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RansFlow - DeVilbiss

1. Wasara SS n rs a SS mm mami mis lt l Ao A AS NO As As As N A A d s d off d eS MF te ND ISO PRI ua DE LA els Vike aie UB EAE M Ko San y ua a ia ARN ADAM DL E DA gt PS MR T EN r KK x 7 24VDC 4 gt LO M n Oo N Te M CN J4 e CN 00 t CN C 00 cO H N N IN N 5VDC THI 24VDC 24VDC 24VDC 2 F 4 F2 F3 71 1A 1A 1A 5VDC 5VDC Ea 71 Ea 71 mec d Hn A secre 47 cole 5 B Resin Air A 46 46 m c ms secre
2. v INDICATES 3 16 0D PARAFLEX TUBING SSP 5014 INDICATES 1 4 OD X 170 ID POLY TUBING 9704 03 a INDICATES 5 32 OD NYLON TUBING TR SSEM 548 SUPPLY AIR SUPPLIED BY OTHERS L CLEAN DRY FILTERED TO 20 MICRON bv OTHERS 507 INDICATES 3 8 0D X 1 4 ID NYLON TUBING 9704 04 90 PSIG MIN TD 100 PSIG MAX E SOLVENT 6 SOLVENT INDICATES 1 2 0D X 3 8 ID POLY TUBING 9704 07 gt x d Q 4 3 SUPPLY 4 PAINT SUPPLY TYP I kr INDICATES 3 8 0D X 1 4 ID PFA TEFLON TUBING SSP 5020 g Lc O ro alc EH INDICATES 3 8 OD X 3 16 ID TEFLON TUBING SHIELDED 74178 02 Im CLA t D INDICATES 3 8 OD X 1 4 ID TEFLON TUBING SHIELDED 74178 01 zum E RESIN COLOR VALVE STACK CATALYST COLOR VALVE STACK 8 ai mar 28 b E a FITTINGS SUPPLIED ON THE E
3. ERK AIRON O RO ROR OR NSM A R N SS PR RN COMO T ME A A A A A A A OA A A A RA Ny A I jum O F PR LO ud N I Sc LO M p S J7 LO LO LO LO st lt H Z N lt H M M M M n N N H N e oO oO st N oO oO N re re H N oO N e oO lt H NI 00 e 24VDC 5VDC Ti cO CO LO LO LO I t m m be M NI NI NI N N J I II PST CPP es Tapa N C N C N C N C N C 11 TP1 O 24VDC GA 5VDC s r y SH r 1 1 L 2 p i P18 p cm l 3 l 2 2K li I M Es l lt Y QA T lt 6y i E eale 77 Sit _ cLKIl e r P15 E O 3 T 1 Jeli I 1M 7 L 14 P16 I ees pt ee cial l GATE2I 4 l L I 4 PS 4 20 E lt l Y oIN1 9 cal a 5 I 09 l 3p R GATES o N2 Ed Ill l Y T i91 C cLiksl 2 1 E cares ct 2 1 I lt 0 201 4 C MEE B cLkal 214 2 4 2 pels N C 125 1 N C 414 l 24 19
4. INPUT TO THE MVR s ARE 10mm O D TUBE FITTINGS B8 HED FOR ELECTRICAL CONNECTION c E I TO THE RANSFLOW NON INTRINSICALLY SAFE a 2 ECON BOXES ROP CONNECTOR NOTE EITHER THE INTRINSICALLY SAFE RES T j s FUSED THE NON INTRINSICALLY SAFE REMOTE p dE MU DISCONNECT SEALOFF OPERATOR PANEL MAY BE USED BUT NOT RES ROP CONDUIT HOLE H BY CUSTOMER TYP SIMULTANEOUSLY BOTH ARE OPTIONAL AH I m 4 gus LID CLOSED 2 ml GUN IN o ran I BE ad ica Hp PURT A LAX CONSTANT VOLTAGE TRANSFORMER a zJ A Fees GATA m c 120 VOLT or 10 Z TCTT SINGLE PHASE 500 WATT CAPACITY SUPPLY AIR FOR ATOMIZATION AIR m ET P BY CUSTOMER TO SPRAY GUNS SUPPLIED BY OTHERS B T PORT B LID CLOSED CLEAN DRY FILTERED TO 20 MICRON 9 TRIGGER AIR IN GUN DUT REGULATED SUPPLY AIR FOR GUNS AR E H APPLICATOR BY OTHERS a T a un FLD B 3 el gt FLUID SUPPLIED TO FLUID PANEL SHOULD FILTERED TO 100 MESH FILTER J Qi Ore roy Bn r e FLUID SUPPLY SHOULD BE FREE HO REGULATED ATOMIZATION AIR OF PULSATION AND SURGES gi a RS SURGE CHAMBERS ARE E TO ATOMIZER REQUIRED IF FLUID DELIVERY FLUID INLET SYSTEM CAUSES PULSATIONS E a GREATER THAN OR 10 PSI
5. grammed in the job parameter for pot life time ing or flushing 36 Job Select Bit 80 Input 24 VDC For remote selection of next job to be loaded See appen nz 7 Ster recommended job loa timing sequence _ 3 Job Select Bit 20 Input 24 VDC For remote selection of next job to be loaded See appen nz _ 7 Ster recommended ob loa timing sequence 38 Job Select Bit 40 Input 24 VDC For remote selection of next job to be loaded See appen P Sama Ster recommended ob oat timing sequence 39 Job Select Bit 8 Input 24 VDC For remote selection of next job to be loaded See appen P Sna s ee V Ster recommended pob ied timing sequences 40 Job Select Bit 10 Input 24 VDC For remote selection of next job to be loaded See appen nz e NOE Ster recommended job ied timing sequences o _ 41 Job Select Bit 2 Input 24 VDC For remote selection of next job to be loaded See appen Sn s NO Sier recommended job ied timing sequences 42 Job Select Bit 4 Input 24 VDC For remote selection of next job to be loaded See appen Gn PS qx or recommended job ed timing sequence o _ omae o e ages 44 H V Enable Gun 1 Output 24 VDC This output goes on once the load sequence is completed qos peser and the gun flush box es is are closed 45 Mixed Volume Output 24 VDC This output goes on when the mixed volume of material has t Imm flowed through the flowmete
6. IT Ransburg PRODUCT MANUAL LN 9409 01 2 RansFlow Fluid Metering System MODEL A12410 XXXXXXX 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 Product Manual Price 50 00 NOTES CONTENTS Section 1 SAFETY 5 9 Safety Precautions Hazards Safeguards Section 2 INTRODUCTION 10 20 RansFlow Specifications Features RansFlow Selection Guide Section 3 INSTALLATION 21 33 System Guidelines Electrical Connections Air Connections Fluid Connections Discrete Gun Inputs amp Outputs Discrete System Inputs amp Outputs Section 4 PROGRAMMING 34 75 Main Screen Configure System Parameters Gun Parameters Channel Parameters Advanced Channel Parameters Job Parameters Alarms Reports Information Color Change Sequence Tools Force I O View Inputs Emulator LN 9409 01 2 RansFlow 3 Section 5 OPERATION 16 78 Emulator Remote Operator Panel Screen Start Spraying Finished Spraying section 6 TROUBLESHOOTING 79 84 Power Supply Flow Too High Flow Too Low Out of Tolerance Reverse Flow No Master Flow section 7 APPENDIX 85 105 Icon Definitions Remote Operator Panel ROP Fault Codes Typical Installation Prints fractional amp metric Control Panel Parts List Fluid Panel Parts List Pneumatic Interface Panel Parts List Interconnect Board Schematic Optical
7. S z HSN14d NNO SYIONGSNVUYL MIVNOILMOdO3d MAW a v 3 o ee T HOLIMS IV HOLIMS IV NOILVZINOLY NOILVZINOLV 1vNOILdO SYIONGSNVYL ONS Lud OILVIAHHOS DILVWNANd Fluid Panel Parts List LN 9409 01 2 RansFlow 91 2 I A SIDE FLOW MEIER oz 758 0 7723 01 TR SsF 052 Qj Ss trsos oo 9 77220 00 po 25 Fo 77214 00 77223 01 76628 00 7e56 16c ss 1505 co AA 1321 01 TABLE C B SIDE FLOW METER Wwe A H w A4 8r 8 B rio mco 7655 0 2722 0 TR SsF 052 J ss 1505 co 7220 0 _ po 25 _RF 1 Fo 77214 00 77223 01 76626 00 7ase 16c ss 50 co AA 13521 01 x PISTON WETER 7226 00 77223 03 729 TABLE E Ne BLOCK EET BLOCK FLUSHABLE 78014 01 EU 2 MIX BLOCK NON FLUSHABLE 78014 02 3 MIX BLOCK HIGH PRESSURE ONLY SEE TABLEF 0 o TABLE F TABLE B A SIDE FLUID CONTROL 2 WEEPLESS WR 76624 0200 1 1 J 1 3 WEEPLESS MR 76624 05 1 1 1 4 WEEPLESS WR 76624 04 1 1 J 1 5 2 WEEPING MWR 78137 02 1 1 1 6 3 WEEPING MR 2 78137 05 1 3 7 4 WEEPING wR 78137 4 t1 3 t RF 1 FIBER OPTIC DASH Ka CABLE LENGTH 67 Lm
8. TO FLUID PANEL a a ELECTRICAL DEVICES THIS SIDE OF BROKEN LINE HAZARDOUS AREA TO BE LOCATED IN NON HAZARDOUS AREA SAFE AREA BILL OF MATERIALS ITEM QTY PART NUMBER PART DESCRIPTION 1 1 AUT 61598 RANSFLOW 2K SYSTEM 5 4 77220 00 FLOWMETER CABLES RF 04 2 A12559 00 REMOIE OPERATOR PANEL TN Re 282 3 ______ 5 2 12605 50 REMOTE OPERAIOR PANEL CABLE 50 FI a T 8 8 40840021 FLUID PANEL FRACTIONAL A 2 76251 00 RF 1 FLOW METER B Dow ol 355V2405 88 CCV VALVE ON INLET OF RESIN 1 78137 03 WEEPING MVR 3 ON CATALYST 78014 02 MIX BLOCK ASSEMBLY NON FLUSHABLE ON MATERIAL SUPPLY TO COLOR VALVE STACK BY OTHERS TUBING SYMBOLS fv INDICATES 6mm OD X 4mm ID NYLON TUBING A10840 XX D IN INDICATES 4mm OD X 2 7mm ID NYLON TUBING A10894 XX AN INDICATES 5 32 OD 4mm OD NYLON TUBING 77536 XX D INDICATES 10mm OD X 8mm ID NYLON TUBING A10839 XX INDICATES 8mm OD X 6mm ID NYLON TUBING A10893 XX kr INDICATES 10 mm OD X 8mm ID PFA TEFLON TUBING A10841 01 INDICATES 8mm OD X 6mm ID PFA TEFLON TUBING A10841 02 0 4mm ID PFA TEFLON TUBING A10841 03 MAIN LINE AIR SUPPLY AIR SUPPLIED BY OTHERS CLEAN DRY FILTERED TO 20 MICRO 90 PSIG MIN TO_100 PSIG MAX RESIN COLOR VALVE STACK FITT
9. e Catalyst MVR Valve e Catalyst MVR Enable Valve e Catalyst Solvent Valve e Dump Valve Step 3 The resin solvent and resin air valves are cycled to cause a scrubbing action inside of the fluid line The user can specify how long each of the two valves is open in each cycle as well as how long they continue the cycling process for During this step the following valves are opened e Resin MVR Valve e Resin MVR Enable Valve e Resin Solvent Valve pulsing e Resin Air Valve pulsing e Dump Valve LN 9409 01 2 RansFlow 63 Color Change Sequencer Screen continued Color Change Sequence sj 1 2 Flush Sequence Time 15 00 sec Load Sequence Time 8 00 sec FLUSH SEQUENCE 1 Resin Push Solvent Solvent Only Solvent 0 250 sec Air O Air 0 250 sec Time 15 000 sec Time 2 000 Sec LOAD SEQUENCE 1 Load to Flowmeter 2 High Flow A Resin Flow Rate 35 ml min Flow Rate 200 ml min B Catalyst C Channel Use Analog e 3 Low Flow Time 3 000 sec Time 2 000 sec Step 4 Allows the user to push out the flushing materials left in the fluid lines with either air or solvent For plural com ponent materials it is often recommended to leave unpressurized solvent in the lines when the system is not in use to soften any material that may have skinned the inside of the fluid lines That material should be flushed out at the start of the next paint cycle The valves that are o
10. 2 This is sometimes seen after a gun has been flushed and left unused for a period of time such as at the end of the day or end of the shift This may be the result of pressure trapped in the line between the MVR valve and the applicator This pressure eventually will back up through the flow meter and out the weep port on the MVR valve To prevent this make sure the applicator stays triggered for a few seconds after the controller is taken out of clean mode to relieve this pressure 3 When electrostatic sprayguns are used it is not uncommon to see a very large value in 100 000 of ml s range displayed for reverse flow This is caused when electrostatic noise is generated at the flow meter That is if the flow meter is not properly grounded and high voltage feeds back through the paint line from the applicator noise is generated in the flow meter cable This noise is read by the software controller as reverse flow Make sure the flow meter is adequately grounded This must be the same ground that is used in the controller LN 9409 01 2 RansFlow 83 NO MASTER FLOW This fault will only occur on guns configured as manual also known as demand mode On guns configured in manual mode as soon as the gun is put in run mode the master channel MVR valve opens to the MVR high setpoint which is usually 100 psi This is typically wide open In this way the operators can demand as much lluid as they wish and all the controller does is insur
11. 96 c o OQ O lt im o Q C LLI T C gt 02 8 8 z 222 vSgArz 160154 IF 154 tt ISEL LOLL BYNSTIONS 3O dOL NO q31v2901 NAOH 3YNSOIING 40 01 NO O a3lvO01 0 qaavosgs 193NNO29331NI Moz 0002000880200 0960900920 e 1102 8 guvog Y OLVIOS 721140 v Q4dvYOB8 dOIV T1OSI 7 21180 NOWINCO 2d 4015 3 83804 30 SOAS 501 d AlddflS 83 4O0d ih isd or 5 790 79905 43 0d 160154 IOA vit 8 8 9 9 LHS 3O 1HOlH N3w01 NI 571 130 NNO2 S d 33S LOH TSOL I OLMS Qno 4901 wad OV N OND 4 ZH 09 08 YZ OVA 072 001 uOj 2BuuO JeMOd Dy seWOoysND 01 2 RansFlow 9409 LN 97 NANI MOIV NOMWOO 20 1012 01092105 V TIdVN3 HAM 01003106 9 1 A 01093105 89102 GIONS TOS 2 D 010 3105 uoo 0IDN3105 y 80105 maus PRU HAM 203 SH39ndSNVdl1 OAS 0IDN310S 801025 01093105 9 GIONS 10S 8 YOLSINNDO n09 01093105 N7102 91092105 6 80105 412 010932105 01 80105 01092105 uly NIS34 010N310 M YOLOSNNOO l ANZATOS NIS33 30S 1J31 dol 010032108 dh nq N9 Oz 1802 L29202 01l0N310S 3352131 GIONS 10S L 1117175 3 TIANI MAN 010 3105 z UNIS onasan 010N31
12. Flow Rate Command Input 0 10 For remote analog control of flow rate If Min Flow is pro Gun 1 VDC grammed at 0 ml s min and Max Flow is programmed at 1000 ml s min and 4 00 volts DC is sent to this input the gun will flow at 400 ml s min Load Gun 2 24 Connecting this input to 24 VDC initiates the load se quence Output 24 Not currently implemented in software bia S MUR RN Ia ages 2f Job Select Bit 80 Input 24 VDC For remote selection of next job to be loaded See appen JSU ti fr recommended ob loa ting eoquence a _ 28 Job Select Bit 20 Input 24 VDC For remote selection of next job to be loaded See appen ns T tor aa 29 Job Select Bit 8 Input 24 VDC For remote selection of next job to be loaded See appen os JU ti fr recommended ob loa ting oquence 30 Job Select Bit 2 Input 24 VDC For remote selection of next job to be loaded See appen os _ NO tr recommended ob loa tuning sequence NE 32 Halt Reset Gun 1 Input 24 VDC Connecting this input to 24 VDC momentarily resets a pon 28000 fasted gut orate an nanpa s 33 Run Gun 1 Input 24 VDC Connecting this input to 24 VDC momentarily puts a m 5 j halted non faulted gun in run active mode 34 Pot Life Expired Output 24 VDC This output goes on when the mixed material in the applica Gun 2 tor has been mixed for a time greater than the time pro
13. 1 n c lt 22_1__n c I lt 6 I lt 264 WH L J5 J6 LAE Tif 94 1 Gun Trigger wl l lt 14 U2 Gun Run wl J J3 a J4 m l 4 Lu PS ror P7 Halt Reset wl 2 Flow Output Command al 1 TP4 Actual Flow el 1 TPB I lt 6 14 I 1 lt l o Clean wl 7 Flow Output el TP5 Pressure Regulator al TPQ lt I I lt 1 I lt d Load wl 9 05 Flow Output cl 2 TP6 Pressure Regulator 2 0 lt 10 t 6 L4 6 L4 5 Job Select 1 al 1 Actuol Flow al 7 Pressure Regulator cl 7 21 I 9 4 Analog 9 j Analog Job Select 2 wl 5 lt 2 I Outputs IS 1 4 Outputs 4 I 10 2 a 24 61 Ti ob Selec lt J oi Rete input aaa Pq x Del a 04 Flow Rote Input TP12 Job Select 10 wl 9 Flow Rate Input el j s l 20 l 4 l MS Analog Job Select 20 al 1 Spore Anolog Input al 2 HOS 2 l lt I 114 Job Select 40 al 5 all Spare Anolog Input el 7 24 Digital 8 e I Inputs lt I4 Job Select A NR US A acl TEST POINTS T E TP1 TRIGGER GUN 1 Job Strobe 3E 2 TP2 TRIGGER GUN 2 lt lt P3 FLOW OUTPUT COMMAND Flush Box Ary 29 _ l 14 P4 FLOW OUTPUT COMMAND B 0 lt 4 44 P5 FLOW OUTPUT COMMAND C E PEUT pais p P6 ACTUAL FLOW A lt 52 lt 6 1 P7 ACTUAL FLOW 2553 i l 2
14. MSS MMA 31S10SNI 318v9 YOLINONOI OS Q0 06tcIV 000H 30 3QISNI HGAI NIYO 33100 30 3903 LV 330 NIVSO ANO CIMON N33N9 3UHM 59viB St aaas O34 3n8 6L _ 7 amm a3u auHM Zt q39 39NvSO SL L j l 3mg 3uHW 39NvsO 9t 3deHs Q3S 3HHM Zh 39NV80 033 31HM G 3dlMIS O38 wOvig 9i pot 39NvHO SUHA DIOvi8 E 3diHIS 31HW 3n18 39NvHo 3UHM 3hB SAILS 3HHA N33H9 fi L7 J N3389 519v18 39NvHO zt _ 0348 39NvJ0 M9v18 OS 39NvHO D9v18 N3382 3dIS 3 HM XOviB Z 39NvHO O034 3018 6 N33495 9v18 034 Ot _ xoviS 3na 3 18 0348 39NvS30 er N3349 038 31HM 39515 MOv18 39NwWO 038 39NvH0 N33489 N3349 034 9v18 Sc 3diMIS M9v18g N3349 6 3mB 31HW O34 9 3uHwovis mB 4z MOviB O3H 8 3m8 5vi8 31IHM Se 3lHA 59vi9 39NvHO 9c 3dhIS xvig 3llHM 2 _ 3mg 3HHM M9via 3HuHwovis N3389 Se 1 1 8o 9 N3389 038 3018 3IHA 5vig 034 vC 1 0 N3345 038 39Nv4O ce G3H Movig 3llnM cc 1 1 1 wWN33u5 _ 3 98 3HHW N3389 Ww Q3s 3uHM MOvid cc 1 1 933 N3385 3IHA O34 Ov 3d31S N3389 39NvHO 12 1 Z N3349 59v18 31HM 5 N33u5 G34 Oc FOI 3MIM NId 40102 Nid 230109 33lA Nid 31971 38lAA OOOH WAN 00 68t Clv
15. POT LIFE VOLUME ml TOLERANCE VOLUME Flush Box Flush Box _ This screen allows the user to configure parameters specific to the gun The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Notused e Not used e Save Gun Parameters to flash memory CHANNELS This box indicates which channels are configured to the gun If it is necessary to change this setting it must be done on the Systems Parameters screen MODE When this box is touched a popup will allow the user to select either Manual or Automatic mode for the gun LN 9409 01 2 RansFlow 41 Gun Parameters Screen continued Gun Parameters v px CHANNELS MODE MANUAL FLUSH MODE CLEAN CHANNELS NO NO TRIGGER ON DELAY ms DEFAULT JOB TRIGGER OFF DELAY ms FLOW TOLERANCE 96 BLOW OFF TIME sec TOLERANCE TIME POT LIFE VOLUME ml TOLERANCE VOLUME 150 Flush Box A Flush Box 9 m r In manual mode there is no flow control on the master channel and the user controls the flow rate either with an exter nal fluid regulator or by adjusting the needle on the applicator The controller monitors the flow of the master channel and simply controls the ratio of the slave channel or channels based on the programmed ratio Note that during the load sequence if there is a flow control valve on the master channel the color change sequencer w
16. The resistance between the part and ground must not exceed 1 mega ohm All electrically conductive objects in the spray area with the exception of those objects required by the process to be at high voltage must be grounded Any person working in the spray area must be grounded Unless specifically approved for use in hazardous loca tions the power supply and other electrical control equipment must NOT be used in Class I Division 1 or 2 locations Follow These Guidelines All electrical equipment must be located outside Class or Il Division 1 or 2 hazardous areas Refer to NFPA 33 2009 Edition Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety cir cuits disabled Before turning the high voltage on make sure no ob jects are within the sparking distance LN 9409 01 2 RansFlow 8 HAZARD Toxic Substances Mechanical Hazard Certain material may be harmful if inhaled or if there is contact with the skin Robot Work Area Mechanical Hazard Improper use or maintenance can lead to hazardous conditions particularly from un expected robot manipulator movement All Areas Improper Inadequate Training Improper operation or maintenance may create a hazard Personnel must be properly trained in the use of this eq
17. and the ratio for channel C should be programmed at 2 Alternately they could also be programmed at 2 50 1 50 1 00 and achieve the same ratio Note that the last parameter does not need to be 1 LN 9409 01 2 RansFlow 55 Job Parameters Screen continued JOB Settings Channels Ratio Parts MVR High Flow Rate Pulses iter MVR Low Max Flow Valve Pressure REG Min Flow Pot Life Notes Pulses Liter Although this value can be programmed on this screen it is recommended that it be setup from the calibration routine It is the number of pulses per liter that the flow meter sends out for the material being flowed This may vary significantly from material to material based on viscosity shear flow rate etc Valve This allows the user to program the color valve that will be opened when this job number is loaded The master channel can control up to 10 color valves and the slave channel can control up to 3 color valves NOTE When running in 1k mode ensure that NO slave channel valve is programmed to be opened MVR High This is the maximum pressure that is allowed by the software to be sent to the flow control valve which in most cases will be an MVR valve This value is used during flushing loading and for the master channel of a manually configured gun This also limits the maximum pressure that is allowed to be sent to the flow control device while running PID con trol so users are warned that specifying too
18. col 4 B Color 10 A ll m gt x ever 3 B Color 9 A 41 i 41 D secre ce 2 B Color 8 A gt ks 39 l 39 1 Color 7 T pm pm A j l a z Enable B Color 6 A L rt rt a l 34 secre l 34 5 Color 5 U t pa 33 l 33 Spore Color 4 A 52 32 rt rts I T j 1 1 Color 3 A S 30 eare 30 2 D 2 l D 9 e Fault B l 9 Ka Color 2 A mu 1 G m N G 27 Jour Active B 27 secre Color 1 A l 26 T 26s T Zl A al A L l L MVR Enable A Z A gt 44 gt gt 25 cotes 3 B 25 Spare 22 22 Fd S Sd T 2 1 2 P l 2 1 20 U 20 U 1 r i 1 9 cotes B S 9 Pet Life Expired S Spare 8 8 l pu 7 Sol l Z 9 Fault A Spare d pt el 4 2 o B 2 e Active A Job Strobe B Resin Solvent B l system Pulse Job Bit 80 B is 2 2 l m a l 0 Resin Air B 0 cotes 3 A Job Bit 40 B T gt 9 10 l 9 eete st 2 A Job Bit 20 B U eL l rt z l S 9 y cotes A Job Bit 10 B 6 6 rt 2 jeer 8 B l 2 rie Sol A Job Bit 8 B 4 4 t l Tt eee 7 B j j Job Bit 4 B 2 2 2 ri rT gt 1 6 l 1
19. continued JOB Settings Channels MVR High Flow Rate MVR Low Max Flow Pressure REG Min Flow Pot Life Notes Min Flow This is the target flow rate desired from the applicator when a 0 VDC signal is received at the analog flow rate input It is expressed in ml s min cc s min Pot Life This is the amount of time it takes for the plural component material to setup The system keeps track of the oldest material in the fluid line which basically is the material in the applicator and sounds an alarm when the mixed material in the applicator has been mixed for this amount of time It is expressed in seconds Notes This box allows the user to enter some simple text notes that they would like displayed with the job data Possibly de scriptions of the material or parts that should be used with these job parameters etc Editing of this text requires con nection of a keyboard inside the controller Contact your ITW Ransburg Representative for more information on adding this text Ratio Parts This parameter controls the mix ratio of the material for plural component materials It must be specified in parts and on all channels configured to the gun For example if it was desired that the mixed ratio of material was to be 50 resin channel A 30 catalyst channel B and 20 solvent channel C the ratio for channel A should be programmed at 5 the ratio for channel B should be programmed at 3
20. e MVR flow control valves e Flowmeters MIX BLOCK e Mixer Block M V R s Material valve regulators e Spiral Mix Tube e Check Valves MIXING TUBE e Calibration Valves FLOW METERS e Optional fluid pressure regulators CHECK VALVES CALIBRATION VALVES CALIBRATION PORTS LN 9409 01 2 RansFlow 14 The flowmeters and MVR valves are available in various sizes for various materials and flow rates Users should consult our technical support group to determine which are required for their specific application The MVR Valves act as both flow control valves and on off valves depending on the application With manual mode guns the master channel MVR opens 100 during operation and the slave channel or channels are controlled to main tain the proper ratio only With guns configured in automatic mode all MVR valves act as flow control valves There are 3 different needle sizes available for the MVR valves 02 for low flow 03 for medium flow and 04 for high flow Fluid Panel Components MVR Valve Three needle sizes available Size 02 Low Flow 15 350 ml min Size 03 Moderate Flow 250 2600 ml min Size 04 High Flow 1000 3500 ml min quu 3o0 7H T 0 pe p o e 3 p CTW Weeping MVR Needles Weepless MVR Needles The flowmeters act as the feedback mechanism to the software s
21. wN P VIEW OF ZENER BARRIER OPTION ne Q P m W ITER LZ VU whi yor T A I q y 427 IN P rs k k 4 I y OMY t EA Y a Dis M a 4 j y I se U a P y yu La De PNEUMATIC TUBING CONNECTION CHART lt 1 gt I gt 1 gt 1P EXHAUST lt E 3 3R TRANSDUCER A 0 TRANSDUCER B TRANSDUCER C lt h TRANSDUCER D o V D r 2 TRANSDUCER E KT 2 TRANSDUCER F T 2 VIEW OF FIBER OPTIC OPTION MVR DR1 SOLENOID BULKHEADS TRANSDUCERS TRANSDUCERS VALVE MANIFOLD ENCLOSURE ASSEMBLY BACK PANEL ASSEMBL Y DOOR ASSEMBLY TOP LEVEL ASSEMBLY A12410 IEM QTY PARTNUMBER DESCRPTON TEM QTY PARTNUMBER DESCRIPTION TEM Gr PARTNUMER DESCRIPTION M QTY O PARTNUMBER DESCRIPTION 00 0 pif i A12412 00 RANSFLOW WALL MOUNT ENCLOSURE 23 TABLE A L 25766 106 PRESSURE SWITCH 7 12 SsF 8147ZN NUT ELASTIC STOP 4 40 STEEL 102 77400 00 CABLE MOUNT 3 INCH 41 FBH 1000 BULKHEAD UNION 1 4 ODT 24 1 15 05100 DOUBLE SIDED CUT TO FIT 176 1 A12422 00 sEAL CONDUCTIVE 90 75 103 2 12415 0 ADHESSIVE HIGH STRENGTH 3M 90 25 2 F TR SSEH 538 TERMINAL BLOC
22. FLOW This parameter allows the user to control how much flow in the reverse direction is allowed before a fault is generated and the system is shut down Note that programming a value of zero 0 here is not recommended because there is some unavoidable reverse flow that occurs because of hydrostatic kickback when some applicators turn their trigger valves off The default value of 50 cc s works well in most cases Note This is the only parameter on this screen that is saved to flash memory and used on all future loaded jobs All other parameters when changed on this screen are tem porary only and will revert back to the values stored with the job when the next job is loaded LN 9409 01 2 RansFlow 51 Advanced Channel Parameters Screen continued Channel Prameters Adyanced COMPONENT REVERSE FLOW C BAND I BAND lol k C BAND This is the control band for the PID control loop In general this setting should never need to be changed unless the flow meter has been changed to a flow meter with a significantly different calibration value This parameter keeps the system steady while maintaining a constant flow rate Too large a value can keep the system from getting to the target flow rate while too small a value may cause the flow rate to oscillate I BAND This is the integrator band for the PID control loop In general this setting should never need to be changed unless the flowmeter has been changed to a flowmeter wit
23. INCLUDE SERVICE MANUALS WITH FLOWMETERS UPON SHIPMENT OF PANEL 77214 00 vis 00 0xx NOTES UNLESS OTHERWISE SPECIFIED 76251 01 FM 00 01 A7 AB A9 A10 TABLE F Y 6698 05 76645 05 A10610 00 lt CONT z reso 7685 06 At0610 00 psp o poe poe L 4p C RR a B2 1 Ea 10 TRIGGER VALVE so AS FHrHNG 3 8T X 3 8 AN 49 AD STEEL TUBE BENT eS a C He moso _ jH 45 BS FERRULE NUT NYLON 4 T WASHER INT TOOTH 10 41 S scnEW 10 32 S H C S BLACK OXIDE 4 TRANSMITTER FLOWMETER 39 7722 0 BRACKET CZ 3 E uras O 1 er EE FITTING 3 8T X 3 8 NPT M 119907 CHECK VALVE 3 8 NPT F BEA 7958 20C SCREW 32 R TUBING 3 8 CUT TO LENGTH 31 CONNECTOR 3 8T X 1 8 NPT M 30 AQ ADAPTER 3 8 STEM X 1 4 T AT sw vave Ex 28 LSMM0059 01 TUBE CALIBRATION ea 2 Weng 26 7958 16C SCREW 10 SEESEEE 2 25 SS 6505 CD WASHER 1 24 SS 1505 CD L WASHER 14 23 A4 saw id 22 772 0 FLUID pne r 20 LS0121 CONNECTOR j G s A now weer DEL hme ew h EISE ELBOW 5 32 T X 1 8 NPT M s mex SCREW MVR MOUNTING _ FITTING 1 4 NPS X 1 8 IDT n CAS e 15 o AB 1 4 NPS X 1 4 ID CsA row
24. INLET 9704 03 TUBING 1 4 ODT CHANNEL C 9704 03 CHANNEL B 9704 03 CHANNEL A 9704 03 EXHAUST 9704 03 MVR TABLE B FLOW CHANNEL QUANTITIES EXAMPLE A12410 011111 TUBING 1 4 ODT TUBING 1 4 ODT TUBING 1 4 ODT xix 129 o o 3 X 3 0 0 3 TUBING 1 4 ODT EAST 33 0 o 3 1 ee _ LABEL TORQUE FOR TERMINALS TABLE F G 20 3111 PIPE PLUG 1 8 NPT 316 SS TABLE D INTRINSIC QUANTITIES TR SSEM 633 WIRE LABELS WRAP AROUND LOT BISA TAT 61 1 SOLALABEL SOLA LED STATUS LABEL SUPPLIED AS PART OF POWER SUPPLY 3 2 9 T 3 6 7486 15 WASHER FLAT ZINC PLATE STEEL xx 26 13 3 63 2 TR SSEH 417 TERMINAL BLOCK GROUNDING RAIL 26 5 o 3 164 1 n TRM 35 038 LABEL GROUND 65 TABLE F G 7703 44C SCREW MACHINED FLAT HEAD S S 78 32 a TABLE F G 7734 03 LOCK WASHER STANDARD HELICAL SPRING 8 TABLE E FIBER OPTIC QUANTITIES DASH No xi ox 3 0 3 TABLE F G 7733 06 NUT 48 32 1 A12463 00 LABEL WIRING DIAGRAM RANSFLOW 35 o 3 fol 1 _ TR SSEH 500 CAP TERMINAL BLOCK a EP ae e 150 TABLE 12527 00 PRESSURE CONTROL E P TRANSDUCER Tres TABLE F SOLENOID VALVES 71 TABLE H S A12528 00 E P TRANSDUCER END CAP SET OF 2 72 TABLE 41 PLG 1001 PLUG 1 4T 73 TABLE H X 41 FTP 1015 FITTING REDUCER 5 32T X 1 4
25. P8 PRESSURE REGULATOR A id 34 U6 P9 PRESSURE REGULATOR B E l S TP10 PRESSURE REGULATOR C spare ou 9 T P11 FLOW RATE INPUT COMMAND A lt 6 4 1 2 lt 20 4 P12 FLOW RATE INPUT COMMAND B Gun Trigger 37 l I lt 21_ p TP 5 SPARE A ALOG INP TA lt 58 lt 22 I TP14 SPARE ANALOG INPUT B gun 59 pe2s P15 FLOWMETER C SOURCE 404 l 24 P16 FLOWMETER C GATE 1 E 28 ESI TP17 FLOWMETER A SOURCE Halt Reset 1 U7 p P18 FLOWMETER A GATE 4214 28 4 P19 FLOWMETER B SOURCE ceo 6 3 27 F P20 FLOWMETER B GATE i L e Load B 6 l I ed Job Select 1 1 47 51 lt 48 4 2044 149 N C JSS lt 0 4 J1 J2 LN 9409 01 2 RansFlow 95 Pneumatic Interface Panel Wiring Diagram 2103106 v 3IBYN3 HAM O 20 3106 B SIBYNS HAM 203706 01025 203106 30109 203105 30109 TIONS IOS 30102 21043105 lt 0702 TIONS IOS 30302 21033105 amaa 211043105 umoa 21043105 6 ara 10037105 0 80709 9 DIONSTOS 010 3195 WINDS NISIA Q QION319S drina O QqIQN319S diON310S ISIYI QqIQN319S z ISYY 2105 ISAWIYS 203106 LNBATOS ISATYLYO od 8O123N Noo TN 3 JIN NOD 6000002000908 00800 LN 9409 01 2 RansFlow
26. PARAMETERS RETURN TO ALARMS SCREEN FLOW TOTALS INFORMATION SCREEN TIMER START VALVE SELECT OPEN OR CLOSED CLEAR VALUES SET TO ZERO FORCE I O SCREEN Be e e E E LN 9409 01 2 RansFlow 86 Icon Definitions continued RUN HALT LOAD RESET JOB SELECT FLUSH REMOTE OPERATOR PANEL ENABLE TURN ON LN 9409 01 2 RansFlow 87 Remote Operator Panel ROP Error Codes ERROR CODE DESCRIPTION 1 Ratio Out of Tolerance Reverse Flow Limit Flow Too Low Flow Too High Integrator Too Low PID loop Ki value set too low No Job Loaded Potlife Expired Bad Job Format Startup Reset OO N O QO A CO N 10 No Master Flow 11 Not in Flush Box A 12 Not in Flush Box B LN 9409 01 2 RansFlow 88 Typical Installation Prints fractional amp metric LN 9409 01 2 RansFlow 89 IB MATERIAL SUPPLY TO COLOR VALVE STACK BY OTHERS TUBING SYMBOLS Qv MAIN LINE AIR BY OTHERS
27. STRAIN RELIEF 98 4 73106 03 STAND OFF NYLON C D E C 41 TABLE 41 1011 RUN TEE 1 8 NPT M X 1 4 ODT 199 1 77384 00 SWITCH OPERATOR RED MUSHROOM HD 42 TABLE B F ssP 6427 ELBOW 1 8 NPT M X 1 4 ODT 100 LSME0004 00 CLIP W LOCKING LEVER s A12416 00 POWER SUPPLY 24VDC 5A 1101 1 LSME0006 00 CONTACT MODULE NORMALLY CLOSED TABLE F G A12418 00 SOLENOID MOUNTING PLATE TABLE F Q A12360 00 MANIFOLD 20 POSITION SOLENOID VALVE TABLE FH 900 47 6 FTRSSEH 499 VERTICAL INTERCONNECT FOR ORDERING USE A12410 ABCDEFGH AS INDICATED BY THE TABLES A DESIGNATES OPERATION MODE TABLE Fees I TABLE A OPERATION MODE B DESIGNATES NUMBER OF CHANNELS TABLE B 49 3orr 6655 13 WIRE G STANDARD DRK BLUE 209A 30 FT A DASH DESCRIPTIONT J K LT MIN _ C DESIGNATES TYPE OF FLOW METER TABLES C D amp E 1 A12417 00 POWER SUPPLY 5 VDC 5 AMP o 2 2 2 2 10 D DESIGNATES NUMBER OF COLOR SOLENOID VALVES TABLE F E DESIGNATES INLET PRESSURE CONTROL TABLE H F DESIGNATES REMOTE OPERATOR PANEL TABLE G MOTE OPERATOR PANEL IS USED TABLE G VR INLET PRESSURE CONTROL IS USED TABLE H 10 COLORS WITH 20 SOLENOID VALVES TABLE F INTRINSICALLY SAFE FLOW METER TABLE C D amp E 1 CHANNEL TABLE B PERATION MODE TABLE A L1 aurovanc o o of o 6 TRANSDUCER ASS Y 9704 03 TUBING 1 4 ODT
28. amp B or B amp C if a 3 channel unit was ordered The radio buttons inside the Horn box allows the user to set when the horn sounds and if the sound will be one continu ous tone or a pulsing tone Options for when the horn sounds are e Never e Ifa gun fault occurs e Ifa pot life timer expires e If either a gun fault or pot life timer expires both radio buttons selected LN 9409 01 2 RansFlow 39 System Parameters Screen continued System Global Settings Q Pot Fault Q General Fault Gun 2 Channels O Pulse Channel Channel B Master Channel C cQ Note If a gun fault occurs whether or not the horn is configured to sound the controller turns off all flow control valves configured to that gun If a pot life time expires the controller does not turn off the flow control valves This is simply a warning to the user that the material in the applicator is approaching the point where it may coagulate Note If the number of channels configured to a gun changes it is necessary to reboot the computer user interface touch screen for change to take effect Hitting the back button returns you to the Configure Selection Screen LN 9409 01 2 RansFlow 40 Gun Parameters Screen Gun Parameters hy 1 CHANNELS MODE i FLUSH MODE CLEAN CHANNELS TRIGGER ON DELAY ms DEFAULT JOB TRIGGER OFF DELAY ms FLOW TOLERANCE BLOW OFF TIME sec TOLERANCE TIME
29. in the Appendix section of this manual Cable Assemblies Interconnections between all control panels and the fluid panels are made using manufactured cable assemblies with heavy duty connectors This simplifies installation and eliminates the possibility of items being wired incorrectly The one exception to this is the discrete interface I O wiring These connections will vary greatly from installation to installa tion This can involve well over 50 connections per control console and therefore require a cable with the proper 50 pin connector on one end P N A12487 XXX Equipment Grounding All panels should be grounded in accordance with either the National Electrical Code or local electrical codes whichever is more stringent Refer to the electrical installation drawings provided in this manual to locate the grounding terminal for all control panels If in doubt contact your ITW Ransburg representative for clarification Equipment Locations All of the RansFlow panels must be located outside of the hazardous area If in doubt contact your ITW Ransburg rep resentative for clarification There are four basic panels used in the RansFlow system e Main Control Console e Fluid Panel e Remote Operator s Panel optional e Pneumatic Interface Panel optional LN 9409 01 2 RansFlow 21 The Fluid Panel should be placed within 20 of the control console or Pneumatic Interface Panel in the case of Gun 2 to minimize pneu
30. in the spray area and test periodically Spray areas must be kept clean to prevent the accumu lation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or maintenance When using solvents for cleaning e Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 1000F 37 80C Spray booth ventilation must be kept at the rates re quired by NFPA 33 2009 Edition OSHA and local codes Ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Non factory replacement parts or unauthorized equip ment modifications may cause fire or injury If used a key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks disabled Never use equipment for use in waterborne installa tions to spray solvent based materials LN 9409 01 2 RansFlow 6 AREA Spray Area Spray Area HAZARD Explosion Improper or inadequate operation and main tenance procedures may cause an explo sion Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent power sup
31. is the material supply pressures Obviously if you are not getting flow too low or flow too high faults the flow rates are getting within the tolerance band of the target Over an extended period of time however the volumes used are not within that same tolerance band Observe the actual ratio on the main screen of the controller Note that the ratio displayed is an average over a period of time In order to get instantaneous ratio information touch the Volume box in the lower right of the main screen and reset its value If the actual ratio of the catalyst is below target adjust the supply pressure to the catalyst MVR valve up 5 psi or so or adjust the resin supply pressure down by 5 psi or so and try to run again Keep adjusting these pressures until the actual ratio locks in on the target Keep in mind that higher is not always better Often times it works better to lower the pressure of the opposite channel rather than raise a channel that is running low in ratio LN 9409 01 2 RansFlow 82 REVERSE FLOW LIMITS As the name indicates the software believes that material has backed up through one of the flow meters This can be caused by any one of the following conditions 1 If any of the check valves on the fluid panel has failed in the open condition and the opposite fluid is at a higher pressure fluid can actually back up into another line If this occurs the system must be flushed immedi ately and the faulty check valve replaced
32. low of a value here can limit the maximum possible flow rate and possibly response time of the PID control loop It is expressed in psi This parameter can also be temporarily changed on the Channel Parameter Screen MVR Low This is the pressure in psi sent to the flow control valve when the gun is in run mode but the applicator is not triggered It acts as an offset to hold the flow control valve just below the cracking pressure of the valve so that when the applica tor is triggered a minimal amount of time is lost opening the valve for flow If this parameter is programmed too high above the cracking pressure of the valve undesirable pressures will develop between the flow control valve and the applicator during trigger off times causing a blooming effect when the applicator triggers until the higher pressure bleeds off This parameter can also be temporarily changed on the Channel Parameter Screen LN 9409 01 2 RansFlow 56 Job Parameters Screen continued JOB Settings Ratio Parts 2 MVR High 100 Flow Rate PulsesA iter 8000 MVR Low 15 Max Flow Valve 1 Pressure REG 0 Min Flow Pot Life C Band 1000 I Band 2000 Pressure REG This is a simple analog output that can optionally be used to control a pilot operated fluid regulator on the inlet of the flow control valves Additional E to P transducers will be required to convert this O to 10 VDC signal to a 0 to 100 psi signal to control these fluid
33. optional and only used on intrinsi cally safe units Find the zener barrier that is connected to the channel you are having a problem with Refer to electrical diagrams in this manual On the side of the zener barriers there are schematics of the internal circuitry Fuse integrity can be verified quite easily with an ohmmeter The flow meter cable itself can also be tested with an ohmmeter LN 9409 01 2 RansFlow 80 If none of these are the problem there are only three other possible problems The first is the high speed counter card mounted on the back side of the touch screen computer It is the top card on the stack of 3 cards The second option would be the ribbon cables or their connectors that run from the interconnect board on the inside top of the control con sole or the ribbon cables that run from the high speed counter card to the optical isolator board The only other possible problem would be the optical isoloator board itself The optical isolator board has some signal conditioning circuitry optical isolators on it that reduce the 24 volt flow meter pulses to 5 volt pulses used by the counter card 5 Another possible cause of these type of faults would be if the transducer that controls the MVR valve would fail Verification that the transducer for the affected channel is functioning properly is as follows If there is not al ready one there place a pressure gauge in the pilot line between the transducer and the MVR valv
34. regulators Thicker materials or higher flow rates often require a higher inlet pressure to the flow control valves This parameter can also be temporarily changed on the Channel Parameter Screen Kp This is the Proportional Gain parameter for the PID loop It controls how fast the PID loop opens the flow control valve when flow is initially requested A value too small here will cause an unnecessary delay in flow on the initial trigger on of the applicator or a slow ramp up of flow Too large of a value here will cause the flow to oscillate The default value of 2000 works well in most cases Ki This is the Integral Gain parameter for the PID loop It controls how fast the PID loop pulls the actual flow back to the target flow after the proportional portion of the PID loop has the actual flow approaching the target This parameter can also be temporarily changed on the Channel Parameter Screen C Band This is the control band for the PID control loop In general this setting should never need to be changed unless the flowmeter has been changed to a flowmeter with a significantly different calibration value This parameter keeps the sys tem steady while maintaining a constant flow rate Too large a value can keep the system from getting to the target flow rate while too small a value may cause the flow rate to oscillate This parameter can also be temporarily changed on the Channel Parameter Screen I Band This is the integrator ban
35. rial supply to the applicator Try running the unit from the calibration ports on the fluid panel Place containers under them open the calibration ports and put the unit in run mode If the unit is being operated in automatic mode the trigger will have to be forced on If the unit operated correctly that way the problem is further downstream 4 Are you seeing any flow at all If it is obvious that material is flowing out of the gun or from the calibration port but the display shows no flow at all then this indicates that the controller is not seeing any pulses coming from the flow meter This could be caused by the gears in the flow meter being stuck a bad sensor on the flow meter a dis connected or damaged flow meter cable a bad zener barrier or a bad counter card Disassemble the affected flow meter and inspect it for stuck gears If it is obvious they are not stuck place the shafts and gears the top half of the flow meter and with the sensor on the flow meter and cable connected turn the gears Watch the flow volume value on the main screen of the controller The volume should increment with fluid flow If it does not than one of the problems mentioned above has occurred Next connect the flow meter to a cable of another channel that is functional and monitor that channel for flow If flow is not indicated you may have a bad flow meter sensor It is also possible that a fuse in the zener barrier has failed Note zener barriers are
36. single channel gun and one two component 2 channel gun The 2 channel gun MUST be configured to be channels B amp C e One three component 3 channel gun e One 2 channel gun can be configured as channels A amp B OR B amp C if a 3 channel unit was ordered Immediately below the gun tab or tabs there is a gun status line indicating the status of that gun i e Run Idle Faulted Loading Flushing etc LN 9409 01 2 RansFlow 34 Main Screen continued GUN 1 RUN ACTUAL Current JOB Ratio 10 0 2 0 Ratio 10 0 0 0 Flow Rate 0 0 ml min Flow Rate 0 0 ml min PotLife sec Pot Life sec Volume 0 0 ml Once a valid job has been loaded the information in the left column of the Main Screen indicates the targets or setpoints for ratio flow rate and the pot life of the material It also indicates what the next job number to be loaded is if one was toggled in externally while still running the current job Note The ratio and flow rate setpoint can be changed on the fly by touching the ratio or flow rate boxes in the left col umn A keypad will popup on the screen allowing the user to change the target ratio or flow rate This is a temporary change only and is not saved to the job data This temporary change will be discarded the instant a new job is loaded even if it is the same job number that is currently running In the right column real time information is provided to allow the user
37. the applicator during flush and load sequences It is turned on in the 3 step of the load sequence and the 4 step of the load sequence Intended to drive the 2 catalyst valve on the catalyst CCV stack A 0 10 VDC output command to drive the E to P transducer which in turn drives the MVR flow control valve Ch C One of the quadrature feedback signals from the channel C flowmeter One of the quadrature feedback signals from the channel A flowmeter One of the quadrature feedback signals from the channel B flowmeter One of the quadrature feedback signals from the channel B flowmeter Connecting this input to 24 VDC starts flow on a gun configured in auto matic mode Intended to drive the enable valve on the inlet of the channel C MVR A 0 10 VDC output command to drive the E to P transducer which in turn drives the MVR flow control valve Ch A Intended to drive the 10 color valve on the CCV stack Intended to drive the 8 color valve on the CCV stack Intended to drive the 6 color valve on the CCV stack Intended to drive the 4 color valve on the CCV stack Intended to drive the 2 color valve on the CCV stack LN 9409 01 2 RansFlow 29 2 Ch A MVR Enable Output Intended to drive the enable valve on the inlet of the channel A MVR Dump Solenoid Output Intended to drive a dump valve at the applicator On in steps 1 amp 2 of the load sequence and steps 1 2 amp 3 of the flush sequence Catalyst 1 Solen
38. the fluid stream prior to component mixing upstream from each applicator This flow meter generates pulses as material flows through it and sends them back to the flow controller The flow controller converts the pulses to ml min using a calibration value defined at setup This actual flow rate will be compared to the operator adjustable set point and ratio The flow controller will then make an adjustment to the MVR fluid regulators located prior to the applicator This process of measuring comparing and adjusting is repeated 50 times per second maintaining the required flow rate and ratio for each material After each component leaves the flow meters they come together in a spiral mix tube assembly prior to delivery to the applicator Automatic mode utilizes inputs from a robot controller or PLC to set flow rates and ratios and activate triggers flushes and fills Manual mode relies on the operator for the operation of the mixed material A remote operator panel depending on the version is mounted inside or outside the spray booth to allow control of the RansFlow by the manual sprayer and to inform the operator of the RansFlow s operating conditions This panel allows the operator to flush fill run and reset faults to the RansFlow from inside the booth and it also indicates the condition of the unit Run Flush Load or Fault Remote operator interface Allows operator to control RansFlow from inside or outside of spray booth Intrinsicall
39. the graduated cylinder and hit enter ENT The software will automatically calculate a new calibration value for the flow meter in pulses per liter and display it in the lower right box under New PPL If this value seems rea sonable touch the small box at the bottom of the screen with the check mark in it This will copy the most recently calcu lated value over to the box at the left labeled OLD PPL This is the value that the software uses to calculate the volume of material as it is counting pulses You should repeat the calibration process until you get at least three consecutive values that are within 5 of each other Touch the top open valve button to close all valves on the channel and color you are calibrating once you are satisfied with the calibration value Once this has been done touch the Save to flash memory button in the lower right hand corner of the screen to save the new PPL value to the selected Job Note that leaving this screen without perform ing this save function will lose the calibration data you just determined This calibration process must be completed for all channels configured to the gun Also note that these calibration val ues must be determined for all materials that are to be used It is recommended that one job number be used for each material as different materials affect the flow meters in different ways and will result in different calibration values Make sure to save values to flash memory after each cali
40. to monitor the current running job number the ac tual ratio the actual flow rate and the remaining pot life of the material currently in the applicator The ratio being dis played is an average over a period of time If the user wants to get a more instantaneous idea of the ratio simply touch the volume box in the right column and a small box will popup asking if you would like to reset the volume If you answer yes the volume box at the bottom of the column will be zeroed and the ratio being displayed will be averaged once again from that point forward LN 9409 01 2 RansFlow 35 Configure Screen Configure When you touch the left function button on the main screen you will be taken to the Configure Selection Screen The icons across the bottom of the screen starting from the left are e Return to the Home Screen e Go back one screen e Save parameters to Excel file e Save Configuration and Job Data to USB Port USB flash drive size MUST be less than 4GB e Read Configuration and Job Data from USB Port Buttons on this screen allow the user to select which parameters they wish to examine or edit e System Parameters e Gun Parameters e Channel Parameters e Job Parameters LN 9409 01 2 RansFlow 36 Configure Screen continued Configure SYSTEM PARAMETERS GUN PARAMETERS CHANNEL PARAMETERS JOB PARAMETERS The icon on the middle key allows users to save parameters in Excel comma separated v
41. version of software installed on the unit The top number indicates the control software version and the bottom number indicates the version of the user interface software These two numbers should be re corded and provided to ITW Ransburg personnel when requesting technical support LN 9409 01 2 RansFlow 60 Color Change Sequencer Screen Color Change Sequence Flush Sequence Time 15 00 sec Load Sequence Time 8 00 sec FLUSH SEQUENCE 1 Resin Push Solvent Solvent Only Solvent 0 250 sec Air O Air 0 250 sec Time 5 000 sec Time 2 000 Sec LOAD SEQUENCE 1 Load to Flowmeter 2 High Flow 3 Low Flow Catal e Flow Rate 375 FlowRate 200 ml min ii O Use Analog Time 3 000 sec j Time 2 000 sec The middle button on the bottom of the Main Screen opens the Color Change Sequencer Screen The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Not used e Not used e Save Flush and Load Parameters to flash memory The top half of this screen allows the user to program the Flush Sequence There are four possible steps in the flush sequence If the time is programmed to be zero 0 for any step that step is skipped LN 9409 01 2 RansFlow 61 Color Change Sequencer Screen continued Color Change Sequence Sh gt Flush Sequence Time 15 00 sec Load Sequence Time 8 00 sec FLUSH SEQUENCE 1 Re
42. 05 1S AT7V1V5 0103105 1N3AT0S 1SA1Y1Y5 u350asNyu1 8 BNNYHS O lt lt c O S e O c c LLI re z 3915 LG NALOG u3ongsNvuL amp Y LNNYHO 123NNOOEGLNI 3o SMd NJ 93530105 38 ALALE AEEA LTTTTETTTTETTTITI NO MWOHS 57 VP 30 77 W x 3mg8 Sw yT v LION e e 01 2 RansFlow 9409 LN 98 Wall Mount Enclosure Wiring Diagram continued MM irr NOWWOO 20 7m 2101 3 aE FZT gt 0 GO O OG BO 2011 2101 2101 NOMMOO 20 ALL WIRING ON THE RIGHT SIDE OF THESE THAM 3 OR HAVE NON CONDUCTIVE INTRINSICALLY SAFE WARING BY NO LESS BE KEPT SEPARATED FROM ALL NON IMPORTANT NOTE ORDERED REFER TO DRAWING A12410 FOR DETAILS 298 5011 WIRING AND ZENERS SHOWN BELOW ARE OPTIONAL NOTE 2011 JOA vZ LN 9409 01 2 RansFlow 99 50 Conductor System I O Cable 0 038 16 310834 SHIM 10 1652 5329189 LS WAJA LE 2 a was N JIW S Xg O24 30 TvAO0Sddv HUM AINO 10010 NYHL H39NO SHINS 21530035 749345 NOdN 318V1IAV 001 NVH1 55371 SHIS9N31 N3HIlO ILONG 3 HI9N31 31879 I SHLINI Q33201S UdVONVIS H39AON Nid HLA 13871 33 4 AYN ANIMAL AYIM amp ZCL
43. 24 VDC H V Enable Gun 2 Fault Gun 2 Job Strobe Gun 2 Pressure Regulator Channel 1 Output Output Output Output Output Input Input Input Input Input Input Input Input Input Input Input N A Output Output Input Output 24 VDC Not currently implemented in software 24 VDC This output goes on when the mixed volume of material has flowed through the flowmeters during the flush cycle 0 10 This is an analog output programmed in the job parameters VDC intended to drive an E to P transducer to drive a fluid regu lator 0 10 This is an analog output programmed in the job parameters VDC intended to drive an E to P transducer to drive a fluid regu lator O Analog indication of actual flow rate If Min Flow is pro grammed at 0 ml s min and Max Flow is programmed at 1000 ml s min and 400 ml s min is flowing this output will be at 4 00 volts DC 0 10 VDC For remote analog control of flow rate If Min Flow is pro grammed at 0 ml s min and Max Flow is programmed at 1000 ml s min and 4 00 volts DC is sent to this input the un will flow at 400 ml s min 24 VDC For remote selection of next job to be loaded See appen dix for recommended job load timing sequence Connecting this input to 24 VDC initiates the flush se quence 24 VDC Connecting this input to 24 VDC momentarily resets a faulted gun or halts a gun in run active mode 24 VDC Connecting this input
44. 55 AB240905 Ez sor mao roe ZF AJ240909 Fas wor Am49 1 ON 78137 XX ASSEMBLES POSITION THE DRAIN VALVE DOWNWARD 77767 01 ELBOW ONCE MOUNTED ONTO FLUID PANEL 63 ij DURING ASSEMBLY OF RF FLOWMETER OBSERVE FLUID FLOW DIRECTION BY ARROW ON METER D APPLY 77715 00 REF ON UPPER LEFT HAND CORNER OF PANEL B TORQUE FITTING TO 50 FT LBS Z APPLY AMOJELL SSL 11 ONTO TAPER OF FITTING PRIOR TO ASSY TO PREVENT GALLING gt ATTACH 78214 00 TAG TO FLUID INPUTS S TUBING OMITTED FROM SIDE VIEWS FOR CLARITY 4 PURCHASE SEPARATELY TR 200963 XX STANDARD FLOWMETER CABLE 77219 PISTON FLOWMETER CABLE TR SSEH 739 TRANSDUCER CABLE 3 NO SILICON LUBRICANTS ARE TO BE USED ON ANY OF THESE COMPONENTS 2 USE PIPE SEALANT 7969 10 OR EQUAL ON ALL SS NPT THD S UNLESS OTHERWISE NOTED 1 WHEN ORDERING USE 78787 AABCCDEF AS INDICATED BY TABLES A THRU F TABLE A DESIGNATES THE A SIDE FLOW METER TABLE B DESIGNATES THE A SIDE FLOW CONTROL TABLE C DESIGNATES THE B SIDE FLOW METER TABLE D DESIGNATES THE B SIDE MVR TABLE E DESIGNATES THE MIXING BLOCK TABLE F DESIGNATES THE PRESSURE EIGHT CHARACTERS MUST FOLLOW THE BASIC PART NUMBER IE BASIC PART NUMBER TABLE B TABLE D fea F or BLANK 78787 350230411M L TABLE E TABLE C IF M IS DESIGNATED SEE PAGE 5 2 i SOLENOID KIT TO BE SHIPPED WITH ASSEMBLY X p TABLE A
45. 923 922 2 9 0 290 2029020 6 280241 e e e e 9 ve ACS e e e e e e 9 NOIO3NNOO Nld 0S 00 88 1 LN 9409 01 2 RansFlow 100 Spare Parts Recommended Quantity Based on the number ofinstalled units of Item PartNumber Description 1 2 4 8 Main Control Console 4 13742 01 Air Flow Switch 1 1 2 4 22 25766 106 Pressure Switch 1 1 2 4 36 73837 08 Zener Barrier 1 1 2 2 37 78643 00 E P Transducer 1 2 2 4 38 SSM 5504 Air Filter 1 2 2 4 42 A12416 00 Power Supply 0 1 1 1 Solenoid Valve 24V Manifold 45 A12359 00 Mount 2 4 4 8 50 A12417 00 Power Supply 0 1 1 1 Touch Panel 6 4 Display 70 A12423 00 PC104 0 1 1 1 72 A12356 01 Digital I O Mod 1 1 1 2 Analog amp Digital I O Module 73 A12357 01 PC104 1 1 1 2 High Speed Counter Module 74 A12358 01 PC104 1 1 1 2 78 A12205 00 Optical Isolator 0 0 1 1 79 A12207 00 Optical Isolator 0 0 1 1 Switch Operator Red Mushroom 92 77384 00 Hd 1 1 2 2 Clip for switch operator With 93 LSME0004 00 Lock 1 1 2 2 94 LSME0006 00 Contact Module 1 1 2 2 108 77454 00 Reciever Fiber 0 1 1 1 109 77452 00 Cable Fiber Op 0 1 1 1 117 A12473 00 Stylus 24 1 2 2 4 LN 9409 01 2 RansFlow 101 Spare Parts continued Recommended Quantity Based on the number ofinstalled units of Item Part Number Description 1 2 4 8 Fluid Panel Note Not all parts below are used on every fluid panel Spiral M
46. A B e Which channels open during flush sequences e Flow Ratio Tolerance MODE MANUAL FLUSH MODE CLEAN CHANNELS NO NO TRIGGER ON DELAY ms e Tolerance Time DEFAULT JOB 1 TRIGGER OFF DELAY ms e Tolerance Volume FLOW TOLERANCE 96 5 BLOW OFF TIME sec e Flush Mode TOLERANCE TIME 3 POT LIFE VOLUME ml 0 Trig ger O na Delay TOLERANCE VOLUME Flush Box A O Flush Box e rigger Off Delay e Blow Off Time e Mixed Volume Gun Parameters Screen e Flush Box Enable Disable LN 9409 01 2 RansFlow 16 Channel Parameters are parameters that affect only that specific channel For two or three channel guns there are independent parameters for each of the channels They include Advanced Channel Parameters include Regulator Type MVR High annel Prameters Advanced MVR Low Pulses Liter Flowmeter Calibration Value Pressure Regulator Pressure REVERSE FLOW C BAND I BAND Kp Reverse Flow Volume Ki C Band I Band Kp Advanced Channel Parameters Screen Ki Job Parameters are parameters that are stored with the specific job number Typically a job number is assigned to a specific material In this way totalization data and PID parameters relate directly to the material These parameters in clude Flow Rate Setpoint Maximum Flow for analog control Minimum Flow for analog control JOB Settings Pot Life Time Ratio Lm Ratio Parts MVR High Pulses Liter flow
47. ATE Optional RansFlow Remote Operator Panel LN 9409 01 2 RansFlow 76 Start Spraying Emulator Hs GUN 1 IDLE 1 OB RESET STOP fa l FLUSH JOB SELECT ARROWS 0 gt Cy FLOW RATE Two steps to start spraying 1 Start up e TurnON AC power and let the software startup 2 Loading a Job Go to the EMULATOR screen e Press the RESET STOP button to clear any initial faults e Press the UP DOWN arrows to select the job you want to use w x x e RansFlow must be in the idle halt state Press HALT If unit is already in idle halt state this button will not be visible e Press LOAD PN 47 e the first load after power up or if a job with a new color is selected the RansFlow will do a flush before it loads e When the load sequence is complete the RansFlow will be placed in RUN mode and the gun applicator will be ready to spray LN 9409 01 2 RansFlow TT Finished Spraying Emulator Pe Te RESET STOP fa FLUSH A JOB SELECT ARROWS 0 gt A D FLOW RATE Two steps when finished spraying 1 Flushing e RansFlow must be in the idle halt state Press HALT If unit is already in idle halt state this button will not be visible e Press FLUSH e he RansFlow will step through the flush sequence leaving the gun clean and idle 2 Recovering from a Fault If a fault occurs first
48. Catalyst 1 Regulator Clear ALL Color 2 Catalyst 2 0 Color 3 Catalyst 3 O lys 7 Horn Q Color 4 All OFF 0 Color 5 Regulator B Pot Fault MVR A Enb r O Color 6 HV Enable O Color 7 MvR_B Enb Actual Flow Mixed Vol Cleared E Color 8 0 MYR C Enb Catalyst Solvent O Color 9 Regulator C Resin Solvent O color 10 0 _ Resin Ar O All OFF View Clear Inputs The fourth column allows you to force the analog outputs that drive the transducers that in turn drive the MVR valves MVR A MVR B MVR C There are three additional analog outputs Regulator A Regulator B and Regulator C that can be forced These outputs allow the user to optionally connect a pilot operated fluid regulator to the input of the MVR valve and specify different inlet pressures for different materials Simply touch the box below the output to be forced and key in the voltage desired out of the analog output Key in a value of O to reset the output The fifth column allows the user to force the horn on and the MVR Enable signals solenoids Simply touch the box next to the text that you wish to force and check mark will appear when the output is turned on Touch the box a second time to turn the output off or touch the Clear ALL button In the bottom right corner of this screen is a button labeled View Inputs Select this option if you wish to monitor the status of any of the digital or analog in
49. FILTERED TO A 100 MESH FILTER FLUID SUPPLY SHOULD BE FREE OF PULSATION AND SURGES SURGE CHAMBERS ARE REQUIRED IF FLUID DELIVERY SYSTEM CAUSES PULSATIONS GREATER THAN OR 10 PSI BILL OF MATERIALS ITEM QTY PART NUMBER PART DESCRIPTION 1 1 AUT 61598 RANSFLOW 2K SYSTEM pees 2 2 A12410 021102 RANSFLOW CONTROL UNIT INTRINSICALLY SAFE NENNEN NEED MERE X 2220 00 FLOWMETER CABLES 1 EN NENNEN EE S O A SO Ao REMOTE OPERATOR PANEL C C EE 5 2 A12605 50 REMOTE OPERATOR PANEL CABLE 50 FT 6 2 78787 40840621M Oo 1 76251 400 C i B 1 9OCCV 403 SS CCV VALVE C 1 78137 03 WEEPING MVR L9 T 80407 01 10 2 MAQ82 P 8 BULKHEAD UNION 8mm BRASS 11 25 41 FTP 1015 STEM REDUCER 1 4 OD STEM X 5 32 ODT 12 4 8X10 14 SS FITTING 1 4 NPS F X 10mm X 8mm TUBE 13 1 A12606 XXX REMOTE OPERATOR PANEL CABLE NON INTRINSICALLY SAFE Control Panel Parts List LN 9409 01 2 RansFlow 90 CUT HOLES IN ENCLOSURE FOR MVR PRESSURE CONTROL BULKHEADS AS NEEDED 7 3 16 1 15 16 1 7 8 TRIM LABEL TO ENCLOSURE HOLE SIZE pA 2 7 16 0 531 TYP 3 PLACES NA N OO O nN O aliii O m 90 DA REF BOTTOM LABEL vet w a A ANAL u Pen Sw 4 a f a 0 X Na 2 x TAS
50. INGS SUPPLIED ON THE INPUT TO THE MVR s o INDICATES 6mm OD X 74 ARE 10mm O D TUBE FITTINGS m B 8 9 CUSTOMER RESPONSIBLE Ez FOR ELECTRICAL CONNECTION TO THE RANSFLOW NON INTRINSICALLY SAFE ROP CONNECTOR FUSED INTRINSICALLY SAFE DISCONNECT SEALOFF ROP CONDUIT HOLE A BY CUSTOMER TYP 5 E O NOTE EITHER THE INTRINSICALLY SAFE OR THE NON INTRINSICALLY SAFE REMOTE OPERATOR PANEL MAY BE USED BUT NOT BOTH SIMULTANEOUSLY BOTH ARE OPTIONAL e MAIN LINE AIR BY OTHERS SOLVENT _ SOLVENT 4E PAINT SUPPLY TYP E PAINT SUPPLY TYP CATALYST COLOR VALVE STACK TYP 2 ECON BOXES PURT D LID CLOSED GUN IN PURT A MAIN AIR IN PURT C PURT B LID CLOSED TRIGGER AIR IN GUN OUT PLUGGED L A CVT CONSTANT VOLTAGE TRANSFORMER al 2 120 VOLT or 10 H SINGLE PHASE 500 WATT CAPACITY BY CUSTOMER ELECTRICAL DEVICES THIS SIDE OF BROKEN LINE TO BE LOCATED IN NON HAZARDOUS AREA SUPPLY AIR FOR ATOMIZATION AIR TO SPRAY GUNS SUPPLIED BY OTHERS CLEAN DRY FILTERED TO 20 MICRON REGULATED SUPPLY AIR FOR GUNS REGULATED ATOMIZATION AIR TO ATOMIZER FLUID INLET FLOWMETER CABLES TO FLUID PANEL SAFE AREA APPLICATOR BY OTHERS Ln FLUID SUPPLIED TO FLUID PANEL SHOULD BE
51. Isolator Board Schematics Pneumatic Interface Panel Wiring Diagram Wall Mount Enclosure Wiring Diagram 50 Conductor System I O Cable Recommended Spare Parts High Voltage Interlock Valve Warranty Policies LN 9409 01 2 RansFlow 4 Section 1 SAFETY Before operating maintaining or servicing any ITW Ransburg electrostatic coating system read and understand all of the technical and safety literature for your ITW Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PRE While this manual lists standard specifications and service VENTING EQUIPMENT PROBLEMS To help you procedures some minor deviations may be found between recognize this information we use the following sym the literature and your equipment Differences in local codes bols and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation drawings and appropriate ITW Rans burg equipment manuals to reconcile such differences CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting WARNING states information to alert in more efficient operation longer trouble free service and you to a situation that m
52. K SEPERATOR 77 1 A12423 00 TOUCH PANEL 6 4 INCH DISPLAY PC104 104 3 7793 00 LUG RING TERMINAL 3 2 4LFTP 102 _ REDUCER 3 8 ODT TO 1 4 ODT 26 1 TRSSEM54i TWOPOLEJUMPER 0 78 e 366 6 i o NUT COMES WITH A12424 00 CABINET 4 TABLE A 13742 01 FLOW SWITCH ASSEMBLY 2 1 n12424 00 ENCLOSURE BACK PANEL A12356 0 Al WASHER LOCK EXTERNAL COMES WITH 12424 00 CABINET een FLOW METER WIRE HARNESS 128 6 7734 04 10 TOOTH SPLIT LOCK WASHER A12357 01 107 0 5 7750 04 WIRE 14 GA GREEN W YELLOW STRIPE C D E Y 29 7 SSF 4034 ZN SCREW 10 32 SLOTTED PAN HEAD ZINC A12358 01 8 1 71 440_ 50 CONDUCTOR RIBBON CABLE ASSEMBLY 44 LONG 6 TABLE A K LsFr0002 00 FITTING BULKHEAD PUSH 1 40DT X 1 8NPT FEMALE 30 1x10in so DIN RAIL SLOTTED 10 INCHES LONG A12413 00 109 1 Al2368 420 24 CONDUCTOR RIBBON CABLE ASSEMBLY 42 LONG 7 A12411 00 AC LOCKOUT 3 POLE ISOLATOR SWITCH BACO 122 102 31 23 TR SSEM 183 WIRE DUCT 1 WIDE HIGH WHITE 8 12 A1l2414 00 110 Al2372 560 64 CONDUCTOR RIBBON CABLE 56 LONG g 1 2249 01 INTERCONNECT BOARD RANSFLOW 32 23 TR SSEM 184 WIRE DUCT COVER 1 WIDE WHITE 84 1 sse827 111 0 1 A12420 00 INTERCONNECT CABLE 9 12 73106005 NYLON 1 4 ODT X 1 4 LONG a E TR SSEH 382 TERMINAL BLOCK END CLAMP H 131 A1205 00 OPTICAL ISOLATOR BOARD A RAN
53. MVR Low Min Flow 1 This is the screen where of the parameters stored with the Job examined modified saved The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Not used e Not used e Save Job Parameters to flash memory If two guns are configured there will be two gun tabs at the top of the screen Select the gun number that you wish to examine or edit Notice the small magnifying glass immediately to the right of the Job number box This button allows you to Examine parameters for any job and edit them if necessary For example if you wanted to examine and edit parameters for job number 22 touch the small box immediately to the right of the word Job A keypad will popup and allow you to enter a job number For the RansFlow valid job numbers range from 1 to 99 Enter the job number 22 or whatever job you wish to examine edit and touch the enter ENT key and then touch the magnifying glass to retrieve the values Ifa valid job 22 was previously stored its parameters will be displayed If that job number is not in memory the job number will change to 0 indicating that this job number is not in memory LN 9409 01 2 RansFlow 53 Job Parameters Screen continued JOB Settings Channels MVR High Flow Rate MVR Low Max Flow Pressure REG Min Flow Pot Life C Band Notes 8 I Ba
54. ON DELAY ms This allows the operator to put a short delay between the time that the controller sees a trigger input signal and when it turns on the flow control valves to start flow This is to prevent flow too low faults if there is a pneumatic delay getting the applicator opened It is specified in milliseconds 250 milliseconds 1 4 second TRIGGER OFF DELAY ms This allows the operator to put a short delay between the time that the controller sees the trigger input signal go off and when it closes the flow control valves This prevents the fluid pressure from dropping off while the applicator is closing BLOW OFF TIME sec This parameter is only functional with manual mode guns This parameter allows a hand painter to blow off a part prior to beginning the spray operation Note that the timer accumulates until the controller sees flow through the master chan nel flow meter LN 9409 01 2 RansFlow 45 Gun Parameters Screen continued Gun Parameters CHANNELS MODE MANUAL FLUSH MODE CLEAN CHANNELS NO NO TRIGGER ON DELAY ms DEFAULT JOB TRIGGER OFF DELAY ms FLOW TOLERANCE 96 BLOW OFF TIME sec TOLERANCE TIME POT LIFE VOLUME ml TOLERANCE VOLUME Flush Box Flush Box 8 aloj The reason this is important is that there is the possibility that the gears in the master channel flowmeter could become stuck If this occurs material can slip by the gears without the gears turning As a result t
55. OR 3 SOLENOID E 1 Keme COLOR 4 SOLENOID udu eoe C 554 4 LIINI G udu TOS LNO EE E eae eB 340553 L3 TNT Cs COLOR 5 SOLENOID V JI8VN3 YAW mr ex g JIaVN3 YAW COLOR 6 SOLENOID T 30102 G Z 40102 O G Ww 9 JO COLOR 7 SOLENOID b O I j S 1O COLOR 8 SOLENOID 9 gt lt Te l 8 3 CS 6 30102 T 2 COLOR 9 SOLENOID heb 0T TO COLOR 10 SOLENOID UIV NISAY JE G 2 1N3ATOS NISJY TS G O I u355r4L 7 RESIN AIR SOLENOID T ISATWLVD TOEO C ISAWLVD c Ee RESIN SOLVENT SOLENOID ISATV1VO Io LN3A T1OS 1SATV LVD IiOo IOUS ll DUMP SOLENOID TRIGGER SOLENOID J O O O CATALYST 1 SOLENOID CATALYST 2 SOLENOID CATALYST 3 SOLENOID CATALYST SOLVENT SOLENOID TO CHANNEL A DR1 TO CHANNEL B DR1 TO CHANNEL C 1 TO CHANNEL A MVR TO CHANNEL B MVR TO CHANNEL C MVR ATOMIZATION AIR IN ATOMIZATION AIR OUT ATOMIZATION AIR IN ATOMIZATION AIR OUT EXHAUST SUPPLY LZLZ AWS 686 NS 161 AVS LOC AVS 181 AVS uec di l e RE S3SHOLIMS 3anss3Md
56. RansFlow 15 Relevent Information The RansFlow control system achieves closed loop control of its fluids via its configured channels and guns A channel consists of one MVR valve one flowmeter one calibration valve and one check valve A gun in most cases repre sents one applicator and may be configured with one channel for flow control only or configured with two or three chan nels for ratio and flow control Each channel operates independently of and simultaneously with all of the other channels in the system The controller therefore provides accurate and dynamic flow control for all channels regardless of external system variables ie fluid inlet pressure backpressure material viscosity flowmeter wear etc Configurable Operating Parameters The design of the RansFlow system allows it to be configured to meet the requirements of the application The large number of parameters allows the RansFlow to be used in almost any application involving flow and or ratio control of coatings System Parameters are parameters that affect the overall system which includes all channels and guns or the user interface They include e Number of guns e Channels assigned to each gun e Function of the alarm horn Gun Parameters are parameters that affect the gun These parameters apply to all channels configured to that gun They include e Mode manual or automatic Gun Parameters A gt e Default Job Number CHANNELS
57. Resin Solvent A 1 Job Bit 2 B L L L J1 J2 J3 to J8 of to J9 of to J1 of MIO Board MIO Board UIO Board E gt 94 LN 9409 01 2 RansFlow ALLT Optical Isolator Board Schematic B
58. SFLOW 4 78909 01 FUSE COVER VINYL 10 1 LSME0024 00 ALARM TABLE TR SSEH 497 TERMINAL BLOCK DOUBLE HIGH 86 1 12207 00 OPTICAL ISOLATOR BOARD A RANSFLOW 3 7438 00 CUP CABE Pit 2 BULKHEAD UNION 3 6 ODT DJE F8 31 aiz371 55 56 CONDUCTOR RIBBON CABLE ASSEMBLY 5 50 LONG maf 2 sd 12 4 sso NUT 1 2 INCH FLAT WASHER 135 1 TR SSEH 539 TERMINAL BLOCK END CAP ss 1 12371 32 50 CONDUCTOR RIBBON CABLE ASSEMBLY 3 2 LONG TABLE RECIEVER FIBER OPTIC FLOWMETER ASSEMBLY TABLE LsFAO0008 00 NUT 1 2 13 STEEL ZINC remm je DIN RAIL SLOTTED 20 INCHES LONG Q js 1 237145 50 CONDUCTOR RIBBON CABLE ASSEMBLY 4 50 LONG C D E C A M TABLE pom 50 CONDUCTOR RIBBON CABLE ASSEMBLY 6 50 LONG 116 TABLE pu CABLE FIBER OPTIC 114 1745 02 HEAT SHRINK 50 INCH BLACK C D E B 131 23707 34 CONDUCTOR RIBBON CABLE ASSEMBLY 7 0 LONG C D E C 15 TABLE 7332 00 LUG RING TERMINAL TABLE 78643 00 E P TRANSDUCER HIGH SPEED HIGH FLOW DIN RAIL MOUNT 992 1 A12366 68 10 CONDUCTOR RIBBON CABLE ASSEMBLY 6 8 LONG 1377 1 72591 01 CABLE SLEEVE WHT NOT SHOWN A N i9 1 41 HDW 1002 FOOT KIT 20 131 a11383 00 BOOT B D TABLE B D 7610 LOCKWASHER INTERNAL TOOTH 41 FP 1003 1 8 NPT M X 1 8 NPT F ELBOW 196 1 A12421 00 LABEL FRONT DOOR 22 TABLE 77437 00 CONNECTOR
59. SHOWN 50 FT REF 138 2 12559 00 REMOTE OPERATOR PANEL SHOWN A12612 00 CABLE ASSEMBLY SERIAL TOUCHSCREEN TO ZENER BARRIER RANSFLOW REMOTE OPERATOR PANEL NOT SHOWN WATERTIGHT CONNECTOR SSW 8230 LSMM0040 LOCK NUT TABLE G ROP TABLE G H AB AC AD AE io jJopjopjopjoponp i o i i o f o jo o i 0 X o t a z 13 6 1 DESCRIPTION NON INTRINSICALLY SAFE INTRINSICALLY TABLE H DR 1 PRESSURE CONTROL E DASHNo R S T U V W X o o o 10 3 QXXX o o o io 3 o Xxx o o o 3 o 0 i 1 2 122 4 1 1 dx 2 1 2 12 5 2 2 xxx 3 i 2 12 6 3 3 uec di LZ le LOCZ AVS 5 1802 AVS Fw ILE AVS 886 AVS bw 6066 AVS LOCZ AVS IP LIEZ AVS L222 AVS NAP LECZ AVS LEC AVS LGE AVS LOCZ AVS F ILLEZ NS A18N3SSV GIOJINVN SATIVA QIONJTOS LEC AVS NAI 66 AVS MVR ENABLE SOLENOID MVR ENABLE B SOLENOID COLOR 1 SOLENOID COLOR 2 SOLENOID Jil BUI TIGVNA WOLY V AH ma 11 umma udu TONLNOD B ime OI IO COL
60. SHOWN IN REMOVE DISCARD FIGURE 1 1 Ht EXISTING FITTING REFERENCE TABLE H 9 NS REPLACE EXISTING FITTING E EXISTING FITTING i9 POUR E em Tmo PAGE IS FOR MEIRIC PANELS ONLY Pneumatic Interface Panel Parts List LN 9409 01 2 RansFlow 92 Interconnect Board Schematic eoi apanan 24 VOL ang el kander Pose Lh 3 GHI M Dkwwler Source Ch 1 GNI kwwier Proce Ln 5 nh Thaneter saw re Cn GNI inreder Prose h GNI lires Source Gh P 2 5 e Ff FH IE Unuzed Urused E7 80 Trigger Don 2 3 cl Pus 2 Hal Peart Gow 2 Chur a 2 1 Guo dob Select Jil 1 bun P GND Urused GHD ka Pate Coreerd Boo 15 GNI ka Pate Bon P in GNI i AK mn J need Spore AK Gan 2 finer GND fo JS FJ Ie waf 2 gt j n se n e fel l l lal 3 SH 2 Bp tg 7 Moisducer 1 lorem J Actuol ke ban 3 Artuol ke bon d Presewe Pegdotor Ch 1 Breszuw o Pegictor Ch 2 Bresew o Pegolotar Ch 7 Wee eem 13 14 Je 15 8 3i 24 04 VOL e aia P4 VOC sa i ae Era Juro Solent Goo 1 ar is ure on 7 4 Cit 42 Bn 1 Cat Say 1 A iysten Puta z ea Gun Tudi Ad Pot Le E pred Gun J E E Hoed Vrluvwe leer ed Guo 1 E H
61. T 74 TABLE H T LSFIO060 TEE 1 4 ODT UNION H U 193 1 Al266 9 5 10 CONDUCTOR RIBBON CABLE ASSEMBLY 9 5 LONG SSM 5504 FILTER AIR 1 A12367 8 5 16 CONDUCTOR RIBBON CABLE ASSEMBLY 8 50 LONG 195 1 Al2369 12 26 CONDUCTOR RIBBON CABLE ASSEMBLY 12 LONG 18 1 72591 04 CABLE SLEEVE BLK NOT SHOWN 65505 WIRE 20 GA GREEN GROUND 120 1 665509 WIRE 20 GA WHT NEUTRAL 121 1 6655 10 WIRE 20 GA BLK HOT 12464 00 FLASH DRIVE 1 MEMORY INCLUDED SHOWN iu Ma A12465 00 USB A MALE TO USB A FEMALE CABLE INCLUDED BUT NOT oO N STYLUS 24 TETHER RANSFLOW INCLUDED BUT NOT SHOWN A12436 00 RANSFLOW ENCLOSURE LABEL SET 126 TABLEG A12529 47 0 10 CONDUCTOR RIBBON CABLE ASS Y ITEM AG O 33oo 2 41 1022 01 REDUCER 5 16 ODT TO 3 8 ODT 1131 A12199 01 LABEL METAL CONTROL PAC TABLE G ITEM AD 73837 11 ZENER DIODE BARRIER HIGH CURRENT S 132 rs TABLE G 73837 10 2 CHANNEL AC SAFESNAP BARRIER ITEM AE i3S5 2 559 7739 5 136 TABLEG A12610 00 CONVERTER DC DC 24V TO 15V 137 TABLEG A12606 50 CABLE NON INTRINSIC SAFE NOT SHOWN 50 FT REF ITEM AB TABLE G ITEM AC TABLE G ITEM AA TABLE G ITEM AH TABLE G ITEM AH TABLE G ITEM AH 12605 50 CABLE INTRINSIC SAFE NOT
62. VV roklp Guo in Parel Hara _ Spore EET Uros d ee Ce f AM lt oe nw 158 Ba 8 E ok Color 4 Sal in 2 5 fal jon 2 nu Job Select J 2 ban 2 E Job Select J 4 lu 2 Jto eleri Jd 3 Gan P PE Xeert 44 T boo E XPert Jd aj Bon P TE4NO doo SPert In 4 bon P uu 4 Job Select ba P Joo ire ban P x kap Bo Peody boa Than Bo B bun Spore DIM Asa Spore WYP 1 naatd A54 46 Ei 1 Sd Car 2 Sal law 3 A21 5 S Color 2 Sal law 1 Coo 4 Sol an 1 5 Sal in is aS amp Sal in J I lar 7 fal l 1 2 i 8 Sal in J 25 9 fal l 1 Cul 10 0 Ba H1 E Colar 7 Sal an Colar Sal an 2 a Color 9 Sal n 2 earns n a ie Pran hir Sokol bun 2 A HE Drain Solvent id le 2 Jwg idm Gu 2 DB AN Trigger Suera Gn 2 A3 Cit H on s rt 46 2 Cit t Ba 2 AG Cat Say 2 JF AS WR 3 Enable J8 KeSID EAR A4 an A Pot Le E pred Gan 2 CHD 55 Hoes Lietred Gun 2 FIA M V roei Gun 2 RE M urused THA Spore TAB Unused SCRA GHD Uruzed GHD Uruzed rev I CONCH A51 WIS 1 2 LN 9409 01 2 RansFlow 93 Optical Isolator Board Schematic A
63. ariables csv format to a memory stick and take them to a printer to be printed out Two files are created one that has all of the job data and second that has all of the totalization data LN 9409 01 2 RansFlow 37 System Parameters Screen System Global Settings Pot Fault Q General Fault Number of Guns EZ Gun 1 Channels Gun 2 Channels O Pulse Channel B B B Master Channel C cO cO The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Not used e Not used e Save System Parameters to flash memory There are only three things that relate to the system that need to be configured e The number of guns e The channels assigned to each gun e Horn configuration LN 9409 01 2 RansFlow 38 System Parameters Screen continued System Global Settings Number of Guns E O Pot Fault Q General Fault Gun 1 Channels Gun 2 Channels Q Pulse Channel A Master Channel B Master Channel C cO c O The number of guns can only be 1 or 2 As stated previously they can be configured one of five different ways e One single channel gun e Two single channel guns e One single channel gun and one two component 2 channel gun The 2 channel gun MUST be configured to be channels B amp C e One three component 3 channel gun e One 2 channel gun can be configured as channels A
64. arting from the left are e Return to Home Screen e Go back one screen e Not used e Not used e Enable the Remote Operator Panel The icons in the upper area of the screen are described below The upper left button is the Reset Halt button It changes its appearance depending upon the mode the gun is in If the gun is faulted this button resets the fault If the gun is running it halts it The gun must be in run mode to flow material LN 9409 01 2 RansFlow 74 Emulator Screen continued FLOW RATE Run this button puts a halted gun in run mode which enables it to flow Flush this button performs a flush of the applicator s Load this button performs a load sequence on the applicator Which in turn loads the job number specified on this screen Previous Next Job Number these two buttons allow the user to select the next job number to load LN 9409 01 2 RansFlow 19 Section 5 OPERATION Emulator Remote Operator Panel Screen Emulator FLUSH v JOB SELECT ARROWS p FLOW RATE Q A Emulator Screen on RansFlow Main Control Panel All gun applicator operation can be done from the Emulator screen or from the optional Remote Operator Panel sT Ransburg C REMOTE OPERATOR FAULT PANEL JOB FAULT HALT RESET FF Jl d 7 x di x x PURGE ma FLOW R
65. bration process has been completed LN 9409 01 2 RansFlow 68 Tools Screen continued Tools w Flow Test Flow Rate Current JOB 1 Current Channel A Calibration x wz Total Volume Volume 0 000 0 New PPL 8000 Flow Test Once calibration has been completed it is a good idea to do some flow tests to insure that the system is flowing at the proper flow rates and giving the proper ratios The Flow Test screen can be used to easily accomplish this Prior to doing a flow test go back to the emulator screen and perform a load sequence for the material Job that you wish to perform the flow test on Take the gun out of run mode by touching the red stop sign button prior to leaving the emulator screen Return to the Tools screen and once again begin by selecting the tab for the gun you wish to perform the flow test on at the top of the screen Next touch the white box below the Flow Rate text and enter the target flow rate that you wish to come out of the applicator total of all channels during the flow test Next program how long in seconds you wish the flow test to run for under Flow Time If there are values displayed under Total Volume or the A B or C channels they can be reset to zero by touching the eraser button on the right side of the screen At this point the gun can be placed in Run Mode by touching the green arrow button on the left side of the Flow Test screen To start the flow te
66. creen continued Current JOB Flow Test Flow Rate 220 30 Paw Total Volume Current Channel 0 000 Volume 0 B New PPL 0 000 8000 Parts B An additional feature of this screen allows you to have the software calculate the actual ratio of the material s that were dispensed Simply touch the white box below the heading Parts A and enter what the target ratio for the master channel was The software will then automatically calculate the other component or other components ratios for easy compari son to the target Once again if any of the component s ratios are outside of acceptable limits recalibration of the flow meter or flow meters is recommended LN 9409 01 2 RansFlow 70 Force I O Screen 0 7 Gun Active O Color 1 O Catalyst 1 Regulator Clear ALL Coane Color 2 Catalyst 2 0 IS C trigger Color 3 Q Catalyst 3 C Horn Can Fault Color 4 All OFF 0 Color 5 Regulator B Color 6 HV Enable O Color 7 MVR_B Enb Actual Flow Q Color 8 0 MYR C Enb O Color 9 Pot Fault MVR Enb Mixed Vol Cleared Catalyst Solvent Resin Solvent O Color 10 Resin Ar O All OFF This screen allows the user to force any of the digital discrete or analog outputs of the RansFlow System Also from this screen the user can select the View Inputs Screen The first column allows you to force the digital status outputs Simply t
67. d for the PID control loop In general this setting should never need to be changed unless the flow meter has been changed to a flow meter with a significantly different calibration value This parameter controls how responsive the system is when the desired flow rate changes Too large a value will cause the system to overshoot the target flow while too small a value may prevent the system from reaching the target flow rate or possibly even cause the flow rate to oscillate This parameter can also be temporarily changed on the Channel Parameter Screen LN 9409 01 2 RansFlow 57 Alarms Screen REPORTS k 1 Alarms Date Time Alarm Description Tue Oct 28 08 14 25 41 PM Flow Too Low Tue Oct 28 08 14 25 41 PM Flow Too Low Tue Oct 28 08 14 05 09 PM Start Up Reset The second button on the main screen takes you to the reports page The first screen you enter is the Alarms page The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Return to Alarms Screen used if you are on the Totals or Information Screens e Flow Totals e Information Screen Software versions etc The last 100 alarms are listed with the latest one always appearing at the top of the screen Older alarms automatically scroll off of the bottom of the screen Simply touch the scroll bar on the right side of the screen to scroll down To clear the screen simply touch the eraser icon
68. d gun SYSTEM 1 0 GUN 2 1 0 LN 9409 01 2 RansFlow 24 STEP 3 CCV and Gun Connections Air Connections CCV and Gun Air Connections LN 9409 01 2 RansFlow 25 CCV and Gun MVR A amp B ENABLE Air output that connects to the CCV valve if equipped on the fluid inlet of the MVR COLOR 1 10 Air output that connects to the associated color valve on the color stack RESIN AIR Air output that connects to the resin air valve on the resin color stack RESIN SOLVENT Air output that connects to the resin solvent valve on the resin color stack DUMP Air output that connects to the dump signal input on the applicator TRIGGER Air output that connects to the trigger signal input on the applicator CATALYST 1 3 Air output that connects to the associated catalyst valve on the catalyst valve stack CATALYST SOLVENT Air output that connects to the solvent valve on the catalyst valve stack STEP 4 Gun Flush Box and Transducer MVR Connection TRANSDUCERS B p oW j AIG ROIS Air Connections O Gun Flush Box 1 GUNFLUSH BOXES This is an air input coming from a gun flush box if used verifying that the lid has been closed Will support up to 2 gun flush boxes Air Connections Transducer MVR 1 TRANSDUCERS A B These are air output connections that connect to the associated air pilot input on the designated Material Valve Regulat
69. d it will start counting again the next time it sees a trigger without flow If you receive this fault it indicates that the gun has been triggered for a period of time specified by the BLOW OFF TIME parameter but did not see any resin flow during that time In most cases the cause of this is that the gears in the master channel flow meter have stopped or become stuck Try flushing the system and watch the flow rate or flow volume on the main screen of the controller during the flush to see if there is flow If there still is no flow disassemble and clean the flow meter If this still does not correct the problem see the section in this manual on FLOW TOO LOW FAULTS If this fault occurs while the operator was not even trying to spray then the air flow switch may be defective This can be verified by looking at Force I O screen for inputs A check mark will show up next to the Trigger input when the controller receives a trigger signal from the air flow switch Verify that the signal turns ON and OFF as the applicator is triggered ON and OFF LN 9409 01 2 RansFlow 84 Section APPENDIX Icon Definitions z ul CONFIGURE REPORTS COLOR CHANGE SEQUENCER TOOLS EMULATOR RETURN TO HOME SCREEN GO BACK ONE SCREEN BACKUP PARAMETERS TO USB PORT RESTORE PARAMETERS FROM USB PORT LN 9409 01 2 RansFlow 85 Icon Definitions continued WRITE DISPLAYED PARAMETERS TO OPERATING GUN ADVANCED
70. e If flow tolerance is set for 5 on a 2 channel gun with a target flow rate of 150 cc s min and a 2 1 target ratio this indicates that the master channel should be flowing at 100 cc s min and the slave channel should be flowing at 50 cc s min So Flow Rate Errors e A flow too low on channel A would occur if the flow rate of A falls below 95 cc s min e A flow too high on channel A would occur if the flow rate of A goes above 105 cc s min e A flow too low on channel B would occur if the flow rate of B falls below 47 5 cc s min e A flow too high on channel B would occur if the flow rate of B goes above 52 5 cc s min Keep in mind that the flow rate has to remain out of tolerance for the duration of the time programmed for tolerance time LN 9409 01 2 RansFlow 43 Gun Parameters Screen continued Gun Parameters v px CHANNELS MODE MANUAL FLUSH MODE CLEAN CHANNELS NO NO TRIGGER ON DELAY ms DEFAULT JOB TRIGGER OFF DELAY ms FLOW TOLERANCE 96 BLOW OFF TIME sec TOLERANCE TIME POT LIFE VOLUME ml TOLERANCE VOLUME 150 Flush Box A Flush Box 9 m r Since a 2 1 ratio results in 66 67 of the channel A material and 33 33 of the channel B material Ratio Errors e Aratio too high fault will occur if the actual ratio calculated is greater than 71 67 of the mixed material e Aratio too low fault will occur if the actual ratio calculated is less than 61 67 of the mixed materia
71. e Go to the Force I O screen on the touch screen of the controller Set MVR pressure for the channel you are troubleshooting at various pressures between 0 psi and 100 psi we suggest every 5 to 10 psi to verify linearity of the transducer Monitor the actual pressure with the gauge again insuring only a 10 variance If the transducer does not perform as described replace it NOTE Make sure there is not a leak in the tubing leading to the MVR valve or in the MVR valve itself The transducers are very low volume devices and are designed to only feed dead headed devices 6 If you notice in test 5 that the transducer is not responding as expected it may be the signal coming from the analog output board in the controller is at fault First make sure you have 24 volts 10 feeding the trans ducers refer to electrical diagrams in this manual and the picture below There are 3 wires connected to the termi nal block in the upper left of the tranducer The far left terminal is the ground terminal wire 2101 the terminal sec ond from left is the 24 VDC terminal wire 2011 and the third from left terminal is the command input The wire numbers for the command signals vary from channel to channel 7 Follow the procedure above in test 5 to send various voltages to the transducer from the analog output card There is a 1 10 ratio between the voltage sent to the transducer and the pressure the transducer should pro duce That is if MVR out
72. e Reverse Flow Parameter when the save button is pressed this parameter is saved to flash memory and is permanent for all jobs until once again changed on this screen Any other changes that are intended to be permanent must be made on the Edit Job Data Screen Note When making changes to the parameters on this screen they have to be saved with the button in the lower right corner of the screen the disk icon before they temporarily take effect They do not take effect when the enter key is pressed on the keypad LN 9409 01 2 RansFlow 48 Channel Parameters Screen continued Channel Prameters COMPONENT REGULATOR TYPE MVR HIGH MYR LOW PULSES PER LITER PRESSURE REGULATOR lol 6 REGULATOR TYPE This parameter allows the user to specify what type of flow control device is being used on that specific channel This is label ONLY and has NO EFFECT on the operation of the system MVR HIGH This parameter allows the user to control the maximum pressure that is sent to the flow control device from the E voltage to P pressure transducer This pressure is used for flush sequences and for opening the master channel on a gun configured for manual operation MVR LOW This parameter allows the user to program the cracking pressure of the flow control valve This parameter should be programmed just below the cracking pressure to prevent leakage of material past the flow control valve when the gu
73. e enabled on this screen Pressure on the switch indicates to the software that the applicator or applicators are in the flush box that the flush box is closed and that the high voltage power supply if used is disabled Once all of these parameters meet your requirements make sure you touch the save button in the bottom right hand corner of the screen to save the parameters to the flash disk LN 9409 01 2 RansFlow 47 Channel Parameters Screen Channel Prameters COMPONENT REGULATOR TYPE MVR HIGH MYR LOW PULSES PER LITER PRESSURE REGULATOR lol The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Not used e Advanced Channel Parameters e Write displayed parameters to operating gun these parameters will not be saved to flash memory Note All channel parameters displayed on this screen and the advanced channel parameters accessed by touching the lock symbol are for temporary changes only except for the Reverse Flow parameter on the Advanced Screen When any of these parameters are changed and then saved by touching the diskette symbol the data is changed for the job currently running on the fly but are not saved to the job Therefore when a new job is loaded even if it is the same job currently running the data programmed in the job file will over write these temporary parameters since this is the only place to modify th
74. e proper ratio by adjusting the MVR on the catalyst side based on the flow rate of the resin It is possible however for the master channel flow meter gears to get stuck and still allow material to pass through the flow meter When this happens the applicator continues to get resin but the controller is not aware material is flowing as the flow meter is not sending any pulses back to the controller Therefore it does not open the catalyst MVR and ratio in any catalyst You therefore get uncatalyzed parts To prevent this from happening air flow switches are supplied that should be tubed in the atomization air line of the applicators When the handgun or handguns are triggered they send a signal into the controller indicating that the handgun is in the triggered state When the controller gets a trigger signal from the gun it immediately looks to see if the resin flow meter is turning If it is not it issues a NO MASTER FLOW fault In many cases however operators use their handguns to blow dust and water off of their parts before spraying They do this by pulling the trigger on the gun back just far enough to get atomization air but no paint When this happens the controller gets a trigger signal and no paint flow which will cause it to fault To allow for this blow off a parameter called BLOW OFF TIME has been added to the software found on the Gun Parameters screen As soon as the 2k sees flow on the resin flow meter this timer is reset an
75. ed Material should be run in this step until mixed material is approaching the dump valve and then this step should end It is not advisable to send mixed material through the dump valve as the next spray cycle may exceed the pot life time of the material and the material could set up in the dump valve The valves that are on during this step are e All MVR Valves are PlIDding e Resin and Catalyst MVR Enable Valves e Resin and Catalyst CCV Valves e Dump Valve LN 9409 01 2 RansFlow 65 Color Change Sequencer Screen continued Color Change Sequence sj 1 2 Flush Sequence Time 15 00 sec Load Sequence Time 8 00 sec FLUSH SEQUENCE 1 Resin Push Solvent Solvent Only Solyent 0 250 sec Air O Air 0 250 sec Time 5 000 Sec Time 2 000 Sec Time 15 000 sec LOAD SEQUENCE 1 Load to Flowmeter 2 High Flow Resin Flow Rate 35 ml min Flow Rate 200 ml min B Catalyst Channel O Use Analg 3 Low Flow Time 3 000 sec Time 2 000 sec The third and final step closes the dump valve and opens the trigger valve Flow rate is normally reduced in this step since the applicator typically cannot handle as high a flow as the dump valve This step is intended to prepare the appli cator for the first trigger on a part This flow rate can be programmed or if the Use Analog radio button is selected the unit will use the signal from the analog input to determine the target flow rate required i
76. ed air flow switch is NOT being used LN 9409 01 2 RansFlow 46 Gun Parameters Screen continued Gun Parameters LINE CH CHANNELS MODE MANUAL FLUSH MODE CLEAN CHANNELS NO NO TRIGGER ON DELAY ms DEFAULT JOB TRIGGER OFF DELAY ms FLOW TOLERANCE 96 BLOW OFF TIME sec TOLERANCE TIME POT LIFE VOLUME mi TOLERANCE VOLUME f Flush Box A Flush Box _ 0 POT LIFE VOLUME ml This volume represents the volume of material in the system that has been mixed a k a mixed volume It basically is all of the material between the top of the spiral mix tube and the applicator or applicators It is calculated based on the inside diameter of the fluid lines and their lengths Use the following formula to calculate this value Volume ml d2 x L x 12 87 Where d the inside diameter of the tubing in inches L the length of the tubing in inches Also add in the appropriate volumes for the spiral mix tube and the applicator or applicators Flush Box A and B Radio Buttons In the lower right hand corner of the screen are two radio buttons one labeled Flush Box A and the other Flush Box B There are two pressure switches in the bottom of the control console that have been provided to interface with gun flush boxes If these radio buttons are enabled on this screen the color change sequencer will not be allowed to operate unless a signal is coming into the pressure switch or switches that ar
77. h a significantly different calibration value This parameter controls how responsive the system is when the desired flow rate changes Too large a value will cause the system to overshoot the target flow while too small a value may prevent the system from reaching the target flow rate or possibly even cause the flow rate to oscillate Kp This is the Proportional Gain parameter for the PID loop It controls how fast the PID loop opens the flow control valve when flow is initially requested A value too small here will cause an unnecessary delay in flow on the initial trigger on of the applicator or a slow ramp up of flow Too large of a value here will cause the flow to oscillate The default value of 2000 works well in most cases Ki This is the Integral Gain parameter for the PID loop It controls how fast the PID loop pulls the actual flow back to the target flow after the proportional portion of the PID loop has the actual flow approaching the target LN 9409 01 2 RansFlow 52 Job Parameters Screen JOB Settings Note f you change any of the parameters on this screen for the job number that is currently running they will not change the parameters currently run ning To actually change pa rameters that are currently run Max Flow 7 ning job must reloaded from the Emulator Screen after the changes to the Job Pa Pot Life rameters Screen have been Notes al saved Channels MVR High Flow Rate
78. he A12613 01 6mm odt pilot were released for applications that require interlock equipment Figure 1 shows the features of the A12613 valve assembly PILOT CONNECTION L A12613 00 1 4 ODT A12613 01 6MM ODT AIR INLET FITTING AIR OUTLET 0 D O Figure 1 A12613 VALVE FEATURES Ransflow Connection When manual applicators are used with the Ransflow product the valve assembly is installed as shown in figure 2 The CYL port of the valve is threaded onto the Inlet port of the flow switch as shown in the illustration A connection tube is required and must be either 6mm or 1 4 ODT and connect from the DUMP port on the Ransflow to the pilot connection on the valve This connection is also shown in figure 2 If more than one applicator is used from the Ransflow then a second valve assembly must be installed and the pilot lines connected together See figure 3 for this connection LN 9409 01 2 RansFlow 103 Warranty Policies LIMITED WARRANTY ITW Ransburg will replace of repair without charge any part or equipment that fails within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with ITW Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items a
79. here is no signal fed back to the controller and it has no way of knowing that master channel component is flowing The controller therefore does not meter in any of the slave component or components This results in only a single component material being applied to the parts If the controller sees a trigger input for a longer time than the blow off time when running the handgun air through the air flow switch it checks to make sure that the master channel flowmeter is spinning and that it is metering in the proper slave material or materials If not the controller generates a no master flow fault and shuts down the gun The system can be operated without the trigger signal the slave channel or channels are controlled based on the flow rate of the master but this is risky If more than one applicator is connected to the output of the fluid panel the trigger signals from all applicators should be paralleled and fed back to the trigger input of the controller Note that this may require a diode array to prevent feeding back voltage to the triggering devices If you are unsure how to implement this scheme contact your ITW Ransburg representative or our technical support group NOTE It is highly recommended that all handguns have air flow switches attached to the atomization airline feeding the hand gun The signal from that air flow switch should be wired back to the trigger input of the controller System I O connec tor if the factory install
80. ight cause se faster easier troubleshooting If you do not have the manu rious injury if instructions are not fol als and safety literature for your Ransburg system contact lowed your local ITW Ransburg representative or ITW Ransburg A WARNING The user MUST read and be familiar with the Safety Section in this manual and the ITW 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 STAN DARD 2009 EDITION prior to installing operating and or servicing this equipment The hazards shown on the following pages may occur during normal use of this equipment Please read the hazard chart beginning on page 6 LN 9409 01 2 RansFlow 5 Spray Area HAZARD Fire Hazard Improper or inadequate operation and main tenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent power supply shut down indicates a problem in the system requiring correction SAFEGUARDS Follow These Guidelines Fire extinguishing equipment must be present
81. ill attempt to control the flow rate of the master channel to prevent flow too high faults as the fluid fills the empty supply lines In automatic mode the controller controls the flow rate and ratio of all channels configured to the gun based on the tar get flow rate and target ratio CLEAN CHANNELS This allows the user to control which materials are flushed during the color change sequences If set for No the color valves and flow control valves will not be opened during the color change sequence These channels have to be manu ally flushed either by pneumatically bypassing the flow control valves regulators or by forcing the necessary valves regulators open on the Force I O Screen DEFAULT JOB This is the job that is automatically loaded into the gun at power up Note that this only loads the gun parameter data and does not automatically initiate a color load sequence LN 9409 01 2 RansFlow 42 Gun Parameters Screen continued Gun Parameters 3 CHANNELS MODE FLUSH MODE CLEAN CHANNELS TRIGGER ON DELAY ms DEFAULT JOB TRIGGER OFF DELAY ms FLOW TOLERANCE 96 BLOW OFF TIME sec TOLERANCE TIME POT LIFE VOLUME ml TOLERANCE VOLUME Flush Box Flush Box loj FLOW TOLERANCE This parameter allows the user to specify how far out of tolerance the flow rate and ratio are allowed to vary before the system generates a fault and closes all valves For exampl
82. in pressure typically 10 psi but changes greater than this or large pressure surges as is seen with piston pumps without surge chambers are a definite problem 2 Has the viscosity of the material changed A significant change in viscosity alters the way in which it passes through the fluid metering equipment MVR valve flow meter check valves Y block spiral mix tube etc Typically an increased viscosity will require more pressure to get to the same flow rate However in some cases as with thixotropic materials the viscosity will actually change as the pressure varies or as the material passes through the MVR valve and the flow meter Note that there is a large pressure drop across the MVR and flow meters Addition ally the material chopped into small chunks as it passes through the flow meter and this can cause some materials to change their properties as they flow 3 Has a restriction formed somewhere in the fluid line This could be a kinked tube contamination in the MVR or flow meter spiral mix tube blockage or sticky check valve Y block blockage to name but a few An easy way to verify that the system is capable of flowing at the flow rate required is to flush the applicator Watch the flow rate during the flush seqeunce If the system cannot get to the required flow rate in flush mode the system will not be able to get there in run mode since MVR valves are wide open in flush mode This tests all fluid lines from the mate
83. in the upper right corner of the screen Note Faults must be cleared on the Emulator Screen LN 9409 01 2 RansFlow 58 Reports Screen Totals Job Totals Channel A B C Total Clean Totals Channel Daily Total 28 750 11 125 0 000 39 875 Daily Total 0 000 0 000 0 000 YTD Total 28 790 11 125 0 000 39 875 YTD Total 0 000 0 000 0 000 The fourth button on the Reports Screen is for examining and resetting flow totalization data Select the job you are interested in retrieving data for and touch the examine button magnifying glass Information is stored separately for all three channels There are two independent values stored for each channel Daily and Year to Date YTD These values are not tied to the clock in any way they are simply two values that both incre ment when material is flowing but can be reset independently They can be used as shift totals totals for production runs of one single part daily totals weekly monthly etc These six values are stored independently for all 99 jobs The clean totals displayed in the bottom half of the screen are the totals that are incremented whenever the channel is flushing These are grand totals for all jobs they are not stored independently for each job number LN 9409 01 2 RansFlow 59 Information Screen REPORTS ITW RansFlow System System Version 01 05 0570 GUI Version 01 05 0461 This screen indicates the current
84. ion equipment such as material pumps regulators trig gering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing 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 coating supplier Any other type of solvent may be used with aluminum equipment LN 9409 01 2 RansFlow T Spray Area High Volt age Equipment Electrical Equipment HAZARD Electrical Discharge There is a high voltage device that can in duce an electrical charge on ungrounded objects which is capable of igniting coating materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion Electrical Discharge High voltage equipment is utilized Arcing in areas of flammable or combustible mate rials may occur Personnel are exposed to high voltage during operation and mainte nance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shutdown indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explosion SAFEGUARDS Follow These Guidelines Parts being sprayed must be supported on conveyors or hangers and be grounded
85. ix Ele ment Low Pres 6 LSMM0056 00 sure 5 10 20 20 Spiral Ele ment High Pres LSMM0056 01 sure 5 10 20 20 9 76805 01 ZHM 02 Flow 1 1 1 2 77214 00 Fiberoptic RF 1 1 1 1 2 77226 00 Piston Flowmeter 1 1 1 2 76251 01 Standard RF 1 1 1 1 2 12 78014 01 Flushable Mix 0 0 1 1 Non Flushable Mix Block As 78014 02 sembly 0 0 1 1 LBALOO16 00 High Pressure 0 0 1 1 Low Flow Weepless MVR 21 76624 02 Valve 1 1 2 2 Medium Flow Weepless MVR 76624 03 Valve 1 1 2 2 High Flow Weepless MVR 76624 04 Valve 1 1 2 2 78137 02 Low Flow Weep 1 1 2 2 Medium Flow Weep Style MVR 78137 03 Valve 1 1 2 2 78137 04 High Flow Weep 1 1 2 2 28 LSMMO0059 01 Calibration Tube 2 2 4 8 29 50067 3 Way Ball Vavle 0 0 1 2 75774 00 3 Way Ball Vavle 0 0 1 2 High Pressure Check Valve 34 75773 00 Assy 1 1 2 4 35 76093 00 Needle Valve 0 0 2 2 40 77227 00 Transmitter Pis 0 0 1 1 51 A10610 00 MVR Trigger 0 0 1 2 LN 9409 01 2 RansFlow 102 High Voltage Interlock Valve Normal use of handheld applicators requires the product to go through color changes During the color change sequence there may be solvent involved to properly clean all the fluid passages When solvent is present in the color change process the electrostatics to the applicator must be off Refer to the warnings in the applicable applicator manual A new normally open valve package was re leased for use with applicators during the color change process The A12613 00 1 4 odt pilot and t
86. l Keep in mind this is based on the value programmed in for tolerance volume TOLERANCE TIME This is the amount of time any error except ratio must persist before a fault is generated It is recommended that this never be programmed less than 3 seconds as numerous nuisance faults will probably occur Note Ratio checks are based on volume not time See Tolerance Volume below TOLERANCE VOLUME This parameter is only used with multiple component guns Flow rates of all channels are checked 50 times second every 20 milliseconds Ratio however is checked based on volume rather than flow rate Every time this volume of material has exited the applicator the controller calculates the actual ratio based on how much of that volume flowed through each of the 2 or 3 channels If the actual ratio based on the volumes measured is outside the flow tolerance setting a ratio fault will occur LN 9409 01 2 RansFlow 44 Gun Parameters Screen continued Gun Parameters CHANNELS MODE MANUAL FLUSH MODE CLEAN CHANNELS NO NO TRIGGER ON DELAY ms DEFAULT JOB TRIGGER OFF DELAY ms FLOW TOLERANCE 96 BLOW OFF TIME sec TOLERANCE TIME POT LIFE VOLUME ml TOLERANCE VOLUME 150 Flush Box A Flush Box 9 m Currently there is only one flush and load sequence saved for all jobs Therefore this should always left at the de fault value of 1 FLUSH MODE TRIGGER
87. losed When you touch this button three things will happen The color valve that you selected will open the MVR enable signal solenoid valve for the channel you se lected will open and the MVR valve will go to its MVR High pressure This allows you to flow material from the color valve down through the MVR valve flow meter calibration valve etc and get any air out of the fluid lines prior to cali brating This button can remain on during the entire calibration process if you have a downstream valve to control the flow of material during calibration such as a calibration ball valve or trigger valve at the applicator etc LN 9409 01 2 RansFlow 67 Tools Screen continued Tools i i 2 Flow Test Flow Rate 220 Current JOB 1 Current Channel valve Number Total volume volume 0 000 0 New PPL 8000 The second button inside of the calibration section of the screen is a large green arrow When this button is pushed the software will begin counting pulses from the flow meter This button changes to a red stop sign when pushed To cali brate simply push this green arrow button and then open your calibration valve or trigger valve and flow an adequate amount of material into a graduated cylinder Close the calibration valve or trigger valve and push the red stop sign button Next touch the white box under the text Volume and a keypad will popup Enter the volume in milliliters that was collected in
88. ly and cy cling the AC power does not restore the output try removing the wires on the output of the supply with the AC power off and then power up the unit If there is still no voltage replace the power supply If the voltage recovers place an ammeter in circuit and check to see if you have exceeded the 5 amp limit of the supply If current draw is less than 5 amps replace the power supply If the current draw is greater than 5 amps look for excessive current draw in the system Proper OSHA Lockout Tagout procedures must be followed prior to performing any equipment mainte nance or repair LN 9409 01 2 RansFlow 19 FLOW TOO LOW OR FLOW TOO HIGH FAULTS These types of faults can be caused by numerous problems We will attempt to describe most of the more common causes below Keep in mind that as the name implies the controller thinks that either too little or too much material is getting to the applicator This troubleshooting manual assumes that the system was running at one time and something has gone wrong It is not meant as a manual for setting up a new system however many of the troubleshooting proce dures described can be used in either case 1 Has your material supply pressure changed What was the material supply pressure when the system was run ning properly Is it the same now Do you really trust the pressure gauge you have been using for the past several years The controller can compensate for small changes
89. matic delays between the E to P transducers and the MVR valves Fluid Regulators It is highly recommended that a pilot operated fluid regulator similar to the ITW DR 1 regulator be used on the inlet of all of the MVR valves unless they are supplied from pressure pots The RansFlow can optionally control the pilot pressure to these fluid regulators It is sometimes necessary to use higher pressures for high viscosity materials than lower viscosity materials etc The RansFlow allows the user to pro gram a different pressure for every job and every channel so that the inlet pressure to the MVR valves can be fine tuned to the specific material and flow rate Pneumatic Interface Panel for Gun 2 If more than one fluid panel is to be controlled from one RansFlow controller it is necessary to use a second pneumatic interface panel In this instance the software will be configured for two guns Gun 1 and Gun 2 See gun configura tion chart below Possible Gun Configurations One 3 channel gun e Channels 1 2 amp 3 Two single channel guns e Gun 1 Channel 1 e Gun 2 Channel 2 One single channel gun and one 2 channel gun e Gun 1 Channel 1 e Gun 2 Channels 2 amp 3 Note Channel 3 cannot be configured as a master channel Control Interface Panel Overview 5VDC Power Supply Interior Components 1 i Electrical Interface Inner Connect Board E P Transducers Te
90. meter calibration values 1 PulsesA iter MVR Low Valve resin and catalyst valve Pressure REG Min Flow MVR High X C Band MVR Low I Band Pressure Regulator Setting Kp Job Parameters Screen C Band I Band Text Note s LN 9409 01 2 RansFlow 17 SPECIFICATIONS Environmental Physical Size e Main Control Console 24 Wide x 24 High x 9 Deep e Remote Operator Panel 9 5 Wide x 6 25 High x 4 Deep e Pneumatic Interface Panel for second gun 24 Wide x 12 High x 9 Deep Operating Temperature e 32 F to 130 F inside enclosures e 100 F maximum ambient outside temperature Operating Humidity e 0 to 95 RH Air Input e 125 psi maximum Power Input e 120 VAC 50 60 Hz 2 25A or e 240 VAC 50 60 Hz 1A auto selecting LCD Display e 6 5 Diagonal Full Color 640 x 480 pixels utilizing a touchscreen for data input Processor e AMD Geode GX533 Flow Capacity e 10 to 4000 ml s min per channel dependant upon material and flowmeter limitations Viscosity Range e 30cp to 500 cp I O update time incl PID loop e 20msec 50 times sec Job Tables e 99 Jobs P Sets per gun LN 9409 01 2 RansFlow 18 FEATURES Control of up to 3 materials from one 24 W x 24 H x 9 D control console Possible gun configurations e One 3 component gun e One 2 component gun and one single component gun e Two single component guns D
91. mponent materials This electronic metering system provides accu racy and repeatability for consistent finish quality The RansFlow System is composed of four basic elements e Main Control Console e Fluid Panel e Remote Operator Panel optional e Pneumatic Interface Panel optional The Main Control Console can control up to 3 channels materials the fluid panels are available in 1 2 or 3 channels and the Remote Pneumatic Interface panels are available in single or 2 channel models Remote Operator Panel FAULT ANEL JOB FAULT 5 a C3 588 a FLOW RATE Main Control Panel Fluid Panel LN 9409 01 2 RansFlow 10 The RansFlow is a dynamic fluid metering system using regulators and flow meters to provide true closed loop flow con trol Operation overview RansF low Controller Flow Meter Signal Fluid Outlet A CHANNEL consists of Transducer Regulator Flow meter A GUN can consist of 1 2 or 3 CHANNELS Gun Channel 1 or A Channel 2 or B Channel 3 or C M en s el LN 9409 01 2 RansFlow 11 The RansFlow can control up to 3 CHANNELS configured as 1 or 2 GUNS This RansFlow will maintain the fluid delivery and ratio at each individual applicator to a tolerance as close as 2 A flow meter will be located in
92. n is triggered off This will result in the fastest possible response in the flow control loop when switching from a no flow state to a flow state A value of 20 psi is recommended for weep style MVR valves and 10 psi is recommended for the weepless style MVR valves LN 9409 01 2 RansFlow 49 Channel Parameters Screen continued Channel Prameters COMPONENT REGULATOR TYPE MVR HIGH MYR LOW PULSES PER LITER PRESSURE REGULATOR _ d PULSES PER LITER This parameter allows the operator to change the calibration values for the flowmeters This is normally done through the calibration routine PRESSURE REGULATOR This allows the operator to program a fixed pressure to be delivered to a pilot operated fluid regulator on the inlet of the flow control valve for each channel Typically thicker materials require a higher inlet pressure to the flow control valve Note that this is an optional feature LN 9409 01 2 RansFlow 50 Advanced Channel Parameters Screen Channel Prameters Adyanced COMPONENT REVERSE FLOW C BAND I BAND Note that this screen is accessed by touching the lock symbol on the Channel Parameters Screen The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Not used e Not used e Write displayed parameters to operating gun these parameters will not be saved to flash memory REVERSE
93. n this step Refer to the section explaining the Job Parameters to program the Min Flow and Max Flow parameters for this analog feature to work LN 9409 01 2 RansFlow 66 Tools Screen Flow Test Flow Rate Current Channel 220 Current JOB Valve Number 1 Total Volume Volume 0 000 0 New PPL 8000 The fourth button from the left on the Main Screen selects the Tools Screen From here users can perform functions such as calibrate the flow meters do flow tests and test all digital and analog inputs and outputs The icons across the bottom of the screen starting from the left are e Return to Home Screen e Go back one screen e Force I O Screens e Not used e Save Calibration Parameters to flash memory Calibration Four items must be selected prior to calibrating The Gun Number tab at the top of the screen the Job Number Current JOB that you want the new calibration values saved to the channel Current Channel which can be A B or C and the Valve Number this is which color valve that should be opened during the calibration process To change the values of Job Channel and Valve simply touch the white box where the value appears that you wish to change and a keypad will popup allowing you to change its value Note There are three buttons inside the calibration section of the tools screen The top button has the image of a valve with a red cross through it This indicates that presently the valves are c
94. nd Modify the parameters as necessary Don t forget to modify all channels with the channel tabs on the right section of the screen If you want to save the parameters to the job number currently being displayed in the job number box sim ply touch the save button The save button is in the lower right corner and has a diskette icon in it If you wish to save the displayed parameters to a different job number or if the job number displayed is 0 change the number in the job number box to the desired value and then touch the save button Channels This value is not adjustable on this screen it appears for informational purposes only Channels and guns are config ured on the System Parameters screen This box simply indicates how many channels are configured to the gun The number of channel tabs on the right side of the screen will match this number Make sure all parameters for all channels are programmed Flow Rate This is the target flow rate for the gun If the gun is configured as a manual mode gun this parameter is ignored If ana log flow control is to be used this value should be 0 That is this value overrides the Min Flow and Max Flow settings It is expressed in ml s min cc s min Max Flow This parameter is the target flow rate desired from the applicator when a 10 VDC signal is received at the analog flow rate input It is expressed in ml s min cc s min LN 9409 01 2 RansFlow 54 Job Parameters Screen
95. o that it knows what the current flow rate of the material is The RansFlow is capable of interfacing with any type of flowmeter that is capable of outputting a square wave whose frequency is proportional to the flow rate Itis highly recommended although not absolutely necessary that these flow meters have quadrature outputs so that reverse flow can be detected The calibration valves are 3 way ball valves used to direct the flow of material away from the mix block to the calibration tubes This is used to calibrate the flowmeters The check valves prevent backflow of material from one source to another Typically the catalyst is run at a higher pressure than the resin to allow it to inject itself into the resin flow stream and can therefore back up into the resin sup ply if an MVR valve is stuck open for any reason The Mix Block is a four port manifold that brings the fluid from the outlet of the resin MVR together with the outlet of the catalyst MVR Attached to the top of the Mix Block is a port for an optional solvent flush valve for quick flushing of only the mixed material from the Mix Block out to the applicator Attached to the outlet of the Mix Block is the spiral mix tube This is simply a piece of tubing with a helical shaped ele ment inside the tube This element causes the two materials resin and catalyst to be folded together numerous times as the materials pass through it thus causing it to mix LN 9409 01 2
96. oid Output Intended to drive the 1 catalyst valve on the catalyst CCV stack Catalyst 3 Solenoid Output Intended to drive the 3 catalyst valve on the catalyst CCV stack 25 26 27 28 29 Cat Solvent Solenoid Output Intended to drive the CCV solvent valve on the catalyst color change valve stack assy It can be programmed to turn on in step 2 of the flush se quence Flowmeter C Source One of the quadrature feedback signals from the channel C flowmeter 31 DC Common to all I O signals and DC power supply voltages 32 Flowmeter A Source One of the quadrature feedback signals from the channel A flowmeter DC Common to all I O signals and DC power supply voltages Ch B MVR Enable Output Intended to drive the enable valve on the inlet of the channel B MVR Flush Box A Ready Signal to be on with gun in flush box and flush box lid closed Flush Box Ready Signal to be on with gun in flush box and flush box lid closed 24 VDC NA LN 9409 01 2 RansFlow 30 Discrete Digital and Analog SYSTEM Inputs and Outputs 7 N C2 N N opare Cleared Gun 2 Pressure Regulator Channel 3 Pressure Regulator Channel 2 Actual Flow Gun 2 Flow Rate Command Gun 2 Job Select Bit 1 Gun 2 Flush Gun 2 Halt Reset Gun 2 Job Strobe Gun 1 Job Select Bit 40 Gun 1 Job Select Bit 10 Gun 1 Job Select Bit 4 Gun 1 Job Select Bit 1 Gun 1 Flush Gun 1
97. ola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Phillips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Telephone 419 470 2021 Fax 419 470 2040 Technical Support Representatives can direct you to the appropriate telephone number for ordering spare parts Form No AA 09 01 NME 2010 Illinois Tool Works Inc All rights reserved Litho in U S A ty S AEE Models and specifications subject to change without notice ACERS 09 10 LN 9409 01 2 RansFlow 106
98. or MVR 2 Pilotsignal tubing guidelines shown below 3 The RansFlow will support up to 3 MVRs MIN MAX LENGTH LENGTH Tubing Size Fluid Regulator Typical LN 9409 01 2 RansFlow 26 STEP 5 Atomization Air and Supply Air Connections Air Connections Atomization Air 1 ATOMIZATION AIR INLET amp OUTLET This is an input and output for the gun atomization air The RansFlow uses this air signal to tell if the gun has been triggered 2 Connects to an air flow switch inside the ATOMIZATION AIR RansFlow cabinet 3 Will support up to 2 guns Air Connections Supply Air 1 SUPPLY Air input for control panel main air supply 100 psi maximum 2 EXHAUST No connection needed here_ This is the exhaust for the transducers inside the RansFlow cabinet A muffler is NOT recommended as it restricts the exhaust flow and will reduce the response time of the MVR EXHAUST SUPPLY valves o WET 100 PSI LN 9409 01 2 RansFlow 27 STEP 6 Fluid Connections Fluid Panel Typical 2k Installation To Applico tor Can support up to 10 colors Can support up to 3 catalysts LN 9409 01 2 RansFlow 28 Discrete Digital and Analog GUN Inputs and Outputs 10 12 13 2 KI NI NI NI NI N gt gt gt gt Oo OO N O oy Resin Air Solenoid Color 9 Solenoid Colo
99. ou will not receive a flow too low or flow too high fault If however the resin is flowing at 280 cc s min and the catalyst is flowing at 107 cc s min both within the 10 flow tolerance you will get an out of tolerance fault The reason for this is the way the 2k software generates out of tol erance faults As was mentioned earlier after each volume of resin specified by Tolerance Volume passes through the resin flowmeter the 2k software looks to see how much catalyst flowed during that same time period The software then determines the ratio based on volume rather than flow rate If that ratio is above or below the preset ratio by more than the Flow Tolerance specified in the parameters it generates an out of tolerance fault In our example above the vol ume of resin would of course be 200 cc s and since it was running low it would have taken 42 857 seconds In that same 42 857 seconds the catalyst was flowing 7 high or at 107 cc s min This would result in a volume of catalyst of 76 43 cc s in that same time The ratio of 200 cc s to 76 43 cc s is 72 35 27 65 which is on the catalyst side more than 10 high The unit will therefore fault with an out of tolerance fault on the catalyst channel 25 2 5 27 5 Keep in mind that ratio is calculated based on total volume therefore the catalyst ratio above is calculated by 76 43 x100 27 65 200 76 43 Most of the time when this fault is seen the cause
100. ouch the square next to the signal you wish to force on and a checkmark will appear in the box indicating that the signal is forced on To remove the force simply touch the box a second time or touch the Clear ALL button in the top right of the screen The second column allows you to force any of the color valve solenoids on Only one can be forced on at a time to pre vent materials backing up from one supply line to another if they don t have matching pressures Simply touch the radio button next to the color valve you wish to turn on To turn it off touch the All OFF radio button at the bottom of the sec ond column or the Clear ALL button The third column allows you to force any of the catalyst valve solenoids on Only one can be forced at a time to prevent materials backing up from one supply line to another if they don t have matching pressures Simply touch the radio but ton next to the catalyst valve you wish to turn on To turn it off select another valve to turn on or touch the All OFF radio button in the third column or the Clear ALL button Also in the third column is a box marked Actual Flow This drives an analog output that is proportional to the flow rate passing through the applicator If you touch the box below the Actual Flow text a keypad will appear allowing you to key in a voltage to send to this analog output Key in the value 0 to reset LN 9409 01 2 RansFlow 71 Force I O Screen continued Color 1 O
101. pened during this step are e Resin MVR Valve e MVR Enable Valve e Resin Solvent or Resin Air Valve e Trigger Valve Note This final step flushes the applicator itself as the dump valve is closed and the trigger valve is opened LN 9409 01 2 RansFlow 64 Color Change Sequencer Screen continued Color Change Sequence i 1 Vj 2 Flush Sequence Time 15 00 sec Load Sequence Time 8 00 sec FLUSH SEQUENCE 1 Resin Push Solvent Solvent 0 250 sec Air 0 250 sec Time 5 000 sec Flow Rate 375 ml min Flow Rate 200 ml min Use Analog Time 2 000 sec The bottom half of the Color Change Sequencer Screen allows the user to control the Load Sequence Once again if any of the times are set to zero the step is skipped In the first step the user can specify which valve or valves should be opened to allow material to flow from the color valve stack to the flow meter and for how long The valves that are opened during this step are e Resin MVR and or Catalyst MVR and or Component C MVR Valves e Resin CCV and or Catalyst CCV Valve note that which of the resin and catalyst CCV valves opened is based on information provided on the Configure Job Screen e Resin and Catalyst MVR Enable Valves e Dump Valve In the second step the controller switches to run mode and starts controlling the flow of the material or materials This should be done at a fairly high flow rate since the dump valve is still open
102. ply shut down indicates a problem in the system requiring correction Explosion Incompatible Materials Halogenated hydrocarbon solvents for ex ample methylene chloride and 1 1 1 Trichloroethane are not chemically compati ble 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 SAFEGUARDS Follow These Guidelines Electrostatic arcing MUST be prevented All electrical equipment must be located outside Class or II Division 1 or 2 hazardous areas in accordance with NFPA 33 2009 Edition Test only in areas free of flammable or combustible materials The current overload sensitivity if equipped MUST be set as described in corresponding section of the equip ment manual Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power shutdown indicates a problem with the system which requires correction Always turn the control panel off prior to flushing clean ing or working on spray system equipment Ensure that the control panel is interlocked with the ventilation system and conveyor in accordance with NFPA 33 2009 Edition Have fire extinguishing equipment readily available and tested periodically Follow These Guidelines Aluminum is widely used in other spray applicat
103. put is set to 1 0 volt a 1 volt signal should be output by the analog output board to the transducer and the transducer should respond with 10 psi on its pneumatic output Likewise 2 volts 20 psi 3 volts 30 psi etc If you suspect a faulty analog output card it should be replaced LN 9409 01 2 RansFlow 81 OUT OF TOLERANCE FAULTS Out of tolerance faults are generated in the following way Every time a certain volume of resin passes through the resin flowmeter specified by the Tolerance Volume Parmeter the controller determines the amount of catalyst that flowed during that same time interval The software then calculates the actual ratio that flowed during that interval and checks to see if the ratio itself is within the Flow Tolerance specification on the Gun Parmeters Screen The reason this fault is generated even though there were no flow too high or flow too low faults is probably best ex plained with an example Take for instance we have a 2k material that is supposed to be mixed at a 3 1 ratio and spray out of the applicator at 400 cc s min We have the Flow Tolerance set to 10 and the Tolerance Volume set to 200 cc s The software sees this to mean it should flow 300 cc s min of resin and at the same time 100 cc s min of catalyst and that is what it attempts to do As long as the resin flow rate remains between 270 cc s min and 330 cc s min 10 and the catalyst flow rate stays between 90 cc s min and 110 cc s min 10 y
104. puts LN 9409 01 2 RansFlow 72 View Inputs Screen Inp Status C Trigger Run Halt Reset Clean Load Job Select bit 1 Job Select bit 2 Job Select bit 4 Job Select bit 8 Job Select bit 10 Job Select bit 20 Job Select bit 40 Job Select bit 80 Job Strobe Flush Box A Ready Flush Box B Ready This screen displays the status of all input signals A checkmark beside any label indicates a signal is present at that 1 Trigger Run Halt Reset Clean 0 Load Job Select bit 1 Job Select bit 2 Job Select bit 4 Job Select bit 8 Job Select bit 10 7 Job Select bit 20 Job Select bit 40 Job Select bit 80 Job Strobe Flush Box A Ready Flush Box B Ready Flow Rate Command Gun 1 0 0 V Flow Rate Command Gun 2 0 0 V input The two Flow Rate Command boxes indicate the input voltage on that input LN 9409 01 2 RansFlow 13 Emulator Screen 1 v A FLOW RATE The fifth button from the left on the Main Screen selects the Emulator Screen From here users can perform functions such as select the job number to load load material to the applicator flush the applicator put the gun in run mode halt the gun reset faults and view the status of the gun the currently running job number and the current flow rate The icons across the bottom of the screen st
105. r 7 Solenoid Color 5 Solenoid Color 3 Solenoid Color 1 Solenoid Ch B Transducer Resin Solvent Sol Trigger Solenoid Catalyst 2 Solenoid Ch C Transducer Flowmeter C Phase Flowmeter A Phase Flowmeter B Phase Flowmeter B Source Ch C MVR Enable Color 10 Solenoid Output Output Output Output Output Output Output Output Output Output Output Input Input Input Input Input Output Output N A Output Output Output Output Output EEEEECEEEEEEEEEBEREEEEEEEREE Description Intended to drive the CCV air valve on the resin color change valve stack assy It can be programmed to turn on in steps 1 and or 3 of the flush se quence and it pulses in step 2 Intended to drive the Z9 color valve on the CCV stack Intended to drive the 7 color valve on the CCV stack Intended to drive the Z5 color valve on the CCV stack Intended to drive the 3 color valve on the CCV stack Intended to drive the 1 color valve on the CCV stack A 0 10 VDC output command to drive the E to P transducer which in turn drives the MVR flow control valve Ch B Intended to drive the CCV solvent valve on the resin color change valve stack assy It can be programmed to turn on in steps 1 and or 3 of the flush sequence and it pulses in step 2 Intended to be shuttled together with the solenoid valve that triggers the ap plicator during normal spray sequences It allows the color change se quencer to trigger
106. re excluded THE USE OF OTHER THAN ITW RANSBURG APPROVED PARTS VOIDS ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NO IMPLIED WARRANTIES NOR WAR RANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANSBURG AS SUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume NO responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if appli cable LN 9409 01 2 RansFlow 104 NOTES LN 9409 01 2 RansFlow 105 Product Manual Price 50 00 U S Manufacturing 1910 North Wayne Street Ang
107. rminal Block TB1 Zener Barriers Pressure Switch Air Flow Switch 3 IS Yk 2 Mn 1 Pneumatic Interface 9 Solenoid Valves gt Mz Flow Meter Connection LN 9409 01 2 RansFlow 22 STEP 1 Main Power to Control Panel Connection Electrical Connections Main Power 1 AC POWER Cabinet entrance point for incoming AC power 2 RansFlow has an auto switching AC power input that will accept 120 240 VAC Proper OSHA Lockout Tagout procedures must be performed priorto equipment installation or maintenance v A C POWER 2 AMP MAX Electrical connections White neutral Black hot Green ground CAUTION N EET mU Wires should be landed on the switch aT titi titi zii 9 j terminal white amp black and the ground block LN 9409 01 2 RansFlow 23 STEP 2 Flow Meters and I O Connections Electrical Connections Flow Meters 1 FLOWMETERS A B C Electrical or fiber FLOW METERS optic cable connection point for external flow meters 2 RansFlow will support up to flow meters Electrical Connections I O 1 ROP Connection point for the opfional Remote Operator Panel ROP cable SYSTEM I O I O cable connection point for extemal system input and output communication with a PLC or robot if used 3 GUN I O connection point to an interface box for an opfional secon
108. rs during the flush cycle LN 9409 01 2 RansFlow 32 A sm ne _ Description Pot Life Expired Output 24 VDC This output goes on when the mixed material in the applica Gun 1 tor has been mixed for a time greater than the time pro grammed in the job parameter for pot life time 1 Gun Fault Gun 1 Output 24 VDC This peer goes on when the gun faults Gc j o ae reaa o a a ing or flushing as long as the RansFlow software is running we 1 LN 9409 01 2 RansFlow 33 Section 4 PROGRAMMING This is the screen that appears immediately after powering up the RansFlow controller All data on this screen upon power up is non valid random data and should be disregarded until a job is loaded from the Emulator Screen The icons across the bottom starting from the left are Configure e Reports GUN 1 RUN e Color Change Sequencer ACTUAL e Tools Next JOB Current JOB 1 e Emulator Operator Panel Ratio 10 0 2 0 Ratio 10 0 0 0 Flow Rate 0 0 ml min FlowRate 0 0 ml min PotLife 0 sec Pot Life 0 sec Volume 0 0 ml If there is more than one gun configured there will be two tabs displayed at the top of the screen Select the gun num ber you wish to monitor or control Note The RansFlow can control up to three channels of fluid They can be configured in any of the following ways e One single channel gun e Two single channel guns e One
109. sin Push Solvent Solvent Only Solyent 0 250 sec Air O Air 0 250 sec Time 5 000 sec Time 2 000 sec Time 5 000 sec LOAD SEQUENCE 1 Load to Flowmeter 2 High Flow 3 Low Flow Resin Flow Rate 35 ml min Flow Rate 200 ml min B Catalyst C Channel Use Analog Time 3 000 sec Time 2 000 sec Step 1 Allows the user to push the material currently in the fluid line with either solvent or air for a specified time period One or the other solvent or air must be selected If solvent is selected the following valves are opened e Resin MVR Valve e Resin MVR Enable Valve e Resin Solvent Valve e Dump Valve If air is selected to be used to push the paint in the initial step the following valves are opened e Resin MVR Valve e Resin MVR Enable Valve e Resin Air Valve e Dump Valve LN 9409 01 2 RansFlow 62 Color Change Sequencer Screen continued Color Change Sequence sj 1 2 Flush Sequence Time 15 00 sec Load Sequence Time 8 00 sec FLUSH SEQUENCE 1 Resin Push Solvent Solvent Only Solyent 0 250 sec Air O Air 0 250 sec Time 15 000 sec Time 2 000 Sec 2 High Flow 3 Low Flow Flow Rate 35 ml min Flow Rate 200 ml min Use Analog e Time 2 000 sec Step 2 Allows the user to push out the catalyst line with solvent if necessary If this step is set for 0 seconds it is skipped If this step is used the following valves are opened
110. st simply touch the middle Timer Start button Flow will start immediately and a signal will be sent from the trigger solenoid valve Make sure to open the applicator if it is not being controlled by the RansFlow s trigger valve or a flow too low fault will occur The unit will continue to flow for the amount of time programmed at which point the trigger valve will be closed and flow will be stopped During the flow process the Total Volume and the vol umes under channels A B and C or whatever channels are configured to the gun will be incremented based on pulses received from the appropriate flow meters If the materials are collected independently of each other from the calibration ports those values can be compared to the volumes that the software calculated as having been dispensed If any of the volumes are outside of acceptable limits the flow meter for that channel should be recalibrated An additional feature of this screen allows you to have the software calculate the actual ratio of the material s that were dispensed Simply touch the white box below the heading Parts A and enter what the target ratio for the master channel was The software will then automatically calculate the other component or other components ratios for easy compari son to the target Once again if any of the component s ratios are outside of acceptable limits recalibration of the flow meter or flow meters is recommended LN 9409 01 2 RansFlow 69 Tools S
111. the unit must be RESET e The unit must be placed back into RUN mode gt e The fault that occurred my be viewed on the Reports Screen LN 9409 01 2 RansFlow 78 Section 6 TROUBLESHOOTING POWER SUPPLY ISSUES There are two DC power supplies in the main control console one at 5 VDC and a 24 VDC both capable of 5 amps maximum Neither power supply is fused If a short in the electrical system does occur greater than 5 amps is sensed the power supply will shut down its output until that short is removed It may be necessary to cycle the AC power feed ing the power supplies to permit them to reset properly The photograph below shows the terminals on the power sup plies that can be used to verify output voltages with a voltmeter The AC power is fed into the bottom of the supplies L Hot and N Neutral The DC power exits the top of the supplies with the positive terminals marked with a plus sign and the ground terminals with a negative sign Note that both power supplies have voltage adjustment screws on them that are fac tory preset but can be readjusted if necessary If the 5 volt supply is not within 10 of 5 00 volts 4 95 to 5 05 it should be adjusted If the 24 volt supply is not within 10 of 24 volts 21 6 to 26 4 it should also be adjusted The larger 24 VDC power supply also has a Single Parallel switch that should be set on the Single position If no voltage is detected on the output of either supp
112. tional Remote Operator Panel uses Hall Effect switches and a magnet for operation This allows the ROP to be mounted outside the booth on a booth window and operated from inside the booth eliminating overspray contamination All I O including PID loop are updated 50 times second Extremely robust PID loop is factory tuned for nearly all setups LN 9409 01 2 RansFlow 19 SELECTION GUIDE CHANNELS SOLENOID VALVES REMOTE OPERATOR PANEL Channels 1 Channels 2 No Valves 0 No 0 Channels 3 10 Colors 1 Yes 1 A12410 X X X X X X OPERATION MODE MVR INLET PRESSURE CONTROL Non Intrinsically Safe 0 Intrinsically Safe 1 Fiber Optic 2 No 0 Yes 1 Manual 0 Automatic 1 Control Panel Configuration Part Number LN 9409 01 2 RansFlow 20 Section 3 INSTALLATION System Guidelines Installation Prints Drawings and information contained in this section of the manual is applicable to most installations However in some special cases ITW Ransburg may supply custom installation drawings for your specific site It is highly recommended that if your installation differs significantly from the installation drawings supplied by ITW Ransburg you notify your ITW Ransburg representative to insure that standard installation practices are not violated and to have your prints updated to reflect the installation accurately for future reference Typical fractional and metric installation prints can be found
113. to 24 VDC momentarily puts a halted non faulted gun in run active mode For remote selection of next job to be loaded See appen dix for recommended job load timing sequence For remote selection of next job to be loaded See appen dix for recommended job load timing sequence For remote selection of next job to be loaded See appen dix for recommended job load timing sequence For remote selection of next job to be loaded See appen dix for recommended job load timing sequence For remote selection of next job to be loaded See appen dix for recommended job load timing sequence Connecting this input to 24 VDC initiates the flush se quence 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC This output goes on once the load sequence is completed and the gun flush box es is are closed 24 VDC This output goes on when the gun faults 24 VDC For remote selection of next job to be loaded See appen dix for recommended job load timing sequence 0 10 This is an analog output programmed in the job parameters VDC intended to drive an E to P transducer to drive a fluid regu lator LN 9409 01 2 RansFlow 31 N name ne Dsm _ 22 Actual Flow Gun 1 Output 0 10 Analog indication of actual flow rate If Min Flow is pro VDC grammed at 0 ml s min and Max Flow is programmed at 1000 ml s min and 400 ml s min is flowing this output will be at 4 00 volts DC 23
114. ual channel guns are configurable as manual ratio control only or automatic flow and ratio control modes Configurable operating parameters for all channels and guns Up to 99 Jobs per Gun can be programmed Full color 6 5 LCD display with touchscreen for setup operation and diagnostics Pot life timer monitoring and alarming Wide range of ratio and flow capabilities Discrete I O capabilities allow interfacing to any manufacturer s PLC USB port allows backup of all operating parameters retrieval of flow totalization data and updating of user interface soft ware stored on flash drive USB flash drive size MUST be less than 4GB User interface software is Windows CE 5 0 based Retrofit option allows current EZ Flow 2k220 2k880 and DynaFlow customers upgrade their electronics and use their existing fluid components Extremely easy to program color change sequencer for flushing and loading can handle up to 10 colors and 3 different catalysts All discrete and analog inputs and outputs can be monitored and forced for diagnostic purposes Analog input capability for flow rate setpoints 0 10 VDC Convenient test points on I O boards make it simple to connect data acquisition hardware for process monitoring and fine tuning All discrete inputs and outputs optically isolated Gun flush box interface I O option is available Optional inlet pressure control allows users to program inlet fluid pressure to MVR valves Op
115. uipment SAFEGUARDS Follow These Guidelines Follow the requirements of the Material Safety Data Sheet supplied by the coating 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 com patible with the material being sprayed and its concen tration Equipment must be as prescribed by an indus trial hygienist or safety expert and be NIOSH ap proved Follow These Guidelines Applicator adjustments or maintenance should be done after the robot is taken out of service Do not adjust or repair the applicator if the robot is operating or standing ready to start Refer to robot operating instructions for the procedures to take a robot out of service Follow all OSHA Lockout Tagout procedures when performing any maintenance Follow These Guidelines Personnel must be given training in accordance with the requirements of NFPA 33 2009 Edition Instructions and safety precautions must understood prior to using this equipment Comply with appropriate codes governing ventilation fire protection operation maintenance and housekeep ing OSHA references are sections 1910 94 and 1910 107 Also refer to NFPA 33 2009 Edition and your insurance company requirements LN 9409 01 2 RansFlow 9 Section 2 INTRODUCTION the RansFlow precisely meters and mixes multi co
116. updating its software and for backing up parameter data The three PC 104 I O cards plug onto the back of the user interface PC and control all I O functions including interfacing with external control devices such as remote PLC s Ribbon cables connect the PC 104 cards to optically isolated interface boards to prevent harmful voltages etc from damaging the user interface P C There two DC power supplies housed in the main control console One is 24 VDC for all discrete I O signals and for the user interface P C The second supply provides 5 VDC for the optical isolator boards On the top of the main control console are three connectors for I O One is for a second gun 37 pins the second 50 pins for all system I O and the third is for the Remote Operator Panel 9 pins The E to P pressure transducers convert a 0 to 10 VDC signal from the channel cards to a proportional 0 to 100 psi air signal This signal is used to pilot the MVR flow control valves The Zener barriers make the flowmeter sensors intrinsically safe for use inside the spray area The air flow switches are used to sense when a handgun is triggered to prevent flow if a master channel flowmeter sticks The pressure switches are used to interface to the optional gun flush boxes to prevent flushing and loading of handguns when they are not in the flush box Fluid Panel The Fluid Panels contain all of the wetted components for the RansFlow These include
117. weer 8 77225 00 MX TUBE BRACKET N ewm t e P wm 5 O TUBE RETAINER EN 4 SsP 6443 ELBOW 3 8 ODT X 1 4 NPT F BRACKET FLOWMETER SIBI emm FITTING 2 41 FIC 1002 3 8 ODT X 1 4 NPT M l 85 6054 CONNECTOR 1 4 ODT X 1 8 NPT M D PART No DESCRIPTION 6 00 v m H 10 508 1956 BE ms ar 4 HH L H e e o iai lt IL 5 Ar aL ez JAIS a 06 Mr Nd s Seed et 71 J P du ETT Tr Ge _ Eu iw e err og GN zd H J T 3 XG o9 A om lt AA 4 100 S N L ey 610258981 D f J NEA 22 79 TABLE H 1 A12592 06 4 3 8 ODT TO 10MM CONVERSION 2 41 FTP 1055 3 NPT TO 4MM CONVERSION 3 A12593 04 3 4MM TO 6MM ODT CONVERSION FOR PANELS W SINGLE MVR ASSEMBLY REMOVE AND REPLACE FITTINGS AND INSTALL OTHER FITTINGS AS SHOWN FIGURE 1 2 REFERENCE TABLE H f REPLACE J Am EXISTING FITTING Jj N F h p A N FE LO BR PANELS WITH DUAL MVR ASSEMBLIES REMOVE AND REPLACE FITTINGS AND 2 3 INSTALL OTHER FITTINGS AS
118. y safe in booth mounting Non Intrinsically safe outside of booth LN 9409 01 2 RansFlow 12 MANUAL MODE examples Example A Manual Guns Example B Reciprocator Bells In Manual Mode the flow rate of the resin is controlled by the demand of the operator s or equipment and the RansFlow supplies the catalyst to maintain the desired ratio set point AUTOMATIC MODE example In Automatic Mode a single applicator is supplied and the RansFlow controls the ratio and flow rate to the applicator The robot can communicate directly with the RansFlow to control the fluid delivery rate with an analog signal Main Control Console The Main Control Console is the heart of the RansFlow System It houses the following items User interface computer incl LCD display and touchscreen PC 104 Interface cards 3 Optically isolated interface boards 20 Solenoid valves E to P transducers 1 to 6 DC Power supplies 2 Air Flow Switches 2 Power l O terminal strip LN 9409 01 2 RansFlow 13 Main Control Console continued e Pressure Switches for gun flush box interfacing e Optional zener barriers for intrinsically safe flowmeters e Optional fiberoptic interface modules for fiberoptic flowmeters The user interface computer is a AMD Geode based P C with a non volatile flash disk that contains a Windows CE 5 0 operating system and the RansFlow user interface software The computer has a USB port for

RansFlow - DeVilbiss

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