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PulseTrack2 (Serv. Man. LN-9248-05.3)

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4. REFERENCE SERVICE MANUAL TOR TROUBLESHOOTING SW1 Figure 18 Control Panel Inside Door View CONTROL INSIDE DOOR VIEW PARTS LIST Figure 18 LIIL GENE NENNNNNNEE RC E A11471 00 Ribbon Cable 2 Assembly LSME0004 00 Block Holder Triple A n
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6. 5 tac es ge Oust uc fu u S Control Card Release Pins 52 Figure 19 Control Panel Inside Cabinet View CONTROL PANEL INSIDE CABINET VIEW PARTS LIST Figure 19 25 Fuse 3A 250V Time Delay 3AG for 11515 120 Input F1 F2 Fuse 1 5A 250V Time Delay 3AG for A11515 XX1XX 240VAC Input F1 F2 26 A11466 01 24VDC Power Supply for 11515 EUN ARN A11466 02 24VDC Power Supply for A11515 XX1XX ENT ENG 4 O O SOL1 SOL6 SOLT 5012 SOL1 5013 5011 5014 SOL 5015 SOL1 SOL6 3 Current to Pressure Transducer Assembly TRD1 TRD6 TRD2 TRD1 TRD6 1 TRD1 IRD2 TRD1 TRD3 TRD1 TRD4 TRD1 TRD5 TRD1 TRD6 77071 03 Line Filter A11477 00 PC Board Assemby Control Card m RECOMMENDED SPARE PARTS LIST Total of Control Panels Part Description Atomizer Card PCB Assembl A 11547 00 Brake Valve Assembly optional bells onl 424 Fiber Optic Cable Assembl Indicator Bulb 24VDC Fuse 34 1 10979 XX Fiber Optic Receiver Module 25766 106 Pressure Switch 41 VSO 1005 Replacement Solenoid optional bells onl A11465 00 Replacement Transducer A11477 00 Control Card PCB Assembly
7. Length 0 None 1 25 ft 7 62 m 3 75 ft 22 86 m 4 100 ft 30 48 m 2 50 ft 15 24 m Rotator Type 0 No rotator 6 10 unidisk 1 6 conical disk 7 12 unidisk 12 conical 2 Standard Aerobell disk 3 Aerobell 33 8 Standard Aerobell w brake 4 6 unidisk option 5 8 unidisk 9 Aerobell 33 w brake option 9 conical disk 115 or 230 VAC Input 0 115 VAC 1 230 VAC Number of Temperature Humidity Cards 0 1 2 3 4 5 Number of Atomizer Cards Rotators 0 1 2 3 4 5 SPECIFICATIONS Environmental Physical Operating Temperature 0 C to 50 C Storage Temperature 20 C to 85 C Humidity 0 to 95 non condensing Size 20 Hx 16 W x 8 D 50 8 cm X 40 6 cm X 20 3 cm Weight 52 Ibs 23 6 kg Electrical AC Input A11515 XX0XX Models 100 120 VAC 50 60 Hz 2 1Arms Fused at 3 Amps A11515 XX1XX Models 200 240 VAC 50 60 Hz 1 1 A rms Fused at 1 5 Amps Analog Inputs Remote Speed Setpoint 0 10 VDC or 4 20mA Switch Selectable Temp Humidity Inputs 4 20mA 250 ft 76 2m maximum cable length Analog Outputs Speed Feedback 0 10 VDC or 4 20mA Switch Selectable Discreet Inputs Master Enable Master Reset Rotator Enable Sourced 24 VDC 2 3mA Active Low connect input to ground to activate Discreet Outputs Temperature Humidity Master Overspeed Master Underspeed Master Loss of Feedback Master Fault Rotator Active Rotator
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9. 2 Deactivatethe enable inputforthe given rotator either by removing air from the corresponding EN input on the right side of the control panel or by deactivating the corresponding electrical enable input see Enable Inputs in the Installation section of this manual This will disable speed control to the corresponding rotator 3 the front panel Master Control Switch to the STOP position or deactivate the electrical master enable input see Electrical 1 0 in the Installation section of this manual This will disable speed control to all rotators 4 Turn the front panel Power ON OFF switch to the OFF position This will disable speed control toallrotators This should be used as a last resort The above methods are preferred over this one FAULT DESCRIPTIONS Atomizer Card The PulseTrack 2 system performs a number of operational diagnostics and will automatically stop a rotator in the event that an unsafe or abnormal condition exists The possible rotator speed faults are listed below These fault conditions are also supplied through remote output signals see Electrical I O in the Installation section of this manual Over Speed oS When this fault occurs oS is displayed on the speed display of the Atomizer Card In addition the Master Overspeed Master Fault and corre sponding Rotator Fault outputs turn on For bell rotators this fault occurs when the rotator speed exceeds the setpoint by 10 00
10. 2 Mark the fiber optic cables for later identification and remove from the receiver module 3 Unplug the terminal block s from the receiver module 4 Using a screwdriver pry the two tabs on the left side of the receiver module mounting base loose from the mounting rail and remove the receiver module 5 Snap the new receiver module onto the mount ing rail and reinstall the terminal block s and fiber optic cable s 6 Secure cabinet door and restore AC power Current to Pressure Transducer refer to Figure 19 Steps 3 4 5 and 9 may be skipped if desired 1 Turn off AC Power to the control 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 pneumatic tubing from transducer assembly IN and EXH ports as well as from each transducer output port 5 Remove the two mounting screws from trans ducer mounting manifold and remove assembly from unit 6 Remove the two mounting screws from the suspect transducer and remove transducer from assembly 7 Remove the 3 manifold O rings and replace with new o rings supplied with the new transducer 8 Mountthe newtransducer using the two mount ing screws 9 Reinstall the manifold assembly in reverse order of disassembly Tubing connections should be made as follows 10 Secure cabinet door and restore supply air
11. Defective analog input Repair or replace input source Source remote mode Defective Control Card Replace Control Card No Connection Fault Loose or defective cable 1 Repair or replace cable nc Temperature from control panel to Humidity Card Only Temperature Humidity Probe Looseinternal wiring from Repair wiring Temperature Humidity inputs TH3 TH7 to breakout board Temperature Humid ity Probe Not Reading Properly Improper rotary DIP switch 1 Verify the rotary DIP switch setting see setting on Temperature Figure 11 is the same as the slot number Humidity Card of the Temperature Humidity Card as indicated by the label inside the cabinet door Defective temperature Replace Temperatue Humidity Probe Humidity probe 5 IDENTIFICATION OQ p 8 28 ea 188 188 am ai uw N AHHA n Qz O oz 02 oz om Ox il 4 79 o D A 4 QN A gogue Figure 17 Control Panel Front Vie
12. See previous parts lists for proper dash numbers A11466 XX 24VDC Power Suppl POLICIES LIMITED Ransburg will replace or repair without charge part and or equipmentthatfalls within the specified time see below because of faulty workmanship or material provided thatthe equipment has been used and maintained in accordance with Rans burg s written safety and operating instructions and has been used under normal operating con ditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG AP PROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THEAPPLICATOR ASSOCIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THEREARE NOIMPLIED WARRANTIES NORWARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEQUEN TIALDAMAGESFORLOSS OF GOODWILLOR PRODUCTION OR INCOME WHI
13. 1 Communicates to each Atomizer Card through a high speed serial I O data bus 2 Receives external 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 analog signal feedback representing temperature and relative humidity from a probe located in a desired zone The feedback signals are scaled as needed and sent to each Tempera ture Humidity Card to be displayed 5 Performs the closed loop rotational speed computations for each atomizer An output control signal is generated and sent the current to pres sure transducers as needed to maintain the desired speed 6 Determines if there is a possible unsafe or abnormal condition and automatically shuts down the rotator and alerts the operator 7 Supplies the signals to control each brake solenoid for bell applications utilizing the brake function 8 The red flashing at upper left corner of control card indicates the microprocessor is active Atomizer Card The Atomizer Card one per atomizer provides the operator controls necessary for basic speed control operation of a given applicator and dis plays the speed and diagnostic information for that atomizer Temperature Humidity Card Optional The Temperature Humidity Card provides a user selectable display of temperature or relative hu midity for each
14. Remove the fitting from the fiber optic input port FO1 FO6 on the side of the control panel and slide over one end of the fiber optic cable Open the control panel door Insert the end of the fiber optic cable through the input port fitting and into the hole of the black rectangular fiber optic recep tacle on the fiber optic receiver module Tighten the screw of the fiber optic receptacle onto the flat of the cable extension and secure the fitting on the side panel Route the fiber optic cable to the rotator and connect the other end of the cable to the fiber optic input fitting of the rotator The fiberoptic cables are integrated into 74 tubing formechanical protection Aminimum bend radius of 3 is required Care must be taken to 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 severely reduce the ability of the cable to transmit light Fiber Optic Tighten Screw on Receptacle Cable Extension sssi Port FO1 3 at ug m V P Fiber Optic EIER Cable Figure 5 Fiber Optic Cable Installation PNEUMATIC CONNECTIONS See Table 2 All pneumatic connections are made to the right side of the PulseTrack 2 control panel Sy
15. usa dg ellcPum T E TYPICAL TURBODISK 2 INSTALLATION WITH TEMPERATURE HUMIDITY CARDS vua prc pee cerae ELECTRICALNOISE uuu INSTALLATION LOCATON akaw Naa INPUT ilM FIBEIS OFTIG CABLE h PNEUMATIC M9 er DIE cents lapel OPERATION THEORY OF OPERATION FRONT PANEL ATOMIZER CARD CONTROLS OPTIONAL TEMPERATURE HUMIDITY E Lee I o T TO ENABLE SPEED CON TROD TO DISABLE SPEED CONTROL FAULT DESCRIPTIONS u us aatassasa ayaqsspankupa MAINTENANCE GENERAL Un AM FEN OD DE SCHEDULED MAINTENANCE REPLACEMENT PROCEDURES TROUBLESHOOTING u Continued Next Page 10 11 26 oO 12 13 etu 13 13 15 16 23 CONTENTS PAGE PARTS IDENTIFICATION 4
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17. this dip switch is on all analog speed setpoint inputs are set for 4 20mA input control Dip Switch SW1 7 This dip switch is used in conjunction with board jumpers E1 E6 to set the mode of the analog speed outputs This is described previously in this section under Analog Speed Outputs and is detailed in Table 4 This switch is factory set to the OFF position Dip Switch SW1 8 This dip switch sets the current to pressure IP transducer input mode for 4 20mA It should always be in the ON position It is not possible to run the transducers in 0 10VDC input mode TABLE 6 CONTROL CARD SW1 DIP SWITCH SETTINGS SW1 1 Brake air not applied when bell turned off Brake air M when bell turned off SW1 2 Not Used Leave set to OFF SW1 4 Not Used Leave set to OFF SW1 5 Not Used Leave set to O Iis s s L N A SW1 6 0 10VDC Analog speed setpoint inputs 4 20mA Analog speed setpoint inputs SW1 7 0 10VDC Analog speed outputs 4 20mA Analog speed outputs SW1 8 DO NOT TURN OFF 4 20mA Transducer input Atomizer Card There is a 4 position dip switch SW2 located near the bottom of each atomizer card see Figure 11 These dip switches set the board for use with the desired rotator and are factory set according to the PulseTrack 2 ordering configuration see Table 7 The control card reads these dip switches and adjusts the PID control to the optimum settings for the rotator in use These settings also determine th
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19. Figure 15 AC Line Filter Top View 24VDC Power Supply refer to Fig ures 6 18 and 19 1 Turn off AC Power to the control panel at the Fused Disconnect 2 Openthe cabinetdoorand pull up onthe center portion of the TB3 F1 and TB3 F2 terminal blocks to open the AC line fuses 3 Using a small blade screwdriver disconnect the wires from TB1 and TB2 ofthe 24VDC supply 4 Using a screwdriver pull back the retaining clamp at the bottom of the power supply on the TB1 side while at the same time lifting up on that side of the supply 5 Remove the power supply from the unit and replace with a new one reconnecting the wires as follows TB3 Ground TB1 1 SW1 B3 LightBlue 6 TB1 2 SWT A4 Swrxi SW TB4 1D Dark Blue COM TB2 4 6 Push fuse blocks back in secure cabinet door and restore AC power Control Card refer to Figure 19 1 Turn off AC Power to the control panel at the Fused Disconnect and open the cabinet door 2 Remove the ribbon cable from the Control Card 3 Depress the two control card release pins 4 Pullthe Control Card out of its mounting socket and replace 5 Install new Control Card in reverse order of disassembly 6 Ensure the new Control Card DIP switch SW1 settings are correct reference Table 6 7 Secure cabinet door and restore AC power Fiber Optic Receiver Module 1 Turn off AC Power to the control panel at the Fused Disconnect and open the cabinet door
20. contact your Ransburg repre sentative or Ransburg Customer Service SCHEDULED MAINTENANCE There is no maintenance schedule for the control panel other than good housekeeping practices These include 1 Keeping the door closed at all times to maintain the dust tight environment that is preferable for the electronic circuit boards and wiring 2 Plug all unused access holes in the cabinet to keep contaminants out 3 The cabinet exterior may be cleaned with a clean dry lint free cloth If necessary isopropyl alcohol or other mild cleaning solutions can be used 4 Window cleaner or a mild solvent may be used to clean the glass window in the small swing out door REPLACEMENT PROCEDURES A WARNING Field repair and troubleshooting of the PulseTrack 2 Control Panel may require exposure to potentials that can cause SERIOUS BODILY INJURY or DEATH if proper procedures are not followed For this reason troubleshooting and field repair should only be accomplished with specif ic test equipment by qualified electronics technicians or authorized Ransburg repre sentatives Fuses F1 F2 reference Figure 4 1 Turn off AC Power to the control panel at the Fused Disconnect 2 Open the cabinet door and locate TB3 in the upper left corner of the cabinet 3 Pull up on the center portion of terminal block TB3 F1 or TB3 F2 to access the fuse 4 Push the fuse out with a small screwdriver or similar tool and re
21. flashes alternately in the speed display along with the current speed When the setpoint is reduced below maximum the rotator begins spinning the new speed In is removed from the speed display and the corresponding Rotator Fault output turns off Optional Temperature Humidity Card No Connection nc This fault occurs when the microcontroller detects a loss of either the temperature or humidity 4 20 mA signal When the temperature humidity switch is in the position of the lost signal nc will be shown on the temperature humidity display both signals are lost unconnected or cut cable nc will be shown in both switch positions Reset Fault Faults reset using of the 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 ToggletheAtomizer Card Enable Disable Reset Switch NOTES GENERAL Developing a good preventive maintenance PM program is key to keeping any system operating properly the frequency of which is determined by eachindividualinstallation Contactyour Ransburg representative or the Ransburg Service depart ment for guidelines or assistance in establishing a preventative maintenance program For maintenance of system components other than the PulseTrack 2 refer to the appropriate manual or
22. other type of solvent may be used with aluminum equipment INTRODUCTION GENERAL DESCRIPTION PulseTrack 2 system is designed to contin uously monitor and maintain the program mable speed of up to six rotary atomizers and monitortem perature and humidity for one or more zones The PulseTrack 2 system is a micro processor based design that optimizes control of rotator speed by utilizing proven proprietary software based on many years of experience This system can monitor and control the speed of rotators offered by Ransburg such as the TurboDisk Aerobell and Aerobell 33 family of applicators The Pul seTrack 2 system is designed to be versatile and adapt easily to system requirements Each PulseTrack 2 system includes a Control Card and up to six Atomizer Cards for control of rotator speed There is one Atomizer Card for each rotator Each Atomizer Card includes a dig ital display for speed and diagnostic readout and the necessary manual control switches required to operate each rotator Optional Temperature Humidity Cards display temperature and relative humidity for signals received from remote mounted probes Additionally discreet as well as analog inputs and outputs are available for use in oper ating the system The basic components of the Pulse Track 2 system are described below Control Card The Control Card is a microprocessor based printed circuit board that performs the following functions
23. remotely mounted probe Degrees Fahrenheit or Celsius can be selected Current to Pressure Transducer A current to pressure transducer is required for control of each rotator Based upon the error between the present speed and the setpoint an electrical analog signalis generated from the Con trol Card Each electrical signal is converted to a pneumatic pressure signal by the transducer The pneumatic signal is then supplied to a 1 1 air piloted regulator volume booster located near the atomizer Fiber Optic Receiver Module Afiber optic transmitter assembly located on each atomizer sends pulses of lightthrough a fiber optic cable to the Fiber Optic Receiver Module The Fiber Optic Receiver Module converts the light pulses to an electrical signal which is then sent to the Control card for processing Brake Solenoids Optional Brake solenoids supply pilot air to the brake valves in order to minimize the time required for transitions from higher speeds to lower speeds Braking is not used on Turbodisk rotators 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 speed Brake valves are not used for Turbodisk rotators A11515 PULSETRACK 2 SPEED CONTROL AND MONITOR SYSTEM MODEL IDENTIFICATION When ordering use A11515 ABCDE Model A11515 A D E
24. steam pipes etc Bolts or screws used for mounting must be at least 3 8 9 5 in diameter If mounting to a non metallic wall the mounting screws must be secured to studs in the wall If mounting to a metal wall the wall must be atleast 0 100 2 5mm thick Brake Valve s Bells Only Optional If a bell system is ordered with the brake option 11547 Brake Valve Assembly will be supplied for each bell Install the brake valve assembly s on the LAO042 Air Manifold Assembly supplied separately as follows see Figure 3 1 Remove the turbine air volume booster from the manifold by loosening the swivel fitting 2 Attach the swivel fitting of the brake valve assembly to the manifold fitting 3 Attach the swivel fitting of the turbine air volume booster to the brake valve fitting The 0042 Air Manifold should be mounted in a convenientlocation such that maximum tubing lengths from the control panel to the brake valve and the brake valve to the rotator do not each exceed 100 ft 30 5m TO BRAKE AIR INPUT OF BELL 3 8 OD TUBE FROM BRAKE CONTROL OUTPUT OF PULSETRACK 2 I 1 4 OD TUBE LAO042 AIR MANIFOLD REF FROM CONTROL OUTPUT OF PULSETRACK 2 5 32 OD TUBE TO REMOTE GAUGE OPTIONAL mmRonsbu o RBINE E H l TO TU AIR
25. the Currentto Pressure Transducer output pilot pressure Ifthe pressure climbs higher than normal or is maximum for an extended period of time then the drive air signal to rotatoris restricted or the rotator is failing If the Current to Pressure Transducer out put pressure is zero or lower than normal replace it Verify connection and operation of the brake solenoid and valve assembly Replace as necessary Verify thatthe proper rotator type is selected on the Atomizer Card DIP switches see Table 7 Observe the Currentto Pressure I P Trans ducer output pilot pressure If the pressure is higher than normal or does not decline then replace the Transducer If the Transducer appears to be operating correct ly then replace the 1 1 air piloted regulator Verify that supply air to the Control Panel and air regulator assemblies is correct and stable Connect or repair TROUBLESHOOTING GUIDE Cont LOSS OF FEEDBACK 3 Defective Fiber Optic Re 3 Check the red speed feedback LED located Fault LF Cont ceiver Module cable or on the Fiber Optic Receiver Module for the transmitter channel in question The LED should come on if the turbine rotates when enabled Ifthe LED does NOT come ON disconnect the fiber optic 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 cab
26. the DC I O Again for maximum noise immunity the cabling must contain overall foil and braided shields and be terminated in a continuous 360 manner as previously de scribed Special fittings have been provided on the control panel for termination of these cables where they enter the cabinet The use of these fittings is described under Electrical 1 0 in the Installation section of this manual s 0 0 020020 T Pigtails poor shielding PORK MI 560 Termination to ground good shielding Figure 2 Cable Connection Examples INSTALLATION LOCATION Control Panel WARNING gt The PulseTrack 2 Control Panel MUST be located outside the hazardous area see NFPA 33 gt This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and requirements for oper ating and servicing safely are followed Install the control panel in a convenient area outside the hazardous location where it will be protected from the possibility of any contact with water vapor or high humidity and ambient tem peratures do not exceed 120 F 49 C The area should be clean dry and well ventilated gt Donotlocate the control panel near or adjacent to heat producing equipment such as ovens high wattage lamps
27. 0 rpm For disk rotators thisfaultoccurs ifthe disk speed becomes greater than 45 000 rpm Under Speed uS not used for disk rotators When this fault occurs uS is displayed on the speed display of the Atomizer Card In addition the Master Underspeed Master Fault and corre sponding Rotator Fault outputs turn on For bell rotators this fault occurs when the rotator speed is less than the 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 Fault outputs turn on This fault occurs when speed control is active and the microcon troller detects that no speed feedback signal is present When the rotator is spinning the fiber optic cable sends pulses of light back to the Fiber Optic Receiver Module located in the PulseTrack 2 control panel The Fiber Optic Receiver Module converts these light pulses to electrical pulses which are then sent to the microcontroller for processing If no pulses are detected by the mi crocontroller and speed control is active a Loss of Feedback fault occurs Invalid Speed Request In This fault occurs when the speed setpoint is set to a value that exceeds the maximum speed of a given rotator In addition the corresponding Rota tor Fault output turns on When this fault occurs the rotator keeps spinning at the last acceptable speed and
28. 2 A20 Rotator 2 Fault Output J2 A26 Rotator 2 Enabled Output J2 A29 24VDC Rotator 5 Enabled Output J3 C21 Master LOF Output J3 C24 24VDC Master Fault Output Analog Speed Output ar i P P paray E a Selection Jumpers d 8 m E1 Rotator 6 alme Cat Gad E2 Rotator 5 T et E3 Rotator 4 3 5 y E y t E4 Rotator 5 8 ac E5 Rotator 2 10 RIG RIS ooi ur N PH a 3 E6 Rotator 1 eh H UE E J mmn 5 19 E 1 amp 2 0 10VDC shown We 5 gr f 8 14 2 5 4 20 3 mgl mes dr RSD RST RSE cet 3 E 3 2 X
29. 5 52 CONTROL PANEL FRONT VIEW PARTS 45 46 CONTROL PANEL INSIDE DOOR VIEW PARTS 47 48 CONTROL PANEL INSIDE CABINET VIEW PARTS 49 50 RECOMMENDED SPARE PARTS LIS irsin beta ute abr p Ruin 51 WARRANTY POLICIES 52 VM TEP A T 52 SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety liter ature 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 informa tion 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 proce dure in progress While this manual lists standard specifications 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 Comp
30. B S B Dy m Ag Sw 9 9 d S a 012545678 e oe U 0 55595698 S 8 9 032 Dip Switch SW1 Figure 10 Control Card DIP SWITCH SETTINGS Control Card There is an 8 position dip switch SW1 located near the bottom of the control card see Figure 10 Positions 2 3 4 and 5 presently have no function and should be set to the OFF position factory setting The remaining dip switches are described below and summarized in Table 6 To change the position of a dip switch perform the following 1 Turn AC power off and access the interior of the cabinet 2 Change the desired dip switch setting 3 Secure the cabinet door and turn AC power back on NOTE The AC power must be cycled for the new dip switch setting to be recognized 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 assist in bringing the bell to a stop when speed control is turned off as well as when decreases in operating speed are made When this switch is off factory setting brake air is only used when decreases in operating speed are made and is NOT applied when speed control is turned off Dip Switch SW1 6 This dip switch is used to set the mode of the an alog speed setpoint inputs When this dip switch is off factory setting all analog speed setpoint inputs are set for 0 10VDC input control When
31. CH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will assume no responsibility for repair or replacement of the item or items The purchas er therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable MANUAL CHANGE SUMMARY This manual was published to 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 from green to red on page 40 Troubleshooting Guide Service Manual Price 25 00 Euro 30 00 U S Manufacturing 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 Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No LN 9248 05 3 2013 Ransburg rights reserved ISO 9001 Litho in U S A Models and specifications subject to change without notice Quality Systems 03 13
32. Fault Brake Control Active High put out 24 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 Inputs 15 psi 1 03 bar minimum to activate 150 psi 10 3 bar maximum Outputs Control Outputs 0 106 ID by 5 32 OD 100 ft 30 5m maximum length to volume booster 0 170 ID x 1 4 OD 100 ft 30 5m maximum length to brake valve assembly Brake Control 1 4 ID x 3 8 OD 100 psi maximum 100 ft 30 5m maximum length from brake valve assembly to rotator Longer tubing lengths may be acceptable de pending on overall total lengths of pilot signals and supply signals andthe specific application However longer lengths may degrade overall speed control performance Brake Supply General Fiber Optic Cable Maximum length is 150 ft 45 7m Temperature Humidity Probe Temperature Range 0 100 32 212 F Accuracy 6 C CE Repeatability 05 Humidity Range 3 95 RH Accuracy 72 F 2 5 from 20 to 80 3 1 lt 20 gt 80 0 1 F 1 RH Drift Repeatability 5000 2 ShOQNVZVH NON 201 SNOGYYZVH 30 3015100 Q31v201 38 ISA 380Nd ALIGINNH SYNLVYSd NAL
33. INPUT OF BELL 3 8 OD TUBE A11547 VALVE ASSEMBLY VOLUME BOOSTER PART OF LA0042 AIR MANIFOLD Figure 3 Optional Brake Control Valve Assembly Bell Systems Only Temperature Humidity Probe s Optional WARNING gt The temperature humidity probes MUST be located outside the hazardous area see NFPA 33 Install the optional temperature humidity probe s in a desired area outside the hazardous location such that the maximum length of cable from the probe to the control panel does not exceed 250 ft 76 2m A 50 ft 15 2m cable assembly is supplied with each probe Additional 50 ft 15 2m cable assemblies p n 77220 00 may be purchased separately to extend this length up to the 250 ft 76 2m maximum INPUT POWER TheAC Input power routing and connections to the control panel should be supplied from a FUSED DISCONNECT rated 10Amps 240VAC or great er and should meet all guidelines of applicable electrical codes and any other requirements as suitable for the location LOCKOUT TAGOUT procedures should be put in place for the fused disconnect Using conduit route the input power wiring 14 AWG 2mm 300V minimum through the AC Power opening in the top left corner of the control panel Forgreatest noise immunity the AC input should be located as close as possible to the AC line filter see Figure 4 For this reason it is recommended that the AC input not be relocated to another
34. M3WOd 20 72 SMS 09 0 v81 noo rto vaL O57 OVA0ZZ X04 MOIS A OSZ 91 Woo a 8L Swop 81 971 11 1619 OVAOLL MOTE MOIS OVE A OGZ Noo az va8L 27105 2 202 1 2 77 2 91 ewo 01 81 2 57 2 Control Panel Schematic Figure 7 REMOTE 2 MES Figure 8 Electrical I O Connectors Cable Grommet Sum Ou EE Ec Figure Cable Hardware Analog 1 0 am 1 0 64 1 1 2 54cm Cabinet Connector Housing Figure 9B Stripping Of I O Cable Inputs Analog Speed Setpoint Inputs Analog speed setpoint inputs are available for rotators 1 through 6 at breakout terminals J2 A1 through J2 A6 Using dip switch 6 of SW1 on the Control Card these inputs can all be set so a 0 10VDC or 4 20mA input signal gives 0 100 000 rpm rotator speed See Switch Settings later in this section For 4 20mA input signals the following equation c
35. Pneumatic transducer output CL 1 CL6 dis connected 3 Fiber Optic Cable is damaged or not connected 4 Faulty air volume booster 5 Transducer electrical input disconnected or faulty transducer 6 Faulty Control Card T Faulty Fiber Optic Receiver module 8 The rotator has seized and will not spin Invalid Speed Request In Fault 1 Speed setpoint set too high 2 Defective atomizer card local mode 3 Defective analog input source remote mode No Connection nc Fault Temperature 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 entire System First try to isolate generally where in the system the problem lies If the same problem is occurring on more than one rotator inspect those system elements that are common to all the problem rotators This includes the air supply pressure to the control panel as well as the re motely mounted air piloted regulators This also includes the Control Card 24VDC power supply front panel switches fuses AC line filter and any wiring associated with them If the problem occurs on one rotator but not oth ers inspect those system elements that are spe cific to each rotator These include the Atomizer Cards current to pressure transducers pressure switches Fiber Optic Receiver Modules brake valves brake solenoids an
36. SERVICE MANUAL Ransburg LN 9248 05 3 Replaces LN 9248 05 2 March 2013 PULSETRACK _ SPEED CONTROLAND MONITOR SYSTEM O k i s s E ex Ox Qum gum T 0 ES Ec o MODEL 11515 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 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 5 SAFE TY PRECAUTIONS HAZARDS SAFEGUARDS u INTRODUCTION GENERAL DESCRIPTION ua A11515 PULSETRACK 2 SPEED CONTROL AND MONITOR SYSTEM MODELIDENTIFIGATIQOIP i
37. a fire hazard Protection against inadver tent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during opera tion Frequent Power Supply or Controller shutdown indi cates a problem in the system requiring correction SAFEGUARDS Tells how to avoid the hazard 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 flushing or main tenance When using solvents for cleaning Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100 F 37 8 Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA country and local codes In addition ventilation must be main tained during cleaning operations using flam mable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance 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 r
38. age Equipment HAZARD Tells what the hazard is Electrical Discharge 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 fire or explosion SAFEGUARDS Tells how to avoid the hazard Parts being sprayed and operators in the spray area must be properly grounded Parts being sprayed must be supported on con veyors or hangers that are properly ground ed The resistance between the part and earth ground must not exceed 1 meg ohm Refer to NFPA 33 Operators must be grounded Rubber soled in sulating 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 ap plicator 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 electrically conductive objects in the spray area with the exception of those objects re quired by the process to be at high voltage must be grounded Grounded conductive flooring must be provided in the spray area Always turn off the power supply prior to flush ing cleaning or working o
39. al to its 4 20mA input to the 1 1 volume booster The volume booster produces a high flow output pressure to the rotator turbine that is equivalent to the pilot input pressure received from the transducer In this manner a speed output that is lower higher than the setpoint creates a positive negative error that increases decreases operating pressure tothe rotator until the setpoint speed is reached Optional Brake Control Bells Only When the speed setpoint of a bell is decreased or speed control is disabled Control Card dip switch SW1 1 ON the microcontrollerturns on the corresponding Brake Solenoid The output of the brake solenoid 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 the Brake Valve Assembly is then directed against the rotator vanes causing it to decrease speed more quickly than if no brake signal was used Once the rotator reaches the desired speed the microcontroller turns off the Brake Solenoid Optional Temperature Humidity Control The temperature humidity probe contains trans ducers that convert humidity and temperature data to 4 20mA signals These signals are then sent back to the microcontroller where they are processed and displayed on the Temperature Humidity Card FRONT PANEL CONTROLS See Figure 12 Power ON OFF Switch This gree
40. an be used to determine the mA input signal corresponding to a given speed speed rpm x NE NE 4 100 000 ram Table 3 shows 0 10VDC and 4 20mADC input signals for speeds from 0 to 100 000 rpm in steps of 5 000 rpm TABLE 3 INPUT SIGNALS FOR GIVEN SPEEDS 0 V 500 10200 20 000 Enable Inputs Discreet enable inputs are available for rotators 1 through 6 to interlock the speed control with a remote signal This can be done pneumatically as described previously under Pneumatic Con nections or electrically The electrical inputs for each rotator are available at breakout terminals J3 C15 through J3 C20 These inputs are active low Thus when they are connected to ground speed control is enabled Master Enable Input A master enable switch exists on the front of the control panel that must be enabled for any rotator speed control to be active Ifitis disabled all rotator speed controls are inactive This convenient if it is desired to turn off all rotators at the same time This active low signal is also available remotely at breakout terminal J3 C14 Thus this discreet input can be made active by connecting J3 C14 to ground via a remote switch or PLC contact Master Reset Input A master reset switch exists on the front panel for the purpose of resetting any faults that may occur This momentary active low signal is also available remotely at breakout terminal J3 C13 Thus this dis
41. and AC power EH ExwustTee N Supply Tee ro TRD3 CL3 TRD4 CL4 TRDS TRD Brake Solenoid bells only refer to Figures 6 16 and 19 1 Turn off AC Power to the control panel at the Fused Disconnect and open the cabinet door 2 Turn off supply air to the cabinet and bleed off pressure 3 Disconnect wires for each solenoid from their termination points on J3 of the breakout board and TB4 4 Remove pneumatic tubing from solenoid as sembly and ports as well as from each solenoid output port 5 Remove two mounting screws from solenoid mounting manifold and remove assembly from unit 6 Remove two mounting screws from solenoid end bracket 7 Remove suspect solenoid and O rings and H o o BA ae ccH er OMe 0000 O Rings ounting Screws Figure 16 Brake Solenoid Disassembly replace 8 Reinstall the two mounting screws in the sole noid end bracket 9 Reinstall the solenoid manifold assembly in reverse order of disassembly Wiring connections should be made as follows 84 50 COM 26C SOL2 Top TB4 6D COM SOL3 Bottom SOL3 Top SOL4 Top SOL6 Top J3 27C 27C TB4 4D COM 28 TB4 5D COM 29 TB4 6D COM J3 30C 30C 10 Secure cabinet door and restore supply air and AC p
42. are this manual with your system installation draw ings and appropriate Ransburg equipment man uals to reconcile such differences Careful study and continued use ofthis manual will provide a better understanding of the equipment and process resulting in more efficient 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 gt The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified gt This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFE TY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment WARNING gt The hazards shown on the following pag es may occur during the normal use of this equipment Please read the hazard chart be ginning on page 2 Tells where hazards may occur Spray Area HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and maintenance procedures will cause
43. ature Humidity Display f TEMPERATURE HUMIDITY Temperature Humidity Switch TEMPERATURE HUMIDITY F Switch TEMP HUMIDIT Y Active CARD Indicator Figure 14 Optional Temperature Humidity Card Controls ENABLE SPEED CONTROL Toenable speed control first make sure the Pulse Track 2 is installed as detailed in the Installation section of this manual Local Mode Operation 1 Turn the front panel Power ON OFF switch to the ON position 2 Ensure the local remote switch on the Atomiz er Card is in the local position 3 Turn the front panel Master Control Switch to the RUN position or activate the electrical master enable input see Electrical I O in the Installation section of this manual 4 Activate the enable input for the given rotator either by supplying air to the corresponding EN input on the right side of the control panel or by activating the corresponding electrical enable input see Enable Inputs in the Installation section of this manual 5 Usingthe Speed Select Thumbwheel Switch on the Atomizer Card set the desired speed setting for the corresponding rotator and press the Speed Enter Button 6 Move the Atomizer Card Enable Disable Re set Switch to the enable position Speed control should begin on the rotator corresponding to the selected atomizer card Remote Mode Operation 1 Set Dip Switch SW1 6 on the Control Card fo
44. creet input can be made active by connecting J3 C 13 to ground via a remote switch or PLC contact Temperature Inputs Analog temperature inputs 4 20 for up to 5 probes are available at breakout terminals J2 A3 through J2 A6 and J4 B1 Signals supplied to these inputs from remote mounted temperature humidity probes optional are processed by the main control board and sent to the corresponding Temperature Humidity Card optional for display Terminals J2 A3 through J2 A6 are dual function terminals They may be used for analog speed setpoint input or temperature input depending on the configuration of the PulseTrack 2 system Humidity Inputs Analog humidity inputs 4 20mA for up to 5 probes are available at breakout terminals J4 B2 through J4 B6 Signals supplied to these inputs from remote mounted temperature humidity probes optional are processed by the main control board and sentto the corresponding Temperature Humidity Card optional for display Outputs Analog Speed Outputs Analog speed output signals are available for rotators 1 through 6 at breakout terminals J2 A13 through J2 A18 These outputs can all be set so that 0 10VDC or 4 20 mA represents 0 to 100 000 rpm using jumpers E1 through E6 and dipswitch SW1 7 on the Control Card see Figure 10 The jumpers and dipswitch are factory set to the 0 10VDC positions Table 4 summarizes the analog output settings Rotator Fault Outputs Discreet fault outputs a
45. d any wiring or tubing associated with them TROUBLESHOOTING GUIDE General Problem No Power Green Power Switch Light Does Not Come On and Displays Are Blank No Displays Green Power Switch Light Is ON But One Or Card Displays Are Blank 1 115 230 VAC source switch on 24VDC power supply set to wrong position 2 ImproperAC input voltage from control panel terminal TB3 L to TB3 N 3 ImproperAC input voltage from control panel terminal TB3 F2 to TB3 F1 4 ImproperAC input voltage from control panel terminal SW1 A3 to SW1 B4 5 ImproperAC input voltage from control panel terminal SW1 A4 to SW1 B3 with switch on 6 ImproperDC voltage from 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 Control Card to each Atomizer and Tem perature Humidity Card Continued On Next Page 1 Set24VDC powersupply source switch to proper position Check factory voltage from the external fused disconnect Replace fuse F1 and or F2 Replace AC line filter LF1 Repair or replace switch SW1 Replace 24VDC power supply Secure any loose or disconnected wires Check for flashing red LED1 at upper left corner of Control Card If not flashing cycle AC power If red LED1 still does not flash replace the Control Card Secure or replace ribbon cable assembly Replace
46. e in hazard ous locations the power supply control cabinet and all other electrical equipment must be locat ed outside Class or II Division 1 and 2 hazard ous 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 flammable or combus tible 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 Follow the requirements of the Material Safety Data Sheet supplied by coating material manu facturer 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 Aluminum is widely used in other spray appli cation equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing 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
47. e maximum speed for the rotator in use If it becomes necessary to change these settings do to a change in rotator type perform the following WARNING gt Use the proper setting for the rotator in use Use of the incorrect setting can result in higher rotator speeds than design per mits This can lead to rotator failure causing property damage and or personal injury 1 Turn AC power off and access the interior of the cabinet 2 Change the desired dip switch settings 3 Secure the cabinet door and turn AC power back on The AC power must be cycled for the new dip switch setting to be recognized TABLE 7 ATOMIZER CARD SW2 DIP SWITCH SETTINGS Ordering Configuration Rotator Type A11515 XXX1X 6 Conical Disk A11515 XXXAX 6 UniDisk A11515 XXX5X 8 UniDisk 4 9 Conical Disk A11515 XXX6X 10 UniDisk A11515 XXX7X 12 UniDisk amp 12 Conical Disk A11515 XXX2X Standard Aerobell mue A11515 XXX3X Aerobell 33 30 amp 57mm Temperature Humidity Card There is also a 4 position dip switch SW2 located near the bottom of each temperature humidity card These dip switches should always be set to the OFF position Rotary DIP Switch There is a rotary DIP switch SW1 located on each Atomizer and Temperature Humidity Card see Figure 11 The setting of this switch must match the slot number the card is occupying as listed on the label inside the front panel door re
48. ectrical equipment must be located outside Class or Division 1 or 2 hazardous areas in accordance with NFPA 33 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 against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power supply shutdown indicates a prob lem in the system which requires correction Always turn the control panel power off prior to flushing 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 accor dance with NFPA 33 EN 50176 Have fire extinguishing equipment readily avail able and tested periodically 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 equip ment Comply with appropriate local state and na tional codes governing ventilation fire protec tion operation maintenance and housekeep ing Reference OSHA NFPA 33 EN Norms and your insurance company requirements Tells where hazards may occur Spray Area High Volt
49. eplacement parts or unautho rized equipment modifications may cause fire or injury If used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks dis abled Never use equipment intended for use in water borne installations to spray solvent based ma terials 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 Tells where hazards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate oper ation and maintenance proce dures will cause a fire hazard Protection against inadvertent arcing that is capable of caus ing fire or explosion is lost if any safety interlocks are dis abled during operation Frequent Power Supply or Controller shutdown indicates a problem in the system requir ing correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Unless specifically approved for use in hazard ous locations all el
50. ference Figure 18 Maximum Speed EE orm OFF 15 0 UE C3 e KS 3 Rotary DIP Switch SW1 k LEER RE 8 4 1 LEDI PULSETRACK CHANNEL CARD A11448 EV Dip Switch 52 Figure 11 Atomizer Card Dip Switch OPERATION THEORY OF OPERATION Speed Control When the rotator is spinning the fiber optic cable sends pulses of light back to the Fiber Optic Re ceiver Module located in the PulseTrack 2 control panel The Fiber Optic Receiver Module converts these light pulses to electrical pulses which are then sent to the microcontroller From these pulses the microcontroller determines the actual speed at which the rotator is currently spinning This speed is then subtracted from the speed setpoint to create an error The error is added to the present drive and output to the Current to Pressure 1 Transducer as a 4 20 mAsignal The transducer outputs 0 100 psi pilot pressure signal proportion
51. gure 12 Front Panel Operating Controls ATOMIZER CARD CONTROLS See Figure 13 Atomizer Speed Display This two digit display indicates rotator speed in rpm x 1000 krpm during normal speed control operation During fault conditions a two digit fault code is displayed to indicate what fault has occurred Speed Select Thumbwheel Switch This switch is used in local mode to manually enter the speed control setpoint in thousands of rpms krpm Press the or switch buttons to incre ment or decrement the desired digit After setting the desired values press the Speed Enter button to confirm the new setpoint If the setpoint is set higherthan the maximum allowable rotator speed In invalid request will flash in the speed display until the setpoint is reduced below the maximum Local Remote Switch When the local remote switch is in the local posi tion the setting on the Speed Select Thumbwheel switch is used to determine the speed output see Local Mode Operation in the Operation section When this switch is in the remote position the analog speed setpoint inputs are used to determine the speed output see Remote Mode Operation in the Operation section Speed Enter Button This button is used in local mode to confirm speed setting changes made using the thumbwheel switch see Speed Select Thumbwheel Switch in the Operation section Enable Disable Reset Switch This switch mustbe in the enable position t
52. hield with an overall braided shield Special noise reduction connectors have been provided at the top of the PulseTrack 2 control panel for routing of all electrical see Figure 8 Signals specific to an individual rotator can be routed through that rotator s ATM connector while common signals can be routed through the SYS connector To make electrical I O connections using these connectors perform the following 1 Remove the cable grommet hardware from the desired connector see Figure 2 Routedesired length of cable through connector housing and mark 1 span of cable that passes through connector housing as shown in Figure 9B 3 Remove cable and strip marked 1 section to the cable braid 4 Slide the cable grommet hardware onto the cable in the order shown in Figure 9A 5 Routethe cable backthrough the cable housing and make the appropriate terminal connections see Table 5 6 Tighten the cable grommet ensuring the grom met spring makes 360 contact with the exposed cable braid 7 Formaximum noise immunity connectthe braid of the cable to earth ground at the end opposite the control panel NOTES NO WO2 29 NOWAO2 89 2 e 2 annog NONNO0 V9 0 n o 2 a sansz g NONN00 vS Nonmoo ay 2 2 e 2 NOAWOO v pgi 92 O0 vZ NOWNOO as ee Qiu NONN00 v NOWNO2 QZ z 2 2 2
53. le If light is observed then replace the fiber optic receiver If the fiber optic cable is replaced and the problem still exists then replace the fiber optic transmitter located on the rotator Hint Afiberoptic cable from an operational rotator can be temporarily switched to a different receiver input to help verify the above Defective volume booster 4 Check Currentto Pressure Transducer output regulator or seized rotator pressure Ifitis increasing and rotator does not spin check volume booster regulator and rotator for cause Current to Pressure Trans ducer disconnected 5 Verify electrical and pneumatic connections defective to Current to Pressure Transducer for corre sponding rotator If all items above are OK and there is no output from the transducer then replace it Defective Control Card If all items above are OK replace the control card Invalid Speed Speed setpoint set too high 1 Lower speed setpoint command Request Fault In on Speed Select Thumb wheel Switch local mode or from remote analog input remote mode Defective Atomizer Card 2 Replace Atomizer Card local mode Defective analog input 3 Repair or replace input source source remote mode Continued On Next Page TROUBLESHOOTING GUIDE Cont Analog Inputs or Improper DIP switch and 1 Correct settings see Tables 4 and 6 Outputs Not Working or jumper settings on Properly Control Card
54. n connect the supplied 1 4 OD tubing from the activation source to the Enable input on the right side of the control panel Typically the pneumatic Enable input is used to interface with an Ransburg Air Logic Panel See the appropriate service manual for further information Optional Brake Control Output s BR1 BR6 Bells Only See Figure 3 Using the supplied 1 4 OD tubing connect the brake control output s to the pilot air input s of the supplied brake valve assembly s Using the supplied 3 8 OD tubing connect the output port of the brake valve assembly s to the brake air input of the bell applicator s When a lower speed is requested than the speed the bellis currently spinning at the brake valve will turn on and apply air against the rotator vanes to assistin a more rapidtransition to the lowerspeed Once the new speed is reached the brake valve will turn off Additionally itis possible to configure the system sothatthe brake turns on when the bell speed is disabled to assist in bringing the bell to a full stop more quickly This is explained further under Dip Switch Settings in the Installation section of this manual a Rotator 6 Brake Valve Assy Pilot ELECTRICAL I O See Table 5 Electrical terminals are available from breakout board inside the PulseTrack 2 control Panel see Figures 6 and 7 For maximum noise immunity all electrical I O should be run in cable having a foil s
55. n spray system equip ment Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class or Il Division 1 or 2 haz ardous areas in accordance with NFPA 33 Tells where hazards may occur Electrical Equipment hem e Toxic Substances Spray Area HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized the process Arcing in the vicinity of flammable or combustible materials may oc cur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correc tion An electrical arc can ignite coat ing materials and cause a fire or explosion Certain material may be harmful if inhaled or if there is contact with the skin Explosion Hazard Incompatible Materials Halogenated hydrocarbon sol vents for example methylene chloride 1 1 1 roethane are not chemically compatible with the aluminum that might be used in many sys tem components The chemical reaction caused by these sol vents reacting with aluminum can become violent and lead to an equipment explosion SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for us
56. n switch turns AC power to the Pulse Track 2 control panel on or off It lights up when AC power is being supplied Master Control Switch When the Master Control switch is in the STOP position speed control to all rotators is disabled regardless of other switch settings Speed con trol cannot be enabled for any rotator unless this switch is in the RUN position Master Reset Switch This switch is used to reset faults that occur on any rotator Speed Fault Indicator This red light illuminates when a fault condition exists on any rotator It remains illuminated until the fault condition is reset Speed Fault Horn The Speed Fault Horn sounds when a fault con dition exists on any rotator It remains on until the fault condition is reset F i i Ei Ei oz oz oz ox H aen ae eem L Master Reset B Switch WI Master Contro Speed Fault L Switch Indicator Speed Fault Horn B Power ON OFF switch BI Ransburg HER Fi
57. ntered and suggestions that may shorten the time involved in troubleshooting the system More detailed information can be found in the Troubleshooting Chart in the Maintenance section Most Common Problems There are no adjustments on the Control Card per taining to speed control The control parameters are established for each rotator through software based on switch settings Once the system is setup correctly and has been in operation any developing problems will be due to air leakage a component failure or a system application issue Troubleshooting a rotator speed control problem generally consists of isolating the problematic system component and replacing that component During troubleshooting it is important to first rec ognize the possible fault modes and consider the circumstances that might cause them The most common system problems and associated fault modes are listed below Underspeed uS Fault 1 Air supply to the system is not adequate 2 Air leak in the system 3 The rotator is damaged or failing 4 The current pressure transducer is not func tioning properly Overspeed oS Fault 1 The braking air solenoid is not functioning properly 2 The brake air line has lost connection to the rotator 3 The brake air valve is defective 4 The currentto pressure transducer is not func tioning properly Loss of Feedback LF Fault 1 Supply air to control panel or rotator turned off 2
58. o enable speed control for a given rotator Ifthis 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 speed control is enabled on a given rotator Atomizer Speed e display Ey Di splay SPEED X1000 Switch Speed Select Buttons Thumbwheel Switch Switch SELECT i Buttons ri Local Remote Switch x Speed Enter oWILC SPEED Button LOCAL 9 ef Enable A ENABLE gt 7 DISABLE RESET Disable Reset Switch Active CARD Indicator c e Figure 13 Atomizer Card Operating Controls OPTIONAL TEMPERATURE HUMIDITY CARD CONTROLS See Figure 14 Temperature Humidity Display This three digit display indicates temperature from 32 to 199 F 0 to 100 C or relative humidity from 0 to 100 Temperature Humidity Switch This switch selects whether temperature or rel ative humidity is displayed on the temperature humidity display F C Switch This switch selects whether the temperature dis play is in Fahrenheit F or Celsius C Active Indicator This green LED illuminates when the Temperature Humidity Card is functioning properly 6 Temper
59. ower TROUBLESHOOTING WARNING gt Field repair and troubleshooting of the PulseTrack 2 Control Panel may require exposure to potentials that can cause SERIOUS BODILY INJURY or DEATH if proper procedures are not followed For this reason troubleshooting and field repair should only be accomplished with specif ic test equipment by qualified electronics technicians or authorized Ransburg repre sentatives WARNING Allsafety precautions listed in the Safety section of this manual must be followed when troubleshooting Contacting Ransburg Representative or Customer Service Before contacting your Ransburg repre sentative or the customer service department be prepared with the following specific information This will help resolve problems quicker Control panel model number and serial number The basic system configuration including type of applicators coating used etc The type of problem that is occurring and the frequency that it occurs if applicable Anything in the system that was changed right before the problem started Anytroubleshooting that has already been attempted BASIC SYSTEM TROUBLESHOOTING Whentracing problems referto system installation drawings the Control Panel Schematic in Figure 7 the Troubleshooting Chart in this section and the Operation and Parts Identification sec tions ofthis manual Thefollowing section outlines the most common problems encou
60. place with a new one 5 Push center portion of terminal block back in secure cabinet door and restore AC power Atomizer or Temperature Humidity Card 1 Turn off AC Power to the control panel at the Fused Disconnect 2 Open the cabinet door and disconnect the rib bon cable from the rear of the card to be replaced 3 Open the small glass door loosen the mounting screws on the front of the card 4 Remove the card from the unit and reinstall the new card in reverse order of disassembly 5 Ensure the SW2 DIP switch settings of a new Atomizer Card are correct for the rotator in use see Figure 11 and Table 7 6 Ensure the SW1 rotary switch setting see Figure 11 is the same as the slot the card is in stalled in as shown on the label inside the cabinet door 7 Securethe cabinet door and restore AC power Front Panel Bulbs Switches or Indicators 1 Turn off AC Power to the control panel at the Fused Disconnect 2 Openthe cabinet door and pull up on the center portion of the TB3 F1 and TB3 F2 terminal blocks to open the AC line fuses 3 Removethe contactblockholderfrom the back of the switch as follows a Forthe AC power switch SW1 there is a small lever that can be moved to the OFF position to remove the contact and pilot light blocks and block holder as one assembly If the contact or pilot light block needs replaced refer to b below for block removal from the holder b For the othe
61. position on the control panel Route the input power wiring through the conduit and attach to terminal block TB3 as shown in Table 1 and Figure 4 TABLE 1 AC INPUT POWER CONNECTIONS AC Neutral TB3 N AC Line Hot TB3 L CAUTION gt After making the input power con nections double check to ensure that the control panel is properly grounded by measuring the resistance from one of the Remote connectors on the top of the panel to an external ground reference The resistance should be less than 0 1 ohms The control panel is preconfigured for 115 or 230 VAC depending on the model number Refer to the Parts Identification section of this manual and the product specification label located on the control panel lt 2 E du AC Input Power E from Fused Z i Disconnect lt lt T T ele 8 Q6 o o 185 Ft Fa 250 V 1 1 4 X 1 4 BAG SLOW BLOW FOR TSK 3119 XXOX P N 4151 11 FOR 5 5119 1 1 5 A P N 4131 03 AC Line Filter Figure 4 AC Input Power Connections FIBER OPTIC CABLE See Figure 5
62. r the desired mode of operation For a 0 10VDC input signal set SW1 6 to the OFF position Fora 4 20mA input signal set SW1 6 to the ON position see Dip Switch Settings in the Installation section of this 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 RUN position or activate the electrical master enable input see Electrical I O in the linstalla tion section of this manual 5 Activate the enable input for the given rotator either by supplying air to the corresponding EN input on the right side of the control panel or by activating the corresponding electrical enable input see Enable Inputs the Installation section of this manual 5 Supply a 0 10VDC or 4 20mADC input sig nal to the electrical I O breakout terminal J2 A1 through J2 A6 corresponding to the given rotator see Table 5 in the Installation section of this manual 6 Move the Atomizer Card Enable Disable Re set Switch to the enable position Speed control should begin on the rotator corresponding to the selected atomizer card TO DISABLE SPEED CONTROL Speed control can be disabled using any of the following methods 1 Move theAtomizer Card Enable Disable Reset Switch to the disable position This will disable speed control to the rotator corresponding to the given Atomizer Card
63. r switches and indicators first remove the 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 bulb can be replaced Then squeeze the clips of the holder together slightly pull back and remove 4 Toreplace a bulb push in on the bulb and twist counter clockwise to remove 5 To replace a switch or indicator remove the nut from the back of the switch or indicator and remove the part from the door panel 5 Replace with new parts and reinstall in reverse order of disassembly 6 Push fuses back in secure cabinet door and restore AC power AC Line Filter See Figure 15 1 Turn off AC Power to the control panel at the Fused Disconnect 2 Open the cabinet door and pull up on the center portion of the TB3 F1 and TB3 F2 terminal blocks to open the AC line fuses 3 Remove the 5 quick connect terminals from the filter 4 Remove the filter mounting hardware 5 Remove the filter and replace with a new one connectingthe quick connectterminals as follows Color To TB3 F Light Blue Filter Terminal 1 TB3 F2 Filter Terminal 3 TB3 Ground Green Yellow Filter Terminal 2 SW1 B4 LightBlue Filter Terminal 4 6 Push fuse blocks back in secure cabinet door and restore AC power 4 E
64. r type is selected on the Atomizer Card DIP switches see Table 7 Check that the red LED on the Fiber Optic Receiver Module is ON and stable while the rotator is turning If not replace fiber optic cable or Receiver Module Check the output pilot pressure from the transducer Ifunstable replace transducer 5 Verify that enable and remote analog speed setpoint signals are stable The Active LED located on the Atomizer card should be stable and not blinking Secure any loose wiring and debug any system control components Verify that supply air to the Control Panel and air regulator assemblies is correct and stable 2 Locate leak and repair TROUBLESHOOTING GUIDE Cont General Problem UNDERSPEED Fault uS Cont OVERSPEED Fault oS LOSS OF FEEDBACK Fault LF 3 Improper rotator type 3 Verify thatthe proper rotator type is selected switch setting on Atomizer Card 4 Failing rotator or restricted drive air 5 Defective Current to Pres sure Transducer 1 Defective brake solenoid or brake valve assembly tubing connection or com ponent bells 2 Improper rotator type DIP switch setting on Atomizer Card 3 Defective Current to Pres sure Transducer 1 No supply air to rotator or control panel 2 Current to Pressure Trans ducer output CL1 CL6 disconnected or broken Continued On Next Page on the Atomizer Card DIP switches see Table 7 Observe
65. re available for rotators 1 through 6 at breakout terminals J2 A19 through J2 A24 to indicate remotely which rotator caused a fault condition These active high outputs put out 24VDC when active Maximum output current from each output is 250 Run Outputs Discreet run outputs are available for rotators 1 through 6 at breakout terminals J2 A25 through J2 A30 to indicate remotely when speed control is enabled for a given rotator These active high outputs put out 24VDC when active Maximum output current from each output is 250 Master LOF Output A24VDC discreet output exists at breakout terminal J3 C21 to indicate when a loss of feedback LOF fault occurs on any rotator Using this output in conjunction with the individual rotator fault output it is possible to remotely determine on which rotator the LOF fault occurred Maximum output current from this output is 250 Master Underspeed Output A24VDC discreet output exists at breakout termi nal J3 C22 to indicate when an underspeed fault occurs on rotator Using this active high output in conjunction with the individual rotator fault out put it is possible to remotely determine on which rotator the underspeed fault occurred Maximum output current from this output is 250 mA Master Overspeed Output A 24VDC discreet output exists at breakout terminal J3 C23 to indicate when an overspeed fault occurs on any rotator Using this output in conjunction with the individ
66. seeFigure3 Fiber Optic Cable Assembly 25 ft 7 Fiber Optic Cable Assembly 50 ft 15 2 Fiber Optic Cable Assembly 75 ft 22 9m Fiber Optic Cable Assembly 100 ft 30 5 _ H238 Tubing Pneumatic 38 00 19040 Tubing Pneumatic V 4 OD 589 TR SSEM 548 Tubing Pneumatic 5 32 OD b SQ 22 s s Le e Le Le amp j uy j uy L Stress Lap i T e ioo de SLOT 5 SLOT 4 SLOT 3 SLOT 2 SLOT 1 S
67. stem components should be installed to minimize the length of pneumatic control lines This will max imize the rotator speed control response Tubing may exceed the maximum lengths as indicated in the Specifications in the Introduction section of this manual dependent on the specific installation requirements however this could degrade overall speed control performance Supply Air Using the supplied 3 8 OD tubing connect the Supply air inlet to a source of clean dry factory air having an operating pressure of 80 psi 5 5 bar minimum and 110 psi 7 6 bar maximum For optimal speed control response ensure the supply air is at least 100 psi minimum operating pressure Control Output s CL1 CL6 Using the supplied 5 32 OD tubing connect the control output s to the pilot signal port s of the volume booster s which are supplying turbine air to the rotator s It may be necessary to install a 5 32 adapter fitting in the volume booster pilot port DO NOT replace this tubing with larger diameter tubing or speed response may be ad versely affected Enable Input s EN1 EN6 The enable input is an interlock which must be made active in order for speed control to occur on a given channel This can be done pneu matically by using the enable inputs on the right side of the control panel or electrically by using a remote switch across the enable input contacts see Electrical I O later in this section For pneumatic activatio
68. the Control Board if no problemis found with the ribbon cable TROUBLESHOOTING GUIDE Cont MASTER RUN 1 Pneumatic or electrical enable input missing or defective Switch Is Turned To RUN But The Rota tor s Do Not Turn ON and No Faults Occur Improper rotary DIP switch Rotator Speed Is Not Stable setting on Atomizer Card Improper supply air to the Control Panel and or air regulator assemblies Improper rotator type DIP switch setting on Atomizer Card Defective Fiber Optic Receiver Module or cable Defective Current to Pressure Transducer Pulsating enable or remote UNDERSPEED Fault uS analog speed setpoint inputs Insufficientsupply airtothe Control Panel and or air regulator assemblies Air leak in the system Continued On Next Page Verify that there is a rotator enable air signal to the corresponding enable input EN1 EN6 on the side of control panel a rotator enable electrical signal to the cor 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 Verify the rotary DIP switch setting see Figure 11 is the same as the slot number of the Atomizer card as indicated by the lable inside the cabinet door Verify that supply air to the Control Panel and air regulator assemblies is correct and stable 2 Verify that the proper rotato
69. trol panel the ground ed enclosure provides this envelope Forfactory supplied control cables shielded cable has been used The shield typically consists of an overall foil 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 as soon as it enters the cabinet This filter filters out any noise that comes in on the AC line For maximum noise immunity the AC line should connect to the 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 recommended method and is required by most codes For maximum noise protection any user supplied input output wiring should be made using shielded cable or conduit which is connected to earth ground in a continuous 360 fashion at both ends The best way to do this is to use a connector fitting at each end of the cable conduit that makes contact to the grounded enclosure in this manner Connecting the drain wire of a shield to a ground point on or in the cabinet usually referred to as pigtailing is not an effective method of shielding and actually making things worse see Figure 2 Cable is recommended for
70. ual rotatorfault output it is possible to remotely determine on which rotator Brake Outputs Optional Bells Only 24VDC brake outputs are located at breakout ter minals J3 C25 through J3 C30 For bell systems configured with the brake option these outputs send 24VDC to the brake solenoids when bell speed is decreased and or disabled the overspeed fault occurred Maximum output current from this output is 250mA Master Fault Output A24VDC master fault indicator exists on the front of the control panel that is lit any time a fault occurs This active high output is also available remotely at breakout terminal J3 C24 Thus this discreet output puts out 24VDC when a fault occurs Max imum output current from this output is 250 TABLE 4 ANALOG OUTPUT SETTINGS 0 10VDC Setting 4 20mA Setting Rotator Jumper Setting Dipswitch 7 Jumper Setting Dipswitch 7 6 FioPmsi amp 2 EionPin283 ON TABLE 5 ELECTRICAL Breakout Terminal J2 A1 J2 A2 J2 A3 J2 A4 J2 A5 J2 A6 J3 C15 J3 C16 J3 C17 J3 C18 Active Low Maintained Rotator 4 Enable Input Type 4 20mA 0 10VDC 4 20mA 0 10VDC 4 20mA 0 10VDC 4 20mA 0 10VDC 4 20mA 0 10VDC 4 20mA 0 10VDC Continued On Next Page TABLE 5 ELECTRICAL Cont Breakout Terminal J3 C19 Active Low Maintained J3 C20 Active Low Maintained 3 13 Active Low Slot 4 Temperature Input J2 A3 Slot 3 Temperature Input J
71. w CONTROL PANEL FRONT VIEW PARTS LIST Figure 17 Ezra A11515 XXXXX PulseTrack 2 Speed Control and Monitor System Atomizer 00 EP XXX1X 6 Conical Disk A11448 03 For A11515 XXX2X Standard Aerobell IEEE For A11515 XXX8X Standard Aerobell W Brake AT1448 05 11515 8 33 L C C Aerobe oo WEYA Op For AT1515 XXX4X Unidisk For A11515 XXX5X 8 Unidisk 9 Conical Disk For A11515 XXX6X 10 Unidisk FP OE ForA11515 XXX7X 12 Unidisk 12 Conical Disk 3 Miao Blank Cover Plate Assembly EMC Cable Gland SYS 1 11358 02 Cable Gland Nut 5 A144820 TemperatureHumidiy Card _____ 11453 00 Fitting Bulkhead Fiber Optic Cable FO1 FO6 11484 00 Compression Nut Fiber Optic Cable FO1 FO6 00 Fitting Bulkhead Pressure Switch EN1 EN6 8 78884 00 Switch MasterControl SW 9 SSP 6004 Fitting Solenoid 1 8 x 1 4 ODT Fitting Swivel Elbow 1 4 x 3 8 ODT A11520 00 Temperature Humidity Probe Assembly 13 77220 00 Cable Assembly Temperature Humidity Probe 50 ft 15 2m 15 LSMEO024 00 ____ AlammHom SpeedFaut 2 16 7696001 Indicator Lens SpeedFaut R T8 Viewing Door Assembly Glass Only Viewing Door x Adhesive Tape Double Sided _ ____ 47 00 BrakeValeAssembly

PulseTrack2 (Serv. Man. LN-9248-05.3)

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