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MODEL: 77376 and A12233 DYNAFLOWTM USER MANUAL

1. AIR SUPPLY AIR SUPPLY PILOT SIGNAL PILOT SIGNAL cel FLUID REGULATOR FLUID REGULATOR FLOW METER FLOW METER d L FLUID SUPPLY FLUID SUPPLY CALIBRATION CALIBRATION CHECKVALVE CHECK VALVE im CHANNEL 3 Ransburg CHANNEL 4 MIX TUBE E P TRANSDUCER AIR SUPPLY PILOT SIGNAL FLUID REGULATOR FLUID SUPPLY ANALOG CONTROL SIGNAL FLOW METER FEEDBACK CALIBRATION CHECKVALVE ANALOG CONTROL SIGNAL FLOW METER FEEDBACK E P TRANSDUCER AIR SUPPLY PILOT SIGNAL FLUID REGULATOR L FLUID SUPPLY CALIBRATION gt CHECK VALVE Y BLOCK MIX TUBE APPLICATOR Figure 3b Block Diagram for a Three Component Gun 18 LN 9400 00 9 Ransburg INPUT POWER Input supply voltage connections should be made from a FUSED DISCONNECT that is located in an accessible area near the Control Enclosure Electrical conduit is recommended for the input power wiring Use 3 cond 14 ga wire for incom ing AC power supply If using SO type portable cord a strain relief rated for the diameter of cord being used is reguired for protection against cord abrasion and damage The protective ground conductor must be termi nated directly to the protective conductor ground terminallocated inside the Control Enclosure whic
2. te Mb 87 WARRANTYPOLICIES yB LIMITED AW ARF AN TY ee RR o YE NG nd 88 Continued Next Page LN 9400 00 9 DynaFlow User Manual Contents Ra n sbu rg CONTENTS Cont PAGE APPENDIX 89 93 ADDENDUM AU 89 90 ADDENDUM E aiii ienien dient Cd GO GG 91 92 8 93 LN 9400 00 9 Ransburg SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety litera ture for your Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EOUIPMENT PROBLEMS To help you recognize this informa tion 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 avoidasituation that might cause minor injury A NOTE is information relevant to the proce dure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant requirements material delivery requireme
3. 935 450 491 INTERFACE MODULE OVA 1081 03 old HO G8P SM d dNl TOMINOO O 21419395 13NNYHO Qld 21410345 W31SAS W3ISAS 531891 Alddns u44MOd Od i 2 09 05 OvOZZ OLL Figure 1 Block Diagram LN 9400 00 9 10 Ransburg DYNAFLOW SPECIFICATIONS Pneumatic Reguirements Transducers The air supplied to the trans ducers must be clean and dry and meet the following general specifications Filtration 20 Micron Supply Pressure 90 PSIG min to 150 PSIG max Volume 0 04 to 0 13 Cv Operating Temperature 32 to 150 F 0 to 65 5 Control Rack Up to 8 Channels Per 1 2 of 19 Rack 83mm H X 250mm W X 184mm D standard half rack Dimensions Power Requirements 24 VDC at 1 Amp typical all 8 installed The following must be followed if the flow control rack and or Operator Interface is to be integrated into a larger system control panel The 24 VDC Power Supply must be located in the same control panel as the fluid flow control DO NOT use a central power supply located else where The power supplies may be sized for and used for other controls within the same cabinet WITH THE EXCEPTION OF HIGH VOLT AGE POWER SUPPLY CONTROLLERS High voltage power supply controllers MUST have a dedicated power supply
4. operations or communi cations Reverse Flow Limits Explanation The controller has sensed that mate rial has flowed backwards through a flow meter and exceeded the preset REVERSE FLOW LIMIT value for that CHANNEL There are several pos sible causes for this 1 The check valve for one of the CHANNELs has failed in the open condition and the oppo site CHANNEL material is at a higher pressure causing the material to back up into the other paint line Corrective Action The system must be flushed immediately and the faulty check valve replaced 2 Sometimes this error can be generated 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 a shift This is probably due to pressure trapped in the line between the fluid regulator and the applicator This pressure could eventually back up through the flow meter and through the weep port if using a weeping type MVR valve or through a small leak in the system Corrective Action Make sure that the applicator stays triggered ON for several seconds after it has been taken out of a CLEAN mode in order to relieve the pressure 3 If operating the GUN for the first time the feed backsignals could be reversed fromthe flow meter Ransburg Corrective Action Verify that the source and gate signals are routed correctly This includes the fiber optic cable con nections at both the flow meter and receiver and wiring connec
5. LN 9400 00 9 23 DynaFlow User Manual Installation Ra nsbur Control Rack Wiring Reference page 82 for terminal identification o gt LI o gt Uu CN e t t 21 m o ad Lu vem pt SULCIS NI TUI L O k O IO A ESSE Sig gt BD y AD Gs B 2 bd tec sd ox 9 8 2 E c8 EET Fw E 2 5 56 6 lt 4 9 6 OFN DX un BCD JOB NUMBER INPUTS m 5 y p 2 5 _ iJ o g 5 5 5 Ls lt t oo o zn s 005202025 6 5 5 8 gt _ gt n Ej gt x og E o E me 1O 0 9 8 pns 1 8 8 gt z m x YY Yow gt O er ac 2524 a o L m zz La 4p oo x 5 a Gen gt M m 8 8 5 8 8 8 lt 8 lt T lt o o E 2 4 o LJ o o oo n E E 8 5 8 8 oe Dy ooo0 0000000000000 0O v a a B
6. FactorySetting Open JMP3 Rate Setpoint Ch B 0 10 VDC Open Closed 4 20 mA Closed JMP2 Spare Input Ch A 0 10 VDC Open Closed 4 20 mA 7 O oan 4 Spare Input Ch B Analog Outputs JMP5 Control Pressure Ch A JMP6 Actual Flow Ch A JMP7 Control Pressure Ch 0 10 VvDC Open Closed X Pin 1 2 Pin 2 3 FactorySetting 0 10 voc x 4 20 mA Closed Open 0 10 Closed 4 20 mA Closed Open 0 10 VDC Open Cosa X 4 20 mA Closed Open JMP8 Flow Ch B 0 10 VDC Open Closed emer Oven Discrete Digital Inputs 9 Trigger Ch A Run Mode Ch A Transparent Mode Ch A Total Hold Ch A JMP10 Gun Mask Ch A Halt Ch A Total Reset Ch A Clean Mode Ch A JMP11 Load Mode Ch A Analog Hold Ch A External Fault Ch A Spare Input Ch A JMP12 Trigger Ch B Run Mode Ch B Transparent Mode Ch B Total Hold Ch B JMP13 Gun Mask Ch B Halt Ch B Total Reset Ch B Clean Mode Ch B JMP14 Load Mode Ch B Analog Hold Ch B External Fault Ch B Spare Input Ch B LN 9400 00 9 Pin 1 2 Pin 2 3 FactorySetting X X X X ee Source X 79 DynaFlow User Manual Maintenance Ra n sbu rg Flowmeter Inputs Jumper Description
7. User Manual Operation 7 Set the Ki parameters for both channels to a NOTES value between 50 and 500 in order to bring each CHANNEL to its exact set point Be sure to cycle the GUN between READY and RUN to send the Ki values to the Channel Modules 8 Normally Kd may remain at zero Set Kd to a value between 50 and 500 if there appears to be a delay in the response LN 9400 00 9 61 DynaFlow User Manual Maintenance MAINTENANCE TROUBLESHOOTING Error Codes The following is a complete list of error codes Some of these codes may not apply depending on the specific control system configuration The corrective actions listed in the table are discussed in more detail later in this section and also included in the HELP screens located on the operator interface Ransburg Example Error Code XXXX 1st Digit 2 GUN Alert 4 DISK Error 9 CHANNEL Fault A GUN Fault B SYSTEM Alert or Fault 2nd and 3rd Digit No specific meaning 4th Digit 62 ERROR CODES f a GUN error the number indicates which GUN 1 8 Ifa CHANNEL error the num ber indicates which CHANNEL 1 8 Displayed Text Fault Cause Corrective Action Pot Life Timer Ex 2022 pired 2061 Gun Not Ready 2062 GUN lt gt 9011 Out Of Tolerance 9012 CHANNEL lt gt Pot Life Timer has expired for GUN indicated Last digit indicates CHANNEL Indicated GUN is not ready This means that the GUN
8. 1 CPU Is ON when the microprocessor is op erating normally 2 ACTIVE Is ON when RIO communication is taking place to an Allen Bradley PLC 3 FAULT Is ON when there is a problem with the module Local Operator Interface Supplied as part of the DynaFlow Stand Alone Control Cabinet Model 77376 and A12233 Permits total control of the system Displays system configuration and data to the operator LN 9400 00 9 DynaFlow User Manual Introduction Computes and displays text and graphic di agnostic information Organizes formats and reports all data and configuration tables The DynaFlow fluid flow control system achieves real time closed loop control through the use of CHANNELs and GUNs A CHANNEL consists of an electrical to pneumatic E P transducer material regulator and fluid flow meter combina tion through which a single material is controlled represents a single applicator through 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 Each CHANNEL operates independently of and simultaneously with all the other CHANNELs This lets the DynaFlow controller provide accurate dy namic regulation for each CHANNEL regard less of minor system wear or changes in system vari a
9. ment such as ovens high wattage lamps steam pipes etc Eguipment Mounting Use the mounting ears supplied to mount the control or interface enclosure on a wall or build ing structure The anchor system used must be rated to support the specified weight of the en closure being mounted see specifications page 13 When properly mounted the anchor system shall be capable of withstanding 4 times the rated weight without causing a hazardous condition A WARNING If improperly located certain electrical equipment can become a source of ignition and create a risk of fire or explosion The Control and Interface Enclosures must be located outside of the Class 1 Division 1 and 2 hazardous locations which are de fined for spray finishing of flammable and or combustible materials Definitions and requirements for classified areas are found in the National Electrical Code NFPA 70 Article 516 and the National Fire Protection Association NFPA 33 DynaFlow User Manual Installation A WARNING The Control Enclosure must be lo cated in such a way that access to the On Off power switch and Stop switch is not blocked The On Off switch turns off AC power to the PC and 24 VDC supply The Stop switch interrupts only the 24 VDC The AC power input FUSED DISCONNECT must be located in an accessible area near the Control Enclosure PILOT SIGNAL GUIDELINES Minimum Maximum Length Length Tubing Size Fluid
10. mount the E P transducer as close to the material regulator as possible Remember that the transducers MUST be mounted outside of the hazardous location refer to NFPA 70 NEC For appli cations where the reguested fluid flow is for the most part consistent and transitional re sponse time of the system is not as critical then the E P transducers may be located in the main control panel Be sure that stainless steel tubing or piping and stainless steel fittings are used for all fluid lines and connections where metal is desired Always mount the flow meter and regula tor as close as feasible to the applicator This reduces paint line pulsation due to applicator reciprocators and reduces the possibility of a paint leak effecting paint delivered to the part NOTES Ransburg LN 9400 00 9 Ransburg LN 9400 00 9 DynaFlow User Manual Installation NOTES 27 DynaFlow User Manual Operation OPERATION OVERVIEW This section will acguaint you with the general operation of the DynaFlow Fluid Flow Controller The following information describing 5 GUNs and PARAMETERS summarize the three main features that form the basis of the fluid flow controller CHANNELs ACHANNEL consists of an electrical to pneumatic E P transducer a material regulator and a fluid flow meter combination through which a single material is controlled One or two CHANNELs may be configured foreach GUN Two component
11. ERROR CODES Cont Displayed Text Fault Cause Corrective Action External GUN EN ABLE Input Not Detected Channels Not Present Out of Tolerance Catalyst Too High CHANNEL lt gt Out of Tolerance Catalyst Too Low CHANNEL Z 24 VDC must be supplied to the external GUN ENABLE input before the GUN can be placed in an active state This is typically used as an interlock with other equipment or hard wired directly to 24 VDC Channel Module is not installed or has failed Theindicated slave catalyst CHAN NEL is above it s maximum toler ance limit as specified by the FLOW TOLERANCE parameter Theindicated slave catalyst CHAN NEL is below it s minimum tolerance limit as specified by the FLOW TOL ERANCE parameter Ransburg Check for 24 VDC on the external GUN ENABLE input 1 Insert Channel Module or change GUN configuration 2 Reboot system and check again 3 Replace Channel Module Check the following 1 Kp or Ki gains set too high 2 Runningthewrong JOB ff which may include the wrong gain values 3 Fluid pressures Either reduce the catalyst supply pressure or increase the resin pressure Try to maintain normal operating pilot pressures to the fluid regulators between 30 60 psi 4 The MVR LOW JOB parameter for the catalyst is set too high above the regulator cracking pressure 5 Air bubbles or cavitation Last digit indicates CHANNEL Check the following 1 Kp o
12. Select Start Cal 8 Collect and measure the fluid Fluid flow will stop once the timer has expired NOTE Itis not important that fluid be flowing or triggered ON for the entire calibration time The calibration procedure is based only on the volume of fluid that was reg istered Automatic mode simply supplies a convenient means to calibrate close to specific flow rate and for an approximate amount of time LN 9400 00 9 DynaFlow User Manual Operation 9 Enter the measured amount 10 Accept or reject the new Pulses Per Liter number that the controller calculated The flow meter calibration will automatically be updated Calibration by Weight If calibrated by volume it is not necessary to calibrate by weight Reguired Specific gravity of material Digital scale accurate to 0 10 grams 1 Weigh the empty beaker and record the tare weight for later calculations 2 Enter the calibration mode for the desired CHANNEL 3 Perform the desired collection procedure above 4 Weigh the fluid in the beaker and subtract the beaker tare weight to get the net weight of the fluid collected 9 Entered the measured weight NOTE unassigned CHANNEL cannot be calibrated The CHANNEL must be assigned to a Gun and the Gun must be configured Ifthe weight method is used the specific gravity of the material must be en tered The new value for pulses per liter will be automatically c
13. Temperature 5 C 40 C 80 to 31 C decreasing to 50 at 40 C non condensing Humidity 13 DynaFlow User Manual Installation INSTALLATION SYSTEM GUIDELINES Prints Specific per Installation Often times installation prints are custom drawn for each site You should check those prints for information that is specific to your installation Any deviations from those prints made during or after installation should be recorded for further reference Cable Assemblies Most electrical interconnections between the Dy naFlow controller and other system components are made through cable assemblies NOTE Any unused conduit holes must be blanked off to prevent solid objects from entering the inte rior of the enclosure Eguipment Grounding The control panel should be grounded in accordance with national and local electrical codes The protective ground conductor must be terminated directly to the protective conduc torground terminal located inside the Control Enclosure which is marked with symbol 5 Ransburg Eguipment Locations With the exception of the following restrictions the installation of the Transducers or Transducer Panel the Remote Operators Station and Regu lator Flow meter assemblies are application and site dependant Specific instructions for location and mounting of these assemblies are covered on the site installation drawings 1 The maximum recommended distance from the
14. Type Pin T2 Pin23 FactorySetting JMP15 Flow Rate Freq Input Source Open Channels A and B Closed Open Memory and Processor Settings Jumper Description Pintz Pin 25 J Factory Setting JMP16 UVEPROM Closed 512KB Open Closed __ 1024 Open Closed JMP17 RAM 8Kx8 Open Closed 77 16Kx8 Closed 32Kx8 Closed Open Xx JMP18 Processor Pin EA Run Open Closed xX Ransburg CAN Bus Address Communication between the Interface Module and Channel Cards The Control Area Network CAN address of the Interface is automatically determined by hardware based on the physical slot location in the rack INTERFACE MODULE DIP SW1 SETTINGS 1 6 OFF RIO Rack address 0 63 Decimal Address 00 position 1 most significant bit MSB 0 77 Octal position 6 7 least significant bit LSB 0 3F Hex 7 8 OFF RIO Starting Quarter position Number of Channel 7 8 Quarters Cards OFF OFF 0 1to4 OFF ON 1 4 1 to 4 OFF 1 2 1103 ON ON 3 4 1 80 LN 9400 00 9 nsbu rg DynaFlow User Manual Maintenance INTERFACE MODULE DIP SW2 SETTINGS Default Setting Description NVRAM Erased Dunn NNUS Reset All data will be lost when OFF NVRAM Maintained set to ON position ON Master Channel outputs Master Chanel flow rate on secondary analog output OFF Master Channel outputs GUN flow rate on sec
15. 25 volts and the RIO Set Point is zero Note When configured for current loop input the minimum 0 25 volts is achieved since 4 ma produces 2 00 volts at the input due to the 500 ohm shunt resistor used in current loop mode Load Mode LOAD MODE is similar to RUN MODE However in LOAD MODE up to 10 faults are permitted be fore the gun will leave LOAD MODE and enter the FAULT MODE All eleven 11 faults will appear in the Error Log screen The GUN will automati cally leave LOAD MODE and return to the READY MODE after a volume greater than or equal to the Mixed Volume has flowed since the last fault LN 9400 00 9 To Place A GUN In LOAD MODE 1 The external GUN enable input must be sup plied tothe Master CHANNEL No systemor GUN faults can be active and the GUN configuration and JOB tables should be properly set 2 A signal must be supplied to the Master CHAN NELLOAD inputora LOAD command issued from the Operator Interface Panel or the host controller 3 Flow will begin when the Trigger signal is sup plied To Exit LOAD MODE 1 Simply remove the LOAD input and apply the HALT input or issue a command from the Opera tor Interface Panel MANUAL HAND GUN APPLICATIONS The DynaFlow controller can provide closed loop regulation for manual hand GUN application of two component materials When used with hand spray GUNs the painter regulates the total fluid flow with the spray GUN or an inline fluid regulator Regulatio
16. BCD BIT 40 BCD BIT 80 v BCD BIT 100 GUN MASK 1 GU ASK 2 GU ASK 3 G ASK 4 G ASK 5 GU ASK 6 m GU ASK 7 m GU ASK 8 JOB SIROBE Figure 6 JOB Selection Timing Diagram Sample 50 LN 9400 00 9 Ransburg JOB Gueue The JOB Queue is an input buffer for each of the 8 possible GUNs in the system JOBs are loaded into the Queue only if the GUN is already operating a JOB in the RUN LOAD CLEAN CALIBRATE modes Each of the 8 GUNs has a JOB Queue with a fixed length of 1 JOB This permits the next JOB number for GUN n to be stored before the current JOB has been halted After the current JOB has been halted the next RUN input signal will initiate the next JOB number located in the queue NOTE If another JOB number is loaded into the Queue before it is emptied the queue contents will be replaced with the second entry See the following examples JOB Number is Loaded into the Queue Before it is Emptied 1 GUN 3 is running JOB 32 and has NOT been halted 2 JOB 47 is in the Queue for GUN 3 3 JOB 54 is now entered into GUN 3 5 Queue 4 This will result in JOB 54 replacing JOB 47 for GUN 3 JOB 47 became lost and was not cessed by GUN 3 The Correct Seguencing Should Be 1 GUN 3 is running JOB 32 and has finished Current JOB 2 JOB 47 is in the Queue for GUN 83 Next JOB 3 GUN 3 is halted 4 The Run input signal is pulsed The Trigger input
17. ERROR LOG F11 Also See Section on Error Codes Each ERROR CODE can representa CHANNEL GUN or system error See the Troubleshooting section for list of error codes It is possible for more than one code to be issued atthe same time The Interface Module stores ten 10 previous error codes until they are read by the Local Operator Interface program at which time they are automatically purged from its log The Local Operator Interface program stores one hundred 100 previous error codes until they are manu ally cleared by the operator The operator may also save the error codes to a floppy diskette for later analysis A PLC may obtain the current error conditions via RIO at any time but it must maintain its own log AUTOMATIC GUN APPLICATIONS Automatic applicators use automatic means to vary the fluid flow through the use of transducers and material regulators When used with single component materials and an automatic spray applicator the DynaFlow controller regulates total material flow When used with two component materials the DynaFlow controller regulates both the total fluid flow rates to the applicator and the mixing ratios Each CHANNEL of the two component material is programmed with predetermined values The following conditions must be met in order for the GUN to allow fluid flow 1 There must be no system faults or GUN faults active 2 There must be valid GUN configurations 3 The proper inputs must
18. If used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks disabled Never use equipment intended for use in waterborne installations to spray solvent based materials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and OSHA requirements LN 9400 00 9 Ransburg AREA Tells where hazards may occur General Use and Maintenance Electrical Eguipment Explosion Hazard Incompatible Materials LN 9400 00 9 HAZARD Tells what the hazard is Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment High voltage equipmentis utilized Arcing in areas of flammable or combustible materials may oc cur 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 Frequent power supply shut down indicates a problem in the system which requires correction An electrical arc can ignite coat ing materials and cause a fire or explosion Halogenated hydrocarbon sol vents for example methylene chloride and 1 1 1 Trichloroeth ane are not chemically compatible with the aluminum that might be usedin many system components The chemical reaction caused by these solvents reacting with al
19. Interface Module Hardware General This Module is responsible for local display keyboard control and communication to the Host control ler Responsible also for non vola tile storage of all JOB data tables and system configuration param eters 3U 130 5 mm H x 7H 35 2 m W standard 19 rack module Dimensions LN 9400 00 9 DynaFlow User Manual Introduction Interface Module Hardware Cont Digital Inputs 24 VDC at 2 3 ma typical per input optically isolated source by de fault sink selectable JOB Select Strobe JOB Select 1 lower significant BCD digit JOB Select 2 JOB Select 4 JOB Select 8 JOB Select 10 middle significant BCD digit JOB Select 20 JOB Select 40 JOB Select 80 JOB Select 100 upper significant BCD digit System Ready Halt Global Gun Enable Digital Outputs 24 VDC sourced at 300 ma maxi mum per output Solid state relay contacts Used as watchdog timer by an external supervisory PLC or com puter Used to activate an alarm and to supply a signal remotely that a System GUN or other fault has occurred System Pulse System Fault Communications RS 232C Port Communication with local Opperator Interface unit Allen Bradley RIO Port For direct high speed communi cation with Allen Bradley PLC s CAN Control Area Network CAN high speed communication with all channel Modules and with other racks Power Requirement 24 VDC
20. Regulator Typical OD Type Application LN 9400 00 9 15 DynaFlow User Manual Installation Ransburg 16 ANALOG CONTROL SIGNAL E P TRANSDUCER FLOW METER FEEDBACK a AIR SUPPLY PILOT SIGNAL APPLICATOR FLUID REGULATOR A FLOW METER VALVE FLUID SUPPLY CALIBRATION Figure 2 Block Diagram for a Single Component Gun LN 9400 00 9 Ransburg CHANNEL 1 E P TRANSDUCER AIR SUPPLY PILOT SIGNAL FLUID REGULATOR FLUID SUPPLY ANALOG CONTROL SIGNAL FLOW METER FEEDBACK 4 CALIBRATION DynaFlow User Manual Installation CHANNEL 2 LN 9400 00 9 CHECK VALVE ANALOG CONTROL SIGNAL E P TRANSDUCER AIR SUPPLY PILOT SIGNAL FLUID REGULATOR FLOW METER FLUID SUPPLY CALIBRATION CHECK VALVE Y BLOCK APPLICATOR Figure 3a Block Diagram for a Two Component Gun 17 DynaFlow User Manual Installation CHANNEL 1 CHANNEL 2 ANALOG CONTROL SIGNAL ANALOG CONTROL SIGNAL E P TRANSDUCER FLOW METER FEEDBACK FLOW METER FEEDBACK E P TRANSDUCER
21. User Manual Operation Color Change Seguencer The redesigned DynaFlow includes an optional color change seguencer that controls the flush load and color change sequences for each gun Each time a job number is loaded into a gun the flush and load sequences are downloaded to this controller A color change sequence is simply a flush sequence followed by a load sequence F9 COLOR CHANGE An optional color change sequencer may have been included with the controller If itwas included the F9 key will indiacte as such If the F9 key is blank your system does not have this option When this function is selected the operator is first prompted for the gun mumber they wish to view or edit the seguence for they are then prompted for which Job Number they wish to view and or Ransburg edit the seguences of and last they are asked if they wantto view edit the seguence for flushing or filling There is a separate flush seguence and load seguence stored for every Job Number and for every gun Once the operator responds to the previous prompts a screen similar to the one on the previ ous oage appears This chart displays a simple 6 step seguencer where the user defines how long they wish each step to take and which valves or signals should be energized at each one of those steps There are 6 steps for the flush cycle and 6 steps for the load cycle When a color change is desired the seguencer automatically runs the
22. and Typical Ranges for Control Parameters chart in this section 5 Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module s LN 9400 00 9 DynaFlow User Manual Operation 6 Trigger the GUN If the flow rate does not oscillate or the oscillations decrease in amplitude in a few seconds increase Ki by 100 and repeat from step 5 Ifthe flow rate oscillates with increas ing amplitude decrease Ki by 50 and repeat from step 5 8lf the flow rate oscillates with a constant amplitude proceed to step 7 7 Set Ki to one half the present value 8 SetKptothe defaultvalue showninthe Default Control Parameters chart and Typical Ranges for Control Parameters chart in this section 9 Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Mod ule s 10 Trigger the GUN If the flow rate does not oscillate or the oscillations decrease in amplitude in a few seconds increase Kp by 30 and repeat from step 9 Ifthe flow rate oscillates with increas ing amplitude decrease Kp by 15 and repeat from step 9 If the flow rate oscillates with a constant amplitude proceed to step 11 11 Set Kp to one third the present value 12 Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module s 13 Trigger the GUN If the flow rate does not oscillate proceed to step 14 If the flow rate is oscillating reduce Ki by 50 and or reduce Kp by 15 and repe
23. and water off of the parts before spraying They do this by pulling the trigger on the GUN back just far enough to get atomization air but no paint When this happens the controller receives a trigger signal and no paint flow which would cause a fault To allow for this blow off a parameter called BLOW OFF TIME is used system configuration parameter The default value of 32 seconds With the default value of 32 seconds the operator is allowed to blow off parts LN 9400 00 9 Ransburg for a total of 32 seconds without faulting As soon as the controller senses flow from the master CHANNEL the timer is reset and will start once again the next time a trigger signal is received with no master CHANNEL flow Corrective Action In most cases this faultis generated bythemaster CHANNEL flow meter gears not turning usually stuck Try flushing the system and watch the flow rate or flow volume on the operator interface If there still is no flow disassemble and clean the flow meter If this still does not correct the prob lem see the section in this manual on FLOW TOO LOW FAULTS If this fault occurs while the operator was not trying to spray then the air flow switch may be defective This can be verified by the GUN status on the operator interface SYSTEM PREVENTIVE MAINTENANCE INSTRUCTIONS Control Panels There is no maintenance schedule for control panels other than good housekeeping practices These include Keeping
24. be supplied When a GUN is placed in the RUN MODE the controller sends a signal to the transducer to open Ransburg to the MVR LOW setting default 0 VDC On the first receipt of a trigger signal the master channel immediately starts its closed loop PID control and updates the information to the transducer at arate determined by the PID Update Time default 30ms to adjust the actual flow rate to match the target flow Atthe same time in a two component system the slave channel catalyst also closes its PID control loop and matches the actual flow rate to the target flow rate as determined by the requested flow rate ratio of the Master CHANNEL resin and slaved CHANNEL catalyst Both channels run closed loop independently of each other If either CHANNEL is not able to achieve the required target flow rate a FLOW TOO LOW or FLOW TOO HIGH fault will be issued by the controller for the offending channel After an amount of material has passed through the Master CHANNEL set by the TOLERANCE VOLUME parameter the DynaFlow controller compares that volume with the volume of the catalyst that flowed during that volume interval If the ratio is outside of the tolerance as set by the FLOW TOLERANCE parameter the DynaFlow controller will issue an OUT OF TOLERANCE fault for the offending GUN Dynamic Flow Rate Set Point Control Dynamic Flow Rate Set Point Control is useful for changing flow rates of a material to achie
25. binary code The system inputs shown in Figure 6 are used to select and enter a JOB number The JOB Select inputs are used in con junction with the GUN Mask inputs to determine which GUNs will accept the JOB number repre sented by the total of the active JOB Select Bits Example JOB 25 is Requested Decimal Number 25 Most Significant Digit 100 s 0 binary 0000 Most Significant Digit 10 s 2 binary 0010 Least Significant Digit 1 s 5 binary 0101 LN 9400 00 9 JOB numbers can be entered into the JOB Queue at any time regardless of the operating mode These signals are used in conjunction with the GUN MASK inputs to determine which GUN S will receive the JOB as input by the program select inputs The JOB SELECT inputs must be present atthe time thatthe JOB SELECT STROBE signal is activated The basic sequence for selecting and entering JOB numbers is 1 Select and hold high the appropriate JOB SELECT input bits 2 Select and hold high the appropriate GUN MASK input s This can be performed simutan eously with the JOB SELECT input bits 3 Pulse the STROBE input 4 Return all inputs to the low state 0 VDC 47 DynaFlow User Manual Operation Ra n sb u rg Figure 5 gives a graphic representation of the timing required for selecting a JOB Normally the JOB SELECT inputs and GUN MASK inputs are held high for a slightly Ionger duration than the STROBE This ensures that the new JOB S
26. command will have no effect unless the hardware input is removed Force CHANNEL Digital Outputs Forcing outputs permits debugging and trouble shooting to determine proper operation of the hardware Force CHANNEL Analog Outputs Forcing analog outputs permits debugging and troubleshooting to determine proper operation of the hardware PLOT DATA F6 This feature allows the operator to generate a real time graph of many of the process variables to monitor the response of the system as it re lates to time to four variables from any of the configured guns can be graphed at any one time All four variable do not have to be from the same gun e g The triggers from 4 guns can be monitored at the same time The following variables can be graphed Trigger Requested Ratio Actual Ratio Requested Flow both channels Actual Flow both channels Requested Flow Chan A amp B Actual Flow Chan A amp B Control Pressure Chan A amp B To select the data to be graphed simply touch the Plot Data button F6 then touch the items you wish to plot one ata time followed by touching the Select Variable button F1 Up to four items can Ransburg be selected Pushing the F3 button removes all items from the selection list and allows the opera tor to make a new selection Pushing F2 will start the data acquisition graph running Each of the 4 graphed values will be plotted in a different color A le
27. does not effect the JOB gueue LN 9400 00 9 DynaFlow User Manual Operation 5 JOB 47 moves up and the Queue empties JOB 47 becomes the current JOB 6 JOB 54 is entered into GUN 3 s Queue JOB 54 is now the next JOB for GUN 3 JOB Queue Defaults If no JOB is entered into the Queue the Queue is empty the current JOB number reverts to the last JOB number entered if the GUN Run signal is made active 1 A Halt signal input will halt the current JOB 2 Pressing Run will restart the GUN with the old JOB number 3 Entering a new JOB number and selecting Run will restart the GUN with the new JOB number Reverse Flow Detection For two component systems both forward and reverse fluid flow is detected through the flow meter if non fiber optic flowmeters are being uti lized Reverse flow detection can help prevent mixed two component material from backing up into the fluid supply system due to check valve failure When the controller detects reverse fluid flow in excess of the programmed REVERSE FLOW LIMIT it will immediately shut OFF the fluid regulator valves and prohibit mixed material from contaminating the fluid supply Reverse flow rate is displayed on the main screen of the Local Operator Interface as a flow rate bar colored red instead of green for normal flow rate Pot Life Fault Each of the GUNs configured as two component has an associated Pot Life Time located the JOB Parameters These
28. feature will be disabled Automatic GUN This parameter is used to scale the flow rate output for the GUN s CHANNEL s to specify the desired flow rate when a 0 VDC or 4 0ma signal is applied to the analog set point input Pot Life Time The time in seconds required for the mixed material being used to set up or harden This in formation is obtainable from the manufacturer of the material The controller will determine if any mixed material is in the paint lines for longer than the Pot Life Time setting It is recommended that this time be somewhat less than the actual set up time to allow time to clean the system in the event that the Pot Life timer expires If the specified time expires a Pot Life alarm is issued warning the operator that this problem exists The Pot Life alarm does not shut off the GUN as this would preventthe operator from triggering and expelling the mixed fluid The Pot Life alarm status will re main until the expired material has been purged Pot Life checking may be disabled by entering a value of zero seconds Since previous versions of the DynaFlow firmware and software used the value 999 minutes to disable Pot Life checking the value of 999 seconds is not permitted and will automatically be changed to zero seconds When upgrading DynaFlow firmware and software JOBs that specified any value other than 999 minutes must be manually converted to seconds after the upgrade is performed A Pot Life alar
29. flush seguence followed by the load seguence 7 N READY READY FAULTS A GUN A JOB 1 COLOR CHANGE SEOUENCE FLUSH Step 1 2 3 4 5 Hold Chop Air Time 0 0 Step Duration 0 0 Chop Solvent Time 0 0 Resi SolvntAirChop _ OFF OF OF OF OFF Opto 11 3 4 Resin Solvent OFF OFF OFF OFF OFF OFF Opto 22 11 3 Resin Air OFF OFF OFF OFF OFF Opto22114 Paint OFF OFF OFF OFF OFF Opto 229 1 4 40 14 11 12 Dump Value OFF OFF OFF OFF OFF Opto 22 12 1 Resin Fluid Override OFF i OFF OFF OFF OFF Opto 22 12 2 Trigger Solenoid 7 OFF or OF OF OFF Opto 22 12 3 Catalyst 1 CCV or or OFF OFF Op 22124 Catalyst 42 CCV OFF OFF OFF OFF OFF OFF 2213 Catalyst 43 CCV OFF OFF OFF OFF OFF OFF 22 13 2 Catalyst Solvent OFF OFF orr OFF OFF Opto 22 13 3 Catalyst Fluld Overid OFF OFF OFF OFF OFF Opto 22 13 4 Run OFF OFF OFF OFF OFF or Halt OFF OFF OFF OFF OFF OFF ESC 2 F2 FE F5 Fe Fa F9 F10 RETURN MODIFY CHOP EDIT SEND COPY READ IN SAVE TO AIR SOLV FILL TO PLC SEQUENCE FILE FILE TIME TIME 4 4 LN 9400 00 9 42 Ransburg The following solenoid valves can be controlled by the seguencer Resi
30. has been given a RUN command without be ing enabled or the GUN has faulted Last digit indicates CHANNEL The indicated CHANNEL is outside its maximum tolerance limit as speci fied by the FLOW TOLERANCE parameter Last digit indicates CHANNEL Verify the following 1 Correct value for Pot Life time 2 Correct value for Mixed Volume If the above values are correct then fluid must be flushed from the GUN immediately Verify that the GUN is enabled and not faulted Each GUN must have the Ext Fault Enable Input active or the Global Gun Enable active Check the following 1 Kp Ki and Kd gains setwrong which may cause unstable fluid regulation 2 Running the wrong JOB which may include the wrong Kp Ki and Kd values LN 9400 00 9 Ransburg DynaFlow User Manual Maintenance ERROR CODES Cont Displayed Text Fault Cause Corrective Action Reverse Flow Limit The amount of reverse flow for the 9023 CHANNEL lt gt Flow Too Low CHANNEL lt gt Flow Too High No Master Flow LN 9400 00 9 indicated CHANNEL has ex ceeded the maximum allowable amount as defined in the CHANNEL parameter set Last digit indicates CHANNEL The flow rate for the indicated CHANNEL is too low Based on the transducer output Not issued for a manual GUN master CHANNEL Last digit indicates CHANNEL The flow rate for the indicated CHANNEL is too high Based on the transducer o
31. is config ured as a manual GUN The software monitors the trigger signal to identify when the spray GUN is triggered Typically this signal comes from an air flow switch located in the atomization air line If the software ever detects a GUN trigger signal without pulses from the master channel flow meter after the Blow Off time has elapsed a No Master Flow fault is issued This prevents a painter from painting if the flow meter sticks In some manual Ransburg applications painters will only trigger the spray GUN enough to get atomization air to flow without material They use this air to blow off or feather the part The software would normally sense this air flow without material flow and then fault the GUN This parameter allows the painter a preset number of seconds of blow off before faulting This parameter is specified in seconds and the default is 5 seconds A setting of zero 0 disables the no master flow fault Change Password F3 Used in conjunction with the Password Timer pa rameter The operator can change the password ifthe previous password is known The password is required for editing or setting all data tables and configuration parameters A password of O will disable password operation Password Timeout Once a valid password has been entered this parameter sets the amount of time in min which is allowed from the last keystroke until password operation is stopped Once the timer has expired the
32. is in dicated at the top of the bar graphs on the main screen and determines the maximum values dis played on the plot graph screens Flow Rate Tolerance Time This parameter allows the user to program how long the flow rate can continue to operate outside of the programmed flow tolerance percentage be fore the unit fualts and stops flow It is expressed in seconds If this number is too small nuisance flow out of tolerance faults may occur and if too large improper film builds could result Master Pot Volume This is the volume of material that a pressure pot will be filled with each time it is refilled There is a pot volume reset button on the Job Totals screen that allows the userto preset these volumes when the pots are filled This value is incremented downwardly as material in the pot is consumed and pot empty fault will occur if the volume ever reaches the value of 0 warning the operator to refill the pot s Slave Pot Volume See Master Pot Volume information 33 34 Display Mode This parameter has three possible values RATIO TOLERANCE MIXED VOLUME and POTLIFE It indicates what type of bar graph will be displayed on the main screen immediately to the left of the flow rate bar graph for each gun Ratio Tolerance This indicates the instantaneous ratio of the mate rial being fed into the static mix tube at any instant in time Mixed Volume This indicates how much of the mixed volume the material b
33. pressure immediately returns to MVR LOW ON If the Trigger OFF Delay is zero when the GUN trigger is removed the E P transducer pressure immediately returns to MVR LOW If the Trigger OFF Delay is non zero the E P transducer pressure remains at the last output value from the PID loop until the Trigger OFF Delay expires Lookup Table Enabled This feature has been obsoleted in current revisions of the software This switch setting applies only to single component GUNS OFF The Lookup Table is updated while in Run mode but it is not used to deter mine the flow rate set point when the GUN is triggered ON The Lookup Table is updated while in Run mode and is used to determine the flow rate set point when the GUN is triggered or when the flow rate set point is changed by more than 10 of the range in flow rate Maximum Flow Rate minus Minimum Flow Rate In addition ifthe GUN has been placed in Transparent mode and a PLC or robot sends a flow rate set point via RIO or Analog Input the value is assumed to be a flow rate rather than a pressure value Alternate PID Equation The Alternate PID Equation should be used whenever the set point for the flow rate is dynamically changed during Run mode OFF 7 The PID Proportional term is based on the error term which is the difference between the desired flow rate set point and actual flow rate ON The PID Proportional term is based on the setpoint 77 DynaFlow User Manual M
34. state 24 VDC When this signal is active the system Ready Halt output will be held ON If the signal is lost ALL GUNS will stop and the READY output is turned OFF The GUNs must be restarted in the normal manner when this signal is again activated The JOB QUEUE for any GUN is not effected by the state of this input The Global GUN Enable is a maintained signal that overrides all of the individual External Fault Enable GUN inputs Reference GUN INPUTS This is most useful when using RIO RS 485 or RS 232C control and the discrete GUN is not used through J3 or 6 of the mother board The System Pulse output can be used as a watchdog function by a PLC or other external controller to determine if the flow controller is operating normally The output is a 5096 duty cycle 0 5 HZ signal 2 pulses per second System Fault A high signal on this output indicates that a system GUN or other fault has occurred The type of fault that causes this output to activate is selectable by the Horn Code located in the System Configuration table System Spare Not used presently LN 9400 00 9 Ransburg Gun I O Discrete GUN I O provides the input control and output status signals required to interface each GUN with a PLC or similar controller or other system control components All GUN I O can also be controlled or monitored through an external host controller operating through a serial data communications link or the state of ea
35. the position of DIP SW1 2 or SW1 6 on the Channel Module In applications where the trigger off pneumatic action is slow DIP switch SW1 2 or SW1 6 on the Channel Module should be turned off so that when the GUN trigger signal is removed the PID loop for the CHANNEL will continue to control the output of the MVR valve for the CHANNEL based on the measured flow rate until the end of the Trigger OFF Delay In applications where the trigger off pneumatic action is fast DIP switch SW1 2 or SW 1 6 on the Channel Card should be turned on so that when the GUN trigger signal is removed the PID loop for the CHANNEL holds at the last output value until the end of the Trigger OFF Delay In this case it is recommended that a trigger valve color control valve be installed at the inlet of the MVR valve This valve should be driven by a solenoid controlled by the MVR Enable signal for the CHANNEL In this way the fluid line will not pressurize to the material supply pressure while the GUN is not triggered and there will be no delay in initiating flow when the trigger is turned on again since the MVR valve is already at the position last commanded by the PID loop for the CHANNEL f a triger valve is not installed at the inlet of the MVR valve then the Trigger OFF Delay should not be set greater than perhaps 0 5 seconds to avoid pressurization of the fluid line during the Trigger OFF Delay If the delay is too long in this situation excessi
36. user will be prompted for the password again if password protected settings are to be edited RIO Rack Address Rack Size Starting Quarter and Baud Rate Displays the RIO communication parameters as decoded from the Interface Module DIP SW1 and SW2 settings SIO Baud Rate and COM Port Displays the SIO communication baud rate as decoded from the Interface Module SW1 and SW2 settings and the COM port COM1 or 2 as defined in the GO INI file Channel Module Firmware Revision s Displays the firmware revision for the installed Channel Modules Interface Module Firmware Revision Displays the firmware revision for the Interface Module User Interface Revision Displays the current version of the user interface software running on the user interface PC LN 9400 00 9 Ransburg System Time and Date Displays the current date and time and permits changing the same Language This allows users to select between English and one Alternate Language The alternate language text is stored on the flash drive or hard drive of the PC in files named TEXTMESS ALT TXT PARAMHLP_ALT TXT LABELS ALT TXT SO LENOIDVALVES ALT TXT and HELP ALT TXT Channel Module DIP SW1 Settings Displays the DIP SW1 settings for each installed Channel Module Interface Module SW1 and SW2 Set tings Displays the DIP SW1 and SW2 settings for the Interface Module CONFIG GUN F2 GUN Configuration Parameters should not be e
37. your mate rial supplier Any other type of solvent may be used with aluminum equipment DynaFlow User Manual Safety Ra n sbu rg AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Certain material may be harmful Followthe requirements ofthe Material Safety Data if inhaled or if there is contact Sheet supplied by coating material manufacturer with the skin Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a maskor respirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equipment must be as prescribed by an industrial hygienist or safety expert and be NIOSH approved 4 LN 9400 00 9 Ransburg DynaFlow User Manual Safety NOTES LN 9400 00 9 5 DynaFlow User Manual Introduction Ransburg INTRODUCTION FEATURES Configurable operating parameters JOBs which can be saved and recalled on demand DESCRIPTION Theability to control the delivery of material greatly increases the overall efficiency of the spray oper ating system and results directly in more uniform and consistent paint finish quality and reduces the amount of material waste The ability of the fluid flow controller to respond with quick concise and repeatable control maximizes finish quality and minimizes material was
38. 0 10 VDC or 4 20 ma output signal selectable on the Channel Module indicating the actual flow rate for the CHANNEL Scaling of the output signal is accomplished through the use of the JOB parameters MAXIMUM FLOW RATE and MINIMUM FLOW RATE where 0 VDC 4 ma equals the MINIMUM FLOW RATE value and 10 VDC 20 ma equals the MAXIMUM FLOW RATE value For the Master Channel if DIP switch 2 2 on the Interface Module is off the total flow rate for the gun is output and if the switch is on only the flow rate for the Master Channel is output For the Slave Channel only the flow rate for the Slave Channel is output On guns configured for dual component operation the pot life expired output on the slave B channel indicates when the fluid line has been completely flushed Once mixed material has entered the fluid line this output is energized and it remains energized until the unit is completely flushed That is in order to turn this bit off the amount of material programmed in for mixed volume must be expended from the applicator while the gun is in clean mode User Interface Displays the current version of the user interface software running on the user interface PC Revision Language This allows users to select between English and one Alternate Language The alternate language text is stored on the flash drive or hard drive of the PC in files named TEXT MESS ALTTXT PARAMHLP ALT TXT LABELS ALT TXT SOLENOIDVALVES ALT TXT and HELP ALT TXT
39. 2 supplies multiple appl icators other then hand guns then Gun 2 should be operated in Manual mode using a for the Master Channel flow controller Additional Guns should be configured for each applicator as shown below to provide automatic flow control for each applicator Gun 3 through 6 Master Channel Material Output of Gun 2 Resin 2 3rd Components Flow Controller DR 1 Flow Meter Gear Type Operating Mode Auto 4 Minimum flow rate for the DynaFlow is deter mined for each channel based on the number of pulses liter for the flow meter for the channel Refer to Addendum for flow limitations LN 9400 00 9 DynaFlow User Manual Operation Parameters The controlling parameters for each GUN and for the CHANNELs assigned to that GUN are called JOBs also commonly referred to as PSETs Color Tables or Recipes The JOB values define flow characteristics such as TARGET FLOW RATE MIX RATIO FLOW TOLERANCE etc JOBs include all of the parameters that may be depen dent on the material used This offers the ability to optimize system control as needed per material and then recall the settings each time that mate rial is requested There are up to 100 JOB s for each GUN By saving frequently used JOB s to memory you can later recall them by loading the number representing that JOB The parameters are viewed and edited through the local Operator Interface or through a remote host computer A s
40. ANUAL GUN operation Pulsed and Maintained Inputs Pulsed inputs detect the transition in voltage ei ther up or down This form of input is comparable to a momentary push button Pulsed inputs are timing sensitive e g the pulse MUST be present at the input at the proper time in relation to other input signals The duration of the pulse is also critical Pulsed inputs should be supplied for at least 0 25 seconds in duration The input signal is ignored after detection by the controller and can be removed at any time after the minimum 0 25 seconds Maintained inputs reguire the voltage to be held at a level either low or high in order to perform the intended function System Inputs and Outputs System applies to all GUNs in the system They provide system status input for JOB numbers and all system commands LN 9400 00 9 Ransburg JOB SELECT INPUTS Discrete System Inputs DynaFlow User Manual Operation Toggles enters the Value Selected Values JOB Select 1 Selects BCD Bit 1 JOB Select 2 Selects BCD Bit 2 JoBSelect 8 17 5 8 JOB Select 880 7 5 89 JOB Select 100 Selects BCD Bit 100 JOB Select Inputs These inputs are used to select a JOB number from the external PLC or other host controller if serial communication is not being used These inputs represent Binary Coded Decimal BCD that translates to 3 digits each digit represented as a 4 bit
41. AR PURPOSE RANSBURG ASSUMES NO LlABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEGUEN TIALDAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EGUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in guestion or other items damaged by this part was improperly installed operated or maintained Ransburg willassume no responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9400 00 9 u rg DynaFlow User Manual Appendix APPENDIX ADDENDUM A Obsolescence of the 77206 01 8 bit Channel Card the 77206 12 10 bit Channel Card and the A10946 00 12 bit Channel Card In 2004 the 77206 01 DynaFlow 8 bit Channel Card was replaced by the 77206 12 10 bit Channel Card to improve the resolution of the analog outputs on this card Then in 2006 the 77206 12 10 bit Channel Card was replaced by a totally redesigned 12 bit Channel Card and it was assigned a part number of A10946 00 Lastly in 2007 the A10946 00 board was obsoleted and replaced by 2 boards the A10946 01 and the A10946 02 The reasons for this final change are explained below This information is also contained in Service Note AF 111307 The IC chip used on the A10946 00 DynaFlow Channel Card that produces the 4 20 mA output for flow rate a
42. B a o o o Qm uw um Dei am m 5 6 6 ux o a CHAN 7 Figure 4 Mother Board Terminals 24 LN 9400 00 9 Ransburg Hardware Configuration Reference Addendum A in the Appendix sec tion for board level hardware settings For new system installations all hardware settings should already be in the correct positions However if replacing any electronic board assembly verify that the settings of the new board are identical to those of the board being replaced In the event that the replacement board is a newer revision and does not appear identical refer to any docu mentation that was supplied with the board or contact your Ransburg representative or contact Ransburg service Transducers The transducers convert electrical control signals from the fluid flow controller to the air pressure signals used to operate the material regulators The transducers can be either current controlled 4 20 ma or voltage controlled 0 10 VDC The transducers can be mounted separately or collec tively depending on the installation reguirements Make sure that the Channel Module jumper set tings match the type of transducer being used refer to Channel Module Mother Board Jumper Settings Channel 1 I O and Channel 2 I O in the Appendix section The electrical to pneumatic E P transducers are supplied as separate sub assemblies or as part of a standard transducer panel The transducer panel offer
43. CLOSED OPEN ACTUAL FLOW CH B 0 10 VDC CLOSED 4 20 CLOSED OPEN JMP9 TRIGGER CH A TRANSPARENT MODE CH A JMPTO So SYN cad zA HALT CH fom ss sm oven PTZ TRIGGER CH B RUN MODE CH B TOTAL HOLD CM B cLosED OPEN Ed UL cR CLEAN MODE CH B snk OPEN A M I m DD JMP16 UVEPROM SIZE JMP17 RAM SIZE oe OFN CLOSED CLOSED JMP18 PROCESSOR PIN EA OPEN CLOSED OPEN 90 LN 9400 00 9 OUTPUTS MEMORY PROC SETTINGS n sb u rg DynaFlow User Manual Appendix ADDENDUM B Remote Operator s Panel arw Ransburg Remote Electrostatic Systems Operator s Panel GUNS IN FLUSH BOXES COLOR SELECT a ACTUAL FLOW C3 NT PAINT SOLVENT FLOW CONTROL FEATHER FILL 7 FILLED RESET Q JOL O 27 PURGE FAULTED READY SPRAY PURGED FAULT RESET RUN TEST H O OOO 5 Y E If the Model A12233 control console and Model A12182 Interface Panel is used the optional Remote Operator Panel P N A11095 be used this Remote Operator s Panel shown above operates in the following manner Color Select This is an eleven position selector switch that allows the operator to select the next color to be loaded I
44. Control Panel to each flow meter is 100 ft as determined by the maximum standard avail able length of the fiber optic cable assemblies or intrinsic electrical cable assemblies 2 The maximum recommended length of air pi lot tubing between the electrical to pneumatic E P transducer and the material regulator is largely determined by the application In general the pilot lines should be kept as short as pos sible to achieve the best fluid flow response and regulation See Pilot Signal Guidelines chart in this section 3 The maximum distance between the optional LBAL5001 XX Pneumatic Interface Panel to the Control Console is 40 ft as determined by the interconnecting electrical cable assembly 4 The maximum recommended 1 4 inch OD hose length from the LBAL5003 Remote Opera tor Panel and the LBAL5001 Pneumatic Inter face Panel is 50 ft however this can be longer depending on the application The maximum distance between the A12182 interface panel and the A12233 console is 100 ft 5 The maximum recommended length for the E P transducer electrical control cable is 95 ft However in some cases 175 ft has been used Generally if a GUN number not atomizers con trols a complete zone of 6 or more atomizers do not exceed 95 ft of cable Consult Ransburg if longer distances than those shown above are desired LN 9400 00 9 Ransburg _ Do not locate the Control Panel near or adjacent to heat producing eguip
45. ELECT and GUN MASKinputs are correct before strobing the information into the controller Job Number Select Inputs GUN Mask Inputs Job Strobe Input 0 0 0 25 0 50 O Ao 1 00 Signal Duration sec Figure 5 JOB Select Timing Diagram 48 LN 9400 00 9 nsburg DynaFlow User Manual Operation Figure 6 shows 4 Toggle Signals By following the dashed line down you can determine the states of the various signals for each example Maintained inputs that are high are active Pulsed signals that go high at that instance are also active The list below will help explain what JOB number is selected and to which of the 8 GUN gueues the JOB is entered into Toggle 1 Toggle 3 JOB number selected JOB number selected GUNs Masked to accept JOB 69 GUNs Masked to accept JOB 63 Toggle 2 Toggle 4 JOB number selected JOB number selected GUNs Masked to accept JOB 26 GUNs Masked to accept JOB 22 LN 9400 00 9 49 DynaFlow User Manual Operation Ra n sbu rg 4 EXAMPLES OF SIGNAL SEOUENCING TOGGLE 1 TOGGLE 2 TOGGLE 5 TOGGLE 4 BCD BIT 1 BCD BIT 2 io BCD BIT 4 BCD BIT 8 BCD BIT 10 is BCD BIT 20
46. HAZARD Tells what the hazard is Fire Hazard Improper orinadeguate opera tion and maintenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lostif any safety interlocks are disabled during op eration Freguent power supply shutdown indicates a problem in the system reguiring correction Ransburg SAFEGUARDS Tells how to avoid the hazard Fire extinguishing eguipment must be presentin the spray area and tested periodically Spray areas must be kept clean to prevent the ac cumulation 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 Those used foreguipmentflushing should have flash points egual to or higher than those of the coating material Those used for general cleaning must have flash points above 1009F 37 8 Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA and local codes In ad dition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high voltage to be on but only as instructed Non factory replacement parts or unauthorized equipment modifications may cause fire or injury
47. IMUM FLOW RATE and MINIMUM FLOW RATE An Analog Set Point signal less than 0 25 VDC will cause the controller to use the SET POINT parameter located in the JOB table instead Not used presently 22 LN 9400 00 9 n sb u rg DynaFlow User Manual Installation GUN OUTPUTS Output P Signal Description This output is 24 VDC when the GUN is configured properly a valid JOB is loaded This output is 24 VDC when the GUN is RUN mode and flowing fluid or prepared to flow fluid This output is 24 VDC if a GUN fault condition occurs Pot Life Timer This output is 24 VDC if the Pot Life Timer has expired This may also initiate a horn if set to do so in the Horn Code Configuration set in the System Configuration This output is 24 VDC when the GUN is placed in Clean Load or Calibrate Mode This output is 24 VDC anytime material should be flowing for the GUN It is used to control trigger valve s installed at the inlet of the MVR valve s on fast trigger JOBs connected to the transducer for control of the material regulator for the CHANNEL The output signal is limited through the use of the JOB parameters MVR HIGH and MVR LOW Scaling is assumed to be 0 VDC 4 ma equals 0 PSIG at the output of the E P transducer and 10 VDC 20 ma equals 100 PSIG at the output of the transducer The MVR HIGH and MVR LOW JOB parameters are based on a percentage of the span of 0 to 100 PSIG This MVR LOW value of 10 equals 10 PSIG This is a
48. Input GND Load 19 andog hod me 88 82 LN 9400 00 9 nsburg DynaFlow User Manual Maintenance Mother Board Signal ldentification Continued MOTHER BOARD SIGNAL IDENTIFICATION J3 4 5 6 CHANNEL MODULES J2 INTERFACE MODULE Pin Description Description 76 Load AnalopHoldinpug2 18A 9C External Fault 9A 206 Spare npt 20A 276 MVR Enable 28C DigiaOuputGND 29C 77 77 77 2890 00 506 LN 9400 00 9 83 DynaFlow User Manual Maintenance 84 MOTHER BOARD SIGNAL IDENTIFICATION J2 INTERFACE MODULE J2 INTERFACE MODULE Pin Description 8B 66 JOBSeedBi2 MSD 6 eC JOB Select Bit 8 MSD oB Console D232A 9C Spare Digital npt mc 508 2c Spare Input 158 Spare Input cC Spare Input SIO GND 17 18 278 288 CAN BUS CAN BUS 05 CAN BUS GND B 24 VDC PWR GND 32C GND LN 9400 00 9 Ransburg nsburg DynaFlow User Manual Ma
49. Parameters The design of the DynaFlow system allows it to be configured to meet the specific reguirements of each application The 8 available CHANNELs can be linked together using 1 of 8 GUNS to control the flow and mixing regulation of two component materials The installed channels can be configured to suit the application If you are using single component coatings the DynaFlow controller can support 8 separate single CHAN NEL GUNS operating simultaneously If you are using two component materials then 4 separate 2 CHANNEL GUNSs operating simultaneously can be supported For example you can use 4 CHANNELs assigned to 2 GUNS to spray 2 dual component paints on automatic machines and 2 CHANNELs assigned to 1 GUN to spray one dual component paint with a manual hand spray GUN In addition to the above a GUN configured for two component operation can be dynamically changed to operate in a single component mode by simply setting the ratio JOB parameter to 100 This allows a GUN to operate in either dual or single component modes by simply changing JOB numbers The controlling parameters for each GUN and the CHANNEL S assigned to that GUN are called JOBs The JOB values define flow characteristics such as Target Flow Rate Mix Ratio Flow Toler ance etc JOBs include all of the parameters that may be dependent on the material used This offers the ability to optimize system control as needed per material and then recall the setti
50. Ra nsburg SERVICE MANUAL LN 9400 00 9 Replaced LN 9400 00 8 December 2012 DYNAFLOW USER MANUAL s 5 Ransburg DynaFlow g E MODEL 77376 and A12233 IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS start ing 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 9400 00 8 to revision LN 9400 00 9 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9400 00 9 nsburg DynaFlow User Manual Contents CONTENTS PAGE SAFETY 1 5 SAFETY 4 HAZARDS SAFEGUARDS ee pinos A a 2 5 FEATURES Ha A YAA eased 6 DESCRIP THON DER 6 9 BLOCK DIAGRAM EET 10 DYNAFEOW SPEGIFIGATIONS erem d Relatos ene ud eo 11 13 SYSTEM GUIDELINES EQUIPMENT GROUNDING LOCATIONS MOUNTING 14 15 BLOCK DIAGRAM FOR A SINGLE COMPONENT GUN 16 BLOCK DIAGRAM FOR A TWO COMPONENT 17 BLOCK DIAGRAM FOR A THREE COMPONENT 18 INPUT POWER tints YN GU CN DM 19 INTERFACING TO THE FLO
51. W 60 20 23 MOTHER BOARD TERMINALS HARDWARECONFIGURATION TRANSDUCERS 24 26 0 20009 30 43 AUTOMATIC GUN APPLICATIONS np GARA Gwy FFR ate M rd rns 44 45 MANUAL HAND GUN 6 2 2 44 4 45 46 GENERAL 46 47 JOB SELECT TIMING DIAGRAM 48 49 JOB SELECT TIMING DIAGRAM SAMPLE JOB QUEUE REVERSE FLOW 50 54 PROCEDURES FIRST TIME STARTUP NORMAL STARTUP 54 56 7 56 61 MAINTENANCE 62 87 TISODUBEFSHOOTINGLG Gl RO OG 62 71 SYSTEM PREVENTIVE MAINTENANCE 71 SYSTEM COMPONENTS AND PARTS 72 RECOMMENDED SPARE 73 74 HARDWARE SETTINGS shai ta Yna a fo p oydd yN 75 78 NEW CHANNEL CARD YRR MYNEDIAD enki nh re 79 80 INTERFACE MODULE DIP SETTINGS rient terrre nre htm ea 81 CONTROL RACK TERMINAL 82 85 SERIAL COMMUNICATION 5 86 CONVERS asu
52. accurate Number of Pulses Displays the actual number of pulses received from the flow meter during calibration Calculated Volume Displays the calculated volume of material that should be in the beaker when the calibration is stopped This value is based on the Current Pulses Liter parameter and the Number of Pulses received so it will be inaccurate if the Current Pulses Liter parameter is inaccurate Measured Volume The measured volume cc s of material in the calibration beaker This value is entered by the operator Once a non zero value is entered the operator may not enter a Measured Weight and Specific Gravity Measured Weight The measured weight of material grams in the calibration beaker less the tare weight of the beaker This value is entered by the operator The scales used should be accurate to 0 10 gram This value is entered by the operator The Mea sured Weight along with the Specific Gravity is used to calculated the Measured Volume Once a non zero value is entered the operator may not enter a Measured Volume Specific Gravity Specific gravity is the ratio of a material s density to the density of water This can be obtained from the material safety data sheet MSDS or directly from the material supplier This value is entered by the operator The Specific Gravity along with the Measured Weight is used to calculated the Measured Volume Once a non zero value is entered the operator may not ente
53. aintenance Ra n sbu rg Interface Module Settings INTERFACE MODULE JUMPER SETTINGS 512K 2 3 ROM size select Factory set Do not change 1024K 1 2 256K 27256 device unless instructed to do so 2 3 512K or 1024K 27512 or 27010 devices a HE Circuit common to earth ground connec tion Source 2 3 Selects 24 VDC source control or grounded sink control for digital inputs 12 15 2 3 24 VDC source 1 2 grounded sink Selects 24 VDC source control or grounded sink control for digital inputs 8 11 2 3 24 VDC source 1 2 grounded sink Selects 24 VDC source control or grounded sink control for digital inputs 0 3 2 3 24 VDC source 1 2 grounded sink z Source Selects 24 VDC source control or grounded sink control for digital inputs 4 7 2 3 24 VDC source 1 2 grounded sink Inserting this jumper adds a 120 Ohm termination resistor across the RS 485 RX and RX lines Inserting this jumper adds a 120 Ohm termination resistor across the CAN Bus 78 LN 9400 00 9 Ransburg DynaFlow User Manual Maintenance The new 12 bit Channel Card for the DynaFlow P N A10946 has a different jumper configuration than the now obsoleted 8 bit module P N 77206 11 Please refer to the table below when setting the jumpers on the new channel cards Analog Inputs JMP1 Flow Rate Setpoint Ch A 0 10 VDC Open Closed 4 20 mA Closed Closed
54. alculated and updated Repeating the calibration procedure is highly recommended to ensure it was performed satisfactorily 53 DynaFlow User Manual Operation Clean Any CHANNEL or Gun can be placed into a CLEAN mode by an external command orthrough the Host controller The Clean mode forces the material regulator fully open until turned OFF GUN Enable and CLEAN inputs must be active and all system or GUN faults cleared To properly exit the CLEAN MODE the GUN Clean input should be removed followed by a GUN Halt signal or a command issued from the Operator Interface Panel host controller Each CHANNEL must be setasa clean CHANNEL in the Clean CHANNEL parameter located in the Gun Configuration table NOTE Make sure the proper channels are configured to clean on the Gun Param eters screen Full Error Detection The DynaFlow controller will detect certain error conditions and indicate the cause of the error with a code The code indicates the faulted Gun and CHANNEL as well as giving you a text error message All errors are categorized by CHANNEL Gun or System depending on the type of error The error codes and conditions are listed in the appendix and include Tolerance errors in fluid flow rates for each material Tolerance errors in fluid flow ratios for each material Reverse fluid flow Low material flow High material flow Pot life timers expired Memory errors Backup d
55. are extremely quick trigger cycles or equipment limitations The Out of Tolerance Flow Too Low and Flow Too High faults will also be disabled while in the Analog Hold condition Load requires a pulsed signal of at least 0 25 seconds duration The LOAD input places a manual two component GUN into LOAD MODE LOAD MODE is a special way to meter both resin and catalyst to the applicator after the system has been through a CLEAN opera tion while assuring accurate ratios A GUN can be placed into the LOAD MODE directly from the RUN MODE For details refer to LOAD MODE in the Operation section of this manual External Fault External Fault will detect a low signal of at least 0 25 seconds duration This signal must be Enable maintained high for normal operation No fluid flow will occur regardless of the operat ing mode if the Enable input is not active This input is supplied as an interlock for other equipment to automatically shut down the fluid flow controller The system must be reset after the External Fault is returned to the high state Reference Recovering From Faults in the Operation section of this manual A Global Gun Enable system input will override this input Not used presently This is a 0 10 VDC or 4 20 ma input signal hardware selectable on the Channel Card which can be used to command flow rate when the applicator is in AUTOMATIC mode The scaling for input signal vs flow rate is determined by the GUN JOB parameters MAX
56. are the same SPARE PARTS FOR 77376 AND A12233 CONSOLE UNIT Total 4 of Consoles Part Description 12 34 5 1 3 LL rms 3 pi 3 73837 08 Fiber Optic Flow Meter Receiver 1 1 2 For 77376 XXXOX Only 77454 00 or 74300 00 Fuse 3 AMP 2 2 2 4131 11 Stop Switch Red Mushroom Head 1 1 1 Included with all stand alone 77384 00 systems Stop Switch Yellow Mushroom 1 1 1 Alternate stop switch available A11375 00 Head special order only for integrated systems when only one red stop switch is permitted in the control room area gt gt Power Line Filter 115 VAC For 77376 Only A10577 00 Power Line Filter 230 VAC 1 1 For 77376 XXXX1 Only A10577 01 74 LN 9400 00 9 nsburg DynaFlow User Manual Maintenance HARDWARE SETTINGS Channel Module Settings CHANNEL MODULE P N 77206 XX Obsolete MOTHER BOARD JUMPER BOARD SETTINGS CHANNEL 1 I O 512K 3 size select Factory set Do not change 1024K 1 2 256K 27256 device unless instructed to do so 2 3 512K or 1024K 27512 or 27010 devices 0 10 VDC Selects 0 10 VDC or 4 20 ma operation for To the E P transducer 1 the analog control output 1 2 3 0 10 VDC 1 2 4 20 mA 0 10 VDC Selects 0 10 VDC or 4 20 ma operation for Actual flow rate for the spare analog output 1 CHANNEL 42 scaled by 2 3 VDC Ma
57. are used remove the front shroud and bell cup to expose the paint feed tube If GUNs are being used point the applicator s downward if pos sible This will prevent the possibility of material from contaminating the applicator and provide additional safety for any per sonnel working near the system Turn ON the main power disconnect to the fluid flow control panel Turn ON the power switch located on the flow control panel LN 9400 00 9 Ransburg Verify that the local Operator Interface is working properly and that no errors are be ing reported Refer to the Operator Inter face manual for additional information Turn ON the system host controller PLC or PC and verify proper operation Con figure the flow controller This is usually performed at the local Operator Interface panel but can be through the system con troller depending on the installation Refer to the Operator Interface manual for addi tional information Turn ON the factory air supply to the E P transducer s and adjust the regulator to 90 psi minimum 110 psi maximum Turn ON the fluid supply pressure to the material regulator or color change valves Inspect the air and fluid system for any 5 and fix before continuing Fluid should NOT be flowing through the system at this point Perform a system flush one GUN at a time Load paint Perform a calibration check of each CHAN NEL Verify operation of any safety or s
58. ased viscosity will reguire more pressure to achieve the same flow rate However in some cases as with thixotropic materials the viscosity will actually change as the pressure varies or as LN 9400 00 9 DynaFlow User Manual Maintenance the material passes through the fluid regulator or flow meter Additionally the material may be broken down into smaller particles as it passes through the fluid delivery system which can also cause some materials to change their properties as they flow The temperature of the fluid can also greatly im pact the flow properties Make sure that the fluid heaters are functioning correctly if temperature control is being used If temperature control is not being used then evaluate how ambient tempera ture may effect the fluid as it is stored including the paint kitchen Also consider the length of the recalculating system and how long the material takes to travel to the applicators The amount in which the control response is effected by changes in fluid properties is also determined by how aggressive the control param eters are set Kp Ki Kd The fluid flow response can be observed as discussed in the Operator Interface manual Also refer to the PID Control in the Operation section of this manual under 3 Fluid Line Restriction Has restriction formed somewhere in the fluid line This could be a pinched painttube contamination in the fluid regulator spiral mix tube blockag
59. at 100 ma typical Operating Temperature 0 to 55 C 11 DynaFlow User Manual Introduction 12 Channel Module Hardware Specifications General Each Channel Module is responsible for processing channel specific dis crete and performing all of the necessary PID closed loop control functions Data and control other than discrete is communicated through Ransburg CAN Bus located on the Motherboard Dimensions 3U 130 5mm H x 7H 35 2mm W standard 19 rack module 24 Digital Inputs 2 Channels 24 VDC at 2 3 ma typical per input optically isolated source by default sink selectable Trigger level Automatic mode only For manual mode fluid starts with fluid flow on master channel Halt edge Stops current JOB no effect on next JOB in queue Clean edge Forces regulator full on for cleaning Run edge Gets next JOB used in conjunc tion with JOB and Toggle select bits Gun Mask edge Used in conjunction with JOB select bits Total Reset edge Resets all totals Total Hold level Holds present total value regardless of fluid flow Transparent PID level When active directs the external analog input directly to the transducer output Analog Hold level Freezes PID and holds cur rent analog control output Load edge Loads fluid with controlled mix ratio for GUNs operating in MANUAL Mode External Fault Enable level Enable signal input Must be acti
60. at from step 12 14 Atthispoint thetuning procedure is completed for most flow control applications However if there is a great amount of lag time from the point of sensing the flow rate to where the material volume regulator is located the derivative term of the PID eguation may be reguired In that case set Kd to the default value shown in Default Control Parameters chart and Typical Ranges for Control Parameters chart in this section 15 Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module s 59 DynaFlow User Manual Operation 16 Trigger the GUN If the flow rate does not oscillate or the oscillations decrease in amplitude in a few seconds increase Kd by 30 and repeat from step 15 Ifthe flow rate oscillates with increas ing amplitude decrease Kd by 15 and repeat from step 15 If the flow rate oscillates with a constant amplitude proceed to step 17 17 Set Kd to one eighth the present value 18 Cycle the GUN from READY to RUN so the new parameters are sentto the ChannelModule s 19 At this point the tuning procedure is com pleted The resulting Kp Ki and Kd parameters should produce the fastest response with minimal over shoot and or oscillation If oscillation does occur with these PID parameters consider re ducing each value by the same percentage This will lower the overall gain resulting in a slightly longer time to achieve the desired set point and slow
61. ate re quested during entire part Precise 2K mixing ratio required at all times Low flow rate applications Applicators mounted on oscillators or re ciprocators that may produce cyclic back pressures within the fluid lines Systems with piston pump type supplies Long pilot line lengths from fluid regulator to transducer General Guidelines The type of fluid regulator represents the larg est overall impact on system response The following table lists control settings for various fluid regulators that should result in stable con trol The determination of these parameters was based upon worst case conditions and therefore constitutes conservative control response It is 57 DynaFlow User Manual Operation 58 Recommended to start with these values and confirm stable response before trying to achieve faster response from the system Generally when adjusting the Proportional Kp and Integral Ki gain parameters adjust both up or down pro portional to themselves In other words if faster response is desired and the system is currently operating stable assume the starting Kp value is 500 and the starting Ki value is 2000 You would adjust the Kp value to 550 10 increase and the Ki value to 2200 also a 109e increase The deadband parameter should be kept to 1 and the differential gain Kd at O Ouick triggering applications For applications reguiring multiple short trigger cycles more stable respon
62. ate the amount of mixed material rather than to under estimate it The DynaFlow system uses the Mixed Volume and the Pot Life Time when it monitors the flow rate of the Gun Pot Lifeis monitored by dividing the Mixed Volume into 40 equal sized buckets of material When amountof material has flowed that equals the bucket volume the 40 buckets are time shifted so the oldest bucket is eliminated representing the material that has vacated the Mixed Volume tubing at the GUN and a new bucket is added If the GUN is in either Run or Load mode a time value of 1 second is placed in the new bucket to represent mixed material If the GUN is in Clean mode a time value of zero is placed in the new bucket representing solvent Every second the time values stored in the buckets are incremented ifthey are non zero i e contain mixed material vs solvent A Pot Life alarm condition exists if any of the 40 buckets contains a time value greater than the Pot Life Time see JOB parameters A Pot Life alarm may be cleared by entering a Pot Life Time of zero seconds Flush Volume This parameter is programmed in cc s It is the volume of flush solvent or flush solvent air mixture required to give an adequate flush of the fluid lines for the gun It is used by the software to determine when an adequate flush has occurred LN 9400 00 9 Ransburg Trigger OFF Delay Forautomatic GUNs only This parameter has two uses depending on
63. aterials in paint spray applications PID is the most widely used method for closed loop controllers in all areas of industrial control ThePID control algorithm develops a control signal composed of three elements The proportional element is simply proportional to the difference between the current fluid flow and the desired fluid flow referred to as the error The integral element of the control output is proportional to the integral of the error signal and the derivative element is proportional to the derivative of the error signal Theseare explained in more detail below A general understanding of how a PID controller works will be beneficial in producing the best overall fluid flow response from the fluid delivery system This can lead directly to reduced paint usage and higher quality of finish Largely the air and fluid control components and their placement with respect to each other deter mine limitations on general fluid flow response This includes the following Type of fluid regulator and needle or dia phragm ratio pilot pressure vs fluid pres sure Rheology of the fluid s such as viscosity and shear Length and diameter volume of the air pi lot lines from the V P or I P transducer to the fluid regulator Back pressures created by fluid control devices such as the applicator fluid pas sage restrictions Error The difference between the requested set point value and the actual process being co
64. ation Fluid Supply Requirements The fluid supply must be free of pulsation and surges A fluid strainer filter must be installed im mediately before the material regulators The elment size of the strainer should be 100 mesh or per the recommendation of your Ransburg representative For Two Component 2K Systems Selector valves are required for calibration or verify ing of the flow meters and should be mount ed close to the mixing block These are sup plied as part of the standard fluid panel Drawings created specifically for your sys tem will provide detailed information about valve type and location Mount the calibra tion valves in an easily accessible area close to the mixing block For most applications the flow meter and material regulator are mounted as an assembly as close as possible to the mixing block and calibration valves For systems with fast trigger cycles that utilize weepless MVR valves or where dynamic control of fluid flow rates different flow rate during a JOB consider installing trigger valves typically color control valves immediately upstream of the MVR valves so that the CHANNELs may be placed in 25 DynaFlow User Manual Installation 26 Analog Hold mode without causing the fluid tubes to pressurize to the material supply pressure while the GUN is not triggered For systems with fast trigger cycles or where dynamic control of fluid flow rates different flow rates during a JOB
65. ational regulations and codes 19 DynaFlow User Manual Installation Ra n sbu rg 20 INTERFACING TO THE FLOW CONTROLLER System I O SYSTEM INPUTS Input m Signals Description JOB Select These inputs are used to select a JOB number from the external PLC or other host controller Inputs These inputs represent Binary Coded Decimal BCD that translates to 3 digits each digit represented as a 4 bit binary code The JOB Select inputs are used in conjunction with the GUN Mask inputs to determine which GUNSs will accept the JOB number represented by the total of the active JOB Select Bits See Operation section of this manual for details These signals must be asserted prior to the JOB Strobe Input and held on slightly after the strobe signal goes low JOB Strobe requires a pulsed signal of at least 0 25 seconds duration This signal is used in conjunction with the GUN MASK inputs and program select inputs to activate a new JOB for any or all GUNs When the controller detects this input the program select inputs and GUN MASK inputs are read and action taken to load the new JOB in the JOB QUEUE The new program select and GUN MASK inputs must be present before the PROGRAM SET STROBE is activated Reference Job Selection Timing Diagram Sample in the Operation section System Ready Halt is a maintained signal that permits activation of any or all GUNs For the controller to operate this signal must be maintained in the high
66. bles With a single component coating material the DynaFlow controller detects changes from the programmed flow rate and adjusts the output to correct it With two component coatings where both the resin and catalyst are regulated and monitored the DynaFlow controller detects any change in the total flow and makes the required adjustments to maintain the programmed flow and ratio This holds the flow rates of the coating components constant Deviations from the desired mix ratio are also immediately corrected using this same closed loop process A detailed guide on PID control is supplied in this manual to assist you should you want to adjust the control parameters There are many additional features included DynaFlow Fluid Flow Con trol which reflect on the many years of experience accumulated by Ransburg The control rack and OPERATOR INTERFACE panels are consistent with and easily integrated with other Ransburg control products into larger custom system control panels This optimizes costs space and functionality for control of multiple applicator spray stations Spray stations may also DynaFlow User Manual Introduction incorporate rotary atomizer speed control shaping air high voltage power supplies and more The standard stand alone control cabinet includes control of up to 8 CHANNELs It incorporates an integrated 15 color LCD touch screen PC based display interface sub panel Configurable Operating
67. boards you are now using If jumpers any of the following jumpers JMP5 JMP6 JMP7 or JMP8 are connected between pins 1 to 2 this most likely indicates that you are using the 4 20 mA option and will reguire the A10946 02 board Unless that channel or output signal is not being used and the jumpers were changed from the factory defaults for some reason all other cases the A10946 01 board should be used See picture on next page Note that pin 1 is toward the top of the board Since this is a totally redesigned board from that of the 77206 series boards we have also included jumper and dip switch setting information with this addendum The dip switch settings for SW1 have not changed Refer to Hardware Settings in current DynaFlow User Manual for these settings LN 9400 00 9 89 DynaFlow User Manual Appendix Ransburg ADDENDUM A Cont 4 TIL m 2 4 5 JMP6 7 5 11111 JUMPER TABLE JUMPER DESCRIPTION PIN 1 2 PIN 2 3 F S JMP1 FLOW RATE SETPOINT CH A 0 10 VDC CLOSED CLOSED OPEN SPARE INPUT CH A 0 10 VDC CLOSED CLOSED OPEN FLOW RATE SETPOINT CH B CLOSED OPEN SPARE INPUT CH B 0 10 VDC CLOSED CLOSED OPEN CONTROL PRESSURE CH A CLOSED CLOSED OPEN CLOSED OPEN JMP7 CONTROL PRESSURE CH B 0 10 VDC CLOSED
68. ch forced active through the local OPERATOR INTERFACE host controller GUN INPUTS Input Signals Description Halt Reset Total Reset LN 9400 00 9 For automatic applicators Starts fluid flow when supplied a 24 VDC signal assuming that the GUN has been put in run mode is configured properly and all other conditions are satisfied For manual GUNs A Trigger signal is required for the LOAD mode The Trigger signal can be generated from an atomizing air flow switch If a Trigger signal is received from the flow switch but no fluid flow is recorded from the catalyst slaved CHANNEL then a FLOW TOO LOW fault is generated This ensures that both material components are present to the GUN If the dip switch Pos 1 on the Channel Card is on then this input is not used Fluid flow through the master channel is used to indicate a TRIGGER ON condition Halt requires a pulsed signal of at least 0 25 seconds duration It is used to stop the JOB currently being executed or to stop a CLEAN PURGE operation GUN faults are also reset While in HALT mode any new JOB selection using the JOB Strobe will be entered into the Queue The GUN will run the JOB located in the Queue when a RUN signal is again supplied The faults can still be viewed in the ERROR LOG data table Halt has no effect on the JOB in the Queue Next JOB to be run Clean requires a pulsed signal of at least 0 25 seconds duration It forces the material regula tors contro
69. constitute half of a standard 19 rack In terms of RIO rack size a full rack consists of 8 groups The Interface Module is one I O group but only uses the high byte of the group Each Channel Module is one I O group with the first CHANNEL in the low byte and the second CHANNEL in the high byte A RIO 1 4 rack is 2 I O groups which consists of the Interface Mod ule and only one 1 Channel Module A RIO 1 2 rack is 4 I O groups which may consist of the Interface Module and from one 1 to three 3 Channel Modules ARIO 3 4 rack is 6 I O groups which may consist of the Interface Module and from one 1 to four 4 Channel Modules ARIO full rack is 8 I O groups which may consist of the Interface Module and from one 1 to four 4 Channel Modules The Interface Module accepts both hard wired discrete I O and RIO discrete and RIO block transfers from a PLC Ransburg LN 9400 00 9 nsbu rg DynaFlow User Manual Maintenance RATIO CONVERSION CHART of Catalyst to Total Parts of Resin to Volume 1 Part 8 Formula for converting percentage of catalyst to parts of resin 100 1 Paris Resin to 1 Part Catalyst of Catalyst y Example 590 catalyst is specified 100 5 1 19 Parts Resin to 1 Part Catalyst Formula for converting parts to percentage 10096 9 Pee oo Example If a ratio setting is 13 13 parts resin to 1 part catalyst a
70. dited while the GUN is running This includes all operational modes NOTE Any modifications to the GUN Config uration Parameters screen data are saved only when the operator presses the Store Data key F5 otherwise the modifica tions will be lost when the screen is exited with the escape ESC key Mode This parameter has three possible settings OFF AUTO and MANUAL OFF This setting completely disables the gun removes its data from the main screen and places the channels tied to the gun available for use by another gun AUTO This setting is used when the user wants to control both the flow rate and the ratio if it is a plural component material of the applicator LN 9400 00 9 DynaFlow User Manual Operation MANUAL This setting is used when the user wishes only to control the ratio of the material Users demand as much material as they wish and the controller will deliver as much as possible while keeping the ratio on target Number of Channels This parameter has three possible settings O 1 and 2 0 This effectively disables the gun 1 This indicates that the gun is to be a single channel flow control only applicator 2 This indicates that the gun is to be configured as a dual channel ratio controlled applicator Master Channel This parameter has eight possible settings 1 8 For single channel guns it simply indicates which channel will be controlling the fl
71. e a sticking check valve or a Y block blockage to name a few Corrective Action An easy way to verify that the system is capable of flowing at the desired rate is to place the GUN in CLEAN MODE and trigger the applicator The CLEAN MODE supplies maximum control pressure to the fluid regulator Watch the flow rate If the desired flow rate cannot be achieved or surpassed in CLEAN MODE it is obvious that it will not be achievable in control mode This tests all fluid lines from the material supply to the applicator If calibration ports valves are available such as on 2K fluid panels try operating the controller with the calibration valves open Place containers under the calibration ports and put the controller in RUN mode If operating in AUTO MATIC MODE the TRIGGER signal has to be 67 DynaFlow User Manual Maintenance 68 forced ON If the desired flow is achieved while in this mode of operation the fluid restriction is located further downstream to the applicator 4 Flow Meter Feedback Is flow being indicated on the controller If it is obvious that material is flowing through the system from the GUN or calibration ports if used but the controller indicates no flow then this indicates that the controller is not detecting flow meter pulses This could be caused by one of the following Flow meter gear stuck Bad flow meter sensor Disconnected or damaged fiber optic cable Bad fiber optic recei
72. e booth exhaust 7 Perform a system flush of each GUN 8 LOAD the material to be sprayed This may be controlled automatically or manually depend ing on the system 9 A dummy JOB can be run to verify the op eration of the entire coating system before spraying production parts In general the longer a system is shutdown the more importance should be placed on the start up procedure Normal Shutdown Procedure The shutdown procedure should be basically op posite of the start up procedure The degree or levelto which the system is shutdown depends on how long the shutdown is to last The following are considerations when shutting down the system 1 Place the system in a safe mode when per sonnel will not be present for extended periods of time 2 It is recommended to keep fluid loaded in the flow meters to prevent the gears from sticking during start up Generally this is the flushing solvent 55 DynaFlow User Manual Operation 56 3 Total system shutdown including AC power air and fluid pressure is recommended if the system is to be shutdown for more than one shift Clean Mode CLEAN mode can only be initiated if the GUN has been given a Haltinputandis enabled and nofaults are active Each CHANNEL can be independently configured to accept the CLEAN command For two component GUNS it may not be desirable to clean both the resin and catalyst at the same time therefore each CHANNEL can be configured a
73. er response to disturbances such as paint pumps 20 For two component repeat steps 4 through 19 for the Slave CHANNEL PID Tuning Methods Alternate PID 1 Set the maximum set point for the GUN 2 Set Ki and Kd parameters to zero Do this for both CHANNELS if this is a two component GUN 3 Set Kp for the Master CHANNEL based on the following formula 8 0 MVR LOW 25 500 Kp 10 Max Gun Set Point Ratio Ratio 1 60 Ransburg For example Max Gun Set Point 400 cc min MVR LOW 15 PSIG Ratio 3 1 8 0 15 25 500 Kp 10 400 3 4 6 5 25 500 300 552 5 550 4 Set Kp for the Slave CHANNEL based on the following formula 8 0 MVR LOW 25 500 Kp 10 Max Gun Set Point Ratio 1 For example Max Gun Set Point 400 cc min MVR LOW 15 PSIG Ratio 3 1 8 0 15 25 500 Kp 10 400 4 6 5 25 500 100 1657 5 1660 5 Cycle the GUN from READY to RUN so the new parameters are sent to the Channel Module s 6 Trigger the GUN Ifthe flow rates do not achieve their individual CHANNEL set points adjust the upstream fluid pressures until they both are on target NOTE This may require repeated triggers and fault resetting Once the proper fluid pressures are set the maximum set point for the gun will be flowing ratioed properly between the CHANNELS with the MVR pressures at 80 PSIG LN 9400 00 9 Ransburg DynaFlow
74. erial Digital scale accurate to 0 10 grams 1 Weigh the empty beaker and record the tare weight for later calculations 2 Enter the calibration mode for the desired CHANNEL 3 Perform the desired collection procedure above 4 Weigh the fluid in the beaker and subtract the beaker tare weight to get the net weight of the fluid collected 5 Entered the measured weight LN 9400 00 9 Ransburg Procedure 2 Automatic 1 Place the controller in Calibration Mode se lect automatic procedure 2 Set desired flow rate The pre set flow rate set point for the selected CHANNEL is based on the Total Flow Rate and Ratio for the GUN as stored in the JOB since calibration should always be performed at the normal flow rate for the CHANNEL The operator may over ride this value if desired 3 Set the desired time to collect fluid The pre set time for the selected CHANNEL is based on the desired flow rate for the CHANNEL so that 200 cc of material will be dispensed The oper ator may override this value if desired 4 Make sure that the applicator is triggered OFF and any calibration valves are closed Also make sure that the fluid has been loaded up to the point at which the fluid sample is to be taken GUN output or calibration valve 5 Place a graduated container at the place of fluid collection GUN or calibration valve 6 Trigger the GUN ON manually or automatic or open the calibration valve 7T
75. et of initial parameter values is included in the controller The initial default values determine the operating conditions ofthe controller when started for the first time Some of these will need to be edited during initial setup based onthe installation 29 DynaFlow User Manual Operation 30 PARAMETER DESCRIPTIONS CONFIG SYSTEM F1 system parameters are password protected unless disabled by setting the password to zero 0 Any time an operator wishes to change any of these parameters they are prompted for the password The password only needs to be entered once as long as the time between keystrokes does not exceed the Password Timer as described below System parameters may be edited at any time regardless of the operating mode if no sys tem errors exist Any active system errors must be cleared NOTE Any modifications to the System Pa rameters screen data are saved only when the operator presses the Store Data key F5 otherwise the modifications will be lost when the screen is exited with the es cape ESC key Horn Code This is a coded number that represents when the supervisor would like the System Faultoutput relay to energize This output is normally connected to a horn The options desired are selected 0 No horn 1 Horn when controller faults 2 Horn when pot life timer has expired 4 Horn when external fault is detected Blow Off Time This parameter is used only if the GUN
76. etween the static mix tube and the applicator has ratio material in it Pot Life This bar graph indicates how old the oldest mixed material is This is the material in the applicator EDIT JOB F4 JOB parameters may be edited at any time How ever if a JOB is edited while active the changes made to CHANNEL related parameters will not take effect until the GUN has been halted and requested to be active again Changes made to GUN related parameters take effect immediately after being saved to the Interface Module NOTE Any modifications to the JOB Param eters screen data are saved only when the operator presses the Store Data key F5 otherwise the modifications will be lost when the screen is exited with the es cape ESC key Mix Ratio Ratio is expressed as parts of Master CHANNEL to parts of Slaved CHANNEL in the form of XX 1 The Master CHANNEL is typically the resin and the slave CHANNEL is typically the catalyst If the desired mix ratio is supplied as a percentage of catalyst to the total volume Use the Master and Slave Percentage boxes instead Ransburg When a GUN is configured for two component operation and the Ratio is 99 0 1 or greater the GUN is said to be operating in pseudo single component mode Inthis case the slave catalyst CHANNEL is NOT set to MVR LOW when the GUN is placed in either Run or Load modes How ever if the slave catalyst CHANNEL is specified as a clean CHANNEL it w
77. f the most counter clockwise position is selected Solv and the Paint Solvent Fill button is pushed the normal load sequence occurs and solvent is loaded into the fluid sytem as if it was a color Paint Solvent Fill Filled This is a green illuminated push button When pushed the paint load sequence runs as programmed from the Load user interface screen The green indicator lamp flashes as the sequence is occurring and stays lit solid when the sequence has completed indicating to the operator that the system is ready If there is already a color loaded i e one of the color valve outputs is already on when this button is pushed the system will execute a flush sequence followed by a load sequence Purge Purged This is an amber illuminated push button When pushed a purge sequence is initi ated as programmed from the Purge user interface screen While the purge sequence is occurring this indicator lamp flashes It remains on solid when the purge sequence is complete indicating to the operator that the purge is complete This indicator will be turned off if a Paint Solvent Fill sequence has been initiated or a color is loaded LN 9400 00 9 91 DynaFlow User Manual Appendix Ra n sbu rg NOTE If both the green Paint Solvent Fill Filled lamp and the amber Purge Purged lamps are flashing simultaneously this indicates that no sequence has been downloaded to the color change sequencer since the last time power was ap
78. ffect the response time The integral gain Ki must be chosen such that oscillations do not occur Increased integral gain will cause faster response times but can lead to process instability and uncontrolled oscillations LN 9400 00 9 DynaFlow User Manual Operation Derivative Action Kd Derivative action is proportional to the rate of change ofthe error The derivative term dampens or slows down process overshoot and improves the response to changes in the process being controlled Another way to view this term is that it anticipates or leads what is happening with the actual flow Derivative action provides a sudden shift in the control output as a result of a guick change in the actualflow transient or set point Ifthe actual flow drops guickly the derivative term will provide a large change in the outputin an attempt to correct the perturbation before it goes too far Derivative action should be associated more with transient response control and less with overshoot inhibition such as during start up or trigger ON Oscillation due to derivative action is typically a cyclic wander away from the set point Putting It All Together The optimum PID controller settings are deter mined based on the application Types of applica tions that will effect PID considerations are Dynamic control of flow rate while spraying parts robot mounted Short GUN trigger times Long trigger times constant flow r
79. flush or load sequence will not be allowed to start until both of these indicators are illuminated These LED s are connected to four pressure switches which are actuated by the two flush boxes The signal from these pressure switches also feed the Paint Fill and Purge push buttons to prevent color changes and purges from occurring unless the guns are in their flush boxes and the boxes are closed These pressure switches should be jumpered if gun flush boxes are not to be used There are jumpers on the PC board inside the panel to bypass these pressure switches Feather Reset This push button is not functional when used in a DynaFlow system Spray Test This is a simple push button that sends a trigger signal back to the controller and also turns on the trigger solenoid to allow operators to verify and test flow etc Note that this button is only functional if fluid has been loaded i e the green Paint Filled indicator lamp is illuminated 92 LN 9400 00 9 DynaFlow User Manual Appendix ADDENDUM C FLOW LIMITATIONS Because of the way the DynaFlow determines flow rate from a flowmeter it has limitations where it can no longer detect flow at the low end and at the high end It uses a software timer to determine the time between pulses rather than a high speed counter card The low end limitation is because the timer overflows between pulses and at the high end the scan time of the program cannot keep u
80. gend at the top left and top right of each of the two graphs indicate which value is which color F1 Time Base This button allows the user to switch the time base resolution of the graph In fast mode the full screen width is graphed in 45 seconds In slow mode the full screen width is 90 seconds F2 Single Plot This button allows the user to record one full screen of data 45 or 90 seconds at which point the graphing stops to allow the user to examine the data continuous data mode when the cursor reaches the right end of the screen it automatically jumps back to the left and over writes the old data F3 Stop Plot This button allows the user to stop the data acquisition process temporarily and freezes the display for analysis or to save the plot to disk or memory stick F5 Start Stop This button allows the user to move both the start time cursor and the stop time cursor at the same time to the left F6 Start Time lt This button allows the user to move the start time cursor to the left F7 Stop Time lt This button allows the user to move the stop time cursor to the left F8 Stop Time gt This button allows the user to move the stop time cursor to the right F10 Save Plot This button allows the user to save the displayed pot to either the flash drive or hard drive ofthe touchscreen orto a USB memory stick It is saved in a bitmap format bmp so it can be printed on a
81. h is marked with symbol If there are large AC voltage fluctuations or voltage transients such as those typically produced by heavyelectricmachinery orwelding eguipment then a constant voltage transformer CVT or an uninterruptedly power supply UPS should be used between the FUSED DISCONNECT and the Control Panel lt Ifa CVT or UPS is to be used on the input to the Control Panel use a CVT with a Volt Amp VA output rating egual to or greater than the output voltage multi plied by the control panel fuse rating see specification section Also make sure that the device input ratings correspond with the voltage and frequency of the source supplied by the FUSED DISCONNECT The device output should be rated for 240 VAC maximum LN 9400 00 9 DynaFlow User Manual Installation Before applying power to the control panel verify that it is set to match the source voltage There may sometimes be a voltage selection switch usually located on the DC power supplies to select be tween 120 VAC and 240 VAC or different indicator bulbs may be required A WARNING Do not install or service this equip ment or perform installation or adjustment procedures unless you are properly trained and qualified Installing and servicing this equipment requires access to parts which could cause electric shock or serious injury if work is not performed properly All work must comply with applicable local and n
82. id regulator Make sure that the air supply pressure to the transducer is at least 100 psi Go to the FORCE I O menu for the CHANNEL in guestion Force Control Output volt age or 4 20 ma to several different values and observe the pressure gauge Reference Analog Sealing chart in this section for correct values If the transducer does not produce the proper pressures check for air leaks in the air pilot tube transducer and fluid regulator The transducers are very low volume devices and are designed for non flow or dead headed operation Also observe the pressure gauge for oscillation and listen to the transducer for fluttering sounds These are other indications that there may be air leaks in the system Another method for isolating small air leaks is to spray or dab a small amount of a soap and water solution around the fittings or valves and look for the continuous formation of air bubbles LN 9400 00 9 Ransburg Pressure PSIG Gun Flow Out of Range Explanation Manual Guns Only This fault in dicates that the total flow rate through a GUN has exceeded the MAXIMUM FLOW RATE JOB parameter value or dropped below the MINIMUM FLOW RATE JOB parameter Out of Tolerance Faults Explanation OUT OF TOLERANCE faults are generated in the following manner Every time a specific volume of fluid passes through the GUN specified by the TOLERANCE VOLUME param eter the controller determines the amount of resin and cata
83. ill be turned on to MVR HIGH in Clean mode When a 2K manual GUN is placed in single com ponent operation the master resin CHANNEL simply turns on to the MVR HIGH output pressure when the GUN is placed in Run mode All fluid flow is accounted for in the JOB totals When a 2K automatic GUN is placed in single component operation the master resin CHAN NEL will control fluid per the set point parameter in the JOB when the GUN is placed in Run mode and a trigger signal is supplied All fluid flow is accounted for in the JOB totals Master Percentage Refer to Mix Ratio information Slave Percentage Refer to Mix Ratio information Flow Rate Set Point This parameter has several functions depending on the mode in which the GUN is configured Manual Mode If the GUN is configured as a manual GUN this value is the total desired flow rate cc s min when the GUN is put in Load Mode See Load Mode in the Operation section of this manual Automatic Mode without Analog Control If the GUN is configured as an automatic GUN and external analog control of the flow rate is not being used this is the total flow rate of the mixed material desired at the spray GUN LN 9400 00 9 Ransburg Automatic Mode with Analog Control Dy namic Control If the GUN is configured as an automatic GUN and external analog control of the flow rate is being used the setpoint value is only active if there is no analog signal Analog c
84. intenance MOTHER BOARD SIGNAL IDENTIFICATION J7 POWER INPUT J10 AUXILIARY CAN BUS PORT r4 J11 Channels 1 amp 2 J8 SERIAL I O J14 Channels 3 amp 4 J17 Channels 5 amp 6 J11 14 17 20 J8 3 CHANNEL I O J9 SYSTEM I O Total Hold 2 12 22 Gn 42 2 2 c nai ieee 2 Fw Meter J12 13 15 16 18 19 21 22 FLOW METER INPUTS J9 12 J9 18 Used for flow meters with reverse flow detection capabilities only This input must be connected to 24 VDC if a single direction flow meter is used LN 9400 00 9 85 DynaFlow User Manual Maintenance 86 SERIAL COMMUNICATION PROTOCOLS NOTE Reference the DynaFlow Program mers s Manual for more information Allen Bradley RIO The Interface Module allows for direct commu nication from an Allen Bradley PLC Remote Input Output RIO port to the DynaFlow Fluid Flow Control system The RIO interface portion of the Interface Module contains some Allen Bradley components thatare licensed to Ransburg These are designed specifically to communicate with the proprietary protocol of the RIO serial link The central component being an application specific IC ASIC which is capable of formatting the RIO information foruse by the central processor CPU Up to four Channel Modules 8 flow control CHAN NELs can be controlled with the Interface Module The Interface Module and four Channel Modules
85. ional E P controller Flow Rate 1 Flow Rate scaled between MINI MUM FLOW RATE MAXI MUM FLOW RATE JOB param eters Flow Rate 2 Flow Rate scaled between MINI MUM FLOW RATE and MAXIMUM LN 9400 00 9 Ransburg Channel Module Hardware Specifi cations Cont FLOW RATE JOB parameters 4 Frequency Inputs From flow meters reverse flow capable Source Signal 1 amp 2 Frequency used to determine flow rate pulses per volume or weight Maximum Frequency 435 Hz Minimum Frequency 1 Hz Refer to Addendum C for flow limitations Phase Signal 1 amp 2 State used to determine direction of flow rate forward or reverse PID Control Closed loop control based on the Kp Ki Kd and deadband JOB parameters 30ms PID up date time default each chan nel Communications CAN ControllerArea Network CAN High speed serial communications to In terface Module RS 232C Port Spare auxiliary communication port Power Requirements 24 VDC at 100 ma typical each Channel Module Operating Temperature 0 to 55 C LN 9400 00 9 DynaFlow User Manual Introduction Control Enclosure A12233 Dimensions 610mm H X 610mm W X 410mm D Weight 45 5 Kg 100 Ibs AC Power 115 230 VAC 3A 50 60 HZ 1 Phase Temperature 5 C 40 Humidity 80 to 31 C decreasing to 50 at 40 C non condensing Interface Enclosure A12182 Dimensions 610mm H X 610mm W X 410mm D Weight 22 7 Kg 50 Ibs
86. ired JOB Z select PROGRAM TOGGLE and JOB inputs have been asserted correctly by the PLC or host computer See Flow Too Low and Flow Too High faults This inputis typically used as an interlock to other control equipment or it is simply hard wired to 24 VDC Supply 24 VDC to the System Ready Halt input Check with the PLC programmer to de termine the correct values for baud rate rack address rack size and rack start ing quarter and then set the DynaFlow Interface Module DIP SW1 and SW2 to the appropriate settings per Interface Module DIP SW2 Settings and Mother Board Signal ID J3 J4 J5 J6 Channel Cards respect ively in this section Check cable connections per Figure 25 65 DynaFlow User Manual Maintenance ERROR CODES Cont Displayed Text Fault Cause B010 RIO Communi Cont cations Error Cont 020 RIO Invalid BTW Type B030 RIO Invalid BTR Type B040 Gun Channel Number B050 RIO Invalid BTR Job Number B060 RIO Invalid BTW Length 66 RIO cable is not properly terminated at each end The PLC has issured a BTW with an invalid BTW data type in the first word offset The PLC has issued a BTW with an invalid BTR data type in the second word offset The PLC has issued a BTW with an invalid gun or channel number in the third word offset The PLC has issued a BTW with an invalid job number in the fourth word offset The PLC has issued a BTW with an i
87. isk errors Configuration errors System errors 54 Ransburg PROCEDURES First Time System Start Up This section is intended for skilled trades person nel Always be aware of safety guidelines while operating equipment Before power is supplied to the DynaFlow Fluid Flow Control take time to familiarize yourself with the controls Unexpected actions can occur during initial power up sequences and you should know which controls shut down the controller The following information serves as a guide for initial systemtesting and start up Operational problems will be avoided if time is taken to follow the steps outlined below Read through the entire sequence first before performing any actions Verify that the Interface and Channel Mod ule dip switch settings are correct Refer ence the HARDWARE SETTINGS section Visually inspect the entire system Review the Installation section of this manual and any related manuals such as the flow meter and material regulator Verify thatall air and fluid lines are routed properly and fittings are secure Make sure that the required fluid filtration is installed Fluid lines should be flushed out manually before installation of the flow meters to ensure that any large particles or contamination located from the fluid filter to the flow meter connection are removed Make sure that the required air filtration for the E P transducer s is installed If rotary applicators
88. l be limited by changes in the fluid mechanics of the system It will take longer to achieve requested flow rate as fluid viscosity increases or fluid supply pressure de creases Inotherwords the same response cannot be achieved for a 50 sec Zahn 2 material as for a 20 sec Zahn 2 material given the same fluid supply pressure and fluid control components This is important to understand especially for 2K systems It may be an advantage to purposely slow down the response of the quicker reacting thinner fluid such that it will remain closer to that of the thicker fluid in 2K systems during triggers or changes in the set point Other options are to decrease the supply pressure for the thinner fluid or increase pressure for the thicker fluid 6 ResetWindup condition Reference Trouble shooting in the Maintenance section Reset windupis a condition when the controller does not have enough strength to reduce the error back to zero This occurs due to unusual restrictions in the fluid control devices orfluid lines and indicates that the system is not tuned properly or there is a problem If the actual fluid flow is less than the requested flow minus the dead band value the controller will continue to increase the output until it reaches the maximum allowable fluid regulator LN 9400 00 9 Ransburg pressure This is due to the Integral term of the PID control If the restriction causing the low flow condition is removed sudden
89. l for digital inputs 16 19 2 3 24 VDC source 1 2 grounded sink Selects 0 10 VDC or 4 20 ma operation for the analog control output 2 2 3 0 10 VDC 1 2 4 20 mA Selects 0 10 VDC or 4 20 ma operation for the analog output 2 2 3 0 10 VDC 1 2 4 20 mA Selects 0 10 VDC or 4 20 ma operation for the analog set point input 2 2 3 0 10 VDC 1 2 4 20 mA Selects 0 10 VDC or 4 20 ma operation for the spare analog input 2 2 3 0 10 VDC 1 2 4 20 mA Trigger 2 Gun Mask 2 Transparent PID 2 Total Hold 1 Inputs effected Load Mode 2 Analog Hold 2 External Fault 2 MVR Enable 2 Inputs effected Run 2 Halt 2 Total Reset 2 Clean 2 To the E P transducer 2 Actual flow rate for CHANNEL 2 scaled by Maximum and Minimum Flow Rate parameters Scaled by Maximum and Minimum Flow Rate parameters LN 9400 00 9 Ransburg DynaFlow User Manual Maintenance CHANNEL MODULE P N 77206 XX or A10946 XX DIP SWITCH SW1 SETTINGS Default n LN 9400 00 9 Trigger Detection Method This switch setting effects only GUNs configured as dual component Manual mode OFF GUN trigger input signal required trigger input signal not required Fluid flow through Master CHANNEL initiates PID on Slave CHANNEL Master CHANNEL flow rate is determined by a manual flow rate adjustment located on the GUN Analog Hold Mode OFF When the GUN trigger is removed the E P transducer
90. lled by the GUN parameters to the full open position This permits the fluid system to be cleaned The removal of the GUN Enable signal or a HALT input signal is required to end the CLEAN operation Actual cleaning sequencing PURGE such as soft air push out is performed by the PLC or other external controller For details refer to Clean Mode in the Operation section of this manual This input will activate the GUN and will allow material flow if all other requirements are met This is identical to pushing the GUN ON switch on the OPERATOR INTERFACE PANELS Run requires a pulsed signal of at least 0 25 seconds duration If this signal is reapplied once the JOB has been started then it is ignored When this signal is supplied following a HALT the JOB stored in the queue will be activated If no new JOB was entered during the previous HALT then the JOB located in the queue will not change and will be used again The Gun Mask input specifies whether a JOB or toggled into GUN n queue This signal is used in conjunction with the system PROGRAM SELECT and PROGRAM STROBE inputs A 24 VDC signal selects the GUN a 0 VDC signal masks the GUN as not used for the JOB selected Multiple gun masks can be asserted simultaneously if it is desired to load more than gun with the same JOB Total Reset requires a pulsed signal of at least 0 25 seconds duration This signal will reset the daily and JOB totals for the GUN The non re
91. ly while a large control output signal exist then a relatively long amount of time is required for the Integral term of the PID to reduce the control output back to a normal range since the Integral term is proportional to time and also due to the inherent response of the system If fluid flow response has changed significantly with the same setup that previously produced good response then inspectthe system for component failure blockages and check the fluid type and viscosity Alternate PID Equation The normal PID equation is based on the error between the desired set point and the actual flow rate for the CHANNEL If the set point is varied dynamically by a PLC via RIO or by a robot via Analog Input it may be desirable to implement an alternate form of the equation The alternate form of the equation uses the set point for the proportional term of the equation The Integral and Derivative terms are the same but slightly different scale factors are used To enable the alternate PID equation turn on DIP SW1 4 or SW1 8 on the Channel Module for each CHANNEL of the GUN PID Tuning Methods Standard PID 1 Select the nominal flow rate for the GUN 2 Set Kp and Kd parameters to zero Do this for both CHANNELS if this is a two component GUN 3 Set Ki for the Slave CHANNEL to zero as suming this is a two component GUN 4 Set Ki for the Master CHANNEL to the de fault value shown in Default Control Parameters chart
92. lyst material that flowed The controller then calculates the actual ratio and determines if itis within the limits as set by the FLOW TOLER ANCE setting Reference the Error Codes table Figure 16 Typical causes for OUT OF TOLERANCE faults are 1 Kp Ki or Kd gains not set correctly 2 Sticking or faulty fluid regulator 3 Sticking or faulty flow meter 4 Running the wrong JOB which may in clude the wrong gain values 5 Fluid supply pressures not adjusted properly LN 9400 00 9 DynaFlow User Manual Maintenance 6 The MVR LOW JOB parameter set too high above the regulator cracking pressure 7 Air bubbles or cavitation in the fluid 8 Unstable fluid supply pressures to the fluid regulators This can be seen with pump supply systems Corrective Action Thecauseisthe material supply pressure in almost every case whenthis faultis observed Obviously if FLOWTOO LOW or FLOW TOO HIGH faults are not occurring the flow rates are operating within therange ofthe fluid regulators Over an extended period of time however the volumes used are not within the appropriate tolerance band Observe the ratio for both the resin and catalyst channels that are producing faults while they are operating or immediately after the controller faults before resetting it If the actual ratio of the catalyst is below target adjust the supply pressure to the catalyst regulator up approximately 5 psi or adjust the resin
93. m may be cleared by entering a Pot Life Time of zero seconds MVR High Pressure Master and Slave This parameter allows the operator to limit the maximum pressure that the transducer is allowed to output to the fluid regulator in any mode 35 DynaFlow User Manual Operation 36 MVR Low Pressure Master and Slave This parameter allows the operator to set the low limit on the pressure sent to the fluid regulator while in the Run or Load modes It can be used to cause a faster response by the transducer regulator system It should be adjusted so that the regulator valve is just short of opening With a standard MVR valve this value should never exceed 30 psi If this value is too high continuous FLOW TOO HIGH faults will occur When a GUN is configured for two component operation and the Ratio is 99 0 1 or greater the GUN is said to be operating in pseudo single component mode Inthis case the slave catalyst CHANNELis NOT set to MVR LOW when the GUN is placed in either Run or Load modes However if the slave catalyst CHANNEL is specified as a clean CHANNEL it will be turned on to MVR HIGH in Clean mode MVR High and MVR Low Effect On PID Operation The PID will only output transducer pressures between MVR LOW and MVR HIGH Pulses Liter Master and Slave The number of pulses sent from the flow meter to the controller for each unit of fluid flow Each pulse represents a volume of fluid and is dependent on flo
94. n Solvent Air Chop Resin Solvent Resin Air Paint Dump Valve Resin Fluid Override Trigger Solenoid Catalyst 1 Catalyst 2 Catalyst 3 Catalyst Solvent Catalyst Override The following DynaFlow inputs can be controlled by the seguencer DynaFlow Run DynaFlow Halt DynaFlow Trigger DynaFlow Load DynaFlow Clean Catalyst Disable Note thatthere are too many valves and signals to be displayed on one screen Therefore the opera tor must scroll down to see the bottom five items Program the time for each step by touching the step duration box under the step to be modified and then push F1 Modify to change it Then toggle any of the signal or valve boxes at each step that you wish to have on during that step and then push the Modify button The steps will toggle between Off and On as you continuously hit the Modify button The Hold step is the final step in the sequence for both flush and fill When the sequence com pletes the signals and valves will be held in the condition selected in the hold step Keep in mind that when changing from one color to another the system performs a flush sequence followed by a fill sequence so the hold step in the flush sequence will only occur momentarily LN 9400 00 9 DynaFlow User Manual Operation There are 8 function keys defined while editing flush load and color change sequences F1 Modify This button brings up a numeric keypad if cursor is on one of the step d
95. n of two component materials is based on pre set ratios located in the JOB tables When the GUN is placed in RUN MODE the master channel resin goes full open or to the setting specified for that channel as MVR HIGH and stays at that value The slave channel goes to the pressure setting specified for that channel by MVR LOW The controller determines the flow 45 DynaFlow User Manual Operation 46 rate of the master channel based on flowmeter feedbackand calculates the setpointofthe slaved catalyst CHANNEL based on the ratio setting for the GUN The detection of a Trigger OFF signal or the lack of Master CHANNEL flow meter pulses will cause the controller to output the MYR LOW setting to the Slave CHANNEL In addition the PID control loop is frozen and the last control output stored Upon reapplication of a Trigger signal or the detection of Master CHANNEL flow meter pulses depending on the dip switch setting on the Channel Module the stored Slave CHANNEL control signalis outputfor a short delay time and then the PID control loop is again initi ated This results in stable control loop operation regardless of the duration or quickness of trigger signals The flow rate of the master CHANNEL will be continuously monitored during operation and the slaved CHANNEL set point adjusted accordingly Ifthe slaved CHANNEL cannot achieve the proper flow rate the software issues a FLOW TOO LOW or FLOW TOO HIGH fault Additi
96. nd I want to know what percentage of the total mixed material is resin and what percentage is catalyst 100 13 1 7 14 Catalyst 100 7 14 92 86 Resin LN 9400 00 9 87 DynaFlow User Manual Warranty Policies 88 Ransburg WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any partand orequipmentthatfalls within the specified time see below because of faulty workmanship or material provided thatthe equipmenthas been used and maintained in accordance with Rans burg s written safety and operating instructions and has been used under normal operating condi tions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG AP PROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e GUNS power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR ASSOCI ATED VALVES AND TUBING AND SUPPORTINGHARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THISWARRANTY IS REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORK MANSHIP OR MATER IALS THERE ARE NO IMPLIED WARRAN TIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICUL
97. nd pressure control is becoming extremely expensive and is currently experiencing very long lead times We have decided to produce two versions of the DynaFlow Channel Card One version will be built as the boards are now The other version will not have the 4 20 mA converter on the board which will effectively eliminate the capability of the board to output 4 20 mA signals for these two outputs Our sales history shows very few users make use of these two output signals The 0 10 VDC outputs for these two signals will still function normally In order to ensure that the proper boards are selected the following changes have been made to the part numbers The A10946 00 part number has been obsoleted The A10946 01 board is the new board without the 4 20 mA IC s and is the board that will be used in all future builds unless the customer specifically reguests 4 20 mA outputs for these two signals The A10946 01 board can be modified by our manufacturing facility to become an A10946 02 when necessary if this option is required Because of the high cost and limited availability of these IC s there will be an additional cost for this option If you currently use the obsoleted A10946 00 boards our technical support personnel will need to know if you are using the 4 20 mA option for either the flow rate output or the pressure control output to be able to determine which of the two new boards to send This can be done by examining the jumpers on the
98. nent 3 K Operation DynaFlow was designed for either single or two componentoperation Three componentoperation is possible by configuring two two component guns The first Gun is set up as follows Gun 1 Master Channel Material Resin Flow Controller Color Change Value CCV Flow Meter Standard Gear Type Slave Channel Material 2 Component Flow Controller MVR with appropriate size needle Flow Meter Piston or Gear Type depending on min max flow rates see Notes 4 and 5 Operating Mode Manual The output of the first Gun is then fed into the Master Channel input of the second Gun The second Gun is setup as follows Gun 2 Master Channel Material Output of Gun 1 Resin 274 Component Flow Controller Color Change Value CCV see Notes 1 2 and 3 Flow Meter Gear Type LN 9400 00 9 Ransburg Slave Channel Material 3 Component Flow Controller MVR with appropriate size needle Flow Meter Piston or Gear Type depending on min max flow rates see Notes 4 and 5 Operating Mode Manual or Auto see Notes 1 2 and 3 NOTES 1 If the output of Gun 2 supplies one or more hand guns then Gun 2 should be operated in Manual mode using a CCV for the Master Chan nel flow controller 2 If the output of Gun 2 supplies a single appl icator then an MVR should be used for the Mas ter Channel flow controller and Gun 2 should be operated in Auto mode 3 If the output of Gun
99. ngs each time that material is requested There are up to 100 JOB s for each GUN By saving frequently used JOB Zs to memory you can later recall them by loading the number representing that JOB Allofthe JOB s can be backed up to and restored from a USB memory device Referencethe Opera Ransburg tor Interface Users Manual and Program mers Manual for details on data transfer operation and available formats Theflow control unitincludes one Interface Module and up to 8 hardware PID control CHANNELs 2 CHANNELs located on each of the 4 possible Channel Modules The Interface Module will com municate to a host controller The host is one of the following using discrete Allen Bradley PLC using RIO Local Operator Interface using an RS 232C communication port 3 K Operation DynaFlow was designed for either single or two component operation Three component operation is possible by configuring two two component guns The first Gun is set up as follows Gun 1 Master Channel Material Resin Flow Controller Color Change Value CCV Flow Meter Standard Gear Type Slave Channel Material 2 Component Flow Controller MVR with appropriate size needle Flow Meter Piston or Gear depending on min max flow rates see Notes 4 and 5 Operating Mode Manual LN 9400 00 9 n sb u rg DynaFlow User Manual Introduction The output of the first Gun is then fed into the NOTE Ma
100. nnel Module The Channel Module represents the core of the system Each Channel Module is responsible for Monitoring the CHANNEL specific inputs and supplying the necessary CHANNEL specific outputs for control and status Receiving and processing the flow meter feedback pulses Determining the analog PID output control signal by performing high speed floating point math Receiving and interpreting commands from the Interface Module through high speed Ransburg CAN Bus communication Supplying data and status upon request to and from the Interface Module LN 9400 00 9 Ransburg Located on the front panel of the Channel Mod ule are several status indicator lights LEDs These are 1 CPU Is ON when the microprocessor is op erating normally 2 ACTIVE Is ON when communication is taking place to the Interface Module 3 FAULT Is ON when there is a problem with the module Interface Module The Interface Module performs the following Stores system configuration and data tables Acts as an interpreter for communication with an external Host computer PLC and or the local Operator Interface Communi cates through a high speed Ransburg CAN Bus data link to each Channel Module Responsible for system specific inputs and supplying the necessary system specific outputs for control and status Located on the front panel of the Interface Mod ule are several status indicator lights LEDs These are
101. ntrolled LN 9400 00 9 Ransburg Deadband This represents a flow range above and below the set point value in which the PID control is suspended This keeps the control output from continually changing and produces stability when close to the reguested value Proportional Action Kp Proportional action simply means that the con troller output changes in proportion to the error between the set point and the actual flow It is also commonly referred to as gain proportional gain and proportional band to name a few If the proportional gain is set too high the system will oscillate If settoo low the fluid flow will wonder due to a lack of responsiveness Integral Action Ki The Integral element of the PID controller forces the actual output flow to match the desired by utilizing the sum of the error in flow rate Integral action is proportional to the sum of the error This term is needed to remove long term or steady state error that cannot be removed by the proportional term Integral action is the most important factor gov erning control near the set point The integral term changes the control output as a result of a continuing error between set point and actual The integral term will continue to shift the output until the actualflow rate falls within the Deadband value Integral action will also effect transition response times The greater the change in reguested flow rate the more the integral action will e
102. nts etc make such variations inevitable Compare this manual with your system installation drawings and appropriate Ransburg equipment manuals to reconcile such differences Careful study and continued use of this manual will provide a better understanding of the equip ment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local Ransburg representa tive or Ransburg LN 9400 00 9 DynaFlow User Manual Safety A WARNING The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment A WARNING 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 DynaFlow User Manual Safety AREA Tells where hazards may occur Spray Area 20
103. nvalid message length word count Ransburg Corrective Action Check cable connections per Figure 25 of this manual Check each end of the cable to de termine if the terminating resistor is installed at each end The DynaFlow system may not be the last rack on the RIO cable The value ofthe terminating resistor is based on cable length baud rate and if Extended Node Capability is enabled at the PLC If Extended Node Capability is enabled the terminating resistors should always be 82 ohms Otherwise the term inating resistors should be 150 ohms for 57 6 and 115 2 Kbaud and 82 ohms for 230 4 Kbaud In any case use 1 2 watt resistors Have the PLC programmer reference the DynaFlow Programmer manual for the correct BTW data types Have the PLC programmer reference the DynaFlow Programmer manual for the correct BTR data types Have the PLC programmer ensure gun and channel numbers are between 1 and 8 or O if not required for the particular data type Have the PLC programmer ensure job numbers are between 1 and 100 or O if not required for the particular data type Have the PLC programmer reference the DynaFlow Programmer manual for the correct BTW message lengths LN 9400 00 9 Ransburg Flow Too Low or Flow Too High Explanation These are CHANNEL specific faults FLOW TOO HIGH and FLOW TOO LOW faults are issued if the reguested fluid flow cannot be obtained This typically means that there is a
104. ny standard P C with a printer attached The file is saved based on the date and time it is saved in the following format File Name AABBCCDD bmp where Month BB Day of Month CC Number of hours since midnight DD Minutes since last hour LN 9400 00 9 Ransburg Data Displays At the top of the graphing screen there may be as many as sixwhite boxes with data in them The center two boxes indicate the time of the start and stop cursors start on top stop on the bottom The other four boxes indicate the value of the graphed variable at the point where the cursors are currently positioned JOB TOTALS F7 Calendar date time data is not available from the Interface Module and must be supplied by the Operator Interface or host computer Daily Total For each JOB per CHANNEL Records accumulated total of all material through a CHANNEL since last reset Any time period as sociated with this total is based on when itis reset For example if it is reset after each rack or part at the end of a shift end of the day or end of day Yearly Total For each JOB per CHANNEL Records the accumulated total of all material through a CHANNEL since last reset Any time period associated with this total is based on when it is reset For example if it is reset at the end of a shift end of the day or end of the year Calibration Total For each JOB per CHANNEL Records the accumulated total of all material thro
105. onally the software verifies ratio after each TOLERANCE VOLUME has flowed through the master channel flow meter by comparing the two volumes that flowed during that time period and calculates a ratio error Ifthaterroris greaterthan the FLOW TOLERANCE parameter the software issues an OUT OF TOLERANCE fault When the GUN is given a HALT command both fluid regulators are set to O psi Load Mode LOAD MODE is similar to RUN MODE However in LOAD MODE up to 10 faults are permitted be fore the gun will leave LOAD MODE and enter the FAULT MODE All eleven 11 faults will appear in the Error Log screen The GUN will automati cally leave LOAD MODE and return to the READY MODE after a volume greater than or egual to the Mixed Volume has flowed since the last fault Ransburg To Place A GUN In LOAD MODE 1 The external GUN Enable input must be sup plied to the Master CHANNEL No system or GUN faults can be active and the GUN configuration and JOB tables should be properly set 2 The GUN Trigger input is not reguired for manual GUNS 3 A signal must be supplied to the Master CHAN NEL LOAD input or a LOAD command issued from the Operator Interface Panel or other host controller 4 Flow will begin immediately To Exit LOAD MODE 1 Simply remove the LOAD input and apply the HALT input or issue a command from the Opera tor Interface Panel host controller GENERAL The following are common to both AUTOMATIC and M
106. ondary analog output RIO Baud rate position 3 4 Baud Rate OFF 57 6 KB ON 115 2 KB 230 4 KB 230 4 KB SIO Baud rate position 5 6 Baud Rate OFF OFF ON ON 19 2 KB 4 8 KB 9 6 KB 38 4 KB RIO Rack Size position Number Of Channel 7 8 Size Modules OFF OFF 1 4Rack 1 ON 1 2 Rack 1103 OFF 3 4 Rack 14 ON Full Rack 1to 4 Es Inserting this jumper adds 120 Ohm termination resistor across the RS 485 RX and RX lines Inserting this jumper adds a 120 Ohm termination resistor across the Ransburg CAN Bus LN 9400 00 9 81 DynaFlow User Manual Maintenance Ra n sbu rg CONTROL RACK TERMINAL IDENTIFICATION MOTHER BOARD SIGNAL IDENTIFICATION J3 4 5 6 4 5 6 CHANNEL MODULES CHANNEL MODULES Pin Description Pf Description 1 j AmalogSetPointinput h 1B OT 2A SpxeAnaoginpuii 28 3A AnaoginutGND 4A Analog Transducer 000086 4B as A 8A Run Input Tanspare PIDmpui 98 10 108 DigtalputGND _ 58 Total Reset Input MB 15A Cean mpi _ _ 16A Digital
107. ontrol is ac tive anytime that the input signal is greater than 0 25 VDC 4 63 ma Automatic Mode with RIO Control Dynamic Control If the GUN is configured as an automatic GUN and RIO control of the flow rate is being used the set point value has no meaning unless the RIO com manded set point is zero In that case the JOB set point is used as the GUN flow rate set point NOTE When operating in 2K mode this pa rameter relates to the total mixed material delivered through the GUN Maximum Flow Rate This parameter has 2 possible meanings depen dent upon how the GUN is configured Manual Gun This parameter is an alarm set point If the total flow rate of the mixed material to the spray GUN exceeds the amount specified by this parameter the GUN will shut OFF as the result of a FLOW OUT OF RANGE FAULT Automatic Gun This parameter is used to scale the flow rate output for the GUN s CHANNEL 5 to specify the desired flow rate when a 10 VDC or 20 ma signal is ap plied to the analog set point input Minimum Flow Rate This parameter has 2 possible meanings depen dent upon how the GUN is configured LN 9400 00 9 Manual GUN This parameter is an alarm set point If the total flow rate of the mixed material to the spray GUN falls below the amount specified by this parameter the GUN will shut OFF as the result of a FLOW OUT OF RANGE FAULT If no alarm is desired set this parameter to zero 0 and the
108. ow control valve and reading the flowmeter for this applicator For dual channel guns this indicates normally which channel will be controlling the resin part of the mixed material It is always desirable for the master channel to have the higher flow rate of the two materials Slave Channel This parameter has four possible values 2 4 6 or 8 It indicates which channel will be the slave typi cally the catalyst to the master channel selected above for ratio control Clean Channels This parameter has four possible values NONE MASTER SLAVE or BOTH This setting determines which of the fluid regula tors or MVR valves are opened to full when the unit is put in Clean Mode for flushing and filling operations Default Sets the JOB which is loaded at power ON 31 32 Flow Tolerance Percentage This is a number in percent that indicates how much deviation above and below the set point is acceptable Increasing this number will reduce nuisance faults but may lead to inaccurate fluid metering if set too high This number is a percent of the specified mix ratio for each of the 2 materials that is allowed to occur before the system faults with an OUT OF TOLER ANCE fault This is only updated after the volume of material as set by the Tolerance Volume has passed through the GUN The accumulated flow volume is reset to O upon the application of each RUN command Tolerance Volume This paramete
109. p with the speed of the incoming pulses Because of this fact the DynaFlow cannot see flow at the low end when the pulses fall below 1 Hz one pulse every second With a gear type flowmeter calibrated to 4 500 pulses liter the DynaFlow will not detect flow below 13 3 cc min With a gear type flowmeter calibrated to 8 000 pulses liter the DynaFlow will not detect flow below 7 5 cc min With a gear type flowmeter calibrated to 40 000 pulses liter the DynaFlow will not detect flow below 1 5 cc min With a piston flowmeter calibrated to 60 000 pulse liter the DynaFlow will not detect flow below 1 cc min At the high end the DynaFlow cannot see flow when the pulses exceed 435 Hz With gear type flowmeter calibrated to 4 500 pulses liter the DynaFlow will not detect flow above 5 800 cc min With gear type flowmeter calibrated to 8 000 pulses per liter the DynaFlow will not detect flow above 3 275 With a gear type flowmeter calibrated t 40 000 pulses liter the DynaFlow will not detect flow above 655 cc min With a piston flowmeter calibrated to 60 000 pulses liter the DynaFlow will not detect flow above 435 cc min LN 9400 00 9 93 DynaFlow User Manual Appendix Ra nsbu rg NOTES 94 LN 9400 00 9 Ransburg MANUAL CHANGE SUMMARY This manual was published to supercede Service Manual LN 9400 00 8 DynaFlow User Manual to make the following changes 1 Added Interface Enclosure A12182 spec
110. plied to the system This can be corrected by loading a job from the user interface screen and executing at least one fill or purge sequence Horn In the top center of the panel is a horn that indicates when the controller has turned on the Fault output from the gun Total Flow This is an LCD display that indictes the current flow rate out of the applicator or appli cators if multiple applicators are fed from one fluid panel It operates from an analog output signal from the controller with 0 VDC being 0 cc min and 10 VDC scaled to 2000 cc min Flow Control This is a potentiometer that varies the analog flow control voltage into the channel card from 0 volts DC to 10 volts DC Users can program what flow rate they want for both extremes by using the Minimum Flow and Maximum Flow parameters under the edit gun screen Faulted Fault Reset This is a red illuminated push button The lamp will be illuminated anytime a fault occurs Pushing this button resets any fault that has caused the fault After resetting a fault the user must then push the Ready Run push button to put the gun back into run mode to resume spraying Ready Run This is a green illuminated push button Pushing this button puts a gun into run mode When in run mode the green lamp is illuminated It is extinguished in either a halted or faulted state Guns in Flush Box These are two LED s that indicate when up to two spray guns are in their re spective flush boxes A
111. r Ki gains set too low 2 Running the wrong JOB which may include the wrong gain values 3 Fluid pressures Either increase the catalyst supply pressure or decrease the resin pressure Try to maintain normal operating pilot pressures to the fluid regulators between 30 60 psi 4 Reguested flow rate exceeds capa bility of the catalyst channel at the given fluid supply pressure Reduce total flow rate or increase catalyst supply pres sure 5 Air bubbles or cavitation Last digit indicates CHANNEL LN 9400 00 9 Ransburg DynaFlow User Manual Maintenance ERROR CODES Cont Displayed Text Fault Cause Corrective Action Non Existent Program lt gt Flow Out of Range System Halted RIO Communi cations Error LN 9400 00 9 JOB number entered for the indi cated GUN does not exist JOB number defaulted to 00 Last digit indicates CHANNEL The total flow rate for GUN has exceeded the MAXIMUM FLOW RATE JOB parameter or fallen below the MINIMUM FLOW RATE JOB parameter For Manual only System Ready Halt input is inactive PLC and DynaFlow are not set to the same baud rate rack address rack size rack starting quarter RIO cable is not connected to the proper terminals at either end Verify the following 1 The JOB has been saved in memory for the indicated GUN 2 The correct JOB is being re guest ed 3 Fordiscrete hard w
112. r a Measured Volume LN 9400 00 9 nsbu rg DynaFlow User Manual Operation Calculated Pulses Liter This is the new Pulses Liter value based on the Number of Pulses received from the flow meter during calibration and eitherthe Measured Volume orthe Measured Weight and Specific Gravity The operator may override the Calculated Pulses Liter value by entering a Calculated Pulses Liter value Current Pulses Liter Displays the current Pulses Liter value used by the Channel Module during calibration If this value is inaccurate at the time which is why cali bration is being performed the Actual Flow Rate and Calculated Beaker Volume values will also be inaccurate Operational Parameters Flow Rate Indicates total flow rate through a GUN Ifin 2K sums the total of each CHANNEL attached to the GUN e If in 1K simply indicates the CHANNEL flow rate GUN Status Indicates the current status of the GUN This can be one of the following GUN Active in run mode GUN Halted CLEAN mode active LOAD mode active CALIBRATION mode active GUN faulted Transparent mode active Analog Hold mode active Pot Life Time Exceeded JOB Gueue Stores the next JOB to be run ARUN command following a HALT will load the next JOB from the Queue If more than one JOB is toggled into the Oueue before the next RUN command then the newest JOB 4 is placed into the Queue and the previous JOB is lost LN 9400 00 9 41 DynaFlow
113. r has no effect on single component GUNS and only effects GUNs configured for two component operation This is the volume over which the ratio accuracy is checked Every time the volume of Master CHANNEL fluid specified in this parameter has flowed the ratio is checked The default value is 150 cc s of the Master CHANNEL This param eter should never be set so low that less than 10 cc s of the slave channel has flowed If this value is set too low nuisance OUT OF TOLERANCE faults will occur The first time a gun is triggered after being placed in Run mode the Tolerance Volume is 150 of the value entered in the job Mixed Volume The amount of mixed material present in the mix tube fluid lines and spray GUN combined The fluid in the spray GUN is always the material that has been mixed the longest The processor keeps track of how long this material has been mixed Pot Life Timer and therefore needs to know the volume from the mix tube to the spray GUN To determine the amount of mixed material in the system 1 Measure the volume of the mixing block 2 Measure the volume of the spray GUN Ransburg 3 Measure total hose length and inside diameter 4 Use the following formula to calculate hose volume 5 Add 10 to calculated value Volume d x L x 12 87 Volume Volume in cc s d 7 Inside diameter of hose L Length of the fluid line from the flow meter to the spray GUN in inches Itis bestto over estim
114. s a clean CHANNEL independently by setting the Clean CHANNELs parameter in the GUN configuration table The CLEAN operation can be started one of several ways The first method is to simply supply the GUN CLEAN input The second method is to initiate the CLEAN mode through the OPERATOR INTER FACE or host controller refer to the appropriate manual Actual cleaning time and seguences including soft air push out purge is performed by the system controller or the pneumatic interface panel and not directly by the fluid flow controller The CLEAN mode is terminated when deactivated from the Operator Interface or when a HALT signal is supplied Calibrate Mode CALIBRATE mode can only be initiated if the GUN is enabled and no faults are active The CALIBRATE operation is initiated and controlled through the OPERATOR INTERFACE or host con troller refer to the appropriate Operator Interface or Programming manual The CALIBRATE mode is terminated when deacti vated from the Operator Interface or if the Enable input is removed Recovering From Faults This section Identify and record the fault Evaluate action s to be taken Perform corrective action s Reset and run Ransburg PID CONTROL The ransburg DynaFlow Fluid Flow Controller incorporates a form of a Proportional Integral Derivative PID algorithm with additional func tions or modifications which are specific to the efficient control and delivery of m
115. s a convenient way to mount transduc ers for 2K applications There are typically two transducers located in each panel with electrical terminals and an air supply input Thetransducers may also be mountedindividually on any air drop outside of the Class 1 Division 1 hazardous location if 1 Tubing and cable lengths do not violate the minimum and maximum lengths specified in the Installation section of this manual under Equipment Locations 2 The air supply meets the specifications as listed in the Introduction section of this manual under Pneumatic Specifications or those pub lished with the transducer A 1 1 volume booster may also be connected LN 9400 00 9 DynaFlow User Manual Installation directly to the transducer output when operating a DR 1 Fluid Regulator if pilot line lengths longer than recommended or of a larger tubing diameter is used other than that recommended Keep the distance between the transducer to the material regulator as short as possible without violating the minimum lengths specified to avoid system response delays and to achieve the op timum fluid flow characteristics for the system Material Regulators and Flow Meters The location and mounting of the material regula tors and flow meters is specific to each installa tion The information presented here is intended as a guideline only Reference should be made to the supplied documentation specific to your install
116. s in Introduction Specifications section 2 Revised Installation section with additional instructions related to Eguipment Locations and Eguipment Mounting assembly location and mounting reguirements including anchor system ratings 3 Revised Installation section with additional instructions related to Eguipment Grounding and Input Power protective earthing requirements input power supply connections wiring size and external switch circuit breaker and external over current protection requirements 4 Revised Back Cover Technical Service As sistance Telephone and Fax Number LN 9400 00 9 Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Phillips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No LN 9400 00 9 O 2012 Ransburg All rights reserved Litho in U S A Models and specifications subject to change without notice 12 12
117. s total is based on when it is reset For example if it is reset at the end of a shift end of the day or end of the year Clean Total For all JOBs per CHANNEL Records the accumulated total of all material for all JOBs through a CHANNEL while in CLEAN MODE of operation since last reset Any time period associated with this total is based on when itis reset For example if it is reset at the end of a shift end of the day or dend of the year CALIB PROC CHANNEL CHANNEL to be calibrated 1 8 Each CHANNEL must be calibrated separately Calibration Mode Sets open loop manual or closed loop automatic calibration mode 39 DynaFlow User Manual Operation 40 Open Loop or Manual Calibration Mode This mode attempts to flow material at the highest flow rate possible by setting the output to the E P transducer at the MVR HIGH parameter located in the JOB table for the selected CHANNEL No less than 200 cc of material should be dispensed during calibration Otherwise the error in cali bration will be too large With 200 cc of material dispensed into a beaker the error in calibration will be limited to 0 5 since the measured volume can be determined to only the nearest cc The operator must open and close the calibration valve or supply a GUN TRIGGER The material volume is entered by the operator and a new Pulses Liter is calculated Closed Loop or Automatic Calibration Mode This mode sets the flow ra
118. se can typically be obtained by adjusting the Kp down to approximately 75 100 while adjusting the Kito approximately 1000 2500 2 The Integral gain is probably the most impor tant setting and has the greatest overall impact on response behavior associated with the fluid flow control system This parameter can also be adjusted through a relatively large range without creating instability 3 The Proportional gain can improve system response especially for large set point changes but care should be taken not to increase by more than approximately 25 of the default setting The system can easily become unstable and go into oscillation if adjusted to high DEFAULT CONTROL PARAMETERS 1200 Fluid Regulator MVR 2 MVR 3 MVR 4 DRT 1 1 DR1 1 2 100 DR1 1 3 100 DR1 1 4 35 71600 116 30 180 DR1 1 8 2 200 DR1 1 10 2200 Ransburg TYPICAL RANGES FOR CONTROL PARAMETERS Fluid Regulator Kp Typical Range Ki Typical Range MVR 2 0 500 600 2400 MVR 3 0 500 500 2000 050 4001600 11 0500 5002000 DR 1 12 0500 600 400 DR1 1 3 0500 700 2800 DR1 1 4 0 500 800 3200 DR1 1 65 0 500 900560 DR1 1 8 0 500 1000 4000 TU 900 1004400 1100 4400 4 The differential gain has the least effect on system performance and should be left at the default setting of zero 0 5 Response times wil
119. settable total will not be effected DynaFlow User Manual Installation 21 DynaFlow User Manual Installation Ransburg GUN INPUTS Continued Total Hold This signal will stop all totals for the CHANNEL as long as the signal is supplied even if the GUN is running and there is fluid flow The non resettable total will not be effected This is most often used during flush or soft air push cycles It can also be used to account for only that material which is delivered onto parts For GUNS configured as single component automatic mode only This input is only acknowl edged for run and load modes This input must be supplied before the clean input or the trig ger input if in run mode This signal will place the CHANNEL in single component open loop mode and redirect the Analog Set Point Input directly to the E P transducer control output MAXIMUM FLOW RATE MINIMUM FLOW RATE MVR HIGH and MVR LOW parameters have no effect while in the transparent mode The Out of Tolerance FLOW TOO LOW and FLOW TOO HIGH faults will also be disabled while in the Transparent condition This signal applies only to GUNs configured for single component automatic mode This signal will suspend PID control and freeze the analog control output to the E P transducer to the current value Normal PID operation will resume when this signal is removed This would typically be used during flushing operations or for control stability in situations where there
120. setup problem maintenanceissue ormechanicalfailure These types of faults can be caused by numer ous problems Most of the more common causes are listed below Keep in mind that the controller senses that either too little or too much material is getting to the applicator and that this is based on JOB parameter settings and fluid flow feedback from the flow meters This troubleshooting section assumes that the system was previously operat ing successfully and then a problem developed The following is not meant for initial system setup however many ofthe troubleshooting procedures described can be used in either case 1 Material Supply Pressure Has the material supply pressure changed What was the supply pressure when the system was operating properly Is the pressure gauge accurate or reliable Has the fluid delivery system been changed Are there any air leaks in the fluid regulator pilot line Are there any leaks in the fluid lines The controller can compensate for small changes in supply pressure but changes such as seen with piston pumps without surge chambers or pressure drop regulators can be a definite problem 2 Material Viscosity Has the material properties such as viscosity or temperature changed Changes in viscosity alter the way in which it passes through the fluid metering and control components regulator flow meter check valves Y Block spiral mix tube etc Typically an in cre
121. ster Channel input of the second Gun The Gun i t foll Referto Addendum C for complete information regarding the flow limitations of 2 an the DynaFlow Channel cards Master Channel Material Output of Gun 1 Resin 274 Component Flow Controller Color Change Value CCV see Notes 1 2 and 3 Flow Meter Gear Type Slave Channel Material 3 Component Flow Controller MVR with appropriate size needle Flow Meter Piston or Gear depending on min max flow rates see Notes 4 and 5 Operating Mode Manual or Auto see Notes 1 2 and 3 NOTES 1 If the output of Gun 2 supplies one or more hand guns then Gun 2 should be operated in Manual mode using a CCV for the Master Channel flow controller 2 If the output of Gun 2 supplies a single appli cator then an MVR should be used for the Master Channel flow controller and Gun 2 should be operated in Auto mode 3 If the output of Gun 2 supplies multiple appl icators other then hand guns then Gun 2 should be operated in Manual mode using a CCV for the Master Channel flow controller Additional Guns should be configured for each applicator as shown below to provide automatic flow control for each applicator Gun 3 through 6 Master Channel Material Output of Gun 2 Resin 2 34 Components Flow Controller DR1 Flow Meter Gear Type Operating Mode Auto LN 9400 00 9 9 Ransburg DynaFlow User Man
122. supply down by approximately 5 psi and try to run again Keep adjusting these pressures until the actual ratio locks in on the target Keep in mind that higher is not always better Many times it is better to lower the pressure of the op posite channel rather than raise a channel that is operating low in ratio The Kp and Ki gain settings located in the JOB tables may also be used to eliminate OUT OF TOLERANCE faults For example if an OUT OF TOLERANCE CATALYST TOO HIGHfaultoccurs adjust the gain settings for the catalyst channel down and vice versa for a OUT OF TOLERANCE CATALYST TOO LOW fault The resin channel also needs to be taken into account for GUNs configured as automatic Gun Not Ready Explanation This is not a fault condition and does not prevent the GUN from operating This error occurs if a GUN has not been configured is not enabled or no JOB s have yet been saved and the GUN is placed in the RUN mode This can be caused by trying to place a GUN in RUN mode either from local display interface or from an ex ternal control device such as a PLC or host PC 69 DynaFlow User Manual Maintenance 70 Corrective Action Simply save a JOB for the indicated GUN making sure the parameters are correct The Gun can be placed in RUN mode without generating the GUN NOT READY error System Errors System errors are not associated with any CHAN NEL or GUN System errors are typically related to the disk drive
123. systems sometimes referred to as 2K systems have two CHANNELSs assigned to a single GUN Single component systems sometimes referred to as 1K systems have only one CHANNEL as signed to a single GUN Each DynaFlow control system has up to 8 CHANNELs available that can be configured to suit the application For example you can use 4 CHANNELs assigned to 2 GUNS to spray 2 dual component paints on automatic machines and 2 CHANNELs assigned to 1 GUN to spray one dual component paint with a manual hand spray GUN Please note that most GUN parameters also apply to single component control as well The CHANNEL that has the greatest flow rate in two component systems is typically called the Master CHANNEL A CHANNEL cannot be assigned to more than one GUN GUNs represents a single applicator through which one or two materials are delivered If you are using single component coatings the DynaFlow controller can support 8 separate single CHANNEL GUNs operating simultaneously If you are using two component materials then 4 separate 2 CHANNEL GUNS operating simultaneously can be supported Adjacent 28 Ransburg CHANNELS 1 amp 2 3 amp 4 5 amp 6 and 7 4 8 can be linked together using 1 of 8 GUNS to control the flow and mixing regulation of two component materials A GUN configured for two component operation can also operate in single component control mode by setting the ratio to 99 or higher Three Compo
124. te Graphic diagnostics for troubleshooting and for achieving maximum system performance Comprehensive help information easily view ed on the OPERATOR INTERFACE e Configurable manual and or automatic GUN applications The DynaFlow Flow Controller design utilizes a form of distributed processing similar to many of the industrial network architectures available today The entire task of fluid flow control is broken up into parts Each portion of the system is de signed for a specific purpose Since each element ofthe system is performing specialized functions and all elements are operating at the same time overall performance of the system is enhanced Functionality of the control system components Dynamic analog fluid control the control of flow rate while running a JOB Reverse fluid flow detection provides added protection for system components NOTE This feature requires flow meters that provide reverse flow output Pot life timer alarms Local and remote monitoring and control Discrete PLC interface capability for remote control Remote RIO communications link for direct connection to Allen Bradley PLCs Process and configuration error and fault de tection and reporting USB memory stick backup of configuration and operational data Versatile system integration Easyto use Help text and troubleshooting guide available on screens is as follows Cha
125. te set point for the se lected CHANNEL based on the Total Flow Rate and Ratio for the selected GUN as stored in the JOB since calibration should always be performed at the normal flow rate for the CHANNEL The Calibration Time is also set based on the flow rate so that no less than 200 cc of material will be dis pensed during calibration Otherwise the error in calibration will betoo large With 200 cc of material dispensed into a beaker the errorin calibration will be limited to 0 5 since the measured volume can be determined to only the nearest cc The operator may override both the Calibration Time and Calibration Set Point if desired The opera tor must open and close the calibration valve or supply a GUN TRIGGER The material volume that passed through the GUN is recorded The measured volume is entered by the operator and a new Pulses Liter value is calculated Automatic calibration mode may not be selected for the Master channel of a Manual Gun since it normally has no MVR to control flow rate Calibration Time Sets the time duration for calibration Flow Rate Set Point Sets to actual flow rate during calibration This value is based on the Current Pulses Liter pa rameter so it will be inaccurate if that parameter is inaccurate Ransburg Actual Flow Rate Displays the actual flow rate during calibration This value is based on the Current Pulses Liter parameter soit will be inaccurate ifthat parameter is in
126. the door closed at all times This will maintain the dust tight environment reguired by the electronic printed circuit boards Plug all unused access holes into the cabinet in order to Keep contamination out Use the following guidelines for cleaning the Operator Interface Use cleaning solution specifically formu lated for computer monitors a mild win dow cleaner or isopropyl alcohol DO NOT use solvents Most importantly use a clean soft paper towel or tissue and use very light force LN 9400 00 9 DynaFlow User Manual Maintenance Fluid Control Components It is recommended to record system settings such as fluid supply and air supply pressures etc Reference the appropriate service literature for maintenance instructions 71 DynaFlow User Manual Maintenance Ra n sbu rg SYSTEM COMPONENTS AND PARTS IDENTIFICATION NNELS 1 amp 2 m NNELS 3 amp 4 MODULE 3 5 GH GG 5 amp 6 r 3 CHANNELS 7 amp 8 SY Jet je 7 ft irw Ransburg TWRansburg myiRansburg mmy Ransburg TwRansburg 9 9 9 RACK D N O ACTIVE O ACTIVE O ACTIVE O ACTIVE O O cPU O O O cPU O O FAULT O FAULT O FAULT O FAULT O FAULT INTERFACE CHANNEL CHANNEL CHANNEL CHANNEL or 251 ot 2 g SLO Figure 7 Card Rack Assembl
127. the set point and actual flow rate for the CHANNEL Integral Gain Ki Master and Slave The integral PID controller gain mainly affects the steady state non transitional response of the DynaFlow system The DynaFlow system must have a non zero value for Ki to operate properly The valve of Ki is divided internally by a factor of 100 000 and is used as a multiplier along with a factor of 3 for the sum of the error term over the time the trigger has been turned on Derivative Gain Kd Master and Slave The differential PID controller gain mainly affects the response of the DynaFlow system to distur bances caused by disturbances that are slow in nature Normally the DynaFlow system may op erate with a Kd value of zero The value of Kd is divided internally by a factor of 1 000 and is used as a multiplier along with a factor of 1 3 for the rate of change in the error term LN 9400 00 9 Ransbu rg DynaFlow User Manual Operation NOTES LN 9400 00 9 37 DynaFlow User Manual Operation 38 Diagnostic Parameters F5 The following parameters are available in the Local Operator Interface program as diagnostic parameters Force CHANNEL Digital Inputs Forcing inputs permits debugging and trouble shooting to determine proper operation of the hardware Each CHANNEL input can be forced ON therefore not requiring a hardware signal for thatinputto become active If an external hardware input is present a forced OFF
128. timers are used for materials thatcan harden or setup after a specifictime Hard ening material in fluid lines or the spray applicator can cause costly downtime and maintenance to correct The output ofthe POT LIFE TIMER alarm can be connected directly to an external PLC for automatic initiation of the cleaning cycle or to an alarm to alert the operator The Horn 51 DynaFlow User Manual Operation Code located in the System configuration table determines if a Pot Life Fault activates the horn A Pot Life Fault can only be reset by eliminating the expired material from the fluid lines or by setting the Pot Life Time to zero in the JOB Parameters The horn will be turned off however by issuing a Clear Faults command A Pot Life Fault does not turn off the GUN The DynaFlow system uses the Mixed Volume and the Pot Life Time when it monitors the flow rate ofthe Gun Pot Life is monitored by dividing the Mixed Volume into 40 equal sized buckets of material When an amount of material has flowed that equals the bucket volume the 40 buckets are time shifted so the oldest bucket is eliminated representing the material that has vacated the Mixed Volume tubing atthe GUN and a new bucket is added If the GUN is in either Run or Load mode a time value of 1 second is placed in the new bucket to represent mixed material If the GUN is in Clean mode a time value of zero is placed in the new bucket rep resenting solvent E
129. tions from the receiver to the control rack mother board 4 If using a single phase flow meter that is not capable of reverse flow detection then the phase signal input must be connected to 24 VDC Ref erence the Mother Board Signal Identification in the Appendix section of this Manual No Master Flow Explanation This fault will only occur on GUNs configured for MANUAL operation For a GUN configured for MANUAL operation as soon as the GUN is placed in RUN mode the master CHAN NEL fluid regulator opens to the MVR HIGH set point usually 100 psi This is typically full open In this way operators can demand as much fluid as they wish with only the slaved typically catalyst CHANNEL being controlled to the desired ratio It is possible however for the master CHANNEL flow meter gears to stick and still allow fluid to pass through the flow meter When this happens the applicator continues to flow resin master CHANNEL but the controller is unaware that material is flowing and therefore does not com mand any catalyst slaved CHANNEL material to flow To prevent this from happening an air flow switch placed in the atomizing air line can send a trigger signal to the controller When the controller receives a trigger signal it immediately determines if the master CHANNEL flow meter is sending pulses If it is not the controller issues a NO MASTER FLOW fault In many cases however operators use their GUNs to blow dust
130. u minum can become violent and lead to an equipment explosion DynaFlow User Manual Safety SAFEGUARDS Tells how to avoid the hazard Personnel must be given training accordance with the reguirements of NFPA 33 Instructions and safety precautions must be read and understood prior to using this eguipment Comply with appropriate local state and national codes governing ventilation fire protection opera tion maintenance and housekeeping Reference OSHA NFPA 33 and your insurance company requirements The power supply optional remote control cabinet and all other electrical equipment must be located outside Class I or ll Division 1 and 2 hazardous areas refer to NFPA 33 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance Aluminum is widely used in other spray application equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equip ment during spraying 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
131. ual Introduction 39v44H31NI OLLVWD3Nd 404 SNOLO4NNOO S13NVd 894 TANNVHO 9295 ONIMIM WHO T4NNVHO Cl TAN ONIMIM 07314 NHO N3LSAS M4MOd SNISIM 91313 S IVNIWS3 L OL __ 124145 40102 9 1 SNno S 1 Nodgdla OL OL NO88l S320 I8 H3AHOSH 0 DISCRETE CHANNEL 1 RIBBON CABLE ASS Y RIBBON CABLE ASS Y DISCRETE CHANNEL 1 0 RIBBON CABLE ASS Y DISCRETE CHANNEL 1 0 DISCRETE CHANNEL 1 0 RIBBON CABLE ASS Y DISCRETE SYSTEM 1 0 ASIQ LE 43N303M wads I 9 N3JAIO3 Sf L Y FIBER OPTIC CABLES FROM FLOW METERS I v H3AI23 OlldO X38 H3AHO3 OlldO 8 Y I L Y L MJH 43MOd PID CONTROL CHANNEL 47 amp 8 44MOd PID CONTROL CHANNEL 5 amp 6 SnENV 9 SNENVO PID CONTROL CHANNEL 3 amp 4 PID CONTROL CHANNEL 1 amp 2 33MOd SOVAYALN u4OlvdddoO
132. ugh a CHANNEL while in CALIBRATION MODE of operation since last reset Grand Total For each JOB per CHANNEL Records the accumulated total of all material through a CHANNEL including while in CALI BRATION MODE of operation since last reset Any time period associated with this total is based on when itis reset For example if itis reset atthe end of a shift end of the day or end of the year LN 9400 00 9 DynaFlow User Manual Operation Daily Total For all JOBs per CHANNEL Records the accumulated total of all material for all JOBs through a CHANNEL since last reset Any time period associated with this total is based on when it is reset For example if it is reset at the end of a shift end of the day or end of the year Yearly Total For all JOBs per CHANNEL Records the accumulated total of all material for all JOBs through a CHANNEL sincle last reset Any time perior associated with this total is based on when it is reset for example if itis reset atthe end of a shift end of the day or end of the year Calibration Total For all JOBs per CHANNEL Records the accumulated total of all material for all JOBs through a CHANNEL while in CALI BRATION MODE of operation since last reset Grand Total For all JOBs per CHANNEL Records the accumulated total of all material for all JOBs through a CHANNEL including while in CALIBRATION MODE of operation since last reset Any time period associated with thi
133. uration cells If cursor is on one of the valve condition cells that cell is toggled from off to on or on to off F2 Chop Air Time This button allows the user to program how long the air valve remains on for each step of the solvent air chop timer F3 Chop Solvent Time This button allows the userto program how long the solvent valve remains on for each step of the solvent air chop timer F4 Edit Fill Flush This button opens the screen that allows viewing and editing of the flush or the fill seguences the button changes to fill if the flush seguence is displayed and to flush if the fill seguence is displayed F5 Send to PLC This button allows the operator to immediately send the edited seguence to the seguencer located in the motor amplifier panel Note that the seguences are automatically sent to the seguencer every time a new Job Number is loaded F8 Copy Sequence This button allows the op eratorto copy sequences from one job to another F9 Read In File This button allows the operator to load flush and load sequences from the flash drive of the touchscreen a USB memory stick or to a floppy diskette F10 Save To File This button allowsthe operator to save flush and load sequences to the flash drive of the touchscreen a USB memory stick or to a floppy diskette All flush and load sequences for all guns are saved in a file named ColorChg par 43 DynaFlow User Manual Operation 44
134. utput Not issued for a manual GUN master CHANNEL Last digit indicates CHANNEL Manual mode only A trigger signal was received and no fluid flow was detected through the master chan nel after the Blowoff timer had elapsed if used Check the following 1 Thatthe Reverse Flow value entered in the JOB is correct 2 Flow meter fiber optic cables are properly connected and not reversed 3 Fluid pressures are properly set and stable 4 All check valves are operating cor rectly 5 All fluid lines filled and all valves open 6 Flow meter is operating properly Check the following 1 There is fluid in the fluid lines for the indicated CHANNEL 2 Fluid pressures are properly set and stable 3 The pilot air line to the fluid regulator is not damaged or leaking 4 Fluid viscosity is correct for the CHANNEL pressure and pipe size 5 The pressure transducer and regula tor are operating properly 6 Transducer air supply is at least 90 psi 7 Kp Ki and Gains are correctly for the indicated CHANNEL Check the following 1 Fluid regulators sticking or faulty 2 Control parameters gains possibly set too high 3 MVR low setting too high Check the following 1 There is fluid in the fluid lines for the indicated CHANNEL 2 Fluid pressure is OK 3 Theflow meter pressure trans ducer and regulator are operating properly 63 DynaFlow User Manual Maintenance 64
135. ve different coating thickness over different areas of the same part Several examples are shown in the Analog Control Settings chart in this section In automatic GUN applications the total flow rate set point for the GUN may be varied in real time using either of two methods Remote I O RIO or Analog Input If the RIO Set Point is zero and Analog Input Set Point is less than 0 25 volts the Total Flow Rate set point comes from the JOB LN 9400 00 9 Ransburg ANALOG CONTROL SETTINGS Minimum Flow Rate CC s Min Minimum Voltage or Maximum Flow Rate CC s Min Current 100 10 volts or 20 ma 10 00 DynaFlow User Manual Operation Maximum Voltage or CC s Volt CC s Ma Current 6 25 300 10 volts or 20 ma 20 00 12 50 RIO Set Point The Total Flow Rate set point for a GUN may also be input via Remote RIO No scaling is reguired since the Total Flow Rate value is sent in cc s minute RIO control is initiated when the value sent is non zero regardless if an Analog Input Set Point greater than 0 25 volts is presented to the Master CHANNEL Analog Input Set Point The Total Flow Rate set point for a GUN may be input via an external analog signal 0 10 VDC or 4 20 ma presented to the Master CHANNEL via the Channel Module The Maximum Flow Rate and Minimum Flow Rate for the JOB determine the scaling applied to this analog input Analog control is initiated when the input signal is greater than 0
136. ve for fluid to be delivered by GUN regardless of the operating mode Spare Not used presently Ransburg Channel Module Hardware Specifications Cont 12 Digital Outputs 2 Channels 24 VDC sourced at 300 ma max imum per output Solid state relay contacts Ready Everything is ready for operation configured correctly and logic OK Active CHANNEL is active and controlling Fault Fault has occurred Pot Life Timer Pot life timer expired Clean Load Calibrate Indicates Clean Load or Calibrate mode is active MVR Enable Used to control trigger valve for CHANNEL in fast trigger applica tions with Analog Hold enabled 4 Analog Inputs 2 Channels Jumper selectable 0 10 VDC de fault or4 20 ma op amp buffered 10 bit A D Set Point Control 1 Used for external analog control When used offset and full scale need to be set This is accomplished through the MAXIMUM FLOW RATE and MINI MUM FLOW RATE JOB parameters Set Point Control 42 Used for external analog 10 bit A D control When used off set and full scale need to be set This is accomplished through the MAXIMUM FLOW RATE and MINIMUM FLOW RATE JOB parameters Spare 1 Not used presently Spare 2 Not used presently 4 Analog Outputs 2 Channels Jumper selectable 0 10 VDC de fault or 4 20 ma op amp buffered 12 bit D A Transducer Control 1 Output to proportional E P 12 bit D A controller Transducer Control 2 Output to proport
137. ve material may be released when the trigger is turned on again due to the higher pressure in the fluid line In either case the CHANNEL output returns to the MVR LOW value at the end of the Trigger OFF Delay Trigger ON Delay For automatic GUNSs only This parameter allows the user to create a delay between the time when the controller receives a trigger ON signal from a remote device to when it actually starts the flow of material This parameter should be used only in special situations where pneumatic delays present a problem LN 9400 00 9 Master and Slave Regulator Type The channel hardware configuration is stored as this parameter It is necessary for the controller to know which fluid regulator type is being used so that the proper default PID control parameters can be loaded Kp Ki Kd Reverse Flow Volume The amount of fluid which is allowed to flow back wards in the GUN before the controller faults Reverse flow could cause catalyzed material to backup into either fluid line if a check valve fails Keep this value small to minimize that possibil ity If the GUN is configured for two component operation than the Reverse Flow value will apply to each of the 5 assigned to the GUN Reverse flow rate is displayed on the main screen of the Local Operator Interface as a flow rate bar colored red instead of green for normal flow rate Bar Chart Maximum Flow Rate This parameter determines what flow rate
138. ver Bad input on the CHANNEL MODULE Fiber optic flow meter transmitter battery has expired Life expectancy is two years minimum Corrective Action Flow Meter Disassemble clean and inspect the flow meter Refer to instructions supplied with the meter Try connecting the flow meter in question to a fiber optic cable from a properly functioning CHANNEL If fluid flow is now observed then the flow meter and pickup sensor are functioning properly Fiber Optic Cable Simply shine a light into one end of the cable and have someone observe the opposite end If light is visible through the cable then it is probably good although it is possible that the cable is damaged and will not conduct enough light to operate properly Fiber Optic Detector With fluid flowing observe the LED located on the fiber optic receiver The LED is an indication that fluid is flowing and pulses are being received from the flow meter If the LED is not ON then replace or swap the fiber optic receiver and try again If everything checks good but no fluid flow is dis Ransburg played replace the CHANNEL MODULE Make sure that the hardware settings located on the module are configured identically to the one be ing replaced 5 Transducer Failure Corrective Action Perform the following with the GUN OFF and calibration valves closed Place a pressure gage if one does not already exist in the pilot line be tween the transducer and the flu
139. very second the time values stored in the buckets are incremented if they are nonzero i e contain mixed material vs solvent A Pot Life alarm condition exists if any of the 40 buckets contains a time value greater than the Pot Life Time see JOB parameters A Pot Life alarm may be cleared by entering a Pot Life Time of zero seconds Calibration Mode The first time that the system is operated after installation or when using new fluids calibration is recommended for the flow meters CHANNELS There are several procedures that can be used for calibration see the Calibration Mode Section Flow meters can be calibrated by fluid weight or by fluid volume All calibration measurements are metric such as weight is measured in grams and volume in cubic centimeters cc Procedure 1 Manual 1 Place the controller in Calibration Mode se lect manual procedure 2 Place a graduated container beneath the cal ibration valve or applicator paint feed tube nozzle 52 Ransburg 3 Start fluid flow Open the calibration valve or trigger the GUN 4 Collect fluid manually into the graduated con tainer for a specific time 5 Stop fluid flow 6 Select Stop Cal 7 Measure the amount of fluid collected 8 Enter the measured volume of fluid 9 Accept or reject the new Pulses Per Liter number that the controller calculated The flow meter calibration will automatically be updated Required Specific gravity of mat
140. w meter size This value can be verified or adjusted during a calibration process to achieve the best accuracy See Calibration Mode in the Operation section of this manual The cali bration of all flow meters should be periodically checked The rheology of some fluids may effect the calibration values therefore a different value for pulses per liter may be used for each material and is entered into the JOB data tables Deadband Master and Slave This represents a flow rate range divided equally above and below the set point flow rate in which the PID controll is suspended This keeps the control output from continually changing and produces stability when close to the requested value For example if the Deadband is set for 5 cc min and flow rate set point is set for 100 cc min the Ransburg Deadband would be between 95 and 105 cc min The PID controller would therefore be suspended whenever the actual flow rate is within this range This parameter should normally be setto 1 cc min Proportional Gain Kp Master and Slave The proportional PID controller gain mainly affects the response of the DynaFlow system to distur bances The DynaFlow system may operate with Kp at zero however response to material supply and delivery pressure disturbances will be poor The value of Kp is divided internally by a factor of 1 000 and is used as a multiplier for the flow rate error term The flow rate error term is the difference between
141. ximum and Minimum Flow 1 2 4 20 mA Rate parameters Selects 24 VDC source control or grounded Inputs effected sink control for digital inputs 8 11 Load Mode 1 2 3 24 VDC source Analog Hold 1 1 2 grounded sink External Fault 1 MVR Enable 1 Source sink control for digital inputs 4 7 Run 1 2 3 24 VDC source Halt 1 1 2 grounded sink Total Reset 1 Clean 1 Selects 24 VDC source control or grounded Inputs effected sink control for digital inputs 0 3 Trigger 1 2 3 24 VDC source Gun Mask 1 1 2 grounded sink Transparent PID 1 Total Hold 1 0 10 VDC Selects 0 10 VDC or 4 20 ma operation for Scaled by Maximum and the analog set point input 1 Minimum Flow Rate 2 3 0 10 VDC parameters 1 2 4 20 mA Source Selects 24 VDC source control or grounded Inputs effected 0 10 VDC Selects 0 10 VDC or 4 20 ma operation for the spare analog input 1 2 3 0 10 VDC 1 2 4 20 mA LN 9400 00 9 75 DynaFlow User Manual Maintenance CHANNEL MODULE P N 77206 XX Obsolete Ransburg DAUGHTER BOARD JUMPER SETTINGS CHANNEL 2 1 0 Selects 24 VDC source control or grounded Inputs effected 2 3 Source 0 10 VDC 76 sink control for digital inputs 12 15 2 3 24 VDC source 1 2 grounded sink Selects 24 VDC source control or grounded sink control for digital inputs 20 23 2 3 24 VDC source 1 2 grounded sink Selects 24 VDC source control or grounded sink contro
142. y DYNAFLOW SYSTEM COMPONENTS AND PARTS IDENTIFICATION Figure 7 Rack Assembly Empty 1 2 Rack 1 Mother Board Rack Assembly Empty Full Rack 1 Mother Board Rack Assembly Empty Full Rack 2 Mother Boards e _Hitertace vague Assembly A10946 01 Module for use with 0 10VDC transducers and for the flow rate indication output A p 6 0 annel Module for use with 0 or 4 20mA transducers and for rate indication a o LBAL5003 00 Pneumatic Operator Panel Note Refer to the DynaFlow Operator Interface manual for parts that are specific to the 77376 and A12233 Stand Alone Control Panel 72 LN 9400 00 9 nsburg DynaFlow User Manual Maintenance RECOMMENDED SPARE PARTS Recommended spare parts list for the DynaFlow rack components only SPARE PARTS FOR DYNAFLOW RACK COMPONENTS Total of Interface Modules in System d 14 410 77377 02 DynaFlow Interface Module 77377 02 RIO Compatible Total of Channel Cards in System AU OHIO gt 16 LN 9400 00 9 73 DynaFlow User Manual Maintenance Ra n sbu rg The following DynaFlow recommended spare parts lists do not include auxiliary fluid control monitor ing equipment such as pneumatic interface panels fluid panels transducer panels etc The recom mended spare parts list for the auxiliary equipment should be derived from previous fluid control lists since their usage and requirements
143. ystem interlocks Perform and verify remaining system oper ation This includes any automatic opera tions such as a color change seguence Observe the fluid flow response of each GUN Refer to Operator Interface manual and related sections of this manual Normal Start Up Procedure Before attempting start up Inspect the entire system and make sure that all air and fluid hoses are in place and secure and that all other system compo nents are in good condition Review and perform any reguired preven tive maintenance procedures Inform personnel in the immediate area that the system is being started Observe the operation of the system as it is started and be ready to shut it down in the event of a problem LN 9400 00 9 DynaFlow User Manual Operation The following procedure assumes thatthe system was running normally when previously operating This is only a recommended procedure Variance from this procedure is dependent on the installa tion operation and protocols 1 Turn on the main power disconnect to the fluid control panel 2 Turn ON the panel power switch 3 Verify that the Operator Interface is operating normally and that there are no errors 4 Turn ON the factory air supply to the E P transducers and any other pneumatic control circuits 5 Supply fluid pressure to the system 6 Turn ON any auxiliary equipment that may be interlocked with the fluid flow controller such as th

MODEL: 77376 and A12233 DYNAFLOWTM USER MANUAL

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