Ransburg 75584 User manual

SERVICE MANUAL

LN-9214-00.2LN-9214-00.2

LN-9214-00.2

DIGITDIGIT

DIGITALAL

ALAL

AL NODE ADAPTERNODE ADAPTER

NODE ADAPTERNODE ADAPTER

NODE ADAPTER

MODEL:MODEL:

MODEL: 7558475584

7558475584

75584

IMPORIMPOR

IMPORTT

TT

TANTANT

ANTANT

ANT: Before using this equipment,: Before using this equipment,

: Before using this equipment,: Before using this equipment,

: Before using this equipment,

carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,

starting on page 1, and all instructions instarting on page 1, and all instructions in

starting on page 1, and all instructions in

this manual. Keep this Service Manual forthis manual. Keep this Service Manual for

this manual. Keep this Service Manual for

future reference.future reference.

future reference.

NOTE:NOTE:

NOTE: This manual has been changed from revision LN-9214-00.1LN-9214-00.1

LN-9214-00.1LN-9214-00.1

LN-9214-00.1 to revision LN-9214-00.2LN-9214-00.2

LN-9214-00.2LN-9214-00.2

LN-9214-00.2.

Reasons for this change are noted under “Manual Change Summary” inside the back

cover of this manual.

LN-9214-00.2

SAFETY:SAFETY:

SAFETY:

SAFETYPRECAUTIONS.........................................................................................................

HAZARDS/SAFEGUARDS.......................................................................................................

PAGEPAGE

PAGE

INTRODUCTION:INTRODUCTION:

INTRODUCTION:

CONTENTSCONTENTS

CONTENTS

GENERALDESCRIPTION.......................................................................................................

ENVIRONMENTAL/PHYSICAL SPECIFICATIONS................................................................

CONNECTION SPECIFICATIONS..........................................................................................

ELECTRICALSPECIFICATIONS.............................................................................................

INSTALLATION:INSTALLATION:

INSTALLATION:

CONNECTIONS AND CONFIGURATIONS............................................................................

E1,E2JUMPERS......................................................................................................................

SWITCHSETTINGS..................................................................................................................

OPERATION:OPERATION:

OPERATION:

MODESOFOPERATION.........................................................................................................

DIGITALMAX.MODE...............................................................................................................

DIGITALMIN.MODE.................................................................................................................

ATOMIZERMAX.MODEBTR..................................................................................................

ATOMIZERMAX.MODEBTW.................................................................................................

ATOMIZERMIN.MODEBTW...................................................................................................

ATOMIZERMIN.MODEBTR...................................................................................................

1-31-3

1-3

4-54-5

4-5

6-86-8

6-8

9-149-14

9-14

1

2

4

5

6

7

8

9

10

11

12

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Digital Node Adapter - Contents

MAINTENANCE:MAINTENANCE:

MAINTENANCE: 1515

1515

15

TROUBLESHOOTING GUIDE................................................................................................. 15

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PARTS IDENTIFICATION: 16-1716-17

16-1716-17

16-17

PARTNUMBERS...................................................................................................................... 16

WARRANTY POLICIES:WARRANTY POLICIES:

WARRANTY POLICIES: 1818

1818

18

LIMITEDWARRANTY............................................................................................................... 18

APPENDIX:APPENDIX:

APPENDIX: 19-2219-22

19-2219-22

19-22

PAINT AND SOLVENT SPECIFICATIONS..............................................................................

ITW RANSBURG VISCOSITY CONVERSION CHART..........................................................

VOLUMETRIC CONTENT OF HOSE OR TUBE.....................................................................

19

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LN-9214-00.2

SAFETYSAFETY

SAFETY

Digital Node Adapter - Safety

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

Before operating, maintaining or servicing any

ITW Ransburg electrostatic coating system,

read and understand all of the technical and

safety literature for your ITW Ransburg prod-

ucts. This manual contains information that is

important for you to know and understand. This

information relates to USER SAFETY and PRE-

VENTING EQUIPMENT PROBLEMS. To help

you recognize this information, we use the fol-

lowing symbols. Please pay particular attention

to these sections.

A WARNING! states information to alert youA WARNING! states information to alert you

A WARNING! states information to alert you

to a situation that might cause serious injuryto a situation that might cause serious injury

to a situation that might cause serious injury

if instructions are not followed.if instructions are not followed.

if instructions are not followed.

A CAUTION! states information that tellsA CAUTION! states information that tells

A CAUTION! states information that tells

how to prevent damage to equipment orhow to prevent damage to equipment or

how to prevent damage to equipment or

how to avoid a situation that might causehow to avoid a situation that might cause

how to avoid a situation that might cause

minor injury.minor injury.

minor injury.

A NOTE is information relevant to the proce-A NOTE is information relevant to the proce-

A NOTE is information relevant to the proce-

dure in progress.dure in progress.

dure in progress.

While this manual lists standard specifications

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 draw-

ings and appropriate ITW Ransburg equipment

manuals to reconcile such differences.

Careful study and continued use of this manual

will provide a better understanding of the equip-

ment and process, resulting in more efficient op-

eration, 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 ITW Ransburg rep-

resentative or ITW Ransburg.

> The user MUSTMUST

MUSTMUST

MUST read and be familiar

with the Safety Section in this manual and

the ITW Ransburg safety literature therein

identified.

>ThismanualMUSTMUST

MUSTMUST

MUSTbereadandthorough-

ly understood by ALLALL

ALLALL

ALL personnel who oper-

ate,cleanormaintainthisequipment! Spe-

cial care should be taken to ensure that the

WARNINGSWARNINGS

WARNINGS and safety requirements for

operating and servicing the equipment are

followed. The user should be aware of and

adhere to ALLALL

ALLALL

ALL local building and fire codes

and ordinancesas wellas NFPA 33 SAFE-NFPA33 SAFE-

NFPA33 SAFE-NFPA 33 SAFE-

NFPA33 SAFE-

TY STANDARD, 2000 EDITION,TY STANDARD, 2000 EDITION,

TY STANDARD, 2000 EDITION, prior

toinstalling,operating,and/orservicingthis

equipment.

> Thehazardsshownonthefollowingpage

may occur during the normal use of this

equipment. Please read the hazard chart

beginningonpage 2.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

W A R N I N GW A R N I N G

W A R N I N G

!!

!

11

1

LN-9214-00.2

AREAAREA

AREA

Tellswhere

hazards may occur.

HAZARDHAZARD

HAZARD

Tells what the hazard is. SAFEGUARDSSAFEGUARDS

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

Tells how to avoid the hazard.

Spray AreaSpray Area

Spray Area

Improperoperationormaintenance

may create a hazard.

Personnelmustbeproperlytrained

in the use of this equipment.

Personnelmustbegiventraininginaccordancewith

the requirements of NFPA-33, Chapter 16, 2000

edition.

Instructionsandsafetyprecautionsmustbereadand

understoodprior to using this equipment.

Comply with appropriate local, state, and national

codesgoverningventilation,fireprotection,operation

maintenance,andhousekeeping. OSHAreferences

are Sections 1910.94 and 1910.107. Also refer to

NFPA-33,2000editionandyourinsurancecompany

requirements.

General Use andGeneral Use and

General Use and

MaintenanceMaintenance

Maintenance

FireHazard

Improperorinadequateopera-

tionandmaintenanceprocedures

will cause a fire hazard.

Protectionagainstinadvertentarc-

ing that is capable of causing fire

or explosion is lost if any safety

interlocksare disabled during op-

eration. Frequent power supply

shutdown indicates a problem in

the system requiring correction.

Fireextinguishingequipmentmustbepresentinthe

sprayareaand tested periodically.

Spray areas must be kept clean to prevent the

accumulationofcombustibleresidues.

Smoking must never be allowed in the spray area.

The high voltage supplied to the atomizer must be

turnedoffpriortocleaning,flushingormaintenance.

When using solvents for cleaning:

Thoseusedforequipmentflushingshouldhaveflash

points equal to or higher than those of the coating

material.

Those used for general cleaning must have flash

pointsabove100oF(37.8oC).

Spray booth ventilation must be kept at the rates

requiredbyNFPA33,2000Edition,OSHAandlocal

codes. In addition, ventilation must be maintained

during cleaning operations using flammable or

combustible solvents.

Electrostatic arcing must be prevented.

Test only in areas free of combustible material.

Testingmayrequirehighvoltagetobeon,butonlyas

instructed.

Non-factory replacement parts or unauthorized

equipment modifications may cause fire or injury.

If used, the key switch by-pass is intended for use

only during set-up operations. Production should

never be done with safety interlocks disabled.

Neveruseequipmentintendedforuseinwaterborne

installations to spray solvent based materials.

Digital Node Adapter - Safety

22

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LN-9214-00.2

AREAAREA

AREA

Tellswhere

hazards may occur.

HAZARDHAZARD

HAZARD

Tells what the hazard is. SAFEGUARDSSAFEGUARDS

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

Tells how to avoid the hazard.

ElectricalElectrical

Electrical

EquipmentEquipment

Equipment Highvoltageequipmentisutilized.

Arcing in areas of flammable or

combustiblematerialsmayoccur.

Personnel are exposed to high

voltage during operation and

maintenance.

Protection against inadvertent

arcing that may cause a fire or

explosion is lost if safety circuits

aredisabledduringoperation.

Frequentpowersupplyshut-down

indicatesaproblemin thesystem

whichrequirescorrection.

Anelectricalarccanignitecoating

materials and cause a fire or

explosion.

Thepower supply, optional remote controlcabinet,

and all other electrical equipment must be located

outside Class I or II, Division 1 and 2 hazardous

areas. Refer to NFPA No. 33, 2000 Edition.

TurnthepowersupplyOFFbefore working on the

equipment.

Test only in areas free of flammable 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.

Spray Area /Spray Area /

Spray Area /

High VoltageHigh Voltage

High Voltage

EquipmentEquipment

Equipment

Thisisahighvoltageungrounded

devicethatcanproduceelectrical

arcs capable of igniting coating

materials.

Partsbeingsprayedmustbesupportedonconveyors

orhangersandbegrounded. Theresistancebetween

the part and ground must not exceed 1 megohm.

(ReferenceNFPA Bulletin No. 33, 2000 Edition.)

A safe distance must be maintained between the

partsbeingcoatedandtheatomizerbell. Adistance

ofatleast1inchforeach10kVofpowersupplyoutput

voltage is required at all times.

Parts must be supported so that they will not swing

andreduce the clearance specified above.

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.

Unless specifically approved for use in hazardous

locations, the power supply and other electrical

equipmentmustnotbeused in Class I, Division 1 or

2 locations.

Digital Node Adapter - Safety

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LN-9214-00.2

ConnectionsConnections

Connections

PLC I/O:PLC I/O:

PLC I/O: 3positionpluggable

terminal strip on DAIF at

backplane connector

Module I/O:Module I/O:

Module I/O: 96-pin DIN 41612

connector

Diagnostic:Diagnostic:

Diagnostic: 10-pin flat cable connect-

or on DAIF

Digital Node Adapter - Introduction

INTRODUCTIONINTRODUCTION

INTRODUCTION

Environmental / PhysicalEnvironmental / Physical

Environmental / Physical

Temp. Operating:Temp. Operating:

Temp. Operating: 0oto 55oC

Storage:Storage:

Storage: -40oC to 85oC

Humidity:Humidity:

Humidity: 95% Non-Condensing

Size:Size:

Size: 100 x 160mm

Eurocard module,

35mmwide

SPECIFICASPECIFICA

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

GENERAL DESCRIPTIONGENERAL DESCRIPTION

GENERAL DESCRIPTION

Each Node Adapter Module can be character-

ized by the same basic block diagram. This

has three parts: (1) RIO interface, (2) central

processor, and (3) input/output circuits.

The RIO interface contains some Allen-Bradley

(A-B) components which are licensed to ITW.

These are designed specifically to communicate

with the proprietary protocol of the RIO serial

link. The central component of this block is an

application specific IC (ASIC) which is capable

of formatting the RIO information for use by the

central processor. The actual termination of the

RIO cable is made to an Interface Board at the

rear of the Node Adapter Module location. An

82 Ohm resistor is provided on the Interface

Board to terminate the RIO cable. Where the

RIO cable is daisy-chained to more than one

Node Adapter, only the last connection point in

the daisy-chain should be terminated by moving

the associated switch to the “TERM” position.

The core of the central processor is an 8032 mi-

croprocessor which communicates with the A-B

ASIC. The 8032 provides an RS-422 port from

which diagnostic functions are accomplished

via internal “debugger” software. The main soft-

ware program, which includes the “debugger”

functions, is contained in an Erasable Program-

mable Read-Only Memory (EPROM). The

EPROM’s for each Node Adapter are of course

unique for its application.

TheRIOinterfaceandcentralprocessorhardware

blocks for each Node Adapter are very similar.

The similarity ends at the input/output circuits, as

they are unique for each module. In each, some

data processing circuitry transfers information

betweenthecentralprocessorandthenecessary

input/output devices. Depending on the Node

Adapter Module, these devices may be A/D

convertors, D/A convertors, data bus managers,

multiplexeror demultiplexers.

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LN-9214-00.2

ElectricalElectrical

Electrical

Power Required:Power Required:

Power Required: 24 VDC at 80 mA

SIGNAL LEVELSSIGNAL LEVELS

SIGNAL LEVELS

PLC I/O:PLC I/O:

PLC I/O: - Compatible with Allen-Bradley RIO

- RIO termination resistor is switchable option on DAIF

DIGITAL MODE (Communication with 75119-02 Digital Module)DIGITAL MODE (Communication with 75119-02 Digital Module)

DIGITAL MODE (Communication with 75119-02 Digital Module)

Output:Output:

Output: 5Vsignal level: 8-bit data bus, 12 discrete outputs (10 Strobe, 2

Lockout)

PLC I/O:PLC I/O:

PLC I/O:

(Max. Mode):(Max. Mode):

(Max. Mode): Up to 82 points in output address, 3/4 logical rack

(Min. Mode):(Min. Mode):

(Min. Mode): Up to 41 points in output address, 1/2 logical rack

Application:Application:

Application:

(Max. Mode):(Max. Mode):

(Max. Mode): DGNA communicates to up to five Digital Modules via 74847, mother

board, and up to five additional Digital Modules in second 74847,

mother board, via DACAB. One DAIF (Digital configuration) is

required for each DGNA and one DACAB is used to connect between

DAIF and second mother board. The slot 5 and slot 10 Digital

Modules may be replaced by A10204-01, Discrete Modules, when

74787-00S, mother board, is used.

(Min. Mode):(Min. Mode):

(Min. Mode): DGNA communicates to up to five Digital Modules via 74847, mother

board. One DAIF (Digital configuration) is required for each DGNA.

ATOMIZER MODEATOMIZER MODE

ATOMIZER MODE

Output:Output:

Output: 5Vsignal level: 8-bit data bus, 30 discrete outputs (10 Strobe, 20

Function Select)

0-10 V signal level: 20 analog outputs

PLC I/O:PLC I/O:

PLC I/O:

(Max. Mode):(Max. Mode):

(Max. Mode): Up to 10 BTW (speed command), 30 BTR (status/speed feedback/

pressure feedback), 1/2 logical rack

(Min. Mode):(Min. Mode):

(Min. Mode): Up to 5 BTW (speed command), 15 BTR (status/speed feedback/

pressure feedback), 1/4 logical rack

Application:Application:

Application:

(Max. Mode):(Max. Mode):

(Max. Mode): DGNA communicates to up to five 74944, Atomizer Modules, via

74847, mother board, and up to five additional Atomizer Modules in a

second 74847, mother board, via DACB. One DAIF (Atomizer config-

uration) is required for each DGNA and one DACB is used to connect

between DAIF and second mother board.

(Min. Mode):(Min. Mode):

(Min. Mode): DGNA communicates to up to five 74944, Atomizer Modules, via

74847, mother board. One DAIF (Atomizer configuration) is required

for each DGNA.

DIAGNOSTICDIAGNOSTIC

DIAGNOSTIC RS-422 port, manual input/output capability, may be used as main

communication port

Digital Node Adapter - Introduction

55

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LN-9214-00.2

Digital Node Adapter - Installation

INSTINST

INSTALLAALLA

ALLAALLA

ALLATIONTION

TIONTION

TION

CONNECTIONS ANDCONNECTIONS AND

CONNECTIONS AND

CONFIGURACONFIGURA

CONFIGURATIONSTIONS

TIONSTIONS

TIONS

Input PowerInput Power

Input Power

Required input power is regulated 24 VDC

which is supplied by the mother board of the

rack which contains the Node Adapter. An on

board dc-dc converter makes 5 VDC for the

modules logic level circuits. In the 74847-00

Mother Board, connect the 24 VDC supply to

TB1-4 (+) and TB1-3 (-).

Remote I/ORemote I/O

Remote I/O

The connection of the Allen-Bradley Remote I/O

(RIO)ismadetotheDigital/AnalogInterface(DAIF)

Board. This is plugged into the Node Adapter

connector at the rearrear

rearrear

rear of the mother board. The

RIO cable wires are connected to J1 on the DAIF

as shown in Figure 1. The RIO cable may be

“daisy-chained” from one node to another per

Allen-Bradleyinstallationspecifications. Wherea

termination resistor is specified, usually the last

terminationpointinachain,theresistorR1onthe

DAIF board may be connected by placing switch

SW1tothe“TERM”position. Thisconnectsthe82

Ohm resistor across blue and clear, appropriate

for 230 k baud rate. If the RIO is configured for

another baud rate, place SW1 in the “OPEN”

position, and connect the appropriate resistor

directly across J1 “BLU” and “CLR”.

DAIF Board JumpersDAIF Board Jumpers

DAIF Board Jumpers

The DAIF board is used with the Digital Node

Adapter. It is configured for each application by

positioning jumpers E1 and E2. Figure 2b

shows the correct jumper position for Digital

Node Adapter communication to the FloTronics

Atomizer Fiber Optic Speed Control Module.

Figure 2a shows the correct jumper position for

Digital Node Adapter communication to the

FloTronics Digital Air Control Module.

Connection to Slave Half-RackConnection to Slave Half-Rack

Connection to Slave Half-Rack

The Digital Node Adapter communicates to five

FloTronicsDigitalorAtomizerModulesviaitsown

motherboard. Itcancommunicatetoanadditional

mother board with modules (slave half-rack) by

connectingtheDigital/Analogcable(DACAB)from

J2 on the DAIF board to J1 on the slave half-rack

motherboard.

Node AdapterNode Adapter

Node Adapter

Addressing / ConfigurationAddressing / Configuration

Addressing / Configuration

The Digital Node Adapter must be set for the

appropriate RIO address. The rack address

and starting quarter are set by switch SW2 as

shown in Figure 3. The Operating Mode, Last

State, Baud Rate and Rack Size are set by

positions 1-5 on switch SW1 as shown in Figure

3.

Figure 1: Remote I/O ConnectionsFigure 1: Remote I/O Connections

Figure 1: Remote I/O Connections

RIO WireRIO Wire

RIO Wire

Blue

Bare

Clear

DAIF J1 PositionDAIF J1 Position

DAIF J1 Position

BLU

SHLD

CLR

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Ransburg 75584 User manual

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