Ransburg 9040 User Manual Download

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SERVICE MANUAL

CP-11- 01.02

9040 Low Voltage Control Unit KIT For The

ESTA-QUICK and Evolver SE Applicators

MODELS:

80072-XXX for use with Esta-Quick Applicator AEMD500 (Atex approved)
80078-XXX for use with Evolver SE (Not Approved)

IMPORTANT: Before using this equipment, care-
fully read SAFETY PRECAUTIONS, starting on
page 1, and all instructions in this manual. Keep
this Service Manual for future reference.

Summary of Contents for 9040

Page 1: ...ators MODELS 80072 XXX for use with Esta Quick Applicator AEMD500 Atex approved 80078 XXX for use with Evolver SE Not Approved IMPORTANT Before using this equipment care fully read SAFETY PRECAUTIONS...

Page 2: ...CP 11 01...

Page 3: ...ANALOG INPUT BOARD LAYOUT 19 TYPICAL ESTA QUICK EVOLVER SE APPLICATOR INSTALLATION 20 22 OPERATION 23 26 OPERATOR CONTROLS 23 OPERATING PROCEDURES 24 25 MAINTENANCE 27 38 ROUTINE PREVENTIVE MAINTENANC...

Page 4: ...e such variations inevitable Compare this manual with your system installation drawings and appropriate Ransburg equipment manuals to reconcile such differences Careful study and continued use of this...

Page 5: ...ose used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for general cleaning must have flash points above 100o F 37 8o C Spray booth v...

Page 6: ...ntrol cabinet Equipment lized Arcing in areas of and all other electrical equipment must be located flammable or combustible outside Class I or II Division 1 and 2 or Zone 1 hazardous areas Refer to p...

Page 7: ...ce NFPA 33 EN 60079 A safe distance must be maintained between the parts being coated and the atomizer A distance of at least 1 inch for each 10 KV of power supply output voltage is required at all ti...

Page 8: ...hall be fitted by suitably trained personnel in accordance with the manufacturer s documentation 8 The certification of this equipment relies upon the following materials used in its construction If t...

Page 9: ...sulation 240 Document serial number X Special conditions for safe use apply Product Marking II 2 G Ex Specific marking of explosive protection II Equipment Group hazardous area charac teristics 2 Equi...

Page 10: ...ected to a grounded target more material is attracted to the target yielding higher painting efficiency The voltage current characteristic is designed to optimize the charging process under varying lo...

Page 11: ...atic applicators as follows 9040 Kit Used with Applicator Type Applicator 80072 1XX Esta Quick 110 120 V inputs AEMD 500 80072 2XX Esta Quick 220 240V inputs AEMD 500 80078 1XX Evolver SE 110 120 V in...

Page 12: ...ntal Cascade Height 400 mm Width 102 mm Square Weight 4 1 kg Electrical Requirements Input Voltage 90 264 VAC Current 0 4 0 2 Amps AC Frequency 50 60 Hertz Wattage 40 Watts Maximum Output Voltage 0 10...

Page 13: ...Knob 6 Cable Fault Hook Off Indicator 7 Overload Indicator and Reset Switch 8 Fuse 9 AC Power On Off Indicator 10 Pressure Switches 11 External Wiring Grommet 12 AC Inlet Receptacle 13 Ground Stud 14...

Page 14: ...ea outside the hazardous location where it will be protected from the possibility of environmental intrusion such as dust or moisture and ambient temperatures do not exceed 49 C 120 F but as close to...

Page 15: ...t 4 Install the Conduit Adapter Plate supplied in the hole where the AC Inlet Receptacle was removed see Figure 3 5 Install the AC line cord through the Conduit Adapter Plate using conduit and wire to...

Page 16: ...the external wiring grommet opening and connect to the existing wires on the inside of External Wiring Plug 2PL 2SOF when necessary Low Voltage Cable Connection Connect the low voltage cable from the...

Page 17: ...2 The interlock contacts should be rated for at least 1 amp at 240 volts AC 5 Slide the chassis back in secure the front panel screws replace the fuse and plug the control unit in C A U T I O N When...

Page 18: ...N NOT be used to trigger the high voltage for multiple control units External Overload Reset The 9040 Cascade control unit allows for use of an external normally closed overload reset button This is c...

Page 19: ...tput current recording device with input resistance of 5 megohms or greater can be connected directly to outside terminal 2PL 8 or for installations requiring conduit connected to the inside terminal...

Page 20: ...cted to TB1 3 will activate Setpoint 2 The third setpoint is determined by the setting of the control unit High Voltage Adjust Knob when both robot or PLC outputs are off 17 High voltage outputs selec...

Page 21: ...ch to the OFF position before flushing cleaning or serving the applicator NOTE To eliminate problems caused by external noise a twisted shielded pair should be used for the analog input con trol wirin...

Page 22: ...9040 Low Voltage Control Unit Kit Installation Figure 5b Combination Triple Setpoint Analog Input Board Layout 19 CP 11 01...

Page 23: ...umber Description 1 9040 Low Voltage Unit 2 AGMD 500 Unit Atex Approved 3 A10560 XXD High Voltage Cable 4 76300 03 External Cascade 5 76298 XX Low Voltage Cable 6 Booth Wall 7 Cascade Ground Connectio...

Page 24: ...9040 Low Voltage Unit 2 Evolver SE A12455 XXXX Non Atex Approved 3 A10560 XXD High Voltage Cable 4 76300 01 External Cascade Oil Filled 5 76298 XX Low Voltage Cable 6 Booth Wall 7 Cascade Ground Conn...

Page 25: ...ntrol Unit Kit Installation Cascade Ground Connection Cascade End Applicator End Figure 7 High Voltage Cable A10560 XXD Connection Cascade End Connection Control Unit End Figure 8 Low Voltage Cable 76...

Page 26: ...ugh the 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 before operating it See th...

Page 27: ...onths of amps mA leaving the applicator electrode High Voltage Adjustment Knob The high voltage adjustment knob allows infinite control of the applicator electrode voltage between 0 and rated kV Overl...

Page 28: ...gh voltage from being present at the applicator if the high voltage trigger device pressure switch PC contact etc has not been triggered If a failure mode should occur that would attempt to send high...

Page 29: ...9040 Low Voltage Control Unit Kit Operation NOTES CP 11 01 26...

Page 30: ...le socket NOTE In the control unit ground is passed from the ground stud to the chassis via the front panel screws Ensure the front panel screws are securely fastened and repeat step 3 before searchin...

Page 31: ...both terminals the high voltage on relay is triggered Thus for testing and troubleshooting high voltage output can be obtained without the need to trigger the applicator or user supplied control devic...

Page 32: ...evice and test again If the problem does not go away then pro ceed with a bench test Equipment Required Volt Ohmmeter This section provides a flow chart for troubleshooting the control unit when impro...

Page 33: ...9040 Low Voltage Control Unit Kit Maintenance NOTES CP 11 01 30...

Page 34: ...9040 Low Voltage Control Unit Kit Maintenance TROUBLESHOOTING FLOW CHARTS ON OFF Switch ON ON OFF Indicator green LED does not light 31 CP 11 01...

Page 35: ...9040 Low Voltage Control Unit Kit Maintenance TROUBLESHOOTING FLOW CHARTS Cont Figure 10 Troubleshooting Diagram CP 11 01 32...

Page 36: ...9040 Low Voltage Control Unit Kit Maintenance Figure 11 9040 Cascade Control Unit Block Diagram 33 CP 11 01...

Page 37: ...ugged from AC outlet loosen front panel screws and slide the control unit chassis out 2 Replace defective fuse see Parts Identification section of this manual for fuse part numbers NOTE A spare F2 PC...

Page 38: ...chassis out 2 Remove the four 4 screws from the combination analog triple setpoint board if installed and remove the board from the 1SUP power supply cover plate 3 Remove the four 4 screws from the 1...

Page 39: ...nect pressure signal input line to pressure switch LED Display Board 1 Ensure control unit is unplugged from AC outlet loosen front panel screws and slide control unit chassis out 2 Unplug display boa...

Page 40: ...to 1POT before unsoldering 4 Remove the hex nut securing 1POT to the front panel and remove 1POT 5 Install the new potentiometer see Parts Identification section for this manual for ordering informati...

Page 41: ...9040 Low Voltage Control Unit Kit Maintenance NOTES CP 11 01 38...

Page 42: ...9040 Low Voltage Control Unit Kit Parts Identification PARTS IDENTIFICATION Figure 12a 9040 Low Voltage Control Unit Kit Parts Diagram For Both 80072 and 80078 Units 39 CP 11 01...

Page 43: ...for location 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 Input 1FU 11 76449 00 Detachable AC Line Cord 12 70539 00 Ground Wire Assembly 13...

Page 44: ...CP 11 01 40...

Page 45: ...X These modules may be ordered and installed as optional equipment with the 9040 unit Installing this option allows control of parameters associated with the application process The kits listed below...

Page 46: ...purchase WRAPPING THE APPLICATOR IN PLASTIC ASSOCIATED VALVES AND TUB ING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONLY OBLI...

Page 47: ...UAL CHANGE SUMMARY This manual was published new with the product release 11 11 Added 76892 42 pc board for the Evolver SE or un approved units 02 12 Removed all reference to AEMD 503 Updated 72562 la...

Page 48: ...al Service Assistance 320 Phillips Ave Telephone 800 233 3366 Fax 419 470 2040 Toledo Ohio 43612 1493 Telephone 419 470 2021 www itwransburg com Technical Support Representative will direct you to the...

Page 49: ...Models and specifications subject to change without notice 07 11...

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