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Serv. Man. LN-9408-06.3

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1. D c add bed by gt gt D o 5 8 g ate 9 9 E S Figure 4 Main Control Console LN 9408 06 3 20 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg 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 Description 10554 00 Terminal Board Assembly DynaPump 11530 00 64 Pin IDC Ribbon Cable Interconnect Board TR SSEH 472 AGC 10 10 Amp Fuse AGC 5 5 Amp Fuse Ethernet Switch 5 Port Compact Power Line Filter 78835 00 Power Supply 24VDC 180 Watts 10705 02 Touch Screen PC Assembly Switch Selector Maintained 77384 00 Switch Mushroom Head E Stop Red I LSME0005 00 Contact Block Normally Open LSMEO007 00 Pilot Light Block 87 01 Ouantity Reguired zi o E ES I c o N N 2 n m I EN SE
2. 55 100 TN Z 1409 qQN3931 19 54105 1640157 usn ojgougj usn J uise 1541009 jpuond uongo 1429 HM anno poocooooo xl ASSY 9901 XIN Bh 934 Josuoes Josuos Sas CC eet I a 5 V HO S id o c enn d 5 a Q un 196 7 594 a used 019 5 AN lt 3 Josues NES sei EF dung 390 4osues 1629 g 18410300 PIU 3540490 Ll 3 20 eas cUm DIL ysna 390 4osues ye E oH i 15410409 E 19 xX K 4 jou isA0102 yo 9 4 3914 pe ue jos E LZS GZS 9 uo jos a 195 694 77105 12401380 M9DIS SADA 49199 LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Manual Change Ransburg MANUAL CHANGE SUMMARY This manual was published to supercede Service Manual LN 9408 06 2 RCS 2 Parts Maintenance and Troubleshooting Manual to make the following changes 1 Change
3. Jeonp Josues SUDJ 4 3 8 15410309 Iguupuo 1106 S i S jJeuJpg S I S JO OW 42 RCS 2 Parts Maintenance Troubleshooting Troubleshooting s4030euuo p409 b5 Iquuf Ransburg 8 4 sjpu6is 2 eunsseig Jeonp SUuDJ 4 3 V I8 upuo sud jndjno plouejos MN 1 1007 35072933 519228 S 1040140 o 5 5 a 5 E 3 3 2 3 2 2 Ig A a voe OVA 021 Figure 18 Motor Amplifier Block Diagram 50 LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Troubleshooting Catalyst Fluid Regulator Optional LH Catalyst Inlet gt Catalyst Flow Sensor Opt Catalyst Pump Inlet Pres Sensor Opt Spiral Static Mix Tube Assy Mix Block OOOXXXXXL 5 9 Hot Catalyst Flush Enable Enable Catalyst Solvent Ransburg Solvent Manifold X Solvent inlet Flush Solvent 8 Resin M Pump Es Outlet Resin Pres Sensor Pum Mag Coupling Solvent Pump E Bypass a Figure 19 Fluid Panel Block Diagram 51 Inlet n Resin Fluid 3 Regulator Optional LN 9408 06 3 R
4. 2495 Interface Board Block Diagram Figure 21 LN 9408 06 3 53 Ransburg RCS 2 Parts Maintenance Troubleshooting Troubleshooting INTERCONNECT CHART FOR CHANNELS 1 3 5 AND 7 Channel A Signals Digital Fast Fill Channel Fill Feather S et Run Halt Fault Reset Trigger 1 Motor Amp Fault Trigger 2 Trigger 3 Trigger 4 Volume Fill Pushout Fault Out put hi Fault Out put low Read y Out put hi Read y Out put low Spra y Shutdown hi Spray Shutdown low Flush Request hi Flush Request low Motor On hi Motor On low Motor Amp Reset hi Motor Amp Reset low Digital Ground Digital Ground 24 VDC 24 VDC 24 VDC Flow Rate Command Analog Ground Feather Pressure Analog Ground Pump Inlet Pressure Analog Ground Pump Outlet Pressure Analog Ground Spare Analog Input Analog Ground Motor Speed Analog Ground Pressure Con trol Analog Ground Actual Flow Rate Analog Ground Pulse d Motor Feedback Motor Feedback A LN 9408 06 3 Channel Board P N 7 8814 Input or 96 Pin DIN Output Connector Input 1 Input 1A Input 2C Input 2A Input 3c Input 3A Input 4 Input 4A Input 5 Input 5A Input 6 Input 6A Output 7C Output TA Output 8c Output 8A Output oc Output 9A Output 10 Output 10A Output 11 Output 11A Output 12C Output 12A N A 30A N A 30B Output 32A Output 32B Output 32 Channel Board P N 7 8814 Input or
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6. el e 9 SE 1225 cnu DOG 1 Oe vg 9 Ole EH eal 1201 Tin P 9 gt LSI NSH 125197 maa eas A AlddNS N3MOd 20 151154 180140 Josues pono oma e 2901 o 501 YAL TH 45410409 Y 1 41538 555 2 902 sioi OSOLNI 3105409 0PO NO 1901 05 2 dO 30 40 Lava 030 TUO goi X9 ra so uu s 199 I 2211507 1501 Ka WOONOO vo ID or co Di TOL TOL I s le lows 070149 8 vor 10 72 ini 1607 5 lt OWA 021 T tor OL ED 5 amp 3 1 85 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg SCHEMATICS Continued APPENDIX G MOTOR
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8. 2291 1 0P0INO 8 0601N3 2191 2 0 01N2 2 0FOLND 003123402 LON 8 0tOIND OL 1091 Y OBSINO OL 1651 8 O6SINO OL 1861 V O4SINO OL 1491 B O4SINO OL 1654 V OPSLNO OL 81 8 OPSINO OL 1260 Y OZSLNO OL 1251 8 0ZSINO nm 1501 sor lt 1 lt 9 1050149 au 1501 30 1 1 1 1501 a 122 1 OVOLND 1501 I 30 nd 1501 LN 9408 06 3 duys puusa 8 24 pappo Duonippo 29404 aui moq 5190 asn jou eio M 910 IOJON Naf RCS 2 Parts Maintenance Troubleshooting Appendix SCHEMATICS Continued APPENDIX G MOTOR AMP PANEL SCHEMATIC r SNIMIM TSATVIVO OSOLND JAYS 11 215 I 10 1 JNnSS3Md LINO 65182 g s Ob 8 elol E 5 zl em edet De OF NIS3H 0 01 2 ev Oli U P 29 ea G3HDSS3Nd LIINI 5 15187 l 39055344 171no wisay S187
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11. 3 vus ung gt yus JSST ESI ELIT NNOO 3WVN VNOIS NNOO 137205 v9 LNdNI 133205 96 394343338 55080 FVD NOHHIlH 012 0 02 79 yndjno sjogwfg Ge 20A vct ERER sjpuiu4e jndu aypoipur sjoquu s 10 G g 8 5 2 a 5617 Wau snis 1615 02 aor cele aor Sele qndup 52595 7 uw ynau 467 3ndu 001 j8qumw 460 E Wau JSquinN Z r Op JequnN 5252 rau 3580mW 101 Peor 160 Egor 180 5232 150 j ms 19eus 1 H ziseno 1 Jo les 1 us 1 1 gt Z yous 1 CISZNO d 110 sus ZLOZNO Jo pog T 84 LN 9408 06 3 Ransburg NONAOO 2d 303 G 01v 335 MNOlLdO 34v SM3IMMVE 310N 7661 2991 1411 OQA 2 2091 n OSOLNO 1411 00 2 891 1 0SOLNO 411 OQA 2554 n 0POLNO 1 11 OQA
12. _15 LSMEO006 00 16 EAM 18 19 Em 23 24 EN 28 m gt N 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 21 LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg Figure 5 Rack Assembly o 2 5 o lt gt m o o lt lt o lt 14 Description 2 Backplane Board Assembly RCS Rack Sub Assembly RCS 2 A10530 00 RIO RCS 2 Interface Board 77377 22 2 78818 00 Interface Board Assembly RCS RCS 2 78814 01 or 02 Channel Board Assembly Cover Assembly Only reguired if using vBradley RIO Ouantity dependant on number of Channels reguired Cover plates used to fill unused slots 22 LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg NOTES 23 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification Figure 6a Old Style Motor Amplifier Panel LN 9408 06 3 24 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg OLD STYLE MOTOR AMPLIFIER PANEL PARTS LIST Figure 6a Description Gty A10795 00 Ethernet Industrial Bulkhead W RJ 45 Connector A10798 00 Ethernet Cable Not Shown A10564 09 26 Socket Bulkhead Assembly W Flying Leads A10564
13. is one 1 year from date of purchase WRAPPING THEAPPLICATORIN PLASTIC SHRINK WRAP ETC WILL VOID THIS WARRANTY LN 9408 06 3 RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORK MANSHIP OR MATERIALS THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG AS SUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will assume no responsibility for repair or replacement of the item or items The purchas er therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable RCS 2 Parts Maintenance Troubleshooting Warranty Policies 60 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX A UPDATING THE FIRMWARE AND SOFT WARE ON THE RCS 2 NOTE gt It is highly recommended that all pa rameter data be backed up to a USB memory stick prior to reprogramming any ofthe cards or replacing the user interface software Programming Cable The cable used for programming both the channel card and the interface card for the RCS 2 has a
14. 8743 v sien oii OT DOR FEF IN 30A 2 JOVEN Su5 9 1100 5158 yuo 91 linod 595 Wu5 DHIInOd 52995 guo e vo Wu5 H UD 46158 Su5 91T888 usni amp o H ESH 20405 40 45 2 Juwopynus Roig H Jawopinus 8 u0 91J RD3M vo 2740 6 7 10 SUMO VUUD IH Suma 575 vuv 8 0 BEET 800 2 790001 2 2 290001 TUS duy duy 3o 80 0 TUITE MOI VUu5 15508 Wi047T0H VUD Ung 2801583 Tr v 82 1 ENA 7HNvd 3105N00 1 5 7081405 gs m m 82 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Append
15. 12845 NONWO 20 I T 83 T 83 7535 OR spuncus 42 TV 742 ony 8703 1950 82795913 95 9097 8 ao Uu 21646 V 995 Tn Sung guna Wu Sung 45 78914 MT 45 sUnssaij 2501653 8 9108 DOR S N IAEF 1587 1 a7 puna BUnGJS TO a 21005 sede W u DHIInOd 1595 VuO DHIInog sedg 7901 vu3 e1 uo J919W 2 1 7552 artes 15158 sni V H wen 4595 VvUJ DH Uscpiug SWOT TRH ER vR roa vuo T ie Wu noun Sup r 890 7 SEBEL
16. 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 de sired ratio and the actual ratio expressed as a percentage error exceeds the Flow Rate Ratio Tol erance Percentage 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 2 Failure of Pump Inlet Pressure sensor Electrical connection problems 2 Failure of Pump Outlet Pressure sensor Electrical connection problems 2 The Remote Analog Setpoint source is configured for voltage instead of current
17. Green Blue Green Umbilical Cord A10487 Pair Red Blk Wht Red Whi Blk Blu Red Grn Blk Blu Blk Blu Blk Brn Blk Brn Blk Yel Blk Yel Blk Orn Blk Orn Bik Yel Red Grn Red Red Blk Wht Red Wht Blk Grn Bik Brn Red Brn Red Orn Red Orn Red Yel Red 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 Channel Fill Ready Lo Motor Speed Shield Flow Rate Command Spare Wire Spare Wire Spare Wire Motor Amp A10776 Wire No LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Troubleshooting EVEN NUMBERED CHANNEL UMBILICAL CORD SIGNALS Control Console A10549 Wire Numbers Channel Channel Channel 4 6 Channel LN 9408 06 3 Pin lt lt gt Umbilical Cord 10487 Wire Black Red Black Red Black Blue Black Brown Black Pair Red Blk Wht Red Wht Blk Blu Red Grn BIk Blu Blk Blu Blk Brn Blk Brn Blk Yellow Yel Blk Black Yel Blk Orn Om Blk Black Orn Bik Red Yel Red Red Grn Red Red Red BIk White Wht Red White Wht Blk Green Gm Blk Red Brn Red Brown Brn Red
18. RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg 35 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 No 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 b0 NoPumpinduded 1 No Pump Included 77844 02 Pump Kit RCS 5 5 M2 Tool Steel 6 1 77844 11 Pump RCS 5 5 M2 Tool Steel 7 7 8 7784413 Pump RCS Poyond vs 9 7784403 Pump 10 0 CC REV M2 Tool Steel B 784 5 Pum RCS 00 Poyond LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification TABLE V CATALYST NON FLUSHABLE PUMPS _ T 6 1 77844 04 Pump Kit RCS 2 92 CC REV M2 Tool Steel TABLE WX COLOR VALVE STACK TABULATION _______ No Coler Valve Stack Installed 02 11418 8 1 5102 111 2 Color CCV Stack Assembly W Solvent Air Push o4 1 4 8 1 CCv5104 111 _ 4 Col
19. Red Orn Red Orange Orn Red Yellow Yel Red Drain N A Blu Red Grn Red Blu Grn Blu Grn Blue Green Blue Green 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 58 RCS 2 Parts Maintenance Troubleshooting Troubleshooting Ransburg NOTES 59 LN 9408 06 3 Ransburg WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipment that within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with Rans burg s written safety and operating instructions and has been used under normal operating con ditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG AP PROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc
20. System 1 64 Conductor Ribbon Cable 50 Conductor TP Ribbon Cable 122 1108 7 Power Line Filter P Ri Channel Board Note The guantities channel boards is dependent on the number of channels used and is therefore included with the Motor Amplifier Panel list 10705 02 78818 0 77377 22 RIO Interface Board Optional A10998 00 78816 0 A10554 00 on 0 1 12 13 14 15 16 17 18 19 1 0 0 Interface Board 1 I 0 9 0 0 N NO NO LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Appendix 76 RCS 2 Parts Maintenance Troubleshooting Appendix 77 Ransburg APPENDIX E RECOMMENDED SPARE PARTS Continued A10776 MOTOR AMPLIFIER PANEL PARTS LIST Quantity Being Purchased Part Description 78814 01 02 Channel Board 1 1 2 Motor Drive Amplifier GE Fanuc Motor Drive Amplifier 24VDC Power Supply 24VDC Relay 5 Amp AGC Fuse 7 6 TR SSEH 472 10 Amp AGC Flow Switch Amplifier 8 22 10466 Flow Monitor Control Unit 9 122 1245 Zener Barrier for 4 20mA Pres Xducers 10 Zener Barrier for 24VDC Rem Oper Panel 11 E to Transducer 12 Tachometer Cable GE Fanuc Amps Motor Drive Cable GE Fanuc Amps Pressure Transducer Cable 15 Catalyst Flow Sensor Cable 16 Power Line Filter Color Change Controller Output Module Opt I A12220 00 Mo
21. 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 proce dure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation draw ings and appropriate Ransburg equipment man uals to reconcile such differences Careful study and continued use of this 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 your Ransburg system contact your local Ransburg representative or Ransburg A WARNING gt The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified gt This manual MUST be read and thoroughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the e
22. will be flashing This is normal 8 Open the Rabbit Field Utility RFU exe program on the PC or Laptop 24 Rabbit Field Utility 2 40 Setup Figure 9 Rabbit Field Utility 9 Select the File pull down menu 10 Select the Load Flash Image 11 Select the file you wish to download LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Appendix Choose Flash Image Flash Image File Location Card 4 2AFMSRABBIT bin Figure 10 Choose File 12 OK will send the file and the following mes sages wil appear during the download process Sending Coldloader Sending Pilot Bios Erasing Flash and Sending Program Progress X Product Software RCS 2 Interface 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 If you receive an error indicating that the 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 progr
23. 1 1 7 gt 9 2 22 930 22 332 2 19 20 9946 800 4 I 7 e These items differ based on desired pump size NO SS 1505 CD_ 22104 22547 sO 7959 280 SS 1505 CD 22808 arber o E C MEN Re i ECCO __ 22875 2284 2245 22692 ____ CA 9946806 S 7 LN 9408 06 3 Ransburg Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification LN 9408 06 3 Figure 10 Flushable Pump Manifold Assembly 40 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS LIST Figure 10 pane Dee 1 22937 BypassVaveAssemby 7 1 2 236_ ORmgSa 172 47 9946 48C 22 935 22 332 3 8 NPS M X 3 4 16 Stainless Steel Adapter Fitting 22 333 20 5740 22 335 97 2271 22 862 22 939 22 545 22 854 77305 00 78202 00 78201 16 M8 X 1 X 16mm HHCS 4 E 8 9 22 875 gt 7564 119 868 Outer Pole Ring Assembly 22 878 78178 00 78179 00 22 867 SS 1505 CD 7959 28C 1 4 20 X 7 8 L SHCS 22 1047 Non Explosion Proof Kollmorgan Motor 22 547 Explosion Proof Kollmorgan Motor 22 1047 2 Non Explosion Proof Motor 55 1505 Lock Washer 1 4 7959 34 1 4 20 X 1 1 16 L SHCS These items differ based on desired pump size A1 LN 9408 06 3 Ransburg RCS 2 Parts Ma
24. 10 26 Socket Bulkhead Assembly W Flying Leads ier A10783 01 Motor Drive Amplifier A11389 00 Power Supply 5VDC amp 24VDC 180 W 78835 01 Power Supply 24VDC 180 W 22 1108 8 TRSSEH47 9 555 7016 TR SSEH 471 A10781 00 22 1050 22 1046 22 1245 78643 00 41 VSO 1005 73837 08 A10785 01 A10786 00 A10787 00 21 A10793 00 Tachometer Bulkhead Cable Assembly 10796 00 76965 00 22 1045 41 1000 1 4 41 1001 3 8 ODT Bulkhead 10789 00 Motor Drive Bulkhead Cable Assembly RCS 2 Motor Amp Panel A10974 00 26 Socket Bulkhead Assembly Used only if the optional Color Change Seguencer is installed Used only if the optional Color Change Seguencer is not installed Refer to Motor Amplifier Panel Model Identification for quantities 2 4 1 1 25 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification SSS FED n LN 9408 06 3 eoeeoooooooo eooooo CHA re REG REG OUT me LL b Figure 6b New Style Motor Amplifier Panel 26 RCS 2 Parts Maintenance Troubleshooting Parts Identifi
25. 2 channel card to turn faster than the motor is capable of turning This typically indicates that improper parameters have been programmed into the RCS 2 Verify parameters such as pump size calibration factor maximum pump speed and maximum flow Feedback Lost This indicates that the motor amplifier is no longer receiv ing feedback from the resolver mounted inside of the motor 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 OV Motor Power Over Voltage This indicates that the voltage being supplied to the motor amplifier is excessive Check the AC power supply voltage to the motor amplifer panel Motor Power Clamp Excessive Duty Cycle Motor Over Current Fault This indicates that the motor amplifier has exceeded the al lowable current limit for the motor This usually indicates a motor pump or magnetic coupling that is bound up and not able to turn freely Motor Over Temperature Fault This indicates that the motor is running excessively hot Look for binding of the motor magnetic coupling or pump Drive Over Temperature This indicates that the driver circuitry in the motor amplifier has exceeded the allowable temperature for that circuitry This could indicate a failure in the motor amplifier itself a failure in the motor or a bound motor pump or magnetic co
26. AMP PANEL SCHEMATIC 1501 zl NONWOO NNID3N 1601 8 5 2 i o q 00 02221 2 ASSY 318VO NOH MOIOW 8vZ OL gg sz Wows 00 02214 ma UED gyn INT T 7507 1 1501 NunI3u Z lt T Z 1122 45 LIBIHNDZdNIO id 1212 LSIHNDZdNIQ AMR L E ps MI n Eros i Eun 1 T s k NI YHo 1n0 v T 2 NI v 1 a 3 dev 2 I m 1602 6L 015 zh 2 1 N WOO 5 N 1802 WOO 5 ol KESIR 5 Z 1 1 1702 Z Tere zinod 1902 3 ZO 8 1 vo oz KA gt 1 21100 6 nid 1502 Nna rcinod 6 NOLOA P Fd fone NOLON D Tore 2 SC Od O4 15 1 1 2 i 1702 dWO YNY 52 C NIS3H gt 5 1665 aD FONO YNY Ta re 1 06 4D YNY M o s1130 ATBW3SSY 318VO 504 519130 A18W3SSv 31892 304 2 40 Z 133HS 9ZZOLV is
27. Analog Ground Actual Flow Rate Analog Ground Motor Feedback Motor Feedback B Solvent Solvent B Channel Board 7881 4 96 78816 96 Socket DIN 96 Pin DIN Connector Output Connector Side Input or Output Inp ut N A Input N A Input N A Input N A Input N A Input N A Output N A Output N A Output N A Input Input Input Input 13C 13A 14C 14A 15C 15A 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24C 24A 30A 30B 32A 32B 32C Channel Board 7881 4 96 1B 30C 13B 30C 14B 30C 15B 30C 16B 30C 17B 30C 19B 30C 20B 30C 21B 13C 13A 14C 14A 15C 15A 16C 16A 17C 17A 18C 18A 19C 19A 20C 20A 21C 21A 22C 22A 23C 23A 24C 24A 30A 30B 32A 32B 32C Connector 64 Cond Ribbon Cable P N A1058 6 96 Socket 64 Socket DIN IDC Back Side Connector Connector 13C 13A 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23A 24C 24A 30A 30B 32A 32B 32C Backplane Board P N 78816 96 Socket DIN 50 Pin lDC Connector Front Side 1B 30C 13B 30C 14B 30C 15B 30C 16B 30C 17B 30C 19B 30C 20B 30C 21B Connector Back Side 1 4 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 13C 25
28. MODULE RACK POSITION O SPARE SLOT RACK POSITION 1 1171 1171 1111 1111 OWA 021 8 o 87 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued LN 9408 06 3 MOTOR AMP PANEL SCHEMATIC 1112 1111 1112 1111 1112 1051 1171 SPARE SLOT RACK POSITION 6 NOWNOO CN1050 Tr vil ri 1 1 1 1 1 1 1 8 a P E 3 8 8 8 uu i gt 5 5 5 5 8 d 8 d ao A se 25 z 5 z z o 2 Cr SGA vc 1171 OVA OZI 1111 NMLD3N 25 1051 1171 SPARE SLOT RACK POSITION 4 1051 NONNOO SPARE SLOT RACK POSITION 5 vt 1171 OWA 021 1111 8 8 6 0 88 RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC a ND 8 NGWNWOD OG 5 5 5 5 5 3 5 3 8 5 8 8 8 8 Begs 24 5 z z gt gt 2 z z z z z 5 E x gt 2 E zy E 5 A 5 a a 8 8 5 8 5 8 8 8 8 8 8 g 9g a ao a F 25
29. 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 A11892 00 Programming Cable Set Programming the Channel Card 78814 01 78814 02 NOTE Always remove the interface card 78818 01 from the rack priorto programming any channel card Failing to do so will damage the interface card 1 is 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 a PC or Laptop and the serial port on the front of the channel card NOTE DO NOT attach the Interface Card Adapter LN 9408 06 3 Ransburg Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix 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 Ransburg If this software is not yet i
30. SHEET 7 6651 SPARE OUTPUT 5 6671 SPARE OUTPUT 4 LED B JE 2 gt a 244 4 L 4 5 4 5 5 8 2z 2z a ao m 5 8 8 o 5 EO a S 3 Ex 5 B E 2o ba a oo 5 5 5 lt 5 5 N 54 B 1171 O 97 1111 4 gt DVA 021 gt 5 x 2 NORWOO 20 2 5 5 5 5 5 5 2 8 5 9 5 3 5 5 2 gt gt gt gt gt gt gt gt T i Y lt 5 lt 3 I gt 5 B 8 al dE i 8 a 2 amp 5 S gt 5 5 2 8 9 D 2 2 gt ul 2 8 29 8 5 5 8 ki z 22 2 az a amp 8 8 5 5 5 8 8 5 8 8 d Ex oo 2o oO a 1171 2 1171 V OZIL gt E 90 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix SCHEMATICS Continued APPENDIX G MOTOR AMP PANEL SCHEMATIC Wann NOWNOO 190 22 0140 318V
31. Young PWS 1200037 791531 pa 900007 VUS TIH 1900905 CR OF Yo THI TANYA OSOINO 43 p amw 8 1 1 1 7081402 e 0000000000000 LN 9408 06 3 83 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg SCHEMATICS Continued APPENDIX G CONTROL CONSOLE SCHEMATIC wan 5295 5 92595 usn gua ei usepynug 0295 lt Su5 DH jesepinus 45255 B uo 1Fposs lt Suo pnfessu gu m F 8 49 g ug ug eds ESI 70 19 SUA g uo r 29651 Huo g 2555 2 0 29551 Huo Wnoj duy 390 2 29651 gt 35 Huo ung ESI TSU 39 aw 35 TUN 350 vuonon 5 595 5095 VWO S1 I0 26 58 lt V u2 tH Juo Jo vuoteen GEA 5 957 vu oeps 45135 0205 ma Vu RP 5 vyo H vuo ud 31545 35 Yd NI SUMA gt JSBBHI Vug g gt Vaz 3 V u9 inoj duy jojo gt Woo seg NP637YPH
32. Z 30 Z 924017 es OL 33434 fan Zu OL 83434 outs yndyno ub lt lt indui joquits OV 021 8 9 86 LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg APPENDIX G SCHEMATICS Continued MOTOR AMP PANEL SCHEMATIC 1112 Wallan 1051 051 NOWNNOD 20 MY AD ap 9999909099 N 2 2 5 5 5 z E 5 u u oo a 3 n on S 5 5 26 A u eee 5 5 5 5 5 S 2 8 amp 8 29 amp x 8 Z x e 1171 90A PZF 1171 1111 1111 OVA 021 8 0 080 8098 8809 99 988 0 1112 1112 1051 1051 NONWOO 1 5 INPUT
33. loop Loss of feedback signal from motor amplifi or flow meter Incorrect Calibration Factor in Channel Configuration Oneorboth channel is unable to deliver the correct flow rate due to restriction in the fluid line lack of material Reference the motor amplifier diagnostics determine the cause of the fault Electrical connection problems 2 Failure of Feather Pressure sensor Electrical connection problems 2 Failure of Spare Analog input sensor This error is normal when operating in Fast Fill or Channel Fill mode For Automatic guns restriction in the fluid line For Automatic guns failure of applicator trigger valve 68 RCS 2 Parts Maintenance Troubleshooting Appendix 69 Ransburg APPENDIX B ERROR LOG CHART Continued Pot Life Expired System Over Pres sure Channel Card Pa rameter Fault Channel Card Inter nal Fault Interface SPI Fault Channel Card Channel Card Channel Card Channel Card Channel Card Interface Card Description Mixed material in the applicator fluid 1 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 entered in either the Channel or Job Configuration No communication via the Serial Peripheral Interface bus has occurre
34. pump binding LN 9408 06 3 Ransburg Ransburg RCS 2 Parts Maintenance Troubleshooting Maintenance 3 Insert driving metering gear 6 into center plate NOTES 7 Manually turn the 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 check torque 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 need to be separated and replaced Individual pump parts are not field replaceable and must be returned to for replace ment 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 of the shaft end opposite the tang Ransburg can supply a Gear Alignment Gauge for this purpose The tool is P N 11 1032 Contact Ransburg for additional information Hollow Dowel 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 place
35. 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 to the rack 2 Remove the Interface Card from the rack 3 To download new software to the interface card requires the card to be putinto 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 is being used in the programming mode Programming Jumper JM7 Figure 5 Removal of Programming Jumper 4 Reinsert the Interface card into the rack 5 Insert the rectangular connector on the Inter face Card Adapter Cable Figure 5 into the port on the lower left side on the front face plate of the module This is the rectangular hole in the aluminum plate labeled PRG DB Figure 6 Interface Card 78818 00 LN 9408 06 3 Ransburg Ransburg 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
36. 13A 26 14C 27 14A 28 15C 29 15A 30 16C 31 16A 32 17C 33 17A 34 18C 35 18A 36 19C 37 19A 38 20C 39 20A 40 21C 41 21A 42 22C 43 22A 44 23C 45 23A 46 24C A7 24A 48 30A 60 30B 32A 64 32B 32C 63 50 Conductor Twisted Pair Ribbon Cable A10587 50 Socket 50 Socket DIN IDC Connector Connector 1 1 4 4 19 19 20 20 Ransburg INTERCONNECT CHART FOR CHANNELS 2 4 6 AND 8 Interconnect Board P N A10554 J1 64 Pin IDC Screw Connector Ierminal 25 1B 26 2B 27 3B 28 4B 29 5B 30 6B 31 7B 32 8B 33 9B 34 10B 35 11B 36 12B 37 13B 38 14B 39 15B 40 16B 41 17B 42 18B 43 19B 44 20B 45 21B 46 22B 47 23 48 24 60 25 64 26 63 26 Interconnect Board P N A10554 J2 50 Socket IDC Conn 1 4 19 20 Screw Terminal LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Troubleshooting INTERCONNECT CHART FOR SYSTEM 0 SIGNALS System Signals Digital Gun 81 Strobe Gun 2 Strobe Gun 3 Strobe Gun 4 Strobe Gun 5 Strobe Gun 6 Strobe Gun 7 Strobe Gun 8 Strobe System Fault Out Hi System Fault Out Lo System Pulse Out Hi System Pulse Out Lo Client Connected Hi Client Connected Lo Job Number 1 Job Number 2 Job Number 4 Job Number 8 Job Number 10 Job Number 20 Job Number 40 Job Number 80 Job Number 100 Spare Input 1 Spare Input 2 Spare Input 3 LN 9408 06 3 Input or Output Input Input
37. 2 TOSE S u5 DH UAGDImus vuo Hnos 1092 TH YUo UH VIT g uo DH iod vuo pHfino3 d 8453 11 Sumix VOCI Sur ROHL 9 80 2 dux Y05063 duy TOTS amp 8 1 295001 5 WADI WOH 0 wun vug ung TOPS TTT aH y GWeS S 5 IH 1900005 900007 1653 8 40 IS NO 3105 02 o8 0 0030006000000 30 19245 uo senunuoj NOWNOO siouuue aypoipu EH Onr TT 83 SER T T 83 2066 208 T 83 DY power hyw spunoio Eu 8 TV Ten 19206 818885813 8 uS UN 5 9 19 Uy 45
38. 3 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 5200 DC input drives external BUS capacitor is too small add capacitance 5200 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 Motor overspeed Invalid hall state Invalid hall transition SFD UART error during SFD initialization Bad motor data check sum The drive will attempt to initialize the SFD up to 4 times If it fails this error is reported Excessive loading on SFD 5 supply Short in the feedback cable on SFD 5 J3 1 to ground Motor and Drive are not compatible Auto setup calculation yielded a desired parameter value outside valid range Incorre
39. 5 amp 5 5 25 8 8 8 O KO a a ox m Y N QUE SH SPSHs Nt E gi TM EU CU m mcum 1171 1171 1111 1111 OVA 021 8 00000 e o 5 8 TNONNOO 8 5 s E a 8 Pas Ao died a EE Jr 22 524 Eo z z z z wes 8 5 EG ES 8 8 3 8 2 5 2 o a o ao _ o a Or Or 5 K n E 5 8 8 8 8 gt 3 52 a a a J a Ex 5 zi 59 oe 5 D 0D mos m 9 QUE 990 9 59 cN E 2 02 gt 8 08 8 89 Ransburg LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued LN 9408 06 3 MOTOR AMP PANEL SCHEMATIC 1112 1111 1112 TYLOSIN 1051 22 4 nad H S gt H Mm zL l NZP SOR ERS 25 NOWNOD A 1 CN1040 TO LINE 7191
40. 8 3 10 13 Ea ES SEE 135 Oor 18 19 25 0202 CO CO CO OO NO 02 PO 2 O O LN 9408 06 3 Ransburg Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification DUAL HEADED PUMP ASSEMBLY PARTS LIST Cont Figure 11 tem weno y o 40 ee 42 853224C T 2 4 20 1671 1 Stick Screw 2 Ratio is controlled based on pump sizes cc s rev and the size of the 2 drive pulleys 54 LN 9408 06 3 44 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg NOTES 45 LN 9408 06 3 Ransburg LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Parts Identification Figure 12 77671 00 5 Way Ball Valve Assembly 46 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg 77671 00 5 WAY BALL VALVE ASSEMBLY PARTS LlST Figure 12 1 20 317 10 32 X 1 2 SHCS 2 78959 00 Housing 3 7554 03 Ring 1 8 ID X 1 4 OD 72 1217 Beam i 5 20 4609 Belleville Washer 4 6 7554 36 O Ring c O SS 7 78957 00 8 7554 09 O Ring 3 8 ID X 1 2 OD 9 78955 00 Sem 7554 07 ORng 20 3467 O Ring 2 78958 00 20 4677 88 32 X 1 2 L SHCS 14 78960 00 Housing 20 2652 8 32 X 3 8 L SHCS 78965 00 Re
41. 8 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Contents CONTENTS Continued PAGE WARRANTY POLICIES 60 EIMETED WARRANT e ce NR AA 60 APPENDIX 61 93 APPENDIX A UPDATING THE FIRMWARE AND SOFTWARE 2 41 i atero be YN 61 66 APPENDIX B ERROR LOG 67 69 APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 1 AND 2 asas 70 73 APPENDIX 0 CALIBRATING THE PRESSURE TRANSDUCERS PART 1 AND 2 n n 74 75 APPENDIX E RECOMMENDED SPARE PARTS 76 79 APPENDIX SYSTEM 02200 2 010 0 000 nnnm nennen isu usar 80 APPENDIX 5 022200 4 0 00 a Mas AG A Ous 81 94 LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety ature for your 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 To help you recognize this informa tion we use the following symbols Please pay particular attention to these sections A WARNING
42. 96 Pin DIN Qutput Connector Input 2B N A 30C Input 3B N A 30C Input 4B N A 30C Input 5B 30 Input 6B N A 30C Output 7B N A 30C Output 8B N A 30C Output 9B 30 Input Input Backplane Board P N 78 816 96 Socket DIN 96 Pin DIN Connector Back Side 1c Connector Front Side 1 78816 96 Socket DIN 50 Pin IDC 64 Cond Ribbon Cable P N A1 0586 96 Socket DIN IDC Connector 1c 50 Conductor Twisted Pair Ribbon Cable P N A10 587 64 Socket Connector Interconnect Board P N A105 54 J1 64 Pin IDC Interconnect Board P N A105 54 54 RCS 2 Parts Maintenance Troubleshooting Troubleshooting 55 Channel B Signals Di gital Fast Fill Channel Fil Feather Set Run Hait Fault Reset Trigger 1 Motor Amp Fault Trigger 2 Trigger 3 Trigger 4 Volume Fill Pushout Fault Output hi Fault Output low Ready Output hi Ready Output low Spray Shutdown hi Spray Shutdown low Flush Request hi Flush Request low Motor On hi Motor On low Motor Amp Reset hi Motor Amp Reset low Digital Ground Digital Ground 24 VDC 24 VDC 24 VDC Analog Hardener Flow Analog Ground Flow Command Analog Ground Feather Pressure Analog Ground Pump Inlet Pressure Analog Ground Pump Outlet Pressure Analog Ground Spare Analog Input Analog Ground Motor Speed Analog Ground Pressure Control
43. 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 firmware bug is preventing service of the SPI bus communications Afirmware bug is preventing completion of required logic in the time between timer in terrupts This error may occur when the system is first powered up and may be ignored LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 1 GE FANUC AMPLIFIER LED Display Explanation and or Possible Causes Power Failure This display indicates that the 120 VAC power supply to the motor amplifier has been cycled turned off and back on LE Loss Enable This display indicates that the enable signal to the motor am plifier from the RCS 2 channel card is low or disabled This is normal when the unit is in the Ready or Halted state Following Error This display indicates that the motor amplifier has command ed the motor to turn at a certain speed but was unable to maintain that speed This usually indicates a motor pump or magnetic coupling that is bound up and not able to turn freely Excessive Command Increment This indicates that the motor amplifer was commanded by the RCS
44. E J PARTS LIS e ak wama mansana 20 21 RACK ASSEMBLY PARTS aberit sss DR 22 MOTOR AMPLIFIER PANEL PARTS LIST 24 27 MOTOR AMPLIFIER PANEL MODEL IDENTIFICATION sene 28 REMOTE OPERATOR S PANEL PARTS LIST 30 31 REMOTE OPERATOR S PANEL MODEL IDENTIFICATION sss 31 FLUID PANEL ASSEMBLY PARTS 32 34 FLUID PANEL ASSEMBLY MODEL IDENTIFICATION a 35 36 NON FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS 38 39 FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS LIST 40 41 DUAL HEADED PUMP ASSEMBLY PARTS LIST 42 44 77671 00 5 WAY BALL VALVE ASSEMBLY PARTS 46 47 TROUBLESHOOTING 48 58 BOOK DIAGRAMS Cu atu Neds antt 48 RIBBON CABLE INTERCONNECT CHARTS sette 48 UMBILIGAI CORD SIGNALS ar 48 CONTROL CONSOLE BLOCK 49 MOTOR AMPLIFIER BLOCK 50 FLUID PANEL BLOCK DIAGRAM a 51 CHANNEL BOARD BLOCK 52 INTERFACE BOARD BLOCK DIAGRAM 53 INTERCONNECT CHART FOR CHANNELS 1 3 5 AND 7 54 INTERCONNECT CHART FOR CHANNELS 2 4 6 AND 8 55 INTERCONNECT CHART FOR SYSTEM I O SIGNALS 56 ODD NUMBERED CHANNEL UMBILICAL CORD 1 5 57 EVEN NUMBERED CHANNEL UMBILICAL CORD 58 Continued On Next Page LN 940
45. F Fitting Stainless Steel ilot Operated Ball Valve all Valve Stainless Steel 8 OD Tubing piral Mixer 22 964 ardener Pump Manifold 22 420 ix Manifold W Check Valve 77652 00 1 8 NPT M Stem 77659 00 8 NPS Nut 22 1043 low Sensor able 22 1045 low Sensor Cable 5 Conductor able Y O 22 1044 anifold for Flow Sensor Table Y A11989 00 olvent Manifold Assembly 77637 00 3 8 NPSM X 3 8 NPT DM 9156 24C Hex Head Bolt 5 16 18 X 3 4 L Cadium Plated SS 1524 CD 16 Stainless Steel Washer 7734 07 16 Lockwasher A11793 32C arriage Bolt 1 4 20 X 1 L A10626 01 able Gland Assembly 9 Position Table able U C Table V E able V F Table V D 41 FTP 1006 _ Fitting Elbow 5 32 ODT X 1 8 NPT M 22 337 ypass Valve Assembly A10976 00 abel Set RCS 2 Fluid Panel A10627 00 CV Mounting Plate able WX G 784074 20C 1 4 20 X 625 L Stainless Steel HHCS Table WX 77588 06 4 Lockwasher able WX I 77485 00 4 20 Hex Nut Stainless Steel able WX Table WX L Table WX M Table WX 78404 20C J4 20 X 5 8 L Stainless Steel HHCS 5 mimi u 5 mimi 2 18 9 __ __12 16 Ww 18 22 2 23 a __27 __ 28 29 33 4 36 38 s s 22 280 1 Check Valve Stainless Steel LN 9408 06 3 34
46. HEMATIC RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX G SCHEMATICS Continued jndyno UD sejoolpul oquu S lt ynduy se popu 2 pejunow 0193 02 35V4331N Fisy 1 1 1 3130901 24 92 psu 03839941 f NNO 1 20A 103135 av 103135 8 109135 a 104135 115 dAV1 437113 NOlLn8HShd dWV1 S3XO8 HSNI NOLIn8HSnd 13534 LINYA daarinvd dWY1 AGY3H NOLINGHSNd 1531 AVNdS 13538 NYOH S N S N 1NIOd13S TWNOIS 1 10 DS 90 2 20A LN 9408 06 3 9209 9 9 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg APPENDIX G SCHEMATICS Continued FLUID PANEL SCHEMATIC Donoejg 94 SALON 20 86892 100 91 6 51 AIA TIV8 dAnd 5 40 131100 1432 3 0205 455 100 SINN ain YN L
47. Input Input Input Input Input Input Output Output Output Output Output Output Input Input Input Input Input Input Input Input Input Input Input Input Interface Board P N 78818 96 Pin DIN Connector Backplane Board P N 78816 96 Socket DIN 96 Pin DIN Connector Connector Front Side Back Side 64 Cond Ribbon Cable P N A10586 96 Socket 64 Socket DIN IDC Connector Connector Interconnect Board P N A11530 J1 64 Pin Screw Terminal TB1 1 TB1 2 TB1 3 5 1 6 1 amp TB7 1 5 3 TB6 3 amp TB7 3 5 5 6 5 amp TB7 5 5 7 TB6 7 amp TB7 7 5 9 6 9 amp TB7 9 5 11 6 11 amp TB7 11 5 2 6 2 amp TB7 2 5 4 6 4 TB7 4 5 6 6 6 amp TB7 6 5 8 6 8 8 7 8 5 10 6 10 amp TB7 10 5 12 TB6 12 amp TB7 12 56 RCS 2 Parts Maintenance Troubleshooting Troubleshooting Ransburg ODD NUMBERED CHANNEL UMBILICAL CORD SIGNALS Control Console A10549 Wire Numbers Channel 1 57 3 Channel 5 7 D E F G H J K L M N P R S T 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
48. O l3NM3HL3 3 m o 91525 55 318vO 00 86 01V 43H ZISZN2 JO dOL NI 19412 92 OVA 021 e e nm NONNOO 50 1901 NOWWO3 20 1501 63x08 IEZA Nn o o z o 7 F OSNO 1124 lt 4 2 NNO L 1817 7599 Hf N05 LP 3838 1714 ir lt 1 OSOIND Tr 1 1 GNYNNOO TELL lt 1 1 1 1 WWT 2035 1 12 lt 21 1 1 1 MO 1607 1 1 1 NNOH NWOGI HS 1207 1 AvadS 1 1 1 G3LTW3 1902 OOK VE 15 gt lt 5 8 S4ZOLV 335 38v SN3IBMVH 3 37 31ON OVA OZI Tm 8006002062020 SA LN 9408 06 3 91 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg SCHEMATICS Continued APPENDIX G REMOTE OPERATOR PANEL SCHEMATIC NONWOD NONWOO 2d 14109135 7915 10V 3 2 20A 72 3 20A 72 3 NYOH 154 3 d d 1531 AVNdS d d NNA NNO 3 AQV3H NNO
49. SCHEMATICS APPENDIX G CONTROL CONSOLE SCHEMATIC NORROD jo doi 40 29uu02 jubu 21402 19419413 Yo 91909 Od ojgoo o qoo 160154 3504 v6 00000 HOLIMS 13N33H13 1404 6 1153 LEEI 2 5 LSE LMS m i reet we lam 9015 3 83804 o 5 55 mova Qqavo QNVOBM3HLON o GNVd OL QuOO N3MOd 290 0 IE ISEEND gt 79845 WNINHAL NO 39018 8 Ov L O3NNOO _ wl L 185 30 HIN NI 1130 NNOD S d 335 OND e ruAldd S 4 V 9 IGA 160154 31713 1801 37 02802 ura 1601 A TT Ete wl VOL OWA 02 thot o 0028 LN 9408 06 3 81 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg SCHEMATICS Continued APPENDIX G CONTROL CONSOLE SCHEMATIC uo s nunuo2 Jo
50. SERVICE MANUAL Ransburg LN 9408 06 3 Replaces LN 9408 06 2 April 2013 RCS 2 PARTS MAINTENANCE AND TROUBLESHOOTING 66608 60 8 MODELS A10549 Control Console A10776 Motor Amplifier Panel A10948 Fluid Panel A11095 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 50 00 U S Ransburg RCS 2 Parts Maintenance Troubleshooting NOTE This service manual has been superceded from service manual number LN 9408 06 2 to service manual number LN 9408 06 3 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9408 06 3 5 2 Parts Maintenance Troubleshooting Contents Ransburg CONTENTS eo lt SAFETY 1 5 SAFETY PRECAUTIONS ia uoo tad ots ND A Rasa 1 HAZARDS SARE GUARDS 2 5 MAINTENANCE 6 19 ELECTRICAL CONT ROE PANEL Ste 6 7 GEARPDNIPSI s dere 7 9 RESIN FLUSHABLE PUMP ASSEMBLY PARTS LIST 10 ASSEMBLY 25 337 PUMP BYPASS HWA OG 11 12 CATALYST NON FLUSHABLE PUMP ASSEMBLY PARTS 97 14 16 PUMP BYPASS VALVE ASSEMBLY PARTS LIST 18 19 PARTS IDENTIFICATION 20 47 MAIN CONTROMCONSOL
51. a fire hazard Protection against inadvertent arcing that is capable of caus ing fire or explosion is lost if any safety interlocks dis abled during operation Freguent Power Supply or Controller shutdown indicates a problem in the system requir ing correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this eguip ment SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Unless specifically approved for use in hazard ous locations all electrical eguipment must be located outside Class I or ll Division 1 or 2 hazardous areas in accordance with NFPA 33 Test only in areas free of flammable or combus tible materials The current overload sensitivity if eguipped MUST be set as described in the correspond ing section of the equipment manual Protec tion against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power supply shutdown indicates a prob lem in the system which requires correction Always turn the control panel power off prior to flushing cleaning or working on spray system equipment Before turning high voltage on make sure no object
52. amming PC or Laptop 64 RCS 2 Parts Maintenance Troubleshooting Appendix 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 Reinstall 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 procedures Interface Card Configuration Procedure 1 Insertthe Serial Cable into the RS 232 port on the front of the face plate of the Interface Card Serial Port Figure 13 RS 232 Port 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 Data Bits 8 Parity None d Stop Bits 1 Flow Control Xon Xoff f Emulation VT100 5 Power up on interface card and the Hyper Ter minal will display the software versio
53. ansburg 83227 Port Controller Motorola MC68HC16 Micro controller Calibration Switch RCS 2 Parts Maintenance Troubleshooting Troubleshooting 24 VDC 32AB amp C Fast Fill A Optical Channel Fill A solators Feather Set A Run A Halt Fault Reset A Trigger 1 A Motor Amp Fault A Trigger 2 Trigger 5 A Trigger 4 Volume Fill A Spare DIN A Fault Output A Ready Output A Buffers lt 5 Spray Shutdown A Flush Request Motor On A Motor Amp Reset Flow Rate Command Feather Pressure A l o lt lt lt 5 Watchdog Timer Flash Memory Static RAM gt o Pump Inlet Pressure Pump Outlet Pressure Spare AIN Motor Speed lt lt AAA AAAAA o lt Pressure Control ko c a e a l gt IG F 5 le o 2 to EPB REEL D iz Flow Rate Output A Motor Feedback A Optical Isolators O ud Motor Feedback B Solvent Feedback Hardener Flow Optical so Buffers Fast Fill Channel Fill B ators Feather Set B iz Halt Fault Reset B x fa EE gt ZN ZN NN e lo E I8 18 H Trigger 1 B Motor A
54. bor press press fit two 2 dowels 8 into the plate assembly 6 Lubricate cap screws 10 and 11 with petro leum jelly 7 Insertcap screws 10 11 rear plate 9 and thread them through all three 3 plates ACAUTION Never tap on tang 15 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Maintenance 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 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 need to be separated and replaced Individual pump parts are not field replaceable and must be returned to for replace ment 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 of the shaft end opposite the tang Ransburg can supply a Gear Alignment Gauge for this purpose The tool is P N 22 1032 Contact Ransburg for additional information Hollow Dowel Ransburg can supply special tools to achieve proper placement of the hollow dowels 8 in the gear plates The dowel s
55. cation Ransburg NEW STYLE MOTOR AMPLIFIER PANEL PARTS LIST Figure 6b Penn 1__ A10795 00 Ethernet Industrial Bulkhead W RJ 45 Connector 1 2 Ai0798 00 Ethemet Cable Not Shown 1 x 3 A10564 09 26 SocketBulkheadAssemblyW FymgLeads 1 4 1056410 26 Socket Bulkhead Assembly WiFlyingLeads 1 174124927 MotrAmpifer S200 TL 2 Power Supply 5VDC amp 24 180 W Power Supple 24 180 W 55 472 A A Ay So Ro Po BYP po a a NO A 27 0796 00 Bulkhead Connector Pm 4 28 A10626 00 CableGlad amp Pot C o 1 24 22 1045 Sensor Cable Assembly 1 4 ODT Bulkhead Used only if the optional Color Change Sequencer is installed Used only if the optional Color Change Sequencer is not installed e P 27 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification MOTOR AMPLIFIER PANEL MODEL IDENTIFICATION When ordering use A10776 ABCDEF as indicated below A10776 AB DEF Basic Part Number 1or2 Intrinsically Safe Remote Operator Panel Number of Motor Amps 0 No 1 Yes 0 No 1 Yes Intrinsically Safe Pressure Transducers Color Change PLC 0 1 Ye
56. ceed 1 meg ohm Refer to NFPA 33 Operators must be grounded Rubber soled in sulating shoes should not be worn Grounding straps on wrists or legs may be used to assure adeguate ground contact Operators must not be wearing or carrying any ungrounded metal objects When using an electrostatic handgun operators must assure contact with the handle of the ap plicator via conductive gloves or gloves with the palm section cut out NOTE REFER TO NFPA 33 OR SPECIFIC COUNTRY SAFETY CODES REGARDING PROPER OPERATOR GROUNDING electrically conductive objects the spray area with the exception of those objects re guired by the process to be at high voltage must be grounded Grounded conductive flooring must be provided in the spray area Always turn off the power supply prior to flush ing cleaning or working on spray system equip ment Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class I or ll Division 1 or 2 haz ardous areas in accordance with NFPA 33 RCS 2 Parts Maintenance Troubleshooting Safety AREA Tells where hazards may occur Electrical Eguipment Substances Spray Area HAZARD Tells what the hazard is Electrical Discharge High voltage eguipment is uti lized the process Arcing in the vicinity of flammable or combustible materials may oc cur Personnel are exposed to high voltage du
57. ct inconsistent motor data loaded into the SFD 72 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 2 Continued AMPLIFIER LED Bik Codo Fault Description Explanation and or Possible Causes SFD Sensor Failure Internal SFD failure Excessive electrical noise in the drive environment causing communications interference SFD UART Error Internal SFD failure SFD Communication Error Feedback cable not connected at the drive or at the motor Feedback cable shield not connected Defective feedback cable Internal SFD failure Excessive electrical noise in the drive environment causing communications interference Option Card Watch Dog Time Out Communication error between option card and main board 19 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 If ExtFaults is AuxFBFault then the AusFB device is in error Check the AuxFB faults AuxFBEnDatFIt AuxFBPTCFit or AuxFBSCDFIt Check to make sure the the drive is set up for the cor rect feedback device and that the device is functioning correctly If ExtFaults is No Extended Fault th
58. d 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 er ror 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 I O 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 in the Slave Channel Configuration is greater than Hardener Flow On value specified in the Slave Channel Configuration
59. en this was a fault induced by the controller such as SynqLost T3 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX D CALIBRATING THE PRESSURE TRANSDUCERS PART 1 Calibrating the 22 546 4 on the power supply Transducer 5 Remove the screw cap covering the adjust ment screw on the pressure transducer if one Calibration Procedure is installed 1 Ensure that the pressure transducer 22 546 is tightened in the manifold to a torgue specification of 42 48 inslbs 6 Adjust the potentiometer in the pressure transducer such the current reading on the ammeter is 4 05 mA 2 Connectthe transducer using the calibration cable 22 1520 to a power supply and a digital ammeter as shown 7 Replace adjustment potentiometer hole 8 Turn off power supply and return pressure t t ice 3 Set ammeter to read current in the range s heeri SANIGE ma If transducer will not adjust to approximately 4 05 mA it should be replaced o TEST AND CALIBRATION POWER CIRCUIT DIAGRAM CALIBRATION ADJUSTMENT SCREW B FLUKE MULTIMETER OR EQUAL 22 546 SENSOR gt DVM ON SCALE Pressure Transducer O Ring 22 1520 Calibration Cable Assembly LN 9408 06 3 74 RCS 2 Parts Maintenance Troubleshoot
60. en touched Sensitivity can be diminished by contaminants or scratches Make sure the guarter turn latch screws on the PC boards and on the rack latched to prevent boards from vibrating loose over time Make sure all latches are in the proper position to retain all ribbon cables in the control panel Temperatures inside of the main control console run significantly above ambient If it is expected that the ambient temperature will ex ceed 100 F some form of external cooling will be reguired Contact Ransburg for suggested methods There are several different versions of the touchscreen PC used in the RCS 2 but all of LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Maintenance 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 are 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 on the motor amplifier panels The only items in the 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 guality of the air being delivered
61. enance Troubleshooting Parts Identification 1 54 23 TYP 29 4 m COLOR s 11 22 21 14 tud 20 18X19 2 16 21 50 6 52 e 9 3 13 PURGE ORAN VALVE NOTE ALL FLUID LINES ARE 3 8 ODT SSP 5020 EXCEPT BETWEEN OUTLET OF CATALYST PUMP AND 3 WAY BALL VALVE WHICH IS 5 16 ODT 76698 02 Figure 8a Fluid Panel Assembly Front LN 9408 06 3 32 RCS 2 Parts Maintenance Troubleshooting Parts Identification 33 Ransburg TYP 8 PLACES Figure 8b Fluid Panel Assembly Back LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification FLUID PANEL ASSEMBLY PARTS LlST Figures 8a amp 8b Para A10949 00 Fluid Panel Details RCS 2 76698 02 3 16 ID X 5 16 OD Tubing A10528 00 Transducer Cable Not Shown Table Z R 22 910 Pressure Transducer Assembly W Manifold amp O Ring Table Z S 77662 00 onnector Swivel 3 8 NPS X 3 16 ID Hose Table Z 22 963 lushable Color Pump Manifold 77784 00 8 NPS F 3 8 OD Tube 90 Elbow 77639 00 1 8 3 8 5 55 6443 77669 00 77671 00 SSP 5020 22 451 8 ODT X 1 4 NPT
62. hould 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 LN 9408 06 3 16 5 2 Parts Maintenance Troubleshooting Maintenance Ransburg NOTES 17 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Maintenance Figure 3 Pump Bypass Valve Assembly PUMP BYPASS VALVE ASSEMBLY PARTS LlST Figure 3 T 12 13 14 9158 16C 18 32 X 50 L Flat Head Slotted Machine Screw Part of P N 22 402 Manfold Assembly LN 9408 06 3 18 RCS 2 Parts Maintenance Troubleshooting Maintenance 19 PUMP BYPASS VALVE ASSEMBLY This section describes the Procedures for Flushing Removing and Replacing the By pass 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 by pass 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 Unlike other components for which all broken seals mus
63. 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 oil before using the system To remove oil flush and purge the system with solvent LN 9408 06 3 Ransburg Ransburg RCS 2 Parts Maintenance Troubleshooting Maintenance Figure 1 Resin Flushable Pump Assembly RESIN FLUSHABLE PUMP ASSEMBLY PARTS LlST Figure 1 22 383 Lip Seal Front Side Plate Arbor N F N F Driven Gear N F Drive Shaft N F N F N F N F Driving Gear Center Plate Hollow Dowel Rear Side Plate Roll Pin Varies Socket Head Cap Screw Lour 8 E v Required Seal Insertion Tool P N 22 543 Not Field Replaceable Varies based on pump size LN 9408 06 3 10 RCS 2 Parts Maintenance Troubleshooting Maintenance 11 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 materials Gear Pump Disassembl
64. ing Appendix Ransburg 75 APPENDIX D CALIBRATING THE PRESSURE TRANSDUCERS PART 2 To calibrate the pressure transducers 22 910 an electronic calibrator will be reguired A10551 The pressure transducer should be removed from the system to be calibrated or insure that all pressure has been released from the system Do not remove the transducer from its manifold block as retightening of the sensor in the manifold block could effect the calibration Use the following steps to calibrate a transducer 1 Prior to connecting anything to the calibrator A10551 power up the unit by pressing the ON button on the calibrator 2 You should be prompted to push the F1 button to continue 3 The unit should then prompt you to connect the cable with the transducer connector on one end to the transducer and then to the left connector in the top of the calibrator 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 6 The calibrator will 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 unit then checks its battery then powers up 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 promp
65. intenance Troubleshooting Parts Identification PUMP 1 THIS SIDE 13 5 32 or 4mm ID TUBE Figure 11 Dual Headed Pump Assembly LN 9408 06 3 42 RCS 2 Parts Maintenance Troubleshooting Parts Identification 43 DUAL HEADED PUMP ASSEMBLY PARTS LIST Figure 11 1 22 1302 Non Explosion Proof Motor A11797 00 Explosion Proof Motor 7959 34C 1 4 20 X 1 1 16 L SHCS For Use With Proof Motor 7421 24C 5 16 18 X 7 8 L SHCS Use With Explosion Proof Motor 3 1 4 Lock Washer For Use With Non Explosion Proof Motor 5 16 Lock Washer For Use With Explosion Proof Motor 4 5 5 16 18 UNC X 4 L SHCS 7 22 1310 Motor Mounting Plate 22 1311 Motor Standoff 1 2 13 Manifold Assembly Flushable 15 O Ring 2 141 16 3 5 cc rev Pump With Fasteners 5 5 cc rev Pump With Fasteners 10 cc rev Pump With Fasteners 17 Fluid Fitting 3 8 18 NPS M X 3 4 16 UNF 2A M 18 O Ring 42 020 19 O Ring 82 018 Seal 3 8 16 X 1 1 2 L SHCS MCV Bypass Block 1 4 20 X 2 L SHCS Fluid Seal 25 5 32 ODT 4mm X 1 16 NPT M Fitting l _ 222 2222 1 27 3 5 Pump With Fasteners 5 5 Pump With Fasteners 10 cc rev Pump With Fasteners 28 Key 1 8 X 1 8 X 3 4 Long 36 37 Retaining Ring 5105 37 Bowded External 39 78002 00 3 8 NPT Plug Continued On Next Page 2 5 6 7
66. ipment must be as prescribed by an industrial hygienist or safety expert and be NIOSH approved Aluminum is widely used in other spray appli cation 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 coating supplier Any other type of solvent may be used with aluminum equipment LN 9408 06 3 Ransburg Ransburg 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 of the pan el A few things be done from a preventative viewpoint to extend the life of the components in the control console 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 having to dothis If the glass is scratched in any way it can effect how the touch screen responds wh
67. ix SCHEMATICS Continued APPENDIX G CONTROL CONSOLE SCHEMATIC gui 7 oy ous 2 o ZISENO of 5 5 INS FJ 28 T I 83 TI 83 239368 T 83 T 83 298 B oH env ri ez 8 VEE ie Joy PssdS ni 31645 ly UN 5545 cL dumg WW IMO Suma TE Sarg dumg dumg EE 7u5 Smssssa REOR ROT JSUSpIDH PEF DOA PEF tat CS 7 3 THEO Yuo 91 1n00 22595 vuo H Inod eds vuo 01 ug 2085 965 east guo H uo 2 0 20108 843 197 Pau Vo vor H ober FORTS 7
68. le Gear Pump Reas sembly Before reassembling the gear pump clean and inspect all parts for damage or wear gt Be careful to scratch or nick any surface of the plates seals gears and dowels inside the pump These parts have very precise tolerances Burrs To Assenible nicks scratches or particles of foreign matter will cause scoring and possibly 1 If parts were separated use a press to press pump seizure arbor 3 into front side plate 2 2 Insert driven gear 4 into center plate 7 Man gt If the gear binds it could damage the 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 pump Determine the cause of the bind ing Nicks burrs or foreign particles 4 Using an arbor press remove the two 2 can cause pump binding dowels 8 from the front plate 2 center plate 7 and rear plate 9 ually turn the gear to ensure it moves freely NOTE 3 Insert driving gear 6 into center plate 7 Manually turn the gear to ensure it moves freely f an arbor press is unavailable an al ternate disassembly method is to partially back off the cap screws and tap the screws with a soft head hammer With the screw heads exposed continue to alternate back ing out the screws and tapping the screws until the plates are free 4 Assemble rear 9 center 7 and front 2 plates 5 Using anar
69. let 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 the Channel Configuation is too high Restriction in the fluid line 2 For Autmatic guns failure of applicator trigger valve Maximum Outlet pressure value specified 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 Failure of Hardener Flow sensor LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX B ERROR LOG CHART Continued 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 Reached LN 9408 06 3 Channel Card Channel Card Channel Card Channel Card Channel Card Channel Card
70. logo LN 9408 06 3 95 Service Manual Price 550 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts 2013 Ransburg All Rights reserved Models and specifications subject to change without notice ISO 9001 Form No LN 9408 06 3 Litho in U S A 04 13
71. ment 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 LN 9408 06 3 12 5 2 Parts Maintenance Troubleshooting Maintenance Ransburg NOTES 13 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Maintenance CATALYST NON FLUSHABLE PUMP ASSEMBLY PARTS LlST Figure 2 22 383 Lip Seal Front Side Plate ______ Arbor Driven Gear 8 lt NFR Drive Shaft Driving Gear 7 Center Plate 8 Hollow Dowel 2 9 NFR ReaSdePae T 1 10 Vares LogCapSrew 4 1 ____ E 12 NFR 17 71 Requires Seal Insertion Tool P N 22 542 Not Field Replaceable Vareis based on pump size NJ IN LN 9408 06 3 14 5 2 Parts Maintenance Troubleshooting Maintenance Ransburg Non Flushable Gear Pump 9 Separate front plate 2 from center plate 7 Disassembl y 6 Separate center plate 7 from rear plate 9 NOTE 7 Remove rear plate 9 It is not recommended to disassemble 8 these pumps in the field unless absolutely necessary If a malfunction occurs they 9 should be returned to Ransburg for service Remove driving gear 6 from center plate 7 Remove driven gear 4 from center plate 7 10 Remove arbor 3 from driven gear 4 ACAUTION Non Flushab
72. mp Fault Trigger 2 B Trigger 3 Trigger 4 B Volume Fill ge Spare DIN ko gt Buffers No Fault Output B Ready Output B Spray Shutdown B Flush Request B Motor On B 5 Motor Amp Reset B Flow Rate Command B Feather Pressure B Pump Inlet Pressure B is Pump Outlet Pressure B ello lt lt Spare Motor Speed lt Pressure Control Flow Rate Output B AA Figure 20 Channel Board Block Diagram LN 9408 06 3 GND 30A amp B 52 Ransburg 8 06 NO yur Jes ulejsAs esing 5 1764 8 5 2 e4DdsS 94Dds 001 qor Mg qof NE qor Mg Mg Mg qor yg Gop uno ung uno uno uno uno uno uno H3 5405 5405 5905 24045 2405 5405 54035 54015 HE AY LO N 58 2 OQA ver RCS 2 Parts Maintenance Troubleshooting Troubleshooting lt N OF o O OF 9 xi lt 10 N m 540 0105 1221190 54090106 109390 51010106 1291390 Od Id Mod S8V cCcV C GC sS esues MOd 49103409 MOd J9J oJ uoo j9u19u13 32422433 OJOIN 0002 Hod IpH S TET SY
73. n followed by some diagnostic information than the IP configu ration information It will then prompt the user to Press any key within 3 seconds to enter console mode 6 Hitthe space bar or any convenientkey to en ter 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 LN 9408 06 3 Ransburg Ransburg 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 pos sible console commands IPCONFIG Allows the user to change the IP configuration data CLEARTOTALS Allows the userto 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 cy cling power RUN Takes the card out of console mode into normal operation mode 7 To setup the address for the card type CONFIG atthe gt prompt and follow the directions Make sure to save the new configuration to flash memory when prompted LN 9408 06 3 8 It is highly recommended that all job data be reset ever time new software has been loaded into the card a
74. nals are carried by which pins wires and wire pairs These charts can be used to aid in tracing down signal or lack of signal issues between the main control console and the motor amplifier panels RCS 2 Parts Maintenance Troubleshooting Troubleshooting 48 Ransburg RCS 2 Parts Maintenance Troubleshooting Troubleshooting youre sjeuuDu3 9296 9400 uoqqni 0 1 996 gx sjeuubu 9 qb pv eet 0 1 Bojpuy 1 996 sjeuuDu 949 294 84 1929 0 1 5olpuy PRE S PUUDYD uoqqni O 9324981 RE sjouUDYD 291 uoqqiy 51950 0 1 sleuupuo Bu eup d4 og 9400 uoqqnj O m Ei sleuubuo 9 sisuuDUo I8uubuo 9 S 8 jeuuDu nac za sjeuod dwp 1 o sejgpo 10 294 09 y uuop O uuo esnow aM ejgnoduion sig Aiddng 40 20 vct 48314 iagram Control Console Block Di Figure 17 LN 9408 06 3 49
75. nstalled 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 File Selected No File Selected Figure 3 Programming Software LN 9408 06 3 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 8062 Chanal Card gl te ga o ex El ew hex hex m rTweoon Figure 3 Select Folder File 8 Select the Open button 9 The downloader software screen should display the file you selected Find File to Download File Selected itw pg v205 hex Figure 4 Ready To Download 62 RCS 2 Parts Maintenance Troubleshooting Appendix 63 10 Push the Download button The program will download the new firmware to the flash memory on the card and show a status bar as itis doing so 11 Oncethe program has completed downloading the entire code the following screen will display Ransburg File Selected All Done 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 On power up the interface card will automatically load the default job parameters to
76. oO ole N ze n o e o e N Pilot Light 130 Volt I LSMEO004 00 Contact Clip Position I LSMEO006 00 Contact Block Normally Closed 77403 20 Recepticle Push On Oval Slot Stud 10530 00 Rack Sub Assembly DynaPump 78818 00 Interface Board Assembly RCS 2 78814 00 Channel Board Assembly RCS 2 77423 00 Pin Detented 77429 01 Shoulder Washer Nylon 77400 00 Cable Mount Ribbon 4 A10586 01__ 64 Conductor Ribbon Cable X 71 Lg A10586 02 64 Conductor Ribbon Cable X 81 Lg AT0586 03 64 Conductor Ribbon Cable X92 L9 A105 m gt gt N NI N N ol BY 5 RY Co O CO C3 BY A 01 O lt gt lt gt O gt gt oo aya co olo NN 50 Conductor Twisted PR Ribbon Cable X 80 Lg 50 Conductor Twisted PR Ribbon Cable X 100 Lg 10795 00 Industrial Ethernet Bulkhead Receptical 2 10918 00 Dust Cap for A10795 00 2 Cable Assembly 26 Socket Bulkhead 2 pae X Channel Number 2 Touch screen may vary slightly frome one shown gt 55 gt gt gt gt gt olojo NI K cn xl 1 16 7 8 9 10 n 12 13 _ 14
77. or CCV Stack Assembly WiSolvent Air Push o 1 4 8 8 1 CCV 5106 111__ 6 Color CCV Stack Assembly W Solvent Air Push 114 8 8 1 CCV 5108 111 8 Color CCV Stack Assembly W Solvent Air Push 10 1 4 81 8 1 5110 111 10 Color CCV Stack Assembly W Solvent Air Push TABLE Y CATALYST FLOW SENSOR TABULATION O 9 2 TABLE Z CATALYST INLET PRESSURE TRANSDUCER TABULATION Description 0 3 3 3 NoPrssueSenor Jj Pressure Sensor Included If no catalyst pump is used 2 and T 2 LN 9408 06 3 36 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg NOTES 37 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification LN 9408 06 3 Figure 9 Non Flushable Pump Manifold Assembly 38 RCS 2 Parts Maintenance Troubleshooting Parts Identification 39 NON FLUSHABLE PUMP MANIFOLD ASSEMBLY PARTS LIST Figure 9 7959 34C 1 4 20 X 1 1 16 L SHCS 4 SS 1505 CD Lock Washer 1 4 4 1047 Non Explosion Kollmorgan Motor 22 547 Explosion Proof Kollmorgan Motor 22 1047 2 Non Explosion Proof Motor sa 4 795928 5c E OS pu a Om 12 1 2 5 SS 1505 CD 22 876 22 567 78178 00 Set Screw 1 4 28 Pt 8179 00 568 TT 7554 119 1 22 875 18 22854 22 945 15 22862
78. quipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment A WARNING gt The hazards shown on the following pages may occur during the normal use of this equip ment Please read the hazard chart beginning on page 2 LN 9408 06 3 Ransburg Ransburg AREA Tells where hazards may occur Spray Area LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Safety HAZARD Tells what the hazard is Fire Hazard Improper or inadeguate operation and maintenance procedures will cause a fire hazard Protection against inadver tent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during opera tion Freguent Power Supply or Controller shutdown indi cates a problem in the system reguiring correction SAFEGUARDS Tells how to avoid the hazard Fire extinguishing eguipment 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 main tenance When using solvents for cleaning Those used for equipment flushing should have flash points egual to or higher
79. ring operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Freguent power supply shut down indicates a problem in the system which reguires correc tion An electrical arc can ignite coat ing materials and cause a fire or explosion Certain material may be harmful if inhaled or if there is contact with the skin SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazard ous locations the power supply control cabinet and all other electrical eguipment must be ed outside Class I or ll Division 1 and 2 hazard ous areas in accordance with NFPA 33 and EN 50176 Turn the power supply OFF before working on the eguipment Test only in areas free of flammable or combus tible 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 Follow the requirements of the Material Safety Data Sheet supplied by coating material manu facturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equ
80. rotect the servo motor from paint leakage Make seals less critical The seals are less critical than a 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 Sincethe 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 LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Maintenance Pumps Color Resin and Harden er Catalyst Some coating applications using the magnetically coupled gear pump require two fluids to be me tered 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 st
81. s NumberofEtoP Transducers Catalyst Flow Sensor Electronics 0 1 or 2 0 No 1 Yes LN 9408 06 3 28 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg NOTES 29 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification 2 3 2 Ransburg uu m pp boxes o 9 e IN ae O O IN ay m AAS C 0 O Figure 7 Remote Operator s Panel LN 9408 06 3 30 RCS 2 Parts Maintenance Troubleshooting Parts Identification Ransburg REMOTE OPERATOR S PANEL PARTS LlST Figure 7 A10794 00 1 1 A10794 00 Are Bulkhead Wire Assembly RCS 2 Remote Operator s Panel A11099 00 Wiring Harness Assembly Pressure Switches RCS 2 ROP 1 13 A11100 00 LED Wiring Harness Assembly RCS 2 Remote Operator s Panel 1 i 16 A11097 00 Potentiometer Harness Assembly RCS 2 Remote operators 1 10909 00 PC Board Assembly DynaPump Remote Operator s Panel 1 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 Basic Part Number Number 2 Reg per 1 Reg per Number of Air Pressure Switches Flush Box Spraygun Flow Switches 31 LN 9408 06 3 Ransburg RCS 2 Parts Maint
82. s are within the safe sparking distance Ensure that the control panel is interlocked with the ventilation system and conveyor in accor dance with NFPA 33 EN 50176 Have fire extinguishing equipment readily avail able and tested periodically Personnel must be given training in accordance with the requirements of NFPA 33 EN 60079 0 Instructions and safety precautions must be read and understood prior to using this equip ment Comply with appropriate local state and na tional codes governing ventilation fire protec tion operation maintenance and housekeep ing Reference OSHA NFPA 33 EN Norms and your insurance company requirements LN 9408 06 3 Ransburg Ransburg AREA Tells where hazards may occur Spray Area High Voltage Eguipment LN 9408 06 3 RCS 2 Parts Maintenance Troubleshooting Safety HAZARD Tells what the hazard is Electrical Discharge There is a high voltage device that can induce an electrical charge on ungrounded objects which is capable of igniting coating materials Inadeguate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion SAFEGUARDS Tells how to avoid the hazard Parts being sprayed and operators in the spray area must be properly grounded Parts being sprayed must be supported on con veyors or hangers that are properly ground ed The resistance between the part and earth ground must not ex
83. s old data can become corrupted in the flashing process If itis necessay to clear the Job data type INITDATA and depress the enter key NOTE This clears all Job data from the battery backed memory onthe 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 re moved and the power turned back on This should complete the interface card setup User Interface Software Touch screen Software 1 The new software should be copied to a USB memory stick Insertthe 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 12 3 Using the Windows software functions find your memory stick and copy the files supplied to you by Ransburg to the RCS 2 folder inside of the My Documents folder on the desktop If 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 interface software reloads automatically on startup RCS 2 Parts Maintenance Troubleshooting Appendix 66 RCS 2 Parts Maintenance Troubleshooting Appendix 67 APPENDIX B ERROR LOG CHART Input Under Pressure Input Over Pre
84. ssure Output Un der Pressure Output Over Pressure Flow Rate Out of Toler ance Hardener Flow Loss Channel Card Channel Card Channel Card Channel Card Channel Card Channel Card Description Pump inlet pressure is below the Minimum Pressure value specified in the Channel Configuration Pump inlet pressure is above the Maximum Pressure value specified in the Channel configuration Pump outlet pressure is below the Minimum Pressure value specified in the Channel Configuration Pump outlet pressure is above the Maximum Pressure value specified in the 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 1 milliamp Ransburg 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 Lossofelectrical supply or control signal to the E P transducer that controls the pump inlet pressure Failure of the E P transducer that controls the pump inlet pressure Failure of the pressure regulator that controls the pump inlet pressure Failure of the pump inlet pressure sensor Minimum In
85. t 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 e 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 disassem bly To Disassemble 1 Remove two 2 screws 4 from clamp block 5 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 LN 9408 06 3 Ransburg Ransburg RCS 2 Parts Maintenance Troubleshooting Parts Identification PARTS IDENTIFICATION
86. t you to push F1 to continue 8 The calibrator will then display ZERO AD JUSTMENT with the options of F1 to quit F2 to increase the value and F3 to decrease the value Examine the value displayed on the DVM Adjust it so it reads 4 01 to 4 03 mA NOTE Each time you press the F2 or F3 buttons to increase or decrease the value the cali brator must download that to the sensor so there is a slight delay The unit will display Writing Done F1 to continue Repeat the process as many times as necessary to get the proper current displayed on the DVM Once the adjustments are completed push the F1 key to exit the unit powers down Disconnect the transducer from the calibrator and return it to service LN 9408 06 3 Ransburg APPENDIX E RECOMMENDED SPARE PARTS A10549 MAIN CONTROL CONSOLE PARTS LIST Quantity Being Purchased Part Description 24 VDC Power Supply TR SSEH 471_ 5 Amp AGC Fuse 55 472 LSME0005 00 LSMEOO06 00 Contact 1 74300 00 ____ 120VAC Pilot Lamp 78835 01 TR SSEH 471 TR SSEH 472 5 0005 00 LSME0006 00 10705 02 78818 00 77377 22 10998 00 78816 00 11530 00 10586 03 10587 02 N gt o o o o o N E Stop Switch Actuator 10530 00 Rack Assembly gt o o o o 7 1 A Touch Screen PC 1 A Ethernet Switch Backplane PC Board Terminal Board Channel Terminal Board
87. tainer Plate L 1 7554 122 OR 79205 00 Seal Upper 4 78951 00 20 78963 00 Body Sie 5 Way Stainless Steel 79204 00 gt j A7 LN 9408 06 3 Ransburg TROUBLESHOOTING BLOCK DIAGRAMS Over the next several pages are block diagrams of the following components of the RCS 2 control system Main Control Console Motor Amplifier Panel Fluid Panel RCS Interface PC Board Channel PC Board These drawings can be used to get an overall picture offunction 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 of the 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 LN 9408 06 3 UMBILICAL CORD SIGNALS Following the ribbon cable charts are charts of the umbilical cords cable assemblies that run from the main control console to the motor am plifier panels These charts outline what sig
88. than those of the coating material Those used for general cleaning must have flash points above 100 F 37 8 Spray booth ventilation must be kept at the rates reguired by NFPA 33 OSHA country and local codes n addition ventilation must be main tained during cleaning operations using flam mable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Test only in areas free of combustible material Testing may reguire high voltage to be on but only as instructed Non factory replacement parts or unautho rized eguipment modifications may cause fire or injury used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks dis abled Never use eguipment intended for use in water borne installations to spray solvent based ma terials The paint process and eguipment should be set up and operated in accordance with NFPA 33 NEC OSHA local country and European Health and Safety Norms RCS 2 Parts Maintenance Troubleshooting Safety AREA Tells where hazards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Explosion Hazard Improper or inadeguate oper ation and maintenance proce dures will cause
89. tial reguirements Never let 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 maintenance 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 op er 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 lubri cate the bearing surfaces Failure to fill the tooth spaces allows air into the pump and can cause low delivery excessive wear reduced seal life and internal cavitation LN 9408 06 3 Ransburg Ransburg Magnetic Coupling There is no rotating shaft connecting the servo motor to the gear pump Instead this product em ploys 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 p
90. to magnetic coupling Magnetic Coupling Transfers rotary motion from the servo motor to the gear pump Servo Motor Transfers rotary motion from the servo motor to the gear pump through the magnetic coupling Performance Capabilities Both magnetically coupled gear pumps use a UL approved servo motor Explosion proof servo mo tors rated for hazardous duty in Class Division 1 Groups C and D environments are available as an option General Handling The magnetically coupled gear pump assemblyisa precision tool designed to provide highly accurate performance over an extended service life The ability of the unit to deliver the performance level it was designed for depends on the user closely following several essential requirements Never let the pump run dry Never pump contaminated fluids Never reuse any 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 me tering 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
91. to the panel Similar to the aforementioned main control con sole there are a few things to keep in mind to help extend the lives of the components in the motor amplifier panels 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 amountof heat temperatures 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 panelto rise above 120 some sort of external cooling may be reguired is recommended that the air supply to this panel be regulated to approximately 100 psi and filtered to at least 20 Microns 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 reguire 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 Keep the door closed at all times to keep dust dirt and moisture out of the control panel Use dry filtered 20 Micron s or less air to pilot the pressure switches and supply the inle
92. tor Drive Cable 1 1 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX E RECOMMENDED SPARE PARTS Continued 10948 FLUID PANEL PARTS LIST Guantity Being Purchased Description i leo een 1 1 2 4 2 Pilot Operated Bellows 3 7766900 Piot Operated Ball Valve 1 4 7767100 Manually Operated Ball i 5 241 5 6 22420 Mix Manifold W Check Valve 1 1 7 221043 CaeystFowSmsr 8 221045 Catalyst Flow Sensor Cabe 9 22104 ManifoldforFlowSensor 10 77844 Resin Pump Assembly 0 11 Catalyst Pump Assembl o 12 Bypass Valve Assembly O 13 Lip Seal for Pump 15 22 336 O Ring Seals for Pump Bypass Valve and 4 between Flushable Pump and Manifold 16 7554 119 O Ring for Bearing Housing 2 NI 2 2 4 2 4 18 22 862 O Ring for Front Side of Magnetic Coupling 2 4 Housing Used on both style pumps 19 22 333 O Ring for Fluid Inlet and Outlet FittingsO 4 Ring used between Non Flushable Pump and 2 4 2 22 379 Manifold 2 21 22 5740 O Ring used between Non Flushable Pump 22 22 335 O Ring used between Non Flushable Pump and Manifold BE Magnetic Coupling Housing Bushing 1 O 22 939 Inner Pole Ring Assembly 2 1 1 1 1 2 1 0 0 __ 0 o 17 22 854 O Ring for Back Side of Magnetic Co
93. ts 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 panel 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 Allwetted components are stainless steel other than the physical pumps themselves In most cases the pumps are manufactured from M2 tool steel which gives them superb wear re sistance over similar designs manufactured from stainless steel Each of the individual components on the fluid panel will be discussed below as to howit operates and how to service it GEAR PUMPS This section explains How to Disassemble Clean and Reassemble the Gear Pump Introduction Themagnetically coupled gear pump is a precision tool designed to provide highly accurate perfor mance over an extended service life The gear pump is constructed of precisely machined com ponents 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 essen
94. ufficient 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 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 2 Continued AMPLIFIER LED Bink Codo Fault Description Explanation and or Possible Causes LN 9408 06 3 Bus Over Voltage Self Resetting The BUS voltage has exceeded the upper threshold limit Bus Under Voltage Self Resetting 200 DC drive fault only BUS voltage is below specified 20 VDC minimum Motor l I or l n Short Line to Line Line to Neutral or Line to PE short on the motor ou put causing an instataneous over current Output Over Current Hall Fault Valid only when drive is set to 6 Step Hall feedback operation SFD Configuration Error J
95. upling LN 9408 06 3 70 RCS 2 Parts Maintenance Troubleshooting Appendix 71 Ransburg APPENDIX C MOTOR AMPLIFIER LED DISPLAY FAULT CODES PART 2 AMPLIFIER Status LED d Blink NEN Fault Description Explanation and or Possible Causes Control power not applied or Loose or open circuit wiring of control power input Low insufficient control power applied input voltage to control power supply No faults power stage Disabled Hardware or Software Enable inactive To enable drive apply hardware enable and set software enable Motor Over Temp Motor temperature exceeds allowed limit Drive Over Under Temp Temperature of drive heatsink chassis is outside of allowed limits Drive 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 automat ically reduces to 0 67 of Dlpeak If foldback is not enabled the drive will fault Motor 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 High ambient temperature at motor Insufficient motor heat sinking from motor mounting Operating above the motor s continuous current rating Motor temperature sensor failure or not connected High or low drive ambient temperature Restriction of cooling air due to ins
96. upling 2 Housing Used on both style pumps 0 1 LN 9408 06 3 n gt 5 2 2 2 5 5 ro gt 78 RCS 2 Parts Maintenance Troubleshooting Appendix Ransburg APPENDIX E RECOMMENDED SPARE PARTS Continued SEAL KITS TOOLS TUBING ETC PARTS LlST Being Purchased Part Description 22 memes Color Sun Pump _ Kit 221285 oto es 22 335 2 22 336 1 3076 20 22 1286 Seal 9 22 22 336 1 22 364 1 22 366 22 122 543 Hardener Seal Insertion Tool 171 1 caer 6 204 FemaleDowelinsertionTool 10 20 B SSP 5020 3 8 00 Tubing 100 9 TR SSEM 548 5 32 OD Polyethylene Tubing 100 77758720 3 18 OD Polyethylene Tubing 700 1 4 OD Polyethylene Tubing 100 H 2338 3 8 OD Polyethylene Tubing 100 2 BEU 1 76698 00 3 16 IC X 5 16 OD Tubing 10 A11095 REMOTE OPERATOR S PANEL PARTS LIST Quantity Being Purchased Part rss 13742254000 lArFlowSwith Switch JPressue Sui 1712 79 LN 9408 06 3 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix APPENDIX F SYSTEM LAYOUT A10776 ABCDFF MOTOR AMPLIFIER PANEL SHOWN 4 PLACES CHANNELS 7 amp 8 CHANNELS 5 amp 6 CHANNELS 5 amp 4 CHANNELS 1 amp 2 FRONT SIDE VIEW REF LN 9408 06 3 80 Ransburg RCS 2 Parts Maintenance Troubleshooting Appendix
97. y gt Be 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 S H C scews 11 3 Using an arbor press remove two 2 dowels 8 from the pump assembly NOTE If an arbor press is unavailable an al ternate disassembly method is to partially back off the cap screws and tap the screws with a soft head hammer With the screw heads exposed continue to alternate back ing out the screws and tapping the screws until the plates are free Never tap on tang 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 dam agethe pump Determine the cause ofthe binding Nicks burrs or foreign particles can cause
98. yles 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 hardness Rc 55 Concentration of entrained particles should not exceed 20 of total fluid volume Contact Ransburg for technical assistance on applications involving metallics micas or water borne 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 Thenon flushable style pumps meter hardener and does not have a bypass assembly RCS 2 Parts Maintenance Troubleshooting Maintenance NOTE Although uncommon there are appli cations for flushable hardener pumps and for non flushable color pumps Major Components The major components of the flushable mag net ically 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 Manifold Connects gear pump

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