MicroPak 2e Single Bell Controller
Contents
1. INTERLOCK INPUTS Z AIR IN Ul NSS AY 100 240 VAC 50 60 Hz EXHAUST 1 OUT HI I NL TURBINE UP PN PILOT 220 LOW DN PILOT NV VOLTAGE on BEARING AIR ow Figure 2 Rear View of Controller Cabinet Bell Control HP404 RP404 A13613 00 TEST O O INTERLOCK INPUTS 02 o ARIN z 2 L LA 100 240 VAC EEER o 50 60 Hz EXHAUST BEES OUT DID I ETHERNET TURBINE f UP AN PILOT Wy AA PILOT Low NI H Sey VOLTAGE bd Sid dee N E 12 Figure 3 Rear View of Controller Cabinet Bell Control RP1000 A13613 01 LN 9625 00 Ransburg MicroPak 2e Single Bell Controller Installation2. m r d MicroPak 2e B High Voltage amp Atomizer Controller nud ES 1 a 24 DC Power Supply H ID IT TI x tul Figure 19 Inside View A13613 02 NOTES LN 9625 00 a MicroPak 2e Single Bell Controller Warranty Policies 34 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 Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG APPROVED PARTS VOID ALL WARRAN TIES 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 THE APPLICATOR ASSO CIATED VALVES AND TUBING AND SUP PORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONLY
3. 00000 I HHT T Figure 7 Fiber Cable Position l LN 9625 00 Ransburg hole Once the hole is clear insert the fiber cable into the hole until it is fully seated Then tighten the nylon screw to hold the cable in place and tighten the compression fitting to retain the looped cable BELL INTERLOCKING The following system interlocks are required to prevent equipment damage Bearing air should remain on at all times and only shut off by turning off the main air to the pneumatic control cabinet Turbine air must be removed if bearing air falls below 80 psi 551 6 kPa at the atom izer To facilitate this Ransburg atomizers provide two interconnected bearing air ports one for supply air and the other to be used as a return signal for measuring bearing air pressure at the atomizer If bearing air falls below 80 psi 551 6 kPa at the atomizer the turbine air should be automatically interlocked to shut off This interlock is provided by the MicroPak 2e Atomizer Controller See current Mi croPak 2e HV amp Atomizer Controller ser vice manual Turbine air and brake air must
4. INTERLOCK INPUTS Sm a ETT pers N ETHERNET p Wat Low m VOLTAGE f Figure 4 Rear View of Controller Cabinet AutoGun HP404 HP505 A13613 02 LN 9625 00 13 MicroPak 2e Single Bell Controller Installation Ransburg ix Connector Housing Terminal Block Cable Assembly Grommet Figure 5 Assembly of Connector P2 Cable Jacket Wires Figure 6 Stripping of I O Cables 14 LN 9625 00 Ransburg DESCRIPTION OF TABLE 1 INTERLOCK AND OUTPUT TERMINALS Interlock Terminals These terminals allow interlocking of high volt age and atomizer operation with safety com ponents In order to obtain high voltage or atomizer operation the enabled MicroPak 2e Single Bell Control interlock terminals must have a connection between the and ter minals by a jumper or voltage free contact When an interlock is enabled if the high volt age is activated without the interlock and terminals being connected together high voltage output will not occur These terminals are provided to interlock the controller with the exhaust fan and conveyor as required by NFPA 33 If an enabled interlock connection is momentarily lost the connecti
5. Figure 16 MP2E Connector Locations LN 9625 00 27 MicroPak 2e Single Bell Controller Maintenance TROUBLESHOOTING GUIDE A WARNING gt The Troubleshooting Guide below re quires measurement of potentials that can cause serious bodily injury if proper mea suring procedures are not followed For this reason proper troubleshooting should ONLY be conducted by qualified electronics techni cians using specific test equipment General Problem MicroPak Power Indicator and Meters do not light up when MicroPak 2e ON OFF Switch is turned ON No or Low kV Out put at Spray Gun when HV ON Indi cator green LED is Lit Ransburg Possible Cause Solution AC Power ON OFF switch on rear of controller not turned ON Turn AC power ON OFF switch ON Improper input line voltage Ensure voltage across terminals 2 and 3 of CON1 see Figure 17 of 24VDC power supply is between 90 and 264 VAC Fuse of 24VDC power supply is de fective Defective 24VDC power supply Defective MicroPak 2e Control Unit High voltage is not set to proper val ue Check fuse and replace if defective see Figure 17 Voltage across terminals 1 and 8 of con nector CON2 see Figure 17 of 24VDC power supply should be 24VDC If not re place 24VDC power supply If none of the suggestions above resolves the issue replace the A13338 MicroPak 2e Control Unit Set the high v
6. ure 11 below Line 1 of the display shows the configured atomizer type Line 2 shows the turbine speed setpoint KRPM Sp in thou sands of RPMs followed by current turbine speed reading RPMAct based on turbine feedback Line 3 of the display shows that there are no atomizer faults Line 4 of the dis play shows the current reading of the Bearing Air feedback pressure in psi ATOMIZER RMA300 500 KRPM Sp 00 RPMAct 00 No Faults Bearing Air 000 psi Figure 11 Atomizer Run Menu Screen MENU OPERATIONS On all of the MicroPak 2e menus if a parame ter can be changed it will be proceeded by a blinking and followed by a blinking to show that it is a changeable value If there is more than one changeable value on a screen pressing the Up or Down and Left or Right Buttons will move the selection gt lt s to the next value If there are no changeable values on a screen then the Active Screen Indicator in the lower right corner will blink When the selection gt lt s surround the value you wish to change press the Set Button If the value to be changed requires a password either the User System or Config Password Menu will be displayed allowing you to enter the required password After entering the Password you are returned to the originally selected value If the password was entered correctly the value may now be changed If the entry was incor rect the password screen will again be dis
7. will enable the high voltage output 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 down position also known as the Reset position will reset clear any faults currently detected by the system Atomizer On Off Switch This is a two position toggle switch When in LOCAL mode it enables or disables an at tached atomizer i e run or stop When the controller is in REMOTE mode this switch is ignored LED S Power LED The Green Power LED is located directly above the ON OFF rocker switch It is on whenever controller 24 VDC power is On HV Fault LED The red HV Fault LED is lit when the system detects a fault condition 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 im mediately be lit as the system detects the fault High Voltage LED The green High Voltage LED displays the cur rent state of the High Voltage Output This LED is illuminated whenever High Voltage is being supplied LN 9625 00 Ransburg Atomizer Fault LED The red Atomizer Fault LED is lit when the At omizer subsystem detects a fault condition This condition will be displayed on the Atomiz er status screen Atomizer LED The green Atomizer LED is lit when the Atom izer controller commands the turbine to spin BUTTONS The seven buttons used
8. 2e Single Bell Controller Operation 22 DISPLAYS Figure 10 and 11 As seen previously in Figure 9 there are two 4 X 20 character LCD displays located on the Front Panel All modification of parameters and real time display of feedback readings is done using them HIGH VOLTAGE DISPLAY The HIGH VOLTAGE display contains infor mation directly related to the high voltage con troller The default High Voltage display is shown in Figure 10 below Line 1 of the display shows the current high voltage setpoint KVSet in kilo volts The arrows which enclose the value 000 indicate that it may be changed Line 2 of the display shows the current high voltage reading KVAct and microAmp reading uAAct from the cascade Line 3 of the dis play shows the status of cascade feedback CHecK and communications COMmun ications as both being OK Line 4 of the dis play shows that high voltage HV is Off and controller STatuS Sts is STPD Stopped i e not active Note at the end of line 4 there is a W block character This indicates the ac tive display that is the one the menu control buttons will act on HIGH VOLTAGE KVSet 000 KVAct 000 uAAct 0000 Com OK Sts STPDm Chk OK HV Figure 10 High Voltage Run Menu Screen ATOMIZER DISPLAY The ATOMIZER display contains information directly related to the atomizer controller when one is included Ransburg The default Atomizer display is shown in Fig
9. Booth Air Booth Air Misc Interlock Trigger Misc Interlock Trigger Remote Stop Remote Stop 21 gt gt S RM gt gt gt 6 RIN ea ee ee MicroPak 2e Single Bell Controller Installation 16 NOTE gt The following sections which describe Bell Connections and Operations do not ap ply to AutoGun controllers i e A13613 02 MICROPAK 2e BELL CONNECTIONS PNEUMATICS Air Supply The air needed to control a Ransburg Atomiz er unit is provided through the A R N connect or shown in Figures 2 and 3 This is a stand ard push to connect air fitting which accepts 5 16 8 mm OD pneumatic tubing Exhaust Out This fitting is used to discharge any waste air from the speed control regulator and brake valve It is a standard push to connect air fit ting which accepts 5 16 8 mm OD pneumat ic tubing The location of the Exhaust Out connector is shown in Figures 2 and 3 Turbine Pilot This output is generated by the E to P speed control Due to the large quantity of air re quired to drive an atomizer unit this output must be used as an air pilot signal to a 1 1 vol ume booster provided by the user One suita ble volume booster is Ransburg part number A11111 00 The TURBINE PILOT connection is a standard push to connect air fitting which accepts 5 32 4 mm OD pneumatic tubing The location of the Turbine Pilot connector is shown in Figures 2 and 3 Brake Pilot T
10. MicroPak 2e Single Bell Controller Operation 23 MicroPak 2e Single Bell Controller Operation 24 controller to boot up and pause waiting for the user to select either Run Configuration or Diagnostics on the ATOMIZER display Use the Up and Down Arrow pushbuttons to move the selection arrows to enclose Configuration and then pressing the SET pushbutton to enter Configuration Mode In put focus then shifts to the HIGH VOLTAGE display where the user can use the Up and Down arrow and the SET pushbuttons to modify the IP address enable the EtherNet IP interface and save the new configuration Refer to the MicroPak 2e HV amp Atomizer Controller manual Ransburg number LN 9624 00 for further details OPERATING PROCEDURES See Figure 1 and 9 for Operating Controls Typical Local Mode 1 Ensure the AC power safety ground low voltage cable and interlock connections are made Ensure the pneumatic connec tions for supply air turbine pilot bearing air feedback and brake air if used are made Also ensure that the fiber optic cable which provides bell speed feedback is installed Refer to the Installation section of this manual for descriptions of the above con nections 2 Enable the main turbine air supply Failure to do this will cause the Atomizer controller to detect a Bearing Air Fault which will prevent all operation 3 Set the Local Remote switch to LOCAL 4 Set the Atomizer On Of
11. Typical Remote Mode 1 Ensure the AC power safety ground low voltage cable interlock and Ethernet con nections are made Ensure the pneumatic connections for supply air turbine pilot bearing air feedback and brake pilot if used are made Also ensure that the fiber optic cable which provides bell speed feed back is installed Refer to the Installation section of this manual for descriptions of the above connections Enable the main turbine air supply Failure to do this will cause the Atomizer controller to detect a Bearing Air Fault which will prevent operation Set the Local Remote switch to REMOTE Set the Atomizer On Off switch to OFF Turn the AC Power ON OFF switch see Figure 1 to the ON position Turn the MicroPak 2e ON OFF switch to the ON position The HIGH VOLTAGE and ATOMIZER displays will become ac tive along with the green MicroPak 2e Power Indicator located above the switch Ensure the remote controller e g PLC is able to establish EtherNet IP communi cations with the MicroPak 2e Single Bell controller The state of communications can easily be verified on the High Voltage Display Fault Screen When a connection is active the status line will display HVC EIP AT When no connection is active the status line will display HVC eip AT Notice that the case of eip is used to dis tinguish whether or not a connection exists Since a description of using EtherNet IP is beyond the
12. be inter locked to prevent both from being used simultaneously This interlock is provid ed by the MicroPak 2e Atomizer Con troller See current MicroPak 2e HV amp Atomizer Controller service manual It should not be possible for the coating material to be sprayed unless the turbine is spinning It is the user s responsibility to implement this interlock High voltage must be interlocked with the solvent valve pilot signal to prevent solvent flow while high voltage is energized direct charge only It is the user s responsibil ity to implement this interlock Any other interlocks required by local na tional code or international code LN 9625 00 MicroPak 2e Single Bell Controller Installation gt When the turbine air is turned off the turbine will continue to operate or coast down for about two minutes Provisions should be made to assure that the operator waits at least three minutes after shutting off the turbine air and before shutting off the main air supply gt The bell cup must be removed when making flow checks If the paint is turned on when the bell cup is mounted and the turbine shaft is not rotating paint will enter the shaft and possibly damage the air bear ing Material flow checks flow rate verifica tion must be made with the bell cup off and the turbine not rotating This is a special maintenance condition and not for normal operation Normally pneumatic interlocks will not allow th
13. played Once a password has been success fully entered it will remain active for a period of time that depends on the password type It LN 9625 00 Ransburg then times out and must be re entered to make further changes During the active time the block character indicating the active screen will alternate with the letters U S or C corresponding to entry of the User System or Config password The activated time period for these password types decreases as the privilege level increases U 4 S 3 and C 2 minutes When a numeric value is being changed a value change menu similar to the one shown in Figure 12 will be displayed In this menu the Left and Right Buttons allow the user to select from the two methods available to change a value HIGH VOLTAGE Value 0000 0000 to 9999 Range to 999 Inc DecDigit Quit Figure 12 Value Change Screen If the Inc Dec method is selected the user is shown the screen seen in Figure 13 In this mode the Up and Down buttons above and below the SET Button can be used to incre mentally change the value The value will in crease with the up button and decrease with the down button until it reaches the maximum or minimum allowed value ATOMIZER Value 000 Range 000 to 100 Inc Dec Mode Figure 13 Inc Dec Change Mode Screen LN 9625 00 If the Digit method is selected the user is shown the screen seen in Figure 14 This shows the current value to be modif
14. to control the viewing and entry of information on the two 4 X 20 character displays are HV AT Button The High Voltage Atomizer Button just below the right display is used to toggle the active display between the Atomizer and High Voltage displays Note that the active display always has block character in the lower right corner MicroPak 2e HIGH VOLTAGE HV FAULT LOCAL REMOTE ATOMIZER FAULT C Screen Button The Screen Button just below the right dis play is used to change toggle to the next Menu screen in the currently selected display 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 move the selection indicator vertically to a value to be selected by the Set Button When in a value entry menu the Up and Down buttons are used to increase or de crease the value being entered 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 Left and Right Buttons The buttons to the right and left of the Set But ton the Left and Right Buttons are used to move the selection horizontally Ransburg ATOMIZER SCREEN ATOMIZER ON Figure 9 Operator Interface LN 9625 00 MicroPak 2e Single Bell Controller Operation 21 MicroPak
15. LN 9625 00 Ransburg August 2014 MicroPak 2e Single Bell Controller MODEL A13613 XX 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 Ransburg NOTE This is the first release of this manual LN 9625 00 Ransburg MicroPak 2e Single Bell Controller Contents CONTENTS PAGE SAFETY 1 7 SAFETY PRECAUTIONS uuu RCP nee E een 1 HAZARDS SAFEGUARDS cssssessosssossssossesssseesssesssisessssesstsesstsesstsssstscssteseaseceasecesseeeaseees 2 6 INTRODUCTION 8 11 GENERAL DESCRIPTION ecc EUH A MEDI LIU LIE 8 SAFE TY FEATURE Ssd sued ou Lad A c 8 tte Bate E I LE E LUE LE 8 SPECIFICATIONS os des am M AMA LEA AL ML LE 9 INSTALLATION 10 17 MICROPAK 2E INPUT POWER 10 ized 10 LOW VOLTAGE GABI ES Lu LLL cto uate 10 ETHERNET 10 INTERLOCKS AND OUTPUTS 11 CONTROLLER CABINET REAR VIEWS 12 13 CONNECTOR P2 ASSEMBLY 14 DESCRIPTION OF TABLE 1 INTERLOCK AND OUTPUT TERMINALS 15 MICROPAK 2E BELL CONNEGCTIDNS 1 16 EN em MN 17 MICROPAK 2E GROUNDING THEOR
16. OBLIGATION UN DER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATER IALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CON SEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR IN COME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PUR CHASER 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 LN 9625 00 Ransburg Ransburg MicroPak 2e Single Bell Controller Warranty Policies LN 9625 00 35 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 Form No LN 9625 00 2014 Ransburg All rights reserved Litho in U S A Models and specifications subject to change without notice 03 14
17. Y sss sssssssssssssssessseesssssssesssssssssseessecesseceaseeesseeeeseeeen 18 OPERATION 20 25 PERATING CONTROL S ect 20 21 MENU OPERATIONS cc ted EL 22 23 ETHERNET IP NETWORK SETUP 23 24 OPERATING PROCEDURES 24 25 MAINTENANCE 26 31 TROUBLESHOOTING 26 TROUBLESHOOTING HIGH VOLTAGE CABLE CONTINUITY TEST 26 TROUBLESHOOTING SPEED CONTROL tenerte 27 TROUBLESHOOTING GUIDE ccssssssssssssssssssssscssssssssecsssessssecssscsssecsssscssseesstecessecesneeesees 28 29 TABLE 2 OHMMETER MEASUREMENTS 30 PARTS 32 33 SINGLE BELL CONTROLLER PARTS DIAGRAM PARTS LIST 32 WARRANTY POLICIES 34 LIMITED WARRANTY 34 LN 9625 00 MicroPak 2e Single Bell Controller Contents Ransburg LN 9625 00 Ransburg SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety literature for your Ransburg products This manual contains information that is important for you to know and understand This infor mation relates to USER SAFETY and PRE VENTING EQUIPMENT PROBLEMS To help you recognize this information we use the fol lowing symbols Please pay particular attention to these sections A WARNING states information to alert you to a s
18. ak 2e Single Bell Controller On or Off NOTE gt This switch is located on the rear of the controller Remaining Controls Figure 9 MicroPak 2e ON OFF Switch The rocker switch at the left edge of the Front Panel is for power On Off selection The switch controls the application of 24V DC to the MicroPak 2e HV Controller Local Remote Switch This is a two position toggle switch used to determine if the Local Front Panel controls are active or if the Remote EtherNet IP con trols are active If the switch is up Local Mode the Front Panel controls can change parameters enable or disable the high volt age and clear faults The Remote EtherNet IP connection can look at parameters and val ues but cannot change them or enable disable the high voltage output If the 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 Note that if the switch is set to Re mote when power is applied the unit will auto matically switch to RUN mode after 3 sec onds Ransburg HV On Off Switch This is a return to center momentary toggle switch It is only active when the Local Remote mode switch is set to Local It is used to enable or disable the High Voltage output and also to clear system faults When the System Checks and Current Status are OK flipping the switch to the up position HV On
19. d be NIOSH approved MicroPak 2e Single Bell Controller Safety AREA Tells where hazards may occur Spray Area HAZARD Tells what the hazard is 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 system components The chemical re action caused by these solvents reacting with aluminum can be come violent and lead to an equipment explosion Ransburg SAFEGUARDS Tells how to avoid the hazard Aluminum is widely used in other spray application equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equip ment 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 9625 00 Ransburg MicroPak 2e Single Bell Controller Safety NOTES LN 9625 00 7 MicroPak 2e Single Bell Controller Introduction INTRODUCTION GENERAL DESCRIPTION The Ransburg MicroPak 2e Single Bell Controller A13613 XX is a free standing unit which provides voltage to a remotely located cascade and closed loop speed control for Ransburg atomizer units The Ran
20. e and atomizer controllers tightly integrated the operational status of each unit can be communicated to the other unit This provides added benefits such as forcing a brake assisted stop of the Atomizer when an interlock opens DISPLAYS The front panel contains two LCD displays each containing four lines of 20 characters These allow real time monitoring of cascade voltage and current as well as bell speed and bearing air pressure All readings are true values derived from feedback signals originating in the cascade and atomizer units In addition to providing a continuous display of operating parameters the front panel display also provides a means to display and change user adjustable operating parameters such as Overcurrent Over voltage Di Dt and Dv Dt The Ransburg MicroPak 2e Single Bell Controller A13613 XX is available as follows pana Derim A13613 00 Bell Control HP404 RP404 A13613 01 A13613 02 Bell Control RP1000 AutoGun HP404 HP505 LN 9625 00 Ransburg SPECIFICATIONS At Sea Level Conditions Environmental Physical Operating Temperature 0 C to 55 C Storage and Shipping Temperature 40 C to 85 C Humidity 95 Non Condensing Cabinet Size 13 0 Wide 18 0 Deep 7 0 Height Weight 23 Ibs Electrical DC Power Required Controller 24V DC 0 5 Amps 24V DC 6 0 Amps fully loaded output RansPak 1000 RP1000 Cascade Cascade 24V DC 2 0 Am
21. e as shown in Table 2 If any of the readings are significantly outside the values listed in Table 2 the low voltage cable and or cascade should be checked for the cause of the prob lem Otherwise the cause of the problem is most likely the controller 5 Reconnect connector J7 and close and re lock the cover of the controller cabinet LN 9625 00 Ransburg MicroPak 2e Single Bell Controller Maintenance CABINET TROUBLESHOOTING KEY LOCK SPEED CONTROL L l 1 During troubleshooting it is important to recog nize the automatic shutdown modes and con a sider the circumstances which might cause o them Some common system problems which cause the MicroPak 2e Atomizer Controller to go to automatic shutdown are E 1 Bearing air supply pressure momentarily drops below the required threshold when the system air supply cannot maintain pressure during periods of high air con sumption 2 Paint or solvent contamination in the rota tor causing blockage of the fiber optic speed feedback signal 3 Damage to the fiber optic cable causing a reduced intensity of the speed feedback signal at the MicroPak 2e Atomizer Con Eo Se troller i e reduced intensity from the fiber o tf optic cable
22. e 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 Chemical Hazard Certain materials may be harm ful if inhaled or if there is con tact with the skin SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazardous locations the power supply control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous 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 manufac turer 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 an
23. e other end into a properly grounded 110 230 Volt AC 50 60 Hz outlet See Figure 1 below for location on the cabinet AC Power ON OFF Switch AC Power Connector Safety Ground Figure 1 Partial Rear View of Cabinet SAFETY GROUND Install the ground wire assembly supplied with the MicroPak 2e Single Bell Controller Cabinet from the ground stud on the rear of the cabinet to a true earth ground For maximum noise immunity cut the ground wire assembly to the shortest length required and reinstall the end lug before making connections Ransburg gt The ground wire assembly MUST be con nected from the MicroPak 2e Single Bell Con troller Cabinet ground stud to a true earth ground LOW VOLTAGE CABLES Standard Low Voltage Cable For HP404 RP404 HP505 A11353 XX Plug the connector of the low voltage cable assembly into the LOW VOLTAGE receptacle on the rear of the controller see Figure 2 When making the connection line the red dot on the connector with the red mark on the receptacle and push in until it clicks To remove simply pull back on the knurled portion of the connector Standard Low Voltage Cable For RP1000 A13745 XX Plug the connector of the low voltage cable assembly into the LOW VOLTAGE receptacle on the rear of the controller see Figure 3 When making the connection align the inner portion of the connector before screwing the connector firm
24. e paint to trigger on when the turbine air is off gt high voltage and or coating mate rial must never be turned on unless the bell cup is mounted on the motor shaft and the turbine is rotating gt Pneumatic input to the turbine air inlet must be controlled to prevent the turbine from exceeding the maximum rated speed of the configured atomizer See Specifications in the Introduction sec tion This behavior is provided by the MicroPak 2e Atomizer Controller See current MicroPak 2e HV amp Atomizer Con troller service manual gt High voltage must never be turned on while cleaning solvent is being sprayed ei ther through the applicator supply or the cup wash line High voltage and both sol vent triggers must be interlocked direct charge only gt Never spray solvent with high voltage on MicroPak 2e Single Bell Controller Installation 18 MICROPAK GROUNDING THEORY Electrical noise refers to stray electrical sig nals in the atmosphere at various signal strengths and frequencies that can affect the operation of electrical equipment One of the best ways to prevent this is to shield the equipment and cables with a continuous ground envelope such that any incident noise will be conducted to earth ground before it can affect the circuit conductors For conductors inside the MicroPak 2e Single Bell Controller the grounded enclosure pro vides this envelope For the low voltage cable
25. en atomiz Overloads er and parts Excessively Overload setpoint set too sensitive Increase the Max uA Limit through either the EtherNet IP interface or the front panel operator interface Defective atomizer or cable Check all wiring connections for integrity Repair wiring as needed Defective MicroPak 2e Control Unit If none of the suggestions above resolves the issue replace the A13338 MicroPak 2e Control Unit Component not Wiring to from component loose or Repair loose or broken wire working but kV Broken Output OK Defective component Replace component LN 9625 00 29 MicroPak 2e Single Bell Controller Maintenance Ransburg TROUBLESHOOTING GUIDE Table 2 Ohm meter Measurements in Ohms from MicroPak 2e Connector J7 through the Low Voltage Cable to the HP404 Cascade ES mene e m qm em remm em em EUM j XX open ckt open ckt open ckt open ckt 19K 21K 400K 600K open ckt XX 0 3 0 3 0 3 open ckt open ckt open ckt 0 3 open ckt open ckt open ckt 6 blue XX 0 3 M 9 400K 600K open ckt 10 gray 16 bare XX Meter reading may vary in the megohms range due to capacitance across pins XX Figure 17 View of CON1 CON2 and Fuse 30 LN 9625 00 Ransburg MicroPak 2e Single Bell Controller Maintenance LN 9625 00 31 MicroPak 2e Single Bell Controller Parts Ran
26. f switch to OFF 10 11 12 13 14 15 Ransburg Turn the AC Power ON OFF switch see Figure 1 to the ON position Turn the MicroPak 2e ON OFF switch to the ON position The HIGH VOLTAGE and ATOMIZER displays will become ac tive along with the green MicroPak 2e Power Indicator located above the switch Press the Set Button to place the controller into RUN mode The two display screens will now look like figures 10 and 11 Ensure the over current setpoint Max uA Limit is set above the maximum expected current or an overload fault will occur The over current setpoint can be adjusted using the front panel operator interface described in the previous section titled MENU OPERATIONS Move the Atomizer On Off Switch to the ON position The green Atomizer On Indi cator should be lit Adjust the bell speed setpoint TurbnSpdSet to the desired value Momentarily push the High Voltage On Off Switch to the ON position The green High Voltage On Indicator should turn on Using the front panel operator interface adjust the KV Setpoint KVSet to the de sired value To turn high voltage off momentarily move the High Voltage On Off Switch to the OFF position To turn the atomizer off move the Atomiz er On Off Switch to the OFF position When finished spraying turn the AC Pow er ON OFF Switch see Figure 1 to the OFF position to prolong the life of the inter nal fan LN 9625 00 Ransburg
27. 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 flammable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A distance of 1 inch for every 10KV of output voltage is re quired 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 unauthorized 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 disabled Never use equipment intended for use in water borne installations to spray solvent based materi als 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 2 LN 9625 00 Ransburg AREA Tells where hazards may occur Spray Area General Use and Maintenance LN 9625 00 MicroPak 2e Single Bell Controller Safety HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate opera tion and maintenance proce dures will cause a fire hazard Protecti
28. his output is generated by an on off air valve It can be used directly to drive the atomizer s brake air input The connection is a standard push to connect air fitting which accepts 5 32 4 mm OD pneumatic tubing The loca tion of the Brake Pilot connector is shown in Figures 2 and 3 Ransburg Bearing Air This input is used to monitor the pressure of the bearing air being supplied to the atomizer It connects directly to a 0 100 psi P to E sen sor which the MP2e controller continuously monitors The low pressure fault setting de faults to 80 psi for all Ransburg atomizers The connection is a standard push to connect air fitting which accepts 5 32 4mm OD pneu matic tubing The location of the Bearing Air connector is shown in Figures 2 and 3 BELL SPEED FEEDBACK Fiber Optic This signal is provided via a fiber optic cable from the atomizer to the MP2e controller It is used to monitor and control the rotational speed of the bell unit The fiber optic cable enters the MP2e Single Bell Controller cabinet through a compression fitting labeled FIBER OPTIC on the rear of the cabinet See Fig ures 2 and 3 Enough cable should be placed inside the cabinet to have a gentle loop before entering the fiber optic cable retaining block See Figure 7 Before inserting the cable into the retaining block verify the nylon clamp screw is not protruding into the cable
29. ied the low and high limits for the selected parameter and the digit mode options to change the cur rent value The option allows the user to negate the current value displayed The Null option causes the current value to be cleared allowing the user to begin entry of a new val ue The number option 0 lt enables the Up and Down Buttons to select the next digit to be added to the value when the user press es the Set Button The Save option saves any changes made in this screen and exits And the Quit option cancels any changed made in the screen and exits ATOMIZER Value 0000 Range 000 to 100 Nullo0 Save Quit Digit Mode Figure 14 Digit Mode Change Screen ETHERNETIIP NETWORK SETUP The EtherNet IP interface of the MicroPak 2e Single Bell Controller is delivered with a de fault IP address of 192 168 0 3 If this address is not compatible with the users private control network the controller address must be cus tomized to reside on the users network This is accomplished by first setting the IP address of the controller to an available address in the users network then enabling the EtherNet IP interface and finally saving the new configura tion before cycling power To make these changes the user must access the MicroPak 2e Configuration menus This is done by setting the Remote Local switch to Local and turning on AC power to the Micro Pak 2e Single Bell Controller This causes the
30. ituation that might cause serious inju ry if instructions are not followed A CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury A NOTE is information relevant to the pro cedure 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 drawings and appropriate Ransburg equipment manuals to reconcile such differences Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more effi cient 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 LN 9625 00 MicroPak 2e Single Bell Controller Safety gt 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
31. ly into place To remove reverse the operation ETHERNET CABLES CAT 5 CABLE WITH RJ45 If the user plans to utilize the MicroPak 2e Single Bell Controllers EtherNet IP interface for remote control they must provide a network connection for the Controller This is done by plugging a standard CAT 5 cable into the RJ45 socket labeled ETHERNET I P on the rear of the controller see Figure 2 LN 9625 00 Ransburg INTERLOCKS AND OUTPUTS Interlock and output connections are made to connector P2 on the rear of the controller P2 consists of three 8 position terminal blocks A B and C see Figure 5 To wire these terminal blocks perform the following see Figure 5 1 Loosen the 2 screws of P2 s connector housing and remove P2 from the control ler 2 Loosen the 4 screws holding the terminal block assembly to the inside of the con nector housing and remove the terminal block assembly from the housing 3 Feed the Output Interlock cable s through the cable grommet attached to the connector housing and pull out the other side It may be necessary to remove the cable grommet to fit the cable s through If so slide the grommet connections onto the cable s in the order shown in Figure 5 before pulling the cable through the con nector housing NOTE gt For maximum noise immunity all wiring should be run in cables having a foil shield with an overall braided shield The foil shield provides 100 shielding
32. ly make things worse see Figure 6 A special cable grommet fitting has been pro vided for I O connector P2 of the controller see Figure 3 When the nut is tightened the spring in the grommet compresses and makes 360 contact with the braid of the cable This electrically connects the cable braid to ground via the connector housing and controller back panel NN NI N Nes Pigtails poor shielding Uzgen 560 Termination to ground good shielding Figure 8 Cable Connection Examples LN 9625 00 Ransburg NOTE REGARDING DIP SWITCHES Unlike previous MicroPak controllers the new MicroPak 2e does not use dipswitches to con trol hardware configuration Configuring the system is now done entirely through configura tion menus which are accessible through the front panel display and interface However there is one set of factory only dipswitches on each of the MicroPak 2e boards These switches are used to set the internal board address and to configure a watchdog timer which aids in detecting soft ware malfunctions Therefore they are not to be changed by the user as they are reserved for factory use only NOTES LN 9625 00 MicroPak 2e Single Bell Controller Installation 19 MicroPak 2e Single Bell Controller Operation 20 OPERATION OPERATING CONTROLS AC Power ON OFF Switch Figure 1 Turns AC Power to the MicroP
33. oes 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 applica tor 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 required 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 flushing cleaning or working on spray system equipment Unless specifically approved for use in hazardous locations all electrical equipment must be located outside Class or II Division 1 or 2 hazardous areas in accordance with NFPA 33 LN 9625 00 Ransburg AREA Tells where hazards may occur Electrical Equipment 5 Toxic Substances LN 9625 00 MicroPak 2e Single Bell Controller Safety HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized in 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 fir
34. oltage setpoint using either the EtherNet IP interface or the front panel operator interface Local remote switch in wrong position Put local remote switch in proper position Defective atomizer or low voltage cable Perform a Cable Continuity Test If proper readings are not obtained check cable or atomizer for cause see current Atomizer Service Manual Loose or broken wire in power supply Continued On Next Page 28 Check all wiring connections for integrity Repair wiring as needed LN 9625 00 Ransburg MicroPak 2e Single Bell Controller Maintenance TROUBLESHOOTING GUIDE General Problem Possible Cause No kV Output at Local remote switch in wrong position Put local remote switch in proper position Spray Gun and HV Improper interlock connection Ensure enabled interlock connections have ON Indicator the and terminals connected together green LED is not through a jumper or voltage free contact as Lit detailed in the Installation section of this manual High Voltage On input not activated Verify the controller operates as expected in local mode Then review the program ming of the EtherNet IP Originator i e PLC Robot or PC to locate a cause Defective MicroPak 2e Control Unit If none of the suggestions above resolves the issue replace the A13338 MicroPak 2e Control Unit Power Supply Parts are too close to the atomizer Ensure sufficient distance betwe
35. on against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent Power Supply or Con troller shutdown indicates a problem in the system requiring correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment 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 distance of 1 inch for every 10KV of output voltage is re quired at all times Unless specifically approved for use in hazardous locations all electrical equipment must be located outside Class or 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 corresponding section of the equipment manual Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the current over load sensitivity is not properly set Frequent power supply shutdown indicates a problem 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 ob jects are within the safe sparking dis
36. on must be re stored and the controller fault cleared before the high voltage output can be turned back on NOTE gt The fourth interlock input Remote Stop cannot be disabled through software If the user does not wish to use the Remote Stop input a jumper must be installed to close the Remote Stop circuit It can be placed be tween A4 and A8 of P2 or between J5 13 and J5 14 of the MicroPak 2e HV Controller See current MicroPak 2e HV amp Atomizer Controller service manual Output Terminals Each output pair is connected to an iso lated relay contact which is rated 30 VDC 2 amps maximum External Power Enable This signal indicates that the MicroPak 2e has power and is operating LN 9625 00 MicroPak 2e Single Bell Controller Installation System Alarm Out This relay output signal indicates the MicroPak 2e Single Bell Controller is shutdown due to a fault condition This signal reflects the fault status of both the HV controller and the Atom izer controller such that if either unit is faulted the alarm will be activated Interlock Out This relay output signal indicates the MicroPak 2e Single Bell Controller has determined all enabled interlocks are closed cascade power is present and cascade feedback signals are operating as expected When this output is active and the System Alarm output is inac tive the controller is ready to be activated TABLE 1 P2 Terminal Z Door Door
37. ps fully loaded output HP404 RP404 HP505 12760 and A12761 Cascades AC Electrical Requirements 90 264 VAC 1 5 Amps 47 63 Hertz DC power supplied from 24VDC built in regu lated power supply which has overcurrent 40 and overvoltage 20 protection LN 9625 00 MicroPak 2e Single Bell Controller Introduction Controls Network EtherNet IP Discrete Signals Inputs Misc IO Interlock Trigger Door Interlock Booth Air Interlock Outputs Interlock Out External Power Enable System Alarm Controller Operating Range High Voltage 0 100kV settable in 1kV increments Current HP404 RP404 0 125 microamps A12760 A12761 0 150 microamps HP505 0 240 microamps RP1000 0 1000 microamps Pneumatic Pneumatic Inputs Supply Air 0 100 psi 0 6 9 bar filtered to 40 microns 80 psi 5 5 bar minimum required for specified per formance Feedback of actual rota tor bearing air pressure Bearing Air Pneumatic Outputs Turbine Pilot Air Zero to input pressure variable Brake Air Zero to input pressure On or Off These I Os are not present on A13613 02 Optical Optical Input Bell Speed Feedback of actual bell speed up to 99K RPM This input is not present on A13613 02 MicroPak 2e Single Bell Controller Installation 10 INSTALLATION MICROPAK 2E INPUT POWER Plug the detachable AC line cord into the receptacle on the rear of the MicroPak 2e Single Bell Controller Cabinet Plug th
38. sburg MicroPak 2e High Voltage Controller Parts List MicroPak 2e HV amp Atomizer Controller A13338 XX XX XX For replacement use the user should order the same model XXXXXX that was listed on the original invoice nid p mi MicroPak 2e High Voltage amp Atomizer Controller gt a E diit Brake Control Solenoid aa L pus D e MicroPak 2 24 DC P High Voltage Power Supply D Controller PC Board Atomizer Control Turbine Speed T E to P oH a g Y Bearing Air T Transducer LI WL tS ooo ae Figure 18 Inside View A13613 00 and A13613 01 32 LN 9625 00 Ransburg MicroPak 2e Single Bell Controller Parts am r
39. sburg MicroPak 2e High Voltage Controller uses a combination of proven high voltage generation technology including microprocessor based control with diagnostic and communication functions variable voltage output is used to supply a cascade that amplifies the voltage to a high value It also uses both current and voltage feedback information to maintain the desired set point The processor circuitry provides the maximum applicator transfer efficiency while maintaining the maximum safety The Ransburg MicroPak 2e Atomizer Controller builds upon previous Ransburg control technology and tightly integrates the MicroPak 2e Atomizer Controller with the MicroPak 2e High Voltage Controller SAFETY FEATURES When used with the appropriate applicators and cascades the Ransburg MicroPak 2e Single Bell Controller provides the ultimate in operational safety The high voltage protections include Overvoltage Overcurrent Di Dt Dv Dt and Interlock Open In addition the microprocessor circuits allow the use of output load curve control which limits the high voltage output to safe levels when the controls are set responsibly and safe distances are observed and followed The protections provided by the atomizer control include Overspeed Underspeed Loss of Bearing Air Loss of Feedback and Interlock Open These safety checks assure that the Atomizer is run within its safe operational limits And finally Ransburg since the high voltag
40. scope of this manual the user is directed to the MicroPak 2e HV amp Atom izer Controller manual for further details Ransburg number LN 9624 00 LN 9625 00 10 11 12 13 From the remote controller set an appro priate value for Max uA Limit based on the expected load and the cascade being used From the remote controller set the desired bell speed and enable the atomizer From the remote controller set the desired KV setpoint and enable high voltage Disable the high voltage from the remote controller Disable the Atomizer from the remote con troller When finished spraying turn the AC Pow er ON OFF Switch see Figure 1 to the OFF position to prolong the life of the in ternal fan MicroPak 2e Single Bell Controller Operation 25 MicroPak 2e Single Bell Controller Maintenance 26 MAINTENANCE FAULT AND WARNING INFORMATION The MicroPak 2e controller has been designed to detect a number of high voltage and speed related faults These faults cause brief fault descriptions 14 characters or less to be dis played on either the High Voltage or Atomizer display screen If the reader requires further clarification regarding a particular fault they should refer to the MicroPak 2e HV amp Atomiz er Controller manual Ransburg number LN 9624 00 for further details TROUBLESHOOTING HIGH VOLTAGE Following are some areas to investigate when high voltage faults occur e Dir
41. 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 servic ing this equipment The hazards shown on the following pages may occur during the normal use of this equipment Please read the haz ard chart beginning on page 2 MicroPak 2e Single Bell Controller Safety Ransburg AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Spray Area Fire Hazard Improper or inadequate opera Fire extinguishing equipment must be present in tion and maintenance proce the spray area and tested periodically dures will cause a fire hazard Spray areas must be kept clean to prevent the ac Protection against inadvertent cumulation of combustible residues arcing that is capable of causing fire or explosion is lost if any Smoking must never be allowed in the spray area safety interlocks are disabled The high voltage supplied to the atomizer must be during operation Frequent Pow turned off prior to cleaning flushing or mainte er Supply or Controller shut nance down indicates a problem in the system requiring correction 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
42. tance Ensure that the control panel is interlocked with the ventilation system and conveyor in accordance with NFPA 33 EN 50176 Have fire extinguishing equipment readily available 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 equipment Comply with appropriate local state and national codes governing ventilation fire protection opera tion maintenance and housekeeping Reference OSHA NFPA 33 EN Norms and your insurance company requirements MicroPak 2e Single Bell Controller Safety AREA Tells where hazards may occur Spray Area High Voltage Equipment 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 coat ing materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion Ransburg 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 convey ors 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 insu lating sh
43. that run from the controller to the atomizer or spray gun a shielded cable has been used The shield consists of an overall foiled shield in combination with an overall braided shield This provides the most effective shielding as the foil covers the holes in the braid and the braid allows for practical 360 termination at both ends of the cable The AC input cord is not shielded but instead is directed to an AC line filter as soon as it en ters the cabinet This filter filters out any noise that comes in on the AC line For maximum noise immunity the AC line is connected to the filter as soon as possible after it enters the cabinet Additional noise protection can be provided by running the AC input line to the controller in grounded conduit which is the recommended method and is required by some codes For maximum noise protection any user sup plied input output I O wiring should be made using shielded cable or conduit which is con nected to earth ground in a continuous 360 fashion at both ends The best way to do this is to use a conductive connector fitting at each end of the cable conduit that makes contact to the shield conduit in a full 360 circle around the shield conduit and makes contact to the grounded enclosure in the same fashion Con necting the drain wire of a shield to a ground point on or in the cabinet usually referred to Ransburg as pigtailing is not an effective method of shielding and can actual
44. ty atomizer interior or exterior e Conductive solvent residue on atomizer assembly e Moisture inside or outside of atomizer body causing continuity or partial continui ty back to ground e Moisture inside or outside of air lines back to ground high humidity e Loose connections or defective low volt age cable e Loose or defective ground connections e Dump lines not clean or dry leading back to ground e Target not grounded and causing arcing to ground Ransburg CABLE CONTINUITY TEST When problems arise the Cable Continuity Test can be performed to help determine whether the problem is with the MicroPak 2e HV controller or the cable and or cascade as sembly A WARNING gt Because this test involves access to the interior of the MicroPak 2e Single Bell controller cabinet where hazardous voltag es may be present it should only be per formed by qualified electronics technicians To conduct the test perform the following 1 Ensure that the controller is disconnected from the AC source 2 Using the supplied cabinet key unlock and open top panel of the controller cabinet see Figure 15 3 Disconnect connector J7 see Figure 16 from the rear of the problem MicroPak 2e HV controller Leave the other end of the Low Voltage Cable connected to the atomizer be ing used 4 Using an ohmmeter measure the re sistance values between the wires of MicroPak connector J7 The readings should b
45. while the braid provides a means of making proper 360 shield terminations at the cable ends 4 Strip the jacket off the cable s 3 from the end and remove the braid 1 5 from the end see Figure 6 5 Strip the individual cable wires install ap propriate wire ferrules and connect to the terminal blocks according to Table 1 LN 9625 00 NOTE gt If multiple Output Interlock cables are used connect the exposed 1 5 cable braids together using copper tape 6 Rotate the connector housing to achieve desired routing of the cable bundle right or left then reinstall the terminal block assembly into the connector housing 7 Tighten the connector grommet ensuring the grommet spring makes 360 contact with the exposed cable braid copper tape for maximum noise immunity For maximum noise immunity the shields of the output and interlock cables should also be connected to earth ground at the end opposite to the MicroPak 2e Single Bell Controller connections If it is necessary or desired to run the interlock and Output cable s through conduit an adapter can be readily purchased that converts the PG21 male threads of the P2 connector housing to 3 4 NPT male threads This adapter is available through McMaster Carr as their Part Number 7842K7 MicroPak 2e Single Bell Controller Installation 11 MicroPak 2e Single Bell Controller Installation Ransburg
Download Pdf Manuals
Related Search