HV Controller (Serv. Man. LN-9623-00.1)
Contents
1. ccn 12 14 PARAMETERS AND SETTING S enc ec e i 14 CONTROL CONDITIONS 15 15 15 EIHERNEEIPIIIEREACE M RE M M 16 20 MAINTENANCE 21 TROUBLESHOOTING GUIDE oe ER tes 21 WARRANTY POLICIES 22 HALTE Geet eee MI E 22 LN 9623 00 1 2 High Voltage Controller Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all ofthe technical and safety literature 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 PROB LEMS To help you recognize this information 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 damage 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 variati2. High Voltage Controller Operation ETHERNET IP OUTPUT BIT DEFINITIONS TABLE 2 Fault Current Mode Unused Communications Fault Parameter Data Value Parameter Data Value Parameter Data Output Object Word 0 Word 1 Word 2 Word 3 0x71 Bit 0 in Caneel Over Current Parameter Data Actual KV Warning Value Value Bit 1 Over Voltage Parameter Data Actual KV ping Warning Value Value Bit 2 OK to Start Under Voltage Parameter Data Actual KV Warning Value Value Bit 3 Remote Mode Uimed Parameter Data Actual KV Value Value Parameter Data Actual KV Bit 4 Warning Unused Male Value Actual KV Value Actual KV Value Actual KV Bit 7 Unused Hardware Fault Value Miss Ee puse Bit 9 Unused dv dt Fault Fixes e Bit 10 Unused didtFauk farmer Actual uA mun TTM Log E SE TE E WE E IL uem M Bit 15 Heartbeat Cable Fault E co LN 9623 00 1 18 High Voltage Controller Operation Output Word 0 Bit 0 In Control This bit is set when control is enabled and the control value has closed within three ofthe setpoint This does not mean that the value is still within three of the setpoint but that it had been at one time Bit 1 Ramping This bitis set when the setpoint has been changed and the current value has not come within three of the setpoint yet During the time it is s
3. If the Set Button is pressed while this menu is still up the system changes to the display contrast Menu automatically to allow for contrast adjustment on initial power up Run Menu Ransburg Figure 10 Run Menu Screen This menu displays the setpoint KVSET if in Volt age Mode uASET if in Current Mode the current actual KV value the current uA value the current hardware check value the High Voltage status and the current controller status The setpoint KVSET or uASET is the only changeable value on this menu 12 High Voltage Controller Operation Ransburg Mode Menu Fault Menu Ransburg Ransburg Figure 11 Voltage Mode Screen Figure 13 Fault Menu Screen This menu displays the current mode Voltage or Current and the high and low limits allowed for the Dependent Value in that mode All of these values are changeable values This menu displays the latest fault and is displayed automatically upon the fault detection Sensitivity Menu Display Contrast Menu Ransburg Ransburg Figure 12 Sensitivity Menu Screen Figure 14 Display Contrast Menu Screen This menu displays the current di dt or dv dt below the password digit being changed instead of limit value and the enable status for di dt or dv dt beside them When the new password is entered depending on the mode These are changeable it will now be used for all values being changed values If the current voltage changes greater than this valu
4. AND OPERATION On all of the menus if there is a parameter that can be changed there are a number of char acters to show that it is an enterable value there is more than one enterable value pressing the Up or Down Buttons will move the s to the next changeable value When the s are next to the value you wish to change press the Set Button This will bring up the Password Menu to allow you to enter the password and change the value Once the password has been entered it will remain active for an appropriate amount of time and then time out requiring you to re enter it When a valid password has been entered for any value even if the value has not been changed different menus will be available These Menus are the Display Contrast Menu the IP Address Menu and the Enter New Password Menu When a numeric value is being changed using the buttons to the left and right of the SET But ton the numeric will increase with the right button and decrease with the left button until it passes the maximum or minimum allowed value at which time it will roll over to the other limit Start Up Menu Ransburg Figure 9 Start Up Menu Screen LN 9623 00 1 High Voltage Controller Operation This is the menu that displays on the unit for 5 seconds approximately at power up It displays the Model Number Copyright Date Serial Num ber Software Version and Hardware Version of the unit It then changes to the Run Menu
5. The system has detected a di dt event Bit 10 di dt Fault The system has detected a di dt event Bit 11 Minimum Output Fault The system has lowered the Variable Voltage Output to zero and still is above the setpoint Bit 12 Maximum Output Fault The system has raised the Variable Voltage Output to the system maximum but could not reach the setpoint Bit 13 Over Voltage Fault The system has exceeded the kV Limit Hi or the Max System Limit LN 9623 00 1 Ransburg High Voltage Controller Operation Bit 14 Over Current Fault NOTES The current value has exceeded the Current I Limit Hi or the Max System Limit Bit 15 Cable Fault This bit is set whenever the voltage or current feedback from the cascade has been lost or fallen below the acceptable value Output Word 2 Bits 0 7 Parameter Data Value This byte 8 bit tells the system the active parameter value Bits 8 14 Parameter Select Code This 7 bit value tells the system which parameter is being displayed Bit 15 Parameter Acknowledge When this bit changes from cleared to set a new Parameter Value is being dis played Itis cleared when the Parameter Read Strobe and Parameter Write Strobe are both cleared Output Word 3 Bits 0 7 Actual kV Value The byte 8 bit value displays the latest voltage reading in kV Bits 8 15 Actual uA Value This byte 8 bit value displays the latest current reading in uA LN 9623 00 1 20 H
6. 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 High Voltage Controller 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 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
7. material Testing may require high voltage to be on but only as instructed Non factory replacement parts or unauthor ized 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 High Voltage Controller Safety AREA Tells where hazards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate opera tion 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 the 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
8. 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 High Voltage Controller 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 materials 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 and 1 1 1 Trichloro ethane are not chemically com patible with the aluminum that might be used in many
9. system components 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 must 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 ap plication equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used
10. 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 tested 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 OSH
11. A NFPA 33 EN Norms and your insurance company requirements LN 9623 00 1 Ransburg AREA Tells where hazards may occur Spray Area High Voltage Equipment LN 9623 00 1 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 materi als and cause a fire or explo sion High Voltage Controller 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 grounded 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 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
12. EN TIALDAMAGES 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 responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable 22 Service Manual Price 25 00 Euro 30 00 U S Ep M M M 1 Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 www ransburg com Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No LN 9623 00 1 2013 Ransburg All rights reserved ISO 9001 Litho in U S A Models and specifications subject to change without notice Quanity Sree 03 13
13. SERVICE MANUAL Ransburg LN 9623 00 1 March 2013 HIGH VOLTAGE CONTROLLER TS il Ransburg visit o e p o e OFF 2 CONTROLLER piss ae MODEL A12311 IMPORTANT Before using this equipment care fully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 25 00 Euro 30 00 U S Ransburg High Voltage Controller Contents CONTENTS PAGE SAFETY 1 5 SAFET PRR AU TON S LM MEE E LL E 1 HAZARDS SAFEGUARDS ttttttttntt ttt ttt ttt ttt ttt tto 2 5 INTRODUCTION 6 9 GENERAL DESCRIP ON 6 SAFETY FEATURE e n sean Ete 6 dum D Lu MM UE 6 crete cece ee ne eect ha 7 PASSWORD 8 OPERATOR INTERFACE snis viriai iiaa a i ena E ET TAS Sai 8 N S NM MM 8 8 9 BUFIONS ou Mu E E E 9 INSTALLATION 10 11 SDN E EU 10 10 INPUT POWER 8 10 ONIN ela EL el 11 C ONNE E ces etre MM LL M 11 OUTPUT TO CASCADE ttt ttt ttt ttt ttd 11 amp 823 CONNECTOR 11 OPERATION 12 20 MENUS AND OPERATION
14. ays the current state of the High Voltage Output This LED is illu minated whenever High Voltage is being supplied BUTTONS The six buttons used to control the viewing and entry of information on the 4 X 20 character dis play are Screen Button The Screen Button at the top is used to change toggle to the next Menu screen The menu Screens wrap around so that after the last screen it will return to the first screen Up and Down Buttons The buttons above and below the Set Button in the middle the Up and Down Buttons are used to change which value on the screen is to be changed Set Button This labeled button in the middle is used to select the value to change and to enter the change after it has been made Increase and Decrease Buttons The buttons to the right and left of the Set Button are the Increase and Decrease Buttons They are used to change the value selected by the Set Button NOTES Ransburg LN 9623 00 1 Ransburg High Voltage Controller Installation INSTALLATION INSTALLATION INPUT POWER CONNECTIONS Figure 4 Installation Figure 5 Input Power Connections MOUNTING Input power must be supplied from a regulated four 4 b Ae di DC power Supply The connection is made at J8 included secure the front panel of the High Volt With VIN at 24VDC 5V GND at 24VDC return age Controller using the supplied mounting holes CGND at Earth Ground The 24 VDC sup
15. e within approximately 100ms a fault signal is issued 13 LN 9623 00 1 Ransburg IP Address Menu Ransburg Figure 14 IP Address Menu Screen This menu allows the setting of the units IPAddress When the new IP Address has been entered the unit must have the power cycled before the new IP Address will be used Password Menu This menu is differentin thatthe s are displayed below the password digit being changed instead of beside them When the password is entered the menu will return to the value being changed Enter New Password Menu This menu is differentin that the s are displayed below the password digit being changed instead of beside them When the new password is entered it will now be used for all values being changed LN 9623 00 1 High Voltage Controller Operation PARAMETERS AND SETTINGS Mode The operating mode can be set to either Voltage or Current mode The mode selection determines which independent setpointis the basis for control kVSet This is the voltage setpoint used Voltage Mode The system attempts to keep the voltage at this value uASet This is the current setpoint used in Current Mode The system attempts to keep the current at this value kV Limit Hi This parameter determines the level where a kV Limit Fault occurs When the voltage rises above this value itissues a kV Limit Fault It only applies in Current Mode kV Limit Lo This parameter determine
16. ed Ifthe setpoint changes outside the control window the status changes to Rising or Falling until the Independent Value again reaches the window at which point it returns to Running HV Off On HV Off the system immediately sets the Vari able Voltage Output to zero volts disables the HV Relay and goes to Stop Mode The System Check goes to NoGo until the High Voltage and Variable Voltage Output feedback again reach the pre determined value Ransburg SYSTEM STATUS STS OK System is off and ready to start Starting Rising Falling System is changing from one voltage current value to another Di dt and dv dt checks are disabled Running System is attempting to keep a steady value on Setpoint the Independent Value All enabled checks are active Stopping System is off and waiting to transient voltages currents to stop Warning System has detected a current or voltage condi tion within 10 of the limit settings Fault System has detected a fault condition stopped and will not allow starting until the fault is cleared If the fault condition has not been cleared it may immediately fault without starting SYSTEM CHECK CHK OK System has passed the checks andis ready to start NoGo System has detected excessive voltage on the High Voltage or Variable Voltage Output Feedbacks and will not allow a start LN 9623 00 1 Ransburg ETHERNET IP INTERFACE The Ethernet IP Interface is defined a
17. et the di dt and dv dt are not active Bit 2 OK to Start This bitis setwhen the system determines that the current voltage values are in a range where it is allowed to start control Bit 3 Remote Mode This bit is set when the front panel switch is set to remote in order to allow remote control of the system Bit 4 HV On Echo This bit is set whenever HV is ON Bit 5 Warning This bit is set whenever any warning is in effect Bit 6 Fault This bit is set whenever any fault is in effect see Fault Descriptions in Troubleshooting Guide in the Maintenance section Bit 7 14 Unused These bits are currently undefined and unused Bit 15 Heartbeat This bit changes state every 1 4 second producing two pulses per second 19 Ransburg Output Word 1 Bit 0 Over Current Warning The current value is within 10 of the upper limit Bit 1 Over Voltage Warning The voltage value is within 10 of the upper limit in current mode Bit 2 Under Voltage Warning The voltage value is within 10 of the lower limit in current mode Bit 3 5 Unused These bits are currently undefined and unused Bit 6 Communication Fault The system has detected a communi cation failure after an Ethernet IP connection was initiated Bit 7 Hardware Fault The system has detected a fatal System Failure Bit 8 Low Voltage Fault The system has fallen below the kV Limit Lo in Current Mode Bit 9 dv dt Fault
18. etected a communication failure after an Ethernet IP connection was initi ated LN 9623 00 1 Ransburg High Voltage Controller Warranty Policies WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipment that falls 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 condi tions 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 supplies control units etc is one 1 year from date of purchase WRAPPING THEAPPLICATOR ASSOCIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY LN 9623 00 1 RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP ORMATERIALS THEREARE NOIMPLIED WARRANTIES NORWARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEQU
19. h the system will attempt to keep the actual at the appropriate setpoint Bit 1 Reset Faults When this bit is changed from low to high cleared to set the system will clear any fault bits if any are set and will set the communication fault if no fault bits are set Bit 2 Current Mode When this bit is set the system will operate in the Current Control Mode and when cleared will operate in the Voltage Control Mode Bit 3 3 15 Unused These bits are currently undefined and unused Input Word 1 Bits 0 7 kV Setpoint This byte 8 bit value determines the active Voltage setpoint in kV Bits 8 15 uA Setpoint This byte 8 bit value determines the active Current setpoint in uA Input Word 2 Bits 0 7 Parameter Value These bits are currently undefined and unused Bit 8 14 Parameter Select Code This 7 bit value determines the parameter to change Bit 15 Parameter Write Strobe When this bit changes from cleared to set the parameter value is written into the selected parameter and displayed in the Output Word 2 Ransburg Input Word 3 Bits 0 7 Unused These bits are currentely undefined and unused Bits 8 14 Parameter Select code The 7 bit value determines the parameter to change Bit 15 Parameter Read Strobe When this bit changes from cleared to set the Current Parameter Value is read from the selected parameter and displayed in the Output Word 3 LN 9623 00 1 Ransburg
20. igh Voltage Controller Maintenance MAINTENANCE TROUBLESHOOTING GUIDE Ransburg Blank Display 1 If the display is blank on initial power up it may be that the display contrast is not set correctly No Fault Current Limit Fault Max Output Fault Min Output Fault kV Limit Fault dv dt Fault di dt Fault Voltage Cable Fault Current Cable Fault 10 Low Voltage Fault 11 Hardware Fault 12 Communication Fault 21 1 Cycle the Power on the unit 2 Within 5 seconds press the SET button 3 Press and hold the right arrow button until the display contrast looks correct 4 When the display contrast looks correct press the SET button again 1 No Fault was detected 2 The current value has exceeded the Limit Hi or the Max System Limit 3 The system has raised the Variable Voltage Output to the system maximum but could not reach the setpoint 4 The system has lowered the Variable Voltage Output to zero and still is above the setpoint 5 The system has exceeded the kV Limit Hi or the Max System Limit 6 The system has detected a dv dt event 7 The system has detected a di dt event 8 The system has detected a loss of the High Voltage Feedback signal 9 The system has detected a loss of the Current Feedback signal 10 The system has fallen below the kV Limit Lo in Current Mode 11 The system has detected a fatal System Failure 12 Thesystem has d
21. l and Reporting Ethernet IP Note Aunique MAC ID address is hard coded into each High Voltage Controller User con trols must be configured to recognize each unique ad dress Internal Controller Scan Time 1 ms all data is taken from a rolling average of 8 scans LN 9623 00 1 Ransburg PASSWORD PROTECTION High Voltage Controller parameters will be pass word protected to prevent an unqualified operator from changing the values Ransburg Figure 2 Password Screen OPERATOR INTERFACE The High Voltage Controller has a physically simple operator interface consisting of three 3 LED s Light Emitting Diodes three 3 switches six 6 buttons and a four line twenty character 4 X 20 alpha numeric display SWITCHES Ransburg a e SCREEN FAULT x Q TOGGLE ON HV LOCAL ON e e F se e OFF HIGH VOLTAGE lel Figure 3 Power Switch LN 9623 00 1 High Voltage Controller Introduction Power Switch The rocker switch on the left and the LED directly above it are for power On Off selection and dis play The green LED is on when the power is On to the controller Local Remote Switch This is usedto determine ifthe Local Front Panel controls have priority or if the Remote Ethernet Connection controls have priority If the switch is up Local Mode the Front Panel controls may change parameters enable or disable the high voltage and clear faults The Remote Ethernet co
22. nnection may look at parameters and values but may not change them or enable disable the high voltage output Ifthe switch is down Remote Mode the opposite is true except that the Front Panel switch may be changed to local Mode at any time to disable the Remote Controls and to enable the Local Controls HV On Off Switch This is a floating toggle switch It is active if the Local Remote mode switch is in Local It is used to enable and disable the High Voltage output and to clear system faults When the System Checks and Current Status are OK flipping the switch to the up position HV On will enable High Voltage Output see Figure 3 Power Swtich in this section Flipping it to the down position HV Off will disable the High Voltage Output If there is a system fault flipping this switch to the OFF position also known as the Reset position it will reset clear any faults currently detected by the system LED S Power LED If the Green Power LED is on then the system power to the controller is On High Voltage Controller Introduction Fault LED The red Fault LED is lit when the system detects a fault condition see Figure 3 Power Switch in this section When operating in Local Mode it is cleared by flipping the HV On Off switch to the Off Reset position If the system is still in a fault condition it will immediately be lit as the system detects the fault High Voltage LED The green High Voltage LED displ
23. ons 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 opera tion 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 thoroughly 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 SAFETY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment A WARNING gt The hazards shown on the following pages may occur during the normal use of this equip ment Please read the hazard chart beginning on page 2 LN 9623 00 1 Ransburg AREA Tells where hazards may occur Spray Area LN 9623 00 1 HAZARD Tells what the hazard is Fire Hazard Improper or
24. ply must be protected against excessive current as well as Over Voltage protected NOTE The Ransburg High Voltage Controller has a in resettable fuse so if it draws a current in excess of 2 5 amps it will open Reset is achieved by turning controller power OFF for 5 minutes then back ON LN 9623 00 1 10 High Voltage Controller Installation 11 ETHERNET CONNECTOR Figure 6 Ethernet Connector Use the appropriate 10 100BASE Ethernet wiring Straight EIA TIA 568A for your installation us ing a RJ 45 plug to connect to the High Voltage Controller INTERLOCK CONNECTION Figure 7 Interlock Connection J9 is supplied to give a hardwire connection thru relay dry contacts rated at 24 VDC 1 amp maximum for when the controller operating power is turned OFF or a fault condition exists They Ransburg are marked as COM Common NC normally closed or NO normally open and can be used by end user OUTPUT TO CASCADE Make connections from J6 of the controller to the cascade per the following table Cascade A12295 00 FRA EE 4526 800 or A12296 00 FRA EE 4626 801 Analog D cla Drive Signa Nomina or Cascade Pin 4 OVDC for Analog Cascade Voltage Pin 5 Analog Cascade Voltage Feedback Pin 6 OVDC for Analog Cascade Current Feedback Signal RS232 CONNECTOR This connector is a service connection for the Ransburg factory LN 9623 00 1 Ransburg OPERATION MENUS
25. s a set of four 16 bit IO words of input and a set of four 16 bit words of output The Ethernet IP Input Assembly is defined as object 0 X 70 and the Ethernet IP Output Assembly is defined as object 0 X 71 The bit definitions are in the following table ETHERNET IP INPUT BIT DEFINITIONS TABLE 1 LN 9623 00 1 High Voltage Controller Operation input Word 0 Word 1 Word 2 Word 3 0x70 Bit 0 Enable Control KV Setpoint Unused Value Bit 1 Reset Faults KV Setpoint Unused Value Bit 2 Current Mode KV Setpoint Unused Value Bit 3 Unused KV Setpoint Por Unused Value Bit 4 KV Setpoint Parameter Unused Value Bit 5 KV Setpoint Unused Value Bit 6 KV Setpoint Unused Value Bit 7 KV Setpoint Unused Value Parameter Parameter Bits aepo Select Code Select Code Parameter Parameter Pip uA Setpomt Select Code Select Code Parameter Parameter Bit 10 nused uA Setpoint Select Code Select Code Parameter Parameter PB Unused uA Setpoint Select Code Select Code 7 Parameter Parameter odis Select Code Select Code Parameter Parameter P p Parameter Parameter Unused nA Setponit Select Code Select Code Parameter Parameter Read Bit 15 Unused uA Setpoint Write Strobe 16 High Voltage Controller Operation 17 Input Word 0 Bit 0 Enable Control When this bit is set hig
26. s the level where a kV Limit Fault occurs When the Voltage falls below this value it issues a kV Limit Fault It only ap plies in Current Mode uA Limit Hi This parameter determines the level where a Cur rent Limit Fault occurs When the current rises above this value it issues a Current Limit Fault It only applies in Voltage Mode Di dt Sensitivity When a rapid current change occurs where cur rent rises faster than this value in approximately 100ms it issues a di dt fault This is only active in Voltage Mode Dv dt Sensitivity When a rapid voltage change occurs where volt age falls faster than this value in approximately 100ms it issues a dv dt fault This is only active in Current Mode 14 High Voltage Controller Operation CONTROL CONDITIONS Power Up On power up the system does several checks to determine hardware status It checks various sig nals to determine that there are no faults including feedback from the Variable Voltage Output and High Voltage Inputs to determine system status If it determines that it is OK to start the Check display on the run menu changes from NoGo to OK and System Status changes to OK HV On When the HV On signal is received the system status changes to Starting and the Variable Volt age Outputis increased until the Indpendent Value rises to within a tolerance window currently 3 of the setpoint value Then the System Status changes to Running Setpoint Chang
27. th current and voltage e e ME le d information to attempt to maintain actual value at CONTROLLER set point The processor circuitry provides the O O maximum in applicator transfer efficiency while maintaining the maximum safety 3 FAULT TOGGLE LOCAL Figure 1 High Voltage Controller SAFETY FEATURES When used with the appropriate applicators and cascades the Ransburg High Voltage Controller provides the ultimate in operational safety The protections include Overvoltage Overcurrent Di Dt and Dv Dt The microprocessor circuits allow the use of the output load curve control which limits the high voltage output to safe levels when the controls are setresponsibly and safe distances are observed and followed LN 9623 00 1 6 High Voltage Controller Introduction Ransburg SPECIFICATIONS NOTES Environmental Physical Operating Temperature Oper OEL OR Storage and Shipping Temperature 40 C to 85 C Humidity 95 Non Condensing Physical Size 5 5 tall X 7 5 wide X 3 5 deep Electrical Power Required 24VDC 5V 2 5 Amps maximum 8 sea level regulated with over voltage protection Note For every 1000 ft of increased elevation the maximum current is increased by 3 High Voltage Output 24 Volts 1Amp Form C relay contact Controller Operating Range High Voltage 0 100kV settable in 1kV increments Current 0 150 microamps Communication Requirements Contro
28. 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 9623 00 1 Ransburg High Voltage Controller Introduction INTRODUCTION GENERAL DESCRIPTION DISPLAY The front panel displays the high voltage and The Ransburg High Voltage Controller A12311 current output from the cascade as true readings 00 or FRA EE 4526 300 in conjunction with an They are derived from feedback signals in the appropriate cascade A12295 00 FRA EE 4526 voltage cable between the controller and the 800 orA12296 00 FRA EE 4626 801 isused cascade to provide high voltage for electrostatic application equipment The controller is packaged in a single package measuring 5 5 tall X 7 5 wide X 3 5 deep The controller can operate in Local and x Remote conditions with either Voltage Mode or Current Mode of high voltage operation Ransburg The Ransburg High Voltage Controller uses combination of proven high voltage generation technology including microprocessor based con trol with diagnostic and communication functions It uses a variable voltage output to drive a cas E cade that amplifies the voltage to a high value It e also uses feedback with bo
Download Pdf Manuals
Related Search