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NOTE

NOTE

NOTE

NOTE

W A R N I N G

!

 

†

Some codes may require the interlock wir-

ing to be run in conduit.  In this case, shielded 

cable is not necessary, but the conductors used 

should still meet the rating specified above.

 

†

The interlock contacts (supplied by user) 

should be rated for at least 1 amp at 240 VAC.

Max. Switching Capacity 

60W 

62.5VA

Max. Operating Voltage 

125VDC  125VAC

Max. Operating Current 

2A 

2A

 

†

An internal 24 VDC source voltage is 

available  at  TB2-1.    Using  a  jumper  wire,  this 

voltage may be connected to TB2-3 to be used 

as the source voltage for the relay contact 

outputs.  In this case, the total current sourced 

should not exceed 1 amp.

 

†

The total resistance of the series interlocks 

between L2 and L3 should be less than 300 Ω.

 

†

The Controller 

MUST

 be 

OFF

 when the 

applicator is removed or reinstalled.

HIGH VOLTAGE CABLE

Position the spray applicator in the spray area and route 

the high voltage cable to the Controller.  The cable 

should be routed so that it is not damaged by foot and 

vehicle traffic and also so that is not  close to areas 

of high temperature (129°F+).  The operator should 

have free movement of the applicator and all bend 

radii of the cable should not be less than 6-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 applicator, care should be 

taken when reinstalling so that the high voltage cable 

is completely engaged.

RELAY CONTACT OUTPUTS

A set of relay contacts for high voltage (CR1) and 

fault (CR2) conditions is provided at TB2-4 and TB2-2 

(See Figure 9).  One end of these relay contacts are 

connected together and also connected to a source 

input terminal TB2-3 (See Figure 12).  When a source 

voltage is present at TB2-3 and either the high voltage 

is on or a fault condition occurs, the source voltage will 

become available at the output end of the corresponding 

contact.  Maximum contact ratings for the relays are 

as follows:

When wiring to TB2, use a shielded cable and route the 

wiring through the standard I/O connector as described 

in the “I/O Connectors” section of this manual.

MAXIMUM CONTACT RATINGS

Description

DC

AC

HANDGUN TRIGGER SIGNAL

Handguns use a flow switch (13742-01 or 13742-02) 

to provide the trigger signal.  One of the listed flow 

switches is mounted inside the 9060 Controller chassis 

via the Air Flow Switch Connector on the side panel.  

When the handgun trigger is pressed and flow starts, 

the flow switch is activated and triggers the high voltage.  

CP-17-02

18

9060 Classic High Voltage Controller -

 

INSTALLATION

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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