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Ransburg MICROPAK A11789 Service Manual

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MICROP
MICROP
MICROP
MICROP AK
MICROP
MODEL: A1
MODEL: A1
MODEL: A1
MODEL: A1 1789
MODEL: A1
TM
TM
TM
AK
AK
TM
TM
CONTROLLER
CONTROLLER
AK
AK
CONTROLLER
CONTROLLER
CONTROLLER
1789
1789
1789
1789
IMPOR
IMPOR
IMPOR
IMPOR
IMPORT T T T T ANT
ANT
ANT: Before using this equipment,
ANT
ANT
carefully read SAFETY PRECAUTIONS,
carefully read SAFETY PRECAUTIONS,
carefully read SAFETY 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 for future
manual. Keep this Service Manual for future
manual. Keep this Service Manual for future
manual. Keep this Service Manual for future
reference.
reference.
reference.
reference.
reference.
I/O
: Before using this equipment,
: Before using this equipment,
: Before using this equipment,
: Before using this equipment,
Service Manual Price: $30.00 (U.S.)
Service Manual Price: $30.00 (U.S.)
Service Manual Price: $30.00 (U.S.)
Service Manual Price: $30.00 (U.S.)
Service Manual Price: $30.00 (U.S.)
SERVICE MANUAL
CP-06-01
CP-06-01
CP-06-01
CP-06-01
CP-06-01
January - 2007

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Summary of Contents for Ransburg MICROPAK A11789

  • Page 1 SERVICE MANUAL CP-06-01 CP-06-01 CP-06-01 CP-06-01 CP-06-01 January - 2007 MICROP MICROP CONTROLLER CONTROLLER MICROP MICROP AK MICROP CONTROLLER CONTROLLER CONTROLLER MODEL: A1 MODEL: A1 1789 1789 MODEL: A1 MODEL: A1 MODEL: A1 1789 1789 1789 IMPOR IMPOR IMPOR IMPOR IMPORT T T T T ANT ANT: Before using this equipment, : Before using this equipment,...
  • Page 2 CP-06-01...

  • Page 3: Table Of Contents

    MicroPak Controller - Contents CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS PAGE PAGE PAGE PAGE PAGE SAFETY: SAFETY: SAFETY: SAFETY: SAFETY: SAFETY PRECAUTIONS......................HAZARDS/SAFEGUARDS......................INTRODUCTION: INTRODUCTION: INTRODUCTION: INTRODUCTION: INTRODUCTION: GENERAL DESCRIPTION......................SAFETY FEATURES........................DISPLAYS............................ CURRENT CONTROL........................ SPECIFICATIONS........................INSTALLATION: INSTALLATION: INSTALLATION: 7-15 7-15 7-15 7-15 7-15...

  • Page 4: Safety

    If you do not have the manuals and safety literature for your ITW Ransburg system, contact your local Ransburg representative or ITW Ransburg. 1 1 1 1 1...

  • Page 5: Hazards/Safeguards

    MicroPak Controller - Safety A R E A A R E A A R E A A R E A A R E A H A Z A R D H A Z A R D H A Z A R D H A Z A R D H A Z A R D SAFEGUARDS...
  • Page 6 MicroPak Controller - Safety A R E A A R E A A R E A H A Z A R D H A Z A R D SAFEGUARDS SAFEGUARDS A R E A A R E A H A Z A R D H A Z A R D H A Z A R D SAFEGUARDS...
  • Page 7 MicroPak Controller - Safety H A Z A R D H A Z A R D H A Z A R D SAFEGUARDS SAFEGUARDS SAFEGUARDS A R E A A R E A H A Z A R D H A Z A R D SAFEGUARDS SAFEGUARDS A R E A...

  • Page 8: Introduction General Description

    MicroPak Controller - Introduction INTRODUCTION INTRODUCTION INTRODUCTION INTRODUCTION INTRODUCTION GENERAL DESCRIPTION GENERAL DESCRIPTION GENERAL DESCRIPTION CURRENT CONTROL CURRENT CONTROL CURRENT CONTROL GENERAL DESCRIPTION GENERAL DESCRIPTION CURRENT CONTROL CURRENT CONTROL The MicroPak MicroPak MicroPak MicroPak MicroPak Controller Controller Controller Controller Controller , is used to provide The current setpoint limits the maximum current voltage to the cascade inside the Spray Gun that the cascade can produce.

  • Page 9: Specifications

    MicroPak Controller - Introduction SPECIFICA SPECIFICA TIONS TIONS N O T E S N O T E S N O T E S SPECIFICA SPECIFICA SPECIFICATIONS TIONS TIONS N O T E S N O T E S (A (A (A (At Sea-Level Conditions) t Sea-Level Conditions) t Sea-Level Conditions)

  • Page 10: Micropak Input Power

    MicroPak Controller - Installation INST INST INST ALLA ALLA ALLA ALLA TION TION TION TION INST INST ALLA TION MICROPAK INPUT MICROPAK INPUT MICROPAK INPUT MICROPAK INPUT MICROPAK INPUT POWER POWER POWER POWER POWER For non-conduit installations, plug the detachable AC line cord into the receptacle on the rear of the MicroPak Controller.

  • Page 11: Safety Ground

    MicroPak Controller - Installation SAFETY GROUND SAFETY GROUND control unit and gun ends of these cables attach SAFETY GROUND SAFETY GROUND SAFETY GROUND as described in the standard low voltage cable section above. Follow the instructions below to wire the junction box ends of these cables: Install the ground wire assembly supplied with the MicroPak Controller from the ground stud on the Junction Box in Hazardous Location...

  • Page 12: Interlocks And I/O

    MicroPak Controller - Installation INTERLOCKS AND I/O INTERLOCKS AND I/O INTERLOCKS AND I/O INTERLOCKS AND I/O INTERLOCKS AND I/O N O T E N O T E N O T E N O T E N O T E If multiple I/O / Interlock cables are used, >...
  • Page 13 MicroPak Controller - Installation Figure 3: Figure 3: Figure 3: Figure 3: Figure 3: Rear View of Controller Rear View of Controller Rear View of Controller Rear View of Controller Rear View of Controller Figure 4: Figure 4: Figure 4: Figure 4: Figure 4: Connector P3 Wiring...

  • Page 14: Description Of Table 1 Interlock

    MicroPak Controller - Installation Figure 6A) will control the over-current setpoint. This mode is convenient if it is desired to supply an analog input signal for the kV setpoint but not for the 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.
  • Page 15 MicroPak Controller - Installation SW3-3 on the MicroPak process board (see Figure Output T Output T erminals erminals Output T Output T Output Terminals erminals erminals 6A) is set to the ON position and the Ready input Each 24VDC output is supplied through a relay is active (the ready input is made active by moving contact capable of handling up to 1 amp of current.

  • Page 16: Dip Switch Summary

    MicroPak Controller - Installation T T T T T able 1 - Electrical I/O able 1 - Electrical I/O able 1 - Electrical I/O able 1 - Electrical I/O able 1 - Electrical I/O MicroPak 1 MicroPak 2 Inputs: P3 Terminal Inputs: P3 Terminal kV Setpoint (0-10VDC)
  • Page 17 MicroPak Controller - Installation Figure 6A: Figure 6A: Figure 6A: MicroPak Process Board MicroPak Process Board MicroPak Process Board Figure 6A: Figure 6A: MicroPak Process Board MicroPak Process Board Figure 6B: Figure 6B: Figure 6B: Figure 6B: Figure 6B: Discreet I/O Board Discreet I/O Board Discreet I/O Board Discreet I/O Board...

  • Page 18: Micropak Ground Theory

    MicroPak Controller - Installation MICROP MICROP AK GROUNDING AK GROUNDING A special cable grommet fitting has been provided MICROP MICROP MICROPAK GROUNDING AK GROUNDING AK GROUNDING for I/O connector P3 of the controller (see Figure THEORY THEORY THEORY THEORY THEORY 4).

  • Page 19: Operation

    MicroPak Controller - Operation OPERA OPERA TION TION OPERA TION TION OPERA OPERA TION OPERA OPERA TING CONTROLS TING CONTROLS OPERA OPERATING CONTROLS OPERA TING CONTROLS TING CONTROLS N O T E N O T E N O T E N O T E N O T E (See Figures 2 &...

  • Page 20: Operating Procedures

    Control Unit should be removed from service and 4. Turn the MicroPak ON/OFF switch to the ON sent back to ITW Ransburg for repair. position. The kV and μA displays will come on along with the yellow MicroPak Power Indicator...

  • Page 21: Operating Controls

    MicroPak Controller - Operation T T T T T ypical Remote Mode ypical Remote Mode ypical Remote Mode ypical Remote Mode 6. Supply a 24VDC signal to the High Voltage On ypical Remote Mode input shown in Table 1. The red High Voltage On 1.

  • Page 22: Maintenance

    MicroPak Controller - Maintenance MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING 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 ! ! ! ! ! Because this test involves access to...

  • Page 23: Troubleshooting Guide

    MicroPak Controller - Maintenance TROUBLESHOOTING GUIDE 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 ! ! ! ! ! The “Troubleshooting Guide”...
  • Page 24 MicroPak Controller - Maintenance T T T T T roubleshooting Guide (Cont.) roubleshooting Guide (Cont.) roubleshooting Guide (Cont.) roubleshooting Guide (Cont.) roubleshooting Guide (Cont.) General Problem General Problem Possible Causes Possible Causes Corrective Action Corrective Action General Problem General Problem General Problem Possible Causes Possible Causes...
  • Page 25 MicroPak Controller - Maintenance T T T T T 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 able 2 - Ohmeter Measurements in Ohms from MicroPak Connector J3 through the Low V Connector J3 through the Low V...

  • Page 26: Parts Identification

    MicroPak Controller - Parts Identification P P P P P AR AR TS IDENTIFICA TS IDENTIFICA TS IDENTIFICA TION TS IDENTIFICA TION TION TION TS IDENTIFICA TION Figure 10: Figure 10: Figure 10: Figure 10: Figure 10: MicroPak Controller Parts Diagram MicroPak Controller Parts Diagram MicroPak Controller Parts Diagram MicroPak Controller Parts Diagram...
  • Page 27 MicroPak Controller - Parts Identification MICROP MICROP AK CONTROLLER - P AK CONTROLLER - P TS LIST TS LIST (Figure 10) (Figure 10) MICROP MICROP MICROPAK CONTROLLER - P AK CONTROLLER - P AK CONTROLLER - PAR ARTS LIST TS LIST TS LIST (Figure 10) (Figure 10)

  • Page 28: A11789-01 Stand-Alone Control / Power Supply Assembly/Parts List

    MicroPak Controller - Parts Identification Figure 11A: Figure 11A: A11789-01 Stand-Alone Control/Power Supply Assembly A11789-01 Stand-Alone Control/Power Supply Assembly Figure 11A: Figure 11A: Figure 11A: A11789-01 Stand-Alone Control/Power Supply Assembly A11789-01 Stand-Alone Control/Power Supply Assembly A11789-01 Stand-Alone Control/Power Supply Assembly Figure 11B: Figure 11B: Figure 11B:...
  • Page 29 MicroPak Controller - Parts Identification Figure 11C: Figure 11C: A11789-01 Stand-Alone Control/Power Supply Assembly A11789-01 Stand-Alone Control/Power Supply Assembly Figure 11C: Figure 11C: Figure 11C: A11789-01 Stand-Alone Control/Power Supply Assembly A11789-01 Stand-Alone Control/Power Supply Assembly A11789-01 Stand-Alone Control/Power Supply Assembly CP-06-01...
  • Page 30 MicroPak Controller - Parts Identification 1789-01 ST 1789-01 ST AND-ALONE CONTROL/POWER SUPPL AND-ALONE CONTROL/POWER SUPPLY Y Y Y Y AND-ALONE CONTROL/POWER SUPPL A11789-01 ST 1789-01 ST 1789-01 STAND-ALONE CONTROL/POWER SUPPL AND-ALONE CONTROL/POWER SUPPL ASSEMBL ASSEMBL ASSEMBL ASSEMBL ASSEMBLY Y Y Y Y - P - PAR ARTS LIST TS LIST...

  • Page 31: Micropak Stand-Alone Control / Power Supply Model Identification

    MicroPak Controller - Parts Identification P P P P P AR ARTS LIST TS LIST TS LIST TS LIST BULLET TS LIST BULLET BULLET BULLET BULLET DEFINITION T DEFINITION T DEFINITION T DEFINITION T DEFINITION TABLE ABLE ABLE ABLE ABLE (Figures 1 (Figures 1 (Figures 1...

  • Page 32: A11789-01 Stand-Alone Control / Power Supply Schematic

    MicroPak Controller - Parts Identification Figure 11e: Figure 11e: Figure 11e: Figure 11e: Figure 11e: A1178-01 Stand-Alone Control/Power Supply Schematic A1178-01 Stand-Alone Control/Power Supply Schematic A1178-01 Stand-Alone Control/Power Supply Schematic A1178-01 Stand-Alone Control/Power Supply Schematic A1178-01 Stand-Alone Control/Power Supply Schematic CP-06-01...
  • Page 33 MicroPak Controller - Parts Identification N O T E S N O T E S N O T E S N O T E S N O T E S CP-06-01...

  • Page 34: Limited Warranty

    SPARE PARTS: One hundred and eighty (180) days from date of purchase, except for rebuilt If, in ITW Ransburg's opinion the warranty item in parts (any part number ending in "R") for which the question, or other items damaged by this part was warranty period is ninety (90) days.
  • Page 35 CP-06-01...
  • Page 36 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 T echnical Support Representative will direct you to the appropriate telephone echnical Support Representative will direct you to the appropriate telephone...

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