RCS-2 Programmers Manual
Contents
1. 9010 45 ErrorCode seta 46 Chanel 108 1 ___ 47 TimeStamp High Sec sinee1 1 80_ 48 TimeStamp low_ Sec sinee1 80_ 49 Rego totow EA AAA The following table describes the Error Codes Description Note Bold Indicates Always Hard Errors Interface Module Battery Low Interface not communicating with channel card in slot 1 Interface not communicating with channel card in slot 3 5 Interface not communicating with channel card in slot 4 LN 9409 03 RCS 2 Programmers Manual Interface not communicating with channel card in slot 2 30 BLOCK TRANSFER DATA continued Code Note Bold Indicates Always Hard Errors 6 31 spare error codes Input Under Pressure Input Over Pressure Pot Life Expired 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 spare error code 53 spare error code 54 spare error code 55 spare error code 56 spare error code 57 spare error code spare error code spare error code System Over Pressure Channel Card Pressure Parameter Fault Channel Card SPI Communication Lost Channel Card Internal Software Fault 58 59 61 62 63 LN 9409 03 RCS 2 Programmers Manual 31 BLOCK TRANSFER DATA continued ALARM CONFIGURATION TYPE 09 RIO Alarm Configuration block transfers allow the user the ability to determine what alarm conditions causes2. LN 9409 03 RCS 2 Programmers Manual 27 BLOCK TRANSFER DATA continued BTR BTW Description Units Value Description Units Value 13 14 15 16 17 18 19 20 21 22 23 24 25 PressurePotContents Cos y The Reset Selected bit field is defined in the following table Bit ResetSelected Total Decimal Value Hex Value 0x0001 0x0002 0x0004 Grand Totalstorvob 8 0x0008 0x0010 0x0020 0x0040 0x0080 256 0x0100 0x0200 Pressure Pot Contents 10 from Job Configuration value 1024 0x0400 Note If it is necessary to retrieve flow totals after every job buck part batch etc it is important to note that the RCS 2 interface card only receives totalization information once every second from the channel card The interface card is the card that stores that infor mation in battery backed RAM and supplies this data to the RCS 2 RIO card For that reason in order to insure accurate totalization data it is necessary to wait at least one second after the gun trigger shuts off after spraying the last part in the batch buck etc be fore requesting totalization data LN 9409 03 RCS 2 Programmers Manual 28 BLOCK TRANSFER DATA continued ERROR LOG TYPE 08 RIO Error Log block transfers are used to obtain a list of the past ten faults recorded by the RCS 2 Interface Module The BTW has no effect on the system and may be used to schedule the next block transfer Error Log Messages Typ
3. Units Value 00 to 09 Fill Enable Fill Enable 0 or 1 Trigger On Delay Master Trigger On Delay Master 0 1 seconds 0 1 seconds Trigger Off Delay Master Trigger Off Delay Master 7 Pump Size cc s revolution Calibration Factor Low Order PPL 96 10 000 Calibration Factor Low Order PPL 96 10 000 Calibration Factor High Order PPL 10 000 Calibration Factor High Order Max Pump Speed Max Pump Speed PM PPL 10 000 RPM Min Pump Speed RPM PSIG PSIG PSIG PSIG 1 0 12 Max Inlet Pressure 13 Min Inlet Pressure 14 Max Outlet Pressure 15 Min Outlet Pressure 16 FolbackKpGan Foldback Kp Gain 17 FoldbackKiGain Foldback Ki Gain 18 FoldackKdGan Foldback Kd Gain LN 9409 03 RCS 2 Programmers Manual 24 BLOCK TRANSFER DATA continued Channel Configuration Data Type 05 BTR BTW Description Units Value Description Units Value 19 PSIG 20 FeaterKpGan FeatherKpGain 21 FeaterKiGan FeatherkiGain 22 FeaterKdGan FeaterKdGan 23 PSIG 24 See Table 25 Sparet Spaet 20 Spare Spare 27 spres spaes 28 Spares Spae4 pares spaes The Inlet Pressure Sensor bit fields are defined in the following table Possible Inlet Pressure Sensor Codes Control Minimum and Maximum Pressure Tests Disabled for All Modes for Both Channels Control Minimum and Maximum Pressure Tests Enabled for All Modes for Both Chan
4. April 17 2009 Rev E Page 9 Changed Spare User Link text in table to User Link Active LN 9409 03 RCS 2 Programmers Manual 42 WARRANTY POLICIES LIMITED WARRANTY ITW Ransburg will replace of repair without charge any part or equipment that fails within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with ITW Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANSBURG APPROVED PARTS VOIDS ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THIS WARRANTY ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NO IMPLIED WARRANTIES NOR WAR RANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANSBURG AS SUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS
5. This manual MUST be read and thoroughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STAN DARD 2009 EDITION prior to installing operating and or servicing this equipment The hazards shown on the following pages may occur during normal use of this equipment Please read the hazard chart beginning on page 6 LN 9409 03 Programmers Manual 5 Spray Area HAZARD Fire Hazard Improper or inadequate operation and main tenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent power supply shut down indicates a problem in the system requiring correction SAFEGUARDS Follow These Guidelines Fire extinguishing equipment must be present in the spray area and test periodically Spray areas must be kept clean to prevent the accumu lation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or maintenance When using solvents for cleaning e Those used for equipment flushing should have fla
6. rwRansburg PRODUCT MANUAL LN 9409 03 RCS 2 RIO INTERFACE PROGRAMMER S MANUAL IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Product Manual Price 50 00 CONTENTS Section 1 SAFETY 4 9 Safety Precautions Hazards Safeguards Section 2 INTRODUCTION 10 Section 3 HARDWARE SETUP 10 Section 4 RIO RACK ADDRESS 10 12 Section 5 RIO RACK INFORMATION 13 RIO Rack Size RIO Starting Quarter RIO Baud Rate Maximum Cable Length and Bus Termination Unused Switches Section 6 DISCRETE I O 14 16 Discrete System I O Discrete Channel Gun MO Section 7 BLOCK TRANSFER DATA 16 33 Null Data Type 00 Gun Operational Status Type 01 Channel Operational Status Type 02 System Configuration Type 03 Gun Configuration Type 04 Channel Configuration Type 05 Job Configuration Data Type 06 Flow Totals Type 07 Error Log Type 08 Alarm Configuration Type 09 LN 9409 03 Programmers Manual 3 Section 8 APPENDIX 35 43 Descriptions of Inputs and Outputs Recommended Digital I O Timing Sequences Recommended Sequences for Block Transfers Changes to the Manual Warranty Policies LN 9409 03 Programmers Manual 4 Section 1 SAFETY Before operating maintaining or servicing any ITW Ransburg electrostatic coating system read and understand all of the tech
7. Delta P Slave Delta P Slave Min Fluid Pressure Slave Min Fluid Pressure Slave Inlet Kp Slave Inlet Kp Slave Inlet Ki Slave Inlet Ki Slave Inlet Kd Slave Inlet Kd Slave Inlet Deadband Slave Inlet Deadband Slave Hardener Sample Time Slave 0 10sec Hardener Sample Time Slave 0 10 sec Hardener No Flow Slave 0 1023 Hardener No Flow Slave 0 1023 LN 9409 03 RCS 2 Programmers Manual 26 BLOCK TRANSFER DATA continued Job Configuration Data Type 06 BTR BTW Description Units Value 28 Hardener Fault On Slave 0 1023 29 PSIG 30 PSIG 31 32 Hardener Fault On Slave Min Control Pressure Master Min Control Pressure Slave Spare 1 Spare 2 Spare 3 Spare 4 33 A Spare 5 34 35 36 37 38 39 40 Spare 6 Spare 7 Spare 8 Spare 9 Spare 10 FLOW TOTALS TYPE 07 RIO Flow Totals block transfers are used to read or reset accumulated flow totals during normal operation BTR Description Units Value Description Units Value BTW Chan and BTR Chan 1108 Next BTR Gun Chan BTW Job st and BTR Job 1 to 199 Next BTR Job Daily Total for Job Reset Selected Bit Field Daily Total for Job 6 YTD Totalsfor Job AA A A CA vrbtoalstorvob Flow Totals Typeor SoiventTotastorJob titers 1 SovenTom foro om Grand Totalsfordob ere Grand TotalstorJob os 1 Channel Fl Total for Job ues
8. Description Units Value 00 to 09 BTW Gun and BTR Gun 1to8 Next BTR Gun 1to8 N A N A 1 to 199 or N A 0 1 or2 0 2 4 0 2 4 MasterChannel 0 8 MasterChamel Slave 1 Channel 0 8 Slaveff1 Channel Slave 42 Channel future NUTS Slave 42 Channel future Slave 3 Channel future monu Slave 3 Channel future 1 Flow Ratio Tolerance 0 100 Flow Ratio Tolerance 0 100 Tolerance Volume Tolerance Volume CC s Auto Reset ie 2 e Auto Reset Alarm Tolerance Time 0 1 seconds Alarm Tolerance Time 0 1 seconds Solvent Calibration Factor Low Solvent Calibration Factor Low Order PPL 10 000 Order PPL 10 000 Solvent Calibration Factor High Solvent Calibration Factor 18 Order PPL 10 000 High Order PPL 10 000 19 Horn Code see table below Horn Code see table below Bit Field 20 Spaet Spret 20 Spare2 Spae2 22 Spare 3 Lo Spare 3 23 Spare 4 Spare 24 Spes spae5 LN 9409 03 RCS 2 Programmers Manual 23 BLOCK TRANSFER DATA continued Possible Horn Codes XXXXXXXXXXXXX11X Horn sounds for Any Error including an expired Pot Life Timer Note X indicates don t care CHANNEL CONFIGURATION TYPE 05 Channel Configuration Data Type 05 BTR Description Units Value BTW Type 1 BTR Type SES Next BTR Type BTW Chan and BTR Chan 4 1to8 Next BTR Gun Chan 1to8 0 Next BTR Job 1 to 199 or N A
9. EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume NO responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if appli cable LN 9409 03 RCS 2 Programmers Manual 43 Product Manual Price 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Phillips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Telephone 419 470 2021 Fax 419 470 2040 Technical Support Representatives can direct you to the appropriate telephone number for ordering spare parts Form No LN 9409 02 NM O 2009 Illinois Tool Works Inc All rights reserved Litho in U S A 06 09 Models and specifications subject to change without notice RAD LN 9409 02 DDP 44
10. comnxio LN 9409 03 RCS 2 Programmers Manual 18 BLOCK TRANSFER DATA continued Gun Operational Status Type 01 BTR BTW Description Units Value Description Units Value 27 Gunk8TargetFlow_ comminxto 28 GunkiAciualFiow_ cominxto 29 Guni2ActualFlow_ cominxto ooo 30 Gun 3 Actual Flow comixio 31 Gun 4 Actual Flow comminxto 32 Gun 5 Actual Flow cominxto o o oo o 33 Gun 6 Actual Flow comminxto 34 Gun 7ActualFiow_ cominxto 35 Gun sActualFlow cominxto 36 Guns Hardener Flow 0t01028 37 Gun 2 Hardener Flow 0t01028 38 Gun 3 Hardener Flow 0t01028 39 Guns4 Hardener Flow 0t01028 40 Gun 5 Hardener Flow 0t01028 4 41 Gun 6 Hardener Flow 0t01028 42 Gun 7 Hardener Flow 0t01028 4 43 Gun 8 Hardener Flow 0t01028 44 Gun t Feather Pressure PSG 45 Gun 2 Feather Pressure PSG 46 Gunk3 Feather Pressure PSG 47 Gunit4 Feather Pressure PSG 48 Gun 5 FeatherPressure PSG 49 Gunk6 Feather Pressure PSG 50 Gun 7 Feather Pressure PSG 51 Gun 8 Feather Pressure PSG T CHANNEL OPERATIONAL STATUS TYPE 02 Channel Operational Status Type 02 BTR BTW Description Units Value Description Units Value o PrevousBTWType 00to09 Brwrpe NA BTR Type Next BTR Type
11. 0x1000 une ains MP IRR ter Fault 0x2000 Channel Card SPI Communication Moses b a l Lost 16384 0x4000 ker se ME PE Fault 32768 0x8000 LN 9409 03 RCS 2 Programmers Manual 33 Section 8 APPENDIX DESCRIPTIONS OF INPUTS AND OUTPUTS SYSTEM INPUTS Gun Strobe Type of Input Gun Type of Signal Pulsed This input signal is used in coordination with the Job Number inputs see below When this input is taken from the non energized state to the energized state for any gun the Job Number that is appearing at the Job Number inputs is loaded into the job queue If the gun is in the halted state the new job becomes active immediately If the gun is in a run state the new job number is held in the queue until the next time the gun is halted or faults Note that the job queue is only one in length If another job is loaded on top of one already in the queue the new job number overwrites the older one in the queue Job Number 1 2 4 8 10 20 40 80 100 Type of Input System Type of Signal Maintained These inputs are simple BCD binary coded decimal inputs that represent the job number that an external controller energizes to load new job numbers into the RCS 2 guns Note that these inputs are common to all guns and they are ignored until one or more of the Gun Strobe inputs are pulsed Allowable job number range from 1 to 199 SYSTEM OUTPUTS System Fault Type of Output System Type of Signal Maintained Thi
12. Fast Fill input is pulsed the unit will run in Fast Fill mode until the volume programmed in for fill volume is dispensed At that time the gun will be halted This happens regardless of the condition of the gun trigger inputs so make sure the applicator is triggered or an overpressure fault may occur When it is desirable to run both modes in parallel it is important to watch the Run output bit to insure the unit has in fact gone into Volume Fill mode prior to sending the Fast Fill bit DISCRETE CHANNEL AND GUN OUTPUTS Fault This output is energized anytime a fault condition is recognized by the software Even if the fault is disabled known as a soft fault on the Configured Alarms screen this output will be energized as long as the condition persists Fluid flow will not be halted when this out put is energized unless it is configured to do so on the Configured Alarms screen If it is configured to be a hard fault this output and the Spray Shutdown output will both be energized and the system will stop spraying see Spray Shutdown below Run This output is energized if the gun is configured properly a good job number has been loaded and the gun has been placed in Run mode or the Volume Fill mode This output goes off if a fault occurs if it is Halted or in the Ready state Spray Shutdown This output is energized if a fault condition exists and the specific fault that exists is enabled on the Configured Alarms screen turned on T
13. RIO card so if invalid data data outside acceptable limits is sent to the RCS 2 via RIO it will most likely generate a fault typically a channel card parameter fault and the system will shut down If this occurs it is necessary to correct the corrupt data prior to restarting the system This can be done by correcting the offending data or reloading a known good parameter set BLOCK TRANSFER TYPES RIO Block Transfer Types BTR Length BTR Length Null Data Gun Operational Status En 2 rand operaiona sius se Channel Configuration LN 9409 03 RCS 2 Programmers Manual 16 BLOCK TRANSFER DATA continued RIO Block Transfer Types BTR Length BTR Length Job Configuration Alarm Configuration Ls EST NULL DATA TYPE 00 A BTW must always precede a BTR in order to inform the RCS 2 Interface Module what data is to be returned in the next BTR Null BTW commands can be used when no data is required prior to the next BTR If the next BTR Type does not require a Gun Number or a Channel Number and or Job Number those fields may be zero Otherwise the Next BTR Type Gun Number Channel Number and Job Number specify the appropriate data to be returned in the next BTR Null Type 00 BTR BTW BUTS Units Value CRA Units Value ER Previous BTW Type 00 to 09 BTW Type 5 BTRType o metermmpe oo GUN OPERATIONAL STATUS TYPE 01 The Gun Operational Status Block transfers are used for normal process control while
14. Shutdown bit via discrete VO or via RIO Execute BTW System Type 03 Gun Type 04 pe Type Job Type 06 Execute BTW Type 08 Wait For response from the RCS that it has received the BTW Wait Forresponse from the ROS that it has received the BTW Wait Forresponse from the RCS that it has received the BTW Execute BTR asking RCS to send data Execute BTR Type 07 asking RCS to send data Execute BTR Type 08 asking RCS to send data Wait Forresponse from RCS that it has completed sending the requested data Wait Forresponse from RCS that it has completed sending the requested data Wait Forresponse from RCS that it has completed sending the requested data Check for Errors Check RIO status registerto insure no errors occurred during transmission If there was an error resend the BTR Check for Errors CheckRIO status registerto insure no errors occurred during transmission If there was an error resend the BTR Check for Errors Check RIO status register to insure no errors occurred during transmission If there was an error resend the BTR Modify the parameter or parameters in PLC temporary storage register s that you wish to change in the RCS Copy and use data Copy the data retumed from temporary storage location in PLC to area used for storage or manipulation of data Copy and use data Copy the da
15. a spray shutdown Configure Alarms Type 09 BTR Description Units Value Description Units Value N N Previous BTW Type 000009 BlWyppe 9 BIRTpe 9 __ NexBTRType 001009 A Na nextBTRGunt ttoBorNWA_ A NA NextBTRJob 1to1990rWVA mes A A Alarm Enable Disable Bits 0 15 Bit Field Bits 0 15 Bit Field Mamtregemsseneies muros metes pad Alarm Enable Disable Bits 16 31 Bit Field Bits 16 31 Bit Field The Active Alarm bit fields are defined in the following table Alarm Enable Disable Note Bold Indicates Always Hard Alarms Decimal Value Hex Value Input Under Pressure 1 oo gt Input Over Pressure 2 ooo Output Under Pressure 4 00004 Output Over Pressure 8 oooe FlowOutofToerane 16 oooo ME Gr 84 ps PNA N A NA O N A BEEN Hardener Flow Loss 0x0020 Pressure Pot Empty 0x0040 2 0x0100 3 6 128 2 Outlet PressureLoss 1024 oxow00 7 10 11 12 13 14 15 16 17 18 19 20 AnalogSpareLoss 1 oo pareemorbiy 8 ooos LN 9409 03 RCS 2 Programmers Manual 1 4 2 4 6 1 6 it it spare error bit 8192 0x2000 it 32 BLOCK TRANSFER DATA continued Alarm Enable Disable Note Bold Indicates Always Hard Alarms Decimal Value Hex Value spare error bit spare error bit spare error bit spare error bit spare error bit 2048 0x0800 4096
16. be pulsed on both channels independently Note that the pilot air signal to the inlet pressure regulator is automatically set to 100 psi while in channel fill mode Feather Set Type of Input Gun Type of Signal Pulsed If the gun is configured as a manual mode gun and the value zero 0 is programmed in for feather pressure under the CONFIG JOB parameters this input can be used to program the feather pressure on the fly That is if a hand sprayer is painting and this input is momentarily energized the RCS 2 controller takes a snapshot of the outbound pressure of the pumps or the pressure at the feather pressure sensor if being used and then starts controlling the speed of the pumps to maintain that pressure The optional Remote Operator s Panel has a pushbutton on it that allows the hand sprayer to utilize this feature Run Type of Input Gun Type of Signal Pulsed This signal takes a configured gun from the halted state to the run state In order for a gun to spray it must first be put into run mode It is essentially a way of enabling a gun Energizing the trigger input of a gun will not cause fluid to flow unless the gun has been placed in run mode When placed in run mode the discrete output labeled Gun Run will be energized Halt Fault Reset Type of Input Gun Type of Signal Pulsed This input takes a configured gun that is in run mode to the halted state essentially disabling the gun from spraying It also resets a fa
17. must be in the halted state prior to this When the gun trigger input goes high the pumps will run at the programmed flow rate and ratio until the volume programmed in for Fill Volume on the Job parameters screen is dispensed If more than one gun trigger input goes high the unit will multiply the flow rate by the number of high inputs but still only run until the programmed volume is dispensed When that volume is reached the gun will be halted See paragraph labeled Volume Fill with Fast Fill below if it is necessary to run this mode in parallel with fast fill Pushout Type of input Gun Type of signal Maintained This input when energized puts the gun in Pushout Mode When initiated the RCS 2 will immediately turn off the catalyst pump and speed up the resin pump to maintain the target flow rate that was being sprayed prior to the initiation of the pushout signal Note that this pushout signal is a maintained signal The RCS 2 will continue to deliver fluid out of the first dual purge side until the volume programmed in for mixed volume has been sprayed and then that gun will automatically be halted taken out of run mode This state will be recognized by the PLC or robot when the Run output from the RCS 2 turns off For more information on using this function refer to the Operator s Manual Volume Fill with Fast Fill Mode It is possible to Volume Fill and Fast Fill simultaneously If the gun is put into Volume Fill mode and then the
18. painting parts This assumes the system and applicators have been initially configured The gun numbers job numbers and setpoints may be specified as 0 if not change is desired for a gun However if a setpoint is specified as non zero a valid job number must be specified Gun Operational Status Type 01 ara Pi Tone E a Description Units Value Description Units Value 0 PrevousBTWTyp 00009 Brwrype 1 LN 9409 03 RCS 2 Programmers Manual 17 BLOCK TRANSFER DATA continued Gun Operational Status Type 01 BTR BTW Description Units Value Description Units Value Next BTR Gun 2 N A N A Chan 1 to 8 or N A Next BTR Job 1 to 199 or N A NEL PA A 4 Gun 1 1to 199 Gun 1 Job 4 0 to 199 O ECCE UTEM 5 Gun 2 1 to 199 Gun 1 Set Point cc min x 10 e mii ipi camera Dude Gun 43 1 to 199 Gun 42 Job 0 to 199 MO RP A 7 Gun 44 1 to 199 Gun 2 Set Point cc min x 10 s ens iim Gnxbe omen Gun 5 1 to 199 Gun 3 Job 0 to 199 Pe ae a o Gun 6 1 to 199 Gun 3 Set Point cc min x 10 x jt ui dii cameo Dee 10 Gun 7 1 to 199 Gun 4 Job 0 to 199 Cr ee PA 11 Gun 8 1 to 199 Gun 4 Set Point cc min x 10 20 GunkiTargetFlow_ comminxto 21 Gunk2TargetFlow_ comminxto 22 Gunk8TargetFlow_ cominx 23 Gunk4TargetFlow_ cominxio 24 Gunk5TargetFlow_ cominx 4 25 Gun 6TargetFlow comminxto 26 Gunk 7TargetFlow_
19. single component material Gun Active Output such as solvent The catalyst motor is halted and the Run Input resin motor speeds upto maintain the target flow rate When loading a Job Bit 41 Input new job the job bits must be asserted Job Bit 2 Input prior to strobing the gun strobe input bit Job Bit 4 Input and those bits should remain on Job Bit 8 Input amp Slightly after the Job Bit 10 Input strobe bit goes off Job Bit 420 Input Job Bit 440 Input FTT Job Strobe Input ga Gun Run Input LN 9409 03 RCS 2 Programmers Manual 40 RECOMMENDED SEQUENCES FOR BLOCK TRANSFERS The recommended sequences below should be used when sending and receiving data to and from the RCS 2 from a PLC via the RIO link Time is not indicated on this chart as it will vary from system to system based on how busy the RIO channel is If there are additional devices on the RIO channel including additional RCS 2 racks times will be extended Once again it is highly rec ommended that a baud rate of 230 KBaud be used on the RIO link Action Retneving Flow Totalization Data See Note 1 Retrieving Fault Data See Note 2 Modifymg System Job Gun or Channel Parameters See Note 3 Wait Afterthe trigger has tumed off after spraying the last part wait one second to allow the interface card to gather data from the Monitor either the Fault output bit orthe Spray
20. violent and lead to an equipment explosion SAFEGUARDS Follow These Guidelines Electrostatic arcing MUST be prevented All electrical equipment must be located outside Class or Il Division 1 or 2 hazardous areas in accordance with NFPA 33 2009 Edition Test only in areas free of flammable or combustible materials The current overload sensitivity if equipped MUST be set as described in corresponding section of the equip ment manual Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power shutdown indicates a problem with the system which requires correction Always turn the control panel off prior to flushing clean ing or working on spray system equipment Ensure that the control panel is interlocked with the ventilation system and conveyor in accordance with NFPA 33 2009 Edition Have fire extinguishing equipment readily available and tested periodically Follow These Guidelines Aluminum is widely used in other spray application equipment such as material pumps regulators trig gering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray If in doubt as to whether or not a coating or cleaning material is compatible contact your coating supplier Any other ty
21. ANNEL GUN I O continued PLC Words 1 to 7 e ER song ons ene eno ona ens one Jony 12 Out Spare Digital In Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 Dus ou spargi ons one ono ona ens ens cnr 13 Out Spare Digital In Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 EE ARAM FAAR 14 n a n a Bit 0 Bit 2 Bit 4 served Bit 8 Bit 10 Bit 12 A oss sles 15 n a n a Bit 1 Bit 3 Bit 5 Bit 7 Bit 9 Bit 11 Bit 13 The Channel Gun 8 discrete I O bits are distributed across PLC words 1 through 7 in bits 14 and 15 as shown above Note The status of the Channel Gun I O bits can be monitored with the RCS 2 user interface software Open the fms exe software select function F7 Dig Ana I O then select Gun I O If the RCS 2 user interface software sees one of its Gun I O bits turned on or off via RIO there will be a R indicator after the ON or OFF indicator in the appropriate box This indicates that the input is being con trolled by RIO Section 7 BLOCK TRANSFER DATA It is highly recommended that any time a change is to be made to a parameter in the RCS 2 via this RIO link it be done in a Read Modify Write fashion That is it is not possible to send just one parameter at a time say for instance the ratio and change just that parameter There are 10 different block transfer types and the amount of data varies from 4 words to 60 words depending on what parameters are to be read or written Data is not filtered by the
22. ANSFER DATA continued Channel Operational Status Type 02 BTR BTW Description Unitsvalue Description Units Value IN EEE 32 Pump ouet Pressure cnans esta 4 s9 Pump ouet Pressure chan 6 psig 34 PumpouterPressure chan 7 psig 35 PumpOutetPressure Chan 8 se 36 Motor Speed Chant Remo 37 Motor Speed Chan 2 remo as Motor Speed Chana Remo as Motor Speed Cha Remo 40 Motor Speed Chan emo 41 motor Speed Ohan 6 Remo 42 Motor Speed Chan emite 48 Motor Speed Chan 8 Remo 44 Pressure Comro chani oo 45 Pressure Control Chan owr as Pressure Control nan a owr 47 Pressure Control Chana oo 48 Pressure Control Chan owr 49 Pressure Control Chane totes 50 Pressure Contol Chan 7 oro1028 61 Pressure Contoh Chane owr 52 Spare Analog input Chan 1 oios 58 Spare Analog input Chan 2 otero 54 Spare Analog input Chan 3 otros 55 Spare Analog input Chan 4 otros 56 Spare Analog input Chan 5 otis 57 Spare Analog Input Ghan 6 owes 58 Spare Analog input Chan 7 otros 59 spare Analog Input chans oos Jf LN 9409 03 RCS 2 Programmers Manual 21 BLOCK TRANSFER DATA continued SYSTEM CONFIGURATION TYPE 03 System Conf
23. Next BTR Gun 2 N A N A Chan N A Next BTR Job LN 9409 03 RCS 2 Programmers Manual 19 BLOCK TRANSFER DATA continued Channel Operational Status Type 02 BTR BTW Description Units Value Description Units Value 4 Target Flow Rate Chan 1 cominxto 5 Target Flow Rate Chan 2 ce minx10 6 Target Flow Rate Chan 3 cominx10 7 Target Flow Rate Chan 4 cominxto J 8 Target Flow Rate Chan 5 ce minx10 9 Target Flow Rate Chan 6 cominx10 10 Target Flow Rate Chan 7 ceminx10 11 Target Flow Rate Chan 8 cominx10 12 Actual Flow Rate Chan 1 cominx10 13 Actual Flow Rate Chan 2 ce minx10 14 Actual Flow Rate Chan 3 cominx10 15 Actual Flow Rate Chan 4 cominx10 16 Actual Flow Rate Chan 5 ce minx10 37 Actual Flow Rate Chan 6 cominx10 18 Actual Flow Rate Chan 7 ce minx10 19 Actual Flow Rate Chan 8 cominx10 m omi roc 20 Chan 1 PSIG m Ow gt roc III 21 Chan 2 PSIG m ome roc I 22 Chan 3 PSIG m owe gt roo I 23 Chan 4 PSIG m om roc 24 Chan 5 PSIG m owes gt roc PIN 25 Chan 6 PSIG m om so OM 26 Chan 7 PSIG m ome roc III 27 Chan 8 PSIG a Get ro 28 Chan 1 PSIG PA ro III 29 Chan 2 PSIG m ws ro I 30 Chan 3 PSIG LN 9409 03 RCS 2 Programmers Manual 20 BLOCK TR
24. SW2 8 to the ON position These switch set tings allow 8 discrete I O words and the ability to use from 1 to 4 RCS 2 Channel Cards RIO STARTING QUARTER The RIO Starting Quarter within the rack must be specified to allow the RIO Interface Card to communicate over the RIO link When used with the RCS 2 the only valid RIO Starting Quarter is 0 since the RIO Rack Size is a Full Rack Therefore always set switches SW1 7 and SW1 8 to the OFF position RIO BAUD RATE MAXIMUM CABLE LENGTH AND BUS TERMINATION The RIO Baud Rate must be specified to allow the RIO Interface Card to communicate over the RIO link The RIO Baud Rate is specified with SW2 positions 3 and 4 If the RCS 2 RIO Interface Card is at the end of the RIO Link a terminating resistor must be installed SW2 4 RIO Baud Rate Max Cable Length RIO Bus Terminator 57 6 Kbaud 3 048 m 10 000 ft 150 Ohm see note 1 8 Watt O FF 230 4 Kbaud 762 m 2 500 ft 82 Ohm 1 8 Watt 230 4 Kbaud 7862 m 2 500 ft 82 Ohm 1 8 Watt SW2 3 i 204 kome TEME Note Use an 82 Ohm resistor unless the RIO master device requires 150 Ohm The terminating resistor is required at both ends of the RIO Link Recommendation Always run the baud rate at the maximum rate possible ITW recommends always using 230 4 Kbaud unless it is necessary to operate at a lower speed because of environmental issues noise cable lengths etc Since reasonably large blocks of data are transfe
25. ata Spare Digital In System Ready 14 RCS2 BTW Spare Digital In System Clear To Send RCS2 RIO Error Spare Digital In Note The status of the System I O bits can be monitored with the RCS 2 user interface software Open the fms exe software select function F7 Dig Ana I O then select System I O If the RCS 2 user interface software sees one of its System I O bits turned on or off via RIO there will be a R indicator after the ON or OFF indicator in the appropriate box This indicates that the input is being con trolled by RIO DISCRETE CHANNEL GUN I O AA AS E a ee er a led Ea pe a o Fat FesFil Ch 1 ch2 cha cna chs che chz 1 Spray Shutdown Eos sudo resmerss ons one ons ons cns one nr Halt Fault Reset E tigger ont one ons ons ons one on7 set Trigger 1 C Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 ra E ME Out Reserved Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 Ch SEN o tiggere ont fone ons ons ons ene Out Trigger 4 C Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 on voumera oni fone ono ena ons one nz Out Volume Fill C Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 Mo memos ont Jone ono ons ens one Out Push Out C Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 Spare Digital Out Trigger 3 h 1 h 1 h 1 h 1 h 1 h 1 h 1 y A Spare Digital 7 Out Trigger 2 C 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 LN 9409 03 RCS 2 Programmers Manual 15 DISCRETE CH
26. e 08 Units Value Units Value Previous BTW Type 00 to 09 BTW Type BTR Type Next BTR Type 00 to 09 N A N A Next BTR Gun Chan 1to 8 or N A 1 to 199 or N A BTR Reference 1 to 100 Next BTR Job or Ref or 1 to 100 Ref 0 1 to 100 Clear Error Log see table Channel 1108 Time Stamp High Sec since 1 1 80 Time Stamp Low Sec since 1 1 80 Ref 1 2 to 100 10 see table 11 Channel 1to8 12 Time Stamp High Sec since 1 1 80 13 Time Stamp Low Sec since 1 1 80 14 Ref 2 3 to 100 15 see table 16 Channel 1to8 17 Time Stamp High Sec since 1 1 80 18 Time Stamp Low Sec since 1 1 80 19 Ref 3 4 to 100 20 see table 21 Channel 1to8 Time Stamp High Sec since 1 1 80 3 Time Stamp Low Sec since 1 1 80 24 Ref 4 5 to 100 25 see table 26 Channel 1to8 Time Stamp High Sec since 1 1 80 Time Stamp Low Sec since 1 1 80 Ref 5 6 to 100 Error Code see table Channel o itos LN 9409 03 RCS 2 Programmers Manual 29 BLOCK TRANSFER DATA continued Error Log Messages Type 08 BT Description Units Value Channel Time Stamp High Sec since 1 1 80 Time Stamp Low Sec since 1 1 80 et Description fe A E gt EAN n 39 Re 7 8010 at Chamas 108 42 TimeStamp Hgh Sec sinee1 1 80 48 TimeStamp Low Secsncet 80 44 Regs
27. e in run mode or volume fill mode prior to initiating this mode or the RCS 2 controller will ignore it If the gun is config ured as a single channel gun and this signal is pulsed the gun will cause the pump to run at its maximum speed typically 150 RPM until the halt signal is pulsed Note that it is not necessary to have the trigger signal energized Flow starts immediately If the gun is configured as a two channel gun and this input is pulsed the pumps will run at the maximum speed possible while maintaining the target ratio That is the software will determine which of the two pumps can be run at its maximum speed and run the opposite chan nel at whatever speed necessary to insure the proper ratio of component A to component B The software determines this based on the programmed pump sizes and the programmed ratio Pulsing the halt reset input takes the gun out of the fast fill mode Note also paragraph below describing using fast fill with volume fill Channel Fill Type of Input Channel Type of Signal Pulsed A gun must be in the halted state to use this mode This mode functions the same for single channel guns as it does for dual channel guns When this input is pulsed the pump for that channel is run at its maximum rate 150 RPM until the halt signal is pulsed It is not necessary for the trigger input to be energized If it is desired to have both channels of a two channel gun run at full speed for flushing etc this input must
28. gone into Volume Fill mode prior to sending the Fast Fill bit DISCRETE CHANNEL AND GUN OUTPUTS Fault This output is energized anytime a fault condition is recognized by the software Even if the fault is disabled known as a soft fault on the Configured Alarms screen this output will be energized as long as the condition persists Fluid flow will not be halted when this output is energized unless it is configured to do so on the Configured Alarms screen If it is configured to be a hard fault this output and the Spray Shutdown output will both be energized and the system will stop spraying see Spray Shutdown below Run This output is energized if the gun is configured properly a good job number has been loaded and the gun has been placed in Run mode or the Volume Fill mode This output goes off if a fault occurs if it is Halted or in the Ready state Spray Shutdown This output is energized if a fault condition exists and the specific fault that exists is enabled on the Configured Alarms screen turned on This indicates that the flow of fluid from the fluid panel has been stopped as the result of a detected fault condition LN 9409 03 RCS 2 Programmers Manual 37 DISCRETE CHANNEL AND GUN OUTPUTS Flush Request This output is energized when the pot life timer has expired For more information see Mixed Volume and Pot Life Timer in the Operation s Manual Motor On This output is energized by the software when i
29. he gun will be halted See paragraph labeled Volume Fill with Fast Fill below if it is necessary to run this mode in parallel with fast fill Pushout Type of input Gun Type of signal Maintained This input when energized puts the gun in Pushout Mode When initiated the RCS 2 will immediately turn off the catalyst pump and speed up the resin pump to maintain the target flow rate that was being sprayed prior to the initiation of the pushout signal Note that this pushout signal is a maintained signal The RCS 2 will continue to deliver fluid out of the first dual purge side until the volume programmed in for mixed volume has been sprayed and then that gun will automatically be halted taken out of run mode This state will be recognized by the PLC or robot when the Run output from the RCS 2 turns off For more information on using this function refer to the Operator s Manual Volume Fill with Fast Fill Mode It is possible to Volume Fill and Fast Fill simultaneously If the gun is put into Volume Fill mode and then the Fast Fill input is pulsed the unit will run in Fast Fill mode until the volume programmed in for fill volume is dispensed At that time the gun will be halted This happens regardless of the condition of the gun trigger inputs so make sure the applicator is triggered or an overpressure fault may occur When it is desirable to run both modes in parallel it is important to watch the Run output bit to insure the unit has in fact
30. her electrical control equipment must NOT be used in Class Division 1 or 2 locations Follow These Guidelines All electrical equipment must be located outside Class or Il Division 1 or 2 hazardous areas Refer to NFPA 33 2009 Edition Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety cir cuits disabled Before turning the high voltage on make sure no ob jects are within the sparking distance LN 9409 03 Programmers Manual 8 HAZARD Toxic Substances Mechanical Hazard Certain material may be harmful if inhaled or if there is contact with the skin Robot Work Area Mechanical Hazard Improper use or maintenance can lead to hazardous conditions particularly from un expected robot manipulator movement All Areas Improper Inadequate Training Improper operation or maintenance may create a hazard Personnel must be properly trained in the use of this equipment SAFEGUARDS Follow These Guidelines Follow the requirements of the Material Safety Data Sheet supplied by the coating manufacturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be com patible with the ma
31. his indicates that the flow of fluid from the fluid panel has been stopped as the result of a detected fault condition Flush Request This output is energized when the pot life timer has expired For more information see Mixed Volume and Pot Life Timer in the Operation s Manual Motor On This output is energized by the software when it wants the motor to turn As long as this output is enabled and the motor amplifier is not faulted the pump will be held rigid in place by the motor amplifier If this output is not on the pump is allowed to free wheel LN 9409 03 RCS 2 Programmers Manual 36 DISCRETE CHANNEL AND GUN INPUTS Motor Amp Enable Type of Input Channel Type of Signal Maintained This is an input to the controller from the motor amplifier indicating that the motor amplifier has detected a problem and has placed itself in a faulted condition Volume Fill Type of input Gun Type of signal Pulsed By pulsing the volume fill discrete input the unit will be put into the V FILL mode The gun must be in the halted state prior to this When the gun trigger input goes high the pumps will run at the programmed flow rate and ratio until the volume programmed in for Fill Volume on the Job parameters screen is dispensed If more than one gun trigger input goes high the unit will multiply the flow rate by the number of high inputs but still only run until the programmed volume is dispensed When that volume is reached t
32. iguration Data Type 03 BTR BTW Description Units Value Description Units Value PE Previous BTW Type 00 to 09 BTW Tye 3 me BTR Type 3 NextBTRType 001009 Next BTR Gun 2 N A N A Chan 1 to 8 or N A Next BTR Job 1 to 199 or N A METTET SEG 4 Over Pressure Limit PSIG Limit PSIG s romere esa oe pe 5 Fold Back Pressure PSIG Sure PSIG 6 SensorLimit PSG Sensortim Psia le Sareri sprer 4 9 po Spre2 spaez 10 Spre8 Spes lap spaes Spre4 12 Spes spares as Spares o spaes o spaez spaez 15 Spares Spre8 36 spaeg Spre9 i7 Sprett Sate 0 18 ControlleriP Address 1 _ oto255 4 19 ControlleriP Address 2 0125 20 ControlleriP Address 3 0to255 4 21 ControlleriP Address 4 0to255 4 22 User interiace SW version 23 ROCaaverson FP 24 itefaceCardSWVersion 25 Channel Card t Version 26 ChamelCads2Vesin 27 ChamelCad 3Vesin 28 Chameicara 4 verion LN 9409 03 RCS 2 Programmers Manual 22 BLOCK TRANSFER DATA continued GUN CONFIGURATION TYPE 04 RIO Gun Configuration Block transfers are typically required when configuring a gun for the first time or periodically adjusting parame ters Gun Configuration Data Type 04 BTR BTW Units Value
33. nels Control and Minimum Pressure Test Enabled for All Modes Except Channel Fill for Resin Channel Control and Minimum Pressure Test Enabled All Modes for Catalyst Channel Maximum Pressure Test Enabled All Modes for Both Channels LN 9409 03 RCS 2 Programmers Manual 25 BLOCK TRANSFER DATA continued JOB CONFIGURATION DATA TYPE 06 RIO Job Configuration Data block transfers are typically required when configuring a gun for the first time or periodically adjusting parameters Job Configuration Data Type 06 BTR Units Value Units Value Previous BTW Type 00 to 09 BTW Type BTR Type Next BTR Type 00 to 09 BTW Gun and BTR Gun 1108 Next BTR Gun 1108 BTW Job and BTR Job 1 to 199 Next BTR Job 4 1 to 199 Ratio Ratio Parts master to 1 part slave Ratio x 100 Parts master to 1 part slave Ratio x 100 Flow Setpoint Flow Setpoint cc s min Maximum Flow cc s min cc s min Minimum Flow cc s min cc s min Bar Graph Limit cc s min cc s min Potlife Timer minutes minutes Feather Pressure PSIG PSIG Fill Volume cc s cc s Pressure Pot Capacity Master cc s Pressure Pot Capacity Master cc s Delta P Master PSIG Delta P Master PSIG Min Fluid Pressure Master PSIG Min Fluid Pressure Master PSIG Inlet Kp Master Inlet Kp Master Inlet Ki Master Inlet Ki Master Inlet Kd Master Inlet Kd Master Inlet Deadband Master Inlet Deadband Master Pressure Pot Capacity Slave Pressure Pot Capacity Slave
34. nical and safety literature for your ITW Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PRE While this manual lists standard specifications and service VENTING EQUIPMENT PROBLEMS To help you procedures some minor deviations may be found between recognize this information we use the following sym the literature and your equipment Differences in local codes bols and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation drawings and appropriate ITW Rans burg equipment manuals to reconcile such differences CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting WARNING states information to alert in more efficient operation longer trouble free service and you to a situation that might cause se faster easier troubleshooting If you do not have the manu rious injury if instructions are not fol als and safety literature for your Ransburg system contact lowed your local ITW Ransburg representative or ITW Ransburg A WARNING The user MUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literature therein identified
35. pe of solvent may be used with aluminum equipment LN 9409 03 Programmers Manual 7 Spray Area High Volt age Equipment Electrical Equipment HAZARD Electrical Discharge There is a high voltage device that can in duce an electrical charge on ungrounded objects which is capable of igniting coating materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion Electrical Discharge High voltage equipment is utilized Arcing in areas of flammable or combustible mate rials may occur Personnel are exposed to high voltage during operation and mainte nance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shutdown indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explosion SAFEGUARDS Follow These Guidelines Parts being sprayed must be supported on conveyors or hangers and be grounded The resistance between the part and ground must not exceed 1 mega ohm All electrically conductive objects in the spray area with the exception of those objects required by the process to be at high voltage must be grounded Any person working in the spray area must be grounded Unless specifically approved for use in hazardous loca tions the power supply and ot
36. rred in several of the block transfers and since RIO is not a deterministic network the amount of time it takes for the data to be returned to the PLC from the RCS 2 controller may be significant and is unpredictable When requesting data from the RCS 2 always wait for the RIO transmission complete bit to be set and verify that there were no errors by checking the RIO error bit prior to using returned data UNUSED SWITCHES When the 77377 22 RIO Interface Card is used in an RCS 2 rack switches SW2 1 SW2 2 SW2 5 and SW2 6 are unused and should be left in the OFF position LN 9409 03 RCS 2 Programmers Manual 13 Section 6 DISCRETE I O DISCRETE I O There are eight 8 16 bit words used for digital discrete inputs and outputs via RIO in the RCS 2 Word 0 is for System inputs and outputs Words 1 through 7 are for Channel 1 through 7 inputs and outputs with each channel having 14 possible inputs and outputs The Channel 8 inputs and outputs are distributed across words 1 through 7 as bits 14 and 15 of these words When a gun is configured with two channels the odd channel and thus odd word is the controlling channel for the gun The RCS 2 also has hard wired discrete I O capabilities and input bits received by the RCS 2 via RIO are logical ORed with these discrete signals prior to being processed by the software Likewise any output bits are sent both to the PLC via RIO and the hard wired discrete outputs Note The speed with
37. rved for handshaking bits to support RIO Block Transfers The RCS 2 Interface Module appears as a single 8 bit I O module in slot 1 Therefore the RCS 2 Interface Module which reports the System I O signals use the high byte bits 8 through 15 of word 0 Each RCS 2 Channel Card appears as two 14 bit I O modules two slots Each of four possible RCS 2 Channel Cards supports two channels for a total of 8 channels Channel 1 through 7 use bits 0 through 13 of RIO words 1 through 7 Channel 8 uses bits 14 and 15 of RIO words 1 through 7 section 4 RIO RACK ADDRESS The RIO Rack Address is used to indicate to which RIO rack the Interface Module is assigned RIO Rack Addresses are specified in octal format There are 64 decimal possible Rack Addresses which are assigned 00 through 77 octal RIO RACK ADDRESS LN 9409 03 RCS 2 Programmers Manual 10 RIO RACK ADDRESS continued Y Y Lu Q Q lt x O lt c 9 tr FF O Octal LN 9409 03 RCS 2 Programmers Manual 11 RIO RACK ADDRESS continued o o o A 3 lt 5 mp gO CC O CC E o LLI CC a m x O CC O E LN 9409 03 RCS 2 Programmers Manual 12 Section 5 RIO RACK INFORMATION RIO RACK SIZE The RIO Rack size must be specified to allow the RIO Interface Card to communicate over the RIO link When used with the RCS 2 the only valid Rack Size is a Full Rack Therefore always set switches SW2 7 and
38. s output is connected to the horn in the top of the control console on the stand alone RCS 2 controllers It can be energized any time there is a system fault It can be enabled and disabled on the CONFIG SYSTEM screen Some examples of system faults are problems with the disk drive hard drive or CDROM of the user interface PC Also certain problems with the interface board or RIO board if used may cause a system fault This output can also be programmed to energize when any of the guns fault This is done on the CONFIG GUN screens Each gun can be configured to cause the horn to sound when it faults independent of each other Note that the horn must be enabled on the CONFIG SYSTEM screen or the horn will not sound for gun faults regardless of whether or not they are configured to do so on the CONFIG GUN screens System Pulse Type of Output System Type of Signal Pulsing This output pulses at approximately a 0 5 hertz rate as long as the processor on the interface board does not detect any on board firmware problems Users may wish to use this signal to detect when the RCS 2 controller is powered up and running Client Connected Type of Output System Type of Signal Maintained This output is energized whenever a client P C is connected and talking to the interface card via Ethernet LN 9409 03 RCS 2 Programmers Manual 34 DISCRETE CHANNEL AND GUN INPUTS Fast Fill Type of Input Gun Type of Signal Pulsed The gun must b
39. sh points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 1000F 37 80C Spray booth ventilation must be kept at the rates re quired by NFPA 33 2009 Edition OSHA and local codes Ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Non factory replacement parts or unauthorized equip ment modifications may cause fire or injury If used a key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks disabled Never use equipment for use in waterborne installa tions to spray solvent based materials LN 9409 03 Programmers Manual 6 Spray Area Spray Area HAZARD Explosion Improper or inadequate operation and main tenance procedures may cause an explo sion Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent power supply shut down indicates a problem in the system requiring correction Explosion Incompatible Materials Halogenated hydrocarbon solvents for ex ample methylene chloride and 1 1 1 Trichloroethane are not chemically compati ble with the aluminum that might be used in many system components The chemical reaction caused by these solvents reacting with aluminum can become
40. t wants the motor to turn As long as this output is enabled and the motor amplifier is not faulted the pump will be held rigid in place by the motor amplifier If this output is not on the pump is allowed to free wheel RECOMMENDED DIGITAL I O TIMING SEQUENCES The recommended timing sequences below should be used when controlling the RCS 2 from a PLC Time displayed in these charts should be programmed to be approximately 0 25 second 250 milliseconds if the RCS 2 is connected via discrete I O or if done via RIO with the RCS 2 being the only remote device on the RIO channel If there are additional devices on the RIO channel including additional RCS 2 racks this time may and probably will have to be extended This assumes a baud rate of 230 KBaud is used on the RIO link Placing the Itis necessary to Gun in Run F putthe gun in run Mode mode to enable it Run Input i ing i un Inpu prior to sending it a trigger signal to Gun Active Output miri Fault If agun is faulted Halt Reset Run Input fl and it is necessary then Run FF to clear the fault and put it back in run mode use this sequence Gun Active Output LJ Spray Shutdown Output Holt Reset Input Volume Fill Volume Fill allows followed by Volume Fill Input the user to program Run T in a fill volume F 4 When put in this iir mode the unit will Gun Active Output xq flow material until Lovin the fill volume has Volume hos flowed flo
41. ta retumed from temporary storage location in PLC to area used for storage or manipulation of data Execute BTW to send modified data backto RCS Step 8 Check RIO status registerto insure no errors occurred during transmission Note 1 Keep in mind that for a dual component gun steps 2 through 7 have to be executed twice once for the resin then again for the catalyst Then if it is necessary to reset the totals a third set of steps is required to do the reset Note 2 There are two digital output bits Fault and Spray Shutdown If the fault that occurs is configured as a soft fault disabled on the Config Alarms screen the Fault output bit goes on but the Spray Shutdown bit does not If the fault that occurs is configured as a hard fault both the Fault bit and the Spray Shutdown bit go on and the unit shuts down stops spraying It is up to the pro grammer to decide if they want to retrieve fault data under either or both conditions Note 3 Anytime data is changed in the RCS via RIO it should be done in a read modify write pattern since only one parameter cannot be sent at a time This will insure that bad data is not sent to the RCS unit as it does not filter data that comes in via RIO as it does the data coming in from the user interface P C LN 9409 03 RCS 2 Programmers Manual 41 CHANGES TO MANUAL April 1 2009 Rev E Pages 5 and 6 Dip switch settings for RIO Rack Address 20 23 30 34 40 47 corrected
42. terial being sprayed and its concen tration Equipment must be as prescribed by an indus trial hygienist or safety expert and be NIOSH ap proved Follow These Guidelines Applicator adjustments or maintenance should be done after the robot is taken out of service Do not adjust or repair the applicator if the robot is operating or standing ready to start Refer to robot operating instructions for the procedures to take a robot out of service Follow all OSHA Lockout Tagout procedures when performing any maintenance Follow These Guidelines Personnel must be given training in accordance with the requirements of NFPA 33 2009 Edition Instructions and safety precautions must understood prior to using this equipment Comply with appropriate codes governing ventilation fire protection operation maintenance and housekeep ing OSHA references are sections 1910 94 and 1910 107 Also refer to NFPA 33 2009 Edition and your insurance company requirements LN 9409 03 Programmers Manual 9 Section 2 INTRODUCTION The RCS 2 System is capable of communicating with Allen Bradley Rockwell Automation style PLC s using Remote I O via the optional RIO Interface Card P N 77377 22 Some of the data to and from the RCS 2 may be in the form of sim ple bits Discrete I O or in the form of tables of data Block Transfer Reads or Writes section 3 HARDWARE SETUP The RCS 2 system uses two slot addressing Slot 0 is rese
43. ult for the gun if it is in the faulted state Trigger 1 2 3 or 4 Type of Input Gun Type of Signal Maintained This input tells the controller to run the pumps if and only if the gun has first been placed in run mode The additional trigger input signals 2 3 and 4 can be used in cases where the output of a fluid panel is split between multiple applicators They work in conjunction with each other to allow up to 4 independent triggers one for each of 4 applicators The soft ware can be configured in such a way that if one of these inputs is on the fluid panel delivers the target flow rate of material If a sec ond input is turned on then the fluid panel will deliver twice the target flow rate If a third input is energized three times the target flow is delivered and if all four inputs are energized the fluid panel will deliver four times the target flow rate It is assumed that each of these inputs are also connected to the trigger inputs on four independent applicators LN 9409 03 RCS 2 Programmers Manual 35 DISCRETE CHANNEL AND GUN INPUTS Motor Amp Enable Type of Input Channel Type of Signal Maintained This is an input to the controller from the motor amplifier indicating that the motor amplifier has detected a problem and has placed itself in a faulted condition Volume Fill Type of input Gun Type of signal Pulsed By pulsing the volume fill discrete input the unit will be put into the V FILL mode The gun
44. wed into the fluid d Ll line and then the Trigger Input unit will halt and pr return to the Ready state The unit Run Input should then be placed in run mode to await the trigger signal LN 9409 03 RCS 2 Programmers Manual 38 Fast Fill Since 2k materials Time based F74 pr are ratioed during fast fills it is Run Input necessary to first putthe unit in run Gun Active Output _ ft mm ra trigger signal is not Fast Fill Input TL required Use a rd F halt signal to exit fast fill mode Halt Reset Input o SJL Pumps spin immediately upon reception of the fast fill bit Volume Fill Itis possible to fast with Fast Fill Volume Fill Input NEI ca hr ee br fill mode must be sae initiated first Wait Gun Active Output for the active signal to be asserted prior to initiating the fast Fast Fill Input TL fill bit M rn Run Input TL Channel Fill Gun must not be in A Fill B Fill the run state to use or AB Fill Channel Fill Input TL channel fill When Lr achannel fill is received the pump S starts spinning immediately a Halt Reset Input trigger signal is not Le required The Gun Active output is not asserted while in A or B Fill modes A Haltis required to take it out of A or B Fill modes Gun Active Output LN 9409 03 RCS 2 Programmers Manual 39 Pushout mode allows the user to Pushout Input pushout a plural component material with a
45. which the RCS 2 responds to discrete inputs and output via the RIO link is very fast and should approach the speed of communicating with it via its physical discrete inputs and outputs In most circumstances where a pulse is required to set the RCS 2 in a desired mode holding the signal on for 0 25 seconds is adequate However there have been instances where that time has not been adequate when the RCS 2 was on a busy RIO channel Some experimentation may be necessary to insure that the unit does in fact react predictably and repeatedly to the commands issued Many of the discrete input commands can be confirmed by monitoring the feedback signals from the RCS 2 Refer to Appendix A for a list of discrete inputs and outputs their functions and how they affect other inputs or outputs For signals that cannot tolerate any delay whatsoever such as gun trigger and analog flow command it is imperative that these sig nals be wired directly to the physical discrete inputs of the RCS and not run via RIO DISCRETE SYSTEM I O Biti PLC Inputs PLC Outputs PLC Word 0 n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a n a System Faulted Spare Digital In System Pulse Spare Digital In 10 User Link Active Spare Digital In 11 Spare Digital Spare Digital In System Out Spare Digital Spare Digital In Out LN 9409 03 RCS 2 Programmers Manual 14 DISCRETE I O continued RCS2 BTR D
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