Carlisle Ransburg MicroPak 2e Service Manual

Page 1

SERVICE MANUAL

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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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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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

Specications ..................................................................................................................................................... 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

Conguration Menus .......................................................................................................................................... 27

Conguration 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

Specications ..................................................................................................................................................... 44

Speed Control .................................................................................................................................................... 46

ATOMIZER CONTROLLER - OPERATION: 48-57

Operation ........................................................................................................................................................... 48

Conguration Menus........................................................................................................................................... 48

Cinguration Parameters and Settings ............................................................................................................... 49

Operating Parameters and Settings ................................................................................................................... 49

Automatic Shutdown .......................................................................................................................................... 50

Interfacing Considerations ................................................................................................................................. 51

User Dened I-O’s ............................................................................................................................................. 51

Ethernet/IP Interface .......................................................................................................................................... 51

DISCRETE IO CONTROLLER

DISCRETE IO CONTROLLER - INTRODUCTION: 58-60

Discrete IO Controller General Description ....................................................................................................... 59

Specications...................................................................................................................................................... 59

Conguration 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 identied.

 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 specications 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 ef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.

 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 modications 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.

Unless specically 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 specically 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 specically 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

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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 amplies 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 efciency, 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 congured 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 conguration: 90 μA max current limit In FM conguration: 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)

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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, Cong, System and User to help prevent unqualied operators from changing the values. The password menu is composed of two screens. The rst screen prompts the user to conrm 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 Cong 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 congured 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

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 specic 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 conguration gives the user

power is

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Page 17

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

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

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.

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 conrmed 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 congured to serve as

an HV Reset input, 3) a miscellaneous interlock, which

can be congured 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

START-UP

Before its’ rst use, the following application specic features of the MicroPak 2e controller must be congured 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 congured

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 conguration. “X” indicates quantity of

A13248-00 boards included. (Note: currently there are

no Single Bell Controller congurations 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

congure 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 congured 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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HV Controller - OPERATION

NOTE

 If the front panel Local/Remote Switch is in the

“Remote” position, this screen will only be displayed for two seconds before the system automatically goes to Run Mode and changes the screen.

HIGH VOLTAGE

Ransburg SN 1434-O121 ©2O14 Software Ver: 1.1.O2

Figure 14a: Start-Up Menu Screen (Left)

Under normal circumstances, the other boards will match the Display and Communications Processor Board and there will be no fault reported. If the version of software on one of the other boards does not match the display board, a fault will be displayed. This indicates that software needs to be updated on one or more of the other

boards. The following picture is an example showing the

fault message.

HIGH VOLTAGE

DCP SW Ver: 1.1.15 HVC SW Ver: 1.1.15 MIO SW Ver: 1.1.15

Figure 14c: Software Versions of each Board

In the event of observing a SwVer Fault, call the Service Assistance number listed on the back cover for help getting the software loaded correctly.

START-UP MENU

The two menus that display on an initialized unit at power up are shown in Figures 15 and 16. The HIGH VOLTAGE screen displays the Serial Number, Copyright Date and Software Version of the unit.

HIGH VOLTAGE

Ransburg SN 133O-OO21 ©2O15 Software Ver: 1.1.O3

HIGH VOLTAGE

Fault: SwVer Mismatch Warn: None

HVC EIP

Figure 14b: Start-Up Menu Screen (Left)

The ATOMIZER screen allows the user to select from

one of three options: RUN mode, Conguration mode, or

Diagnostics mode. In addition, the bottom line displays the status of the system connections.

Figure 15: Start-Up Menu Screen (Left)

ATOMIZER

Run

NOTE

 Starting with V1.1.07, an additional HIGH VOLTAGE screen has been added that will display the software versions of each board present in the system.

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Configuration Diagnostics HVC eip

Figure 16: Start-Up Menu Screen (Right)

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HV Controller - OPERATION

The status is displayed via upper or lower case letters which indicate the associated board is communicating (upper case) or not communicating (lower case). The letters “HVC” represent the High Voltage Control board and “EIP” represents the Ethernet/IP host connection, When included in the system, “AT” represents an Atomizer Controller and “IO” represents a Discrete IO interface.

NOTE

 When the REMOTE/LOCAL switch is set to

REMOTE at power-up, the controller automatically

switches to RUN mode after approximately 5 seconds.

When the REMOTE/LOCAL switch is set to LOCAL at power-up, the controller remains in the start-up screens until the user selects a mode. In software V1.1.02 and higher, if the user changes the REMOTE/ LOCAL switch to REMOTE, the system immediately switches to RUN mode.

MENUS AND OPERATION

When a numeric value is being changed, a value change menu, similar to the one shown in Figure 17, 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= O Range O to 9999 Inc/Dec Digit Quit

Figure 17: Value Change Screen

If the Inc/Dec method is selected, the user is shown the screen seen in Figure 18. In this mode, the Up and Down buttons (above and below the SET Button) can be used to incrementally change the value. The value will increase with the up button and decrease with the down button until

it reaches the maximum or minimum allowed value.

On all of the menus, if a parameter 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 “ ”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 “ ”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 Cong 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 incorrect, the password screen will again be displayed. Once a password has been successfully entered, it will remain active for a period of time that depends on the password type. It 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 Cong

password. The activated time period for these password types decreases as the privilege level increases (U = 4, S = 3 and C = 2 minutes).

ATOMIZER

Value= O Range O to 1OO

Inc/Dec Mode

Figure 18: Inc/Dec Change Mode Screen

If the Digit method is selected, the user is shown the screen seen in Figure 19. This shows the current value to be

modied, the low and high limits for the selected parameter

and the digit mode options to change the current value. The “-” displayed. The “Null” option causes the current value to be cleared allowing the user to begin entry of a new value. The ‘number’ option (“ 0 ”) enables the Up and Down Buttons to select to the value when the user presses the Set Button. The “Save” option saves any changes made in this screen and

exits. And the “Quit” option cancels any changes made in the screen and exits.

option allows the user to negate the current value

the next digit to be added

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HV Controller - OPERATION

ATOMIZER

Value = O Range O to 1OO

- Null O Save Quit Digit Mode

Figure 19: Digit Mode Change Screen

RUN MENUS

High Voltage Run Menu

This menu displays the KVSet value in Voltage Mode. Also displayed by this menu are the control mode and cascade type, the current actual KV value, the current

μA value, the current hardware check value, the High

Voltage status, and the current controller status. KVSet is the only changeable value on this menu. In Current

Control Mode the menu displays μASet as the changeable

value instead of KVSet.

HIGH VOLTAGE

DiDt Mode Dis O Max UA Limit O

Save_Changes

Figure 21: Voltage Mode Screen

The menu in Fig 22 is only displayed in Current Control Mode. It displays whether or not the DvDt feature is enabled and the sensitivity of this feature. If the voltage changes by more than this value in a 100 millisecond interval, a fault occurs. The last two items displayed are KV Low Limit and KV High Limit. These are used to set a lower and upper bound for the output voltage. If the bounds

are exceeded a fault will occur. This menu also includes a Save Changes option so that modied values can be

saved across power cycles.

High Voltage Fault Menu

HIGH VOLTAGE

KVSet O V4O4 KVAct O uAAct O Chk:OK Com: OK HV: Off Sts: STP

Figure 20: Run Menu Screen

Voltage Mode Menu

The menu in Fig 21 is displayed when Voltage Control Mode

is congured. It displays whether or not the DiDt feature is enabled and the sensitivity of this feature which is specied

in units of µAmps per 100 milliseconds. If enabled, a fault occurs when the output current changes faster than the

sensitivity value. The next element displayed on this screen

is a user settable limit on cascade output current. This limit

has a range of 0 to the maximum current for the currently congured cascade. It also provides an option to Save

Changes to the parameter values. Selecting this option will

cause the current values to be stored in ash memory, so

that they will be available after a power cycle. If this option is not used, all parameter changes are discarded at the

next power cycle when the saved parameters are restored. The rst three values can be selected and changed.

HIGH VOLTAGE

DvDt Mode Dis O KV Low Limit 5 KV High Limit 1OO Save_Changes

Figure 22: Current Mode Screen

This menu displays the latest fault and any current warning.

HIGH VOLTAGE

Fault: HV Power Off Warn: None

HVC EIP

Figure 23: Fault Menu Screen

Current Mode Menu

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HV Controller - OPERATION

Software Versions Menu

Starting with V1.1.07, an additional HIGH VOLTAGE menu has been added that displays the software versions

of each board present in the system. It is the next screen

displayed if the user presses the “screen” button. (This is the ONLY place this screen can be accessed).

HIGH VOLTAGE

DCP SW Ver: 1.1.15 HVC SW Ver: 1.1.15 MIO SW Ver: 1.1.15

Figure 24: Software Versions of each Board

Atomizer Run and Fault Menu

When an atomizer is congured, this menu displays the congured atomizer type on line 1, followed by the Turbine

Speed Set Point value and the current actual Turbine Speed value. In addition, the current Fault status of the Atomizer Controller and the current Bearing Air pressure

are displayed. If no atomizer is congured, this screen

shows the high voltage controller’s fault and connection

status information similar to gure 23.

ATOMIZER

ATf:RansNet CommLost HVflt:HV Power Off HVWrn:None HV AT

Figure 26: Gun Fault Menu Screen

CONFIGURATION MENUS

High Voltage Controller Conguration Menus

The following seven menus are displayed on the HIGH VOLTAGE screen (left panel).

Cascade Menu

This menu allows the factory to congure the type of cascade

connected to the controller.

HIGH VOLTAGE

Cascade HP4O4 MaxI 125 uA V 1OO KV Freq 67.5 kHz Array Member? Dis

ATOMIZER

RMA3OO-5OO kRPM:Set O Act O No Faults Bearing Air O psi

Figure 25: Run Menu Screen (Right)

Automatic Gun Fault Menu

This menu displays the latest faults for both the atomizer and high voltage controllers. In addition, it displays any current high voltage warning and the current connection status.

Figure 27: Cascade Menu Screen

Beginning in MP2e software version V1.1.10, a new

conguration parameter, “Array Member”, has been added.

Some applications place multiple applicators close together. In some cases, the applicators may be close enough that one MP2e may detect voltage feedback

which actually originates from an adjacent applicator as

a fault condition. Turning all the near-by applicators on and off at the same time and at similar levels avoids most interaction issues. However, if near-by applicators are at very different output levels, the MP2e at the lower output level may detect a “Minimum Output” condition which should not be considered to be a fault condition.

When “Array Member” is set to “Enabled” (“Ena”), the MP2e will not declare a fault for a “Minimum Output” condition. “Disabled” is the default setting for “Array Member”. Reference Service Instruction SI-17-04 to access and

change the “Array Member” conguration parameter.

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Interlock Menu

The three Interlock inputs which can be enabled or disabled

are congured in this screen. As seen in Figure 28, the rst input is dedicated to use as an interlock and is labeled

Door. The second interlock is labeled MiscIO. This input can serve as either an Interlock input or as a Trigger input.

It is congured to the trigger function by selecting Interlock

and pressing the Set button. It can similarly be returned to the interlock function by selecting Trigger and pressing the Set button. The third interlock is labeled Booth. This input can serve as either an Interlock input or as an HV

Reset input. It is congured to the HV Reset function by

selecting Interlock and pressing the Set button. It can similarly be returned to the interlock function by selecting HV Reset and pressing the Set button.

HV Controller - OPERATION

NOTE

 The system DEFAULTS to have all interlocks ENABLED. So if the interlocks are not wired closed, the controller will remain in a faulted condition.

 The fourth interlock input, Remote Stop, cannot

be disabled. 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.

 When a Discrete IO Controller is congured or Ethernet/IP is enabled, the MiscIO and Booth inputs are forced to operate as Interlock inputs, i.e. the Trigger and HV Reset functions are not available.

HIGH VOLTAGE

Door Ena MiscIO Ena Trigger Booth Ena Reset Remote Option 4

Figure 28: Interlock Menu Screen

Beginning in MP2e software version V1.1.07, a new

conguration parameter, “Remote Option”, has been

added. To determine which number (1-5) is the correct option for you, refer to the table shown below.

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HV Controller - OPERATION

The conguration options that have been set for your

system at the factory will dictate the MP2e Remote Options that are available for you to choose from. In the Remote

Options Table above, the “Conguration Options” columns

with the purple header illuminate some of the questions that need to be answered before Remote Options are made available to you. These questions include:

1. Do you have a Single Bell Controller (SBC) or a Control Pak (CP)?

2. Do you have an Atomizer MIO Board congured

as Enabled ?

3. Do you have a Discrete IO Board (DIO) congured

as Enabled ?

Cell entries in the columns with the purple header show the acceptable answers to these questions for the Remote Option of interest.

Once you have identied which Remote Options are available to you based on your factory conguration,

you may choose from among them according to the instructions found in steps 1-5 above. The Remote Option Parameter that you choose will be master to the other system settings shown in the Remote Options Filtering Table in the “System Options” columns with the green header. This ensures that related system parameters are set to compatible and consistent setting combinations. Cell entries in the columns with green headers show the settings that system options will be set to when corresponding Remote Options are chosen. In the instances where there are two options shown in one

cell - for example: “Dis or Int” - you may use the methods

described in the MP2e Service Manual (LN-9625-00) to

choose how you would like these I/O signals congured.

If you enter a numeric value for the Remote Option Parameter that is not supported by your Factory Set

Conguration as shown in the columns above with the

purple header, your entry will not be accepted.

applied. This is normally set as direct for all cascades

except the RP1000 when used with an indirect charge ring,

The V-I limiting function is always enabled. It controls a software function which limits the voltage and current load curves to levels very similar to those used in the original MicroPak controller. The Cabinet Selection option is used to enable or disable use of the full complement of Atomizer

IO signals. This is a factory congured setting.

HIGH VOLTAGE

Control Mode Voltag Charge Type Direct uPak VIlimiting Ena SingleBell Cabinet

Figure 29: MicroPak V-I Limiting Screen

IP Address Menu

This menu provides the user with four options. It allows setting the Ethernet/IP Address for the controller, provides control over whether Ethernet/IP communications are enabled or not, provides control over whether DHCP is used to acquire an IP address and allows the user to save any

Conguration changes that have been made. Note that the Save or Quit options will place the unit into run mode. This is the only way to exit the Conguration Menus other

than cycling controller power.

HIGH VOLTAGE

IP 192 168:OOO:OO3 Ethernet IP Dis DHCP Dis Hardware Quit Save_Changes

Figure 30: IP Address Menu Screen

MicroPak V-I Limiting Menu

This menu displays four settings that the factory congures

to match the product(s) purchased with the controller. These settings cannot be changed by the user.

The control mode indicates if the controller is set to control Voltage or Current. The Charge Type corresponds to how the high voltage charge is transferred to the material being

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When DHCP is disabled and a new IP Address has been entered and saved, power must be cycled on the unit before the new IP Address will be used.

When DHCP is enabled, the IP address, network mask and Gateway IP address will be requested from a local DHCP server. The user is responsible for providing a server to respond to these requests. If no DHCP server

is available the MicroPak 2e will wait indenitely for a

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HV Controller - OPERATION

response. In addition, when DHCP is enabled, an Ethernet/

IP controller can congure the MicroPak 2e to save the current conguration and use it at the next power cycle

instead of requesting an address via DHCP. Similarly,

the remote Ethernet/IP controller can also recongure the MicroPak 2e to request its IP conguration from a DHCP server at the next power cycle.

NOTE

 Beginning with V1.1.07, the user cannot change the “Ethernet IP” setting using this screen. Instead set the “Remote Option” setting described previously to be equal to ‘2’.

Feedback Fault Menu

This menu gives the user control over the use of the Feedback Fault. It allows this fault to be disabled and provides the means to modify the delay before a fault is generated after detection.

It also allows the user to modify the Communications Timeout value. The Communications Time Out value has a range of 500—5000 milliseconds with a default value of 1000. This parameter is used by the Display & Communications Control processor to determine how long to wait before signaling a fault when Ethernet/IP messages are not being received.

HIGH VOLTAGE

Feedback Fault Ena FB Fault Delay 5OO

Date Menu

This menu allows the user to set the date and time for the controller’s real-time clock (RTC). The RTC information is

then used by the controller to apply a timestamp to log le entries. This is done to aid in later analysis. As gure 32 shows, there are six settable values on the date and time

screen. Month, Day, Year, Hours, Minutes and Seconds.

HIGH VOLTAGE

Date 11 26-2O12 Time 1O:O8:3O

Quit Save_Changes

Figure 32: Date Screen

Change Passwords Menu

This menu requires the user to enter the current password before they are allowed to set a new password. When the new password is entered, it will immediately be used for all values being changed.

NOTE

 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

ComTimeOut 1OOO msec Quit Save_Changes

Figure 31: Feedback Menu Screen

Change Passwords:

HIGH VOLTAGE

User Password ????

NOTE

 The Feedback Fault settings should only be

changed when adjacent indirect charge applicators

cause Feedback Faults. In all other cases the defaults shown above should be used.

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Sys Password ???? Cfg Password ????

Figure 33: Change Passwords Screen

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HV Controller - OPERATION

Broadcast Control Menu

This menu allows the user to control the ltering of excessive

broadcast packets. The principal use of this feature is as

an aid in conrming the presence of excessive broadcast trafc. Setting Suppression to “Ena” will enable the

removal of broadcast packets if the count of packets per

measurement interval exceeds the percentage specied by

Storm Level. In normal use this feature should be disabled. In addition, the MAC address assigned to the Display and Communications Processor board (DCP) is displayed at the top of the screen.

HIGH VOLTAGE

MACOO:5O:C2:FA:DO:37 Broadcast Cntrl Menu Suppression Dis Storm Level 1 %

Figure 34: Broadcast Control Screen

CONFIGURATION PARAMETERS AND SETTINGS

Cascade Type

The MicroPak 2e Controller currently supports the following types of cascades.

• HP404

• HP505

• RP1000

• CONSOLIDATED

• RP404

• LEPS5002

• ATEX-HP404

• FM-HP404

• NONE (No Cascade attached. Permits MP2e to be

used as a Speed Controller.)

Date

This parameter consists of the Month, Day and Year which is maintained by the embedded real-time clock hardware.

The controller uses it to apply a time stamp to log le entries.

Time

This parameter consists of the Hour, Minute and Second which is maintained by the embedded real-time clock hardware. The controller uses it to apply a time stamp to

log le entries.

IP Address

This is the IP (Internet Protocol) address assigned to the controller. It is set by default to 192.168.0.3 but can be changed to allow the use of multiple MicroPak 2e Controllers and to accommodate the local network settings.

Ethernet/IP

This parameter controls whether the MicroPak 2e Controller

will allow a host system to connect and remotely congure

and command the controller via an Ethernet/IP connection.

Atomizer MIO

This parameter enables or disables the use of an MIO

Atomizer Controller. This setting is factory congured.

Discrete MIO

This parameter enables or disables the use of an MIO

Discrete IO interface. This setting is factory congured.

MiscIO

This parameter controls whether the MicroPak 2e Controller will use the state of the MiscIO hardware input in its control calculations.

MiscIO Interlock or Trigger

This parameter controls whether the MiscIO hardware input will be used as an interlock signal or as a trigger to enable HV.

NOTE

 MiscIO must be enabled and Ethernet/IP disabled

NOTE

 The cascade type is congured by the factory based on the equipment ordered by the customer.

In addition to conguring the controller for one of

the cascade types shown above, the factory will

also congure JMP2, JMP3 and JMP4 to match the

cascade type.

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before the controller will allow the Trigger function to be selected.

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HV Controller - OPERATION

Booth (Air)

This parameter controls whether the MicroPak 2e Controller will use the state of the Booth (Air) hardware input in its control calculations.

Booth Interlock or Reset

This parameter controls whether the Booth (Air) hardware input will be used as an interlock signal or as an HV Reset signal.

NOTE

 Booth must be enabled and Ethernet/IP disabled

before the controller will allow the Reset function to be selected.

Door

This parameter controls whether the MicroPak 2e Controller will use the state of the Door hardware input in its control calculations.

Unilink Mode

This parameter indicates the status of Unilink operation. When enabled the MP2e uses the Unilink Select input to determine if a Bell or Gun is mounted. This is a factory

congured setting.

Unilink Select

When Unilink Mode is enabled, this parameter allows the user to manually select either Bell or Gun to match the atomizer which is currently attached. This selection can also be made through the Ethernet/IP interface.

Password

This parameter is the value entered for the user password.

System Password

This parameter is the value entered for the system password.

Note the INDIRECT type can only be selected when an

RP1000 no cascade is congured. All other cascades will force Charge Type to be congured as DIRECT.

The following table shows the passwords required to

change the Conguration parameters.

TABLE 6

Parameter

Booth (Air) System Booth Interlock or Reset System Broadcast Suppress System

Cabinet Type Cong Cascade Type Cong Charge Type Cong

ComTimeOut System

Cong Password Cong

Date User DHCP System Door System Ethernet/IP Enable User FB Fault Delay System Feedback Fault System IP Address System MiscIO System MiscIO Interlock or Trigger System

Mode Cong

Storm Level System System Password System Time User

uPak VI Limiting Cong

User Password User

Remote Cong System

Array Member System

Password Level

Mode

The operating mode can be set to either Voltage or Current mode. The mode selection determines which independent

setpoint (i.e. kVSet or μASet) is the basis for control.

Charge Type

The charge type can be set to either DIRECT or INDIRECT type. This setting must match the type of charging provided by the applicator being used as it controls the calculations of the KV actual value.

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DIAGNOSTICS MENU

Selecting Diagnostics from the Startup Menu shown in Figure 16 causes menu screens shown in Figures 35 and 36 to be displayed. Note that once the Diagnostic menu

is entered, a power OFF cycle must be done to exit the

Diagnostic menu.

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HIGH VOLTAGE

Keys=udlrcsaLoraE

Figure 35: Diagnostic Key Screen

HV Controller - OPERATION

The second screen, Figure 36 shows A2D (Analog to Digital) readings for three of the system voltages along with the current system status. The items displayed are as follows:

ATOMIZER

PWR= 282O LGIC= 2685

1.8V= 2320

Sts: STP

Figure 36: Diagnostic Voltage Screen

PWR — this reading shows the main cascade power

(+24V DC) connected to J4. It’s nominal value is 2820.

LGIC — this reading shows the Logic power (+24V DC)

connected to J11. It’s nominal value is 2685.

Front Panel Switches

The rst screen, Figure 35, only uses the rst line of the

display. This line begins with “Keys=“ and is followed by single characters showing the current state of the front panel push buttons and switches. This allows a user to verify that all the front panel switches, shown above, work

as expected.

Typically a lower case letter indicates the corresponding key is inactive while an upper case letter indicates activity. Working from left to right across the list of letters we have:

“u U” - the Up arrow button.

“d D” - the Down arrow button.

“l L” - the Left arrow button.

“r R” - the Right arrow button.

“c C” - the SET button located in the Center of the arrows.

“s S” - the Screen button.

“a H” - the HV/AT button.

“L R” - the Local/Remote switch.

“o O” - the HV On switch.

“r R” - the momentary HV off switch which is used to

Reset faults.

“a A” - the Atomizer on/off switch.

“E e” - the External stop input. Note the “E” indicates the

external contact is closed which is the state required

for normal operation.

1.8V — this reading shows the internal 1.8V DC power supply. It’s nominal value is 2320.

Sts — this shows the current system state which can

be either Stopped or Faulted.

OPERATING PARAMETERS AND SETTINGS

Once the system has been placed into Run mode operation,

the Conguration settings previous described can no longer be adjusted.

There are also several additional operating High Voltage

control parameter settings which can be adjusted with

the system in RUN mode. This section describes these parameters.

kVSet

This is the voltage setpoint, used in Voltage Control Mode. The system attempts to keep the voltage at this value when operating at low current levels, but as the current level is increased the voltage will be reduced to stay within the I-V curve of the selected cascade. When operating in Current Mode, kVSet is not displayed since the upper and lower voltage limits are determined by kV Low Limit and kV High Limit.

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HV Controller - OPERATION

HIGH VOLTAGE

KVSet 55 V-CONSL KVAct O uAAct O Chk: OK Com: OK HV: Off Sts: STPD

Figure 37: kv setpoint

μASet

This is the current setpoint, used in Current Control Mode. The system attempts to keep the current at this value when running.

HIGH VOLTAGE

I-CONSL uASet 33 KVAct O uAAct O Chk: OK Com: OK HV: Off Sts: FALT

di/dt Sensitivity

In Voltage Control Mode, this allows the user to control how rapid a current change can occur before a fault is

generated. Allowable settings are 0 to 60, specied in

units of µAmps per 100 milliseconds. For direct charge solvent borne applicators, a setting of 15 is suggested as a starting point.

Anytime a Di/Dt fault occurs, the cause of the fault must be determined before changes are made to the Di/Dt Sensitivity. If it is determined to be a nuisance fault, then the Di/Dt Sensitivity can be incremented to permit a larger current change per unit of time. This type of fault-analyze-

adjust cycle must be performed repeatedly to be sure the

minimum Di/Dt Sensitivity is being used.

WARNING

 Setting di/dt Sensitivity arbitrarily high will reduce the effectiveness of the setting in detecting unsafe operating conditions. To achieve the safest possible operation, the user should perform tests to determine the minimum setting which avoids nuisance faults.

Figure 38: uAmp setpoint

di/dt Ena/Dis

This allows the user to enable or disable the controller’s detection of rapid current increases. This feature is only available in Voltage Control Mode and is not recommended for indirect charge applications.

The Di/Dt detection feature improves the ability of the power supply to prevent discharges when a grounded

object is approaching at rates greater than approximately 4

inches per second. Slower rates of approach are typically

sensed by Max µA Limit, assuming Max µA Limit was properly set. The Di/Dt Sensitivity and Max µA Limit must

be set correctly to minimize discharges when using metal (unlisted) applicators.

HIGH VOLTAGE

DiDt Mode Dis 5O Max uA Limit 9O

HIGH VOLTAGE

DiDt Mode Dis 5O Max uA Limit 9O

Save_Changes

Figure 40: didt sensitivity

dv/dt Ena/Dis

This allows the user to enable or disable the controller’s detection of rapid voltage changes. This is only available in Current Mode.

HIGH VOLTAGE

DvDt Mode Dis 5O KV Low Limit 2O KV High Limit 1OO

Save_Changes

Figure 39: didt enabled disabled

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Save_Changes

Figure 41: dv dt enabled disabled

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HV Controller - OPERATION

dv/dt Sensitivity

In current control mode, this allows the user to control how rapid a voltage change can occur before a fault is generated. Allowable settings are 0 to 60 (kV per 100 milliseconds). A setting of 15 is suggested as a starting point for Solvent borne paint.

WARNING

 Setting dv/dt Sensitivity arbitrarily high will reduce the effectiveness of the setting in detecting unsafe operating conditions. To achieve the safest possible operation, the user should perform tests to determine the minimum setting which avoids nuisance faults.

HIGH VOLTAGE

DvDt Mode Dis 5O KV Low Limit 2O KV High Limit 1OO Save_Changes

Figure 42: dv dt sensitivity

Max μA Limit

This parameter determines the level where a Current Limit Fault occurs. It is the primary means of preventing discharges when the current level rises slowly. Therefore to ensure safe operation this setting, like the previously discussed Di/Dt Sensitivity, should be carefully set to the minimum value which eliminates nuisance faults. For Solvent borne applications, a value of 30 is a reasonable starting point.

When the current is greater than 90% of this value, a Current Limit Warning is generated. When the current rises above this value, it issues a Current Limit Fault.

kV Low Limit

This parameter determines the level where a kV Low Limit Fault occurs. When the Voltage falls below this value, it issues a kV Lo Fault. It only applies in Current Mode.

HIGH VOLTAGE

DvDt Mode Dis 5O KV Low Limit 2O KV High Limit 1OO Save_Changes

Figure 44: kv low limit

kV High Limit

This parameter determines the level where a kV High Limit

Warning occurs. When the voltage exceeds 90% of this

value, it issues a kV High Limit Warning and prevents the

voltage from exceeding the limit value. It only applies in

Current Mode.

HIGH VOLTAGE

DvDt Mode Dis 5O KV Low Limit 2O KV High Limit 1OO Save_Changes

Figure 45: kv high limit

The following table lists the operating parameters and the passwords required to change each parameter.

TABLE 7

Parameter

HIGH VOLTAGE

Max uA Limit 9O

Save_Changes

Figure 43: max uAmp Limit

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kVSet -none-

µASet -none-

Di/Dt Enable User

Di/Dt Sensitivity User

Dv/Dt Enable User

Dv/Dt Sensitivity User

Max μA Limit System

KV Low Limit -none-

KV High Limit System

Password Level

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HV Controller - OPERATION

CONTROL CONDITIONS

Power Up

On power up, the system does several checks to determine hardware status. It checks various signals to determine that there are no faults, including feedback from the Variable Voltage Output and High Voltage Inputs to determine system status. If it determines that it is OK to start, the Check display on the run menu changes from VOL or INT to OK and System Status changes to OK.

HV On

When the HV On signal is received and Check is OK, the system status changes to “Starting” and the Variable Voltage Output is increased until the Independent Value rises to within a tolerance window (currently +/-3) of the setpoint value. Then the System Status changes to “Running”.

Setpoint Changed

If the setpoint changes outside the control window, the status changes to “Rising” or “Falling” until the Independent Value again reaches the control window at which point it returns to “Running”.

WARN

System has detected a current or voltage condition within 10% of the limit settings. The abbreviation stands for Warning.

FALT

System has detected a fault condition, stopped and will not allow starting until the fault is reset. If the fault condition has not been cleared, it may immediately fault without starting. The abbreviation stands for Fault.

SYSTEM CHECK (CHK)

System has passed the checks and is ready to start.

POWER

System is detecting a lack of cascade power.

INTLK

System is detecting an interlock failure.

HV Off

When HV Off is activated the system immediately sets the Variable Voltage Output to zero volts, disables the HV Relay and goes to Stop Mode.

The System Check goes to OK. However, before allowing the output to be enabled again, it checks the High Voltage and Variable Voltage Output feedback signals to verify that they have both decreased since the high voltage was disabled.

SYSTEM STATUS (STS)

STRT / RISE / FALL / STPG

System is changing from one voltage/current value to another. Di/dt and dv/dt checks are disabled. The abbreviations stand for Starting. Rising, Falling and Stopping.

RUN

System is attempting to keep a steady value on Setpoint (the Independent Value). All enabled checks are active.

STPD

System output is off and awaiting a command. The abbreviation stands for Stopped.

SYSTEM FAULT BEHAVIOR

The following tables specify how High Voltage or Atomizer Faults effect the operation of each other.

VOLTG

System has detected excessive voltage on the High Voltage

or Variable Voltage Output Feedback signals and will not allow a start.

NOTE

 Sometimes the operating conditions can cause

VOLTG to display, such as:

1. A system with multiple applicators near each other, where some applicators are ON/active and others are OFF/inactive. The inactive applicators can receive / detect the voltage generated and fed back by the active applicators.

2. A system with an RP-404, which has a slow discharge rate (bleed-down), when the system is turned off. This VOLTG will display while the charge is dissipating, then changes to OK.

INTLK

System is detecting an interlock failure.

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HV Controller - OPERATION

SYSTEM FAULT BEHAVIOR

The following tables specify how High Voltage or Atomizer Faults effect the operation of each other.

High Voltage Faults

Interlock Fault Disable

Comm Time Out Fault Disable

Communications Fault Disable

Hardware Fault Disable

KV Low Fault No effect**

DIDT or DVDT Fault No effect**

HV Feedback Fault No effect**

Min Output Fault No effect**

Max KV Fault No effect**

Over Voltage Fault No effect**

Over Current Fault No effect**

Voltage Cable Fault Fault No effect**

Current Cable Fault Fault No effect**

HV Action

Atom Action

Other HV Faults

Remote Stop Fault Disable

HVC Power OFF Fault Disable

System Mode Fault No effect

HVC WDog Reset Fault *RansNet Lost Fault

DCP WDog Reset Fault No effect

HV Action

Atom Action

Ethernet/IP INTERFACE

The Ethernet/IP Interface for the MicroPak 2e Controller is

dened as a set of four 16 bit words of input plus a set of

four 16 bit words of output. The Assembly instances are

dened for the controller as follows:

Instance

Input 100. (0x64) 4 16 bits

Output 116. (0x74) 4 16 bits

Conguration 1. (0x01) 0 8 bits

Number

Count Size

The 1st table shows the four High Voltage Controller faults that will stop the Atomizer along with 9 which will leave the Atomizer in its current state. These faults are all reported over Ethernet/IP.

The atomizer will continue to operate when these faults

occur, but the Paint Triggers will be inhibited as a safety

precaution to prevent the possibility of feeding a re.

The second table shows that ALL Atomizer Faults will stop the High Voltage Controller.

Other HV Faults

Bell Overspeed Disable Fault

Bell Underspeed Disable Fault

Loss Of Feedback Disable Fault

Low Bearing Air Disable Fault

Comm. Lost Disable Fault

The third table shows ve other miscellaneous faults. Note

the HVC WDog Reset fault causes the Atomizer to stop since it will loose it’s communications link.

HV Action

Atom Action

NOTE

 When dening the IO Instances to the host system, specify the input object of the controller as the output object of the host and the output object of the controller as the input object of the host.

 The Ethernet/IP interface of the MicroPak 2e only supports Real-Time Implicit messaging

using the Assemblies specied in this manual. The use of Explicit messaging to read and

set individual parameters is not supported.

 Sending commands to the MP2e while it is starting up and has not yet entered RUN STATE should be

avoided as it may result in unexpected behavior.

Starting with V1.1.02, any incoming Ethernet/IP commands will be ignored until the MP2e has entered RUN STATE.

The Input bit denitions are shown in Table 8 and the Output bit denitions are shown in Table 9 on the following pages.

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Description of Interface Elements

Input Word 0

Bit 0 - Enable Control

When this bit is set (high) the system will attempt

to keep the actual at the appropriate setpoint.

Bit 1 - Reset Faults

When this bit is changed from low to high (cleared

to set) the system will clear any fault bits if any are set and will set the communication fault if no fault bits are set.

Bit 2 - Current Mode

When this bit is set, the system will operate in the

Current Control Mode and when cleared will operate in the Voltage Control Mode.

Bits (3-15) - Unused

These bits are currently undened and unused.

Input Word 1

Bits (0-7) - kV Setpoint

This byte (8 bit) value determines the active Voltage

setpoint in kV.

Bits (8-15) - μA Setpoint

This byte (8 bit) value determines the active Current

setpoint in μA.

HV Controller - OPERATION

NOTE

 When an RP1000 or LEPS5002 cascade is

selected, this value is multiplied by 5 to set the actual

μA setpoint.

Input Word 2

Bits (0-7) - Parameter Value

These bits are currently undened and unused.

Bit (8-14) - Parameter Select Code

This 7 bit value determines the parameter to change.

Bit 15 - Parameter Write Strobe

When this bit changes from cleared to set, the

parameter value is written into the selected parameter and displayed in the Output Word 2.

Input Word 3

Bits (0-7) - Unused

These bits are currently undened and unused.

Bits (8-14) - Parameter Select Code

The 7 bit value determines the parameter to change.

Bit 15 - Parameter Read Strobe

When this bit changes from cleared, to set the

Current Parameter Value is read from the selected parameter and displayed in the Output Word 3.

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HV Controller - OPERATION

TABLE 8 - MICROPAK 2e Ethernet/IP INPUT DEFINITIONS

INPUT OBJECT (0X64)

Bit Word 0 Word 1 Word 2 Word 3

0 HV Enable Control kV Setpoint Parameter Value

1 Reset Faults kV Setpoint Parameter Value

2 Current Mode kV Setpoint Parameter Value

3 kV Setpoint Parameter Value

4 kV Setpoint Parameter Value

5 kV Setpoint Parameter Value

6 kV Setpoint Parameter Value

7 kV Setpoint Parameter Value

8 μA Setpoint Parameter Select Code Parameter Select Code

9 μA Setpoint Parameter Select Code Parameter Select Code

10 μA Setpoint Parameter Select Code Parameter Select Code

11 μA Setpoint Parameter Select Code Parameter Select Code

12 μA Setpoint Parameter Select Code Parameter Select Code

13 μA Setpoint Parameter Select Code Parameter Select Code

14 μA Setpoint Parameter Select Code Parameter Select Code

15 μA Setpoint Parameter Write Strobe Parameter Read Strobe

TABLE 9 - MICROPAK 2e Ethernet/IP OUTPUT DEFINITIONS

OUTPUT OBJECT (0X44)

Bit Word 0 Word 1 Word 2 Word 3

0 In Control Over Current Warning Parameter Data Value Actual kV Value

1 Ramping Over Voltage Warning Parameter Data Value Actual kV Value

2 OK to Start Under Voltage Warning Parameter Data Value Actual kV Value

3 Remote Mode Max Output Warning Parameter Data Value Actual kV Value

4 HV On Echo Communications Time Out Fault Parameter Data Value Actual kV Value

5 Warning Interlock Fault Parameter Data Value Actual kV Value

6 Fault Communications Fault Parameter Data Value Actual kV Value

Current Mode

8 Atomizer Fault Low Voltage Fault Parameter Select Code Actual μA Value

9 Door Interlock Status dv/dt Fault Parameter Select Code Actual μA Value

Booth Air Interlock Status

11 Miscellaneous Interlock Status Minimum Output Fault Parameter Select Code Actual μA Value

12 Remote Stop (Interlock) Status Feedback Fault Parameter Select Code Actual μA Value

13 Not in RUN STATE Over Voltage Fault Parameter Select Code Actual μA Value

14 Over Current Fault Parameter Select Code Actual μA Value

15 Heartbeat Cable Fault

Hardware Fault Parameter Data Value Actual kV Value

di/dt Fault Parameter Select Code Actual μA Value

Parameter Acknowledge

Actual μA Value

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HV Controller - OPERATION

Output Word 0

Bit 0 - In Control

This bit is set when control is enabled and the

controlled value has reached within three of the setpoint. This does not mean that the value is still within three of the setpoint, but that it had been at one time.

Bit 1 - Ramping

This bit is set when the setpoint has been changed

and the controlled value has not yet come within three of the setpoint value.

During the time this bit is set, the di/dt and dv/dt

checks are not active.

Bit 2 - OK to Start

This bit is set when the system determines that the

voltage values are in a range where it is allowed to start control. Will remain 0 until the MP2e enters the RUN STATE.

Bit 3 - Remote Mode

This bit is set when the front panel switch is set to

remote. When set, an external unit can control the

system.

Bit 4 - HV On Echo

This bit is set whenever HV is ON

Bit 5 - Warning

This bit is set whenever any warning is in effect.

Bit 6 - Fault

This bit is set whenever any fault is in effect (see

“Fault Descriptions” in “Troubleshooting Guide” in the “Maintenance” section).

Bit 7 - Current Mode

This bit is set when Current Mode Control is active.

Bit 8 - Atomizer Caused Fault

This bit indicates that an Atomizer Fault caused the

shutdown.

Bit 9 - Door Interlock Status

This bit is set when the interlock was open when the

HVC Fault occurred.

Bit 10 - Booth Air Interlock Status

This bit is set when the interlock was open when the

HVC Fault occurred.

Bit 12 - Remote Stop (Interlock) Status

This bit is set when the interlock was open when the

HVC Fault occurred.

Bit 13 - Not in RUN STATE

This bit is set when the MP2e is not in RUN STATE.

This provides an indication when the MP2e has changed from a BOOTING STATE to the RUN STATE. This was added in V1.1.02 to allow remote detection of an MP2e being inadvertently left in Local mode after power is cycled.

Bit 14 - Unused

Currently undened.

Bit 15 - Heartbeat

This bit changes state every 1/4 second producing

two pulses per second.

Output Word 1

Bit 0 - Over Current Warning

The current value is within 10% of the upper limit.

Bit 1 - Over Voltage Warning

The voltage value is within 10% of the upper limit in

current mode.

Bit 2 - Under Voltage Warning

The voltage value is within 10% of the lower limit in

current mode.

Bit 3 - Max Output Warning

The control voltage has reached its maximum value.

Bit 4 - Communication Time Out Fault

The system has detected a communication loss which

was greater than the value specied by ComTimeOut.

Bit 5 - Interlock Fault

The system has detected one of the active interlock

input in an open state.

Bit 6 - Communication Fault

The system has detected a communication failure

after an Ethernet/IP connection was initiated.

Bit 7 - Hardware Fault

The system has detected a fatal System Failure.

Bit 11 - Miscellaneous Interlock Status

This bit is set when the interlock was open when the

HVC Fault occurred.

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HV Controller - OPERATION

Bit 8 - Low Voltage Fault

The system has fallen below the kV Limit Lo while

in Current Mode.

Bit 9 - Not Used

Bit 10 - di/dt Fault or dv/dt Fault

The system has detected a di/dt fault (Voyage Mode)

or dv/dt fault (Current Mode).

Bit 11 - Minimum Output Fault

The system has lowered the Variable Voltage Output

to zero and still is above the setpoint.

Bit 12 - Feedback Fault

The system has measured an high level of voltage

or current feedback .which does not correspond to the level of the control outputs being applied.

Bit 13 - Over Voltage Fault

The system has exceeded the kV Limit Hi or the Max

System Limit.

Bit 14 - Over Current Fault

The current value has exceeded the Current (I) Limit

Hi or the Max SystemLimit.

Bit 15 - Cable Fault

This bit is set whenever the voltage or current feedback from the cascade has been lost or fallen below the acceptable value.

Bits (8-15) - Actual μA Value

This byte (8 bit) value displays the latest current

reading in μA.

NOTE

 When an RP1000 or LEPS5002 cascade is

selected, the μA value returned is the actual value

divided by 5.

Parameter Select Codes

Parameter Select = 1: DvDt

READ - returns value of DvDT threshold WRITE - sets value of DvDT threshold

Parameter Select = 2: DiDt

READ - returns value of DiDT threshold WRITE - sets value of DiDT threshold

Parameter Select = 3: kVHi

READ - returns value of max KV allowed WRITE - sets value of max KV allowed

Parameter Select = 4: iHi

READ - returns value of max I allowed WRITE - sets value of max I allowed

NOTE

Output Word 2

Bits (0-7) - Parameter Data Value

This byte (8 bit) tells the system the active parameter

value.

Bits (8-14) - Parameter Select Code

This 7 bit value tells the system which parameter is

being displayed.

Bit 15 - Parameter Acknowledge

When this bit changes from cleared to set a new

Parameter Value is being displayed. It is cleared when the Parameter Read Strobe and Parameter Write Strobe are both cleared.

Output Word 3

Bits (0-7) - Actual kV Value

The byte (8 bit) value displays the latest voltage

reading in kV.

 When an RP1000 or LEPS5002 cascade is

selected, the μA value passed is scaled by 5 from the

actual value.

Parameter Select = 5: kVLo

READ - returns value of kVLo WRITE - sets value of kVLo

Parameter Select = 6: DxDtEna

READ - returns value of DxDtEna WRITE - sets value of DxDtEna

NOTE

 DxDtEna will enable the DxDt check available in the control mode currently active. I.E. DiDT when in Voltage Mode and DvDT when in Current Mode.

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Parameter Select = 7: Password 1

READ - returns rst character of user password

WRITE - (Unsupported)

Parameter Select = 8: Password 2

READ -

returns second character of the password

Parameter Select = 9: Password 3

READ - returns third character of user password

WRITE - (Unsupported)

Parameter Select = 10: Password 4

READ -

WRITE -

returns fourth character of user password

(Unsupported)

TABLE 10

HV Controller - OPERATION

Parameter

DvDT 0 60

DiDt 0 60

kVHi 20 100

iHi 10 Per Cascade

kVLo 0 80

DxDtEna 0 = Disable 1 = Enable

Password 1 0 9

Password 2 0 9

Password 3 0 9

Password 4 0 9

Min Value

Max Value

NOTE

 The per Cascade iHi values can be found in the

Electrical Specications located in the Introduction

section.

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Atomizer Controller

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Atomizer Controller - INTRODUCTION

ATOMIZER CONTROLLER GENERAL DESCRIPTION

The Atomizer Controller for use with the MicroPak 2e Controller is designed to continuously monitor and maintain the programmable speed of a rotary atomizer as well as provide a universal I/O interface for many atomizer functions.

This module utilizes closed-loop control via a ber optic cable to maintain the rotator speed. A number of conguration

options are available to the end user. These include built in support for many Ransburg rotary atomizers as well as an assortment of inputs and outputs available to the user.

Figure 46: MicroPak 2e Multi I/O Board

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: 2” tall X 7.5” X 4.75” (51mm x 191mm x 121mm)

Mounting: Figure 48 in Appendix

Environmental Requirements

Power Required:

J15 - Controller : 24V DC @ 0.25 Amps No IO’s

Note: 24V DC power supply must be regulated and have over current and over voltage protection.

Electrical - Communication Requirements

Control and Reporting: Ethernet/IP (Implicit Messaging only)

Electrical - Controls in Local Mode

Analog In: (0-10V or 4-20mA) BEARING AIR FEEDBACK

Analog Out: (0-10V or 4-20mA with option) BELL DRIVE, Bell Speed Read Out

Discrete In: (0-24V) (None Active)

Discrete Out: (0-24V, Current Sourcing) BRAKE, Overspeed Warn/Fault, Underspeed Warn/Fault,

Feedback Warn/Fault

NOTE:

In Local Mode, the functions of the Analog and Discrete input signals are performed by the Front Panel user interface.

, Low Bearing Air Warn/Fault, Speed Out of Tolerance Warn

Loss of Bell

(Continued on next page)

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Atomizer Controller - INTRODUCTION

SPECIFICATIONS (At Sea-Level Conditions) (Cont.)

NOTE

 Signals shown above in BOLD are minimum required functions for Atomizer control to operate. This note regarding the I/O names in BOLD also applies to the following descriptions.

Electrical - Controls in Remote Ethernet/IP Mode

Analog In: (0-10V or 4-20mA) BEARING AIR FEEDBACK

Analog Out: (0-10V or 4-20mA with option) BELL DRIVE, Bell Speed Read Out, Flowrate #1,

Flowrate #2, Shaping Air #1, Shaping Air #2

Discrete In: (0-24V) User Input #1, User Input #2

Discrete Out: (0-24V, Current Sourcing) BRAKE,

Fluid Override #1, Fluid Overri User Output #2

Paint Trigger #1, Paint Trigger #2, Dump #1, Dump #2,

de #2, Cup Wash, Atomizer Faulted, HV On, User Output #1,

Electrical - Controls in Remote Discrete Mode

Analog In: (0-10V or 4-20mA) BEARING AIR FEEDBACK, Bell Speed Setpoint, Flowrate Setpoint #1,

Flowrate Setpoint #2, Shaping Air Setpoint #1, Shaping Air Setpoint #2

Analog Out: (0-10V or 4-20mA with option) BELL DRIVE, Bell Speed Read Out, Flowrate #1, Flowrate #2, Shaping Air #1, Shaping Air #2

Discrete In: (0-24V) BELL SPIN ENABLE, Fluid Override #1, Fluid Override #2, Cup Wash

Discrete Out: (0-24V, Current Sourcing) BRAKE, Paint Trigger #1, Paint Trigger #2, Dump #1, Dump #2, Fluid Override #1, Fluid Override #2, Cup Wash, Overspeed Warn/Fault, Low Bearing Air Warn/Fault, Loss of Bell Feedback Warn/Fault, Speed Out of Tolerance Warn, Atomizer Failed,

HV On

Paint Trigger #1, Paint Trigger #2,

Dump #1, Dump #2,

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Atomizer Controller - INTRODUCTION

SPEED CONTROL

The Atomizer Controller is used in a closed-loop rotational speed control system for rotary atomizers as shown in Figure 47. It accepts a requested speed command and, after comparing this with the actual speed feedback from the atomizer, provides an output to maintain the requested speed.

When a speed request is received, the controller activates the Turbine Drive signal which controls the output of an E to P transducer providing an air pilot signal to a 1:1 volume booster. The volume booster supplies high volume drive air to the rotary atomizer.

The atomizer speed is monitored by a ber optic cable to a ber optic transceiver mounted on the Atomizer Controller

board. The transceiver provides a speed feedback signal to the Atomizer Controller which is timed to determine the rotational speed. The speed, in increments of 1000’s rpm, is displayed on the MicroPak 2e Controller front panel.

An optional braking system provides for rapid slowdown. When changing speeds from high to low (change greater than 3,000 rpm), the controller provides an electrical brake signal to drive a pneumatic solenoid which delivers high pressure air to the brake input of the atomizer. Ransburg

part numbers, for each of the components described, are listed in the MicroPak 2e High Voltage Controller Parts List

located in this manual.

NOTE

 A speed command of 1 krpm is recognized by the controller as an emergency stop condition and will cause the brake to stay engaged until the speed reaches 2 krpm from which the turbine will coast to a stop.

 A speed command of 0 krpm does not actuate the brake but allows the turbine to coast to a stop condition.

Figure 47: MicroPak 2e Controller/Atomizer Minimal System

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Page 47

The speed feedback signal is designed to drop out at about 2 krpm and the controller will set a Loss of Feedback Fault. A new speed command will reset the fault at the Atomizer Controller, but the MicroPak 2e Controller will only reset

its fault indication when commanded by the Ethernet/IP

interface or the front panel HV On/Off switch.

An electrical input is provided and required for atomizer bearing air sensing and interlock. Minimum bearing air pressure threshold is set at 80 psi.

The following table lists the maximum allowed speed

and minimum bearing air for atomizers supported by the Atomizer Controller. While there are no minimum speed limits set by the Atomizer Controller, the low speed operation is limited by the drop out of the speed feedback signal at about 2 krpm.

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Atomizer Controller - INTRODUCTION

Atomizer Type

RMA300-500 100 80

RMA303-SBA 70 70

AeroBell 60 80

AeroBell33 55 80

RMA100-200 50 80

TurboDisk 40 -

AutoGun - -

RMA-550 55 80

Max K RPM

Min Bearing Air PSI

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Atomizer Controller - OPERATION

OPERATION

The Atomizer Controller currently supports three different operating modes with varying levels of capabilities.

Remote Ethernet/IP Control

This mode gives the remote system full access atomizer parameters and allows control of starting and stopping as well as collection of fault information.

Remote Discrete Control

This mode is only available when Ethernet/IP is disabled. While it provides no access to the atomizer parameters, it does allow the remote system to control starting, stopping and various other functions provided through the Atomizer Controller inputs and outputs. See tables 16, 17, 18, and 19 for a complete list of I/O functions.

Local Front Panel Control

This mode is available whenever the MicroPak 2e Controller is in Local mode. In the current software release, operation is limited to starting and stopping the atomizer by means of the Atomizer On/Off switch located on the front panel.

to the

ATOMIZER

Atomizer MIO Dis

Discrete MIO Dis

Figure 48: Atomizer Use Screen

Atomizer Conguration Menu

The Atomizer Conguration menu displays the factory congured Atomizer type on the rst line and the minimum

bearing air pressure it requires on the second line. The third line displays whether or not Unilink operation was ordered with the controller. When Unilink operation is enabled, the fourth line allows the user to manually select which atomizer is attached, i.e. Bell or Gun. The selection is ignored if Unilink Mode is disabled.

ATOMIZER

Atomizer RMA3OO-5OO

NOTE

 In local mode the Turbine Speed Set point

can be set from the front panel and that value will

be used for local operation. Upon exiting Local

mode, control of the Turbine Speed Setpoint reverts to either the Ethernet/IP interface or the Discrete inputs.

CONFIGURATION MENUS

The following four menus are displayed on the ATOMIZER screen (right panel). They are included in the base MicroPak 2e Controller but are only displayed when an Atomizer and/

or Discrete IO Controller board is congured.

Atomizer/Discrete IO Cong Menu

This menu shows if the Atomizer or Discrete IO controllers

were congured by the factory.

Bearing Air >= 8Opsi Unilink Mode Dis Unilink Select Bell

Figure 49: Bearing Air SetPoint Screen

Atomizer / Discrete IO Analog Inputs Menus

These screens allow the user to select the mode of each analog input on the Atomizer and Discrete IO Controllers. Two options are available, “V” or “I”. “V” represents a 0-10 volt input and “I” represents a 4-20 milliamp input.

ATOMIZER

Atom Analog Inputs V=O-1OV I=4-2OmA #1 V #2 V #3 V #4 V #5 V #6 V #7 V

Figure 50: Atomizer Analog Input Screen

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Atomizer Controller - OPERATION

ATOMIZER

Discrete Analog Ins V=O-1OV I=4-2OmA #1 V #2 V #3 V #4 V #5 V #6 V #7 V

Figure 51: Discrete IO Analog Input Screen

NOTE

 Jumpers JMP15 through JMP9 must be set to match the selections on the Analog Inputs screens. For further information see the operation section of the Atomizer Controller or Discrete IO Controller portion of this manual.

CONFIGURATION PARAMETERS AND SETTINGS

Atomizer

This Atomizer controller currently supports the following types of atomizers.

• RMA300-500

• RMA303-SBA

• AeroBell

• AeroBell 33

• RMA100-200

• TurboDisk

• Auto Gun

• RMA-550

NOTE

 The RMA-550 Atomizer cannot be selected unless the Cascade is set to FM-HP404 and the Control Mode is set to Voltage. Once the RMA-550 Atomizer is selected, the Cascade type and Control Mode cannot be changed until the Atomizer selection is changed.

 The Auto Gun Atomizer cannot be selected if the Unilink Mode is enabled. Once the Auto Gun Atomizer is selected, the Unilink Mode cannot be enabled until the Atomizer selection is changed.

WARNING

 ONLY USE the type of atomizer which the controller

was congured for by the factory. Using a different

type atomizer may allow for operation outside the recommended parameters and values for the applicator and can result in damage or unsafe operation.

TABLE 11

Parameter

ATOMIZER MIO Settings

Atom Analog Inputs System

Atomizer MIO Cong

Atomizer Type Cong

Unilink Mode Cong

Unilink Select System

Password Level

OPERATING PARAMETERS AND SETTINGS

Turbine Speed Setpoint

This parameter sets the turbine speed which will be commanded by the controller when in LOCAL mode. When in Remote mode it displays the speed setpoint commanded by the remote controller.

NOTE

 The following Atomizer settings and features

are only available when the Atomizer Controller is

congured for use with a ControlPak.

Atomizer Shape Air Menu

This menu allows the user to manually adjust both the shaping air outputs and the paint ow rate outputs. The values used are expressed as percentages since the controller can be congured to provide either 0-10 V or

4-20 mA analog outputs.

ATOMIZER

ShapeAirSP1 O % ShapeAirSP2 O % PFlowRateSP1 O % PFlowRateSP2 O %

Figure 52: Shape Menu Screen

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Atomizer Controller - OPERATION

ShapeAirSP1

This parameter determines the level in percent (i.e. 0-100%) that will be applied to the Shaping Air 1 output.

ShapeAirSP2

This parameter determines the level in percent (i.e. 0-100%) that will be applied to the Shaping Air 2 output.

PFlowRateSP1

This parameter determines the level in percent (i.e. 0-100%) that will be applied to the Paint Flow Rate 1 output.

PFlowRateSP2

This parameter determines the level in percent (i.e. 0-100%) that will be applied to the Paint Flow Rate 2 output.

Atomizer Fluid Maintenance Menu

This menu enables the user to safely perform paint ow calibration or ushing operations by disabling the Fluid Interlocks. Disabling the uid interlocks cause both the

high voltage and atomizer to be disabled (forced off). While at the same time allowing the paint and solvent triggers to occur without checking the rotational speed of the atomizer.

ATOMIZER

this interlock is to prevent uid from being applied when it could easily ood the turbine. The second interlock prevents

the solvent control output (i.e. Bell Cup, Disk or Gun Wash) from activating when the high voltage controller is active.

This is done to minimize the risk of a re caused by a high voltage discharge while solvent uid is present.

TABLE 12

Parameter

Turbine Speed Setpoint -none-

Shaping Air 1 User

Shaping Air 2 User

Paint Flow Rate 1 User

Paint Flow Rate 2 User

FluidInterLock System

Password Level

AUTOMATIC SHUTDOWN

The Atomizer Controller continuously monitors turbine operation and detects common fault conditions and will automatically stop the atomizer when one is detected.

Atomizer Fluid Maint ** Remove CUP ** before Disabling FluidInterlock Ena

Figure 53: Atomizer Maint Menu Screen

FluidInterLock

This parameter allows the user to disable the uid interlocks

between the high voltage controller and the atomizer controller. It is intended to allow maintenance activities

such as paint ow calibrations. In addition, it can be used in an emergency to allow ushing of an atomizer when it

cannot be run up to speed.

A description of the uid interlocks follows:

There are two uid interlocks implemented in the Atomizer which this parameter enables or disables. The rst interlock

normally prevents the Atomizers Paint Trigger and Wash outputs from being activated when the atomizer is below a

minimum safe speed for uid application. The purpose of

1. Overspeed: If the speed feedback exceeds the speed setpoint.

Liquid Bell - 10,000 rpm above setpoint Disk - any speed over 30 krpm Time delay is 0.5 seconds

2. Underspeed: If the speed feedback is less than the

speed setpoint:.

Liquid Bell - 10,000 rpm under setpoint Disk - No underspeed checks made Time delay is 0.5 seconds.

3. Loss of Feedback: Senses when feedback should be present but is not.

Pulses received from the ber optics must

be no greater than 800 msec apart during normal operation. Start-up delay:

Liquid Bell - 1 second for the rst pulse

Disk - 7 seconds

Once the rst pulse has been received, the

800 msec interval applies.

4. Invalid Speed Command: Will not process speed

requests higher than rated maximum. Internally set

speed command to zero.

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Atomizer Controller - OPERATION

5. Low Bearing Air Pressure: If the bearing air pressure feedback drops below the minimum bearing air threshold. There is a 4 second time delay for all settings.

6. Interlock Open: If an active interlock is opened while the atomizer is running, all outputs will be disabled and a brake assisted ESTOP will be done before faulting.

Out of Tolerance (WARNING)

Speed is not within +/- 5% of setpoint, no internal

action taken, 1 second delay.

Signal may be used externally as desired.

INTERFACING CONSIDERATIONS

When using an Atomizer there are some operational restrictions that must be observed to avoid damaging the

turbine. Six of these conditions were listed in the Automatic

Shutdown section and are automatically enforced by the Atomizer Controller. There are also two other conditions which the controller is programmed to prevent. Both involve

stopping the ow of paint to the bell. 1) When the Atomizer

is not spinning, and 2) When the HV has faulted. These operational interlocks are accomplished by deactivating the signals Paint Trigger #1 and Paint Trigger #2 whenever the Atomizer is not running, or the HV controller is FAULTED.

CAUTION

 If the user chooses not to use the discrete outputs Paint Trigger #1 and Paint Trigger #2 provided by the Atomizer Controller, then they are responsible for implementing comparable interlocks between

Atomizer and HV operation and paint ow. Failure to

do so may result in a turbine failure or increased risk

of a re.

Ethernet/IP INTERFACE

The Ethernet/IP Interface for the Atomizer Controller is

dened as two assembly instances that contain the MicroPak 2e interface in the rst four words of the input and output sets. Six additional words for the Atomizer Controller have been

added at the end of the MicroPak 2e Ethernet/IP interface.

This means that the Atomizer Controller interface is a set of ten 16 bit words of input plus a set of ten 16 bit

words of output. The Assembly instances are dened as objects 101 (0x65) and 117 (0x75), where object 101 is the input assembly and object 117 is the output assembly. A Conguration assembly is not used and can be dened

as 1 with a size of 0.

Since the rst four words of the Atomizer Controller interface are identical to those dened for the MicroPak 2, the following interface description only includes the six words which are specic to the Atomizer Controller. The Input bit denitions are shown in Table 11 and the Output bit denitions are

shown in Table 12 on the following pages.

NOTE

 The Ethernet/IP interface of the MicroPak 2e only supports Real-Time Implicit messaging

using the Assemblies specied in this manual. The use of Explicit messaging to read and

set individual parameters is not supported.

 Sending commands to the MP2e while it is

USER DEFINED I-O’S

When the Ethernet/IP Interface for the Atomizer Controller

is enabled, the denition of the discrete IO’s is expanded to provide two user dened discrete inputs and two discrete

outputs. The two inputs are passed directly to the PLC or Robot via the Ethernet/IP interface. Both inputs are available for use by the control system to read the state of suitable input signals. Similarly, the two outputs are under the direct control of the PLC or Robot via the Ethernet/IP interface.

The inputs are designed to accept a 0 to 24 VDC signal and the outputs provide a 0 to 24 VDC signal which can source up to 250 mA.

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starting up and has not yet entered RUN STATE

should be avoided as it may result in unexpected

behavior. Starting with V1.1.02, any incoming Ethernet/IP commands will be ignored until the MP2e has entered RUN STATE.

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Atomizer Controller - OPERATION

TABLE 13 - ATOMIZER CONTROLLER Ethernet/IP INPUT

BIT DEFINITIONS INPUT OBJECT (0X65)

Bit Word 4 Word 5 Word 6 Word 7 Word 8 Word 9

0 Atomizer RPM ShapeAir 1 ShapeAir 2 Param Parameter Enable Setpoint Setpoint Setpoint Read Code Value

1 Reset RPM ShapeAir 1 ShapeAir 2 Param Parameter Faults Setpoint Setpoint Setpoint Read Code Value

2 RPM ShapeAir 1 ShapeAir 2 Param Parameter Setpoint Setpoint Setpoint Read Code Value

3 RPM ShapeAir 1 ShapeAir 2 Param Parameter Setpoint Setpoint Setpoint Read Code Value

4 Paint RPM ShapeAir 1 ShapeAir 2 Param Parameter Trigger #1 Setpoint Setpoint Setpoint Read Code Value

5 Dump #1 RPM ShapeAir 1 ShapeAir 2 Param Parameter Setpoint Setpoint Setpoint Read Code Value

6 Fluid RPM ShapeAir 1 ShapeAir 2 Param Parameter Override #1 Setpoint Setpoint Setpoint Read Code Value

7 RPM ShapeAir 1 ShapeAir 2 Param Parameter Setpoint Setpoint Setpoint Read Strobe Value

8 Paint FlowRate 1 FlowRate 2 Parameter Parameter Trigger #2 Setpoint Setpoint Write Code Value

9 Dump #2 FlowRate 1 FlowRate 2 Parameter Parameter Setpoint Setpoint Write Code Value

10 Fluid FlowRate 1 FlowRate 2 Parameter Parameter Override #2 Setpoint Setpoint Write Code Value

11 FlowRate 1 FlowRate 2 Parameter Parameter Setpoint Setpoint Write Code Value

12 Bell Cup FlowRate 1 FlowRate 2 Parameter Parameter Wash Setpoint Setpoint Write Code Value

13 FlowRate 1 FlowRate 2 Parameter Parameter Setpoint Setpoint Write Code Value

14 User FlowRate 1 FlowRate 2 Parameter Parameter Output #1 Setpoint Setpoint Write Code Value

15 User FlowRate 1 FlowRate 2 Parameter Parameter Output #2 Setpoint Setpoint Write Strobe Value

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Atomizer Controller - OPERATION

Input Word 4

Bit 0 - Atomizer Enable

When this bit is set (high) the system will attempt

to keep the actual at the appropriate setpoint.

Bit 1 - Reset Atomizer Faults

When this bit is changed from low to high (cleared

to set) the system will clear any fault bits if any are set and will set the communication fault if no fault bits are set.

Bit 2 - Unused

This bit is currently unused

Bit 3 - Unused

This bit is currently unused

Bit 4 - Paint Trigger #1

When this bit is set, the system will activate the

Paint Trigger #1 output and when cleared will deactivate the Paint Trigger #1 output. This output is only active when the bell is running and no HV faults are present.

Bit 5 - Dump #1

When this bit is set, the system will activate the

Dump #1 output and when cleared will de-activate the Dump #1 output.

Bit 6 - Fluid Override #1

When this bit is set, the system will activate the

Fluid Override #1 output and when cleared will de-activate the Fluid Override #1 output.

Bit 7 - Unused

This bit is currently unused.

Bit 8 - Paint Trigger #2

When this bit is set, the system will activate the

Paint Trigger #2 output and when cleared will deactivate the Paint Trigger #2 output. This output is only active when the bell is running and no HV faults are present.

Bit 9 - Dump #2

When this bit is set, the system will activate the

Dump #2 output and when cleared will de-activate the Dump #2 output.

Bit 12 - Bell Cup Wash

When this bit is set, the system will activate the Bell

Cup Wash output and when cleared will de-activate the Bell Cup Wash output.

Bit 13 - Unused

This bit is currently unused.

Bits (14-15) - User Outputs #1 and #2

These bits give an integrator the ability to control

two discrete outputs, which can be used by their

external control system.

Input Word 5

Bits (0-7) - RPM Setpoint

This byte (8 bit) value determines the active atomizer speed setpoint in thousands of RPMs.

Bits (8-15) - Unused

These bits are currently unused.

Input Word 6

Bits (0-7) - Shape Air 1 Setpoint

This byte (8 bit) value determines the Shaping Air

1 setpoint in % of full scale.

Bits (8-15) - Flow Rate 1 Setpoint

This byte (8 bit) value determines the Flow Rate 1

setpoint in % of full scale.

Input Word 7

Bits (0-7) - Shape Air 2 Setpoint

This byte (8 bit) value determines the Shaping Air

2 setpoint in % of full scale.

Bits (8-15) - Flow Rate 2 Setpoint

This byte (8 bit) value determines the Flow Rate 2

setpoint in % of full scale.

Bit 10 - Fluid Override #2

When this bit is set, the system will activate the

Fluid Override #2 output and when cleared will de-activate the Fluid Override #2 output.

Bit 11 - Unused

This bit is currently unused.

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Atomizer Controller - OPERATION

Input Word 8

Bits (0-6) - Parameter Read Code

This 6 bit value determines the parameter to read.

Bit 15 - Parameter Write Strobe

When this bit changes from cleared to set, the

parameter value is written into the selected

parameter and displayed in Output Word 7.

Bit 7 - Parameter Read Strobe

When this bit changes from cleared to set, the

parameter value is read from the selected parameter and displayed in Output Word 7.

Bits (8-14) - Parameter Write Code

This 6 bit value determines the parameter to set.

Input Word 9

Bits (0-15) - Parameter Value

This 16 bit value is written to the parameter being

changed.

TABLE 14 - ATOMIZER CONTROLLER Ethernet/IP OUTPUT

BIT DEFINITIONS OUTPUT OBJECT (0X75)

Bit Word 4 Word 5 Word 6 Word 7 Word 8 Word 9

0 Bell Bell Overspread Parameter Parameter Actual RPM Actual Flow Running Warning Read Code Read Valve Value 1 (Future)

1 Bell Underspread Parameter Parameter Actual RPM Actual Flow Warning Read Code Read Valve Value 1 (Future)

2 OK to Loss of Feedback Parameter Parameter Actual RPM Actual Flow Start Warning Read Code Read Valve Value 1 (Future)

3 Remote Speed Out of Parameter Parameter Actual RPM Actual Flow Mode Tolerance Warning Read Code Read Valve Value 1 (Future)

4 Parameter Parameter Actual RPM Actual Flow Read Code Read Valve Value 1 (Future)

5 Atomizer Parameter Parameter Actual RPM Actual Flow Warning Read Code Read Valve Value 1 (Future)

6 Atomizer Atomizer Comm Parameter Parameter Actual RPM Actual Flow Fault Fault Read Code Read Valve Value 1 (Future)

7 Parameter Parameter Actual RPM Actual Flow Acknowledge Read Valve Value 1 (Future)

HVC Caused

Fault Warning Valve Read Valve Air Value 2 (Future)

9 Bell Underspread Turbine Drive Parameter Actual Bearing Actual Flow Warning Valve Read Valve Air Value 2 (Future)

10 Loss of Feedback Turbine Drive Parameter Actual Bearing Actual Flow Fault Valve Read Valve Air Value 2 (Future)

11 Turbine Drive Parameter Actual Bearing Actual Flow Valve Read Valve Air Value 2 (Future)

12 Low Bearing Air Turbine Drive Parameter Actual Bearing Actual Flow Fault Valve Read Valve Air Value 2 (Future)

13 Not In Turbine Drive Parameter Actual Bearing Actual Flow

14 User Turbine Drive Parameter Actual Bearing Actual Flow Input #1 Valve Read Valve Air Value 2 (Future)

15 User Turbine Drive Parameter Actual Bearing Actual Flow Input #2 Valve Read Valve Air Value 2 (Future)

RUN STATE

Bell Overspread Turbine Drive Parameter Actual Bearing Actual Flow

Valve Read Valve Air Value 2 (Future)

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Atomizer Controller - OPERATION

Output Word 4

Bit 0 - Bell Running

This bit is set when the atomizer control is enabled.

It means that the atomizer controller is actively attempting to control the bell speed.

Bit 1 - Unused

Bit 2 - OK to Start

This bit is set when the system determines that the

voltage values are in a range where it is allowed to start control. Will remain 0 until the MP2e enters the RUN STATE.

Bit 3 - Remote Mode

This bit is set when the front panel switch is set

to remote. When set, an external unit can control

the system.

Bit 4 - Unused

Bit 5 - Warning

This bit is set whenever an Atomizer warning is in

effect.

Bit 6 - Fault

This bit is set whenever an Atomizer fault is in

effect (see “Fault Descriptions” in “Troubleshooting Guide” in the “Maintenance” section).

Bits 7 - Unused

Bits 8 - HVC Caused Fault

This bit indicates that an HVC Fault caused the

Atomizer to stop.

Bits (9-12) - Unused

Bit 13 - Not in RUN STATE

MP2e is not in RUN STATE. Provides a positive

indication from a BOOTING STATE to the RUN STATE. Allows remote detection of an MP2e being inadvertently left in Local mode after power is cycled.

Bits (14 & 15) - User Inputs #1 and #2

These bits give an integrator the ability to read two

discrete inputs, which can be used by their external

control system.

Bit 1 - Bell Underspeed Warning

This bit is set when the Atomizer detects

an underspeed condition as described in the “Automatic Shutdown” section.

Bit 2 - Loss of Feedback Warning

This bit is set when the Atomizer detects a loss of

feedback condition as described in the “Automatic Shutdown” section.

Bit 3 - Speed Out of Tolerance Warning

This bit is set when the Atomizer detects a speed out

of tolerance condition as described in the “Automatic Shutdown” section.

Bits (4-5) - Unused

Bit 6 - Atomizer Communication Fault

The system has detected a communication failure after an Ethernet/IP connection was initiated.

Bit 7 - Unused

Bit 8 - Bell Overspeed Fault

This bit is set when the Atomizer faults due to an

overspeed condition as described in the “Automatic Shutdown” section.

Bit 9 - Bell Underspeed Fault

This bit is set when the Atomizer faults due to

an underspeed condition as described in the “Automatic Shutdown” section.

Bit 10 - Loss of Feedback Fault

This bit is set when the Atomizer faults

a loss of feedback condition as described in the “Automatic Shutdown” section.

due to

Bit 11 - Unused

Bit 12 - Low Bearing Air Fault

This bit is set when the Atomizer faults due to a

low bearing air pressure condition as described in the “Automatic Shutdown” section.

Bit (13 -15) Unused

Output Word 6

Bits (0-6) - Parameter Read Code

Output Word 5

Bit 0 - Bell Overspeed Warning

This bit is set when the Atomizer detects an

overspeed condition as described in the “Automatic Shutdown” section.

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This 7 bit value tells the system which parameter

is being displayed.

Bit 7 - Parameter Acknowledge

When this bit changes from cleared to set a new

Parameter Value is being displayed. It is cleared when the Parameter Read Strobe and Parameter Write Strobe are both cleared.

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Atomizer Controller - OPERATION

Bits (8-15) - Turbine Drive Value

This byte (8 bit) value displays the air pressure

applied to the Atomizer turbine. If this value is monitored for each speed and paint combination, it can be used as an indicator of correct operation or a potential problem.

Output Word 7

Bits (0-15) - Parameter Read Value

This 16 bit value tells the system which parameter

is being displayed.

Output Word 8

Bits (0-7) - Actual RPM Value

The byte (8 bit) value displays the latest turbine

speed in 1000 RPM.

Bits (8-15) - Actual Bearing Air Value

This byte (8 bit) value displays the latest bearing

air pressure reading.

Parameter Select = 3: Input Mode

READ — returns bit values of 0-127 WRITE — sets bit values of 0-127 See Table 13 for bit details

See table for corresponding jumpers

TABLE 15

Bit

0 1) Bearing Air Feedback

1 2) Bell Speed Setpoint

2 3) Paint Flow Rate 1 Setpoint

3 4) Paint Flow Rate 2 Setpoint

4 5) Shaping Air 1 Setpoint

5 6) Shaping Air 2 Setpoint

7 7) (unassigned)

A “0” bit = Voltage Mode (0-10V) A “1” bit = Current Mode (4-20mA)

Parameter Select = 4: Min Bearing Air

READ — returns value 0—100 WRITE — is not supported

Analog Input

Output Word 9

Bits (0-7) - Actual Flow #1 Value

In the future this byte (8 bit) value will be used to

display the latest measurement of ow rate #1.

Bits (8-15) - Actual Flow #2 Value

In the future this byte (8 bit) value will be used to

display the latest measurement of ow rate #2.

Parameter Select Codes

Parameter Select = 1: Atom Enabled

READ — returns value 0=Disabled 1= Enabled WRITE — is not supported

Parameter Select = 2: Atom Type

READ — returns value 0= RMA300-500 1= AeroBell 2= AeroBell33 3= RMA100-200 4= TurboDisk 5= Auto Gun 6= RMA303-SBA 7= RMA550 WRITE — is not supported.

Parameter Select = 5: Unilink Mode

READ — returns value 0 = Disabled 1 = Enabled WRITE — is not supported

Parameter Select = 6: Unilink Gun Sel

READ — returns value 0 = Bell 1 = Gun WRITE — sets value 0 = Bell 1 = Gun

Hardware Signals

TABLE 16

J14

J14-1 1—Bearing Air Feedback JMP15

J14-3 2—Bell Speed Setpoint JMP14

J14-5 3—Paint Flow Rate 1 Setpoint JMP13

J14-7 4—Paint Flow Rate 2 Setpoint JMP12

J14-9 5—Shaping Air 1 Setpoint JMP11

J14-11 6—Shaping Air 2 Setpoint JMP10

J14-13 7—(unassigned) JMP9

even pins

Analog Input Jumper setting: Pins 1-2 = Voltage Mode (0-10V) Pins 2-3 = Current Mode (4-20mA)

Ground

Analog Inputs

V-I Select

Jumper

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Atomizer Controller - OPERATION

TABLE 17

Bit

J5-1 1—Bell Spin Enable

J5-3 2—Paint Trigger 1

J5-5 3—Paint Trigger 2

J5-7 4—Dump 1

J5-9 5—Dump 2

J5-11 6—Fluid Override 1

J5-13 7—Fluid Override 2

J5-15 8—Bell Cup Wash

J5-17 9—(unassigned)

J5-19 10—Unilink Gun Select

J5-21 11—User Input #1

J5-23 12—User Input #2

J5-2, 4, 6, 8, 10, 12 , 14, 16, 18, Ground

20, 22, 24

Digital Input

NOTE

 Digital Input 10 (Unilink Gun Select) is only active when Unilink Mode is enabled and the Ethernet/IP interface is disabled.

TABLE 18

J4-1 1—Bell Drive JMP1

J4-3 2—Bell Speed Read Out JMP2

J4-5 3—Paint Flow Rate 1 JMP3

J4-7 4—Paint Flow Rate 2 JMP4

J4-9 5—Shaping Air 1 JMP5

J4-11 6—Shaping Air 2 JMP5

J4-13 7—(future) JMP7

J4-15 8—(future) JMP8

even pins Ground

J4-17, J4-18

Analog Output Jumper setting: Pins 1-2 = Voltage Mode (0-10V) Pins 2-3 = Current Mode (4-20mA)

(N.C.)

Analog Outputs

V-I Select

Jumper

NOTE

 Current mode output requires the installation of an op-

tional 4-20 mA converter: Ransburg part number A13248-00.

 Location of the jumpers and I/O connectors referred

to in tables 16, 17, 18 & 19 can be found in Figure 56 in

the Appendix.

TABLE 19

J1-1 1—Brake

J1-3 2—Paint Trigger 1

J1-5 3—Paint Trigger 2

J1-7 4—Dump 1

J1-9 5—Dump 2

J1-11 6—Fluid Override 1

J1-13 7—Fluid Override 2

J1-15 8—Bell Cup Wash

J1-17 9—Overspeed Warning/Fault

J1-19 10—Underspeed Warning/Fault

J1-21 11—Loss of Bell Feed Back Warning/Fault

J1-23 12—Low Bearing Air Warning/Fault

J1-25 13—Speed Out of Tolerance Warning

J1-27 14—(unassigned)

J1-29 15—(unassigned)

J1-31 16—HV On

J1-33 17—User Output #1

J1-35 18—User Output #2

J1-2, 4, 6, 8, 10, 12 , 14, 16, 18, 20, 22, 24, Ground 26, 28, 30, 32, 34, 36

Digital Output

NOTE

 Digital Outputs 9 to 13 (Atomizer Fault signals) are only active when Ethernet/IP is disabled, i.e. when operating in Discrete mode.

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Page 58

Discrete IO Controller

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Discrete IO Controller - INTRODUCTION

DISCRETE IO CONTROLLER GENERAL DESCRIPTION

The Discrete IO Controller, for use with the MicroPak 2e Controller, is designed to provide a universal I/O interface for high voltage controller functions. It is intended to be used in installations which do not support the standard MicroPak 2e Ethernet/IP control interface.

NOTE

 When the Discrete IO option is ordered and enabled by the factory, this indicates the user intends to use physically wired I/O signals to control the system. Therefore the software will disable the ability for the user to enable the Ethernet IP functionality.

Figure 54: MicroPak 2e Multi I/O Board

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: 2” tall X 7.5” X 4.75” (5.1cm x 19.1 x 12.1cm)

Mounting: Figure 48 in Appendix

Environmental Requirements

Power Required:

J15 - Controller : 24V DC @ 0.25 Amps

Note: 24V DC power supply must be regulated and have over current and over voltage protection.

Electrical - Communication Requirements

Control and Reporting: Ethernet to the MicroPak 2e, port J8 or J9

Note: A unique MAC address is hard coded into each Discrete IO Controller.

(Continued on next page)

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Discrete IO Controller - INTRODUCTION

SPECIFICATIONS (At Sea-Level Conditions)

Electrical - Controls in Local Mode

Analog In: (0-10V or 4-20mA) (None Active)

Analog Out: (0-10V or 4-20mA with option) HV Output Level, Current Output Level

Discrete In: (0-24V) (None Active)

Discrete Out: (0-24V, Current Sourcing) HV Ready, HV On, Current Fault, dx/dt Fault, V/I Feedback Fault,

Local, Alarm Out, Interlock Fault

NOTE:

Electrical - Controls in Remote Discrete Mode

Analog In: (0-10V or 4-20mA), HV Setpoint, Over Current Setpoint, dx/dt Sensitivity

Analog Out: (0-10V or 4-20mA with option), HV Output Level, Current Output Level

Discrete In: (0-24V),

Part in position, HV On (Latching)

Discrete Out: (0-24V, Current Sourcing), HV Ready, HV On, Current Fault, dx/dt Fault,

V/I Feedback Fault, Local, Alarm Out, Interlock Fault

In Local Mode, the functions of the Analog and Discrete input signals are performed by the Front Panel user interface.

HV Enable (On), HV Disable (Off) / Fault Reset, dx/dt Disable,

CONFIGURATION PARAMETERS AND SETTINGS

TABLE 20

Parameter

DISCRETE MIO Settings

Disc Analog Inputs System

Discrete MIO Cong

Password Level

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Discrete IO Controller - OPERATION

The Discrete IO Controller supports two operating modes.

Remote Discrete Control

Remote control mode is activated when the front panel Local/Remote switch is set to the Remote position. In this mode, the Discrete IO controller’s inputs are used to control the operation of the HV controller.

Local Front Panel Control

This mode is activated whenever the front panel Local/ Remote switch of the MicroPak 2e Controller is set to Local. In this mode, the MicroPak 2e HV controller is operated from the front panel controls.

Control Input Scaling

The scaling of the analog control inputs is determined by

the conguration of the MP2e.

Analog Inputs in Voltage Control Mode

High Voltage Setpoint: 0-100 KV OverCurrent Setpoint: 0-1000 µA (RP1000) 0-250 µA (nonRP1000) di/dt Sensitivity: 0-60 µA/100 msec

Hardware Signals

TABLE 21

J14

J14-1 1 — High Voltage Setpoint JMP15

J14-3 2 — Over Current Setpoint JMP14

J14-5 3 — dx/dt sensitivity percentage,

0% (insensitive) to 100% JMP13 (very sensitive)

J14-7 4 — Unassigned) JMP12

J14-9 5 — Unassigned) JMP11

J14-11 6 — Unassigned) JMP10

J14-13 7 — unassigned) JMP9

even pins Ground

Analog Input Jumper setting: Pins 1-2 = Voltage Mode (0-10V) Pins 2-3 = Current Mode (4-20mA)

Analog Inputs

V-I Select

Jumper

Analog Outputs

HV Output Level: 0-100 KV Current Output Level: 0-1000 µA (RP1000) 0-250 µA (nonRP1000)

TABLE 22

J5-1 1 — HV Enable (On)

J5-3 2 — HV Disable (Off)

J5-5 3 — dx/dt Disable pulled

high == enabled

J5-7 4 — Part in Position (Future)

J5-9 5 — HV On (Latching)

J5-11 6 — (Unassigned)

J5-13 7 — (Unassigned)

J5-15 8 — (Unassigned)

J5-17 9 — (unassigned)

J5-19 10 — (Unassigned)

J5-21 11 — (Unassigned)

J5-23 12 — (Unassigned)

J5-2, 4, 6, 8, 10, 12 , 14, 16, 18, Ground

20, 22, 24

Digital Inputs

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Discrete IO Controller - OPERATION

DISCRETE I/O CONTROLLER LOGIC RELATING TO INPUTS ON CONNECTOR J5

(Refer to signals in Table 22)

Priority of inputs affecting the enabling of HV output

Starting with software version V1.1.03, the Discrete I/O

controller software has been modied to include logic to

prioritize these input signals.

• Front panel switch for local/remote has highest priority

• Changing the state of the switch will :

• Disable HV_Output_Enabled (if active)

• NOT affect any interlock faults

• Change which reset input signals are enabled for clearing faults (local or remote)

• In “Remote Mode” (with Ethernet/IP disabled and DIO present and enabled):

• HV_Disable (DIO.J5-3) has next highest priority.

While active it will:

• Override any interlock faults and put system into STPD mode

• Interlock faults will automatically retrigger if still asserted when HV_Disable clears

• Override the HV_On signal enabling of HV_Output_ Enabled and put system into STPD mode

• HV_ON will NOT automatically retrigger

• Reset/Override HV_On_Latching enabling of HV_ Output_Enabled and put system into STPD mode

• HV_On_Latching will NOT automatically retrigger

• Interlock input signals (see HV Controller) have the next

highest priority. When active they will:

• Override the HV_On signal enabling of HV_Output_ Enabled and put system in FALT mode

• HV_ON will NOT automatically retrigger

• Reset/Override HV_On_Latching enabling of HV_ Output_Enabled and put system in FALT mode

• HV_On_Latching will NOT automatically retrigger

• HV_On (DIO.J5-1) has the next highest priority.

• On its rising edge going active, it will enable HV_ Output_Enabled and put system in RUN mode

• On its falling edge going inactive, it will disable HV_ Output_Enabled and put system in STPD mode

• HV_On_Latching (DIO.J5-9) has the lowest priority.

• On its rising edge going active, it will enable HV_ Output_Enabled and put system in RUN mode.

• This signal will have no further affect until the next

rising edge transition.

J4-1 1—HV Output Level JMP1 J4-3 2—(Unassigned) JMP2 J4-5 3—(Unassigned) JMP3 J4-7 4—Current Output Level JMP4 J4-9 5—(Unassigned) JMP5 J4-11 6—(Unassigned) JMP5 J4-13 7—(Unassigned) JMP7 J4-15 8—(Unassigned) JMP8 even pins Ground J4-17, J4-18

TABLE 23

(N.C.)

Analog Output Jumper setting: Pins 1-2 = Voltage Mode (0-10V) Pins 2-3 = Current Mode (4-20mA)

Analog Outputs

NOTE

 Current mode output requires the installation of an optional 4-20 mA converter: Ransburg part number A13248-00.

 Location of the jumpers and I/O connectors referred to in tables 21, 22, 23 & 24 can be found in

Figure 56 in the Appendix.

TABLE 24

J1-1 1—HV Ready J1-3 2—HV On J1-5 3—Current Fault

J1-7 4—dx/dt Fault

J1-9 5—V/I Feedback Fault J1-11 6—Local J1-13 7—Alarm Out J1-15 8—Interlock Fault J1-17 9—(Unassigned) J1-19 10—(Unassigned) J1-21 11—(Unassigned) J1-23 12—(Unassigned) J1-25 13—(Unassigned) J1-27 14—(unassigned) J1-29 15—(unassigned) J1-31 16—(Unassigned) J1-33 17—(Unassigned) J1-35 18—(Unassigned) Even Pins Ground

Digital Output

V-I Select

Jumper

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INTEGRATION NOTES

MicroPak 2e Controls - INTEGRATION NOTES

GUIDELINES

Controller DIP Switch Settings

Each of the MP2e boards have DIP switches. These are

congured at the factory and should be left as received.

The following information is included to support servicing.

Both the High Voltage Control Processor and the Display and Communications Processor boards have a 2 position dip switch labeled S1. Switch 1 is not currently used and switch 2 which is for factory use only, should remain in the CLOSED position for normal operation.

Likewise, the MicroPak 2e Multifunction I/O Boards (Atomizer and Discrete IO Controllers) contain a 6 position

dip switch labeled S1. The rst four switch positions are

used to determine the I/O function of the Multi I/O Board. For the Atomizer board, switches 1, 3 & 4 must be CLOSED and switch 2 must be OPEN. For the Discrete IO board, switches 1, 2 & 3 must be CLOSED and switch 4 must be OPEN. On both boards, switch 5 is not currently used and switch 6, which is for factory use only, should remain in the CLOSED position for normal operation.

Connecting MIO / DIO Controllers

When an Atomizer Controller or a Discrete IO Controller is used with a MicroPak2e. the Controller’s Multi-Function IO Board(s) must be connected to the MP2e HVCP board via Cat 5 Ethernet cabling. When a single add-on controller is present, the cable should run from J8 or J9 of the add-on controller to J17 or J18 of the MP2e HVCP Controller board. When more than one add-on controller is used, the second and subsequent controllers should be connected to the remaining open port (J8 or J9) of the preceding controller. This use of a daisy chain connection is acceptable, since all the MicroPak 2e boards use a 3 port Ethernet Switch

to implement external Ethernet connections.

Discrete IO Characteristics

Both the MP2e Interlock Inputs and the MIO Discrete Inputs are implemented as a resistor divider followed by a

lter capacitor, feeding into a Schmidt trigger. This input conguration requires that the applied input voltage (0-24V)

is referenced to the 24V ground of the controller.

The MIO Discrete Outputs are implemented using IC drivers which source current from the 24VDC controller power. The

current draw on these outputs should not exceed 250 mA.

Atomizer Operation

When deciding how to control an atomizer, there are several important issues to consider.

1. The atomizer must not be run without an adequate supply of bearing air.

2. The ow of paint must be interlocked with the atomizer’s rotation. That is, paint must not ow if the atomizer is not rotating. Failure to stop the ow of paint will result in “ooding” which can destroy an atomizer.

The ow of paint must be interlocked with the fault state of the HV controller. That is, paint must not ow if the HV

controller is faulted. Failure to observe this could increase

the risk of res.

4. The ow of solvent must be interlocked with the

atomizer’s rotation and also with the high voltage control.

Compliance with item 1 is built into the Atomizer Controller and requires user action to defeat. The user is responsible for the effects of defeating this operational interlock.

Compliance with items 2 and 3 is easily achieved by using the Paint Trigger outputs of the Atomizer Controller. The controller has been programmed to interlock these outputs with the atomizer’s rotation and the lack of a HV controller fault, thereby freeing the user from adding additional control logic to meet these requirement. This behavior is included in all input modes.

Compliance with item 4 is also easily achieved by using the Wash output (Bell Cup/Disk/Gun) of the Atomizer Controller. The controller has been programmed to interlock this output with the high voltage controller, so that if high voltage controller is enabled, the Bell Cup Wash output will not activate. This will prevent solvent from being dispensed when high voltage is present.

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CAUTION

INTEGRATION NOTES

• Monitor the Ethernet/IP control network to conrm it

remains isolated.

 Failure to interlock the flow of paint with atom-

izer rotation may cause damage to the atomizer.

Atomizer Interlock Behavior

To help implement a safer paint booth, the High Voltage controller has been programmed to provide the state of the interlocks to the Atomizer controller with each update packet. This enables the Atomizer Controller to perform a forced stop, using the air brake, if an interlock opens while the atomizer is in motion. In addition, the atomizer controller will also immediately disable the paint and solvent outputs.

Atomizer - MP2e Power Cycling

When the MP2e power is cycled quickly using the front panel switch (i.e. OFF for less than 3 seconds), an Atomizer fault

may occur. This is because the Atomizer Controller executes

a reboot operation every time a failure of the RansNet communications link is detected. This behavior ensures

the Atomizer Controller always has current conguration

data from the MP2e.

Ethernet/IP Networking

It is important to use a suitably congured network for Ethernet/

IP communications. Ransburg’s recommendations follow:

• Use a private switched LAN for an Ethernet/IP control network.

•

If remote monitoring from the plant LAN is necessary, use

a managed gateway to limit access to the private LAN.

For further guidance refer to ODVA document: Network

Infrastructure for Ethernet/IPTM, Publication Number:

PUB00035R0.

Ethernet/IP TCP Conguration

The present implementation of TCP Conguration through

Ethernet/IP, requires that the MicroPak 2e does not have another active Ethernet/IP connection when the TCP

Conguration message exchange occurs. This means that if a PC is being used to set the TCP conguration, there

must not be a PLC or robot link to the MicroPak 2e (i.e. the Fault Menu Screen must show “eip” in lower case).

Ethernet/IP Monitoring of MP2e Faults

When programming the controlling PLC to detect faults the user should always:

• Use bit 6 of output word zero to detect a Voltage

Controller fault.

• Use bit 6 of output word four to detect an Atomizer

Controller fault.

The bits contained in output words zero, one, four and ve

are provided to aid fault isolation. These bits should not be relied on for fault detection, since it is not guaranteed that a fault will always set an isolating bit.

•

For large installations the use of a switch which supports IGMP Snooping is recommended. These switches can

direct multicast trafc to only the multicast group members

instead of broadcasting it to all connected ports.

• Do not allow Internet access from the Ethernet/IP control network.

NOTE

 The MicroPak 2e does not support

communications.

 Many PLCs and robots make use of multicast communications to minimize packet transmissions. Low cost Ethernet switches treat these as broadcasts and send these messages to all connected devices. This can present a substantial processing load for devices which are not group members.

multicast

Sending Ethernt/IP Remote Commands

Sending commands to the MP2e while it is starting up and has not yet entered RUN STATE should be avoided as it

may result in unexpected behavior.

Starting with V1.1.02, any incoming Ethernet/IP commands will be ignored until the MP2e has entered RUN STATE. The MP2e now provides Ethernet/IP Outputs (Word 0, Bit 13 and Word 4, Bit 13) which will be set (“1”) when the MP2e is not in RUN STATE.

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INTEGRATION NOTES

HIGH VOLTAGE CONTROLLER LOGIC RELATING TO INPUTS ON CONNECTOR J5

(Interlocks and Remote signals)

Starting with software version V1.1.07, the High Voltage

Controller software has been modied to include logic to

prioritize these input signals.

Input signals on HVC Connector J5 (Table 5)

• J5-7/8 (+/-) Door Interlock

• CAN BE disabled (Ignored)

• J5-9/10 (+/-) Booth Air Interlock / HV_Reset

• CAN BE disabled (Ignored)

• CAN BE congured as Booth Air Interlock

• CAN BE congured as HV_Reset signal

• NOT available if Ethernet/IP enabled

• NOT available if DIO enabled

• Only active in REMOTE operation

• Only means to Clear Faults in REMOTE operation

• J5-11/12 (+/-) Misc Interlock / Trigger (HV_On)

• CAN BE disabled (Ignored)

• CAN BE congured as Misc. Interlock

• CAN BE congured as Trigger (HV_On) signal

• NOT available if Ethernet/IP enabled

• NOT available if DIO enabled

• Only active in REMOTE operation

• Requires use of KV_Setpoint input signal for setting KV output level (no input signal will result in a KV Setpoint of 0KV)

• J5-13/14 (+/-) Remote Stop

• ALWAYS active

• J5–15/16 (+/Gnd) KV Setpoint

• NOT available if Ethernet/IP enabled

• NOT available if DIO enabled

• Only active in REMOTE operation

NOTE

 Currently there is NO standard SBC conguration which routes this signal pair outside of the SBC enclosure.

 Currently there are 4 pairs of unassigned pins on the SBC Interlock connector.

Priority of inputs affecting the enabling of HV output

• Front panel switch for local/remote has highest priority

• Changing the state of the switch will :

• Disable HV_Output_Enabled (if active)

• NOT affect any interlock faults

• Change which reset input signals are enabled for clearing faults (local or remote)

• In “Remote Mode” (with Ethernet/IP and DIO disabled):

• Any enabled and active Interlocks have next

highest priority

• HV_Reset (HVC.J5-9) is ignored

• HV_On_Trigger (HVC.J5-11) is ignored

• System is in FALT mode

• HV_Output is Off

• HV_Reset (HVC.J5-9) has the next highest priority

While active it will:

• Override the HV_On_Trigger signal enabling of HV_ Output_Enabled and put system into STPD mode

• HV_On_Trigger will NOT automatically retrigger

• HV_On_Trigger (HVC.J5-11) has the lowest priority

• On its rising edge going active, it will enable HV_ Output_Enabled and puts system in RUN mode

•

On its falling edge going inactive, HV_Output_ Enabled will remain active until HV_Reset becomes active

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MAINTENANCE

WARNING

 Before troubleshooting gun and control unit

problems, ush the gun with solvent and purge with

air. Some of the tests will require high voltage to be applied to the gun, so the gun must be empty of paint and solvent.

TROUBLESHOOTING GUIDE

Fault Descritpion Solution

MAINTENANCE

Cable Fault (CF)

The Cable Fault indicates the control unit does not detect a high voltage section on the end of the cable. The fault typically occurs at a high voltage trigger.

1. Check for loose wiring between the pc board connector and the high voltage section by pulling on each wire. Repair if necessary. Ensure both connectors are secure and re-test for CF fault.

2. Replace high voltage section or send unit in for repair.

3. Send unit in for repair.

4. Low Voltage cable interface, poor or no connection.

5. No Low Voltage cable.

NOTE

 When the system is congured as “CabinetType = ControlPak”, there is a front panel menu option for “FluidInterlock”. When “FluidInterlock” is set to “Disabled”, that will turn off Atomizer checking for faults and warnings.

TROUBLESHOOTING GUIDE - Fault / Warn

General Problem Fault Report Explanation

Atom Faults

No Fault

Bell Overspeed

Bell Underspeed

Loss of Feedback

Low Bearing Air

RansNet CommLost

Faulted by HVC

Interlock

No Fault was detected.

The bell speed feedback indicated the bell exceeded the setpoint. *

The bell speed feedback indicated the bell was below the setpoint. *

The ber optic speed feedback signal was not detected. *

The bearing air monitor indicated the pressure was too low. *

The Ethernet communications between the HVC and speed controller were interrupted.

The speed controller has been stopped due to an HVC fault.

The Atomizer controller has detected an open interlock. *

Atom Warns

* For further information, see “Automatic Shutdown” in the section of this manual on Operation of the Atomizer.

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Speed Out of Tol

Speed is not within +/- 5% of setpoint. *

(Continued On Next Page)

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TROUBLESHOOTING GUIDE - Fault / Warn (Cont.)

MAINTENANCE

General Problem Explanation

HVC Faults

Fault Report

No Fault

Over Current

MAX KV

Min Output

kV Limit

DVDT

DIDT

Cascade Feedback

Voltage Cable

Current Cable

KV Low

Communications

No Fault was detected.

The current value has exceeded the I Limit Hi or the Max System Limit.

The system has raised the Variable Voltage Output to the system

maximum, but could not reach the setpoint.

The system has lowered the Variable Voltage Output to zero and still is above the setpoint.

The system has exceeded the kV Limit Hi or the Max System Limit.

The system has detected a dv/dt event.

The system has detected a di/dt event.

The current or voltage feedback from the cascade is out of range.

The system has detected a loss of the High Voltage Feedback signal from a Consolidated cascade.

The system has detected a loss of the Current Feedback signal from a Consolidated cascade.

The system has fallen below kV Lo Limit while operating in Current Mode.

The system has detected an Ethernet/IP communication failure. Possible causes are:

• Receipt of a reset command when no fault was active.

• Receipt of an invalid high voltage controller parameter value.

• Receipt of an invalid atomizer parameter value, Atomizer Fault LED will also be lit

HVC Warns

FLT’d by Atom

Comm Timeout

System Mode

Interlock

Remote Stop

HVC WDog Reset

DSP WDog Reset

HV Power Off

Over Current

Over Voltage

Under Voltage

Max Output

KV High Limit

An atomizer fault has caused the high voltage controller to stop.

Either the MP2e or the “originating” Ethernet/IP controller failed to receive a message for three update intervals, so the connection was dropped.

The control software detected an invalid state.

One of the enabled interlock input circuits was broken, i.e. the circuit was opened.

The Remote Stop input circuit was opened.

The high voltage control processor board was reset by the WatchDog Timer.

The display processor board was reset by the WatchDog Timer.

External power was removed from the cascade power input—J4.

The current level is within 10% of Max µA Limit.

The voltage level is within 10% of KV High Limit (current mode only).

The voltage level is within 10% of KV Low Limit (current mode only).

Vct is maximum and the kV setpoint has not been reached.

The voltage level (kV) is within 10% of kV Maximum, i.e. 110 kV.

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PARTS IDENTIFICATION

MICROPAK 2e HIGH VOLTAGE CONTROLLER - PARTS LIST

Part No. Description

A13338-XXXXXXXX MicroPak 2e HV & Atomizer Controller For replacement use, the user should order the same model number (-XXXXXXXX) listed on the original invoice.

A13245-X1 MicroPak 2e Multi-Function Board, “X” indicates quantity of A13248-00 boards included

A13248-00 MicroPak 2e Analog Output, 4-20mA add-on board

A11111-00 Volume Booster, 1:1

78643-00 E/P Transducer, High Speed, High Flow, DIN Rail Mount, 0-10V : 0-100PSI

A11485-01 Pneumatic Solenoid, minimum 4mm bore, 0-120 PSI

A13596 Pressure Transducer, 0-100 PSI : 0-10V

A13245-X8 MicroPak 2e Multi-Function Board, Discrete I/O conguration. “X” indicates

quantity of A13248-00 boards included.

* NOTE: All nozzles available in kits of 3.

LN-9624-00-R3 (05/2018) 68 / 74 www.carlisleft.com

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APPENDIX

.139

(4.83mm)

4.540

(115.3mm)

8.160

(207.3mm)

APPENDIX

.139

(4.83mm)

.167

(4.24mm)

Ø.112

(2.84mm)

#4-40 Tapped Hole

2.609

(66.27mm)

2.609

(66.27mm)

Figure 55: MicroPak 2e Controller Panel Mount Layout

2.609

(66.27mm)

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4.7500

APPENDIX

3.425

[87.00]

7.100

[180.34]

3.675

[93.35]

7.100

[180.34]

4.350

[110.49]

Figure 56: MicroPak 2e Controller/Multi-Function IO Layout

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APPENDIX

INITIALIZATION SCREENS

On receipt from the factory, all MP2e units delivered with Software Version 1.1.00 and above will display the following 11 initialization screens. These screens must be stepped though and the requested parameters set before the MP2e will operate.

If the user is unfamiliar with operation of the MP2e front panel, it is suggested he read the section titled MENUS AND OPERATIONS before proceeding with the following initialization steps.

Figure 57, shown below, informs the user that the Initialization sequence is active and the SCREEN pushbutton should be used to advance through the screens shown on the right hand ATOMIZER display. Figures 58-67 will display

a ashing S in the lower right corner to indicate the user

has System privilege and that the ATOMIZER screen menu is active.

HIGH VOLTAGE

ATOMIZER

For Solventborne Aps a reasonable initial Over Current Limit setting is 30 uA. S

Figure 60: Init Menu Screen 4 (Right)

Figures 59 - 60 above, inform the user of the need to

set application specic values for three parameters which

help assure safe operation.

ATOMIZER

Set OverCurrent Limit now. Max uA Limit OOOO S

*Initialization of * * MP2e Parameters * Use SCREEN Button to move to next display

Figure 57: Init Menu Screen 1 (Left)

ATOMIZER

Three application dependent HV params must be set before the MP2e can be useS

Figure 58: Init Menu Screen 2 (Right)

ATOMIZER

The parameters are: Over Current Limit Di/Dt Enable/Disable & Di/Dt SensitivityS

Figure 61: Init Menu Screen 5 (Right)

Figure 61 above, requires the user to set the Over Current Limit. This is done as follows:

• Press SET to change the value .

• Press Rt ARROW to ‘select’ Digit .

• Press SET to begin digit by digit entry.

• Use Up/Dn ARROWS followed by SET to enter the new value, one digit at a time.

• Press Rt ARROW to ‘select’ Save .

• Press SET to return to the menu of Fig 61.

NOTE

 The menu in Fig 61 cannot be exited until a

non-zero value has been set.

ATOMIZER

If Di/Dt protection is needed, it must be enabled by the user. S

Figure 59: Init Menu Screen 3 (Right)

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Figure 62: Init Menu Screen 6 (Right)

Page 72

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APPENDIX

ATOMIZER

If Di/Dt is enabled Di/Dt Sensitivity should be set to a non-zero value. S

Figure 63: Init Menu Screen 7 (Right)

ATOMIZER

For safe operation Di/Dt Sensitivity should be set to the lowest value posiblS

Figure 64: Init Menu Screen 8 (Right)

ATOMIZER

*** NOTE ***

ATOMIZER

Congure DiDt mode

and Sensitivity now:

DiDt Mode Ena OO S

Figure 66: Init Menu Screen 10 (Right)

Figure 66 above, allows the user to set the Di/Dt Mode and Di/Dt Sensitivity. The factory default setting enables Di/Dt at

the maximum sensitivity (0). If the users application allows

using Di/Dt, the Mode can be left as is and only the sensitivity changed. Di/DT Sensitivity can be changed as follows:

• Press Rt ARROW to ‘select’ 00 .

• Press SET to change the 00 .

• Press Rt ARROW to ‘select’ Digi .

• Press SET to begin digit by digit entry.

• Use Up/Dn ARROWS followed by SET to enter the new value, one digit at a time.

• Press Rt ARROW to ‘select’ Save .

• Press SET to return to the menu of Fig 66.

• Press SCREEN to advance to Fig 67.

Di/Dt Sensitivity is spec

ified

in units

of uA/1OO millisecnS

Figure 65: Init Menu Screen 9 (Right)

Figures 62 - 65 above, inform the user of the need to set

application specic values for Di/Dt operation.

NOTE

 If Di/Dt is enabled with Sensitivity = 0, the control-

ler will probably generate continuous faults.

ATOMIZER

MP2e INITIALIZATION

-- FINISHED -Press SET to enter CONFIGURATION S

Figure 67: Init Menu Screen 11 (Right)

Figure 67 above, informs the user they will next enter the Conguration Menus described in the Operations section

of this manual.

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MANUAL CHANGE SUMMARY

LN-9624-00-R3 - Replaces LN-9624-00.2 with the folowing changes:

MANUAL CHANGES

No.

1. Update manual to new design All Pages

2. Format Manual to show three contorollers; HV, Atomizer, and Discrete I/O All Pages

3. Update “SPECIFICATIONS” 12-13

4. Change the range on the second screen (Figure 3), update ﬁgure numbers and add “User Password Menu” from pg 27 13

5. Insert “Software Mismatch Fault” section 23

6. Insert NOTE after ﬁgure 14b. 24

7. Add “Software Version Menu” text between ﬁgures 23 and 24 and update ﬁgure numbers 26

8. Move “Atomizer Shape Air Menu” to pg 49, “Atomizer Fluid Maintenance Menu” to pg 50 and update ﬁgure numbers 27

9. Change ﬁgure 29 to ﬁgure 28 28

10. Delete “Remote Option Conﬁguration Settings” section and update ﬁgure numbers 29

11. Update ﬁgure numbers 30-31

12. Update ﬁgure numbers 33

13. Update ﬁgure numbers and realign arrows in the screens 34-35

14. Replace text in second “NOTE” and add TABLE 6 with “DIAGNOSTICS MENU” section from page 31 32

15. Add new “NOTE” 36

16. Update copy for Bits 9 and 10 41

17. Update ﬁgure number 44-48

18. Update ﬁgure numbers and add “Atomizer Shape Air Menu” text from page 27 49

19. Update ﬁgure numbers and add “Atomizer Fluid Maintenance Menu” text from page 27 50

20. Update ﬁgure number to 54 59

21. Correct spacing and add line to Parameter Select = 2 56

22. Add title “CONFIGURATION PARAMETERS AND SETTINGS” and renumber table number to 20 60

23. Update copy for both tables 21 and 22 61

24. Add “High Voltage Controller Logic” section 65

25. Update ﬁgure numbers 69-72

Change Description

Page(s)

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WARRANTY POLICY

This product is covered by Carlisle Fluid Technologies materials and workmanship limited warranty.

The use of any parts or accessories, from a source other than Carlisle Fluid Technologies, will void

all warranties. For specic warranty information please contact Carlisle Fluid Technologies.

Carlisle Fluid Technologies is a global leader in innovative nishing technologies.

Carlisle Fluid Technologies reserves the right to modify equipment specications without prior notice.

DeVilbiss®, Ransburg®, MS®, BGK®, and Binks®,

are registered trademarks of Carlisle Fluid Technologies, Inc.

For technical assistance or to locate an authorized distributor, contact one of our international sales

and customer support locations.

Region

Americas

Europe, Africa

Middle East, India

China

Japan

Australia

Industrial / Automotive

Tel: 1-800-992-4657

Fax: 1-888-246-5732

Tel: +44 (0)1202 571 111

Fax: +44 (0)1202 573 488

Tel: +8621-3373 0108

Fax: +8621-3373 0308

Tel: +81 45 785 6421

Fax: +81 45 785 6517

Tel: +61 (0) 2 8525 7555

Fax: +61 (0) 2 8525 7575

Automotive Renishing

Tel: 1-800-445-3988

Fax: 1-800-445-6643

For the latest information about our products, visit www.carlisleft.com.

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