Ransburg 22-1589 Service Manual
SERVO AMPLIFIER
SERVICE MANUAL
LN-9405-00.1
Replaces (LN-9405-00)
MODEL: 22-1589
IMPORTANT: Before using this equipment, carefully read
SAFETY PRECAUTIONS, starting on page 1, and all
instructions in this manual. Keep this Service Manual for
future reference.
Service Manual Price: $20.00
LN-9405-00.1
Servo Amplier - Contents
CONTENTS
SAFETY:
SAFETY PRECAUTIONS..........................................................................................................
HAZARDS / SAFEGUARDS......................................................................................................
PAGE
1-3
1
2-3
INTRODUCTION:
GENERAL DESCRIPTION.........................................................................................................
SERIAL AND NETWORK COMMUNICATION PORTS...........................................................
ESTABLISH COMMUNICATION TO AMPLIFIER.....................................................................
CONNECT AND CONFIGURE AMPLIFIER.............................................................................
DOWNLOADING PROCEDURE...............................................................................................
INSTALLATION:
SETUP AND OPERATION.........................................................................................................
PROGRAM MODES...................................................................................................................
RETROFIT KIT (78694), RCS AMPLIFIER RETROFIT............................................................
RETROFIT KIT (78694-02), PULSE MODE OPERATION.......................................................
RETROFIT KIT (78694-01), ANALOG MODE OPERATION....................................................
GE FANUC S2K AMPLIFIER TERMINATION...........................................................................
TROUBLESHOOTING GUIDE
FRONT PANEL LED DIAGNOSTIC..........................................................................................
PARTS IDENTIFICATION:
4-5
4
4
4-5
5
5
6-16
6
7-9
10-12
13
14
15-16
17
17
18
ORDERING PROCEDURE........................................................................................................
PART NUMBERS........................................................................................................................
WARRANTY POLICIES:
LIMITED WARRANTY................................................................................................................
APPENDIX:
PAINT AND SOLVENT SPECIFICATIONS..............................................................................
VISCOSITY CONVERSION CHART.........................................................................................
VOLUMETRIC CONTENT OF HOSE OR TUBE......................................................................
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18
18
19
19
20-23
20
21-22
23
Servo Amplier - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety literature for your Ransburg products. This manual
contains information that is important for you to
know and understand. This information relates to
USER SAFETY and PREVENTING EQUIPMENT
PROBLEMS. To help you recognize this information, we use the following symbols. Please pay
particular attention to these sections.
A WARNING! states information to alert you to a
situation that might cause serious injury if instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard specications
and service procedures, some minor deviations
may be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements,
etc., make such variations inevitable. Compare
this manual with your system installation drawings
and appropriate Ransburg equipment
manuals to reconcile such differences.
W A R N I N G
> The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
> 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 re
codes and ordinances as well as NFPA 33
SAFETY STANDARD, 1995 EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
!
> The hazards shown on the following
page may occur during the normal use of
this equipment. Please read the hazard
chart beginning on page 2.W A
Careful study and continued use of this manual
will provide a better understanding of the equip-
ment and process, resulting in more efcient
operation, longer trouble-free service and faster,
easier troubleshooting. If you do not have the
manuals and safety literature for your Ransburg
system, contact your local Ransburg representative or Ransburg.
1
LN-9405-00.1
Servo Amplier - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate opera-tioning and maintenance
procedures will cause a re
hazard.
Protection against inadvertent
arcing that is capable of caus-
ing re or explosion is lost if
any safety interlocks are disabled during operation. Frequent power supply shutdown
indicates a problem in the
system requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Fire extinguishing equipment must be present
in the spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray
area.
The high voltage supplied to the atomizer
must be turned off prior to cleaning, ushing or
maintenance.
When using solvents for cleaning:
Those used for equipment ushing should have
ash points equal to or higher than those of the
coating material.
Those used for general cleaning must have
ash points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by NFPA 33, 2000 Edition, OSHA and
local codes. In addition, ventilation must be
maintained during cleaning operations using
ammable or combustible solvents.
Electrostatic arcing must be prevented.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but
only as instructed.
Non-factory replacement parts or unauthor-
ized equipment modications may cause re
or injury.
If used, the key switch by-pass is intended for
use only during set-up operations. Production
should never be done with safety interlocks
disabled.
LN-9405-00.1
Never use equipment intended for use in waterborne installations to spray solvent based
materials.
2
Servo Amplier - Safety
AREA
Tells where hazards
may occur.
General Use and
Maintenance
Electrical
Equipment
HAZARD
Tells what the hazard is.
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
High voltage equipment is
utilized. Arcing in areas of ammable or combustible materials may occur. Personnel are
exposed to high voltage during
operation and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shutdown indicates a problem in the
system which requires correction.
SAFEGUARDS
Tells how to avoid the hazard.
Personnel must be given training in accordance
with the requirements of NFPA-33, Chapter 16,
1995 edition.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, re protection, operation maintenance, and housekeeping. OSHA
references are Sections 1910.94 and 1910.107.
Also refer to NFPA-33, 1995 edition and your
insurance company requirements.
The power supply, optional remote control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas. Refer to NFPA No. 33, 1995 Edition.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of ammable or combustible material.
Testing may require high voltage to be on, but
only as instructed.
Production should never be done with the safety
circuits disabled.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
3
Before turning the high voltage on, make sure no
objects are within the sparking distance.
LN-9405-00.1
INTRODUCTION
Servo Amplier - Introduction
(For a General Description, Features, and
Specications, Reference GE Fanuc S2K
Series Standalone Motion Controller User’s
Manual, GFK-1848)
SERIAL AND NETWORK
COMMUNICATION PORTS
Summary of DIP Switch Functions
Refer to the S2K Hardware Manual for an explanation of the DIP Switch functions. Set the DIP
Switches for Device Net Address and baud rate
if used.
Serial Port
The S2K includes a serial port that is used to set
the operational parameters. The serial port is an
RS-232 port designed to operate a 7 data bits, 1
stop bit, and odd parity.
AMPLIFIER
(For a General Description of programing
protocol, reference GE Fanuc Generation D
Real-Time Operating System Program-ing
Manual, GFK-2205.)
Cable Connection
Connect the serial cable to the serial port on the
S2K amplier and tighten screws to fasten the
connector. Connect the opposite end of serial
cable into the RS-232 serial communication port
of computer. Tighten the screws to fasten the
connector.
Install Operating Software
The operating software for this amplier is proprietary of GE Fanuc. The operating software is
titled “CCS Win32.” Insert CCS Win32 CD into
computer and install. Follow typical Window installation methods.
A typical 2 conductor shielded cable can be used
to communicate to the S2K amplier. The connectors are the standard 9-pin D-Sub connector
style. The wiring is a straight through style where
the shield is connected to pin 5 of both D-Sub
connectors. The red wire is connected to pin 3
and the black wire is connected to pin 2 of both
connector ends. Refer to the Hardware Manual
(GE Fanuc, S2K Series Manual) for additional
wiring information.
Cable Length Maximum
Communication cables exceeding 30 meters
in length must be enclosed in grounded metal
conduit.
ESTABLISH
COMMUNICATION TO
Communicating to Amplier
1. Open CCS
2. From Terminal window, select
Options/Communication Setup
3. Select Serial Communication
4. Select the appropriate COM Port setting
5. Leave Baud Rate set to its default value of 9600
6. Click OK
7. Select Options/Controller Settings
8. Select Serial as the Communication Type
9. Select S2K as the Controller Type
10. Click OK
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11. Press enter and the S2K will sign on.
4
Servo Amplier - Introduction
CONNECT AND
CONFIGURE AMPLIFIER
Amplier Termination
• Complete the motor, power, and I/O wiring to
the S2K Amplier. (Reference system prints and
GE Fanuc Manual.)
• Maximum encoder cable length is 15 meters
using factory supplied cables.
• Maximum resolver cable length is 50 meters
using factory supplied cables.
• Positive feedback cables exceeding 30 meters
in length must be enclosed in grounded metal
conduit.
• Reference system drawings for specic appli-
cation terminations.
• Operation with a Pulse Source or Operation
with an Analog Input voltage can also be used
for reference.
• Jumper ENABLE to Common if using internal
12- volt supply or to your external supply common.
Jumper ENABLE + to + voltage if using internal
+12 Volt supply or to your external supply + voltage. (Reference the system drawings as this
Enable signal may already be terminated.)
DOWNLOADING
PROCEDURE
Summary of Downloading Procedure
(Refer to the GE Fanuc Generation D Real-Time
Operating System Programing Manual, GFK-2205
for further explanation.)
• Type STF (Set Fault, faults program)
• Type KLALL (Kill All, halts programs which
enables programs to be up or down loaded.)
• Type UPS=O (UPS must be set to its default
value of zero before CLM command will function.)
• Type CLM (Clear Memory) Are your sure you
want to clear all the user memory and reset the
registers to their default valves?
• Type Y (Yes) (User memory cleared.)
• Click Tools/Send Files
• Select program to download
• Do you wish to save Programs and Motion
Blocks? Click on Yes
• Type Yes (Then the screen will tell you that
the user memory has been saved.)
Enable the Drive
Close the Enable switch from your external device to clear the fault condition. The digital status
LED on the front of the S2K will change to OK.
By toggling this Enable bit, it will allow the operator to clear faults and enter programs during the
programming mode.
5
• Click OK or OPEN
Program is in the form of a text le and will be
downloaded to the Amplier.
LN-9405-00.1
INSTALLATION
Servo Amplier - Installation
SETUP AND OPERATION
Summary of Dip Switch Functions
(Refer to the S2K Hardware Manual for an explanation of the DIP Switch functions. Reference the
system prints for the correct settings.)
Software Programmable Parameters
The SMD emulator program in the S2K allows
all of the original SMD parameters to be set in
software in the S2K. Following is a list of the parameters. These parameters must be set with the
power ON, but with the Enable input set to OFF.
DEFAULT PROGRAMMABLE PARAMETERS
To Query a parameter, type (addr)
variable?<Enter>where<Enter>is the Enter key
on your terminal.
For example: 1VI1?<Enter>will report the mode:
0=pulse input, 1=analog input.
To set a parameter, type (addr) variable = <Enter>
where<Enter>is the Enter key on your terminal.
For example: 1PLA=512<Enter>sets the gear
ratio to 1:1.
Parameter
PLA
VI1
VI4
VF10
VF11
VF12
VF13
VF14
VF15
VF16
VF18
VF19
The above parameters are the factory default setting and any modications must be programmed.
Proceed to Program Modes.
Sets gear ratio
Control mode
Direction
Analog input zero
Analog input full scale
Output shaft speed scale factor, rpm/volt
Accel time constant, milleseconds
Maximum motor current, amps
Control stiffness, %
Torque to Inertia ratio
Maximum shaft output speed, rpm
Analog input time constant
Function
Figure 2: Default Programmable Parameters Table
Minimum
512 = 1:1
0 = Pulse
0 = CW
-10.0
+2.0
10.0
2
0.5
25
330
10
Maximum
5120 = 1:1
1 = Analog
1 = CCW
+10.0
+10.0
25.0
100
3.0
200
60000
255
Default
512
1
0
0.0
+10.0
15.0
22
3.0
100
3000
150
4
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