LN-9257-07 Serial Digital Module User Manual.pmd
Contents
1. 100 x 160mm Eurocard module 35mm wide 0 100 psi 0 6 8 bar 250 psi 17 0 bar 1 75 SCFM Max 10 micron 1 3 g m Max 0 1 mg kg Oil Water Max 1 9 SCFM 1 Valve On 1 2 SCFM All Valves On Valve Effective Area 0 9mm Electrical Requirements Input Voltage Input Current Input Current Protection 24 VDC 760 mA All valves on Polyfuse Auto Reset LN 9257 07 ITovRansburg MODES OF I O The Serial Digital Module may run in three different UO modes 1 Discrete Inputs 2 Serial Bus 3 Parallel TTL Bus retrofit only Discrete 24 VDC Signals Replaces 75119 01 The following settings must be made by the user to enable this mode Switch SW1 Jumper E2 OUT Valves are actuated by a 24 VDC signal applied to the 8 pin pluggable terminal strip on the rear side of the motherboard The ground reference for these inputs is the 24 VDC ground terminal The actual terminal numbers vary depending on which motherboard is used In this mode of operation the following motherboards may be used 78145 00 78147 00 and 74847 00 retrofit The Lockout signal used to defeat the operation of the front panel push buttons is set on each module by setting SW1 1 to ON Serial Bus via the LECU4012 Serial Node Adapter SERNA or the 78553 Node Adapter Plus NA The following settings must be made by the user to enable this mode Switch SW1 4 Position Switch OFF Down Position Jum2. The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD 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 LN 9257 07 ITovRansburg AREA HAZARD Tells where hazards Tells what the hazard is may occur Spray Area LN 9257 07 Fire Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent power supply shutdown indicates a problem in the system requiring correction Serial Digital Module Safety SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accumulation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off priorto cleaning flushing or maintenance When using solvents for cleaning Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above
3. rwRansburg SERVICE MANUAL July 2007 SERIAL DIGITAL MODULE USER MANUAL i vave gt 5 O vu L ER 0 wwe y 6 a VALVE 5 6 6 VALVE 6 O vue 0 VALVE g SERIAL DIGITAN MODEL 76911 IMPORTANT Before using this equipment care fully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 25 00 Euro 30 00 U S rrovRansburg LN 9257 07 rwRansburg Serial Digital Module Contents CONTENTS PAGE SAFETY SAFETY PRECAUTIONS aguas Ds DGE ee HAZARDSSAFEGUARES suas er INTRODUCTION 1 4 2 4 GENEBALDESERIPTION 2 u uuu ala er SPECIFICA ONS asas ie babu ee MODES OF VO a unu US eine SERIAL DIGITAL MODULE SETTINGS seen INSTALLATION WARRANTY POLICIES LIMITED WARRANT Y sa ee LN 9257 07 Serial Digital Module Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any ITW Ransburg electrostatic coating system read and understand all of the technical and safety literature for your ITW Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this information we use the following symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that m
4. 100 F 37 8 C Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA and local codes In addition ventilation must be 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 If used the key switch bypass is intended for use only during set up 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 Serial Digital Module Safety AREA HAZARD Tells where hazards Tells what the hazard is may occur General Use and Maintenance Electrical Equipment Improper operation or maintenance may create a hazard Personnel must be properly trained in the use of this equipment High voltage equipment is uti lized Arcing in areas of flammable or combustible materials may occur Personnel are ex posed 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 Fr
5. 7 LN 9257 07 rrovRansburg Serial Digital Module Introduction NOTES LN 9257 07 8 Serial Digital Module Installation INSTALLATION POWER Connect 24 VDC to J7 Pin 4 and 24 VDC return GND to J7 Pin 3 CONTROL SIGNALS 1 Discrete 24 V Inputs Connect individual 24 VDC Inputs to the 8 Pin terminal strip for each module 2 Serial Bus via Serial Node Adapter Connect Serial Bus output from Serial Node Adapter to J4 using shielded twisted pair cable connecting shield to GND terminal to and to If Serial Bus goes onto other motherboards connect cable to J10 otherwise connect 120 ohm from J10 to J10 PNEUMATIC CONNECTIONS Connect supply air to the bottom connector for each module using 1 4 OD tube Make connections to the pneumatic devices being controlled using 5 32 OD 4mm tube ITovRansburg REMOTE WO Direct connection to Rockwell Allen Bradly Remote I O can be made via the Serial Node Adapter or Serial Node Adapter Connect the Allen Bradley AB RIO cable directly to the motherboard of the Node Adapter 78145 00 or LECU4012 Ifthe Serial Digital Module is in the same motherboard as the Serial Node Adapter 78145 00 no further connection is necessary Ifthe Serial Digital Module is located in a different motherboard 78147 00 the local serial bus must be connected via the connector labeled Serial Bus LN 9257 07 rwRansburg Serial Digital Module Installat
6. AR RANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANS BURG ASSUMES NO LIABILITY FOR IN JURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PUR CHASER OR OTHERS EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume no responsibility for repair or replacement of the item or items The pur chaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9257 07 rrovRansburg LN 9257 07 Service Manual Price 25 00 Euro 30 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 www itwransburg com Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts RN Form No LN 9257 07 E Litho in U S A IZ 07 07 p ERC O 2007 Illinois Tool Works Inc All rights reserved Models and specifications subject to change without notice
7. at high voltage must be grounded Unless specifically approved for use in hazardous locations the power supply and other electrical equipment must not be used in Class I Division 1 or 2 locations Serial Digital Module Introduction INTRODUCTION GENERAL DESCRIPTION The Serial Digital Pneumatic Module converts electronic signals to eight pneumatic signals itis packaged as a Eurocard module and fits into a Eurocard rack with a 78145 series motherboard When configured in retrofit mode it plugs into a 74847 motherboard The module has an electrical connector and a quick disconnect pneumatic connector The Serial Digital Pneumatic Module may be commanded from any of three sources Serial bus Discrete 24 VDC inputs new or retrofit ITW Ransburg parallel TTL bus for retrofit applications On the module front panel LED s indicate when each valve is energized Also the front panel switches provide momentary manual override for each valve These front panel switches can be locked out with an on module switch setting or by a signal from the electrical connector ITovRansburg SPECIFICATIONS Environmental Physical Temperature Operating Storage Humidity Size Pneumatic Input Input Pressure Burst Pressure Leak Rate Req Filtration Water Vapor Content Oil Vapor Content Pneumatic Output Module Flow Rate Valve CV Factor Oto 55 C 40 C to 85 C 95 Non Condensing Max
8. e not chemically compatible with the aluminum that might be used in many system components The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion This is a high voltage device that can produce electrical arcs capable of igniting coating materials Serial Digital Module Safety SAFEGUARDS Tells how to avoid the hazard 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 equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray If in doubt as to whether or not a coating or cleaning material is compatible contact your material supplier Any other type of solvent may be used with aluminum equipment Parts being sprayed must be supported on conveyors or hangers and be grounded The resistance between the part and ground must not exceed 1 megohm Reference NFPA 33 A safe distance must be maintained between the parts being coated and the atomizer bell A distance of at least 1 inch for each 10 KV of power supply output voltage is required at all times Parts must be supported so that they will not swing and reduce the clearance specified above All electrically conductive objects in the spray area with the exception of those objects required by the process to be
9. equent power supply shutdown indicates a problem in the sys tem which requires correction An electrical arc can ignite coat ing materials and cause a fire or explosion ITovRansburg SAFEGUARDS Tells how to avoid the hazard Personnel must be given training in accordance with the requirements of NFPA 33 Instructions and safety precautions must be read and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping Reference OSHA NFPA 33 and your insurance company requirements The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas Referto 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 LN 9257 07 ITovRansburg AREA HAZARD Tells where hazards Tells what the hazard is may occur Explosion Hazard Incompatible Materials Spray Area High Voltage Equipment LN 9257 07 Halogenated hydrocarbon solvents for example methylene chloride and 1 1 1 Trichloroethane ar
10. ight cause serious injury if instructions are not followed A CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury A NOTE is information relevant to the procedure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation drawings and appropriate ITW Ransburg equipment manuals to reconcile such differences Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local ITW Ransburg representative or ITW Ransburg ITovRansburg A WARNING gt The user MUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literaturethereiniden tified gt This manual MUST be read and thoroughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed
11. ion O 060000000000000000000000000000000 e soceoe ee eeecesn rro e Figure 2 Serial Digital Module Installation SERIAL DIGITAL MODULE E eum Serial Serial Digital Modules sss Modules LN 9257 07 10 Serial Digital Module Warranty Policies 11 ITovRansburg WARRANTY POLICIES LIMITED WARRANTY ITW Ransburg will replace or repair without charge any part and or equipment that falls within the specified time see below because of faulty workmanship or material provided that the equip ment has been used and maintained in accor dance with ITW Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANSBURG APPROVED 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 IN PLAS TIC ASSOCIATED VALVES AND TUB ING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOIDE THIS WARRANTY ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATE RIALS THERE ARE NO IMPLIED W
12. per E2 OUT 2 Position In this mode of operation all communication to the valves is by serial bus from the SERNA or NA on the 78145 00 or 78147 00 motherboards The PLC addressing is shown in the SERNA or NA manual LN 9257 07 Serial Digital Module Introduction Parallel TTL Bus Replaces 75119 02 The following settings must be made by the user to enable this mode Switch SW1 4 Position Switch ON Jumper E2 IN This mode is for retrofit applications in the 74847 01 motherboard only Communication is via the 75586 01 RansPak Node Adapter with A10044 00 Node per Bell Slave Adapter or via the 75584 00 Digital Node Adapter Manual Valve Operation Valves may be manually operated using the black front panel push buttons The push buttons require very little travel and may be operated with a finger against the panel If the valve is already On by an external signal operation of the manual push button will turn that valve Off The manual push button operation is defeated when in Manual Lockout mode Serial Digital Module Introduction ITovRansburg JUMPER E2 PARALLEL BUS IN PLACE w SERIAL BUS OR DISCRETE OUT SWITCH SW1 ZO N G i Ka swt MANUAL LOCKOUT OFF MANUAL LOCKOUT BY REMOTE SIGNAL ON MANUAL LOCKOUT ON SW2 AND 3 NOT USED SW4 COMMUNICATION MODE ON PARALLEL BUS OFF SERIAL BUS OR DISCRETE 24VDC Figure 1 Serial Digital Module Settings
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