MicroPak (Serv. Man. LN-9218-00.13)
Contents
1. 5 Q3 LD3NNOO OL UNG OL 01748 exar 0 4 _ QGINALSO Hlev3 anal JO WNNIXYN Y OL LXAN OL 1 ions Connect GND 4 ing Proper Power Supply and Ground Figure 3 11 Ransburg MicroPak Installation MICROPAK CONTROL UNIT INTEGRATED INTO SYSTEM CONTROL CABINET PLC OR 52 1888 7 5 _ DISCRETE 1 0 0 10 3 ON OFF 8 5 HIGH VOLTAGE CONTROLLER MODULE APPLICATOR LOW VOLTAGE CABLE Figure 4 Typical MicroPak 1000 RP404 Layout LN 9218 00 13 12 MicroPak Operation 13 OPERATION OPERATOR CONTROL Operator control may be accomplished by 1 front panel controls 2 CANBus serial com2. 605 008 S0 00 100 S0 00 Goe 00 199 uedo pio uedo XX E Go Ge Or oe tuner er uuweug feo waum usso 19109 91M apa 32A S 4ed0Jol A pejoeuuoosip duis m epeose 0001 xXedsues ejqeo ef suluQ sjueuleunseeui WYO 1 6 A O gt LN 9218 00 13 Figure 9 Ohm Meter Measurements for RansPak 1000 Cascade 31 Ransburg MicroPak Parts Identification PARTS IDENTIFICATION MICROPAK APPLICATION TABLE MicroPak Controller LECU5004 01 Application Aerobell 33 Robot HP404 Voltage Regulator ABB LECU5004 01 Aerobell 33 Powder HP404 Voltage Regulator ABB LECU5004 01 EFM or EFMD HP404 Voltage Regulator ABB LECU5004 02 RP1000 Voltage Regulator ABB Industrial LECUS5004 03 RP1000 Current Regulator ABB Industrial LECUS5004 04 Aerobell 33 Powder HP404 Current Regulator ABB LECU5004 11 Aerobell 33 Robot HP404 Voltage Regulator Ransburg LECUS004 11 Aerobell 33 Powder HP404 Voltage Regulator Ransburg L
3. 7 uedQ 7 2 90 20 100 L rz o uedo 140 S0 00 2 60 100 L 2 o uedo 0 140 S0 00 uedo uedo XX o uedo xo uedo uedo 49 uedo 3o uedo uedo uedo o uedo 140 uedo 100 20 vr o uedo uedo S0 00 Yz 2 100 100 rc o uedo j uedo 32 uedo uedo 606 006 uedo 142 uedo u do o 05 0 1 zoo o 710 uedo uedo uedo uedo uedo 08 0 XX Do uedo yo uedo 120 uedo c 370 uedo zoo epjo 130 Xx 2 60 jo 2742 po uedo 3 0 20 zoo lt P uedo uedo o uedo io 2 50 o uedo 142 uedo uedo 230 yyo uedo 20 xo
4. 17 VERSION 3 9 GOFTWJARE 17 SWITCH TINGS 18 sv ia 19 FOUTPEIT SESINBIUS 20 23 MICROPAR NODE ADAPTER PLC e terra Cr ER rro Seueri i ine 23 27 DIAGNOSTICS 28 MAINTENANCE 29 31 6 qr 29 OHM METER MEASUREMENTS CASCADE 30 OHM METER MEASUREMENTS FOR RANSPAK 1000 CASCADE 31 PARTS IDENTIFICATION 32 33 APPLICATION TABLE siccscccusadstncetansntininenaateansnastactntnocninenysiddenansntseadisaanocnnimni 32 MICROPAK PARTS 33 WARRANTY POLICIES 34 LIMITED WARRANTY 34 LN 9218 00 13 MicroPak Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety liter ature for your Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this informa tion we use the following symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that might cause serious injury if instructions are not followed A CAUTION states information that tells how to prevent damag
5. lis mi 202 i 1 8 i 29 n C32 A32 8 tT Sg 8 T T R32 am MicroPak Controller Output Board LOCAL FENDTE SWITCH Moat er CURRENT Rotary Sequence Switch Location upg 9 PROCESS PCB 4557 LECU400B8 REV een ce SW3 DIEM P N 08 g cil I mne 225 5 5 R3 B RESET EE L 8 RE 9 um EE Di b 4 22 4 Bu
6. 19 3 mE ws 330 330 330 e Figure 6 Switch Settings CAS ZAS 5538007 518 2 IT 2 MS LN 9218 00 13 19 MicroPak Operation Ransburg MICROPAK CONTROLLER OUTPUT ASSY PN LECU4007 REV PN LECUO021 REV B T TV Ransburg 400 C R4 gum 7 L m 073 CRI d 3 p g Ese 4 nh B QT gt 8 02 Q3 RIB OUT MM EIN 2 8 1 LEDI Fae p 2 FI C9 RE u7 7 g C36 7 c3 2 6 eps Bi 4 05 06 09 zg
7. When using an electrostatic handgun operators must assure contact with the handle of the ap plicator via conductive gloves or gloves with the palm section cut out NOTE REFER TO NFPA 33 OR SPECIFIC COUNTRY SAFETY CODES REGARDING PROPER OPERATOR GROUNDING All electrically conductive objects in the spray area with the exception of those objects re quired by the process to be at high voltage must be grounded Grounded conductive flooring must be provided in the spray area Always turn off the power supply prior to flush ing cleaning or working on spray system equip ment Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class or Il Division 1 or 2 haz ardous areas in accordance with NFPA 33 MicroPak Safety AREA Tells where hazards may occur Electrical Equipment hem e Toxic Substances Spray Area HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized the process Arcing in the vicinity of flammable or combustible materials may oc cur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correc tion An electrical arc can ignite coat ing mater
8. SERVICE MANUAL LN 9218 00 13 Ransburg REPLACES LN 9218 00 12 February 2013 MICROPAK Ransburg e SN E 5 2 OFF MICROPAK CONTROLLER XXXXX MODEL LECU5004 IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 50 00 U S MicroPak Ransburg NOTE This manual has been changed from revision LN 9218 00 12 to revision LN 9218 00 13 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9218 00 13 Ransburg MicroPak Contents CONTENTS PAGE SAFETY 45 _ SAFETY PRECAUTIONS n pua MCI 1 HAZARDS SAFEGUAIRLEDS DERE E cutn cu M Eben xs 2 5 GENERAL DESCRIP TION UD LEE 6 Pd YF EAD URES 6 6 SPECIFICATIONS AN 6 7 INSTALLATION 8 12 s zsps c 8 12 OPERATION 13 28 OPERATOR CONTROL eraa 13 MODES OF OPERATION GONPIGURATION 13 17 VERSION 3 8 SOP T WARE
9. 5 6 7 8 9 The di dt overload is disabled for the time required to ramp voltage from a lower requested kV to a higher value This time will vary based on the magnitude of the kV increase The HV ON LED will flash ON and OFF during each di dt inhibit period Local mode only When the applicator is moved quickly e g ro bot SLP 7 8 or 9 should be used to avoid nuisance faults For di dt modes of operation the di dt function is enabled by setting SW7 6 located on the Micro Pak Process PCB to the ON down position For all other applications where di dt does not apply SW7 6 must be set to the OFF up position This is the default setting for all MicroPak control unit models that do not have the di dt function Separate ground connections MUST be used for grounding the part and the Power Supply LN 9218 00 13 Ransburg To Read the Di dt Setting Push the SET push button twice within one second The kV display will read SLP and the display will indicate a number between 0 and 9 This number represents different levels of di dt sensitivity with 0 being most sensitive If the SET push button is not pressed again the display will automatically return to normal output current display To Adjust the Di dt Value Local Mode Once a di dt sensitivity level is displayed it can be changed by pressing the SET button again and holding in The sensitivity level will incr
10. MicroPak With HP505 Cascade Output 100 kV 0 pA 240 uA 0 Cascade Size 1 50 1 56 7 0 HP404 1 50 X 1 56 x 7 0 RP404 4 X4 X 12 LN 9218 00 13 Ransburg INSTALLATION CONNECTIONS For MicroPak with HP404 RP404 amp HP505 24 VDC For MicroPak with RP1000 28 VDC Input Power This must be supplied from a regulated power supply Connection is made at J2 for 24 28 V 24 28 VRET and Factory Ground The 24 28 VDC supply is protected against excessive current draw by an automatically resetting fuse internal to the MicroPak In case of a current draw over 6 the fuse will open circuit and automatically reset when 24 28 VDC power is removed gt The 24VRET must be connected to Fac tory Ground at the 24 VDC power supply see Figures 1 and 2 Node Adapter Discrete I O Power When a Node Adapter or Discrete I O Module is used power must be supplied to it via J10 Con nect 24 VDC to J10 1 and 24 VRET to J10 2 see Figures 1 and 2 Output To Cascade HP404 HP505 amp RP404 Make connections to J3 per Figure 1 Use the appropriate cable assemblies HP404 HP505 see MicroPak parts list at back of this manual Use only the A12971 cable assembly for RP404 RP1000 Make connections to J3 per Figure 2 Use only the 74947 cable assembly LN 9218 00 13 MicroPak Installation The two wire braids must be connected to a dedi cated HV power supply ground bus This b
11. prior to installing operating and or servicing this equipment A WARNING The hazards shown on the following pag es may occur during the normal use of this equipment Please read the hazard chart be ginning on page 2 LN 9218 00 13 Ransburg AREA Tells where hazards may occur Spray Area LN 9218 00 13 HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard Protection against inadver tent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during opera tion Frequent Power Supply or Controller shutdown indi cates a problem in the system requiring correction MicroPak Safety SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accumulation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or main tenance When using solvents for cleaning e Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100 F 37 8 Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA country and
12. Fault OLB Indicates either the DC output current has RED exceeded the setpoint or the current rate of rise has exceeded the di dt sensitivity setpoint OR GRN Feedback Fault FBFLTB Indicates abnormal signal levels are present on the kV and or Current Feedback signals from the cascade See Diagnostic in the Operation section for a detailed description Local LOC Indicates front panel switch is in Local position In Local the set points for kV and Current are received from the front panel controls and not from remote inputs Sequence SEQB Indicates Sequence rotary switch is in a Non Zero position Sequence Mode Timing Diagram is shown in Figure 4 Fluid Trigger Active FLTRIGB Indicates the Fluid Trigger output to the EFM gun is active applies in both sequenced and non sequenced modes Air Trigger Active AIRTRIGB Indicates Air Trigger output to EFM gun is active Overspeed Fault Indicates module has shut down drive to bell because speed is 10 krpm above setpoint Underspeed Fault Indicates module has shut down drive to bell because speed is 5 krpm under setpoint Loss of Feedback Fault Indicates module has shut down drive to bell because the maximum time allowed between feedback pulses has been exceeded Status signal available in Node Adapter applications only Input Output Signals Continued On Next Page LN 9218 00 13 22 MicroPak Operation 23
13. SW7 la beled Node Address positions 2 4 with position 4 being the LSB see Figure 6 In applications where Discrete Module is used the MicroPak must be set at CANBus address 01 In Node Adapter applications the MicroPak s must be set to a CANBus address corresponding to the locations in the PLC tables Each MicroPak must have a unique address from 01 04 Di dt Operating Mode A di dt rate of change in current with respect to time safety overload function can be used in addition to the fixed current overload This is an adjustable setting which determines the maximum current increase that can occur during a fixed time period The di dt detection feature will improve the ability of the power supply to prevent discharges to the applicatorwhen a grounded objectis approaching at rates greater than approximately 4 inches per second Slower rates of approach are typically sensed by the fixed current overload if properly set The di dt and fixed current overloads must be set correctly to prevent discharges when using metal unlisted applicators The MicroPak controller monitors the output current and compares the value to the rate of change set point SLP provided by the user set ting See the MicroPak Di dt Sensitivity Chart for corresponding rates of change for each SLP setting number Ransburg MICROPAK di dt SENSITIVITY LEVELS Sensitivity 100 Sec SLP 0 1 2 3 4
14. local codes In addition ventilation must be main tained during cleaning operations using flam mable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Test only in areas free of combustible material Testing may require high voltage to be on but only as instructed Non factory replacement parts or unautho rized equipment modifications may cause fire or injury If used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks dis abled Never use equipment intended for use in water borne installations to spray solvent based ma terials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC OSHA local country and European Health and Safety Norms MicroPak Safety AREA Tells where hazards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate oper ation and maintenance proce dures will cause a fire hazard Protection against inadvertent arcing that is capable of caus ing fire or explosion is lost if any safety interlocks are dis abled during operation Frequent Power Supply or Controller shutdown indicates a problem in t
15. supplies control units etc is one 1 year from date of purchase WRAPPING THEAPPLICATORIN PLASTIC SHRINK WRAP ETC WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NOIMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG LN 9218 00 13 ASSUMES NO LIABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEQUEN TIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will assume no responsibility for repair or replacement of the item or items The purchas er therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable 34 MicroPak Change Summary 35 Ransburg MANUAL CHANGE SUMMARY This manual was published to replace Service Manual LN 9218 00 12 MicroPak to make the following changes 1 Removed di dt communication information from the Remote Mode paragraph in Operation and referred user to the I O tables for Discrete I O Module or Serial Node Adapter as appropriate 2 Corrected the Discrete Inputs table in the Input Output Signals section
16. ECU5004 11 EFM or EFMD HP404 Voltage Regulator Ransburg LECUS5004 12 RP1000 Voltage Regulator Ransburg LECUS5004 12 1000 REA IIl Voltage Regulator Ransburg LECUS5004 13 RP1000 Current Regulator Ransburg LECUS5004 14 HP404 Current Regulator Ransburg LECUS5004 15 LECUS5004 16 RP1000 Retrofit Aerobell Il Ransburg w Di dt RP1000 Aerobell II Indirect Voltage Regulator Ransburg 100m Probes W 40 meg In Line LECUS5004 17 RP100 Aerobell II Indirect Voltage Regulator Ransburg 160m Probes LECU5004 18 HP505 Voltage Regulator Ransburg LECUS5004 19 HP505 Current Regulated Ransburg LECU5004 31 HP404 FM Voltage Regulator Ransburg LECUS5004 40 LN 9218 00 13 RP404 Voltage Regulator Ransburg 32 MicroPak Parts Identification 33 Ransburg MICROPAK PARTS LIST Part LECU5004 XX LECU4014 02 Description Control Unit MicroPak See MicroPak Application table for appropriate dash Mother PCB Assembly 1 4 Rack Discrete Input 7604 1 XX 79008 XX A12239 XX A12241 XX A12243 XX LV Cable HP404 Cascade Dash denotes length in feet Available dash 15 25 50 75 100 74947 04 05 06 LV Cable LEPS5002 or RP1000 Cascade 04 75 05 100 06 30 A12971 XX LV Cable RP404 Cascade 00 25 01 50 02 75 03 100 74793 01 02 RP1000 Cascade 01 Right Angle 02 In Li
17. ET 0 100 kV HV Set Ground KVSETGND Over Current Setpoint ISET 0 1000 pA 1000 mode or 0 2501 HP404 RP404 or HP505 mode OC Set Ground ISETGND Atomizer Speed Setpoint see SW2 2 position for scaling Speed Setpoint Ground Di dt Sensitivity 0 to 9 Scale equals the most sensitive position Note For DIO module 76037 00 and 76037 03 analog inputs are 0 10 VDC 150 k Ohm input impedance For DIO module 76037 02 and 76037 04 analog inputs are 4 20 mA 249 Ohm input impedance Input Output Signals Continued On Next Page LN 9218 00 13 20 MicroPak Operation Ransburg INPUT OUTPUT SIGNALS Cont ANALOG OUTPUTS 3mA Max High Voltage Output Level KVFB 0 10 VDC 0 100 kV HV Out Ground KVFBGND WH Current Output Level IFB 0 10 VDC 0 1000 1000 mode or 0 10 0 2501 HP404 RP404 HP505 mode BLA Current Output Ground IFBGND RED Atomizer Speed Feedback see SW2 2 position for scaling BLA Speed Pressure Feedback Ground BLA RED Drive Pressure Feedback 0 10 VDC 0 100 psi DISCRETE INPUTS 24 VDC Source or Sink Referenced to 18A WH BLA RED 14A RED GRN or 13A BLU RED For Source Set DIO Module Jumpers E5 and E6 to 2 3 For Sink Set DIO Module Jumper E5 and to 1 2 Signal Description BLU BLA High Voltage On HVON If HVRDY is active supplying 24 VDC causes high voltage to be present at cascade output OR BLA Hi
18. IG MNA OL sna LN 9218 00 13 3NII JCA ve lt gt J ve o o END 3 zn 8 0 15097931 Nd 4 1070931 Nd SS 899 M qg YIHLON 0 40521 PETES TERS ee 9 ana S S i SR 9 H Wr on er L3 1 YN 9r e e e 40 37892 29021 ND 3THVJ 1709 LI e e o er RS i s gn 2 Es B 0 9 18 89d 290 EE ovi 0095 Assy 24 o
19. MicroPak 3 Fluid Trigger Di dt Delay Air Trigger MicroPak 4 HV On Command MicroPak 4 HV Reset MicroPak 4 Fluid Trigger Di dt Delay MicroPak 4 Air Trigger LN 9218 00 13 Ransburg MicroPak Operation MICROPAK NODE ADAPTER PLC I O Cont MicroPak Mode DISCRETE OUTPUT BIT DEFINITION MicroPak 1 HV On Command MicroPak 1 HV Reset MicroPak 1 Fluid Trigger Di dt Delay MicroPak 1 Air Trigger MicroPak 2 HV On Command MicroPak 2 HV Reset MicroPak 2 Fluid Trigger Di dt Delay MicroPak 2 Air Trigger MicroPak 3 HV On Command MicroPak 3 HV Reset MicroPak 3 Fluid Trigger Di dt Delay MicroPak 3 Air Trigger MicroPak 4 HV On Command MicroPak 4 HV Reset MicroPak 4 Fluid Trigger Di dt Delay MicroPak 4 Air Trigger BLOCK TRANSFER WRITES BTW Word MicroPak 1 BTW Block Configuration High Voltage Setpoint Value of 0 100 corresponds to 0 100 kV MicroPak 1 Current Limit Setpoint Value of 250 corresponds to 0 250 pA MicroPak 1 Di dt Setpoint 0 9 corresponds to max to min sensitivity Not Used MicroPak 2 High Voltage Setpoint Value of 0 100 corresponds to 0 100 kV MicroPak 2 Current Limit Setpoint Value of 250 corresponds to 0 250 pA MicroPak 2 Di dt Setpoint 0 9 cor
20. Ransburg INPUT OUTPUT SIGNALS DISCRETE OUTPUTS Cont Contact Ratings 2 A 28 VDC Resistive 0 5 A 120 VAC Resistive One Side Common With 30C White Black Wire Signal Description BLA WH Invalid Data Fault Indicates module has shut down drive to bell because speed setpoint is above the operating range of the bell GRN WH Low Bearing Air Fault Indicates module has shut down drive to bell because bearing air pressure is below the level set by Serial Atomizer switch SW2 7 and 8 GRN BLA WH 25C Speed out of Tolerance Indicates bell speed is outside the window of 5 of setpoint This is a status signal only and does not shut down drive to bell R BLA WH 24 VDC utility output may be used to power relay contact common 300 0 1 Amps Max Status signal available in Node Adapter applications only MICROPAK NODE ADAPTER PLC I O MicroPak Mode DISCRETE OUTPUT CONFIGURATION Not Used MicroPak 1 Di dt Inhibit MicroPak 2 Di dt Inhibit MicroPak 3 Di dt Inhibit MicroPak 4 Di dt Inhibit Not Used MicroPak 1 HV On Command MicroPak 1 HV Reset MicroPak 1 Fluid Trigger Di dt Delay MicroPak 1 Air Trigger MicroPak 2 MicroPak 2 HV On Command HV Reset MicroPak 2 Fluid Trigger Di dt Delay MicroPak 2 Air Trigger MicroPak 3 HV On Command MicroPak 3 HV Reset MicroPak 3
21. ascades 28 VDC at 6A fully loaded output RansPak 1000 RP1000 Cascade Note 24 VDC and 28 VDC power supplies must be regulated and have overcurrent 4096 and overvoltage 2096 protection MicroPak Introduction Electrical Controls 1 All communication to Controller by CANBus 2 Direct A B RIO communication via additional Node Adapter Module LECU4012 or Serial Node Adapter Module Part 78553 One Node Adapter per rack 3 Discrete signals available via additional Module 76037 in place of Node Adapter with levels as shown below Analog In Analog Out Discrete Out Discrete In Trigger Out 0 10 VDC or 4 20 mA DC kV Set Current Set Overcurrent Setpoint Di dt Sensitivity 0 10 VDC OUTPUT kV OUTPUT CURRENT Dry Contact HV ON FB FAULT HV READY OVER CURRENT FAULT LOCAL HV RESET 24 VDC Source or Sink HV OFF HV ON FLUID TRIGGER AIRTRIGGER SEQUENCER START 24 VDC 150 mA Maximum For EFM Gun AIR TRIGGER Ransburg MicroPak with HP404 RP404 Cascades Output 100 kV 0 pA 125 0 Cascade Size MicroPak With RP1000 Cascade Output 100 kV 1000 pA 75 Duty Cycle Cascade Size 4 4 12 MicroPak With LEPS5002 Cascade Output 100 kV 1000 pA 75 Duty Cycle Cascade Size 14 X 12 X 12 MicroPak With HP404 FM Cascade Output 100 kV 0 85 Max Cascade Size 1 50 1 56 7 0
22. corresponds to 0 15 krpm Reference Discrete Output Bit Definition chart 00 MicroPak 1 HV On Command 03 i 0 85 corresponds to 0 85 pA HP404 FM 0 1000 corresponds to 0 1000 pA for RP1000 or LEPS5002 applications BLOCK TRANSFER READS BTR Word Module BTR Block Configuration MicroPak High Voltage Feedback Value of 0 100 corresponds to 0 100 kV MicroPak Current Feedback Value of 0 250 corresponds to 0 250 MicroPak MicroPak Status Word Atomizer Atomizer Status Word Atomizer Atomizer Drive Pressure Value of 0 60 corresponds to 0 60 psi Atomizer Atomizer Speed Liquid Value of 0 50 corresponds to 0 50 krpm Atomizer Speed Powder Value of 0 150 corresponds to 0 15 krpm Reference MicroPak Status Word table Reference Atomizer Status Word table LN 9218 00 13 26 MicroPak Operation 27 Ransburg MICROPAK NODE ADAPTER PLC Cont Node per Bell Mode MICROPAK STATUS WORD HV Held In Reset ATOMIZER STATUS WORD Bit Bearing Air 8 bits HV Ready HV On Overspeed Underspeed Di dt Fault Loss of Feedback HV Overload Invalid Data Input Bit 00 01 02 03 04 05 Feedback Fault Sequence Low Bearing Air Bell Running Local Speed out of Tolerance Fluid Trigger Active Air Trigger Active 06 07 08 09 10 11 Di dt E
23. d MicroPak 4 High Voltage Feedback Value of 0 100 corresponds to 0 100 kV MicroPak 4 Current Feedback Value of 0 250 corresponds to 0 250 MicroPak 4 Status Word oO BR WwW gt O Held In Reset HV Ready HV On Di dt Fault HV Overload Feedback Fault Sequence Local Fluid Trigger Active Air Trigger Active Di dt Enabled kV Out of Tolerance Under Current Overvoltage Not Used Not Used 0 85 corresponds to 0 85 pA for HP404 FM 0 1000 corresponds to 0 1000 pA for RP1000 or LEPS5002 applications Reference Atomizer Status Word table LN 9218 00 13 Ransburg MicroPak Operation MICROPAK NODE ADAPTER PLC I O Cont DISCRETE OUTPUT BIT DEFINITION Node per Bell Mode DISCRETE OUTPUT CONFIGURATION Discrete Output Word Configuration Not Used 1 Discrete Output Bits MicroPak 1 Fluid Trigger Di dt Delay MicroPak 1 Air Trigger MicroPak 1 Di dt Inhibit BLOCK TRANSFER WRITES BTW Word Module BTW Block Configuration MicroPak High Voltage Setpoint Value of 0 100 corresponds to 0 100 kV MicroPak Current Limit Setpoint Value of 0 250 corresponds to 0 250 MicroPak Di dt Setpoint 0 9 corresponds to max to min sensitivity Not Used Atomizer Speed Command Liquid Value of 0 50 corresponds to 0 50 krpm Speed Command Powder Value of 0 150
24. deal of testing under high voltage corona conditions has confirmed that this cascade ground should be connected directly ata single pointto the signal ground plane of the MicroPak power supply controller This single point method maintains a clean feedback signal while limiting the amount of high frequency noise that is dumped onto the signal ground and therefore other grounds in the overall system such as the PLC LN 9218 00 13 Ransburg MicroPak Installation J2 J3 MICROPAK FACT GND lt 1 24 2 UAFB 24 VRET 5 J10 DR_B 24 VDC lt 1 _ 24 2 OR DISCRETE O MODULE AIRTRIG FLTRIG J6 MULTGND KVFB 1 HVON JUMPER SW3 3 CONTROL 96 POSITION 2 1 2 OFF PANEL 3 OPEN VCTRET 3 42 FACT lt 1 28 VOC 92 28 VRET 3 MICROPAK J10 24 1 FOR NODE ADAPTER 24 2 OR DISCRETE 1 0 MODULE AIRTRIG an Oo 6 MULTGND o a ONTROL J6 POSITION 11 WH BLACK 2 FRONT 1 2 La is o PANEL 3 OPEN 0 2 Figure 2 MicroPak Controller W LEPS5002 or 74793 Cascade RansPak 1000 LN 9218 00 13 10 Ransburg MicroPak Installation 1 HLAVA 0Z VddN 13315 ON
25. e to equipment or how to avoidasituation that might cause minor injury A NOTE is information relevant to the proce dure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation draw ings and appropriate Ransburg equipment man uals to reconcile such differences Careful study and continued use ofthis manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg Ransburg A WARNING The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified gt This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFE TY STANDARD LATEST EDITION
26. ement slowly Once the desired level is displayed 0 9 then release the SET button The new value is stored in memory when the SET push button is released This setting should be set as sensitive as possible smallest di dt value without nuisance overloads occurring This should be done with paint loaded and normal production parts present Remote Mode In remote mode the above sensitivity levels are set by the numbers 0 to 9 in a Block Transfer Write BTW similiar to the method for setting the setpoint for kV The BTW information is shown in the MicroPak Node Adapter in the Operation section The di dt sensitivity level in Minimized Remote Mode Remote mode where SW3 1 is in OFF position will still be set as in Local mode In this mode the kV setpoint is still remote and the uA setpoint is still from internal pot R21 The di dt function can be inhibited when needed during the application process to avoid nuisance shutdown To understand the details of using this feature with either the Discrete Module or Serial Node Adapter reference the appropriate tables further back in this Operation section LN 9218 00 13 MicroPak Operation Determining if a Di dt Overload Occurred The OVER LED overload will flash on and off if a di dt caused an overload otherwise the OVER LED will stay on continuously if a fixed current overload occurred This will help determine the type of high vol
27. er directly from CANBus or from the Discrete Module except as described below The MicroPak can be configured for a fixed in ternal adjustment uA overload setpoint while accepting a remote analog kV setpoint To enable this feature see figure 6 In this configuration the pA setpoint comes from pot R21 at the top of the Process PCB instead of the external analog signal Holding in the SET button will display the analog kV setpoint and the fixed internal uA setpoint HV Cascade Regulation Mode The MicroPak is factory configured for HP404 RP404 or HP505 cascade applications or plications using the 74793 XX or LEPS5002 HV units In addition the cascades may be operated in voltage regulation or current regulation modes Each configuration has a specific part number as shown in the Parts Identification section of this manual HV On Control Remote When remote HV On controls are used SW3 3 should be set to ON Motherboard terminal J6 3 should be jumpered to J6 2 to enable the HV Ready mode LN 9218 00 13 Ransburg WARNING gt In no case should the J6 3 to 2 jumper be used with SW3 3 in the OFF position This will turn HV On any time Unit Power is On Remote Sequenced The same connections apply here as for the Re mote mode If the Sequence Rotary Switch see Figure 7 is setto a non zero position the HV and fluid trigger are turned on and off in the sequence described in Figures 5a a
28. gh Voltage Reset HVOFF Supplying 24 VDC turns off HV over riding HVON signal or resets fault conditions RED BLA Fluid Trigger FLTRIG Supplying 24 VDC causes fluid trigger to EFM gun to be active with di dt activation delayed 5 seconds WH RED Air Trigger AIRTRIG Supplying 24 VDC causes air trigger to EFM gun to be active In Sequence Mode sequence rotary switch in non zero position starts programmed sequence of air trigger fluid trigger and HV on Di dt Inhibit Supplying 24 VDC causes di dt to be disabled Bell Spin Enable 24 VDC must be supplied to send the speed setpoint to the Atom izer This may also be used as a fault reset leaving the speed command constant Input Output Signals Continued On Next Page 21 LN 9218 00 13 Ransburg MicroPak Operation INPUT OUTPUT SIGNALS Cont DISCRETE OUTPUTS Contact Ratings 2 28 VDC Resistive 0 5 120 VAC Resistive One Side Common With 30C White Black Wire Signal Description Bell Running Indicates that Drive air pressure is being supplied to the bell High Voltage Ready HVRDYB Indicates interlock is satisfied High Voltage Reset is not active and neither Over Current Fault or Feedback Fault is present In High Voltage Ready mode a signal to the High Voltage ON input will cause High Voltage to come on GRN BLA High Voltage On HVONB Indicates High Voltage is on Over Current Fault di dt
29. he system requir ing correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment Ransburg SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class Il Division 1 or 2 hazardous areas in accordance with NFPA 33 Test only in areas free of flammable or combus tible materials The current overload sensitivity if equipped MUST be set as described in the correspond ing section of the equipment manual Protec tion against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power supply shutdown indicates a prob lem in the system which requires correction Always turn the control panel power off prior to flushing cleaning or working on spray system equipment Before turning high voltage on make sure no objects are within the safe sparking distance Ensure that the control panel is interlocked with the ventilation system and conveyor in accor dance with NFPA 33 EN 50176 Have fire extinguishing equipment readily avail able and te
30. high voltage cable Loose ground connections or defective ground connections wire on atomizer holder or mecha nism Dump lines not clean or dry leading back to ground Target not grounded and causing arcing to ground from target Di dt SLP set too sensitive for the application conditions 24 or 28 VDC DC Power Supply to the Micro Pak is unstable Excessive robot tip speed near neighboring parts LN 9218 00 13 lt E ev 1 Ac OZ 38 61 eq pinoys Buipeai y AH 1 e 2 65 suid ssojoe Mea Aew L o 9485 uedo uedo uedo 1 uop gt 1096 1957 2 Pio yo pj 2 4066 4602 Pi uedo po 140 0 9 086 076 9 u do pj uedo uedo 6702 36 61 o yo uedo Do uedo 085 058 092 089 370 uedo uedo uedo uedo pio uedo po ued
31. ials and cause a fire or explosion Certain material may be harmful if inhaled or if there is contact with the skin Explosion Hazard Incompatible Materials Halogenated hydrocarbon sol vents for example methylene chloride 1 1 1 roethane are not chemically compatible with the aluminum that might be used in many sys tem components The chemical reaction caused by these sol vents reacting with aluminum can become violent and lead to an equipment explosion Ransburg SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazard ous locations the power supply control cabinet and all other electrical equipment must be locat ed outside Class or 11 Division 1 and 2 hazard ous areas in accordance with NFPA 33 and EN 50176 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combus tible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance Follow the requirements of the Material Safety Data Sheet supplied by coating material manu facturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask m
32. mp 5b The sequence is initiated by activating the air trigger signal when the sequence rotary switch is in a non zero position Be sure that no connection is made to Motherboard terminal J6 3 MicroPak Operation Front Panel When front panel controls are used SW3 3 can be set to OFF so that the HV ON mode is always enabled meaning that anytime the HV Ready mode is entered HV is turned on This allows the front panel kV switch to enable the HV Ready and HV on modes at the same time Fluid Delay A milliseconds No Sequence 0 150 250 0 100 150 200 300 400 Figure 5a Sequence Mode Operation HV Delay B milliseconds No Sequence ON FLUIDTRIG bes AIRTRIG 1 Figure 5b Sequence Mode Operation Not for Indirect Charge Mode LN 9218 00 13 14 MicroPak Operation 15 CANBus Address The MicroPak must be set at a non zero CANBus address when CANBus communication is used whetherfrom an outside CANBus source Discrete Module or Node Adapter When front panel controls are used SW3 3 can be setto OFF so that the HV ON mode is always enabled meaning that anytime the HV Ready mode is entered HV is turned on This allows the front panel kV switch to enable the HV Ready and HV On modes at the same time The address is set in binary by Switch
33. munication 3 node adapter 4 discrete analog and digital I O 1 Front panel controls are provided for power on high voltage set point over current set point di dt sensitivity and high voltage on off 2 CANBus connection provides expanded control and monitor functions shown as analog in out and discrete in out in the MicroPak Spec ifications 3 Node Adapter connection converts an external serial protocol such asAllen Bradley Remote I O to CANBus for communication to the MicroPak The format for Allen Bradley communication is shown under MicroPak Node Adapter PLC in the Operation section of this manual 4 Discrete I O connections are made the 76111 xx cable which connects to connector J12 The 76111 connector must be secured to the J12 connector shroud by the two screws on the connector body The pin out of the discrete signals begins on page 14 The Discrete I O Module switch SW2 position 1 must be set for the cascade in use with the Mi croPak For RP1000 or LEPS5002 application SW2 1 is OFF For HP404 RP404 and HP505 application SW2 1 is ON Ransburg MODES OF OPERATION CONFIGURATION Refer to Figure 6 Local Remote The Local Remote switch located on the front panel determines the source for the setpoints for di dt and Over Current In the Local Position these come from the front panel controls labeled kV and In the Remote position these come from the Node Adapt
34. nabled kV Out of Tolerance 12 Under Current 13 Overvoltage 14 Not Used 15 Not Used Not Used LN 9218 00 13 Ransburg DIAGNOSTICS Fault Conditions These are conditions that turn off HV ON mode signal operator and require an HV Reset signal before HV can be turned on again NOTE gt In the Current Regulation mode the actual threshold is 30 higher than the set point This allows the set point to con trol the level at which the current is regu lated without having Over Current faults Over Current The MicroPak is designed to turn off HV anytime the output current exceeds a threshold determined by the Over Current Setpoint level Overcurrent setpoint is important and must be set to the lowest functional setting In an event where a HV cable should fail or an electrical discharge may occur or if the applicator supply lines or other factors cause abnormal increase in current circuit will shut off Typical set point is 1 3 1 5 times the normal running current during operation FM listed current overloads to approx 50pA above the highest observed operating current Di dt The Di dt Fault monitors the rate of change of current and shuts down the High Voltage if this exceeds a threshold The operation is fully ex plained in the Operations section Overvoltage The Over Voltage Fault monitors output kV feed back and shuts down the High Voltage if this e
35. ndition when in HV ON status the kV feedback is over or under the kV setpoint by 596 in direct charge modes and over by 5 or under by 15 in Indirect Charge modes This is in effect in Remote Mode only This con dition must be present for 5 seconds before the signal goes active Under Current RP1000 mode This signal indicates a condition where the out put current is lower than it should be in order to detect a failed or disconnected HV cable This is in effect in Indirect Charge Modes only 28 MicroPak Maintenance 29 MAINTENANCE TROUBLESHOOTING The Ohm Meter Measurements for HP404 RP404 HP505 Cascades and RansPak 1000 Cascade charts are shown in the Maintenance section see Figures 8 and 9 and will assist in making Ohm meter measurements through the low voltage cable for troubleshooting Note that one table is for the HP404 RP404 HP505 cascades and one is for the RansPak 1000 cascade Also note that measurements should be taken with the low voltage cable terminal strip disconnected from the motherboard Troubleshooting Di dt Faults Areas to investigate for cause Dirty atomizer interior or exterior Conductive solventresidue on atomizer assembly Moisture is inside or outside of atomizer body causing continuity or partial continuity back to ground Ransburg Moisture inside or outside of air lines back to ground High humidity Loose high voltage connections or defective
36. ne A10560 XX LEPS5002 High Voltage Cable Dash denotes length in feet Available dash 5 are 05 15 20 25 75 100 Multiple Output Industrial RP1000 Cascade 75933 00 79010 01 79010 00 Cascade Assembly HP404 LECUA4012 000r 78553 00 Node Adapter Serial Node Adapter or Serial Node Adapter Plus A12927 00 Cascade Assembly RP404 76037 03 Discrete Module 0 10 V Analog 76037 04 Discrete Module 4 20 mA Analog 76111 XX Cable Assembly MicroPak Discrete Dash denotes length in feet Available dash 5 05 10 15 20 A10565 00 Cascade Assembly HP505 LN 9218 00 13 Ransburg MicroPak Warranty Policies WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipmentthat within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with Rans burg s written safety and operating instructions and has been used under normal operating con ditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG AP PROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power
37. o uedo po 086 076 092 089 po pio uedo 79 uedo pio uedo 130 uedo uedo uedo pio 340 v e 2 2 pi uedo uedo io uedo ouedo Pl uedo rt XX 2 E Z 230 uedo uedo Dio uedo yo uado 342 E Z e z E Z pi Lo xo uedo o uedo yo PI uedo c 6 2 uedo 0 5 07 bo PO pio uedo 299 2 9 p 6e 9 p mp ow ee La pejoeuuoosip duis euius Jeuez A43 10 12661 pue 13661 sjeuDis ospy Ssepeoseo 20 99 01 ejqeo ef SUUYO sjueuleJnseeuJ JejeuJ gt E o c Ohm Meter Measurements for 404 404 505 Cascade Figure 8 30 LN 9218 00 13 o suid ssoJoe eouejioedeo Mea Aew sepoip peseiq
38. oad up to the kV Setpoint The operation is different than the voltage regulation mode in that when the kV Setpoint is reached there is no over voltage function and the unit maintains the output voltage at the setpoint and allows the current to drop It stays in this mode until the load changes such that the current in creases up to its setpoint then it limits at the set point and the voltage drops The big difference between voltage and current regulation is that the Current Setpoint is used to set a limit and not an Over Current shutdown point The actual Over Current threshold is set 30 SW7 5 OFF above the Current Setpoint so that in a dynamic situation where the current can actually rise above the limit point the Over Current function is still active VERSION 3 8 SOFTWARE This version adds some switch settings for the new HP505 cascade The HP404 settings hav ing zero voltage corrections factors K may be used for HP505 For voltage correction using the HP505 switches must be set per Figure 6 Note thatthis changes the function of SW7 1 from node addressing to cascade selection It is not needed for node addressing VERSION 3 9 SOFTWARE This version adds appropriate switch settings for the new RP404 cascade These can be found in Figure 6 Ransburg LN 9218 00 13 MicroPak Operation Ransburg 18 8 AH Ni Q318vVN3 NO H 339 TYNSIS WNAI 33038 NO 1 0 135 vn XI NO 1408136 v 330
39. of Operation A signal sent to J7 Pin 15C activates di dt inhibit not delay and a signal sent to J7 Pin 17C includes a di dt delay of 5 seconds with the activation of the fluid trigger for EFM guns Previous revision Service Manual LN 9218 00 12 MicroPak included the following changes from its prior revision 11 1 Revised Figure 2 MicroPak Controller w LEPS5002 or 74793 Cascade RansPak 1000 in the Installation section Cable connection point 1 is not connected N C inside the MicroPak It was erroneously shown as GND prior 2 Revised Figure 6 Switch Settings in the Operation section Added the RP 404 cascade and respective switch settings 3 Revised various references within the entire manual to add RP404 cascade LN 9218 00 13 Ransburg Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Philips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts 2013 Ransburg All rights reserved Form No LN 9218 00 13 Models and specifications subject to change without notice Litho in U S A 2 13
40. ply 2 Shields from the low voltage cable must be connected to a bus isolated from panel ground then by a 3 4 braid to the building steel or ground grid if available 3 The24 or28 VDC power supply common should be connected to the factory ground for safety even though they are connected to the isolated bus via the MicroPak motherboard MicroPak Grounding Theory 1 The low voltage cable has a large amount of high frequency noise on the shields and grounds from being in proximity to the high voltage generator Taking these grounds directly to earth ground ora ground grid through good high frequency conduc tors braid keeps this high frequency noise from interfering with the low voltage control circuitry This is why they are isolated from panel ground This is consistent with standard practice for light ning protection See NFPA 70 and NFPA 780 Ransburg 2 The feedback signals for kV and are devel oped with respect to the cascade ground If the cascade ground were routed only to earth ground via the above mentioned shields the feedback conditioning circuitry would have to depend on the panel ground or power supply common to get a ground reference for the feedback signals This means the low level return current for these signals would have to flow to earth ground and back to the controller via factory ground or power supply common This adds large amounts of noise to these low voltage signals 3 Agreat
41. responds to max to min sensitivity Not Used MicroPak 3 High Voltage Setpoint Value of 0 100 corresponds to 0 100 kV MicroPak 3 Current Limit Setpoint Value of 0 250 corresponds to 0 250 pA MicroPak 3 Di dt Setpoint 0 9 corresponds to max to min sensitivity Not Used MicroPak 4 High Voltage Setpoint Value of 0 100 corresponds to 0 100 kV MicroPak 4 Current Limit Setpoint Value of 0 250 corresponds to 0 250 MicroPak 4 Di dt Setpoint 0 9 corresponds to max to min sensitivity Not Used 0 85 corresponds to 0 85 for HP404 FM 0 1000 corresponds to 0 1000 pA for RP1000 or LEPS5002 applications LN 9218 00 13 24 MicroPak Operation Ransburg 25 MICROPAK NODE ADAPTER PLC I O Cont MicroPak Mode BLOCK TRANSFER READS BTR Word Module BTR Block Configuration MicroPak 1 High Voltage Feedback Value of 0 100 corresponds to 0 100 kV MicroPak 1 Current Feedback Value of 0 250 corresponds to 0 250 MicroPak 1 Status Word MicroPak 2 High Voltage Feedback Value of 0 100 corresponds to 0 100 kV MicroPak 2 Current Feedback Value of 0 250 corresponds to 0 250 MicroPak 2 Status Word MicroPak 3 High Voltage Feedback Value of 0 100 corresponds to 0 100 kV MicroPak 3 Current Feedback Value of 0 250 corresponds to 0 250 MicroPak 3 Status Wor
42. s us LT 1765 ne H RDY ON L E X ur 17 18 f RS P umy c RE La m Ci RDY OFF H Sm 1 ne B LEDS T re 83 c 5 L E 4 9 OVER Rel ECT ust BR 266 a ROM LR 512 Can 1084 RIS cis EB cis we ues GET DE me DE ERR cai L d FL Ree ueo ug 4 1 T n n T LEDS 29 8 8 R ma RRAS pu R Ra a J a D ee g FBE E 1 2 143 LOCAL 8 a E E ex REMOTE I 5 SHB Rez E3 R26 O w r H 8 S TERM Ute ADDR Node Address Switch SW7 MicroPak Controller Process Board Figure 7 Switch Configuration LN 9218 00 13 Ransburg MicroPak Operation INPUT OUTPUT SIGNALS Discrete I O Mode The Discrete Module may be used to connect discrete signals to one MicroPak Controller one Atomizer Turbine Speed Control Module Use the 76111 xx DIO cable assembly to make connections The following signals are available for control and monitoring via the discrete I O module Cascade RP1000 HP404 RP404 HP505 Speed Command Feedback Scaling 0 50 krpm 0 100 krpm Analog Input Offset 0 10 2 10 4 20 ANALOG INPUTS Wire Color Signal Description High Voltage Setpoint KVS
43. sted periodically Personnel must be given training in accordance with the requirements of NFPA 33 EN 60079 0 Instructions and safety precautions must be read and understood prior to using this equip ment Comply with appropriate local state and na tional codes governing ventilation fire protec tion operation maintenance and housekeep ing Reference OSHA NFPA 33 EN Norms and your insurance company requirements LN 9218 00 13 Ransburg AREA Tells where hazards may occur Spray Area High Voltage Equipment LN 9218 00 13 HAZARD Tells what the hazard is Electrical Discharge There is a high voltage device that can induce an electrical charge on ungrounded objects which is capable of igniting coating materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion MicroPak Safety SAFEGUARDS Tells how to avoid the hazard Parts being sprayed and operators in the spray area must be properly grounded Parts being sprayed must be supported on con veyors or hangers that are properly ground ed The resistance between the part and earth ground must not exceed 1 meg ohm Refer to NFPA 33 Operators must be grounded Rubber soled in sulating shoes should not be worn Grounding straps on wrists or legs may be used to assure adequate ground contact Operators must not be wearing or carrying any ungrounded metal objects
44. tage fault that occurred Voltage Boost Mode The MicroPak software has been revisedto provide two voltage correction modes when configured for the HP404 cascade The purpose of this change is to compensate for the voltage drop in the cas cade s current limiting resistor Position 1 see Figure 6 voltage correction 1 mode provides correction when the output current is always below 50 Position 2 see Figure 6 voltage correction 2 mode is the default mode and provides correction when the output current runs or may range above 50 pA Voltage Regulation To date the mostcommontype of output regulation for electrostatic painting applications is voltage regulation This means sensing the output volt age comparing this to the voltage setpoint and adjusting the cascade drive to maintain the output equal to the setpoint In this mode the current varies depending on the load up to the Current Setpoint where the unit switches to Over Current turning off the output Current Regulation The MicroPak is also capable of current regu lation which is desired for some applications In this mode the functions of voltage and current are reversed from the voltage regulation mode This means sensing the output current comparing this to the current setpoint and adjusting the cascade drive to maintain the current output equal to the current setpoint In this mode the voltage varies 16 MicroPak Operation 17 depending on the l
45. ty The microprocessor circuits allow the use of output load curve control which limits the high voltage output to safe levels even with the controls set at maximum levels and does so without a hard shut down The Over current set point which can be monitored on the ya Display by pressing the SET push button and holding for one second does pro vide a hard shutdown if the output current exceeds the set point The kV set point is also displayed on the kV display when the SET push button is pressed for one second DISPLAYS The front panel displays for output voltage and current indicate the outputs from the cascade of direct charge applicators or the probe tip voltage in the case of indirect charge applicators They are derived from feedback signals in the low voltage cable between the controller and the cascade LN 9218 00 13 MicroPak Introduction In RansPak 1000 mode beginning with software version 3 2 the signal used for the current uA display is conditioned to subtract out the internal cascade bleeder current and thus display the actual output current SPECIFICATIONS At Sea Level Conditions Environmental Physical Temp Operating 0 to 55 C Storage 40 C to 85 C Humidity 9596 Non Condensing Size 100 X 160mm Eurocard module total width 3 2 in one module Electrical Requirements Power Required per MicroPak 24 VDC at 2 5A fully loaded output HP404 RP404 and HP505 C
46. us must be isolated from the system ground bus except at the termination point to earth ground A WARNING gt If these connections are not made in this manner damage will result to system elec tronic components and system safety may be compromised Remote I O If applicable connect Remote I O Blue to J5 B Shield to J5 S and Clear to J5 C CANBus Provide a jumper from the MicroPak mother board connector J8 CAN to pneumatic mother board connector J4 This should be done with a short section of shielded pair cable while observing the and to convention See Figure 3 In Node Adapter applications provide additional jumper wires from pneumatic mother board to the next pneumatic mother board up to a maximum of four 4 mother boards Interlock Terminal strip J6 provides a connection point for system interlock to prevent generation of high voltage Terminal J6 1 must be connected to J6 2 by jumper or voltage free contact in order to make the High Voltage Ready HVRDY mode If this connection is momentarily broken HVRDY must be reset Make no connection to J6 3 before reading HV On Control in the Operation section of this manual MicroPak Installation MicroPak Grounding 1 The Power Supply must be referenced to true earth ground at only one point Refer to Figures 1 2 and 3 for Grounding Connections Separate ground connections MUST be used for grounding the part and the Power Sup
47. ust be compatible with the material being sprayed and its concentration Equipment must be as prescribed by an industrial hygienist or safety expert and be NIOSH approved Aluminum is widely used in other spray appli cation equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray If in doubt as to whether or not a coating or cleaning material is compatible contact your coating supplier Any other type of solvent may be used with aluminum equipment LN 9218 00 13 Ransburg INTRODUCTION GENERAL DESCRIPTION The MicroPak Controller in conjunction with an appropriate cascade is used to provide high voltage for electrostatic application equipment The controller is packaged in a single 3 2 inch wide Eurocard module and thus consumes less than 1 4 of the available space in a 19 inch rack The MicroPak uses a combination of proven high voltage generation technology including micropro cessor based control with diagnostic and commu nication functions The processor circuitry provides the maximum in applicator transfer efficiency while maintaining the maximum safety when used in conjunction with FM listed applicators SAFETY FEATURES When used with FM listed applicators the Micro Pak provides the ultimate in operational safe
48. xceeds setpoint by more than 10 kV for more than 5 seconds This can occur when equipment LN 9218 00 13 MicroPak Operation discharges too slowly after a voltage setpoint reduction An overvoltage fault is indicated on the front panel by the FB led flashing on and off FB Fault The Feedback Fault monitors the HV and Current feedback signals from the cascade for abnormal signal levels When high voltage is off a FB Fault indicates in general one of two conditions 1 an open circuitin the connection between the control ler caused by a broken wire or bad connection or 2 a situation where HV is actually present even though the MicroPak is not generating it either from another HV source or because the MicroPak has been recently turned off and there is a very large amount of energy storage in the HV load causing the HV to decay very slowly When high voltage is on a FB Fault indicates that there is sufficient drive being sent to the cascade but no feedback on either or both of the kV and Current feedback signals This could be caused by a faulty or disconnected cable or a faulty cascade HV Held In Reset This signal indicates the MicroPak is seeing an HV Reset input and cannot turn on HV until the HV Reset signal is removed Status Indications The following indicates conditions which the op erator may need to know but do not interrupt the HV ON status kV Out of Tolerance RP1000 mode This signal indicates a co
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