IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine
/// Application Tooling
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Operation and Maintenance Manual – Issue 3
Mini-ray Tool
IR1759-MK5-AT3130-EDCont
PCN.CV3948-000
Language: (original version English)
Page 1: ... EDCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 1 of 36 Operation and Maintenance Manual Issue 3 Mini ray Tool IR1759 MK5 AT3130 EDCont PCN CV3948 000 Language original version English ...
Page 2: ... TE Connectivity Tyco Raychem Specifications are subject to change without notice In addition TE Connectivity Tyco Electronics reserve the right to make changes in materials or processing without notification to Buyer which do not affect compliance with any applicable specification TE Connectivity No part of this manual may be reproduced or transmitted in any form or by any means electronic or mec...
Page 3: ...50 60 Hz1 Voltage lamp 23 5 24 v AC Connection 3 pin IEC Fuses 4AT Mains 16AT to Gun Mini Ray hand tool IR1759MK5 Weight 1 1 kg Noise 51db Cable length 3 meters Volts 23 5 24 v AC Watts 250 Lamp Type Tungsten Connection Type 6 pin connector Cord Length 3 1 M Application Max Product diameter mm 6 Max product length mm 25 Max product length with clamps mm 19 Technical Specifications ...
Page 4: ...urfaces 12 3 4 Eye protection and Optical Radiation Hazard 13 3 5 General instructions 13 3 6 Standard electrical rating label 14 4 Installation 15 4 1 Installation and Set up 15 4 2 Changing the Aperture 17 5 Operation 22 6 Maintenance 23 6 1 General Maintenance and service 23 6 2 Gun Maintenance 24 6 3 Lamp and filter replacement 25 6 4 Replacing trigger PCB 27 7 Spares Ordering information 28 8...
Page 5: ...NIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 5 of 36 1 Revision history Rev Date Description Name Issue 1 Jan 2014 New Tool UL approved Issue 2 Feb 2015 Add section Issue 3 May 2019 Updated information ...
Page 6: ...onnel Failure to follow the manufacturer s instructions may void the warranty of this equipment The IR1759 MK5 MINIRAY Hand Tool and Controllers must be operated in accordance with safe working practices and local safety codes and regulations Do not use the IR1759 MK5 MINIRAY Hand Tool and Controllers for any purpose other than its intended function The IR1759 MK5 MINIRAY Hand Tool control module ...
Page 7: ... from the lamp allowing the operator to observe the heating process and reducing eye strain to the operator The Mini ray Hand tool is supplied with cable and connector ready to connect to this specific UL approved ED 7 CONT Controllers ON OFF Trigger Control The function of the Mini ray Hand tool trigger is to switch power to lamp when required The switch provides for continuous operation of up to...
Page 8: ...ler always provides full power to the Hand tool for as long as the trigger is depressed Controller ED 7 CONT 230 110V MK5 provides a controlled and regulated voltage to the lamp in the Mini ray hand tool while the trigger is depressed This controlled voltage ensures that the lamp will not see more than 24V AC The Triac controller can be operated from either a 220V 240V or 110V 115V AC supply and w...
Page 9: ... live and neutral lines are fused protected at the connector Fig1 Fig 2 Fig 3 MINIRAY Hand Tool Connector The output connection is a male 6 pin socket on the rear panel Fig 2 The input connection is a 6 pin female plug at the end of the supply lead The plug is fitted with a locking ring and is connected to the output socket As shown in Fig 3 Note IR1759 MK5 AT3130 EDCONT should not be connected to...
Page 10: ...DCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 10 of 36 2 3 System Description continued ED 7 Cont 230 110V Mains ON LED ON OFF MAIN POWER FUSES MAINS INPUT HEAT GUN CONNECTION LAMP ON LED ...
Page 11: ...rs or dropped into water return it to a service centre 8 Do not pull or carry by cord use cord as a handle close a door on cord or pull cord around sharp edges or corners Do not run equipment over cord Keep cord away from heated surfaces 9 Do not unplug by pulling on cord To unplug grasp the plug not the cord 10 When an extension cord is used it must be minimum 14 guage 3 wire grounded cord rated ...
Page 12: ...rotected by a 30mA residual current device The MINIRAY equipment must not be hard wired to a mains supply Use only specified fuse types and ratings Power connections for the tool must conform to local standards and regulations Potentially hazardous voltages will be exposed if the equipment covers are removed while it is powered or if any of the cables are damaged Do not use the equipment if the ca...
Page 13: ...serious injury This equipment must be operated and maintained only by fully trained and qualified personnel Failure to follow the manufacturer s instructions may void the warranty of this equipment The IR1759 MK5 MINIRAY equipment must be operated in accordance with safe working practices and local safety codes and regulations Do not use the IR1759 MK5 MINIRAY equipment for any purpose other than ...
Page 14: ...ency stop system Use The ON OFF switch Fig page 9 on the rear panel Or removing the power lead from the mains supply can be used to disconnect the equipment from the mains supply MINIRAY Hand Tool Supply Cable The cable between the Controller and the MINIRAY Hand Tool carries supply and signal voltages and should not be disconnected whilst the controller is switched on 3 6 Standard Electrical Rati...
Page 15: ...trollers are supplied with a 2 5m mains lead and Hand Tool with a 3 1m control lead Mains electrical leads should be routed to help prevent damage or entanglement Work in areas with good lighting Never use the tool near solids liquids or gases that burn easily The tool shall be maintained well Electrical connections Ref photo page 10 The mini ray system must be installed in accordance with establi...
Page 16: ...secure the locking ring 4 Connect the mains supply cable to the Control 5 Plug the mains supply cable into the electricity supply socket Selecting the Hand Tool Aperture Two MINIRAY Hand Tool types are available the difference between models is the aperture size IR 1759 Standard IR 3104 Large A kit AE 897 is available to convert between standard and large aperture sizes The kit contains the releva...
Page 17: ... and lens to the left 4 Remove the two body fixing screws and separate the two halves of the Hand Tool Fig 3 page 8 5 Remove the optical block and optical filter assembly taking care not to touch the surface of the filter Then remove the inner reflector Do not touch the lamp 6 If you accidentally touch any of these parts you must clean them with a soft clean cotton cloth dipped in isopropyl alcoho...
Page 18: ...e MINIRAY equipment can be used to install a variety of TE s SolderSleeve termination products In order to ensure correct positioning of the product in the heating zone a range of fixtures are available Each fixture attaches to the front of the MINIRAY Hand Tool The available fixtures are shown in the following illustrations AT 3130 Standard V Block AT 3131 Solder tact Block ...
Page 19: ...IR1759 MK5 AT3130 EDCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 19 of 36 AT 3132 V Block with Clamp AT 3132 Mk31 V Block with Clamp 5mm Wide Mask ...
Page 20: ...IR1759 MK5 AT3130 EDCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 20 of 36 AT 3134 Standard V Block Large Aperture AT 3147 V Block with Clamp Large Aperture ...
Page 21: ...IR1759 MK5 AT3130 EDCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 21 of 36 AT 3191 Special V Block Standard ...
Page 22: ...of the controller 5 The fan in the Mini ray Hand tool will start 6 Press the Mini ray Hand tool trigger to start the process and switch power to the lamp Power to the lamp is gradually applied Soft Start controlled by the internal processor The LAMP ON green LED will be lit Continuous hand tool operation is limited to a maximum of 70 Seconds The mode indicated by the green ON LED going OFF this ha...
Page 23: ...24 if cleaning is required Check the operation of the fan in the MINIRAY Hand Tool Ref page 24 Monthly Check that the fan is clear of accumulated dust etc 3 Monthly Check the condition of the power cord to the controller and the MINIRAY Hand Tool cord Check the operation of the LEDs Wipe the Controller front panel with a soft clean cloth Annually Check the earth bonding of all MINIRAY CONTROLLER e...
Page 24: ...he rear reflector and inner face of the lamp filter are protected from the work area so contamination is less likely Contaminated surface should be cleaned with a soft cloth and isopropyl alcohol Fan and Housing Cleaning Since the lamp draws large quantities of air through the tool dirt and lint may accumulate in the fan area and gradually restrict the air flow Therefore this part of the tool shou...
Page 25: ...fully clean the filter using a soft cloth Note This may reduce the filter life Lamp Replacement Instructions Drawing reference page 26 1 Remove the 2 body fixing screws in the side of the Hand tool 2 Separate the two halves 3 Lift the adapter and the optical filter assembly from its location slots locate in pegs in the Hand tool 4 Remove inner reflector Page 17 5 Remove lamp carefully by pulling i...
Page 26: ... MK5 AT3130 EDCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 26 of 36 Lamp Replacement Body Fixing Screws Optic Filter Reflector Lamp Fan Trigger Handle Screws Connector Cable ...
Page 27: ...g the lamp from the ceramic holder taking care not to touch the glass surface Step 8 Remove the PCB fan ceramic holder micro switch and Controller cord Step 9 Locate and fasten the replacement PCB and the Controller cord taking care that all wires are routed to avoid contact with the micro switch and trigger Step 10 Replace the fan and the ceramic lamp holder Step 11 Connect the Controller cord ea...
Page 28: ...4265 IEC 127 Mains Fuse 4A T Lamp Fuse 16A T For ordering the complete tool spares accessories use the following description and part numbers Description Information Part No IR1759 MK5 AT3130 EDCONT Hand Tool Reflector Control Box CV3948 000 IR 1759 MK5 GUN Hand Tool Standard Aperture CV4411 000 ED 7 CONT 230 110V MK5 CV4409 000 7 1 Spares Ordering information P ...
Page 29: ...ion Information Part No NAE 143 3 Lamp 250W 24V 988208 000 AES IR1759 100 FILTER DUL Standard Filter 431468 000 AE 153 Inner Reflector for Large Aperture IR 3104 988285 000 AE 424 Inner Reflector for Standard Aperture 547918 000 ED 7 CONT MK5 PCB Main Controller PCB CV4414 000 AE 900 Filter Spring IR 1759 277774 000 ...
Page 30: ... for SolderTacts Contacts Image Pg 18 988300 000 AT 3132 Reflector to Fit Standard Aperture Image Pg 19 988301 000 AT 3132 MK31 1 Reflector to Fit Standard Aperture with Clamps Image Pg 19 879865 000 AT 3134 Reflector to Fit Large Aperture with Standard Vee Block Image Pg 20 988303 000 AT 3147 Reflector to Fit Large Aperture with Clamps Image Pg 20 988328 000 AT 3191 Reflector to Fit Standard Aper...
Page 31: ...RIGGER PCB PCB for Trigger Handle CV4416 000 IR 1759 3104 CABLE ASSY Trigger PCB Cable Fan Lamp Holder Thermal Switch CV4412 000 AE 205 Linear Reflector for Standard Aperture 988596 000 AE 226 Linear Reflector for Large Aperture 988314 000 IR1759 MK5 REPCON DEPINTL Replacement Connector De Pin Tool and Instructions EG2846 000 LAMP HOLDER TRIGGER PCB FAN ...
Page 32: ...IR1759 MK5 AT3130 EDCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 32 of 36 8 Wiring PCB Diagrams 8 1 Electrical circuit ...
Page 33: ...IR1759 MK5 AT3130 EDCONT MINIRAY TE Connectivity Aerospace Defence Marine Application Tooling Page 33 of 36 8 2 Trigger PCB ...
Page 34: ...TER Check fuses as shown in the diagram below when there 0 volts at the connection 2 Lamp good No power to lamp when trigger pressed Check 16AT fuse at the rear of controller 3 No power to lamp when trigger pressed check fuse on PCB View below showing fuse 1 AT for PCB The controller is programmed when purchased as Fig A Check the position of switches 2 X 4 AT FUSES 8 3 Fault Finding ...
Page 35: ...ated by the green ON LED going off Further action of the Hand tool is inhibited until the TIMEOUT period of 2 seconds as lapsed This process is programmed by the four switches shown below and in fig 2 page 32 To accesses this you need to remove the four screws in the top cover of the controller Check the switches are in the set position shown and not been re sett Fig A 9 Contact TE Tyco Electronic...
Page 36: ...nt a Solder Tact contact adaptor the user has to remove the basic clamp on one side and insert the adaptor AT 1319 XX The distance between contact adaptor and cable clamp should be approximately 38 mm 1 5 inch Adaptor and cable clamp should be adjusted to be in line TECHNICAL SPECIFICATION Dimensions W x L 180 x 150 mm 7 x 6 approx Weight 300 g 67lbs PRODUCT RANGE SolderSleeve splices Dura Seal Mi...
