Ransburg 9060 LV User Manual
SERVICE MANUAL
CP-13-07.2
MAY - 2013
9060 CASCADE LOW VOLTAGE
CONTROLLER
(LV3 - Handguns)
MODEL: 80131-XXX
IMPORTANT: Before using this equipment, carefully read
SAFETY PRECAUTIONS, starting on page 1, and all instructions
in this manual. Keep this Service Manual for future reference.
Service Manual Price: $50.00 (U.S.)
Service Manual Price: $50.00 (U.S.)
Service Manual Price: $50.00 (U.S.)Service Manual Price: $50.00 (U.S.)
CP-13-07.2
9060 Cascade Low Voltage Controller - Contents
CONTENTS
SAFETY:
SAFETY PRECAUTIONS ......................................................................................................... 1
HAZARDS / SAFEGUARDS................................................................................................... 2-5
INTRODUCTION:
7-12
PAGE
1-6
GENERAL DESCRIPTION ........................................................................................................ 7
SAFETY FEATURES ................................................................................................................ 7
DISPLAYS ................................................................................................................................ 7
SPECIFICATIONS .................................................................................................................... 8
CONTROLLER FEATURES ...................................................................................................... 9
OPERATOR INTERFACE ....................................................................................................... 10
SWITCHES ............................................................................................................................. 10
LEDS ...................................................................................................................................... 10
BUTTONS .......................................................................................................................... 10-11
CONNECTION INTERFACE ................................................................................................... 11
CONNECTORS....................................................................................................................... 11
FUSES .................................................................................................................................... 12
SIGNAL INTERFACE ............................................................................................................. 12
INSTALLATION: 13-20
GENERAL INFORMATION ..................................................................................................... 13
LOCATION OF THE 9060 ....................................................................................................... 13
ELECTRICAL NOISE .............................................................................................................. 14
I/O CONNECTIONS ................................................................................................................ 15
AC INPUT CONNECTIONS ............................................................................................... 15-16
SAFETY GROUND ................................................................................................................. 17
INPUT VOLTAGE SELECTION .............................................................................................. 17
INTERLOCKS .................................................................................................................... 17-19
LOW VOLTAGE CABLE ......................................................................................................... 19
RELAY CONTACT OUTPUTS ................................................................................................ 19
HANDGUN TRIGGER SIGNAL ............................................................................................... 20
OPERATION: 21-26
START-UP .............................................................................................................................. 21
BASIC OPERATIONS ........................................................................................................ 21-22
LOCKOUTS ....................................................................................................................... 22-23
KV TEST JUMPER ................................................................................................................. 23
SETPOINT OPERATIONS ...................................................................................................... 24
FAULT DESCRIPTIONS .................................................................................................... 24-26
CP-13-07.2
9060 Cascade Low Voltage Controller - Contents
CONTENTS
MAINTENANCE: 27-30
TROUBLESHOOTING GUIDE ................................................................................................ 27
FAULT TROUBLESHOOTING GUIDE ............................................................................... 27-29
PARTS IDENTIFICATION: 31-32
LOW VOLTAGE CONTROLLER MODEL IDENTIFICATION .................................................. 31
PARTS LIST ........................................................................................................................... 32
ACCESSORIES: 33-34
ACCESSORIES LIST .............................................................................................................. 33
WARRANTY POLICIES: 35
LIMITED WARRANTY ............................................................................................................ 35
PAGE
CP-13-07.2
CP-13-07.2
9060 Cascade Low Voltage Controller - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your Ransburg products. This
manual contains information that is important
for you to know and understand. This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help
you recognize this information, we use the following symbols. 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 specifications
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 appropriate Ransburg
equipment manuals to reconcile such differences.
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 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 fire
codes and ordinances as well as NFPA-33
SAFETY STANDARD, prior to installing,
operating, and/or servicing this equipment.
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.
W A R N I N G
!
W A R N I N G
!
Careful study and continued use of this manual
will provide a better understanding of the
equipment and process, resulting in more efficient 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.
1 CP-13-07.2
9060 Cascade Low Voltage Controller - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate operation and maintenance procedures 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 Controller 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 using 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 responsibility 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 unauthorized 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 disabled.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be set
up and operated in accordance with NFPA-33,
NEC, and European Health and Safety Norms.
CP-13-07.2 2
9060 Cascade Low Voltage Controller - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire and/or explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing MUST be prevented.
The 78789 control panel, LEPS5001 power supply and all other electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
Test only in areas free of flammable or combustible materials.
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 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 off prior to flushing, cleaning, or working on spray system equipment.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accordance with NFPA-33, EN 50176.
Have fire extinguishing equipment readily available 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 equipment.
Comply with appropriate local, state, and national codes governing ventilation, fire protection,
operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
3 CP-13-07.2
9060 Cascade Low Voltage Controller - Safety
AREA
Tells where hazards
may occur.
Electrical
Equipment
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 arcing that may cause a fire 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 fire or explosion.
SAFEGUARDS
Tells how to avoid the hazard.
The power supply, optional remote control
cabinet, and all other electrical equipment
must be located outside Class I or II, Division
1 and 2 hazardous areas. Refer to NFPA-33
or EN 50176.
Turn the power supply OFF before working on
the equipment.
Test only in areas free of flammable 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.
Toxic Substances
Certain material may be harmful if
inhaled, or if there is contact with
the skin.
Follow the requirements of the Material 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.
CP-13-07.2 4
9060 Cascade Low Voltage Controller - Safety
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
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 fire or explosion.
SAFEGUARDS
Tells how to avoid the hazard.
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 50176)
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 locations, the power supply and other electrical control
equipment must not be used in Class 1, Division 1 or
2 locations or Class 1, Zone 0 for European Applications.
5 CP-13-07.2
9060 Cascade Low Voltage Controller - Safety
N O T E S
CP-13-07.2 6
9060 Cascade Low Voltage Controller - Introduction
INTRODUCTION
GENERAL DESCRIPTION
The Ransburg 9060 Cascade Low Voltage
Controller (80131-XXX) is used to provide
high voltage for electrostatic application
equipment. It uses a combination of proven
high voltage generation technology and
microprocessor-based control. It uses a
variable voltage output to drive an external
cascade that amplifies the voltage to a high
kV level. It 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 provides the selection
and adjustment of set point values is performed from the controller front panel. The
trigger of the HV is initiated by the airflow
switch built into the controller which senses
airflow triggered by a standard handgun.
DISPLAYS
The front panel displays the high voltage set
point as well as a reading of gun current output. The gun current is derived from feedback signals in the low voltage cable between the controller and the cascade.
Figure 1: 9060 Cascade Low Voltage Controller
SAFETY FEATURES
When used with the appropriate applicators
and cascades, the Ransburg 9060 Cascade
Low Voltage Controller provides maximized
operational safety. The protections include
detection of Ground Faults, Cable Faults,
Feedback 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 applicator
settings are used and when safe distances
between the applicator and target are observed and followed. The maximum efficiency
of the low voltage controller is based on load.
The 9060 Low Voltage Controller (80131XXX) is available as follows:
Part #: Description
80131-21X Vector R70AS Handgun
80131-31X Vector R90AS Handgun
80131-41X Vector AA90 Handgun
80131-51X Vector R90AS Waterborne Handgun
7 CP-13-07.2
9060 Cascade Low 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: 14.0 cm (5.5 inches)
Width: 21.6 cm (8.5 inches)
Depth: 19.1 cm (7.5 inches)
Weight: 3.4 kg (7.5 lbs.)
Electrical
Input Voltage: 100-240 VAC
Frequency: 50 or 60 Hz
Current: 1 A max. RMS
Wattage: 40 watts (max.)
Output Voltage: 20-VDC (max.)
Output Current: 1A DC (max.)
Ground: Use known good earth ground
CP-13-07.2 8
Loading...