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Carlisle Ransburg DynaFlow 77376 Service Manual

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SERVICE MANUAL
EN
Model: 77376 and A12233
IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
LN-9406-00-R4 (08/2018)
DynaFlow
Programmer's Manual
TM
1 / 50
www.carlisleft.com

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Summary of Contents for Carlisle Ransburg DynaFlow 77376

  • Page 1 SERVICE MANUAL DynaFlow Programmer’s Manual Model: 77376 and A12233 IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all instructions in this manual. Keep this Service Manual for future reference. LN-9406-00-R4 (08/2018) 1 / 50 www.carlisleft.com...
  • Page 2 MANUAL CHANGES NOTE: This manual has been changed from revision LN-9406-00.3 to revision LN-9406-00-R4. Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual. LN-9406-00-R4 (08/2018) 2 / 50 www.carlisleft.com...

  • Page 3: Table Of Contents

    CONTENTS CONTENTS SAFETY: Safety Precautions ..............................4 Hazards / Safegaurds ..............................5 INTRODUCTION: 9-43 Description ................................9 Allen Bradley Remote I/O (RIO) ..........................9 RIO Protocol ................................9 RIO Discrete I/O ................................ 9 RIO Starting Quarter ............................10 System I/O - PLC Word O ..........................

  • Page 4: Safety

    SAFETY Return To Contents SAFETY SAFETY PRECAUTIONS Before operating, maintaining or servicing any Ransburg WA R N I N G electrostatic coating system, read and understand all of the technical and safety literature for your Ransburg products. † The user MUST read and be familiar with the This manual contains information that is important for you Safety Section in this manual and the Ransburg to know and understand.
  • Page 5 SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Fire Hazard Spray Area Fire extinguishing equipment must be present in the Improper or inadequate spray area and tested periodically. operation and maintenance procedures will cause a fire Spray areas must be kept clean to prevent the...
  • Page 6 SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Explosion Hazard Spray Area Improper or inadequate Electrostatic arcing must be prevented. Safe sparking operation and maintenance distance must be maintained between the parts being procedures will cause a coated and the applicator.
  • Page 7 SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Spray Area / Electrical Discharge High Voltage There is a high voltage device Parts being sprayed and operators in the spray Equipment that can induce an electrical area must be properly grounded.
  • Page 8 SAFETY Return To Contents AREA SAFEGUARDS HAZARD Tells where hazards Tells how to avoid the hazard. Tells what the hazard is. may occur. Electrical Discharge Electrical Unless specifically approved for use in hazardous Equipment locations, the power supply, control cabinet, and all High voltage equipment is utilized in the process.

  • Page 9: Introduction

    INTRODUCTION Return To Contents INTRODUCTION ALLEN-BRADLEY REMOTE DESCRIPTION I/O (RIO) NOTE The DynaFlow System is capable of communicating RIO Operation with remote host computers or Allen Bradley PLC's via the The RIO interface contains a proprietary Allen-Bradley Interface Module. The Interface Module supports three (3) application specific IC (ASIC) that is licensed to Ransburg.

  • Page 10: Rio Starting Quarter

    INTRODUCTION Return To Contents The following table describes the RIO signals with their respective bit locations in the discrete I/O RIO words. RIO Starting Quarter STARTING QUARTER I/O Group Interface Module Channel Card #1 Interface Module Channel Card #2 Channel Card #1 Channel Card #3 Interface Module Channel Card #4...

  • Page 11: Channel I/O - Plc Words 1 To 4

    INTRODUCTION Return To Contents CHANNEL I/O - PLC WORDS 1 TO 4 PLC WORDS 1 TO 4 Bit # Inputs Outputs Word 1 Word 2 Word 3 Word 4 Ready Trigger Ch. 1 Ch. 3 Ch. 5 Ch. 7 Active Ch.

  • Page 12: Null Data - Type 00

    INTRODUCTION Return To Contents Operational Data - Type 01 The System Configuration and Gun Configuration data must be sent first to the DynaFlow Interface Module RIO Operational Data block transfers are used for normal when the system is powered up, or commissioned for process control while painting parts.
  • Page 13 INTRODUCTION Return To Contents OPERATIONAL DATA - TYPE 01 Word Description Units/Value Description Units/Value Previous BTW Type 00 to 08 BTW Type BTR Type Next BTR Type 00, or 01 to 08 Gun #1 Job # 1 to 100 Next BTR Gun # 0, or 1 to 8 Gun #2 Job # 1 to 100...

  • Page 14: Operational Data - Type 01

    INTRODUCTION Return To Contents OPERATIONAL DATA - TYPE 01 (Cont.) Word Description Units/Value Description Units/Value Channel #1 Analog Output 0 to 255 Channel #1 Current Job Daily Total Liters CC’s Channel #2 Set Point CC/min Channel #2 Actual Flow Rate CC/min Channel #2 Analog Output 0 to 255...

  • Page 15: Gun Configuration - Type 2

    INTRODUCTION Return To Contents Gun Configuration - Type 02 RIO Gun Configuration Block transfers are typically required when configuring a gun for the first time or periodically adjusting parameters. GUN CONFIGURATION - TYPE 02 Word Description Units/Value Description Units/Value Previous BTW Type 00 to 08 BTW Type BTR Type...
  • Page 16 INTRODUCTION Return To Contents Channel Regulator Types are passed as a bit field where each of sixteen (16) possible types has a value of a binary power of two. Thus only one bit should be set at any time. Regulator Decimal Value Hex Value DR1 1:1...

  • Page 17: Job Table - Type 3

    INTRODUCTION Return To Contents Job Table - Type 03 RIO Job Table Block Transfers are typically required when configuring a Gun for the first time or periodically adjusting parameters. JOB TABLE - TYPE 03 Word Description Units/Value Description Units/Value Previous BTW Type 00 to08 BTW Type BTR Type...

  • Page 18: System Configuration - Type 04

    INTRODUCTION Return To Contents System Configuration - Type 04 SYSTEM CONFIGURATION - TYPE 04 Word Description Units/Value Description Units/Value Previous BTW Type 00 to08 BTW Type BTR Type Next BTR Type 00, or 01 to 08 Horn Code 0 to 7 Next BTR Gun # or Channel # 0, or 1 to 8 Blow Off Time...

  • Page 19: Flow Totals - Type 05

    INTRODUCTION Return To Contents Flow Totals - Type 05 RIO Flow Totals block transfers are used to read or reset accumulated flow totals during normal operation. FLOW TOTALS - TYPE 05 Word Description Units/Value Description Units/Value Previous BTW Type 00 to 08 BTW Type BTR Type Next BTR Type...

  • Page 20: Alarms Table - Type

    INTRODUCTION Return To Contents The Reset Selected bit field is defined as follows: Reset Selected Total Decimal Value Hex Value Daily Total for Selected Job 0x0001 YTD Total for Selected Job 0x0002 Calibrate Total for Selected Job 0x0004 Grand Total for Selected Job 0x0008 Daily Total for All Jobs 0x0010...
  • Page 21 INTRODUCTION Return To Contents The Active Alarm bit fields are defined as follows: Alarm Decimal Value Hex Value Alarm Word Gun #1 Pot Life Exceeded 0x0001 Gun #2 Pot Life Exceeded 0x0002 Gun #3 Pot Life Exceeded 0x0004 Gun #4 Pot Life Exceeded 0x0008 Gun #5 Pot Life Exceeded 0x0010...
  • Page 22 INTRODUCTION Return To Contents Alarm Word Alarm Decimal Value Hex Value Channel #1 Out of Tolerance 0x0001 Channel #2 Out of Tolerance 0x0002 Channel #3 Out of Tolerance 0x0004 Channel #4 Out of Tolerance 0x0008 Channel #5 Out of Tolerance 0x0010 Channel #6 Out of Tolerance 0x0020...
  • Page 23 INTRODUCTION Return To Contents Alarm Word Alarm Decimal Value Hex Value Channel #1 No Master Flow 0x0001 Channel #2 No Master Flow 0x0002 Channel #3 No Master Flow 0x0004 Channel #4 No Master Flow 0x0008 Channel #5 No Master Flow 0x0010 Channel #6 No Master Flow 0x0020...
  • Page 24 INTRODUCTION Return To Contents Alarm Word Alarm Decimal Value Hex Value Gun #1 Flow Out of Range 0x0001 Gun #2 Flow Out of Range 0x0002 Gun #3 Flow Out of Range 0x0004 Gun #4 Flow Out of Range 0x0008 Gun #5 Flow Out of Range 0x0010 Gun #6 Flow Out of Range 0x0020...
  • Page 25 INTRODUCTION Return To Contents Alarm Word Alarm Decimal Value Hex Value Reserved 0x0001 Reserved 0x0002 Reserved 0x0004 Reserved 0x0008 Reserved 0x0010 Reserved 0x0020 Reserved 0x0040 Reserved 0x0080 Reserved 0x0100 Reserved 0x0200 Reserved 1,024 0x0400 Reserved 2,048 0x0800 Reserved 4,096 0x1000 Reserved 8,192 0x2000...

  • Page 26: Calibration Table - Type 07

    INTRODUCTION Return To Contents Calibration Table - Type 07 RIO Calibration Table block transfers are used to automatically calibrate the Channels under PLC control. CALIBRATION TABLE - TYPE 07 Word Description Units/Value Description Units/Value Previous BTW Type 00 to 08 BTW Type BTR Type Next BTR Type...

  • Page 27: Calibration Procedures For Rio

    INTRODUCTION Return To Contents CALIBRATION PROCEDURES FOR RIO 9. Calculate the pulses/liter based on the pulses received 1. Make sure the channel to be calibrated is not running divided by the cc of material and by 1000 cc/L. and stop it if is running. 2.

  • Page 28: Lookup Tables - Type 08

    INTRODUCTION Return To Contents Lookup Tables - Type 08 RIO Calibration Table block transfers are used to automatically calibrate the Channels under PLC control. LOOKUP TABLES - TYPE 08 Word Description Units/Value Description Units/Value Previous BTW Type 00 to 08 BTW Type BTR Type Next BTR Type...

  • Page 29: Ransburg Host Sio

    INTRODUCTION Return To Contents RANSBURG HOST SIO SIO Operation sent simply as the hex value 0x00 to 0xFF. Sixteen (16) The Ransburg Host Serial I/O port is capable of bit words are sent as two bytes with the high order byte communicating with a general purpose computer, personal sent first.
  • Page 30 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <00> Re-Send Previous Data Request for Re-Send of data from Host <01> Request for Gun Process data: Response: <01><LL><0G> <01><LL><0G><TR><RR><RR><MA><MA><MP><SA> <SA><SP><AS><AS> Where: 1) <LL>...
  • Page 31 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <03> Request for Gun Process data: Response: <03><LL><OG> <03><LL><NG><MS><MD><CC><DJ><RF><RF><MX><M> <FT><FT><FT><FT><TT><TT><TV><TV><TF><TF><TN> <TN><VT><VT><MH><MH><SH><SH><GI><GI><<GO> <GO><RG><FI><FI><FO><RS> Where: Where: 1) <LL> = message length=<01h>. <LL> = message length = <23h>. 2) <OG>...
  • Page 32 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) RIO Gun Input byte: Bit 0 = Trigger Bit 1 = Run Bit 2 = Transparent Mode Bit 3 = Total Hold Bit 4 = Halt Bit 5 = Total Reset Bit 6 = Clean...
  • Page 33 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) Gun Output & Forced Gun Output bytes: Bit 0 = Ready bit 1 = Active Bit 2 = Fault Bit 3 = Pot Life Fault Bit 4 = Clean Bit 5 = Load Bit 6 = Calibrate...
  • Page 34 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) Bit 1 = Job Select BCD 002 Bit 2 = Job Select BCD 004 Bit 3 = Job Select BCD 008 Bit 4 = Job Select BCD 010 Bit 5 = Job Select BCD 020 Bit 6 = Job Select BCD 040...
  • Page 35 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) Where: Where: 1) <LL> = message length = <01h>. 1) <LL> = message length = <10h> 2) <0G> = Gun #. 2) <0G>...
  • Page 36 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) For Gun and Channel Codes, the gun or channel number appears in the lower nibble. System Codes / Error Description: 0xB000 = System Halted 0xB010 = Remote I/O (RIO) Communication Error 0xB020 = Invalid RIO BTW Code 0xB030 = Invalid RIO BTR code...
  • Page 37 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <09> Request for Engineering Backdoor data: Response: <09><LL><0G><JJ> <09><LL><0G><JJ><AN><PT><AT><KP><K- P><KI><KI><KD> Where: <KD><CP><CP><CI><CI><CD><C- 1) <LL> = message length = <02h>. D><OP><OP><OI><OI><OD> 2) <0G> = Gun #. <OD><UG><UG><UP><UP><DC><DC><DP><D- 3) <JJ>...
  • Page 38 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <0D> Request to Reset Clean Totals for a Channel Response: for All Jobs: <0D><LL><0C> Where: <FF> 1) <LL> = message length = <01h>, 2) <0C>...
  • Page 39 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <12> Request to Copy a Single Job Parameter Response: from Gun/Job to a Range of Gun W/Job X to Gun Y/Job Z: <FF>...
  • Page 40 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <13> Request to Stop Calibration for a Channel: Response: <13><LL><0C> <13><LL><0C><CN><CN><CP><CP><CT><CT> Where: Where: 1) <LL> = message length = <01h>. 1) <LL> = message length = <07h>. 2) <0C>...
  • Page 41 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <16> Request to Force Analog Output: Response: <16><LL><OC><A1><A2> <FF> Where: 1) <LL> = message length = <03h>. Note: The Gun that the Channel is co nfigured to must be 2) <0C>...
  • Page 42 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) <1C> Request Lookup Table data: Response: <1C><LL><0G><JJ> <1C><LL><OG><JJ> <F0><F0><O0><F1><F1><O!><F2><F2><O2><F3><F3> Where <O3><F4><F4><O4><F5><F5><O5><F6><F6><O6> 1) <LL> = message length = <02h>. <F7><F7><O7> <F8><F8><O8><F9><O9> 2) <OG> = Gun #. 3) <JJ>...
  • Page 43 INTRODUCTION Return To Contents Command Response Or Action From User Interface Response Or Action From Interface Module Type (Hex) RIO BTR/BTW Buffer: <1E> Response: <1E><LL><DL><DH> <1E><LL><DL><DH><00h><7Fh> Where: Where: 1) <LL> = message length = <02h>. 1) <LL> = message length = <82h>. 2) <DL>...

  • Page 44: Installation

    INSTALLATION Return To Contents INSTALLATION RIO Hardware Settings The DynaFlow system uses two-slot addressing and appears to a PLC as a collection of 8-bit modules of I/O. The DynaFlow Interface Module (77377-02) has several DIP In other words, each module has 8 inputs and 8 outputs. switch settings that establish the operating characteristics The Interface Module appears as a single 8-bit I/O module of the RIO port.
  • Page 45 INSTALLATION Return To Contents The RIO Rack Address and SIO Multi-Drop Node Address is specified in SW1, positions 1-6 as shown below. (Factory default settings in bold) RIO RACK ADDRESS AND SIO MULTI-DROP NODE ADDRESS RIO Rack Address (Octal) SW1-1 SW1-2 SW1-3 SW1-4...
  • Page 46 INSTALLATION Return To Contents RIO RACK ADDRESS AND SIO MULTI-DROP NODE ADDRESS (Cont.) RIO Rack Address (Octal) SW1-1 SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 LN-9406-00-R4 (08/2018) 46 / 50 www.carlisleft.com...

  • Page 47: Rio Rack Size

    INSTALLATION Return To Contents RIO Rack Size RIO BAUD RATE The RIO Rack Size must also be specified in order for the ASIC to communicate over the RIO link. The RIO Rack Baud Rate SW2-3 SW2-4 Size must be set to allow at least 2, 3, 4, or 5 discrete I/O 57.6 Kbaud words to be assigned to the DynaFlow Interface Module, depending on the number of Channel Cards included in...

  • Page 48: Sio Hardware Settings

    INSTALLATION Return To Contents SIO Hardware Settings Jumper E5 on the Interface Module selects either RS- 232C or RS-422 mode. Jumper E5 controls whether 120 The DynaFlow Interface Module (77377-02) has several ohm terminating resistor is installed for RS-422 or RS-485 DIP switch and jumper settings that establish the operating operation.

  • Page 49: Manual Change Summary

    MANUAL CHANGES Return To Contents MANUAL CHANGE SUMMARY LN-9406-00-R4 - Replaces LN-9406-00.03 with the following changes: Change Description Page(s) Update to new manual format All Pages Replace image and change model number to A12233 Cover Update lines 5 and 7 values and second column head Update lines 5 and 7 values and second column head.
  • Page 50 This product is covered by Carlisle Fluid Technologies materials and workmanship limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid Technologies, will void all warranties. For specific warranty information please contact Carlisle Fluid Technologies.

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Ransburg dynaflow a12233

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