Carlisle Ransburg DynaFlow 77376 User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
Model: 77376 and A12233
DynaFlowTM Programmer’s Manual
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision LN-9406-00.3 to revision
LN-9406-00-R4. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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MANUAL CHANGES
EN

CONTENTS
SAFETY: 4-8
Safety Precautions .................................................................................................................................................... 4
Hazards / Safegaurds ................................................................................................................................................ 5
INTRODUCTION: 9-43
Description ................................................................................................................................................................ 9
Allen Bradley Remote I/O (RIO) ................................................................................................................................ 9
RIO Protocol .............................................................................................................................................................. 9
RIO Discrete I/O ........................................................................................................................................................ 9
RIO Starting Quarter ....................................................................................................................................... 10
System I/O - PLC Word O ............................................................................................................................... 10
Channel I/O - PLC Words 1 to 4 ..................................................................................................................... 10
RIO Block Transfers (BTR & BTW) ..........................................................................................................................11
Null Data - Type 00 ......................................................................................................................................... 12
Operational Data - Type 01 ............................................................................................................................. 13
Gun Conguration - Type 2 ............................................................................................................................. 15
Job Table - Type 3 ........................................................................................................................................... 17
System Conguration - Type 04 ...................................................................................................................... 18
Flow Totals - Type 05 ...................................................................................................................................... 19
Alarms Table - Type 06 ................................................................................................................................... 20
Calibration Table - Type 07 ............................................................................................................................. 26
Calibration Procedures For RIO .............................................................................................................................. 27
Lookup Tables - Type 08 ................................................................................................................................. 28
Ransburg Host SIO ................................................................................................................................................. 29
SIO Operation ................................................................................................................................................. 29
SIO Protocol ................................................................................................................................................... 29
INSTALLATION: 44-48
RIO Hardware Setting .............................................................................................................................................. 44
RIO Rack Address ................................................................................................................................................... 45
RIO Rack Size ......................................................................................................................................................... 46
RIO Starting Quarter ............................................................................................................................................... 46
RIO Braud Rate ....................................................................................................................................................... 46
RIO Non-Used Switch Settings ............................................................................................................................... 46
RIO Cable Connections ........................................................................................................................................... 46
SIO Hardware Settings ............................................................................................................................................ 48
SIO Port Conguration ............................................................................................................................................ 48
SIO Baud Rate ........................................................................................................................................................ 48
SIO Driver Levels .................................................................................................................................................... 48
SIO Cable Connection ............................................................................................................................................. 48
MANUAL CHANGE SUMMARY: 53
Manual Changes ..................................................................................................................................................... 53
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
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.
A WARNING! states information to alert you to
a situation that might cause serious injury if
instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard specications 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 efcient 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.
WARNING
!
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the Ransburg
safety literature therein identied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly un-
derstood by ALL personnel who operate, clean or
maintain this equipment! Special care should be tak-
en to ensure that the WARNINGS and safety require-
ments for operating and servicing the equipment are
followed. The user should be aware of and adhere
to ALL local building and re codes and ordinances
as well as NFPA-33 AND EN 50176 SAFETY STAN-
DARDS, LATEST EDITION, or applicable country
safety standards, prior to installing, operating, and/or
servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment.
SAFETY
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
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 prior to cleaning, ushing or maintenance.
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained
during cleaning operations using ammable or
combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance of
1 inch for every 10KV of output voltage is required
at all times.
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 modications may cause re 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.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
OSHA, local, country, and European Health and
Safety Norms.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Improper or inadequate
operation and maintenance
procedures will cause a
re hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch for
every 10KV of output voltage is required at all times.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible
materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding
section of the equipment manual. Protection against
inadvertent arcing that is capable of causing re
or explosion is lost if the current overload sensitivity
is not properly set. Frequent power supply
shutdown indicates a problem in the system which
requires correction.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no objects
are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA-33, EN 50176.
Have re extinguishing equipment readily available
and tested periodically.
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, re protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
General Use and
Maintenance
Spray Area Explosion Hazard
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re
or explosion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on
conveyors or hangers that are properly grounded.
The resistance between the part and earth ground
must not exceed 1 meg ohm. (Refer to NFPA-33.)
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator
via conductive gloves or gloves with the palm section
cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
Grounded conductive ooring must be provided in
the spray area.
Always turn off the power supply prior to ushing,
cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Avoid installing an applicator into a uid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re 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
coating materials and cause a
re or explosion.
Unless specically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 50176.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of ammable 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.
Electrical Discharge
Electrical
Equipment
Certain materials may be
harmful if inhaled, or if there is
contact with the skin.
Follow the requirements of the 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.
Chemical HazardToxic Substances
Spray applicators require that aluminum inlet ttings
be replaced with stainless steel.
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, ushing, 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 coating supplier. Any other type of solvent may
be used with aluminum equipment.
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.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

INTRODUCTION
NOTE
NOTE
DESCRIPTION
The DynaFlowTM System is capable of communicating
with remote host computers or Allen Bradley PLC's via the
Interface Module. The Interface Module supports three (3)
serial ports. Two of these ports can be used to communi-
cate with remote hosts.
The rst port is reserved for debugging purposes and is
not used for communicating with remote hosts.
The second port is called the Serial I/O, or SIO, port. It
may be used to communicate with a remote host computer
using either RS-232C or RS-422. This port may also be
connected to an Ethernet terminal server to allow com-
munications over 10/100 Base-T connections using either
TCP/IP sockets or as a COM port on a Windows-based
PC using a special device driver.
The third port is called the Remote I/O, or RIO, port. It
may be used to communicate with any PLC that supports
Allen-Bradley's Remote I/O (RIO) protocol.
All three of the communication channels may be in use at
the same time. However, data written to the Interface Mod-
ule from one channel is not passed to the other channels.
Any host computer connected to a channel is responsible
for reading data from the Interface Module in order to stay
current with the data within the Interface Module. The In-
terface Module is the master source of all DynaFlow data.
Host computers must read-modify-write data stored in the
Interface Module.
The ow control parameters and job specic
parameters required for each uid is referred to by
different names depending on operator preferences
and installation requirements. Color Table, Job,
P-Set, and Recipe all mean the same thing. The
term Job will be used in this manual. The term Gun
in this manual refers to any applicator such as a bell,
gun, or disk. A Gun can be single-component or
dual-component.
ALLEN-BRADLEY REMOTE
I/O (RIO)
RIO Operation
The RIO interface contains a proprietary Allen-Bradley
application specic IC (ASIC) that is licensed to Ransburg.
This ASIC formats the information to and from the RIO link.
RIO PROTOCOL
The DynaFlow Interface Module communicates with Al-
len-Bradley PLC's using remote I/O protocol. Two types
of data are supported:
1. Discrete I/O
2. Block Transfers
RIO DISCRETE I/O
There are ve (5) words of discrete inputs and ve (5) words
of discrete outputs possible for each DynaFlow Interface
Module. Each DynaFlow Interface Module supports up to
four (4) Channel Cards and each Channel Card has two
(2) Channels for a total of eight (8) Channels. The PLC
discrete I/O RIO output bits are logical OR'd with the discrete
I/O hard-wired signals so that either hard-wired signals or
PLC control signals may control the system. Likewise, the
DynaFlow hard-wired outputs are sent to the PLC via the
discrete I/O RIO inputs.
The DynaFlow System uses two-slot addressing and
appears to a PLC as a collection of 8-bit modules of I/O.
In other words, each module has 8 inputs and 8 outputs.
The Interface Module appears as a single 8-bit I/O module
in slot 1, or the odd slot of a pair of slots. Therefore, the
Interface Module, which reports the System I/O signals,
uses the high byte of word 0.
Each DynaFlow Channel Card appears as two 8-bit I/O
modules. The rst channel appears in the low byte and
the second channel appears in the high byte of each suc-
cessive word in the RIO discrete I/O space.
The following table describes the RIO signals with their
respective bit locations in the discrete I/O RIO words.
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INTRODUCTION
EN

The following table describes the RIO signals with their
respective bit locations in the discrete I/O RIO words.
RIO Starting Quarter
Interface Module
Channel Card #1
Channel Card #2
Channel Card #3
Channel Card #4
Interface Module
Channel Card #1
Channel Card #2
Channel Card #3
Channel Card #4
Interface Module
Channel Card #1
Channel Card #2
Channel Card #3
Interface Module
Channel Card #1
I/O Group 0 1 2 3
STARTING QUARTER
0
1
2
3
4
5
6
7
The following tables describe the RIO signals with their
respective bit locations in the discrete I/O words.
System I/O - PLC Word 0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
System Pulse
System Fault
System Spare
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
System Halt
Fault Reset
Global Gun Enable
Reserved
Reserved
Reserved
Reserved
Reserved
Bit # Inputs Outputs
PLC WORD O
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INTRODUCTION
EN

CHANNEL I/O - PLC WORDS 1 TO 4
RIO BLOCK TRANSFERS
(BTR & BTW)
All DynaFlow parameters, congurations, and operational
data can be transferred between the DynaFlow Interface
Module and a PLC via the RIO communication link using
Block Transfer Read and Block Transfer Write. Each type
of data uses a unique structure for the block transfer. The
description of the data parameters can be referenced in
the most current DynaFlow User's Manual and the Dy-
naFlow Operator Interface Manual with the exception
of the differences that exist with RIO operation.
NOTE
NOTE
Bit # Inputs Outputs Word 1
PLC WORDS 1 TO 4
Word 2 Word 3 Word 4
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Ready
Active
Fault
Pot Life Alarm
Clean
Load
Calibrate
MVR Enable
Ready
Active
Fault
Pot Life Alarm
Clean
Load
Calibrate
MVR Enable
Ch. 1
Ch. 1
Ch. 1
Ch. 1
Ch. 1
Ch. 1
Ch. 1
Ch. 1
Ch. 2
Ch. 2
Ch. 2
Ch. 2
Ch. 2
Ch. 2
Ch. 2
Ch. 2
Ch. 3
Ch. 3
Ch. 3
Ch. 3
Ch. 3
Ch. 3
Ch. 3
Ch. 3
Ch. 4
Ch. 4
Ch. 4
Ch. 4
Ch. 4
Ch. 4
Ch. 4
Ch. 4
Ch. 5
Ch. 5
Ch. 5
Ch. 5
Ch. 5
Ch. 5
Ch. 5
Ch. 5
Ch. 6
Ch. 6
Ch. 6
Ch. 6
Ch. 6
Ch. 6
Ch. 6
Ch. 6
Trigger
Run
Transparent/Open-Loop
Total Hold
Halt
Total Reset
Clean
Load
Trigger
Run
Transparent/Open-Loop
Total Hold
Halt
Total Reset
Clean
Load
Ch. 7
Ch. 7
Ch. 7
Ch. 7
Ch. 7
Ch. 7
Ch. 7
Ch. 7
Ch. 8
Ch. 8
Ch. 8
Ch. 8
Ch. 8
Ch. 8
Ch. 8
Ch. 8
The BTW and BTR commands issued by the
PLC must be issued for the exact number of
words required.
Type Description BTR
Length
BTW
Length
RIO BLOCK TRANSFER TYPES
00
01
02
03
04
05
06
07
08
Null Data
Operational Data
Gun Conguration Data
Job Table Data
System Conguration Data
Flow Totals
Alarms
Calibration Control & Data
Lookup Table Data
4
58
20
25
15
23
12
11
24
4
20
20
25
13
5
4
8
24
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INTRODUCTION
EN

The System Conguration and Gun Conguration data
must be sent rst to the DynaFlow Interface Module
when the system is powered up, or commissioned for
the rst time. The Job Table data must then be sent
for each Job for each Gun. The conguration and ow
totals data are stored in non-volatile memory in the
DynaFlow Interface Module and therefore do not need
to be sent after a power cycle unless only to "Refresh"
the information to be certain of its content.
All gun, channel, and job numbers are sent as one-based
values. In other words, gun or channel numbers are
sent as 1 to 8 and job numbers are sent as 1 to 100.
Null Data - Type 00
A BTW must always precede a BTR in order to inform
the DynaFlow Interface Module what data is to be
returned in the next BTR. Null BTW commands can
be used when no data must be sent prior to the next
BTR. If the next BTR Type does not require a Gun #
or Channel # and/or Job #, those elds may be zero.
Otherwise, the Next BTR Type, Gun # or Channel #
and Job # specify the appropriate data to be returned
in the next BTR.
Operational Data - Type 01
RIO Operational Data block transfers are used for normal
process control while painting parts. This assumes the
system and applicators have been initially congured.
The gun job numbers and set points may be specied as
zero if no change is desired for a gun. However, if a set
point is specied as non-zero, a valid job number must be
specied.
In PID Mode, the set point is cc/minute.
In Transparent Mode, the Gun Set Point represents a 0 to
100% request that is passed directly to the analog output.
For 2K operation, the lower byte is the % resin and the
upper byte is the % catalyst, where 0 to 255 represents
0% to 100%.
In Open Loop mode (Transparent mode with DIP switch 3
up on the Channel Card), the set point value is used directly
as a cc/minute set point to use for picking an output value
from the Lookup Table.
Word Description Units/Value
NULL DATA - TYPE 00
0
1
2
3
BTW Type
Next BTR Type
Next BTR Gun # or Channel #
Next BTR Job #
00
00, or 01 to 08
0, or 1 to 8
0, or 1 to 100
BTW
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INTRODUCTION
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0 Previous BTW Type 00 to 08 BTW Type 01
1 BTR Type 01 Next BTR Type 00, or 01 to 08
2 Gun #1 Job # 1 to 100 Next BTR Gun # 0, or 1 to 8
3 Gun #2 Job # 1 to 100 Next BTR Job # 0, or 1 to 100
4 Gun #3 Job # 1 to 100 Gun #1 Job # 0, or 1 to 100
5 Gun #4 Job # 1 to 100 Gun #1 Set Point CC/min.for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
6 Gun #5 Job # 1 to 100 Gun #2 Job # 0, or 1 to 100
7 Gun #6 Job # 1 to 100 Gun #2 Set Point CC/min.for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
8 Gun #7 Job # 1 to 100 Gun #3 Job # 0, or 1 to 100
9 Gun #8 Job # 1 to 100 Gun #3 Set Point CC/min.for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
10 Gun #1 Actual Ratio Ratio x 100 Gun #4 Job # 0, or 1 to 100
11 Gun #2 Actual Ratio Ratio x 100 Gun #4 Set Point CC/min.for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
12 Gun #3 Actual Ratio Ratio x 100 Gun #5 Job # 0, or 1 to 100
13 Gun #4 Actual Ratio Ratio x 100 Gun #5 Set Point CC/min.for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
14 Gun #5 Actual Ratio Ratio x 100 Gun #6 Job # 0, or 1 to 100
15 Gun #6 Actual Ratio Ratio x 100 Gun #6 Set Point CC/min for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
16 Gun #7 Actual Ratio Ratio x 100 Gun #7 Job # 0, or 1 to 100
17 Gun #8 Actual Ratio Ratio x 100 Gun #7 Set Point CC/min for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
18 Channel #1 Set Point CC/min Gun #8 Job # 0, or 1 to 100
19 Channel #1 Actual Flow Rate CC/min Gun #8 Set Point CC/min for gun 0 to 255 for Master
DAC in low byte
0 to 255 for slave
in high byte
BTW
Description
Word
Units/Value Description Units/Value
OPERATIONAL DATA - TYPE 01
BTR
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INTRODUCTION
EN

20 Channel #1 Analog Output 0 to 255
21 Channel #1 Current Job Daily Total Liters
22 CC’s
23 Channel #2 Set Point CC/min
24 Channel #2 Actual Flow Rate CC/min
25 Channel #2 Analog Output 0 to 255
26 Channel #2 Current Job Daily Total Liters
27 CC’s
28 Channel #3 Set Point CC/min
29 Channel #3 Actual Flow Rate CC/min
30 Channel #3 Analog Output 0 to 255
31 Channel #3 Current Job Daily Total Liters
32 CC’s
33 Channel #4 Set Point CC/min
34 Channel #4 Actual Flow Rate CC/min
35 Channel #4 Analog Output 0 to 255
36 Channel #4 Current Job Daily Total Liters
37 CC’s
38 Channel #5 Set Point CC/min
39 Channel #5 Actual Flow Rate CC/min
40 Channel #5 Analog Output 0 to 255
41 Channel #5 Current Job Daily Total Liters
42 CC’s
43 Channel #6 Set Point CC/min
44 Channel #6 Actual Flow Rate CC/min
45 Channel #6 Analog Output 0 to 255
46 Channel #6 Current Job Daily Total Liters
47 CC’s
48 Channel #7 Set Point CC/min
49 Channel #7 Actual Flow Rate CC/min
50 Channel #7 Analog Output 0 to 255
51 Channel #7 Current Job Daily Total Liters
52 CC’s
53 Channel #8 Set Point CC/min
54 Channel #8 Actual Flow Rate CC/min
55 Channel #8 Analog Output 0 to 255
56 Channel #8 Current Job Daily Total Liters
57 CC’s
BTW
Description
Word
Units/Value Description Units/Value
OPERATIONAL DATA - TYPE 01 (Cont.)
BTR
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Gun Conguration - Type 02
RIO Gun Conguration Block transfers are typically required
when conguring a gun for the rst time or periodically
adjusting parameters.
0 Previous BTW Type 00 to 08 BTW Type 02
1 BTR Type 02 Next BTR Type 00, or 01 to 08
2 Gun # 1 to 8 Gun # and Next BTR Gun # 1 to 8
3 Mode 0 = Automatic Next BTR Job # 1 to 100
1 = Manual
2 = Undened
4 Number of Channels 1 to 2 Mode 0 = Automatic
1 = Manual
2 = Undened
5 Master Channel # 1 to 8 Number of Channels 1 to 2
6 Slave Channel # 1 to 8 Master Channel # 1 to 8
7 Flow Tolerance Time 0.1 seconds Slave Channel # 1 to 8
8 Clean Channels Bit Field Flow Tolerance Time 0.1 seconds
9 Default Job# 1 to 100 Clean Channels Bit Field
10 Flow Tolerance Percentage 0 to 100 Default Job# Bit Field
11 Mixed Volume CC Flow Tolerance Percentage 0 to 100
12 Tolerance Volume CC Mixed Volume CC
13 Trigger Off Delay 0.1 Seconds Tolerance Volume CC
14 Trigger Off Delay 0.1 Seconds Trigger Off Delay 0.1 seconds
15 Reverse Flow Allowed CC Trigger On Delay 0.1 seconds
16 Master Channel Regulator Type Bit Field Reverse Flow Allowed CC
17 Slave Channel Regulator Type Bit Field Master Channel Regulator Type Bit Field
18 Tolerance Volume Time (Not Used) 0.1 Seconds Slave Channel Regulator Type Bit Field
19 Tolerance Volume Time (Not Used) 0.1 seconds
BTW
Description
Word
Units/Value Description Units/Value
GUN CONFIGURATION - TYPE 02
BTR
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Channel Regulator Types are passed as a bit eld where
each of sixteen (16) possible types has a value of a binary
power of two. Thus only one bit should be set at any time.
Clean Channels are passed as a bit eld with only two bits
presently dened. Both bits may be set.
0 DR1 1:1 1 0x0001
1 DR1 1:2 2 0x0002
2 DR1 1:3 4 0x0004
3 DR1 1:4 8 0x0008
4 DR1 1:5 16 0x0010
5 DR1 1:6 32 0x0020
6 DR1 1:8 64 0x0040
7 DR1 1:10 128 0x0080
8 MVR #2 256 0x0100
9 MVR #3 512 0x0200
10 MVR #4 1,024 0x0400
11 Other 2,048 0x0800
12 Reserved 4,096 0x1000
13 Reserved 8,192 0x2000
14 Reserved 16,384 0x4000
15 Reserved 32,768 0x8000
Regulator
Bit Decimal Value Hex Value
Channel
Bit Decimal Value Hex Value
0 Master 1 0x0001
1 Slave 2 0x0002
2 Reserved 4 0x0004
3 Reserved 8 0x0008
4 Reserved 16 0x0010
5 Reserved 32 0x0020
6 Reserved 64 0x0040
7 Reserved 128 0x0080
8 Reserved 256 0x0100
9 Reserved 512 0x0200
10 Reserved 1,024 0x0400
11 Reserved 2,048 0x0800
12 Reserved 4,096 0x1000
13 Reserved 8,192 0x2000
14 Reserved 16,384 0x4000
15 Reserved 32,768 0x8000
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Job Table - Type 03
RIO Job Table Block Transfers are typically required when
conguring a Gun for the rst time or periodically adjusting
parameters.
NOTE: When a GUN is congured for single-component operation, the Slave data is not used and will be ignored for BTW commands
and returned as zeros for BTR commands.
0 Previous BTW Type 00 to08 BTW Type 03
1 BTR Type 3 Next BTR Type 00, or 01 to 08
2 Gun # 1 to 8 Gun # and Next BTR Gun # 1 to 8
3 Job # 1 to 100 Job # and Next BTR Job # 1 to 100
4 Ratio (Parts Master to 1 Part Slave) Ratio x 100 Ratio (Parts Master to 1 Part Slave) Ratio x 100
5 Flow Set Point CC/min Flow Set Point CC/min
6 Maximum Flow Rate CC/min Maximum Flow Rate CC/min
7 Minimum Flow Rate CC/min Minimum Flow Rate CC/min
8 Pot Life Timer seconds Pot Life Timer seconds
9 Master MVR High 0 to 100 PSIG Master MVR High 0 to 100 PSIG
10 Master MVR Low 0 to 100 PSIG Master MVR Low 0 to 100 PSIG
11 Master Pulse Per Liter PPL % 10,000 Master Pulse Per Liter PPL % 10,000
12 PPL / 10,000 PPL / 10,000
13 Master PID Dead Band CC/min Master PID Dead Band CC/min
14 Master PID Proportional Gain Master PID Proportional Gain
15 Master PID Integral Gain Master PID Integral Gain
16 Master PID Derivative Gain Master PID Derivative Gain
17 Slave MVR High 0 to 100 PSIG Slave MVR High 0 to 100 PSIG
18 Slave MVR Low 0 to 100 PSIG Slave MVR Low 0 to 100 PSIG
19 Slave Pulses Per Liter PPL % 10,000 Slave Pulses Per Liter PPL % 10,000
20 PPL / 10,000 PPL / 10,000
21 Slave PID Dead Band CC/min Slave PID Dead Band CC/min
22 Slave PID Proportional Gain Slave PID Proportional Gain
23 Slave PID Integral Gain Slave PID Integral Gain
24 Slave PID Derivative Gain Slave PID Derivative Gain
BTW
Description
Word
Units/Value Description Units/Value
JOB TABLE - TYPE 03
BTR
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System Conguration - Type 04
BTW
Description
Word
Units/Value Description Units/Value
BTR
SYSTEM CONFIGURATION - TYPE 04
0 Previous BTW Type 00 to08 BTW Type 04
1 BTR Type 4 Next BTR Type 00, or 01 to 08
2 Horn Code 0 to 7 Next BTR Gun # or Channel # 0, or 1 to 8
3 Blow Off Time 0 to 255 seconds Next BTR Job # 0, or 1 to 100
4 Interface SW1 (low) & SW2 (high) Hexadecimal Horn Code 0 to 7
5 Channel Cards 1 (low) & 2 (high) DIP SW1 CC/min Blow Off Time 0 to 255 seconds
6 Channel Cards 3 (low) & 4 (high) DIP SW1 Hexadecimal Reserved 0
7 Interface Version Hexadecimal Reserved 0
8 Password (high word) 0 to 99,900 Reserved 0
9 Channel #6 Actual Flow Rate Reserved 0
10 Password Timer 0 to 255 minutes Password (low word) 0 to 99,900
11 Channel Card 1 Version Hexadecimal Password (high word)
12 Channel Card 2 Version Hexadecimal Password Timer 0 to 255 minutes
13 Channel Card 3 Version Hexadecimal
14 Channel Card 4 Version Hexadecimal
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Flow Totals - Type 05
RIO Flow Totals block transfers are used to read or reset
accumulated ow totals during normal operation.
BTW
Description
Word
Units/Value Description Units/Value
FLOW TOTALS - TYPE 05
BTR
0 Previous BTW Type 00 to 08 BTW Type 05
1 BTR Type 05 Next BTR Type 00, or 01 to 08
2 Channel # 1 to 8 Channel # and Next BTR Channel # 1 to 8
3 Daily Total for Selected Job Liters Job # and Next BTR Job # 1 to 100
4 CC’s Reset Selected Bit Field
5 YTD Total for Selected Job Liters
6 CC’s
7 Calibrate Total for Selected Job Liters
8 CC’s
9 Grand Total for Selected Job Liters
10 CC’s
11 Daily Total for All Jobs Liters
12 CC’s
13 YTD Total for All Jobs Liters
14 CC’s
15 Calibrate Total for All Jobs Liters
16 CC’s
17 Grand Total for All Jobs Liters
18 CC’s
19 Clean Total for All Jobs Liters
20 CC’s
21 Sum of ABS (Error) for Selected Job Liters
22 CC’s
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The Reset Selected bit eld is dened as follows:
Alarm Table - Type 06
RIO Alarms block transfers are used to read the log of the
past ten (10) faults recorded by the DynaFlow Interface
Module. The BTW has no effect on the system and may
be used to schedule the next block transfer.
BTW
Description
Word
Units/Value Description Units/Value
BTR
ALARM TABLE - TYPE 06
0 Previous BTW Type 0 BTW Type 00
1 BTR Type 06 Next BTR Type 06
2 Alarm Word 1 Bit Field Next BTR Gun # 00
3 Alarm Word 2 Bit Field Next BTR Job # 00
4 Alarm Word 3 Bit Field
5 Alarm Word 4 Bit Field
6 Alarm Word 5 Bit Field
7 Alarm Word 6 Bit Field
8 Alarm Word 7 Bit Field
9 Alarm Word 8 Bit Field
10 Alarm Word 9 Bit Field
11 Alarm Word 10 Bit Field
0 Daily Total for Selected Job 1 0x0001
1 YTD Total for Selected Job 2 0x0002
2 Calibrate Total for Selected Job 4 0x0004
3 Grand Total for Selected Job 8 0x0008
4 Daily Total for All Jobs 16 0x0010
5 YTD Total for All Jobs 32 0x0020
6 Calibrate Total for All Jobs 64 0x0040
7 Grand Total for All Jobs 128 0x0080
8 Clean Total for All Jobs 256 0x0100
9 Reserved 512 0x0200
10 Reserved 1,024 0x0400
11 Reserved 2,048 0x0800
12 Reserved 4,096 0x1000
13 Reserved 8,192 0x2000
14 Reserved 16,384 0x4000
15 Reserved 32,768 0x8000
Reset Selected Total
Bit Decimal Value Hex Value
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