SERVICE MANUAL CP-13-06.2 MAY - 2013 9060 CLASSIC HIGH VOLTAGE CONTROLLER (HV3—Handguns) MODEL: 80130-XXX 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.
CP-13-06.
9060 Classic High Voltage Controller - Contents CONTENTS SAFETY: PAGE 1-6 SAFETY PRECAUTIONS ......................................................................................................... 1 HAZARDS / SAFEGUARDS................................................................................................... 2-5 INTRODUCTION: 7-12 GENERAL DESCRIPTION........................................................................................................ 7 SAFETY FEATURES ....................
9060 Classic High Voltage Controller - Contents CONTENTS PAGE OPERATION (Cont.): 21-26 LOCKOUTS ....................................................................................................................... 22-23 KV TEST JUMPER ................................................................................................................. 23 SETPOINT OPERATIONS ...................................................................................................... 24 FAULT DESCRIPTIONS ..........
CP-13-06.
9060 Classic High Voltage Controller - 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 information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the following symbols.
9060 Classic High Voltage Controller - Safety AREA HAZARD Tells where hazards Tells what the hazard is. may occur. Spray Area Fire Hazard SAFEGUARDS Tells how to avoid the hazard. Fire extinguishing equipment must be present in the spray area and tested periodically. Improper or inadequate operation and maintenance proce- Spray areas must be kept clean to prevent the accumulation of combustible residues. dures will cause a fire hazard.
9060 Classic High Voltage Controller - Safety AREA HAZARD SAFEGUARDS Tells where hazards may occur. Tells what the hazard is. Tells how to avoid the hazard. Spray Area Fire and/or explosion. Electrostatic arcing MUST be prevented. The 78789 control panel, LEPS5001 power supply and all other electrical equipment must be located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33. Test only in areas free of flammable or combustible materials.
060 Classic High Voltage Controller - Safety AREA HAZARD Tells where hazards Tells what the hazard is. Electrical Equipment 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. SAFEGUARDS Tells how to avoid the hazard. The power supply, optional remote control cabinet, and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas.
9060 Classic High Voltage Controller - Safety AREA HAZARD 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 ungrounded objects which is capable of igniting coating materials. 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.
9060 Classic High Voltage Controller - Safety NOTES CP-13-06.
9060 Classic High Voltage Controller - Introduction INTRODUCTION GENERAL DESCRIPTION The Ransburg 9060 High Voltage Controller (80130-XXX) is used to provide high voltage for electrostatic application equipment. It uses a combination of proven high voltage generation technology and microprocessorbased 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.
9060 Classic High Voltage Controller - Introduction SPECIFICATIONS Environmental Operating Temperature: Storage and Shipping Temperature: 0°C to +40°C -40°C to +85°C (Allow power supply to go to room temperature before use) 95% Non-Condensing Humidity: Physical Height: 16.5 cm (6.5 inches) Width: 37.8 cm (14.9 inches) Depth: 30.7 cm (12.1 inches) 10.2 kg (22.5 lbs.) Weight: Electrical Input Voltage: 100-240 VAC 50 or 60 Hz Frequency: Current: 1 A max. RMS Wattage: 40 watts (max.
9060 Classic High Voltage Controller - Introduction Figure 2: 9060 High Voltage Controller Features 9060 CONTROLLER FEATURES 9 No. Description No.
9060 Classic High Voltage Controller - Introduction 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 bargraph, and two (2) screens containing sevensegment displays. control button on the center of the operator interface. This LED is lit when the Controller is used with Handguns.
9060 Classic High Voltage Controller - Introduction Left (-)/Right (+) Buttons The left(-)/right(+) buttons in the normal operating mode are used to modify, decrease and increase respectively, the currently 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.
9060 Classic High Voltage Controller - Introduction 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.
9060 Classic High Voltage Controller - Installation INSTALLATION GENERAL INFORMATION LOCATION OF THE 9060 The following section contains general information on the installation of 9060 High Voltage Controller. Install the controller in an area outside the hazardous location in accordance with federal, state, and local codes.
9060 Classic High Voltage Controller - Installation ELECTRICAL NOISE Electrical noise refers to stray electrical signals in the atmosphere at various signal strengths and frequencies that can affect the operation of equipment. One of the best ways to prevent this is to shield the equipment and cables within a continuous ground envelope, such that any incident noise will be conducted to earth ground before it can affect the circuit conductors.
9060 Classic High Voltage Controller - Installation affected by electrical noise when the above methods are utilized. I/O CONNECTIONS For maximum noise immunity, I/O wiring should be run in conduit or cables having a foil shield with an overall braided shield. The foil shield provides 100% shielding, while the braid provides a means of making proper 360° shield terminations at the cable to cabinet connection points.
9060 Classic High Voltage Controller - Installation NOTE In general, conduit must be used for approved AC installation, however, if national and local codes permit, the AC power may be supplied via the factory supplied line cord. If conduit is utilized, the Controller AC input wiring may be routed through an optional explosion proof switch mounted on or near the spray booth where it will be convenient to the operator.
9060 Classic High Voltage Controller - Installation SAFETY GROUND ! WARNING Failure to connect interlocks could re- 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. sult in a fire or explosion. ! WARNING ALWAYS ensure that high voltage is ! OFF before flushing the spray applicator with solvent.
9060 Classic High Voltage Controller - Installation Figure 12: Controller Schematic CP-13-06.
9060 Classic High Voltage Controller - Installation and 105°C and its conductors should be 0.8mm2 (18 AWG) minimum. Secure the cable to the interlock connector as described in “I/O Connections” in the “Installation” section of this manual so that the shield of the cable is connected to the chassis of the enclosure. 5. Secure the cabinet door, replace the fuses, and reconnect the AC source. NOTE Some codes may require the interlock wiring to be run in conduit.
9060 Classic High Voltage Controller - Installation HANDGUN TRIGGER SIGNAL Handguns use a flow switch (13742-01 or 13742-02) to provide the trigger signal. One of the listed flow switches is mounted inside the 9060 Controller chassis via the Air Flow Switch Connector on the side panel. When the handgun trigger is pressed and flow starts, the flow switch is activated and triggers the high voltage.
9060 Classic High Voltage Controller - Installation 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 µA (microamp) display will show the current software revision level as shown in Figure 15. These items are displayed for approximately 10 seconds. WARNING DO NOT adjust the gun configuration jumpers.
9060 Classic High Voltage Controller - Installation 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 maintenance of applicator and external equipment of the power supply. LOCKOUTS There are lockouts that may be done at the PC board (see Figure 18). These lockouts may be used individually or in combination as required.
9060 Classic High Voltage Controller - Operation KV TEST JUMPER Figure 19: Jumper Location - Front Panel Lockout Overload 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.
9060 Classic High Voltage Controller - Operation and 3. Each of these setpoints can be individually adjusted between 20 kV and full kV DC. The three (3) factory preset voltages are listed in the following table: Factory Presets Preset Controller shown in Figure 16. Single pushes of the + or - buttons will increment or decrement the currently selected preset in units of 1.
9060 Classic High Voltage Controller - Operation Cable Fault (CF) Overload Fault (OL) This fault will occur if high voltage is active and the microprocessor detects that no current is being supplied to the high voltage section. This indicates a connection problem from the control unit to the high voltage section or external cascade. Check the wiring harness for loose pins, or replace the high voltage section. In external cascade applications, a failed low voltage cable can cause this fault.
9060 Classic High Voltage Controller - Operation Voltage Cable Fault (UC) Feedback Fault (FF) This fault will occur if the microprocessor detects 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. This fault will occur if the microprocessor detects a loss of the current feedback signal. If this occurs, reset the fault.
9060 Classic High Voltage Controller - 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 available. Power cycle the unit off and back on. 2. Blown fuse 3. Faulty +24 volt power supply 2. Check Fuses and replace if blown using the replacement fuses inside the lid of the unit. 3. Check green LED on 24 volt power supply, when power is applied led must be on.
9060 Classic High Voltage Controller - Maintenance Fault Description Solution Ground Fault (GF) 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 setpoint to 20kV and turn on the high voltage.
9060 Classic High Voltage Controller - Maintenance Fault Description Solution Voltage Cable Fault (UC) 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 HV test jumper J8 in shorted position. If the UC fault occurs, send the high voltage controller in for repair. If no fault occurs, continue. 3.
9060 Classic High Voltage Controller - Parts Identification PARTS IDENTIFICATION 9060 HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION * When ordering, use 80130-A1B as indicated by Table A and B. Three digits must follow the basic part number, for example: 80130 - A 1 B 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 Dash No.
9060 High Voltage Controller - Parts Identification 9060 High Voltage Controller - Parts List Part # Description 13742-01 Air Flow Switch (80130-21X, 31X, 51X Units) 13742-02 Air Flow Switch (80130-41X Units) 72771-06 Fuse (250V, 1A, 5mm x 20mm) 79390-01 9060 High Voltage Controller PC Mainboard for 80130-21X 79390-02 9060 High Voltage Controller PC Mainboard for 80130-31X, 51X 79390-03 9060 High Voltage Controller PC Mainboard for 80130-41X 79428-00 Power Supply, 24V (24VDC Power Supply 1PS
9060 High Voltage Controller - Accessories ACCESSORIES 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) CP-13-06.
9060 Classic High Voltage Controller - 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.
9060 Classic High Voltage Controller - 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. © 2013 Ransburg. All rights reserved. Models and specifications subject to change without notice. CP-13-06.
