9040 Cascade LV Control Unit (CP97043sm)
SERVICE MANUAL
CP-97-04.3
(Replaces CP-97-04.2)
May - 2008
A
R
C
H
IV
E
9040 CASCADE LOW VOL
TAGE
VOLT
CONTROL UNIT FOR THE REA / REM™
CASCADE COA
TING SYSTEMS
COATING
MODELS:
76580-1XXXX
76580-4XXXX
76580-5XXXX
76580-6XXXX
76580-7XXXX
76580-8XXXX
76580-9XXXX
REA-70 APPLICA
TOR
APPLICAT
OMA
TIC
AUTOMA
OMATIC
REM AUT
REA9000 AUT
OMA
TIC
AUTOMA
OMATIC
REA-90 W
ATERBORNE APPLICA
TOR
WA
APPLICAT
REA-90 SOL
VENTBORNE APPLICA
TOR
SOLVENTBORNE
APPLICAT
REA-90 SOL
VENTBORNE AUT
OMA
TIC
AUTOMA
OMATIC
SOLVENTBORNE
REA-90 W
ATERBORNE AUT
OMA
TIC
WA
AUTOMA
OMATIC
IMPOR
TANT
IMPORT
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 CP-97-04.2 to revision CP-97-04.3. Reasons for
this change are noted under “Manual Change Summary” inside the back cover of this
manual.
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Contents
CONTENTS
PAGE
1-4
SAFETY:
SAFETY PRECAUTIONS........................................................................................................... 1
HAZARDS/SAFEGUARDS......................................................................................................... 2-4
ATEX
5-6
EUROPEAN ATEX DIRECTIVE................................................................................................. 5
EUROPEAN ATEX LABELS....................................................................................................... 6
INTRODUCTION:
7-10
DESCRIPTION............................................................................................................................ 7-9
SPECIFICATIONS....................................................................................................................... 9
9040 CASCADE CONTROL UNIT FEATURES ....................................................................... 10
INSTALLATION:
11-20
LOCATION................................................................................................................................... 11
INPUT CONNECTIONS.............................................................................................................. 11-12
EXTERNAL CONNECTIONS..................................................................................................... 13-18
COMBINATION TRIPLE SETPOINT /
ANALOG INPUT BOARD LAYOUT........................................................................................... 19
TYPICAL REA / REM APPLICATOR INSTALLATION.............................................................. 19-20
OPERATION:
21-24
OPERATOR CONTROLS........................................................................................................... 21
OPERATING PROCEDURES.................................................................................................... 22-23
MAINTENANCE:
25-36
ROUTINE PREVENTIVE MAINTENANCE................................................................................ 25
TROUBLESHOOTING................................................................................................................ 25-28
TROUBLESHOOTING FLOW CHARTS.................................................................................... 29-30
TROUBLESHOOTING DIAGRAM............................................................................................. 30
9040 CASCADE CONTROL UNIT BLOCK DIAGRAM............................................................. 31
SERVICE LEVEL......................................................................................................................... 32
REPLACEMENT PROCEDURES.............................................................................................. 32-35
PARTS IDENTIFICATION:
37-40
9040 CASCADE LOW VOLTAGE CONTROL UNIT
PARTS DIAGRAM / PARTS LIST............................................................................................... 37-39
RECOMMENDED SPARE PARTS............................................................................................ 40
WARRANTY POLICIES:
41
LIMITED WARRANTY................................................................................................................. 41
CP-97-04.3
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9040 Cascade Low Voltage Control Unit - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
ITW Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your ITW Ransburg products. This
manual contains information that is important for
you to know and understand. This information
relates to USER SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help you
recognize this information, we use the following
symbols. Please pay particular attention to these
sections.
A W
ARNING! states information to alert you
WARNING!
to a situation that might cause serious injury
if instructions are not followed.
A CAUTION! states information that tells
how to prevent damage to equipment or how
to avoid a situation that might cause minor
injury
injury..
A NOTE is information relevant to the
procedure in progress.
While this manual lists standard specifications and
service procedures, some minor deviations may
be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this
manual with your system installation drawings and
appropriate ITW Ransburg equipment
manuals to reconcile such differences.
!
WARNING
> The user MUST read and be familiar with
the Safety Section in this manual and the
ITW Ransburg safety literature therein identified.
> This manual MUST be read and thoroughly
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 fire codes
and ordinances as well as NFPA-33
SAFETY STANDARD, prior to installing,
operating, and/or servicing this equipment.
!
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.
Careful study and continued use of this manual
will provide a better understanding of the
equipment and process, resulting in more efficient
operation, longer trouble-free service and faster,
easier troubleshooting. If you do not have the
manuals and safety literature for your Ransburg
system, contact your local ITW Ransburg
representative or ITW Ransburg.
1
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Spray Area
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Fire Hazard
Improper or inadequate operation
and maintenance procedures will Spray areas must be kept clean to prevent the
accumulation of combustible residues.
cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation. Frequent power
supply shutdown indicates a
problem in the system requiring
correction.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.
Those used for general cleaning must have flash
points above 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, and local codes. In
addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.
Electrostatic arcing must be prevented.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipment modifications may cause fire or injury.
If used, the key switch bypass is intended for use
only during set-up operations. Production should
never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne
installations to spray solvent based materials.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC, and
OSHA requirements.
CP-97-04.3
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2
9040 Cascade Low Voltage Control Unit - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
General Use and
Maintenance
Improper operation or maintenance Personnel must be given training in accordance with
may create a hazard.
the requirements of NFPA-33.
Personnel must be properly trained Instructions and safety precautions must be read and
in the use of this equipment.
understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33, and your insurance company requirements.
Electrical
Equipment
High voltage equipment is utilized.
Arcing in areas of
flammable or combustible
materials may occur. Personnel
are ex-posed to high voltage during
operation and maintenance.
The power supply, optional remote control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas. Refer to NFPA-33.
Turn the power supply OFF before working on the
equipment.
Protection against inadvertent
arcing that may cause a fire or Test only in areas free of flammable or combustible
explosion is lost if safety circuits material.
are disabled during operation.
Testing may require high voltage to be on, but only
Frequent power supply shutdown as instructed.
indicates a problem in the sys-tem
Production should never be done with the safety
which requires correction.
circuits disabled.
An electrical arc can ignite coating materials and cause a fire or Before turning the high voltage on, make sure no
explosion.
objects are within the sparking distance.
3
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Spray Area /
High Voltage
Equipment
This is a high voltage device that
can produce electrical arcs
capable of igniting coating
materials.
Parts being sprayed must be supported on conveyors
or hangers and be grounded. The resistance between
the part and ground must not exceed 1 megohm.
(Reference NFPA-33.)
A safe distance must be maintained between the parts
being coated and the atomizer bell. A distance of at
least 1 inch for each 10 KV of power supply output
voltage is required at all times.
Parts must be supported so that they will not swing
and reduce the clearance specified above.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
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.
CP-97-04.3
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4
9040 Cascade Low Voltage Control Unit - Atex
EUROPEAN A
TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
ATEX
The following instructions apply to equipment
covered by certificate number Sira
08ATEX5040X:
1. The equipment may be used with flammable
gases and vapors with apparatus groups II and
with temperature class T6.
2. The equipment is only certified for use in
ambient temperatures in the range +12.8°C to
+40°C and should not be used outside this range.
3. Installation shall be carried out by suitably
trained personnel in accordance with the
applicable code of practice e.g. EN 6007914:1997.
4. Inspection and maintenance of this equipment
shall be carried out by suitably trained personnel
in accordance with the applicable code of practice
e.g. EN 60079-17.
5. Repair of this equipment shall be carried out
by suitable trained personnel in accordance with
the applicable code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and
adjustment of the equipment shall be fitted by
suitably trained personnel in accordance with the
manufacturer's documentation.
Refer to the "Table of Contents" of this service
manual:
a.
b.
c.
d.
Installation
Operation
Maintenance
Parts Identification
7. Components to be incorporated into or used
as replacement parts of the equipment shall be
fitted by suitably trained personnel in accordance
with the manufacturer's documentation.
5
8. The certification of this equipment relies upon
the following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the
responsibility of the user to take suitable
precautions that prevent it from being adversely
affected, thus ensuring that the type of protection
provided by the equipment is not compromised.
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
Suitable precautions: e.g. regular checks as part
of routine inspections or establishing from the
material's data sheets that it is resistant to specific
chemicals.
Refer to "Specifications" in the "Introduction"
section:
a. All fluid passages contain stainless steel
or nylon fittings.
b. High voltage cascade is encapsulated with
a solvent resistant epoxy.
9. A recapitulation of the certification marking is
detailed in the "Atex" section, on the next page,
drawing numbers: 72562 and 79318.
10. The characteristics of the equipment shall be
detailed e.g. electrical, pressure, and voltage
parameters.
The manufacturer should note that, on being
put into service, the equipment must be
accompanied by a translation of the
instructions in the language or languages
of the country in which the equipment is to
be used and by the instructions in the
original language.
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Atex
9040 Cascade Low V
oltage
Voltage
Control Unit A
TEX Product
ATEX
Marking Definitions
Label 72562
Ex Certificate Number: Sira 08ATEX5040X
Sira = Notified Body performing EC-type
examination
08 = Year of certification
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
040 = Document serial number
X = Special conditions for safe use apply
Label 79318
Product Marking
II 2 G
Ex = Specific marking of explosive protection
II = Equipment Group hazardous area characteristics
2 = Equipment Category
G = Type of explosive atmosphere (gases,
vapors, or mists)
EEx 0.24mJ = The 76580-XX 9040 Cascade
Control Unit is suitable for use in electrostatic
spraying installations complying with EN 50176
as they are a Type A class with a discharge energy
limit of 0.24mJ.
CP-97-04.3
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6
9040 Cascade Low Voltage Control Unit - Introduction
INTRODUCTION
DESCRIPTION
The ITW Ransburg REA Process
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 applicator nozzle electrode, creating an
electrostatic field between the atomizer and the
target object. The target is electrically grounded
through its support that may be either stationary
or moving.
A regulated pressure fluid system delivers coating
material to the atomizer. At the atomizer, air is
applied that atomizes the coating material forming
a spray mist that, under the influence of the
electrostatic field, becomes electrically charged.
The charged particles are attracted to, and
deposited on, the target object. The forces
between 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. Therefore, a high
percentage of the spray is deposited on the target.
The ITW Ransburg REM
Process
This is a combined air-airless atomization method
for electrostatically applying coatings to objects.
The REM System applies a high voltage DC
charge to the applicator nozzle electrode, creating
an electrostatic field between the atomizer and
the target object. The target is electrically grounded
through its support that may be either stationary
or moving.
A regulated high pressure fluid system delivers
coating material to the atomizer. There the coating
material is atomized by passing through an orifice
under pressure. The resulting spray mist then
becomes electrically charged under the influence
of the electrostatic field surrounding the atomizer.
The charged particles are attracted to and
deposited on the target object. The forces
7
between 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 deposited on the target.
9040 Cascade Low V
oltage
Voltage
Control Unit
The 9040 Cascade Control Unit converts
standard AC line voltage to a high frequency, low
voltage signal ranging from 0 to 10 Vrms. This
signal is supplied to the REA/REM applicator via
the low voltage cable. At the applicator, the low
voltage signal is converted to DC high voltage.
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 low voltage output to the
applicator, the 9040 Cascade control unit also
provides controls for AC power ON/OFF, infinite
high voltage adjustment, a high voltage meter, a
current meter, an AC power ON indicator, a high
voltage ON indicator, a cable fault indicator, and a
current overload indicator and reset switch.
Additionally, output terminals are provided for
remote overload reset, analog current output, and
high voltage control. Interlock connections for a
conveyor and exhaust fan are also provided. A
combination triple setpoint/analog input control
board is also supplied with 9040 Cascade control
units powering automatic spray applicators.
Optional 1/4 rack Totalizer and Pneumatics
modules are available that will slide into the
existing 9040 full rack enclosure. The Totalizer
module is an open loop flow metering system that
provides an easy and accurate means of
monitoring fluid flow rates and totals. The
pneumatics module consists of the required
regulators, gage, and filters to deliver air to one
or more electrostatic spray applicators. Utilizing
these modules in addition to the 9040 Cascade
control unit, allows for grouping of all controls
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Introduction
required to operate the spray applicator in one
convenient location. See “Parts Identification”
section of this manual for information on ordering
Totalizer or Pneumatics modules.
The 9040 Cascade control unit has also been
modularly designed so that two half rack 9040
chassis will fit into one full rack enclosure, in
multiple applicator installations. The full rack
enclosure has been designed for mounting in
standard 19-inch rack mount cabinets.
The 78398-0X, 9040 Control Unit for single bell
applications, includes an additional normally open
pressure switch (3PS) connected between fuse
1FU and ON/OFF switch 1SW. The air input to
this pressure switch is located at the rear of the
control unit and is labeled 3PS. When the air
9040
Part #
76580-AXXXX
76580-BXXXX
76580-1BCDE
76580-2BCDE
76580-4BCDE
76580-5BCDE
76580-6BCDE
76580-7BCDE
76580-8BCDE
76580-9BCDE
78398-0X
signal is removed from this input, the contacts of
the pressure switch are open and AC power to
the control unit is disconnected. The high voltage
output from the 78837 Aerobell Control Module
removes the air signal from pressure switch 3PS
whenever the dump or solvent outputs are active.
In this manner it is ensured that the control unit is
powered OFF whenever the system is in dump
or solvent mode.
The 9040 Cascade Control Unit is available for
hand and automatic REA/REM Cascade spray
applicators as follows:
Used with Applicator T
ype
Type
Applicator #
M90 Applicator
REA900A Automatic
REA-70 Applicator
REM Applicator
REM Automatic
REA9000 Robot or Automatic
REA-90 Waterborne Applicator
REA-90 Solventborne Applicator
REA-90 Solventborne Automatic
REA-90 Waterborne Automatic
Aerobell 33
RPM Aerobell
77073
77359
72074
72364
73499
76110, 75795
75786
75785
75787X-XXXX1
75787X-XXXX2
AER5001-XX4X1
RPM-5XXXX-PSX
B - Designates domestic (1) or export (2) version
C - Designates no (0), intrinsically safe (1), or fiber optic (2) Totalizer module
D - Designates no (0), applicator (1), or automatic applicator (2) Pneumatics module
E - Designates the number of Pneumatics and/or Totalizer modules desired
NOTE
> Except where indicated, this manual is
applicable to all models of the 9040 Cascade control unit.
CP-97-04.3
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8
9040 Cascade Low Voltage Control Unit - Introduction
The 9040 Cascade control unit is available from
the factory in the following versions only:
SPECIFICA
TIONS
SPECIFICATIONS
1. One control unit with no Totalizer or Pneumatics
modules
Environmental / Physical
Height:
5.2-Inches
2. One control unit with one Totalizer module and
no Pneumatics module
Width:
16.9-Inches
(19-Inches ear to ear)
3. One control unit with one Totalizer module and
one Pneumatics module
Depth:
12.1-Inches
Weight:
15 lbs.
4. One control unit with one Pneumatics module
and no Totalizer module
For applications requiring two Totalizer or
Pneumatics modules in a rack with one control
unit, the required modules can be purchased
separately as a kit. (See “Parts Identification”
section.)
Electrical Requirements
Input:
V
oltage
Voltage
90-264 VAC
Currentr:
0.4/0.2 Amps AC
Frequency:
50/60 Hertz
W
attage:
Wattage:
40 Watts (Maximum)
Output:
V
oltage:
Voltage:
Current:
0-10 V RMS
1.5 Amp RMS (Maximum)
Pneumatic
Supply Air:
100 psi maximum
The 13742-01 Air Flow Switch assembly used in
the following 9040 Control Units has a maximum
working pressure of 100 psi:
76580-1XXXX REA 70 Applicator
76580-6XXXX REA90 Waterborne Applicator
76580-7XXXX REA90 Solventborne Applicator
Exceeding this pressure may cause the flow
switch to burst. Ensure that the air input to the IN
port of the flow switch on these units is supplied
from a 100 psi or less regulated and filtered air
supply.
9
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Introduction
FRONT VIEW
BACK VIEW
* Air Flow Switch used in -1XXXX, -6XXXX, and -7XXXX.
Two pressure switches used in -3XXXX, -4XXXX, -5XXXX, -8XXXX, and -9XXXX.
No pressure switch or flow switch used in -2XXXX.
Figure 1: 9040 Cascade Control Unit Features
CP-97-04.3
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10
9040 Cascade Low Voltage Control Unit - Installation
INST
ALLA
TION
INSTALLA
ALLATION
! WARNING
!
> The 9040 Cascade control unit MUST be
located outside the hazardous area. (See
NFPA-33, OSHA, and ITW Ransburg
Literature “Operating Your Electrostatic
Coating System Safely”.)
> The user MUST read and be familiar with
the SAFETY and SAFETY PRECAUTIONS.
> This manual MUST be read and thoroughly
understood by ALL personel who operate,
clean, or maintain this equipment! Special
care should be taken to ensure that the
WARNINGS and requirements for operating
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 OSH prior to installing,
operating, and/or servicing this equipment.
NOTE
As each installation is unique, this
information is intended to provide general installation information for the 9040
Cascade control unit. Consult your authorized ITW Ransburg representative
for specific directions pertaining to the
installation of your equipment.
CAUTION
> DO NOT locate the control unit near
or adjacent to heat producing equipment
such as ovens, high wattage lamps, etc.
NOTE
When rack mounting the 9040 Cascade control unit in a 19-inch cabinet or
Eurorack, it may be necessary to remove
the rubber feet from the bottom of the
9040 enclosure.
>
INPUT CONNECTIONS
For non-conduit installations, plug the detachable
AC line cord into the receptacle in the rear of the
9040 Cascade control unit. Plug the other end of
the line cord into a properly grounded 120-volt AC
outlet.
>
LOCA
TION
LOCATION
Install the 9040 Cascade control unit in an area
outside the hazardous location, where it will be
protected from the possibility of environmental
intrusion, such as dust or moisture, and ambient
temperatures do not exceed 120°F, but as close
to the applicator as possible to minimize the length
of low voltage cable. The control unit may be free
standing on any flat surface or rack mounted in
any 19-inch or Eurorack cabinet.
11
NOTE
> In general, conduit must be used for
approved AC installation; however, if national and local codes permit, the AC
power may be supplied via the factory
supplied line cord. If conduit is utilized,
the control unit AC input 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.
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Installation
For installations where it is required to run the AC
input wiring in conduit, perform the following:
1. Ensure the AC line cord is unplugged and
remove the AC Inlet Receptacle wiring from 1TBL1, 1TB-N and 1TB-Ground (see Figure 2 for AC
input wiring locations).
Figure 2: T
erminal Block One (1TB)
Terminal
Conduit Adapter Plate
! WARNING
Figure 3: Installation of Conduit
Adaptor Plate
> Always double check that the control unit
is unplugged from its AC outlet before working
with any internal wiring connected to 1TB-L1,
1TB-L2, 1TB-N, 1FU, 1SW, or 8PL.
2. Remove the mounting hardware from the AC
Inlet Receptacle and remove it from the rear of
the control unit.
3. Install the Conduit Adapter Plate (supplied) in
the hole where the AC Inlet Receptacle was
removed (see Figure 3).
4. Install the AC line cord through the Conduit
Adapter Plate using conduit and wire to TB1 as
follows:
Hot/Line
Neutral/Common
Ground
CP-97-04.3
to
to
to
1TB-L1
1TB-N
1TB-Ground
NOTE
When using conduit to route the AC
input wiring to the control unit, the last
several feet of conduit attached to the
control unit should be of a flexible type,
such that the control unit module can still
be slid out of the enclosure for testing and
setup purposes.
>
The 9040 Cascade control unit accepts universal
input voltage between 90 and 264 VAC. There is
no need to change any switch settings when
changing input from 115 to 230 VAC or vice-aversa.
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12
9040 Cascade Low Voltage Control Unit - Installation
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, it is recommended that
the fuse be changed in order to keep the
same level of protection. Both fuses are
shipped with 9040 control units.
EXTERNAL
CONNECTIONS
> When connecting external wires to the
9040 Cascade control unit, some of the
wires will be connected to the External
Wiring Plug 2PL and some routed through
the External Wiring Grommet. When
wiring through the External Wiring Grommet, leave enough slack in the wires so
that the 9040 control unit chassis can still
be slid out of its enclosure if required. For
installations requiring conduit, route all
wires through the external wiring grommet opening and connect to the existing
wires on the inside of External Wiring
Plug 2PL (2SOF) when necessary.
Low V
oltage Cable Connection
Voltage
Connect the low voltage cable from the spray
applicator to the Low Voltage Cable Socket
located on the back of the control unit. Hand
tighten only.
Connect the other end of the low voltage cable to
the applicator, using a wrench to tighten.
For 78398-OX 9040 control units, connect the low
voltage cable from the low voltage cable socket
on the rear of the control unit to the low voltage
input receptacle on the side of the 76300-XX
External Cascade.
13
> DO NOT over tighten low voltage
cable connection to applicator. Damage
to plastic parts may occur.
Safety Ground
Crimp the appropriate connector onto the Ground
Wire Assembly and install from the control unit
ground stud, located on the back of the control
unit to a true earth ground.
!
NOTE
CAUTION
CAUTION
> The Ground Wire Assembly MUST
be connected from the power supply
ground stud to a true earth ground.
Supplemental ground is provided via the
ground stud to the enclosure, through
the front panel screws, and to the
chassis module. Therefore, ensure the
front panel screws in the 9040 Cascade
control unit module are securely fastened to the rack enclosure during
operation. If it becomes necessary to
slide the chassis out for testing purposes, connect a ground wire from the
enclosure to the chassis.
Interlocks
! WARNING
> ALWAYS ensure that high voltage is OFF
before flushing the spray applicator with
solvent. NEVER flush the spray applicator
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 ITW Ransburg representative for
information on interlocking the high voltage
OFF signal with the solvent flush signal.
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Installation
As outlined in NFPA-33 and OSHA, the AC power
line must be series interlocked with both the
exhaust fan and conveyor. To interlock the 9040
Cascade control unit with the exhaust fan and
conveyor perform the following:
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF switch
is in the OFF positon.
2. Loosen the front panel screws and slide the
control unit chassis out.
External Relay Contacts
A set of external relay contacts for high voltage
(K1) and overload (K2) conditions is provided at
External Wiring Plug 2PL-5, -6 & -7 (outside) and
2SOC-5, -6 & -7 (inside). (See Figure 11 for exact
wiring locations.) These relay contacts are
sometimes useful in configuring the control of the
spray applicator system.
Maximum contact ratings are as follows:
Maximum Switching Power
Maximum Switching Voltage
Maximum Switching Current
! WARNING
> Always double check that the control unit
is unplugged from its AC outlet before working
with any internal wiring connected to 1TB-L1,
1TB-L2, 1TB-N, 1FU, 1SW, or 8PL.
DC
60W
220VDC
2A
AC
125VA
250VAC
2A
Pneumatic Connections
76580-1XXXX, -6XXXX, and -7XXXX
3. Using a small blade screwdriver, remove the
factory installed test jumper from 1TB-L1 to 1TBL2.
4. Route exhaust fan and conveyor interlock
(supplied by user) wiring through external wiring
grommet on the back of the control unit and
connect to 1TB-L1 and 1TB-L2 as shown in Figure
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.
!
CAUTION
> When highly conductive, solventbased paints are used it is also recommended that the high voltage control be
series interlocked with the atomization
air. This prevents the possibility of a
charged stream of fluid creating an arc,
and subsequent fire, as it approaches
the floor (or some other grounded
object). Consult your authorized ITW
Ransburg representative for information
on interlocking the high voltage with the
atomization air.
CP-97-04.3
Connect the Air Filter Assembly (supplied) to the
IN port of the air flow switch on the back of the
9040 Cascade control unit. Connect regulated
(100 psi maximum) factory air to the other end of
the Air Filter Assembly. Be sure that the fittings
remain clean and are securely tightened. Attach
the spray applicator air line to the OUT port of the
air flow switch.
When the spray applicator is triggered, the resulting
air flow closes the contacts of the air flow switch,
thereby activating high voltage at the spray
applicator.
76580-4XXXX, -5XXXX, -8XXXX, and
-9XXXX
Connect an atomization air pressure signal to one
pressure switch port and a trigger air pressure
signal to the other. When pressure signals are
applied to both switches, their contacts close
thereby activating high voltage at the spray
applicator. Both pressure switches must be
activated to receive high voltage. Pressures
greater than 15 psi are required to activate the
pressure switches. Maximum operating pressure
is 150 psi.
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14
9040 Cascade Low Voltage Control Unit - Installation
External High V
oltage Control
Voltage
External Overload Reset
If a method of high voltage triggering, other than
the factory supplied method, is required, the 9040
Cascade control unit allows for external high
voltage control from a PLC, pressure switch,
airflow switch, or other user-supplied device. To
turn the high voltage on, the user-supplied device
must create a contact closure between terminals
1 and 2 of the External Wiring Plug (2PL). The
wiring from the user-supplied external high voltage
control device can be connected directly to the
outside terminals of 2PL, or for installations
requiring conduit, connected to the inside terminals
2SOC-1 and 2 as follows:
The 9040 Cascade control unit allows for use of
an external (normally closed) overload reset
button. This is convenient when the control unit
is mounted in a hard to reach or inconvenient
location or when it is desired to control overload
reset of several control units from a single location.
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF switch
is in the OFF position.
2. Loosen the front panel screws and slide the
control unit chassis out.
3. Route the contact wires of the control device
through the external wiring grommet opening and
connect to the existing wiring for 2SOC-1 and
2SOC-2. The control device contacts must
be rated for at least 100 milliamps at 15
volts DC.
4. Slide the chassis back in, secure the front panel
screws, replace the fuse, and plug in the control
unit.
NOTE
> A separate normally open (NO) exter-
nal high voltage control contact MUST be
used for each control unit in multiple control unit applications. One contact CANNOT be used to trigger the high voltage
for multiple control units.
The wiring from the user supplied external
overload reset device can be connected directly
to the outside terminals 2PL-2 and -3 (remove
factory installed jumper from 2PL-2 to 2PL-3), or
for installations requiring conduit, connected to the
inside terminals 2SOC-2 and 3 as follows:
1. Remove the factory-installed jumper from 2PL2 to 2PL-3.
2. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF switch
is in the OFF position.
3. Loosen the front panel screws and slide the
control unit chassis out.
NOTE
> A separate normally open (NO) exter-
nal high voltage control contact MUST be
used for each control unit in multiple control unit applications. One contact CANNOT be used to trigger the high voltage
for multiple control units.
4. Route the contact wires of the external reset
device through the external wiring grommet
opening and connect to the existing wiring for
2SOC-2 and 2SOC-3. The external reset
device contacts must be rated for at least
100 milliamps at 15 volts DC. The contacts
of the external reset device must be
normally closed.
5. Slide the chassis back in, secure the front panel
screws, replace the fuse, and plug in the control
unit.
15
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Installation
Analog Current Output Signal
An analog current output signal is available from
the 9040 control unit at 2PL-8 (outside) or 2SOC8 (inside). This signal can be connected to a
recording device (strip chart recorder, data
acquisition unit, etc.) to monitor the output current
of the control unit over time. This signal should
be referenced to earth ground. The input
resistance of the recording device should be 5
megohms or greater.
Figure 4: Main PC Board
NOTE
> If the input resistance of the recording
device is less than 5 megohms, it will
affect the reading on the 9040 control unit
microampmeter.
The analog current output signal can be adjusted
such that 0 to 10 VDC represents 0 to 100
microamps or 0 to 200 microamps, by opening or
shorting jumper JP8 on the main PC board (see
Figure 4 for JP8 location). The board is factory
supplied with JP8 shorted (covering both
terminals) such that 0 to 10 VDC represents 0 to
200 microamps. To set the analog output current
so that 0 to 10 VDC represents 0 to 100
microamps open jumper JP8 (reposition so that it
covers only one terminal).
The wiring from the user supplied analog output
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
2SOC-8 as described below. Connect common
of the recording device directly to earth ground.
3. Route the wire of the external recording device
through the External Wiring Grommet opening and
connect to the existing wiring for 2SOC-8.
4. Slide the chassis back in, secure the front panel
screws, replace the fuse, and plug the control unit
back in.
Triple Set Point/Analog Input
Control Connections
(76580-4XXXX, -5XXXX, 8XXXX, and -9XXXX only)
9040 Cascade control units for automatic
applicatorss are shipped with a combination Triple
Setpoint/Analog Input Interface Board installed.
When set for triple setpoint operation, three
discreet setpoints for high voltage output at the
spray applicator can be selected, using two 24
VDC input signals. When set for analog input
operation a 0 – 10 VDC or 4 – 20 mADC input
signal can be used to select continuous kV output
at the spray applicator from 0 to rated kV. With
either setting a PLC, robot, ext. can thus select
from different voltages to suit the spray application.
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF switch
is in the OFF position.
2. Loosen the front panel screws and slide the
control unit chassis out.
CP-97-04.3
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16
9040 Cascade Low Voltage Control Unit - Installation
To utilize the T
riple Setpoint Feature perform
Triple
the following (refer to Figures 5a and 5b):
1. Ensure the front panel fuse is removed, the
control unit is unplugged, and the ON/OFF switch
is in the OFF position.
High voltage outputs selected by TB1-1 (Setpoint
1) and TB1-3 (Setpoint 2) can be adjusted by
tweaking potentiometers P1 and P2 on the Triple
Setpoint Board, respectively. Typically P1 is
factory set to provide approximately 50% of
maximum kV, while P2 is set to provide
approximately 75% of maximum kV.
2. Loosen the front panel screws and slide the
control unit chassis out.
3. Ensure JP2 jumpers on triple set point/analog
input board are set to TSP ON position as shown
on PC board silkscreen.
4. Route the wiring through the External Wiring
Grommet and connect to the Triple Setpoint Board
as follows:
Robot or PLC Common
24 VDC Setpoint 1 Select
24 VDC Setpoint 2 Select
to
to
to
TB1-2
TB1-1
TB1-3
NOTE
> Jumper J1 on the Triple Setpoint Board
should be positioned so that it covers only
one terminal (open) for proper operation.
Turn the control unit power OFF before
flushing, cleaning, or servicing the applicator.
To utilize the Analog Input Feature perform
the following (refer to Figure 5b):
1. Ensure the control unit is OFF< unplugged from
the AC outlet, and the front panel fuse is removed.
2. Loosen the front panel screws and slide the
control unit chassis out.
NOTE
An interlock line with the control unit
power and overload signal is provided
across terminals TB1-4 and 5. This line
can be used to indicate that high voltage
is ready (control unit is on and not in
overload state) if desired.
>
3. Set JP2 jumpers on Triple Setpoint/Analog Input
Board to ANLG ON position as shown on PC
board silkscreen.
NOTE
5. Slide the chassis back into the cabinet, secure
the front panel screws, replace the fuse, and plug
the control unit in.
The Triple Setpoint Board is now ready for use.
Turning on the robot or PLC output connected to
TB1-1 will activate Setpoint 1, while turning on the
robot or PLC output connected 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
When JP2 is set to TSP ON position
and no 24 VDC triple setpoint inputs are
applied, high voltage control is from the
High Voltage Adjust Knob on the front of
the control unit.
>
4. Set JP3 jumpers on Triple Setpoint/Analog
Input board to desired input (0 to 10 VDC or 4 to
20 mADC) position, as shown on PC board
silkscreen.
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Installation
!
CAUTION
!
CAUTION
> DO NOT operate the Analog Input
Feature with the jumpers removed from
JP2 or JP3, or with the jumpers in any
other positions that those shown on the
PC board silkscreen.
> DO NOT use the analog input board
as a method for turning high voltage ON
and OFF. The control unit has specific
inputs for this purpose (see “Pneumatic
Connections and External High Voltage
Control” in this section).
5. Connect the positive analog control input
(source) to TB1-6 and the negative analog input
(common or return) to TB1-7. Route the wiring
through the external wiring grommet on the rear
of the 9040 control unit.
> ALWAYS turn the control unit’s AC
Power ON/OFF switch to the OFF
position before flushing, cleaning, or
serving the applicator.
NOTE
NOTE
> The input resistance of the Analog Input
To eliminate problems caused by
external noise, a twisted, shielded pair
should be used for the analog input control wiring. Connect the shield to ground
at the analog control source ONLY.
>
Board feature is:
0-10 VDC Operation: 200 Kilohms
4-20 mADC Operation: 249 Ohms
5. An interlock line with the control unit power and
overload signal is provided across terminals TB14 and 5. This line can be used to indicate that high
voltage is ready (control unit is on and not in
overload state) if desired.
6. Slide the chassis back into the cabinet, secure
the front panel screws, replace the fuse, and plug
the control unit in.
The Analog Input board is now ready for use. A
0-10 VDC or 4-20 mADC input signal will produce
an applicator output of 0 to rated kV.
CP-97-04.3
Figure 5a: Triple Setpoint Schematic
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18
9040 Cascade Low Voltage Control Unit - Installation
Figure 5b: Combination Triple Setpoint/Analog Input Board Layout
Figure 6: T
ypical REA Applicator Installation
Typical
19
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Installation
Figure 7: T
ypical REM Applicator Installation
Typical
CP-97-04.3
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20
9040 Cascade Low Voltage Control Unit - Operation
OPERA
TION
OPERATION
! WARNING
! WARNING
> The user MUST read and be familiar with
the SAFETY PRECAUTIONS and
SAFETY SECTIONS of this manual and
the ITW Ransburg safety literure therein
identified BEFORE OPERATING the 9040
Cascade control unit.
> The electrical discharge that 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
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 the
appropriate applicator manual.) If improper
readings are obtained, check that the control
unit is grounded. (See “Ground Test
Procedures” in the “Maintenance Troubleshooting” section of this manual.)
Figure 8: Operating Controls
21
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Operation
OPERA
TING
OPERATING
PROCEDURES
High V
oltage Adjustment Knob
Voltage
1. Ensure that the AC power, pneumatic and low
voltage cables are connected as described in the
“Installation” section of this manual.
Overload Indicator/Reset Button
!
The high voltage adjustment knob allows infinite
control of the applicator electrode voltage between
0 and rated kV.
CAUTION
Check that the control unit is
>
properly grounded!
2. Be sure that the high voltage adjustment knob
is turned FULLY counter-clockwise.
3. Turn the ON/OFF switch to the ON position.
The green LED will light indicating that AC power
is being supplied to the control unit.
4. The voltage to the REA-70 and REA-90
applicators is activated by supplying adequate air
to the flow switch when the applicator is triggered.
The voltage to the REM applicator is activated by
a magnet in the applicator air valve assembly
which triggers a reed switch inside the low voltage
cable assembly. The voltage to automatic
applicators is activated by supplying adequate
pressure signals to the control unit pressure
switches or be triggering an external high voltage
control device connected across 2PL-1 and 2PL2.
5. Turn the voltage adjustment knob to the desired
operating point as indicated by the kilovolt and
microamp meters.
Kilovolt and Microamp Meters
The kilovolt meter indicates the voltage in
thousands of volts (kv) present at the applicator
electrode. The microamp meter indicates the
current in millionths of amps (uA) leaving the
applicator electrode.
CP-97-04.3
Lighting of the yellow overload/reset lamp
indicates that an overload condition has occurred.
The overload circuitry is integral to the control unit
and is factory calibrated and sealed. It allows
normal operation, testing and maintenance. It will
only activate if the spray applicator load conditions
exceed the pre-set limit as a result of component
(barrel, transformer, cable) failure or improper
applicator to target distance. If the overload should
trip, locate and correct the problem. Then reset
the overload by pushing the reset switch in, or
turning the ON/OFF switch OFF and back ON
again.
The overload feature can be turned ON or OFF
by moving jumper JP5 on the main PC board (see
Figure 4 for location of JP5). To turn the overload
circuit OFF position jumper JP5 so that it covers
(shorts) pins 2 and 2. To turn the overload circuit
ON position jumper JP5 so that it covers (shorts)
pins 2 and 3.
NOTE
> Control units for applicators are shipped
from the factory with the overload circuit
OFF, while those for automatic applicators are shipped with the overload circuit
ON. This is because during normal use,
manually operated applicators may come
in close proximity to the part, causing an
overload which requires the operator to
cease the painting operation while going
to reset the overload. In addition, the
operator will notice when a failed part may
be causing the applicator to operate at
less than optimum performance, thus the
overload circuit is not necessary for this
purpose.
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22
9040 Cascade Low Voltage Control Unit - Operation
Automatic applicators, however, typically have a
fixed distance between electrode and target and
thus it is not likely that the spray applicator 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 may be corrected. Additionally, since
there is no operator with automatic applicators,
the overload circuit is required to alert maintenance
when failed parts may be causing the applicator
to operate at less than optimum performance.
NOTE
> Because of the manner of high voltage
triggering employed in the REM applicator, the Cable Fault/Hook OFF Indicator
will not function if either wire to the reed
switch, located in the applicator handle,
becomes open circuited (such as when
the cable is disconnected or completely
cut through).
When turning the overload circuit ON for applicator
units it may be necessary to adjust the setpoint at
which overload occurs. If so, contact your
authorized ITW Ransburg representative for
assistance.
High V
oltage Safety Circuit
Voltage
The 9040 Main PC board contains a safety circuit
that prevents high voltage from being present at
the applicator if the high voltage trigger device
(flow switch, pressure switch, PC contact, etc.)
has not been triggered. If a failure mode should
occur that would attempt to send high voltage to
the applicator, even though the high voltage trigger
has not been activated, the PC board will shut
down and enter an overload condition. If the
control unit repeatedly overloads even though the
high voltage trigger has not bee activated, the main
PC board has failed and should be replaced.
High V
oltage ON Indicator
Voltage
The red AC power ON LED will light when the AC
Power ON/OFF switch is in the ON position.
Cable Fault/Hook OFF Indicator
The yellow cable fault/hook OFF LED will light
whenever the low voltage signal to the applicator
is open circuited. This will occur if the cable is
not connected or if the cable becomes damaged
such that power cannot be transmitted to the
applicator. With applicators having hook
transformer mounted ON/OFF switches, the cable
fault/hook OFF indicator will also light when the
switch is placed in its OFF position.
23
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Operation
NOTES
CP-97-04.3
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24
9040 Cascade Low Voltage Control Unit - Maintenance
MAINTENANCE
ROUTINE PREVENTIVE
MAINTENANCE
In general, little maintenance is necessary to
ensure proper operation. It is important, however,
to keep the interior of the unit clean and free from
moisture or foreign material. For this reason:
3. Disconnect the low voltage applicable cable and
connect one lead of the ohmmeter to the ground
stud and the other to the center pin of the low
voltage cable socket on the control unit. If the
ohmmeter reads greater than 25 ohms, repair the
internal connections between these points (green
wires from 1TB-GROUND TO 1GND (see Figure
10) and from 1TB-GROUND to center pin of low
voltage cable socket).
• Keep the exterior of the unit free from dust
accumulation.
• Always clean the exterior prior to accessing the
interior.
• Access the interior only to perform maintenance or repair.
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 searching for faulty
internal connections.
>
TROUBLESHOOTING
Ground T
est Procedure
Test
Equipment Required:
measure resistance
Ohmmeter - to
If shocks or sparks are noticed at any point in the
spray system, immediately turn off the control unit
and check the complete system for proper
grounding. Proper grounding of the applicator
system can be verified as follows:
1. Ensure that the clamp of the Ground Wire
Assembly is connected to true earth ground. The
resistance between 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 control unit ground stud. If the ohmmeter reads
greater than 25 ohms replace the Ground Wire
Assembly.
25
4. Connect one end of the ohmmeter to the center
pin of the low voltage cable connector on the cable,
and the other to the metal applicator body
(automatics) or handle bracket (applicators). If
the ohmmeter reads greater than 25 ohms replace
the low voltage cable.
NOTE
> On applicators, ground is passd from
the low voltage cable to the handle via the
handle set screw. Ensure the set screw
is completely tightened and repeat step 4
before replacing the low voltage cable on
applicator units.
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Maintenance
Control Unit Output T
est
Test
PC Board T
est Jumper
Test
When a lack of high voltage at the applicator
indicates a problem, perform a Control Unit Output
Test on the control unit to determine whether it is
at fault.
To assist in testing and troubleshooting, a jumper
(JP4) has been incorporated on the 9040 PC
board. By covering (shorting) both terminals the
high voltage on relay is triggered. Thus, for testing
and troubleshooting, high voltage output can be
obtained without the need to trigger the applicator
or user supplied 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 4 - Main PC
Board” for location of test jumper JP4.)
Equipment Required: ITW Ransburg
LTST5000 L
V Control Unit T
est
LV
Test
Assembly
1. Turn control unit power OFF and remove low
voltage cable from control unit.
2. Connect tester cable to control unit.
3. Move switch on tester to FRONT PANEL kV
METER position.
4. Turn control unit ON and adjust control unit
high voltage adjust knob fully clockwise.
5. Read the control unit front panel kV meter.
Reading should be rated kV of applicator ±5 kV.
turn the control unit OFF.
If the voltage read correctly, the problem is not in
the control unit and the low voltage cable and
applicator should be checked for the cause. If
proper readings are not obtained, the problem is
with the control unit. Consult the “Troubleshooting
Flowchart” in this section to locate the specific
problem.
NOTE
The LTST5000 Test Assembly can
also be used to test the low voltage cable.
Consult the LTST5000 service manual
for further information on using the
LTST5000 Test Assembly.
>
CP-97-04.3
!
CAUTION
If JP4 is left covering (shorting)
>
bother terminals, high voltage will
be on whenever AC power is
turned on. This could be hazardous in some applications.
Theory of Operation
Line voltage (90-264 VAC) is applied to input
terminals 8PL-1 and 8PL-2 of power supply 1 SUP
through the user supplied exhaust fan and
conveyor interlocks, fuse IFU, and ON/OFF
switch 1SW.
The output of power supply 1SUP, through PC
board fuse F2, provides the DC voltage which
powers the PC board regulators and the AC Power
ON LED. The DC input to the oscillator circuit is
obtained from a board regulator through high
voltage adjust knob 1POT. The oscillator circuit
outputs a low voltage, high frequency AC signal
through the low voltage cable socket 3SOC to
the applicator. The high voltage cascade located
in the applicator rectifies the AC voltage to DC
and steps it up to provide rated kV. The high
voltage adjust knob controls the level of output
voltage from the oscillator to the high voltage
cascade. In this manner, complete adjustability
from 0 to maximum kV of the applicator is
achieved.
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26
9040 Cascade Low Voltage Control Unit - Maintenance
The DC input to the oscillator is interlocked with
2PL terminals 1 and 2, such that the oscillator will
not function unless terminals 1 and 2 of 2PL are
connected together. In this manner, high voltage
to the applicator is controlled as follows:
1. When air flows through the flow switch, the
switch contacts close connecting 2PL-1 and 2
together, thereby providing voltage to the REA70 and REA-90 applicators.
2. Pulling the trigger on the REM applicator
activates a reed switch in the applicator handle
that connects 2PL-1 and 2 together, thereby
providing voltage to the applicator.
3. When pressure signals are supplied to the
pressure switches, the switch contacts close
connecting 2PL-1 and 2 together, thereby
providing voltage to automatic applicators.
4. Contact closure of a programmable controller
output, robot output, or some other user supplied
device connected to terminals 2PL-1 and 2 will
activate high voltage at the applicator.
5. For testing and troubleshooting, board jumper
JP4 connects 2PL-1 and 2 together, thereby
providing high voltage output (see “PC Board Test
Jumper” previouslly discussed in this section).
Bench T
esting
Testing
NOTE
> Before going through the trouble of a
complete bench test, jumper JP4 on the
main PC board to trigger the high voltage
and see if the suspected problem goes
away. If it does, replace the high voltage
trigger device (flow switch, pressure
switch, PC contact, etc.) or repair the
internal wiring of the control unit connected to the trigger device, and test again. If
the problem does not go away then proceed with a bench test.
27
Equipment Required: V
olt/
Volt/
Ohmmeter
This section provides a flow chart for
troubleshooting the control unit when improper
operation is obtained and the problem has been
traced to the control unitl. Proper troubleshooting
should ONLY be accomplished with specific test
equipment, by qualified electronics technicians,
or authorized ITW Ransburg representatives.
! WARNING
> The troubleshooting procedure outlined in
“Troubleshooting Flow Charts” requires
measurement 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
technicians or authorized ITW Ransburg
representatives.
Before troubleshooting, ensure that the control unit
is plugged into a live outlet of the appropriate
voltage. All electrical measurements in the
“Troubleshooting Flowchart” are nominal and may
vary as much as +/- 10% depending on the test
conditons and the test equipment used. Refer to
“Figure 4 - Main PC Board” and “Figure 9 Troubleshooting Diagram” for location of parts
called out in “Troubleshooting Flowcharts”.
For bench testing, jumper JP4 should be used to
trigger the high voltage output (see “PC Board Test
Jumper” previously discussed in this section).
ARCHIVE
CP-97-04.3
9040 Cascade Low Voltage Control Unit - Maintenance
NOTES
CP-97-04.3
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28
9040 Cascade Low Voltage Control Unit - Maintenance
TROUBLESHOOTING FLOW CHARTS
ON / OFF Switch ON
ON / OFF Indicator (green LED) does not
light
29
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Maintenance
TROUBLESHOOTING FLOW CHARTS (Cont.)
Figure 9: Troubleshooting Diagram
CP-97-04.3
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30
9040 Cascade Low Voltage Control Unit - Maintenance
Figure 10: 9040 Cascade Control Unit Block Diagram
31
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Maintenance
! WARNING
> Always turn power to the control unit OFF,
unplug the electrical cord from its outlet,
remove the front panel fuse, and lock the
control unit out before making repairs or
replacements.
3. Remove fuse from fuse holder and replace
with new fuse (see “Parts Identification” section
of this manual for fuse part number).
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
(See Figure 4 for fuse location.)
SERVICE LEVEL
Personnel who service this unit must be qualified
electronics technicians.
Replacement parts are designed to be made at
the assembly level. (See “Parts Identification”
section of this manual for replacement
assemblies.)
1. Ensure control unit is unplugged 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 board fuse is included
CAUTION
> Do not attempt to make repairs to the
printed circuit board! Do not attempt to make
repairs beyond those described. All others
should be made ONLY by ITW Ransburg
service personnel.
from the factory.
location.)
(See Figure 10 for
3. Slide chassis in, secure front panel screws
and plug control unit back in.
ON/OFF Switch 1SW
REPLACEMENT
PROCEDURES
1. Ensure control unit is unplugged from AC outlet,
loosen front panel screws, and slide the control
unit chassis out.
Before making replacements, check for defective
wiring or connections between the affected
components. If there is broken wire, defective
insulation or dirty, loose or corroded connections,
repair or replace them before going to the expense
of replacing a component.
! WARNING
> Always double check that the control unit is
unplugged from its AC outlet before working
with any internal wiring connected to 1TB-N,
1TB-L, 1TB-L2, 1FU, 1SW, or 8PL.
Front Panel Fuse 1FU
1. Insert screwdriver into slot in front panel fuse
holder, push in, and rotate counter-clockwise.
2. Remove the four (4) quick connect terminals
from the rear of ON/OFF switch 1SW.
2. Remove screwdriver and fuse holder will slide
out.
CP-97-04.3
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32
9040 Cascade Low Voltage Control Unit - Maintenance
NOTE
! WARNING
> It is recommended that the four (4) ON/
OFF switch wires be tagged with their
respective terminal connections to 1SW
before removing.
3. Press panel retaining clips on top and bottom
of switch 1SW together and push switch out of
panel from the inside.
4. Press new switch (see “Parts Identification”
section of this manual to order) into panel opening
with terminals 1A and 2A to the bottom of the
cabinet.
5. Reconnect the four (4) quick connect terminals
to the new switch as follows:
From
T
o
To
1FU-2
1TB-N
8PL-2
8PL-1
1SW-1
1SW-2
1SW-1A
1SW-2A
> Always double-check that the control unit
is unplugged from its AC outlet before
removing the cover plate from power supply
1SUP.
4. Remove connectors 8PL and 10PL from power
supply 1SUP.
5. Remove the four (4) cover plate standoffs from
power supply 1SUP and remove the power supply
from the unit.
6. Install new 1SUP power supply (See “Parts
Identfication” section of this manual to order) using
the four (4) cover plate standoffs. Ensure larger
connector (10PL) of power supply 1SUP faces
front of unit as shown in Figure 9.
7. Connect connectors 8PL and 10PL to new
power supply and reinstall cover plate and analog/
triple setpoint board.
8. Slide chassis in, secure front panel screws,
and plug control unit back in.
6. Slide chassis in, secure front panel screws,
and plug control unit backing.
Flow Switch 1FS
(76580-1XXXX, -6XXXX, and
-7XXXX)
Power Supply 1SUP
1. Disconnect air lines from flow switch.
1. Ensure control unit is unplugged from AC outlet,
loosen front panel screws, and slide the control
unit 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 1SUP
power supply cover plate and remove the plate.
2. Ensure control unit is unplugged from AC outlet,
loosen front panel screws, and slide control unit
chassis out.
3. Remove two (2) wires from flow switch
terminals.
4. Remove hex nuts from flow switch inlet and
outlet.
5. Pull out defective flow switch.
6. Attach two (2) wires to new flow switch (See
“Parts Identification” section of this manual for
ordering information) terminals (it does not matter
which one goes where).
33
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Maintenance
7. With flow switch terminals pointing towards
the main PC board, install new flow switch through
chassis mounting holes.
8. Secure flow switch to side panel with two (2)
hex nuts.
9. Slide chassis in, secure front panel screws,
and plug control unit back in.
10. Reconnect air lines to flow switch.
Pressure Switch (76580-4XXXX,
-5XXXX, -8XXXX, and -9XXXX)
1. Disconnect pressure signal input line from
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 board connector 9PL from main
PC board.
3. Remove two (2) screws that mount display
board to inside of front panel and remove display
board from control unit.
4. Install new display board (see “Parts
Identification” section of this manual for
information) in control unit.
5. Reconnect connector 9PL to main PC board.
2. Ensure control unit is unplugged from AC outlet,
loosen front panel screws, and slide control unit
chassis out.
6. Slide chassis in, secure front panel screws,
and plug control unit back in.
3. Remove two (2) wires from pressure seitch
terminals.
Kilovolt (kV) or Microamp (uA)
Meter
4. Loosen hex nut from fitting and remove
pressure switch and fitting from control unit.
1. Ensure control unit is unplugged from AC outlet,
loosen front panel screws, and slide control unit
chassis out.
5. Remove fitting from defective pressure switch
and install on new pressure switch (see “Parts
Identification” of this manual for ordering
information).
6. Install new pressure switch in control unit by
securing hex nut to fitting.
7. Attach two (2) wires to the NO (normally open)
and C (common) terminals of the pressure switch
(it does not matter which one goes where). Do
not attach any wires to the NC terminal fo the
pressure switch.
8. Slide chassis in, secure front panel screws,
and plug control unit back in.
2. Remove two (2) hex nuts from wiring terminals
and remove wire lugs.
3. Remove four (4) hex nuts that mount meter to
front panel.
4. Remove old meter and install new one (see
“Parts Identification” section of this manual for
ordering information).
5. Reconnect wire lugs to meter (purple wire goes
to + termianl of meter).
6. Slide chassis in, secure front panel screws,
and plug control unit back in.
9. Reconnect pressure signal input line to
pressure switch.
CP-97-04.3
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34
9040 Cascade Low Voltage Control Unit - Maintenance
HV Adjust Potentiometer
PC Board
1. Remove knob from HV adjust potentiometer
by using a 1/16” Allen wrench to remove the two
(2) set screws.
1. Ensure control unit is unplugged from AC outlet,
loosen front panel screws, and slide control unit
chassis out.
2. Ensure control unit is unplugged from AC outlet,
loosen front panel screws, and slide control unit
chassis out.
2. Disconnect plugs 6PL, 7PL, and 9PL (see
Figure 4).
3. Remove heat shrink tubing and unsolder the
wires from HV adjust potentiometer 1 POT.
3. Remove two (2) screws from heat sink base
and lift the PC board out.
!
NOTE
It is recommended that the three (3)
wires be tagged with their respective terminal connections 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 fo this manual for ordering
information) in the front panel.
CAUTION
> DO NOT remove the PC board from the
heat sink as it is an integrated assembly.
4. Insert new PC board (see “Parts Identification”
section of thismanual for ordering information) and
secure the two (2) heat sink screws.
5. Reconnect plugs 6PL, 7PL, and 9PL.
6. Slide chassis in, secure front panel screws,
and plug control unit back in.
6. Using heat shrink tubing and appropriate solder
techniques, solder the wires to the new
potentiometer as follows:
From
7PL-1
1SOC-6
7PL-5
IM-
T
o
To
1POT-1 *
1POT-2
1POT-3
1POT-1 *
* Indicated 2 connections to the same point.
7. slide chassis in, secure front panel screws,
and plug control unit back in.
8. Reinstall adjust knob using 1/16” Allen wrench.
35
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Maintenance
NOTES
CP-97-04.3
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36
9040 Cascade Low Voltage Control Unit - Parts Identification
PAR
TS
ARTS
IDENTIFICA
TION
IDENTIFICATION
Figure 1
1: 9040 Cascade Low V
oltage Control Unit Parts Diagram
11:
Voltage
37
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CP-97-04.3
9040 Cascade Low Voltage Control Unit - Parts Identification
VOLT
PAR
ARTS
9040 CASCADE LOW VOL
TAGE CONTROL UNIT - P
AR
TS LIST
11)
(Figure 1
1)
Item #
Part #
1
76892-01
76892-02
76892-04
76892-05
76892-06
76892-07
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
76892-08
76892-09
76892-16
76892-17
76434-01
70556-03
76436-91
76436-92
72231-00
13742-01
13028-01
8012-00
6039-00
25766-106
75337-05
LSME082-04
72771-06
72771-01
76449-00
70539-00
76455-01
76442-01
76441-00
76443-01
5627-00
76031-05
76031-06
76031-07
76031-08
76031-10
76892-11
76895-18
Description
Notation
PC Board and Heat Sink Assembly:
For 76580-1XXXX, REA70 Applicator (72074)
For 76580-2XXXX, REM Applicator (72364)
For 76580-4XXXX, REM Automatic (73499)
For 76580-5XXXX, REA9000 Automatic (75795), Robot (76110), and
76580-BXXXX, REA900 Automatic (77359)
For 76580-6XXXX, REA90 Waterborne Applicator (75786)
For 76580-7XXXX, REA90 Solventborne Applicator (75785) and
76580-AXXXXX, M90 Applicator (77073)
For 76580-8XXXX, REA90 Solventborne Automatic (75787X-XXXX1)
For 76580-9XXXX, REA90 Waterborne Automatic (75787X-XXXX2)
For 78398-01, Single Bell, Domestic
For 78398-02, Single Bell, Export
ON./OFF Switch
1SW
High Voltage Adjust Potentiometer
1POT
Kilovolt (kV) Meter
1M
Microamp (uA)
2M
Low Voltage Cable Socket
3SOC
Air Flow Switch Assembly:
1FS
Housing
Switch Assembly
Piston
Pressure Switch *
1PS, 2PS
Power Supply, 18VDC
1SUP
Fuse, PC Board, Slow Blow, 4 Amp (See Figure 5 for location.)
F2
Fuse, Front Panel:
Slow Blow, 1 Amp, 110-120 VAC Input
1FU
Slow Blow, 0.5 Amp, 220-240 Input
1FU
Detachable AC Line Cord
Ground Wire Assembly
LED Display Board
Overload Indicator and Reset Switch Assembly:
Reset Switch (normally closed)
Lens, Yellow
Bulb
Rubber Feet
Triple Setpoint/Analog Input Interface Board:
For REA90 Solventborne Automatic
For 76580-8XXXX, REA90 Waterborne Automatic
Ror 76580-4XXXX, REM Automatic
For REA9000 Automatic or Robot
For 78398-01, Single Bell, Domestic
For 78398-02, Single Bell, Export
For 76580-BXXXX, REA900 Automatic
* Air flow switch used on 76580-1XXXX, -6XXXX, and -7XXXX.
Pressure switches used on 76580-4XXX, -5XXXX, -8XXXX, and -9XXXX.
(Continued On Next Page)
CP-97-04.3
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38
9040 Cascade Low Voltage Control Unit - Parts Identification
VOLT
9040 CASCADE LOW VOL
TAGE CONTROL UNIT ARTS
11)
PAR
TS LIST (Figure 1
1) (Cont.)
Item #
Part #
17
76612-01
76612-02
76612-03
76612-04
18
19
20
39
76613-11
76613-21
76613-12
76613-22
LTST5000
77653-00
Description
Totalizer Fluid Monitoring Module
(all parts required to add Totalizer system to existing 9040 Rack):
Intrinsically Safe U.S. Version
(120VAC input with totals in gallons)
Intrinsically Safe Export Version
(240VAC input with totals in liters)
Fiber Optic U.S. Version
(120VAC input with totals in gallons)
Fiber Optic Export Version
(240VAC input with totals in liters)
Pneumatics Module:
Single Applicator Version
Dual Applicator Version
Single Automatic Applicator Version
Dual Automatic Applicator Version
Control Unit Test Assembly
Pressure Switch, 78398-0X Only
ARCHIVE
Notation
3PS
CP-97-04.3
9040 Cascade Low Voltage Control Unit - Parts Identification
Recommended Spare Parts for 9040 Cascade Control Unit for
REA70, REA90, and REM Applicators
(Models 76580-1XXXX, -2XXXX, -6XXXX, -7XXXX)
Description
Part Number
No. of
Applicators
Notes
1-2 3-4 5-6 7-8
PC Board Assembly,
REA Applicator
PC Board Assembly,
REM Applicator
PC Board Assembly,
REA90 Applicator
PC Board Assembly,
REA90 Applicator
Fuse, PC Board
Fuse, Front Panel
Tester
76893-01
1
1
1
2
For 76580-1XXXX
76892-02
1
1
1
2
For 76580-2XXXX
76892-06
1
1
1
2
Waterborne, for 76580-6XXXX
76892-07
LSME0082-04
72771-06
LTST5000-00
1
2
2
1
1
4
4
1
1
6
6
1
2
8
8
1
Solvent, for 76580-7XXXX
For testing control unit and cable.
Recommended Spare Parts for 9040 Cascade Control Unit for
REA70, REA90, REA9000, and REM Automatic Applicators
(Models 76580-3XXXX, -4XXXX, -8XXXX, -9XXXX)
Description
Part Number
No. of
Applicators
Notes
1-2 3-4 5-6 7-8
PC Board Assembly,
REA70 Automatic
PC Board Assembly,
REM Automatic
PC Board Assembly,
REA9000 Automatic
PC Board Assembly,
REA90A Solventborne
PC Board Assembly,
REA90A
PC Board Assembly,
Triple Setpoint
PC Board Assembly,
Analog Input
PC Board Assembly,
Analog Input
PC Board Assembly,
Analog Input
Fuse, PC Board
Fuse, Front Panel
Tester
CP-97-04.3
76892-03
1
1
1
2
For 76580-3XXXX
76892-04
1
1
1
2
For 76580-4XXXX
76892-05
1
1
1
2
For 76580-5XXXX
76892-08
1
1
1
2
For 76580-8XXXX
76892-09
1
1
1
2
Solvent, for 76580-9XXXX
76031-15
1
1
1
2
For 76580-8XXXX
76031-16
1
1
1
2
For 76580-9XXXX
76031-17
1
1
1
2
For 76580-4XXXX
76031-18
LSME0082-04
72771-06
LTST5000-00
1
2
2
1
1
4
4
1
1
6
6
1
2
8
8
1
For 76580-5XXXX
ARCHIVE
For testing control unit and cable.
40
9040 Cascade Low Voltage Control Unit - Warranty Policies
WARRANTY POLICIES
LIMITED W
ARRANTY
WARRANTY
ITW 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 accordance with ITW 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 ITW RANSBURG
APPROVED PARTS, VOID ALL WARRANTIES.
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 IN PLASTIC, ASSOCIATED VALVES AND TUBING, AND SUPPORTING HARDWARE IN
PLASTIC, SHRINK-WRAP, OR ANY
OTHER NON-APPROVED COVERING,
WILL VOIDE THIS WARRANTY.
41
ITW RANSBURG'S ONLY OBLIGATION
UNDER THIS WARRANTY IS TO REPLACE
PARTS THAT HAVE FAILED BECAUSE
OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
ITW RANSBURG ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FOR
CONSEQUENTIAL DAMAGES FOR LOSS
OF GOODWILL OR PRODUCTION OR
INCOME, WHICH RESULT FROM USE OR
MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS.
EXCLUSIONS:
If, in ITW Ransburg's opinion the warranty item in
question, or other items damaged by this part was
improperly installed, operated or maintained, ITW
Ransburg will assume no responsibility for repair
or replacement of the item or items. The purchaser, therefore will assume all responsibility for
any cost of repair or replacement and service
related costs if applicable.
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CP-97-04.3
MANUAL CHANGE SUMMAR
Y
SUMMARY
This manual was published to replace Service
Manual CP-97-04.2 to make the following
changes:
1. Added “
“ to the “Front Cover”.
2. Added “Atex” section and “Labels 42562 and
79318” to the “Atex” section.
CP-97-04.3
ARCHIVE
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
Industrial Systems
Ransburg Guns
www.itwransburg.com
Telephone: 800/ 626-3565 Fax: 419/ 470-2040
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
A
R
C
H
IV
E
Technical Support Representative will direct you to the appropriate telephone
number for ordering Spare Parts.
© 2008 Illinois Tool Works Inc. All rights reserved.
Models and specifications subject to change without notice.
Form No. CO-97-04.3
Litho in U.S.A.
05/08
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