Carlisle Ransburg User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
Model: 80102-21X (Electric Motor)
9060 High Voltage Controller for
No.2 Process Handgun
(HV2 - Electric Motor)
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision CP-13-03.3 to revision
CP-13-03-R4. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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MANUAL CHANGES
EN

CONTENTS
SAFETY: 4-8
Safety Precautions .................................................................................................................................................... 4
Hazards / Safeguards ................................................................................................................................................ 5
INTRODUCTION: 9-13
General Description ................................................................................................................................................... 9
Safety Features ......................................................................................................................................................... 9
Displays ..................................................................................................................................................................... 9
Specications .......................................................................................................................................................... 10
9060 Controller Features ..........................................................................................................................................11
Operator Interface ................................................................................................................................................... 12
Switches .................................................................................................................................................................. 12
LEDs ........................................................................................................................................................................ 12
Buttons .................................................................................................................................................................... 12
Connection Interface ............................................................................................................................................... 12
Connectors .............................................................................................................................................................. 12
Fuses ....................................................................................................................................................................... 13
Signal Interface ....................................................................................................................................................... 13
INSTALLATION: 14-16
General Information.................................................................................................................................................. 14
Location of the 9060 ................................................................................................................................................ 14
AC Input Connections ............................................................................................................................................. 14
Safety Ground ......................................................................................................................................................... 15
Input Voltage Selection ............................................................................................................................................ 15
High Voltage Cable .................................................................................................................................................. 15
No. 2 Process Handgun Trigger Signal ................................................................................................................... 15
Controller Schematic (HV2) ..................................................................................................................................... 16
OPERATION: 17-21
Start-Up ................................................................................................................................................................... 17
Basic Operations ..................................................................................................................................................... 17
kV Test Jumper ........................................................................................................................................................ 18
Setpoint Operations ................................................................................................................................................. 18
Faults ....................................................................................................................................................................... 18
Fault Descriptions .................................................................................................................................................... 18
MAINTENANCE: 22-30
Routine Preventive Maintenance ............................................................................................................................ 22
Troubleshooting - Ground Test Procedure .............................................................................................................. 22
Fault Troubleshooting Guide ................................................................................................................................... 24
General Troubleshooting Guide .............................................................................................................................. 26
Service Level ........................................................................................................................................................... 28
Replacement Procedures ........................................................................................................................................ 28
9060 Internal Component Locations ....................................................................................................................... 30
PARTS IDENTIFICATION: 31-33
9060 Model Identication ........................................................................................................................................ 31
Parts Identication.................................................................................................................................................... 32
Accessories List ...................................................................................................................................................... 33
MANUAL CHANGE SUMMARY: 34
Manual Changes ..................................................................................................................................................... 34
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system , read and understand all of the technical
and safety literature for your products. This manual
contains information that is important for you to know and
understand. This information relates to USER SAFETY
and PREVENTING EQUIPMENT PROBLEMS. To help you
recognize this information, we use the following symbols.
Please pay particular attention to these sections.
A WARNING! states information to alert you to
a situation that might cause serious injury 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 procedure
in progress.
While this manual lists standard specications and service
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and asscoiated equipment
manuals to reconcile such differences.
WARNING
!
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the safety literature
therein identied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly
understood by ALL personnel 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 re codes
and ordinances as well as NFPA-33 AND EN 16985
SAFETY STANDARDS, LATEST EDITION, or
applicable country safety standards, prior to installing,
operating, and/or servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment.
SAFETY
Repairs may only be performed by authorized personnel.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
in more efcient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your equipment, contact your local
Carlisle Fluid Technologies representative or Carlisle Fluid
Technologies technical support.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
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, ushing or maintenance.
Spray booth ventilation must be kept at the rates
required by NFPA-33, EN 16985, country, and local
codes. In addition, ventilation must be maintained
during cleaning operations using ammable or
combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance of
1 inch for every 10KV of output voltage is required
at all times.
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 unauthorized
equipment modications may cause re or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
OSHA, local, country, and European Health and
Safety Norms.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Improper or inadequate
operation and maintenance
procedures will cause a
re hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch for
every 10KV of output voltage is required at all times.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible
materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding
section of the equipment manual. Protection against
inadvertent arcing that is capable of causing re
or explosion is lost if the current overload sensitivity
is not properly set. Frequent power supply
shutdown indicates a problem in the system which
requires correction.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no objects
are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA-33, EN 16985.
Have re extinguishing equipment readily available
and tested periodically.
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
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 equipment.
Comply with appropriate local, state, and national
codes governing ventilation, re protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
General Use and
Maintenance
Spray Area Explosion Hazard
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re
or explosion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on
conveyors or hangers that are properly grounded.
The resistance between the part and earth ground
must not exceed 1 megohm. (Refer to NFPA-33,
EN 16985.)
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator
via conductive gloves or gloves with the palm section
cut out.
NOTE: REFER TO NFPA-33, EN 16985 OR
SPECIFIC COUNTRY SAFETY CODES
REGARDING PROPER OPERATOR
GROUNDING.
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.
Grounded conductive ooring must be provided in
the spray area.
Always turn off the power supply prior to ushing,
cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Avoid installing an applicator into a uid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled 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
re or explosion.
Unless specically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 16985.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of ammable or combustible
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.
Electrical Discharge
Electrical
Equipment
Certain materials may be
harmful if inhaled, or if there
is contact with the skin.
Follow the requirements of the Safety Data Sheet
supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the air
free of accumulations of toxic materials.
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. Equipment must be as prescribed
by an industrial hygienist or safety expert, and be
NIOSH approved.
Chemical HazardToxic Substances
Spray applicators require that aluminum inlet ttings
be replaced with stainless steel.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum
equipment during spraying, ushing, or cleaning.
Read the label or data sheet for the material you
intend to spray. If in doubt as to whether or not a
coating or cleaning material is compatible, contact
your coating supplier. Any other type of solvent may
be used with aluminum equipment.
Halogenated hydrocarbon
solvents for example:
methylene chloride and 1,1,1,
- Trichloroethane are not
chemically compatible with the
aluminum that might be used
in many system components.
The chemical reaction
caused by these solvents
reacting with aluminum can
become violent and lead to an
equipment explosion.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

INTRODUCTION
NOTE
GENERAL DESCRIPTION
The Ransburg No. 2 Handgun Process
The No. 2 ProcessTM is an electrical atomization method
for applying coatings to objects electrostatically. The No. 2
Process Handgun system applies a high voltage, negative,
DC charge to the applicator bell, creating an electrostatic
eld between the bell and the target object. The target is
electrically grounded through its support which may be
stationary or moving; or through an electrical connection
to a known true earth ground.
A regulated pressure uid system delivers coating mate-
rial to the bell when the gun is triggered. There, the uid
travels across the face of the rotating bell and becomes
charged. The uid is electrically atomized at the edge of
the bell forming a ne mist which, under the inuence of the
electrostatic eld, is attracted to and deposited on the target
object. The forces between the charged particles and the
grounded target are sufcient to turn almost all overspray
around and deposit it on the side and back surfaces of the
target. Thus, a high percentage of the spray is deposited
on the target and overspray is controlled.
The 9060 High Voltage Controller
The Ransburg 9060 High Voltage Controller (80102-21X)
is used to provide high voltage for the No. 2 Process
Handgun. It uses a combination of proven high voltage
generation technology and microprocessor-based con-
trol. It uses current feedback information to maintain the
required kV output for the No. 2 Process Handgun. The
processor circuitry provides the maximum in applicator
transfer efciency, while maintaining the maximum safety.
The 9060 Controller for the No. 2 Process Handgun has
a xed setpoint value which can NOT be adjusted. The
triggering of the HV is initiated by the on-off switch on the
No. 2 Process Handgun.
SAFETY FEATURES
The Ransburg 9060 High Voltage Controller provides maxi-
mized operational safety. The protections include detection
of Boot Faults, Ground Faults, Cable Faults, Feedback
Signal Fault, Current Limit Fault and Overvoltage Fault.
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 applicator settings are used and when safe
distances between the applicator and target are observed
and followed. The maximum efciency 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 feedback signals between the controller and
the cascade.
Figure 1: 9060 High Voltage Controller (HV2)
The 9060 High Voltage Controller is factory
supplied with a latch that can be opened using a tool
such as quarter or at screwdriver.
The 9060 High Voltage Controller is available as follows:
Used with No. 2 Gun Type
9060 Part #
9060 HIGH VOLTAGE CONTROLLER
80102-211 Electric Motor, Domestic 19372-XX
80102-212 Electric Motor, European 19372-XX
80102-213 Electric Motor, China 19372-XX
Gun No.
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INTRODUCTION
EN

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 lbs.)
SPECIFICATIONS
Operating Temperature: 0°C to +40°C
32°F to +104°F
Storage and Shipping Temperature: -40°F to +185°F
-40°F to +185°F
Humidity: 95% Non-Condensing
Environmental
Physical
Electrical
Input Voltage: 100-240 VAC
Input Current: 1A RMS (max)
Frequency: 50 or 60 Hertz
Wattage: 40 Watts (max)
Output Voltage: 100 kV DC (80102-21X)
Output Current: 160 Microamps (max)
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INTRODUCTION
EN

Figure 2: 9060 High Voltage Controller Features (HV2)
10
4321
7
6 5
889
Description
No.
9060 CONTROLLER FEATURES
1 kV Display
2 High Voltage On Indicator
3 Reset Button
4 µA Display
5 Fault Indicator
6 On-Off Switch
7 High Voltage Cable Connector
8 Fuses
9 Ground Lug
10. AC Inlet Receptacle
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INTRODUCTION
EN

NOTE
OPERATOR INTERFACE
The 9060 HV2 Controller shown in Figure 3, has a simple
operator interface consisting of two (2) LED (Light Emitting
Diode) indicators, one (1) power switch, one (1) button, one
(1) current LED bargraph, and two (2) screens containing
seven-segment displays. The following describes the
behavior of the interface components used with the No. 2
Process Handgun.
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 period
of approximately 5 seconds.
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 deter-
mined by the microprocessor. When a fault occurs the
light will turn on and the identication code for the fault will
be displayed, blinking, on the µA meter display. For more
information on the faults and fault ID codes, please refer
the Fault Descriptions section in the Operation portion of
this manual.
Figure 3: 9060 Operator Interface
BUTTONS
Reset Button
The reset button is used to clear fault or overload conditions
when the trigger signal if OFF. This will NOT prevent any
other active fault conditions from triggering a new fault.
There is a 5 second fault reset delay timer that
inhibits the triggering of high voltage immediately
after a fault reset.
CONNECTION INTERFACE
The 9060 Controller connection interface shown in Figure
4, provides all of the required connections for setting up
a No. 2 Process Handgun (80102-21X). This connection
interface consists of one (1) high voltage cable connector,
one (1) ground lug connection, two (2) fuses, and one (1)
AC inlet receptacle.
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.
This connector is designed for use with the superex high
voltage cable 19370 that connects with the No. 2 Process
Handgun.
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.
AC Inlet Receptacle
The AC inlet receptacle is a standard IEC C14 Appliance
Inlet connector with a maximum rating of 250 VAC. It can
handle both 115VAC and 230 VAC inputs at 50 or 60 Hz.
The unit is shipped with the appropriate rated AC cord for
the particular installation.
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INTRODUCTION
EN

FUSES
Fuses
There are two (2) time delay fuses (250V, 1A, 5mm x
20mm) installed in fuse holders on the connection interface.
They are located directly above the ground lug connection.
They are present to provide a measure of safety against
power surges through the AC input. The top fuse holder
is connected in series between the HOT line (L) input
connection and the Interlock AC line connection terminal
1TB-L2. The bottom fuse holder is connected in series
between the neutral AC input connection and the neutral
input connection of the AC line power lter.
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.
SIGNAL INTERFACE
The 9060 Controller, when congured for use with the No.
2 Process Handgun, requires only one signal input for
operation, the trigger signal.
The trigger signal input (J3-5) is controlled directly from
the on-off switch located on the No. 2 Process Handgun.
Figure 4: 9060 Connection Interface
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INTRODUCTION
EN

INSTALLATION
WARNING
!
NOTE
CAUTION
!
GENERAL INFORMATION
The following section contains general information on the
installation of 9060 High Voltage Controller.
The 9060 Controller MUST be located a mini-
mum of 6.1m (20’) outside or away from the target
being sprayed.
The User MUST read and be familiar with the
“Safety” section of this manual.
This manual MUST be read and thoroughly
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 re codes and ordinances as well as NFPA-33,
OSHA, and all related country safety codes prior to
installing, operating, and/or servicing this equipment.
Only approved applicators should be used with
the 9060 High Voltage Controller.
DO NOT locate the Controller near or adjacent to
heat producing equipment such as ovens, high watt-
age lamps, etc.
As each installation is unique, this information
is intended to provide general installation informa-
tion for the 9060 Controller. Consult your authorized
Ransburg distributor for specic directions pertaining
to the installation of your equipment.
LOCATION OF THE 9060
Installation of the Controller must be a minimum of 6.1m
(20’) from where the spray target is located in accordance
with federal, state, and local codes. The area should protect
the Controller from the possibility of environmental intrusion
(such as dust or moisture), have ambient temperatures that
do not exceed 40°C, and be as close to the applicator as
possible to minimize the length of the high voltage cable.
AC INPUT CONNECTIONS
For non-conduit installations, plug the detachable 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
120 volt AC outlet.
For those few installations where it is required to run the
AC input wiring in conduit, perform the following:
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 5).
2. Remove the mounting hardware from the AC inlet
receptacle and remove it from the side of Controller.
3. Install the Conduit Adapter Plate (See Accessories
Section) in the hole where the AC inlet receptacle was
removed (see Figure 6).
4. Install theAC input wiring (0.8mm2(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
Figure 5: Location of TB1 & TB2 in Controller
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INSTALLATION
EN

NOTE
CAUTION
!
WARNING
!
SAFETY GROUND
Crimp the appropriate connector onto the ground wire as-
sembly and install from the Controller ground stud, located
on the side panel, to a true earth ground.
INPUT VOLTAGE SELECTION
The 9060 Controller accepts universal input voltage be-
tween 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.
All 9060 units (80102-21X) shipped from the fac-
tory for either 110 VAC input or 240 VAC input will
have a 72771-06, 1 Amp front panel fuses installed.
Figure 6: Installation of Conduit Adapter Plate
HIGH VOLTAGE CABLE
Position the No. 2 Process Handgun in the spray area
and route the high voltage cable to the Controller. The
cable should be routed so that it is not damaged by foot
and vehicle trafc 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). Connect
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 required to remove it from the No.
2 Handgun, care should be taken when reinstalling so that
the high voltage cable is completely engaged.
The Controller MUST be OFF when the No. 2
Handgun is removed or reinstalled.
Do NOT rely on the ground connection provided
by generators and other portable power generation
devices.
The ground wire assembly MUST be connected
from the Controller ground stud to a true earth
ground.
NO. 2 PROCESS HANDGUN
TRIGGER SIGNAL
The No. 2 Process Handgun (80102-21X) uses the on-off
switch on the back of the gun to activate the trigger input
at J3-5. This signal causes the PC mainboard to turn on
the high voltage.
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INSTALLATION
EN

Figure 7: Controller Schematic (HV2)
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INSTALLATION
EN

OPERATION
WARNING
!
NOTE
Figure 8: Controller Start-Up Display
The controller comes precongured for the No. 2 Process
Handgun from the factory. The following table lists the
display value and jumper settings for the unit. This table is
a reference to verify that the gun conguration jumpers are
in their correct positions if unexpected behavior is observed.
VERIFY that the gun jumper conguration is set for
the applicator type that is being used for the system.
DONOTadjust the gun conguration jumpers. If they
are incorrect, contact your Ransburg representative.
USE ONLY the gun type conguration for the No.
2 Process Handgun (80102-21X). Using the wrong
conguration may allow for operation outside the rec-
ommended parameters and values for the applicator
and can result in damage or un-safe operation.
BASIC OPERATIONS
The basic operations are general operations that
are available.
Triggering High Voltage
High voltage is actuated by the presence of an active trigger
signal. This is accomplished by turning the on-off switch
of the No. 2 Process Handgun to the “on” position. The
kV is displayed on the kV display, the actual current draw
on the µA display, and the high voltage light illuminates.
Under the µA display is a bar graph meter that illuminates
according to the actual current draw shown in Figure 9.The
green and yellow regions of the bar graphs meter indicate
output current is in the optimum range for maximum transfer
efciency. The red region of the bar graph indicates high
output current causing decreased transfer efciency. If
high output, check maintenance of applicator and external
equipment of the power supply.
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 congured for and the µA (microamp)
display will show the current software revision level as shown
in Figure 8. These items are displayed for approximately
5 seconds after the board powers up.
After the initial start-up delay, the unit will be congured for
the applicator based on the gun type jumper settings and
is ready for standard operation.
During start-up, the gun on-off switch should NOT
be in the on position. If this switch is ON it will cause
a non-resettable boot fault (bF) and prevent the unit
from being operated. This is designed to prevent un-
intended ring of the high-voltage immediately after
start-up. Please refer to the “Fault Section” of this
manual for more information.
Description
Type
START-UP DISPLAY
99 No. 2 Process Handgun (Electric Motor) 13
Jumpers
GUN TYPE NUMBER SOFTWARE REVISION LEVEL
OFF-ON SWITCH
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WARNING
!
NOTE
Figure 9: µA Bar Graph Meter Display
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 trouble-
shooting, high voltage output can be obtained without the
need to turn on the gun on-off switch. After testing, the
jumper must be repositioned so that it covers only one
terminal (open) or the high voltage will stay on all the
time. See Figure 10 for the location of KV test jumper J8.
Ensure the jumper is installed on ONLY ONE post during
power on to prevent a boot fault “bF”. The terminals should
only be shorted after the unit is completely powered on.
If jumper J8 is left covering (shorting) both
terminals, the high voltage will remain on or cause a
boot fault (bF) when the unit is powered on.
Use Ransburg Calibrated Equipment ONLY for
testing and troubleshooting. Refer to the “Accesso-
ries” section of this manual for part numbers for test-
ing equipment.
SETPOINT OPERATIONS
Voltage Setpoint
The voltage on the 9060 High Voltage Controller, when
congured for use with the No. 2 Process Handgun (80102-
21X), is NOT adjustable. The Electric Motor No. 2 Handgun
is designed to operate only at a set point of 100kV. The
display will always show 99kV.
FAULTS
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 No. 2 Handgun
on-off switch MUST be turned off and then press the Re-
set 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 Oper-
ation Section of this Service manual for more information
on a specic fault and how to correct it.
Figure 10: KV Test Jumper Location
µA BAR GRAPH METER DISPLAY
kV TEST JUMPER
LOCKOUT JUMPER LOCATIONS
NOTE
There is a 5 second fault reset delay timer that
inhibits the triggering of high voltage immediately
after a fault reset.
FAULT DESCRIPTIONS
For in depth troubleshooting information on the 9060,
please refer to the “Fault Troubleshooting” portion of the
Maintenance Section of this service manual. If a fault occurs,
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NOTE
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.
Figure 11: Cable Fault Display
Cable Fault (CF)
This fault will occur if high voltage is active and the micro-
processor detects that no current is being supplied to the
applicator. This indicates a connection problem from the
control unit to the cascade or handgun barrel assembly.
Typical causes include a faulty low voltage cable, stuck
pins on the plug assembly, or contaminated contacts on the
applicator. This may also indicate a faulty barrel assembly
for a handgun. This could also indicate a connection prob-
lem between the pc board and the high voltage section.
Check the wiring harness for loose pins, or replace the
high voltage section. For additional information, refer to
the Fault Troubleshooting Section.
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. If this fault occurs, reset the fault.
This fault can be caused by a broken ground path between
the applicator and the control unit and may indicate a faulty
cable or plug assembly. It can also be caused by a broken
ground path between the high voltage section and the pc
board. Check the wiring to the high voltage section. For
more information, refer to Fault Troubleshooting Section.
Figure 12: Ground Fault Display
The ground fault error code displayed on the uA dis-
play appears very similar to the boot fault. Verify that the
rst character appears as a “6” representing the charac-
ter “G” and not a lowercase “b” for a boot fault.
CABLE FAULT ILLUMINATES FAULT
INDICATOR AND DISPLAYS “CF”
GROUND FAULT ILLUMINATES FAULT
INDICATOR AND DISPLAYS “GF”
the Fault Indicator on the front of the Controller will light
and a fault code will be displayed on the 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.
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Current Limit Fault (CL)
This fault occurs if the output current exceeds the maxi-
mum current by 20µA. This fault can be caused by ex-
cessive overspray on the applicator or a paint formulation
that is too conductive. It may also be caused by a bad pc
board. Clean the applicator, check the paint formulation,
or replace the pc board. See Fault Troubleshooting Sec-
tion for more information.
Figure 13: Current Limit Fault Display
Voltage Cable Fault (UC)
This fault will occur if the microprocessor detects a loss
of the voltage feedback signal. This can be caused by a
failed high voltage cable, a failed high voltage section,
or a failed pc board. Replace the high voltage cable and
re-test. If still faulty, replace the high voltage section or pc
board and re-test.
Figure 14: Voltage Cable Fault Display
Feedback Fault (FF)
This fault will occur if the microprocessor detects a loss of
the current feedback signal. If this occurs, reset the fault.
If this fault occurs repeatedly, refer to the Fault Trouble-
shooting Section to determine if the problem is with the
high voltage section or the main pc board.
Figure 16: Feedback Fault Display
Figure 15: Over Voltage Fault Display
Over Voltage Fault (OU)
This fault will occur if the microprocessor detects the unit is
trying to output voltage above the required for the specic
applicator type. If this occurs, reset the Controller. If this
fault continues to occur, replace the main PC board.
CURRENT LIMIT FAULT ILLUMINATES FAULT
INDICATOR AND DISPLAYS “CL”
VOLTAGE CABLE FAULT ILLUMINATES FAULT
INDICATOR AND DISPLAYS “UC”
OVERVOLTAGE FAULT ILLUMINATES FAULT
INDICATOR AND DISPLAYS “OU”
FEEDBACK FAULT ILLUMINATES FAULT
INDICATOR AND DISPLAYS “FF”
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OPERATION
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