CP-13-04.1 9060 Service Manual for No 2 Gun
Contents
1. 11 SIGNAL INTEREAGE am mama ng 12 INSTALLATION 13 16 GENERAL INFORMATION nana tien iae tate bane 13 LOCATION OE FHE 90DD x 55554664 oe Ta hte ena bene e o eet NA NN 13 AG INPUT CONNEG TIONS oacodexs cet eene pae rad adan aksen naas 13 14 SAFETY GROUND es naa Ne BN an na ana 14 INPUT VOLTAGE SEEEG TION tique Se a ER Heg Iron tre 14 HIGH VOLTAGE CABLE ea p eo eii Nine man 14 NO 2 PROCESS HANDGUN TRIGGER 16 OPERATION 17 22 D EE tr tuat oU tate i tt 17 BASIC OPERATIONS mnta nera aeter oo E ESEE x test 17 18 eb Sa PI MU TER 18 19 KV PEST JUMPER enam ee o e tense tg 19 SETPOINT OPERATIONS Qu eem fece aa Sauna 20 PAUL TIDESCRIP TIONS etae e pet en eite epe uites 20 22 CP 13 04 1 9060 for No 2 Process Handgun Contents Ransburg CONTENTS PAGE MAINTENANCE 23 26 TROUBLESHOOTING GUIDE c etse agnita as atte dis bestie 23 FAULT TROUBLESHOOTING GUIDE debet cen nope eda ee ee 23 25 PARTS IDENTIFICATION 27 282. WARNING ALWAYS double check that the troller is unplugged from its AC outlet before working with any internal wiring 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 the shunt covering pins 1 and 2 5 Secure the cabinet door replace the fuses and reconnect the AC source 13 04 1 1 Ground Screw amp e Ground Screw on Base Plate Figure 8 TPIQTPEOTP Dy FA 2 el sonne ni 8 EN 8 23 pa Cre 1 a E ES R2 eo L 7 pint Pal E d m bi T s P m BsESTPS H 11 2 PCT cones EPS UX cuc Bj De c 7 L o Figure 9 PC Mainboard Jumper J5 Location 9060 for No 2 Process Handgun Installation 16 90
3. SERVICE MANUAL Ransburg CP 13 04 1 MARCH 2013 9060 HIGH VOLTAGE CONTROLLER for No 2 Process Handgun HV2 Air Motor RESET ANT USED IMPORT THIS GROUND 15 MODEL 80102 31X Air Motor ATEX APPROVED FOR USE WITH 80086 XX 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 50 00 U S Ransburg CP 13 04 1 Ransburg 9060 for No 2 Process Handgun Contents CONTENTS PAGE SAFETY 1 6 SAFETY PRECAUTIONS iu e o eden ouis is peo hama 1 HAZARDS SAFEGUARDS Sa mn unta ama 2 5 INTRODUCTION 7 12 GENERAL DESCRIPTION siet ena rae 7 SAFETY FEATURES oo bangsa asma nisa 7 BN ror 7 SPECIFICATIONS Be mna aan 8 CONTROLLER FEATURES Ma nu OA te che 9 OPERATOR INTEREACE uod an cuia te Ate Ac tants aa an 10 SSVI ES ak PA Sa aa 10 eu to MM T E LEE 10 5 DUI Sa tu EI Se E DI ME EE 10 11 CONNECTION INTERFACE bee een eto 11 CONNECTORS i manakala samaan 11 FUSES aena a M EI M ea ico a tt 11 SPARE FS ES
4. ing materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials 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 grounded Unless specifically approved for use in hazardous lo cations the power supply and other electrical control equipment must not be used in Class 1 Division 1 or 2 locations or Class 1 Zone 0 for European Applica tions CP 13 04 1 Ransburg 9060 for No 2 Process Handgun Safety NOTES CP 13 04 1 d 9060 for No 2 Process Handgun Introduction INTRODUCTION GENERAL DESCRIPTION The Ransburg No 2 Handgun Process The 2 Process is an electrical atomiza tion method for applying coatings to objects electrostatically The No 2 Process Handgun System applies a high voltage negative DC charge to the applicator bell creating an electrostatic field between the bell and the target object The target is electrically ground ed through its support which may be station ary or moving or through an electrical con nection to a known true earth ground A regulated pressure fluid sys
5. This will clear the fault status and put the unit back into operation unless a fault condition is still present Please refer to the Fault Description portion of the Operation Section of this Service manual for more information on a specific fault and how to correct it FAULT DESCRIPTIONS For in depth troubleshooting information on the 9060 please refer to the Fault Troubleshoot ing portion of the Maintenance Section of this service manual If a fault occurs the Fault Indicator on the front of the Controller will light and a fault code will be displayed on the microamp display Faults can be reset by pressing the Reset button on the front of the Controller or by using the remote I O reset signal NOTE Any fault code not listed that appear on the screen are a likely indication of a PC board failure due to possible arc damage 20 9060 for No 2 Process Handgun Operation Cable Fault CF This fault will occur if high voltage is active and the microprocessor detects that no current is being supplied to the applicator This indicates a connection problem from the control unit to the cascade or handgun barrel assembly Typical causes include a faulty 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
6. or if there is contact with the skin SAFEGUARDS Tells how to avoid the hazard The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or 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 distance Follow the requirements of the Material Safe ty Data Sheet supplied by coating material manufacturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materi als 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 Equip ment must be as prescribed by an industrial hygienist or safety expert and be NIOSH ap proved 9060 for No 2 Process Handgun Safety AREA HAZARD Ransburg SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Spray Area High Voltage Equipment There is a high voltage device that can induce an electrical charge on un grounded objects which is capable of igniting coat
7. 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 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 nation al codes governing ventilation fire protection operation maintenance and housekeeping Ref erence OSHA NFPA 33 EN Norms and your insurance company requirements CP 13 04 1 Ransburg AREA Tells where hazards Electrical Equipment Toxic Substances 13 04 1 9060 for 2 Process Handgun Safety HAZARD Tells what the hazard is High voltage equipment is utilized Arcing in areas of flammable or combustible materials may occur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arc ing that may cause a fire or explo sion is lost if safety circuits are dis abled during operation Frequent power supply shut down indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explo sion Certain material may be harmful if inhaled
8. B Plug Selection European 27 13 04 1 Ransburg 9060 for No 2 Process Handgun Parts 9060 High Voltage Controller Parts List Pus eim OOO sues Ar Few NN Cable Assembly Superflex 2 Air Motor denotes cable length 9060 High Voltage Cascade Switch Rocker On Off Switch Power Supply 24V 24VDC Power Supply 1PS 79428 00 AC Figure 25 Identifications 13 04 1 28 9060 for No 2 Process Handgun Accessories 29 Ransburg ACCESSORIES 9060 High Voltage Controller Accessories List Par Description S 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 13 04 1 Ransburg 9060 for No 2 Process Handgun Warranty Policies WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipment that falls within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded 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 FIT
9. 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 not have the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg Ransburg WARNING The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified 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 SAFETY STANDARD prior to installing operating and or servicing this equipment WARNING The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 CP 13 04 1 Ransburg AREA Tells where hazards may occur Spray Area 13 04 1 9060 for 2 Process Handgun Safety HAZARD Tells what the hazard is Fire Hazard Improper or inadequate opera a
10. wiring harness for loose pins or replace the high voltage section For additional information refer to the Fault Troubleshooting Section CABLE FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS CF al Figure 18 Cable Fault Display Ground Fault GF If this fault occurs the fault indicator on the control unit 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 If this fault occurs reset the fault This fault can be caused by a broken ground path between the applicator and the control unit and may indicate a faulty cable or plug assembly It can also be caused by a broken ground path between the high voltage section and the pc board Check the wiring to the high voltage section For more information refer to Fault Troubleshooting Section 21 Ransburg GROUND FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS FAUN nasa Figure 19 Ground Fault Display Overload Fault OL This fault will occur if the overload feature is active see Overload Activation previously in the Operation section and the output current exceeds the overload current value This can be caused by excessive overspray on the ap plicator or paint formulation that is too conduc tive Clean the applicator check the paint for mulation or move overload jumper JP17 to the open p
11. 12 Air Motor European 80086 XX Physical 80102 313 Air Motor China 80086 XX Height 16 5cm 6 5 inches Width 37 8 cm 14 9 inches Depth 30 7 cm 12 1 inches Weight 10 2 kg 22 5 Ibs 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 1kV increments Ground Use known good earth ground CP 13 04 1 8 9060 for No 2 Process Handgun Introduction Ransburg Figure 2 9060 High Voltage Controller Features 9060 CONTROLLER FEATURES No Description Description kV Display kV Setpoint Adjust Buttons High Voltage On Indicator High Voltage Cable Connector Reset Button Fuses Display Ground Lug Fault Indicator AC Inlet Receptacle On Off Switch Air Flow Switch Hose Connections Local Remote Mode Indicator One Touch kV Setpoint Buttons N 9 13 04 1 Ransburg OPERATOR INTERFACE The 9060 Controller shown in Figure 3 has a simple operator interface consisting of 7 LEDs Light Emitting Diodes one 1 power switch seven 7 buttons one 1 current LED bar graph and two 2 screens containing seven segment displays MA KV fz FAULT Figure 3 9060 Operator Interface SWITCHES Power Switch The 9060 Controller contains a single rocker swit
12. 60 for No 2 Process Handgun Operation OPERATION START UP After all installation procedures are completed operation of the applicator may begin When the ON OFF switch is turned on the kV display will show the applicator type the 9060 Controller is configured for and the A microamp display will show the current software revision level as shown in Figure 10 These items are displayed for approximately 10 seconds GUN TYPE NUMBER SOFTWARE REVISION LEVEL ON OFF SWITCH Figure 10 Controller Start Up Display The controller comes preconfigured for the No 2 Process Handgun Air Motor from the factory The following table lists the display value and jumper setting for the unit This table is a reference to verify that the gun configura tion jumpers are in their correct positions if unexpected behavior is observed START UP DISPLAY m querens 17 Ransburg WARNING DO NOT agjust the gun configuration jumpers If they are incorrect contact your Ransburg representative USE ONLY the gun type configuration for the No 2 Process Handgun Using the wrong configuration may allow for op eration outside the recommended param eters and values for the applicator and can result in damage or un safe opera tion 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 OPERATI
13. HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION oom 27 PARTS sce E EET 28 ACCESSORIES 29 ACCESSORIES LIS Ta ee a a te 29 WARRANTY POLICIES 30 LIMITED WARRANT a i cea tenia er ea deed ee 30 CP 13 04 1 Ransburg 13 04 1 9060 for No 2 Process Handgun Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety literature for your Ransburg products This manual contains information that is important for you to know and understand This infor mation relates to USER SAFETY and PRE VENTING EQUIPMENT PROBLEMS To help you recognize this information we use the fol lowing symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that might cause serious inju ry 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 pro cedure in progress While this manual lists standard specifications and service procedures some minor devia tions may be found between this literature and your equipment Differences in local codes and plant requirements material delivery require ments etc make such variations inevitable Compare this manual with your system instal
14. NESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY THE USE OF OTHER THAN RANSBURG PURCHASER OR OTHERS APPROVED PARTS VOID ALL WARRAN TIES EXCLUSIONS 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 THE APPLICATOR ASSO CIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY 13 04 1 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 responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable 30 9060 for No 2 Process Handgun Warranty Policies Ransburg Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Philips Ave Toledo Ohio 43612 1493 Telephon
15. ONS The basic operations are general operations that are available Triggering High voltage is actuated by the presence of an active trigger signal This is normally accom plished by pulling the trigger of the No 2 Process Handgun to start the flow of air through the applicator The flow of air activates the air flow switch which sends a trigger signal to the 9060 unit The kV setpoint is displayed on the kV display the actual current draw on the pA display and the high voltage light illuminates Under the display is a bar graph meter that illuminates according to the actual current draw shown in Figure 11 The green and yellow regions of the bar graphs meter indicate output current is in the optimum range for maximum transfer efficiency The red region of the bar graph indicates high output current causing decreased transfer efficiency If high output check mainte nance of applicator and external equipment of the power supply CP 13 04 1 Ransburg GRAPH BAR Figure 11 uA Bar Graph Meter Display Measuring Time The 9060 High Voltage Controller records the amount of time the high voltage is triggered on up to 99 999 hours This value is display on the kV and pA displays of the unit There are two registers that retain this information one that may be reset the other that is permanently retained in memory The number of hours the units high voltage has been on may be dis pl
16. Voltage Controller provides maximized operational safety The protections include detection of Ground Faults Cable Faults Feedback Signal Faults Overvoltage and Overcurrent The microprocessor circuits provide a controlled output load curve which limits the high voltage output to safe levels while monitoring control and feedback signals for unsafe conditions Maximum operational safety is obtained when the correct applicator settings are used and when safe distances between the applicator and target are observed and followed The maximum efficiency of the high voltage controller is based on load DISPLAYS The front panel displays the high voltage set point as well as a reading of gun current output The gun current is derived from feedback signals between the controller and the cascade Figure 1 9060 High Voltage Controller HV2 CP 13 04 1 Ransburg n n Intr ion Ransburg 9060 for No 2 Process Handgu troductio NOTE SPECIFICATIONS The 9060 High Voltage Controller is Environmental factory supplied with a latch 5 1 065 091 that can be opened using the sup Operating Temperature 0 C to 40 C plied key E3 2 Storage and Shipping The 9060 High Voltage Controller is availa Temperature 40 C to 85 C ble as follows Allow power supply to go to room temperature 9060 Part Used with No 2 Gun un No before use No Type Humidity 95 Non Condensing 80102 311 Air Motor Domestic 80086 XX 80102 3
17. and local codes The area should protect the Controller from the possibility of environmental intrusion such as dust or mois ture have ambient temperatures that do not exceed 40 C and be as close to the applicator as possible to minimize the length of the high voltage cable DO NOT locate the Controller near or adjacent to heat producing equipment such as ovens high wattage lamps etc AC INPUT CONNECTIONS For non conduit installations plug the detacha ble AC line cord into the receptacle on the side of the 9060 Controller Plug the other end of the line cord into a properly grounded 120 volt AC outlet For those installations where it is required to run the AC input wiring in conduit perform the following 1 Ensure the AC line cord is unplugged and remove the AC inlet receptacle wiring from TB1 N TB1 L1 and TB1 EARTH GROUND See Figures 5 and 7 2 Remove the mounting hardware from the AC inlet receptacle and remove it from the side of Controller 3 Install the Conduit Adapter Plate supplied in the hole where the AC inlet receptacle was removed see Figure 6 4 Install the input wiring 0 8mm 18AWG minimum through the Conduit CP 13 04 1 Ransburg Adapter Plate using conduit and wire to TB1 as follows Hot Line to TB1 L1 Neutral Common to TB1 N Ground to TB1 EARTH GROUND 182 FRONT OF_ YY Figure 5 Location of TB1 amp TB2 in Controll
18. andgun indicating that the trigger has been actuated This signal is used to turn on the High Voltage output AC Inlet Receptacle The AC inlet receptacle is a standard IEC C14 Appliance Inlet connector with a maximum rating of 250 VAC It can handle both 110VAC and 240 VAC inputs at 50 or 60 Hz The unit is shipped with the appropriate rated AC cord for the particular installation FUSES Fuses There are two 2 time delay fuses 250V 1A 5mm x 20mm installed in fuse holders on the connection interface They are 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 line L input connection and the Interlock AC line connection terminal 1TB L2 The bottom fuse holder is connected 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 mounted in holders inside the lid of the Controller 13 04 1 Ransburg 9060 for No 2 Process Handgun Introduction SIGNAL INTERFACE The 9060 Controller when configured for use with 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 dir
19. ayed by depressing at the same time the preset 1 and reset buttons See Figure 12 The display will show hours of use for 3 sec onds This is the resettable register High Voltage On To reset this register press the reset button while the hours are displayed To view the non resettable register press the preset 2 and reset buttons at the same time This display will show the hours for 3 seconds DISPLAY OF ON TIME IN HOURS PRESS AND HOLD BOTH FOR RESETTABLE ON TIME REGISTER RESS AND HOLD BOTH FOR NON RESETTABLE ON TIME REGISTER Figure 12 Display High Voltage On Time LOCKOUTS There are lockouts that may be done at the PC 13 04 1 board see Figure 13 These lockouts may 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 NOTE Some lockouts are sealed using sealant to prevent them from being modified for safety reasons These lockouts should ONLY be modified by Ransburg Authorized Representatives LOCKOUT JUMPER LOCATIONS Figure 13 Lockout Jumper Location Front Panel Lockout This feature locks out any changes to the kV setting from the front panel of the Controller 1 Set the kV to the desired value using the front panel buttons This must be set prior to installi
20. ch for power On Off selection When the unit is powered on the screens should be lit and display the gun display type information and the software version number for a short period of time LEDs High Voltage On Indicator The red High Voltage On Indicator is lit when a trigger signal has been received by the unit and the high voltage output from the cascade has been enabled Fault Indicator The red Fault Indicator is lit when a fault occurs as determined by the microprocessor When a fault occurs the light will turn on and the identifi cation code for the fault will be displayed blinking on the yA meter display For more information on the faults and fault ID codes please refer the Fault Descriptions section in the Operations portion of this manual CP 13 04 1 LOCAL Mode LED Indicator The LOCAL mode LED indicator is a left pointing triangle and is located on the left 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 select the desired preset in READY mode the preset LED indicator directly above the button pressed will light up Only one 1 preset light should be l
21. ct a high voltage section on the end of the cable The fault typically occurs at a high voltage trigger The Cable Fault indicates the con 1 Check for loose wiring between the pc board connector and the high voltage sec tion by pulling on each wire Repair if nec essary Insure both connectors are secure and re test for CF fault Replace high voltage section or send unit in for repair Send unit in for repair CP 13 04 1 Ransburg Ground Fault GF Over Voltage Fault OU Over Load Fault OL Current Limit Fault CL Feedback Fault FF 13 04 1 9060 for 2 Process Handgun Maintenance The Ground Fault is typically caused by a ground connection problem and can create a safety hazard It can occur without high voltage and will not reset The Over Voltage Fault indicates the output voltage exceeds the design specifications It typically occurs during a high voltage trig ger 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 pA below the maximum output of the applicator The Current Limit Fault indicates the current output of the gun has exceeded the maximum allowable output current It typically occurs with the high voltage on The Feedback Fault indicates there is no current feedback or it is incorrect It typically occurs with the high v
22. e toll free 800 233 3366 Fax 419 470 2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No CP 13 04 1 Litho in U S A 03 13 2013 Ransburg All rights reserved Models and specifications subject to change without notice 31 CP 13 04 1
23. ear fault or over load conditions This will NOT prevent any other active fault conditions from triggering a new fault HV Control Button This button shown in the center of Figure 3 is not functional for handgun units CONNECTION INTERFACE The 9060 Controller connection interface shown in Figure 4 provides all of the required connec tions for setting up a No 2 Process Handgun painting system This connection interface consists of one 1 high voltage cable connect or one 1 ground lug connection one 1 air flow switch connection two 2 fuses and one 1 AC inlet receptacle CONNECTORS High Voltage Cable Connector The high voltage cable connector is the largest connector and is located on the far right of the connection interface This connector is de signed for use with the superflex high voltage cable 20988 that connects with the No 2 Process Handgun Ground Lug Connection The ground lug connection is located 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 Ransburg HV Cable Connector Figure 4 9060 Connection Interface voltage cable ground Air Flow Switch Connection The air flow switch connection is installed to provide a pneumatic trigger signal for the No 2 Process H
24. ecific applicator type If this occurs reset the Controller If this fault continues to occur replace the main PC board CP 13 04 1 9060 for No 2 Process Handgun Operation f OVERVOLTAGE FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS oU Figure 23 Over Voltage Fault Display Feedback Fault FF This fault will occur if the microprocessor de tects a loss of the current feedback signal If this occurs reset the fault If this fault occurs repeatedly refer to the Fault Troubleshooting Section to determine if the problem is with the high voltage section or the main pc board FEEDBACK FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS FF Figure 24 Current Limit Fault Display 22 9060 for No 2 Process Handgun Maintenance Ransburg MAINTENANCE TROUBLESHOOTING GUIDE Blank Display 11 power 2 Blown fuse Check the power connections and verify they are fully connected and power is avail able Power cycle the unit off and back on Check Fuses and replace if blown using the replacement fuses inside the lid of the unit FAULT TROUBLESHOOTING GUIDE WARNING 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 applied to the gun so the gun must be empty of paint and solvent Cable Fault CF 23 trol unit does not dete
25. ectly to the air flow switch Please refer to Installation section of this service manual for more information 13 04 1 12 9060 for No 2 Process Handgun Installation INSTALLATION GENERAL INFORMATION The following section contains general infor mation on the installation of 9060 High Voltage Controller 7 WARNING The 9060 Controller MUST be located outside of the hazardous area The User MUST read and be familiar with the Safety section of this manual 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 of operating and servicing safely are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 OSHA and all related country safety codes prior to installing op erating and or servicing this equipment Only approved applicators should be used with the 9060 High Voltage Controller NOTE As each installation is unique this infor mation is intended to provide general in stallation information for the 9060 Control ler Consult your authorized Ransburg distributor for specific directions pertaining to the installation of your equipment 13 Ransburg LOCATION OF THE 9060 Install the Controller in an area outside the hazardous location in accordance with feder al state
26. er 7 s y D 2 N Ic CONDUIT ADAPTER PLATE SIDE VIEW Figure 6 Installation of Conduit Adapter Plate SAFETY GROUND Crimp the appropriate connector onto the ground wire assembly and install from the Controller ground stud located on the side panel to a true earth ground CP 13 04 1 The ground wire assembly MUST be connected from the Controller ground stud to a true earth ground INPUT VOLTAGE SELECTION The 9060 Controller accepts universal input voltage between 100 and 240 VAC at 50 or 60 Hz There is no need to change any switch settings when changing input from 110 to 240 or from 240 to 110 NOTE All 9060 units 80102 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 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 that is 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 cable to the Controller and tighten the retaining nut and set screw If during the routing of the high voltage cable it is required to remove it from the No 2 Hand
27. f 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 repositioned so that it covers onl one terminal open or the high voltage will stay on all the time See Figure 16 for the location of KV test jumper J8 WARNING gt If jumper J8 is left covering shorting both terminals high voltage will be on whenever the AC power is turned on NOTE Use Ransburg Calibrated Equipment ONLY for testing and troubleshooting Re fer to the Accessories section of this man ual for part numbers for testing equipment KV TEST JUMPER u a u 85 al Eu 5 a 9o SE um B u 00 Figure 16 Lockout Location 13 04 1 Ransburg SETPOINT OPERATIONS Voltage Setpoints The voltage on the 9060 High Voltage Control ler is adjustable between 20 kV and full kV DC There are 3 voltage setpoints presets 1 2 and 3 Each of these setpoints can be individu ally adjusted between 20 kV and full kV DC The three 3 factory preset voltages are listed in the following table Factory Presets Pes H 1 1 Full kV minus 20 kV Pr Full kV minus 10 kV Full kV NOTE The full kV DC value is determined by the gun type configuration for the part
28. gun care should be taken when reinstalling so that the high voltage cable is completely engaged WARNING The Controller MUST be OFF when the No 2 Handgun is removed or reinstalled 9060 for No 2 Process Handgun Installation 14 Ransburg 9060 for No 2 Process Handgun Installation Sal HOLIMS ATINISSY 3v2Sv2 H ONIE I3NIHVO OL 4144905 ATOWISSY Q4vOH Od HILSYW 8 9 5 lt ama naz 71 2351 5 2 2 z AT NAD m 0381 T 9 2 2 N N M3MOd 402 INN MOAJANOI ONY IShvHX3 HUM 2v OL Xr Figure 7 Controller Schematic 13 04 1 15 Ransburg NO 2 PROCESS HAND GUN TRIGGER SIGNAL The No 2 Process Handgun uses a flow switch 13742 02 to provide the trigger signal The listed flow switch is mounted inside the 9060 Controller chassis via the Air Flow Switch Connector on the side panel When the No 2 Process Handgun trigger is pressed and flow starts the flow switch is activated and triggers the high voltage For reference when replacing a flow switch perform the following 1 Turn the 9060 Controller off disconnect it from its AC source and remove the fuses
29. icu lar applicator that is being used NOT the full KV value of the cascade Setting the Setpoint When the No 2 Handgun is off the present setpoint can be changed by pressing the 1 2 or 3 buttons on the front panel shown in Figure 17 The setpoint that is currently selected will have the LED light in the upper right corner of the button lit SINGLE PUSHES INCREMENT VOLTAGE DOWN OR N UP IN SINGLE INCREMENTS HOLDING BUTTON NN INCREMENTS VOLTAGE DOWN up 4 IN INCREMENTS 5 kV POINT SELECT BUTTON Figure 17 kV Adjust Setpoint Buttons 13 04 1 9060 for No 2 Process Handgun Operation Adjusting Presets To adjust one of the preset setpoints ensure the No 2 Handgun is off in LOCAL mode and select the desired setpoint by pressing the corresponding setpoint button The setpoint can then be adjusted between 20 kV and full kV using 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 conditions or if any problems with the 9060 unit arise a fault occurs to reset a fault turn off the No 2 Handgun and press the Reset Button
30. it at any one time BUTTONS The seven buttons on the operator interface are used to select the KV presets reset overloads and faults access other modes and to navigate as well as modify information that is displayed on the two seven segment display screens and kV Preset 1 Button The Preset 1 Button on the left below the kV display is used by itself to select Voltage Preset 1 If pressed with the reset button at the same time the screen will display the resettable High Voltage ON operating hours for 3 seconds on the display screens Preset 2 Button The Preset 2 Button in the center below the kV display is used by itself to select Voltage Preset 2 If pressed with the reset button at the same time the screen will display the non resettable High Voltage ON operating hours for 3 seconds on the display screens Preset 3 Button The Preset 3 Button on the right below the kV display is used to select Voltage Preset 3 9060 for No 2 Process Handgun Introduction 10 9060 for No 2 Process Introduction 11 Left Right Buttons The left right buttons are used to modify decrease and increase respectively the cur rently selected preset value If the button is pressed and released the preset value is changed by 1 kV at a time If the button is held for over a 1 2 second the value will begin changing by 5 kV increments Reset Button The reset button is used to cl
31. nd maintenance dures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent Con troller shutdown indicates 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 maintenance 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 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 during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high voltage to be on but only as instructed Non factory replacement parts or unauthor ized equipment modifications ma
32. ng the jumper 2 Turn AC power off and access the interior of the Controller 3 Place the jumper across the two 2 pins at location 16 on the main PC board See Figure 14 4 Close the Controller and turn AC power back on Pressing the front panel or setpoint buttons will now have no affect on the kV setting 9060 for No 2 Process Handgun Operation 18 9060 for No 2 Process Handgun Operation 19 JUMPER 16 INSTALLED FRONT PANEL CONTROL DE ACTIVATED Figure 14 Jumper Location Front Panel Lockout Overload The overload circuit may be activated for applications that reguire overload indication or notification of high current draws of the applica tor The default overload value is set in the software to the maximum microamp rating minus 10 microamps 1 Turn AC power off and access the interior of the Controller 2 Place the jumper across the two 2 pins at location 17 on the main PC board See Figure 15 3 Close the Controller and turn AC power back on An overload fault will now occur if the microamp display exceeds the overload value 4 ayaa LL JUMPER 17 INSTALLED OVERLOAD ACTIVATED Figure 15 Jumper Location Overload Activation Ransburg 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 o
33. oltage on Check for loose wiring between the pc board connector and the high voltage sec tion by pulling on each wire Repair if nec essary Insure both connectors are secure and re test for GF fault Adjust the setpoint to 20kV and turn on the high voltage A GF fault indicates a faulty pc board replace Replace high voltage section or send unit in for repair Send unit in for repair Check connections using two finger pull test to ensure they are connected Replace the pc board Send unit in form repair This may indicate the paint conductivity is too high resistance too low or the outside of the applicator is contaminated with paint Clean outside of the applicator Replace barrel or applicator Send applicator in for repair Securely attach a ground wire to the appli cator electrode Set the high voltage to maximum and place a jumper across the flow switch The current reading on the control unit should rise up to the maximum current out put If it does not send the applicator in for repair 24 9060 for No 2 Process Handgun Maintenance Ransburg Voltage Cable Fault UC 25 The Voltage Feedback Fault indi cates the cascade drive signal is not present It typically occurs when high voltage is triggered Turn off the voltage controller and remove the high voltage cable from the voltage controller Turn on the power and place a jumper across the flow switch If the fault occu
34. osition OVERLOAD FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS OL DAY i L T T Figure 20 Overload Fault Display Current Limit Fault CL This fault occurs if the output current exceeds the maximum current by 20 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 formulation or replace the pc board See Fault Troubleshooting Section for more information 13 04 1 Ransburg CURRENT LIMIT FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS CL Figure 21 Current Limit Fault Display Voltage Cable Fault 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 VOLTAGE CABLE FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS UC Figure 22 Voltage Cable Fault Display Over Voltage Fault OU This fault will occur if the microprocessor de tects the unit is trying to output voltage above the required for the sp
35. rs send the voltage controller in for repair If no fault occurs continue 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 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 Measure the resistance using a tri meter connected to the black end of the tube and screwdriver in the other end The measurement must be 150 to 170 Mega ohms Replace resistor tube if the reading is not correct Replace high voltage cable or send appli cator unit in for repair 13 04 1 Ransburg 9060 for No 2 Process Handgun Maintenance NOTES CP 13 04 1 2 9060 for No 2 Process Handgun Parts Identification Ransburg PARTS IDENTIFICATION 9060 HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION When ordering use 80102 A1B as indicated by Table A and B Three digits must follow the basic part number for example 80102 A1B Basic Part Number Plug Selection TABLE B Model Selection TABLE A Model number and serial number of the voltage controller is located on the left outside face of the main enclosure Table A Model Selection DasnNo Desorpton 2 Process Gun Air Motor 3 P N 80086 XX Table
36. tem delivers coating material to the bell when the gun is triggered There the fluid travels across the face of the rotating bell and becomes charged The fluid is electrically atomized at the edge of the bell forming a fine mist which under the influence of the electrostatic field is attracted to and deposited on the target object The forces between the charged particles and the grounded target are sufficient to turn almost all overspray around and deposit it on the side and back surfaces of the target Thus a high percentage of the spray is deposited on the target and overspray is controlled The 9060 High Voltage Controller The Ransburg 9060 High Voltage Controller 80102 31X is used to provide high voltage for the No 2 Process Handgun 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 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 The 9060 Controller selection and adjust ment of set point values is performed from the controller front panel The triggering of the HV is initiated by the airflow switch built into the controller which senses airflow triggered by the No 2 Process Handgun SAFETY FEATURES The Ransburg 9060 High
37. y 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 disa bled Never use equipment intended for use in water borne installations to spray solvent based mate rials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and European Health and Safety Norms 9060 for 2 Process Handgun Safety Ransburg AREA Tells where hazards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Fire and or explosion 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 The 78789 control panel LEPS5001 power sup ply and all other electrical equipment must be located outside Class or 1 Division 1 or 2 haz ardous areas in accordance with NFPA 33 Test only in areas free of flammable or combus tible materials The current overload sensitivity MUST be set as described in the OVERLOAD ADJUSTMENT Procedures section of this manual Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the cur rent overload sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which requires correc tion
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