Ransburg A10406 User Manual
SERVICE MANUAL
LN-9622-00.5
(REPLACES: LN-9622-00.4)
April - 2013
MICROPAK CONTROLLER
Ransburg
EVOLVER
TM
MODEL: A10406
IMPORTANT: Before using this equipment,
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
Service Manual Price: $50.00 (U.S.)
Evolver MicroPak Controller
NOTE: This manual has been changed from LN-9622-00.4 to revision LN-9622-00.5.Reasons for this
change are noted under “Manual Change Summary” page 33 of this manual.
Ransburg
LN-9622-00.5
Ransburg
Evolver MicroPak Controller - Contents
CONTENTS
SAFETY: 1-5
SAFETY PRECAUTIONS ......................................................................................................1
HAZARDS / SAFEGUARDS ..................................................................................................2-5
ATEX: 6-7
EUROPEAN ATEX DIRECTIVE ............................................................................................6-7
INTRODUCTION: 8-9
GENERAL DESCRIPTION ....................................................................................................8
SAFETY FEATURES .............................................................................................................8
DISPLAYS .............................................................................................................................8
SPECIFICATIONS .................................................................................................................8-9
INSTALLATION: 10-18
PAGE
MICROPAK INPUT POWER .................................................................................................10
SAFETY GROUND .................................................................................................................11
LOW VOLTAGE CABLE .........................................................................................................11
INTERLOCKS AND I/O ..........................................................................................................12-13
DESCRIPTION OF TABLE 1 INTERLOCK AND I/O TERMINALS.........................................14-16
DIP SWITCH SUMMARY .......................................................................................................16-17
MICROPAK GROUNDING THEORY .....................................................................................18
OPERATION: 19-21
OPERATOR CONTROL ........................................................................................................19-20
OPERATING PROCEDURES ...............................................................................................20-21
MAINTENANCE: 22-25
TROUBLESHOOTING ..........................................................................................................22
CABLE CONTINUITY TEST ..................................................................................................22
TROUBLESHOOTING GUIDE ..............................................................................................23-24
TABLE 2. OHMETER MEASUREMENTS ..............................................................................25
PARTS IDENTIFICATION: 26-27
EVOLVER MICROPAK CONTROLLER PARTS DIAGRAM / PARTS LIST .......................... 26-27
RECOMMENDED SPARE PARTS ....................................................................................... 27
WARRANTY POLICIES: 28
LIMITED WARRANTY ...........................................................................................................28
APPENDIX: 29-32
PAINT AND SOLVENT SPECIFICATIONS ............................................................................29
VISCOSITY CONVERSION CHART ......................................................................................30-31
VOLUMETRIC CONTENT OF HOSE OR TUBE ...................................................................32
LN-9622-00.5
Evolver MicroPak Controller - Safety
SAFETY
Ransburg
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety literature for your Ransburg products. This manual
contains information that is important for you to
know and understand. This 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.
A NOTE is information relevant to the procedure in progress.
W A R N I N G
!
The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
This manual MUST be read and thor-
oughly understood by ALL personnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGS and safety requirements for
operating and servicing the equipment are
followed. The user should be aware of and
adhere to ALL local building and re codes
and ordinances as well as NFPA-33 SAFETY STANDARD, LATEST EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
!
While this manual lists standard specications
and service procedures, some minor deviations
may be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements,
etc., make such variations inevitable. Compare
this manual with your system installation drawings and appropriate Ransburg equipment manuals to reconcile such differences.
Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efcient operation,
longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system,
contact your local Ransburg representative or
Ransburg.
The hazards shown on the following pag-
es may occur during the normal use of this
equipment. Please read the hazard chart beginning on page 2.
1
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Ransburg
Evolver MicroPak Controller - 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.
When using solvents for cleaning:
• Those used for equipment ushing should
have ash points equal to or higher than
those of the coating material.
• Those used for general cleaning must have
ash points above 100°F (37.8°C).
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 unautho-
rized equipment modications may cause re or
injury.
If used, the key switch bypass is intended for
use only during setup operations. Production
should never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be
set up and operated in accordance with NFPA33, NEC, OSHA, local, country, and European
Health and Safety Norms.
LN-9622-00.5
2
Evolver MicroPak Controller - Safety
Ransburg
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate operation and maintenance proce-
dures will cause a re hazard.
Protection against inadvertent
arcing that is capable of caus-
ing re or explosion is lost if
any safety interlocks are disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2
hazardous areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding section of the equipment manual. Protection against inadvertent arcing that is capable
of causing re or explosion is lost if the current
overload sensitivity is not properly set. Frequent power supply shutdown indicates a problem in the system which requires correction.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no
objects are within the safe sparking distance.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accordance with NFPA-33, EN 50176.
Have re extinguishing equipment readily available and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be
read and understood prior to using this equipment.
Comply with appropriate local, state, and national codes governing ventilation, re protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms
and your insurance company requirements.
3
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Ransburg
Evolver MicroPak Controller - Safety
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The resistance between the part and earth
ground must not exceed 1 meg ohm. (Refer to
NFPA-33.)
Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the
palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray
area, with the exception of those objects required by the process to be at high voltage, must
be grounded. Grounded conductive ooring
must be provided in the spray area.
Always turn off the power supply prior to ushing, cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
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4
Evolver MicroPak Controller - Safety
Ransburg
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 oc-
cur. 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 coat-
ing materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous locations, the power supply, control cabinet,
and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN
50176.
Turn the power supply OFF before working on
the equipment.
Test only in areas free of ammable or combustible material.
Testing may require high voltage to be on, but
only as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Toxic Substances
Spray Area
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Explosion Hazard –
Incompatible Materials
Halogenated hydrocarbon sol-
vents for example: methylene
chloride and 1,1,1,-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 Material 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.
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.
5
LN-9622-00.5
Ransburg
Evolver MicroPak Controller - Atex
EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
The following instructions apply to equipment
covered by certicate number Sira 05ATEX5127X:
1. The equipment may be used with ammable
gases and vapors with apparatus groups II and
with temperature class T6.
2. The equipment is only certied for use in ambient temperatures in the range +12.8°C to +55°C
and should not be used outside this range.
3. Installation shall be carried out by suitably trained
personnel in accordance with the applicable code
of practice e.g. EN 60079-14:
4. Inspection and maintenance of this equipment
shall be carried out by suitably trained personnel
in accordance with the applicable code of practice
e.g. EN 60079-17.
5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19.
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility
of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring that
the type of protection provided by the equipment
is not compromised.
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
Suitable precautions: e.g. regular checks as
part of routine inspections or establishing from
the material's data sheets that it is resistant to
specic chemicals.
Refer to "Specications" in the "Introduction"
section:
a. All uid passages contain stainless steel or
nylon ttings.
b. High voltage cascade is encapsulated with
a solvent resistant epoxy.
6. Putting into service, use, assembling, and
adjustment of the equipment shall be tted by
suitably trained personnel in accordance with the
manufacturer's documentation.
Refer to the "Table of Contents" of this service
manual:
a. Installation
b. Operation
c. Maintenance
d. Parts Identication
7. Components to be incorporated into or used as
replacement parts of the equipment shall be tted
by suitably trained personnel in accordance with
the manufacturer's documentation.
8. The certication of this equipment relies upon
the following materials used in its construction:
9. A recapitulation of the certication marking is
detailed in the "ATEX" section, on the next page,
drawing numbers: A10752, A10754, A10775, and
A10915.
10. The characteristics of the equipment shall
be detailed e.g. electrical, pressure, and voltage
parameters.
The manufacturer should note that, on being
put into service, the equipment must be accompanied by a translation of the instructions
in the language or languages of the country in
which the equipment is to be used and by the
instructions in the original language.
LN-9622-00.5
6
Evolver MicroPak Controller - Atex
Ransburg
MICROPAK A10406 ATEX
PRODUCT MARKING DEFINITIONS
Ex Certicate Number: Sira 05 ATEX 5 127 X
Sira = Notied Body performing EC-type
examination
05 = Year of certication
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
127 = Document serial number
X = Special conditions for safe use apply
Special conditions for safe use: The Evolver 79190,
Series Automatic Atomizers shall only be used
with associated MicroPak A10406 or LECU5004Power Supplies.
Product Marking
II 2 G
31
NOTES
Ex = Specic marking of explosive protection
II = Equipment Group hazardous area characteristics
2 = Equipment Category
G = Type of explosive atmosphere (gases, vapors,
or mists)
EEx 0.24mJ = The MicroPak A10406 Power
Supply is suitable for use in automatic spraying
installations complying with EN 50176 as they
are a Type A class with a discharge energy limit
of 0.24mJ.
7
LN-9622-00.5
Ransburg
INTRODUCTION
Evolver MicroPak Controller - Introduction
GENERAL DESCRIPTION
The Evolver MicroPakTM Controller, is used to
provide voltage to the cascade inside the Evolver
Spray Gun Assembly.
The Evolver MicroPak Controller together with the
Evolver Spray Gun Assembly and it’s Low Voltage
Cable is an “FM” Listed System. It is unique in
that it contains a built-in DC Power Supply and is
capable of operating either 1 or 2 Evolver MicroPak control units.
The MicroPak uses a combination of proven high
voltage generation technology including microprocessor-based control with diagnostic and communication functions. The processor circuitry provides
the maximum in applicator transfer efciency, while
maintaining the maximum safety when used in
conjunction with FM listed applicators.
SAFETY FEATURES
When used with FM listed applicators, the MicroPak provides the ultimate in operational safety.
The microprocessor circuits allow the use of output
load curve control, which limits the high voltage
output to safe levels, even with the controls set
at maximum levels, and does so without a hard
shut down. The Over-current setpoint, which can
be monitored on the μa Display by pressing the
SET push-button and holding for one second,
does provide a hard shut down if the output
current exceeds the setpoint. The KV setpoint is
also displayed on the KV display when the SET
pushbutton is pressed for one second.
DISPLAYS
The front panel displays for output voltage and
current indicate the true outputs from the cascade or the tip voltage for indirect charge, and
waterborne applications. They are derived from
feedback signals in the low voltage cable between
the controller and the cascade.
SPECIFICATIONS
(At Sea-Level Conditions)
Environmental / Physical
Temp. Operating: (0
Storage: (-40
Humidity: (95% Non-Condensing)
Cabinet Size: 13.0” Wide
19.0” Deep
7.0” Height
Weight: 19 lbs.
Electrical
DC Power Required: *
(per MicroPak) 24 VDC at 2.5A
(fully loaded output),
HP404, Cascade
AC Electrical Requirements:
90-264 VAC @ 1.5 amps @
47/63 Hertz
o
to 55o C)
o
C to 85o C)
LN-9622-00.5
* DC power supplied from 24VDC built-in, regulated power supy which has overcurrent (40%)
and overvoltage (20%) protection.
8
Evolver MicroPak Controller - Introduction
Ransburg
Electrical (Cont.)
Controls:
1) Discrete signals available via discrete
I/O Module
Analog In: KV SET (0-10VDC)
OVER CURRENT SET
(0-10VDC)
Discrete Out: HV ON (+24V)
HV READY (+24V)
OVER CURRENT
FAULT
(+24V)
Discrete In: HV RESET (+24V)
HV ON (+24V)
MicroPak With HP404 FM
Output: 100 kV @ 0 μA
(85 μA Max.)
NOTES
Cascade Size: 1.50” x 1.56” x 7.0”
9
LN-9622-00.5
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