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Carlisle Fluid Technologies Ransburg IntelliFlow RM2 Manual

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CONTROLS MANUAL
EN
IntelliFlow RM2
www.carlisleft.com
Manual 77-3153-R1 (03/2022)

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Summary of Contents for Carlisle Fluid Technologies Ransburg IntelliFlow RM2

  • Page 1 CONTROLS MANUAL IntelliFlow RM2 www.carlisleft.com Manual 77-3153-R1 (03/2022)

  • Page 2: Table Of Contents

    CONTENTS CONTENTS SAFETY ........................4 SAFETY PRECAUTIONS ........................4 EU DECLARATION OF CONFORMITY ..................9 INTRODUCTION ......................11 FEATURES ............................11 SYSTEM COMPONENTS ........................12 COMPLETE SYSTEM PART NUMBERING ..................14 TECHNICAL SPECIFICATIONS ...................... 14 WALL MOUNT DIMENSIONS ......................15 FLOOR STAND DIMENSIONS (OPTIONAL) .................
  • Page 3 CONTENTS REGULAR INSPECTION ........................57 COMPONENT VIEWS & SPARE PARTS ..................58 ELECTRICAL DIAGRAMS ........................ 62 MANUAL CHANGE SUMMARY ................86 WARRANTY POLICY ....................87 www.carlisleft.com Manual 77-3153-R1 (03/2022)

  • Page 4: Safety

    SAFETY SAFETY WARNING SAFETY PRECAUTIONS Before operating, maintaining or servicing any Carlisle The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature system, read and understand all of the technical and safety literature for your products.
  • Page 5 SAFETY WARNING Read the following warnings before using this equipment AUTOMATIC EQUIPMENT Automatic equipment may start STATIC CHARGE Fluid may develop a static charge that suddenly without warning. must be dissipated through proper grounding of the equipment, objects to be sprayed and all other electrically conductive objects in the dispensing area.
  • Page 6 SAFETY AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Toxic ISOCYANATE Conditions Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized Substances particulates. Workers exposed to isocyanates can develop a range of short and long-term health problems.
  • Page 7 SAFETY AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Toxic Chemical Hazard Follow the requirements of the Safety Data Sheet supplied by coating material manufacturer. Substances Certain materials may be harmful if Adequate exhaust must be provided to keep the air free inhaled, or if there is contact with the of accumulations of toxic materials.
  • Page 8 SAFETY CAUTION Do not operate the RM2 before reading this section. Additional Safety Information The RM2 has a main operator panel emergency stop (E-Stop) pushbutton. Included with the unit. In the event of a safety fault, all operations for the RM2 will halt, all solenoid outputs will be turned off, and all pressure pilot signals will go to zero psi/BAR.

  • Page 9: Eu Declaration Of Conformity

    EU DECLARATION OF CONFORMITY www.carlisleft.com Manual 77-3153-R1 (03/2022)
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  • Page 11: Introduction

    INTRODUCTION INTRODUCTION The RM2 system is designed to accurately mix most two component (2K) and one component (1K) paints. It will supply any low-pressure manual or automatic spray gun and can easily handle very low flow rates or high ratio materials (greater than 20:1).

  • Page 12: System Components

    INTRODUCTION SYSTEM COMPONENTS Control Panel Fluid Control Module Mix Manifold Pedestal (Optional) Control Panel External Components Status light Main power entry Main power disconnect switch Panel opening latch Emergency stop button www.carlisleft.com Manual 77-3153-R1 (03/2022)
  • Page 13 INTRODUCTION Internal Components Solenoid stack USB flash drive Linear actuator Air flow switches Main power disconnect switch connector Connection to status light Connection to HMI and emergency stop button HMI (Internal) IO block 10. 24VDC circuit breakers 11. 24VDC power supply 12.

  • Page 14: Complete System Part Numbering

    INTRODUCTION COMPLETE SYSTEM PART NUMBERING # of Colors 0= No color stack Pressure Compatibility Flowmeter Dispensing 1= 300 PSI 1= Standard 0= None 1= 600 CC 1= 1 Color 3= 3 Colors 2= 3,000 PSI 2= Acid 1= Gear 2= 300 CC 2= Coriolis 5= Pulse 7= 7 Colors...

  • Page 15: Wall Mount Dimensions

    INTRODUCTION WALL MOUNT DIMENSIONS Requirements: • Ensure wall is able to support weight of complete system, including air and fluid hoses and other connected devices. Minimum 91 kg (200 lbs.). • Ensure clearance for electrical and fluid connections to system, and door swing radius. •...

  • Page 16: Floor Stand Dimensions (Optional)

    INTRODUCTION FLOOR STAND DIMENSIONS (OPTIONAL) Requirements: • Stand should be bolted to the floor. www.carlisleft.com Manual 77-3153-R1 (03/2022)

  • Page 17: Installation

    INSTALLATION INSTALLATION Before operating the RM2, ensure all the below installation steps are complete. Schematics and further information are provided separately from this manual. ELECTRICAL The RM2 can accept either 120VAC or 240VAC as a power source. Its internal 24VDC power supply automatically detects the input voltage and produces control power accordingly.

  • Page 18: Pneumatics

    INSTALLATION Process Locate the main power entry plug (a) in the upper right section of the cabinet Locate the disconnect switch connector (b) inside of the control panel Make sure the main power entry plug is connected at the top (c), opposite their secondary connections (d) below.
  • Page 19 INSTALLATION Attach a final 3/8" main air line in the front panel connector (c) that will lead to the gun’s air input. Solenoid Air Input Locate the air inlet connection on the back of the system chassis (a). Attach a 3/8" main air line to the air inlet. Continued in next page...
  • Page 20 INSTALLATION Material A Air Input Locate the Material A valve stack (a). Locate the top right valve (b). Using a 3/8" air line, connect your air source to the valve (c). NOTE It is recommended to install an air pressure regulator between your air source and the air valve to monitor maximum air pressure.

  • Page 21: Paint Materials

    INSTALLATION PAINT MATERIALS Your system may include up to 7 material valves. The process to connect each is the same; repeat the steps below as needed. The number of valves on the stack will depend on your application and needs. Paint resins and hardeners may be supplied to the RM2 system via pressure tanks or pumps.

  • Page 22: Disposal Information

    INSTALLATION Locate the material B pump input connector (f). Connect your material B hose into the pump inlet. Connect a material hose between the pump outlet (g) and the second mix block connector (h). Connect the mix block to the mixing tube (i) using the bottom connector (j).

  • Page 23: Operation

    OPERATION OPERATION POWERING UP THE SYSTEM Before powering-up the system, ensure that main power has been installed correctly. See section on electric installation for more details. To power-up: On the righthand side of the control module enclosure, turn the rotary disconnect switch clockwise. The system will go through a boot-up sequence.
  • Page 24 OPERATION Navigation Bar Except on certain menus that have special purposes, the navigation bar shown below will be visible in the upper section of the screen. Each section will be discussed separately in this manual. Access Drop-down Access Login/User Menu Alarm menu actions Pressing the Menu button opens a drop-down menu to access other menus.
  • Page 25 OPERATION Color Change Screen The color change screen is used for changing colors and flushing the system with the flush/load sequence programmed in the settings screen. Displays the Color current color selection for loaded in the color system switching Time frames Time frames for color for color...
  • Page 26 OPERATION Alarms Screen This screen displays all of the available system alarms (a). If an alarm sounds it will be highlighted, and the Reset button in the main spray screen must be pushed before the system can spray again. Alarm history (b) is also saved in this screen.
  • Page 27 OPERATION Prime Screen Use this screen to prime the RM2 unit with Resin (A) and Hardener (B). Buttons will independently operate the Resin color valves (A0-A9), or the B Pump for material loading. Gun atomizing air must be off while priming. Press button to Press button to open selected...
  • Page 28 OPERATION Settings Screen Select the settings button from the dropdown menu to access system settings. Before opening this screen a password prompt for access will take over the screen. Viewing or changing settings requires user permissions (varied between normal users and administrators). Each screen will be reviewed separately in the next pages of this manual.
  • Page 29 OPERATION User Options To access the user options page, log in as an administrator and then press the ‘user’ (a) menu key in the navigation bar to open the user actions dialog. A dialog box will open and the administrator will see an option called ‘User Options’ (b). From the user options menu you can Edit users (c), Add users (d), Delete users (e), or change User permissions (f).
  • Page 30 OPERATION Add user The operator interface supports up to fifty individual users. To add a user, enter the Add User menu. Fill in the parameters (i) including user name, group assignment and initial password. Delete user To delete a user, enter the Delete User menu. Select the user (j) you want to delete.
  • Page 31 OPERATION Exor Internal Menu The Exor (1) dropdown dialog (2) allows access to the root settings for the Exor operator interface’s internal settings. Setting IP addresses for the three networks provided with the interface (described in the Installation section above), and setting the date and time displayed on the panel are the only operations that are necessary to operate the RM2.
  • Page 32 OPERATION Gun Flush Boxes: Indicate if zero, 1 or 2 flush boxes are installed. Gun 2 Enable: Indicates that a second gun is installed, and this affects visibility of Gun 2 selections on other menus. Two Gun Manifold Installed: The two gun manifold enables the user to select one or both guns to be loaded, and disable guns that are not selected.
  • Page 33 OPERATION System Settings Pressing the System Settings button (5) in the fluid system group, will open up the settings screen to the right. Some of these set values will trigger alarms on the system when upper or lower limits are exceeded during operations.
  • Page 34 OPERATION Cycle Counter This menu (8) displays the amount of times each solenoid in the system has been activated. If desired (due to replacement of a solenoid for example) to reset these values, select each field to be reset by pressing and highlighting the icon to the left of the value and press and hold the ‘Reset’...
  • Page 35 OPERATION Language Pressing the Language button (10) in the Global Configuration group, will open up the Language change dialog. You can also access these options from the Dropdown menu of the navigation bar in the bottom button. Choose the preferred language by clicking in the corresponding flag.
  • Page 36 OPERATION The Remote Color Change Box is an optional purchase compatible with this system. The color-change controller is connected through an Intrinsic Barrier (Zener Barrier) located outside the hazardous area to the RM2 device. Instructions for installation of the remote color change box are included with it.
  • Page 37 OPERATION Recipe Screen The Recipe Menu allows set up of parameters that are specific to resins that are loaded. In the top part of the menu are material parameters—these are: Type (1K or 2K) - if 1K, the catalyst pump will not be activated (no mixing will be required) but flow rates will be measured and recorded and resin-max flow alarm will still be active.
  • Page 38 OPERATION Flushing Recommendations Suggested Initial Name Description Setting First Flush Air or Solvent to initially flush fluid lines. Duration of first flush. This flush is used to move paint First Flush Time 15 seconds out of the system before attempting to “clean” with the Air Chop Time 1 second Duration of each air burst in the chop process...
  • Page 39 OPERATION Reports Screen This menu allows process data to be tracked by ‘jobs’ that can be stored to a USB stick if installed in the HMI USB Slot. Job files in CSV format can be removed from the USB stick and stored and viewed through a CSV viewing software such as MS Excel.

  • Page 40: Startup Guide

    OPERATION STARTUP GUIDE Use the following pages as a quick reference to make electrical, air, and fluid connections to the RM2 and begin operation. Familiarize with the configuration of the machine and any options or accessories attached. Return to the User Interface Guide section of this manual for information on configuration and settings.
  • Page 41 OPERATION Startup Procedure When air and material connections have been tested for leaks the machine should be ready to power on. Startup for systems without gun flush boxes Startup for systems with gun flush boxes Ensure all compressed air and fluid sources are Ensure all compressed air and fluid sources are connected to the RM2 and energized.

  • Page 42: Daily Operations

    OPERATION DAILY OPERATIONS Daily use of the RM2 system involves several procedures. Understanding how the system works and knowing the properties of the paint materials in use is the best way to ensure continuous use with few alarms and repairs. Study the procedures and tips below to better understand the function of the system.
  • Page 43 OPERATION Loading a Color Follow steps 1 through 8 of the Daily Start Up Procedure section before proceeding. Go to the Home screen and ensure atomizing air is turned off. For systems with gun flush boxes, place the gun in the box and close the lid.
  • Page 44 OPERATION End of Day Flushing Procedure To shut down the machine for longer periods or overnight follow the steps below. Flush the Mixed Material using one of the methods below. Color 0 Load: Perform a color 0 load to clear the fluid lines of material and load with solvent. For information on loading, see Loading a Color.
  • Page 45 OPERATION System Depressurization Process Flush the system if it will not be used for extended periods. Ensure all guns are in gun flush boxes, and that lids are securely closed. If not using flush boxes or ACO, shut off atomizing air for the next steps and use a grounded metal waste container.

  • Page 46: B Pump Operation

    OPERATION B PUMP OPERATION Material is delivered to be mixed by a piston and cylinder dispense pump. An inlet and an outlet valve on each end of the pump controls the material flow. When the piston is moving down, the bottom inlet valve is closed, and the bottom outlet valve is open.

  • Page 47: Flow Meter

    OPERATION FLOW METER The flow meter is a gear-type positive displacement meter specially designed for paint and will measure flow up to 1900cc per minute. A sensor detects the movement of the inner gears and sends an electronic signal in the form of a pulse to the controller.
  • Page 48 OPERATION Flow Meter Calibration For the best accuracy in ratio performance of the RM2, it is necessary to calibrate the flowmeter per the material that is being used. The calibration menu can be reached through the recipe menu and allows a quick check of the material volume dispensed versus what is calculated.

  • Page 49: Maintenance, Troubleshooting & Spare Parts

    MAINTENANCE MAINTENANCE, TROUBLESHOOTING & SPARE PARTS ALARM TROUBLESHOOTING System alarms are used to alert the user to conditions which may result in off-ratio spraying or fluid pressure out of range. Refer to the table below to troubleshoot RM2 alarms. Troubleshooting suggestions are listed in order of difficulty with the easier solutions presented first.
  • Page 50 MAINTENANCE Alarm Message Alarm Condition(s) Action(s) Upper Transducer Fault Improper electrical signal from Check electrical connection and wiring Confirm upper pressure transducer on B pump is upper pressure transducer on B functioning properly Lower Transducer Fault Improper electrical signal from Check electrical connection and wiring Confirm upper pressure transducer on B pump is lower pressure transducer on B...
  • Page 51 MAINTENANCE Alarm Message Alarm Condition(s) Action(s) Color Change Fault Color change sequence has been Confirm stop button was not pressed interrupted Confirm atomization air is not detected during color change If equipped - Confirm applicator(s) are in gun flush box(s) and lid(s) are closed If equipped - Confirm proper operation of gun flush box(s) High Resin Flow Rate...

  • Page 52: B Pump Troubleshooting

    MAINTENANCE B PUMP TROUBLESHOOTING Use this checklist to help identify potential problems with the B pump - avoid unnecessary disassembly. If the problem is still not corrected, it may be necessary to remove the B Pump and clean it thoroughly after flushing it with a solvent. Look for clogged passageways and evidence of fluid leaks.

  • Page 53: Power Outage Cleaning Procedure

    MAINTENANCE POWER OUTAGE CLEANING PROCEDURE In the event of a facility power outage RM2 can be cleared of mixed material manually if air pressure supply continues. If the fluid lines are not cleared, it is possible that the mix manifold, downstream fluid lines, and spray gun may become clogged with hardened material.

  • Page 54: Flow Meter Troubleshooting

    MAINTENANCE FLOW METER TROUBLESHOOTING Flowmeter problems can be caused by improperly filtered fluid. Particulates in the fluid can cause gear binding, resulting in improper signals for the actual flow rate. Maintain the fluid filters according to the instructions from the filter manufacturer.

  • Page 55: Maintenance Procedures

    MAINTENANCE MAINTENANCE PROCEDURES There are no enclosure components which should require cleaning if the enclosure door is kept shut. If material seepage occurs, be sure to correct the problem and maintain a clean work area. To avoid hardening of the paint inside the fluid lines, the system must be cleaned by a complete flushing procedure at the end of operations.

  • Page 56: Preventive Maintenance

    MAINTENANCE PREVENTIVE MAINTENANCE The RM2 system requires periodic inspection and regular maintenance. Follow the corresponding table as a guide to perform routine maintenance at suggested intervals. These intervals are recommendations and largely depend on the material being sprayed. Daily / Each Shift: •...

  • Page 57: Regular Inspection

    MAINTENANCE REGULAR INSPECTION Continuous use or lack of use of the system may both lead to system malfunctioning. Please conduct regular inspections to the system according to the frequency table below. Frequency Description Inspection Method System flushed with solvent Visual Daily Check for leaks Visual...

  • Page 58: Component Views & Spare Parts

    MAINTENANCE COMPONENT VIEWS & SPARE PARTS Part Number Description Recommended Qty Fitting, 3/8 ODT x 1/4 NPS, 90 1414-SS-90-T Static Mix Assembly, 300cc 240-3122-300 Static Mix Assembly, 600cc 240-3122-600 300cc dispense pump 240-5136-300 As Desired 600cc dispense pump 240-5136-600 15 PSI PRESSURE SWITCH 240-5156 Circuit Breaker, 2A 240-5180...
  • Page 59 MAINTENANCE Part Number Description Recommended Qty Stepper Motor Cable Assembly As Desired 240-5368 FLOW METER BODY 310-9010 DUAL LEG PICKUP 310-9011 CHECK VALVE ASSY FOR MIX MANIFOLD 6SN-6CV SEAT ASSEMBLY - MCV 77367-00 MCV VALVE ASSEMBLY 78949-00 VALVE ASSEMBLY CCV-503-SS Hose, 3/8 ODT x 1/4 ID FEP-0604 50 ft...
  • Page 60 MAINTENANCE Flow Meter www.carlisleft.com Manual 77-3153-R1 (03/2022)
  • Page 61 MAINTENANCE B Pump 300cc Part Number Description Quantity Packing Lube, 250ML 0114-016099 DOWEL PIN, 3/16 DIA X 1/2 LONG, SS 20-4844 Flat Washer 237-727 Retaining Ring 237-729 Rod Seal 240-3211 Piston Seal, 300CC 240-3212-300 HOLDER,SEAL 240-3221 2-010 O-ring, Kalrez 79001-05 o-ring, 2-015, solvent proof 79001-09 O-RING, 2-020, PERFLUOROELASTOMER...

  • Page 62: Electrical Diagrams

    MAINTENANCE ELECTRICAL DIAGRAMS www.carlisleft.com Manual 77-3153-R1 (03/2022)
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  • Page 86: Manual Change Summary

    MANUAL VERSION MANUAL CHANGE SUMMARY XX/XX/XXXX 1st Draft www.carlisleft.com Manual 77-3153-R1 (03/2022)

  • Page 87: Warranty Policy

    For the latest information about our products, visit www.carlisleft.com Carlisle Fluid Technologies is a global leader in innovative finishing technologies. Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice. BGK™, Binks®, DeVilbiss®, Hosco®, MS®, and Ransburg®...

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