Owners Manual

for
AACD #3 (PV600)
(Automatic Average Current Density)

PV600 Model
Rectifier Option # 11913

Your Name Here

Important! Save These Instructions. Published Sept. 2003

Please Read This Manual Before Using Equipment. All Rights Reserved.
Reproduction Without
Permission is Prohibited.

Revision 3
Part # 109746
 Table of Contents

Introduction Page

Safety 1.1
Theory of Operation 1.1
Specifications 1.1

Installation

Selecting a location 2.1

AC input 2.1
Wiring to Rectifier 2.1

Component Description

Component names and location 3.1

Programming Preparation

Record your history 4.1

Programming

Power up 5.1
Main Menu Screen 5.1
Entering Information 5.2
Set-Up Screen 1 5.2
Set-Up Screen 2 5.3
Set-Up Screen 2 continued 5.4
Voltage Compensation Level 5.5
Reference Guide for # Steps, Sample Timer and VCL 5.6

Operating

Operation Check 6.1

Main View Screen 6.1

Help Screens

Help Screens 7.1

Parts 8.1

Warranty 9.1

License Agreement 10.1

Introduction

Safety

The AACD device is very safe in terms of operational and personnel safety. All components are
provided in a NEMA 1 type industrial enclosure that requires a hand tool to open. Internal voltages
are usually 120 volts or less, but some may have up to 400 volts.

-EXERCISE EXTREME CAUTION IF THE DOOR

TO THE AACD IS OPEN FOR ANY REASON ! -

The Operator Interface Terminal (OIT) is either touch-screen or keypad type. These terminals are
designed for industrial applications that incur heavy use, and can be subject to wet conditions.

All wires used to communicate with the rectifiers are fully enclosed. A simple On/Off switch
located on the front panel gives the user the ability to turn the AACD system on or off. The off
position returns normal rectifier function via customer PLC, remote or rectifier door panel controls.

Theory of Operation

In simple easy terms, the AACD device automatically adjusts the Rectifier DC output voltage to a
calculated voltage level that is desirable for the present load conditions. The execution of the
voltage adjustment is completely automatic, and determined by loading conditions. The load
conditions will vary, depending on the size of the part(s) and quantity entering the tank.

The results of the automatic voltage adjustments will be more consistent film thickness over a
variety of load sizes. Naturally, less paint will be used. You will be able to better meet target film
thickness levels for your diverse customer requirements. Conveyor/Hoist loading requirements
can be less organized, although some semblance of organization will help the AACD determine
the proper voltage to apply.

The AACD will not give 100% accurate film coatings with different part sizes, it is intended to
narrow the film variation. The performance will vary with the users operating conditions, and
optimum programming settings.

Specifications

Enclosure: NEMA 1 type. Ventilated, gasketed. 16”W x 20”H x 8”D typical.

Weight: Approximately 40 lbs.
Color: Industrial White Hi-Gloss Epoxy (special Acid resistant paint).
PLC: Processor with I/O (processor type varies)
OIT: Allen-Bradley Panel view 600 touch-screen or keypad
AC Input: 120vac, Single phase, 60 Hz, 5 amperes.

1.1
Installation

Selecting a Location

The AACD device is provided in a steel enclosure suitable for mounting to a wall, the side of the
Rectifier or Unistrut® type mounting channel. The AACD device should be located in an area that
is easily accessible to the operator, but not in a high traffic area where tampering may occur. The
AACD should be mounted high enough where the OIT is at eye level (67 inches or less for most
ergonomic directives). Allow 3 feet in front of the AACD for easy accessibility.

AC Input

The AC input power for the AACD system requires 120 volts. Although the device only requires 5
amperes or less to operate, good electrical practice should dictate a dedicated 15 amp feed, with
upstream fuse or circuit breaker protection.

Wiring to Rectifier

The interconnecting wiring between the Rectifier(s) and the AACD should be performed by CPC
personnel, or a qualified electrician. Certain minor modifications my be required within the
Rectifier to accept the AACD device and coordinate operational functions like 2-level output
control, slope control or other optional features already in the Rectifier.

There are high-voltage signals (120vac) and low voltage signals (10vdc) between the AACD and
Rectifier controls. The DC signals should be wired with BLUE colored wire, and the AC wires
should be YELLOW in color. In certain cases, the AACD can be powered from the control power
(120vac) inside of the Rectifier. In this case, Yellow wire should still be used for the 120vac
power. Yellow wire indicates a separate source of power. Qualified personnel opening the AACD
OR Rectifier door will identify the Yellow wire and exercise care.

If the AACD device is located more than 5 feet from the Rectifier, separate conduit must be used
to separate the low voltage wire from the high-voltage wire. This will help prevent cross-talk or
induced noise. Any length of “wire run” should have separated wires for high and low voltage
signals.

It is highly recommended that authorized personnel from Controlled Power Company be used to
make the final wiring installation of the AACD device within the Rectifier. Because some
modifications may be required, this will maintain the AACD/Rectifier warranty, and expedite the
final installation without harm to the Rectifier or AACD system.

2.1
Component Description

AC Power Supply
Operator Interface OIT Voltage and
Terminal (OIT) Power Supply Control Relay Inter-connection terminal strip
(terminal strip location may vary)

Chassis

On/Off Switch PLC Processor I/O Modules Consisting of:

and AC input module
Power Supply Relay module
(PLC Type varies) Analog input and output module
(I/O module type varies)

Item Description
PLC processor Programmable Logic Controller Of AACD System
Allen-Bradley PV 600 OIT Operator Monitor and programming terminal
Power Supply Power supply for Programmable Controller (if required)
Sola DC Power Supply 24vdc power for OIT (0ptional)
I/O Modules Interface devices between “PLC” and Rectifier
Voltage Control Relay Switches Rectifier Voltage input signal
On/Off Switch Turns on the AACD and overrides the Rectifier.
Chassis Frame used to plug in all PLC hardware (type varies)
Interconnection Terminal Convenient means of connecting AACD to Rectifier

3.1
Programming Preparation

Record Your History

You will expedite the programming stages of the AACD device by keeping a diary of Rectifier
voltage as it is required to obtain your target paint thickness. Mandatory information includes DC
current levels as it relates to the particular part(s) in the tank, and voltage levels that are best
suited to meet the required paint thickness. Continuous conveyor users should note the current
levels and desired voltage levels with staged part entries to help determine an average anticipated
current density rating. Other useful recordings are for time settings which will vary depending on
line speed, part gapping and frequency of irregular loaded parts on the carrier.

Example: Dial the rectifier voltage to a level that has been known or calculated to give a desired
film thickness. (Note: The paint supplier can help, and usually makes the recommendation). Run
only the smallest amount of expected parts through the tank. Record your maximum current level
from the Rectifier’s ammeter, and note the time it took to reach the maximum current value. Also
record the amount of time it took from the moment the current started to rise, and the time it
dropped because it exited from the tank. Perform this same exercise, but with the largest
expected load (Don’t forget to dial in the new required voltage for correct film thickness). Another
recording should be done during normal production loading, to gain recordings that reflect the
medley of product painting. You will then have the minimum, maximum and average feel for
rectifier power requirements to meet the coating criteria.

Every user will have different loading methods whether they are controlled or not. A sample
history chart is provided below. More tables are available in the back of the manual.

*A column regarding time is mentioned for those using Hoist (Batch) Operations. This is optional
programming if the hoist is not automated. A timer will shut the Rectifier off automatically.

*Time
Part Voltage Current **Time
Description Required
Size Required Draw Delay
(Optional)

40 Sq Ft. Hood 320 235 Immediate 18 Seconds

Large Door 295 180 2 Seconds 16 Seconds

Small Lower A arm 270 70 3 Seconds 14 Seconds

etc etc etc etc etc etc

**Time Delay will be used for the sample timer setting.

4.1
Programming

Power Up

Turn the “AACD On/Off” switch to the Off” position. Apply the 120v input to the AACD and the
Main Menu Screen will appear. You may begin to program the system with numerical values that
you previously recorded or that which you believe will provide the best results. Refer to the
following pages for detailed instructions. The AACD does not adjust the rectifier voltage until the
AACD switch is turn to the “On” position. You may watch the “Voltage Set point” value in the
Operator or VCL view screens to verify operation within the limits you prescribe prior to allowing
the AACD to take over the Rectifier voltage control.

Note: It may take subsequent attempts at re-programming to “feather” the system to reach
optimum performance. It is normal to take several days even a week or more to program,
measure results and readjust the system.

Main Menu Screen

When AC power is applied to the AACD, the main screen will appear as shown below. The (▲,▼)
buttons on the right hand side of the screen moves the cursor. Press enter (↵) to select the
desired screen.

At any time you need help in understanding what the AACD device is asking for, simply press the
“Main Menu” button to return to this screen. From here you can access other screens by scrolling
down and highlighting the desired screen and pressing the “Enter” key. An alarm may also be
silenced with the “Alarm Silence” button on this screen. Optional screens in Spanish are available.

(2)
Your Company Name

Cursor

Optional

5.1
Set-Up Screens continued
Entering Information

The entering of data is easy. Simply press the area that you wish to enter data. For example,
press the number ### representing “Low Voltage Set”. This will display a vertical line next to the
number, indicating that it is selected and ready for a value to be inserted, and a key pad will
appear. Enter the desired value using this keypad and press the Press the “↵ Enter” Key to save
the data point. Do this for all ### value fields until programming is complete.

Set-Up Screen 1

Example: The smallest part (or group of parts)

in your tank draws 100 amps and requires 230
volts to achieve 1.0 mil film thickness. The
largest part (or group) draws 350 amps and
requires 280 volts for 1.0 mils. Then Enter:
Low Voltage Set = 230
High Voltage Set = 280
Low Current Set = 100
High Current Set = 350

Low Voltage Set.

This is the minimum DC voltage level that the AACD will allow the rectifier to fall to with the
exception of the VCL setting. The lowest voltage output will be this level plus or minus the VCL
level. This is your base line voltage, and is the level required to maintain desired film thickness on
the smallest part or rack with the lightest density of parts.

Caution- If changed when the actual rectifier current is above the Low Current Set Point, the
voltage output will drop to this setting plus or minus the VCL level. Time for monitoring and
calculation time must take place before voltage variation will commence.

High Voltage Set.

This is the maximum DC voltage level that the AACD will allow the rectifier to rise to with the
exception of the VCL setting. The highest voltage output will be this level plus or minus the VCL
level. This is the highest voltage that the rectifier should ever deliver to the process. It is desirable
to enter a level best suited for the largest part, or rack with the highest density of parts.

Caution- This level should be lower than the voltage level known to cause paint rupture.

Low Current Set.

This is the level of current that starts the AACD to start looking for the changes in load size.
Anything below this level is considered to be small in size, and the AACD will remain at the Low
Voltage Settings plus or minus the VCL level.

High Current Set.

This is the level of current that the AACD will stop looking for changes in load size. Current levels
just under this setting will usually have the AACD running at the High Voltage Settings plus or
minus the VCL level.
5.2
Set-Up Screens continued

Entering Information

Set-Up Screen 2

Set-Up Screen 2 Example: You have a conveyor line with a

wide variety of part sizes, and the conveyor
stops for short durations. Also, apply the
example on the previous page. Then Enter:
Number of Steps = 18
Sample Timer = 4
Volt/Comp Level = 10
Undervolt Setpoint = 210
Overvolt Setpoint = 360
Holding Voltage = 40

Number of Steps
This feature controls the number of voltage steps between the low and high voltage set points. It
gives flexibility for customers with conveyor and hoist systems. Typical values are between 3 and 25.
It is desirable to keep the value above 15 to minimize large steps in voltage for conveyor lines. Hoist
line users may prefer to enter lower values for immediate progression of voltage correction. See the
expanded explanation page 5.5

Always keep this setting in mind when “fine-tuning” the programming.

Sample Timer
This timer sets the time between voltage adjustments. Changes in current reflect changes in load
density, thus part size. The voltage will be adjusted automatically when the current change exceeds
the value calculated from the # of steps value. It is Recommended that the values lower than 3 are
avoided to prevent voltage oscillation, and values no higher than 10 be used so changes in density
are not missed. Conveyor users with dwell times lasting longer than 90 seconds may need to set the
timer longer than 10 seconds.

Always keep this setting in mind when “fine-tuning” the programming.

Volt / Comp Level

This level determines the amount of voltage change that will occur with each increase or decrease of
the Voltage Compensation Level located on the VCL screen. For Example: Entering a value of “15”
and selecting “2” on the VCL screen will raise the voltage 30 volts when the load density changes.
The VCL screen is a useful tool that the operator should use frequently to fine-tune the system and
comes in especially handy for necessary changes in voltage due to changes in bath chemistry.

Always keep this setting in mind when “fine-tuning” the programming.

5.3
Set-Up Screens continued

Entering Information

Set-Up Screen 2 (continued)

Set-Up Screen 2

Example: You have a conveyor line with a

wide variety of part sizes, and the conveyor
stops for short durations. Also, apply the
example on the previous page. Then Enter:
Number of Steps = 18
Sample Timer = 4
Volt/Comp Level = 10
Undervolt Setpoint = 210
Overvolt Setpoint = 360
Holding Voltage = 40

Undervolt Setpoint
This feature is a very important tool to recognize and alarm if problems with the AACD or Rectifier
operation occurs. Any failure in the AACD or Rectifier will usually result in a low or loss of voltage.
By monitoring for under-voltage conditions the user can be immediately notified of this condition. A
relay contact is available for Plant monitoring or connection to an audible alarm annunciator.

We highly recommend to the customer that use of this alarm is planned during the installation of the
system.

Overvolt Setpoint
Likewise with the under-voltage feature, any over-voltage condition can also be monitored. Typical if
the Rectifier malfunctions because of internal electronic control problem or shorted SCR
regulator/rectifier circuit,

Holding Voltage
Normally set between 0 and 50 volts, this is the level that the AACD device will force the Rectifier
output to when the conveyor stops. The Holding voltage is controlled by the AACD only when the
AACD device is on. The AACD is wired into the rectifier so no interference of the normal control
design will occur if the AACD is turned off.

The “HOLDING VOLTAGE SET POINT” should be set to match the Rectifier manual settings. The
paint supplier should help determine the level required. Conveyor stops of long duration should
require a low voltage of “0” or “10” volts. Shorter durations may require 30-50 volts.

5.4
 Set-Up Screens continued

VCL Screen

VOLTAGE COMPENSATION LEVEL

Changes in temperature and bath chemistry require adjustments to the operating voltage levels.
The AACD will adjust all voltage settings up or down. The value entered in this field represents the
scaling factor for the ‘VOLTAGE COMPENSATION LEVEL” add/subtract instruction. This value
may always tend to be small, providing the Paint Chemistry is maintained and minor daily voltage
adjustments are not necessary.

This screen also provides indications for DC on/off, conveyor running/stopped, actual output
voltage level, output current level and voltage set point level. A button is provided on this screen
to access to the Main Menu.

VCL Screen

Voltage Compensation Level (+ / -)

Use the (▲,▼) keys on the screen to raise

or lower the Voltage Compensation Level.

Press Enter ↵ key to store the setting.

Set-up 2 screen VOLTAGE

COMPENSATION
LEVEL Multiplied
by ### Value from Volt/Comp
entered on Set up 2 screen
= ###

Actual Voltage
Compensation
Level

Example 1: You would like to fine tune during the initial set-up phase, adjust the VCL by only a factor of
“1” (plus or minus) until a new history of paint thickness samples indicates improvements in the form of
less film deviation.

Example 2: Your paint bath temperature is colder than normal. It will require a higher voltage for more
throwing power to compensate. Adjust the VCL in a positive direction by 1 or 2. You will know the “feel”
for the proper adjustment after practice.

5.5
 Guide Sheet for # of Steps, VCL and Sample Timer
# of Steps
# of steps is the value used to divide the difference of current from the high level to the low level in order to
determine if a change in voltage is required.

This is also used to determine how much the voltage will change once enough current has triggered the voltage
adjustment.
Example The # of Steps is set for a value of 10
For Current:
The High Current is 350 The Difference between the two limits is 250
The Low Current is 100 Divide 250 by 10 to get a value of 25

It takes 25 amps of change in order for the voltage to adjust. How much will the voltage adjust ?...

Example The # of Steps is set for a value of 10

For Voltage:
The High Voltage is 280 The Difference between the two limits is 50
The Low Voltage is 230 Divide 50 by 10 to get a value of 5

For every time the current changes by 25 amps, the voltage will change by 5 volts.
If the current rises, the voltage rises. If the current lowers, the voltage lowers.

Sample Timer
Sample timer sets up the time delay between voltage changes. The AACD unit always samples the current
whether or not the AACD switch is on or off. The timer adds a delay time between changes in voltage.

Delay Time Delay Time Delay Time

Time Execute
Voltage
Change

Volt/Comp Level
Linearly adjusts the voltage and current thresholds positive or negative all at the same time. Useful for typical
changes due to bath chemistry or a quick convenient skew of setpoints for fine tuning.

310v
el •
4
3 280v
• 280v Ne
w L ev
• 280v
•
• •
Volts
Volts

2 260v 260v
1
0 230v
• 230v
• 230v
• Ne
w L ev
el

•
-1
200v
-2
-3
-4 Time Time Time
VCL
VCL set for Nominal or “0” VCL set for “+3” and VCL set for “-3” and
located
Volt/Comp level set for 10 Volt/Comp level set for 10
in VCL Screen
Voltage points rise by 30 volts Voltage points lowers by 30 volts

5.6
 Operating
Operation Check

Once all programming is completed, it is recommended that the AACD control switch is left in the OFF
position until automatic voltage adjustments are verified. Do this by watching the Operator View
Screen shown below. The “Voltage Setpoint” shows the voltage level commanded be the AACD. The
analog dials and numerical values always represent the actual rectifier voltage and current levels.

Once you are comfortable with the results, switch the AACD on. The AACD will override the rectifier
controls without interruption.

Operator View Screen

Designed for the operator to monitor on a daily basis. Includes graphical as well as text display of
the real-time voltage and current levels.

The conveyor and DC running status is also shown.

The voltage set point “###” is shown also, so the operator can compare the AACD command with
the actual output voltage level.

AACD Voltage Command

Actual Voltage Actual Current

6.1
Help Screens

This page shows all of the help screens available through the OIT.

Alarm Screen
The alarm screen appears for the following conditions:

Under Voltage
Over Voltage
Over Current

The screen can be cleared by pressing the F1 key.

The alarm contact will not latch, but will remain closed as
long as the alarm condition is present.
7.1
Part List

PLC Hardware Vendor Part # CPC Part #

AB PLC Processor # 1762-L24AWA 109159

AB Panelview # 2711-T6C5L1 109344
AB Analog Expansion # 1762-IF202F2 109161
AB Net AIC # 1761-NET-AIC 109339
Sola Power Supply # SDN-2.5-24-100 109102
PV to AIC Cable # 1761-CBL-AS09 109342
AIC to 1200PLC Cable # 1761-CBL-AM00 109343

PLC Software

AACD #3 Rev 1 N/A 109341

(Hoist)

Other

Remote Enclosure N/A 415014

On/Off Switch (handle) ZB4-BD2 2-pos 104134
On/Off Switch (Base) ZB4-BZ101 N.O. 104135
Control Relay 27E166 (SY4S-05) (Omron) 013789
Signal Conditioner Voltage N/A 201549
Signal Conditioner Current N/A 201527
Relay Socket MY4AC-110/120 016286
Terminals 019590
Terminal barrier 016457
Marker Strip 016458

Parts may vary with each system.

8.1
 CONTROLLED POWER COMPANY
AACD Option # 11913
WARRANTY
***Warranty void unless this form is completed and returned to
Controlled Power Company.***

Controlled Power Company warrants that the AACD Device and its components will remain free from
defects in material and workmanship for the period of one (1) year from the date of delivery, and agrees to
replace F.O.B. its factory, any parts which fault through defect in material or workmanship during such
period.

This Warranty applies only to the original purchaser who must properly register the product within (10) days
of receipt.

1. The Warranty shall be effective only if and so long as the system is installed and operated in the
manner specified in this manual which accompanied the AACD Device and operated within the
ratings on the nameplate of the system.

2. The Warranty shall be void if any alteration is made to the system or any of its components are
altered by anyone other than an authorized Controlled Power Service Personnel without the
written permission of Controlled Power Company.

3. The Warranty shall be effective provided the purchaser pays the cost of transporting the
questionable component to and from the Controlled Power Company factory at his own expense.
The cost of installation of the defective component is the responsibility of the purchaser. Factory
servicemen are not included in this warranty. If the component fault has been caused by misuse or
abnormal conditions in the judgement of Controlled Power Company, after inspection, the customer
will be charged for repairs based on parts and labor required. The Warranty does not cover fuses,
light bulbs and other normal expendable items.

4. This Warranty is in lieu of all other warranties, expressed or implied. Controlled Power Company
neither assumes nor authorizes any person to assume for it, any liability other than that specifically
set forth in this Warranty. Except for its obligations, Controlled Power Company assumes no
responsibility for consequential or other damages resulting from defects in or failure of the system
or any component.

AACD System # Rectifier Model #

Date: Application: Electro-deposition of Paint (E-Coat)

Company:

Address:

City/State/Zip:

Contact: Phone #:

Start-Up Organization:

Please complete form and return to: Controlled Power Company

Attn: Customer Support
1955 Stephenson Highway
Troy, MI. 48083

9.1
 Controlled Power Company
Option # 11913 “AACD”
(Automatic Average Current Density)
Licensing Agreement
YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS BEOFORE OPENING
OR OPERATING THE SOFTWARE PACKAGE. YOUR USE OF THE MEDIA OR ACCESS OF SUCH
WITHIN THE PLC ON WHICH THE SOFTWARE IS RECORDED INDICATES YOUR ACCEPTANCE OF
THESE TERMS AND CONDITIONS. IF YOU DO NOT AGREE WITH THEM, YOU SHOULD
IMMEDIATELY CONTACT CONTROLLED POWER COMPANY.

LICENSE
You May:
1. Use the program on the single PLC processor hardware supplied by Controlled Power Company.

2. Merge other programs with the program, but will do so at your own risk. Any programs or
modifications attempted by non-CPC personnel will be subject to terms and remaining conditions of
this agreement.

3. Transfer the program and license to another party if the other party agrees to accept the terms and
conditions of this agreement.

YOU MAY NOT USE OR TRANSFER THE PROGRAM IN WHOLE OR PART EXCEPT AS EXPRESSLY
PROVIDE FOR IN THIS LICENSE.

YOU MAY NOT COPY OR MODIFY THE PROGRAM IN WHOLE OR IN PART.

TERMS
The license is effective until terminated. You may terminate it at any time by destroying the diskettes or tape
(hereby known as “media”) contained in this package or within the Controlled Power Company provided
hardware system. Terminating the license does not eliminate any prior failure on your part to comply with
any terms or condition of this agreement. You agree further upon termination to destroy the program
together with any unpermitted copies, modifications and /or merged portions of any form.

LIMITED WARRANTY
THE PROGRAM AND HARDWARE MATERIALS ARE PORVIDED “AS IS” WITHOUT WARRANTY OF
ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE ENTIRE
RISK AS TO QUALITY AND PERFORMANCE OF THE PROGRAM AND ENCLOSED MATERIAL IS
ASSUMED BY YOU.

However, to the original purchaser only, Controlled Power Company does warrant the media on which the
program was recorded [or the original hardware system installed by Controlled Power Company] to be free
from defects and faulty workmanship under normal use and service for a period of thirty (30) days from the
date of installation. If during the thirty (30) day period, a defect occurs, then the media will be replace
without charges to you, or the hardware will be replaced (not including on- site service charges) without
charge to you provided that (1) you have previously sent in your warranty registration card and (2) returned
the defective media to Controlled Power Company. Contact Service Support for an RMA number and
instructions.

LIMITATION OF REMEDIES
Controlled Power Company’s entire liability and your exclusion remedy shall be replacement of the media or
hardware if you have met the conditions described under “Limited Warranty”.

In no event shall Controlled Power Company be liable to you for any other damages arising out of use of the
AACD Device and software program.

10.1
Loading History
Film Target ____________ Date __________________
Part Size Description Voltage Current Time Delay Time Required

Film Target ____________ Date __________________

Part Size Description Voltage Current Time Delay Time Required
Loading History
Film Target ____________ Date __________________
Part Size Description Voltage Current Time Delay Time Required

Film Target ____________ Date __________________

Part Size Description Voltage Current Time Delay Time Required
NOTES
NOTES