Ransburg 9060 User manual

SERVICE MANUAL
CP-17-02
AUGUST - 2017 Ransburg
9060 CLASSIC HIGH VOLTAGE
CONTROLLER
(HV3 - Handguns)
Service Manual Price: $50.00 (U.S.)
IMPORTANT: Before using this equipment, carefully read SAFETY
PRECAUTIONS, starting on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
MODEL: 80180-212

CONTENTS
SAFETY: 1-5
Safety Precautions ......................................................................................................................................... 1
Hazards / Safeguards ..................................................................................................................................... 2
General Description ........................................................................................................................................6
Safety Features ...............................................................................................................................................6
Displays...........................................................................................................................................................6
Specications ..................................................................................................................................................7
Controller Features..........................................................................................................................................8
Operator Interface ...........................................................................................................................................9
Switches ..........................................................................................................................................................9
LEDs................................................................................................................................................................9
Buttons ............................................................................................................................................................9
Connection Interface .....................................................................................................................................10
Connectors ....................................................................................................................................................10
Fuses............................................................................................................................................................. 11
Signal Interface.............................................................................................................................................. 11
INTRODUCTION: 6-11
INSTALLATION: 12-19
General Information ..................................................................................................................................... 12
Location of the 9060..................................................................................................................................... 12
Electrical Noise..............................................................................................................................................13
I/O Connections.............................................................................................................................................14
AC Input Connections....................................................................................................................................14
Safety Ground ...............................................................................................................................................16
Input Voltage Selection..................................................................................................................................16
Interlocks .......................................................................................................................................................16
High Voltage Cable........................................................................................................................................18
Relay Contact Outputs ..................................................................................................................................18
Handgun Trigger Signal.................................................................................................................................18
OPERATION: 20-25
Start-Up ......................................................................................................................................................... 20
Basic Operations ........................................................................................................................................... 20
Lockouts ........................................................................................................................................................21
KV Test Jumper .............................................................................................................................................22
Setpoint Operations.......................................................................................................................................22
Fault Descriptions..........................................................................................................................................23
MAINTENANCE: 26-28
Troubleshooting Guide .................................................................................................................................. 26
Fault Troubleshooting Guide ......................................................................................................................... 26
CP-17-02
9060 Classic High Voltage Controller - CONTENTS

CONTENTS
PARTS IDENTIFICATION: 29-31
9060 High Voltage Controller Model Identication......................................................................................... 29
Parts List........................................................................................................................................................ 30
Accessories ................................................................................................................................................... 31
WARRANTY POLICIES: 32
Limited Warranty ........................................................................................................................................... 32
CP-17-02
9060 Classic High Voltage Controller - CONTENTS

W A R N I N G
!
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
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 50176 SAFETY STANDARDS, LATEST
EDITION, or applicable country safety standards,
prior to installing, operating, and/or servicing this
equipment.
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. Dierences
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 dierences.
Careful study and continued use of this manual will provide
a better understanding of the equipment and process,
resulting in more e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
W A R N I N G
!
The hazards shown on the following pages
may occur during the normal use of this equipment.
Please read the hazard chart beginning on page 2.
Return To Contents
CP-17-02 1
9060 Classic High Voltage Controller - SAFETY

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.
When using solvents for cleaning:
• Those used for equipment ushing should have
ash points equal to or higher than those of the
coating material.
• Those solvents used for general cleaning must
have a ash point at minimum of 15°C (27°F)
greater than the ambient temperature. It is the
end user’s responsibility to insure this condition
is met.
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.
Never use equipment intended for use in
waterborne installations to spray solvent
based materials.
The paint process and equipment should be
set up and operated in accordance with NFPA-
33, NEC, OSHA, local, country, and European
Health and Safety Norms.
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CP-17-02 2
9060 Classic High Voltage Controller - SAFETY

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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CP-17-02 3
9060 Classic High Voltage Controller - SAFETY

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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CP-17-02 4
9060 Classic High Voltage Controller - SAFETY

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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CP-17-02 5
9060 Classic High Voltage Controller - SAFETY

GENERAL DESCRIPTION
The Ransburg 9060 High Voltage Controller (80180-
212) 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)
80180-212 Vector R70AS Handgun
INTRODUCTION
9060 HIGH VOLTAGE
CONTROLLER
Description
Part #
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CP-17-02 6
9060 Classic High Voltage Controller - INTRODUCTION

SPECIFICATIONS
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
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.)
Physical:
Input Voltage: 100-240 VAC
Frequency: 50 or 60 Hz
Current: 1A RMS (max)
Wattage: 40 watts (max)
Output Voltage: 20-50 kV DC (max) adjustable in 1kV increments
Ground: Use known good earth ground
Electrical:
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CP-17-02 7
9060 Classic High Voltage Controller - INTRODUCTION

9060 CONTROLLER FEATURES
No. Description
Figure 2: 9060 High Voltage Controller Features
341 2
56
7
11
12
16 10
1314
15
8
9
FRONT VIEW
SIDE VIEW
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
DescriptionNo.
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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CP-17-02 8
9060 Classic High Voltage Controller - INTRODUCTION

OPERATOR INTERFACE
The 9060 Controller shown in Figure 3, has a simple
operator interface consisting of 7 LEDs (Light Emitting
Diodes), one (1) power switch, seven (7) buttons, one (1)
current LED bargraph, and two (2) screens containing
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 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.
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.
Figure 3: 9060 Operator Interface
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
operating 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.
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.
kV
CP-17-02 9
9060 Classic High Voltage Controller - INTRODUCTION

NOTE
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
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 con-
nector 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 con-
nectors of the air ow switch will come covered with
red protected caps.
AC Inlet Receptacle
TheAC inlet receptacle is a standard IEC C14Appliance
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.
CP-17-02 10
9060 Classic High Voltage Controller - INTRODUCTION

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 Relay Common Input as the signal source. For
information regarding the relay contact voltage ratings,
please refer to the “Relay Output Contacts” portion
of the “Installation” section of the manual. This relay
signal is activated when a Fault Condition or Overload
Condition has faulted the 9060 Controller.
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.
CP-17-02 11
9060 Classic High Voltage Controller - INTRODUCTION

NOTE
GENERAL INFORMATION
The following section contains general information on
the installation of 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.
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.
W A R N I N G
!
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.
INSTALLATION
CAUTION
!
FRONT VIEW
SIDE VIEW
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CP-17-02 12
9060 Classic High Voltage Controller - INSTALLATION

ELECTRICAL NOISE
Electrical noise refers to stray electrical signals in the
atmosphere at various signal strengths and frequencies
that can affect the operation of equipment. One of the
best ways to prevent this is to shield the equipment and
cables within a continuous ground envelope, such that
any incident noise will be conducted to earth ground
before it can affect the circuit conductors.
For conductors inside the control unit or Controller, the
grounded enclosures provide this envelope. For the
cables that connect the applicator to the control unit
or Controller, a shielded cable has been used. The
shield consists of an overall foil shield in combination
with an overall braided shield. This provides the most
effective shielding, as the foil covers the “holes” in the
braid, and the braid allows for practical 360° termination
at both ends of the cable.
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
theAC input line to the control panel in grounded conduit.
For maximum noise protection any user supply input/
output (I/O) wiring should be made using shielded
cable (or conduit) which is connected to earth ground
in a continuous 360° fashion at both ends. The best
way to do this is to use a connector (conduit 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.
Cable is recommended for all of the analog and digital
Figure 6: Pigtailing Connection
remote I/O control signals including the relay controlled
DC I/O (high voltage output signal, fault output signal).
Again, for maximum noise immunity the cabling
must contain overall foil and braided shields and be
terminated in a continuous 360° manner as described
in the preceding paragraph. Special 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.
PIGTAILS (POOR SHIELDING)
360° TERMANATION TO GROUND
(GOOD SHIELDING)
Return To Contents
CP-17-02 13
9060 Classic High Voltage Controller - INSTALLATION

Figure 8: I/O Cable Stripping
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.
Figure 7: Cable Grommet
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 AC outlet.
CABLE
GROMMET
CONNECTOR
HOUSING
INSIDE OF
CABINET
1” (2.54cm)
1/4” (0.64cm)
ANALOG I/O CABLE
CP-17-02 14
9060 Classic High Voltage Controller - INSTALLATION

NOTE
NOTE
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 the AC input wiring (0.8mm2(18AWG) min-
imum) through the Conduit Adapter Plate using
conduit and wire to TB1 as follows:
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.
Hot/Line to TB1-L1
Neutral/Common to TB1-N
Ground to TB1-EARTH GROUND
Figure 9: Location of TB1 & TB2 in Controller Figure 11: Installation of Conduit Adapter Plate
Interlocks should be DRY CONTACTS and
should be rated to handle 1 amp.
Interlock series resistance should not
exceed 20kΩ.
Figure 10: TB1 Interlock Wiring
SIDE VIEW
CP-17-02 15
9060 Classic High Voltage Controller - INSTALLATION

W A R N I N G
!
W A R N I N G
!
W A R N I N G
!
NOTE
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.
Failure to connect interlocks could result in
a re or explosion.
ALWAYS ensure that high voltage is OFF
before ushing the spray applicator with solvent.
NEVER ush the spray applicator with high volt-
age 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 sol-
vent ush signal so that high voltage is automati-
cally locked out whenever ushing occurs. Con-
sult 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.
Do NOT rely on the ground connection pro-
vided by generators and other portable power
generation devices.
The ground wire assembly MUST be con-
nected from the Controller ground stud to a true
earth ground.
All 9060 units shipped from the factory for
either 110 VAC input or 240 VAC input will have
a 72771-06, 1 Amp front panel fuses installed.
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.
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 (sup-
plied 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
reconnect the AC source.
CAUTION
!
CP-17-02 16
9060 Classic High Voltage Controller - INSTALLATION

Figure 12: Controller Schematic
CP-17-02 17
9060 Classic High Voltage Controller - INSTALLATION