect sign during position move or IP given during forced
deceleration
25 Variable not given in “IN” command
50 Not enough fields
53 Error in {}
55 Missing [ or []

- 67 -
ID Description
58 Unrecognized command in a command response (i.e. _GNX)
62 Too many labels
66 Array space full
82 Undefined array

- 68 -
Appendix D – Wiring Schematic Legend
Wire Numbering

DC Control 400 - 599 400
DC Supply 300 - 399 300
AC Control 200 - 299 200
AC Supply Power nLm 1L2 Segment 1 of AC Supply Phase
2
Ground GND GND
Neutral NEU NEU
Wire Color Code
NOTE: This color code does not apply to m ulti-conductor cables.
Type Color Example

DC (<150 V) BLUE 0 VDC, 80 VDC
DC (>150 V) BLACK 200 VDC
AC (<150 V) RED 120 VAC
AC (>150 V) BLACK 208 VAC, 480 VAC
Neutral WHITE
Remote YELLOW Remote control
circuit

- 69 -
ID Description
58 Unrecognized command in a command response (i.e._GNX)
62 Too many labels
66 Array space full
82 Undefined array
Operation and Maintenance Manual Rev R /08

- 70 -
Appendix D – Closed Loop Speed Settings
Maximum Speed settings
The “closed loop” design of the PVA servo driven systems will generate a position error if the speed, acce-
leration or deceleration parameters are set to high. If the system is commanded to move at a speed that the
motors are not capable of achieving, the motion controller does not know the capabilities of the motor and
will therefore expect the motors to keep pace. Since the motors cannot keep pace, the difference between
the commanded position from the motion controller and the actual motor position from the encoder will
increase to a predetermined maximum (typically 1000 counts), and then the controller will generate a posi-
tion error.
PVA550 / PVA650
Axis Max Speed Max Scaled Speed Max Accel / Max Accel / Decel Scaled
(10x) Decel (10x)
X-Axis 125000 cnts/sec N/A 700000 cnts/sec2 700000 cnts/sec2
Y-Axis 125000 cnts/sec N/A 700000 cnts/sec2 700000 cnts/sec2
Z-Axis 125000 cnts/sec 12500 cnts/sec 700000 cnts/sec2 70000 cnts/sec2
PVA2000 / PVA3000
Axis Max Speed Max Scaled Speed Max Accel / Max Accel / Decel Scaled
(10x) Decel (10x)
X-Axis 125000 cnts/sec N/A 700000 cnts/sec2 N/A
Y-Axis 125000 cnts/sec N/A 700000 cnts/sec2 N/A
Z-Axis 125000 cnts/sec N/A 700000 cnts/sec2 N/A
W-Axis 80000 cnts/sec N/A 500000 cnts/sec2 N/A
Conversion
5080 cnts = 1 inch
200 cnts = 1 millimeter
Note:
The Parameters listed above are general guidelines. The load on each axis will have a large impact on
these parameters. The load on each axis can vary greatly depending on machine configuration. The para-
meters listed above may not be optimal for all processes. Typically the dispense or spray speed (vector
Speed for coordinated motion) is much slower than the move speed (independent motion).

- 71 -
Appendix E – Wiring Schematic Legend
Wire Numbering

DC Control 400 - 599 400
DC Supply 300 - 399 300
AC Control 200 - 299 200
AC Supply Power nLm 1L2 Segment 1 of AC Supply Phase 2
Ground GND GND
Neutral NEU NEU
Wire Color Code

NOTE: This color code does not apply to multi-conductor cables.
Type Color Example

DC (<150 V) BLUE 0 Vdc, 80 Vdc
DC (>150 V) BLACK 200 Vdc
AC (<150 V) RED 120 Vac
AC (>150 V) BLACK 208 Vac, 480 Vac
Neutral WHITE
Remote YELLOW Remote control circuit

- 72 -
Appendix E – Wiring Schematic Legend
Wire Numbering

DC Control 400 - 599 400
DC Supply 300 - 399 300
AC Control 200 - 299 200
AC Supply Power nLm 1L2 Segment 1 of AC Supply Phase 2
Ground GND GND
Neutral NEU NEU
Wire Color Code

NOTE: This color code does not apply to multi-conductor cables.
Type Color Example

DC (<150 V) BLUE 0 Vdc, 80 Vdc
DC (>150 V) BLACK 200 Vdc
AC (<150 V) RED 120 Vac
AC (>150 V) BLACK 208 Vac, 480 Vac
Neutral WHITE
Remote YELLOW Remote control circuit
Operation and Maintenance Manual Rev P 9/07

- 73 -
PathMaster®
Configuration
PathMaster® Manual
3
Cut Sheets
Schematics
Software
PathMaster® Manual
Certain warning symbols are affixed to t he machine a nd corres pond to n otations i n t his manual. B efore
operating the Dispensing System, identify these warning labels and read the notices described below. No t
all labels may be used on any specific system.
Always wear approved safety glasses when operating or working near the
Dispensing System.
6040
In s ituations where in attention cou ld cau se eith er pers onal in jury or

damage to equipment a warning notice is used.
6014
Do no t s moke near t he D ispensing System. Always have a fire

extinguisher available for emergency use.
6019
Before operating the s ystem, read and understand t he manuals provided

with the unit.
6017
Before perf orming any repai rs or maintenance t o t he sy stem, t urn o ff

power and lock out the power disconnect switch.
6011
Never place h ands or tools in areas designated b y this symbol when the
machine is in operation. A dangerous condition may exist.
6008
Warning notices are us ed to em phasize that hazardous voltages, current,
temperatures, or oth er conditions that could case personal injury exist in
this equ ipment or may be associated with its us e. O nly qu alified
personnel should enter areas designated with this symbol.
6010
Before perf orming a ny repair s or m aintenance to th e s ystem, read an d

understand t he manuals provided with the unit. S ervice should only be
performed by a qualified individual.
6018
Exercise cau tion when pres surized v essels are pres ent. Iden tify an d
repair any leaks immediately. Always wear appropriate safety equipment
when working with pressurized vessels or vessels containing chemicals.
6054
Laser light source present. Do not s tare directl y into th e bea m. Do not
use in the presence of highly reflective surfaces.
6003
1012
1099
6043
6060
This d ocument i s b ased o n information av ailable at t he ti me o f it s p ublication. W hile e fforts h ave b een
made to be accu rate, the information contained herein does not purport to cover all detail s or v ariations in
hardware o r so ftware, n or t o p rovide f or ev ery p ossible co ntingency i n co nnection with in stallation,
operation, o r m aintenance. Featu res may b e d escribed h erein which are n ot p resent in all h ardware a nd
software systems. P recision Valve & Automation, Inc. assumes no obligation of notice to holders of this
document with respect to changes subsequently made.
Precision Valve & Automation, Inc. makes no representation or warranty, expressed, implied, or s tatutory
with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of
the information contained herein. No warranties of merchantability or fitness for purpose shall apply.
This document, including the information contained herein, is the property of Precision Valve &
Automation, Inc. and is considered confidential and proprietary information. It is delivered on the
express condition that it not be used, disclosed, or reproduced in whole or in part, for any reason without
prior written consent of Precision Valve & Automation, Inc.

Preface
Notice & Disclaimer
This manual appl ies t o on e of t he f ollowing au tomated w orkcells produ ced by Pr ecision V alve &
Automation, Inc.:
• PVA250™
• PVA550™
• PVA750™
• PVA1000™
• PVA2000™
• PVA200C™
• PVA3000™
All machines are re ferenced throughout the manual as the Dispensing System or W orkcell. T his manual
provides information and functionality descriptions covering all the common options and configurations for
a Dispensing System. The particular machine associated with this manual may not contain all items or may
have ad ditions. If th e manual refers to a n o ption that was not p urchased, ig nore that section. If o ptions
exist on the machine not mentioned in this manual, please consult the Optional Equipment sec tion o f the
Operating Guide for more information on these additions.

The f ollowing li st d escribes th e major rev isions i n th is manual (Re v. H 6 /03) as co mpared to previous
manuals:
• Rewrite for PathMaster® version 2.05, including subroutine information.
• Update for PathMaster® version 2.3. 6/23/03 TMB

Definitions. Definitions for commonly used terms.
Notices and Warning. Basic safety practices are reviewed.
Getting Started. Instructions on establishing communication with the Dispensing System and installing the
Working with Materials. Overview on the basics of liquid dispensing.
Beginning Programming. Prerequisite information for using PathMaster®.
PathMaster® Overview. Basic description of features and tools of PathMaster® software.
Using PathMaster®. Detailed manual on using the PathMaster® software.
DMC Error Code. A list of error codes that may be encountered while using the Dispensing System.
PathMaster® Manual Rev. H 6/03

- iv -
Contents
Table of Contents
Preface .......................................................................................................................................................... iv
Notice & Disclaimer .................................................................................................................................. iv
Revisions to This Manual .......................................................................................................................... iv
Content of This Manual ............................................................................................................................. iv
Contents ......................................................................................................................................................... v
Table of Contents........................................................................................................................................ v
List of Tables ...........................................................................................................................................viii
Definitions...................................................................................................................................................... 9
Notices and Warnings................................................................................................................................. 11
Getting Started............................................................................................................................................ 12
Necessary Skills ........................................................................................................................................ 12
Hardware & Software Requirements ........................................................................................................ 12
Installing PathMaster® .............................................................................................................................. 12
Tutorials................................................................................................................................................ 12
Communications ....................................................................................................................................... 12
DMC-1500 Dip Switch Settings ........................................................................................................... 12
Computer Settings................................................................................................................................. 13
Uninstalling PathMaster®.......................................................................................................................... 13
Multiple Dispensing System Issues .......................................................................................................... 13
Year 2000 Compliance ............................................................................................................................. 13
If Something Goes Wrong . . . .................................................................................................................. 14
Calling Technical Support .................................................................................................................... 14
Working with Materials ............................................................................................................................. 15

Overview................................................................................................................................................... 15
System Components ................................................................................................................................. 15
Material Feed ........................................................................................................................................ 15
Dispense (Needle) Valve ...................................................................................................................... 15
Spray Valve........................................................................................................................................... 15
Programming ........................................................................................................................................ 16
Beginning Programming ............................................................................................................................ 17

Overview................................................................................................................................................... 17
Planning Path Programs............................................................................................................................ 17
Incorrect Valve Usage........................................................................................................................... 17
Inserting Valve Commands into Programs ........................................................................................... 17
Inter-Path Movement ................................................................................................................................ 18
Main Program Modifications .................................................................................................................... 18
Common Main Program Changes......................................................................................................... 18
PathMaster® Overview.............................................................................................................................. 20
General...................................................................................................................................................... 20
PathMaster® Window .............................................................................................................................. 20
Upper Status Bar ................................................................................................................................... 20
Lower Status Bar .................................................................................................................................. 20

-v-
Main Menu................................................................................................................................................ 21
File Menu.............................................................................................................................................. 21
Edit Menu ............................................................................................................................................. 21
Teach Menu .......................................................................................................................................... 21
Modify Menu ........................................................................................................................................ 21
Run Menu ............................................................................................................................................. 22
Download Menu ................................................................................................................................... 22
Utilities Menu ....................................................................................................................................... 22
Setup Menu ........................................................................................................................................... 22
Help Menu ............................................................................................................................................ 22
Right-Click Menu ..................................................................................................................................... 22
Teach..................................................................................................................................................... 22
Modify .................................................................................................................................................. 23
Run........................................................................................................................................................ 23
Programming Toolbar............................................................................................................................... 23
Programming Tools .............................................................................................................................. 23
PathMaster® Database.............................................................................................................................. 24
General.................................................................................................................................................. 24
Multiple Dispensing Systems ............................................................................................................... 24
Machine Configuration ............................................................................................................................. 24
Path Programs ........................................................................................................................................... 24
Project Files .............................................................................................................................................. 24
Using PathMaster®...................................................................................................................................... 25
Starting PathMaster®................................................................................................................................ 25
Configuring PathMaster®......................................................................................................................... 25
Machine Parameters.............................................................................................................................. 25
Database Backup and Restoration............................................................................................................. 29
Automatic Backup ................................................................................................................................ 29
Manual Backup ..................................................................................................................................... 29
Database Restoration ............................................................................................................................ 30
Important Reminders ................................................................................................................................ 30
Machine Selection..................................................................................................................................... 30
Project Selection ....................................................................................................................................... 31
Reading a Program.................................................................................................................................... 31
Playback.................................................................................................................................................... 32
Edit Windows ........................................................................................................................................... 32
Interacting With the Dispensing System................................................................................................... 33
Manual/Jog/Teach Mode ...................................................................................................................... 33
Trackball Control.................................................................................................................................. 33
Teach Pendant....................................................................................................................................... 34
OIT Jog Control .................................................................................................................................... 35
TracMouse™ ........................................................................................................................................ 36
Pneumatic Commands .......................................................................................................................... 36
Programming Tools .................................................................................................................................. 36
Adding Comments ................................................................................................................................ 36
Move ..................................................................................................................................................... 37
2D Path ................................................................................................................................................. 38
3D Path ................................................................................................................................................. 39
Arc ........................................................................................................................................................ 40
Circle..................................................................................................................................................... 41
Area....................................................................................................................................................... 42
PolyLine................................................................................................................................................ 46
Dot ........................................................................................................................................................ 47
Head...................................................................................................................................................... 49
Step Over .............................................................................................................................................. 49

- vi -
Quick Play ............................................................................................................................................ 50
Dwell..................................................................................................................................................... 50
Subroutine............................................................................................................................................. 50
I/O ......................................................................................................................................................... 52
DMC Command.................................................................................................................................... 53
Valve Offsets ............................................................................................................................................ 53
Offline Programming (FastPath™)........................................................................................................... 56
Setting Up the Image ............................................................................................................................ 56
Valve Selection ..................................................................................................................................... 56
Drawing a Program ............................................................................................................................... 57
Commands ............................................................................................................................................ 58
Move ..................................................................................................................................................... 58
Head...................................................................................................................................................... 58
2D Line ................................................................................................................................................. 58
Arc ........................................................................................................................................................ 58
Circle..................................................................................................................................................... 58
Area....................................................................................................................................................... 58
FastMask™ ........................................................................................................................................... 58
Dot ........................................................................................................................................................ 59
Editing the commands........................................................................................................................... 59
Password Protection.................................................................................................................................. 59
Download Password ............................................................................................................................. 59
Save Password ...................................................................................................................................... 59
Changing Password............................................................................................................................... 59
Resetting Password ............................................................................................................................... 59
Importing Files.......................................................................................................................................... 60
CAD Files ............................................................................................................................................. 60
PathMaster® 1.5 & Pre 1.5 Projects ..................................................................................................... 64
Text File................................................................................................................................................ 64
DMC File .............................................................................................................................................. 64
Subroutine............................................................................................................................................. 64
Exporting Files.......................................................................................................................................... 64
Text File................................................................................................................................................ 64
DMC File .............................................................................................................................................. 64
Subroutine............................................................................................................................................. 65
Utilities ..................................................................................................................................................... 65
View FastPath ....................................................................................................................................... 65
Measure Distance.................................................................................................................................. 65
Machine Debugger................................................................................................................................ 65
Refresh Communication ....................................................................................................................... 73
Jog Toolbar ........................................................................................................................................... 73
Path Preview ......................................................................................................................................... 73
Show Code............................................................................................................................................ 73
DMC Error Codes ...................................................................................................................................... 74

- vii -
List of Tables
Table 1 – DMC-1500 Dip Switch Settings for PathMaster®......................................................................... 12
Table 2 – Communication Program Settings ................................................................................................ 13
Table 3 – Coordinate System Locations ....................................................................................................... 19
Table 4 – Variable Explanations................................................................................................................... 19
Table 5 - Required CAD File Elements ........................................................................................................ 60
Table 6 – Important DMC Commands ......................................................................................................... 67
Table 7 – DMC Error Codes......................................................................................................................... 74

- viii -
Definitions
Auto Cycle – Machine state where cycles are running.
Auto Purge – A machine function that automatically purges material after a predefined period of time.
Calibration Position – The location in the workspace where the X, Y, Z and W locations for the needle(s)
is normalized.
Cycle Stop – Machine state where no action is occurring and the machine is at the standby position.
Depress – Press and hold for the duration of the operation.
Dispense Path – A continuous motion profile. T he valve is on (dispensing or s praying) during the entire
motion profile. Also known as a Path or Motion Sequence.
DMC – Language used to program the motion controller in the Dispensing System.
End Effector – The dispense head assembly. The end effector is moved by the axes.
Head – Dispensing, or spray valve (or any other part processing device).
Home Position – The (0, 0, 0, 0) location of the workspace. This position is determined by the location of
the home sensors. It is NOT the same as the Standby Position.
Jog – One or m ore ax es are command t o t raverse con tinuously at a s pecified s peed u ntil com manded t o
stop.
Light Tower – The light tower consists of three stacked lights, red, amber and green (top to bottom). It is
used to indicate the status of the machine.
Main program file – T ext fi le c ontaining t he c ode t hat r uns t he D ispensing S ystem d uring normal
operations.
Motion Sequence – A continuous motion profile. T he valve is on (di spensing) d uring the entire motion
profile. Also known as a Dispense Path, Coating Path or Path.
Offline Programming - A m anor of programming Path Programs without being connected to t he
Dispensing System. Known as FastPath™.
Path – A continuous motion profile. The valve is o n (dispensing) during the entire motion profile. A lso
known as a Dispense Path or Motion Sequence.
PathMaster® – Wi ndows® programming software. U sed to create, maintain and download program files
for the Dispensing System.
Press – Press and release.
Program – A collection (or series) of motion sequences.
Project – File containing the code for one or more programs.
Purge Position – T he location i n t he workspace where th e head moves to perf orm all au to p urge
operations.
PVA – Precision Valve & Automation, Inc. Precision Valve & Automation.
Solvent Cups – A container filled with an agent designed to prevent the spray and dispensing valves from
clogging when idle for a specified period of time. Also known as Solvent Rest.

-9-
Solvent Purge – An Auto Purge performed after the valves move from the solvent cups prior to processing
product.
Standby Position – The rest position for the end effector. The machine moves here after homing and after
each cycle. T his position is usually located near the start point for the program(s). It i s NOT the same as
the Home Position.
Terminal – A program used as a communication link between the controller and operator.
WSDK-1500 – Windows® Servo D esign K it 1500. This s oftware i s used t o s etup a nd t une t he s ervo
system.

- 10 -
• Safety glasses, g loves, an d long s leeved cloth ing are neces sary precau tions when w orking with
• Read and understand all operating manuals before using this equipment.
• Do not disable the safety features of the machine.
• Lock-out and tag the air and power supplies before servicing or cleaning any part of this equipment.
• Do not remove any hose, either air or fluid, without relieving the pressure.
• Do not replace any hose with a hose of inadequate pressure rating.
• Use only replacement parts recommended or supplied by the manufacturer.
• Always remain clear of all moving parts when the system is in operation.

- 11 -
Getting Started
Necessary Skills
The Disp ensing S ystem o perator m ust b e f amiliar with W indows® an d its most co mmon f eatures. T his
includes Notepad (or a similar text editing program), Explorer (or File Manager) and how to cut-and-paste
information from o ne pl ace t o an other. It i s STRONGLY reco mmended t hat pers onnel be thoroughly
versed in these subjects before attempting to program the machine.
Hardware & Software Requirements

PathMaster® requires a P entium processor and at leas t 32 MB of RAM for W indows® 95, 98, NT, 2000,
me, or XP operating systems.
Installing PathMaster®
To install PathMaster®, first close any applications that may be open . If the install is done via 3½” disks,
take disk #1 of the PathMaster® installation disks and place it in the floppy drive, making sure it is secure.
Run setup.exe and follow the instructions on the screen. For CD-ROM installations, insert the CD into the
CD drive. Run setup.exe on the CD drive and follow the instructions on the screen.
NOTE: PVA recommends installing the software in its default directory (c:\Program Files\PVA).
Tutorials
In the tutorials directory of the PathMaster® CD-ROM are a number of audio/visual tutorials. These can be
accessed via the Help→Contents option in PathMaster® or the pathmaster.hlp file.
NOTE: If the computer in use does not have a sound card or the card is not installed properly, the audio
portion of the tutorials will not function.
Communications
The Dispensing System communicates with a computer using the EIA RS-232C standard. The computer is
the Data T erminal Eq uipment (DT E Dev ice) an d the co ntroller is t he Data Co mmunications Eq uipment
(DCE Device). A programming port is located on the front of the machine. T he controller baud rate an d
handshaking function are set with dip s witches o n t he controller inside t he Dispensing System e nclosure.
The settings for the controller and the computer must be the same.
WARNING The computer must be at the same ground potential as the machine. Damage to
the machine or computer may result if the ground potentials are different. Use the Dispensing
System service outlet for computer power.
DMC-1500 Dip Switch Settings

The main RS-232 port on the DMC-1500 controller must be configured as follows to communicate with the
Table 1 – DMC-1500 Dip Switch Settings for PathMaster®

MRST OFF Master Reset Switch
1200 O FF Baud rate

- 12 -
9600 O N Baud rate
19200 O FF Baud rate
HSHK ON Hardware Handshaking Switch
NOTE: If hardware handshaking is enabled, and the program uses the message command and a
computer is not attached to the Main RS-232 port, the controller eventually halts. A computer must be
attached to the controller when handshaking is enabled and message commands are used.
Computer Settings
The f ollowing are th e co rrect settin gs to co mmunicate with th e motion co ntroller. P athMaster®
automatically sets the data bits, parity and stop bits.
Table 2 – Communication Program Settings
Option Setting
Baud rate 9600
Data bits 8
Parity no ne
Stop bits 1
Uninstalling PathMaster®
To u ninstall t he s oftware go t o Wi ndows® Control Panel an d s elect Add/Remove Programs. T he
Install/Uninstall screen appears. S croll down and highlight PathMaster. Then click on the Add/Remove
button. PathMaster® is removed by Windows®.
As W indows® re moves all t he co mponents as sociated with P athMaster®, it may q uery the o perator
concerning shared files. If in dou bt, Precision Valve & Automation, Inc. recommends NOT deleting any
shared files. Precision Valve & Automation, Inc. assumes no responsibility for any difficulties arising from
the deletion of shared files during the uninstall procedure of PathMaster®.
NOTE: This process completely eliminates the PathMaster® software and all its components, including
registry entries.
Multiple Dispensing System Issues

Unless a m ultiple m achine cro ss-programming s ystem w as purchased with the Di spensing S ystem,
Precision Val ve & Automation, In c. P recision Val ve & Automation STRONGLY recom mends that
customers n ot at tempt t o ru n prog rams dev eloped w ith one D ispensing Sy stem o n a s econd D ispensing
System. W hile machines may appear s imilar, minor diff erences in th e homing sequence, pn eumatic
actuators, etc. can be sufficient to cause an externally-developed program to damage a Dispensing System.
Precision Valve & Automation, Inc. is not responsible for damages incurred in any such attempt.

PathMaster® is compliant with and comprehends the year 2000 cen tury date change. PathMaster® will not
have a ny operation al i mpediments, malfunction, ceas e to perf orm, generate i ncorrect or a mbiguous data
and/or pro duce in correct or a mbiguous res ults with res pect to s ame-century a nd multi-century f ormulas,
functions, date values and date-data interfaces.

- 13 -
Some probl ems e ncountered when us ing t he D ispensing System are easy t o i dentify a nd s olve. O thers
require more extensive help. It is best to program in small increments, so problems appear quickly and can
be diagnosed easily. Save work frequently during the programming process.
For non-immediate problems or to report suggestions, please email [email protected].

The t echnical su pport s taff i s al ways a vailable t o h elp s olve any probl ems. T he ph one n umber i s (518)
371-2684. To as sist i n t he troubleshooting proces s, it i s bes t i f as many o f t he following i tems are
1) Note the serial number of the Dispensing System. The serial number can be found on the legend plate
located on the front of the electrical enclosure.
2) Record all the information on the OIT or PC when the error occurred.
3) If the error was not serious, attempt to repeat t he error. If t he error does not repeat, the problem may
have been operator generated.
4) Use a ter minal screen to comm unicate with t he co ntroller. Mos t trou bleshooting re quires i ssuing
5) A hard copy or em ail of t he program i n qu estion may be requ ested by PV A. Pl ease b e prepared t o
send it. T he PVA fax number is (518) 3 71-2688, or t he customer service representative will provide
an email address, if all parties are email capable.

- 14 -
Working with Materials
Overview
The Dis pensing S ystem workcell is des igned to operate with many di fferent materials in a variety o f
applications. Learning to use and program with these materials is both an art and a science. T here are no
concrete rules for an operator to follow; the best method for establishing settings for the system is trial-and-
error. Once acceptable parameters are found it is easy to maintain those parameters over time.
System Components
Each part of th e m aterial del ivery s ystem must be ad justed an d o ptimized f or th e s elected m aterial. In
general, it is best to approach the problems in the order listed below.
Material Feed
Usually, material is moved through the system by one of two methods, either a pump or a pressure vessel.
For eith er method, t he o perator’s first ta sk is to co nsult the manufacturer’s material s pecifications a nd
determine the appropriate settings for the material delivery system. I f a p ump is used o n the system, the
separate pum p manual sh ould be t horoughly read an d u nderstood t o det ermine t he bes t s ettings f or t he
material. For a pres sure v essel, if t he pres sure is too h igh t he v alve ou tput will be ex cessive an d
inconsistent i n f low a nd air m ay b e f orced in to th e material. Too little p ressure p rovides in sufficient
output.
Dispense (Needle) Valve

The only direct adj ustment for the needle valve is the stroke. Turning the knurled knob on the top of the
valve coun ter-clockwise in creases f low th rough th e v alve. A f ine s teady s tream o f material is all th at is
needed. On ce a satisf actory setting is found, secu re th e st roke p osition with th e lo cking n ut. On ce th e
locking nut is secure verify the valve flow rate before continuing.
Needle Selection
Experiment with different needle sizes to determine the best size for the system. If the needle is too large a
drip develops at the end of the needle. To small a needle yields insufficient flow.
Spray Valve
Two adjustments are available for the spray valve: Valve stroke and atomizing air. The stroke controls the
flow of material t hrough the valve. T urning the knurled knob on t he top of t he valve c ounter-clockwise
increases flow through the valve. Atomizing air is controlled by a pressure regulator located on the front of
the machine. T urning this clockwise increases the air pressure. T his pressure can only be adjusted while
the valve is active. O nce satisfactory settings are f ound for these items, secure the stroke position on the
valve using the locking nut. Secure the regulator by pressing the cap or tightening the lock nut. Once the
locking nut is secure verify the valve flow rate before continuing.
When first operating the machine, follow this list of instructions to adjust the spray valve:
1) Set the atomizing air to 0 P.S.I.
2) Take off the spray cap.
3) Turn the stroke down all the way.
4) Using t he pu rge fun ction i n Manual mode, open t he stroke t o a f ew drops per s econd. It m ay be
necessary to cycle the valve on and off while adjusting the stroke.

- 15 -
5) Replace the spray cap.
6) While purging, adjust the atomizing air until the spray is satisfactory. Test the spray pattern on scrap.
If the atomizing air is too high, the spray will be misty. If it is too low, there will be splatter. Thin, solvent
based materials usually require as little as 0.5 P.S.I., while some silicones require as much as 15 P.S.I.
Extended Spray Cap

This cap is exclusive to the FCS100-ES valve. It is identified by its small long cylinder nozzle. T his cap
can reach into tight areas between tall components, were a very defined pattern is required.
Round Spray Cap

This p rovides a circu lar sp ray p attern. It is id entified b y i ts lack o f e xternal air p orts. I t works well for
solvent based materials or where a smaller, more defined pattern is required.
Flat Spray Cap

The spray from this cap is rectangular/oval in shape. It is identified by the protruding atomizing air ports.
It works best with non-solvent based materials and provides a wider spray path for increased coverage.
Programming
Once t he phy sical para meters are s uccessfully es tablished for th e deliv ery s ystem, t hey s hould never be
altered. The best method for changing the material output is to alter the program. In most cases, raising or
lowering the speed of a dispense path is enough to change the material output to the desired level.
When programming with the dispense valve, lo wer the valve so that the end of the needle is close to t he
part s urface, bu t not too clos e s uch t hat v arying needle le ngth tolera nces will caus e the n eedle to make
contact with the surface of the product.
With the spray valve, a good rule of t humb is to start about ¾” (19 mm) above the product surface. With
atomizing a ir, t his sh ould pro duce a s pray width approx imately ½” t o ¾ ” (19 mm) wide. If n ecessary,
adjust the spray height so the pattern on the product is consistent and uniform.

- 16 -
Beginning Programming
Overview
This section provides important information every operator must know before programming the Dispensing
System. A thorough understanding is recommended.
Planning Path Programs

It is best to plan the path program on paper before starting on the machine. Break the planned program into
individual paths and number each path and the points within it, a long with which valve is active and what
pneumatic operations must be perf ormed. T he path numbers and point numbers should correspond to the
order in which the program proceeds. This documentation is very useful when debugging programs.
Breaking t he path prog ram into s maller s egments is wise an d prov ides th ree adv antages. Firs t, eac h
segment can have different on, off and speed parameters. Second, the operator can focus on programming
and debu gging on e s egment at a t ime. T hird, i f on e s egment of t he prog ram must be ch anged, t he
remaining segments are not affected. This reduces debugging time and makes the program maintainable.
When programming, the operator should co mment the program as needed to enable anyone to follow the
logic. Again, this decreases debugging problems and saves time in the long run.
NOTE: If a stop or dwell must be added at one of the points after a path is completed, then the path
must be broken into two paths or entirely reprogrammed.
Incorrect Valve Usage

When programming or operat ing the Dispensing System, t he valves should NEVER be used for moving
components or boards. Precision Valve & Automation is not responsible for damages incurred from using
the valves in an inappropriate manner.
Inserting Valve Commands into Programs

Pneumatic p ositions (h ead up/down, ro tary selection) are n ot au tomatically p rogrammed b y P athMaster®
and th ere i s no co mmunication bet ween t he D ispensing System a nd P athMaster® con cerning t he acti ve
valve or its pneumatic position. T herefore, it is the responsibility of the operator to s elect the appropriate
valve within PathMaster® and insert the necessary pneumatic commands into the program after a path has
been completed.
It is important these commands are not inserted at incorrect locations. In general, try to follow these rules:
• Program each segment with the corresponding valve slide in the down position.
• Actuate a valve rotary before lowering a valve slide.
• Move the XY(W) axes into position prior to actuating a valve slide or valve rotary.
• Insert valve slide down and valve rotary B commands before any segment(s) that require them.
• Insert valve slide up and rotary A commands once finished with the valve.
• Raise a valve slide before returning a rotary to A.
• Insert all the code for each segment after completing it.
• If suddenly changing valves, insert a non-dispense move on the Z axis to 0, to allow room for the new
valve to lower. (See Inter-Path Movement on page 18 for more detail.)

- 17 -
Inter-Path Movement
When programming the Dispensing System via PathMaster® it is easy to determine the movement, point-
to-point, within a path program via the playback feature. However, it is more difficult to gauge movement
between segments. After completing a segment, the Dispensing System immediately moves the axes to the
start point of the next segment. If there are obstacles in the way, the machine does not know this, since this
route was not tested and programmed intentionally.
There are dif ferent ways to co mbat th is proble m. T he bes t s olution i s to f ollow t he reco mmended
procedure and map out the path program to allow for direct movements between segments. If that was not
done, or obstacles cannot be avoided, then the operator should insert ‘safety’ moves of the Z axis to avoid
inadvertently hitting a nything. T his i s acco mplished b y p rogramming a ‘Z o nly’ move, with t he Z-axis
target set to 0.
It is u ltimately th e o perator’s resp onsibility to en sure no c ombination o r seq uence o f p ath se gments are
harmful to the machine or any product the operator is running.
Main Program Modifications

Sometimes it is necessary to make changes in the main program that runs the Dispensing System. Usually
it in volves sett ing up p oints for th e machine to use. If the o perator m ust d o th is, it is i mperative to
download t he correct ed main file properl y t o a void a ny probl ems. O pen t he Main p rogram u sing a t ext
editor, such as Windows® Notepad or Winpad.
Common Main Program Changes

There are a few sets of points that commonly need changing: Standby position, purge position, solvent cup
position, and calibration position. In the main program these settings are lo cated in the Machine Specific
Information section (near the end of the file), an example of which is shown below:
REM !!!! Machine-Specific Information !!!!
#IMACH;MT 1,1,1,1
CE 0,0,0,0;FSTX=20000;SLWX=10000;FSTY=20000;SLWY=10000
FSTZ=10000;SLWZ=5000;FSTW=10000;SLWW=5000
KNHEAD=3;A_HEAD[1]="FCS100";R_HEAD[1]=0
A_HEAD[2]="FC100 ";R_HEAD[2]=1
A_HEAD[3]="DISPSE";R_HEAD[3]=1
PT_APG[0]=80000;PT_APG[1]=65000;PT_APG[2]=0;PT_APG[3]=3000
PT_SOL[0]=80000;PT_SOL[1]=65000;PT_SOL[2]=0;PT_SOL[3]=3000
PT_CAL[0]=15000;PT_CAL[1]=15000;PT_CAL[2]=500;PT_CAL[3]=2000
PT_SBY[0]=25000;PT_SBY[1]=25000;PT_SBY[2]=250;PT_SBY[3]=3500
AP_EN=0;AP_LEN=2000;AP_TIME=30000;PNTO=4000;LT_EN=1;AC_TMR=1
SLP_TM=30000;SO_EN=0;LLA_EN=0;LLB_EN=0
#TUNE;AC*=325000;DC*=300000;SP*=120000;VA*=70000;VD*=70000
BL -4000,-4000,-1000,-1000
FL 83000,85000,15000,30000;TL*=9.9999
KD 67.99,82.43,76.09,50.00
KP 5.66,6.75,8.38,5.00
KI 0.25,0.19,0.34,0.50;EN

- 18 -
The following tables display the command variables that an operator may wish to change.
Table 3 – Coordinate System Locations
Axis
Locations X Y Z W
Auto Purge Location PT_APG[0] PT_APG[1] PT_APG[2] PT_APG[3]
Solvent Cup Location PT_SOL[0] PT_SOL[1] PT_SOL[2] PT_SOL[3]
Calibration Location PT_CAL[0] PT_CAL[1] PT_CAL[2] PT_CAL[3]
Standby Location PT_SBY[0] PT_SBY[1] PT_SBY[2] PT_SBY[3]
Table 4 – Variable Explanations
Variable Explanation
AP_EN Default value for auto purge. 1=on, 0=off.
AP_LEN Length of auto purge, in milliseconds.
AP_TIME Time between auto purges, in millesends.
SLP_TM Sleep timer value for solvent rest, in millesends.
SO_EN Solvent rest enable / disable. 1=enable, 0=disable.
Once Main program modifications have been made, the new program must be downloaded to the controller
using the PathMaster® Download -> Main function.

- 19 -
PathMaster® Overview
General
Precision Valve & Automation, Inc. has developed a Wi ndows® application to facilitate the development,
maintenance and execution of programs for the Dispensing System. PathMaster® combines the ease of use
in typical Windows® applications with the specific functionality necessary for programming the Dispensing
System.
PathMaster® Window
Title Bar
Main Menu
Upper Status Bar
Programming
Toolbar
Program Table
Lower Status Bar
Upper Status Bar
The u pper s tatus bar dis plays t he acti ve machine co nfiguration, c urrent proj ect f ile and cu rrent pat h
program. The current path program can be changed via the drop-down list box.
Lower Status Bar
The lower status bar shows the current status of the Dispensing System. Whether or not, the PC is
communicating with the Dispensing System is reflected in the ‘Connected’ display. The ‘Manual’ display
indicates if the machine is in Manual mode. The ‘Error’ display reports if the machine is currently in a

- 20 -
state of error. The ‘Units’ field is the measurement system in use when programming, and can be altered in
the Setup section of PathMaster®.
NOTE: In order to teach path programs online, PathMaster® must be connected, in Manual mode, and
not in a state of error.
Main Menu
File Menu
• Machine – Select a machine configuration.
• New – Create a new project.
• Open – Open an existing project or subroutine.
• Close – Close the current project.
• Delete – Delete the current project, or current program.
• Save – Save the current project.
• Save As – Save the current project under a different name.
• Print – Print the current program, or print the entire compiled program.
• Database – Backup or restore the PathMaster® database.
• Import – Import a project, program, or subroutine.
• Export – Export a project, program, or subroutine.
• Exit – Exit the application.
Edit Menu
• Program – Edit the program name, auxiliary code, or background image.
• Undo Delete – Undo the last Delete operation.
• Cut – Remove highlighted path segment(s) and copy to the clipboard.
• Copy – Copy highlighted path segment(s) to the clipboard.
• Paste – Copy path segment(s) from the clipboard and insert it into the program.
• Delete – Delete highlighted path segment(s).
• Select All – Select all path segments from the displayed program.
Teach Menu
• Move – Code a move to a specific location.
• 3D Path – Teach a 3D path segment and specify valve activity.
• 2D Path – Teach a 2D path segment and specify valve activity.
• Dot – Dispense at a defined point for a length of time and specify valve activity.
• Area – Teach an “Area” path segment that covers a rectangular shape.
• Circle – Teach a circular path segment and specify valve activity.
• Arc – Teach an arc path segment and specify valve activity.
• FastMask – Teach a FastMask™ path segment (specify keep out areas).
• Polyline – Teach a path segment consisting of 2D, circle, and arc path segments
• Subroutine – Create a new or insert an existing PathMaster® subroutine.
• Dwell – Teach a delay between path segments in seconds.
• I/O – Reference inputs or outputs within the program.
• Head – Insert valve functions (up/down, rotary, etc.).
• Comment – Insert comments into the path program.
• DMC Command – Write DMC machine code into the path program.
Modify Menu
• Properties – Modify properties of selected path segment.
• Offset – Apply an offset to any axis for selected path segments, or the entire program.
• Speed – Modify speed for selected path segments, or the entire program.

- 21 -
• Valve Parameters – Modify parameters for selected path segments, or the entire program.
• Subroutine Call – Change a subroutine call for the selected path segments.
Run Menu
• Selection – Run (playback) the highlighted path segment on the Dispensing System.
• Program – Run (playback) the current program on the Dispensing System.
Download Menu
• Project – Download the current project file.
• Main – Download the Main operating program for the Dispensing System.
NOTE: The operator must activate the EMERGENCY STOP button when downloading files to the
controller!
Utilities Menu
• View FastPath – Open the FastPath™ window for offline programming.
• Measure Distance – Calculate the position between two points.
• Machine Debugger – An array of tools useful for debugging.
• Refresh Communications – Issue an attempt to reestablish communication with the workcell.
• Jog Toolbar – Toolbar used to jog the head from PathMaster®
• View Tools – Enable programming toolbar.
• Path Preview – Graphic view of the selected path segments.
• Show Code – Show machine code for selected path segments.
Setup Menu
• Machine Parameters – Setup machine parameters for the current machine profile.
• Passwords – Set password for downloading and saving projects.
Help Menu
• Contents – PathMaster® online help.
• Commands – Online help manual for the Galil DMC-1500 controller.
• About – Information about PathMaster®, including release version.
Right-Click Menu
Using the right mouse button while highlighting a function accesses this menu.
Teach
Move – Code a move to a specific location.
3D Path – Teach a 3D path segment and specify valve activity.
Dot – Dispense at a defined point for a length of time and specify valve activity.
Area – Teach an “Area” path segment that covers a rectangular shape.
Circle – Teach a circular path segment and specify valve activity.
Arc – Teach an arc path segment and specify valve activity.
FastMask – Teach a FastMask™ path segment (specify keep out areas).
Polyline – Teach an path segment consisting of 2D, circle, and arc path segments
Subroutine – Create a new or insert an existing PathMaster® subroutine.
Dwell – Teach a delay between path segments in seconds.
I/O – Reference inputs or outputs within the program.
Head – Insert valve functions (up/down, rotary, etc.).
Comment – Insert comments into the program path
DMC Command – Write DMC machine code into the path program.

- 22 -
Modify
Properties – Modify properties of selected path segment.
Offset – Apply an offset to any axis for selected path segments, or the entire program.
Speed – Modify speed for selected path segments, or the entire program.
Valve Parameters – Modify parameters for selected path segments, or the entire program.
Run
Selection – Run (playback) the highlighted path segment on the Dispensing System.
Program – Run (playback) the current program on the Dispensing System.
Move To First Point – Move to the first point of the selected path segment(s).
Show Code – Show machine code for selected path segment(s).
Path Preview – Graphic view of the selected path segment(s).
Cut – Remove highlighted path segment(s) and copy to the clipboard.
Copy – Copy highlighted path segment(s) to the clipboard.
Paste – Copy path segment(s) from the clipboard and insert it into the program.
Programming Toolbar
The programming toolbar provides quick access to the most frequently used programming tools.
Programming Tools
Programming t ools are u sed t o creat e pat h s egments, which make u p a pat h prog ram. Pat hMaster®
contains a variety of useful prog ramming t ools which can be us ed t o creat e 2 di mensional an d 3
dimensional path motion. Many of the most commonly used tools are located on the toolbar, while the less
frequently used tools can be accessed from the Teach menu.
Comment – Insert comments into the program
Move – Code a move to a specific location.
Arc – Teach an arc path segment and specify valve activity.
Circle – Teach a circular path segment and specify valve activity.
Area – Teach an “Area” path segment that covers a rectangular shape.
FastMask – Teach a FastMask™ path segment (specify keep out areas).
PolyLine – Teach a path segment consisting of 2D, circle, and arc path segments
Dot – Dispense at a defined point for a length of time and specify valve activity.

- 23 -
Head – Insert valve functions (up/down, rotary, etc.).
Step Over Program – Step to the previous, or next path segment.
Play – Play back the selected path segments.
FastPath – Open the FastPath™ window for offline programming.
PathMaster® Database
General
The PathMaster® ap plication u tilizes a f lexible d atabase stru cture to sto re all parameter an d p rogram
information. T he database structure allows for a central s torage location for all data, which can easily be
backed up and restored. When projects and path programs are saved, the user will save them under a name
of there choice, however, the name that they give there projects and path programs will not be visible to the
user as a file on t heir h ard driv e. T he pro ject an d pr ogram n ames are s tored as record s in t he databas e
rather than t he co nventional file structure used i n previous versions o f P athMaster®. P recision Val ve &
Automation strongly recommends that the entire database be backed up before and after any changes are
made t o pro jects or p rograms. Preci sion V alve & Automation i s n ot res ponsible f or any l ost dat a or
production time due to improper database backup procedures.
Multiple Dispensing Systems

The database structure employs a s ystem, which will allow as many Dispensing System configurations as
needed. In a p roduction environment where multiple machines with varying configurations are utilized, a
single PathMaster® database can use and maintain the configurations for each of these machines.
Machine Configuration
Pathmaster® w ill u tilize the d efault m achine configuration on startu p u nless there are m ultiple m achine
configurations stored in the database. If there are multiple machine configurations available, PathMaster®
will prompt the user to select the machine or machine configuration that they will be using.
Path Programs
A pat h prog ram is a col lection of pat h s egments t hat make u p a di spensing or s pray prog ram. Pat h
segments are made u p of any com bination of prog ramming fu nctions. Each pat h prog ram can con tain a
unique n ame o f 12 ch aracters or l ess. T he pat h prog ram n ame is di splayed on t he workcell O IT w hile
running product.
Project Files
PathMaster® project files can be t hought of as a collection of storage bins for up to thirty path programs.
Each one of these 30 bins can hold one path program. When a project file is downloaded to the Dispensing
System, all 30 of the storage bins are downloaded to the workcell controller, even if some are empty. The
empty bins simple do nothing if they are selected to run.

- 24 -
Using PathMaster®
Starting PathMaster®
The f irst ti me you ru n P athMaster® it will n eed to b e c onfigured to ru n p roperly with th e Di spensing
System. To start the PathMaster® application, locate and double-click the PathMaster® icon. The Select
Project di alog box will di splay. Cl ick the Create a New Project radi o bu tton an d s elect OK. An
information box will appear indicating that no communication settings were found for your controller. This
is normal for the initial startup. Click the OK button to continue.
Configuring PathMaster®
Before P athMaster® can be u sed, it must be con figured to s uit t he machine an d machine applicatio n.
Communication parameters must also be configured to allo w PathMaster® to i nteract with the Dispensing
System.
Machine Parameters
The m achine p arameter f orm is u sed to set attrib utes sp ecific to th e so ftware as well as th e h ardware.
Machine parameters are unique to the machine profile. The settings on the machine parameter form apply
only to the current machine profile. The current machine profile is displayed in the upper status bar of the
main PathMaster® window.

- 25 -
Dispensing Parameters
The d ispensing p arameters ar e the d efault p arameters for a ll co ordinated p ath motion. These p arameters
can be modified within each programming function for each path segment.
• Path Acceleration - Set default acceleration for all coordinated motion.

• Path Deceleration – Set default deceleration for all coordinated motion.
• Z-Retract – Set default relative z retract for Dot function.
• Dot On Dwell - Set default valve on time for Dot function.
• Dot Off Dwell - Set default valve off time for Dot function.
Move Parameters
The move parameters are the default parameters for all independent path motion for each axis of motion.
• Move Speed – Set default move speed for all independent path motion.
• Move Acceleration – Set default acceleration for all independent path motion.
• Move Deceleration – Set default deceleration for all independent path motion.
Units
Select the preferred measurement system (encoder counts, millimeters, inches).
Machine Type
Configure P athMaster f or a tw o, th ree, or f our ax is g antry. C heck t he Stepper Motors box if you are
running Pat hMaster® on a PV A250™, PV A750™, PV A2000C™, or an y ot her open loop s tepper PV A
Dispensing System.
Valves
Name and configure valve heads as they are u sed throughout the software. T he names are located in the
Configuration section of the Operating Guide, along with the options present for each valve. The ‘Enabled’
box should be checked for all the valves present on the machine. ‘Z-Slide’ and ‘Rotary’ should be checked
if they are installed.
Valve Parameters
• On Delay Wait – The pause after turning the valve on but before starting the path.
• Off Delay Wait – The pause after finishing the path and turning the valve off but before moving to the
next point.
• On Delay Distance – Distance the path traveled before turning the valve on.
• Off Delay Distance – Distance the path traveled when turning the valve off, before the path finishes.
• Speed – Vector speed for any programming function using the corresponding valve.
• Valve Height – Distance from the surface of the product to the lowest point of the valve as taught
using the valve offset function (offline programming only).
• Area Spacing – Distance between runs when executing an Area path.
Valve Offsets
Valve Offset is a wizard used to step through the configuration process of setting the offsets between each
valve and a pointing device. These offsets are used for offline program, as well as for online programming
with a pointing device.
Machine Auxiliary
The m achine a uxiliary fu nction is u sed to h ardcode cu stom software o ptions in to th e m achine so ftware.
This function is typically preprogrammed by Precision Valve & Automation and provided to the customer
with specific instruction on how to use it.

- 26 -
Communications
Communications i s us ed t o c onfigure t he RS 232 co mmunication s ettings bet ween t he c omputer a nd t he
Dispensing System. P athMaster® uses control handles to s tore all com munication settings for a machine.
A control handle can be thought of as a record in a database that has multiple fields in which to store vital
pieces of inf ormation. T he inf ormation i n t he con trol handles is s tored in th e W indows® reg istry.
PathMaster® can have multiple control handles configured, but can have only one control handle selected
at a time.
To c onfigure co mmunications, click the Edit Controller button o n th e Mach ine P arameters form. I f a
message appears in dicating t hat P athMaster® co uld n ot fi nd any co ntrollers i n t he W indows® Registry,
click OK. This simply means that no control handles have been configured yet.
When the Edit Registry window appears, click New Controller.
Select the controller model installed in the Dispensing System from the table below:
PVA Workcell Controller Model

PVA250 D MC-2100
PVA550 D MC-1500
PVA750 D MC-2100
PVA1000 D MC-1500
PVA2000 D MC-1500
PVA2000C D MC-2100
PVA3000 D MC-1500
All other’s DMC-2100
Use t he def ault T imeout v alve for all con trollers a nd Se rial f or C onnection T ype. NOTE: Not all
controller models require configuration of Connection Type.
- Click Next -

- 27 -
Select the communication port that your PC is using:
The Comm. Speed should match the co mm. speed set on the controller. T his is set to 9600 by Precision
Valve & Automation prior to shipping.
Select hardware handshaking.
- Click Finish -
Acknowledge the dialog box stating that the controller has been added.
• Control handle properties can be modified by highlighting the controller and clicking Properties.
• Multiple control handles can be added.
• Control handles can be deleted by clicking the Delete button.
- Click Close -
Once one or more control handles have been created, you must select the control handle that PathMaster®
will use to communicate with the Dispensing System. To select a control handle:
• Click the Change Controller button on the Machine Parameters form.

- 28 -
• Select the control handle to be used.
• Click the OK button.
Saving Machine Parameters
Once all machine parameters have been set, click the Save & Close button to save the parameters and return
to the main PathMaster® window.
Database Backup and Restoration

It i s e xtremely i mportant t hat t he Pat hMaster® dat abase be back ed u p properl y. Preci sion Valve &
Automation strongly recommends t hat the entire databas e be backed up ( manually) be fore and after any
changes are made to projects or prog rams. Preci sion Valve & Automation is not responsible for any lost
data or production time due to improper database backup procedures.
Automatic Backup
PathMaster® will p erform a n au tomatic b ackup o f th e entire d atabase each d ay t hat P athMaster® is
executed. PathMaster® utilizes a ro lling ten day a utomatic backup scheme, therefore, backup file will be
stored f or th e last ten d ays th at P athMaster® was ex ecuted. A ll au tomatic b ackups are sto red in th e
Db\Daily s ub f older o f th e P athMaster® ap plication f older. The d efault lo cation of th ese files is
“c:\program files\pva\pathmaster\db\daily”.
Manual Backup
A manual database backup is by far the safest method. This method requires a conscious effort by the user,
and therefore, should be part of a t heir programming procedure. T o perform a manual database backup,
select the File -> Database -> Backup option from the main menu. S ave the project if prompted to do s o.
When the Backup Files form opens, click the Backup button.
NOTE: Additional files can be added

to the backup by clicking the Add
button and selecting the file. This is
not normally necessary for a
complete PathMaster® database
backup.
The Sav e As dialog box open s. Select a des tination an d a f ilename f or th e backu p f ile (th e back up will
only be 1 file). The backup file extension will be ‘bck’. Click the Save button. The PathMaster® database
backup is complete.

- 29 -
Database Restoration
To restore the PathMaster® d atabase, select t he File -> Database -> Re store option from the main menu.
You can restore a *.bck (standard backup) or *.abck (automatic backup) file using this option.
WARNING: Restoring a PathMaster® database will completely overwrite all existing data prior to the
restore operation. If you are attempting to restore partial data, a database restore is not the correct
procedure.
Once th e file dialog box ope ns, s elect t he location an d f ile y ou wish to res tore. C lick th e Open button.
Once the restore successful message displays, click OK. Restart PathMaster®.
Important Reminders
• Inserting Code – When the operator uses PathMaster® programming functions to insert code, the code
is placed at t he current highlighted location on the screen. It is the operator’s responsibility to ensure
the proper area is highlighted to accommodate the new path.
• Inserting Valve Commands – C ommands to move t he h eads or v alves are NOT au tomatically
inserted into PathMaster® the path programs. If the operator needs a head to change position (up/down,
rotary) the appropriate com mand must be ins erted manually via t he Head prog ramming tool. Please
read Inserting Valve Commands into Programs on page 17 for more information on this subject.
• Downloading – The operator must activate the EMERGENCY STOP button when downloading files to
the controller.
Machine Selection
If more th an o ne machine co nfiguration e xists i n t he P athMaster® databas e, it is necessary to s elect t he

appropriate m achine bef ore prog ramming. T his opt ion pre sents i tself whenever Pat hMaster® beg ins an d
there are multiple machine profiles. P rojects are assi gned to p articular Di spensing Systems, so it i s
necessary, when changing machines, to select a new project.

- 30 -
Project Selection
It is necessary to select the appropriate project before programming. This option presents itself on startup,
whenever P athMaster® ch anges t he c urrent machine s etting or t he operat or wishes t o open a di fferent
project.
• OK – Select the highlighted project as current.

• Cancel – Exit this function without making changes.
Reading a Program
The P athMaster® prog ram dis play is arrang ed in a table f ormat. Us e t he ch art belo w to determ ine th e
purpose of the text that appears in each field.
COLUMN USE EXAMPLE EXPLANATION

Command Programmed command. DOT Dot program.
NOTE: A command LINE(3D) 3 D Line
uses all the lines below
it until another
command reference
appears in the
command column.
Position C oordinates. 4555,3000,760 Cartesian coordinates
for current point.
On Valve or I/O on. (1)W.5 Activate head 1, valve
on time of .5 seconds.
(2)D300 Activate head 2, valve
on distance of 300
counts.
I49 Wait for input 49 to be
on.
O32 Turn on output 32.
Off Valve or I/O off. W.75 Deactivate the path’s

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head 1, valve off time of
.75 seconds.
D500 Deactivate the path’s
head, valve off distance
of 500 counts.
I51 Wait for input 51 to be
off.
O35 Turn off output 35.
Speed Path speed. 2000 Path speed of 2000
counts/second.
Other Varies according to Z=250 Z axis relative move of
path. 250 counts after
completing a dot path.
Playback
Paths can be played back using two methods in addition to downloading and running the entire program via
the Dispensing System:
1) Highlight an i ndividual pat h and s elect Run→Selection f rom t he drop- down menu or t he ri ght-click
menu.
2) Play an entire program by selecting Run→Program from the drop-down menu or the right-click menu.
Before playback begins, the user will be prompted to select a Wet or Dry playback.
Wet playback activates the valve(s) while running the path. Dry playback does not activate the valve(s).
Edit Windows
Path to ols with ed iting cap ability allo w t he o perator to ch ange a p ath seg ment o nce it has b een created .
Examples of edit windows appear in each path section that is editable. T he coordinates box appears in the
upper left hand corner of the edit window, showing all the coordinates programmed. T he following icons
and buttons appear in edit windows to facilitate path editing:
Move to Point – Move to the point highlighted in the coordinates box.
Edit Point – Edit the point highlighted in the coordinates box.
Previous Point – Move to the preceding point in the path (if one exists).

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Next Point – Move to the next point in the path (if one exists).
Insert Point – Insert a new point BEFORE the current highlighted point.
Delete Point – Delete the highlighted point.
Append Point – Add a point to the end of the path.
Interacting With the Dispensing System

For PathMaster® to operate pr operly it must work in concert with the Dispensing System. The Dispensing
System must be in Ma nual mode in order to teach a path program o nline with P athMaster®. If in C ycle
Stop, the Dispensing System can be placed in to this mode by pressing F4. For m ore information on using
the Di spensing S ystem apart f rom P athMaster® pleas e co nsult t he s eparate Operation and Main tenance
Manual within the Operating Guide.
Manual/Jog/Teach Mode
Manual Mode
EXIT Teach VLV RUN PURG TP CONV AXIS
F1 F2 F3 F4 F5 F6 F7 F8
[F1] EXIT – Leave Manual/Jog/Teach mode and return to Cycle Stop.

[F2] TEACH – Program the current point.
[F3] VLV – Switch to Valve Selection.
[F4] RUN – Run singular cycles of the current program.
[F5] PURG – Actuate the current valve.
[F6] TP – Momentary switch that displays the current position of the head.
[F7] CONV – Switch to Conveyor Control.
[F8] AXIS – Switch to Trackball Control.
NOTE: Playback of a path is only possible if the operator is in Manual mode or one of its sub modes.
Valve Select ion, C onveyor C ontrol an d T rackball C ontrol are th e oth er areas acces sible f rom Manu al
mode. Valve Selection selects which valve is currently operational on the Dispensing System. Conveyor
Control operates the board stop and the conveyor.
Trackball Control
(All models except PVA250™, PVA750™, PVA2000C™)
Trackball Control
EXIT Teach PRG X&Y X Y Z W
F1 F2 F3 F4 F5 F6 F7 F8

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Trackball Control allows the operator to switch the active axis on the trackball.
[F1] EXIT – Leave Trackball Control and return to the previous mode.
[F4] X&Y – Operate the X and Y axes simultaneously.
[F5] X – Operate only the X axis.
[F6] Y – Operate only the Y axis.
[F7] Z – Operate only the Z axis.
[F8] W – Operate only the W axis.
Teach Pendant
PVA550™, PVA2000™, and PVA3000™ are equipped with a teach pendant which has a trackball, teach
button, purge button, axis selection button, and LED indicators for selected axes and teach function.
TRACKBALL – The trackball allows the operator to jog each axis independently or X and Y together.
Teach – The teach button mimics the teach button found on the Dispensing System OIT in that it will
register the gantry position back to PathMaster® when teaching a motion profile.
Purge – The purge button mimics the purge button found on the Dispensing System OIT in that it will
purge material from the active valve.
Axis – The axis button allows the operator to toggle through the available axis configurations. Typical
configurations are X only, Y only, Z only, W only, and X & Y together.
LED’s – The X, Y, Z and W LED’s represent the selected axis configuration. The teach LED indicates a
successful response from PathMaster® when a position is taught. The teach LED is accompanied by a
‘beep’ from the light tower buzzer.

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OIT Jog Control
(PVA250™, PVA750™, PVA2000C™ models only)
Jog Mode
EXIT Teach PRG AXIS -Y -X +X +Y
F1 F2 F3 F4 F5 F6 F7 F8
OIT Jog Control allows the operator to jog the gantry via the OIT function keys to perform teach functions.
[F1] EXIT – Leave OIT Jog Control and return to the previous mode.
[F4] AXIS – Toggle axis control between X, Y and Z.
[F5] -Y – Jog the Y axis in the negative direction.
[F6] -X – Jog the X axis in the negative direction.
[F7] +X– Jog the X axis in the positive direction.
[F8] +Y – Jog the Y axis in the positive direction.
To jog an axis, press and hold the function key that corresponds to the axis and direction of motion desired.
Once the axis is in motion for approx. 1 sec, the speed will increase by a factor of 15.

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TracMouse™
PathMaster® is eq uipped with the capability to jog the workcell gantry using a p ointing device with your
computer, such as a mouse or t rackball. This feature is especially useful on PVA250™, PVA750™, and
PVA2000C™ machines that are not equipped with a teach pendant or built in trackball.
The T racMouse™ has an activation pad or T racPad inside of each P athMaster® programming tool. T he
TracPad™ is th e dark g ray s quare or rectan gle located on each tool form. Left clic k t he T racPad™ to
activate the T racMouse™. To move the gantry, press and hold the left mouse button while dragging the
mouse cursor on the TracPad™. To switch between axes, right click the TracPad™ until the desired axis
combination is d isplayed i n th e upper lef t hand co rner o f th e acti vation p ad. Do uble clic k o n t he
TracPad™ to teach a point while the TracMouse™ is active.
TracPad™
Pneumatic Commands
Pneumatic positions (head up/down, rotary selection) are not automatically programmed by PathMaster®
and there is no communication between the Dispensing System and PathMaster® concerning the valves
pneumatic position. Therefore, it is the responsibility of the operator to select the appropriate valve within
PathMaster® and insert the necessary pneumatic commands into the edit window after a path has been
programmed. Physically, the pneumatics are operated from the Valve Selection screen on the Dispensing
System.
Programming Tools
Adding Comments
It is a good practice to add comments to each path program in a manor in which anyone that views the path
program ca n understand what t he prog ram i s doi ng. All com ments are s tripped f rom t he prog ram on
compilation; therefore, they do not use any controller memory.
Comment Edit Window

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Move
Programmed
Teach Screen Edit Screen
This tool allows the operator to program an absolute move. This is a non dispense move.
• Approach Type – S elect t he order of movement for the fu nction. “ XY Only” m eans the controller
moves along the X and Y a xes simultaneously. “XY then Z” means the controller first moves X &Y
and once that motion is complete it moves Z. The total list of options:
XY only XYZ
X only XYW
Y only XYW then Z
Z only W only
XY then Z XY then W then Z
• Current Position – If th ere is co mmunication estab lished with th e co ntroller, th e cu rrent p osition
appears in the text box. Use the trackball on the Dispensing System to change the position.
• Input Coordinates – Manual entry of target position.
• Teach – Record current position and add to the program. Equivalent to the F2 key on the Dispensing
System.
• Teach Position – Record current position and alter program to use it. Equivalent to the F2 key on the
Dispensing System.
• Teach Coordinates – Record entered position and alter program to use it.
• Cancel – Quit without altering the program.

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2D Path
Programmed
Teach Screen
Edit Screen
This tool teaches 2D path segments. The Z axis does not alter its position during the path.
• Dispensing Parameters – Se lect appropriate parameters for the current dispense, including the active
valve.
Valve On Time – The pause after turning the valve on but before starting the dispense path.
Valve Off Time – T he p ause af ter f inishing th e p ath an d tu rning th e valve o ff b ut before
moving to the next point.
Valve On Distance – Distance the path traveled before turning the valve on.
Valve Off Distance – Dista nce th e p ath tra veled when tu rning the v alve o ff, b efore th e p ath
finishes.
• Teach – Record the current point. Equivalent to the F2 key on the Dispensing System.
• Done – Add to the program.

- 38 -
NOTES: Playback is only allowed if the Dispensing System is currently in Manual/Jog/Teach mode.
3D Path
Programmed
Teach Screen
Edit Screen
This tool teaches 3D path segments.
valve.
Valve On Time – The pause after turning the valve on but before starting the dispense path.
Valve Off Time – T he p ause af ter f inishing th e p ath an d tu rning th e valve o ff b ut before
moving to the next point.
finishes.
• Teach – Record the current point. Equivalent to the F2 key on the Dispensing System.

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Arc
Programmed
Teach Screen
Edit Screen
This tool teach es an arc. Th e operator m ust s elect th ree (3) points on th e arc le ngth, in cluding t he
beginning and end points, moving (clockwise or coun ter-clockwise) in the direction the axes must move.
The Z axis does not alter its position during the path.
NOTE: When selecting points, space them evenly around the arc.
valve.
Valve On Wait – The pause after turning the valve on but before starting the dispense path.
Valve Off Wait – The pause after finishing the path and turning the valve off but before moving
to the next point.

- 40 -
finishes.
• Teach – Record current position. Equivalent to the F2 key on the Dispensing System.
Only three points can be plotted for the arc function.
Circle
Programmed
Teach Screen
Edit Screen
This tool teach es a circle. The operator m ust s elect th ree (3) poin ts on th e circum ference of th e circle,
including the start point, moving (clockwise or counter-clockwise) in the direction the axes must move. The
Z axis does not alter its position during the path.
NOTES: When selecting points, space them evenly around the circle. Do not use the same point as the
first and last point.

- 41 -
valve.
to the next point.
finishes.
• Teach – Record current position. Equivalent to the F2 key on the Dispensing System.
Only three points can be plotted for the circle function.
Area
Programmed
Teach Screen
Edit Screen

- 42 -
This tool teaches rectangular paths. The Z axis does not alter its position during the path.
valve.
to the next point.
finishes.
Area (or Path) Spacing – Distance between runs.
• Teach – Record the current point. Eq uivalent to the F2 key o n the Dispensing System. T his button
becomes inactive after the third point is taught.
Only three points are required for the Area tool.
How the Area tool works
Area #1 Area #2
1 1 2
3
23
Points

- 43 -
By using only three points ‘Area’ path segments are calculated in the following manner:
Point 1 defines the start of the pattern. P oint 2 defines the direction and length of the pattern. After the
direction of t he pat tern i s det ermined, t he di stance from poi nt 1 t o poi nt 3 det ermines the width of t he
pattern. The width is divided by the ‘Area Spacing’ (or ‘Path Spacing’) parameter on the Area tool screen.
The resulting value is the number of passes needed to fill the given area.
NOTE: For the above drawings, the X axis is vertical and the Y axis is horizontal.
Area #1
1) Point 1 defines the start.
2) Point 2 is alo ng the X axis, so that is the direction of the path. T he length of the path is the distance
over the X axis. Therefore, the width is along the Y axis.
3) Point 3 defines the width. The width is the difference in Y between points 1 and 3. This is divided by
the ‘Area Spacing’ (or ‘Path Spacing’) parameter resulting in the number of paths the machine needs to
run to fill the given area.
Area #2
1) Point 1 defines the start.
2) Point 2 is alo ng the Y axis, so that is the direction of the path. T he length of the path is the distance
over the Y axis. Therefore, the width is along the X axis.
3) Point 3 defines the width. The width is the difference in X between points 1 and 3. This is divided by
the ‘Area Spacing’ (or ‘Path Spacing’) parameter resulting in the number of paths the machine needs to
run to fill the given area.
FastArea™
FastArea™ quickens the pace of the standard area by eliminating valve cycling between rows. This feature
can have a dram atic impact on cycle time. To activ ate the FastArea™ feature; teach a s tandard area, an d
then check the FastArea™ check box.
FastArea™
Check box

- 44 -
FastMask™
The FastMask™ tool will create an area to be coated a s well as keep outs of within that area. There can be
up to 99 keep out areas defined within the coating area.
Sample PCB
Keepouts
Once the Fastmask™ tool is selected, a wizard will open:
Select the appropriate valve parameters, then teach the opposing corners of the area t o be coat ed, point 1
and point 2.
Click Next to continue:
Teach the opposing corners of the first keep out area. Click Add to add the keep out to the FastMask™ list.
Keep addin g k eep ou t areas (u p to 99 k eep ou ts) u ntil all n on-coat areas h ave been in cluded in th e
FastMask™ list.

- 45 -
Select the direction of the brush stroke. This is the direction the coating valve will travel when completing
the FastMask™ pattern.
The FastMask™ wizard is complete. Click Finish.

The FastMask ™ p attern will al ways b egin at th e p oint t aught clo sest to th e o rigin o f th e g antry (t he
smallest coordinate in the pattern).
PolyLine
A polyline is a series o f 2 dimensional lines, arcs, and circles. P olylines can be very useful in applications
that require tight directional changes at h igher speeds. Combining lines with arcs a nd circles will smooth
the motion and create uniform corners and circles.
A polyline can be created using two different methods. M ultiple path se gments ca n be created using the
conventional method and t hen converted to a poly line, or the pol yline ca n be created us ing t he P olyLine
tool.
New Polyline
To create a new polyline, open the PolyLine tool, and select a programming tool from the polyline toolbar
on th e le ft. T each th e poin ts requ ired f or th e tool s elected, an d s et th e s peed. As you co mplete each
segment it is added to the command list on the left of the polyline program table. The polyline is limited to
511 points for all segments. Set the valve parameters.

- 46 -
NOTE: When teaching each segment in a polyline, the last point of the last segment will be used as the
first point of the new segment. For example, a polyline arc (assuming it is not the first segment of the
polyline) will only require teaching two points since the first point will be taken from the last point of the
previous segment.
Select a s egment in the co mmand list and clic k the Edit Point button or the Edit Speed button to edit the
points and speed for each segment. T he polyline can also be ex ploded into individual path segments and
modified on the main PathMaster® program table.
Once the polyline is complete click the Done button.
PolyLine
Toolbar
Command
List
Polyline Program
Table
From Selected Line

To create a polyline from existing path segments, simply select the path segments to include in the polyline,
access the Teach menu and select PolyLine -> From Selected Lines. If the endpoints of the path segments
do not match up exactly, PathMaster® will ask you if you would like to match up the endpoints. If you
choose not to match up the points the polyline will not be created. If you choose to match up the points, the
polyline will match up the points using the best fit.
When creat ing a pol yline from e xisting path s egments, t he v alve para meters will be ta ken from t he firs t
path segment in the series. The speeds will be retained for each path segment.
WARNING: Be sure that all path segments selected for a polyline use the same valve as PathMaster®
will assume that the valve used in the first segment is used throughout.
Dot
Programmed
Teach Screen

- 47 -
Edit Screen
This function teaches a timed dispense.
valve.
Valve On Wait – The length of time the valve remains on.
Valve Off Wait – The pause after turning the valve off but before moving to the next point.
Z Retract (Relative) – Distance to raise the Z axis after completing certain moves.
• Teach – Record current position and add to the program. Equivalent to the F2 key on the Dispensing
System.

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Head
Programmed
Entry Screen
This function allows the operator to en ter head (valve) commands into the edit window. T he command is
placed at th e activ e field location . A h ead function on ly appears in t he head tool on ce it h as been
configured in the machine parameter setup. P neumatic positions (head up/down, rotary selection) are n ot
automatically programmed by PathMaster® and there is no communication between the Dispensing System
and PathMaster® with regard to the active valve or its pneumatic position. Therefore, it is the responsibility
of th e operator t o s elect th e appro priate v alve within P athMaster® an d to in sert th e n ecessary p neumatic
commands i nto t he prog ram af ter a path has been co mpleted. See In serting Valve C ommands i nto
Programs on page 17 for further information about head function programming.
• Teach – Accept the current command and insert into the edit window.
• Cancel – Quit without generating code.
Step Over
The step over tool will allow you to step to the previous or next path segment and play it back wet or dry.

- 49 -
Quick Play
The quick play tool will play back the selected path segments in wet or dry mode. This is the equivalent of
using the Run Selection option on the menu.
Dwell
The Dwell tool will set a delay in program execution in between path segments.
Subroutine
Creating
• Highlight the commands to be included in the subroutine.
• Select the Teach -> Subroutine -> Create option from the main menu.
• This fu nction allo ws t he o perator to u se an e xisting co mmand l ine ele ment e xcluding DMC
commands, i n an arra y sequence or i n ra ndom place ment. You a lso have t he option to ins ert
existing subroutines in your program using ‘Insert’.

- 50 -
• Choose a n abbrev iated na me a nd bri ef • Choose a ref erence poi nt on t he part t o
description f or t he su broutine. T he des cription group th e co mmand lin e s equences. Each
serves to as sist th e operator when selecting execution of t he su broutine t o be array ed
from multiple saved subroutines. or ran dom p laced will b e referen ced f rom
this point of origin.
• Choose to create an arra y or s elect ran dom • This s creen corres ponds to ran dom
placement of the subroutine. program pl acement. B y sel ecting t he
‘Teach’ bu tton, P athMaster® utilizes t he
current location o f th e e nd e ffector as an
execution point.
• Select t he directio n o f t he a rray. T he arro ws • Define t he number of el ements i n t he X

assist in determining the direction in relation to direction and the Y direction.
X,Y 0,0 origin of the current machine.

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• Assign t he first a nd l ast poi nts of ex ecution. • This s creen co nfirms t he final s tep. B y
The coordinates to be entered are relative to the selecting f inish, PathMaster® sa ves your
point of ori gin a ssigned i n t he prev ious s teps. created array or ran dom pl acement an d
PathMaster® then calc ulates t he distance for X inserts it in to your p rogram. T he ch osen
and Y spacing. execution positions will appear in the main
window.
Editing
• Save the current project.
• Select File -> Open -> Subroutine and choose the subroutine from the list.
• The stored subroutine code appears. Edit it like normal.
• Save the subroutine and reopen the current project.
I/O
Teach Screen
This function allows the operator to control outputs or wait for an input to be in a particular state. The I/O
for this Dispensing System is located in the Machine Specific Information section of the Operating Guide.
Operators who understand discrete I/O and its usage should only use this command.
• Function – Select “ Wait f or in put” to h old th e p rogram u ntil an i nput i s in t he d esired state. “ Set
Output” turns a discrete output on or off.
• Bit # – Location of the discrete I/O bit referenced.
• Value – The ON/OFF status desired.
• Teach – Accept the current command and add to the program.

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DMC Command
Programmed
Teach Screen
Edit Screen
This f unction allo ws t he o perator to en ter DMC co de i nto th e p rogram. Op erators who th oroughly
understand the DMC language and its usage should only use this.
• Done – Accept the current code and add to the program.

Valve Offsets
To use the offline programming feature or a poi nting device with PathMaster® the valve offsets must be
set correctl y. A valve off set i s th e dis tance bet ween a poin ting de vices a nd a v alve. A poin ting dev ice
could be another valve, a laser pointer, or a camera.
Open the Machine parameters window by selecting the Setup -> Machine Parameters option from the main
menu. Click the Valve Offsets button. The valve offsets form will display. PathMaster® must measure the
offset f or each v alve relativ e to th e p ointing d evice. T o m easure th is d istance t he o ffset wizard will s tep
through a series of instructional screens. The process will be to teach a valve at a fiducial point and then the
pointing device. This process repeats for each valve until all offsets are programmed
The process in ou r example will be for a two valve system. The first valve is called spray and the second
valve is called needle. Follow the directions on the screen.

- 53 -
Move valve one (spray) over a fiducial which both the pointing device and valve one can reach. Click the
Teach button when valve one is over the fiducial, making sure that the Z height is considered in the taught
position.
Next move the pointing device over the fiducial. Click the Teach button. The distance between the pointing
device and the fiducial has now been taught.

- 54 -
The next offset must be taught. Move valve two over the fiducial and click the Teach button.
Move the pointing device to the same location and press the Teach button.
The valve distances have now been taught.

- 55 -
The offsets have been taught. Click the Done button to save the valve offsets.
Click the Save and Close button to exit Machine Parameters.
Offline Programming (FastPath™)

Before usi ng Fa stPath™, va lve o ffsets must b e c onfigured. Fo r m ore i nformation o n configuring va lve
offsets, refer to the Valve Offsets section of this manual.
Setting Up the Image

Open a n ew prog ram. Click Edit- >Program->Background I mage. C hoose th e backg round i mage b y
clicking the Change Image button. If no image is selected the default image will be used. The default image
is a 500 mm b y 500 mm i mage with a workspace o f t he s ame s ize. T he back ground i mage must be of a
known size preferably the same size as your circuit board or entity to be dis pensed upon. Type the board
width (left to right) and the board height (top to bottom) of your board into the appropriate boxes using the
corresponding un its of measurement. Align your i mage to your workspace. T he i mage may be ali gned a
number of ways. A good re ference poi nt cou ld be t he l ower ri ght of your i mage an d t he v alve on e
coordinates for the intersection of the front rail and the board s top of your machine. Choose the reference
point type and then find the machine coordinates for the same location. Type the valve one coordinates into
the robot reference point edit boxes.
You h ave s uccessfully setup your machine to u se off line prog ramming. R epeat th ese s teps f or each path
program that will be taught using FastPath™.
Valve Selection
Valve selection selects the valve for each s uccessive path s egment for FastPath™. T he valve selection is
important because the valve offsets are taken into consideration to make the robot coat on the image where
requested. If the valve o ffsets are n ot properly setup prior to using Fa stPath™, the path program will not
run correctly. Select the appropriate valve prior to selecting a programming tool. The selected valve can be
changed while us ing any pro gramming t ool a s l ong as the n ew valve i s s elected pri or t o co mpleting t he
path segment. For ex ample: if user creates the first two coordinates of an area with valve one then selects
valve 2 and completes the third point the path segment will be created using valve two.

- 56 -
Drawing a Program
You have setup you machine and program for FastPath™ and now it is time to draw your program on your
image.
Press CNTRL+F (or click the FastPath™ icon on the programming toolbar) to open the FastPath™
window. The window opens. Press the Zoom-In and Zoom-Out buttons to get the image to a working size.
Next choose which command you would like to use to generate a path segment. Each command will be
inserted into your program above the highlighted portion of your path program. Each command will be
added to the program table in succession until another object or path segment is selected. Once another
object or path segment is selected, the insertion point for the next path segment will be above the
highlighted or selected path segment in the program table. Press CNTRL+F to close the FastPath™
window and return to the normal PathMaster® editing window.
Most PathMaster® programming tools are available when using FastPath™. Each programming tool is
used within FastPath™ similar to the way it would be used for online programming. Once a tool is
selected, instead of pointing and teaching a position on the workcell, the FastPath™ points will be taught
on the board image in the FastPath™ window using the corresponding valve.

- 57 -
Commands
NOTE: All programming tool procedures listed below are for FastPath™ only. Each path segment
taught corresponds to the valve selected in the FastPath™ toolbar.
Move
Click the Move Icon on the FastPath™ toolbar. Next click the location within the image where you would
like to move. T he move f orm i s d isplayed a s normal. M ake a ny modifications to t he move lo cation a nd
click the Done button. The Cancel button will cancel the creation of the move command.
Head
The head tool adds an appropriate pneumatics head command to the path program.
2D Line
The 2D Line tool creates a line less than or equal to 511 points. Click the 2D Line button to select the tool.
Next click all the points of the line on the image form. Each time a p oint is taught, the cursor will briefly
become a cros shair indicating that t he point was registered. W hen you are don e creati ng all points, ri ght
click the mouse to co mplete the 2D Line. T he 2 dimensional line will display on the board image with a
spray or dispense width equal to the area spacing parameter of the selected valve. The 2D line can be edited
graphically. See editing offline commands.
Arc
The Arc tool is created with two endpoints and a mid point. Click the Arc button to select the tool. Eac h
time a p oint is ta ught, the c ursor will b riefly b ecome a cro sshair indicating that t he p oint was registered.
The arc will display on the board image as a complete circle. The playback of the arc will be the number of
degrees between the points.
Circle
The Circle to ol is si milar to t he Arc to ol ex cept t hat a full circle is created with th ree p oints. Click th e
Circle b utton to selec t th e to ol. Each ti me a p oint is ta ught, the c ursor will b riefly b ecome a cro sshair
indicating that the point was registered. The circle will display on the board image. You may edit the circle
by dragging any point of the circle to a new location. This will change the radius and location of the entire
circle. Dragging the center point does nothing. It is displayed for reference.
Area
The Area tool is created using three points. Click the Area button to select the tool. C lick any three points
to generate an area co mmand. The area command will behave as normal and the brush stroke will be from
point one to point two. The area pattern will progress one brush stroke at a time in the direction from point
two to point three.
FastMask™
The FastMask™ tool is used to create a coating area followed b y keep o ut areas within the coating area.
Click t he FastMask™ bu tton t o s elect t he tool. T he f irst two poi nt taught us ing FastMask™ def ine t he
opposing corners of the coating area. After the coating area is defined, a dialog box will appear asking the
user to def ine the number of keep out areas within the coating area. A maximum of 99 keep ou t areas are
allowed. Enter the number of keep out areas and click OK. Teach the opposing corners of each successive
keep out area u ntil the total number of keep out areas h ave been defined. The FastMask™ will display on
the board image as a blue coating area with red keep outs.

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Dot
The Dot to ol creates a d ot at the specified location on the board image. Click the Dot button to select t he
tool. The default dot on and off parameters for the selected valve are used for each dot.
Editing the commands

Objects taught on the board image may be modified once created. To modify or edit an object, click on the
object to select it. O nce the object is selected, its points can be dragged to a new location. An Area object
can be resized by dragging its corners. The FastMask™ object can be resized in a similar manor. T he 2D
Line object can be modified by selecting the object. On ce the object is selected, ri ght click the object to
reveal t he edi t menu (a popup menus will appear). S elect Edi t Pat h. T he vertex poi nts of t he pat h will
appear as s quares. T hese points may be dragg ed arou nd t o ch ange t he 2D Li ne. Poi nts may be added or
deleted. Right click on a point and then left click on Delete to delete this point. Right click in between two
points an d cl ick Add Poi nt t o add a poi nt. Wh en f inished edi ting t he obj ect, cl ick back ground i mage
outside of the object to register your changes and update the object.
Password Protection
To p revent unauthorized or accidental c hanges to proj ect f iles i n P athMaster® a nd i n t he D ispensing
System, password protection can be added to the download and save functions in PathMaster®.
Download Password
To add password protection to the download function in PathMaster®, select the Setup -> Password -> Set
Download Password option from the main menu. If no password exists, you will be asked if you would
like to create one. I f a previous password exists, you must enter it correctly to continue. Nex t enter th e
new p assword, c lick OK. Then re -enter t he pas sword f or v erification an d clic k OK. T he P athMaster®
Download P roject and Download Main functions are n ow password protected. W hen either do wnload is
attempted, a password will be required to perform the download. If the password is entered incorrectly, the
download is aborted.
Save Password
To add password protection to the save function in PathMaster®, select the Setup -> Passwords -> Set Save
Password option from the main menu. If no password exists, you will be asked if you would like to create
one. If a prev ious password exists, you must enter it correctly to co ntinue. Next enter the new password,
click OK. Then re-enter the password for verification and click OK. The PathMaster® save function is now
password protected. When a Save or Save As function is attempted, a password will be required to perform
the save. If the password is entered incorrectly, the save is aborted.
Changing Password
To ch ange t he save or do wnload pas sword, repeat th e corres ponding proces s l isted abov e using t he new
password in place of the old.
Resetting Password
To reset the save or download password, repeat the corresponding process listed above, but do enter a new
password in the new or confirm password fields.

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Importing Files
The PathMaster® import function can import programs, projects, subroutines, and CAD files.
CAD Files
A 2-dimensional drawing generated in CAD can be imported into PathMaster® as a path program.
There are several steps required for a successful import. These include:
• Creation of the path drawing in CAD.
• Adding PathMaster® codes to the CAD drawing.
• Orienting the CAD drawing relative to the Dispensing System gantry.
• Exporting the CAD drawing to a *.dxf (AutoDesk Drawing Exchange Format)
• Importing the CAD drawing into PathMaster® using the CAD wizard.
Preparation of the CAD File

Below is the original drawing (Figure 1) and the required elements. (Table 5) NOTE: The CAD X+ and
CAD Y+ arrows are for reference only. These are not required.
Figure 1: Original CAD Layout
Required Element Description

BEGIN1, BEGIN2, etc. Defines the start o f th e se gment. T he v alve will t urn
ON at this point.
END1, END2, etc. Defines the end of the segment. The valve will turn OFF
at this point.
UNITS=IN. or Defines t he units u sed for c reating t he d rawing. Note:
UNITS=MM. or During the import process the path will be
UNITS=CNTS. automatically converted to the units defined in
PathMaster.
Table 5 - Required CAD File Elements
After al l necessary ele ments have been in cluded i n the dra wing it must be MIR RORED on th e Y a xis.
(Figure 2) NOTE: In AutoCAD be sure to “Delete Old Objects” when prompted”.

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Figure 2: CAD drawing Mirrored on Y axis
The drawing must be Rotated Clockwise 90 degrees (-90deg for standard AutoCAD Setup). (Figure 3)
Figure 3: CAD Drawing rotated 90deg.
The final step is to export the file to a *.dxf.

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In AutoCAD:
• Click the File->Export menu.
• When the Export Data window comes up, select Save As Type AutoCAD R12/LT2DXF.
• Under the Options button ensure that the Export Format is ASCII.
• Give the file a name and save it.
Importing the file into PathMaster

The path will be imported to a new program.
Click on File ->Import ->Program ->DXF File. Te following screen appears. (Figure 4)
Figure 4: PathMaster import screen #1
The snap to tolerance must be set properly to allow the import process to recognize the proper associations
between drawing segments in the CAD file. A minimum of 0.015” is recommended. NOTE: This does
not affect the accuracy of the path. It only allows for proper translation of the drawing entities.
Choose the method of importation (Figure 5). Paths from Begin to End will import the file as d rawn, with
proper s egment orderi ng (BEG IN1,END1, et c.) obs erved. All Entities ig nores co mmands f or order of
operations, bu t is u seful f or l arge f iles with many paths, s uch as placement of dots, where each s egment
may not be numbered.
Choose the location of the starting point. (Figure 6) This can be taught via trackball from the machine OIT
or a typed location.

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Select the file to import. (Figure 7)
After a successful import the path will be displayed in a path preview window.
The file will be imported as individual paths. (Line, Arc, etc.) The paths are ready for playback or may be
converted to a polyline.

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PathMaster® 1.5 & Pre 1.5 Projects
To import a Pat hMaster® 1.5 or p re 1.5 project, select the File -> Import -> Project -> PathMaster 1.5 or
Pre PathMaster 1.5 option from the main menu. When the file dialog box opens, select the location and the
file name of the project to import. Click Open.
NOTE: You may need to change the file filter (type) to *.txt, or *.dmc to see the project file in the dialog
box.
Text File
A properly format tab delimited text file can be i mported into PathMaster® as a pat h program. Select the
File -> Import -> Program -> Text File option from the main menu. When the file dialog box opens, select
the location and the file name of the project to import. Cli ck Open. A text file program is t ypically a file
that was exported as a text file from PathMaster®
NOTE: You may need to change the file fitler (type) to *.txt to see the project file in the dialog box.
DMC File
A p roperly f ormat DMC file can b e im ported in to P athMaster® as a p ath p rogram. Select th e File - >
Import -> Program -> DMC File option from the main menu. W hen the file dialog box open s, select the
location and the file name of the project to import. Click Open.
NOTE: You may need to change the file filter (type) to *.dmc to see the project file in the dialog box.
Subroutine
A properl y formated subroutine ca n be i mported i nto Pat hMaster® us ing t he i mport su broutine opt ion.
Select the File -> Import -> Subrotuine -> Text File option from the main PathMaster® menu or the File ->
Import s ubroutine opt ion from t he subroutine edi t window menu. S elect t he l ocation an d n ame o f t he
subroutine and click the Open button.
NOTE: You may need to change the file filter (type) to *.txt to see the project file in the dialog box.
Once the import is complete, the subroutine edit window will be open.
Exporting Files
The PathMaster® export function can export programs, projects and subroutines.
Text File
To export a p rogram to a tab delimited text file, select the File -> Export -> Program -> Text File o ption
from the main menu. W hen the dialog box appears, select a location and file name for the program, and
click Save.
DMC File
To export a project to a DMC or DMC compressed file, select the File -> Export -> Project - > DMC File
or C ompressed DMC File from t he main menu. W hen t he dialog box appears , s elect a location an d file
name for the program, and click Save.

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Subroutine
To export a P athMaster® subroutine to a tab delimited text file, select the File -> Export -> Subroutine ->
Text File o ption f rom t he main P athMaster® menu o r th e File - > Ex port Su broutine option f rom th e
subroutine edit window menu. Select the location and name of the subroutine and click the Save button.
Utilities
PathMaster® has a variety o f utilitie s to h elp with debugg ing, t he Di spensing S ystem, as well as pat h
programs. These utilities can be found under the Utilities menu.
View FastPath
To open the FastPath™ window for offline programming, select the Utilities -> View FastPath option from
the main menu.
NOTE: The FastPath™ window can also be accessed using the FastPath™ button on the programming
toolbar.
Measure Distance
The dis tance measurement t ool is u sed to m easure th e dis tance bet ween t wo poin t u sing cu rrent
measurement units. To open the tool, click the Utilities -> Measure Distance option from the main menu.
To measure distance, move the head to th e first point, click Teach Point 1. Move the head to th e second
point, c lick Teach Point 2. Click th e Calculate Distance bu tton. T he dis tance will be calcu lated and
display.
Machine Debugger
The machine debugger is an array of tools to aid in the debugging of the Dispensing System. To access one
of th e debu gging tools , s elect Utilities -> Mach ine Debugg er f rom th e main menu. W hen t he machine
debugger opens, select the tab for the tool to be used.

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Terminal
The term inal lets t he operator s end com mands directl y t o th e con troller. To s end a com mand to th e
controller, ensure the keyboard caps lock is on, type the co mmand in the ter minal window, and press the
Enter key. A response from the controller will display under the command that was issued. If the controller
does not understand what it received, it will respond with a “?”.
Some guidelines for working directly with the controller are listed below. Fo r more information on using
the terminal or working directly with controller, consult the online controller manual.
DMC Programming Basics

• All commands must be given in uppercase letters.
• Positions are given in counts. In most cases there are 5080 counts per inch, 200 counts per millimeter.
• No line of code may contain more than 80 characters.
• A semicolon (;) is used as a carriage return. This allows for multiple commands on the same line and
can be used to save space in the program.
Labels
Sections of a program (subroutines) are defined by labels. Labels start with the pound (#) sign followed by
a maximum o f se ven c haracters. The f irst ch aracter must b e a letter; af ter th at, n umbers are p ermitted.
Spaces are n ever per mitted. P athMaster® g enerates i ts ow n l abels for prog rams. T hese l abels do n ot
appear in the edit window, so the operator cannot alter them.
No du plicate labels are allo wed any where in memory. T he Main prog ram a nd Pat hMaster® are written
without an y d uplicate lab els. Ho wever, it may b e n ecessary for th e o perator to in sert sp ecial lab els in to
programs. If any duplicate labels occur anywhere within a PathMaster® project, the operator must find the
duplication a nd f ix it. T hese errors m ost co mmonly occu r when a section o f code h as been copied an d
pasted elsewhere. T here can be no duplicates anywhere within a project, which includes all 3 0 programs
in that project.

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Labels must appear at t he start of a li ne. An operator m anually entering code must ensure that no labels
exist in the middle of a line. This generates an error when running the program.
Important Commands
The DMC programming language contains over 135 commands. For programming the Dispensing System
the majority of t hese co mmands are n ot u sed an d ev en f ewer are u sed f or creating dis pense path s. T he
following co mmands are th e m ost i mportant for an adv anced operator to k now. A complete li st of
commands can be found in the separate DMC-1500 manual that accompanied the machine. Any reference
to manually ch anging o r q uerying i n the ex amples b elow req uires t he use o f th e te rminal o ption i n
PathMaster® to communicate directly with the controller.
Table 6 – Important DMC Commands
Cmd Description E xample Tips

AC Acceleration for AC*=100000 (sets all Make sure the value of the
independent moves are in axes), ACX=100000 (only acceleration is high enough to get the
counts per second². sets the X axis motion to speed within a reasonable
acceleration) amount of time.
AM After move. This command AM (wait for all axes to finish The AM command tests for profile
holds the program until the its motion), AMS (wait for completion. Use the AM command
movement on the specified coordinate sequence to finish to separate multiple movements.
axes is completed. motion).
AV After vector distance. This AV1000 (wait until the axes The AV command resets to zero
command holds the program have moved 1000 counts). after every use. It can be calculated
until a specified distance has by summing the distances between
been traveled during a each point on the coordinated move.
coordinated move. The units
are in counts.
BG Begin. BG starts a motion on BGX (begin motion on the X A second BG command cannot be
an axis or a sequence. axis), BGS (begin motion given until the first BG motion is
sequence), BG (begin motion finished. The AM command can be
on all axes). used to hold the program until the
first motion is complete. It is best to
specify the exact axes to put into
motion. The BG command by itself
starts ALL the axes according to the
last specified motions.
BL Reverse Software Limit
CB Clear bit. Clears a bit on the CB40 (clears the bit for the Clearing a bit in DMC terminology
output port. buzzer). turns the bit on. The opposite of CB
is SB (set bit). A complete list of the
outputs can be found in the Machine
Specific Information section of the
Operating Guide.
CR Circle. Specifies a radius, a CR 5000,90,180 (arc with The circle command is a coordinated
starting angle and the angle to length of 5000 counts, starting two dimensional move. The structure
be traversed. Movement is at 90° and doing a half circle is the same as all other coordinated
counterclockwise, by default, (180°)). moves, using the VM, VP and VE
in the Cartesian coordinate commands (see Examples of
system. This is either Dispense Programs on page 44).A
clockwise or start angle of 0° produces a circle,
counterclockwise, as viewed relative to the start point, entirely
from the front of the machine, negative in the X direction and half
depending upon the positive, half negative in the Y.
mechanical setup of the Starting at 180° yields an entirely

- 67 -
machine. Specifying a positive X circle and a half positive,
negative traverse angle yields half negative Y. Similarly, 90° is an
clockwise motion in the entirely negative Y circle, 180°
Cartesian coordinate system. entirely positive Y, with both having
X half positive, half negative.
CS Clear Sequence Clears Memory of prior coordinated sequences.
DC Deceleration for independent DC*=100000 (sets all axes), The higher the deceleration, the
moves. The units are in counts DCX=100000 (only sets the X axis faster an axis stops its move.
per second². deceleration), DC
10000,30000,40000 (sets X, Y and
Z Decelerations separately).
DE Dual (Auxiliary) Encoder Position
DL Download. This transfers a text DL (then select a text file to Use the HX (halt execution)
file from the computer to the download). command before using DL.
controller. Damage may result otherwise.
EN End. This terminates a subroutine, EN The Dispensing System also
program thread or program. has a subroutine used for a
conditional end.The command
JP#NOOP operates the same as
the EN command.
FL Fo rward Software Limit
HX Halt execution. Halts the execution HX1 (halt thread 1), HX (halt Always use the HX command
of the program or any of its the entire program). before executing a DL
threads. command.
JG Jog
JP Jump to a program location. JP#NOOP (jump to location It is important not to confuse
Locations are marked by labels. #NOOP), JP with JS. Using a JP when a
This command can be used in a JP#NOOP,COUNT>10 (jump JS is required results in the
conditional statement and the jump to location #NOOP if the value thread being halted once the
occurs if the conditional is true. of COUNT exceeds 10). EN command is reached.
JS Jump to subroutine. Subroutines JS#H1UP (jump to subroutine It is important not to confuse
are marked by labels. #H1UP). JS with JP. Using a JS when a
JP is required can result in
“nesting” the program
continuously until a nesting
error occurs. Subroutines can
only be nested 16 deep.
LI Linear Interpolation Distance
LM Linear Interpolation Mode
LS List. The operator can list a single LS 300,0 (show line 300), LS If a runtime error occurs, use
line or multiple lines of the 250,270 (show lines 250 to the LS command in the
program in a terminal screen. 270), LS (show all lines in terminal screen to check the
memory). line containing the error.
MG Message. This command sends MG “Path Complete” (displays Do not put message commands
data out the bus. It can also be the message “Path Complete” in programs! If there are
used by the operator to query the on the terminal screen), message commands, and there
controller for information. MG@IN[60] (displays the is no computer attached to the
value of input 60, where 0 is on Dispensing System, the
and 1 is off). controller halts once the output

- 68 -
buffer is full.
MO Motor off. Shuts off motor control. MO (turn all motors off), MOX MO shuts off the motor(s).The
(turn off only the X axis motors are reactivated with the
motor). SH (servo here) command.
MR Reverse Motion to Position
MT Motor Type
NO No operation. This command NO!!! PROGRAM 1!!!! A semicolon (;) terminates the
performs no action and is used to (description for program). NO command. Any statements
comment a program. following a semicolon are
executed.
PA Position absolute. This sets the PA 10000,10000,1000 It is best to limit the use of the
destination of a move, referenced (commanded position for X, Y PA command to designating
to the origin. The units are in and Z axes), PAX=10000 the start of a dispense path.
counts. (commanded position of X Overuse of the PA command
axis). complicates program editing.
PF P osition Format
PR Position relative. This sets the PR 10000,10000,1000 Be careful not to confuse PA
incremental position of the next (commanded change in with PR. The PR command
move, referenced to the current position for X, Y and Z axes), begins its move from the
position. The units are in counts. PRX=10000 (commanded current position, without
change in position of X axis). reference to the origin.
RS Reset. Resets the controller to its RS If PathMaster™ fails to
power on state. All the information download a file properly, the
in the controller’s RAM is erased. program may be halted in the
controller. Executing an RS
command from the terminal
screen restarts the program.
SB Set bit. Sets a bit on the output SB40 (sets the bit for the Setting a bit in DMC
port. buzzer). terminology turns the bit off.
The opposite of SB is CB
(clear bit).A complete list of
the outputs can be found in the
Machine Specific Information
section of the Operating Guide.
SC S top Code
SH Servo here. The controller uses the SH (activate all motors), SHZ The opposite of SH is MO
current position as the command (activate only the Z motor). (motor off).SH resets all
position and enables motor position errors to zero.
control.
SP Speed. Sets the speed for SP*=100000 (sets all axes), Make sure the value of the
independent moves. Units are in SPX=100000 (only sets the X acceleration is high enough to
counts per second. axis speed), SP get the motion to speed within
10000,30000,40000 (sets X, Y a reasonable amount of time.
and Z speeds separately).
ST Stop. Halts motion on the STX (stop motion on the X Use the AM command after the
specified axes. If no axes are axis), ST (stop all motion and ST command to wait for
specified, it halts program halt the program). motion to be stopped.
execution.
TB

- 69 -
TC Tell error code. Displays the TC1
number and a text description for a
command error.
TD Tell Dual Encoder
TE Tell error. This returns the current TE Use this command in the
position error of the motors. Units terminal screen if a motor
are in counts. appears to be working
incorrectly. The Dispensing
System is programmed to
disregard errors of less than
1000 counts.
TP Tell Position. Returns the current TP (All axes). TPX (X axis Use in the terminal screen to
position of the motors. only). verify the current location of
the motors. In addition, the
Manual/Jog/Teach mode of the
Dispensing System has a push
button that accomplishes the
same task.
VA Acceleration for coordinated VA 100000. Make sure the value of the
moves. The units are in counts per acceleration is high enough to
second². get the motion to speed within
a reasonable amount of time.
VD Deceleration for coordinated VA 100000. Make sure the value of the
moves. The units are in counts per acceleration is high enough to
second². get the motion to speed within
VE Vector Sequence End
VP Vecto r Position
VS Vector Speed. Sets the speed for VS 100000. Query the Make sure the value of the
coordinated moves. Units are in controller with the command acceleration is high enough to
counts per second. MG_VS. get the motion to speed within
WT Wait. Holds program execution for WT500 Use the WT command
specified time. whenever the program needs to
pause, particularly if another
action needs time for
completion.

- 70 -
Digital I/O
The digital I/O to ol allows for toggling of most digital IO points on the controller. Find the button for the
I/O point you wish to toggle, and click it. T he button will change colors when the I/O point changes state.
The refresh interval is the frequency of the tool display refresh in milliseconds.
Analog Input
The analog input tool will monitor the value of analog input feedback. The refresh interval is the frequency
of the tool display refresh in milliseconds.

- 71 -
Resources
The resources tool allows monitoring of controller resources such as available program labels, and program
variables. T he t ype of res ources di splayed on t his form will v ary depen ding on t he model o f con troller
being used.
Variable Watch
The variable watch tool will monitor a list of program variables entered by the user. Type a valid program
variable n ame i nto th e watch list o n t he lef t, clic k Start Watch and th e v alue o f th e v ariable will b e
displayed o n th e ri ght. Mu ltiple v ariables can b e monitored si multaneously. T he ref resh in terval i s th e
frequency of the tool display refresh in milliseconds.

- 72 -
Refresh Communication
If P athMaster® lo oses co mmunication with th e Disp ensing S ystem, select th e Uti lities - > Refresh
Communications option f rom th e main menu. If com munication i s n ot rees tablished, ch eck cables a nd
communication setting.
Jog Toolbar
The jog tools bar can be used to jog the X or Y axis a specified distance. Select the Utilites -> Jog Toolbar
option from the main menu. Enter the distance to jog, and click the button indicating the axis and direction
to move.
NOTE: The jog toolbar also has a TracPad™ that can be activated to
jog the head. Refer to the TracMouse™ section of this manual for more
information on using the TracPad™.
Path Preview
The path preview will give a graphic representation of t he path program or s egments. Highlight all path
segments to be displayed in the preview. Se lect the Utilites -> Path Preview option from the main menu.
The path preview window will display:
Right click the path preview window to reveal a zoom, pan, rotate, coordinate info menu. C lick the Reset
button to return the preview to its default display.
Show Code
The sh ow co de o ption will d isplay t he co mpiled machine code f or th e selec ted seg ments. Hi ghlight t he
path segments; select the Utilities -> Show Code option from the main menu. A form will open displaying
the machine code fro the selected segments. The code can be saved to a text file, or printed to a hard copy.

- 73 -
DMC Error Codes
# Description
1 Un recognized command
4 Operan d error
5 Input buffer full
9 Variable error
15 EEPROM checkwrite error
16 IP incorrect sign during position move or IP given during forced deceleration
25 Variable not given in IN command
50 N ot enough fields
53 Error in {}
55 Missing [ or [ ]
58 Unrecognized command in a command response (i.e._GNX)
59 Mis matched parentheses

- 74 -
# Description
62 Too many labels
66 A rray space full
82 U ndefined array

- 75 -
Cut Sheets
Configuration
PathMaster® Manual
4 Cut Sheets
Schematics
Software
Cut Sheets
Included on this cd are technical data sheets for componants installed on the
Workcell. To view these documents click the button below.
Select Cut Sheet

Schematics
Configuration
PathMaster® Manual
Cut Sheets
5 Schematics
Software
Schematics
Included on this cd is a set of schematics for this unit. To view these schematics
online, click the button below.
NOTE: Before you can view the schematics, you must have an AutoCAD ® compatible
viewer installed. The AutoCAD ® viewer, Volo™ View Express, is provided on this cd.
Select Schematic
Software
Configuration
PathMaster® Manual
Cut Sheets
Schematics
6 Software
Software
CD ROM
• One (1) CD ROM is included with this manual. It contains the PathMaster®
software used to program the Dispensing System via A windows interface.
To “Install PathMaster®” NOTE: If you have previously installed PathMaster®,
be sure to uninstall the old version before installing the new version.
• This CD also includes a few helpful tutorials explaining some of the most often
used functions of the PathMaster® software.
Note: Your PathMaster® CD comes equipped with the ability to produce floppy disks.
On this CD you will find a director y labeled “144 MB”. Simply copy the files from each
disk directory to individual floppies for a complete set of installation floppy disks.
Program (s)
• On this CD you will f ind a directory labeled Software it c ontains a backup copy
of the main program xxxx_m01.txt, where xxxx is the serial number of the machine
and m01 is the main prog ram revision. The mach ine was shipped from Precision
Valve & Automation, Inc. with the original copy of this main program resident in
memory. In certain situations, a PathMaster® project backup file xxxx_P01.bck
may also be included o n the folde r, whe re xxxx is the se rial number of the
machine and p01 is the project file revision.
To prevent unitentional alteration of the files, the disk has been write-protected.

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Using The Electronic Manual

Opening the Manual

• The electronic manual was started using the ‘Startupmenu.exe’ file.

Copyright© 1997-2004 Precision Valve & Automation, Inc.

All Rights Reserved.

Warnings, Cautions, and Notes

Always wear-approved safety glasses when operating or working

In situations where inattention could cause either personal injury

Do not smoke near the workcell. Always have a fire extinguisher

Before operating the system, read and understand the manuals

Before performing any repairs or maintenance to the system, turn

Never place hands or tools in areas designated by this symbol

Before performing any repairs or maintenance to the system, read

Exercise caution when pressurized vessels are present. Identify

Pinch hazard from moving parts. Avoid contact.

Shear hazard from moving parts. Avoid contact.

Hot surface. Avoid contact.

Do not remove protective guarding.

Copyright © 2008 Precision Valve & Automation, Inc.

Main Office PVA

Tel (518) 371-2684

Fax (518) 371-2688

Technical Support Tel (518) 371-2684

Operation and Maintenance Manual Rev A 9/07

o First Edition for 650 Flip Top Workcell

Operation and Maintenance Manual Rev A 9/07

Introduction: Provides an overview of the workcell functionality and physical characteristics.

Troubleshooting: Provides a guide to troubleshooting the workcell. A fault diagnosis table is

Maintenance: Provides a preventive maintenance schedule and replacement procedures.

Appendix A – Definitions: Definitions for commonly used terms.

Appendix B – Serial Communication: A brief overview of establishing communication with the

Operation and Maintenance Manual Rev A 9/07

Contents ........................................................................................................................................ vii

Installation and Setup................................................................................................................ 15

Operation and Maintenance Manual Rev A 9/07

Operating Safety ......................................................................................................................... 21

Operation and Maintenance Manual Rev A 9/07

Appendix A – Definitions ........................................................................................................... 63

Appendix B – Serial Communication ....................................................................................... 65

Operation and Maintenance Manual Rev A 9/07

Appendix C – Error Codes .......................................................................................................... 67

Appendix D – Wiring Schematic Legend ................................................................................. 69

Figure 1 – workcell Functional Block Diagram .......................................................................... 11

Operation and Maintenance Manual Rev A 9/07

NOTE: Not all m odels are equipped w ith lex an guarding.

Figure 1 – workcell Functional Block Diagram

Operation and Maintenance Manual Rev A 9/07

• Do not wear loose clothes or jewelry while operating the system

• Do not touch the dispense head while is moving

• Immediately press Emergency Stop if personnel is in danger

Year 2000 Compliance

• Using incompatibles tools

• Removing doors interlocks or bypassing safety devices

• Making custom mechanics or fluid delivery modifications

• Change material from original design

• Unexpected head movement

Operation and Maintenance Manual Rev A 9/07

Emergency Stop Recovery

• Close the doors and pull the stop button out