Ransburg DynaFlow User Manual

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SERVICE MANUAL

LN-9400-00.9

(Replaced LN-9400-00.8) December 2012

DYNAFLOW

USER MANUAL

MODEL: 77376 and A12233

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting on page 1, and all instructions in this manual. Keep this Service Manual for future reference.

Service Manual Price: $50.00 (U.S.)

NOTE: This manual has been changed from revision LN-9400-00.8 to revision LN-9400-00.9

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

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DynaFlowTM User Manual - Contents

SAFETY:

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

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

PAGE

1-5

1 2-5

INTRODUCTION:

FEATURES........................................................................................................................

DESCRIPTION.................................................................................................................

BLOCK DIAGRAM.............................................................................................................

DYNAFLOW SPECIFICATIONS...................................................................................

INSTALLATION:

SYSTEM GUIDELINES, EQUIPMENT GROUNDING, LOCATIONS, MOUNTING.............

BLOCK DIAGRAM FOR A SINGLE-COMPONENT GUN................................................

BLOCK DIAGRAM FOR A TWO-COMPONENT GUN.............................................................

BLOCK DIAGRAM FOR A THREE-COMPONENT GUN.........................................................

INPUT POWER.............................................................................................................

INTERFACING TO THE FLOW CONTROLLER........................................................

MOTHER BOARD TERMINALS, HARDWARECONFIGURATION, TRANSDUCERS.........

OPERATION:

OVERVIEW.....................................................................................................................

PARAMETER DESCRIPTIONS.........................................................................................

AUTOMATIC GUN APPLICATIONS.................................................................................

MANUAL HAND GUN APPLICATIONS.............................................................................

GENERAL........................................................................................................................

JOB SELECT TIMING DIAGRAM..................................................................................

JOB SELECT TIMING DIAGRAM SAMPLE, JOB QUEUE, REVERSE FLOW.................

PROCEDURES, FIRST TIME STARTUP, NORMAL STARTUP..........................

PID CONTROL........................................................................................................

6-13

6 6-9 10 11-13

14-27

14-15 16 17 18 19 20-23 24-26

28-61

28-29 30-43 44-45 45-46 46-47 48-49 50-54 54-56 56-61

MAINTENANCE:

TROUBLESHOOTING......................................................................................................

SYSTEM PREVENTIVE MAINTENANCE INSTRUCTIONS............................................

SYSTEM COMPONENTS AND PARTS IDENTIFICATION...........................................

RECOMMENDED SPARE PARTS................................................................................

HARDWARE SETTINGS................................................................................................

NEW CHANNEL CARD JUMPERS...........................................................................

INTERFACE MODULE DIP SETTINGS.................................................................

CONTROL RACK TERMINAL IDENTIFICATION......................................................

SERIAL COMMUNICATION PROTOCOLS................................................................

RATIO CONVERSION......................................................................................

WARRANTY POLICIES:

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

(Continued Next Page)

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62-87

62-71 71 72 73-74 75-78 79-80 81 82-85 86 87

DynaFlowTM User Manual - Contents

CONTENTS (Cont.)

PAGE

APPENDIX:

ADDENDUM A....................................................................................................................

ADDENDUM B..................................................................................................................

ADDENDUM C................................................................................................................

89-93

89-90 91-92 93

LN-9400-00.9

SAFETY

DynaFlowTM User Manual - Safety

SAFETY PRECAUTIONS

Before operating, maintaining or servicing any Ransburg electrostatic coating system, read and understand all of the technical and safety literature for your 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 you to a situation that might cause serious injury if instructions are not followed.

A CAUTION! states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury.

A NOTE is information relevant to the procedure in progress.

W A R N I N G

The user MUST read and be familiar with

the Safety Section in this manual and the

Ransburg safety literature therein identied.

This manual MUST be read and thoroughly understood by ALL personnel who operate, clean or maintain this equipment! Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed. The user should be aware of and adhere

to ALL local building and re codes and

ordinances as well as NFPA-33 SAFETY STANDARD, LATEST EDITION, prior to installing, operating, and/or servicing this equipment.

W A R N I N G

While this manual lists standard specications

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 Ransburg equipment manuals to reconcile such differences.

Careful study and continued use of this manual will provide a better understanding of the equip-

ment and process, resulting in more efcient

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 Ransburg representative or Ransburg.

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.

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DynaFlowTM User Manual - Safety

AREA

Tells where hazards may occur.

Spray Area

HAZARD

Tells what the hazard is.

Fire Hazard

Improper or inadequate opera-tion and maintenance procedures will

cause a re hazard.

Protection against inadvertent arcing that is capable of causing

re or explosion is lost if any safety

interlocks are disabled during operation. Frequent power supply shutdown indicates a problem in the system requiring correction.

SAFEGUARDS

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, ushing or maintenance.

When using solvents for cleaning:

Those used for equipment ushing should have ash

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

Those used for general cleaning must have ash

points above 100

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 ammable or combustible solvents.

F (37.8oC).

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 modications may cause re or injury.

If used, the key switch bypass is intended for use only during setup 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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DynaFlowTM User Manual - Safety

AREA

Tells where hazards may occur.

General Use and Maintenance

Electrical Equipment

HAZARD

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 ammable or

combustible materials may oc-

cur. Personnel are exposed to

high voltage during operation and maintenance.

Protection against inadvertent

arcing that may cause a re 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 coat-

ing materials and cause a re or explosion.

SAFEGUARDS

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, re protection, operation maintenance, and housekeeping. Reference OSHA, 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 ammable 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.

Explosion Hazard/ Incompatible Materials

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Halogenated hydrocarbon solvents for example: methylene chloride and 1,1,1,-Trichloroethane are not chemically compatible with the aluminum that might be used in many system components. The chemical reaction caused by these solvents reacting with aluminum can become violent and

lead to an equipment explosion.

Aluminum is widely used in other spray application equipment - such as material pumps, regulators, triggering valves, etc. Halogenated hydrocarbon solvents must never be used with aluminum equip-

ment during spraying, ushing, or cleaning. Read

the label or data sheet for the material you intend to spray. If in doubt as to whether or not a coating or cleaning material is compatible, contact your material supplier. Any other type of solvent may be used with aluminum equipment.

DynaFlowTM User Manual - Safety

AREA

Tells where hazards may occur.

Toxic Substances

HAZARD

Tells what the hazard is.

Certain material may be harmful if inhaled, or if there is contact with the skin.

SAFEGUARDS

Tells how to avoid the hazard.

Follow the requirements of the Material Safety Data Sheet supplied by coating material manufacturer.

Adequate exhaust must be provided to keep the air free of accumulations of toxic materials.

Use a mask or respirator whenever there is a chance of inhaling sprayed materials. The mask must be compatible with the material being sprayed and its concentration. Equipment must be as prescribed

by an industrial hygienist or safety expert, and be

NIOSH approved.

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NOTES

DynaFlowTM User Manual - Safety

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DynaFlowTM User Manual - Introduction

INTRODUCTION

FEATURES

• Congurable operating parameters (JOBs)

which can be saved and recalled on demand.

• Graphic diagnostics for troubleshooting and

for achieving maximum system performance.

• Comprehensive help information easily view-

ed on the OPERATOR INTERFACE.

• Congurable manual and/or automatic GUN

applications.

• Dynamic analog uid control – the control of

ow rate while running a JOB.

• Reverse uid ow detection provides added

protection for system components.

NOTE

DESCRIPTION

The ability to control the delivery of material greatly increases the overall efciency of the spray operating system and results directly in more uniform

and consistent paint nish quality and reduces the amount of material waste. The ability of the uid ow controller to respond with quick, concise, and repeatable control maximizes nish quality and

minimizes material waste.

The DynaFlowTM Flow Controller design utilizes a form of distributed processing similar to many of the industrial network architectures available

today. The entire task of uid ow control is broken

up into parts. Each portion of the system is de-

signed for a specic purpose. Since each element

of the system is performing specialized functions, and all elements are operating at the same time, overall performance of the system is enhanced. Functionality of the control system components is as follows:

This feature requires ow meters that

provide reverse ow output.

• Pot-life timer alarms.

• Local and remote monitoring and control.

• Discrete PLC interface capability for remote

control.

• Remote I/O (RIO) communications link for

direct connection to Allen-Bradley PLCs.

• Process and conguration error and fault de-

tection and reporting.

• USB memory stick, backup of conguration

and operational data.

• Versatile system integration.

• Easy to use.

Channel Module

The Channel Module represents the core of the system. Each Channel Module is responsible for:

• Monitoring the CHANNEL specic inputs and

supplying the necessary CHANNEL specic

outputs for control and status.

• Receiving and processing the ow meter

feedback pulses.

• Determining the analog PID output control

signal by performing high-speed oating-

point math.

• Receiving and interpreting commands from

the Interface Module through high speed Ransburg CAN Bus communication.

• Supplying data and status upon request to

and from the Interface Module.

• Help text and troubleshooting guide available

on screens.

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DynaFlowTM User Manual - Introduction

Located on the front panel of the Channel Module are several status indicator lights (LEDs). These are:

1. CPU - Is ON when the microprocessor is operating normally.

2. ACTIVE - Is ON when communication is taking place to the Interface Module.

3. FAULT - Is ON when there is a problem with the module.

Interface Module

The Interface Module performs the following:

• Stores system conguration and data

tables.

• Acts as an interpreter for communication

with an external Host computer, PLC and/

or the local Operator Interface. Communi cates through a high speed Ransburg CAN Bus data link to each Channel Module.

• Responsible for system specic inputs and

supplying the necessary system specic

outputs for control and status.

Located on the front panel of the Interface Module are several status indicator lights (LEDs). These are:

1. CPU - Is ON when the microprocessor is operating normally.

2. ACTIVE - Is ON when RIO communication is taking place to an Allen-Bradley PLC.

3. FAULT - Is ON when there is a problem with the module.

Local Operator Interface

Supplied as part of the DynaFlow Stand-Alone Control Cabinet, Model# 77376 and A12233.

• Permits total control of the system.

• Displays system conguration and data to

the operator.

• Computes and displays text and graphic di-

agnostic information.

• Organizes, formats, and reports all data

and conguration tables.

The DynaFlow uid ow control system achieves

real-time closed loop control through the use of CHANNELs and GUNs. A CHANNEL consists of an electrical-to-pneumatic (E/P) transducer, material regulator and uid ow meter combination through which a single material is controlled. A GUN represents a single applicator through which one or more materials are delivered. One

or more CHANNELs are congured for each GUN.

Two-component delivery systems (referred to as 2K systems) have two CHANNELs assigned to

a single GUN. The materials are statically mixed

before being delivered to the GUN.

Each CHANNEL operates independently of, and simultaneously with all the other CHANNELs. This lets the DynaFlow controller provide accurate dynamic regulation for each CHANNEL, regard-less of minor system wear or changes in system variables. With a single-component coating material, the DynaFlow controller detects changes from the

programmed ow rate and adjusts the output to

correct it. With two-component coatings (where both the resin and catalyst are regulated and monitored), the DynaFlow controller detects any

change in the total ow and makes the required adjustments to maintain the programmed ow and ratio. This holds the ow rates of the coating

components constant. Deviations from the desired

mix ratio are also immediately corrected using this

same closed loop process.

A detailed guide on PID control is supplied in this

manual to assist you should you want to adjust

the control parameters. There are many additional features included in the DynaFlow Fluid Flow Con-

trol which reect on the many years of experience

accumulated by Ransburg.

The control rack and OPERATOR INTERFACE panels are consistent with and easily integrated with other Ransburg control products into larger custom system control panels. This optimizes costs, space and functionality for control of multiple applicator spray stations. Spray stations may also

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DynaFlowTM User Manual - Introduction

incorporate rotary atomizer speed control, shaping air, high voltage power supplies and more.

The standard stand-alone control cabinet includes control of up to 8 CHANNELs. It incorporates an integrated 15" color LCD touch screen, PC based display/interface sub-panel.

Congurable Operating

Parameters

The design of the DynaFlow system allows it to

be congured to meet the specic requirements

of each application. The 8 available CHANNELs can be linked together, using 1 of 8 GUNs, to

control the ow and mixing regulation of two-

component materials. The installed channels can

be congured to suit the application. If you are

using single-component coatings, the DynaFlow controller can support 8 separate single CHANNEL GUNs operating simultaneously. If you are using two-component materials, then 4 separate 2-CHANNEL GUNs operating simultaneously

can be supported. For example, you can use 4

CHANNELs assigned to 2 GUNs to spray 2 dual component paints on automatic machines, and 2 CHANNELs assigned to 1 GUN to spray one dual component paint with a manual hand spray GUN.

In addition to the above, a GUN congured for

two-component operation can be dynamically changed to operate in a single-component mode by simply setting the ratio JOB parameter to

100. This allows a GUN to operate in either dual or single-component modes by simply changing JOB numbers.

The controlling parameters for each GUN and the CHANNEL(S) assigned to that GUN, are called

JOBs. The JOB values dene ow characteristics such as Target Flow Rate, Mix Ratio, Flow Toler-

ance, etc. JOBs include all of the parameters that may be dependent on the material used. This offers the ability to optimize system control as needed per material and then recall the settings each time that material is requested. There are up to 100 JOB #s for each GUN. By saving frequently used JOB #s to memory you can later recall them by loading the number representing that JOB #. All of the JOB #s can be backed-up to, and restored from a USB memory device. Reference the "Opera-

tor Interface Users Manual" and "Program-mers Manual" for details on data transfer operation and available formats.

The ow control unit includes one Interface Module

and up to 8 hardware PID control CHANNELs, 2 CHANNELs located on each of the 4 possible Channel Modules. The Interface Module will communicate to a host controller. The host is one of the following:

• PLC using discrete I/O

• Allen-Bradley PLC using RIO

• Local Operator Interface using an RS-

232C communication port

3-K Operation

DynaFlow was designed for either single or twocomponent operation. Three-component operation

is possible by conguring two, two-component, guns. The rst Gun is set up as follows:

Gun 1 = Master Channel = Material = Resin Flow Controller = Color Change Value (CCV) Flow Meter = Standard Gear-Type

Slave Channel = Material = 2nd Component Flow Controller = MVR, with appropriate size needle Flow Meter = Piston or Gear, depending on

min/max ow rates

(see Notes 4 and 5) Operating Mode = Manual

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DynaFlowTM User Manual - Introduction

The output of the rst Gun is then fed into the

Master Channel input of the second Gun. The second Gun is setup as follows:

Gun 2 = Master Channel = Material = Output of Gun 1 (Resin + 2

Component) Flow Controller = Color Change Value (CCV) (see Notes 1, 2, and 3) Flow Meter = Gear-Type

Slave Channel = Material = 3rd Component Flow Controller = MVR, with appropriate size needle Flow Meter = Piston or Gear, depending on

min/max ow rates

(see Notes 4 and 5) Operating Mode = Manual or Auto (see Notes 1, 2, and 3)

NOTE

Refer to Addendum C for complete

information regarding the ow limitations of

the DynaFlow Channel cards.

NOTES:

1. If the output of Gun 2 supplies one or more hand guns, then Gun 2 should be operated in Manual mode using a CCV for the Master

Channel ow controller.

2. If the output of Gun 2 supplies a single applicator, then an MVR should be used for the

Master Channel ow controller and Gun 2

should be operated in Auto mode.

3. If the output of Gun 2 supplies multiple applicators other then hand guns, then Gun 2 should be operated in Manual mode using a CCV for the

Master Channel ow controller. Additional Guns should be congured for each applicator as shown below to provide automatic ow control for each

applicator.

Gun 3 through 6 = Master Channel = Material = Output of Gun 2 (Resin + 2

+ 3rd Components) Flow Controller = DR1 Flow Meter = Gear-Type Operating Mode = Auto

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DynaFlowTM User Manual - Introduction

Figure 1: Block Diagram

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DynaFlowTM User Manual - Introduction

DYNAFLOW SPECIFICATIONS

Pneumatic Requirements

Transducers: The air supplied to the trans-

ducers must be clean and dry and meet the following general

specications:

Filtration: 20 Micron

Supply Pressure: 90 PSIG min. to 150 PSIG

max.

Volume: 0.04 to 0.13 Cv

Operating Temperature:

32o to 150o F (0o to 65.5o C)

Control Rack (Up to 8 Channels Per 1/2 of 19" Rack)

Dimensions: 83mm H X 250mm W X

184mm D standard half rack

Power Requirements:

24 VDC at 1 Amp typical, all 8 CHANNELs installed

The following must be followed if the ow control

rack and/or Operator Interface is to be integrated into a larger system control panel:

- The 24 VDC Power Supply must be located in the

same control panel as the uid ow control.

- DO NOT use a central power supply located else where. The power supplies may be sized for and used for other controls within the same cabinet WITH THE EXCEPTION OF HIGH VOLT- AGE POWER SUPPLY CONTROLLERS. High voltage power supply controllers MUST have a dedicated power supply.

Interface Module Hardware

General: This Module is responsible for

local display/keyboard control and communication to the Host control ler. Responsible also for non-vola tile storage of all JOB data tables

and system conguration param-

eters.

Dimensions: 3U (130.5 mm) H x 7H

(35.2 m) W standard 19" rack module

Interface Module Hardware (Cont.)

Digital Inputs: 24 VDC at 2.3 ma typical per input

(optically isolated, source by de fault, sink selectable)

- JOB Select Strobe

- JOB Select 1 (lower signicant

BCD digit)

- JOB Select 2

- JOB Select 4

- JOB Select 8

- JOB Select 10 (middle signicant

BCD digit)

- JOB Select 20

- JOB Select 40

- JOB Select 80

BCD digit)

- System Ready/Halt

- Global Gun Enable

Digital Outputs: 24 VDC sourced at 300 ma maxi-

mum per output (Solid state relay contacts)

System Pulse: Used as watchdog timer by an

external supervisory PLC or com-

puter.

System Fault: Used to activate an alarm and to

supply a signal remotely that a System, GUN, or other fault has occurred.

Communications RS-232C Port: Communication with local

Opperator Interface unit.

Allen-Bradley RIO Port: For direct high-speed communi-

cation with Allen-Bradley PLC's.

CAN: Control Area Network (CAN) high

speed communication with all channel Modules and with other racks.

Power Requirement: 24 VDC at 100 ma typical

Operating Temperature: 0

JOB Select 100 (upper signi

to 55o C

cant

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DynaFlowTM User Manual - Introduction

Channel Module Hardware

Specications

General: Each Channel Module is responsible

for processing channel specic dis-

crete I/O and performing all of the necessary PID closed loop control functions. Data and control I/O other than discrete is communicated through Ransburg CAN Bus located on the Motherboard.

Dimensions: 3U (130.5mm) H x 7H (35.2mm) W

standard 19" rack module

24 Digital Inputs (2 Channels):

(optically isolated, source by default, sink selectable) Trigger (level): Automatic mode only - For

manual mode, uid starts with uid ow on master channel.

Halt (edge): Stops current JOB # (no effect on

next JOB # in queue)

Clean (edge): Forces regulator full on for cleaning Run (edge): Gets next JOB # - used in conjunc- tion with JOB # and Toggle select bits Gun Mask (edge): Used in conjunction with JOB # select bits Total Reset (edge): Resets all totals Total Hold (level): Holds present total value

regardless of uid ow

Transparent/PID (level): When active directs

the external analog input directly to

the transducer output Analog Hold (level): Freezes PID and holds cur- rent analog control output

Load (edge): Loads uid with controlled mix ratio

for GUNs operating in MANUAL Mode

External Fault/

Enable (level): Enable signal input. Must

be active for uid to be delivered by

GUN regardless of the operating mode.

Spare: Not used presently

24 VDC at 2.3 ma typical per input

Channel Module Hardware

Specications (Cont.)

12 Digital Outputs (2 Channels): 24 VDC sourced at 300 ma max-

imum per output (Solid state relay contacts) Ready: Everything is ready for operation,

congured correctly and I/O logic

OK Active: CHANNEL is active and controlling Fault: Fault has occurred Pot Life Timer: Pot life timer expired Clean/Load/Calibrate: Indicates Clean, Load, or Calibrate mode is active MVR Enable: Used to control trigger valve for CHANNEL in fast trigger applica-

tions with Analog Hold enabled

4 Analog Inputs (2 Channels): Jumper selectable 0-10 VDC (de-

10-bit A/D. Set Point Control #1: Used for external analog control. When used, offset and full scale need to be set. This is accomplished through the MAXIMUM FLOW RATE and MINI MUM FLOW RATE JOB parameters. Set Point Control #2: Used for external analog 10-bit A/D control. When used, off set and full scale need to be set. This is accomplished through the MAXIMUM FLOW RATE and MINIMUM FLOW RATE JOB parameters. Spare #1: Not used presently Spare #2: Not used presently

4 Analog Outputs (2 Channels): Jumper selectable 0-10 VDC (de-

12-bit D/A. Transducer Control #1: Output to proportional E/P 12-bit D/A controller Transducer Control #2: Output to proportional E/P controller Flow Rate #1: Flow Rate (scaled between MINI MUM FLOW RATE and MAXI MUM FLOW RATE JOB param-

eters)

Flow Rate #2: Flow Rate (scaled between MINI MUM FLOW RATE and MAXIMUM

fault) or 4-20 ma, op-amp buff

ered,

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DynaFlowTM User Manual - Introduction

Channel Module Hardware Specications (Cont.)

FLOW RATE JOB parameters)

4 Frequency Inputs: From ow meters (reverse

ow capable)

Source Signal #1 & #2:

Frequency used to determine

ow rate (pulses per volume or

weight).

Maximum Frequency = 435 Hz

Minimum Frequency = 1 Hz

(Refer to Addendum C for ow limitations.)

Phase Signal #1 & #2: State used to determine

direction of ow rate, forward or

reverse.

PID Control: Closed loop control based on

the Kp, Ki, Kd and deadband JOB parameters. 30ms PID up date time (default), each chan-

nel.

Control Enclosure (A12233)

Dimensions: 610mm H X 610mm W X 410mm D

Weight: 45.5 Kg (100 lbs)

AC Power: 115/230 VAC, 3A

50/60 HZ 1 Phase

Temperature: 5°C - 40° C

Humidity: 80% to 31° C decreasing to 50% at

40° C non-condensing

Interface Enclosure (A12182)

Dimensions: 610mm H X 610mm W X 410mm D

Weight: 22.7 Kg (50 lbs)

Temperature: 5°C - 40° C

Communications CAN: Controller Area Network (CAN) High-

speed serial communications to In terface Module.

RS-232C Port:

Spare auxiliary communication port.

Power Requirements: 24 VDC at 100 ma

typical – each Channel Module

Operating Temperature: 0

to 55o C

Humidity: 80% to 31° C decreasing to 50% at

40° C non-condensing

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DynaFlowTM User Manual - Installation

INSTALLATION

SYSTEM GUIDELINES

Prints Specic per Installation

Often times, installation prints are custom drawn for each site. You should check those prints for

information that is specic to your installation.

Any deviations from those prints made during or after installation should be recorded for further reference.

Cable Assemblies

Most electrical interconnections between the DynaFlow controller and other system components are made through cable assemblies.

NOTE

Any unused conduit holes must be blanked off to prevent solid objects from entering the interior of the enclosure.

Equipment Locations

With the exception of the following restrictions,

the installation of the Transducers or Transducer Panel, the Remote Operators Station and Regulator/Flow meter assemblies are application and

site dependant. Specic instructions for location

and mounting of these assemblies are covered on the site installation drawings.

1. The maximum recommended distance from the Control Panel to each ow meter is 100-ft. as determined by the maximum standard available length of the ber-optic cable assemblies or

intrinsic electrical cable assemblies.

2. The maximum recommended length of air pi-

lot tubing between the electrical-to-pneumatic (E/P) transducer and the material regulator is largely determined by the application. In general, the pilot lines should be kept as short as pos-

sible to achieve the best uid ow response and

regulation. See "Pilot Signal Guidelines" chart in this section.

Equipment Grounding

C A U T I O N

The control panel should be grounded in accordance with national and local electrical codes.

The protective ground conductor must be terminated directly to the protective conductor ground terminal located inside the Control Enclosure which is marked with symbol -

3. The maximum distance between the optional

LBAL5001-XX Pneumatic Interface Panel to the Control Console is 40-ft., as determined by the interconnecting electrical cable assembly.

4. The maximum recommended 1/4-inch OD

hose length from the LBAL5003, Remote Operator Panel, and the LBAL5001, Pneumatic Interface Panel, is 50-ft., however this can be longer

depending on the application. The maximum

distance between the A12182 interface panel and the A12233 console is 100-ft.

5. The maximum recommended length for the

E/P transducer electrical control cable is 95 ft. However, in some cases 175-ft. has been used. Generally, if a GUN number (not atomizers) controls a complete zone of 6 or more atomizers, do

not exceed 95-ft. of cable.

Consult Ransburg if longer distances than those shown above are desired.

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DynaFlowTM User Manual - Installation

C A U T I O N

Do not locate the Control Panel

near or adjacent to heat producing equipment such as ovens, high wattage lamps, steam pipes, etc.

Equipment Mounting

Use the mounting ears supplied to mount the control or interface enclosure on a wall or building structure. The anchor system used must be

rated to support the specied weight of the enclosure being mounted (see specications, page

13). When properly mounted, the anchor system shall be capable of withstanding 4 times the rated weight without causing a hazardous condition.

W A R N I N G

If improperly located, certain electrical

equipment can become a source of ignition

and create a risk of re or explosion.

W A R N I N G

The Control Enclosure must be lo-

cated in such a way that access to the On/ Off power switch and Stop switch is not blocked.

The On/Off switch turns off AC power to the PC and 24 VDC supply.

The Stop switch interrupts only the 24 VDC.

The AC power input FUSED DISCONNECT must be located in an accessible area near the Control Enclosure

The Control and Interface Enclosures must be located outside of the Class 1, Division 1 and 2 hazardous locations which are de-

ned for spray nishing of ammable and/ or combustible materials. Denitions and requirements for classied areas are found

in the National Electrical Code, NFPA-70, Article 516 and the National Fire Protection Association (NFPA-33).

PILOT SIGNAL GUIDELINES

Tubing Size ODFluid Regulator

Application

Two-component

Single-Component

1/4"

Type

MVR

DR1

Typical

Minimum

Length

Feet Meters

4.6

Maximum

Length

Feet

100

Meters

15.3

30.5

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DynaFlowTM User Manual - Installation

Figure 2: Block Diagram for a Single-Component Gun

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DynaFlowTM User Manual - Installation

CHANNEL 1

CHANNEL 2

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Figure 3a: Block Diagram for a Two-Component Gun

CHANNEL 1

CHANNEL 2

DynaFlowTM User Manual - Installation

E/P TRANSDUCER

AIR SUPPLY

FLUID SUPPLY

PILOT SIGNAL

FLUID

REGULATOR

ANALOG CONTROL SIGNAL

FLOW METER FEEDBACK

FLOW

METER

VALVE

FLOW METER FEEDBACK

CALIBRATION CALIBRATION

CHECK VALVE

Y BLOCK

MIX TUBE

ANALOG CONTROL SIGNAL

VALVE

CHECK VALVE

FLOW

METER

E/P TRANSDUCER

AIR SUPPLY

PILOT SIGNAL

FLUID

REGULATOR

FLUID SUPPLY

E/P TRANSDUCER

AIR SUPPLY

PILOT SIGNAL

FLUID

REGULATOR

CHANNEL 3

FLOW

METER

ANALOG CONTROL SIGNAL

FLOW METER FEEDBACK

VALVE

CHANNEL 4

ANALOG CONTROL SIGNAL

FLOW METER FEEDBACK

VALVE

FLOW

METER

E/P TRANSDUCER

AIR SUPPLY

PILOT SIGNAL

FLUID

REGULATOR

FLUID SUPPLY

CHECK VALVE

Figure 3b: Block Diagram for a Three-Component Gun

CALIBRATIONCALIBRATION

CHECK VALVE

Y BLOCK

MIX TUBE

APPLICATOR

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User Manual - Installation

INPUT POWER

Input supply voltage connections should be made from a FUSED DISCONNECT that is located in an accessible area near the Control Enclosure.

Electrical conduit is recommended for the input power wiring. Use 3 cond. 14 ga. wire for incoming AC power supply.

If using SO type portable cord, a strain relief rated for the diameter of cord being used is required for protection against cord abrasion and damage.

The protective ground conductor must be terminated directly to the protective conductor ground terminal located inside the Control Enclosure which is marked with symbol -

If there are large AC line voltage uctuations or

voltage transients such as those typically produced by heavy electric machinery or welding equipment, then a constant voltage transformer (CVT) or an uninterruptedly power supply (UPS) should be used between the FUSED DISCONNECT and the Control Panel.

C A U T I O N

Before applying power to the control

panel, verify that it is set to match the source voltage. There may sometimes be a voltage selection switch (usually located on the DC power supplies) to select between 120 VAC and 240 VAC or different indicator bulbs may be required.

W A R N I N G

Do not install or service this equip-

ment or perform installation or adjustment

procedures unless you are properly trained

and qualied.

Installing and servicing this equipment requires access to parts which could cause

electric shock or serious injury if work is not

performed properly.

C A U T I O N

If a CVT or UPS is to be used on the

input to the Control Panel, use a CVT with a Volt-Amp (VA) output rating equal to or greater than the output voltage multiplied by the control panel fuse rating (see

specication section). Also make sure that

the device input ratings correspond with the voltage and frequency of the source supplied by the FUSED DISCONNECT. The device output should be rated for 240

VAC maximum.

All work must comply with applicable local and national regulations and codes.

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INTERFACING TO THE FLOW CONTROLLER

System I/O

SYSTEM INPUTS

Input

Signals

JOB Select Inputs

JOB Strobe Input

System Ready/ Halt Input

Description

These inputs are used to select a JOB number from the external PLC or other host controller.

These inputs represent Binary Coded Decimal (BCD) that translates to 3 digits, each digit

represented as a 4-bit binary code. The JOB Select inputs are used in conjunction with the

GUN Mask inputs to determine which GUNs will accept the JOB number represented by the total of the active JOB Select Bits. See "Operation" section of this manual for details. These signals must be asserted prior to the JOB Strobe Input and held on slightly after the strobe signal goes low.

JOB Strobe requires a pulsed signal of at least 0.25 seconds duration. This signal is used in

conjunction with the GUN MASK inputs and program select inputs to activate a new JOB # for

any or all GUNs. When the controller detects this input, the program select inputs and GUN MASK inputs are read and action taken to load the new JOB # in the JOB # QUEUE. The new program select and GUN MASK inputs must be present before the PROGRAM SET STROBE is activated. Reference "Job Selection Timing Diagram Sample" in the "Operation" section.

System Ready/Halt is a maintained signal that permits activation of any or all GUNs. For the controller to operate, this signal must be maintained in the high state (24 VDC). When this signal is active, the system Ready/Halt output will be held ON.

If the signal is lost, ALL GUNs will stop and the READY output is turned OFF. The GUNs must be restarted in the normal manner when this signal is again activated. The JOB # QUEUE for any GUN is not effected by the state of this input.

Global GUN Enable

The Global GUN Enable is a maintained signal that overrides all of the individual External

Fault/Enable GUN inputs. Reference "GUN INPUTS". This is most useful when using RIO, RS-485, or RS-232C control and the discrete GUN I/O is not used through J3, J4, J5, or J6 of the mother board.

SYSTEM OUTPUTS

Output

Signals

System Pulse Output

System Fault

System Spare

Description

The System Pulse output can be used as a watchdog function by a PLC or other external controller to determine if the ow controller is operating normally. The output is a 50% duty

cycle, 0.5 HZ signal (2 pulses per second).

A high signal on this output indicates that a system, GUN or other fault has occurred. The type of fault that causes this output to activate is selectable by the Horn Code located in the

System Conguration table.

Not used presently.

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Gun I/O

Discrete GUN I/O provides the input control and output status signals required to interface each GUN with a PLC or similar controller, or other system control components. All GUN I/O can also be controlled

or monitored through an external host controller operating through a serial data communications link

or the state of each forced active through the local OPERATOR INTERFACE/host controller.

GUN INPUTS

Input

Signals

Trigger

Description

For automatic applicators: Starts uid ow when supplied a 24 VDC signal assuming that the GUN has been put in run mode, is congured properly, and all other conditions are satised.

For manual GUNs: A Trigger signal is required for the LOAD mode. The Trigger signal can

be generated from an atomizing air ow switch. If a Trigger signal is received from the ow switch but no uid ow is recorded from the catalyst (slaved) CHANNEL, then a FLOW TOO

LOW fault is generated. This ensures that both material components are present to the GUN.

If the dip switch, Pos #1 on the Channel Card is on, then this input is not used. Fluid ow

through the master channel is used to indicate a TRIGGER ON condition.

Halt/Reset

Clean

Run

Gun Mask

Halt requires a pulsed signal of at least 0.25 seconds duration. It is used to stop the JOB #

currently being executed or to stop a CLEAN/PURGE operation. GUN faults are also reset.

While in HALT mode, any new JOB # selection using the JOB # Strobe will be entered into the Queue. The GUN will run the JOB # located in the Queue when a RUN signal is again supplied. The faults can still be viewed in the ERROR LOG data table. Halt has no effect on

the JOB # in the Queue (Next JOB # to be run).

Clean requires a pulsed signal of at least 0.25 seconds duration. It forces the material regula-

tors controlled by the GUN parameters to the full open position. This permits the uid system

to be cleaned. The removal of the GUN Enable signal or a HALT input signal is required to end the CLEAN operation. Actual cleaning sequencing (PURGE) such as soft air push-out is

performed by the PLC, or other external controller. For details, refer to "Clean Mode" in the

"Operation" section of this manual.

This input will activate the GUN and will allow material ow if all other requirements are met.

This is identical to pushing the GUN ON switch on the OPERATOR INTERFACE PANELS. Run requires a pulsed signal of at least 0.25 seconds duration. If this signal is reapplied once the JOB # has been started, then it is ignored. When this signal is supplied following a HALT, the JOB # stored in the queue will be activated. If no new JOB # was entered during the previous HALT, then the JOB # located in the queue will not change and will be used again.

The Gun Mask input species whether a JOB # or toggled into GUN #n queue. This signal is used in conjunction with the system PROGRAM SELECT and PROGRAM STROBE inputs.

A 24 VDC signal selects the GUN, a 0 VDC signal masks the GUN as ‘not used for the JOB # selected’. Multiple gun masks can be asserted simultaneously if it is desired to load more than one gun with the same JOB #.

Total Reset

LN-9400-00.9

Total Reset requires a pulsed signal of at least 0.25 seconds duration. This signal will reset the daily and JOB totals for the GUN. The non-resettable total will not be effected.

DynaFlowTM User Manual - Installation

GUN INPUTS (Continued)

Input

Signals

Total Hold

Transparent/ PID

Analog Hold

Load

Description

This signal will stop all totals for the CHANNEL as long as the signal is supplied, even if the

GUN is running and there is uid ow. The non-resettable total will not be effected. This is most often used during ush or soft air push cycles. It can also be used to account for only

that material which is delivered onto parts.

For GUNs congured as single-component, automatic mode only. This input is only acknowledged for run and load modes. This input must be supplied before the clean input or the trigger input if in run mode. This signal will place the CHANNEL in single-component, open loop mode and redirect the Analog Set Point Input directly to the E/P transducer control output. MAXIMUM FLOW RATE, MINIMUM FLOW RATE, MVR HIGH and MVR LOW parameters have no effect while in the transparent mode. The Out of Tolerance, FLOW TOO LOW and FLOW TOO HIGH faults will also be disabled while in the Transparent condition.

This signal applies only to GUNs congured for single-component automatic mode. This

signal will suspend PID control and freeze the analog control output to the E/P transducer to the current value. Normal PID operation will resume when this signal is removed. This would

typically be used during ushing operations or for control stability in situations where there are extremely quick trigger cycles or equipment limitations. The Out of Tolerance, Flow Too

Low and Flow Too High faults will also be disabled while in the Analog Hold condition.

Load requires a pulsed signal of at least 0.25 seconds duration. The LOAD input places a manual, two-component GUN into LOAD MODE. LOAD MODE is a special way to meter both resin and catalyst to the applicator after the system has been through a CLEAN operation while assuring accurate ratios. A GUN can be placed into the LOAD MODE directly from the RUN MODE. For details, refer to LOAD MODE in the "Operation" section of this manual.

External Fault/

Enable

Spare Digital Input

Analog Set Point

Spare Analog Input

External Fault will detect a low signal of at least 0.25 seconds duration. This signal must be

maintained high for normal operation. No uid ow will occur regardless of the operat- ing mode if the Enable input is not active. This input is supplied as an interlock for other

equipment to automatically shut down the uid ow controller. The system must be reset after the External Fault is returned to the high state. Reference "Recovering From Faults" in the

"Operation" section of this manual. A Global Gun Enable system input will override this input.

Not used presently.

This is a 0-10 VDC or 4-20 ma input signal (hardware selectable on the Channel Card) which

can be used to command ow rate when the applicator is in AUTOMATIC mode. The scaling for input signal vs. ow rate is determined by the GUN JOB # parameters, MAXIMUM FLOW

RATE and MINIMUM FLOW RATE. An Analog Set Point signal less than 0.25 VDC will cause the controller to use the SET POINT parameter located in the JOB table instead.

Not used presently.

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GUN OUTPUTS

DynaFlowTM User Manual - Installation

Output

Signal

Ready

Active

Fault

Pot Life Timer

Clean/Load/ Calibrate

MVR Enable

Analog Control Output

Description

This output is 24 VDC when the GUN is congured properly, a valid JOB is loaded.

This output is 24 VDC when the GUN is RUN mode and owing uid or prepared to ow uid.

This output is 24 VDC if a GUN fault condition occurs.

This output is 24 VDC if the Pot-Life Timer has expired. This may also initiate a horn if set to do so in the Horn Code Conguration, set in the System Conguration.

This output is 24 VDC when the GUN is placed in Clean, Load, or Calibrate Mode.

This output is 24 VDC anytime material should be owing for the GUN. It is used to control

trigger valve(s) installed at the inlet of the MVR valve(s) on fast-trigger JOBs.

This is a 0-10 VDC or 4-20 ma output signal (selectable on the Channel Module) which is connected to the transducer for control of the material regulator for the CHANNEL. The output signal is limited through the use of the JOB parameters, MVR HIGH and MVR LOW. Scaling is assumed to be 0 VDC (4 ma) equals 0 PSIG at the output of the E/P transducer and 10 VDC (20 ma) equals 100 PSIG at the output of the transducer. The MVR HIGH and MVR LOW JOB parameters are based on a percentage of the span of 0 to 100 PSIG. This an MVR LOW value of 10% equals 10 PSIG.

Analog Flow Rate Output

Fluid Line Flushed Output

User Interface Revision

Language

This is a 0-10 VDC or 4-20 ma output signal (selectable on the Channel Module) indicating

the actual ow rate for the CHANNEL. Scaling of the output signal is accomplished through

the use of the JOB parameters MAXIMUM FLOW RATE and MINIMUM FLOW RATE, where 0 VDC (4 ma) equals the MINIMUM FLOW RATE value and 10 VDC (20 ma) equals the MAXIMUM FLOW RATE value.

For the Master Channel, if DIP switch 2/2 on the Interface Module is off, the total ow rate for the gun is output and if the switch is on only the ow rate for the Master Channel is output.

For the Slave Channel, only the ow rate for the Slave Channel is output.

On guns congured for dual component operation, the pot-life expired output on the slave (B) channel indicates when the uid line has been completely ushed. Once mixed material has entered the uid line, this output is energized and it remains energized until the unit is completely ushed. That is, in order to turn this bit off, the amount of material programmed in for mixed volume must be expended from the applicator while the gun is in clean mode.

Displays the current version of the user-interface software running on the user-interface PC.

This allows users to select between English and one Alternate Language. The alternate language text is stored on the ash drive or hard drive of the PC in les named: TEXTMESS_ALT.TXT, PARAMHLP_ALT.TXT, LABELS_ALT.TXT, SOLENOIDVALVES_ALT.TXT, and HELP_ALT.TXT.

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DynaFlowTM User Manual - Installation

Control Rack Wiring

(Reference page 82 for terminal identication.)

Figure 4: Mother Board Terminals

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DynaFlowTM User Manual - Installation

Hardware Conguration

Reference "Addendum A" in the "Appendix" section for board level hardware settings. For new system installations, all hardware settings should already be in the correct positions. However, if replacing any electronic board assembly, verify that the settings of the new board are identical to those of the board being replaced. In the event that the replacement board is a newer revision and does not appear identical, refer to any documentation that was supplied with the board, or contact your Ransburg representative or contact Ransburg service.

Transducers

The transducers convert electrical control signals

from the uid ow controller to the air pressure

signals used to operate the material regulators. The transducers can be either current controlled (4-20 ma) or voltage controlled (0-10 VDC). The transducers can be mounted separately or collectively depending on the installation requirements.

Make sure that the Channel Module jumper settings match the type of transducer being used (refer to "Channel Module Mother Board Jumper Settings Channel 1 I/O and Channel 2 I/O" in the

"Appendix" section).

The electrical-to-pneumatic (E/P) transducers are supplied as separate sub-assemblies or as part of a standard transducer panel. The transducer panel offers a convenient way to mount transducers for 2K applications. There are typically two transducers located in each panel with electrical terminals and an air supply input.

The transducers may also be mounted individually on any air drop outside of the Class 1, Division 1 hazardous location if:

1. Tubing and cable lengths do not violate the

minimum and maximum lengths specied in the

"Installation" section of this manual under Equipment Locations".

2. The air supply meets the specications as

listed in the "Introduction" section of this manual

under "Pneumatic Specications" or those pub-

lished with the transducer. A 1:1 volume booster may also be connected

directly to the transducer output when; operating a DR-1 longer than recommended, or of a larger tubing diameter is used other than that recommended.

Keep the distance between the transducer to the material regulator as short as possible, without

violating the minimum lengths specied, to avoid

system response delays and to achieve the op-

timum uid ow characteristics for the system.

Fluid Regulator, if pilot line lengths are

Material Regulators and Flow Meters

The location and mounting of the material regulators and ow meters is specic to each installation. The information presented here is intended as a guideline only. Reference should be made

to the supplied documentation specic to your

installation.

Fluid Supply Requirements

• The uid supply must be free of pulsation

and surges.

• A uid strainer/lter must be installed im-

mediately before the material regulators. The elment size of the strainer should be 100 mesh or per the recommendation of your Ransburg representative.

• For Two-Component (2K) Systems: Selector valves are required for calibration or verify-

ing of the ow meters and should be mount ed close to the mixing block. These are sup plied as part of the standard uid panel. Drawings created specically for your sys-

tem will provide detailed information about valve type and location. Mount the calibra tion valves in an easily accessible area close

to the mixing block. For most applications the ow meter and material regulator are

mounted as an assembly as close as possible

to the mixing block and calibration valves.

• For systems with fast trigger cycles that utilize weepless MVR valves, or where

dynamic control of uid ow rates (different ow rate during a JOB), consider installing

trigger valves (typically color control valves) immediately upstream of the MVR valves so that the CHANNELs may be placed in

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DynaFlowTM User Manual - Installation

Analog Hold mode without causing the uid

tubes to pressurize to the material supply pressure while the GUN is not triggered.

• For systems with fast trigger cycles or where

dynamic control of uid ow rates (different ow rates during a JOB), mount the E/P

transducer as close to the material regulator as possible. Remember that the transducers MUST be mounted outside of the hazardous location (refer to NFPA-70, NEC). For appli-

cations where the requested uid ow is for

the most part consistent, and transitional re sponse time of the system is not as critical, then the E/P transducers may be located in the main control panel.

• Be sure that stainless steel tubing or piping

and stainless steel ttings are used for all uid lines and connections where metal is

desired.

• Always mount the ow meter and regula-

tor as close as feasible to the applicator. This reduces paint line pulsation due to applicator reciprocators and reduces the possibility of a paint leak effecting paint delivered to the part.

NOTES

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NOTES

DynaFlowTM User Manual - Installation

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DynaFlowTM User Manual - Operation

OPERATION

OVERVIEW

This section will acquaint you with the general operation of the DynaFlow Fluid Flow Controller. The following information describing CHANNELs, GUNs and PARAMETERS summarize the three

main features that form the basis of the uid ow

controller.

CHANNELs

A CHANNEL consists of an electrical-to-pneumatic

(E/P) transducer, a material regulator and a uid ow meter combination through which a single

material is controlled. One or two CHANNELs

may be congured for each GUN. Two-component

systems (sometimes referred to as 2K systems) have two CHANNELs assigned to a single GUN. Single-component systems (sometimes referred to as 1K systems) have only one CHANNEL assigned to a single GUN.

Each DynaFlow control system has up to 8

CHANNELs available that can be congured to suit the application. For example, you can use 4

CHANNELs assigned to 2 GUNs to spray 2 dual component paints on automatic machines, and 2 CHANNELs assigned to 1 GUN to spray one dual component paint with a manual hand spray GUN.

Please note that most GUN parameters also apply to single-component control as well. The

CHANNEL that has the greatest ow rate in two-

component systems is typically called the Master CHANNEL. A CHANNEL cannot be assigned to more than one GUN.

GUNs

A GUN represents a single applicator through which one or two materials are delivered.

If you are using single-component coatings, the DynaFlow controller can support 8 separate single CHANNEL GUNs operating simultaneously. If you are using two-component materials, then 4 separate 2-CHANNEL GUNs operating

simultaneously can be supported. Adjacent

CHANNELs (1 & 2, 3 & 4, 5 & 6, and 7 & 8) can be linked together, using 1 of 8 GUNs, to control

the ow and mixing regulation of two-component materials. A GUN congured for two-component

operation can also operate in single-component control mode by setting the ratio to 99, or higher.

Three Component (3-K) Operation

DynaFlow was designed for either single or twocomponent operation. Three-component operation

is possible by conguring two, two-component, guns. The rst Gun is set up as follows:

Gun 1 = Master Channel = Material = Resin Flow Controller = Color Change Value (CCV) Flow Meter = Standard Gear-Type

Slave Channel = Material = 2nd Component Flow Controller = MVR, with appropriate size needle Flow Meter = Piston or Gear-Type,

depending on min/max ow rates (see Notes 4 and 5)

Operating Mode = Manual

The output of the rst Gun is then fed into the

Master Channel input of the second Gun. The second Gun is setup as follows:

Gun 2 = Master Channel = Material = Output of Gun 1 (Resin + 2nd Component) Flow Controller = Color Change Value (CCV) (see Notes 1, 2, and 3) Flow Meter = Gear-Type

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DynaFlowTM User Manual - Operation

Slave Channel = Material = 3 Flow Controller = MVR, with appropriate size needle Flow Meter = Piston or Gear-Type, depending on

min/max ow rates

(see Notes 4 and 5) Operating Mode = Manual or Auto (see Notes 1, 2, and 3)

NOTES:

1. If the output of Gun 2 supplies one or more hand guns, then Gun 2 should be operated in Manual mode using a CCV for the Master Chan-

nel ow controller.

2. If the output of Gun 2 supplies a single applicator, then an MVR should be used for the Mas-

ter Channel ow controller and Gun 2 should be

operated in Auto mode.

3. If the output of Gun 2 supplies multiple applicators other then hand guns, then Gun 2 should be operated in Manual mode using a CCV for

the Master Channel ow controller. Additional Guns should be congured for each applicator as shown below to provide automatic ow

control for each applicator.

Component

Parameters

The controlling parameters for each GUN, and for the CHANNELs assigned to that GUN, are called JOBs (also commonly referred to as PSETs, Color

Tables or Recipes). The JOB values dene ow

characteristics such as TARGET FLOW RATE, MIX RATIO, FLOW TOLERANCE, etc. JOBs include all of the parameters that may be dependent on the material used. This offers the ability to optimize system control as needed per material and then recall the settings each time that material is requested. There are up to 100 JOB #s for each GUN. By saving frequently used JOB #s to memory you can later recall them by loading the number representing that JOB #. The parameters are viewed and edited through the local Operator Interface or through a remote host computer.

A set of initial parameter values is included in the controller. The initial (default) values determine the operating conditions of the controller when started

for the rst time. Some of these will need to be

edited during initial setup based on the installation.

Gun 3 through 6 = Master Channel = Material = Output of Gun 2 (Resin + 2nd + 3rd Components) Flow Controller = DR1 Flow Meter = Gear-Type Operating Mode = Auto

4. Minimum ow rate for the DynaFlow is deter-

mined for each channel based on the number

of pulses/liter for the ow meter for the channel. (Refer to "Addendum C" for ow limitations.)

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DynaFlowTM User Manual - Operation

PARAMETER DESCRIPTIONS

CONFIG SYSTEM (F1)

All system parameters are password protected, unless disabled by setting the password to zero (0). Any time an operator wishes to change any of these parameters, they are prompted for the password. The password only needs to be entered once as long as the time between keystrokes does

not exceed the Password Timer as described

below. System parameters may be edited at any time regardless of the operating mode if no sys-

tem errors exist. Any active system errors must

be cleared.

NOTE

Any modications to the System Pa-

rameters screen data are saved only when the operator presses the "Store Data" key

(F5), otherwise the modications will be lost when the screen is exited with the es-

cape (ESC) key.

applications, painters will only trigger the spray

GUN enough to get atomization air to ow without

material. They use this air to blow off or feather the part. The software would normally sense this

air ow without material ow and then fault the

GUN. This parameter allows the painter a preset number of seconds of blow off time before faulting.

This parameter is specied in seconds, and the

default is 5 seconds. A setting of zero (0) disables

the no master ow fault.

Change Password (F3)

Used in conjunction with the Password Timer parameter. The operator can change the password if the previous password is known. The password is required for editing or setting all data tables and

conguration parameters. A password of '0' will

disable password operation.

Password Timeout

Once a valid password has been entered, this parameter sets the amount of time (in min) which is allowed from the last keystroke until password

operation is stopped. Once the timer has expired,

the user will be prompted for the password again if password protected settings are to be edited.

Horn Code

This is a coded number that represents when the supervisor would like the System Fault output relay to energize. This output is normally connected to a horn. The options desired are selected.

0 = No horn 1 = Horn when controller faults

2 = Horn when pot-life timer has expired 4 = Horn when external fault is detected

Blow Off Time

This parameter is used only if the GUN is congured as a manual GUN. The software monitors the trigger signal to identify when the spray GUN is triggered. (Typically this signal comes from an

air ow switch located in the atomization air line.)

If the software ever detects a GUN trigger signal

without pulses from the master channel ow meter

after the ‘Blow Off’ time has elapsed, a No Master Flow fault is issued. This prevents a painter from

painting if the ow meter sticks. In some manual

RIO Rack Address, Rack Size, Starting Quarter, and Baud Rate

Displays the RIO communication parameters, as decoded from the Interface Module DIP SW1 and SW2 settings.

SIO Baud Rate and COM Port

Displays the SIO communication baud rate, as decoded from the Interface Module DIP SW1 and SW2 settings, and the COM port (COM1 or

COM2), as dened in the GO.INI le.

Channel Module Firmware Revision(s)

Displays the rmware revision for the installed

Channel Modules.

Interface Module Firmware Revision

Displays the rmware revision for the Interface

Module.

User Interface Revision

Displays the current version of the user-interface software running on the user-interface PC.

LN-9400-00.9

DynaFlowTM User Manual - Operation

System Time and Date

Displays the current date and time and permits changing the same.

Language

This allows users to select between English and one Alternate Language. The alternate language

text is stored on the ash drive or hard drive of the PC in les named: TEXTMESS_ALT.TXT,

PARAMHLP_ALT.TXT, LABELS_ALT.TXT, SOLENOIDVALVES_ALT.TXT, and HELP_ALT.TXT.

Channel Module DIP SW1 Settings

Displays the DIP SW1 settings for each installed Channel Module.

Interface Module DIP SW1 and SW2 Settings

Displays the DIP SW1 and SW2 settings for the Interface Module.

MANUAL - This setting is used when the user wishes only to control the ratio of the material. Users can 'demand' as much material as they wish and the controller will deliver as much as possible while keeping the ratio on target.

- Number of Channels

This parameter has three possible settings: 0, 1, and 2.

0 - This, effectively, disables the gun. 1 - This indicates that the gun is to be a single

channel, ow control only applicator. 2 - This indicates that the gun is to be congured

as a dual-channel, ratio controlled applicator.

- Master Channel

This parameter has eight possible settings: 1-8.

For single channel guns, it simply indicates which

channel will be controlling the ow control valve and reading the owmeter for this applicator.

CONFIG GUN (F2)

GUN Conguration Parameters should not be edited while the GUN is running. This includes

all operational modes.

NOTE

Any modications to the GUN Cong-

uration Parameters screen data are saved only when the operator presses the "Store

Data" key (F5), otherwise the modications will be lost when the screen is exited

with the escape (ESC) key.

- Mode

This parameter has three possible settings: OFF, AUTO, and MANUAL.

OFF - This setting completely disables the gun, removes its data from the main screen, and places the channels tied to the gun available for use by another gun.

For dual-channel guns, this indicates (normally) which channel will be controlling the resin part of

the mixed material. It is always desirable for the master channel to have the higher ow rate of the

two materials.

- Slave Channel

This parameter has four possible values: 2, 4, 6, or 8.

It indicates which channel will be the slave (typically the catalyst) to the master channel (selected above) for ratio control.

- Clean Channels

This parameter has four possible values: NONE, MASTER, SLAVE, or BOTH.

This setting determines which of the uid regulators (or MVR valves) are opened to full when the

unit is put in 'Clean Mode' for ushing and lling

operations.

Default JOB#

Sets the JOB# which is loaded at power ON.

AUTO - This setting is used when the user wants

to control both the ow rate and the ratio (if it is

a plural component material) of the applicator.

LN-9400-00.9

Flow Tolerance Percentage

This is a number (in percent) that indicates how much deviation above and below the set point is acceptable. Increasing this number will reduce

nuisance faults, but may lead to inaccurate uid

metering if set too high.

Measure total hose length and inside diameter.

4. Use the following formula to calculate hose volume.

5. Add 10% to calculated value.

This number is a percent of the specied mix ratio

for each of the 2 materials that is allowed to occur before the system faults with an OUT OF TOLERANCE fault. This is only updated after the volume of material, as set by the Tolerance Volume, has

passed through the GUN. The accumulated ow

volume is reset to 0 upon the application of each RUN command.

Tolerance Volume

This parameter has no effect on single-component

GUNs and only effects GUNs congured for two-

component operation.

This is the volume over which the ratio accuracy is checked. Every time the volume of Master

CHANNEL uid specied in this parameter has owed, the ratio is checked. The default value is

150 cc’s of the Master CHANNEL. This parameter should never be set so low that less than 10

cc’s of the slave channel has owed. If this value

is set too low, nuisance OUT OF TOLERANCE faults will occur.

The rst time a gun is triggered after being placed

in Run mode, the Tolerance Volume is 150% of

the value entered in the job.

Mixed Volume

The amount of mixed material present in the mix tube, uid lines, and spray GUN combined. The uid in the spray GUN is always the material that has been mixed the longest. The processor

keeps track of how long this material has been

mixed (Pot-Life Timer), and therefore needs to know the volume from the mix tube to the spray GUN. To determine the amount of mixed material

in the system:

Volume = d2 x L x 12.87

Volume = Volume in cc’s d = Inside diameter of hose

L = Length of the uid line from the ow

meter to the spray GUN in inches

It is best to over-estimate the amount of mixed material rather than to under-estimate it!

he DynaFlow system uses the Mixed Volume and the Pot-Life Time when it monitors the ow rate of the Gun. Pot-Life is monitored by dividing the Mixed

Volume into 40 equal sized 'buckets' of material.

When an amount of material has owed that equals

the 'bucket' volume, the 40 'buckets' are time-shifted so the oldest 'bucket' is eliminated, representing

the material that has vacated the Mixed Volume

tubing at the GUN, and a new 'bucket' is added. If the GUN is in either Run or Load mode, a time value of 1 second is placed in the new 'bucket' to

represent mixed material. If the GUN is in Clean

mode, a time value of zero is placed in the new 'bucket' representing solvent. Every second, the time values stored in the 'buckets' are incremented

if they are non-zero (i.e. contain mixed material vs.

solvent). A Pot-Life alarm condition

exists if any of the 40 'buckets' contains a time

value greater than the Pot-Life Time (see JOB parameters). A Pot-Life alarm may be cleared by entering a Pot-Life Time of zero seconds.

Flush Volume

This parameter is programmed in cc's. It is the

volume of ush solvent or ush solvent/air mixture required to give an adequate ush of the uid lines

for the gun. It is used by the software to determine

when an adequate ush has occurred.

1. Measure the volume of the mixing block.

2. Measure the volume of the spray GUN.

LN-9400-00.9

Trigger OFF Delay

For automatic GUNs only. This parameter has two uses, depending on the position of DIP SW1-2 (or SW1-6) on the Channel Module.

In applications where the trigger off pneumatic action is slow, DIP switch SW1-2 (or SW1-6) on the Channel Module should be turned off so that when the GUN trigger signal is removed, the PID loop for the CHANNEL will continue to control the output of the MVR valve for the CHANNEL based

on the measured ow rate until the end of the

Trigger OFF Delay.

In applications where the trigger off pneumatic action is fast, DIP switch SW1-2 (or SW-1-6) on the Channel Card should be turned on so that when the GUN trigger signal is removed, the PID loop for the CHANNEL holds at the last output value until the end of the Trigger OFF Delay. In this case, it is recommended that a trigger valve (color control valve) be installed at the inlet of the MVR valve. This valve should be driven by a solenoid controlled by the MVR Enable signal for

the CHANNEL. In this way, the uid line will not

pressurize to the material supply pressure while the GUN is not triggered and there will be no

delay in initiating ow when the trigger is turned

on again, since the MVR valve is already at the position last commanded by the PID loop for the CHANNEL. If a triger valve is not installed at the inlet of the MVR valve, then the Trigger OFF Delay should not be set greater than perhaps 0.5

seconds to avoid pressurization of the uid line

during the Trigger OFF Delay. If the delay is too

long in this situation, excessive material may be

released when the trigger is turned on again due

to the higher pressure in the uid line.

In either case, the CHANNEL output returns to the MVR LOW value at the end of the Trigger OFF Delay.

Trigger ON Delay

For automatic GUNs only. This parameter allows the user to create a delay between the time when the controller receives a trigger ON signal from a

remote device to when it actually starts the ow

of material. This parameter should be used only in special situations where pneumatic delays present a problem.

Master and Slave Regulator Type

The channel hardware conguration is stored as

this parameter. It is necessary for the controller

to know which uid regulator type is being used

so that the proper default PID control parameters can be loaded (Kp, Ki, Kd).

Reverse Flow Volume

The amount of uid which is allowed to ow backwards in the GUN before the controller faults.

Reverse ow could cause catalyzed material to backup into either uid line if a check valve fails.

Keep this value small to minimize that possibil-

ity. If the GUN is congured for two-component

operation, than the Reverse Flow value will apply to each of the CHANNELs assigned to the GUN.

Reverse ow rate is displayed on the main screen of the Local Operator Interface as a ow rate bar colored red, instead of green for normal ow rate.

Bar Chart Maximum Flow Rate

This parameter determines what ow rate is indicated at the top of the bar-graphs on the main screen and determines the maximum values displayed on the plot graph screens.

Flow Rate Tolerance Time

This parameter allows the user to program how

long the ow rate can continue to operate outside of the programmed ow tolerance percentage before the unit fualts and stops ow. It is expressed

in seconds. If this number is too small, nuisance

ow out of tolerance faults may occur and if too large, improper lm builds could result.

Master Pot Volume

This is the volume of material that a pressure pot

will be lled with each time it is relled. There is a

pot-volume reset button on the Job Totals screen that allows the user to preset these volumes when

the pots are lled. This value is incremented

downwardly as material in the pot is consumed and pot empty fault will occur if the volume ever reaches the value of 0, warning the operator to

rell the pot(s).

Slave Pot Volume

See "Master Pot Volume" information.

LN-9400-00.9

Display Mode

This parameter has three possible values: RATIO TOLERANCE, MIXED VOLUME, and POT LIFE. It indicates what type of bar-graph will be displayed on the main screen immediately to the left of the

ow rate bar-graph for each gun.

- Ratio Tolerance

This indicates the instantaneous ratio of the mate-

rial being fed into the static mix tube at any instant

in time.

- Mixed Volume

This indicates how much of the mixed volume (the material between the static mix tube and the

applicator) has ratio material in it.

When a GUN is congured for two-component

operation and the Ratio is 99.0:1, or greater, the GUN is said to be operating in pseudo singlecomponent mode. In this case, the slave (catalyst)

CHANNEL is NOT set to MVR LOW when the GUN is placed in either Run or Load modes. How-

ever, if the slave (catalyst) CHANNEL is specied

as a clean CHANNEL, it will be turned on to MVR HIGH in Clean mode. When a 2K manual GUN is placed in single-component operation, the master (resin) CHANNEL simply turns on to the MVR HIGH output pressure

when the GUN is placed in Run mode. All uid ow is accounted for in the JOB totals.

- Pot Life

This bar-graph indicates how old the oldest mixed

material is. (This is the material in the applicator.)

EDIT JOB (F4)

JOB parameters may be edited at any time. However, if a JOB is edited while active, the changes made to CHANNEL related parameters will not take effect until the GUN has been halted and requested to be active again. Changes made to GUN related parameters take effect immediately after being saved to the Interface Module.

NOTE

Any modications to the JOB Param-

eters screen data are saved only when the operator presses the "Store Data" key

(F5), otherwise the modications will be lost when the screen is exited with the es-

cape (ESC) key.

Mix Ratio

Ratio is expressed as parts of Master CHANNEL

to parts of Slaved CHANNEL in the form of XX:1. The Master CHANNEL is typically the resin and the slave CHANNEL is typically the catalyst. If

the desired mix ratio is supplied as a percentage

of catalyst to the total volume. Use the Master

and Slave Percentage boxes instead.

When a 2K automatic GUN is placed in singlecomponent operation, the master (resin) CHAN-

NEL will control uid per the set point parameter

in the JOB when the GUN is placed in Run mode

and a trigger signal is supplied. All uid ow is

accounted for in the JOB totals.

Master Percentage

Refer to "Mix Ratio" information.

Slave Percentage

Refer to "Mix Ratio" information.

Flow Rate Set Point

This parameter has several functions depending

on the mode in which the GUN is congured.

- Manual Mode

If the GUN is congured as a manual GUN, this value is the total desired ow rate (cc’s/min) when

the GUN is put in Load Mode (See "Load Mode" in the "Operation" section of this manual).

- Automatic Mode without Analog Control

If the GUN is congured as an automatic GUN and external analog control of the ow rate is not being used, this is the total ow rate of the mixed

material desired at the spray GUN.

LN-9400-00.9

- Automatic Mode with Analog Control (Dynamic Control)

If the GUN is congured as an automatic GUN and external analog control of the ow rate is

being used, the setpoint value is only active if there is no analog signal. Analog control is active anytime that the input signal is greater than

0.25 VDC (4.63 ma).

- Manual GUN

This parameter is an alarm set point. If the total

ow rate of the mixed material to the spray GUN falls below the amount specied by this parameter,

the GUN will shut OFF as the result of a FLOW OUT OF RANGE FAULT. If no alarm is desired, set this parameter to zero (0) and the feature will be disabled.

- Automatic Mode with RIO Control (Dynamic Control)

If the GUN is congured as an automatic GUN and RIO control of the ow rate is being used, the set

point value has no meaning unless the RIO commanded set point is zero. In that case, the JOB

set point is used as the GUN ow rate set point.

NOTE

When operating in 2K mode, this pa-

rameter relates to the total mixed material

delivered through the GUN.

Maximum Flow Rate

This parameter has 2 possible meanings, depen-

dent upon how the GUN is congured.

- Automatic GUN

This parameter is used to scale the ow rate

output for the GUN's CHANNEL(s) to specify the

desired ow rate when a 0 VDC (or 4.0ma) signal

is applied to the analog set point input.

Pot-Life Time

The time, in seconds, required for the mixed

material being used to set up or harden. This information is obtainable from the manufacturer of the material. The controller will determine if any

mixed material is in the paint lines for longer than

the Pot-Life Time setting. It is recommended that this time be somewhat less than the actual set up time to allow time to clean the system in the event

that the Pot-Life timer expires. If the specied time expires, a Pot-Life alarm is issued, warning the operator that this problem exists. The Pot-Life

alarm does not shut off the GUN, as this would

prevent the operator from triggering and expelling the mixed uid. The Pot-Life alarm status will remain until the expired material has been purged.

- Manual Gun

This parameter is an alarm set point. If the total

ow rate of the mixed material to the spray GUN exceeds the amount specied by this parameter,

the GUN will shut OFF as the result of a FLOW OUT OF RANGE FAULT.

- Automatic Gun

This parameter is used to scale the ow rate output

for the GUN's CHANNEL(s) to specify the desired ow rate when a 10 VDC (or 20 ma) signal is applied to the analog set point input.

Minimum Flow Rate

This parameter has 2 possible meanings, depen-

dent upon how the GUN is congured.

LN-9400-00.9

Pot-Life checking may be disabled by entering a value of zero seconds. Since previous versions

of the DynaFlow rmware and software used the

value 999 minutes to disable Pot-Life checking, the value of 999 seconds is not permitted and will automatically be changed to zero seconds. When

upgrading DynaFlow rmware and software, JOBs that specied any value other than 999 minutes

must be manually converted to seconds after the upgrade is performed. A Pot-Life alarm may be cleared by entering a Pot-Life Time of zero seconds.

MVR High Pressure (Master and Slave)

This parameter allows the operator to limit the

maximum pressure that the transducer is allowed to output to the uid regulator in any mode.

DynaFlowTM User Manual - Operation

MVR Low Pressure (Master and Slave)

This parameter allows the operator to set the low

limit on the pressure sent to the uid regulator

while in the Run or Load modes. It can be used to cause a faster response by the transducer/

regulator system. It should be adjusted so that the regulator valve is just short of opening. With

a standard MVR valve, this value should never

exceed 30 psi. If this value is too high, continuous

FLOW TOO HIGH faults will occur.

When a GUN is congured for two-component

operation and the Ratio is 99.0:1, or greater, the GUN is said to be operating in pseudo singlecomponent mode. In this case, the slave (catalyst) CHANNEL is NOT set to MVR LOW when the GUN is placed in either Run or Load modes. However,

if the slave (catalyst) CHANNEL is specied as

a clean CHANNEL, it will be turned on to MVR HIGH in Clean mode.

MVR High and MVR Low Effect On PID Operation

The PID will only output transducer pressures between MVR LOW and MVR HIGH.

Pulses/Liter (Master and Slave)

The number of pulses sent from the ow meter to the controller for each unit of uid ow. Each pulse represents a volume of uid and is dependent on ow meter size. This value can be veried or adjusted during a calibration process to achieve

the best accuracy (See "Calibration Mode" in the "Operation" section of this manual). The cali-

bration of all ow meters should be periodically checked. The rheology of some uids may effect

the calibration values, therefore a different value for pulses per liter may be used for each material and is entered into the JOB data tables.

Deadband would be between 95 and 105 cc/min. The PID controller would therefore be suspended

whenever the actual ow rate is within this range.

This parameter should normally be set to 1 cc/min.

Proportional Gain (Kp) (Master and Slave)

The proportional PID controller gain mainly affects the response of the DynaFlow system to disturbances. The DynaFlow system may operate with Kp at zero, however response to material supply and delivery pressure disturbances will be poor. The value of Kp is divided internally by a factor

of 1,000 and is used as a multiplier for the ow rate error term. The ow rate error term is the difference between the set point and actual ow

rate for the CHANNEL.

Integral Gain (Ki) (Master and Slave)

The integral PID controller gain mainly affects the steady-state (non-transitional) response of the DynaFlow system. The DynaFlow system must have a non-zero value for Ki to operate properly. The valve of Ki is divided internally by a factor of 100,000 and is used as a multiplier, along with a factor of 3, for the sum of the error term over the time the trigger has been turned on.

Derivative Gain (Kd) (Master and Slave)

The differential PID controller gain mainly affects the response of the DynaFlow system to disturbances caused by disturbances that are slow in nature. Normally, the DynaFlow system may operate with a Kd value of zero. The value of Kd is divided internally by a factor of 1,000 and is used as a multiplier, along with a factor of 1/3, for the rate of change in the error term.

Deadband (Master and Slave)

This represents a ow rate range divided equally above and below the set point ow rate in which the

PID controll is suspended. This keeps the control output from continually changing and produces stability when close to the requested value. For

example, if the Deadband is set for 5 cc/min and ow rate set point is set for 100 cc/min, the

LN-9400-00.9

NOTES

DynaFlowTM User Manual - Operation

LN-9400-00.9

DynaFlowTM User Manual - Operation

Diagnostic Parameters (F5)

The following parameters are available in the Local Operator Interface program as diagnostic parameters.

Force CHANNEL Digital Inputs

Forcing inputs permits debugging and troubleshooting to determine proper operation of the hardware. Each CHANNEL input can be forced ON therefore not requiring a hardware signal for

that input to become active. If an external hardware

input is present, a forced OFF command will have no effect unless the hardware input is removed.

Force CHANNEL Digital Outputs

Forcing outputs permits debugging and troubleshooting to determine proper operation of the hardware.

Force CHANNEL Analog Outputs

Forcing analog outputs permits debugging and troubleshooting to determine proper operation of the hardware.

PLOT DATA (F6)

This feature allows the operator to generate a real-time graph of many of the process variables to monitor the response of the system as it relates to time. Up to four variables from any of

the congured guns can be graphed at any one

time. All four variable do not have to be from the same gun. (e.g. The triggers from 4 guns can be monitored at the same time.)

The following variables can be graphed:

be selected.) Pushing the F3 button removes all items from the selection list and allows the operator to make a new selection. Pushing F2 will start the data acquisition graph running. Each of the 4 graphed values will be plotted in a different color. A legend at the top left and top right of each of the two graphs indicate which value is which color.

(F1) Time Base – This button allows the user to

switch the time base (resolution) of the graph. In fast mode, the full screen width is graphed in 45 seconds. In slow mode, the full screen width is 90 seconds.

(F2) Single Plot – This button allows the user to

record one full screen of data (45 or 90 seconds) at which point the graphing stops to allow the

user to examine the data. In continuous data

mode, when the cursor reaches the right end of

the screen, it automatically jumps back to the left

and over writes the old data.

(F3) Stop Plot – This button allows the user to

stop the data acquisition process temporarily and freezes the display for analysis or to save the plot to disk or memory stick.

(F5) Start Stop ß - This button allows the user to move both the start-time cursor and the stoptime cursor at the same time to the left.

(F6) Start Time ß - This button allows the user to move the start-time cursor to the left.

(F7) Stop Time ß - This button allows the user to move the stop-time cursor to the left.

- Trigger

- Requested Ratio

- Actual Ratio

- Requested Flow (both channels)

- Actual Flow (both channels)

- Requested Flow (Chan. A & B)

- Actual Flow (Chan. A & B)

- Control Pressure (Chan. A & B)

To select the data to be graphed, simply touch the Plot Data button (F6) then touch the items you wish to plot one at a time followed by touching the Select Variable button (F1). (Up to four items can

(F8) Stop Time à - This button allows the user to move the stop-time cursor to the right.

(F10) Save Plot – This button allows the user to save the displayed pot to either the ash drive or

hard drive of the touchscreen or to a USB memory stick. It is saved in a bitmap format (.bmp) so it can be printed on any standard P.C. with a printer

attached. The le is saved based on the date and

time it is saved in the following format… File Name: AABBCCDD.bmp where…

AA = Month, BB = Day of Month, CC = Number of hours since midnight, DD = Minutes since last hour.

LN-9400-00.9

DynaFlowTM User Manual - Operation

Data Displays – At the top of the graphing screen there may be as many as six white boxes with data in them. The center two boxes indicate the time

of the start and stop cursors (start on top, stop

on the bottom). The other four boxes indicate the

value of the graphed variable at the point where the cursors are currently positioned.

JOB TOTALS (F7)

Calendar date/time data is not available from the Interface Module and must be supplied by the Operator Interface or host computer.

Daily Total (For each JOB per CHANNEL)

Records accumulated total of all material through a CHANNEL since last reset. Any time period associated with this total is based on when it is reset.

For example, if it is reset after each rack or part,

at the end of a shift, end of the day, or end of day.

Daily Total (For all JOBs per CHANNEL)

Records the accumulated total of all material for all JOBs through a CHANNEL since last reset. Any time period associated with this total is based on

when it is reset. For example, if it is reset at the

end of a shift, end of the day, or end of the year.

Yearly Total (For all JOBs per CHANNEL)

Records the accumulated total of all material for all JOBs through a CHANNEL sincle last reset. Any time perior associated with this total is based

on when it is reset. for example, if it is reset at the

end of a shift, end of the day, or end of the year.

Calibration Total (For all JOBs per CHANNEL)

Records the accumulated total of all material for all JOBs through a CHANNEL while in CALIBRATION MODE of operation since last reset.

Yearly Total (For each JOB per CHANNEL)

Records the accumulated total of all material through a CHANNEL since last reset. Any time period associated with this total is based on when

it is reset. For example, if it is reset at the end of

a shift, end of the day, or end of the year.

Calibration Total (For each JOB per CHANNEL)

Records the accumulated total of all material through a CHANNEL while in CALIBRATION MODE of operation since last reset.

Grand Total (For each JOB per CHANNEL)

Records the accumulated total of all material through a CHANNEL, including while in CALIBRATION MODE of operation, since last reset. Any time period associated with this total is based

on when it is reset. For example, if it is reset at the

end of a shift, end of the day, or end of the year.

Grand Total (For all JOBs per CHANNEL)

Records the accumulated total of all material for all JOBs through a CHANNEL, including while in CALIBRATION MODE of operation, since last reset. Any time period associated with this total

is based on when it is reset. For example, if it is

reset at the end of a shift, end of the day, or end of the year.

Clean Total (For all JOBs per CHANNEL)

Records the accumulated total of all material for all JOBs through a CHANNEL, while in CLEAN MODE of operation, since last reset. Any time period associated with this total is based on when

it is reset. For example, if it is reset at the end of

a shift, end of the day, or dend of the year.

CALIB PROC

CHANNEL #

CHANNEL to be calibrated (1-8). Each CHANNEL must be calibrated separately.

LN-9400-00.9

Calibration Mode

Sets open-loop manual or closed-loop automatic calibration mode.

DynaFlowTM User Manual - Operation

- Open-Loop or Manual Calibration Mode

This mode attempts to ow material at the highest ow rate possible by setting the output to the E/P

transducer at the MVR HIGH parameter, located in the JOB table, for the selected CHANNEL. No less than 200 cc of material should be dispensed during calibration. Otherwise, the error in calibration will be too large. With 200 cc of material dispensed into a beaker, the error in calibration will be limited to+/- 0.5%, since the measured volume can be determined to only the nearest cc. The operator must open and close the calibration valve, or supply a GUN TRIGGER. The material volume is entered by the operator and a new Pulses/Liter is calculated.

- Closed-Loop or Automatic Calibration Mode

This mode sets the ow rate set point for the selected CHANNEL based on the Total Flow Rate and Ratio for the selected GUN, as stored in the JOB, since calibration should always be performed

at the normal ow rate for the CHANNEL. The Calibration Time is also set based on the ow rate

so that no less than 200 cc of material will be dispensed during calibration. Otherwise, the error in calibration will be too large. With 200 cc of material dispensed into a beaker, the error in calibration will be limited to +/- 0.5%, since the measured volume can be determined to only the nearest cc. The operator may override both the Calibration Time and Calibration Set Point, if desired. The operator must open and close the calibration valve, or supply a GUN TRIGGER. The material volume that passed through the GUN is recorded. The measured volume is entered by the operator and a new Pulses/Liter value is calculated.

Actual Flow Rate

Displays the actual ow rate during calibration.

This value is based on the Current Pulses/Liter parameter, so it will be inaccurate if that parameter is inaccurate.

Number of Pulses

Displays the actual number of pulses received

from the ow meter during calibration.

Calculated Volume

Displays the calculated volume of material that should be in the beaker when the calibration is stopped. This value is based on the Current Pulses/Liter parameter and the Number of Pulses received, so it will be inaccurate if the Current Pulses/Liter parameter is inaccurate.

Measured Volume

The measured volume (cc’s) of material in the calibration beaker. This value is entered by the operator. Once a non-zero value is entered, the operator may not enter a Measured Weight and

Specic Gravity.

Measured Weight

The measured weight of material (grams) in the calibration beaker (less the tare weight of the beaker). This value is entered by the operator. The scales used should be accurate to 0.10 gram. This value is entered by the operator. The Mea-

sured Weight, along with the Specic Gravity, is

used to calculated the Measured Volume. Once a non-zero value is entered, the operator may not enter a Measured Volume.

Automatic calibration mode may not be selected for the Master channel of a Manual Gun since it

normally has no MVR to control ow rate.

Calibration Time

Sets the time duration for calibration.

Flow Rate Set Point

Sets to actual ow rate during calibration. This

value is based on the Current Pulses/Liter parameter, so it will be inaccurate if that parameter is inaccurate.

Specic Gravity

Specic gravity is the ratio of a material’s density

to the density of water. This can be obtained from the material safety data sheet (MSDS), or directly from the material supplier. This value is entered

by the operator. The Specic Gravity, along with

the Measured Weight, is used to calculated the Measured Volume. Once a non-zero value is entered, the operator may not enter a Measured Volume.

LN-9400-00.9

Calculated Pulses/Liter

This is the new Pulses/Liter value based on the

Number of Pulses received from the ow meter

during calibration and either the Measured Volume,

or the Measured Weight and Specic Gravity. The

operator may override the Calculated Pulses/Liter value by entering a Calculated Pulses/Liter value.

Current Pulses/Liter

Displays the current Pulses/Liter value used by the Channel Module during calibration. If this value is inaccurate at the time, which is why calibration is being performed, the Actual Flow Rate and Calculated Beaker Volume values will also be inaccurate.

Operational Parameters

Flow Rate

• Indicates total ow rate through a GUN.

• If in 2K, sums the total of each CHANNEL

attached to the GUN.

• If in 1K, simply indicates the CHANNEL

ow rate.

DynaFlowTM User Manual - Operation

GUN Status

Indicates the current status of the GUN. This can be one of the following:

GUN Active (in run mode) GUN Halted CLEAN mode active LOAD mode active CALIBRATION mode active GUN faulted Transparent mode active Analog Hold mode active

Pot Life Time Exceeded

JOB Queue

Stores the next JOB to be run. A RUN command following a HALT will load the next JOB # from

the Queue. If more than one JOB # is toggled into

the Queue before the next RUN command, then

the newest JOB # is placed into the Queue and the previous JOB # is lost.

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DynaFlowTM User Manual - Operation

Color Change Sequencer

The redesigned DynaFlow includes an optional

color change sequencer that controls the ush,

load, and color change sequences for each gun.

Each time a job number is loaded into a gun, the ush and load sequences are downloaded to this

controller. (A color change sequence is simply

a ush sequence followed by a load sequence.)

F9: COLOR CHANGE

An optional color change sequencer may have been included with the controller. If it was included, the F9 key will indiacte as such. If the F9 key is blank, your system does not have this option.

When this function is selected, the operator is rst

prompted for the gun mumber they wish to view or edit the sequence for, they are then prompted for which Job Number they wish to view and/or

edit the sequences of, and last, they are asked if

they want to view/edit the sequence for ushing or lling. (There is a separate ush sequence and

load sequence stored for every Job Number and for every gun.)

Once the operator responds to the previous prompts, a screen similar to the one on the previous oage appears.

This chart displays a simple 6 step sequencer

where the user denes how long they wish each

step to take and which valves or signals should be energized at each one of those steps. There

are 6 steps for the ush cycle and 6 steps for the

load cycle. When a color change is desired, the

sequencer automatically runs the ush sequence

followed by the load sequence.

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DynaFlowTM User Manual - Operation

The following solenoid valves can be controlled by the sequencer:

Resin/Solvent Air Chop Resin Solvent Resin Air Paint Dump Valve Resin Fluid Override Trigger Solenoid Catalyst #1 Catalyst #2 Catalyst #3 Catalyst Solvent Catalyst Override

The following DynaFlow inputs can be controlled by the sequencer:

DynaFlow Run DynaFlow Halt DynaFlow Trigger DynaFlow Load DynaFlow Clean Catalyst Disable

Note that there are too many valves and signals to be displayed on one screen. Therefore, the opera-

tor must scroll down to see the bottom ve items.

Program the time for each step by touching the

step duration box under the step to be modied

and then push F1 (Modify) to change it. Then

toggle any of the signal or valve boxes at each

step that you wish to have on during that step and then push the Modify button. The steps will toggle between Off and On as you continuously hit the Modify button.

The Hold step is the nal step in the sequence (for both ush and ll). When the sequence com-

pletes, the signals and valves will be held in the condition selected in the hold step. Keep in mind that when changing from one color to another, the

system performs a ush sequence followed by a ll sequence so the hold step in the ush sequence

will only occur momentarily.

There are 8 function keys dened while editing ush, load, and color change sequences:

F1: Modify – This button brings up a numeric

keypad if cursor is on one of the step duration cells. If cursor is on one of the valve condition cells, that cell is toggled from off to on or on to off.

F2: Chop Air Time – This button allows the user

to program how long the air valve remains on for each step of the solvent/air chop timer.

F3: Chop Solvent Time - This button allows the user to program how long the solvent valve remains on for each step of the solvent/air chop timer.

F4: Edit Fill/Flush – This button opens the screen that allows viewing and editing of the ush or the ll sequences (the button changes to ll if the ush sequence is displayed and to ush if the ll

sequence is displayed).

F5: Send to PLC – This button allows the operator

to immediately send the edited sequence to the

sequencer (located in the motor amplier panel).

Note that the sequences are automatically sent to the sequencer every time a new Job Number is loaded.

F8: Copy Sequence – This button allows the operator to copy sequences from one job to another.

F9: Read In File – This button allows the operator to load ush and load sequences from the ash

drive of the touchscreen, a USB memory stick, or

to a oppy diskette.

F10: Save To File – This button allows the operator to save ush and load sequences to the ash drive

of the touchscreen, a USB memory stick, or to a

oppy diskette. All ush and load sequences for all guns are saved in a le named: ColorChg.par.

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DynaFlowTM User Manual - Operation

ERROR LOG (F11)

- Also See Section on Error Codes

Each ERROR CODE can represent a CHANNEL, GUN or system error. See the Troubleshooting section for list of error codes. It is possible for more than one code to be issued at the same time.

The Interface Module stores ten (10) previous error codes until they are read by the Local Operator Interface program at which time they are automatically purged from its log. The Local Operator Interface program stores one hundred (100) previous error codes until they are manually cleared by the operator. The operator may

also save the error codes to a oppy diskette for

later analysis.

A PLC may obtain the current error conditions via RIO at any time, but it must maintain its own log.

AUTOMATIC GUN APPLICATIONS

Automatic applicators use automatic means to

vary the uid ow through the use of transducers

and material regulators. When used with singlecomponent materials and an automatic spray applicator, the DynaFlow controller regulates total

material ow.

to the MVR LOW setting (default = 0 VDC). On the

rst receipt of a trigger signal, the master channel

immediately starts its closed loop (PID) control and updates the information to the transducer at a rate determined by the PID Update Time (default

= 30ms) to adjust the actual ow rate to match the target ow.

At the same time, in a two-component system, the slave channel (catalyst) also closes its PID control

loop and matches the actual ow rate to the target ow rate as determined by the requested ow rate

ratio of the Master CHANNEL (resin) and slaved CHANNEL (catalyst).

Both channels run closed loop, independently of each other. If either CHANNEL is not able to

achieve the required target ow rate, a FLOW TOO

LOW or FLOW TOO HIGH fault will be issued by the controller for the offending channel.

After an amount of material has passed through the Master CHANNEL (set by the TOLERANCE VOLUME parameter), the DynaFlow controller compares that volume with the volume of the

catalyst that owed during that volume interval. If

the ratio is outside of the tolerance as set by the FLOW TOLERANCE parameter, the DynaFlow controller will issue an OUT OF TOLERANCE fault for the offending GUN.

When used with two-component materials, the

DynaFlow controller regulates both the total uid ow rates to the applicator and the mixing ratios.

Each CHANNEL of the two-component material is programmed with predetermined values.

The following conditions must be met in order for

the GUN to allow uid ow:

1. There must be no system faults or GUN faults active.

2. There must be valid GUN congurations.

3. The proper inputs must be supplied.

When a GUN is placed in the RUN MODE, the controller sends a signal to the transducer to open

Dynamic Flow Rate Set Point Control

Dynamic Flow Rate Set Point Control is useful

for changing ow rates of a material to achieve

different coating thickness over different areas of

the same part. Several examples are shown in

the "Analog Control Settings chart" in this section.

In automatic GUN applications, the total ow rate

set point for the GUN may be varied in real time using either of two methods; Remote I/O (RIO) or Analog Input. If the RIO Set Point is zero and Analog Input Set Point is less than 0.25 volts, the Total Flow Rate set point comes from the JOB.

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ANALOG CONTROL SETTINGS

DynaFlowTM User Manual - Operation

Minimum

Flow Rate

CC's/Min

100

Maximum Flow Rate

CC's/Min

100

300

Minimum

Voltage or

Current

0 volts or 4 ma

RIO Set Point

The Total Flow Rate set point for a GUN may also be input via Remote I/O (RIO). No scaling is required, since the Total Flow Rate value is sent in cc's/minute. RIO control is initiated when the value sent is non-zero, regardless if an Analog Input Set Point greater than 0.25 volts is presented

to the Master CHANNEL.

Analog Input Set Point

The Total Flow Rate set point for a GUN may be

input via an external analog signal (0-10 VDC or

4-20 ma) presented to the Master CHANNEL via

the Channel Module. The Maximum Flow Rate

and Minimum Flow Rate for the JOB determine the scaling applied to this analog input. Analog control is initiated when the input signal is greater than 0.25 volts and the RIO Set Point is zero.

Note: When congured for current loop input,

the minimum 0.25 volts is achieved since 4 ma produces 2.00 volts at the input due to the 500 ohm shunt resistor used in current loop mode.

Maximum

Voltage or

Current

10 volts or 20 ma

CC's/Volt

10.00

20.00

CC's/Ma

6.25

12.50

To Place A GUN In LOAD MODE:

1. The external GUN enable input must be supplied to the Master CHANNEL. No system or GUN

faults can be active and the GUN conguration

and JOB tables should be properly set.

2. A signal must be supplied to the Master CHANNEL LOAD input or a LOAD command issued from the Operator Interface Panel or the host controller.

3. Flow will begin when the Trigger signal is supplied.

To Exit LOAD MODE:

1. Simply remove the LOAD input and apply the HALT input or issue a command from the Operator Interface Panel.

MANUAL HAND GUN APPLICATIONS

Load Mode

LOAD MODE is similar to RUN MODE. However, in LOAD MODE, up to 10 faults are permitted before the gun will leave LOAD MODE and enter the FAULT MODE. All eleven (11) faults will appear in the Error Log screen. The GUN will automatically leave LOAD MODE and return to the READY MODE after a volume greater than or equal to

the Mixed Volume has owed since the last fault.

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The DynaFlow controller can provide closed loop regulation for manual hand GUN application of two-component materials. When used with hand

spray GUNs, the painter regulates the total uid ow with the spray GUN or an inline uid regulator.

Regulation of two-component materials is based on pre-set ratios located in the JOB tables.

When the GUN is placed in RUN MODE, the master channel (resin) goes full open, or to the

setting specied for that channel as MVR HIGH,

and stays at that value. The slave channel goes

to the pressure setting specied for that channel by MVR LOW. The controller determines the ow

DynaFlowTM User Manual - Operation

rate of the master channel based on owmeter

feedback and calculates the set point of the slaved (catalyst) CHANNEL based on the ratio setting for the GUN. The detection of a Trigger OFF signal

or the lack of Master CHANNEL ow meter pulses

will cause the controller to output the MVR LOW setting to the Slave CHANNEL. In addition, the PID control loop is frozen and the last control output stored. Upon reapplication of a Trigger signal,

or the detection of Master CHANNEL ow meter

pulses depending on the dip switch setting on the Channel Module, the stored Slave

CHANNEL control signal is output for a short delay time and then the PID control loop is again initiated. This results in stable control loop operation regardless of the duration or quickness of trigger signals.

The ow rate of the master CHANNEL will be

continuously monitored during operation and the

slaved CHANNEL set point adjusted accordingly.

To Place A GUN In LOAD MODE:

1. The external GUN Enable input must be sup-

plied to the Master CHANNEL. No system or GUN

faults can be active and the GUN conguration

and JOB tables should be properly set.

2. The GUN Trigger input is not required for manual GUNS.

3. A signal must be supplied to the Master CHANNEL LOAD input or a LOAD command issued from the Operator Interface Panel or other host controller.

4. Flow will begin immediately.

To Exit LOAD MODE:

1. Simply remove the LOAD input and apply the HALT input, or issue a command from the Operator Interface Panel (host controller).

If the slaved CHANNEL cannot achieve the proper

ow rate, the software issues a FLOW TOO LOW

or FLOW TOO HIGH fault.

Additionally, the software veries ratio after each TOLERANCE VOLUME has owed through the master channel ow meter by comparing the two volumes that owed during that time period and

calculates a "ratio error". If that error is greater than the FLOW TOLERANCE parameter, the software issues an OUT OF TOLERANCE fault.

When the GUN is given a HALT command, both

uid regulators are set to 0 psi.

Load Mode

the Mixed Volume has owed since the last fault.

GENERAL

The following are common to both AUTOMATIC and MANUAL GUN operation.

Pulsed and Maintained Inputs

Pulsed inputs detect the transition in voltage, either up or down. This form of input is comparable to a momentary push-button. Pulsed inputs are timing sensitive, e.g. the pulse MUST be present at the input at the proper time in relation to other input signals. The duration of the pulse is also critical. Pulsed inputs should be supplied for at least 0.25 seconds in duration. The input signal is ignored after detection by the controller and can be removed at any time after the minimum

0.25 seconds.

Maintained inputs require the voltage to be held at a level, either low or high in order to perform the intended function.

System Inputs and Outputs

System I/O applies to all GUNs in the system. They provide system status, input for JOB numbers, and all system commands.

LN-9400-00.9

JOB SELECT INPUTS

DynaFlowTM User Manual - Operation

Discrete System

Inputs

JOB Select #1 JOB Select #2 JOB Select #4 JOB Select #8 JOB Select #10 JOB Select #20 JOB Select #40 JOB Select #80 JOB Select #100

Selects BCD Bit #1 Selects BCD Bit #2 Selects BCD Bit #4 Selects BCD Bit #8 Selects BCD Bit #10 Selects BCD Bit #20 Selects BCD Bit #40 Selects BCD Bit #80 Selects BCD Bit #100

JOB Select Inputs

These inputs are used to select a JOB number

from the external PLC or other host controller if

serial communication is not being used. These inputs represent Binary Coded Decimal (BCD) that translates to 3 digits, each digit represented as a 4-bit binary code. The system inputs shown in Figure 6 are used to select and enter a JOB

number. The JOB Select inputs are used in con-

junction with the GUN Mask inputs to determine

which GUNs will accept the JOB number represented by the total of the active JOB Select Bits.

Example: JOB #25 is Requested

Toggles (enters) the

Selected Values

JOB numbers can be entered into the JOB Queue at any time regardless of the operating mode.

These signals are used in conjunction with the

GUN MASK inputs to determine which GUN(S) will receive the JOB # as input by the program select inputs. The JOB SELECT inputs must be present at the time that the JOB SELECT STROBE signal is activated.

The basic sequence for selecting and entering JOB numbers is:

1. Select and hold high the appropriate JOB SELECT input bits.

Value

1 2 4

8 10 20 40 80

100

Decimal Number = 25

Most Signicant Digit (100's) = 0 = binary 0000 Most Signicant Digit (10's) = 2 = binary 0010 Least Signicant Digit (1's) = 5 = binary 0101

LN-9400-00.9

2. Select and hold high the appropriate GUN MASK input(s). This can be performed simutaneously with the JOB SELECT input bits.

3. Pulse the STROBE input.

4. Return all inputs to the low state (0 VDC).

DynaFlowTM User Manual - Operation

Figure 5 gives a graphic representation of the timing required for selecting a JOB #. Normally, the JOB SELECT inputs and GUN MASK inputs are held high for a slightly longer duration than the STROBE. This ensures that the new JOB SELECT and GUN MASK inputs are correct before strobing the information into the controller.

Figure 5: JOB Select Timing Diagram

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DynaFlowTM User Manual - Operation

Figure 6 shows 4 Toggle Signals. By following the dashed line down you can determine the states of

the various signals for each example. Maintained inputs that are high are “active”. Pulsed signals that go high at that instance are also active. The list below will help explain what JOB number is selected,

and to which of the 8 GUN queues the JOB is entered into.

Toggle 1

JOB number selected: 69 GUNs Masked to accept JOB #69: 1,3

Toggle 2

JOB number selected: 26 GUNs Masked to accept JOB #26: 2,5,8

Toggle 3

JOB number selected: 63 GUNs Masked to accept JOB #63: NONE

Toggle 4

JOB number selected: 22 GUNs Masked to accept JOB #22: 4

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DynaFlowTM User Manual - Operation

Figure 6: JOB Selection Timing Diagram Sample

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DynaFlowTM User Manual - Operation

JOB Queue

The JOB Queue is an input buffer for each of the 8 possible GUNs in the system. JOBs are loaded into the Queue only if the GUN is already operating a JOB in the RUN, LOAD, CLEAN, CALIBRATE modes. Each of the 8 GUNs has a JOB Queue

with a xed length of 1 (JOB). This permits the next JOB number for GUN #n to be stored before

the current JOB has been halted. After the current

JOB has been halted the next RUN input signal will initiate the next JOB number located in the queue.

NOTE

If another JOB number is loaded into

the Queue before it is emptied, the queue contents will be replaced with the second

entry. See the following examples.

JOB Number is Loaded into the Queue Before it is Emptied

1. GUN #3 is running JOB #32 and has NOT been halted.

2. JOB #47 is in the Queue for GUN #3.

3. JOB #54 is now entered into GUN #3’s Queue.

4. This will result in JOB #54 replacing JOB #47 for GUN #3.

JOB #47 became "lost" and was not processed by GUN #3.

5. JOB #47 moves up and the Queue empties. JOB #47 becomes the current JOB #.

6. JOB #54 is entered into GUN #3’s Queue.

JOB #54 is now the next JOB for GUN #3.

JOB Queue Defaults

If no JOB is entered into the Queue (the Queue is empty) the current JOB number reverts to the last JOB number entered if the GUN Run signal is made active.

1. A Halt signal input will halt the current JOB.

2. Pressing Run will restart the GUN with the old JOB number.

3. Entering a new JOB number and selecting Run will restart the GUN with the new JOB number.

Reverse Flow Detection

For two-component systems, both forward and

reverse uid ow is detected through the ow meter if non-ber optic owmeters are being utilized. Reverse ow detection can help prevent mixed two-component material from backing up into the uid supply system due to check valve failure. When the controller detects reverse uid ow in excess of the programmed REVERSE FLOW LIMIT, it will immediately shut OFF the uid regulator valves and prohibit mixed material from contaminating the uid supply.

Reverse ow rate is displayed on the main screen of the Local Operator Interface as a ow rate bar colored red, instead of green for normal ow rate.

The Correct Sequencing Should Be:

1. GUN #3 is running JOB #32 and has NOT

nished. (Current JOB #)

2. JOB #47 is in the Queue for GUN #3. (Next

JOB #)

3. GUN #3 is halted.

4. The Run input signal is pulsed. (The Trigger input does not effect the JOB queue)

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Pot-Life Fault

Each of the GUNs congured as two-component

has an associated Pot Life Time located in the JOB Parameters. These timers are used for materials

that can harden or setup after a specic time. Hardening material in uid lines or the spray applicator

can cause costly downtime and maintenance to correct. The output of the POT-LIFE TIMER alarm

can be connected directly to an external PLC for

automatic initiation of the cleaning cycle, or to an alarm to alert the operator. The Horn

DynaFlowTM User Manual - Operation

Code, located in the System conguration table,

determines if a Pot-Life Fault activates the horn. A Pot-Life Fault can only be reset by eliminating the

expired material from the uid lines, or by setting

the Pot Life Time to zero in the JOB Parameters. The horn will be turned off, however by issuing a Clear Faults command. A Pot-Life Fault does not turn off the GUN.

The DynaFlow system uses the Mixed Volume and the Pot-Life Time when it monitors the ow

rate of the Gun. Pot-Life is monitored by dividing

the Mixed Volume into 40 equal sized "buckets"

of material. When an amount of material has

owed that equals the "bucket" volume, the 40

"'buckets" are time-shifted so the oldest "bucket" is eliminated, representing the material that has

vacated the Mixed Volume tubing at the GUN, and

a new 'bucket' is added. If the GUN is in either Run or Load mode, a time value of 1 second is

placed in the new "bucket" to represent mixed

material. If the GUN is in Clean mode, a time value of zero is placed in the new "bucket" representing solvent. Every second, the time values stored in the "buckets" are incremented if they are

nonzero (i.e. contain mixed material vs. solvent). A Pot-Life alarm condition exists if any of the 40

"buckets" contains a time value greater than the Pot-Life Time (see JOB parameters). A Pot-Life alarm may be cleared by entering a Pot-Life Time of zero seconds.

Calibration Mode

The rst time that the system is operated after installation or when using new uids, calibration is recommended for the ow meters (CHANNELs).

There are several procedures that can be used for calibration (see the Calibration Mode Section).

Flow meters can be calibrated by uid weight or by uid volume. All calibration measurements are

metric, such as weight is measured in grams and volume in cubic centimeters (cc).

3. Start uid ow. Open the calibration valve or

trigger the GUN.

4. Collect uid manually into the graduated container for a specic time.

5. Stop uid ow.

6. Select "Stop Cal".

7. Measure the amount of uid collected.

8. Enter the measured volume of uid.

9. Accept or reject the new Pulses Per Liter number that the controller calculated. The ow

meter calibration will automatically be updated.

Required:

- Specic gravity of material

- Digital scale, accurate to 0.10 grams

1. Weigh the empty beaker and record the tare weight for later calculations.

2. Enter the calibration mode for the desired CHANNEL.

3. Perform the desired collection procedure above.

4. Weigh the uid in the beaker and subtract the

beaker tare weight to get the net weight of the

uid collected.

5. Entered the measured weight.

Procedure 1 (Manual)

1. Place the controller in Calibration Mode - select manual procedure.

2. Place a graduated container beneath the calibration valve or applicator paint feed tube/ nozzle.

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DynaFlowTM User Manual - Operation

Procedure 2 (Automatic)

1. Place the controller in Calibration Mode - select automatic procedure.

2. Set the desired ow rate. The pre-set ow

rate set point for the selected CHANNEL is based on the Total Flow Rate and Ratio for the GUN, as stored in the JOB, since calibration

should always be performed at the normal ow

rate for the CHANNEL. The operator may override this value, if desired.

3. Set the desired time to collect uid. The pre-

set time for the selected CHANNEL is based on

the desired ow rate for the CHANNEL so that

200 cc of material will be dispensed. The operator may override this value, if desired.

4. Make sure that the applicator is triggered OFF and any calibration valves are closed. Also

make sure that the uid has been loaded up to the point at which the uid sample is to be taken

(GUN output or calibration valve).

5. Place a graduated container at the place of

uid collection (GUN or calibration valve).

9. Enter the measured amount.

10. Accept or reject the new Pulses Per Liter number that the controller calculated. The ow

meter calibration will automatically be updated.

Calibration by Weight

If calibrated by volume, it is not necessary to calibrate by weight.

Required:

- Specic gravity of material

- Digital scale, accurate to 0.10 grams

1. Weigh the empty beaker and record the tare weight for later calculations.

2. Enter the calibration mode for the desired CHANNEL.

3. Perform the desired collection procedure above.

4. Weigh the uid in the beaker and subtract

the beaker tare weight to get the net weight of the

uid collected.

6. Trigger the GUN ON (manually or automatic) or open the calibration valve.

7. Select "Start Cal".

8. Collect and measure the uid. Fluid ow will stop once the timer has expired.

NOTE

It is not important that uid be owing,

or triggered ON, for the entire calibration time. The calibration procedure is based only on the volume of uid that was registered. Automatic mode simply supplies a convenient means to calibrate close to

specic ow rate and for an approximate

amount of time.

5. Entered the measured weight.

NOTE

An unassigned CHANNEL cannot

be calibrated. The CHANNEL must be assigned to a Gun and the Gun must be

congured.

If the weight method is used, the

specic gravity of the material must be entered.

The new value for pulses per liter will

be automatically calculated and updated.

Repeating the calibration procedure

is highly recommended to ensure it was performed satisfactorily.

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Clean

Any CHANNEL or Gun can be placed into a CLEAN

mode by an external command or through the Host

controller. The Clean mode forces the material regulator fully open until turned OFF. The GUN Enable and CLEAN inputs must be active and all

system or GUN faults cleared. To properly exit

the CLEAN MODE, the GUN Clean input should be removed followed by a GUN Halt signal, or a command issued from the Operator Interface Panel (host controller). Each CHANNEL must be set as a "clean" CHANNEL in the Clean CHANNEL

parameter located in the Gun Conguration table.

NOTE

Make sure the proper channels are

congured to "clean" on the Gun Parameters screen.

Full Error Detection

The DynaFlow controller will detect certain error conditions and indicate the cause of the error with a code. The code indicates the faulted Gun

and CHANNEL, as well as giving you a text error

message. All errors are categorized by CHANNEL, Gun or System depending on the type of error. The error codes and conditions are listed in the

appendix and include:

• Tolerance errors in uid ow rates for each

material

• Tolerance errors in uid ow ratios for each

material

• Reverse uid ow

• Low material ow

• High material ow

• Pot-life timers expired

• Memory errors

• Backup disk errors

• Conguration errors

• System errors

PROCEDURES

First-Time System Start-Up

This section is intended for skilled trades personnel. Always be aware of safety guidelines while operating equipment.

Before power is supplied to the DynaFlow Fluid Flow Control, take time to familiarize yourself

with the controls. Unexpected actions can occur

during initial power-up sequences and you should know which controls shut down the controller. The following information serves as a guide for initial system testing and start-up. Operational problems will be avoided if time is taken to follow the steps outlined below. Read through the entire sequence

rst before performing any actions.

• Verify that the Interface and Channel Mod-

ule dip switch settings are correct. Refer ence the HARDWARE SETTINGS section.

• Visually inspect the entire system. Review

the "Installation" section of this manual and

any related manuals such as the ow meter

and material regulator. Verify that all air and

uid lines are routed properly and ttings

are secure.

• Make sure that the required uid ltration is

installed. Fluid lines should be ushed out manually before installation of the ow

meters to ensure that any large particles or

contamination located from the uid lter to the ow meter connection are removed.

• Make sure that the required air ltration for

the E/P transducer(s) is installed.

• If rotary applicators are used, remove the

front shroud and bell cup to expose the

paint feed tube. If GUNs are being used, point the applicator(s) downward if pos sible. This will prevent the possibility of material from contaminating the applicator and provide additional safety for any per sonnel working near the system.

• Turn ON the main power disconnect to the

uid ow control panel.

• Turn ON the power switch located on the

ow control panel.

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• Verify that the local Operator Interface is

working properly and that no errors are be ing reported. Refer to the "Operator Inter face" manual for additional information.

• Turn ON the system host controller (PLC

or PC) and verify proper operation. Con-

gure the ow controller. This is usually

performed at the local Operator Interface panel, but can be through the system con troller depending on the installation. Refer to the "Operator Interface" manual for addi tional information.

• Turn ON the factory air supply to the E/P

transducer(s) and adjust the regulator to 90 psi minimum, 110 psi maximum.

• Turn ON the uid supply pressure to the

material regulator or color change valves.

• Inspect the air and uid system for any

leaks and x before continuing. Fluid

should

NOT be owing through the system at this

point.

• Perform a system ush, one GUN at a

time.

• Load paint.

• Perform a calibration check of each CHAN-

NEL.

• Verify operation of any safety or system

interlocks.

• Perform and verify remaining system oper-

ation. This includes any automatic opera tions such as a color change sequence.

• Observe the uid ow response of each

GUN. Refer to "Operator Interface" manual and related sections of this manual.

Normal Start-Up Procedure

Before attempting start-up:

• Inspect the entire system and make sure

that all air and uid hoses are in place and

secure, and that all other system compo nents are in good condition.

• Review and perform any required preven-

tive maintenance procedures.

• Inform personnel in the immediate area

that the system is being started.

• Observe the operation of the system as it

is started and be ready to shut it down in the event of a problem.

The following procedure assumes that the system was running normally when previously operating. This is only a recommended procedure. Variance from this procedure is dependent on the installation, operation and protocols.

1. Turn on the main power disconnect to the

uid control panel.

2. Turn ON the panel power switch.

3. Verify that the Operator Interface is operating normally and that there are no errors.

4. Turn ON the factory air supply to the E/P transducers and any other pneumatic control circuits.

5. Supply uid pressure to the system.

6. Turn ON any auxiliary equipment that may be interlocked with the uid ow controller such as the booth exhaust.

7. Perform a system ush of each GUN.

8. LOAD the material to be sprayed. This may be controlled automatically or manually depending on the system.

9. A "dummy" JOB can be run to verify the operation of the entire coating system before spraying production parts. In general, the longer a system is shutdown, the more importance should be placed on the start-up procedure.

Normal Shutdown Procedure

The shutdown procedure should be basically opposite of the start-up procedure. The degree or level to which the system is shutdown depends on how long the shutdown is to last. The following are considerations when shutting down the system.

1. Place the system in a safe mode when per-

sonnel will not be present for extended periods

of time.

2. It is recommended to keep uid loaded in the ow meters to prevent the gears from sticking during start-up. Generally this is the ushing

solvent.

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3. Total system shutdown, including AC power,

air and uid pressure is recommended if the

system is to be shutdown for more than one shift.

Clean Mode

CLEAN mode can only be initiated if the GUN has been given a Halt input and is enabled and no faults are active. Each CHANNEL can be independently

congured to accept the CLEAN command. For

two-component GUNs, it may not be desirable to clean both the resin and catalyst at the same time, therefore each CHANNEL can be

congured as a “clean” CHANNEL independently

by setting the Clean CHANNELs parameter in the

GUN conguration table.

The CLEAN operation can be started one of several

ways. The rst method is to simply supply the GUN

CLEAN input. The second method is to initiate the CLEAN mode through the OPERATOR INTERFACE or host controller (refer to the appropriate manual). Actual cleaning time and sequences, including soft air push-out (purge) is performed by the system controller or the pneumatic interface

panel, and not directly by the uid ow controller.

PID CONTROL

The ransburg DynaFlow Fluid Flow Controller incorporates a form of a Proportional-IntegralDerivative (PID) algorithm with additional func-

tions or modications which are specic to the efcient control and delivery of materials in paint

spray applications. PID is the most widely used method for closed loop controllers in all areas of industrial control.

The PID control algorithm develops a control signal composed of three elements. The proportional element is simply proportional to the difference

between the current uid ow and the desired uid ow, referred to as the error. The integral element

of the control output is proportional to the integral of the error signal, and the derivative element is proportional to the derivative of the error signal.

These are explained in more detail below. A general

understanding of how a PID controller works will

be benecial in producing the best overall uid ow response from the uid delivery system. This can

lead directly to reduced paint usage and higher

quality of nish.

The CLEAN mode is terminated when deactivated from the Operator Interface or when a HALT signal is supplied.

Calibrate Mode

CALIBRATE mode can only be initiated if the GUN is enabled and no faults are active. The CALIBRATE operation is initiated and controlled through the OPERATOR INTERFACE or host controller (refer to the appropriate Operator Interface or Programming manual).

The CALIBRATE mode is terminated when deactivated from the Operator Interface or if the Enable input is removed.

Recovering From Faults

This section:

• Identify and record the fault

• Evaluate action(s) to be taken

• Perform corrective action(s)

• Reset and run

Largely the air and uid control components and

their placement with respect to each other deter-

mine limitations on general uid ow response.

This includes the following:

• Type of uid regulator and needle or dia-

phragm ratio (pilot pressure vs. uid pres-

sure).

• Rheology of the uid(s) such as viscosity,

and shear.

• Length and diameter (volume) of the air pi-

lot lines from the V/P or I/P transducer to

the uid regulator.

• Back pressures created by uid control

devices such as the applicator uid pas-

sage restrictions.

Error

The difference between the requested (set point) value and the actual process being controlled.

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Deadband

This represents a ow range above and below

the set point value in which the PID control is suspended. This keeps the control output from continually changing and produces stability when close to the requested value.

Proportional Action (Kp)

Proportional action simply means that the controller output changes in proportion to the error

between the set point and the actual ow. It is

also commonly referred to as gain, proportional gain and proportional band to name a few. If the proportional gain is set too high, the system will

oscillate. If set too low, the uid ow will "wonder"

due to a lack of responsiveness.

Integral Action (Ki)

The Integral element of the PID controller forces

the actual output (ow) to match the desired by utilizing the sum of the error in ow rate.

Integral action is proportional to the sum of the error. This term is needed to remove long term, or steady-state error that cannot be removed by the proportional term.

Integral action is the most important factor governing control near the set point. The integral term changes the control output as a result of a continuing error between set point and actual. The integral term will continue to shift the output until

the actual ow rate falls within the Deadband value.

Integral action will also effect transition response

times. The greater the change in requested ow

rate, the more the integral action will effect the response time.

The integral gain, Ki, must be chosen such that oscillations do not occur. Increased integral gain will cause faster response times, but can lead to process instability and uncontrolled oscillations.

Derivative Action (Kd)

Derivative action is proportional to the rate of change of the error. The derivative term dampens, or slows down process overshoot and improves the response to changes in the process being controlled. Another way to view this term is that it "anticipates" or leads what is happening with

the actual ow.

Derivative action provides a sudden shift in the control output as a result of a quick change in the

actual ow (transient) or set point. If the actual ow

drops quickly, the derivative term will provide a large change in the output in an attempt to correct the perturbation before it goes too far.

Derivative action should be associated more with transient response control and less with overshoot inhibition such as during start-up, or trigger ON.

Oscillation due to derivative action is typically a cyclic "wander" away from the set point.

Putting It All Together

The optimum PID controller settings are determined based on the application. Types of applications that will effect PID considerations are:

• Dynamic control of ow rate while spraying

parts - robot mounted,

• Short GUN trigger times

• Long trigger times - constant ow rate re-

quested during entire part

• Precise 2K mixing ratio required at all times

• Low ow rate applications

• Applicators mounted on oscillators or re-

ciprocators that may produce cyclic back

pressures within the uid lines

• Systems with piston pump type supplies

• Long pilot line lengths from uid regulator

to transducer

General Guidelines

1. The type of uid regulator represents the

larg-est overall impact on system response. The following table lists control settings for various uid regulators that should result in stable control. The determination of these parameters was based upon worst case conditions and therefore constitutes "conservative" control response. It is

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Recommended to start with these values and

conrm stable response before trying to achieve

faster response from the system. Generally,

when adjusting the Proportional (Kp) and Integral (Ki) gain parameters, adjust both up or down pro-

portional to themselves. In other words, if faster response is desired and the system is currently operating stable, assume the starting Kp value is 500 and the starting Ki value is 2000. You would

adjust the Kp value to 550 (10% increase) and

the Ki value to 2200 (also a 10% increase). The deadband parameter should be kept to 1 and the differential gain (Kd) at 0.

Quick triggering applications: For applications requiring multiple, short trigger cycles, more stable response can typically be obtained by

adjusting the Kp down to approximately 75-100, while adjusting the Ki to approximately 1000-2500.

2. The Integral gain is probably the most important setting and has the greatest overall impact

on response behavior associated with the uid ow control system. This parameter can also be adjusted through a relatively large range without

creating instability.

3. The Proportional gain can improve system response, especially for large set point changes, but care should be taken not to increase by more

than approximately 25% of the default setting. The

system can easily become unstable and go into

oscillation if adjusted to high.

DEFAULT CONTROL PARAMETERS

Fluid

Regulator

MVR #2 MVR #3

MVR #4 DR1, 1:1 DR1, 1:2 DR1, 1:3 DR1, 1:4 DR1, 1:6 DR1, 1:8

DR1, 1:10

Kp Ki

10 15 20 50 45 40 35 30 25 20

1200 1000

800 1000 1200 1400 1600 1800 2000 2200

TYPICAL RANGES FOR CONTROL PARAMETERS

Fluid

Regulator

MVR #2 MVR #3

MVR #4 DR1, 1:1 DR1, 1:2 DR1, 1:3 DR1, 1:4 DR1, 1:6 DR1, 1:8

DR1, 1:10

4. The differential gain has the least effect on system performance and should be left at the default setting of zero (0).

5. Response times will be limited by changes in

the uid mechanics of the system. It will take longer to achieve requested ow rate as uid viscosity increases or uid supply pressure de-

creases. In other words, the same response cannot be achieved for a 50 sec, Zahn #2 material as for

a 20 sec, Zahn #2 material given the same uid supply pressure and uid control components.

This is important to understand, especially for 2K systems. It may be an advantage to purposely slow down the response of the quicker reacting

(thinner) uid such that it will remain closer to that of the thicker uid in 2K systems during triggers

or changes in the set point. Other options are to

decrease the supply pressure for the thinner uid or increase pressure for the thicker uid.

6. "Reset Windup" condition. Reference "Troubleshooting" in the "Maintenance" section. Reset windup is a condition when the controller does not have enough strength to reduce the error back to zero. This occurs due to unusual restrictions in

the uid control devices or uid lines and indicates

that the system is not tuned properly or there is

a problem. If the actual uid ow is less than the requested ow (minus the dead band value), the

controller will continue to increase the output until

it reaches the maximum allowable uid regulator

Kp Typical

Range

0-500 0-500 0-500 0-500 0-500 0-500 0-500 0-500 0-500 0-500

Ki Typical

Range

600-2400 500-2000 400-1600 500-2000 600-2400 700-2800 800-3200

900-3600 1000-4000 1100-4400

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DynaFlowTM User Manual - Operation

pressure. This is due to the Integral term of the PID control. If the restriction causing the low

ow condition is removed suddenly while a large control output signal exist, then a relatively long

amount of time is required for the Integral term of the PID to reduce the control output back to a normal range since the Integral term is proportional to time and also due to the inherent response of

the system. If uid ow response has changed signicantly with the same setup that previously

produced good response, then inspect the system for component failure, blockages, and check the

uid type and viscosity.

Alternate PID Equation

The normal PID equation is based on the error

between the desired set point and the actual ow

rate for the CHANNEL. If the set point is varied dynamically by a PLC via RIO or by a robot via Analog Input, it may be desirable to implement an alternate form of the equation. The alternate form of the equation uses the set point for the proportional term of the equation. The Integral and Derivative terms are the same, but slightly different scale factors are used.

6. Trigger the GUN. If the ow rate does not

oscillate, or the oscillations decrease in amplitude in a few seconds, increase Ki by 100 and repeat from step 5. If the ow rate oscillates with increasing amplitude, decrease Ki by 50 and repeat from

step 5. 8If the ow rate oscillates with a constant

amplitude, proceed to step 7.

7. Set Ki to one-half the present value.

8. Set Kp to the default value shown in the "Default Control Parameters chart" and Typical Ranges for Control Parameters chart" in this section.

9. Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module(s).

10. Trigger the GUN. If the ow rate does not

oscillate, or the oscillations decrease in amplitude in a few seconds, increase Kp by 30 and repeat from step 9. If the ow rate oscillates with increasing amplitude, decrease Kp by 15 and repeat from

step 9. If the ow rate oscillates with a constant

amplitude, proceed to step 11.

To enable the alternate PID equation, turn on DIP SW1-4 (or SW1-8) on the Channel Module for each CHANNEL of the GUN.

PID Tuning Methods - Standard PID

1. Select the nominal ow rate for the GUN.

2. Set Kp and Kd parameters to zero. Do this for both CHANNELS if this is a two-component GUN.

3. Set Ki for the Slave CHANNEL to zero (assuming this is a two-component GUN).

4. Set Ki for the Master CHANNEL to the default value shown in "Default Control Parameters" chart and "Typical Ranges for Control Parameters" chart in this section.

5. Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module(s).

11. Set Kp to one-third the present value.

12. Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module(s).

13. Trigger the GUN. If the ow rate does not oscillate, proceed to step 14. If the ow rate is

oscillating, reduce Ki by 50 and/or reduce Kp by 15 and repeat from step 12.

14. At this point, the tuning procedure is completed

for most ow control applications. However, if

there is a great amount of lag time from

the point of sensing the ow rate to where the

material volume regulator is located, the derivative term of the PID equation may be required. In that case, set Kd to the default value shown in "Default Control Parameters" chart and "Typical Ranges for Control Parameters" chart in this section.

15. Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module(s).

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16. Trigger the GUN. If the ow rate does not

oscillate, or the oscillations decrease in amplitude in a few seconds, increase Kd by 30 and repeat from step 15. If the ow rate oscillates with increasing amplitude, decrease Kd by 15 and repeat from

step 15. If the ow rate oscillates with a constant

amplitude, proceed to step 17.

17. Set Kd to one-eighth the present value.

18. Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module(s).

19. At this point, the tuning procedure is completed. The resulting Kp, Ki, and Kd parameters should produce the fastest response with minimal over-shoot and/or oscillation. If oscillation does occur with these PID parameters,consider reducing each value by the same percentage. This will lower the overall gain resulting in a slightly longer time to achieve the desired set point and a slow- er response to disturbances, such as paint pumps.

20. For two-component GUNs, repeat steps 4 through 19 for the Slave CHANNEL.

PID Tuning Methods - Alternate PID

1. Set the maximum set point for the GUN.

2. Set Ki and Kd parameters to zero. Do this for both CHANNELS if this is a two-component GUN.

3. Set Kp for the Master CHANNEL based on the following formula:

(8.0 - MVR LOW) * 25,500 Kp = 10

(Max. Gun Set Point * Ratio)

(Ratio + 1)

For example: Max. Gun Set Point = 400 cc/min.

MVR LOW = 15 PSIG Ratio = 3:1 (8.0 - 15) * 25,500 Kp = 10 (400 * 3) ( 4 ) = 6.5 * 25,500 300 = 552.5 = 550

4. Set Kp for the Slave CHANNEL based on the following formula:

(8.0 - MVR LOW) * 25,500 Kp = 10

(Max. Gun Set Point)

(Ratio +1)

For example: Max. Gun Set Point = 400 cc/min.

MVR LOW = 15 PSIG Ratio = 3:1 (8.0 - 15) * 25,500 Kp = 10 (400) ( 4 ) = 6.5 * 25,500 100 = 1657.5 = 1660

5. Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module(s).

6. Trigger the GUN. If the ow rates do not achieve their individual CHANNEL set points, adjust the upstream uid pressures until they both are on

target.

NOTE: This may require repeated triggers and

fault resetting. Once the proper uid pressures are set, the maximum set point for the gun will be owing, ratioed properly between the CHANNELS,

with the MVR pressures at 80 PSIG.

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7. Set the Ki parameters for both channels to a value between 50 and 500 in order to bring each

CHANNEL to its exact set point. Be sure to cycle

the GUN between READY and RUN to send the Ki values to the Channel Modules.

8. Normally, Kd may remain at zero. Set Kd to a value between 50 and 500 if there appears to be a delay in the response.

NOTES

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MAINTENANCE

TROUBLESHOOTING

Error Codes

The following is a complete list of error codes. Some of these codes may not apply depending

on the specic control system conguration.

The corrective actions listed in the table are discussed in more detail later in this section and also included in the "HELP" screens located on the operator interface.

ERROR CODES

Code

2021 2022 2023 2024 2025 2026 2027 2028

Displayed Text Fault Cause Corrective Action

Pot-Life Timer Expired GUN #<>

Pot-Life Timer has expired for GUN

indicated.

Last digit indicates CHANNEL #.

Example Error Code: XXXX

1st Digit: 2 = GUN Alert 4 = DISK Error 9 = CHANNEL Fault A = GUN Fault B = SYSTEM Alert or Fault 2nd and 3rd Digit:

No specic meaning

4th Digit:

- If a GUN error, the number indicates which GUN (1-8)

- If a CHANNEL error, the num ber indicates which CHANNEL (1-8)

Verify the following:

1. Correct value for Pot-Life time.

2. Correct value for Mixed Volume.

If the above values are correct, then

uid must be ushed from the GUN

immediately.

2061 2062 2063 2064 2065 2066 2067 2068

9011 9012 9013 9014 9015 9016 9017 9018

Gun Not Ready GUN #<>

Out Of Tolerance CHANNEL #<>

Indicated GUN # is not ready. This means that the GUN # has been given a RUN command without being enabled, or the GUN has faulted.

Last digit indicates CHANNEL #.

The indicated CHANNEL is outside

it’s maximum tolerance limit as specied by the FLOW

TOLERANCE parameter.

Last digit indicates CHANNEL #.

Verify that the GUN is enabled and not

faulted. Each GUN must have the Ext.

Fault/Enable Input active, or the Global Gun Enable active.

Check the following:

1. Kp, Ki, and Kd gains set wrong which

may cause unstable uid regulation.

2. Running the wrong JOB # which may include the wrong Kp, Ki, and Kd values.

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ERROR CODES (Cont.)

DynaFlowTM User Manual - Maintenance

Code

9021 9022 9023 9024 9025 9026 9027 9028

9031 9032 9033 9034 9035 9036 9037 9038

Displayed Text Fault Cause Corrective Action

Reverse Flow Limit

CHANNEL #<>

Flow Too Low CHANNEL #<>

The amount of reverse ow for the indicated CHANNEL has ex-ceeded the maximum allowable amount as dened in the CHANNEL parameter

set.

Last digit indicates CHANNEL #.

The flow rate for the indicated CHANNEL # is too low. Based on the transducer output. Not issued for a manual GUN, master CHANNEL.

Last digit indicates CHANNEL #.

Check the following:

1. That the Reverse Flow value entered in the JOB # is correct.

2. Flow meter ber-optic cables are

properly connected and not reversed.

3. Fluid pressures are properly set and stable.

4. All check valves are operating correctly.

5. All uid lines lled and all valves

open.

6. Flow meter is operating properly.

Check the following:

1. There is uid in the uid lines for the

indicated CHANNEL.

2. Fluid pressures are properly set and stable.

3. The pilot air line to the uid regulator

is not damaged or leaking.

4. Fluid viscosity is correct for the CHANNEL pressure and pipe size.

5. The pressure transducer and regulator are operating properly.

6. Transducer air supply is at least 90 psi.

7. Kp, Ki, and Kd Gains are set correctly for the indicated CHANNEL.

9041 9042 9043 9044 9045 9046 9047 9048

9071 9072 9073 9074 9075 9076 9077 9078

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Flow Too High

No Master Flow Manual mode only. A trigger signal

The flow rate for the indicated CHANNEL # is too high. Based on the transducer output. Not issued for a manual GUN, master CHANNEL.

Last digit indicates CHANNEL #.

was received and no fluid flow was detected through the master chan-nel after the Blowoff timer had elapsed (if used).

Check the following:

1. Fluid regulators - sticking or faulty.

2. Control parameters - gains possibly set too high.

3. MVR low setting too high.

Check the following:

1. There is uid in the uid lines for the

indicated CHANNEL.

2. Fluid pressure is OK.

3. The ow meter, pressure trans-ducer,

and regulator are operating properly.

DynaFlowTM User Manual - Maintenance

ERROR CODES (Cont.)

Code

9081 9082 9083 9084 9085 9086 9087 9088

9091 9093 9095 9097

9111 9112 9113 9114 9115 9116 9117 9118

Displayed Text Fault Cause Corrective Action

External GUN ENABLE Input Not Detected

Channels Not Present

Out of Tolerance

-Catalyst Too High CHANNEL #<>

24 VDC must be supplied to the

external GUN ENABLE input before

the GUN can be placed in an active state. This is typically used as an interlock with other equipment or hard-wired directly to 24 VDC.

Channel Module is not installed or has failed.

The indicated slave (catalyst) CHAN-

NEL is above it's maximum tolerance limit as specied by the FLOW

TOLERANCE parameter.

Check for 24 VDC on the external

GUN ENABLE input.

1. Insert Channel Module or change

GUN conguration.

2. Reboot system and check again.

3. Replace Channel Module.

Check the following:

1. Kp or Ki gains set too high.

2. Running the wrong JOB #, which may include the wrong gain values.

3. Fluid pressures. Either reduce the catalyst supply pressure or increase the resin pressure. Try to maintain normal

operating pilot pressures to the uid

regulators, between 30-60 psi.

4. The MVR LOW JOB parameter for the catalyst is set too high (above the regulator cracking pressure).

5. Air bubbles or cavitation.

9211 9212 9213 9214 9215 9216 9217 9218

Out of Tolerance

-Catalyst Too Low CHANNEL #<>

The indicated slave (catalyst) CHANNEL is below it's minimum tolerance limit as specied by the FLOW TOLERANCE parameter.

Last digit indicates CHANNEL #.

Check the following:

1. Kp or Ki gains set too low.

2. Running the wrong JOB #, which may include the wrong gain values.

3. Fluid pressures. Either increase the catalyst supply pressure or decrease the resin pressure. Try to maintain normal

operating pilot pressures to the uid

regulators, between 30-60 psi.

4. Requested ow rate exceeds capability of the catalyst channel at the given

uid supply pressure. Reduce total ow

rate or increase catalyst supply pressure.

5. Air bubbles or cavitation.

Last digit indicates CHANNEL #.

LN-9400-00.9

ERROR CODES (Cont.)

DynaFlowTM User Manual - Maintenance

Code

A011 A012 A013 A014 A015 A016 A017 A018

A021 A022 A023 A024 A025 A026 A027 A028

B001

Displayed Text Fault Cause Corrective Action

Non-Existent

Program GUN #<>

GUN Flow Out of Range

System Halted

JOB # number entered for the indi-

cated GUN does not exist. JOB #

number defaulted to 00.

Last digit indicates CHANNEL #.

The total ow rate for GUN # has exceeded the MAXIMUM FLOW

RATE JOB parameter or fallen below the MINIMUM FLOW RATE JOB parameter. For Manual GUNs only.

System Ready/Halt input is inactive.

Verify the following:

1. The JOB # has been saved in memory for the indicated GUN.

2. The correct JOB # is being re-quested.

3. For discrete hard-wired JOB # select, PROGRAM TOGGLE and JOB # inputs have been asserted correctly by the PLC or host computer.

See "Flow Too Low" and "Flow Too High" faults.

This input is typically used as an interlock to other control equipment or it is simply hard-wired to 24 VDC. Supply 24 VDC to the System Ready/Halt input.

B010

RIO - Communications Error

PLC and DynaFlow are not set to the same:

- baud rate

- rack address

- rack size

- rack starting quarter

RIO cable is not connected to the proper terminals at either end.

Check with the PLC programmer to determine the correct values for baud rate, rack address, rack size, and rack starting quarter and then set the DynaFlow Interface Module DIP SW1 and SW2 to the appropriate settings per "Interface Module DIP SW2 Settings" and "Mother Board Signal ID (J3, J4, J5, J6 Channel Cards" respect-ively in this section. Check cable connections per Figure 25

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DynaFlowTM User Manual - Maintenance

ERROR CODES (Cont.)

Displayed Text Fault Cause Corrective ActionCode

B010

(Cont.)

B020

B030

RIO - Communications Error (Cont.)

RIO - Invalid BTW Type

RIO - Invalid BTR Type

RIO cable is not properly terminated at each end.

The PLC has issured a BTW with

an invalid BTW data type in the rst

word offset.

The PLC has issued a BTW with an invalid BTR data type in the second word offset.

Check cable connections per Figure 25 of this manual.

Check each end of the cable to determine if the terminating resistor is installed at each end. The DynaFlow system may not be the last rack on the RIO cable. The value of the terminating resistor is based on cable length, baud

rate, and if Extended Node Capability is enabled at the PLC. If Extended Node

Capability is enabled, the terminating resistors should always be 82 ohms. Otherwise, the term-inating resistors should be 150 ohms for 57.6 and 115.2 Kbaud and 82 ohms for 230.4 Kbaud. In any case, use 1/2 watt resistors.

Have the PLC programmer reference the "DynaFlow Programmer" manual for the correct BTW data types.

Have the PLC programmer reference the "DynaFlow Programmer" manual for the correct BTR data types.

B040

B050

B060

Gun/Channel Number

RIO - Invalid BTR Job Number

RIO - Invalid BTW Length

The PLC has issued a BTW with an invalid gun or channel number in the third word offset.

The PLC has issued a BTW with

an invalid job number in the fourth

word offset.

The PLC has issued a BTW with an invalid message length (word count).

Have the PLC programmer ensure gun and channel numbers are between 1 and 8, or 0 if not required for the particular data type.

Have the PLC programmer ensure job

numbers are between 1 and 100, or 0 if not required for the particular data type.

Have the PLC programmer reference the "DynaFlow Programmer" manual for the correct BTW message lengths.

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DynaFlowTM User Manual - Maintenance

Flow Too Low -or- Flow Too High

Explanation: These are CHANNEL specic faults.

FLOW TOO HIGH and FLOW TOO LOW faults

are issued if the requested uid ow cannot be

obtained. This typically means that there is a setup problem, maintenance issue, or mechanical failure.

These types of faults can be caused by numerous problems. Most of the more common causes are listed below. Keep in mind that the controller senses that either too little or too much material is getting to the applicator and that this is based on

JOB parameter settings and uid ow feedback from the ow meters. This troubleshooting section

assumes that the system was previously operating successfully and then a problem developed. The following is not meant for initial system setup, however, many of the troubleshooting procedures described can be used in either case.

1. Material Supply Pressure

- Has the material supply pressure changed?

- What was the supply pressure when the system was operating properly?

- Is the pressure gauge accurate or reliable?

- Has the uid delivery system been

changed?

- Are there any air leaks in the uid regulator

pilot line?

- Are there any leaks in the uid lines?

The controller can compensate for small changes in supply pressure, but changes such as seen with piston pumps without surge chambers or pressure

drop regulators can be a denite problem.

2. Material Viscosity

- Has the material properties such as viscosity or temperature changed?

Changes in viscosity alter the way in which it

passes through the uid metering and control components (regulator, ow meter, check valves, Y-Block, spiral mix tube, etc.). Typically, an in-

creased viscosity will require more pressure to

achieve the same ow rate. However, in some cases, as with thixotropic materials, the viscosity

will actually change as the pressure varies or as

the material passes through the uid regulator or ow meter. Additionally, the material may be

broken down into smaller particles as it passes

through the uid delivery system which can also

cause some materials to change their properties

as they ow.

The temperature of the uid can also greatly impact the ow properties. Make sure that the uid

heaters are functioning correctly if temperature control is being used. If temperature control is not being used, then evaluate how ambient tempera-

ture may effect the uid, as it is stored including

the paint kitchen. Also, consider the length of the recalculating system and how long the material takes to travel to the applicators.

The amount in which the control response is

effected by changes in uid properties is also

determined by how aggressive the control param-

eters are set (Kp, Ki, Kd). The uid ow response

can be observed as discussed in the "Operator Interface" manual. Also, refer to the "PID Control" in the "Operation" section of this manual under

3. Fluid Line Restriction

- Has a restriction formed somewhere in

the uid line?

This could be a pinched paint tube, contamination

in the uid regulator, spiral mix tube blockage,

a sticking check valve, or a Y block blockage to name a few.

Corrective Action:

An easy way to verify that the system is capable

of owing at the desired rate is to place the GUN

in CLEAN MODE and trigger the applicator. The

CLEAN MODE supplies maximum control pressure to the uid regulator. Watch the ow rate. If the desired ow rate cannot be achieved or surpassed

in CLEAN MODE, it is obvious that it will not be

achievable in control mode. This tests all uid

lines from the material supply to the applicator. If calibration ports (valves) are available, such

as on 2K uid panels, try operating the controller

with the calibration valves open. Place containers under the calibration ports and put the controller in RUN mode. If operating in AUTO-MATIC MODE, the TRIGGER signal has to be

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DynaFlowTM User Manual - Maintenance

forced ON. If the desired ow is achieved while in this mode of operation, the uid restriction is

located further downstream to the applicator.

4. Flow Meter Feedback

- Is ow being indicated on the controller?

If it is obvious that material is owing through

the system (from the GUN or calibration ports if

used), but the controller indicates no ow, then

this indicates that the controller is not detecting

ow meter pulses. This could be caused by one

of the following:

• Flow meter gear stuck

• Bad ow meter sensor

• Disconnected or damaged ber-optic

cable

• Bad ber-optic receiver

• Bad input on the CHANNEL MODULE

• Fiber-optic ow meter transmitter battery

has expired. Life expectancy is two years

minimum.

Corrective Action:

Flow Meter: Disassemble, clean, and inspect

the ow meter. Refer to instructions supplied with

the meter.

played, replace the CHANNEL MODULE. Make sure that the hardware settings located on the module are congured identically to the one being replaced.

5. Transducer Failure

Corrective Action:

Perform the following with the GUN OFF and calibration valves closed. Place a pressure gage

(if one does not already exist) in the pilot line between the transducer and the uid regulator. Make

sure that the air supply pressure to the is at least 100 psi. Go to the FORCE I/O

transducer

menu for the CHANNEL in question. Force Control Output voltage (or 4-20 ma) to several different values and observe the pressure gauge. Reference "Analog Sealing" chart in this section for correct values.

If the transducer does not produce the proper pressures, check for air leaks in the air pilot tube,

transducer and uid regulator. The transducers

are very low volume devices and are designed

for non-ow, or dead-headed operation. Also,

observe the pressure gauge for oscillation and

listen to the transducer for uttering sounds. These

are other indications that there may be air leaks in the system.

Try connecting the ow meter in question to a ber-

optic cable from a properly functioning CHANNEL.

If uid ow is now observed, then the ow meter

and pickup sensor are functioning properly.

Fiber-Optic Cable: Simply shine a light into one end of the cable and have someone observe the opposite end. If light is visible through the cable then it is probably good, although it is possible that the cable is damaged and will not conduct enough light to operate properly.

Fiber-Optic Detector: With uid owing, observe the LED located on the ber-optic receiver. The LED is an indication that uid is owing and pulses are being received from the ow meter. If the LED is not ON, then replace or swap the ber-optic

receiver and try again. If everything checks good but no uid ow is dis-

Another method for isolating small air leaks is to spray or dab a small amount of a soap and water

solution around the ttings or valves and look for

the continuous formation of air bubbles.

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DynaFlowTM User Manual - Maintenance

Control Output

ANALOG SEALING

Pressure

0 - 10 VDC

0 1 2 3 4 5 6 7 8 9

4-20 mA

5.6

7.2

8.8

10.4

12.0

13.6

15.2

16.8

18.4

20.0

(PSIG)

0 10 20 30 40 50 60 70 80 90

100

Gun Flow Out of Range

Explanation: (Manual Guns Only) This fault indicates that the total ow rate through a GUN has exceeded the MAXIMUM FLOW RATE JOB

parameter value or dropped below the MINIMUM FLOW RATE JOB parameter.

Out of Tolerance Faults

Explanation: "OUT OF TOLERANCE" faults are

generated in the following manner. Every time a

specic volume of uid passes through the GUN (specied by the TOLERANCE VOLUME param-

eter), the controller determines the amount of resin

and catalyst material that owed. The controller

then calculates the actual ratio and determines if it is within the limits as set by the FLOW TOLERANCE setting.

Reference the "Error Codes" table (Figure 16). Typical causes for OUT OF TOLERANCE faults are:

6. The MVR LOW JOB parameter set too high (above the regulator cracking pressure).

7. Air bubbles or cavitation in the uid.

8. Unstable uid supply pressures to the uid

regulators. This can be seen with pump supply systems.

Corrective Action:

The cause is the material supply pressure in almost every case when this fault is observed. Obviously, if FLOW TOO LOW or FLOW TOO HIGH faults are

not occurring, the ow rates are operating within the range of the uid regulators. Over an extended

period of time, however, the volumes used are not within the appropriate tolerance band. Observe the ratio for both the resin and catalyst channels that are producing faults while they are operating or immediately after the controller faults (before resetting it). If the actual ratio of the catalyst is

below target, adjust the supply pressure to the catalyst regulator up approximately 5 psi, or adjust the resin supply down by approximately 5 psi and try to run again. Keep adjusting these pressures

until the actual ratio locks in on the target. Keep in mind that higher is not always better. Many times it is better to lower the pressure of the opposite channel, rather than raise a channel that is operating low in ratio.

The Kp and Ki gain settings located in the JOB tables may also be used to eliminate OUT OF

TOLERANCE faults. For example, if an OUT OF

TOLERANCE - CATALYST TOO HIGH fault occurs,

adjust the gain settings for the catalyst channel

down and vice-versa for a OUT OF TOLERANCE

- CATALYST TOO LOW fault. The resin channel also needs to be taken into account for GUNs

congured as automatic.

1. Kp, Ki, or Kd gains not set correctly.

2. Sticking or faulty uid regulator.

3. Sticking or faulty ow meter.

4. Running the wrong JOB #, which may include the wrong gain values.

5. Fluid supply pressures not adjusted properly.

LN-9400-00.9

Gun Not Ready

Explanation: This is not a fault condition and does

not prevent the GUN from operating. This error

occurs if a GUN has not been congured, is not

enabled, or no JOB #s have yet been saved and the GUN is placed in the RUN mode. This can be caused by trying to place a GUN in RUN mode either from local display/interface or from an external control device such as a PLC or host PC.

DynaFlowTM User Manual - Maintenance

Corrective Action:

Simply save a JOB # for the indicated GUN making sure the parameters are correct. The Gun can be placed in RUN mode without generating the GUN NOT READY error.

System Errors

System errors are not associated with any CHANNEL or GUN. System errors are typically related to the disk drive, le I/O operations or communications.

Reverse Flow Limits

Explanation: The controller has sensed that material has owed backwards through a ow meter and exceeded the preset REVERSE FLOW LIMIT

value for that CHANNEL. There are several possible causes for this.

1. The check valve for one of the CHANNELs has failed in the open condition and the oppo site CHANNEL material is at a higher pressure causing the material to back up into the other paint line.

Corrective Action:

The system must be ushed immediately and the

faulty check valve replaced.

2. Sometimes this error can be generated after

a GUN has been ushed and left unused for

a period of time, such as at the end of the day or end of a shift. This is probably due to pressure

trapped in the line between the uid regulator

and the applicator. This pressure could eventually

back up through the ow meter and through the

weep port if using a weeping type MVR valve, or through a small leak in the system.

Corrective Action:

Make sure that the applicator stays triggered ON for several seconds after it has been taken out of a CLEAN mode in order to relieve the pressure.

3. If operating the GUN for the rst time, the feedback signals could be reversed from the ow meter.

Corrective Action:

Verify that the source and gate signals are routed

correctly. This includes the ber-optic cable connections at both the ow meter and receiver and

wiring connections from the receiver to the control rack mother board.

4. If using a single phase ow meter that is not capable of reverse ow detection, then the "phase"

signal input must be connected to +24 VDC. Ref-

erence the "Mother Board Signal Identication" in the "Appendix" section of this Manual.

No Master Flow

Explanation: This fault will only occur on GUNs congured for MANUAL operation. For a GUN congured for MANUAL operation, as soon as the

GUN is placed in RUN mode, the master CHAN-

NEL uid regulator opens to the MVR HIGH set

point (usually 100 psi). This is typically full open. In

this way, operators can demand as much uid as

they wish with only the slaved (typically catalyst) CHANNEL being controlled to the desired ratio. It is possible, however, for the master CHANNEL

ow meter gears to stick, and still allow uid to pass through the ow meter. When this happens, the applicator continues to ow resin (master

CHANNEL) but the controller is unaware that material is owing and therefore does not command any catalyst (slaved CHANNEL) material

to ow. To prevent this from happening, an air ow switch placed in the atomizing air line can

send a trigger signal to the controller. When the controller receives a trigger signal, it immediately

determines if the master CHANNEL ow meter is

sending pulses. If it is not, the controller issues a NO MASTER FLOW fault.

In many cases, however, operators use their GUNs to blow dust and water off of the parts before spraying. They do this by pulling the trigger on

the GUN back just far enough to get atomization

air but no paint. When this happens, the controller

receives a trigger signal and no paint ow, which

would cause a fault. To allow for this "blow off" , a parameter called BLOW OFF TIME is used

(system conguration parameter). The default

value of 32 seconds. With the default value of 32 seconds the operator is allowed to blow off parts

LN-9400-00.9

DynaFlowTM User Manual - Maintenance

for a total of 32 seconds without faulting. As soon

as the controller senses ow from the master

CHANNEL, the timer is reset and will start once

again the next time a trigger signal is received with no master CHANNEL ow.

Corrective Action:

In most cases, this fault is generated by the master

CHANNEL ow meter gears not turning (usually stuck). Try ushing the system and watch the ow rate or ow volume on the operator interface. If there still is no ow, disassemble and clean the ow meter. If this still does not correct the prob-

lem, see the section in this manual on FLOW TOO LOW FAULTS. If this fault occurs while the

operator was not trying to spray, then the air ow switch may be defective. This can be veried by

the GUN status on the operator interface.

SYSTEM PREVENTIVE MAINTENANCE

Fluid Control Components

It is recommended to record system settings such

as uid supply and air supply pressures, etc.

Reference the appropriate service literature for maintenance instructions.

INSTRUCTIONS

Control Panels

There is no maintenance schedule for control panels other than good housekeeping practices. These include.

• Keeping the door closed at all times. This will maintain the dust-tight environment required by the electronic printed circuit boards.

• Plug all unused access holes into the cabinet in order to keep contamination out.

• Use the following guidelines for cleaning the Operator Interface:

Use cleaning solution specically formu-

lated for computer monitors, a mild win dow cleaner, or isopropyl alcohol. DO NOT use solvents. Most importantly, use a clean, soft paper towel or tissue and use very light force.

LN-9400-00.9

DynaFlowTM User Manual - Maintenance

SYSTEM COMPONENTS AND PARTS IDENTIFICATION

Figure 7: Card Rack Assembly

DYNAFLOW SYSTEM COMPONENTS AND PARTS IDENTIFICATION (Figure 7)

Item #

1 77383-01 Rack Assembly, Empty, 1/2 Rack, 1 Mother Board 77383-02 Rack Assembly, Empty, Full Rack, 1 Mother Board 77383-03 Rack Assembly, Empty, Full Rack, 2 Mother Boards 2 77377-02 Interface Module Assembly, With RIO

3 A10946-01 Channel Module for use with 0-10VDC transducers and for the ow rate

indication output A10946-02 Channel Module for use with 0-10VDC or 4-20mA transducers and for the

ow rate indication output

77378-00 Mother Board Assembly LBAL0021-00 Interface Cable Assembly, Interface Panel to Control Panel, 40 ft. LBAL5001-00 Interface Panel, Standard Two Component LBAL5001-01 Interface Panel, GUN 1 LBAL5001-02 Interface Panel, GUN 2 A12182 Interface Panel W/Color Change LPNE5002-00 Pneumatic Color Change Panel LBAL5003-00 Pneumatic Operator Panel

Note: Refer to the "DynaFlow Operator Interface" manual for parts that are specic to the 77376

and A12233 Stand-Alone Control Panel.

Part # Description

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DynaFlowTM User Manual - Maintenance

RECOMMENDED SPARE PARTS

Recommended spare parts list for the DynaFlow rack components only.

SPARE PARTS FOR DYNAFLOW RACK COMPONENTS

Total # of Interface Modules

in System

Part # Description

77377-02

DynaFlow Interface Module

1-4 4-10 >10

Notes

77377-02 RIO Compatible

77378-00

DynaFlow Mother Board

Part # Description

A10946-01/-02 DynaFlow Channel Module

Total # of Channel

Cards in System

1-8 9-16 >16

1 2 3

Notes

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DynaFlowTM User Manual - Maintenance

The following DynaFlow recommended spare parts lists do not include auxiliary uid control/monitor- ing equipment such as pneumatic interface panels, uid panels, transducer panels, etc. The recommended spare parts list for the auxiliary equipment should be derived from previous uid control lists

since their usage and requirements are the same.

SPARE PARTS FOR 77376 AND A12233 CONSOLE UNIT

Total # of

Consoles

Part # Description

1-2 3-4 5+

Notes

77377-02

A10946-01/-

77378-00

A11224-00

73837-08

77454-00 or

A12720-00

77382-00

74300-00

4131- 11

77384-00

A11375-00

DynaFlow Interface Module

DynaFlow Channel Module

Mother Board

Power Supply Assy., 24 VDC

Intrinsic Safety Barrier

Fiber-Optic Flow Meter Receiver

Ribbon Cable Adaptor

Bulb, 130 VAC

Fuse, 3 AG, 3 AMP

Stop Switch, Red Mushroom Head

Stop Switch, Yellow Mushroom

Head

For 77376-XXX1X Only

For 77376-XXX0X Only

Included with all stand-alone

systems

Alternate stop switch, available

special order only, for integrated

systems when only one red

stop switch is permitted in the

control room area.

A10577-00

A10577-01

Power Line Filter (115 VAC)

Power Line Filter (230 VAC)

For 77376-XXXX0 Only

For 77376-XXXX1 Only

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DynaFlowTM User Manual - Maintenance

HARDWARE SETTINGS

Channel Module Settings

CHANNEL MODULE P/N: 77206-XX (Obsolete) MOTHER BOARD JUMPER BOARD SETTINGS (CHANNEL 1 I/O)

Jumper

Default Setting

512K

1024K

0-10 VDC

Source

2-3

Description Comments

ROM size select. 1-2 = 256K, 27256 device 2-3 = 512K or 1024K, 27512 or 27010 devices

Selects 0-10 VDC or 4-20 ma operation for the analog control output #1. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Selects 0-10 VDC or 4-20 ma operation for the spare analog output #1. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Selects 24 VDC source control or grounded sink control for digital inputs 8-11. 2-3 = 24 VDC source 1-2 = grounded sink

Factory set. Do not change unless instructed to do so.

To the E/P transducer #1

Actual ow rate for

CHANNEL #2, scaled by

Maximum and Minimum Flow

Rate parameters

Inputs effected: Load Mode #1 Analog Hold #1

External Fault #1

MVR Enable #1

E10

LN-9400-00.9

Source

0-10 VDC

Selects 24 VDC source control or grounded

2-3

sink control for digital inputs 4-7. 2-3 = 24 VDC source 1-2 = grounded sink

Selects 24 VDC source control or grounded

2-3

sink control for digital inputs 0-3. 2-3 = 24 VDC source 1-2 = grounded sink

Selects 0-10 VDC or 4-20 ma operation for

2-3

the analog set point input #1. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Selects 0-10 VDC or 4-20 ma operation for

2-3

the spare analog input #1. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Inputs effected: Run #1 Halt #1 Total Reset #1 Clean #1

Inputs effected: Trigger #1 Gun Mask #1 Transparent/PID #1 Total Hold #1

Scaled by Maximum and

Minimum Flow Rate parameters

DynaFlowTM User Manual - Maintenance

CHANNEL MODULE P/N: 77206-XX (Obsolete) DAUGHTER BOARD JUMPER SETTINGS (CHANNEL 2 I/O)

Jumper

Default Setting

Source

0-10 VDC

2-3

Description Comments

Selects 24 VDC source control or grounded sink control for digital inputs 12-15. 2-3 = 24 VDC source 1-2 = grounded sink

Selects 24 VDC source control or grounded sink control for digital inputs 20-23. 2-3 = 24 VDC source 1-2 = grounded sink

Selects 24 VDC source control or grounded sink control for digital inputs 16-19. 2-3 = 24 VDC source 1-2 = grounded sink

Selects 0-10 VDC or 4-20 ma operation for the analog control output #2. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Inputs effected: Trigger #2 Gun Mask #2 Transparent/PID #2 Total Hold #1

Inputs effected: Load Mode #2 Analog Hold #2

External Fault #2

MVR Enable #2

Inputs effected: Run #2 Halt #2 Total Reset #2 Clean #2

To the E/P transducer #2

0-10 VDC

Selects 0-10 VDC or 4-20 ma operation for

2-3

the analog output #2. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Selects 0-10 VDC or 4-20 ma operation for

2-3

the analog set point input #2. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Selects 0-10 VDC or 4-20 ma operation for

2-3

the spare analog input #2. 2-3 = 0-10 VDC 1-2 = 4-20 mA

Actual ow rate for

CHANNEL #2, scaled by

Maximum and Minimum Flow

Rate parameters

Scaled by Maximum and

Minimum Flow Rate parameters

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CHANNEL MODULE P/N: 77206-XX or A10946-XX DIP SWITCH SW1 SETTINGS

Position

1 / 5 Trigger Detection Method

2 / 6 Analog Hold Mode

3 / 7 OFF Lookup Table Enabled (This feature has been obsoleted in current revisions of the

Default Setting

OFF

Description

This switch setting effects only GUNs congured as dual-component, Manual mode.

OFF = GUN trigger input signal required.

ON = GUN trigger input signal not required. Fluid ow through Master CHANNEL initiates PID on Slave CHANNEL. Master CHANNEL ow rate is determined by a manual ow rate adjustment located on the GUN.

OFF = When the GUN trigger is removed, the E/P transducer pressure immediately returns to MVR LOW. ON = If the Trigger OFF Delay is zero, when the GUN trigger is removed, the E/P transducer pressure immediately returns to MVR LOW. If the Trigger OFF Delay is non-zero, the E/P transducer pressure remains at the last output value from the PID

loop until the Trigger OFF Delay expires.

software.) This switch setting applies only to single-component GUNS. OFF = The Lookup Table is updated while in Run mode, but it is not used to deter-

mine the ow rate set point when the GUN is triggered.

ON = The Lookup Table is updated while in Run mode and is used to determine

the ow rate set point when the GUN is triggered, or when the ow rate set point is changed by more than 10% of the range in ow rate (Maximum Flow Rate minus

Minimum Flow Rate). In addition, if the GUN has been placed in Transparent mode

and a PLC or robot sends a ow rate set point via RIO or Analog Input, the value is assumed to be a ow rate, rather than a pressure value.

4 / 8 OFF Alternate PID Equation

The Alternate PID Equation should be used whenever the set point for the ow rate

is dynamically changed during Run mode. OFF = The PID Proportional term is based on the error term, which is the difference

between the desired ow rate (set point) and actual ow rate.

ON = The PID Proportional term is based on the setpoint.

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DynaFlowTM User Manual - Maintenance

Interface Module Settings

INTERFACE MODULE JUMPER SETTINGS

Jumper

E10

Default Setting

512K

1024K

RS-232C

Source

2-3

Out

2-3

Description Comments

ROM size select. 1-2 = 256K, 27256 device 2-3 = 512K or 1024K, 27512 or 27010 devices

RS-232C/RS-485 select

RS-485 termination resistor

CAN Bus termination resistor

Circuit common to earth ground connection.

Selects 24 VDC source control or grounded sink control for digital inputs 12-15. 2-3 = 24 VDC source 1-2 = grounded sink

Selects 24 VDC source control or grounded sink control for digital inputs 8-11. 2-3 = 24 VDC source 1-2 = grounded sink

Factory set. Do not change unless instructed to do so.

* Inserting this jumper adds a 120 Ohm termination resistor across the RS-485 RX+ and

RX- lines.

** Inserting this jumper adds a 120 Ohm termination resistor across the CAN Bus.

Source

Selects 24 VDC source control or grounded

2-3

sink control for digital inputs 4-7. 2-3 = 24 VDC source 1-2 = grounded sink

Selects 24 VDC source control or grounded

2-3

sink control for digital inputs 0-3. 2-3 = 24 VDC source 1-2 = grounded sink

LN-9400-00.9

DynaFlowTM User Manual - Maintenance

The new 12-bit Channel Card for the DynaFlow (P/N: A10946) has a different jumper conguration

than the now obsoleted 8-bit module (P/N: 77206-11). Please refer to the table below when setting

the jumpers on the new channel cards.

Analog Inputs:

Jumper

JMP1

JMP2

JMP3

JMP4

Description

Flow Rate Setpoint, Ch. A

Spare Input, Ch. A

Flow Rate Setpoint, Ch. B

Spare Input, Ch. B

Analog Outputs:

Jumper

JMP5

JMP6

JMP7

JMP8

Description

Control Pressure, Ch. A

Actual Flow, Ch. A

Control Pressure, Ch. B

Actual Flow, Ch. B

Discrete (Digital) Inputs:

Jumper

Description

Type

0-10 VDC 4-20 mA 0-10 VDC 4-20 mA 0-10 VDC 4-20 mA 0-10 VDC 4-20 mA

Type

0-10 VDC 4-20 mA 0-10 VDC 4-20 mA 0-10 VDC 4-20 mA 0-10 VDC 4-20 mA

Type

Pin 1-2

Open Closed Open Closed Open Closed Open Closed

Pin 1-2

Open Closed Open Closed Open Closed Open Closed

Pin 1-2

Pin 2-3

Closed Open Closed Open Closed Open Closed Open

Pin 2-3

Closed Open Closed Open Closed Open Closed Open

Pin 2-3

FactorySetting

JMP9

JMP10

JMP11

JMP12

JMP13

JMP14

Trigger, Ch. A Run Mode, Ch. A Transparent Mode, Ch. A Total Hold, Ch. A Gun Mask, Ch. A Halt, Ch. A Total Reset, Ch. A Clean Mode, Ch. A Load Mode, Ch. A Analog Hold, Ch. A

External Fault, Ch. A

Spare Input, Ch. A Trigger, Ch. B Run Mode, Ch. B Transparent Mode, Ch. B Total Hold, Ch. B Gun Mask, Ch. B Halt, Ch. B Total Reset, Ch. B Clean Mode, Ch. B Load Mode, Ch. B Analog Hold, Ch. B

External Fault, Ch. B

Spare Input, Ch. B

Source

Sink

Source

Sink

Source

Sink

Source

Sink

Source

Sink

Source

Sink

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

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DynaFlowTM User Manual - Maintenance

Flowmeter Inputs:

Jumper

Description

Type

Pin 1-2

Pin 2-3

FactorySetting

JMP15 Flow Rate Freq. Input,

Channels A and B

Memory and Processor Settings:

Jumper

JMP16

JMP17

JMP18

Description

UVEPROM

RAM

Processor Pin EA

Ransburg CAN Bus Address

Communication between the Interface Module and Channel Cards.

The Control Area Network (CAN) address of the Interface is automatically determined by hardware based on the physical slot location in the rack.

Source Sink

Type

256KB 512 KB 1024 KB

8Kx8 16Kx8 32Kx8

Run Prog.

Open Closed

Pin 1-2

Closed Open Open Open Closed Closed Open Closed

Closed Open

Pin 2-3

Open Closed Closed Closed Open Open Closed Open

FactorySetting

X X

INTERFACE MODULE DIP SW1 SETTINGS

Position

1-6

7-8

Default Setting

OFF

Address = 00

OFF

Description Comments

RIO Rack address

position 1 = most signicant bit (MSB) position 6 = least signicant bit (LSB)

RIO Starting Quarter position 7 8 Quarters OFF OFF = 0 OFF ON = 1/4 ON OFF = 1/2 ON ON = 3/4

0 - 63 Decimal 0 - 77 Octal

0 - 3F Hex

Number of Channel Cards: 1 to 4 1 to 4 1 to 3 1

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DynaFlowTM User Manual - Maintenance

INTERFACE MODULE DIP SW2 SETTINGS

Position

3-4

5-6

Default Setting

OFF

Description Comments

ON = NVRAM Erased & Reset OFF = NVRAM Maintained

ON = Master Channel outputs Master

Chanel ow rate on secondary

analog output.

OFF = Master Channel outputs GUN ow

rate on secondary analog output.

RIO Baud rate position 3 4 Baud Rate OFF OFF = 57.6 KB OFF ON = 115.2 KB ON OFF = 230.4 KB ON ON = 230.4 KB

SIO Baud rate position 5 6 Baud Rate OFF OFF = 19.2 KB OFF ON = 4.8 KB ON OFF = 9.6 KB ON ON = 38.4 KB

All data will be lost when set to ON position.

7-8

* Inserting this jumper adds a 120 Ohm termination resistor across the RS-485 RX+ and

RX- lines.

** Inserting this jumper adds a 120 Ohm termination resistor across the Ransburg CAN Bus.

OFF

RIO Rack Size position 7 8 Size OFF OFF = 1/4 Rack OFF ON = 1/2 Rack ON OFF = 3/4 Rack ON ON = Full Rack

Number Of Channel Modules: 1 1 to 3 1 to 4 1 to 4

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DynaFlowTM User Manual - Maintenance

CONTROL RACK TERMINAL IDENTIFICATION

MOTHER BOARD SIGNAL IDENTIFICATION

J3, 4, 5, 6 CHANNEL MODULES

Pin #

10A 11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A 32A

Description

Analog Set Point Input #1

Spare Analog Input #1

Analog Input GND

Analog Transducer Control #1

Analog Flow Rate Output #1

Analog Output GND

Trigger Input #1

Run Input #1

Transparent/PID Input #1 Total Hold Input #1 Digital Input GND Gun Mask Input #1 Halt Input #1 Total Reset Input #1 Clean Input #1 Digital Input GND Load Input #1 Analog Hold Input #1

External Fault Input #1

Spare Input #1 Digital Input GND Ready Output #1 Active Output #1 Fault Output #1 Pot Life Timer Output #1 Clean/Load/Calibrate Output #1 MVR Enable Output #1 Digital Output GND

Console Rx232

Console GND +24 VDC PWR GND

J3, 4, 5, 6 CHANNEL MODULES

Pin #

10B 11B 12B 13B 14B 15B 16B 17B 18B 19B 20B 21B 22B 23B 24B 25B 26B 27B 28B 29B 30B 31B 32B

Description

1B 2B 3B 4B 5B 6B 7B 8B 9B

Flow Meter Input #1A Flow Meter #1A GND Flow Meter Input #1B Flow Meter #1B GND Flow Meter Input #2A Flow Meter #2A GND Flow Meter Input #2B Flow Meter #2B GND CAN BUS+ CAN BUSCAN BUS GND +24 VDC PWR GND

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DynaFlowTM User Manual - Maintenance

Mother Board Signal Identication

(Continued)

MOTHER BOARD SIGNAL IDENTIFICATION

J3, 4, 5, 6 CHANNEL MODULES

Pin #

10C 11C 12C 13C 14C 15C 16C 17C 18C 19C 20C 21C 22C 23C 24C 25C 26C 27C 28C 29C 30C 31C 32C

Description

Analog Set Point Input #2

Spare Analog Input #2

Analog Input GND

Analog Transducer Control #2

Analog Flow Rate Output #2

Analog Output GND

Trigger Input #2

Run Input #2

Transparent/PID Input #2 Total Hold Input #2 Digital Input GND Gun Mask Input #2 Halt Input #2 Total Reset Input #2 Clean Input #2 Digital Input GND Load Input #2 Analog Hold Input #2

External Fault Input #2

Spare Input #2 Digital Input GND Ready Output #2 Active Output #2 Fault Output #2 Fluid Line Flushed Clean/Load/Calibrate Output #2 MVR Enable Output #2 Digital Output GND

Console Tx232

Console GND +24 VDC PWR GND

J2 INTERFACE MODULE

Pin #

10A

11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A 22A 23A 24A 25A 26A 27A 28A 29A 30A 31A 32A

Description

Digital Input GND

Digital Input GND Digital Input GND Digital Input GND Digital Input GND Digital Input GND Digital Input GND Digital Input GND Digital Input GND

Digital Input GND Digital Input GND Digital Input GND Digital Input GND Digital Input GND Digital Input GND

+24 VDC PWR GND

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DynaFlowTM User Manual - Maintenance

MOTHER BOARD SIGNAL IDENTIFICATION

J2 INTERFACE MODULE

Pin #

10B 11B 12B 13B 14B 15B 16B 17B 18B 19B 20B 21B 22B 23B 24B 25B 26B 27B 28B 29B 30B 31B 32B

Description

SIO Rx485+

SIO Rx485-

SIO Tx485+

SIO Tx485-

SIO 485 GND 6B 7B

Console Rx232A

8B 9B

Console Tx232A

Console GND

SIO Rx232B

SIO Tx232B

SIO GND

CAN BUS+CAN BUS-

CAN BUS-

CAN BUS GND

+24 VDC

PWR GND

J2 INTERFACE MODULE

Pin #

10C 11C 12C 13C 14C 15C 16C 17C 18C 19C 20C 21C 22C 23C 24C 25C 26C 27C 28C 29C 30C 31C 32C

Description

JOB Select Bit 1, LSD

JOB Select Bit 2, LSD

JOB Select Bit 4, LSD

JOB Select Bit 8, LSD

JOB Select Bit 1, MSD

JOB Select Bit 2, MSD

JOB Select Bit 4, MSD

JOB Select Bit 8, MSD

Spare Digital Input JOB Select Strobe Input System Ready/Halt Input Spare Input Spare Input Spare Input Spare Input Spare Input

System Fault Output System Pulse Output Spare Output Spare Output Spare Output Spare Output

+24 VDC PWR GND

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DynaFlowTM User Manual - Maintenance

MOTHER BOARD SIGNAL IDENTIFICATION

J7 POWER INPUT

Terminal

J7-1 J7-2 J7-3 J7-4

Description

+24 VDC +24 VDC PWR GND PWR GND

J8 SERIAL I/O

Terminal

J8-1 J8-2 J8-3 J8-4 J8-5 J8-6 J8-7 J8-8 J8-9 J8-10 J8-11 J8-12 or J8A-1 J8-13 or J8A-2 J8-14 or J8A-3

J9 SYSTEM I/O

Terminal

J9-1 J9-2 J9-3 J9-4 J9-5 J9-6 J9-7 J9-8 J9-9

J9-10

J9-11 J9-12 J9-13 J9-14 J9-15 J9-16 J9-17 J9-18

LN-9400-00.9

Description

JOB Select BCD, Units 1 Input JOB Select BCD, Units 2 Input JOB Select BCD, Units 4 Input JOB Select BCD, Units 8 Input JOB Select BCD, Tens 1 Input JOB Select BCD, Tens 2 Input JOB Select BCD, Tens 4 Input JOB Select BCD, Tens 8 Input JOB Select BCD, Hundreds 1 Input JOB Select Strobe Input System Ready/Halt Input Spare Input System Fault Output System Pulse Output Spare Output GND GND GND

Description

SIO Rx485+ SIO Rx485SIO Tx485+ SIO Tx485-

SIO 485 GND

Console Rx232A Console Tx232A

Console GND

SIO Rx232B SIO Tx232B

SIO GND RIO Blue RIO Shield RIO Clear

J10 AUXILIARY CAN BUS PORT

Terminal

J10-1 J10-2 J10-3

Description

CAN BUS+ CAN BUSCAN BUS GND

J11 = Channels 1 & 2 J14 = Channels 3 & 4 J17 = Channels 5 & 6 J20 = Channels 7 & 8

J11, 14, 17, 20 CHANNEL I/O

Terminal

Jn-1 Jn-2 Jn-3 Jn-4 Jn-5 Jn-6 Jn-7 Jn-8

Jn-9 Jn-10 Jn-11 Jn-12

J12 = Channel #1 Flow Meter J13 = Channel #2 Flow Meter J15 = Channel #3 Flow Meter J16 = Channel #4 Flow Meter J18 = Channel #5 Flow Meter J19 = Channel #6 Flow Meter J21 = Channel #7 Flow Meter J22 = Channel #8 Flow Meter

Description

Analog Set Point #1 Analog Set Point #2 Analog Transducer Signal #1 Analog Transducer Signal #2 Trigger Input #1 Trigger Input #2 Run #1 Run #2 Transparent/PID Input #1 Transparent/PID Input #2 Total Hold #1 Total Hold #2

J12, 13, 15, 16, 18, 19, 21, 22 FLOW METER INPUTS

Terminal

Jn-1 Jn-2

*Jn-3

Jn-4

* Used for ow meters with reverse ow detection

capabilities only. This input must be connected to

+24 VDC if a single direction ow meter is used.

Description

Source Signal Source GND Phase Signal Phase GND

DynaFlowTM User Manual - Maintenance

SERIAL COMMUNICATION PROTOCOLS

NOTE

Reference the "DynaFlow Program-

mers's Manual" for more information.

Allen-Bradley RIO

The Interface Module allows for direct communication from an Allen-Bradley PLC Remote Input/ Output (RIO) port to the DynaFlow Fluid Flow Control system. The RIO interface portion of the Interface Module contains some Allen-Bradley components that are licensed to Ransburg. These

are designed specically to communicate with the

proprietary protocol of the RIO serial link. The

central component being an application specic

IC (ASIC) which is capable of formatting the RIO information for use by the central processor (CPU).

NOTES

Up to four Channel Modules (8 ow control CHANNELs) can be controlled with the Interface Module. The Interface Module and four Channel Modules constitute half of a standard 19" rack. In terms of RIO rack size, a full rack consists of 8 I/O groups. The Interface Module is one I/O group, but only uses the high byte of the group. Each Channel Module is one I/O group with the

rst CHANNEL in the low byte and the second

CHANNEL in the high byte. A RIO 1/4 rack is 2 I/O groups, which consists of the Interface Module and only one (1) Channel Module. A RIO 1/2 rack is 4 I/O groups, which may consist of the Interface Module and from one (1) to three (3) Channel Modules. A RIO 3/4 rack is 6 I/O groups, which may consist of the Interface Module and from one (1) to four (4) Channel Modules. A RIO full rack is 8 I/O groups, which may consist of the Interface Module and from one (1) to four (4) Channel Modules.

The Interface Module accepts both hard-wired discrete I/O and RIO discrete and RIO block transfers from a PLC.

LN-9400-00.9

RATIO CONVERSION CHART

DynaFlowTM User Manual - Maintenance

% of Catalyst to Total

Volume

1 2 3 4

4.76 5

6.25

9.09 10

11. 11

12.5

14.28 15

16.67 20 25 30

33.33 35 40 45 50

Parts of Resin to

1 Part Catalyst

99 49

32.33 24 20 19 15 10 9 8 7 6

5.67 5 4 3

2.33 2

1.86

1.5

1.22 1

Formula for converting percentage of catalyst to parts of resin:

100%

- 1 = Parts Resin to 1 Part Catalyst % of Catalyst

Example: 5% catalyst is specied

100%

- 1 = 19 Parts Resin to 1 Part Catalyst 5%

Formula for converting "parts" to percentage:

100% = % of Catalyst (Parts Resin + 1)

Example: If a ratio setting is 13 (13 parts resin to 1 part catalyst), and I want to know what percentage of the total mixed material is resin and what percentage is catalyst.

100% = 7.14% Catalyst (13 + 1)

100% - 7.14% = 92.86% Resin

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DynaFlowTM User Manual - Warranty Policies

WARRANTY POLICIES

LIMITED WARRANTY

Ransburg will replace or repair without charge any

part and/or equipment that falls within the specied

time (see below) because of faulty workmanship or material, provided that the equipment has been used and maintained in accordance with Ransburg's written safety and operating instructions, and has been used under normal operating condi-

tions. Normal wear items are excluded.

THE USE OF OTHER THAN RANSBURG APPROVED PARTS, VOID ALL WARRANTIES.

SPARE PARTS: One hundred and eighty (180)

days from date of purchase, except for rebuilt

parts (any part number ending in "R") for which the warranty period is ninety (90) days.

EQUIPMENT: When purchased as a complete unit, (i.e., GUNs, power supplies, control units, etc.), is one (1) year from date of purchase. WRAPPING

THE APPLICATOR, ASSOCI-ATED VALVES AND TUBING, AND SUPPORTING HARDWARE IN PLASTIC, SHRINK-WRAP, OR ANY OTHER NON-APPROVED COVERING, WILL VOID THIS WARRANTY. RANSBURG'S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORK-

MANSHIP OR MATER-IALS. THERE ARE NO IMPLIED WARRAN-TIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. RANSBURG ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME, WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS.

EXCLUSIONS:

If, in Ransburg's opinion the warranty item in question, or other items damaged by this part was improperly installed, operated or maintained, Ransburg will assume no responsibility for repair or replacement of the item or items. The purchaser, therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable.

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DynaFlowTM User Manual - Appendix

APPENDIX

ADDENDUM A:

Obsolescence of the 77206-01 8-bit Channel Card, the 77206-12 10-bit Channel Card and the A10946-00 12-bit Channel Card.

In 2004, the 77206-01 DynaFlow 8-bit Channel Card was replaced by the 77206-12 10-bit Channel Card to improve the resolution of the analog outputs on this card. Then in 2006, the 77206-12 10-bit Channel Card was replaced by a totally redesigned 12-bit Channel Card and it was assigned a part number of A10946-00. Lastly, in 2007, the A10946-00 board was obsoleted and replaced by 2 boards,

the A10946-01 and the A10946-02. The reasons for this nal change are explained below: (This

information is also contained in Service Note AF-111307.)

The IC chip used on the A10946-00 DynaFlow Channel Card that produces the 4-20 mA output for

ow rate and pressure control is becoming extremely expensive and is currently experiencing very

long lead times. We have decided to produce two versions of the DynaFlow Channel Card. One version will be built as the boards are now. The other version will not have the 4-20 mA converter IC on the board, which will effectively eliminate the capability of the board to output 4-20 mA signals for these two outputs. (Our sales history shows very few users make use of these two output signals.) The 0-10 VDC outputs for these two signals will still function normally.

In order to ensure that the proper boards are selected, the following changes have been made to the part numbers: The A10946-00 part number has been obsoleted. The A10946-01 board is the new board without the 4-20 mA IC’s and is the board that will be used in all future builds unless the

customer specically requests 4-20 mA outputs for these two signals. The A10946-01 board can be modied by our manufacturing facility to become an A10946-02, when necessary, if this option is

required. (Because of the high cost and limited availability of these IC’s, there will be an additional cost for this option.)

If you currently use the obsoleted A10946-00 boards, our technical support personnel will need to know

if you are using the 4-20 mA option for either the ow rate output or the pressure control output to be able to determine which of the two new boards to send. This can be done by examining the jumpers on the boards you are now using. If jumpers any of the following jumpers: JMP5, JMP6, JMP7, or JMP8

are connected between pins 1 to 2, this most likely indicates that you are using the 4-20 mA option and will require the A10946-02 board. (Unless that channel or output signal is not being used and the

jumpers were changed from the factory defaults for some reason.) In all other cases, the A10946-01 board should be used. (See picture on next page. Note that pin #1 is toward the top of the board.)

Since this is a totally redesigned board from that of the 77206 series boards, we have also included

jumper and dip switch setting information with this addendum. The dip switch settings for SW1 have

not changed. Refer to "Hardware Settings" in current DynaFlow User Manual for these settings.

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DynaFlowTM User Manual - Appendix

ADDENDUM A (Cont.):

LN-9400-00.9

ADDENDUM B:

Remote Operator's Panel

DynaFlowTM User Manual - Appendix

If the Model A12233 control console and Model A12182 Interface Panel is used, the optional Remote Operator Panel (P/N: A11095) can be used. this Remote Operator's Panel (shown above) operates in the following manner:

Color Select - This is an eleven position selector switch that allows the operator to select the next

color to be loaded. If the most counter-clockwise position is selected (Solv) and the Paint (Solvent)

Fill button is pushed, the normal load sequence occurs and solvent is loaded into the uid sytem as

if it was a color.

Paint (Solvent) Fill/Filled - This is a green illuminated push-button. When pushed, the paint load

sequence runs (as programmed from the "Load" user interface screen). The green indicator lamp

ashes as the sequence is occurring and stays lit solid when the sequence has completed, indicating

to the operator that the system is ready.

If there is already a color loaded (i.e., one of the color valve outputs is already on) when this button is

pushed, the system will execute a ush sequence, followed by a load sequence.

Purge/Purged - This is an amber illuminated push-button. When pushed, a purge sequence is initi-

ated (as programmed from the "Purge" user interface screen). While the purge sequence is occurring,

this indicator lamp ashes. It remains on solid when the purge sequence is complete, indicating to the

operator that the purge is complete. This indicator will be turned off if a "Paint (Solvent) Fill" sequence has been initiated or a color is loaded.

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DynaFlowTM User Manual - Appendix

NOTE: If both the green Paint (Solvent) Fill/Filled lamp and the amber Purge/Purged lamps are ashing

simultaneously, this indicates that no sequence has been downloaded to the color change sequencer

since the last time power was applied to the system. This can be corrected by loading a job from the user interface screen and executing at least one ll or purge sequence.

Horn - In the top center of the panel is a horn that indicates when the controller has turned on the

"Fault" output from the gun.

Total Flow - This is an LCD display that indictes the current ow rate out of the applicator (or appli-

cators, if multiple applicators are fed from one uid panel). It operates from an analog output signal

from the controller with 0 VDC being 0 cc'min. and 10 VDC scaled to 2000 cc/min.

Flow Control - This is a potentiometer that varies the analog ow control voltage into the channel

card from 0 volts DC to 10 volts DC. Users can program what ow rate they want for both extremes by using the Minimum Flow and Maximum Flow parameters under the edit gun screen.

Faulted/Fault Reset - This is a red illuminated push-button. The lamp will be illuminated anytime a

fault occurs. Pushing this button resets any fault that has caused the fault. After resetting a fault, the user must then push the Ready Run push-button to put the gun back into run mode to resume spraying.

Ready/Run - This is a green illuminated push-button. Pushing this button puts a gun into run mode.

When in run mode, the green lamp is illuminated. It is extinguished in either a halted or faulted state.

Guns in Flush Box - These are two LED's that indicate when up to two spray guns are in their re-

spective ush boxes. A ush or load sequence will not be allowed to start until both of these indicators

are illuminated. These LED's are connected to four pressure switches, which are actuated by the two

ush boxes. The signal from these pressure switches also feed the Paint Fill and Purge push-buttons to prevent color changes and purges from occurring unless the guns are in their ush boxes and the boxes are closed. These pressure switches should be jumpered if gun ush boxes are not to be used. There are jumpers on the PC board inside the panel to bypass these pressure switches.

Feather Reset - This push-button is not functional when used in a DynaFlow system.

Spray Test - This is a simple push-button that sends a trigger signal back to the controller and also

turns on the trigger solenoid to allow operators to verify and test ow, etc. Note that this button is only functional if uid has been loaded (i.e., the green Paint Filled indicator lamp is illuminated).

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DynaFlowTM User Manual - Appendix

ADDENDUM C:

FLOW LIMITATIONS

Because of the way the DynaFlow determines ow rate from a owmeter, it has limitations where it can no longer detect ow at the low end and at the high end. (It uses a software timer to determine

the time between pulses rather than a high speed counter card.) The low end limitation is because

the timer overows between pulses and at the high end, the scan time of the program cannot keep

up with the speed of the incoming pulses.

Because of this fact, the DynaFlow cannot see ow at the low end when the pulses fall below 1 Hz

(one pulse every second).

- With a gear-type owmeter calibrated to 4,500 pulses/liter, the DynaFlow will not detect ow

below 13.3 cc/min.

- With a gear-type owmeter calibrated to 8,000 pulses/liter, the DynaFlow will not detect ow

below 7.5 cc/min.

- With a gear-type owmeter calibrated to 40,000 pulses/liter, the DynaFlow will not detect ow

below 1.5 cc/min.

- With a piston owmeter calibrated to 60,000 pulse/liter, the DynaFlow will not detect ow below

1 cc/min.

At the high end, the DynaFlow cannot see ow when the pulses exceed 435 Hz.

- With gear-type owmeter calibrated to 4,500 pulses/liter, the DynaFlow will not detect ow

above 5,800 cc/min.

- With gear-type owmeter calibrated to 8,000 pulses per liter, the DynaFlow will not detect ow

above 3,275 cc/min.

- With a gear-type owmeter calibrated t 40,000 pulses/liter, the DynaFlow will not detect ow

above 655 cc/min.

- With a piston owmeter calibrated to 60,000 pulses/liter, the DynaFlow will not detect ow

above 435 cc/min.

LN-9400-00.9

DynaFlowTM User Manual - Appendix

NOTES

LN-9400-00.9

MANUAL CHANGE SUMMARY

This manual was published to supercede Service Manual LN-9400-00.8, DynaFlow User Manual, to make the following changes:

1. Added Interface Enclosure (A12182) specs in

Introduction / Specications section

2. Revised Installation section with additional instructions related to Equipment Locations and Equipment Mounting; assembly, location, and mounting requirements, including anchor system ratings.

3. Revised Installation section with additional instructions related to Equipment Grounding and Input Power; protective earthing requirements, input power supply connections, wiring size, and

external switch, circuit breaker, and external over-

current protection requirements.

4. Revised Back Cover - Technical Service As-

sistance - Telephone and Fax Number.

LN-9400-00.9

Manufacturing

1910 North Wayne Street Angola, Indiana 46703-9100 Telephone: 260-665-8800

Fax: 260-665-8516

Technical Service - Assistance

320 Phillips Ave. Toledo, Ohio 43612-1493 Telephone (toll free): 800-233-3366

Fax: 419-470-2233

Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts.

Models and specications subject to change without notice.

Form No. LN-9400-00.9 Litho in U.S.A. 12/12

Ransburg DynaFlow User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

SAFETY

INTRODUCTION

DYNAFLOW SPECIFICATIONS

INSTALLATION

INPUT POWER

OPERATION

PARAMETER DESCRIPTIONS

Color Change Sequencer

AUTOMATIC GUN APPLICATIONS

MANUAL HAND GUN APPLICATIONS

PID CONTROL

MAINTENANCE

TROUBLESHOOTING

SYSTEM COMPONENTS AND PARTS IDENTIFICATION

RECOMMENDED SPARE PARTS

HARDWARE SETTINGS

CONTROL RACK TERMINAL IDENTIFICATION

SERIAL COMMUNICATION PROTOCOLS

WARRANTY POLICIES

APPENDIX

ADDENDUM A:

MANUAL CHANGE SUMMARY