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Appendix D: Communication Configuration

Appendix

Appendix

Appendix D:

D:

D: Communication

Communication

Communication Configuration

Configuration

Configuration

When installing a system, each component requires
communication cables. See the diagram below for
sample configurations.

NOTE:

NOTE:

NOTE: The last fiber optic converter in the system
must have the RS-485 termination resistor installed
on the uncabled connector to properly terminate the

circuit. The termination resistor is installed on the
fiber optic converter in the Supervisor Box in the
factory. Relocate it if additional fiber optic converters
are installed in the system.

Allen

Allen

Allen Bradley

Bradley

Bradley PowerFlex

PowerFlex

PowerFlex

C1 C2

C1 C2

Master

4

5

TxRxD-

TxRxD+

TxRxD-

TxRxD+

TxRxD-

TxRxD+

Shield

Shield

Shield

120 ohm resistor

120 ohm resistor

X

X

X

FRONT

PIN 8

PIN 1

TxRxD-

TxRxD+

RS485

(DSI)

RS485

(DSI)

AK-U0-RJ45-TB2P

R/L1S/L2 T/L3 U/T1V/T2W/T3

R/L1S/L2 T/L3 U/T1V/T2W/T3

BR+

BR-

DC-DC+

BR+

BR-

DC-DC+

TxRxD-

TxRxD+

PowerFlex 525

Node 1

4

5

PowerFlex 523

Node 2

4

5

PowerFlex 525

Node “n”

Figure 106 Modbus Wiring Diagram

TxRxD+ = B(+)

TxRxD- = A(-)

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Summary of Contents for 25A693

Page 1: ... a paint paint paint kitchen kitchen kitchen For For For professional professional professional use use use only only only Important Important Important Safety Safety Safety Instructions Instructions Instructions Read all warnings and instructions in this manual and all related manuals before using the equipment Save Save Save these these these instructions instructions instructions Touchscreen Bo...

Page 2: ...trol Components Components Components The following components are described in this manual For all other components see the specific component manual Part Part Part No No No Description Description Description Usage Usage Usage Operating Operating Operating Voltage Voltage Voltage Approvals Approvals Approvals 25A693 Touchscreen Box Used to monitor and control functions of the paint kitchen compo...

Page 3: ...r 3A4409 E Flo DC Motor Three Phase 3A2527 E Flo DC Control Module Kit Pump Control Module 3A5991 Tank Control Module Kit 3A5753 Reed Switch Cycle Count Kit 406421 Proximity Sensor Accessory Kit 311595 Pneumatic Back Pressure Regulators 3A4548 Electric Driven Back Gear Drum Agitators 3A4553 Electric Direct Drive Agitator 3A4793 Variable Frequency Drives 313542 Beacon Tower The following component ...

Page 4: ...ns Never spray of flush solvent at high pressure Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into a pail Do not use pail liners unless they are antistatic or conductive Stop Stop Stop oper...

Page 5: ...the lowest rated system component See Technical Technical Technical Specifications Specifications Specifications in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Technical Technical Specifications Specifications Specifications in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your mat...

Page 6: ...he Pressure Pressure Pressure Relief Relief Relief Procedure Procedure Procedure and disconnect all power sources PERSONAL PERSONAL PERSONAL PROTECTIVE PROTECTIVE PROTECTIVE EQUIPMENT EQUIPMENT EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This equipment includes but is not ...

Page 7: ...feet 330 meters away from the fluid handling components Sensors continuously monitor conditions within the fluid circulation system Typically data such as tank level agitator speed pressure at one or more locations and flow rate is collected from each station and sent to a Pump Control Module which is attached to each agitator and pump The Pump Control Module and Tank Control Module allow local co...

Page 8: ...known as PLC The Supervisor Box converts information from the Graco Touchscreen Box J or Programmable Logic Controller into fiber optic signals used by the system components One Supervisor Box can control up to 10 stations 20 if an Expansion Box is used Each station is connected to the Supervisor Box with a pair of optical fiber cables B Variable Frequency Drive In verter page 16 Controls the spee...

Page 9: ...aint kitchen circulation lines Each Pressure Transducer communicates with the Supervisor Box A which monitors the pressure and controls the E Flo DC Pump C to maintain the fluid pressure of the fluid leaving the pump The Pressure Transducer can monitor pressure at the pump outlet at the Back Pressure Regulator E or both L Agitator Primary Tank page 15 Continuously mixes and stirs the contents prev...

Page 10: ...e for use in the hazardous location One is needed for each Secondary Tank H that uses an electric agitator R or Radar Level Sensor T The Tank Control Module connects to related components in the hazardous location and to the Pump Control Module PD providing a communication connection between the station and the Supervisor Box A U Run Stop Switch page 13 When installed stops or pauses the E Flo DC ...

Page 11: ...w sensors connect to the Pump Control Module PD Each pump can be locally controlled using its Pump Control Module See Pump Control Module PD 24P822 17V232 page 12 To set up connections to the E Flo pump see Connections to the E Flo DC Pump page 26 For complete warnings and operation instructions see the following manuals E Flo DC 2 Ball Piston Pump manual 333389 E Flo DC 4 Ball Piston Pump manual ...

Page 12: ... to the Intelligent Paint Kitchen software Figure 4 Pump Control Module For information on connecting cables to the correct ports for pump control see the cable connection section of the DC Control Module Kit manual 3A2527 and Set Up Pump Control Module Configurable I O page 49 in this manual See the DC Control Module Kit manual 3A2527 for complete warnings and operation instructions Pressure Pres...

Page 13: ...ontroller pass through the Pump Control Module allowing for closed loop pressure control in the circulation line For complete warnings and operation instructions see the Pneumatic Back Pressure Regulator manual 311595 Figure 5 Back Pressure Regulator and Controller Run Stop Run Stop Run Stop Switch Switch Switch U U U 16U729 16U729 16U729 Install the Run Stop Switch U using the Run Stop Switch Kit...

Page 14: ...l Module Connect the Tank Control Module to a fiber optic converter in the Supervisor Box A NOTE NOTE NOTE The Pump Control Module and Tank Control Module look identical to each other but they are not interchangeable Each type of control module has its own unique software installed Figure 6 Tank Control Module For complete warnings and operation instructions see the Tank Control Module manual 3A59...

Page 15: ... the Pneumatic Remote Transfer Fill Pump Agitator Agitator Agitator L L L R R R One agitator L R is typically mounted on each tank The agitator s purpose is to keep the fluid mixed without incorporating air into the fluid Each agitator may be electric or pneumatic however the Intelligent Paint Kitchen system can only communicate with an electric agitator An electric agitator s speed is controlled ...

Page 16: ... three phase 1 17N042 208 240 VAC single or three phase 208 240 VAC three phase 1 17N043 380 480 VAC three phase 380 480 VAC three phase 1 One Variable Frequency Drive Inverter is needed for each electric agitator in the system Software installed in each Variable Frequency Drive Inverter allows communication between each Variable Frequency Drive Inverter and the Supervisor Box A Warnings installat...

Page 17: ...map with each node slotted in a specific set of addresses The Supervisor Box can communicate via Modbus TCP with the Touchscreen Box J The Supervisor Module can manage up to 20 stations Up to 10 fiber optic converters can fit in the Supervisor Box If additional fiber optic converters are needed beyond what fits in the Supervisor Box an Expansion Box can be used to create more space See Expansion B...

Page 18: ...onnection is made between each fiber optic converter and the Supervisor Module and the fiber optic converters within one Supervisor Box or one Expansion Box are all wired in series to the 24 VDC power supply Figure 11 Serial to Fiber Optic Converter Item Item Item Description Description Description 39 Serial communication connection to Supervisor Module 40 24 VDC power connection RX Fiber optic c...

Page 19: ...Box The Expansion Box has a DC power supply installed to provide power to the fiber optic converters Expansion Boxes are shipped with one fiber optic converter 38 installed Each box also contains one power supply 35 and one Supervisor Module 36 Install up to 12 fiber to optic converters 38 in each Expansion Box needed by the system Figure 12 Expansion Box Components Ref Ref Ref Function Function F...

Page 20: ...chen components and change operating conditions A 2 GB SD flash card can be used to install and update the software used by the Touchscreen Box The SD card must be formatted using the FAT16 file system A USB cable can be connected to download the stored log files generated by the Intelligent Paint Kitchen system Figure 13 Touchscreen Box Components Ref Ref Ref Function Function Function 2 Power ro...

Page 21: ...he bottom of the Touchscreen Box Figure 14 Touchscreen Box Connections Ref Ref Ref Function Function Function TSA Power TSB USB device connection for PC USB B TSC RS 485 Port B not used TSD Auxiliary Ethernet Port 2 Modbus TCP connection TSE USB host connection for jump drive TSF Ethernet Port 1 LAN TSG RS 232 Port A PGM not used TSH RS 485 Port A not used TSJ RS 232 Port B not used 3A4030C 21 ...

Page 22: ...cable splitter 17R629 to make the connections Connections Connections Connections in in in a a a System System System with with with One One One Pump Pump Pump Control Control Control Module Module Module and and and No No No Tank Tank Tank Control Control Control Module Module Module Hazardous Hazardous Hazardous Location Location Location Non Non Non Hazardous Hazardous Hazardous Location Locati...

Page 23: ... Module and and and One One One Tank Tank Tank Control Control Control Module Module Module Hazardous Hazardous Hazardous Location Location Location Non Non Non Hazardous Hazardous Hazardous Location Location Location Figure 16 Ref Ref Ref Component Component Component A Supervisor Box fiber optic converter M Primary Tank Radar Level Sensor S DC Power Supply with Barrier 3A4030C 23 ...

Page 24: ...s Hazardous Location Location Location Non Non Non Hazardous Hazardous Hazardous Location Location Location Figure 17 Ref Ref Ref Component Component Component A Supervisor Box fiber optic converter C Pump E Flo DC shown F Back Pressure Regulator Controller K Pressure Transducer M Primary Tank Radar Level Sensor P Fill Pump Transfer Solenoid PD Pump Control Module S DC Power Supply with Barrier T ...

Page 25: ...pending on the number of stations the configuration and the specific components being used The following general steps apply to most Intelligent Paint Kitchens 1 Mount the components Supervisor Box Variable Frequency Drive Touchscreen Box and DC Power Supply with Barrier in the non hazardous location 2 Make all required ground connections 3 Connect the components together in the non hazardous loca...

Page 26: ...CAN cable Use cable 16P911 3 feet 1 meter or cable 16P912 25 feet 8 meters as needed 1 Connect one end of the cable to the power terminal PT on the motor 2 Connect the other end of the cable to Port 3 on the bottom of the Pump Control Module Figure 18 Pump Control Module Connections to E Flo DC Pump Single Phase Figure 19 Pump Control Module Connections to E Flo DC Pump Three Phase Connections Con...

Page 27: ...ufacturer s manual that is shipped with the product Connect Connect Connect a a a Radar Radar Radar Level Level Level Sensor Sensor Sensor to to to a a a Pump Pump Pump Control Control Control Module Module Module or or or Tank Tank Tank Control Control Control Module Module Module Use this procedure to connect a Radar Level Sensor M T to a Pump Control Module PD or Tank Control Module TD For info...

Page 28: ...er jumper wires Figure 24 Variable Frequency Drive Inverter Jumper Wires Termi Termi Termi nal nal nal Description Description Description Note Note Note 1 Digital Input Start Stop Input resistance 4 3 kΩ 2 Analog Common 5 Analog Input 0 10 VDC Input resistance 50 kΩ Termi Termi Termi nal nal nal Description Description Description Note Note Note 6 Internal DC supply for speed pot 10 VDC max 10 mA...

Page 29: ...wiring For more information see Modbus RS 485 Wiring page 34 5 Plug the connector into the RS 485 module 6 Align the terminal cover for re fitting 7 Connect the RS 485 module cord to the drive 8 Close the cover and secure it Label Label Label All All All Mounted Mounted Mounted Components Components Components As a best practice to avoid confusion clearly label each component mounted in the non ha...

Page 30: ... be provided during installation Branch circuit protection of 15 amp maximum must be provided during installation Power wires must be made of copper and have a minimum temperature rating of 60 C 140 F The wire gauge size must be 12 14 AWG 1 Turn off power rocker switch 2 to ensure the Supervisor Box A is off 2 Open the electrical enclosure door 3 Route the power cable through the strain relief in ...

Page 31: ... Rail Rail Improper wiring may cause electric shock or other serious injury if work is not performed properly Turn off and disconnect power at the main switch before servicing or installing equipment Disconnect the power before servicing the equipment Components located inside the Supervisor Boxes and Expansion Boxes are to be mounted on a 35 mm standard DIN rail The DIN rail clip on each componen...

Page 32: ...hes before mounting the fiber optic converters inside the Supervisor Box or Expansion Box These settings are for RS 485 two wire cable connections Set the selector switch to RS 422 485 Use the settings in the DIP Switch Settings 57600 baud rate figure for systems using a 57600 baud rate Use the settings in the DIP Switch Settings 38400 baud rate figure for systems using a 38400 baud rate In the fo...

Page 33: ... shipped with one fiber optic converter installed and connected to the 24 VDC power supply If multiple converters are installed in the box connect them to the Supervisor Box power supply as shown in the following figure Connect 24 VDC Power Supply to Fiber Optic Converters When installing wires torque terminals to 4 4 5 3 in lb 0 5 0 6 N m Expansion Expansion Expansion Boxes Boxes Boxes If used Ex...

Page 34: ...dentifying Label Modbus Modbus Modbus RS RS RS 485 485 485 Wiring Wiring Wiring If a Supervisor Box A contains more than one fiber optic converter the converters must be wired in series and the first converter connected to the Supervisor Module 36 Use solid blue and white blue RS 485 data communication rated cables On the final fiber optic converter in the series install a 120 ohm resistor to term...

Page 35: ...nnected to the Supervisor Module 36 in one long series NOTE The Modbus RS 485 shield wire is intended to be connected to the EMC ground terminal 7a in the Supervisor Box A only Figure 33 Fiber Optic Converters in an Supervisor Box shown at left Wired in Series to the Expansion Box shown at right Figure 34 Detail Ground the Wired Series at the Supervisor Box EMC Ground Terminal 3A4030C 35 ...

Page 36: ...ve Inverter to control the agitator connect a blue and white blue twisted wire from the Variable Frequency Drive Inverter to the last fiber optic converter in the wired series Figure 35 Connect a Variable Frequency Drive Inverter Lenze model shown at top to the Supervisor Module shown at bottom If a station is connected to multiple Variable Frequency Drives Inverters wire the Variable Frequency Dr...

Page 37: ...ply cord NOTE A means of disconnect must be provided during installation Branch circuit protection of 15 amp maximum must be provided during installation Power lines must be made of copper and have a minimum temperature rating of 60 C 140 F The wire gauge size must be 12 14 AWG 1 Turn off power rocker switch 2 to ensure the Expansion Box is off 2 Open the electrical enclosure door 3 Route the powe...

Page 38: ...ble FA into Port 1 and Port 2 on the Tank Control Module b Plug the two connectors at the other end of cable FA into Port 5 and Port 6 on the Pump Control Module 3 Connect the Pump Control Module in the hazardous location to a fiber optic converter in the Supervisor Box in the non hazardous location a Plug the two connectors at one end of cable FB into Port 1 and Port 2 on the Pump Control Module ...

Page 39: ...le Length Length Length 17T898 10 feet 3 m 16M172 50 feet 16 m 16M173 100 feet 30 m 17B160 330 feet 100 m Use cables 17T898 16M172 16M173 or 17B160 depending on the length needed Graco recommends using the shortest cable needed to make the fiber optic connections Figure 39 Connect Fiber Optic Converter to Pump or Tank Control Module 3A4030C 39 ...

Page 40: ... must be provided during installation Branch circuit protection of 15 amp maximum must be provided during installation Power wires must be made of copper and have a minimum temperature rating of 60 C 140 F The wire gauge size must be 12 14 AWG 1 Turn off power rocker switch 2 to ensure the Touchscreen Box is off 2 Open the electrical enclosure door 3 Route the power cable through the strain relief...

Page 41: ...rvisor Box A Connect a CAT5 Ethernet cable from Ethernet port 2 on the Touchscreen Box to either Ethernet port on the Supervisor Box Figure 41 Connect the Supervisor Box bottom to the Touchscreen Box top I O I O I O Module Module Module 17T198 17T198 17T198 The I O module is part of the optional light tower kit 122193 Indicator Indicator Indicator Terminal Terminal Terminal Common 1 and 4 Red ligh...

Page 42: ... Remove the rubber module plug PL Figure 43 Attach the I O Module b Use two screws to secure the I O module to the Touchscreen Module Tighten to 6 in lb 0 68 N m 4 Install a black jumper wire between terminals 1 and 4 on the I O module 5 Connect the light tower wires to the I O module as follows Orange wire Connect to terminal 3 Green wire Connect to terminal 5 Red wire Connect to terminal 2 6 To ...

Page 43: ...NOTE If you turn the power off to the Touchscreen Box only the system continues to operate Power Power Power On On On Turn the AC Power Switches 2 on I ON 0 OFF for each of the following Intelligent Paint Kitchen components Touchscreen Box Supervisor Box or Boxes Expansion Box or Boxes The Graco logo displays while the system initializes followed by the Stations screen Figure 45 Power Switches On ...

Page 44: ...elligent Paint Kitchen software in the non hazardous location and the following components in the hazardous location of the station Level Sensor for the Primary Secondary Tank Agitators M T Pneumatic Fill Pump Transfer Solenoid P NOTE NOTE NOTE When a station contains both a Pump Control Module and a Tank Control Module some component connections move from the Pump Control Module to the Tank Contr...

Page 45: ...p It does not set the speed or pressure of each pump Later in this setup process you can create pump profiles that determine pump operation under different conditions See Create Pump Profiles page 85 Set Set Set Up Up Up Tank Tank Tank Controls Controls Controls For complete warnings and operation instructions see the Tank Control Module Kit manual 3A5991 Tank Tank Tank Control Control Control Mod...

Page 46: ... I O page 51 Enter the unique node ID generated by the Intelligent Paint Kitchen software for the control module See Configure Each Station page 64 See the E Flo DC Control Module Kit manual 3A2527 or the Tank Control Module Kit manual 3A5991 for complete warnings and operating instructions including how to use the keypad to access and change the software settings Figure 46 Control Module Keypad a...

Page 47: ...rol module Setup screens 2 Use the Up Arrow and Down Arrow keys to navigate to Setup Screen 14 Figure 47 Setup Screen 14 3 Confirm that Pump 1 is displayed on the Pump No menu If not highlight the menu and select 1 Figure 48 Setup Screen 14 Pump Menu 4 Select a control location local or remote from the menu Figure 49 Setup Screen 14 Local or Remote Control Location Menu 5 Set the Modbus node ID fr...

Page 48: ... Down Arrow keys to navigate to Setup Screen 5 Figure 52 Setup Screen 5 3 Select a control location local or remote from the menu Figure 53 Setup Screen 5 Local or Remote Control Location Menu 4 Set the Modbus node ID from 1 to 247 Figure 54 Setup Screen 5 Modbus Node ID Field 5 Select a Modbus communications failure notification type from the menu Select X for disabled or for deviation Figure 55 ...

Page 49: ...reed switch to be connected The current reed switch cycle rate appears next to the cycle rate icon in cycles per minute Agitator Halt Drum Cover Switch Configures Port 4 pin 4 as an input to allow a pressure switch to be connected If the drum cover is lifted while this configuration is properly connected the agitator shuts down The current input status appears in the agitator status field A Superv...

Page 50: ...olume of the Primary Tank Select the manual output box and hold the button to control the output manually After you release the button the manual activation is terminated Auxiliary Solenoid Configures Port 4 pin 4 as an output to allow for another solenoid to be connected and controlled from the device Select the manual output box and hold the button to control the auxiliary solenoid manually Afte...

Page 51: ...rm Output Secondary Tank Low Alarm Output General Purpose Output Select the manual output box and hold the button to control the auxiliary solenoid manually After you release the button the manual activation is terminated 5 When all control module settings are correct press the Exit Screen key to exit setup mode Set Set Set Up Up Up a a a Radar Radar Radar Level Level Level Sensor Sensor Sensor Us...

Page 52: ...text press these two keys to close the help text for a parameter Press these two keys for two seconds to return to the home screen For text and numeric fields press these two keys to close the editor without applying changes Press E E E to enter the setup screen press to highlight the setup menu and then press E E E to enter the setup menu Enter the setup information for each screen Setup Setup Se...

Page 53: ... is defined manually in the Mapping Mapping Mapping end end end point point point parameter Distance OK The measured distance matches the actual distance Distance unknown The actual distance is unknown Distance too small The measured distance is less than the actual distance Distance too big The measured distance is more than the actual distance Tank empty The tank is completely empty Delete map D...

Page 54: ...ut of Local mode and set it to communicate with the Intelligent Paint Kitchen software When this procedure has been completed Variable Frequency Drive Inverter settings and operation are controlled from the Intelligent Paint Kitchen software with no local control at the Variable Frequency Drive Inverter display and keypad Operating Operating Operating the the the Variable Variable Variable Frequen...

Page 55: ...ital Input 21 External Fault NOTE Wire in a motor thermal overload switch P194 Password 0 Allows the Supervisor Module to control the Variable Frequency Drive Inverter P400 Network Protocol 02 Modbus RTU P410 Network Address 101 120 for a primary agitator 121 140 for a secondary agitator Set to the node ID generated by the Intelligent Paint Kitchen for this Variable Frequency Drive Inverter P411 N...

Page 56: ...nstructions for complete menu descriptions and information NOTE NOTE NOTE Entering the correct node ID into each Variable Frequency Drive Inverter allows the Intelligent Paint Kitchen software to communicate with each Variable Frequency Drive Inverter It does not tell the Variable Frequency Drive Inverter the speed of each agitator motor during operation You can use the Intelligent Paint Kitchen s...

Page 57: ...the current production schedule for the system See Manage Production Schedule page 98 Graphs Screen Displays live and historical operational data for station components See View the Graphs Screen page 100 Stations Screen Displays an overview of station component status Use this screen to navigate to detailed screens for each component See View the Stations Screen page 102 Pumps Screen Displays the...

Page 58: ...tings menu Navigate through the software by pressing buttons keys fields and icons with your finger Pressing any of the controls on the screen brings you to another screen or displays a popup screen that requires your input NOTE NOTE NOTE Selection fields and buttons that are grayed out on the screens are not currently active Table Table Table 3 3 3 Touchscreen Touchscreen Touchscreen Controls Con...

Page 59: ...ld Press Cancel twice to close the popup screen without changing any values Press Return to keep the entered values and close the popup screen Numeric keypads display the range of valid entries Only valid entries are accepted when you press Return An onscreen keyboard displays when text input is needed for example when entering a name for each station in your system Press the keys to enter text in...

Page 60: ...een icons along the bottom of the Touchscreen interface For example you could navigate to the Primary Agitator Status screen either from the Stations screen or from the Station Status screen Depending on which Run screen icon is highlighted in green you know the path you took to get there For ease of navigation the Run screen icon that you pressed is highlighted in green Press one or more times to...

Page 61: ...hen installation Use this screen to specify the components that are installed and node IDs where needed Follow the procedure in Configure Each Station page 64 Node Communication Press to display the Node Communication screen used to perform these functions Set up pump control nodes See Pump Control Module Nodes page 45 Set up tank control nodes See Tank Control Module Nodes page 45 Set up Variable...

Page 62: ...his feature to set the inactive time after which the screen saver is displayed Set the time and the date See Set the Time and Date page 136 Press Utilities Utilities Utilities to display the Utilities Menu screen used to access these Intelligent Paint Kitchen software functions Format and use an SD card in the Touchscreen Module See Use an SD Card page 135 Format and use a USB drive in the Touchsc...

Page 63: ...Create Create the the the Stations Stations Stations Begin the setup process by entering the number of stations in the system The system creates each station and assigns a number 1 20 that corresponds to each station 1 Press on any Run screen to enter the Setup Menu screen The Number Number Number of of of Stations Stations Stations field indicates the number of stations that currently exist 2 Pre...

Page 64: ... Number Number field NOTE For a newly created station all fields on the Station Configuration screen contain No No No or None None None 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured 5 One at a time press each item s response field and use the keypad to specify the equipment used in the selected station For a list of field descriptions...

Page 65: ...talled Secondary VFD Select the manufacturer of the Variable Frequency Drive Inverter used to control the agitator installed on the Secondary Tank Lenze Lenze Lenze or PowerFlex PowerFlex PowerFlex 4M 4M 4M See Variable Frequency Drive Inverter B 17N041 17N042 17N043 page 16 for supported Variable Frequency Drives Inverters Select None None None if there is no Variable Frequency Drive Inverter for...

Page 66: ...c converter before creating and naming the stations You could also do this in the opposite order by first creating the stations in the Intelligent Paint Kitchen software then naming each station and then connecting each fiber optic converter to the corresponding station Each physical station must be connected to the one fiber optic converter that matches the station number generated by the softwar...

Page 67: ...s VFD VFD VFD Nodes Nodes Nodes to turn on communication to each Variable Frequency Drive Inverter in the system Each primary Variable Frequency Drive Inverter controls the speed of a Primary Tank agitator Each secondary Variable Frequency Drive Inverter controls the speed of a Secondary Tank agitator 4 Initially the blue Off Off Off button indicates that all communication is turned off between th...

Page 68: ... Setup menu screen 2 Press E Flo E Flo E Flo DC DC DC 3 On the E Flo DC Setup screen press the Station Station Station Number Number Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured in the following steps The station name is displayed directly below the station ...

Page 69: ...ute cc min cc min cc min Cubic centimeters per minute oz min oz min oz min Ounces per minute Cycles min Cycles min Cycles min Cycles per minute Agitator Speed Units Select the units for the agitator speed of the pump or tank Hz Hz Hz RPM RPM RPM Stop BPR Enter a number 0 100 to specify the percentage of back pressure regulation to hold fluid line pressure when the pump is stopped Remote Run Stop E...

Page 70: ... Production Profile Enable Disable Off Production mode on pump Profile 4 indicates Off Production station with no tank control Tank Fill is disabled Tank Freeze alarm is enabled Production Profile Enable Disable Production profile Profile 1 becomes the production profile 70 3A4030C ...

Page 71: ...Station Station Number Number Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured in the following steps The station name is displayed directly below the Station Number 5 Press each item s response field and use the keypad that displays to specify the equipment use...

Page 72: ...e function Reed Reed Reed Switch Switch Switch Count Count Count Used to count the cycle rate of the fill pump Agitator Agitator Agitator Halt Halt Halt When the pressure switch attached to the tank cover elevator closes the pump control automatically disables the primary agitator Auxiliary IO Function Select the function Reed Reed Reed Switch Switch Switch Count Count Count Input Input Input Used...

Page 73: ...ly the tank level percentage is displayed Figure 68 Primary Tank Screen 1 Press on any Run screen to enter the Setup menu screen 2 Press Primary Primary Primary Tank Tank Tank 3 On the Primary Tank screen press the Station Station Station Number Number Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field ...

Page 74: ...ppears Use this button to navigate to the Primary Tank Agitator setup Level Sensor Type Select the type of level sensor installed on this Primary Tank None None None Default Radar Radar Radar NOTE NOTE NOTE When a Level Sensor Type is configured the Volume Configuration button appears Use this button to navigate to the Primary Tank Volume Configuration setup Level Sensor Location Select the locati...

Page 75: ... Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured The station name is displayed directly below the Station Number 5 Press each item s data field and use the keypad that displays to specify the equipment used in the selected station NOTE NOTE NOTE For a newly cre...

Page 76: ... 16 Agitator Profile Select Enable Enable Enable to allow the primary tank agitator to be controlled by agitator profiles Select Disable Disable Disable to disable agitator profiles See Set Up Agitator Profile page 87 for more information about setting up agitator profiles Production Enable Select Enable Enable Enable to enable the following features When the system goes into production it will mo...

Page 77: ... Number Number Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured The station name is displayed directly below the Station Number 5 Press each item s data field and use the keypad that displays to specify the equipment used in the selected station NOTE NOTE NOTE F...

Page 78: ... the primary tank type Unknown Unknown Unknown Default Cylinder Cylinder Cylinder Volume Units Select the unit to display the primary tank volume Gallons Gallons Gallons Default Liters Liters Liters Length Units Select the unit used to specify tank dimensions in in in Default cm cm cm mm mm mm Diameter D Enter the primary tank diameter 0 0 999 9 Full Height F Enter the fluid height from the bottom...

Page 79: ...Tank 3 On the Secondary Tank screen press the Station Station Station Number Number Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured The station name is displayed directly below the Station Number 5 Press each item s data field and use the keypad that displays t...

Page 80: ... Hz Back Back Back Gear Gear Gear Maximum frequency of 43 Hz For part numbers see Appendix F Agitator Part Numbers page 159 NOTE NOTE NOTE When an Agitator Type is configured the Agitator button appears Use this button to navigate to the Secondary Tank Agitator setup Level Sensor Type Select the type of level sensor installed on this Secondary Tank None None None Default Radar Radar Radar NOTE NOT...

Page 81: ... Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured The station name is displayed directly below the Station Number 5 Press each item s data field and use the keypad that displays to specify the equipment used in the selected station For a list of fields see Fields on the Secondary Agi...

Page 82: ...43 page 16 Agitator Profile Select Enable Enable Enable to allow the secondary tank agitator to be controlled by agitator profiles Select Disable Disable Disable to disable agitator profiles See Set Up Agitator Profile page 87 for more information about setting up agitator profiles Production Enable Select Enable Enable Enable to enable the following features When the system goes into production i...

Page 83: ... Number Number Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured The station name is displayed directly below the Station Number 5 Press each item s data field and use the keypad that displays to specify the equipment used in the selected station For a list of fi...

Page 84: ...ect the secondary tank type Unknown Unknown Unknown Default Cylinder Cylinder Cylinder Volume Units Select the unit to display the secondary tank volume Gallons Gallons Gallons Default Liters Liters Liters Length Units Select the unit used to specify tank dimensions in in in Default cm cm cm mm mm mm Diameter D Enter the secondary tank diameter 0 0 999 9 Full Height F Enter the fluid height from t...

Page 85: ...em is in non production mode where a low flow rate or pressure is needed to circulate paint through the system Use this procedure to create up to four profiles for each pump Each profile determines how a pump performs under a set of specified conditions 1 Press on any Run screen to enter the Setup menu screen 2 Press Profiles Profiles Profiles 3 On the Profiles screen press Pump Pump Pump Figure 7...

Page 86: ...rking pressure Pressure Pressure Pressure The Intelligent Paint Kitchen uses output pressure from the pump to decide if this profile should be used In pressure mode the motor adjusts the pump speed to maintain the fluid pressure percentage If the flow limit is reached before the target pressure the unit stops driving to the pressure if set as an alarm Target Pressure Use the keypad to enter the pu...

Page 87: ...press the Station Station Station Number Number Number field 4 On the Station Station Station Number Number Number keypad enter the number of the station to be configured The number in the field is the station that is being configured The station name is displayed directly below the Station Number 5 Press each item s data field and use the keypad that displays to specify the equipment used in the ...

Page 88: ...minimum tank level 0 100 Minimum Level L Enter the minimum tank level 0 100 Maximum Speed Enter the maximum speed set point for the agitator at the maximum tank level 0 100 Maximum Level H Enter the maximum tank level 0 100 On Time Enter the On time when using agitator duty cycle The agitator will cycle between the specified On time and Off time 0 59 minutes Off Time Enter the Off time when using ...

Page 89: ...tup Screen Ref Ref Ref Item Item Item Description Description Description 1 Preset Production schedule preset 1 3 2 Time Each day offers up to 6 different times to toggle between production and off production 00 00 23 59 3 Day of Week Day of the week to be configured Monday Sunday 4 Production Off Production Production Off Production 3A4030C 89 ...

Page 90: ..._ symbols that might be used in an email address Figure 78 Email Address Screen Item Item Item Description Description Description User Name Optional Enter a name to identify the person who receives emails or text messages Email Address Enter the complete email address of the user The address must be in a format suitable for the required transport For example name domain To send a text message usi...

Page 91: ...tion Notification Notification Send Send Send a a a Test Test Test Email Email Email Message Message Message Use this procedure to send a test email to an email address to verify SMTP configuration 1 Press on any Run screen 2 On the Setup Menu screen press Email Email Email 3 On the Email Setup screen press SMTP SMTP SMTP 4 On the SMTP Server Configuration screen press Send Send Send Test Test Tes...

Page 92: ...d by your IT team to connect to your facility network for example 10 20 156 34 Subnet Mask Subnet mask that matches your network settings Gateway Gateway that matches your network settings DNS1 Your DNS1 setting DNS2 Your DNS2 setting MAC ID MAC ID of your device 6 Press Apply Apply Apply to enter the changes and have them take effect The Network Configuration screen appears again showing the upda...

Page 93: ...Edit Edit Edit Config Config Config b On the editable Supervisor Network Configuration screen press one of the data fields to be changed Use the popup screen to enter the network setting Field Field Field Value Value Value IP Address 192 168 1 201 Subnet Mask 255 255 255 0 Gateway 192 168 1 1 c Repeat as needed until all the network configuration settings are correct d To enter the changes and hav...

Page 94: ...p press Send Send Send Test Test Test Email Email Email For more information see Send a Test Email Message page 91 To check communication between the SMTP server and the Supervisor Module on the SMTP Server Configuration screen press Ping Ping Ping The Ping Status Success message appears if the connection is working 4 On the Email Setup screen press Users Users Users to enter contact information f...

Page 95: ...ny user who knows the current password can change or disable remove that password 1 Press on any Run screen 2 On the Enter Password screen press and log in using the current password 3 On the Setup Menu screen press Password Password Password 4 On the Password screen press the Enter Enter Enter Password Password Password field 5 On the Password popup screen enter a new password or disable the curr...

Page 96: ...y Levels Levels Levels There are two levels of Administrator access Administrator Administrator Administrator Right to access and change all values Operator Operator Operator Right to change E Flo DC active profile Figure 79 Security Levels Screen 96 3A4030C ...

Page 97: ...el Run screens to control the system and view current operating conditions in each station Access the Run screens by pressing the icon on the bottom of the Touchscreen interface See Manage Production Schedule page 98 See View the Graphs Screen page 100 See View the Stations Screen page 102 See View the Pumps Screen page 116 See View the Tanks Screen page 118 3A4030C 97 ...

Page 98: ...ef Ref Ref Item Item Item Description Description Description 1 Preset Current roduction schedule preset 1 3 2 Time Each day offers up to 6 different times to toggle between production and off production 00 00 23 59 3 Day of Week Day of the week to be configured Monday Sunday 4 Current Production Off Production Production Off Production 98 3A4030C ...

Page 99: ...Item Item Description Description Description 5 Stations Allows grouping of stations that will be controlled by the production schedule 6 Weekend Mode Sets all current preset Saturday and Sunday times to off production 3A4030C 99 ...

Page 100: ...ation 5 seconds Liters min Gallons min cc min oz min Cycles min Pump Speed Displays data on actual operating speed of the pump in the selected station 5 seconds Cycles per minute Transducer 1 Displays data obtained from pressure sensor 1 on the pump if the sensor is installed 5 seconds psi Bar MPa Transducer 2 Displays data obtained from pressure sensor 2 on the pump if the sensor is installed 5 s...

Page 101: ...on pressed on the Graph Menu screen 6 Shows the name of the currently selected station 7 Shows the date and time that data on the right edge of the screen was obtained 8 If the Intelligent Paint Kitchen controls multiple stations press the up or down arrow to display the current graph for a different station 9 Press to scroll one screen to the left and view older data 10 Press to scroll slightly t...

Page 102: ...ents one station that has been created and configured through the Intelligent Paint Kitchen software Each control icon displayed in a row indicates a component that is physically installed in the station and has been configured to communicate with the Intelligent Paint Kitchen software See Configure Each Station page 64 Any space that is empty does not contain an icon indicates a component that is...

Page 103: ...n On On The button changes to Off Off Off and turns blue to indicate that the station is disabled View the Station Status screen for a station Press the Station Station Station button for the station See Station Status Screen page 104 View the Pump Status screen for a station In the Pump Pump Pump column for the station press the pump icon See Pump Status Screen page 107 View the Primary Tank Stat...

Page 104: ...Status screen the Primary Tank Status screen the Secondary Tank Status screen and the Agitator Status screens for any components present in the selected station 3 2 11 12 13 1 5 6 14 15 16 17 18 7 8 9 10 4 Figure 83 Station Status Screen Ref Ref Ref Item Item Item Description Description Description 1 Station Number Displays the number of the station for which information is displayed Press to dis...

Page 105: ... the agitator is operating its blades are shown in motion on this screen 9 Tank Status Read only Displays the level of fluid in the Primary Tank 10 Select Pump Profile Press the image of the pump to display the Profile Select popup screen Use the popup to enable or disable a profile for the selected pump 11 E Flo DC Pump Status Read only Displays current operating conditions in the pump Profile Di...

Page 106: ...f the icon indicates the status of the agitator 17 Secondary tank icon Press to display the Secondary Tank Status screen The color of the icon indicates the status of the tank 18 Secondary agitator icon Press to display the Secondary Agitator Status screen The color of the icon indicates the status of the agitator Pump agitator icons Green Running Yellow Running with deviations Red Stopped with al...

Page 107: ...ation 1 3 4 5 6 7 8 2 9 10 11 12 13 14 15 Figure 84 Pump Status Screen Ref Ref Ref Item Item Item Description Description Description 1 Station Number Displays the number of the station Press to display a keypad and select a different station to view 2 Station Name Displays the name of the currently selected station 3 Comm Status Indicates the communication status between the pump and the Intellig...

Page 108: ...M Real time display of the pump operating speed in cycles per minute 11 Pressure Real time display of the pump output pressure Displayed in the units of measure chosen when the pump was set up Press to view or change the pump output pressure 12 Flow Real time display of the pump flow rate Displayed in the units of measure chosen when the pump was set up 13 BPR Real time display of the Back Pressur...

Page 109: ...Tank installed in the selected station Station Number Displays the number of the station for which information is displayed Press to display a keypad and select a different station to view Station Name Displays the name of the currently selected station For example TEST 1 Status Actual Level Read only Displays the current fluid level in the Primary Tank Freeze Level High Level Alarm HL Press to di...

Page 110: ...isplay a keypad used to specify the fluid level in the tank This level 0 100 must be in between the high level alarm setting and the low level alarm setting Fill Level FL Press to display a keypad used to specify the tank fill percentage that turns on the remote transfer pump 110 3A4030C ...

Page 111: ... Number Displays the number of the station for which information is displayed Press to display a keypad and select a different station to view Station Name Displays the name of the currently selected station For example TEST1 Actual Level Read only Displays the current fluid level in the Secondary Tank Low Level Deviation LD Press to display a keypad used to set the fluid level 0 100 at which a Se...

Page 112: ...Run Screen Ref Ref Ref Item Item Item Description Description Description 1 Station Number Displays the number of the station Press to display a keypad and select a different station to view 2 Station Name Displays the name of the currently selected station 3 Comm Status Indicates the communication status between the variable frequency drive and the Intelligent Paint Kitchen software OK Error 4 Pr...

Page 113: ...f the Variable Frequency Drive Inverter is Off press Enable to start the Variable Frequency Drive Inverter If the Variable Frequency Drive Inverter is On press Disable to stop the Variable Frequency Drive Inverter 6 Status Fault Lockout Fault Start Pending IDE Not Done Inhibit Stop Lower Transistor Switching On Run IDE Run Accel Decel Decel Override DC Brake Flying Restart Slow Current Limit Fast ...

Page 114: ... Fault 8 Internal Fault 9 Internal Fault 0 Personality Fault AD Offset Fault Remote Keypad Lost Assertion Level Fault Follower Lost ISO Comm Fault SPI Timeout Invalid Message Received Network Timeout 8 Idle Time Current amount of time that the agitator has been off while the agitator is in production 9 Agitator Halt Status If the auxiliary input on the pump control or tank control is set up for Ag...

Page 115: ...gitator profiles 17 On Time Current on time for the agitator in minutes when using agitator profiles 18 Off Time Current off time for the agitator in minutes when using agitator profiles 19 Load Current agitator load as a percentage of the drivers output current rating 20 Profiles Each column 1 2 displays the settings of an agitator profile When one of these profiles is selected the chosen column ...

Page 116: ...chen software Figure 88 Pumps Screen You can perform any of the following tasks from the Pumps screen Task Task Task Action Action Action Enable a station In the Production Production Production column for the station press Off Off Off The button changes to On On On and turns green to indicate that the station is successfully enabled Disable a station In the Production Production Production column...

Page 117: ...em has two pressure transducers only the pressure on Port 7 is displayed To change the units of measure for the pump see Set Up Tank Control Modules page 71 Flow Read only Indicates the output of the pump in liters per minute gallons per minute cubic centimeters cc per minute ounces oz per minute or cycles per minute as chosen when the pump was set up Speed Read only Indicates the current operatin...

Page 118: ...ectly to any Station screen and you can view current operational data for the Primary Tank or Secondary Tank in the system Each row on the screen represents one station that has been created and configured using the Intelligent Paint Kitchen software Press on any Run screen to display the Tanks screen Each row of controls represents one station that has been created and configured through the Inte...

Page 119: ...Station Station Station button for the station See Station Status Screen page 104 You can view the following information for each tank or drum in the Intelligent Paint Kitchen system Item Item Item Description Description Description Primary Read only Indicates the current level 0 100 of the Primary Tank in the selected station Speed Read only Indicates the current speed of the agitator if present...

Page 120: ... successful the following screen appears Figure 90 Removable Disk Click View View View Logs Logs Logs or Remote Remote Remote View View View to display information from the connected Intelligent Paint Kitchen system View View View Logs Logs Logs Use this function to access all log files on the unit in CSV format Logs can only be viewed they cannot be downloaded The following data is available for ...

Page 121: ...he 200 most recent events with date time and description Use the following procedures to set up and specify how events are generated and responded to Set Set Set Up Up Up Events Events Events Use this procedure to specify how Intelligent Paint Kitchen events are handled by the system You can specify how events are handled for different parts of the pump system from the Pump Events screen Press IO ...

Page 122: ... of the screen This screen is read only It provides the following information about each recorded event Date and time the event occurred Station number where the event occurred The error code that was detected Go to the Error Codes page 123 to view a full description of each error code A brief description of the event Figure 91 Event Log Screen 1 Press on any Run screen to enter the Event Log scre...

Page 123: ...celerate the motor Increase P109 and or A402 accel time or reduce the load so the drive output current does not exceed the current set by the Current Limit parameter A441 F7 Motor Overload Internal electronic overload trip An excessive motor load exists Reduce the load so the drive output current does not exceed the current set by the Motor OL Current parameter P103 Verify the Boost Select setting...

Page 124: ...and the SW Current Trip setting A448 F64 Drive Overload A drive rating of 150 for one minute or 200 for three seconds has been exceeded Reduce the load or extend accel time F70 Power Unit Failure has been detected in the drive power section Cycle power Replace the drive if the fault cannot be cleared F71 Net Loss The communication network has faulted Cycle power Check the communications cabling Ch...

Page 125: ...Increase active decel time P105 P126 P127 Check mains voltage and P107 F_EF External P121 P124 21 and that digital input has been opened P121 P124 22 and that digital input has been closed Correct the external fault condition Make sure digital input is set properly for NC or NO circuit F_F1 EPM EPM is missing or defective Power down and replace the EPM F_F2 through F_F12 Internal Contact technical...

Page 126: ...nId No Motor ID An attempt was made to start the drive in Vector or Enhanced V Hz mode before performing the Motor Auto calibration Refer to parameters P300 P399 for Drive Mode setup and calibration F_ntF Module Communication Communication failure between the drive and the network module Check the module connections F_nF1 through F_nF9 Network Refer to the module documentation for causes and remed...

Page 127: ...nchronize with the motor during a restart attempt P110 5 or 6 Check the motor and load F_SF Single Phase A mains phase has been lost Check the mains voltage F_UF Start The Start command was present when power was applied P110 0 or 2 Wait at least two seconds after powering up to apply the Start command Consider an alternate starting method P110 F_FAU TB5 0 10V signal Threshold 0 10V signal at TB5 ...

Page 128: ...n 16 CBN_ Basic and Advanced 2 4 Deviation Temporary circuit board communication failure CCN_ Basic and Advanced 3 6 Alarm Circuit board communication failure END_ Basic and Advanced 5 6 Advisory A calibration of the encoder and stroke range is in progress ENN_ Advanced None Advisory Dual lower system calibration completed successfully E5F_ Advanced None Advisory Dual lower system calibration erro...

Page 129: ...d 1 3 Alarm Pressure is below minimum limit P2I_ Advanced None Deviation Pressure is below minimum limit P3I_ Advanced None Deviation Pressure exceeds maximum target P4I_ Advanced 1 4 Alarm Pressure exceeds maximum target P5DX Advanced None Deviation More than one pump is assigned to a transducer The assignment for that transducer is automatically cleared under this condition User must reassign P6...

Page 130: ...display s system type on the Setup Units screen screen 15 WMC_ Basic and Advanced 4 5 Alarm Internal software error WNC_ Basic and Advanced 3 4 Alarm Software versions do not match WNN_ Advanced None Alarm System type mismatch motor is an E Flo DC single lower system and the display configuration does not match Change the display s system type on the Setup Units screen screen 12 in dual lower mode...

Page 131: ...The Modbus node ID is set for the correct pump The serial port baud rate is set to 57600 See Enter the Node IDs page 44 The dip switch settings are incorrect Verify the dip switch settings on the fiber to serial converter See Set DIP Switches on the Fiber Optic Converters page 32 Switch 1 On Switch 2 On Switch 3 On Switch 4 On Switch 5 Off Switch 6 On Switch 7 Off Switch 8 On Switch 9 Off Switch 1...

Page 132: ...ncorrectly Verify the wiring See Wire the Variable Frequency Drive Inverter to the Supervisor Module page 36 Node communication is not enabled Turn on node communication See Turn on Node Communication page 67 The Radar Level Sensor is not connected to the correct port Verify that the Radar Level Sensor M T is connected to the correct port See Connect a Radar Level Sensor to a Pump Control Module o...

Page 133: ... update the Intelligent Paint Kitchen firmware Follow the procedure in Use a USB Drive page 135 Touch Calibration Press to calibrate the Touchscreen interface Follow the procedure in Calibrate the Touchscreen Interface page 134 Touch Tester Press to test the Touchscreen interface and determine whether calibration is needed Follow the procedure in Test the Touchscreen Interface page 133 Test Test T...

Page 134: ...n to press to select that control Figure 92 Touchscreen Calibration Screen 1 Press on any Run screen 2 On the Setup Menu screen press Utilities Utilities Utilities 3 On the Utilities Menu screen press Touch Touch Touch Calibration Calibration Calibration 4 On the Touch Calibration screen follow the prompts The green squares turn red one at a time Press each red square as it appears 5 When finished...

Page 135: ...ss Mount Mount Mount to begin using an SD card that has been inserted and formatted Use Use Use a a a USB USB USB Drive Drive Drive A USB drive can be inserted into the designated port on the bottom of the Touchscreen Module 14 A USB device is used to store the log files generated by the Intelligent Paint Kitchen system You can remove the USB device and use to copy log files onto a computer When y...

Page 136: ...ur 1 Press on any Run screen 2 On the Setup Menu screen press Utilities Utilities Utilities 3 On the Utilities Menu screen press Time Time Time 4 On the Time screen press the current date and time displayed on the screen 5 Use the Label Label Label popup to enter the current time and date Use mm dd yyyy hh mm format 6 Press Return to enter the changes 136 3A4030C ...

Page 137: ...dule The Touchscreen Module 14 uses a 3 volt lithium battery to run the internal clock during times when the system is not powered 1 Disconnect the power to the Touchscreen Box 2 Remove the battery cover on the rear of the Touchscreen Module 3 Grasp the top edge of the battery and push to the left to remove the battery from the holder 4 Lift the battery out and replace with a new battery Observe t...

Page 138: ...upervisor Supervisor Supervisor Module Module Module 1 Disconnect the power 2 Disconnect red white blue wires from connectors B 7 and 8 Disconnect blue black wires from connectors A 5 and 6 3 Remove the Supervisor Module 36 from the DIN rail 4 Install the new Supervisor Module onto the DIN rail 5 Connect the white blue wire from the fiber optic converter 38 to terminal A on the ACS Connect the blu...

Page 139: ...le 1 Disconnect the power 2 Disconnect the red wire and the black wire Also disconnect the Line L power wire and the Neutral N wire 3 Remove the power supply 35 from the DIN rail 4 Install a new power supply 35 onto the DIN rail 5 Reconnect line power L from terminal 1 on the power switch 2 to terminal L on the power supply Reconnect the neutral N wire from terminal 4 on the power switch to termin...

Page 140: ...ONNECTOR Ethernet RJ45 2 4 RAIL mounting 1 5 SCREW pan head 10 32 x 3 8 in 2 6 BLOCK clamp end 4 7 BLOCK terminal ground 2 8 17K909 POWER SUPPLY 24 VDC 1 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 9 BLOCK terminal 2 10 COVER end 1 11 ENCLOSURE 1 12 PLUG 1 13 WIRE grounding door 1 14 17K908 MODULE Touchscreen control 1 Replacement safety labels tags and cards are ava...

Page 141: ...nd 1 33 CLAMP end 2 34 115306 FILTER power line 1 35 121314 POWER SUPPLY 2 A 1 36 17R317 MODULE Supervisor 1 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 37 15V342 SWITCH Ethernet 8 port 1 38 24N978 CONVERTER serial to fiber optic 1 39 CONNECTOR circuit board 5 position 1 40 CONNECTOR circuit board 2 position 1 41 WIREWAY base 1 42 COVER wireway 1 43 ENCLOSURE 1 44 19...

Page 142: ...lock 2 32 COVER end 1 33 CLAMP end 2 34 115306 FILTER power line 1 35 121314 POWER SUPPLY 2 A 1 38 24N978 CONVERTER serial to fiber optic 1 Ref Ref Ref Part Part Part Description Description Description Qty Qty Qty 39 CONNECTOR circuit board 5 position 1 40 CONNECTOR circuit board 2 position 1 41 WIREWAY base 1 42 COVER wireway 1 43 ENCLOSURE 1 44 194337 WIRE grounding door 1 45 GROMMET cable entr...

Page 143: ...s Signal Signal Signal Description Description Description Amber Light The system has a deviation Red Light An alarm exists The system goes to Standby Green Light Not used Audible Buzzer A system warning is active Verify the alarm To adjust the buzzer volume see the vendor manual Transfer Transfer Transfer Pump Pump Pump Mounting Mounting Mounting Kit Kit Kit 17S959 17S959 17S959 Install this kit ...

Page 144: ...hscreen Touchscreen Touchscreen Box Box Box Dimensions Dimensions Dimensions Reference Reference Reference U S U S U S Metric Metric Metric A 15 00 in 381 0 mm B 17 50 in 444 5 mm C 8 51 in 216 2 mm D 12 00 in 304 8 mm E 16 75 in 425 5 mm 144 3A4030C ...

Page 145: ...sion Expansion Box Box Box Dimensions Dimensions Dimensions Figure 100 Supervisor Box Figure 101 Expansion Box Reference Reference Reference U S U S U S Metric Metric Metric A 15 00 in 381 0 mm B 17 50 in 444 5 mm C 8 25 in 209 6 mm D 12 00 in 304 8 mm E 16 75 in 425 5 mm 3A4030C 145 ...

Page 146: ...mponents not listed in the following table see the specific component manuals for technical specifications US US US Metric Metric Metric Electrical Electrical Electrical Power Power Power Requirements Requirements Requirements 100 240 VAC 2 0 amp maximum 50 or 60 Hz single phase Weight Weight Weight Touchscreen Box 25A693 41 lb 18 6kg Supervisor Box 25A830 as shipped 43 lb 19 5 kg Expansion Box 25...

Page 147: ...ligent Paint Kitchen interacts with each station Design your own Intelligent Paint Kitchen by following these general steps 1 Specify the number of stations to be connected to the Intelligent Paint Kitchen 2 For each station choose the components to build that station s fluid circulation system a One pump with a Pump Control Module PD sized according to output volume and pressure requirements b On...

Page 148: ...ted to the Supervisor Box d More Supervisor Boxes and Expansion Boxes if needed to accommodate up to 20 stations in the Intelligent Paint Kitchen system See Scaling Up the System page 149 e One DC Power Supply with Barrier S to provide power to the Tank Control Module when used in each station f One Variable Frequency Drive Inverter B to individually control each Radar Level Sensor M in the system...

Page 149: ...mmodate a maximum of 20 fiber optic converters controlling up to 20 stations NOTE NOTE NOTE One Supervisor Box can hold up to 10 fiber optic converters and one Expansion Box can hold up to 12 fiber optic converters making a total of 22 fiber optic converters However only 20 connections can actually be made from one Supervisor Box Expansion Box pair to the stations Number Number Number of of of Sta...

Page 150: ...to a Supervisor Box 3 Use to connect each Variable Frequency Drive Inverter to a Supervisor Box 3 feet 1 m 16P911 IS CAN Cable Female Female 25 feet 8 m 16P912 Use to connect a Pump Control Module PD to a pump 10 feet 3 m 17T898 50 feet 16 m 16M172 100 feet 30 m 16M173 Fiber Optic Cable 330 feet 100 m 17B160 1 Use to connect each Pump Control Module to a fiber optic converter inside the Supervisor...

Page 151: ...ERNET ETHERNET CONNECTOR 2 ETHERNET CONNECTOR 1 RJ45 123922 CONNECTOR ETHERNET RJ45 123922 AUXILIARY ETHERNET USB HOST SWITCH 116320 GND TERMINAL 112443 USB DEVICE RS485 PORT B RS232 PORT A RS485 PORT A RS232 PORT B 261098 GRN YELLOW CABLE 16W159 CABLE 16W159 6 4 2 5 3 1 RED BLACK BLACK WHITE BLACK WHITE GND L N TB1 TB2 TERMINAL TB1 120491 TERMINAL TB2 120491 POWER IN NOT INSTALLED GND CLASS 2 USE...

Page 152: ...D 8 7 6 5 4 3 2 1 1 2 3 4 5 6 A B C D E 1 RED BLACK RED SHIELDED CABLE 17S109 FL1 N FL1 PE FL1 P FL1 P1 FL1 N1 DC OK BLACK CABLE 120050 ETHERNET RED CABLE 16W159 CABLE 16W159 CABLE 16W159 CABLE 16W159 ETHERNET CONNECTOR 1 ETHERNET CONNECTOR 2 CABLE 121994 7 6 5 2 3 4 A B CABLE 120050 WIRE 261098 GRN YELLOW DRAIN WIRE BLUE WHITE WHITE BLUE BLACK RS485 TB2 TB1 N1 L1 S1 4 S1 1 S1 5 S1 1 PS1 L PS1 N L...

Page 153: ... 4 2 5 3 1 GND TERMINAL 112443 TERMINAL TB2 120491 TERMINAL TB1 120491 N L GND 17Y899 3 WIRE HARNESS POWER IN NOT INSTALLED RED WHITE GRN BLACK BLACK WHITE BLACK WHITE BLACK 18A995 HARNESS DC OK CONVERTER 16K465 1 1 1 2 CLASS 2 USE CLASS 2 CONDUCTORS CLASS 1 A B C D E 1 TORQUE TERMINALS TO 5 3 7 0 in lbs 0 6 0 8 N m 2 TORQUE TERMINAL TO 4 4 5 3 in lbs 0 5 0 6 N m Figure 105 Expansion Box Schematic...

Page 154: ...termination resistor is installed on the fiber optic converter in the Supervisor Box in the factory Relocate it if additional fiber optic converters are installed in the system Allen Allen Allen Bradley Bradley Bradley PowerFlex PowerFlex PowerFlex C1 C2 C1 C2 Master 4 5 TxRxD TxRxD TxRxD TxRxD TxRxD TxRxD Shiel d Shield Shield 120ohmresistor 120 ohmresistor X X X FRONT PIN8 PIN1 TxRxD TxRxD RS485...

Page 155: ...e Pot 2 Keypad Freq 3 3 3 Serial DSI Serial DSI Serial DSI 4 Network Opt 5 0 10V Input 6 4 20mA Input 7 Preset Freq 8 Anlg In Mult 9 MOP 10 Pulse Input 11 PID1 Output 12 PID2 Output 13 Step Logic 14 Encoder 15 EtherNet IP 16 Positioning Speed Source C123 0 1200 1 2400 2 4800 3 9600 4 19200 5 5 5 38400 38400 38400 RS 485 Data Rate C124 101 120 Primary 121 140 Secondary RS 485 Node Address C125 0 Fa...

Page 156: ...er Parameter Parameter Value Value Value Description Description Description C126 0 1 60 seconds Communication Loss Time C127 0 RTU 8 N 1 1 RTU 8 E 1 2 RTU 8 O 1 4 4 4 RTU RTU RTU 8 8 8 N N N 2 2 2 5 RTU 8 E 2 6 RTU 8 O 2 RS 485 Format 156 3A4030C ...

Page 157: ...Appendix D Communication Configuration Mitusbishi Mitusbishi Mitusbishi Figure 107 Wiring Diagram Figure 108 Wiring Routing 3A4030C 157 ...

Page 158: ...e 0 Frequency command source is communication P340 Communication Startup Mode Selection 10 The inverter starts up in the Network operation mode The operation mode can be changed between the PU operation mode and the Network operation mode from the operation panel If an instantaneous power failure occurs when 12 is set running is continued at the condition before the instantaneous power failure P54...

Page 159: ...tator 25C486 Back Gear Agitator with Siphon 25C374 Back Gear Agitator with Drum Cover and Elevator 25C451 Back Gear Agitator with Drum Cover Elevator and Siphon 50 50 50 Hz Hz Hz Direct Direct Direct Drive Drive Drive Part Part Part No No No Description Description Description 25C464 3 Quick clamp Flange Mount Agitator Motor 25C576 4 Quick clamp Flange Mount Agitator Motor 25C463 7 5 OD flange Mou...

Page 160: ...r 2 Connect the A to B USB cable to your computer and to the USB Device Port DP on the bottom of the Touchscreen Module 14 Figure 109 USB Connection on the Bottom of the Touchscreen Module When connected the Intelligent Paint Kitchen system displays as a Removable Disk on your computer Figure 110 Removable Disk 3 Double click to open the removable disk 4 Replace the image ci3 image ci3 image ci3 f...

Page 161: ...ture the two displays must have unique Port 2 IP addresses on the network The IP addresses are assigned independently from each display See Network Setup and Configuration page 92 The default Master display should have a Port 2 IP address of 192 168 1 50 Note The display with this IP address is always recognized as the Master if both displays are detected during power up The default Client display...

Page 162: ... Screen Screen Screen Item Item Item Description Description Description Multiple Displays Select ON ON ON to enable the Master Client feature Select OFF OFF OFF to disable the Master Client feature Timeout Specify the number of seconds the Client display will wait before taking control as the Master display When the Client display sends a request the Master display has a specified amount of time ...

Page 163: ...Client HMI doesn t detect the Master HMI it will make itself Master and when the default Master HMI eventually comes online it will automatically request to become Master During During During Normal Normal Normal Operation Operation Operation The current role of the display is always reported in the bottom left corner of the display The following screen shot is an example of a Master display Figur...

Page 164: ... user can press on Client to send a request to the Master to gain control The following messages appear simultaneously on the local and remote HMIs Local Local Local HMI HMI HMI Waiting for Response Remote Remote Remote HMI HMI HMI Client Display is requesting control 164 3A4030C ...

Page 165: ...mote HMI user acknowledged the request the local HMI becomes the Master and the remote HMI becomes the Client Request Request Request Rejected Rejected Rejected The remote HMI user rejected the request and the roles remain unchanged Request Request Request Timeout Timeout Timeout The request was neither Acknowledged nor Re jected by remote HMI user and the Timeout see Configure Multiple Displays p...

Page 166: ... WARRANTY WARRANTY WARRANTY AND AND AND DISCLAIMS DISCLAIMS DISCLAIMS ALL ALL ALL IMPLIED IMPLIED IMPLIED WARRANTIES WARRANTIES WARRANTIES OF OF OF MERCHANTABILITY MERCHANTABILITY MERCHANTABILITY AND AND AND FITNESS FITNESS FITNESS FOR FOR FOR A A A PARTICULAR PARTICULAR PARTICULAR PURPOSE PURPOSE PURPOSE IN IN IN CONNECTION CONNECTION CONNECTION WITH WITH WITH ACCESSORIES ACCESSORIES ACCESSORIES ...

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