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Carlisle Ransburg DynaFlow 77376 Service Manual Download Page 61

Displayed Text

Fault Cause

Corrective Action

ERROR CODES

 (Cont.)

Code

TROUBLESHOOTING GUIDE

 (Cont.)

(Continued On Next Page)

Non-Existent 
Program - 
GUN #<>

JOB # number entered for the indicated 
GUN does not exist.  JOB # number 
defaulted to 00.

Last digit indicates 

CHANNEL #

.

Verify the following:
1.  The JOB # has been saved in memory for 
the indicated GUN.
2.  The correct JOB # is being re-quested.
3.  For discrete hard-wired JOB # select, 
PROGRAM TOGGLE and JOB # inputs have 
been asserted correctly by the PLC or host 
computer.

A011

A012
A013
A014
A015
A016
A017
A018

A021
A022
A023
A024
A025
A026
A027
A028

B001

B010

GUN Flow Out 
of Range

System Halted

RIO - 
Communications 
Error

The  total  flow  rate  for  GUN  #  has 
exceeded the MAXIMUM FLOW RATE 
JOB parameter or fallen below the 
MINIMUM FLOW RATE JOB parameter.  
For Manual GUNs only.

System Ready/Halt input is 
inactive.

PLC and DynaFlow are not set to the same:
 - baud rate
 - rack address
 - rack size
 - rack starting quarter

RIO cable is not connected to the proper 
terminals at either end.

See "Flow Too Low" and "Flow Too High" faults.

This input is typically used as an interlock to other 
control equipment or it is simply hard-wired to 24 
VDC. Supply 24 VDC to the System Ready/Halt 
input.

Check with the PLC programmer to determine the 
correct values for baud rate, rack address, rack 
size, and rack starting quarter and then set the 
DynaFlow Interface Module DIP SW1 and SW2 to 
the appropriate settings per "Interface Module DIP 
SW2 Settings" and "Mother Board Signal ID (J3, J4, 
J5, J6 Channel Cards" respect-ively in this section.
Check cable connections per Figure 25 

RIO cable is not properly terminated at 
each end.

Check cable connections per Figure 25 of this 
manual.

Check each end of the cable to de-termine if the 
terminating resistor is installed at each end.  The 
DynaFlow system may not be the last rack on the 
RIO cable.  The value of the terminating resistor is 
based on cable length, baud rate, and if Extended 
Node Capability is enabled at the PLC.  If Extended 
Node Capability is enabled, the terminating resis-
tors should always be 82 ohms.  Otherwise, the 
term-inating resistors should be 150 ohms for 57.6 
and 115.2 Kbaud and 82 ohms for 230.4 Kbaud.  
In any case, use 1/2 watt resistors.

Return To Contents

LN-9400-00-R11  (08/2018)

61 / 96

www.carlisleft.com

MAINTENANCE

Summary of Contents for Ransburg DynaFlow 77376

Page 1: ...is 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 LN 9400 00 R11 08 2018 1 96...

Page 2: ...been changed from revision LN 9400 00 9 to revision LN 9400 00 10 Reasonsforthischangearenotedunder ManualChange Summary inside the back cover of this manual LN 9400 00 R11 08 2018 2 96 www carlislef...

Page 3: ...er 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 C...

Page 4: ...priateRansburg equipment manuals to reconcile such differences Careful study and continued use of this manual will provide a betterunderstandingoftheequipmentandprocess resulting in more efficient ope...

Page 5: ...y 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 flammable or combustible solv...

Page 6: ...rtent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which require...

Page 7: ...ring 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...

Page 8: ...tact 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...

Page 9: ...nce 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 com...

Page 10: ...red One or more CHANNELs are configuredforeachGUN Two componentdeliverysystems referred to as 2K systems have two CHANNELs assigned to a single GUN The materials are statically mixed before being deli...

Page 11: ...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 Referenc...

Page 12: ...w 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 Mas...

Page 13: ...Figure 1 Block Diagram Return To Contents LN 9400 00 R11 08 2018 13 96 www carlisleft com INTRODUCTION...

Page 14: ...PLY 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...

Page 15: ...egulator 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 T...

Page 16: ...MUM FLOW RATE JOB parameters 4 Frequency Inputs From flow meters reverse flow capable Source Signal 1 2 Frequency used to determine flow rate pulses per volume or weight Maximum Frequency 435 Hz Minim...

Page 17: ...In general the pilot lines should be kept as short as possible to achieve the best fluid flow response and regulation See Pilot Signal Guidelines chart in this section 3 Themaximumdistancebetweentheo...

Page 18: ...ausing 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 an...

Page 19: ...Figure 2 Block Diagram for a Single Component Gun Return To Contents LN 9400 00 R11 08 2018 19 96 www carlisleft com INSTALLATION...

Page 20: ...Figure 3a Block Diagram for a Two Component Gun CHANNEL 1 CHANNEL 2 Return To Contents LN 9400 00 R11 08 2018 20 96 www carlisleft com INSTALLATION...

Page 21: ...Figure 3b Block Diagram for a Three Component Gun Return To Contents LN 9400 00 R11 08 2018 21 96 www carlisleft com INSTALLATION...

Page 22: ...for incoming AC power supply If using SO type portable cord a strain relief rated for the diameter of cord being used is required for protection against cord abrasion and damage The protective ground...

Page 23: ...l that permits activation of any or all GUNs For the controller to operate this signal must be maintained in the high state 24 VDC When this signal is active the system Ready Halt output will be held...

Page 24: ...viewed in the ERROR LOG data table Halt has no effect on the JOB in the Queue Next JOB to be run Clean requires a pulsed signal of at least 0 25 seconds duration It forces the material regulators cont...

Page 25: ...ut of Tolerance Flow Too Low and Flow Too High faults will also be disabled while in the Analog Hold condition Load requires a pulsed signal of at least 0 25 seconds duration The LOAD input places a m...

Page 26: ...s 10 PSIG This is a 0 10 VDC or 4 20 ma output signal selectable on the Channel Module indicating the actual flow rate for the CHANNEL Scaling of the output signal is accomplished through the use of t...

Page 27: ...Figure 4 Mother Board Terminals Control Rack Wiring Reference page 82 for terminal identification Return To Contents LN 9400 00 R11 08 2018 27 96 www carlisleft com INSTALLATION...

Page 28: ...aterial Regulators and Flow Meters The location and mounting of the material regulators and flow meters is specific to each installation The information presented here is intended as a guideline only...

Page 29: ...GUNs operating simultaneously If you are using two component materials then 4 separate 2 CHANNEL GUNs operating simultaneously can be supported Adjacent CHANNELs 1 2 3 4 5 6 and 7 8 can be linked tog...

Page 30: ...r mined for each channel based on the number of pulses liter for the flow meter for the channel Refer to Addendum C for flow limitations PARAMETER DESCRIPTIONS CONFIG SYSTEM F1 All system parameters a...

Page 31: ...Configuration Parameters should not be edited while the GUN is running This includes all operational modes System Time and Date Displays the current date and time and permits changing the same Languag...

Page 32: ...s of the Master CHANNEL This parameter should never be set so low that less than 10 cc s of the slave channel has flowed If this value is set too low nuisance OUT OF TOLERANCE faults will occur The f...

Page 33: ...ANNEL output returns to the MVR LOW value at the end of the Trigger OFF Delay Trigger ON Delay For automatic GUNs only This parameter allows the user to create a delay between the time when the contro...

Page 34: ...mode and a trigger signal is supplied All fluid flow is accounted for in the JOB totals Master Percentage Refer to Mix Ratio information Slave Percentage Refer to Mix Ratio information Flow Rate Set P...

Page 35: ...ed material has been purged Pot Life checking may be disabled by entering a value of zero seconds Since previous versions of the DynaFlow firmware and software used the value 999 minutes to disable Po...

Page 36: ...Slave This represents a flow rate range divided equally above and below the set point flow rate in which the PID controll is suspended This keeps the control output from contin ually changing and pro...

Page 37: ...be as many as six white boxes with data in them The center two boxes indicate the time of the start and stop cursors start on top stop on the bottom The other four boxes indicate the value of the grap...

Page 38: ...normal flow rate for the CHANNEL The Calibration Time is also set based on the flow rate so that no less than 200 cc of material will be dis pensedduringcalibration Otherwise theerrorincalibration wil...

Page 39: ...n run mode GUN Halted CLEAN mode active LOAD mode active CALIBRATION mode active GUN faulted Transparent mode active Analog Hold mode active Pot Life Time Exceeded JOB Queue Stores the next JOB to be...

Page 40: ...the sequence for they are then 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 flushing or filling Ther...

Page 41: ...change sequences F1 Modify This button brings up a numeric keypad if cursor is on one of the step duration cells If cursor is on one of the valve condition cells that cell is toggled from off to on or...

Page 42: ...DC On the first receipt of a trigger signal the master channel immediately starts its closed loop PID control and updates the infor mation to the transducer at a rate determined by the PID Update Time...

Page 43: ...00 100 300 Minimum Voltage or Current 0 volts or 4 ma 0 volts or 4 ma 10 volts or 20 ma 10 volts or 20 ma Maximum Voltage or Current CC s Volt 10 00 20 00 6 25 12 50 CC s Ma ANALOG CONTROL SETTINGS To...

Page 44: ...is not required for manual GUNS 3 AsignalmustbesuppliedtotheMasterCHANNELLOAD input or a LOAD command issued from the Operator Interface Panel or other host controller 4 Flow will begin immediately To...

Page 45: ...in conjunction with the GUN MASK inputs to determine which GUN S will receive the JOB as input by the program select inputs The JOB SELECT inputs must be present at the time that the JOB SELECT STROB...

Page 46: ...and GUN MASK inputs are held high for a slightly longer duration than the STROBE This ensures that the new JOB SELECT and GUN MASK inputs are correct before strobing the information into the controlle...

Page 47: ...Signals By following the dashed line down you can determine the states of the various sig nals for each example Maintained inputs that are high are active Pulsed signals that go high at that instance...

Page 48: ...t JOB 2 Pressing Run will restart the GUN with the old JOB number 3 Entering a new JOB number and selecting Run will restart the GUN with the new JOB number Reverse Flow Detection Fortwo componentsyst...

Page 49: ...re time shifted so the oldest bucket is eliminated representing the material that has vacated the Mixed Volume tubing at the GUN and a new bucket is added If the GUN is in either Run or Load mode a ti...

Page 50: ...calibrate by weight Required Specific gravity of material Digital scale accurate to 0 10 grams 1 Weigh the empty beaker and record the tare weight for later calculations 2 Enter the calibration mode f...

Page 51: ...actions can occur during initial power up sequences and you should know which controls shut down the controller The following information serves as a guide forinitialsystemtestingandstart up Operatio...

Page 52: ...vel to which the system is shutdown depends on how long the shutdown is to last The following are considerations when shutting down the system 1 Place the system in a safe mode when personnel will not...

Page 53: ...Flow Fluid Flow Controller incorporates a form of a Proportional Integral Derivative PID algorithm with additional functions or modifications which are specific to the efficient control and delivery o...

Page 54: ...iveactionprovidesasuddenshiftinthecontroloutput as a result of a quick change in the actual flow transient or set point If the actual flow drops quickly the derivative term will provide a large change...

Page 55: ...flow minus the dead band value the controller will continue to increase the output until it reaches the maximum allowable fluid regulator Quicktriggeringapplications Forapplicationsrequiring multiple...

Page 56: ...meters are sent to the Channel Module s 6 Trigger the GUN If the flow rate does not oscillate or theoscillationsdecreaseinamplitudeinafewseconds increase Ki by 100 and repeat from step 5 If the flow r...

Page 57: ...he Master CHANNEL based on the following formula 8 0 MVR LOW 25 500 Kp 10 Max Gun Set Point Ratio Ratio 1 For example Max Gun Set Point 400 cc min MVR LOW 15 PSIG Ratio 3 1 8 0 15 25 500 Kp 10 400 3 4...

Page 58: ...1 Correct value for Pot Life time 2 Correct value for Mixed Volume If the above values are correct then fluid must be flushed from the GUN immediately 2021 2022 2023 2024 2025 2026 2027 2028 9011 901...

Page 59: ...ANNEL 2 Fluid pressures are properly set and stable 3 The pilot air line to the fluid regulator is not damaged or leaking 4 FluidviscosityiscorrectfortheCHANNEL pressure and pipe size 5 The pressure t...

Page 60: ...e the wrong gain values 3 Fluidpressures Eitherreducethecatalystsupply pressure or increase the resin pressure Try to maintainnormaloperating pilotpressurestothe fluid regulators between 30 60 psi 4 T...

Page 61: ...input is typically used as an interlock to other control equipment or it is simply hard wired to 24 VDC Supply 24 VDC to the System Ready Halt input Check with the PLC programmer to determine the corr...

Page 62: ...an invalid job number in the fourth word offset The PLC has issued a BTW with an invalid message length word count Have the PLC programmer reference the DynaFlowProgrammer manualforthecorrect BTW dat...

Page 63: ...h the fluid regulator or flow meter Additionally the material may be broken down into smaller particles as it passes through the fluid delivery system which can also cause some materials to change the...

Page 64: ...ber optic receiver The LED is an indication that fluid is flowing and pulses are being received from the flow meter If the LED is not ON then replace or swap the fiber optic receiver and try again If...

Page 65: ...ntheappropriatetoleranceband Observe the ratio for both the resin and catalyst channels that are producingfaultswhiletheyareoperatingorimmediatelyafter the controller faults before resetting it If the...

Page 66: ...ion as soon as the GUN is placed in RUN mode the master CHANNEL fluid regulator opens to the MVR HIGH set point usually 100 psi This is typically full open In this way operators can demand as much flu...

Page 67: ...p contamination out Use the following guidelines for cleaning the Operator Interface Usecleaningsolutionspecificallyformulatedforcomputer monitors a mild window cleaner or isopropyl alcohol DO NOT use...

Page 68: ...7378 00 Mother Board Assembly LBAL0021 00 Interface Cable Assembly Interface Panel to Control Panel 40 ft LBAL5001 00 Interface Panel Standard Two Component LBAL5001 01 Interface Panel GUN 1 LBAL5001...

Page 69: ...AG 3 AMP 1 2 2 77384 00 Stop Switch Red Mushroom Head 1 1 1 Included with all stand alone systems A11375 00 Stop Switch Yellow Mushroom Head 1 1 1 Alternate stop switch available special order only fo...

Page 70: ...1 2 grounded sink Selects 0 10 VDC or 4 20 ma operation for the analog set point input 1 2 3 0 10 VDC 1 2 4 20 mA Selects 0 10 VDC or 4 20 ma operation for the spare analog input 1 2 3 0 10 VDC 1 2 4...

Page 71: ...point input 2 2 3 0 10 VDC 1 2 4 20 mA Selects 0 10 VDC or 4 20 ma operation for the spare analog input 2 2 3 0 10 VDC 1 2 4 20 mA Inputs effected Trigger 2 Gun Mask 2 Transparent PID 2 Total Hold 1 I...

Page 72: ...ble is updated while in Run mode but it is not used to determine the flow rate set point when the GUN is triggered ON The Lookup Table is updated while in Run mode and is used to determine the flow ra...

Page 73: ...ce control or grounded sink control for digital inputs 12 15 2 3 24 VDC source 1 2 grounded sink Selects 24 VDC source control or grounded sink control for digital inputs 8 11 2 3 24 VDC source 1 2 gr...

Page 74: ...en Closed Closed Open Closed Open Closed Open Closed Open JMP5 JMP6 JMP7 JMP8 Control Pressure Ch A Actual Flow Ch A Control Pressure Ch B Actual Flow Ch B X X X X 0 10 VDC 4 20 mA 0 10 VDC 4 20 mA 0...

Page 75: ...ween the Interface Module and Channel Cards The Control Area Network CAN address of the Interface is automatically determined by hardware based on the physical slot location in the rack Jumper Descrip...

Page 76: ...F 230 4 KB ON ON 230 4 KB SIO Baud rate position 5 6 Baud Rate OFF OFF 19 2 KB OFF ON 4 8 KB ON OFF 9 6 KB ON ON 38 4 KB RIO Rack Size position 7 8 Size OFF OFF 1 4 Rack OFF ON 1 2 Rack ON OFF 3 4 Rac...

Page 77: ...8A Run Input 1 9A Transparent PID Input 1 10A Total Hold Input 1 11A Digital Input GND 12A Gun Mask Input 1 13A Halt Input 1 14A Total Reset Input 1 15A Clean Input 1 16A Digital Input GND 17A Load I...

Page 78: ...3C Active Output 2 24C Fault Output 2 25C Fluid Line Flushed 26C Clean Load Calibrate Output 2 27C MVR Enable Output 2 28C Digital Output GND 29C Console Tx232 30C Console GND 31C 24 VDC 32C PWR GND 1...

Page 79: ...Bit 1 MSD 6C JOB Select Bit 2 MSD 7C JOB Select Bit 4 MSD 8C JOB Select Bit 8 MSD 9C Spare Digital Input 10C JOB Select Strobe Input 11C System Ready Halt Input 12C Spare Input 13C Spare Input 14C Spa...

Page 80: ...3 Analog Transducer Signal 1 Jn 4 Analog Transducer Signal 2 Jn 5 Trigger Input 1 Jn 6 Trigger Input 2 Jn 7 Run 1 Jn 8 Run 2 Jn 9 Transparent PID Input 1 Jn 10 Transparent PID Input 2 Jn 11 Total Hold...

Page 81: ...A RIO 1 2 rack is 4 I O groups whichmayconsistoftheInterfaceModuleandfrom one 1 to three 3 Channel Modules A RIO 3 4 rack is 6 I O groups which may consist of the Interface Module and from one 1 to fo...

Page 82: ...he A10946 00 part number has been obsoleted The A10946 01 board is the new board without the 4 20 mA IC s and is the board that will be used in all future builds unless the customer specifically reque...

Page 83: ...D X TOTAL RESET CH A CLEAN MODE CH A SINK CLOSED OPEN JMP11 LOAD MODE CH A ANALOG HOLD CH A SOURCE OPEN CLOSED X EXTERNAL FAULT CH A SPARE INPUT CH A SINK CLOSED OPEN JMP12 TRIGGER CH B RUN MODE CH B...

Page 84: ...tem is ready If there is already a color loaded i e one of the color valve outputs is already on when this button is pushed the system will execute a flush sequence followed by a load sequence Purge P...

Page 85: ...bypass these pressure switches Feather Reset This push button is not functional when used in a DynaFlow system SprayTest Thisisasimplepush buttonthatsendsatrigger signal back to the controller and al...

Page 86: ...LE C B SIDE FLOW METER A H W A4 B1 B2 B3 0 NONE 0 0 0 0 0 0 2 2 WEEPLESS MVR 76624 02C 1 1 1 0 0 2 3 3 WEEPLESS MVR 76624 03C 1 1 1 0 0 2 4 4 WEEPLESS MVR 76624 04C 1 1 1 0 0 2 5 2 WEEPING MVR 78137 0...

Page 87: ...Dash Description TABLE F G I K L M N O See Sht P Q R S T 1 LS0067 77663 01 SSP 5020 77663 02 76698 03 76849 06 2 LS0067 77663 01 SSP 5020 77663 02 76698 03 76849 06 3 75774 00 77766 00 LSFI0033 00 Das...

Page 88: ...17 SSP 6427 Elbow 5 32 T X 1 8 NPT M V 18 A8 Tubing 2 19 A Flow Meter 2 20 LSO121 Connector 1 21 B 1 22 77221 00 MVR Assembly Side B 1 23 A4 Screw 2 24 SS 1505 CD L Washer 14 25 SS 6505 CD Washer 10 2...

Page 89: ...r INT Tooth 10 2 43 77223 01 Bracket 1 44 B2 Cable 1 45 B3 Ferrule Nut Nylon 2 46 77103 00 Fitting X 47 48 49 A2 Steel Tube Bent 2 50 A3 Fitting 3 8T X 3 8 AN 2 51 52 77715 00 Label 1 STANDARD COMPONE...

Page 90: ...Fluid Panel Sheet 1 Return To Contents LN 9400 00 R11 08 2018 90 96 www carlisleft com APPENDIX...

Page 91: ...Fluid Panel Sheet 2 Return To Contents LN 9400 00 R11 08 2018 91 96 www carlisleft com APPENDIX...

Page 92: ...Fluid Panel Sheet 3 Return To Contents LN 9400 00 R11 08 2018 92 96 www carlisleft com APPENDIX...

Page 93: ...8 ODT TO 10MM CONVERSION 4 2 41 FTP 1006 NPT TO 4MM CONVERSION 3 3 A12593 04 4MM TO 6MM ODT CONVERSION 3 TABLE H Figures 1a and 1b METRIC PANELS Figure 1a Figure 1b Return To Contents LN 9400 00 R11 0...

Page 94: ...alve Three needle sizes available Size 2 Low Flow 15 350 ml min Size 3 Moderate Flow 250 2600 ml min Size 4 High Flow 1000 3500 ml min Weeping MVR Needles Weepless MVR Needles ADDENDUM E The calibrati...

Page 95: ...nt number 4 17 4 Update the feet measurments in table 18 5 Change triger to trigger in paragraph 5 33 6 Change Most to Middle 45 7 Change the first part number in second table to 77377 12 69 8 Change...

Page 96: ...s a global leader in innovative finishing technologies Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice DeVilbiss Ransburg MS BGK and Binks are re...

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