Carlisle Ransburg - MicroPak 2e Customer Integration Kit A14145 A14165 User manual

Brand: Carlisle

Model: Ransburg - MicroPak 2e Customer Integration Kit A14145 A14165

Type: User manual

Carlisle Ransburg - MicroPak 2e Customer Integration Kit A14145 A14165 offers a range of options for controlling electrostatic coating systems. The A14145 is tailored towards rotary applicators, while the A14165 is designed for automatic applicators. Both kits provide the necessary components for integrating MicroPak 2e HV controllers into your system, including low voltage cables, power supplies, and mounting hardware. With these kits, you can easily configure your system to suit your specific needs and optimize the performance of your electrostatic coating process.

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all

instructions in this manual. Keep this Service Manual for future reference.

Model: A14145 and A14165

MicroPak 2e Custom

Integration Kit

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SERVICE MANUAL

NOTE: This manual has been changed from revision LN-9627-00 to revision

LN-9627-00-R1. Reasons for this change are noted under “Manual

Change Summary” inside the back cover of this manual.

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MANUAL CHANGES

CONTENTS

SAFETY: 4-8

Safety Precautions ..................................................................................................................................................... 4

Hazards / Safeguards ................................................................................................................................................. 5

INTEGRATOR KIT OPTIONS: 9-16

A14145-AABCD: Rotary Applicators ...........................................................................................................................9

Congurations ...........................................................................................................................................................10

Ethernet Connection .................................................................................................................................................. 12

Wiring for Pneumatic Parts ........................................................................................................................................ 13

Pneumatic Tubing ...................................................................................................................................................... 14

A14165-AAB: Automatic Applicators .........................................................................................................................15

Congurations ...........................................................................................................................................................16

PARTS LIST: 17-24

A14164: MicroPak 2e for Rotary Applicators ............................................................................................................. 17

A13987: Low Voltage Cable Assembly ...................................................................................................................... 17

A13746: Low Voltage Cable Assembly ...................................................................................................................... 18

A14080: 24V 300W Power Supply ............................................................................................................................18

A13245: Multifunction I/O Board ................................................................................................................................19

A14158: Multifunction I/O Board DIN Rail Mounting Kit ............................................................................................19

A14096: Solenoid Assembly ...................................................................................................................................... 20

A14095: E/P Transducer DIN Rail Assembly .............................................................................................................20

A14166: MicroPak 2e Mounting Kit ...........................................................................................................................21

A13596: Pressure Transducer ................................................................................................................................... 21

A12433-25: 25’ Low Voltage Cable Extension ..........................................................................................................22

A13393-00: Low Voltage Cable Mounting Brackets ..................................................................................................22

A14168-00: DIN Rail Mounting Kit for Pneumatics ....................................................................................................23

A14174-00: DIN Rail Mounting Kit for 300W Power Supply ...................................................................................... 23

80557-00: AC Plug with Line Filter ............................................................................................................................24

INTRODUCTION: 25

About this manual ...................................................................................................................................................... 25

INSTALLATION: 26-27

Location of Connections ........................................................................................................................................... 27

ELECTRICAL CONNECTIONS: 28-32

MicroPak 2e Input Power Connections .....................................................................................................................28

Grounding the Input Power Supply (and Protecting Against Electrical Noise) ..........................................................29

Low Voltage Cable Connections (Output to Cascade) ..............................................................................................29

Interlock Connections ................................................................................................................................................31

Ethernet Cable Connections ......................................................................................................................................31

DIP Switch and Jumper Settings ...............................................................................................................................31

Conguration Screens ................................................................................................................................................31

(Continued on next page)

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CONTENTS

MECHANICAL MOUNTING: 33-42

MicroPak 2e HV Controller Cut Out ...........................................................................................................................33

Low Voltage Cable .....................................................................................................................................................34

Low Voltage Cable Extension ..................................................................................................................................... 35

Power Supply DIN Rail Mounting Hardware...............................................................................................................36

Mount kits for MIO/DIO Boards ..................................................................................................................................39

DIN Rail Mount kits for Solenoid Assemblies and E-to-P Units ..................................................................................40

CONTENTS (Cont.)

MANUAL CHANGE SUMMARY: 44

Manual Changes .......................................................................................................................................................44

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CONTENTS

CAUTION

WARNING

NOTE

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.

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.

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 tak-

en to ensure that the WARNINGS and safety require-

ments 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.

The hazards shown on the following pages may

occur during the normal use of this equipment.

SAFETY

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SAFETY

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area 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.

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.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the 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.

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 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.

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.

Improper operation or

maintenance may create

a hazard.

Personnel must be properly

trained in the use of this

equipment.

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.

General Use and

Maintenance

Spray Area Explosion Hazard

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SAFETY

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area /

High Voltage

Equipment

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.

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.

Electrical Discharge

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SAFETY

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

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 shut-

down indicates a problem in

the system which requires

correction.

An electrical arc can ignite

coating materials and cause a

re or explosion.

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.

Electrical Discharge

Electrical

Equipment

Certain materials may be

harmful if inhaled, or if there is

contact with the skin.

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.

Chemical HazardToxic Substances

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.

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.

Explosion Hazard —

Incompatible Materials

Spray Area

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SAFETY

DescriptionItem #

A14145 - AABCD: ROTARY APPLICATORS

1 A14164-AABC MicroPak 2e Ethernet IP High Voltage Controller

2 A13245-01 Multifunction IO (MIO) Processor Board

3 A13987-10 or A13746-10 Internal Low Voltage Cable Assembly MicroPak 2e

4 A14096-01 Solenoid Assembly, Mechanical and Electrical

5 A14095-00 E-to-P Transducer Assembly

6 A13596-00 Pressure Transducer

7 A13591-00 Female Connector

Included in many congurations, but not shown above, is the 24V 300W Power Supply (A14080-00).

Not all components will be used in all congurations of A14145.

INTEGRATOR KIT OPTIONS

Figure 1: Major Components

MAJOR COMPONENTS - PARTS LIST (Figure 1)

Part #

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INTEGRATOR KIT OPTIONS

-01 (RMA-560, RMA-580, RWA-303 Direct X X

DIRECT CHARGE)

A11303,A12300, A12303, A12867,

A12868, A13364, A13367, A13100

-02 (RMA-202, RWA-101, Direct X X

DIRECT CHARGE) 79014, 78862

-03 RMA-303 - SPECIAL BEARING AIR Direct X X X

(70K @ 70 PSI BEARING LOW LIMIT)

-04 (MMA-570 DIRECT CHARGE) Direct X X

A11400,A12400, A12870, A13366

-05 (AEROBELL, AEROBELL II, Direct X X

AEROBELL 2.5, AEROBELL 168

DIRECT CHARGE)

RPM-5XXX-XXX, A12381, A12787,

77603, A10924

-09 (MMA-570 DIRECT CHARGE) Direct X X

A11400,A12400, A12870, A13366

-10 (MMA-303, MMA-570 INDIRECT Indirect X X

CHARGE)

A11400, A12400, A12870, A13366

-11 (AEROBELL, AEROBELL II, Direct X X

AEROBELL 2.5, AEROBELL 168

DIRECT CHARGE)

RPM-5XXX-XXX, A12381, A12787,

77603, A10924

-12 (AEROBELL II & 2.5 INDIRECT Indirect X X

CHARGE) 77603, A10924

-13 (AEROBELL 33 DIRECT CHARGE- Direct X X

30MM AND 57MM BELL CUP)

AER5000/AER5001

-14 (TURBODISK & TURBODISK 2) Direct X X

A11376, 78715

Description“AA” NO CASCADECharge HP-404 RP-404 RP-1000 LEPS-5002

TABLE AA - REFERENCE CONFIGURATIONS

REFERENCE CONFIGURATION TABLES

A14145 - AA - B - C - D

TABLE D - BELL SPEED / CASCADE CONTROL

TABLE C - UNILINK CONFIGURATION

TABLE B - MULTIFUNCTION I-O BOARD CONFIGURATION

TABLE AA - APPLICATOR TYPE AND CASCADE

BASIC PART NUMBER

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INTEGRATOR KIT OPTIONS

Description“AA” NO CASCADECharge HP-404 RP-404 RP-1000 LEPS-5002

-15 (RMA-303, RMA-570, RMA-590 Indirect X X

INDIRECT CHARGE)

A11300, A11600, A12869,

A13365, A13368

-16 MMA-303 - SPECIAL BEARING AIR Direct X X

(70K @ 70 PSI BEARING LOW LIMIT)

-17 (MMA-570 DIRECT CHARGE) Direct X

A11400,A12400, A12870, A13366

-18 (MMA-303, MMA-570 INDIRECT Indirect X

CHARGE) A11400, A12400,

A12870, A13366

-19 (AEROBELL, AEROBELL II, Direct X

AEROBELL 2.5, AEROBELL 168

DIRECT CHARGE)

RPM-5XXX-XXX, A12381, A12787,

77603, A10924

-20 (AEROBELL II & 2.5 INDIRECT Indirect X

CHARGE) 77603, A10924

-21 (AEROBELL 33 DIRECT CHARGE- Direct X

30MM AND 57MM BELL CUP)

AER5000/AER5001

-22 (TURBODISK & TURBODISK 2) Direct X

A11376, 78715

-23 (RMA-303, RMA-570, RMA-590 Indirect X

INDIRECT CHARGE) A11300, A11600,

A12869, A13365, A13368

-24 MMA-303 - SPECIAL BEARING AIR Direct X

(70K @ 70 PSI BEARING LOW LIMIT)

TABLE AA - REFERENCE CONFIGURATIONS (Cont.)

Description“B” Qty of Boards

UNILINK Mode“C”

Description“D”

TABLE B

TABLE C

TABLE D

1 Ethernet Control 1

2 Discrete Control 2

1 Disabled

2 Enabled

0 Cascade Control with Bell Speed

1 Bell Speed Only

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INTEGRATOR KIT OPTIONS

If the user plans to utilize the MicroPak 2e Ethernet/IP

interface for remote control, they must provide a network

connection for the Controller.

ETHERNET CONNECTION

(CAT 5 CABLE WITH RJ45 CONNECTOR):

Figure 2: External PLC Ethernet connection

Figure 3: Ethernet Connection for MIO/DIO Boards

Ethernet to external

network/PLC

ETHERNET CABLES

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INTEGRATOR KIT OPTIONS

Figure 4: Electrical Connections for E/P Transducer to Solenoids

SOLENOID 1 SOLENOID 2

V- V-V+ V+

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INTEGRATOR KIT OPTIONS

Figure 5: Pneumatic Connections for E/P Transducer to Solenoid

Tubing Part Number From Length (inches) To

A10893-07 T1 5 S4

A10893-07 T2 2 AIR IN

77536-08 T3 2.7 TURBINE PILOT

77536-08 T4 5.8 S6

77536-08 T5 6.7 EXHAUST OUT

77536-08 T6 5.2 S1

77536-08 S2 4 S5

77536-08 S3 9 BRAKE PILOT

PNEUMATIC POINT TO POINT CONNECTIONS

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INTEGRATOR KIT OPTIONS

DescriptionItem # Part #

A14165 – AAB: AUTOMATIC APPLICATORS

Figure 6: Major Components

MAJOR COMPONENTS (Figure 6)

1 A14164 MicroPak 2e Ethernet IP High Voltage Controller

2 A13987-10 or A13746-10 Internal Low Voltage Cable Assembly MicroPak 2e

3 A13245-01 Multifunction IO (MIO) Processor Board

Included in many congurations, but not shown above, is the 24V 300W Power Supply (A14080-00).

Not all components will be used in all congurations of A14165.

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INTEGRATOR KIT OPTIONS

DescriptionDash # “A”

Description“B” Qty of Boards

-25 (RPA-1, RPA-2, MPA POWDER) DIRECT X

A11200, A12950, A11673

-26 (EVOLVER 202, EVOLVER 303, DIRECT X

EVOLVER 500 )

A11918, A11976, A12374

-27 NO ATOMIZER N/A X X

-28 NO ATOMIZER N/A X

-29 NO ATOMIZER N/A X

REFERENCE CONFIGURATION TABLES

A14165 - AA - B

TABLE B - MULTI I-O BOARD CONFIGURATION

TABLE AA - APPLICATOR TYPE AND CASCADE

BASIC PART NUMBER

0 Ethernet Control 0

2 Discrete Control 2

Charge HP-404 RP-404 RP-1000 LEPS5002 HP-505

TABLE AA

TABLE B

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INTEGRATOR KIT OPTIONS

A14164: MicroPak 2e Controller

PARTS LIST

The following are component parts that may be used

in the A14145 and A14165 Integrator Kits listed in this

manual. Congurations may vary depending on each

individual application.

Figure 7: MicroPak 2e Controller

Figure 8: Low Voltage Cable Assembly

A13987: Low Voltage Cable Assembly

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PARTS LIST

A13746: Low Voltage Cable Assembly

Figure 9: Low Voltage Cable Assembly

A14080: 24V 300W Power Supply

Figure 10: 24V 300W Power Supply

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PARTS LIST

A13245: Multifunction I/O Board

Figure 11: Multifunction I/O Board

A14158: Multifunction I/O Board DIN Rail Mounting Kit

Figure 12 – Multifunction I/O Board DIN Rail Mounting Kit

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PARTS LIST

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Carlisle Ransburg - MicroPak 2e Customer Integration Kit A14145 A14165 User manual

Carlisle Ransburg - MicroPak 2e Customer Integration Kit A14145 A14165 User manual

Carlisle Ransburg - MicroPak 2e Customer Integration Kit A14145 A14165 User manual

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