NMSPSAE5.DOC 1

RCV-1 - SmartPad

AUTOMATION AND CONTROL TOUCH-PAD FORACCUDRAFT

INSTALLATION AND TECHNICAL MANUAL

INSTALLATION AND STARTUP

The State of Art suggest:- Keeping the signal cables (probes and digital transmitters) far from power circuits and cables;route these lines with screened cables.- Installing instruments far from power components like contactors, motors, motor drives, variablefrequency drives, and so on...

Make electrical connections according to the wiring diagram included in this manual.WARNING: the RCV-1 unit must be supplied with voltage at 24V AC as shown on the instrumentrating plates. Make sure to power the electronic equipments with the correct voltage, neverconnect the supply line directly to power components that may generate spikes and spuriousfrequencies or use the RCV-1 terminals to supply other power components.The RCV-1 is resistant to electrical noise, but in case of non-stabilized supply lines, or if strongelectrical noise is present in the factory networks, we suggest that you install a suitable main filteron the power panel.When switching noise is present, install suitable RC filters across load coils.Do not overload the RCV-1 output relays, which are rated at 5A/250V AC on resistive loads.When driving reactive loads such as motors, contactors, etc, the spurious current generated maybe 8-10 times the standard contact rating.

The operation of this unit is advised and granted inside the temperature range32°F (0°C) ÷ 125°F (55°C).Starting from lower temperature it may be necessary for the unit to reach this range in few minutesthanks to the internal burn-in temperature.

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INDEX

1. FRONT PANEL1.1 Operator panel description pag.31.2 Description of displays, leds and keys pag.4

2. PARAMETERS FOR REGULATION AND CONFIGURATION2.1 Regulation parameters menu pag.52.2 Configuration parameters menu pag.6

3. TIME COUNTER pag.103.1 Resetting time counter pag.10

4. OPERATION4.1 Switching on the automation panel pag.104.2 Preparation and spraying pag.114.3 Flashing pag.124.4 Curing pag.124.5 Function of the IntellCure system pag.134.6 Cooling pag.134.7 Autotuning pag.14

5. PRESSURE REGULATION5.1 Booth not equipped with V.F.D. pag.145.1.1 Manual pressure control pag.145.1.2 Automatic pressure control pag.155.2 Spray booth equipped with V.F.D. pag.155.2.1 Manual pressure control pag.165.2.2 Automatic pressure control pag.17

6. ALARMS pag.18

7. RELAYS CYCLE and TIMING pag.19

8. CONNECTIONS ON TERMINAL BOARD pag.20

9. WIRINGS pag.22

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1.2 DESCRIPTION OF DISPLAYS, LEDS AND KEYS :

Display 1: shows temperature read by probe (in °C or °F)

Display 2: shows Set-Point of spraying temperatureDisplay 3: shows Set-Point of flashing temperatureDisplay 4: shows Set-Point of curing temperature.Display 5: shows Set-Point of cooling temperature.Display 6: shows pressure in booth read by electronic pressure transducer

If no pressure transducer is installed, this display remains off.Display 7: shows total and partial hours of booth functionDisplay 8: shows unit of measurement: °C or °F

Key 1: START process cycle

Key 2: permit programs selection (M.o.1. and M.o.2.) and parameters visualization.

Key 3: advance process key: serves to pass from one stage of the cycle to another.

Key 4: UP arrow: serves to edit parameters

Key 5: DOWN arrow: serves to edit parameters

Key 6: TIMER : serves for programming and editing timing for the flashing, curing and cooling stages (in minutes).

Key 7: adjust aperture of modulating damper (0-100 %) or motor speed of fans in booth with variable frequency drive (0-100 %).

Key 8 : switch on lights 1.

Key 9 : switch on lights 2.

Key 10: change Set-Point of spraying temperature

Key 11: change Set-Point of flashing temperature

Key 12: change Set-Point of curing temperature

Key 13: change Set-Point of cooling temperature

Key 14: serves to edit the Set-Point of the pressure in automatic control mode the Set-Point value is limited by the parameters in configuration L.h.P. and L.L.P.

Key 15: burner on/off

Key 16: STOP processing stage in progress press once (led on key will blink) to skip to the cooling stage. If you press it again (led on key remains lit) the cycle is stopped completely.

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2. PARAMETERS FOR REGULATION AND CONFIGURATION

RCV-1-S does not require knowledge of the software programming languages. It isadapted to the system through parameters:

- regulation parameters: adapt operation of the RCV-1-S to the desired specifications

- configuration parameters: serves to adapt the RCV-1-S to the type of machine orsystem.

The units are supplied already equipped with a base parametrization according theprototype setup, on which value adjustment can be effected from the customer when thefinal destination of the booth has been established, or units can be supplied fullyconfigurated by ITM via SW according customer parameters value.

2.1 REGULATION PARAMETERS MENU

To access the regulation parameters, press the UP and DOWN keys together for 2 sec.,set a code value of 123 for C.n.F. with the UP key (password) and confirm with key 2 (P).Display 6 will show the code of the parameter and display 7 will show the value that canbe edited with the UP and DOWN arrows.

Depending on how the working output is configured (ON/OFF, or PID) the parametersdiffer.There are also different parameters between programs for spraying (Spray = S) and thosefor curing (curing-off = b).Use key 2 (P) to go to the next parameter until you are ready to exit the menu.

Configuration of work output ON/OFF:

h.L.S. hysteresis at bottom point of work in the spray, flash, cool stage (0÷19.9 °C)h.h.S. hysteresis at the top point of work in the spray, flash, cool stage (0÷19.9 °C)h.L.b. hysteresis at the bottom point of work in the curing stage (0÷19.9 °C)h.h.b. hysteresis at the top point of work in the curing stage (0÷19.9 °C)A.L.S. threshold to order 2nd flame of burner in the spray, flash, cool stage (±19.9 °C)h.A.S. hysteresis to order 2nd flame of burner in the spray, flash, cool stage (0÷19.9 °C )A.1.S. threshold of minimum pressure alarm in booth in spray, flash, cool stage (-1÷-99

Pa )A.2.S. threshold of maximum pressure alarm in booth in spray, flash, cool stage (1÷99

Pa )A.L.b. threshold to order 2nd flame of burner in the curing stage (±19.9 °C )h.A.b. hysteresis to order 2nd flame of burner in the curing stage (0÷19.9 °C )

With automatic pressure regulation in booth (parameters P.r.E. = 1 and i.n.o. = 1)there are also parameters for pressure control:i.P. integral pressure regulation time (1÷999 sec. )P.h.h. upper limit of pressure dead bandP.h.L. lower limit of pressure dead bandP.S.t. pressure regulation pause time (1÷99 sec. )

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Configuration of PID work output:

P.S. proportional band working point of spray, flash, cool stage (0÷999 °C )i.S. integral time working point of spray, flash, cool stage (0÷999 sec. )d.S. derivative time working point of spray, flash, cool stage (0÷999 sec.)P.b. proportional band working point of curing stage (0÷999 °C)i.b. integral time working point of curing stage (0÷999 sec.)d.b. derivative time working point of curing stage (0÷999 sec.)A.u.t. Autotuning.A.L.S. threshold to order 2nd flame of burner in the spray, flash, cool stage (±19.9 °C)h.A.S. hysteresis to order 2nd flame of burner in the spray, flash, cool stage (0÷19.9 °C )A.1.S. threshold of minimum pressure alarm in booth in spray, flash, cool stage (-1÷-99

Pa )A.2.S. threshold of maximum pressure alarm in booth in spray, flash, cool stage (1÷99

Pa )A.L.b. threshold to order 2nd flame of burner in the curing stage (±19.9 °C )h.A.b. hysteresis to order 2nd flame of burner in the curing stage (0÷19.9 °C )

With automatic pressure regulation in booth (parameters P.r.E. = 1 and i.n.o. = 1)there are also parameters for pressure control:i.P. integral pressure regulation time (1÷999 sec. )P.h.h. upper limit of pressure dead bandP.h.L. lower limit of pressure dead bandP.S.t. pressure regulation pause time (1÷99 sec. )

2.2 CONFIGURATION PARAMETERS MENU

Access to the configuration parameters is only possible when no program is running.Press the UP and DOWN keys together for 2 seconds, enter a value of 321 for C.n.F.(password) and confirm with key 2 (P). Display 6 will show the code of the parameter anddisplay 7 will show the value of the parameter which can be edited with the UP andDOWN arrows. Use key 2 (P) to go to the next parameter until you are ready to exit themenu.

i.n.1. selection of the type of input temperature probe (0÷7)0 = thermocouple J 0÷870°C1 = thermocouple J 0÷999°F2 = thermocouple K 0÷999°C3 = thermocouple K 0÷999 °F4 = PT100 9.9÷99,9 °C5 = PT100 9.9÷99,9 °F6 = PT100 99÷500 °C7 = PT100 9÷999 °F;

i.S.1. offset of calibration of temperature value (±19.9 °C)

L.r.1. selection of type of regulation of work output:1 = heating ON/OFF2 = cooling ON/OFF3 = heating PID4 = cooling PID7 = P.I.D. for open-stop-close motorized valve;

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t.c.1 cycle time of work output (0÷999 sec.)NOTE: the cycle time is on only with PID adjustment

with t.c.1. = 0 the output is continuously on 4÷20 mA;

L.A.1. RA output logic ( 2nd burner flame)0 = output off5 = output on (±19.9°C with respect to working SET point);

u.P. pressure’s readings unit measure0 = Pascal1 = in WC;

P.t.r. presence of pressure transducer0 = pressure transducer absent1 = pressure transducer present;

i.S.P. offset of calibration in reading of pressure transducer (±100 pascal);S.h.P. scale top of input of pressure transducer (±999 pascal );S.L.P. scale bottom of input of pressure transducer (±199 pascal);L.h.P. upper limit of pressure Set-Point in automatic regulation mode;L.L.P. lower limit of pressure Set-Point in automatic regulation mode;L.P.A. alarm value of minimum pressure in the booth;h. P.A. alarm value of max pressure in the booth;

P.r.E. pressure regulation0 = manual pressure regulation1 = automatic pressure regulation;

S.h.S. scale top for temperature of spraying stage;S.L.S. scale bottom for temperature of spraying stage;S.L.F. scale bottom for temperature of flashing stage;h.F.t. maximum time settable for flashing;L.F.t. minimum time settable for flashing;

S.h.b. scale top for temperature of curing stage;S.L.b. scale bottom for temperature of curing stage;h.b.t. maximum time settable for curing;L.b.t. minimum time for settable for curing;

S.h.c. scale top for cooling temperature;S.L.c. scale bottom for cooling temperature;h.c.t. maximum time settable for cooling;L.c.t. minimum time settable for cooling;

E.i.1. program n°1, stand-by (preparation) stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

S.i.1. program n°1, spraying stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

F.i.1. program n°1, flash-off stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

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b.i.1. program n°1, curing stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

c.i.1. program n°1, cooling stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

E.i.2. program n°2, stand-by (preparation) stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

S.i.2. program n°2, spraying stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

F.i.2. program n°2, flash-off stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

b.i.2. program n°2, curing stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

c.i.2. program n°2, cooling stage: fan-motors intake, percent (0÷100%) of V.F.D. frequency;

L.A.P. switch on lights during flashing stage0 = lights off during the stage (they can be switched on with keys 8 and 9)1 = lights on during the stage (they can be switched off with keys 8 and 9);

L.E.S. switch on lights during curing stage0 = lights off during the stage (they cannot be switched on with keys 8 and 9)1 = lights off during the stage (they can be switched on with keys 8 and 9);

L.r.A. switch on lights during cooling stage0 = lights off during the stage (they cannot be switched on with keys 8 and 9)1 = lights off during the stage (they can be switched on with keys 8 and 9);

L.E.n. switch on lights at end of cycle0 = lights off at end of cycle1 = lights on at end of cycle;

b.u.r. operating mode of burner during cooling stage0 = burner always off1 = burner on upon reaching Set-Point of cooling stage;

t.1.S. delay starting fan motor on intake in spraying stage (relay RVI) 0÷99 sec;t.2.S. delay starting fan motor on exhaust in spraying stage (relay RVE) 0÷99 sec;

t.0.b. delay switching over gate in curing stage (relay RS) 0÷99 sec;t.1.b. delay starting fan motor on intake in curing stage (relay RVI) 0÷99 sec.

(t.1.b. = 0 the motor does not pause);

t.2.b. delay starting motor on exhaust fan in curing stage (relay RVE) 0÷99sec.(t.2.b. = 0 the motor does not pause);

t.0.c. delay switching over gate at end of cooling stage (relay RS) 0÷99 sec.t.1.c. delay starting fan motor on intake in cooling stage (relay RVI) 0÷99 sec.

(t.1.c. = 0 the motor does not pause);

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t.2.c. delay starting motor on exhaust fan in cooling stage (relay RVE) 0÷99 sec.(t.2.c. = 0 the motor does not pause);

d.A.P. delay activating pressure alarm in booth at start of cycle and/or start of motor after delay for change of stage.delay in start of automatic pressure regulation at start of process cycle and/or start of motors after delay for change of stage;

S.b.t. Curing time start on reaching temperature setting with respect to Set-Point (0÷-199);

b.t. curing-time: time after which curing stage timer starts even if S.b.t. value not reached(0÷99 min.)

b.t. = 0 function off;

i.n.o. fan motor control0 = no inverters (pressure regulation with damper1 = with 2 inverters (1 for intake and 1 for exhaust);

E.i.E. exhaust fan motor enabled during curing stage (0-1)0 = exhaust fan motor off (relay RVE off)1 = exhaust fan motor on (relay RVE on);

i.c.S. IntellCure system function0 = function disabled1 = function enabled;

t.S. burner motorized valve (three position, open-stop-close): opening valve time (10÷300 seconds);

d.y. minimum step of motorized valve adjustment (1÷10%);

L.E.i. preparation stage intake motor speed: minimum percent (0÷100%) settable;

L.E.E. preparation stage exhaust motor speed: minimum percent (0÷100%) settable;

L.S.i. spraying stage intake motor speed: minimum percent (0÷100%) settable;

L.S.E. spraying stage, exhaust motor: minimum percent (0÷100%) settable;

L.F.i. flash-off stage intake motor speed: minimum percent (0÷100%) settable;

L.F.E. flash-off stage, exhaust motor: minimum percent (0÷100%) settable;

L.b.i. curing stage intake motor speed: minimum percent (0÷100%) settable;

h.b.E. curing stage, exhaust motor: maximum percent (0÷100%) settable;

L.c.i. cooling stage intake motor speed: minimum percent (0÷100%) settable;

L.c.E. cooling stage, exhaust motor: minimum percent (0÷100%) settable;

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3. TIME COUNTER

With the cycle stopped, display “7“ shows the total hours of operation of the booth.During spraying stage, display “7“ shows the hours of spraying time.

3.1 RESETTING THE TIME COUNTER

Resetting the time counter should be done after stopping the process: press the UP andDOWN keys together, use the UP key to enter the value CnF = 500, then press key 2 (P).After a few seconds the timer will reset and the displays will return to stand-by status.

4. OPERATION

4.1 SWITCHING ON THE AUTOMATION PANEL

When the equipment is switched on the following displays are on: display 1 (probetemperature), display 8 (°C or °F as unit of measurement), display 2 (Set-point fortemperature in spraying stage), display 3 (Set-Point for temperature in flashing stage),display 4 (Set-Point for curing stage), display 5 (Set-Point for cooling stage if parameterb.u.r. =1, otherwise it remains off), display 6 (pressure in booth if equipped with pressuretransducer, otherwise it remains off), display 7 (total working hours of booth) and the ledon key “15“.Before starting a process cycle, the temperature and timing can be programmed (there isno timing for the spraying stage) of all stages.Editing the Set-Point of the temperature is done by pressing the Set-Point key (the led inthe key will blink) for the stage affected, then using the UP (4) and DOWN (5) keys: pressthe Set-Point key again to confirm. The led stops blinking and the new setting remains inthe memory. To edit the timing of each stage (except spraying) press the Set-Point key ofthe stage then press key 6 (TIMER) (the led blinks) : the time setting appears on the leftdigits of display 7 and can be changed using the UP (4) and DOWN (5) keys, press key 6(TIMER) again to save the new setting. To edit the Set-Point of the temperature andtiming (editing of timing is temporary if the stage in which the value is changed has alreadybegun) can be done while the process is running. Press keys ”8” and “9“ to light therespective leds and relays for the control of lights 1 and 2.Two different work cycle operation modes can be set:

Mode 1 = M.o.1.Mode 2 = M.o.2.

Mode 1 includes following stages:

Preparation (stand-by): (present only with fan-motors V.F.D.);Spraying: (enabled by input signal on terminal boards n°62-63 from spay-gun action);Flash-off: (by pushing the “advance” key, n°3);Curing: (up to n°2 curing steps at different programmable values of temperature and

time);Cooling.

Undesidered stages are avoided by setting their time = 0.

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Mode 2 according water-paints use:

Preparation (stand-by);Spraying;Flash-off;Spraying;Flash off (enabled by the “advance” key n°3 pushing);Curing (up to n°2 curing steps at different programmable values of temperature and time).

Stages whose time is set to 0 are avoided, and cycle go-on with the following stage);

Cooling.

M.o.1. standard work cycle start with preparation step (not used without V.F.D.) andgoes-on to spraying stage (to reach to spraying stage is required spray-gun approval on62-63 RCV-1 wirings): successively the cycle continue (by pressing n°3 key) to flash-off,curing (2 steps curing possible with different temperature and time) and cooling stages.Step with setted time = 0 are excluded and the cycle proceed with next step.Work cycle M.o.2. is appropriate for water paint. Stepped-out preparation, spraying andflash-off stage, M.o.2. permit to have a second spraying stage; by pushing n°3 key(advance) the cycle proceed to a second flash-off stage and then, to curing stage (it ispossible to have 2 curing steps with different time and temperature) and cooling.Step with setted time = 0 are excluded and the cycle proceed with next step.NOTE: To repeat a series of spraying and flash-off operations, push “P” key after sprayingto enter flash-off stage with the repetition of this sequence.To stop the sequence and enter the next stage (for instant curing), push the “advance“ key(n°3).

4.2 PREPARATION AND SPRAY STAGES

The program to run (M.o.1 or M.o.2.) is selected by pushing the “P” key.The preparation stage is activated by pushing the “START” key (LED on).The spray-gun approval, (62-63 wirings of RCV-1) allow to cross from preparation step tospraying step.After 90 seconds of unused spray-gun, cycle return from sprayng step to preparation step.NOTE: On booth equipped with V.F.D., in preparation step, different values of intake andexhaust fan motors velocity are programmable than other values in spraying stage: onbooth without V.F.D. there are no difference between preparation and spraying stages.Display 2 shows the set-point of the preparation and spray stage: press key ”10“ (led on)to change the Set-Point of the spraying stage using the “UP” and “DOWN“ keys.Displays 3, 4, 5 are off, display 6 shows the pressure in the booth (if provided with theelectronic pressure transducer with signal 4÷20 mA, otherwise the display remains off),display 7 shows the hours of operation of the booth in the spraying + flashing + coolingstages. During the preparation and spray stage the lights are on, the intake and exhaustfans motors are on, the burner is on and consent is given to the spray gun for spraying.Consent is given to the burner or hot water battery only after the start of fan-motors on theintake (ON relay RVI). Consent to the solenoid valve of the spray gun (ON relay RE) isgiven only after the exhaust fan motor starts (ON relay RVE).Press “STOP“ to stop the spraying stage; pressing it once (the led on the key will blink) theprocessing stage goes on to perform the cooling stage, pressing it again (the led on thekey remains on with fixed light) the process is stopped completely.

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4.3 FLASHING

To go from the spraying stage to the flashing stage press key “3“ (the led in the key lightsup).Display 3 shows the set-point of the flashing stage: press key ”11“ (led on) to edit the Set-Point of the flashing stage with the “UP” and “DOWN”Display 7 on the 2 left digits shows the initial time of duration of the flashing stage (0÷99min.) while the two right digits show the count-down of the remaining time blinking.Press key “6“ (TIMER) to edit with the “UP“ and “DOWN“ keys the blinking count-down ondisplay 7 (right digits)Displays 2,4,5 are off, display 6 shows the pressure in the booth (if provided with theelectronic pressure transducer with signal 4÷20 mA, otherwise the display remains off),display 7 shows on the 2 left digits the duration of flashing and on the 2 right digits theblinking count-down of time remaining.During the flashing stage the lights are on (they can be off as a parameter),the intake andexhaust fans motors are on, the burner is on: there is no consent to the spray gunsolenoid for spraying.At the end of flashing time and depending on the selected program, the work cycle will goon as follow:

M.o.1. program: the cycle enter the curing stage.M.o.2. program: the cycle returns in spraying stage (see 4.1 paragraph “Switching

on the automation pad”).It is permitted to stop the flashing stage before of the set time and to start the next stagewith a five seconds long pushing the key n°3 (advance cycle).Flashing stage is stopped by pushing the key STOP as follows:Single time pushing (led begins to flash) enables the cooling stage.Two times pushing (led remains lit) permits the work cycle stop.

4.4 CURING

Display 4 shows the set-point of the curing stage: press key ”12 “ (led on) to edit the Set-Point of the curing stage with the "UP" and "DOWN" keys. Display 7 shows the initialduration of the curing stage on the 2 left digits (0÷99 min.) while the two right digits showthe blinking count-down of time remaining. Press key “ 6 “ (TIMER) to edit, with the "UP"and "DOWN" keys, the blinking count-down of remaining time on display 7 (right digits)Displays 2,3,5 are off, display 6 shows the booth pressure (if provided with the electronicpressure transducer with signal 4÷20 mA, otherwise the display remains off), display 7shows the total duration of the curing stage on the 2 left digits and the blinking count-downof the time remaining on the 2 right digits.Note: the count-down of the time in the curing stage starts from when the set temperatureis reached (parameter S. b. t.).During the curing stage the intake and exhaust fans motors are on (the exhaust fan motorcan be off as a parameter setting), the burner is off: the lights are off and there is noconsent to the solenoid valve on the spray gun for spraying, the gate for air recycling isswitched over (ON relay RS).Consent to the burner or hot water battery is only given after starting the intake fan motor(relay RVI). During the curing stage automatic pressure regulation is disabled.At the end of the curing stage, the process continues with the cooling stagePress key “3“ (advance process) for 5 seconds to go from the curing stage to the coolingstage before the end of the curing time. Press key “STOP“ to stop the curing stage;

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pressing it once (the led on the key will blink) the processing stage goes on to perform thecooling stage, pressing it again (the led on the key remains on with fixed light) the processis stopped completely.

4.5 FUNCTION OF THE INTELLCURE SYSTEM

If you set parameter i.c.S. = 1, the process after flashing performs a sequence of 2 curingstages (temperature and timing are programmable) and ends with the cooling stage.Press key “ 12 “ (Set-Point for curing stage ); on display “1“ you will read “P.b.P .“(Pre Curing Period); on display “ 4 “ you will read the value of the Set-Point of the 1st

curing stage, which can be edited using the “UP“ and “DOWN“ keys, press key “6“(TIMER) will show on display “7“ the time (in minutes) of the 1st curing stage, which can beedited with the "UP“ and “DOWN“ keys (the count-down of the time starts upon reachingthe temperature Set-Point). During the count-down display “4“ also blinks.Pressing key “12“ twice in a row on display “1“ after the message “P.b.P.“ will display themessage “b.P.“ (Curing Period); on display “4“ you will read the value of the Set-Point ofthe 2nd curing stage, which can be edited with the "UP" and "DOWN" keys, pressing key“6“(TIMER) on display “7“ will show the time (in minutes) of the 2nd curing stage, which canbe edited with the “UP “ and “DOWN“ keys. Time and temperature can be edited before orduring the process stage.

4.6 COOLING

Display 5 shows the set-point of the cooling stage only if parameter b.u.r . = 1, otherwise itremains off: pressing key ” 13 “ (led on) you can edit the Set-Point of the cooling stagewith the “UP” and “DOWN“ keys. Display 7 shows the initial duration time of the coolingstage on the 2 left digits ( 0-99 min.) while the two right digits show the blinking count-down of time remaining. Press key “ 6 “ (TIMER) to edit, with the "UP" and "DOWN" keys,the blinking count-down of remaining time on display 7 (right digits). Displays 2,3,5 are off,display 6 shows the booth pressure (if provided with the electronic pressure transducerwith signal 4÷20 mA, otherwise the display remains off), display 7 shows the total durationof the cooling stage on the 2 left digits and the blinking count-down of the time remainingon the 2 right digits. During the cooling stage the intake and exhaust fan motors are on;the lights are off, the burner is off (it starts again at the cooling Set-Point if parameterb.u.r. = 1): there is no consent to the solenoid valve of the spray gun for spraying, therecycle gate returns to the OFF position.Note: with parameter b.u.r. = 1 the burner (or control of the hot water battery) starts againon reaching the cooling Set-Point.At the end of the cooling time the process ends: the led on the “STOP“ key will blink andthe automation panel returns to the initial conditions prior to starting the process.Press key “3“ (advance process) for 5 seconds to end the stage in progress before theend of the cooling time.

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4.7 AUTOTUNING

When the continuous output at 4÷20 mA is on with PID action it is possible to determine,with the autotuning function, the optimum parameters for the functions P,I,D, in thespraying (PS. iS. dS.) and curing (Pb. ib. db.) stages.Autotuning is done at the Set-Point of the program selected for spraying or curing.To enable the autotuning function (only possible with the program running) enterparameter A.u.t. = 1 and exit the regulation parameters menu: display “1“ will blink untilthe end of the autotuning process.In case of interruption of the program or passage to the next stage interrupting theautotuning function if in progress will maintain the previous P, i, d, parameters in thememory.

5. PRESSURE REGULATION

The RCV-1-S unit is provided with input from the pressure transducer 4÷20 mA for readingof the booth pressure.Display 6 (pressure reading) remains off if there is no electronic pressure transducer in thebooth (parameter P.t.r. = 0)With pressure transducer installed (parameter P.t.r. = 1) it is possible to read the boothpressure on display 6 and adjust it manually or automatically.

5.1 BOOTH NOT EQUIPPED WITH V.F.D.:

In this case the pressure control is effected by a damper controlled by a modulatingmotorvalve (belimo).

5.1.1 MANUAL PRESSURE CONTROL (parameters P.r.E. = 0 , i.n.o. = 0 ):

Manual control can be done with or without the installation of a pressure transducerWithout the pressure transducer, under normal operating conditions, display 6 remains off:press “7“ key (% out) to light its led and use the UP and DOWN keys to edit output 4÷20mA that controls the Belimo of the damper to determine the pressure in the booth: display“7“ shows the percentage of damper position (0÷100 %). Press “7“ key again to exit thepressure editing stage.With the pressure transducer in normal operating conditions, display 6 shows the boothpressure (in pascal or in WC).Press “7“ key (% out) to light the respective led and use the UP and DOWN keys to editoutput 4÷20 mA that controls the Belimo of the damper, to determine the pressure in thebooth: display “7“ shows the percentage of damper position (0÷100 %). Press “7“ keyagain to exit the pressure editing stage.N°14 key (SP) is disabled during manual pressure regulation.

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5.1.2 AUTOMATIC PRESSURE CONTROL (parameters P.r.E. = 1, P.t.r. = 1, i.n.o. = 0):

Automatic pressure control, work only in presence of pressure transducer: display “6”visualize the booth’s pressure (Pascal or inWC).By pushing n°14 key (key SP led will blink), display “6” show the booth pressure Set-Point:Set-Point value may be modified by using “UP” & “DOWN” key inside the range given byL.h.P. and L.L.P., pushing again n°14 key confirm the setted value and then, display “6”show the booth pressure readings.Damper exhaust opening, is automatically regulated to keep the booth pressure to Set-Point setted value (Pascal or inWC): damper exhaust opening increase (increase 4÷20mA signal to Belimo) if the booth pressure increase; and decrease (decrease 4÷20 mAsignal to Belimo) if booth pressure decrease.The parameters for automatic control of the pressure are found in the regulationparameters menù, and are:P.h.h., P.h.L.: parameters that determine the pressure range within which the boothpressure has to remain with respect to the pressure Set-Point.i.P.: (signal integration time) the speed with which the output of the exhaust fan invertercorrects the pressure variations with respect to the setting. (1÷999 sec.)P.S.t.: pause between one variation of the inverter output and the next (1÷99 sec.)Automatic control of the pressure starts at the beginning of the cycle and/or after startingthe motors for change of stage after the d.A.P time.Automatic booth pressure control is disabled during the curing stageDuring automatic pressure control key “7“ (key % out serves to display the motor speed(0÷100%) of the exhaust fans on display “7“ but cannot be used to edit the value: in thecuring stage, where automatic pressure regulation is disabled, after pressing key “7“, youcan use the “UP“ and “DOWN“ keys to edit the motor speed of the exhaust fans.Automatic booth pressure control is disabled when the booth doors are open (microswitchcontact open on terminals 66-67). In case of malfunction of the circuit of the pressuretransducer so that the signal goes beyond the scale top and scale bottom setting, display1 will blink (h.P.A. or L.P.A.), and the process is completely stopped.In case of malfunction of the pressure transducer it is possible to continue in the processby setting pressure regulation in “manual“ mode (with parameters P.t.r. = 0 and P.r.E. =0).The following values:

- Belimo valve input (4÷20 mA);- Exhaust damper opening percent (0÷100 %);

so as they have been calculated in the run of last work cycle, they remain memorized andadopted for every following cycle.It is possible to calibrate the position of the damper with reference to the displayed percentvalues (as can be necessary during the first installation of the booth or after the change offilters).In this evenience and when the cycle is stopped push the “% OUT” key and, by operatingon “UP” and “DOWN” keys, adjust the percent value indicated on n°7 display.

5.2 SPRAY BOOTH EQUIPPED BY VARIABLE FREQUENCY DRIVES

With V.F.D. present, the automatic pressure control is the normal operating mode but, ifneeded, RCV-1 permits also to operate in manual mode.

NMSPSAE5.DOC 16

5.2.1 MANUAL PRESSURE CONTROL (parameters P.r.E. = 0, i.n.o. = 1)

This manual control can be effected if the digital pressure transducer is present or not.

In a booth operating in normal work condition and equipped by the pressure transducer,the display n°6 will show the pressure value in Pascal or WC measure unity (both growthsare keyboard configurable).

In absence of the pressure transducer (P.t.r. value = 0), the n°6 display is OFF.

As you can remenber the intake motor-fan speed has been fixed by the parameters values(of the configuration menù) according the stage of the selected program.

M.o.1. programParameters E.i.1., S.i.1., F.i.1., b.i.1., c.i.1..

M.o.2. programParameters E.i.2., S.i.2., F.i.2., b.i.2., c.i.2..

Exhaust motor-fan speed can be manually controlled inside 0÷100% on every single stageof the two M.o.1. or M.o.2. programs.To adjust the exhaust motor-fan speed during the work cycle run, push “% OUT” key.The display n°7 shows the percent speed of exhaust motors, runnig inside the operatingwork stage.By “UP” and “DOWN” keys it is possible to set a new percent value, which will bememorized by pushing again “% OUT” key.The exhaust motor speed, so as set for every work stage, is memorized and recalled inevery following work cycle.The operating way can be repeated for any work stage to modify the exhaust motorspeed.In particular different speed values can be memorized on a different programs M.o.1. andM.o.2.During the manual control of the pressure the key “SP” (n°14) is disabled.The setted velocity value for exhaust fan motors remain the same for each other cycle.During the first installation of the booth, or after the filter sobstitution, it is possible (cyclestopped) to set the exhaust fan motors velocity (0÷100 %) for each step.By pushing the “P” key (led will blink), display “1” shows M.o.1., push “% out” key and next“SP” key: on display “7” appear the exhaust fan motors V.F.D. velocity (0÷100 %) duringthe preparation step, by “UP” and “DOWN” key it is possible to modify the value; pushagain the “SP” key to confirm the setted value.To set velocity value of the V.F.D. exhaust fan motors for other steps, proceed likedescription for preparation stage with this difference: after pushing “P” and “%out” key,push n°10 key for spraying step value, n°11 key for flash-off step value, n°12 key forcuring step value and n°13 key for cooling step value.To set value of the exhaust motor velocity for M.o.2. program, select with “P” key theM.o.2. program and repeat all the things write before for M.o.1..

ATTENTION: for safety condition it is necessary that the booth is equipped with safetypressostats; calibrated to limit overpressure as well underpressure dangerous events.RCV-1 terminals n°64 and 65are dedicated to the input (24 Vac) of the alarm signal (AL5)of safety pressostats.

NMSPSAE5.DOC 17

5.2.2 AUTOMATIC PRESSURE CONTROL (parameters P.r.E. = 1, P.t.r =1 , i.n.o. = 1)

Automatic pressure regulation work only in presence of pressure transducer: display “6”show booth pressure (Pascal or inWC).Intake fan motors velocity is setted from parameters of the configuration menù (for M.o.1.program: E.i.1., S.i.1., F.i.1., b.i.1., c.i.1.; for M.o.2. program: E.i.2., S.i.2., F.i.2., b.i.2.,c.i.2.), instead, exhaust fan motors velocity (0÷100 %) is automatically regulated on eachstep of two programs M.o.1. and M.o.2..Pushing n°14 key, display 6 show the booth pressure Set-Point. The Set-Point value maybe modify using “UP” & “”DOWN” key inside the range given by L.h.P. and L.L.P.parameters; confirm the value by pushing again n°14 key (SP), then the display show thebooth pressure readings.Automatic pressure regulation in booth with V.F.D. regulate the exhaust fan motorsvelocity which increase (increase the 4÷20 mA signal of V.F.D.) if the pressure in thebooth increase, instead decrease (decrease the 4÷20 mA signal of V.F.D.) if decrease thebooth pressure.The automatic pressure regulation parameters are:P.h.h., P.h.L.: which determine the pressure range to keep inside the booth towards Set-Point.i.P.: (integral time signal) it is the velocity that the V.F.D. use to control the exhaust motorto correct the pressure variation towards setted value (1÷999 sec.).P.S.t.: Pause between output variation of the V.F.D. and the next one (1÷99 sec.).Automatic pressure regulation starts at the beginning of the cycle, and/or after the starts ofthe motor phase changing after the d.A.P. time.Automatic pressure regulation inside the booth is inhibited during the curing step.During the automatic pressure regulation, n°7 key allow the velocity visualization (0÷100%) of the exhaust fan motors on display 7, but doesn’t modify the value: on curing step(with automatic pressure regulation excluded) by pushing n°7 key and “UP” & “DOWN”keys it is possible to modify the exhaust fan motor velocity.Automatic pressure regulation of the booth is inhibited when the doors are open (66-67open contact).In case of damage to the pressure transducer, “L.PA. or h.P.A” will blink on display 1 andthen the cycle will be blocked.In case of damage to the pressure transducer it is possible to go-on with all other workingstep by setting the pressure regulation in manual mode (P.t.r. = 0 and P.r.E. = 0).

Exhaust fan motors velocity value setted for each step, remain the same for next cycle.

During the first installation of the booth or after the substitution of the filters, it is possible,with stopped cycle, to set the exhaust fan motor velocity for each step.Press “P” key, display 1 show M.o.1. writing, push “%out” key and then “SP” key: ondisplay 7 will appear the exhaust fan motors velocity (0÷100 %) during the preparationstep, by using “UP” & “DOWN” keys it is possible to modify the value. Pushing again “SP”key to confirm the new setted value.To set new value for exhaust motor V.F.D. velocity for other step, proceed like thepreparation step, with this difference: after push “P” and “%out” keys, push: n°10 key forspraying step value, n°11 key for flash-off step value, n°12 key for curing step value andn°13 key for cooling step value.To set the value of exhaust fan motor velocity on program M.o.2., select with “P” keyM.o.2. program and repeat all the things write for M.o.1. program.

NMSPSAE5.DOC 18

6. ALARMS

AL1: SAFETY THERMOSTATThe message AL1 appears on display “1“ , the led on key 15 goes off and the relay RAL isenergized: the burner control is blocked (relay RA and RB not energized , output 4-20 mA of themodulating valve is at 4 mA), the fans motors remain on: press key 15 to eliminate the alarmcondition and enable the burner control again

AL2: BURNER BLOCKEDThe message AL2 on display “1” and the led on the burner blink, the relay RAL is energized: thefans motors remain on: press key 15 (key for activation of burner) or another key to eliminate thealarm condition

AL3: FIRE DAMPERThe message AL3 on display “1” blinks and relay RAL is energized: the cycle is completelyblocked.

AL4: MOTOR OVERHEATThe message AL4 on display “1” blinks and relay RAL is energized: the cycle is completelyblocked.

AL5: SAFETY PRESSURE SWITCHThe message AL5 on display “1” blinks and relay RAL is energized: the cycle is completelyblocked.

READING OF DISPLAY 6 BLINKING: PRESSURE IN BOOTHDuring the process, if the pressure in the booth exceeds either the minimum or maximum boothsetting (parameters A.1.S, A.2.S. for the spraying, flashing and cooling stages: the curing stage isexcluded as it is not subject to pressure regulation), the display of the booth pressure readingblinks. Blinking of the pressure reading stops when the pressure returned within the minimum andmaximum settings. At the beginning of every process or when the motors are started after thedelay for change of process stage, the alarm for error of the booth pressure is given with a delaydetermined by the parameter d.A.P. which serves to allow the booth pressure to return withinbounds.

AL7: ANOMALOUS PRESENCE OF GAS DETECTIONThe booth must be equipped by dangerous gas sniffer.The sniffer activates the alarms AL7, displayed on display n°1, and RAL relay is energized. Motor-fans remain enabled and the burner and the spray-gun electrovalve are cut off. This alarm isenabled only in preparation and spray stages.

LLL, hhh: SHORT CIRCUIT, BREAKDOWN OF TEMPERATURE PROBEIn case of short circuit or breakdown of the circuit of the temperature probe, display “1“ showsrespectively LLL and hhh and the outputs that control the burner are automaticallyde-energized.

L.P.A.: MINIMUM BOOTH PRESSURE ALARMWhen the pressure in the booth falls under the value set on parameter L.P.A., a full stop of thework cycle occur and display n°1 shows the alarm L.P.A..

h.P.A.: MAX BOOTH PRESSURE ALARMIf the over pressure in the booth reaches the value set on the configuration parameter h.P.A., a fullstop of work cycle occur and display n°1 shows alarm h.P.A..

NMSPSAE5.DOC 19

7. RELAYS CICLE and TIMING

NMSPSAE5.DOC 20

8. CONNECTIONS ON TERMINAL BOARD RCV-1-S

1-) 24V AC POWER SUPPLY3-)

2-) GND

4-COM )5- NA ) RB – RELAY OF 1ST FLAME OF BURNER6- NC )

7- COM )8- NA ) RA – RELAY OF 2ND FLAME OF BURNER9- NC )

10- COM )11- NA ) RL1 – RELAY FOR CONTROL OF LIGHTS 112- NC )

13- COM )14- NA ) RL2 – RELAY FOR CONTROL OF LIGHTS 215- NC )

16- COM )17- NA ) RE - SPRAY GUN SOLENOID18- NC )

19- COM )20- NA ) RS – RELAY FOR CONTROL OF DAMPER21- NC )

22- COM )23- NA ) RAL – RELAY FOR ALARM SIGNALS24- NC )

25- COM )26- NA ) RVI - RELAY FOR INTAKE FAN MOTOR27- NC )

28- NA ) RVE- RELAY FOR EXHAUST FAN MOTOR29- COM )

30- ( + ) INI – OUTPUT 4÷20 mA FOR INVERTER FOR CONTROL OF INTAKE31- ( - ) FAN MOTOR

NMSPSAE5.DOC 21

32- ( + ) INE - OUTPUT 4÷20 mA FOR INVERTER FOR CONTROL OF EXHAUST33- ( - ) FAN MOTOR

34- ( + ) ANALOGUE OUTPUT FOR MODULATING VALVE (4÷20 mA)35- ( - )

36- ( + ) OUTPUT 14V DC TO POWER PRESSURE TRANSDUCER

40- )41- ) INPUT PT10042- )

46- ( + ) INPUT OF PRESSURE TRANSDUCER ( 4 ÷ 20 mA )47- ( - )

54- ) INPUT OF SAFETY THERMOSTAT ALARM ( 24V AC )55- )

56- ) INPUT OF BLOCKED BURNER ALARM ( 24V AC )57- )

58- ) INPUT OF FIRE DAMPER ALARM ( 24V AC )59- )

60- ) INPUT OF MOTOR OVERHEAT ALARM ( 24V AC )61- )

62- ) INPUT OF SPRAY-GUN (FOR THE CHANGE FROM PREPARATION63- ) TO SPRAY STAGE) - clean contact.

64- ) INPUT OF SAFETY PRESSURE SWITCH ALARM ( 24V AC )65- )

66- ) INPUT OF MICROSWITCH ON BOOTH DOORS ( 24V AC )67- ) (the contact closed enabled automatic pressure control)

68- ) INPUT OF SNIFFER ALARM (TO REVEAL DANGEROUS GAS PRESENCE)69- )

Note: The connections of the two wires pressure transducer 4÷20 mA to RCV-1terminal blocks are following:

- Positive connected with n°36;- Negative connected with n°46

NMSPSAE5.DOC 22

9. WIRINGS