Ransburg DynaFlow User Manual
SERVICE MANUAL
LN-9400-00.9
(Replaced LN-9400-00.8)
December 2012
DYNAFLOW
TM
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.
LN-9400-00.9
DynaFlowTM User Manual - Contents
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
88
88
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 identied.
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 specications
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 efcient
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.
LN-9400-00.9
1
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.
o
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 modications 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.
2
LN-9400-00.9
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
LN-9400-00.9
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.
3
DynaFlowTM User Manual - Safety
AREA
Tells where hazards
may occur.
Toxic Substances
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.
4
LN-9400-00.9
NOTES
DynaFlowTM User Manual - Safety
LN-9400-00.9
5
DynaFlowTM User Manual - Introduction
INTRODUCTION
FEATURES
• Congurable 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.
• Congurable 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 efciency 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 specic 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 conguration error and fault de-
tection and reporting.
• USB memory stick, backup of conguration
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 specic inputs and
supplying the necessary CHANNEL specic
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.
6
LN-9400-00.9
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 conguration 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 specic inputs and
supplying the necessary system specic
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 conguration and data to
the operator.
• Computes and displays text and graphic di-
agnostic information.
• Organizes, formats, and reports all data
and conguration 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 congured 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 reect 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
LN-9400-00.9
7
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.
Congurable Operating
Parameters
The design of the DynaFlow system allows it to
be congured to meet the specic 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 congured 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 congured 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 dene 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 conguring 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
8
LN-9400-00.9
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
nd
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 congured 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
nd
+
3rd Components)
Flow Controller = DR1
Flow Meter = Gear-Type
Operating Mode = Auto
LN-9400-00.9
9
DynaFlowTM User Manual - Introduction
10
Figure 1: Block Diagram
LN-9400-00.9
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
specications:
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 conguration 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 signicant
BCD digit)
- JOB Select 2
- JOB Select 4
- JOB Select 8
- JOB Select 10 (middle signicant
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
o
to 55o C
cant
LN-9400-00.9
11
DynaFlowTM User Manual - Introduction
Channel Module Hardware
Specications
General: Each Channel Module is responsible
for processing channel specic 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
Specications (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,
congured 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
fault) or 4-20 ma, op-amp buff
ered,
ered,
12
LN-9400-00.9
DynaFlowTM User Manual - Introduction
Channel Module Hardware Specications (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
o
to 55o C
Humidity: 80% to 31° C decreasing to 50% at
40° C non-condensing
LN-9400-00.9
13
DynaFlowTM User Manual - Installation
INSTALLATION
SYSTEM GUIDELINES
Prints Specic per Installation
Often times, installation prints are custom drawn
for each site. You should check those prints for
information that is specic 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. Specic 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.
14
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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 specied weight of the enclosure being mounted (see specications, 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. Denitions and
requirements for classied 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"
1/4"
Type
MVR
DR1
Typical
Minimum
Length
Feet Meters
15
15
4.6
4.6
Maximum
Length
Feet
50
100
Meters
15.3
30.5
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DynaFlowTM User Manual - Installation
16
Figure 2: Block Diagram for a Single-Component Gun
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CHANNEL 1
CHANNEL 2
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Figure 3a: Block Diagram for a Two-Component Gun
17
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
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
18
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 qualied.
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
specication 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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DynaFlowTM User Manual - Installation
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
20
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 Conguration table.
Not used presently.
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User Manual - Installation
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 congured properly, and all other conditions are satised.
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 species 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.
21
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 congured 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 congured 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.
22
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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 congured 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 Conguration, set in the System Conguration.
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 congured 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 identication.)
24
Figure 4: Mother Board Terminals
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DynaFlowTM User Manual - Installation
Hardware Conguration
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 specied in the
"Installation" section of this manual under
Equipment Locations".
2. The air supply meets the specications as
listed in the "Introduction" section of this manual
under "Pneumatic Specications" 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 specied, to avoid
system response delays and to achieve the op-
timum uid ow characteristics for the system.
TM
Fluid Regulator, if pilot line lengths are
Material Regulators and
Flow Meters
The location and mounting of the material regulators and ow meters is specic to each installation. The information presented here is intended
as a guideline only. Reference should be made
to the supplied documentation specic 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 specically 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
26
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