SERVICE MANUAL
EN
MicroPak 2e Controls
Model: A13338
IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting
on page 5, and all instructions in this manual. Keep this Service Manual for future reference.
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EN
MANUAL CHANGES
NOTE: This manual has been changed from revision LN-9624-00.2 to revision
LN-9624-00-R3. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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EN
CONTENTS
CONTENTS
SAFETY: 5-9
Safety Precautions ............................................................................................................................................... 5
Hazards / Safegaurds .......................................................................................................................................... 6
HV CONTROLLER
HV CONTROLLER - INTRODUCTION: 10-15
General Description .............................................................................................................................................11
Safety Features ...................................................................................................................................................11
Displays ...............................................................................................................................................................11
Specications ..................................................................................................................................................... 12
Password Protections ......................................................................................................................................... 13
Operator Interface .............................................................................................................................................. 14
Switches ............................................................................................................................................................. 14
LED’s .................................................................................................................................................................. 14
Buttons ............................................................................................................................................................... 15
HV CONTROLLER - INSTALLATION: 16-22
General Information ........................................................................................................................................... 16
Location of Product ............................................................................................................................................ 16
Mounting ............................................................................................................................................................ 16
Input Power Connections ................................................................................................................................... 16
Ethernet Connections ........................................................................................................................................ 17
Output to Cascade ............................................................................................................................................. 18
Electrical Noise .................................................................................................................................................. 18
Interlock Connections ........................................................................................................................................ 22
HV CONTROLLER - OPERATION: 23-42
Start-Up ............................................................................................................................................................... 23
Software Mismatch Fault .................................................................................................................................... 23
Start-Up Menu .................................................................................................................................................... 24
Menus and Operation ........................................................................................................................................ 25
Run Menus ......................................................................................................................................................... 26
Conguration Menus .......................................................................................................................................... 27
Conguration Parameters and Settings ............................................................................................................. 31
Diagnostics Menu .............................................................................................................................................. 32
Operating Parameters and Settings ................................................................................................................... 33
Control Conditions ............................................................................................................................................. 36
System Status (STS) ......................................................................................................................................... 36
System Check (CHK) ......................................................................................................................................... 36
System Fault Behavior ....................................................................................................................................... 36
Ethernet/IP Interface .......................................................................................................................................... 37
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CONTENTS
CONTENTS (Cont.)
ATOMIZER CONTROLLER
ATOMIZER CONTROLLER - INTRODUCTION: 43-47
Atomizer Controller General Description ........................................................................................................... 44
Specications ..................................................................................................................................................... 44
Speed Control .................................................................................................................................................... 46
ATOMIZER CONTROLLER - OPERATION: 48-57
Operation ........................................................................................................................................................... 48
Conguration Menus........................................................................................................................................... 48
Cinguration Parameters and Settings ............................................................................................................... 49
Operating Parameters and Settings ................................................................................................................... 49
Automatic Shutdown .......................................................................................................................................... 50
Interfacing Considerations ................................................................................................................................. 51
User Dened I-O’s ............................................................................................................................................. 51
Ethernet/IP Interface .......................................................................................................................................... 51
DISCRETE IO CONTROLLER
DISCRETE IO CONTROLLER - INTRODUCTION: 58-60
Discrete IO Controller General Description ....................................................................................................... 59
Specications...................................................................................................................................................... 59
Conguration Parameters and Settings .............................................................................................................. 60
DISCRETE IO CONTROLLER - OPERATION: 61-62
Operations ......................................................................................................................................................... 61
Discrete I/O Controller Logic Relating to Inputs on Connector J5 ...................................................................... 62
MicroPak 2e CONTROLS
INTEGRATION NOTES: 63-65
Guidelines .......................................................................................................................................................... 63
High Voltage Controller Logic Relating to Inputs On Connector J5 .................................................................... 65
MAINTENANCE: 66-67
Troubleshooting Guide ...................................................................................................................................... 66
PARTS IDENTIFICATION: 68
MicroPak 2e High Voltage Controller - Parts List .............................................................................................. 68
APPENDIX: 69-72
MicroPak 2e Controller Panel Mount Layout ..................................................................................................... 69
MicroPak 2e Controller/MultipFunction IO Layout ............................................................................................. 70
Initialization Screens ......................................................................................................................................... 71
MANUAL CHANGE SUMMARY: 73
Manual Changes ................................................................................................................................................ 73
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SAFETY
SAFETY PRECAUTIONS
SAFETY
Before operating, maintaining or servicing any
electrostatic coating system
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 PROBLEMS.
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 avoid a
situation that might cause minor injury.
, read and understand all of the
WARNING
CAUTION
Ransburg
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the Ransburg
safety literature therein identied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly un-
derstood 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 re codes and ordinances
as well as NFPA-33 AND EN 50176 SAFETY STAN-
DARDS, LATEST EDITION, or applicable country
safety standards, prior to installing, operating, and/or
servicing this equipment.
WARNING
!
NOTE
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard specications 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 efcient 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.
The hazards shown on the following pages may
occur during the normal use of this equipment. Please
read the hazard chart beginning on page 2.
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SAFETY
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
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, ushing or maintenance.
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained
during cleaning operations using ammable 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 required
at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipment modications may cause re 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.
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.
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SAFETY
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate
operation and maintenance
procedures will cause a
re hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
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 required at all times.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible
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 re
or explosion is lost if the current overload sensitivity
is not properly set. Frequent power supply
shutdown indicates a problem in the system which
requires correction.
General Use and
Maintenance
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
Always turn the control panel power off prior to
ushing, 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 accordance with
NFPA-33, EN 50176.
Have re 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, re protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
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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
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re
or explosion.
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
conveyors 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
insulating 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 applicator
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 ooring must be provided in
the spray area.
Always turn off the power supply prior to ushing,
cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Avoid installing an applicator into a uid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
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SAFETY
AREA
Tells where hazards
may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shutdown indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
re or explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, 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 ammable or combustible
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.
Spray Area
Chemical HazardToxic Substances
Certain materials may be
harmful if inhaled, or if there is
contact with the skin.
Explosion Hazard —
Incompatible Materials
Halogenated hydrocarbon
solvents for example:
methylene chloride and
1,1,1,-Trichloroethane are not
chemically compatible with the
aluminum that might be used
in many system components.
The chemical reaction
caused by these solvents
reacting with aluminum can
become violent and lead to an
equipment explosion.
Follow the requirements of the Safety Data Sheet
supplied by coating material manufacturer.
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.
Spray applicators require that aluminum inlet ttings
be replaced with stainless steel.
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
equipment during spraying, ushing, 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.
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HV Controller
HV Controller
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HV Controller - INTRODUCTION
HV Controller - INTRODUCTION
GENERAL DESCRIPTION
The Ransburg MicroPak 2e (A13338-00), in conjunction
with an appropriate cascade is used to provide high
voltage for electrostatic application equipment. The
controller is packaged in a single package measuring 5.1”
tall X 8.5” wide X 6.5” deep (12.9cm tall x 21.6cm wide
x 16.5cm deep). The controller can operate in “Local”
and “Remote” conditions with either “Voltage Mode” or
“Current Mode” of high voltage control.
The Ransburg MicroPak 2e Controller uses a combination
of proven high voltage generation technology including
microprocessor-based control with diagnostic and
communication functions. It uses a variable voltage
output to drive a cascade that amplies 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 in applicator
transfer efciency, while maintaining the maximum safety
The MicroPak 2e also supports the use of Multifunction
I/O Controllers (MIO) to provide additional functions.
Currently two add-on controller versions are supported:
1) an Atomizer Controller and 2) a Discrete IO Interface.
SAFETY FEATURES
When used with the appropriate applicators and
cascades, the Ransburg MicroPak 2e Controller provides
the ultimate in operational safety. The protections include
Overvoltage, Overcurrent and Di/Dt or Dv/Dt which are
detailed in the Operating Parameters and Settings section
of this manual. The micro-processor 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.
DISPLAYS
The front panel displays the high voltage and current
output from the cascade as true readings. They are
derived from feedback signals in the low voltage cable
between the controller and the cascade.
MicroPak 2e Controller
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HV Controller - INTRODUCTION
SPECIFICATIONS (At Sea-Level Conditions)
Environmental/Physical
Operating Temperature: 0°C to +55°C
Storage & Shipping Temp.: -40°C to +85°C
Humidity: 95% Non-Condensing
Physical Size: 5.1” tall X 8.5” wide X 6.5” deep (12.9cm tall x 21.6cm wide x 16.5cm deep)
Environmental Requirements
Power Required: (per controller)
J11 - Controller : 24V DC @ 0.5 Amps
J4 - Cascade: 24V DC @ 6.0 Amps (fully loaded output), RansPak 1000 (RP1000 or LEPS5002) Cascade
Note: 24V DC power supply must be regulated and have over current and over voltage protection.
Electrical
24V DC @ 2.0 Amps (fully loaded output), HP404, RP404, HP505 and CONSOLIDATED Cascades
Controls:
High Voltage Power: 24 Volts, 10Amp, Form C relay contact
Discrete In:
KV Setpoint (0-10V)
Discrete Out: (3, Dry Contacts) Interlock Out, External Power Enable, System Alarm
Controller Operating
Range High Voltage: 0-100kV, settable in 1kV increments
Current:
HP404/RP404 0-125 microamps
CONSOLIDATED 0-150 microamps
HP505 0-240 microamps
RP1000 0-1000 microamps
LEPS5002 0-1000 microamps
Network Interface: Ethernet/IP (Implicit Messaging only)
Note: A unique MAC address is hard coded into each MicroPak 2e & Atomizer Controller. User controls must be congured to
recognize each unique address.
Internal Controller Scan Time:
(0-24 V) Remote Stop, Misc IO Interlock/Trigger, Door Interlock, Booth Air Interlock, (Analog)
1 msec (all data is taken from a rolling average of 16 scans)
HP404 / RP404 Cascades
Output: 100 kV @ 0 μA 125 μA @ 0 kV
In ATEX conguration: 90 μA max current limit
In FM conguration: 90 μA max current limit 90 kV max voltage limit
Cascade Size: HP404 1.50” X 1.56” x 7.0” (38mm x 40mm x 178mm)
RP404 4” X 4” X 12” (102mm x 102mm x 305mm)
RP1000 / LEPS5002 Cascades
Output: 100 kV @ 0 μA 1000 μA @ 0 kV
Cascade Size: RP1000 4” X 4” X 12” (102mm x 102mm x 305mm)
LEPS5002 17”x13”x13” (43cm x 33cm x 33cm)
(Continued on next page)
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HV Controller - INTRODUCTION
SPECIFICATIONS (At Sea-Level Conditions) (Cont.)
HP505 Cascade
Output: 100 kV @ 0 μA 240 μA @ 0 kV
Cascade Size: 1.50” X 1.56” x 7.0” (38mm x 40mm x 178mm)
CONSOLIDATED Cascade
Output: 100 kV @ 0 μA 150 μA @ 0 kV
Cascade Sizes:
A12760-02 (IN LINE): 3” X 3” x 16.97” (7.6cm x 7.6cm x 43.1cm)
A12761-02 (RIGHT ANGLE): 3” X 7.64” x 11.8” (7.6cm x 19.4cm x 30cm)
PASSWORD PROTECTION
MicroPak 2e Controller parameters are password protected
with three levels, Cong, System and User to help prevent
unqualied operators from changing the values. The
password menu is composed of two screens. The rst
screen prompts the user to conrm they wish to enter the
required password, while the second screen accepts the
entry of the password digits. The three levels represent a
hierarchy with Cong at the top, System in the middle and
User at the bottom. This means that while a higher level
password is active, the user will not be required to enter
a lower level password if they change a parameter which
requires it.
ATOMIZER
System Password Menu
Enter Password O
Exit
HIGH VOLTAGE
User Password Menu
Enter Password O
Exit
Figure 2: User Password Screen
HIGH VOLTAGE
Value= O
Range
O to 9999
- Null O Save Quit
Digit Mode
Figure 3: Password Entry Screen
NOTE
Figure 1: System Password Screen
User Password Menu
When the password has been entered, the user will be
returned to the value being changed.
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The MicroPak 2e controller is shipped with the
following default passwords:
It is recommended these be changed at installation
by the customer, to prevent changes being made by
anyone who has access to this manual.
User - 7734 System - 7735
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HV Controller - INTRODUCTION
OPERATOR INTERFACE
The MicroPak 2e Controller shown in gure 4, has a
physically simple operator interface consisting of ve (5)
LED’s (Light Emitting Diodes), four (4) switches, seven (7)
buttons, and two four line twenty character (4 X 20) alpha/
numeric displays.
Figure 4: Operator Interface
SWITCHES
Ethernet/IP parameters. This means that when switching
between Local and Remote modes, operating parameters
will typically change. Parameters which always change
are the ones passed as variables in the Ethernet/
IP Assemblies, e.g. KV Setpoint and Turbine Speed
Setpoint. Parameters which are set indirectly using the
Parameter Write function of the Assemblies, e.g Max
µA Limit, will use the Local Mode settings until they are
changed through the Ethernet/IP interface. Once one
of these parameters is changed using Ethernet/IP, the
MicroPak 2e will toggle between the Local and Remote
values at each mode change. This behavior will continue
until the next power cycle of the controller.
HV On / Off Switch
This is a return-to-center momentary toggle switch. It is
active only when the Local/Remote mode switch is set to
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, ipping the switch to the up
position (HV On) will enable High Voltage Output (see
“Figure 4 - Operator Interface” in this section). Flipping it
to the down position (HV Off) will disable the High Voltage
Output. If there is a system fault, ipping this switch to the
OFF position (also known as the Reset position) will reset
(clear) any faults currently detected by the system.
Power Switch
The rocker switch on the left and the LED directly above
it are for power On/Off selection and display. The green
LED is on when the power is On to the controller.
Local / Remote Switch
This is a two position toggle switch used to determine
if the Local (Front Panel) controls have priority or if the
Remote controls (Ethernet/IP Connection or Discrete
inputs) 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/IP connection may look at parameters and
values, but may not 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.
Beginning with Software Version V1.1.00, when Ethernet/
IP is enabled the MicroPak 2e maintains Local Mode
parameters separate from the
Atomizer On / Off Switch
This is a two position toggle switch. It is used to enable
and disable (i.e. start and stop) a congured atomizer
when in LOCAL mode. When the controller is in REMOTE
mode it is ignored.
LED’S
Power LED
If the Green Power LED is on, then the system power to
the controller is On.
HV Fault LED
The red HV Fault LED is lit when the system detects a
fault condition (see “Figure 4 - Operator Interface” in the
SWITCHES section). When operating in “Local Mode”,
it is cleared by ipping 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.
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High Voltage LED
The green High Voltage LED displays the current state
of the High Voltage Output. This LED is illuminated
whenever High Voltage is being supplied.
Atomizer Fault LED
The red Atomizer Fault LED is lit when the Atomizer
subsystem detects a fault condition. This condition will
be displayed on the Atomizer status screen.
HV Controller - INTRODUCTION
So when the High Voltage is the active display, it will look
like “Figure 3 - 2nd Password Screen” in the PASSWORD
PROTECTION section.
Screen Button
The Screen Button (just below the right display) 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 rst screen.
Atomizer LED
The green Atomizer LED is lit when the Atomizer controller
commands the turbine to spin.
BUTTONS
The seven buttons used 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 a (block character) in the
lower right corner.
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 decrease 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 Button (the
Left and Right Buttons) are used to move the selection
horizontally.
Figure 5: Buttons
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HV Controller - INSTALLATION
HV Controller - INSTALLATION
GENERAL INFORMATION
WARNING
!
The MicroPak 2e Controller MUST be located
outside of the hazardous area.
The User MUST read and be familiar with the
“Safety” section of this manual.
The User MUST set SAFE values for Max µA
Limit, Di/Dt Mode and Di/Dt Sensitivity based on the
operating environment. The controller ships with these
values set to zero, which forces the user to complete
an initialization sequence before the unit will function.
See the appendix for details of the sequence.
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 requirements of
operating and servicing safely are followed. The user
should be aware of and adhere to ALL local building
and re codes and ordinances as well as NFPA-33,
OSHA, and all related country safety codes prior to
installing, operating, and/or servicing this equipment.
LOCATION OF PRODUCT
Install the controller assembly in a control cabinet that is
protected from the possibility of any contact with water,
vapor or high humidity. Ambient temperature should not
exceed 131°F (55°C). The area should be clean, dry and
well ventilated.
CAUTION
!
DO NOT locate the Controller near or adjacent
to heat producing equipment such as ovens, high
wattage lamps, etc.
NOTE
As each installation is unique, this information is
intended to provide general installation information for
the MicroPak 2e Controller. Consult your authorized
Ransburg distributor or Ransburg Technical Service
for specic directions pertaining to the installation of
your equipment.
Figure 6: A13338 Control Module
MOUNTING
Using eight (8) #4-40 or M3 screws (not included), secure
the front panel of the MicroPak 2e & Atomizer Controller,
using the supplied mounting holes, to enclosure. See
Figure 46 in the appendix for a mounting diagram.
INPUT POWER CONNECTIONS
Input power must be supplied from one or two regulated DC
power supplies. Two connectors, J4 and J11 are provided
so that controller operating power may be separated from
cascade operating power. Cascade operating
delivered through J4 and controller operating power is
delivered through J11. This conguration gives the user
power is
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the ability to provide an ESTOP by inserting a suitable
switch or contactor in the J4 power leads. When separate
control of the cascade power is not required, power to J4
and J11 can be run from one DC power supply.
protected against excessive current and provide Over
Voltage protection.
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CAUTION
!
Power supplies connected to J4 and J11 must be
HV Controller - INSTALLATION
NOTE
The Ransburg MicroPak 2e Controller has a built
in resettable fuse in the controller power lead, so if the
controller logic draws a current in excess of 1.5 amps
it will open. Reset is achieved by turning controller
power OFF for 5 minutes then back ON.
ETHERNET CONNECTORS
Figure 7: Input Power Connections
TABLE 1
Signal Name
+VPWR Pin 1 + 24 VDC
+VPWR Pin 2 + 24 VDC
GND Pin 3 DC return
GND Pin 4 DC return
CHGND Pin 5 Earth Ground
J4 Connection
Power Supply
TABLE 2
Signal Name
+VPWR Pin 1 + 24 VDC
GND Pin 2 DC return
J11 Connection
Power Supply
Figure 8: Ethernet Connector
Use the appropriate 10/100BASE-T Ethernet wiring
(Straight EIA/TIA 568A) for your installation with an
RJ-45 plug to connect to the MicroPak 2e Controller.
Connection can be made using either J7 or J10 as shown
in Figure 8 above.
NOTE
The Ethernet connectors J7 and J10 use an
integrated Ethernet Switch to connect to the controller.
This allows the MicroPak 2e Controller to be networked
with the LAN of a Robot or PLC and still provide a
connection for a local networked display.
Tables 1 & 2 show the connections for Cascade and
Controller power.
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HV Controller - INSTALLATION
OUTPUT TO CASCADE
Make connections from either J6 or J7 of the controller,
depending on the cascade in use. Refer to Table 3 for J6
connections and Table 4 for J7 connections.
Figure 9: Outputs to Cascade
TABLE 3
J6
HVGND Pin 1 0 VDC for R+ and E+ Power
VCT/R+ Pin 2 Analog DC Cascade Drive Signal
+15V/E+ Pin 3 Nominal 15 VDC for
Cascade Electronics
SAFETY /GND
Voltage Feedback
KVFB/ V-FB Pin 5 Analog Cascade Voltage
Feedback Signal
SHIELD/GND Pin 6 0 VDC for Analog Cascade
Current Feedback
Cascades A12760-02 / A12761-02
Pin 4 0 VDC for Analog Cascade
TABLE 4
J7
HVGND Pin 1 0 VDC for VCT Power
µAFB Pin 2 Analog Cascade Current
Feedback Signal
VCT Pin 3 Analog DC Cascade Drive Signal
VCT Pin 4 Analog DC Cascade Drive Signal
HP_DR B Pin 5 High Power Cascade Drive Signal
(HP404, HP505)
HP_DR A Pin 6 High Power Cascade Drive Signal
(HP404, HP505)
N.C.
N.C.
MULTI-GND
Voltage Feedback
KVFB Pin 10 Analog Cascade Voltage
Feedback Signal
N.C.
HVGND Pin 12 0 VDC for VCT Power
RP DR B
(RP1000, LEPS5002)
RP DR A
(RP1000, LEPS5002)
HVGND Pin 15 0 VDC for VCT Power
HVGND Pin 16 0 VDC for VCT Power
Cascades: HP404, RP404, HP505,
RP1000, LEPS5002
Pin 7 (Termination point; No Connection)
Pin 8 (Termination point; No Connection)
Pin 9 0 VDC for Analog Cascade
Pin 11 (Termination point; No Connection)
Pin 13 Logic Level Cascade Drive Signal
Pin 14 Logic Level Cascade Drive Signal
ELECTRICAL NOISE
µAFB/ I-FB Pin 7 Analog Cascade Current
Feedback Signal
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MicroPak 2e Grounding
1. The Power Supply must be referenced to true earth
ground at only one point, through the controller’s
chassis ground connection. (Refer to Figures 10, 11,
and 12 for Grounding Connections.)
2. Shields from the low voltage cable must be connected
to the chassis ground where the controller’s ground
connection is made, then by a 3/4” braid to the building
steel or ground grid if available.
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HV Controller - INSTALLATION
3. The low voltage cable has a large amount of high
frequency noise on the shields and grounds from
being in proximity to the high voltage generator. Taking
these grounds
grid through good high frequency conductors (braid)
keeps this high frequency noise from interfering with
the low voltage control circuitry.
4. The feedback signals for kV and μA are developed with
respect to the cascade ground signal (MULTIGND). If
the cascade ground were routed only to earth ground via
the above mentioned shields, the feedback conditioning
circuitry would have to depend on the panel ground or
power supply common to get a ground reference for
the feedback signals. This means the low level return
current for these signals would have to ow to earth
ground and back to the controller via factory ground
directly to earth ground or a ground
or power supply common. This adds large amounts of
noise to these low voltage signals. To combat these
effects, the controller PCB provides a connection for
MULTIGND which is separately routed to the CHGND
pin of J4. This is the single ground point for MULTIGND,
HVGND and logic GND to minimize noise on the
cascade feedback signals.
5. A great deal of testing under high voltage corona
conditions has conrmed that this cascade ground
should be connected directly at a single point to the
signal ground plane of the MicroPak 2e power supply
controller. This single point method maintains a “clean”
feedback signal while limiting the amount of high
frequency noise that is dumped onto the signal ground
and therefore other grounds in the overall system, such
as a PLC or robot.
Figure 10: MicroPak 2e Controller W/HP404, RP-404 & HP505 Cascade
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HV Controller - INSTALLATION
Figure 11: MicroPak 2e Controller W/LEPS5002 or 74793 Cascade (RansPak 1000)
Figure 12: MicroPak 2e Controller W/CONSOLIDATED Cascade
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HV Controller - INSTALLATION
Figure 13: Proper Power Supply and Grounding Connections
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HV Controller - INSTALLATION
INTERLOCK CONNECTIONS
Figure 14: Interlock Connector
J5 is supplied to give the end-user access to interlock
connections for integrating the controller into the user’s
system. Three output signals are provided thru dry
contacts (rated 30 VDC @ 2 amps maximum). These
three signals indicate: 1) the state of controller operating
power, 2) when a controller fault exists, and 3) the state
of the controller interlock inputs. Four input signals are
provided which should only be connected to dry contact
outputs from the user’s system. The four interlock
signals are designated as: 1) a door interlock, 2) a
booth air interlock, which can be congured to serve as
an HV Reset input, 3) a miscellaneous interlock, which
can be congured to serve as a HV Trigger input, and
4) a remote stop input which removes power from the
cascade drive circuits when sensed by the Display and
Communications Processor. A fth input which accepts
a 0-10 VDC analog control signal is provided to allow
control of the high voltage setpoint.
NOTE
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
placed between J5-13 and J5-14 to close the Remote
Stop circuit.
Table 5 shows the pin assignments for the interlock
signals.
TABLE 5 - J5 CONNECTOR SIGNALS
Outputs
External Power Enable Pin 1, 2
System Alarm Out Pin 3, 4
Interlock Out Pin 5, 6
Interlock Inputs
Door Interlock (+) Pin 7 *
Door Interlock (-) Pin 8
Booth Air Interlock/ HV Reset (+) Pin 9 *
Booth Air Interlock/ HV Reset (-) Pin 10
Misc.Interlock/Trigger(+) Pin 11 *
Misc. Interlock/Trigger(-) Pin 12
Remote Stop (+) Pin 13 *
Remote Stop (-) Pin 14
Analog Inputs
KV Setpoint (+) Pin 15
KV Setpoint (Gnd) Pin 16
* Refer to the following note.
NOTE
The positive interlock input pins are directly
connected to the internal +24VDC of the MP2e
controller. It is recommended that these pins not
be run outside of the MP2e enclosure without the
addition of series limiting resistors (3.3K, 1/4w). This
will prevent overloading the MP2e internal current
limit if a positive input is accidentally shorted to
ground. Alternatively, the user can provide a separate
+24VDC supply external to the MP2e to power the (-)
interlock inputs.
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HV Controller - OPERATION
HV Controller - OPERATION
START-UP
Before its’ rst use, the following application specic
features of the MicroPak 2e controller must be congured
by the user. Refer to the appendix for 1st time initialization
menus.
• The Over Current Limit (Max µA Limit) must be set to a
value that is appropriate for the paint process being used.
• The di/dt sensitivity must be set to a value appropriate
for the paint process being used.
• If the Ethernet/IP interface will be used, it must
be enabled.
• If Ethernet/IP is being used, an IP address from the
local network must be assigned.
NOTE
The following MicroPak 2e features are congured
at the factory based on the system: 1) Cascade type,
2) If an Atomizer Controller is included, 3) Atomizer
type included, 4) HV Charging Mode, 5) Control
Mode, 6) If a Discrete IO Controller is included, 7)
Cabinet type and 8) If Unilink support is included.
SOFTWARE MISMATCH FAULT
The Micropak 2e family of products incorporate multiple
smart boards. These include:
• A13338-XXXXXXXXXX - Micropak 2e HV & Atomizer
Controller. For replacement use, the user should order
the same model number (-XXXXXXXXXX) listed on
the original invoice. This module includes two separate
boards:
A13239 - Display and Communications Processor.
A13240 - High Voltage Control Processor.
• A13245-X1 - Micropak 2e Multi-Function Board, “X”
indicates quantity of A13248-00 Boards included.
• A13245-X8 - Micropak 2e Multi-Function Board,
Discrete I/O conguration. “X” indicates quantity of
A13248-00 boards included. (Note: currently there are
no Single Bell Controller congurations which include
this board).
Each of these boards has a processor and has software
to run the board. For the MP2e system to be assured
of operating correctly, the software version of each
board must be at the same revision. When the system
starts up, the boards communicate to each other. If the
software versions to do not match, a fault is set. This fault
is displayed as “SwVer Mismatch”. This fault cannot be
cleared or bypassed.
In addition, if MIO Controllers are present, the user must
congure the type, i.e. voltage (0-10V) or current (4-
20mA), of each signal being supplied to the analog inputs
of the MIO controllers.
NOTE
For correct operation of the analog inputs, jumpers
JMP9 to JMP15 on the MIO Controller must also be
set to the matching V or I mode. See the sections on
Atomizer or Discrete IO operation for further details.
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Under normal circumstances, this fault will never
been seen as all the boards are congured with the same
version of software when shipped from the factory. This
fault situation could occur if one of the boards is replaced
with a new board that has a different version of software
than the other boards in the system. It is important when
purchasing replacement boards to ensure all boards in
your MicroPak 2e have the same version of software.
How To Tell What Version of Software is
Loaded on a Micropak 2e System
When the Micropak 2e system is powered on, it will display the
SW Version of the Display and Communications Processor
board as noted in the image below. The picture is depicting
an example of a system with software version 1.0.02.
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