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CP-13-05.2 9060 Classic Service Manual Model

1. Figure 26 Analog Signal Monitoring Index 0 NOTE The value displayed can range from 0 to 1023 The pA display can only display 3 digits so the display will run 000 to 999 000 to 023 1000 to 1023 This range can be easily tested by slowly increasing the analog signal starting from 0 Analog Index Reference A Index 22 13 05 2 9060 High Voltage Controller Operation To navigate through the analog indexes use the and buttons Both buttons change the index by 1 for each press and will automatically wrap back around when the either end of the list is reached Digital Signal Monitoring Mode In the digital signal monitoring mode the kV display will show a d with the being the digital signal index as shown in Figure 27 and Figure 28 The ON OFF state of the currently selected digital signal is displayed on the pA display as either ON Figure 27 or OFF Figure 28 There are a total of 5 digital signal inputs that can be monitored they are listed in the digital index reference table under their respective index KV Figure 28 Digital Signal Monitoring Index 3 OFF Triple Set 1 Lr 9060 High Voltage Controller Operation 35 To navigate through the digital indexes use the and buttons Both buttons change the index by 1 for each press and will automat
2. do et eus 31 13 05 2 9060 High Voltage Controller Contents Ransburg CONTENTS e E OPERATION Cont 29 42 LOCKOUT cem 32 33 mW 33 REMOTE I O MONITORING DIAGNOSTIC MODE 33 35 PARAMETER ADJUSTMENT 35 36 KOGA MODE ONLY OPERATIONS 25295 9 EN Ded 36 37 REMOTE MODE ONLY nnne 37 39 FAULT DESCRIPTIONS 52252525 lude dde E uu 39 41 MAINTENANCE 43 46 TROUBLESHOOTING GUIDE d Seca itt a Da a 43 FAULT TROUBLESHOOTING GU e eimi 43 45 PARTS 47 48 HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION sen 47 PARTS STR Ae uc Ld ud e RN M ND 48 ACCESSORIES 49 ACCESSORIES D d DM M M 49 WARRANTY POLICIES 50 dee RE 50 CP 13 05 2 Ransburg CP 13 05 2 9060 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 infor mation relates to USER SAFETY and PRE VENTING EQUIPMENT PRO
3. Controller Schematic Figure 12 22 CP 13 05 2 9060 High Voltage Controller Installation Ransburg 23 of 300V and 105 C and its conductors should be 0 8mm 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 In this case shielded cable is not necessary but the conductors used should still meet the rat ing specified above NOTE The interlock contacts supplied by us er should be rated for at least 1 amp at 240 VAC NOTE The total resistance of the series inter locks between L2 and L3 should be less than 300 HIGH VOLTAGE CABLE Position the spray applicator in the spray area and route the high voltage cable to the Control ler The cable should be routed so that it is not damaged by foot and vehicle traffic and also so that is not close to areas of high temperature 129 F The operator should have free movement of the applicator and all bend radii of the cable should not be less than 6 inches 15 cm the high voltage cable to the Controller and tighten the retaining nut and set screw If during the routing of the high voltage cable it is req
4. BLINKS WHEN SELECTED USED TO SWITCH PARAMETERS USED TO MODIFY VALUE IF SELECTED dee D EXIT PARAMETER ADJUSTMENT MODE SET AS DEFAULT VALUE IF SELECTED SELECT DESELECT CURRENT PARAMETER SAVES CHANGES IF SELECTED Figure 30 Summary of Adjustment Operations LOCAL MODE ONLY OPERATIONS Voltage Setpoints The voltage on the 9060 High Voltage Control ler is adjustable between 20 kV and full kV DC In the LOCAL mode 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 The three 3 factory preset voltages are listed in the following table Factory Presets Full kV minus 10 kV NOTE The full kV DC value is determined by the gun type configuration for the particu lar applicator that is being used NOT the full KV value of the cascade Setting the Setpoint When the applicator is off in LOCAL mode the present setpoint can be changed by pressing the 1 2 or 3 buttons on the front panel shown in Figure 31 The setpoint that is currently selected will have the LED light in the upper right corner of the button lit 36 9060 High Voltage Controller Operation PUSHES INCREMENT VOLTAGE DOWN OR UP IN SINGLE INCREMENTS HOLDING BUTTON N INCREMENTS VOLTAGE DOWN OR UP IN W INCREMENTS 5 KV SET POINT SELECT BUTTON Figure 31 kV Adjust Setpoint Buttons Adjusting Presets
5. 11 12 III MM M MOL de 12 SPARE EUSES re n 12 EOCAL HEMOTE BOARD 12 SIGNAL INTERFACE LOCAL 13 SIGNAL INTERFACE 13 16 INSTALLATION 17 28 GENERAL INEORMAT issver arseen retta eterne a e aa 17 LOGATION QF THE 55 cob uet 17 ELECTRICAL NOIS E 18 19 UC GONNECTIONS ce tee e nido e ete ae St cle 19 AG INPUT GONNEGCTIOBS 5 reet etr Sonn ee 19 20 SAFETY GROUND E aa 21 INPUT VOLTAGE 5 5 21 c edad 21 23 HIGH AGE GABLE a ducti dette eii etie E Ut eut 23 RELAY CONTACT OUTPUTS taste a ch cena EE apa UU ub cre cc dE 23 EDCAE MODE SIGNALS 2 E EE 24 25 REMOTETO MODE SIGNALS 25 28 OPERATION 29 42 AP MON e RECHT TAE 29 RM 29 30
6. 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 Form No CP 13 05 2 Litho in U S A 05 13 2013 Ransburg All rights reserved Models and specifications subject to change without notice CP 13 05 2
7. High Voltage output from the cascade TRIGGER SIGNAL TIMING The trigger signal minimum hold time is 10 ms The signal Hold Times are the minimum required for the processor to detect the signal During actual operations signal time durations are expected to be much greater than the minimums FAULT DESCRIPTIONS For in depth troubleshooting information on the 9060 please refer to the Fault Troubleshoot ing portion of the Maintenance Section of this service manual If a fault occurs the Fault Indicator on the front of the Controller will light and a fault code will be displayed on the 39 Ransburg microamp display Faults can be reset by pressing the Reset button on the front of the Controller or by using the remote I O reset signal NOTE Any fault code not listed that appear on the screen are a likely indication of a PC board failure due to possible arc damage Boot Fault bF This fault will occur during the start up se quence if an active trigger signal is present It is designed to prevent immediate triggering after start up as the unit should be allowed to enter the ready state prior to being triggered This fault also prevents the high voltage from being fired if the microprocessor resets For additional information refer to the Fault Trou bleshooting Section BOOT FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS bF Figure 32 Boot Fault Display C
8. Sheet supplied by coating material manufacturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materi als Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equip ment must be as prescribed by an industrial hygienist or safety expert and be NIOSH ap proved 9060 High Voltage Controller Safety AREA HAZARD Ransburg 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 un grounded objects which is capable of igniting coat ing materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials cause a fire or explosion 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 Reference NFPA 33 or EN 50 176 All electrically conductive objects in the spray area with the exception of those objects required by the process to be at high voltage must be grounded Any person working in the spray area must be grounded Unless specifically approved for use in hazardous lo cations the power supply and other electrical control equipment must not be used in Class 1 Di
9. fault conditions from triggering a new fault HV Control Button This button shown in the center of Figure 3 is not used to perform mode changes t is reserved for future use The unit defaults to LOCAL mode To enter REMOTE mode a remote l O signal input local remote mode selection indicates when the unit should be in REMOTE mode When this remote 1 signal is active the unit will be in REMOTE mode otherwise the unit will be in LOCAL mode Ransburg CONNECTION INTERFACE The 9060 Controller connection interface shown in Figure 4 provides all of the required connec tions for setting up either a remote 1 con trolled painting system or a local controlled painting system This connection interface consists of one 1 high voltage cable connect or one 1 standard I O connector one 1 interlock I O connector one 1 ground lug connection one 1 air flow switch connection two 2 fuses and one 1 AC inlet receptacle Standard I O Interlock I O HV Cable Connector 0 Inlet Figure 4 9060 Connection Interface CONNECTORS High Voltage Cable Connector The high voltage cable connector is the largest connector and is located on the far right of the connection interface The connector will come covered with a factory installed red protective cap This connector is designed for use with standard high voltage cables such as A10560 79518 and 79519 The specific cable r
10. flow switch is activated and the trigger signal is issued to the 9060 unit In REMOTE mode the control System logic issues the trigger signal to the 9060 unit directly In either case the kV setpoint is displayed on the kV display the actual current draw on the display and the high voltage light illumi nates Under the pA display is a bar graph meter that illuminates according to the actual current draw shown in Figure 19 y uA BAR GRAPH METER Figure 19 uA Bar Graph Meter Display The green and yellow regions of the bar graphs meter indicate output current is in 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 Measuring Time The 9060 High Voltage Controller records the amount of time the high voltage is triggered on up to 99 999 hours This value is display on the kV and pA displays of the unit There are two registers that retain this information one that may be reset the other that is permanently retained in memory The number of hours the units high voltage has been on may be dis played by depressing at the same time the preset 1 and reset buttons See Figure 20 The display will show hours of use for 3 sec High Voltage On CP 13 05 2 9060 High Voltage Controller Operation onds T
11. ground lines that will be required and select a shielded I O cable that has at least that many lines gt Create a table of O signals to con ductor wire color Including the terminal block location in this table is also helpful for reference Locate all of the required signal termi nal connections in advance to determine the amount of wire length required gt It is better to connect no more than two 2 conductors into any single terminal block connection To operate the Controller in the REMOTE mode using any number of the discrete I O signals perform the following 1 Turn the 9060 Controller off disconnect it from its AC source and remove the fuses 2 Open the Controller cabinet door WARNING gt ALWAYS double check the Con ed from its AC outlet troller is unplu before working with any internal wiring CP 13 05 2 3 Route the selected shielded cable through the standard I O connector and secure it to the connector as described in I O Connec tions in the Installation section of this manual so that the shield of the cable is connected to the chassis of the enclosure Ensure that enough wire length is available to allow for proper wiring of all of the I O signals 4 Connect the conductors to the respective remote 1 signal locations Screw down the terminal block screws to secure the conductors in place The 1 Signal Loca tions table contains the complete list
12. select a setpoint the tripleset signals must be set to the correspond ing binary combination as listed in the Tripleset Selection Table TRIPLESET SIGNAL TIMING The minimum hold time for the setpoint selec tion signals is 10 ms For tripleset to control the kV setpoint no analog kV set signal should be active NOTE After the hold time the simultaneous signals can be returned to off but they must be at the same time to avoid falsely selecting a different setpoint Tripleset Selection T 000 gt The presets can NOT be adjusted in remote mode The unit must be in LO CAL mode and the preset values must be adjusted using the front panel gt If adjustable voltage setpoints are needed analog kV setpoint signaling is required CP 13 05 2 Ransburg Analog Setpoint Control The analog control signals are the dominant setpoint control signals When one of the signals is present it will override tripleset setpoint control when the minimum analog control signal value is reached The minimum signal required is the equivalent to 20kV While analog control is used the control signal can be adjusted between control signal s minimum and maximum values to adjust the output ANALOG SETPOINT SIGNAL TIMING The analog setpoint signal minimum hold time is 80 ms to allow for analog sampling Output will begin to adjust after the setpoint has been updated ANALOG VOLTAGE SIGNALING Control Sig
13. used at time to control the setpoint value Analog Common Signal The analog common signal 3TB 8 is the connection for the common reference of the analog signal source It is used as the com mon for both the voltage and current signal NOTE gt Although the allowable range for the analog current signal does include OmA 3mA it will normally be listed as 4 20mA as the 0 3mA portion of the range is insuf ficient to override KV setpoint control Ransburg Analog Output The 9060 High Voltage Controller provides a single analog output signal that can be used for monitoring the current output This output can be used for simple monitoring or it can be used by the control system to allow for closed loop analog setpoint adjustment Analog Current Signal The analog current signal 3TB 9 is a scaled version of the actual feedback current The real feedback current is in pA where as the current signal provided at 3TB 9 is in mA to make it easily integrated with common sys tems like PLCs Relay Contact Outputs The relay contact outputs are the HV On and Fault outputs that were previously described in the Signal Interface Local Mode section Their descriptions are duplicated here for completeness High Voltage On Relay Output Dry Contact The on signal 2TB 4 is available in both LOCAL and REMOTE modes This signal being a relay controlled signal can be config ured as either an AC or DC signal using
14. value that was used Local Remote Mode Selection The local remote mode selection signal is used to determine when the unit should be in LOCAL mode or REMOTE mode This signal must remain in the active ON state for the unit to operate in REMOTE mode LOCAL REMOTE MODE SIGNAL TIMING The local remote mode signal hold time for a mode change is 10 ms NOTE The 9060 Controller is designed to pre vent false triggering when the unit chang es between LOCAL and REMOTE modes Following any mode change there is a 300 ms delay during which all triggers are ignored 9060 High Voltage Controller Operation Reset Signal While in REMOTE mode if a fault occurs the fault can be detected by the control system using the fault relay contact outputs If the fault relay signal is active the Reset Signal can be used to clear the fault status To clear a fault using the reset signal turn off the trigger signal then turn on the reset signal for approximately 10 ms to reset the fault Then turn off the reset signal RESET SIGNAL TIMING The reset signal has a minimum hold time of 10 ms NOTE There is a 5 second fault reset delay timer that inhibits the triggering of high voltage immediately after a fault reset The Reset button on the front panel can also be used in REMOTE mode to clear a fault condition as long as the front panel lockout jumper is not installed Trigger Signal The trigger signal is used to activate the
15. 11 2 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 Description Table B Plug Selection Description 47 CP 13 05 2 Ransburg 9060 High Voltage Controller Parts 9060 High Voltage Controller Parts List ant en _ AXE TOYS Figure 40 Identifications 13 05 2 48 9060 High Voltage Controller Accessories 49 Ransburg ACCESSORIES 9060 High Voltage Controller Accessories List Parts Description S 76652 01 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 05 2 Ransburg 9060 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 RANSBURG S ONLY OBLIGATION UND ER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE O
16. BLEMS To help you recognize this information we use the fol lowing symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that might cause serious inju ry if instructions are not followed A CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury A NOTE is information relevant to the pro cedure in progress While this manual lists standard specifications and service procedures some minor devia tions may be found between this literature and your equipment Differences in local codes and plant requirements material delivery require ments etc make such variations inevitable Compare this manual with your system instal lation drawings and appropriate Ransburg equipment manuals to reconcile such differ ences Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more effi cient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg Ransburg WARNING The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified This manual MUST be read and thor oughly understood by ALL perso
17. F FAULTY WORKMANSHIP OR MAT ERIALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY THE USE OF OTHER THAN RANSBURG PURCHASER OR OTHERS APPROVED PARTS VOID ALL WARRAN TIES EXCLUSIONS SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR 550 CIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY CP 13 05 2 If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will assume responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable 50 9060 High Voltage Controller Ransburg Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax
18. High Voltage when the unit is not in the desired operating mode As the 9060 Controller was designed to operate in both LOCAL or REMOTE mode it must be configured for the desired mode of opera tion If configured for LOCAL mode the local remote board has jumpers set in a bypass mode that prevents the unit from being put into REMOTE mode trigger signal input can directly activate high voltage If configured for REMOTE mode the local remote board has jumpers set so that the trigger signal routing is controlled by the local remote mode signal If the local remote signal is off the unit will be placed in LOCAL mode and the high voltage is disabled This allows the user to safely adjust the voltage presets If the local remote signal is on the unit will be placed in REMOTE mode and the trigger signal will activate the high voltage NOTE A slight delay 300 milliseconds is im posed between mode changes and the high voltage from being activated This is to prevent a trigger signal that may al ready be present from instantly turning on the high voltage when a mode change Occurs 9060 High Voltage Controller Introduction 12 9060 High Voltage Controller Introduction 13 SIGNAL INTERFACE LOCAL MODE The 9060 Controller LOCAL mode is normal ly used for handguns or very simple auto matic gun systems Handguns require only one signal input for operation the trigger signal Though not necessary for op
19. LOCKOUT JUMPER IS INSTALLED Figure 29 Parameter Adjustment Mode Overload Adjustable Parameters t Decimal marker urren on code means Overload 20 190 5 overload jumper is installed N A Available only on 51X Units Available only on 51X Units Hd Startup 2 15 0 5 Holdtime seconds sec Time i e Navigating Parameters When a parameter is currently not selected the and buttons are used to navigate from one parameters to another If the button is pressed the previous parameter will be display If the button is pressed the next parameter will be displayed The parameter adjustment menu has a wrap around indexing so it if the end of the parameter list is reached in one direction it will automatically moved to the other end Selecting Deselect Parameters The preset 2 button is used to select deselect the currently displayed parameter to allow it to be modified When pressed to select the parameter the value on the pA display will begin flashing This indicates the parameter has been selected and can be edited If the preset 2 button is pressed when a parameter is already selected it will be deselected and all modifications will be lost The parameter s value will stop flashing indicating it has been deselected CP 13 05 2 Ransburg Be careful when using the parameter adjustment mode if you select something and are unsure if you ve changed it dese lect it usi
20. SE 80100 31X Atex Approved for use with Esta Quick 80100 41X Non Approved for use with Evolver SE 80100 51X Atex Approved for use with Aerobell 168 CP 13 05 2 Ransburg 9060 High Voltage Controller Introduction SPECIFICATIONS Environmental Operating Temperature 0 C to 40 C Storage and Shipping Temperature 40 C to 85 C Allow power supply to go to room temperature before use Humidity 95 Non Condensing Physical Height 16 5 cm 6 5 inches Width 37 8 cm 14 9 inches Depth 30 7 cm 12 1 inches Weight 10 2 kg 22 5 Ibs Electrical Input Voltage 100 240 VAC Frequency 50 or 60 Hz Current max RMS Wattage 40 watts max Output Voltage 20 90kV MAX DC adjustable in 1kV increments Ground Use known good earth ground 13 05 2 8 9060 High Voltage Controller Introduction Ransburg SIDE VIEW Figure 2 9060 High Voltage Controller Features 9060 CONTROLLER FEATURES No Description Description kV Display kV Setpoint Adjust Buttons i High Voltage On Indicator Air Flow Switch Hose Connections Reset Button High Voltage Cable Connector Display Standard I O Connector Fault Indicator Fuses On Off Switch Ground Lug Local Remote Mode Indicator AC Inlet Receptacle One Touch kV Setpoint Buttons 16 Interlock I O Connector oO 9 CP 13 05 2 Ransburg OPERATOR INTERFACE The 9060 Controller show
21. SERVICE MANUAL Ransburg CP 13 05 2 MAY 2013 9060 HIGH VOLTAGE CONTROLLER HV1 Automatic Guns MODEL 80100 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 Ransburg CP 13 05 2 Ransburg 9060 High Voltage Controller Contents CONTENTS PAGE SAFETY 1 6 SAFETY PRECAUTIONS iu e o eden ouis is peo 1 HAZARDS SAFEGUARDS 2 5 INTRODUCTION 7 16 GENERAL DESCRIPTION occa exer eese Leute ees 7 SAFETY PEAT URES 7 9115 d c ror 7 SPECIFICATIONS 8 CONTROLLER FEATURES te che 9 OPERATOR INTEREACE Avent tants Remy ats Ao 10 SSVI ES ae ee 10 LEDS tacet eu meu ee to ae een ee 10 BUT ONS oc DUI Sasa oe EI Sat E DI ME a 10 11 CONNECTION INTERFACE ete eost bee een eto 11 CONNECT ORS
22. TOR AND DISPLAYS I wi Y gt Figure 37 Voltage Cable Fault Display Over Voltage Fault OU This fault will occur if the microprocessor de tects the unit is trying to output voltage above the required for the specific applicator type this occurs reset the Controller If this fault continues to occur replace the main PC board ILLUMINATES FAULT INDICATOR AND p OVERVOLTAGE FAULT 1 DISPLAYS ou Figure 38 Over Voltage Fault Display Feedback Fault FF This fault will occur if the microprocessor de tects a loss of the current feedback signal If this occurs reset the fault If this fault occurs repeatedly replace the cascade or send the high voltage controller in for repair 41 Ransburg FEEDBACK FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS Figure 39 Feedback Fault Display DI DT Overload Fault dOL This fault is ONLY applicable to 80100 51X units This fault will occur if the microproces sor detects that the rate of current change has exceeded the limits specified in the user DI DT settings If this occurs reset the fault Check to ensure that no object is moving toward the applicator within the minimum safe distance adjust the DI DT settings if necessary and re test operation If this fault continues to occur contact your Ransburg Rep
23. To adjust one of the preset setpoints ensure the applicator is off in LOCAL mode and select the desired setpoint by pressing the corre sponding setpoint button The setpoint can then be adjusted between 20 kV and full kV using the and buttons on the front panel of the 9060 Controller shown in Figure 31 Single pushes of the or buttons will increment or decrement the currently selected preset in units of 1 When the or buttons are held in for longer than 1 second the kV display will begin incrementing or decrementing in units of 5 NOTE The three setpoints can ONLY be ad justed in LOCAL mode Resetting Faults During operation various faults can occur based upon the operating conditions or if any problems with the 9060 unit arise If a fault occurs to reset a fault the trigger signal MUST be off and then press the Reset Button This will clear the fault status and put the unit back into operation unless a fault condition is still present Please refer to the Fault Description portion of the Operation Section of this Service manual for more information on a specific fault and how to correct it NOTE gt There is a 5 second fault reset delay timer that inhibits the triggering of high voltage immediately after a fault reset 37 Ransburg REMOTE MODE ONLY OPERATIONS Tripleset Selection The tripleset signals are used to select voltage setpoints presets that are used during Local Mode operation To
24. a tor The default overload value is set in the software to the maximum microamp rating minus 10 microamps 1 Turn AC power off and access the interior of the Controller 2 Place the jumper across the two 2 pins at location 17 on the main PC board See Figure 24 3 Close the Controller and turn AC power back on An overload fault will now occur if the microamp display exceeds the overload value _ JUMPER 17 INSTALLED OVERLOAD ACTIVATED Figure 24 Jumper Location Overload Activation NOTE The overload circuit can NOT be deac tivated for the AB168 Gun Type 9 Config uration 32 9060 High Voltage Controller Operation 33 NOTE Some of the newer applicators Type 7 Evolver SE Esta Quick and Type 9 Aerobell 168 have adjustable overload values Please refer to the Parameter Ad justment Menu part of the Operations section for information on adjusting the overload value 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 Thus for testing and troubleshooting high voltage output can be obtained without the need to trigger air through the spray applicator After testing the jumper must be repositioned so that it covers only one terminal open or the high voltage will stay on all the ti
25. able Fault CF 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 In external cascade applications a failed low voltage cable can cause this fault For additional information refer to the Fault Troubleshooting Section CP 13 05 2 Ransburg CABLE FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS CF FAULT Figure 33 Cable Fault Display Ground Fault GF If this fault occurs the fault indicator on the control unit will illuminate a GF indication will show in the uA display This fault will occur if the microprocessor detects a loss of ground at the high voltage section or external cascade If this fault occurs reset the fault This fault can be caused by a broken ground path between the high voltage section and the pc board In external cascade applications a failed low voltage cable can cause this problem Check the wiring to the high voltage section For more information refer to Fault Troubleshoot ing Section GROUND FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS Figure 34 Ground Fault Display Overload Fault OL This fault will occur if the overload feature is active see Overload Activation previously in the Operation section and the output
26. age cable from the voltage controller Turn on the power and place HV test jump er J8 in shorted position If the UC fault occurs send the high voltage controller in for repair If no fault occurs continue The high voltage cable may have failed Replace the high voltage cable and re test Send applicator unit in for repair Turn off the voltage controller Ensure that the gun trigger is not pressed or for remote units that the remote trigger input signal is not active Turn on the voltage controller to verify that a trigger signal is not present and that the unit enters the ready state Send the voltage controller in for repair or contact technical support Ensure that the target and no other object is approaching the applicator within the minimum safe distance during applica tion Reset the fault and re test operation Using the parameter adjustment mode adjust the sensitivity and sample time inter val configuration values for DI DT Re test operation for different values Contact technical support for further assis tance CP 13 05 2 Ransburg 9060 High Voltage Controller Maintenance NOTES CP 13 05 2 46 9060 High Voltage Controller Parts Identification Ransburg PARTS IDENTIFICATION 9060 HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION When ordering use 80100 A1B as indicated by Table A and B Three digits must follow the basic part number for example 80100 A 1B Basic Part Number 21
27. aid See Figure 8 3 Remove cable and strip marked 1 section to cable braid 4 Slide the cable grommet hardware onto the cable in the order shown in Figure 7 5 Route the cable back through the connector housing and connect its wires to the desired I O terminals inside the 9060 Controller 6 Tighten the cable grommet ensuring the grommet spring makes 360 contact with the exposed braid of the cable for maxi mum noise immunity 7 For maximum noise immunity connect the braid of the cable to earth ground at the end opposite the Controller Ransburg T Cable We ANNs N lt T Figure 7 Cable Grommet Analog Cable ES Inside of Cabinet Connector Housing Figure 8 1 Cable Stripping AC INPUT CONNECTIONS For non conduit installations plug the detacha ble AC line cord into the receptacle on the side of the 9060 Controller Plug the other end of the line cord into a properly grounded 110 volt AC outlet CP 13 05 2 Ransburg NOTE n general conduit must be used for approved AC installation however if na tional 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 For installa
28. al SA These parameters can be adjusted in the Parameter Adjustment Mode Refer to the Parameter Adjustment Mode portion of the Operation section of this manual for information on adjusting these parameters The sensitivity SE parameter determines the amount of current change that must be exceed ed during the sampling time interval The following table specifies the average amount of current change that must occur during the time interval to produce a fault based on each SE setting EHE per sampling interval The sample time interval SA parameter determines the number of samples that must be collected before a rate of change calculation is performed This parameter can be set from 2 to 50 with a sample taken every 10 ms This produces a sample time interval range from 20ms to 500ms Using a larger time interval produces a di dt configuration that is less sensitive to current spikes which are averaged out over the sample time interval and can be used to remove nuisance faults 13 05 2 Ransburg LOCKOUTS There are lockouts that may be done at the PC board see Figure 22 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 NOTE Some lockouts are sealed using sealant to prevent them from being modified for safety re
29. asons These lockouts should ONLY be modified by Ransburg Authorized Representatives 1 wd Ma E DU 000 H ind 22 2 NO mpi HC POE 74 LOCKOUT JUM LOCATIONS Figure 22 Lockout Jumper Location Front Panel Lockout This feature locks out any changes to the kV setting from the front panel of the Controller 1 Set the kV to the desired value using the front panel buttons This must be set prior to installing the jumper 2 Turn AC power off and access the interior of the Controller 3 Place the jumper across the two 2 pins at location 16 on the main PC board See Figure 23 4 Close the Controller and turn AC power back on Pressing the front panel or setpoint buttons will now have no affect on the kV setting CP 13 05 2 9060 High Voltage Controller Operation L JUMPER 16 INSTALLED FRONT PANEL CONTROL DE ACTIVATED Figure 23 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 applic
30. ctor 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 REMOTE MODE EXTERNAL SIGNALS The REMOTE mode is designed for use with automatic applicators such as the Estaquick and Evolver SE where the control of the appli cator and Controller are driven by a external control system using discrete analog and digital For example a programmable logic control ler PLC can be used as the control system There can be up to thirteen 13 or more signal wires present depending on the signals that are intended to be used by the control system More wires may be needed depending on the number of power and ground lines required for any particular installation CP 13 05 2 Ransburg The Relay Contact Outputs are normally included as output signal indicators for a control system and are wired using a few of the con ductors in the 1 cable For more information about the Relay Contact Outputs wiring please refer to the prior Installation section on that topic A complete description of all of the signals available in remote mode is provided in the Introduction section of this service manual For more information on the behavior or timing requirements for any of the signals please refer to the Operations section of this service manual NOTE Before performing any wiring verify the number of I O signals supply and
31. current exceeds the overload current value This can be caused by excessive overspray on the ap plicator or paint formulation that is too conduc tive Clean the applicator check the paint for mulation or move overload jumper JP17 to the open position CP 13 05 2 9060 High Voltage Controller Operation OVERLOAD FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS OL ED Figure 35 Overload Fault Display Current Limit Fault CL This fault occurs if the output current exceeds the maximum current by 20 This fault can be caused by excessive overspray on the ap plicator or a paint formulation that is too con ductive It may also be caused by a bad pc board Clean the applicator check the paint formulation and re test If still a problem re place the pc board See Fault Troubleshooting Section for more information CURRENT LIMIT FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS CL 11 wy Lo 1 FAULI Figure 36 Current Limit Fault Display Voltage Cable Fault UC This fault will occur if the microprocessor de tects 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 40 9060 High Voltage Controller Operation VOLTAGE CABLE FAULT 1 ILLUMINATES FAULT INDICA
32. de a pneumatic trigger signal for hand guns indicating that the trigger has been actuated This signal is normally used for the local mode to turn on the High Voltage output Both threaded connectors of the air flow switch if installed will come covered with red protected caps AC Inlet Receptacle The AC inlet receptacle is a standard IEC C14 Appliance Inlet connector with maximum rating of 250 VAC It can handle both 110VAC and 240 VAC inputs at 50 or 60 Hz The unit is shipped with the appropriate rated AC cord for the particular installation FUSES Fuses There are two 2 time delay fuses 250V 1 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 CP 13 05 2 HOT line L input connection and the Interlock AC line connection terminal 1TB L2 The bottom fuse holder is connected in series between the neutral AC input connec tion and the neutral input connection of the AC line power filter Spare Fuses The Controller also comes with two 2 spare fuses 250V 1A 5mm x 20mm mounted in holders inside the lid of the Controller LOCAL REMOTE BOARD The 9060 Controller contains a local remote trigger protection board that is used to protect against trigger signals from falsely triggering the
33. e DO NOT locate the Controller near or adjacent to heat producing equipment such as ovens high wattage lamps etc The Controller may be free standing on any flat surface or wall mounted wall mount brackets not supplied as shown in Figure 5 SIDE Figure 5 Typical Controller Mounting 13 05 2 Ransburg 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 For conductors inside the control unit or Con troller the grounded enclosures provide this envelope For the cables that connect the applicator to the control unit or Controller a shielded cable has been used The shield consists of an overall foil shield in combination with an overall braided shield This provides the most effective shielding as the foil covers the holes in the braid and the braid allows for practical 360 termination at both ends of the cable The AC input cord is not shielded but is di rected to an AC line filter as soon as it enters the cabinet This method filters out most of the noise that comes in on the AC line For maxi mum noise immunity if the AC line is wired usin
34. entative for information on interlocking the high voltage OFF sig nal with the solvent flush signal As outlined in NFPA 33 OSHA and EN 50176 the AC power line must be series interlocked with both the exhaust fan and conveyor To install the Controller interlocks perform the following 1 Turn the 9060 Controller off disconnect it from its AC source and remove the fuses 7 WARNING gt ALWAYS double check that the Con troller is unplugged from its AC outlet before working with any internal wiring 3 Using a small blade screwdriver remove the factory installed test jumper from TB1 L2 to TB1 L3 4 Using a shielded cable for the interlock wiring supplied by user route through the interlock connector on the side of the 9060 Controller and terminate TB1 L2 and TB1 L3 as shown in Figure 10 and 12 The shielded cable must have a minimum rating CP 13 05 2 9060 High Voltage Controller Installation Ransburg 1 w3sn 100 310W38 1v501 1 SONG 2 lt tald A BN3SSV Od MH31SVW 355 3972549 H anor a JI3NIHVO OL ann 71 2341 1 lt SNOLLOSNNOD M3MOd 402 INN xr ONY ISAWHXS HUM 2v 20 1H31NI OL
35. equired depends on the applicator being used Please refer to the applicator manual for the cable required Standard I O Connector The standard I O connector is located just left of the high voltage cable connector This connector is provided as the entry point for a shielded multi conductor cable used for remote signals and includes the required cable grommet hardware to keep the cable in place with minimal strain For more information on remote I O signal wiring see the Installation section of the service manual CP 13 05 2 Ransburg Interlock 1 Connector The interlock I O connector is located just above the AC inlet receptacle This connector is provided as the entry point for interlock signal wiring for the booth fan conveyor and solvent supply The connector includes the required cable grommet hardware to keep wiring in place with minimal strain For more information on the interlock connections please see the Installation section of the service manual Ground Lug Connection The ground lug connection is located directly below the fuses and has a ground logo sticker directly below it This lug is provided as an external ground connection point used to ground the 9060 to an earth ground via a ground cable This ground lug connection can also be used as the ground point for the high voltage cable ground Air Flow Switch Connection Optional The air flow switch connection can be installed to provi
36. eration there are also two 2 output relay contact signals HV on and Fault that can be useful for triggering remote devices such as lights or other safety indicators The physical signal interface is provided via the 2 terminal blocks 2TB and 3TB Trigger Signal The trigger signal input 3TB 5 is a signal shared between the LOCAL and REMOTE modes Due to this this input must be configured for either LOCAL or REMOTE mode prior to operation This signal can be configured as either a sourcing or a sinking signal Please refer to the Installation section of this service manual for LOCAL mode configuration information High Voltage On Relay Output Dry Contact The HV on signal 2TB 4 is available in both LOCAL and REMOTE modes This signal being a relay controlled signal can be configured as either an AC or DC signal using the Relay Common Input as the signal source For information regarding the relay contact voltage ratings please refer to the Relay Output Contacts portion of the Installation section of the manual This relay signal is activated when the High Voltage cascade is turned on Fault Relay Output Dry Contact The Fault signal 2TB 2 is available in both LOCAL and REMOTE modes This signal being a relay controlled signal can be configured as either an AC or DC signal using the Relay Common Input as the signal source For information regarding the relay contact voltage ratings please refer
37. g LOCAL mode operation via the three preset buttons on the left side of the front panel The two signals are used together as a binary number to select the corresponding preset value The selected preset value will not change unless a different preset value is input The binary combinations and their resulting selection are listed in the Triple Set Combinations table CP 13 05 2 The tripleset signals can be used to se lect a preset from the three 3 preset volt ages The preset values can NOT be ad justed from REMOTE mode To adjust the preset values stored in the 9060 the unit MUST be in LOCAL mode If the voltage setpoint must change between more than 3 values one of the analog KV setpoint signals should be used Analog Inputs Two 2 analog input signals along with an analog common input are provided on the 9060 High Voltage Controller for analog control the KV setpoint value One signal is provided for analog control using a voltage signal the other for a current signal The analog inputs are intended for applicator Systems that require either more than 3 presets or an adjustable setpoint voltage Analog Setpoint Control The analog control signals are the dominant setpoint control signals When one of the signals is present it will override control of the set point as soon as the minimum analog signal value is reached The minimum signal required to override setpoint control is the value equivalent to appr
38. g conduit instead of the provided AC line cord it should connect to the filter as soon as it enters the cabinet with as short of leads as possible Additional noise protection can be provided by running the AC input line to the control panel in grounded conduit For maximum noise protection any user supply input output I O wiring should be made using shielded cable or conduit which is connected to earth ground in a continuous 360 fashion at both ends The best way to do this is to use a connector conduit fitting at each end of the cable conduit that makes contact to the shield conduit in a full 360 circle around the cable conduit and makes contact to the grounded enclosure in the same fashion Connecting the drain wire of a shield to a ground point on or in the cabinet usually referred to as pigtailing is not an effective method of shielding and actual ly makes things worse see Figure 6 CP 13 05 2 360 Termination to ground good shielding Figure 6 Pigtailing Connection It is recommended that all AC interlocks be run in conduit If desired and codes permit cabling may be used for these signals but for maximum noise immunity the cabling must contain overall foil and braided shields and be terminated as described in the preceding paragraph Cable is recommended for all of the analog and digital remote I O control signals including the relay controlled DC I O high voltage output signal fault outp
39. g the 9060 Controller to N 5 the AC source 9 Secure the cabinet door replace the fuses and reconnect the AC source 10 Refer to the Operations section of this service manual and use the Remote monitoring diagnostic mode to verify that all of the I O input connections are func tioning CP 13 05 2 28 9060 High 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 type the 9060 Controller is configured for and the microamp display will show the current software revision level as shown in Figure 18 These items are displayed for approximately 10 seconds GUN TYPE NUMBER SOFTWARE REVISION LEVEL ON OFF SWITCH Figure 18 Controller Start Up Display The following table lists the applicator types shown on the display as per the current revi sion of this manual as a reference START UP DISPLAY Ransburg 7 WARNING gt VERIFY that the gun jumper configura tion is set for the applicator type that is being used for the system DO NOT adjust the gun configuration jumpers If they are incorrect contact your Ransburg representative USE ONLY the gun type configuration for the specific applicator being used Us ing the wrong configuration may allow for operation outside the recommended pa rameters a
40. he left below the kV display is used by itself to select Voltage Preset 1 in the normal operating mode If 9060 High Voltage Controller Introduction 10 9060 High Voltage Controller Introduction 11 pressed with the reset button at the same time the screen will display the resettable High Voltage ON operating hours for 3 seconds on the display screens Preset 2 Button The Preset 2 Button in the center below the kV display is used by itself to select Voltage Preset 2 in the normal operating mode If pressed with the reset button at the same time the screen will display the non resettable High Voltage ON operating hours for 3 seconds on the display screens Preset 3 Button The Preset 3 Button to the right below the kV display is used by itself to select Voltage Preset 3 in the normal operating mode If pressed with the reset button at the same time the system will enter the general diagnostic mode Left Right Buttons The left right buttons in the normal operat ing 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 Reset Button The reset button is used in the normal operat ing mode to clear fault or overload conditions This will NOT prevent any other active
41. heck connections using two finger pull test to ensure they are connected Replace the main pc board Send high voltage control unit in for repair This may indicate the paint conductivity is too high resistance too low or the outside of the applicator is contaminated with paint Test paint for proper conductivity or clean applicator with non polar solvent Ensure dump lines are clean This may indicate the paint conductivity is too high resistance too low or the outside of the applicator is contaminated with paint Test paint for proper conductivity or clean applicator with non polar solvent Ensure dump lines are clean Replace applicator and re test If problem still exists replace main pc board Send applicator in for repair Send high voltage controller in for repair 44 9060 High Voltage Controller Maintenance Boot Fault bF DI DI Overload Fault dOL For 80100 51X units only 45 The Voltage Feedback Fault indi cates the cascade drive signal is not present It typically occurs when high voltage is triggered The Boot Fault indicates that an active trigger signal was detected during the start up sequence The DI DT Overload Fault indi cates that the change in current has exceeded the user specified current limit sensitivity SE dur ing the user selected time interval Sample Time SA Ransburg Voltage Cable Fault UC Turn off the voltage controller and remove the high volt
42. his is the resettable register To reset this register press the reset button while the hours are displayed To view the non resettable register press the preset 2 and reset buttons at the same time This display will show the hours for 3 seconds OF Hv ON TIME IN HOURS RESS AND HOLD BOTH FOR NON RESETTABLE ON TIME REGISTER 3 PRESS AND HOLD BOTH FOR RESETTABLE ON TIME REGISTER Figure 20 Display High Voltage On Time Local Remote Mode HV Control Button The 9060 Controller is designed for both LOCAL and REMOTE use Although present on the front panel the Local Remote mode button has no functionality Local Remote mode selection is controlled by the remote local remote signal line The LOCAL and REMOTE mode triangle indicators on the left and right side of the mode button are shown in Figure 21 The indicator corresponding to the unit s current operating mode should be lit while the unit is on Figure 21 Local Remote Mode Button gt If the unit is in remote mode with no ex ternal signals connected the unit is not functioning properly Check remote termi nal block for input signal and if none ex ists send the control unit in for repair 9060 High Voltage Controller Operation 31 DI DT CONFIGURATION For 80100 51X Units Only The 9060 Voltage Controller model 80100 51 X for use with the ATEX approved Aerobell 168 applicator contains a di dt rate of change in c
43. ically wrap back around when the either end of the list is reached Gun Type Firmware Version Mode This sub mode will display the gun type display value on the kV display and the firmware version number on the pA display as shown during startup in Figure 18 during startup As this is a sub mode of the remote 1 monitoring diagnostic mode it will not have a limited display duration and will remain on the screen until either a different sub mode is entered or the diagnostic mode is exited NOTE The Parameter Adjustment Mode is available for Type 7 Esta Quick Evolver SE and Type 9 Aerobell 168 automatic applicators PARAMETER ADJUSTMENT MODE Certain parameters within the 9060 High Voltage Controller can be adjusted depending on the applicator being used To enter the parameter adjustment mode press the preset 1 and preset 3 keys at the same time This will bring up the parameter adjustment mode as shown in Figure 29 A summary of key opera tions for parameter adjustment mode is shown in Figure 30 In parameter adjustment mode the kV display will show the 2 character code for the parame ter and the pA display will show the currently set value for the parameter Each parameter has its own specific range limits increment values and indicators if applicable The adjustable parameter table lists the currently available parameters by character code along with their attributes Ransburg INDICATES OVERLOAD
44. ined in the use of this equip ment Ransburg SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing MUST be prevented The 78789 control panel LEPS5001 power sup ply and all other electrical equipment must be located outside Class or 11 Division 1 or 2 haz ardous areas in accordance with NFPA 33 Test only in areas free of flammable or combus tible materials The current overload sensitivity MUST be set as described in the OVERLOAD ADJUSTMENT Procedures section of this manual Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the cur rent overload sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which requires correc tion Always turn the control panel off prior to flush ing cleaning or working on spray system equip ment Ensure that the control panel is interlocked with the ventilation system and conveyor in accord ance with NFPA 33 EN 50 176 Have fire extinguishing equipment readily availa ble and tested periodically Personnel must be given training in accordance with the requirements of NFPA 33 EN 60079 0 Instructions and safety precautions must be read and understood prior to using this equip ment Comply with appropriate local state and nation al codes governing ventilation fire protection operation maintenance and housekeeping Ref erence OSHA NFPA 33 EN Norms and your insu
45. ing solvents for cleaning Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those solvents used for cleaning must have a flash point at minimum of 5 C 9 F greater than ambient temperature It is the end users respon sibility to ensure this condition is met Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA and local codes In addition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high voltage to be on but only as instructed Non factory replacement parts or unauthor ized equipment modifications may cause fire or injury If used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks disa bled Never use equipment intended for use in water borne installations to spray solvent based mate rials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and European Health and Safety Norms 9060 High Voltage Controller Safety AREA HAZARD Tells where hazards Tells what the hazard is may occur Spray Area Fire and or explosion General Use and Improper operation or mainte Maintenance nance may create a hazard Personnel must be properly tra
46. it in for repair 43 CP 13 05 2 Ransburg Ground Fault GF Over Voltage Fault OU Over Load Fault OL Current Limit Fault CL Feedback Fault FF CP 13 05 2 9060 High Voltage Controller Maintenance 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 The Over Voltage Fault indicates the output voltage exceeds the design specifications It typically occurs during a high voltage trig ger 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 below the maximum output of the applicator The Current Limit Fault indicates the current output of the gun has exceeded the maximum allowable output current It typically occurs with the high voltage on The Feedback Fault indicates there is no current feedback or it is incorrect It typically occurs with the high voltage on Check for loose wiring between the pc board connector and the high voltage sec tion by pulling on each wire Repair if nec essary Insure both connectors are secure and re test for GF fault For external cas cades measure resistance between ground and external cascade ground stud if greater than 5 ohms replace low voltage cable Replace high voltage section Send unit in for repair C
47. ly and install from the Controller ground stud located on the side panel to a true earth ground The ground wire assembly MUST be connected from the Controller ground stud to a true earth ground INPUT VOLTAGE SELECTION 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 NOTE gt All 9060 units 80100 XXX shipped from the factory for either 110 VAC input or 240 VAC input will have a 72771 06 1 Amp front panel fuses installed INTERLOCKS Interlocks required by code are as follows e Booth Fan Interlock When the booth fan is on a contact closure is made e Conveyor Interlock When the conveyor is moving a contact closure is made e Solvent Interlock When solvent supply to the applicator is off a contact closure is made Ransburg 7 WARNING Failure to connect interlocks could re sult in a fire or explosion WARNING gt ALWAYS ensure that high voltage is OFF before flushing the spray applicator with solvent NEVER flush the spray ap plicator with high voltage ON as this is a severe fire hazard and risk to personnel safety Itis recommended that the high voltage control be interlocked with the sol vent flush signal so that high voltage is automatically locked out whenever flush ing occurs Consult your authorized Ransburg repres
48. me See Figure 25 for the location of test jumper J8 V TEST JUMPER A 05 0609 DB as c rag m pz J m F alk one Figure 25 KV Test Jumper Location A WARNING gt f jumper J8 is left covering shorting both terminals high voltage will be on whenever the AC power is turned on NOTE Use Ransburg Calibrated Equipment ONLY for testing and troubleshooting Re fer to the Accessories section for this manual for part numbers for testing equip ment Ransburg REMOTE I O MONITORING DIAGNOSTIC MODE The remote I O monitoring diagnostic mode has three 3 sub modes The first two 2 sub modes provide the ability to monitor the state of the analog and digital signals The third sub mode displays the gun type value and firmware version To enter the remote I O monitoring and diagnostic mode ensure that the high voltage is not activated and press all 3 preset buttons 1 2 and 3 at the same time This will put the unit into the Analog Signal Monitoring sub mode with the preset 1 LED indicator lit Each sub mode is entered by pressing one of the three preset buttons and
49. n 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 bar graph and two 2 screens containing seven segment displays KV 1 FAULT A m T POWER Figure 3 9060 Operator Interface SWITCHES Power Switch The 9060 Controller contains a single rocker switch for power On Off selection When the unit is powered on the screens should be lit and display the gun display type information and the software version number for a short period of time LEDs High Voltage On Indicator The red High Voltage On Indicator is lit when a trigger signal has been received by the unit and the high voltage output from the cascade has been enabled Fault Indicator The red Fault Indicator is lit when a fault occurs as determined by the microprocessor When a fault occurs the light will turn on and the identifi cation code ID Code for the fault will be displayed blinking on the pA meter display For more information on the faults and fault ID codes please refer the Fault Descriptions section in the Operations portion of this manual CP 13 05 2 LOCAL Mode LED Indicator The LOCAL mode LED indicator is a left pointing triangle and is located on the left side the HV control button on the center of the operator interface This LED is lit when the Contr
50. nal Range 0 10V Minimum Signal 20kV 2 0V ANALOG CURRENT SIGNALING Control Signal Range OmA 20mA Minimum Signal 20kV 4mA The analog input signals are calibrated during manufacturing The following table lists the analog input voltages corresponding to their respective setpoints from 20kV to 90kV in 10kV increments The actual analog value can vary slightly from unit to unit but should be no more than 0 1V off the value listed below Analog Input Voltages CP 13 05 2 9060 High Voltage Controller Operation NOTE f the setpoint values are NOT matching closely to the values listed in the table the unit may need recalibrated or re paired Please contact your Ransburg representative The 9060 Controller automatically trun cates the maximum setpoint value to the maximum voltage allowed for the applica tor being used Control signal increases beyond the maximum voltage equivalent will have no effect A WARNING DO NOT attempt to use both analog voltage and analog current at the same time The analog inputs are mutually ex clusive Using both inputs simultaneous ly will damage the input circuit Only one analog input current or voltage can be used at time to control the setpoint value If the analog setpoint control signal drops below the minimum setpoint value tripleset selection will automatically take control again This will cause the setpoint to return to the last tripleset
51. nd values for the applicator and can result in damage or un safe op eration NOTE During start up the gun trigger or remote trigger input should NOT be active An ac tive trigger signal will cause a non resettable boot fault DF and prevent the unit from being operated This is designed to prevent unintended firing of the high voltage immediately after start up Please refer to the Fault Section of this manual for more information BASIC OPERATIONS The basic operations are general operations that are available in both REMOTE and LOCAL modes Evolver SE Esta Quick b After the initial start up delay the unit will be configured for the applicator based on the gun type jumper settings It will then enter LOCAL mode unless a REMOTE mode signal is already present At this point the unit is ready for standard operation 29 A 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 and current overload faults while the applicator is be ing charged Ensure that NO OBJECTS approach the bell during charging CP 13 05 2 Ransburg Triggering High voltage is actuated by the presence of an active trigger signal In LOCAL mode this is normally accomplished by pulling the trigger of the handgun to start the flow of atomizing and fan control air through the applicator When the applicator is triggered an air
52. ng Preset 2 Modifying a Parameter After a parameter has been selected using the preset 2 button and is flashing the and keys can be used to increase or decrease the value of the parameter Each parameter has its own incremental values and limits listed in the Adjustable Parameters Table When the parameter value has been adjust ed appropriately it must be saved using the save parameter button preset 1 f the select preset 2 button is pressed during modification all changes will be lost and the parameter will be deselected Loading Parameter Defaults For any parameter setting there is a default value For example there is a default overload value for each gun type After a parameter has been selected the default value can be loaded by pressing the preset 3 button This new default value will only be saved if the parame ter modifications are saved using the Save parameter button Saving Parameter Modifications After a parameter has been selected any changes to the value can be saved by pressing the preset 1 button This will save the changes to memory and de select the parameter NOTE The saved changes to parameters will immediately take effect and do not require power cycling of the unit Exiting the Parameter Adjust ment Mode When no parameter is selected pressing the Reset key will exit parameter adjustment mode CP 13 05 2 9060 High Voltage Controller Operation DISPLAYS PARAMTER VALUE
53. nnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD prior to installing operating and or servicing this equipment WARNING The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 CP 13 05 2 Ransburg AREA Tells where hazards may occur Spray Area CP 13 05 2 9060 High Voltage Controller Safety HAZARD Tells what the hazard is Fire Hazard Improper or inadequate opera tion and maintenance dures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent Con troller shutdown indicates a problem in the system requiring correction SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accumulation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or maintenance When us
54. nputs on the 9060 High Voltage Controller are 24 VDC signals that can be configured as either sourcing or sinking inputs For information regarding configuring the inputs refer to the Installation section of this manual CP 13 05 2 Ransburg Ransburg Local Remote Mode Signal The local remote mode signal 2 indicates to the 9060 Controller whether the system is currently in LOCAL mode or REMOTE mode f the signal is off the system will be in LOCAL mode If the signal is on the system will be in REMOTE mode Reset Signal The reset signal 3TB 1 will reset any fault or overload condition that has occurred It will NOT prevent any other existing fault conditions from re faulting the system immediately after resetting Please refer to the Operation section of this service manual for fault reset and troubleshooting information Remote Trigger Signal The remote trigger signal 3 5 is used to indicate to the 9060 Controller to turn on the high voltage This signal connection is routed to the main PC board connector J3 5 Input J3 5 is the same signal input that is used in LOCAL mode triggering Due to this the local remote trigger protection board Assy A13123 is present for trigger control Tripleset 1 and Tripleset 0 TS1 and TSO The tripleset signals TS1 and TSO 3TB 3 and 4 are a pair of signals that are used to select one of the three preset voltages that are normally selected durin
55. ntroller is designed to handle both a sinking or sourcing trigger input DO NOT use a sourcing trigger signal with the 9060 jumpers set for sinking in puts or vice versa Sourcing and sinking inputs have different current flow paths Using the wrong settings for the wrong type input can have unexpected behavior and or cause damage to the input circuits Ground Screw J 10 Figure 13 Ground Screw on Base Plate NOTE The standard air flow switch 13742 01 or 13742 02 used in the 9060 is wired as a sinking switch When the flow switch is activated it connects the trigger signal input to ground This requires that the local remote trigger protection board be setup to accept a sinking input If sourc ing inputs are needed the flow switch ground wire must be changed to a 24V DC connection available on the terminal blocks 24 9060 High Voltage Controller Installation 25 LT LT 9 Trigger Signal Position 5 LA A alil Figure 14 Remote I O Signal Terminal Block NOTE gt If a different switch is being used for the trigger signal read the
56. of all O ground and 24VDC supply locations as well as their normal voltage current values The locations of the I O terminal blocks are shown in Figure 16 Seo Block Analog Feedback 3 9 0 200mA Current 10 Normal Value 24VDC 24VDC 24VDC via JTB 1 24VDC 24VDC or GND 24VDC or GND 24VDC or GND 9060 High Voltage Controller Installation 26 UT uU Terminal Block 2 2TB Terminal Block 3 Nw Figure 16 Terminal Block Locations NOTE After securing the conductors to the ter minal blocks positions it is best to per form a continuity test between the termi nal block screw and the opposite end of the shielded cable for each conductor to ensure a good connection has been made with each conductor Also a 2 finger pull test should be done Pull on each con ductor with 2 fingers to ensure it is tight 5 Determine whether the digital signals will be configured as sinking grounding input or sourcing powering input NOTE gt All of the digital inputs including the trigger signal MUST be configured as ei ther all sourcing or all sinking The trigger signal is configured through the local remote trigger protection board jumper settings WARNING gt DO NOT use a sourcing signal with
57. oller is in LOCAL mode REMOTE Mode LED Indicator The REMOTE mode LED indicator is a right pointing triangle and is located on the right side the HV control button on the center of the operator interface This LED is lit when the Controller is in REMOTE mode Active Preset LED Indicators 3 The active preset LED indicators are located directly above each of the Preset Buttons When a preset button is pushed to select the desired preset in READY or RUN mode the preset LED indicator directly above the button pressed will light up Only one 1 preset light should be lit at any one time The preset LED indicators also have alternate meanings for the remote input output l O monitoring diagnostic mode When in this mode the preset LED indicators specify which diagnostic sub mode is currently activated For more information please refer the remote input output I O monitoring diagnostic mode portion of the operations section of this service manual BUTTONS The seven buttons on the operator interface are used to select the KV presets reset overloads and faults access other modes and to navigate as well as modify information that is displayed on the two seven segment display screens UA and kV The following lists the standard operating mode behavior for each button for behaviors for other modes please refer to the operation portion of this service manual for the specific mode Preset 1 Button The Preset 1 Button on t
58. ote I O set point signals are provided one for current and one for voltage and can be used to control the set point See the Operation portion of this Manual for more information The REMOTE mode triggering of HV is performed using a single discrete remote 1 trigger signal SAFETY FEATURES When used with the appropriate applicators and cascades the Ransburg 9060 High Voltage Controller provides maximized opera tional safety The protections include detection of Ground Faults Cable Faults Feedback Ransburg Signal Faults Overvoltage and Overcurrent The microprocessor circuits provide a controlled output load curve which limits the high voltage output to safe levels while monitoring control and feedback signals for unsafe conditions Maximum operational safety is obtained when the correct applica tor settings are used and when safe distanc es between the applicator and target are observed and followed The maximum efficiency of the high voltage controller is based on load DISPLAYS The front panel displays the high voltage set point as well as a reading of the gun current output The gun current is derived from feed back signals in the low voltage cable be tween the controller and the cascade 82 au Ransburg IMP ORTANT Figure 1 9060 High Voltage Controller The 9060 High Voltage Controller 80100 XXX is available as follows pH 80100 21X Non Approved for use with Evolver
59. oximately 20 kV After reaching the minimum signal the control signal can be adjusted between the minimum and the maximum for the control signal being used current or voltage The 9060 Controller automatically truncates the maximum setpoint value to the maximum voltage value for the applicator being used 9060 High Voltage Controller Introduction Triple Set Combinations No Change 14 9060 High Voltage Controller Introduction 15 Any control signal increases that would push the setpoint beyond this value will have no effect This is done to protect the applicator from adverse damage Analog Voltage Signal The analog voltage signal 3TB 7 is an input control signal that adjusts the KV setpoint scaled relative to the voltage signal applied The allowable range for the voltage control signal is 0 10V The minimum signal re quired to override the KV setpoint control is 2 0V Analog Current Signal The analog current signal 3TB 6 is an input control signal that adjusts the KV setpoint scaled relative to the current signal applied The allowable range for the current control signal is OmA 20mA with the minimum required to override the KV setpoint being 4mA A WARNING DO NOT attempt to use both analog voltage and analog current at the same time The analog inputs are mutually ex clusive Using both inputs simultaneous ly will damage the input circuit Only one analog input current or voltage can be
60. rance company requirements CP 13 05 2 Ransburg AREA Tells where hazards may occur Electrical Equipment Toxic Substances CP 13 05 2 9060 High Voltage Controller Safety HAZARD Tells what the hazard is 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 Protection against inadvertent arc ing that may cause a fire or explo sion is lost if safety circuits are dis abled during operation Frequent power supply shut down indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explo sion Certain material may be harmful if inhaled or if there is contact with the skin SAFEGUARDS Tells how to avoid the hazard The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or II Division 1 and 2 hazardous areas Refer to NFPA 33 or EN 50 176 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or com bustible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance Follow the requirements of the Material Safe ty Data
61. resentative D DT OVERLORAD FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS dOL Figure 40 DI DT Overload Fault Display 13 05 2 Ransburg CP 13 05 2 9060 High Voltage Controller Operation NOTES 42 9060 High Voltage Controller Maintenance Ransburg MAINTENANCE TROUBLESHOOTING GUIDE Blank Display No power Check the power connections and verify they are fully connected and power is avail Blown fuse i able Power cycle the unit off and back on Faulty 24 volt power supply Check Fuses and replace if blown using the replacement fuses inside the lid of the unit Check green led on 24 volt power supply when power is applied LED must be on If the LED is not on replace 24 volt power supply FAULT TROUBLESHOOTING GUIDE A 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 Cable Fault CF The Cable Fault indicates the con 1 Check for loose wiring between the pc trol unit does not detect a high board connector and the high voltage sec voltage section on the end of the tion by pulling on each wire Repair if nec cable The fault typically occurs at essary Insure both connectors are secure a high voltage trigger and re test for CF fault Replace high voltage section Send un
62. stems Most handguns use a flow switch 13742 01 or 13742 02 to provide the trigger signal The listed flow switches can be mount ed 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 Due to this only a single trigger signal input is required to operate in LOCAL mode As the 9060 Controller is designed to operate in both REMOTE and LOCAL modes it contains all of the wiring connections for both modes and requires some minor setting changes to allow operation in LOCAL mode using only the trigger input signal To operate the Controller in the LOCAL mode which uses only the high voltage trigger signal perform the following 1 Turn the 9060 Controller off disconnect it from its AC source and remove the fuses 2 Open the Controller cabinet door WARNING gt ALWAYS double check that the Con ed from its AC outlet troller is unplu before working with any internal wiring 3 If the flow switch is being used connect the ground green lead from the flow switch to the ground screw on the base plate shown in Figure 13 The trigger signal blue lead should be connected to the trigger signal on the remote I O terminal block connector Position 5 as shown in Figure 14 CP 13 05 2 9060 High Voltage Controller Installation A WARNING The 9060 High Voltage Co
63. switch documenta tion for the wiring instructions for the spe cific switching element Verify whether sinking or sourcing is to be used so the local remote trigger protection board jumpers are set correctly For further in formation consult your authorized Ransburg distributor for specific directions pertaining to your installation or call Cus tomer Service 4 The local remote board Assy A13123 shown in Figure 14 at the bottom below the remote I O signal terminal block is de signed for trigger protection in REMOTE mode It must have the jumpers adjusted into bypass position to allow for LOCAL mode operation for the desired input type The location of the jumpers on the board is displayed in Figure 15 Use the LOCAL mode jumper settings table for the jumper settings based upon your specific input LOCAL Mode Jumper Settings Ransburg Jumper 2 2 R3 Jumper 1 24V _ om M LOCAL REMOTE BD Assy A13123 Figure 15 Local Remote Board Jumper Headers 5 Secure the cabinet door replace the fuses and reconnect the AC source For any installation that includes a trigger signal that is generated by a switch or source that is external to the 9060 Controller unit the signal should be routed in through the standard I O connector using a shielded cable supplied by user Secure the cable to the standard I O conne
64. the 9060 jumpers set for sinking inputs or vice versa Sourcing and sinking inputs has different current flow paths Using the wrong settings for the wrong type input can have unexpected behavior and or cause damage to the input circuits 9060 High Voltage Controller Installation Ransburg 6 The local remote board Assy A13123 jumpers must be adjusted into one of the two REMOTE settings based on the desired input type to allow for REMOTE mode operation The location of the jump ers on the board is displayed in Figure 15 Use the REMOTE mode jumper settings table for the jumper settings based upon your specific input REMOTE Mode Jumper 7 Set the main PC board sink source jumper 45 for the rest of the digital I O signals The location of this jumper is shown in Fig ure 17 Set the jumper the correct pins for the desired input type as listed in the fol lowing table PC Board Jumper 5 Settings Mode dumper Pins 7 TPIQTPEOTPD 80 16 39 20 el 2223 CT LI T 5 c e De Figure 17 PC Mainboard Jumper J5 Location CP 13 05 2 Ransburg 9060 High Voltage Controller Installation 8 Complete the control system I O wiring be fore reconnectin
65. the Relay Common Input as the signal source For information regarding the relay contact voltage ratings please refer to the Relay Output Contacts portion of the Installation section of the manual This relay signal is activated when the High Voltage cascade is turned on Fault Relay Output Dry Contact The Fault signal 2TB 2 is available in both LOCAL and REMOTE modes This signal being a relay controlled signal can be config ured as either an AC or DC signal using the Relay Common Input as the signal source For information regarding the relay contact voltage ratings please refer to the Relay Output Contacts portion of the Installation section of the manual This relay signal is activated when a Fault Condition or Overload Condition has faulted the 9060 Controller CP 13 05 2 Ransburg 9060 High Voltage Controller Introduction Relay Common Input NOTES The relay common input 2TB 3 is a shared connection between the Fault and HV on relay outputs This is the source of their output voltage It can be wired to either an AC or DC signal It is most commonly connected to the 24 VDC power provided at 2TB 1 This allows the relays to output 24 VDC signals without the use of any outside power sources CP 13 05 2 16 9060 High Voltage Controller Installation 17 INSTALLATION GENERAL INFORMATION The following section contains general infor mation on the installation of both local and remote s
66. the corresponding LED indicator will light up The following table lists which sub mode corresponds to which preset To exit the diagnostic mode from any sub mode press the Reset Button Remote I O Diagnostic Modes Preset Button Sub Mode Analog Signal Monitoring Digital Signal Monitoring Gun Type Firmware Version NOTE gt Remote I O Monitoring Diagnostic Mode can ONLY be entered when the High Volt age is OFF and is ONLY available for type 7 Esta Quick Evolver SE and Type 9 Aerobell 168 applicators While the unit is in remote I O monitoring and diagnostic mode the High Voltage will NOT be able to be activated via the trigger signal NOTE Each time a signal monitoring sub mode is entered the signal index is reset to zero 0 moving it back to the start of the signal list for the selected mode Preset 1 Preset 2 Preset 3 CP 13 05 2 Ransburg Analog Signal Monitoring Mode In the analog signal monitoring mode the kV display will show with the being the analog signal index as shown in Figure 26 The analog to digital converted ADC value of the currently selected analog signal is displayed on the display The displayed value can be in the range of 0 to 1023 with 0 corresponding to the minimum analog input value There are a total of 8 analog signal inputs that can be monitored they are listed in the analog index reference table under their respective index
67. tions where it is required to run the AC input wiring in conduit perform the follow ing 1 Ensure the AC line cord is unplugged and remove the AC inlet receptacle wiring from TB1 N TB1 L1 and TB1 EARTH GROUND See Figures 9 and 10 Remove the mounting hardware from the AC inlet receptacle and remove it from the side of Controller Install the Conduit Adapter Plate supplied in the hole where the AC inlet receptacle was removed see Figure 11 Install the input wiring 0 8mm 18AWG minimum through the Conduit Adapter Plate using conduit and wire to TB1 as follows Hot Line to TB1 L1 Neutral Common to TB1 N Ground to TB1 EARTH GROUND CP 13 05 2 9060 High Voltage Controller Installation FRONT mj CABINET Figure 9 Location of TB1 amp TB2 in Controller L USER SUPPLIED L CONTACT CLOSURES BOOTH FAN INTERLOCK 1 CONVEYOR INTERLOCK 1 SOLVENT 4 HUS S 1 3 INTERLOCK SUPPLY S 612 INTERLOCK NE S6 Lo LAS SI AC IN COMMON NEUTRAL N N EARTH GROUND CLS ST AC IN HOT Figure 10 TB1 Interlock Wiring 7 4 2 5 2 9 n E N X CONDUIT ADAPTER PLATE SIDE VIEW Figure 11 Installation of Conduit Adapter Plate 20 9060 High Voltage Controller Installation 21 SAFETY GROUND Crimp the appropriate connector onto the ground wire assemb
68. to the Relay Output Contacts portion of the Installation section of the manual This relay signal is activated when a Fault Condi tion or Overload Condition has faulted the 9060 Controller Relay Common Input The relay common input 2TB 3 is a shared connection between the Fault and HV on relay outputs This is the source of their output voltage It can be wired to either an AC or DC signal It is most commonly connected to the 24 VDC power provided at 2TB 1 This allows the relays to output 24 VDC signals without the use of any outside power sources SIGNAL INTERFACE REMOTE MODE The REMOTE mode is designed for use with automatic applicators such as the Estaquick and Evolver SE where the control of the applicator and Controller are driven by a external control system using discrete analog and digital 1 For example a programmable logic controller PLC can be used as the control system The physical signal interface is provided via the 2 terminal blocks 2TB and 3TB The 9060 High Voltage Controller remote mode signal interface is composed of five 5 digital inputs two 2 analog inputs two 2 relay contact outputs AC or DC and one 1 analog output For information on how to correctly install the wiring for the remote signal interface please refer to the Installation section of this service manual The following section describes all of the remote I O signals Digital Inputs All of the digital i
69. uired to remove it from the spray applicator care should be taken when rein stalling so that the high voltage cable is com pletely engaged V WARNING The Controller MUST be OFF when the applicator is removed or reinstalled RELAY CONTACT OUTPUTS A set of relay contacts for high voltage CR1 and fault CR2 conditions is provided at 2TB 4 and 2TB 2 See Figure 9 One end of these relay contacts are connected together and also connected to a source input terminal 2TB 3 See Figure 12 When a source voltage is present at 2TB 3 and either the high voltage is on or a fault condition occurs the source voltage will become available at the output end of the corresponding contact Maximum contact ratings are as follows MAXIMUM CONTACT RATINGS Description AC Max Switching Capacity 62 5VA Max Operating Voltage 125VDC 125 Max Operating Current 2A When wiring to 2TB use a shielded cable and route the wiring through the standard connector as described in the I O Connectors section of this manual NOTE An internal 24 VDC source voltage is available at 2TB 1 Using a jumper wire this voltage may be connected to 2TB 3 to be used as the source voltage for the relay contact outputs In this case the total current sourced should not exceed 1 amp CP 13 05 2 Ransburg LOCAL MODE TRIGGER SIGNAL ONLY The LOCAL mode is normally used only for handguns or very simple automatic gun Sy
70. urrent with respect to time safety overload fault and is used in addition to the standard current overload fault This is an adjustable setting which determines the maximum current increase that can occur during a specific time period Both the time period and sensitivity of the DI DT configuration can be adjusted to maximize detection The di dt detection feature improves the ability of the power supply to prevent discharges from the applicator to a grounded object when the object is approaching the applicator at fast speeds Slow rates of approach are typically sensed by the current overload The di dt and current overloads must be set correctly to prevent discharges The controller monitors the output current values and compares the average rate of change over the selected time interval to the user specified settings to determine if a fault condition has occurred fault occurs the unit with turn off the high voltage and display the dOL fault code as shown in the Fault Descriptions section of this manual 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 dur ing charging Ransburg Adjusting DI DT Parameters The di dt safety overload fault is configured based upon two 2 parameters Sensitivity SE and Sample Time Interv
71. ut signal Again for maximum noise immunity the cabling must contain overall foil and braided shields and be terminated in a continuous 360 manner as described in the preceding paragraph Special fittings have been provided on the control panel for termina tion of these cables at that point The use of these fittings is described in the corresponding sections of this manual Using the methods previously described the 9060 Controller have been successfully tested to the stringent standards of the Electromagnet ic Compatibility Directive of the European Union The results conclude that these units are neither a source of electrical noise nor 9060 High Voltage Controller Installation 18 9060 High Voltage Controller Installation 19 affected by electrical noise when the above methods are utilized CONNECTIONS For maximum noise immunity 1 wiring should be run in conduit or cables having a foil shield with an overall braided shield The foil shield provides 10096 shielding while the braid provides a means of making proper 360 shield terminations at the cable to cabinet connection points To make 1 connections using shield ed cable perform the following 1 Remove the cable grommet hardware from the desired I O connector housing See Figure 7 2 Route the desired length of I O cable through the connector housing and mark 1 span of cable that passes through the connector housing to be stripped to br
72. vision 1 or 2 locations or Class 1 Zone 0 for European Applica tions CP 13 05 2 Ransburg 9060 High Voltage Controller Safety NOTES CP 13 05 2 6 9060 High Voltage Controller Introduction INTRODUCTION GENERAL DESCRIPTION The Ransburg 9060 High Voltage Control ler 80100 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 a cascade that amplifies the voltage to a high kV level t also uses current feedback information to maintain the desired set point The processor circuitry provides the maximum in applicator transfer efficiency while maintaining the maximum safety The 9060 Controller can operate in either LOCAL mode or REMOTE mode conditions In the LOCAL mode the selection and adjust ment of set point values is performed from the controller front panel The triggering of the HV in LOCAL mode is initiated by the optional airflow switch built into the controller which senses airflow triggered by a standard hand gun or via a single discrete remote 1 trigger signal In REMOTE mode the selection and adjustment of the set point can be performed using either discrete or analog remote l O signals Two tripleset signals are provided that can be used to select one of the same three presets that are set and used in LOCAL mode Two analog rem
73. ystems using the 9060 High Voltage Controller The 9060 Controller MUST be located outside of the hazardous area The User MUST read and be familiar with the Safety section of this manual This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the warnings and requirements of operating and servicing safely are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 OSHA and all related country safety codes prior to installing op erating and or servicing this equipment Only approved applicators should be used with the 9060 High Voltage Controller NOTE As each installation is unique this infor mation is intended to provide general in stallation information for the 9060 Control ler Consult your authorized Ransburg distributor for specific directions pertaining to the installation of your equipment Ransburg LOCATION OF THE 9060 Install the Controller in an area outside the hazardous location in accordance with feder al state and local codes The area should protect the Controller from the possibility of environmental intrusion such as dust or mois ture have ambient temperatures that do not exceed 40 and be as close to the applicator as possible to minimize the length of the high voltage cabl

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