- 9060 Power Supply Faults SI-22-06 [ English ]
SERVICE INSTRUCTION EN
SI-22-06
®
9060 POWER SUPPLY 80102-2XX NO. 2 ELECTRIC MOTOR bF FAULTS
After multiple repair evaluations the cause of bF ,Boot Faults, has been determined for which this service instruction
includes steps that can be taken to resolve this issue.
Repeated boot faults during painting indicate a voltage surge has reached the pc board, which can eventually cause
damage to the circuitry.
Boot Faults, displayed as bF are caused due to:
• Before painting, without HV ON indicates the control unit has been powered up and the gun switch was turned on
before the control unit reached ‘ready state’, indicated by 000 on the mA display.
• During painting, with HV ON typically indicates arcing inside the cascade or inside the #2 gun.
(Correcting this problem will prevent failure of the 80116-28 pc board and prevent downtime.)
CORRECTIVE ACTION STEPS
1. Arcing Inside Of Gun Shaft
Arcing from the spring to the resistor, or from the spring to the motor (ground) inside the #2 gun shaft can occur. To
insure good connections that prevent arcing, measure the shaft connection to the handle resistance with a Mega ohm
meter or Ransburg Tri-meter, 76634-00, as follows:
a. Disconnect power to the control unit.
b. Remove the bell cup (item #4) by loosening the screw (item #3). As shown below connect a Mega ohm meter to
the bell contact and the gun handle.
c. The reading must be 9 – 11 Giga ohms.
NOTE: A Ransburg Tri-meter, 76634-00, can also be used, but will not read correctly unless there are secure
connections on both ends (i.e. the probes cannot be held by hand to make the connection). Attach alligator clips to both
the bell connection and the gun handle. After connection, wait until the reading is stable. If a stable reading cannot be
obtained, a Mega ohm meter must be used.
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If the reading is higher than 11 Giga ohms, the resistor may be damaged or the spring may not be making contact.
Point the gun up and unscrew the shaft nut. Remove the spring and resistor while being careful to not drop the resistor
out from the center of the shaft.
The resistor must be replaced if it is missing any coating as this indicates arcing. Next, measure the resistor as it must
read between 9 – 11 Giga ohms.
If the resistor measures correctly and is not damaged then the spring is not making contact. The spring should be at
least 1.5(38mm) long to ensure contact with the resistor and the motor. The spring may need to pulled out longer to
compensate for any compression.
Insert the resistor and the spring. If the spring is captured in the shaft, push it in until the end is 0.75 (19mm) in from the
end of the shaft. Then push and pull the shaft back and forth. If you can feel the resistor move, push the spring in 1/8
(3.2mm) farther and repeat the resistance test.
2. Incorrect Assembly Order
Incorrect assembly order of the resistor (item #3) and seal (item #4) can cause the seal to push away from the resistor
(due to captured air), creating a small air gap which preventing connection from the resistor to the seal. To confirm correct
order assembly follow these steps:
a. To measure the resistor first disconnect the high voltage cable from the control unit.
b. Using a Mega ohm meter or Ransburg Tri-meter, 76634-00, set on GΩ scale, measure from the wire of the brush
to the center of the high voltage cable (control unit end). The value should be 500 Mega ohms to 560 Mega ohms
(0.50 to 0.56 Giga ohms on Ransburg Tri-meter, 76634-00).
If the reading is higher than the value specified, either the resistor is damaged, or the resistor seal is not in
contact with the resistor.
To correct the assembly of the resistor and seal remove the handle and place a small amount of LSCH0009-00 dielectric
grease into the front of resistor housing. Apply a heavy coat to the O.D. of the resistor with dielectric grease and insert into
the resistor housing, until approximately 1/2 (12.7mm) is sticking out the end of the tube.
Install a 7554-06 O-ring on the 3959-00 contact and set onto the resistor with the hole down. While applying pressure
against the 3959-00 contact, push resistor into tube.
Secure the resistor in place with a 7747-16C screw and a 7486-06 washer using a long slot screwdriver.
EN
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3. Cascade Causing Arcing
If the cascade is part number 79350-03 and serial number older than 2246XXXX, replace the cascade with 79350-03R.
In this case replace the cascade as follows:
a. Unplug the 3PL connector (shown in blue below) on the side of the cascade.
b. If a relay board is present on the cascade bracket, unplug the connector.
c. Remove the six screws, flat washers, and lock washers shown.
If the cascade is a –03R, typically the gun resistor connections are the problem, and the cascade will not need replaced.
Optional: For easier re-assembly later, instead of removing the top three screws in the picture, they can be loosened and
the cascade bracket slid down (the top three holes in the bracket are slotted).
d. Unscrew and remove the three screws, flat washers, and lock washers from the cascade bracket. Note the high
voltage tube is left of center with the cascade bracket installed.
e. Re-assemble the new cascade in the bracket and install the screws, flat washers, and lock washers. Notice the
cascade must be installed with the high voltage tube offset from center, to align with the High Voltage output port
of the control unit.
f. Re-install the cascade and bracket assembly in the control unit. If the top three screws had only been loosened,
a magnet can be used to pull the washers away from the back panel before sliding the cascade bracket under
the washers.
g. Plug in the cascade and make sure all the cascade pins are covered with the connector.
h. Plug in the relay board (if present).
Test the unit for proper kV output using a HV probe. The output must be 92-100 kV.
EN
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The use of parts or accessories from sources other than Binks will void all warranties. Failure to follow reasonable
maintenance guidance provided can invalidate the warranty.
For specific warranty information, please contact Binks.
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