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9060 for No. 2 Process Handgun - Introduction

9

CP-13-04.1

No.

Description

No. Description

1

kV Display

9

kV Setpoint/Adjust Buttons

2

High Voltage On Indicator

10

High Voltage Cable Connector

3

Reset Button

11

Fuses

4

µA Display

12

Ground Lug

5

Fault Indicator

13

AC Inlet Receptacle

6

On-Off Switch

14

Air Flow Switch Hose Connections

7

Local/Remote Mode Indicator

8

“One Touch” kV Setpoint Buttons

9060 CONTROLLER FEATURES

Figure 2: 9060 High Voltage Controller Features

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Summary of Contents for 9060

Page 1: ...S starting on page 1 and all instructions in this manual Keep this Service Manual for future reference SERVICE MANUAL CP 13 04 1 MARCH 2013 9060 HIGH VOLTAGE CONTROLLER for No 2 ProcessTM Handgun HV2 Air Motor Service Manual Price 50 00 U S Service Manual Price 50 00 U S Service Manual Price 50 00 U S Service Manual Price 50 00 U S ...

Page 2: ...CP 13 04 1 ...

Page 3: ...10 SWITCHES 10 LEDS 10 BUTTONS 10 11 CONNECTION INTERFACE 11 CONNECTORS 11 FUSES 11 SPARE FUSES 11 SIGNAL INTERFACE 12 INSTALLATION 13 16 GENERAL INFORMATION 13 LOCATION OF THE 9060 13 AC INPUT CONNECTIONS 13 14 SAFETY GROUND 14 INPUT VOLTAGE SELECTION 14 HIGH VOLTAGE CABLE 14 NO 2 PROCESS HANDGUN TRIGGER SIGNAL 16 OPERATION 17 22 START UP 17 BASIC OPERATIONS 17 18 LOCKOUTS 18 19 KV TEST JUMPER 19...

Page 4: ...NTENTS PAGE MAINTENANCE 23 26 TROUBLESHOOTING GUIDE 23 FAULT TROUBLESHOOTING GUIDE 23 25 PARTS IDENTIFICATION 27 28 HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION 27 PARTS LIST 28 ACCESSORIES 29 ACCESSORIES LIST 29 WARRANTY POLICIES 30 LIMITED WARRANTY 30 ...

Page 5: ...CP 13 04 1 ...

Page 6: ...e 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 continued use of this manual will provide a better understanding of the equipment and process resulting in more effi cient operation longer trouble free service and faster easier troubleshooting If you do...

Page 7: ...ing 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 the end users respon sibility to ensure this condition is met Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA and local codes In addition ventilation must be maintained dur...

Page 8: ... set 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 Ensure that the control panel is interlocked with the ventilation system and conveyor in accord ance with NFPA 33 EN 50176 Have fire extinguishing equipment readily availa ble and tested periodically Gen...

Page 9: ...r II Division 1 and 2 hazardous areas Refer to NFPA 33 or EN 50176 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or com bustible 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 di...

Page 10: ...cause 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 50176 All electrically conductive objects in the spray area with the exception of those objects required by the process to be at high voltage must be grounded Any person working in the spray area must be...

Page 11: ...9060 for No 2 Process Handgun Safety CP 13 04 1 6 N O T E S ...

Page 12: ...ndgun It uses a combination of proven high voltage generation technology and microprocessor based control It uses a variable voltage output to drive a cascade that amplifies the voltage to a high kV level It also uses current feedback information to maintain the desired set point The processor circuitry provides the maximum in applicator transfer efficiency while main taining the maximum safety Th...

Page 13: ...20 90kV MAX DC adjustable in 1kV increments Ground Use known good earth ground Physical Environmental Height 16 5 cm 6 5 inches Width 37 8 cm 14 9 inches Depth 30 7 cm 12 1 inches Weight 10 2 kg 22 5 lbs The 9060 High Voltage Controller is factory supplied with a latch E5 1 065 091 that can be opened using the sup plied key E3 2 N O T E 9060 Part No Used with No 2 Gun Type Gun No 80102 311 Air Mot...

Page 14: ...gh Voltage On Indicator 10 High Voltage Cable Connector 3 Reset Button 11 Fuses 4 µA Display 12 Ground Lug 5 Fault Indicator 13 AC Inlet Receptacle 6 On Off Switch 14 Air Flow Switch Hose Connections 7 Local Remote Mode Indicator 8 One Touch kV Setpoint Buttons 9060 CONTROLLER FEATURES Figure 2 9060 High Voltage Controller Features ...

Page 15: ...ft side the HV control button on the center of the operator interface This LED is lit when the Controller is used with the No 2 Process Handgun Remote Mode LED Indicator The remove mode LED indicator should NOT be lit for No 2 Process Handgun units Active Preset LED Indicators 3 The active preset LED indicators are located directly above each of the Preset Buttons When a preset button is pushed to...

Page 16: ... directly below the fuses and has a ground logo sticker directly below it This lug is provided as an external ground connection point used to ground the 9060 to an earth ground via a ground cable This ground lug connection can also be used as the ground point for the high voltage cable ground Air Flow Switch Connection The air flow switch connection is installed to provide a pneumatic trigger sign...

Page 17: ...th the No 2 Process Handgun requires only one signal input for operation the trigger signal Trigger Signal The trigger signal input J3 5 for a No 2 Process Handgun comes preconfigured as a sinking input wired directly to the air flow switch Please refer to Installation section of this service manual for more information ...

Page 18: ...rmation for the 9060 Control ler Consult your authorized Ransburg distributor for specific directions pertaining to the installation of your equipment N O T E LOCATION OF THE 9060 Install the Controller in an area outside the hazardous location in accordance with feder al state and local codes The area should protect the Controller from the possibility of environmental intrusion such as dust or mo...

Page 19: ...02 31X shipped from the factory for either 110 VAC input or 240 VAC input will have a 72771 06 1 Amp front panel fuses installed N O T E Figure 6 Installation of Conduit Adapter Plate HIGH VOLTAGE CABLE Position the No 2 Process Handgun in the spray area and route the high voltage cable to the Controller The cable should be routed so that it is not damaged by foot and vehicle traffic and also so t...

Page 20: ...9060 for No 2 Process Handgun Installation 15 CP 13 04 1 Figure 7 Controller Schematic ...

Page 21: ...nect it from its AC source and remove the fuses 2 Open the controller cabinet door 3 If the flow switch is being used connect the ground green lead from the flow switch to the ground screw on the base plate shown in Figure 8 The trigger signal blue lead should be connected to the trigger signal input on the JB 5 plug header that is connected to the PC board 4 Verify that J5 shown in Figure 9 has t...

Page 22: ...he applicator and can result in damage or un safe opera tion W A R N I N G After the initial start up delay the unit will be configured for the applicator based on the gun type jumper settings and is ready for standard operation BASIC OPERATIONS The basic operations are general operations that are available Triggering High voltage is actuated by the presence of an active trigger signal This is nor...

Page 23: ...igure 12 Display High Voltage On Time board see Figure 13 These lockouts may be used individually or in combination as required If the jumpers are disconnected the original functions are re enabled After changing any jumpers the AC power must cycled for the new setting to take affect Front Panel Lockout This feature locks out any changes to the kV setting from the front panel of the Controller 1 S...

Page 24: ...ad Activation KV TEST JUMPER To assist in testing and troubleshooting a jumper J8 has been added to the main PC board By covering shorting both terminals of this jumper the high voltage of the spray applicator can be activated Thus for testing and troubleshooting high voltage output can be obtained without the need to trigger air through the spray applicator After testing the jumper must be reposi...

Page 25: ...the and buttons on the front panel of the 9060 Controller shown in Figure 17 Single pushes of the or buttons will incre ment or decrement the currently selected preset in units of 1 When the or buttons are held in for longer than a 1 2 second the kV display will begin incrementing or decrementing in units of five 5 Resetting Faults During operation various faults can occur based upon the operating...

Page 26: ...low voltage cable stuck pins on the plug assembly or contaminated contacts on the applicator This may also indicate a faulty barrel assembly for a handgun This could also indicate a connection problem between the pc board and the high voltage section Check the wiring harness for loose pins or replace the high voltage section For additional information refer to the Fault Troubleshooting Section Ove...

Page 27: ...t UC This fault will occur if the microprocessor de tects a loss of the voltage feedback signal This can be caused by a failed high voltage cable a failed high voltage section or a failed pc board Replace the high voltage cable and re test If still faulty replace the high voltage section or pc board and re test Figure 22 Voltage Cable Fault Display Over Voltage Fault OU This fault will occur if th...

Page 28: ...problems flush the gun with solvent and purge with air Some of the tests will require high voltage to be applied to the gun so the gun must be empty of paint and solvent W A R N I N G Fault Description Solution Cable Fault CF The Cable Fault indicates the con trol unit does not detect a high voltage section on the end of the cable The fault typically occurs at a high voltage trigger 1 Check for lo...

Page 29: ...nd unit in form repair Over Load Fault OL The Over 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 µA below the maximum output of the applicator 1 This may indicate the paint conductivity is too high resistance too low or the outside of the applicator is contaminated with pain...

Page 30: ... continue 3 Either the high voltage cable or if using a hand gun the gun resistor tube has failed If available replace the high voltage cable or continue to test the resistor tube 4 To test the resistor tube remove the resis tor tube from the gun and inspect for signs of burning or arcing Cracks or black marks indicate failure of the resistor tube indicating the resistor tube must be re placed Mea...

Page 31: ...9060 for No 2 Process Handgun Maintenance CP 13 04 1 26 N O T E S ...

Page 32: ...igits must follow the basic part number for example 80102 A 1 B Basic 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 Dash No Description 3 No 2 Process Gun Air Motor P N 80086 XX Table B Plug Selection Dash No Description 1 Domestic 2 European 3 Chi...

Page 33: ... Switch 1 0 2 0 SCFM 72771 06 Fuse 250V 1A 5mm x 20mm 79390 03 9060 High Voltage Controller PC Mainboard 20988 XX Cable Assembly Superflex 2 Air Motor XX denotes cable length 79350 01 9060 High Voltage Cascade 76434 01 Switch Rocker On Off Switch 79428 00 Power Supply 24V 24VDC Power Supply 1PS Figure 25 Part Identifications ...

Page 34: ...9 CP 13 04 1 9060 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 Paint Test Probe ACCESSORIES ...

Page 35: ... 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 ONLY OBLIGATION UND ER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MAT ERIALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR...

Page 36: ...516 Technical Service Assistance 320 Philips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 Form No CP 13 04 1 2013 Ransburg All rights reserved Litho in U S A Models and specifications subject to change without notice 03 13 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts ...

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