Carlisle Ransburg DynaFlow 77376 User manual

DYNAFLOW TM
IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting
on page 4, and all instructions in this manual. Keep this Service Manual for future reference.
Models: 77376 and A12233
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision LN-9400-00.9 to revision
LN-9400-00.10. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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MANUAL CHANGES

CONTENTS
SAFETY: 4-8
Safety Precautions ................................................................................................................................................4
Hazards / Safegaurds ............................................................................................................................................5
INTRODUCTION: 9-16
Features ................................................................................................................................................................ 9
Description............................................................................................................................................................. 9
Block Diagram ..................................................................................................................................................... 13
Specications ...................................................................................................................................................... 14
INSTALLATION: 17-28
System Guidelines ..............................................................................................................................................17
Block Diagram For A Single-Component Gun .....................................................................................................19
Block Diagram For A Two-Component Gun.........................................................................................................20
Block Diagram For A Three-Component Gun......................................................................................................21
Input Power..........................................................................................................................................................22
Interfacing To The Flow Controller.......................................................................................................................23
Mother Board Terminals, Hardware Conguration, Transducers.........................................................................27
OPERATION: 29-46
Overview ............................................................................................................................................................. 29
Parameter Descriptions....................................................................................................................................... 30
Automatic Gun Applications................................................................................................................................. 42
Manual Hand Gun Applications ........................................................................................................................... 43
General................................................................................................................................................................ 44
Job Select Timing Diagram.................................................................................................................................. 46
Troubleshooting Guide ........................................................................................................................................ 58
System Preventive Maintenance Instructions...................................................................................................... 67
System Components ........................................................................................................................................... 68
Recommended Spare Parts ................................................................................................................................ 69
Hardware Settings............................................................................................................................................... 70
Control Rack Terminal Identication .................................................................................................................... 77
Serial Communication Protocols ......................................................................................................................... 81
Ratio Conversion................................................................................................................................................. 81
MAINTENANCE: 58-81
APPENDIX: 82-94
Addendum A........................................................................................................................................................ 82
Addendum B........................................................................................................................................................ 84
Addendum C........................................................................................................................................................ 85
Addendum D........................................................................................................................................................ 86
Addendum E........................................................................................................................................................ 94
MANUAL CHANGE SUMMARY: 95
Manual Changes .................................................................................................................................................95
PARTS IDENTIFICATION: 47-57
4 Examples of Signal Sequencing ...................................................................................................................... 47
Procedures .......................................................................................................................................................... 51
PID Control.......................................................................................................................................................... 53
CONTENTS
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CONTENTS

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
understood by ALL personnel who operate, clean
or maintain this equipment! Special care should be
taken to ensure that the WARNINGS and safety
requirements for operating and servicing the
equipment are followed. The user should be aware
of and adhere to ALL local building and re codes
and ordinances as well as NFPA-33 AND EN 50176
SAFETY STANDARDS, 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. Please
read the hazard chart beginning on page 5.
SAFETY
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SAFETY

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

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

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

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

FEATURES
• Congurable operating parameters (JOBs) which can
be saved and recalled on demand.
• Graphic diagnostics for troubleshooting and for achieving
maximum system performance.
• Comprehensive help information easily viewed on the
OPERATOR INTERFACE.
• Congurable manual and/or automatic GUN applications.
• Dynamic analog uid control – the control of ow rate
while running a JOB.
• Reverse uid ow detection provides added protection
for system components.
• Pot-life timer alarms.
DESCRIPTION
The ability to control the delivery of material greatly in-
creases the overall efciency of the spray operating system
and results directly in more uniform and consistent paint
nish quality and reduces the amount of material waste.
The ability of the uid ow controller to respond with quick,
concise, and repeatable control maximizes nish quality
and minimizes material waste.
The DynaFlowTM Flow Controller design utilizes a form
of distributed processing similar to many of the industrial
network architectures available today. The entire task of
uid ow control is broken up into parts. Each portion of
the system is designed for a specic purpose. Since each
element of the system is performing specialized functions,
and all elements are operating at the same time, overall
performance of the system is enhanced. Functionality of
the control system components is as follows:
Channel Module
The Channel Module represents the core of the system.
Each Channel Module is responsible for:
• Monitoring the CHANNEL specic inputs and supplying
the necessary CHANNEL specic outputs for control
and status.
• Receiving and processing the ow meter feedback pulses.
• Determining the analog PID output control signal by
performing high-speed oating-point math.
• Receiving and interpreting commands from the Inter-
face Module through high speed Ransburg CAN Bus
communication.
• Supplying data and status upon request to and from
the Interface Module.
• Local and remote monitoring and control.
• Discrete PLC interface capability for remote control.
• Remote I/O (RIO) communications link for direct
connection to Allen-Bradley PLCs.
• Process and conguration error and fault detection and
reporting.
• USB memory stick, backup of configuration and
operational data.
• Versatile system integration.
• Easy to use.
• Help text and troubleshooting guide available on screens.
NOTE
This feature requires ow meters that provide
reverse ow output.
INTRODUCTION
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INTRODUCTION

Located on the front panel of the Channel Module are
several status indicator lights (LEDs). These are:
1. CPU - Is ON when the microprocessor is
operating normally.
2. ACTIVE - Is ON when communication is taking
place to the Interface Module.
3. FAULT - Is ON when there is a problem with
the module.
Interface Module
The Interface Module performs the following:
• Stores system conguration and data tables.
• Acts as an interpreter for communication with an external
Host computer, PLC and/or the local Operator Interface.
Communicates through a high speed Ransburg CAN
Bus data link to each Channel Module.
• Responsible for system specic inputs and supplying the
necessary system specic outputs for control and status.
Located on the front panel of the Interface Module are
several status indicator lights (LEDs). These are:
1. CPU - Is ON when the microprocessor is
operating normally.
2. ACTIVE - Is ON when RIO communication is
taking place to an Allen-Bradley PLC.
3. FAULT - Is ON when there is a problem with
the module.
Local Operator Interface
Supplied as part of the DynaFlow Stand-Alone Control
Cabinet, Model# 77376 and A12233.
• Permits total control of the system.
• Displays system conguration and data to the operator.
• Computes and displays text and graphic diagnostic
information.
• Organizes, formats, and reports all data and
conguration tables.
The DynaFlow uid ow 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 uid ow 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
congured for each GUN. Two-component delivery systems
(referred to as 2K systems) have two CHANNELs assigned
to a single GUN. The materials are statically mixed before
being delivered to the GUN.
Each CHANNEL operates independently of, and
simultaneously with all the other CHANNELs. This lets the
DynaFlow controller provide accurate dynamic regulation
for each CHANNEL, regard-less of minor system wear or
changes in system variables. With a single-component
coating material, the DynaFlow controller detects changes
from the programmed ow rate and adjusts the output
to correct it. With two-component coatings (where both
the resin and catalyst are regulated and monitored), the
DynaFlow controller detects any change in the total ow
and makes the required adjustments to maintain the
programmed ow and ratio. This holds the ow rates of the
coating components constant. Deviations from the desired
mix ratio are also immediately corrected using this same
closed loop process.
A detailed guide on PID control is supplied in this manual to
assist you should you want to adjust the control parameters.
There are many additional features included in the DynaFlow
Fluid Flow Control which reect on the many years of
experience accumulated by Ransburg.
The control rack and OPERATOR INTERFACE panels are
consistent with and easily integrated with other Ransburg
control products into larger custom system control panels.
This optimizes costs, space and functionality for control of
multiple applicator spray stations. Spray stations may also
incorporate rotary atomizer speed control, shaping air, high
voltage power supplies and more.
The standard stand-alone control cabinet includes control of
up to 8 CHANNELs. It incorporates an integrated 15” color
LCD touch screen, PC based display/interface sub-panel.
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INTRODUCTION

Congurable Operating Parameters
The design of the DynaFlow system allows it to be cong-
ured to meet the specic requirements of each application.
The 8 available CHANNELs can be linked together, using
1 of 8 GUNs, to control the ow and mixing regulation of
two-component materials. The installed channels can be
congured to suit the application. If you are using single-com-
ponent coatings, the DynaFlow controller can support 8
separate single CHANNELGUNs operating simultaneously.
If you are using two-component materials, then 4 separate
2-CHANNEL GUNs operating simultaneously can be sup-
ported. For example, you can use 4 CHANNELs assigned
to 2 GUNs to spray 2 dual component paints on automatic
machines, and 2 CHANNELs assigned to 1 GUN to spray
one dual component paint with a manual hand spray GUN.
In addition to the above, a GUN congured for two-compo-
nent operation can be dynamically changed to operate in
a single-component mode by simply setting the ratio JOB
parameter to 100. This allows a GUN to operate in either
dual or single-component modes by simply changing JOB
numbers.
The controlling parameters for each GUN and the CHAN-
NEL(S) assigned to that GUN, are called JOBs. The JOB
values dene ow characteristics such as Target Flow
Rate, Mix Ratio, Flow Tolerance, etc. JOBs include all of
the parameters that may be dependent on the material
used. This offers the ability to optimize system control
as needed per material and then recall the settings each
time that material is requested. There are up to 100 JOB
#s for each GUN. By saving frequently used JOB #s to
memory you can later recall them by loading the number
representing that JOB #.
All of the JOB #s can be backed-up to, and restored from
a USB memory device. Reference the "Operator Interface
Users Manual" and "Program-mers Manual" for details on
data transfer operation and available formats.
The ow control unit includes one Interface Module and
up to 8 hardware PID control CHANNELs, 2 CHANNELs
located on each of the 4 possible Channel Modules. The
Interface Module will communicate to a host controller. The
host is one of the following:
• PLC using discrete I/O
• Allen-Bradley PLC using RIO
• Local Operator Interface using an RS-232C
communication port
3-K Operation
DynaFlow was designed for either single or two-compo-
nent operation. Three-component operation is possible
by conguring two, two-component, guns. The rst Gun
is set up as follows:
Gun 1 =
Master Channel =
Material = Resin
Flow Controller = Color Change Value (CCV)
Flow Meter = Standard Gear-Type
Slave Channel =
Material = 2nd Component
Flow Controller = MVR, with appropriate size needle
Flow Meter = Piston or Gear, depending on min/max
ow rates (see Notes 4 and 5)
Operating Mode = Manual
The output of the rst Gun is then fed into the Master
Channel input of the second Gun. The second Gun is
setup as follows:
Gun 2 =
Master Channel =
Material = Output of Gun 1 (Resin + 2nd Component)
Flow Controller = Color Change Value (CCV)
(see Notes 1, 2, and 3)
Flow Meter = Gear-Type
Slave Channel =
Material = 3rd Component
Flow Controller = MVR, with appropriate size needle
Flow Meter = Piston or Gear, depending on min/max
ow rates (see Notes 4 and 5)
Operating Mode = Manual or Auto
(see Notes 1, 2, and 3)
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INTRODUCTION

NOTE
Refer to Addendum C for complete information
regarding the ow limitations of the DynaFlow
Channel cards.
NOTES:
1. If the output of Gun 2 supplies one or more hand guns,
then Gun 2 should be operated in Manual mode using a
CCV for the Master Channel ow controller.
2. If the output of Gun 2 supplies a single applicator, then an
MVR should be used for the Master Channel ow controller
and Gun 2 should be operated in Auto mode.
3. If the output of Gun 2 supplies multiple appl-icators other
then hand guns, then Gun 2 should be operated in Manual
mode using a CCV for the Master Channel ow controller.
Additional Guns should be congured for each applicator
as shown below to provide automatic ow control for each
applicator.
Gun 3 through 6 =
Master Channel =
Material = Output of Gun 2
(Resin + 2nd + 3rd Components)
Flow Controller = DR1
Flow Meter = Gear-Type
Operating Mode = Auto
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INTRODUCTION

Figure 1: Block Diagram
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INTRODUCTION

Interface Module Hardware
DYNAFLOW
SPECIFICATIONS
Pneumatic Requirements
Transducers: The air supplied to the transducers must be clean and dry and meet the following
general specications:
Filtration: 20 Micron
Supply Pressure: 90 PSIG min. to 150 PSIG max.
Volume: 0.04 to 0.13 Cv
Operating Temperature: 32oto 150oF (0oto 65.5oC)
Control Rack (Up to 8 Channels Per 1/2 of 19" Rack)
Dimensions: 83mm H X 250mm W X 184mm D standard half rack
Power Requirements: 24 VDC at 1 Amp typical, all 8 CHANNELs installed
The following must be followed if the ow control rack and/or Operator Interface is to be integrated into a larger system
control panel:
- The 24 VDC Power Supply must be located in the same control panel as the uid ow control.
- DO NOT use a central power supply located else where. The power supplies may be sized for and used for other controls
within the same cabinet WITH THE EXCEPTION OF HIGH VOLTAGE POWER SUPPLY CONTROLLERS. High voltage
power supply controllers MUST have a dedicated power supply.
General: This Module is responsible for local display/keyboard control and communication
to the Host controller. Responsible also for non-volatile storage of all JOB data
tables and system conguration parameters.
Dimensions: 3U (130.5 mm) H x 7H (35.2 m) W standard 19” rack module
Digital Inputs: 24 VDC at 2.3 ma typical per input (optically isolated, source by default, sink selectable)
- JOB Select Strobe
- JOB Select 1 (lower signicant BCD digit)
- JOB Select 2
- JOB Select 4
- JOB Select 8
- JOB Select 10 (middle signicant BCD digit)
- JOB Select 20
- JOB Select 40
- JOB Select 80
-
JOB Select 100 (upper signi cant BCD digit)
- System Ready/Halt
- Global Gun Enable
Digital Outputs: 24 VDC sourced at 300 ma maximum per output (Solid state relay contacts)
System Pulse: Used as watchdog timer by an external supervisory PLC or computer.
System Fault: Used to activate an alarm and to supply a signal remotely that a System, GUN, or other
fault has occurred.
(Continued On Next Page)
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INTRODUCTION

Channel Module Hardware Specications
Interface Module Hardware (Cont.)
Communications RS-232C Port: Communication with local Opperator Interface unit.
Allen-Bradley RIO Port: For direct high-speed communication with Allen-Bradley PLC’s.
CAN: Control Area Network (CAN) high speed communication with all channel Modules
and with other racks.
Power Requirement: 24 VDC at 100 ma typical
Operating Temperature: 0oto 55oC
General: Each Channel Module is responsible for processing channel specic discrete I/O and
performing all of the necessary PID closed loop control functions. Data and control
I/O other than discrete is communicated through Ransburg CAN Bus located on the
Motherboard.
Dimensions: 3U (130.5mm) H x 7H (35.2mm) W standard 19" rack module
24 Digital Inputs (2 Channels):
24 VDC at 2.3 ma typical per input (optically isolated, source by default, sink selectable)
Trigger (level): Automatic mode only - For manual mode, uid starts with uid ow on master channel.
Halt (edge): Stops current JOB # (toggles in next job if one is in queue)
Clean (edge): Forces regulator full on for cleaning
Run (edge): Enables next JOB # - used in conjunction with JOB # and Toggle select bits
Gun Mask (level): Used in conjunction with JOB # select bits
Total Reset (edge): Resets all totals
Total Hold (level): Holds present total value regardless of uid ow
Transparent/PID (level): When active directs the external analog input directly to the transducer output
Analog Hold (level): Freezes PID and holds current analog control output
Load (edge): Loads uid with controlled mix ratio for GUNs operating in MANUAL Mode
External Fault/Enable (level): Enable signal input. Must be active for uid to be delivered by GUN regardless of the
operating mode.
Spare: Not used presently
12 Digital Outputs (2 Channels): 24 VDC sourced at 300 ma maximum per output (Solid state relay contacts)
Ready: Everything is ready for operation, congured correctly and I/O logic OK
Active: CHANNEL is active and controlling
Fault: Fault has occurred
Pot Life Timer: Pot life timer expired
Clean/Load/Calibrate: Indicates Clean, Load, or Calibrate mode is active
MVR Enable: Used to control trigger valve for CHANNEL in fast trigger applications with Analog
Hold enabled
(Continued On Next Page)
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INTRODUCTION

Channel Module Hardware Specications (Cont.)
4 Analog Inputs (2 Channels): Jumper selectable 0-10 VDC (default) or 4-20 ma, op-amp buffered, 10-bit A/D.
Set Point Control #1: Used for external analog control. When used, offset and full scale need to be set.
This is accomplished through the MAXIMUM FLOW RATE and MINIMUM FLOW
RATE JOB parameters.
Set Point Control #2: Used for external analog 10-bit A/D control. When used, offset and full scale need
to be set. This is accomplished through the MAXIMUM FLOW RATE and MINIMUM
FLOW RATE JOB parameters.
Spare #1: Not used presently
Spare #2: Not used presently
4 Analog Outputs (2 Channels): Jumper selectable 0-10 VDC (default) or 4-20 ma, op-amp buffered, 12-bit D/A.
Transducer Control #1: Output to proportional E/P 12-bit D/A controller
Transducer Control #2: Output to proportional E/P controller
Flow Rate #1: Flow Rate (scaled between MINIMUM FLOW RATE and MAXIMUM FLOW RATE
JOB parameters)
Flow Rate #2: Flow Rate (scaled between MINIMUM FLOW RATE and MAXIMUM FLOW RATE
JOB parameters)
4 Frequency Inputs: From ow meters (reverse ow capable)
Source Signal #1 & #2: Frequency used to determine ow rate (pulses per volume or weight).
Maximum Frequency = 435 Hz
Minimum Frequency = 1 Hz
(Refer to Addendum C for ow limitations.)
Phase Signal #1 & #2: State used to determine direction of ow rate, forward or reverse.
PID Control: Closed loop control based on the Kp, Ki, Kd and deadband JOB parameters. 30ms
PID update time (default), each channel.
Communications CAN:
Controller Area Network (CAN) High-speed serial communications to Interface Module.
RS-232C Port: Spare auxiliary communication port.
Power Requirements: 24 VDC at 100 ma typical – each Channel Module
Operating Temperature: 0oto 55oC
Control Enclosure (A12233)
Dimensions: 610mm H X 610mm W X 410mm D
Weight: 45.5 Kg (100 lbs)
AC Power: 115/230 VAC, 3A 50/60 HZ 1 Phase
Temperature: 5°C - 40°C
Humidity: 80% to 31°C decreasing to 50% at 40°C non-condensing
Interface Enclosure (A12182)
Dimensions: 610mm H X 610mm W X 410mm D
Weight: 22.7 Kg (50 lbs)
Temperature: 5°C - 40° C
Humidity: 80% to 31° C decreasing to 50% at 40° C non-condensing
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INTRODUCTION

INSTALLATION
SYSTEM GUIDELINES
Prints Specic Per Installation
Often times, installation prints are custom drawn for each
site. You should check those prints for information that
is specic to your installation. Any deviations from those
prints made during or after installation should be recorded
for further reference.
Cable Assemblies
Most electrical interconnections between the DynaFlow
controller and other system components are made through
cable assemblies.
Equipment Locations
With the exception of the following restrictions, the
installation of the Transducers or Transducer Panel, the
Remote Operators Station and Regulator/Flow meter
assemblies are application and site dependant. Specic
instructions for location and mounting of these assemblies
are covered on the site installation drawings.
Equipment Grounding
1. The maximum recommended distance from the Control
Panel to each ow meter is 100-ft. as determined by the
maximum standard available length of the ber-optic
cable assemblies or intrinsic electrical cable assemblies.
2. The maximum recommended length of air pilot tubing
between the electrical-to-pneumatic (E/P) transducer
and the material regulator is largely determined by the
application. In general, the pilot lines should be kept as
short as possible to achieve the best uid ow response
and regulation. See "Pilot Signal Guidelines" chart in
this section.
3. The maximum distance between the optional LBAL5001-
XX Pneumatic Interface Panel to the Control Console
is 40-ft., as determined by the interconnecting electrical
cable assembly.
4. The maximum recommended 1/4-inch OD hose length
from the LBAL5003, Remote Operator Panel, and the
LBAL5001, Pneumatic Interface Panel, is 20-ft., however
this can be longer depending on the application. The
maximum distance between theA12182 interface panel
and the A12233 console is 50-ft.
5. The maximum recommended length for the E/P
transducer electrical control cable is 95 ft. However, in
some cases 175-ft. has been used. Generally, if a GUN
number (not atomizers) controls a complete zone of 6
or more atomizers, do not exceed 95-ft. of cable.
Consult Ransburg if longer distances than those shown
above are desired.
CAUTION
!
NOTE
Any unused conduit holes must be blanked off
to prevent solid objects from entering the interior of
the enclosure.
The control panel should be grounded in
accordance with national and local electrical codes.
The protective ground conductor must be
terminated directly to the protective conductor ground
terminal located inside the Control Enclosure which is
marked with symbol -
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INSTALLATION

CAUTION
!
WARNING
!
WARNING
!
PILOT SIGNAL GUIDELINES
Tubing Size
OD
Fluid Regulator
Type
Typical
Application Feet Meters Feet Meters
Maximum Length
Minimum Length
1/4" MVR Two-component 15 4.6 20 15.3
1/4" DR1 Single-Component 15 4.6 50 30.5
Do not locate the Control Panel near or adjacent
to heat producing equipment such as ovens, high
wattage lamps, steam pipes, etc.
Equipment Mounting
Use the mounting ears supplied to mount the control or
interface enclosure on a wall or building structure. The
anchor system used must be rated to support the specied
weight of the enclosure being mounted (see specications,
page 13). When properly mounted, the anchor system
shall be capable of withstanding 4 times the rated weight
without causing a hazardous condition.
The Control Enclosure must be located in such
a way that access to the On/Off power switch and
Stop switch is not blocked.
The On/Off switch turns off AC power to the PC
and 24 VDC supply.
The Stop switch interrupts only the 24 VDC.
The AC power input FUSED DISCONNECT
must be located in an accessible area near the
Control Enclosure
If improperly located, certain electrical equip-
ment can become a source of ignition and create a
risk of re or explosion.
The Control and Interface Enclosures must
be located outside of the Class 1, Division 1 and
2 hazardous locations which are dened for spray
nishing of ammable and/or combustible materials.
Denitions and requirements for classied areas
are found in the National Electrical Code, NFPA-
70, Article 516 and the National Fire Protection
Association (NFPA-33).
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INSTALLATION

Figure 2: Block Diagram for a Single-Component Gun
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INSTALLATION

Figure 3a: Block Diagram for a Two-Component Gun
CHANNEL 1 CHANNEL 2
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INSTALLATION