Ransburg 22-1589 User manual

SERVICE MANUAL
LN-9405-00.1
Replaces (LN-9405-00)
SERVO AMPLIFIER
MODEL: 22-1589
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: $20.00

LN-9405-00.1

LN-9405-00.1
CONTENTS
SAFETY:
SAFETY PRECAUTIONS..........................................................................................................
HAZARDS / SAFEGUARDS......................................................................................................
INTRODUCTION:
GENERALDESCRIPTION.........................................................................................................
SERIAL AND NETWORK COMMUNICATION PORTS...........................................................
ESTABLISH COMMUNICATION TO AMPLIFIER.....................................................................
CONNECT AND CONFIGURE AMPLIFIER.............................................................................
DOWNLOADING PROCEDURE...............................................................................................
FRONT PANEL LED DIAGNOSTIC..........................................................................................
WARRANTY POLICIES:
LIMITED WARRANTY................................................................................................................
PARTS IDENTIFICATION:
ORDERING PROCEDURE........................................................................................................
PART NUMBERS........................................................................................................................
APPENDIX:
PAINT AND SOLVENT SPECIFICATIONS..............................................................................
VISCOSITY CONVERSION CHART.........................................................................................
VOLUMETRIC CONTENT OF HOSE OR TUBE......................................................................
PAGE
1-3
4-5
1
2-3
4
4
4-5
5
5
18
18
19
19
18
20-23
20
21-22
23
Servo Amplier - Contents
INSTALLATION: 6-16
SETUP AND OPERATION.........................................................................................................
PROGRAM MODES...................................................................................................................
RETROFIT KIT (78694), RCS AMPLIFIER RETROFIT............................................................
RETROFIT KIT (78694-02), PULSE MODE OPERATION.......................................................
RETROFIT KIT (78694-01), ANALOG MODE OPERATION....................................................
GE FANUC S2K AMPLIFIER TERMINATION...........................................................................
6
7-9
10-12
13
14
15-16
TROUBLESHOOTING GUIDE 17
17

LN-9405-00.1
SAFETY
Servo Amplier - Safety
1
> The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
>This manual MUST be read and thor-
oughly 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 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
SAFETY STANDARD, 1995 EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety litera-
ture 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 informa-
tion, 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 instruc-
tions 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 equip-
ment 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 representa-
tive or Ransburg.
> The hazards shown on the following
page may occur during the normal use of
this equipment. Please read the hazard
chart beginning on page 2.W A
W A R N I N G
!

LN-9405-00.1
Servo Amplier - Safety
2
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 op-
era-tioning and maintenance
procedures 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 dis-
abled during operation. Fre-
quent power supply 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.
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, 2000 Edition, OSHA and
local codes. In addition, ventilation must be
maintained during cleaning operations using
ammable or combustible solvents.
Electrostatic arcing must be prevented.
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 unauthor-
ized equipment modications may cause re
or injury.
If used, the key switch by-pass is intended for
use only during set-up operations. Production
should never be done with safety interlocks
disabled.
Never use equipment intended for use in wa-
terborne installations to spray solvent based
materials.

LN-9405-00.1
Servo Amplier - Safety
3
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Electrical
Equipment
High voltage equipment is
utilized. Arcing in areas of am-
mable or combustible materi-
als 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 correc-
tion.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
The power supply, optional remote control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas. Refer to NFPA No. 33, 1995 Edition.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of ammable or combus-
tible 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.
Improper operation or mainte-
nance may create a hazard.
Personnel must be properly
trained in the use of this equip-
ment.
Personnel must be given training in accordance
with the requirements of NFPA-33, Chapter 16,
1995 edition.
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, opera-
tion maintenance, and housekeeping. OSHA
references are Sections 1910.94 and 1910.107.
Also refer to NFPA-33, 1995 edition and your
insurance company requirements.
General Use and
Maintenance

LN-9405-00.1
Servo Amplier - Introduction
4
INTRODUCTION
(For a General Description, Features, and
Specications, Reference GE Fanuc S2K
Series Standalone Motion Controller User’s
Manual, GFK-1848)
SERIAL AND NETWORK
COMMUNICATION PORTS
Summary of DIP Switch Functions
Refer to the S2K Hardware Manual for an expla-
nation of the DIP Switch functions. Set the DIP
Switches for Device Net Address and baud rate
if used.
Serial Port
The S2K includes a serial port that is used to set
the operational parameters. The serial port is an
RS-232 port designed to operate a 7 data bits, 1
stop bit, and odd parity.
A typical 2 conductor shielded cable can be used
to communicate to the S2K amplier. The con-
nectors are the standard 9-pin D-Sub connector
style. The wiring is a straight through style where
the shield is connected to pin 5 of both D-Sub
connectors. The red wire is connected to pin 3
and the black wire is connected to pin 2 of both
connector ends. Refer to the Hardware Manual
(GE Fanuc, S2K Series Manual) for additional
wiring information.
Cable Length Maximum
Communication cables exceeding 30 meters
in length must be enclosed in grounded metal
conduit.
ESTABLISH
COMMUNICATION TO
AMPLIFIER
(For a General Description of programing
protocol, reference GE Fanuc Generation D
Real-Time Operating System Program-ing
Manual, GFK-2205.)
Cable Connection
Connect the serial cable to the serial port on the
S2K amplier and tighten screws to fasten the
connector. Connect the opposite end of serial
cable into the RS-232 serial communication port
of computer. Tighten the screws to fasten the
connector.
Install Operating Software
The operating software for this amplier is pro-
prietary of GE Fanuc. The operating software is
titled “CCS Win32.” Insert CCS Win32 CD into
computer and install. Follow typical Window in-
stallation methods.
Communicating to Amplier
1. Open CCS
2. From Terminal window, select
Options/Communication Setup
3. Select Serial Communication
4. Select the appropriate COM Port setting
5. Leave Baud Rate set to its default value of 9600
6. Click OK
7. Select Options/Controller Settings
8. Select Serial as the Communication Type
9. Select S2K as the Controller Type
10. Click OK
11. Press enter and the S2K will sign on.

LN-9405-00.1
Servo Amplier - Introduction
5
CONNECT AND
CONFIGURE AMPLIFIER
Amplier Termination
• Complete the motor, power, and I/O wiring to
the S2K Amplier. (Reference system prints and
GE Fanuc Manual.)
• Maximum encoder cable length is 15 meters
using factory supplied cables.
• Maximum resolver cable length is 50 meters
using factory supplied cables.
• Positive feedback cables exceeding 30 meters
in length must be enclosed in grounded metal
conduit.
• Reference system drawings for specic appli-
cation terminations.
• Operation with a Pulse Source or Operation
with an Analog Input voltage can also be used
for reference.
• Jumper ENABLE to Common if using internal
12- volt supply or to your external supply common.
Jumper ENABLE + to + voltage if using internal
+12 Volt supply or to your external supply + volt-
age. (Reference the system drawings as this
Enable signal may already be terminated.)
Enable the Drive
Close the Enable switch from your external de-
vice to clear the fault condition. The digital status
LED on the front of the S2K will change to OK.
By toggling this Enable bit, it will allow the opera-
tor to clear faults and enter programs during the
programming mode.
DOWNLOADING
PROCEDURE
Summary of Downloading Procedure
(Refer to the GE Fanuc Generation D Real-Time
Operating System Programing Manual, GFK-2205
for further explanation.)
• Type STF (Set Fault, faults program)
• Type KLALL (Kill All, halts programs which
enables programs to be up or down loaded.)
• Type UPS=O (UPS must be set to its default
value of zero before CLM command will func-
tion.)
• Type CLM (Clear Memory) Are your sure you
want to clear all the user memory and reset the
registers to their default valves?
• Type Y (Yes) (User memory cleared.)
• Click Tools/Send Files
• Select program to download
• Do you wish to save Programs and Motion
Blocks? Click on Yes
• Type Yes (Then the screen will tell you that
the user memory has been saved.)
• Click OK or OPEN
Program is in the form of a text le and will be
downloaded to the Amplier.

LN-9405-00.1
Servo Amplier - Installation
6
INSTALLATION
SETUP AND OPERATION
Summary of Dip Switch Functions
(Refer to the S2K Hardware Manual for an expla-
nation of the DIP Switch functions. Reference the
system prints for the correct settings.)
Software Programmable Parameters
The SMD emulator program in the S2K allows
all of the original SMD parameters to be set in
software in the S2K. Following is a list of the pa-
rameters. These parameters must be set with the
power ON, but with the Enable input set to OFF.
To Query a parameter, type (addr)
variable?<Enter>where<Enter>is the Enter key
on your terminal.
For example: 1VI1?<Enter>will report the mode:
0=pulse input, 1=analog input.
To set a parameter, type (addr) variable = <Enter>
where<Enter>is the Enter key on your terminal.
For example: 1PLA=512<Enter>sets the gear
ratio to 1:1.
Figure 2: Default Programmable Parameters Table
The above parameters are the factory default setting and any modications must be programmed.
Proceed to Program Modes.
PLA
VI1
VI4
VF10
VF11
VF12
VF13
VF14
VF15
VF16
VF18
VF19
Sets gear ratio
Control mode
Direction
Analog input zero
Analog input full scale
Output shaft speed scale factor, rpm/volt
Accel time constant, milleseconds
Maximum motor current, amps
Control stiffness, %
Torque to Inertia ratio
Maximum shaft output speed, rpm
Analog input time constant
Function
DEFAULT PROGRAMMABLE PARAMETERS
Parameter
512 = 1:1
0 = Pulse
0 = CW
-10.0
+2.0
10.0
2
0.5
25
330
10
Minimum
5120 = 1:1
1 = Analog
1 = CCW
+10.0
+10.0
25.0
100
3.0
200
60000
255
Maximum
512
1
0
0.0
+10.0
15.0
22
3.0
100
3000
150
4
Default

LN-9405-00.1
Servo Amplier - Installation
7
PROGRAM MODES
Operation With A Pulse Source
Complete a motor, power, and I/O wiring to the
terminal block. When wiring for pulse and direc-
tion, Channel A is the pulse input and Channel B
is the direction input. Apply a soure of 115 VAC to
the IMJ. Connect the S2K serial port to a personal
computer or other serial terminal device. Refer
to the S2K Hardware Manual for serial port wir-
ing and Serial Port. (Refer to Page 4) Congure
your serial terminal for 9600 baud, 7 data bits, 1
stop bit, and odd parity. Verify that the serial port
is working by typing 1FC?<Enter> and observe
the response. Then proceed with the following:
• Type STF<CR>, the controller will respond
“*”.
• Type KLALL<CR>, the controller will respond
“*”.
• Type VI1=0<CR>, the controller will respond
“*”.
• Type VF10 through VF18 to the appropriate
values. (The factory supplied default values
should work for most applications. Contact Rans-
burg if there are any questions about what values
should be entered.) (Refer to Figure 3)
• Select desired PLA to correspond to the re-
quired gear ratio.
• Type SAVE, the controller will respond, “Sav-
ing user memory... User memory saved.”
• Once all parameters have been set, type EXP1,
the controller will respond, “Variables have been
saved to ash memory.”
This indicates that all variables, registers, and
programs have been saved. To start the motor,
cycle the “Enable” input from false to true.
• Toggle the “Enable” signal.
The S2K will rotate the motor in synchronism with
the input pulse source. In this mode, the motor
displacement is proportional to the number of
pulses received, and motor speed is proportional
to the frequency of the pulse train.
The following table represents typical Pulse
Source setup parameters. However, depending
on the vintage of the system that this amplier
is being retrotted to, the following parameters
could be different:
• VI1 should be setup to a value of 0, (VI1 tells
the amplifer how to function, in either pulse mode
or analog mode).
• VI4 should be set to 0, but a verication of
direction may be required and a setting of 1 may
be required in some applications (VI4 tells the
amplier what direction the motor is to be running).
• VF18 should be set for 150, but an older vin-
age system may require a setup of 120 (VF18
tells the amplier what the maximum shaft output
speed is to be).

LN-9405-00.1
Servo Amplier - Installation
8
Figure 3: Default Pulse Mode Programmable Parameters Table
PLA
VI1
VI4
VF10
VF11
VF12
VF13
VF14
VF15
VF16
VF18
VF19
Sets gear ratio
Control mode
Direction
Analog input zero
Analog input full scale
Output shaft speed scale factor, rpm/volt
Accel time constant, milleseconds
Maximum motor current, amps
Control stiffness, %
Torque to Inertia ratio
Maximum shaft output speed, rpm
Analog input time constant
Function
DEFAULT PULSE MODE PROGRAMMABLE
PARAMETERS CHART
Parameter
512 = 1:1
0 = Pulse
0 = CW
-10.0
+2.0
10.0
2
0.5
25
330
10
Minimum
5120 = 10:1
1 = Analog
1 = CCW
+10.0
+10.0
25.0
100
3.0
200
60000
255
Maximum
512
0
0
+0.0
+10.0
15.0
22
3.0
100
3000
150/120
4
Default
Operation With An Analog Input
Voltage
Complete the motor, power, and I/O wiring to the
S2K and wire the analog control voltage to analog
input terminals AI+, AI-, and ACOM on the screw
terminal block. Apply a source of 115 VAC to the
IMJ and set VI1 = 1. Set PLA, VI4, and VF10
through VF18 to appropriate values. (The factory
supplied default values should work for most ap-
plications.) Cycle the Enable input from False to
True. When the Run Input on I/O terminal is True,
the S2K will accelerate and rotate the motor at a
speed proportional to the analog input voltage.
Analog Input Calibration Sequence
1. Connect the S2K analog input to the device
producing the motor speed control voltage. If the
rest of the system wiring is not in place, connect
the S2K power input terminals to a source of 90
to 130 VAC. Disable (turn OFF) the Enable input.
2. Connect the S2K port to a personal computer
or other serial terminal device. (Refer to the S2K
Hardware Manual for serial port wiring.) Congure
your serial terminal for 9600 baud, 7 data bits, 1
stop bit, and odd parity. Verify that the serial port
is working by typing 1FC?<Enter> and observing
the response.
3. If changes need to be made to any of the pa-
rameters, the following procedure MUST be done:
• Type STF<CR>, the controller will respond
“*”.
• Type KLALL<CR>, the controller will respond
“*”.
• Type VI1=1<CR>, the controller with respond
“*”.
! Type VF10 through VF18 to the appropriate
values. (The factory supplied default values
should work for most applications. Contact Rans-
burg if there are any questions about what values
should be entered.) (Reference Figure 4)

LN-9405-00.1
Servo Amplier - Installation
9
• Select desired PLA to correspond to the re-
quired gear ratio.
• Type SAVE, the controller wil respond, “Sav-
ing user memory... User memory saved.”
This indicates that all variables, registers, and
programs have been saved.
• Once all parameters have been set, type XP1,
the controller will respond, “Variables
have been saved to ash memory.”
• To start the motor, cycle the “Enable” input
from False to True.
This completes the Analog Input Calibration se-
quence. All of the parameters are automatically
saved to memory as soon as they are entered.
The following table represents a typical Analog
Source setup parameters.
PLA
VI1
VI4
VF10
VF11
VF12
VF13
VF14
VF15
VF16
VF18
VF19
Sets gear ratio
Control mode
Direction
Analog input zero
Analog input full scale
Output shaft speed scale factor, rpm/volt
Accel time constant, milleseconds
Maximum motor current, amps
Control stiffness, %
Torque to Inertia ratio
Maximum shaft output speed, rpm
Analog input time constant
Function
DEFAULT ANALOG MODE PROGRAMMABLE
PARAMETERS CHART
Parameter
512 = 1:1
0 = Pulse
0 = CW
-10.0
+2.0
10.0
2
0.5
25
330
10
Minimum
5120 = 10:1
1 = Analog
1 = CCW
+10.0
+10.0
25.0
100
3.0
200
60000
255
Maximum
512
1
0
0
+10.0
15.0
22
3.0
100
3000
150
4
Default
Figure 4: Default Analog Mode Programmable Parameters Table

LN-9405-00.1
Servo Amplier - Installation
10
RETROFIT KIT (78694),
RCS AMPLIFIER RETROFIT
Retrot Kit Description
This Retrot Kit enables the end user to upgrade to
the current level of amplier. Retrot Kit (78694)
allows the end user the backward compatibility
option to utilize the GE Fanuc Amplier in their
existing systems. The older Whedco Amplier
can be removed and this Retrot Kit along with the
new GE Fanuc Amplier will mount in the same
location. In other words, the GE Fanuc Amplier
along with the Retrot Kit (78694) will allow for a
direct drop in replacement to the Whedco style
manufactured amplier.
There are two versions of the Retrot Kit (See
Figures 7 and 8), reference this information as
to the proper implementation of the Retrot Kit.
Retrot Kit Termination Description
The following tables illustrate the terminal des-
ignations and descriptions for each application
possible. Reference Retrot Kit (78694-02) Pulse
Mode Operation (See Figure 7) and Retrot Kit
(78694-01) Analog Mode Operation (See Figure
8 for the proper termination and description of
individual applications.)
1
2
3
4
5
6
7
8
9
10
11
12
13
S2K RETROFIT KIT TRANSITION BOARD
TERMINAL DESCRIPTIONS
S2K Retrot
Terminal
Block
Al+
ACOM
N.C.
A-
B-
GND
EN-
OK-
N.C.
R2
S3
S4
GND/
SHLD
I.D.
Analog +
DC Common
(Not Used)
Channel A-
Channel B-
DC Common
Enable -
OK -
(Not Used)
Motor Resolver
Motor Resolver
Motor Resolver
Motor Thermal
O.L. Gnd.
Signal
Description
DAC A+
DC Common
(Not Used)
Freq. Out from MCM
MON/OFF A+
DC Common
Enable -
CLR AMP FAULT
(Not Used)
Motor Resolver
Motor Resolver
Motor Resolver
Motor Thermal O.L.
Gnd.
Color Amplier
Signal Description
DAC B+
DC Common
(Not Used)
Freq. Out from MCM
MON/OFF B+
DC Common
Enable -
HD AMP Fault
(Not Used)
Motor Resolver
Motor Resolver
Motor Resolver
Motor Thermal O.L.
Gnd.
Hardener Amplier
Signal Description
Figure 5: S2K Retrot Kit Transition Board Terminal Description Table

LN-9405-00.1
Servo Amplier - Installation
11
14
15
16
17
18
19
20
21
22
23
24
25
26
S2K RETROFIT KIT TRANSITION BOARD
TERMINAL DESCRIPTIONS (Cont.)
S2K Retrot
Terminal
Block
Al-
N.C.
N.C.
N.C.
N.C.
PULS OUT
EN+
OK+
R1
S1
S2
THRM
N.C.
I.D.
Analog-
(Not Used)
(Not Used)
(Not Used)
(Not Used)
N.FREQ.
Enable +
OK +
Motor Resolver
Motor Resolver
Motor Resolver
Motor Thermal O.L.
(Not Used)
Signal Description
DAC A-
(Not Used)
(Not Used)
(Not Used)
(Not Used)
N. FREQ.A
Enable +
24 VDC
Motor Resolver
Motor Resolver
Motor Resolver
Motor Thermal
O.L. (Not Used)
Color Amplier
Signal Description
DAC B-
(Not Used)
(Not Used)
(Not Used)
(Not Used)
N.FREQ.B
Enable +
24VDC
Motor Resolver
Motor Resolver
Motor Resolver
Motor Thermal
O.L. (Not Used)
Hardener Amplier
Signal Description
Reference Figure 5 for the signal description of the terminations of the Retrot Kit. Further explana-
tion of these signals can be obtained by referencing the User’s Manual for the Raio Control Module
22-461 (Doc. 122-63).
Figure 5: S2K Retrot Kit Transition Board Terminal Description Table (Cont.)

LN-9405-00.1
Servo Amplier - Installation
12
Reference the S2K Retrot Kit Transition Board
Terminal Description for the signal description
of the terminations of the Retrot Kit. Further
explanation of these signals can be obtained by
referencing the User’s Manual for the Ratio Con-
trol Module 22-461 (Doc. 122-63).
Figure 6: S2K Retrot Kit Transition Board Terminals (78653) Table
S2K Retrot Kit Transition Board Terminals
1
Al+
ACOM
N.C.
A-
B-
14
Al-
N.C.
N.C.
N.C.
N.C.
PLS OUT
EN+
OK+
R1
S1
S2
THRM
N.C
26
TB1
13
TB2
13 1
14 2
15 3
16 4
17 5
18 6
19 7
20 8
21 9
22 10
23 11
24 12
25
GND
EN-
OK-
N.C.
R2
S3
S4
GND
/
SHLD
D - Sub
Connector

LN-9405-00.1
Servo Amplier - Installation
13
RETROFIT KIT (78694-02)
PULSE MODE OPERATION
This kit is used in RCS Systems that utilize the
Motor Control Modules (MCM 22-556). Reference
the following table for information on how to ter-
minate the Retrot Kit (78694-02). Wire numbers
have been denoted to illustrate the typical wire
numbering used. Reference the system prints
for the correct wire number donotation.
Figure 7: S2K Retrot Kit - Pulse Mode
1
Al+
ACOM
N.C.
A-
B-
GND
EN-
OK-
N.C.
R2
S3
S4
GND/
SHLD
13
14
Al-
N.C.
N.C.
N.C.
N.C.
PLS OUT
EN+
OK+
R1
S1
S2
THRM
N.C
26
N.U
N.U.
N.U.
N.U.
N.U.
N.FREQ.
A/B
24 VDC
24 VDC
R1
S1
S2
THRM
Description
Typical Wire #
Color / Hard
4028 / 4089
1260
1260
4030 / 4091
4032 / 4093
4034 / 4095
4051 / 4111
Description
N.U
N.U.
N.U.
CHANL A-
DC COMMON
AMP RESET
AMP FAULT
R2
S3
S4
GND
Typical Wire #
Color / Hard
4021 / 4070
1071
4143
X22 / X23
4031 / 4092
4033 / 4094
4035 / 4096
4052 / 4112
TB1 TB2

LN-9405-00.1
Servo Amplier - Installation
14
RETROFIT KIT (78694-
01) ANALOG MODE
OPERATION
This kit is used in RCS Systems that use the UL
Listed and non-UL Listed Whedco Ampliers (22-
1589). Reference Figure 8 for information on how
to terminate the Retrot Kit (78694-01).
Wire numbers have been denoted to illustrate the
typical wire numbering used. Reference the Sys-
tem prints for the correct wire number denotation.
Figure 8: S2K Retrot Kit - Analog Mode Operation
14
Al-
N.C.
N.C.
N.C.
N.C.
PLS OUT
EN+
OK+
R1
S1
S2
THRM
N.C
26
DAC - (A/B)
N.U
N.U.
N.U.
N.U.
N.FREQ.
A/B
24 VDC
24 VDC
R1
S1
S2
THRM
Description
Typical Wire #
Color / Hard
4011 / 4101
4028 / 4128
1260
1260
4030 / 4130
4032 / 4132
4034 / 4134
4051 / 4151
1
Al+
ACOM
N.C.
A-
B-
GND
EN-
OK-
N.C.
R2
S3
S4
GND/
SHLD
13
Description
DAC + (A/B)
DC COMMON
N.U.
N.U.
MON/OFF (A/B)
DC COMMON
AMP RESET
AMP FAULT
R2
S3
S4
GND
Typical Wire #
Color / Hard
4020 / 4110
1071
4010 / 4100
1071
4080
X22 / X23
4031 / 4131
4033 / 4133
4035 / 4135
4052 / 4152
TB1 TB2

LN-9405-00.1
Servo Amplier - Installation
15
GE FANUC S2K AMPLIFIER
TERMINATION
S2K Auxilary I/O Cable Description
The following Tables depict the terminations used
for the GE Fanuc S2K Style ampliers. These
show the wiring of post June 2002 systems, where
a Retrot Kit was not required. (Reference docu-
mentation Schematic, RCS, 22-1035 (77809),
sheet 4 of 8.) (Reference the system prints for
the correct wire number denotation.)
This table can be referenced against Ransburg
RCS Amplier Cable (78615) for additional clari-
cation.
Figure 9: S2K Auxiliary I/O Cable Table
1
2
5
6
7
8
14
19
20
21
S2K RETROFIT KIT TRANSITION BOARD
TERMINAL DESCRIPTIONS
S2K
Ausiliary
I/O Cable
Al+
I.D.
Analog +
DC Common
Channel B-
DC Common
Enable -
OK -
Analog -
N. FREQ.
Enable +
OK +
Signal
Description
DAC A+
DC Common
MON/OFF A+
DC Common
Enable -
CLR AMP FAULT
(DAC A-
N.FREQ. A
Enable +
24 VDC
Color
Amplier
Signal
Description
DAC B+
DC Common
MON/OFF B+
DC Common
Enable -
HD AMP Fault
DAC B-
N.FREQ. B
Enable +
24 VDC
Hardener
Amplier Signal
Description
4020
1071
4010
1071
4080
X22
4011
4028
1260
1260
Color
Amplier
Signal
Number
4110
1071
4100
1071
4080
X23
4101
4128
1260
1260
Hardner
Amplier
Signal
Number

LN-9405-00.1
Servo Amplier - Installation
16
Figure 10: S2K Position Feedback Cable Table
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Thrm. OL
MTR. Thrm. OL
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
S2K POSITION FEEDBACK CABLE
S2K
Ausiliary
I/O Cable
R1
R2
S1
S3
S2
S4
Thrm
GND/
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
I.D.
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Thrm. OL
MTR. Thrm. OL
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
Signal
Description
Color
Amplier
Signal
Description
4030
4031
4032
4033
4034
4035
4051
4052
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
Color
Amplier
Wire
Number
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Resolver
Mtr. Thrm. OL
MTR. Thrm. OL
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
Hardener
Amplier
Signal
Description
4130
4131
4132
4133
4134
4135
4151
4152
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
SHLD
Hardener
Amplier
Wire
Number
Figure 11: S2K Motor Winding and Line Power Terminations Table
GND
Mtr. Winding
Mtr. Winding
Mtr. Winding
GND
120 VAC
120 VAC
(Not Used)
GND
T
S
R
GND
L3
L2
L1
S2K MOTOR WINDING AND LINE
POWER TERMINATIONS
S2K
Contacts
Color
Amplier
Signal
Description
GND
4063
4062
4061
GND
2
1080
(Not Used)
Color
Amplier
Wire
Number
GND
Mtr. Winding
Mtr. Winding
Mtr. Winding
GND
120 VAC
120 VAC
(Not Used)
Hardener
Amplier
Signal
Description
GND
4163
4162
4161
GND
2
1100
(Not Used)
Hardener
Amplier
Wire
Number

LN-9405-00.1
TROUBLESHOOTING GUIDE
Servo Amplier - Troubleshooting Guide
17
Figure 12: Diagnostic Faults Table
OK
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
Faulted
OK / Faulted
OK / Faulted
Drive enabled CPU’s and operating system functional
Motor power clamp over current
Drive over temperature
Motor power clamp excessive duty cycle
Excessive command increment
Excess following error
Feedback lost (Servo)
Lost enable
Motor over temperature (Servo only)
Motor over current
Motor power over voltage
Power failure
Position register overow
Software fault
Motor power under voltage
DeviceNet node address
Flashing decimal indicates serial communication is occurring.
OK
CC
DT
EC
EI
FE
FL
LE
MT
OC
OV
PF
PO
SF
UV
00-63
•
Mnemonic Description
LED DIAGNOSTIC FAULTS
Controller
Status
Fault and status registers are also available to report faults for the system, input, general I/O, axis status, program
status, and system status. Those register messages, their causes, and their possible solutions are documented
in GE Fanuc manuals, GFK-2205 and GFK-1848.
FRONT PANEL LED
DIAGNOSTICS
The front panel LED on S2K controllers reports
real-time diagnostic as shown in Figure 12.