Ransburg RCS-2 RIO Programmer's Manual
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Ransburg RCS-2 RIO Programmer's Manual

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SERVICE MANUAL
LN-9409-03.1
JUNE - 2014
PROGRAMMERS MANUAL
MODEL: A10549 Control Console
RCS-2 RIO INTERFACE
A10776 Motor Amplifier Panel
A10948 Fluid Panel
A11095 Remote Operator's 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.)

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  • Page 1 SERVICE MANUAL LN-9409-03.1 JUNE - 2014 RCS-2 RIO INTERFACE PROGRAMMERS MANUAL MODEL: A10549 Control Console A10776 Motor Amplifier Panel A10948 Fluid Panel A11095 Remote Operator’s 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.

  • Page 2: Table Of Contents

    RCS-2 Programmer’s Manual - Contents CONTENTS PAGE SAFETY: SAFETY PRECAUTIONS ......................1 HAZARDS / SAFEGUARDS ....................2-5 INTRODUCTION: GENERAL INFORMATION .....................6 HARDWARE SETUP: GENERAL INFORMATION ....................6 RIO RACK ADDRESS: RIO RACK ADDRESS ......................7-8 RIO RACK INFORMATION: RIO RACK SIZE ........................9 RIO STARTING QUARTER ....................9 RIO BAUD RATE, MAXIMUM CABLE LENGTH, AND BUS TERMINATION ......9 UNUSED SWITCHES ......................9 DISCRETE I/O:...
  • Page 3 RCS-2 Programmer’s Manual - Contents CONTENTS (CONT.) PAGE APPENDIX: 26-34 DESCRIPTIONS OF INPUTS AND OUTPUTS ..............26 DISCRETE CHANNEL AND GUN INPUTS ................26-28 DISCRETE CHANNEL AND GUN OUTPUTS ................28 DISCRETE CHANNEL AND GUN INPUTS ................29 DISCRETE CHANNEL AND GUN OUTPUTS ................29-30 RECOMMENDED DIGITAL I/O TIMING SEQUENCES ............30-33 RECOMMENDED SEQUENCES FOR BLOCK TRANSFERS ..........34 WARRANTY POLICIES:...

  • Page 4: Safety

    If you do not have the manuals and safety literature for your Ransburg system, contact your local Ransburg representative or Ransburg. LN-9409-03.1...

  • Page 5: Hazards / Safeguards

    RCS-2 Programmer’s Manual - Safety HAZARD SAFEGUARDS AREA Tells what the hazard is. Tells how to avoid the hazard. Tells where hazards may occur. Spray Area Fire Hazard Fire extinguishing equipment must be present Improper or inadequate in the spray area and tested periodically. operation and maintenance procedures Spray areas must be kept clean to prevent the...
  • Page 6 RCS-2 Programmer’s Manual - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. Explosion Hazard Spray Area Electrostatic arcing must be prevented. Safe Improper or inadequate sparking distance must be maintained between operation and maintenance the parts being coated and the applicator.
  • Page 7 RCS-2 Programmer’s Manual - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. Spray Area / Electrical Discharge High Voltage Parts being sprayed and operators in the spray There is a high voltage device Equipment area must be properly grounded.
  • Page 8 RCS-2 Programmer’s Manual - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. Electrical Electrical Discharge Equipment Unless specifically approved for use in High voltage equipment is hazardous locations, the power supply, control utilized in the process.

  • Page 9: Introduction

    RCS-2 Programmer’s Manual - Introduction/Hardware Setup 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 simple bits (Discrete I/O) or in the form of tables of data (Block Transfer Reads or Writes).

  • Page 10: Rio Rack Address

    RCS-2 Programmer’s Manual - RIO Rack Address 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).
  • Page 11 RCS-2 Programmer’s Manual - RIO Rack Address RIO RACK ADDRESS (Cont.) RIO Rack Address SW1-1 SW1-1 SW1-1 SW1-1 SW1-1 SW1-1 (Octal) LN-9409-03.1...

  • Page 12: Rio Rack Information

    The RIO Baud Rate is specified with SW2, When the 77377-22 RIO Interface Card is used in positions 3 and 4. If the RCS-2 RIO Interface Card an RCS-2 rack, switches SW2-1, SW2-2, SW2-5, is at the end of the RIO Link, a terminating resistor and SW2-6 are unused and should be left in the must be installed.

  • Page 13: Discrete I/Odiscrete I/O

    RCS-2 Programmer’s Manual - Discrete I/O DISCRETE I/O DISCRETE I/O NOTE There are eight (8) 16-bit words used for digital † The speed with which the RCS-2 (discrete) inputs and outputs via RIO in the RCS-2. responds to discrete inputs and output via the RIO link is very fast and should Word 0 is for System inputs and outputs.

  • Page 14: Discrete Channel / Gun I/O

    RCS-2 Programmer’s Manual - Discrete I/O DISCRETE SYSTEM I/O (Cont.) Bit # PLC Inputs PLC Outputs PLC Word 0 Spare Digital Out Spare Digital In System Spare Digital Out Spare Digital In System RCS2 BTR Data Ready Spare Digital In System RCS2 BTW Clear To Send Spare Digital In...

  • Page 15: Block Transfer Data

    RCS-2 Programmer’s Manual - Block Transfer Data BLOCK TRANSFER DATA It is highly recommended that any time a change not filtered by the RIO card so if invalid data (data is to be made to a parameter in the RCS-2 via outside acceptable limits) is sent to the RCS-2 via this RIO link it be done in a Read-Modify-Write RIO it will most likely generate a fault (typically a...
  • Page 16 RCS-2 Programmer’s Manual - Block Transfer Data GUN OPERATIONAL STATUS - TYPE 01 The gun numbers, job numbers, and setpoints The Gun Operational Status Block transfers are may be specified as 0 if no change is desired used for normal process control while painting for a gun.

  • Page 17: Gun Operation Status - Type 01

    RCS-2 Programmer’s Manual - Block Transfer Data GUN OPERATION STATUS - TYPE 01 (Cont.) Word Description Description Unit/Value Unit/Value Gun #6 Actual Flow cc/min x 10 Gun #7 Actual Flow cc/min x 10 Gun #8 Actual Flow cc/min x 10 Gun #1, Hardener Flow 0 to 1023 Gun #2, Hardener Flow...
  • Page 18 RCS-2 Programmer’s Manual - Block Transfer Data CHANNEL OPERATION STATUS - TYPE 02 (Cont.) Word Description Description Unit/Value Unit/Value Actual Flow Rate, Chan. 1 cc/min x 10 Actual Flow Rate, Chan. 2 cc/min x 10 Actual Flow Rate, Chan. 3 cc/min x 10 Actual Flow Rate, Chan.

  • Page 19: System Configuration - Type 03

    RCS-2 Programmer’s Manual - Block Transfer Data CHANNEL OPERATION STATUS - TYPE 02 (Cont.) Word Description Description Unit/Value Unit/Value Spare Analog Input, Chan. 1 0 to 1023 Spare Analog Input, Chan. 2 0 to 1023 Spare Analog Input, Chan. 3 0 to 1023 Spare Analog Input, Chan.

  • Page 20: Gun Configuration - Type 04

    RCS-2 Programmer’s Manual - Block Transfer Data GUN CONFIGURATION - TYPE 04 RIO Gun Configuration Block transfers are typically required when configuring a gun for the first time or periodically adjusting parameters. GUN CONFIGURATION - TYPE 04 Word Description Description Unit/Value Unit/Value Previous BTW Type...

  • Page 21: Possible Horn Codes

    RCS-2 Programmer’s Manual - Block Transfer Data POSSIBLE HORN CODES Horn Code Value Description XXXXXXXXXXXXX000 Horn never sounds XXXXXXXXXXXXX001 Horn only sounds on a Spray Shut Down condition XXXXXXXXXXXXX010 Horn sounds for All Errors (not including expired pot life) XXXXXXXXXXXXX100 Horn only sounds if the Pot Life Timer expires XXXXXXXXXXXXX101 Horn sounds if a Spray Shut Down occurs or if the Pot Life Timer expires XXXXXXXXXXXXX11X...

  • Page 22: Possible Inlet Pressure Sensor Codes

    RCS-2 Programmer’s Manual - Block Transfer Data The Inlet Pressure Sensor bit fields are defined in the following table: POSSIBLE INLET PRESSURE SENSOR CODES Value Description 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 Channels 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...
  • Page 23 RCS-2 Programmer’s Manual - Block Transfer Data JOB CONFIGURATION DATA - TYPE 06 (Cont.) Word Description Description Unit/Value Unit/Value 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 –...

  • Page 24: Flow Totals - Type 07

    RCS-2 Programmer’s Manual - Block Transfer Data FLOW TOTALS - TYPE 07 (Cont.) Word Description Description Unit/Value Unit/Value Grand Totals for Job cc’s Channel Fill Totals for Job Liters Channel Fill Totals for Job cc’s Daily Total for All Jobs Liters Daily Total for All Jobs cc’s...
  • Page 25 RCS-2 Programmer’s Manual - Block Transfer Data 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.

  • Page 26: Error Log Messages - Type 08

    RCS-2 Programmer’s Manual - Block Transfer Data ERROR LOG MESSAGES - TYPE 08 (Cont.) Word Description Unit/Value Description Unit/Value Time Stamp (Low) Sec. since 1/1/80 Ref. # + 7 8 to 100 Error Code (see table) Channel # 1 to 8 Time Stamp (High) Sec.

  • Page 27: Alarm Configuration - Type 09

    RCS-2 Programmer’s Manual - Block Transfer Data ERROR CODES (Cont.) Error Reset Selected Total Code (Note: Bold Indicates Always Hard Errors) Analog Remote Loss Ratio Out of Tolerance (spare error code) Motor Amp Fault Analog Feather Loss Analog Spare Loss Fold Back Pressure Reached Pot Life Expired (spare error code) (spare error code) (spare error code) (spare error code)

  • Page 28: Active Alarm

    RCS-2 Programmer’s Manual - Block Transfer Data The Active Alarm bit fields are defined in the following table: ACTIVE ALARM Alarm Enable/Disable Decimal Value Hex Value (Note: Bold Indicates Always Hard Alarms) Input Under Pressure 0x0001 Input Over Pressure 0x0002 Output Under Pressure 0x0004 Output Over Pressure 0x0008 0x0010 Flow Out of Tolerance Hardener Flow Loss...

  • Page 29: Appendix

    RCS-2 Programmer’s Manual - Appendix APPENDIX DESCRIPTIONS OF INPUTS the CONFIG SYSTEM screen). Some examples of system faults are problems with the disk drive, AND OUTPUTS hard drive, or CDROM of the user-interface PC. Also, certain problems with the interface board SYSTEM INPUTS or RIO board (if used) may cause a system fault.
  • Page 30 RCS-2 Programmer’s Manual - Appendix (typically 150 RPM) until the halt signal is pulsed. (Note that it is not necessary to have the trigger Type of Input: Gun signal energized. Flow starts immediately.) If the Type of Signal: Pulsed gun is configured as a two-channel gun, and this This signal takes a configured gun from the halted input is pulsed, the pumps will run at the maximum state to the “run”...

  • Page 31: Discrete Channel And Gun Outputs

    RCS-2 Programmer’s Manual - Appendix DISCRETE CHANNEL AND Volume Fill Type of input: Gun GUN OUTPUTS Type of signal: Pulsed By pulsing the volume fill discrete input, the unit Fault will be put into the V. FILL mode. (The gun must This output is energized anytime a fault condition be in the halted state prior to this.) When the gun is recognized by the software.

  • Page 32: Discrete Channel And Gun Inputs

    RCS-2 Programmer’s Manual - Appendix DISCRETE CHANNEL AND Volume Fill with Fast Fill Mode: It is possible to Volume Fill and Fast Fill simultane- GUN INPUTS ously. If the gun is put into Volume Fill mode, and then the Fast Fill input is pulsed, the unit will run Motor Amp Enable in Fast Fill mode until the volume programmed in for fill volume is dispensed.

  • Page 33: Recommended Digital I/O Timing Sequences

    RCS-2 Programmer’s Manual - Appendix RECOMMENDED DIGITAL Flush Request This output is energized when the pot-life timer I/O TIMING SEQUENCES has expired. (For more information, see “Mixed Volume and Pot-Life Timer” in the “Operation’s The recommended timing sequences below Manual”.) should be used when controlling the RCS-2 from a PLC.
  • Page 34 RCS-2 Programmer’s Manual - Appendix RECOMMENDED DIGITAL I/O TIMING SEQUENCES Action Signal Sequence Notes Fault, Halt/Reset If a gun is faulted then Run and it is necessary Run Input to clear the fault and put it back in run mode, use this sequence. Halt/Reset Input Gun Active Output Spray Shutdown Output...
  • Page 35 RCS-2 Programmer’s Manual - Appendix RECOMMENDED DIGITAL I/O TIMING SEQUENCES (Cont.) Action Signal Sequence Notes Volume Fill with It is possible to fast Fat Fill fill while in volume Volume Fill Input fill mode. Volume fill mode must be initiated first. Wait for the active signal Gun Active Output to be asserted prior to initiating the fast...
  • Page 36 RCS-2 Programmer’s Manual - Appendix RECOMMENDED DIGITAL I/O TIMING SEQUENCES (Cont.) Action Signal Sequence Notes Strobe in New When loading a Job Bit #1 Input Job Number new job, the job bits must be as- Job Bit #2 Input serted prior to strobing the gun Job Bit #4 Input strobe input bit and those bits should...

  • Page 37: Recommended Sequences For Block Transfers

    RCS-2 Programmer’s Manual - Appendix RECOMMENDED is not indicated on this chart as it will vary from system to system (based on how busy the RIO SEQUENCES FOR BLOCK channel is). If there are additional devices on the TRANSFERS RIO channel (including additional RCS-2 racks), times will be extended.
  • Page 38 RCS-2 Programmer’s Manual - Manual Changes MANUAL CHANGES April 1, 2009 (Rev. E), Pages 5 and 6: Dip switch settings for RIO Rack Address 20 – 23, 30 – 34, 40 - 47 corrected. April 17, 2009 (Rev. E), Page 9: Changed Spare User Link text in table to User Link Active.

  • Page 39: Warranty Policies

    ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR Ransburg will replace or repair without charge any PRODUCTION OR INCOME, WHICH RESULT part and/or equipment that falls within the specified time (see below) because of faulty workmanship...
  • Page 40 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 Fax: 419-470-2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts. © 2014 Finishing Brands, Inc. All rights reserved. Form No. LN-9409-03.1 Models and specifications subject to change without notice. Litho in U.S.A.

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