Carlisle Ransburg RCS2 A14084-00 User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
Model: A14084-00 RCS2 Interface with Ethernet/IP Card
RCS2 Ethernet/IP Implicit
Communications Programmer’s
Manual
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EN
SERVICE MANUAL

CONTENTS
SAFETY: 3-7
Safety Precautions .................................................................................................................................................... 3
Hazards / Safeguards ................................................................................................................................................ 4
ETHERNET/IP IMPLICIT COMMUNICATIONS INTERFACE: 8
Description ................................................................................................................................................................ 8
 RCS2Ethernet/IPConguration-AllenBradleyControlLogix ................................................................................. 9
OUTPUT STATUS DATA (TARGET TO ORIGINATOR ASSEMBLY): 10-12
 RCS2Ethernet/IPImplicitOutputDenitionsTable................................................................................................. 10
 SystemStatusFlagsWorldTable.............................................................................................................................11
 GunStatusFlagsWorldTable..................................................................................................................................11
System Outputs ........................................................................................................................................................11
Gun Outputs (Status Bits) ....................................................................................................................................... 12
Gun Outputs (Valve) ................................................................................................................................................ 12
INPUT COMMANDS (ORIGINATOR TO TARGET ASSEMBLY): 13-16
Considerations ......................................................................................................................................................... 13
 RCS2Ethernet/IPImplicitInputDenitions............................................................................................................. 14
 GunCommandFlagsWordTable ........................................................................................................................... 14
Gun Inputs (Command Bits) .................................................................................................................................... 14
Gun Inputs (Value) ................................................................................................................................................... 16
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any Ransburg
electrostatic coating system , read and understand all of the
technicalandsafetyliteratureforyourRansburgproducts.
This manual contains information that is important for you
to know and understand. This information relates to USER
SAFETY and PREVENTING EQUIPMENT PROBLEMS.
To help you recognize this information, we use the following
symbols.Pleasepayparticularattentiontothesesections.
A WARNING! states information to alert you to
a situation that might cause serious injury if
instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
Whilethismanuallistsstandardspecications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efcient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.
WARNING
!
WARNING
!
The user MUSTreadandbefamiliarwiththe
SafetySectioninthismanualandtheRansburg
safetyliteraturethereinidentied.
Thisequipmentisintendedtobeusedby
trained personnel ONLY.
This manual MUST be read and thoroughly un-
derstood by ALL personnel who operate, clean or
maintainthisequipment!Specialcareshouldbetak-
en to ensure that the WARNINGS and safety require-
ments for operating and servicing the equipment are
followed. The user should be aware of and adhere
to ALLlocalbuildingandrecodesandordinances
as well as NFPA-33 AND EN 50176 SAFETY STAN-
DARDS, LATEST EDITION, or applicable country
safety standards, prior to installing, operating, and/or
servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment
SAFETY
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area 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.
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.
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unauthorized
equipmentmodications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.
Thepaintprocessandequipmentshouldbesetup
andoperatedinaccordancewithNFPA-33,NEC,
OSHA, local, country, and European Health and
Safety Norms.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the 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.
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specically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.
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.
Improper operation or
maintenance may create
a hazard.
Personnelmustbeproperly
trained in the use of this
equipment.
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.
General Use and
Maintenance
Spray Area Explosion Hazard
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
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.
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specically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.
Avoidinstallinganapplicatorintoauidsystem
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcingthatmaycauseareor
explosionislostifsafetycircuits
aredisabledduringoperation.
Frequent power supply shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
reorexplosion.
Unless specically 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.
Electrical Discharge
Electrical
Equipment
Certainmaterialsmaybe
harmful if inhaled, or if there is
contact with the skin.
Follow the requirements of the 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.
Chemical HazardToxic Substances
Sprayapplicatorsrequirethataluminuminletttings
bereplacedwithstainlesssteel.
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.
Halogenatedhydrocarbon
solvents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.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

ETHERNET/IP IMPLICIT COMMUNICATIONS INTERFACE
The Ethernet/IP interface of the RCS2 supports Real-
TimeImplicitmessagingusingtheAssembliesspeciedin
thismanual.TheImplicitdataiscontinuouslyexchanged.
In contrast, Explicit messaging is done periodically “on-
demand”.TheRCS2Explicitcommandsaredescribedin
a separate document.
The Ethernet/IP Implicit Interface for the RCS2 Controller
isdenedasasetofseventeen16bitwordsofinputplus
asetofseventeen16bitwordsofoutput.TheAssembly
instancesaredenedforthecontrollerasfollows:
NOTE
When dening the IO Instances to the host
system, specify the input object of the controller
as the output object of the host and the output ob-
ject of the controller as the input object of the host.
RCS2 will ignore any incoming EIP commands
untilthesystemhascompleteditsboot-uptasks.
NumberInstance Count Size
Input 103(0x67) 17 16bits
Output 119(0x77) 17 16bits
Conguration 1(0x01) 0 8bits
TheOutputbitdenitionsareshowninTable1andtheInput
bitdenitionsareshowninTable2onthefollowingpages.
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INTERFACE
EN

RCS2 ETHERNET I/P CONFIGURATION -
ALLEN BRADLEY CONTROL LOGIX
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EN INTERFACE

OUTPUT STATUS DATA
(TARGET TO ORIGINATOR ASSEMBLY)
The following section describes the structure and
content of the Implicit status data output from the RCS2
Interface-EIPcard.Alldataeldswillbecontinuously
transmitted whether or not the Gun is currently
conguredinthesystem.
Data ContainedWord # Units
0 System-StatusFlags Flags-seetable1.1below
1 Gun1-StatusFlags Flags-seetable1.2below
2 Gun 1 – Actual Flow Rate cc’s/min
3 Gun2-StatusFlags Flags-seetable1.2below
4 Gun 2 – Actual Flow Rate cc’s/min
5 Gun3-StatusFlags Flags-seetable1.2below
6 Gun 3 – Actual Flow Rate cc’s/min
7 Gun4-StatusFlags Flags-seetable1.2below
8 Gun 4 – Actual Flow Rate cc’s/min
9 Gun5-StatusFlags Flags-seetable1.2below
10 Gun5–ActualFlowRate cc’s/min
11 Gun6-StatusFlags Flags-seetable1.2below
12 Gun 6 – Actual Flow Rate cc’s/min
13 Gun7-StatusFlags Flags-seetable1.2below
14 Gun7–ActualFlowRate cc’s/min
15 Gun8-StatusFlags Flags-seetable1.2below
16 Gun 8 – Actual Flow Rate cc’s/min
TABLE 1 - RCS2 ETHERNET/IP IMPLICIT OUTPUT DEFINITIONS
LN-9418-01-R0 (08/2018) 10 / 17 www.carlisleft.com
OUTPUT
EN