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IMPORTANT:

  Before using this equipment, carefully read SAFETY PRECAUTIONS and all 

instructions in this manual.  Keep this Service Manual for future reference.

Model:

 

80102-21X (Electric Motor)

9060 High Voltage Controller for 

No.2 Process Handgun

(HV2 - Electric Motor)

CP-13-03-R4  (05/2020)

1 / 35

www.carlisleft.com

EN

SERVICE MANUAL

Summary of Contents for Ransburg

Page 1: ...PRECAUTIONS and all instructions in this manual Keep this Service Manual for future reference Model 80102 21X Electric Motor 9060 High Voltage Controller for No 2 Process Handgun HV2 Electric Motor CP...

Page 2: ...een changed from revision CP 13 03 3 to revision CP 13 03 R4 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual CP 13 03 R4 05 2020 2 35 www carlisleft...

Page 3: ...ltage Cable 15 No 2 Process Handgun Trigger Signal 15 Controller Schematic HV2 16 OPERATION 17 21 Start Up 17 Basic Operations 17 kV Test Jumper 18 Setpoint Operations 18 Faults 18 Fault Descriptions...

Page 4: ...ncile such differences WARNING WARNING The user MUST read and be familiar with the Safety Section in this manual and the safety literature therein identified This equipment is intended to be used by t...

Page 5: ...booth ventilation must be kept at the rates required by NFPA 33 EN 16985 country and local codes In addition ventilation must be maintained during cleaning operations using flammable or combustible so...

Page 6: ...rtent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which require...

Page 7: ...ring or carrying any ungrounded metal objects When using an electrostatic handgun operators must assure contact with the handle of the applicator via conductive gloves or gloves with the palm section...

Page 8: ...tact with the skin Follow the requirements of the Safety Data Sheet supplied by coating material manufacturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials...

Page 9: ...Handgun The processor circuitry provides the maximum in applicator transfer efficiency while maintaining the maximum safety The 9060 Controller for the No 2 Process Handgun has a fixed setpoint value...

Page 10: ...torage and Shipping Temperature 40 F to 185 F 40 F to 185 F Humidity 95 Non Condensing Environmental Physical Electrical Input Voltage 100 240 VAC Input Current 1A RMS max Frequency 50 or 60 Hertz Wat...

Page 11: ...No 9060 CONTROLLER FEATURES 1 kV Display 2 High Voltage On Indicator 3 Reset Button 4 A Display 5 Fault Indicator 6 On Off Switch 7 High Voltage Cable Connector 8 Fuses 9 Ground Lug 10 AC Inlet Recep...

Page 12: ...ger signal if OFF This will NOT prevent any other active fault conditions from triggering a new fault There is a 5 second fault reset delay timer that inhibits the triggering of high voltage immediate...

Page 13: ...ed in series between the neutral AC input connection and the neutral input connection of the AC line power filter Spare Fuses The Controller also comes with two 2 spare fuses 250V 1A 5mm x 20mm mounte...

Page 14: ...quipment LOCATION OF THE 9060 Installation of the Controller must be a minimum of 6 1m 20 fromwherethespraytargetislocatedinaccordance withfederal state andlocalcodes Theareashouldprotect theControlle...

Page 15: ...s not close to areas of high temperature 129 F The operator should have free movement of the applicator and all bend radii of the cable should not be less than 6 inches 15 cm Connect the high voltage...

Page 16: ...Figure 7 Controller Schematic HV2 Return To Contents CP 13 03 R4 05 2020 16 35 www carlisleft com INSTALLATION EN...

Page 17: ...actual current draw shown in Figure 9 The green and yellow regions of the bar graphs meter indicate outputcurrentisintheoptimumrangeformaximumtransfer efficiency The red region of the bar graph indic...

Page 18: ...oltage Setpoint The voltage on the 9060 High Voltage Controller when configured for use with the No 2 Process Handgun 80102 21X isNOTadjustable TheElectricMotorNo 2Handgun is designed to operate only...

Page 19: ...will show in the uA display This faultwilloccurifthemicroprocessordetectsalossofground atthehighvoltagesection Ifthisfaultoccurs resetthefault This fault can be caused by a broken ground path between...

Page 20: ...able Fault Display Feedback Fault FF This fault will occur if the microprocessor detects a loss of the current feedback signal If this occurs reset the fault If this fault occurs repeatedly refer to t...

Page 21: ...e Fault Troubleshooting Section Figure 17 Boot Fault Display The boot fault error code displayed on the uA display appears very similar to the ground fault Verify that the first character appears as a...

Page 22: ...To Measure Resistance If shocks or sparks are noticed at any point in the spray system immediatelyturnoffthepowersupplyandcheckthe complete system for proper grounding Proper grounding of the spray g...

Page 23: ...ectly the problem is with the power supply Consult the Troubleshooting Guide to locate the specific problem 8 Disconnect the Test Probe 76652 01 and reposition jumper J8 so that it covers only one ter...

Page 24: ...if jumper 17 is shorted The overload threshold for the 80102 21X units is set to 140 A Checkforloosewiringbetweenthepcboardconnector and the high voltage section by pulling on each wire Repair if nece...

Page 25: ...oltage controller Turn on the power and place a jumper across the KV Test Jumper If the fault occurs send the voltage controller in for repair If no fault occurs continue Eitherthehighvoltagecableorif...

Page 26: ...is between 90 and 264 VAC Replace blown defective fuse Properly attach connector Verify connection to the voltage across terminals L2 and N of 1TB is between 90 and 264 VAC Voltage across terminals 1A...

Page 27: ...ly attach connector J3 and verify that trigger input line is connected into the 5th position from bot tom of case Verify continuity between 1CON 3 and J3 5 See Figure 18 Properly attach J2 and verify...

Page 28: ...rom the factory are located on the inside of the top lid of the cabinet Fuses 1FU 2FU 1 Insertscrewdriverintoslotintotherespectivefuseholder push in and rotate counter clockwise 2 Remove screwdriver a...

Page 29: ...C Board 1 Ensure power supply is unplugged from AC outlet and open cabinet lid 2 Disconnect plugs connectors J7 J3 J2 and J1 from main PC board see Figure 18 3 Remove 3 screws from heat sink base and...

Page 30: ...Figure 18 9060 80102 21X Internal Component Locations J1 J2 J3 J7 3 2 Return To Contents CP 13 03 R4 05 2020 30 35 www carlisleft com MAINTENANCE EN...

Page 31: ...al number of the voltage controller is located on the left outside face of the main enclosure 2 No 2 Process Gun Electric Motor 1 Domestic 2 European 3 China 80102 2 1 X TABLE B PLUG SELECTION TABLE A...

Page 32: ...6 28 9060 High Voltage Controller PC Mainboard 79428 00 Power Supply 24V 24VDC Power Supply 1PS 19370 XX Cable Assembly Superflex XX denotes cable length not shown 79350 03 9060 High Voltage Cascade S...

Page 33: ...de HV Probe Meter w Test Leads and Paint Test Probe LSCH0009 Dielectric Grease 88 oz tube 76453 00 Conduit Adapter Kit 20868 00 120 Volt Circuit Tester Description Part No 9060 HIGH VOLTAGE CONTROLLER...

Page 34: ...ption CP 13 03 R4 Replaces CP 13 03 3 with the folowing changes 1 Update manual to latest design format All 2 Add 20868 00 120 Volt Circuit Tester 33 Page s Return To Contents CP 13 03 R4 05 2020 34 3...

Page 35: ...es is a global leader in innovative finishing technologies Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice DeVilbiss Ransburg MS BGK and Binks ar...

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