Ransburg 77070-33 User manual

SERVICE MANUAL
CP-08-01CP-08-01
CP-08-01CP-08-01
CP-08-01
November - 2008
MODEL: 77070-33MODEL: 77070-33
MODEL: 77070-33MODEL: 77070-33
MODEL: 77070-33
IMPORIMPOR
IMPORIMPOR
IMPORTT
TT
TANTANT
ANTANT
ANT: Before using this equipment,: Before using this equipment,
: Before using this equipment,: Before using this equipment,
: Before using this equipment,
carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,
carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,
carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions instarting on page 1, and all instructions in
starting on page 1, and all instructions instarting on page 1, and all instructions in
starting on page 1, and all instructions in
this manual. Keep this Service Manual forthis manual. Keep this Service Manual for
this manual. Keep this Service Manual forthis manual. Keep this Service Manual for
this manual. Keep this Service Manual for
future reference.future reference.
future reference.future reference.
future reference.
9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL
9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL
9040 CLASSIC HIGH VOLTT
TT
TAGE POWER SUPPLAGE POWER SUPPL
AGE POWER SUPPLAGE POWER SUPPL
AGE POWER SUPPLYY
YY
Y
Service Manual Price:Service Manual Price:
Service Manual Price:Service Manual Price:
Service Manual Price: €25.00 (Euro)25.00 (Euro)
25.00 (Euro)25.00 (Euro)
25.00 (Euro)
$30.00 (U.S.)$30.00 (U.S.)
$30.00 (U.S.)$30.00 (U.S.)
$30.00 (U.S.)
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CP-08-01
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CP-08-01
CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
9040 Classic HV Power Supply - Contents
SAFETY:SAFETY:
SAFETY:SAFETY:
SAFETY:
SAFETY PRECAUTIONS...........................................................................................................
HAZARDS / SAFEGUARDS.......................................................................................................
PAGEPAGE
PAGEPAGE
PAGE
INTRODUCTION:INTRODUCTION:
INTRODUCTION:INTRODUCTION:
INTRODUCTION:
GENERAL DESCRIPTION.........................................................................................................
SPECIFICATIONS......................................................................................................................
9040 CLASSIC HIGH VOLTAGE POWER SUPPLY FEATURES...........................................
OPERATION:OPERATION:
OPERATION:OPERATION:
OPERATION:
OPERATING CONTROLS.........................................................................................................
THEORY OF OPERATION........................................................................................................
OPERATING PROCEDURES....................................................................................................
MAINTENANCE:MAINTENANCE:
MAINTENANCE:MAINTENANCE:
MAINTENANCE:
ROUTINE PREVENTIVE MAINTENANCE................................................................................
TROUBLESHOOTING................................................................................................................
SERVICE LEVEL.........................................................................................................................
REPLACEMENT PROCEDURES..............................................................................................
TROUBLESHOOTING GUIDE...................................................................................................
TROUBLESHOOTING ...............................................................................................................
77070-33 CLASSIC HIGH VOLTAGE POWER SUPPLY BLOCK DIAGRAM.........................
1-61-6
1-61-6
1-6
7-87-8
7-87-8
7-8
13-1613-16
13-1613-16
13-16
17-3017-30
17-3017-30
17-30
1
2-5
7
7
8
13
14
14-15
17
17-20
21
21-25
26-27
28
29
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS IDENTIFICATION:
9040 CLASSIC HIGH VOLTAGE POWER SUPPLY
PARTS DIAGRAM / PARTS LIST................................. ...........................................................
RECOMMENDED SPARE PARTS............................................................................................
ACCESSORIES..........................................................................................................................
31-3431-34
31-3431-34
31-34
31-32
33
33
WARRANTY POLICIES:WARRANTY POLICIES:
WARRANTY POLICIES:WARRANTY POLICIES:
WARRANTY POLICIES: 3535
3535
35
LIMITED WARRANTY.................................................................................................................35
INSTALLATION:INSTALLATION:
INSTALLATION:INSTALLATION:
INSTALLATION:
LOCATION..................................................................................................................................
INPUT VOLTAGE SELECTION.................................................................................................
INPUT CONNECTIONS.............................................................................................................
EXTERNAL CONNECTIONS.....................................................................................................
9-129-12
9-129-12
9-12
9
9
10
10-12
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CP-08-01
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
ITW Ransburg coating system, read and
understand all of the technical and safety literature
for your ITW 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 youA WARNING! states information to alert you
A WARNING! states information to alert youA WARNING! states information to alert you
A WARNING! states information to alert you
to a situation that might cause serious injuryto a situation that might cause serious injury
to a situation that might cause serious injuryto a situation that might cause serious injury
to a situation that might cause serious injury
if instructions are not followed.if instructions are not followed.
if instructions are not followed.if instructions are not followed.
if instructions are not followed.
A CAUTION! states information that tellsA CAUTION! states information that tells
A CAUTION! states information that tellsA CAUTION! states information that tells
A CAUTION! states information that tells
how to prevent damage to equipment or howhow to prevent damage to equipment or how
how to prevent damage to equipment or howhow to prevent damage to equipment or how
how to prevent damage to equipment or how
to avoid a situation that might cause minorto avoid a situation that might cause minor
to avoid a situation that might cause minorto avoid a situation that might cause minor
to avoid a situation that might cause minor
injury.injury.
injury.injury.
injury.
A NOTE is information relevant to theA NOTE is information relevant to the
A NOTE is information relevant to theA NOTE is information relevant to the
A NOTE is information relevant to the
procedure in progress.procedure in progress.
procedure in progress.procedure in progress.
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 ITW 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 ITW Ransburg representative
or ITW Ransburg.
SAFETYSAFETY
SAFETYSAFETY
SAFETY
> The user MUSTMUST
MUSTMUST
MUST read and be familiar
with the Safety Section in this manual and
the ITW Ransburg safety literature therein
identified.
>This manual MUSTMUST
MUSTMUST
MUST be read and thor-
oughly understood by ALLALL
ALLALL
ALL personnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGSWARNINGS
WARNINGSWARNINGS
WARNINGS and safety requirements
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to ALLALL
ALLALL
ALL local building and fire
codes and ordinances as well as NFPA-33NFPA-33
NFPA-33NFPA-33
NFPA-33
SAFETY STANDARDSAFETY STANDARD
SAFETY STANDARDSAFETY STANDARD
SAFETY STANDARD prior to installing,
operating, and/or servicing this equipment.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
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.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
9040 Classic HV Power Supply - Safety
11
11
1
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CP-08-01
9040 Classic HV Power Supply - Safety
22
22
2
Spray AreaSpray Area
Spray AreaSpray Area
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
shutdown indicates a problem in
the system requiring correction.
The 76447 power supply MUST be installed in a
NON-hazardous location in accordance with NFPA-
33.
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 used for general cleaning must have flash
points above 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, and local 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 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,
and OSHA requirements.
AREAAREA
AREAAREA
AREA
Tells where hazards
may occur.
HAZARDHAZARD
HAZARDHAZARD
HAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
Tells how to avoid the hazard.
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9040 Classic HV Power Supply - Safety
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33
3
AREAAREA
AREAAREA
AREA
Tells where hazards
may occur.
HAZARDHAZARD
HAZARDHAZARD
HAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
Tells how to avoid the hazard.
Spray AreaSpray Area
Spray AreaSpray Area
Spray Area Electrostatic Arcing Ensure the ground wire assembly is connected from the
power supply ground stud to a true earth ground.
Ensure that the power supply is plugged into a properly
groundedoutlet.
If shocks or sparks are noticed at any point in the spray
system, immediately turn off the power supply and check
the complete system for the cause. DO NOT use the
system again until the problem has been identified and
corrected.
Neveroperatetheapplicator withoutproperlygroundingthe
following:
A. OperatorsOperators
OperatorsOperators
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
leg straps may be used.
Operators must maintain contact with the handleof
the applicator. If work gloves are used, the palm
section should be cut out.
Operators must remove from themselves all metal
objects that are not grounded.
B. Partsbeingsprayed. Resistancebetweenthepartand
a grounded conveyor must not exceed 1 megohm.
C. Every metal and conductive object in the spray
area. This includes the booth, parts hangers, fire
extinguishers, conductive flooring, etc.
Grounded conductive flooring must be provided in the
spray area.
Turn off voltage at the power supply before flushing out,
cleaning, or removing any parts from the applicator.
Provideproper protectionforwaterbornesupplysystems.
Never install an applicator into a fluid system using an
isolated solvent supply.
Alwaysdischargewaterbornesystemcapacitancepriorto
servicing.
Do not touch applicator electrode while applicator is
energized.
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CP-08-01 44
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9040 Classic HV Power Supply - Safety
AREAAREA
AREAAREA
AREA
Tells where hazards
may occur.
HAZARDHAZARD
HAZARDHAZARD
HAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
Tells how to avoid the hazard.
Explosion Hazard/Explosion Hazard/
Explosion Hazard/Explosion Hazard/
Explosion Hazard/
IncompatibleIncompatible
IncompatibleIncompatible
Incompatible
MaterialsMaterials
MaterialsMaterials
Materials
Halogenatedhydrocarbon 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
chemicalreactioncausedbythese
solvents reacting with aluminum
can become violent and lead to an
equipment explosion.
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, flushing, 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 material supplier. Any other type of solvent
may be used with aluminum equipment.
Improperoperationor maintenance
may create a hazard.
Personnelmustbeproperly trained
in the use of this equipment.
Personnel must be given training in accordance with
the requirements of NFPA-33.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codesgoverningventilation,fireprotection,operation
maintenance, and housekeeping.
Always turn power to the power supply OFF, unplug
the electrical cord from its outlet, and remove the
front panel fuse, before opening the power supply
door. If necessary, lock the power supply out so that
it cannot be turned ON until the work is finished.
Whenever removing high voltage cables from
equipment, ground the contact end of the cable by
holding the cable such that the contact touches
earth ground for several seconds. Do not touch the
contact until it has been grounded. This will reduce
the possibility of residual charge causing electrical
shock.
Thehighvoltagemultiplierassemblycontainsenergy
storage components that can cause serious shock
injury, and therefore is not field repairable. Warranty
will be voided if the high voltage multiplier seal is
broken. If the high voltage multiplier is defective
contactyourauthorized ITW Ransburgrepresentative
for exchange or repair.
The high voltage multiplier and high voltage cable
contain significant capacitance that will store charge.
Allow approximately 10 seconds for this charge to
bleedoffbeforeopeningthecabinetdoororremoving
the high voltage cable from the power supply or
spray applicator.
General Use andGeneral Use and
General Use andGeneral Use and
General Use and
MaintenanceMaintenance
MaintenanceMaintenance
Maintenance
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CP-08-01
9040 Classic HV Power Supply - Safety
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5
AREAAREA
AREAAREA
AREA
Tells where hazards
may occur.
HAZARDHAZARD
HAZARDHAZARD
HAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
Tells how to avoid the hazard.
Toxic SubstancesToxic Substances
Toxic SubstancesToxic Substances
Toxic Substances Certain material may be harmful if
inhaled, or if there is contact with
the skin.
Follow the requirements of the Material 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.
Personnel SafetyPersonnel Safety
Personnel SafetyPersonnel Safety
Personnel Safety Skin puncturing by sharp
electrode.
Take precautions to see that flesh is not punctured by
sharp electrode.
Personnel SafetyPersonnel Safety
Personnel SafetyPersonnel Safety
Personnel Safety
(High Pressure
Equipment)
Fluid Injection Injury Never let any part of the body come in direct contact
with the fluid stream exiting from the nozzle. If fluid
leaks occur in the applicator or in the fluid delivery
components, depressurize fluid system before
servicing.
Never aim the applicator at any part of the body under
any circumstances.
If you are injured by high pressure fluid injection then
immediate medical treatment MUST be sought.
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9040 Classic HV Power Supply - Safety
NOTESNOTES
NOTESNOTES
NOTES
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CP-08-01
INTRODUCTIONINTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
9040 Classic HV Power Supply - Introduction
77
77
7
SPECIFICASPECIFICA
SPECIFICASPECIFICA
SPECIFICATIONSTIONS
TIONSTIONS
TIONS
PhysicalPhysical
PhysicalPhysical
Physical
Height:Height:
Height:Height:
Height: 156mm (6 1/8-Inches )
Width:Width:
Width:Width:
Width: 394mm (15 1/2-Inches)
Depth:Depth:
Depth:Depth:
Depth: 292mm (11 1/2-Inches)
Weight:Weight:
Weight:Weight:
Weight: 10.8 Kg (24-Lbs.)
GENERAL DESCRIPTIONGENERAL DESCRIPTION
GENERAL DESCRIPTIONGENERAL DESCRIPTION
GENERAL DESCRIPTION
The 9040 Classic High VThe 9040 Classic High V
The 9040 Classic High VThe 9040 Classic High V
The 9040 Classic High Voltageoltage
oltageoltage
oltage
Power SupplyPower Supply
Power SupplyPower Supply
Power Supply
The 9040 Classic High Voltage Power Supply
converts standard AC line voltage to a high
frequency, low voltage signal ranging from 0 to 10
Vrms. This signal is supplied to the high voltage
multiplier where it is converted to DC high voltage.
The high voltage DC is then transferred from the
9040 Classic High Voltage Power Supply to the
applicator through a high voltage cable. 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 high voltage output to the
applicator, the 9040 Classic High Voltage Power
Supply also provides controls for AC power ON/
OFF,infinite high voltageadjustment, ahigh voltage
meter, a current meter, a POWER ON indicator, a
HIGH VOLTAGE ON indicator, and a CURRENT
OVERLOAD indicator and reset switch. Addition-
ally, output terminals are provided for remote
overload reset and interlock connections for a
conveyor, exhaust fan and high voltage control on
all 9040 Classic High Voltage Power Supplies.
ElectricalElectrical
ElectricalElectrical
Electrical
INPUTINPUT
INPUTINPUT
INPUT
Voltage:Voltage:
Voltage:Voltage:
Voltage: 90-264 VAC
Current:Current:
Current:Current:
Current: 0.6/0.3 Amps AC
Frequency:Frequency:
Frequency:Frequency:
Frequency: 50/60 Hertz
Wattage:Wattage:
Wattage:Wattage:
Wattage: 60 Watts (maximum)
OUTPUTOUTPUT
OUTPUTOUTPUT
OUTPUT
Voltage:Voltage:
Voltage:Voltage:
Voltage: 100kV DC (77070-33)
Current:Current:
Current:Current:
Current: 170 Microamps (maximum)
2.71 bar (25 psi) minimum
PneumaticPneumatic
PneumaticPneumatic
Pneumatic
Supply Air:Supply Air:
Supply Air:Supply Air:
Supply Air: 6.9 bar (100 psi) maximum
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CP-08-01 88
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9040 Classic HV Power Supply - Introduction
Figure 1: 9040 Classic High Voltage Power Supply FeaturesFigure 1: 9040 Classic High Voltage Power Supply Features
Figure 1: 9040 Classic High Voltage Power Supply FeaturesFigure 1: 9040 Classic High Voltage Power Supply Features
Figure 1: 9040 Classic High Voltage Power Supply Features
9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL
9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL
9040 CLASSIC HIGH VOLTT
TT
TAGE POWER SUPPLAGE POWER SUPPL
AGE POWER SUPPLAGE POWER SUPPL
AGE POWER SUPPLYY
YY
YFEAFEA
FEAFEA
FEATURESTURES
TURESTURES
TURES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Kilovolt Meter
Microamp Meter
High Voltage On Indicator
Overload Indicator / Overload Reset
On / Off Switch
Fuse Holder
Fuse Holder
High Voltage Adjust Knob
External Wiring Grommet
Pressure Switch Connection
Pressure Switch Connection
High Voltage Cable Connection
AC Line Cord
Ground Connection
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CP-08-01
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
LOCALOCA
LOCALOCA
LOCATIONTION
TIONTION
TION
Install the 9040 Classic High Voltage Power
Supply 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 120oF
(49°C), but as close to the applicator as possible
to minimize the length of high voltage cable.
INPUTINPUT
INPUTINPUT
INPUT VOLVOL
VOLVOL
VOLTT
TT
TAGEAGE
AGEAGE
AGE
SELECTIONSELECTION
SELECTIONSELECTION
SELECTION
The 9040 Classic High Voltage Power Supply
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 from 230 to 115 VAC.
> The 9040 Classic High Voltage Power
Supply MUSTMUST
MUSTMUST
MUST be located outside the
hazardous area. (See local or national
installation codes and ITW Ransburg
Bulletin - "Operating Your Electrostatic
Coating System Safely").
> The user MUSTMUST
MUSTMUST
MUST read and be familiar
with the "SAFETY" section of this manual.
> This manual MUSTMUST
MUSTMUST
MUST be read and thor-
oughly understood by ALLALL
ALLALL
ALL personnel who
operate, clean, or maintain this equipment!
Special care should be taken to ensure that
the warnings and requirements for operat-
ing and servicing safely are followed. The
user should be aware of and adhere to ALLALL
ALLALL
ALL
local building and fire codes and ordinances
as well as any local country codes prior to
installing, operating, and/or servicing this
equipment.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
> As each installation is unique, this infor-
mation is intended to provide general instal-
lation information for the 9040 Classic High
Voltage Power Supply. Consult your autho-
rized ITW Ransburg distributor for specific
directions pertaining to the installation of
your equipment.
NOTENOTE
NOTENOTE
NOTE
> 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 High Voltage Power Supplies.
NOTENOTE
NOTENOTE
NOTE
> DO NOTDO NOT
DO NOTDO NOT
DO NOT locate the power supply
near or adjacent to heat producing equip-
ment such as ovens, high wattage lamps,
etc.
C A U T I O NC A U T I O N
C A U T I O NC A U T I O N
C A U T I O N
!!
!!
!
9040 Classic HV Power Supply - Installation
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CP-08-01
9040 Classic HV Power Supply - Installation
1010
1010
10
INPUT CONNECTIONSINPUT CONNECTIONS
INPUT CONNECTIONSINPUT CONNECTIONS
INPUT CONNECTIONS
Plug the AC line cord into a properly grounded
AC outlet.
EXTERNALEXTERNAL
EXTERNALEXTERNAL
EXTERNAL
CONNECTIONSCONNECTIONS
CONNECTIONSCONNECTIONS
CONNECTIONS
High VHigh V
High VHigh V
High Voltage (High Voltage (High V
oltage (High Voltage (High V
oltage (High Voltage)oltage)
oltage)oltage)
oltage)
Cable ConnectionCable Connection
Cable ConnectionCable Connection
Cable Connection
Remove the plastic protective plug from the high
voltage cable connector and apply enough LSCH-
0009 dielectric lubricant onto the high voltage
cable to cover the electrical contact point.
Safety GroundSafety Ground
Safety GroundSafety Ground
Safety Ground
Crimp the appropriate connector onto the ground
wire assembly and install from the power supply
ground stud, located on the side panel, to a true
earth ground.
InterlocksInterlocks
InterlocksInterlocks
Interlocks
The AC power line must be series interlocked with
both the exhaust fan and conveyor. To interlock
the 9040 Classic High Voltage Power Supply with
the exhaust fan and conveyor, perform the
following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged, and the ON/OFF
switch is in the OFF position.
2. Open the power supply cabinet door.
> In general, conduit must be used for ap-
proved AC installation, however, if national
and local codes permit, the AC power may
be supplied via the factory installed line
cord. If conduit is utilized, the power supply
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.
NOTENOTE
NOTENOTE
NOTE
> When connecting external wires to the
9040 Classic High Voltage Power Supply,
route the wiring through the external wir-
ing grommet located on the side panel.
NOTENOTE
NOTENOTE
NOTE
> Applying LSCH-0009 dielectric lubri-
cant on the high voltage cable contact sig-
nificantly reduces corona discharge that
can cause deterioration of the high volt-
age connection components.
NOTENOTE
NOTENOTE
NOTE
> ALWAYSALWAYS
ALWAYSALWAYS
ALWAYS ensure that high voltage is
OFFOFF
OFFOFF
OFF before flushing the spray gun with
solvent. NEVERNEVER
NEVERNEVER
NEVER flush the spray applicator
with high voltage ONON
ONON
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 ITW Ransburg representative for
information on interlocking the high voltage
OFFOFF
OFFOFF
OFF signal with the solvent flush signal.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
> ALWAYSALWAYS
ALWAYSALWAYS
ALWAYS double check that the power
supply is unplugged from its AC outlet
before working with any internal wiring.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
> The ground wire assembly MUSTMUST
MUSTMUST
MUST be
connected from the power supply ground
stud to a true earth ground.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
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CP-08-01
9040 Classic HV Power Supply - Installation
1111
1111
11
3. Using a small blade screwdriver, remove the
factory installed test jumper from 1TB-L1to 1TB-
L2.
4. Route exhaust fan and conveyor interlock
(supplied by user) wiring through the external
wiring grommet on the side of the power supply
and connect to 1TB-L1 and 1TB-L2 as shown in
Figure 2. The interlock contacts should beThe interlock contacts should be
The interlock contacts should beThe interlock contacts should be
The interlock contacts should be
rated for at least 1 Amp at 240 volts AC.rated for at least 1 Amp at 240 volts AC.
rated for at least 1 Amp at 240 volts AC.rated for at least 1 Amp at 240 volts AC.
rated for at least 1 Amp at 240 volts AC.
5. Secure the cabinet door, replace the fuse and
plug the power supply in.
Figure 2: Terminal Block One (1TB)Figure 2: Terminal Block One (1TB)
Figure 2: Terminal Block One (1TB)Figure 2: Terminal Block One (1TB)
Figure 2: Terminal Block One (1TB)
External Relay ContactsExternal Relay Contacts
External Relay ContactsExternal Relay Contacts
External Relay Contacts
A set of external relay contacts for high voltage
(K1) and overload (K2) conditions is provided at
6PL-5, -6 & -7. See Figure 10 for exact wiring
locations. These relay contacts are sometimes
useful in configuring the control of the applicator
system.
Pneumatic ConnectionsPneumatic Connections
Pneumatic ConnectionsPneumatic Connections
Pneumatic Connections
(76447-13x)(76447-13x)
(76447-13x)(76447-13x)
(76447-13x)
Connect an atomization air pressure signal to one
pressure switch port and a trigger air pressure
signal to the other. When pressure signals (25 psi
minimum, 100 psi maximum) are applied to both
switches their contacts close, thereby activating
high voltage at the applicator. Both pressure
switches must be activated to receive high voltage.
External High VExternal High V
External High VExternal High V
External High Voltage Controloltage Control
oltage Controloltage Control
oltage Control
If a method of high voltage triggering, other than
the factory supplied method, is required, the 9040
Classic High Voltage Power Supply allows for
external high voltage control from a PLC, pressure
switch or other user supplied device. To turn the
high voltage on, the user supplied device must
create a contact closure between terminals 6 and
7 of terminal block one (1TB). To connect the user
supplied, external high voltage control device,
perform the following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged, and the ON/OFF
switch is in the OFF position.
2. Open the power supply cabinet door.
3. Route the contact wires of the control device
through the external wiring grommet and connect
to the existing wiring for 1TB-6 and 1TB-7. TheThe
TheThe
The
control device contacts must be rated for atcontrol device contacts must be rated for at
control device contacts must be rated for atcontrol device contacts must be rated for at
control device contacts must be rated for at
least 100 millamps at 15 volts DC.least 100 millamps at 15 volts DC.
least 100 millamps at 15 volts DC.least 100 millamps at 15 volts DC.
least 100 millamps at 15 volts DC.
4. Secure the cabinet door, replace the fuse, and
plug in the power supply.
External Overload ResetExternal Overload Reset
External Overload ResetExternal Overload Reset
External Overload Reset
The 9040 Classic High Voltage Power Supply
allows for use of an external (normally closed)
overload reset button. This is convenient when
the power supply is mounted in a hard to reach or
inconvenient location or when it is desired to
control overload reset of several power supplies
from a single location.
To utilize the external overload reset perform the
following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged and the ON/OFF switch
is in the OFF position.
2. Open the power supply cabinet door.
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3. Remove the factory installed jumper from 1TB-
5 to 1TB-6 and replace with contact wires of the
external reset device. The external reset deviceThe external reset device
The external reset deviceThe external reset device
The external reset device
contacts must be rated for at least 100contacts must be rated for at least 100
contacts must be rated for at least 100contacts must be rated for at least 100
contacts must be rated for at least 100
milliamps at 15 volts DC. The contacts ofmilliamps at 15 volts DC. The contacts of
milliamps at 15 volts DC. The contacts ofmilliamps at 15 volts DC. The contacts of
milliamps at 15 volts DC. The contacts of
the external reset device must be normallythe external reset device must be normally
the external reset device must be normallythe external reset device must be normally
the external reset device must be normally
closed.closed.
closed.closed.
closed.
4. Secure the cabinet door, replace the fuse, and
plug in the power supply.
NOTESNOTES
NOTESNOTES
NOTES
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OPERAOPERA
OPERAOPERA
OPERATIONTION
TIONTION
TION
Figure 3: Operating ControlsFigure 3: Operating Controls
Figure 3: Operating ControlsFigure 3: Operating Controls
Figure 3: Operating Controls
> The user MUSTMUST
MUSTMUST
MUST read and be familiar
with the Safety PrecautionsSafety Precautions
Safety PrecautionsSafety Precautions
Safety Precautions and
"Safety" Section"Safety" Section
"Safety" Section"Safety" Section
"Safety" Section in this manual and the
ITW Ransburg safety literature therein
identified BEFORE OPERATINGBEFORE OPERATING
BEFORE OPERATINGBEFORE OPERATING
BEFORE OPERATING the
9040 Classic High Voltage Power Supply.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
9040 CLASSIC HIGH VOLTAGE9040 CLASSIC HIGH VOLTAGE
9040 CLASSIC HIGH VOLTAGE9040 CLASSIC HIGH VOLTAGE
9040 CLASSIC HIGH VOLTAGE
OPERATING CONTROLSOPERATING CONTROLS
OPERATING CONTROLSOPERATING CONTROLS
OPERATING CONTROLS
1
2
3
4
5
6
7
8
Kilovolt Meter
Microamp Meter
High Voltage On Indicator
Overload Indicator / Overload Reset
On / Off Switch
Fuse Holder
Fuse Holder
High Voltage Adjust Knob
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THEORTHEOR
THEORTHEOR
THEORYY
YY
YOF OPERAOF OPERA
OF OPERAOF OPERA
OF OPERATIONTION
TIONTION
TION
Line voltage (90-264 VAC) is applied to input
terminals 8PL-1 and 8PL-2 of power supply 1SUP
through the user supplied exhaust fan and
conveyor interlocks, fuse 1FU and ON/OFF switch
1SW.
The output of power supply 1SUP, through PC
board fuse F2 provides the DC voltage which
powers the PC board regulators and the AC
Power ON LED. The DC input to the oscillator
circuit is obtained from a board regulator through
high voltage adjust knob 1POT. The oscillator
circuit outputs a low voltage, high frequency AC
signal to the high voltage multiplier circuit. The
highvoltage multiplier circuitrectifies theAC voltage
to DC and steps it up to provide rated kV to the
spray applicator via the high voltage cable. The
high voltage adjust knob controls the level of
output voltage from the oscillator to the high voltage
multiplier. In this manner, complete adjustability
from 0 to maximum kV of the spray applicator is
achieved.
The DC input to the oscillator is interlocked with
1TB terminals 6 and 7, such that the oscillator
will not function unless terminals 6 and 7 are
connected together. In this manner, high voltage
to the spray applicator is controlled as follows:
1. When pressure signals are supplied to the
pressure switches, the switch contacts close
connecting1TB-6 and 7together,thereby providing
voltage to the applicator.
2. Contact closure of a programmable controller
output, robot output, or some other user supplied
device connected to terminals 1TB-6 and 7 will
activate high voltage at the spray applicator.
3. For testing and troubleshooting, board jumper
JP4 connects 1TB-6 and 7 together, thereby
providing high voltage output (see "PC Board Test
Jumper" in the "Maintenance" section of this
manual).
2. Be sure that the high voltage adjustment knob
is turned FULLY counter-clockwise.
3. Turn the ON/OFF switch to the ON position.
The green LED will light indicating that AC power
is being supplied to the power supply.
4. The voltage to the automatic applicator is
activated by supplying adequate pressure signals
to the power supply pressure switches.
5. Turn the voltage adjustment knob to the desired
operating point as indicated by the kilovolt and
microamp meters.
Kilovolt and Microamp MetersKilovolt and Microamp Meters
Kilovolt and Microamp MetersKilovolt and Microamp Meters
Kilovolt and Microamp Meters
Thekilovolt meter indicates thevoltage in thousands
of volts (kV) present at the spray applicator. The
microamp meter indicates the current in millionths
of amps (μA) leaving the applicator.
High VHigh V
High VHigh V
High Voltage Adjustment Knoboltage Adjustment Knob
oltage Adjustment Knoboltage Adjustment Knob
oltage Adjustment Knob
The high voltage adjustment knob allows infinite
control of the spray applicator electrode voltage
between 0 and rated kV.
> Check that the power supply is properly
grounded!
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
OPERAOPERA
OPERAOPERA
OPERATINGTING
TINGTING
TING
PROCEDURESPROCEDURES
PROCEDURESPROCEDURES
PROCEDURES
1. Ensure that the AC power, pneumatics and
high voltage cables are connected as described in
the "Installation" section of this manual.
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High VHigh V
High VHigh V
High Voltage Safety Circuitoltage Safety Circuit
oltage Safety Circuitoltage Safety Circuit
oltage Safety Circuit
The 9040 Printed Circuit Board (PCB) contains a
safety circuit that prevents high voltage from being
present at the applicator if the high voltage trigger
device (pressure switch, PC contact, etc.) has not
been triggered. If a failure mode should occur that
wouldattempt to send high voltage to theapplicator,
even though the high voltage trigger has not been
activated, the PC board will shut down and enter
an overload condition. If repeated overloads occur,
every time the overload reset button is pushed,
open the cabinet door and see if the red LED (see
Figure 5, in the "Maintenance" section for
LED1location) on the PC board lights for about 2
seconds after pushing the reset button. If it does,
the PC board has failed and should be replaced.
High VHigh V
High VHigh V
High Voltage ON Indicatoroltage ON Indicator
oltage ON Indicatoroltage ON Indicator
oltage ON Indicator
The red high voltage on LED will light when high
voltage is present at the spray applicator.
AC Power ON IndicatorAC Power ON Indicator
AC Power ON IndicatorAC Power ON Indicator
AC Power ON Indicator
The green AC power ON LED will light when the
AC Power ON/OFF switch is in the ON position.
> Power supplies for applicators shipped
from the factory with the overload circuit
ON. Automatic applicators typically have a
fixed distance between electrode and target
and thus it is not likely that the spray appli-
cator would come into close proximity with
the part during normal use. If it should, then
it is desired that an overload occur to alert
maintenance so that the condition can be
corrected. Additionally, since there is no
operator with automatic applicators, the
overload circuit is required to alert mainte-
nance when failed parts may be causing
the spray applicator to operate at less than
optimum performance.
NOTENOTE
NOTENOTE
NOTE
Overload Indicator/Reset ButtonOverload Indicator/Reset Button
Overload Indicator/Reset ButtonOverload Indicator/Reset Button
Overload Indicator/Reset Button
Lighting of the yellow overload/reset lamp indicates
that an overload condition has occurred. The
overload circuitry is integral to the power supply
and is factory calibrated and sealed. It allows
normal operation, testing, and maintenance. It will
only activate if the spray applicator current exceeds
the preset limit as a result of component (barrel,
transformer, cable) failure or improper applicator
to target distance. If the overload should trip,
locate and correct the problem. Then reset the
overload by pushing the reset switch in, or turning
the ON/OFF switch OFF and back ON again.
The overload feature can be turned ON or OFF by
moving jumper JP5 on the main PC Board (see
Figure 5, in the "Maintenance" section for location
of JP5). To turn the overload circuit OFF, position
jumper JP5 so that it covers (shorts) pins 1 and 2.
To turn the overload circuit ON, position jumper
JP5 so that it covers (shorts) pins 2 and 3.
Figure 4: Component TerminologyFigure 4: Component Terminology
Figure 4: Component TerminologyFigure 4: Component Terminology
Figure 4: Component Terminology
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NOTESNOTES
NOTESNOTES
NOTES
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MAINTENANCEMAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE
ROUTINE PREVENTIVEROUTINE PREVENTIVE
ROUTINE PREVENTIVEROUTINE PREVENTIVE
ROUTINE PREVENTIVE
MAINTENANCEMAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE
In general, little maintenance is necessary to
ensure proper operation. However, it is important
to keep the interior of the unit clean and free from
moisture or foreign material. For this reason the
following must be done:
1. Keep the exterior of the unit free from dust
accumulation.
2. Always clean the exterior prior to opening the
cabinet door.
3. Open the cabinet door only to perform
maintenance or repair.
4. If the power supply end of the high voltage
cable becomes dirty, clean the end of the cable
with a suitable, clean, non-polar solvent and apply
a light coat of dielectric grease. On a yearly basis,
check to ensure that the LSCH-0009 dielectric
lubricant is covering the electrical contact point in
the high voltage tube. If not, add oil as needed.
TROUBLESHOOTINGTROUBLESHOOTING
TROUBLESHOOTINGTROUBLESHOOTING
TROUBLESHOOTING
PC Board TPC Board T
PC Board TPC Board T
PC Board Test Jumperest Jumper
est Jumperest Jumper
est Jumper
To assist in testing and troubleshooting, a jumper
(JP4) has been incorporated on the 9040 PC
board. By covering (shorting) both terminals, the
high voltage on relay is triggered. Thus, for testing
and troubleshooting, high voltage output can be
obtained without the need to trigger the spray
applicator or user supplied control device. Just
remember to reposition the jumper after testing, so
that it covers only one terminal or the high voltage
will stay on all the time. (See Figure 5 for location
of test jumper JP4.)
Figure 5: Main PC BoardFigure 5: Main PC Board
Figure 5: Main PC BoardFigure 5: Main PC Board
Figure 5: Main PC Board
> Applying LSCH-0009 dielectric lubri-
cant to the high voltage cable end signifi-
cantly reduces corona discharge that can
cause deterioration of the high voltage
connection components.
NOTENOTE
NOTENOTE
NOTE
> If JP4 is left covering (shorting) both
terminals, high voltage will be on whenever
AC power is turned on. This could be
hazardous in some applications.
C A U T I O NC A U T I O N
C A U T I O NC A U T I O N
C A U T I O N
!!
!!
!
9040 Classic HV Power Supply - Maintenance
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