Professional Documents
Culture Documents
CP-97-02.5
(Replaces CP-97-02.4)
May - 2008
E
IV
H
C
R
A
MODEL:
76447-10X / REA-IV APPLICA
APPLICATT OR
76447-12X / REA-III APPLICA
APPLICATT OR
76447-13X / REA-III AUT OMA
AUTOMA TIC
OMATIC
76447-14X / M90 CLASSIC APPLICA T OR
APPLICAT
IMPOR
IMPORT TANT
ANT:: 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: 25.00
25.00 (Euro)
$30.00 (U.S.)
N O T E : This manual has been changed from revision CP-97-02.4 to revision CP-97-02.5
CP-97-02.5.
Reasons for this change are noted under Manual Change Summary inside the back
cover of this manual.
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CP-97-02.5
9040 Classic for REA & M90 Systems - Contents
CONTENTS
PAGE
SAFETY: 1-6
SAFETY PRECAUTIONS........................................................................................................... 1
HAZARDS / SAFEGUARDS....................................................................................................... 2-5
ATEX 7-8
EUROPEAN ATEX DIRECTIVE................................................................................................. 7
EUROPEAN ATEX LABELS....................................................................................................... 8
INTRODUCTION: 9-11
GENERAL DESCRIPTION......................................................................................................... 9-10
SPECIFICATIONS...................................................................................................................... 10
9040 CLASSIC FOR REA / M90 FEATURES............................................................................ 11
INSTALLATION: 12-16
LOCATION.................................................................................................................................. 12
INPUT VOLTAGE SELECTION................................................................................................. 12
INPUT CONNECTIONS............................................................................................................. 13
EXTERNAL CONNECTIONS..................................................................................................... 13-15
TYPICAL REA AND M90 APPLICATOR INSTALLATIONS...................................................... 16
OPERATION: 17-20
OPERATING CONTROLS......................................................................................................... 17
THEORY OF OPERATION........................................................................................................ 18
OPERATING PROCEDURES.................................................................................................... 18-19
MAINTENANCE: 21-34
ROUTINE PREVENTIVE MAINTENANCE................................................................................ 21
TROUBLESHOOTING................................................................................................................ 21-24
SERVICE LEVEL......................................................................................................................... 24
REPLACEMENT PROCEDURES.............................................................................................. 25-29
TROUBLESHOOTING GUIDE................................................................................................... 30-31
TROUBLESHOOTING DIAGRAM............................................................................................. 32
9040 CLASSIC POWER SUPPLY BLOCK DIAGRAM............................................................. 33
WARRANTY POLICIES: 39
LIMITED WARRANTY.................................................................................................................39
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CP-97-02.5
9040 Classic for REA & M90 Systems - Safety
SAFETY
SAFETY PRECAUTIONS ! WARNING
Before operating, maintaining or servicing any
> The user MUST read and be familiar
ITW Ransburg coating system, read and
with the Safety Section in this manual and
understand all of the technical and safety literature
the ITW Ransburg safety literature therein
for your ITW Ransburg products. This manual
identified.
contains information that is important for you to
know and understand. This information relates to
USER SAFETY and PREVENTING EQUIPMENT
> This manual MUST be read and thor-
PROBLEMS. To help you recognize this oughly understood by ALL personnel who
information, we use the following symbols. Please operate, clean or maintain this equipment!
pay particular attention to these sections. Special care should be taken to ensure that
the WARNINGS and safety requirements
A WARNING! states information to alert you for operating and servicing the equipment
to a situation that might cause serious injury are followed. The user should be aware of
if instructions are not followed. and adhere to ALL local building and fire
codes and ordinances as well as NFPA-33
A CAUTION! states information that tells SAFETY STANDARD prior to installing,
how to prevent damage to equipment or how operating, and/or servicing this equipment.
to avoid a situation that might cause minor
injury.
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1 CP-97-02.5
9040 Classic for REA & M90 Systems - Safety
Spray Area Fire Hazard The 76447 power supply MUST be installed in a
NON-hazardous location in accordance with NFPA-
Improper or inadequate operation 33.
and maintenance procedures will
cause a fire hazard. Fire extinguishing equipment must be present in the
spray area and tested periodically.
Protection against inadvertent
arcing that is capable of causing Spray areas must be kept clean to prevent the
fire or explosion is lost if any safety accumulation of combustible residues.
interlocks are disabled during
operation. Frequent power supply Smoking must never be allowed in the spray area.
shutdown indicates a problem in
the system requiring correction. The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing, or maintenance.
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CP-97-02.5 2
9040 Classic for REA & M90 Systems - Safety
NOTE:REFER TONFPA-33,REGARDINGOPERATOR
GROUNDING.
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9040 Classic for REA & M90 Systems - Safety
Personnel must be properly trained Instructions and safety precautions must be read
in the use of this equipment. and understood prior to using this equipment.
Explosion Hazard/ Halogenated hydrocarbon Aluminum is widely used in other spray application
Incompatible solvents for example: methylene equipment - such as material pumps, regulators,
Materials chloride and 1,1,1,-Trichloroethane triggering valves, etc. Halogenated hydrocarbon
are not chemically compatible with solvents must never be used with aluminum
the aluminum that might be used equipment during spraying, flushing, or cleaning.
in many system components. The Read the label or data sheet for the material you
chemical reaction caused by these intend to spray. If in doubt as to whether or not a
solvents reacting with aluminum coating or cleaning material is compatible, contact
can become violent and lead to an your material supplier. Any other type of solvent
equipment explosion. may be used with aluminum equipment.
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CP-97-02.5 4
9040 Classic for REA & M90 Systems - Safety
Personnel Safety Skin puncturing by sharp electrode. Take precautions to see that flesh is not punctured by
sharp electrode.
Personnel Safety Fluid Injection Injury Never let any part of the body come in direct contact
(High Pressure with the fluid stream exiting from the nozzle. If fluid
Equipment) leaks occur in the applicator or in the fluid delivery
components, depressurize fluid system before
servicing.
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5 CP-97-02.5
9040 Classic for REA & M90 Systems - Safety
NOTES
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CP-97-02.5 6
9040 Classic for REA & M90 Systems - Atex
The following instructions apply to equipment 8. The certification of this equipment relies upon
covered by certificate number Sira 08ATEX5040X: the following materials used in its construction:
1. The equipment may be used with flammable If the equipment is likely to come into contact with
gases and vapors with apparatus groups II and aggressive substances, then it is the responsibility
with temperature class T6. of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring
2. The equipment is only certified for use in that the type of protection provided by the equipment
ambient temperatures in the range +12.8C to is not compromised.
+40C and should not be used outside this range.
Aggressive substances: e.g. acidic liquids or
3. Installation shall be carried out by suitably gases that may attack metals, or solvents that
trained personnel in accordance with the applicable may affect polymeric materials.
code of practice e.g. EN 60079-14:1997.
Suitable precautions: e.g. regular checks as part
4. Inspection and maintenance of this equipment of routine inspections or establishing from the
shall be carried out by suitably trained personnel material's data sheets that it is resistant to specific
in accordance with the applicable code of practice chemicals.
e.g. EN 60079-17.
Refer to "Specifications" in the "Introduction"
5. Repair of this equipment shall be carried out by section:
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19. a. All fluid passages contain stainless steel
or nylon fittings.
6. Putting into service, use, assembling, and b. High voltage cascade is encapsulated with
adjustment of the equipment shall be fitted by a solvent resistant epoxy.
suitably trained personnel in accordance with the
manufacturer's documentation. 9. A recapitulation of the certification marking is
detailed in the "Atex" section, on the next page,
Refer to the "Table of Contents" of this service drawing number: 76454-XX.
manual:
10. The characteristics of the equipment shall be
a. Installation detailed e.g. electrical, pressure, and voltage
b. Operation parameters.
c. Maintenance
d. Parts Identification The manufacturer should note that, on being put
into service, the equipment must be accompanied
7. Components to be incorporated into or used as by a translation of the instructions in the language
replacement parts of the equipment shall be fitted or languages of the country in which the equipment
by suitably trained personnel in accordance with is to be used and by the instructions in the original
the manufacturer's documentation. language.
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7 CP-97-02.5
9040 Classic for REA & M90 Systems - Atex
Product Marking
II 2 G
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CP-97-02.5 8
9040 Classic for REA & M90 Systems - Introduction
INTRODUCTION
GENERAL DESCRIPTION the charged particles and the grounded target are
sufficient to turn most normal overspray around
and deposit it on the side and back surfaces of the
target. Thus, a high percentage of the spray is
The ITW Ransburg REA Process
deposited on the target.
The REA Process is an air atomized method for
applying coatings to objects electrostatically. The
REA system applies a high voltage DC charge to The 9040 Classic High Voltage
Voltage
the applicator nozzle electrode, creating an Power Supply
electrostatic field between the atomizer and the The 9040 Classic Power Supply converts standard
target object. The target is electrically grounded AC line voltage to a high frequency, low voltage
through its support which may be either stationary signal ranging from 0 to 10 Vrms. This signal is
or moving. supplied to the High Voltage Multiplier where it is
converted to DC high voltage. The high voltage
A regulated pressure fluid system delivers coating DC is then transferred from the 9040 Classic
material to the atomizer. At the atomizer, air is Power Supply to the REA/M90 applicator through
applied which atomizes the coating material forming a super flex high voltage cable. The voltage/
a spray mist which, under the influence of the current characteristic is designed to optimize the
electrostatic field, becomes electrically charged. charging process under varying load conditions
The charged particles are attracted to, and and to limit the operating current to a safe maximum
deposited on, the target object. The forces between value.
the charged particles and the grounded target are
sufficient to turn most normal over-spray around In addition to supplying high voltage output to the
and deposit it on the side and back surfaces of the applicator, the 9040 Classic Power Supply also
target. Therefore, a high percentage of the spray provides controls for AC power ON/OFF, infinite
is deposited on the target. high voltage adjustment, a high voltage meter, a
current meter, a POWER ON indicator, a HIGH
The ITW Ransburg M90 Process VOLTAGE ON indicator, and a CURRENT
This is a combined air-airless atomization method OVERLOAD indicator and reset switch. Addition-
for electrostatically applying coatings to objects. ally, output terminals are provided for remote
The M90 system applies a high voltage DC charge overload reset and interlock connections for a
to the applicator nozzle electrode, creating an conveyor, exhaust fan and high voltage control on
electrostatic field between the atomizer and the all 9040 Classic Power Supplies.
target object. The target is electrically grounded
through its support, which may be either stationary
or moving.
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9 CP-97-02.5
9040 Classic for REA & M90 Systems - Introduction
NOTE SPECIFICATIONS
SPECIFICATIONS
> The 9040 Classic Power Supply is fac-
tory supplied with a cabinet latch that can Physical
be opened using a slotted screwdriver. If Height: 14-inches
desired, the standard latch can be easily
replaced with a latch that requires the use Width: 12-inches
of a key to open. This key lock can be or-
dered from: Austin Hardware, Inc., 8001 Depth: 6-inches
Central Ave. N. E., Minneapolis, MN
55432; 1-800-328-2423; Key Lock Part Weight: 24-lbs.
Number: C8052-14A. Electrical
INPUT
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CP-97-02.5 10
9040 Classic for REA & M90 Systems - Introduction
Figure 1: 9040 Classic Power Supply Features for the REA/M90 Systems
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11 CP-97-02.5
9040 Classic for REA & M90 Systems - Installation
INSTALLA
INSTALLATION
ALLATION
shown in Figure 2. In either case, the power
! WARNING supply MUST be mounted in an upright position.
> The 9040 Classic Power Supply MUST DO NOT lay the power supply on its side or back.
be located outside the hazardous area.
(See NFPA-33, OSHA, and ITW Ransburg
Bulletin - "Operating Your Electrostatic ! CAUTION
Coating System Safely".)
> DO NOT locate the power supply
> The user MUST read and be familiar near or adjacent to heat producing equip-
with the "SAFETY" section of this manual. ment such as ovens, high wattage lamps,
etc.
> 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 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-33 and OSHA prior to
installing, operating, and/or servicing this
equipment.
Figure 2: Wall Mount Brackets
LOCATION
LOCATION
NOTE
> 9040 units shipped from the factory for
Install the 9040 Classic Power Supply in an area
115 VAC input will have a 72771-06, 1 amp
outside the hazardous location, where it will be
front panel fuse installed. While 9040 units
protected from the possibility of environmental
shipped from the factory for 230 VAC input
intrusion, such as dust or moisture, and ambient
will have a 72771-01, 0.5 amp front panel
temperatures do not exceed 120oF, but as close to
fuse installed. If the other input is required,
the applicator as possible to minimize the length of
it is recommended that the fuse be changed
high voltage cable. The power supply may be free
in order to keep the same level of protec-
standing on any flat surface or wall mounted by
tion. Both fuses are shipped with 9040
rotating the wall mount brackets (supplied) as
Power Supplies.
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CP-97-02.5 12
9040 Classic for REA & M90 Systems - Installation
NOTE
! CAUTION
> In general, conduit must be used for ap-
proved AC installation, however, if national > The Ground Wire Assembly MUST be
and local codes permit, the AC power may connected from the Power Supply Ground
be supplied via the factory installed line Stud to a true earth ground.
cord. If conduit is utilized, the power supply
wiring MAY be routed through an optional
explosion proof switch mounted on or near
Interlocks
the spray booth where it will be convenient
to the operator. ! WARNING
> ALWAYS ensure that high voltage is
EXTERNAL OFF before flushing the spray gun with
solvent. NEVER flush the spray applicator
CONNECTIONS with high voltage ON
ON, as this is a severe fire
hazard and risk to personnel safety. It is
recommended that the high voltage control
NOTE be interlocked with the solvent flush signal
> When connecting external wires to the so that high voltage is automatically locked
9040 Classic Power Supply, route the wir- out whenever flushing occurs. Consult your
ing through the external wiring grommet authorized ITW Ransburg representative for
located on the side panel. information on interlocking the high voltage
OFF signal with the solvent flush signal.
High Voltage (High V
Voltage oltage)
Voltage)
Cable Connection As outlined in NFPA-33 and OSHA, the AC power
Remove the plastic protective plug from the High line must be series interlocked with both the
Voltage Cable Connector and squirt enough exhaust fan and conveyor. To interlock the 9040
dielectric oil (70863-00 (supplied)) into the high Classic Power Supply with the exhaust fan and
voltage tube to cover the electrical contact point. conveyor, perform the following:
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13 CP-97-02.5
9040 Classic for REA & M90 Systems - Installation
3. Using a small blade screwdriver, remove the When the applicator is triggered, the resulting air
factory installed test jumper from 1TB-L1to 1TB- flow closes the contacts of the air flow switch,
L2. thereby activating high voltage at the applicator.
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9040 Classic for REA & M90 Systems - Installation
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15 CP-97-02.5
9040 Classic for REA & M90 Systems - Installation
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CP-97-02.5 16
9040 Classic for REA & M90 Systems - Operation
OPERATION
OPERATION
! WARNING ! WARNING
> The user MUST read and be familiar > The electrical discharge, which is
with the Safety Precautions and available from the charging electrode of the
"Safety" Section in this manual and the applicator, must not exceed 0.25 mJ of
ITW Ransburg safety literature therein energy. To achieve this limit, any flow of
identified BEFORE OPERATING the energy from the paint supply through the
9040 Classic power supply. paint line to the applicator electrode MUST
be prevented by grounding the paint line at
the applicator handle or body. Verify that
the applicator is actually grounded BE-
FORE operating it! (See the appropriate
applicator manual.) If improper readings are
obtained, check that the power supply is
grounded. (See "Ground Test Procedure" in
the "Maintenance" section of this manual).
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17 CP-97-02.5
9040 Classic for REA & M90 Systems - Operation
The DC input to the oscillator is interlocked with 3. Turn the ON/OFF switch to the ON position.
1TB terminals 6 and 7, such that the oscillator The green LED will light indicating that AC power
will not function unless terminals 6 and 7 are is being supplied to the power supply.
connected together. In this manner, high voltage
to the spray applicator is controlled as follows: 4. The voltage to the REA-III, REA-IV, and M90
Classic applicators is activated by supplying
1. When air flows through the flow switch, the adequate air to the flow switch when the applicator
switch contacts close connecting 1TB-6 and 7 is triggered. The voltage to the REA III Automatic
together, thereby providing voltage to the REA-III, applicator is activated by supplying adequate
REA-IV, and M90 Classic applicators. pressure signals to the power supply pressure
switches.
2. When pressure signals are supplied to the
pressure switches, the switch contacts close 5. Turn the voltage adjustment knob to the desired
connecting 1TB-6 and 7 together, thereby providing operating point as indicated by the kilovolt and
voltage to the REA-III automatic applicator. microamp meters.
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CP-97-02.5 18
9040 Classic for REA & M90 Systems - Operation
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19 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
NOTES
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CP-97-02.5 20
9040 Classic for REA & M90 Systems - Operation
MAINTENANCE
ROUTINE PREVENTIVE obtained without the need to trigger the spray
applicator or user supplied control device. Just
MAINTENANCE 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 7 for location
In general, little maintenance is necessary to of test jumper JP4.)
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: ! CAUTION
> If JP4 is left covering (shorting) both
1. Keep the exterior of the unit free from dust terminals, high voltage will be on whenever
accumulation. AC power is turned on. This could be
hazardous in some applications.
2. Always clean the exterior prior to opening the
cabinet door.
NOTE
> Squirting 70863-00 dielectric oil down Ground Test Procedure
Test
the HV tube significantly reduces corona
discharge that can cause deterioration of Equipment Required:
the HV connection components. - Ohmmeter (to measure resistance)
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21 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
2. Place one end of the ohmmeter on the clamp of 3. Turn the high voltage adjust knob FULLY
the ground wire assembly and the other end on the counter-clockwise.
power supply ground stud. If the ohmmeter reads
greater than 25 ohms, replace the 14 AWG ground 4. Open the cabinet door and position jumper JP4
wire assembly. on the main PC Board so that it covers (shorts)
both terminals.
3. Connect one end of the ohmmeter to the Power
Supply Ground Stud and the other to the metal 5. Attach the appropriate high voltage cable to the
applicator body (automatics) or handle bracket 20791 Test Probe, properly ground the probe to a
(applicators). If the ohmmeter reads greater than true earth ground, and turn the test probe meter on
25 ohms, repair or replace the high voltage cable. (see the "Operation Manual" for the 20791 Tester).
kV Output Test
Test
When a lack of high voltage at the spray applicator 7. Turn the power supply ON.
indicates a problem, perform a kV Output Test of
the power supply to determine whether it is at fault. 8. Turn the high voltage adjust knob FULLY
clockwise and read the output voltage displayed
Equipment Required: on the meter, then turn the power supply OFF. If
- Calibrated ITW Ransburg 20791 High Voltage the voltage read correctly (see "Specifications" in
Test Probe & Meter the "Introduction" section of this manual), the
problem is not in the power supply and the high
kV Output Test Procedure voltage cable and spray applicator should be
1. Turn AC power to the power supply OFF
OFF. checked for the cause. If the voltage did not read
correctly, the problem is with the power supply.
2. Remove the high voltage cable from the power Consult the "Troubleshooting Guide" to locate the
supply. specific problem.
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CP-97-02.5 22
9040 Classic for REA & M90 Systems - Maintenance
2. Remove the high voltage cable from the power 8. Turn the power supply OFF. Disconnect the
supply. current meter (76652-02) and remove the test
resistor (16688-01). Reposition JP4 so that it
covers only one terminal. When ready to resume
spray operations, reconnect the high voltage cable
! WARNING and turn the power supply ON.
> 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 POWER SUPPLIES AND
been grounded. This will eliminate the SCI VALUES
possibility of residual charge causing electri- SCI Range
cal shock. Power Supply (in A)
76447-10x, REA-IV 90 - 140 A
76447-12x, REA-III Applicator 120 - 170 A
3. Turn the high voltage adjust knob FULLY 76447-13x, REA-III Automatic 120 - 170 A
counter-clockwise. 76447-14x, M90 Classic Applicator 70 - 115 A
! CAUTION
> Ensure the current meter (76652-02) is
set to the A scale.
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23 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
Bench Testing
Testing NOTE
Equipment Required:
- Volt/ohmmeter > Before going through the trouble of a
complete bench test, jumper JP4 on the
The "Troubleshooting Guide" provides information main PC Board to trigger the high voltage
for troubleshooting the power supply when improper and see if the suspected problem goes
operation is obtained and the problem has been away. If it does, replace the high voltage
traced to the power supply. Proper troubleshooting trigger device (flow switch, pressure
should ONLY be accomplished with specific test switch, PC contact, etc.) or repair the in-
equipment by qualified electronics technicians or ternal wiring of the power supply con-
authorized ITW Ransburg representatives. nected to the trigger device, and test
again. If the problem does not go away,
then proceed with a bench test.
! WARNING
> The troubleshooting procedure outlined
in the "Troubleshooting Guide" requires SERVICE LEVEL
measurement of voltage potentials that can
cause SERIOUS BODILY INJURY if
proper measuring procedures are not Personnel who service this unit must be qualified
followed. For this reason, proper trouble- electronics technicians. Replacement parts are
shooting should ONLY be accomplished designed to be made at the assembly level. (See
with specific test equipment by qualified the "Parts Identification" section of this manual for
electronics technicians or authorized ITW replacement assemblies and part numbers.)
Ransburg representatives.
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CP-97-02.5 24
9040 Classic for REA & M90 Systems - Maintenance
NOTE From To
1FU-2 1SW-1
> A spare F2 PC board fuse, included 1TB-N 1SW-2
from the factory, is located in the lower 1TB-S1 1SW-1A
right hand corner inside the cabinet door.
1TB-S2 1SW-2A
3. Secure power supply cabinet door and plug 6. Secure cabinet door and plug power supply
power supply back in. back in.
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25 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
AC Line Cord 6. Attach two (2) wires to new flow switch (see
1. Ensure power supply is unplugged from AC "Parts Identification" section of this manual for
outlet and open the cabinet door. ordering information) terminals (it does not matter
which one goes where).
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CP-97-02.5 26
9040 Classic for REA & M90 Systems - Maintenance
8. Secure cabinet door and plug power supply 9. Plug connector 1PL back into the High Voltage
back in. Multiplier.
9. Reconnect pressure signal input line to 10. Secure the cabinet door and plug the power
pressure switch. supply back in.
2. Ensure power supply is unplugged from AC 5. Reconnect connector 9PL to main PC Board.
outlet and open cabinet door.
6. Secure the cabinet door and plug the power
3. Unplug connector 1PL from the top of the High supply back in.
Voltage Multiplier.
Kilovolt (kV) or
4. Remove the six (6) screws that mount the High
Voltage Multipliers aluminum housing to the back Microamp (A) Meter
panel. 1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
5. Remove the High Voltage Multiplier Assembly
from the power supply. 2. Remove two (2) hex nuts from wiring terminals
and remove wire lugs.
6. Remove the three (3) screws that secure the
aluminum housing to the High Voltage Multiplier. 3. Remove four (4) hex nuts that mount meter to
door.
7. Install the aluminum housing on the new High
Voltage Multiplier (see "Parts Identification" section 4. Remove old meter and install new one. (See
of this manual for part numbers and ordering "Parts Identification" section of this manual for
information). Ensure connector 1PL faces the ordering information.)
front of the housing before installing.
5. Reconnect wire lugs to meter (purple wire goes
8. Install the High Voltage Multiplier Assembly in to + terminal of meter).
the power supply by securing the six (6) mounting
screws to the back panel. 6. Secure cabinet door and plug power supply
back in.
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27 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
3. Remove two (2) screws from heat sink base 6. Using heat shrink tubing and appropriate solder
and lift the PC Board out. techniques, solder the three (3) wires to the new
potentiometer as follows:
From To
! CAUTION
7PL-1 1POT-1
> DO NOT remove the PC Board from 7PL-4 1POT-2
the heat sink as it is an integrated assem- 7PL-5 1POT-3
bly.
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9040 Classic for REA & M90 Systems - Maintenance
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29 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
TROUBLESHOOTING GUIDE
General Problem Possible Cause Solution
AC Power ON 1. Front panel fuse 1FU or PC board 1. Replace defective fuse.
Indicator (Green fuse F2 defective
LED) Does Not
Light when ON/OFF 2. Connector 7PL or 9PL not properly 2. Properly attach connector.
Switch is ON plugged into main PC board
6. Defective power supply 1SUP 6. Voltage across terminals 2 and 3 of plug 7PL
on main PC board should be 18 VDC. If not,
replace power supply 1SUP.
7. Defective LED display board 7. If all other functions of power supply are
normal, replace LED display board.
No or Low kV 1. High voltage adjust knob not set to 1. Set high voltage adjust knob to proper value.
Output at Spray proper value
Applicator when HV
ON Indicator (Red 2. Connector 6PL or 1PL not properly 2. Properly attach connector.
LED) is Lit plugged into respective locations
3. Defective spray applicator or high 3. Perform a kV Output Test on the power supply.
voltage cable If proper readings are obtained, check cable or
spray applicator for cause (see spray applicator
service manual).
4. Loose or broken wire in power 4. Check all wiring connections for integrity.
supply Repair wiring as needed.
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CP-97-02.5 30
9040 Classic for REA & M90 Systems - Maintenance
3. Defective high voltage trigger 3. Short PC board jumper JP4. If high voltage
device (flow switch, pressure comes on, replace high voltage trigger device
switch, etc.) or wiring or repair wiring from trigger device to PC board.
1. Parts are too close to the spray 1. Ensure sufficient distance between spray
Power Supply applicator applicator and parts.
Overloads
Excessively 2. Overload set point set too sensitive 2. Adjust PC board potentiometer 1 turn counter-
clockwise to make less sensitive. Repeat if
necessary.
3. Defective spray applicator 3. Disconnect high voltage cable from spray
applicator and test in open air, at least 1-foot
from surrounding objects. If overload goes
away, check spray applicator for cause.
(Warning: Contact end of cable will be at
high voltage; after testing, discharge
contact by contacting to ground before
touching!)
4. Defective high voltage cable 4. Test power supply with high voltage cable
removed. If overload goes away, replace the
high voltage cable.
5. Main PC board defective 5. Place PC board jumper JP5 over pins 1 and 2
(overload OFF) and test. If power supply
overloads, replace main PC board.
6. Defective high voltage multiplier 6. If 1 thru 5 above are OK, replace the high
voltage Multiplier.
Component Not 1. Wiring to/from component loose 1. Repair loose or broken wire.
Working, but kV or broken
Output OK
2. Defective component 2. Replace component.
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31 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
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CP-97-02.5 32
9040 Classic for REA & M90 Systems - Maintenance
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33 CP-97-02.5
9040 Classic for REA & M90 Systems - Maintenance
NOTES
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CP-97-02.5 34
9040 Classic for REA & M90 Systems - Parts Identification
PARTS IDENTIFICA
ARTS TION
IDENTIFICATION
Figure 11: 9040 Classic for REA and M90 - Parts Diagram
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35 CP-97-02.5
9040 Classic for REA & M90 Systems - Parts Identification
PAR
9040 CLASSIC for REA & M90 - PARTS
ARTS LIST 11)
(Figure 11)
Item # Part # Description Notation
1 PC Board and Heat Sink Assembly:
76892-10 For 76447-10X, REA-IV Applicator (70404)
76892-12 For 76447-12X, REA-III Applicator (70929, 72316)
76892-13 For 76447-13X, REA-III Automatic (70393)
76892-15 For 76447-14X, M90 Classic Applicator (77132)
2 High Voltage Multiplier (Oil-Filled):
76304-02 For 76447-10X, 65kV
76304-07 For 76447-14X, 85kV
76304-01 For 76447-12X and 76447-13X, 90kV
3 76434-01 ON/OFF Switch 1SW
4 70556-03 High Voltage Adjust Potentiometer 1POT
5 76436-91 Kilovolt (kV) Meter 1M
6 76436-92 Microamp (A) Meter 2M
7 Air Flow Switch Assembly: 1FS
13742-01 For 76447-10X and 76447-12X
13742-02 For 76447-14X
25766-106 Pressure Switch for 76447-13X 1PS, 2PS
8 75337-05 Power Supply, 18 VDC 1SUP
9 LSME0082-04 Fuse, PC Board, Slow Blow, 4 Amp F2
10 Fuse, Front Panel:
72771-06 Slow Blow, 1 Amp, 110-120 VAC Input 1FU
72771-01 Slow Blow, 0.5 Amp, 220-240 VAC Input 1FU
11 6262-00 AC Line Cord
12 70539-00 Ground Wire Assembly
13 76455-02 LED Display Board
14 Overload Indicator and Reset Switch Assembly:
76442-01 Reset Switch, Normally Closed
76441-00 Lens, Yellow
76443-01 Bulb
15 5627-00 Rubber Feet
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CP-97-02.5 36
9040 Classic for REA & M90 Systems - Parts Identification
SPARE
9040 CLASSIC for REA & M90 - RECOMMENDED SP PAR
ARE PARTS
ARTS
Description Part # No. of Applicators Notes
Fuse, Front Panel 72771-06 1 1 2 2
Deluxe Test Kit 76652-04 1 1 1 1 For Troubleshooting
Purposes Only
Test Resistor 16688-01 1 1 1 1 For Troubleshooting
Purposes Only
Fuse, PC Board LSME0082-04 2 4 6 8
PC Board Assembly, 76892-10 1 1 1 2 For 76447-10
REA-IV Hand
PC Board Assembly, 76892-12 1 1 1 2 For 76447-12
REA-III Hand
PC Board Assembly, 76892-13 1 1 1 2 For 76447-13
REA-III Auto
PC Board Assembly, 76892-15 1 1 1 2 For 76447-14
M90 Classic
High Voltage Multiplier 76304-01 1 1 1 1 For 76447-12 & -13
High Voltage Multiplier 76304-02 1 1 1 1 For 76447-10
High Voltage Multiplier 76304-07 1 1 1 1 For 76447-14
Power Supply Tester LTST5000-00 1 1 1 1 For Troubleshooting
Purposes Only
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37 CP-97-02.5
9040 Classic for REA & M90 Systems - Parts Identification
NOTES
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CP-97-02.5 38
9040 Classic for REA & M90 Systems - Warranty Policies
WARRANTY POLICIES
ITW RANSBURG'S ONLY OBLIGATION
LIMITED WARRANTY
WARRANTY UNDER THIS WARRANTY IS TO REPLACE
PARTS THAT HAVE FAILED BECAUSE
ITW Ransburg will replace or repair without charge OF FAULTY WORKMANSHIP OR MATER-
any part and/or equipment that falls within the IALS. THERE ARE NO IMPLIED WARRAN-
specified time (see below) because of faulty TIES NOR WARRANTIES OF EITHER
workmanship or material, provided that the MERCHANTABILITY OR FITNESS FOR A
equipment has been used and maintained in PARTICULAR PURPOSE. ITW RANS-
accordance with ITW Ransburg's written safety BURG ASSUMES NO LIABILITY FOR
and operating instructions, and has been used INJURY, DAMAGE TO PROPERTY OR
under normal operating conditions. Normal wear FOR CONSEQUENTIAL DAMAGES FOR
items are excluded. LOSS OF GOODWILL OR PRODUCTION
OR INCOME, WHICH RESULT FROM USE
THE USE OF OTHER THAN ITW RANS- OR MISUSE OF THE EQUIPMENT BY
BURG APPROVED PARTS, VOID ALL PURCHASER OR OTHERS.
WARRANTIES.
EXCLUSIONS:
SPARE PARTS: One hundred and eighty (180)
days from date of purchase, except for rebuilt If, in ITW Ransburg's opinion the warranty item in
parts (any part number ending in "R") for which the question, or other items damaged by this part was
warranty period is ninety (90) days. improperly installed, operated or maintained, ITW
Ransburg will assume no responsibility for repair
EQUIPMENT: When purchased as a complete or replacement of the item or items. The purchaser,
unit, (i.e., guns, power supplies, control units, therefore will assume all responsibility for any cost
etc.), is one (1) year from date of purchase. of repair or replacement and service related costs
WRAPPING THE APPLICATOR, ASSO- if applicable.
CIATED VALVES AND TUBING, AND
SUPPORTING HARDWARE IN PLASTIC,
SHRINK-WRAP, OR ANY OTHER NON-
APPROVED COVERING, WILL VOID THIS
WARRANTY.
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39 CP-97-02.5
MANUAL CHANGE SUMMARY
SUMMARY
This manual was published to replace Service
Manual CP-97-02.4, 9040 Classic High Voltage
Power Supply for the REA/REM/M90 Classic
Coating Systems, to make the following changes:
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CP-97-02.5
Service Manual Price: 25.00
25.00 (Euro)
$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 I 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
www.itwransburg.com
E
Technical Support Representative will direct you to the appropriate telephone number
for ordering Spare Parts. IV
H
C
R
A