rcs-2 user manual - robotics & automation · rcs-2 user manual - safety 3 area tells where...

SERVICE MANUALLN-9407-00.1LN-9407-00.1LN-9407-00.1LN-9407-00.1LN-9407-00.1(Replaces LN-9407-00)(Replaces LN-9407-00)(Replaces LN-9407-00)(Replaces LN-9407-00)(Replaces LN-9407-00)December - 2009

RCS-2 USER MANUALRCS-2 USER MANUALRCS-2 USER MANUALRCS-2 USER MANUALRCS-2 USER MANUAL

MODELS:MODELS:MODELS:MODELS:MODELS: A10549 CONTROL CONSOLEA10549 CONTROL CONSOLEA10549 CONTROL CONSOLEA10549 CONTROL CONSOLEA10549 CONTROL CONSOLEA10776 MOTA10776 MOTA10776 MOTA10776 MOTA10776 MOTOR AMPLIFIER POR AMPLIFIER POR AMPLIFIER POR AMPLIFIER POR AMPLIFIER PANELANELANELANELANELA10948 FLUID PA10948 FLUID PA10948 FLUID PA10948 FLUID PA10948 FLUID PANELANELANELANELANEL

IMPORIMPORIMPORIMPORIMPORTTTTTANTANTANTANTANT: Before using this equipment,: Before using this equipment,: Before using this equipment,: Before using this equipment,: Before using this equipment,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,starting on page 1, and all instructions in thisstarting on page 1, and all instructions in thisstarting on page 1, and all instructions in thisstarting on page 1, and all instructions in thisstarting on page 1, and all instructions in thismanual. Keep this Service Manual for futuremanual. Keep this Service Manual for futuremanual. Keep this Service Manual for futuremanual. Keep this Service Manual for futuremanual. Keep this Service Manual for futurereference.reference.reference.reference.reference.

Service Manual Price:Service Manual Price:Service Manual Price:Service Manual Price:Service Manual Price: €40.00 (Euro)40.00 (Euro)40.00 (Euro)40.00 (Euro)40.00 (Euro)$50.00 (U.S.)$50.00 (U.S.)$50.00 (U.S.)$50.00 (U.S.)$50.00 (U.S.)

LN-9407-00.1

PAGEPAGEPAGEPAGEPAGE

CONTENTSCONTENTSCONTENTSCONTENTSCONTENTS

12-4

566-9999-101112

RCS-2 User Manual - Contents

SAFETY:SAFETY:SAFETY:SAFETY:SAFETY:

SAFETY PRECAUTIONS..........................................................................................................HAZARDS / SAFEGUARDS......................................................................................................

INTRODUCTION:INTRODUCTION:INTRODUCTION:INTRODUCTION:INTRODUCTION:

FEATURES..................................................................................................................................SPECIFICATIONS......................................................................................................................GENERAL DESCRIPTION.........................................................................................................CHANNELS AND GUNS ...........................................................................................................CONTROL RACK INTEGRATION.............................................................................................CONFIGURABLE OPERATING PARAMETERS......................................................................BLOCK DIAGRAMS....................................................................................................................FLUID PANEL SCHEMATIC.......................................................................................................

INSTALLATION:INSTALLATION:INSTALLATION:INSTALLATION:INSTALLATION:

OPERATION:OPERATION:OPERATION:OPERATION:OPERATION:

1-41-41-41-41-4

5-125-125-125-125-12

13-2613-2613-2613-2613-26

27-4827-4827-4827-4827-48

1314-161617-1919-2020-21212122-23242526

2727-282828-2930-48

SYSTEM GUIDELINES..............................................................................................................DIMENSIONAL INFORMATION................................................................................................INPUT POWER...........................................................................................................................DISCRETE CHANNEL AND GUN INPUTS..............................................................................DISCRETE CHANNEL AND GUN OUTPUTS..........................................................................ANALOG INPUTS.......................................................................................................................ANALOG OUTPUTS...................................................................................................................FREQUENCY INPUTS...............................................................................................................SYSTEM INPUTS AND OUTPUTS............................................................................................ODD NUMBER CHANNEL CONNECTIONS TABLE...............................................................EVEM NUMBER CHANNEL CONNECTIONS TABLE.............................................................SYSTEM I/O CONNECTIONS TABLE.......................................................................................

SETUP AND OPERATION.........................................................................................................BUTTON FUNCTIONS...............................................................................................................PASSWORD OPERATION........................................................................................................CONFIGURABLE OPERATING PARAMETERS......................................................................USER INTERFACE SOFTWARE...............................................................................................

LIMITED WARRANTYLIMITED WARRANTYLIMITED WARRANTYLIMITED WARRANTYLIMITED WARRANTY:

LIMITED WARRANTY.................................................................................................................

4949494949

49

(Continued On Next Page.)(Continued On Next Page.)(Continued On Next Page.)(Continued On Next Page.)(Continued On Next Page.)

LN-9407-00.1

RCS-2 User Manual - Contents

A - STANDARD KEYBOARD FUNCTIONS..............................................................................B - CALIBRATION DATA AND FLOW RANGES OF STANDARD RCS-2 PUMP...................................................................................................C - CHANNEL BOARD JUMPER SETTINGS...........................................................................D - INTERFACE BOARD JUMPER SETTINGS........................................................................E - CHANNEL AND GUN I/O TERMINALS...............................................................................F - SYSTEM I/O TERMINALS.....................................................................................................G - CATALYST FLOW SENSOR...............................................................................................H - FEATHERING.......................................................................................................................I - REMOTE OPERATORS PANEL..........................................................................................J - MOTOR AMPLIFIER LED DISPLAY FAULT CODES

(PART 1 AND 2)....................................................................................................................K - ERROR CODES..................................................................................................................L - PUSHOUT.............................................................................................................................M - TRIGGER LOG.....................................................................................................................N - IMPROVING THE ACCURACY OF THE RCS-2................................................................

APPENDIX:APPENDIX:APPENDIX:APPENDIX:APPENDIX: 50-7650-7650-7650-7650-76

50

515253545556-5859-6061-62

63-6667-707172-7374-76

PAGEPAGEPAGEPAGEPAGE

CONTENTS (Cont.)CONTENTS (Cont.)CONTENTS (Cont.)CONTENTS (Cont.)CONTENTS (Cont.)

LN-9407-00.1

SAFETYSAFETYSAFETYSAFETYSAFETY

RCS-2 User Manual - Safety

> The user MUSTMUSTMUSTMUSTMUST read and be familiarwith the Safety Section in this manual andthe ITW Ransburg safety literature thereinidentified.

> This manual MUSTMUSTMUSTMUSTMUST be read andthoroughly understood by ALLALLALLALLALL personnelwho operate, clean or maintain this equip-ment! Special care should be taken toensure that the WARNINGSWARNINGSWARNINGSWARNINGSWARNINGS and safetyrequirements for operating and servicingthe equipment are followed. The usershould be aware of and adhere to ALLALLALLALLALLlocal building and fire codes and ordinanc-es as well as NFPA-33 SAFETYNFPA-33 SAFETYNFPA-33 SAFETYNFPA-33 SAFETYNFPA-33 SAFETYSTANDARD, STANDARD, STANDARD, STANDARD, STANDARD, prior to installing, operat-ing, and/or servicing this equipment.

W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G!!!!!

> The hazards shown on the followingpage may occur during the normal use ofthis equipment. Please read the hazardchart beginning on page 2.

W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G!!!!!

11111

SAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSBefore operating, maintaining or servicing anyITW Ransburg electrostatic coating system,read and understand all of the technical andsafety literature for your ITW Ransburg products.This manual contains information that is importantfor you to know and understand. This informationrelates to USER SAFETY and PREVENTINGEQUIPMENT PROBLEMS. To help you recognizethis information, we use the following symbols.Please pay particular attention to these sections.

A WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryif instructions are not followed.if instructions are not followed.if instructions are not followed.if instructions are not followed.if instructions are not followed.

A CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellshow to prevent damage to equipment or howhow to prevent damage to equipment or howhow to prevent damage to equipment or howhow to prevent damage to equipment or howhow to prevent damage to equipment or howto avoid a situation that might cause minorto avoid a situation that might cause minorto avoid a situation that might cause minorto avoid a situation that might cause minorto avoid a situation that might cause minorinjury.injury.injury.injury.injury.

A NOTE is information relevant to theA NOTE is information relevant to theA NOTE is information relevant to theA NOTE is information relevant to theA NOTE is information relevant to theprocedure in progress.procedure in progress.procedure in progress.procedure in progress.procedure in progress.

While this manual lists standard specificationsand service procedures, some minor deviationsmay be found between this literature and yourequipment. Differences in local codes and plantrequirements, material delivery requirements, etc.,make such variations inevitable. Compare thismanual with your system installation drawingsand appropriate ITW Ransburg equipmentmanuals to reconcile such differences.

Careful study and continued use of this manual willprovide a better understanding of the equipmentand process, resulting in more efficient operation,longer trouble-free service and faster, easiertroubleshooting. If you do not have the manualsand safety literature for your Ransburg system,contact your local ITW Ransburg representativeor ITW Ransburg.

LN-9407-00.1


22222

AREAAREAAREAAREAAREA

Tells where hazards

may occur.

HAZARDHAZARDHAZARDHAZARDHAZARD

Tells what the hazard is.

SAFEGUARDSSAFEGUARDSSAFEGUARDSSAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Spray AreaSpray AreaSpray AreaSpray AreaSpray Area Fire Hazard

Improper or inadequate operationand maintenance procedures willcause a fire hazard.

Protection against inadvertentarcing that is capable of causingfire or explosion is lost if anysafety interlocks are disabledduring operation. Frequent powersupply shutdown indicates aproblem in the system requiringcorrection.

Fire extinguishing equipment must be present in thespray area and tested periodically.

Spray areas must be kept clean to prevent theaccumulation of combustible residues.

Smoking must never be allowed in the spray area.

The high voltage supplied to the atomizer must beturned off prior to cleaning, flushing or maintenance.

When using solvents for cleaning:

Those used for equipment flushing should have flashpoints equal to or higher than those of the coatingmaterial.

Those used for general cleaning must have flashpoints above 100oF (37.8oC).

Spray booth ventilation must be kept at the ratesrequired by NFPA-33, OSHA, and local codes. Inaddition, ventilation must be maintained duringcleaning operations using flammable or combustiblesolvents.

Electrostatic arcing must be prevented.

Test only in areas free of combustible material.

Testing may require high voltage to be on, but onlyas instructed.

Non-factory replacement parts or unauthorizedequipment modifications may cause fire or injury.

If used, the key switch bypass is intended for useonly during set-up operations. Production shouldnever be done with safety interlocks disabled.

Never use equipment intended for use in waterborneinstallations to spray solvent based materials.

The paint process and equipment should be set upand operated in accordance with NFPA-33, NEC,and OSHA requirements.

LN-9407-00.1


33333


Tells where hazards

may occur.





ElectricalElectricalElectricalElectricalElectricalEquipmentEquipmentEquipmentEquipmentEquipment

High voltage equipment is utilized.Arcing in areas of flammable orcombustible materials may occur.Personnel are exposed to highvoltage during operation andmaintenance.

Protection against inadvertentarcing that may cause a fire orexplosion is lost if safety circuitsare disabled during operation.

Frequent power supply shut-downindicates a problem in the systemwhich requires correction.

An electrical arc can ignite coatingmaterials and cause a fire orexplosion.

The power supply, optional remote control cabinet,and all other electrical equipment must be locatedoutside Class I or II, Division 1 and 2 hazardousareas. Refer to NFPA-33.

Turn the power supply OFF before working on theequipment.

Test only in areas free of flammable or combustiblematerial.

Testing may require high voltage to be on, but onlyas instructed.

Production should never be done with the safetycircuits disabled.

Before turning the high voltage on, make sure noobjects are within the sparking distance.

ExplosionExplosionExplosionExplosionExplosionHazard /Hazard /Hazard /Hazard /Hazard /IncompatibleIncompatibleIncompatibleIncompatibleIncompatibleMaterialsMaterialsMaterialsMaterialsMaterials

Halogenated hydrocarbon solventsfor example: methylene chlorideand 1,1,1,-Trichloroethane are notchemically compatible with thealuminum that might be used inmany system components. Thechemical reaction caused by thesesolvents reacting with aluminumcan become violent and lead to anequipment explosion.

Aluminum is widely used in other spray applicationequipment - such as material pumps, regulators,triggering valves, etc. Halogenated hydrocarbonsolvents must never be used with aluminumequipment during spraying, flushing, or cleaning.Read the label or data sheet for the material youintend to spray. If in doubt as to whether or not acoating or cleaning material is compatible, contactyour material supplier. Any other type of solventmay be used with aluminum equipment.

Improper operation or maintenancemay create a hazard.

Personnel must be properly trainedin the use of this equipment.

Personnel must be given training in accordance withthe requirements of NFPA-33.

Instructions and safety precautions must be readand understood prior to using this equipment.

Comply with appropriate local, state, and nationalcodes governing ventilation, fire protection, operationmaintenance, and housekeeping. Reference OSHA,NFPA-33, and your insurance company require-ments.

General Use andGeneral Use andGeneral Use andGeneral Use andGeneral Use andMaintenanceMaintenanceMaintenanceMaintenanceMaintenance

LN-9407-00.1


44444


Tells where hazards

may occur.





Spray Area/Spray Area/Spray Area/Spray Area/Spray Area/High VoltageHigh VoltageHigh VoltageHigh VoltageHigh VoltageEquipmentEquipmentEquipmentEquipmentEquipment

There is a high voltage devicethat can induce an electrical chargeon objects which is capable ofigniting coating mater-ials.

Inadequate grounding will causea spark hazard. A spark canignite many coating materials andcause a fire or explosion.

Parts being sprayed must be supported on conveyorsor hangers and be grounded. The resistance betweenthe part and ground must not exceed 1 megohm.(Reference NFPA-33.)

All electrically conductive objects in the spray area,with the exception of those objects required by theprocess to be at high voltage, must be grounded.

Any person working in the spray area must begrounded.

Unless specifically approved for use in hazardouslocations, the power supply and other electrical controlequipment must not be used in Class 1, Division 1 or2 locations.

Personnel Safety/Personnel Safety/Personnel Safety/Personnel Safety/Personnel Safety/MechanicalMechanicalMechanicalMechanicalMechanicalHazardsHazardsHazardsHazardsHazards

The bell atomizer can rotate atspeeds up to 50,000 rpm. Atthese speeds, the edge of theapplicator can easily cut into skin.Loose articles of clothing can alsobe caught by the rotating bell.

Personnel must stay clear of the bell whenever it isrotating.

Before touching the bell, the turbine air must be shutoff.

If the bell has been rotating, allow at least two minutesfor it to come to a complete stop before touching it.

Toxic SubstancesToxic SubstancesToxic SubstancesToxic SubstancesToxic Substances Certain material may be harmful ifinhaled, or if there is contact withthe skin.

Follow the requirements of the Material Safety DataSheet supplied by coating material manufacturer.

Adequate exhaust must be provided to keep the airfree of accumulations of toxic materials.

Use a mask or respirator whenever there is a chanceof inhaling sprayed materials. The mask must becompatible with the material being sprayed and itsconcentration. Equipment must be as prescribed byan industrial hygienist or safety expert, and be NIOSHapproved.

LN-9407-00.1

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

RCS-2 User Manual - Introduction

FEAFEAFEAFEAFEATURESTURESTURESTURESTURES

• Control of up to 8 gear pumps from one 24"W X 24" H X 17" D control console

• Guns configurable as single or dual channelguns. (Configurable as 8 single channelguns, 4 dual channel guns, or almost anycombination of the two.)

• Dual channel guns configurable as automatic(flow and ratio control) or as manual (flow,ratio, and pressure control) modes

• Configurable operating parameters for allchannels and guns. (Up to 199 "Jobs" pergun can be programmed.)

• Full color graphical screens for setup, opera-tion, and diagnostics.

• Comprehensive help information availablefrom all screens.

• Pot life timer monitoring and alarming.

• Pressure pot volume monitoring and alarm-ing.

• Configurable alarms, faulting conditions, andalarm tolerance times.

• With proper pump sizes selected, has virtu-ally unlimited ratio and flow capabilities.(Currently available pumps provide flowranges from 0.9 cc/min to 1500 cc/min perchannel.)

• Discrete I/O capabilities allow interfacing toany manufacturer's PLC.

• Allen Bradley Remote I/O capabilities (op-tional)

• USB ports allow backup of all operatingparameters, retrieval of flow responsegraphs, and updating of user interface software.

• Firmware on control cards is stored in flashmemory and can be updated using a laptopwith a serial port. (Firmware and softwareupdates can be emailed to site.)

• User interface computer can be located any-where and a simple Ethernet cable run frominterface PC to RCS-2 interface card.

• Retrofit option allows RCS customers toupgrade their electronics and use theirexisting fluid components.

• All discrete digital and analog inputs and out-putscan be monitored and forced for diag-nostic purposes.

• All parameter screens can be password pro-tected.

• Most analog inputs and outputs configurablefor 0-10 VDC or 4-20 mA.

• Data acquisition style trending screens avail-able for setup, diagnostics, and fine tuning ofthe system.

55555

LN-9407-00.1


66666

Size:Size:Size:Size:Size: Stand Alone Cart Mount Version:

71" High x 28" Wide x 32" Deep(180.34 cm X 71.12 cm X 81.28 cm)

Main Control Console:24" High x 24" Wide x 17" Deep(61 cm X 61 cm X 43.18 cm)

Motor Amplifier Panel:24" High x 24" Wide x 13" Deep(61 cm X 61 cm X 33 cm)

Fluid Panel:34" High x 21" Wide x 24" Deep(86.36 cm X 53.34 cm X 61 cm)

Weight: Weight: Weight: Weight: Weight: 400 lbs. (181.5 Kg)

Operating Temperature: Operating Temperature: Operating Temperature: Operating Temperature: Operating Temperature: 32°F to 120°F (0°C to 49°C)

Operating Humidity: Operating Humidity: Operating Humidity: Operating Humidity: Operating Humidity: 0% to 95%

Power Requirements: Power Requirements: Power Requirements: Power Requirements: Power Requirements: 120 VAC at 10 Amps (240 VAC at 5 Amps)

Pneumatic Air Consumption: Pneumatic Air Consumption: Pneumatic Air Consumption: Pneumatic Air Consumption: Pneumatic Air Consumption: Less than 5 cfm

Pneumatic Air Inlet Size:Pneumatic Air Inlet Size:Pneumatic Air Inlet Size:Pneumatic Air Inlet Size:Pneumatic Air Inlet Size: 3/8" ODT

Pneumatic Air Outlet Size: Pneumatic Air Outlet Size: Pneumatic Air Outlet Size: Pneumatic Air Outlet Size: Pneumatic Air Outlet Size: ¼” ODT

User Interface Processor:User Interface Processor:User Interface Processor:User Interface Processor:User Interface Processor: 1 GHz Intel® PIIIRunning WindowsEmbedded XP

Interface Board Processor: Interface Board Processor: Interface Board Processor: Interface Board Processor: Interface Board Processor: Rabbit 2000™

Channel Board Processor:Channel Board Processor:Channel Board Processor:Channel Board Processor:Channel Board Processor:Motorola MC68HC16

Fluid Capacity: Fluid Capacity: Fluid Capacity: Fluid Capacity: Fluid Capacity: 0.9 cc/min to 1500 cc/min per pump

Fluid Inlet Size: Fluid Inlet Size: Fluid Inlet Size: Fluid Inlet Size: Fluid Inlet Size: 3/8" ODT

Fluid Viscosity Range:Fluid Viscosity Range:Fluid Viscosity Range:Fluid Viscosity Range:Fluid Viscosity Range: 20–1000 centipoise

Fluid Inlet Pressure: Fluid Inlet Pressure: Fluid Inlet Pressure: Fluid Inlet Pressure: Fluid Inlet Pressure: 0 psi to 200 psi

Fluid Outlet Pressure: Fluid Outlet Pressure: Fluid Outlet Pressure: Fluid Outlet Pressure: Fluid Outlet Pressure: 200 psi maximum

GENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTION

The RCS-2 RCS-2 RCS-2 RCS-2 RCS-2 System System System System System is composed of four basicelements:

• Main Control Console• Motor Amplifier Panel• Fluid Panel• Remote Operator's Panel

The Main Control Console can control up to 8pumps, the Motor Amplifier Panels will interfacewith either one or two pumps, and the Fluid Pan-els are available with either one or two pumps.

Main Control ConsoleMain Control ConsoleMain Control ConsoleMain Control ConsoleMain Control ConsoleThe Main Control Console is the heart of thesystem. It houses the following items:

• User-interface computer• Control card rack• Ethernet switch• Interface card• Channel card(s)• 15" color LCD touch screen display• DC power supply• Ribbon cable interface boards• Power and I/O terminal strip• Noise filter and fuses• I/O connectors for motor amplifier panels

The User Interface ComputerUser Interface ComputerUser Interface ComputerUser Interface ComputerUser Interface Computer is a Pentium®

based PC with a non-volatile flash-disk that containsa Windows XP® Embedded operating system andthe RCS-2 user-interface software. It has an on-board Ethernet port to allow interface with theinterface card. The computer has USB ports forupdating its software and for backing-up parameterdata. Keyboard and mouse ports are also availableon the unit for setup, diagnostics, andtroubleshooting, if necessary.

The control card rack control card rack control card rack control card rack control card rack is a half-width 19" rackwith space for one RIO card, one interface card,and up to four channel cards. It is powered from24 VDC and utilizes up to 9 ribbon cableconnections (if all 8 channels are used). Highspeed communications between cards isaccomplished using a Motorola® SPI bus.

SPECIFICASPECIFICASPECIFICASPECIFICASPECIFICATIONSTIONSTIONSTIONSTIONS

LN-9407-00.1


77777

to eight 26-pin military-style connectors, one foreach channel. These I/O connectorsI/O connectorsI/O connectorsI/O connectorsI/O connectors allow themain control console to be interfaced with themotor amplifer panel(s) via the 26-conductor"umbilical cables". Also, on the top of the maincontrol panel are two Ethernet connectors used toconnect to the interface card and user interfacecomputer.

Motor Amplifier PanelsMotor Amplifier PanelsMotor Amplifier PanelsMotor Amplifier PanelsMotor Amplifier PanelsThe Motor Amplifer Panels act as the interfacebetween the CPU on the channel cards and the"real world" devices such as motors, pressuretransducers, and flow switches. They house thefollowing items:

• Motor Drive Amplifiers• E to P Pressure Transducers• Zener Barriers• Interface Modules for Flow Sensor• 24 VDC Power Supply• Corr-Com Power Filter• Control Relay• Terminal Strip• Optional Color Change Sequencer

The motor drive amplifiers motor drive amplifiers motor drive amplifiers motor drive amplifiers motor drive amplifiers convert a 0 to 10VDC signal from the channel cards to a proportionalRPM (0 to 150) at the motors. They also receivethe feedback from the resolvers attached to themotors. In this way, they can generate a fault if theactual motor RPM does not match the targetRPM.

The E to P pressure transducersE to P pressure transducersE to P pressure transducersE to P pressure transducersE to P pressure transducers convert a 0to 10 VDC signal or optionally a 4 to 20 mA signalfrom the channel cards to a proportional 0 to 100psi air signal. This signal is used to pilot fluidregulators on the inlet of the pumps, allowing thechannel card to control the inlet pressure of thepumps.

The optional Zener barriersZener barriersZener barriersZener barriersZener barriers make the pressuresensors and the optional Remote Operator's Panelintrinsically safe for use inside the spray area.

The optional catalyst flow sensor interfacecatalyst flow sensor interfacecatalyst flow sensor interfacecatalyst flow sensor interfacecatalyst flow sensor interface

The interface card interface card interface card interface card interface card houses a Rabbit 2000®

embedded processor. This board performs thefollowing functions:

• It handles all communications betweenthe user-interface computer and the chan-nel cards.

• It stores all parameter data in battery-backed RAM.

• Has an Ethernet port used to communi-cate with the user-interface PC and thecolor change sequencer.

• Handles all discrete system I/O (job num-ber inputs, strobe inputs, system fault out-puts, etc.).

Each channel card channel card channel card channel card channel card houses a Motorola®

MC68HC16 embedded processor. These boardsperform the following funtions:

• Controls all gun and channel specific dis-crete inputs and outputs.

• Controls all gun and channel specific ana-log inputs and outputs.

• Holds firmware for PID loops that controlmotor amplifiers.

• Holds firmware for PID loops that controlinlet pressure transducers.

The LCD touch-screen displayLCD touch-screen displayLCD touch-screen displayLCD touch-screen displayLCD touch-screen display is a 15" diag-onal, full color LCD display with 1024 by 768 pixelresolution.

There is one DC power supply DC power supply DC power supply DC power supply DC power supply housed in themain control console. It supplies 24 VDC for alldiscrete I/O signals and for the boards in thecontrol rack.

The ribbon cable interface boards ribbon cable interface boards ribbon cable interface boards ribbon cable interface boards ribbon cable interface boards provideeasy screw-terminal access to all analog anddigital input and output signals. They also providespecific test points to allow easy connection oftest devices and data acquisition equipment.

The terminal stripterminal stripterminal stripterminal stripterminal strip is used for connecting ACpower to the unit and for access to the 24 VDCpower supply for external I/O devices. Theterminal strip has two fusesfusesfusesfusesfuses, one for the incomingAC power and one for the 24 VDC control power.On the buttom of the terminal strip is a Corr-Com®

power filter for the incoming AC.On the top of the main control console there are up

LN-9407-00.1

module module module module module powers and monitors the flow sensortypically used in the catalyst line of the fluid panel.An additional module converts the flow signal to a4 to 20 mA signal that is proportional to the flow rateof the catalyst. That signal is then fed back to thechannel card so it can be used to generate faultswhen catalyst flow falls below a preset point or if airis detected in the supply line.

The 24 VDC power supply24 VDC power supply24 VDC power supply24 VDC power supply24 VDC power supply powers the E to Ptransducers, the pressure sensors, catalyst flowsensor modules, and the optional RemoteOperators's Panel.

If the optional color change sequencer is installed,this power supply will also have a +5 VDC outputto power the color change sequencer.

The optional Color Change Sequencer is a smallP.L.C. like processor that controls the flush, load,and color change sequences for each gun and jobnumber. Each time a job number is loaded into agun, the flush and load sequences are downloadedto this controller. (A color change sequence issimply a flush sequence followed by a loadsequence.)

Fluid PanelsFluid PanelsFluid PanelsFluid PanelsFluid PanelsThe Fluid Panels contain all of the "wetted"components for the RCS-2 as well as the drivemotors. These include:

• Gear Pumps• Pump Manifolds• Servo Motors• Pressure Sensors• Catalyst Flow Sensor (optional)• Mix-Block• Spiral Mix Tube• Color Valve Stack (optional)• Solvent Manifold• Pump Bypass Valve

The gear pumpsgear pumpsgear pumpsgear pumpsgear pumps are available in various sizes forvarious materials and flow rates. Users shouldconsult ITW Ransburg technical support group todetermine which pumps are required for theirspecific application. (Refer to "Appendix B" for alist of currently available pump sizes.)

88888

The pump manifoldspump manifoldspump manifoldspump manifoldspump manifolds house the magneticcouplings which tie the servo motors to the gearpumps.

The servo motorsservo motorsservo motorsservo motorsservo motors actually house both an ACdrive servo motor and a feedback resolver in thesame physical housing. They get their drivesignals from the motor drive amplifiers and theresolvers feed their rotational information back tothe motor drive amplifiers. (Explosion proof servomotors are available as an option.)

The pressure sensorspressure sensorspressure sensorspressure sensorspressure sensors convert the fluid pressurefrom the fluid inlet and outlet of the pumps to a 4 to20 mA signal which is then fed through the zenerbarriers and back to the channel boards (in thecontrol rack). Standard units have a pressurerange of 0 psi to 200 psi.

The catalyst flow sensor catalyst flow sensor catalyst flow sensor catalyst flow sensor catalyst flow sensor is a thermal sheddingtype flow sensor that is immersed in the catalystflow stream. It detects flow by heating the sensorand then sensing how much of the heat is beingremoved from the sensor by the flow of catalyst.(More flow = more heat removed from the sensorhead.) An optional explosion-proof version of thissensor is available for use in hazardous areas.

The Mix-BlockMix-BlockMix-BlockMix-BlockMix-Block is a three-port manifold thatbrings the fluid from the outlet of the resin pumptogether with the outlet of the catalyst pump. Theblock houses a check valve in the catalyst streamto prevent resin from backing up into the catalystflow stream. Attached to the bottom of the Mix-Block is a solvent flush valve for quick flushing ofonly the mixed material from the Mix-Block out tothe applicator.

Attached to the outlet of the Mix-Block is the spiralspiralspiralspiralspiralmix tubemix tubemix tubemix tubemix tube. This is simply a piece of tubing with ahelical-shaped element inside the tube. Thiselement causes the two materials (resin andcatalyst) to be "folded" together numerous timesas the materials pass through it, thus causing it tomix.

The optional CCV style color valve stackcolor valve stackcolor valve stackcolor valve stackcolor valve stack allowsusers to do color changes on the resin side of upto 10 colors.


LN-9407-00.1


99999

CHANNELS AND GUNSCHANNELS AND GUNSCHANNELS AND GUNSCHANNELS AND GUNSCHANNELS AND GUNS

The RCS-2 control system achieves closed-loopcontrol of its fluids via its configured channelschannelschannelschannelschannelsand gunsand gunsand gunsand gunsand guns. A channel consists of one pump, onemotor, one motor amplifier, two pressuretransducers, and one half of a channel card. Agun, in most cases, represents one applicator andmay be configured with one channel (for flowcontrol only) or configured with two channels (forratio and flow control).

Each channel operates independently of andsimultaneously with all of the other channels in thesystem. The controller, therefore, providesaccurate dynamic flow control for all channels.

CONTROL RACKCONTROL RACKCONTROL RACKCONTROL RACKCONTROL RACKINTEGRAINTEGRAINTEGRAINTEGRAINTEGRATIONTIONTIONTIONTION

The control rack has been designed to beconsistent with other ITW Ransburg products toallow integration of the RCS-2 control rack inlarger control consoles. These consoles mayhouse rotary atomizer speed control, shaping andfan air control, high voltage setpoints, etc.

CONFIGURABLECONFIGURABLECONFIGURABLECONFIGURABLECONFIGURABLEOPERAOPERAOPERAOPERAOPERATINGTINGTINGTINGTINGPPPPPARAMETERSARAMETERSARAMETERSARAMETERSARAMETERS

The design of the system allows it to be configuredto meet the requirements of the application. Thelarge number of parameters allows the system tobe used in almost any application involving flowand/or ratio control of fluids.

System ParametersSystem ParametersSystem ParametersSystem ParametersSystem Parameters are parameters that affectthe overall system, which includes all channelsand guns or the user interface. They include:

• Over Pressure Limit• Foldback Pressure• Pressure Sensor Limit• Horn Enable/Disable• Password• Password Timeout• Controller I/P Address• Interface Card Name• Software and Firmware Version Information• User Program IP Port• System Time• System Date

Gun ParametersGun ParametersGun ParametersGun ParametersGun Parameters are parameters that affect thegun. These parameters apply to all channelsconfigured to that gun. They include:

• Mode (manual or automatic)• Number of channels configured to gun• Master Channel Number• Slave Channel Number• Number of Applicators• Default Job Number• Mixed Volume• Flow/Ratio Tolerance• Tolerance Volume• Alarm Tolerance Time• Solvent Flow Meter Calibration Factor• Horn Code• Auto Reset Enable/Disable

The solvent manifold solvent manifold solvent manifold solvent manifold solvent manifold supplies solvent for flushingas well as filling of the magnetic coupling chamber.

The pump bypass valvepump bypass valvepump bypass valvepump bypass valvepump bypass valve is mounted on the resinpump and allows the fluid passing into the inlet ofthe resin pump to bypass the gears and go directlyto the outlet port. This can decrease flush and loadtimes.

> This valve should not be used whileloading 2k materials as improper ratioswill result.

NOTENOTENOTENOTENOTE

LN-9407-00.1


1010101010

Channel ParametersChannel ParametersChannel ParametersChannel ParametersChannel Parameters are parameters that affectonly that specific channel. For two channel guns,there are independent parameters for each of thetwo channels. They include:

• Fill Enable/Disable• Trigger On-Delay Time• Trigger Off-Delay Time• Pump Size• Pump Pulses Per Liter• Maximum Pump Speed• Miniumum Pump Speed• Maximum Inlet Pressure• Minimum Inlet Pressure• Maximum Outlet Pressure• Minimum Outlet Pressure• Inlet Pressure Sensor Enable/Disable• Foldback Kp• Foldback Ki• Foldback Kd• Foldback Deadband• Feather Kp• Feather Ki• Feather Kd• Feather Deadband

Job ParametersJob ParametersJob ParametersJob ParametersJob Parameters are parameters that are storedwith the specific job number. Typically, a jobnumber is assigned to a specific material. In thisway, totalization data and PID parameters relatedirectly to the material. These parameters include:

• Ratio• Flow Setpoint• Maximum Flow (for analog control)• Minimum Flow (for analog control)• Bar-Graph Limit• Pot-Life Time• Feather Pressure• Fill Volume• Pressure Pot Capacity• Pressure Differential (across the pump)• Minimum Pressure• Inlet Presure Control PID Parameters• Hardener Sample Time• Hardener No Flow Setpoint• Hardener Flow On Point

Alarm Configuration ParametersAlarm Configuration ParametersAlarm Configuration ParametersAlarm Configuration ParametersAlarm Configuration Parameters allow theuser to specify what conditions cause a "sprayshutdown" to occur. They include:

• Input Under Pressure• Input Over Pressure• Output Under Pressure• Output Over Pressure• Flow Rate Out of Tolerance• Hardener Flow Loss• Pressure Pot Empty• Inlet Pressure Loss• Analog Remote Loss• Ratio Out of Tolerance• Motor Amp Fault *• Analog Feather Loss• Analog Spare Loss• Foldback Pressure Reached• Pot Life Expired• System Over Pressure *• Channel Card Parameter Fault *• Channel Card SPI Fault *• Channel Card Internal Fault *

> Items marked with an asterisk (*) can-not be disabled


LN-9407-00.1


1111111111

BLOCK DIAGRAMSBLOCK DIAGRAMSBLOCK DIAGRAMSBLOCK DIAGRAMSBLOCK DIAGRAMS

Figure 1: Control Console Block DiagramFigure 1: Control Console Block DiagramFigure 1: Control Console Block DiagramFigure 1: Control Console Block DiagramFigure 1: Control Console Block Diagram

Figure 2: Motor Amplifier Panel Block DiagramFigure 2: Motor Amplifier Panel Block DiagramFigure 2: Motor Amplifier Panel Block DiagramFigure 2: Motor Amplifier Panel Block DiagramFigure 2: Motor Amplifier Panel Block Diagram

LN-9407-00.1


1212121212

Figure 3: Fluid Panel SchematicFigure 3: Fluid Panel SchematicFigure 3: Fluid Panel SchematicFigure 3: Fluid Panel SchematicFigure 3: Fluid Panel Schematic

LN-9407-00.1

RCS-2 User Manual - Installation

1313131313

INSTINSTINSTINSTINSTALLAALLAALLAALLAALLATIONTIONTIONTIONTION

SYSTEM GUIDELINESSYSTEM GUIDELINESSYSTEM GUIDELINESSYSTEM GUIDELINESSYSTEM GUIDELINES

Customized PrintsCustomized PrintsCustomized PrintsCustomized PrintsCustomized PrintsDrawings and information contained in this sectionof the manual is applicable to most installations.However, in many cases, ITW will supply custominstallation drawings for your specific site. It ishighly recommended that if your installation differssignificantly from the installation drawings suppliedby ITW, you notify your ITW representative toensure that standard installation practices are notviolated and to have your prints updated to reflectthe installation accurately for future reference.

Cable AssembliesCable AssembliesCable AssembliesCable AssembliesCable AssembliesInterconnections between all control panels andthe fluid panels are made using custommanufactured cable assemblies with military styleconnectors. This simplifies installation andeliminates the possibility of items being wiredincorrectly. The one exception to this is thediscrete interface I/O wiring. These connectionswill vary greatly from installation to installation.This can involve well over 100 connections percontrol console and, therefore, require that conduitbe run to the control console and multiple cables orwires pulled from the control console to thecontrolling medium (PLC, robot, etc.).

Equipment GroundingEquipment GroundingEquipment GroundingEquipment GroundingEquipment GroundingAll panels should be grounded in accordance witheither the National Electrical Code or local electricalcodes (whichever is more stringent). Refer to theelectrical installation drawings provided by ITW tolocate the grounding terminal for all control panels.

Equipment LocationsEquipment LocationsEquipment LocationsEquipment LocationsEquipment LocationsAll of the panels must be located outside of thehazardous area with the exception of the intrinsicallysafe version of the Remote Operator’s Panel (andin some cases the fluid panel). If in doubt, refer tolocal codes and ordinances, or contact your ITWrepresentative for clarification.

There are four basic panels used in the RCS-2system:

• Main Control Console• Motor Amplifier Panel• Fluid Panel• Remote Operator’s Panel

The motor amplifier panels must be placed within100-feet of the control console, the fluid panelsmust be placed within 10-feet of their respectivemotor amplifier panel, and the remote operator’spanel must be placed within 25-feet of its respectivemotor amplifier panel. If longer distances than thisare necessary, contact your ITW representative.

Fluid RegulatorsFluid RegulatorsFluid RegulatorsFluid RegulatorsFluid RegulatorsIt is highly recommended that a pilot operated fluidregulator (similar to the ITW DR-1 regulator) beused on the inlet of all of the gear pumps. Theaccuracy of the pumps depends to a high degreeon controlling the differential pressure across thepump. The system includes pressure transducersin the motor amplifier panels to pilot these fluidregulators. In this way, the software has fullcontrol of fluid inlet pressure of the pumps and can,therefore, control the differential pressure acrosseach pump. By using this feature, the extremelyaccurate flow rates and ratios can be maintained,without the need to calibrate the pumps.

Intrinsic SafetyIntrinsic SafetyIntrinsic SafetyIntrinsic SafetyIntrinsic SafetyThe motor amplifier panels can be ordered withoptional zener barriers that make the fluid panelsand the remote operator panels intrinsically safefor operation inside hazardous areas. An optionalexplosion-proof catalyst flow sensor and motorsare also available. They must be hard-piped ifused in hazardous areas.

LN-9407-00.1


1414141414

Figure 4: Stand-Alone UnitFigure 4: Stand-Alone UnitFigure 4: Stand-Alone UnitFigure 4: Stand-Alone UnitFigure 4: Stand-Alone Unit

DIMENSIONAL INFORMATIONDIMENSIONAL INFORMATIONDIMENSIONAL INFORMATIONDIMENSIONAL INFORMATIONDIMENSIONAL INFORMATION

Figure 5: Motor Amplifier PanelFigure 5: Motor Amplifier PanelFigure 5: Motor Amplifier PanelFigure 5: Motor Amplifier PanelFigure 5: Motor Amplifier Panel

LN-9407-00.1


1515151515

Figure 6: Control Panel AssemblyFigure 6: Control Panel AssemblyFigure 6: Control Panel AssemblyFigure 6: Control Panel AssemblyFigure 6: Control Panel Assembly

LN-9407-00.1


1616161616

Figure 7: Fluid Panel AssemblyFigure 7: Fluid Panel AssemblyFigure 7: Fluid Panel AssemblyFigure 7: Fluid Panel AssemblyFigure 7: Fluid Panel Assembly

INPUT POWERINPUT POWERINPUT POWERINPUT POWERINPUT POWER

Input power supply connections should be madefrom a fused disconnect. With the exception of thestand alone, cart mounted RCS-2; conduit shouldbe used for bringing the input power into the controlpanel and motor amplifier panels. In the case ofthe stand alone unit, SO cord will be provided withstandard AC grounded plugs.

Both the control panel and the motor amplifierpanels operate from 120 VAC at 60 Hz with amaximum current draw of 10 amps (for eachpanel). The fluid panels get their power from themotor amplifier panel and, therefore, require nopower connections.

If there is the possibility of AC line voltagefluctuations of greater than ±10% of the line voltage,a constant voltage transformer (CVT) should beused between the fused disconnect and the controlpanel and motor amplifier panels. (Thesefluctuations are commonly seen when heavyelectric machinery or welding equipment is beingused nearby.)

Refer to Figures 8 and 9 to determine proper ACpower and ground connections to the controlpanel and the motor amplifier panels.

Figure 8: Control Panel Input PowerFigure 8: Control Panel Input PowerFigure 8: Control Panel Input PowerFigure 8: Control Panel Input PowerFigure 8: Control Panel Input Power

Figure 9: Motor Amplifier Panel Input PowerFigure 9: Motor Amplifier Panel Input PowerFigure 9: Motor Amplifier Panel Input PowerFigure 9: Motor Amplifier Panel Input PowerFigure 9: Motor Amplifier Panel Input Power

LN-9407-00.11717171717


There are two types of discrete digital inputs,pulsed inputs and maintained inputs. The pulsedinputs must be turned on and held on for 250milliseconds minimum, to insure operation. Multiplepulsed signals to a gun should also be separatedby 250 milliseconds. For example, don't turn thehalt/reset signal off at the same time that the runsignal is being turned on as results will beunpredictable. Maintained signals operate as longas the input remains energized.

DISCRETE CHANNELDISCRETE CHANNELDISCRETE CHANNELDISCRETE CHANNELDISCRETE CHANNELAND GUN INPUTSAND GUN INPUTSAND GUN INPUTSAND GUN INPUTSAND GUN INPUTS

All discrete digital inputs are optically isolated andwill function with an input voltage in the range of 10VDC to 45 VDC. Factory jumper settings on theinterface and channel boards require that voltagebe sourced to the discrete input. If, however, asinking input is required, inputs can be reconfiguredby changing those jumpers. (See Appendix C forChannel Board Jumper Settings.) It isrecommended that the 24 VDC power supply inthe controller be used to source these inputs(terminal #1331). Optionally, if an external supplyis used as the source for these inputs, it must bereferenced to the ground terminal (terminal #1113).

Figure 10: Gun I-O Sourcing-SinkingFigure 10: Gun I-O Sourcing-SinkingFigure 10: Gun I-O Sourcing-SinkingFigure 10: Gun I-O Sourcing-SinkingFigure 10: Gun I-O Sourcing-Sinking

> Times stated above are for discretedigital inputs only. When interfacing usingAllen Bradley's Remot I/O (aka RIO),these times may vary significantly. (Referto the RCS-2 RIO Interface Programmer'sManual for more details.)


Some discrete digital inputs are specific to a gunand others are specific for a channel. If it is a guninput and the gun is configured as a two channelgun, field wiring must always be connected to themaster channel terminals (channel A).

Fast FillFast FillFast FillFast FillFast FillType of Input: Type of Input: Type of Input: Type of Input: Type of Input: GunType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Pulsed

The gun must be in run mode prior to initiating thismode or the RCS-2 controller will ignore it.

If the gun is configured as a single channel gun andthis signal is pulsed, the gun will be put in fast fillmode. This will cause the pump to run at itsmaximum rate (150 RPM) until the halt signal ispulsed. (It is not necessary to have the triggersignal energized.)

If the gun is configured at a two-channel gun, andthis input is pulsed, the gun will be placed in fast fillmode. The pumps will run at the maximum speedpossible while maintaining the target ratio. That is,the software will determine which of the two pumpscan be run at its maximum speed (150 RPM) andrun the opposite channel at whatever speed isnecessary to ensure the proper ratio of component

LN-9407-00.1 1818181818

A to component B. The software determines thisbased on the programmed pump sizes and theprogrammed ratio. Pulsing the halt/reset inputtakes the gun out of the fast fill mode.

Channel FillChannel FillChannel FillChannel FillChannel FillType of Input:Type of Input:Type of Input:Type of Input:Type of Input: ChannelType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Pulsed

A gun must be in the ready state to use this mode.

This mode functions the same for single channelguns as it does for dual channel guns.

When this input is pulsed, the pump for that channelis run at its maximum rate (150 RPM) until the haltsignal is pulsed. It is not necessary for the triggerinput to be energized. If it is desired to have bothchannels of a two channel gun run at full speed (forflushing, etc.) this input must be pulsed on bothchannels. The halt signal for the specific channelthat is channel filling must be pulsed. For example:if both channels are channel filling, both halt signalsmust be pulsed to stop them.

Feather SetFeather SetFeather SetFeather SetFeather SetType of Input:Type of Input:Type of Input:Type of Input:Type of Input: GunType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Pulsed

If the gun is configured as a manual mode gun andthe value zero (0) is programmed in for featherpressure (under the CONFIG JOB parameters)this input can be used to program the featherpressure "on the fly". That is, if a handsprayer ispainting and this input is momentarily energized,the RCS-2 controller takes a snapshot of theoutbound pressure of the pumps (or the pressureat the optional feather pressure sensor, if it is beingused) and then starts controlling the speed of thepumps to maintain that pressure. The optionalRemote Operator’s Panel has a pushbutton on itthat allows the handsprayer to utilize this feature.(Refer to "Appendix H" for more details onfeathering.)


RunRunRunRunRunType of Input:Type of Input:Type of Input:Type of Input:Type of Input: GunType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Pulsed

This signal takes a configured gun from the readystate to the "run" mode. In order for a gun to spray,it must first be put into run mode. It is essentiallya way of enabling a gun. Energizing the triggerinput of a gun will not cause fluid to flow unless thegun has first been placed in run mode.

Halt/Fault ResetHalt/Fault ResetHalt/Fault ResetHalt/Fault ResetHalt/Fault ResetType of Input: Type of Input: Type of Input: Type of Input: Type of Input: GunType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Pulsed

This input takes a configured gun that is in runmode to the ready state, essentially disabling thegun from spraying. It also resets a fault for the gunif it is in the faulted state.

TTTTTrigger 1rigger 1rigger 1rigger 1rigger 1Type of Input: Type of Input: Type of Input: Type of Input: Type of Input: GunType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Maintained

This input tells the controller to run the pumps ifand only if the gun has first been placed in runmode.

Motor Amp EnableMotor Amp EnableMotor Amp EnableMotor Amp EnableMotor Amp EnableType of Input: Type of Input: Type of Input: Type of Input: Type of Input: ChannelType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Maintained

This is an input to the controller from the motoramplifier indicating that the motor amplifier hasbeen enabled by the channel card and that thereare no problems.

TTTTTriggers 2, 3, and 4riggers 2, 3, and 4riggers 2, 3, and 4riggers 2, 3, and 4riggers 2, 3, and 4Type of Input:Type of Input:Type of Input:Type of Input:Type of Input: GunType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Maintained

These signals are additional trigger input signals.They would be used in cases where the output ofa fluid panel was split between multiple applicators.They work in conjunction with the trigger 1 input toallow up to 4 independent triggers, one for each of4 applicators. The software can be configured insuch a way that if one of these inputs is on, the fluidpanel delivers the target flow rate of material. If asecond input is turned on, then the fluid panel willdeliver twice the target flow rate. If a third input isenergized, three times the target flow is deliveredand if all four inputs are energized, the fluid panel

LN-9407-00.1


1919191919

DISCRETE CHANNELDISCRETE CHANNELDISCRETE CHANNELDISCRETE CHANNELDISCRETE CHANNELAND GUN OUTPUTSAND GUN OUTPUTSAND GUN OUTPUTSAND GUN OUTPUTSAND GUN OUTPUTS

All discrete outputs have two terminals, one labeledHi and one labeled Lo. They operate very similarto a dry contact relay with allowable current limitedto 1 amp 45 volts, AC or DC (exceeding this limitmay damage the output on the channel card).Although a myriad of voltages could be used, it isrecommended that the Hi signal be connected tothe +24 VDC terminal (terminal #1331) and theoutput be taken from the Lo output terminal. Thisterminal will supply 24 VDC when the output isenergized by the software. (Referenced groundterminal is #1113.)

An alternate way of connecting these outputswould be to connect the positive supply voltage tothe load, the common of the load to the Hi outputterminal of the RCS-2 output, and connect the Looutput terminal to both the ground of the supplyconnected to the load and the ground terminal(terminal #1113). Once again, current must belimited to 1 amp and should never exceed 40 volts.

will deliver four times the target flow rate. It isassumed that each of these inputs are alsoconnected to the trigger inputs on four independentapplicators.

VVVVVolume Fillolume Fillolume Fillolume Fillolume FillType of input: Type of input: Type of input: Type of input: Type of input: GunType of signal: Type of signal: Type of signal: Type of signal: Type of signal: Pulsed

By pulsing the volume fill discrete input, the unit willbe put into the V. FILL mode. (The gun must be inthe ready state prior to this.) When the gun triggerinput goes high, the pumps will run at theprogrammed flow rate and ratio until the volumeprogrammed in for Fill Volume (on the Jobparameters screen) is dispensed. If more thanone gun trigger inputs goes high (triggers 2, 3, or4) the unit will multiply the flow rate by the numberof high inputs but still only run until the programmedvolume is dispensed. When that volume is reached,the gun will be halted and returned to the readystate.

VVVVVolume Fill with Fast Fill Modeolume Fill with Fast Fill Modeolume Fill with Fast Fill Modeolume Fill with Fast Fill Modeolume Fill with Fast Fill ModeIt is possible to volume fill and fast fill simultaneously.If the gun is put into volume fill mode, and then thefast fill input is pulsed, the unit will run in fast fillmode until the volume programmed in for fill volumeis dispensed. At that time, the gun will be haltedand returned to the ready state. This happensregardless of the condition of the gun triggerinputs.

Push OutPush OutPush OutPush OutPush OutType of Input:Type of Input:Type of Input:Type of Input:Type of Input: GunType of signal:Type of signal:Type of signal:Type of signal:Type of signal: Pulsed

This feature allows a customer that uses dualpurge applicators to use two resin pumps thatshare a common catalyst pump and pushout theresin with solvent on one side of the dual purgeapplicator while loading the other side of theapplicator with the next material to be sprayed.For additional details on how to implement thisfeature, refer to" Appendix L".

Figure 11: Sourcing-Sinking OutputsFigure 11: Sourcing-Sinking OutputsFigure 11: Sourcing-Sinking OutputsFigure 11: Sourcing-Sinking OutputsFigure 11: Sourcing-Sinking Outputs

LN-9407-00.1

FaultFaultFaultFaultFaultThis output is energized anytime a fault conditionis recognized by the software. Even if the fault isdisabled (turned off) on the Configured Alarmsscreen, this output will be energized as long as thecondition persists. Fluid flow will not be haltedwhen this output is energized unless it is con-figured to do so on the Configured Alarms screen.

ReadyReadyReadyReadyReadyThis output is energized if the gun is configuredproperly, a good job number has been loaded, andthe gun has been placed in run mode. This outputgoes off if a fault occurs.

Spray ShutdownSpray ShutdownSpray ShutdownSpray ShutdownSpray ShutdownThis output is energized if a fault condition existsand the specific fault that exists is enabled on theConfigured Alarms screen (turned on). Thisindicates that the flow of fluid from the fluid panelhas been stopped as the result of a detected faultcondition.

Flush RequestFlush RequestFlush RequestFlush RequestFlush RequestThis output is energized when the pot-life timerhas expired from the mixed material. (For moreinformation, see "Mixed Volume and Pot-Life Timer"in the "Operation" section.)

Motor OnMotor OnMotor OnMotor OnMotor OnThis output is energized by the software when itwants to control the motor. It is connected to theinput of the motor amplifier that causes the motorto be controlled. Do not connect external devicesto this terminal.

Motor Amp ResetMotor Amp ResetMotor Amp ResetMotor Amp ResetMotor Amp ResetThis output is energized by the software when it isnecessary to reset a faulted motor amplifier.Typically, by pushing the Clear Faults button onthe front panel or by pulsing the Halt/Reset digitalinput, this output will be energized momentarily toreset the amplifier. Do not connect external devicesto this terminal.


2020202020

ANALOG INPUTSANALOG INPUTSANALOG INPUTSANALOG INPUTSANALOG INPUTS

Analog inputs are jumper selectable to be 0 to 10VDC or 4-20 mA with the exception of the hardenerflow sensor which is fixed at 4-20 mA.

Hardener FlowHardener FlowHardener FlowHardener FlowHardener FlowType of Input: Type of Input: Type of Input: Type of Input: Type of Input: ChannelType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Fixed at 4-20 mAFactory Setting: Factory Setting: Factory Setting: Factory Setting: Factory Setting: Not applicable

This is a 4-20 mA input that is normally connectedto the output of a thermal shedding type flowsensor placed in the catalyst fluid stream. Sincethe feedback from the motor tachometer can onlyindicate that the motor is turning and not that fluidis actually flowing, this optional sensor is added toprevent spraying fluid without any catalyst.

Flow RateFlow RateFlow RateFlow RateFlow RateType of input: Type of input: Type of input: Type of input: Type of input: GunType of signal:Type of signal:Type of signal:Type of signal:Type of signal: Jumper SelectableFactory Setting:Factory Setting:Factory Setting:Factory Setting:Factory Setting: 0-10 VDC

This input is used if it is desired to have the abilityto vary the flow rate as the unit is spraying.Minimum and maximum flow rates are programmedand an external device (robot, PLC, potentiometer,etc.) controls the actual flow rate by varying theinput between 0 and 10 volts or 4 and 20 milliamps.(See "Minimum Flow and Maximum Flow in the"Operation" section.)

Feather PressureFeather PressureFeather PressureFeather PressureFeather PressureType of Input: Type of Input: Type of Input: Type of Input: Type of Input: GunType of Signal:Type of Signal:Type of Signal:Type of Signal:Type of Signal: Jumper SelectableFactory Setting:Factory Setting:Factory Setting:Factory Setting:Factory Setting: 4-20 mA

This input allows an optional pressure sensor tobe placed near the spraygun. Handgun operatorscan use this to program a set feather pressure atthe inlet of the spraygun and the RCS-2 willmaintain that pressure while spraying.

LN-9407-00.1


2121212121

Pump Inlet PressurePump Inlet PressurePump Inlet PressurePump Inlet PressurePump Inlet PressureType of Input: Type of Input: Type of Input: Type of Input: Type of Input: ChannelType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Jumper SelectableFactory Setting: Factory Setting: Factory Setting: Factory Setting: Factory Setting: 4-20 mA

This input is typically connected to a pressuresensor located near the input of the pump. Whenused in conjunction with a pilot operated fluidregulator on the inlet of the pump, it minimizes thedifferential pressure across the pump, therebyincreasing the accuracy of the pump.

Pump Outlet PressurePump Outlet PressurePump Outlet PressurePump Outlet PressurePump Outlet PressureType of Input: Type of Input: Type of Input: Type of Input: Type of Input: ChannelType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Jumper SelectableFactory Setting: Factory Setting: Factory Setting: Factory Setting: Factory Setting: 4-20 mA

This input is typically connected to a pressuresensor located near the output of the pump. Thisis used to monitor and control the differentialpressure across the pump, thereby increasing theaccuracy of the pump.

This outlet pressure is also used as the featherpressure for manual spray guns if an optionalfeather pressure sensor is not used.

ANALOG OUTPUTSANALOG OUTPUTSANALOG OUTPUTSANALOG OUTPUTSANALOG OUTPUTS

Most of the analog outputs are jumper selectableto be 0 to 10 VDC or 4-20 mA. Actual Flow,however, is fixed at 0-10 VDC.

Motor SpeedMotor SpeedMotor SpeedMotor SpeedMotor SpeedType of Output: Type of Output: Type of Output: Type of Output: Type of Output: ChannelType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Jumper SelectableFactory Setting: Factory Setting: Factory Setting: Factory Setting: Factory Setting: 0-10 VDC

This output is connected to the analog input on theservo motor controller located in the motor amplifierpanel. A 0 VDC signal tells the servo controller torun at 0 RPM, a 10 VDC signal tells it to run at theprogrammed maximum RPM for that pump.

Pressure ControlPressure ControlPressure ControlPressure ControlPressure ControlType of Output: Type of Output: Type of Output: Type of Output: Type of Output: ChannelType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Jumper SelectableFactory Setting: Factory Setting: Factory Setting: Factory Setting: Factory Setting: 0-10 VDC

This output is normally connected a voltage topressure transducer which converts a 0 to 10VDC signal to a 0 to100 psi air pressure. Thepressure is then used to control the pilot port on afluid regulator. This fluid regulator is then used tocontrol the fluid inlet pressure of the pump.

Actual FlowActual FlowActual FlowActual FlowActual FlowType of Output: Type of Output: Type of Output: Type of Output: Type of Output: GunType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: 0-10 VDC

This output is 0 to 10 VDC output that is proportionalto the actual flow of material coming out of theapplicator. 0 VDC means no flow and 10 VDCindicates 2000 cc/min. (Therefore, 3.40 VDCwould indicate 680 cc/min.)

FREQUENCY INPUTSFREQUENCY INPUTSFREQUENCY INPUTSFREQUENCY INPUTSFREQUENCY INPUTS

All frequency inputs are optically isolated andexpect a maximum amplitude square wave of 24VDC and a maximum frequency of 1.5 KHz. Bothsides of the optical isolators are accessible,allowing the RCS-2 to sink or source any of thefrequency signals.

Motor FeedbackMotor FeedbackMotor FeedbackMotor FeedbackMotor FeedbackType of Output: Type of Output: Type of Output: Type of Output: Type of Output: ChannelType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Frequency

This signal is a square wave output from the servomotor controller, indicating the actual speed of themotor that is driving the pump. It is used by thefirmware to determine the current flow rate of thematerial out of the pump. (It can alternately beconnected to the output of a flow meter placed inthe fluid stream.)

Solvent FlowmeterSolvent FlowmeterSolvent FlowmeterSolvent FlowmeterSolvent FlowmeterType of Output: Type of Output: Type of Output: Type of Output: Type of Output: GunType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Frequency

This input allows users to connect a flowmeter inthe solvent supply line and collect totalization dataon solvent usage.

LN-9407-00.1

System InputsSystem InputsSystem InputsSystem InputsSystem InputsGun StrobeGun StrobeGun StrobeGun StrobeGun Strobe

Type of Input: Type of Input: Type of Input: Type of Input: Type of Input: GunType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Pulsed

This input signal is used in coordination with theJob Number inputs (see below). When this inputis taken from the non-energized state to theenergized state for any gun, the Job Number thatis appearing at the Job Number inputs is loadedinto the job queue. If the gun is in the halted, ready,or faulted state, the new job becomes activeimmediately. If the gun is in a run state, the new jobnumber is held in the queue until the next time thegun is halted (or faults). Note that the job queue isonly one in length. If another job is loaded on topof one already in the queue, the new one overwritesthe older one in the queue.

Job Number (1, 2, 4, 8, 10, 20, 40, 80,Job Number (1, 2, 4, 8, 10, 20, 40, 80,Job Number (1, 2, 4, 8, 10, 20, 40, 80,Job Number (1, 2, 4, 8, 10, 20, 40, 80,Job Number (1, 2, 4, 8, 10, 20, 40, 80,100)100)100)100)100)

Type of Input: Type of Input: Type of Input: Type of Input: Type of Input: SystemType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Maintained

These inputs are simple BCD (binary codeddecimal) inputs that represent the job number thatan external controller energizes to load new jobnumbers into the RCS-2 guns. Note that theseinputs are common to all guns and they are ignoreduntil one or more of the Gun Strobe inputs isenergized. Allowable job number range from 1 to199.

System OutputsSystem OutputsSystem OutputsSystem OutputsSystem OutputsSystem FaultSystem FaultSystem FaultSystem FaultSystem Fault

Type of Output: Type of Output: Type of Output: Type of Output: Type of Output: SystemType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Maintained

This output is normally connected to the horn in thetop of the control console. It can be energizedanytime there is a system fault. (It can be enabledand disabled on the CONFIG SYSTEM screen.)Some examples of system faults are problemswith the disk drive, hard drive, or CDROM of theuser-interface PC. Also, certain problems with theinterface board or RIO board (if used) may causea system fault.

This output can also be programmed to energizewhen any of the guns fault. This is done on theCONFIG GUN screens. Each gun can beconfigured to cause the horn to sound when it


2222222222

Figure 12: System I-O Sourcing-SinkingFigure 12: System I-O Sourcing-SinkingFigure 12: System I-O Sourcing-SinkingFigure 12: System I-O Sourcing-SinkingFigure 12: System I-O Sourcing-Sinking

SYSTEM INPUTS ANDSYSTEM INPUTS ANDSYSTEM INPUTS ANDSYSTEM INPUTS ANDSYSTEM INPUTS ANDOUTPUTSOUTPUTSOUTPUTSOUTPUTSOUTPUTS

All discrete system inputs and outputs can beconfigured to either sink or source current. Allsystem inputs connect to the system via theinterface board. Refer to " Appendix D" to configurethe jumpers on the interface board for the discretesystem inputs.

To source (current or voltage) from the systemoutputs, simply connect the positive terminal ofthe desired output to the positive terminal of apower supply (10 VDC to 40 VDC) and the negativeterminal of the desired output to the positive inputof the device. The negative input to the devicemust be grounded to the aforementioned powersupply. To sink current on the interface board,simply connect the negative output terminal of thedesired output to ground, the positive outputterminal to the negative input to the device, and thepositive input to the device to the positive terminalof the appropriate power supply.

LN-9407-00.1


2323232323

faults independent of each other. Note that thehorn must be enabled on the CONFIG SYSTEMscreen or the horn will not sound for gun faultsregardless of whether or not they are configured todo so on the CONFIG GUN screens.

System PulseSystem PulseSystem PulseSystem PulseSystem PulseType of Output: Type of Output: Type of Output: Type of Output: Type of Output: SystemType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Pulsing

This output pulses at approximately a 0.5 hertzrate as long as the processor on the interfaceboard does not detect any on-board firmwareproblems. Users may wish to use this signal todetect when the RCS-2 controller is powered upand running.

System User LinkSystem User LinkSystem User LinkSystem User LinkSystem User LinkType of Output: Type of Output: Type of Output: Type of Output: Type of Output: SystemType of Signal: Type of Signal: Type of Signal: Type of Signal: Type of Signal: Maintained

This output is energized as long as the Ethernetlink between the user interface PC and the interfacecard is functioning.

NOTESNOTESNOTESNOTESNOTES

LN-9407-00.1


2424242424

* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.

Fast FillChannel FillFeather Set

RunHalt/Fault Reset

TriggerMotor Amp Enable

Trigger 2Trigger 3Trigger 4

Volume FillPush Out

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

+24 VDCFlow Rate Command

Feather PressurePump Inlet Pressure

Pump Outlet PressureSpare Analog Input

Motor SpeedPressure Control

Actual FlowAnalog Ground

Motor Feedback (A+)Motor Feedback (A-)

Signal NameSignal NameSignal NameSignal NameSignal Name

1A2A3A4A5A6A7A8A9A10A11A12A13A14A15A16A17A18A19A20A21A22A23A24AD.G.+2431A32A33A34A35A36A37A38AA.G.41A42A

TerminalTerminalTerminalTerminalTerminalLabe lLabe lLabe lLabe lLabe l

AAAAAAAAAAAAAAAAAAAAAAAA

A or BA or B

AAAAAAAAAAA

InputInputInputInputInputInputInputInputInputInputInputInput

OutputOutputOutputOutputOutputOutputOutputOutputOutputOutputOutputOutput

N/AN/AInputInputInputInputInput

OutputOutputOutput

----InputInput

Input orInput orInput orInput orInput orOutputOutputOutputOutputOutput

2021202320312033204120432051205320612063207120732081208320912093210121032111211321212123213121331113133122032211221322212223223122332241----

28012803

Channel #1Channel #1Channel #1Channel #1Channel #1Wire No. *Wire No. *Wire No. *Wire No. *Wire No. *

2521252325312533254125432551255325612563257125732581258325912593260126032611261326212623263126331113133127032711271327212723273127332741----

28012803


3021302330313033304130433051305330613063307130733081308330913093310131033111311331213123313131331113133132033211321332213223323132333241----

33013303


3521352335313533354135433551355335613563357135733581358335913593360136033611361336213623363136331113133137033711371337213723373137333741----

38013803

Channel #7Channel #7Channel #7Channel #7Channel #7Wire No. *Wire No. *Wire No. *Wire No. *Wire No. *Channe lChanne lChanne lChanne lChanne l

TABLE 1 - ODD NUMBER CHANNEL CONNECTIONSTABLE 1 - ODD NUMBER CHANNEL CONNECTIONSTABLE 1 - ODD NUMBER CHANNEL CONNECTIONSTABLE 1 - ODD NUMBER CHANNEL CONNECTIONSTABLE 1 - ODD NUMBER CHANNEL CONNECTIONS

LN-9407-00.1


2525252525

* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.** Refer to "Appendix E" for Termination Board Drawing.

Fast FillChannel FillFeather Set

RunHalt/Fault Reset

Trigger 1Motor Amp Enable

Trigger 2Trigger 3Trigger 4

Volume FillPush Out

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

+24 VDCHardner Flow

Flow Rate CommandFeather Pressure

Pump Inlet PressurePump Outlet Pressure

Spare Analog InputMotor Speed

Pressure ControlActual Flow

Analog GroundMotor Feedback (B+)Motor Feedback (B-)

Solvent (B+)Solvent (B-)

Signal NameSignal NameSignal NameSignal NameSignal Name

1B2B3B4B5B6B7B8B9B10B11B12B13B14B15B16B17B18B19B20B21B22B23B24BD.G.+2430B31B32B33B34B35B36B37B38BA.G.41B42B43B44B

TerminalTerminalTerminalTerminalTerminalLabe lLabe lLabe lLabe lLabe l

BBBBBBBBBBBBBBBBBBBBBBBB

A or BA or B

BBBBBBBBBBBB

N/AN/A

InputInputInputInputInputInputInputInputInputInputInputInput

OutputOutputOutputOutputOutputOutputOutputOutputOutputOutputOutputOutput

N/AN/AInputInputInputInputInputInput

OutputOutputOutput

----InputInputInputInput


20222024203220342042204420522054206220642072207420822084209220942102210421122114212221242132213411131331220222042212221422222224223222342242----

2302230429112312


25222524253225342542254425522554256225642572257425822584259225942602260426122614262226242632263411131331270227042712271427222724273227342742----

2802280428112812


30223024303230343142304430523054306230643072307430823084309230943102310431123114312231243132313411131331320232043212321432223224323232343242----

3302330433113312


35223524353235343542354435523554356235643572357435823584359235943602360436123614362236243632363411131331370237043712371437223724373237343742----

3802380438113812

Channel #8Channel #8Channel #8Channel #8Channel #8Wire No. *Wire No. *Wire No. *Wire No. *Wire No. *Channe lChanne lChanne lChanne lChanne l

TABLE 2 - EVEN NUMBER CHANNEL CONNECTIONSTABLE 2 - EVEN NUMBER CHANNEL CONNECTIONSTABLE 2 - EVEN NUMBER CHANNEL CONNECTIONSTABLE 2 - EVEN NUMBER CHANNEL CONNECTIONSTABLE 2 - EVEN NUMBER CHANNEL CONNECTIONS

LN-9407-00.1


2626262626

* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479* Reference Drawing Number A10479** Refer to "Appendix F" for Termination Board Drawing.** Refer to "Appendix F" for Termination Board Drawing.** Refer to "Appendix F" for Termination Board Drawing.** Refer to "Appendix F" for Termination Board Drawing.** Refer to "Appendix F" for Termination Board Drawing.

Strobe, Gun 1Strobe, Gun 2Strobe, Gun 3Strobe, Gun 4Strobe, Gun 5Strobe, Gun 6Strobe, Gun 7Strobe, Gun 8

System SignalsSystem SignalsSystem SignalsSystem SignalsSystem SignalsCN4012-1CN4012-3CN4012-5CN4012-7CN4012-2CN4012-4CN4012-6CN4012-8

TerminalTerminalTerminalTerminalTerminalLabelLabelLabelLabelLabel

SSSSSSSS

ChannelChannelChannelChannelChannelInputInputInputInputInputInputInputInput


40214031404140514023403340434053

SystemSystemSystemSystemSystemWire No. *Wire No. *Wire No. *Wire No. *Wire No. *

TABLE 3 - SYSTEM I/O CONNECTIONSTABLE 3 - SYSTEM I/O CONNECTIONSTABLE 3 - SYSTEM I/O CONNECTIONSTABLE 3 - SYSTEM I/O CONNECTIONSTABLE 3 - SYSTEM I/O CONNECTIONS

System Fault (Hi)System Fault (Low)System Pulse (Hi)

System Pulse (Low)System User Link (Hi)

System User Link (Low)

Job Number 1Job Number 2Job Number 4Job Number 8

Job Number 10Job Number 20Job Number 40Job Number 80

Job Number 100

Spare System InputSpare System InputSpare System Input

CN4012-13CN4012-14CN4012-15CN4012-16CN4012-17CN4012-18

CN4012-25CN4012-27CN4012-29CN4012-31CN4012-33CN4012-35CN4012-26CN4012-28CN4012-30

CN4012-32CN4012-34CN4012-36

SSSSSS

SSSSSSSSS

SSS

OutputOutputOutputOutputOutputOutput

InputInputInputInputInputInputInputInputInput

InputInputInput

408140834091409341014103

414141514161417141814191414341534163

417341834193

LN-9407-00.1

RCS-2 User Manual - Operation

2727272727

OPERAOPERAOPERAOPERAOPERATIONTIONTIONTIONTION

SETUPSETUPSETUPSETUPSETUP AND OPERA AND OPERA AND OPERA AND OPERA AND OPERATIONTIONTIONTIONTION

The operator interface was designed to be userfriendly and to supply all of the necessaryinformation for the operation of the RCS-2 controldirectly to the operator. Most information located inthe manual regarding the operation of the RCS-2system is available directly through the operatorinterface screens. All of the screens offer "‘on-line" descriptive information and help text. Graphicinformation is also displayed for a quickdetermination of system performance.

Power ONPower ONPower ONPower ONPower ONWhen power is first applied to the RCS-2 system,the interface card and any installed channel cardslocated in the card rack immediately performinitialization and place all GUNs in the ready stateassuming valid configurations and successful selftests. The interface card will determine whichchannel cards are installed and that the installedcards are communicating properly. The PC, uponapplication of power, will load the WindowsEmbedded XP operating system and then displaya RCS-2 icon. Double tapping the icon will startthe user-interface software.

Power OFFPower OFFPower OFFPower OFFPower OFFIt is very important that the power to the maincontrol console not be shut off until a Windowsshutdown is performed (using the F12 functionkey). The LCD display will indicate to the userwhen it is okay to turn the power off to the controller.

E-Stop ButtonE-Stop ButtonE-Stop ButtonE-Stop ButtonE-Stop ButtonThe E-Stop button on the RCS-2 controller doesnot completely remove power from the RCS-2control console. When this button is pushed, the24 volt supply to the control card rack isdisconnected. Therefore, all control power isremoved from the system and all fluid flow will bestopped. (The motor amplifier panels will loose allpower as there is a 24 VDC control relay in thempowered from the E-Stop button in the control

console.) This is the button that should be used toremove power from the card rack when adding,removing, or changing interface and channel cards.This avoids the long wait times involved whenWindows goes through its shutdown and startupsequences.

BUTTON FUNCTIONSBUTTON FUNCTIONSBUTTON FUNCTIONSBUTTON FUNCTIONSBUTTON FUNCTIONS

F1–F12 Soft ButtonsF1–F12 Soft ButtonsF1–F12 Soft ButtonsF1–F12 Soft ButtonsF1–F12 Soft ButtonsF1 through F12 are known as soft buttons. Thefunction of these keys will change depending onwhich user-interface screen is active on the LCDdisplay. The function for each button is showninside the button.

ESCESCESCESCESCThis button is used to exit any active screen orpop-up box.

GUN 1 - GUN 8 ON/OFFGUN 1 - GUN 8 ON/OFFGUN 1 - GUN 8 ON/OFFGUN 1 - GUN 8 ON/OFFGUN 1 - GUN 8 ON/OFFThese buttons allow manual activation anddeactivation of each GUN. Pressing a GUN ON/OFF button is the same as supplying an externalGUN RUN or GUN HALT input signal. Thesebuttons also display the status of each gun.(READY, RUN, HALTED, FAULT, A FILL, B FILL,AB FILL, CHAN FILL, FLUSH REQ, FAST FILL,VOLUME FILL, OR HALTED.)

FAST FILLFAST FILLFAST FILLFAST FILLFAST FILLThe FAST FILL button causes a pop-up box toappear on the current screen. Any GUN can bemanually placed in FAST FILL MODE by simplypressing the number for the desired GUN. TheFAST FILL MODE is deactivated by pressing theGUN number again or pushing the ESC button.This is the same as supplying an external FASTFILL input signals. (See "Discrete Inputs - FastFill" in the "Installation" section for details on thefast fill mode.)

Note that the pumps will start running the instantthe gun number is pushed.

LN-9407-00.1


2828282828

CHANNEL FILLCHANNEL FILLCHANNEL FILLCHANNEL FILLCHANNEL FILLThe CHANNEL FILL button causes a pop-up boxto appear on the current screen. Any CHANNELcan be manually placed in CHANNEL FILL MODEby simply pressing the number for the desiredCHANNEL. The mode is deactivated by pressingthe CHANNEL number again or by pushing theESC button. This is the same as supplying anexternal CHANNEL FILL input signal. (See"Discrete Inputs - Channel Fill" in the "Installation"section for details on the channel fill mode.) Notethat the motor will start running the instant thechannel number is pushed.

HELPHELPHELPHELPHELPThe HELP button can be pressed at any time. It willprovide more detailed help for the current activescreen.

CLEAR GUN FAULTSCLEAR GUN FAULTSCLEAR GUN FAULTSCLEAR GUN FAULTSCLEAR GUN FAULTSPressing this button will immediately clear anyfaults reported by the controller regardless of thecurrent screen. If the fault resulted in the stoppageof fluid, then a GUN RUN signal is required to startflow again. Enter the ERROR LOG screen to viewthe error that occurred. Pot-life faults can only be‘cleared’ by evacuating the volume of fluid asdetermined by the Mixed Volume parameter locatedin the GUN CONFIGURATION screen . Pressingthe Clear Faults button will silence the horn, if it isenabled.

ERROR LOGERROR LOGERROR LOGERROR LOGERROR LOGPressing this button opens up the error log window,which displays the last 100 faults that haveoccurred. These faults are time and date stampedand can be saved to a diskette or memory stick, ifdesired.

PPPPPASSWORD OPERAASSWORD OPERAASSWORD OPERAASSWORD OPERAASSWORD OPERATIONTIONTIONTIONTIONWhen enabled, the password is required for editingany system or GUN configurations, loadinginformation from files, editing Job tables or forcinginputs and outputs. A pop-up screen will appearrequesting the password when attempting toperform a password protected operation. Once apassword is entered correctly, it will not be requiredagain until the password timer has elapsed. Thepassword and password timer can be set in theSYSTEM CONFIGURATION screen. Thepassword timer starts after the last button ispushed. Every additional keystroke before thepassword timer elapses resets the timer. Thismakes it convenient for an operator to changemultiple parameters without having to continuallyreenter the password. In the event that thepassword is lost or is not recognized by thecontroller, contact ITW Ransburg Service.Entering a "O" (zero) for the password will disablepassword protection.

CONFIGURABLECONFIGURABLECONFIGURABLECONFIGURABLECONFIGURABLEOPERAOPERAOPERAOPERAOPERATINGTINGTINGTINGTINGPPPPPARAMETERSARAMETERSARAMETERSARAMETERSARAMETERS

The design of the RCS-2 system allows it to beconfigured to meet the requirements of theapplication. The large number of parametersallows the RCS-2 to be used in almost anyapplication involving flow and/or ratio control offluids.

System ParametersSystem ParametersSystem ParametersSystem ParametersSystem Parameters are parameters that affectthe overall system, which includes all channelsand guns or the user interface. They include:

• Over Pressure Limit• Foldback Pressure• Pressure Sensor Limit• Horn Enable• Password Timeout• Interface Card Name• Interface Card I/P Address• User Program IP Port• Password• Software and Firmware Version Information• System Date and Time

> Note that the interface card stores theprevious fault information in battery-backed memory but it does not contain areal-time clock. Therefore, the date andtime of the faults are provided by the user-interface PC. If the unit is powered upwith faults still stored in the Error Log, thedate and time of those faults on the ErrorLog Screen will either be left blank or maybe random values.


LN-9407-00.1


2929292929

Gun ParametersGun ParametersGun ParametersGun ParametersGun Parameters are parameters that affect thegun. These parameters apply to all channelsconfigured to that gun. They include:

• Mode (manual or automatic)• Number of channels configured to gun• Master Channel Number• Slave Channel Number• Default Job Number• Number of Applicators• Default Job Number• Mixed Volume• Tolerance Percentage• Tolerance Volume• Tolerance Time• Solvent Pulses Per Liter• Horn Code• Auto Reset

Channel ParametersChannel ParametersChannel ParametersChannel ParametersChannel Parameters are parameters that affectonly that specific channel. For two channel guns,there are independent parameters for each of thetwo channels. They include:

• Fill Enable/Disable• Trigger On-Delay Time• Trigger Off-Delay Time• Pump Size• Pump Pulses Per Liter• Maximum Pump Speed• Miniumum Pump Speed• Maximum Inlet Fluid Pressure• Minimum Inlet Fluid Pressure• Maximum Outlet Fluid Pressure• Minimum Outlet Fluid Pressure• Inlet Pressure Sensor Enable/Disable• Foldback Kp• Foldback Ki• Foldback Kd• Foldback Deadband• Feather Kp• Feather Ki• Feather Kd• Feather Deadband

Job ParametersJob ParametersJob ParametersJob ParametersJob Parameters are parameters that are storedwith the specific job number. Typically, a jobnumber is assigned to a specific material. In thisway, totalization data and PID parameters relatedirectly to the material. These parameters include:

• Ratio• Flow Rate Setpoint• Max. Flow Rate• Min. Flow Rate• Bar Graph Limit• Pot Life Timer• Feather Pressure• Fill Volume• Pressure Pot Capacity• Delta Pressure• Min. Inlet Fluid Pressure• Min. Inlet Control Pressure• Inlet Cont. Pressure Kp• Inlet Cont. Pressure Ki• Inlet Cont. Pressure Kd• Inlet Cont. Pressure Db• Hardener Sample Time• Hardener No Flow Limit• Hardener Flow On Limit

Alarm Configuration ParametersAlarm Configuration ParametersAlarm Configuration ParametersAlarm Configuration ParametersAlarm Configuration Parameters allow theuser to specify what conditions cause a "sprayshutdown" to occur. They include:

• Input Under Pressure• Input Over Pressure• Output Under Pressure• Output Over Pressure• Flow Out of Tolerance• Hardener Flow Loss• Pressure Pot Empty• Inlet Pressure Loss• Outlet Pressure Loss• Analog Remote Loss• Ratio Out of Tolerance• Motor Amp Fault *• Analog Feather Loss• Foldback Pressure Reached• Pot Life Expired• System Over Pressure *• Channel Card Parameter Fault *• Channel Card SPI Fault *• Channel Card Internal Fault *

> Items above marked with an asterisk(*) cannot be disabled.


LN-9407-00.1


3030303030

USER INTERFACEUSER INTERFACEUSER INTERFACEUSER INTERFACEUSER INTERFACESOFTWARESOFTWARESOFTWARESOFTWARESOFTWARE

When the RCS-2 is started up, users are presentedwith the main user interface screen. An exampleis shown below:

Anywhere from 0 to 8 guns may be displayedwhen the system first starts up, depending on howthe system was last used.

The following information is available on the MainScreen:

• Which channels are configured to whichguns

• Currently running job number for the gun• The next (queued) job for the gun• The mode that the gun is configured for• The current status for the gun (Running,

halted, faulted, etc.)• Status of the trigger input• Target flow rate for the gun• Actual flow rate for the gun• Actual flow rate of the master channel• Actual flow rate of the slave channel• Requested ratio for the gun (if 2 channel

gun)• Actual ratio for the gun (if 2 channel gun)• Volume remaining in pressure pot (or pots,

if 2 channel)• Which, if any, forces are active

Setting Up A New SystemSetting Up A New SystemSetting Up A New SystemSetting Up A New SystemSetting Up A New SystemNotice the function buttons at the bottom of thescreen. Users setting up a new system should,typically, start configuring the system with the F1function button and work progressively to theright, one function button at a time.

F1: Config SystemF1: Config SystemF1: Config SystemF1: Config SystemF1: Config System

Overpressure LimitOverpressure LimitOverpressure LimitOverpressure LimitOverpressure LimitThis is the pressure limit of the entire system. Ifany pressure sensor in the system reaches orexceeds this pressure, a system overpressurefault is issued by the software and the pumpsconfigured for that gun are halted. This faultcannot be disabled.

Foldback PressureFoldback PressureFoldback PressureFoldback PressureFoldback PressureWhen the outbound pressure of the pump exceedsthis setting, the software starts a gradual slowdownof the pumps (while keeping the ratio at its propersetpoint). This prevents nuisance overpressurefaults when fluid pressures spike during loadsequences, etc. It is expressed in pounds persquare inch (psi).

Sensor LimitSensor LimitSensor LimitSensor LimitSensor LimitThis is the maximum pressure that the pressuresensors in the system can detect. It is expressedin pounds per square inch (psi).

LN-9407-00.1


3131313131

There are eight function buttons defined for usefrom the System Parameter Screen:

F1: ModifyF1: ModifyF1: ModifyF1: ModifyF1: Modify - - - - - This button allows the user to stepthrough the possible options for this parameter orpresents a numeric keypad if a numerical value isrequired.

F2: Version InfoF2: Version InfoF2: Version InfoF2: Version InfoF2: Version Info - This button allows the user todetermine what version of user interface softwareis installed on the user interface computer andwhat firmware revision is currently installed on allinstalled cards in the rack.

F3: Change PasswordF3: Change PasswordF3: Change PasswordF3: Change PasswordF3: Change Password - This button allowsuser to change the password that limits access tovarous user interface screens. If a password waspreviously stored, user has to know the passwordto make a change to it. Entering a password of 0disables the password option.

F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - This button takes the datadisplayed on the current screen and sends it to theinterface card where it is then stored in non-volatile memory. Any changes made to theparameters on this screen will be lost if the screenis exited prior to sending it to the interface cardusing this button.

F7: Read in all files – F7: Read in all files – F7: Read in all files – F7: Read in all files – F7: Read in all files – This function reads in thedata from all parameter files (System, Gun, Channel,Job, Alarms, Totals, and Color Change) from anymedia and sends them to the interface card to bestored in non-volatile memory. This differs fromthe F9 key in that the F9 key only reads systemparameter data and sends it to the interface card.

F8: Save to all files – F8: Save to all files – F8: Save to all files – F8: Save to all files – F8: Save to all files – This function reads allparameter data currently stored in non-volatilememory on the interface card and stores it on themedia selected by the user (internal flash, floppydrive, USB memory, or CDROM). This includesSystem, Gun, Channel, Job, Alarms, Totals, andColor Change parameters. This differs from theF10 save function in that F10 saves only the datadisplayed on the current System ParameterScreen.

Horn EnableHorn EnableHorn EnableHorn EnableHorn EnableThis enables or disables the horn to sound whensystem or gun faults occur.

Password TPassword TPassword TPassword TPassword TimeoutimeoutimeoutimeoutimeoutThis is the amount of time (in minutes) that thesystem allows a user to examine and modifypassword restricted parameters after the pass-word has been entered. This eliminates con-stantly having to re-enter the password whensetting up numerous parameters at the sametime.

Interface Card NameIn some cases one user-interface PC is used tomonitor more than one RCS-2 rack. When thisis done, it is more convenient to give each racka name (such as Prime, or Line 1, etc.) to easilyidentify which rack is being controlled by the PC.When this is done it is possible for each rack(effectively each interface card) to be given aunique name. This is done in the fms.ini file onthe hard drive of the user-interface PC. ContactITW Ransburg’s technical support departmentfor details on how to implement this feature.

Interface Card IP AddressThis is the Ethernet IP address of the interfacecard that this PC is currently communicatingwith (or trying to communicate with). It can onlybe modified in the fms.ini file on the hard drive ofthe user-interface PC.

User Program IP PortThis determines if this user-interface PC is inread-write mode or read-only mode. If the user-interface PC is using Port 3000, it is in read-writemode. If it is using Port 3001 it is in read-onlymode. PC’s configured in read only mode canmonitor the functioning of the RCS-2 but cannotmake any changes or save any data. ContactITW Ransburg’s technical support departmentfor details on how to implement this feature.

System Time and DateThese two fields allow the user to examine andchange the system time and date for the user-interface PC without exiting to the Windows XPoperating system.

LN-9407-00.1


3232323232

ModeModeModeModeModeThis parameter has three possible settings: OFF,AUTO, and MANUAL.

OFFOFFOFFOFFOFF - This setting completely disables the gun,removes its data from the main screen, and placesthe channels tied to this gun available for use byanother gun.

AUTOAUTOAUTOAUTOAUTO - This setting is used when the userwishes to control the flow rate of the applicator. Ifthis is to be a 2 channel gun, it also controls theratio of the two materials.

F9: Read in FileF9: Read in FileF9: Read in FileF9: Read in FileF9: Read in File - This button allows operatorsto load the system parameters from any media.They are stored in a file named system.parsystem.parsystem.parsystem.parsystem.par.

F10: Save to FileF10: Save to FileF10: Save to FileF10: Save to FileF10: Save to File - This button allows operatorsto save the parameters on this screen to anywriteable media. They are stored in a file namedsystem.parsystem.parsystem.parsystem.parsystem.par.

F2: Config GunF2: Config GunF2: Config GunF2: Config GunF2: Config GunWhen F2 is selected from the main screen, theoperator will be prompted to select the gun numberthey wish to create or modify the parameters for.Once a gun number is selected, the followingscreen will appear.

MANUALMANUALMANUALMANUALMANUAL - This setting is used when the userwishes only to control the ratio of the material.Users can "demand" as much material as theywish and the controller will deliver as much aspossible while keeping the ratio on target. (Amaximum flow rate can be programmed.)

No. of ChannelsNo. of ChannelsNo. of ChannelsNo. of ChannelsNo. of ChannelsThis parameter has 3 possible settings: 0, 1, or 2.

00000 - This effectively disables the gun

11111 - This indicates that the gun is to be a singlechannel, flow control only gun.

22222 - This indicates that the gun is to be a dualchannel, ratio controlled gun.

Master ChannelMaster ChannelMaster ChannelMaster ChannelMaster ChannelThis parameter has 8 possible settings: 1-8. Forsingle channel guns, it simply indicates whichchannel will be controlling the pump for this gun.For dual channel guns it indicates (normally) whichchannel will be controlling resin pump.

Slave ChannelSlave ChannelSlave ChannelSlave ChannelSlave ChannelThis parameter has 4 possible settings: 2, 4, 6, or8. It indicates which channel will be slave to themaster channel (selected above) for ratio control.

Number of ApplicatorsNumber of ApplicatorsNumber of ApplicatorsNumber of ApplicatorsNumber of ApplicatorsThe range of allowable values for this parameter isany integer from 1 to 4.

This parameter indicates how many applicatorswill be connected to the fluid panel controlled bythis gun. It is used by the multiple trigger inputcapabilities of the RCS-2 to multiply the target flowrate by the number of triggers being input. Forexample: if the target flow rate is 100 cc/min and1 gun is triggered, the RCS-2 will deliver 100 cc/min to the outlet of the fluid panel, if 3 trigger inputsare energized, the RCS-2 will deliver 300 cc/min tothe outlet of the fluid panel.

LN-9407-00.1


3333333333

Alarm Tolerance TimeAlarm Tolerance TimeAlarm Tolerance TimeAlarm Tolerance TimeAlarm Tolerance TimeThis parameter is in seconds and can be anyvalue from 0.000 to 20.000 seconds. Thisparameter allows users to program how long anerror condition can persist before the unit issues afault for that gun. Users are warned againstprogramming this value too small as nuisancefaults may become a problem. A value of 3.000seconds has been found to be a good value formost applications.

Solvent Pulses Per LiterSolvent Pulses Per LiterSolvent Pulses Per LiterSolvent Pulses Per LiterSolvent Pulses Per LiterThis parameter can be any integer value for 1 to100,000 pulses per liter.

This value is used by totalization software to trackthe amount of flush solvent used by the gun.

Horn CodeHorn CodeHorn CodeHorn CodeHorn CodeThis allows the user to enable or disable the horn(on top of the control console) for various errorsand faults. There are 6 possible settings for thisparameter:

a. Disabled - the horn will not sound for any gun faults or errors.

b. SSD - the horn sounds only if a SprayShutDown for that gun occurs.

c. AE - the horn sounds if Any Error occurs onthat gun, even if they are not programmed tocause a spray shutdown.

d. PLT - the horn sounds if the Pot-Life Timerexpires.

e. SSD+PLT - the horn sounds if either a sprayshutdown occurs or a pot-life timer expires forthat gun

f. AE+PLT - the horn sounds if any gun errorsoccur or if the pot-life timer expires.

Default Job NumberDefault Job NumberDefault Job NumberDefault Job NumberDefault Job NumberThis parameter can be any integer from 1 to 199.It indicates which job number an operator wants toautomatically load into the gun upon power up ofthe system.

Mixed VolumeMixed VolumeMixed VolumeMixed VolumeMixed VolumeThe range of allowable volumes for this parameteris from 1 cc to 5000 cc. This volume is the amountof material in the fluid lines between the mix-blockand the applicator or applicators. It is used by thepot-life timer to keep track of the age of the mixedmaterial. If the material in the applicator (the ma-terial that has been mixed the longest) exceedsthe programmed pot-life of the material, a flushrequest is issued by the RCS-2 for that gun.

Tolerance PercentageTolerance PercentageTolerance PercentageTolerance PercentageTolerance PercentageAllowable value for this parameter is any integerform 1% to 100%.

This parameter indicates how far off from thetarget flow rate any channel is allowed to be or howfar off from the target ratio the actual ratio isallowed to be before a fault is issued by the RCS-2 controller.

Tolerance VolumeTolerance VolumeTolerance VolumeTolerance VolumeTolerance VolumeAllowable volumes for this parameter are from0 cc to 255 cc's.

This parameter indicates how often the softwareverifies that the actual ratio being expelled from thefluid panel is within the programmed tolerance limitof the target ratio. Every time this volume ofmaterial passes out of the mix tube, the controllercalculates the actual ratio based on the actualvolume of resin and the actual volume of catalystthat was contained in that sample. It then comparesthat ratio to the target ratio and checks to see if theactual ratio is within the tolerance limit of the targetratio. If not, a Ratio Out of Tolerance Fault isissued by the controller.

If a 0 (zero) is entered for the tolerance volumeprarameter, ratio is automatically checked every10 milliseconds. This check,however, is basedon flow rate data, not volume data.

LN-9407-00.1


3434343434

Auto ResetAuto ResetAuto ResetAuto ResetAuto ResetThis allows the user to enable or disable the autofault reset feature. While enabled, anytime a gunfault occurs, it can be automatically reset bysimply turning off the gun trigger signal and turningit back on. (This allows a handgun operator theability to reset a fault without returning to a controlpanel.) Note: All trigger signals for that gun mustremain off for at least 0.5 second to cause a reset.

There are six function buttons defined for use fromthe Gun Parameters Screen:

F1: ModifyF1: ModifyF1: ModifyF1: ModifyF1: Modify - This button allows the user to stepthrough the possible options for this parameter orpresents a numeric keypad if a numerical value isrequired.

F2: Previous Gun – F2: Previous Gun – F2: Previous Gun – F2: Previous Gun – F2: Previous Gun – This button opens the GunConfiguration screen for the previous gun. Notethat any data changed on this screen prior topushing this button will be lost if F5 (Send to RCS-2) is not used.

F3: Next Gun – F3: Next Gun – F3: Next Gun – F3: Next Gun – F3: Next Gun – This button opens the GunConfiguration screen for the next gun. Note thatany data changed on this screen prior to pushingthis button will be lost if F5 (Send to RCS-2) is notused.

F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - This button takes the datadisplayed on the current screen and sends it to theinterface card where it is then stored in non-volatile memory. Any changes made to theparameters on this screen will be lost if the screenis exited prior to sending it to the interface cardusing this button.

F9: Read in File -F9: Read in File -F9: Read in File -F9: Read in File -F9: Read in File - This button allows operatorsto load the parameters contained on this screenfrom a floppy disk, internal flash memory, USBmemory, or CDRom. They are stored in a filenamed gunconfig.par.gunconfig.par.gunconfig.par.gunconfig.par.gunconfig.par.

F10: Save to File -F10: Save to File -F10: Save to File -F10: Save to File -F10: Save to File -This button allows oepratorsto save the parameters on this screen to a floppydisk, internal flash memory, USB memory, orCDROM. They are stored in a file named gun-gun-gun-gun-gun-config.par.config.par.config.par.config.par.config.par.

F3: Config ChannelF3: Config ChannelF3: Config ChannelF3: Config ChannelF3: Config ChannelWhen F3 is selected from the Main Screen, theoperator will be prompted to select the gun numberthey wish to examine or edit parameters for (andif it is a two channel gun whether they wish toaccess the master or the slave channel for thatgun). At that time, the following screen will appear:

Fill EnableFill EnableFill EnableFill EnableFill EnableAllowable settings for this parameter are: Yes orNo.

This parameter allows the operator to enable ordisable the channel fill button on the top of the MainScreen. This allows a supervisor to prevent a gunfrom being put into channel fill mode without theoperator knowing the password. (This preventsan applicator that is being used in production fromapplying the wrong flow rate or ratio of material.)

> This setting has no effect on Fast Fill.


LN-9407-00.1


3535353535

Maximum Inlet Fluid PressureMaximum Inlet Fluid PressureMaximum Inlet Fluid PressureMaximum Inlet Fluid PressureMaximum Inlet Fluid PressureThe allowable range of values for this parameter isany integer from 0 psi to 200 psi.

This parameter allows the operator to limit themaximum pressure at the inlet to the pump for thischannel. If too much pressure is allowed at theinlet of the pump, fluid may "blow by" the pumpwithout being metered, thus causing inaccurateflow rates or ratios. Exceeding this setpoint willcause the controller to generate an InletOverpressure Fault. This check is only active inRun Mode.

Minimum Inlet Fluid PressureMinimum Inlet Fluid PressureMinimum Inlet Fluid PressureMinimum Inlet Fluid PressureMinimum Inlet Fluid PressureThe allowable range of values for this parameter isany integer from 0 psi to 200 psi.

This parameter allows the operator to limit theminimum pressure at the inlet to the pump for thischannel. If too little pressure is allowed at the inletof the pump, the pump will "cavitate" or have to pullfluid into it, which could seriously effect itsaccuracy, thus causing inaccurate flow rates orratios. Falling below this setpoint will cause thecontroller to generate an Inlet Underpressure Fault.This check is only active in Run Mode.

Minimum Pump SpeedMinimum Pump SpeedMinimum Pump SpeedMinimum Pump SpeedMinimum Pump SpeedThe allowable range of values for this parameter isany integer from 0 RPM to 65,535 RPM.

This is the minimum speed at which that thesystem will allow the pump to run. If thecommanded flow rate or ratio would result in apump running below this setpoint, the pump (orpumps) assigned to that gun will not run. Gearpumps do not typically function accurately atspeeds less than 3 RPM and this is the recommend-ed setting for this parameter.

Trigger On DelayTrigger On DelayTrigger On DelayTrigger On DelayTrigger On DelayThe allowable range of values for this parameter isfrom 0.000 seconds to 5.000 seconds.

This indicates how long after receiving a triggersignal the controller will wait before it actuallystarts running the pump(s) for that gun. Thisallows the operator to compensate for pneumaticdelays inherent with some applicators.

Trigger Off DelayTrigger Off DelayTrigger Off DelayTrigger Off DelayTrigger Off DelayThe allowable range of values for this parameter isfrom 0.000 seconds to 5.000 seconds.

This indicates how long to run the pump(s) afterthe trigger signal has been removed. This allowsthe operator to compensate for pneumatic delaysinherent with some applicators.

Pump SizePump SizePump SizePump SizePump SizeThe allowable range of values for this parameter isfrom 0.000 to 10.000 cc/rev.

This is the volume of material that the pump beingused on this channel allows to pass with eachcomplete revolution of its gears.

Pump Pulses Per LiterPump Pulses Per LiterPump Pulses Per LiterPump Pulses Per LiterPump Pulses Per LiterThe allowable range of values for this parameter isany integer from 1,000 to 1,000,000 pulses/liter.

This is the number of pulses received by thechannel card from the sensing device (motoramplifier, flowmeter, etc.) for each liter of materialthat passes through the channel.

Maximum Pump SpeedMaximum Pump SpeedMaximum Pump SpeedMaximum Pump SpeedMaximum Pump SpeedThe allowable range of values for this parameter isany integer from 1 RPM to 65,535 RPM.

This is the maximum allowable speed at which thatthe pump can be run. It is assumed by the con-troller that this will be the speed that the pump willrun at when a 10 volt DC signal is sent to the motoramplifier. The recommended setting for thisparameter is 150 RPM.

> If the RCS-2 controller determines thateither pump must run below this limit toobtain the desired flow rate or ratio, thecontroller will stop both motors and aMotorTach Loss fault may be generated.


LN-9407-00.1


3636363636

Maximum Outlet Fluid PressureMaximum Outlet Fluid PressureMaximum Outlet Fluid PressureMaximum Outlet Fluid PressureMaximum Outlet Fluid PressureThe allowable range of values for this parameter isany integer from 0 psi to 200 psi.

This is the maximum allowable outbound pressurefor the pump. Exceeding this setpoint will causethe controller to generate an Outlet OverpressureFault. This check is only active in Run Mode.

Minimum Outlet Fluid PressureMinimum Outlet Fluid PressureMinimum Outlet Fluid PressureMinimum Outlet Fluid PressureMinimum Outlet Fluid PressureThe allowable range of values for this parameter isany integer from 0 psi to 200 psi.

This is the minimum allowable outbound pressurefor the pump. If the outbound pressure from thepump falls below this setpoint while the gun istriggered, an Outlet Underpressure Fault will begenerated by the controller. This check is onlyactive in Run Mode.

Inlet Pressure SensorInlet Pressure SensorInlet Pressure SensorInlet Pressure SensorInlet Pressure SensorThis allows the user to enable or disable the inletpressure sensor. If the system is being operatedwithout an inlet pressure sensor, this must bedisabled or a fault will occur.

Foldback PID LoopFoldback PID LoopFoldback PID LoopFoldback PID LoopFoldback PID LoopThe PID parameters for foldback control how fastthe motors respond when they enter foldbackmode but they also control how fast the motorsrespond (acceleration and deceleration) when thetrigger signal changes state and when there are“on the fly” changes in the requested flow rate.

Foldback Pressure KpFoldback Pressure KpFoldback Pressure KpFoldback Pressure KpFoldback Pressure KpThe allowable range of values for this parameter isany integer from 0 to 65,535. It has no units. Thisallows the operator to control the proportional gainfor the foldback PID loop.

> When this is disabled, closed loopcontrol of the inlet pressure of the pump isalso disabled.


Foldback Pressure KiFoldback Pressure KiFoldback Pressure KiFoldback Pressure KiFoldback Pressure KiThe allowable range of values for this parameter isany integer from 0 to 65,535. It has no units. Thisallows the operator to control the integral gain forthe foldback PID loop.

Foldback Pressure KdFoldback Pressure KdFoldback Pressure KdFoldback Pressure KdFoldback Pressure KdThe allowable range of values for this parameter isany integer from 0 to 65,535. It is expressed inPSI. This allows the operator to control thederivative gain for the foldback PID loop.

Foldback Pressure DeadbandFoldback Pressure DeadbandFoldback Pressure DeadbandFoldback Pressure DeadbandFoldback Pressure DeadbandThe allowable range of values for this parameter isany integer from 0 to 65,535. It is expressed in psi.This allows the operator to control the deadbandfor the foldback PID loop.

Feather Pressure KpFeather Pressure KpFeather Pressure KpFeather Pressure KpFeather Pressure KpThe allowable range of values for this parameter isany integer from 0 to 65,535. It has no units. Thisallows the operator to control the proportional gainfor the feather PID loop.

Feather Pressure KiFeather Pressure KiFeather Pressure KiFeather Pressure KiFeather Pressure KiThe allowable range of values for this parameter isany integer from 0 to 65,535. It has no units. Thisallows the operator to control the integral gain forthe feather PID loop.

Feather Pressure KdFeather Pressure KdFeather Pressure KdFeather Pressure KdFeather Pressure KdThe allowable range of values for this parameter isany integer from 0 to 65,535. It has no units. Thisallows the operator to control the derivative gainfor the feather PID loop.

Feather Pressure DeadbandFeather Pressure DeadbandFeather Pressure DeadbandFeather Pressure DeadbandFeather Pressure DeadbandThe allowable range of values for this parameter isany integer from 0 to 65,535. It is expressed inPSI. This allows the operator to control thedeadband for the feather PID loop.

LN-9407-00.1


3737373737

F4: Config JobF4: Config JobF4: Config JobF4: Config JobF4: Config JobWhen F4 is selected from the Main Screen, theoperator will be prompted to select the gun numberthey wish to examine and/or edit parameters forand what Job Number they wish to examine/edit.At that time, the following screen will appear:

RatioRatioRatioRatioRatioThe allowable range of values for this parameter isany number from 0.001 to 99.999.

This is the taget ratio of resin to catalyst that thecontroller is going to try to maintain while triggered.The ratio of 1 for the slave channel is assumed.For example: if 12.345 was programmed here, aratio of 12.345 parts of resin would be metered into1 part of catalyst. If a value less than 1.000 isprogrammed here, the flow of the catalyst will begreater than the flow of the resin. For example: if0.250 was programmed here, a ratio of 4 parts ofcatalyst (slave channel material) would be meteredinto 1 part of resin (master channel material).

A value of 65 or higher will cause only resin (singlecomponent) to flow. (The ratio tolerance bar-graph, the B Channel bar-graph, the ratio and all BChannel text are not shown on the main screen forsingle component ratios.)

Flow SetpointFlow SetpointFlow SetpointFlow SetpointFlow SetpointThe allowable range of values for this parameter isany integer from 0 cc/min to 10,000 cc/min.

This is the target flow rate for the output of the fluidpanel associated with this gun.

There are 6 function buttons defined for use fromthe Channel Parameter Screen:

F1: ModifyF1: ModifyF1: ModifyF1: ModifyF1: Modify - This button allows the user to stepthrough the possible options for this parameter ora numeric keypad is presented if a numericalvalue is required.

F2: Edit MasterF2: Edit MasterF2: Edit MasterF2: Edit MasterF2: Edit Master - This button allows the userto switch to viewing and editing the master channelparameters.

F3: Edit SlaveF3: Edit SlaveF3: Edit SlaveF3: Edit SlaveF3: Edit Slave - This button allows the user toswitch to viewing and editing the slave channelparameters (if it is a 2 channel gun).

F5: Send to RCS-2 F5: Send to RCS-2 F5: Send to RCS-2 F5: Send to RCS-2 F5: Send to RCS-2 ----- This button takes thedata displayed on the current screen and sends itto the interface card where it is then stored in non-volatile memory. Any changes made to theparameters on this screen will be lost if the screenis exited prior to sending it to the interface card,using this button.

F9: Read in FileF9: Read in FileF9: Read in FileF9: Read in FileF9: Read in File - This button allows operatorsto load the parameters contained on this screenfrom any media. They are stored in a file namedchanconfig.par.chanconfig.par.chanconfig.par.chanconfig.par.chanconfig.par.

F10: Save to FileF10: Save to FileF10: Save to FileF10: Save to FileF10: Save to File - This button allows operatorsto save the parameters on this screen to anywriteable media. They are stored in a file namedchanconfig.par.chanconfig.par.chanconfig.par.chanconfig.par.chanconfig.par.

LN-9407-00.1


3838383838

Maximum FlowMaximum FlowMaximum FlowMaximum FlowMaximum FlowThe allowable range of values for this parameter isany integer from 0 cc/min to 10,000 cc/min.

When using an analog input to control the targetflow rate, this is the flow rate that the controller willtry to maintain if the maximum voltage (10 VDC) orcurrent (20 mA) is applied to the analog input.

Minimum FlowMinimum FlowMinimum FlowMinimum FlowMinimum FlowThe allowable range of values for this parameter isany integer from 0 cc/min to 10,000 cc/min.

When using an analog input to control the targetflow rate, this is the flow rate that the controller willtry to maintain if the minimum voltage (0 VDC) orcurrent (4 mA) is applied to the analog input.

Bar Graph LimitBar Graph LimitBar Graph LimitBar Graph LimitBar Graph LimitThe allowable range of values for this parameter isany integer from 0 cc/min to 10,000 cc/min.

This is the flow rate indicated by top of the flow ratebar-graphs on the Main Screen and determinesthe maximum value displayed on the plot-graphs.

Pot-Life TimerPot-Life TimerPot-Life TimerPot-Life TimerPot-Life TimerThe allowable range of values for this parameter isany integer from 0 min. to 1000 min. This is theamount of time that mixed plural componentmaterial is allowed to remain in the fluid streamafter being mixed before a flush-request outputand error is issued by the controller.

Feather PressureFeather PressureFeather PressureFeather PressureFeather PressureThe allowable range of values for this parameter isany integer value from 0 psi to 255 psi.

This value is the pressure that will be maintainedat the outlet of the pump (or pumps) when a gun isconfigured as a manual mode gun and the oper-ator is feathering the spray gun. (See Appendix Hfor more details on Feather Modes.)

Fill VolumeFill VolumeFill VolumeFill VolumeFill VolumeThis is the amount of material that the user wishesto flow through the pump(s) when the gun is placedin the volume fill mode.

The following 8 parameters have a masterThe following 8 parameters have a masterThe following 8 parameters have a masterThe following 8 parameters have a masterThe following 8 parameters have a masterchannel component and a slave channelchannel component and a slave channelchannel component and a slave channelchannel component and a slave channelchannel component and a slave channelcomponent. (Note the master and slavecomponent. (Note the master and slavecomponent. (Note the master and slavecomponent. (Note the master and slavecomponent. (Note the master and slavecolumns on the screen.) Both values mustcolumns on the screen.) Both values mustcolumns on the screen.) Both values mustcolumns on the screen.) Both values mustcolumns on the screen.) Both values mustbe programmed for plural componentbe programmed for plural componentbe programmed for plural componentbe programmed for plural componentbe programmed for plural componentmaterials.materials.materials.materials.materials.

Pressure Pot CapacityPressure Pot CapacityPressure Pot CapacityPressure Pot CapacityPressure Pot CapacityThe allowable range of values for this parameter isany value from 0.000 liters to 255.000 liters.

This value is simply the volume of material that thepressure pot will be filled with each time it is refilled.There is a pot reset button on the Job Totalsscreen (F9) that must be actuated every time a potis filled.

Delta PressureDelta PressureDelta PressureDelta PressureDelta PressureThe allowable range of values for this parameter isany integer value from 0 psi to 20 psi.

This is the target differential pressure that thecontroller tries to maintain across the pump.

Keeping the differential pressure across the pumpto a minimum is essential, especially with low-viscosity materials. If the outbound pressure ofthe pump is significantly higher than the inboundpressure and the pump has any significant wear,it is possible for the gear teeth to “slip by” a smallvolume of material and less material will bedelivered per revolution of the pump. If the inboundpressure is significantly higher than the outboundpressure, then material can “blow by” the pumpand more material than desired will be delivered.The pump should essentially act as a meteringdevice as opposed to a pumping device.

Minimum Inlet Fluid PressureMinimum Inlet Fluid PressureMinimum Inlet Fluid PressureMinimum Inlet Fluid PressureMinimum Inlet Fluid PressureThe allowable range of values for this parameter isany integer value from 0 psi to 200 psi.

This is the target pressure that the controller triesto maintain on the inlet of the pump as long as theminimum inlet control pressure setting is not greaterthan this setting.

LN-9407-00.1

Hardener Sample TimeHardener Sample TimeHardener Sample TimeHardener Sample TimeHardener Sample TimeThe allowable range of values for this parameter isany integer from 0 seconds to 10 seconds.

This parameter allows the operator to programhow often (in accumulated seconds) the flow ofthe slave channel is verified.

Hardener No FlowHardener No FlowHardener No FlowHardener No FlowHardener No FlowThe allowable range of values for this parameter is4 mA to 20 mA.

This parameter allows the user to program in thecurrent (in milliamps) below which the controllerassumes that no catalyst is flowing.

Hardener Flow OnHardener Flow OnHardener Flow OnHardener Flow OnHardener Flow OnThe allowable range of values for the parameter is4 mA to 20 mA.

This is the value above which the controller willassume that catalyst is flowing. It must always begreater than the Hardener No Flow Parameter.

If the controller sees a value between hardener noflow and hardener flow on, it examines the slope ofthe current. As long as the current is increasingwhile the gun is triggered, the controller assumescatalyst is flowing. If the current is decreasing orremains stable while the gun is triggered, thecontroller will assume no catalyst flow andincrement the hardener sample time timer.

Edit Job Function KeysEdit Job Function KeysEdit Job Function KeysEdit Job Function KeysEdit Job Function KeysThere are 9 function keys defined for use from theJob Parameters screen:

F1: Modify – F1: Modify – F1: Modify – F1: Modify – F1: Modify – This button allows the user tomodify the currently selected parameter(highlighted).

> See "Appendix G" for details on ad-justing the following three parameters.



3939393939

Minimum Inlet Control PressureMinimum Inlet Control PressureMinimum Inlet Control PressureMinimum Inlet Control PressureMinimum Inlet Control PressureThe allowable range of values for this parameter isany integer value from 0 psi to 100 psi.

This is the minimum pressure that the E to Ptransducer in the motor amplifier panel will beallowed to go down to. Even if the fluid pressureat the inlet of the pump is above the minimum inletfluid pressure setpoint, the control (pilot) pressurefrom the E to P transducer will not go below thissetpoint. This can be used as an offset to keep thefluid regulator at its cracking point to allow for rapidresponse by the fluid regulator at the trigger onpoints.

Inlet KpInlet KpInlet KpInlet KpInlet KpThe allowable range of values for this parameter isany integer from 0 to 65,535. The value has nounits.

This value is the proportional gain factor for thePID loop that controls the inlet pressure to thepump.

Inlet KiInlet KiInlet KiInlet KiInlet KiThe allowable range of values for this parameter isany integer from 0 to 65,535. The value has nounits.

This value is the integral gain factor for the PIDloop that controls the inlet pressure to the pump.

Inlet KdInlet KdInlet KdInlet KdInlet KdThe allowable range of values for this parameter isany integer from 0 to 65,535. The value has nounits.

This value is the derivative gain factor for the PIDloop that controls the inlet pressure to the pump.

Inlet DeadbandInlet DeadbandInlet DeadbandInlet DeadbandInlet DeadbandThe allowable range of values for this parameter isany integer from 0 to 65,535. It is expressed inPSI.

This value is the deadband for the PID loop thatcontrols the inlet pressure to the pump.

LN-9407-00.1

F2: Previous Job – F2: Previous Job – F2: Previous Job – F2: Previous Job – F2: Previous Job – This button allows the userto view and edit the previous job to the onecurrently displayed (for that gun).

F3: Next Job – F3: Next Job – F3: Next Job – F3: Next Job – F3: Next Job – This button allows the user toview and edit the next job for that gun.

F4: Previous Gun – F4: Previous Gun – F4: Previous Gun – F4: Previous Gun – F4: Previous Gun – This button allows the userto view and edit the job parameters for the previousgun.

F5: Send to RCS-2 – F5: Send to RCS-2 – F5: Send to RCS-2 – F5: Send to RCS-2 – F5: Send to RCS-2 – This button takes the datadisplayed on the current screen and sends it to theinterface card where it is then stored in non-volatile memory. Any changes made to theparameters on this screen will be lost if the screenis exited prior to sending it to interface card, usingthis button.

F6: Next Gun F6: Next Gun F6: Next Gun F6: Next Gun F6: Next Gun - This button allows the user toview and edit the job parameters for the next gun.

F7: Copy Parameter – F7: Copy Parameter – F7: Copy Parameter – F7: Copy Parameter – F7: Copy Parameter – This button allows theuser to copy the data from the highlightedparameter on the screen to any other job, range ofjobs, gun, or range of guns.

F8: Copy Job – F8: Copy Job – F8: Copy Job – F8: Copy Job – F8: Copy Job – This button allows the user tocopy the data from any job to any other job. Usersare also prompted for which gun or guns they wishthe job data copied to.

F9: Read file – F9: Read file – F9: Read file – F9: Read file – F9: Read file – This button reads in the totalizationdata from the internal flash drive, the floppy diskdrive, a USB memory drive, or the CDROM andsends them to the interface card to be stored innon-volatile memory.

F10: Save to file – F10: Save to file – F10: Save to file – F10: Save to file – F10: Save to file – This button reads alltotalization data currently stored in non-volatilememory on the interface card and stores it on themedia selected by the user (internal flash, floppydrive, USB memory, or CDROM). The data isstored in a file named jobs.par jobs.par jobs.par jobs.par jobs.par .

F5: Load JobF5: Load JobF5: Load JobF5: Load JobF5: Load JobThis function allows operators to load a differentjob number to a gun. Note that if the gun is in runmode when the new job is seleted, the new job willnot become active until the gun is halted and putback in run mode.


4040404040

> The new job will also become active ifthe gun faults, as this generates a halt forthat gun.


F6: Configure AlarmsF6: Configure AlarmsF6: Configure AlarmsF6: Configure AlarmsF6: Configure AlarmsThis screen allows the operator to program whicherrors and faults actually cause a spray shutdowncondition. That is, what errors and faults (whenthey occur) will actually halt the pumps and causespray to cease.

If the alarm is turned off, the main screen willindicate that the gun is faulted but running. TheStatus line on the main screen will show:

STATUS: RUNSTATUS: RUNSTATUS: RUNSTATUS: RUNSTATUS: RUN(The word RUN will be printed in red.)

LN-9407-00.1


4141414141

There are four function buttons defined while editingalarm configuration data:

F1: ModifyF1: ModifyF1: ModifyF1: ModifyF1: Modify - This button toggels an off state(disabled) to an on state (enabled).

F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - F5: Send to RCS-2 - This button takes the datadisplayed on the current screen and sends it to theinterface card where it is then stored in non-volatile memory. Any changes made to the pa-rameters on this screen will be lost if the screen isexited prior to sending it to the interface card usingthis button.

F9: Read In FileF9: Read In FileF9: Read In FileF9: Read In FileF9: Read In File - This button allows the operatorto load alarm configurations from any media.

F10: Save To FileF10: Save To FileF10: Save To FileF10: Save To FileF10: Save To File - This button allows theoperator to save alarm configurations to anywriteable media. All configurations are saved in afile named alarmcfg.paralarmcfg.paralarmcfg.paralarmcfg.paralarmcfg.par.

F7: Digital and Analog I/OF7: Digital and Analog I/OF7: Digital and Analog I/OF7: Digital and Analog I/OF7: Digital and Analog I/OThe following 3 screens allow the operator toexamine all digital and analog inputs and outputsas well as force most of them for debug andtroubleshooting purposes.

Note that there are more signals than there is roomfor on one screen so operator must scroll down tosee additional outputs.

Option 1 - Gun (Digital) Inputs and OutputsOption 1 - Gun (Digital) Inputs and OutputsOption 1 - Gun (Digital) Inputs and OutputsOption 1 - Gun (Digital) Inputs and OutputsOption 1 - Gun (Digital) Inputs and Outputs(For detailed explanations for each of these inputsand outputs, see the "I/O Descriptions" in the"Installation" section.)

INPUTS:INPUTS:INPUTS:INPUTS:INPUTS:Fast FillChannel FillFeather SetRunHalt/ResetTrigger 1Motor Amp EnableTrigger 2Trigger 3Trigger 4Volume FillPush Out

OUTPUTS:OUTPUTS:OUTPUTS:OUTPUTS:OUTPUTS:Gun FaultGun RunSpray ShutdownFlush RequestMotor OnGun Ready

Option 2 - System Inputs and OutputsOption 2 - System Inputs and OutputsOption 2 - System Inputs and OutputsOption 2 - System Inputs and OutputsOption 2 - System Inputs and Outputs

LN-9407-00.1


4242424242

INPUTS:INPUTS:INPUTS:INPUTS:INPUTS:Strobe Gun 1Strobe Gun 2Strobe Gun 3Strobe Gun 4Strobe Gun 5Strobe Gun 6Strobe Gun 7Strobe Gun 8Job #[1]Job #[2]Job #[4]Job #[8]Job #[10]Job #[20]Job #[40]Job #[80]Job #[100]System Spare 1System Spare 2System Spare 3

OUTPUTS:OUTPUTS:OUTPUTS:OUTPUTS:OUTPUTS:System FaultSystem PulseSystem User Link

Option 3 - Analog Inputs and OutputsOption 3 - Analog Inputs and OutputsOption 3 - Analog Inputs and OutputsOption 3 - Analog Inputs and OutputsOption 3 - Analog Inputs and Outputs

INPUTS:INPUTS:INPUTS:INPUTS:INPUTS:Flow Rate Setpoint

Actual Flow Rate Motor RPM Solvent Flow Rate Hardener Flow Sensor Feather Pressure Inlet Pressure Outlet Pressure

OUTPUTS:OUTPUTS:OUTPUTS:OUTPUTS:OUTPUTS: Actual Flow Rate Motor RPM Pressure Control

On all of the Force I/O screens, there are 3function buttons defined:

F1: Toggle On/Off or Modify ForceF1: Toggle On/Off or Modify ForceF1: Toggle On/Off or Modify ForceF1: Toggle On/Off or Modify ForceF1: Toggle On/Off or Modify Force - Thisbutton allows the user to toggle forces on and off.If the parameter requires a numeric input, a popupkeypad is displayed. (User must first use the F2button to enable the force prior to using this key.)

F2: Toggle ForceF2: Toggle ForceF2: Toggle ForceF2: Toggle ForceF2: Toggle Force - This button allows the userto enable or disable the particular force under thecursor. A letter F in parenthesis will appear if theforce is enabled next to the value in that cell.

F3: Reset AllF3: Reset AllF3: Reset AllF3: Reset AllF3: Reset All - This button allows the user toremove all forces for the displayed screen. Toreset all forces (gun, system, and analog) usermust go to each of the three screens and push theF3 button.

F8: Plot DataF8: Plot DataF8: Plot DataF8: Plot DataF8: Plot DataThis feature allows operators to generate a graphof many of the process variables to monitor theresponse of the system as it relates to time. Upto 4 var-iables from any of the configured guns canbe graphed at any one time. All 4 variables to begraphed do not need to be from the same gun.(e.g. The triggers of 4 guns can be graphed at thesame time.)

LN-9407-00.1


4343434343

The following variables can be graphed:TriggerRequested Ratio (2 channel guns only)Actual Ratio (2 channel guns only)Total Flow (for both channels together)Requested Flow (for either or both channels)Actual Flow (for either or both channels)Inlet Pressure (for the pump on either or bothchannels)Outlet Pressure (for the pump on either or bothchannels)Hardener Flow

Setup:Setup:Setup:Setup:Setup:

Each of the 4 variables is graphed in a differentcolor: red, green, blue, or black. The order inwhich the operator selects the variables determinesin which order they appear on the screen.

F1: Time Base – F1: Time Base – F1: Time Base – F1: Time Base – F1: Time Base – This button allows the user toswitch the time base (resolution) of the graph. Infast mode, the full-screen width is graphed in 40seconds. In slow mode, the full-screen width isgraphed in 80 seconds.

F2: Single Plot – F2: Single Plot – F2: Single Plot – F2: Single Plot – F2: Single Plot – This button allows the user torecord one full screen of data (40 or 80 seconds)at which point the graphing stops to allow the userto examine the data. In continuous data mode,when the cursor reaches the right end of thegraph, it automatically jumps back to the left endof the graph and writes over old data.

F3: Stop Plot – F3: Stop Plot – F3: Stop Plot – F3: Stop Plot – F3: Stop Plot – This button allows the user tostop the data acquisition process temporarily andfreeze the display for analysis or to save the plot.

F4: Start Stop (<--) – F4: Start Stop (<--) – F4: Start Stop (<--) – F4: Start Stop (<--) – F4: Start Stop (<--) – This button allows theuser to move both the start-time cursor and thestop-time cursor at the same time to the left.

F5: Start Time (<--) – F5: Start Time (<--) – F5: Start Time (<--) – F5: Start Time (<--) – F5: Start Time (<--) – This button allows theuser to move the start-time cursor to the left.

F6: Start Time (-->) – F6: Start Time (-->) – F6: Start Time (-->) – F6: Start Time (-->) – F6: Start Time (-->) – This button allows theuser to move the start-time cursor to the right.

Operator simply highlights the variables they wishgraphed and then pushes the F1 key to selectthem. The selected variables will then show up inthe box in the lower left of the screen. Variablescan be removed by simply pushing the F3 button.

Selecting F2 will cause the graphed data to runcontinuously. After a full screen of data has beengraphed, the screen is cleared and the graphingrestarts on the left end of the screen.

Graphing:Graphing:Graphing:Graphing:Graphing:

LN-9407-00.1


4444444444

Total volume usage is recorded for each Jobnumber independent of each other. (The lowerhalf of the screen shows total volumes for all jobssummed together.) Job totals are stored in twoindependent registers, Daily Volume, and Year toDate Volume. These volumes are in no way tiedto the clock or calendar, they simply are twoseparately resetable volumes.

(Operators may wish to use the Daily Volume asa Shift Volume and the Year to Date as a WeeklyVolume, etc.) Both volumes are incrementedwhen material flows.

Job TJob TJob TJob TJob Totals Function Keysotals Function Keysotals Function Keysotals Function Keysotals Function KeysThere are 11 function keys defined for use fromthe Job Totals screen:

F1: Reset Total – F1: Reset Total – F1: Reset Total – F1: Reset Total – F1: Reset Total – This button allows the user toreset the currently selected (highlighted) value.

F2: Reset Channel – F2: Reset Channel – F2: Reset Channel – F2: Reset Channel – F2: Reset Channel – This button allows the userto reset the totals for the currently selected channel.

F3: Reset Gun - F3: Reset Gun - F3: Reset Gun - F3: Reset Gun - F3: Reset Gun - This button allows the user toreset the totals for the currently selected gun. (Ifit is a two channel gun, both channels will bereset.)

F7: Stop Time (-->) – F7: Stop Time (-->) – F7: Stop Time (-->) – F7: Stop Time (-->) – F7: Stop Time (-->) – This button allows theuser to move the stop-time cursor to the left.

F8: Stop Time (-->) – F8: Stop Time (-->) – F8: Stop Time (-->) – F8: Stop Time (-->) – F8: Stop Time (-->) – This button allows theuser to move the start-time cursor to the right.

F9: Start Stop (-->) – F9: Start Stop (-->) – F9: Start Stop (-->) – F9: Start Stop (-->) – F9: Start Stop (-->) – This button allows theuser to move both the start-time cursor and thestop-time cursor at the same time to the right.

F10: Save Plot – F10: Save Plot – F10: Save Plot – F10: Save Plot – F10: Save Plot – This button allows the operatorto save the graph in a bitmap (.bmp) format forlater examination and printing. The operator isgiven the option of saving the data to any writablemedia. Users are cautioned against storing themon the internal flash drive (drive C:\) as this drivehas limited space. The file name that is used forthe graph is based on the date and time that it issaved…

It is in the form of: AABBCCDD.bmp, where…AA = MonthBB = Day of monthCC = Number of hours since midnightDD = Minutes since last hour

Data Displays: Data Displays: Data Displays: Data Displays: Data Displays: At the top of the graphing screenthere may be as many as 6 white boxes with datain them. The center two boxes indicate the time ofthe start and stop cursors (start on top, stop onbottom). The other 4 boxes indicate the value ofthe graphed variable at the point where the cursorsare currently positioned.

F9: Job TF9: Job TF9: Job TF9: Job TF9: Job TotalsotalsotalsotalsotalsWhen F9 is selected from the main screen, theoperator is prompted to enter a Job number. Oncethis has been done, the following screen appears.

LN-9407-00.1


4545454545

F4: Reset All – F4: Reset All – F4: Reset All – F4: Reset All – F4: Reset All – This button allows the user toreset the totals for all jobs, guns, and channels.

F5: Previous Job – F5: Previous Job – F5: Previous Job – F5: Previous Job – F5: Previous Job – This button allows the userto examine the totals for the next job.

F6: Select Job – F6: Select Job – F6: Select Job – F6: Select Job – F6: Select Job – This button allows the user tochoose another job to examine/reset data for.

F7: Next Job – F7: Next Job – F7: Next Job – F7: Next Job – F7: Next Job – This button allows the user toexamine the totals for the next job.

F8: Toggle Units – F8: Toggle Units – F8: Toggle Units – F8: Toggle Units – F8: Toggle Units – This button allows the userto toggle the units that the data is displayed inbetween liters and gallons.

F9: Read file – F9: Read file – F9: Read file – F9: Read file – F9: Read file – This button reads in the totalizationdata from the internal flash drive, the floppy diskdrive, a USB memory drive, or the CDROM andsends them to the interface card to be stored innon-volatile memory.

F10: Save To file – F10: Save To file – F10: Save To file – F10: Save To file – F10: Save To file – This button reads alltotalization data currently stored in non-volatilememory on the interface card and stores it on themedia selected by the user (internal flash, floppydrive, USB memory, or CDROM). The data isstored in a file named totals.par totals.par totals.par totals.par totals.par .

F11: Pot Reset – F11: Pot Reset – F11: Pot Reset – F11: Pot Reset – F11: Pot Reset – This button allows the user toreset the volume counters for pressure pot tracking.This is typically done when the pots are filled.

F10: TF10: TF10: TF10: TF10: Trigger Logrigger Logrigger Logrigger Logrigger LogWith this feature, users can monitor and recordthe trigger on and off times as well as the fluid thatflowed during those trigger on times for up to 200successive triggers. When this feature is selected,the user will be prompted to select which gun theywish to monitor. Recording of data will not startuntil the Start Logging (F1) button is pushed. Keepin mind that data will not appear in the screen untilthe second on-trigger (on dwell) event hasoccurred to allow the software the ability to recordthe time of the first off-trigger (off dwell) event. Thejob number that was running during the trigger isalso recorded. The status of three flags are alsorecorded with each event. These flags reflect thestatus of the three spare system digital inputs.

Note that volumes are rounded to the nearest cc.The latest events are displayed at the top of thescreen and the older events are pushed off of thebottom of the screen (but can be accessed byusing the Windows scroll bar). Values can also besaved to writeable media by using the F10 key butrecording must first be stopped to allow saving ofthis data. (Refer to "Appendix M" for more detailson how to use this feature.)

F1F1F1F1F11: Color Changer1: Color Changer1: Color Changer1: Color Changer1: Color ChangerAn optional color change sequencer may havebeen included with the controller. If it was includ-ed, the F11 button will indicate as such on the mainscreen. If the F11 key is blank, your system doesnot have this option.

When this function is selected, the operator is firstprompted for the gun number they wish to view oredit the sequence for, they are then prompted forwhich Job Number they wish to view and/or editthe sequences of, and last, they are asked if theywant to view/edit the sequence for flushing orfilling. (There is a separate flush sequence and fillsequence stored for every Job Number and forevery gun.)

LN-9407-00.1


4646464646

Once the operator responds to the above prompts,a screen similar to the following appears:

This chart displays a simple 6 step sequencerwhere the user defines how long they wish eachstep to take and which valves or signals should beenergized at each one of those steps. There are6 steps for the flush cycle and 6 steps for the fillcycle. When a color change is desired, thesequencer automatically runs the flush sequencefollowed by the load sequence.

The following solenoid valves can be controlled bythe sequencer:

Resin/Solvent Air ChopResin SolventResin AirPaintResin Pump BypassResin Pump FlushTrigger SolenoidResin OverrideDump ValveCatalyst Select ValveCatalyst SolventCatalyst Override

The following RCS-2 inputs can be controlled bythe sequencer:

RCS-2 RunRCS-2 HaltRCS-2 Fast FillRCS-2 A FillRCS-2 B FillRCS-2 Trigger

Note that there are too many valves and signals tobe displayed on one screen. Therefore, the operatormust scroll down to see the bottom five items.

There are 8 function buttons defined while editingflush, load, and color change sequences:

F1: ModifyF1: ModifyF1: ModifyF1: ModifyF1: Modify - This button brings up a numerickeypad if cursor is on one of the step durationcells. If cursor is on one of the valve conditioncells, that cell is toggled from off to on or on to off.

F2: Air Chop TimeF2: Air Chop TimeF2: Air Chop TimeF2: Air Chop TimeF2: Air Chop Time - This button allows the userto program how long the air valve remains on foreach step of the solvent/air chop timer.

F3: Solvent Chop Time -F3: Solvent Chop Time -F3: Solvent Chop Time -F3: Solvent Chop Time -F3: Solvent Chop Time - This button allows theuser to program how long the solvent valve re-mains on for each step of the solvent/air choptimer.

F4: Edit Flush or FillF4: Edit Flush or FillF4: Edit Flush or FillF4: Edit Flush or FillF4: Edit Flush or Fill - This button opens thescreen that allows viewing and editing of thesequences. (If the flush screen is displayed, itswitches to fill, or vice-versa.)

F5: Send to Opto22F5: Send to Opto22F5: Send to Opto22F5: Send to Opto22F5: Send to Opto22 - This button allows theoperator to immediately send the edited sequenceto the sequencer (located in the motor amplifierpanel). Note that the sequences are automaticallysent to the sequencer every time a new JobNumber is loaded.

F9: Read In FileF9: Read In FileF9: Read In FileF9: Read In FileF9: Read In File - This button allows the operatorto load flush and load sequences from a diskette.Note that all sequences for all guns and all jobs areoverwitten on the flash drive, using the data on thediskette.

LN-9407-00.1


4747474747

F10: Save To FileF10: Save To FileF10: Save To FileF10: Save To FileF10: Save To File - This button allows theoperator to save flush and load sequences to anywriteable media. All flush and load sequences forall guns are saved in a file named ColorChg.parColorChg.parColorChg.parColorChg.parColorChg.par.

Note that there are nine solenoid valves whosetext descriptors are in red. (Paint, Resin Bypass,Resin Pump Flush, Trigger Solenoid, ResinOverride, Dump Valve, Catalyst Select, CatalystSolvent, and Catalyst Override) These functionsmay not always be required in all systems andtherefore can be renamed and used for otherfunctions. Inside of the RCS-2 folder on the harddrive of the user-interface computer there is a textfile named: Solenoid_Valves.txt. In it the above 9valves are named. Users are free to rename anyor all of those valves and use them for otherfunctions during the color change sequences thatthey program. Simply exit the user-interfacesoftware, open the file with any text editor(Wordpad, etc.), change the names as required,and resave the file. The next time the user-interface software is opened, it will use the newnames when the color change sequencer screensare opened.

F12: ShutdownF12: ShutdownF12: ShutdownF12: ShutdownF12: ShutdownThis function key allows the RCS-2 to perform anorderly shutdown of the Windows XP Embeddedoperating system. The operating system (storedon the flash drive, drive C:\) can be damaged if theunit is powered off with the power switch on thefront door of the controller without performing thisshutdown procedure first.

User-Interface Software Buttons:User-Interface Software Buttons:User-Interface Software Buttons:User-Interface Software Buttons:User-Interface Software Buttons:(top of screen)(top of screen)(top of screen)(top of screen)(top of screen)On the top-right of the user interface screen, thereare 5 buttons. The function of these buttons are asfollows…

Channel Fill - Channel Fill - Channel Fill - Channel Fill - Channel Fill - This function allows the operatorto run any of the 8 pumps at their maximum flowrate (typically 150 RPM). This is typically used forflushing purposes and for rapidly getting materialfrom a color valve stack down to the pump, prior tousing Fast Fill. The gun that the channel isassigned to must be in the Ready state before itwill be allowed to channel fill. Also, Fill Enablemust be set to Yes for the channel in the Config.Channel parameter screen. When the ChannelFill button is pushed, the operator will be promptedwith a display showing 8 buttons (one for eachchannel). The instant any of those buttons arepushed, the pump for that channel will run at itsmaximum RPM (typically 150 RPM). Make surethe applicator is triggered prior to pushing thesebuttons or an overpressure fault may occur. Anycombinations of these buttons can be turned onsimultaneously. Pushing the button a second timewill take that channel out of Channel Fill Mode andstop the pump (if it was put in Channel Fill Modefrom this screen). If either the enter or the escapebutton (below the channel number buttons) ispushed, the Channel Fill Screen will be exited andall pumps that had been put in Channel Fill Modefrom this screen will stop.

Fast Fill – Fast Fill – Fast Fill – Fast Fill – Fast Fill – This function allows the operator to fillthe fluid lines as fast as possible at the ratiocurrently programmed for the loaded job number.That is, one of the two pumps will run at itsmaximum RPM (typically 150 RPM), and the otherpump will be slaved to it to deliver material at theproper ratio. The software will determine which ofthe two pumps will run at the maximum RPMbased on the ratio setting and the two pump sizes.In order to run a gun in Fast Fill Mode, the gun mustfirst be in Run Mode prior to selecting Fast Fill.When the user pushes this button, they arepresented with a screen showing gun numbers 1through 8. The user simply pushes the gunnumber that they wish to put in Fast Fill Mode.Note that the pumps will start running immediately,so make sure the applicator is triggered or either

LN-9407-00.1


4848484848

an overpressure fault will occur or the system willfold-back. Any combinations of guns can beplaced in Fast Fill Mode simultaneously. To takea gun out of Fast Fill Mode, simply push the gunnumber button a second time. Pushing either theenter or escape button (below the gun numberbuttons) will take any and all guns that were put inFast Fill Mode via this screen out of Fast Fill Mode,as the screen exits. Exiting this screen while agun is Fast Filling that has been initiated elsewhere(discretely, via RIO, or via Ethernet) will not betaken out of Fast Fill Mode.Help – Help – Help – Help – Help – This function allows the operator to getcontext-sensitive help for the current screen beingdisplayed. That is, the portion of the help text filethat refers to the screen currently displayed willautomatically be displayed when this button ispushed. Users can scroll up and down throughthe entire help file once it is displayed. Pushing theCancel button exits the help screen.

Error Log -Error Log -Error Log -Error Log -Error Log - This button allows the operator toview the last 100 errors or faults generated by thesystem. Errors and faults are channel, date, andtime stamped for easy identification as to whenthey occurred and for which channels. Faults canalso be reset from within this screen.

If the error log is displayed, users can save the logto a diskette or to the flash drive by pushing the F8key. The data is stored in a file namedErrorLog.TxtErrorLog.TxtErrorLog.TxtErrorLog.TxtErrorLog.Txt and is a simple text file, viewablewith any word processor or text editor. Onceagain, users are cautioned against saving data onthe flash drive (Drive C:\) because of its limitedspace.

Clear Gun Faults – Clear Gun Faults – Clear Gun Faults – Clear Gun Faults – Clear Gun Faults – This button will flash with ared outline if any guns are faulted. By pushing thisbutton, any and all guns that are faulted will bereset. The gun or guns that were faulted have tobe put back in run mode (if so desired) by pushingthe appropriate Gun On/Off button in the upper leftof the user interface section.

If the outline of this button is flashing yellow, thisindicates that the Ethernet communication linkbetween the user-interface computer and theinterface card has been broken. This can be theresult of the rack not having power (check the E-Stop pushbutton), a disconnected Ethernet cable,a non-functioning Ethernet switch, etc.

If the outline of this button is flashing blue, thisindicates that the user-interface computer isrunning in simulate mode. This is normally doneif you are running the software on a computer thatis not connected to an RCS-2 rack. This mode iscontrolled by an entry in the fms.ini file on the harddrive of the user-interface computer. Adding a lineof text with the word: simulate puts the software inthis mode. This is required when running withouta rack connected as every time the softwareenters a new screen, it asks for data from theinterface card an you will receive a Network Errorif it is not in simulate mode. This line of text mustbe removed or commented out in order to talk to aninterface card.

Gun On/Off Buttons – Gun On/Off Buttons – Gun On/Off Buttons – Gun On/Off Buttons – Gun On/Off Buttons – The buttons in the topleft of the screen can be used to turn guns on or off(switches them between Run mode and Readymode). Note that guns must be in Run mode tospray. Faulted guns are noted by a flashing redboarder around the button of the gun that isfaulted. Pushing this button once when it is faultedwill reset the fault and pushing it a second timeputs the gun back in Run mode to put it back intooperation.

LN-9407-00.1

RCS-2 User Manual - Warranty Policies

4949494949

WWWWWARRANTYARRANTYARRANTYARRANTYARRANTY POLICIES POLICIES POLICIES POLICIES POLICIES

LIMITED WLIMITED WLIMITED WLIMITED WLIMITED WARRANTYARRANTYARRANTYARRANTYARRANTY

ITW Ransburg will replace or repair without chargeany part and/or equipment that falls within thespecified time (see below) because of faultyworkmanship or material, provided that theequipment has been used and maintained inaccordance with ITW Ransburg's written safetyand operating instructions, and has been usedunder normal operating conditions. Normal wearitems are excluded.

THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-BURG APPROVED PARTS, VOID ALLBURG APPROVED PARTS, VOID ALLBURG APPROVED PARTS, VOID ALLBURG APPROVED PARTS, VOID ALLBURG APPROVED PARTS, VOID ALLWARRANTIES.WARRANTIES.WARRANTIES.WARRANTIES.WARRANTIES.

SPARE PARTS: One hundred and eighty (180)days from date of purchase, except for rebuiltparts (any part number ending in "R") for which thewarranty period is ninety (90) days.

EQUIPMENT: When purchased as a completeunit, (i.e., guns, power supplies, control units,etc.), is one (1) year from date of purchase.WRAPPING THE APPLICATOR IN PLAS-WRAPPING THE APPLICATOR IN PLAS-WRAPPING THE APPLICATOR IN PLAS-WRAPPING THE APPLICATOR IN PLAS-WRAPPING THE APPLICATOR IN PLAS-TIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOIDTHIS WARRANTY.THIS WARRANTY.THIS WARRANTY.THIS WARRANTY.THIS WARRANTY.

ITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATIONUNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEOF FAULTY WORKMANSHIP OR MATER-OF FAULTY WORKMANSHIP OR MATER-OF FAULTY WORKMANSHIP OR MATER-OF FAULTY WORKMANSHIP OR MATER-OF FAULTY WORKMANSHIP OR MATER-IALS. THERE ARE NO IMPLIED WARRAN-IALS. THERE ARE NO IMPLIED WARRAN-IALS. THERE ARE NO IMPLIED WARRAN-IALS. THERE ARE NO IMPLIED WARRAN-IALS. THERE ARE NO IMPLIED WARRAN-TIES NOR WARRANTIES OF EITHERTIES NOR WARRANTIES OF EITHERTIES NOR WARRANTIES OF EITHERTIES NOR WARRANTIES OF EITHERTIES NOR WARRANTIES OF EITHERMERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-BURG ASSUMES NO LIABILITY FORBURG ASSUMES NO LIABILITY FORBURG ASSUMES NO LIABILITY FORBURG ASSUMES NO LIABILITY FORBURG ASSUMES NO LIABILITY FORINJURY, DAMAGE TO PROPERTY ORINJURY, DAMAGE TO PROPERTY ORINJURY, DAMAGE TO PROPERTY ORINJURY, DAMAGE TO PROPERTY ORINJURY, DAMAGE TO PROPERTY ORFOR CONSEQUENTIAL DAMAGES FORFOR CONSEQUENTIAL DAMAGES FORFOR CONSEQUENTIAL DAMAGES FORFOR CONSEQUENTIAL DAMAGES FORFOR CONSEQUENTIAL DAMAGES FORLOSS OF GOODWILL OR PRODUCTIONLOSS OF GOODWILL OR PRODUCTIONLOSS OF GOODWILL OR PRODUCTIONLOSS OF GOODWILL OR PRODUCTIONLOSS OF GOODWILL OR PRODUCTIONOR INCOME, WHICH RESULT FROM USEOR INCOME, WHICH RESULT FROM USEOR INCOME, WHICH RESULT FROM USEOR INCOME, WHICH RESULT FROM USEOR INCOME, WHICH RESULT FROM USEOR MISUSE OF THE EQUIPMENT BYOR MISUSE OF THE EQUIPMENT BYOR MISUSE OF THE EQUIPMENT BYOR MISUSE OF THE EQUIPMENT BYOR MISUSE OF THE EQUIPMENT BYPURCHASER OR OTHERS.PURCHASER OR OTHERS.PURCHASER OR OTHERS.PURCHASER OR OTHERS.PURCHASER OR OTHERS.

EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:

If, in ITW Ransburg's opinion the warranty item inquestion, or other items damaged by this part wasimproperly installed, operated or maintained, ITWRansburg will assume no responsibility for repairor replacement of the item or items. The purchaser,therefore will assume all responsibility for any costof repair or replacement and service related costsif applicable.

LN-9407-00.1

APPENDIXAPPENDIXAPPENDIXAPPENDIXAPPENDIX

RCS-2 User Manual - Appendix

5050505050

When operating the user-interface software from a PC or laptop, the touchscreen buttons are notavailable. Below is a handy cross-reference table that associates available functions to a standardqwerty keyboard.

APPENDIX A: STAPPENDIX A: STAPPENDIX A: STAPPENDIX A: STAPPENDIX A: STANDARD KEYBOARD FUNCTIONSANDARD KEYBOARD FUNCTIONSANDARD KEYBOARD FUNCTIONSANDARD KEYBOARD FUNCTIONSANDARD KEYBOARD FUNCTIONS

FunctionFunctionFunctionFunctionFunction KeyKeyKeyKeyKey0-9............................................................................. 0-9Asterisk (*)................................................................*Channel Fill............................................................... Space BarClear Faults...............................................................CDot (.)........................................................................ (.)Enter......................................................................... Enter KeyEscape......................................................................Esc. Key (undo, previous menu, etc.)F1 - F12.....................................................................F1 - F12 KeyFast Fill......................................................................Backspace KeyGun 1 On/Off............................................................ A or aGun 2 On/Off............................................................ S or sGun 3 On/Off............................................................ D or dGun 4 On/Off............................................................ F or fGun 5 On/Off............................................................ G or gGun 6 On/Off............................................................ H or hGun 7 On/Off............................................................ J or jGun 8 On/Off............................................................ K or kHelp...........................................................................L or lHome.........................................................................Home KeyScroll Down...............................................................Down Arrow KeyScroll Left.................................................................. Left Arrow KeyScroll Right................................................................Right Arrow KeyScroll Up................................................................... Up Arrow Key

LN-9407-00.1


5151515151

APPENDIX B: APPENDIX B: APPENDIX B: APPENDIX B: APPENDIX B: CALIBRACALIBRACALIBRACALIBRACALIBRATION DATION DATION DATION DATION DATTTTTAAAAA AND FLOW RANGES AND FLOW RANGES AND FLOW RANGES AND FLOW RANGES AND FLOW RANGESOF STOF STOF STOF STOF STANDARD RCS-2 PUMPSANDARD RCS-2 PUMPSANDARD RCS-2 PUMPSANDARD RCS-2 PUMPSANDARD RCS-2 PUMPS

Using New Style Motor Using Old Style Motor Using ProximityAmplifier Feedback Amplifier Feedback Sensor Feedback

(500 pulses/revolution) (64 pulses/revolution) (60 pulses/revolution)

Pump Size Flow Rate Flow Rate Calibration Factor Calibration Factor Calibration Factor(cc's/rev) @ 3 RPM @ 150 RPM (pulses/liter) (pulses/liter) (pulses/liter)

0.297 0.9 45 1,683,502 215,488 202,020

0.584 1.8 88 856,164 109,589 102,740

1.752 5.3 263 285,388 36,530 34,247

2.920 8.8 438 171,233 21,918 20,548

3.500 10.5 525 142,857 18,286 17,143

5.500 16.5 825 90,909 11,636 10,909

10.000 30.0 1500 50,000 6,400 6,000

Pump Size - Specified by pump manufacturer (in cc's per revolution)

Flow Rate @ 3 RPM - Calculated by mutiplying the pump size by 3 RPM.

Flow Rate @ 150 RPM - Calculated by multiplying the pump size by 150 RPM.

Calibration Factor - Calculated by taking 1000 (cc's/liter), dividing by the pump size, then multiplying by the number of pulses/rev received from then motor amplifier.

LN-9407-00.1


5252525252

Jumper Number

Channel

Position

Function

JMP1 A 1 – 2 2 – 3 *

All discrete (chann el A) inputs source current All discrete (chann el A) inputs sink current

JMP2 A 1 – 2 * 2 – 3

Feather pressure sensor in put = 0 – 10 volts Feather pressure sensor in put = 4 – 20 mA

JMP3 A 1 – 2 * 2 – 3

Flow ra te analog inp ut = 0 – 10 volts Flow ra te analog inp ut = 4 – 20 mA

JMP4 A 1 – 2 2 – 3 *

Pump outlet pressure a nalog input = 0 – 10 volts Pump outlet pressure a nalog input = 4 – 20 mA

JMP5 A 1 – 2 2 – 3 *

Pump inlet pressure analog inpu t = 0 – 10 volts Pump inlet pressure analog inpu t = 4 – 20 mA

JMP6 ** A 1 – 2 * 2 – 3

Mot or speed analog output = 0 – 1 0 volts Mot or speed analog output = 4 – 2 0 mA

JMP7 ** A 1 – 2 * 2 – 3

Pressure control analog ou tput = 0 – 1 0 volts Pressure control analog ou tput = 4 – 2 0 mA

JMP8 B 1 – 2 2 – 3 *

All discrete (chann el B) inputs source current All discrete (chann el B) inputs sink current

JMP9 A 1 – 2 * 2 – 3

Spare analog in put = 0 – 10 volts Spare analog in put = 4 – 20 m A

JMP10 B 1 – 2 * 2 – 3

Spare analog in put = 0 – 10 volts Spare analog in put = 4 – 20 m A

JMP11 B 1 – 2 * 2 – 3

Flow ra te analog inp ut = 0 – 10 volts Flow ra te analog inp ut = 4 – 20 mA

JMP12 B 1 – 2 * 2 – 3

Feather pressure sensor in put = 0 – 10 volts Feather pressure sensor in put = 4 – 20 mA

JMP13 B 1 – 2 * 2 – 3

Pump inlet pressure analog inpu t = 0 – 10 volts Pump inlet pressure analog inpu t = 4 – 20 mA

JMP14 B 1 – 2 2 – 3 *

Pump outlet pressure a nalog input = 0 – 10 volts Pump outlet pressure a nalog input = 4 – 20 mA

JMP15 ** B 1 – 2 * 2 – 3

Mot or speed analog output = 0 – 1 0 volts Mot or speed analog output = 4 – 2 0 mA

JMP16 ** B 1 – 2 * 2 – 3

Pressure control analog ou tput = 0 – 1 0 volts Pressure control analog ou tput = 4 – 2 0 mA

APPENDIX C: CHANNEL BOARD JUMPER SETTINGSAPPENDIX C: CHANNEL BOARD JUMPER SETTINGSAPPENDIX C: CHANNEL BOARD JUMPER SETTINGSAPPENDIX C: CHANNEL BOARD JUMPER SETTINGSAPPENDIX C: CHANNEL BOARD JUMPER SETTINGS

* Indicates default (factory) settings.** 78814-01 Channel Cards do not support 4-20 mA outputs.

LN-9407-00.1


5353535353

APPENDIX D: INTERFAPPENDIX D: INTERFAPPENDIX D: INTERFAPPENDIX D: INTERFAPPENDIX D: INTERFACE BOARD JUMPER SETTINGSACE BOARD JUMPER SETTINGSACE BOARD JUMPER SETTINGSACE BOARD JUMPER SETTINGSACE BOARD JUMPER SETTINGS

* Indicates default factory settings.

Jumper Number

Position

Function

JMP1 Off * On

Backplane serial port setting for RS422 Backplane serial port setting for RS485

JMP2 1 – 2 * 2 – 3

Backplane serial port setting for RS232 Backplane serial port setting for RS422 or RS485

JMP3 1 – 2 * 2 – 3


JMP4 Off * On


JMP5 Off On *

Backplane serial port setting for RS422 or RS485 Backplane serial port setting for RS232

JMP6 Off * On

Backplane serial port setting for RS422 Backplane serial port setting for RS485

JMP7 Off On *

Disable Watchdog Timer Enable Watchdog Timer

JMP8 128K 512K *

On-board non-volatile memory size = 128K On-board non-volatile memory size = 512K

JMP9 1 – 2 * 2 – 3

Strobe Gun Inputs sink current Strobe Gun Inputs source current

JMP10 1 – 2 * 2 – 3

Job Number Inputs sink current Job Number Inputs source current

JMP11 Off On *

Disconnect CMOS memory battery Enable CMOS memory battery

LN-9407-00.1


5454545454

APPENDIX E: APPENDIX E: APPENDIX E: APPENDIX E: APPENDIX E: CHANNEL AND GUN I/O TERMINALSCHANNEL AND GUN I/O TERMINALSCHANNEL AND GUN I/O TERMINALSCHANNEL AND GUN I/O TERMINALSCHANNEL AND GUN I/O TERMINALS

Notes:1. Do not use more than 2 wires in each terminal or an unreliable connection will exist. If more than 2 connectionsare required, use an external terminal block or a butt splice.2. Do not supply 24 volts to the +24 terminals on this board! The +24 terminals on this board should only be usedto supply voltage to other terminals on this board that are to be pulled high.

LN-9407-00.1


5555555555

APPENDIX F: APPENDIX F: APPENDIX F: APPENDIX F: APPENDIX F: SYSTEM I/O TERMINALSSYSTEM I/O TERMINALSSYSTEM I/O TERMINALSSYSTEM I/O TERMINALSSYSTEM I/O TERMINALS

OLD SYSTEM I-O BOARDOLD SYSTEM I-O BOARDOLD SYSTEM I-O BOARDOLD SYSTEM I-O BOARDOLD SYSTEM I-O BOARD

NEW SYSTEM I-O BOARDNEW SYSTEM I-O BOARDNEW SYSTEM I-O BOARDNEW SYSTEM I-O BOARDNEW SYSTEM I-O BOARD

LN-9407-00.1


5656565656

APPENDIX G: CAAPPENDIX G: CAAPPENDIX G: CAAPPENDIX G: CAAPPENDIX G: CATTTTTALALALALALYSTYSTYSTYSTYST FLOW SENSOR FLOW SENSOR FLOW SENSOR FLOW SENSOR FLOW SENSOR

CACACACACATTTTTALALALALALYSTYSTYSTYSTYST FLOW FLOW FLOW FLOW FLOWSENSORSENSORSENSORSENSORSENSOR

DESCRIPTION ANDDESCRIPTION ANDDESCRIPTION ANDDESCRIPTION ANDDESCRIPTION ANDOPERAOPERAOPERAOPERAOPERATIONTIONTIONTIONTION

The FLOW MONITOR control system used todetect no-flow in the hardener fluid system consistsof three components, a sensor, the controlamplifier, and the analog output amplifier. Thesensor is a thermal shedding type that uses theprinciple of thermal conductivity. The temperaturecompensated sensing head is inserted into thefluid stream via a manifold and is heated up a fewdegrees higher than the medium. The controlamplifier provides all of the necessary electronicsto provide heater current, temperature comp-ensation, level adjustment for the sensor and a lowlevel analog output signal which is a function offlow. The third component is the analog outputamplifier which provides a 4-20ma control signalto the microprocessor on the channel board. Theoperation of the flow monitor system is as follows…The sensor is heated up a few degrees above theambient temperature of the fluid. If the fluid ismoving, the heat generated in the sensor isconducted away from the sensor head and thesensor is cooled. If the fluid is at rest or at a no-flowcondition, the temperature of the sensor headrises. Thermistors are used in the sensor to convertthe temperature into an electrical signal which is

processed by the control amplifier. The controlamplifier also compensates for changes in fluidtemperature at a rate of up to 15° C/min. Whenthere is flow, the analog output voltage increases,and when there is no flow, the analog outputvoltage decreases. The analog output voltage isthen fed into the analog output amplifier whichoutputs a 4-20ma signal that is used by the channelboard to determine flow status. The program in thechannel board determines whether there is flow orno-flow by checking the slope of the analog signaland by checking the programmable flow/no-flowlevels. The program also allows for the adjustmentof the flow-on and the no-flow levels via parametersin the user interface software. Also, to allow for thedelay in the thermal sensor signal, a programmabletime delay is available to prevent nuisance faults.

SPECIFICASPECIFICASPECIFICASPECIFICASPECIFICATIONSTIONSTIONSTIONSTIONS

Input Power Requirements: Input Power Requirements: Input Power Requirements: Input Power Requirements: Input Power Requirements:Voltage- +24vdc +/-10%Current - 80ma (maximum)

Ambient Temperature Range: Ambient Temperature Range: Ambient Temperature Range: Ambient Temperature Range: Ambient Temperature Range: 0 - 55° C

Compensated Fluid Compensated Fluid Compensated Fluid Compensated Fluid Compensated Fluid Temperature Range: Temperature Range: Temperature Range: Temperature Range: Temperature Range: -25 to 80° C

Minimum Flow Rate: Minimum Flow Rate: Minimum Flow Rate: Minimum Flow Rate: Minimum Flow Rate: 20cc’s/min

Operating Flow Rate Range: Operating Flow Rate Range: Operating Flow Rate Range: Operating Flow Rate Range: Operating Flow Rate Range: 20 - - - - - 600cc/min

Analog Output Signal: Analog Output Signal: Analog Output Signal: Analog Output Signal: Analog Output Signal: 4 - 20ma

Response Time: Response Time: Response Time: Response Time: Response Time: Flow Rate Dependent

Maximum Fluid Pressure: Maximum Fluid Pressure: Maximum Fluid Pressure: Maximum Fluid Pressure: Maximum Fluid Pressure: 200psi

Controls: Controls: Controls: Controls: Controls: (1) Zero Flow Adjust

LN-9407-00.1


5757575757

Since all catalysts are not the same and havediffering abilities to remove heat from this sensor,the sensor must be calibrated prior to use.

Setup and AdjustmentsSetup and AdjustmentsSetup and AdjustmentsSetup and AdjustmentsSetup and AdjustmentsRefer to the System Interconnect Diagrams in theMaintenance/Troubleshooting manual beforeproceeding with any of the following setup andadjustment procedures.

Access the Digital/Analog I/O screen on the UserInterface Screen of the RCS-2. Select the AnalogI/O option. On this screen, the current comingfrom the analog output amplifier can be monitored.

1. Fill the system to be monitored with the fluid tobe monitored (NOTE: YOU CANNOT USE AIRAS THE FLUID!)

2. Monitor the output current from analog outputamplifier (P/N: 22-1050) on the User InterfaceAnalog I/O Screen.

3. Let the fluid stand in the line (NO Fluid Flow) fora minimum of 60 seconds. (The longer you can letthe fluid stand, the better the accuracy andresponse time of the Flow Monitor System.)

4. Make sure the switch on the control amplifier (P/N: 22-1046) is set to position 1 (LIQUID).

5. Adjust the trim potentiometer on the controlamplifier until the output current displayed on theUser Interface Screen is equal to 4.80mA +/-0.10mA.

User Interface Parameter SetupUser Interface Parameter SetupUser Interface Parameter SetupUser Interface Parameter SetupUser Interface Parameter SetupThere are three parameters that must beprogrammed for this feature to work correctly.

Hardener Flow On – Hardener Flow On – Hardener Flow On – Hardener Flow On – Hardener Flow On – This is the level (inmilliamps) above which the hardener is consideredto be flowing.

Hardener No Flow -Hardener No Flow -Hardener No Flow -Hardener No Flow -Hardener No Flow - This is the level (in milliamps)below which the hardener is considered as notflowing.

(The Hardener Flow On parameter must alwaysbe greater than the Hardener No Flow parameter.)

Note that if the current being sensed is betweenthe Hardener No Flow nad the Hardener Flow Onsetpoint, as long as the flow is increasing, theprocessor will assume that hardener is flowing.If the flow being sensed is between these twovalues and is not changing or is decreasing, theprocessor will assume that there is no hardenerflow.

Hardener Sample Time – Hardener Sample Time – Hardener Sample Time – Hardener Sample Time – Hardener Sample Time – This is the time periodof no hardener flow that the hardener no flow timershould accumulate to before generating a fault.This time continues to accumulate as long as theprocessor sees no hardener flow regardless ofthe number of applicator triggers. The timer isreset every time the flow meets or exceeds thevalue programmed in for Hardener Flow On.

The initial setup for these parameters should beset to the following values: delay time = 4 seconds,no-flow = 6 mA, flow-on = 10 mA. After the zeroflow calibration has been done correctly, thesystem can now be programmed to fit theapplication. The delay time is used to preventnuisance hardener flow errors. To properly setthis time to minimize delays and prevent nuisanceerrors, the delay time should be set to a valuewhich is less than the minimum spray-on time ofthe system being measured. The delay time iscumulative to allow for short spray-on times usedin some applications. The smallest differencebetween the delay time and the minimum spray-ontime should be 100 mSec. Smaller values can beused, but more nuisance errors can occur. Ifvalues larger than the minimum spray-on time are

> If the current continues to vary afteryou adjust the pot, you have not waitedlong enough.


6. This completes the zero flow adjustment of thehardener no-flow detect system.

LN-9407-00.1


5858585858

programmed, hardener flow errors will be detectedbecause the delay time accumulates every timethe spray-on is turned on and off without detectinga valid current input level (i.e. positive slope at alevel above the value programmed for no-flow or avalue above the programmed flow-on level).

The no-flow and flow-on levels can now beprogrammed to fit the application. Current measuredat the output of the analog output amplifier providesinformation to the RCS-2 channel card. Program-ming specific values can speed up or slow downsystem response to given flow conditions.Programming the no-flow value as low as possible,will help minimize response time from a no-flow toflow-on condition, but if it is too low, fluid noisecould periodically cause indications of flow when,in reality, there is no flow.

Programming the flow-on value to the lowestpossible value will minimize response time to aflow-on to no-flow condition, but in this case fluidnoise could cause nuisance errors when there isactually flow. The best way to set up the no-flow/flow-on values is to begin with the default valuesindicated above. Monitor the output current fromthe Analog I/O Screen with the system operatingnormally. Set the flow-on value to about 1-2 mAbelow the minimum measured current duringnormal operation. (Note: Fluid must be flowing toproperly set this value.) To set the no-flow value,turn the hardener supply off. Monitor the outputcurrent from the analog output amplifier. The currentshould begin to decrease and steadily fall until itbegins to approach a level of approximately 4.8mA, (the no-flow zero reference value). Note: Inorder to prevent system shutdown, go to theConfigure Alarm setup screen on the User InterfaceScreen of the RCS-2 and temporarily program thesystem for no shutdown on hardener flow loss).This will allow the motor to continue to run andprovide a good indication of fluid noise at the no-flow condition. Observe the output current levelunder these conditions and program the no-flowlevel to approximately 0.5 mA above the peakcurrent level measured. Best system performancewill vary depending upon the system and setupaccuracy.

> Remember to reprogram the systemto shut down on Hardener Flow Lossafter completing this setup, if required.

C A U T I O NC A U T I O NC A U T I O NC A U T I O NC A U T I O N!!!!!

> The above should only be used as aguide. the final parameters for the Harden-er flow Monitoring system will vary with therequirements for each individual system,and they will be the final determining fac-tors of these parameters.


LN-9407-00.1


5959595959

APPENDIX H: FEAAPPENDIX H: FEAAPPENDIX H: FEAAPPENDIX H: FEAAPPENDIX H: FEATHERINGTHERINGTHERINGTHERINGTHERING

When a gun is configured as a manual mode gun,the operator has two possible ways of operatingthe system. When in manual mode, it is assumedthat handguns are being used.

Pressure Pot Mode: Pressure Pot Mode: Pressure Pot Mode: Pressure Pot Mode: Pressure Pot Mode: If a value greater than zero(0) is programmed in for the feather pressureparameter (on the Config. Job screen), the unitsimulates a pressure pot set to the programmedfeather pressure. That is, it controls the outboundpressure of the pumps such that the greaterpressure of the two (resin or catalyst) alwaysequals the programmed feather pressure.Therefore, within the flow limits of the pumps beingused and the ratio selected, the controller willcontinuously regulate the outbound pressure ofthe pumps, targeting the programmed featherpressure. In this mode, air flow switches are notrequired on the handguns as the system maintainsthe outlet pressure to the applicators regardlessas to whether or not it sees trigger signal inputs.(Note that air flow switches are still required if theauto-reset feature is used.) The feather PIDparameters may have to be adjusted to controlhow fast the pumps respond to changes in flow.This directly effects how close to the target featherpressure the actual outlet pressure is maintained.

Feather Set Mode:Feather Set Mode:Feather Set Mode:Feather Set Mode:Feather Set Mode: If a value of zero (0) isprogrammed as the feather pressure parameter(on the Config. Job screen), the unit operates infeather set mode. In this mode, a feather setpushbutton is required to program the featherpressure. This can be a normally open momentarypushbutton connected to the feather set discreteinput for the gun (see Appendix E) or, use thefeather set pushbutton on the optional RemoteOperator’s Panel (see Appendix I). Also requiredin this mode are air flow switches for each handgun.(It is not recommended that more than 2 handgunsbe fed from each fluid panel as it becomes verydifficult to control flow and pressure while morethan 2 handguns are being triggered and featheredsimultaneously.)

Operating the unit in feather set mode involves thefollowing steps:

1. Zero (0) psi must be programmed for thefeather pressure parameter under the Config. Jobscreen.

2. A desired flow rate for each handgun must beprogrammed for the parameter Target Flow, underthe Config. Job screen.

3. All handguns should be triggered simulta-neously and the triggers held wide open. (Air flowswitches must be connected to all handguns, inthis mode.)

4. Press and hold the feather set button to achievethe desired flow rate for the number of gunstriggered. Releasing the button records the featherpressure.

5. From then on, the operators can spray (andfeather) normally. If the controller can achieve thetarget flow rate with both guns triggered withoutexceeding the pressure recorded in step 4 above,it will do so. If, however, the recorded pressure isreached before it reaches the target flow rate (asif one or both painters are feathering), then theRCS-2 controller regulates the flow by targetingthe prerecorded outbound pressure. If only onegun is triggered, the controller tries to flow at thetarget flow rate for one gun, unless it reaches theprerecorded outbound pressure first, at whichtime it again controls flow by targeting theprerecorded outbound pressure.

LN-9407-00.1


6060606060

6. If the spraygun tips start to become plugged orsome other restriction occurs, causing the actualflow to fall significantly below the targeted flowrate, the operators can again trigger bothhandguns, push and hold the feather setpushbutton (until the target flow rate is achieved)then release the feather set pushbutton, and anew (higher) feather set pressure will be recorded.

Once again, the master channel feather pressurePID parameters may have to be adjusted to controlhow fast the pumps respond to a change in flow.This directly effects how close to the target featherpressure the actual outlet pressure is maintained.


LN-9407-00.1


6161616161

APPENDIX I: REMOTE OPERAAPPENDIX I: REMOTE OPERAAPPENDIX I: REMOTE OPERAAPPENDIX I: REMOTE OPERAAPPENDIX I: REMOTE OPERATTTTTOR'S POR'S POR'S POR'S POR'S PANELANELANELANELANEL

The Remote Operator’s Panel (shown above)operates in the following manner:

Color Select – Color Select – Color Select – Color Select – Color Select – This is an eleven position selectorswitch that allows the operator to select the nextcolor to be loaded. If the most counterclockwiseposition is selected (Solv.) and the Paint (Solvent)Fill button is pushed, the normal load sequenceoccurs and solvent is loaded into the fluid systemas if it is was a color.

Paint (Solvent) Fill/Filled – Paint (Solvent) Fill/Filled – Paint (Solvent) Fill/Filled – Paint (Solvent) Fill/Filled – Paint (Solvent) Fill/Filled – This is a greenilluminated pushbutton. When pushed, the paintload sequence runs (as programmed from the“Load” user interface screen). The green indicatorlamp flashes as the sequence is occurring andstays lit solid when the sequence has completed,indicating to the operator that the system is ready.

If there is already a color loaded (ie. one of thecolor valve outputs is already on) when this buttonis pushed, the system will execute a flushsequence, followed by a load sequence.

Purge/Purged – Purge/Purged – Purge/Purged – Purge/Purged – Purge/Purged – This is an amber illuminatedpushbutton. When pushed, a purge sequence isinitiated (as programmed from the “Purge” userinterface screen). While the purge sequence isoccurring, this indicator lamp flashes. It remainson solid when the purge sequence is complete,indicating to the operator that the purge is complete.This indicator will be turned off if a “Paint (Solvent)Fill sequence has been initiated or a color isloaded.

> If both the green Paint (Solvent) Fill/Filled lamp and the amber Purge/Purgedlamps are flashing simultaneously, thisindicates that no sequence has been down-loaded to the color change sequencersince the last time power was applied tothe system. This can be corrected byloading a job from the user interface screen.


LN-9407-00.1


6262626262

Horn – Horn – Horn – Horn – Horn – In the top center of the panel is a horn thatindicates when the RCS-2 controller has turnedon the “Spray Shutdown” output for the gun.

Total Flow – Total Flow – Total Flow – Total Flow – Total Flow – This is an LCD display that indicatesthe current flow rate out of the applicator (orapplicators, if multiple applicators are fed from onefluid panel). It operates from an analog outputsignal from the RCS-2 controller with 0 VDC being0 cc’s/min and 10 VDC scaled to be 2000 cc’s/min.

Flow Control – Flow Control – Flow Control – Flow Control – Flow Control – This is a potentiometer thatvaries the analog flow control voltage into theRCS-2 channel card from 0 volts DC to 10 voltsDC. Users can program what flow rate they wantfor both extremes by using the Min. Flow and Max.Flow parameters under the edit gun screen.

Faulted/Fault Reset – Faulted/Fault Reset – Faulted/Fault Reset – Faulted/Fault Reset – Faulted/Fault Reset – This is a red illuminatedpushbutton. The lamp will be illuminated any timea fault occurs in the RCS-2, whether that faultcauses a spray shutdown condition or not. Pushingthis button resets any fault that has caused aspray shutdown condition. It does not reset a non-fatal fault (one that is disabled in the “Config.Alarms” setup screen of the RCS-2). After resettinga fatal fault, the user must then push the Ready/Run pushbutton to put the gun back into run modeto resume spraying. Note that this lamp will flickerwhen the controller is folding back the outboundpressure of the pumps.

Ready/Run – Ready/Run – Ready/Run – Ready/Run – Ready/Run – This is a green illuminatedpushbutton. Pushing this button puts a gun intorun mode. When in run mode, the green lamp isilluminated. It is extinguished in ready, halted, orfaulted state.

Guns in Flush Box – Guns in Flush Box – Guns in Flush Box – Guns in Flush Box – Guns in Flush Box – These are two LED’s thatindicate when up to two sprayguns are in theirrespective flush boxes. A flush or load sequencewill not be allow to start until both of these indicatorsare illuminated. These LED’s are connected tofour pressure switches, which are actuated by thetwo flush boxes. (One indicates that the gun is inthe box and the other indicates that the flush boxis closed.) The signal from these pressure switchesalso feeds the Paint Fill and Purge pushbuttons toprevent color changes and purges from occurring

unless the guns are in their flush boxes and theboxes are closed. These pressure switchesshould be jumpered if gun flush boxes are not to beused. There are jumpers on the PC board insidethe panel to bypass these pressure switches.

Feather Reset – Feather Reset – Feather Reset – Feather Reset – Feather Reset – This is a simple pushbutton thatsends a Feather Reset signal back to the RCS-2control console.

Spray Test – Spray Test – Spray Test – Spray Test – Spray Test – This is a simple pushbutton thatsends a trigger signal back to the RCS-2 channelcard and also turns on the trigger solenoid to allowoperators to verify and test flow, etc. (A valid colormust be loaded for this button to work.)

Jumpers – Jumpers – Jumpers – Jumpers – Jumpers – In the lower right corner of the PCboard inside the panel there are four jumperslabeled: JMP1, JMP2, JMP3, and JMP4. If asingle gun flush box is being used, remove thejumper at position JMP1. If two gun flush boxesare being used, remove jumpers JMP1 and JMP2.JMP3 and JMP4 should always remain installed.

LN-9407-00.1


6363636363

APPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAYYYYYFFFFFAULAULAULAULAULTTTTT CODES (P CODES (P CODES (P CODES (P CODES (PARARARARARTTTTT 1) 1) 1) 1) 1)

LED DisplayLED DisplayLED DisplayLED DisplayLED Display DefinitionDefinitionDefinitionDefinitionDefinition Explanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible Causes

P FP FP FP FP F

LELELELELE

F EF EF EF EF E

E IE IE IE IE I

FLFLFLFLFL

OVOVOVOVOV

ECECECECEC

OCOCOCOCOC

MTMTMTMTMT

DTDTDTDTDT

Power Failure

Loss Enable

Following Error

Excessive Command Increment

Feedback Lost

Motor Power Over Voltage

Motor Power Clamp Excessive DutyCycleMotor Over-Current Fault

Motor Over-Temperature Fault

Drive Over-Temperature

This display indicates that the 120 VAC power supply tothe motor amplifier has been cycled (turned off and backon).This display indicates that the enable signal to the motoramplifier from the RCS-2 channel card is low or disabled.(This is normal when the unit is in the Ready or Haltedstate.)This display indicates that the motor amplifier has com-manded the motor to turn at a certain speed but was un-able to maintain that speed. This usually indicates a mo-tor, pump, or magnetic coupling that is bound up and notable to turn freely.This indicates that the motor amplifer was commandedby the RCS-2 channel card to turn faster than the motoris capable of turning. This typically indicates that im-proper parameters have been programmed into the RCS-2. Verify parameters such as pump size, calibration fac-tor, maximum pump speed, and maximum flow.This indicates that the motor amplifier is no longer receiv-ing feedback from the resolver mounted inside of the mo-tor enclosure. Check the two cables running from theback of the motor to the bottom of the motor amplifierpanel and the cables inside of the motor amplifier panelrunning from the motor amplifier to the bottom of thepanel.This indicates that the voltage being supplied to the mo-tor amplifier is excessive. Check the AC power supplyvoltage to the motor amplifer panel.

This indicates that the motor amplifier has exceeded theallowable current limit for the motor. This usually indi-cates a motor, pump, or magnetic coupling that is boundup and not able to turn freely.This indicates that the motor is running excessively hot.Look for binding of the motor magnetic coupling, orpump.This indicates that the driver circuitry in the motor ampli-fier has exceeded the allowable temperature for that cir-cuitry. This could indicate a failure in the motor amplifieritself, a failure in the motor, or a bound motor, pump, ormagnetic coupling.

GE FGE FGE FGE FGE FANUC AMPLIFIERANUC AMPLIFIERANUC AMPLIFIERANUC AMPLIFIERANUC AMPLIFIER

LN-9407-00.1


6464646464

APPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAYYYYYFFFFFAULAULAULAULAULTTTTT CODES (P CODES (P CODES (P CODES (P CODES (PARARARARARTTTTT 2) 2) 2) 2) 2)

DANAHER AMPLIFIERDANAHER AMPLIFIERDANAHER AMPLIFIERDANAHER AMPLIFIERDANAHER AMPLIFIERStatus LEDStatus LEDStatus LEDStatus LEDStatus LEDBlink CodeBlink CodeBlink CodeBlink CodeBlink Code Fault DescriptionFault DescriptionFault DescriptionFault DescriptionFault Description Explanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible Causes

ONONONONON

OFFOFFOFFOFFOFF

Fast BlinkFast BlinkFast BlinkFast BlinkFast Blink

11111

22222

33333

44444

55555

66666

No faults, power stage Enabled

Control power not applied orinsufficient control power applied

No faults, power stage Disabled

Not Assigned

Motor Over Temp

Motor temperature exceeds allowedlimit

Drive Over/Under Temp

Temperature of drive heatsink/chassis is outside of allowed limits

Drive I*t Too HighThe product of the drives outputcurrent multiplied by time hasexceeded allowed limits.

If current foldback is enabled, thedrive peak output current automati-cally reduces to 0.67% of DIpeakDIpeakDIpeakDIpeakDIpeak.If foldback is not enabled, the drivewill fault.

Motor I*I*t Too High

Motor current amplitude squaredmultiplied by time has exceedallowed limits

Optional Battery low

Optional fault used to indicate SFDbattery supply voltage is low

Normal opertion.

Loose or open circuit wiring of control power input. Lowinput voltage to control power supply.

Hardware or Software Enable inactive. To enable drive,apply hardware enable and set software enable.

High ambient temperature at motor.Insufficient motor heat sinking from motor mounting.Operating above the motor's continuous current rating.Motor temperature sensor failure or not connected.

High or low drive ambient temperature.Restriction of cooling air due to insufficient space aroundunit.Operating above the drive's continuous current rating.

Mechanically-jammed motor.Motion profile acceleration requires peak current for toolong of a time duration.Machine load on the motor increased by friction.Wiring problem between drive and motor yieldingimproper motion.Motor commutation error.Drive under-sized for application, friction, or load.

Mechanically-jammed motor.Motion profile acceleration requires peak current for toolong 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-9407-00.1


6565656565

APPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAYYYYY F F F F FAULAULAULAULAULTTTTT CODES CODES CODES CODES CODES(P(P(P(P(PARARARARARTTTTT 2) ( 2) ( 2) ( 2) ( 2) (ContinuedContinuedContinuedContinuedContinued)))))


77777

88888

99999

1010101010

1111111111

1212121212

1313131313

1414141414

Bus Over Voltage - Self Resetting

The BUS voltage has exceededthe upper threshold limit

Bus Under Voltage - Self Resetting

S200 DC drive fault only

BUS voltage is below specified 20VDC minimum

Motor I-I or I-n Short

Line-to-Line, Line-to-Neutral, orLine-to-PE short on the motorouput causing an instataneousover current

Output Over Current

Hall Fault

Valid only when drive is set to 6Step (Hall feedback) operation

SFD Configuration Error

J3 FB +5V Short

Excessive current drain on SFD +5supply output

SFD Motor Data Error

Motor data in SFD is outside drivelimits or is inconsistent

AC Line voltage (AC unit) or DC bus power supplyvoltage (DC unit) is too high.Regenative energy during deceleration is cusing the BUSto rise:On AC Drives add regen resistor.On S200 DC input drives external BUS capacitor is toosmall; add capacitance.

On S200 DC input drives:BUS voltage is too low.BUS voltage is pulled down during high acceleration orloading.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 sheetspecification causing excessive motor line-to-earthground/neutral capacitance.Internal motor winding short circuit.Motor L too small.KIPKIPKIPKIPKIP set too large.

Insufficient motor inductanceKIPKIPKIPKIPKIP or KII KII KII KII KII improperly set causing excessive outputcurrent 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 setupcalculation yielded a desired parameter value outsidevalid range.Incorrect/inconsistent motor data loaded into the SFD.

LN-9407-00.1


6666666666

APPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTAPPENDIX J: MOTOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAOR AMPLIFIER LED DISPLAYYYYY F F F F FAULAULAULAULAULTTTTT CODES CODES CODES CODES CODES(P(P(P(P(PARARARARARTTTTT 2) (C 2) (C 2) (C 2) (C 2) (Continuedontinuedontinuedontinuedontinued)))))


1515151515

1616161616

1717171717

1818181818

1919191919

2020202020

SFD Sensor Failure

SFD UART Error

SFD Communication Error

Option Card Watch Dog Time Out

Position Error Too Large

Option Card Fault

Internal SFD failure.Excessive electrical noise in the drive environmentcausing communications interference.

Internal SFD failure.

Feedback cable not connected at the drive or at themotor.Feedback cable shield not connected.Defective feedback cable.Internal SFD failure.Excessive electrical noise in the drive environmentcausing communications interference.

Communication error between option card and mainboard.

Check ExtFaultsExtFaultsExtFaultsExtFaultsExtFaults:ExtFaultsExtFaultsExtFaultsExtFaultsExtFaults = Step size over flow meansGearOut/GearIn GearOut/GearIn GearOut/GearIn GearOut/GearIn GearOut/GearIn is too large.ExtFaultsExtFaultsExtFaultsExtFaultsExtFaults = Position error over flow means that thefollowing error, = PosErr= PosErr= PosErr= PosErr= PosErr, has exceeded ±128 revs.Check if the motor is stalling or if the commanded speedis higher than the motor can achieve at the present busvoltage.

Check ExtFaultsExtFaultsExtFaultsExtFaultsExtFaults:If ExtFaultsExtFaultsExtFaultsExtFaultsExtFaults is AuxFBFaultAuxFBFaultAuxFBFaultAuxFBFaultAuxFBFault, then the AusFB device isin error.Check the AuxFB faults: AuxFBEnDatFlt,AuxFBPTCFit, or AuxFBSCDFlt.Check to make sure the the drive is set up for the correctfeedback device and that the device is functioningcorrectly. If ExtFaultsExtFaultsExtFaultsExtFaultsExtFaults is "No Extended Fault", then thiswas a fault induced by the controller, such as SynqLost.

LN-9407-00.1


6767676767

APPENDIX K: ERROR CODESAPPENDIX K: ERROR CODESAPPENDIX K: ERROR CODESAPPENDIX K: ERROR CODESAPPENDIX K: ERROR CODES

ErrorErrorErrorErrorErrorNameNameNameNameName DescriptionDescriptionDescriptionDescriptionDescription Explanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible CausesExplanation and/or Possible Causes

Input UnderInput UnderInput UnderInput UnderInput UnderPressurePressurePressurePressurePressure

Input OverInput OverInput OverInput OverInput OverPressurePressurePressurePressurePressure

OutputOutputOutputOutputOutputUnderUnderUnderUnderUnderPressurePressurePressurePressurePressure

OutputOutputOutputOutputOutputOverOverOverOverOverPressurePressurePressurePressurePressure

Flow RateFlow RateFlow RateFlow RateFlow RateOut ofOut ofOut ofOut ofOut ofToleranceToleranceToleranceToleranceTolerance

HardenerHardenerHardenerHardenerHardenerFlow LossFlow LossFlow LossFlow LossFlow Loss

Pump inlet pressure is below theMinimum Pressure value specified inthe Channel Configuration

Pump inlet pressure is above theMaximum Pressure value specifiedin the Channel configuration.

Pump outlet pressure is below theMinimum Pressure value specified inthe Channel Configuration

Pump outlet pressure is above theMaximum Pressure value specifiedin the Channel Configuration

The difference between thecommanded flow rate (RPM) of thepump and the actual flow ratemeasured from the feedback signalexceeds +/- 2 times the Flow Rate/Ratio Tolerance Percentage valuespecified in the Gun Configuration

The electrical current from theHardener Flow sensor is less than1 milliamp

1. No material available to pump inlet.2. Material supply pressure is too low.3. Loss of supply air to the E/P transducer that

controls the pump inlet pressure.4. Loss of electrical supply or control signal to

the E/P transducer that controls the pumpinlet pressure.

5. Failure of the E/P transducer that controlsthe pump inlet pressure.

6. Failure of the pressure regulator thatcontrols the pump inlet pressure.

7. Failure of the pump inlet pressure sensor.8. Minimum Inlet Pressure value specified in

the Channel Configuration is too high.



3. Maximum Inlet Pressure value specified inthe Channel Configuration is too low.

1. Pump is not turning.2. Material is not available at pump inlet.3. Failure of pump outlet pressure sensor.4. Minimum Outlet Pressure value specified in

the Channel Configuation is too high.

1. Restriction in the fluid line.2. For Autmatic guns, failure of applicator

trigger valve.3. Maximum Outlet pressure value specified in

the Channel Configuration is too low.

1. Loss of feedback signal from motor amplifieror flow meter.

2. Incorrect Calibration Factor in ChannelConfiguration.

1. There is no hardener flow due to the pumpnot operating or an obstruction in thehardener fluid line.

2. Electrical connection problems.3. Failure of Hardener Flow sensor.

SourceSourceSourceSourceSource

ChannelCard

ChannelCard

ChannelCard

ChannelCard

ChannelCard

ChannelCard

LN-9407-00.1


6868686868

APPENDIX K: ERROR CODES APPENDIX K: ERROR CODES APPENDIX K: ERROR CODES APPENDIX K: ERROR CODES APPENDIX K: ERROR CODES (Continued)(Continued)(Continued)(Continued)(Continued)


PressurePressurePressurePressurePressurePot EmptyPot EmptyPot EmptyPot EmptyPot Empty

InletInletInletInletInletPressurePressurePressurePressurePressureLossLossLossLossLoss

OutletOutletOutletOutletOutletPressurePressurePressurePressurePressureLossLossLossLossLoss

AnalogAnalogAnalogAnalogAnalogRemoteRemoteRemoteRemoteRemoteLossLossLossLossLoss

Ratio OutRatio OutRatio OutRatio OutRatio Outo fo fo fo fo fToleranceToleranceToleranceToleranceTolerance

MotorMotorMotorMotorMotorAmplifierAmplifierAmplifierAmplifierAmplifierFaultFaultFaultFaultFault

AnalogAnalogAnalogAnalogAnalogFeatherFeatherFeatherFeatherFeatherLossLossLossLossLoss

AnalogAnalogAnalogAnalogAnalogSpareSpareSpareSpareSpareLossLossLossLossLoss

FoldbackFoldbackFoldbackFoldbackFoldbackPressurePressurePressurePressurePressureReachedReachedReachedReachedReached

The system has determined thepressure pot is empty for therespective channel

The electrical current from the PumpInletPressure Sensor is less than 1milliamp

The electrical current from the PumpOutletPressure sensor is less than 1milliamp

The electrical current from theRemote Analog Setpoint source isless than 1 milliamp

The difference between the desiredratio and the actual ratio, expressedas a percentage error, exceeds theFlow Rate/Ratio Tolerance Percent-age value specified in the GunConfiguration.

The motor amplifier has detected afault condition.

The electrical current from theFeather pressure sensor is less than1 milliamp

The electrical current from the SpareAnalog Input sensor is less than 1milliamp

The Pump Outlet pressure hasexceeded the Foldback Pressurevalue specified in the SystemConfiguration

1. The value entered for the pressure potCapacity in the Job Configuration isIncorrect.

2. The operator neglected to reset thePressure Pot.Capacity when it was last filled.

3. Pressure Pot is empty.

1. Electrical connection problems.2. Failure of Pump Inlet Pressure sensor.

1. Electrical connection problems.2. Failure of Pump Outlet Pressure sensor.

1. Electrical connection problems.2. The Remote Analog Setpoint source is

configured for voltage instead of currentloop.

1. Loss of feedback signal from motor amplifieror flow meter.

2. Incorrect Calibration Factor in ChannelConfiguration.

3. One or both channel is unable to deliver thecorrect flow rate due to restriction in the fluidline, lack of material.

1. Reference the motor amplifier diagnostics todetermine the cause of the fault.

1. Electrical connection problems.2. Failure of Feather Pressure sensor.

1. Electrical connection problems.2. Failure of Spare Analog input sensor.

1. This error is normal when operating in FastFill or Channel Fill mode.

2. For Automatic guns, restriction in the fluidline.

3. For Automatic guns, failure of applicatortrigger valve.


ChannelChannelChannelChannelChannelCardCardCardCardCard









LN-9407-00.1


6969696969



Pot LifePot LifePot LifePot LifePot LifeExpiredExpiredExpiredExpiredExpired

SystemSystemSystemSystemSystemOverOverOverOverOverPressurePressurePressurePressurePressure

ChannelChannelChannelChannelChannelCardCardCardCardCardParameterParameterParameterParameterParameterFaultFaultFaultFaultFault

ChannelChannelChannelChannelChannelCard SPICard SPICard SPICard SPICard SPIFaultFaultFaultFaultFault

ChannelChannelChannelChannelChannelCardCardCardCardCardInternalInternalInternalInternalInternalFaultFaultFaultFaultFault

Mixed material in the applicator fluidline has remained beyond the PotLife Time specified in the JobConfiguration.

Either the Pump Outlet or Inlet pres-sure exceeded the Over-PressureLimit specified in the SystemConfiguration.

Invalid parameter entered in eitherthe Channel or Job Configuration.

No communication via the SerialPeripheral Interface (SPI) bus hasoccurred between the Interface Cardand Channel Card for more than onesecond.

The timer interrupt service routine isunable to execute the required firm-ware logic in the time between timeinterrupts.

1. Mixed material has remained in theapplicator fluid line beyond the Pot Life Timespecified in the Job Configuration.

2. The Flow Rate Setpoint specified in the JobConfiguration, or via the Remote AnalogSetpoint, or via Remote I/O, is not highenough to move the Mixed Volume specifiedin the Gun Configuration during the Pot LifeTime specified in the Job Configuration.



3. Restriction in the fluid line.4. For Automatic guns, failure of applicator

trigger valve.5. Over-Pressure Limit value specified in the

System Configuration is too low.

1. Hardener No Flow value specified in theSlave Channel Configuration is less than 4.0milliamps.

2. Hardener Flow On value specified in theSlave Channel Configuration is greater than20.0 milliamps.

3. Hardener No Flow value specified in theSlave Channel Configuration is greater thanHardener Flow On value specified in theSlave Channel Configuration.

4. Any Minimum Pressure or MaximumPressure value specified in the ChannelConfiguration or Feather Pressure specifiedin the Job Configuration exceeds the OverPressure Limit value specified in theSystem Configuration.

1. Interface Card is no longer functioning.2. Failure of the mother board (backplane).3. A firmware bug is preventing service of the

SPI bus communications.

1. A firmware bug is preventing completion ofrequired logic in the time between timer interrupts.







LN-9407-00.1


7070707070


BattteryBattteryBattteryBattteryBattteryLowLowLowLowLow

No slavesNo slavesNo slavesNo slavesNo slavesPresentPresentPresentPresentPresent

InterfaceInterfaceInterfaceInterfaceInterfaceSPI FaultSPI FaultSPI FaultSPI FaultSPI Fault

NetworkNetworkNetworkNetworkNetworkErrorErrorErrorErrorErrorXXXXXXXXXXXXXXXXXXXXXXXXX

Opto-22Opto-22Opto-22Opto-22Opto-22FailureFailureFailureFailureFailure

The battery that maintains the dataparameters is below the minimumoperating voltage.

On power up, the Interface Cardcould not communicate with any ofthe four (4) possible Channel Cards,referred to as slaves on the SerialPeripheral Interface (SPI) bus.

The Interface Card detected an errorwhile attempting to communicatewith a Channel Card via the SerialPeripheral Interface (SPI) bus.

The User - Interface Computer is notable to communicate with theinterface card.

The User - Interface Computer is notable to communicate with the colorchange sequencer brain.

1. The power to the Interface Card may havebeen off for too long resulting in prematurefailure of the battery.

1. There are no Channel Cards inserted intothe card rack and mother board (backplane).

2. The SPI bus device on the Interface Cardmay not be functioning.

3. One of the SPI bus devices on a ChannelCard may not be functioning in such a wayas to prevent communications by any otherChannel Card.

1. This error may occur when the system isfirst powered up and may be ignored.

1. Check for power on the rack (E-Stop buttonout)?

2. Check all Ethernet cables, switches, etc.

1. Check for power on the motor amp panel.2. Check all Ethernet cables, switches, etc.


InterfaceInterfaceInterfaceInterfaceInterfaceCardCardCardCardCard



User -User -User -User -User -InterfaceInterfaceInterfaceInterfaceInterfaceComputerComputerComputerComputerComputer

User -User -User -User -User -InterfaceInterfaceInterfaceInterfaceInterfaceComputerComputerComputerComputerComputer


LN-9407-00.1


7171717171

A new feature has been added to the RCS-2software called “Pushout”. This feature allows acustomer that uses dual purge applicators to usetwo resin pumps that share a common catalystpump and pushout the resin with solvent on oneside of the dual purge applicator while loading theother side of the applicator with the next materialto be sprayed.

The system employs a small relay panel thatswitches the command signals for the catalystmotor drive between two slave channels in theRCS-2 control console. (Contact ITW Ransburgfor design details for this relay panel.)

The process steps to implement this feature areoutlined below:

1. Assume the applicator is running 2 componentmaterial through one side of a dual purge applicatorand that material is being controlled by channels1 and 2 of the RCS-2 where channel 1 is the resinand channel 2 is the catalyst.

2. As the last part, buck, rack, etc. approaches therobot for the presently running color, either thePLC or the robot sends a “Pushout” signal to theRCS-2. At that instant, the RCS-2 will immediatelyturn off the catalyst pump and speed up the resinpump to maintain the target flow rate that wasbeing sprayed prior to the initiation of the pushoutsignal. (Note that this pushout signal is amaintained signal.)

3. Simultaneous with the pushout signal beingturned on, the PLC or robot will turn off the colorvalve and turn on the solvent valve on the resincolor valve stack connected to the first resinpump. Depending on how the catalyst is controlled,it may be necessary to also switch off the catalystvalve or at least change its direction. Note that notall pumps are capable of accurately dispensingsolvent (because of its low viscosity). It is up tothe user to ascertain if the pump they are using isaccurate enough when metering solvent tomaintain a proper film builds on their parts.

APPENDIX L: PUSHOUTAPPENDIX L: PUSHOUTAPPENDIX L: PUSHOUTAPPENDIX L: PUSHOUTAPPENDIX L: PUSHOUT

4. The RCS-2 will continue to deliver fluid out of thefirst dual purge side until the volume programmedin for mixed volume has been sprayed and thenthat gun (in this case Gun #1) will automatically behalted (taken out of run mode). This state will berecognized by the PLC or robot when the Runoutput from the RCS-2 turns off.

5. The PLC or robot must then energize a seriesof relays in the relay panel which switches thesignals connected between the catalyst motordrive and the channel card from channel 2 tochannel 4.

6. While the first dual purge side is being pushedout, gun #2 (configured as channels 3 and 4) canbegin to load dual component material, using theresin pump connected to channel 3 and the catalystpump that is now controlled by channel 4. (Singlecomponent material can also be loaded by usingthe proper 1k ratio programmed in the jobparameters.)

7. As the applicator continues to spray dualcomponent material out of the second side, thefirst side can be flushed using A Fill, solvent/airchops, pump bypass signals, etc. Note: Thepushout signal must be asserted with the A Fillsignal or the software will attempt to enable thechannel B motor drive. (This is done to preventbackflow of resin in the catalyst line on 2kconfigured guns.)

8. When the last part approaches the robot for thepresently running color occurs again, theprocedure repeats for the second side of the dualpurge applicator (see step 2, above) with theexception of in step 5, the relays are de-energizedto reconnect the catalyst motor drive to channel 2.

LN-9407-00.1


7272727272

A new feature has been added to the RCS-2software package that allows the user to monitortrigger on and off times, the volume sprayed induring each trigger on time, and the status of fourdiscrete (digital) inputs to the RCS-2.

The option is accessed by selecting Function F10(Trigger Log) from the main screen of the User-Interface Software. When you open the TriggerLog display, a screen similar to this will bedisplayed (although there will be no data present).

APPENDIX M: TRIGGER LOGAPPENDIX M: TRIGGER LOGAPPENDIX M: TRIGGER LOGAPPENDIX M: TRIGGER LOGAPPENDIX M: TRIGGER LOG

There will be a START LOGGING function buttondisplayed that will start logging trigger data as itoccurs. (This button changes to a Stop Loggingbutton when logging begins.) New data will beentered on the top line and the older data pusheddown as new data arrives. This data is live, as itoccurs. Note that the very first trigger time (OnDwell) that occurs after the Start Logging button ispushed will not be displayed. This is because thesoftware does not start timing until the first on to offtransition occurs as the Off Dwell time is alwayscaptured first.

Scrolling down to examine data that has scrolledoff of the bottom of the screen is a problem whiledata is being captured because every time a newtrigger event occurs, the scroll bar will return to thetop, newest, entry. (This is controlled externallyby the Windows operating system.) Once the

logging is stopped with the STOP LOGGINGfunction button, the user may easily scroll down tolook at the older events. There is also a SAVE toFILE function button to create a CSV file of thelogged events using Excel, or any otherspreadsheet program capable of displaying CSVfiles.

The first column of data is the date that the triggeroccurred (obtained from the real time clock in thePC running the User-Interface Software.)

The second column of data is the time that thetrigger occurred (obtained from the real time clockin the PC running the User-Interface Software.)

The third column shows the amount of time (inseconds) that the trigger signal(s) remained in theoff state. (Trigger Off Condition (Off Dwell) =Channel A Triggers 1 through 4 must all be off.)

The fourth column shows the amount of time (inseconds) that the trigger(s) were energized (on).(Trigger On Condition (On Dwell) = Any timeChannel A receives an trigger input signal. Thiscan be any of the 4 trigger inputs for channel A.)

The Off Dwell Time is the time from previousevent’s trigger off to the new event’s trigger on, theOn Dwell Time is the time from this event’s triggeron to this event’s trigger off.

The fifth column indicates what job number wasrunning in the RCS-2 during this trigger event.

The sixth column shows the status of four binaryflags (digital inputs) at the start of this triggerevent. The four trigger inputs for channel B are notrequired for dual component guns and so aremonitored and displayed on the Trigger Log screento allow users to use them as flags. (Flags aremarkers in time to indicate when certain eventsoccur.)

LN-9407-00.1


7373737373

Flags “wxyz” are displayed as four binary bits0 = off, or 1 = on:

w = Channel B Trigger Input 4x = Channel B Trigger Input 3y = Channel B Trigger Input 2z = Channel B Trigger Input 1

Columns 7, 8, and 9 indicate the volume of resin,catalyst, and the total, respectively during thattrigger on event.

APPENDIX M: TRIGGER LOG (APPENDIX M: TRIGGER LOG (APPENDIX M: TRIGGER LOG (APPENDIX M: TRIGGER LOG (APPENDIX M: TRIGGER LOG (Continued)Continued)Continued)Continued)Continued)


LN-9407-00.1


7474747474

There are many ways that the accuracy of theRCS-2 system can be improved. This articlepresents three things that can and should beexamined if it is necessary to improve the accuracyof the machine.

Differential Pressure Control:Differential Pressure Control:Differential Pressure Control:Differential Pressure Control:Differential Pressure Control:One of the first things that should be examined isthe differential pressure across the pumps. It hasbeen found that by keeping this differential pressureto a minimum (5 psi or less), the pumps act moreas metering devices than pumps and this allowsthem to be extremely accurate. If the inlet pressureis too high, the material will tend to “blow by” thepump gears (slippage) and more material thandesired will pass through the pump If the inletpressure is too low, the pump may be starved and“cavitate” thus delivering too low of a volume ofmaterial. (Cavitation is rarely a problem as long asthe supply tubing is of adequate size.) Thesoftware in the RCS-2 is designed to automaticallycontrol this differential pressure as long aspressure transducers are installed at both the inletand outlet of the pumps and pilot-operated fluidregulators (such as the ITW Ransburg DR-1) areprovided on the inlets of the pumps. (The air pilotsmust be controlled by the voltage to pressuretransducers in the RCS-2 motor amplifier panel.)Since the outbound pressure of the pumps variesbased on fluid flow rate, fluid viscosity, hoselengths, hose diameters, applicator orifices, etc.the inlet pressure must be dynamic, as well. Notethat slippage is rarely a problem if the viscosity ofthe material is 25 cps or greater and cavitationissues can be minimized by insuring that the fluiddelivery tubing is of adequate size. Inlet fluidregulators are seldom required when supplyingfluid from pressure pots.

Pump Volume per Revolution and FlowPump Volume per Revolution and FlowPump Volume per Revolution and FlowPump Volume per Revolution and FlowPump Volume per Revolution and FlowRate:Rate:Rate:Rate:Rate:Note that the channel cards in the RCS-2 do notperform closed loop control of the motor RPMbased on a comparison of the desired RPM andthe speed feedback from the motor amplifier. The

APPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFTHE RCS-2THE RCS-2THE RCS-2THE RCS-2THE RCS-2

channel card commands the motor amplifier tospin the motor at the desired RPM and the motoramplifier has its own closed loop control with themotor. If the motor is not able to run at the desiredRPM, the motor amplifier generates a fault, whichis then fed back to the RCS-2 channel card. TheRCS-2 channel card does confirm that the motoris running at the desired RPM (within the toleranceprogrammed on the Configure Gun screen) but itdoes not try to compensate for over or underspeed conditions by modifying the analog signalto the motor amplifier.

On the Configure Channel screen of the RCS-2user-interface software there is a value namedPump Size. It is expressed in cc’s/revolution ofthe pump. This value is normally obtained fromthe pump manufacturer and is accurate enough inalmost all applications. There are cases, however,(especially after a pump has been used for quitesome time) when accuracy can be improved bymodifying this value slightly. The way that theRCS-2 channel card determines how fast to spinthe pump is based simply on two values, the targetflow rate of the material and the value entered forPump Size on the Configure Channel screen. Forexample, if the pump is programmed as a 10 cc/rev. pump and the desired flow rate is 300 cc’s/min, the software can easily determine that it hasto run the pump at 30 RPM. Since the motoramplifier has been programmed to spin at 0 RPMwith a 0 volt input and at 150 RPM with a 10 voltinput, the software can then determine it mustsend exactly 2.000 volts to the motor amplifier toobtain the desired 30 RPM. However, because ofvery minor inaccuracies in the pump, the analogoutput of the channel card, the analog input of themotor amplifier, cable and connector resistances,etc. the desired 300 cc’s/min could be off slightly.By making very minor adjustments to the PumpSize value on the Configure Channel screen,these minor variations can be accounted for andthe channel’s accuracy improved significantly.

LN-9407-00.1


7575757575

APPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFAPPENDIX N: IMPROVING THE ACCURACY OFTHE RCS-2 (THE RCS-2 (THE RCS-2 (THE RCS-2 (THE RCS-2 (Continued)Continued)Continued)Continued)Continued)

Calibration of the pumps can be performed in thefollowing manner: Program the RCS-2 controllerto flow at some fixed value in the middle of therange of flows expected. That is, if the range offlow rates of the pump during normal operation isexpected to be from 100 cc’s/min to 500 cc’s/min,set the target flow rate to 300 cc’s/min. Flowmaterial for a significant amount of time (we suggesta minimum of 2 minutes) into a beaker and measurethe volume. It is highly recommended that thematerial be weighed as opposed to measured forincreased accuracy.1 If the flow rate multiplied bythe time results in more material than was actuallyobtained in the flow test, than the Pump Sizeprogrammed in the Configure Channel screen istoo large. Try reducing the value by the samepercentage that the volume exceeded the expectedvolume and try the test again. If the actual volumeof material obtained was greater than thecalculated value, try increasing the Pump Sizevalue by that percentage and try the test again.Repeat this several times until acceptable volumesresult.

Example:Pump Size = 5.5 cc’s/revProgrammed flow rate = 300 cc’s/minFlow time = 3 minutesCalculated volume = 3 minutes x 300 cc’s/min =900 cc’sActual volume collected = 887 cc’s

887 cc’s 900 cc’s5.5 cc/rev x New PS

Therefore, New PS = 900 x 5.5 = 5.58 cc/rev5.58 cc/rev5.58 cc/rev5.58 cc/rev5.58 cc/rev 887

Put 5.58 cc’s/rev in for the Pump Size on theConfigure Channel screen, push Send to RCS-2and retest.

Pump Pulses per Liter and Totalization:Pump Pulses per Liter and Totalization:Pump Pulses per Liter and Totalization:Pump Pulses per Liter and Totalization:Pump Pulses per Liter and Totalization:On the Configure Channel screen of the user-interface software there is a value named PumpPulses per Liter. All of the RCS-2 flow rate andvolume displays are based on this value. Themotor amplifier sends 500 pulses per revolutionback to the RCS-2 channel card no matter whatRPM it is running at. Therefore, it is easy tocalculate a volume of material per pulse or anumber of pulses per volume (in this case, perliter). However, by adjusting the Pump Size value(as shown above) the pulses per liter value willalso be affected and should be adjusted. Thereare two ways this can be accomplished:Mathematically or experimentally.

Mathematically: Simply divide 500,000 (1000 cc’s/liter x 500 pulses/rev) by the new pump size. Inthe case above, 500000/5.58 = 89605 pulses/89605 pulses/89605 pulses/89605 pulses/89605 pulses/literliterliterliterliter.

Experimentally: Zero the volume on one of thetotalizer values on the Flow Totals screen of theRCS-2 then flow a random volume of material intoa beaker and measure the actual volume. (Onceagain, it is highly recommended that the volumebe determined by weight as opposed to trying tomeasure it based on the fluid level in the beaker.1)Compare the actual volume with the volumerecorded on the RCS-2 Totalization screen. If theactual volume obtained was greater than whatwas displayed on the totalization screen, then thePump Pulses per Liter value is too small. If theactual volume obtained was less than thatdisplayed on the totalization screen, the PumpPulses per Liter is too large. Modify the value upor down as required by the percentage they differand retest.

LN-9407-00.1


7676767676

Enter the new value for the Pump Pulses per Litervalue on the Configure Channel screen, send it tothe RCS-2 and retest. Repeat the test severaltimes until the accuracy required is obtained andthe values (actual volume vs. displayed volume)are repeatedly very close to one another.

1 Note: In order to convert the weighed material toa volume, the specific weight of the material mustbe known. (Specific weight is defined as theweight of the material per unit volume.) This isnormally available from the manufacturer of thematerial. If this information is unavailable or thematerial has been reduced, the specific weight willneed to be experimentally determined. Obtain avery accurate measuring device such as a syringe,pipette, 10 cc graduated cylinder, etc. and weighthe container prior to filling it with material. Thenput exactly 10 cc’s of material in the container andreweigh the container. Subtract the weight of theempty container from the weight of the full one anddivide that difference by 10. The resulting value isthe material’s weight per cc. This value can thenbe used to very accurately determine the volumeof material collected in the above tests.

Example:300 cc’s (totalization screen value) X 305 cc’s (actual volume collected)90909 (current pulse per liter value) New Pulse/Liter value

Therefore, New Pulse/Liter Value = 305 X 90909 = 92424 pulses/liter92424 pulses/liter92424 pulses/liter92424 pulses/liter92424 pulses/liter 300

LN-9407-00.1

MANUALMANUALMANUALMANUALMANUAL CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMARYYYYYThis manual was published to supercede Service Service Service Service ServiceManual LN-9407-00, RCS-2 User ManualManual LN-9407-00, RCS-2 User ManualManual LN-9407-00, RCS-2 User ManualManual LN-9407-00, RCS-2 User ManualManual LN-9407-00, RCS-2 User Manual tomake the following changes:

1. Replaced ""Front Cover" figure.

2. Added "Service Manual Price: €40.00 (Euro)"to "Front and Back Covers".

Introduction SectionIntroduction SectionIntroduction SectionIntroduction SectionIntroduction Section3. Revised "Features - removed "Device Net I/OCapabilities (optional), Ethernet I/P interface allowsinterfacing to all Ethernet I/P enabled controllers,and Floppy disk drive, CD Rom, and 10/100 basedEthernet ports".

4. Revised "Specifications - Fluid Inlet Pressure:Ø to 200 psi".

5. Added "General Description - Main ControlConsole - The Interface card houses a Rabbit2000® embedded processor. This board performsthe following functions - Has an Ethernet port usedto communicate with the user interface PC and thecolor change sequencer" and removed"Communicates to Ethernet I/P enabled externalPLC's, computers, etc. via its Ethernet Port".

6. Removed "General Description - Fluid Panels- "This is done through two independent cables,one for the motor drive voltages and one for theresolver feedback signals".

7. Added "General Description - Fluid Panels -Note - This valve should not be used while loading2k materials as improper ratios will result".

8. Revised "Configurable Operating Parameters- System Parameters, Channel Parameters,andAlarm Configuration Parameters".

9. New "Figure 1 - Control Console BlockDiagram" and "Figure 2 - Motor Amplifier PanelBlock Diagram", and "Figure 3 - Fluid PanelSchematic".

Installation SectionInstallation SectionInstallation SectionInstallation SectionInstallation Section10. New "Figure 4 - Stand Alone Unit, Figure 5 -Motor Amplifier Panel, Figure 6 - Control PanelAssembly, Figure 7 - Fluid Panel Assembly, Figure8 - Control Panel Input Power, and Figure 9 - MotorAmplifier Panel Input Power".

11. Added "Discrete Channel and Gun Inputs -new Figure 10 - Gun I/O Sourcing/Sinking".

12. Added "Discrete Channel and Gun Inputs -Note: Times stated above are for discrete digitalinputs only. When interfacing using Allen Bradley'sRemove I/O (aka RIO), these times may varysignificantly. (Refer to the RCS-2 RIO InterfaceProgramer's Manual for more details.)"

13. Added "Discrete Channel and Gun Inputs -Push Out".

14. Revised "Analog Inputs - An analog input isjumper selectable to be 0 to 10 VDC or 4-20 mAwith the exception of the hardener flow sensorwhich is fixed at 4-20 mA".

15. Added "System Inputs and Outputs - newFigure 11 - System I/O Sourcing/Sinking".

16. Revised "Table 1 - Odd Number ChannelConnections - Signal Name - Motor Amp Enableand Push Out", "Table 2 - Even Numer ChannelConnections - Signal Name - Motor Amp Enableand Push Out", and "Table 3 - System I/OConnections - Terminal Lable changed - should beCN4012-XX".

Operation SectionOperation SectionOperation SectionOperation SectionOperation Section17. Added "Note -Note that the interface cardstores the previous fault information in battery-backed memory but it does not contain a real-timeclock. Therefore, the date and time of the faultsare provided by the user-interface PC. If the unitis powered up with faults still stored in the ErrorLog, the date and time of those faults on the ErrorLog Screen will either be left blank or may berandom values".

LN-9407-00.1

18. Revised "Configurable Operating Parameters- System Parameters - added "Interface CardName and User Program IP Port", Gun Parameters- added Default Job Number, Channel Parameters- Inlet Pressure Sensor Enable/Disable - removedHardener Samp Time, Hardener No Flow Setpoint,Hardener Flow On Point, and Inlet Pressure SensorEnable/Disable, Job Parameters revised, AlarmConfiguration Parameters - added Outlet PressureLoss, Motor Amp Fault *, System Over Pressure*, Channel Card SPI Fault *, and Channel CardInternal Fault *".

19. Added - "Note - Items above marked with anasterisk (*) cannot be disabled".

20. Revised "User Interface Software - Main UserInterface Screen and F1: Config SystemParameter screen".

21. Removed "Interface Card IP Address - This isthe IP address of the interface card in the RCS-2rack that this user interface software is going tocommunicate with."

22. Revised "F2: Config Gun screen".

23. Revised "F3: Config Channel screen".

24. Added "User Interface Software - MinimumPump Speed - Note: If the RCS-2 Controllerdetermines that either pump must run below thislimit to obtain the desired flow rate or ratio, thecontroller will stop both motors and a Motor TachLoss fault may be generated".

25. Added "Inlet Pressure Sensor - Foldback PIDLoop - The PID parameters for foldback controlhow fast the motors respond when they enterfoldback mode but they also control how fast themotors respond (acceleration and deceleration)when the trigger signal changes state and whenthere are “on the fly” changes in the requested flowrate".

26. Revised "F4: Config Job screen".

27. Revised "Delta Pressure".

28. Revised "F6: Cofigurer Alarms screen".

29. Revised "F7: Digital and Analog I/O - Option1 - Gun (Digital) Inputs and Outputs screen,Inputs, and Outputs".

30. Revised "F7: Digital and Analog I/O - Option2 - System Inputs and Outputs Screen and Inputs".

31. Revised "F7: Digital and Analog I/O - Option3 - Analog Inputs and Outputs Screen and Inputs".

32. Revised "F7: Digital and Analog I/O - F8: PlotData - Setup Screen, and Graphing screen".

33. Revised "F7: Digital and Analog I/O - F8: PlotData text".

34. Revised "F8: Job Totals screen".

35. Added "Job Totals Function Keys - F10Trigger Log".

36. Revised "F11: Color Changer screen".

37. Added "F10: Save To File text".

38. Added ""User Interface Software Buttons (Topof Screen) - Clear Gun Faults and Gun On/OffButton".

Appendix SectionAppendix SectionAppendix SectionAppendix SectionAppendix Section39. Revised "Appendix C: Channel Board JumperSettings Cart".

40. Replaced "Appendix E - Channel and GunI/O Terminals".

41. Revised "Appendix F - System I/O Terminals- added New Style Controllers figure".

42. Revised "Appendix J - Motor Amplifier LEDDisplay Fault Codes - added Part 2 - DanaherAmplifiers".

43. Revised "Appendix K - Error Codes".

44. Added "Appendix L - Pushout" and AppendixM - Improving the Accuracy of the RCS-2".

45. Removed "Paint and Solvent Specifications,Viscosity Conversion Chart, and VolumetricContent of Hose or Tube" - See literature IL-307 -Technical Supplement for All Products.

Form No. LN-9407-00.1Litho in U.S.A.12/09

© 2009 Illinois Tool Works, Inc. All Rights reserved.Models and specifications subject to change without notice.

ManufacturingManufacturingManufacturingManufacturingManufacturing1910 North Wayne StreetAngola, Indiana 46703-9100Telephone: 260/665-8800Fax: 260/665-8516

TTTTTechnical/Service Assistanceechnical/Service Assistanceechnical/Service Assistanceechnical/Service Assistanceechnical/Service AssistanceAutomotive Assembly and Tier I Telephone: 800/ 626-3565 Fax: 419/ 470-2040Ransburg Guns Telephone: 800/ 233-3366 Fax: 419/ 470-2071

TTTTTechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephonenumber for ordering Spare Parts.number for ordering Spare Parts.number for ordering Spare Parts.number for ordering Spare Parts.number for ordering Spare Parts.

Service Manual Price:Service Manual Price:Service Manual Price:Service Manual Price:Service Manual Price: €40.00 (Euro)40.00 (Euro)40.00 (Euro)40.00 (Euro)40.00 (Euro)$50.00 (U.S.)$50.00 (U.S.)$50.00 (U.S.)$50.00 (U.S.)$50.00 (U.S.)

rcs-2 user manual - robotics & automation · rcs-2 user manual - safety 3 area tells where...

Documents