Ransburg DynaFlow User Manual

SERVICE MANUAL

LN-9400-00.9

(Replaced LN-9400-00.8)

December 2012

DYNAFLOWTM 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
	PAGE
SAFETY:	1-5
SAFETY PRECAUTIONS.........................................................................................
	1
HAZARDS / SAFEGUARDS..............................................................................................
	2-5
INTRODUCTION:	6-13
FEATURES........................................................................................................................	6
DESCRIPTION.................................................................................................................	6-9
BLOCK DIAGRAM.............................................................................................................	10
DYNAFLOW SPECIFICATIONS...................................................................................	11-13
INSTALLATION:	14-27
SYSTEM GUIDELINES, EQUIPMENT GROUNDING, LOCATIONS, MOUNTING.............	14-15
BLOCK DIAGRAM FOR A SINGLE-COMPONENT GUN................................................	16
BLOCK DIAGRAM FOR A TWO-COMPONENT GUN.............................................................	17
BLOCK DIAGRAM FOR A THREE-COMPONENT GUN.........................................................	18
INPUT POWER.............................................................................................................	19
INTERFACING TO THE FLOW CONTROLLER........................................................	20-23
MOTHER BOARD TERMINALS, HARDWARECONFIGURATION, TRANSDUCERS.........	24-26
OPERATION:	28-61
OVERVIEW.....................................................................................................................	28-29
PARAMETER DESCRIPTIONS.........................................................................................	30-43
AUTOMATIC GUN APPLICATIONS.................................................................................	44-45
MANUAL HAND GUN APPLICATIONS.............................................................................	45-46
GENERAL........................................................................................................................	46-47
JOB SELECT TIMING DIAGRAM..................................................................................	48-49
JOB SELECT TIMING DIAGRAM SAMPLE, JOB QUEUE, REVERSE FLOW.................	50-54
PROCEDURES, FIRST TIME STARTUP, NORMAL STARTUP..........................	54-56
PID CONTROL........................................................................................................	56-61
MAINTENANCE:	62-87
TROUBLESHOOTING......................................................................................................	62-71
SYSTEM PREVENTIVE MAINTENANCE INSTRUCTIONS............................................	71
SYSTEM COMPONENTS AND PARTS IDENTIFICATION...........................................	72
RECOMMENDED SPARE PARTS................................................................................	73-74
HARDWARE SETTINGS................................................................................................	75-78
NEW CHANNEL CARD JUMPERS...........................................................................	79-80
INTERFACE MODULE DIP SETTINGS.................................................................	81
CONTROL RACK TERMINAL IDENTIFICATION......................................................	82-85
SERIAL COMMUNICATION PROTOCOLS................................................................	86
RATIO CONVERSION......................................................................................	87
WARRANTY POLICIES:	88
LIMITED WARRANTY..............................................................................................	88
(Continued Next Page)

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DynaFlowTM User Manual - Contents

CONTENTS (Cont.)
	PAGE
APPENDIX:	89-93
ADDENDUM A....................................................................................................................	89-90
ADDENDUM B..................................................................................................................	91-92
ADDENDUM C................................................................................................................	93

LN-9400-00.9

DynaFlowTM User Manual - Safety

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 SAFETYand 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.

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

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

!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 identified.

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 fire 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

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	HAZARD	SAFEGUARDS
Tells where hazards	Tells what the hazard is.	Tells how to avoid the hazard.
may occur.
Spray Area	Fire Hazard	Fire extinguishing equipment must be present in the
	Improperorinadequateopera-tion	spray area and tested periodically.
	and maintenance procedures will	Spray areas must be kept clean to prevent the ac-
	cause a fire hazard.	cumulation of combustible residues.
	Protection against inadvertent	Smoking must never be allowed in the spray area.
	arcing that is capable of causing
	fireorexplosionislostifanysafety	The high voltage supplied to the atomizer must be
	interlocks are disabled during op-	turnedoffpriortocleaning,flushingormaintenance.
	eration. Frequent power supply
	shutdown indicates a problem in	When using solvents for cleaning:
	the system requiring correction.	Thoseusedforequipmentflushingshouldhaveflash
		points equal to or higher than those of the coating
		material.
		Those used for general cleaning must have flash
		points above 100oF (37.8oC).
		Spray booth ventilation must be kept at the rates
		required by NFPA-33, OSHA, and local codes. In ad-
		dition, ventilation must be maintained during cleaning
		operationsusingflammableorcombustiblesolvents.
		Electrostatic arcing must be prevented.
		Test only in areas free of combustible material.
		Testing may require high voltage to be on, but only
		as instructed.
		Non-factory replacement parts or unauthorized
		equipment modifications may cause fire or injury.
		If used, the key switch bypass is intended for use
		only during 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	HAZARD	SAFEGUARDS
Tells where hazards	Tells what the hazard is.	Tells how to avoid the hazard.
may occur.
General Use and	Improper operation or mainte-	Personnel must be given training in accordance with
Maintenance	nance may create a hazard.	the requirements of NFPA-33.
	Personnel must be properly	Instructions and safety precautions must be read
	trained in the use of this equip-	and understood prior to using this equipment.
	ment.	Comply with appropriate local, state, and national
		codes governing ventilation, fire protection, opera-
		tion maintenance, and housekeeping. Reference
		OSHA, NFPA33, and your insurance company
		requirements.
Electrical	High voltage equipment is utilized.	The power supply, optional remote control cabinet,
Equipment	Arcing in areas of flammable or	and all other electrical equipment must be located
	combustible materials may oc-	outside Class I or II, Division 1 and 2 hazardous
	cur. Personnel are exposed to	areas refer to NFPA-33.
	high voltage during operation and
	maintenance.	Turn the power supply OFF before working on the
	Protection against inadvertent	equipment.
	arcing that may cause a fire or	Test only in areas free of flammable or combustible
	explosion is lost if safety circuits	material.
	are disabled during operation.	Testing may require high voltage to be on, but only
	Frequent power supply shut-down	as instructed.
	indicates a problem in the system
	which requires correction.	Production should never be done with the safety
	An electrical arc can ignite coat-	circuits disabled.
	ing materials and cause a fire or	Before turning the high voltage on, make sure no
	explosion.	objects are within the sparking distance.
Explosion Hazard/	Halogenated hydrocarbon sol-	Aluminum is widely used in other spray application
Incompatible	vents for example: methylene	equipment - such as material pumps, regulators,
Materials	chloride and 1,1,1,-Trichloroeth-	triggering valves, etc. Halogenated hydrocarbon
	ane are not chemically compatible	solvents must never be used with aluminum equip-
	with the aluminum that might be	ment during spraying, flushing, or cleaning. Read
	usedinmanysystemcomponents.	the label or data sheet for the material you intend to
	The chemical reaction caused by	spray. If in doubt as to whether or not a coating or
	these solvents reacting with alu-	cleaning material is compatible, contact your mate-
	minum can become violent and	rial supplier. Any other type of solvent may be used
	lead to an equipment explosion.	with aluminum equipment.

LN-9400-00.9

3

DynaFlowTM User Manual - Safety

AREA	HAZARD	SAFEGUARDS
Tells where hazards	Tells what the hazard is.	Tells how to avoid the hazard.
may occur.
Toxic Substances
Toxic Substances	Certain material may be harmful	Follow the requirements of the Material Safety Data
	if inhaled, or if there is contact	Sheet supplied by coating material manufacturer.
	with the skin.	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

DynaFlowTM User Manual - Safety

NOTES

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5

DynaFlowTM User Manual - Introduction

INTRODUCTION

FEATURES

•Configurable 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 viewed on the OPERATOR INTERFACE.

•Configurable manual and/or automatic GUN applications.

•Dynamic analog fluid control – the control of flow rate while running a JOB.

•Reverse fluid flow detection provides added protection for system components.

NOTE

This feature requires flow meters that provide reverse flow 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 configuration error and fault detection and reporting.

description

The ability to control the delivery of material greatly increases the overall efficiency of the spray operating system and results directly in more uniform andconsistentpaintfinishqualityandreducesthe amount of material waste. The ability of the fluid flowcontrollertorespondwithquick,concise,and repeatable control maximizes finish 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.Theentiretaskoffluidflowcontrolisbroken up into parts. Each portion of the system is designedforaspecificpurpose.Sinceeachelement 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:

Channel Module

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

•Monitoring the CHANNEL specific inputs and supplying the necessary CHANNEL specific outputs for control and status.

•Receiving and processing the flow meter feedback pulses.

•Determining the analog PID output control signal by performing high-speed floatingpoint math.

•USB memory stick, backup of configuration and operational data.

•Versatile system integration.

•Easy to use.

•Help text and troubleshooting guide available on screens.

•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.

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 configuration and data tables.

•Acts as an interpreter for communication with an external Host computer, PLC and/ or the local Operator Interface. Communicates through a high speed Ransburg CAN Bus data link to each Channel Module.

•Responsible for system specific inputs and supplying the necessary system specific 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 configuration and data to the operator.

•Computes and displays text and graphic diagnostic information.

•Organizes, formats, and reports all data and configuration tables.

The DynaFlow fluid flow 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 fluid flow meter combination through which a single material is controlled. A GUN represents a single applicator through which one or more materials are delivered. One ormoreCHANNELsareconfiguredforeachGUN.

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 flow 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 flow and makes the required adjustments to maintain the programmed flow and ratio. This holds the flow rates of the coating components constant. Deviations from the desired mixratioarealsoimmediatelycorrectedusingthis 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 Control which reflect 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.

Configurable Operating

Parameters

The design of the DynaFlow system allows it to be configured to meet the specific requirements of each application. The 8 available CHANNELs can be linked together, using 1 of 8 GUNs, to control the flow and mixing regulation of twocomponent materials. The installed channels can be configured 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 configured 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 define flow 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 #. All of the JOB #s can be backed-up to, and restored fromaUSBmemorydevice.Referencethe"Opera-

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

TheflowcontrolunitincludesoneInterfaceModule 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 RS232C communication port

3-K Operation

DynaFlow was designed for either single or two- componentoperation.Three-componentoperation is possible by configuring two, two-component, guns. The first 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 flow rates

(see Notes 4 and 5) Operating Mode = Manual

8	LN-9400-00.9

The output of the first 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

Slave Channel =

Material = 3rd Component

Flow Controller = MVR, with appropriate size needle

Flow Meter = Piston or Gear, depending on min/max flow 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

Channel flow controller.

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

Master Channel flow 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 flow controller. Additional Guns shouldbeconfiguredforeachapplicatorasshown below to provide automatic flow control for each applicator.

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

DynaFlowTM User Manual - Introduction

NOTE

Refer to Addendum C for complete information regarding the flow limitations of the DynaFlow Channel cards.

LN-9400-00.9

9

DynaFlowTM User Manual - Introduction

Figure 1: Block Diagram

10	LN-9400-00.9

DynaFlowTM User Manual - Introduction

DYNAFLOW

Specifications

Pneumatic Requirements

Transducers: The air supplied to the transducers must be clean and dry and meet the following general specifications:

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 flow 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 fluid flow 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 VOLTAGE 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 controller. Responsible also for non-vola- tile storage of all JOB data tables and system configuration parameters.

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

(35.2 m) W standard 19" rack module

LN-9400-00.9

Interface Module Hardware (Cont.)

Digital Inputs: 24 VDC at 2.3 ma typical per input (optically isolated, source by default, sink selectable)

-JOB Select Strobe

-JOB Select 1 (lower significant

BCD digit)

-JOB Select 2

-JOB Select 4

-JOB Select 8

-JOB Select 10 (middle significant

BCD digit)

-JOB Select 20

-JOB Select 40

-JOB Select 80

-JOB Select 100 (upper significant BCD digit)

-System Ready/Halt

-Global Gun Enable

Digital Outputs: 24 VDC sourced at 300 ma maximum per output (Solid state relay contacts)

System Pulse: Used as watchdog timer by an external supervisory PLC or computer.

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 communication 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: 0o to 55o C

11

DynaFlowTM User Manual - Introduction

Channel Module Hardware

Specifications

General: Each Channel Module is responsible for processing channel specific discrete 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): 24 VDC at 2.3 ma typical per input (optically isolated, source by default, sink selectable)

Trigger (level): Automatic mode only - For manual mode, fluid starts with fluid flow 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 conjunction 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 fluid flow

Transparent/PID (level): When active directs the external analog input directly to

the transducer output

Analog Hold (level):

Freezes PID and holds current analog control output

Load (edge): Loads fluid with controlled mix ratio for GUNs operating in MANUAL

Mode

External Fault/

Enable (level): Enable signal input. Must

be active for fluid to be delivered by

GUN regardless of the operating mode.

Spare: Not used presently

12

Channel Module Hardware

Specifications (Cont.)

12 Digital Outputs

(2 Channels): 24 VDC sourced at 300 ma maximum per output (Solid state relay contacts)

Ready: Everything is ready for operation, configured 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 (default) or 4-20 ma, op-amp buffered, 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, offset 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 (default) or 4-20 ma, op-amp buffered, 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 MINIMUM FLOW RATE and MAXIMUM FLOW RATE JOB parameters)

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

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DynaFlowTM User Manual - Introduction

Channel Module Hardware Specifications (Cont.)

FLOW RATE JOB parameters)

4 Frequency Inputs: From flow meters (reverse flow capable)

Source Signal #1 & #2:

Frequency used to determine flow rate (pulses per volume or weight).

Maximum Frequency = 435 Hz

Minimum Frequency = 1 Hz

(Refer to Addendum C for flow limitations.)

Phase Signal #1 & #2: State used to determine direction of flow 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.

Communications

CAN: ControllerArea 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: 0o to 55o C

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

Humidity: 80% to 31° C decreasing to 50% at 40° C non-condensing

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13

DynaFlowTM User Manual - Installation

INSTALLATION

SYSTEM GUIDELINES

Prints Specific per Installation

Often times, installation prints are custom drawn for each site. You should check those prints for information that is specific 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 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 conductorgroundterminallocatedinsidetheControl Enclosure which is marked with symbol -

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. Specific 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 flow meter is 100-ft. as determined by the maximum standard available length of the fiber-optic cable assemblies or intrinsic electrical cable assemblies.

2.The maximum recommended length of air pilot 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 possible to achieve the best fluid flow response and regulation. See "Pilot Signal Guidelines" chart in this section.

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 theA12182 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	LN-9400-00.9

!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 specified weight of the enclosure being mounted (see specifications, page

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

DynaFlowTM User Manual - Installation

!W A R N I N G

The Control Enclosure must be located 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

!W A R N I N G

If improperly located, certain electrical equipment can become a source of ignition and create a risk of fire or explosion.

The Control and Interface Enclosures must be located outside of the Class 1, Division 1 and 2 hazardous locations which are defined for spray finishing of flammable and/ or combustible materials. Definitions and requirements for classified areas are found in the National Electrical Code, NFPA-70, Article 516 and the National Fire Protection Association (NFPA-33).

PILOT SIGNAL GUIDELINES

				Minimum		Maximum
				Length		Length
	Tubing Size	Fluid Regulator	Typical	Feet	Meters	Feet	Meters
	OD	Type	Application
	1/4"	MVR	Two-component	15	4.6	50	15.3
	1/4"	DR1	Single-Component	15	4.6	100	30.5

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DynaFlowTM User Manual - Installation

Figure 2: Block Diagram for a Single-Component Gun

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CHANNEL 1		CHANNEL 2

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

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CHANNEL 1		CHANNEL 2
	ANALOG CONTROL SIGNAL	ANALOG CONTROL SIGNAL
E/P TRANSDUCER	FLOW METER FEEDBACK	FLOW METER FEEDBACK	E/P TRANSDUCER
AIR SUPPLY			AIR SUPPLY
PILOT SIGNAL			PILOT SIGNAL
FLUID			FLUID
REGULATOR			REGULATOR
	FLOW	FLOW
	METER	METER
	VALVE	VALVE
FLUID SUPPLY			FLUID SUPPLY
	CALIBRATION	CALIBRATION
	CHECK VALVE	CHECK VALVE	CHANNEL 3		CHANNEL 4
		Y BLOCK
				ANALOG CONTROL SIGNAL	ANALOG CONTROL SIGNAL
		MIX TUBE	E/P TRANSDUCER	FLOW METER FEEDBACK	FLOW METER FEEDBACK	E/P TRANSDUCER
			AIR SUPPLY			AIR SUPPLY
			PILOT SIGNAL			PILOT SIGNAL
			FLUID			FLUID
			REGULATOR			REGULATOR
				FLOW	FLOW
				METER	METER
				VALVE	VALVE
			FLUID SUPPLY			FLUID SUPPLY
				CALIBRATION	CALIBRATION
				CHECK VALVE	CHECK VALVE
					Y BLOCK

MIX TUBE

APPLICATOR

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

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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 terminallocatedinsidetheControlEnclosurewhich is marked with symbol -

If there are large AC line voltage fluctuations 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

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 specification 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.

DynaFlowTM User Manual - Installation

!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 equipment or perform installation or adjustment procedures unless you are properly trained and qualified.

Installing and servicing this equipment requires access to parts which could cause electric shock or serious injury if work is not performed properly.

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	Description
	Signals
	JOB Select	These inputs are used to select a JOB number from the external PLC or other host controller.
	Inputs	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	JOB Strobe requires a pulsed signal of at least 0.25 seconds duration. This signal is used in
	Input	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/	System Ready/Halt is a maintained signal that permits activation of any or all GUNs. For the
	Halt Input	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	The Global GUN Enable is a maintained signal that overrides all of the individual External
	Enable	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	Description
	Signals
	System Pulse	The System Pulse output can be used as a watchdog function by a PLC or other external
	Output	controller to determine if the flow controller is operating normally. The output is a 50% duty
		cycle, 0.5 HZ signal (2 pulses per second).
	System Fault	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 Configuration table.
	System Spare	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	Description
Signals
Trigger	For automatic applicators: Starts fluid flow when supplied a 24 VDC signal assuming that the
	GUN has been put in run mode, is configured properly, and all other conditions are satisfied.
	For manual GUNs: A Trigger signal is required for the LOAD mode. The Trigger signal can
	be generated from an atomizing air flow switch. If a Trigger signal is received from the flow
	switch but no fluid flow 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 flow
	through the master channel is used to indicate a TRIGGER ON condition.
Halt/Reset	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	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 fluid 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.
Run	This input will activate the GUN and will allow material flow 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.
Gun Mask	The Gun Mask input specifies whether a JOB # or toggled into GUN #n queue. This signal
	is used in conjunction with the system PROGRAM SELECTand 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	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.

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GUN INPUTS (Continued)

	Input	Description
	Signals
	Total Hold	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 fluid flow. The non-resettable total will not be effected. This is
		most often used during flush or soft air push cycles. It can also be used to account for only
		that material which is delivered onto parts.
	Transparent/	For GUNs configured as single-component, automatic mode only. This input is only acknowl-
	PID	edged for run and load modes. This input must be supplied before the clean input or the trig-
		ger 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.
	Analog Hold	This signal applies only to GUNs configured 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 flushing 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	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 opera-
		tion 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/	External Fault will detect a low signal of at least 0.25 seconds duration. This signal must be
	Enable	maintained high for normal operation. No fluid flow 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 fluid flow 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.
	Spare Digital	Not used presently.
	Input
	Analog Set	This is a 0-10 VDC or 4-20 ma input signal (hardware selectable on the Channel Card) which
	Point	can be used to command flow rate when the applicator is in AUTOMATIC mode. The scaling
		for input signal vs. flow 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.
	Spare Analog	Not used presently.
	Input

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GUN OUTPUTS

	Output	Description
	Signal
	Ready	This output is 24 VDC when the GUN is configured properly, a valid JOB is loaded.
	Active	This output is 24 VDC when the GUN is RUN mode and flowing fluid or prepared to flow fluid.
	Fault	This output is 24 VDC if a GUN fault condition occurs.
	Pot Life Timer	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 Configuration, set in the System Configuration.
	Clean/Load/	This output is 24 VDC when the GUN is placed in Clean, Load, or Calibrate Mode.
	Calibrate
	MVR Enable	This output is 24 VDC anytime material should be flowing for the GUN. It is used to control
		trigger valve(s) installed at the inlet of the MVR valve(s) on fast-trigger JOBs.
	Analog Control	This is a 0-10 VDC or 4-20 ma output signal (selectable on the Channel Module) which is
	Output	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	This is a 0-10 VDC or 4-20 ma output signal (selectable on the Channel Module) indicating
	Rate Output	the actual flow 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 flow rate for
		the gun is output and if the switch is on only the flow rate for the Master Channel is output.
		For the Slave Channel, only the flow rate for the Slave Channel is output.
	Fluid Line	On guns configured for dual component operation, the pot-life expired output on the slave
	Flushed Output	(B) channel indicates when the fluid line has been completely flushed. Once mixed material
		has entered the fluid line, this output is energized and it remains energized until the unit is
		completely flushed. 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.
	User Interface	Displays the current version of the user-interface software running on the user-interface PC.
	Revision
	Language	This allows users to select between English and one Alternate Language. The alternate
		language text is stored on the flash drive or hard drive of the PC in files named: TEXT-
		MESS_ALT.TXT, PARAMHLP_ALT.TXT, LABELS_ALT.TXT, SOLENOIDVALVES_ALT.TXT,
		and HELP_ALT.TXT.

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Control Rack Wiring

(Reference page 82 for terminal identification.)

Figure 4: Mother Board Terminals

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Hardware Configuration

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 fluid flow 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 specified in the

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

2.The air supply meets the specifications as listed in the "Introduction" section of this manual under "Pneumatic Specifications" or those published with the transducer.

A 1:1 volume booster may also be connected

DynaFlowTM User Manual - Installation

directly to the transducer output when; operating a DR-1TM Fluid Regulator, if pilot line lengths are 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 specified, to avoid system response delays and to achieve the optimum fluid flow characteristics for the system.

Material Regulators and Flow Meters

The location and mounting of the material regulators and flow meters is specific to each installation. The information presented here is intended as a guideline only. Reference should be made to the supplied documentation specific to your installation.

Fluid Supply Requirements

•The fluid supply must be free of pulsation and surges.

•A fluid strainer/filter must be installed immediately 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 verifying of the flow meters and should be mounted close to the mixing block. These are supplied as part of the standard fluid panel. Drawings created specifically for your system will provide detailed information about valve type and location. Mount the calibration valves in an easily accessible area close to the mixing block. For most applications the flow 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 fluid flow rates (different flow 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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Analog Hold mode without causing the fluid 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 fluid flow rates (different flow 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 applications where the requested fluid flow is for the most part consistent, and transitional response 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 fittings are used for all fluid lines and connections where metal is desired.

•Always mount the flow meter and regulator 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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