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
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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.
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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
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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
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.
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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.
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INTRODUCTION
EN

The pilot light socket, located in the power switch
that is located on the door, is rated for 120 VAC and
must be changed if 240 VAC input power is used.
The appropriate power line lter must be speci-
ed for operation at either 115 or 230 VAC.
INSTALLATION
NOTE
NOTE
CAUTION
!
INPUT POWER
Input supply voltage connections should be made from a
FUSED DISCONNECT. Generally, conduit should be used
for the input power wiring with the appropriate connectors
into the Control Panel.
If there are large AC line voltage uctuations or voltage
transients such as those typically produced by heavy electric
machinery or welding equipment, then a constant voltage
transformer (CVT) or a UPS should be used between the
FUSED DISCONNECT and the Control Panel.
- REFER ALSO TO THE DYNAFLOW USER MANUAL
INTRINSICALLY SAFE
FLOW METERS
(Refer to wiring diagrams, Figures 1a and 1b.)
SYSTEM CONNECTIONS
GUN Control I/O
All GUN specic control wiring to the control rack is termi-
nated at the ribbon cable to discrete converter blocks TB1-
TB4 located on the rear panel of the DynaFlow enclosure
(refer to Figure 1c). For DynaFlow panels congured for use
with the remote electrical-to-pneumatic interface panels,
the GUN control wiring is supplied to circular connectors
located on the top of the panel.
The GUN control I/O is ignored for any Slave (catalyst)
CHANNELs. Therefore, connections need only be made
to CHANNELs congured as Master CHANNELs.
Interface Panels
There are up to eight circular connectors located on top of
the DynaFlow Control Panel depending on the number of
CHANNELs. These are labeled GUN #1-GUN #8.
For two-component GUN's: Since all of the interface wiring
necessary for a two-component GUN is supplied through
a single cable to the LBAL5001 Interface Panel, connec-
tion for a two-component GUN must be made to the odd
numbered GUN connectors (#1, #3, #5, or #7).
For single-component GUN's: Simply connect each GUN
in order, GUN #1 to connector #1, etc.
System and Power I/O
All system control I/O, AC and DC power connections are
made at terminal blocks comprising TB5 (refer to Figure 1c).
If a constant voltage transformer (CVT) is to be
used on the input to the Control Panel, use a CVT
with a Volt-Amp (VA) output rating equal to or greater
than the output voltage multiplied by the control panel
fuse rating. Also make sure that the CVT input ratings
correspond with the voltage and frequency of the
source supplied by the FUSED DISCONNECT. The
CVT output should be rated for 240 VAC maximum.
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INSTALLATION
EN

Figure 1a: Wiring For Intrinsically Safe Flow Meters (77376)
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INSTALLATION
EN

Figure 1b: Wiring For Intrinsically Safe Flow Meters (A12233)
NOTE: For the A12233 version of the DynaFlow, the zener
barriers are housed in the A12812 interface panel.
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INSTALLATION
EN

Figure 1c: System Connections (77376)
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INSTALLATION
EN

Figure 1d: System Connections (A12233)
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INSTALLATION
EN

Figure 1e: Input Power Schematic
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INSTALLATION
EN

OPERATION
GENERAL
The Operator Interface was designed to be user friendly
and to supply all of the necessary information for the op-
eration of the DynaFlow control directly to the operator.
Most information located in the manuals regarding the
operation of the DynaFlow system is available directly
through the Operator Interface. All of the screens offer
‘on-line’ descriptive information and help text that includes
troubleshooting. Graphic information is also displayed for
a quick determination of system performance.
Power ON
When power is rst applied to the DynaFlow system, the
Interface and any installed Channel Cards located in the
card rack immediately perform initialization and place all
GUNs in the ready state assuming valid congurations and
successful self tests. The Interface Module will determine
which Channel Cards are installed and that they are com-
municating properly. The PC, upon application of power,
will load the Windows XP operating system.
Power OFF
All analog and control outputs to the uid system are re-
moved if power is turned off to the card rack. This means
that uid ow will be immediately stopped for all CHANNELs.
An Emergency Stop should be supplied for this purpose.
The stand-alone DynaFlow panel incorporates an E-Stop
front panel switch with an additional unused set of normally
open and normally closed contacts for use by the customer
to interlock other system functions.
The Emergency Stop switch does not remove AC power
from the touch panel PC. The On/Off switch removes AC
power to the 24VDC power supply and the touch panel PC.
KEY FUNCTIONS
ESC
This key is used to exit any active screen or pop-up box.
F1 - F12 Function Keys
F1 through F12 are soft keys. The function of these keys
will change depending on which screen is active. The
description for each key is shown in boxes on the bottom
of the display.
GUN 1 - GUN 8 ON/OFF
These keys allow manual activation and deactivation of
each GUN. Pressing a GUN ON/OFF switch is the same
as supplying an external GUN RUN or GUN HALT input
signal. When using a PC, the corresponding keys on the
keyboard are (all lower case):
GUN 1 a
GUN 2 s
GUN 3 d
GUN 4 f
GUN 5 g
GUN 6 h
GUN 7 j
GUN 8 k
CURSOR (Arrow Keys)
The cursor keys allow the operator to move to a data eld
for editing or to a command eld. In addition to pressing
the ENTER key, edited data will also be accepted when a
cursor key is pressed.
HOME
Pressing this key will return the editing cursor to the rst
data eld in the screen.
LOAD (Backspace)
The LOAD key causes a small pop-up box to appear in the
current screen. Any GUN can be manually placed in LOAD
MODE by simply pressing the number for the desired GUN
on the numeric portion of the keypad. The LOAD MODE
is deactivated by pressing the GUN number again. This is
the same as supplying an external GUN LOAD and GUN
HALT input signals. When using a PC, the corresponding
key on the keyboard is the backspace key.
CLEAN (Space Bar)
The CLEAN key causes a small pop-up box to appear in the
current screen.Any GUN can be manually placed in CLEAN
MODE by simply pressing the number for the desired GUN
on the numeric portion of the keypad. The CLEAN MODE
is deactivated by pressing the GUN number again. This is
the same as supplying an external GUN CLEAN or GUN
HALT input signal. When using a PC, the corresponding
key on the keyboard is the space key.
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OPERATION
EN

HELP (Lower Case L)
The HELP key can be pressed at any time. It will provide
more detailed help for the current active screen. In addi-
tion, there is troubleshooting information also available
through the HELP screens. When using a PC, the corre-
sponding key on the keyboard is lower case L.
ENTER
Edited information in the currently selected data eld is
accepted when the ENTER key is pressed. The next logical
data eld is then selected.
CLEAR FAULTS (Lower Case c)
Pressing this key will immediately clear any faults reported
by the controller regardless of the current screen. If the fault
resulted in the stoppage of uid, then a GUN RUN signal is
required to start ow again. Enter the ERROR LOG screen
to view the error that occurred. Pot Life faults can only be
‘cleared’ by evacuating the volume of uid as determined
by the Mixed Volume parameter located in the GUN CON-
FIGURATION screen through the GUN or cycling power
to the DynaFlow controller. Pressing the Clear Faults key
will silence the horn. When using a PC, the corresponding
key on the keyboard is lower case c.
Exit To Operating System
The '*' key followed by the F9 key, or CTRL with F1, from
the main screen will exit to the operating system. From
the touch screen, simply push F12. The password may
be required.
PASSWORD OPERATION
The password is required for editing any system or GUN
congurations, loading information from les, editing JOB
tables or forcing I/O.Apop-up screen will appear requesting
the password when attempting to perform a password
protected operation. Once a password is entered correctly,
it will not be required again until the password timer has
elapsed. The password and password timer can be set in the
SYSTEM CONFIGURATION screen. The password timer
starts after the last keystroke is sensed. Every additional
keystroke before the password timer elapses resets the
timer. This makes it convenient for an operator to change
multiple parameters without having to continually reenter
the password. In the event that the password is lost or
is not recognized by the controller, contact Ransburg
Technical Support. Entering a ‘0’ for the password will
disable password protection.
SCREENS
Main Screen
The appearance of the main screen will be determined by
the number of CHANNELs installed and the GUN congu-
rations. GUN faults may also be cleared from this screen.
If the GUN conguration is changed, then the main screen
will automatically reect the changes when the operator
returns to the main screen. Each GUN is shown in a box
with the assigned CHANNEL(S). Relevant operational
information is also shown in the GUN box such as GUN
mode, GUN status, requested ow rate, actual ow rate
and ow tolerance (error). The actual ow and tolerance
are also shown in bar graph form.
The ow bar graphs are color coded as follows:
Green = Normal Flow
Red = Reverse Flow
White = Flow During Clean (Solvent)
Cyan = Flow During Load (Material)
Yellow = Flow During Pot-Life Alarm
Blue = Flow in the Ready State
Tolerance Bargraph
The far left bargraph of a dual-component gun on the main
screen has traditionally been used to display ratio tolerance.
With version 4.0.05 and later versions of the user-interface
software, this bargraph has two new options; Mixed Volume
and Pot Life. The bargraph can be congured in the
Cong. Gun Screen under the Display Mode parameter.
The Mixed Volume option gives a graphical representation
of the amount of mixed material in the tubing running from
the spiral mix tube to the applicator. The Pot Life option
gives a graphical representation of the age of the oldest
mixed material (which is the material in the applicator at
any point in time).
Congure System Screen (F1)
Contains system parameters that are not GUN or JOB
specic.
The rmware versions and DIP switch settings of the
Interface Module and Channel Cards are displayed in this
screen.
The date and time may be changed in this screen.
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OPERATION
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Congure GUN Screen (F2)
Contains parameters that effect a GUN regardless of
the JOB. The GUN conguration parameters should not
be changed if the GUN is active. If a CHANNEL is to be
reassigned to a different GUN, then it must rst be removed
from any other GUN.
Load Job # (F3)
Simply allows the operator to select the next JOB for a GUN.
The selected JOB is placed in a ‘queue’ for the selected
GUN. The new JOB will be loaded at the next GUN RUN
signal following a GUN HALT signal. A GUN can be halted
by pressing the GUN ON/OFF key or supplying the GUN
HALT/RESET hardware input. If the GUN is already in
the halted state (ready), then no additional HALT signal
is required. The main screen indicates the current JOB
only which was loaded at the time of the last GUN RUN
command.
Edit JOB Screen (F4)
While in the EDIT JOBS screen, a selected parameter for
the current JOB may be copied to any number of other JOBs
or the entire JOB table can be copied to other selected
GUNs and JOBs. This is accomplished by selecting the
COPY PARAMETER and COPY JOB soft keys. Selecting
either soft key will cause a pop-up screen to appear. The
operator will be prompted to enter the requested range for
GUNs and JOBs.
Digital/Analog I/O Screens (F5)
Allows the operator to view the status of system and GUN
specic inputs and outputs as well as monitoring RIO PLC
signals. The operator can also ‘force’input and output states
for troubleshooting purposes.
Plotting Screen (F6)
Provides a convenient means to graphically monitor
operational data with respect to time, similar to a data
logging or charting device. This feature supplies the operator
with uid ow and related response information in order to
evaluate the system or set up the control parameters for
optimum performance. There are four parameters that can
be selected for plotting. Each parameter is automatically
given a unique color and is displayed with it’s own
corresponding scale and description. All of the possible
plotting parameters are shown in the setup screen for
each congured GUN. The operator can select any of the
parameters for any of the GUNs. Simply use the cursor keys
to move to the desired parameter and press the SELECT
(F1) soft key to select that parameter. Pushing F1 again
will remove the parameter. Each selected parameter will
be displayed in a small box at the lower left of the setup
screen along with the color assigned to that parameter.
Once the desired parameters are selected, then press the
PLOT soft key to start the plotting screen. The operator
can then choose to scroll the plot continuously, freeze,
or stop the plot, or save the screen to a compressed bit
mapped le. The compressed le can then be converted
to a standard .BMP le by using the utility called decomp.
exe located on the DynaFlow software Disk or on drive C:
of the DynaFlow controller. Simply type ‘decomp’ followed
by the name of the saved le.
Job Totals (F7)
The Job Totals screen allows users to monitor material
usage. Values are stored according to the Job number
so if each material being sprayed is assigned its own Job
number, totals will be recorded for each material sprayed.
There are two values stored for each material and each
job and are known as a Daily Total and a Year to Date
total. These totals are not related to the clock or calendar
in any way, they are simply two totals that can be reset
independent of each other. For instance, one may be
used for a batch of parts total and the other may be used
as a shift total, etc. Separate totals are also maintained for
Clean mode (how much material owed while the unit was
in clean mode). Keep in mind that if solvent/air chop cycles
are used this total will not be extremely accurate. There
is also an independent value recorded for volumes used
while in the calibrate mode. Totals can also be reset on this
screen except for the GRAND TOTALS. (This allows for a
secure, non-resettable value for EPA reporting purposes.)
Calibration Screen (F8)
The calibration procedure is a CHANNEL (ow meter)
specic operation and must be performed on only one
CHANNEL at a time. The calibration screen offers a
convenient means to verify or adjust the ow meter pulses
per liter (P/L) setting based on actual measurements. The
procedure can be performed by one person and eliminates
the need to do manual calculations.
Color Change (F9)
An optional color change sequencer may have been included
with the controller. If it was included, the F9 key will indicate
as such. If the F9 key is blank, your system does not have
this option. The optional color change sequencer is a
PLC-like controller that performs the load, ush, and color
change sequences that were programmed by the user from
the color change setup screens. Load and ush sequences
and times are downloaded to this controller (via Ethernet)
by the user-interface P.C. every time a new Job Number
is toggled into the respective gun. When this function is
selected, the operator is rst prompted for the gun number
they wish to view or edit the sequence for, they are then
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OPERATION
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FILE I/O
Saving/Retrieving Data
System conguration, GUN conguration, JOB tables
data, and ow totals can be saved or retrieved to disk les.
Binary les (*.VAL) store the actual data and are the only
type used to restore data. The binary les may be saved
to the FLASH drive.
System conguration data: SYSPAR.VAL
GUN conguration data: GUNPAR.VAL
JOB tables: PROGDATA.VAL
Totals: TOTALS.VAL
The plotting screen is saved as a standard bitmap le
(MMDDhhmm.BMP). The plot le names are formed from
the month (MM), day (DD), hour (hh), and minute (mm)
when the plot was saved. When saving a plot le, note the
date and time in a log detailing what was plotted.
Data for all GUNs or all JOBs are saved automatically,
regardless of the specic GUN or JOB being viewed or
edited. For example, to save all JOB tables for all GUNs,
simply enter the JOB EDIT screen for any GUN, any JOB,
and press the “Save To File” key. The same is true for
recalling data from previously saved les. To completely
save all conguration and totals data:
• From the CONFIG SYSTEM screen, press the
“Save To File” key.
• From the CONFIG GUN screen (select any GUN),
press the “Save To File” key.
• From the EDIT JOB screen (select any GUN and
any JOB), press the “Save To File” key.
• From the TOTALS screen, press the “Save To File” key.
To recall all previously saved congurations:
• From the CONFIG SYSTEM screen, press the
“Read In File” key.
• From the CONFIG GUN screen (select any GUN),
press the “Read In File” key.
• From the EDIT JOB screen (select any GUN and
any JOB), press the “Read In File” key.
• From the TOTALS screen, press the “Read In File” key.
NOTE
The following is important to note when changing
or entering data in the System Conguration, GUN
Conguration, or Edit JOB screens. Any modications to
data made in these screens will NOT take effect until the
"Store Data F5" key is pressed, which causes the new
data to be sent to the DynaFlow Interface Module and
automatically saved to the FLASH drive. If the "ESC" key
is pressed rst, any changes will be lost when exiting the
screen. Each screen reads the data from the Interface
Module upon entry to ensure that changes made by a
PLC will be recognized by the DynaFlow program.
prompted for which Job Number they wish to view and/or
edit the sequences of, and last, they are asked if they want
to view/edit the sequence for ushing or lling. (There is
a separate ush sequence and load sequence stored for
every Job Number and for every gun.)
Error Log Screen (F11)
This screen displays the previous 10 system errors or
GUN faults that have occurred. For each of the errors,
the error code and descriptive text will indicate the GUN
and specic type of error. Errors can be cleared from the
screen by pressing the F7 key. The actual fault condition
can only be cleared by pressing the CLEAR FAULTS key
or supplying a GUN HALT hardware input.
Load GUN
To manually place a GUN in LOAD MODE from the PC in-
terface, push the LOAD key. A small pop-up box will appear
in the upper left corner of the current screen. Simply push
the number of the GUN to immediately start loading uid
for the selected GUN. The number selected will appear in
the pop-up box. To stop loading a GUN, press the GUN
number again. Push the ESC key to exit the LOAD MODE.
Clean GUN
To manually place a GUN in CLEAN MODE from the PC
interface, push the CLEAN key. A small pop-up box will
appear in the upper left corner of the current screen. Simply
push the number of the GUN to immediately start cleaning
for the selected GUN. Each CHANNEL assigned to a GUN
can be selected as a ‘clean’ CHANNEL in the CONFIGURE
SYSTEM screen. To stop cleaning, press the GUN number
again. Push the ESC key to exit the CLEAN MODE. (Guns
in clean mode when this screen is exited will remain in clean
mode until the GUN ON/OFF button is pushed.)
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OPERATION
EN