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RCS-2 Maintenance Service Manual LN-9408-06
- RCS-2 Maintenance Service Manual LN-9408-06 EN [ English ]
SERVICE MANUAL
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Models: A10549 Control Console
A10776 Motor Amplifier Panel
A10948 Fluid Panel
A11095 Remote Operator's Panel
RCS-2 Parts, Maintenance
and Troublshooting
MANUAL CHANGES EN
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NOTE: This manual has been changed from revision LN-9408-06-R4 to
revision LN-9408-06-R5. Reasons for this change are noted under
Manual Change Summary inside the back cover of this manual.
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CONTENTSEN
CONTENTS
(Continued On Next Page)
SAFETY: 5-9
Safety Precautions ..................................................................................................................................................... 5
Hazards / Safeguards ................................................................................................................................................. 6
MAINTENANCE: 10-19
Electrical Control Panels .......................................................................................................................................... 10
Gear Pumps ..............................................................................................................................................................11
Resin (Flushable) Pump Assembly - Parts List......................................................................................................... 13
Assembly 22-337 Pump Bypass............................................................................................................................... 14
Catalyst (Non-Flushable) Pump Assembly - Parts List.............................................................................................. 15
Pump Bypass Valve Assembly - Parts List................................................................................................................ 18
Pump Bypass Valve Assembly.................................................................................................................................. 19
PARTS IDENTIFICATION: 20-43
Main Control Console - Parts List ............................................................................................................................. 20
Rack Assembly - Parts List ....................................................................................................................................... 22
Old Style Motor Amplifier Panel - Parts List.............................................................................................................. 23
New Style Motor Amplifier Panel - Parts List ............................................................................................................ 25
Motor Amplifier Panel Model Identification ............................................................................................................... 27
Remote Operator’s Panel - Parts List ....................................................................................................................... 28
Remote Operator’s Panel Model Identification ......................................................................................................... 29
Fluid Panel Assembly - Parts List ............................................................................................................................. 30
Fluid Panel Assembly Model Identification ............................................................................................................... 33
Non-Flushable Pump/Manifold Assembly - Parts List .............................................................................................. 35
Flushable Pump/Manifold Assembly - Parts List ...................................................................................................... 37
Dual-Headed Pump Assembly (A11800) - Parts List ................................................................................................ 39
77669-00 5-Way Ball Valve Assembly - Parts List .................................................................................................... 42
TROUBLESHOOTING: 44-52
Block Diagrams ........................................................................................................................................................ 44
Ribbon Cable Interconnect Charts ........................................................................................................................... 44
Umbilical Cord Signals ............................................................................................................................................. 44
Control Console Block Diagram ............................................................................................................................... 45
Motor Amplifier Block Diagram ................................................................................................................................. 46
Fluid Panel Block Diagram ....................................................................................................................................... 47
Interconnect Chart for Channels .............................................................................................................................. 48
Interconnect Chart for System I/O Signals ............................................................................................................... 50
Odd Numbered Channel Umbilical Cord Signals ..................................................................................................... 51
Even Numbered Channel Umbilical Cord Signals .................................................................................................... 52
APPENDIX: 53-89
APPENDIX A:
Updating the Firmware and Software on the RCS-2............................................................................................ 53
APPENDIX B:
Error Log Chart .................................................................................................................................................... 59
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CONTENTS EN
CONTENTS (Cont.)
APPENDIX: (Cont.) 53-89
APPENDIX C:
Motor Amplifier LED Display Fault Codes (Part 1) - GE Fanuc Amplifier............................................................. 63
Motor Amplifier LED Display Fault Codes (Part 2) - Danaher (Kollmorgen) Amplifier ......................................... 64
APPENDIX D:
Calibrating the Pressure Transducers (Part 1) - Determining Transducer Type................................................... 67
Calibrating the Pressure Transducers (Part 1) - Calibrating the Type 1 Transducer............................................ 67
Calibrating the Pressure Transducers (Part 2) - Calibrating the Type 2 Transducer ........................................... 69
Calibrating the Pressure Transducers (Part 2) - Calibrating the Type 3 Transducer - Parts List.......................... 70
APPENDIX E:
Recommended Spare Parts - A10549 Main Control Console - Parts List............................................................ 71
Recommended Spare Parts - A10776 Motor Amplifier Panel - Parts List............................................................. 72
Recommended Spare Parts - A10948 Fluid Panel - Parts List............................................................................. 73
Recommended Spare Parts - Seal Kits, Tools, Tubing, Etc. - Parts List.............................................................. 74
Recommended Spare Parts - A11095 Remote Operator’s Panel - Parts List...................................................... 74
APPENDIX F:
System Layout...................................................................................................................................................... 75
APPENDIX G:
Schematics........................................................................................................................................................... 76
MANUAL CHANGE SUMMARY: 90
Manual Changes ...................................................................................................................................................... 90
SAFETYEN
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CAUTION!
WA R N I N G!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system, read and understand all of the technical
and safety literature for your 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 specifications 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 associated equipment
manuals to reconcile such differences.
WA R N I N G!
WA R N I N G!
� The user MUST read and be familiar with the
Safety Section in this manual and the safety literature
therein identified.
� This equipment is intended to be used by
trained personnel ONLY.
� This manual MUST be read and thoroughly
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 fire codes
and ordinances as well as NFPA-33 AND EN 16985
SAFETY STANDARDS, 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
Repairs may only be performed by personnel authorized
by Binks.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
in more efficient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your equipment, contact your local
Binks representative or Binks technical support.
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SAFETY EN
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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 fire
hazard.
Protection against inadvertent
arcing that is capable of
causing fire 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, flushing or maintenance.
Spray booth ventilation must be kept at the rates
required by NFPA-33, EN 16985, country, and local
codes. In addition, ventilation must be maintained
during cleaning operations using flammable 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 modifications may cause fire 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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SAFETYEN
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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
fire hazard.
Protection against inadvertent
arcing that is capable of
causing fire 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.
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.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
General Use and
Maintenance
Spray Area Explosion Hazard
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 specifically 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 flammable 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 fire
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
flushing, 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 16985.
Have fire extinguishing equipment readily available
and tested periodically.
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SAFETY EN
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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 fire
or explosion.
Electrical Discharge
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 megohm. (Refer to NFPA-33,
EN 16985.)
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, EN 16985 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 flooring must be provided in
the spray area.
Always turn off the power supply prior to flushing,
cleaning, or working on spray system equipment.
Unless specifically 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 fluid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
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SAFETYEN
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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 flammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a fire 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
fire or explosion.
Electrical DischargeElectrical
Equipment
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 Certain materials may be
harmful if inhaled, or if there
is contact with the skin.
Unless specifically 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 16985.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of flammable 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.
Spray applicators require that aluminum inlet fittings
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, flushing, 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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MAINTENANCE EN
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MAINTENANCE
ELECTRICAL CONTROL PANELS
Main Control Console
There is minimal (if any) routine maintenance necessary on
the main control console. There are no moving parts aside
from the power and emergency stop switches on the door
of the panel. A few things can be done from a preventative
viewpoint to extend the life of the components in the control
console:
• Keep the door closed at all times to keep dust, dirt, and
moisture out of the control panel and off of the PC boards.
• Avoid touching the touch screen display with sharp objects
or with hands or gloves that have paint on them. The screen
is glass and a razor blade can be used to remove dried
paint, etc., if absolutely necessary, however, it is best to
avoid having to do this. If the glass is scratched in any
way, it can effect how the touch screen responds when
touched. (Sensitivity can be diminished by contaminants
or scratches.)
• Make sure the quarter turn latch screws on the PC boards
and on the rack are latched to prevent boards from vibrating
loose over time.
• Make sure all latches are in the proper position to retain all
ribbon cables in the control panel.
• Temperatures inside of the main control console run
significantly above ambient. If it is expected that the ambient
temperature will exceed 100° F for long periods of time, some
form of external cooling will be required. Contact Ransburg
for suggested methods.
• There are several different versions of the touchscreen PC
used in the RCS-2, but all of them employ cooling fans and
air vents. On some of them, fans are visible on the outside
frame of the computer and on others, they are internal to the
PC. Periodically, check to make sure the fans are running
and vent holes are not blocked by dust or other obstructions.
Motor Amplifier Panels
There is minimal routine maintenance necessary on the motor
amplifier panels. The only items in the motor amplifier panel
that have moving parts are the power relay, the solenoid
valves, and the E to P transducers. (The later two items are
optional.) Note that some of the E to P transducers also have
small in-line filters (P/N: SSM-5504) on their inlet ports that
may need periodic replacement, depending on the quality
of the air being delivered to the panel.
Similar to the aforementioned main control console, there
are a few things to keep in mind to help extend the lives of
the components in the motor amplifier panels:
• Keep the door closed at all times to keep dust, dirt, and
moisture out of the control panel.
• Because the motor amplifiers can dissipate a significant
amount of heat, temperatures inside of the motor amplifier
panels can run as much as 20° F above ambient. If that
will cause the internal temperature of the motor amplifier
panel to rise above 120° F, some sort of external cooling
may be required.
• It is recommended that the air supply to this panel be
regulated to approximately 100 psi and filtered to at least
20 Microns.
Remote Operator’s Panel
As with the other control panels, there are not many items in
the remote operator’s panel that should require much routine
maintenance. The only moving parts are the pushbuttons,
color select switch, flow control potentiometer and the optional
pressure and air-flow switches. All indicator lamps are LED’s
and should, therefore, never fail. A couple of items to keep
in mind are listed below to insure uninterrupted service from
the remote operator’s panel:
• Keep the door closed at all times to keep dust, dirt, and
moisture out of the control panel.
• Use dry, filtered (20 Micron’s or less) air to pilot the pressure
switches and supply the inlets to the air flow switches.
Fluid Panels
As with all fluid delivery and control systems, the part of the
system that sees the most wear and tear and will require
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MAINTENANCEEN
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the most maintenance and repair is the section that actually
makes contact with the fluids. In the case of the RCS-2,
this section is referred to as the fluid panel.
The fluid panel portion of the RCS-2 is basically a stainless
steel plate with most of the components that come in contact
with the fluids being metered mounted on it. All wetted
components are stainless steel or PTFE other than the
physical pumps themselves. In most cases, the pumps are
manufactured from M2 tool steel, which gives them superb
wear resistance over similar designs manufactured from
stainless steel.
Each of the individual components on the fluid panel will be
discussed below as to how it operates and how to service it.
GEAR PUMPS
This section explains How to Disassemble, Clean, and
Reassemble the Gear Pump.
Introduction
The magnetically coupled gear pump is a precision tool
designed to provide highly accurate performance over an
extended service life. The gear pump is constructed of
precisely machined components with tight running tolerances
of 0.00025 inches. Burrs, nicks, or particles of foreign matter
can score an internal surface or cause the pump to seize
up. The ability of the unit to deliver the performance level
it was designed for depends on the user closely following
several essential requirements:
• Never let a pump run dry
• Never pump contaminated fluids
• Never reuse any seal (Always replace separated seals
with a new seal.)
• Consult the factory before using micas, metallic’s, or
waterborne coatings
• Provide advance filtration for all fluids
• Provide skilled and careful maintenance
• Respect exceptionally close tolerances
Gear Pump Operation
The gear pump's internal bearing surfaces are lubricated
by the metered fluids being pumped through the assembly.
The recommended operating speed range for these pumps
is between 3 and 150 rpm. Pump speeds over 150 rpm are
not recommended.
Increasing the pump's operating speed improves its
efficiency, but also shortens the time fluid is allowed to fill
the gear tooth spaces and lubricate the bearing surfaces.
Failure to fill the tooth spaces allows air into the pump and
can cause low delivery, excessive wear, reduced seal life,
and internal cavitation.
Magnetic Coupling
There is no rotating shaft connecting the servo motor to
the gear pump. Instead, this product employs a magnetic
coupling to transfer power from the servo motor to the positive
displacement gear pump. The magnetic coupling provides
several advantages over conventional rotary
shaft systems:
• Protects servo motor from paint leaks
The magnetic coupling provides a physical barrier between
the servo motor and the gear pump, and serves to protect
the servo motor from paint leakage.
• Make seals less critical
The seals are less critical than in a conventional rotary
shaft system. If seals leak in the pump, the system will
still operate without the danger of paint entering the drive
system.
• Provide more up-time
Since the seals are less critical and the magnetic coupling
is durable, the system delivers higher equipment utilization
and shorter maintenance procedures.
• Lasts longer
The magnetically coupled gear pump and motor will have
a longer operational life than a conventional rotary shaft
system.
Applications
Because of the precise servo control and rapid acceleration
and deceleration of paint delivery, this product is ideally
suited for almost all automotive or industrial applications.
This product will provide superior delivery in applications
that require:
• High performance paint metering
• Single and multi-component applications
• Precision flow rates
• Quick and accurate flow rate changes
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MAINTENANCE EN
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The parts of each pump are similar. Except for plate
configuration, the main difference between the two styles
is the seal plate on the hardener pump. This section covers
both pumps and the instructions will identify where the
procedure only applies to one style.
Restricted Materials
Paints and fluids for use with this system must meet the
following conditions:
• Non-abrasive materials
• Maximum entrained particle size: 6 microns (0.00025)
• Maximum hardness: Rc 55
• Concentration of entrained particles should not exceed
20% of total fluid volume.
Contact Ransburg for technical assistance on applications
involving metallics, micas, or waterborne systems.
Applicable Models and Styles
The Service Information in this manual covers two basic
product styles:
• Flushable
The flushable style pumps meter color and incorporates a
pump bypass assembly.
• Non-flushable
The non-flushable style pumps meter hardener and do not
have a bypass assembly.
Major Components
The major components of the flushable magnetically coupled
gear pumps include:
• Bypass Assembly (Flushable units only)
Allows rapid flushing of the pump.
• Gear Pump
Is made from precision machined parts with tolerances of
0.00025. The gear pump is the heart of the delivery system
and controls the flow of paint for a precise, accurate coating.
• Manifold
Connects gear pump to magnetic coupling.
• Magnetic Coupling
Transfers rotary motion from the servo motor to the
gear pump.
• Servo Motor
Converts an analog signal from the controller to a
proportional rotary RPM.
General Handling
The magnetically coupled gear pump assembly is a precision
tool designed to provide highly accurate performance over
an extended service life. The ability of the unit to deliver the
performance level it was designed for depends on the user
closely following several essential requirements:
• Never let the pump run dry
• Never pump contaminated fluids
• Never reuse any seal
• Always replace damaged or worn seals with a new seal
• Consult the factory before using micas, metallic's, or
waterborne systems
• Provide filtration for suspect fluids
• Provide skilled and careful maintenance
• Respect exceptionally close tolerances
Precision Metering Pump
The heart of the system is the high precision metering gear
pump constructed of M2 tool steel. To maintain the gear
pump assembly in factory-new condition, the guidelines
and procedures for pump servicing covered in this manual
should be carefully followed.
With tight running tolerances of a remarkable 0.00025 inches,
there can be no allowance of casual handling that might be
appropriate for a less exacting assembly. Burrs, nicks, or
particles of foreign matter could score an internal surface
and cause the pump to seize up.
System Start-Up
Pump assemblies are shipped from the factory protected with
rust preventive oil. Remove this oil before using the system.
A MSDS sheet is included with the fluid panel for this oil. To
remove oil, flush and purge the system with solvent.
NOTE
� Although uncommon, there are applications for flush-
able hardener pumps and for non-flushable color pumps.
Pumps, Color (Resin), and Hardener (Catalyst)
Some coating applications using the magnetically coupled
gear pump require two fluids to be metered. Thus, there
are two styles of pumps:
• Color Pump (Resin), which are flushable
• Hardener Pump (Catalyst) which are non-flushable.
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MAINTENANCEEN
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1 22-315 * Lip Seal 1
2 N.F.R. ** Front Side Plate 1
3 N.F.R. Arbor 1
4 N.F.R. Driven Gear 1
5 N.F.R. Drive Shaft 1
6 N.F.R. Driving Gear 1
7 N.F.R. Center Plate 1
8 N.F.R. Hollow Dowel 2
9 N.F.R. Rear Side Plate 1
10 Varies *** Roll Pin 4
11 Varies *** Socket Head Cap Screw 4
* Required Seal Insertion Tool, P/N: 22-543
** Not Field Replaceable
*** Varies based on pump size
Item # Description Qty
Figure 1: Resin (Flushable) Pump Assembly
RESIN (FLUSHABLE) PUMP ASSEMBLY - PARTS LIST (Figure 1)
Part #
1 2
3 4
5
6
7
8 9
11
10
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ASSEMBLY 22-337 PUMP BYPASS
Flushable gear pumps have an air activated cylinder with
two (2) ports that allow flushing of coating material from
the gear pump. This feature reduces the time required to
fill or purge the pump of paint. (See Pump Bypass Valve
Assembly in the Maintenance section.)
Gear Pump Disassembly
1. Remove the four (4) socket head cap screws attaching
the pump to the manifold.
2. Remove S.H.C. scews [11].
3. Using an arbor press, remove two (2) dowels [8] from
the pump assembly.
4. Separate front plate [2] from center plate [7], and from
rear plate [9].
Gear Pump Reassembly
Before reassembling the gear pump, clean and inspect all
parts for damage or wear.
To Assemble:
1. If parts were separated, use a press to press arbor [3]
into front side plate [2].
2. Insert driven metering gear [4] into center plate [7]. Man-
ually turn the metering gear to ensure it moves freely.
5. Remove driving gear [6] from center plate [7].
6. Remove driven gear [4] from center plate [7].
7. Remove arbor [3] from driven gear [4].
3. Insert driving metering gear [6] into center plate [7]. Manually
turn the metering gear to ensure it moves freely.
4. Assemble rear [9], center [7], and front [2] plates.
5. Using an arbor press, press-fit two (2) dowels [8] into the
plate assembly.
6. Lubricate roll pins [10] and cap screws [11] with petro-
leum jelly.
7. Insert roll pins [10] and cap screws [11] into rear plate
[9] and thread them through all three (3) plates. Torque
to 160 lbs•in.
8. After assembly, check torque by turning driving gear (torque
not to exceed 4 lbs•in).
Drive Gear and Shaft
In case of separate damage or wear, the drive gear [6] and
drive shaft [5] may need to be separated and replaced.
(Individual pump parts are not field replaceable and must be
returned for replacement.) To separate, use an arbor press
to remove the gear [6] from the drive shaft. In reassembly,
position the bottom of the gear .909 +/- .003 from the
bottom of the shaft (end opposite the tang). Ransburg can
supply a Gear Alignment Gauge for this purpose. The tool is
P/N: 11-1032. Contact Ransburg for additional information.
Hollow Dowel
Ransburg can supply special tools to achieve proper
placement of the hollow dowels [8] in the gear plates. The
dowel should extend .093 +/- .005 above the end plate on
the pump shaft end (tang end). To allow dowel placement
from either end of the pump, two tools are required:
• Dowel Insertion Tool - Male P/N: 22-1033
• Dowel Insertion Tool - Female P/N: 22-1034
NOTE
CAUTION!
CAUTION!
CAUTION!
NOTE
� If an arbor press is unavailable, an alternate disas-
sembly method is to partially back-off the cap screws
and tap the screws with a soft head hammer. With
the screw heads exposed, continue to alternate back-
ing-out the screws and tapping the screws until the
plates are free.
� Opening the pump bypass valve is not recom-
mended on plural component materials during load
and run cycles.
� Be careful not to scratch or nick any surface of
the plates, seals, gears, and dowels inside the pump.
These parts have very precise tolerances. Burrs,
nicks, scratches, or particles of foreign matter will
cause scoring and possibly pump seizure.
� If the metering gear binds, it could damage the
pump. Determine the cause of the binding. Nicks, burrs,
or foreign particles can cause pump binding.
� Never tap on any part of the drive shafts!
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MAINTENANCEEN
LN-9408-06-R6 (09/2025)15 / 91www.binks.com
Figure 2: Catalyst (Non-Flushable) Pump Assembly
* Required Seal Insertion Tool, P/N: 22-542
** Not Field Replaceable
*** Varies based on pump size
Item # Description QtyPart #
CATALYST (NON-FLUSHABLE) PUMP ASSEMBLY - PARTS LIST (Figure 2)
1 22-383 * Lip Seal 1
2 N.F.R. ** Front Side Plate 1
3 N.F.R. Arbor 1
4 N.F.R. Driven Gear 1
5 N.F.R. Drive Shaft 1
6 N.F.R. Driving Gear 1
7 N.F.R. Center Plate 1
8 N.F.R. Hollow Dowel 2
9 N.F.R. Rear Side Plate 1
10 Varies *** Long Cap Screw 4
11 Varies *** Short Cap Screw 2
12 N.F.R. Seal Plate 1
13 Varies *** Socket Head Cap Screw 4
1 2
3
4
5
6
8
11
7
10
12
13
9
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MAINTENANCE EN
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Non-Flushable Gear Pump Disassembly
1. Remove the four (4) socket head cap screws attaching
the pump to the manifold.
2. Remove the seal plate [12].
3. Remove bolts [10] and [11].
4. Using an arbor press, remove the two (2) dowels [8] from
the front plate [2], center plate [7], and rear plate [9].
5. Separate front plate [2] from center plate [7].
6. Separate center plate [7] from rear plate [9].
7. Remove rear plate [9].
8. Remove driving gear [6] from center plate [7].
9. Remove driven gear [4] from center plate [7].
10. Remove arbor [3] from driven gear [4].
Non-Flushable Gear Pump Reassembly
Before reassembling the gear pump, clean and inspect all
parts for damage or wear.
To Assemble:
1. If parts were separated, use a press to press arbor [3]
into front side plate [2].
2. Insert driven gear [4] into center plate [7]. Manually turn
the gear to ensure it moves freely.
3. Insert driving gear [6] into center plate [7]. Manually turn
the gear to ensure it moves freely.
8. Install seal plate [12] onto rear plate [9] using four (4)
socket head cap screws [13]. Torque to 50 lbs•in.
9. After assembly, check torque by turning drive gear (torque
not to exceed 4 lbs•in).
NOTE
CAUTION!
CAUTION!
CAUTION!
NOTE
NOTE
� It is not recommended to disassemble these pumps
in the field unless absolutely necessary. If a malfunction
occurs, they should be returned to Ransburg for service.
� If an arbor press is unavailable, an alternate disas-
sembly method is to partially back-off the cap screws
and tap the screws with a soft head hammer. With
the screw heads exposed, continue to alternate back-
ing-out the screws and tapping the screws until the
plates are free.
� Be careful not to scratch or nick any surface of
the plates, seals, gears, and dowels inside the pump.
These parts have very precise tolerances. Burrs,
nicks, scratches, or particles of foreign matter will
cause scoring and possibly pump seizure.
� Never tap on any part of the drive shafts!
� If the gear binds, it could damage the pump. Deter-
mine the cause of the binding. Nicks, burrs, or foreign
particles can cause pump binding.
� The non-flushable pump uses two (2) short cap
screws [11] and four (4) long cap screws [10] that ex-
tend through to the four (4) threaded holes in the front
side plate [2]. torque to 120 lbs•in.
4. Assemble rear [9], center [7], and front [2] plates.
5. Using an arbor press, press-fit two (2) dowels
[8] into the plate assembly.
6. Lubricate cap screws [10] and [11] with petroleum jelly.
7. Insert cap screws [10] and [11] into rear plate [9] and
thread them through all three (3) plates.
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MAINTENANCEEN
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Drive Gear and Shaft
In case of separate damage or wear, the drive gear [6] and
drive shaft [5] may need to be separated and replaced.
(Individual pump parts are not field replaceable and must be
returned for replacement.) To separate, use an arbor press
to remove the gear [6] from the drive shaft. In reassembly,
position the bottom of the gear .909 +/- .003 from the bottom
of the shaft (end opposite the tang). Ransburg can supply
a Gear Alignment Gauge for this purpose. The tool is P/N:
22-1032. Contact Ransburg for additional information.
Hollow Dowel
Ransburg can supply special tools to achieve proper place-
ment of the hollow dowels [8] in the gear plates. The dowel
should extend .093 +/- .005 above the end plate on the
pump shaft end (tang end). To allow dowel placement from
either end of the pump, two tools are required:
• Dowel Insertion Tool - Male - P/N: 22-1033
• Dowel Insertion Tool - Female - P/N: 22-1034
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MAINTENANCE EN
LN-9408-06-R6 (09/2025) 18 / 91 www.binks.com
Figure 3: Pump Bypass Valve Assembly
* Part of P/N: 22-402 Manfold Assembly
Item # Description QtyPart #
1 97-2396 Double Acting Cylinder 1
2 LS00122 Breather 1
3 41-FTP-1018 5/32 ODT X 1/8 NPT Tube Fitting 1
4 7959-28C 1/4-20 X 7/8 L, SHCS 2
5 77303-00 Clamp Block 1
6 97-2009 Bushing 1
7 77306-00 Plunger 1
8 8532-32C * 5/16-18 X 1 L, SHCS 3
9 22-399 * Adapter Plate 1
10 97-2016 Diaphragm 1
11 22-398 * Manifold Plate 1
12 22-403 Gasket 1
13 22-336 Seal 1
14 9158-16C #8-32 X 50 L, Flat Head, Slotted Machine Screw 3
PUMP BYPASS VALVE ASSEMBLY - PARTS LIST (Figure 3)
2
3
4
5
6
8
11
7
10
12
13
9
1
14
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MAINTENANCEEN
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PUMP BYPASS VALVE
ASSEMBLY
This section describes the Procedures for Flushing,
Removing, and Replacing the Bypass On the Flushable
Magnetically Coupled Gear Pump.
Introduction
The flushable magnetic gear pump has a pump bypass as-
sembly which allows cleaning of paint from the gear pump
by allowing paint, solvent, or a solvent-air mixture to bypass
the gears, thus reducing flush and load times. Typically, the
bypass is mounted on the pump which meters color.
Servicing the Pump Bypass Valve Assembly
Unlike other components for which all broken seals must be
replaced before reassembly, two (2) of the fluid seals in the
bypass need only be replaced if damaged or worn.
Guidelines for bypass parts replacement:
• O-Ring Seals [13]: always replace after disassembly.
• Gasket [12]: replace only if there is visible wear or damage.
• Diaphragm [10]: replace only if there is visible wear or damage.
To Disassemble:
1. Remove two (2) screws [4] from clamp block [5].
2. Remove bushing [6] and plunger [7] from clamp block [5].
3. Remove three (3) screws [8] holding adapter plate [9] and
manifold plate [11] to gear pump. Handle plates carefully to
avoid damage to gasket [12].
4. Remove three (3) screws [14] holding adapter plate [9]
to manifold plate [11]. Separate plates carefully to avoid
damaging diaphragm [10].
To Reassemble:
1. Place diaphragm [10] in recess in adapter plate [9].
2. Install three (3) screws [14] to fasten manifold plate [11]
to adapter plate [9].
3. Install two (2) seals [13] and gasket [12] on manifold
plate [11].
4. Install three (3) scews [8] to fasten adapter plate [9] to
gear pump.
5. Insert plunger [7] and bushing [6] into clamp block [5].
6. Install two (2) screws [4] to fasten clamp block [5] to
adapter plate [9]. This completes assembly.
NOTE
� It is possible (however uncommon) to use a bypass
valve on a hardener pump. Don't assume that a pump
with a bypass is always a color pump.
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PARTS IDENTIFICATION EN
LN-9408-06-R6 (09/2025) 20 / 91 www.binks.com
PARTS IDENTIFICATION
Figure 4: Main Control Console
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PARTS IDENTIFICATIONEN
LN-9408-06-R6 (09/2025)21 / 91www.binks.com
1 A10554-00 Terminal Board Assembly, RCS-2 1 2 3 4
2 A11530-00 System I/O Terminal Board, RCS-2 1 1 1 1
3 TR-SSEH-472 AGC-10, 10 Amp Fuse 1 1 1 1
4 4131-10 Fuse, 6.25 Amp 1 1 1 1
5 A10998-01 Ethernet Switch, 8 Port, Compact 1 1 1 1
6 22-1108 Power Line Filter 1 1 1 1
7 A13908-00 Power Supply, 24 VDC @ 150 Watts 1 1 1 1
8 A10705-02 * Touch Screen, PC Assembly 1 1 1 1
9 76948-00 Switch, Selector, Maintained 1 1 1 1
10 77384-00 Switch, Mushroom Head, E-Stop, Red 1 1 1 1
11 LSME0005-00 Contact Block, Normally Open 1 1 1 1
12 LSME0007-00 Pilot Light Block 1 1 1 1
13 74300-00 Pilot Light, 130 Volt 1 1 1 1
14 LSME0004-00 Contact Clip, 3 Position 2 2 2 2
15 LSME0006-00 Contact Block, Normally Closed 1 1 1 1
16 77403-00 Recepticle, Push-On, Oval Slot Stud 2 2 2 2
17 A10530-00 Rack Sub-Assembly, RCS-2 1 1 1 1
18 78818-01 Interface Board Assy., RCS-2 1/0 1/0 1 1
A14084-01 Interface Board Assy., RCS-2, with Ethernet/IP 0/1 0/1 N/A N/A
19 78814-01/02 Channel Board Assy., RCS-2 1 2 3 4
20 77423-00 Pin, Detented 1 1 1 1
21 77429-01 Shoulder Washer, Nylon 2 2 2 2
22 77400-00 Cable Mount, Ribbon, 4 1 1 1 1
23 A10586-01 64 Conductor Ribbon Cable, X 58.5 Lg. 1 1 1 1
24 A10586-02 64 Conductor Ribbon Cable, X 68.5 Lg. 1 2 3 3
25 A10586-03 64 Conductor Ribbon Cable, X 81 Lg. 0 0 0 1
26 A10587-01 50 Conductor Twisted PR Ribbon Cable,X 80 Lg. 1 1 1 1
27 A10587-02 50 Conductor Twisted PR Ribbon Cable, X 100 Lg. 0 1 2 3
28 A10795-00 Industrial Ethernet Bulkhead Receptical 5 5 5 5
29 A10819-00 Dust Cap for A10795-00 5 5 5 5
30 A10564-0X Cable Assembly, 26 Socket Bulkhead (X=Channel Number) 2 4 6 8
31 A10817-00 Dust Cap for A10564 2 4 6 8
32 LSME0024-00 Horn, 24 VDC 1 1 1 1
Quanity Required
DescriptionPart #
Part Number Tabulation:
A10549-02 = 2 Channel Controller
A10549-04 = 4 Channel Controller
A10549-05 = 6 Channel Controller
A10549-08 = 8 Channel Controller
A10549-12 = 2 Channel Controller with Ethernet/IP
A10549-14 = 4 Channel Controller with Ethernet/IP
-02/12 -04/14 -06 -08
* Touch screen may vary slightly from one shown.
MAIN CONTROL CONSOLE - PARTS LIST (Figure 4)
Item #
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PARTS IDENTIFICATION EN
LN-9408-06-R6 (09/2025) 22 / 91 www.binks.com
Figure 5: Rack Assembly
1 78816-00 Backplane Board Assembly, RCS-2 1
2 A10530-00 Rack Sub-Assembly, RCS-2 1
3 77377-22 * Interface Board, RIO, RCS-2 (Obsolete) 0-1
4a 78818-00 Interface Board Assembly, RCS-2 0-1
4b A14084-01** Interface Board w/Ethernet/IP, RCS-2 0-1
5 78814-01 or 02 *** Channel Board Assembly, RCS-2 1-4
6 75086-01 **** Cover Assembly 0-4
* Only required if RIO Interface to PLC is used.
** Only Required if Ethernet/IP Interface is required.
*** Quantity dependant on number of Channels required. (A maximum of only 2 channel cards can be used with the Ethernet/IP Interface Card.)
**** Cover plates used to fill unused slots.
Item # Description QtyPart #
RACK ASSEMBLY - PARTS LIST (Figure 5)
12
3
4a
5
6
4b
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PARTS IDENTIFICATIONEN
LN-9408-06-R6 (09/2025)23 / 91www.binks.com
Figure 6a: Old Style Motor Amplifier Panel
31 2 4
65 7
19
18
20
9
10
8
12
13
11
14
1617 15
21
2728 2526
22
23 24
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PARTS IDENTIFICATION EN
LN-9408-06-R6 (09/2025) 24 / 91 www.binks.com
* Used only if the optional Color Change Sequencer is installed.
** Used only if the optional Color Change Sequencer is not installed.
*** Refer to Motor Amplifier Panel Model Identification for quantities.
Item # Description QtyPart #
1 A10795-00 Ethernet Industrial Bulkhead W/RJ-45 Connector 1
2 A10798-00 Ethernet Cable (Not Shown) 1
3 A10564-09 26 Socket Bulkhead Assembly W/Flying Leads 1
4 A10564-10 26 Socket Bulkhead Assembly W/Flying Leads 1
5 A10783-01 Motor Drive (Amplifier) 2
6 A11389-00 * Power Supply, 5VDC & 24VDC, 180 W 1
78835-01 ** Power Supply, 24VDC, 180 W 1
7 22-1108 Power Line Filter 1
8 TR-SSEH-472 AGC-10, 10 Amp Fuse 1
9 SSS-7016 24VDC Relay 1
10 TR-SSEH-471 AGC-5, 5 Amp Fuse 1
11 A10781-00 Special Signal Inverting Terminal Block 2
12 22-1050 Flow Switch Amplifier 1
13 22-1046 Flow Monitor Control Unit 1
14 22-1245 Zener Barrier for 4-20mA 4
15 78643-00 Transducer Assembly, E to P 2
16 41-VSO-1005 24VDC Solenoid Valve Assembly 20
17 73837-08 Zener Barrier for Voltage 12
18 A10785-01 * Opto-22 Brain W/Ethernet (Programmed) 1
19 A10786-00 * Opto-22 DC Input Module 3
20 A10787-00 * Opto-22 DC Output Module 9
21 A10793-00 Tachometer Bulkhead Cable Assembly, RCS-2 Motor Amp Panel 2
22 A10796-00 Bulkhead Connector, 4-Pin, Amphenol 4
23 76965-00 Cable Strain Relief, Liquid Tight 1
24 22-1045 Flow Sensor Cable Assembly 1
25 41-FBH-1000 1/4 ODT Bulkhead C ***
26 41-FBH-1001 3/8 ODT Bulkhead C ***
27 A10789-00 Motor Drive Bulkhead Cable Assembly, RCS-2 Motor Amp Panel 2
28 A10974-00 26 Socket Bulkhead Assembly B ***
OLD STYLE MOTOR AMPLIFIER PANEL - PARTS LIST (Figure 6a)
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PARTS IDENTIFICATIONEN
LN-9408-06-R6 (09/2025)25 / 91www.binks.com
Figure 6b: New Style Motor Amplifier Panel
31 2 4
65 7
19
18
20
9
10
8
12
13
11
14
1617 15
21
27
28
2526
22
23 24
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PARTS IDENTIFICATION EN
LN-9408-06-R6 (09/2025) 26 / 91 www.binks.com
1 A10795-00 Ethernet Industrial Bulkhead W/RJ-45 Connector 0/1
2 A10798-00 Ethernet Cable (Not Shown) 0/1
3 A10564-09 26 Socket Bulkhead Assembly W/Flying Leads 1
4 A10564-10 26 Socket Bulkhead Assembly W/Flying Leads 0/1
5 A12219-01 Motor Amplifier, S200 1/2
6 A13908-00 Power Supply, 24 VDC, 150 W 1
7 22-1108 Power Line Filter 1
8 TR-SSEH-472 AGC-10, 10 Amp Fuse 1
9 SSS-7016 24VDC Relay 1
10 4131-10 Fuse, 6.25 Amp 1
11 A10781-00 Special Signal Inverting Terminal Block 2
12 A12268-00 Motor Hold Module 1
13 22-1245 Zener Barrier for 4-20mA 0/4
14 A12425-00 Catalyst Flow Sensor Module 0/1
15 78643-03 Transducer Assembly, E to P 0/1/2
16 41-VSO-1005 24VDC Solenoid Valve Assembly 0/20
17 73837-08** Zener Barrier for Voltage 0/12
18 A14212-00* Color Change Sequencer Brain 0/1
19 A10786-00* Opto-22 DC Input Module 0/3
20 A10787-00* Opto-22 DC Output Module 0/9
21 A12220-00 Cable, S200, AKM-33 1/2
22 A10796-00 Bulkhead Connector, 4-Pin, Amphenol 2/4
23 A10626-00 Cable Gland, 4-Port 1
24 22-1045 Flow Sensor Cable Assembly 0/1
25 41-FBH-1000 1/4 ODT Bulkhead 0/1/2
26 41-FBH-1001 3/8 ODT Bulkhead 2
27 A10974-00 26 Socket Bulkhead Assembly 1
28 A13847-00* 24VDC to 5VDC Converter Module 0/1
* Used only if the optional Color Change Sequencer is installed.
** Only required if intrinsically safe ROP is to be used.
Item # Description QtyPart #
NEW STYLE MOTOR AMPLIFIER PANEL - PARTS LIST (Figure 6b)
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PARTS IDENTIFICATIONEN
LN-9408-06-R6 (09/2025)27 / 91www.binks.com
When ordering, use A10776-ABCDEF as indicated below.
MOTOR AMPLIFIER PANEL
MODEL IDENTIFICATION
A10776 - A B C D E F
F - INTRINSICALLY SAFE REMOTE OPERATOR PANEL
(0 = NO, 1 = YES)
E - INTRINSICALLY SAFE PRESSURE TRANSDUCERS
(0 = NO, 1 = YES)
D - CATALYST FLOW SENSOR ELECTRONICS
(0 = NO, 1 = YES)
C - NUMBER OF E TO P TRANSDUCERS
(0, 1, OR 2)
B - COLOR CHANGE SEQUENCER
(0 = NO, 1 = YES)
A - NUMBER OF MOTOR AMPS
(1 OR 2)
BASIC PART NUMBER
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PARTS IDENTIFICATION EN
LN-9408-06-R6 (09/2025) 28 / 91 www.binks.com
Figure 7: Remote Operator's Panel
3
1
2
4
6
5
7
18
9 10
8
12
13
11
14
16
17
15
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PARTS IDENTIFICATIONEN
LN-9408-06-R6 (09/2025)29 / 91www.binks.com
When ordering, use A11095-AB as indicated below.
* Refer to Remote Operator's Panel Model Identification for quantities.
REMOTE OPERATOR’S PANEL
MODEL IDENTIFICATION
A11095 - A B
NUMBER OF AIR FLOW SWITCHES
(1 REQ. PER SPRAYGUN)
NUMBER OF PRESSURE SWITCHES
(2 REQ. PER FLUSH BOX)
BASIC PART NUMBER
Item # Description QtyPart #
REMOTE OPERATOR'S PANEL - PARTS LIST (Figure 7)
1 A10794-00 Enclosure Details, RCS-2 Remote Operator's Panel 1
2 A11093-00 Faceplate Label, RCS-2 Remote Operator's Panel 1
3 LSME0024-00 Horn 1
4 SSH-409 Knob 2
5 A11108-00 24V AC/DC LED for Use In IDEC Panel Mount Lamps 4
6 LSF10002-00 1/4 ODT X 1/8 NPT(F) Bulkhead Union, Alkon 4
7 A11096-00 Color Select Rotary Switch Harness Assembly 1
8 25766-106 Pressure Switch Assembly, 15# A *
9 13742-01 Air Flow Switch Assembly B *
10 72143-01 In/Out Nameplate B *
11 A11105-00 Bulkhead/Wire Assembly, RCS-2 Remote Operator's Panel 1
12 A11099-00 Wiring Harness Assembly, Pressure Switches, RCS-2 ROP 1
13 A11100-00 LED Wiring Harness Assembly, RCS-2 Remote Operator's Panel 1
14 A11110-00 Wiring, Harness Assembly, Horn 1
15 A11102-00 LCD Display for RCS-2 Remote Operator's Panel 1
16 A11097-00 Potentiometer Harness Assembly, RCS-2 Remote Operator's Panel 1
17 A11098-00 Wiring Harness Assembly, LCD Display, RCS-2 ROP 1
18 A10909-00 PC Board Assembly, Remote Operator's Panel, RCS-2 1
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PARTS IDENTIFICATION EN
LN-9408-06-R6 (09/2025) 30 / 91 www.binks.com
Figure 8a: Fluid Panel Assembly (Front)
23 37
34
38
1
29
40
8
7
22
7
17
4
33
12
32
24
11
5
16
21
19
31
20
32
11
24
14
5
15
13
7
8
2
6
30
43
18
34
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PARTS IDENTIFICATIONEN
LN-9408-06-R6 (09/2025)31 / 91www.binks.com
Figure 8b: Fluid Panel Assembly (Back)
35
39383728
36 37 38
25 26 27
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PARTS IDENTIFICATION EN
LN-9408-06-R6 (09/2025) 32 / 91 www.binks.com
1 A10949-00 Fluid Panel Details, RCS-2 1
2 76698-02 3/16 ID X 5/16 OD, Tubing 36
3 A10528-10 Transducer Cable (Not Shown), 10’ - 0 L. Table Z - R
4 22-910* Pressure Transducer Assembly W/Manifold & O-Ring Table Z - S
5 77662-00 Connector, Swivel, 3/8 NPS X 3/16 ID, Hose Table Z - T
6 22-963 Flushable Color Pump Manifold 1
7 77784-00 3/8 NPS(F) X 3/8 OD Tube, 90° Elbow 4
8 77639-00 1/8 NPT(M) X 3/8 NPS(M) Nipple 4
9 ---- ---- --
10 ---- ---- --
11 SSP-6443 3/8 ODT X 1/4 NPT(F) Fitting, Stainless Steel 1
12 77669-00 Pilot Operated Ball Valve 1
13 77671-00 Ball Valve, Stainless Steel 2
14 SSP-5020 3/8 OD Tubing 120
15 22-451 Spiral Mixer 1
16 22-964 Hardener Pump Manifold 1
17 22-420 Mix Manifold W/Check Valve 1
18 77652-00 1/8 NPT(M) Stem 1
19 77659-00 3/8 NPS Nut 1
20 22-1043 Flow Sensor Table Y - N
21 22-1045 Flow Sensor Cable (5 Conductor) Table Y - O
22 22-1044 Manifold for Flow Sensor Table Y - P
23 A11989-00 Solvent Manifold Assembly 1
24 77637-00 Nipple, 3/8 NPSM X 3/8 NPT DM 2
25 8156-24C Hex Head Bolt, 5/16-18 X 3/4 L (Cadium Plated) 8
26 SS-1524-CD 5/16 Stainless Steel Washer 8
27 7734-07 5/16 Lockwasher 8
28 A11793-32C Carriage Bolt, 1/4-20 X 1 L. 4
29 A10626-01 Cable Gland Assembly, 9 Position 1
30 Table U - B Table U - C Table U - A
31 Table V - E Table V - F Table V - D
32 41-FTP-1018 5/32 ODT x 1/8 NPT Straight Fitting 4
33 22-337 Bypass Valve Assembly 1
34 A10976-00 Label Set, RCS-2 Fluid Panel 1
35 A10627-00 MCV/CCV Mounting Plate Table WX - G
36 784074-20C 1/4-20 X .625 L, Stainless Steel, HHCS Table WX - H
37 77588-06 1/4 Lockwasher Table WX - I
38 77485-00 1/4-20 Hex Nut, Stainless Steel Table WX - J
39 Table WX - L Table WX - M Table WX - K
40 78404-20C 1/4 - 20 X 5/8 L. Stainless Steel, HHCS 4
41 ---- ---- --
42 ---- ---- --
43 22-280-1 Check Valve, Stainless Steel 1
44 LS00122 Breather ---
Item # Description QtyPart #
FLUID PANEL ASSEMBLY - PARTS LIST (Figures 8a & 8b)
* Sensor without manifold P/N: 22-546-1
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PARTS IDENTIFICATIONEN
LN-9408-06-R6 (09/2025)33 / 91www.binks.com
0 -- -- No Pump Included -- -- --
1 1 77844-01 Pump Kit, RCS 3.5 CC/REV M2 Tool Steel No
2 1 77844-08 Pump, RCS 3.5 CC/REV M2 Tool Steel Yes
3 1 77844-09 Pump, RCS 3.5 CC/REV Polyond No
4 1 77844-10 Pump, RCS 3.5 CC/REV Polyond Yes
5 1 77844-02 Pump Kit, RCS 5.5 CC/REV M2 Tool Steel No
6 1 77844-11 Pump, RCS 5.5 CC/REV M2 Tool Steel Yes
7 1 77844-12 Pump, RCS 5.5 CC/REV Polyond No
8 1 77844-13 Pump, RCS 5.5 CC/REV Polyond Yes
9 1 77844-03 Pump Kit, RCS 10.0 CC/REV M2 Tool Steel No
A 1 77844-14 Pump, RCS 10.0 CC/REV M2 Tool Steel Yes
B 1 77844-15 Pump, RCS 10.0 CC/REV Polyond No
GroovedDescriptionNo.
When ordering, use A10776-ABCDEF as indicated below.
FLUID PANEL ASSEMBLY
MODEL IDENTIFICATION
A10948 - U V W X Y Z
TABLE Z - CATALYST INLET PRESSURE TRANSDUCERS
(0 = NO, 1 = YES)
TABLE Y - CATALYST FLOW SENSOR
(0 = NO, 1 = YES)
TABLE WX - NUMBER OF COLORS
00 = NO COLOR VALVE STACK
02 = 2 COLOR CCV STACK
04 = 4 COLOR CCV STACK
06 = 6 COLOR CCV STACK
08 = 8 COLOR CCV STACK
10 = 10 COLOR CCV STACK
TABLE V - CATALYST PUMP
TABLE U - RESIN PUMP
BASIC PART NUMBER
TABLE U - RESIN (FLUSHABLE) PUMPS
A B
Size Material
C
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PARTS IDENTIFICATION EN
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00 0 0 0 0 0 -- No Color Valve Stack Installed
02 1 4 8 8 1 CCV-5102-111 2-Color CCV Stack Assembly W/Solvent - Air Push
04 1 4 8 8 1 CCV-5104-111 4-Color CCV Stack Assembly W/Solvent - Air Push
06 1 4 8 8 1 CCV-5106-111 6-Color CCV Stack Assembly W/Solvent - Air Push
08 1 4 8 8 1 CCV-5108-111 8-Color CCV Stack Assembly W/Solvent - Air Push
10 1 4 8 8 1 CCV-5110-111 10-Color CCV Stack Assembly W/Solvent - Air Push
0 0 0 2 No Flow Sensor
1 1 1 3 Flow Sensor Included
0 3 3 * 3 * No Pressure Sensor
1 4 4 4 Pressure Sensor Included
* If no catalyst pump is used, S = 2 and T = 2.
No.
TABLE WX - COLOR VALVE STACK TABULATION
GroovedDescriptionNo.
TABLE V - CATALYST (NON-FLUSHABLE) PUMPS
D E
Size Material
F
0 -- -- No Pump Included -- -- --
1 1 77844-06 Pump Kit, RCS 0.297 CC/REV M2 Tool Steel No
2 1 77844-07 Pump Kit, RCS 0.297 CC/REV M2 Tool Steel Yes
3 1 77844-16 Pump, RCS 0.297 CC/REV Stainless Steel No
4 1 77844-17 Pump, RCS 0.584 CC/REV M2 Tool Steel No
5 1 77844-05 Pump Kit, RCS 1.752 CC/REV M2 Tool Steel No
6 1 77844-04 Pump Kit, RCS 2.92 CC/REV M2 Tool Steel No
G H I J K L M
No. N O P Description
TABLE Y - CATALYST FLOW SENSOR TABULATION
No. R S T Description
TABLE Z - CATALYST INLET PRESSURE TRANSDUCER TABULATION
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PARTS IDENTIFICATIONEN
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Figure 9: Non-Flushable Pump/Manifold Assembly
1
2
4
3
6
8
9
11
13
14
15
18
19 20
21
22
23
16
17
10
12
5
7
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PARTS IDENTIFICATION EN
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1 7959-34C 1/4-20 X 1-1/16 L, SHCS 4
2 SS-1505-CD Lock Washer, 1/4 4
3 22-1047 Non-Explosion Proof Kollmorgen Motor (B-204 Series) 1
22-1047-2 Non-Explosion Proof Kollmorgen Motor (AKM-33 Series) 2
4 7959-28C 1/4-20 X 7/8 L, SHCS 2
5 SS-1505-CD Lock Washer, 1/4 2
6 22-878 Key 1
7 22-867 Gear 1
8 78178-00 Set Screw, 1/4-28, Cup Pt. 1
9 78179-00 Pin,Spirol, 5/64 X 3/4 1
10 22-868 Outer Pole Ring Assembly 1
11 7554-119 O-Ring 1
12 22-875 Bearing Housing 1
13 22-854 O-Ring 1
14 22-945 Coupling Housing Assembly 1
15 22-862 O-Ring 1
16 22-939 Jump Pole Ring Assembly 1
17 22-872 Manifold Assembly 1
18 22-332 3/8 NPS(M) X 3/4-16, Stainless Steel, Adapter Fitting 2
19 22-333 O-Ring 2
20 A12975-00 Gasket 1
21 9946-80C 3/8-16 X 2-1/2 L, SHCS 4
22 * Non-Flushable Pump 1
23 * SHCS 4
* These items differ based on desired pump size.
Item # Description QtyPart #
NON-FLUSHABLE PUMP/MANIFOLD ASSEMBLY - PARTS LIST (Figure 9)
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PARTS IDENTIFICATIONEN
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Figure 10: Flushable Pump/Manifold Assembly
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PARTS IDENTIFICATION EN
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* These items differ based on desired pump size.
Item # Description QtyPart #
FLUSHABLE PUMP/MANIFOLD ASSEMBLY - PARTS LIST (Figure 10)
1 22-337 Bypass Valve Assembly 1
2 22-336 O-Ring Seal 4
3 * SHCS 4
4 * Flushable Pump Assembly 1
5 9946-48C 3/8-16 X 1.5 L, SHCS 4
6 22-935 Manifold Assembly 1
7 22-332 3/8 NPS(M) X 3/4-16 Stainless Steel Adapter Fitting 2
8 22-333 11/16 X 0.070 O-Ring 2
9 20-5740 O-Ring 1
10 22-335 O-Ring 1
11 97-2271 Check Valve 1
12 22-862 O-Ring 1
13 22-939 Inner Pole Ring Assembly 1
14 22-945 Coupling Housing Assembly 1
15 22-854 O-Ring 1
16 77305-00 Name Plate W/Serial Number 1
17 78202-00 Drive Pin 2
18 78201-16 M8 X 1 X 16mm L, HHCS 1
19 22-875 Bearing Housing 1
20 7554-119 O-Ring 1
21 22-868 Outer Pole Ring Assembly 1
22 22-878 Key 1
23 78178-00 Set Screw, 1/4-28, Cup Pt. 1
24 78179-00 Pin, Spirol, 5/64 X 3/4 1
25 22-867 Gear 1
26 SS-1505-CD Lock Washer, 1/4 2
27 7959-28C 1/4-20 X 7/8 L, SHCS 2
28 22-1047 Non-Explosion Proof Kollmorgan Motor 1
22-547 Explosion Proof Kollmorgan Motor 1
22-1047-2 Non-Explosion Proof Motor 1
29 SS-1505-CD Lock Washer, 1/4 4
30 7959-34C 1/4-20 X 1-1/16 L, SHCS 4
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PARTS IDENTIFICATIONEN
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Figure 11: Dual-Headed Pump Assembly (A11800)
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PARTS IDENTIFICATION EN
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Item # Description QtyPart #
1 22-1302 Non-Explosion Proof Motor 1
A11797-00 Explosion Proof Motor 1
2 7959-34C 1/4-20 UNC X 1 1/16 L, SHCS (For Use With Non-Explosion Proof Motor) 4
7421-24C 5/16-18 UNC X 7/8 L, SHCS (For Use With Explosion Proof Motor) 4
3 SS-1515-CD 1/4 Lock Washer (For Use With Non-Explosion Proof Motor) 7
7734-07 5/16 Lock Washer (For Use With Explosion Proof Motor) 4
4 20-6621 3/8-16 X 1/2 L, Slotted, Round Head, Cap Screw 2
5 22-1309 Cover 1
6 20-6614 5/16-18 UNC X 4 L, SHCS 4
7 22-1310 Motor Mounting Plate 1
8 22-1311 Motor Standoff 4
9 --- --- ---
10 22-1303 Base, Machined 1
11 LSOR0005-05 O-Ring 2
12 22-954 Coupling Housing Assembly 2
13 22-939 Inner Magnetic Element 2
14 22-1332 Manifold Assembly (Flushable) 2
15 22-862 O-Ring, #2-141 2
16 77844-01 3.5 cc/rev Pump (With Fasteners) 1
77844-02 5.5 cc/rev Pump (With Fasteners)
77844-03 10 cc/rev Pump (With Fasteners)
17 22-332 Fluid Fitting, 3/8-18 NPS(M) X 3/4-16 UNF-2A(M) 4
18 13076-20 O-Ring, #2-020 2
19 79001-02 O-Ring, #2-018 2
20 22-336 Seal 8
21 9946-48C 3/8-16 X 1 1/2 L, SHCS 8
22 A11796-00 MCV Bypass Block 2
23 76566-72C 1/4-20 X 2 L, SHCS 6
24 22-333 Fluid Seal 4
25 78716-01 5/32 ODT (4mm) X 1/16 NPT(M), Fitting 2
26 --- --- ---
27 77844-01 * 3.5 cc/rev Pump (With Fasteners) 1
77844-02 * 5.5 cc/rev Pump (With Fasteners)
77844-03 * 10 cc/rev Pump (With Fasteners)
28 7899-00 Valve Assembly 2
29 22-1313 Idler Plate 1
30 22-1315 Idler Standoff 1
DUAL-HEADED PUMP ASSEMBLY - PARTS LIST (Figure 11)
(Continued On Next Page)
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PARTS IDENTIFICATIONEN
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* Ratio is controlled based on pump sizes (cc's/rev.) and the size of the 2 drive pulleys
Item # Description QtyPart #
DUAL-HEADED PUMP ASSEMBLY - PARTS LIST (Figure 11) (Cont.)
31 22-139 Bearing, Idler Pulley 2
32 22-1317 Machined Idler Pulley 1
33 A11799 * 28 Tooth, Timing Belt Pulley 2
34 22-1316 Key, 1/8 X 1/8 X 3/4 Long 4
35 8156-48C 5/16-18 X 1 1/2 L, HHCS 2
36 7486-07 5/16 X 3/4, Flat Washer 2
37 7734-07 5/16, Lock Washer 4
38 20-6613 Retaining Ring, 5105-37. Bowded External 2
39 78002-00 3/8 NPT Plug 4
40 --- --- ---
41 22-1348 Timing Belt 1
42 8532-24C 5/16-18 X 3/4 L, SHCS 2
43 77367-00 Valve Seat 2
44 20-3667 #6 Flat Washer 1
45 20-4332 #6 Lock Washer 1
46 20-6619 #6-32 X 1/4 L, Button Head Machine Screw 1
47 20-6612 Retaining Ring, 5101-50, Bowded External 2
48 22-1330 Outer Magnetic Element Assembly 2
49 20-6199 Set Screw, #10-32 X 3/16 Long 2
50 22-1328 Bearing Retainer 2
51 22-1327 Bearing 4
52 22-1326 Drive Shaft 2
53 20-3111 1/8 NPT, Pipe Plug 4
54 20-6664 Retaining Ring, 5101-37, Bowded External 2
55 22-335 Seal, Solvent Inlet Port 2
56 22-6494 Screw, M8 X 1, 16mm Long 4
57 77305-00 Name Plate 1
58 20-1671-1 Stick Screw 2
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PARTS IDENTIFICATION EN
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Figure 12: 77669-00 5-Way Ball Valve Assembly
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PARTS IDENTIFICATIONEN
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Item # Description QtyPart #
77669-00 5-WAY BALL VALVE ASSEMBLY - PARTS LIST (Figure 12)
1 20-317 #10-32 X 1/2, SHCS 4
2 78959-00 Housing 1
3 7554-03 O-Ring, 1/8 ID X 1/4 OD 1
4 72-1217 Bearing 1
5 20-4609 Belleville Washer 4
6 7554-36 O-Ring 1
7 78957-00 Piston 1
8 7554-09 O-Ring, 3/8 ID X 1/2 OD 1
9 78955-00 Stem 1
10 7554-07 O-Ring 1
11 20-3467 O-Ring 2
12 78958-00 Gasket 1
13 20-4677 #8-32 X 1/2 L, SHCS 2
14 78960-00 Housing 1
15 20-2652 #8-32 X 3/8 L, SHCS 4
16 78965-00 Retainer Plate 1
17 7554-122 O-Ring 1
18 79205-00 Seal, Upper 1
19 78951-00 Ball 1
20 78963-00 Body, 5-Way, Stainless Steel 1
21 79204-00 Lower Seal 1
22 78953-00 Plug 1
Refer to service manual #ASI-4002-R5 for more information.
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TROUBLESHOOTING EN
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TROUBLESHOOTING
BLOCK DIAGRAMS
Over the next several pages are block diagrams of the fol-
lowing components of the RCS-2 control system:
• Main Control Console
• Motor Amplifier Panel
• Fluid Panel
• RCS Interface PC Board
• Channel PC Board
These drawings can be used to get an overall picture of func-
tion of each panel and control board and how they interact.
RIBBON CABLE
INTERCONNECT CHARTS
Following the block diagrams are charts showing how the
ribbon cable assemblies connect the channel boards and
the interface board to the breakout boards mounted on the
back panel of the main control console. (The breakout boards
are simply pass-through circuit boards that breakout the
ribbon cable signals to screw terminals for easy field connec-
tions.) These charts detail what signals are passed to/from
the channel boards and the interface board so that these
signals can be easily traced for troubleshooting purposes.
UMBILICAL CORD SIGNALS
Following the ribbon cable charts are charts of the umbili-
cal cords (cable assemblies that run from the main control
console to the motor amplifier panels). These charts outline
what signals are carried by which pins, wires, and wire pairs.
These charts can be used to aid in tracing down signal (or
lack of signal) issues between the main control console and
the motor amplifier panels.
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TROUBLESHOOTINGEN
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Figure 17: Control Console Block Diagram
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TROUBLESHOOTING EN
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Figure 18: Motor Amplifier Block Diagram
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TROUBLESHOOTINGEN
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Figure 19: Fluid Panel Block Diagram
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TROUBLESHOOTING EN
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Analog
Input or
Output
Channel Board
(P/N: 78814)
96 Pin DIN
Connector
96 Socket DIN
Connector
Front Side
Backplane Board
(P/N: 78816)
50 Pin IDC
Connector
Back Side
50 Conductor Twisted Pair
Ribbon Cable (P/N: A10587)
50 Socket
DIN
Connector
Interconnect Board
(P/N: A10554)
INTERCONNECT CHART FOR CHANNELS 1, 3, 5, AND 7
Digital
Fast Fill Input 1C 1C 1C 1C 1 1 1A
Channel Fill Input 1A 1A 1A 1A 2 2 2A
Feather Set Input 2C 2C 2C 2C 3 3 3A
Run Input 2A 2A 2A 2A 4 4 4A
Halt/Fault Reset Input 3C 3C 3C 3C 5 5 5A
Trigger 1 Input 3A 3A 3A 3A 6 6 6A
Motor AMP Fault Input 4C 4C 4C 4C 7 7 7A
Trigger 2 Input 4A 4A 4A 4A 8 8 8A
Trigger 3 Input 5C 5C 5C 5C 9 9 9A
Trigger 4 Input 5A 5A 5A 5A 10 10 10A
Volume Fill Input 6C 6C 6C 6C 11 11 11A
Pushout Input 6A 6A 6A 6A 12 12 12A
Fault Output (hi) Output 7C 7C 7C 7C 13 13 13A
Fault Output (low) Output 7A 7A 7A 7A 14 14 14A
Ready Output (hi) Output 8C 8C 8C 8C 15 15 15A
Ready Output (low) Output 8A 8A 8A 8A 16 16 16A
Spray Shutdown (hi) Output 9C 9C 9C 9C 17 17 17A
Spray Shutdown (low) Output 9A 9A 9A 9A 18 18 18A
Flush Request (hi) Output 10C 10C 10C 10C 19 19 19A
Flush Request (low) Output 10A 10A 10A 10A 20 20 20A
Motor On (hi) Output 11C 11C 11C 11C 21 21 21A
Motor On (low) Output 11A 11A 11A 11A 22 22 22A
Spare (hi) Output 12C 12C 12C 12C 23 23 23A
Spare (low) Output 12A 12A 12A 12A 24 24 24A
Digital Ground N/A 30A 30A 30A 30A 60 60 25A
Digital Ground N/A 30B 30B 30B 30B
+24 VDC Output 32A 32A 32A 32A 64 64 26A
+24 VDC Output 32B 32B 32B 32B
+24 VDC Output 32C 32C 32C 32C 63 63 26A
Input or
Output
Channel Board
(P/N: 78814)
96 Pin DIN
Connector
96 Socket DIN
Connector
Front Side
Backplane Board
(P/N: 78816)
96 Pin DIN
Connector
Back Side
64 Cond. Ribbon Cable
(P/N: A10586)
96 Socket
DIN
Connector
64 Socket
IDC
Connector
Interconnect Board
(P/N: A10554)
(J1) 64 Pin
IDC
Connector
Screw
Terminal
50 Socket
IDC
Connector
(J2) 50
Socket
IDC Connector
Screw
Terminal
Flow Rate Command Input 1C 1C 3 3 3 3 28A
Analog Ground N/A 30C 30C 4 4 4 4 A.G.
Feather Pressure Input 2C 2C 5 5 5 5 29A
Analog Ground N/A 30C 30C 6 6 6 6 A.G.
Pump Inlet Pressure Input 3C 3C 7 7 7 7 30A
Analog Ground N/A 30C 30C 8 8 8 8 A.G.
Pump Outlet Pressure Input 4C 4C 9 9 9 9 31A
Analog Ground N/A 30C 30C 10 10 10 10 A.G.
Spare Analog Input Input 5C 5C 11 11 11 11 32A
Analog Ground N/A 30C 30C 12 12 12 12 A.G.
Motor Speed Input 6C 6C 13 13 13 13 33A
Analog Ground N/A 30C 30C 14 14 14 14 A.G.
Pressure Control Output 7C 7C 15 15 15 15 34A
Analog Ground N/A 30C 30C 16 16 16 16 A.G.
Actual Flow Rate Output 8C 8C 17 17 17 17 35A
Analog Ground N/A 30C 30C 18 18 18 18 A.G.
Pulsed:
Flush Request (hi) Input 25C 25C 35 35 35 35 36A
Flush Request (low) Input 26C 26C 36 36 36 36 37A
CHANNEL A SIGNALS
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TROUBLESHOOTINGEN
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INTERCONNECT CHART FOR CHANNELS 2, 4, 6, AND 8
Analog
Input or
Output
Channel Board
(P/N: 78814)
96 Pin DIN
Connector
96 Socket DIN
Connector
Front Side
Backplane Board
(P/N: 78816)
50 Pin IDC
Connector
Back Side
50 Conductor Twisted Pair
Ribbon Cable (P/N: A10587)
50 Socket
DIN
Connector
Interconnect Board
(P/N: A10554)
Digital
Fast Fill Input 13C 13C 13C 13C 25 25 1B
Channel Fill Input 13A 13A 13A 13A 26 26 2B
Feather Set Input 14C 14C 14C 14C 27 27 3B
Run Input 14A 14A 14A 14A 28 28 4B
Halt/Fault Reset Input 15C 15C 15C 15C 29 29 5B
Trigger 1 Input 15A 15A 15A 15A 30 30 6B
Motor AMP Fault Input 16C 16C 16C 16C 31 31 7B
Trigger 2 Input 16A 16A 16A 16A 32 32 8B
Trigger 3 Input 17C 17C 17C 17C 33 33 9B
Trigger 4 Input 17A 17A 17A 17A 34 34 10B
Volume Fill Input 18C 18C 18C 18C 35 35 11B
Pushout Input 18A 18A 18A 18A 36 36 12B
Fault Output (hi) Output 19C 19C 19C 19C 37 37 13B
Fault Output (low) Output 19A 19A 19A 19A 38 38 14B
Ready Output (hi) Output 20C 20C 20C 20C 39 39 15B
Ready Output (low) Output 20A 20A 20A 20A 40 40 16B
Spray Shutdown (hi) Output 21C 21C 21C 21C 41 41 17B
Spray Shutdown (low) Output 21A 21A 21A 21A 42 42 18B
Flush Request (hi) Output 22C 22C 22C 22C 43 43 19B
Flush Request (low) Output 22A 22A 22A 22A 44 44 20B
Motor On (hi) Output 23C 23C 23C 23C 45 45 21B
Motor On (low) Output 23A 23A 23A 23A 46 46 22B
Spare (hi) Output 24C 24C 24C 24C 47 47 23B
Spare (low) Output 24A 24A 24A 24A 48 48 24B
Digital Ground N/A 30A 30A 30A 30A 60 60 25B
Digital Ground N/A 30B 30B 30B 30B
+24 VDC Output 32A 32A 32A 32A 64 64 26B
+24 VDC Output 32B 32B 32B 32B
+24 VDC Output 32C 32C 32C 32C 63 63 26B
Input or
Output
Channel Board
(P/N: 78814)
96 Pin DIN
Connector
96 Socket DIN
Connector
Front Side
Backplane Board
(P/N: 78816)
96 Pin DIN
Connector
Back Side
64 Cond. Ribbon Cable
(P/N: A10586)
96 Socket
DIN
Connector
64 Socket
IDC
Connector
Interconnect Board
(P/N: A10554)
(J1) 64 Pin
IDC
Connector
Screw
Terminal
CHANNEL B SIGNALS
50 Socket
IDC
Connector
(J2) 50
Socket
IDC Connector
Screw
Terminal
Harden or Flow Input 1B 1B 1 1 1 1 27B
Analog Ground N/A 30C 30C 4 4 4 4 A.G.
Flow Rate Command Input 13B 13B 19 19 19 19 28B
Analog Ground N/A 30C 30C 20 20 20 20 A.G.
Feather Pressure Input 14B 14B 21 21 21 21 29B
Analog Ground N/A 30C 30C 22 22 22 22 A.G.
Pump Inlet Pressure Input 15B 15B 23 23 23 23 30B
Analog Ground N/A 30C 30C 24 24 24 24 A.G.
Pump Outlet Pressure Input 16B 16B 25 25 25 25 31B
Analog Ground N/A 30C 30C 26 26 26 26 A.G.
Spare Analog Input Input 17B 17B 27 27 27 27 32B
Analog Ground N/A 30C 30C 28 28 28 28 A.G.
Motor Speed Input 19B 19B 29 29 29 29 33B
Analog Ground N/A 30C 30C 30 30 30 30 A.G.
Pressure Control Output 20B 20B 31 31 31 31 34B
Analog Ground N/A 30C 30C 32 32 32 32 A.G.
Actual Flow Rate Output 21B 21B 33 33 33 33 35B
Analog Ground N/A 30C 30C 34 34 34 34 A.G.
Pulsed:
Motor Feedback (B+) Input 27C 27C 37 37 37 37 36B
Motor Feedback (B-) Input 28C 28C 38 38 38 38 37B
Solvent (B+) Input 29C 29C 39 39 39 39 38B
Solvent (B-) Input 29B 29B 40 40 40 40 39B
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TROUBLESHOOTING EN
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INTERCONNECT CHART FOR SYSTEM I/0 SIGNALS
Digital
Gun #1 Strobe Input 1C 1C 1C 1C 1 1 TB1-1
Gun #2 Strobe Input 2C 2C 2C 2C 3 3 TB1-2
Gun #3 Strobe Input 3C 3C 3C 3C 5 5 TB1-3
Gun #4 Strobe Input 4C 4C 4C 4C 7 7 TB1-4
Gun #5 Strobe Input 1A 1A 1A 1A 2 2 TB1-5
Gun #6 Strobe Input 2A 2A 2A 2A 4 4 TB1-6
Gun #7 Strobe Input 3A 3A 3A 3A 6 6 TB1-7
Gun #8 Strobe Input 4A 4A 4A 4A 8 8 TB1-8
System Fault Out (Hi) Output 7C 7C 7C 7C 13 13 TB3-1
System Fault Out (Lo) Output 7A 7A 7A 7A 14 14 TB4-1
System Pulse Out (Hi) Output 8C 8C 8C 8C 15 15 TB3-2
System Pulse Out (Lo) Output 8A 8A 8A 8A 16 16 TB4-2
Client Connected (Hi) Output 9C 9C 9C 9C 17 17 TB3-3
Client Connected (Lo) Output 9A 9A 9A 9A 18 18 TB4-3
Job Number 1 Input 13C 13C 13C 13C 25 25 TB5-1, TB6-1, & TB7-1
Job Number 2 Input 14C 14C 14C 14C 27 27 TB5-3, TB6-3, & TB7-3
Job Number 4 Input 15C 15C 15C 15C 29 29 TB5-5, TB6-5, & TB7-5
Job Number 8 Input 16C 16C 16C 16C 31 31 TB5-7, TB6-7, & TB7-7
Job Number 10 Input 17C 17C 17C 17C 33 33 TB5-9, TB6-9, & TB7-9
Job Number 20 Input 18C 18C 18C 18C 35 35 TB5-11, TB6-11, & TB7-11
Job Number 40 Input 13A 13A 13A 13A 26 26 TB5-2, TB6-2, & TB7-2
Job Number 80 Input 14A 14A 14A 14A 28 28 TB5-4, TB6-4, & TB7-4
Job Number 100 Input 15A 15A 15A 15A 30 30 TB5-6, TB6-6, & TB7-6
Spare Input 1 Input 16A 16A 16A 16A 32 32 TB5-8, TB6-8, & TB7-8
Spare Input 2 Input 17A 17A 17A 17A 34 34 TB5-10, TB6-10, & TB7-10
Spare Input 3 Input 18A 18A 18A 18A 36 36 TB5-12, TB6-12, & TB7-12
Input or
Output
Interface Board
(P/N: 78818)
96 Pin DIN
Connector
96 Socket DIN
Connector
Front Side
Backplane Board
(P/N: 78816)
96 Pin DIN
Connector
Back Side
64 Cond. Ribbon Cable
(P/N: A10586)
96 Socket
DIN
Connector
64 Socket
IDC
Connector
Interconnect Board
(P/N: A10530)
(J1) 64 Pin
IDC
Connector
Screw
Terminal
SYSTEM I/O SIGNALS
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TROUBLESHOOTINGEN
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ODD NUMBERED CHANNEL UMBILICAL CORD SIGNALS
2202 2702 3202 3702 A Black Red/Blk Hardner Flow 1411
A.G. A.G. A.G. A.G. B Red Wht/Red Inlet Pressure (-) 1542
A.G. A.G. A.G. A.G. C Black Wht/Blk Outlet Pressure (-) 1562
1331 1331 1331 1331 D Red Blu/Red +24 VDC 1041
1113 1113 1113 1113 E Black Grn/Blk GND 1051
2053 2553 3053 3553 F Blue Blu/Blk Trigger 2 7211
1113 1113 1113 1113 G Black Blu/Blk GND 1051
2083 2583 3083 3583 H Brown Brown/Blk Fault Out 7051
2303 2803 3303 3803 J Black Brown/Blk Motor Feedback (-) 2092
2131 2631 3131 3631 K Yellow Yel/Blk Spare D.O. N/C
2051 2551 3051 3551 L Black Yel/Blk Motor Amp Fault 2061
2043 2543 3043 3543 M Orange Orn/Blk Trigger 1 6631
2121 2621 3121 3621 N Black Orn/Blk Motor On (Hi) 2081
A.G. A.G. A.G. A.G. P Red Yel/Red Motor Speed (-) 2041
2103 2603 3103 3603 R Gray N/A Spray Shutdown (Lo) 7071
2233 2733 3233 3733 S Red Red/Blk Pressure Control 1231
2213 2713 3213 3713 T White Wht/Red Inlet Pressure (+) 1532
2221 2721 3221 3721 U White Wht/Blk Outlet Pressure (+) 1552
2241 2741 3241 3741 V Green Grn/Blk Act. Flow Analog Out 7091
2041 2541 3041 3541 W Red Brown/Red Halt/Fault Reset 6451
2021 2521 3021 3521 X Brown Brown/Red Fast Fill 6471
2023 2523 3023 3523 Y Red Grn/Red A Channel Fill 6491
2093 2593 3093 3593 Z Green Grn/Red Ready (Lo) 7111
2231 2731 3231 3731 a Yellow Yel/Red Motor Speed (+) 2031
1113 1113 1113 1113 b Drain N/A Shield 1051
2203 2703 3203 3703 c Blue Blu/Red Flow Rate Command 7131
Channel
#1
Control Console (A10549) Wire Numbers Umbilical Cord (A10487) CN1040
Motor Amp
(A10776)
Wire No.Channel
#3
Channel
#5
Channel
#7
Pin Wire Pair
Signal Name
UMBILICAL CORD SIGNALS
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EVEN NUMBERED CHANNEL UMBILICAL CORD SIGNALS
Channel
#2
Control Console (A10549) Wire Numbers Umbilical Cord (A10487) CN1050
Motor Amp
(A10776)
Wire No.Channel
#4
Channel
#6
Channel
#8
Pin Wire Pair
Signal Name
2202 2702 3202 3702 A Black Red/Blk Hardner Flow 1411
A.G. A.G. A.G. A.G. B Red Wht/Red Inlet Pressure (-) 1592
A.G. A.G. A.G. A.G. C Black Wht/Blk Outlet Pressure (-) 1612
1331 1331 1331 1331 D Red Blu/Red +24 VDC 1041
1113 1113 1113 1113 E Black Grn/Blk GND 1051
--- --- --- --- F Blue Blu/Blk Spare ---
1113 1113 1113 1113 G Black Blu/Blk GND 1051
2033 2533 3033 3533 H Brown Brown/Blk Run - Channel A 6431
2304 2804 3304 3804 J Black Brown/Blk Motor Feedback (-) 2452
2132 2632 3132 3632 K Yellow Yel/Blk Spare D.O. N/C
2052 2552 3052 3552 L Black Yel/Blk Motor Amp Fault 2421
2031 2531 3031 3531 M Orn Orn/Blk Feather Set-Channel A 7171
2122 2622 3122 3622 N Black Orn/Blk Motor On (Hi) 2441
A.G. A.G. A.G. A.G. P Red Yel/Red Motor Speed (-) 2401
4021 4031 4041 4051 R Gray N/A Gun Strobe 5091
2234 2734 3234 3734 S Red Red/Blk Pressure Control 1271
2214 2714 3214 3714 T White Wht/Red Inlet Pressure (+) 1582
2222 2727 3222 3737 U White Wht/Blk Outlet Pressure (+) 1602
4141 4141 4141 4141 V Green Grn/Blk Job #1 Bit 4611
4151 4151 4151 4151 W Red Brown/Red Job #2 Bit 4631
4161 4161 4161 4161 X Brown Brown/Red Job #4 Bit 4651
2024 2524 3024 3524 Y Red Grn/Red B Channel Fill 6611
4171 4171 4171 4171 Z Green Grn/Red Job #8 Bit 4671
2232 2732 3232 3732 a Yellow Yel/Red Motor Speed (+) 2391
1113 1113 1113 1113 b Drain N/A Shield 1051
4181 4181 4181 4181 c Blue Blu/Red Job #10 Bit 5071
UMBILICAL CORD SIGNALS
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APPENDIXEN
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APPENDIX
APPENDIX A:
UPDATING THE FIRMWARE AND
SOFTWARE ON THE RCS-2
Programming Cable
The cable used for programming both the 78814-XX channel
card and the 78818-01 interface card for the RCS-2 has a
Part Number A11892-00. It has two separate parts. One is
simply a length of ribbon cable with a DB-9 male connector
at one end and a DB-9 female connector at the other end.
This cable is used to flash the memory on the channel
card as well as accessing the serial port on the 78818-00
interface card for resetting job data and totals or modifying
Ethernet configuration data. When flashing the memory on
the interface card, the two cables should be used together.
(See Figure 1)
Figure 1: A11892-00 Programming Cable Set
Programming the Channel Card
(78814-01, 78814-02)
1. It is highly recommended that all connections and dis-
connections to programming ports on all PC boards be
made with the power turned off to the RCS-2 rack. That
being said, power down the rack prior to proceeding
with this process.
2. Plug the RCS-2 Serial Cable (see Figure 1) into the
serial port of a PC or Laptop and the serial port on the
front of the channel card.
Serial Cable
Interface Card
Adapter
NOTE
NOTENOTE
� It is highly recommended that all parameter
data be backed up to a USB memory stick prior to
reprogramming any of the cards or replacing the user-
interface software.
1. Always remove the interface card (78818-01) from
the rack prior to programming any channel card!
Failing to do so will damage the interface card.
2. Only Firmware version 4.00 and lower can be pro-
grammed in the field. Newer versions require the
board be returned to Ransburg for programming.
� DO NOT attach the Interface Card Adapter when
programming the channel cards.
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Figure 2: Channel Card (78814-01, 78814-02)
Figure 3: Programming Software
Figure 4: Ready To Download
Figure 3: Select Folder/File
3. Turn power on to the rack.
4. On the PC, select the Bootloader program supplied to
you by Ransburg. (If this software is not yet installed
on the PC or Laptop, please install it at this time.)
5. Once the software is running, a screen that looks like
Figure 3 should appear.
6. Select the Find File to Dowload button.
7. Select the drive and folder where the new firmware is
located and then select the file.
8. Select the Open button.
9. The downloader software screen should display the
file you selected.
Serial Port For
Programming
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Figure 4: Download Completed
Figure 5: Removal of Programming Jumper
Figure 6: Interface Card (78818-00)
10. Push the Download button. The program will download
the new firmware to the flash memory on the card and
show a status bar as it is doing so.
11. Once the program has completed downloading the entire
code, the following screen will display.
12. Push the Done button to close the program.
13. Once the download process is complete, the power
should be cycled on the rack to reset the channel card
and allow it to reload its job parameters.
14. After power has been cycled, the faults on the RCS-2
may need to be cleared. On power-up, the interface card
will automatically load the default job parameters to the
channel card. If an alternate set of job data is required,
follow the standard procedure to load the proper job data.
Programming
Port
Programming Jumper JMP7
Programming the Interface Card (78818-01)
1. Backup all parameters to a USB flash drive prior to
upgrading the software.
2. Turn the power off to the rack.
3. Remove the Interface Card from the rack.
4. To download new software to the interface card requires
the card to be put into programming mode. This is done
by removing the jumper JMP7 from the board (see Figure
5). To prevent the jumper from being misplaced, it is
recommended that you plug one side of the jumper into
one of the 2 pins. This will hold the jumper while the
module is being used in the programming mode.
5. Reinsert the Interface card into the rack.
6. Insert the rectangular connector on the Interface Card
Adapter Cable (Figure 5) into the port on the lower
left side on the front face plate of the module. (This
is the rectangular hole in the aluminum plate labeled
PRG/DB.)
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Figure 9: Rabbit Field Utility
Figure 10: Choose File
Figure 11: Programming Status Bar
The cable should be inserted with the red marking on
the cable in the up or top position. If the cable has two
rectangular connectors on it, use the one labeled PROG.
7. The other end of the cable should be plugged into the
serial port of the programming terminal (PC or Laptop).
Use the Serial Cable extension, if necessary.
8. Apply power to the rack.
9. Open the Rabbit Field Utility (RFU.exe) program on the
PC or Laptop.
10. Select the File pull down menu.
11. Select the Load Flash Image.
12. Select the file you wish to download.
13. OK will send the file and the following messages
wil appear during the download process: Sending
Coldloader, Sending Pilot Bios, Erasing Flash, and
Sending Program.
Error Notes:
a. If you receive an error such as coldloader.bin file or Flash
Table file not found, select the Setup pulldown menu and
then select File Locations. There are 3 fields that need to
be filled in with the locations of those files.
b. If you receive an error indicating that the Rabbit Processor
was not found or an Error Reading or Writing Bits, make sure
the rack is powerd up, the jumper JMP7 is removed from the
board, the connector is firmly connected to the programming
port, and that the programming connector is inserted with
Pin #1 in the up position.
14. Once programming is complete, power down the rack.
15. Remove the Rabbit programming cable from the card and
programming PC or Laptop.
16. Remove the Interface Card from the Rack.
17. Replace jumper JMP7 in its original location.
NOTE
� The Reset lamp on the Interface Card will be
flashing. This is normal.
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Figure 13: RS-232 Port
Serial Port
18. Reinsert the Interface Card into the Rack.
19. Reinstall Channel Card or Cards if they were removed prior
to software upgrade.
20. Power up the rack.
21. Errors may be indicated on the Error Log screen. They can
be reset.
22. The new version of software can be validated by confirming
the new software in the CONFIG SYSTEM (F1) touch screen
and selecting VERSION INFO (F2).
Interface Card Configuration Procedure
1. Insert the Serial Cable into the RS-232 port on the front of
the face plate of the Interface Card.
2. The other end of the Serial Cable is to be plugged into the
serial port of the programming terminal (PC or Laptop).
3. Open the Hyper Terminal program from the Windows
Start Menu (or any other similar terminal emulation
program that works with the RS-232 serial port).
4. If HyperTerminal was not previously setup for use with
the RCS-2 Interface Card, configure it with the following
settings:
a. Baud Rate = 38400
b. Data Bits =8
c. Parity = None
d. Stop Bits = 1
e. Flow Control = Xon/Xoff
f. Emulation = VT100
5. Power up on interface card and the Hyper Terminal will
display the software version followed by some diagnostic
information than the IP configuration information. It will
then prompt the user to Press any key within 3 seconds
to enter console mode.
6. Hit the space bar (or any convenient key) to enter the
console configurator. The unit will respond to the key
press with a > prompt. (If repeated key hits fails to
get a response from the unit and it continues on into
normal operation mode, make sure you have Xon/Xoff
setup as your flow control mode and emulation is setup
as VT100.)
Figure 14: Interface Configuration Screen
NOTE
� Jumper JMP7 must be installed on the board
during the following setup procedures.
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7. To setup the IP address for the card, type IPCONFIG at the
> prompt and follow the directions. (Make sure to save
the new configuration to flash memory when prompted.)
8. It is highly recommended that all job data be reset every
time new software has been loaded into the card as old
data can become corrupted in the flashing process. If
it is necessay to clear the Job data, type INITDATA and
depress the enter key.
9. Type Run and hit the enter key to restart the software
running on the interface card.
10. Upon completion of the previous steps, the power
should be turned off, the serial cables removed, and
the power turned back on.
This should complete the interface card setup.
User Interface Software (Touchscreen Software)
1. The new software should be copied to a USB memory
stick. Insert the memory stick into any one of the USB
ports on the back of the touchscreen.
2. Shutdown the User-Interface software from the main
screen of the RCS-2 (F12).
3. Using the Windows software functions, find your memory
stick and copy the files supplied to you by Ransburg
to the RCS-2 folder inside of the My Documents folder
on the desktop. If prompted, confirm the overwriting
of existing files with the same file names.
4. Remove the memory device from the RCS-2 main
control PC.
5. Cycle power and verify that the user interface software
reloads automatically on startup.
NOTE
� There are 7 possible commands that can be
executed from the console mode:
• HELP - This command lists all the possible
console commands.
• IPCONFIG - Allows the user to change the IP
configuration data.
• CLEARTOTALS - Allows the user to clear all
totalization data stored in memory.
• INITDATA - Allows user to delete all job data
stored in memory.
• PING - Allows user to ping devices on the
Ethernet network.
• RESET - Resets the card (same as cycling power).
• RUN - Takes the card out of console mode into
normal operation mode.
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APPENDIXEN
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(Continued On Next Page)
APPENDIX B: ERROR LOG CHART
Source Explanation and/or Possible CauseDescriptionError Name
Input
Under
Pressure
Input
Over
Pressure
Output
Under
Pressure
Output
Over
Pressure
Flow Rate
Out of
Tolerance
Pump inlet pressure is below the
Minimum Pressure value specified in
the Channel Configuration
Pump inlet pressure is above the
Maximum Pressure value specified in
the Channel configuration.
Pump outlet pressure is below the
Minimum Pressure value specified in
the Channel Configuration
Pump outlet pressure is above the
Maximum Pressure value specified in
the Channel Configuration
The difference between the commanded
flow rate (RPM) of the pump and the
actual flow rate measured from the
feedback signal exceeds the Flow
Rate/Ratio Tolerance Percentage value
specified in the Gun Configuration
No material available to pump inlet.
Material supply pressure is too low.
Loss of supply air to the E/P transducer that controls the
pump inlet pressure.
Loss of electrical supply or control signal to the E/P transducer
that controls the pump inlet pressure.
Failure of the E/P transducer that controls the pump inlet pressure.
Failure of the pressure regulator that controls the pump
inlet pressure.
Failure of the pump inlet pressure sensor.
Minimum Inlet Pressure value specified in the Channel Con-
figuration is too high.
Failure of the E/P transducer that controls the pump
inlet pressure.
Failure of the pressure regulator that controls the pump
inlet pressure.
Maximum Inlet Pressure value specified in the Channel
Configuration is too low.
Pump is not turning.
Material is not available at pump inlet.
Failure of pump outlet pressure sensor.
Minimum Outlet Pressure value specified in the Channel
Configuation is too high.
Restriction in the fluid line.
For Autmatic guns, failure of applicator trigger valve.
Maximum Outlet pressure value specified in the Channel
Configuration is too low.
Loss of feedback signal from motor amplifier or flow meter.
Incorrect Calibration Factor in Channel Configuration.
Required flow rate cannot be achieved because it exceeds
the maximum RPM of the motor.
Channel card analog outputs not callibrated.
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
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(Continued On Next Page)
APPENDIX B: ERROR LOG CHART (Cont.)
Source Explanation and/or Possible CauseDescriptionError Name
There is no hardener flow due to the pump not operating or
an obstruction in the hardener fluid line.
Electrical connection problems.
Failure of Hardener Flow sensor.
Pressure Pot is empty.
The operator neglected to reset the Pressure Pot Capacity
when it was last filled.
The value entered for the pressure pot Capacity in the Job
Configuration is Incorrect.
Electrical connection problems.
Failure of Pump Inlet Pressure sensor.
Electrical connection problems.
Failure of Pump Outlet Pressure sensor.
Electrical connection problems.
The Remote Analog Setpoint source is configured for
current instead of voltage.
Loss of feedback signal from motor amplifier or flowmeter.
Incorrect Calibration Factor in Channel Configuration.
One or both channel is unable to deliver the correct flow rate
due to restriction in the fluid line, lack of material, etc.
Reference the motor amplifier diagnostics to determine the
cause of the fault.
Electrical connection problems.
Failure of Feather Pressure sensor.
Check settings of JMP2 & JMP12 on channel card.
Electrical connection problems.
Failure of Spare Analog input sensor.
This error is normal when operating in Fast Fill or Channel
Fill mode.
For Automatic guns, restriction in the fluid line.
For Automatic guns, failure of applicator trigger valve.
The electrical current from the
Hardener Flow sensor is less than
1 milliamp
The system has determined the
pressure pot is empty for the
respective channel
The electrical current from the Pump
Inlet Pressure Sensor is less than 1
milliamp
The electrical current from the Pump
Outlet Pressure sensor is less than 1
milliamp
The electrical current from the Remote
Analog Setpoint source is less than 1
milliamp
The difference between the desired
ratio and the actual ratio, expressed as
a percentage error, exceeds the Flow
Rate/Ratio Tolerance Percentage val-
ue specified in the Gun Configuration.
The motor amplifier has detected a
fault condition.
The electrical current from the Feather
pressure sensor is less than 1 milliamp
The electrical current from the Spare
Analog Input sensor is less than 1
milliamp
The Pump Outlet pressure has ex-
ceeded the Foldback Pressure value
specified in the System Configuration
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Hardener
Flow Loss
Pressure
Pot
Empty
Inlet
Pressure
Loss
Outlet
Pressure
Loss
Analog
Remote
Loss
Ratio
Out of
Tolerance
Motor
Amplifier
Fault
Analog
Feather
Loss
Analog
Spare
Loss
Foldback
Pressure
Reached
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(Continued On Next Page)
APPENDIX B: ERROR LOG CHART (Cont.)
Source Explanation and/or Possible CauseDescriptionError Name
Pot Life
Expired
System
Over
Pressure
Channel
Card
Parameter
Fault
Channel
Card SPI
Fault
Channel
Card
Internal
Fault
Mixed material in the applicator
fluid line has remained beyond the
Pot Life Time specified in the Job
Configuration.
Either the Pump Outlet or Inlet pressure
exceeded the Over-Pressure Limit
specified in the System Configuration.
Invalid parameter entered in either the
Channel or Job Configuration.
No communication via the Serial Pe-
ripheral Interface (SPI) bus has oc-
curred between the Interface Card and
Channel Card for more than one seond.
The timer interrupt service routine is
unable to execute the required firm-
ware logic in the time between time
interrupts.
Mixed material has remained in the applicator fluid line beyond
the Pot Life Time specified in the Job Configuration.
The Flow Rate Setpoint specified in the Job Configuration,
or via the Remote Analog Setpoint, or via Remote I/O, is
not high enough to move the Mixed Volume specified in the
Gun Configuration during the Pot Life Time specified in the
Job Configuration.
Failure of the E/P transducer that controls the pump
inlet pressure.
Failure of the pressure regulator that controls the pump
inlet pressure.
Restriction in the fluid line.
For Automatic guns, failure of applicator trigger valve.
Over-Pressure Limit value specified in the System Configuration
is too low.
Hardener No Flow value specified in the Slave Channel
Configuration is less than 4.0 milliamps.
Hardener Flow On value specified in the Slave Channel
Configuration is greater than 20.0 milliamps.
Hardener No Flow value specified in the Slave Channel
Configuration is greater than Hardener Flow On value specified
in the Slave Channel Configuration.
Any Minimum Pressure or Maximum Pressure value specified
in the Channel Configuration or Feather Pressure specified in
the Job Configuration exceeds the Over Pressure Limit value
specified in the System Configuration.
Possible noise on the SPI bus on the backplane.
Interface Card is no longer functioning.
Failure of the mother board (backplane).
A firmware bug is preventing service of the SPI bus
communications.
A firmware bug is preventing completion of required logic in
the time between timer interrupts.
Possible noise on the SPI bus on the backplane.
Channel
Card
Channel
Card
Channel
Card
Channel
Card
Channel
Card
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(Continued On Next Page)
APPENDIX B: ERROR LOG CHART (Cont.)
Source Explanation and/or Possible CauseDescriptionError Name
Batttery
Low
No slaves
Present
Interface
SPI Fault
Network
Error
XXXXX
Opto-22
Failure
The battery that maintains the data
parameters is below the minimum
operating voltage.
On power up, the Interface Card could
not communicate with any of the four (4)
possible Channel Cards, referred to as
slaves on the Serial Peripheral Interface
(SPI) bus.
The Interface Card detected an error
while attempting to communicate with a
Channel Card via the Serial Peripheral
Interface (SPI) bus.
The User - Interface Computer is not able
to communicate with the interface card.
The User - Interface Computer is not able
to communicate with the color change
sequencer brain.
The power to the Interface Card may have been off for too
long resulting in premature failure of the battery.
There are no Channel Cards inserted into the card rack and
mother board (backplane).
The SPI bus device on the Interface Card may not be
functioning.
One of the SPI bus devices on a Channel Card may not be
functioning in such a way as to prevent communications by
any other Channel Card.
This error may occur when the system is first powered up
and may be ignored.
Check for power on the rack (E-Stop button out)?
Check all Ethernet cables, switches, etc.
Check IP address of interface card and user-interface
computer.
Check for power on the motor amp panel.
Check all Ethernet cables, switches, etc.
Interface
Card
Interface
Card
Interface
Card
User -
Interface
Computer
User -
Interface
Computer
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APPENDIXEN
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GE FANUC AMPLIFIER
LED Display Definition Explanation and/or Possible Causes
APPENDIX C: MOTOR AMPLIFIER LED DISPLAY FAULT
CODES (PART 1)
PF
LE
FE
EI
FL
OV
EC
OC
MT
DT
Power Failure
Loss Enable
Following Error
Excessive Command Increment
Feedback Lost
Motor Power Over Voltage
Motor Power Clamp Excessive
Duty Cycle
Motor Over-Current Fault
Motor Over-Temperature Fault
Drive Over-Temperature
This display indicates that the 120 VAC power supply to the
motor amplifier has been cycled (turned off and back on).
This display indicates that the enable signal to the motor
amplifier from the RCS-2 channel card is low or disabled.
(This is normal when the unit is in the Ready or Halted state.)
This display indicates that the motor amplifier has commanded
the motor to turn at a certain speed but was unable to maintain
that speed. This usually indicates a motor, pump, or magnetic
coupling that is bound up and not able to turn freely.
This indicates that the motor amplifer was commanded by the
RCS-2 channel card to turn faster than the motor is capable
of turning. This typically indicates that improper parameters
have been programmed into the RCS-2. Verify parameters
such as pump size, calibration factor, maximum pump speed,
and maximum flow.
This indicates that the motor amplifier is no longer receiving
feedback from the resolver mounted inside of the motor
enclosure. Check the two cables running from the back of
the motor to the bottom of the motor amplifier panel and the
cables inside of the motor amplifier panel running from the
motor amplifier to the bottom of the panel.
This indicates that the voltage being supplied to the motor
amplifier is excessive. Check the AC power supply voltage
to the motor amplifer panel.
This indicates that the motor amplifier has exceeded the
allowable current limit for the motor. This usually indicates a
motor, pump, or magnetic coupling that is bound up and not
able to turn freely.
This indicates that the motor is running excessively hot. Look
for binding of the motor magnetic coupling, or pump.
This indicates that the driver circuitry in the motor amplifier
has exceeded the allowable temperature for that circuitry. This
could indicate a failure in the motor amplifier itself, a failure
in the motor, or a bound motor, pump, or magnetic coupling.
(Continued On Next Page)
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(Continued On Next Page)
Status LED
Blink Code Fault Description Explanation and/or Possible Causes
APPENDIX C: MOTOR AMPLIFIER LED DISPLAY
FAULT CODES (PART 2)
DANAHER (KOLLMORGEN) AMPLIFIER
ON
OFF
Fast Blink
1
2
3
4
5
6
No faults, power stage Enabled
Control power not applied or
insufficient control power applied
No faults, power stage Disabled
Not Assigned
Motor Over Temp
Motor temperature exceeds
allowed limit
Drive Over/Under Temp
Temperature of drive heatsink/
chassis is outside of allowed limits
Drive I*t Too High
The product of the drives output
current multiplied by time has
exceeded allowed limits.
If current foldback is enabled,
the drive peak output current
automatically reduces to 0.67% of
DIpeak. If foldback is not enabled,
the drive will fault.
Motor I*I*t Too High
Motor current amplitude squared
multiplied by time has exceed
allowed limits
Optional Battery low
Optional fault used to indicate
SFD battery supply voltage is low
Normal opertion.
Loose or open circuit wiring of control power input. Low
input voltage to control power supply.
Hardware or Software Enable inactive. To enable drive,
apply hardware enable and set software enable.
• High ambient temperature at motor.
• Insufficient motor heat sinking from motor mounting.
• Operating above the motor's continuous current rating.
• Motor temperature sensor failure or not connected.
• High or low drive ambient temperature.
• Restriction of cooling air due to insufficient space around unit.
• Operating above the drive's continuous current rating.
• Mechanically-jammed motor.
• Motion profile acceleration requires peak current for too
long of a time duration.
• Machine load on the motor increased by friction.
• Wiring problem between drive and motor yielding
improper motion.
• Motor commutation error.
• Drive under-sized for application, friction, or load.
• Mechanically-jammed motor.
• Motion profile acceleration requires peak current for too
long of a time duration.
• Machine load on the motor increased by friction.
• Motor commutation error.
• Motor under-sized for application, friction, or load.
• Battery low fault enabled and battery is not installed.
• SFD Battery back-up voltage is low.
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APPENDIXEN
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Status LED
Blink Code Fault Description Explanation and/or Possible Causes
APPENDIX C: MOTOR AMPLIFIER LED DISPLAY
FAULT CODES (PART 2) (Cont.)
DANAHER (KOLLMORGEN) AMPLIFIER
(Continued On Next Page)
7
8
9
10
11
12
13
14
Bus Over Voltage - Self Resetting
The BUS voltage has exceeded
the upper threshold limit
Bus Under Voltage - Self Resetting
S200 DC drive fault only
BUS voltage is below specified 20
VDC minimum
Motor I-I or I-n Short
Line-to-Line, Line-to-Neutral, or
Line-to-PE short on the motor ou-
put causing an instataneous over
current
Output Over Current
Hall Fault
Valid only when drive is set to 6
Step (Hall feedback) operation
SFD Configuration Error
J3 FB +5V Short
Excessive current drain on SFD +5
supply output
SFD Motor Data Error
Motor data in SFD is outside drive
limits or is inconsistent
• AC Line voltage (AC unit) or DC bus power supply voltage
(DC unit) is too high.
Regenative energy during deceleration is cusing the BUS to rise:
• On AC Drives add regen resistor.
• On S200 DC input drives external BUS capacitor is too
small; add capacitance.
On S200 DC input drives:
• BUS voltage is too low.
• BUS voltage is pulled down during high acceleration
or loading.
• External BUS capacitor is too small.
• Motor power wiring short circuit - line-to-ground/neutral.
• Motor cable short line-to-line.
• Motor power cable length exceeds the data sheet
specification causing excessive motor line-to-earth
ground/neutral capacitance.
• Internal motor winding short circuit.
• Motor L too small.
• KIP set too large.
• Insufficient motor inductance
• KIP or KII improperly set causing excessive output
current overshoots.
• Invalid configuration.
• Motor overspeed.
• Invalid hall state.
• Invalid hall transition.
• SFD UART error during SFD initialization.
• Bad motor data check sum.
• The drive will attempt to initialize the SFD up to 4 times.
If it fails, this error is reported.
• Excessive loading on SFD +5 supply.
• Short in the feedback cable on SFD +5 (J3-1) to ground.
• Motor and Drive are not compatible. Auto setup
calculation yielded a desired parameter value outside
valid range.
• Incorrect/inconsistent motor data loaded into the SFD.
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APPENDIX EN
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Status LED
Blink Code Fault Description Explanation and/or Possible Causes
APPENDIX C: MOTOR AMPLIFIER LED DISPLAY
FAULT CODES (PART 2) (Cont.)
DANAHER (KOLLMORGEN) AMPLIFIER
15
16
17
18
19
20
SFD Sensor Failure
SFD UART Error
SFD Communication Error
Option Card Watch Dog Time Out
Position Error Too Large
Option Card Fault
• Internal SFD failure.
• Excessive electrical noise in the drive environment
causing communications interference.
Internal SFD failure.
• Feedback cable not connected at the drive or at the motor.
• Feedback cable shield not connected.
• Defective feedback cable.
• Internal SFD failure.
• Excessive electrical noise in the drive environment causing
communications interference.
Communication error between option card and main board.
Check ExtFaults:
ExtFaults = Step size over flow means
GearOut/GearIn is too large.
ExtFaults = Position error over flow means that the
following error, = PosErr, has exceeded ±128 revs.
Check if the motor is stalling or if the commanded speed
is higher than the motor can achieve at the present bus
voltage.
Check ExtFaults:
• If ExtFaults is AuxFBFault, then the AusFB device
is in error.
Check the AuxFB faults:
• AuxFBEnDatFlt, AuxFBPTCFit, or AuxFBSCDFlt.
• Check to make sure the the drive is set up for the
correct feedback device and that the device is
functioning correctly. If ExtFaults is No Extended
Fault, then this was a fault induced by the controller,
such as SynqLost.
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APPENDIXEN
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DETERMINING TRANSDUCER TYPE
There have been three different types of pressure trans-
ducers used on the RCS-2 fluid panels over the years and
each one uses a different method for calibration. Use the
figures below to determine the type and use the appropri-
ate calibration method outlined in the following text.
Pressure Transducer Type 1
Pressure Transducer Type 2
Pressure Transducer Type 3
APPENDIX D: CALIBRATING THE PRESSURE
TRANSDUCERS (PART 1)
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APPENDIX EN
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APPENDIX D: CALIBRATING THE PRESSURE
TRANSDUCERS (PART 1)
CALIBRATING THE TYPE 1
TRANSDUCER
Calibration Procedure:
1. Ensure that the pressure transducer is tightened in the
manifold to a torque specification of 42 -48 in•lbs2.
2. Connect the transducer using the calibration cable (22-
1520) to a power supply and a digital ammeter as shown.
3. Set the ammeter to read current in the range of 0
to 20 mA.
4. Turn on the power supply.
5. Remove the screw cap covering the adjustment screw
on the pressure transducer (if one is installed).
6. Adjust the potentiometer in the pressure transducer such
the current reading on the ammeter is 4.05 mA.
7. Replace cap in adjustment potentiometer hole.
8. Turn off power supply and return pressure transducer
to service.
If transducer will not adjust to approximately 4.05 mA, it
should be replaced.
1 22-911 Manifold Assembly
2 22-546 Pressure Transducer
3 7554-12 O-Ring
4 22-1520 Calibration Cable Assembly
Item # DescriptionPart #
22-546 TRANSDUCER - PARTS LIST
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APPENDIXEN
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To calibrate the Type 2 pressure transducers an electronic
calibrator will be required (A10551).
The pressure transducer should be removed from the sys-
tem to be calibrated or insure that all pressure has been
released from the system. Do not remove the transducer
from its manifold block as retightening of the sensor in the
manifold block could effect the calibration.
Use the following steps to calibrate a transducer:
1. Prior to connecting anything to the calibrator (A10551),
power up the unit by pressing the ON button on the
calibrator.
2. You should be prompted to push the F1 button to continue.
3. The unit should then prompt you to connect the cable with
the transducer connector on one end to the transducer
and then to the left connector in the top of the calibrator.
4. You should then be prompted to connect the second
cable to the mA input of a DVM and the other end to the
right connector in the top of the calibrator.
5. You will then be prompted to set the DVM for current.
6. The calibrator will then advise that it is about to connect
to the transducer and prompt you to push F1 to continue
or F2 to quit.
7. The unit then checks its battery, then powers up the trans-
ducer, connects to the transducer, then downloads the
necessary data from the transducer. The calibrator will
display the serial number of the transducer and prompt
you to push F1 to continue.
8. The calibrator will then display: ZERO ADJUSTMENT,
with the options of F1 to quit, F2 to increase the value,
and F3 to decrease the value.
Examine the value displayed on the DVM. Adjust it so it
reads 4.01 to 4.03 mA.
APPENDIX D: CALIBRATING THE PRESSURE
TRANSDUCERS (PART 2)
Once the adjustments are completed, push the F1 key to
exit.The unit powers down.
Disconnect the transducer from the calibrator and return
it to service.
CALIBRATING THE TYPE 2
TRANSDUCER
NOTE
� Each time you press the F2 or F3 buttons to in-
crease or decrease the value, the calibrator must
download that to the sensor so there is a slight delay.
The unit will display: Writing... Done, F1 to continue.
Repeat the process as many times as necessary to get
the proper current displayed on the DVM.
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APPENDIX EN
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1 22-911 Manifold Assembly 1
2 22-546-1 Pressure Transducer 1
3 79001-09 O-Ring (Solvent Proof) 1
4 22-1520 Calibration Cable Assembly 1
Item # DescriptionPart #
22-546-1 TYPE 3 TRANSDUCER - PARTS LIST
Qty.
1. Install the sensor in the 22-911 manifold and torque it to
42 to 46 in/lbs2.
2. Using cable assembly P/N: 22-1520, wire the circuit as
shown above. (Alternately, the unit can be calibrated
with the calibration cable connected to one of the pres-
sure transducer cables on an RCS-2 controller.)
3. Remove the four socket head cap screws from the con-
nector on the top of the sensor.
4. Underneath the connector, you will find a potentiometer
with a small slotted adjustment screw on top of it. Using
a small screwdriver, adjust that screw so the ammeter
reads 4.09 ± 0.07 mA.
CALIBRATING THE TYPE 3
TRANSDUCER
5. Loosen and then retorque the sensor on the manifold at
the torque specified above to ensure the sensor calibra-
tion remains with in specified limits.
6. If it falls out of specified limits, readjust the potentiom-
eter setting and once again, loosen and retorque the
sensor until it remains in limits.
7. If unit will not remain in limits after repeated tries, reject
the unit.
8. Once calibrated, replace the connector on top of the
unit and carefully replace the four socket-head cap
screws.
Return To Contents
APPENDIXEN
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APPENDIX E: RECOMMENDED
SPARE PARTS
Item # DescriptionPart #
8
Quantity Being Purchased
421
A10549 MAIN CONTROL CONSOLE - PARTS LIST
1 A13908-00 24 VDC Power Supply, 150W 1 1 1 2
2 4131-10 Fuse, 6.25 Amp 5 5 5 10
3 TR-SSEH-472 10 Amp (AGC) Fuse 5 5 5 10
4 LSME0005-00 NO Contact Block 1 1 2 2
5 LSME0006-00 NC Contact Block 1 1 2 2
6 74300-00 120VAC Pilot Lamp 1 1 2 5
7 76948-00 On-Off Switch Actuator 0 0 1 1
8 77384-00 E-Stop Switch Actuator 0 0 1 1
9 A10530-00 Rack Assembly 0 0 0 1
10 A10705-02 Touch Screen PC 0 0 1 1
11 78818-01 Interface Board* 1 1 2 2
12 77377-22 RIO Interface Board (Optional)* 1 1 1 2
13 A14084-01 Ethernet I/P Interface Board (Optional)* 1 1 2 2
14 A10998-01 Ethernet Switch, 8 Port 0 0 1 1
15 78816-00 Backplane PC Board 0 0 0 1
16 A10554-00 Terminal Board (Channel I/O) 0 0 1 1
17 A11530-00 Terminal Board (System I/O) 0 0 0 1
18 A10586-03 64 Conductor Ribbon Cable 0 0 1 1
19 A10587-02 50 Conductor (TP) Ribbon Cable 0 0 1 1
20 22-1108 Power Line Filter 0 1 1 2
21 -- Channel Board
(Note: The quantities of channel boards are
dependent on the number of channels
used and is, therefore, included with the
Motor Amplifier Panel spare parts list.)
* Indicate firmware version number when ordering.
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APPENDIX EN
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Item # DescriptionPart #
8
Quantity Being Purchased
421
A10776 MOTOR AMPLIFIER PANEL - PARTS LIST
1
1
1
1
5
5
0
0
1
1
1
1
1
1
1
1
1
0
0
0
1
0
2
1
1
1
5
5
1
1
1
1
2
1
1
1
2
1
1
0
0
1
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Channel Board*
Motor Drive Amplifier (GE Fanuc)
Motor Drive Amplifier (Danaher/Kollmorgen)
24VDC Power Supply
24VDC Relay
Fuse, 6.25 Amp
10 Amp (AGC) Fuse
Flow Switch Amplifier
Flow Monitor Control Unit
Zener Barrier for 4-20mA (Pres. Xducers)
Zener Barrier for 24VDC (Rem. Oper. Panel)
E to P Transducer
Tachometer Cable (GE Fanuc Amps)
Motor Drive Cable (GE Fanuc Amps)
Motor Drive Cable (Danaher/Kollmorgen)
Pressure Transducer Cable
Catalyst Flow Sensor Cable
Power Line Filter
Color Change Controller Brain (Opt.)
Color Change Controller Input Module (Opt.)
Color Change Controller Output Module (Opt.)
Solenoid Valve (Opt.)
Catalyst Flow Sensor Module
78814-01/-02
A10783-01
A12219-01
A13908-00
SSS-7016
4131-10
TR-SSEH-472
22-1050
22-1046
22-1245
73837-08
78643-XX
A10490-00
A10491-00
A12220-00
A10528-00
22-1045
22-1108
A10785-01 or
A14212-01
A10786-00
A10787-00
41-VSO-1005
A12425-00
1
1
1
1
5
5
0
0
1
1
1
1
1
1
1
1
0
0
0
0
1
0
4
2
2
2
10
10
1
1
2
2
3
2
2
2
4
2
2
1
1
2
4
1
* Indicate firmware version number when ordering.
APPENDIX E: RECOMMENDED SPARE
PARTS (Cont.)
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APPENDIXEN
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Item # DescriptionPart #
8
Quantity Being Purchased
421
A10948 FLUID PANEL - PARTS LIST
1
1
1
1
4
1
0
0
0
1
1
0
0
0
1
4
2
2
2
4
2
1
1
0
0
2
1
1
2
8
2
1
0
0
1
1
1
1
1
2
8
4
4
4
8
4
2
2
1
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Pressure Transducer Assembly
Pilot Operated Bellows Valve
Pilot Operated Ball Valve
Manually Operated Ball Valve
Spiral Mixer
Mix Manifold W/Check Valve
Catalyst Flow Sensor
Catalyst Flow Sensor Cable
Manifold for Flow Sensor
Resin Pump Assembly
Catalyst Pump Assembly
Bypass Valve Assembly
Lip Seal for Flushable Pumps
Lip Seal for Non-Flushable Pump
Diaphragm for Pump Bypass Valve
O-Ring Seals for Pump Bypass Valve and between
Flushable Pump and Manifold
O-Ring for Bearing Housing
O-Ring for Back Side of Magnetic Coupling Housing
(Used on both style pumps.)
O-Ring for Front Side of Magnetic Coupling Housing
(Used on both style pumps.)
O-Ring for Fluid Inlet and Outlet Fittings O-Ring used
between Non-Flushable Pump and Manifold
O-Ring used between Non-Flushable Pump & Manifold
O-Ring used between Non-Flushable Pump & Manifold
Magnetic Coupling Housing Bushing
Magnetic Coupling Housing Assembly
Inner Pole Ring Assembly
22-910
22-556
77669-00
77671-00
22-451
22-420
22-1043
22-1045
22-1044
77844-XX
77844-XX
22-337
22-315
22-383
97-2019
22-336
7554-119
22-854
22-862
22-333
22-379
22-335
22-947
22-945
22-939
1
0
1
1
2
1
0
0
0
0
0
0
0
0
1
4
2
2
2
4
2
1
1
0
0
4
2
2
4
16
4
1
1
1
1
1
2
2
2
4
16
8
8
8
16
8
4
4
1
1
APPENDIX E: RECOMMENDED SPARE
PARTS (Cont.)
Return To Contents
APPENDIX EN
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1
1
2
1
1
2
Air Flow Switch
Pressure Switch
13742-01
25766-106
1
1
4
2
Item # DescriptionPart #
8
Quantity Being Purchased
421
SEAL KITS, TOOLS, TUBING, ETC. - PARTS LIST
2
2
1
1
1
1
10'
20'
50'
50'
50'
50'
4
4
1
1
1
1
20'
40'
50'
50'
50'
50'
1
2
3
4
5
6
7
8
9
10
11
12
Color (Resin) Pump Seal Kit
Includes: (1) 22-335, (2) 22-336, (1) 3076-20
Hardener (Catalyst) Pump Seal Kit
Includes: (1) 22-336, (1) 22-364, (1) 22-366, (1) 22-379
Hardener Seal Insertion Tool
Color Seal Insertion Tool
Male Dowel Insertion Tool
Female Dowel Insertion Tool
3/16 IC X 5/16 OD Tubing
3/8 OD Tubing
5/32 OD Polyethylene Tubing
3/16 OD Polyethylene Tubing
1/4 OD Polyethylene Tubing
3/8 OD Polyethylene Tubing
22-1285
22-1286
22-543
22-542
22-1033
22-1034
76698-00
SSP-5020
TR-SSEM-548
77587-00
9704-03
H-2338
1
1
1
1
1
1
10'
20'
50'
50'
50'
50'
8
8
2
2
2
2
50'
100'
100'
100'
100'
100'
Item # DescriptionPart #
8
Quantity Being Purchased
421
A11095 REMOTE OPERATOR’S PANEL - PARTS LIST
APPENDIX E: RECOMMENDED SPARE
PARTS (Cont.)
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APPENDIXEN
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APPENDIX F: SYSTEM LAYOUT
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APPENDIX EN
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APPENDIX G: SCHEMATICS
CONTROL CONSOLE SCHEMATIC
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APPENDIX G: SCHEMATICS (Cont.)
CONTROL CONSOLE SCHEMATIC
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APPENDIX G: SCHEMATICS (Cont.)
CONTROL CONSOLE SCHEMATIC
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APPENDIXEN
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APPENDIX G: SCHEMATICS (Cont.)
CONTROL CONSOLE SCHEMATIC
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APPENDIX EN
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MOTOR AMP PANEL SCHEMATIC
APPENDIX G: SCHEMATICS (Cont.)
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APPENDIXEN
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APPENDIX G: SCHEMATICS (Cont.)
MOTOR AMP PANEL SCHEMATIC
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APPENDIX EN
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APPENDIX G: SCHEMATICS (Cont.)
MOTOR AMP PANEL SCHEMATIC
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APPENDIXEN
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APPENDIX G: SCHEMATICS (Cont.)
MOTOR AMP PANEL SCHEMATIC
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APPENDIX EN
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APPENDIX G: SCHEMATICS (Cont.)
MOTOR AMP PANEL SCHEMATIC
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APPENDIXEN
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APPENDIX G: SCHEMATICS (Cont.)
MOTOR AMP PANEL SCHEMATIC
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APPENDIX EN
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APPENDIX G: SCHEMATICS (Cont.)
MOTOR AMP PANEL SCHEMATIC
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APPENDIXEN
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REMOTE OPERATOR PANEL SCHEMATIC
APPENDIX G: SCHEMATICS (Cont.)
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APPENDIX EN
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APPENDIX G: SCHEMATICS (Cont.)
REMOTE OPERATOR PANEL SCHEMATIC
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APPENDIXEN
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FLUID PANEL SCHEMATIC
APPENDIX G: SCHEMATICS (Cont.)
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MANUAL CHANGES EN
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MANUAL CHANGE SUMMARY
No. Change Description
LN-9408-06-R5 - Replaces LN-9408-06-R4 with the folowing changes:
1. Update manual to new design. All
2. Add PTFE to first paragraph. 11
3. Remove the second sentence from bullet points 2 and 3 in column 1. 19
4. New imgae for figure 4. 20
5. Update table information. 21-22
6. Add asterisk to 18, 19, and 20. 24
7. Update text in table. 26
8. Update text in both B and C. 27
9. Update text for items 15 and 18. 29
10. Make teaxt changes for items 3, 4, 13, and 27. Add asterisk to the bottom of the table. 32
11. Change and delete text for item 3 36
12. New image for figures 17 and 18 45-46
13. Update table information 51-52
14. Add 2 model numbers to paragraph one 53
15. Add a new number 1 bullet and renumber 2-21 55-57
16. Change can to must in the NOTE 57
17. Remove NOTE 58
18. Update text in column 4 60
19. Change 2 to superscript 2 in bullet item 1 70
20. Update table information 71
21. Update table information 72
22. Update table information 73
23. Add new image 75
Page(s)
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EN
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