2 High Voltage Controls   MARMCP7AP07071E REV.

2.17.1.1 HV Cable Installation Procedure

1. Obtain the appropriate replacement cable. See table in the Overview ITW section.

2. Run the Super Purge Cycle to clean out the applicator and lines.

3. Position the robot outer arm so it is accessible with J4, J5, and J6 near 0° (Only J4 and J5 if P-500 robot). This unwinds the process bundle through the wrist to allow ease of installation and promotes maximum cable/hose life.

4. Remove and lockout all sources of hazardous energy to the entire robotic cell.

5. Remove robot over spray covers if applicable.

6. Remove the outer arm hard cover to expose the High Voltage Cable if applicable.

Figure 2-27: P-500 HV cable

1. Use a spanner wrench to remove the applicator. P-500 Robot applicator shown for example.

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Figure 2-28: P-500 applicator quick disconnect

2. Loosen the two bolts in the process bundle clamp.

Figure 2-29: P-500 process bundle clamp

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3. Loosen the cord grip and remove the HV Cable from the cascade.

Figure 2-30: P-500 HV cable / cascade connection

4. Locate and remove the part number label from the tubing on the High Voltage cable that will be removed. The clearance between the tubing and the hole through the quick disconnect will not allow the label to pass.

Figure 2-31: HV cable part number label

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5. Pull the HV Cable out through the applicator QD plate. Put the part number tag back on if sending the cable to FANUC Robotics.

Figure 2-32: HV Cable in applicator QD Figure 2-33: HV Cable pulled through applicator QD

6. Remove the part number label from the tubing on the new cable, save to reapply.

7. Verify the hose bundle is not crossed or tangled as it runs through the wrist and outer arm.

8. Feed the new HV Cable through the applicator QD and into the arm.

Figure 2-34: HV cable inside of robot wrist

9. Feed the HV Cable under the tubing clamp in the center of the process bundle.

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Figure 2-35: HV cable fed back through process bundle clamp

10. Feed the HV Cable through the cord grip and into the cascade. The white insertion gauge should remain half exposed when the cable is fully inserted.

Figure 2-36: HV cable / cascade connection

11. Tighten the cord grip on the cascade to 120 in/lbs.

12. Tighten the two bolts on the outer arm process bundle clamp to 11 in/lbs.

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Figure 2-37: Process bundle clamp bolt position

13. Reapply the part number label to the nylon tube covering the HV cable between the outer arm clamp and wrist.

Figure 2-38: HV cable part number position

14. Apply Dielectric grease to the applicator and HV Cable petticoats. Be careful not to get grease on the metal pin or socket.

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Figure 2-39: Dielectric grease locations

15. Reinstall the applicator using the spanner wrench.

16. Reinstall the outer arm cover.

17. Reinstall robot over spray pajamas if applicable.

18. Perform manual HV Tests below and then run “Ghost” simulation jobs to confirm that the new HV Cable is operating correctly.

• Reset the system in Manual mode and send the applicator shaping air shroud clear of all grounded metal.

• From the GUI Fluid Maintenance screen, run a High Voltage test at 60KV(step5) for 60 seconds.
Verify the voltage feedback is within 5KV of the set point and the current feedback is less than 5uA.

• Move the applicator shaping air shroud within 50-100mm(2-4”) of a well grounded metal object.

• From the GUI Fluid Maintenance screen, run a High Voltage test at 60KV(step5) for 60 seconds. Verify the voltage feedback is within 5KV of the set point and the current feedback is greater than 10uA. Current draw may be excessive
and cause an I-max or di/dt fault.

Table 2-25: High voltage test positions and conditions

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2.17.2 Legacy Cascade Maintenance - Greasing Procedure

This procedure is used for legacy style cascades used on VersaBell Applicators, ServoBell Applicators, and P-700 Flex Application systems.

For used cascades, clean all old grease out of the cascade petticoat area using cotton swabs. When clean of all grease use an alcohol moistened swab to remove any residual grease. Wipe off the outer cascade body with clean rags and
wipe clean with an alcohol moistened clean rag or pad to remove remaining grease. Let dry.

Figure 2-40: Clean grease locations

New Cascades:
Wipe all areas with provided alcohol pad.

1. Anytime a cascade is replaced, clean all old grease out of the cascade petticoat area in the manifold using cotton swabs. When clean of all grease use an alcohol moistened swab to remove any residual grease. Let dry.

Figure 2-41: High voltage petticoat location

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2. Cover the HV-contact and petticoat area with a light coat of dielectric grease. Use only the recommended grease (Polytac #2) and not Vaseline. Use a small brush to apply a light coat to the petticoat area. The area must be covered
100%. Too much grease will not allow for proper seating of the cascade in the applicator. The appropriate amount of grease is shown below.

Figure 2-42: Dielectric grease applied to a cascade

Figure 2-43: Fanuc Robotics dielectric grease

3. Cover the outside diameter from the metal area to two inches to the front of the cascade with a VERY LIGHT coat of dielectric grease. The area must be covered 100%. Do not cover the metal area or the low voltage connector with
any grease. Too much grease will not allow for proper seating of the cascade in the applicator.

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Figure 2-44: Cascade dielectric locations

4. Install the cascades into the manifold. Tighten the cascade holding screw and than cover the outside diameter with a VERY LIGHT coat of dielectric grease. The area must be covered 100%. No gaps. Too much grease will not
allow for proper seating of the cascade in the applicator.

2.17.3 Integrated Cascade Maintenance

The P-500iA, P-700iA (non-Flex) and P-250iA integrated cascades do not require the application of any dielectric grease to be applied. Grease SHOULD NOT be applied into the well of the high voltage cable.

Figure 2-45: Cascade loaction for NO dielectric grease

2.18 Troubleshooting – High voltage Controller FB-200 HVU

2.18.1 HV Control Unit Alarms
The following faults are displayed on the High Voltage Controller:

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2.18.1.1 Switched-Off because of CABLE-BREAK

This fault indicator appears if a wire fails, i.e. has broken or is not connected on the cable between power supply and cascade. The high voltage is switched off and the “HV-fault” is activated. The HV controller can detect three different
CABLE-BREAK conditions, both of the feedback signals and for R+. After the CABLE-BREAK is a text character (I,U, or R). The descriptive text character is displayed for software version 1.21f and later. This character indicates on
which wire the cable-break was detected.

Possible causes are:

1. Cause: A broken low voltage wire section between the high voltage power supply and the cascade.
Remedy: Ring out the wiring for continuity and replace the broken wire or cable. See the appropriate diagram below for cable
locations in your particular system. Refer to the system electrical prints for wiring functionality.

2. Cause: A loose connection at the one of the low voltage terminal strips for one of the low voltage cables.
Remedy: Check screw connections on all terminal strips, this includes the Phoenix connector within the Robot FRP unit in the P200E and Amphenol connector in the P500.

3. Cause: A loose or damaged connection/pin at the cascade low voltage connector.

Remedy: Check the pins to see if they are bent or broken or the solder joint is loose. Attempt to straighten/solder or replace the pins if bent, if broken on the cascade replace the cascade.

4. Cause: A loose/ broken connection at the high voltage power supply back-plane,
Remedy: Check all wires to see if they are properly connected into the terminal strips and are correctly tightened.

5. Cause: Cascade holder bolts are loose causing intermittent connection of the cascade to the connector.
Remedy: Tighten the bolts

6. Cause: VersaBell applicator or cascade in VersaBell not properly tightened allowing the cascade connection to the connector to be marginal.
Remedy: Tighten the applicator using the correct spanner wrench.

7. Cause: In P500 systems only, the cascade holder connection nut within in the FRP unit has loosened causing an intermittent and marginal electrical connection.
Remedy: Remove the black cascade holder from the FRP, check the connection nut for tightness. If loose use Loctite 242 sealant on the threads and tighten properly.

8. Cause: A defective high voltage cascade.

Remedy: Remove the cascade and replace with a new one.

2.18.1.2 Switched-Off because of dV/dt-FAULT

This fault indicates the rate of current change (in Voltage operation) is rising faster than expected. The high voltage is switched off and the “HV-fault” is activated.

Possible causes are:

1. Cause: Applicator covers are built up with excessive paint overspray.
Remedy: Change the cover.

2. Cause: Clean washed covers vs. new covers were placed on the applicator and faults occurred.
Remedy: Replace with unwashed covers and contact cover suppler for non-conductive covers.

3. Cause: Distance between the applicator bell cup and/or shaping air assembly is too close to a vehicle.
Remedy: Check for the following possible situations and/or problems and correct it:
a) Vehicle is skewed in the booth on the carrier. Check the vehicle and skid tolerance.
b) Check that the proper job is in the booth.

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c) Vehicle skid is bent. Tag skid for repair.

d) Vehicle may have slipped on the conveyor and is not being tracked correctly.
e) Vehicle gas door is open or out of position
f) Vehicle door or tailgate is open or out of position.
g) Door clip or fixture is out of position and is too close to applicator.
h) Path may have been adjusted and is now too close to the vehicle. Target should be 1 inch per 10KV + 1 inch between vehicle bell cup and side of the shaping air assembly.
i) Path preset step value was changed (increased) without regard to target distance.
j) Step setting values may have been changed. Compare to original values.
k) Booth humidity too high. Adjust if possible.
l) Paint resistivity is too high. Check the paint kitchen to see if new paint or solvent was added to the paint tanks. High aluminum flake content may cause problems.
m) Applicator had excessive solvent used for cleaning and may have seeped between the applicator components.
n) Paint leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
o) Solvent leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
p) Wash line is not properly purged with air after a color change. Check the purge cycle to insure it is blown down.
q) One of the paint valves is leaking either externally or internally.
r) Possible electrical noise from improper shield or ground connections.

2.18.1.3 Switched-Off because of dI/dt-FAULT

This fault indicates the rate of current change (in Voltage operation) is rising faster than expected. The high voltage is switched off and the “HV-fault” is activated.

Possible causes are:

1. Cause: Applicator covers are built up with excessive paint overspray.
Remedy: Change the cover.

2. Cause: Clean washed covers vs. new covers were placed on the applicator and faults occurred.
Remedy: Replace with unwashed covers and contact cover suppler for non-conductive covers.

3. Cause: Distance between the applicator bell cup and/or shaping air assembly is too close to a vehicle.
Remedy: Check for the following possible situations and/or problems and correct it:
a) Vehicle is skewed in the booth on the carrier. Check the vehicle and skid tolerance.
b) Check that the proper job is in the booth.
c) Vehicle skid is bent. Tag skid for repair.
d) Vehicle may have slipped on the conveyor and is not being tracked correctly.
e) Vehicle gas door is open or out of position
f) Vehicle door or tailgate is open or out of position.
g) Door clip or fixture is out of position and is too close to applicator.
h) Path may have been adjusted and is now too close to the vehicle. Target should be 1 inch per 10KV + 1 inch between vehicle bell cup and side of the shaping air assembly.
i) Path preset step value was changed (increased) without regard to target distance.
j) Step setting values may have been changed. Compare to original values.
k) Booth humidity too high. Adjust if possible.
l) Paint resistivity is too high. Check the paint kitchen to see if new paint or solvent was added to the paint tanks. High aluminum flake content may cause problems.
m) Applicator had excessive solvent used for cleaning and may have seeped between the applicator components.
n) Paint leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
o) Solvent leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
p) Wash line is not properly purged with air after a color change. Check the purge cycle to insure it is blown down.

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q) One of the paint valves is leaking either externally or internally.

r) Possible electrical noise from improper shield or ground connections.

2.18.1.4 Switched-Off because of EXCEEDING POWER DISSIPATION

This fault indicates exceeding power dissipation of the HV-generator. If this fault indicator appears, the HV-generator is defective or is overheated. The high voltage is switched off and the “HV-fault” is activated.

1. Cause: The cascade is defective.

Remedy: Replace the cascade.

2.18.1.5 Switched-Off because of OVERLOAD (Vmin)

This fault indicates the Voltage is below the minimum allowed for the requested current. The high voltage is switched off and the “HV-fault” is activated.

Possible causes are:

1. Cause: Applicator covers are built up with excessive paint overspray.
Remedy: Change the cover.

2. Cause: Clean washed covers vs. new covers were placed on the applicator and faults occurred.
Remedy: Replace with unwashed covers and contact cover suppler for non-conductive covers.

3. Cause: Distance between the applicator bell cup and/or shaping air assembly is too close to a vehicle.
Remedy: Check for the following possible situations and/or problems and correct it:
a) Vehicle is skewed in the booth on the carrier. Check the vehicle and skid tolerance.
b) Check that the proper job is in the booth.
c) Vehicle skid is bent. Tag skid for repair.
d) Vehicle may have slipped on the conveyor and is not being tracked correctly.
e) Vehicle gas door is open or out of position
f) Vehicle door or tailgate is open or out of position.
g) Door clip or fixture is out of position and is too close to applicator.
h) Path may have been adjusted and is now too close to the vehicle. Target should be 1 inch per 10KV + 1 inch between
vehicle bell cup and side of the shaping air assembly.
i) Path preset step value was changed (increased) without regard to target distance.
j) Step setting values may have been changed. Compare to original values.
k) Booth humidity too high. Adjust if possible.
l) Paint resistivity is too high. Check the paint kitchen to see if new paint or solvent was added to the paint tanks. High aluminum flake content may cause problems.
m) Applicator had excessive solvent used for cleaning and may have seeped between the applicator components.
n) Paint leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
o) Solvent leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
p) Wash line is not properly purged with air after a color change. Check the purge cycle to insure it is blown down.
q) One of the paint valves is leaking either externally or internally.
r) Possible electrical noise from improper shield or ground connections.

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2.18.1.6 Switched-Off because of OVERLOAD (Imax)

This fault indicates that the operating current has exceeded the maximum allowed value for the requested Voltage. The high voltage is switched off and the “HV-fault” is activated.

Possible causes are:

1. Cause: Applicator covers are built up with excessive paint overspray.
Remedy: Change the cover.

2. Cause: Clean washed covers vs. new covers were placed on the applicator and faults occurred.
Remedy: Replace with unwashed covers and contact cover suppler for non-conductive covers.

3. Cause: Distance between the applicator bell cup and/or shaping air assembly is too close to a vehicle.
Remedy: Check for the following possible situations and/or problems and correct it:
a) Vehicle is skewed in the booth on the carrier. Check the vehicle and skid tolerance.
b) Check that the proper job is in the booth.
c) Vehicle skid is bent. Tag skid for repair.
d) Vehicle may have slipped on the conveyor and is not being tracked correctly.
e) Vehicle gas door is open or out of position
f) Vehicle door or tailgate is open or out of position.
g) Door clip or fixture is out of position and is too close to applicator.
h) Path may have been adjusted and is now too close to the vehicle. Target should be 1 inch per 10KV + 1 inch between vehicle bell cup and side of the shaping air assembly.
i) Path preset step value was changed (increased) without regard to target distance.
j) Step setting values may have been changed. Compare to original values.
k) Booth humidity too high. Adjust if possible.
l) Paint resistivity is too high. Check the paint kitchen to see if new paint or solvent was added to the paint tanks. High aluminum flake content may cause problems.
m) Applicator had excessive solvent used for cleaning and may have seeped between the applicator components.
n) Paint leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
o) Solvent leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
p) Wash line is not properly purged with air after a color change. Check the purge cycle to insure it is blown down.
q) One of the paint valves is leaking either externally or internally.
r) Possible electrical noise from improper shield or ground connections.

4. Cause: Cascade holder bolts or cascade connector is loose causing an intermittent connection of the cascade to the connector
Remedy: Tighten the bolts or estat cable connector nut. Apply Loctite 242 sealant to prevent loosening.

5. Think about using points Max-I load (3.13.49) and I-max off (3.13.32) on water based systems.

2.18.2 PaintTool HV Alarms

The following faults are displayed on the Teach Pendant and GUI Alarms screen:

2.18.2.1 PAIN-351 "Estat controller warning"

Cause: The FB-200-HVU High Voltage Controller detected a Warning. This indicates a potential system fault that is not yet at the fault level.
Remedy: Check the status screen on the FB-200-HVU High Voltage Controller. Monitor for conditions such as high current or low voltage while painting that may cause the warning to occur.

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2.18.2.2 PAIN-352 "Estat controller fault"

Cause: The FB-200-HVU High Voltage Controller detected a fault. The FB-200-HVU sends this fault signal to the robot controller so that all painting is stopped.
Remedy: Check the operator console GUI for a fault and/or fault status on the panel and display of the FB-200-HVU High Voltage Controller. If the fault is not displayed on the GUI after 5 seconds check the FB-200 HVU display for
fault details.

2.18.2.3 PAIN-353 "Estats disabled"

Cause: The Estat Disconnect Switch is off or the Enable Key Switch on the FB-200-HVU High Voltage Controller is off.
Remedy: Turn the Disconnect switch to ON or turn the FB-200-HVU High Voltage Controller, Enable Key Switch to ON.

2.18.2.4 PAIN-354 "Estat controller not in remote"

Cause: The Local / Remote Rotary switch on the FB-200-HVU High Voltage Controller is in the Local Mode.
Remedy: Turn the toggle switch on the FB-200-HVU High Voltage Controller to the REMOTE mode.

2.18.2.5 PAIN-355 "Estat HVON Failed"

Cause: This is a real alarm not a nuisance, when the message occurs the paint job quality is poor due to no high voltage present at the applicator. The root cause of the problem is that the robot controller sent the HVON signal to the FB-
200-HVU High Voltage Controller but did not get a signal back indicating it received the signal. The HV On Alarm is a PaintTool generated alarm not an actual high voltage alarm from the FB-200 HVU High Voltage Controller. When
the robot controller commands voltage, the robot controller turns on the HV ON output that is wired to the FB-200-HVU High Voltage Controller input. The FB-200 HVU High Voltage Controller sends the voltage command to the
cascade when it receives the HV ON signal. When the FB-200-HVU High Voltage Controller senses any energy in the system, it turns on the HV ON output that is wired to the input card in the robot controller. When PaintTool turns on
the HV ON output, it looks for the HV ON input echo from the FB-200-HVU High Voltage Controller. If it does not get the signal after a predetermined time (HVON Input Timeout), the robot controller issues a Warning.

Remedy: Confirm that this is a real problem by monitoring the display on the FB-200-HVU High Voltage Controller. If the step value is between 1 and 7 and the HV ON signal is on and the Actual KV value is 0, then there is a problem
in the system. To debug this problem, start by looking at the FB-200 HVU High Voltage Controller. If the HV On signal is on only when there is a valid step command and the feedback is correct, look at the pendant and confirm the
Digital Input HV ON signal is on. For the P-500 check (DI 257 (Eq1) DI 385 (Eq2)). For P-155 and P-200 compare with another robot to check these Digital Input Signals as many configurations are possible. If any signals are missing,
check the wiring to the I/O card and back plane. If this doesn't clear the problem, start checking ALL the cable connectors and terminal connections associated with the low voltage wiring of the high voltage system.

Possible causes are:

1. Cascade is defective.
2. Defective high voltage cable (purple) from the cascade to the applicator.
3. Problem with FB-200-HVU High Voltage Controller.
4. Problem with wiring on FB-200-HVU High Voltage Controller back plane or FANUC I/O card (HV ON signal or step signal) in the robot controller cabinet.
5. Defective robot controller I/O card.
6. The FB-200 High Voltage Controller not seeing feedback from the cascades(cable / wiring problem)
7. The FB-200 High Voltage Controller not commanding Voltage (cable / wiring problem - see cable break fault)
8. No Step command with HV ON command. Possible causes are: The preset is set to an invalid value, a wiring problem exist, or the step I/O was mapped incorrectly at the robot controller).

2.18.2.6 PAIN-356 "Estat set point not reached"*

*Note:
PaintTool V5.30-1 to V6.22-1
PAIN-356
PaintTool V6.31-1 to V7.30-1

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PNT1-678 (Eq1)
PNT1-691 (Eq2)

Cause: The set point reached signal from the FB-200-HVU High Voltage Controller was not received by the robot controller within the appropriate time limit.
Remedy: Check the voltage and set point reached light on the FB-200-HVU High Voltage Controller. The system may be having trouble reaching the requested voltage. If not adjust the set point reached time out setting.

2.19 Spare Parts – High voltage Controller FB-200 HVU

2.19.1 Spare Parts
Part Number Description Replacement
Period
PWRSO000000052O SCHNIER #FB-200-HV V1.25 UNIT Upon failure

PWRSO000000047O SCHNIER #FB-200-HV V1.24 UNIT Upon failure

PWRSO000000043O SCHNIER #FB-200-HV V1.23 UNIT Upon failure

PWRSO000000042O SCHNIER #FB-200-HV V1.21 UNIT Upon failure
PWRSO000000001O SCHNIER #FB-200-HV V1.16 UNIT Upon failure
EO-4526-110-000 Cascade #810230 (legacy type) Upon failure
ALT: EE-4526-800 ALT: ITW A12295-00 (legacy type)
Note:
To use ITW cascade with Schnier HV Controller,
then Schnier V1.16 software is required. Other
hardware modifications may be required. Contact
FANUC Robotics.
EE-4526-801 Integrated Cascade Upon failure
ALT: EE-4526-801 ALT: ITW A12296-00 (integrated type)
Note:
To use ITW cascade with Schnier HV Controller,
then Schnier V1.16 software is required. Other
hardware modifications may be required. Contact
FANUC Robotics.
EE-4696-625-XXX High Voltage Cable – Robot configuration specific 4000 Hours
lengths. See Overview ITW section for table of
robot model specific HV cable lengths.

Table 2-26: Spare parts and replacement schedule

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3 BELL SPEED CONTROL SYSTEM

3.1 Overview
3.1.1 Introduction
The Bell Speed Control System adjusts the pressure of the drive air supplied to the turbine in order to maintain the commanded bell speed. The closed-loop control of this system is provided by the PaintTool software. Bell speed is
monitored by the fiber optic feedback system. This feedback is used to determine what adjustments need to be made to the I/P regulator on the turbine drive air in order to control turbine speed. An air brake is used to quickly reduce
speed or stop the turbine when necessary.

The fiber optic feedback also allows the software to monitor and report problems with the Bell Speed Control System. Abrupt changes in bell speed, slow transition between set-points, turbine over-speed, and insufficient turbine speed
are all diagnosed and reported as faults and warnings by the Bell Speed Control System.

The components in the fiber optic feedback system are calibrated at assembly. An automatic setup procedure is used to set the cruise speed (or idle speed) of the turbine.

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3.1.2 System Components – Block Diagram Overview

These components are in the Process Control Enclosure (PCE)

Digital
Output
(Brake)

Analog
Robot Output Brake (air)
Solenoid
Controller (turbine Turbine
Turbine Drive (air)
pressure) I/P Regulator

Light signal (fiber optic)

Analog Frequency Keyence Optical
Input Converter Voltage pulses Sensor Unit
(turbine Pulsed light reflected
speed) from encoder (fiber
optic)

Turbine is driven by air.

Air pressure for turbine drive is commanded by robot
controller.
Fiber optic system measures speed of spinning turbine
and provides feedback for closed loop control
Brake is air driven also.
Braking air is commanded when actual speed is higher
than command speed.

Figure 3-1: D/Q PCE Block Diagram

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These components are in the Process Control Enclosure (PCE)

Digital
Output
(Brake)

Analog
Robot Output Brake (air)
Solenoid
Controller (turbine Turbine
Turbine Drive (air)
pressure) I/P Regulator

Light signal (fiber optic)

Analog Keyence Optical
Input Voltage pulses Sensor Unit
(turbine Pulsed light reflected
speed) from encoder (fiber
optic)

Turbine is driven by air.

Air pressure for turbine drive is commanded by robot
controller.
Fiber optic system measures speed of spinning turbine
and provides feedback for closed loop control
Brake is air driven also.
Braking air is commanded when actual speed is higher
than command speed.

Figure 3-2: Flowmeter Block Diagram Overview

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Figure 3-3: P-500iA 1k Arm with VersaBell II Applicator – Bell Speed Control Components Overview

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Figure 3-4: P-500iA Process Control Enclosure with Air Flowemeter – Bell Speed Control Components

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Figure 3-5: P-500iA D/Q Process Control Enclosure – Bell Speed Control Components

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Figure 3-6: P-700iA 1k Arm with VersaBell II Applicator – Bell Speed Control Components Overview

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Figure 3-7: P-700iA Process Control Enclosure with Air Flowmeter – Bell Speed Control Components

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Figure 3-8: P-700iA D/Q Process Control Enclosure – Bell Speed Control Components

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3.2 Operation and Setup

The following sections describe the installation of the components of the Bell Speed Control System and any software setup that is required for this system.

3.2.1 Pressure Regulator (I/P)

The I/P (analog input to pressure) is an electronically controlled pressure regulator that is used to control the turbine drive air. The Pneumatic Control System receives the command signal from the PaintTool application in the robot
controller and transmits this signal to the I/P. The I/P adjusts the turbine drive air pressure according to the command. The pressure is increased in order to increase turbine speed or in response to increased load. The pressure is
decreased in order to decrease turbine speed or in response to decreased load.

3.2.1.1 Installation
The I/P is mounted by two 4mm screws that attach to a mounting plate through holes in the body of the device.

Figure 3-9: MPPE - Turbine Drive I/P

The electrical cable connects the I/P to an analog output on the Pneumatic Control System. The turbine supply hoses connect to the supply fitting and deliver air from the air supply manifold. The turbine drive hoses connect to the outlet
fitting and regulated air to the turbine drive at the applicator. The exhaust hose connects to the exhaust fitting, and directs the I/P exhaust to the exhaust manifold.

The I/P requires no other setup.

3.2.2 Fiber Optic Sensor (O/E)

The O/E (optical to electrical convertor) emits a light beam to one element of the fiber optic cable. The light is reflected off of an indicator wheel in the turbine that has alternating reflective and non-reflective sections. The reflected
light is transmitted back up the other element of the fiber optic cable to the receiver in the O/E. The O/E then converts the reflected light pulse to an electrical voltage pulse and outputs this chain of pulses to the Frequency Converter

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(F/I). The O/E display shows current value (CV) of the received light intensity in red (0-4095) and the preset valve (PV) in green.

3.2.2.1 Installation
The O/E is mounted to a DIN rail by a snap-on connector. To install the O/E hook the fixed side of the device over the lip of the DIN rail and push the end in the direction of arrow 2 until a snapping sound indicates the connector is
engaged. To remove the O/E from the rail, push the device in the direction of arrow 1 and then pull off the rail in the direction of arrow 3.

Figure 3-10: O/E Installation

Install the optical fibers as shown below. Open the dust cover in the direction of arrow 1. Move the fiber lock lever in the direction of arrow 2. Ensure that the ends of the optical fibers are free of dust and debris. Insert an optical fiber
into each of the insertion holes to the depth of the fiber insertion sign on the side of the device (approximately 14mm). Return the fiber lock lever to its original position by moving it in the direction of arrow 4.

Figure 3-11: Optical Fiber Insertion

The electrical connection to the O/E is permanently attached to the device. Terminate the ends of this cable in the Frequency Converter (F/I) as indicated by the electrical schematic. For process I/O systems that in clued an air flowmeter,
the Keyence sensor is connected directly to a frequency counter input that is part of the EX600 process I/O rack.

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3.2.2.2 Setup
The O/E has a number of functional modes. The procedures below are used to setup the proper mode for use in the Bell Speed Control System. These procedures are performed during assembly at FRA and are only required if the O/E is
replaced.

3.2.2.3 Preset Valve Programming

The O/E requires calibration to establish the levels of light and dark regions on the indicator in the turbine. Level Calibration is set during assembly and should only be necessary if the O/E is replaced. To set the Level Calibration, open the dust
cover as shown in Figure X. Change the Preset Value (PV) to 1400 by pressing the manual button in the direction indicated to increase or decrease the value displayed in green.

Figure 3-12: O/E Level Setting

Mode Selection
The O/F should be set to the following settings for use in the Bell Speed Control System:
x Access mode: easy
x Power mode: fine
x Timer function: toff

These parameters are set during assembly. If they are inadvertently changed to then they can be restored with the following procedure.

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Figure 3-13: O/E Mode selection

Press the mode button for at least 3 seconds then use the manual button to select ‘easy mode’. Press the mode button again and then use the manual button to select ‘fine’. Press the mode button again and then use the manual button to
select ‘toff’. Press the mode button again to exit the mode selection menu.

Key Lock
The function keys on the front of the O/E can be locked so that accidental inputs do not change settings. To lock the function keys, simultaneously press the mode and manual buttons for at least 3 seconds. The display will read ‘Loc’
when the keys have been locked. To unlock the keys simultaneously press the mode and manual buttons for 3 seconds again.

Figure 3-14: O/E key lock display

3.2.3 Frequency Converter (F/I)

The F/I device measures the frequency of the pulse chain from the F/I and converts it into an analog signal that reports the turbine speed to the control system. For a CPX based configuration, the F/I is a standalone unit that converts a
frequency based signal from the O/E to a 4-20 mA signal. For EX600 based systems, there is no need for a F/I device, as the EX600 has an counter input module that accepts the O/E electrical pulses and converts them to a frequency
count reading that is transmitted over the Ethernet/IP connection to the robot controller.

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3.2.3.1 Installation
The F/I is mounted to a DIN rail by a snap-on connector. To install the F/I, hook the top of the device over the lip of the DIN rail and push the device in the direction of arrow 1 (shown in the figure below) until a snapping sound
indicates the connector is engaged. To remove the F/I from the rail, insert a screwdriver into the silver slot on the bottom of the device, near the DIN rail. Tip the device in the direction of arrow 2 and pull it off of the rail.

Figure 3-15: F/I – side view

If replacing an existing F/I, the terminal strips can be disconnected from the body of the device and then reattached to the replacement part. This allows the user to replace the F/I without having to disconnect and reconnect each lead in
the cables. To disconnect a terminal strip, insert a small screwdriver in the notch shown in figure below, and pry the terminal strip out.

Figure 3-16: F/I Terminal Connections

See the product specific process equipment manual for the proper termination of cables at the F/I. Insert the leads of the cables in the terminals as shown and secure by tightening the screw with a small flat-head screwdriver.

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Figure 3-17: F/I Faceplate

The F/I comes pre-programmed for the bell speed control system. If settings have been accidentally changes, see EG-00305 for instruction on reprogramming the F/I.

3.2.4 Turbine
Refer to the Applicator Poster for information on the Turbine.

3.2.5 Fiber Optic Cable

The Fiber Optic Cable between the O/E and the indicator wheel on the turbine is split into three sections.
x Refer to robot manual for the specific process equipment manual for information on the section that attaches to the O/E.
x Refer to robot manual for specific applicator hose bundle for information on the section that connects the Applicator to the terminal in the FRP.
x Refer to applicator poster for information on the section that passes through the Applicator to the Turbine.

3.2.6 Software Setup

The bell speeds that are used while processing a job are commanded by entering the requested values as entries in System Color Preset table data. Bell speed commands during color change are entered as parameters in Color Change
Presets. The PaintTool software application in the robot control system sends these commands to the Bell Speed Control System.

Setting Cruise Speed

The cruise speed is the commanded bell speed when the robot is not processing a job or is idle. The cruise speed is typically 30,000 RPM.

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3.3 Troubleshooting
This section provides troubleshooting guidelines for faults generated by the Bell Speed Control System. This section is organized by PaintTool fault number (note that PNT1 faults are documented here, but PNT2 faults with the same
fault name would have the same troubleshooting procedure.). PNT1 faults generally reference robot equipment 1 and 2 (eq1,andeq2) . PNT2 faults generally reference equipment 3 through 6 Each bell speed fault has its PaintTool
manual description and remedy. The most common faults are then followed by a “Troubleshooting procedure” which offers instruction on steps to take to isolate the malfunction.

3.3.1 PNT1-701 PAUS %sMax. output has speed < setpoint

Cause: With a maximum control output the speed was measured to be lower than the setpoint (requested speed). This can occur if:
1. The gun is clogged.
2. The turbine air or turbine pilot air line is pinched.
3. The turbine air pressure is too low.

Remedy: Check the turbine lines for pinching, especially at places where they flex. Check the turbine air supply pressure. Check and replace the I/P transducer, if necessary.

Troubleshooting procedure:
1. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.
2. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.
3. First, verify bearing air is turned on then check turbine. If spindle won’t turn easily by hand then replace turbine.
4. If spindle turns, then
a. Replace turbine with a part that is known to be good.

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b. Command replacement turbine at speeds up to set point. If each speed is met with no alarms, then replace turbine.
c. If PNT1-701 alarm reoccurs, then check turbine air lines for kink or other issues.
d. If no issues with hose, perform Keyence optical feedback test.
e. If either maximum value is less than 2000 then perform Bell speed feedback troubleshooting.
f. If both maximums are 2000 or greater, then replace I/P Transducer (in PCE).The original turbine may be returned to the applicator.

3.3.2 PNT1-702 WARN %sRequested speed over valid range

Cause: The requested turbine speed output command is above the range that is considered valid Adjust the turbine speed command that is used in the preset table so it is within an acceptable range.

Remedy: N/A

3.3.3 PNT1-703 WARN %sFailed to reach setpoint

Cause: The turbine speed failed to come within the Tolerance Band setting within the time setting of Min. set point reached (ms) value. This can be caused by noise in the speed sensor signals, low air supply pressure or other failures.
This may occur with the alarm Max. output has speed < setpoint . If the Max. output has speed < setpoint alarm is also in the alarm log follow the remedies for that alarm. Examine the displayed turbine speed and evaluate if it is bouncing
a lot. If so decrease the PID gains. Possibly increase the Tolerance Band parameter by about 30% to 50%, for example from 1.8% to 2.3%. Increase the Min. set point reached value by about 30% to 50%.

Remedy: N/A

Troubleshooting procedure:
1. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.
2. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.
3. Check bell speed setup parameters:
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The SET POINT REACHED TOLERANCE (%) value is near the bottom of the list. The default is 3. If the actual value is less than 3, change the value to 3 and re-test bell speed.
4. IF PNT1-703 alarm reoccurs then continue troubleshooting.
5. First, verify bearing air is turned on then check turbine. If spindle won’t turn easily by hand then replace turbine.
6. If spindle turns, then check bell speed fiber optic circuit as follows:
a. Perform Keyence optical feedback test and Bell speed feedback troubleshooting (if necessary).
b. If both maximum values are greater than 2000, then
x Run a ghost job and collect bell speed DMON data, and send the data to FRA for analysis.
x Replace the turbine

3.3.4 PNT1-704 PAUS %sZero turbine speed timeout

Cause: All of the conditions were set for the turbine to be spinning but a zero speed was measured for a set time period. This might be due to no turbine air pressure or pilot air pressure. One of the following items might be broken: the
I/P transducer, speed sensor pickup, speed sensor interface. The Zero speed timeout might be set too short.

Remedy: If the turbine can be seen spinning, check the following: the speed sensor interface and speed sensor pickup. Otherwise, check the other items listed above. Possibly increase the Zero speed timeout by about 50%.

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Troubleshooting procedure:
1. Observe the bell. If it is spinning during the alarm then:
a. Check bell speed setup parameters:
x On teach pendant, choose SETUP menu for BELL SPEED
x The ZERO SPEED TIMEOUT (ms) value is near the bottom of the list. The default is 3000 (3000 ms = 3 seconds). If the actual value is less than 3000, change the value to 3000 and re-test bell speed.
2. If PNT1-704 re-occurs then there is a feedback issue
x Perform the Keyence optical feedback test.
x Perform the Bell speed feedback troubleshooting procedure.
b. If the bell is not spinning

3. If the bell is not spinning

a. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.
b. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.

4. Verify bearing air is turned on then check turbine. If spindle won’t turn easily by hand then replace turbine.

5. If spindle turns, then verify connections to turbine drive I/P transducer (in PCE):
a. Verify electrical cable is connected properly.
b. Verify air connections are plumbed properly.

6. If no issues are found with the connections of the I/P transducer, then replace the I/P transducer.

3.3.5 PNT1-705 PAUS %sTurbine over speed

Cause: While the turbine was operating the RPM level was above the Over speed limit . When this error occurs, braking will be applied to bring the turbine speed to within the acceptable operating range. Check and replace the I/P
transducer if necessary. Possibly increase the Over speed limit value.

Remedy: N/A

Troubleshooting procedure:
1. Check bell speed setup parameters:
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The MAXIMUM SPEED (krpm) default value is 65. If the actual value is less than 65, change the value to 65 and re-test bell speed.

2. If the fault continues with MAXIMUM SPEED set to 65, then reset the I/P transducer:
a. Put the controller in TEACH Mode.
b. Cycle power on the controller.

3. If the fault continues to occur then perform the Keyence optical feedback test
a. If either maximum value from the Keyence optical feedback test is less than 2000, then perform the Bell speed feedback troubleshooting procedure.
b. If both maximum values are above 2000, then replace the turbine drive I/P transducer.

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3.3.6 PNT1-706 WARN %sTurbine under speed fault

Cause: While the turbine was operating and the gun was on or enabled, the RPM level was below the Under speed limit . Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures, if either one is low,
increase it. Possibly decrease the Under speed limit value.

Remedy: N/A

Troubleshooting procedure:
1. Check bell speed setup parameters:
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The AUTO UNDER SPEED LIMIT (krpm) should be set to 0.
c. The MANUAL UNDER SPEED LIMIT (krpm) should be set to 0.
d. Correct the parameter values.

3.3.7 PNT1-707 WARN %sTurbine under speed warning

Cause: While the gun was off or disabled and the turbine was operating the RPM level was below the Under speed limit, Manual . Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures, if either one
is low, increase it. Possibly decrease the Under speed limit, Manual value.

Remedy: N/A

Troubleshooting procedure:
1. Check bell speed setup parameters:
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The AUTO UNDER SPEED LIMIT (krpm) should be set to 0.
c. The MANUAL UNDER SPEED LIMIT (krpm) should be set to 0.
d. Correct the parameter values.

3.3.8 PNT1-708 WARN %sSpeed avg. error excessive

Cause: Checks for how far the speed is from the set point have been too high. Possible causes are:
x A sticking I/P transducer
x Low supply air pressure
x Low pilot air pressure
x PID Gains that are too large.

Remedy: Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures. If either one is low, increase it. Possibly decrease the Max. error from setpoint parameter.

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3.3.9 PNT1-709 PAUS %sBearing Air NOT OK

Cause: The digital input signal indicating the Bear Air is above the minimum pressure is not ON. Check the supply pressure to the Bearing Air or verify the digital input signal is working correctly.

Remedy: N/A

Troubleshooting
1. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct. If pressure is correct then continue troubleshooting.
2. Use a gage that is known to be good and verify the pressure reading of the bearing air sensor. Replace the bearing air sensor if its reading is incorrect.

3.3.10 PNT1-710 WARN %sCruise Speed not established

Cause: The Cruise Speed determined during the Bell Speed Startup Test could not be established.

Remedy: Redo the Bell Speed Startup Test to determine a new Cruise Speed, or check the turbine or regulator.

3.3.11 PNT1-716 WARN %sTurbine Startup Test Not Complete

Cause: The Bell Speed Control Startup Test for the turbine is not complete. This test must be performed before running the turbine.

Remedy: Check the Start Mode field on the Bell Speed SETUP menu to check the status of the Startup Test. If it has not been performed, run the Bell Speed Control Startup Test.

3.3.12 PNT1-717 PAUS %sMax.dV/dT detected

Cause: A velocity change within a measured time has exceeded the maximum dV/dT setting for this turbine.

Remedy: Check the hardware to determine if the feedback signal from the turbine is consistent.

3.3.13 PNT1-718 PAUS %sMax. output has speed < setpoint

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Cause: With a maximum control output the speed was measured to be lower than the setpoint (requested speed). The gun might be clogging. The turbine air or turbine pilot air line might be pinched. The turbine air pressure might have
become too low.

Remedy: Check the turbine lines for pinching, especially at places where they flex. Check the turbine air supply pressure. Check and replace the I/P transducer if necessary.

Troubleshooting procedure:
1. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.

2. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.

3. First, verify bearing air is turned on then check turbine. If spindle won’t turn easily by hand then replace turbine.

4. If spindle turns, then

a. Replace turbine with a part that is known to be good.
b. Command replacement turbine at speeds up to set point. If each speed is met with no alarms, then replace turbine.
c. If PNT1-718 alarm reoccurs, then check turbine air lines for kink or other issues.
d. If no issues with hose, perform Keyence optical feedback test.
e. If either maximum value is less than 2000 then perform Bell speed feedback troubleshooting.
f. If both maximums are 2000 or greater, then replace I/P Transducer (in PCE).The original turbine may be returned to the applicator.

3.3.14 PNT1-719 WARN %sRequested speed over valid range

Cause: The requested turbine speed output command is above the range that is considered valid Adjust the turbine speed command that is used in the preset table so it is within an acceptable range.

Remedy: N/A

3.3.15 PNT1-720 WARN %sFailed to reach setpoint

Cause: The turbine speed failed to come within the Tolerance Band setting within the time setting of Min. set point reached (ms) value. This can be caused by noise in the speed sensor signals, low air supply pressure or other failures.
This might occur with the Max. output has speed < setpoint alarm.

Remedy: If the Max. output has speed < setpoint alarm is also in the alarm log, follow the remedies for that alarm. Examine the displayed turbine speed and evaluate if it is bouncing a lot. If so, decrease the PID gains. Possibly increase
the Tolerance Band parameter by about 30% to 50%, for example from 1.8% to 2.3%. Increase the Min. set point reached value by about 30% to 50%.

Troubleshooting procedure:
1. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.

2. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.

3. Check bell speed setup parameters:

a. On teach pendant, choose SETUP menu for BELL SPEED

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b. The SET POINT REACHED TOLERANCE (%) value is near the bottom of the list. The default is 3. If the actual value is less than 3, change the value to 3 and re-test bell speed.

4. IF PNT1-720 alarm reoccurs then continue troubleshooting.

5. First, verify bearing air is turned on then check turbine. If spindle won’t turn easily by hand then replace turbine.

6. If spindle turns, then check bell speed fiber optic circuit as follows:
a. Perform Keyence optical feedback test and Bell speed feedback troubleshooting (if necessary).
b. If both maximum values are greater than 2000, then:
x Run a ghost job and collect bell speed DMON data, and send the data to FRA for analysis.
x Replace the turbine

3.3.16 PNT1-721 PAUS %sZero turbine speed timeout

Cause: All of the conditions were set for turbine to be spinning and a zero speed was measured for a set time period. This may be due to no turbine air pressure or pilot air pressure. One of the following items may be broken: the I/P
transducer, speed sensor pickup, speed sensor interface. The Zero speed timeout may be set too short. If turbine can be seen spinning, check: speed sensor interface, speed sensor pickup. Otherwise check the other items listed above.
Possibly iwncrease the Zero speed timeout by about 50%.

Remedy: N/A

Troubleshooting procedure:
1. Observe the bell. If it is spinning during the alarm then:
a. Check bell speed setup parameters:
x On teach pendant, choose SETUP menu for BELL SPEED
x The ZERO SPEED TIMEOUT (ms) value is near the bottom of the list. The default is 3000 (3000 ms = 3 seconds). If the actual value is less than 3000, change the value to 3000 and re-test bell speed.
b. If PNT1-721 re-occurs then there is a feedback issue:
x Perform the Keyence optical feedback test.
x Perform the Bell speed feedback troubleshooting procedure.

2. If the bell is not spinning:

a. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.
b. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.

3. Verify bearing air is turned on then check turbine. If spindle won’t turn easily by hand then replace turbine

4. If spindle turns, then verify connections to turbine drive I/P transducer (in PCE):
x Verify electrical cable is connected properly.
x Verify air connections are plumbed properly.

5. If no issues are found with the connections of the I/P transducer, then replace the I/P transducer.

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3.3.17 PNT1-722 PAUS %sTurbine over speed

Cause: While the turbine was operating the RPM level was above the Over speed limit . When this error occurs, braking will be applied to bring the turbine speed to within the acceptable operating range. Check and replace the I/P
transducer if necessary. Possibly increase the Over speed limit value.

Remedy: N/A

Troubleshooting procedure:
1. Check bell speed setup parameters:
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The MAXIMUM SPEED (krpm) default value is 65. If the actual value is less than 65, change the value to 65 and re-test bell speed.

2. If the fault continues with MAXIMUM SPEED set to 65, then reset the I/P transducer:
a. Put the controller in TEACH Mode.
b. Cycle power on the controller.

3. If the fault continues to occur then

a. perform the Keyence optical feedback test
x If either maximum value from the Keyence optical feedback test is less than 2000, then perform the Bell speed feedback troubleshooting procedure.
x If both maximum values are above 2000, then replace the turbine drive I/P transducer.

3.3.18 PNT1-723 WARN %sTurbine under speed fault

Cause: While the turbine was operating and the gun was on or enabled, the RPM level was below the Under speed limit . Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures, if either one is low,
increase it. Possibly decrease the Under speed limit value.

Remedy: N/A

Troubleshooting procedure:
1. Check bell speed setup parameters:
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The AUTO UNDER SPEED LIMIT (krpm) should be set to 0.
c. The MANUAL UNDER SPEED LIMIT (krpm) should be set to 0.
d. Correct the parameter values

3.3.19 PNT1-724 WARN %sTurbine under speed warning

Cause: While the gun was off or disabled and the turbine was operating the RPM level was below the Under speed limit, Manual . Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures, if either one
is low, increase it. Possibly decrease the Under speed limit, Manual value.

Remedy: N/A

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Troubleshooting procedure:
1. Check bell speed setup parameters:
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The AUTO UNDER SPEED LIMIT (krpm) should be set to 0.
c. The MANUAL UNDER SPEED LIMIT (krpm) should be set to 0.
d. Correct the parameter values

3.3.20 PNT1-725 WARN %sSpeed avg. error excessive

Cause: Checks for how far the speed is from the set point have been too high. Possible causes are:
x A sticking I/P transducer
x Low supply air pressure
x Low pilot air pressure
x PID Gains that are too large.

Remedy: Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures. If either value is low, increase it. Possibly decrease the Max. error from setpoint parameter.

3.3.21 PNT1-726 PAUS %sBearing Air NOT OK

Cause: The digital input signal indicating the Bear Air is above the minimum pressure is not ON. Check the supply pressure to the Bearing Air or verify the digital input signal is working correctly.

Remedy: N/A

Troubleshooting
1. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct. If pressure is correct then continue troubleshooting.
2. Use a gage that is known to be good and verify the pressure reading of the bearing air sensor. Replace the bearing air sensor if its reading is incorrect.

3.3.22 PNT1-727 WARN %sCruise Speed not established

Cause: The Cruise Speed determined during the Bell Speed Startup Test could not be established.

Remedy: Redo the Bell Speed Startup Test to determine a new Cruise Speed, or check the turbine or regulator.

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3.4 Troubleshooting Procedure

3.4.1 Keyence optical feedback test:
This test will evaluate the strength of the optical signal used to control the bell speed. The Keyence fiber optic sensor sends and receives an optical signal that is reflected off a spinning surface in the applicator turbine. The strength of the
reflected signal is displayed in a digital readout on the fiber optic sensor the maximum value is 4095. At FANUC robotics, systems are verified to read between 3850 and 4095 under ideal conditions. When values of the signal reflected
from the mirror are below 2000, the fiber optic system should be repaired.

1. The Keyence fiber optic sensor is visible thru window in PCE.

2. The Keyence Fiber-optic unit displays two numbers. The green number is the signal threshold (factory setting = 1400) and the red number is the signal value.
3. While slowly turning the bell cup by hand observe the signal value (red number on the Fiber-optic sensor).
4. As bell is turned one full rotation, the signal value should rise and fall twice. Record the two maximum values (they should occur about 180 degrees apart).
5. If either maximum value is 2000 or less then perform the Bell speed feedback troubleshooting procedure.

3.4.2 Bell speed feedback troubleshooting procedure.

Use this procedure when Keyence optical feedback test produces maximum feedback values less than 2000. When bell speed feedback is weak, there are three components which may be the cause of the feedback losses: the fiber optic
wrist cable, the applicator fiber optic cable and the turbine. This procedure may help identify which of these components is causing the problem.

1. Remove applicator and perform inspections of bell speed feedback system.

2. Remove turbine and verify all 3 o-rings on back face of turbine are installed correctly.
3. Inspect mirror (silver region) of speed wheel . This is visible through the hole adjacent to an alignment pin (near the turbine exhaust). Gently turn spindle to observe speed wheel. If mirror dirty, clean it (through the hole) with alcohol and a lint-free
cloth. IMPORTANT!: Do not disassemble turbine. Re-assembly without the proper tools can damage the turbine.

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Speed “mirror” is visible through

this hole

Figure 3-18: Turbine speed wheel mirror location

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4. Inspect turbine end of applicator fiber optic cable. If fiber ends appear damaged or scratched, replace the applicator fiber optic cable. Clean the fiber ends with a soft cloth if necessary. Use only water or alcohol to clean the
fiber (other solvents will damage the fiber).

Applicator fiber-optic cable

Figure 3-19: Applicator fiber-optic cable nose location

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Inspect the quick disconnect end of the applicator fiber optic cable. If fiber optic ends appear damaged or scratched replace the applicator fiber optic cable. Clean the fiber ends with a soft cloth if necessary. Use only water or alcohol to
clean the fiber (other solvents will damage the fiber).

Applicator fiber optic cable

Figure 3-20: Applicator fiber-optic rear location

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5. Inspect the quick disconnect end of the wrist fiber optic cable. If fiber optic ends appear damaged or scratched replace the wrist fiber optic cable (see EG-00439 or EB-03658 for proper procedure). Clean the fiber ends with a soft
cloth if necessary. Use only water or alcohol to clean the fiber (other solvents will damage the fiber.

Wrist Fiber Optic Cable

Figure 3-21: Wrist Fiber-Optic Cable

1. If changes were made based on the above inspections, re-assemble the applicator and repeat Keyence optical feedback test. If both maximum feedback numbers are below 2000, or if no changes were made, continue
troubleshooting.
2. Inspect connection of wrist fiber optic cable at connector at the FRP. Verify that the connectors are retained by the plastic clips by pulling gently on the connectors. If the connection was loose, correct it and repeat the
Keyence optical feedback test.
3. If none of these inspections reveal a clear problem, then replace the components in this order (repeat the Keyence optical feedback test after each replacement to observe the impact of the new component.

i. Fiber optic wrist cable

ii. Turbine
iii. Applicator fiber optic cable.

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MARMCP7AP07071E REV. B 3 Bell Speed Control System

3.5 Spare Parts & Tools

3.5.1 Spare Parts Required
Bell Speed Fiber Optic Cable Assembly Current Rev. Location Robot Model / Version

EE-4560-651-001 E Servo Bell Applicator N/A / N/A

EE-4560-652-002 F Servo Bell Applicator N/A / N/A

EE-4526-653-001 E VersaBell I Applicator N/A / N/A

EE-4560-653-001 F VersaBell II Applicator (90 deg) N/A / N/A

EE-4560-653-002 C VersaBell II Applicator (60 deg) N/A / N/A

EE-4560-654-001 H Outer Arm - FRP to QD P-500 / 1k (Short Arm)

EE-4560-654-002 E Outer Arm - FRP to QD P-500 / WB (Short Arm)
P-700 / All Versions
EE-4560-654-003 E Outer Arm - FRP to QD P-500 / 1k (Long Arm)
EE-4560-654-004 E Outer Arm - FRP to QD P-500 / WB (Long Arm)
EE-4560-654-005 E Outer Arm - FRP to QD NOT USED
EE-4560-654-006 D Outer Arm - FRP to QD P-250 / 1k (Short Arm)
EE-4560-654-007 D Outer Arm - FRP to QD P-250 / 1k (Long Arm)

EE-4560-655-001 E Inner Arm - PCE - FRP P-500 / N/A

EE-4560-655-002 A Inner Arm - PCE - FRP P-700 / N/A
Table 3-1: Spare parts required

Keyence O/E Converter Assemblies Current Rev. Robot Model / Version

EE-4696-020 B P-500 / P-700iA with CPX process I/O package
EE-4696-021 A P-500iA / P-700iA with EX600 process I/O package
EE-4696-022 B P-700iA with EG / EX600 process I/O package
EE-4696-023 A P-250iA with Remote PCE
Frequency F/I Converter Assembly
EE-4696-010 A P-500 / P-700iA with CPX process I/O package

Table 3-2: Keyence O/E assemblies

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3 Bell Speed Control System   MARMCP7AP07071E REV. B

3.5.2 Tools Required

No special tools are required for servicing the bell speed control system other than the tools specified for servicing the VersaBell applicator.

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MARMCP7AP07071E REV. B 4 Bearing Air control

4 BEARING AIR CONTROL

4.1 Overview
4.1.1 Introduction
The bearing air supply and monitoring system supplies air to the turbine bearing and verifies that the pressure stays above 75 psi. The bearing air of the turbine keeps the turbine rotor (shaft) floating so that the turbine rotor is allowed to
rotate freely and not come into contact with the turbine housing.

The bearing air must always be on when the turbine is spinning. If the turbine is commanded to rotate when the bearing air is off, the turbine shaft will come into contact with the turbine housing while rotating and damage the turbine.
All air delivered to the turbine must be clean and dry to prevent damage to the bearing surfaces.

4.1.2 System Components

Figure 4-1: Bearing Air Schematic

4.2 Operations and Setup

The bearing air circuit starts at the supply panel manual regulator. The manual regulator at the supply panel connects to 2 accumulator tanks. The outlet of the accumulator tanks connects to a 8mm push to lock fitting. A dedicated 6 x 8
mm nylon hose runs from the supply panel, through the cattrac, to the PCE. Inside the PCE, the 8mm line plugs into a fitting a Y-fitting that also connects to the Bearing Air P/I Pressure Sensor. The Y-fitting outlet is 6mm. The bearing
air is then supplied through a 4 x 6 mm nylon hose to the applicator wrist manifold, where it connects to a 6mm barrel fitting. The identifying mark on the FRP plate and the quick disconnect manifold is BEAR.

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4 Bearing Air control   MARMCP7AP07071E REV. B

4.2.1 Manual regulator at supply panel

The manual regulator located at the supply panel regulates the flow of the air supplied to the robots connected to each pneumatic panel. The pressure setting for this regulator is 6 bar measured dynamically, i.e. when the robots are
spraying material.

Figure 4-2: Manual supply pressure regulator on the Pneumatic Supply Regulator

4.2.2 Accumulator Tanks

Figure 4-3: Accumulator tank location on the Pneumatic Supply Panel

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MARMCP7AP07071E REV. B 4 Bearing Air control

4.2.3 Bearing Air P/I

The Bearing Air P/I reads the pressure of the Bearing Air line inside the PCE, and sends the analog feedback value to the control system via the BEAR cable. Please see the robot specific manual for bearing air P/I location.

4.3 Maintenance and Repair

There is no preventative maintenance for this system.

4.4 Troubleshooting
4.4.1 PNT1-709 PAUS %sBearing Air NOT OK
Cause: The digital input signal indicating the Bear Air is above the minimum pressure is not ON.

Remedy:
x If the Bearing Air pressure is below the specified value, verify that the pressure sensor at the Pneumatic Air Supply panel is at least 85psi dynamic. If not, use the manual regulator located at the Pneumatic Air Supply panel to
increase the pressure to the correct level

x If the Pneumatic Air Supply panel pressure is at the correct level, check the Bearing Air line for any leaks. If necessary, change any fittings or lines that have leaks.

x If there are no leaks and the Bearing Air low pressure is not a problem for all robots in the zone, switch applicators with another robot that has a verified Bearing Air pressure value higher than the threshold.

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MARMCP7AP07071E REV. B 5 Shape Air Control System - D/Q

5 SHAPE AIR CONTROL SYSTEM - D/Q

5.1 Overview
5.1.1 Introduction
The Shape Air Control System delivers the requested shape air flow rate to the applicator using a mechanical closed loop device to compensate for downstream pressure fluctuations and the Shape Air Sense (SAS) feedback to monitor
the system for leaks or plugged shape air nozzles. The Shape Air Sense feedback watches the manifold pressure at the Shape Air Nozzle and compares the measured value to the expected value. If the measured value falls outside the
allowed range, a warning or fault is posted to alert the user of a problem in the shape air system.

The flow control system is calibrated during assembly and does not need to be recalibrated in the field. A simple automatic procedure is used to calibrate the Shape Air Sense monitoring for the particular shape air nozzle or applicator
that is installed.

5.1.2 System Components

The schematic below shows the components of the Shape Air Control System and how they are connected to each other.

Figure 5-1: D/Q Shape Air Schematic

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5 Shape Air Control System - D/Q   MARMCP7AP07071E REV. B

5.2 Operation and Setup

The following sections describe the installation of the components of the Shape Air Control System and the software setup features that are required for operation.

5.2.1 D/Q Air Flow Control Valve

The DQ Air Flow Control Valve (Digital to Flow) controls the shaping air flow rate in the Shape Air Control System. It receives the commanded flow rate from the Pneumatic Control System via the communication system. Internal
valves are opened or closed to deliver the requested shaping air flow rate. A mechanical closed loop flow control device continuously makes fine adjustments to compensate for down stream pressure fluctuations.

Installation
The DQ valve is connected to the Pneumatic Control System by a 9-pin communication cable as shown in the schematic in section 6.1.2. The communication cable is connects to the top of the D/Q Valve and is secured with small screws
retained by the cable connector. It may be necessary to connect the cable and tighten the screws before mounting the D/Q Valve in the robot.

The D/Q valve is mounted to the robot with two 6 mm socket head screws through the body of the valve.

The air inlet and Shape Air outlet ports on the bottom of the DQ valve are 3/8 G thread. The exhaust port on the side of the D/Q valve is a 1/4 G thread. Pipe dope or Teflon tape should not be applied to the threads of the fittings.
Tighten the fittings until the seal of the G fitting is tight against the body of the DQ Valve.

The D/Q Valve air supply must be dry, filtered, and regulated to 85 psig (air quality per DIN ISO 8573-1: 3.4.4). Depending on air usage, the system pressure regulator may need to be set to 87-89 psig in order to maintain 85 psig at the
D/Q Valve inlet. Inconsistent supply pressure to the D/Q Valve will cause errors in the shape air flow regulation.

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MARMCP7AP07071E REV. B 5 Shape Air Control System - D/Q

Figure 5-2: D/Q valve block

5.2.2 P/I (analog output pressure gage)

The P/I is the pressure sensor in the Shape Air Sense system. It reads the manifold pressure from the Shape Air Sense (SAS) line and sends the analog feedback value to the control system via the SAS cable.
Installation
The P/I is mounted to a DIN rail by a spring-loaded clip. A push-lock fitting receives the 4mm air line (SAS). The electrical cable is connected at the top of the sensor. The sensor is set to the proper units during assembly and does not
need to be adjusted in the field.

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5 Shape Air Control System - D/Q   MARMCP7AP07071E REV. B

Figure 5-3: Pressure Sensor (P/I)

5.2.3 Software Setup

Shaping air flow rates that are used while processing a job are commanded by entering the requested values as entires in System Color Preset table data. Shaping air flow rate commands during color change are entered as parameters in
Color Change Presets. The PaintTool software application in the robot control system sends these commands to the Shape Air Control System.

5.2.3.1 D/Q Air Control Valve Calibration

D/Q Valve calibration is only necessary if the D/Q valve is replaced or if the calibration table stored the controller memory is lost. Note: You must have the proper security level to change the D/Q calibration. A calibration table is
supplied with each D/Q Valve and is associated to the D/Q Valve by serial number.

Warning: D/Q Valve Calibration requires that the D/Q Valve supply pressure is 85 psig. If the supply pressure is greater or less than 85 psig, the actual flow rate will be higher or lower than expected.

To edit the calibration table for D/Q valve, enter the ‘DQ Shaping Air Calibration’ screen in Paint Works.

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MARMCP7AP07071E REV. B 5 Shape Air Control System - D/Q

Figure 5-4: D/Q Valve Calibration Screen in PaintWorks

To calibrate the Shape Air Sense feature:

x Choose 10 data points of Command Value and Flow (SLPM) from the calibration table.
x Choose points that represent the full range of flow rates (for example: 25, 50, 75, 100, 125, 150, 175, 200, 225, & 250 Command Values).
x Enter these data points in the given fields on the DQ Calibration Screen.
x After updating the D/Q Valve Calibration you should perform Shape Air Sense Calibration (see section 6.2.3.2).

Shape Air Sense Calibration

In order to provide maximum sensitivity, the Shape Air Sense feature must be calibrated whenever the Shape Air Nozzle or Applicator is changed.

Warning: Only calibrate the Shape Air Sense feature on newly cleaned Shape Air Nozzles! Calibrating using a dirty Shape Air Nozzle will reduce the sensitivity of Shape Air Sense and may result in nuisance alarms.

To calibrate the Shape Air Sense feature:

x Select the calibrate button on the Shaping Air Calibration screen.

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5 Shape Air Control System - D/Q   MARMCP7AP07071E REV. B

x Select the robot(s) to calibrate and select the Auto Calibrate button. It takes about two minutes for the calibration to finish.
x The expected pressure for each flow value is saved in the calibration table. These values are used to set warning and fault limits for the Shape Air Sense feature.

Figure 5-5: Shape Air Sense Calibration Screen in PaintWorks

Startup Test
After the D/Q Valve and Shape Air Sense have been calibrated, a startup test can be performed on the Shape Air Control System in order to verify that it is working properly. To perform this test:
x Verify that the robot is in Manual Mode and at its home position.
x Verify that the applicator is enabled.
x Open the Fluid Maintenance Screen in Paint Works.

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MARMCP7AP07071E REV. B 5 Shape Air Control System - D/Q

Figure 5-6: Fluid Mantenance Screen in PaintWorks.

xSelect the robot to be tested.

xEnter a valid Shape Air flow rate (50-500) in the Shaping Air (SLPM) field.
xEnter a time (in seconds) for the Test Duration field
xPress the ‘Start Test’ button.
xThe manifold pressure (as measured by SAS) is reported in the Actual field.
xThe system is working properly if this value matches the Expected Manifold Pressure within the tolerance.

5.2.3.2 Shape Air Control System Parameters

The following parameters can be viewed on the DQ Calibration Screen or Shape Air Sense calibration screen in Paint Works.

DQ Cal Status
Displays the result of the Shape Air Sense calibration for the DQ Valve.

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5 Shape Air Control System - D/Q   MARMCP7AP07071E REV. B

Calibration Step Delay (ms)

Default: 5000
Range: 1000-9999
During calibration, the DQ system increases the command output to the DQ valve in even increments, waiting this length of time at each level, and records the air pressure on the output and manifold transducers. This value should be
long enough for the system to react to the command change and stabilize

Grace Period (ms)

Default: 5000
Range: 0-9999
This item is the delay time that needs to expire before the Output and Manifold pressures are monitored. The Grace period time and the Calibration step delay should be equal, allowing the DQ system to react and stabilize before
pressures are monitored

Out of Tolerance Time (ms)

Default: 5000
Range: 0-9999
This item is the time duration that the pressure needs to be out of tolerance before a warning or an alarm is posted. This time duration starts when the grace period time ends.

Manifold Pressure Warning (%)

Default: 10
Range: 1-15
This item is the percent warning tolerance of the manifold pressure that is being monitored. If the current pressure exceeds the ideal pressure by this percentage value for the duration specified by the Out Of Tolerance Time, a warning is
posted.

Manifold Pressure Alarm (%)

Default: 20
Range: 16-30
This item is the percent alarm tolerance of the manifold pressure that is being monitored. When the current pressure exceeds the ideal pressure by this percentage value for the duration specified by Out of tolerance time, an alarm is
posted.

5.3 Maintenance and Repair

The Shape Air Control System is designed to function without planned maintenance for the life of the robot. Occasionally a failure of the supply air filter system can cause contamination the D/Q Valve and degrade its performance. The
following procedures can be used to clean the D/Q Valve of this contamination.

5.3.1 Cautions & Warnings

The following cautions and warnings should be observed every time a D/Q Valve is serviced.

Never Adjust Calibration Screws

The caps identified the figure below, cover (4) calibration screws for the D/Q Valve. There are (4) additional calibration screws under the Name Plate on the front of the valve. Adjustment of any of these screws is not necessary during
the service life of the D/Q Valve. Adjustment of these screws will result in inaccurate Shape Air flow rates, and require the unit be returned to the manufacturer for recalibration.

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MARMCP7AP07071E REV. B 5 Shape Air Control System - D/Q

Figure 5-7: Calibration Screw Covers

Never Interchange Internal Components between D/Q Valves
The piston, cylinder, and spring significantly affect the performance of the D/Q Valve. During cleaning, care should be taken to ensure that these components are reinstalled into the same valves from which they were removed.
Interchanging components between D/Q Valves may result in inaccurate Shape Air flow rates.

Replacement of Lost or Damaged Parts

Replacement parts for the D/Q Valve are available in the D/Q Valve Spare Parts Kit (EO-4696-110-031). Refer to Section 3 of this Engineering Bulletin for a replacement procedure. Any components that are not included in this kit (for
example the piston, cylinder, or spring) are not available as spare parts. If a component that is not part of the Spare Parts Kit is lost or damaged, the D/Q Valve must be returned to the manufacturer to be rebuilt and recalibrated.

5.3.2 D/Q Valve Cleaning Procedure

This procedure provides instruction on the proper way to clean a D/Q Valve. This procedure can be used to clean all D/Q Valves

1. Using a 3/16” hex wrench, remove the (4) stainless steel screws in the bottom of the D/Q Valve and separate the upper valve block (aluminum) and the lower valve block (black delrin).

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