Ransburg 9060 Service Manual
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Ransburg 9060 Service Manual

High voltage controller for no. 2 process handgun (hv2 - electric motor)
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SERVICE MANUAL
CP-13-03.3
OCTOBER - 2015
9060 HIGH VOLTAGE CONTROLLER
for No. 2 Process
MODEL: 80102-21X (Electric Motor)
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.
(HV2 - Electric Motor)
TM
Handgun
Service Manual Price:
Service Manual Price:
Service Manual Price:
Service Manual Price:
$50.00 (U.S.)
$50.00 (U.S.)
$50.00 (U.S.)
$50.00 (U.S.)

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  • Page 1 SERVICE MANUAL CP-13-03.3 OCTOBER - 2015 9060 HIGH VOLTAGE CONTROLLER for No. 2 Process Handgun (HV2 - Electric Motor) MODEL: 80102-21X (Electric Motor) 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.
  • Page 2 CP-13-03.3...

  • Page 3: Table Of Contents

    9060 for No. 2 Process Handgun - Contents CONTENTS PAGE SAFETY: SAFETY PRECAUTIONS......................1 HAZARDS / SAFEGUARDS ....................2-5 INTRODUCTION: 7-11 GENERAL DESCRIPTION ......................7 SAFETY FEATURES ........................ 7 DISPLAYS ..........................7 SPECIFICATIONS ........................8 CONTROLLER FEATURES ...................... 9 OPERATOR INTERFACE ....................... 10 SWITCHES ..........................
  • Page 4 9060 for No. 2 Process Handgun - Contents CONTENTS PAGE MAINTENANCE: 20-28 ROUTINE PREVENTIVE MAINTENANCE ................20 TROUBLESHOOTING ....................... 20-21 FAULT TROUBLESHOOTING GUIDE ................22-23 GENERAL TROUBLESHOOTING GUIDE ................. 24-25 SERVICE LEVEL ........................26 REPLACEMENT PROCEDURES ..................26-27 INTERNAL COMPONENT LOCATIONS (80102-21X) ............28...
  • Page 5 CP-13-03.3...

  • Page 6: Safety

    9060 for No. 2 Process Handgun - Safety SAFETY SAFETY PRECAUTIONS W A R N I N G ! ! ! ! The user MUST read and be familiar Before operating, maintaining or servicing any with the Safety Section in this manual and...

  • Page 7: Hazards / Safeguards

    9060 for No. 2 Process Handgun - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. Fire Hazard Fire extinguishing equipment must be present in Spray Area the spray area and tested periodically.
  • Page 8 9060 for No. 2 Process Handgun - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. Fire and/or explosion. Spray Area Electrostatic arcing MUST be prevented. The 78789 control panel, LEPS5001 power sup-...
  • Page 9 9060 for No. 2 Process Handgun - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. High voltage equipment is utilized. The power supply, optional remote control Electrical Arcing in areas of flammable or...
  • Page 10 9060 for No. 2 Process Handgun - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. There is a high voltage Parts being sprayed must be supported on conveyors...
  • Page 11 9060 for No. 2 Process Handgun - Safety N O T E S CP-13-03.3...

  • Page 12: Introduction

    9060 for No. 2 Process Handgun - Introduction INTRODUCTION The 9060 Controller for the No. 2 Process GENERAL DESCRIPTION Handgun has a fixed setpoint value which can NOT be adjusted. The triggering of the The Ransburg HV is initiated by the on-off switch on the No.

  • Page 13: Specifications

    9060 for No. 2 Process Handgun - Introduction SPECIFICATIONS N O T E Environmental The 9060 High Voltage Controller is factory supplied with a latch that can be Operating Temperature: 0° C to +40° C opened using a tool such as quarter or flat 32°...

  • Page 14: Controller Features

    9060 for No. 2 Process Handgun - Introduction Figure 2: 9060 High Voltage Controller Features (HV2) 9060 CONTROLLER FEATURES Description Description kV Display Ground Lug High Voltage On Indicator AC Inlet Receptacle Reset Button µA Display Fault Indicator On-Off Switch...

  • Page 15: Operator Interface

    The red Fault Indicator is lit when a fault occurs external ground connection point used to as determined by the microprocessor. When a ground the 9060 to an earth ground via a fault occurs the light will turn on and the identifi- ground cable. This ground lug connection can...

  • Page 16: Connection Interface

    9060 for No. 2 Process Handgun - Introduction AC Inlet Receptacle N O T E S The AC inlet receptacle is a standard IEC C14 Appliance Inlet connector with a maximum rating of 250 VAC. It can handle both 115VAC and 230 VAC inputs at 50 or 60 Hz.

  • Page 17: Installation

    AC line cord into the receptacle on the side building and fire codes and ordinances as of the 9060 Controller. Plug the other end of well as NFPA-33, OSHA, and all related the line cord into a properly grounded 120 volt country safety codes prior to installing, op- AC outlet.

  • Page 18: Safety Ground

    9060 for No. 2 Process Handgun - Installation Hot/Line to TB1-L1 INPUT VOLTAGE Neutral/Common to TB1-N SELECTION Ground to TB1-EARTH GROUND 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 VAC or from 240 to 110 VAC.

  • Page 19: Controller Schematic (Hv2)

    9060 for No. 2 Process Handgun - Installation Figure 7: Controller Schematic (HV2) CP-13-03.3...

  • Page 20: Operation

    9060 for No. 2 Process Handgun - Installation OPERATION START-UP W A R N I N G ! ! ! ! VERIFY that the gun jumper configura- After all installation procedures are completed, tion is set for the applicator type that is operation of the applicator may begin.

  • Page 21: Kv Test Jumper

    KV test jumper J8. Ensure the jumper is problems with the 9060 unit arise. If a fault installed on ONLY ONE post during power on to occurs, to reset a fault, the No. 2 Handgun on- prevent a boot fault “bF”.

  • Page 22: Fault Descriptions

    9060 for No. 2 Process Handgun - Installation Ground Fault (GF) FAULT DESCRIPTIONS If this fault occurs, the fault indicator on the control unit will illuminate, a GF indication will For in depth troubleshooting information on the show in the uA display. This fault will occur if 9060, please refer to the “Fault Troubleshoot-...
  • Page 23 9060 for No. 2 Process Handgun - Operation Current Limit Fault (CL) Over Voltage Fault (OU) This fault occurs if the output current exceeds This fault will occur if the microprocessor de- the maximum current by 20µA. This fault can...
  • Page 24 9060 for No. 2 Process Handgun - Operation Boot Fault (bF) N O T E S This fault will occur during the start-up se- quence if the No. 2 Handgun on-off switch is in the on position. It is designed to prevent immediate triggering after start-up as the unit should be allowed to enter the “ready”...

  • Page 25: Maintenance

    9060 for No. 2 Process Handgun - Maintenance MAINTENANCE ROUTINE PREVENTIVE Equipment Required: Ohmmeter—To Measure Resistance MAINTENANCE If shocks or sparks are noticed at any point In general, little maintenance is necessary to in the spray system, immediately turn off the ensure proper operation.
  • Page 26 9060 for No. 2 Process Handgun - Maintenance 8. Disconnect the Test Probe (76652-01) 2. Remove the high voltage (HV) cable from the power supply. and reposition jumper J8 so that it covers only one terminal. When ready to resume spray operations, reconnect the...

  • Page 27: Fault Troubleshooting Guide

    9060 for No. 2 Process Handgun - Maintenance FAULT TROUBLESHOOTING GUIDE W A R N I N G ! ! ! ! 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.
  • Page 28 9060 for No. 2 Process Handgun - Maintenance Fault Description Solution Current Limit The Current Limit Fault indi- 1. Clean outside of the applicator. cates the current output of the Fault (CL) 2. Replace barrel or applicator. gun has exceeded the maxi- 3.

  • Page 29: General Troubleshooting Guide

    9060 for No. 2 Process Handgun - Maintenance GENERAL TROUBLESHOOTING GUIDE General Problem Possible Cause Solution Black Display when from 1. No AC power present 1. Ensure voltage across terminals L1 and N of terminal block 1TB is be- panel switch is turned to 2.
  • Page 30 9060 for No. 2 Process Handgun - Maintenance General Problem Possible Cause Solution Front Panel Display On, 1. Defective spray gun or high 1. Test gun switch and cable (See Spray voltage cable. Gun’s Service Manual). Gun Switch On, No kV at Gun, Motor Not Rotat- 2.

  • Page 31: Service Level

    9060 for No. 2 Process Handgun - Maintenance SERVICE LEVEL N O T E Personnel who service this unit must be Two (2) spare fuses, included from the qualified electronics technicians. Replace- factory, are located on the inside of the ment parts are designed to be made at the top lid of the cabinet.
  • Page 32 9060 for No. 2 Process Handgun - Maintenance From Main PC Board 1LF-RED or BLACK 1SW-1 1. Ensure power supply is unplugged from AC outlet and open cabinet lid. 1LF-BLUE 1SW-2 2. Disconnect plugs/connectors J7, J3, J2, 2TB-3 1SW-1A and J1 from main PC board. (see Figure 18).

  • Page 33: Internal Component Locations (80102-21X)

    9060 for No. 2 Process Handgun - Maintenance (J7) (J3) (J2) (J1) Figure 18: 9060 (80102-21X) Internal Component Locations CP-13-03.3...

  • Page 34: Parts Identification

    9060 for No. 2 Process Handgun - Parts Identification 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 - 2 1 X...

  • Page 35: Parts List

    9060 for No. 2 Process Handgun - Parts Identification 9060 High Voltage Controller - Parts List Description Part # 72771-06 Fuse (250V, 1A, 5mm x 20mm) 76434-01 Switch, Rocker (On-Off Switch) 80116-28 9060 High Voltage Controller PC Mainboard 79428-00 Power Supply, 24V (24VDC Power Supply 1PS)

  • Page 36: Accessories

    9060 for No. 2 Process Handgun - Accessories ACCESSORIES 9060 High Voltage Controller - Accessories List Description Part # 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) LSCH0009 Dielectric Grease (.88 oz tube)

  • Page 37: Warranty Policies

    9060 for No. 2 Process Handgun - Warranty Policies WARRANTY POLICIES RANSBURG'S ONLY OBLIGATION LIMITED WARRANTY UNDER THIS WARRANTY IS TO RE- PLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP MATER-IALS. THERE Ransburg will replace or repair without charge...
  • Page 38 Telephone (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-13-03.3 © 2014 Ransburg. All rights reserved. Litho in U.S.A. Models and specifications subject to change without notice. 12/14 CP-13-03.3...

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