Ransburg Pulsetrack 2 Service Manual Download Page 1

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SERVICE MANUAL

LN-9248-05.3

(Replaces LN-9248-05.2)

March - 2013

MODEL: A11515-XXXXX

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:

€25.00 (Euro)

$30.00 (U.S.)

PULSETRACK

SPEED CONTROL AND

MONITOR SYSTEM

Ransburg

Summary of Contents for Pulsetrack 2

Page 1: ...XXXXX 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...

Page 2: ...NOTE This manual has been changed from revision LN 9248 05 2 to revision LN 9248 05 3 Reasons for this change are noted under Manual Change Summary on page 53 of this manual...

Page 3: ...ER FIBER OPTIC CABLE PNEUMATIC CONNECTIONS ELECTRICAL I O DIP SWITCH SETTINGS 1 5 6 10 11 26 1 2 6 6 7 7 8 9 10 11 12 12 13 13 13 15 16 23 24 26 OPERATION THEORY OF OPERATION FRONT PANEL CONTROLS ATOM...

Page 4: ...NTROL PANEL FRONT VIEW PARTS LIST CONTROL PANEL INSIDE DOOR VIEW PARTS LIST CONTROL PANEL INSIDE CABINET VIEW PARTS LIST RECOMMENDED SPARE PARTS LIST 45 46 47 48 49 50 51 WARRANTY POLICIES 52 LIMITEDW...

Page 5: ...nts etc make such variations inevitable Compare this manual with your system installation draw ings and appropriate Ransburg equipment man uals to reconcile such differences Carefulstudyandcontinuedus...

Page 6: ...coating material Those used for general cleaning must have flash 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 additi...

Page 7: ...Test only in areas free of flammable or combus tible materials The current overload sensitivity if equipped MUST be set as described in the correspond ing section of the equipment manual Protec tion a...

Page 8: ...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 electrost...

Page 9: ...ecifically approved for use in hazard ous locations the power supply control cabinet and all other electrical equipment must be locat ed outside Class I or II Division 1 and 2 hazard ous areas in acco...

Page 10: ...nal digital and analog control signals from a system PLC or host controller and processes the commands 3 Receives the rotational feedback signals from the integrated fiber optic receiver s 4 Receives...

Page 11: ...ors Brake Air Valves Optional The brake air valve is an air piloted three way valve that supplies the necessary volume across the rotator motor vanes in reverse direction to produce quick reduction in...

Page 12: ...4 VDC when active 0 25A maximum per output Pneumatic Inputs Supply Air 1 4 ID x 3 8 OD 110 psi 7 6 bar maximum operating 80 psi 5 5 bar minimum operating 40 micron filtration Pressure Switches Enable...

Page 13: ...Figure 1 Typical Turbodisk 2 Installation With Temperature Humidity Cards...

Page 14: ...filter as soon as it enters the cabinet with as short of leads as pos sible Additional noise protection is provided by running the AC input line to the control panel in grounded conduit which is the...

Page 15: ...plied for each bell Install the brake valve assembly s on the LA0042 Air Manifold Assembly supplied separately as follows see Figure 3 1 Remove the turbine air volume booster from the manifold by loos...

Page 16: ...4 For this reason it is recommended that the AC input not be relocated to another position on the control panel Route the input power wiring through the conduit and attach to terminal block TB3 as sho...

Page 17: ...prevent kinking for protection of the fiber optic cables Avoid exposure of the cable ends to chemicals such as paint or solvents Exposing the cable ends to such chemicals will cause damage and can se...

Page 18: ...acts see Electrical I O later in this section For pneumatic activation connect the supplied 1 4 OD tubing from the activation source to the Enable input on the right side of the control panel Typicall...

Page 19: ...Supply CL1 CL2 CL3 CL4 CL5 CL6 EN1 EN2 EN3 EN4 EN5 EN6 BR1 BR2 BR3 BR4 BR5 BR6 To Supply Air to PulseTrack 2 Rotator 1 Transducer Output Control Signal Rotator 2 Transducer Output Control Signal Rota...

Page 20: ...ector To make electrical I O connections using these connectors perform the following 1 Remove the cable grommet hardware from the desired connector see Figure 9A 2 Routedesiredlengthofcablethroughcon...

Page 21: ...Figure 6 Electrical I O Breakout Terminal Locations...

Page 22: ...Figure 7 Control Panel Schematic...

Page 23: ...Figure 8 Electrical I O Connectors Figure 9A Cable Grommet Hardware Figure 9B Stripping Of I O Cable...

Page 24: ...V 6 5 V 7 0 V 7 5 V 8 0 V 8 5 V 9 0 V 9 5 V 10 0 V 0 10VDC Input Signal Inputs Analog Speed Setpoint Inputs Analog speed setpoint inputs are available for rotators 1 through 6 at breakout terminals J2...

Page 25: ...puts 4 20mA forupto5probes are available at breakout terminals J4 B2 through J4 B6 Signals supplied to these inputs from remote mounted temperature humidity probes optional areprocessedbythemaincontro...

Page 26: ...noids when bell speed is decreased and or disabled 1 E6 on Pins 1 2 OFF E6 on Pins 2 3 ON 2 E5 on Pins 1 2 OFF E5 on Pins 2 3 ON 3 E4 on Pins 1 2 OFF E4 on Pins 2 3 ON 4 E3 on Pins 1 2 OFF E3 on Pins...

Page 27: ...t Rotator 2 Enabled Output Rotator 3 Enabled Output Rotator 4 Enabled Output Rotator 5 Enabled Output Rotator 6 Enabled Output Master LOF Output Master Underspeed Output Master Overspeed Output Master...

Page 28: ...ew dip switch setting to be recognized NOTE Dip Switch SW1 1 This dip switch can be used with bell systems configured for optional brake control When this dip switch is on brake air is applied to assi...

Page 29: ...izer card see Figure 11 These dip switches set the board for use with the desired rotator and are factory set according to thePulseTrack2orderingconfiguration seeTable 7 The control card reads these d...

Page 30: ...cupying as listed on the label inside the front panel door reference Figure 18 Figure 11 Atomizer Card Dip Switch 6 Conical Disk 6 UniDisk 8 UniDisk 9 Conical Disk 10 UniDisk 12 UniDisk 12 Conical Dis...

Page 31: ...is supplied as a pilot signal to the A11547 Brake Valve Assembly The pilot input of the high flow Brake Valve Assembly causes it to turn on and pass it s input pressure to its output The output of th...

Page 32: ...what fault has occurred Speed Select Thumbwheel Switch Thisswitchisusedinlocalmodetomanuallyenter the speed control setpoint in thousands of rpms krpm Press the or switch buttons to incre ment or decr...

Page 33: ...switch is in the disable position speed control for that rotator is disabled Faults may also be reset by moving this switch to the disable position Active Indicator This green LED illuminates when spe...

Page 34: ...is manual 2 Turn the front panel Power ON OFF switch to the ON position 3 Move the local remote switch on the Atomizer Card to the remote position 4 Turn the front panel Master Control Switch to the R...

Page 35: ...setpoint by 10 000 rpm or more Loss of Feedback LF When this fault occurs LF is displayed on the speed display of the Atomizer Card In addition the Master LOF Master Fault and corresponding Rotator Fa...

Page 36: ...e following methods 1 Press the Master Reset Switch located on the front panel 2 Activate the momentary external Master Re set Input see Electrical I O in the Installation section of this manual 3 Tog...

Page 37: ...lutions can be used 4 Window cleaner or a mild solvent may be used to clean the glass window in the small swing out door Field repair and troubleshooting of the PulseTrack 2 Control Panel may require...

Page 38: ...he contact or pilot light blocks from the block holder using a small screwdriver to pry between the block and the numbered portion of the holder at this point the contact block pilot light block or bu...

Page 39: ...new one reconnecting the wires as follows Color From TB3 Ground SW1 B3 SW1 A4 SW1 X1 TB4 1C SW1 X2 TB4 1D Wire ID Green Yellow Light Blue Black Dark Blue Dark Blue Dark Blue Dark Blue GND 6 7 24 24 C...

Page 40: ...trol panel at the Fused Disconnect and open the cabinet door 2 Turn off supply air to the cabinet and bleed off pressure 3 Remove the electrical connector from each transducer assembly 4 Remove pneuma...

Page 41: ...remove assembly from unit 6 Remove two mounting screws from solenoid end bracket 7 Remove suspect solenoid and O rings and Figure 16 Brake Solenoid Disassembly replace 8 Reinstall the two mounting sc...

Page 42: ...roblems refertosystem installation drawings the Control Panel Schematic in Figure 7 the Troubleshooting Chart in this section and the Operation and Parts Identification sec tionsofthismanual Thefollow...

Page 43: ...erature Humidity Card 1 Loose or defective cable connection between control panel and Temperature Humidity Probe A speed control problem may be associated with any of the components that make up the e...

Page 44: ...with switch on 6 ImproperDCvoltagefrom TB2 1 to TB2 4 of 24VDC power supply 7 Faulty wiring to any of above 1 Defective Control Card 2 Misconnected or defec tive ribbon cable assembly from the Contro...

Page 45: ...r responding electrical enable input terminal J3 C15 to J3 C20 Also verify that the ENABLE DISABLE switch located on the Atomizer Card is in the ENABLE position 2 Verify the rotary DIP switch setting...

Page 46: ...es see Table 7 4 ObservetheCurrenttoPressureTransducer output pilot pressure If the pressure climbs higher than normal or is maximum for an extended period of time then the drive air signaltotherotato...

Page 47: ...c cable enable the rotator and look for a red light from the cable while the rotator is spinning If no light can be ob served then replace the fiber optic cable If light is observed then replace the f...

Page 48: ...om control panel to Temperature Humidity Probe 2 Looseinternalwiringfrom Temperature Humidity inputs TH3 TH7 to breakout board 1 Improper rotary DIP switch setting on Temperature Humidity Card 2 Defec...

Page 49: ...PARTS IDENTIFICATION Figure 17 Control Panel Front View...

Page 50: ...ch Master Control SW2 9 SSP 6054 Fitting Brake Solenoid 1 8 NPTM x 1 4 ODT BR1 BR6 10 78776 01 Fitting Bulkhead Union 5 32 ODT CL1 CL6 11 41 FTP 1007 Fitting Swivel Elbow 1 4 NPTM x 3 8 ODT SUPPLY 12...

Page 51: ...Figure 18 Control Panel Inside Door View...

Page 52: ...e SW2 SW3 R 21 LSME0005 00 Contact Block Normally Open SW1 SW2 SW3 22 75763 00 Pilot Light Bulb 24VDC SW1 R 23 LSME0007 00 Pilot Light Block SW1 R 24 LSME0004 00 Block Holder Triple SW1 Item CONTROL P...

Page 53: ...Figure 19 Control Panel Inside Cabinet View...

Page 54: ...L1 SOL3 A11485 04 Solenoid Assembly 4 Solenoids SOL1 SOL4 A11485 05 Solenoid Assembly 5 Solenoids SOL1 SOL5 A11485 06 Solenoid Assembly 6 Solenoids SOL1 SOL6 32 Current to Pressure Transducer Assembly...

Page 55: ...lve Assembly optional bells only 1 1 SMC 424 X Fiber Optic Cable Assembly 1 2 22 75763 00 Indicator Bulb 24VDC 2 4 25 4131 XX Fuse 5 10 26 A11466 XX 24VDC Power Supply 1 2 28 10979 XX Fiber Optic Rece...

Page 56: ...PPING THEAPPLICATOR ASSOCIATEDVALVESAND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVEDCOVERING WILLVOIDTHIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS...

Page 57: ...replace Service Manual LN 9248 05 2 PulseTrack 2 Speed Control and Monitor System to make the fol lowing changes 1 Added item 8 The red LED to Control Card desciption on page 5 2 Changed color of LED1...

Page 58: ...ufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 www ransburg com Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 Technical Sup...

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