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Carlisle Fluid Technologies Ransburg IntelliFlow RF2 Programming Manual

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PROGRAMMING MANUAL
EN
77-3152-5
IntelliFlow™ RF2

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Summary of Contents for Carlisle Fluid Technologies Ransburg IntelliFlow RF2

  • Page 1 PROGRAMMING MANUAL 77-3152-5 IntelliFlow™ RF2...

  • Page 2: Additional Resources

    ADDITIONAL RESOURCES For additional information or copies of your IntelliFlow Flow Meter manual, please visit us online at: https://carlisleft.com Or use this QR code with your mobile device: 77-3152-5 R1.0 (07/2024) www.carlisleft.com...
  • Page 3 Chapter 02. Table of Contents. Chapter 03. Safety–Safety, hazard, and warning rules. All current and applicable certifications shown in this manual confirm Carlisle Fluid Technologies adherence to Chapter 04. Fieldbus I/O–RF2 external communications the strict standards met to obtain the required regulatory methods, setup, and Input/Output array data tables.
  • Page 4 INTRODUCTION RF2 RELATED MANUALS & PUBLICATIONS Part Number Description 77-3152-1 RF2 Installation Manual 77-3152-2 RF2 Operation Manual 77-3152-3 RF2 Service Guide 77-3152-4 RF2 Kit Instructions and Spare Parts 77-3154 Flow Meter Kit 77-3155 Remote Fluid Panel Kit-Barrier and F.O. Transceiver Box 77-3156 Flow Meter Sensor Battery Replacement Kit 77-3157...

  • Page 5: Table Of Contents

    02. TABLE OF CONTENTS 02 CONTENTS 03 SAFETY 03.1 SAFETY PRECAUTIONS AND HAZARDS ......................1 03.2 ADDITIONAL SAFETY INFORMATION ....................... 7 04 FIELDBUS I/O 9-28 04.1 FIELDBUS INTRODUCTION ..........................9 04.1.1 DATA ORGANIZATION ..........................9 04.2 DIRECT ACCESS/CIP COMMUNICATIONS ......................10 04.2.1 FIELDBUS COMMUNICATIONS: IP ADDRESS SETTING (W/O GATEWAY) ..........
  • Page 6 02. TABLE OF CONTENTS This page intentionally left blank. 77-3152-5 R1.0 (07/2024) iv / iv www.carlisleft.com...

  • Page 7: Safety Precautions And Hazards

    Notice: Indicates information considered important but WARNING not hazard related. The hazards shown on the pages that follow can occur during the normal use of this Carlisle Fluid Technologies SAFETY equipment, but not all listed hazards will be applicable to your product model or equipment.

  • Page 8: Safety

    03. SAFETY AREAS HAZARDS SAFEGUARDS Indicate possible Indicate possible hazards. Prevention of possible hazards. hazard occurrences. Spray Areas Fire Hazards Fire extinguishing equipment must be present in the spray area. Periodically run a test to make sure the Improper or unsatisfactory equipment stays usable.
  • Page 9 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicate possible Indicate possible hazards. Prevention of possible hazards. hazard occurrences. Spray Areas Explosion Hazard Prevent electrostatic arcing. Maintain spark-safe work distance between the parts that get coated and Improper or unsatisfactory the applicator. A span of one inch for every 10KV of operation and maintenance output voltage is necessary.
  • Page 10 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicate possible Indicate possible hazards. Prevention of possible hazards. hazard occurrences. Spray Area High Electrical Discharge Operators in the spray area and the parts to be sprayed must be sufficiently grounded. Voltage Equipment This equipment contains a All conductive objects inside the spray area must be high-voltage device that can grounded.
  • Page 11 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicate possible Indicate possible hazards. Prevention of possible hazards. hazard occurrences. Spray Areas Toxic Fluid or Fumes Read the Safety Data Sheet (SDS) for instructions to know and understand how to handle the specific Toxic fluids or fumes can hazards of the fluids used, and the effects of long- cause severe injury or death if term exposure.
  • Page 12 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicate possible Indicate possible hazards. Prevention of possible hazards. hazard occurrences. Equipment Skin and Clothing Burns Do not touch hot fluid or equipment during operation. and Fluids Equipment surfaces and fluids Do not let clothing touch the equipment during can become very hot during operation or immediately after the equipment is operation.
  • Page 13 03. SAFETY AREAS HAZARDS SAFEGUARDS Indicate possible Indicate possible hazards. Prevention of possible hazards. hazard occurrences. Spray Areas Do Not Touch Do not use a rag or gloved hand against the bell edge to stop or slow down a bell during rotation. The effect of paint flow rates Do not try to clean the bell edge during rotation.

  • Page 14: Additional Safety Information

    03. SAFETY CAUTION Only operate the equipment after you have read this section. 03.2 ADDITIONAL SAFETY INFORMATION The IntelliFlow has an emergency stop (E-Stop) pushbutton on the main operator panel. During an emergency, all operations for the IntelliFlow will halt when the E-Stop is engaged. The operator must disengage the E-Stop and reset the system to recover from this state.

  • Page 15: Fieldbus I/O

    IP on the RF2 side. Tag registers within the RF2 are overwritten by the tags communicated through the gateway. Carlisle Fluid Technologies can provide sample or importable code for Allen Bradley software solutions for Floating Point (REAL) both methods above.

  • Page 16: Direct Access/Cip Communications

    04. FIELDBUS I/O 04.2 DIRECT ACCESS/CIP COMMUNICATIONS 8. Set the IP address as desired to communicate to the master controller and click "OK." 04.2.1 Fieldbus Communications: IP Address Setting With these steps completed, set the PLC/IP address (without gateway) back to Run or remote mode. RF2 control units use an Allen Bradley Compact Logix NOTICE PLC with two separate ethernet networks as the primary...

  • Page 17: Fieldbus Communications: Ethernet

    04. FIELDBUS I/O 04.2.2 Fieldbus Communications: Ethernet RF2 Node Setup in an Allen Bradley PLC. The master controller handles communication with the RF2 controller to make sure that the RF2 is adaptable NOTICE to communication with various devices with different IP address configurations.

  • Page 18: Message Configuration

    04. FIELDBUS I/O 04.2.3 Message Configuration If an Allen Bradley Logix PLC is used, or another controller where direct access to the RF2 input and output arrays (AuxInArr, AuxOut1Arr, AuxOut2Arr) is possible, no gateway or special hardware is needed to communicate to the RF2.
  • Page 19 04. FIELDBUS I/O RF2 Output Array 1-Master PLC Read (b): The output array shown above is used to report active and inactive recipe values. www.carlisleft.com 13 / 38 77-3152-5 R1.0 (07/2024)
  • Page 20 04. FIELDBUS I/O RF2 Output Array 2 (Master PLC Read) (c): The output array shown above is only used to report active recipe values. Message Polling: It is recommended that messages be polled at periodic intervals. In the example code, the RF2 Inputs and Outputs are offset by 20 milliseconds.

  • Page 21: Communications Via Anybus Gateway

    04. FIELDBUS I/O 04.3 COMMUNICATIONS VIA 04.4 ENDIAN WARNING ANYBUS GATEWAY When the Anybus gateway is used, the data may not be in the correct data format for your controller. The data is If purchased, the RF2 may come equipped with an transmitted in little-endian format.

  • Page 22: Intelliflow Rf2 Input Arrays

    04. FIELDBUS I/O 04.5 USER TO INTELLIFLOW RF2 INPUT ARRAYS RF2 communication input array data tables are listed on the pages that follow: RF2 INPUT ARRAY-SINT 496 Size Byte Type Description (Bytes) SINT System Control Byte 0 - See Detail Below BOOL Fault Reset BOOL...
  • Page 23 04. FIELDBUS I/O RF2 INPUT ARRAY-SINT 496 (cont.) Size Byte Type Description (Bytes) BOOL Seq Select Bit 1 * BOOL Seq Select Bit 2 * BOOL Seq Select Bit 3 * When Seq Run Bit is active, the selected sequence is the binary representation of the Seq Select Bits. A value of 0-15 will call sequence 1-16 in the sequence list.
  • Page 24 04. FIELDBUS I/O RF2 INPUT ARRAY-SINT 496 (cont.) Size Byte Type Description (Bytes) 20.3 BOOL Trigger 4 20.4 BOOL Spare 20.5 BOOL Spare 20.6 BOOL Spare 20.7 BOOL Spare 21, 22 Gun/Mix 3 Flow Command (0-3500 cc) SINT Gun/Mix 4 Trigger 23.0 BOOL Trigger 1...
  • Page 25 04. FIELDBUS I/O RF2 INPUT ARRAY-SINT 496 (cont.) Size Byte Type Description (Bytes) 85, 86 Override Data - Gun/Mix Selected In Byte 82 - Max Flow Command (0-3500) 87, 88 Override Data - Gun/Mix Selected In Byte 82 - Min Flow Command (0-3500) 89, 90 Override Data - Gun/Mix Selected In Byte 82 - Ratio tolerance (1-100%) 91, 92...

  • Page 26: Intelliflow Rf2 Output Arrays

    04. FIELDBUS I/O 04.6 USER TO INTELLIFLOW RF2 OUTPUT ARRAYS RF2 communication output array data tables are listed on the pages that follow: RF2 OUTPUT ARRAY 1-SINT 496 Size Byte Type Description (Bytes) SINT System Status Byte 0 - See Detail Below BOOL Comm Heartbeat BOOL...
  • Page 27 04. FIELDBUS I/O RF2 OUTPUT ARRAY 1-SINT 496 Size Byte Type Description (Bytes) 14.3 BOOL Trigger 4 14.4 BOOL Spare 14.5 BOOL Pot Life Expired 14.6 BOOL Warning 14.7 BOOL Spray Shutdown 15..18 REAL Gun/Mixer #1 Actual Flow A (cc/min) 19..22 REAL Gun/Mixer #1 Actual Flow B (cc/min)
  • Page 28 04. FIELDBUS I/O RF2 OUTPUT ARRAY 1-SINT 496 Size Byte Type Description (Bytes) 85..88 REAL Gun/Mixer #3 Actual Total Flow (cc/min) 89..92 REAL Gun/Mixer #3 Actual Ratio A (parts) 93..96 REAL Gun/Mixer #3 Actual Ratio B (parts) 97..100 REAL Gun/Mixer #3 Actual Ratio C (%) SINT Gun/Mixer #4 Status Byte - See Detail Below 101.0...
  • Page 29 04. FIELDBUS I/O RF2 OUTPUT ARRAY 1-SINT 496 (cont.) Size Byte Type Description (Bytes) 172.2 BOOL Manual Override Active 172.3 BOOL Spare 172.4 BOOL Spare 172.5 BOOL Spare 172.6 BOOL Spare 172.7 BOOL Spare SINT Reserved 174..177 REAL Channel #2 Actual Inlet Pressure (psi) if applicable 178..181 REAL Channel #2 Actual Outlet Pressure (psi) if applicable...
  • Page 30 04. FIELDBUS I/O RF2 OUTPUT ARRAY 1-SINT 496 (cont.) Size Byte Type Description (Bytes) SINT Reserved 258..261 REAL Channel #4 Actual Inlet Pressure (psi) if applicable 262..265 REAL Channel #4 Actual Outlet Pressure (psi) if applicable 266..269 REAL Channel #4 Actual Flow (cc/min) 270..273 REAL Channel #4 Actual Flow Command (cc/min)
  • Page 31 04. FIELDBUS I/O RF2 OUTPUT ARRAY 1-SINT 496 (cont.) Size Byte Type Description (Bytes) SINT Alarm Word 8 - Byte 0 SINT Alarm Word 8 - Byte 1 SINT Alarm Word 8 - Byte 2 SINT Alarm Word 8 - Byte 3 SINT Alarm Word 9 - Byte 0 SINT...
  • Page 32 04. FIELDBUS I/O RF2 OUTPUT ARRAY 2-SINT 496 (Used only to report active recipe values) Size Byte Type Description (Bytes) Station selected in RF2 Input Array[50] - Active Command Data - Component A - SINT Valve Number Station selected in RF2 Input Array[50] - Active Command Data - Component B - SINT Valve Number Station selected in RF2 Input Array[50] - Active Command Data - Component C -...
  • Page 33 04. FIELDBUS I/O RF2 OUTPUT ARRAY 2-SINT 496 (Used only to report active recipe values) Size Byte Type Description (Bytes) 83..86 REAL Channel selected in RF2 Input Array[123] - Flow Kp 87..90 REAL Channel selected in RF2 Input Array[123] - Flow Ki 91..94 REAL Channel selected in RF2 Input Array[123] - Flow Kd...

  • Page 34: Basic Remote Operations

    04. FIELDBUS I/O When using more than one trigger, the user must 04.7 BASIC REMOTE OPERATIONS make the appropriate fluid system design to ensure the 04.7.1 Timing Basics appropriate flow reaches each gun. The data to and from the Anybus gateway is updated in a If the Gun/Mix Flow command falls to 0, the system 10-ms cycle.
  • Page 35 04. FIELDBUS I/O Step Load Spray Flush 100 ms Fault Reset Start Pulse Stop Pulse Strobe Recipe Recipe Select Using Purge Purge Calling A Sequence Seq Run Bit Seq Select 0..3 Fault Exists Run Mode Fluid sequence Active www.carlisleft.com 29 / 38 77-3152-5 R1.0 (07/2024)
  • Page 36 04. FIELDBUS I/O This page intentionally left blank. 77-3152-5 R1.0 (07/2024) 30 / 38 www.carlisleft.com...

  • Page 37: Appendix

    05. APPENDIX 05.1 INTELLIFLOW RF2 ALARMS RF2 communication alarms data tables are listed on the pages that follow: RF2 ALARM LIST Alarm Description Alarm Array Alarm Array Bit Alarm[0] Safety Fault Alarm[0] Festo VTEM Pressure Regulator Module 1 Fault Alarm[0] Festo VTEM Pressure Regulator Module 2 Fault Alarm[0] Festo VTEM Pressure Regulator Module 3 Fault...
  • Page 38 05. APPENDIX RF2 ALARM LIST Alarm Description Alarm Array Alarm Array Bit Alarm[2] Mix 3 - Ratio Out Of Tolerance Alarm[2] Mix 3 - Flow Rate Out Of Tolerance Alarm[2] Mix 3 - Ratio Shutdown Alarm[2] Mix 3 - Flow Rate Shutdown Alarm[2] Mix 3 - No Master Flow Alarm[2]...
  • Page 39 05. APPENDIX RF2 ALARM LIST Alarm Description Alarm Array Alarm Array Bit Alarm[4] Channel 2 - Inlet Pressure Loss of Feedback Alarm[4] Channel 2 - Outlet Pressure Loss of Feedback Alarm[4] Channel 2 - Motor Fault Alarm[4] Channel 2 - Foldback Pressure Reached Alarm[4] Channel 2 - Flow Out of Range Alarm[4]...
  • Page 40 05. APPENDIX This page intentionally left blank. 77-3152-5 R1.0 (07/2024) 34 / 38 www.carlisleft.com...

  • Page 41: Manual Revisions

    06. MANUAL REVISIONS MANUAL CHANGE SUMMARY Date Description Version 05/15/2024 1st Draft. Split manual into five, put into new format, and restarted at Rev 1.0 R1.0 www.carlisleft.com 35 / 38 77-3152-5 R1.0 (07/2024)
  • Page 42 06. MANUAL REVISIONS This page intentionally left blank. 77-3152-5 R1.0 (07/2024) 36 / 38 www.carlisleft.com...

  • Page 43: Warranty Policy

    This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited warranty. The use of parts or accessories from sources other than Carlisle Fluid Technologies will void all warranties. Failure to follow reasonable maintenance guidance provided can invalidate the warranty.
  • Page 44 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® are registered trademarks of Carlisle Fluid Technologies, LLC. ©2024 Carlisle Fluid Technologies, LLC. All rights reserved.

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