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LN-9408-06.1 RCS-2 Parts, Maint

1. 29 2 Z i 59 y 7 A Figure 6b New Style Motor Amplifier Panel 25 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID NEW STYLE MOTOR AMPLIFIER PANEL PARTS LIST Figure 6b tema Desorption 1 A1079500 Ethernet industrialBulkheadW RJ 45 Connector 1 2 107800 EthernetCable NotShown 1 3 106459 26 Socket Bulkhead Assembly W Flying Leads ____ 1 4 1056410 26 Socket Bulkhead Assembly W Flyng Leads 1 2 25 5 5 2 2 le Power Supply 5VDC amp 24VDC 180 W 78835 01 Power Supply 24VDC 180 W 8 TR SSEH472 AGC 10 10AmpFuse 1 e BREL a Ee EE eee eS 13 221046 FlowMonitorControlUnit_ 1 14 221245 ZenerBamerfor4 20mA 4 15 7864300 Transducer Assembly EtoP 2 16 41 VSO 1005 24VDCSolenoidValve Assembly 20 1078 00 Opto 22DCOutputModule 9 21 1222000 Cable DanaherS200 AKM 33 1 2 22 A1079600 Bulkhead Connector 4 Pin Amphenol 4 23 106600 4
2. Ransburg NOTE ALI Figure 8a 31 CEPT B FLUID LINES ARE 3 E JTLET O BALL VALVE Fluid Panel Assembly Front LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID Figure 8b Fluid Panel Assembly Back LN 9408 06 1 32 RCS 2 Parts Maintenance Troubleshooting Parts ID FLUID PANEL ASSEMBLY PARTS LIST Figures 8a amp 8b ftom Tran Ty 3 16 ID X 5 16 OD Teflon Tubing Connector Swivel 3 8 NPS X 3 16 ID Hose 6 22963 FlushableColorPumpManifold 3 8 NPS F X 3 8 OD Tube 90 Elbow 8 77639 00 1 8 NPT M X 3 8 NPS M Nipple 0 O 210 qe ee o O EE 3 8 ODT X 1 4 NPT F Fitting Stainless Steel 12 776900 Pilot Operated Ball CEC 13 7767100 Ball Valve Stainless 5 LL 1 8 Stem Table Table Y P 23 A1198920 Solvent Manifold Assembly Nipple 3 8 NPSM X 3 8 NPT DM 2 Hex Head Bolt 5 16 18 X 3 4 L Cadium Plated 0801 26 55452 0 5 16 Stainless 8 k 0 1 Fitting Elbow 5 32 ODT X 1 8 NPT M 1 4 20 X 625 L Stainless Steel HHCS Table WX 1 38 77485 00 1 4 20 Nut Stainless Steel Table WX J 40 7840
3. 50 CHANNEL BOARD BLOCK 51 INTERFACE BOARD BLOCK DIAGRAM 55555 52 INTERCONNECT CHART FOR CHANNELS 1 3 5 AND 7 2240 etm t ania 53 INTERCONNECT CHART FOR CHANNELS 2 4 6 AND 54 INTERCONNECT CHART FOR SYSTEM VO SIGNALS rata t ea tenui 55 ODD NUMBERED CHANNEL UMBILICAL CORD 5 56 EVEN NUMBERED CHANNEL UMBILICAL CORD SIGNALS 57 Continued On Next Page LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Contents RCS 2 Parts Maintenance Troubleshooting Contents Ransburg CONTENTS Continued PAGE WARRANTY POLICIES 58 58 APPENDIX 60 93 APPENDIX A UPDATING THE FIRMWARE AND SOFTWARE ON 84 60 65 APPENDIX B ERROR LOG CHART ttt tnter ttti 66 68 APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 1 AND 2 69 72 APPENDIX D CALIBRATING THE PRESSURE TRANSDUCERS PART 1 AND 3 73 74 APPENDIX E RECOMMENDED SPARE PARTS 75 78 APPENDIX SYSTEM LAYOUT 79 APPENDIX SCHEMATICR 80 93 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Contents LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Safety SAFETY SAFETY PRECAUTIONS Before ope
4. 13538 LINYA ver NONWOD 20 NOWWOO 20 1 decus dNV1 031104 NNO pool FT wen 04135 073 gt i ag L DENN L 1 Alana 88891 5 Pian 1 TZ 1 jeg 1 OUS S IT Cg gt os 19V le UR E M 11 21 al IVNL V Z NI 90 NI 90 vZ ad x 3114 NYOH 1 20 19 13838 1 2 lsz gt rine 1 a d 158 HIV34 tc 1 0 123135 80100 2 los 1531 AVHdS ZE 1531 Aude al AQv3u Nns ad NNO It 2 las 5 1 3 ow 0800006000006000 LN 9408 06 1 600006066066066088 9 988080 91 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued REMOTE OPERATOR PANEL SCHEMATIC z 55 lt n 09602080020 LN 9408 06 1 92 RCS 2 Parts Maintenance Troubleshooting Appendix rrRansburg APPENDIX SCHEMATICS Continued FLUID PANEL SCHEMATIC Ki gt 201 93 L
5. 3 Non Explosion Proof Kollmorgan Motor Explosion Proof Kollmorgan Motor Non Explosion Proof Danaher Motor a 75025 1 4 20 X 7 8 L SHCS Washer tie 6 2258 Key gt O o 8 7817800 ____ Set Screw 1 4 28 Cup Pt o 787500 PinSpirdl 5764 X 34 10 22868 OuterPoleRingAssembly f T 3i 755448 08 _ i2 228 5 BeangHoumg O 13 22854 22945 CouplingHousingAssemby 1 ae e pu m 3S WSNCGH Same 1 1 1 O Ring 7 Ring EE ee These items differ based on desired pump size We LN 9408 06 1 38 rrRansburg RCS 2 Parts Maintenance Troubleshooting Parts ID Flushable Pump Manifold Assembly Figure 10 LN 9408 06 1 39 RCS 2 Parts Maintenance Troubleshooting Parts ID FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS LIST Figure 10 em amp Description 1 22337 Bypass Valve Assembly II 2 2336 ORng amp a 4 FusnbiePumpAssemby 1 38 16 X 15 L SHCS er 6 22905 Manifold Assembly HE 3 8 NPS M X 3 4 16 Stainless Steel Adapter Fitting 2 8 22333 _11 16 X 0 070 O Ring o 9 osm 1 i0
6. LN 9408 06 1 34 RCS 2 Parts Maintenance Troubleshooting Parts ID TABLE V CATALYST AR PUMPS iT Ransburg po __ NoPumpinciuded o RE e 6 1 77844 04 Pump Kit RCS 2 92 CC REV M2 Tool Steel TABLE WX COLOR VALVE STACK TABULATION No No Color Valve Stack Installed Valve Stack Installed NE AL 04 11 4 f 8 1 5104 1 4 Color CCV Stack Assembly W Solvent Air Push 06 1 4 8 8 1 5106 111 6 Color CCV Stack Assembly W Solvent Air Push 08 114 8 8 1 CCV 5108 111 8 Color CCV Stack Assembly W Solvent Air Push 1 4 8 8 1 CCV 5110 111 10 Color CCV Stack Assembly W Solvent Air Push TABLE Y CATALYST FLOW SENSOR TABULATION 0 0 2 NoFlowSensor TABLE 2 CATALYST INLET PRESSURE TRANSDUCER TABULATION 3 3 3 NoPressureSensor Cd f no catalyst pump is used S 2 and T 2 35 LN 9408 06 1 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID NOTES 36 RCS 2 Parts Maintenance Troubleshooting Parts ID rrRansburg Figure 9 Non Flushable Pump Manifold Assembly 37 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID NON FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS LIST Figure 9 tem Description 1 7959 34 4 20 14 6 6668 24
7. nsburg SERVICE MANUAL LN 9408 06 1 Replaces LN 9408 06 November 2009 RCS 2 PARTS MAINTENANCE AND TROUBLESHOOTING t MODELS A10549 Control Console A10776 Motor Amplifier Panel A10948 Fluid Panel 11095 Remote Operator s 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 iT Ransburg NOTE This service manual has been superceded from service manual number LN 9408 06 to service manual number LN 9408 06 1 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9408 06 1 iT Ransburg CONTENTS PAGE SAFETY 1 4 e RE AT aa tess 1 opp Ma nh Pr 2 4 5 19 ELECTRICAL CONTROL PAINE nie imer tun 5 6 etcetera 6 8 RESIN FLUSHABLE PUMP ASSEMBLY PARTS 9 10 ASSEMBLY 22 337 PUMP BYPASS PARTS LIST trier terreni 10 11 CATALYST NON FLUSHABLE PUMP ASSEMBLY PARTS 13 15
8. 1 24 221045 FlowSensorCableAssemby 1 1 4 ODT Bulkhead 5 Used only if the optional Color Change Sequencer is installed Used only if the optional Color Change Sequencer is not installed LN 9408 06 1 26 RCS 2 Parts Maintenance Troubleshooting Parts ID MOTOR AMPLIFIER PANEL MODEL IDENTIFICATION When ordering use A10776 ABCDEF as indicated below 10776 ABCDEF Basic Part Number Number of Motor Amps 1 2 Color Change 0 1 Yes Number of E to P Transducers 0 1 or 2 27 0 1 0 No 1 Yes ir Ransburg Intrinsically Safe Remote Operator Intrinsically Safe eS Pressure Transducers Catalyst Flow Sensor Electronics LN 9408 06 1 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID NOTES 28 RCS 2 Parts Maintenance Troubleshooting Parts ID Ransburg E 6 Figure 7 Remote Operator s Panel 29 LN 9408 06 1 LN 9408 06 1 iT Ransburg REMOTE OPERATOR S PANEL PARTS LIST Figure 7 en ran Tessier 1 1079 00 Enclosure Details RCS 2RemoteOperatorsPanel 1 Snn o
9. PipePug 4 20 6664 Retaining Ring 5101 37 Bowded External 2 55 2235 Seal Solvent inlet Por Teflon 2 56 22644 ScewMBXi i mmlog amp 773000 NamePMe SS 1 Ratio is controlled based on pump sizes cc s rev and the size of the 2 drive pulleys 43 LN 9408 06 1 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID NOTES 44 RCS 2 Parts Maintenance Troubleshooting Parts ID fo 2 Ki Figure 12 77671 00 5 Way Ball Valve Assembly 45 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID 77671 00 5 WAY BALL VALVE ASSEMBLY PARTS LIST Figure 12 Mem 4 Description 1 __ 20317 10 32 1 2 5 8 4 2 78550 Housing 0 1 O Ring 1 8 ID X 1 4 OD JL 5 204600 4 6 755436 8 755409 O Ring 3 8 ID X 1 2 OD ___1 9 79500 Stem 7554 07 __ 1414 11 203467 OR 122 12 7865800 Gasket 2046 7 8832X12 LSHCOS 1 2 O 14 78900000 Housing 141 8 32 X 3 8 L SHCS 16 7896500 RetanerPlate 1 __ 19 78951 00 me 79204 00 LN 9408 06 1 46 RCS 2 Parts Maintenance Tro
10. AREA HAZARD SAFEGUARDS Tells where hazards may occur General Use and Maintenance Electrical Equipment Explosion Hazard Incompatible Materials Tells what the hazard is Improperoperation ormaintenance may create a hazard Personnel mustbe 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 must be given training in accordance with the requirements of NFPA 33 Instructions and safety precautions mustbe read and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping
11. Temperaturesinside ofthe main control console run significantly above ambient Ifitis expected that the ambient temperature will exceed 100 F some form of external cooling will be required Contact ITW Ransburg for suggested methods There are several different versions of the touchscreen PC used in the RCS 2 but all of them employ cooling fans and air vents On some of them fans are visible on the outside frame of the computer and on others they internal to the PC Periodically check to make sure the fans are running and vent holes are not blocked by dust or other obstructions Motor Amplifier Panels There is minimal routine maintenance necessary onthe motor amplifier panels The only items inthe motor amplifier panel that have moving parts are the power relay the solenoid valves and the E to P transducers The later two items are optional Note that the E to P transducers also have small in line filters P N SSM 5504 on their inlet ports that may need periodic replacement depending on the quality of the air being delivered to the panel Similarto the aforementioned main control console there are a few things to keep in mind to help extend the lives of the components in the motor amplifier panels e Keep the door closed at all times to keep dust dirt and moisture out of the control panel Because the motor amplifiers can dissipate a significant amount of heat temperatures
12. 285 O Ring Sei Check Valve O JP 4 gt 2280 ORmg i8 2295 InerPoleRigAssemby 1 4 2294 CoupigHousngAssemby 1 16 7730500 NamePleteW SeralNumber 18 7620 6 MeXi Xi mmLHHCS O 1 22868 Outer Pole Ring Assembly T k Set Screw 1 4728 Cup Pt 24 781790 Pin Spiro se xa 2557 26 55450500 Lock Washer 28 22 1047 Non Explosion Proof Kollmorgan Motor 22 547 Explosion Proof Kollmorgan Motor 22 1047 2 Non Explosion Proof Danaher Motor SS 1505 CD Lock Washer 1 4 7959 34C 1 4 20 X 1 1 16 L SHCS These items differ based on desired pump size LN 9408 06 1 40 agent WU 20 ZE G Ransburg 15 SIHL T RCS 2 Parts Maintenance Troubleshooting Parts ID Dual Headed Pump Assembly Figure 11 LN 9408 06 1 41 RCS 2 Parts Maintenance Troubleshooting Parts ID DUAL HEADED PUMP ASSEMBLY PARTS LIST Figure 11 Mem Description 1 22 1302 Non Explosion Proof Motor A11797 00 Explosion Proof Motor 2 1 4 20 UNC X 1 1 16 L SHCS For Use With Non Explosion Proof Motor 5 16 18 UNC X 7 8 L SHCS For Use With Explosion Proof Motor 3 1 4 Lock Washer For U
13. 7 221108 PowerLineFilter 1 OE 8 55 4 2 AGC 10 10AmpFuse_ 12 14 10781 00 Special Signal Inverting Terminal Block 22 1050 Flow Switch Amplifier 22 1046 Flow Monitor Control Unit 78643 00 Transducer Assembly E to P 41 VSO 1005 24VDC Solenoid Valve Assembl 2 10785 01 2 10787 00 Opto 22DCOutputModule 9 Tachometer Bulkhead Cable Assembly RCS 2 Motor Amp Panel 41 FBH 1000 1 4 ODT Bulkhead 41 1001 3 8 ODT Bulkhead A10789 00 Motor Drive Bulkhead Cable Assembly RCS 2 Motor Amp Panel A10974 00 26 Socket Bulkhead Assembly Bm Used only if the optional Color Change Sequencer is installed Used only if the optional Color Change Sequencer is not installed Refer to Motor Amplifier Panel Model Identification for quantities L9 fi 0 12 1 LN 9408 06 1 24 RCS 2 Parts Maintenance Troubleshooting Parts ID rrRansburg N 0 9 T 209 ZE o 18 3 4
14. 2 center plate 7 and rear plate 9 NOTE If an arbor press is unavailable an alternate disassembly method is to par tially back off the cap screws and tap the screws with a soft head hammer With the screw heads exposed continue to alter nate backing out the screws and tapping the screws until the plates are free A CAUTION LN 9408 06 1 5 Separate front plate 2 from center plate 7 6 Separate center plate 7 from rear plate 9 7 Remove rear plate 9 8 Remove driving gear 6 from center plate 7 9 Remove driven gear 4 from center plate 7 10 Remove arbor 3 from driven gear 4 Non Flushable Gear Pump Reassembly Before reassembling the gear pump clean and inspect all parts for damage or wear To Assemble 1 If parts were separated use a press to press arbor 3 into front side plate 2 2 Insert driven gear 4 into center plate 7 Manually turn the gear to ensure it moves freely gt Ifthe gear binds it could damage the pump Determine the cause of the binding Nicks burrs or foreign parti cles can cause pump binding 3 Insert driving gear 6 into center plate 7 Manually turn the gear to ensure it moves freely 4 Assemble rear 9 center 7 and front 2 plates 5 Using an arbor press press fit two 2 dowels 8 into the plate assembly 6 Lubricate cap screws 10 and 11 with petroleum jelly 7 Insert cap screws 10 and 11 into rear
15. Analog Ground N A 30C 30C A G Pump Outlet Pressure Input 5B 5B 31A Analog Ground N A 30C 30C A G Spare Analog Input Input 6B 6B 32A Analog Ground N A 30C 30C A G Motor Speed Output 7B 7B 33A Analog Ground N A 30C 30C A G Pressure Control Output 8B 8B 34A Analog Ground N A 30C 30C A G Actual Flow Rate Output 9B 9B 35A Analog Ground N A 30C 30C A G Pulsed Motor Feedback A Input 25C 25C 36A Motor Feedback A Input 26C 26C 37A 53 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Troubleshooting INTERCONNECT CHART FOR CHANNELS 2 4 6 AND 8 Channel B Signals Backplane Board 64 Cond Ribbon Cable Interconnect Board Channel Board P N 78816 P N 1058 6 P N A10554 P N 78814 96 Socket 96 Pin DIN 96 Socket 64 Socket J1 64 Pin Di gital 96 Pin DIN Connector DIN IDC IDC Screw Back Side Connector Connector Connector Terminal Fast Fill 13C 13C 25 25 1B Channel F ill 13A 13A 26 26 2B Feather Set 14C 14C 27 27 3B Run 14A 14A 28 28 4B Halt Fault Reset 15C 15C 29 29 5B Trigger 1 15A 15A 30 30 6B Motor Amp Fault 16C 16C 31 31 7B Trigger 2 16A 16A 82 32 8B Trigger 3 176 176 33 33 9B Trigger 4 17A 17A 34 34 10B Volume Fill 18C 18C 35 35 11B Pushout 18A 18A 36 36 12B Fault Output hi 19C 19C 37 37 13B Fault Output low 19A 19A 38 38 14B Ready Output hi 20C 20C 39 39 15B Ready Output lo w 20A 20A 40 40 16B Spray Shutdown 11 21C 21C 41 41 17B Spray Shutdown low 21A
16. Ransburg PARTS IDENTIFICATION 2 eech ON 5 Figure 4 Control Console LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID Part Number Tabulation A10549 02 2 Channel Controller A10549 04 4 Channel Controller A10549 05 6 Channel Controller A10549 08 8 Channel Controller MAIN CONTROL CONSOLE PARTS LIST Figure 4 Quantity Required Part Description Terminal Board Assembly DynaPump 64 Pin IDC Ribbon Cable Interconnect Board AGC 10 10 Amp Fuse AGC 5 5 Amp Fuse Ethernet Switch 5 Port Compact Power Line Filter Power Supply 24VDC 180 Watts Touch Screen PC Assembl Switch Selector Maintained Switch Mushroom Head E Stop Red Contact Block Normally Open Pilot Light Block Pilot Light 130 Volt Contact Clip 3 Position Contact Block Normally Closed Recepticle Push On Oval Slot Stud Rack Sub Assembly DynaPump Interface Board Assembly RCS 2 Channel Board Assembly RCS 2 20 Pin Detented 21 Shoulder Washer Nylon 22 77400 00 Cable Mount Ribbon 4 23 24 25 26 50 Conductor Twisted PR Ribbon Cable X 80 Lg 50 Conductor Twisted PR Ribbon Cable X 10
17. Reference NFPA 33 and yourinsurance company requirements The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or 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 9408 06 1 Tells where hazards may occur Spray Area High Voltage Equipment Personnel Safety LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Safety HAZARD Tells what the hazard is Certain material may be harmful if inhaled or if there is contact with the skin There is a high voltage device tha
18. WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If ITW Ransburg s opinion the warranty item question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume no responsibility for repair orreplacementofthe item oritems The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9408 06 1 APPENDIX A UPDATING THE FIRMWARE AND SOFTWARE ON THE RCS 2 NOTE Itis highly recommended that all param eter data be backed up to a USB memory stick prior to reprogramming any of the cards or replacing the user interface soft ware Programming Cable The cable used for programming both the channel card and the interface card for the RCS 2 has a Part Number A11892 00 It has two separate parts One is simply a length of ribbon cable with a DB 9 male connector at one end and a DB 9 female connector at the other end This cable is used to flash the memory on the channel card as well as accessing the serial port on the interface card for resetting job data and totals or modifying Ethernet configuration data When flashing the memory on the interface card the two cables should be used together See Figure 1 Figure 1 11892 00 Programming Cable Set LN 9408 06 1 Programming the Channel Card 78814 01 78814 02 NOTE gt Always
19. ei 4914408 51 lt 19010 lt JOON 049 sbuni4 indino plouajos 4 SJ0129uuo3 99 bo5 Iquuf RCS 2 Parts Maintenance Troubleshooting Troubleshooting IT Ransburg 32075933 54211208 ei 1240390 Ko 5 o gt 3 o 3 2 3 o D 2 Motor Amplifier Block Diagram Figure 18 LN 9408 06 1 49 RCS 2 Parts Maintenance Troubleshooting Troubleshooting Solvent Catalyst Manifold Fluid Regulator Catalyst Optional Inlet gt X ee th Hot Catalyst Flow Flush Sensor Opt U 4 Solvent Catalyst Pump Inlet Catalyst Pres Sensor Opt Pump Outlet Pres Sensor Resin Resin ump Outlet Pres Sensor Spiral Static Mix Tube Assy Mix Block lt XXXXXXXX Resin Mag Coupling Solvent Fluid Outlet 4 Regulator Optional Catalyst Flush Enable Enable Catalyst Figure 19 Fluid Panel Block Diagram LN 9408 06 1 50 RCS 2 Parts Maintenance Troubleshooting Troubleshooting rrRansburg M a 12V 2 Supply 24V to 5V Power Supply 24V to 12 Serial Controller Debug Port Calibration Switch Motoro MC68HC16 51 Micro controller Bu
20. scratches or particles of foreign matter will cause scoring and possibly pump seizure 1 Remove the four 4 socket head cap screws attaching the pump to the manifold 2 Remove S H C scews 11 3 Using an arbor press remove two 2 dowels 8 from the pump assembly LN 9408 06 1 NOTE If an arbor press is unavailable an alternate disassembly method is to par tially back off the cap screws and tap the screws with a soft head hammer With the screw heads exposed continue to alter nate backing out the screws and tapping the screws until the plates are free A CAUTION 4 Separate front plate 2 from center plate 7 and from rear plate 9 5 Remove driving gear 6 from center plate 7 6 Remove driven gear 4 from center plate 7 7 Remove arbor 3 from driven gear 4 Gear Pump Reassembly Before reassembling the gear pump clean and inspect all parts for damage or wear To Assemble 1 If parts were separated use a press to press arbor 3 into front side plate 2 2 Insert driven metering gear 4 into center plate 7 Manually turn the metering gear to ensure it moves freely gt Ifthe metering gear binds it could damage the pump Determine the cause of the binding Nicks burrs or foreign particles can cause pump binding 10 RCS 2 Parts Maintenance Troubleshooting Maintenance 11 3 Insert driving metering gear 6 into center plate 7 Manually turn the
21. 10 Input Job Number 20 Input Job Number 40 Input Job Number 80 Input Job Number 100 Input TB5 8 TB6 8 amp TB7 8 5 10 TB6 10 amp TB7 10 TB5 12 TB6 12 amp TB7 12 Spare Input 1 Input Spare Input 2 Input Spare Input 3 Input 55 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Troubleshooting ODD NUMBERED CHANNEL UMBILICAL CORD SIGNALS Umbilical Cord A10487 Control Console A10549 Wire Numbers Channel Channel Channel Channel 1 3 5 7 LN 9408 06 1 Pin A B D G H J K L M N P R 5 U V X Y Z a b Wire Black Red Black Red Black Blue Black Brown Black Yellow Black Orn Black Red Red Red White White Green Red Brown Red Orange Yellow Drain Blue Green Blue Green Pair Wht Red Wht Blk Blu Red Grn BIk Blu Blk Brn Blk Brn Blk Yel Blk Yel BIk Orn BIk Orn BIk Yel Red Grn Red Red BIk Wht Red Wht Blk Grn BIk Brn Red Brn Red Orn Red Orn Red Yel Red N A Blu Red Grn Red Blu Grn Blu Grn Signal Name Catalyst Flow Inlet Pressure Outlet Pressure 24 VDC GND Trigger 2 GND Fault Out Motor Feedback Motor Amp Reset Hi Motor Amp Fault Trigger 1 Motor On Hi Motor Speed Spray Shutdown Lo Pressure Control Inlet Pressure Outlet Pressure Act Flow Analog Out Halt Fault Reset Fast Fill A Chann
22. 2 locations Personnel must stay clear of the bell whenever it is rotating Before touching the bell the turbine air must be shut off Ifthe bell has been rotating allow atleast two minutes for it to come to a complete stop before touching it RCS 2 Parts Maintenance Troubleshooting Maintenance MAINTENANCE ELECTRICAL CONTROL PANELS Main Control Console There is minimal if any routine maintenance necessary on the main control console There are no moving parts aside from the power and emergency stop switches on the door ofthe panel A few things can be done from a preventative viewpoint to extend the life of the components in the control console e Keep the door closed at all times to keep dust dirt and moisture out of the control panel and off of the PC boards Avoid touching the touch screen display with sharp objects or with hands or gloves that have paint on them The screen is glass and a razor blade can be used to remove dried paint etc if absolutely necessary however it is best to avoid havingto dothis Ifthe glass is scratched in any way it can effect how the touch screen responds when touched Sensitivity can be diminished by contaminants or scratches e Make sure the quarter turn latch screws on the PC boards and on the rack are latched to prevent boards from vibrating loose over time e Make sure alllatches are in the proper position to retain all ribbon cables in the control panel
23. 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Maintenance NOTES LN 9408 06 1 12 RCS 2 Parts Maintenance Troubleshooting Maintenance rrRansburg Figure 2 Catalyst Non Flushable Pump Assembly CATALYST NON FLUSHABLE PUMP ASSEMBLY PARTS LIST Figure 2 fem Description Qty 1 22 383 LipSeal __2 NER FrontSidePlate 1 NFER Cape J 1 4 NFR 11 Lech ech HollowDowel NFR ______ Rear Side Plate Varies Requires Seal Insertion Tool P N 22 542 Not Field Replaceable Vareis based on pump size 13 LN 9408 06 1 H RCS 2 Parts Maintenance Troubleshooting Maintenance Non Flushable Gear Pump Disassembly NOTE It is not recommended to disassemble these pumps in the field unless absolutely necessary If a malfunction occurs they should be returned to ITW Ransburg for service gt careful not to scratch or nick any surface of the plates seals gears and dowels inside the pump These parts have very precise tolerances Burrs nicks scratches or particles of foreign matter will cause scoring and possibly pump seizure 1 Remove the four 4 socket head cap screws attaching the pump to the manifold 2 Remove the seal plate 12 3 Remove bolts 10 and 11 4 Using an arbor press remove the two 2 dowels 8 from the front plate
24. OUTPUT 64 CONDUCTOR RIBBON CABLE CROSS SIGNAL NAME 96 SOCKET DIN CONN N 7 666600660006888888 83 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC gt MZ 3 gt 5 z 8 gt e 55 ex 53 4 8 6 5 50 DA d Ka T 55 2 eg eoQ lege edo wen 2 1 1 666 2 Gogo 660 600 666 5 E 999 660 5 5 17 xX NX be 3 i s N TE FECE 4505 ee B i ix 2 1122 01 21 2 EE 5 S E S E 990002 3 a 5 ecg mA 8 5 5 i gt EN 5 NS S NS 5 Oz SET 5 NO ll 853 g ey PES 22 i o o st us E 7 2 O lt O e 1 50 kel bs cl gt z 5 x lt n ER 3 5 E E 4 5 ac B o Zeen pls leren gon a 221 1 KN 2251 15 HR SS Iz 1901 15 el 3 y 5 5 x Be CH pelea te on Y tZ 5 9 d 5 OLS 85 RC 2 4 sD a 88 ge orc mI S bi oro z 28 5 88 8809 90900088800800 LN 9408 06 1 84 85 RCS 2 Parts Maintenance Troubleshooting Appendix rmyRansburg APPENDIX G SC
25. PUMP BYPASS VALVE ASSEMBLY PARTS rrr rte retia rer echa eta eie 17 19 PARTS IDENTIFICATION 21 46 MAIN CONTROL CONSOLE PARTS ies toi eibi ege dees 21 22 RACK ASSEMBLY PARTS LIS iato dara 23 MOTOR AMPLIFIER PANEL PARTS a 25 26 MOTOR AMPLIFIER PANEL MODEL IDENTIFICATION eere 27 REMOTE OPERATORS PANEL PARTS eset 29 30 REMOTE OPERATOR S PANEL MODEL IDENTIFICA TION 30 FLUID PANEL ASSEMBLY 7 PARTS LIS D tubae nno 31 33 FLUID PANEL ASSEMBLY MODEL IDENTIFIGAT ION n E ke oto SIR coin 34 35 NON FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS 37 38 FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS 39 40 DUAL HEADED PUMP ASSEMBLY PARTS EIS T peor sectae ifs 41 43 77671 00 5 WAY BALL VALVE ASSEMBLY PARTS 5 45 46 TROUBLESHOOTING 47 58 BLOCK DIAGRAMS 47 RIBBON CABLE INTERCONNEG FCAPS teeta 47 UMBILICAL CORD mm 47 CONTROL CONSOLE BLOCK BIAGBUAM itat reri ten cereis 48 MOTOR AMPLIFIER BLOCK DIAGRAM Pav IR ra na tu 49 FLUID PANEL BLOCK
26. Unlike other components for which all broken seals must be replaced before reassembly two 2 of the fluid seals in the bypass need only be replaced if damaged or worn Guidelines for bypass parts replace ment O Ring Seals 13 always replace after disassembly Gasket 12 replace only if there is visible wear or damage Always replace after disassembly Diaphragm 10 replace only if there is visible wear or damage Always replace after disassembly LN 9408 06 1 To Disassemble 1 Remove two 2 screws 4 from clamp block B 2 Remove bushing 6 and plunger 7 from clamp block 5 3 Remove three 3 screws 8 holding adapter plate 9 and manifold plate 11 to gear pump Handle plates carefully to avoid damage to gasket 12 4 Remove three 3 screws 14 holding adapter plate 9 to manifold plate 11 Separate plates carefully to avoid damaging diaphragm 10 To Reassemble 1 Place diaphragm 10 in recess in adapter plate 9 2 Install three 3 screws 14 to fasten manifold plate 11 to adapter plate 9 3 Install two 2 seals 13 and gasket 12 on manifold plate 11 4 Install three 3 scews 8 to fasten adapter plate 9 to gear pump 5 Insert plunger 7 and bushing 6 into clamp block 5 6 Install two 2 screws 4 to fasten clamp block 5 to adapter plate 9 This completes assembly 18 RCS 2 Parts Maintenance Troubleshooting Parts ID
27. 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 A firmware bug is preventing completion of required logic in the time between timer in terrupts This error may occur when the system is first powered up and may be ignored 68 RCS 2 Parts Maintenance Troubleshooting Appendix rmyRansburg APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 1 GE FANUC AMPLIFIER LED Display Explanation and or Possible Causes Loss Enable Following Error Excessive Command Increment Feedback Lost Motor Power Over Voltage Motor Power Clamp Excessive Duty Cycle Motor Over Current Fault Motor Over Temperature Fault PF LE FL V EC MT DT Drive Over Temperature 69 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 Hal
28. plate 9 and thread them through all three 3 plates 14 RCS 2 Parts Maintenance Troubleshooting Maintenance rrRansburg NOTE NOTES The non flushable pump uses two 2 short cap screws 11 and four 4 long cap screws 10 that extend through to the four 4 threaded holes in the front side plate 2 torque to 120 Ibs in 8 Install seal plate 12 onto rear plate 9 using four 4 socket head cap screws 13 Torque to 50 Ibsein 9 After assembly check torque by turning drive gear torque not to exceed 4 Ibs in Drive Gear and Shaft In case of separate damage or wear the drive gear 6 and drive shaft 5 may needto be separated and replaced Individual pump parts are not field replaceable and must be returned to ITW for replacement To separate use an arbor press to remove the gear 6 from the drive shaft In reassembly position the bottom of the gear 909 003 from the bottom ofthe shaft end opposite the tang ITW Ransburg can supply a Gear Alignment Gauge for this purpose The tool is P N 22 1032 Contact ITW Ransburg for additional information Hollow Dowel ITW Ransburg can supply specialtools to achieve proper placement of the hollow dowels 8 in the gear plates The dowel should extend 093 005 above the end plate on the pump shaft end tang end To allow dowel placement from either end of the pump two tools are required Dowel Insertion Tool Male P N 22 1033 D
29. 0 Lg 2 Dust Cap 10795 00 2 Cable Assembly 26 Socket Bulkhead X Channel Number Dust Cap for A10564 2 Horn 24VDC 1 Touch screen may vary slightly frome one shown 472 10 11 12 13 14 15 16 17 18 19 r palala Rll Z mix Nye 2 oli Ol amp o ei ojo 2 SIE NIN Wei m o DIR lt 8 85 0 o 9 aR 5 elo 09 e gt Oo gt gt e o 27 28 29 30 02 04 06 08 ish 9 2 2 2 1 2 1 4 6 8 1 1i 1 4 gt gt gt gt gt gt gt wech wech ol ololo o alo al ala ala lt olo S Ala 31 32 1 m LN 9408 06 1 20 rmyRansburg RCS 2 Parts Maintenance Troubleshooting Parts ID Rack Assembly Figure 5 3 2 E Ss V 4 lt e z Qty 78814 01 or02 Channel Board Assembly RCS 2 6 75086 01 Description RIO RCS 2 Assembly RCS 2 Backplane Board Assem
30. 21A 42 42 18B Flush Request hi 22C 22C 43 43 19B Flush Request low 22A 22A 44 44 20B Motor On hi 23C 23C 45 45 21B Motor On low 23A 23A 46 46 22B Motor Amp Reset hi 24C 24C 47 47 23B Motor Am p Reset low 24A 24A 48 48 24B Digital Ground 30A 30A 60 60 25B Digital Ground 30B 30B 24 VDC 32A 32A 64 64 26B 24 VDC 32B 32B 24 VDC 32C 32C 63 63 26B 50 Conductor Twisted Backplane Board Pair Ribbon Cable Interconnect Board Channel Board P N 7881 6 P N 10587 P N A10554 78814 96 Socket DIN 50 PinIDC 50 Socket 50 Socket J2 50 Input orl 96 Pin DIN Connector Connector DIN IDC Socket Screw Analog Output Connector Eront Side Back Side Connector Connector IDC Conn Terminal Hardener Flow Inp ut 1B 1 1 1 1 27B Analog Ground N A 30C 4 4 4 4 A G Flow Rate Command Input 13B 19 19 19 19 28B Analog Ground N A 30C 20 20 20 20 A G Feather Pressure Input 14B 21 21 21 21 29B Analog Ground N A 30C 22 22 22 22 A G Pump Inlet Pressure Input 15B 23 23 23 23 30B Analog Ground N A 30C 24 24 24 24 A G Pump Outlet Pressure Input 16B 25 25 25 25 31B Analog Ground N A 30C 26 26 26 26 A G Spare Analog Input Input 17B 27 27 27 27 32B Analog Ground N A 30C 28 28 28 28 A G Motor Speed Output 19B 29 29 29 29 33B Analog Ground N A 30C 30 30 30 30 A G Pressure Control Output 20B 31 31 31 31 34B Analog Ground N A 30C 32 32 32 32 A G Actual Flow Rate Output 21B 33 33 33 33 35B Analog Ground N A 30C 34 34 34 34 A
31. 420C 1 4 20 X 5 8 L Stainless Steel HHCS 4 ___ ___ _42 e o S o O 22 280 1 Check Valve Stainless Steel 10 Carriage Bolt 1 4 20 X 1 L O 2 __ 10 33 LN 9408 06 1 Ir Ransburg RCS 2 Parts Maintenance Troubleshooting Parts ID FLUID PANEL ASSEMBLY MODEL IDENTIFICATION When ordering use A10948 UVWXYZ as indicated by Tables U V W X Y and Z For example A10948 U V WX Y Z Basic Part Number Catalyst Inlet Pressure Transducer Resin Pump Size 0 No 1 Yes Catalyst Pump Size Catalyst Flow Sensor Number of Colors 0 1 Yes 00 No Color Valve Stack 02 2 Color CCV Stack 04 4 Color CCV Stack 06 6 Color CCV Stack 08 8 Color CCV Stack 10 10 Color CCV Stack TABLE U RESIN FLUSHABLE PUMPS KSE 22 01 32 1 NoPumpincluded DC oe 1 1 77844 01 Pump Kit RCS 3 5CC REV M2 Tool Steel 2 1 7784408 Pump RCS 3 5 2 Tool Steel Yes 3 1 77844 09 Pump RCS 3 5 Polyond No 4 1 1 77844 10 Pump RCS 35 Yes 5 1 77844 02 Pump Kit RCS 5 5CC REV 2 Tool Steel 6 1 7784441 Pump RCS 55 M2ToolStel Yes 7 1 77844 12 Pump RCS 55 8 9 1 77844 03 Pump kit RCS 10 0 CC REV M2 Tool Steel 77844 14 Pump RCS 10 0 CC REV M2 Tool Steel 1 77844 15 Pump RCS 10 0 CC REV Polyond
32. 6 Socket DIN 96 Pin DIN 96 Socket 64 Socket J1 64 Pin Digital Input or 96 Pin DIN Connector Connector DIN IDC IDC Output Connector Front Side Back Side Connector Connector Fast Fill Input 1C 1C 1C 1C Channel Fill Input 1A 1A 1A 1A Feather S et Input 2C 2C 2C 2C Run Input 2A Halt F ault Reset Input 3C Trigger 1 Input 3A Motor Amp Fault Input 4C Trigger 2 Input 4A Trigger 3 Input 5C Trigger 4 Input 5A Volume Fill Input 6C Pushout Input 6A Fault Out put hi Output 7C Fault Out put low Output 7A Read y Output hi Output 8C Read y Output low Output 8A Spra y Shutdown hi Output 9C Spray Shutdown low Output 9A Flush Request hi Output 10C Flush Request low Output 10A Motor On hi Output 110 Motor On low Output 11A Motor Amp Reset hi Output 12 Motor Amp Reset low Output 12A Digital Ground N A 30A Digital Ground N A 30B 24 VDC Output 32A 24 VDC Output 32B 24 VDC Output 32C 50 Conductor Twisted Backplane Board Pair Ribbon Cable Interconnect Board Channel Board P N 78816 P N A10587 P N A105 54 78814 96 Socket DIN 50 Pin IDC 50 Socket 50 Socket J2 50 Input or 96 Pin DIN Connector Connector DIN IDC Socket Screw Analog Output Connector Eront Side Back Side Connector Connector IDC Conn Terminal Flow Rate Comm and Input 2B 2B 3 28A Analog Ground N A 30C 30C A G Feather Pressure Input 3B 3B 29A Analog Ground N A 30C 30C A G Pump Inlet Pressure Input 4B 4B 30A
33. DO lt 08800808080800666066 aN 7 S d V 2 2 TT pH Ai Lei E n gt 08800000000000606600 LN 9408 06 1 88 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC gt gt p 4 eue oa Cr ol 5 gt 2 HERPES 4 p L 4 Q 5 A To 2 2 22 a as 0 KO KO E e 2a gt lt lt E c 888686666006066009090 gt NN 9 Si G G S 9 G N st Uu KO EO E gt 2 Oz D D 89 rmyRansburg LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC NOWNOO 20 gt of epunn lt SL ze D o 2 D gt gt flee Sa Ci PE D x o o gt p N gt LN 9408 06 1 90 rmyRansburg REMOTE OPERATOR PANEL SCHEMATIC RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued
34. G Motor Feedb ack B Input 27C 37 37 37 37 36B Motor Feedback B Input 28C 38 38 38 38 37B Solvent B Input 29C 39 39 39 39 38B Solvent B Inp ut 29B 40 40 40 40 39B LN 9408 06 1 54 RCS 2 Parts Maintenance Troubleshooting Troubleshooting Ransburg INTERCONNECT CHART FOR SYSTEM 1 0 SIGNALS System UO Signals Interface Backplane Board 64 Cond Ribbon Cable Interconnect Board Board P N 78816 P N A10586 P N A11530 78818 96 Socket DIN 96 Pin DIN 96 Socket 64 Socket J1 64 Pin Digital Input 96 Pin DIN Connector Connector DIN IDC IDC Screw Output Connector Front Side Back Side Connector Connector Connector Terminal Gun 1 Strobe Input 1 1 1 1 1 1 2 Strobe Input 20 2C 2C 2C S TB1 2 Gun 3 Strobe Input 3C 3C 3C 3C Gun 4 Strobe Input Gun 5 Strobe Input Gun 6 Strobe Input Gun 7 Strobe Input Gun 8 Strobe Input System Fault Out Hi Output System Fault Out Lo Output System Pulse Out Hi Output System Pulse Out Lo Output Client Connected Hi Output Client Connected Lo Output TB5 1 TB6 1 amp TB7 1 TB5 3 TB6 3 amp TB7 3 TB5 5 TB6 5 amp TB7 5 TB5 7 TB6 7 amp TB7 7 TB5 9 TB6 9 amp TB7 9 TB5 11 TB6 11 amp TB7 11 TB5 2 TB6 2 amp TB7 2 TB5 4 TB6 4 amp TB7 4 TB5 6 TB6 6 amp TB7 6 Job Number 1 Input Job Number 2 Input Job Number 4 Input Job Number 8 Input Job Number
35. HEMATICS Continued MOTOR AMP PANEL SCHEMATIC o 2 4 4 i A B N 95 IE EE 2 6 Sis 38 757 SZ c Luew 25 xs 88000000000880606000 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC N 12 20 z C 20 3 500 gt 200 Se gt Ke gt lt lt zo b lt ee la Lai M NGO ee km e 2 ER ee JZ 2 20 2 14 Me 20 2 a 5 gx E zu 5 Ne PEEL E 4 Soa eee 7 6980000006660000886 d LN 9408 06 1 86 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC nt m A lt e N 2 vi E gt L 08388000000660000 Ss 2 9 z z Oo o 72 2 2 Y wea lov o x Q NS gt 87 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC gt ES 5 tans 8 S S S aS 85 Oi u Tu Sa 56 Net SS
36. Maintenance Troubleshooting Troubleshooting NOTES LN 9408 06 1 58 RCS 2 Parts Maintenance Troubleshooting Warranty Policies Ransburg 59 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 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 THIS WARRANTY ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR 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
37. My Recent Documents rrwBOOTL HEX Dpen File name pg 205 Network Files of type Hex files hex Figure 3 Select Folder File 8 Select the Open button 9 The downloader software screen should display the file you selected 7 5 Find File to Download File Selected itw_pg_v205 hex Figure 4 Ready To Download LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix 10 Push the Download button The program will download the new firmware to the flash memory on the card and show status bar as it is doing so 11 Once the program has completed downloading the entire code the following screen will display oder 5 Programming Jumper JM7 Figure 5 Removal of Programming Jumper File Selected 4 Reinsert the Interface card into the rack All Done 5 Insertthe rectangular connector on the Interface Card Adapter Cable Figure 5 into the port on the lower left side onthe front face plate of the module This is the rectangular hole in the aluminum plate labeled PRG DB Figure 4 Download Completed 12 Push the Done button to close the program 13 Once the download process is complete the power should be cycled on the rack to reset the channel card and allow it to reload its job parameters 14 After power has been cycled the faults on the RCS 2 may need to be cleared O
38. N 9408 06 1 rRansburg RCS 2 Parts Maintenance Troubleshooting Appendix MANUAL CHANGE SUMMARY This manual was published to supercede Service Manual LN 9408 06 8 2 Parts Maintenance and Troubleshooting Manual to make the following changes 1 Added Service Manual Price 40 00 Euro to Front and Back Covers Maintenance Section 2 Revised Electrical Control Panels Main Control Console 3 Added Note to Assembly 22 337 Pump Bypass 4 Revised Assembly 22 337 Pump Bypass Gear Pump Disassembly 5 Revised Assembly 22 337 Pump Bypass Drive Gear and Shaft 6 Revised Assembly 22 337 Pump Bypass Non Flushable Gear Pump Disassembly 7 Added Note to Assembly 22 337 Pump Bypass Drive Gear and Shaft Parts Identification 8 Added Note Main Control Console Parts List 9 New Figure 4 Main Control Console 10 Added Figure 6b New Style Motor Amplifier Panel 11 New Figure 8a Fluid Panel Assembly Front 12 New Figure 8b Fluid Panel Assembly Back 13 Revised Fluid Panel Assembly Parts List Items 9 10 16 17 23 28 40 41 42 and 43 14 New Figure 9 Non Flushable Pump Manifold Assembly LN 9408 06 1 15 Revised Non Flushable Pump Manifold Assembly Parts List Item 3 16 New Figure 10 Flushable Pump Manifold Assembly 17 Revised Flushable Pump Manifold Assembly Parts List Item 28 18 Added to Dual H
39. Reached 67 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 Causes 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 Failure of Pump Inlet Pressure sensor Electrical connection problems Failure of Pump Outlet Pressure sensor Electrical c
40. all Channel Card or Cards if they were removed prior to software upgrade 19 Power up the rack 20 Errors may be indicated on the Error Log screen They can be reset 21 The new version of software can be validated by confirming the new software in the CONFIG SYSTEM F1 touch screen and selecting VERSION INFO F2 NOTE Jumper JMP7 can be installed on the board during the following setup proce dures Interface Card Procedure 1 Insert the Serial Cable into the RS 232 port on the front of the face plate of the Interface Card Configuration Serial Port Figure 13 RS 232 Port LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix 2 The other end of the Serial Cable is to be plugged into the serial port of the programming terminal PC or Laptop 3 Open the Hyper Terminal program from the Windows Start Menu or any other similar terminal emulation program that works with the RS 232 serial port 4 If HyperTerminal was not previously setup for use with the RCS 2 Interface Card configure it with the following settings a Baud Rate 38400 b Data Bits 8 c Parity None d Stop Bits 1 e Flow Control 2 Xon Xoff f Emulation VT100 5 Power up on interface card and the Hyper Terminal will display the software version followed by some diagnostic information than the IP configuration information It will then prompt the user to Press any key within 3 seconds to enter conso
41. ass Valve Assembl 0 11 77844 XX Catalyst Pump 1 RS 13 22 383 Lip Seal for Pump 0 0 H __ o1 1 __ 1 97 2019 Diaphragm for Pump Bypass Valve 15 22 336 O Ring Seals for Pump Bypass Valve and between Flushable Pump and Manifold 16 O Ring for Bearing Housing O Ring for Back Side of Magnetic Coupling Housing Used on both style pumps O Ring for Front Side of Magnetic Coupling Housing Used on both style pumps O Ring for Fluid Inlet and Outlet o BRE used between Non Flushable Pump and 4 8 and Manifold and Manifold 1 22 947 Magnetic Coupling Housing Bushing 22 945 Magnetic Coupling Housing Assembl 22 939 Inner Pole Ring Assembly LN 9408 06 1 rmyRansburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX E RECOMMENDED SPARE PARTS Continued SEAL KITS TOOLS TUBING ETC PARTS LIST Quantity Being Purchased Description 1 22 1285 Color Resin Pump Seal Kit Includes 1 22 335 2 22 336 1 3076 20 2 22 1286 Hardener Catalyst Pump Seal Kit Includes 1 22 336 1 22 364 1 22 366 1 22 379 3 Hardener Seal Insertion Tool 4 Color Seal Insertion Tool 5 Male Dowel Insertion Tool Female Dowel Insertion Tool 3 16 IC X 5 16 OD Teflon Tubing 3 8 OD Teflon Tubing 9 5 32 OD Polyethylene Tubing 3 16 OD Polyethylene Tubing 11 1 4 OD Polyethylene Tubing H 2338 3 8 OD Polyethylene T
42. bly RCS 2 Rack Sub Interface Board 77377 22 10530 00 2 78818 00 Interface Board Assembly RCS 04 Cover Assembly Quantity dependant on number of Channels required Only required if using Allen Bradley RIO Cover plates used to fill unused slots LN 9408 06 1 21 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID NOTES 22 RCS 2 Parts Maintenance Troubleshooting Parts ID rrRansburg 00 G 4 d 5 6 2 H 9 B 8 0 Ce 9 20 10F 9 i 2 11 US EECH 7 Dis 15 0 18 E 14 4 H 17 16 15 1 OF 12 1 OF 20 D a Qv Figure 6a Old Style Motor Amplifier Panel 23 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Parts ID OLD STYLE MOTOR AMPLIFIER PANEL PARTS LIST Figure 6a ltem Pat Description 1 A1079500 Ethernet industrial Bulkhead W RJ 45Connector __ 1 3 1056409 26 Socket Bulkhead Assembly W FlyingLeads 1 4 1056410 26SocketBulkhead Assembly W FlyingLeads IL 5 1078301 Motor Drive Amplifie 2 Power Supply 5VDC amp 24VDC 180 11 Power Supply 24VDC 180 1
43. ce the seals are less critical and the magnetic coupling is durable the system delivers higher equipment utilization and shorter maintenance procedures Lasts longer The magnetically coupled gear pump and motor will have a longer operational life than a conventional rotary shaft sytem Applications Because of the precise servo control and rapid acceleration and deceleration of paint delivery this product is ideally suited for almost all automotive or industrial applications This product will provide superior delivery in applications that require High performance paint metering Single and multi component applications Precision flow rates Quick and accurate flow rate changes Pumps Color Resin and Hardener Catalyst Some coating applications using the magnetically coupled gear pump require two fluids to be metered Thus there are two styles of pumps Color Pump Resin which are flushable Hardener Pump Catalyst which are non flushable The parts of each pump are similar Except for plate configuration the main difference between the two styles is the seal plate on the hardener pump This section covers both pumps and the instructions will identify where the procedure only applies to one style Restricted Materials Paints and fluids for use with this system must meet the following conditions Non abrasive materials Maximum entrained particle size 6 microns 0 00025 Maximum hard
44. d follow the Make sure to save the new configuration to flash memory when prompted directions 65 iT Ransburg 8 It is highly recommended that all job data be reset evertime new software has been loaded into the card as old data can become corrupted in the flashing process If itis necessay to clearthe Job data type INITDATA and depress the enter key NOTE This clears all Job data from the battery backed memory on the interface card Make sure this data has been backed up prior to doing Step 2 9 Type Run and hit the enter key to restart the software running on the interface card 10 Upon completion of the previous steps the power should be turned off the serial cables removed and the power turned back on This should complete the interface card setup User Interface Software Touchscreen Software 1 The new software should be copied to a USB memory stick Insert the memory stick into any one of the USB ports on the back of the touchscreen 2 Shutdown the User Interface software from the main screen of the RCS 2 F12 3 Using the Windows software functions find your memory stick and copy the files supplied to you by ITW Ransburg to the RCS 2 folder inside of the My Documents folder on the desktop prompted confirm the overwriting of existing files with the same file names 4 Remove the memory device from the RCS 2 main control PC 5 Cycle power and verify that the user interfac
45. d in 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 The Interface Card detected an error while attempting to communicate with a Channel Card via the Serial Peripheral Interface SPI bus Explanation and or Possible Causes 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 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 Configuration 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
46. dent on the number of channels used and is therefore included with the Motor Amplifier Panel list uu ni LN 9408 06 1 rmyRansburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX E RECOMMENDED SPARE PARTS Continued A10776 MOTOR AMPLIFIER PANEL PARTS LIST Quantity Being Purchased Description Ee 78814 01 02 Channel Board 2 2 3 10783 01 Motor Drive Amplifier GE Fanuc A12219 01 Motor Drive Amplifier Danaher 3 75337 06 24VDC Power Suppl 4 75337 06 555 7016 24VDC Rela TR SSEH 471 5 Amp AGC Fuse TR SSEH 472 10 Amp AGC Fuse 22 1050 Flow Switch Amplifier 22 1046 _____ Flow Monitor Control Unit Zener Barrier for 24VDC Rem Oper Panel 11 E to P Transducer 12 Tachometer Cable GE Fanuc Amps Motor Drive Cable GE Fanuc Amps Catalyst Flow Sensor Cable 16 Power Line Filter 12220 00 Motor Drive Cable Danaher LN 9408 06 1 76 RCS 2 Parts Maintenance Troubleshooting Appendix rrRansburg 77 APPENDIX E RECOMMENDED SPARE PARTS Continued A10948 FLUID PANEL PARTS LIST Description i EE 2 4 2 Pilot Operated Bellows Valve 2 O 6 22420 Mix Manifold W Check Valve 1 7 2403 CatalystElowSensor 8 22145 CatalystFlowSensorCable 0 9 122 1044 Manifold for Flow Sensor 5 12 22 337 Byp
47. e software reloads automatically on startup LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX B ERROR LOG CHART Input Under Pressure Input Over Pressure Output Under Pressure Output Over Pressure Flow Rate Out of Tolerance Hardener LN 9408 06 1 Channel Card Channel Card Channel Card Channel Card Channel Card Description Pump inlet pressure is below the Minimum Pressure value specified inthe Channel Configuration Pump inlet pressure is above the Maximum Pressure value specified inthe Channel configuration Pump outlet pressure is below the Minimum Pressure value specified inthe Channel Configuration Pump outlet pressure is above the Maximum Pressure value specified inthe Channel Configuration The difference between the commanded flow rate RPM of the pump and the actual flow rate measured from the feedback signal exceeds 2 times the Flow Rate Ratio Tolerance Percentage value specified in the Gun Configuration The electrical current from the Hardener Flow sensor is less than Explanation and or Possible Causes No material available to pump inlet Material supply pressure is too low 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 contr
48. eaded Pump Assembly Parts List Items 27 and 38 Troubleshooting Section 19 Revised Interconnect Chart for Channels 1 3 5 and 7 Digital Pushout 20 Revised Interconnect Chart for Channels 2 4 6 and 8 Digital Pushout 21 Replaced Appendix A with Appendix A RCS 2 Programming Procedure 22 Replaced Appendix B with Appendix B Error Log Chart 23 Replaced Appendix E with Appendix C Motor Amplifier LED Display Fault Codes Part 1 and 2 24 Added Appendix D Calibrating the Pressure Transducers Part 1 25 Changed Appendix H to Appendix F System Layout 26 Changed Appendix G Recommended Spare Parts to Appendix E 27 Changed Appendix H System Layout to Appendix F 28 Changed Appendix Schematics to Appendix 29 Revised Appendix G Schematics 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 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts GEL ISO 9001 Form LN 9408 06 1 2009 Illinois Works Inc All Rights reserved Quality Systems 8 Litho in U S A lt Models and specifications sub
49. eded 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 9408 06 1 iT Ransburg APPENDIX C FAULT CODES PART 2 DANAHER AMPLIFIER RCS 2 Parts Maintenance Troubleshooting Appendix MOTOR AMPLIFIER LED DISPLAY Status LED Blink Fault Description Explanation and or Possible Causes ENIM Control power not applied or insufficient control power applied Loose or open circuit wiring of control power input Low input voltage to control power supply Fast Blink 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 If foldback is not enabled the drive will fault Motor 114 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 9408 06 1 High ambient temperature at motor Insufficient motor heat si
50. el Fill Ready Lo Motor Speed Shield Flow Rate Command Spare Wire Spare Wire Spare Wire Motor Amp A10776 Wire No 56 RCS 2 Parts Maintenance Troubleshooting Troubleshooting Ransburg EVEN NUMBERED CHANNEL UMBILICAL CORD SIGNALS Umbilical Cord A10487 Control Console A10549 Wire Numbers Channel Channel Channel Channel 2 4 6 8 57 2 5 Wire Black Red Black Red Black Blue Black Brown Black Yellow Black Orn Black Red Red Red White White Green Red Brown Red Orange Yellow Drain A B C D E F G H J K L M N P R S T U V X Y Z a b Blue Green Blue Green Pair Red BIk Wht Red Wht Blk Blu Red Grn BIk Blu BIk Brn BIk Brn BIk Yel BIk Yel BIk Orn BIk Orn BIk Yel Red Grn Red Wht Red Wht BIk Grn BIk Brn Red Brn Red Orn Red Orn Red Yel Red N A Blu Red Grn Red Blu Grn Blu Grn Signal Name Catalyst Flow Inlet Pressure Outlet Pressure 24 VDC GND Spare GND Run Channel A Motor Feedback Motor Amp Reset Hi Motor Amp Fault Feather Set Channel A Motor On Hi Motor Speed Gun 1 Strobe Pressure Control Inlet Pressure Outlet Pressure Job 1 Bit Job 2 Bit Job 4 Bit B Channel Fill Job 8 Bit Motor Speed Shield Job 10 Bit Spare Wire Spare Wire Spare Wire Motor Amp A10776 Wire No LN 9408 06 1 RCS 2 Parts
51. eshoot RCS 2 Parts Maintenance Duwa 9 6 sjeuubu joule 84 S euupu 51909 0 1 8 sjeuubpu 2149409 0 1 97G sjeuuDu 21959 0 919J2s1g 976 sjauUuDYD CSL sjeuupu 21959 91402 0 1 waysks 2291 5 21909 21909 0 81942514 5 sjeuuDYyD 22 5 21409 uoqqni 0 21922514 5 91409 9392514 84 sjauuDYyD Lg B BE sjauod 19 Se qpo 20 S40129uu02 Q uuo9 g 2 esnow 5 219809109 Dd 5 Aoidsiq q21 a e ng 03 p409 z 9 p109 v 9 9 8 44949 p109 YOUMS 1949433 gt dul volo OVA 051 Control Console Block Diagram Figure 17 48 LN 9408 06 1 g j s pubis 2 J010N 105 6 eJnsseJg 4 TT 10525 M0 J 15410109
52. ffers Buffers Buffers 24 VDC 32A B amp C Fast Fill Channel Fill A Feather Set A Run A Halt Fault Reset A Trigger 1 A Motor Amp Fault A Trigger 2 A Trigger 3 A Trigger 4 A Volume Fill A Spare DIN A Fault Output A Ready Output Spray Shutdown A Flush Request A Motor On A Motor Amp Reset A Oe EES 5355 ge 8 8018 Flow Rate Command Feather Pressure A Pump Inlet Pressure Pump Outlet Pressure A mm 18 18 18 18 18 lt Spare A lt 15 8 18 Motor Speed A Pressure Control A Flow Rate Output Optical Motor Feedback A Motor Feedback B Isolators Solvent Feedback Buffers Buffers Buffers Hardener Flow Fast Fill B Channel Fill B Feather Set B Run B Halt Fault Reset B Trigger 1 B Motor Amp Fault B Trigger 2 B Trigger 5 B Trigger 4 B Volume Fill B Spare DIN B Fault Output B Ready Output B Spray Shutdown B Flush Request B Motor On B Motor Amp Reset B Flow Rate Command B Feather Pressure B Pump Inlet Pressure Pump Outlet Pressure B Spare AIN B Motor Speed B Pressure Cont
53. g 1 6 LSF10002 00 1 4 ODT X 1 8 NPT F Bulkhead Union Alkon EE 8 25 66106 Pressure Switch Assembly 158 Ar 9 13 2201 Flow Switch Assembly __ 1 Be 10 7214301 ___ In OutNameplate TB Wiring Hamess Assembly Pressure Switches RCS 2 ROP 1 A11100 00 LED Wiring Harness Assembly RCS 2 Remote Operator s Panel A11110 00 Wiring Harness Assembly Horn 11102 00 LCD Display for DynaPump Remote Operators Panel 16 A11097 00 Potentiometer Harness Assembly RCS 2 Remote Operator s Panel A11098 00 Wiring Harness Assembly LCD Display RCS 2 ROP A10909 00 PC Board Assembly DynaPump Remote Operator s Panel Refer to Remote Operator s Panel Model Identification for quantities REMOTE OPERATOR S PANEL MODEL IDENTIFICATION When ordering use A11095 AB as indicated below A11095 A B Basic Part Number Number of 2 Req per 1 Req per Number of Air Pressure Switches Flush Box Spraygun Flow Switches RCS 2 Parts Maintenance Troubleshooting Parts ID 30 RCS 2 Parts Maintenance Troubleshooting Parts ID PEARS DRAIN VALVE
54. hort on the motor ouput causing an instataneous over current Output Over Current Hall Fault Valid only when drive is set to 6 Step 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 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 or improperly set causing excessive output current overshoots Invalid configuration Motoroverspeed 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
55. inside of the motor amplifier panels can run as much as 20 F above ambient If that will cause the internal temperature of the motor amplifier panel to rise above 120 F some sort of external cooling may be required tis recommended that the air supply to this panel be regulated to approximately 100 psi and filtered to at least 20 Microns LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Maintenance Remote Operator s Panel As with the other control panels there are not many items in the remote operator s panel that should require much routine maintenance The only moving parts are the pushbuttons color select switch flow control potentiometer and the optional pressure and air flow switches All indicator lamps are LED s and should therefore never fail A couple of items to keep in mind are listed below to insure uninterrupted service from the remote operator s panel e Keep the door closed at all times to keep dust dirt and moisture out of the control panel e Usedi ry filtered 20 Micron s or less air to pilot the pressure switches and supply the inlets to the air flow switches Fluid Panels As with all fluid delivery and control systems the part of the system that sees the most wear and tear and will require the most maintenance and repair is the section that actually makes contact with the fluids In the case of the RCS 2 this section is referred to as the fluid panel The fluid pa
56. ire 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 addition ventilation mustbe 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 materials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and OSHA requirements RCS 2 Parts Maintenance Troubleshooting Safety rmyRansburg
57. ject to change without notice 11 09
58. le mode 6 Hit the space bar or any convenient key to enter the console configurator The unit will respond to the key press with a gt prompt If repeated key hits fails to get a response from the unit and it continues on into normal operation mode make sure you have Xon Xoff setup as your flow control mode and emulation is setup as VT100 64 RCS 2 Parts Maintenance Troubleshooting Appendix Size 262144 Sector size 4096 bytes Num sectors 128 No second flash RAH Information 10 01 Size 131972 bytes User Block status 0 HAC address 00 90 C2 C0 88 E9 IP address 10 1 1 1 Ethernet ICP IP initialized Press a key within seconds to enter console Entering Keyboard Node Connected 0 15 10 detect Figure 14 Interface Configuration Screen NOTE There are 7 possible commands that can be executed from the console mode HELP This command lists all the possible console commands IPCONFIG Allows the user to change the IP configuration data CLEARTOTALS Allows the user to clear all totalization data stored in memory INITDATA Allows user to delete all job data stored in memory PING Allows user to ping devices on the Ethernet network RESET Resets the card same as cycling power RUN Takes the card out of console mode into normal operation mode 7 To setup the IP address for the card type IPCONFIG at the gt prompt an
59. ll then advise that it is about to connect to the transducer and prompt you to push F1 to continue or F2 to quit 7 The unitthen checks its battery then powers the transducer connects to the transducer then downloads the necessary data from the transducer The calibrator will display the serial number of the transducer and prompt you to push F1 to continue 8 The calibrator will then display ZERO ADJUSTMENT with the options of F1 to quit F2 to increase the value and F3 to decrease the value Tocalibrate the pressure transducers 22 910 an electronic calibrator will be required A10551 Examine the value displayed on the DVM Adjust it so it reads 4 01 to 4 03 mA The pressure transducer should be removed from the system to be calibrated or insure that all pressure has been released from the system Do NOTE not remove the transducer from its manifold block as retightening of the sensor in the manifold block gt Each time you press the F2 or F3 could effect the calibration buttons to increase or decrease the value the calibrator must download that to the Use the following steps to calibrate a transducer sensor so there is a slight delay The unit will display Writing Done F1 to 1 Prior to connecting anything to the calibrator tinue Repeat the process as many times A10551 power up the unit by pressing the ON as necessary to get the proper current button on the calibrator displa
60. metering gear to ensure it moves freely 4 Assemble rear 9 center 7 and front 2 plates 5 Using an arbor press press fit two 2 dowels 8 into the plate assembly 6 Lubricate roll pins 10 and cap screws 11 with petroleum jelly 7 Insert roll pins 10 and cap screws 11 into rear plate 9 and thread them through all three 3 plates Torque to 160 Ibs in 8 Afterassembly checktorque by turning driving gear torque not to exceed 4 Ibs in Drive Gear and Shaft In case of separate damage or wear the drive gear 6 and drive shaft 5 may needto be separated and replaced Individual pump parts are not field replaceable and must be returned to ITW for replacement To separate use an arbor press to remove the gear 6 from the drive shaft In reassembly position the bottom of the gear 909 003 from the bottom ofthe shaft end opposite the tang ITW Ransburg can supply a Gear Alignment Gauge for this purpose The tool is P N 11 1032 Contact ITW Ransburg for additional information Hollow Dowel ITW Ransburg can supply special tools to achieve proper placement of the hollow dowels 8 in the gear plates The dowel should extend 093 005 above the end plate on the pump shaft end tang end To allow dowel placement from either end of the pump two tools are required Dowel Insertion Tool Male P N 22 1033 Dowel Insertion Tool Female P N 22 1034 NOTES rmyRansburg LN
61. n power up the interface card will automatically load the default job parameters to the channel card If an alternate set of job data is required follow the standard procedure to load the proper job data Programming the Interface Card 78818 01 1 Turn the power off the rack Qc 2 Remove the Interface Card from the rack 1 PRG DB 3 To download new software to the interface card requires the card to be put into programming mode This is done by removing the jumper JMP7 from the board see Figure 5 To prevent the jumper from being misplaced it is recommended that you plug one side of the jumper into one of the 2 pins This will hold the jumper while the module Figure 6 Interface Card 78818 00 is being used in the programming mode Programming Port LN 9408 06 1 62 RCS 2 Parts Maintenance Troubleshooting Appendix The cable should be inserted with the red marking on the cable in the up or top position If the cable has two rectangular connectors on it use the one labeled PROG 6 The other end of the cable should be plugged into the serial port of the programming terminal PC or Laptop Use the Serial Cable extension if necessary 7 Apply power to the rack NOTE The Reset lamp on the Interface Card will be flashing This is normal 8 Openthe Rabbit Field Utility RFU exe program on the PC or Laptop iti Rabbit Field Utility 2 40 File Setup Help Figure 9 Rabbit Field Utilit
62. nel portion of the RCS 2 is basically a stainless steel plate with most of the components that come in contact with the fluids being metered mounted All wetted components are stainless steel Teflon or Kalrez other than the physical pumps themselves In most cases the pumps are manufactured from M2 tool steel which gives them superb wear resistance over similar designs manufactured from stainless steel Each of the individual components on the fluid panel will be discussed below as to how it operates and how to service it LN 9408 06 1 GEAR PUMPS This section explains How to Disassemble Clean and Reassemble the Gear Pump Introduction The magnetically coupled gear pumpis a precision tool designed to provide highly accurate performance over an extended service life The gear pump is constructed of precisely machined components with tight running tolerances of 0 00025 inches Burrs nicks or particles of foreign matter can score an internal surface or cause the pump to seize up The ability of the unit to deliver the performance level it was designed for depends on the user closely following several essential requirements Neverlet a pump run dry Never pump contaminated fluids Never reuse any seal Always replace separated seals with a new seal Consult the factory before using micas metallic s or waterborne coatings Provide advance filtration for all fluids Provide skilled and careful mai
63. ness 55 Concentration of entrained particles should not exceed 20 of total fluid volume Contact ITW Ransburg for technical assistance on applications involving metallics micas or waterborne systems Applicable Models and Styles The Service Information in this manual covers two basic product styles Flushable The flushable style pumps meter color and incorporates a pump bypass assembly Non flushable The non flushable style pumps meter hardener and does not have a bypass assembly LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Maintenance NOTE Although uncommon there are applica tions for flushable hardener pumps and for non flushable color pumps Major Components The major components of the flushable mag netically coupled gear pumps include Bypass Assembly Flushable units only Allows rapid flushing of the pump Gear Pump Is made from precision machined parts with tolerances of 0 00025 The gear pump is the heart of the delivery system and controls the flow of paint for a precise accurate coating e Manifold Connects gear pump to magnetic coupling e Magnetic Coupling Transfers rotary motion from the servo motor to the gear pump Servo Motor Transfers rotary motion from the servo motor tothe gearpumpthrough the magnetic coupling Performance Capabilities Both magnetically coupled gear pumps use a UL approved servo motor Explosion proof servo mo
64. nking 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 70 RCS 2 Parts Maintenance Troubleshooting Appendix iT Ransburg APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES Continued DANAHER AMPLIFIER Bii Code Fault Description Explanation and or Possible Causes PART 2 71 Bus Over Voltage Self Resetting The BUS voltage has exceeded the upper threshold limit Bus Under Voltage Self 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 s
65. ntenance Respect exceptionally close tolerances Gear Pump Operation The gear pump s internal bearing surfaces are lubricated by the metered fluids being pumped through the assembly The recommended oper ating speed range for these pumps is between 3 and 150 rpm Pump speeds over 150 rpm are not recommended Increasing the pump s operating speed improves its efficiency but also shortens the time fluid is allowed to fill the gear tooth spaces and lubricate the bearing surfaces Failure to fill the tooth spaces allows airinto the pump and can cause low delivery excessive wear reduced seal life and internal cavitation RCS 2 Parts Maintenance Troubleshooting Maintenance Magnetic Coupling There is no rotating shaft connecting the servo motor to the gear pump Instead this product employs a magnetic coupling to transfer power from the servo motor to the positive displacement gear pump The magnetic coupling provides several advantages over conventional rotary shaft systems Protects servo motor from paint leaks The magnetic coupling provides a physical barrier between the servo motor and the gear pump and serves to protect the servo motor from paint leakage Make seals less critical Theseals are less critical than ina conventional rotary shaft system If seals leak in the pump the system will still operate without the danger of paint entering the drive system Provide more up time Sin
66. oil before using the system To remove oil flush and purge the system with solvent RCS 2 Parts Maintenance Troubleshooting Maintenance Figure 1 Resin Flushable Pump Assembly RESIN FLUSHABLE PUMP ASSEMBLY PARTS LIST Figure 1 Qt Description y Lip Seal Front Side Plate Arbor Driven Gear Drive Shaft Driving Gear Center Plate Hollow Dowel Rear Side Plate Roll Pin Socket Head Cap Screw Required Seal Insertion Tool P N 22 543 Not Field Replaceable Varies based on pump size LipSeal 111 DrivenGear 1 Drive Shat DrivingGear LL 1 LHolovDowd RearSidePlaie l Cd 9 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Maintenance ASSEMBLY 22 337 PUMP BYPASS Flushable gear pumps have an air activated cylinder with two 2 ports that allow flushing of coating material from the gear pump This feature reduces the time required to fill or purge the pump of paint See Pump Bypass Valve Assembly in the Maintenance section NOTE Opening the pump bypass valve is not recommended on plural component mate rials Gear Pump Disassembly gt careful not to scratch or nick any surface of the plates seals gears and dowels inside the pump These parts have very precise tolerances Burrs nicks
67. ols 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 Failure of the E P transducer that controls the pump inlet pressure Failure of the pressure regulator that controls the pump inlet pressure Maximum Inlet Pressure value specified in the Channel Configuration is too low Pump is not turning Material is not available at pump inlet Failure of pump outlet pressure sensor Minimum Outlet Pressure value specified in the Channel Configuation is too high Restriction in the fluid line For Autmatic guns failure of applicator trigger valve Maximum Outlet pressure value specified in the Channel Configuration is too low Loss of feedback signal from motor ampli fier or flow meter Incorrect Calibration Factor in Channel Configuration There is no hardener flow due to the pump not operating or an obstruction in the hardener fluid line Electrical connection problems 66 RCS 2 Parts Maintenance Troubleshooting Appendix ir Ransburg APPENDIX B ERROR LOG CHART Continued Error Name Pressure Pot Empty Inlet Pressure Loss Outlet Pressure Loss Analog Remote Loss Ratio Out of Tolerance Motor Amplifier Fault Analog Feather Loss Analog Spare Loss Foldback Pressure
68. onnection problems 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 Oneor 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 Failure of Feather Pressure sensor Electrical connection problems 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 LN 9408 06 1 rRansburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX B ERROR LOG CHART Continued ame eem Pot Life Expired System Over Pressure Channel Card Parameter Fault Channel Card SPI Fault Channel Card Internal Fault Interface SPI Fault LN 9408 06 1 Channel Card Channel Card Channel Card Channel Card Interface Card 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 entere
69. our Ransburg system contact your local ITW Ransburg representative or ITW Ransburg AWARNING The user MUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literature therein identified 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 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 9408 06 1 Tells where hazards may occur Spray Area LN 9408 06 1 RCS 2 Parts HAZARD Tells what the hazard is Fire Hazard Improper orinadequate operation and maintenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosionis lost if any safety interlocks are disabled during operation Frequent power supply shutdown indicates a problem in the system requiring correction Maintenance Troubleshooting Safety SAFEGUARDS Tells how to avoid the hazard F
70. owel Insertion Tool Female P N 22 1034 15 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Maintenance NOTES LN 9408 06 1 16 RCS 2 Parts Maintenance Troubleshooting Maintenance Figure 3 Pump Bypass Valve Assembly ir Ransburg PUMP BYPASS VALVE ASSEMBLY PARTS LIST Figure 3 Description Double Acting Cylinder Breather 5 32 ODT X 1 8 NPT Tube Fitting 4 20 X 7 8 L SHCS lamp Block 6 ushing lunger 8 853232C ____ 5 16 18 X 1 L SHCS 9 2259 Adapter Plate Diaphragm Manifold Plate Teflon Gasket Seal UW 9158 16C 88 32 X 50 L Flat Head Slotted Machine Screw Part of P N 22 402 Manfold Assembly 17 lt LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Maintenance PUMP BYPASS VALVE ASSEMBLY This section describes the Procedures for Flushing Removing and Replacing the Bypass On the Flushable Magnetically Coupled Gear Pump Introduction The flushable magnetic gear pump has a pump bypass assembly which allows cleaning of paint from the gear pump by allowing paint solvent or a solvent air mixture to bypass the gears thus reducing flush and load times Typically the bypass is mounted on the pump which meters color NOTE It is possible however uncommon to use a bypass valve on a hardener pump Don t assume that a pump with a bypass is always a color pump Servicing the Pump Bypass Valve Assembly
71. rating 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 yourecognize 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 manual 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 y
72. remove the interface card 78818 01 from the rack prior to programming channel card Failing to do so will damage the interface card 1 Itis highly recommended that all connections and disconnections to programming ports on all PC boards be made with the power turned off to the RCS 2 rack That being said power down the rack prior to proceeding with this process Plug the RCS 2 Serial Cable see Figure 1 into the serial port of aPC or Laptop and the serial port on the front of the channel card NOTE gt DO NOT attach the Interface Card Adapter RCS 2 Parts Maintenance Troubleshooting Appendix 60 RCS 2 Parts Maintenance Troubleshooting Appendix 61 Serial Port for Programming Figure 2 Channel Card 78814 01 78814 02 3 Turn power on to the rack 4 On the PC select the Bootloader program supplied to you by ITW Ransburg If this software is not yet installed on the PC or Laptop please install it at this time 5 Once the software is running a screen that looks like Figure 3 should appear srv7Ransburg Find File to Download File Selected No File Selected Figure 3 Programming Software 6 Select the Find File to Dowload button 7 Select the drive and folder where the new firmware is located and then select the file Look in RCS2 Channel Card v202 hex pg v203 hex iw pg v204 hex
73. rol B Flow Rate Output B GND 3OA amp B Figure 20 Channel Board Block Diagram LN 9408 06 1 ing ing Troubleshoot Troubleshoot RCS 2 Parts Maintenance yur aes es ing 5 1104 uiejsKs 1 0 indu esods indu 0017 qom 081 gor 6 010 05 102340 lt lt lt N o lt 0 gor gor gor gor gor lt lt kel ped 64010 05 pondo o gor gor co 01 aa aia 1 eqons gZ uno 99035 ung o o 9905 uns 94016 CH uno eqons ung eqons CH uno S401DJOS 102440 N 5 uno 59015 uns 20 145 687 607 0 6 5 KPNI asuas og K10UJ9 N 95935 45014 9 491043409 4101 3902903 19u49u13 0004 we 14409 093085 1 2 62 59 J AI OSUDI 2142 Interface Board Block Diagram Figure 21 52 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Troubleshooting rrRansburg INTERCONNECT CHART FOR CHANNELS 1 3 5 AND 7 Channel A Signals Backplane Board 64 Cond Ribbon Cable Interconnect Board Channel Board P N 78816 P N A10586 P N A10554 78814 9
74. se With Non Explosion Proof Motor 5 16 Lock Washer For Use With Explosion Proof Motor 3 8 16 X 1 2 L Slotted Round Head Cap Screw 22 1310 Motor Mounting Plate 22 1311 Motor Standoff 3 5 cc rev Pump With Fasteners 5 5 cc rev Pump With Fasteners 10 cc rev Pump With Fasteners 4 2 2 3 8 16 X 1 1 2 L SHCS 2 22 333 Fluid Seal 4 78716 01 5 32 ODT 4mm X 1 16 Fitting 2 ET 3 5 cc rev Pump With Fasteners 5 5 cc rev Pump With Fasteners 10 cc rev Pump With Fasteners 5 16 18 X 1 1 2 L HHCS Retaining Ring 5105 37 Bowded External 78002 00 3 8 NPT Plug __6 o8 29 39 Continued On Next Page LN 9408 06 1 42 RCS 2 Parts Maintenance Troubleshooting Parts ID Ransburg DUAL HEADED PUMP ASSEMBLY PARTS LIST Cont Figure 11 em Part Description 41 22498 5 16 18 X 3 4 L SHCS ___ __ 44 20367 _____ 6FatWaser O 1 45 204882 s6LockWasher 46 206619 6 32X1 4 L Button Head Machine Sorew 1 7 47 206612 Retaining Ring 5101 50 Bowded Extemal 2 48 22130 Outer Magnetic Element Assembly 2 49 206199 Set Screw 10 32Xa 16 Long_ 2 50 221598 BeamgHeelne 20 2 52 __ 2 196 55 20811
75. 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 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 2 Continued DANAHER AMPLIFIER LED Geer Fault Description Explanation and or Possible Causes SFD Sensor Failure Internal SFD failure Excessive electrical noise in the drive environment causing communications interference SFDUART 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 128 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 ExtFaults is AuxFBFault then the AusFB device is in error Check the AuxFB faults A
76. t caninduce an electrical charge on objects which is capable of igniting coating mater ials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause afire or explosion The bell atomizer can rotate at speeds upto 50 000 rpm Atthese speeds the edge ofthe applicator can easily cut into skin Loose articles of clothing can also be caught by the rotating bell SAFEGUARDS Tells how to avoid the hazard Follow the requirements of the Material Safety Data Sheet supplied by coating material manufacturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use 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 anindustrial hygienist or safety expert and be NIOSH approved Parts being sprayed must be supported on conveyors orhangers and be grounded Theresistance between the part and ground must not exceed 1 megohm Reference NFPA 33 All electrically conductive objects in the spray area with the exception of those objects required by the process to be at high voltage must be grounded 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
77. ted 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 current 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 exce
78. tors rated for hazardous duty in Class l Division 1 Groups C and D environments are available as an option LN 9408 06 1 General Handling The magnetically coupled gear pump assembly is aprecisiontool designedto provide highly accurate performance over an extended service life The ability of the unitto deliverthe performance level it was designed for depends on the user closely following several essential requirements Neverlet the pump run dry Never pump contaminated fluids e Never reuse any Teflon seal Always replace damaged or worn seals with a new seal Consult the factory before using micas metallic s or waterborne systems Provide advance filtration for suspect fluids Provide skilled and careful maintenance Respect exceptionally close tolerances Precision Metering Pump The heart of the system is the high precision metering gear pump constructed of M2 tool steel To maintain the gear pump assembly in factory new condition the guidelines and procedures for pump servicing covered in this manual should be carefully followed With tight running tolerances of a remarkable 0 00025 inches there can be no allowance of casual handling that might be appropriate for a less exacting assembly Burrs nicks or particles of foreign matter could score an internal surface or cause the pump to seize up System Start Up Pump assemblies are shipped from the factory protected with rust preventive oil Remove this
79. ubing e 10 12 1 13742 01 Air Flow Switch 2 25766 106 Pressure Switch LN 9408 06 1 78 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX F SYSTEM LAYOUT LN 9408 06 1 1NOMJ C433 3015 832814 27 5 TANYA 01113 2 896011 2 4 84 1 TANYA 33098 92017 8 Z 996 STANNVHO STANNVHO STANNVHO STANNVHO 79 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS CONTROL CONSOLE SCHEMATIC PS1091 6606666606680680080 MOTHERBOARD CARD RACK Y ASSEMBL gt 24 Ee 5 1 s lt o 5 gt N 000000000002000002080 LN 9408 06 1 80 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX SCHEMATICS Continued CONTROL CONSOLE SCHEMATIC 888 98000660600 81 rmyRansburg 800 LN 9408 06 1 iT Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued CONTROL CONSOLE SCHEMATIC LN 9408 06 1 CN3O11 2844 oo000000000000009898 82 RCS 2 Parts Maintenance Troubleshooting Appendix rrRansburg APPENDIX G SCHEMATICS Continued CONTROL CONSOLE SCHEMATIC REFERENCE INPUT OR
80. ubleshooting Troubleshooting rrRansburg TROUBLESHOOTING BLOCK DIAGRAMS UMBILICAL CORD SIGNALS Over the next several pages are block diagrams of the following components of the RCS 2 control system Following the ribbon cable charts are charts of the umbilical cords cable assemblies that run from the main control console to the motor amplifier Main Control Console panels These charts outline what signals are Motor Amplifier Panel Fluid Panel carried by which pins wires and wire pairs RCS Interface PC Board These charts can be used to aid in tracing down Channel PC Board signal or lack of signal issues between the main control console and the motor amplifier panels These drawings can be used to get an overall picture of function of each panel and control board and how they interact RIBBON CABLE INTERCONNECT CHARTS Following the block diagrams are charts showing how the ribbon cable assemblies connect the channel boards and the interface board to the breakout boards mounted on the back panel ofthe main control console The breakout boards are simply pass through circuit boards that breakout the ribbon cable signals to screw terminals for easy field connections These charts detail what signals are passed to from the channel boards and the interface board so that these signals can be easily traced for troubleshooting purposes 47 LN 9408 06 1 ng i Troubleshoot ing Troubl
81. uxFBEnDatFlt 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 9408 06 1 72 RCS 2 Parts Maintenance Troubleshooting Appendix rmyRansburg APPENDIX D CALIBRATING THE PRESSURE TRANSDUCERS PART 1 Calibrating the 22 546 Transducer Calibration Procedure 1 Ensure that the pressure transducer 22 546 is tightened inthe manifold to a torque specification of 42 48 inelbs 2 Connectthe transducer using the calibration cable 22 1520 to a power supply and a digital ammeter as shown 4 Turn on the power supply 5 Removethe screw cap covering the adjustment screw on the pressure transducer if one is installed 6 Adjust the potentiometer in the pressure transducer such the current reading on the ammeter is 4 05 mA 7 Replace cap in adjustment potentiometer hole 8 Turn off power supply and return pressure transducer to service 3 Setthe ammeter to read currentin the range of 0 to 20 mA If transducer will not adjust to approximately 4 05 mA it should be replaced 3T AND CALIBRATION CIRCUIT DIAGRAM Calibration Cable Assembly 73 LN 9408 06 1 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX D CALIBRATING THE PRESSURE TRANSDUCERS PART 2 6 The calibrator wi
82. y 9 Select the File pull down menu 10 Select the Load Flash Image 11 Select the file you wish to download 63 Ira Ransburg Choose Flash Image Flash Image File Location face Card V4 02 FMSRABBIT bin OK Cancel Help Figure 10 Choose File 12 OK will sendthe file andthe following messages wil appear during the download process Sending Coldloader Sending Pilot Bios Erasing Flash and Sending Program Progress X Product Software RCS 2 Interface Sending Program Figure 11 Programming Status Bar Error Notes a If you receive an error such as coldloader bin file or Flash Table file not found select the Setup pulldown menu and then select File Locations There are 3 fields that need to be filled in with the locations of those files b Ifyou receive an error indicating thatthe Rabbit Processor was not found or an Error Reading or Writing Bits make sure the rack is powerd up the jumper JMP7 is removed from the board the connector is firmly connected to the programming port and that the programming connector is inserted with Pin 1 in the up position 13 Once programming is complete power down the rack 14 Remove the Rabbit programming cable from the card and programming PC or Laptop LN 9408 06 1 rmyRansburg 15 Remove the Interface Card from the Rack 16 Replace jumper JMP7 in its original location 17 Reinsert the Interface Card into the Rack 18 Reinst
83. yed on the DVM 2 You should be prompted to push the F1 button to continue 3 The unit should then prompt youtoconnectthe Once the adjustments are completed push the F1 cable with the transducerconnectorononeendto key to exit the unit powers down the transducer and then to the left connector in the top of the calibrator Disconnect the transducer from the calibrator and return it to service 4 You should then be prompted to connect the second cable to the mA input of a DVM and the other end to the right connector in the top of the calibrator 5 You will then be prompted to set the DVM for current LN 9408 06 1 74 RCS 2 Parts Maintenance Troubleshooting Appendix 75 rmyRansburg APPENDIX E RECOMMENDED SPARE PARTS A10549 MAIN CONTROL CONSOLE PARTS LIST Description E 2 TR TR SSEH 471 5 Amp AGC Fuse 10 Amp AGC Fuse a TLSME0005 00 NO Contact Block 1 1 210 6 740000 120 PilotLamp 0 a 8 7 38400 E Stop Switch Actuator LH 1 1 Fs E EEUU Interface Board RIO Interface Board Optional is Ethernet Switch 14 7881600 Backplane PC Board 002100 1 0 9 BEES TerminalBoard Channel vO f 1 1 Terminal Board System 64 Conductor Ribbon Cable 18 1058702 80 Conductor TP Mbenga L 19 2n Meowerline rer Channel Board Note The quantities channel boards is depen

LN-9408-06.1 RCS-2 Parts, Maint

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