Ransburg DynaFlow User Manual User Manual

SERVICE MANUALLN-9400-00.9(Replaced LN-9400-00.8)December 2012MODEL: 77376 and A12233IMPORTANT: Before using this equipment, carefully read SAFETY P

LN-9400-00.9INTRODUCTIONDynaFlowTM User Manual - Introduction6FEATURES• Congurable operating parameters (JOBs) which can be saved and recalled on

Form No. LN-9400-00.9Litho in U.S.A.12/12© 2012 Ransburg. All rights reserved.Models and specications subject to change without notice.Manufacturing

LN-9400-00.9 DynaFlowTM User Manual - Introduction7Located on the front panel of the Channel Mod-ule are several status indicator lights (LEDs). Thes

LN-9400-00.9DynaFlowTM User Manual - Introduction8incorporate rotary atomizer speed control, shaping air, high voltage power supplies and more.The sta

LN-9400-00.9 DynaFlowTM User Manual - Introduction9The output of the rst Gun is then fed into the Master Channel input of the second Gun. The second

LN-9400-00.910Figure 1: Block DiagramDynaFlowTM User Manual - Introduction

LN-9400-00.9 DYNAFLOW SPECIFICATIONSTransducers: The air supplied to the trans- ducers must be clean and dry and meet the following general spec

LN-9400-00.9DynaFlowTM User Manual - Introduction12General: Each Channel Module is responsible for processing channel specic dis- crete I/O and

LN-9400-00.9 Channel Module Hardware Speci-cations (Cont.)DynaFlowTM User Manual - Introduction13 FLOW RATE JOB parameters)4 Frequency Inputs: F

LN-9400-00.9DynaFlowTM User Manual - Installation14INSTALLATIONSYSTEM GUIDELINESPrints Specic per InstallationOften times, installation prints are cu

LN-9400-00.9 DynaFlowTM User Manual - Installation15 Do not locate the Control Panel near or adjacent to heat producing equip-ment such as ovens, hig

LN-9400-00.9NOTE: 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 C

LN-9400-00.9Figure 2: Block Diagram for a Single-Component GunDynaFlowTM User Manual - Installation16

LN-9400-00.9 DynaFlowTM User Manual - Installation17Figure 3a: Block Diagram for a Two-Component GunCHANNEL 1CHANNEL 2

LN-9400-00.9Y BLOCKMIX TUBEFLUIDREGULATORFLOWMETERVALV ECHECK VALVEE/P TRANSDUCERAIR SUPPLYFLUID SUPPLYANALOG CONTROL SIGNALFLOW METER FEEDBACKPILOT S

LN-9400-00.9 If a CVT or UPS 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

LN-9400-00.9DynaFlowTM User Manual - Installation20INTERFACING TO THE FLOW CONTROLLERSystem I/OSYSTEM INPUTSInput SignalsDescriptionJOB Select InputsJ

LN-9400-00.9 Discrete GUN I/O provides the input control and output status signals required to interface each GUN with a PLC or similar controller, or

LN-9400-00.9DynaFlowTM User Manual - Installation22GUN INPUTS (Continued)DescriptionTotal HoldTransparent/PIDAnalog HoldLoadExternal Fault/EnableSpare

LN-9400-00.9 DynaFlowTM User Manual - Installation23GUN OUTPUTSOutputSignalDescriptionReadyActiveFaultPot Life TimerClean/Load/CalibrateMVR EnableAnal

LN-9400-00.9DynaFlowTM User Manual - Installation24Figure 4: Mother Board TerminalsControl Rack Wiring(Reference page 82 for terminal identication.)

LN-9400-00.9 Hardware CongurationReference "Addendum A" in the "Appendix" sec-tion for board level hardware settings. For new sy

LN-9400-00.9 SAFETY:SAFETY PRECAUTIONS...HAZARDS / SAFEGUARDS...

LN-9400-00.9 Analog Hold mode without causing the uid tubes to pressurize to the material supply pressure while the GUN is not triggered. • For

LN-9400-00.9 DynaFlowTM User Manual - Installation27NOTES

LN-9400-00.9DynaFlowTM User Manual - Operation28OPERATIONOVERVIEWThis section will acquaint you with the general operation of the DynaFlow Fluid Flow

LN-9400-00.9 DynaFlowTM User Manual - Operation29ParametersThe controlling parameters for each GUN, and for the CHANNELs assigned to that GUN, are cal

LN-9400-00.9PARAMETER DESCRIPTIONSCONFIG SYSTEM (F1)All system parameters are password protected, unless disabled by setting the password to zero (0).

LN-9400-00.9 DynaFlowTM User Manual - Operation31CONFIG GUN (F2)GUN Conguration Parameters should not be edited while the GUN is running. This i

LN-9400-00.9Flow Tolerance PercentageThis is a number (in percent) that indicates how much deviation above and below the set point is acceptable. Incr

LN-9400-00.9 Trigger OFF DelayFor automatic GUNs only. This parameter has two uses, depending on the position of DIP SW1-2 (or SW1-6) on the Channel

LN-9400-00.9Display ModeThis parameter has three possible values: RATIO TOLERANCE, MIXED VOLUME, and POT LIFE. It indicates what type of bar-graph w

LN-9400-00.9 - Automatic Mode with Analog Control (Dy-namic Control)If the GUN is congured as an automatic GUN and external analog control of the ow

LN-9400-00.9DynaFlowTM User Manual - ContentsPAGEAPPENDIX:89-93ADDENDUM A...

LN-9400-00.9DynaFlowTM User Manual - Operation36Deadband would be between 95 and 105 cc/min. The PID controller would therefore be suspended whenever

LN-9400-00.9 DynaFlowTM User Manual - Operation37 NOTES

LN-9400-00.9Diagnostic Parameters (F5)The following parameters are available in the Local Operator Interface program as diagnostic parameters.Force CH

LN-9400-00.9 DynaFlowTM User Manual - Operation39Data Displays – At the top of the graphing screen there may be as many as six white boxes with data i

LN-9400-00.9- Open-Loop or Manual Calibration ModeThis mode attempts to ow material at the highest ow rate possible by setting the output to the E/P

LN-9400-00.9 Operational ParametersFlow Rate • Indicates total ow rate through a GUN. • If in 2K, sums the total of each CHANNEL attached to t

LN-9400-00.9DynaFlowTM User Manual - Operation42Color Change SequencerThe redesigned DynaFlow includes an optional color change sequencer that control

LN-9400-00.9 43DynaFlowTM User Manual - OperationThe following solenoid valves can be controlled by the sequencer: Resin/Solvent Air Chop Resin Solv

LN-9400-00.9ERROR LOG (F11)- Also See Section on Error CodesEach ERROR CODE can represent a CHANNEL, GUN or system error. See the Troubleshooting sec

LN-9400-00.9 RIO Set PointThe Total Flow Rate set point for a GUN may also be input via Remote I/O (RIO). No scaling is required, since the Total Flo

LN-9400-00.9 SAFETY PRECAUTIONSBefore operating, maintaining or servicing any Ransburg electrostatic coating system, read and understand all of the t

LN-9400-00.9DynaFlowTM User Manual - Operationrate of the master channel based on owmeter feedback and calculates the set point of the slaved (cataly

LN-9400-00.9 DynaFlowTM User Manual - OperationJOB Select InputsThese inputs are used to select a JOB number from the external PLC or other host contr

LN-9400-00.948DynaFlowTM User Manual - OperationFigure 5 gives a graphic representation of the timing required for selecting a JOB #. Normally, the J

LN-9400-00.9 DynaFlowTM User Manual - Operation49Toggle 1JOB number selected: 69GUNs Masked to accept JOB #69: 1,3Toggle 2JOB number selected:

LN-9400-00.9DynaFlowTM User Manual - Operation50Figure 6: JOB Selection Timing Diagram Sample

LN-9400-00.9 51DynaFlowTM User Manual - OperationJOB QueueThe JOB Queue is an input buffer for each of the 8 possible GUNs in the system. JOBs are loa

LN-9400-00.9DynaFlowTM User Manual - Operation52Calibration ModeThe rst time that the system is operated after installation or when using new u

LN-9400-00.9 DynaFlowTM User Manual - Operation53Procedure 2 (Automatic)1. Place the controller in Calibration Mode - se-lect automatic procedure.2.

LN-9400-00.9DynaFlowTM User Manual - Operation54CleanAny CHANNEL or Gun can be placed into a CLEAN mode by an external command or through the Host con

LN-9400-00.9 DynaFlowTM User Manual - Operation55Normal Start-Up ProcedureBefore attempting start-up: • Inspect the entire system and make sure th

LN-9400-00.9DynaFlowTM User Manual - SafetyAREATells where hazards may occur.HAZARDTells what the hazard is.SAFEGUARDSTells how to avoid the hazard.Sp

LN-9400-00.9DynaFlowTM User Manual - Operation56 3. Total system shutdown, including AC power, air and uid pressure is recommended if the system is

LN-9400-00.9 DynaFlowTM User Manual - Operation57Derivative Action (Kd)Derivative action is proportional to the rate of change of the error. The deriv

LN-9400-00.9DynaFlowTM User Manual - Operation58Recommended to start with these values and conrm stable response before trying to achieve faster resp

LN-9400-00.9 DynaFlowTM User Manual - Operation59pressure. This is due to the Integral term of the PID control. If the restriction causing the low ow

LN-9400-00.9DynaFlowTM User Manual - Operation6016. Trigger the GUN. If the ow rate does not oscillate, or the oscillations decrease in amplitude i

LN-9400-00.9 DynaFlowTM User Manual - Operation61NOTES7. Set the Ki parameters for both channels to a value between 50 and 500 in order to bring each

LN-9400-00.9DynaFlowTM User Manual - Maintenance62MAINTENANCETROUBLESHOOTINGError CodesThe following is a complete list of error codes. Some of these

LN-9400-00.9 DynaFlowTM User Manual - Maintenance63Displayed Text Fault Cause Corrective ActionReverse Flow Limit - CHANNEL #<>The amount of rev

LN-9400-00.9DynaFlowTM User Manual - Maintenance64Displayed Text Fault Cause Corrective ActionExternal GUN EN-ABLE Input Not Detected24 VDC must be su

LN-9400-00.9 DynaFlowTM User Manual - Maintenance65Displayed Text Fault Cause Corrective ActionNon-Existent Program - GUN #<>JOB # number entere

LN-9400-00.9 3DynaFlowTM User Manual - SafetyElectricalEquipmentHigh voltage equipment is utilized. Arcing in areas of ammable or combustible mat

LN-9400-00.9DynaFlowTM User Manual - Maintenance66Displayed Text Fault Cause Corrective ActionCodeB010(Cont.)B020B030B040B050B060RIO - Communi-cations

LN-9400-00.9 DynaFlowTM User Manual - Maintenance67Flow Too Low -or- Flow Too HighExplanation: These are CHANNEL specic faults.FLOW TOO HIGH and FLOW

LN-9400-00.968DynaFlowTM User Manual - Maintenanceforced ON. If the desired ow is achieved while in this mode of operation, the uid restriction is l

LN-9400-00.9 69DynaFlowTM User Manual - MaintenanceGun Flow Out of RangeExplanation: (Manual Guns Only) This fault in-dicates that the total

LN-9400-00.9Corrective Action:Simply save a JOB # for the indicated GUN making sure the parameters are correct. The Gun can be placed in RUN mode with

LN-9400-00.9 71DynaFlowTM User Manual - Maintenancefor a total of 32 seconds without faulting. As soon as the controller senses ow from the m

LN-9400-00.972DynaFlowTM User Manual - MaintenanceSYSTEM COMPONENTS AND PARTS IDENTIFICATIONFigure 7: Card Rack Assembly 1 77383-01 Rack Assembly,

LN-9400-00.9 73DynaFlowTM User Manual - MaintenanceRECOMMENDED SPARE PARTSRecommended spare parts list for the DynaFlow rack components only.SPARE PAR

LN-9400-00.974DynaFlowTM User Manual - MaintenanceThe following DynaFlow recommended spare parts lists do not include auxiliary uid control/monitor-i

LN-9400-00.9 75DynaFlowTM User Manual - MaintenanceHARDWARE SETTINGSChannel Module SettingsJumperDescription CommentsE1E5E6E8E10E9E4E3ROM size select.

LN-9400-00.9Toxic SubstancesCertain material may be harmful if inhaled, or if there is contact with the skin.Follow the requirements of the Material S

LN-9400-00.976DynaFlowTM User Manual - MaintenanceJumperDescription CommentsSelects 24 VDC source control or grounded sink control for digital inputs

LN-9400-00.9 77DynaFlowTM User Manual - Maintenance4 / 8 OFF Alternate PID EquationThe Alternate PID Equation should be used whenever the set point fo

LN-9400-00.978DynaFlowTM User Manual - MaintenanceInterface Module SettingsJumperDescription CommentsE4E5E10E2E3E6E7E8E9ROM size select.1-2 = 256K, 27

LN-9400-00.9 79DynaFlowTM User Manual - MaintenanceThe new 12-bit Channel Card for the DynaFlow (P/N: A10946) has a different jumper conguration than

LN-9400-00.980DynaFlowTM User Manual - Maintenance0 - 63 Decimal0 - 77 Octal0 - 3F HexNumber of Channel Cards:1 to 41 to 41 to 31PositionDescription C

LN-9400-00.9 81DynaFlowTM User Manual - MaintenanceAll data will be lost when set to ON position.Number Of Channel Modules:11 to 31 to 41 to 4Position

LN-9400-00.982DynaFlowTM User Manual - MaintenanceCONTROL RACK TERMINAL IDENTIFICATIONMOTHER BOARD SIGNAL IDENTIFICATION1B2B3B4B5B6B7B8B9B10B11B12B13B

LN-9400-00.9 83DynaFlowTM User Manual - MaintenancePin #Description1C2C3C4C5C6C7C8C9C10C11C12C13C14C15C16C17C18C19C20C21C22C23C24C25C26C27C28C29C30C31

LN-9400-00.984DynaFlowTM User Manual - MaintenanceMOTHER BOARD SIGNAL IDENTIFICATIONPin #Description1B2B3B4B5B6B7B8B9B10B11B12B13B14B15B16B17B18B19B20

LN-9400-00.9 85DynaFlowTM User Manual - MaintenanceTerminalDescriptionJ7-1J7-2J7-3J7-4+24 VDC+24 VDCPWR GNDPWR GNDJ7 POWER INPUTMOTHER BOARD SIGNAL ID

LN-9400-00.9 5DynaFlowTM User Manual - SafetyNOTES

LN-9400-00.986DynaFlowTM User Manual - MaintenanceSERIAL COMMUNICATION PROTOCOLSAllen-Bradley RIOThe Interface Module allows for direct commu-nication

LN-9400-00.9 87DynaFlowTM User Manual - Maintenance12344.7656.259.091011.1112.514.281516.6720253033.3335404550RATIO CONVERSION CHART% of Catalyst to T

LN-9400-00.9WARRANTY POLICIES88DynaFlowTM User Manual - Warranty PoliciesLIMITED WARRANTYRansburg will replace or repair without charge any part and/o

LN-9400-00.9 89DynaFlowTM User Manual - AppendixAPPENDIXADDENDUM A:Obsolescence of the 77206-01 8-bit Channel Card, the 77206-12 10-bit Channel Card a

LN-9400-00.990DynaFlowTM User Manual - AppendixADDENDUM A (Cont.):

LN-9400-00.9 91DynaFlowTM User Manual - AppendixADDENDUM B:Remote Operator's PanelIf the Model A12233 control console and Model A12182 Interface

LN-9400-00.992DynaFlowTM User Manual - AppendixNOTE: If both the green Paint (Solvent) Fill/Filled lamp and the amber Purge/Purged lamps are ashing

LN-9400-00.9 93DynaFlowTM User Manual - AppendixADDENDUM C:FLOW LIMITATIONSBecause of the way the DynaFlow determines ow rate from a owmeter, it has

LN-9400-00.9DynaFlowTM User Manual - Appendix94NOTES

LN-9400-00.9 MANUAL CHANGE SUMMARYThis manual was published to supercede Service Manual LN-9400-00.8, DynaFlow User Manual, to make the following chan