Ransburg 77070-33, Service Manual

Page 1: ... all instructions in starting on page 1 and all instructions in starting on page 1 and all instructions in this manual Keep this Service Manual for this manual Keep this Service Manual for this manual Keep this Service Manual for this manual Keep this Service Manual for this manual Keep this Service Manual for future reference future reference future reference future reference future reference 904...

Page 2: ...CP 08 01 ARCHIVE ...

Page 3: ...ESHOOTING GUIDE TROUBLESHOOTING 77070 33 CLASSIC HIGH VOLTAGE POWER SUPPLY BLOCK DIAGRAM 1 6 1 6 1 6 1 6 1 6 7 8 7 8 7 8 7 8 7 8 13 16 13 16 13 16 13 16 13 16 17 30 17 30 17 30 17 30 17 30 1 2 5 7 7 8 13 14 14 15 17 17 20 21 21 25 26 27 28 29 PARTS IDENTIFICATION PARTS IDENTIFICATION PARTS IDENTIFICATION PARTS IDENTIFICATION PARTS IDENTIFICATION 9040 CLASSIC HIGH VOLTAGE POWER SUPPLY PARTS DIAGRAM...

Page 4: ...ormation relevant to the A NOTE is information relevant to the A NOTE is information relevant to the procedure in progress procedure in progress procedure in progress procedure in progress procedure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant req...

Page 5: ...o 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 ventilation must be kept at the rates required by NFPA 33 OSHA and local codes In addition ventilation must be maintained during cleaningoperationsusingflammableorcombustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible mat...

Page 6: ...rators Operators Operators Operators Operators must be grounded Rubber soled insulatingshoesshouldnotbeworn Grounding leg straps may be used Operators must maintain contact with thehandleof the applicator If work gloves are used the palm section should be cut out Operators must remove from themselves all metal objectsthatarenotgrounded B Partsbeingsprayed Resistancebetweenthepartand agroundedconve...

Page 7: ...entraininginaccordancewith the requirements of NFPA 33 Instructions and safety precautions must be read and understood prior to using this equipment Comply with appropriate local state and national codesgoverningventilation fireprotection operation maintenance andhousekeeping AlwaysturnpowertothepowersupplyOFF unplug the electrical cord from its outlet and remove the front panel fuse before openin...

Page 8: ...terials The mask must be compatible with the material being sprayed and its concentration Equipment must be as prescribed by anindustrialhygienistorsafetyexpert andbeNIOSH approved Personnel Safety Personnel Safety Personnel Safety Personnel Safety Personnel Safety Skin puncturing by sharp electrode Takeprecautionstoseethatfleshisnotpuncturedby sharpelectrode Personnel Safety Personnel Safety Pers...

Page 9: ...CP 08 01 6 6 6 6 6 9040 Classic HV Power Supply Safety NOTES NOTES NOTES NOTES NOTES ARCHIVE ...

Page 10: ... a high voltage cable The voltage current characteristic is designed to optimize the charging process under varying load conditions and to limit the operating current to a safe maximum value In addition to supplying high voltage output to the applicator the 9040 Classic High Voltage Power Supply also provides controls for AC power ON OFF infinitehighvoltageadjustment ahighvoltage meter a current m...

Page 11: ...L 9040 CLASSIC HIGH VOL 9040 CLASSIC HIGH VOL 9040 CLASSIC HIGH VOL 9040 CLASSIC HIGH VOLT T T T TAGE POWER SUPPL AGE POWER SUPPL AGE POWER SUPPL AGE POWER SUPPL AGE POWER SUPPLY Y Y Y Y FEA FEA FEA FEA FEATURES TURES TURES TURES TURES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Kilovolt Meter Microamp Meter High Voltage On Indicator Overload Indicator Overload Reset On Off Switch Fuse Holder Fuse Holder Hig...

Page 12: ...rstood by ALL ALL ALL ALL 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 ALL ALL ALL ALL local building and fire codes and ordinances as well as any local country codes prior to installing operating and or servicing thi...

Page 13: ... installed line cord If conduit is utilized the power supply wiring MAY be routed through an optional explosion proof switch mounted on or near the spray booth where it will be convenient to the operator NOTE NOTE NOTE NOTE NOTE When connecting external wires to the 9040 Classic High Voltage Power Supply route the wiring through the external wir ing grommet located on the side panel NOTE NOTE NOTE...

Page 14: ... High V External High V External High V External High V External High Voltage Control oltage Control oltage Control oltage Control oltage Control If a method of high voltage triggering other than the factory supplied method is required the 9040 Classic High Voltage Power Supply allows for externalhighvoltagecontrolfromaPLC pressure switch or other user supplied device To turn the high voltage on t...

Page 15: ...acts must be rated for at least 100 contacts must be rated for at least 100 milliamps at 15 volts DC The contacts of milliamps at 15 volts DC The contacts of milliamps at 15 volts DC The contacts of milliamps at 15 volts DC The contacts of milliamps at 15 volts DC The contacts of the external reset device must be normally the external reset device must be normally the external reset device must be...

Page 16: ...afety Section in this manual and the ITW Ransburg safety literature therein identified BEFORE OPERATING BEFORE OPERATING BEFORE OPERATING BEFORE OPERATING BEFORE OPERATING the 9040 Classic High Voltage Power Supply W A R N I N G W A R N I N G W A R N I N G W A R N I N G W A R N I N G 9040 CLASSIC HIGH VOLTAGE 9040 CLASSIC HIGH VOLTAGE 9040 CLASSIC HIGH VOLTAGE 9040 CLASSIC HIGH VOLTAGE 9040 CLASSI...

Page 17: ...robot output or some other user supplied device connected to terminals 1TB 6 and 7 will activate high voltage at the spray applicator 3 For testing and troubleshooting board jumper JP4 connects 1TB 6 and 7 together thereby providinghighvoltageoutput see PCBoardTest Jumper in the Maintenance section of this manual 2 Be sure that the high voltage adjustment knob is turned FULLY counter clockwise 3 T...

Page 18: ... and target and thus it is not likely that the spray appli cator would come into close proximity with the part during normal use If it should then it is desired that an overload occur to alert maintenance so that the condition can be corrected Additionally since there is no operator with automatic applicators the overload circuit is required to alert mainte nance when failed parts may be causing t...

Page 19: ...CP 08 01 9040 Classic HV Power Supply Maintenance 16 16 16 16 16 NOTES NOTES NOTES NOTES NOTES ARCHIVE ...

Page 20: ...ING TROUBLESHOOTING PC Board T PC Board T PC Board T PC Board T PC Board Test Jumper est Jumper est Jumper est Jumper est Jumper To assist in testing and troubleshooting a jumper JP4 has been incorporated on the 9040 PC board By covering shorting both terminals the highvoltageonrelayistriggered Thus fortesting and troubleshooting high voltage output can be obtained without the need to trigger the ...

Page 21: ... Required Equipment Required Calibrated ITW Ransburg 20791 High Voltage Test Probe and Meter kV Output Test Procedure kV Output Test Procedure kV Output Test Procedure kV Output Test Procedure kV Output Test Procedure 1 Turn AC power to the power supply OFF OFF OFF OFF OFF 2 Remove the high voltage cable from the power supply 3 Turn the high voltage adjust knob FULLY counter clockwise 4 Openthecab...

Page 22: ... by contacting the plug to electrical ground DO NOT DO NOT DO NOT DO NOT DO NOT touch the plug until it has been grounded This will eliminate the possibility of residual charge causing electri cal shock W A R N I N G W A R N I N G W A R N I N G W A R N I N G W A R N I N G Ensure the Current Meter 76652 02 is set to the μA scale C A U T I O N C A U T I O N C A U T I O N C A U T I O N C A U T I O N ...

Page 23: ...age multiplier and high voltage cable contain significant capaci tance that will store charge ALLOW ALLOW ALLOW ALLOW ALLOW approximately 10 seconds for this charge to bleed off BEFORE BEFORE BEFORE BEFORE BEFORE opening the cabinet door OR REMOVING OR REMOVING OR REMOVING OR REMOVING OR REMOVING the high voltage cable from the power supply or spray applicator C A U T I O N C A U T I O N C A U T I...

Page 24: ...VEL Personnel who service this unit must be qualified electronics technicians Replacement parts are designed to be made at the assembly level See the Parts Identification section of this manual for replacement assemblies and part numbers ALWAYS ALWAYS ALWAYS ALWAYS ALWAYS turn power to the power supply OFF OFF OFF OFF OFF unplug the electrical cord from its outlet remove the front panel fuse and l...

Page 25: ... Pressure Switch Pressure Switch Pressure Switch Pressure Switch Pressure Switch 1 Disconnect pressure signal input line from pressure switch 2 Ensure power supply is unplugged from AC outlet and open cabinet door 3 Remove two 2 wires from pressure switch terminals 4 Loosenhexnutfromfittingandremovepressure switch and fitting from the power supply 5 Remove fitting from defective pressure switch an...

Page 26: ...faces the front of the housing before installing 8 Install the high voltage multiplier assembly in the power supply by securing the six 6 mounting screws to the back panel 9 Plug connector 1PL back into the high voltage Multiplier 10 Secure the cabinet door and plug the power supply back in 11 Reinstall the high voltage cable LED Display Board LED Display Board LED Display Board LED Display Board ...

Page 27: ... manual for part numbers in the cabinet door 6 Usingheatshrinktubingandappropriatesolder techniques solder the three 3 wires to the new potentiometer as follows 7 Secure the cabinet door and plug the power supply back in 8 Reinstalladjustknobusing1 16 Allenwrench Power Supply 1SUP Power Supply 1SUP Power Supply 1SUP Power Supply 1SUP Power Supply 1SUP 1 Ensure 9040 Classic Power Supply is unplugge...

Page 28: ...arts Identification section of this manual for part numbers using the four 4 cover plate standoffs Ensurelargerterminalstrip 10PL ofpowersupply 1SUP faces left side of unit as shown in Figure 9 6 Connect connectors 8PL and 10PL to new power supply and reinstall cover plate 7 Secure cabinet door and plug power supply back in ARCHIVE ...

Page 29: ...Defectivesprayapplicatororhigh voltage cable 4 Loose or broken wire in power supply 5 Main PC board defective 6 Defective high voltage multiplier General Problem General Problem General Problem General Problem General Problem Possible Cause Possible Cause Possible Cause Possible Cause Possible Cause Solution Solution Solution Solution Solution 1 Replace defective fuse 2 Properly attach connector 3...

Page 30: ...use Solution Solution Solution Solution Solution 1 Properly attach connector 2 Turn signal on and adjust to proper setting 3 Short PC board jumper JP4 If high voltage comes on replace high voltage trigger device orrepairwiringfromtriggerdevicetoPCboard 4 Replace main PC board 1 Ensure sufficient distance between spray applicator and parts 2 AdjustPCboardpotentiometer1turncounter clockwise to make ...

Page 31: ...CP 08 01 9040 Classic HV Power Supply Maintenance 28 28 28 28 28 Figure 7 Troubleshooting Figure 7 Troubleshooting Figure 7 Troubleshooting Figure 7 Troubleshooting Figure 7 Troubleshooting ARCHIVE ...

Page 32: ...age Power Supply Block Diagram Figure 8 77070 33 Classic High Voltage Power Supply Block Diagram Figure 8 77070 33 Classic High Voltage Power Supply Block Diagram Figure 8 77070 33 Classic High Voltage Power Supply Block Diagram Figure 8 77070 33 Classic High Voltage Power Supply Block Diagram ARCHIVE ...

Page 33: ...CP 08 01 9040 Classic HV Power Supply Maintenance 30 30 30 30 30 NOTES NOTES NOTES NOTES NOTES ARCHIVE ...

Page 34: ...c High Voltage Power Supply Parts Diagram Figure 9 9040 Classic High Voltage Power Supply Parts Diagram Figure 9 9040 Classic High Voltage Power Supply Parts Diagram 9040 Classic HV Power Supply Parts Identification P P P P PAR AR AR AR ARTS IDENTIFICA TS IDENTIFICA TS IDENTIFICA TS IDENTIFICA TS IDENTIFICATION TION TION TION TION 31 31 31 31 31 ARCHIVE ...

Page 35: ...e Front Panel Fuse Front Panel Fuse Front Panel Fuse Front Panel 76469 00 Fuse Holder 1FU 2FU 72771 06 Slow Blow 1 Amp 110 120 VAC Input 1FU 72771 01 Slow Blow 0 5 Amp 220 240 VAC Input 1FU 11 70539 00 Ground Wire Assembly 12 Overload Indicator and Reset Switch Assembly Overload Indicator and Reset Switch Assembly Overload Indicator and Reset Switch Assembly Overload Indicator and Reset Switch Ass...

Page 36: ...SSIC HIGH VOL 9040 CLASSIC HIGH VOL 9040 CLASSIC HIGH VOL 9040 CLASSIC HIGH VOLT T T T TAGE POWER SUPPL AGE POWER SUPPL AGE POWER SUPPL AGE POWER SUPPL AGE POWER SUPPLY Y Y Y Y RECOMMENDED SP RECOMMENDED SP RECOMMENDED SP RECOMMENDED SP RECOMMENDED SPARE P ARE P ARE P ARE P ARE PAR AR AR AR ARTS TS TS TS TS Description Description Description Description Description Part Part Part Part Part Fuse F...

Page 37: ...CP 08 01 9040 Classic HV Power Supply Parts Identification 34 34 34 34 34 NOTES NOTES NOTES NOTES NOTES ARCHIVE ...

Page 38: ...NTY IS TO REPLACE UNDER THIS WARRANTY IS TO REPLACE UNDER THIS WARRANTY IS TO REPLACE UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE PARTS THAT HAVE FAILED BECAUSE PARTS THAT HAVE FAILED BECAUSE PARTS THAT HAVE FAILED BECAUSE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATER OF FAULTY WORKMANSHIP OR MATER OF FAULTY WORKMANSHIP OR MATER OF FAULTY WORKMANSHIP OR MATER O...

Page 39: ...CP 08 01 ARCHIVE ...

Page 40: ...Support Representative will direct you to the appropriate telephone number Technical Support Representative will direct you to the appropriate telephone number Technical Support Representative will direct you to the appropriate telephone number Technical Support Representative will direct you to the appropriate telephone number Technical Support Representative will direct you to the appropriate te...