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 Operator Interface Manual
LN-9401-00-R6 (08/2018) 1 / 39 www.carlisleft.com
EN
SERVICE MANUAL

NOTE: This manual has been changed from revision LN-9401-00.5 to revision
LN-9401-00-R6. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
LN-9401-00-R6 (08/2018) 2 / 39 www.carlisleft.com
MANUAL CHANGES
EN

CONTENTS
SAFETY: 4-8
Safety Precautions .................................................................................................................................................... 4
Hazards / Safeguards ................................................................................................................................................ 5
INTRODUCTION: 9-10
Description ................................................................................................................................................................ 9
Specications .......................................................................................................................................................... 10
INSTALLATION: 11-16
Input Power ...............................................................................................................................................................11
Intrinsically Safe Flow Meters ...................................................................................................................................11
System Connections ................................................................................................................................................11
Wiring For Intrinsic Flow Meters .............................................................................................................................. 12
System Connections ............................................................................................................................................... 14
Input Power Schematic ............................................................................................................................................ 16
OPERATION: 17-26
General .................................................................................................................................................................... 17
Key Functions .......................................................................................................................................................... 17
Password Operation ................................................................................................................................................ 18
Screens ................................................................................................................................................................... 18
File I/O ..................................................................................................................................................................... 20
Installing/Updating Software .................................................................................................................................... 21
Parameter Locations ............................................................................................................................................... 22
Screen Menu Tree ................................................................................................................................................... 24
MAINTENANCE: 27-28
Troubleshooting ....................................................................................................................................................... 27
Troubleshooting Guide ............................................................................................................................................ 28
PARTS IDENTIFICATION: 29-35
DynaFlow Door ........................................................................................................................................................ 29
DynaFlow Sub-Panel................................................................................................................................................ 30
DynaFlow Parts List ................................................................................................................................................. 31
DynaFlow Spare Parts ............................................................................................................................................. 32
DynaFlow Control Console (A12233 Version).......................................................................................................... 33
DynaFlow Interface Panel (A12177) ........................................................................................................................ 35
APPENDIX: 36-37
Conversions ............................................................................................................................................................ 36
Ratio Conversion Chart ........................................................................................................................................... 37
MANUAL CHANGE SUMMARY: 38
Manual Changes ..................................................................................................................................................... 38
LN-9401-00-R6 (08/2018) 3 / 39 www.carlisleft.com
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
Return To Contents
LN-9401-00-R6 (08/2018) 4 / 39 www.carlisleft.com
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.
Return To Contents
LN-9401-00-R6 (08/2018) 5 / 39 www.carlisleft.com
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
Return To Contents
LN-9401-00-R6 (08/2018) 6 / 39 www.carlisleft.com
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
Return To Contents
LN-9401-00-R6 (08/2018) 7 / 39 www.carlisleft.com
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
Return To Contents
LN-9401-00-R6 (08/2018) 8 / 39 www.carlisleft.com
SAFETY
EN

INTRODUCTION
DESCRIPTION
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. 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 ow 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 Embedded 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 single-component or
two-component uids when used in conjunction with a rack-
mounted Interface Module and Channel Cards. Reference
This manual is intended as a guide for operators of the
DynaFlowTM Fluid Flow Controller Model 77376 or
A12233. This manual is intended as a compliment 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 specically 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 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 uid control and system interfacing is
accomplished through the card rack components. The
Operator Interface simply supplies a convenient means
to view and modify congurations 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 Panel: The touch panel provides a
convenient method of interacting with the user interface.
The touch panel is chemically resistant and easy to clean.
• Embedded PC: Embedded computers are 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.
• USB Ports: USB ports are provided that may be
used to save or load data.
• LCD Display: The LCD display is a 15”, 1024 X 768
pixel TFT active matrix color display with a built-in
backlight.
• Interface Panel A12182: Contains the color change
sequencer controller, E to P transducers, zener barriers,
ber optic receiver, solenoid valves, etc. necessary to
interface with the control components.
Return To Contents
LN-9401-00-R6 (08/2018) 9 / 39 www.carlisleft.com
INTRODUCTION
EN

SPECIFICATIONS
Power Input: 100-240 VAC, 1.6A, 50/60 HZ
LCD Display: 15" (38 cm), 1024 x 768 pixels, colors, Ultra wide viewing angle
CPU: 1.86 GHz Intel Celeron
4GB RAM
150GB HDD
O.S.: Microsoft Windows 7
RS-232 Ports: COM 1 attaches to the card rack 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 p anel
COM 4: Not used
USB Ports: Drives D:, E:, F:, etc.
Ethernet: 10/100 BASE-T
Parallel Port: Standard
Video Port: Standard
DIO Port: Not used
NOTE
The embedded CPU board and interconnecting
cable assemblies are subject to change.
Return To Contents
LN-9401-00-R6 (08/2018) 10 / 39 www.carlisleft.com
INTRODUCTION
EN