9040 CLASSIC HIGH VOL 9040 CLASSIC HIGH
Contents
1. 13 TROUBLESHOOTING GUIDE 17 9040 CLASSIC NO 2 POWER SUPPLY BLOCK DIAGRAM 19 SERVIOCEIEEVELJ 20 REPLACEMENT 20 PARTS IDENTIFICATION 24 27 9040 CLASSIC NO 2 POWER SUPPLY PARTS LIST 24 RECOMMENDED SPARE PARTS 9 26 ACCESSORY PARTS LIST 26 WARRANTY POLICIES UMITEDWARRANT Y uiui tiec erecta rr tenen 28 APPENDIX 29 33 PAINT AND SOLVENT 29 VISCOSITY CONVERSION 30 VOLUMETRIC CONTENT OF HOSE TUBE 32 KV OUTPUT TEST GROUND TEST 06 33 CP 97 03 6 ARCHIVE Ransburg CP 97 03 6 97 03 6 Ransburg SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg coating system read and understand all of the technical and safety literature for your Ransburg products This manual contains in formation that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this infor mation 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 t2. ti ae Tilt possibility of residual charge causing electri N un 3 Open the cabinet door and position jumper JP4 on the main PC Board so that it covers shorts both terminals eumd 6PL Fuse F2 Figure 7 Main PC Board 15 9040 Classic for No 2 Process Handgun Maintenance Bench Testing Equipment Required Volt ohmmeter The Troubleshooting Guide Figure 9 pro vides information for troubleshooting the power supply when improper operation is obtained and the problem has been traced to the power sup ply Proper troubleshooting should ONLY be accomplished with specific test equipment by qualified electronics technicians or authorized Ransburg representatives AWARNING Procedures outlined in the Trouble shooting Guide Figure 9 require measure ment of voltage potentials that can cause SERIOUS BODILY INJURY if proper measuring procedures are not followed For this reason proper troubleshooting should ONLY be accomplished with specific test equipment by qualified electronics techni cians or authorized Ransburg representa tives Before troubleshooting ensure that the power supply is plugged into a live outlet of the appro priate voltage All electrical measurements in the Troubleshooting Guide Figure 9 are nominal and may vary as much as 10 de pending on the test conditions and the test equipment used Refer to Figures 7 and 8 f
3. 2 8 juognq 4 8 21818 8 sis 818 esiodyjuey S N a N N ISIS 818 1818 S 9 N 10 T N N N 5 lt v 10 i6 M sp x o Qu it gt gt 9040 Classic for the No 2 Process Appendix CP 97 03 6 30 9040 Classic for the No 2 Process Appendix Ransburg 3 lt lI O 9 t S QO gt 7 Q 2 gt 31 EE DLE EH D ELLE dng uewsyei9 NSS Comparisons are made with a material having a specific gravity of 1 0 ecjojojojojoljojojoeljlojojojoljoljoljoljojojojojojoljoljoljojolilojojojoejoljoijlojojoljoljojo OoOj ojojojojoljojojojojojojoljojojoljojojojojojoljoljolijojojojojoljojojojojojoljoljo jo H TO TP NEN sr LO PO co r lt 10 co r o0 O O O A
4. INTRODUCTION GENERAL DESCRIPTION The Ransburg No 2 Handgun Process The No 2 Process is an electrical atomization method for applying coatings to objects electro statically The No 2 Process Handgun system applies a high voltage negative DC charge to the applicator bell creating an electrostatic field between the bell and the target object The tar get is electrically grounded through its support which may be stationary or moving or through an electrical connection to a known true earth ground A regulated pressure fluid system delivers coat ing material to the bell when the gun is triggered There the fluid travels across the face of the rotating bell and becomes charged The fluid is electrically atomized at the edge of the bell form ing a fine mist which under the influence of the electrostatic field is attracted to and deposited on the target object The forces between the charged particles and the grounded target are sufficient to turn almost all overspray around and deposit it on the side and back surfaces of the target Thus a high percentage of the spray is deposited on the target and overspray is con trolled The 9040 Classic High Voltage Power Supply The 9040 Classic Power Supply converts stan dard 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 t
5. Figure 3 Wall Mount Brackets INPUT VOLTAGE SELECTION The 9040 Classic Power Supply accepts uni versal 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 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 itis recommended that the fuse be changed in order to keep the same level of protection Both fuses are shipped with 9040 power supplies 97 03 6 Ransburg INPUT CONNECTIONS Plug the AC line cord into a properly grounded AC outlet Any extension of the AC line cord MUST conform to the following It must be properly connected to wire with ground It must be 14 gauge minimum It must be less than 100 feet total length It should be continuous as few connections as possible NOTE For portable use the 9040 Classic No 2 Power Supply comes factory wired with an AC line cord For permanent instal lations conduit is generally required How ever if national and local codes permit the AC power may be supplied via the factory installed line cord for permanent installations also If conduit is utilized the power supply wiring MAY be routed through an optional explosion proof switc
6. CP 97 03 6 9040 Classic for the No 2 Process Handgun Safety HAZARD Tells what the hazard is Electrostatic Arcing SAFEGUARDS Tells how to avoid the hazard Never operate the spray gun without properly grounding the following A Operators Operators must be grounded Rubber soled insulating shoes should not be worn Grounding leg straps may be used Operators must maintain contact with the handle of the gun If work gloves are used the palm section should be cut out Operators must remove from themselves all metal objects that are not grounded NOTE REFER TO NFPA 33 CHAPTER 10 2000 EDITION REGARDING OPERATOR GROUNDING B Parts being sprayed Resistance between the part and a grounded conveyor must not exceed 1 megohm Every metal and conductive object in the spray area This includes the booth parts hangers fire extinguishers conductive flooring etc 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 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 gun Never install a spray gun into a fluid system using an isolated solvent supply Do not touch gun electrode while gun is energized Ensure the Ground Wire Assembly is connected from the power supply ground stud to
7. CP 97 03 6 9040 Classic for the No 2 Process Handgun Parts Identification NOTES 9040 Classic No 2 Process Warranty Policies WARRANTY POLICIES 28 LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipment that falls within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in ac cordance with Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG APPROVED PARTS VOID ALL WAR RANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR ASSO CIATED VALVES AND TUBING AND SUPPORTING HARDWARE PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY FLUID HANDLING One 1 year from date of purchase i e Totalizer CCV Valves etc AIR BEARING ROTATORS Fifteen thousand 15 000 hours or three 3 years whichever oc curs first Warranty period begins on the date of purchase ARCHIVE Ransburg RANSBURG S ONLY OBLIGATION UN DER THIS
8. F2 defective Connector 7PL or 9PL not properly plugged into main PC board Improper input line voltage Improper exhaust fan or conveyor interlock connections Defective ON OFF switch 19W Defective power supply 1SUP Defective LED display board Connector 6PL or 1PL not properly plugged in to respective locations Defective spray gun or high voltage cable Loose or broken wire in power supply Main PC board defective Defective high voltage multiplier 1 9040 Classic for the No 2 Process Handgun Maintenance Replace defective fuse Properly attach connector Ensure voltage across terminals L1 and terminal block 1TB is between 90 and 264 VAC Correct connection so that voltage across terminals L2 and N of 1TB is between 90 and 264 VAC Voltage across terminals 1A and of ON OFF switch 1SW should be between 90 and 264 VAC If not replace switch 1SW Voltage across terminals 2 and 3 of plug 7PL on main PC board should be 18 VDC If not replace power supply 1SUP Ifall otherfunctions of power supply are normal replace LED display board Properly attach connector Perform a Current Output Test on the power supply If proper readings are obtained check cable or spray gun for cause See Spray Gun s Service Manual Check all wiring connections for integrity Repair wiring as needed Disconnect 1PL from high voltage multiplier and plug in to LTST5000 Tester If improper rea
9. LOW DIACETONE ALCOHOL Ketones 123 422 LOW 2 BUTOXYETHANOL Butyl Cellosolve Glycol Ethers 111 762 LOW CYCLOHEXANOL Alcohols 108 93 0 LOW AROMATIC 150 SC 150 Aromatic Hydrocarbons j HIGH AROMATIC 200 Aromatic Hydrocarbons Y HIGH CAS Number Chemical Abstract Service Number 04 2003 Illinois Tool Works Inc All rights reserved Electrical Resistance using the Ransburg Meter Solvent Base SOR ASH OR Information Obtained From http solvdb ncms or The lowest temperature at which a volatile fluid will ignite Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1 0 NOTE Chart provides resistance and control information that we feel is necessary when using Ransburg equipment enema 0 5 5 8 5 2 5 8 8 TOE 818 8 8 18818 v ual 0 SIR AINA Aa amp 8 8 8 8 S 8 8 8 5 S 3 5 8 Oj w s do o ojo Os lt N 8 8 og elg 5 9 2 2 9 2 5 SIS S 5 2 2 25 8 10 0 N 5 5 Ransburg NSS 5 OL 2 4 9 01 218 5 2 juognq
10. Ransburg CP 97 03 6 Ransburg MANUAL CHANGE SUMMARY This manual was published to replace Service Manual CP 97 03 5 9040 Classic High Voltage Power Supply for the No 2 Process Handgun to make the following changes 1 Revised Paint and Solvent Specifications in the Appendix section CP 97 03 6 ARCHIVE Service Manual Price 30 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts gt 9 2004 Illinois Tool Works Inc rights reserved ISO 9001 4 Form 97 03 6 Models and specifications subject to change without notice ORAS 10 04 Ib
11. WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATE RIALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF THER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRO DUCTION OR INCOME WHICH RE SULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTH ERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or main tained Ransburg will assume no responsibility for repair or replacement of the item or items The purchaser therefore will assume all re sponsibility for any cost of repair or replacement and service related costs if applicable CP 97 03 6 Ransburg 9040 Classic for the No 2 Process Handgun Appendix APPENDIX PAINT AND SOLVENT SPECIFICATIONS AEROBELL 11 AEROBELL AEROBELL 33 REA EFM REM M90 NO 2 HAND GUN TURBODISK RMA 101 RECOMMENDED VISCOSITY USING A ZAHN NO 2 18 TO 30 SEC 18 TO 30 SEC 20 TO 60 SEC 20 TO 60 SEC 20 TO 60 SEC PAINT ELECTRICAL RESISTANCE 1TO1MQ AMQTOce AMQTOce RECOMMENDED DELIVERY UP TO 1000 cc min 1500 cc min 180 cc min 1000 cc min 500 cc min GUIDE TO USABLE SOLVENT SELECTION Chemical Common Category Flash CAS Evap DICHLOROMETHANE Methylene Chloride Chlorinat
12. a true earth ground Ensure that the power supply is plugged in to a properly grounded outlet 9040 Classic for No 2 Process Handgun Safety Ransburg AREA HAZARD SAFEGUARDS Tells where Tells what the hazard is Tells how to avoid the hazard hazards may occur General Use and Improperoperation or mainte Personnel must be given training in accordance Maintenance nance may create a hazard with the requirements of NFPA 33 Chapter 16 2000 edition Personnel must be properly trained in the use of this equip Instructions and safety precautions must be read ment and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection opera tion maintenance and housekeeping OSHA refer ences are Sections 1910 94 and 1910 107 Also refer to NFPA 33 2000 edition and your insurance company requirements Always turn power to the power supply OFF un plug the electrical cord from its outlet and remove the front panel fuse before opening the power sup ply door If necessary lock the power supply out so that it cannot be turned ON until the work is fin ished 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 e
13. across terminals 1 and 6 of plug Fast 2SUP 10PL of power supply 2SUP should be 24VDC If not replace power supply 250 Excessive Current 1 Shortin cable or gun 1 Remove cable from power supply If problem Draw goes away check gun or cable for cause 2 Defective main PC board 2 Test PC board with LTST5000 Tester Replace PC board if improper results are obtained 3 Defective high voltage 3 If 1 and 2 above are okay replace high multiplier voltage multiplier Excessive Shocking 1 Discontinuity in ground 1 Performthe Ground Test Procedure as circuit described in the Maintenance section of this manual Figure 9 Troubleshooting Guide Continued ARCHIVE 18 CP 97 03 6 9040 Classic for No 2 Process Handgun Maintenance Ransburg SNOILO3NNOO H3MOd QOO JNN 15 OV OO H31NI 01 X M3dWnr 3AOW3U A 2 o c 2 an 5 2 d 9 a VAN ANA x a o T g di 2 oe t p dnsz 21 Xr 97792 Alddns 504 2092 H 9 LI Ap IM f NO o 3 l 3 o 3 3 3 V Au 5 D 7 u 70 T 7 70 70 m dfc n n m ln on 11011
14. fire codes and ordinances as well as NFPA 33 SAFETY STANDARD 2000 EDITION prior to installing operating and or servic ing this equipment A WARNING 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 9040 Classic for No 2 Process Handgun Safety Ransburg AREA HAZARD SAFEGUARDS Tells where Tells what the hazard is Tells how to avoid the hazard hazards may occur Spray Area Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically Improperorinadequate opera tion and maintenance procedures Spray areas must be clean to prevent the 4 will 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 priorto cleaning flushing or maintenance during operation Frequent power supply shutdown indicates When using solvents for cleaning a problem in the system requir ing correction Those usedfor equipmentflushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100 F 37 8 C Spray booth ventilation must be kept at the rates require
15. manual is applicable to all models of the 9040 Clas sic No 2 Process Handgun Power Sup ply CP 97 03 6 Ransburg 9040 Classic for the No 2 Process Handgun Introduction SPECIFICATIONS Electrical Physical Input Height 14 inches 35 6 cm Voltage 90 264 VAC Width 12 inches 30 5 cm Current 0 6 0 3 Amps AC Depth 6 inches 15 2 cm Frequency 50 60 Hertz Weight 24 pounds 10 9 kg Wattage 60 Watts Maximum Output Voltage 0 100 kV DC Current 100 Microamps Max High Voltage Cable AC Power Connector ON Indicator High Voltage ON Indicator S Kilovolt Meter 040 Classic External x mE JL Microamp Meter Wiring O C a Grommet ON OFF Switch Ground Stud Fuse ITW Ransburg Electrostotic Systems 2 Ground Wire Assembly Figure 2 9040 Classic No 2 Power Supply Features 9040 Classic No 2 Process Installation INSTALLATION AWARNING The 9040 Classic Power Supply MUST be located outside the hazardous area See National Fire Protection Association Bulletin No 33 the Occupational Safety and Health Act of 1970 sections 1910 106 and 1910 107 and Ransburg Bulletin IL 247 Operating Your Electrostatic Coating System Safely The user MUST read and be familiar with the SAFETY and SAFETY PRECAU TIONS SECTIONS of this manual This manual MUST be read and thor oughly und
16. technicians Replacement parts are designed to be made at the assembly level See Parts Identification section of this manual for part numbers and ordering information AWARNING gt ALWAYS turn power to the power supply OFF unplug the electrical cord from its outlet remove the front panel fuse and lock the power supply out before making repairs or replacements DONOT attempt to make repairs to the printed circuit board gt DO NOT attempt to make repairs beyond those described All others should be made ONLY by Ransburg service personnel REPLACEMENT PROCEDURES Before making replacements check for defec tive wiring or connections between the affected components If there is a broken wire defective insulation or dirty loose or corroded connec tions repair or replace them before going to the expense of replacing a component Front Panel Fuse 1FU 1 Insert screwdriver into slot in front panel fuse holder push in and rotate counter clockwise 2 Remove screwdriver and fuse holder will slide out 3 Remove fuse from fuse holder and re place with new fuse see Parts Identifi cation section of this manual for part numbers 20 ARCHIVE Ransburg 4 Insert fuse holder back into front panel and with a slight inward pressure rotate screwdriver clockwise until it locks into place PC Board Fuse F2 REFER TO FIGURE 7 FOR FUSE LOCATION 1 Ensure power supply is unplugged from AC outle
17. Ensure connector 1PL faces the front of the housing before in 1TB GROUND Line Cord Ground Stalling ea ze 9 Install the high voltage multiplier assem M TB L1 Line CordHot Line Cord Hot Line bivindhe power supply Dyebcnting the 6 mounting screws to the back panel 5 Tighten side panel grommet 10 Plug connector 1PL back into the high 6 Secure cabinet door and plug power voltage multiplier reconnect 8PL and supply back in 10PL to 24 VDC supply 2SUP and se cure the relay board 22 9040 Classic for 2 Process Maintenance Ransburg 11 Secure the cabinet door and plug the power supply back in 12 Reinstall the HV cable LED Display Board 1 Ensure power supply is unplugged from AC outlet and open cabinet door 2 Unplug display board connector from 9PL on main PC board 3 Remove 2 hex nuts that mount display board to inside of cabinet door and re move display board from power supply 4 Install new display board see Parts Identification section of this manual for part numbers in power supply 5 Reconnect connector 9PL to main PC board 6 Secure the cabinet door and plug the power supply back in Kilovolt kV or Microamp pA Meter 1 Ensure power supply is unplugged from AC outlet and open cabinet door 2 Remove 2 hex nuts from wiring termi nals and remove wire lugs 3 Remove 4 hex nuts that mount meter to door 4 Remove old met
18. SERVICE MANUAL Ransburg CP 97 03 6 Supercedes CP 97 03 5 9040 CLASSIC HIGH VOLTAGE POWER SUPPLY for the No 2 Process Handgun MODELS 76657 14 NO 2 HANDGUN ELECTRIC MOTOR DOMESTIC VERSION 76657 142 NO 2 HANDGUN ELECTRIC MOTOR EXPORT VERSION IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 30 00 U S NOTE This manual has been changed from revision CP 97 03 5 to revision CP 97 03 6 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual Ransburg 9040 Classic for the No 2 Process Handgun Contents CONTENTS 0 SAFETY 1 5 SAFETY 0 2 1 HAZARDS SAFEGUARD S 2 INTRODUCTION amp 7 7 GENERAL DESCRIPTION cnra co ion ene 6 SPECIFICATIONS 5er ien cet ree ter ent dens 7 LOCATION eeeeeeeeeeeee nnnm 8 INPUT VOLTAGE 2 40 0 2 0 1 8 INPUT 22 2520 2 128 9 EXTERNAL 65 9 OPERATION 11 12 THEORY OFOPERATIGON t i caue ei neue tere 11 OPERATING 8 12 MAINTENANCE 13 23 ROUTINE PREVENTIVE MAINTENANCE 13 TROUBLESHOOTING eese esent
19. T 1 En EX _ __ BR KR AN NS IN ANS ATA A C ATA 1 59 79 5 O F E pl om DA 23 a aL 893 HlNv3 L Eh ur 4151 A1dans M gt gt 43MOd 24 81 2 2 146 QNnONO QuvOH 20 81 NEM gt gt Y 00 6 S0Z ASSY ANNONS I SAVON e d 9 1401 9 00 2929 QHO9 3N OV i 10 29 51 1 uiv HOLIMS sil noi QVO TH3A0 Svp NO 26 96 9 YLLIN dWVONOIN Wz 4 SL 10 16 9 9 YILIN 1 WL 39N34J343U zi 1dL XX v0 9Z ASSY H30QV1 JOVLIOA 0 7 65 21919313 14405 dnsz Ly 00 67992 YOLOW 21812313 AV13Y 8242 146 50 7 lt lt 67 Aldd S 20781 9151 1 2689 Od 809 OO FrSSL XSSv 801025802 7H NODI 824 A18W3SSV GYVOE Od 2689 20 65792 QNHVOH 19510 031 8241 10 92 1540 430 0 83004 HOllMS MSI 0 68911 5 VL ISNI v3 0 28003 51 5 Vy ISNI Z3 10 12221 18 015 OVAOZZ 3504 90 17427 MO18 MOIS VL 2 011 3504 nui N d 25 T08MAS 9040 Classic No 2 Power Supply Block Diagram Figure 10 19 CP 97 03 6 9040 Classic for No 2 Process Handgun Maintenance SERVICE LEVEL Personnel who service this unit must be quali fied electronics
20. aintenance Attach the appropriate HV cable to the Test Probe 76652 01 properly ground the probe to a true earth ground and turn the Test Probe Meter on see Operation Manual of 76652 01 Tester Insert the Test Probe HV cable into the Power Supply HV Tube until it bottoms out NOTE gt Ensure that the Test Probe HV cable makes good contact both inside the Test Probe and inside the Power Supply HV Tube Turn the power supply ON Read the output voltage displayed on the meter then turn the power supply OFF If the voltage DOES READ correctly see Specifications in the Introduction section of this manual the problem is not in the Power Supply therefore the HV Cable and spray gun should be checked for the cause If the voltage DOES NOT READ correctly the problem is with the power supply Con sult the Troubleshooting Guide Figure 1 EE AC power to the power supply 9 to locate the specific problem FF 8 Disconnect Test Probe 76652 01 2 Remove the high voltage HV cable and reposition JP4 so that it covers only from the power supply one terminal When ready to resume spray operations reconnect the spray WARNING gun HV cable and turn the power supply Whenever removing high voltage cables 5 from equipment ground the plug end of the cable s by contacting the plug to electrical LED1 JP4 ground DO NOT touch the plug until it has TES idm been grounded This will eliminate the om
21. ated by turning the toggle switch on the back of the gun to the ON position Kilovolt and Microamp Meters The kilovolt meter indicates the voltage in thou sands of volts kV present at the bell edge The microamp meter indicates the current in mil lionths of amps pA leaving the bell edge High Voltage Safety Circuit The 9040 Printed Circuit Board PCB contains a safety circuit that prevents high voltage from being present at the gun if the high voltage trig ger device gun toggle switch flow switch pres sure switch PC contact etc has not been trig gered If a failure mode should occur that would attempt to send high voltage to the gun even though the high voltage trigger has not been ac tivated the PC Board will shut down and enter an overload condition If repeated overloads oc cur every time the overload reset button is pushed open the cabinet door and see if the red LED LED1 see Figure 7 for location on the PC Board lights for about 2 seconds after push ing the reset button If it does the PC Board has failed and should be replaced High Voltage ON Indicator The red high voltage on LED will light when high voltage is present at the spray gun AC Power ON Indicator The green AC power ON LED will light when the AC Power ON OFF switch is in the ON posi tion CP 97 03 6 97 03 6 Ransburg MAINTENANCE ROUTINE PREVENTIVE MAINTENANCE In general little maintenance is necessary to ensu
22. d by NFPA 33 2000 Edition 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 voltageto be on but only as instructed Non factory replacement parts or unauthorized equipment modifications may cause fire or injury The paint process and equipment should be set up andoperatedin accordance with NFPA 33 NEC and OSHA requirements Explosion Hazard Halogenated hydrocarbon solvents Aluminum is widely used in other spray application Incompatible for example methylene chloride equipment such as material pumps regulators Materials and 1 1 1 Trichloroethane are not triggering valves etc Halogenated hydrocarbon chemically compatible with solvents mustneverbe used with aluminum equipment aluminum that might be used during spraying flushing or cleaning Read the label many system components data sheet for the material you intend to spray If chemical reaction caused by these in doubt as to whether or not a coating or cleaning solvents reacting with aluminum material is compatible contact your material supplier can become violent and lead to an Any othertype of solvent may be used with aluminum equipment explosion equipment CP 97 03 6 Ransburg AREA Tells where hazards may occur Spray Area
23. dings are obtained replace main PC board Disconnect HV cable from power supply If problem is still present connect LTST5000 Tester to 1PL and test If results of test are okay replace high voltage multiplier Figure 9 Troubleshooting Guide Continued on Next Page 17 97 03 6 9040 Classic for 2 Process Maintenance Ransburg Motor Not Rotating 1 Improperinputline voltage 1 Ensure voltage across terminals 1 and 2 of And No kV Output At to connector 8PL connector 8PL is between 90 and 264 VAC Spray Gun LED1 Off 2 Defective 24 VDC power 2 Voltage across terminals 1 and 6 of plug supply 2SUP 10PL of power supply 250 should be 24VDC If not replace power supply 2SUP Motor Not Rotating 1 Defective control wires in 1 Check for continuity from 2TB 3 of relay And No kV Output At cable or switch in gun board to gun handle when switch at gun is Spray Gun LED1 On ON If no continuity replace high voltage cable or gun ON OFF switch 2 Defective relay board 2 1 above checks ok replace relay board Motor Not Rotating 1 Defective relay board fuse 1 Replace defective fuse But kV Output Ok LED2 Off Motor Not Rotating 1 Defective control wiresin 1 Replace high voltage cable But kV Output Ok high voltage cable LED2 On Intermittent Motor 1 Defective high voltage 1 Replacehigh voltage multiplier Operation multiplier Motor Rotating Too 1 Defective power supply 1 Voltage
24. ed Solvents 75 09 2 HIGH VM amp NAPHTHA Naptha Aliphatic Hydrocarbons 8030 30 6 HIGH ACETONE Ketones 67 64 1 LOW METHYL ACETATE Esters 79 20 9 LOW BENZENE Aromatic Hydrocarbons 71 43 2 HIGH ETHYL ACETATE Esters 141 78 6 MEDIUM 2 BUTANONE MEK Ketones 78 93 3 i MEDIUM ISO PROPYL ACETATE Esters 108 21 4 i LOW ISOPROPYL ALCOHOL IPA Alcohols 67 63 0 i LOW 2 PENTANONE MPK Ketones 107 87 9 MEDIUM METHANOL Methyl Alcohol Alcohols 67 56 1 i LOW PROPYL ACETATE n Propyl Acetate Esters 109 60 4 LOW TOLUOL Toluene Aromatic Hydrocarbons 108 88 3 HIGH METHYL ISOBUTYL KETONE MIBK Ketones 108 10 1 MEDIUM ISOBUTYL ACETATE Esters 110 19 0 LOW ETHANOL Ethyl Alcohol Alcohols 64 17 5 LOW BUTYL ACETATE Esters 123 86 4 1 LOW ETHYLBENZENE Aromatic Hydrocarbons 100 41 4 HIGH 1 PROPANOL n Propyl Alcohol Alcohols 71 23 8 LOW 2 BUTANOL sec Butyl Alcohol Alcohols 78 922 LOW XYLOL Xylene Aromatic Hydrocarbons 1330 02 07 HIGH AMYLACETATE Esters 628 63 7 MEDIUM 2 METHYLPROPANOL iso Butyl Alcohol Alcohols 78 83 LOW METHYL AMYL ACETATE Esters 108 84 9 LOW 5 METHYL 2 HEXANONE MIAK Ketones 110 12 3 MEDIUM 1 BUTANOL n Butyl Alcohol Alcohols 71 36 33 LOW 2 ETHOXYETHANOL Glycol Ethers 110 80 5 LOW 2 HEPTANONE MAK Ketones 110 43 0 MEDIUM CYCLOHEXANONE Ketones 108 94 1 MEDIUM AROMATIC 100 SC 100 Aromatic Hydrocarbons HIGH DIISOBUTYL KETONE DIBK Ketones 108 83 8 MEDIUM 1 PENTANOL Amyl Alcohol Alcohols 71 41 0
25. ent Output SCI Test should be performed to help determine if the power supply is at fault see Figure 6 NOTE gt Ifthe power supply SCI is normal and the control circuit operates correctly when jumpered then any lack of high voltage or control malfunction should be isolated to the gun and or high voltage cable Equipment Required Test Assembly 76652 02 Test Resistor 16688 02 Clip Lead User Supplied 1 Turn high voltage OFF and disconnect AC power to the unit 2 Remove the high voltage HV cable from the power supply AWARNING Whenever removing high voltage cables from equipment ground the plug end of the cable s by contacting the plug to electrical ground DO NOT touch the plug until it has been grounded This will eliminate the possibil ity of residual charge causing electrical shock 3 Using the 76652 02 Test Assembly with gun test leads attached or other suitable connect the negative lead white to the grooved metal end of the Test Resistor 16688 02 and the positive lead black to the rim of the High Volt age Cable Connector AWARNING ALWAYS ensure step 3 has been completed before proceeding with step 4 4 Insert the Test Resistor 16688 02 into the High Voltage Tube of the power sup ply 5 Set the switch on the Test Assembly 76652 02 to the uA position if using a VOM set the scale for 200 microamps 6 Connect the AC source power and turn the pow
26. er and install new one See Parts Identification section of this manual for part numbers 5 Reconnect wire lugs to meter purple wire goes to terminal of meter 6 Secure cabinet door and plug power supply back in Main PC Board 1 Ensure power supply is unplugged from AC outlet and open cabinet door 2 Disconnect plugs 6PL 7PL and 9PL see Figure 7 3 Remove 2 screws from heat sink base and lift the PC board out gt DO NOT remove the PC board from the heat sink as it is an integrated assem bly 4 Insert new PC Board see Parts Identifi cation section of this manual for part numbers and secure the 2 heat sink Screws 5 Reconnect plugs 6PL 7PL and 9PL 6 Secure cabinet door and plug power supply back in Relay Board 1 Ensure power supply is unplugged from AC outlet and open cabinet door 2 Disconnect plug 2TB from the relay board 3 Remove the 4 mounting screws from the relay board 4 Install new relay board see Parts Iden tification section of this manual for part numbers and secure mounting screws 5 Reconnect plug 2TB to the relay board 6 Secure the cabinet door and plug the power supply back in 97 03 6 Ransburg Power Supply 1SUP i Ensure power supply is unplugged from AC outlet and open the cabinet door 2 Remove the 4 screws from the 1SUP power supply cover plate and remove the plate AWARNING ALWAYS double check that
27. er supply ON OFF switch to the ON position 7 Using the clip lead short circuit the High Voltage Cable Connector pin 1CON 3 to ground rim of High Voltage Cable Con nector as shown in the balloon of Fig ure 6 When proper connection is made the red high voltage ON Indicator will light NOTE PC Board Test Jumper JP4 may be used instead of the user supplied clip lead to trigger the high voltage on See PC Board Test Jumper discussed earlier in this section for further information 8 Read the current draw on the Test As sembly 76652 02 or VOM The read ing should be approximately 75 to 110 microamps Readings outside of these limits are indications of a defective power supply Refer to the Trouble shooting Guide Figure 9 to locate the specific problem 9 Turn all power OFF wait 10 seconds to allow high voltage charge to drain off remove the Test Assembly and Resis tor and restore the unit to operating con dition 14 CP 97 03 6 Ransburg 9040 Classic for the No KV Output Test 4 When lack of high voltage at the spray gun indicates a problem a kV Output Test of the Power Supply may be performed to help deter mine whether it is at fault oH Me Figure 6 Current Output Test Equipment Required Calibrated Ransburg High Voltage Test Probe and Meter 76652 01 KV Output Test Procedure 2 Process Handgun M
28. erstood by 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 ALL local building and fire codes and ordinances as well as NFPA Standard 33 and The Occupational Safety and Health Act of 1970 OSHA prior to installing operating and or servicing this equipment NOTE Aseachinstallation is unique this in formation is intended to provide general in stallation information for the 9040 Classic Power Supply Consult your authorized Ransburg distributor for specific directions pertaining to the installation of your equip ment LOCATION Install the 9040 Classic Power Supply in an area outside the hazardous location where it will be protected from the possibility of environ mental intrusion such as dust or moisture and ambient temperatures do not exceed 120 F but as close to the applicator as possible to mini Ransburg mize the length of the high voltage cable The Power Supply may be free standing on any flat surface or wall mounted by rotating the wall mount brackets supplied as shown in Figure 3 In either case the power supply MUST be mounted in an upright position DO NOT lay the power supply on its side or back DO NOT locate the power supply near or adjacent to heat producing equipment such as ovens high wattage lamps etc
29. h mounted on or near the spray booth where it will be convenient to the operator Input Circuit Test Prior to applying AC power to the Power Sup ply the phase and ground of the AC receptacle and or extension cord MUST be tested using the Circuit Tester P N 20868 00 If the circuit is found to be faulty or out of phase the circuit MUST be corrected before operating the power supply Operation of the power supply on an ungrounded or improper circuit can lead to component failure or unsafe operation CP 97 03 6 9040 Classic for the No 2 Process Handgun Installation EXTERNAL CONNECTIONS NOTE When connecting external control wires to the 9040 Classic Power Supply route the wiring through the external wiring grommet located on the side panel High Voltage HV Cable Connection Remove the plastic protective plug from the HV Cable Connector and squirt enough of the sup plied dielectric oil 70863 00 into the HV Tube to cover the electrical contact point NOTE Squirting dielectric 70863 00 down the HV Tube significantly reduces corona discharge that can cause deterioration of the HV connection components With a clean dry cloth wipe the end of the HV Cable Insert the HV Cable into the HV Cable Connector and tighten the cable nut securely Safety Ground Crimp the appropriate connector onto the Ground Wire Assembly and install from the power supply ground stud located on the side
30. hat 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 proce dure 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 draw ings and appropriate Ransburg equipment manuals to reconcile such differences Careful study and continued use of this manual will provide a better understanding of the equip ment and process resulting in more efficient op eration 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 represen tative or Ransburg 9040 Classic for the No 2 Process Handgun Safety A WARNING The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified This manual MUST be read and thor oughly 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
31. hen transferred from the 9040 Classic Power Supply to the No 2 Pro cess spray gun through a super flex high volt age cable The voltage current characteristic is designed to optimize the charging process un der varying load conditions and to limit the oper ating current to a safe maximum value Ransburg In addition to supplying high voltage output to the spray gun the 9040 Classic power supply also provides controls for AC power ON OFF a high voltage meter a current meter a POWER ON indicator a HIGH VOLTAGE ON indicator and a CURRENT OVERLOAD indicator and reset switch Additionally output terminals are provided for remote overload reset and interlock connections for a conveyor exhaust fan and high voltage control on all 9040 Classic Power Supplies NOTE 9040 Classic No 2 Power Supply is factory supplied with a cabinet latch that can be opened using a slotted screw driver If desired the standard latch can be easily replaced with a latch that re quires the use of a key to open This key lock can be ordered from Austin Hard ware Inc 8001 Central Ave N E Minneapolis MN 55432 1 800 328 2423 Key Lock Part Number C8052 14A The 9040 Classic Power Supply is available as follows 9040 Used with No 2 Part No Gun Type 76657 14 Electric Motor Domestic 19372 76657 142 Electric Motor Export 19372 Figure 1 9040 Classic Power Supply Availability NOTE gt Except where indicated this
32. ied control device Just remember to reposition the jumper after testing so that it covers only one terminal open or the high voltage will stay on all the time see Figure 7 for location of test jumper JP4 gt f 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 Ground Test Procedure Equipment Required Ohmmeter To Measure Resistance 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 proper grounding Proper grounding of the spray gun system can be verified as follows 1 Ensure that clamp of the 14 AWG Ground Wire Assembly is connected to true earth ground The resistance be tween the clamp and a known earth ground should read less than 25 ohms 2 Place one end of the ohmmeter on the clamp of the Ground Wire Assembly and the other end on the Power Supply ground stud If the ohmeter reads greater than 25 ohms replace the 14 AWG Ground Wire Assembly 1 9040 Classic for 2 Process Maintenance Ransburg 3 Connect one end of the ohmeter to the Power Supply ground stud and the other to the metal gun handle If the ohmeter reads greater than 25 ohms repair or re place the high voltage cable Current Output SCI Test When a lack of high voltage at the applicator in dicates a problem a Curr
33. internal wiring 3 Using a small blade screw driver re move the factory installed jumper from 1 TB L1 to 1TB L2 4 Route exhaust fan and conveyor inter lock 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 4 The Interlock contacts should be rated for at least 1 Amp at 240 volts AC 5 Secure the cabinet door replace the fuse and plug the power supply in Ransburg yo by User Remote 1TB HV Trigger 7 11 Voltage Trigger froml or Remote Switch Iz ela In Ground In Common Neutral Interlock Hot Line Interlock Exhaust Fan Interlock Conveyor In Hot Line 1SUP 2SUP Line G s2 To 150 2SUP Neutral From 1SW 1A From 1SW 2A Figure 4 Terminal Block One 1TB External Relay Contacts A set of external relay contacts for High Voltage K1 and overload K2 conditions is provided at 6PL 5 6 amp 7 See Figure 10 in the Mainte nance section of this manual for exact wiring locations These relay contacts are sometimes useful in configuring the control of the spray gun system External High Voltage Control If a method of high voltage triggering other than the factory supplied method is required the 9040 Classic Power Supply allows for external high voltage control from a PLC pressure
34. l is broken If the high voltage multiplier is defective con tact your authorized Ransburg representa tive for exchange or repair 1 Remove HV cable from power supply 2 Ensure power supply is unplugged from 6 Secure cabinet door and plug power AC outlet and open cabinet door supply back in 3 Unplug connector 1PL from the top of AC Line Cord the high voltage multiplier Ie Ensure power supply is unplugged from 4 R h h he hi AC outlet and open the cabinet door emgve Ie serews that high voltage multipliers aluminum housing to WARNING the back panel gt ALWAYS double check that the power 5 Disconnect 8PL and 10PL from 24 VDC supply is unplugged from its AC outlet power supply 2SUP and remove 4 before working with any internal wiring mounting screws from the relay board 2 Using a screwdriver disconnect dam 6 Rotate the high voltage multiplier assem aged line cord from 1TB L1 1TB N and bly out from the power supply 1TB GROUND 7 Remove the 3 screws that secure the 3 Loosen the line cord grommet on side aluminum housing to the high voltage panel and pull damaged cord out multiplier 4 Insert new line cord see Parts Identifi 8 Install the aluminum housing on the new cation section of this manual for part high voltage multiplier see Parts Identi numbers through grommet and connect fication section of this manual for order to 1TB as follows ing information
35. lectrical shock The High Voltage Multiplier Assembly contains en ergy storage components that can cause serious shock injury and therefore is not field repairable Warranty will be voided if the High Voltage Multi plier seal is broken If the High Voltage Multiplier is defective contact your authorized Ransburg rep resentative 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 bleed off before opening the cabinet door or removing the high voltage cable from the power supply or spray gun CP 97 03 6 Ransburg 9040 Classic for the No 2 Process Handgun Safety AREA HAZARD SAFEGUARDS Tells where Tells what the hazard is Tells how to avoid the hazard hazards may occur Toxic Substances Certain material may be harmful Follow the requirements of the Material Safety Data if inhaled or if there is contact Sheet supplied by coating material manufacturer with the skin 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 pre scribed by an industrial hygienist or safety expert and be NIOSH approved 9040 Classic for No 2 Process Introduction
36. los est to bottom of unit when installing Reinstall high voltage multiplier assem bly in power supply Plug connector 1PL back into the high voltage multiplier Reconnect plugs 8PL and 10PL to the 24 VDC supply and resecure the relay board Secure the cabinet door plug the power supply back in and reinstall the HV cable 23 9040 Classic the 2 Process Ransburg Parts Identification PARTS IDENTIFICATION 1 o o 99 6 3sw E 9 LSS tri S S 1 dH S 619 IS SI SS SS 2 9 6 8 5 Eres oe Figure 11 9040 Classic No 2 Power Supply Parts Diagram CP 97 03 6 24 Ransburg 9040 Classic for the No 2 Process Parts Identification 9040 CLASSIC 2 POWER SUPPLY PARTS LIST Figure 11 Lem Descrion Number Notation _____ memo 76657 14 76657 142 76892 14 76657 14 76657 142 76304 03 Kilovolt kV Meter Microamp uj Meter 76435 92 18 75337 05 1SUP Fuse PC Board Slow Blow 4 Amp See Figure 7 for Location LSME0082 04 F2 Fuse Front Panel Slow Blow 1 Amp 110 120 VAC Input 72771 06 1FU Slow Blow 0 5 Amp 220 240 VAC Input 72771 01 1FU AC Line C
37. or location of parts called out in the Troubleshoot ing Guide For bench testing jumper JP4 should be used to trigger the high voltage output see PC Board Test Jumper previously discussed in this section TheHigh Voltage Multiplier and high voltage cable contain significant capaci tance that will store charge ALLOW approximately 10 seconds for this charge to bleed off BEFORE opening the cabinet door OR REMOVING the high voltage cable from the power supply or spray gun Ransburg Diagnostic LED s There are two diagnostic LED s located on the relay board inside the cabinet see Figure 8 is a green LED that indicates 24 VDC in put is being received from power supply 2SUP LED1 should lit whenever the power supply ON OFF switch is ON LED2 is a red LED that indicates 24 VDC is being output to the gun mo tor LED2 should be lit whenever the toggle switch at the back of the gun is turned ON HIGH VOLTAGE LED2 LED1 RELAY 8PL BOARD Figure 8 Troubleshooting Diagram CP 97 03 6 Ransburg TROUBLESHOOTING GUIDE AC Power ON Indicator 1 Green LED Does Not Light When ON OFF Switch Is On Motor Rotating But No Or Low kV Output At Spray Gun Front panel fuse 1FU or PC Board fuse
38. ord 6262 00 Ground Wire Assembly 70539 00 LED Display Board 76455 02 11 13 Overload Indicator amp Reset Switch Assembly Reset Switch Normally Closed 76442 01 Lens Yellow 76441 00 Bulb 76443 01 Fi 25 9040 Classic No 2 Process Parts Identification Ransburg 9040 CLASSIC NO 2 POWER SUPPLY RECOMMENDED SPARE PARTS LIST Pp y O 76436 92 2 Fuse Front Panel 72771 06 2 4 Two Required Fuse PC Board LSME0082 04 1 2 __ _____ 1 Deluxe Test Kit 76652 04 For Troubleshooting Purposes Only Test Resistor 16688 02 For Troubleshooting Purposes Only Main PC Board 76892 14 High Voltage Multiplier 76304 03 ________ Relay Board 76649 00 Pp y 18 75337 05 1 1 Tester LTST5000 00 1 1 For Troubleshooting Purposes Only 1 1 24 VDC Supply 75337 04 Fuse Relay Board 11689 03 Figure 12 9040 Classic High Voltage Power Supply Recommended Spare Parts List 9040 CLASSIC HIGH VOLTAGE POWER SUPPLY ACCESSORY PARTS LIST Control Unit Power Supply Test Assembly LTST5000 00 High Voltage Test Probe and Meter 76652 01 Ll Circuit Tester 20868 00 Po D Ld Test Resistor 525 Megohms 16688 02 Deluxe Test Kit Includes Items 2 amp 4 above and 76652 04 Paint Meter Test Probe Figure 13 9040 Classic High Voltage Power Supply Accessory Parts List Test Assembly SCI amp ARCHIVE 26 CP 97 03 6 Ransburg
39. panel to a true earth ground The Ground Wire Assembly MUST be connected from the Power Supply ground stud to a true earth ground DO NOT attach the ground wire from the Power Supply to the part being coated Damage to the power supply will occur Separate ground wires MUST be used for grounding the part and the Power Supply 10 9040 Classic No 2 Process Installation Interlocks AWARNING ALWAYS ensure that high voltage 15 OFF before flushing the spray gun with solvent NEVER flush the spray gun 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 As outlined in NFPA 33 and OSHA standard 1910 the AC power line must be series inter locked with both the exhaust fan and conveyor To interlock the 9040 Classic power supply with the exhaust fan and conveyor perform the fol lowing 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 AWARNING ALWAYS double check that the power supply is unplugged from its AC Outlet before working with any
40. re proper operation It is important how ever to keep the interior of the unit clean and free from moisture or foreign material For this reason 1 Keep the exterior of the unit free from dust accumulation 2 Always clean the exterior prior to open ing the cabinet door 3 Open the cabinet door only to perform maintenance or repair 4 If the power supply end of the high volt age 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 dielectric oil 70863 00 is covering the electrical contact point in the High Voltage Tube If not add oil as needed NOTE Squirting dielectric 70863 00 down the HV Tube significantly reduces corona discharge that can cause deterioration of the HV connection components Perform a Current Output SCI Test ap proximately every 50 hours of high volt age operation Never immerse any part of or all of an assembled applicator in any liquid 9040 Classic for the No 2 Process Handgun Maintenance TROUBLESHOOTING PC Board Test 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 volt age output can be obtained without the need to trigger the spray gun or user suppl
41. sr OLS 10 0 10 OC O NEN Y sr t0 10 A Note All viscosity comparisons are as accurate as E with existing information CP 97 03 6 9040 Classic for No 2 Process Handgunf Appendix Ransburg VOLUMETRIC CONTENT OF HOSE OH TUBE English Units LD Cross Length cc ft Section nches s 60 BEEBEdE 3E IEEE 4 fl oz 81 02 121 02 204 02 4 fl OZ 02 18 fl OZ 28 fl OZ 461 02 9 2 fl 02 1 6 fl oz 3 3 fl oz 4 9 fl oz 8 2 fl oz 16 3 fl oz CR ae 2 5 fl oz 511 02 761 OZ 12 7 fl OZ 25 5 fl 02 LO LT 7 rano 3 7 fl oz 731 OZ 110 fl OZ 184 fl OZ 367 fl OZ 8 6 051 gal 102 gal 153 gal 255 gal 510 gal 6 5 fl oz 13 1 fl oz 19 6 fl oz 32 6 fl oz 65 3 fl oz VOLUMETRIC CONTENT OF HOSE TUBE Metric Units Cross I D cc m Section E mm 15m som asm 32 CP 97 03 6 Ransburg 9040 Classic for the No 2 Process Handgun Appendix kV Output Test Ground Test Pages 16 amp 17 Yearly Pages 15 amp 16 Yearly Figure 14 kV Output Test amp Ground Test Log 5
42. switch air flow switch or other user supplied device Toturn the high voltage on the user supplied device must create a contact closure between terminals 6 and 7 ofterminal blockone 1TB To connectthe 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 grom met and connect to the existing wiring for 1TB 6 and 1TB 7 The control de vice contacts must be rated for at least 100 milliamps at 15 volts DC 4 Secure the cabinet door replace the fuse and plug in the power supply CP 97 03 6 Ransburg 9040 Classic for the No 2 Process Handgun Operation OPERATION AC Power ON Kilovolt Meter indicator 2 N gt Y 9040 Classic Microamp Meter AC Power ON OFF Switch High Voltage ON Indicator Figure 5 Operating Controls AWARNING The user MUST read and be familiar with the SAFETY SECTION of this AWARNING electrical discharge which is available from the charging electrode of the applicator must not exceed 0 25 mJ of energy To achieve this limit any flow of energy from the paint supply through the paint line to the gun electrode MUST be prevented by grounding the paint line at
43. t age cable 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 volt age to the spray gun is controlled as follows 1 Turning the ON OFF toggle switch at the back of the spray gun to the ON position grounds relay board coil K3 thereby ac tivating the coil Activation of the coil closes its two normally open contacts Closure of one set of contacts supplies LED2 and 24 VDC to the motor Clo sure of the second set of contacts con nects 1TB 6 and 7 together thereby pro viding high voltage to the handgun 2 Contact closure of a programmable con troller output robot output or some other user supplied device connected to termi nals 1TB 6 and 7 will activate high volt age at the spray gun 3 For testing and troubleshooting board jumper JP4 connects 1TB 6 and 7 to gether thereby providing high voltage output See PC Board Test Jumper in the Maintenance section of this manual OPERATING PROCEDURES 1 Ensure that the AC power and high volt age cables are connected as described in the Installation section of this manual Ransburg Check that the power supply is properly grounded 2 Turn the ON OFF switch to the ON posi tion The green LED will light indicating that AC power is being supplied to the power supply 3 The voltage to the No 2 hand gun is ac tiv
44. t and open cabinet door 2 Replace defective fuse see Parts Iden tification section of this manual for part numbers NOTE gt A spare F2 PC board fuse included from the factory is located in the lower right hand corner inside the cabinet door 3 Secure cabinet door and plug power supply back in ON OFF Switch 1SW 1 Ensure power supply is unplugged from AC outlet and open the cabinet door AWARNING ALWAYS double check that the power supply is unplugged from its AC outlet before working with any internal wiring 2 Remove the four quick connect termi nals from the rear of ON OFF switch 1SW NOTE gt It is recommended that the four ON OFF switch wires be tagged with their re spective terminal connections to 1SW be fore removing 3 Press panel retaining clips on top and bottom of switch 1SW together and push switch out of panel from the inside CP 97 03 6 Ransburg 9040 Classic for the No 2 Process Handgun Maintenance 4 Press new switch see Parts Identifica High Voltage Multiplier tion section of this manual for part num bers into panel opening with terminals NOTE 1A and 2A to the bottom of the cabinet Because high voltage multiplier 5 Reconnect the four quick connect termi contains energy storage components that nals to the new switch as follows can cause serious shock injury it is not field repairable Warranty will be voided if the high voltage multiplier sea
45. the TH EORY OF OPERATION gun handle or body Verify that the appli cator is actually grounded BEFORE REFER TO FIGURE 10 operating it See the appropriate spray gun manual If improper readings are Line Voltage 90 264 VAC is applied to input obtained check that the power supply is terminals 11PL 1 and 11PL 2 of 18 VDC Power grounded see Ground Test Procedure in Supply 1SUP through the user supplied exhaust the Maintenance section of this manual fan and conveyor interlocks fuse 1FU and ON OFF switch 1SW Line voltage from ON OFF switch 1SW is also supplied to the input of the 24 VDC power supply 2SUP The 24 VDC out put of the power supply is then supplied to CP 97 03 6 ARCHIVE 11 manual and the Ransburg safety literature therein identified BEFORE OPERATING the 9040 Classic power supply 9040 Classic No 2 Process Handgun Operation 12 LED1 the end of relay coil mounted on the relay board and one of its normally open contacts 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 The oscillator circuit outputs a low voltage high fre quency AC signal to the High Voltage Multiplier Circuit The High Voltage Multiplier Circuit recti fies the AC voltage to DC and steps it up to pro vide rated kV to the spray gun via the high vol
46. the power supply is unplugged from its AC outlet before removing the cover plate from power supply 1SUP 3 Remove connectors 11PL and 12PL from power supply 1SUP 4 Remove the 4 cover plate standoffs from power supply 1SUP and remove the power supply from the unit 5 Install new 1SUP power supply see Parts Identification section of this manual for part numbers using the 4 cover plate standoffs Ensure larger ter minal strip 12PL of power supply 1SUP faces left side of unit as shown in Figure 8 6 Connect connectors 11PL and 12PL to new power supply and reinstall cover plate 7 Secure cabinet door and plug power supply back in 24 VDC Power Supply 2SUP 1 Remove HV cable from power supply 2 Ensure power supply is unplugged from AC outlet and open cabinet door 3 Unplug connector 1PL from the top of the high voltage multiplier 10 11 9040 Classic for the No 2 Process Maintenance Remove the screws that mount the high voltage multipliers aluminum housing to the back panel Disconnect plugs 8PL and 10PL from 24 VDC power supply 2SUP and remove the 4 mounting screws from the relay board Rotate the high voltage multiplier assem bly out from the power supply Remove the 4 mounting screws from the 24 VDC supply Install the new 24 VDC supply see Parts Identification section of this manual for part numbers Ensure two pin connector of 24 VDC supply is c
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