Ransburg 9040 User manual

SERVICE MANUAL
CP-11- 01.02
9040 Low Voltage Control Unit KIT For The
ESTA-QUICK and Evolver SE Applicators
MODELS:
80072-XXX for use with Esta-Quick Applicator AEMD500 (Atex approved)
80078-XXX for use with Evolver SE (Not Approved)
IMPORTANT: Before using this equipment, care-
fully read SAFETY PRECAUTIONS, starting on
page 1, and all instructions in this manual. Keep
this Service Manual for future reference.

CP-11-01

9040 Low Voltage Control Unit Kit- Contents
CONTENTS
PAGE
SAFETY:
1-4
SAFETY PRECAUTIONS ............................................................................................................1
HAZARDS/SAFEGUARDS .......................................................................................................... 2-4
ATEX 5-6
EUROPEAN ATEX DIRECTIVE .................................................................................................5
EUROPEAN ATEX LABELS .......................................................................................................6
INTRODUCTION: 7-10
DESCRIPTION ............................................................................................................................ 7-9
SPECIFICATIONS .......................................................................................................................9
9040 CASCADE CONTROL UNIT FEATURES .........................................................................10
INSTALLATION: 11-20
LOCATION ...................................................................................................................................11
INPUT CONNECTIONS ..............................................................................................................11-12
EXTERNAL CONNECTIONS ......................................................................................................13-18
COMBINATION TRIPLE SETPOINT /
ANALOG INPUT BOARD LAYOUT ............................................................................................19
TYPICAL ESTA-QUICK/EVOLVER SE APPLICATOR INSTALLATION ...................................20-22
OPERATION: 23-26
OPERATOR CONTROLS ............................................................................................................23
OPERATING PROCEDURES .....................................................................................................24-25
MAINTENANCE: 27-38
ROUTINE PREVENTIVE MAINTENANCE ..................................................................................27
TROUBLESHOOTING ..................................................................................................................27-30
TROUBLESHOOTING FLOW CHARTS ......................................................................................31-32
TROUBLESHOOTING DIAGRAM ...............................................................................................32
9040 CASCADE CONTROL UNIT BLOCK DIAGRAM ...............................................................33
SERVICE LEVEL ..........................................................................................................................34
REPLACEMENT PROCEDURES ................................................................................................34-37
PARTS IDENTIFICATION:
39-41
9040 CASCADE LOW VOLTAGE CONTROL UNIT
PARTS DIAGRAM / PARTS LIST ...............................................................................................39-41
RECOMMENDED SPARE PARTS / OPTIONAL EQUIPMENT …………………………….…..41
WARRANTY POLICIES:
40
LIMITED WARRANTY .................................................................................................................40
CP-11-01

9040 Low Voltage Control Unit Kit- Safety
SAFETY
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 specifications
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
efficient 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.
!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 iden-
tified.
> 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 fire codes
and ordinances as well as NFPA-33 SAFETY
STANDARD or European Norms , prior to
installing, operating, and/or servicing this
equipment.
!W A R N I N G
> The hazards shown on the following page
may occur during the normal use of this
equipment. Please read the hazard chart
beginning on page 2.
1 CP-11-01

9040 Low Voltage Control Unit Kit- Safety
AREA HAZARD SAFEGUARDS
Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.
Spray Area
Fire Hazard Fire extinguishing equipment must be present in the
spray area and tested periodically.
Improper or inadequate operation
and maintenance procedures will Spray areas must be kept clean to prevent the
cause a fire hazard. accumulation of combustible residues.
Protection against inadvertent Smoking must never be allowed in the spray area.
arcing that is capable of causing
fire or explosion is lost if any The high voltage supplied to the atomizer must be
safety interlocks are disabled turned off prior to cleaning, flushing or maintenance.
during operation. Frequent power
supply shutdown indicates a When using solvents for cleaning:
problem in the system requiring
correction. Those used for equipment flushing should have flash
points equal to or hi
g
her than those of the coatin
g
material.
Those used for general cleaning must have flash
points above 100
o
F (37.8
o
C).
Spray booth ventilation must be kept at the rates
required by European Norms, NFPA-33, OSHA,
and local or international codes.
In addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.
Electrostatic arcing must be prevented.
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 set-up 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 European Norms,
NFPA-33 or
OSHA requirements.
CP-11-01 2

9040 Low Voltage Control Unit Kit- Safety
AREA HAZARD SAFEGUARDS
Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.
General Use and
Improper operation or maintenance Personnel must be given training in accordance with
Maintenance
may create a hazard. the requirements of NFPA-33 or European norms.
Personnel must be properly trained Instructions and safety precautions must be read and
in the use of this equipment. understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33, European Norms, and your insurance
company requirements.
Electrical
High voltage equipment is uti- The power supply, optional remote control cabinet,
Equipment
lized. Arcin
g
in areas of and all other electrical equipment must be located
flammable or combustible
outside Class I or II, Division 1 and 2 or Zone 1
hazardous areas. Refer to proper European Norm
or NFPA 33.
materials may occur. Personnel
are ex-posed to high voltage during
operation and maintenance. Turn the power supply OFF before working on the
equipment.
Protection against inadvertent
arcing that may cause a fire or Test only in areas free of flammable or combustible
explosion is lost if safety circuits material.
are disabled during operation.
Testing may require high voltage to be on, but only
Frequent power supply shutdown as instructed.
indicates a problem in the sys-tem
which requires correction. Production should never be done with the safety
circuits disabled.
An electrical arc can ignite coat-
ing materials and cause a fire or Before turning the high voltage on, make sure no
explosion. objects are within the sparking distance.
3 CP-11-01

9040 Low Voltage Control Unit Kit- Safety
AREA HAZARD SAFEGUARDS
Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.
Spray Area /
This is a high voltage device that Parts being sprayed must be supported on conveyors
High Voltage
can produce electrical arcs or han
g
ers and be
g
rounded. The resistance between
Equipment
ca
p
able of i
g
nitin
g
coatin
g
the
p
art and
g
round must not exceed 1 Me
g
a

.
materials.
(
Reference NFPA-33, EN 60079.
)
A safe distance must be maintained between the parts
being coated and the atomizer . A distance of at
least 1 inch for each 10 KV of power supply output
voltage is required at all times.
Parts must be supported so that they will not swing
and reduce the clearance specified above.
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.
Unless specifically approved for use in hazardous
locations, the power supply and other electrical
equipment must not be used in Class I, Division 1 or
2 locations or in Zone 1.
CP-11-01 4

9040 Low Voltage Control Unit Kit- Atex
EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
The following instructions apply to equipment
covered by certificate number Sira
11ATEX5240X:
1. The equipment may be used with flammable
gases and vapors with apparatus groups II and
with temperature class T6.
2. The equipment is only certified for use in
ambient temperatures in the range +12.8C to
+40C and should not be used outside this range.
3. Installation shall be carried out by suitably
trained personnel in accordance with the
applicable code of practice e.g. EN 60079-
14:1997.
4. Inspection and maintenance of this
equipment shall be carried out by suitably
trained personnel in accordance with the
applicable code of practice e.g. EN 60079-17.
5. Repair of this equipment shall be carried out
by suitable trained personnel in accordance with
the applicable code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and
adjustment of the equipment shall be fitted by
suitably trained personnel in accordance with
the manufacturer's documentation.
Refer to the "Table of Contents" of this service
manual:
a. Installation
b. Operation
c. Maintenance
d. Parts Identification
7. Components to be incorporated into or used
as replacement parts of the equipment shall be
fitted by suitably trained personnel in accordance
with the manufacturer's documentation.
8. The certification of this equipment relies upon
the following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility
of the user to take suitable precautions that
prevent it from being adversely affected, thus
ensuring that the type of protection provided by
the equipment is not compromised.
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
Suitable precautions: e.g. regular checks as
part of routine inspections or establishing from
the material's data sheets that it is resistant to
specific chemicals.
Refer to "Specifications" in the "Introduction"
section:
a. All fluid passages contain stainless
steel or nylon fittings.
b. High voltage cascade is encapsulated
with a solvent resistant epoxy.
9. A recapitulation of the certification marking
is detailed in the "Atex" section, on the next
page, drawing numbers: 72562 and 80075.
10. The characteristics of the equipment shall
be detailed e.g. electrical, pressure, and voltage
parameters.
The manufacturer should note that, on being
put into service, the equipment must be
accompanied by a translation of the instructions
in the language or languages of the country in
which the equipment is to be used and by the
instructions in the original language.
5 CP-11-01

9040 Low Voltage Control Unit Kit- Atex
9040 Cascade Low Voltage
Control Unit Kit ATEX Product
Marking Definitions
Ex Certificate Number: Sira 11ATEX5240X
Sira = Notified Body performing EC-type
examination
11 = Year of certification
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
240 = Document serial number
X = Special conditions for safe use apply
Product Marking
II 2 G
Ex = Specific marking of explosive protection
II = Equipment Group hazardous area charac-
teristics
2 = Equipment Category
G = Type of explosive atmosphere (gases,
vapors, or mists)
EEx 0.24mJ. The 80072-XXX 9040 Cascade
Control Unit Kit is suitable for use in
electrostatic spraying installations complying
with EN 50 176 as they are a Type A class with
a discharge energy limit of 0.24mJ.
Label 72562
Label 80075
CP-11-01 6

9040 Low Voltage Control Unit Kit- Introduction
INTRODUCTION
DESCRIPTION
The Ransburg spray Process
The Ransburg Spray Process is an air atomized
method for applying coatings to objects
electrostatically. This system applies a high
voltage DC charge to the applicator nozzle
electrode, creating an electrostatic field
between the atomizer and the target object. The
target is electrically grounded through its
support that may be either stationary or moving.
A regulated pressure fluid system delivers coating
material to the atomizer. At the atomizer, air is
applied that atomizes the coating material forming a
spray mist that, under the influence of the
electrostatic field, becomes electrically charged. The
charged particles are attracted to, and deposited on,
the target object. The forces between the charged
particles and the grounded target are sufficient to
turn most normal overspray around and deposit it on
the side and back surfaces of the target. Therefore,
a high percentage of the spray is deposited on the
target.
9040 Cascade Low Voltage
Control Unit Kit
The 9040 Cascade Control Unit converts standard
AC line voltage to a high frequency, low voltage
signal ranging from 0 to 10 Vrms. This signal is
supplied to an external cascade through a low
voltage cable. The external cascade converts the
low voltage signal into a high voltage. This high
voltage is transmitted through the cable to the
applicator. At the applicator an electrode in the
applicator creates a DC high voltage field the
spray goes through and picks up the electrostatic
charge. When the material is directed to a
grounded target, more material is attracted to the
target yielding higher painting efficiency.
The voltage/current characteristic is designed to
optimize the charging process under varying load
conditions, and to limit the operating current to a
safe maximum value.
In addition to supplying low voltage output to the
applicator, the 9040 Cascade control unit also
provides controls for AC power ON/OFF, infinite
high voltage adjustment, a high voltage meter, a
current meter, an AC power ON indicator, a high
voltage ON indicator, a cable fault indicator, and a
current overload indicator and reset switch.
Additionally, output terminals are provided for
remote overload reset, analog current output, and
high voltage control. Interlock connections for a
conveyor and exhaust fan are also provided. A
combination triple setpoint/analog input control
board is also supplied with 9040 Cascade control
units powering automatic spray applicators.
9040 Cascade Low Voltage
Control Unit Kit 80072 and
80078
The 9040 Cascade Low Voltage Kit 80072-XXX
and 80078-XXX are designed to be used with
either the Esta-Quick Applicator (AEMD 500) or
the Evolver SE product (A12455-XXXX). The
difference in the units is the 80072-XXX has a
potted cascade where the 80078-XXX has an oil
filled cascade.
The only combination of units that carry any
approval is the AEMD500 used with the 80072-
XXX units as described in this manual. Any other
combination of applicator and 9040 unit does not
have any agency approval associated with it.
When using equipment that is not approved, the
user needs to be aware of the code requirements
needed to operate safely. If there is any question
regarding safe installation requirements when
using this product, refer to European Norms (EN
50 176) or NFPA-33.
7 CP-11-01
Note

9040 Low Voltage Control Unit Kit- Introduction
The 9040 Cascade control unit has also been
modularly designed so that two half rack 9040
chassis will fit into one full rack enclosure, in
multiple applicator installations. The full rack
enclosure has been designed for mounting in
standard 19-inch rack mount cabinets.
The 9040 Control Unit Kit for automatic
applications includes an additional normally open
pressure switch (3PS) connected between fuse
1FU and ON/OFF switch 1SW. The air input to
this pressure switch is located at the rear of the
control unit and is labeled 3PS. When the air
signal is removed from this input, the contacts of
the pressure switch are open and AC power to the
control unit is disconnected.
The 9040 Cascade Control Unit is available for
automatic applicators as follows:
9040
Kit # Used with Applicator Type Applicator #
80072-1XX** Esta-Quick (110/120 V inputs) AEMD-500
80072-2XX** Esta-Quick (220/240V inputs) AEMD-500
80078-1XX Evolver SE (110/120 V inputs) A12455
80078-2XX Evolver SE (220/240 V inputs) A12455
**Note:CE/Atex approval with this power source is only for the AEMD-500
9040 Low Voltage Control Unit Kit Part Structure
80072-ABC (Atex approved when used with AEMD500)
A-Unit Power Type
-1 For 110/120 V Input Power (USA)
-2 For 220/240 V Input Power
B- High Voltage Cable Length
-1 For 4.5 m (15 ft.)
-2 For 7.5 m (25 ft.)
-3 For 15 m (50 ft.)
-4 For 22.5m (75 ft.)
C-Low Voltage Cable Length
-1 For 3 m (10 ft.)
-2 For 7.5 m (25 ft.)
-3 For 11 m (36 ft.)
80078-ABC (Not Approved)
A-Unit Power Type
-1 For 110/120 V Input Power (USA)
-2 For 220/240 V Input Power
B- High Voltage Cable Length
-1 For 4.5 m (15 ft.)
-2 For 7.5 m (25 ft.)
-3 For 15 m (50 ft.)
-4 For 22.5m (75 ft.)
C-Low Voltage Cable Length
-1 For 3 m (10 ft.)
-2 For 7.5 m (25 ft.)
-3 For 11 m (36 ft.)
CP-11-01 8


9040 Low Voltage Control Unit Kit- Introduction
9
SPECIFICATIONS
Environmental / Physical-Control Unit
Height: 132 mm
Width: 429 mm
(483 mm ear to ear)
Depth: 308 mm
Weight: 6.8 kg
Environmental / Cascade
Height: 400 mm
Width:
102 mm Square
Weight: 4.1 kg
Electrical Requirements
Input:
Voltage 90-264 VAC
Current: 0.4/0.2 Amps AC
Frequency: 50/60 Hertz
Wattage: 40 Watts (Maximum)
Output:
Voltage: 0-10 V RMS
Current: 1.5 Amp RMS (Maximum)
Pneumatic 6.9 bar maximum
Supply Air:
Cascade
Umax: 90 kV maximum
Cascade 120
m A maximum
Max Current:
Overload
Factory Setting: 90 m A maximum
CP-11-01

9040 Low Voltage Control Unit Kit- Introduction
Front
View
Rear
View
Figure 1: 9040 Cascade Control Unit Features
Number Descri
p
tion
1 Kilovolt Meter
2 A
C
Power
O
N Indicator
3 Hi
g
h Volta
g
e
O
n Indicator
4 Micro Am
p
Meter
5 Hi
g
h Volta
g
e Ad
j
ust Knob
6
C
able Fault
/
Hook
Off
Indicator
7
O
verload Indicator and Reset
S
witch
8 Fuse
9 A
C
Power
O
n
/Off
Indicator
10 Pressure
S
witches
11 External Wirin
g
G
rommet
12 A
C
Inlet Rece
p
tacle
13
G
round
S
tud
14
G
round Wire Assembl
y
15 Low Volta
g
e
C
able
S
ocket
16 External Wirin
g
Plu
g
2PL
(
Removable
)
17
C
ascade Hi
g
h Volta
g
e
C
able
C
onnection
18
C
ascade Low Volta
g
e
C
able
C
onnection
19
C
ascade
G
round Lu
g
C
onnector
Table 1 Feature Descriptions
CP-11-01 10

9040 Low Voltage Control Unit Kit- Installation
INSTALLATION
!W A R N I N G
> The 9040 Cascade control unit MUST
be located outside the hazardous area.
(See NFPA-33, European Norms, and
Ransburg Literature “Operating Your
Electrostatic Coating System Safely”.)
> The user MUST read and be familiar with
the SAFETY and SAFETY PRECAUTIONS.
> 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 for operating and servicing
safely are followed. The user should be aware
of and adhere to ALL local building and fire
codes and ordinances as well as NFPA-33 and
European Norms prior to installing, operating,
and/or servicing this equipment.
NOTE
> As each installation is unique, this
information is intended to provide gener-
al
installation information for the 9040
Cascade control unit. Consult your au-
thorized Ransburg representative for
specific directions pertaining to the
installation of your equipment.
LOCATION
Install the 9040 Cascade control unit and external
cascade in an area outside the hazardous
location, where it will be protected from the
possibility of environmental intrusion, such as dust
or moisture, and ambient temperatures do not
exceed 49°C (120F), but as close to the
applicator as possible to minimize the length of
low and high voltage cables. The control unit may
be free standing on any flat surface or rack
mounted in any 19-inch or Eurorack cabinet.
11
!C A U T I O N
> DO NOT locate the control unit near
or adjacent to heat producing equipment
such as ovens, high wattage lamps, etc.
NOTE
> When rack mounting the 9040 Cas-
cade control unit in a 19-inch cabinet or
Eurorack, it may be necessary to
remove the rubber feet from the bottom
of the 9040 enclosure.
INPUT CONNECTIONS
For non-conduit installations, plug the
detachable AC line cord into the receptacle in
the rear of the 9040 Cascade control unit. Plug
the other end of the line cord into a properly
grounded 120-volt AC outlet.
NOTE
> 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 control unit 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.
CP-11-01

9040 Low Voltage Control Unit Kit- Installation
For 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
1TB-L1, 1TB-N and 1TB-Ground (see Figure 2
for AC input wiring locations).
Figure 2: Terminal Block One (1TB)
!W A R N I N G
> Always double check that the control unit
is unplugged from its AC outlet before
working with any internal wiring connected to
1TB-L1, 1TB-L2, 1TB-N, 1FU, 1SW, or 8PL.
3. Remove the mounting hardware from the AC
Inlet Receptacle and remove it from the rear of
the control unit.
4. Install the Conduit Adapter Plate (supplied)
in the hole where the AC Inlet Receptacle was
removed (see Figure 3).
5. Install the AC line cord through the Conduit
Adapter Plate using conduit and wire to TB1 as
follows:
Hot/Line to 1TB-L1
Neutral/Common
to 1TB-N
Ground
to 1TB-Ground
Conduit Adapter Plate
Figure 3: Installation of Conduit
Adaptor Plate
NOTE
> When using conduit to route the AC
input wiring to the control unit, the last
several feet of conduit attached to the
control unit should be of a flexible type,
such that the control unit module can
still be slid out of the enclosure for
testing and setup purposes.
The 9040 Cascade control unit accepts
universal input voltage between 90 and 264
VAC. There is no need to change any switch
settings when changing input from 115 to 230
VAC or vice-a-versa.
CP-11-01 12

9040 Low Voltage Control Unit Kit- Installation
NOTE
> 9040 units shipped from the factory for
115 VAC input will have a 72771-06, 1 amp
front panel fuse installed. While 9040 units
shipped from the factory for 230 VAC input
will have a 72771-01, 0.5 amp front panel
fuse installed. If the other input is required,
it is recommended that the fuse be
changed in order to keep the same level of
protection. Both fuses are shipped with
9040 control units.
!C A U T I O N
> DO NOT over tighten high voltage
cable connection to applicator. Damage
to plastic parts may occur.
Ground Connections
Crimp the appropriate connector onto the
Ground Wire Assembly and install from the
control unit ground stud, located on the back of
the control unit to a true earth ground.
Again crimp the appropriate connector on to the
cascade Ground Wire Assembly. Attach
Ground Wire Assembly from the external
cascade lug to a separate true earth ground.
EXTERNAL
CONNECTIONS
NOTE
> When connecting external wires to the
9040 Cascade control unit, some of the
wires will be connected to the External
Wiring Plug 2PL and some routed through
the External Wiring Grommet. When wiring
through the External Wiring Grommet,
leave enough slack in the wires so that the
9040 control unit chassis can still be slid
out of its enclosure if required. For
installations requiring conduit, route all
wires through the external wiring grommet
opening and connect to the existing wires
on the inside of External Wiring Plug 2PL
(2SOF) when necessary.
Low Voltage Cable Connection
Connect the low voltage cable from the side of
the external cascade to the Low Voltage Cable
Socket located on the back of the control unit.
Hand tighten only.
High Voltage Cable Connection
Connect the high voltage cable by securing the
grounded end of the cable into the external
cascade then securing the other end to the
applicator.
13
!C A U T I O N
> The Ground Wire Assembly MUST
be connected from the power supply
ground stud to a true earth ground.
Supplemental ground is provided via the
ground stud to the enclosure, through the
front panel screws, and to the chassis
module. Therefore, ensure the front panel
screws in the 9040 Cascade control unit
module are securely fas-tened to the rack
enclosure during operation. If it becomes
necessary to slide the chassis out for
testing purpos-es, connect a ground wire
from the enclosure to the chassis.
Interlocks
!W A R N I N G
> ALWAYS ensure that high voltage is OFF
before flushing the spray applicator with
solvent. NEVER flush the spray applicator
with high voltage ON, as this is a severe fire
hazard and risk to personnel safety. It is
recommended that the high voltage control
be interlocked with the solvent flush signal
so that high voltage is automatically locked
out whenever flushing occurs. Consult your
authorized Ransburg representative for
information on interlocking the high voltage
OFF signal with the solvent flush signal.
CP-11-01

9040 Low Voltage Control Unit Kit- Installation
As outlined in NFPA-33 and OSHA, the AC
power line must be series interlocked with both
the exhaust fan and conveyor. To interlock the
9040 Cascade control unit with the exhaust fan
and conveyor perform the following:
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF
switch is in the OFF position.
2. Loosen the front panel screws and slide the
control unit chassis out.
!W A R N I N G
> Always double check that the control unit is
unplugged from its AC outlet before working
with any internal wiring connected to 1TB-L1,
1TB-L2, 1TB-N, 1FU, 1SW, or 8PL.
3. Using a small blade screwdriver, remove the
factory installed test jumper from 1TB-L1 to
1TB-L2.
4. Route exhaust fan and conveyor interlock
(supplied by user) wiring through external wiring
grommet on the back of the control unit and connect
to 1TB-L1 and 1TB-L2 as shown in Figure 2.
2. The interlock contacts should be rated for
at least 1 amp at 240 volts AC.
5. Slide the chassis back in, secure the front
panel screws, replace the fuse, and plug the
control unit in.
!C A U T I O N
> When highly conductive, solvent-based
paints are used it is also recommended
that the high voltage control be series
interlocked with the atomization air. This
prevents the possibility of a charged
stream of fluid creating an arc, and
subsequent fire, as it approaches the
floor (or some other grounded object).
Consult your authorized Ransburg
representative for information on
interlocking the high voltage with the
atomization air.
CP-11-01
External Relay Contacts
A set of external relay contacts for high voltage
(K1) and overload (K2) conditions is provided at
External Wiring Plug 2PL-5, -6 & -7 (outside)
and 2SOC-5, -6 & -7 (inside). (See Figure 11
for exact wiring locations.) These relay contacts
are sometimes useful in configuring the control
of the spray applicator system.
Maximum contact ratings are as follows:
DC AC
Maximum Switching Power
60W 125VA
Maximum Switching Voltage 220VDC 250VAC
Maximum Switching Current
2A 2A
14

9040 Low Voltage Control Unit Kit- Installation
External High Voltage Control
If a method of high voltage triggering, other than
the factory supplied method, is required, the 9040
Cascade control unit allows for external high
voltage control from a PLC, pressure switch,
airflow switch, or other user-supplied device. To
turn the high voltage on, the user-supplied device
must create a contact closure between terminals
1 and 2 of the External Wiring Plug (2PL). The
wiring from the user-supplied external high
voltage control device can be connected directly
to the outside terminals of 2PL, or for installations
requiring conduit, connected to the inside
terminals 2SOC-1 and 2 as follows:
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF
switch is in the OFF position.
2. Loosen the front panel screws and slide the
control unit chassis out.
3. Route the contact wires of the control device
through the external wiring grommet opening
and connect to the existing wiring for 2SOC-1
and 2SOC-2. The control device contacts must
be rated for at least 100 milliamps at 15 volts
DC.
4. Slide the chassis back in, secure the front
panel screws, replace the fuse, and plug in the
control unit.
NOTE
> A separate normally open (NO) exter-
nal high voltage control contact MUST
be used for each control unit in multiple
con-trol unit applications. One contact
CAN-NOT be used to trigger the high
voltage for multiple control units.
External Overload Reset
The 9040 Cascade control unit allows for use of an
external (normally closed) overload reset button.
This is convenient when the control unit is mounted
in a hard to reach or inconvenient location or when it
is desired to control overload reset of several control
units from a single location.
NOTE
> A separate normally open (NO) exter-
nal high voltage control contact MUST
be used for each control unit in multiple
control unit applications. One contact
CAN-NOT be used to trigger the high
voltage for multiple control units.
The wiring from the user supplied external
overload reset device can be connected directly to
the outside terminals 2PL-2 and -3 (remove
factory installed jumper from 2PL-2 to 2PL-3), or
for installations requiring conduit, connected to
the inside terminals 2SOC-2 and 3 as follows:
1. Remove the factory-installed jumper from
2PL-2 to 2PL-3.
2. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF
switch is in the OFF position.
3. Loosen the front panel screws and slide the
control unit chassis out.
4. Route the contact wires of the external reset
device through the external wiring grommet
opening and connect to the existing wiring for
2SOC-2 and 2SOC-3. The external reset device
contacts must be rated for at least
100 milliamps at 15 volts DC. The contacts of
the external reset device must be normally
closed.
5. Slide the chassis back in, secure the front
panel screws, replace the fuse, and plug in the
control unit.
15 CP-11-01

9040 Low Voltage Control Unit Kit- Installation
Analog Current Output Signal
An analog current output signal is available
from the 9040 control unit at 2PL-8 (outside) or
2SOC-8 (inside). This signal can be connected
to a recording device (strip chart recorder, data
acquisition unit, etc.) to monitor the output
current of the control unit over time. This signal
should be referenced to earth ground. The input
resistance of the recording device should be 5
megohms or greater.
Figure 4: Main PC Board
NOTE
> If the input resistance of the recording
device is less than 5 megohms, it will
affect the reading on the 9040 control
unit microampmeter.
The analog current output signal can be adjusted
such that 0 to 10 VDC represents 0 to 100
microamps or 0 to 200 microamps, by opening or
shorting jumper JP8 on the main PC board (see
Figure 4 for JP8 location). The board is factory
supplied with JP8 shorted (covering both
terminals) such that 0 to 10 VDC represents 0 to
200 microamps. To set the analog output current
so that 0 to 10 VDC represents 0 to 100
microamps open jumper JP8 (reposition so that it
covers only one terminal).
The wiring from the user supplied analog output
current recording device (with input resistance of
5 megohms or greater) can be connected directly
to outside terminal 2PL-8, or for installations
requiring conduit, connected to the inside terminal
2SOC-8 as described below. Connect common of
the recording device directly to earth ground.
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF
switch is in the OFF position.
2. Loosen the front panel screws and slide the
control unit chassis out.
3. Route the wire of the external recording device
through the External Wiring Grommet opening
and connect to the existing wiring for 2SOC-8.
4. Slide the chassis back in, secure the front
panel screws, replace the fuse, and plug the
control unit back in.
Triple Set Point/Analog Input
Control Connections
9040 Cascade control units for automatic applicators
are shipped with a combination Triple
Setpoint/Analog Input Interface Board installed.
When set for triple setpoint operation, three discreet
setpoints for high voltage output at the spray
applicator can be selected, using two 24 VDC input
signals. When set for analog input operation a 0 —
10 VDC or 4 — 20 mADC input signal can be used to
select continuous kV output at the spray applicator
from 0 to rated kV. With either setting a PLC, robot,
ext. can thus select from different voltages to suit the
spray application.
CP-11-01 16

9040 Low Voltage Control Unit Kit- Installation
To utilize the Triple Setpoint Feature perform
the following (refer to Figures 5a and 5b):
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF
switch is in the OFF position.
2. Loosen the front panel screws and slide the
control unit chassis out.
3. Ensure JP2 jumpers on triple set
point/analog input board are set to TSP ON
position as shown on PC board silkscreen.
4. Route the wiring through the External Wiring
Grommet and connect to the Triple Setpoint
Board as follows:
Robot or PLC Common to TB1-2
24 VDC Setpoint 1 Select
to TB1-1
24 VDC Setpoint 2 Select
to TB1-3
NOTE
> An interlock line with the control unit
power and overload signal is provided
across terminals TB1-4 and 5. This line
can be used to indicate that high
voltage is ready (control unit is on and
not in overload state) if desired.
5. Slide the chassis back into the cabinet,
secure the front panel screws, replace the fuse,
and plug the control unit in.
The Triple Setpoint Board is now ready for use.
Turning on the robot or PLC output connected
to TB1-1 will activate Setpoint 1, while turning
on the robot or PLC output connected to TB1-3
will activate Setpoint 2. The third setpoint is
determined by the setting of the control unit
High Voltage Adjust Knob when both robot or
PLC outputs are off.
17
High voltage outputs selected by TB1-1 (Setpoint
1) and TB1-3 (Setpoint 2) can be adjusted by
tweaking potentiometers P1 and P2 on the Triple
Setpoint Board, respectively. Typically P1 is
factory set to provide approximately 50% of
maximum kV, while P2 is set to provide
approximately 75% of maximum kV.
NOTE
> Jumper J1 on the Triple Setpoint
Board
should be positioned so that it
covers only one terminal (open) for
proper operation. Turn the control unit
power OFF before flushing, cleaning,
or servicing the applicator.
To utilize the Analog Input Feature perform the
following (refer to Figure 5b):
1. Ensure the control unit is OFF< unplugged from
the AC outlet, and the front panel fuse is removed.
2. Loosen the front panel screws and slide the
control unit chassis out.
3. Set JP2 jumpers on Triple Setpoint/Analog
Input Board to ANLG ON position as shown on
PC board silkscreen.
NOTE
> When JP2 is set to TSP ON position
and no 24 VDC triple setpoint inputs
are applied, high voltage control is from
the High Voltage Adjust Knob on the
front of the control unit.
4. Set JP3 jumpers on Triple Setpoint/Analog
Input board to desired input (0 to 10 VDC or 4
to 20 mADC) position, as shown on PC board
silkscreen.
CP-11-01