Ransburg 77376, A12233 Fluid Flow Controller Service Manual

SERVICE MANUAL

(Replaces LN-9401-00.4)

March 2012

OPERA

T OR INTERF ACE MANUAL

0 1

POWER

E-STOP

IMPOR T ANT : Before using this equipment,

Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual.

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Operator Interface Manual - Contents

SAFETY PRECAUTIONS............................................................................................................

1

HAZARDS / SAFEGUARDS........................................................................................................

2-4

DESCRIPTION.............................................................................................................................

SPECIFICATIONS.......................................................................................................................

5-6

6

INPUT POWER............................................................................................................................

INTRINSICALLY SAFE FLOWMETERS.....................................................................................

SYSTEM CONNECTIONS..........................................................................................................

WIRING FOR INTRINSICALLY SAFE FLOWMETERS (A12233).............................................

7

7

7

8

WIRING FOR INTRINSICALLY SAFE FLOW METERS (77376)..............................................

SYSTEM CONNECTIONS (77376).............................................................................................

INPUT POWER SCHEMATIC.....................................................................................................

9

10

11

GENERAL.....................................................................................................................................

13

KEY FUNCTIONS........................................................................................................................

PASSWORD OPERATION.........................................................................................................

13-14

14-15

SCREENS....................................................................................................................................

FILE I/O.........................................................................................................................................

16-17

17

INSTALLING/UPDATING SOFTWARE......................................................................................

PARAMETER LOCATIONS.........................................................................................................

18

19-21

SCREEN MENU TREE................................................................................................................

21-22

TROUBLESHOOTING / TROUBLESHOOTING GUIDE..........................................................

23-24

DYNAFLOW DOOR (77376 VERSION).....................................................................................

DYNAFLOW SUB-PANEL (77376 VERSION)............................................................................

25

26

DYNAFLOW PARTS LIST...........................................................................................................

27

DYNAFLOW SPARE PARTS......................................................................................................

DYNAFLOW DOOR (A12233 VERSION) / PARTS LIST...........................................................

DYNAFLOW INTERFACE PANEL (A12177) / PARTS LIST......................................................

28

29-30

31

LIMITED WARRANTY.................................................................................................................. 33

CONVERSIONS...........................................................................................................................

34

RATIO CONVERSION CHART...................................................................................................

35

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Operator Interface Manual - Safety

Before operating, maintaining or servicing any

Ransburg electrostatic coating system, read and understand all of the technical and safety literature for your Ransburg products. This manual contains information that is important for you to know and understand. This information relates to USER

SAFETY and PREVENTING EQUIPMENT

PROBLEMS. To help you recognize this information, we use the following symbols. Please pay particular attention to these sections.

!!!!!

>

The user MUST with the Safety Section in this manual and the Ransburg safety literature therein identified.

>

This manual MUST operate, clean or maintain this equipment!

Special care should be taken to ensure ments for operating and servicing the equipment are followed. The user should building and fire codes and ordinances as or servicing this equipment.

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

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

Ransburg.

!!!!!

>

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.

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Operator Interface Manual - Safety

Tells where hazards may occur.

Tells what the hazard is.

Tells how to avoid the hazard.

Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically.

Improper or inadequate opera-tion and maintenance procedures will cause a fire hazard.

Spray areas must be kept clean to prevent the accumulation of combustible residues.

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.

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 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 100

°

F (37.8°C).

Spray booth ventilation must be kept at the rates required by NFPA-33, OSHA and local codes. In addition, ventilation must be main-tained during cleaning operations using flammable or combust-ible 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 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.

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Operator Interface Manual - Safety

Tells where hazards may occur.

Tells what the hazard is.

Tells how to avoid the hazard.

Improper operation or maintenance may create a hazard.

Personnel must be given training in accordance with the requirements of NFPA-33.

Personnel must be properly trained in the use of this equipment.

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.

High voltage equipment is utilized.

Arcing in areas of flammable or combustible materials may occur.

Personnel are exposed to high voltage during operation and maintenance.

The power supply, optional remote control cabinet, and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas. Refer to NFPA-33.

Turn the power supply OFF before working on the equipment.

Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation.

Test only in areas free of flammable or combustible material.

Testing may require high voltage to be on, but only as instructed.

Frequent power supply shut-down indicates a problem in the system which requires correction.

Production should never be done with the safety circuits disabled.

An electrical arc can ignite coating materials and cause a fire or explosion.

Before turning the high voltage on, make sure no objects are within the sparking distance.

Halogenated hydrocarbon solvents for example: methylene chloride and 1,1,1,-Trichloroethane are not chemically compatible with the aluminum that might be used in many system components. The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion.

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.

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Operator Interface Manual - Safety

Tells where hazards may occur.

Tells what the hazard is.

Tells how to avoid the hazard.

Toxic Substances

Certain material may be harmful if inhaled, or if there is contact with the skin.

Follow the requirements of the Material Safety Data

Sheet supplied by coating material manufacturer.

Adequate exhaust must be provided to keep the air free of accumulations of toxic materials.

Use a mask or respirator whenever there is a chance of inhaling sprayed materials. The mask must be 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.

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Operator Interface Manual - Introduction

This manual is intended as a guide for operators of the DynaFlow TM to the DynaFlow User and DynaFlow Programmer’s Manuals. The detailed description of the operational parameters and system operation and/ or procedures is located in the User manual. This manual specifically covers those items pertaining to the operation of the DynaFlow control software when installed in the Ransburg Operator Interface

Panel or from a PC.

The DynaFlow fluid flow control system achieves real-time closed loop control through the use of

CHANNELs and GUNs. A CHANNEL consists of an electrical-to-pneumatic (E/P) transducer, material regulator, and fluid flow meter combination through which a single material is controlled. A

GUN represents a single applicator through which one or more materials are delivered. One or more

CHANNELs are configured for each GUN. Twocomponent delivery systems (referred to as 2K systems) have two CHANNELs assigned to a single GUN. The materials are statically mixed before being delivered to the GUN. This unit includes:

•

A standard rack assembly populated with an Interface Module and the appropriate number of Channel Cards.

•

Fiber optic receivers or intrinsic safety barriers for interfacing to the flow meters.

•

Terminals and connectors for external control wiring.

•

An Operator Interface that includes an embedded PC, control software, a 15” color display with integral touch screen.

The DynaFlow control software is a PC program that runs under the Windows XP operating system.

The software can be installed in the Operator

Interface assembly or a standard PC running

Windows 9X, 2000, or XP.

The DynaFlow control software supplies the means to monitor and command the delivery of singlecomponent or two-component fluids when used in conjunction with a rack-mounted Interface Module and Channel Cards. Reference the DynaFlow

User manual for a detailed description of the

DynaFlow system components and their relation to each other. An RS-232 connection is established between the Operator Interface assembly and the

Interface Module located in the Eurocard rack assembly through which all information is passed.

If the system was ordered with the optional color change sequencer, an Ethernet connection is established between the operator interface PC and the color change controller brain in the interface panel (A12182). All of the actual fluid control and system interfacing is accomplished through the card rack compo-nents. The Operator Interface simply supplies a convenient means to view and modify configurations and data and to send manual operational commands. Data can also be saved and retrieved through the Operator Interface.

The major components of the Operator Interface

Assembly are:

• Integral Touch Pane provides a convenient method of interacting with the user interface. The touch panel is chemically resistant and easy to clean.

• Embedded PC reduced size versions of the standard desktop computers. This is done such that

OEM suppliers can cost effectively include

(embed) a computer, typically performing a dedicated function, into their design. Embedded PCs conform to industry standards and run the same software and operating system that are used in standard desktop computers. The DynaFlow software, for example, will operate the same on a desktop or industrial computer.

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Operator Interface Manual - Introduction

• USB Ports: that may be used to save or load data.

• LCD Display

1024 X 768 pixel TFT active matrix color display with a built-in backlight.

•

Interface Panel A12182: color change sequencer controller, E to P transducers, zener barriers, fiber optic receiver, solenoid valves, etc. necessary to interface with the control components.

SPECIFICA

TIONS colors, Ultra wide viewing angle

40 GB HDD

1 GB RAM

Interface Module

- 19200 BAUD, 8 data bits, 1 stop bit, no parity, No handshaking

The serial port is connected to J8 on the card rack mother board as follows:

- J8-9 RS-232A Receive (Rx)

- J8-10 RS-232A Transmit (Tx)

- J8-11 RS-232A Ground

COM 2: Not used

COM 3: Reserved for touch panel

COM 4: Not used

Drives D:, E:, F:, etc.

10/100 BASE-T

Parallel Port: Standard

Standard

Not used

>

The embedded CPU board and interconnecting cable assemblies are subject to change.

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DynaFlow TM Operator Interface Manual - Installation

INST

ALLA TION

-----

REFER ALSO TO THE DYNAFLOW

INTRINSICALL

Y

(Refer to Figures 1a and 1b.)

Input supply voltage connections should be made conduit should be used for the input power wiring with the appropriate connectors into the Control

Panel.

If there are large AC line voltage fluctuations or voltage transients such as those typically produced by heavy electric machinery or welding equipment, then a constant voltage transformer (CVT) or an

UPS should be used between the FUSED

DISCONNECT and the Control Panel.

All GUN specific control wiring to the control rack is terminated at the ribbon cable to discrete converter blocks TB1-TB4 located on the rear panel of the DynaFlow enclosure (refer to Figure

1c). For DynaFlow panels configured for use with the remote electrical-to-pneumatic interface panels, the GUN control wiring is supplied to circular connectors located on the top of the panel.

The GUN control I/O is ignored for any Slave

(catalyst) CHANNELs. Therefore, connections need only be made to CHANNELs configured as

Master CHANNELs.

>

If a constant voltage transformer (CVT) is to be used on the input to the Control

Panel, use a CVT with a Volt-Amp (VA) output rating equal to or greater than the output voltage multiplied by the control panel fuse rating. Also make sure that the CVT input ratings correspond with the voltage and frequency of the source supplied by the

FUSED DISCONNECT. The CVT output should be rated for 240 VAC maximum.

!!!!!

>

The pilot light socket, located in the power switch that is located on the door, is rated for 120 VAC and must be changed if

240 VAC input power is used.

>

The appropriate power line filter must be specified or operation at either 115 or 230

VAC.

There are up to eight circular connectors located on top of the DynaFlow Control Panel depending on the number of CHANNELs. These are labeled

GUN #1-GUN #8.

For two-component GUN's: Since all of the interface wiring necessary for a two-component

GUN is supplied through a single cable to the

LBAL5001 Interface Panel, connection for a twocomponent GUN must be made to the odd numbered GUN connectors (#1, #3, #5, or #7).

For single-component GUN's: Simply connect each GUN in order, GUN #1 to connector #1, etc.

All system control I/O, AC and DC power connections are made at terminal blocks comprising TB5 (refer to Figure 1c).

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DynaFlow TM Operator Interface Manual - Installation

DynaFlow

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Operator Interface Manual - Installation

>

For the A12233 version of the

DynaFlow, the zener barriers are housed in the A12182 interface panel.

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DynaFlow TM Operator Interface Manual - Installation

DynaFlow

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Operator Interface Manual - Installation

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Operator Interface Manual - Installation

DynaFlow

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Operator Interface Manual - Operation

OPERA

TION

The Operator Interface was designed to be user friendly and to supply all of the necessary information for the operation of the DynaFlow control directly to the operator. Most information located in the manuals regarding the operation of the DynaFlow system is available directly through the Operator Interface. All of the screens offer ‘online’ descriptive information and help text that includes troubleshooting. Graphic information is also displayed for a quick determination of system performance.

This key is used to exit any active screen or popup box.

F1 through F12 are soft keys. The function of these keys will change depending on which screen is active. The description for each key is shown in boxes on the bottom of the display.

When power is first applied to the DynaFlow system, the Interface and any installed Channel

Cards located in the card rack immediately perform initialization and place all GUNs in the ready state assuming valid configurations and successful self tests. The Interface Module will determine which

Channel Cards are installed and that they are communicating properly. The PC, upon application of power, will load the Windows XP operating system.

These keys allow manual activation and deactivation of each GUN. Pressing a GUN ON/

OFF button is the same as supplying an external

GUN RUN or GUN HALT input signal. When using a PC, the corresponding keys on the keyboard are (all lower case):

GUN 1

GUN 2

GUN 3

GUN 4

GUN 5

GUN 6

GUN 7

GUN 8 j f a s d g h k

All analog and control outputs to the fluid system are removed if power is turned off to the card rack.

This means that fluid flow will be immediately stopped for all CHANNELs. An Emergency Stop should be supplied for this purpose. The standalone DynaFlow panel incorporates an E-Stop front panel switch with an additional unused set of normally open and normally closed contacts for use by the customer to interlock other system functions.

The Emergency Stop switch does not remove AC power from the touch panel PC. The green On/Off switch removes AC power to the 24VDC power supply and the touch panel PC.

The cursor keys allow the operator to move to a data field for editing or to a command field. In addition to pressing the ENTER key, edited data will also be accepted when a cursor key is pressed.

Pressing this key will return the editing cursor to the first data field in the screen.

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Operator Interface Manual - Operation

The LOAD key causes a small pop-up box to appear in the current screen. Any GUN can be manually placed in LOAD MODE by simply pressing the number for the desired GUN on the numeric portion of the keypad. The LOAD MODE is deactivated by pressing the GUN number again.

This is the same as supplying an external GUN

LOAD and GUN HALT input signals. When using a PC, the corresponding key on the keyboard is the backspace key.

controller. Pressing the Clear Faults key will silence the horn. When using a PC, the corresponding key on the keyboard is lower case c.

Exit T o Operating System

The

'*'

key followed by the F9 key, or CTRL with

F1, from the main screen will exit to the operating system. From the touch screen, simply push F12.

The password may be required.

P

ASSWORD OPERA TION

The CLEAN key causes a small pop-up box to appear in the current screen. Any GUN can be manually placed in CLEAN MODE by simply pressing the number for the desired GUN on the numeric portion of the keypad. The CLEAN MODE is deactivated by pressing the GUN number again.

This is the same as supplying an external GUN

CLEAN or GUN HALT input signal. When using a

PC, the corresponding key on the keyboard is the space key.

The HELP key can be pressed at any time. It will provide more detailed help for the current active screen. In addition, there is troubleshooting information also available through the HELP screens. When using a PC, the corresponding key on the keyboard is lower case L.

The password is required for editing any system or GUN configurations, loading information from files, editing JOB tables or forcing I/O. A pop-up screen will appear requesting the password when attempting to perform a password protected operation. Once a password is entered correctly, it will not be required again until the password timer has elapsed. The password and password timer can be set in the SYSTEM CONFIGURATION screen. The password timer starts after the last keystroke is sensed. Every additional keystroke before the password timer elapses resets the timer. This makes it convenient for an operator to change multiple parameters without having to continually reenter the password. In the event that the password is lost or is not recognized by the controller, contact Ransburg Service. Entering a

‘0’ for the password will disable password protection.

Edited information in the currently selected data field is accepted when the ENTER key is pressed.

The next logical data field is then selected.

CLEAR F AUL TS (Lower Case c)

Pressing this key will immediately clear any faults reported by the controller regardless of the current screen. If the fault resulted in the stoppage of fluid, then a GUN RUN signal is required to start flow again. Enter the ERROR LOG screen to view the error that occurred. Pot Life faults can only be

‘cleared’ by evacuating the volume of fluid as determined by the Mixed Volume parameter located in the GUN CONFIGURATION screen through the GUN or cycling power to the DynaFlow

The appearance of the main screen will be determined by the number of CHANNELs installed and the GUN configurations. GUN faults may also be cleared from this screen. If the GUN configuration is changed, then the main screen will automatically reflect the changes when the operator returns to the main screen. Each GUN is shown in a box with the assigned CHANNEL(S). Relevant operational information is also shown in the GUN box such as GUN mode, GUN status, requested flow rate, actual flow rate and flow tolerance (error).

The actual flow and tolerance are also shown in bar graph form.

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DynaFlow TM Operator Interface Manual - Operation

The flow bar graphs are color coded as follows:

Green = Normal Flow

Red = Reverse Flow

White = Flow During Clean (Solvent)

Cyan = Flow During Load (Material)

Yellow = Flow During Pot-Life Alarm

Blue = Flow In the Ready State

HALT/RESET hardware input. If the GUN is already in the halted state (ready), then no additional HALT signal is required. The main screen indicates the current JOB which was loaded at the time of the last GUN RUN command.

T olerance Bargraph

The far left ba rgraph of a dual-component gun on the main screen has traditionally been used to display ratio tolerance. With version 4.0.05 and later versions of the user-interface software, this bar graph has two new options; Mixed Volume and

Pot Life. The bar graph can be configured in the

Config. Gun Screen under the Display Mode parameter. The Mixed Volume option gives a graphical representation of the amount of mixed material in the tubing running from the spiral mix tube to the applicator. The Pot Life option gives a graphical representation of the age of the oldest mixed material (which is the material in the applicator at any point in time).

While in the EDIT JOBS screen, a selected parameter for the current JOB may be copied to any number of other JOBs or the entire JOB table can be copied to other selected GUNs and JOBs.

This is accomplished by selecting the COPY

PARAMETER and COPY JOB soft keys. Selecting either soft key will cause a pop-up screen to appear. The operator will be prompted to enter the requested range for GUNs and JOBs.

Allows the operator to view the status of system and GUN specific inputs and outputs as well as monitoring RIO PLC signals. The operator can also ‘force’ input and output states for troubleshooting purposes.

Contains system parameters that are not GUN or

JOB specific.

The firmware versions and DIP switch settings of the Interface Module and Channel Cards are displayed in this screen.

The date and time may be changed in this screen.

Contains parameters that effect a GUN regardless of the JOB. The GUN configuration parameters should not be changed if the GUN is active. If a

CHANNEL is to be reassigned to a different GUN, then it must first be removed from any other GUN.

Simply allows the operator to select the next JOB for a GUN. The selected JOB is placed in a ‘queue’ for the selected GUN. The new JOB will be loaded at the next GUN RUN signal following a GUN

HALT signal. A GUN can be halted by pressing the GUN ON/OFF key or supplying the GUN

Provides a convenient means to graphically monitor operational data with respect to time, similar to a data logging or charting device. This feature supplies the operator with fluid flow and related response information in order to evaluate the system or set up the control parameters for optimum performance. There are four parameters that can be selected for plotting. Each parameter is automatically given a unique color and is displayed with it’s own corresponding scale and description. All of the possible plotting parameters are shown in the setup screen for each configured

GUN. The operator can select any of the parameters for any of the GUNs. Touch the desired parameter and press the SELECT (F1) soft key to select that parameter. Pushing F1 again will remove the parameter. Each selected parameter will be displayed in a small box at the lower left of the setup screen along with the color assigned to that parameter. Once the desired parameters are selected, then press the PLOT soft key to start the plotting screen. The operator can then choose to scroll the plot continuously, freeze, or stop the plot, or save the screen to a compressed bit mapped file. The compressed file can then be

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DynaFlow TM Operator Interface Manual - Operation converted to a standard .BMP file by using the utility called decomp.exe located on the DynaFlow software Disk or on drive C: of the DynaFlow controller. Simply type ‘decomp’ followed by the name of the saved file.

Job T otals (F7)

The Job Totals screen allows users to monitor material usage. Values are stored according to the Job number so if each material being sprayed is assigned its own Job number, totals will be recorded for each material sprayed. There are two values stored for each material and each job and are known as a Daily Total and a Year to Date total. These totals are not related to the clock or calendar in any way, they are simply two totals that can be reset independent of each other. For instance, one may be used for a batch of parts total and the other may be used as a shift total, etc.

Separate totals are also maintained for Clean mode (how much material flowed while the unit was in clean mode). Keep in mind that if solvent/ air chop cycles are used this total will not be extremely accurate. There is also an independent value recorded for volumes used while in the calibrate mode. Totals can also be reset on this screen except for the GRAND TOTALS. (This allows for a secure, non-resettable value for EPA reporting purposes.) and flush sequences and times are downloaded to this controller (via Ethernet) by the user-interface

P.C. every time a new Job Number is toggled into the respective gun. When this function is selected, the operator is first prompted for the gun number they wish to view or edit the sequence for, they are then prompted for which Job Number they wish to view and/or edit the sequences of, and last, they are asked if they want to view/edit the sequence for flushing or filling. (There is a separate flush sequence and load sequence stored for every Job

Number and for every gun.)

Error Log Screen (F1

1)

This screen displays the previous 10 system errors or GUN faults that have occurred. For each of the errors, the error code and descriptive text will indicate the GUN and specific type of error.

Errors can be cleared from the screen by pressing the F7 key. The actual fault condition can only be cleared by pressing the CLEAR FAULTS key or supplying a GUN HALT hardware input.

The calibration procedure is a CHANNEL (flow meter) specific operation and must be performed on only one CHANNEL at a time. The calibration screen offers a convenient means to verify or adjust the flow meter pulses per liter (P/L) setting based on actual measurements. The procedure can be performed by one person and eliminates the need to do manual calculations.

An optional color change sequencer may have been included with the controller. If it was included, the F9 key will indicate as such. If the F9 key is blank, your system does not have this option. The optional color change sequencer is a PLC-like controller that performs the load, flush, and color change sequences that were programmed by the user from the color change setup screens. Load

To manually place a GUN in LOAD MODE from the PC interface, push the LOAD key. A small pop-up box will appear in the upper left corner of the current screen. Simply push the number of the

GUN to immediately start loading fluid for the selected GUN. The number selected will appear in the pop-up box. To stop loading a GUN, press the

GUN number again. Push the ESC key to exit the

LOAD MODE.

To manually place a GUN in CLEAN MODE from the PC interface, push the CLEAN key. A small pop-up box will appear in the upper left corner of the current screen. Simply push the number of the

GUN to immediately start cleaning for the selected

GUN. Each CHANNEL assigned to a GUN can be selected as a ‘clean’ CHANNEL in the

CONFIGURE SYSTEM screen. To stop cleaning, press the GUN number again. Push the ESC key to exit the CLEAN MODE. (Guns in clean mode when this screen is exited will remain in clean mode until the GUN ON/OFF button is pushed.)

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DynaFlow TM Operator Interface Manual - Operation

>

The following is important to note when changing or entering data in the System

Configuration, GUN Configuration, or Edit

JOB screens. Any modifications to data until the "Store Data F5" key is pressed, which causes the new data to be sent to the

DynaFlow Interface Module and automatically saved to the FLASH drive. If the "ESC" key is pressed first, any changes will be lost when exiting the screen. Each screen reads the data from the Interface Module upon entry to ensure that changes made by a PLC will be recognized by the DynaFlow program.

System configuration, GUN configuration, JOB tables data, and flow totals can be saved or retrieved to disk files. Binary files (*.VAL) store the actual data and are the only type used to restore data. The binary files may be saved to either the FLASH drive C: or the floppy diskette drive A:

System configuration data:

SYSPAR.VAL

GUN configuration data:

GUNPAR.VAL

JOB tables:

PROGDATA.VAL

Totals:

TOTALS.VAL

The plotting screen is saved as a standard bitmap file (MMDDhhmm.BMP). The plot file names are formed from the month (MM), day (DD), hour (hh), and minute (mm) when the plot was saved. When saving a plot file, note the date and time in a log detailing what was plotted.

Data for all GUNs or all JOBs are saved automatically, regardless of the specific GUN or

JOB being viewed or edited. For example, to save all JOB tables for all GUNs, simply enter the JOB

EDIT screen for any GUN, any JOB, and press the "Save To File" key. The same is true for recalling data from previously saved files. To completely save all configuration and totals data:

•

•

•

•

From the CONFIG SYSTEM screen, press the "Save To File" key.

From the CONFIG GUN screen (select any GUN), press the "Save To File" key.

From the EDIT JOB screen (select any

GUN and any JOB), press the "Save To

File" key.

From the TOTALS screen, press the "Save

To File" key.

To recall all previously saved configurations:

•

•

•

•

From the CONFIG SYSTEM screen, press the "Read In File" key.

From the CONFIG GUN screen (select any GUN), press the "Read In File" key.

From the EDIT JOB screen (select any

GUN and any JOB), press the "Read In

File" key.

From the TOTALS screen, press the "Read

In File" key.

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DynaFlow TM Operator Interface Manual - Operation

INST ALLING/UPDA TING

SOFTW ARE

To install or upgrade the DynaFlow software, follow the directions included with the media. Any previously stored data sets and/or configurations located on the hard drive will not be overwritten.

This includes any configuration, JOB and Totals data previously saved. You will be prompted for any additional information that is required. It is recommended that all configuration and JOB data be saved to an USB memory stick before upgrading software.

This is a small box located on some of the screens.

The information displayed in this box describes illegal data or configuration entry attempts made by the operator, confirmation of a command or additional instructions.

Contact Ransburg Technical Service if the operating system should become corrupted. A restore CD-ROM can be made available.

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Operator Interface Manual - Operation

P

ARAMETER LOCA TIONS

The following lists the parameters associated with each screen.

Horn Code

Blowoff Time

Password Timeout

RIO Rack Address

RIO Rack Size

RIO Starting Quarter

RIO Baud Rate

SIO Baud Rate

SIO COM Port

Channel Card #1 Verison

Channel Card #2 Version

Channel Card #3 Version

Channel Card #4 Version

Interface Module Version

User Interface Version

System Time

System Date

Select Language

Mode (Auto/Manual)

No. of CHANNELs

Master CHANNEL

Slave CHANNEL

Clean CHANNELs

Default JOB Number

Flow Tolerance %

Tolerance Volume

Mixed Volume

Flush Volume

Trigger Off Delay

Trigger On Delay

Master CHANNEL Regulator Type

Slave CHANNEL Regulator Type

Reverse Flow Volume

Bar Chart Maximum Flow Rate

Flow Rate Tolerance Time

Master Pot Volume

Slave Pot Volume

Display Mode

Channel Card #1 DIP SW1

Channel Card #2 DIP SW1

Channel Card #3 DIP SW1

Channel Card #4 DIP SW1

Interface Module DIP SW1

Interface Module DIP SW2

Mix Ratio

Master Percentage

Slave Percentage

Flow Rate Setpoint

Maximum Flow Rate

Minimum Flow Rate

Pot Life Time

Master MVR High Pressure

Master MVR Low Pressure

Master Pulses Per Liter

Master Deadband

Slave MVR High Pressure

Slave MVR Low Pressure

Slave Pulses Per Liter

Slave Deadband

Master Proportional Gain (Kp) Slave Proportional Gain (Kp)

Master Integral Gain (Ki) Slave Integral Gain (Ki)

Master Dirative Gain (Kd) Slave Derivative Gain (Kd)

LN-9401-00.5

DynaFlow

TM

Operator Interface Manual - Operation

F5 DIGITAL/ANALOG I/O

1: DISCRETE DIGITAL GUN

I/O

2: ANALOG I/O

Trigger Gun

Run Mode

Halt Gun

Clean Mode

Spare Input

Total Reset

Total Hold

Transparent

Flow Rate Set Point

Spare Analog Input

Control Pressure

Actual Flow Rate

Forced Control Pressure

Forced Actual Flow Rate

Analog Hold

Job # GUN Mask

Load Mode

Enable Gun

Quad-Driver 1 OK (12-bit Only)

Quad-Driver 2 OK (12-bit Only)

Quad-Driver 3 OK (12-bit Only)

10-bit or 12-bit DAC

3: DISCRETE AND REMOTE

SYSTEM I/O

JOB # 001

JOB # 002

JOB # 004

JOB # 008

JOB # 010

JOB # 020

JOB # 040

JOB # 080

JOB # 100

JOB # Strobe

JOB # Decimal

System Ready

Global GUN Enable

RIO System Halt

RIO Fault Reset

RIO Global GUN Enable

Ready

Run (Active) Mode

Faulted

Pot Life Alarm

Clean/Load/Calibrate Mode

MVR Enable

4: DISCRETE REMOTE I/O

Trigger Gun

Run Mode

Transparent

Total Hold

Halt Gun

Total Reset

Clean Mode

Load Mode

Ready

Run (Active) Mode

Faulted

Pot Life Alarm

Clean Mode

Load Mode

Calibrate Mode

MVR Enable

5: BTW/BTR REMOTE I/O BUFFER

Display

Hex

Decimal

BTW/BTR

BTW

BTR

Data Type

Null

Operational

Gun Configuration

Job Configuration

System Configuration

Flow Totals

System Alarms

Calibration

Lookup Table

Help

System Fault

System Pulse

System Spare

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Operation

F6 PLOT DA

T

A

Trigger

Requested Ratio

Actual Ratio

Requested Flow Rate

Actual Flow Rate

Master Requested Flow Rate

Master Actual Flow Rate

Master Control Pressure

Slave Requested Flow Rate

Slave Actual Flow Rate

Slave Control Pressure

F7 JOB FLOW T OT ALS

Daily Volume

Integral of Absolute Value (IABS) of

Error Volume

Year To Date Volume

Calibrate Volume

Grand Total Volume

Step Duration

Resin Solvent Air Chop

Resin – Solvent

Resin – Air

Paint

Dump Valve

Resin Fluid Override

Trigger Solenoid

Catalyst #1 CCV

Catalyst #2CCV

Catalyst #3CCV

Catalyst Solvent

Catalyst Fluid Override

Run

Halt

Trigger

Load

Clean

Catalyst Disable

Chop Air Time

Chop Solvent Time

Daily Volume

Year To Date Volume

Calibrate Volume

Clean Volume

Grand Total Volume

F 8 CALIBRA TE PROCEDURE

Mode

Calibration Time

Calibration Flow Rate Set Point

Calibration Actual Flow Rate

Number of Pulses Received

Calculated Volume

Measured Volume

Measured Weight

Specific Gravity

Calculated Pulses/Liter

Current Pulses/Liter

NOTE: ESC is availble from any menu or popup box to return to the previous screen.

Enter Password

F1 Modify Value

F3 Change Password

F5 Store Data

F7 Read In All Files

F8 Save To All Files

F9 Read In File

F10 Save To File

F11 Error Log

F 2 CONFIG GUN

Enter Password

Select GUN #

F1 Modify Value

F2 Previous GUN

F3 Next GUN

F5 Store Data

F9 Read In File

F10 Save To File

F11 Error Log

LN-9401-00.5

F 3 SELECT JOB

Enter Password

Select GUN #

Enter JOB #

Enter Password

Select GUN #

Enter JOB #

F1 Modify Value

F2 Next GUN

F3 Next JOB

F4 JOB Directory

F5 Store Data

F6 Lookup Talbe

F7 Copy Parameter

F8 Copy Job

F9 Read In File

F10 Save To File

F11 Error Log

F6 PLOT DA

T

A

F1 Select Variable

F2 Plot Variable(s)

F1 Time 90/45 Seconds

F2 Single Plot/Scroll Plot

F3 Stop Plot/Start Plot

F5 Start Time Cursor

F6 Start Time Cursor

F7 Stop Time Cursor

F8 Stop Time Cursor

F10 Save To Plot

F11 Error Log

F3 Clear All Variables

F11 Error Log

F 7 JOB FLOW T OT ALS

Enter Password

Enter JOB #

F1 Reset Total

F2 Reset CHANNEL

F3 Reset GUN

F4 Reset All

F5 Previous JOB

F6 Select JOB

F7 Next JOB

F8 Toggle Units

F9 Read In file

F10 Save To File

F11 Error Log

DynaFlow TM Operator Interface Manual - Operation

F 8 CALIBRA TION PROC.

Enter Password

Enter CHANNEL #

Enter JOB #

F1 Modify (Mode)

F2 Start Calibration

F3 Stop Calibration

F4 Fluid Load

F10 Save To File

F11 Error Log

F7 Save New Pulses/Liter To

This One JOB

F8 Save New Pulses/Liter To All

JOBs

F11 Error Log

Clear Faults

Clear Log

Save To File

Help

1 - Yes

2 - No

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Maintenance

There is no maintenance schedule for control panels other than good housekeeping practices.

These include:

1. Keeping the door closed at all times. This will maintain the dust-tight environment required by the electronic printed circuit boards.

2. Plug all unused access holes into the cabinet in order to keep contamination out.

3. Use the following guidelines for cleaning the

Operator Interface.

Use cleaning solution specifically formulated for computer monitors, a mild window cleaner, or isopropyl alcohol. Most importantly, use a clean, soft paper towel or tissue and use very light force.

The touch panel has been tested with Isopropyl

Alcohol, Butyl Acetate, Methyl Ethyl Keystone, and Xylene, use of solvents to clean the surface should be minimized.

The "Troubleshooting Guide" lists possible problems associated with the Operator Interface only. Reference the DynaFlow User manual for additional troubleshooting information not specific to the Operator Interface assembly.

>

Fluid flow control is not dependent on the Operator Interface being active. The system will operate and control fluid based on the last settings entered and the state of the hardware digital and/or analog I/O.

dirt or paint can accumulate, a sheet of clear plastic can be taped over the entire display.

For maintenance of system components other than the DynaFlow control panel, refer to the appropriate manual or contact Ransburg

Customer Service.

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Maintenance

General Problem

Cause

Serial Communication

Error

1.

Connected to wrong serial port

1.

The PC should be connected to the Interface

Module serial port 2.

J8-9 (Rx)

J8-10 (Tx)

J8-11 (GND)

LCD Display

Floppy Disk Drive

Touch Panel

Password

GUN Faults or

System Errors

DynaFlow Software

2.

Wiring to serial port incorrect

3.

Interface Module not communicating

2.

Check wiring to serial port.

3.

Observe the lights located on the front of the

Interface Module. If they are all flashing slowly or indicate red, a problem with the Interface

Module exists. Replace the Interface Module and restore configurations and JOB data.

4.

Check wiring and perform PC troubleshooting.

4.

PC port not communicating

1.

Display is blank 1.

Press the display on/off button below the display.

1. Contact Ransburg Service.

1.

Green light on the disk drive does not turn on when reading or writing to the drive, or when booting the system

2.

The disk drive light comes on when attempting to read or write, but data errors occur

2.

Try a different disk.

1.

Does not work

1.

The password is not recognized or has been forgotten

1.

Error or faults reported in the Error Log screen

1.

1.

Contact Ransburg Service.

Contact Ransburg Service for instructions.

1.

Refer to the help text on the screen and to current the DynaFlow User manual.

1.

Does not run, reports

Windows error or C: drive not recognized

1.

Contact Ransburg Service.

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Parts Identification

P

AR TS IDENTIFICA TION

LN-9401-00.5

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Parts Identification

DC ON

ALMV.ADJ

H

+V +V -V

Output Details

-V

Continuous Loading 24VDC/7.5A

Made in China

Input Details

100-240VAC 2.7A Maximum

Power Factor Corrected

Frequency : 50/60Hz

L N

DynaFlow TM Operator Interface Manual - Parts Identification

DYNAFLOW P AR TS LIST (Figures 2 & 3)

7

8

5

6

2

3

N/A

1

4

77376-WXYZV *

A10705-00

A11224-00

A10577-XX

4131-11

74300-00

77454-00

73837-08

77382-00

DynaFlow Control Panel

CPU Sub-Assembly

Power Supply Assembly, 24 VDC

Power Line Filter

Fuse, 3AG, 3A

Bulb, 130 VAC

Fiber Optic Receiver Assembly

Intrinsic Safety Barrier

Ribbon Cable Interface

* P AR

TS LIST

REFERENCE

T ABLE "W" (# CHANNELs)

6

8

2

4

2 CHANNEL

4 CHANNEL

6 CHANNEL

8 CHANNEL

* P AR

TS LIST

REFERENCE

T ABLE "Y"

* P AR

TS LIST

REFERENCE

T ABLE "X" (E/P Interface)

* P

T

0

1

None (Automatic Applications)

Interface Connections (Manual

GUN Applications)

AR

TS LIST

ABLE "Z"

REFERENCE

1 RIO

* P AR TS LIST REFERENCE

T ABLE "V" (V oltage)

0

1

115VAC

230VAC

0

1

Fiber Optic

Intrinsic Safety Barrier

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Parts Identification such as pneumatic interface panels, fluid panels, transducer panels, etc. The spare parts lists for the auxiliary equipment should be derived from previous fluid control lists since their usage and requirements are the same.

DYNAFLOW SP ARE P

AR TS LIST

Part No.

Description

77377-02

------------------

A10946-00

77378-00

A11224-00

73837-08

------------------

77454-00

77382-00

74300-00

4131-11

DynaFlow Interface Module

--------------------------------------------------------

DynaFlow Channel Card

DynaFlow Mother Board

Power Supply Assembly, 24 VDC

Intrinsic Safety Barrier

--------------------------------------------------------

Fiber Optic Flow Meter Receiver

Ribbon Cable Adapter

Bulb, 130 VAC

Fuse, 3 AG, 3 AMP

1

----------

1

0

1

1

----------

1

0

1

1

2

----------

2

0

1

1

----------

1

1

2

2

2

----------

3

1

1

2

----------

2

1

2

2

----------------------------------

For 77376-XXXX only

----------------------------------

For 77376-XXXX only

LN-9401-00.5

DynaFlow

TM

Operator Interface Manual - Parts Identification

LN-9401-00.5

DynaFlow

TM

Operator Interface Manual - Parts Identification

8

9

6

7

10

3

4

1

2

5

11

12

13

14

15

16

17

18

19

DYNAFLOW DOOR P AR TS LIST (A12233 V

A10705-01

76948-00

LSME0005-00

22-1108

SS7016

LSME0004-00

8318-38

77384-00

LSME0006-00

77431-12

77380-02

77380-01

77435-00

A10946-01

A10946-02

77377-02

A12231-00

A10998-00

A11224-00

77382-00

Touch Screen PC, DynaFlow

Switch, Selector, Maintained, Green

Contact Block, Normally Open

Pilot Light Block

Bulb, 130 VDC Power Supply

Relay Socket

2.2 K Ohm, 1/4 Watt Resistor

Switch, Mushroom Head, E-Stop, Red

Contact Block, Normally Closed

Rack with Cards, 2-Channel DynaFlow

Ribbon Cable Assembly, 64-Conductor

Ribbon Cable Assembly, 64-Conductor

Serial Cable Assembly

Channel Card, DynaFlow, Voltage Output Only

Channel Card, DynaFlow, Voltage and Current Outputs

Interface Card, DynaFlow with RIO

Diode Module

Ethernet Switch, 5 Port

Power Supply, 24 VDC, 100-240 VDC in 240W

64-Pin Ribbon Cable to Discrete Breakout Board

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Parts Identification

1

2

3

4

5

8

9

6

7

10

11

DYNAFLOW INTERF ACE P ANEL P

AR

TS LIST (A12177 V ersion)

A10786-00

A11389-00

78835-00

A10787-00

22-7018

SS-7016

TR-SSEH-519

78643-00

41-VSO-1005

A12720-00

73837-08

A10785-00

Output Module

Power Supply, +5 VDC, +24 VOD (Used with CC Sequencer)

Power Supply, +24 VDC Only (Used without CC Sequencer)

Output Module

Power Filter

12VDC Power Supply

Relay Socket

Transducer, Voltage to Pressure

Solenoid Valve, 24 VDC Coil

Fiber Optic Receiver

Zener Barrier, 24 VDDC @ 50mA

Color Change Sequencer Brain

LN-9401-00.5

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Parts Identification

DynaFlow

TM

Operator Interface Manual - Warranty Policies

W

ARRANTY POLICIES

LIMITED W

ARRANTY

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 equipment has been used and maintained in accordance with

Ransburg's written safety and operating instructions, and has been used under normal operating conditions. Normal wear items are excluded.

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.

If, in Ransburg's opinion the warranty item in question, or other items damaged by this part was improperly installed, operated or maintained,

Ransburg will assume no responsibility for repair or replacement of the item or items. The purchaser, therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable.

LN-9401-00.5

DynaFlow

TM

Operator Interface Manual - Appendix

Gallons (US)

Gallons (US)

Gallons (US)

Gallons (US)

Gallons (US)

Quarts (US)

Fluid Ounces (US)

Fluid Ounces (US)

Liter

Liter

Liter

-----------------------------

Feet/Min.

Feet/Sec.

Feet/Min.

Feet/Min.

-----------------------------

Square Inches

Square Centimeters

Square Feet

Square Yards

Square Feet

-----------------------------

Gallons/Min.

Gallons/Min.

Cubic Feet/Sec.

Cubic Feet/Min. (cfm)

Liters/Hour

Cubic Centimeters (cc)

Liter

Cubic Meters

Cubic Inches

Gallon (lmp)

Liter

Cubic Inches

Cubic Centimeters (cc)

Cubic Meters

Cubic Centimeters (cc)

Cubic Inches

-----------------------------

-----------------------------

Meter/Min.

Meter/Sec.

Inches/Sec.

Mile/Hr.

-----------------------------

-----------------------------

Square Centimeters

Square Feet

Square Meters

Square Meters

Square Yards

-----------------------------

-----------------------------

Liter/Min.

Cubic Meters/Sec.

Cubic Meters/Sec.

Cubic Meters/Hr.

Cubic Feet/Min. (cfm)

3785.00

3.785

.003785

231.00

.83268

.946

1.8047

29.574

Kilogram

Ton (2000 lb.)

Ounce Gram 28.349

Pound

-----------------------------

Gram 453.59

----------------------------

------------------

---------------------------------------------

Meter

Feet

Pound (lb.)

Kilogram

Inches

Meter

2.205

907.18

39.37

3048

.001

1000.00

61.024

Inches

Inches

Mil (thickness)

Millimeters

Centimeters

Millimeters

25.4

2.54

-----------------Mil (thickness)

-----------------Yards

.3048

Microns

3048

.200

Microns

Mils

Inches

Meters

Meters

Mils

Microns

.0254

.001

.9144

.000001

.04

25.4

.011364

------------------

--------------------------------------------------------------------------

--------------------------------------------

------------------

6.452

.001076

.0929

Ft. Lbs.

Newton Meter

Gram Centimeter

In. Lbs.

In. Lbs.

In. Lbs.

12.00

8.85

.00087

--------------------------------------------------------------------------

.836

.111

Bar (atmosphere)

-----------------Inches HG

--------------------------------------------

PSI

PSI

14.696

.4912

-----------------Inches Water

3.785

.00006309

Lbs./Sq. In.

-----------------------------

PSI

Kg./Sq. cm

.03613

.07

----------------------------------------------

.028317

1.699

2.118

º

º

F

C

º

º

----------------------------

C

F

º

º

-----------------

C=9(ºF-32)÷1.8

F=(1.8xºC)+32

LN-9401-00.5

DynaFlow TM Operator Interface Manual - Appendix

RA TIO CONVERSION CHAR T

10

11.11

12.5

14.28

15

16.67

20

25

3

4

1

2

4.76

5

6.25

9.09

30

33.33

35

40

45

50

2.33

2

1.86

1.5

1.22

1

7

6

9

8

4

3

5.67

5

20

19

15

10

99

49

32.33

24

100%

- 1 = Parts Resin to 1 Part Catalyst

% of Catalyst

Example: 5% catalyst is specified

100%

- 1 = 20 Parts Resin to 1 Part Catalyst

5%

100%

= % of Catalyst

(Parts Resin + 1)

Example: If a ratio setting is 13 (13 parts resin to 1 part catalyst), and I want to know what percentage of the total mixed material is resin and what percentage is catalyst.

100%

= 7.14% Catalyst

(13 + 1)

100% - 7.14% = 92.86% Resin

LN-9401-00.5

MANUAL

CHANGE SUMMAR Y

This manual was published to replace Service

Manual LN-9401-00.4

DynaFlow Operator

Interface, to make the following changes:

1. Added "Model A12233" to Front Cover.

2. Revised "Description".

3. Revised "Specifications".

4. New "Figure 1a - Wiring for Intrinsically Safe

Flow Meters (77376)".

5. New "Figure 1b - Wiring for Intrinsically Safe

Flow Meters (A12233 Version)".

6. New "Figure 1c - System Connections

(77376)".

7. Added "Figure 1d -Input Power Schematic".

8. Revised "Screens - Main Screen".

9. Added "Job Totals in Screens".

10. Added "Color Change in Screens".

11. Removed "Operating the DynaFlow

Software from a PC".

12. Revised "Parameter Locations".

13. Revised "Screen Menu Tree".

14. Added "Figure 4 - DynaFlow Door (A12233

Version)".

15. Added "Figure 5 - DynaFlow Sub Panel

(A12233 Version)".

16. Removed "Appendix - Paint and Solvent

Specifications, Viscosity Conversion

Charts, and Volumetric Content of Hose or

Tube (English and Metric Units)".

LN-9401-00.5

1910 North Wayne Street

Angola, Indiana 46703-9100

Telephone: 260/665-8800

Fax: 260/665-8516 www.itwransburg.com

T echnical/Service Assistance

Automotive Assembly and Tier I

Ransburg Guns

Telephone: 800/ 626-3565 Fax: 419/ 470-2040

Telephone: 800/ 233-3366 Fax: 419/ 470-2071

T echnical Support Representative will direct you to the appropriate telephone

© 2012 Ransburg. All rights reserved.

Models and specifications subject to change without notice.

Form No. LN-9401-00.5

Litho in U.S.A.

03/12