Ransburg RCS 2 User Manual
Ransburg
SERVICE MANUAL
LN-9407-00.3
(Replaces LN-9407-00.2)
March - 2013
RCS-2 USER MANUAL
MODELS: A10549 CONTROL CONSOLE
A10776 MOTOR AMPLIFIER PANEL
A10948 FLUID PANEL
IMPORTANT: Before using this equipment,
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
Service Manual Price: $50.00 (U.S.)
RCS-2 User Manual - Contents
CONTENTS
SAFETY:
Ransburg
PAGE
1-5
SAFETY PRECAUTIONS..........................................................................................................
HAZARDS / SAFEGUARDS......................................................................................................
INTRODUCTION:
FEATURES..................................................................................................................................
SPECIFICATIONS......................................................................................................................
GENERAL DESCRIPTION.........................................................................................................
CHANNELS AND GUNS ...........................................................................................................
CONTROL RACK INTEGRATION.............................................................................................
CONFIGURABLE OPERATING PARAMETERS......................................................................
BLOCK DIAGRAMS....................................................................................................................
FLUID PANEL SCHEMATIC.......................................................................................................
INSTALLATION:
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.......................................................................................
1
2-5
6-13
6
7
7-10
10
10
10-11
12
13
14-27
14
15-17
17
18-20
20-21
21-22
22
22
23-24
25
26
27
OPERATION:
SETUP AND OPERATION.........................................................................................................
BUTTON FUNCTIONS...............................................................................................................
PASSWORD OPERATION........................................................................................................
CONFIGURABLE OPERATING PARAMETERS......................................................................
USER INTERFACE SOFTWARE...............................................................................................
LIMITED WARRANTY:
LIMITED WARRANTY.................................................................................................................
(Continued On Next Page.)
28-49
28
28-29
29
29-30
31-49
50
50
LN-9407-00.2
Ransburg
CONTENTS (Cont.)
RCS-2 User Manual - Contents
PAGE
APPENDIX:
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................................................................
51-77
51
52
53
54
55
56
57-59
60-61
62-63
64-67
68-71
72
73-74
75-77
LN-9407-00.2
RCS-2 User Manual - Safety
SAFETY
Ransburg
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.
W A R N I N G
!
The user MUST read and be familiar with the
Safety Secon in this manual and the Ransburg
safety literature therein idened.
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 operang 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, LATEST EDITION, prior to installing,
operang, and/or servicing this equipment.
W A R N I N G
!
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.
Careful study and continued use of this manual will
provide a better understanding of the equipment
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.
The hazards shown on the following pages
may occur during the normal use of this equipment. Please read the hazard chart beginning on
page 2.
1
LN-9407-00.2
Ransburg
RCS-2 User Manual - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent arcing that is capable of
causing re or explosion is
lost if any safety interlocks
are disabled during operation. Frequent Power Supply
or Controller 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, OSHA, country, and local
codes. In addition, ventilation must be maintained during cleaning operations using ammable or combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
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 unautho-
rized equipment modications may cause re or
injury.
If used, the key switch bypass is intended for
use only during setup operations. Production
should never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be
set up and operated in accordance with NFPA33, NEC, OSHA, local, country, and European
Health and Safety Norms.
LN-9407-00.2
2
RCS-2 User Manual - Safety
Ransburg
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate operation and maintenance proce-
dures 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 or
Controller shutdown indicates
a problem in the system requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2
hazardous areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding section of the equipment manual. Protection against inadvertent arcing that is capable
of causing re or explosion is lost if the current
overload sensitivity is not properly set. Frequent power supply shutdown indicates a problem in the system which requires correction.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no
objects are within the safe sparking distance.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accordance with NFPA-33, EN 50176.
Have re extinguishing equipment readily available and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be
read and understood prior to using this equipment.
Comply with appropriate local, state, and national codes governing ventilation, re protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms
and your insurance company requirements.
3
LN-9407-00.2
Ransburg
RCS-2 User Manual - Safety
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The resistance between the part and earth
ground must not exceed 1 meg ohm. (Refer to
NFPA-33.)
Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the
palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
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. Grounded conductive ooring
must be provided in the spray area.
Always turn off the power supply prior to ushing, cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
LN-9407-00.2
4
RCS-2 User Manual - Safety
Ransburg
AREA
Tells where hazards
may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may oc-
cur. 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.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous locations, the power supply, control cabinet,
and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN
50176.
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.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Toxic Substances
Spray Area
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Explosion Hazard –
Incompatible Materials
Halogenated hydrocarbon sol-
vents for example: methylene
chloride and 1,1,1,-Trichloroethane are not chemically
compatible with the aluminum
that might be used in many system components. The chemical
reaction caused by these solvents reacting with aluminum
can become violent and lead to
an equipment explosion.
Follow the requirements of the Material Safety
Data Sheet supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
Use a mask or respirator whenever there is a
chance of inhaling sprayed materials. The mask
must be compatible with the material being
sprayed and its concentration. Equipment must
be as prescribed by an industrial hygienist or
safety expert, and be NIOSH approved.
Aluminum is widely used in other spray application equipment - such as material pumps,
regulators, triggering valves, etc. Halogenated
hydrocarbon solvents must never be used with
aluminum equipment during spraying, ushing,
or cleaning. Read the label or data sheet for the
material you intend to spray. If in doubt as to
whether or not a coating or cleaning material is
compatible, contact your coating supplier. Any
other type of solvent may be used with aluminum
equipment.
5
LN-9407-00.2
Ransburg
INTRODUCTION
FEATURES
RCS-2 User Manual - Introduction
• Control of up to 8 gear pumps from one 24"
W X 24" H X 17" D control console
• Guns congurable as single or dual channel
guns. (Congurable as 8 single channel
guns, 4 dual channel guns, or almost any
combination of the two.)
• Dual channel guns congurable as automatic
(ow and ratio control) or as manual (ow,
ratio, and pressure control) modes
• Congurable operating parameters for all
channels and guns. (Up to 199 "Jobs" per
gun can be programmed.)
• Full color graphical screens for setup, opera tion, and diagnostics.
• Comprehensive help information available
from all screens.
• USB ports allow backup of all operating
parameters, retrieval of ow response
graphs, and updating of user interface soft
ware.
• Firmware on control cards is stored in ash
memory and can be updated using a laptop
with a serial port. (Firmware and software
updates can be emailed to site.)
• User interface computer can be located any where and a simple Ethernet cable run from
interface PC to RCS-2 interface card.
• Retrot option allows RCS customers to
upgrade their electronics and use their
existing uid components.
• All discrete digital and analog inputs and out puts can be monitored and forced for diag nostic purposes.
• Pot life timer monitoring and alarming.
• Pressure pot volume monitoring and alarm ing.
• Congurable alarms, faulting conditions, and
alarm tolerance times.
• With proper pump sizes selected, has virtu-
ally unlimited ratio and ow capabilities.
(Currently available pumps provide ow
ranges from 0.9 cc/min to 1500 cc/min per
channel.)
• Discrete I/O capabilities allow interfacing to
any manufacturer's PLC.
• Bradley Remote I/O capabilities (op tional)
• All parameter screens can be password pro tected.
• Most analog inputs and outputs congurable
for 0-10 VDC or 4-20 mA.
• Data acquisition style trending screens avail-
able for setup, diagnostics, and ne tuning of
the system.
LN-9407-00.2
6
RCS-2 User Manual - Introduction
Ransburg
SPECIFICATIONS
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 Amplier 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: 400 lbs. (181.5 Kg)
Operating Temperature: 32°F to 120°F
(0°C to 49°C)
Operating Humidity: 0% to 95%
Power Requirements: 120 VAC at 10
Amps
(240 VAC at 5 Amps)
Pneumatic Air Consumption: Less
than 5 cfm
Pneumatic Air Inlet Size: 3/8" ODT
GENERAL DESCRIPTION
The RCS-2 System is composed of four basic
elements:
• Main Control Console
• Motor Amplier Panel
• Fluid Panel
• Remote Operator's Panel
The Main Control Console can control up to 8
pumps, the Motor Amplier Panels will interface
with either one or two pumps, and the Fluid
Panels are available with either one or two
pumps.
Main Control Console
The Main Control Console is the heart of the
system. 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 lter and fuses
• I/O connectors for motor amplier panels
Pneumatic Air Outlet Size: ¼” ODT
User Interface
Processor: 1 GHz Intel® PIII
Running Windows
Embedded XP
Interface Board Processor: Rabbit 2000™
Channel Board Processor:
Motorola MC68HC16
Fluid Capacity: 0.9 cc/min to 1500 cc/min
per pump
Fluid Inlet Size: 3/8" ODT
Fluid Viscosity Range: 20–1000 centipoise
Fluid Inlet Pressure: 0 psi to 200 psi
Fluid Outlet Pressure: 200 psi maximum
7
The User Interface Computer is a Pentium®
based PC with a non-volatile ash-disk that
contains a Windows XP® Embedded operating
system and the RCS-2 user-interface software.
It has an on-board Ethernet port to allow interface
with the interface card. The computer has USB
ports for updating its software and for backing-up
parameter data. Keyboard and mouse ports are
also available on the unit for setup, diagnostics,
and troubleshooting, if necessary.
The control card rack is a half-width 19" rack
with space for one RIO card, one interface card,
and up to four channel cards. It is powered from
24 VDC and utilizes up to 9 ribbon cable connections (if all 8 channels are used). High speed
communications between cards is accomplished
using a Motorola® SPI bus.
LN-9407-00.2
Ransburg
RCS-2 User Manual - Introduction
The interface card houses a Rabbit 2000®
embedded processor. This board performs the
following functions:
• It handles all communications between
the 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 the
color change sequencer.
• Handles all discrete system I/O (job num ber inputs, strobe inputs, system fault out puts, etc.).
Each channel card houses a Motorola®
MC68HC16 embedded processor. These boards
perform the following funtions:
• Controls all gun and channel specic dis-
crete inputs and outputs.
• Controls all gun and channel specic ana-
log inputs and outputs.
• Holds rmware for PID loops that control
motor ampliers.
• Holds rmware for PID loops that control
inlet pressure transducers.
The LCD touch-screen display is a 15" diag-onal, full color LCD display with 1024 by 768
pixel resolution.
There is one DC power supply housed in the
main control console. It supplies 24 VDC for
all discrete I/O signals and for the boards in the
control rack.
The ribbon cable interface boards provide easy
screw-terminal access to all analog and digital input
and output signals. They also provide specic test
points to allow easy connection of test devices
and data acquisition equipment.
On the top of the main control console there are
up to eight 26-pin military-style connectors, one
for each channel. These I/O connectors allow
the main control console to be interfaced with
the motor amplifer panel(s) via the 26-conductor
"umbilical cables". Also, on the top of the main
control panel are two Ethernet connectors used
to connect to the interface card and user interface
computer.
Motor Amplier Panels
The Motor Amplifer Panels act as the interface
between the CPU on the channel cards and the
"real world" devices such as motors, pressure
transducers, and ow switches. They house the
following items:
• Motor Drive Ampliers
• 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 ampliers convert a 0 to 10
VDC signal from the channel cards to a proportional RPM (0 to 150) at the motors. They also
receive the feedback from the resolvers attached
to the motors. In this way, they can generate a
fault if the actual motor RPM does not match the
target RPM.
The E to P pressure transducers convert a 0 to
10 VDC signal or optionally a 4 to 20 mA signal
from the channel cards to a proportional 0 to 100
psi air signal. This signal is used to pilot uid
regulators on the inlet of the pumps, allowing the
channel card to control the inlet pressure of the
pumps.
The terminal strip is used for connecting AC
power to the unit and for access to the 24 VDC
power supply for external I/O devices. The terminal strip has two fuses, one for the incoming
AC power and one for the 24 VDC control power.
On the buttom of the terminal strip is a Corr-Com®
power lter for the incoming AC.
LN-9407-00.2
The optional Zener barriers make the pressure
sensors and the optional Remote Operator's Panel
intrinsically safe for use inside the spray area.
The optional catalyst ow sensor interface
module powers and monitors the ow sensor
8
RCS-2 User Manual - Introduction
Ransburg
typically used in the catalyst line of the uid panel.
An additional module converts the ow signal to
a 4 to 20 mA signal that is proportional to the ow
rate of the catalyst. That signal is then fed back
to the channel card so it can be used to generate
faults when catalyst ow falls below a preset point
or if air is detected in the supply line.
The 24 VDC power supply powers the E to P
transducers, the pressure sensors, catalyst ow
sensor modules, and the optional Remote Operators's Panel.
If the optional color change sequencer is installed,
this power supply will also have a +5 VDC output
to power the color change sequencer.
The optional Color Change Sequencer is a small
P.L.C. like processor that controls the ush, load,
and color change sequences for each gun and
job number. Each time a job number is loaded
into a gun, the ush and load sequences are
downloaded to this controller. (A color change
sequence is simply a ush sequence followed by
a load sequence.)
The pump manifolds house the magnetic couplings which tie the servo motors to the gear pumps.
The servo motors actually house both an AC drive
servo motor and a feedback resolver in the same
physical housing. They get their drive signals
from the motor drive ampliers and the resolvers
feed their rotational information back to the motor
drive ampliers. (Explosion proof servo motors
are available as an option.)
The pressure sensors convert the uid pressure
from the uid inlet and outlet of the pumps to a
4 to 20 mA signal which is then fed through the
zener barriers and back to the channel boards (in
the control rack). Standard units have a pressure
range of 0 psi to 200 psi.
The catalyst ow sensor is a thermal shedding
type ow sensor that is immersed in the catalyst
ow stream. It detects ow by heating the sensor
and then sensing how much of the heat is being
removed from the sensor by the ow of catalyst.
(More ow = more heat removed from the sensor
head.) An optional explosion-proof version of this
sensor is available for use in hazardous areas.
Fluid Panels
The Fluid Panels contain all of the "wetted" components for the RCS-2 as well as the drive motors.
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 pumps are available in various sizes for
various materials and ow rates. Users should
consult Ransburg technical support group to
determine which pumps are required for their
specic application. (Refer to "Appendix B" for a
list of currently available pump sizes.)
The Mix-Block is a three-port manifold that brings
the uid from the outlet of the resin pump together
with the outlet of the catalyst pump. The block
houses a check valve in the catalyst stream to
prevent resin from backing up into the catalyst
ow stream. Attached to the bottom of the MixBlock is a solvent ush valve for quick ushing of
only the mixed material from the Mix-Block out to
the applicator.
Attached to the outlet of the Mix-Block is the spiral
mix tube. This is simply a piece of tubing with a
helical-shaped element inside the tube. This element causes the two materials (resin and catalyst)
to be "folded" together numerous times as the
materials pass through it, thus causing it to mix.
The optional CCV style color valve stack allows
users to do color changes on the resin side of up
to 10 colors.
9
LN-9407-00.2
Ransburg
RCS-2 User Manual - Introduction
The solvent manifold supplies solvent for ushing
as well as lling of the magnetic coupling chamber.
The pump bypass valve is mounted on the resin
pump and allows the uid passing into the inlet
of the resin pump to bypass the gears and go
directly to the outlet port. This can decrease ush
and load times.
NOTE
> This valve should not be used while
loading 2k materials as improper ratios
will result.
CHANNELS AND GUNS
The RCS-2 control system achieves closed-loop
control of its uids via its congured channels and
guns. A channel consists of one pump, one motor,
one motor amplier, two pressure transducers,
and one half of a channel card.
A gun, in most cases, represents one applicator
and may be congured with one channel (for ow
control only) or congured with two channels (for
ratio and ow control).
Each channel operates independently of and
simultaneously with all of the other channels in
the system. The controller, therefore, provides
accurate dynamic ow control for all channels.
CONTROL RACK
INTEGRATION
The control rack has been designed to be consistent with other Ransburg products to allow
integration of the RCS-2 control rack in larger
control consoles. These consoles may house
rotary atomizer speed control, shaping and fan
air control, high voltage setpoints, etc.
CONFIGURABLE
OPERATING
PARAMETERS
The design of the system allows it to be congured
to meet the requirements of the application. The
large number of parameters allows the system to
be used in almost any application involving ow
and/or ratio control of uids.
System Parameters are parameters that affect
the overall system, which includes all channels
and 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 Parameters are parameters that affect the
gun. These parameters apply to all channels
congured to that gun. They include:
• Mode (manual or automatic)
• Number of channels congured 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
LN-9407-00.2
10
RCS-2 User Manual - Introduction
Ransburg
Channel Parameters are parameters that affect
only that specic channel. For two channel guns,
there are independent parameters for each of the
two 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 Parameters are parameters that are stored
with the specic job number. Typically, a job
number is assigned to a specic material. In this
way, totalization data and PID parameters relate
directly 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 Conguration Parameters allow the
user to specify what conditions cause a "spray
shutdown" 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 *
NOTE
> Items marked with an asterisk (*) can-
not be disabled
11
LN-9407-00.2
Ransburg
BLOCK DIAGRAMS
RCS-2 User Manual - Introduction
Figure 1: Control Console Block Diagram
LN-9407-00.2
Figure 2: Motor Amplier Panel Block Diagram
12
RCS-2 User Manual - Introduction
Ransburg
13
Figure 3: Fluid Panel Schematic
LN-9407-00.2
Ransburg
INSTALLATION
RCS-2 User Manual - Installation
SYSTEM GUIDELINES
Customized Prints
Drawings and information contained in this section
of the manual is applicable to most installations.
However, in many cases, will supply custom
installation drawings for your specic site. It is
highly recommended that if your installation differs
signicantly from the installation drawings supplied
by, you notify your representative to ensure that
standard installation practices are not violated and
to have your prints updated to reect the installation
accurately for future reference.
Cable Assemblies
Interconnections between all control panels and
the uid panels are made using custom manufactured cable assemblies with military style connec-
tors. This simplies installation and eliminates the
possibility of items being wired incorrectly. The
one exception to this is the discrete interface I/O
wiring. These connections will vary greatly from
installation to installation. This can involve well
over 100 connections per control console and,
therefore, require that conduit be run to the control
console and multiple cables or wires pulled from
the control console to the controlling medium
(PLC, robot, etc.).
There are four basic panels used in the RCS-2
system:
• Main Control Console
• Motor Amplier Panel
• Fluid Panel
• Remote Operator’s Panel
The motor amplier panels must be placed within
100-feet of the control console, the uid panels
must be placed within 10-feet of their respective
motor amplier panel, and the remote operator’s
panel must be placed within 25-feet of its respective
motor amplier panel. If longer distances than
this are necessary, contact your representative.
Fluid Regulators
It is highly recommended that a pilot operated
uid regulator (similar to the DR-1 regulator) be
used on the inlet of all of the gear pumps. The
accuracy of the pumps depends to a high degree
on controlling the differential pressure across the
pump. The system includes pressure transducers
in the motor amplier panels to pilot these uid
regulators. In this way, the software has full con-
trol of uid inlet pressure of the pumps and can,
therefore, control the differential pressure across
each pump. By using this feature, the extremely
accurate ow rates and ratios can be maintained,
without the need to calibrate the pumps.
Equipment Grounding
All panels should be grounded in accordance with
either the National Electrical Code or local electrical codes (whichever is more stringent). Refer to
the electrical installation drawings provided by to
locate the grounding terminal for all control panels.
Equipment Locations
All of the panels must be located outside of the
hazardous area with the exception of the intrinsically safe version of the Remote Operator’s Panel
(and in some cases the uid panel). If in doubt,
refer to local codes and ordinances, or contact
your representative for clarication.
LN-9407-00.2
Intrinsic Safety
The motor amplier panels can be ordered with
optional zener barriers that make the uid panels
and the remote operator panels intrinsically safe
for operation inside hazardous areas. An optional
explosion-proof catalyst ow sensor and motors
are also available. They must be hard-piped if
used in hazardous areas.
14
RCS-2 User Manual - Installation
DIMENSIONAL INFORMATION
Ransburg
Figure 4: Stand-Alone Unit
15
Figure 5: Motor Amplier Panel
LN-9407-00.2
Ransburg
RCS-2 User Manual - Installation
LN-9407-00.2
Figure 6: Control Panel Assembly
16
RCS-2 User Manual - Installation
Ransburg
Figure 7: Fluid Panel Assembly
INPUT POWER
Input power supply connections should be made
from a fused disconnect. With the exception of
the stand alone, cart mounted RCS-2; conduit
should be used for bringing the input power into
the control panel and motor amplier panels. In
the case of the stand alone unit, SO cord will be
provided with standard AC grounded plugs.
Both the control panel and the motor amplier
panels operate from 120 VAC at 60 Hz with a
maximum current draw of 10 amps (for each
panel). The uid panels get their power from the
motor amplier panel and, therefore, require no
power connections.
If there is the possibility of AC line voltage uctuations of greater than ±10% of the line voltage, a
constant voltage transformer (CVT) should be used
between the fused disconnect and the control panel
and motor amplier panels. (These uctuations
are commonly seen when heavy electric machinery or welding equipment is being used nearby.)
Figure 8: Control Panel Input Power
Refer to Figures 8 and 9 to determine proper AC
power and ground connections to the control panel
and the motor amplier panels.
17
Figure 9: Motor Amplier Panel Input Power
LN-9407-00.2
Ransburg
RCS-2 User Manual - Installation
DISCRETE CHANNEL AND
GUN INPUTS
All discrete digital inputs are optically isolated and
will function with an input voltage in the range of
10 VDC to 45 VDC. Factory jumper settings on
the interface and channel boards require that
voltage be sourced to the discrete input. If, however, a sinking input is required, inputs can be
recongured by changing those jumpers. (See
Appendix C for Channel Board Jumper Settings.)
It is recommended that the 24 VDC power supply
in the controller be used to source these inputs
(terminal #1331). Optionally, if an external supply
If the gun is congured as a single channel gun
and this signal is pulsed, the gun will be put in
fast ll mode. This will cause the pump to run at
its maximum rate (150 RPM) until the halt signal
is pulsed. (It is not necessary to have the trigger
signal energized.)
NOTE
> Times stated above are for discrete
digital inputs only. When interfacing using Bradley's Remot I/O (aka RIO), these
times may vary signicantly. (Refer to the
RCS-2 RIO Interface Programmer's Manual for more details.)
pulsed signals to a gun should also be separated
by 250 milliseconds. For example, don't turn the
halt/reset signal off at the same time that the run
signal is being turned on as results will be unpredictable. Maintained signals operate as long as
the input remains energized.
Figure 10: Gun I-O Sourcing-Sinking
is used as the source for these inputs, it must be
referenced to the ground terminal (terminal #1113).
There are two types of discrete digital inputs,
pulsed inputs and maintained inputs. The pulsed
inputs must be turned on and held on for 250 milliseconds minimum, to insure operation. Multiple
Some discrete digital inputs are specic to a gun
and others are specic for a channel. If it is a gun
input and the gun is congured as a two channel
gun, eld wiring must always be connected to the
master channel terminals (channel A).
Fast Fill
Type of Input: Gun
Type of Signal: Pulsed
The gun must be in run mode prior to initiating
this mode or the RCS-2 controller will ignore it.
If the gun is congured at a two-channel gun, and
this input is pulsed, the gun will be placed in fast
ll mode. 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 (150
RPM) and run the opposite channel at whatever
speed is necessary to ensure the proper ratio
of component A to component B. The software
LN-9407-00.2
18
RCS-2 User Manual - Installation
Ransburg
determines this based on the programmed pump
sizes and the programmed ratio. Pulsing the halt/
reset input takes the gun out of the fast ll mode.
Channel Fill
Type of Input: Channel
Type of Signal: Pulsed
A gun must be in the ready 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 ushing, etc.) this input must be pulsed on
both channels. The halt signal for the specic
channel that is channel lling must be pulsed. For
example: if both channels are channel lling, both
halt signals must be pulsed to stop them.
Feather Set
Type of Input: Gun
Type of Signal: Pulsed
If the gun is congured 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 y". That is, if a handsprayer 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 optional feather pressure sensor, if it is 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 handsprayer to utilize this fea-
ture. (Refer to "Appendix H" for more details on
feathering.)
Run
Type of Input: Gun
Type of Signal: Pulsed
This signal takes a congured gun from the ready
state to the "run" mode. In order for a gun to spray,
it must rst be put into run mode. It is essentially
a way of enabling a gun. Energizing the trigger
input of a gun will not cause uid to ow unless
the gun has rst been placed in run mode.
Halt/Fault Reset
Type of Input: Gun
Type of Signal: Pulsed
This input takes a congured gun that is in run
mode to the ready state, essentially disabling the
gun from spraying. It also resets a fault for the
gun if it is in the faulted state.
Trigger 1
Type of Input: Gun
Type of Signal: Maintained
This input tells the controller to run the pumps if and
only if the gun has rst been placed in run mode.
Motor Amp Enable
Type of Input: Channel
Type of Signal: Maintained
This is an input to the controller from the motor
amplier indicating that the motor amplier has
been enabled by the channel card and that there
are no problems.
Triggers 2, 3, and 4
Type of Input: Gun
Type of Signal: Maintained
These signals are additional trigger input signals.
They would be used in cases where the output of
a uid panel was split between multiple applicators. They work in conjunction with the trigger 1
input to allow up to 4 independent triggers, one
for each of 4 applicators. The software can be
congured in such a way that if one of these inputs
is on, the uid panel delivers the target ow rate
of material. If a second input is turned on, then
the uid panel will deliver twice the target ow
rate. If a third input is energized, three times the
target ow is delivered and if all four inputs are
energized, the uid panel will deliver four times the
target ow rate. It is assumed that each of these
inputs are also connected to the trigger inputs on
four independent applicators.
19
LN-9407-00.2
Ransburg
RCS-2 User Manual - Installation
Volume Fill
Type of input: Gun
Type of signal: Pulsed
By pulsing the volume ll discrete input, the unit
will be put into the V. FILL mode. (The gun must
be in the ready state prior to this.) When the
gun trigger input goes high, the pumps will run
at the programmed ow rate and ratio until the
volume programmed in for Fill Volume (on the
Job parameters screen) is dispensed. If more
than one gun trigger inputs goes high (triggers 2,
3, or 4) the unit will multiply the ow 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 and
returned to the ready state.
Volume Fill with Fast Fill Mode
It is possible to volume ll and fast ll simultaneously. If the gun is put into volume ll mode, and
then the fast ll input is pulsed, the unit will run in
fast ll mode until the volume programmed in for
ll volume is dispensed. At that time, the gun will
be halted and returned to the ready state. This
happens regardless of the condition of the gun
trigger inputs.
to a dry contact relay with allowable current limited
to 1 amp 45 volts, AC or DC (exceeding this limit
may damage the output on the channel card).
Although a myriad of voltages could be used, it
is recommended that the Hi signal be connected
to the +24 VDC terminal (terminal #1331) and the
output be taken from the Lo output terminal. This
terminal will supply 24 VDC when the output is
energized by the software. (Referenced ground
terminal is #1113.)
An alternate way of connecting these outputs
would be to connect the positive supply voltage to
the load, the common of the load to the Hi output
terminal of the RCS-2 output, and connect the Lo
output terminal to both the ground of the supply
connected to the load and the ground terminal
(terminal #1113). Once again, current must be
limited to 1 amp and should never exceed 40 volts.
Push Out
Type of Input: Gun
Type of signal: Pulsed
This feature allows a customer that uses dual purge
applicators to use two resin pumps that share a
common catalyst pump and pushout the resin with
solvent on one side of the dual purge applicator
while loading the other side of the applicator with
the next material to be sprayed. For additional
details on how to implement this feature, refer to"
Appendix L".
DISCRETE CHANNEL AND
GUN OUTPUTS
All discrete outputs have two terminals, one labeled
Hi and one labeled Lo. They operate very similar
Figure 11: Sourcing-Sinking Outputs
LN-9407-00.2
20
RCS-2 User Manual - Installation
Ransburg
Fault
This output is energized anytime a fault condition
is recognized by the software. Even if the fault
is disabled (turned off) on the Congured Alarms
screen, this output will be energized as long as
the condition persists. Fluid ow will not be halted
when this output is energized unless it is con-gured to do so on the Congured Alarms screen.
Ready
This output is energized if the gun is congured
properly, a good job number has been loaded,
and the gun has been placed in run mode. This
output goes off if a fault occurs.
Spray Shutdown
This output is energized if a fault condition exists
and the specic fault that exists is enabled on
the Congured Alarms screen (turned on). This
indicates that the ow of uid from the uid 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 from the mixed material. (For more
information, see "Mixed Volume and Pot-Life
Timer" in the "Operation" section.)
Motor On
This output is energized by the software when it
wants to control the motor. It is connected to the
input of the motor amplier that causes the motor
to be controlled. Do not connect external devices
to this terminal.
Motor Amp Reset
This output is energized by the software when it
is necessary to reset a faulted motor amplier.
Typically, by pushing the Clear Faults button on
the front panel or by pulsing the Halt/Reset digital
input, this output will be energized momentarily
to reset the amplier. Do not connect external
devices to this terminal.
ANALOG INPUTS
Analog inputs are jumper selectable to be 0 to 10
VDC or 4-20 mA with the exception of the hardener
ow sensor which is xed at 4-20 mA.
Hardener Flow
Type of Input: Channel
Type of Signal: Fixed at 4-20 mA
Factory Setting: Not applicable
This is a 4-20 mA input that is normally connect-
ed to the output of a thermal shedding type ow
sensor placed in the catalyst uid stream. Since
the feedback from the motor tachometer can only
indicate that the motor is turning and not that uid
is actually owing, this optional sensor is added to
prevent spraying uid without any catalyst.
Flow Rate
Type of input: Gun
Type of signal: Jumper Selectable
Factory Setting: 0-10 VDC
This input is used if it is desired to have the ability to
vary the ow rate as the unit is spraying. Minimum
and maximum ow rates are programmed and an
external device (robot, PLC, potentiometer, etc.)
controls the actual ow rate by varying the input
between 0 and 10 volts or 4 and 20 milliamps.
(See "Minimum Flow and Maximum Flow in the
"Operation" section.)
Feather Pressure
Type of Input: Gun
Type of Signal: Jumper Selectable
Factory Setting: 4-20 mA
This input allows an optional pressure sensor to
be placed near the spraygun. Handgun operators
can use this to program a set feather pressure
at the inlet of the spraygun and the RCS-2 will
maintain that pressure while spraying.
21
LN-9407-00.2
Ransburg
RCS-2 User Manual - Installation
Pump Inlet Pressure
Type of Input: Channel
Type of Signal: Jumper Selectable
Factory Setting: 4-20 mA
This input is typically connected to a pressure
sensor located near the input of the pump. When
used in conjunction with a pilot operated uid
regulator on the inlet of the pump, it minimizes
the differential pressure across the pump, thereby
increasing the accuracy of the pump.
Pump Outlet Pressure
Type of Input: Channel
Type of Signal: Jumper Selectable
Factory Setting: 4-20 mA
This input is typically connected to a pressure
sensor located near the output of the pump. This
is used to monitor and control the differential
pressure across the pump, thereby increasing
the accuracy of the pump.
This outlet pressure is also used as the feather
pressure for manual spray guns if an optional
feather pressure sensor is not used.
ANALOG OUTPUTS
Most of the analog outputs are jumper selectable
to be 0 to 10 VDC or 4-20 mA. Actual Flow, how-
ever, is xed at 0-10 VDC.
Motor Speed
Type of Output: Channel
Type of Signal: Jumper Selectable
Factory Setting: 0-10 VDC
This output is connected to the analog input on
the servo motor controller located in the motor
amplier panel. A 0 VDC signal tells the servo
controller to run at 0 RPM, a 10 VDC signal tells
it to run at the programmed maximum RPM for
that pump.
Pressure Control
Type of Output: Channel
Type of Signal: Jumper Selectable
Factory Setting: 0-10 VDC
This output is normally connected a voltage to
pressure transducer which converts a 0 to 10
VDC signal to a 0 to100 psi air pressure. The
pressure is then used to control the pilot port on
a uid regulator. This uid regulator is then used
to control the uid inlet pressure of the pump.
Actual Flow
Type of Output: Gun
Type of Signal: 0-10 VDC
This output is 0 to 10 VDC output that is propor-
tional to the actual ow of material coming out
of the applicator. 0 VDC means no ow and 10
VDC indicates 2000 cc/min. (Therefore, 3.40 VDC
would indicate 680 cc/min.)
FREQUENCY INPUTS
All frequency inputs are optically isolated and
expect a maximum amplitude square wave of
24 VDC and a maximum frequency of 1.5 KHz.
Both sides of the optical isolators are accessible,
allowing the RCS-2 to sink or source any of the
frequency signals.
Motor Feedback
Type of Output: Channel
Type of Signal: Frequency
This signal is a square wave output from the servo
motor controller, indicating the actual speed of the
motor that is driving the pump. It is used by the
rmware to determine the current ow rate of the
material out of the pump. (It can alternately be
connected to the output of a ow meter placed in
the uid stream.)
Solvent Flowmeter
Type of Output: Gun
Type of Signal: Frequency
This input allows users to connect a owmeter
in the solvent supply line and collect totalization
data on solvent usage.
LN-9407-00.2
22
Loading...