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9060 High Voltage Controller - Safety

CP-13-05.3

6

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Summary of Contents for 80100 Series

Page 1: ...page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 50 00 U S Service Manual Price 50 00 U S Service Manual Price 50 00 U S Service Manual Pri...

Page 2: ...CP 13 05 3...

Page 3: ...RS 11 12 FUSES 12 SPARE FUSES 12 LOCAL REMOTE BOARD 12 SIGNAL INTERFACE LOCAL MODE 13 SIGNAL INTERFACE REMOTE MODE 13 16 INSTALLATION 17 28 GENERAL INFORMATION 17 LOCATION OF THE 9060 17 ELECTRICAL NO...

Page 4: ...35 36 LOCAL MODE ONLY OPERATIONS 36 37 REMOTE MODE ONLY OERATIONS 37 40 FAULT DESCRIPTIONS 40 42 MAINTENANCE 43 46 TROUBLESHOOTING GUIDE 43 FAULT TROUBLESHOOTING GUIDE 43 45 PARTS 47 48 HIGH VOLTAGE C...

Page 5: ...CP 13 05 3...

Page 6: ...ments etc make such variations inevitable Compare this manual with your system instal lation drawings and appropriate Ransburg equipment manuals to reconcile such differ ences Careful study and contin...

Page 7: ...g should have flash points equal to or higher than those of the coating material Those solvents used for cleaning must have a flash point at minimum of 5 C 9 F greater than ambient temperature It is t...

Page 8: ...et Frequent power supply shutdown indicates a problem in the system which requires correc tion Always turn the control panel off prior to flush ing cleaning or working on spray system equip ment Ensur...

Page 9: ...I or II Division 1 and 2 hazardous areas Refer to NFPA 33 or EN 50 176 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or com bustible material Testing m...

Page 10: ...use a fire or explosion Parts being sprayed must be supported on conveyors or hangers and be grounded The resistance between the part and ground must not exceed 1 megaohm Reference NFPA 33 or EN 50 17...

Page 11: ...9060 High Voltage Controller Safety CP 13 05 3 6 N O T E S...

Page 12: ...signals are provided one for current and one for voltage and can be used to control the set point See the Operation portion of this Manual for more information The REMOTE mode triggering of HV is perf...

Page 13: ...o room temperature before use Humidity 95 Non Condensing Electrical Input Voltage 100 240 VAC Frequency 50 or 60 Hz Current 1 A max RMS Wattage 40 watts max Output Voltage 20 90kV MAX DC adjustable in...

Page 14: ...nal Air Flow Switch Hose Connections 3 Reset Button 11 High Voltage Cable Connector 4 A Display 12 Standard I O Connector 5 Fault Indicator 13 Fuses 6 On Off Switch 14 Ground Lug 7 Local Remote Mode I...

Page 15: ...e This LED is lit when the Controller is in LOCAL mode REMOTE Mode LED Indicator The REMOTE mode LED indicator is a right pointing triangle and is located on the right side the HV control button on th...

Page 16: ...icates when the unit should be in REMOTE mode When this remote I O signal is active the unit will be in REMOTE mode otherwise the unit will be in LOCAL mode CONNECTION INTERFACE The 9060 Controller co...

Page 17: ...located directly above the ground lug connection They are present to provide a measure of safety against power surges through the AC input The top fuse holder is connected in series between the HOT li...

Page 18: ...her an AC or DC signal using the Relay Common Input as the signal source For information regarding the relay contact voltage ratings please refer to the Relay Output Contacts portion of the Installati...

Page 19: ...alues stored in the 9060 the unit MUST be in LOCAL mode If the voltage setpoint must change between more than 3 values one of the analog KV setpoint signals should be used N O T E Analog Inputs Two 2...

Page 20: ...an input Although the allowable range for the analog current signal does include 0mA 3mA it will normally be listed as 4 20mA as the 0 3mA portion of the range is insuf ficient to override KV setpoint...

Page 21: ...ilable in both LOCAL and REMOTE modes This signal being a relay controlled signal can be config ured as either an AC or DC signal using the Relay Common Input as the signal source For information rega...

Page 22: ...approved applicators should be used with the 9060 High Voltage Controller W A R N I N G DO NOT locate the Controller near or adjacent to heat producing equipment such as ovens high wattage lamps etc...

Page 23: ...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 conduit fitting at each end of...

Page 24: ...ing and mark 1 span of cable that passes through the connector housing to be stripped to braid See Figure 8 3 Remove cable and strip marked 1 section to cable braid 4 Slide the cable grommet hardware...

Page 25: ...emoved see Figure 11 4 Install the AC input wiring 0 8mm2 18AWG minimum through the Conduit Adapter Plate using conduit and wire to TB1 as follows In general conduit must be used for approved AC insta...

Page 26: ...flush the spray ap plicator with high voltage ON as this is a severe fire hazard and risk to personnel safety It is recommended that the high voltage control be interlocked with the sol vent flush si...

Page 27: ...9060 High Voltage Controller Installation CP 13 05 3 22 Figure 12 Controller Schematic...

Page 28: ...the high voltage cable it is required to remove it from the spray applicator care should be taken when rein stalling so that the high voltage cable is com pletely engaged The Controller MUST be OFF w...

Page 29: ...ing used connect the ground green lead from the flow switch to the ground screw on the base plate shown in Figure 13 The trigger signal blue lead should be connected to the trigger signal on the remot...

Page 30: ...al Sink JMP1 1 3 1 3 JMP1 2 4 4 6 JMP2 2 3 1 2 LOCAL Mode Jumper Settings Figure 15 Local Remote Board Jumper Headers Jumper 1 Jumper 2 5 Secure the cabinet door replace the fuses and reconnect the AC...

Page 31: ...Signal Loca tions table contains the complete list of all I O ground and 24VDC supply locations as well as their normal voltage current values The locations of the I O terminal blocks are shown in Fi...

Page 32: ...shielded cable for each conductor to ensure a good connection has been made with each conductor Also a 2 finger pull test should be done Pull on each con ductor with 2 fingers to ensure it is tight N...

Page 33: ...g be fore reconnecting the 9060 Controller to the AC source 9 Secure the cabinet door replace the fuses and reconnect the AC source 10 Refer to the Operations section of this service manual and use th...

Page 34: ...fic applicator being used Us ing the wrong configuration may allow for operation outside the recommended pa rameters and values for the applicator and can result in damage or un safe op eration W A R...

Page 35: ...The LOCAL and REMOTE mode triangle indicators on the left and right side of the mode button are shown in Figure 21 The indicator corresponding to the unit s current operating mode should be lit while...

Page 36: ...tage is triggered turned on there is a 4 second timer that inhibits the DI DT overload fault while the applicator is being charged Ensure that NO OBJECTS approach the bell dur ing charging W A R N I N...

Page 37: ...panel or setpoint buttons will now have no affect on the kV setting Figure 22 Lockout Jumper Location Figure 23 Jumper Location Front Panel Lockout Overload The overload circuit may be activated for...

Page 38: ...ls The third sub mode displays the gun type value and firmware version To enter the remote I O monitoring and diagnostic mode ensure that the high voltage is not activated and press all 3 preset butto...

Page 39: ...they are listed in the digital index reference table under their respective index Figure 26 Analog Signal Monitoring Index 0 Analog Index Reference Index Analog Signal 0 Buffered Gun Current Feedback...

Page 40: ...Max Inc Indicators OL Current Overload 20 190 5 Decimal marker on code means overload jumper is installed Hd Startup Holdtime 2 15 seconds 0 5 sec N A Adjustable Parameters SA Sample Time 2 50 1 Avai...

Page 41: ...rameter has been selected any changes to the value can be saved by pressing the preset 1 button This will save the changes to memory and de select the parameter The saved changes to parameters will im...

Page 42: ...erate in either Tripleset Selection mode or Analog I O mode By default the unit comes from the factory configured to operate in Tripleset Selection mode Follow the following instructions to modify the...

Page 43: ...TIMING The analog setpoint signal minimum hold time is 80 ms to allow for analog sampling Output will begin to adjust after the setpoint has been updated ANALOG VOLTAGE SIGNALING Control Signal Range...

Page 44: ...60 Controller automatically trun cates the maximum setpoint value to the maximum voltage allowed for the applica tor being used Control signal increases beyond the maximum voltage equivalent will have...

Page 45: ...nit will illuminate a GF indication will show in the uA display This fault will occur if the microprocessor detects a loss of ground at the high voltage section or external cascade If this fault occur...

Page 46: ...A This fault can be caused by excessive overspray on the ap plicator or a paint formulation that is too con ductive It may also be caused by a bad pc board Clean the applicator check the paint formula...

Page 47: ...urs reset the Controller If this fault continues to occur replace the main PC board Figure 40 Over Voltage Fault Display Figure 41 Feedback Fault Display DI DT Overload Fault dOL This fault is ONLY ap...

Page 48: ...UBLESHOOTING GUIDE FAULT TROUBLESHOOTING GUIDE Before troubleshooting gun and control unit problems flush the gun with solvent and purge with air Some of the tests will require high voltage to be appl...

Page 49: ...Load Fault indicates the current output has exceeded the overload threshold This fault is only active if jumper 17 is shorted The overload threshold is normally set at 10 A below the maximum output of...

Page 50: ...ntroller 2 Ensure test jumper J8 is not shorted on both posts Ensure that the gun trigger is not pressed or for remote units that the re mote trigger input signal is not active 3 Turn on the voltage c...

Page 51: ...9060 High Voltage Controller Maintenance CP 13 05 3 46 N O T E S...

Page 52: ...Part Number Model Selection TABLE A Plug Selection TABLE B Model number and serial number of the voltage controller is located on the left outside face of the main enclosure Table A Model Selection D...

Page 53: ...6 41 9060 High Voltage Controller PC Mainboard for 80100 21X 31X 41X A13123 00 9060 High Voltage Controller Local Remote Board 79350 01 9060 High Voltage Cascade 79428 00 Power Supply 24V 24VDC Power...

Page 54: ...0 High Voltage Controller Accessories List Part Description 76652 01 HV Probe 76652 02 Meter w Test Leads 76652 03 Paint Test Probe w Meter 76652 04 Deluxe Kit Include HV Probe Meter w Test Leads and...

Page 55: ...ear from date of purchase WRAPPING THE APPLICATOR ASSO CIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONL...

Page 56: ...uration uses the following Sourcing Configured Digital Inputs Apply 24VDC to activate the input Permanently Wired into Remote Mode Jumper Wire from TB3 10 to TB3 2 Normally Open NO Contact to Activate...

Page 57: ...Sourcing Configured Digital Inputs Apply 24VDC to activate the input Permanently Wired into Remote Mode Jumper Wire from TB3 10 to TB3 2 Normally Open NO Contact to Activate Reset when unit is Faulte...

Page 58: ...e the input Normally Open NO Contact to Activate Reset when unit is Faulted Normally Open NO Contact to Activate HV Trigger to turn on HV Cascade Normally Open NO Contact to Activate remote mode Turn...

Page 59: ...ng Sinking Configured Digital Inputs Apply GND to activate the input Permanently Wired into Remote Mode Jumper Wire from TB3 11 to TB3 2 Normally Open NO Contact to Activate Reset when unit is Faulted...

Page 60: ...l Service Assistance 320 Philips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 Form No CP 13 05 3 2013 Ransburg All rights reserved Litho in U S A Models and specificati...

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