Carlisle Ransburg 9060 User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
Model: 80130-XXX
9060 Classic High Voltage Controller
(HV3 - Handguns)
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision CP-13-06.4 to revision
CP-13-06-R5. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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MANUAL CHANGES
EN

CONTENTS
SAFETY: 4-8
Safety Precautions ................................................................................................................................................4
Hazards / Safeguards ............................................................................................................................................5
INTRODUCTION: 9-14
General Description............................................................................................................................................... 9
Safety Features ..................................................................................................................................................... 9
Displays................................................................................................................................................................. 9
Specications ...................................................................................................................................................... 10
Controller Features...............................................................................................................................................11
Operator Interface ............................................................................................................................................... 12
Switches .............................................................................................................................................................. 12
LEDs.................................................................................................................................................................... 12
Buttons ................................................................................................................................................................ 12
Connection Interface ........................................................................................................................................... 13
Connectors .......................................................................................................................................................... 13
Fuses................................................................................................................................................................... 14
Signal Interface.................................................................................................................................................... 14
INSTALLATION: 15-21
General Information ............................................................................................................................................ 15
Location of the 9060 ........................................................................................................................................... 15
Electrical Noise.................................................................................................................................................... 16
I/O Connections................................................................................................................................................... 17
AC Input Connections ......................................................................................................................................... 17
Safety Ground .................................................................................................................................................... 18
Input Voltage Selection ....................................................................................................................................... 18
Interlocks ............................................................................................................................................................. 18
Controller Schematic .......................................................................................................................................... 19
High Voltage Cable ............................................................................................................................................. 20
Relay Contact Outputs ........................................................................................................................................ 20
Handgun Trigger Signal....................................................................................................................................... 20
OPERATION: 22-27
Start-Up .............................................................................................................................................................. 22
Basic Operations ................................................................................................................................................ 22
Lockouts ............................................................................................................................................................. 23
KV Test Jumper .................................................................................................................................................. 24
Setpoint Operations............................................................................................................................................. 25
Fault Descriptions ............................................................................................................................................... 25
MAINTENANCE: 28-30
Troubleshooting Guide ....................................................................................................................................... 28
Fault Troubleshooting Guide .............................................................................................................................. 28
PARTS IDENTIFICATION: 31-32
High Voltage Controller Model Identication - Parts List .................................................................................... 31
9060 High Voltage Controller - Parts List ............................................................................................................ 32
Accessories ........................................................................................................................................................ 32
MANUAL CHANGE SUMMARY: 33
Manual Changes ................................................................................................................................................ 33
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
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 specications and service
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and appropriate Ransburg
equipment manuals to reconcile such differences.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
in more efcient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system, contact your
local Ransburg representative or Ransburg.
WARNING
!
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the Ransburg
safety literature therein identied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly un-
derstood by ALL personnel who operate, clean or
maintain this equipment! Special care should be tak-
en to ensure that the WARNINGS and safety require-
ments for operating and servicing the equipment are
followed. The user should be aware of and adhere
to ALL local building and re codes and ordinances
as well as NFPA-33 AND EN 50176 SAFETY STAN-
DARDS, LATEST EDITION, or applicable country
safety standards, prior to installing, operating, and/or
servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment.
SAFETY
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, ushing or maintenance.
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained
during cleaning operations using ammable or
combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance of
1 inch for every 10KV of output voltage is required
at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipment modications may cause re or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
OSHA, local, country, and European Health and
Safety Norms.
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SAFETY
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Improper or inadequate
operation and maintenance
procedures will cause a
re hazard.
Protection against inadvertent
arcing that is capable of
causing re or explosion is lost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch for
every 10KV of output voltage is required at all times.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible
materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding
section of the equipment manual. Protection against
inadvertent arcing that is capable of causing re
or explosion is lost if the current overload sensitivity
is not properly set. Frequent power supply
shutdown indicates a problem in the system which
requires correction.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no objects
are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA-33, EN 50176.
Have re extinguishing equipment readily available
and tested periodically.
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, re protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
General Use and
Maintenance
Spray Area Explosion Hazard
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SAFETY
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re
or explosion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on
conveyors or hangers that are properly grounded.
The resistance between the part and earth ground
must not exceed 1 meg ohm. (Refer to NFPA-33.)
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator
via conductive gloves or gloves with the palm section
cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
Grounded conductive ooring must be provided in
the spray area.
Always turn off the power supply prior to ushing,
cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Avoid installing an applicator into a uid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
re or explosion.
Unless specically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 50176.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of ammable or combustible
material.
Testing may require high voltage to be on, but only
as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Electrical Discharge
Electrical
Equipment
Certain materials may be
harmful if inhaled, or if there
is contact with the skin.
Follow the requirements of the Safety Data Sheet
supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the air
free of accumulations of toxic materials.
Use a mask or respirator whenever there is a chance
of inhaling sprayed materials. The mask must be
compatible with the material being sprayed and its
concentration. Equipment must be as prescribed
by an industrial hygienist or safety expert, and be
NIOSH approved.
Chemical HazardToxic Substances
Spray applicators require that aluminum inlet ttings
be replaced with stainless steel.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum
equipment during spraying, ushing, or cleaning.
Read the label or data sheet for the material you
intend to spray. If in doubt as to whether or not a
coating or cleaning material is compatible, contact
your coating supplier. Any other type of solvent may
be used with aluminum equipment.
Halogenated hydrocarbon
solvents for example:
methylene chloride and 1,1,1,
- Trichloroethane are not
chemically compatible with the
aluminum that might be used
in many system components.
The chemical reaction
caused by these solvents
reacting with aluminum can
become violent and lead to an
equipment explosion.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

INTRODUCTION
GENERAL DESCRIPTION
The Ransburg 9060 High Voltage Controller (80130-XXX)
is used to provide high voltage for electrostatic application
equipment. It uses a combination of proven high voltage
generation technology and microprocessor-based control.
It uses a variable voltage output to drive a cascade that
amplies 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 efciency, while maintaining the maximum safety.
The 9060 Controller selection and adjustment of set point
values is performed from the controller front panel. The
triggering of the HV is normally initiated by the airow switch
built into the controller which senses airow triggered by
a standard handgun.
SAFETY FEATURES
When used with the appropriate applicators and cascades,
the Ransburg 9060 High Voltage Controller provides
maximized operational safety. The protections include
detection of Boot Faults, Ground Faults, Cable Faults,
Feedback Signal Faults, Overvoltage, and Overcurrent.
The microprocessor circuits provide a controlled output load
curve, which limits the high voltage output to safe levels
while monitoring control and feedback signals for unsafe
conditions. Maximum operational safety is obtained when
the correct applicator settings are used and when safe
distances between the applicator and target are observed
and followed. The maximum efciency of the high voltage
controller is based on load.
DISPLAYS
The front panel displays the high voltage set point as well
as a reading of gun current output. The gun current is
derived from feedback signals between the controller and
the cascade.
Figure 1: 9060 High Voltage Controller (HV3)
The 9060 High Voltage Controller (80130-XXX) is available
as follows:
80130-21X Vector R70AS Handgun
80130-31X Vector R90AS Handgun
80130-41X Vector AA90 Handgun
80130-51X Vector R90AS Waterborne Handgun
9060 HIGH VOLTAGE
CONTROLLER
Part # Description
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INTRODUCTION
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SPECIFICATIONS
Physical
Environmental
Operating Temperature: 0°C to +40°C 32°F to +104°F
Storage and Shipping Temperature: -40°C to +85°C -40°F to +185°F
(Allow power supply to go to room temperature before use)
Humidity: 95% Non-Condensing
Height: 16.5 cm (6.5 inches)
Width: 37.8 cm (14.9 inches)
Depth: 30.7 cm (12.1 inches)
Weight: 10.2 kg (22.5 lbs.)
Electrical
Input Voltage: 100-240 VAC
Frequency: 50 or 60 Hz
Current: 1A max. RMS
Wattage: 40 watts (max.)
Output Voltage: 20-90kV MAX. DC, adjustable in 1kV increments
Ground: Use known good earth ground
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INTRODUCTION
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Figure 2: 9060 High Voltage Controller Features
1 kV Display
2 High Voltage On Indicator
3 Reset Button
4 µA Display
5 Fault Indicator
6 On-Off Switch
7 Local/Remote Mode Indicator
8 “One Touch” kV Setpoint Buttons
9060 CONTROLLER FEATURES
Description Description
No.No.
9 kV Setpoint/Adjust Buttons
10 Air Flow Switch Hose Connections
11 High Voltage Cable Connector
12 Standard I/O Connector
13 Fuses
14 Ground Lug
15 AC Inlet Receptacle
16 Interlock I/O Connector
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INTRODUCTION
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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
seven-segment displays.
SWITCHES
Power Switch
The 9060 Controller contains a single rocker switch for
power On/Off selection. When the unit is powered on,
the screens should be lit and display the gun display type
information and the software version number for a period
of approximately 5 seconds.
LEDs
High Voltage On Indicator
The red High Voltage On Indicator is lit when a trigger
signal has been received by the unit and the high voltage
output from the cascade has been enabled.
Fault Indicator
The red Fault Indicator is lit when a fault occurs as deter-
mined by the microprocessor. When a fault occurs the light
will turn on and the identication code (ID) for the fault will
be displayed, blinking, on the µA meter display. For more
information on the faults and fault ID codes, please refer
the Fault Descriptions section in the Operation portion of
this manual.
Figure 3: 9060 Operator Interface
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 used with Handguns.
Remote Mode LED Indicator
The remote mode LED indicator should NOT be lit for
handgun units.
Active Preset LED Indicators (3)
The active preset LED indicators are located directly above
each of the Preset Buttons. When a preset button is pushed
to select the desired preset, in READY 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.
BUTTONS
The seven buttons on the operator interface are used to
select the KV presets, reset overloads and faults, access
other modes and to navigate as well as modify information
that is displayed on the two seven-segment display screens
(µA and kV).
The following lists the standard operating mode behavior
for each button.
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 op-
erating mode. If pressed with the reset button, at the same
time, the screen will display the resettable High Voltage
ON operating hours for 3 seconds on the display screens.
Preset 2 Button
The Preset 2 Button (in the center below the kV display)
is used by itself to select “Voltage Preset 2” in the normal
operating mode. If pressed with the reset button, at the
same time, the screen will display the non-resettable High
Voltage ON operating hours for 3 seconds on the display
screens.
Preset 3 Button
The Preset 3 Button (on the right below the kV display)
is used by itself to select “Voltage Preset 3” in the normal
operating mode.
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INTRODUCTION
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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 when the trigger signal is
OFF. This will NOT prevent any other active fault conditions
from triggering a new fault.
Figure 4: 9060 Connection Interface
NOTE
There is a 5 second fault reset delay timer that
inhibits the triggering of high voltage immediately
after a fault reset.
HV Control Button
This button, shown in the center of Figure 3, is not functional
for handgun units.
.
CONNECTION INTERFACE
The 9060 Controller connection interface shown in Figure
4, provides all of the required connections for setting up a
local controlled painting system. This connection interface
consists of one (1) high voltage cable connector, one (1)
standard I/O connector, one (1) interlock I/O connector,
one (1) ground lug connection, one (1) air ow switch
connection, two (2) fuses, and one (1) AC inlet receptacle.
CONNECTORS
High Voltage Cable Connector
The high voltage cable connector is the largest connector
and is located on the far right of the connection interface.
The connector will come covered with a factory installed
red protective cap. This connector is designed for use with
standard high voltage cables such as 79518 and 79519.
The specic cable required depends on the applicator
being used. Please refer to the applicator manual for the
cable required.
Standard I/O Connector
The standard I/O connector is located just left of the high
voltage cable connector. This connector is provided as the
entry point for a shielded multi-conductor cable used for
remote I/O signals and includes the required cable grommet
hardware to keep the cable in place with minimal strain.
This connector is NOT used for handgun units.
Interlock I/O Connector
The interlock I/O connector is located just above the AC inlet
receptacle. This connector is provided as the entry point
for interlock signal wiring for the booth fan, conveyor, and
solvent supply. The connector includes the required cable
grommet hardware to keep wiring in place with minimal
strain. For more information on the interlock connections,
please see the “Installation” section of the service manual.
Ground Lug Connection
The ground lug connection is located directly below the
fuses and has a ground logo sticker directly below it. This
lug is provided as an external ground connection point
used to ground the 9060 to an earth ground via a ground
cable. This ground lug connection can also be used as the
ground point for the high voltage cable ground.
Air Flow Switch Connection
The air ow switch connection is installed to provide a
pneumatic trigger signal for handguns indicating that the
trigger has been actuated. This signal is used to turn on
the High Voltage output. Both threaded connectors of the
air ow switch 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.
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INTRODUCTION
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FUSES
Fuses
There are two (2) time delay fuses (250V, 1A, 5mm x
20mm) installed in fuse holders on the connection interface.
They are located directly above the ground lug connection.
They are present to provide a measure of safety against
power surges through the AC input. The top fuse holder
is connected in series between the HOT line (L) input
connection and the Interlock AC line connection terminal
TB1-L2. The bottom fuse holder is connected in series
between the neutral AC input connection and the neutral
input connection of the AC line power lter.
Spare Fuses
The Controller also comes with two (2) spare fuses (250V,
1A, 5mm x 20mm) mounted in holders, inside the lid of
the Controller.
SIGNAL INTERFACE
The 9060 controller local mode is 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 terminal block TB2 and the connector J3 on the PC
Mainboard.
Trigger Signal
The trigger signal input (J3-5) for handgun units comes
precongured as a sinking signal input wired directly to
the air ow switch. Please refer to the “Installation” section
of this service manual for more information.
High Voltage On (Relay Output, Dry Contact)
The “HV on” signal (TB2-4) is a relay controlled signal,
can be congured 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 (TB2-2) is a relay controlled signal, can
be congured as either an AC or DC signal using the Re-
lay 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.
Relay Common Input
The relay common input (TB2-3) is a shared connection
between the Fault and HV on relay outputs. This is the
source of their output voltage. It can be wired to either an
AC or DC signal. It is most commonly connected to the
24 VDC power provided at (TB2-1). This allows the relays
to output 24 VDC signals without the use of any outside
power sources.
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INTRODUCTION
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INSTALLATION
WARNING
!
GENERAL INFORMATION
The following section contains general information on the
installation of 9060 High Voltage Controller.
The controller may be free standing on any at surface
or wall mounted (wall mount brackets not supplied) as
shown in Figure 5.
Figure 5: Typical Controller Mounting
LOCATION OF THE 9060
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.
NOTE
CAUTION
!
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 thoroughly
understood by ALL personnel who operate, clean,
or maintain this equipment! Special care should be
taken to ensure that the warnings and requirements of
operating and servicing safely are followed. The user
should be aware of and adhere to ALL local building
and re codes and ordinances as well as NFPA-33,
OSHA, and all related country safety codes prior to
installing, operating, and/or servicing this equipment.
Only approved applicators should be used with
the 9060 High Voltage Controller.
DO NOT locate the Controller near or adjacent
to heat producing equipment such as ovens, high
wattage lamps, etc.
As each installation is unique, this information is
intended to provide general installation information
for the 9060 Controller. Consult your authorized
Ransburg distributor for specic directions pertaining
to the installation of your equipment.
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INSTALLATION
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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.
The AC input cord is not shielded, but is directed to an AC
line lter as soon as it enters the cabinet. This method
lters 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 lter 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 con-
tinuous 360° fashion at both ends. The best way to do this
is to use a connector (conduit tting) 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 6).
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.
Figure 6: Pigtailing Connection
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 con-
tain overall foil and braided shields and be terminated in
a continuous 360° manner as described in the preceding
paragraph. Special ttings have been provided on the
control panel for termination of these cables at that point.
The use of these ttings 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 affected by electrical noise
when the above methods are utilized.
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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:
1. Remove the cable grommet hardware from the desired
I/O connector housing (See Figure 7).
2. Route the desired length of I/O cable through the
connector housing and mark 1” span of cable that
passes through the connector housing to be stripped
to braid (See Figure 8).
3. Remove cable and strip marked 1” section to cable braid.
4. Slide the cable grommet hardware onto the cable in
the order shown in Figure 7.
5. Route the cable back through the connector housing
and connect its wires to the desired I/O terminals inside
the 9060 Controller.
6. Tighten the cable grommet ensuring the grommet
spring makes 360° contact with the exposed braid of
the cable, for maximum noise immunity.
7. For maximum noise immunity, connect the braid of the
cable to earth ground at the end opposite the Controller.
AC INPUT CONNECTIONS
For non-conduit installations, plug the detachable AC line
cord into the receptacle on the side of the 9060 Controller.
Plug the other end of the line cord into a properly grounded
120 volt AC outlet.
Cable Grommet
Figure 7: Cable Grommet
For those installations where it is required to run the AC
input wiring in conduit, perform the following:
1. Ensure the AC line cord is unplugged and remove
the AC inlet receptacle wiring from TB1-N, TB1-L1 and
TB1-EARTH GROUND (See Figures 9 and 10).
2. Remove the mounting hardware from the AC inlet
receptacle and remove it from the side of Controller.
3. Install the Conduit Adapter Plate (See Accessories
Section) in the hole where the AC inlet receptacle was
removed (see Figure 11).
4. Install theAC input wiring (0.8mm2(18AWG) minimum)
through the Conduit Adapter Plate using conduit and
wire to TB1 as follows:
NOTE
Hot/Line to TB1-L1
Neutral/Common to TB1-N
Ground to TB1-EARTH GROUND
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.
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Figure 9: Location of TB1 & TB2 in Controller
Figure 10: TB1 Interlock Wiring
Figure 11: Installation of Conduit Adapter Plate
NOTE
Interlocks should be DRY CONTACTS and should
be rated to handle 1 amp.
Interlock series resistance should not exceed 20kΩ
SIDE VIEW
SAFETY GROUND
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.
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.
INTERLOCKS
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.
•Solvent Interlock - When solvent supply to the applicator
is off, a contact closure is made.
CAUTION
!
Do NOT rely on the ground connection provided by
generators and other portable power generation devices.
The ground wire assembly MUST be connected from
the Controller ground stud to a true earth ground.
NOTE
All 9060 units (80130-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.
WARNING
!
Failure to connect interlocks could result in a re
or explosion.
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As outlined in NFPA-33, OSHA, and EN 50176, the AC
power line must be series interlocked with both the exhaust
fan and conveyor.
To install the Controller interlocks perform the following:
1. Turn the 9060 Controller off, disconnect it from its
AC source, and remove the fuses.
2. Open the Controller cabinet door.
3. Using a small blade screwdriver, remove the factory
installed test jumper from TB1-L2 to TB1-L3.
4. Using a shielded cable for the interlock wiring (supplied
by user), route through the interlock connector on the
side of the 9060 Controller and terminate TB1-L2 and
TB1-L3 as shown in Figure 12. The shielded cable
must have a minimum rating 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. Secure the cabinet door, replace the fuses, and recon-
nect the AC source.
WARNING
!WARNING !
ALWAYS ensure that high voltage is OFF before
ushing the spray applicator with solvent. NEVER
ush the spray applicator with high voltage ON, as this
is a severe re hazard and risk to personnel safety.
It is recommended that the high voltage control
be interlocked with the solvent ush signal so that
high voltage is automatically locked out whenever
ushing occurs. Consult your authorized Ransburg
representative for information on interlocking the
high voltage OFF signal with the solvent ush signal.
ALWAYS double check that the Controller is
unplugged from its AC outlet before working with
any internal wiring.
Figure 12: Controller Schematic
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HIGH VOLTAGE CABLE
Position the spray applicator in the spray area and route the
high voltage cable to the Controller. The cable should be
routed so that it is not damaged by foot and vehicle trafc
and also so that is not close to areas of high temperature
(129°F+). The operator should have free movement of
the applicator and all bend radii of the cable should not
be less than 6-inches (15 cm). Connect the high voltage
cable to the Controller and tighten the retaining nut and
set screw. If during the routing of the high voltage cable
it is required to remove it from the spray applicator, care
should be taken when reinstalling so that the high voltage
cable is completely engaged.
RELAY CONTACT OUTPUTS
Aset of relay contacts for high voltage (CR1) and fault (CR2)
conditions is provided at TB2-4 and TB2-2 (See Figure 9).
One end of these relay contacts are connected together
and also connected to a source input terminal TB2-3 (See
Figure 12). When a source voltage is present at TB2-3 and
either the high voltage is on or a fault condition occurs, the
When wiring to TB2, 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
WARNING
!
NOTE
NOTE
NOTE
Max. Switching Capacity 60W 62.5VA
Max. Operating Voltage 125VDC 125VAC
Max. Operating Current 2A 2A
MAXIMUM CONTACT RATINGS
Description DC AC
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 specied above.
The interlock contacts (supplied by user)
should be rated for at least 1 amp at 240 VAC.
The Controller MUST be OFF when the applicator
is removed or reinstalled.
An internal 24 VDC source voltage is available
at TB2-1. Using a jumper wire, this voltage may be
connected to TB2-3 to be used as the source voltage
for the relay contact outputs. In this case, the total
current sourced should not exceed 1 amp.
The total resistance of the series interlocks
between L2 and L3 should be less than 300 Ω.
source voltage will become available at the output end of
the corresponding contact. Maximum contact ratings for
the relays are as follows:
HANDGUN TRIGGER SIGNAL
Handguns use a ow switch (13742-01 or 13742-02) to
provide the trigger signal. One of the listed ow switches
is mounted inside the 9060 Controller chassis via the
Air Flow Switch Connector on the side panel. When the
handgun trigger is pressed and ow starts, the ow switch
is activated and triggers the high voltage.
For reference, when replacing a ow switch, perform the
following:
1. Turn the 9060 Controller off, disconnect it from its
AC source, and remove the fuses.
WARNING
!
ALWAYS double check that the Controller is
unplugged from its AC outlet before working with
any internal wiring.
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INSTALLATION
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