DynaFlow Operator Interface (Serv. Man. LN-9401
Contents
1. Figure 3 DynaFlow Sub Panel 77376 Version 26 DynaFlow Operator Interface Manual Parts Identification Ransburg DYNAFLOW PARTS LIST Figures 2 amp 3 ten s rate Descrption 77376 WXYZV DynaFlow Control Panel A10705 00 CPU Sub Assembl A11224 00 Power Supply Assembly 24 VDC A10577 XX Power Line Filter 4131 11 Fuse 3AG 3A 74300 00 Bulb 130 VAC 6 77454 00 Fiber Optic Receiver Assembl 73837 08 Intrinsic Safety Barrier 8 11382 00 Ribbon Cable Interface PARTS LIST REFERENCE TABLE W CHANNELS 6 CHAN2. Q EX ES 5 A Gy 0 o E pe 0 a go SIS n pa Hal co D LO bp SEI is Ol tate ei S bib u Sk S S 7 ast e m J B A 0 PAEAN z 6 S Hi a e m H K o o j 3 3 3 3 3 E 3 3 a B a E o 9 3 DEE Fe Ji AS E Bg U A lt z JI a d e 8 Z e EE 2 a 9 3 H jue Lj Figure 4 DynaFlow Door A12233 Version 29 LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Parts Identification DYNAFLOW DOOR PARTS LIST A12233 Version ten s Pare peseripiom 14 22 1108 Pilot Light Block 6 LSMEO004 00 Relay Socket 8 77384 00 Switch Mushroo
3. LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Toxic Substances Certain material may be harmfulif Follow the requirements ofthe Material S afety Data inhaled or if there is contact with Sheetsupplied by coating material manufacturer the skin Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a maskorrespirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equipmentmustbe as prescribed by an industrial hygienistor safety expert and be NIOSH approved LN 9401 00 5 4 DynaFlow Operator Interface Manual Introduction INTRODUCTION This manualis intended as a guide foroperators of the DynaFlow Fluid Flow Controller Model A12233 This manualis intended as a compliment to the DynaFlow User and DynaFlow Program mer s Manuals The detailed description of the operational parameters and system operation and or procedures is located in the User manual This manual specifically covers those items pertaining to the operation ofthe DynaF low control software when installed in the Ransburg O perator Interface Panelorfroma PC DESCRIPTION The DynaF low fluid flow control system achieves real time closed loop control through the use of CHANNELs and GUNs
4. 23 24 PARTS IDENTIFICATION 25 32 DYNAFLOW DOOR 77376 VERSION 25 DYNAFLOW SUB PANEL 77376 VER SION 26 REENEN 27 D NAPLOW SPARE PARTS SN en 28 DYNAFLOW DOOR A12233 VERSION PARTS LIST 29 30 DYNAFLOW INTERFACE PANEL 12177 PARTS LIST 3l WARRANTY POLICIES 33 UNITED WARRANT Y E NAF 33 APPENDIX 34 35 GG DICIS NERONE TR NOUO 34 RATIO CONVERSION CHART 35 LN 9401 00 5 DynaFlow Operator Interface Manual Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all ofthe technical and safety literature foryour Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this information we use the following symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that might cause serious injury if instructions are not followed A CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury A NOTE is information relevant to the procedure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant requirement
5. Replace the Interface Module and restore configurations and J OB data 4 PC portnotcommuni 4 Checkwiring and perform PC troubleshooting cating LCD Display l Display is blank 1 Press the display on off button below the display Floppy Disk Drive 1 Green light on the disk 1 ContactRansburg Service drive does notturn on when reading or writing to the drive or when booting the system 2 The disk drive light comes 2 Try a different disk on when attempting to read or write but data errors occur Touch Panel 1 Does notwork 1 ContactRansburgService Password 1 The passwordis not 1 ContactRansburg Service for instructions recognized orhas been forgotten GUN Faults or Errororfaults reported Refer to the help text on the screen and to current System Errors in the Error Log screen the DynaFlow Usermanual DynaF low Software Does notrun reports 1 ContactRansburg Service Windows error or C drive notrecognized LN 9401 00 5 24 DynaFlow Operator Interface Manual Parts Identification Ransburg PARTS IDENTIFICATION NA RK NE Z Pa PIN EN N 7 ES L SZ 1 a IT i F Ll Ll LL LI Fg Vd Vg Vg Fg Vg I LI S E GEIER Figure 2 DynaFlow Door 77376 Version 25 LN 9401 00 5 Ransburg LN 9401 00 5 DynaFlow Operator Interface Manual Parts Identification 000 000 000 000
6. The next logical data field is then selected CLEAR FAULTS Lower Case c Pressing this key will immediately clear any faults reported by the controller regardless ofthe current screen Ifthe faultresulted in the stoppage offluid then a GUN RUN signal is required to start flow again Enter the ERROR LOG screen to view the error that occurred Pot Life faults can only be cleared by evacuating the volume of fluid as determined bythe Mixed Volume parameterlocated in the GUN CONFIGURATION screen through the GUN or cycling power to the DynaFlow LN 9401 00 5 DynaFlow Operator Interface Manual Operation controller P ressing the ClearF aults key will silence thehorn When using a PC the corresponding key on the keyboard is lower case c Exit To Operating System The key followed by the F9 key or CTRL with F1 from the main screen will exit to the operating system From the touch screen simply push F 12 The password may be required PASSWORD OPERATION The password is required for editing any system or GUN configurations loading information from files editing J OB tables or forcing 1 0 A pop up screen will appear requesting the password when attempting to perform a password protected operation Once a password is entered correctly itwill notbe required again until the password timer has elapsed The password and password timer can be set in the SYSTEM CONFIGURATION screen The password timer starts after the last key
7. was in clean mode Keep in mind that if solvent air chop cycles are used this total will not be extremely accurate There is also anindependent value recorded for volumes used while in the calibrate mode Totals can also be reset on this screen except for the GRAND TOTALS This allows for a secure non resettable value for EPA reporting purposes Calibration Screen F8 The calibration procedure is a CHANNEL flow meter specific operation and must be performed on only one CHANNEL ata time The calibration screen offers a convenient means to verify or adjustthe flow meter pulses per liter P L setting based on actual measurements The procedure can be performed by one person and eliminates the need to do manual calculations Color Change F9 An optional color change sequencer may have been included with the controller Ifitwas included the F9 key will indicate as such If the F9 key is blank yoursystem does nothave this option The optional color change sequencer is a PLC like controller that performs the load flush and color change sequences that were programmed by the user from the color change setup screens Load LN 9401 00 5 DynaFlow Operator Interface Manual Operation andflush sequences andtimes are downloaded to this controller via Ethernet by the user interface P C every time a new J ob Numberis toggled into the respective gun Whenthis function is selected the operator is first prompted for the gun numbe
8. OB Number Flow Tolerance 96 Tolerance Volume Mixed Volume Flush Volume F3 SELECT JOB F4 EDIT JOB Mix Ratio Master Percentage Slave Percentage Flow Rate Setpoint Maximum Flow R ate Minimum Flow Rate PotLife Time Trigger Off Delay Trigger On Delay Master CHANNEL Regulator Type Slave CHANNEL Regulator Type Reverse Flow Volume Bar Chart Maximum Flow Rate Flow Rate Tolerance Time Master P ot Volume Slave Pot Volume Display Mode Master MVR High Pressure Master MVR Low Pressure Master Pulses Per Liter Master Deadband Master Proportional Gain Kp Master Integral Gain Ki Master Dirative Gain Kd Slave MVR High Pressure Slave MVR Low Pressure Slave Pulses Per Liter Slave Deadband Slave Proportional Gain Kp Slave Integral Gain Ki Slave Derivative Gain Kd LN 9401 00 5 Ransburg F5 DIGITAL ANALOG IO 1 DISCRETE DIGITAL GUN 1 0 INPUTS Trigger Gun Run Mode Halt Gun Clean Mode Spare Input TotalReset Total Hold Transparent Analog Hold Job GUN Mask Load Mode Enable Gun DynaFlow Operator Interface Manual Operation 2 ANALOG 1 0 INPUTS Flow Rate Set Point Spare Analog Input OUTPUTS Control Pressure Actual Flow R ate Forced Control Pressure Forced Actual Flow Rate Quad Driver 1 OK 12 bit Only Quad Driver 2 OK 12 bit Only Quad Driver 3 OK 12 bit Only 10 bitor 12 bit DAC OUTPUTS Ready Run Active Mode Faulted PotLife Alarm Clean Load C alibrate Mo
9. Rate SetPoint Calibration Actual Flow Rate Number of Pulses Received Calculated Volume Measured Volume Measured Weight Specific Gravity Calculated P ulses Liter Current P ulses Liter Ransburg F9 COLOR CHANGE FLUSH FILL Step Duration Resin Solvent Air Chop Resin Solvent Resin Air Paint Dump Valve Resin Fluid Override Trigger Solenoid Catalyst 1 CCV Catalyst 2CCV Catalyst 3CCV Catalyst Solvent Catalyst Fluid Override Run Halt Trigger Load Clean Catalyst Disable Chop Air Time Chop Solvent Time F11 ERROR LOG SCREEN MENU TREE NOTE ESC is availble from any menu or pop up box to return to the previous screen F1 CONFIG SYSTEM Enter Password F1 Modify Value F3 Change Password F5 Store Data F7 Read In All Files F8 Save To All Files F9 Read In File F10 Save To File F11 Error Log F2 CONFIG GUN Enter Password Select GUN F1 Modify Value F2 Previous GUN F3 Next GUN F5 Store Data F9 Read In File F10 Save To File F11 Error Log LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Operation F3 SELECT JOB F8 CALIBRATION PROC Enter Password Enter Password Select GUN Enter CHANNEL EnterJOB Enter OB F1 Modify Mode F4 EDIT JOB F2 StartCalibration Enter Password F3 Stop Calibration Select GUN F4 Fluid Load Enter OB F10 Save To File F1 Modify Value F11 Error Log F2 Next GUN F7 Save New Pulses Liter To F3 Next OB This One JOB F4 J OB Direc
10. hard drive will not be overwritten This includes any configuration J OB and Totals data previously saved You will be prompted for any additional information that is required It is recommended thatall configuration and OB data be saved to anUSB memory stick before upgrading software Message Box This is a small box located on some ofthe screens The information displayed in this box describes illegal data or configuration entry attempts made by the operator confirmation of a command or additional instructions Restoring the Windows XP Operating System Contact Ransburg Technical Service if the operating system should become corrupted A restore CD ROM can be made available LN 9401 00 5 18 DynaFlow Operator Interface Manual Operation Ransburg PARAMETER LOCATIONS The following lists the parameters associated with each screen F1 CONFIG SYSTEM Horn Code Channel Card 1 Verison Blowoff Time Channel Card 2 Version Password Timeout Channel Card 3 Version RIO Rack Address Channel Card 4 Version RIO Rack Size Interface Module Version RIO Starting Quarter User Interface Version RIO Baud Rate S ystem Time SIO Baud Rate S ystem Date SIO COM Port SelectLanguage F2 CONFIG GUN Channel Card 1 DIP SW1 Channel Card 2 DIP SW1 Channel Card 3 DIP SW1 Channel Card 4 DIP SW1 Interface Module DIP SW1 Interface Module DIP SW2 Mode Auto Manual No of CHANNELs Master CHANNEL Slave CHANNEL Clean CHANNELs Default
11. is established betweenthe Operator Interface assembly and the Interface Module located in the Eurocard rack assemblythrough which all information is passed If the system was ordered with the optional color change sequencer an Ethernet connection is established between the operator interface PC and the color change controller brain in the interface panel 412182 All ofthe actual fluid control and system interfacing is accomplished through the card rack compo nents The Operator Interface simply supplies a convenient means to view and modify configurations and data and to send manual operational commands Data can also be saved and retrieved through the Operator Interface The major components of the Operator Interface Assembly are Integral Touch Panel The touch panel provides a convenient method of interacting with the user interface The touch panel is chemically resistant and easy to clean Embedded PC Embedded computers are reduced size versions of the standard desktop computers This is done such that OEM suppliers can cost effectively include embed a computer typically performing a dedicated function into their design E m bedded P Cs conform to industry standards and run the same software and operating system that are used in standard desktop computers The DynaF low software for ex ample will operate the same on a desktop or industrial computer LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual
12. only during setup operations Production should neverbe done with safety interlocks disabled Neveruse equipmentintended for use in waterborne installations to spray solvent based materials The paint process and equipment should be set up and operated in accordance with NF P A 33 NEC and OSHA requirements LN 9401 00 5 2 DynaFlow Operator Interface Manual Safety AREA Tells where hazards may occur General Use and Maintenance Electrical E guipment Explosion Hazard Incompatible Materials HAZARD Tells whatthe hazard is Improperoperation ormaintenance may create a hazard P ersonnelmustbe properlytrained in the use of this eguipment High voltage eguipmentis utilized Arcing in areas of flammable or combustible materials may occur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequentpowersupply shut down indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explosion Halogenated hydrocarbon solvents for example methylene chloride and 1 1 1 Trichloroethane are not chemically compatible with the aluminum that might be used in many system components The chemicalreaction caused bythese solvents reacting with aluminum can become violentand lead to an equip
13. 3 12
14. A CHANNEL consists of an electrical to pneumatic E P transducer materialregulator andfluid flow metercombination through which a single material is controlled A GUN represents a single applicatorthrough which one or more materials are delivered One or more CHANNELs are configured for each GUN Two component delivery systems referred to as 2K systems have two CHANNELS assigned to a single GUN The materials are statically mixed before being delivered to the GUN This unit includes A standard rack assembly populated with an Interface Module and the appropriate number of Channel Cards e Fiber optic receivers or intrinsic safety bar riers for interfacing to the flow meters e Terminals and connectors for external con trol wiring An Operator Interface that includes an em bedded PC control software a 15 color display with integral touch screen The DynaF low control software is a PC program thatruns underthe Windows XP operating system Ransburg The software can be installed in the Operator Interface assembly or a standard PC running Windows 9X 2000 or XP The DynaF low controlsoftware supplies the means to monitor and command the delivery of single componentortwo componentfluids when used in conjunction with a rack mounted Interface Module and Channel Cards Reference the DynaFlow User manual for a detailed description of the DynaFlow system components and their relation to each other An RS 232 connection
15. FIGURE SYSTEM screen To stop cleaning press the GUN number again Push the ESC key to exitthe CLEAN MODE Guns in clean mode when this screen is exited will remain in clean mode until the GUN ON OFF button is pushed 16 DynaFlow Operator Interface Manual Operation NOTE The following is important to note when changing or entering data in the System Configuration GUN Configuration or Edit JOB screens Any modifications to data made in these screens will NOT take effect until the Store Data F5 key is pressed which causes the new data to be sentto the DynaFlow Interface Module and automatically saved to the FLASH drive If the ESC key is pressed first any changes will be lost when exiting the screen Each screen reads the data from the Interface Module upon entry to ensure that changes made by a PLC will be recognized by the DynaFlow program FILE 1 0 Saving Retrieving Data System configuration GUN configuration OB tables data and flow totals can be saved or retrieved to disk files Binary files VAL store the actual data and are the only type used to restore data The binary files may be saved to either the FLASH drive C or the floppy diskette drive A System configuration data SYSPAR VAL GUN configuration data GUNPAR VAL JOB tables PROGDATA VAL Totals TOTALS VAL The plotting screen is saved as a standard bitmap file MMDDhhmm BMP The plot file names are formed from the month MM d
16. Introduction USB Ports USB ports are provided SPECIFICATIONS that may be used to save or load data Power Input 100 240 VAC 1 6A 50 60 HZ LCD Display The LCD display is a 15 1024 X 768 pixel TFT active matrix color LCD Display 15 38 cm 1024 x 768 pixels display with a built in backlight colors Ultra wide viewing angle Interface Panel A12182 Contains the Sc AM color change seguencer controller E to P transducers zener barriers fiber optic re RS 232 Ports COM 1 attaches to the card rack ceiver solenoid valves etc necessary to Interface Module interface with the control components 19200 BAUD 8 data bits 1 stop bit no parity No handshaking The serial port is connected to J 8 on the card rack mother board as follows J 8 9 RS 232A Receive Rx J 8 10 RS 232A Transmit T x J 8 11 RS 232A Ground COM 2 Notused COM 3 Reserved for touch panel COM 4 Notused USB Ports Drives D E F etc Ethernet 10 100 BASE T Parallel Port Standard Video Port Standard DIO Port Notused NOTE Theembedded CPU board and inter connecting cable assemblies are subject to change LN 9401 00 5 6 DynaFlow Operator Interface Manual Installation INSTALLATION REFER ALSO TO THE DYNAFLOW USER MANUAL INPUT POWER Inputsupply voltage connections should be made from a FUSED DISCONNECT Generally conduit should be used for the input power wiring with the appropriate connectors into th
17. NEL 8 CHANNEL PARTS LIST REFERENCE TABLE Y Allen Bradley RIO z RO PARTS LIST REFERENCE TABLE V Voltage Dash No Description 0 esae v 27 PARTS LIST REFERENCE TABLE X E P Interface None Automatic Applications Interface Connections Manual GUN Applications PARTS LIST REFERENCE TABLE Z Flow Meter Interface Intrinsic Safety Barrier LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Parts Identification The following DynaF low spare parts lists DO NOT include auxiliary fluid control monitoring equipment such as pneumatic interface panels fluid panels transducer panels etc The spare parts lists for the auxiliary equipmentshould be derived from previous fluid control lists since their usage and requirements are the same DYNAFLOW SPARE PARTS LIST Total of Consoles of Consoles Part No Description p mron ovation eee eue lolo r a Na nn DEER EES r 3 tuens mene oi po poi emm CT oo UU KG LT I i nr REC dani 4300 00 mmuowc Z 3 Ja 2 1 ana ruwe saesae Jo Ta 2 LN 9401 00 5 28 DynaFlow Operator Interface Manual Parts Identification Ransburg
18. Ransburg SERVICE MANUAL LN 9401 00 5 Replaces LN 9401 00 4 March 2012 DYNAFLOW OPERATOR INTERFACE MANUAL TU Ransburg cc gt MODEL 77376 and A12233 IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 50 00 U S Ransburg NOTE This manual has been changed from revision LN 9401 00 4 to revision LN 9401 00 5 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Contents CONTENTS PAGE SAFETY 1 4 SAREE je EE 1 HAZARDS SAFEGUAR DS 2 4 INTRODUCTION 5 6 reda M 5 6 SEET 6 INSTALLATION 7 12 Diano 7 INTRINSICALLY SAFE FLOWMETERS tte 7 SYSTEM CONNECTIONS geet mi tetes 7 WIRING FOR INTRINSICALLY SAFE FLOWMETERS A12233 8 WIRING FOR INTRINSICALLY SAFE FLOW METERS 77376 9 SYSTEM CONNECTIONS 77376 10 INPUT POWER SCHEMATIC ttti YY NU 11 OPERATION 13 22 GENERA MMC cM 13 KETONG NON ee 13 14 PASSWORD OPERATION 14 15 ne 16 17 SIE EE 17 INSTALLING UP DATING SOFTWARE 18 PARAMETERLOCATIONS EE 19 21 SCREEN MENU TREE ttti HWNNW W 21 22 MAINTENANCE 23 24 TROUBLESHOOTING TROUBLESHOOTING GUIDE
19. S SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any partnumberending in R forwhich 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 PLAS TIC SHRINK WRAP ETC WILL VOID THIS WARRANTY 33 RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATER IALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this partwas improperly installed operated or maintained Ransburg will assume no responsibility for repair orreplacementofthe item oritems The purchaser therefore willassume all responsibility for any cost of repairorreplacementand service related costs if applicable LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Appendix CONVERSIONS From ro Multiply From ro Muitiply Volume e M Weight uen ang Galons US Gelon mp E mu fovens US iter la Le
20. ata will also be accepted when a cursorkey is pressed HOME Pressing this key will return the editing cursor to the first data field in the screen LN 9401 00 5 Ransburg LOAD Backspace The LOAD key causes a small pop up box to appear in the current screen Any GUN can be manually placed in LOAD MODE by simply pressing the number for the desired GUN on the numeric portion of the keypad The LOAD MODE is deactivated by pressing the GUN number again This is the same as supplying an external GUN LOAD and GUN HALT inputsignals When using a PC the corresponding key on the keyboard is the backspace key CLEAN Space Bar The CLEAN key causes a small pop up box to appear in the current screen Any GUN can be manually placed in CLEAN MODE by simply pressing the number for the desired GUN on the numeric portion ofthe keypad The CLEAN MODE is deactivated by pressingthe GUN numberagain This is the same as supplying an external GUN CLEAN or GUN HALT inputsignal When using a PC the corresponding key on the keyboard is the space key HELP Lower Case L The HELP key can be pressed at any time It will provide more detailed help for the current active screen In addition there is troubleshoot ing information also available through the HELP screens When using a PC the corresponding key on the keyboard is lower case L ENTER Edited information in the currently selected data field is accepted when the ENTER key is pressed
21. ay DD hour hh and minute mm when the plotwas saved When saving a plot file note the date and time in a log detailing what was plotted Ransburg Data for all GUNs or all JOBs are saved automatically regardless of the specific GUN or JOB being viewed or edited Forexample to save all OB tables for all GUNs simply enter the J OB EDIT screen for any GUN any J OB and press the Save To File key The same is true for recalling data from previously saved files To completely save all configuration and totals data From the CONFIG SYSTEM screen press the Save To File key From the CONFIG GUN screen select any GUN press the Save To File key From the EDIT J OB screen select any GUN and any JOB press the Save To File key e From the TOTALS screen press the Save ToFile key To recall all previously saved configurations From the CONFIG SYSTEM screen press the Read In File key From the CONFIG GUN screen select any GUN press the Read In File key From the EDIT J OB screen select any GUN and any J OB press the Read In File key From the TOTALS screen press the Read In File key LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Operation INSTALLING UPDATING NOTES SOFTWARE Installing New Software To install or upgrade the DynaFlow software follow the directions included with the media Any previously stored data sets and or configurations located on the
22. d parameter and press the SELECT F1 softkey to selectthat parameter P ushing F 1 again will remove the parameter Each selected parameter will be displayed in a small box at the lower left of the setup screen along with the color assigned to that parameter Once the desired parameters are selected then press the PLOT softkey to startthe plotting screen The operator can then choose to scroll the plot continuously freeze or stop the plot or save the screen to a compressed bit mapped file The compressed file can then be LN 9401 00 5 Ransburg converted to a standard BMP file by using the utility called decomp exe located onthe DynaF low software Disk or on drive C of the DynaFlow controller Simply type decomp followed by the name of the saved file Job Totals F7 The Job Totals screen allows users to monitor material usage Values are stored according to the J ob number so if each material being sprayed is assigned its own Job number totals will be recorded for each material sprayed There are two values stored for each material and each job andare known as a Daily Total and a Yearto Date total These totals are not related to the clock or calendar in any way they are simply two totals that can be resetindependent of each other For instance one may be used Tora batch ofparts total and the other may be used as a shift total etc Separate totals are also maintained for Clean mode how much material flowed while the unit
23. d the Windows XP operating system Power OFF All analog and control outputs to the fluid system are removed if power is turned off to the card rack This means that fluid flow will be immediately stopped for all CHANNELs An Emergency Stop should be supplied for this purpose The stand alone DynaFlow panel incorporates an E Stop frontpanelswitch with an additional unused setof normally open and normally closed contacts for use by the customer to interlock other system functions The Emergency Stop switch does notremove AC powerfromthe touch panelP C The green On Off switch removes AC power to the 24VDC power supply and the touch panel PC Ransburg KEY FUNCTIONS ESC This key is used to exit any active screen or pop up box F1 F12 Function Keys F1 through F12 are soft keys The function of these keys will change depending on which screen is active The description for each key is shown in boxes on the bottom of the display GUN 1 GUN 8 ON OFF These keys allow manual activation and deactivation of each GUN Pressing a GUN ON OFF button is the same as supplying an external GUN RUN or GUN HALT input signal When using a PC the corresponding keys on the keyboard are all lower case GUN 1 a GUN 2 S GUN 3 d GUN 4 f GUN 5 g GUN 6 h GUN 7 j GUN 8 k CURSOR Arrow Keys The cursor keys allow the operator to move to a data field for editing or to a command field In addition to pressing the ENTER key edited d
24. de MVR Enable 4 DISCRETE REMOTE 1 0 INPUTS Trigger Gun Run Mode Transparent Total Hold Halt Gun Total Reset Clean Mode Load Mode OUTPUTS Ready Run Active Mode Faulted PotLife Alarm Clean Mode Load Mode Calibrate Mode MVR Enable LN 9401 00 5 3 DISCRETE AND REMOTE SYSTEM 1 0 INPUTS JOB 001 JOB 002 JOB 004 JOB 008 JOB 010 JOB 020 JOB 040 JOB 080 JOB 100 JOB Strobe JOB Decimal System Ready Global GUN Enable RIO System Halt RIO Fault Reset RIO Global GUN Enable OUTPUTS System Fault System Pulse System Spare 5 BTW BTR REMOTE I O BUFFER Display Hex Decimal BTW BTR BTW BTR Data Type Null Operational Gun Configuration J ob Configuration S ystem Configuration Flow Totals S ystem Alarms Calibration Lookup Table Help 20 DynaFlow Operator Interface Manual Operation F6 F7 F8 21 PLOT DATA Trigger Requested Ratio Actual Ratio Requested Flow Rate Actual Flow Rate Master Requested Flow Rate Master Actual Flow Rate Master Control Pressure Slave Requested Flow Rate Slave Actual Flow Rate Slave Control Pressure JOB FLOW TOTALS FLOW TOTALS PER JOB Daily Volume Integral of Absolute Value IABS of Error Volume Year To Date Volume Calibrate Volume Grand Total Volume FLOW TOTALS FOR ALL JOBS Daily Volume Year To Date Volume Calibrate Volume Clean Volume Grand Total Volume CALIBRATE PROCEDURE Mode Calibration Time Calibration Flow
25. e Control Panel If there are large AC line voltage fluctuations or voltage transients such as those typically produced by heavy electric machinery orwelding equipment then a constant voltage transformer CVT or an UPS should be used between the FUSED DIS CONNECT and the Control Panel NOTE gt Ifa constant voltage transformer CVT is to be used on the input to the Control Panel use a CVT with a VoltAmp VA out put rating equal to or greater than the output voltage multiplied by the control panel fuse rating Also make sure that the CVT input ratings correspond with the voltage and fre quency of the source supplied by the FUSED DISCONNECT The CVT output should be rated for 240 VAC maximum The pilot light socket located in the power switch that is located on the door is rated for 120 VAC and must be changed if 240 VAC input power is used The appropriate power line filter must be specified or operation at either 115 or 230 VAC Ransburg INTRINSICALLY FLOWMETERS Refer to Figures 1a and 1b SYSTEM CONNECTIONS SAFE GUN Control 1 0 All GUN specific control wiring to the control rack is terminated at the ribbon cable to discrete converter blocks TB1 TB4 located on the rear panel of the DynaFlow enclosure refer to Figure 1c For DynaFlow panels configured for use with the remote electrical to pneumaticinterface panels the GUN control wiring is supplied to circular connectors located on the top
26. e hazard is Tells how to avoid the hazard may occur Spray Area Fire Hazard Fire extinguishing equipment must be presentin the spray area and tested periodically Improperorinadequate opera tion and maintenance procedures will Spray areas must be kept clean to prevent the cause a fire hazard accumulation of combustible residues Protection against inadvertent 5moking must never be allowed in the spray area arcing that is capable of causing fireorexplosionis lostifany safety The high voltage supplied to the atomizer must be interlocks are disabled during turned off priorto cleaning flushing or maintenance operation Frequentpowersupply shutdown indicates a problem in When using solvents for cleaning the system requiring correction Those usedforequipmentflushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100 F 37 8 C Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA and local codes In addition ventilation must be main tained during cleaning operations using flammable orcombust ible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high voltage to be on butonly as instructed Non factory replacement parts or unauthorized equipment modifications may cause fire or injury Ifused the key switch bypass is intended for use
27. ed The main screen indicates the current OB which was loaded atthe time of the last GUN RUN command Edit JOB Screen F4 While in the EDIT JOBS screen a selected parameter for the current OB may be copied to any number of other OBs or the entire J OB table can be copied to other selected GUNs and J OBs This is accomplished by selecting the COPY PARAMETER and COPY J OB softkeys S electing either soft key will cause a pop up screen to appear The operator will be prompted to enterthe requested range for GUNs and J OBs Digital Analog 1 0 Screens F5 Allows the operator to view the status of system and GUN specific inputs and outputs as well as monitoring RIO PLC signals The operator can also force input and output states for trouble shooting purposes Plotting Screen F6 Provides a convenient means to graphically monitor operational data with respect to time similar to a data logging or charting device This feature supplies the operator with fluid flow and related response information in order to evaluate the system or set up the control parameters for optimum performance There are four parameters that can be selected for plotting Each parameter is automatically given a unique color and is displayed with it s own corresponding scale and description Allofthe possible plotting parameters are shown in the setup screen for each configured GUN The operator can select any of the parameters forany ofthe GUNs Touch the desire
28. elhas beentested with Isopropyl Alcohol Butyl Acetate Methyl E thyl Keystone and Xylene use of solvents to clean the surface should be minimized Hint Ifinstalled in a harsh environmentwhere dirt or paint can accumulate a sheet of clear plastic can be taped over the entire display For maintenance of system components other than the DynaFlow control panel refer to the appropriate manual or contact Ransburg Customer Service 23 Ransburg TROUBLESHOOTING The Troubleshooting Guide lists possible problems associated with the Operator Interface only Reference the DynaFlow User manual for additionaltroubleshooting information notspecific to the Operator Interface assembly NOTE Fluid flow control is not dependent on the Operator Interface being active The system will operate and control fluid based on the last settings entered and the state ofthe hardware digital and or analog 1 0 LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Maintenance TROUBLESHOOTING GUIDE preo ler ECS Serial Communication 1 Connected o wrong serial 1 The PC should be connected to the Interface port Module serial port 2 8 9 Rx J 8 10 TX J8 11 GND 2 Wiring to serial port 2 Check wiring to serial port incorrect 3 Interface Module not 3 Observe the lights located on the front of the communicating Interface Module If they are all flashing slowly or indicate red a problem with the Interface Module exists
29. ersions of the user interface software this bargraph hastwo new options Mixed Volume and PotLife The bar graph can be configured in the Config Gun Screen under the Display Mode parameter The Mixed Volume option gives a graphical representation of the amount of mixed material in the tubing running from the spiral mix tube to the applicator The PotLife option gives a graphical representation of the age of the oldest mixed material which is the material in the applicator at any point in time Configure System Screen F1 Contains system parameters that are not GUN or J OB specific The firmware versions and DIP switch settings of the Interface Module and Channel Cards are displayed in this screen The date and time may be changed in this screen Configure GUN Screen F2 Contains parameters thateffecta GUN regardless of the J OB The GUN configuration parameters should not be changed if the GUN is active If a CHANNEL is to bereassignedto a different GUN then itmustfirstbe removed from any other GUN Load JOB F3 Simply allows the operator to selectthe next OB fora GUN The selected OB is placed ina queue forthe selected GUN The new OB will be loaded at the next GUN RUN signal following a GUN HALT signal A GUN can be halted by pressing the GUN ON OFF key or supplying the GUN 15 Ransburg HALT RESET hardware input If the GUN is already in the halted state ready then no additional HALT signalis requir
30. escription 3 Revised Specifications 4 New Figure 1a Wiring for Intrinsically S afe Flow Meters 77376 5 New Figure 1b Wiring for Intrinsically S afe Flow Meters A12233 Version 6 New Figure 1c System Connections 77376 7 Added Figure 1d Input Power Schematic Operation Section 8 Revised Screens Main Screen 9 Added J ob Totals in Screens 10 Added Color Change in Screens 11 Removed Operating the DynaF low Software from a PC 12 Revised Parameter Locations 13 Revised Screen Menu Tree 14 Added Figure 4 DynaFlow Door A12233 Version 15 Added Figure 5 DynaFlow Sub Panel A12233 Version 16 Removed Appendix Paint and Solvent S pecifications Viscosity Conversion Charts and Volumetric Content of Hose or Tube English and Metric Units Service Manual Price 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 www itwransburg com Technical S ervice Assistance Automotive Assembly and Tier I Telephone 800 626 3565 Fax 419 470 2040 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts ENN 2012 Ransburg All rights reserved Models and specifications subject to change without notice SITA vi Form No LN 9401 00 5 p Litho in U S A wd 0
31. m Head E Stop Red 9 LSMEO006 00 Contact Block Normally Close Channel Card DynaFlow Voltage Output Onl 71382 00 64 Pin Ribbon Cable to Discrete Breakout Board LN 9401 00 5 30 DynaFlow Operator Interface Manual Parts Identification Ransburg Figure 5 DynaFlow Interface Panel A12177 Version DYNAFLOW INTERFACE PANEL PARTS LIST A12177 Version ten s rake Descrpion Output Module Lt ALTO Output Module Power Supply 5 VDC 24 VOD Used with CC Sequencer Power Supply 24 VDC Only Used without CC Sequencer 4 2230185 Power Fer 6 TR SSEH 519 39g Relay Socket 8 41 VSO 1005 Solenoid Valve 24 VDC Coil 9 A12720 00 Fiber Optic Receiver I O A10785 00 Color Change Sequencer Brain 31 LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Parts Identification NOTES LN 9401 00 5 32 DynaFlow Operator Interface Manual Warranty Policies Ransburg WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace orrepairwithoutcharge any partand orequipmentthatfalls within the specified time see below because of faulty workmanship ormaterial provided thatthe equipmenthas been used and maintained in accordance with Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANS BURG APPROVED PARTS VOIDS ALL WARRANTIE
32. mentexplosion Ransburg SAFEGUARDS Tells how to avoid the hazard Personnel mustbe given training in accordance with the requirements of NF P A 33 Instructions and safety precautions mustbe read and understood priorto using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping R eference OSHA NFPA 33 and yourinsurance company requirements The power supply optional remote control cabinet and all other electrical equipment must be located outside Class I or Il Division 1 and 2 hazardous areas Referto NFPA 33 Turn the power supply OFF before working on the equipment Testonly in areas free of flammable or combustible material Testing may require high voltage to be on butonly as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance Aluminum is widely used in other spray application equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents mustneverbe 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 contactyour material supplier Any other type ofsolventmay be used with aluminum equipment
33. ngth eedd EE T lm Velocity r Nen jema Wie NIH mu ep aaa E EE NI ULE CA Ec ft cl 1na mu were GH ns E SqureYaris SwareMetes E Pressure a Lc CU Jam Flow dem Inches Water PSI 03613 O Gals laneneeskec 0000880 m E cubicFeetsec CubicMetrssec 02517 Temperature tesWow cucreem em nus x riw LN 9401 00 5 34 DynaFlow Operator Interface Manual Appendix Ransburg RATIO CONVERSION CHART Total Volume 1 Part Catalyst 1 WEE ag E 0 JN T 0 Formula for converting percentage of catalyst to parts of resin 100 1 Parts Resin to 1 Part Catalyst of Catalyst d Example 596 catalyst is specified 1009 x 1 20 Parts Resin to 1 Part Catalyst 0 Formula for converting parts to percentage 100 of Catalyst Parts Resin 1 a y Example If a ratio setting is 13 13 parts resin to 1 part catalyst and I wantto know what percentage of the total mixed material is resin and what percentage is catalyst 100 7 149 talyst 13 1 7 1496 Catalys 100 7 14 92 86 Resin 35 LN 9401 00 5 Ransburg MANUAL CHANGE SUMMARY This manual was published to replace Service Manual LN 9401 00 4 DynaFlow Operator Interface to make the following changes 1 Added Model A12233 to Front Cover Introduction Section 2 Revised D
34. of the panel The GUN control I O is ignored for any Slave catalyst CHANNELs Therefore connections need only be made to CHANNELS configured as Master CHANNELs Interface Panels There are up to eight circular connectors located on top of the DynaFlow Control P anel depending on the number of CHANNE Ls These are labeled GUN 1 GUN 8 For two component GUN s Since all of the interface wiring necessary for a two component GUN is supplied through a single cable to the LBAL5001 Interface Panel connection for a two component GUN must be made to the odd numbered GUN connectors 1 3 5 or 7 For single component GUN s Simply connect each GUN in order GUN 1 to connector 1 etc System and Power 1 0 All system control 1 0 AC and DC power connections are made at terminal blocks comprising TB5 refer to F igure 1c LN 9401 00 5 DynaFlow Operator Interface Manual Installation Ransburg Figure 1a Wiring for Intrinsically Safe Flowmeters 77376 LN 9401 00 5 DynaFlow Operator Interface Manual Installation Ransburg NOTE K Forthe A12233 version of the D ynaF low the zener barriers are housed inthe A12182 interface panel Figure 1b Wiring for Intrinsically Safe Flow Meters A12233 Version 9 LN 9401 00 5 Ransbu
35. r they wish to view or editthe sequence for they are then prompted for which J ob Numberthey wish to view and or editthe sequences of and last they are asked if they wantto view edit the sequence for flushing or filling There is a separate flush sequence and load sequence stored for every ob Number and for every gun Error Log Screen F11 This screen displays the previous 10 system errors or GUN faults thathave occurred For each of the errors the error code and descriptive text will indicate the GUN and specific type of error Errors can be cleared from the screen by pressing the F7 key The actual fault condition can only be cleared by pressing the CLEAR FAULTS key or supplying a GUN HALT hardware input Load GUN To manually place a GUN in LOAD MODE from the PC interface push the LOAD key A small pop up box will appear in the upper left corner of the currentscreen Simply push the numberofthe GUN to immediately start loading fluid for the selected GUN The number selected willappearin the pop up box To stop loading a GUN press the GUN number again Push the ESC key to exit the LOAD MODE Clean GUN To manually place a GUN in CLEAN MODE from the PC interface push the CLEAN key A small pop up box will appear in the upper left corner of the currentscreen S imply push the number of the GUN to immediately startcleaning forthe selected GUN Each CHANNEL assigned to a GUN can be selected as a clean CHANNEL in the CON
36. rg DynaFlow Operator Interface Manual Installation un a z Lo gt in TB1 TB2 TB3 TB4 CHANNEL 1 3 5 7 C Figure 1c System Connections 77376 LN 9401 00 5 10 DynaFlow Operator Interface Manual Installation ile x De E T1211 AC POWER CN1241 Figure 1d Input Power Schematic 11 Ransburg LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Installation NOTES LN 9401 00 5 12 DynaFlow Operator Interface Manual Operation 13 OPERATION GENERAL The Operator Interface was designed to be user friendly and to supply all of the necessary information for the operation of the DynaFlow control directly to the operator Most information located in the manuals regarding the operation of the DynaFlow systemis available directly through the Operator Interface All ofthe screens offer on line descriptive information and help text that includes troubleshooting Graphic information is also displayed fora quick determination of system performance Power ON When power is first applied to the DynaFlow system the Interface and any installed Channel Cards located in the card rackimmediately perform initialization and place all GU Ns in the ready state assuming valid configurations and successful self tests The Interface Module will determine which Channel Cards are installed and that they are communicating properly The P C upon application of power will loa
37. s material delivery requirements etc make such variations inevitable Compare this manual with your system installation drawings and appropriate Ransburg equipment manuals to reconcile such differences Careful study and continued use ofthis manual will provide a better understanding of the equipment and process resulting in more efficientoperation longer trouble free service and faster easier troubleshooting If you do nothave the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg Ransburg AWARNING The user MUST read and be familiar with the S afety Section in this manual and the Ransburg safety literature therein identified This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment S pecial care should be taken to ensure that the WARNINGS and safety require ments 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 prior to installing operating and or servicing this equipment AWARNING K The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 LN 9401 00 5 Ransburg DynaFlow Operator Interface Manual Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what th
38. stroke is sensed Every additional keystroke before the password timer elapses resets the timer This makes it convenient for an operator to change multiple parameters without having to continually reenter the password In the eventthat the password is lost or is not recognized by the controller contact Ransburg Service Entering a 0 for the password will disable password protection SCREENS Main Screen The appearance of the main screen will be determined by the numberofCHANNE Ls installed and the GUN configurations GUN faults may also be cleared from this screen If the GUN configuration is changed then the main screen will automatically reflectthe changes when the operator returns to the main screen Each GUN is shown in a box with the assigned CHANNEL S Relevant operational information is also shown in the GUN box such as GUN mode GUN status requested flow rate actual flow rate and flow tolerance error The actual flow and tolerance are also shown in bar graph form 14 DynaFlow Operator Interface Manual Operation The flow bar graphs are color coded as follows Green Normal Flow Red Reverse Flow White Flow During Clean Solvent Cyan Flow During Load Material Yellow Flow During Pot Life Alarm Blue Flow In the Ready State Tolerance Bargraph The far left ba rgraph of a dual componentgun on the main screen has traditionally been used to display ratio tolerance With version 4 0 05 and later v
39. tory F8 Save New Pulses Liter To All F5 Store Data EHE 1 F6 Lookup Talbe TOF RO F7 Copy Parameter F8 Copy J ob F11 ERROR LOG F9 Read In File Clear Faults F10 Save To File Clear Log F11 Error Log Save To File Help F6 PLOT DATA F1 Select Variable F12 SHUT DOWN F2 Plot Variable s 1 Yes F1 Time 90 45 Seconds 2 No F2 Single Plot Scroll Plot F3 Stop Plot Start Plot F5 Start Time Cursorq F6 Start Time Cursor 3 F7 Stop Time Cursorq F8 Stop Time Cursor g F10 Save To Plot F11 Error Log F3 Clear AI Variables F11 Error Log F7 JOB FLOW TOTALS Enter Password Enter OB F1 ResetTotal F2 Reset CHANNEL F3 Reset GUN F4 ResetAll F5 Previous JOB F6 Select OB F7 NextJOB F8 Toggle Units F9 Read In file F10SaveToFile F11 Error Log LN 9401 00 5 22 DynaFlow Operator Interface Manual Maintenance MAINTENANCE There is no maintenance schedule for control panels otherthan good housekeeping practices These include 1 Keeping the door closed at all times This will maintain the dust tight environment re quired by the electronic printed circuit boards 2 Plug all unused access holes into the cabi net in order to keep contamination out 3 Usethe following guidelines for cleaning the Operator Interface Use cleaning solution specifically formulated forcomputer monitors a mild window cleaner or isopropyl alcohol Most importantly use a clean softpaper towel or tissue and use very light force Thetouch pan
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