Ransburg 9060 User manual

9060 HIGH VOLTAGE
CONTROLLER
(HV1 - AUTOMATIC GUNS)
MODEL: 80100-XXX
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.
CP-13-05.4
SERVICE MANUAL
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NOTE: This manual has been changed from revision CP-13-05.3 to revision
CP-13-05.4. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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MANUAL CHANGES

CONTENTS
SAFETY: 5-9
Safety Precautions ................................................................................................................................................5
Hazards / Safegaurds ............................................................................................................................................6
INTRODUCTION: 10-18
General Description............................................................................................................................................. 10
Safety Features ................................................................................................................................................... 10
Displays............................................................................................................................................................... 10
Specications .......................................................................................................................................................11
Controller Features.............................................................................................................................................. 12
Operator Interface ............................................................................................................................................... 13
Switches .............................................................................................................................................................. 13
LEDs.................................................................................................................................................................... 13
Buttons ................................................................................................................................................................ 13
Connection Interface ........................................................................................................................................... 14
Connectors .......................................................................................................................................................... 14
Fuses................................................................................................................................................................... 15
Local/Remote Board............................................................................................................................................ 15
Signal Interface - Local Mode.............................................................................................................................. 15
Signal Interface - Remote Mode.......................................................................................................................... 16
INSTALLATION: 19-28
General Information ............................................................................................................................................ 19
Location of the 9060 ........................................................................................................................................... 19
Electrical Noise.................................................................................................................................................... 19
I/O Connections................................................................................................................................................... 20
AC Input Connections ......................................................................................................................................... 21
Safety Ground .................................................................................................................................................... 22
Input Voltage Selection ....................................................................................................................................... 22
Interlocks ............................................................................................................................................................. 22
High Voltage Cable ............................................................................................................................................. 23
Relay Contact Outputs ........................................................................................................................................ 23
Controller Schematic .......................................................................................................................................... 24
Local Mode.......................................................................................................................................................... 25
Remote Mode External Signals........................................................................................................................... 26
OPERATION: 29-41
Start-Up ...............................................................................................................................................................29
Basic Operations .................................................................................................................................................29
DI/DT Conguration..............................................................................................................................................31
Lockouts ..............................................................................................................................................................31
KV Test Jumper ...................................................................................................................................................33
Remote I/O Monitoring Dianostic Mode................................................................................................................33
Parameter Adjustment Mode................................................................................................................................35
Local Mode Only Operations................................................................................................................................36
Remote Mode Only Operations............................................................................................................................36
Fault Descriptions ................................................................................................................................................39
(Continued On Next Page)
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CONTENTS

MAINTENANCE: 42-44
Troubleshooting Guide ....................................................................................................................................... 42
Fault Troubleshooting Guide .............................................................................................................................. 42
PARTS IDENTIFICATION: 45-46
High Voltage Controller Model Identication - Parts List .................................................................................... 45
9060 High Voltage Controller - Parts List ............................................................................................................ 46
Accessories ........................................................................................................................................................ 46
CONTENTS (Cont.)
MANUAL CHANGE SUMMARY: 51
Manual Changes ................................................................................................................................................ 51
WIRING CONFIGURATIONS: 47-50
Common Remote Congurations ....................................................................................................................... 47
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CONTENTS

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any Ransburg
electrostatic coating system , read and understand all of the
technical and safety literature for your Ransburg products.
This manual contains information that is important for you
to know and understand. This information relates to USER
SAFETY and PREVENTING EQUIPMENT PROBLEMS.
To help you recognize this information, we use the following
symbols. Please pay particular attention to these sections.
A WARNING! states information to alert you to
a situation that might cause serious injury if
instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard specications and service
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and appropriate Ransburg
equipment manuals to reconcile such differences.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
in more efcient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system, contact your
local Ransburg representative or Ransburg.
WARNING
!
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the Ransburg
safety literature therein identied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly
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.
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.
SAFETY
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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.
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

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

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re
or explosion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on
conveyors or hangers that are properly grounded.
The resistance between the part and earth ground
must not exceed 1 meg ohm. (Refer to NFPA-33.)
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator
via conductive gloves or gloves with the palm section
cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
Grounded conductive ooring must be provided in
the spray area.
Always turn off the power supply prior to ushing,
cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Avoid installing an applicator into a uid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY

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

INTRODUCTION
GENERAL DESCRIPTION
The Ransburg 9060 High Voltage Controller (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
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 can operate in either LOCAL mode
or REMOTE mode conditions. In the LOCAL mode, the
selection and adjustment of set point values is performed
from the controller front panel. The triggering of the HV
in LOCAL mode is initiated by the optional airow switch
built into the controller (which senses airow triggered
by a standard handgun) 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 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 the gun current output. The gun current
is derived from feedback signals in the low voltage cable
between the controller and the cascade.
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
Part # Description
Figure 1: 9060 High Voltage Controller
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INTRODUCTION

SPECIFICATIONS
Physical
Environmental
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
Height: 16.5 cm (6.5 inches)
Width: 37.8 cm (14.9 inches)
Depth: 30.7 cm (12.1 inches)
Weight: 10.2 kg (22.5 lbs.)
Electrical
Input Voltage: 100-240 VAC
Frequency: 50 or 60 Hz
Current: 1 A max. RMS
Wattage: 40 watts (max.)
Output Voltage: 20-90kV MAX. DC, adjustable in 1kV increments
Ground: Use known good earth ground
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INTRODUCTION

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
Figure 2: 9060 High Voltage Controller Features
9060 CONTROLLER FEATURES
Description Description
No.No.
9 kV Setpoint/Adjust Buttons
10 Optional 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
FRONT VIEW
SIDE VIEW
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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 deter-
mined by the microprocessor. When a fault occurs the light
will turn on and the identi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 informa-
tion 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 specic 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 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.
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INTRODUCTION

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 operating mode
are used to modify, decrease and increase respectively,
the currently selected preset value. If the button is pressed
and released, the preset value is changed by 1 kV at a
time. If the button is held for over a 1/2 second, the value
will begin changing by 5 kV increments.
Reset Button
The reset button is used in 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
conditions from triggering a new fault.
Figure 4: 9060 Connection Interface
NOTE
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, indi-
cates 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 connections for setting up
either a remote I/O controlled painting system or 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) optional air ow switch
connection, two (2) fuses, and one (1) AC inlet receptacle.
CONNECTORS
High Voltage Cable Connector
The high voltage cable connector is the largest connector
and is located on the far right of the connection interface.
The connector will come covered with a factory installed
red protective cap. This connector is designed for use
with standard high voltage cables such as A10560, 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.
For more information on remote I/O signal wiring, see the
“Installation” section of the service manual.
Interlock I/O Connector
The interlock I/O connector is located just above theAC 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.
There is a 5 second fault reset delay timer that
inhibits the triggering of high voltage immediately
after a fault reset.
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.
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INTRODUCTION

Air Flow Switch Connection (Optional)
The air ow switch connection can be installed to provide
a pneumatic trigger signal for handguns 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 ow 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 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.
LOCAL/REMOTE BOARD
The 9060 Controller contains a local/remote trigger protec-
tion board that is used to protect against falsely triggering the
High Voltage when the unit is not in the desired operating
mode. As the 9060 Controller was designed to operate in
either LOCAL or REMOTE mode, it must be congured for
the desired mode of operation.
If congured 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 congured 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.
NOTE
A slight delay, 300 milliseconds, is imposed
between mode changes and the high voltage from
being activated. This is to prevent a trigger signal
that may already be present from instantly turning on
the high voltage when a mode change occurs.
SIGNAL INTERFACE -
LOCAL MODE
The 9060 Controller LOCAL mode is normally used for
handguns, or very simple automatic gun systems. Hand-
guns 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 congured for either LOCAL or REMOTE mode
prior to operation. This signal can be congured as either
a sourcing or a sinking signal. Please refer to the “Instal-
lation” section of this service manual for LOCAL mode
conguration 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 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.
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INTRODUCTION

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 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.
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 andTB3.
The 9060 High Voltage Controller remote mode signal in-
terface is composed of ve (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.
NOTE
Example remote I/O conguration diagrams are
provided in the Wiring Congurations section at the
end of this manual.
Digital Inputs
All of the digital inputs on the 9060 High Voltage Controller are
24 VDC signals that can be congured as either all sourcing
or all sinking inputs. The trigger signal is congured on the
Local/Remote Board. For information regarding conguring
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 immedi-
ately after resetting. Please refer to the “Operation” section
of this service manual for fault reset and troubleshooting
information.
NOTE
Sinking and Sourcing refers to the signal 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.
NOTE
There is a 5 second fault reset delay timer that
inhibits the triggering of high voltage immediately af-
ter a fault reset.
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 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 combi-
nations and their resulting selection are listed in the Triple
Set Combinations table. These signals can only be used
when the Remote Mode Conguration is set to disable
Analog Control. For more information on how to congure
Remote Mode, please see the Operation section of this
service manual.
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INTRODUCTION

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 specic gun conguration.
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 setpoint 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 outputting 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 con-
trol 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 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 (2mAper 10kV). When the analog signal is less
than 4mA, the KV setpoint is set to 0kV and the cascade
outputs no voltage.
NOTE
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 pro-
vided 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 Remote Mode Conguration is set to
enable Analog Control. For more information on how to
congure Remote Mode, please see the Operation section
of this Service manual.
The tripleset signals can be used to select a
preset from the three (3) preset voltages. The preset
values can NOT be adjusted 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.
TRIPLE SET COMBINATIONS
0 (off) 0 (off) No Change
0 (off) 1 (on) Preset 1
1 (on) 0 (off) Preset 2
1 (on) 1 (on) Preset 3
Setpoint 1 Setpoint 0 Selection
NOTE
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cient to override KV setpoint control.
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 common 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 sig-
nal scaled to represent a 0-200µA current output range
(20µA/1V or approximately 1uA/50mV). The current signal
provided can easily be integrated with common systems
like PLCs.
WARNING
!
DO NOT attempt to use both analog voltage
and analog current at the same time. The analog
inputs are mutually exclusive. Using both inputs
simultaneously will damage the input circuit. Only
one analog input, current or voltage, can be used at
time to control the setpoint value.
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INTRODUCTION

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 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 available in both LOCAL and
REMOTE modes. This signal, being 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.
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.
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INTRODUCTION

INSTALLATION
WARNING
!
GENERAL INFORMATION
The following section contains general information on the
installation of both local and remote systems using the
9060 High Voltage Controller.
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.
The Controller may be free standing on any at surface or
wall mounted (wall mount brackets not supplied) as shown
in Figure 5.
Figure 5: Typical Controller Mounting
LOCATION OF THE 9060
Install the Controller in an area outside the hazardous
location in accordance with federal, state, and local codes.
The area should protect the Controller from the possibility
of environmental intrusion (such as dust or moisture), have
ambient temperatures that do not exceed 40°C, and be as
close to the applicator as possible to minimize the length
of the high voltage cable.
NOTE
CAUTION
!
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.
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.
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INSTALLATION

Figure 6: Pigtailing Connection
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
remote I/O control signals including the relay controlled
DC I/O (high voltage output signal, fault output signal).
Again, for maximum noise immunity the cabling must con-
tain overall foil and braided shields and be terminated in
a continuous 360° manner as described in the preceding
paragraph. Special ttings have been provided on the
control panel for termination of these cables at that point.
The use of these ttings is described in the corresponding
sections of this manual.
Using the methods previously described, the 9060 Controller
have been successfully tested to the stringent standards of
the Electromagnetic Compatibility Directive of the European
Union. The results conclude that these units are neither a
source of electrical noise nor affected by electrical noise
when the above methods are utilized.
For conductors inside the control unit or Controller, the
grounded enclosures provide this envelope. For the cables
that connect the applicator to the control unit or Controller,
a shielded cable has been used. The shield consists of
an overall foil shield in combination with an overall braided
shield. This provides the most effective shielding, as the
foil covers the “holes” in the braid, and the braid allows for
practical 360° termination at both ends of the cable.
The AC input cord is not shielded, but is directed to an AC
line lter as soon as it enters the cabinet. This method
lters out most of the noise that comes in on the AC line.
For maximum noise immunity, if the AC line is wired using
conduit instead of the provided AC line cord, it should
connect to the lter as soon as it enters the cabinet with
as short of leads as possible. Additional noise protection
can be provided by running the AC input line to the control
panel in grounded conduit.
For maximum noise protection any user supply input/
output (I/O) wiring should be made using shielded cable
(or conduit) which is connected to earth ground in a con-
tinuous 360° fashion at both ends. The best way to do this
is to use a connector (conduit tting) at each end of the
cable (conduit) that makes contact to the shield (conduit)
in a full 360° circle around the cable (conduit) and makes
contact to the grounded enclosure in the same fashion.
Connecting the drain wire of a shield to a ground point on
or in the cabinet (usually referred to as pigtailing) is not
an effective method of shielding and actually makes things
worse (see Figure 6).
I/O CONNECTIONS
For maximum noise immunity, I/O wiring should be run in
conduit or cables having a foil shield with an overall braid-
ed 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 con-
nector 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.
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INSTALLATION