- RCS-2 Service Manual LN-9409-03 EN [ English ]
LN-9409-03.2
September-2025
Service Manual Price: $50.00 (U.S.)
RCS-2 RIO INTERFACE
PROGRAMMERS MANUAL
IMPORTANT: Before using this equipment,
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
MODEL: A10549 Control Console
A10776 Motor Amplifier Panel
A10948 Fluid Panel
A11095 Remote Operator’s Panel
NOTE: This manual has been changed from revision LN-9409-03.1 to revision LN-9409-03.2.
Reasons for this change are noted under Manual Change Summary on page 35
of this manual.
RCS-2 Programmer’s Manual - Manual Changes
LN-9409-03.2
SAFETY: 1-5
SAFETY PRECAUTIONS .......................................................................................................1
HAZARDS / SAFEGUARDS ...................................................................................................2-5
PAGE
INTRODUCTION: 6
CONTENTS
GENERAL INFORMATION......................................................................................................6
HARDWARE SETUP: 6
GENERAL INFORMATION .....................................................................................................6
RIO RACK ADDRESS: 7-8
RIO RACK ADDRESS ............................................................................................................7-8
RIO RACK SIZE .....................................................................................................................9
RIO STARTING QUARTER.....................................................................................................9
RIO BAUD RATE, MAXIMUM CABLE LENGTH, AND BUS TERMINATION..........................9
UNUSED SWITCHES.............................................................................................................9
RIO RACK INFORMATION: 9
BLOCK TRANSFER TYPES ..................................................................................................12
NULL DATA - TYPE 00............................................................................................................12
GUN OPERATION STATUS - TYPE 01..................................................................................13-14
CHANNEL OPERATION STATUS - TYPE 02.........................................................................14-16
SYSTEM CONFIGURATION - TYPE 03.................................................................................16
GUN CONFIGURATION - TYPE 04........................................................................................17
POSSIBLE HORN CODES.....................................................................................................18
CHANNEL CONFIGURATION DATA - TYPE 05.....................................................................18
POSSIBLE INLET PRESSURE SENSOR CODES.................................................................19
JOB CONFIGURATION DATA - TYPE 06...............................................................................19-20
FLOW TOTALS - TYPE 07......................................................................................................20-21
RESET BIT FIELD...................................................................................................................21
ERROR LOG MESSAGES - TYPE 08....................................................................................22-23
ERROR CODES......................................................................................................................23-24
ALARM CONFIGURATION - TYPE 09....................................................................................24
ACTIVE ALARM......................................................................................................................25
BLOCK TRANSFER DATA: 12-25
DISCRETE I/O: 10-11
DISCRETE I/O.........................................................................................................................10
DISCRETE SYSTEM I/O.........................................................................................................10-11
DISCRETE CHANNEL / GUN I/O...........................................................................................11
RCS-2 Programmer’s Manual - Contents
LN-9409-03.2
APPENDIX: 26-34
DESCRIPTIONS OF INPUTS AND OUTPUTS ......................................................................26
DISCRETE CHANNEL AND GUN INPUTS ............................................................................26-28
DISCRETE CHANNEL AND GUN OUTPUTS.........................................................................28
DISCRETE CHANNEL AND GUN INPUTS.............................................................................29
DISCRETE CHANNEL AND GUN OUTPUTS.........................................................................29-30
RECOMMENDED DIGITAL I/O TIMING SEQUENCES..........................................................30-33
RECOMMENDED SEQUENCES FOR BLOCK TRANSFERS...............................................34
PAGE
CONTENTS (CONT.)
WARRANTY POLICIES: 36
LIMITED WARRANTY ............................................................................................................36
RCS-2 Programmer’s Manual - Contents
LN-9409-03.2
W A R N I N G!
W A R N I N G!
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your Ransburg products. This
manual contains information that is important for
you to know and understand. This information
relates to USER SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help you recognize
this information, we use the following symbols.
Please pay particular attention to these sections.
A WARNING! States information to alert you
to a situation that might cause serious injury
if instructions are not followed.
A CAUTION! States information that tells how
to prevent damage to equipment or how to
avoid a situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard 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 appropriate Ransburg equipment
manuals to reconcile such differences.
Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efficient operation,
longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals and
safety literature for your Ransburg system, contact
your local Ransburg representative or Ransburg.
�� The hazards shown on the following
pages may occur during the normal use
of this equipment. Please read the hazard
chart beginning on page 2.
�� The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identified.
�� 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
SAFETY STANDARD, LATEST EDITION,
prior to installing, operating, and/or servicing
this equipment.
RCS-2 Programmer’s Manual - Safety
LN-9409-03.2 1
Spray Area
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
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.
When using solvents for cleaning:
•• Those used for equipment flushing should
have flash points equal to or higher than those
of the coating material.
•• The flash point of the cleaning solvent shall
be at least 15° C (27° F) above the ambient
temperature. Otherwise, the cleaning process
must be carried out in an area with forced air
ventilation. It is the end user’s responsibility to
insure this condition is met.
Spray booth ventilation must be kept at the
rates required by NFPA-33, OSHA, country, and
local codes. In addition, ventilation must be
maintained during cleaning operations using
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.
Never use equipment intended for use in
waterborne installations to spray solvent based
materials.
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.
RCS-2 Programmer’s Manual - Safety
LN-9409-03.2 2
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area
Improper operation or
maintenance may create
a hazard.
Personnel must be
properly trained in the use
of this equipment.
Explosion 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.
General Use and
Maintenance
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 50176.
Have fire extinguishing equipment readily
available and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
RCS-2 Programmer’s Manual - Safety
LN-9409-03.2 3
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
Electrical Discharge
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.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported
on conveyors or hangers that are properly
grounded. The resistance between the part
and earth ground must not exceed 1 meg ohm.
(Refer to NFPA-33.)
Operators must be grounded. Rubber
soled insulating shoes should not be worn.
Grounding straps on wrists or legs may be used
to assure adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the
applicator via conductive gloves or gloves with
the palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray
area, with the exception of those objects
required by the process to be at high voltage,
must be grounded. Grounded conductive
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.
RCS-2 Programmer’s Manual - Safety
LN-9409-03.2 4
Toxic Substances Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Follow the requirements of the Material
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.
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Electrical
Equipment
Electrical Discharge
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.
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 50176.
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.
Explosion Hazard –
Incompatible Materials
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.
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.
Spray Area
RCS-2 Programmer’s Manual - Safety
LN-9409-03.2 5
INTRODUCTION
HARDWARE SETUP
The RCS-2 system uses two-slot addressing. Slot 0 is reserved for handshaking bits to support RIO
Block Transfers.
The RCS-2 Interface Module appears as a single 8-bit I/O module in slot 1. Therefore, the RCS-2 In-
terface Module, which reports the System I/O signals, uses the high byte (bits 8 through 15) of word 0.
Each RCS-2 Channel Card appears as two 14-bit I/O modules (two slots). Each of four possible RCS-2
Channel Cards supports two channels for a total of 8 channels. Channel 1 through 7 use bits 0 through
13 of RIO words 1 through 7. Channel 8 uses bits 14 and 15 of RIO words 1 through 7.
The RCS-2 System is capable of communicating with Allen Bradley (Rockwell Automation) style
PLC’s using Remote I/O via the optional RIO Interface Card (P/N: 77377-22). Some of the data to
and from the RCS-2 may be in the form of simple bits (Discrete I/O) or in the form of tables of data
(Block Transfer Reads or Writes).
RCS-2 Programmer’s Manual - Introduction/Hardware Setup
LN-9409-03.2 6
RCS-2 Programmer’s Manual - RIO Rack Address
LN-9409-03.2 7
SW1-1
RIO RACK ADDRESS
RIO RACK ADDRESS
The RIO Rack Address is used to indicate to which
RIO rack the Interface Module is assigned. RIO
Rack Addresses are specified in octal format. There
are 64 (decimal) possible Rack Addresses, which
are assigned 00 through 77 (octal).
OFF OFF OFF OFF OFF OFF 0
OFF OFF OFF OFF OFF ON 1
OFF OFF OFF OFF ON OFF 2
OFF OFF OFF OFF ON ON 3
OFF OFF OFF ON OFF OFF 4
OFF OFF OFF ON OFF ON 5
OFF OFF OFF ON ON OFF 6
OFF OFF OFF ON ON ON 7
OFF OFF ON OFF OFF OFF 10
OFF OFF ON OFF OFF ON 11
OFF OFF ON OFF ON OFF 12
OFF OFF ON OFF ON ON 13
OFF OFF ON ON OFF OFF 14
OFF OFF ON ON OFF ON 15
OFF OFF ON ON ON OFF 16
OFF OFF ON ON ON ON 17
OFF ON OFF OFF OFF OFF 20
OFF ON OFF OFF OFF ON 21
OFF ON OFF OFF ON OFF 22
OFF ON OFF OFF ON ON 23
OFF ON OFF ON OFF OFF 24
OFF ON OFF ON OFF ON 25
OFF ON OFF ON ON OFF 26
OFF ON OFF ON ON ON 27
OFF ON ON OFF OFF OFF 30
OFF ON ON OFF OFF ON 31
OFF ON ON OFF ON OFF 32
OFF ON ON OFF ON ON 33
OFF ON ON ON OFF OFF 34
OFF ON ON ON OFF ON 35
OFF ON ON ON ON OFF 36
SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 RIO Rack Address
(Octal)
RCS-2 Programmer’s Manual - RIO Rack Address
LN-9409-03.2 8
SW1-1
RIO RACK ADDRESS (Cont.)
SW1-2 SW1-3 SW1-4 SW1-5 SW1-6 RIO Rack Address
(Octal)
OFF ON ON ON ON ON 37
ON OFF OFF OFF OFF OFF 40
ON OFF OFF OFF OFF ON 41
ON OFF OFF OFF ON OFF 42
ON OFF OFF OFF ON ON 43
ON OFF OFF ON OFF OFF 44
ON OFF OFF ON OFF ON 45
ON OFF OFF ON ON OFF 46
ON OFF OFF ON ON ON 47
ON OFF ON OFF OFF OFF 50
ON OFF ON OFF OFF ON 51
ON OFF ON OFF ON OFF 52
ON OFF ON OFF ON ON 53
ON OFF ON ON OFF OFF 54
ON OFF ON ON OFF ON 55
ON OFF ON ON ON OFF 56
ON OFF ON ON ON ON 57
ON ON OFF OFF OFF OFF 60
ON ON OFF OFF OFF ON 61
ON ON OFF OFF ON OFF 62
ON ON OFF OFF ON ON 63
ON ON OFF ON OFF OFF 64
ON ON OFF ON OFF ON 65
ON ON OFF ON ON OFF 66
ON ON OFF ON ON ON 67
ON ON ON OFF OFF OFF 70
ON ON ON OFF OFF ON 71
ON ON ON OFF ON OFF 72
ON ON ON OFF ON ON 73
ON ON ON ON OFF OFF 74
ON ON ON ON OFF ON 75
ON ON ON ON ON OFF 76
ON ON ON ON ON ON 77
NOTE
�� Use an 82 Ohm resistor, unless the
RIO master device requires 150 Ohm.
The terminating resistor is required at
both ends of the RIO Link.
RIO RACK INFORMATION
RCS-2 Programmer’s Manual - RIO Rack Information
LN-9409-03.2 9
RIO RACK SIZE
The RIO Rack size must be specified to allow the
RIO Interface Card to communicate over the RIO
link. When used with the RCS-2, the only valid
Rack Size is a Full Rack. Therefore, always set
switches SW2-7 and SW2-8 to the ON position.
These switch settings allow 8 discrete I/O words
and the ability to use from 1 to 4 RCS-2 Channel
Cards.
RIO STARTING QUARTER
The RIO Starting Quarter within the rack must
be specified to allow the RIO Interface Card to
communicate over the RIO link. When used with
the RCS-2, the only valid RIO Starting Quarter is 0,
since the RIO Rack Size is a Full Rack. Therefore,
always set switches SW1-7 and SW1-8 to the
OFF position.
RIO BAUD RATE, MAXIMUM
CABLE LENGTH, AND BUS
TERMINATION
The RIO Baud Rate must be specified to allow the
RIO Interface Card to communicate over the RIO
link. The RIO Baud Rate is specified with SW2,
positions 3 and 4. If the RCS-2 RIO Interface Card
is at the end of the RIO Link, a terminating resistor
must be installed.
OFF OFF 57.6 Kbaud 3,048 m (10,000 ft) 150 Ohm (see note), 1/8 Watt
OFF ON 115.2 Kbaud 1,524 m (5,000 ft) 150 Ohm (see note), 1/8 Watt
ON OFF 230.4 Kbaud 762 m (2,500 ft) 82 Ohm, 1/8 Watt
ON ON 230.4 Kbaud 762 m (2,500 ft) 82 Ohm, 1/8 Watt
SW2-3 SW2-4 RIO Baud Rate Max. Cable Length RIO Bus Termination
RIO BAUD RATE, MAXIMUM CABLE LENGTH, AND BUS TERMINATION
Recommendation
Always run the baud rate at the maximum rate
possible. Ransburg recommends always using
230.4 Kbaud unless it is necessary to operate at
a lower speed because of environmental issues
(noise, cable lengths, etc.). Since reasonably large
blocks of data are transferred in several of the
block transfers and since RIO is not a deterministic
network, the amount of time it takes for the data to
be returned to the PLC from the RCS-2 controller
may be significant and is unpredictable. When
requesting data from the RCS-2, always wait for
the RIO transmission complete bit to be set and
verify that there were no errors by checking the
RIO error bit prior to using returned data.
UNUSED SWITCHES
When the 77377-22 RIO Interface Card is used in
an RCS-2 rack, switches SW2-1, SW2-2, SW2-5,
and SW2-6 are unused and should be left in the
OFF position.
DISCRETE I/O
DISCRETE I/O
There are eight (8) 16-bit words used for digital
(discrete) inputs and outputs via RIO in the RCS-2.
Word 0 is for System inputs and outputs.
Words 1 through 7 are for Channel 1 through 7
inputs and outputs with each channel having 14
possible inputs and outputs. The Channel 8 inputs
and outputs are distributed across words 1 through
7 as bits 14 and 15 of these words. When a gun
is configured with two channels, the odd channel,
and thus odd word, is the controlling channel for
the gun.
The RCS-2 also has hard-wired discrete I/O ca-
pabilities and input bits received by the RCS-2 via
RIO are logical ORed with these discrete signals
prior to being processed by the software. Likewise,
any output bits are sent both to the PLC via RIO
and the hardwired discrete outputs.
For signals that cannot tolerate any delay what-
soever (such as gun trigger and analog flow
command) it is imperative that these signals be
wired directly to the physical discrete inputs of the
RCS and not run via RIO.
NOTE
�� The speed with which the RCS-2
responds to discrete inputs and output
via the RIO link is very fast and should
approach the speed of communicating
with it via its physical discrete inputs
and outputs. In most circumstances
where a pulse is required to set the
RCS-2 in a desired mode, holding
the signal on for 0.25 seconds is ad-
equate. However, there have been in-
stances where that time has not been
adequate (when the RCS-2 was on a
busy RIO channel). Some experimen-
tation may be necessary to insure that
the unit does in fact react predictably
and repeatedly to the commands is-
sued. Many of the discrete input com-
mands can be confirmed by monitoring
the feedback signals from the RCS-2.
(Refer to Appendix A for a list of dis-
crete inputs and outputs, their func-
tions, and how they affect other inputs
or outputs.)
RCS-2 Programmer’s Manual - Discrete I/O
LN-9409-03.2 10
Bit #
DISCRETE SYSTEM I/O
PLC Inputs PLC Outputs PLC Word 0
0 n/a n/a n/a
1 n/a n/a n/a
2 n/a n/a n/a
3 n/a n/a n/a
4 n/a n/a n/a
5 n/a n/a n/a
6 n/a n/a n/a
7 n/a n/a n/a
8 System Faulted Spare Digital In System
9 System Pulse Spare Digital In System
10 User Link Active Spare Digital In System
(Continued on next page)
NOTE
RCS-2 Programmer’s Manual - Discrete I/O
LN-9409-03.2 11
Bit #
DISCRETE SYSTEM I/O (Cont.)
PLC Inputs PLC Outputs PLC Word 0
11 Spare Digital Out Spare Digital In System
12 Spare Digital Out Spare Digital In System
13 RCS2 BTR Data Ready Spare Digital In System
14 RCS2 BTW Clear To Send Spare Digital In System
15 RCS2 RIO Error Spare Digital In System
Bit #
DISCRETE CHANNEL / GUN I/O
PLC Inputs PLC Outputs
1 2 3 4 5 6 7
PLC Words 1 to 7
0 Fault Fast Fill Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
1 Gun Running Channel Fill Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
2 Spray Shutdown Feather Set Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
3 Flush Request Run Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
4 Motor On Halt/Fault Reset Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
5 Gun Ready Trigger 1 Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
6 Spare Digital Out Reserved Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
7 Spare Digital Out Trigger 2 Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
8 Spare Digital Out Trigger 3 Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
9 Spare Digital Out Trigger 4 Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
10 Spare Digital Out Volume Fill Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
11 Spare Digital Out Push Out Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
12 Spare Digital Out Spare Digital In Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
13 Spare Digital Out Spare Digital In Ch. 1 Ch. 2 Ch. 3 Ch. 4 Ch. 5 Ch. 6 Ch. 7
14 n/a n/a Ch. 8 Ch. 8 Ch. 8 Re- Ch. 8 Ch. 8 Ch. 8
Bit 0 Bit 2 Bit 4 served Bit 8 Bit 10 Bit 12
15 n/a n/a Ch. 8 Ch. 8 Ch. 8 Ch. 8 Ch. 8 Ch. 8 Ch. 8
Bit 1 Bit 3 Bit 5 Bit 7 Bit 9 Bit 11 Bit 13
The Channel (Gun) 8 discrete I/O bits are
distributed across PLC words 1 through 7 in bits
14 and 15 as shown above. �� The status of the Channel/Gun I/O
bits can be monitored with the RCS-2
user-interface software. Open the fms.
exe software, select function F7 (Dig/
Ana I/O), then select Gun I/O. If the
RCS-2 user-interface software sees
one of its Gun I/O bits turned on or off
via RIO, there will be a (R) indicator af-
ter the ON or OFF indicator in the ap-
propriate box. This indicates that the
input is being controlled by RIO.
BLOCK TRANSFER DATA
It is highly recommended that any time a change
is to be made to a parameter in the RCS-2 via
this RIO link it be done in a Read-Modify-Write
fashion. That is, it is not possible to send just one
parameter at a time (say for instance, the ratio)
and change just that parameter. There are 10
different block transfer types and the amount of
data varies from 4 words to 60 words depending on
what parameters are to be read or written. Data is
BLOCK TRANSFER TYPES
NULL DATA - TYPE 00
A BTW must always precede a BTR in order to
inform the RCS-2 Interface Module what data is to
be returned in the next BTR. Null BTW commands
can be used when no data is required prior to the
next BTR. If the next BTR Type does not require
0 Previous BTW Type 00 to 09 BTW Type 0
1 BTR Type 0 Next BTR Type 00 to 09
2 N/A N/A Next BTR Gun # 1 to 8 or N/A
3 N/A N/A Next BTR Job # 1 to 199 or N/A
not filtered by the RIO card so if invalid data (data
outside acceptable limits) is sent to the RCS-2 via
RIO it will most likely generate a fault (typically a
channel card parameter fault) and the system will
shut down. If this occurs, it is necessary to correct
the corrupt data prior to restarting the system. This
can be done by correcting the offending data or
reloading a known good parameter set.
RIO BLOCK TRANSFER TYPES
0 Null Data 4 4
1 Gun Operational Status 52 20
2 Channel Operational Status 60 N/A
3 System Configuration 29 29
4 Gun Configuration 25 25
5 Channel Configuration 30 30
6 Job Configuration 41 41
7 Flow Totals 26 5
8 Error Log 54 5
9 Alarm Configuration 6 6
Type Description BTR Length BTW Length
a Gun Number or a Channel Number and/or Job
Number, those fields may be zero. Otherwise, the
Next BTR Type, Gun Number, Channel Number
and Job Number specify the appropriate data to
be returned in the next BTR.
NULL - TYPE 00
Word
Description Unit/Value Description Unit/Value
BTWBTR
RCS-2 Programmer’s Manual - Block Transfer Data
LN-9409-03.2 12
0 Previous BTW Type 00 to 09 BTW Type 1
1 BTR Type 1 Next BTR Type 00 to 09
2 N/A N/A Next BTR Gun/Chan. # 1 to 8 or N/A
3 N/A N/A Next BTR Job # 1 to 199 or N/A
4 Current Running Job # for Gun #1 1 to 199 Gun #1 Job # 0 to 199
5 Current Running Job # for Gun #2 1 to 199 Gun #1 Set Point cc/min x 10
6 Current Running Job # for Gun #3 1 to 199 Gun #2 Job # 0 to 199
7 Current Running Job # for Gun #4 1 to 199 Gun #2 Set Point cc/min x 10
8 Current Running Job # for Gun #5 1 to 199 Gun #3 Job # 0 to 199
9 Current Running Job # for Gun #6 1 to 199 Gun #3 Set Point cc/min x 10
10 Current Running Job # for Gun #7 1 to 199 Gun #4 Job # 0 to 199
11 Current Running Job # for Gun #8 1 to 199 Gun #4 Set Point cc/min x 10
12 Gun #1 Actual Ratio Ratio x 100 Gun #5 Job # 0 to 199
13 Gun #2 Actual Ratio Ratio x 100 Gun #5 Set Point cc/min x 10
14 Gun #3 Actual Ratio Ratio x 100 Gun #6 Job # 0 to 199
15 Gun #4 Actual Ratio Ratio x 100 Gun #6 Set Point cc/min x 10
16 Gun #5 Actual Ratio Ratio x 100 Gun #7 Job # 0 to 199
17 Gun #6 Actual Ratio Ratio x 100 Gun #7 Set Point cc/min x 10
18 Gun #7 Actual Ratio Ratio x 100 Gun #8 Job # 0 to 199
19 Gun #8 Actual Ratio Ratio x 100 Gun #8 Set Point cc/min x 10
20 Gun #1 Target Flow cc/min x 10
21 Gun #2 Target Flow cc/min x 10
22 Gun #3 Target Flow cc/min x 10
23 Gun #4 Target Flow cc/min x 10
24 Gun #5 Target Flow cc/min x 10
25 Gun #6 Target Flow cc/min x 10
26 Gun #7 Target Flow cc/min x 10
27 Gun #8 Target Flow cc/min x 10
28 Gun #1 Actual Flow cc/min x 10
29 Gun #2 Actual Flow cc/min x 10
30 Gun #3 Actual Flow cc/min x 10
31 Gun #4 Actual Flow cc/min x 10
32 Gun #5 Actual Flow cc/min x 10
GUN OPERATIONAL
STATUS - TYPE 01
The Gun Operational Status Block transfers are
used for normal process control while painting
parts. This assumes the system and applicators
have been initially configured.
The gun numbers, job numbers, and setpoints
may be specified as 0 if no change is desired
for a gun. However, if a setpoint is specified as
non-zero, a valid job number must be specified.
GUN OPERATION STATUS - TYPE 01
Word
Description Unit/Value Description Unit/Value
BTWBTR
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LN-9409-03.2 13
GUN OPERATION STATUS - TYPE 01 (Cont.)
Word
Description Unit/Value Description Unit/Value
BTWBTR
33 Gun #6 Actual Flow cc/min x 10
34 Gun #7 Actual Flow cc/min x 10
35 Gun #8 Actual Flow cc/min x 10
36 Gun #1, Hardener Flow 0 to 1023
37 Gun #2, Hardener Flow 0 to 1023
38 Gun #3, Hardener Flow 0 to 1023
39 Gun #4, Hardener Flow 0 to 1023
40 Gun #5, Hardener Flow 0 to 1023
41 Gun #6, Hardener Flow 0 to 1023
42 Gun #7, Hardener Flow 0 to 1023
43 Gun #8, Hardener Flow 0 to 1023
44 Gun #1, Feather Pressure PSIG
45 Gun #2, Feather Pressure PSIG
46 Gun #3, Feather Pressure PSIG
47 Gun #4, Feather Pressure PSIG
48 Gun #5, Feather Pressure PSIG
49 Gun #6, Feather Pressure PSIG
50 Gun #7, Feather Pressure PSIG
51 Gun #8, Feather Pressure PSIG
CHANNEL OPERATIONAL
STATUS - TYPE 02
CHANNEL OPERATION STATUS - TYPE 02
Word
Description Unit/Value Description Unit/Value
BTWBTR
0 Previous BTW Type 00 to 09 BTW Type N/A
1 BTR Type 2 Next BTR Type N/A
2 N/A N/A Next BTR Gun/Chan. # N/A
3 N/A N/A Next BTR Job # N/A
4 Target Flow Rate, Chan. 1 cc/min x 10
5 Target Flow Rate, Chan. 2 cc/min x 10
6 Target Flow Rate, Chan. 3 cc/min x 10
7 Target Flow Rate, Chan. 4 cc/min x 10
8 Target Flow Rate, Chan. 5 cc/min x 10
9 Target Flow Rate, Chan. 6 cc/min x 10
10 Target Flow Rate, Chan. 7 cc/min x 10
11 Target Flow Rate, Chan. 8 cc/min x 10
RCS-2 Programmer’s Manual - Block Transfer Data
LN-9409-03.2 14
12 Actual Flow Rate, Chan. 1 cc/min x 10
13 Actual Flow Rate, Chan. 2 cc/min x 10
14 Actual Flow Rate, Chan. 3 cc/min x 10
15 Actual Flow Rate, Chan. 4 cc/min x 10
16 Actual Flow Rate, Chan. 5 cc/min x 10
17 Actual Flow Rate, Chan. 6 cc/min x 10
18 Actual Flow Rate, Chan. 7 cc/min x 10
19 Actual Flow Rate, Chan. 8 cc/min x 10
20 Pump Inlet Pressure, Chan. 1 PSIG
21 Pump Inlet Pressure, Chan. 2 PSIG
22 Pump Inlet Pressure, Chan. 3 PSIG
23 Pump Inlet Pressure, Chan. 4 PSIG
24 Pump Inlet Pressure, Chan. 5 PSIG
25 Pump Inlet Pressure, Chan. 6 PSIG
26 Pump Inlet Pressure, Chan. 7 PSIG
27 Pump Inlet Pressure, Chan. 8 PSIG
28 Pump Outlet Pressure, Chan. 1 PSIG
29 Pump Outlet Pressure, Chan. 2 PSIG
30 Pump Outlet Pressure, Chan. 3 PSIG
31 Pump Outlet Pressure, Chan. 4 PSIG
32 Pump Outlet Pressure, Chan. 5 PSIG
33 Pump Outlet Pressure, Chan. 6 PSIG
34 Pump Outlet Pressure, Chan. 7 PSIG
35 Pump Outlet Pressure, Chan. 8 PSIG
36 Motor Speed, Chan. 1 RPM x 10
37 Motor Speed, Chan. 2 RPM x 10
38 Motor Speed, Chan. 3 RPM x 10
39 Motor Speed, Chan. 4 RPM x 10
40 Motor Speed, Chan. 5 RPM x 10
41 Motor Speed, Chan. 6 RPM x 10
42 Motor Speed, Chan. 7 RPM x 10
43 Motor Speed, Chan. 8 RPM x 10
44 Pressure Control, Chan. 1 0 to 1023
45 Pressure Control, Chan. 2 0 to 1023
46 Pressure Control, Chan. 3 0 to 1023
47 Pressure Control, Chan. 4 0 to 1023
48 Pressure Control, Chan. 5 0 to 1023
49 Pressure Control, Chan. 6 0 to 1023
50 Pressure Control, Chan. 7 0 to 1023
51 Pressure Control, Chan. 8 0 to 1023
CHANNEL OPERATION STATUS - TYPE 02 (Cont.)
Word
Description Unit/Value Description Unit/Value
BTWBTR
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LN-9409-03.2 15
SYSTEM CONFIGURATION - TYPE 03
0 Previous BTW Type 00 to 09 BTW Type 3
1 BTR Type 3 Next BTR Type 00 to 09
2 N/A N/A Next BTR Gun/Chan. # 1 to 8 or N/A
3 N/A N/A Next BTR Job # 1 to 199 or N/A
4 Over Pressure Limit PSIG Over Pressure Limit PSIG
5 Fold Back Pressure PSIG Fold Back Pressure PSIG
6 Sensor Limit PSIG Sensor Limit PSIG
7 Horn Enable 0 or 1 Horn Enable 0 or 1
8 Spare 1 Spare 1
9 Spare 2 Spare 2
10 Spare 3 Spare 3
11 Spare 4 Spare 4
12 Spare 5 Spare 5
13 Spare 6 Spare 6
14 Spare 7 Spare 7
15 Spare 8 Spare 8
16 Spare 9 Spare 9
17 Spare 10 Spare 10
18 Controller IP Address (1) 0 to 255
19 Controller IP Address (2) 0 to 255
20 Controller IP Address (3) 0 to 255
21 Controller IP Address (4) 0 to 255
22 User Interface SW Version
23 RIO Card Version
24 Interface Card SW Version
25 Channel Card #1 Version
26 Channel Card #2 Version
27 Channel Card #3 Version
28 Channel Card #4 Version
CHANNEL OPERATION STATUS - TYPE 02 (Cont.)
Word
Description Unit/Value Description Unit/Value
BTWBTR
52 Spare Analog Input, Chan. 1 0 to 1023
53 Spare Analog Input, Chan. 2 0 to 1023
54 Spare Analog Input, Chan. 3 0 to 1023
55 Spare Analog Input, Chan. 4 0 to 1023
56 Spare Analog Input, Chan. 5 0 to 1023
57 Spare Analog Input, Chan. 6 0 to 1023
58 Spare Analog Input, Chan. 7 0 to 1023
59 Spare Analog Input, Chan. 8 0 to 1023
SYSTEM CONFIGURATION DATA - TYPE 03
Word
Description Unit/Value Description Unit/Value
BTWBTR
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LN-9409-03.2 16
GUN CONFIGURATION - TYPE 04
RIO Gun Configuration Block transfers are typically required when configuring
a gun for the first time or periodically adjusting parameters.
0 Previous BTW Type 00 to 09 BTW Type 4
1 BTR Type 4 Next BTR Type 00 to 09
2 BTR Gun # 1 to 8 BTW Gun # and Next
BTR Gun # 1 to 8
3 N/A N/A Next BTR Job # 1 to 199 or N/A
4 Mode 0, 1, or 2 Mode 0, 1, or 2
5 No. of Channels 0 – 2 (4) No. of Channels 0 – 2 (4)
6 Master Channel 0 – 8 Master Channel 0 – 8
7 Slave #1 Channel 0 – 8 Slave #1 Channel 0 – 8
8 Slave #2 Channel (future) 0 – 8 Slave #2 Channel (future) 0 – 8
9 Slave #3 Channel (future) 0 – 8 Slave #3 Channel (future) 0 – 8
10 Default Job # 0 – 199 Default Job # 0 – 199
11 Number of Applicators 1 – 4 Number of Applicators 1 – 4
12 Mixed Volume cc’s Mixed Volume cc’s
13 Flow/Ratio Tolerance 0 – 100 Flow/Ratio Tolerance 0 – 100
14 Tolerance Volume cc’s Tolerance Volume cc’s
15 Auto Reset Auto Reset
16 Alarm Tolerance Time 0.1 seconds Alarm Tolerance Time 0.1 seconds
17 Solvent Calibration Factor (Low Order) PPL% 10,000 Solvent Calibration Factor
(Low Order) PPL % 10,000
18 Solvent Calibration Factor (High Order) PPL / 10,000 Solvent Calibration Factor
(High Order) PPL / 10,000
19 Horn Code (see table below) Bit Field Horn Code (see table below) Bit Field
20 Spare 1 Spare 1
21 Spare 2 Spare 2
22 Spare 3 Spare 3
23 Spare 4 Spare 4
24 Spare 5 Spare 5
GUN CONFIGURATION - TYPE 04
Word
Description Unit/Value Description Unit/Value
BTWBTR
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LN-9409-03.2 17
XXXXXXXXXXXXX000 Horn never sounds
XXXXXXXXXXXXX001 Horn only sounds on a Spray Shut Down condition
XXXXXXXXXXXXX010 Horn sounds for All Errors (not including expired pot life)
XXXXXXXXXXXXX100 Horn only sounds if the Pot Life Timer expires
XXXXXXXXXXXXX101 Horn sounds if a Spray Shut Down occurs or if the Pot Life Timer expires
XXXXXXXXXXXXX11X Horn sounds for Any Error (including an expired Pot Life Timer)
Note: X indicates ‘don’t care’.
CHANNEL CONFIGURATION - TYPE 05
0 Previous BTW Type 00 to 09 BTW Type 5
1 BTR Type 5 Next BTR Type 00 to 09
2 BTR Chan. # 1 to 8 BTW Chan. # and Next
BTR Gun/Chan. # 1 to 8
3 N/A N/A Next BTR Job # 1 to 199 or N/A
4 Fill Enable 0 or 1 Fill Enable 0 or 1
5 Trigger On Delay (Master) 0.1 seconds Trigger On Delay (Master) 0.1 seconds
6 Trigger Off Delay (Master) 0.1 seconds Trigger Off Delay (Master) 0.1 seconds
7 Pump Size cc’s/revolution Pump Size cc’s/revolution
8 Calibration Factor (Low Order) PPL % 10,000 Calibration Factor (Low Order) PPL % 10,000
9 Calibration Factor (High Order) PPL / 10,000 Calibration Factor (High Order) PPL / 10,000
10 Max. Pump Speed RPM Max. Pump Speed RPM
11 Min. Pump Speed RPM Min. Pump Speed RPM
12 Max. Inlet Pressure PSIG Max. Inlet Pressure PSIG
13 Min. Inlet Pressure PSIG Min. Inlet Pressure PSIG
14 Max. Outlet Pressure PSIG Max. Outlet Pressure PSIG
15 Min. Outlet Pressure PSIG Min. Outlet Pressure PSIG
16 Foldback Kp Gain Foldback Kp Gain
17 Foldback Ki Gain Foldback Ki Gain
18 Foldback Kd Gain Foldback Kd Gain
19 Foldback Deadband PSIG Foldback Deadband PSIG
20 Feather Kp Gain Feather Kp Gain
21 Feather Ki Gain Feather Ki Gain
22 Feather Kd Gain Feather Kd Gain
23 Feather Deadband PSIG Feather Deadband PSIG
24 Inlet Pressure Sensor See Table Inlet Pressure Sensor See Table
25 Spare 1 Spare 1
26 Spare 2 Spare 2
27 Spare 3 Spare 3
28 Spare 4 Spare 4
29 Spare 5 Spare 5
POSSIBLE HORN CODES
Horn Code Value Description
CHANNEL CONFIGURATION DATA - TYPE 05
Word
Description Unit/Value Description Unit/Value
BTWBTR
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The Inlet Pressure Sensor bit fields are defined
in the following table:
0 Control, Minimum, and Maximum Pressure Tests Disabled for All Modes for Both Channels
1 Control, Minimum, and Maximum Pressure Tests Enabled for All Modes for Both Channels
2 Control and Minimum Pressure Test Enabled for All Modes, Except Channel Fill, for Resin Channel
Control and Minimum Pressure Test Enabled All Modes for Catalyst Channel
Maximum Pressure Test Enabled All Modes for Both Channels
POSSIBLE INLET PRESSURE SENSOR CODES
Value Description
JOB CONFIGURATION DATA - TYPE 06
Word
Description Unit/Value Description Unit/Value
BTWBTR
JOB CONFIGURATION DATA- TYPE 06
RIO Job Configuration Data block transfers are typically required when configuring a gun for the
first time or periodically adjusting parameters.
0 Previous BTW Type 00 to 09 BTW Type 6
1 BTR Type 6 Next BTR Type 00 to 09
2 BTR Gun # 1 to 8 BTW Gun # and Next BTR Gun # 1 to 8
3 BTR Job # 1 to 199 BTW Job # and Next BTR Job # 1 to 199
4 Ratio (Parts master to 1 part slave) Ratio x 100 Ratio (Parts master to 1 part slave) Ratio x 100
5 Flow Setpoint cc’s/min Flow Setpoint cc’s/min
6 Maximum Flow cc’s/min Maximum Flow cc’s/min
7 Minimum Flow cc’s/min Minimum Flow cc’s/min
8 Bar Graph Limit cc’s/min Bar Graph Limit cc’s/min
9 Potlife Timer minutes Potlife Timer minutes
10 Feather Pressure PSIG Feather Pressure PSIG
11 Fill Volume cc’s Fill Volume cc’s
12 Pressure Pot Capacity (Master) cc’s Pressure Pot Capacity (Master) cc’s
13 Delta P (Master) PSIG Delta P (Master) PSIG
14 Min. Fluid Pressure (Master) PSIG Min. Fluid Pressure (Master) PSIG
15 Inlet Kp (Master) Inlet Kp (Master)
16 Inlet Ki (Master) Inlet Ki (Master)
17 Inlet Kd (Master) Inlet Kd (Master)
18 Inlet Deadband (Master) Inlet Deadband (Master)
19 Pressure Pot Capacity (Slave) cc’s Pressure Pot Capacity (Slave) cc’s
20 Delta P (Slave) PSIG Delta P (Slave) PSIG
21 Min. Fluid Pressure (Slave) PSIG Min. Fluid Pressure (Slave) PSIG
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JOB CONFIGURATION DATA - TYPE 06 (Cont.)
Word
Description Unit/Value Description Unit/Value
BTWBTR
22 Inlet Kp (Slave) Inlet Kp (Slave)
23 Inlet Ki (Slave) Inlet Ki (Slave)
24 Inlet Kd (Slave) Inlet Kd (Slave)
25 Inlet Deadband (Slave) Inlet Deadband (Slave)
26 Hardener Sample Time (Slave) 0 – 10 sec. Hardener Sample Time (Slave) 0 – 10 sec.
27 Hardener No Flow (Slave) 0 – 1023 Hardener No Flow (Slave) 0 – 1023
28 Hardener Fault On (Slave) 0 – 1023 Hardener Fault On (Slave) 0 – 1023
29 Min. Control Pressure (Master) PSIG Min. Control Pressure (Master) PSIG
30 Min. Control Pressure (Slave) PSIG Min. Control Pressure (Slave) PSIG
31 Spare 1 Spare 1
32 Spare 2 Spare 2
33 Spare 3 Spare 3
34 Spare 4 Spare 4
35 Spare 5 Spare 5
36 Spare 6 Spare 6
37 Spare 7 Spare 7
38 Spare 8 Spare 8
39 Spare 9 Spare 9
40 Spare 10 Spare 10
FLOW TOTALS - TYPE 07
RIO Flow Totals block transfers are used to read or reset accumulated flow totals
during normal operation.
FLOW TOTALS - TYPE 07
Word
Description Unit/Value Description Unit/Value
BTWBTR
0 Previous BTW Type 00 to 09 BTW Type 7
1 BTR Type 7 Next BTR Type 00 to 09
2 BTR Chan. # 1 to 8 BTW Chan. # and Next BTR
Gun/Chan. # 1 to 8
3 BTR Job # 1 to 199 BTW Job # and Next BTR Job # 1 to 199
4 Daily Total for Job Liters Reset Selected Bit Field
5 Daily Total for Job cc’s
6 YTD Totals for Job Liters
7 YTD Totals for Job cc’s
8 Solvent Totals for Job Liters
9 Solvent Totals for Job cc’s
10 Grand Totals for Job Liters
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11 Grand Totals for Job cc’s
12 Channel Fill Totals for Job Liters
13 Channel Fill Totals for Job cc’s
14 Daily Total for All Jobs Liters
15 Daily Total for All Jobs cc’s
16 YTD Totals for All Jobs Liters
17 YTD Totals for All Jobs cc’s
18 Solvent Totals for All Jobs Liters
19 Solvent Totals for All Jobs cc’s
20 Grand Totals for All Jobs Liters
21 Grand Totals for All Jobs cc’s
22 Channel Fill Totals for All Jobs Liters
23 Channel Fill Totals for All Jobs cc’s
24 Pressure Pot Contents Liters
25 Pressure Pot Contents cc’s
FLOW TOTALS - TYPE 07 (Cont.)
Word
Description Unit/Value Description Unit/Value
BTWBTR
RESET BIT FIELD
Bit Reset Selected Total Decimal Value Hex Value
The Reset Selected bit field is defined in the following table:
0 Daily Total for Job 1 0x0001
1 YTD Totals for Job 2 0x0002
2 Solvent Totals for Job 4 0x0004
3 Grand Totals for Job 8 0x0008
4 Channel Fill Totals for Job 16 0x0010
5 Daily Total for All Jobs 32 0x0020
6 YTD Totals for All Jobs 64 0x0040
7 Solvent Totals for All Jobs 128 0x0080
8 Grand Totals for All Jobs 256 0x0100
9 Channel Fill Totals for All Jobs 512 0x0200
10 Pressure Pot Contents (from Job Configuration value) 1 024 0x0400
Note: If it is necessary to retrieve flow totals after every job (buck, part, batch, etc.) it is important to note that
the RCS-2 interface card only receives totalization information once every second from the channel card. (The
interface card is the card that stores that information in battery-backed RAM and supplies this data to the RCS-
2 RIO card.) For that reason, in order to insure accurate totalization data, it is necessary to wait at least one
second after the gun trigger shuts off after spraying the last part in the batch (buck, etc.) before requesting
totalization data.
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LN-9409-03.2 21
ERROR LOG MESSAGES - TYPE 08
Word
Description Unit/Value Description Unit/Value
BTWBTR
0 Previous BTW Type 00 to 09 BTW Type 8
1 BTR Type 8 Next BTR Type 00 to 09
2 N/A N/A Next BTR Gun/Chan. # 1 to 8 or N/A
3 BTR Reference # 1 to 100 Next BTR Job # or Ref. # 1 to 199 or N/A
or 1 to 100
4 Ref. # + 0 1 to 100 Clear Error Log 1
5 Error Code (see table)
6 Channel # 1 to 8
7 Time Stamp (High) Sec. since 1/1/80
8 Time Stamp (Low) Sec. since 1/1/80
9 Ref. # + 1 2 to 100
10 Error Code (see table)
11 Channel # 1 to 8
12 Time Stamp (High) Sec. since 1/1/80
13 Time Stamp (Low) Sec. since 1/1/80
14 Ref. # + 2 3 to 100
15 Error Code (see table)
16 Channel # 1 to 8
17 Time Stamp (High) Sec. since 1/1/80
18 Time Stamp (Low) Sec. since 1/1/80
19 Ref. # + 3 4 to 100
20 Error Code (see table)
21 Channel # 1 to 8
22 Time Stamp (High) Sec. since 1/1/80
23 Time Stamp (Low) Sec. since 1/1/80
24 Ref. # + 4 5 to 100
25 Error Code (see table)
26 Channel # 1 to 8
27 Time Stamp (High) Sec. since 1/1/80
28 Time Stamp (Low) Sec. since 1/1/80
29 Ref. # + 5 6 to 100
30 Error Code (see table)
31 Channel # 1 to 8
32 Time Stamp (High) Sec. since 1/1/80
33 Time Stamp (Low) Sec. since 1/1/80
34 Ref. # + 6 7 to 100
35 Error Code (see table)
36 Channel # 1 to 8
37 Time Stamp (High) Sec. since 1/1/80
ERROR LOG - TYPE 08
RIO Error Log block transfers are used to obtain a list of the past ten faults recorded by the
RCS-2 Interface Module. The BTW has no effect on the system and may be used to schedule
the next block transfer.
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LN-9409-03.2 22
ERROR LOG MESSAGES - TYPE 08 (Cont.)
Word
Description Unit/Value Description Unit/Value
BTWBTR
38 Time Stamp (Low) Sec. since 1/1/80
39 Ref. # + 7 8 to 100
40 Error Code (see table)
41 Channel # 1 to 8
42 Time Stamp (High) Sec. since 1/1/80
43 Time Stamp (Low) Sec. since 1/1/80
44 Ref. # + 8 9 to 100
45 Error Code (see table)
46 Channel # 1 to 8
47 Time Stamp (High) Sec. since 1/1/80
48 Time Stamp (Low) Sec. since 1/1/80
49 Ref. # + 9 10 to 100
50 Error Code (see table)
51 Channel # 1 to 8
52 Time Stamp (High) Sec. since 1/1/80
53 Time Stamp (Low) Sec. since 1/1/80
ERROR CODES
Error
Code
Reset Selected Total
(Note: Bold Indicates Always Hard Errors)
The following table describes the Error Codes:
0 No Error
1 Interface Module Battery Low
2 Interface not communicating with channel card in slot 1
3 Interface not communicating with channel card in slot 2
4 Interface not communicating with channel card in slot 3
5 Interface not communicating with channel card in slot 4
6 – 31 (spare error codes)
32 Input Under Pressure
33 Input Over Pressure
34 Output Under Pressure
35 Output Over Pressure
36 Flow Out of Tolerance
37 Hardener Flow Loss
38 Pressure Pot Empty
39 (spare error bit)
40 (spare error bit)
41 Inlet Pressure Loss
42 Outlet Pressure Loss
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LN-9409-03.2 23
ERROR CODES (Cont.)
Error
Code
Reset Selected Total
(Note: Bold Indicates Always Hard Errors)
43 Analog Remote Loss
44 Ratio Out of Tolerance
45 (spare error code)
46 Motor Amp Fault
47 Analog Feather Loss
48 Analog Spare Loss
49 Fold Back Pressure Reached
50 Pot Life Expired
51 (spare error code)
52 (spare error code)
53 (spare error code)
54 (spare error code)
55 (spare error code)
56 (spare error code)
57 (spare error code)
58 (spare error code)
59 (spare error code)
60 System Over Pressure
61 Channel Card (Pressure) Parameter Fault
62 Channel Card SPI Communication Lost
63 Channel Card Internal Software Fault
ALARM CONFIGURATION - TYPE 09
Word
Description Unit/Value Description Unit/Value
BTWBTR
ALARM CONFIGURATION - TYPE 09
RIO Alarm Configuration block transfers allow the user the ability to determine what alarm
conditions causes a spray-shutdown.
0 Previous BTW Type 00 to 09 BTW Type 9
1 BTR Type 9 Next BTR Type 00 to 09
2 N/A N/A Next BTR Gun # 1 to 8 or N/A
3 N/A N/A Next BTR Job # 1 to 199 or N/A
4 Alarm Enable/Disable Bits 0-15 Bit Field Alarm Enable/Disable Bits 0-15 Bit Field
5 Alarm Enable/Disable Bits 16-31 Bit Field Alarm Enable/Disable Bits 16-31 Bit Field
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The Active Alarm bit fields are defined in the following table:
0 Input Under Pressure 1 0x0001
1 Input Over Pressure 2 0x0002
2 Output Under Pressure 4 0x0004
3 Output Over Pressure 8 0x0008
4 Flow Out of Tolerance 16 0x0010
5 Hardener Flow Loss 32 0x0020
6 Pressure Pot Empty 64 0x0040
7 (spare error bit) 128 0x0080
8 (spare error bit) 256 0x0100
9 Inlet Pressure Loss 512 0x0200
10 Outlet Pressure Loss 1024 0x0400
11 Analog Remote Loss 2048 0x0800
12 Ratio Out of Tolerance 4096 0x1000
13 (spare error bit) 8192 0x2000
14 Motor Amp Fault 16384 0x4000
15 Analog Feather Loss 32768 0x8000
16 Analog Spare Loss 1 0x0001
17 Fold Back Pressure Reached 2 0x0002
18 Pot Life Expired 4 0x0004
19 (spare error bit) 8 0x0008
20 (spare error bit) 16 0x0010
21 (spare error bit) 32 0x0020
22 (spare error bit) 64 0x0040
23 (spare error bit) 128 0x0080
24 (spare error bit) 256 0x0100
25 (spare error bit) 512 0x0200
26 (spare error bit) 1024 0x0400
27 (spare error bit) 2048 0x0800
28 System Over Pressure 4096 0x1000
29 Channel Card (Pressure) Parameter Fault 8192 0x2000
30 Channel Card SPI Communication Lost 16384 0x4000
31 Channel Card Internal Software Fault 32768 0x8000
ACTIVE ALARM
Bit Alarm Enable/Disable
(Note: Bold Indicates Always Hard Alarms) Decimal Value Hex Value
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DESCRIPTIONS OF INPUTS
AND OUTPUTS
SYSTEM INPUTS
Gun Strobe
Type of Input: Gun
Type of Signal: Pulsed
This input signal is used in coordination with the
Job Number inputs (see below). When this input
is taken from the non-energized state to the en-
ergized state for any gun, the Job Number that
is appearing at the Job Number inputs is loaded
into the job queue. If the gun is in the halted state,
the new job becomes active immediately. If the
gun is in a run state, the new job number is held
in the queue until the next time the gun is halted
(or faults). Note that the job queue is only one in
length. If another job is loaded on top of one already
in the queue, the new job number overwrites the
older one in the queue.
Job Number
[1, 2, 4, 8, 10, 20, 40, 80, 100]
Type of Input: System
Type of Signal: Maintained
These inputs are simple BCD (binary coded deci-
mal) inputs that represent the job number that an
external controller energizes to load new job num-
bers into the RCS-2 guns. Note that these inputs
are common to all guns and they are ignored until
one or more of the Gun Strobe inputs are pulsed.
Allowable job number range from 1 to 199.
SYSTEM OUTPUTS
System Fault
Type of Output: System
Type of Signal: Maintained
This output is connected to the horn in the top
of the control console on the stand-alone RCS-2
controllers. It can be energized anytime there is a
system fault. (It can be enabled and disabled on
the CONFIG SYSTEM screen). Some examples
of system faults are problems with the disk drive,
hard drive, or CDROM of the user-interface PC.
Also, certain problems with the interface board
or RIO board (if used) may cause a system fault.
This output can also be programmed to energize
when any of the guns fault. This is done on the
CONFIG GUN screens. Each gun can be con-
figured to cause the horn to sound when it faults
independent of each other. Note that the horn must
be enabled on the CONFIG SYSTEM screen or
the horn will not sound for gun faults regardless
of whether or not they are configured to do so on
the CONFIG GUN screens.
System Pulse
Type of Output: System
Type of Signal: Pulsing
This output pulses at approximately a 0.5 hertz rate
as long as the processor on the interface board
does not detect any on-board firmware problems.
Users may wish to use this signal to detect when
the RCS-2 controller is powered up and running.
Client Connected
Type of Output: System
Type of Signal: Maintained
This output is energized whenever a client (P.C.)
is connected and talking to the interface card via
Ethernet.
DISCRETE CHANNEL AND
GUN INPUTS
Fast Fill
Type of Input: Gun
Type of Signal: Pulsed
The gun must be in run mode or volume fill mode
prior to initiating this mode or the RCS-2 controller
will ignore it. If the gun is configured as a single
channel gun and this signal is pulsed, the gun
will cause the pump to run at its maximum speed
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 26
APPENDIX
(typically 150 RPM) until the halt signal is pulsed.
(Note that it is not necessary to have the trigger
signal energized. Flow starts immediately.) If the
gun is configured as a two-channel gun, and this
input is pulsed, the pumps will run at the maximum
speed possible while maintaining the target ratio.
That is, the software will determine which of the
two pumps can be run at its maximum speed
and run the opposite channel at whatever speed
necessary to insure the proper ratio of component
A to component B. The software determines this
based on the programmed pump sizes and the
programmed ratio. Pulsing the halt/reset input
takes the gun out of the fast fill mode. (Note also
paragraph below describing using fast fill with
volume fill.)
Channel Fill
Type of Input: Channel
Type of Signal: Pulsed
A gun must be in the halted state to use this mode.
This mode functions the same for single channel
guns as it does for dual channel guns. When this
input is pulsed, the pump for that channel is run at
its maximum rate (150 RPM) until the halt signal is
pulsed. It is not necessary for the trigger input to
be energized. If it is desired to have both channels
of a two channel gun run at full speed (for flushing,
etc.) this input must be pulsed on both channels
independently. Note that the pilot air signal to the
inlet pressure regulator is automatically set to 100
psi while in channel fill mode.
Feather Set
Type of Input: Gun
Type of Signal: Pulsed
If the gun is configured as a manual mode gun and
the value zero (0) is programmed in for feather
pressure (under the CONFIG JOB parameters)
this input can be used to program the feather
pressure ‘on the fly’. That is, if a hand sprayer is
painting and this input is momentarily energized,
the RCS-2 controller takes a snapshot of the out-
bound pressure of the pumps (or the pressure at
the feather pressure sensor, if being used) and
then starts controlling the speed of the pumps to
maintain that pressure. The optional Remote Op-
erator’s Panel has a pushbutton on it that allows
the hand sprayer to utilize this feature.
Run
Type of Input: Gun
Type of Signal: Pulsed
This signal takes a configured gun from the halted
state to the run state. In order for a gun to spray,
it must first be put into run mode. It is essentially
a way of enabling a gun. Energizing the trigger
input of a gun will not cause fluid to flow unless the
gun has been placed in run mode. When placed
in run mode, the discrete output labeled Gun Run
will be energized.
Halt/Fault Reset
Type of Input: Gun
Type of Signal: Pulsed
This input takes a configured gun that is in run
mode to the halted state, essentially disabling the
gun from spraying. It also resets a fault for the gun
if it is in the faulted state.
Trigger [1, 2, 3 or 4]
Type of Input: Gun
Type of Signal: Maintained
This input tells the controller to run the pumps if
and only if the gun has first been placed in run
mode. The additional trigger input signals (2, 3,
and 4) can be used in cases where the output of
a fluid panel is split between multiple applicators.
They work in conjunction with each other to allow
up to 4 independent triggers, one for each of 4
applicators. The software can be configured in
such a way that if one of these inputs is on, the
fluid panel delivers the target flow rate of material.
If a second input is turned on, then the fluid panel
will deliver twice the target flow rate. If a third
input is energized, three times the target flow is
delivered and if all four inputs are energized, the
fluid panel will deliver four times the target flow
rate. It is assumed that each of these inputs are
also connected to the trigger inputs on four inde-
pendent applicators.
Motor Amp Enable
Type of Input: Channel
Type of Signal: Maintained
This is an input to the controller from the motor
amplifier indicating that the motor amplifier has
detected a problem and has placed itself in a
faulted condition.
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 27
Volume Fill
Type of input: Gun
Type of signal: Pulsed
By pulsing the volume fill discrete input, the unit
will be put into the V. FILL mode. (The gun must
be in the halted state prior to this.) When the gun
trigger input goes high, the pumps will run at the
programmed flow rate and ratio until the volume
programmed in for Fill Volume (on the Job param-
eters screen) is dispensed. If more than one gun
trigger input goes high the unit will multiply the
flow rate by the number of high inputs but still only
run until the programmed volume is dispensed.
When that volume is reached, the gun will be
halted. See paragraph labeled Volume Fill with
Fast Fill below if it is necessary to run this mode
in parallel with fast fill.
Pushout
Type of input: Gun
Type of signal: Maintained
This input when energized puts the gun in Pushout
Mode. When initiated, the RCS-2 will immedi-
ately turn off the catalyst pump and speed up the
resin pump to maintain the target flow rate that
was being sprayed prior to the initiation of the
pushout signal. (Note that this pushout signal is
a maintained signal.) The RCS-2 will continue to
deliver fluid out of the first dual purge side until
the volume programmed in for mixed volume has
been sprayed and then that gun will automatical-
ly be halted (taken out of run mode). This state
will be recognized by the PLC or robot when the
Run output from the RCS-2 turns off. For more
information on using this function, refer to the
Operator’s Manual.
Volume Fill with Fast Fill Mode:
It is possible to Volume Fill and Fast Fill simultane-
ously. If the gun is put into Volume Fill mode, and
then the Fast Fill input is pulsed, the unit will run
in Fast Fill mode until the volume programmed in
for fill volume is dispensed. At that time, the gun
will be halted. This happens regardless of the
condition of the gun trigger inputs so make sure
the applicator is triggered or an overpressure fault
may occur. When it is desirable to run both modes
in parallel, it is important to watch the Run output
bit to insure the unit has in fact gone into Volume
Fill mode prior to sending the Fast Fill bit.
DISCRETE CHANNEL AND
GUN OUTPUTS
Fault
This output is energized anytime a fault condition
is recognized by the software. Even if the fault is
disabled (known as a soft-fault) on the Configured
Alarms screen, this output will be energized as
long as the condition persists. Fluid flow will not
be halted when this output is energized unless it
is configured to do so on the Configured Alarms
screen. If it is configured to be a hard-fault, this
output and the Spray Shutdown output will both
be energized and the system will stop spraying
(see Spray Shutdown, below).
Run
This output is energized if the gun is configured
properly, a good job number has been loaded,
and the gun has been placed in Run mode or the
Volume Fill mode. This output goes off if a fault
occurs, if it is Halted, or in the Ready state.
Spray Shutdown
This output is energized if a fault condition exists
and the specific fault that exists is enabled on
the Configured Alarms screen (turned on). This
indicates that the flow of fluid from the fluid panel
has been stopped as the result of a detected fault
condition.
Flush Request
This output is energized when the pot-life timer
has expired. (For more information, see Mixed
Volume and Pot-Life Timer in the Operation’s
Manual.)
Motor On
This output is energized by the software when
it wants the motor to turn. As long as this output
is enabled and the motor amplifier is not faulted,
the pump will be held rigid in place by the motor
amplifier. If this output is not on, the pump is al-
lowed to free-wheel.
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 28
DISCRETE CHANNEL AND
GUN INPUTS
Motor Amp Enable
Type of Input: Channel
Type of Signal: Maintained
This is an input to the controller from the motor
amplifier indicating that the motor amplifier has
detected a problem and has placed itself in a
faulted condition.
Volume Fill
Type of input: Gun
Type of signal: Pulsed
By pulsing the volume fill discrete input, the unit
will be put into the V. FILL mode. (The gun must
be in the halted state prior to this.) When the gun
trigger input goes high, the pumps will run at the
programmed flow rate and ratio until the volume
programmed in for Fill Volume (on the Job param-
eters screen) is dispensed. If more than one gun
trigger input goes high the unit will multiply the
flow rate by the number of high inputs but still only
run until the programmed volume is dispensed.
When that volume is reached, the gun will be
halted. See paragraph labeled Volume Fill with
Fast Fill below if it is necessary to run this mode
in parallel with fast fill.
Pushout
Type of input: Gun
Type of signal: Maintained
This input when energized puts the gun in Pushout
Mode. When initiated, the RCS-2 will immedi-
ately turn off the catalyst pump and speed up the
resin pump to maintain the target flow rate that
was being sprayed prior to the initiation of the
pushout signal. (Note that this pushout signal is
a maintained signal.) The RCS-2 will continue to
deliver fluid out of the first dual purge side until
the volume programmed in for mixed volume has
been sprayed and then that gun will automatical-
ly be halted (taken out of run mode). This state
will be recognized by the PLC or robot when the
Run output from the RCS-2 turns off. For more
information on using this function, refer to the
Operator’s Manual.
Volume Fill with Fast Fill Mode:
It is possible to Volume Fill and Fast Fill simultane-
ously. If the gun is put into Volume Fill mode, and
then the Fast Fill input is pulsed, the unit will run
in Fast Fill mode until the volume programmed in
for fill volume is dispensed. At that time, the gun
will be halted. This happens regardless of the
condition of the gun trigger inputs so make sure
the applicator is triggered or an overpressure fault
may occur. When it is desirable to run both modes
in parallel, it is important to watch the Run output
bit to insure the unit has in fact gone into Volume
Fill mode prior to sending the Fast Fill bit.
DISCRETE CHANNEL AND
GUN OUTPUTS
Fault
This output is energized anytime a fault condition
is recognized by the software. Even if the fault is
disabled (known as a soft-fault) on the Configured
Alarms screen, this output will be energized as
long as the condition persists. Fluid flow will not
be halted when this output is energized unless it
is configured to do so on the Configured Alarms
screen. If it is configured to be a hard-fault, this
output and the Spray Shutdown output will both
be energized and the system will stop spraying
(see Spray Shutdown, below).
Run
This output is energized if the gun is configured
properly, a good job number has been loaded,
and the gun has been placed in Run mode or the
Volume Fill mode. This output goes off if a fault
occurs, if it is Halted, or in the Ready state.
Spray Shutdown
This output is energized if a fault condition exists
and the specific fault that exists is enabled on
the Configured Alarms screen (turned on). This
indicates that the flow of fluid from the fluid panel
has been stopped as the result of a detected fault
condition.
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 29
Flush Request
This output is energized when the pot-life timer
has expired. (For more information, see Mixed
Volume and Pot-Life Timer in the Operation’s
Manual.)
Motor On
This output is energized by the software when
it wants the motor to turn. As long as this output
is enabled and the motor amplifier is not faulted,
the pump will be held rigid in place by the motor
amplifier. If this output is not on, the pump is al-
lowed to free-wheel.
RECOMMENDED DIGITAL
I/O TIMING SEQUENCES
The recommended timing sequences below
should be used when controlling the RCS-2 from
a PLC. Time displayed in these charts should be
programmed to be approximately 0.25 second
(250 milliseconds) if the RCS-2 is connected via
discrete I/O or if done via RIO with the RCS-2
being the only remote device on the RIO channel.
If there are additional devices on the RIO channel
(including additional RCS-2 racks), this time may
(and probably will) have to be extended. (This
assumes a baud rate of 230 KBaud
RECOMMENDED DIGITAL I/O TIMING SEQUENCES
Action Signal Sequence Notes
Run Input
Gun Active Output
Spray Shutdown Output
Halt/Reset Input
Gun Active Output
Run Input
Placing the
Gun in
Run Mode
It is necessary to
put the gun in run
mode to enable it
prior to sending it
a trigger signal to
start flow.
Fault, Halt/Reset
then Run
If a gun is faulted
and it is necessary
to clear the fault
and put it back in
run mode, use this
sequence.
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 30
RECOMMENDED DIGITAL I/O TIMING SEQUENCES
Action Signal Sequence Notes
Run Input
Gun Active Output
Spray Shutdown Output
Halt/Reset Input
Volume Fill Input
Gun Active Output
Trigger Input
Run Input
Fault, Halt/Reset
then Run
If a gun is faulted
and it is necessary
to clear the fault
and put it back in
run mode, use this
sequence.
Volume Fill
followed by
Run
Volume Fill allows
the user to pro-
gram in a fill vol-
ume. When put in
this mode the unit
will flow material
until the fill volume
has flowed into the
fluid line and then
the unit will halt
and return to the
Ready state. The
unit should then be
placed in run mode
to await the trigger
signal.
Run Input
Gun Active Output
Fast Fill Input
Halt/Reset Input
Fast Fill
(Time-based)
Since 2k materials
are ratioed during
fast fills, it is neces-
sary to first put the
unit in run mode
then initiate fast
fill mode. A trigger
signal is not re-
quired. Use a halt
signal to exit fast
fill mode. (Pumps
spin immediately
upon reception of
the fast fill bit.
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 31
RECOMMENDED DIGITAL I/O TIMING SEQUENCES (Cont.)
Action Signal Sequence Notes
Volume Fill Input
Gun Active Output
Fast Fill Input
Run Input
Channel Fill Input
Gun Active Output
Halt/Reset Input
Volume Fill with
Fat Fill
It is possible to fast
fill while in volume
fill mode. Volume
fill mode must be
initiated first. Wait
for the active signal
to be asserted prior
to initiating the fast
fill bit.
Channel Fill
(A Fill, B Fill, or
AB Fill)
Gum must not be
in the run state to
use channel fill.
When a channel
fill is received, the
pump starts spin-
ning immediately,
a trigger signal is
not required. The
Gun Active output
is not asserted
while in A or B Fill
modes. A Halt is
required to take it
out of A or B Fill
modes.
Pushout Input
Gun Active Output
Run Input
Pushout Pushout mode al-
lows the user to
pushout a plural
component mate-
rial with a single
component materi-
al such as solvent.
The catalyst motor
is halted and the
resin motor speeds
up to maintain the
target flow rate.
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 32
RECOMMENDED DIGITAL I/O TIMING SEQUENCES (Cont.)
Action Signal Sequence Notes
Job Bit #40 Input
Job Strobe Input
Gun Run Input
Job Bit #20 Input
Job Bit #10 Input
Job Bit #8 Input
Job Bit #4 Input
Job Bit #2 Input
Job Bit #1 InputStrobe in New
Job Number
When loading a
new job, the job
bits must be as-
serted prior to
strobing the gun
strobe input bit and
those bits should
remain on slightly
after the strobe bit
goes off.
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 33
RECOMMENDED
SEQUENCES FOR BLOCK
TRANSFERS
The recommended sequences below should be
used when sending and receiving data to and
from the RCS-2 from a PLC via the RIO link. Time
Note 1: Keep in mind that for a dual component gun, steps 2 through 7 have to be executed twice, once for the
resin, then again for the catalyst. Then, if it is necessary to reset the totals, a third set of steps is required to do
the reset.
Note 2: There are two digital output bits, Fault and Spray Shutdown. If the fault that occurs is configured as a
soft-fault (disabled on the Config Alarms screen) the Fault output bit goes on but the Spray Shutdown bit does
not. If the fault that occurs is configured as a hard-fault, both the Fault bit and the Spray Shutdown bit go on
and the unit shuts down (stops spraying). It is up to the programmer to decide if they want to retrieve fault data
under either or both conditions.
Note 3: Anytime data is changed in the RCS via RIO it should be done in a read-modify-write pattern since only
one parameter cannot be sent at a time. This will insure that bad data is not sent to the RCS unit as it does not
filter data that comes in via RIO as it does the data coming in from the user-interface P.C.
RECOMMENDED SEQUENCES FOR BLOCK TRANSFERS
Action Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8
Retrieving
Flow Total-
ization Data
(See note 1)
Retrieving
Fault Data
(See note 2)
Modifying
System,
Job, Gun,
or Channel
Parameters
(See note 3)
Wait: After the
trigger has
turned off after
spraying the
last part, wait
one second
to allow the
interface card
to gather data
from the chan-
nel card(s).
Monitor: Mon-
itor either the
Fault output bit
or the Spray
Shutdown bit
via discrete
I/O or via RIO.
Execute BTW
(System, Type
03) (Gun, Type
04) (Channel,
Type 05) (Job,
Type 06)
Execute:
BTW (Type 07)
Execute:
BTW (Type 08)
Wait:
For response
from the RCS
that it has
received the
BTW.
Wait: For
response from
the RCS that
it has received
the BTW.
Wait: For
response from
the RCS that
it has received
the BTW.
Execute: BTR,
asking RCS to
send data.
Execute: BTR
(Type 07),
asking RCS to
send data.
Execute: BTR
(Type 08),
asking RCS to
send data.
Wait: For
response from
RCS that it
has completed
sending the
requested
data.
Wait: For
response
from RCS
that it has
completed
sending the
requested
data.
Wait: For
response
from RCS
that it has
completed
sending the
requested
data.
Check for
Errors: Check
RIO status
register to
insure no er-
rors occurred
during trans-
mission. (If
there was an
error, resend
the BTR)
Check for
Errors: Check
RIO status
register to
insure no er-
rors occurred
during trans-
mission. (If
there was an
error, resend
the BTR)
Check for
Errors: Check
RIO status
register to
insure no er-
rors occurred
during trans-
mission. (If
there was an
error, resend
the BTR)
Modify the
parameter or
parameters in
PLC tempo-
rary storage
register(s) that
you wish to
change in the
RCS.
Copy and use
data: Copy the
data returned
from tempo-
rary storage
location in PLC
to area used
for storage or
manipulation
of data.
Copy and use
data: Copy the
data returned
from tempo-
rary storage
location in PLC
to area used
for storage or
manipulation
of data.
Execute BTW
to send modi-
fied data back
to RCS.
Check RIO
status register
to insure no
errors oc-
curred during
transmission.
is not indicated on this chart as it will vary from
system to system (based on how busy the RIO
channel is). If there are additional devices on the
RIO channel (including additional RCS-2 racks),
times will be extended. (Once again, it is highly
recommended that a baud rate of 230 KBaud be
used on the RIO link.)
RCS-2 Programmer’s Manual - Appendix
LN-9409-03.2 34
LN-9409-03.2 replaces Service Manual LN-9409-03.1, with the following changes:
1. Updated column heads (Page 7).
2. Updated column heads (Page 8).
3. Updated items 1 and 5 in table 2 (Page 11).
4. Add new page indicating manual changes (2nd page).
5. Update safety information (Page 2).
6. Update logo and design of back page (Back Page).
April 1, 2009
(Rev. E), Pages 5 and 6: Dip switch settings for RIO
Rack Address 20 – 23, 30 – 34, 40 - 47 corrected.
April 17, 2009
(Rev. E), Page 9: Changed Spare User Link text
in table to User Link Active.
MANUAL CHANGES
RCS-2 Programmer’s Manual - Manual Changes
LN-9409-03.2 35
WARRANTY POLICIES
LIMITED WARRANTY
Ransburg will replace or repair without charge any
part and/or equipment that falls within the specified
time (see below) because of faulty workmanship
or material, provided that the equipment has been
used and maintained in accordance with Ransburg’s
written safety and operating instructions, and has
been used under normal operating conditions.
Normal wear items are excluded.
THE USE OF OTHER THAN RANSBURG
APPROVED PARTS, VOID ALL WARRANTIES.
SPARE PARTS: One hundred and eighty (180) days
from date of purchase, except for rebuilt parts (any
part number ending in R) for which the warranty
period is ninety (90) days.
EQUIPMENT: When purchased as a complete unit,
(i.e., guns, power supplies, control units, etc.), is
one (1) year from date of purchase. WRAPPING
THE APPLICATOR IN PLASTIC, SHRINK-WRAP,
ETC., WILL VOID THIS WARRANTY.
RANSBURG’S ONLY OBLIGATION UNDER
THIS WARRANTY IS TO REPLACE PARTS
THAT HAVE FAILED BECAUSE OF FAULTY
WORKMANSHIP OR MATERIALS. THERE ARE
NO IMPLIED WARRANTIES NOR WARRANTIES
OF EITHER MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE. RANSBURG
ASSUMES NO LIABILITY FOR INJURY, DAMAGE
TO PROPERTY OR FOR CONSEQUENTIAL
DAMAGES FOR LOSS OF GOODWILL OR
PRODUCTION OR INCOME, WHICH RESULT
FROM USE OR MISUSE OF THE EQUIPMENT
BY PURCHASER OR OTHERS.
EXCLUSIONS:
If, in Ransburg’s opinion the warranty item in
question, or other items damaged by this part
was improperly installed, operated or maintained,
Ransburg will assume no responsibility for repair or
replacement of the item or items. The purchaser,
therefore will assume all responsibility for any cost
of repair or replacement and service related costs
if applicable.
RCS-2 Programmer’s Manual - Warranty
LN-9409-03.2 36
Form No. LN-9409-03.2
Litho in U.S.A.
01/16
© 2025 Binks US, LLC
All rights reserved. Models and specifications subject to change without notice.
