Quick Start Guide Owner manual
Fault Description Solution
BOOT FAULT
(BF)
PAGE #39
The Boot Fault indicates that an active trigger signal
was detected during the start-up sequence.
1. Turn off the voltage controller.
2. Ensure that the gun trigger is not pressed.
3. Turn on the voltage controller to verify that a trigger signal is not present and that the unit enters the ‘ready’
state..
4. Send the voltage controller in for repair or contact technical support.
CABLE FAULT
(CF)
PAGE #39
The Cable Fault indicates the control unit does not
detect a high voltage section on the end of the ca-
ble. The fault typically occurs at a high voltage trig-
ger.
1. Check for loose wiring between the pc board connector and the high voltage section by pulling on each wire.
Repair if necessary. Insure both connectors are secure and re-test for CF fault.
2. Replace high voltage section or send unit in for repair.
3. Send unit in for repair.
CURRENT LIMIT
FAULT (CL)
PAGE #40
The Current Limit Fault indicates the current output
of the gun has exceeded the maximum allowable
output current. It typically occurs with the high volt-
age on.
1. Clean outside of the applicator.
2. Replace barrel or applicator.
3. Send applicator in for repair.
GROUND FAULT
(GF)
PAGE #40
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.
1. Check for loose wiring between the pc board connector and the high voltage section by pulling on each wire.
Repair if necessary. Insure both connectors are secure and re-test for GF fault.
2. Adjust the set point to 20kV and turn on the high voltage. A GF fault indicates a faulty pc board - replace.
3. Replace high voltage section or send unit in for repair.
4. Send unit in for repair.
VOLTAGE CABLE
FAULT (UC)
PAGE #40
The Voltage Feedback Fault indicates the cascade
drive signal is not present. It typically occurs when
high voltage is triggered.
1. Turn off the voltage controller and remove the high voltage cable from the voltage controller.
2. Turn on the power and place a jumper across the flow switch. If the fault occurs, send the voltage controller
in for repair. If no fault occurs, 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 resistor 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 replaced.
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.
5. Replace high voltage cable or send applicator unit in for repair.
DI/DT OVERLOAD
FAULT
(DOL)
PAGE #40
(For 80100-51X
UNITS ONLY)
The DI/DT Overload Fault indicates that the
change in current has exceeded the user
specified current limit (sensitivity, SE), during
the user selected time interval (Sample Time,
SA).
1. Ensure that the target and no other object is approaching the applicator within the minimum
safe distance during application. Reset the fault and re-test operation.
2. Using the parameter adjustment mode, adjust the sensitivity and sample time interval configura-
tion values for DI/DT. Re-test operation for different values.
3. Contact technical support for further assistance.
OVER LOAD FAULT
(OL)
PAGE #41
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 maxi-
mum 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 paint.
FEEDBACK FAULT
(FF)
PAGE #41
The Feedback Fault indicates there is no current
feedback or it is incorrect. It typically occurs with the
high voltage on.
1. Securely attach a ground wire to the applicator electrode.
2. Set the high voltage to maximum and place a jumper across the flow switch.
3. The current reading on the control unit should rise up to the maximum current output. If it does not, send the
applicator in for repair.
OVER-VOLTAGE
FAULT (OU)
PAGE #41
The Over Voltage Fault indicates the output voltage
exceeds the design specifications. It typically occurs
during a high voltage trigger.
1. Check connections using two finger pull test to ensure they are connected.
2. Replace the pc board.
3. Send unit in form repair.
QUICK START GUIDE
MODEL 80100-XXX
END USER MUST READ AND UNDERSTAND THE SERVICE MANUAL PROVIDED WITH THIS PRODUCT.
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.
IL-421-03
CUSTOMER /TECHNICAL SUPPORT CALL 800-233-3366
WARNING:
(For 80100-51X Units ONLY)
Every time the high voltage 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 during charging.
STEP #1
CONNECT TO I/O
STEP #2
CONNECT HV CABLE FROM APPLICATOR /
LV CABLE TO 80104-XX.
STEP #3
CONNECT TO TRUE EARTH GROUND.
STEP #4
CONNECT TO TRUE EARTH GROUND.
STEP #5
CONNECT LV CABLE FROM POWER SUPPLY.
STEP #6
CONNECT HV CABLE TO APPLICATOR.
STEP #7
TURN ON POWER.
QUICK START INSTRUCTIONS
NOTE: IF POWER IS PROVIDED FROM AN ALTERNATE SOURCE SUCH
AS PORTABLE GENERATOR THE USER MUST INSURE THE EQUIPMENT IS
CONNECTED TO TRUE EARTH GROUND.
80104-XX