SERVICE MANUAL CP-13-07.2 MAY - 2013 9060 CASCADE LOW VOLTAGE CONTROLLER (LV3 - Handguns) MODEL: 80131-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-13-07.
9060 Cascade Low Voltage Controller - Contents CONTENTS SAFETY: PAGE 1-6 SAFETY PRECAUTIONS ......................................................................................................... 1 HAZARDS / SAFEGUARDS................................................................................................... 2-5 INTRODUCTION: 7-12 GENERAL DESCRIPTION........................................................................................................ 7 SAFETY FEATURES .....................
9060 Cascade Low Voltage Controller - Contents CONTENTS PAGE MAINTENANCE: 27-30 TROUBLESHOOTING GUIDE ................................................................................................ 27 FAULT TROUBLESHOOTING GUIDE ............................................................................... 27-29 PARTS IDENTIFICATION: 31-32 LOW VOLTAGE CONTROLLER MODEL IDENTIFICATION .................................................. 31 PARTS LIST ......................................................
CP-13-07.
9060 Cascade Low 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 Cascade Low 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 dures will cause a fire hazard. accumulation of combustible residues.
9060 Cascade Low 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 Cascade Low Voltage Controller - Safety AREA HAZARD Tells where hazards Tells what the hazard is. may occur. 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 Cascade Low 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 Cascade Low Voltage Controller - Safety NOTES CP-13-07.
9060 Cascade Low Voltage Controller - Introduction INTRODUCTION GENERAL DESCRIPTION DISPLAYS The Ransburg 9060 Cascade Low Voltage Controller (80131-XXX) is used to provide high voltage for electrostatic application equipment. It uses a combination of proven high voltage generation technology and microprocessor-based control. It uses a variable voltage output to drive an external cascade that amplifies the voltage to a high kV level.
9060 Cascade Low 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: 14.0 cm (5.5 inches) Width: 21.6 cm (8.5 inches) Depth: 19.1 cm (7.5 inches) 3.4 kg (7.5 lbs.) Weight: Electrical Input Voltage: 100-240 VAC 50 or 60 Hz Frequency: Current: 1 A max. RMS Wattage: 40 watts (max.
9060 Cascade Low Voltage Controller - Introduction 1 3 7 2 6 5 4 9 13 10 11 14 8 12 9060 CONTROLLER FEATURES No. Description No.
9060 Cascade Low 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 in local mode.
9060 Cascade Low Voltage Controller - Introduction Left (-)/Right (+) Buttons handgun units. 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 Cascade Low 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 Cascade Low Voltage Controller - Installation INSTALLATION GENERAL INFORMATION LOCATION OF THE 9060 The following section contains general information on the installation of the 9060 Cascade Low Voltage Controller. Install the Controller in an area outside the hazardous location in accordance with federal, state, and local codes.
9060 Cascade Low 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 Cascade Low 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 Cascade Low Voltage Controller - Installation NOTE TB1 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 Cascade Low 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 Cascade Low Voltage Controller - Installation Figure 11: Controller Schematic CP-13-07.
9060 Cascade Low 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. Replace the top cover, secure the screws, replace the fuses, and reconnect the AC source. NOTE Some codes may require the interlock wiring to be run in conduit.
9060 Cascade Low Voltage Controller - Installation HANDGUN TRIGGER SIGNAL Ground Screw 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. For reference, when replacing a flow switch, perform the following: 1.
9060 Cascade Low Voltage Controller - 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 configuration 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. Gun Type Number Software Rev.
9060 Cascade Low Voltage Controller - Operation 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. If the jumpers are disconnected, the original functions are re-enabled.
9060 Cascade Low Voltage Controller - Operation Figure 21: Lockout Jumper Location Figure 19: Jumper Location - Front Panel Lockout Overload The overload circuit may be activated for applications that require overload indication or notification of high current draws of the applicator. The default overload value is set in the software to the maximum microamp rating minus 10 microamps. Turn AC power off and access the interior of the Controller. 2.
9060 Cascade Low Voltage Controller - Operation kV DC. There are 3 voltage setpoints (presets); 1, 2, and 3. Each of these setpoints can be individually adjusted between 20 kV and full kV DC.
9060 Cascade Low 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 applicator. This indicates a connection problem from the control unit to the 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.
9060 Cascade Low 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 may indicate a failed pc board. See Fault Troubleshooting Section for more information. This fault will occur if the microprocessor detects a loss of the current feedback signal. If this occurs, reset the fault. If this fault occurs repeatedly, replace the handgun barrel or the pc board.
9060 Cascade Low 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 2. Check Fuses and replace if blown using the replacement fuses inside the lid of the unit.
9060 Cascade Low 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 connection on the low voltage cable, and tighten if necessary. Insure both connectors are secure and re-test for GF fault. 2. Turn off control unit power.
9060 Cascade Low 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. Replace the barrel assembly and re-test. Boot Fault (bF) The Boot Fault indicates that an active trigger signal was detected during the start-up sequence. 1. Turn off the voltage controller. 2. Replace the main pc board and re-test. 2.
9060 Cascade Low Voltage Controller - Maintenance NOTES CP-13-07.
9060 Cascade Low Voltage Controller - Parts Identification PARTS IDENTIFICATION 9060 CASCASDE LOW VOLTAGE CONTROLLER MODEL IDENTIFICATION * When ordering, use 80131-A1B as indicated by Table A and B. Three digits must follow the basic part number, for example: 80131 - 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 Cascade Low Voltage Controller - Parts Identification 9060 Cascade Low Voltage Controller - Parts List Part # Description 13742-01 Air Flow Switch (80131-21X, 31X, 51X Units) 13742-02 Air Flow Switch (80131-41X Units) 72771-06 Fuse (250V, 1A, 5mm x 20mm) 79390-20 9060 Cascade Low Voltage Controller PC Mainboard for 80131-21X 79390-22 9060 Cascade Low Voltage Controller PC Mainboard for 80131-31X, 51X 79390-24 9060 Cascade Low Voltage Controller PC Mainboard for 80131-41X 79428-00 Power
9060 High Voltage Controller - Accessories ACCESSORIES 9060 Low Voltage Controller - Accessories List 33 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-13-07.
9060 High Voltage Controller CP-13-07.
9060 Cascade Low 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 Cascade Low 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-13-07.
