Ransburg 80100 Series User manual

MODEL: 80100-XXX
IMPORTANT: Before using this equipment, carefully read
AFETY PRECAUTION , starting on page 1, and all instructions
in this manual. Keep this ervice Manual for future reference.
ervice Manual Price: $50.00 (U. .)
ervice Manual Price: $50.00 (U. .)ervice Manual Price: $50.00 (U. .)
ervice Manual Price: $50.00 (U. .)
SERVICE MANUAL
CP-13-05.3
FEBURARY — 2014
9060 HIGH VOLTAGE CONTROLLER
(HV1—Automatic Guns)

CP-13-05.3

9060 High Voltage Controller - Contents
CP-13-05.3
CONTENTS
PAGE
SAFETY: 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
SPARE 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
RELAY CONTACT OUTPUTS ................................................................................................ 23
LOCAL MODE SIGNALS ................................................................................................... 24-25
REMOTE I/O MODE SIGNALS .......................................................................................... 25-28
OPERATION: 29-42
START-UP.............................................................................................................................. 29
BASIC OPERATIONS........................................................................................................ 29-30
DI/DT CONFIGURATION (80100-51X UNITS ONLY) ............................................................. 31

9060 High Voltage Controller - Contents
CP-13-05.3
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................................................................................ 37-40
FAULT DESCRIPTIONS.................................................................................................... 40-42
MAINTENANCE: 43-46
TROUBLESHOOTING GUIDE................................................................................................ 43
FAULT TROUBLESHOOTING GUIDE............................................................................... 43-45
PARTS: 47-48
HIGH VOLTAGE CONTROLLER MODEL IDENTIFICATION ................................................. 47
PARTS LIST ........................................................................................................................... 48
ACCESSORIES: 49
ACCESSORIES LIST.............................................................................................................. 49
WARRANTY POLICIES: 50
LIMITED WARRANTY ............................................................................................................ 50
WIRING CONFIGURATIONS: 51-54
COMMON REMOTE CONFIGURATIONS ......................................................................... 51-54

CP-13-05.3

9060 High Voltage Controller - Safety
1 CP-13-05.3
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 infor-
mation relates to USER SAFETY and PRE-
VENTING EQUIPMENT PROBLEMS. To help
you recognize this information, we use the fol-
lowing symbols. Please pay particular attention
to these sections.
A WARNING! states information to alert you
to a situation that might cause serious inju-
ry 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 pro-
cedure in progress.
While this manual lists standard specifications
and service procedures, some minor devia-
tions may be found between this literature and
your equipment. Differences in local codes and
plant requirements, material delivery require-
ments, etc., make such variations inevitable.
Compare this manual with your system instal-
lation drawings and appropriate Ransburg
equipment manuals to reconcile such differ-
ences.
Careful study and continued use of this manual
will provide a better understanding of the
equipment and process, resulting in more effi-
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.
SAFETY


 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.
! W A R N I N G
! W A R N I N G


 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.

9060 High Voltage Controller - Safety
CP-13-05.3 2
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 opera-
tion and maintenance proce-
dures will cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation. Frequent Con-
troller 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, 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 respon-
sibility 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 unauthor-
ized 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 disa-
bled.
Never use equipment intended for use in water-
borne installations to spray solvent based mate-
rials.
The paint process and equipment should be set
up and operated in accordance with NFPA-33,
NEC, and European Health and Safety Norms.

9060 High Voltage Controller - Safety
3 CP-13-05.3
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area
Fire and/or explosion. Electrostatic arcing MUST be prevented.
The 78789 control panel, LEPS5001 power sup-
ply and all other electrical equipment must be
located outside Class I or II, Division 1 or 2 haz-
ardous areas, in accordance with NFPA-33.
Test only in areas free of flammable or combus-
tible 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 cur-
rent overload sensitivity is not properly
set. Frequent power supply shutdown indicates
a problem in the system which requires correc-
tion.
Always turn the control panel off prior to flush-
ing, cleaning, or working on spray system equip-
ment.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accord-
ance with NFPA-33, EN 50 176.
Have fire extinguishing equipment readily availa-
ble and tested periodically.
General Use and
Maintenance
Improper operation or mainte-
nance may create a hazard.
Personnel must be properly
trained in the use of this equip-
ment.
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 equip-
ment.
Comply with appropriate local, state, and nation-
al codes governing ventilation, fire protection,
operation maintenance, and housekeeping. Ref-
erence OSHA, NFPA-33, EN Norms and your
insurance company requirements.

9060 High Voltage Controller - Safety
CP-13-05.3 4
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
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.
Protection against inadvertent arc-
ing that may cause a fire or explo-
sion is lost if safety circuits are dis-
abled during operation.
Frequent power supply shut-down
indicates a problem in the system
which requires correction.
An electrical arc can ignite coating
materials and cause a fire or explo-
sion.
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
the equipment.
Test only in areas free of flammable or com-
bustible material.
Testing may require high voltage to be on, but
only as instructed.
Production should never be done with the
safety circuits disabled.
Before turning the high voltage on, make sure
no objects are within the sparking distance.
Toxic Substances
Certain material may be harmful if
inhaled, or if there is contact with
the skin.
Follow the requirements of the Material Safe-
ty Data Sheet supplied by coating material
manufacturer.
Adequate exhaust must be provided to keep
the air free of accumulations of toxic materi-
als.
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. Equip-
ment must be as prescribed by an industrial
hygienist or safety expert, and be NIOSH ap-
proved.

9060 High Voltage Controller - Safety
5 CP-13-05.3
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 un-
grounded objects which
is capable of igniting coat-
ing materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many
coating materials and
cause a fire or explosion.
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
process to be at high voltage, must be grounded.
Any person working in the spray area must be
grounded.
Unless specifically approved for use in hazardous lo-
cations, 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 Applica-
tions.

9060 High Voltage Controller - Safety
CP-13-05.3 6
N O T E S

9060 High Voltage Controller - Introduction
7 CP-13-05.3
INTRODUCTION
GENERAL DESCRIPTION
The Ransburg 9060 High Voltage Control-
ler (80100-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 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 adjust-
ment 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 hand-
gun) 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 High
Voltage Controller provides maximized opera-
tional safety. The protections include detection
of Boot Faults, Ground Faults, Cable Faults,
DISPLAYS
The front panel displays the high voltage set
point as well as a reading of the gun current
output. The gun current is derived from feed-
back signals in the low voltage cable be-
tween the controller and the cascade.
Figure 1: 9060 High Voltage Controller
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 high voltage
controller is based on load.
Part #: Description
80100-21X Non-Approved for use with Evolver SE
80100-31X Atex Approved for use with Esta-Quick
80100-41X Non-Approved for use with Evolver SE
80100-51X Atex Approved for use with Aerobell 168
The 9060 High Voltage Controller (80100-
XXX) is available as follows:

9060 High Voltage Controller - Introduction
CP-13-05.3 8
SPECIFICATIONS
Operating Temperature: 0°C to +40°C
Storage and Shipping
Temperature: -40°C to +85°C
(Allow power supply to go to room temperature
before use)
Humidity: 95% Non-Condensing
Electrical
Input Voltage: 100-240 VAC
Frequency: 50 or 60 Hz
Current: 1 A max. RMS
Wattage: 40 watts (max.)
Output Voltage: 20-90kV MAX DC,
adjustable in
1kV increments
Ground: Use known good earth ground
Physical
Environmental
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.)

9060 High Voltage Controller - Introduction
9 CP-13-05.3
No. Description No. Description
1 kV Display 9 kV Setpoint/Adjust Buttons
2 High Voltage On Indicator 10 Optional Air Flow Switch Hose Connections
3 Reset Button 11 High Voltage Cable Connector
4 µA Display 12 Standard I/O Connector
5 Fault Indicator 13 Fuses
6 On-Off Switch 14 Ground Lug
7 Local/Remote Mode Indicator 15 AC Inlet Receptacle
8 “One Touch” kV Setpoint Buttons 16 Interlock I/O Connector
9060 CONTROLLER FEATURES
Figure 2: 9060 High Voltage Controller Features

9060 High Voltage Controller - Introduction
CP-13-05.3 10
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 bar-
graph, 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 determined by the microprocessor. When a
fault occurs the light will turn on and the identifi-
cation 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 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 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)
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.
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, 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 LOCAL operating mode. If

9060 High Voltage Controller - Introduction
11 CP-13-05.3
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 LOCAL 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 (to the right below the kV
display) is used by itself to select “Voltage
Preset 3” in the LOCAL operating mode.
Left (-)/Right (+) Buttons
The left(-)/right(+) buttons in the LOCAL operat-
ing 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 LOCAL or REMOTE
operating mode to clear fault or overload
conditions when the trigger signal is OFF. This
will NOT prevent any other active fault condi-
tions 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, 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.
CONNECTION INTERFACE
The 9060 Controller connection interface shown
in Figure 4, provides all of the required connec-
tions for setting up either a remote I/O con-
trolled painting system or a local controlled
painting system. This connection interface
consists of one (1) high voltage cable connect-
or, one (1) standard I/O connector, one (1)
interlock I/O connector, one (1) ground lug
connection, one (1) optional air flow switch
connection, two (2) fuses, and one (1) AC inlet
receptacle.
Figure 4: 9060 Connection Interface
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 A10560,
79518, and 79519. The specific 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. For more information on
remote I/O signal wiring, see the “Installation”
section of the service manual.
 There is a 5 second fault reset delay
timer that inhibits the triggering of high
voltage immediately after a fault reset.
N O T E

9060 High Voltage Controller - Introduction
CP-13-05.3 12
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
(Optional)
The air flow switch connection can be installed
to provide a pneumatic trigger signal for hand-
guns 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 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 connec-
tion and the neutral input connection of the
AC line power filter.
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.
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 opera-
tion.
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.
 A slight delay, 300 milliseconds, is im-
posed between mode changes and the
high voltage from being activated. This is
to prevent a trigger signal that may al-
ready be present from instantly turning on
the high voltage when a mode change
occurs.
N O T E

9060 High Voltage Controller - Introduction
13 CP-13-05.3
SIGNAL INTERFACE -
LOCAL MODE
The 9060 Controller LOCAL mode is normal-
ly used for handguns, or very simple auto-
matic 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 2 terminal
blocks, TB2 and TB3.
Trigger Signal
The trigger signal input (TB3-5) 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 “HV on” signal (TB2-4) 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 (TB2-2) 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 Condi-
tion 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.
SIGNAL INTERFACE -
REMOTE MODE
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 2 terminal
blocks, TB2 and TB3.
The 9060 High 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.
Digital Inputs
All of the digital inputs on the 9060 High
Voltage Controller are 24 VDC signals that
 Example remote I/O configuration dia-
grams are provided in the Wiring Configu-
rations section at the end of this manual.
N O T E

9060 High Voltage Controller - Introduction
CP-13-05.3 14
can be configured as either all sourcing or all
sinking inputs. For information regarding
configuring the inputs, refer to the
“Installation” section of this manual.
Local/Remote Mode Signal
The local/remote mode signal (TB3-2)
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 (TB3-1) 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 (TB3-5) is used to
indicate to the 9060 Controller to turn on the
high voltage.
Tripleset Signals
(Setpoint 0 and Setpoint 1)
The tripleset signals, Setpoint 0 and Setpoint
1 (TB3-3 and TB3-4), are a pair of signals
that are used to select one of the three
Setpoint 1 Setpoint 0 Selection
0 (off) 0 (off) No Change
0 (off) 1 (on) Preset 1
1 (on) 0 (off) Preset 2
Triple Set Combinations
1 (on) 1 (on) Preset 3
 The tripleset signals can be used to se-
lect a preset from the three (3) preset volt-
ages. The preset values can NOT be ad-
justed 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.
N O T E
Analog Inputs
Two (2) analog input signals, along with an
analog common input, are provided on the
9060 High 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.
These signals can only be used when the
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. These signals can only
be used when the Remote Mode Configura-
tion is set to disable Analog Control. For
more information on how to configure
Remote Mode, please see the Operation
section of this service manual.
 Sinking and Sourcing refers to the sig-
nal that is applied to activate an input. If
you are applying a +24 VDC signal to the
input to activate it, you are sourcing. If
you are applying a GROUND signal to the
input, you are sinking.
N O T E
 There is a 5 second fault reset delay
timer that inhibits the triggering of high
voltage immediately after a fault reset.
N O T E

9060 High Voltage Controller - Introduction
15 CP-13-05.3
Remote Mode Configuration is set to enable
Analog Control. For more information on how
to configure Remote Mode, please see the
Operation section of this Service manual.
Analog Setpoint Control
In analog setpoint control, the unit will output
voltage from the minimum voltage of 20kV (2V
or 4mA) up to the maximum kV allowed for the
specific gun configuration. Depending on the
analog control signal being used, the signal
can be adjusted from 0-10V (or 0-20mA) which
are mapped directly to 0-100kV. For example,
8 VDC (or 16mA) will produce an 80kV set-
point if it is within the maximum voltage of the
applicator. After the applicator’s maximum
setpoint is reached, further increases in analog
signal will NOT result in a setpoint increase.
The lower part of the range below 2V (4mA)
will set the cascade to output 0kV allowing for
the cascade to remain energized while output-
ting no voltage. The analog control signal
value can be adjusted at any time during
operation of the unit as long as the unit is in
remote mode, regardless of the state of the HV
trigger signal.
Analog Voltage Signal
The analog voltage signal (TB3-7) 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 mapped directly to a setpoint
range of 0-100kV, or (1V per 10kV). When the
analog signal is less than 2V, the KV setpoint
is set to 0kV and the cascade outputs no
voltage.
Analog Current Signal
The analog current signal (TB3-6) is an input
 Although the allowable range for the
analog current signal does include 0mA-
3mA, it will normally be listed as 4-20mA
as the 0-3mA portion of the range is insuf-
ficient to override KV setpoint control.
N O T E
control signal that adjusts the KV setpoint
scaled relative to the current signal applied.
The allowable range for the current control
signal is 0-20mA mapped directly to a setpoint
range of 0-100kV, or (2mA per 10kV). When
the analog signal is less than 4mA, the KV
setpoint is set to 0kV and the cascade outputs
no voltage.


 DO NOT attempt to use both analog
voltage and analog current at the same
time. The analog inputs are mutually ex-
clusive. Using both inputs simultaneous-
ly will damage the input circuit. Only one
analog input, current or voltage, can be
used at time to control the setpoint value.
! W A R N I N G
Analog Common Signal
The analog common signal (TB3-8) is the
connection for the common reference (-) of the
analog signal source. It is used as the com-
mon for both the voltage and current signal.
Analog Output
The 9060 High 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 output signal (TB3-9) is a 0
-10V signal scaled to represent a 0-200µA
current output range (20µA/1V or approximate-
ly 1uA/50mV). The current signal provided can
easily be 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.