CP-13-02.2 9060 Cascade Service Manual Model

CP-13-02.2 9060 Cascade Service Manual Model
SERVICE MANUAL
CP-13-02.2
MAY — 2013
9060 CASCADE LOW VOLTAGE
CONTROLLER
(LV1 - Automatic Guns)
MODEL: 80120-XXX
IMPORTANT: Before using this equipment, carefully read
SAFETY PRECAUTIONS, starting on page 1, and all instructions
in this manual. Keep this Service Manual for future reference.
Service Manual Price:
$50.00 (U.S.)
CP-13-02.2
9060 Cascade Low Voltage Controller - Contents
CONTENTS
SAFETY:
PAGE
1-6
SAFETY PRECAUTIONS ......................................................................................................... 1
HAZARDS / SAFEGUARDS................................................................................................... 2-5
INTRODUCTION:
7-16
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.................................................................................................................. 11-12
FUSES .................................................................................................................................... 12
LOCAL/REMOTE BOARD ...................................................................................................... 12
SIGNAL INTERFACE - LOCAL MODE ................................................................................... 13
SIGNAL INTERFACE - REMOTE MODE ........................................................................... 13-16
INSTALLATION:
17-28
GENERAL INFORMATION ..................................................................................................... 17
LOCATION OF THE 9060 ....................................................................................................... 17
ELECTRICAL NOISE ......................................................................................................... 18-19
I/O CONNECTIONS ................................................................................................................ 19
AC INPUT CONNECTIONS ............................................................................................... 19-20
SAFETY GROUND ................................................................................................................. 21
INPUT VOLTAGE SELECTION .............................................................................................. 21
INTERLOCKS .................................................................................................................... 21-23
HIGH VOLTAGE CABLE......................................................................................................... 23
LOW VOLTAGE CABLE ......................................................................................................... 23
RELAY CONTACT OUTPUTS ................................................................................................ 24
LOCAL MODE SIGNALS ................................................................................................... 24-26
REMOTE I/O MODE SIGNALS .......................................................................................... 26-28
OPERATION:
29-42
START-UP .............................................................................................................................. 29
BASIC OPERATIONS ........................................................................................................ 29-30
DI/DT CONFIGURATION ........................................................................................................ 31
CP-13-02.2
9060 Cascade Low Voltage Controller - Contents
CONTENTS
PAGE
OPERATION (Cont.):
29-42
LOCKOUTS ....................................................................................................................... 32-33
KV TEST JUMPER ................................................................................................................. 33
REMOTE I/O MONITORING DIAGNOSTIC MODE ........................................................... 33-35
PARAMETER ADJUSTMENT MODE ................................................................................ 35-36
LOCAL MODE ONLY OPERATIONS ................................................................................. 36-37
REMOTE MODE ONLY OERATIONS................................................................................ 37-39
FAULT DESCRIPTIONS .................................................................................................... 39-41
MAINTENANCE:
43-46
TROUBLESHOOTING GUIDE ................................................................................................ 43
FAULT TROUBLESHOOTING GUIDE ............................................................................... 43-45
PARTS:
47-48
LOW VOLTAGE CONTROLLER MODEL IDENTIFICATION .................................................. 47
PARTS LIST ........................................................................................................................... 48
ACCESSORIES:
49
ACCESSORIES LIST .............................................................................................................. 49
WARRANTY POLICIES:
50
LIMITED WARRANTY ............................................................................................................ 50
CP-13-02.2
CP-13-02.2
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.
!
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 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.
!
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.
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-13-02.2
9060 Cascade Low Voltage Controller - Safety
AREA
HAZARD
Tells where hazards Tells what the hazard is.
may occur.
Spray Area
Fire Hazard
SAFEGUARDS
Tells how to avoid the hazard.
Fire extinguishing equipment must be present in
the spray area and tested periodically.
Improper or inadequate operation and maintenance proce- Spray areas must be kept clean to prevent the
dures will cause a fire hazard.
accumulation of combustible residues.
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.
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-13-02.2
2
9060 Cascade Low Voltage Controller - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
may occur.
Tells what the hazard is.
Tells how to avoid the hazard.
Spray Area
Fire and/or explosion.
Electrostatic arcing MUST be prevented.
The 78789 control panel, LEPS5001 power supply and all other electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
Test only in areas free of flammable or combustible materials.
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.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accordance with NFPA-33, EN 50 176.
Have fire extinguishing equipment readily available and tested periodically.
General Use and
Maintenance
Improper operation or mainte- Personnel must be given training in accordance
nance may create a hazard.
with the requirements of NFPA-33, EN 60079-0.
Personnel must be properly Instructions and safety precautions must be
trained in the use of this equip- read and understood prior to using this equipment.
ment.
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-13-02.2
9060 Cascade Low Voltage Controller - Safety
AREA
HAZARD
Tells where hazards Tells what the hazard is.
Electrical
Equipment
High voltage equipment is utilized.
Arcing in areas of flammable or
combustible materials may occur.
Personnel are exposed to high
voltage during operation and
maintenance.
SAFEGUARDS
Tells how to avoid the hazard.
The power supply, optional remote control
cabinet, and all other electrical equipment
must be located outside Class I or II, Division
1 and 2 hazardous areas. Refer to NFPA-33
or EN 50 176.
Turn the power supply OFF before working on
Protection against inadvertent arcthe equipment.
ing that may cause a fire or explosion is lost if safety circuits are disTest only in areas free of flammable or comabled during operation.
bustible material.
Frequent power supply shut-down
indicates a problem in the system Testing may require high voltage to be on, but
only as instructed.
which requires correction.
An electrical arc can ignite coating Production should never be done with the
materials and cause a fire or explo- safety circuits disabled.
sion.
Before turning the high voltage on, make sure
no objects are within the sparking distance.
Toxic Substances
Certain material may be harmful if Follow the requirements of the Material Safeinhaled, or if there is contact with ty Data Sheet supplied by coating material
the skin.
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-13-02.2
4
9060 Cascade Low Voltage Controller - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.
Spray Area /
High Voltage
Equipment
There is a high voltage
device that can induce an
electrical charge on ungrounded objects which
is capable of igniting coating materials.
Parts being sprayed must be supported on conveyors
or hangers and be grounded. The resistance between
the part and ground must not exceed 1 megaohm.
(Reference NFPA-33 or EN 50 176)
All electrically conductive objects in the spray area,
with the exception of those objects required by the
Inadequate grounding will process to be at high voltage, must be grounded.
cause a spark hazard. A
spark can ignite many Any person working in the spray area must be
coating materials and grounded.
cause a fire or explosion.
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-13-02.2
9060 Cascade Low Voltage Controller - Safety
NOTES
CP-13-02.2
6
9060 Cascade Low Voltage Controller - Introduction
INTRODUCTION
GENERAL DESCRIPTION
The Ransburg 9060 Cascade Low Voltage
Controller (80120-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 can operate in either
LOCAL mode or REMOTE mode conditions.
In the LOCAL mode, the selection and adjustment 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 handgun) or via a single discrete remote I/O trigger
signal. In REMOTE mode, the selection and
adjustment of the set point can be performed
using either discrete or analog remote I/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 remote 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 I/O trigger signal.
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,
7
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.
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
The 9060 High Voltage Controller (80120XXX) is available as follows:
Part #:
Description
80120-31X
Atex Approved for use with Esta-Quick
80120-41X
Non-Approved for use with Evolver SE
80120-51X
Atex Approved for use with Aerobell 168
CP-13-02.2
9060 Cascade Low Voltage Controller - Introduction
SPECIFICATIONS
Environmental
Operating Temperature:
Storage and Shipping
Temperature:
0°C to +40°C
-40°C to +85°C
(Allow power supply to go to room temperature
before use)
95% Non-Condensing
Humidity:
Physical
Height:
14.0 cm (5.5 inches)
Width:
21.6 cm (8.5 inches)
Depth:
19.1 cm (7.5 inches)
3.4 kg (7.5 lbs.)
Weight:
Electrical
Input Voltage:
100-240 VAC
50 or 60 Hz
Frequency:
Current:
1 A max. RMS
Wattage:
40 watts (max.)
Output Voltage:
20-VDC (max.)
Output Current:
1A DC (max.)
Ground:
CP-13-02.2
Use known good earth ground
8
9060 Cascade Low Voltage Controller - Introduction
FRONT
BACK
9060 CONTROLLER FEATURES
No. Description
No. Description
1
Kilovolt Display
8
Standard I/O Connector
2
Micro Amp Display
9
Fuses
3
High Voltage On Indicator
10
Low Voltage Cable Connector
4
Unit ON — OFF Switch
11
AC Inlet Receptacle
5
Set Point Adjust Buttons
12
Ground Wire Assembly and Lug
6
Fault Indicator
13
Air Flow Switch Connectors (Optional)
7
Reset Button
14
Interlock I/O Connector
Figure 2: 9060 Cascade Low Voltage Controller Features
9
CP-13-02.2
9060 Cascade Low Voltage Controller - Introduction
OPERATOR INTERFACE
The 9060 Controller shown in Figure 3, has a
simple operator interface consisting of 7 LEDs
(Light Emitting Diodes), one (1) power switch,
seven (7) buttons, one (1) current LED bargraph, and two (2) screens containing sevensegment displays.
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
Controller 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)
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 type information and the
software version number for a short period of
time.
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 (I/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.
LEDs
BUTTONS
High Voltage On Indicator
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 (µA
and kV).
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 identification code (ID 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 Operations portion of this manual.
CP-13-02.2
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 the left below the kV
display) is used by itself to select “Voltage
Preset 1” in the normal operating mode. If
10
9060 Cascade Low Voltage Controller - Introduction
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.
CONNECTION INTERFACE
The 9060 Controller connection interface shown
in Figure 4, provides all of the required connections for setting up either a remote I/O controlled painting system or a local controlled
painting system.
This connection interface
consists of one (1) low voltage cable connector,
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.
Optional Air Flow Switch Connectors
Preset 3 Button
The Preset 3 Button (on 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 operating mode are used to modify, decrease and
increase respectively, the currently selected
preset value. If the button is pressed and
released, the preset value is changed by 1 kV
at a time. If the button is held for over a 1/2
second, the value will begin changing by 5 kV
increments.
Reset Button
The reset button is used in the normal operating mode to clear fault or overload conditions.
This will NOT prevent any other active 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. It is
reserved for future use. The unit defaults to
LOCAL mode. To enter REMOTE mode, a
remote I/O signal input, local/remote mode
selection, that indicates when the unit should be
in REMOTE mode. When this remote I/O signal
is active, the unit will be in REMOTE mode,
otherwise the unit will be in LOCAL mode.
11
Figure 4: 9060 Connection Interface
CONNECTORS
Low Voltage Cable Connector
The low voltage cable connector is located on
the far lower right of the connection interface.
This connector is designed for use with standard low voltage cable 76298. The low voltage
cable connects the 9060 controller to the
external cascade.
Standard I/O Connector
The standard I/O connector is located just left
of the low voltage cable connector.
This
connector is provided as the entry point for a
shielded multi-conductor cable used for remote
I/O 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-13-02.2
9060 Cascade Low Voltage Controller - Introduction
Interlock I/O Connector
The interlock I/O connector is located just to the
right of 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 below the
standard I/O connector and has a ground logo
sticker to the right of 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 provide a pneumatic trigger signal for handguns 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 a 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, 1A,
5mm x 20mm) installed in fuse holders on the
connection interface. They are located directly
above the AC inlet receptacle. 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
CP-13-02.2
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 filter.
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 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 operation.
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. The 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 imposed between mode changes and the
high voltage from being activated. This is
to prevent a trigger signal that may already be present from instantly turning on
the high voltage when a mode change
occurs.
12
9060 Cascade Low Voltage Controller - Introduction
SIGNAL INTERFACE LOCAL MODE
relay signal is activated when a Fault Condition or Overload Condition has faulted the
9060 Controller.
The 9060 Controller LOCAL mode is normally used for handguns, or very simple automatic gun systems. Handguns require only
one signal input for operation, the trigger
signal. Though not necessary for operation,
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 3 terminal
blocks, 2TB, 3TB and 4TB.
Relay Common Input
Trigger Signal
SIGNAL INTERFACE REMOTE MODE
The trigger signal input (2TB-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 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 I/O. For example, a
programmable logic controller (PLC), can be
used as the control system. The physical
signal interface is provided via the 3 terminal
blocks, 2TB, 3TB and 4TB.
The “HV on” signal (4TB-3) 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.
The 9060 Cascade Low 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.
Fault (Relay Output, Dry Contact)
Digital Inputs
The “Fault” signal (4TB-1) 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
13
The relay common input (4TB-2) 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
(4TB-4). This allows the relays to output 24
VDC signals without the use of any outside
power sources.
All of the digital inputs on the 9060 Cascade
Low 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-13-02.2
9060 Cascade Low Voltage Controller - Introduction
Local/Remote Mode Signal
The local/remote mode signal (2TB-4)
indicates to the 9060 Controller whether the
system is currently in LOCAL mode or
REMOTE mode. If 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 (2TB-3) 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 (2TB-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 TS0)
The tripleset signals, TS1 and TS0 (3TB-1
and 2TB-2), are a pair of signals that are
used to select one of the three preset
voltages that are normally selected during
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-13-02.2
Triple Set Combinations
TS0
Selection
0 (off)
0 (off)
No Change
0 (off)
1 (on)
Preset 1
1 (on)
0 (off)
Preset 2
1 (on)
1 (on)
Preset 3
TS1
NOTE
The tripleset signals can be used to se-
lect a preset from the three (3) preset voltages. The preset values can NOT be adjusted 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 Cascade Low 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 approximately 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.
14
9060 Cascade Low Voltage Controller - Introduction
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-3) 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 required to override the KV setpoint control is
2.0V.
Analog Current Signal
The analog current signal (3TB-2) 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 0mA-20mA, with the minimum
required to override the KV setpoint being
4mA.
!
WARNING
DO NOT attempt to use both analog
voltage and analog current at the same
time. The analog inputs are mutually exclusive. Using both inputs simultaneously will damage the input circuit. Only one
analog input, current or voltage, can be
used at time to control the setpoint value.
Analog Common Signal
The analog common signal (3TB-4) is the
connection for the common reference (-) of the
analog signal source. It is used as the common for both the voltage and current signal.
NOTE
Although the allowable range for the
analog current signal does include 0mA3mA, it will normally be listed as 4-20mA
as the 0-3mA portion of the range is insufficient to override KV setpoint control.
15
Analog Output
The 9060 Cascade Low 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-5) is a scaled
version of the actual feedback current. The
real feedback current is in µA where as the
current signal provided at 3TB-5 is in mA to
make it easily integrated with common systems 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 “HV on” signal (4TB-3) 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 (4TB-1) 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 a Fault Condition or Overload
Condition has faulted the 9060 Controller.
CP-13-02.2
9060 Cascade Low Voltage Controller - Introduction
Relay Common Input
The relay common input (4TB-2) 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 (4TB-4). This
allows the relays to output 24 VDC signals
without the use of any outside power sources.
CP-13-02.2
NOTES
16
9060 Cascade Low Voltage Controller - Installation
INSTALLATION
GENERAL INFORMATION
LOCATION OF THE 9060
The following section contains general information on the installation of both local and
remote systems using the 9060 Cascade Low
Voltage Controller.
Install the Controller in an area outside the
hazardous location 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.
!
WARNING
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, operating, and/or servicing this equipment.
!
CAUTION
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.
Only approved applicators should be
used with the 9060 Cascade Low Voltage
Controller.
NOTE
As each installation is unique, this information is intended to provide general installation information for the 9060 Controller. Consult your authorized Ransburg
distributor for specific directions pertaining
to the installation of your equipment.
17
CP-13-02.2
9060 Cascade Low Voltage Controller - Installation
ELECTRICAL NOISE
Electrical noise refers to stray electrical signals
in the atmosphere at various signal strengths
and frequencies that can affect the operation of
equipment. One of the best ways to prevent
this is to shield the equipment and cables within
a continuous ground envelope, such that any
incident noise will be conducted to earth ground
before it can affect the circuit conductors.
For conductors inside the control unit or Controller, 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.
Figure 5: Pigtailing Connection
The AC input cord is not shielded, but is directed 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 maximum noise immunity, if the AC line is wired
using 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 actually makes things worse (see Figure 5).
CP-13-02.2
It is recommended that all AC I/O (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 output 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 termination 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 Electromagnetic Compatibility Directive of the European
Union. The results conclude that these units
are neither a source of electrical noise nor
18
9060 Cascade Low Voltage Controller - Installation
affected by electrical noise when the above
methods are utilized.
I/O CONNECTIONS
For maximum noise immunity, I/O wiring should
be run in conduit or cables having a foil shield
with an overall braided shield. The foil shield
provides 100% shielding, while the braid
provides a means of making proper 360° shield
terminations at the cable to cabinet connection
points. To make I/O connections using shielded cable, perform the following:
Figure 6: Cable Grommet
1. Remove the cable grommet hardware from
the desired I/O connector housing (See
Figure 6).
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 braid
(See Figure 7).
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.
Figure 7: I/O Cable Stripping
6. Tighten the cable grommet ensuring the
grommet spring makes 360° contact with
the exposed braid of the cable, for maximum noise immunity.
7. For maximum noise immunity, connect the
braid of the cable to earth ground at the end
opposite the Controller.
19
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 110 volt
AC outlet.
CP-13-02.2
9060 Cascade Low Voltage Controller - Installation
NOTE
TB1
In general, conduit must be used for
approved AC installation, however, if national and local codes permit, the AC
power may be supplied via the factory
supplied line cord. If conduit is utilized,
the Controller AC input wiring may be
routed through an optional explosion
proof switch mounted on or near the
spray booth where it will be convenient to
the operator.
For installations where it is required to run the
AC input wiring in conduit, perform the following:
Back of Cabinet
Figure 8: Location of TB1 in Controller
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 8 and 9).
2. Remove the mounting hardware from the
AC inlet receptacle and remove it from the
side of Controller.
3. Install the Conduit Adapter Plate (supplied)
in the hole where the AC inlet receptacle
was removed (see Figure 10).
4. Install the AC input wiring (0.8mm2
(18AWG) minimum) through the Conduit
Adapter Plate using conduit and wire to TB1
as follows:
Hot/Line
Figure 9: TB1 Interlock Wiring
Conduit
Adapter Plate
to TB1-L1
Neutral/Common to TB1-N
Ground
to TB1-EARTH GROUND
SIDE VIEW
Figure 10: Installation of Conduit Adapter Plate
CP-13-02.2
20
9060 Cascade Low Voltage Controller - Installation
SAFETY GROUND
!
WARNING
Failure to connect interlocks could re-
Crimp the appropriate connector onto the
ground wire assembly and install from the
Controller ground stud, located on the side
panel, to a true earth ground.
sult in a fire or explosion.
!
WARNING
ALWAYS ensure that high voltage is
!
OFF before flushing the spray applicator
with solvent. NEVER flush the spray applicator with high voltage ON, as this is a
severe fire hazard and risk to personnel
safety. It is recommended that the high
voltage control be interlocked with the solvent flush signal so that high voltage is
automatically locked out whenever flushing occurs. Consult your authorized
Ransburg representative for information
on interlocking the high voltage OFF signal with the solvent flush signal.
CAUTION
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.
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:
NOTE
1.
All 9060 units (80120-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.
Turn the 9060 Controller off, disconnect
it from its AC source, and remove the
fuses.
!
INTERLOCKS
ALWAYS double check that the Con-
troller is unplugged from its AC outlet
before working with any internal wiring.
Interlocks required by code are as follows:
•
Booth Fan Interlock - When the booth fan is
on, a contact closure is made.
•
Conveyor Interlock - When the conveyor is
moving, a contact closure is made.
•
21
Solvent Interlock - When solvent supply to
the applicator is off, a contact closure is
made.
WARNING
3. Using a small blade screwdriver, remove
the factory installed test jumper from 1TBL2 to 1TB-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 1TB-L2 and 1TBL3 as shown in Figure 9 and 11. The
shielded cable must have a minimum rating
CP-13-02.2
9060 Cascade Low Voltage Controller - Installation
Figure 11: Controller Schematic
CP-13-02.2
22
9060 Cascade Low Voltage Controller - Installation
of 300V and 105°C and its conductors
should be 0.8mm2 (18 AWG) minimum.
Secure the cable to the interlock connector
as described in “I/O Connections” in the
“Installation” section of this manual so that
the shield of the cable is connected to the
chassis of the enclosure.
5. Replace the top cover, secure the screws,
replace the fuses, and reconnect the AC
source.
Voltage Controller
Applicator
High Voltage
Cable
Low Voltage Cable
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 rating specified above.
NOTE
External Cascade
Figure 12: High and Low Voltage Cabling
Connection-Cascade End
The interlock contacts (supplied by user) should be rated for at least 1 amp at
240 VAC.
NOTE
Connection-Control Unit End
The total resistance of the series inter-
locks between L2 and L3 should be less
than 300 Ω.
HIGH VOLTAGE CABLE
Position the spray applicator in the spray area
and route the high voltage cable to the External
Cascade. 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 or robot
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 External Cascade 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 spray applicator,
care should be taken when reinstalling so that
the high voltage cable is completely engaged.
23
Figure 12a: Low Voltage Cable
LOW VOLTAGE CABLE
Insert the connection control unit end of the
low voltage cable into the controller. Make
sure that the male notch on the low voltage
cable lines up with the female notch on the
controller, push in (by hand) as far as it will go,
then tighten the nut. Use the same procedure
at the cascade end. Refer to figures 12 and
12a.
!
WARNING
The Controller MUST be OFF when the
applicator is removed or reinstalled.
CP-13-02.2
9060 Cascade Low Voltage Controller - Installation
RELAY CONTACT
OUTPUTS
LOCAL MODE
(TRIGGER SIGNAL ONLY)
A set of relay contacts for high voltage (CR1)
and fault (CR2) conditions is provided at 4TB-3
and 4TB-1 (See Figure 8). One end of these
relay contacts are connected together and also
connected to a source input terminal 4TB-2
(See Figure 11). When a source voltage is
present at 4TB-2 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:
The LOCAL mode is normally used only for
handguns, or very simple automatic gun
systems.
Most handguns use a flow switch
(13742-01 or 13742-02) to provide the trigger
signal. The listed flow switches can be mounted inside the 9060 Controller chassis via the Air
Flow Switch Connector on the back 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.
MAXIMUM CONTACT RATINGS
Description
DC
AC
Max. Switching Capacity
60W
62.5VA
Max. Operating Voltage
Max. Operating Current
125VDC 125VAC
2A
2A
When wiring to 4TB, use a shielded cable and
route the wiring through the standard I/O
connector as described in the “I/O Connectors”
section of this manual.
NOTE
An internal 24 VDC source voltage is
available at 4TB-4. Using a jumper wire,
this voltage may be connected to 4TB-2
to be used as the source voltage for the
relay contact outputs. In this case, the
total current sourced should not exceed 1
amp.
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.
Unscrew the front four (4) screws and slide
the cover off.
!
WARNING
ALWAYS double check that the Con-
troller is unplugged from its AC outlet
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 (black) lead
should be connected to the trigger signal on
the remote I/O terminal block connector
(Position 5) as shown in Figure 14.
CP-13-02.2
24
9060 Cascade Low Voltage Controller - Installation
!
WARNING
Trigger Signal Position 5
In TB2
The 9060 Cascade Low Voltage Controller 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 inputs 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.
Figure 14: Remote I/O Signal Terminal Block
NOTE
Ground Screw
If a different switch is being used for the
trigger signal, read the switch documentation for the wiring instructions for the specific switching element. Verify whether
sinking or sourcing is to be used so the
local/remote trigger protection board
jumpers are set correctly. For further information, consult your authorized
Ransburg distributor for specific directions
pertaining to your installation or call Customer Service.
Back of Cabinet
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 sourcing inputs are needed, the flow switch
ground wire must be changed to a 24V
DC connection (available on the terminal
blocks).
25
4. The local/remote board (Assy# A13123),
shown in Figure 14 at the bottom below the
remote I/O signal terminal block, is designed 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 16. Use the LOCAL
mode jumper settings table for the jumper
settings based upon your specific input.
LOCAL Mode Jumper Settings
Local Source
Local Sink
JMP1
1-3
1-3
JMP1
2-4
4-6
JMP2
2-3
1-2
Jumper
CP-13-02.2
9060 Cascade Low Voltage Controller - Installation
Jumper 2
Jumper 1
Figure 15: Local/Remote Board Jumper Headers
The Relay Contact Outputs are normally
included as output signal indicators for a control
system and are wired using a few of the conductors in the I/O 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
5. Replace the top cover, replace the fuses,
and reconnect the AC source.
Before performing any wiring, verify the
number of I/O signals, supply, and ground
lines that will be required and select a
shielded I/O cable that has at least that
many lines.
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
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.
Create a table of I/O signals to conductor 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.
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 applicator and Controller are driven by a external
control system using discrete analog and digital
I/O. For example, a programmable logic controller (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.
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.
Unscrew the front four (4) screws and slide
the cover off.
!
WARNING
ALWAYS double check that the Con-
troller is unplugged from its AC outlet
before working with any internal wiring.
CP-13-02.2
26
9060 Cascade Low Voltage Controller - Installation
3. Route the selected shielded cable through
the standard I/O connector and secure it to
the 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.
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 I/O signal locations. Screw down
the terminal block screws to secure the
conductors in place. The I/O Signal Locations table contains the complete list of all I/
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.
5. Determine whether the digital signals will
be configured as sinking (grounding input)
or sourcing (powering input).
I/O Signal Locations
Signal
Normal
Value
3TB-6, 4TB-4
24VDC
Fault
4TB-1
24VDC
Relay Common
4TB-2
24VDC
HV On
4TB-3
24VDC
Reset
2TB-3
24VDC or GND
Local/Remote
2TB-4
24VDC or GND
Tripleset 1 (TS1)
2TB-2
24VDC or GND
Tripleset 0 (TS0)
3TB-1
24VDC or GND
Trigger
2TB-5
24VDC or GND
Analog Current
3TB-2
0-20mA
Analog Voltage
3TB-3
0-10V
Analog Common
3TB-4
Ground (0V)
Analog Feedback
Current
3TB-5
0-200mA
2TB-6, Ground
Lug
Ground (0V)
24 VDC
Ground
27
Terminal
Block
TB3
TB2
TB4
Figure 16: I/O Terminal Block Locations
NOTE
After securing the conductors to the terminal blocks positions, it is best to perform a continuity test between the terminal 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 conductor with 2 fingers to ensure it is tight.
NOTE
All of the digital inputs, including the
trigger signal, MUST be configured as either all sourcing or all sinking. The trigger
signal is configured through the local/
remote trigger protection board jumper
settings.
!
WARNING
DO NOT use a sourcing signal with 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.
CP-13-02.2
9060 Cascade Low Voltage Controller - Installation
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 jumpers 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 Settings
Remote Source
Remote Sink
JMP1
3-4
3-4
JMP1
5-7
5-7
JMP2
2-3
1-2
Jumper
8. Complete the control system I/O wiring before reconnecting the 9060 Controller to
the AC source.
9. Secure the cover, replace the fuses, and
reconnect the AC source.
10. Refer to the “Operations” section of this
service manual and use the “Remote I/O
monitoring diagnostic mode” to verify that
all of the I/O input connections are functioning.
7. Set the main PC board sink/source jumper
(J5) for the rest of the digital I/O signals.
The location of this jumper is shown in Figure 17. Set the jumper the correct pins for
the desired input type as listed in the following table.
PC Board Jumper 5 Settings
Mode
Jumper Pins
Sinking
1-2
Sourcing
2-3
Pin 1
Figure 17: PC Mainboard Jumper J5 Location
CP-13-02.2
28
9060 Cascade Low Voltage Controller - Operation
OPERATION
START-UP
!
After all installation procedures are completed,
operation of the applicator may begin. When
the ON-OFF switch is turned on, the kV display
will show the applicator type the 9060 Controller
is configured for and the µA (microamp) display
will show the current software revision level as
shown in Figure 18. These items are displayed
for approximately 10 seconds.
WARNING
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
Gun Type Number
Software Rev. Lev-
for the specific applicator being used. Using the wrong configuration may allow for
operation outside the recommended parameters and values for the applicator
and can result in damage or un-safe operation.
NOTE
On-Off Switch
Figure 18: Controller Start-Up Display
The following table lists the applicator types
shown on the display as per the current revision of this manual as a reference.
During start-up, the gun trigger or remote
trigger input should NOT be active. An active trigger signal will cause a nonresettable boot fault (bF) and prevent the
unit from being operated. This is designed
to prevent unintended firing of the highvoltage immediately after start-up. Please
refer to the “Fault Section” of this manual
for more information.
START-UP DISPLAY
Applicator Type
Description
ES
Evolver SE/Estaquick
90
90 kV Classic
Ab
Aerobell 168
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
BASIC OPERATIONS
The basic operations are general operations
that are available in both REMOTE and LOCAL
modes.
!
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 being charged. Ensure that NO OBJECTS
approach the bell during charging.
CP-13-02.2
9060 Cascade Low Voltage Controller - Operation
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 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
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 19.
seconds. This 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.
Display of “HV ON” Time in Hours
Press and hold
Both For Resettable
On Time Register
Press and hold
Both For Non-Resettable
On Time Register
Figure 20: Display “High Voltage On” Time
Local/Remote Mode (HV Control)
Button
Figure 19: µA 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 .
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 I/O
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.
Measuring “High Voltage On”
Time
The 9060 Cascade Low 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 µA 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 unit’s high voltage has been on
may be displayed by depressing at the same
time the preset 1 and reset buttons (See Figure
20). The display will show hours of use for 3
CP-13-02.2
Figure 21: Local/Remote Mode Button
!
CAUTION
If the unit is in remote mode with no ex-
ternal signals connected, the unit is not
functioning properly. Check remote terminal block for input signal and if none exists, send the control unit in for repair.
30
9060 Cascade Low Voltage Controller - Operation
DI/DT CONFIGURATION
(For 80100-51X Units Only)
The 9060 Voltage Controller, model 80100-51X,
for use with the ATEX approved Aerobell 168
applicator, contains a di/dt (rate of change in
current 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. If a 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)
Adjusting DI/DT Parameters
The di/dt safety overload fault is configured
based upon two (2) parameters; Sensitivity
(SE), and Sample Time Interval (SA). These
parameters can abe 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 exceeded 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.
Sensitivity Values
Average Rate of Change
(per sampling interval)
SE Setting
(Most Sensitive) 2.0
4uA
3.0
6uA
4.0
8uA
5.0
10uA
6.0
12uA
7.0
14uA
8.0
16uA
9.0
18uA
10.0
20uA
11.0
22uA
(Least Sensitive) 12.0
24uA
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 during charging.
31
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.
CP-13-02.2
9060 Cascade Low Voltage Controller - Operation
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.
Figure 23: Jumper Location - Front Panel Lockout
NOTE
Some lockouts are sealed using sealant
to prevent them from being modified for
safety reasons. These lockouts should
ONLY be modified by Ransburg Authorized
Representatives.
Figure 22: Lockout Jumper Location
Overload
The overload circuit may be activated for
applications that require overload indication or
notification of high current draws of the applicator. The default overload value is set in the
software to the maximum microamp rating
minus 10 microamps.
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.
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-13-02.2
Figure 24: Jumper Location - Overload Activation
NOTE
The overload circuit can NOT be deac-
tivated for the AB168 (Gun Type 9) Configuration.
32
9060 Cascade Low Voltage Controller - Operation
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 Adjustment 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 time. See Figure 22 for the
location of test jumper J8.
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 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
Preset 1
Analog Signal Monitoring
Preset 2
Digital Signal Monitoring
Preset 3
Gun Type / Firmware Version
NOTE
Figure 25: KV Test Jumper Location
!
WARNING
If 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. Refer to the “Accessories” section for this
manual for part numbers for testing equipment.
33
Remote I/O Monitoring Diagnostic Mode
can ONLY be entered when the High Voltage 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.
CP-13-02.2
9060 Cascade Low Voltage Controller - Operation
Analog Signal Monitoring Mode
In the analog signal monitoring mode the kV
display will show an “A#” 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 µA 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.
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 µA
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.
Figure 26 Analog Signal Monitoring (Index 0)
NOTE
The value displayed can range from 0 to
1023. The µA 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
Figure 27: Digital Signal Monitoring (Index 0 - ON)
Analog Index Reference
Index
Analog Signal
0
Buffered Gun Current Feedback
1
Current Control Feedback
2
N/A
Index
Analog Signal
3
Voltage Control Feedback
0
Reset
4
Gun Switch
1
Local/Remote Select
5
KV Setpoint (Current or Voltage)
2
Triple Set 0
6
N/A
3
Triple Set 1
7
N/A
4
Trigger
CP-13-02.2
Figure 28: Digital Signal Monitoring (Index 3 - OFF)
Digital Index Reference
34
9060 Cascade Low Voltage Controller - Operation
To navigate through the digital 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.
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 µA display as shown
during startup in Figure 18 during startup. As
this is a sub mode of the remote I/O 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.
Figure 29: Parameter Adjustment Mode (Overload)
Adjustable Parameters
Code Parameter Min/Max Inc.
OL
Current
Overload
Hd
Startup
Holdtime
NOTE
The Parameter Adjustment Mode is ON-
LY available for Type 7 (Esta-Quick, Evolver SE) and Type 9 (Aerobell 168) automatic
applicators.
PARAMETER
ADJUSTMENT MODE
Certain parameters within the 9060 Cascade
Low 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 operations for parameter adjustment mode
is shown in Figure 30.
In parameter adjustment mode, the kV display
will show the 2-character code for the parameter and the µA 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.
35
20/190
5
2/15
0.5
seconds
sec.
Indicators
Decimal marker
on code means
overload jumper is
installed
N/A
SA
Sample
Time
2-50
1
Available only
on 51X Units
SE
Sensitivity
1.0-12.0
1
Available only
on 51X Units
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 µA 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-13-02.2
9060 Cascade Low Voltage Controller - Operation
!
CAUTION
Be careful when using the parameter
adjustment mode, if you select something
and are unsure if you’ve changed it, deselect it using 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 adjusted appropriately, it must be saved using the
save parameter button (preset 1). If 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 parameter 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 Adjustment Mode
When no parameter is selected, pressing the
Reset key will exit parameter adjustment mode.
CP-13-02.2
Figure 30: Summary of Adjustment Operations
LOCAL MODE ONLY
OPERATIONS
Voltage Setpoints
The voltage on the 9060 Cascade Low Voltage
Controller 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
Preset
Value
1
Full kV minus 20 kV
2
Full kV minus 10 kV
3
Full kV
NOTE
The full kV DC value is determined by
the gun type configuration for the particular 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 Cascade Low Voltage Controller - Operation
Single Pushes Increment Voltage Down (-) or Up (+)in
Single Increments. Holding Button Increments Voltage
Down (-) or Up (+) in Increments of 5 Kv.
REMOTE MODE ONLY
OPERATIONS
Tripleset Selection
Set Point Select Button
Figure 31: kV Adjust/Setpoint Buttons
Adjusting Presets
To adjust one of the preset setpoints, ensure
the applicator is off in LOCAL mode and select
the desired setpoint by pressing the corresponding 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 tripleset signals are used to select voltage
setpoints (presets) that are used during Local
Mode operation. To select a setpoint, the
tripleset signals must be set to the corresponding binary combination as listed in the Tripleset
Selection Table.
TRIPLESET SIGNAL TIMING:
The minimum hold time for the setpoint selection 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.
The three setpoints can ONLY be adjusted 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
There is a 5 second fault reset delay
timer that inhibits the triggering of high
voltage immediately after a fault reset.
37
CAUTION
!
Tripleset Selection
TS0
Selection
0 (off)
0 (off)
No Change
0 (off)
1 (on)
Preset 1
1 (on)
0 (off)
Preset 2
1 (on)
1 (on)
Preset 3
TS1
NOTE
The presets can NOT be adjusted in
remote mode. The unit must be in LOCAL mode and the preset values must be
adjusted using the front panel.
If adjustable voltage setpoints are
needed, analog kV setpoint signaling is
required.
CP-13-02.2
9060 Cascade Low Voltage Controller - Operation
Analog Setpoint Control
NOTE
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 Signal Range:
0 - 10V
Minimum Signal (20kV):
2.0V
ANALOG CURRENT SIGNALING:
Control Signal Range:
0mA - 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-13-02.2
Setpoint
Analog Voltage
20kV
2.0V
30kV
3.0V
40kV
4.0V
50kV
5.0V
60kV
6.0V
70kV
7.0V
80kV
8.0V
90kV
9.0V
If the setpoint values are NOT matching
closely to the values listed in the table,
the unit may need recalibrated or repaired. Please contact your Ransburg
representative.
The 9060 Controller automatically trun-
cates the maximum setpoint value to the
maximum voltage allowed for the applicator being used. Control signal increases
beyond the maximum voltage equivalent
will have no effect.
!
WARNING
DO NOT attempt to use both analog
voltage and analog current at the same
time. The analog inputs are mutually exclusive. Using both inputs simultaneously 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 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 prevent false triggering when the unit changes between LOCAL and REMOTE
modes. Following any mode change,
there is a 300 ms delay during which all
triggers are ignored.
38
9060 Cascade Low 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.
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 sequence 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 Troubleshooting Section.
Trigger Signal
The trigger signal is used to activate the High
Voltage output from the cascade.
TRIGGER SIGNAL TIMING:
The trigger signal minimum hold time is 10 ms.
!
CAUTION
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
Figure 32: Boot Fault Display
Cable Fault (CF)
This fault will occur if high voltage is active and
the microprocessor detects that no current is
being supplied to the applicator. This indicates
a connection problem from the control unit to
the external cascade. A failed low voltage cable
can cause this fault. For additional information,
refer to the Fault Troubleshooting Section.
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, 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
39
CP-13-02.2
9060 Cascade Low Voltage Controller - Operation
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 Troubleshooting Section.
Figure 35: Overload Fault Display
Current Limit Fault (CL)
This fault occurs if the output current exceeds
the maximum current by 20µA. This fault can
be caused by excessive 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, and re-test. If still a problem, replace the pc board. See Fault Troubleshooting
Section for more information.
Figure 36: Current Limit Fault Display
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 current
exceeds the overload current value. This can
be caused by excessive overspray on the applicator or paint formulation that is too conductive. Clean the applicator, check the paint formulation, or move overload jumper (JP17) to
the open position.
CP-13-02.2
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.
40
9060 Cascade Low Voltage Controller - Operation
Figure 37: Voltage Cable 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 specific applicator type. If
this occurs, reset the Controller. If this fault
continues to occur, replace the main PC
board.
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 microprocessor 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 retest operation. If this fault continues to occur,
contact your Ransburg Representative.
Figure 38: Over Voltage Fault Display
Feedback Fault (FF)
Figure 40: DI/DT Overload Fault Display
This fault will occur if the microprocessor detects a loss of the current feedback signal. If
this occurs, reset the fault. If this fault occurs
repeatedly, replace the external cascade or
send the high voltage controller in for repair.
41
CP-13-02.2
9060 Cascade Low Voltage Controller - Operation
NOTES
CP-13-02.2
42
9060 Cascade Low Voltage Controller - Maintenance
MAINTENANCE
TROUBLESHOOTING GUIDE
General Problem
Possible Cause
Solution
Blank Display
1. No power
1. Check the power connections and verify
they are fully connected and power is available. Power cycle the unit off and back on.
2. Blown fuse
3. Faulty +24 volt power supply
2. Check Fuses and replace if blown using
the replacement fuses inside the lid of the
unit.
3. Check green led on 24 volt power supply
when power is applied LED must be on. If
the LED is not on, replace 24 volt power
supply.
FAULT TROUBLESHOOTING GUIDE
!
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.
Fault
Description
Solution
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 secvoltage section on the end of the
tion by pulling on each wire. Repair if neccable. The fault typically occurs at
essary. Insure both connectors are secure
a high voltage trigger.
and re-test for CF fault.
2. Replace high voltage section or send unit
in for repair.
3. Send unit in for repair.
43
CP-13-02.2
9060 Cascade Low Voltage Controller - Maintenance
Fault
Description
Solution
Ground Fault (GF)
The Ground Fault is typically
caused by a ground connection
problem, and can create a safety
hazard. It can occur without high
voltage and will not reset.
1. Check for secure connection on both ends
of the low voltage cable and tighten if necessary. Re-test for GF fault.
2. Replace low voltage cable.
3. Replace external cascade or send in for
repair.
Over-Voltage Fault The Over Voltage Fault indicates
the output voltage exceeds the
(OU)
design specifications. It typically
occurs during a high voltage trigger.
Over-Load Fault
(OL)
1. Check connections using two finger pull
test to ensure they are connected.
2. Replace the pc board.
3. Send unit in for repair.
The Over Load Fault indicates the 1. This may indicate the paint conductivity is
too high (resistance too low) or the outside
current output has exceeded the
of the applicator is contaminated with paint.
overload threshold. This fault is
Test paint for proper conductivity or clean
only active if jumper 17 is shorted.
The overload threshold is normally
applicator with non-polar solvent.
set at 10 µA below the maximum
output of the applicator.
Current Limit Fault The Current Limit Fault indicates
the current output of the gun has
(CL)
1. This may indicate the paint conductivity is
too high (resistance too low) or the outside
exceeded the maximum allowable
of the applicator is contaminated with paint.
output current. It typically occurs
Test paint for proper conductivity or clean
with the high voltage on.
applicator with non-polar solvent.
2. Replace applicator and re-test. If problem
still exists, replace main pc board.
3. Send applicator in for repair.
Feedback Fault
(FF)
CP-13-02.2
The Feedback Fault indicates
there is no current feedback or it
is incorrect. It typically occurs
with the high voltage on.
1. Send high voltage controller in for repair.
44
9060 Cascade Low Voltage Controller - Maintenance
Fault
Description
Solution
Voltage Cable
Fault (UC)
The Voltage Feedback Fault indicates the cascade drive signal is
not present. It typically occurs
when high voltage is triggered.
1. Turn off the voltage controller and remove
the high voltage cable from the voltage
controller.
2. Turn on the power and place HV test jumper J8 in shorted position. If the UC fault
occurs, send the high voltage controller in
for repair. If no fault occurs, continue.
3. The high voltage cable may have failed.
Replace the high voltage cable and re-test.
4. Send applicator unit in for repair.
Boot Fault (bF)
The Boot Fault indicates that an
active trigger signal was detected
during the start-up sequence.
1. Turn off the voltage controller.
2. Ensure that the gun trigger is not pressed
or for remote units that the remote trigger
input signal is not active.
3. Turn on the voltage controller to verify that
a trigger signal is not present and that the
unit enters the ‘ready’ state.
4. Send the voltage controller in for repair or
contact technical support.
DI/DI Overload
Fault (dOL)
(For 80100-51X
units only)
The DI/DT Overload Fault indicates that the change in current
has exceeded the user specified
current limit (sensitivity, SE), during the user selected time interval
(Sample Time, SA).
1. Ensure that the target and no other object
is approaching the applicator within the
minimum safe distance during application. Reset the fault and re-test operation.
2. Using the parameter adjustment mode,
adjust the sensitivity and sample time interval configuration values for DI/DT. Re-test
operation for different values.
3. Contact technical support for further assistance.
45
CP-13-02.2
9060 Cascade Low Voltage Controller - Maintenance
NOTES
CP-13-02.2
46
9060 Cascade Low Voltage Controller - Parts Identification
PARTS IDENTIFICATION
9060 CASCASDE LOW VOLTAGE CONTROLLER MODEL
IDENTIFICATION *
When ordering, use 80120-A1B as indicated by Table A and B. Three digits must follow the basic
part number, for example:
80120 - A 1 B
Basic Part Number
Plug Selection
(TABLE B)
Model Selection
(TABLE A)
* Model number and serial number of the voltage controller is located on the left outside face of
the main enclosure.
Table A - Model Selection
Dash No.
Description
3
External Cascade - Atex Approved with Esta-Quick
4
External Cascade - Non-Approved with Evolver SE
5
External Cascade—Atex Approved with Aerobell 168
Table B - Plug Selection
Dash No. Description
47
1
Domestic
2
Europe
3
China
CP-13-02.2
9060 Cascade Low Voltage Controller - Parts Identification
9060 Cascade Low Voltage Controller - Parts List
Part #
Description
72771-06
Fuse (250V, 1A, 5mm x 20mm)
80116-41
9060 Cascade Low Voltage Controller PC Mainboard (80120-31X, 41X)
80116-68
9060 Cascade Low Voltage Controller PC Mainboard (80120-51X)
80124-00
9060 Cascade Low Voltage Controller Local/Remote Board (A13123)
79428-00
Power Supply, 24V (24VDC Power Supply 1PS)
76434-01
Switch, Rocker (On-Off Switch)
Figure 40: Part Identifications
CP-13-02.2
48
9060 Cascade Low Voltage Controller - Accessories
ACCESSORIES
9060 Low Voltage Controller - Accessories List
49
Part #
Description
76652-01
HV Probe
76652-02
Meter w/Test Leads
76652-03
Paint Test Probe w/Meter
76652-04
Deluxe Kit (Include HV Probe, Meter w/Test Leads, and Paint Test Probe)
CP-13-02.2
9060 Cascade Low Voltage Controller - Warranty Policies
WARRANTY POLICIES
LIMITED WARRANTY
Ransburg will replace or repair without charge
any part and/or equipment that falls within the
specified time (see below) because of faulty
workmanship or material, provided that the
equipment has been used and maintained in
accordance with Ransburg's written safety and
operating instructions, and has been used
under normal operating conditions. Normal
wear items are excluded.
THE USE OF OTHER THAN RANSBURG
APPROVED PARTS, VOID ALL WARRANTIES.
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.
RANSBURG'S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE
PARTS THAT HAVE FAILED BECAUSE
OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. RANSBURG
ASSUMES NO LIABILITY FOR INJURY,
DAMAGE TO PROPERTY OR FOR
CONSEQUENTIAL DAMAGES FOR LOSS
OF GOODWILL OR PRODUCTION OR
INCOME, WHICH RESULT FROM USE OR
MISUSE OF THE EQUIPMENT BY
PURCHASER OR OTHERS.
EXCLUSIONS:
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 no
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.
WRAPPING THE APPLICATOR, ASSOCIATED VALVES AND TUBING, AND
SUPPORTING HARDWARE IN PLASTIC,
SHRINK-WRAP, OR ANY OTHER NONAPPROVED COVERING, WILL VOID THIS
WARRANTY.
CP-13-02.2
50
9060 Cascade Low Voltage Controller
Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260-665-8800
Fax: 260-665-8516
Technical Service—Assistance
320 Philips Ave.
Toledo, Ohio 43612-1493
Telephone (toll free): 800-233-3366
Fax: 419-470-2233
Technical Support Representative will direct you to the appropriate telephone number for
ordering Spare Parts.
© 2013 Ransburg. All rights reserved.
Models and specifications subject to change without notice.
Form No. CP-13-02.2
Litho in U.S.A.
05/13
CP-13-02.2
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