Carlisle Ransburg 9060 User manual

Model: 80143-XXX
for use with Esta-Quick Applicator AEMD600 (ATEX Approved)
80146-XXX
for use with Evolver 560SE (Non-Approved)
9060 Power Supply Kit For
80104 External Cascade
IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
CP-13-01-R5 (10/2019) 1 / 24 www.carlisleft.com
EN
SERVICE MANUAL

NOTE: This manual has been changed from revision CP-13-01.4 to revision
CP-13-01-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
9060 Power Supply Kit Part Structure ..................................................................................................................... 10
 Specications ...........................................................................................................................................................11
80100 Cascade Control Unit Features .................................................................................................................... 12
80120 Cascade Control Unit Features .................................................................................................................... 13
80104 Cascade Control Unit Features .................................................................................................................... 14
ATEX: 15-16
European Atex Directive .......................................................................................................................................... 15
Labels ...................................................................................................................................................................... 16
INSTALLATION: 17-20
Typical Installation Schematics ................................................................................................................................ 18
High/Low Voltage Cables ........................................................................................................................................ 19
OPERATION / MAINTENANCE: 21
Instructions .............................................................................................................................................................. 21
PARTS IDENTIFICATION: 22
80104 External Cascade Components .................................................................................................................... 22
MANUAL CHANGE SUMMARY: 23
Manual Changes ..................................................................................................................................................... 23
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system , read and understand all of the technical
and safety literature for your products. This manual
contains information that is important for you to know and
understand. This information relates to USER SAFETY
and PREVENTING EQUIPMENT PROBLEMS. To help you
recognize this information, we use the following symbols.
Please pay particular attention to these sections.
A WARNING! states information to alert you to
a situation that might cause serious injury if
instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
Whilethismanuallistsstandardspecicationsandservice
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and asscoiated equipment
manuals to reconcile such differences.
WARNING
!
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the safety literature
thereinidentied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly
understood by ALL personnel who operate, clean
or maintain this equipment! Special care should
be taken to ensure that the WARNINGS and safety
requirements for operating and servicing the
equipment are followed. The user should be aware
of and adhere to ALL local building and re codes
and ordinances as well as NFPA-33 AND EN 50177
SAFETY STANDARDS, LATEST EDITION, or
applicable country safety standards, prior to installing,
operating, and/or servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment.
SAFETY
Repairs may only be performed by authorized personnel.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
inmoreefcientoperation,longertrouble-freeserviceand
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your equipment, contact your local
Carlisle Fluid Technologies representative or Carlisle Fluid
Technologies technical support.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate
operation and maintenance
procedureswillcauseare
hazard.
Protection against inadvertent
arcing that is capable of
causingreorexplosionislost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turnedoffpriortocleaning,ushingormaintenance.
Spray booth ventilation must be kept at the rates
requiredbyNFPA-33,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
EN

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

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
There is a high voltage device
that can induce an electrical
chargeonungroundedobjects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materialsandcauseare
or explosion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on
conveyors or hangers that are properly grounded.
The resistance between the part and earth ground
mustnotexceed1megohm.(RefertoNFPA-33.)
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
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcingthatmaycauseareor
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
reorexplosion.
Unless specically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas in
accordancewithNFPA-33andEN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

NOTE
INTRODUCTION
GENERAL DESCRIPTION
The Ransburg Spray Process
The Ransburg Spray Process is an air atomized method
for applying coatings to objects electrostatically.  This
system applies a high voltage DC charge to the applicator
nozzleelectrode,creatinganelectrostaticeldbetweenthe
atomizerandthetargetobject.Thetargetiselectrically
grounded through its support that may be either stationary
or moving.
Aregulatedpressureuidsystemdeliverscoatingmaterial
to the atomizer. At the atomizer, air is applied that atomizes
the coating material forming a spray mist that, under the
inuence of the electrostatic eld, becomes electrically
charged. The charged particles are attracted to, and
depositedon,thetargetobject.Theforcesbetweenthe
chargedparticlesandthegroundedtargetaresufcientto
turn most normal overspray around and deposit it on the
side and back surfaces of the target. Therefore, a high
percentage of the spray is deposited on the target.
9060 Power Supply
The 9060 Cascade Control Unit converts standard AC line
voltage to a high frequency, low voltage signal ranging
from 0 to 10 Vrms. This signal is supplied to an external
cascade through a low voltage cable. The external cascade
converts the low voltage signal into a high voltage. This high
voltage is transmitted through the cable to the applicator.
At the applicator an electrode in the applicator creates a
DChighvoltageeldthespraygoesthroughandpicksup
the electrostatic charge. When the material is directed to
a grounded target, more material is attracted to the target
yieldinghigherpaintingefciency.
The voltage/current characteristic is designed to optimize
the charging process under varying load conditions, and
to limit the operating current to a safe maximum value.
In addition to supplying low voltage output to the applicator,
the 9060 Cascade control unit also provides controls for
ACpowerON/OFF,precisehighvoltageadjustment,ahigh
voltage meter, a current meter, an AC power ON indicator,
a high voltage ON indicator, a cable fault indicator, and a
current overload indicator and reset switch. Additionally,
output terminals are provided for remote overload reset,
analog current output, and high voltage control. Interlock
connections for a conveyor and exhaust fan are also
provided. Acombination triple setpoint/analog input control
board is also supplied with 9060 Cascade control units
powering automatic spray applicators.
9060 Power Supply Kit 80143 and 80146
The9060PowerSupplyKit80143-XXXand80146-XXXare
designedtobeusedwitheithertheEsta-QuickApplicator
(AEMD 600) or the Evolver 560SE product (A13901). Both
useanoillledcascade.
The only combination of units that carry any
approval is the AEMD600 used with the 80143-
XXX units as described in this manual.Any other
combination of applicator and 9060 unit does
not have any agency approval associated with it.
When using equipment that is not approved, the
user needs to be aware of the code requirements
needed to operate safely. If there is any question
regarding safe installation requirements when using
thisproduct, refer to EuropeanNorms (EN 50176)
orNFPA-33.
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INTRODUCTION
EN

The 9060 Power Supply Kit is available for automatic
applicators as follows:
9060 POWER SUPPLY KIT
PART STRUCTURE
80143-ABC (Atex approved when used with
AEMD600)-Esta-Quick
A-Unit Power Type
 -1For110/120VInputPower(Domestic)10”Rack
 -2For220/240VInputPower(European)10”Rack
 -3For220/240VInputPower(Chinese)10”Rack
 -4For110/120VInputPower(Domestic)BoxStyle
 -5For220/240VInputPower(European)BoxStyle
 -6For220/240VInputPower(Chinese)BoxStyle
B- High Voltage Cable Length
 -1For4.5m(15ft.)
 -2For7.5m(25ft.)
 -3For15m(50ft.)
 -4For22.5m(75ft.)
C-Low Voltage Cable Length
 -110mLVCable
 -215mLVCable
NOTE
CE/Atex approval with this power source is only
fortheAEMD-600
80146-ABC (non- approved when used with
AA13901X) Evolver 560SE
A-Unit Power Type
 -1For110/120VInputPower(Domestic)10”Rack
 -2For220/240VInputPower(European)10”Rack
 -3For220/240VInputPower(Chinese)10”Rack
 -4For110/120VInputPower(Domestic)BoxStyle
 -5For220/240VInputPower(European)BoxStyle
 -6For220/240VInputPower(Chinese)BoxStyle
B- High Voltage Cable Length
 -1For4.5m(15ft.)
 -2For7.5m(25ft.)
 -3For15m(50ft.)
 -4For22.5m(75ft.)
C-Low Voltage Cable Length
 -110mLVCable
 -215mLVCable
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INTRODUCTION
EN

SPECIFICATIONS
Physical - 10” Rack 9060 P/N 80120-31X
Physical - Cascade #80104
Electrical Requirements
Height: 132mm (5.2 inches)
Width: 429mm (16.9 inches) (483mm ear to ear) (19 inches)
Depth: 308mm (12.1 inches)
Weight: 6.8 kg (15.1 lbs.)
Physical - 19” Box 9060 P/N 80100-31X
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.)
Height: 400mm(15.7inches)
Width: 102mm Square (4.0 inches)
Weight: 4.1 kg (9.1 lbs.)
Input:
Voltage: 90-264VAC
Current: 0.4/0.2 Amps AC
Frequency: 50/60 Hertz
Wattage: 40 watts (Max.)
Output:
Voltage: 0-10VRMS
Current: 1.5 Amps RMS (max.)
Pneumatic:
Supply Air: 6.9 Bar (Max.) (100 PSI)
Cascade:
Umax: 90kv (Maxi.)
Max. Current: 120 mA (Max.)
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INTRODUCTION
EN

Figure 1: 80100 Cascade Control Unit Features
5
Item # Description
80100 CASCADE CONTROL UNIT FEATURES
1 Kilovolt Display
2 Micro Amp Display
3 High Voltage On Indicator
4 Unit ON/OFF Switch
5 SetPointAdjustButtons
6 Fault Indicator
7 ManualResetPad
8 External Wiring Grommet
9 Fuse
10 Low Voltage Cable Connector
11 AC Inlet Receptacle
12 Ground Wire Assembly
1326
74
11
8
10
9
12
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INTRODUCTION
EN

Figure 2: 80120 Cascade Control Unit Features
Item # Description
80120 CASCADE CONTROL UNIT FEATURES
1 Kilovolt Display
2 Micro Amp Display
3 High Voltage On Indicator
4 Unit ON/OFF Switch
5 SetPointAdjustButtons
6 Fault Indicator
7 ManualResetPad
8 External Wiring Grommet
9 Fuse
10 Low Voltage Cable Connector
11 AC Inlet Receptacle
12 Ground Wire Assembly
5
132
6
7
4
12
12
11
8
10
9
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INTRODUCTION
EN

Figure 3: 80104 Cascade Control Unit Features
Item # Description
80104 CASCADE CONTROL UNIT FEATURES
1 Low Voltage Cable Connector
2 Ground Lug Connector
3 Cascade High Voltage Connection
4 Ground Wire Assembly
2
1
4
3
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INTRODUCTION
EN

The following instructions apply to equipment covered
by certicate number Sira 11ATEX5240X:
1.Theequipmentmaybeusedwithammablegasesand
vapors with apparatus groups II and with temperature
class T6.
2.Theequipmentisonlycertiedforuseinambienttem-
peratures in the range +12.8oC to +40oC and should
not be used outside this range.
3. Installation shall be carried out by suitably trained
personnel in accordance with the applicable code of
practicee.g.EN60079-14:1997.
4. Inspection and maintenance of this equipment shall be
carried out by suitably trained personnel in accordance
withtheapplicablecodeofpracticee.g.EN60079-17.
5. Repair of this equipment shall be carried out by suitable
trained personnel in accordance with the applicable
codeofpracticee.g.EN60079-19.
6.Puttingintoservice,use,assembling,andadjustmentof
theequipmentshallbettedbysuitablytrainedpersonnel
in accordance with the manufacturer’s documentation.
Refer to the “Table of Contents” of this service manual:
a. Installation
b. Operation
c. Maintenance
  d.PartsIdentication
7.Componentstobeincorporatedintoorusedasreplace-
mentpartsoftheequipmentshallbettedbysuitably
trained personnel in accordance with the manufacturer’s
documentation.
8. Thecerticationofthisequipmentreliesuponthefol-
lowing materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility
of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring that
the type of protection provided by the equipment
is not compromised.
EUROPEAN ATEX DIRECTIVE 2014/34/EU, ANNEX II, 1.0.6
Aggressive substances: e.g. acidic liquids or gases
that may attack metals, or solvents that may affect
polymeric materials.
Suitable precautions: e.g. regular checks as part of
routine inspections or establishing from the material’s
datasheetsthatitisresistanttospecicchemicals.
 Referto“Specications”inthe“Introduction”section:
a.Alluidpassagescontainstainlesssteelor
 nylonttings.
b. High voltage cascade is encapsulated with a
solvent resistant epoxy.
9. Arecapitulationofthecerticationmarkingisdetailedin
the “Atex” section, on the next page, drawing numbers:
80108and80075.
10. The characteristics of the equipment shall be detailed
e.g. electrical, pressure, and voltage parameters.
The manufacturer should note that, on being put into
service, the equipment must be accompanied by a
translation of the instructions in the language or lan-
guages of the country in which the equipment is to be
used and by the instructions in the original language.
CP-13-01-R5 (10/2019) 15 / 24 www.carlisleft.com
ATEX
EN

9060 Cascade Low Voltage Control Unit Kit
ATEX Product 80143-XXX Marking Denitions
ExCerticateNumber:Sira11ATEX5240X
 Sira=NotiedBodyperformingEC-typeexamination
 11=Yearofcertication
ATEX =ReferencetoATEXDirective
5 = Protection Concept Code
(Code 5 is titled Encapsulation)
240 = Document serial number
 X=Specialconditionsforsafeuseapply
Product Marking
II 2 G
 Ex =Specicmarkingofexplosiveprotection
II = Equipment Group hazardous area characteristics
2 = Equipment Category
G = Type of explosive atmosphere
(gases, vapors, or mists)
EEx0.24mJ.The80143-XXX9060CascadeControlUnit
Kit is suitable for use in electrostatic spraying installations
complyingwithEN50176astheyareaTypeAclasswith
a discharge energy limit of 0.24mJ.
Label 80108
Label 80075
Label 80081
SIRA 11ATEX5240X
2813 II2G
EEx 0.24mJ
E N 50 050 COM P LI ANT
CP-13-01-R5 (10/2019) 16 / 24 www.carlisleft.com
ATEX
EN

INSTALLATION
Refer to CP-13-05 or CP-13-02 (Included
with Your Kit) for Control Unit Installation
Instructions.
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 thoroughly un-
derstood 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.
CP-13-01-R5 (10/2019) 17 / 24 www.carlisleft.com
INSTALLATION
EN

1 9060 Low Voltage Unit
2 AEMD-600Unit(AtexApproved)WITHMACHINEADAPTERAEMD-4500-6
3 A10560-XXDHighVoltageCable
4 80104-01ExternalCascade
5 79338-XXLowVoltageCable
6 Booth Wall
7 CascadeGroundConnection
8 Cascade Separate True Earth Ground
9 Control Unit Separate True Earth Ground
Figure 4: Typical Installation 80143-XXX
10”VERSION80120-X1X
19”VERSION80100-X1X
5
6
2
3
8
7
4
9
1
Item # Description
TYPICAL INSTALLATION 80143-XXX
CP-13-01-R5 (10/2019) 18 / 24 www.carlisleft.com
INSTALLATION
EN

Figure 5: High Voltage Cable A10560-XXD
CASCADE END
CASCADE GROUND CONNEC-
TION
APPLICATOR END
CONNECTION-CASCADEEND
Figure 6: Low Voltage Cable 79338-XX
CONNECTION-CONTROLUNIT
END
CABLE BOOT
CP-13-01-R5 (10/2019) 19 / 24 www.carlisleft.com
INSTALLATION
EN

Insert the grounded cable end of the high voltage cable and
the associated connector parts into the external cascade
in the order shown.
HIGH VOLTAGE CABLE TO CASCADE CONNECTION
Strain Relief
Before tightening the cable strain relief, assure the cable
is fully inserted and seated into the bottom of the high
voltage tube.
CP-13-01-R5 (10/2019) 20 / 24 www.carlisleft.com
INSTALLATION
EN