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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 flow 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 specific cable required 

depends on the applicator being used. Please refer to 

the applicator manual for the cable required.  

Standard I/O Connector

The standard I/O connector is located just left of the high 

voltage cable connector.  This connector is provided 

as the entry point for a shielded multi-conductor cable 

used for remote I/O signals and includes  the required 

cable grommet hardware to keep the cable in place 

with minimal strain.  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 flow 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 flow switch will come covered with 

red protected caps.

AC Inlet Receptacle

The AC inlet receptacle is a standard IEC C14 Appliance 

Inlet connector with a maximum rating of 250 VAC.  It 

can handle both 110VAC and 240 VAC inputs at 50 or 

60 Hz.  The unit is shipped with the appropriate rated 

AC cord for the particular installation.

CP-17-02

10

9060 Classic High Voltage Controller -

 

INTRODUCTION

Summary of Contents for 80180-212

Page 1: ...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...

Page 2: ...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 Rela...

Page 3: ...S PARTS IDENTIFICATION 29 31 9060 High Voltage Controller Model Identification 29 Parts List 30 Accessories 31 WARRANTY POLICIES 32 Limited Warranty 32 CP 17 02 9060 Classic High Voltage Controller CO...

Page 4: ...se 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 tha...

Page 5: ...f 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...

Page 6: ...vertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which requi...

Page 7: ...ring 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...

Page 8: ...tact 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...

Page 9: ...and cascades the Ransburg 9060 High Voltage Controller providesmaximizedoperationalsafety Theprotections include detection of Boot Faults Ground Faults Cable Faults Feedback Signal Faults Overvoltage...

Page 10: ...ing 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 Watt...

Page 11: ...n 4 A Display 5 Fault Indicator 6 On Off Switch 7 Local Remote Mode Indicator 8 One Touch kV Setpoint Buttons Description No 9 kV Setpoint Adjust Buttons 10 Air Flow Switch Hose Connections 11 High Vo...

Page 12: ...dicators are located directly above each of the Preset Buttons When a preset buttonispushedtoselect thedesiredpreset inREADY mode thepresetLEDindicatordirectlyabovethebutton pressed will light up Only...

Page 13: ...rovided 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 connect...

Page 14: ...preconfigured as a sinking signal input wired directly to the air flow switch Please refer to the Installation section of this service manual for more information High Voltage On Relay Output Dry Cont...

Page 15: ...ller 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 possibletominimizethelengthofthehig...

Page 16: ...to do this is to use a connector conduit fitting 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 groun...

Page 17: ...strip marked 1 section to cable braid 4 Slide the cable grommet hardware onto the cable in the order shown in Figure 7 5 Routethecablebackthroughtheconnectorhousing and connect its wires to the desire...

Page 18: ...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 c...

Page 19: ...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 Interlo...

Page 20: ...Figure 12 Controller Schematic CP 17 02 17 9060 Classic High Voltage Controller INSTALLATION...

Page 21: ...inches 15 cm Connect the high voltage cable to the Controller and tighten the retaining nut and set screw If during the routing of the high voltage cable it is required to remove it from the spray app...

Page 22: ...n the Controller cabinet door 3 Theflowswitchshouldhavetheground green lead connected to the ground screw on the base plate shown in Figure 13 The trigger signal blue lead should be connected to the t...

Page 23: ...ly 5 seconds START UP DISPLAY Type Unit Gun Jumpers The controller comes preconfigured for its correspond ing handgun from the factory The following table lists the applicator types shown on the displ...

Page 24: ...reset button while the hours are displayed To view the non resettable register press the preset 2 and reset buttons at the same time This display will show the hours for 3 seconds LOCKOUTS There are l...

Page 25: ...ssories section of this manual for part numbers for testing equipment KV TEST JUMPER To assist in testing and troubleshooting a jumper J8 has been added to the main PC board By covering shorting both...

Page 26: ...e 22 Single pushes of the or buttons will increment or decrement the currently selected preset in units of 1 When the or buttons are held in for longer than a 1 2 second the kV display will begin incr...

Page 27: ...ase b for a boot fault Ground Fault GF If this fault occurs the fault indicator on the control unit will illuminate a GF indication will show in the uA dis play This fault will occur if the microproce...

Page 28: ...e applicator check the paint formulation or replace the pc board See Fault Troubleshooting Section for more information Overload Fault OL This fault will occur if the overload feature is active see Ov...

Page 29: ...Replace power switch See Parts Identification Section Send unit in for repair W A R N I N G Before troubleshooting gun and control unit problems flush the gun with solvent and purge with air Some of t...

Page 30: ...high voltage on 1 Check for loose wiring between the pc board connector and the high voltage section by pulling on each wire Repair if necessary Insure both connectors are secure and re test for GF fa...

Page 31: ...tor tube 4 To test the resistor tube remove the resistor tube from the gun and inspect for signs of burning or arcing Cracks or black marks indicatefailureoftheresistortube indicating theresistortubem...

Page 32: ...assembly When ordering use 80180 A1B as indicated by Tables A and B Three 3 digits must follow the basic part number For Example 80180 A 1B TABLE B PLUG SELECTION TABLE A MODEL SELECTION BASIC PART NU...

Page 33: ...rd for 80180 212 79428 00 Power Supply 24V 24VDC Power Supply 1PS 76434 01 Switch Rocker On Off Switch 79350 XX 9060 High Voltage Cascade Figure 31 Part Identifications 9060 HIGH VOLTAGE CONTROLLER PA...

Page 34: ...e w Meter 76652 04 Deluxe Kit Include HV Probe Meter w Test Leads and Paint Test Probe 76453 00 Conduit Adapter Kit 9060 HIGH VOLTAGE CONTROLLER ACCESSORIES LIST Part No Description Return To Contents...

Page 35: ...ESANDTUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP ORANYOTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED...

Page 36: ...Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Phillips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 2015 Carlisle F...

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