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LN-9407-00.1 RCS-2 User Manual (Draft 11-30-09).pmd

1. Job Totals Function Keys There are 11 function keys defined for use from the Job Totals screen F1 Reset Total This button allows the user to reset the currently selected highlighted value F2 Reset Channel This button allows the user to reset the totals forthe currently selected channel F3 Reset Gun This button allows the user to reset the totals for the currently selected gun If it is a two channel gun both channels will be reset 44 RCS 2 User Manual Operation F4 Reset All This button allows the user to reset the totals for all jobs guns and channels F5 Previous Job This button allows the user to examine the totals for the next job F6 Select Job This button allows the user to choose another job to examine reset data for F7 Next Job This button allows the user to examine the totals for the next job F8 Toggle Units This button allows the user to toggle the units that the data is displayed in between liters and gallons F9 Read file This button reads in the totalization data from the internal flash drive the floppy disk drive a USB memory drive or the CDROM and sends them to the interface card to be stored in non volatile memory F10 Save To file This button reads all totalization data currently stored in non volatile memory on the interface card and stores it on the media selected by the user internal flash floppy drive USB memory or CDROM The
2. RCS 2 User Manual Operation MANUAL This setting is used when the user wishes only to control the ratio of the material Users can demand as much material as they wish and the controller will deliver as much as possible while keeping the ratio on target A maximum flow rate can be programmed No of Channels This parameter has 3 possible settings 0 1 or 2 0 This effectively disables the gun 1 This indicates that the gun is to be a single channel flow control only gun 2 This indicates that the gun is to be a dual channel ratio controlled gun Master Channel This parameter has 8 possible settings 1 8 For single channel guns it simply indicates which channel will be controlling the pump for this gun For dual channel guns it indicates normally which channel will be controlling resin pump Slave Channel This parameter has 4 possible settings 2 4 6 or 8 It indicates which channel will be slave to the master channel selected above for ratio control Number of Applicators The range of allowable values for this parameter is any integer from 1 to 4 This parameter indicates how many applicators will be connected to the fluid panel controlled by this gun It is used by the multiple trigger input capabilities of the RCS 2 to multiply the target flow rate by the number of triggers being input For example if the target flow rate is 100 cc min and 1 gun is triggered the RCS 2 will deliver 100 cc
3. This is the maximum allowable speed at which that the pump can be run It is assumed by the con troller that this will be the speed that the pump will run at when a 10 volt DC signal is sent to the motor amplifier The recommended setting for this parameter is 150 RPM 35 Iru Ranshurg Minimum Pump Speed The allowable range of values for this parameter is any integer from 0 RPM to 65 535 RPM This is the minimum speed at which that the system will allow the pump to run If the commanded flow rate or ratio would result in a pump running below this setpoint the pump or pumps assigned to that gun will not run Gear pumps do not typically function accurately at speeds less than 3 RPM andthisis the recommend ed setting for this parameter NOTE gt Ifthe RCS 2 controller determines that either pump must run below this limit to obtain the desired flow rate or ratio the controller will stop both motors and a MotorTach Loss fault may be generated Maximum Inlet Fluid Pressure The allowable range of values for this parameter is any integer from 0 psi to 200 psi This parameter allows the operator to limit the maximum pressure at the inlet to the pump for this channel If too much pressure is allowed at the inlet of the pump fluid may blow by the pump without being metered thus causing inaccurate flow rates or ratios Exceeding this setpoint will cause the controller to generate an Inlet Overpressure Fault This check is o
4. CONTROL RACK INTEGRATION The control rack has been designed to be consistent with other ITW Ransburg products to allow integration of the RCS 2 control rack in larger control consoles These consoles may house rotary atomizer speed control shaping and fan air control high voltage setpoints etc Iru Ranshurg CONFIGURABLE OPERATING PARAMETERS The design ofthe system allows itto be configured to meet the requirements of the application The large number of parameters allows the system to be used in almost any application involving flow and or ratio control of fluids System Parameters are parameters that affect the overall system which includes all channels and guns or the user interface They include e Over Pressure Limit e Foldback Pressure e Pressure Sensor Limit e Horn Enable Disable e Password e Password Timeout e Controller I P Address e Interface Card Name e Software and Firmware Version Information e User Program IP Port e System Time e System Date Gun Parameters are parameters that affect the gun These parameters apply to all channels configured to that gun They include e Mode manual or automatic e Number of channels configured to gun e Master Channel Number e Slave Channel Number e Number of Applicators e Default Job Number e Mixed Volume e Flow Ratio Tolerance e Tolerance Volume e Alarm Tolerance Time e Solvent Flow Meter Calibration Factor e Horn Code e Auto Reset Enable
5. amplifier which provides a 4 20ma control signal Response Time Flow Rate Dependent to the microprocessor on the channel board The operation of the flow monitor systemis as follows Maximum Fluid Pressure 200psi The sensor is heated up a few degrees above the ambient temperature of the fluid If the fluid is Controls 1 Zero Flow Adjust moving the heat generated in the sensor is conducted away from the sensor head and the sensor is cooled Ifthe fluid is at rest or ata no flow condition the temperature of the sensor head rises Thermistors are used inthe sensor to convert the temperature into an electrical signal which is LN 9407 00 1 56 RCS 2 User Manual Appendix Since all catalysts are not the same and have differing abilities to remove heat from this sensor the sensor must be calibrated prior to use Setup and Adjustments Refer to the System Interconnect Diagrams in the Maintenance Troubleshooting manual before proceeding with any of the following setup and adjustment procedures Access the Digital Analog I O screen on the User Interface Screen of the RCS 2 Select the Analog I O option On this screen the current coming fromthe analog output amplifier can be monitored 1 Fill the system to be monitored with the fluid to be monitored NOTE YOU CANNOT USE AIR AS THE FLUID 2 Monitor the output current from analog output amplifier P N 22 1050 on the User Interface Analog I O Screen 3 Let the flu
6. e Input Over Pressure e Output Under Pressure e Output Over Pressure e Flow Rate Out of Tolerance e Hardener Flow Loss e Pressure Pot Empty e Inlet Pressure Loss e Analog Remote Loss e Ratio Out of Tolerance e Motor Amp Fault e Analog Feather Loss e Analog Spare Loss e Foldback Pressure Reached e Pot Life Expired e System Over Pressure e Channel Card Parameter Fault e Channel Card SPI Fault e Channel Card Internal Fault NOTE gt Items marked with an asterisk can not be disabled 10 RCS 2 User Manual Introduction rmy Ransburg BLOCK DIAGRAMS Figure 1 Control Console Block Diagram N E IN A Y IW gt pe W YY YY E YY S L A ey ey 1 Y Y Y Y Y Y L AA A d bbe F TEREE Figure 2 Motor Amplifier Panel Block Diagram 11 LN 9407 00 1 RCS 2 User Manual Introduction rruvRansburg Fluid Panel Schematic Figure 3 12 LN 9407 00 1 RCS 2 User Manual Installation 13 INSTALLATION SYSTEM GUIDELINES Customized Prints Drawings and information contained in this section of the manual is applicable to most installations However in many cases ITW will supply custom installation drawings for your specific site It is highly recommended that if your installation differs significantly from the installation drawings supplied by ITW you notify your ITW representative to ensure that standard i
7. FLAGS RESIN CATALYST TOTAL F11 Color Changer An optional color change sequencer may have been included with the controller If it was includ ed the F11 button will indicate as such on the main screen If the F11 key is blank your system does not have this option When this function is selected the operator is first prompted forthe gun number they wish to view or edit 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 There is a separate flush sequence and fill sequence stored for every Job Number and for every gun LN 9407 00 1 rruvRansburg Once the operator responds to the above prompts a screen similar to the following appears or for for for for for fouzsrewreni fore for for for for formers for for or for for or omnes a err for jor for for for for fuer for for for for for or CTI for for for for for omens This chart displays a simple 6 step sequencer where the user defines how long they wish each step to take and which valves or signals should be energized at each one of those steps There are 6 steps for the flush cycle and 6 steps for the fill cycle When a color change is desired the sequencer automatically runs the flush sequence followed by the load sequence The following solenoid valves can be controlled by the s
8. Pulsed By pulsing the volume fill discrete input the unit will be put into the V FILL mode The gun must be in the ready state priortothis When the gun trigger input goes high the pumps will run at the programmed flow rate and ratio until the volume programmed in for Fill Volume on the Job parameters screen is dispensed If more than one gun trigger inputs goes high triggers 2 3 or 4 the unit will multiply the flow rate by the number of high inputs but still only run until the programmed volume is dispensed Whenthatvolume is reached the gun will be halted and returned to the ready state Volume Fill with Fast Fill Mode Itis possible to volume fill and fast fill simultaneously If the gun is put into volume fill mode and then the fast fill input is pulsed the unit will run in fast fill mode until the volume programmed in for fill volume is dispensed At that time the gun will be halted and returned to the ready state This happens regardless of the condition of the gun trigger inputs Push Out Type of Input Gun Type of signal Pulsed This feature allows a customer that uses dual purge applicators to use two resin pumps that share a common catalyst pump and pushout the resin with solvent on one side of the dual purge applicator while loading the other side of the applicator with the next material to be sprayed For additional details on how to implement this feature refer to Appendix L Iru Ranshurg DISCRE
9. interface PC without exiting to the Windows XP operating system Iru Ranshurg There are eight function buttons defined for use from the System Parameter Screen F1 Modify This button allows the user to step through the possible options forthis parameter or presents a numeric keypad if a numerical value is required F2 Version Info This button allows the user to determine what version of user interface software is installed on the user interface computer and what firmware revision is currently installed on all installed cards in the rack F3 Change Password This button allows userto change the password that limits access to varous user interface screens Ifa password was previously stored user has to know the password to make a change to it Entering a password of 0 disables the password option F5 Send to RCS 2 This button takes the data displayed onthe current screen and sends it to the interface card where it is then stored in non volatile memory Any changes made to the parameters on this screen will be lost if the screen is exited prior to sending it to the interface card using this button F7 Read in all files This function reads in the data fromall parameter files System Gun Channel Job Alarms Totals and Color Change from any media and sends them to the interface card to be stored in non volatile memory This differs from the F9 key in that the F9 key only reads system parameter data and sends i
10. properly a good job number has been loaded and the gun has been placed in run mode This output goes off if a fault occurs Spray Shutdown This output is energized if a fault condition exists and the specific fault that exists is enabled on the Configured Alarms screen turned on This indicates that the flow of fluid from the fluid panel has been stopped as the result of a detected fault condition Flush Request This output is energized when the pot life timer has expired from the mixed material For more information see Mixed Volume and Pot Life Timer in the Operation section Motor On This output is energized by the software when it wants to control the motor It is connected to the input of the motor amplifier that causes the motor to be controlled Do not connect external devices to this terminal Motor Amp Reset This output is energized by the software when itis necessary to reset a faulted motor amplifier Typically by pushing the Clear Faults button on the front panel or by pulsing the Halt Reset digital input this output will be energized momentarily to resetthe amplifier Do not connect external devices to this terminal LN 9407 00 1 RCS 2 User Manual Installation ANALOG INPUTS Analog inputs are jumper selectable to be 0 to 10 VDC or 4 20 mA with the exception of the hardener flow sensor which is fixed at 4 20 mA Hardener Flow Type of Input Channel Type of Signal Fixed at 4 20 mA Fact
11. speeds up to 50 000 rpm At rotating these speeds the edge of the applicatorcan easily cutinto skin Before touching the bell the turbine air must be shut Loose articles of clothing can also off be caught by the rotating bell Ifthe bell has been rotating allow atleasttwo minutes for it to come to a complete stop before touching it LN 9407 00 1 4 RCS 2 User Manual Introduction INTRODUCTION FEATURES e Control of up to 8 gear pumps from one 24 W X 24 H X 17 D control console Guns configurable as single or dual channel guns Configurable as 8 single channel guns 4 dual channel guns or almost any combination of the two e Dual channel guns configurable as automatic flow and ratio control or as manual flow ratio and pressure control modes e Configurable operating parameters for all channels and guns Up to 199 Jobs per gun can be programmed e Full color graphical screens for setup opera tion and diagnostics e Comprehensive help information available from all screens e Pot lre timer monitoring and alarming e Pressure pot volume monitoring and alarm ing e Configurable alarms faulting conditions and alarm tolerance times e With proper pump sizes selected has virtu ally unlimited ratio and flow capabilities Currently available pumps provide flow ranges from 0 9 cc min to 1500 cc min per channel e Discrete I O capabilities allow interfacing to any manufacturer s
12. 2 3 Strobe Gun Inputs source current JMP10 1 2 Job Number Inputs sink current 2 3 Job Number Inputs source current JMP11 Off Disconnect CMOS memory battery On Enable CMOS memory battery Indicates default factory settings 53 LN 9407 00 1 rm Ransburg RCS 2 User Manual Appendix APPENDIX E CHANNEL AND GUN I O TERMINALS Channels _ _ Channels _ 1 3 5 amp 2 4 O amp 8 Notes 1 Do not use more than 2 wires in each terminal or an unreliable connection will exist If more than 2 connections are required use an external terminal block or a butt splice 2 Do not supply 24 volts to the 24 terminals on this board The 24 terminals on this board should only be used to supply voltage to other terminals on this board that are to be pulled high LN 9407 00 1 54 RCS 2 User Manual Appendix Ir Ransburg APPENDIX F SYSTEM I O TERMINALS OLD SYSTEM I O BOARD NEW SYSTEM 1 O BOARD W Ransburg System 1 0 V j 55 LN 9407 00 1 rm Ransburg RCS 2 User Manual Appendix APPENDIX G CATALYST FLOW SENSOR CATALYST FLOW processed by the control amplifier The control amplifier also compensates for changes in fluid SENSOR temperature at a rate of up to 15 C min When there is flow the analog output voltage increases and when there is no flow the analog output voltage decreases The analog output voltage is then fed into the analog output amplifier which outputs a 4 20ma signal tha
13. 43 Chan 3 Mates Tach Loss fians OFF Aug 26 2009 09 03 43 Chan 1 Motor Tach Loss LN 9407 00 1 RCS 2 User Manual Operation Clear Gun Faults This button will flash with a red outline if any guns are faulted By pushing this button any and all guns that are faulted will be reset The gun or guns that were faulted have to be put back in run mode if so desired by pushing the appropriate Gun On Off button in the upper left of the user interface section If the outline of this button is flashing yellow this indicates that the Ethernet communication link between the user interface computer and the interface card has been broken This can be the result of the rack not having power check the E Stop pushbutton a disconnected Ethernet cable a non functioning Ethernet switch etc If the outline of this button is flashing blue this indicates that the user interface computer is running in simulate mode This is normally done if you are running the software on a computer that is not connected to an RCS 2 rack This mode is controlled by an entry in the fms ini file on the hard drive of the user interface computer Adding aline of text with the word simulate puts the software in this mode This is required when running without a rack connected as every time the software enters a new screen it asks for data from the interface card an you will receive a Network Error if itis not in simulate mode This line of text must
14. Amplifier Panel e Fluid Panel e Remote Operators Panel The motor amplifier panels must be placed within 100 feet of the control console the fluid panels must be placed within 10 feet of their respective motor amplifier panel and the remote operator s panel must be placed within 25 feet of its respective motor amplifier panel Iflonger distancesthan this are necessary contact your ITW representative Fluid Regulators Itis highly recommended that a pilot operated fluid regulator similar to the ITW DR 1 regulator be used on the inlet of all of the gear pumps The accuracy of the pumps depends to a high degree on controlling the differential pressure across the pump The system includes pressure transducers in the motor amplifier panels to pilot these fluid regulators In this way the software has full control of fluid inlet pressure of the pumps and Can therefore control the differential pressure across each pump By using this feature the extremely accurate flow rates and ratios can be maintained without the need to calibrate the pumps Intrinsic Safety The motor amplifier panels can be ordered with optional zener barriers that make the fluid panels and the remote operator panels intrinsically safe for operation inside hazardous areas An optional explosion proof catalyst flow sensor and motors are also available They must be hard piped if used in hazardous areas LN 9407 00 1 Ir Ransburg RCS 2 User Manual Installatio
15. Analog Ground Motor Feedback B Reference Drawing Number A10479 Refer to Appendix E for Termination Board Drawing vvv 100 100 10 100 09 09 100 w 00 09 00 W 09 W wow 100 W 00 DD 25 LN 9407 00 1 Ira Ransburg RCS 2 User Manual Installation TABLE 3 SYSTEM I O CONNECTIONS Terminal Input or System System Signals Label Channel Output Wire No Strobe Gun 1 CN4012 1 Input Strobe Gun 2 CN4012 3 Input Strobe Gun 3 CN4012 5 Input Strobe Gun 4 CN4012 7 Input Strobe Gun 5 CN4012 2 Input Strobe Gun 6 CN4012 4 Input Strobe Gun 7 CN4012 6 Input Strobe Gun 8 CN4012 8 Input DD 1D MN MN MN ON System Fault Hi CN4012 13 System Fault Low CN4012 14 System Pulse Hi CN4012 15 System Pulse Low CN4012 16 Output Output Output Output Output Output System User Link Hi CN4012 17 System User Link Low CN4012 18 JNJN Job Number 1 CN4012 25 Job Number 2 CN4012 27 Job Number 4 CN4012 29 Job Number 8 CN4012 31 Job Number 10 CN4012 33 Job Number 20 CN4012 35 Job Number 40 CN4012 26 4143 O O Reference Drawing Number A10479 Refer to Appendix F for Termination Board Drawing Input Input Input Input Input Input Input nanan LN 9407 00 1 26 RCS 2 User Manual Operation OPERATION SETUP AND OPERAT
16. I t Too High Motor current amplitude squared multiplied by time has exceed allowed limits Optional Battery low Optional fault used to indicate SFD battery supply voltage is low LN 9407 00 1 High ambient temperature at motor Insufficient motor heat sinking from motor mounting Operating above the motor s continuous current rating Motor temperature sensor failure or not connected High or low drive ambient temperature Restriction of cooling air due to insufficient space around unit Operating above the drive s continuous current rating Mechanically jammed motor Motion profile acceleration requires peak current for too long of a time duration Machine load on the motor increased by friction Wiring problem between drive and motor yielding improper motion Motor commutation error Drive under sized for application friction or load Mechanically jammed motor Motion profile acceleration requires peak current for too long of a time duration Machine load on the motor increased by friction Motor commutation error Motor under sized for application friction or load Battery low fault enabled and battery is not installed SFD Battery back up voltage is low 64 RCS 2 User Manual Appendix APPENDIX J PART 2 Continued DANAHER AMPLIFIER Status LED Blink Code 65 Bus Over Voltage Self Resetting The BUS voltage has exceeded the upper threshold limit Bus Under Voltage Sel
17. It has no units This allows the operator to control the proportional gain for the feather PID loop Feather Pressure Ki The allowable range of values for this parameter is any integer from 0 to 65 535 It has no units This allows the operator to control the integral gain for the feather PID loop Feather Pressure Kd The allowable range of values for this parameter is any integer from 0 to 65 535 It has no units This allows the operator to control the derivative gain for the feather PID loop Feather Pressure Deadband The allowable range of values for this parameter is any integer from 0 to 65 535 It is expressed in PSI This allows the operator to control the deadband for the feather PID loop 36 RCS 2 User Manual Operation There are 6 function buttons defined for use from the Channel Parameter Screen F1 Modify This button allows the user to step through the possible options forthis parameter or a numeric keypad is presented if a numerical value is required F2 Edit Master This button allows the user to switch to viewing and editing the master channel parameters F3 Edit Slave This button allows the user to switch to viewing and editing the slave channel parameters if it is a 2 channel gun F5 Send to RCS 2 This button takes the data displayed on the current screen and sends it to the interface card where it is then stored in non volatile memory Any changes made to the parameters on this screen
18. PLC e Allen Bradley Remote I O capabilities op tional Iru Ranshurg USB ports allow backup of all operating parameters retrieval of flow response graphs and updating of user interface soft ware Firmware on control cards is stored in flash memory and can be updated using a laptop with a serial port Firmware and software updates can be emailed to site User interface computer can be located any where and a simple Ethernet cable run from interface PC to RCS 2 interface card Retrofit option allows RCS customers to upgrade their electronics and use their existing fluid components All discrete digital and analog inputs and out putscan be monitored and forced for diag nostic purposes All parameter screens can be password pro tected Most analog inputs and outputs configurable for 0 10 VDC or 4 20 mA Data acquisition style trending screens avail able for setup diagnostics and fine tuning of the system LN 9407 00 1 rruvRansburg SPECIFICATIONS Size Stand Alone Cart Mount Version 71 High x 28 Wide x 32 Deep 180 34 cm X 71 12 cm X 81 28 cm Main Control Console 24 High x 24 Wide x 17 Deep 61 cm X 61 cm X 43 18 cm Motor Amplifier Panel 24 High x 24 Wide x 13 Deep 61 cm X 61 cm X 33 cm Fluid Panel 34 High x 21 Wide x 24 Deep 86 36 cm X 53 34 cm X 61 cm Weight 400 Ibs 181 5 Kg Operating Temperature 32 F to 120 F 0 C to 49 C Operating Humidity 0
19. Pressure Loss e Outlet Pressure Loss e Analog Remote Loss e Ratio Out of Tolerance e Motor Amp Fault e Analog Feather Loss e Foldback Pressure Reached e Pot Life Expired e System Over Pressure e Channel Card Parameter Fault e Channel Card SPI Fault e Channel Card Internal Fault NOTE K Items above marked with an asterisk cannot be disabled LN 9407 00 1 rm Ransburg USER INTERFACE SOFTWARE When the RCS 2 is started up users are presented with the main user interface screen An example is shown below A Prime GUN 1 core CHAN 11 CHAN 2 Not 1 s pl H HEHH per HTH z i 7 EI H 88 PERE Hr SSR H floeg Anywhere from O to 8 guns may be displayed whenthe system first starts up depending on how the system was last used The following information is available on the Main Screen e Which channels are configured to which guns e Currently running job number for the gun e The next queued job for the gun e The mode that the gun is configured for e The current status for the gun Running halted faulted etc e Status of the trigger input e Target flow rate for the gun e Actual flow rate for the gun e Actual flow rate of the master channel e Actual flow rate of the slave channel e Requested ratio for the gun if 2 channel gun e Actual ratio for the gun if 2 channel gun e Volume remaining in pressure pot or pots if 2 chan
20. controller calculates the actual ratio based on the actual volume of resin and the actual volume of catalyst that was contained in that sample Itthen compares that ratio to the target ratio and checks to see if the actual ratio is within the tolerance limit of the target ratio If not a Ratio Out of Tolerance Fault is issued by the controller If a O zero is entered for the tolerance volume prarameter ratio is automatically checked every 10 milliseconds This check however is based on flow rate data not volume data 33 Iru Ranshurg Alarm Tolerance Time This parameter is in seconds and can be any value from 0 000 to 20 000 seconds This parameter allows users to program how long an error condition can persist before the unitissues a fault for that gun Users are warned against programming this value too small as nuisance faults may become a problem A value of 3 000 seconds has been found to be a good value for most applications Solvent Pulses Per Liter This parameter can be any integer value for 1 to 100 000 pulses per liter This value is used by totalization software to track the amount of flush solvent used by the gun Horn Code This allows the user to enable or disable the horn on top of the control console for various errors and faults There are 6 possible settings for this parameter a Disabled the horn will not sound for any gun faults or errors b SSD the horn sounds only if a Spray ShutDown fo
21. following variables can be graphed Trigger Requested Ratio 2 channel guns only Actual Ratio 2 channel guns only Total Flow for both channels together Requested Flow for either or both channels Actual Flow for either or both channels Inlet Pressure for the pump on either or both channels Outlet Pressure for the pump on either or both channels Hardener Flow Operator simply highlights the variables they wish graphed and then pushes the F1 key to select them The selected variables will then show up in the box in the lower left of the screen Variables can be removed by simply pushing the F3 button Selecting F2 will cause the graphed data to run continuously After a full screen of data has been graphed the screen is cleared and the graphing restarts on the left end of the screen 43 rruvRansburg Graphing Line 1 GUN 1 CHAN 1 Act Flow 00 39 95 0 Line 1 GUN 1 CHAN 2 Act Flow Line 1 GUN 1 CHAN 1 Trigger OFF 3995 o Line 1 GUN 1 CHAN 1 Act Ratio 60 20 L 45 10 100 30 100 0 OFF oo 0 0 0 so 10 0 15 0 200 25 0 CU 35 0 40 0 Esc ra RETURN START STOP n Each of the 4 variables is graphed in a different color red green blue or black The order in whichthe operatorselectsthe variables determines in which order they appear on the screen F1 Time Base This button allows the user to switch the time base resolution of the graph In fast mode the full screen
22. for Pump Size onthe Configure Channel screen For example if the pump is programmed as a 10 cc rev pump and the desired flow rate is 300 cc s min the software can easily determine that it has to run the pump at 30 RPM Since the motor amplifier has been programmed to spin at 0 RPM with a 0 volt input and at 150 RPM with a 10 volt input the software can then determine it must send exactly 2 000 volts to the motor amplifier to obtain the desired 30 RPM However because of very minor inaccuracies in the pump the analog output of the channel card the analog input of the motor amplifier cable and connector resistances etc the desired 300 cc s min could be off slightly By making very minor adjustments to the Pump Size value on the Configure Channel screen these minor variations can be accounted for and the channel s accuracy improved significantly 74 RCS 2 User Manual Appendix Iru Ranshurg APPENDIX N IMPROVING THE ACCURACY OF 75 THE RCS 2 Continued Calibration ofthe pumps can be performed in the following manner Program the RCS 2 controller to flow at some fixed value in the middle of the range of flows expected That is if the range of flow rates ofthe pump during normal operation is expected to be from 100 cc s min to 500 cc s min set the target flow rate to 300 cc s min Flow material for a significant amount of time we suggest aminimum of 2 minutes into a beakerand measure the volume It is highly r
23. line Electrical connection problems Failure of Hardener Flow sensor 67 LN 9407 00 1 rruvRansburg RCS 2 User Manual Appendix APPENDIX K ERROR CODES Continued Pressure Pot Empty Inlet Pressure Loss Outlet Pressure Loss Analog Remote Loss Ratio Out of Tolerance Motor Amplifier Fault Analog Feather Loss Foldback Pressure Reached LN 9407 00 1 Channel Card Channel Card Channel Card Channel Card Channel Card Channel Card Channel Card Channel Card Channel Card Description The system has determined the pressure pot is empty for the respective channel The electrical current from the Pump Inlet Pressure Sensor is less than 1 milliamp The electrical current from the Pump Outlet Pressure sensor is less than 1 milliamp The electrical current from the Remote Analog Setpoint source is less than 1 milliamp The difference between the desired ratio and the actual ratio expressed as a percentage error exceeds the Flow Rate Ratio Tolerance Percent age value specified in the Gun Configuration The motor amplifier has detected a fault condition The electrical current from the Feather pressure sensor is less than 1 milliamp The electrical current from the Spare Analog Input sensor is less than 1 milliamp The Pump Outlet pressure has exceeded the Foldback Pressure value specified in the System Configuration Explanation and or Possible C
24. number buttons will take any and all guns that were put in Fast Fill Mode via this screen out of Fast Fill Mode as the screen exits Exiting this screen while a gunis Fast Filling that has been initiated elsewhere discretely via RIO or via Ethernet will not be taken out of Fast Fill Mode Help This function allows the operator to get context sensitive help for the current screen being displayed That is the portion of the help text file that refers to the screen currently displayed will automatically be displayed when this button is pushed Users can scroll up and down through the entire help file once itis displayed Pushing the Cancel button exits the help screen Error Log This button allows the operator to view the last 100 errors or faults generated by the system Errors and faults are channel date and time stamped for easy identification as to when they occurred and for which channels Faults can also be reset from within this screen If the error log is displayed users can save the log to a diskette or to the flash drive by pushing the F8 key The data is stored in a file named ErrorLog Txt and is a simple text file viewable with any word processor or text editor Once again users are cautioned against saving data on the flash drive Drive C because of its limited space LINE 1 GUN 1 Chan 1 Job e Next e a C 1 Chan OY Aug 26 2009 09 08 43 Chan 1 Mare Tach Loss v Aug 26 2009 09 08
25. panel Note thatthe sequences are automatically sent to the sequencer every time a new Job Number is loaded F9 Read In File This button allows the operator to load flush and load sequences from a diskette Note that all sequences for all guns and all jobs are overwitten on the flash drive using the data on the diskette 46 RCS 2 User Manual Operation F10 Save To File This button allows the operator to save flush and load sequences to any writeable media All flush and load sequences for all guns are saved in a file named ColorChg par Note that there are nine solenoid valves whose text descriptors are in red Paint Resin Bypass Resin Pump Flush Trigger Solenoid Resin Override Dump Valve Catalyst Select Catalyst Solvent and Catalyst Override These functions may not always be required in all systems and therefore can be renamed and used for other functions Inside of the RCS 2 folder on the hard drive of the user interface computer there is a text file named Solenoid_Valves txt Init the above 9 valves are named Users are free to rename any or all of those valves and use them for other functions during the color change sequences that they program Simply exit the user interface software open the file with any text editor Wordpad etc change the names as required and resave the file The next time the user interface software is opened it will use the new names when the color change sequencer screens are o
26. pressure analog input 4 20 mA JMP14 B 1 2 Pump outlet pressure analog input 0 10 volts 2 3 Pump outlet pressure analog input 4 20 mA JMP15 B 1 2 Motor speed analog output 0 10 volts 2 3 Motor speed analog output 4 20 mA JMP16 B 1 2 Pressure control analog output 0 10 volts 2 3 Pressure control analog output 4 20 mA Indicates default factory settings 78814 01 Channel Cards do not support 4 20 mA outputs LN 9407 00 1 52 RCS 2 User Manual Appendix APPENDIX D rruvRansburg INTERFACE BOARD JUMPER SETTINGS 7 j y l L Jumper Number Position Function JMP1 Off Backplane serial port setting for RS422 On Backplane serial port setting for RS485 JMP2 1 2 Backplane serial port setting for RS232 2 3 Backplane serial port setting for RS422 or RS485 JMP3 1 2 Backplane serial port setting for RS232 2 3 Backplane serial port setting for RS422 or RS485 JMP4 Off Backplane serial port setting for RS232 On Backplane serial port setting for RS422 or RS485 JMP5 Off Backplane serial port setting for RS422 or RS485 On Backplane serial port setting for RS232 JMP6 Off Backplane serial port setting for RS422 On Backplane serial port setting for RS485 JMP7 Off Disable Watchdog Timer On Enable Watchdog Timer JMP8 128K On board non volatile memory size 128K 512K On board non volatile memory size 512K JMP9 1 2 Strobe Gun Inputs sink current
27. reenter the password In the event that the password is lost or is not recognized by the controller contact ITW Ransburg Service Entering a O zero for the password will disable password protection CONFIGURABLE OPERATING PARAMETERS The design of the RCS 2 system allows it to be configured to meet the requirements of the application The large number of parameters allows the RCS 2 to be used in almost any application involving flow and or ratio control of fluids System Parameters are parameters that affect the overall system which includes all channels and guns or the user interface They include e Over Pressure Limit e Foldback Pressure e Pressure Sensor Limit s Horn Enable e Password Timeout e Interface Card Name e Interface Card I P Address e User Program IP Port e Password e Software and Firmware Version Information e System Date and Time 28 RCS 2 User Manual Operation Gun Parameters are parameters that affect the gun These parameters apply to all channels configured to that gun They include e Mode manual or automatic e Number of channels configured to gun e Master Channel Number e Slave Channel Number e Default Job Number e Number of Applicators e Default Job Number e Mixed Volume e Tolerance Percentage e Tolerance Volume e Tolerance Time e Solvent Pulses Per Liter e Horn Code e Auto Reset Channel Parameters are parameters that affect only that specific channel Fortwo
28. regulator on the inlet ofthe pump it minimizes the differential pressure across the pump thereby increasing the accuracy of the pump Pump Outlet Pressure Type of Input Channel Type of Signal Jumper Selectable Factory Setting 4 20 mA This input is typically connected to a pressure sensor located near the output of the pump This is used to monitor and control the differential pressure across the pump thereby increasing the accuracy of the pump This outlet pressure is also used as the feather pressure for manual spray guns if an optional feather pressure sensor is not used ANALOG OUTPUTS Most of the analog outputs are jumper selectable to be 0 to 10 VDC or 4 20 mA Actual Flow however is fixed at 0 10 VDC Motor Speed Type of Output Channel Type of Signal Jumper Selectable Factory Setting 0 10 VDC This outputis connected to the analog input on the servo motor controller located inthe motor amplifier panel AO VDC signal tells the servo controller to run at O RPM a 10 VDC signal tells it to run at the programmed maximum RPM for that pump Iru Ranshurg Pressure Control Type of Output Channel Type of Signal Jumper Selectable Factory Setting 0 10 VDC This output is normally connected a voltage to pressure transducer which converts a O to 10 VDC signal to a 0 to100 psi air pressure The pressure is then used to control the pilot porton a fluid regulator This fluid regulator is then used to control the
29. the Clear Faults button will silence the horn if it is enabled ERROR LOG Pressing this button opens up the error log window which displays the last 100 faults that have occurred These faults are time and date stamped and can be saved to a diskette or memory stick if desired NOTE gt Note that the interface card stores the previous fault information in battery backed memory but it does not contain a real time clock Therefore the date and time of the faults are provided by the user interface PC Ifthe unit is powered up with faults still stored in the Error Log the date and time of those faults on the Error Log Screen will either be left blank or may be random values LN 9407 00 1 RCS 2 User Manual Operation PASSWORD OPERATION When enabled the passwordis required for editing any system or GUN configurations loading information from files editing Job tables or forcing inputs and outputs A pop up screen will appear requesting the password when attempting to perform a password protected operation Once a passwordis entered correctly it willnot 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 button is pushed 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
30. the Paint Fill and Purge pushbuttons to prevent color changes and purges from occurring LN 9407 00 1 RCS 2 User Manual Appendix unless the guns are in their flush boxes and the boxes are closed These pressure switches should be jumpered if gun flush boxes are notto be used There are jumpers on the PC board inside the panel to bypass these pressure switches Feather Reset This is a simple pushbutton that sends a Feather Reset signal back to the RCS 2 control console Spray Test This is a simple pushbutton that sends a trigger signal back to the RCS 2 channel card and also turns on the trigger solenoid to allow operators to verify and test flow etc A valid color must be loaded for this button to work Jumpers In the lower right corner of the PC board inside the panel there are four jumpers labeled JMP1 JMP2 JMP3 and JMP4 If a single gun flush box is being used remove the jumper at position JMP1 If two gun flush boxes are being used remove jumpers JMP1 and JMP2 JMP3 and JMP4 should always remain installed 62 RCS 2 User Manual Appendix Iru Ranshurg APPENDIX J MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 1 GE FANUC AMPLIFIER LED Display Explanation and or Possible Causes _ Following Error Excessive Command Increment Feedback Lost Motor Power Over Voltage Motor Power Clamp Excessive Duty Cycle Motor Over Current Fault LR Motor Over Temperature Fault B Drive Over Tem
31. the outlet of the Mix Block is the spiral mix tube This is simply a piece of tubing with a helical shaped element inside the tube This element causes the two materials resin and catalyst to be folded together numerous times as the materials pass through it thus causing it to mix The optional CCV style color valve stack allows users to do color changes on the resin side of up to 10 colors RCS 2 User Manual Introduction The solvent manifold supplies solvent for flushing as well as filling ofthe magnetic coupling chamber The pump bypass valve is mounted on the resin pump and allows the fluid passing into the inlet of the resin pumpto bypass the gears and go directly to the outlet port This can decrease flush and load times NOTE This valve should not be used while loading 2k materials as improper ratios will result CHANNELS AND GUNS The RCS 2 control system achieves closed loop control of its fluids via its configured channels and guns A channel consists of one pump one motor one motor amplifier two pressure transducers and one half of achannel card A gun inmost cases represents one applicator and may be configured with one channel for flow control only or configured with two channels for ratio and flow control Each channel operates independently of and simultaneously with all of the other channels in the system The controller therefore provides accurate dynamic flow control for all channels
32. to 95 Power Requirements 120 VAC at 10 Amps 240 VAC at 5 Amps Pneumatic Air Consumption Less than 5 cfm Pneumatic Air Inlet Size 3 8 ODT Pneumatic Air Outlet Size 1 4 ODT User Interface Processor 1 GHz Intel PIII Running Windows Embedded XP Interface Board Processor Rabbit 2000 Channel Board Processor Motorola MC68HC16 Fluid Capacity 0 9 cc min to 1500 cc min per pump Fluid Inlet Size 3 8 ODT Fluid Viscosity Range 20 1000 centipoise Fluid Inlet Pressure O psi to 200 psi Fluid Outlet Pressure 200 psi maximum LN 9407 00 1 RCS 2 User Manual Introduction GENERAL DESCRIPTION The RCS 2 System is composed of four basic elements e Main Control Console e Motor Amplifier Panel e Fluid Panel e Remote Operators Panel The Main Control Console can control up to 8 pumps the Motor Amplifier Panels will interface with either one or two pumps and the Fluid Pan els are available with either one or two pumps Main Control Console The Main Control Console is the heart of the system It houses the following items e User interface computer e Control card rack e Ethernet switch e Interface card e Channel card s e 15 color LCD touch screen display e DC power supply e Ribbon cable interface boards e Power and I O terminal strip e Noise filter and fuses 1 0 connectors for motor amplifier panels The User Interface Computer is a Pentium based PC with a non volatile flash di
33. width is graphed in 40 seconds In slow mode the full screen width is graphed in 80 seconds F2 Single Plot This button allows the user to record one full screen of data 40 or 80 seconds at which point the graphing stops to allow the user to examine the data In continuous data mode when the cursor reaches the right end of the graph it automatically jumps back to the left end of the graph and writes over old data F3 Stop Plot This button allows the user to stop the data acquisition process temporarily and freeze the display for analysis or to save the plot F4 Start Stop lt This button allows the user to move both the start time cursor and the stop time cursor at the same time to the left F5 Start Time lt This button allows the user to move the start time cursor to the left F6 Start Time gt This button allows the user to move the start time cursor to the right LN 9407 00 1 rruvRansburg F7 Stop Time gt This button allows the user to move the stop time cursor to the left F8 Stop Time gt This button allows the user to move the start time cursor to the right F9 Start Stop gt This button allows the user to move both the start time cursor and the stop time cursor at the same time to the right F10 Save Plot This button allows the operator to save the graph in a bitmap bmp format for later examination and printing The operator is give
34. will be lost if the screen is exited prior to sending it to the interface card using this button F9 Read in File This button allows operators to load the parameters contained on this screen from any media They are stored in a file named chanconfig par F10 Save to File This button allows operators to save the parameters on this screen to any writeable media They are stored in a file named chanconfig par 37 rruvRansburg F4 Config Job When F4 is selected from the Main Screen the operator will be prompted to select the gun number they wish to examine and or edit parameters for and what Job Number they wish to examine edit At that time the following screen will appear Description The master to slave ratio for the mbced plural componant material Note Set ratio to 65 1 for all resin no catalyst Range Float 0 001 to 65 000 Ratio The allowable range of values for this parameter is any number from 0 001 to 99 999 This is the taget ratio of resin to catalyst that the controller is going totry to maintain while triggered The ratio of 1 for the slave channel is assumed For example if 12 345 was programmed here a ratio of 12 345 parts of resin would be metered into 1 part of catalyst If a value less than 1 000 is programmed here the flow of the catalyst will be greater than the flow of the resin For example if 0 250 was programmed here a ratio of 4 parts of catalyst slave channel material w
35. 00 1 mrvRansburg 18 Revised Configurable Operating Parameters System Parameters added Interface Card Name and User Program IP Port Gun Parameters added Default Job Number Channel Parameters Inlet Pressure Sensor Enable Disable removed Hardener Samp Time Hardener No Flow Setpoint Hardener Flow On Point and Inlet Pressure Sensor Enable Disable Job Parameters revised Alarm Configuration Parameters added Outlet Pressure Loss Motor Amp Fault System Over Pressure Channel Card SPI Fault and Channel Card Internal Fault 19 Added Note Items above marked with an asterisk cannot be disabled 20 Revised User Interface Software Main User Interface Screen and F1 Config System Parameter screen 21 Removed Interface Card IP Address This is the IP address of the interface card in the RCS 2 rack that this user interface software is going to communicate with 22 Revised F2 Config Gun screen 23 Revised F3 Config Channel screen 24 Added User Interface Software Minimum Pump Speed Note If the RCS 2 Controller determines that either pump must run below this limit to obtain the desired flow rate or ratio the controller will stop both motors and a Motor Tach Loss fault may be generated 25 Added Inlet Pressure Sensor Foldback PID Loop The PID parameters for foldback control how fast the motors respond when they enter foldback mode but they also control how fast the motor
36. 8 revs Check if the motor is stalling or if the commanded speed is higher than the motor can achieve at the present bus voltage Option Card Fault Check ExtFaults If ExtFaults is AuxFBFault then the AusFB device is in error Check the AuxFB faults AuxFBEnDatFlt AuxFBPTCFit or AUxFBSCDFIt Check to make sure the the drive is set up for the correct feedback device and that the device is functioning correctly If ExtFaults is No Extended Fault then this was a fault induced by the controller such as SynqLost LN 9407 00 1 66 RCS 2 User Manual Appendix rr Ransburg APPENDIX K ERROR CODES EEN Description Explanation and or Possible Causes Input Under Channel Pump inlet pressure is below the No material available to pump inlet Pressure Card Minimum Pressure value specified in 2 Material supply pressure is too low the Channel Configuration Loss of supply air to the E P transducer that controls the pump inlet pressure Loss of electrical supply or control signal to the E P transducer that controls the pump inlet pressure Failure of the E P transducer that controls the pump inlet pressure Failure of the pressure regulator that controls the pump inlet pressure Failure of the pump inlet pressure sensor Minimum Inlet Pressure value specified in the Channel Configuration is too high Input Over Channel Pump inlet pressure is above the Failure of the E P transducer that controls Pressure Card Maxim
37. Appendix C for Channel Board Jumper Settings It is recommended that the 24 VDC power supply in the controller be used to source these inputs terminal 1331 Optionally ifan external supply is used as the source for these inputs it must be referencedtothe ground terminal terminal 1113 Channel 1 0 Connection Board Channel 1 0 Connection Board Figure 10 Gun I O Sourcing Sinking Iru Ranshurg There are two types of discrete digital inputs pulsed inputs and maintained inputs The pulsed inputs must be turned on and held on for 250 milliseconds minimum toinsure operation Multiple pulsed signals to a gun should also be separated by 250 milliseconds For example don t turn the halt reset signal off at the same time that the run signal is being turned on as results will be unpredictable Maintained signals operate aslong as the input remains energized NOTE Times stated above are for discrete digital inputs only When interfacing using Allen Bradley s Remot l O aka RIO these times may vary significantly Refer to the RCS 2 RIO Interface Programmer s Manual for more details Some discrete digital inputs are specific to a gun and others are specific fora channel If it is a gun input and the gun is configured as a two channel gun field wiring must always be connected to the master channel terminals channel A Fast Fill Type of Input Gun Type of Signal Pulsed The gun must be in run mode prior to initi
38. Disable LN 9407 00 1 RCS 2 User Manual Introduction rruvRansburg Channel Parameters are parameters that affect only that specific channel Fortwo channel guns there are independent parameters for each of the Alarm Configuration Parameters allow the user to specify what conditions cause a spray shutdown to occur They include two channels They include e Fill Enable Disable e Trigger On Delay Time e Trigger Off Delay Time e Pump Size e Pump Pulses Per Liter e Maximum Pump Speed e Miniumum Pump Speed e Maximum Inlet Pressure e Minimum Inlet Pressure e Maximum Outlet Pressure e Minimum Outlet Pressure e Inlet Pressure Sensor Enable Disable e Foldback Kp e Foldback Ki e Foldback Kd e Foldback Deadband e Feather Kp e Feather Ki e Feather Kd e Feather Deadband Job Parameters are parameters that are stored with the specific job number Typically a job number is assigned to a specific material In this way totalization data and PID parameters relate directly to the material These parameters include e Ratio e Flow Setpoint e Maximum Flow for analog control e Minimum Flow for analog control e Bar Graph Limit e Pot Life Time e Feather Pressure e Fill Volume e Pressure Pot Capacity e Pressure Differential across the pump e Minimum Pressure e Inlet Presure Control PID Parameters e Hardener Sample Time e Hardener No Flow Setpoint e Hardener Flow On Point LN 9407 00 1 e Input Under Pressure
39. HIS WARRANTY 49 ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATER IALS THERE ARE NO IMPLIED WARRAN TIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANS BURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume no responsibility for repair orreplacement ofthe item oritems The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9407 00 1 rm Ransburg RCS 2 User Manual Appendix APPENDIX APPENDIX A STANDARD KEYBOARD FUNCTIONS When operating the user interface software from a PC or laptop the touchscreen buttons are not available Below is a handy cross reference table that associates available functions to a standard qwerty keyboard Function Key e a A 0 9 Asterisk sir id Channel Fl occasion Space Bar e nn nn C rn aa A Ge ee eee ee Enter Key PSG pati ner a ee te ere Esc Key undo previous menu etc ERP eee ne ere a ains F1 F12 Key Fast Fill aa Backspace Key G n TOM
40. ION The operator interface was designed to be user friendly and to supply all of the necessary information for the operation of the RCS 2 control directlytothe operator Mostinformationlocatedin the manual regarding the operation of the RCS 2 system is available directly through the operator interface screens All of the screens offer on line descriptive information and help text Graphic information is also displayed for a quick determination of system performance Power ON When power is first applied to the RCS 2 system the interface card and any installed channel cards located in the card rack immediately perform initialization and place all GUNs in the ready state assuming valid configurations and successful self tests The interface card will determine which channel cards are installed and that the installed cards are communicating properly The PC upon application of power will load the Windows Embedded XP operating system and then display a RCS 2 icon Double tapping the icon will start the user interface software Power OFF It is very important that the power to the main control console not be shut off until a Windows shutdown is performed using the F12 function key The LCD display will indicate to the user when itis okay to turn the power off to the controller E Stop Button The E Stop button on the RCS 2 controller does not completely remove power from the RCS 2 control console When this button is pushed th
41. K The new job will also become active if the gun faults as this generates a halt for that gun F6 Configure Alarms This screen allows the operator to program which errors and faults actually cause a spray shutdown condition That is what errors and faults when they occur will actually halt the pumps and cause spray to cease Description Toggle ON to allow alarm to cause a eprayshut own Toggle OFF to display a tsuh but Coatinue runaisg If the alarm is turned off the main screen will indicate that the gun is faulted but running The Status line on the main screen will show STATUS RUN The word RUN will be printed in red 40 RCS 2 User Manual Operation There arefourfunction buttons defined while editing alarm configuration data F1 Modify This button toggels an off state disabled to an on state enabled F5 Send to RCS 2 This button takes the data displayed on the current screen and sends it to the interface card where it is then stored in non volatile memory Any changes made to the pa rameters on this screen will be lost if the screen is exited prior to sending itto the interface card using this button F9 Read In File This button allows the operator to load alarm configurations from any media F10 Save To File This button allows the operator to save alarm configurations to any writeable media All configurations are saved in a file named alarmcfg par F7 Digital a
42. Motor Feedback A gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt P gt gt Input Input gt gt gt gt gt gt gt gt gt gt gt Reference Drawing Number A10479 Refer to Appendix E for Termination Board Drawing LN 9407 00 1 24 RCS 2 User Manual Installation Ir Ransburg TABLE 2 EVEN NUMBER CHANNEL CONNECTIONS otar nuna Mis oee Sgt er Signal Name Label Channel Output Wire No Wire No Wire No Wire No Fast Fill 1B Input Channel Fill 2B Input Feather Set 3B Input Run 4B Input Halt Fault Reset 5B Input Trigger 1 6B Input Motor Amp Enable Input Trigger 2 Input Trigger 3 Input Trigger 4 Input Volume Fill Input Push Out Input Fault Output hi Output Fault Output low Output Ready Output hi Output Ready Output low Output Spray Shutdown hi Output Spray Shutdown low Output Flush Request hi Output Flush Request low Output Motor On hi Output Motor On low Output Motor Amp Reset hi Output Motor Amp Reset low Output Digital Ground G N A 24 VDC N A Hardner Flow Input Flow Rate Command Input Feather Pressure Input Pump Inlet Pressure Input Pump Outlet Pressure Input Spare Analog Input Input Motor Speed Output Pressure Control Output Actual Flow Output
43. O fosse aiii Aora G n 2 id sasa Sors CSUN CAO aaa sas Dord Gun 4 elle Forf G n SOMO f neiere i Gorg G n 6 elie esm Horh CUIT ele aeran r kaa a a laa l ska a S hals Jorj GUN ele ereer aa a Kork o A Lor PMsn atico ae asa Home Key NOM iii Down Arrow Key Scroll R aci Left Arrow Key enel STs l A te a err tce re Tre ry Right Arrow Key SIO scares here n EP PP e Up Arrow Key LN 9407 00 1 50 RCS 2 User Manual Appendix Ir Ransburg APPENDIX B CALIBRATION DATA AND FLOW RANGES OF STANDARD RCS 2 PUMPS Using New Style Motor Using Old Style Motor Using Proximity Amplifier Feedback Amplifier Feedback Sensor Feedback 500 pulses revolution 64 pulses revolution 60 pulses revolution Pump Size Flow Rate Flow Rate Calibration Factor Calibration Factor Calibration Factor cc s rev 3RPM 150 RPM pulses liter pulses liter pulses liter 0 297 0 9 45 1 683 502 215 488 202 020 0 584 1 8 88 856 164 109 589 102 740 1 752 5 3 263 285 388 36 530 34 247 2 920 8 8 438 171 233 21 918 20 548 3 500 10 5 525 142 857 18 286 17 143 5 500 16 5 825 90 909 11 636 10 909 10 000 30 0 1500 50 000 6 400 6 000 Pump Size Specified by pump manufacturer in cc s per revolution Flow Rate 3 RPM Calculated by mutiplying the pump size by 3 RPM Flow Rate 150 RPM Calculated by multiplying the pump size by 150 RPM Calibration Factor Calculated by taking 1000 cc s liter dividing by the pump size then multiplying by t
44. R b SERVICE MANUAL IT AT ans urg LN 9407 00 1 Replaces LN 9407 00 December 2009 RCS 2 USER MANUAL MODELS A10549 CONTROL CONSOLE A10776 MOTOR AMPLIFIER PANEL A10948 FLUID PANEL IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 40 00 Euro 50 00 U S RCS 2 User Manual Contents CONTENTS Iru Ranshurg PAGE SAFETY 1 4 SAFETY PBRECAUTIONS nadhan ka nanka kakanan aAA nA nAn EAA AARAA EAAAA AEAEE A AARAA EAEE anaana 1 HAZARDS SAFEGUARDS ccccescescesccscesccsccecssccecessesscstcsecescsscesccscsecssesaeaecatsateateauesucaucascaueess 2 4 INTRODUCTION 5 12 FEATURES 5 ESPECIFICA ON e id donas 6 GENERAL DESCRHIBTION aankan tana nuna anann ARAR AA EAA AA AEAEE EA REDEE E RERED EAn nanas 6 9 CHANNELS AND GUNS ccccsccsescceccecceccecccccseccsecsecaecsucsucausausaucaussscsessaesaesaecausausausaucaucaueeueenes 9 CONTROL RACK INTEGRATION c ccccssssscsscsccecccccsecceesecceccecsetsscescestestesscsteceessesaecensensansaneas 9 CONFIGURABLE OPERATING PBARAMETERHS kanankuna nanus kunanka kakanin knna ana 9 10 ELIAS ec cited tad 11 FLUID PANEL SCHEMATIC 12 INSTALLATION 13 26 SYSTEM GUIDELUINES a EA EASES naana 13 DIMENSIONALINFORMATION cccccccoscoscoscesccsceccccecsecaccaecascsscsucsucaucaucausaecsussussussuesareassaseaeeas 14 16 INF UTPO
45. Section 3 Revised Features removed Device Net I O Capabilities optional Ethernet I P interface allows interfacing to all Ethernet I P enabled controllers and Floppy disk drive CD Rom and 10 100 based Ethernet ports 4 Revised Specifications Fluid Inlet Pressure to 200 psi 5 Added General Description Main Control Console The Interface card houses a Rabbit 2000 embedded processor This board performs the following functions Has an Ethernet port used to communicate with the user interface PC andthe color change sequencer and removed Communicates to Ethernet I P enabled external PLC s computers etc via its Ethernet Port 6 Removed General Description Fluid Panels This is done through two independent cables one for the motor drive voltages and one for the resolver feedback signals 7 Added General Description Fluid Panels Note This valve should not be used while loading 2k materials as improper ratios will result 8 Revised Configurable Operating Parameters System Parameters Channel Parameters and Alarm Configuration Parameters 9 New Figure 1 Control Console Block Diagram and Figure 2 Motor Amplifier Panel Block Diagram and Figure 3 Fluid Panel Schematic Installation Section 10 New Figure 4 Stand Alone Unit Figure 5 Motor Amplifier Panel Figure 6 Control Panel Assembly Figure 7 Fluid Panel Assembly Figure 8 Control Panel Input Power and F
46. TE CHANNEL AND GUN OUTPUTS All discrete outputs have two terminals one labeled Hi and one labeled Lo They operate very similar to adry contact relay with allowable current limited to 1 amp 45 volts AC or DC exceeding this limit may damage the output on the channel card Although a myriad of voltages could be used it is recommended that the Hi signal be connected to the 24 VDC terminal terminal 1331 and the output be taken from the Lo output terminal This terminal will supply 24 VDC when the output is energized by the software Referenced ground terminal is 1113 An alternate way of connecting these outputs would be to connect the positive supply voltage to the load the common of the load to the Hi output terminal of the RCS 2 output and connect the Lo output terminal to both the ground of the supply connected to the load and the ground terminal terminal 1113 Once again current must be limited to 1 amp and should never exceed 40 volts Figure 11 Sourcing Sinking Outputs LN 9407 00 1 rruvRansburg Fault This output is energized anytime a fault condition is recognized by the software Even if the fault is disabled turned off on the Configured Alarms screen this output will be energized as long as the condition persists Fluid flow will not be halted when this output is energized unless it is con figured to do so on the Configured Alarms screen Ready This output is energized if the gun is configured
47. The no flow and flow on levels can now be programmedtofitthe application Current measured atthe output ofthe analog output amplifier provides information to the RCS 2 channel card Program ming specific values can speed up or slow down system response to given flow conditions Programming the no flow value as low as possible will help minimize response time from a no flow to flow on condition but if it is too low fluid noise could periodically cause indications of flow when in reality there is no flow Programming the flow on value to the lowest possible value will minimize response time to a flow on to no flow condition but in this case fluid noise could cause nuisance errors when there is actually flow The best way to set up the no flow flow on values is to begin with the default values indicated above Monitor the output current from the Analog I O Screen with the system operating normally Set the flow on value to about 1 2 mA below the minimum measured current during normal operation Note Fluid must be flowing to properly set this value To set the no flow value turn the hardener supply off Monitor the output currentfrom the analog output amplifier The current should begin to decrease and steadily fall until it begins to approach a level of approximately 4 8 mA the no flow zero reference value Note In order to prevent system shutdown go to the Configure Alarm setup screen onthe User Interface Screen of the RCS 2 and
48. WER a e o 16 DISCRETE CHANNEL AND GUN INPUTS akaaka a nanka nannaa nananana nannaa 17 19 DISCRETE CHANNEL AND GUN OUTBUTS 19 20 ANALOGINPUT Sucios die dde a a aaa k 20 21 ANALOG UT nhn kn Anana nanna MARAR EAAA EA RAn ARAARA RARER A RARESA ARAR anaana a 21 EFREOUENCYINBUTS ss 21 SYSTEM INPUTS AND OUTBUTS non nn nn nn nn non rnn enana 22 23 ODD NUMBER CHANNEL CONNECTIONS TABLE 24 EVEM NUMBER CHANNEL CONNECTIONS TABLE 25 SYSTEM I O CONNECTIONS TABLE 26 OPERATION 27 48 SETUP AND OPERATION 27 BUTTON PUIG TOONS soc tai 27 28 PASSWORD OPERATION iasssisissssaraniukukasaukuka sanka annnka nkan n AAAA AAAA ARASA EA RASE AEA RASARE EERE a eanan 28 CONFIGURABLE OPERATING PBARAMETERHS non nonnonnannonnonnonnons 28 29 USER INTERFACE SOFTWARE nen nnnnnnnnnr nr annannnnn 30 48 LIMITED WARRANTY 49 LIMITED WARRANTY is 49 Continued On Next Page LN 9407 00 1 Ir Ransburg RCS 2 User Manual Contents CONTENTS Cont PAGE APPENDIX 50 76 A STANDARD KEYBOARD FUNCTIONS sss eee 50 B CALIBRATION DATA AND FLOW RANGES OF STANDARD RCS 2 PUM Pisin lor vika A 51 C CHANNEL BOARD JUMPER SET PUIG Socia iran 52 D INTERFACE BOARD JUMPER SETTINGS curia 53 E CHANNEL AND GUN O TERMINALS scr ia 54 Fx SYSTEMVO TERMINALES css o 55 G CATALYST FLOW SENSOR sieninge raa E a ar 56 58 A FEATHERING a a E E E 59 60 l REMOTE OPERATORS PANEL osa 61 62 J MOTOR AMPLIFIER LED DISPLAY FAULT CODES O a o es 63 66 ERROR CODES
49. a small relay panel that switches the command signals for the catalyst motor drive between two slave channels in the RCS 2 control console Contact ITW Ransburg for design details for this relay panel The process steps to implement this feature are outlined below 1 Assume the applicator is running 2 component material through one side of a dual purge applicator and that material is being controlled by channels 1 and 2 of the RCS 2 where channel 1 is the resin and channel 2 is the catalyst 2 As the last part buck rack etc approaches the robot for the presently running color either the PLC or the robot sends a Pushout signal to the RCS 2 Atthatinstant the RCS 2 will immediately turn off the catalyst pump and speed up the resin pump to maintain the target flow rate that was being sprayed prior to the initiation of the pushout signal Note that this pushout signal is a maintained signal 3 Simultaneous with the pushout signal being turned on the PLC or robot will turn off the color valve and turn on the solvent valve on the resin color valve stack connected to the first resin pump Depending on howthe catalystis controlled it may be necessary to also switch off the catalyst valve or atleast change its direction Note that not all pumps are capable of accurately dispensing solvent because of its low viscosity It is up to the user to ascertain if the pump they are using is accurate enough when metering solvent to m
50. aintain a proper film builds on their parts Iru Ranshurg 4 The RCS 2 will continueto deliver fluid out ofthe first dual purge side until the volume programmed in for mixed volume has been sprayed and then that gun in this case Gun 1 will automatically be halted taken out of run mode This state will be recognized by the PLC or robot when the Run output from the RCS 2 turns off 5 The PLC or robot must then energize a series of relays in the relay panel which switches the signals connected between the catalyst motor drive and the channel card from channel 2 to channel 4 6 While the first dual purge side is being pushed out gun 2 configured as channels 3 and 4 can begin to load dual component material using the resin pump connected to channel 3 andthe catalyst pump that is now controlled by channel 4 Single component material can also be loaded by using the proper 1k ratio programmed in the job parameters 7 As the applicator continues to spray dual component material out of the second side the first side can be flushed using A Fill solvent air chops pump bypass signals etc Note The pushout signal must be asserted with the A Fill signal or the software will attempt to enable the channel B motor drive This is done to prevent backflow of resin in the catalyst line on 2k configured guns 8 When the last part approaches the robot for the presently running color occurs again the procedure repeats for the seco
51. al will provide a better understanding of the equipment and process resulting in more efficient 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 ITW Ransburg representative or ITW Ransburg Iru Ranshurg AWARNING K The user MUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literature therein identified K This manual MUST be read and thoroughly understood by ALL personnel who operate clean or maintain this equip ment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinanc es as well as NFPA 33 SAFETY STANDARD prior to installing operat ing and or servicing this equipment AWARNING K The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 LN 9407 00 1 rruvRansburg AREA Tells where hazards may occur Spray Area LN 9407 00 1 HAZARD Tells what the hazard is Fire Hazard Improperorinadequate operation and maintenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are di
52. an error while attempting to communicate with a Channel Card via the Serial Peripheral Interface SPI bus The User Interface Computeris not able to communicate with the interface card The User Interface Computeris not able to communicate with the color change sequencer brain Explanation and or Possible Causes The power to the Interface Card may have been off for too long resulting in premature failure of the battery There are no Channel Cards inserted into the card rack and mother board backplane The SPI bus device on the Interface Card may not be functioning One of the SPI bus devices on a Channel Card may not be functioning in such a way as to prevent communications by any other Channel Card This error may occur when the system is first powered up and may be ignored Check for power on the rack E Stop button out Check all Ethernet cables switches etc Check for power on the motor amp panel Check all Ethernet cables switches etc 70 RCS 2 User Manual Appendix 71 APPENDIX L PUSHOUT A new feature has been added to the RCS 2 software called Pushout This feature allows a customer that uses dual purge applicators to use two resin pumps that share a common catalyst pump and pushout the resin with solvent on one side of the dual purge applicator while loading the other side of the applicator with the next material to be sprayed The system employs
53. and sends it to the interface card where it is then stored in non volatile memory Any changes made to the parameters on this screen will be lost if the screen is exited prior to sending it to interface card using this button F6 Next Gun This button allows the user to view and edit the job parameters for the next gun F7 Copy Parameter This button allows the user to copy the data from the highlighted parameter on the screen to any other job range of jobs gun or range of guns F8 Copy Job This button allows the user to copy the data from any job to any other job Users are also prompted for which gun or guns they wish the job data copied to F9 Read file This button reads in the totalization data from the internal flash drive the floppy disk drive a USB memory drive or the CDROM and sends them to the interface card to be stored in non volatile memory F10 Save to file This button reads all totalization data currently stored in non volatile memory on the interface card and stores it on the media selected by the user internal flash floppy drive USB memory or CDROM The data is stored in a file named jobs par LN 9407 00 1 RCS 2 User Manual Operation F5 Load Job This function allows operators to load a different job number to a gun Note that if the gun is in run mode when the new jobis seleted the new job will not become active until the gun is halted and put back in run mode NOTE
54. ansducer will not go below this setpoint This can be used as an offset to keep the fluid regulator atits cracking pointto allow for rapid response by the fluid regulator at the trigger on points Inlet Kp The allowable range of values for this parameter is any integer from 0 to 65 535 The value has no units This value is the proportional gain factor for the PID loop that controls the inlet pressure to the pump Inlet Ki The allowable range of values for this parameter is any integer from 0 to 65 535 The value has no units This value is the integral gain factor for the PID loop that controls the inlet pressure to the pump Inlet Kd The allowable range of values for this parameter is any integer from 0 to 65 535 The value has no units This value is the derivative gain factor for the PID loop that controls the inlet pressure to the pump Inlet Deadband The allowable range of values for this parameter is any integer from O to 65 535 It is expressed in PSI This value is the deadband for the PID loop that controls the inlet pressure to the pump T Ransburg NOTE K See Appendix G for details on ad justing the following three parameters Hardener Sample Time The allowable range of values for this parameter is any integer from 0 seconds to 10 seconds This parameter allows the operator to program how often in accumulated seconds the flow of the slave channel is verified Hardener No Flow The allowa
55. applicator that is being used in production from applying the wrong flow rate or ratio of material NOTE K This setting has no effect on Fast Fill 34 RCS 2 User Manual Operation Trigger On Delay The allowable range of values forthis parameteris from 0 000 seconds to 5 000 seconds This indicates how long after receiving a trigger signal the controller will wait before it actually starts running the pump s for that gun This allows the operator to compensate for pneumatic delays inherent with some applicators Trigger Off Delay The allowable range of values for this parameter is from 0 000 seconds to 5 000 seconds This indicates how long to run the pump s after the trigger signal has been removed This allows the operator to compensate for pneumatic delays inherent with some applicators Pump Size The allowable range of values for this parameter is from 0 000 to 10 000 cc rev This is the volume of material that the pump being used on this channel allows to pass with each complete revolution of its gears Pump Pulses Per Liter The allowable range of values for this parameter is any integer from 1 000 to 1 000 000 pulses liter This is the number of pulses received by the channel card from the sensing device motor amplifier flowmeter etc for each liter of material that passes through the channel Maximum Pump Speed The allowable range of values for this parameter is any integer from 1 RPM to 65 535 RPM
56. asta ao 67 70 Es PUSHOU Losa a Seal Gaeta dis 71 Me TRIGGER LO asa a 72 73 N IMPROVING THE ACCURACY OF THE RES lt 2 ninia iia lidia 74 76 LN 9407 00 1 RCS 2 User Manual Safety SAFETY 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 products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS Tohelp 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 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 drawings and appropriate ITW Ransburg equipment manuals to reconcile such differences Careful study and continued use ofthis manu
57. ate the operators can again trigger both handguns push and hold the feather set pushbutton until the target flow rate is achieved then release the feather set pushbutton and a new higher feather set pressure will be recorded Once again the master channel feather pressure PID parameters may have to be adjusted to control how fast the pumps respond to a change in flow This directly effects how close to the target feather pressure the actual outlet pressure is maintained LN 9407 00 1 60 RCS 2 User Manual Appendix 61 APPENDIX l Iru Ranshurg REMOTE OPERATOR S PANEL The Remote Operators Panel shown above operates in the following manner Color Select This is an eleven position selector switch that allows the operator to select the next color to be loaded If the most counterclockwise position is selected Solv and the Paint Solvent Fill button is pushed the normal load sequence occurs and solvent is loaded into the fluid system as if it is was a color Paint Solvent Fill Filled This is a green illuminated pushbutton When pushed the paint load sequence runs as programmed from the Load user interface screen The green indicator lamp flashes as the sequence is occurring and stays lit solid when the sequence has completed indicating to the operator that the system is ready If there is already a color loaded ie one of the color valve outputs is already on when this button is pushed
58. ating this mode or the RCS 2 controller will ignore it Ifthe gun is configured as a single channel gun and this signal is pulsed the gun will be put in fast fill mode This will cause the pump to run at its maximum rate 150 RPM until the halt signal is pulsed It is not necessary to have the trigger signal energized Ifthe gun is configured at a two channel gun and this input is pulsed the gun will be placed in fast fill mode The pumps will run atthe maximum speed possible while maintaining the target ratio Thatis the software will determine which ofthe two pumps can be run at its maximum speed 150 RPM and run the opposite channel at whatever speed is necessary to ensure the proper ratio of component LN 9407 00 1 rruvRansburg A to component B The software determines this based on the programmed pump sizes and the programmed ratio Pulsing the halt reset input takes the gun out of the fast fill mode Channel Fill Type of Input Channel Type of Signal Pulsed A gun must be in the ready state to use this mode This mode functions the same for single channel guns as it does for dual channel guns When this inputis pulsed the pump for that channel is run at its maximum rate 150 RPM until the halt signal is pulsed It is not necessary for the trigger input to be energized If it is desired to have both channels of atwo channel gun run at full speed for flushing etc this input must be pulsed on both channels T
59. ation Motor overspeed Invalid hall state Invalid hall transition SFD UART error during SFD initialization Bad motor data check sum The drive will attempt to initialize the SFD up to 4 times If it fails this error is reported Excessive loading on SFD 5 supply Short in the feedback cable on SFD 5 J3 1 to ground Motor and Drive are not compatible Auto setup calculation yielded a desired parameter value outside valid range Incorrect inconsistent motor data loaded into the SFD LN 9407 00 1 rm Ransburg RCS 2 User Manual Appendix APPENDIX J MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 2 Continued DANAHER AMPLIFIER Status LED e E S Fault Description Explanation and or Possible Causes SFD Sensor Failure Internal SFD failure Excessive electrical noise in the drive environment causing communications interference SFD UART Error Internal SFD failure SFD Communication Error Feedback cable not connected at the drive or at the motor Feedback cable shield not connected Defective feedback cable Internal SFD failure Excessive electrical noise in the drive environment causing communications interference Option Card Watch Dog Time Out Communication error between option card and main board Position Error Too Large Check ExtFaults ExtFaults Step size over flow means GearOut Gearln is too large ExtFaults Position error over flow means that the following error PosErr has exceeded 12
60. auses The value entered for the pressure pot Capacity in the Job Configuration is Incorrect The operator neglected to reset the Pressure Pot Capacity when it was last filled Pressure Pot is empty Electrical connection problems 2 Failure of Pump Inlet Pressure sensor Electrical connection problems 2 Failure of Pump Outlet Pressure sensor Electrical connection problems 2 The Remote Analog Setpoint source is configured for voltage instead of current loop Loss of feedback signal from motor amplifier or flow meter Incorrect Calibration Factor in Channel Configuration One or both channel is unable to deliver the correct flow rate due to restriction in the fluid line lack of material Reference the motor amplifier diagnostics to determine the cause of the fault Electrical connection problems 2 Failure of Feather Pressure sensor Electrical connection problems 2 Failure of Spare Analog input sensor This error is normal when operating in Fast Fill or Channel Fill mode For Automatic guns restriction in the fluid line For Automatic guns failure of applicator trigger valve 68 RCS 2 User Manual Appendix mrRansburg APPENDIX K ERROR CODES Continued Pot Life Expired System Over Pressure Channel Card Parameter Fault Channel Card SPI Fault Channel Card Internal Fault 69 Channel Card Channel Card Cha
61. be removed or commented outin order to talk to an interface card Gun On Off Buttons The buttons in the top left of the screen can be used to turn guns on or off switches them between Run mode and Ready mode Note that guns must be in Run mode to spray Faulted guns are noted by a flashing red boarder around the button of the gun that is faulted Pushing this button once when itis faulted will reset the fault and pushing it a second time puts the gun back in Run mode to put it back into operation 48 RCS 2 User Manual Warranty Policies Iru Ranshurg WARRANTY POLICIES LIMITED WARRANTY ITW Ransburg will replace or repair without charge any part and or equipment that falls within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with ITW Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANS BURG APPROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLAS TIC SHRINK WRAP ETC WILL VOID T
62. ble range of values for this parameter is 4 mA to 20 mA This parameter allows the user to program in the current in milliamps below which the controller assumes that no catalyst is flowing Hardener Flow On The allowable range of values for the parameter is 4 mA to 20 mA This is the value above which the controller will assume that catalyst is flowing It must always be greater than the Hardener No Flow Parameter Ifthe controller sees a value between hardener no flow and hardener flow on it examines the slope of the current As long as the current is increasing while the gun is triggered the controller assumes catalyst is flowing If the current is decreasing or remains stable while the gun is triggered the controller will assume no catalyst flow and increment the hardener sample time timer Edit Job Function Keys There are 9 function keys defined for use from the Job Parameters screen F1 Modify This button allows the user to modify the currently selected parameter highlighted LN 9407 00 1 Iru Ransburg F2 Previous Job This button allows the user to view and edit the previous job to the one currently displayed for that gun F3 Next Job This button allows the user to view and edit the next job for that gun F4 Previous Gun This button allows the user toviewand edit the job parameters for the previous gun F5 Send to RCS 2 This button takes the data displayed on the current screen
63. channel guns there are independent parameters for each of the two channels They include Iru Ranshurg Job Parameters are parameters that are stored with the specific job number Typically a job number is assigned to a specific material In this way totalization data and PID parameters relate directly tothe material These parameters include Ratio Flow Rate Setpoint Max Flow Rate Min Flow Rate Bar Graph Limit Pot Life Timer Feather Pressure Fill Volume Pressure Pot Capacity Delta Pressure Min Inlet Fluid Pressure Min Inlet Control Pressure Inlet Cont Pressure Kp Inlet Cont Pressure Ki Inlet Cont Pressure Kd Inlet Cont Pressure Db Hardener Sample Time Fill Enable Disable Trigger On Delay Time Trigger Off Delay Time Pump Size Pump Pulses Per Liter Maximum Pump Speed Miniumum Pump Speed Maximum Inlet Fluid Pressure Minimum Inlet Fluid Pressure Maximum Outlet Fluid Pressure Minimum Outlet Fluid Pressure Inlet Pressure Sensor Enable Disable Foldback Kp Foldback Ki Foldback Kd Foldback Deadband Feather Kp Feather Ki Feather Kd Feather Deadband s Hardener No Flow Limit s Hardener Flow On Limit Alarm Configuration Parameters allow the user to specify what conditions cause a spray shutdown to occur They include e Input Under Pressure e Input Over Pressure e Output Under Pressure e Output Over Pressure e Flow Out of Tolerance e Hardener Flow Loss e Pressure Pot Empty e Inlet
64. d of no hardener flow that the hardener no flow timer should accumulate to before generating a fault This time continues to accumulate as long as the processor sees no hardener flow regardless of the number of applicator triggers The timer is reset every time the flow meets or exceeds the value programmed in for Hardener Flow On The initial setup for these parameters should be settothe following values delay time 4 seconds no flow 6 mA flow on 10 mA After the zero flow calibration has been done correctly the system can now be programmed to fit the application The delay time is used to prevent nuisance hardener flow errors To properly set this time to minimize delays and prevent nuisance errors the delay time should be set to a value which is less than the minimum spray on time of the system being measured The delay time is cumulative to allow for short spray on times used in some applications The smallest difference between the delay time and the minimum spray on time should be 100 mSec Smaller values can be used but more nuisance errors can occur If values larger than the minimum spray on time are LN 9407 00 1 rruvRansburg programmed hardener flow errors will be detected because the delay time accumulates every time the spray on is turned on and off without detecting a valid current input level i e positive slope at a level above the value programmed for no flow ora value above the programmed flow on level
65. d from 0 volts DC to 10 volts DC Users can program what flow rate they want for both extremes by using the Min Flow and Max Flow parameters under the edit gun screen Faulted Fault Reset This is a red illuminated pushbutton The lamp will be illuminated any time a fault occurs in the RCS 2 whether that fault causes a spray shutdown condition or not Pushing this button resets any fault that has caused a spray shutdown condition It does not reset a non fatal fault one that is disabled in the Config Alarms setup screen ofthe RCS 2 After resetting a fatal fault the user must then push the Ready Run pushbutton to put the gun back into run mode to resume spraying Note that this lamp will flicker when the controller is folding back the outbound pressure of the pumps Ready Run This is a green illuminated pushbutton Pushing this button puts a gun into run mode When in run mode the green lamp is illuminated It is extinguished in ready halted or faulted state Guns in Flush Box These are two LED s that indicate when up to two sprayguns are in their respective flush boxes A flush or load sequence will not be allow to start until both of these indicators are illuminated These LED s are connected to four pressure switches which are actuated by the two flush boxes One indicates that the gun is in the box and the other indicates that the flush box is closed The signalfrom these pressure switches also feeds
66. data is stored in a file named totals par F11 Pot Reset This button allows the user to resetthe volume counters for pressure pottracking This is typically done when the pots are filled F10 Trigger Log With this feature users can monitor and record the trigger on and off times as well as the fluid that flowed during those trigger on times for up to 200 successive triggers When this feature is selected the user will be prompted to select which gun they wish to monitor Recording of data will not start until the Start Logging F1 buttonis pushed Keep in mind that data will not appear in the screen until the second on trigger on dwell event has occurred to allow the software the ability to record the time of the first off trigger off dwell event The job number that was running during the trigger is also recorded The status of three flags are also recorded with each event These flags reflect the status of the three spare system digital inputs 45 Iru Ranshurg Note that volumes are rounded to the nearest cc The latest events are displayed at the top of the screen and the older events are pushed off ofthe bottom of the screen but can be accessed by using the Windows scroll bar Values can also be saved to writeable media by using the F10 key but recording must first be stopped to allow saving of this data Refer to Appendix M for more details on how to use this feature DATE TIME OFF DWELL ON DWELL JOB
67. e real world devices such as motors pressure transducers and flow switches They house the following items e Motor Drive Amplifiers e E to P Pressure Transducers e Zener Barriers e Interface Modules for Flow Sensor e 24 VDC Power Supply Corr Com Power Filter e Control Relay e Terminal Strip e Optional Color Change Sequencer The motor drive amplifiers convert a 0 to 10 VDC signal from the channel cards to a proportional RPM 0 to 150 at the motors They also receive the feedback from the resolvers attached to the motors In this way they can generate a fault ifthe actual motor RPM does not match the target RPM The E to P pressure transducers convert a 0 to 10 VDC signal or optionally a 4 to 20 mA signal from the channel cards to a proportional 0 to 100 psi air signal This signal is used to pilot fluid regulators on the inlet of the pumps allowing the channel card to control the inlet pressure of the pumps The optional Zener barriers make the pressure sensors and the optional Remote Operators Panel intrinsically safe for use inside the spray area The optional catalyst flow sensor interface LN 9407 00 1 rruvRansburg module powers and monitors the flow sensor typically used in the catalyst line of the fluid panel An additional module converts the flow signal to a 4to 20 mA signal thatis proportional to the flow rate of the catalyst That signal is then fed back to the channel card so it can be used to gen
68. e 24 volt supply to the control card rack is disconnected Therefore all control power is removed from the system and all fluid flow will be stopped The motor amplifier panels will loose all power as there is a 24 VDC control relay in them powered from the E Stop button in the control 27 Iru Ranshurg console This is the button that should be used to remove power from the card rack when adding removing or changing interface and channel cards This avoids the long wait times involved when Windows goes through its shutdown and startup sequences BUTTON FUNCTIONS F1 F12 Soft Buttons F1 through F12 are known as soft buttons The function of these keys will change depending on which user interface screen is active on the LCD display The function for each button is shown inside the button ESC This button is used to exit any active screen or pop up box GUN 1 GUN 8 ON OFF These buttons allow manual activation and deactivation of each GUN Pressing a GUN ON OFF button is the same as supplying an external GUN RUN or GUN HALT input signal These buttons also display the status of each gun READY RUN HALTED FAULT AFILL B FILL AB FILL CHAN FILL FLUSH REQ FAST FILL VOLUME FILL OR HALTED FAST FILL The FAST FILL button causes a pop up box to appear on the current screen Any GUN can be manually placed in FAST FILL MODE by simply pressing the number for the desired GUN The FAST FILL MODE is deactivated by pre
69. e Pump Pulses per Liter value on the Configure Channel screen send it to the RCS 2 and retest Repeat the test several times until the accuracy required is obtained and the values actual volume vs displayed volume are repeatedly very close to one another 1 Note In order to convert the weighed material to a volume the specific weight of the material must be known Specific weight is defined as the weight of the material per unit volume This is normally available from the manufacturer of the material If this information is unavailable or the material has been reduced the specific weight will need to be experimentally determined Obtain a very accurate measuring device such as asyringe pipette 10 cc graduated cylinder etc and weigh the container prior to filling it with material Then put exactly 10 cc s of material in the container and reweigh the container Subtract the weight of the empty container from the weight of the full one and divide that difference by 10 The resulting value is the material s weight per cc This value can then be used to very accurately determine the volume of material collected in the above tests LN 9407 00 1 76 Iru Ranshurg MANUAL CHANGE SUMMARY This manual was published to supercede Service Manual LN 9407 00 RCS 2 User Manual to make the following changes 1 Replaced Front Cover figure 2 Added Service Manual Price 40 00 Euro to Front and Back Covers Introduction
70. ecommended that the material be weighed as opposed to measured for increased accuracy Ifthe flow rate multiplied by the time results in more material than was actually obtained in the flow test than the Pump Size programmed in the Configure Channel screen is too large Try reducing the value by the same percentage that the volume exceeded the expected volume and try the test again Ifthe actual volume of material obtained was greater than the calculated value try increasing the Pump Size value by that percentage and try the test again Repeatthis several times until acceptable volumes result Example Pump Size 5 5 cc s rev Programmed flow rate 300 cc s min Flow time 3 minutes Calculated volume 3 minutes x 300 cc s min 900 cc s Actual volume collected 887 cc s 887 cc s 900 cc s 5 5 cc rev x New PS Therefore New PS 900 x 5 5 5 58 cc rev 887 Put 5 58 cc s rev in for the Pump Size on the Configure Channel screen push Send to RCS 2 and retest Pump Pulses per Liter and Totalization On the Configure Channel screen of the user interface software there is a value named Pump Pulses per Liter All of the RCS 2 flow rate and volume displays are based on this value The motor amplifier sends 500 pulses per revolution back to the RCS 2 channel card no matter what RPM it is running at Therefore it is easy to calculate a volume of material per pulse or a number of pulses per volume in this case
71. el A receives an trigger input signal This can be any of the 4 trigger inputs for channel A The Off Dwell Time is the time from previous event s trigger off to the new event s trigger on the On Dwell Time is the time from this event s trigger on to this event s trigger off The fifth column indicates what job number was running in the RCS 2 during this trigger event The sixth column shows the status of four binary flags digital inputs at the start of this trigger event The fourtrigger inputs for channel B are not required for dual component guns and so are monitored and displayed onthe Trigger Log screen to allow users to use them as flags Flags are markers in time to indicate when certain events occur 72 RCS 2 User Manual Appendix APPENDIX M TRIGGER LOG Continued Flags wxyz are displayed as four binary bits O off or 1 on w Channel B Trigger Input 4 x Channel B Trigger Input 3 y Channel B Trigger Input 2 z Channel B Trigger Input 1 Columns 7 8 and 9 indicate the volume of resin catalyst and the total respectively during that trigger on event 73 NOTES Iru Ranshurg LN 9407 00 1 rruvRansburg APPENDIX N THE RCS 2 There are many ways that the accuracy of the RCS 2 system can be improved This article presents three things that can and should be examinedifitis necessary to improve the accuracy of the machine Differential Pressure Control One of the first thing
72. equencer Resin Solvent Air Chop Resin Solvent Resin Air Paint Resin Pump Bypass Resin Pump Flush Trigger Solenoid Resin Override Dump Valve Catalyst Select Valve Catalyst Solvent Catalyst Override LN 9407 00 1 RCS 2 User Manual Operation The following RCS 2 inputs can be controlled by the sequencer RCS 2 Run RCS 2 Halt RCS 2 Fast Fill RCS 2 A Fill RCS 2 B Fill RCS 2 Trigger Note that there are too many valves and signals to be displayed on one screen Therefore the operator must scroll down to see the bottom five items There are 8 function buttons defined while editing flush load and color 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 on to off F2 Air Chop Time This button allows the user to program how long the air valve remains on for each step of the solvent air chop timer F3 Solvent Chop Time This button allows the user to program how long the solvent valve re mains on for each step of the solvent air chop timer F4 Edit Flush or Fill This button opens the screen that allows viewing and editing of the sequences If the flush screen is displayed it switches to fill or vice versa F5 Send to Opto22 This button allows the operator to immediately send the edited sequence to the sequencer located in the motor amplifier
73. erate faults when catalyst flow falls below a preset point or if air is detected in the supply line The 24 VDC power supply powers the E to P transducers the pressure sensors catalyst flow sensor modules and the optional Remote Operators s Panel Ifthe optional color change sequenceris installed this power supply will also have a 5 VDC output to power the color change sequencer The optional Color Change Sequenceris a small P L C like processor that controls the flush load and color change sequences for each gun and job number Each time a job number is loaded into a gun the flush andload sequences are downloaded to this controller A color change sequence is simply a flush sequence followed by a load sequence Fluid Panels The Fluid Panels contain all of the wetted components for the RCS 2 as well as the drive motors These include e Gear Pumps e Pump Manifolds e Servo Motors e Pressure Sensors e Catalyst Flow Sensor optional e Mix Block e Spiral Mix Tube e Color Valve Stack optional e Solvent Manifold e Pump Bypass Valve The gear pumps are available in various sizes for various materials and flow rates Users should consult ITW Ransburg technical support group to determine which pumps are required for their specific application Refer to Appendix B fora list of currently available pump sizes LN 9407 00 1 RCS 2 User Manual Introduction The pump manifolds house the magnetic coupling
74. erefore within the flow limits of the pumps being used and the ratio selected the controller will continuously regulate the outbound pressure of the pumps targeting the programmed feather pressure In this mode air flow switches are not required on the handguns as the system maintains the outlet pressure to the applicators regardless as to whether or not it sees trigger signal inputs Note that air flow switches are still required if the auto reset feature is used The feather PID parameters may have to be adjusted to control how fast the pumps respond to changes in flow This directly effects how close to the target feather pressure the actual outlet pressure is maintained Feather Set Mode If a value of zero 0 is programmed as the feather pressure parameter on the Config Job screen the unit operates in feather set mode In this mode a feather set pushbutton is required to program the feather pressure This can be anormally open momentary pushbutton connected to the feather set discrete input for the gun see Appendix E or use the feather set pushbutton on the optional Remote Operator s Panel see Appendix I Also required inthis mode are air flow switches for each handgun Itis not recommended that more than 2 handguns be fed from each fluid panel as it becomes very difficult to control flow and pressure while more than 2 handguns are being triggered and feathered simultaneously Operating the unit in feather set mode inv
75. et Pressure Job 1 Job 2 aba OUTPUTS Job 8 Ei Job 10 Actual Flow Rate Motor RPM Job 20 Pressure Control Job 40 aca On all of the Force I O screens there are 3 System Spare 1 function buttons defined System Spare 2 System Spare 3 F1 Toggle On Off or Modify Force This button allows the user to toggle forces on and off If the parameter requires a numeric input a popup OUTPUTS keypad is displayed User must first use the F2 System Fault button to enable the force prior to using this key System Pulse System User Link F2 Toggle Force This button allows the user to enable or disable the particular force under the cursor A letter F in parenthesis will appear if the force is enabled next to the value in that cell Option 3 Analog Inputs and Outputs F3 Reset All This button allows the user to remove all forces for the displayed screen To reset all forces gun system and analog user must go to each of the three screens and push the F3 button F8 Plot Data This feature allows operators to generate a graph of many of the process variables to monitor the response of the system as it relates to time Up to 4 var iables from any of the configured guns can be graphed at any one time All 4 variables to be graphed do not need to be from the same gun e g The triggers of 4 guns can be graphed at the same time LN 9407 00 1 42 RCS 2 User Manual Operation The
76. f Resetting S200 DC drive fault only BUS voltage is below specified 20 VDC minimum Motor l I or l n Short Line to Line Line to Neutral or Line to PE short on the motor ouput causing an instataneous over current Output Over Current Hall Fault Valid only when drive is set to 6 Step Hall feedback operation SFD Configuration Error J3 FB 5V Short Excessive current drain on SFD 5 supply output SFD Motor Data Error Motor data in SFD is outside drive limits or is inconsistent Iru Ranshurg MOTOR AMPLIFIER LED DISPLAY FAULT CODES Fault Description Explanation and or Possible Causes AC Line voltage AC unit or DC bus power supply voltage DC unit is too high Regenative energy during deceleration is cusing the BUS to rise On AC Drives add regen resistor On S200 DC input drives external BUS capacitor is too small add capacitance On S200 DC input drives BUS voltage is too low BUS voltage is pulled down during high acceleration or loading External BUS capacitor is too small Motor power wiring short circuit line to ground neutral Motor cable short line to line Motor power cable length exceeds the data sheet specification causing excessive motor line to earth ground neutral capacitance Internal motor winding short circuit Motor L too small KIP set too large Insufficient motor inductance KIP or KII improperly set causing excessive output current overshoots Invalid configur
77. f values for this parameter is any integer from 0 min to 1000 min This is the amount of time that mixed plural component material is allowed to remain in the fluid stream after being mixed before a flush request output and error is issued by the controller Feather Pressure The allowable range of values for this parameter is any integer value from 0 psi to 255 psi This value is the pressure that will be maintained at the outlet of the pump or pumps when a gunis configured as a manual mode gun and the oper ator is feathering the spray gun See Appendix H for more details on Feather Modes Fill Volume This is the amount of material that the user wishes to flow through the pump s when the gun is placed in the volume fill mode LN 9407 00 1 RCS 2 User Manual Operation The following 8 parameters have a master channel component and a slave channel component Note the master and slave columns on the screen Both values must be programmed for plural component materials Pressure Pot Capacity The allowable range of values for this parameter is any value from 0 000 liters to 255 000 liters This value is simply the volume of material that the pressure pot will be filled with each time itis refilled There is a pot reset button on the Job Totals screen F9 that must be actuated every time a pot is filled Delta Pressure The allowable range of values for this parameter is any integer value from 0 psi to 20 psi This
78. fluid inlet pressure of the pump Actual Flow Type of Output Gun Type of Signal 0 10 VDC This outputis Oto 10 VDC outputthatis proportional to the actual flow of material coming out of the applicator 0 VDC means no flow and 10 VDC indicates 2000 cc min Therefore 3 40 VDC would indicate 680 cc min FREQUENCY INPUTS All frequency inputs are optically isolated and expect a maximum amplitude square wave of 24 VDC and a maximum frequency of 1 5 KHz Both sides of the optical isolators are accessible allowing the RCS 2 to sink or source any of the frequency signals Motor Feedback Type of Output Channel Type of Signal Frequency This signal is a square wave output from the servo motor controller indicating the actual speed of the motor that is driving the pump It is used by the firmware to determine the current flow rate of the material out of the pump It can alternately be connected to the output of a flow meter placed in the fluid stream Solvent Flowmeter Type of Output Gun Type of Signal Frequency This input allows users to connect a flowmeter in the solvent supply line and collect totalization data on solvent usage LN 9407 00 1 rruvRansburg SYSTEM INPUTS AND OUTPUTS All discrete system inputs and outputs can be configured to either sink or source current All system inputs connect to the system via the interface board Referto Appendix D to configure the jumpers on the interface board for the di
79. he halt signal for the specific channel thatis channel filling must be pulsed For example if both channels are channelfilling both halt signals must be pulsed to stop them Feather Set Type of Input Gun Type of Signal Pulsed If the gun is configured as a manual mode gun and the value zero 0 is programmed in for feather pressure under the CONFIG JOB parameters this input can be used to program the feather pressure on the fly That is if a handsprayer is painting and this input is momentarily energized the RCS 2 controller takes a snapshot of the outbound pressure of the pumps or the pressure at the optional feather pressure sensor if itis being used and then starts controlling the speed of the pumps to maintain that pressure The optional Remote Operators Panel has a pushbutton on it that allows the handsprayer to utilize this feature Refer to Appendix H for more details on feathering LN 9407 00 1 RCS 2 User Manual Installation Run Type of Input Gun Type of Signal Pulsed This signal takes a configured gun from the ready state to the run mode In order fora gunto spray it must first be put into run mode It is essentially a way of enabling a gun Energizing the trigger input of a gun will not cause fluid to flow unless the gun has first been placed in run mode Halt Fault Reset Type of Input Gun Type of Signal Pulsed This input takes a configured gun that is in run mode to the ready state essen
80. he number of pulses rev received from then motor amplifier 51 LN 9407 00 1 rm Ransburg RCS 2 User Manual Appendix APPENDIX C CHANNEL BOARD JUMPER SETTINGS Jumper Number Channel Position Function JMP1 A 1 2 All discrete channel A inputs source current 2 3 All discrete channel A inputs sink current JMP2 A 1 2 Feather pressure sensor input 0 10 volts 2 3 Feather pressure sensor input 4 20 mA 1 2 Flow rate analog input 0 10 volts 2 3 Flow rate analog input 4 20 mA 1 2 Pump outlet pressure analog input 0 10 volts 2 3 Pump outlet pressure analog input 4 20 mA JMP5 1 2 Pump inlet pressure analog input 0 10 volts 2 3 Pump inlet pressure analog input 4 20 mA JMP6 1 2 Motor speed analog output 0 10 volts 2 3 Motor speed analog output 4 20 mA 1 2 Pressure control analog output 0 10 volts 2 3 Pressure control analog output 4 20 mA 1 2 All discrete channel B inputs source current 2 3 All discrete channel B inputs sink current 1 2 Spare analog input 0 10 volts 2 3 Spare analog input 4 20 mA 1 2 Spare analog input 0 10 volts 2 3 Spare analog input 4 20 mA 1 2 Flow rate analog input 0 10 volts 2 3 Flow rate analog input 4 20 mA 1 2 Feather pressure sensor input 0 10 volts 2 3 Feather pressure sensor in put 4 20 mA 1 2 Pump inlet pressure analog input 0 10 volts 2 3 Pump inlet
81. id stand in the line NO Fluid Flow for aminimum of 60 seconds The longer you can let the fluid stand the better the accuracy and response time of the Flow Monitor System 4 Make sure the switch on the control amplifier P N 22 1046 is set to position 1 LIQUID 5 Adjust the trim potentiometer on the control amplifier until the output current displayed on the User Interface Screen is equal to 4 80mA 0 10mA NOTE gt If the current continues to vary after you adjust the pot you have not waited long enough 6 This completes the zero flow adjustment of the hardener no flow detect system 57 Iru Ranshurg User Interface Parameter Setup There are three parameters that must be programmed for this feature to work correctly Hardener Flow On This is the level in milliamps above which the hardener is considered to be flowing Hardener No Flow This is the level in milliamps below which the hardener is considered as not flowing The Hardener Flow On parameter must always be greater than the Hardener No Flowparameter Note that if the current being sensed is between the Hardener No Flownad the Hardener Flow On setpoint as long as the flow is increasing the processor will assume that hardener is flowing If the flow being sensed is between these two values and is not changing or is decreasing the processor will assume that there is no hardener flow Hardener Sample Time This is the time perio
82. igure 9 Motor Amplifier Panel Input Power 11 Added Discrete Channel and Gun Inputs new Figure 10 Gun I O Sourcing Sinking 12 Added Discrete Channel and Gun Inputs Note Times stated above are for discrete digital inputs only When interfacing using Allen Bradley s Remove l O aka RIO these times may vary significantly Refer to the RCS 2 RIO Interface Programer s Manual for more details 13 Added Discrete Channel and Gun Inputs Push Out 14 Revised Analog Inputs An analog input is jumper selectable to be 0 to 10 VDC or 4 20 mA with the exception of the hardener flow sensor which is fixed at 4 20 mA 15 Added System Inputs and Outputs new Figure 11 System I O Sourcing Sinking 16 Revised Table 1 Odd Number Channel Connections Signal Name Motor Amp Enable and Push Out Table 2 Even Numer Channel Connections Signal Name Motor Amp Enable and Push Out and Table 3 System 1 O Connections Terminal Lable changed should be CN4012 XX Operation Section 17 Added Note Note that the interface card stores the previous fault information in battery backed memory but it does not contain a real time clock Therefore the date and time of the faults are provided by the user interface PC If the unit is powered up with faults still stored in the Error Log the date and time of those faults on the Error Log Screen will either be left blank or may be random values LN 9407
83. is the target differential pressure that the controller tries to maintain across the pump Keeping the differential pressure across the pump to a minimum is essential especially with low viscosity materials If the outbound pressure of the pump is significantly higher than the inbound pressure and the pump has any significant wear itis possible for the gear teeth to slip by a small volume of material and less material will be delivered per revolution ofthe pump Ifthe inbound pressure is significantly higher than the outbound pressure then material can blow by the pump and more material than desired will be delivered The pump should essentially act as a metering device as opposed to a pumping device Minimum Inlet Fluid Pressure The allowable range of values for this parameter is any integer value from 0 psi to 200 psi This is the target pressure that the controller tries to maintain on the inlet of the pump as long as the minimum inletcontrol pressure setting is not greater than this setting 38 RCS 2 User Manual Operation 39 Minimum Inlet Control Pressure The allowable range of valuesforthis parameteris any integer value from 0 psi to 100 psi This is the minimum pressure that the E to P transducer in the motor amplifier panel will be allowed to go down to Even if the fluid pressure at the inlet of the pump is above the minimum inlet fluid pressure setpoint the control pilot pressure from the E to P tr
84. ix M Improving the Accuracy of the RCS 2 45 Removed Paint and Solvent Specifications Viscosity Conversion Chart and Volumetric Content of Hose or Tube See literature IL 307 Technical Supplement for All Products Service Manual Price 40 00 Euro 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier Telephone 800 626 3565 Fax 419 470 2040 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts ONME y ISO 9001 STAND Form No LN 9407 00 1 2009 Illinois Tool Works Inc All Rights reserved Quality Systems E Litho in U S A Q Models and specifications subject to change without notice K 12 09
85. luid from pressure pots Pump Volume per Revolution and Flow Rate Note that the channel cards in the RCS 2 do not perform closed loop control of the motor RPM based on a comparison of the desired RPM and the speed feedback from the motor amplifier The LN 9407 00 1 RCS 2 User Manual Appendix IMPROVING THE ACCURACY OF channel card commands the motor amplifier to spin the motor at the desired RPM and the motor amplifier has its own closed loop control with the motor If the motor is not able to run at the desired RPM the motor amplifier generates a fault which is then fed back to the RCS 2 channel card The RCS 2 channel card does confirm that the motor is running atthe desired RPM within the tolerance programmed on the Configure Gun screen but it does not try to compensate for over or under speed conditions by modifying the analog signal to the motor amplifier On the Configure Channel screen of the RCS 2 user interface software there is a value named Pump Size It is expressed in cc s revolution of the pump This value is normally obtained from the pump manufacturer andis accurate enough in almost all applications There are cases however especially after a pump has been used for quite some time when accuracy can be improved by modifying this value slightly The way that the RCS 2 channel card determines how fast to spin the pump is based simply on two values the target flow rate of the material and the value entered
86. m Type of Signal Pulsing This output pulses at approximately a 0 5 hertz rate as long as the processor on the interface board does not detect any on board firmware problems Users may wish to use this signal to detect when the RCS 2 controller is powered up and running System User Link Type of Output System Type of Signal Maintained This output is energized as long as the Ethernet link between the user interface PC and the interface card is functioning 23 LN 9407 00 1 Ira Ransburg RCS 2 User Manual Installation TABLE 1 ODD NUMBER CHANNEL CONNECTIONS ra nuna a enone A Signal Name Label Channel Output Wire No Wire No Wire No Wire No Fast Fill Input Channel Fill Input Feather Set Input Run Input Halt Fault Reset Input Trigger Input Motor Amp Enable Input Trigger 2 Input Trigger 3 Input Trigger 4 Input Volume Fill Input Push Out Input Fault Output hi Output Fault Output low Output Ready Output hi Output Ready Output low Output Spray Shutdown hi Output Spray Shutdown low Output Flush Request hi Output Flush Request low Output Motor On hi Output Motor On low Output Motor Amp Reset hi Output Motor Amp Reset low Output Digital Ground G N A 24 VDC N A Flow Rate Command Input Feather Pressure Input Pump Inlet Pressure Input Pump Outlet Pressure Input Spare Analog Input Input Motor Speed Output Pressure Control Output Actual Flow Output Analog Ground Motor Feedback A
87. me willtake that channel out of Channel Fill Mode and stop the pump if it was put in Channel Fill Mode from this screen If either the enter or the escape button below the channel number buttons is pushed the Channel Fill Screen will be exited and all pumps that had been put in Channel Fill Mode from this screen will stop Fast Fill This function allows the operator to fill the fluid lines as fast as possible at the ratio currently programmed for the loaded job number That is one of the two pumps will run at its maximum RPM typically 150 RPM andthe other pump will be slaved to it to deliver material at the proper ratio The software will determine which of the two pumps will run at the maximum RPM based onthe ratio setting and the two pump sizes In order to run a gun in Fast Fill Mode the gun must first be in Run Mode prior to selecting Fast Fill When the user pushes this button they are presented with a screen showing gun numbers 1 through 8 The user simply pushes the gun number that they wish to put in Fast Fill Mode Note thatthe pumps will start running immediately so make sure the applicator is triggered or either LN 9407 00 1 rrvRansburg an overpressure fault will occur or the system will fold back Any combinations of guns can be placed in Fast Fill Mode simultaneously To take a gun out of Fast Fill Mode simply push the gun number button a second time Pushing either the enter or escape button below the gun
88. min to the outlet of the fluid panel if 3 trigger inputs are energized the RCS 2 will deliver 300 cc minto the outlet of the fluid panel 32 RCS 2 User Manual Operation Default Job Number This parameter can be any integer from 1 to 199 Itindicates which job number an operator wants to automatically load into the gun upon power up of the system Mixed Volume The range of allowable volumes for this parameter is from 1 cc to 5000 cc This volume is the amount of material in the fluid lines between the mix block and the applicator or applicators It is used by the pot life timer to keep track of the age of the mixed material If the material in the applicator the ma terial that has been mixed the longest exceeds the programmed pot life of the material a flush request is issued by the RCS 2 for that gun Tolerance Percentage Allowable value for this parameter is any integer form 1 to 100 This parameter indicates how far off from the target flow rate any channel is allowed to be or how far off from the target ratio the actual ratio is allowed to be before a fault is issued by the RCS 2 controller Tolerance Volume Allowable volumes for this parameter are from 0 cc to 255 cc s This parameter indicates how often the software verifies that the actual ratio being expelled from the fluid panelis within the programmed tolerance limit of the target ratio Every time this volume of material passes out of the mix tube the
89. n DIMENSIONAL INFORMATION i SI IS T i a a o o N v gt N Mo Amplifier Panel rol H Fluid Panel d fs d ar 7 L D gt I l W k Figure 4 Stand Alone Unit TOP OF PANEL f fa INSIDE OF PANEL F y a J j L J a i r s F Ze 00908000QGOOGSOOOCOGGOO 7 E oe A b t JE LL 24 BOTTOM OF PANEL Figure 5 Motor Amplifier Panel LN 9407 00 1 14 RCS 2 User Manual Installation Ir Ransburg dea ar e y Ethernet Porls INSIDE OF PANEL a FRONT DOOR Figure 6 Control Panel Assembly 15 LN 9407 00 1 Ira Ransburg RCS 2 User Manual Installation Figure 7 Fluid Panel Assembly INPUT POWER Input power supply connections should be made i l mi froma fused disconnect With the exception of the T stand alone cart mounted RCS 2 conduit should BG be used for bringing the input power int
90. n the option of saving the data to any writable media Users are cautioned against storing them on the internal flash drive drive CA as this drive has limited space The file name that is used for the graph is based on the date and time that it is saved It is in the form of AABBCCDD bmp where AA Month BB Day of month CC Number of hours since midnight DD Minutes since last hour Data Displays At the top of the graphing screen there may be as many as 6 white boxes with data inthem The center two boxes indicate the time of the start and stop cursors start on top stop on bottom The other 4 boxes indicate the value of the graphed variable at the point where the cursors are currently positioned LN 9407 00 1 RCS 2 User Manual Operation F9 Job Totals When F9 is selected from the main screen the operator is prompted to enter a Job number Once this has been done the following screen appears Total volume usage is recorded for each Job number independent of each other The lower half of the screen shows total volumes for all jobs summed together Job totals are stored in two independent registers Daily Volume and Year to Date Volume These volumes are in no way tied to the clock or calendar they simply are two separately resetable volumes Operators may wish to use the Daily Volume as a Shift Volume and the Year to Date as a Weekly Volume etc Both volumes are incremented when material flows
91. nd Analog I O The following 3 screens allow the operator to examine all digital and analog inputs and outputs as well as force most of them for debug and troubleshooting purposes Note that there are more signals than there is room for on one screen so operator must scroll down to see additional outputs Option 1 Gun Digital Inputs and Outputs For detailed explanations for each of these inputs and outputs see the I O Descriptions in the Installation section GUNI GUNZ GUNI GUN4 GUNS GUM 6 wand aah HELP ERROR CLEAR ar aore ci eter irre al ar 03 KA ee Prime GUN CHANNEL I O INPUTS CHANT CHAN CHAR gt uNa OUNs CAN K L OMN 8 rear or for for for for lor or EC m E E FS C C or for Jor ore or _ or for C for for CC Gon a or orr or orr o or mr orr ESC rz Fy RETURN TOGGLE Ir Ransburg INPUTS Fast Fill Channel Fill Feather Set Run Halt Reset Trigger 1 Motor Amp Enable Trigger 2 Trigger 3 Trigger 4 Volume Fill Push Out OUTPUTS Gun Fault Gun Run Spray Shutdown Flush Request Motor On Gun Ready Option 2 System Inputs and Outputs LN 9407 00 1 Ira Ransburg RCS 2 User Manual Operation INPUTS INPUTS Strobe Gun 1 Flow Rate Setpoint Strobe Gun 2 Actual Flow Rate Strobe Gun 3 Motor RPM Strobe Gun 4 Solvent Flow Rate Strobe Gun 5 Hardener Flow Sensor Strobe Gun 6 Feather Pressure Strobe Gun 7 Inlet Pressure Strobe Gun 8 Outl
92. nd side of the dual purge applicator see step 2 above with the exception ofin step 5 the relays are de energized to reconnect the catalyst motor drive to channel 2 LN 9407 00 1 rrvRansburg RCS 2 User Manual Appendix APPENDIX M TRIGGER LOG A new feature has been added to the RCS 2 software package that allows the user to monitor trigger on and off times the volume sprayed in during each trigger on time and the status of four discrete digital inputs to the RCS 2 The option is accessed by selecting Function F10 Trigger Log from the main screen of the User Interface Software When you open the Trigger Log display a screen similar to this will be displayed although there will be no data present 14 00 52 14 00 49 1 30 1 30 14 00 47 1 10 1 10 1 4 1 3 1 3 14 00 44 0 60 2 10 1 5 14 00 42 0 80 1 60 1 3 14 00 39 0 30 0 50 1 1 14 00 38 1 50 2 80 1 0000 6 14 00 34 1 50 1 60 1 3 14 00 31 1 40 2 30 1 5 14 00 27 0 90 1 00 1 2 14 00 25 1 20 0 90 1 2 14 00 23 1 50 0 70 1 1 Dec 05 2000 14 00 21 0 40 0 20 1 1 mo N AND NINA NA Was Fl Stop Logging F10 mr There will be a START LOGGING function button displayed that will start logging trigger data as it occurs This button changes to a Stop Logging button when logging begins New data will be entered on the top line and the older data pushed down as new data arrives This data is live as it occurs Note that the very first trigger time On D
93. nel e Which if any forces are active LN 9407 00 1 RCS 2 User Manual Operation Setting Up A New System Notice the function buttons at the bottom of the screen Users setting up a new system should typically start configuring the system with the F1 function button and work progressively to the right one function button at a time F1 Config System Overpressure Limit This is the pressure limit of the entire system If any pressure sensor in the system reaches or exceeds this pressure a system overpressure fault is issued by the software and the pumps configured for that gun are halted This fault cannot be disabled Foldback Pressure When the outbound pressure of the pump exceeds this setting the software starts a gradual slowdown of the pumps while keeping the ratio at its proper setpoint This prevents nuisance overpressure faults when fluid pressures spike during load sequences etc It is expressed in pounds per square inch psi Sensor Limit This is the maximum pressure that the pressure sensors in the system can detect It is expressed in pounds per square inch psi 30 RCS 2 User Manual Operation 31 Horn Enable This enables or disables the horn to sound when system or gun faults occur Password Timeout This is the amount of time in minutes that the system allows a user to examine and modify password restricted parameters after the pass word has been entered This eliminate
94. nfiguration is less than 4 0 milliamps Hardener Flow On value specified in the Slave Channel Configuration is greater than 20 0 milliamps Hardener No Flow value specified in the Slave Channel Configuration is greater than Hardener Flow On value specified in the Slave Channel Configuration Any Minimum Pressure or Maximum Pressure value specified in the Channel Configuration or Feather Pressure specified in the Job Configuration exceeds the Over Pressure Limit value specified in the System Configuration Interface Card is no longer functioning Failure of the mother board backplane A firmware bug is preventing service of the SPI bus communications Afirmware bug is preventing completion of required logic in the time between timer in terrupts LN 9407 00 1 rruvRansburg RCS 2 User Manual Appendix APPENDIX K ERROR CODES Continued Error Name Batttery Low No slaves Present Interface SPI Fault Network Error XXXXX Opto 22 Failure LN 9407 00 1 Interface Card Interface Card Interface Card User Interface Computer User Interface Computer Description The battery that maintains the data 1 parameters is below the minimum operating voltage On power up the Interface Card could not communicate with any of the four 4 possible Channel Cards referred to as slaves on the Serial Peripheral Interface SPI bus The Interface Card detected
95. nly active in Run Mode Minimum Inlet Fluid Pressure The allowable range of values for this parameter is any integer from 0 psi to 200 psi This parameter allows the operator to limit the minimum pressure at the inlet to the pump for this channel If too little pressure is allowed at the inlet of the pump the pump will cavitate or have to pull fluid into it which could seriously effect its accuracy thus causing inaccurate flow rates or ratios Falling below this setpoint will cause the controller to generate an Inlet Underpressure Fault This check is only active in Run Mode LN 9407 00 1 rruvRansburg Maximum Outlet Fluid Pressure The allowable range of values for this parameter is any integer from 0 psi to 200 psi This is the maximum allowable outbound pressure for the pump Exceeding this setpoint will cause the controller to generate an Outlet Overpressure Fault This check is only active in Run Mode Minimum Outlet Fluid Pressure The allowable range of values for this parameter is any integer from 0 psi to 200 psi This is the minimum allowable outbound pressure for the pump If the outbound pressure from the pump falls below this setpoint while the gun is triggered an Outlet Underpressure Fault will be generated by the controller This check is only active in Run Mode Inlet Pressure Sensor This allows the user to enable or disable the inlet pressure sensor If the system is being operated without an inlet pres
96. nnel Card Channel Card Channel Card Description Mixed material in the applicator fluid line has remained beyond the Pot Life Time specified in the Job Configuration Either the Pump Outlet or Inlet pres sure exceeded the Over Pressure Limit specified in the System Configuration Invalid parameter enteredin either the Channel or Job Configuration No communication via the Serial Peripheral Interface SPI bus has occurred between the Interface Card and Channel Card for more than one second The timer interrupt service routine is unable to execute the required firm ware logic in the time between time interrupts Explanation and or Possible Causes 1 Mixed material has remained in the applicator fluid line beyond the Pot Life Time specified in the Job Configuration The Flow Rate Setpoint specified in the Job Configuration or via the Remote Analog Setpoint or via Remote 1 0 is not high enough to move the Mixed Volume specified in the Gun Configuration during the Pot Life Time specified in the Job Configuration Failure of the E P transducer that controls the pump inlet pressure Failure of the pressure regulator that controls the pump inlet pressure Restriction in the fluid line For Automatic guns failure of applicator trigger valve Over Pressure Limit value specified in the System Configuration is too low Hardener No Flow value specified in the Slave Channel Co
97. nstallation practices are not violated and to have your prints updated to reflect the installation accurately for future reference Cable Assemblies Interconnections between all control panels and the fluid panels are made using custom manufactured cable assemblies with military style connectors This simplifies installation and eliminates the possibility of items being wired incorrectly The one exception to this is the discrete interface I O wiring These connections will vary greatly from installation to installation This can involve well over 100 connections per control console and therefore require that conduit be runto the control console and multiple cables or wires pulled from the control console to the controlling medium PLC robot etc Equipment Grounding All panels should be grounded in accordance with either the National Electrical Code or local electrical codes whichever is more stringent Refer to the electrical installation drawings provided by ITW to locate the grounding terminal for all control panels Equipment Locations All of the panels must be located outside of the hazardous area with the exception ofthe intrinsically safe version of the Remote Operator s Panel and in some cases the fluid panel If in doubt refer to local codes and ordinances or contact your ITW representative for clarification Iru Ranshurg There are four basic panels used in the RCS 2 system e Main Control Console e Motor
98. o the control ri panel and motor amplifier panels In the case of 20 the stand alone unit SO cord will be provided with standard AC grounded plugs Both the control panel and the motor amplifier panels operate from 120 VAC at 60 Hz with a maximum current draw of 10 amps for each panel The fluid panels get their power from the motor amplifier panel and therefore require no F power connections SBS If there is the possibility of AC line voltage S fluctuations ofgreaterthan 10 ofthe line voltage a constant voltage transformer CVT should be used betweenthe fused disconnectandthe control panel and motor amplifier panels These fluctuations are commonly seen when heavy electric machinery or welding equipment is being SS Sap re CON used nearby S Figure 8 Control Panel Input Power Refer to Figures 8 and 9 to determine proper AC power and ground connections to the control IJ panel and the motor amplifier panels HS RIS ste Figure 9 Motor Amplifier Panel Input Power LN 9407 00 1 16 RCS 2 User Manual Installation 17 DISCRETE CHANNEL AND GUN INPUTS All discrete digital inputs are optically isolated and will function with an input voltage in the range of 10 VDC to 45 VDC Factory jumper settings on the interface and channel boards require that voltage be sourced to the discrete input If however a sinking inputis required inputs can be reconfigured by changing those jumpers See
99. olves the following steps 1 Zero 0 psi must be programmed for the feather pressure parameter under the Config Job screen 2 A desired flow rate for each handgun must be programmed for the parameter Target Flow under the Config Job screen 3 All handguns should be triggered simulta neously and the triggers held wide open Air flow switches must be connected to all handguns in this mode 4 Press and hold the feather set button to achieve the desired flow rate for the number of guns triggered Releasing the button records the feather pressure 5 From then on the operators can spray and feather normally Ifthe controller can achieve the target flow rate with both guns triggered without exceeding the pressure recorded in step 4 above it will do so If however the recorded pressure is reached before it reaches the target flow rate as if one or both painters are feathering then the RCS 2 controller regulates the flow by targeting the prerecorded outbound pressure If only one gun is triggered the controller tries to flow at the target flow rate for one gun unless it reaches the prerecorded outbound pressure first at which time it again controls flow by targeting the prerecorded outbound pressure LN 9407 00 1 rm Ransburg RCS 2 User Manual Appendix 6 If the spraygun tips start to become plugged or NOTES some other restriction occurs causing the actual flow to fall significantly below the targeted flow r
100. ory Setting Not applicable This is a 4 20 mA input that is normally connected to the output of a thermal shedding type flow sensor placed in the catalyst fluid stream Since the feedback from the motor tachometer can only indicate that the motor is turning and not that fluid is actually flowing this optional sensor is added to prevent spraying fluid without any catalyst Flow Rate Type of input Gun Type of signal Jumper Selectable Factory Setting 0 10 VDC This input is used if it is desired to have the ability to vary the flow rate as the unit is spraying Minimum and maximum flow rates are programmed andan external device robot PLC potentiometer etc controls the actual flow rate by varying the input between 0 and 10 volts or4 and 20 milliamps See Minimum Flow and Maximum Flow in the Operation section Feather Pressure Type of Input Gun Type of Signal Jumper Selectable Factory Setting 4 20 mA This input allows an optional pressure sensor to be placed near the spraygun Handgun operators can use this to program a set feather pressure at the inlet of the spraygun and the RCS 2 will maintain that pressure while spraying 20 RCS 2 User Manual Installation 21 Pump Inlet Pressure Type of Input Channel Type of Signal Jumper Selectable Factory Setting 4 20 mA This input is typically connected to a pressure sensor located near the input of the pump When used in conjunction with a pilot operated fluid
101. ould be metered into 1 part of resin master channel material Avalue of 65 or higher will cause only resin single component to flow The ratio tolerance bar graph the B Channel bar graph the ratio and all B Channel text are not shown on the main screen for single component ratios Flow Setpoint The allowable range of values for this parameter is any integer from 0 cc min to 10 000 cc min This is the target flow rate for the output of the fluid panel associated with this gun LN 9407 00 1 Ir Ransburg Maximum Flow The allowable range of values for this parameter is any integer from 0 cc min to 10 000 cc min When using an analog input to control the target flow rate this is the flow rate that the controller will try to maintain if the maximum voltage 10 VDC or current 20 mA is applied to the analog input Minimum Flow The allowable range of values for this parameter is any integer from 0 cc min to 10 000 cc min When using an analog input to control the target flow rate this is the flow rate that the controller will try to maintain if the minimum voltage 0 VDC or current 4 mA is applied to the analog input Bar Graph Limit The allowable range of values for this parameter is any integer from 0 cc min to 10 000 cc min This is the flow rate indicated by top of the flow rate bar graphs on the Main Screen and determines the maximum value displayed on the plot graphs Pot Life Timer The allowable range o
102. pened F12 Shutdown This function key allows the RCS 2 to perform an orderly shutdown of the Windows XP Embedded operating system The operating system stored on the flash drive drive C can be damaged if the unit is powered off with the power switch on the front door of the controller without performing this shutdown procedure first 47 Iru Ranshurg User Interface Software Buttons top of screen On the top right of the user interface screen there are 5 buttons The function of these buttons are as follows Channel Fill This function allows the operator to run any of the 8 pumps at their maximum flow rate typically 150 RPM This is typically used for flushing purposes and for rapidly getting material from acolor valve stack down to the pump priorto using Fast Fill The gun that the channel is assigned to must be in the Ready state before it will be allowed to channel fill Also Fill Enable must be set to Yes for the channel in the Config Channel parameter screen When the Channel Fill button is pushed the operator will be prompted with a display showing 8 buttons one for each channel The instant any of those buttons are pushed the pump for that channel will run at its maximum RPM typically 150 RPM Make sure the applicator is triggered prior to pushing these buttons or an overpressure fault may occur Any combinations of these buttons can be turned on simultaneously Pushing the button a second ti
103. per liter However by adjusting the Pump Size value as shown above the pulses per liter value will also be affected and should be adjusted There are two ways this can be accomplished Mathematically or experimentally Mathematically Simply divide 500 000 1000 cc s liter x 500 pulses rev by the new pump size In the case above 500000 5 58 89605 pulses liter Experimentally Zero the volume on one of the totalizer values on the Flow Totals screen of the RCS 2 then flow a random volume of material into a beaker and measure the actual volume Once again it is highly recommended that the volume be determined by weight as opposed to trying to measure it based on the fluid level in the beaker Compare the actual volume with the volume recorded on the RCS 2 Totalization screen Ifthe actual volume obtained was greater than what was displayed on the totalization screen then the Pump Pulses per Liter value is too small If the actual volume obtained was less than that displayed on the totalization screen the Pump Pulses per Liter is too large Modify the value up or down as required by the percentage they differ and retest LN 9407 00 1 rm Ransburg RCS 2 User Manual Appendix Example 300 cc s totalization screen value X 305 cc s actual volume collected 90909 current pulse per liter value New Pulse Liter value Therefore New Pulse Liter Value 305 X 90909 92424 pulses liter 300 Enter the new value for th
104. perature 63 FL V MT DT This display indicates that the 120 VAC power supply to the motor amplifier has been cycled turned off and back on This display indicates that the enable signal to the motor amplifier from the RCS 2 channel card is low or disabled This is normal when the unit is in the Ready or Halted state This display indicates that the motor amplifier has com manded the motor to turn at a certain speed but was un able to maintain that speed This usually indicates a mo tor pump or magnetic coupling that is bound up and not able to turn freely This indicates that the motor amplifer was commanded by the RCS 2 channel card to turn faster than the motor is capable of turning This typically indicates that im proper parameters have been programmed into the RCS 2 Verify parameters such as pump size calibration fac tor maximum speed and maximum flow This indicates that the motor amplifier is no longer receiv ing feedback from the resolver mounted inside of the mo tor enclosure Check the two cables running from the back of the motor to the bottom of the motor amplifier panel and the cables inside of the motor amplifier panel running from the motor amplifier to the bottom of the panel This indicates that the voltage being supplied to the mo tor amplifier is excessive Check the AC power supply voltage to the motor amplifer panel This indicates that the motor amplifier has exceeded the allowable cur
105. r PID loops that control motor amplifiers e Holds firmware for PID loops that control inlet pressure transducers The LCD touch screen display is a 15 diag onal full color LCD display with 1024 by 768 pixel resolution There is one DC power supply housed in the main control console It supplies 24 VDC for all discrete I O signals and for the boards in the control rack The ribbon cable interface boards provide easy screw terminal access to all analog and digital input and output signals They also provide specific test points to allow easy connection of test devices and data acquisition equipment The terminal strip is used for connecting AC power to the unit and for access to the 24 VDC power supply for external I O devices The terminal strip has two fuses one for the incoming AC power and one for the 24 VDC control power On the buttom of the terminal strip is a Corr Com power filter for the incoming AC On the top of the main control console there are up Iru Ranshurg to eight 26 pin military style connectors one for each channel These O connectors allow the main control console to be interfaced with the motor amplifer panel s via the 26 conductor umbilical cables Also on the top of the main control panel are two Ethernet connectors used to connect to the interface card and user interface computer Motor Amplifier Panels The Motor Amplifer Panels act as the interface between the CPU on the channel cards and th
106. r that gun occurs c AE the horn sounds if Any Error occurs on that gun even if they are not programmed to cause a spray shutdown d PLT the horn sounds if the Pot Life Timer expires e SSD PLT the horn sounds if either a spray shutdown occurs or a pot life timer expires for that gun f AE PLT the horn sounds if any gun errors occur or if the pot life timer expires LN 9407 00 1 rrvRansburg Auto Reset This allows the user to enable or disable the auto fault reset feature While enabled anytime a gun fault occurs it can be automatically reset by simply turning off the gun trigger signal and turning it back on This allows a handgun operator the ability to reset a fault without returning to a control panel Note All trigger signals for that gun must remain off for at least 0 5 second to cause a reset There are six function buttons defined for use from the Gun Parameters Screen F1 Modify This button allows the user to step through the possible options for this parameter or presents a numeric keypad if a numerical value is required F2 Previous Gun This button opens the Gun Configuration screen for the previous gun Note that any data changed on this screen prior to pushing this button will be lost if F5 Send to RCS 2 is not used F3 Next Gun This button opens the Gun Configuration screen for the next gun Note that any data changed on this screen prior to pushing this button will be los
107. rent limit for the motor This usually indi cates a motor pump or magnetic coupling that is bound up and not able to turn freely This indicates that the motor is running excessively hot Look for binding of the motor magnetic coupling or pump This indicates that the driver circuitry in the motor ampli fier has exceeded the allowable temperature for that cir cuitry This could indicate a failure in the motor amplifier itself a failure in the motor or a bound motor pump or magnetic coupling LN 9407 00 1 RCS 2 User Manual Appendix rruvRansburg APPENDIX J MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 2 DANAHER AMPLIFIER Status LED ae Blink Fault Description Explanation and or Possible Causes Control power not applied or Loose or open circuit wiring of control power input Low insufficient control power applied input voltage to control power supply No faults power stage Disabled Hardware or Software Enable inactive To enable drive apply hardware enable and set software enable Motor Over Temp Motortemperature exceeds allowed limit Drive Over Under Temp Temperature of drive heatsink chassis is outside of allowed limits Drive I t Too High The product of the drives output current multiplied by time has exceeded allowed limits If current foldback is enabled the drive peak output current automati cally reduces to 0 67 of Dipeak If foldback is not enabled the drive will fault Motor I
108. rials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and OSHA requirements RCS 2 User Manual Safety Iru Ranshurg AREA HAZARD SAFEGUARDS Tells where hazards may occur General Use and Maintenance Electrical Equipment Explosion Hazard Incompatible Materials Tells what the hazard is Improperoperation or maintenance may create a hazard Personnel must be properly trained in the use of this equipment High voltage equipmentis utilized Arcing in areas of flammable or combustible materials may occur 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 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 fire or explosion Halogenated hydrocarbonsolvents 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 ells how to avoid the hazard Personnel mustbe given training in accordance with the requirements of NFPA 33 Instructions and safety precautions must be read and unders
109. s con stantly having to re enter the password when setting up numerous parameters at the same time Interface Card Name In some cases one user interface PC is used to monitor more than one RCS 2 rack When this is done it is more convenient to give each rack aname such as Prime or Line 1 etc to easily identify which rack is being controlled by the PC When this is done it is possible for each rack effectively each interface card to be givena unique name This is done in the fms ini file on the hard drive of the user interface PC Contact ITW Ransburg s technical support department for details on how to implement this feature Interface Card IP Address This is the Ethernet IP address of the interface card that this PC is currently communicating with or trying to communicate with It can only be modified in the fms ini file on the hard drive of the user interface PC User Program IP Port This determines if this user interface PC is in read write mode or read only mode Ifthe user interface PC is using Port 3000 it isin read write mode If it is using Port 3001 it is in read only mode PC s configured in read only mode can monitor the functioning of the RCS 2 but cannot make any changes or save any data Contact ITW Ransburg s technical support department for details on how to implement this feature System Time and Date These two fields allow the user to examine and change the system time and date for the user
110. s respond acceleration and deceleration when the trigger signal changes state and when there are on the fly changes inthe requested flow rate 26 Revised F4 Config Job screen 27 Revised Delta Pressure 28 Revised F6 Cofigurer Alarms screen LN 9407 00 1 29 Revised F7 Digital and Analog I O Option 1 Gun Digital Inputs and Outputs screen Inputs and Outputs 30 Revised F7 Digital and Analog I O Option 2 System Inputs and Outputs Screen and Inputs 31 Revised F7 Digital and Analog I O Option 3 Analog Inputs and Outputs Screen and Inputs 32 Revised F7 Digital and Analog I O F8 Plot Data Setup Screen and Graphing screen 33 Revised F7 Digital and Analog I O F8 Plot Data text 34 Revised F8 Job Totals screen 35 Added Job Totals Function Keys F10 Trigger Log 36 Revised F11 Color Changer screen 37 Added F10 Save To File text 38 Added User Interface Software Buttons Top of Screen Clear Gun Faults and Gun On Off Button Appendix Section 39 Revised Appendix C Channel Board Jumper Settings Cart 40 Replaced Appendix E Channel and Gun UO Terminals 41 Revised Appendix F System I O Terminals added New Style Controllers figure 42 Revised Appendix J Motor Amplifier LED Display Fault Codes added Part 2 Danaher Amplifiers 43 Revised Appendix K Error Codes 44 Added AppendixL Pushout and Append
111. s that should be examined is the differential pressure across the pumps Ithas been found that by keeping this differential pressure to a minimum 5 psi or less the pumps act more as metering devices than pumps and this allows them to be extremely accurate Ifthe inlet pressure is too high the material will tend to blow by the pump gears slippage and more material than desired will pass through the pump If the inlet pressure is too low the pump may be starved and cavitate thus delivering too low of a volume of material Cavitation is rarely a problemas long as the supply tubing is of adequate size The software in the RCS 2 is designed to automatically control this differential pressure as long as pressure transducers are installed at both the inlet and outlet of the pumps and pilot operated fluid regulators such as the ITW Ransburg DR 1 are provided on the inlets ofthe pumps The air pilots must be controlled by the voltage to pressure transducers in the RCS 2 motor amplifier panel Since the outbound pressure of the pumps varies based on fluid flow rate fluid viscosity hose lengths hose diameters applicator orifices etc the inlet pressure must be dynamic as well Note that slippage is rarely a problem if the viscosity of the material is 25 cps or greater and cavitation issues can be minimized by insuring that the fluid delivery tubing is of adequate size Inlet fluid regulators are seldom required when supplying f
112. s which tie the servo motors to the gear pumps The servo motors actually house both an AC drive servo motor and a feedback resolver in the same physical housing They get their drive signals from the motor drive amplifiers and the resolvers feed their rotational information back to the motor drive amplifiers Explosion proof servo motors are available as an option The pressure sensors convert the fluid pressure from the fluid inlet and outlet of the pumps to a4 to 20 mA signal which is then fed through the zener barriers and back to the channel boards in the control rack Standard units have a pressure range of 0 psi to 200 psi The catalyst flow sensor is a thermal shedding type flow sensor that is immersed in the catalyst flow stream It detects flow by heating the sensor and then sensing how much of the heat is being removed from the sensor by the flow of catalyst More flow more heat removed from the sensor head An optional explosion proof version of this sensor is available for use in hazardous areas The Mix Block is a three port manifold that brings the fluid from the outlet of the resin pump together with the outlet of the catalyst pump The block houses a check valve in the catalyst stream to prevent resin from backing up into the catalyst flow stream Attached to the bottom of the Mix Block is a solvent flush valve for quick flushing of only the mixed material from the Mix Block out to the applicator Attached to
113. sabled during operation Frequent power supply shutdown indicates a problem in the system requiring correction RCS 2 User Manual Safety SAFEGUARDS Tells how to avoid the hazard 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 flushing or maintenance When using solvents for cleaning Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100 F 37 8 C Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA and local 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 Testing may require high voltage to be on but only as instructed Non factory replacement parts or unauthorized equipment modifications may cause fire or injury If used the key switch bypass is intended for use only during set up operations Production should never be done with safety interlocks disabled Never use equipment intended for use in waterborne installations to spray solvent based mate
114. screte system inputs To source current or voltage from the system outputs simply connect the positive terminal of the desired output to the positive terminal of a power supply 10 VDC to 40 VDC and the negative terminal of the desired output to the positive input of the device The negative input to the device must be grounded to the aforementioned power supply To sink current on the interface board simply connect the negative output terminal of the desired output to ground the positive output terminal to the negative input to the device andthe positive input to the device to the positive terminal of the appropriate power supply System 1 0 Connection Board System 1 0 Connection Board Figure 12 System I O Sourcing Sinking LN 9407 00 1 RCS 2 User Manual Installation System Inputs Gun Strobe Type of Input Gun Type of Signal Pulsed This input signal is used in coordination with the Job Number inputs see below When this input is taken from the non energized state to the energized state for any gun the Job Number that is appearing at the Job Number inputs is loaded intothe job queue Ifthe gun is inthe halted ready or faulted state the new job becomes active immediately Ifthe gunisinarun state the new job number is held in the queue until the next time the gunis halted or faults Note that the job queue is only one in length If another job is loaded on top of one already inthe queue the new one o
115. sk that contains a Windows XP Embedded operating system and the RCS 2 user interface software It has an on board Ethernet port to allow interface with the interface card The computer has USB ports for updating its software and forbacking up parameter data Keyboard and mouse ports are also available on the unit for setup diagnostics and troubleshooting if necessary The control card rack is a half width 19 rack with space for one RIO card one interface card and up to four channel cards ltis powered from 24 VDC and utilizes up to 9 ribbon cable connections if all 8 channels are used High speed communications between cards is accomplished using a Motorola SPI bus RCS 2 User Manual Introduction The interface card houses a Rabbit 2000 embedded processor This board performs the following functions e It handles all communications between the user interface computer and the chan nel cards e It stores all parameter data in battery backed RAM e Has an Ethernet port used to communi cate with the user interface PC and the color change sequencer e Handles all discrete system I O job num ber inputs strobe inputs system fault out puts etc Each channel card houses a Motorola MC68HC16 embedded processor These boards perform the following funtions e Controls all gun and channel specific dis crete inputs and outputs e Controls all gun and channel specific ana log inputs and outputs e Holds firmware fo
116. ssing the GUN number again or pushing the ESC button This is the same as supplying an external FAST FILL input signals See Discrete Inputs Fast Fill in the Installation section for details on the fast fill mode Note that the pumps will start running the instant the gun number is pushed LN 9407 00 1 rruvRansburg CHANNEL FILL The CHANNEL FILL button causes a pop up box to appear on the current screen Any CHANNEL can be manually placedin CHANNEL FILLMODE by simply pressing the number for the desired CHANNEL The mode is deactivated by pressing the CHANNEL number again or by pushing the ESC button This is the same as supplying an external CHANNEL FILL input signal See Discrete Inputs Channel Fill inthe Installation section for details on the channel fill mode Note that the motor will start running the instant the channel number is pushed HELP The HELP button can be pressed at anytime It will provide more detailed help for the current active screen CLEAR GUN FAULTS Pressing this button will immediately clear any faults reported by the controller regardless of the current screen Ifthe fault resulted in the stoppage of fluid then a GUN RUN signal is required to start flow again Enter the ERROR LOG screen to view the error that occurred Pot life faults can only be cleared by evacuating the volume of fluid as determined by the Mixed Volume parameter located inthe GUN CONFIGURATION screen Pressing
117. sure sensor this must be disabled or a fault will occur NOTE K When this is disabled closed loop control of the inlet pressure of the pump is also disabled Foldback PID Loop The PID parameters for foldback control how fast the motors respond when they enter foldback mode but they also control how fast the motors respond acceleration and deceleration when the trigger signal changes state and when there are on the fly changes in the requested flow rate Foldback Pressure Kp The allowable range of values for this parameter is any integer from 0 to 65 535 It has no units This allows the operator to control the proportional gain for the foldback PID loop LN 9407 00 1 RCS 2 User Manual Operation Foldback Pressure Ki The allowable range of values for this parameter is any integer from 0 to 65 535 It has no units This allows the operator to control the integral gain for the foldback PID loop Foldback Pressure Kd The allowable range of values for this parameter is any integer from 0 to 65 535 It is expressed in PSI This allows the operator to control the derivative gain for the foldback PID loop Foldback Pressure Deadband The allowable range of values for this parameter is any integer from 0 to 65 535 Itis expressed in psi This allows the operator to control the deadband for the foldback PID loop Feather Pressure Kp The allowable range of values for this parameter is any integer from 0 to 65 535
118. t if F5 Send to RCS 2 is not used F5 Send to RCS 2 This button takes the data displayed onthe current screen and sends it to the interface card where it is then stored in non volatile memory Any changes made to the parameters on this screen will be lost if the screen is exited prior to sending it to the interface card using this button F9 Read in File This button allows operators to load the parameters contained on this screen from a floppy disk internal flash memory USB memory or CDRom They are stored in a file named gunconfig par LN 9407 00 1 RCS 2 User Manual Operation F10 Save to File This button allows oeprators to save the parameters on this screen to a floppy disk internal flash memory USB memory or CDROM They are stored in a file named gun config par F3 Config Channel When F3 is selected from the Main Screen the operator willbe prompted to select the gun number they wish to examine or edit parameters for and if it is a two channel gun whether they wish to access the master or the slave channel for that gun Atthattime the following screen will appear Fill Enable Allowable settings for this parameter are Yes or No This parameter allows the operator to enable or disable the channel fill button on the top of the Main Screen This allows a supervisor to prevent a gun from being put into channel fill mode without the operator knowing the password This prevents an
119. t to the interface card F8 Save to all files This function reads all parameter data currently stored in non volatile memory on the interface card and stores it on the media selected by the user internal flash floppy drive USB memory or CDROM This includes System Gun Channel Job Alarms Totals and Color Change parameters This differs from the F10 save function in that F10 saves only the data displayed on the current System Parameter Screen LN 9407 00 1 mrvRansburg F9 Read in File This button allows operators to load the system parameters from any media They are stored in a file named system par F10 Save to File This button allows operators to save the parameters on this screen to any writeable media They are stored in a file named system par F2 Config Gun When F2 is selected from the main screen the operator will be prompted to select the gun number they wish to create or modify the parameters for Once a gun number is selected the following screen will appear Mode This parameter has three possible settings OFF AUTO and MANUAL OFF This setting completely disables the gun removes its data from the main screen and places the channels tied to this gun available for use by another gun AUTO This setting is used when the user wishes to control the flow rate of the applicator If this is to be a 2 channel gun it also controls the ratio of the two materials LN 9407 00 1
120. temporarily program the system for no shutdown on hardener flow loss This will allow the motor to continue to run and provide a good indication of fluid noise at the no flow condition Observe the output current level under these conditions and program the no flow level to approximately 0 5 mA above the peak current level measured Best system performance will vary depending upon the system and setup accuracy LN 9407 00 1 RCS 2 User Manual Appendix NOTE The above should only be used as a guide the final parameters forthe Harden er flow Monitoring system will vary with the requirements for each individual system and they will be the final determining fac tors of these parameters gt Remember to reprogram the system to shut down on Hardener Flow Loss after completing this setup if required 58 RCS 2 User Manual Appendix 59 Iru Ranshurg APPENDIX H FEATHERING When a gun is configured as a manual mode gun the operator has two possible ways of operating the system When in manual mode it is assumed that handguns are being used Pressure Pot Mode If a value greater than zero 0 is programmed in for the feather pressure parameter on the Config Job screen the unit simulates a pressure pot set to the programmed feather pressure Thatis it controls the outbound pressure of the pumps such that the greater pressure of the two resin or catalyst always equals the programmed feather pressure Th
121. the system will execute a flush sequence followed by a load sequence Purge Purged This is an amber illuminated pushbutton When pushed a purge sequence is initiated as programmed from the Purge user interface screen While the purge sequence is occurring this indicator lamp flashes It remains on solid when the purge sequence is complete indicating to the operator thatthe purge is complete This indicator will be turned off if a Paint Solvent Fill sequence has been initiated or a color is loaded NOTE gt If both the green Paint Solvent Fill Filled lamp and the amber Purge Purged lamps are flashing simultaneously this indicates that no sequence has been down loaded to the color change sequencer since the last time power was applied to the system This can be corrected by loading ajob from the user interface screen LN 9407 00 1 rrvRansburg Horn In the top center of the panel is a horn that indicates when the RCS 2 controller has turned on the Spray Shutdown output for the gun Total Flow This is an LCD display that indicates the current flow rate out of the applicator or applicators if multiple applicators are fed from one fluid panel It operates from an analog output signal from the RCS 2 controller with O VDC being 0 cc s min and 10 VDC scaled to be 2000 cc s min Flow Control This is a potentiometer that varies the analog flow control voltage into the RCS 2 channel car
122. tially disabling the gun from spraying It also resets a fault for the gun if it is in the faulted state Trigger 1 Type of Input Gun Type of Signal Maintained This input tells the controller to run the pumps if and only if the gun has first been placed in run mode Motor Amp Enable Type of Input Channel Type of Signal Maintained This is an input to the controller from the motor amplifier indicating that the motor amplifier has been enabled by the channel card and that there are no problems Triggers 2 3 and 4 Type of Input Gun Type of Signal Maintained These signals are additional trigger input signals They would be used in cases where the output of a fluid panel was split between multiple applicators They work in conjunction with the trigger 1 input to allow up to 4 independenttriggers one for each of 4 applicators The software can be configured in such a way thatif one of these inputs is on the fluid panel delivers the target flow rate of material If a second input is turned on then the fluid panel will deliver twice the target flow rate If a third input is energized three times the target flow is delivered and if all four inputs are energized the fluid panel 18 RCS 2 User Manual Installation 19 will deliver four times the target flow rate It is assumed that each of these inputs are also connectedtothetriggerinputs onfourindependent applicators Volume Fill Type of input Gun Type of signal
123. tis used by the channel board to determine flow status The program inthe channel board determines whether there is flow or no flow by checking the slope of the analog signal and by checking the programmable flow no flow levels The program also allows for the adjustment of the flow on and the no flow levels via parameters inthe user interface software Also to allow for the delay inthe thermal sensor signal a programmable time delay is available to prevent nuisance faults DESCRIPTION AND OPERATION SPECIFICATIONS Input Power Requirements The FLOW MONITOR control system used to Voltage 24vdc 10 detect no flow in the hardener fluid system consists Current 80ma maximum of three components a sensor the control amplifier and the analog output amplifier The Ambient Temperature Range 0 55 C sensor is a thermal shedding type that uses the principle of thermal conductivity The temperature Compensated Fluid compensated sensing head is inserted into the Temperature Range 25 to 80 C fluid stream via a manifold and is heated up a few degrees higher than the medium The control Minimum Flow Rate 20cc s min amplifier provides all of the necessary electronics to provide heater current temperature comp Operating Flow Rate Range 20 600cc min ensation level adjustment forthe sensor anda low level analog output signal which is a function of Analog Output Signal 4 20ma flow The third component is the analog output
124. tood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping Reference OSHA NFPA 33 and your insurance company require ments The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas Refer to NFPA 33 Turn the power supply OFF before 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 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 flushing 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 material supplier Any other type of solvent may be used with aluminum equipment LN 9407 00 1 Ir Ransburg RCS 2 User Manual Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Certain materialmay be harmf
125. ulif Follow the requirements of the Material Safety Data inhaled or if there is contact with Sheet supplied by coating material manufacturer the skin 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 Spray Area There is a high voltage device Parts being sprayed must be supported on conveyors High Voltage thatcaninduceanelectricalcharge or hangers and be grounded The resistance between Equipment on objects which is capable of the part and ground must not exceed 1 megohm igniting coating mater ials Reference NFPA 33 Inadequate grounding will cause All electrically conductive objects in the spray area a spark hazard A spark can with the exception of those objects required by the ignite many coating materials and process to be at high voltage must be grounded cause a fire or explosion Any person working in the spray area must be grounded Unless specifically approved for use in hazardous locations the powersupply and other electrical control equipment must not be used in Class 1 Division 1 or 2 locations Personnel Safety The bell atomizer can rotate at Personnel must stay clear of the bell whenever it is
126. um Pressure value specified the pump inlet pressure inthe Channel configuration Failure of the pressure regulator that controls the pump inlet pressure Maximum Inlet Pressure value specified in the Channel Configuration is too low Output Channel Pump outlet pressure is below the Pump is not turning Under Card Minimum Pressure value specified in 2 Material is not available at pump inlet Pressure the Channel Configuration Failure of pump outlet pressure sensor Minimum Outlet Pressure value specified in the Channel Configuation is too high Output Channel Pump outlet pressure is above the Restriction in the fluid line Over Card Maximum Pressure value specified For Autmatic guns failure of applicator Pressure inthe Channel Configuration trigger valve Maximum Outlet pressure value specified in the Channel Configuration is too low Flow Rate Channel The difference between the Loss of feedback signal from motor amplifier Out of Card commanded flow rate RPM of the or flow meter Tolerance pump and the actual flow rate Incorrect Calibration Factor in Channel measured from the feedback signal Configuration exceeds 2 times the Flow Rate Ratio Tolerance Percentage value specified in the Gun Configuration Hardener Channel The electrical current from the There is no hardener flow due to the pump Flow Loss Card Hardener Flow sensor is less than not operating or an obstruction in the 1 milliamp hardener fluid
127. verwrites the older one in the queue Job Number 1 2 4 8 10 20 40 80 100 Type of Input System Type of Signal Maintained These inputs are simple BCD binary coded decimal inputs that represent the job number that an external controller energizes to load new job numbers into the RCS 2 guns Note that these inputs are common toall guns and they are ignored until one or more of the Gun Strobe inputs is energized Allowable job number range from 1 to 199 System Outputs System Fault Type of Output System Type of Signal Maintained This output is normally connected to the horn inthe top of the control console It can be energized anytime there is a system fault It can be enabled and disabled on the CONFIG SYSTEM screen Some examples of system faults are problems with the disk drive hard drive or CDROM of the user interface PC Also certain problems with the interface board or RIO board if used may cause a system fault This output can also be programmed to energize when any of the guns fault This is done on the CONFIG GUN screens Each gun can be configured to cause the horn to sound when it 22 RCS 2 User Manual Installation Ir Ransburg faults independent of each other Note that the NOTES horn must be enabled on the CONFIG SYSTEM screen or the horn will not sound for gun faults regardless of whether or not they are configured to do so on the CONFIG GUN screens System Pulse Type of Output Syste
128. well that occurs after the Start Logging buttonis pushed will not be displayed This is because the software does not start timing until the first on to off transition occurs as the Off Dwell time is always captured first Scrolling down to examine data that has scrolled off of the bottom of the screen is a problem while data is being captured because every time a new trigger event occurs the scroll bar will return to the top newest entry This is controlled externally by the Windows operating system Once the LN 9407 00 1 logging is stopped with the STOP LOGGING function button the user may easily scroll down to look at the older events There is also a SAVE to FILE function button to create a CSV file of the logged events using Excel or any other spreadsheet program capable of displaying CSV files The first column of data is the date that the trigger occurred obtained from the real time clock in the PC running the User Interface Software The second column of data is the time that the trigger occurred obtained from the real time clock in the PC running the User Interface Software The third column shows the amount of time in seconds that the trigger signal s remained in the off state Trigger Off Condition Off Dwell Channel A Triggers 1 through 4 must all be off The fourth column shows the amount of time in seconds that the trigger s were energized on Trigger On Condition On Dwell Any time Chann

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