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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 fire 

hazard.

Protection  against  inadvertent 

arcing that is capable of 

causing fire or explosion is lost 

if any safety interlocks  are  

disabled  during operation. 

Frequent 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, flushing or maintenance.

When using solvents for cleaning:
•  Those used for equipment flushing should have 

flash points equal to or higher than those of the 

coating material.

•  Those solvents used for general cleaning must 

have a flash 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  flammable  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 modifications may cause fire or injury.

If used, the key switch bypass is intended for use 

only during setup operations. Production should 

never be done with safety interlocks 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.

Return To Contents

CP-17-02

2

9060 Classic High Voltage Controller -

 

SAFETY

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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