Ransburg 9060 Service Manual
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Ransburg 9060 Service Manual

High voltage controller for no. 2 process handgun
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SERVICE MANUAL
CP-13-04.1
MARCH — 2013
9060 HIGH VOLTAGE CONTROLLER
for No. 2 Process
(HV2 - Air Motor)
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.
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-13-04.1 MARCH — 2013 9060 HIGH VOLTAGE CONTROLLER for No. 2 Process Handgun (HV2 - Air Motor) 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.
  • Page 2 CP-13-04.1...

  • Page 3: Table Of Contents

    9060 for No. 2 Process Handgun - Contents CONTENTS PAGE SAFETY: SAFETY PRECAUTIONS ......................1 HAZARDS / SAFEGUARDS....................2-5 INTRODUCTION: 7-12 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: 23-26 TROUBLESHOOTING GUIDE ....................23 FAULT TROUBLESHOOTING GUIDE ................23-25 PARTS IDENTIFICATION: 27-28 HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION ..........27 PARTS LIST ........................... 28 ACCESSORIES: ACCESSORIES LIST ......................29 WARRANTY POLICIES: LIMITED WARRANTY ......................
  • Page 5 CP-13-04.1...

  • 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 Ransburg electrostatic coating system, read...

  • 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. 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-13-04.1...

  • Page 12: Introduction

    9060 for No. 2 Process Handgun - Introduction INTRODUCTION GENERAL DESCRIPTION The 9060 Controller selection and adjust- ment of set point values is performed from The Ransburg the controller front panel. The triggering of No. 2 Handgun Process the HV is initiated by the airflow switch built into the controller which senses airflow 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 (#E5-1-065- 091) that can be opened using the sup- Operating Temperature: 0° C to +40° C plied key (#E3-2).

  • Page 14: Controller Features

    9060 for No. 2 Process Handgun - Introduction Figure 2: 9060 High Voltage Controller Features 9060 CONTROLLER FEATURES Description Description kV Display kV Setpoint/Adjust Buttons High Voltage On Indicator High Voltage Cable Connector Reset Button Fuses µA Display Ground Lug...

  • Page 15: Operator Interface

    LOCAL Mode LED Indicator OPERATOR INTERFACE The LOCAL mode LED indicator is a left The 9060 Controller shown in Figure 3, has a pointing triangle and is located on the left side simple operator interface consisting of 7 LEDs the HV control button on the center of the (Light Emitting Diodes), one (1) power switch, operator interface.

  • Page 16: Connection Interface

    The Controller also comes with two (2) spare external ground connection point used to fuses (250V, 1A, 5mm x 20mm) mounted in ground the 9060 to an earth ground via a holders, inside the lid of the Controller. ground cable. This ground lug connection can also be used as the ground point for the high CP-13-04.1...

  • Page 17: Signal Interface

    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...

  • Page 18: Installation

    NFPA-33, OSHA, and all related ble AC line cord into the receptacle on the side of the 9060 Controller. Plug the other end of country safety codes prior to installing, op- the line cord into a properly grounded 120 volt erating, and/or servicing this equipment.

  • Page 19: Safety Ground

    9060 for No. 2 Process Handgun - Installation Adapter Plate using conduit and wire to TB1 C A U T I O N as follows: The ground wire assembly MUST be connected from the Controller ground Hot/Line to TB1-L1 stud to a true earth ground.
  • Page 20 9060 for No. 2 Process Handgun - Installation Figure 7: Controller Schematic CP-13-04.1...

  • Page 21: 2 Process Handgun Trigger Signal

    9060 for No. 2 Process Handgun - Installation NO. 2 PROCESS HAND- GUN TRIGGER SIGNAL The No. 2 Process Handgun uses a flow switch Ground Screw (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.

  • Page 22: Operation

    9060 for No. 2 Process Handgun - Operation OPERATION START-UP W A R N I N G DO NOT adjust the gun configuration After all installation procedures are completed, jumpers. If they are incorrect, contact your operation of the applicator may begin. When Ransburg representative.

  • Page 23: Lockouts

    9060 for No. 2 Process Handgun - Operation 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.

  • Page 24: Kv Test Jumper

    9060 for No. 2 Process Handgun - Operation 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.

  • Page 25: Setpoint Operations

    During operation, various faults can occur based upon the operating conditions or if any Full kV minus 20 kV problems with the 9060 unit arise. If a fault Full kV minus 10 kV occurs, to reset a fault, turn off the No. 2 Handgun and press the Reset Button .
  • Page 26 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.
  • Page 27 9060 for No. 2 Process Handgun - Operation Figure 21: Current Limit Fault Display Figure 23: Over Voltage Fault Display Voltage Cable Fault (UC) This fault will occur if the microprocessor de- Feedback Fault (FF) tects a loss of the voltage feedback signal.

  • Page 28: Maintenance

    9060 for No. 2 Process Handgun - Maintenance MAINTENANCE TROUBLESHOOTING GUIDE General Problem Possible Cause Solution Blank Display 1. No power 1. Check the power connections and verify they are fully connected and power is avail- 2. Blown fuse able. Power cycle the unit off and back on.
  • Page 29 9060 for No. 2 Process Handgun - Maintenance Fault Description Solution The Ground Fault is typically 1. Check for loose wiring between the pc Ground Fault (GF) caused by a ground connection board connector and the high voltage sec- problem, and can create a safety tion by pulling on each wire.
  • Page 30 9060 for No. 2 Process Handgun - Maintenance Fault Description Solution The Voltage Feedback Fault indi- 1. Turn off the voltage controller and remove Voltage Cable cates the cascade drive signal is the high voltage cable from the voltage Fault (UC) not present.
  • Page 31 9060 for No. 2 Process Handgun - Maintenance N O T E S CP-13-04.1...

  • Page 32: 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 - A 1 B...

  • Page 33: Parts List

    9060 for No. 2 Process Handgun - Parts 9060 High Voltage Controller - Parts List Description Part # 13742-02 Air Flow Switch (1.0 - 2.0 SCFM) 72771-06 Fuse (250V, 1A, 5mm x 20mm) 79390-03 9060 High Voltage Controller PC Mainboard...

  • Page 34: 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)

  • Page 35: Warranty Policies

    9060 for No. 2 Process Handgun - Warranty Policies WARRANTY POLICIES RANSBURG'S ONLY OBLIGATION UND- LIMITED WARRANTY ER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MAT- ERIALS. THERE ARE NO IMPLIED WAR- Ransburg will replace or repair without charge...
  • Page 36 9060 for No. 2 Process Handgun - Warranty Policies 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 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.

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