Ransburg A10159 User Manual

ADAPTADAPT

ARCHIVE

ADAPT

ADAPTADAPT

AFLOWAFLOW

AFLOW

AFLOWAFLOW

SERVICE MANUAL

TMTM

TM

TMTM

NODE ADAPTER NODE ADAPTER

NODE ADAPTER

NODE ADAPTER NODE ADAPTER

LN-9217-00.2LN-9217-00.2

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MODEL:MODEL:

MODEL:

MODEL:MODEL:

A10159A10159

A10159

A10159A10159

IMPORIMPOR

IMPOR

IMPORIMPOR
carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions instarting on page 1, and all instructions in

starting on page 1, and all instructions in

starting on page 1, and all instructions instarting on page 1, and all instructions in
this manual. Keep this Service Bulletin forthis manual. Keep this Service Bulletin for

this manual. Keep this Service Bulletin for

this manual. Keep this Service Bulletin forthis manual. Keep this Service Bulletin for
future reference.future reference.

future reference.

future reference.future reference.

TT

ANTANT

T

ANT

TT

ANTANT

: Before using this equipment,: Before using this equipment,

: Before using this equipment,

: Before using this equipment,: Before using this equipment,

Service Manual Price: $ 20.00 (U.S.)Service Manual Price: $ 20.00 (U.S.)

Service Manual Price: $ 20.00 (U.S.)

Service Manual Price: $ 20.00 (U.S.)Service Manual Price: $ 20.00 (U.S.)

NOTE:NOTE:

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NOTE: This manual has been changed from revision

NOTE:NOTE:
Reasons for this change are noted under “Manual Change Summary” inside the back cover of this
manual.

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LN-9217-00.1 to revision

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LN-9217-00.2. LN-9217-00.2.

LN-9217-00.2.

LN-9217-00.2. LN-9217-00.2.

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CONTENTSCONTENTS

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CONTENTS

CONTENTSCONTENTS

SAFETY:SAFETY:

SAFETY:

SAFETY:SAFETY:

AdaptaFlow Node Adapter - Contents

PAGEPAGE

PAGE

PAGEPAGE

1-41-4

1-4

1-41-4

SAFETY PRECAUTIONS...........................................................................................................

HAZARDS/SAFEGUARDS........................................................................................................

INTRODUCTION:INTRODUCTION:

INTRODUCTION:

INTRODUCTION:INTRODUCTION:

GENERAL DESCRIPTION.........................................................................................................

SPECIFICATIONS......................................................................................................................

ADAPTAFLOW SYSTEM RACK................................................................................................

INSTALLATION:INSTALLATION:

INSTALLATION:

INSTALLATION:INSTALLATION:

NODE ADAPTER SETUP..........................................................................................................

NODE ADAPTER SWITCH SETTINGS....................................................................................

NODE ADAPTER.......................................................................................................................

NODE ADAPTER INTERFACE SETUP....................................................................................

CARD RACK MOTHER BOARD...............................................................................................

NODE ADAPTER INTERFACE.................................................................................................

OPERATION:OPERATION:

OPERATION:

OPERATION:OPERATION:

DISCRETE I/O............................................................................................................................

INPUT WORD 1 & 2 / OUTPUT WORD 1 & 2...........................................................................

BLOCK TRANSFER I/O.............................................................................................................

1
2-4

5-65-6

5-6

5-65-6
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7-107-10

7-10

7-107-10
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7
8
9
9
10

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11-21

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12
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MAINTENANCE:MAINTENANCE:

MAINTENANCE:

MAINTENANCE:MAINTENANCE:

TROUBLESHOOTING GUIDE..................................................................................................

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PARTS IDENTIFICATION:

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PART NUMBERS........................................................................................................................

WARRANTY POLICIES:WARRANTY POLICIES:

WARRANTY POLICIES:

WARRANTY POLICIES:WARRANTY POLICIES:

LIMITED WARRANTY................................................................................................................

2222

22

2222
22

2323

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2323
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AdaptaFlow Node Adapter - Safety

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SAFETYSAFETY

SAFETY

SAFETYSAFETY

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

!!

!

!!

Before operating, maintaining or servicing any
ITW Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your ITW Ransburg products. This
manual contains information that is important for
you to know and understand. This information
relates to USER SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help you recognize
this information, we use the following symbols.
Please pay particular attention to these sections.

A WARNING! states information to alert youA WARNING! states information to alert you

A WARNING! states information to alert you

A WARNING! states information to alert youA WARNING! states information to alert you
to a situation that might cause serious injuryto a situation that might cause serious injury

to a situation that might cause serious injury

to a situation that might cause serious injuryto a situation that might cause serious injury
if instructions are not followed.if instructions are not followed.

if instructions are not followed.

if instructions are not followed.if instructions are not followed.
A CAUTION! states information that tellsA CAUTION! states information that tells

A CAUTION! states information that tells

A CAUTION! states information that tellsA CAUTION! states information that tells
how to prevent damage to equipment or howhow to prevent damage to equipment or how

how to prevent damage to equipment or how

how to prevent damage to equipment or howhow to prevent damage to equipment or how
to avoid a situation that might cause minorto avoid a situation that might cause minor

to avoid a situation that might cause minor

to avoid a situation that might cause minorto avoid a situation that might cause minor
injury.injury.

injury.

injury.injury.
A NOTE is information relevant to theA NOTE is information relevant to the

A NOTE is information relevant to the

A NOTE is information relevant to theA NOTE is information relevant to the
procedure in progress.procedure in progress.

procedure in progress.

procedure in progress.procedure in progress.
While this manual lists standard specifications

and service procedures, some minor deviations
may be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this
manual with your system installation drawings
and appropriate ITW Ransburg equipment
manuals to reconcile such differences.

> The user

with the Safety Section in this manual and
the ITW Ransburg safety literature therein
identified.

> This manual

oughly understood by
operate, clean or maintain this equipment!
Special care should be taken to ensure
that the
ments for operating and servicing the
equipment are followed. The user should
be aware of and adhere to
building and fire codes and ordinances as
well as
operating, and/or servicing this equip­ment.

> The hazards shown on the following

page may occur during the normal use of
this equipment. Please read the hazard
chart beginning on page 2.

MUSTMUST

MUST read and be familiar

MUSTMUST

MUSTMUST

MUST be read and thor-

MUSTMUST

ALLALL

ALL personnel who

ALLALL

WARNINGSWARNINGS

WARNINGS and safety require-

WARNINGSWARNINGS

ALLALL

ALL local

ALLALL

NFPA-33, NFPA-33,

NFPA-33, prior to installing,

NFPA-33, NFPA-33,

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

!!

!

!!

Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efficient operation,
longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system,
contact your local ITW Ransburg representative
or ITW Ransburg.

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AdaptaFlow Node Adapter - Safety

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AREAAREA

AREA

AREAAREA

Tells where hazards
may occur.

Spray AreaSpray Area

Spray Area

Spray AreaSpray Area

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

Fire Hazard
Improper or inadequate opera-

tioning and maintenance pro­cedures will cause a fire hazard.

Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any safety
interlocks are disabled during
operation. Frequent power supply
shutdown indicates a problem in
the system requiring correction.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Fire extinguishing equipment must be present in the
spray area and tested periodically.

Spray areas must be kept clean to prevent the
accumulation of combustible residues.

Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be

turned off prior to cleaning, flushing or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash

points equal to or higher than those of the coating
material.

Those used for general cleaning must have flash
points above 100°F (37.8°C).

Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, and local codes. In
addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.

Electrostatic arcing must be prevented.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only as

instructed.
Non-factory replacement parts or unauthorized

equipment modifications may cause fire or injury.
If used, the key switch bypass is intended for use

only during set-up operations. Production should
never be done with safety interlocks disabled.

Never use equipment intended for use in waterborne
installations to spray solvent based materials.

The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC, and
OSHA requirements.

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AdaptaFlow Node Adapter - Safety

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AREAAREA

AREA

AREAAREA

Tells where hazards
may occur.

General Use andGeneral Use and

General Use and

General Use andGeneral Use and

MaintenanceMaintenance

Maintenance

MaintenanceMaintenance

ElectricalElectrical

Electrical

ElectricalElectrical
EquipmentEquipment

Equipment

EquipmentEquipment

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

Improper operation or maintenance
may create a hazard.

Personnel must be properly trained
in the use of this equipment.

High voltage equipment is utilized.
Arcing in areas of flammable or
combustible materials may occur.
Personnel are exposed to high
voltage during operation and
maintenance.

Protection against inadvertent
arcing that may cause a fire or
explosion is lost if safety circuits
are disabled during operation.

Frequent power supply shut-down
indicates a problem in the system
which requires correction.

An electrical arc can ignite coating
materials and cause a fire or
explosion.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Personnel must be given training in accordance with
the requirements of NFPA-33.

Instructions and safety precautions must be read and
understood prior to using this equipment.

Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. OSHA references
are Sections 1910.94 and 1910.107. Also refer to
NFPA-33 and your insurance company requirements.

The power supply, optional remote control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas. Refer to NFPA-33.

Turn the power supply OFF before working on the
equipment.

Test only in areas free of flammable or combustible
material.

Testing may require high voltage to be on, but only as
instructed.

Production should never be done with the safety
circuits disabled.

Before turning the high voltage on, make sure no
objects are within the sparking distance.

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AdaptaFlow Node Adapter - Safety

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AREAAREA

AREA

AREAAREA

Tells where hazards
may occur.

Spray Area /Spray Area /

Spray Area /

Spray Area /Spray Area /
High VoltageHigh Voltage

High Voltage

High VoltageHigh Voltage
EquipmentEquipment

Equipment

EquipmentEquipment

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

This is a high voltage ungrounded
device that can produce electrical
arcs capable of igniting coating
materials.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Parts being sprayed must be supported on conveyors
or hangers and be grounded. The resistance between
the part and ground must not exceed 1 megohm.
(Reference NFPA-33)

A safe distance must be maintained between the
parts being coated and the atomizer bell. A distance
of at least 1 inch for each 10 kV of power supply output
voltage is required at all times.

Parts must be supported so that they will not swing
and reduce the clearance specified above.

All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.

Unless specifically approved for use in hazardous
locations, the power supply and other electrical
equipment must not be used in Class I, Division 1 or
2 locations.

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AdaptaFlow Node Adapter - Introduction

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INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

GENERAL DESCRIPTIONGENERAL DESCRIPTION

GENERAL DESCRIPTION

GENERAL DESCRIPTIONGENERAL DESCRIPTION

This manual covers the operation and use of the
AdaptaFlowTM 5000 Node Adapter and is meant to
complement the AdaptaFlow 5000 Fluid Flow
Monitoring and Control Manual.

The AdaptaFlow Node Adapter Module allows for
direct communication from an Allen-Bradley PLC
Remote Input/Output(RIO) port to the AdaptaFlow
5000 Fluid Flow Control system. Up to four
channels of control per half of a standard 19" rack
can be controlled with one Node Adapter Module.
The Node Adapter accepts standard data transfers
from PLC remote I/O and converts the information
to the proper AdaptaFlow protocol for each of the
possible four Channel Cards.

The Node Adapter Module is divided into three
functional blocks: (1)
processorprocessor

processor, and (3)

processorprocessor

RIO interfaceRIO interface

RIO interface, (2)

RIO interfaceRIO interface

parallel IO busparallel IO bus

parallel IO bus.

parallel IO busparallel IO bus

centralcentral

central

centralcentral

Programmable Read-Only Memory (EPROM).
The Node Adapter Module communicates to each
AdaptaFlow Channel Card through a digital
IO busIO bus

IO bus located on the Card Rack Bus Board.

IO busIO bus
There are two LED indicators located on the front

panel of the Node Adapter Module:

CPUCPU

1.

CPU - Is on when the microprocessor is

CPUCPU
operating normally.
ACTIVEACTIVE

2.

ACTIVE - Is on when communication is

ACTIVEACTIVE
taking place.

The Node Adapter Interface Module is used as a
hardware interface from the PLC remote I/O cable
to the AdaptaFlow card rack. This board is always
required when using the Node Adapter Card. It is
plugged into J6 located on the card rack Bus
Board.

parallelparallel

parallel

parallelparallel

RIO interfaceRIO interface

The

RIO interface contains some Allen-Bradley

RIO interfaceRIO interface
components which are licensed to ITW Ransburg.
These are designed specifically to communicate
with the proprietary protocol of the RIO serial link.
The central component of this block is an application
specific IC (ASIC) which is capable of formatting
the RIO information for use by the central
processor(CPU). The actual termination of the
RIO cable is made to the Node Adapter Interface
Board which is connected to the Card Rack Bus
Board.

The core of the
microprocessor which communicates with the
Allen-Bradley ASIC. The 8032 provides an RS­422 port from which diagnostic functions are
accomplished via internal “debugger” software.
The main software program, which includes the
“debugger” functions, is contained in an Erasable

central processorcentral processor

central processor is an 8032

central processorcentral processor

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AdaptaFlow Node Adapter - Introduction

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SPECIFICASPECIFICA

SPECIFICA

SPECIFICASPECIFICA

Environmental / PhysicalEnvironmental / Physical

Environmental / Physical

Environmental / PhysicalEnvironmental / Physical

Temp. Operating:Temp. Operating:

Temp. Operating: 0° to 55°C

Temp. Operating:Temp. Operating:
Storage: Storage:

Storage: -40°C to 85°C

Storage: Storage:
Humidity:Humidity:

Humidity: 95% Non-Condensing

Humidity:Humidity:
Size:Size:

Size: 100 x 160mm

Size:Size:

ConnectionsConnections

Connections

ConnectionsConnections

PLC I/O:PLC I/O:

PLC I/O: 3 position pluggable

PLC I/O:PLC I/O:

Module I/O:Module I/O:

Module I/O: 96-pin DIN 41612

Module I/O:Module I/O:

Diagnostic:Diagnostic:

Diagnostic: 10-pin flat cable connect-

Diagnostic:Diagnostic:

TIONSTIONS

TIONS

TIONSTIONS

Eurocard module,
25mm wide

terminal strip located on
the Node Adapter Interface
Board

connector

or located on the Node
Adapter Interface Board

ElectricalElectrical

Electrical

ElectricalElectrical

Power Required:Power Required:

Power Required: 24 VDC at 80 mA

Power Required:Power Required:
SIGNAL LEVELSSIGNAL LEVELS

SIGNAL LEVELS

SIGNAL LEVELSSIGNAL LEVELS
PLC I/OPLC I/O

PLC I/O

PLC I/OPLC I/O

Diagnostic:Diagnostic:

Diagnostic: RS-422 port, manual

Diagnostic:Diagnostic:

::

: Compatible with

::

Allen-Bradley RIO

input/output capability,
may be used as main
communication port

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Figure 1: AdaptaFlow System RackFigure 1: AdaptaFlow System Rack

Figure 1: AdaptaFlow System Rack

Figure 1: AdaptaFlow System RackFigure 1: AdaptaFlow System Rack

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