Ransburg MICROPAK A11789 User Manual Download

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SERVICE MANUAL
CP-06-01

CP-06-01

CP-06-01
January - 2007

MICROP

MICROPAK

CONTROLLER

MODEL: A1

MODEL: A11789

1789

IMPOR

IMPORT

TANT

ANT

ANT: Before using this equipment,

: Before using this equipment,

carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions in this

starting on page 1, and all instructions in this

starting on page 1, and all instructions in this
manual. Keep this Service Manual for future

manual. Keep this Service Manual for future

manual. Keep this Service Manual for future
reference.

reference.

Service Manual Price: $30.00 (U.S.)

I/O

Summary of Contents for MICROPAK A11789

Page 1: ...TY PRECAUTIONS carefully read SAFETY PRECAUTIONS carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this starting on page 1 and all instructions in this starting on page 1 and all instructions in this starting on page 1 and all instructions in this starting on page 1 and all instructions in this manual Keep this Service Manual for future manual Keep this Service Manual fo...

Page 2: ...CP 06 01 ...

Page 3: ...Y POLICIES WARRANTY POLICIES WARRANTY POLICIES WARRANTY POLICIES LIMITEDWARRANTY PARTS IDENTIFICATION PARTS IDENTIFICATION PARTS IDENTIFICATION PARTS IDENTIFICATION PARTS IDENTIFICATION MICROPAK CONTROLLER PARTS DIAGRAM PARTS LIST A11789 01 STAND ALONE CONTROL POWER SUPPLY ASSEMBLY PARTSLIST MICROPAK STAND ALONE CONTROL POWER SUPPLY MODELIDENTIFICATION A11789 01 STAND ALONE CONTROL POWER SUPPLY SC...

Page 4: ...he A NOTE is information relevant to the A NOTE is information relevant to the A NOTE is information relevant to the A NOTE is information relevant to the procedure in progress procedure in progress procedure in progress procedure in progress procedure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and y...

Page 5: ...ied to the atomizer must be turned off prior to cleaning flushing or maintenance When using solvents for cleaning Thoseusedforequipmentflushingshouldhaveflash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100o F 37 8o C Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA and local codes In addition v...

Page 6: ... the high voltage on make sure no objects are within the sparking distance AREA AREA AREA AREA AREA Tells where hazards may occur HAZARD HAZARD HAZARD HAZARD HAZARD Tells what the hazard is SAFEGUARDS SAFEGUARDS SAFEGUARDS SAFEGUARDS SAFEGUARDS Tells how to avoid the hazard Explosion Explosion Explosion Explosion Explosion Hazard Hazard Hazard Hazard Hazard Incompatible Incompatible Incompatible I...

Page 7: ... and the atomizer bell A distance of at least 1 inch for each 10 KV of power supply output voltage is required at all times Parts must be supported so that they will not swing and reduce the clearance specified above 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 Unless specifically approved f...

Page 8: ...FEATURES TURES TURES TURES TURES V V V V Voltage Control oltage Control oltage Control oltage Control oltage Control The Over Current setpoint can be monitored on the μa Display by pressing the SET push button andholdingforonesecond Itdoesprovideahard shut down if the output current exceeds the setpoint The kV setpoint is also displayed on the kV display when the SET push button is pressed for one...

Page 9: ...lated power supy which has over current regulated power supy which has over current regulated power supy which has over current 40 and over voltage 20 protection 40 and over voltage 20 protection 40 and over voltage 20 protection 40 and over voltage 20 protection 40 and over voltage 20 protection Environmental Physical Environmental Physical Environmental Physical Environmental Physical Environmen...

Page 10: ...TB N and 1TB Ground see Figure 1 for AC input wiring locations W A R N I N G W A R N I N G W A R N I N G W A R N I N G W A R N I N G Always double check that the control unit is unplugged from its AC outlet before working with any internal wiring 3 Remove the mounting hardware from the AC Inlet Receptacle and remove it from the rear of the control unit 4 Install the Conduit Adapter Plate supplied ...

Page 11: ...e the amount of cable that has to be replaced if a failure of the cable occurs The control unit and gun ends of these cables attach as described in the standard low voltage cable section above Follow the instructions below to wire the junction box ends of these cables Junction Box in Hazardous Location Junction Box in Hazardous Location Junction Box in Hazardous Location Junction Box in Hazardous ...

Page 12: ... and pull out the other side It may be necessary to remove the cable grommet to fit the cable s through Ifso slidethegrommetconnectionsonto the cable s in the order shown in Figure 4 before pulling the cable through the connector housing For maximum noise immunity all wiring should be run in cables having a foil shield with an overall braided shield The foil shield provides 100 shielding while the...

Page 13: ...troller Figure 3 Rear View of Controller Figure 3 Rear View of Controller Figure 3 Rear View of Controller Figure 3 Rear View of Controller Figure 4 Connector P3 Wiring Figure 4 Connector P3 Wiring Figure 4 Connector P3 Wiring Figure 4 Connector P3 Wiring Figure 4 Connector P3 Wiring ...

Page 14: ...entiometer R21 on the top of the MicroPak process board see Figure 6A will control the over current setpoint This mode is convenient if it is desired to supply an analoginputsignalforthekVsetpointbutnotforthe over current setpoint Finally if the local remote switch is in the local position the over current setpoint is controlled by the μA adjust knob on the front of the MicroPak If any of the mode...

Page 15: ...ion HV Ready and HV On will occur at the same time NOTE NOTE NOTE NOTE NOTE Output T Output T Output T Output T Output Terminals erminals erminals erminals erminals Each 24VDC output is supplied through a relay contact capable of handling up to 1 amp of current However if one or more outputs are active at the same time the total output current should not exceed 2 amps Overload 24VDC Overload 24VDC...

Page 16: ...alog input or from R21 of the MicroPak process board If dipswitch SW3 1 is ON control is from the remote analog input If dipswitch SW3 1 is OFF control is from potentiometerR21 MicroPak Process Board MicroPak Process Board MicroPak Process Board MicroPak Process Board MicroPak Process Board Dipswitch SW3 3 Dipswitch SW3 3 Dipswitch SW3 3 Dipswitch SW3 3 Dipswitch SW3 3 Determines whether high volt...

Page 17: ...croPak Process Board Figure 6A MicroPak Process Board Figure 6A MicroPak Process Board Figure 6A MicroPak Process Board Figure 6B Discreet I O Board Figure 6B Discreet I O Board Figure 6B Discreet I O Board Figure 6B Discreet I O Board Figure 6B Discreet I O Board Version ___________ P N ______________ ...

Page 18: ...roller to the Evolver spray guns a shieldedcablehasbeenused Theshieldconsists of an overall foiled shield in combination with an overall braided shield This provides the most effective shielding as the foil covers the holes in the braid and the braid allows for practical 360 termination at both ends of the cable The AC input cord is not shielded but instead is directed to an AC line filter in the ...

Page 19: ...V High Voltage Ready Indicator oltage Ready Indicator oltage Ready Indicator oltage Ready Indicator oltage Ready Indicator Glows yellow when High Voltage Ready to the MicroPak is enabled High V High V High V High V High Voltage ON Indicator oltage ON Indicator oltage ON Indicator oltage ON Indicator oltage ON Indicator Glows red when high voltage to the applicator is enabled High V High V High V H...

Page 20: ...OFF position to prolong the life of the internal fan 0 to 10VDC kV setpoint input When in local mode the over current setpoint is adjusted by using the uA Adjust Knob When in remote mode the over current setpoint is adjusted by potentiometer R21 if dipswitch SW3 1 is OFF or by the remote 0 to 10VDC over current setpoint input if dipswitch SW3 1 is ON Feedback Fault Indicator Feedback Fault Indicat...

Page 21: ...input shown in Table 1 The yellow High Voltage Ready Indicator should turn on Figure 8 Operating Controls Figure 8 Operating Controls Figure 8 Operating Controls Figure 8 Operating Controls Figure 8 Operating Controls 6 Supply a 24VDC signal to the High Voltage On input shown in Table 1 The red High Voltage On Indicator should turn on 7 Adjust the 0 10VDC kV setpoint input to obtain the desired va...

Page 22: ...ontroller or the cable and or cascade assembly To conduct the test perform the following 1 Ensure that the controller is disconnected from the AC source 2 Using a screwdriver pry open the 6 screw covers on the top panel of the controller remove the screws and remove the top panel see Figure 9 3 Disconnect connector J3 see Figure 9 from the rear of the problem MicroPak unit 1 or 2 Leave the other e...

Page 23: ...ned ON turned ON No or Low kV Output No or Low kV Output No or Low kV Output No or Low kV Output No or Low kV Output at Spray Gun when at Spray Gun when at Spray Gun when at Spray Gun when at Spray Gun when HV ON Indicator red HV ON Indicator red HV ON Indicator red HV ON Indicator red HV ON Indicator red LED is Lit LED is Lit LED is Lit LED is Lit LED is Lit 1 AC Power ON OFF switch on rear of co...

Page 24: ...rking but kV working but kV Output OK Output OK Output OK Output OK Output OK 1 Improperinterlockconnection 2 High voltage ready condition not activated 3 High Voltage On input not activated 4 Defective MicroPak Control Unit 1 Parts are too close to the spray gun 2 Overload setpoint set too sensitive 3 Defective spray gun or cable 4 Defective MicroPak Control Unit 1 Ready input is active and dipsw...

Page 25: ... bare XX Meter reading may vary in the megohms range due to capacitance across pins T T T T Table 2 Ohmeter Measurements in Ohms from MicroPak able 2 Ohmeter Measurements in Ohms from MicroPak able 2 Ohmeter Measurements in Ohms from MicroPak able 2 Ohmeter Measurements in Ohms from MicroPak able 2 Ohmeter Measurements in Ohms from MicroPak Connector J3 through the Low V Connector J3 through the L...

Page 26: ...ATION TION TION TION TION 23 23 23 23 23 MicroPak Controller Parts Identification Figure 10 MicroPak Controller Parts Diagram Figure 10 MicroPak Controller Parts Diagram Figure 10 MicroPak Controller Parts Diagram Figure 10 MicroPak Controller Parts Diagram Figure 10 MicroPak Controller Parts Diagram ...

Page 27: ...ER P AK CONTROLLER PAR AR AR AR ARTS LIST TS LIST TS LIST TS LIST TS LIST Figure 10 Figure 10 Figure 10 Figure 10 Figure 10 Part Part Part Part Part Description Description Description Description Description T T T T TABLE A ABLE A ABLE A ABLE A ABLE A CABLES CABLES CABLES CABLES CABLES Part Part Part Part Part Description Description Description Description Description Low Voltage Cable Stand Alo...

Page 28: ...ssembly Figure 11A A11789 01 Stand Alone Control Power Supply Assembly Figure 11A A11789 01 Stand Alone Control Power Supply Assembly Figure 11B A11789 01 Stand Alone Control Power Supply Assembly Figure 11B A11789 01 Stand Alone Control Power Supply Assembly Figure 11B A11789 01 Stand Alone Control Power Supply Assembly Figure 11B A11789 01 Stand Alone Control Power Supply Assembly Figure 11B A11...

Page 29: ...nd Alone Control Power Supply Assembly Figure 11C A11789 01 Stand Alone Control Power Supply Assembly Figure 11C A11789 01 Stand Alone Control Power Supply Assembly Figure 11C A11789 01 Stand Alone Control Power Supply Assembly Figure 11C A11789 01 Stand Alone Control Power Supply Assembly ...

Page 30: ...eConnector EMC 1 28 A11243 00 Label Warning Danger 1 29 A10515 00 Fan 1 30 A10518 00 Back Panel 1 31 A10516 00 Switch 1 32 76433 01 AC Socket 120V 1 33 A10523 00 Back Panel Label 1 34 35 A11377 00 Power Supply Sub Assembly 1 36 7747 20C 6 32 X 625 Long Pan Head Screw 2 37 A10521 00 Terminal Strip Block 1 38 76468 02 Terminal Block 1 39 76463 01 Label Terminal Strip 1 40 7776 06 Lockwasher Internal...

Page 31: ... SUPPL SUPPL SUPPL SUPPLY Y Y Y Y MODEL MODEL MODEL MODEL MODEL IDENTIFICA IDENTIFICA IDENTIFICA IDENTIFICA IDENTIFICATION TION TION TION TION When ordering use part number A11789 AA as indicated by Table A Two digits must follow the basic part number For example 01 02 03 04 05 06 07 08 T T T T TABLE A Single or Dual MicroPak ABLE A Single or Dual MicroPak ABLE A Single or Dual MicroPak ABLE A Sin...

Page 32: ...d Alone Control Power Supply Schematic Figure 11e A1178 01 Stand Alone Control Power Supply Schematic Figure 11e A1178 01 Stand Alone Control Power Supply Schematic Figure 11e A1178 01 Stand Alone Control Power Supply Schematic Figure 11e A1178 01 Stand Alone Control Power Supply Schematic ...

Page 33: ...CP 06 01 30 30 30 30 30 MicroPak Controller Parts Identification NOTES NOTES NOTES NOTES NOTES ...

Page 34: ...AVE FAILED BECAUSE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATE OF FAULTY WORKMANSHIP OR MATE OF FAULTY WORKMANSHIP OR MATE OF FAULTY WORKMANSHIP OR MATE OF FAULTY WORKMANSHIP OR MATE RIALS THERE ARE NO IMPLIED WAR RIALS THERE ARE NO IMPLIED WAR RIALS THERE ARE NO IMPLIED WAR RIALS THERE ARE NO IMPLIED WAR RIALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF EITHER RANTIES NOR ...

Page 35: ...CP 06 01 ...

Page 36: ...sistance echnical Service Assistance Automotive Assembly and Tier I Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 T T T T Technical Support Representative will direct you to the appropriate telephone echnical Support Representative will direct you to the appropriate telephone echnical Support...

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