(Serv. Man. CP-08-01) (CP0801sm)

(Serv. Man. CP-08-01) (CP0801sm)
SERVICE MANUAL
CP-08-01
November - 2008
A
R
C
H
IV
E
9040 CLASSIC HIGH VOL
TAGE POWER SUPPL
Y
VOLT
SUPPLY
MODEL: 77070-33
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.)
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CP-08-01
9040 Classic HV Power Supply - Contents
CONTENTS
PAGE
SAFETY:
1-6
SAFETY PRECAUTIONS........................................................................................................... 1
HAZARDS / SAFEGUARDS....................................................................................................... 2-5
INTRODUCTION:
7-8
GENERAL DESCRIPTION......................................................................................................... 7
SPECIFICATIONS...................................................................................................................... 7
9040 CLASSIC HIGH VOLTAGE POWER SUPPLY FEATURES........................................... 8
INSTALLATION:
9-12
LOCATION.................................................................................................................................. 9
INPUT VOLTAGE SELECTION................................................................................................. 9
INPUT CONNECTIONS............................................................................................................. 10
EXTERNAL CONNECTIONS..................................................................................................... 10-12
OPERATION:
13-16
OPERATING CONTROLS......................................................................................................... 13
THEORY OF OPERATION........................................................................................................ 14
OPERATING PROCEDURES.................................................................................................... 14-15
MAINTENANCE:
17-30
ROUTINE PREVENTIVE MAINTENANCE................................................................................ 17
TROUBLESHOOTING................................................................................................................ 17-20
SERVICE LEVEL......................................................................................................................... 21
REPLACEMENT PROCEDURES.............................................................................................. 21-25
TROUBLESHOOTING GUIDE................................................................................................... 26-27
TROUBLESHOOTING ............................................................................................................... 28
77070-33 CLASSIC HIGH VOLTAGE POWER SUPPLY BLOCK DIAGRAM......................... 29
PARTS IDENTIFICATION:
31-34
9040 CLASSIC HIGH VOLTAGE POWER SUPPLY
PARTS DIAGRAM / PARTS LIST................................. ........................................................... 31-32
RECOMMENDED SPARE PARTS............................................................................................ 33
ACCESSORIES.......................................................................................................................... 33
WARRANTY POLICIES:
35
LIMITED WARRANTY.................................................................................................................35
CP-08-01
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9040 Classic HV Power Supply - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
ITW Ransburg 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 WARNING! states information to alert you
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.
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-08-01
9040 Classic HV Power Supply - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Spray Area
Fire Hazard
The 76447 power supply MUST be installed in a
NON-hazardous location in accordance with NFPAImproper or inadequate operation 33.
and maintenance procedures will
Fire extinguishing equipment must be present in the
cause a fire hazard.
spray area and tested periodically.
Protection against inadvertent
arcing that is capable of causing Spray areas must be kept clean to prevent the
fire or explosion is lost if any safety accumulation of combustible residues.
interlocks are disabled during
operation. Frequent power supply Smoking must never be allowed in the spray area.
shutdown indicates a problem in
the system requiring correction. The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing, or maintenance.
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 setup 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-08-01
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2
9040 Classic HV Power Supply - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
Electrostatic Arcing
Ensure the ground wire assembly is connected from the
power supply ground stud to a true earth ground.
may occur.
Spray Area
Ensure that the power supply is plugged into a properly
grounded outlet.
If shocks or sparks are noticed at any point in the spray
system, immediately turn off the power supply and check
the complete system for the cause. DO NOT use the
system again until the problem has been identified and
corrected.
Never operate the applicator without properly grounding the
following:
A. Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
leg straps may be used.
Operators must maintain contact with the handle of
the applicator. If work gloves are used, the palm
section should be cut out.
Operators must remove from themselves all metal
objects that are not grounded.
B. Parts being sprayed. Resistance between the part and
a grounded conveyor must not exceed 1 megohm.
C. Every metal and conductive object in the spray
area. This includes the booth, parts hangers, fire
extinguishers, conductive flooring, etc.
Grounded conductive flooring must be provided in the
spray area.
Turn off voltage at the power supply before flushing out,
cleaning, or removing any parts from the applicator.
Provide proper protection for waterborne supply systems.
Never install an applicator into a fluid system using an
isolated solvent supply.
Always discharge waterborne system capacitance prior to
servicing.
Do not touch applicator electrode while applicator is
energized.
3
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CP-08-01
9040 Classic HV Power Supply - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
General Use and Improper operation or maintenance Personnel must be given training in accordance with
may create a hazard.
the requirements of NFPA-33.
Maintenance
Personnel must be properly trained Instructions and safety precautions must be read
in the use of this equipment.
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping.
Always turn power to the power supply OFF, unplug
the electrical cord from its outlet, and remove the
front panel fuse, before opening the power supply
door. If necessary, lock the power supply out so that
it cannot be turned ON until the work is finished.
Whenever removing high voltage cables from
equipment, ground the contact end of the cable by
holding the cable such that the contact touches
earth ground for several seconds. Do not touch the
contact until it has been grounded. This will reduce
the possibility of residual charge causing electrical
shock.
The high voltage multiplier assembly contains energy
storage components that can cause serious shock
injury, and therefore is not field repairable. Warranty
will be voided if the high voltage multiplier seal is
broken. If the high voltage multiplier is defective
contact your authorized ITW Ransburg representative
for exchange or repair.
The high voltage multiplier and high voltage cable
contain significant capacitance that will store charge.
Allow approximately 10 seconds for this charge to
bleed off before opening the cabinet door or removing
the high voltage cable from the power supply or
spray applicator.
Explosion Hazard/ Halogenated hydrocarbon solvents Aluminum is widely used in other spray application
for example: methylene chloride equipment - such as material pumps, regulators,
Incompatible
and 1,1,1,-Trichloroethane are not triggering valves, etc. Halogenated hydrocarbon
Materials
chemically compatible with the
aluminum that might be used in
many system components. The
chemical reaction caused by these
solvents reacting with aluminum
can become violent and lead to an
equipment explosion.
CP-08-01
solvents must never be used with aluminum
equipment during spraying, flushing, or cleaning.
Read the label or data sheet for the material you
intend to spray. If in doubt as to whether or not a
coating or cleaning material is compatible, contact
your material supplier. Any other type of solvent
may be used with aluminum equipment.
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4
9040 Classic HV Power Supply - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Toxic Substances Certain material may be harmful if Follow the requirements of the Material Safety Data
inhaled, or if there is contact with Sheet supplied by coating material manufacturer.
the skin.
Adequate exhaust must be provided to keep the air
free of accumulations of toxic materials.
Use a mask or respirator whenever there is a chance
of inhaling sprayed materials. The mask must be
compatible with the material being sprayed and its
concentration. Equipment must be as prescribed by
an industrial hygienist or safety expert, and be NIOSH
approved.
Personnel Safety Skin puncturing by sharp
Take precautions to see that flesh is not punctured by
sharp electrode.
Personnel Safety Fluid Injection Injury
(High Pressure
Equipment)
Never let any part of the body come in direct contact
with the fluid stream exiting from the nozzle. If fluid
leaks occur in the applicator or in the fluid delivery
components, depressurize fluid system before
servicing.
electrode.
Never aim the applicator at any part of the body under
any circumstances.
If you are injured by high pressure fluid injection then
immediate medical treatment MUST be sought.
5
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CP-08-01
9040 Classic HV Power Supply - Safety
NOTES
CP-08-01
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6
9040 Classic HV Power Supply - Introduction
INTRODUCTION
GENERAL DESCRIPTION
SPECIFICA
TIONS
SPECIFICATIONS
The 9040 Classic High V
oltage
Voltage
Power Supply
Physical
The 9040 Classic High Voltage Power Supply
converts standard AC line voltage to a high
frequency, low voltage signal ranging from 0 to 10
Vrms. This signal is supplied to the high voltage
multiplier where it is converted to DC high voltage.
The high voltage DC is then transferred from the
9040 Classic High Voltage Power Supply to the
applicator through 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, infinite high voltage adjustment, a high voltage
meter, a current meter, a POWER ON indicator, a
HIGH VOLTAGE ON indicator, and a CURRENT
OVERLOAD indicator and reset switch. Additionally, output terminals are provided for remote
overload reset and interlock connections for a
conveyor, exhaust fan and high voltage control on
all 9040 Classic High Voltage Power Supplies.
Height:
156mm (6 1/8-Inches )
Width:
394mm (15 1/2-Inches)
Depth:
292mm (11 1/2-Inches)
Weight:
10.8 Kg (24-Lbs.)
Electrical
INPUT
Voltage:
90-264 VAC
Current:
0.6/0.3 Amps AC
Frequency:
50/60 Hertz
Wattage:
60 Watts (maximum)
OUTPUT
Voltage:
100kV DC (77070-33)
Current:
170 Microamps (maximum)
2.71 bar (25 psi) minimum
Pneumatic
Supply Air:
7
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6.9 bar (100 psi) maximum
CP-08-01
9040 Classic HV Power Supply - Introduction
Figure 1: 9040 Classic High Voltage Power Supply Features
VOLT
SUPPLY
FEATURES
9040 CLASSIC HIGH VOL
TAGE POWER SUPPL
Y FEA
TURES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
CP-08-01
Kilovolt Meter
Microamp Meter
High Voltage On Indicator
Overload Indicator / Overload Reset
On / Off Switch
Fuse Holder
Fuse Holder
High Voltage Adjust Knob
External Wiring Grommet
Pressure Switch Connection
Pressure Switch Connection
High Voltage Cable Connection
AC Line Cord
Ground Connection
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8
9040 Classic HV Power Supply - Installation
INST
ALLA
TION
INSTALLA
ALLATION
! WARNING
!
> The 9040 Classic High Voltage Power
Supply MUST be located outside the
hazardous area. (See local or national
installation codes and ITW Ransburg
Bulletin - "Operating Your Electrostatic
Coating System Safely").
The user MUST read and be familiar
with the "SAFETY" section of this manual.
>
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 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 any local country codes prior to
installing, operating, and/or servicing this
equipment.
CAUTION
> DO NOT locate the power supply
near or adjacent to heat producing equipment such as ovens, high wattage lamps,
etc.
INPUT VOL
TAGE
VOLT
SELECTION
>
NOTE
> As each installation is unique, this information is intended to provide general installation information for the 9040 Classic High
Voltage Power Supply. Consult your authorized ITW Ransburg distributor for specific
directions pertaining to the installation of
your equipment.
The 9040 Classic High Voltage Power Supply
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 from 230 to 115 VAC.
NOTE
> 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 High Voltage Power Supplies.
LOCA
TION
LOCATION
Install the 9040 Classic High Voltage Power
Supply 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 120oF
(49°C), but as close to the applicator as possible
to minimize the length of high voltage cable.
9
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CP-08-01
9040 Classic HV Power Supply - Installation
INPUT CONNECTIONS
Plug the AC line cord into a properly grounded
AC outlet.
Safety Ground
Crimp the appropriate connector onto the ground
wire assembly and install from the power supply
ground stud, located on the side panel, to a true
earth ground.
! WARNING
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 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.
EXTERNAL
CONNECTIONS
NOTE
> When connecting external wires to the
9040 Classic High Voltage Power Supply,
route the wiring through the external wiring grommet located on the side panel.
High V
oltage (High V
oltage)
Voltage
Voltage)
Cable Connection
Remove the plastic protective plug from the high
voltage cable connector and apply enough LSCH0009 dielectric lubricant onto the high voltage
cable to cover the electrical contact point.
NOTE
The ground wire assembly MUST be
connected from the power supply ground
stud to a true earth ground.
>
Interlocks
! WARNING
> ALWAYS ensure that high voltage is
OFF before flushing the spray gun with
solvent. NEVER flush the spray applicator
with high voltage ON
ON, as this is a severe fire
hazard and risk to personnel safety. It is
recommended that the high voltage control
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.
The AC power line must be series interlocked with
both the exhaust fan and conveyor. To interlock
the 9040 Classic High Voltage Power Supply with
the exhaust fan and conveyor, perform the
following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged, and the ON/OFF
switch is in the OFF position.
2. Open the power supply cabinet door.
> Applying LSCH-0009 dielectric lubricant on the high voltage cable contact significantly reduces corona discharge that
can cause deterioration of the high voltage connection components.
CP-08-01
! WARNING
> ALWAYS double check that the power
supply is unplugged from its AC outlet
before working with any internal wiring.
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10
9040 Classic HV Power Supply - Installation
3. Using a small blade screwdriver, remove the
factory installed test jumper from 1TB-L1to 1TBL2.
4. Route exhaust fan and conveyor interlock
(supplied by user) wiring through the external
wiring grommet on the side of the power supply
and connect to 1TB-L1 and 1TB-L2 as shown in
Figure 2. The interlock contacts should be
rated for at least 1 Amp at 240 volts AC.
5. Secure the cabinet door, replace the fuse and
plug the power supply in.
External High V
oltage Control
Voltage
If a method of high voltage triggering, other than
the factory supplied method, is required, the 9040
Classic High Voltage Power Supply allows for
external high voltage control from a PLC, pressure
switch or other user supplied device. To turn the
high voltage on, the user supplied device must
create a contact closure between terminals 6 and
7 of terminal block one (1TB). To connect the user
supplied, external high voltage control device,
perform the following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged, and the ON/OFF
switch is in the OFF position.
2. Open the power supply cabinet door.
3. Route the contact wires of the control device
through the external wiring grommet and connect
to the existing wiring for 1TB-6 and 1TB-7. The
control device contacts must be rated for at
least 100 millamps at 15 volts DC.
Figure 2: Terminal Block One (1TB)
4. Secure the cabinet door, replace the fuse, and
plug in the power supply.
External Overload Reset
External Relay Contacts
A set of external relay contacts for high voltage
(K1) and overload (K2) conditions is provided at
6PL-5, -6 & -7. See Figure 10 for exact wiring
locations. These relay contacts are sometimes
useful in configuring the control of the applicator
system.
Pneumatic Connections
(76447-13x)
Connect an atomization air pressure signal to one
pressure switch port and a trigger air pressure
signal to the other. When pressure signals (25 psi
minimum, 100 psi maximum) are applied to both
switches their contacts close, thereby activating
high voltage at the applicator. Both pressure
switches must be activated to receive high voltage.
11
The 9040 Classic High Voltage Power Supply
allows for use of an external (normally closed)
overload reset button. This is convenient when
the power supply is mounted in a hard to reach or
inconvenient location or when it is desired to
control overload reset of several power supplies
from a single location.
To utilize the external overload reset perform the
following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged and the ON/OFF switch
is in the OFF position.
2. Open the power supply cabinet door.
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CP-08-01
9040 Classic HV Power Supply - Installation
3. Remove the factory installed jumper from 1TB5 to 1TB-6 and replace with contact wires of the
external reset device. 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.
NOTES
4. Secure the cabinet door, replace the fuse, and
plug in the power supply.
CP-08-01
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12
9040 Classic HV Power Supply - Operation
OPERA
TION
OPERATION
Figure 3: Operating Controls
! WARNING
The user MUST read and be familiar
with the Safety Precautions and
"Safety" Section in this manual and the
ITW Ransburg safety literature therein
identified BEFORE OPERATING the
9040 Classic High Voltage Power Supply.
>
13
9040 CLASSIC HIGH VOLTAGE
OPERATING CONTROLS
1
2
3
4
5
6
7
8
Kilovolt Meter
Microamp Meter
High Voltage On Indicator
Overload Indicator / Overload Reset
On / Off Switch
Fuse Holder
Fuse Holder
High Voltage Adjust Knob
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CP-08-01
9040 Classic HV Power Supply - Operation
THEOR
Y OF OPERA
TION
THEORY
OPERATION
Line voltage (90-264 VAC) is applied to input
terminals 8PL-1 and 8PL-2 of power supply 1SUP
through the user supplied exhaust fan and
conveyor interlocks, fuse 1FU and ON/OFF switch
1SW.
OPERA
TING
OPERATING
PROCEDURES
1. Ensure that the AC power, pneumatics and
high voltage cables are connected as described in
the "Installation" section of this manual.
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 to the high voltage multiplier circuit. The
high voltage multiplier circuit rectifies the AC voltage
to DC and steps it up to provide rated kV to the
spray applicator via the high voltage cable. The
high voltage adjust knob controls the level of
output voltage from the oscillator to the high voltage
multiplier. In this manner, complete adjustability
from 0 to maximum kV of the spray applicator is
achieved.
2. Be sure that the high voltage adjustment knob
is turned FULLY counter-clockwise.
The DC input to the oscillator is interlocked with
1TB terminals 6 and 7, such that the oscillator
will not function unless terminals 6 and 7 are
connected together. In this manner, high voltage
to the spray applicator is controlled as follows:
5. Turn the voltage adjustment knob to the desired
operating point as indicated by the kilovolt and
microamp meters.
1. When pressure signals are supplied to the
pressure switches, the switch contacts close
connecting 1TB-6 and 7 together, thereby providing
voltage to the applicator.
2. Contact closure of a programmable controller
output, robot output, or some other user supplied
device connected to terminals 1TB-6 and 7 will
activate high voltage at the spray applicator.
! WARNING
> Check that the power supply is properly
grounded!
3. Turn the ON/OFF switch to the ON position.
The green LED will light indicating that AC power
is being supplied to the power supply.
4. The voltage to the automatic applicator is
activated by supplying adequate pressure signals
to the power supply pressure switches.
Kilovolt and Microamp Meters
The kilovolt meter indicates the voltage in thousands
of volts (kV) present at the spray applicator. The
microamp meter indicates the current in millionths
of amps (μA) leaving the applicator.
High V
oltage Adjustment Knob
Voltage
The high voltage adjustment knob allows infinite
control of the spray applicator electrode voltage
between 0 and rated kV.
3. For testing and troubleshooting, board jumper
JP4 connects 1TB-6 and 7 together, thereby
providing high voltage output (see "PC Board Test
Jumper" in the "Maintenance" section of this
manual).
CP-08-01
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14
9040 Classic HV Power Supply - Operation
NOTE
> Power supplies for applicators shipped
Figure 4:
Component Terminology
from the factory with the overload circuit
ON. Automatic applicators 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 can 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 spray applicator to operate at less than
optimum performance.
Overload Indicator/Reset Button
Lighting of the yellow overload/reset lamp indicates
that an overload condition has occurred. The
overload circuitry is integral to the power supply
and is factory calibrated and sealed. It allows
normal operation, testing, and maintenance. It will
only activate if the spray applicator current exceeds
the preset 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 5, in the "Maintenance" section for location
of JP5). To turn the overload circuit OFF, position
jumper JP5 so that it covers (shorts) pins 1 and 2.
To turn the overload circuit ON, position jumper
JP5 so that it covers (shorts) pins 2 and 3.
High V
oltage Safety Circuit
Voltage
The 9040 Printed Circuit Board (PCB) contains a
safety circuit that prevents high 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 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 repeated overloads occur,
every time the overload reset button is pushed,
open the cabinet door and see if the red LED (see
Figure 5, in the "Maintenance" section for
LED1location) on the PC board lights for about 2
seconds after pushing the reset button. If it does,
the PC board has failed and should be replaced.
High V
oltage ON Indicator
Voltage
The red high voltage on LED will light when high
voltage is present at the spray applicator.
AC Power ON Indicator
The green AC power ON LED will light when the
AC Power ON/OFF switch is in the ON position.
15
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CP-08-01
9040 Classic HV Power Supply - Maintenance
NOTES
CP-08-01
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16
9040 Classic HV Power Supply - Maintenance
MAINTENANCE
ROUTINE PREVENTIVE
MAINTENANCE
TROUBLESHOOTING
PC Board T
est Jumper
Test
In general, little maintenance is necessary to
ensure proper operation. However, it is important
to keep the interior of the unit clean and free from
moisture or foreign material. For this reason the
following must be done:
1. Keep the exterior of the unit free from dust
accumulation.
2. Always clean the exterior prior to opening the
cabinet door.
3. Open the cabinet door only to perform
maintenance or repair.
4. If the power supply end of the high voltage
cable becomes dirty, clean the end of the cable
with a suitable, clean, non-polar solvent and apply
a light coat of dielectric grease. On a yearly basis,
check to ensure that the LSCH-0009 dielectric
lubricant is covering the electrical contact point in
the high voltage tube. If not, add oil as needed.
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 spray
applicator or user supplied control device. Just
remember to reposition the jumper after testing, so
that it covers only one terminal or the high voltage
will stay on all the time. (See Figure 5 for location
of test jumper JP4.)
CAUTION
!
> If JP4 is left covering (shorting) both
terminals, high voltage will be on whenever
AC power is turned on. This could be
hazardous in some applications.
NOTE
> Applying LSCH-0009 dielectric lubricant to the high voltage cable end significantly reduces corona discharge that can
cause deterioration of the high voltage
connection components.
Figure 5: Main PC Board
17
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CP-08-01
9040 Classic HV Power Supply - Maintenance
kV Output Test Procedure
Ground T
est Procedure
Test
1. Turn AC power to the power supply OFF
OFF.
Equipment Required:
- Ohmmeter (to measure resistance)
If shocks or sparks are noticed at any point in the
spray system, immediately turn off the power
supply and check the complete system for proper
grounding. Proper grounding of the spray applicator
system can be verified as follows:
1. Ensure that the clamp of the 14 AWG 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
power supply ground stud. If the ohmmeter reads
greater than 25 ohms, replace the 14 AWG ground
wire assembly.
3. Connect one end of the ohmmeter to the power
supply ground stud and the other to the metal
applicator body (automatics) or handle bracket
(applicators). If the ohmmeter reads greater than
25 ohms, repair or replace the high voltage cable.
NOTE
> On applicators, ground is passed from
the high voltage cable to the handle by
way of the handle set screw. Ensure the
set screw is completely tightened and repeat step 3 before replacing the high voltage cable on applicator units.
2. Remove the high voltage cable from the power
supply.
! WARNING
> Whenever removing high voltage cables
from equipment, ground the plug end of the
cable(s) by contacting the plug to electrical
ground. DO NOT touch the plug until it has
been grounded. This will eliminate the
possibility of residual charge causing electrical shock.
3. Turn the high voltage adjust knob FULLY
counter-clockwise.
4. Open the cabinet door and position jumper JP4
on the main PC Board so that it covers (shorts)
both terminals.
5. Attach the appropriate high voltage cable to the
20791 Test Probe, properly ground the probe to a
true earth ground, and turn the test probe meter on
(see the Operation Manual for the 20791 High
Voltage Test Probe and Meter).
6. Insert the test probe high voltage cable into the
power supply high voltage tube until it bottoms out.
NOTE
> Ensure that the test probe high voltage cable makes good contact both inside
the test probe and inside the power supply high voltage tube.
kV Output T
est
Test
When a lack of high voltage at the spray applicator
indicates a problem, perform a kV Output Test of
the power supply to determine whether it is at fault.
7. Turn the power supply ON.
Equipment Required:
- Calibrated ITW Ransburg 20791 High Voltage
Test Probe and Meter
CP-08-01
ARCHIVE
18
9040 Classic HV Power Supply - Maintenance
8. Turn the high voltage adjust knob FULLY
clockwise and read the output voltage displayed
on the meter, then turn the power supply OFF. If
the voltage read correctly (see "Specifications" in
the "Introduction" section of this manual), the
problem is not in the power supply and the high
voltage cable and spray applicator should be
checked for the cause. If the voltage did not read
correctly, the problem is with the power supply.
Consult the "Troubleshooting Guide" in the
"Maintenance" section to locate the specific
problem.
9. Disconnect the 20791 Test Probe and Meter
and reposition JP4 so that it covers only one
terminal. When ready to resume spray operations,
reconnect the spray applicator high voltage cable
and turn the power supply on.
Current Output (SCI) T
est
Test
When a lack of high voltage at the applicator
indicates a problem a Current Output (SCI) Test
may be performed, in addition to the kV output test,
to help determine if the power supply is at fault.
Equipment Required:
- Test Resistor (16688-01)
- Current Meter (76652-02)
1. Turn AC power to the power supply OFF
OFF.
2. Remove the high voltage cable from the power
supply.
! WARNING
4. Connect one end of the test resistor (1668801) through the current meter (76652-02) to ground
as shown in Figure 5. Insert the other end of the
test resistor into the high voltage output tube of the
power supply.
!
CAUTION
> Ensure the Current Meter (76652-02) is
set to the μA scale.
5. Open the cabinet door and position jumper JP4
on the main PC board so that it covers (shorts)
both terminals.
6. Turn the AC power to the power supply ON.
7. SLOWLY adjust the kV adjust knob fully
clockwise. The external Current Meter (7665202) should read within the ranges noted in Figure
4. If it reads correctly, the problem is not in the
power supply and the high voltage cable and
spray applicator should be checked for the cause.
If the reading is not within the specified range refer
to "Bench Testing" in the "Maintenance" section of
this manual. If the external current meter reads
correctly, but the meter on the power supply does
not, replace the power supply meter.
8. Turn the power supply OFF. Disconnect the
Current Meter (76652-02) and remove the Test
Resistor (16688-01). Reposition JP4 so that it
covers only one terminal. When ready to resume
spray operations, reconnect the high voltage cable
and turn the power supply ON.
> Whenever removing high voltage cables
from equipment, ground the plug end of the
cable(s) by contacting the plug to electrical
ground. DO NOT touch the plug until it has
been grounded. This will eliminate the
possibility of residual charge causing electrical shock.
POWER SUPPLIES AND
SCI VALUES
Power Supply
SCI Range
(in μA)
77070-33
120 - 170 μA
3. Turn the high voltage adjust knob FULLY
counter-clockwise.
19
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CP-08-01
9040 Classic HV Power Supply - Maintenance
Before troubleshooting, ensure that the power
supply is plugged into a live outlet of the appropriate
voltage. All electrical measurements in the
"Troubleshooting Guide" are nominal and may
vary as much as +/- 10% depending on the test
conditions and the test equipment used. Refer to
Figures 6 and 9 for location of parts called out in the
"Troubleshooting Guide" in this section.
Figure 6: Current Output Test
For bench testing, jumper JP4 should be used to
trigger the high voltage output (see "PC Board
Test Jumper" discussed at the beginning of the
"Maintenance" section).
!
Bench T
esting
Testing
CAUTION
> The high voltage multiplier and high
Equipment Required:
- Volt / Ohmmeter
The "Troubleshooting Guide" provides information
for troubleshooting the power supply when improper
operation is obtained and the problem has been
traced to the power supply. Proper troubleshooting
should ONLY be accomplished with specific test
equipment by qualified electronics technicians or
authorized ITW Ransburg representatives.
voltage cable contain significant capacitance that will store charge. ALLOW
approximately 10 seconds for this charge
to bleed off BEFORE opening the cabinet
door OR REMOVING the high voltage
cable from the power supply or spray
applicator.
NOTE
> Before going through the trouble of a
! WARNING
> The troubleshooting procedure outlined
in the "Troubleshooting Guide" 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.
CP-08-01
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 power supply connected to the trigger device, and test
again. If the problem does not go away,
then proceed with a bench test.
ARCHIVE
20
9040 Classic HV Power Supply - Maintenance
3. Remove fuse from fuse holder and replace with
new fuse (see "Parts Identification" in this manual
for part numbers).
SERVICE LEVEL
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.)
4. Insert fuse holder back into front panel and with
a slight inward pressure, rotate screwdriver
clockwise until it locks into place.
PC Board Fuse F2
(Refer to Figure 3 for Fuse Location)
! WARNING
ALWAYS turn power to the power
supply OFF
OFF, unplug the electrical cord from
its outlet, remove the front panel fuse, and
lock the power supply out before making
repairs or replacements.
>
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Replace defective fuse (see "Parts Identification" section of this manual for part numbers).
NOTE
!
CAUTION
> A spare F2 PC board fuse, included
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, is located in the lower
right hand corner inside the cabinet door.
3. Secure power supply cabinet door and plug
power supply back in.
ON/OFF Switch 1SW
REPLACEMENT
PROCEDURES
1. Ensure power supply is unplugged from AC
outlet and open the cabinet door.
Before making replacements, check for defective
wiring or connections between the affected
components. If there is a broken wire, defective
insulation, or dirty, loose, or corroded connections,
repair or replace them before going to the expense
of replacing a component.
Front Panel Fuse 1FU
1. Insert screwdriver into slot in front panel fuse
holder, push in, and rotate counter-clockwise.
! WARNING
ALWAYS double check that the control
unit is unplugged from its AC outlet BEFORE working with any internal wiring.
>
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.
21
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CP-08-01
9040 Classic HV Power Supply - Maintenance
3. Loosen the line cord grommet on side panel
and pull damaged cord out.
NOTE
> 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 for part number) 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:
4. Insert new line cord (see "Parts Identification"
section of this manual for part numbers) through
grommet and connect to 1TB as follows:
From
To
1TB-GROUND
1TB-N
1TB-L1
Line Cord Ground
Line Cord Neutral/Common
Line Cord Hot/Line
5. Tighten side panel grommet.
6. Secure cabinet door and plug power supply
back in.
Pressure Switch
From
To
1. Disconnect pressure signal input line from
pressure switch.
1FU-2
1TB-N
1TB-S1
1TB-S2
1SW-1
1SW-2
1SW-1A
1SW-2A
2. Ensure power supply is unplugged from AC
outlet and open cabinet door.
6. Secure cabinet door and plug power supply
back in.
AC Line Cord
1. Ensure power supply is unplugged from AC
outlet and open the cabinet door.
3. Remove two (2) wires from pressure switch
terminals.
4. Loosen hex nut from fitting and remove pressure
switch and fitting from the power supply.
5. Remove fitting from defective pressure switch
and install on new pressure switch (see "Parts
Identification" section of this manual for part
numbers).
6. Install new pressure switch in power supply by
securing hex nut to fitting.
! WARNING
> ALWAYS double check that the control
unit is unplugged from its AC outlet BEFORE working with any internal wiring.
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 of the
pressure switch.
2. Using a screwdriver, disconnect damaged line
cord from 1TB-L1, 1TB-N, and 1TB-GROUND.
CP-08-01
ARCHIVE
22
9040 Classic HV Power Supply - Maintenance
8. Secure cabinet door and plug power supply
back in.
9. Plug connector 1PL back into the high voltage
Multiplier.
9. Reconnect pressure signal input line to pressure
switch.
10. Secure the cabinet door and plug the power
supply back in.
High V
oltage Multiplier
Voltage
11. Reinstall the high voltage cable.
LED Display Board
NOTE
> Because the high voltage multiplier
contains energy storage components that
can cause serious shock injury, it is not
field repairable. Warranty will be voided if
the high voltage multiplier seal is broken.
If the high voltage multiplier is defective
contact your authorized ITW Ransburg
representative for exchange or repair.
1. Remove high voltage cable from power supply.
2. Ensure power supply is unplugged from AC
outlet and open cabinet door.
3. Unplug connector 1PL from the top of the high
voltage multiplier.
4. Remove the six (6) screws that mount the high
voltage multipliers’ aluminum housing to the back
panel.
5. Remove the high voltage multiplier assembly
from the power supply.
6. Remove the three (3) screws that secure the
aluminum housing to the high voltage multiplier.
7. Install the aluminum housing on the new high
voltage multiplier (see "Parts Identification" section
of this manual for part numbers and ordering
information). Ensure connector 1PL 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.
23
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Unplug display board connector from 9PL on
main PC Board.
3. Remove two (2) screws that mount display
board to inside of cabinet door and remove display
board from power supply.
4. Install new display board (see "Parts
Identification" section of this manual for part
numbers) in power supply.
5. Reconnect connector 9PL to main PC board.
6. Secure the cabinet door and plug the power
supply back in.
Kilovolt (kV) or
Microamp (μA) Meter
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Remove two (2) hex nuts from wiring terminals
and remove wire lugs.
3. Remove four (4) hex nuts that mount meter to
door.
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 + terminal of meter).
6. Secure cabinet door and plug power supply
back in.
ARCHIVE
CP-08-01
9040 Classic HV Power Supply - Maintenance
Main PC Board
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Disconnect plugs 6PL, 7PL, and 9PL (see
Figure 7).
3. Remove two (2) screws from heat sink base
and lift the PC Board out.
!
4. Remove the hex nut securing 1POT to the
cabinet door and remove 1POT.
5. Install the new potentiometer (see "Parts
Identification" section of this manual for part
numbers) in the cabinet door.
6. Using heat shrink tubing and appropriate solder
techniques, solder the three (3) wires to the new
potentiometer as follows:
CAUTION
From
To
7PL-1
7PL-4
7PL-5
1POT-1
1POT-2
1POT-3
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 this manual for part numbers) and
secure the two (2) heat sink screws.
7. Secure the cabinet door and plug the power
supply back in.
8. Reinstall adjust knob using 1/16" Allen wrench.
5. Reconnect plugs 6PL, 7PL, and 9PL.
Power Supply 1SUP
6. Secure cabinet door and plug power supply
back in.
1. Ensure 9040 Classic Power Supply is
unplugged from AC outlet and open the cabinet
door.
High V
oltage Adjust
Voltage
Potentiometer
2. Remove the four (4) screws from the 1SUP
power supply cover plate and remove the plate.
1. Remove knob from high voltage adjust
potentiometer by using a 1/16" Allen wrench to
remove the two (2) set screws.
2. Ensure power supply is unplugged from AC
outlet and open cabinet door.
3. Remove the heat shrink tubing and unsolder
the three (3) wires from high voltage adjust
potentiometer 1POT.
! WARNING
ALWAYS double check that the power
supply is unplugged from its AC outlet
BEFORE removing the cover plate from
power supply 1SUP.
>
3. Remove connectors 8PL and 10PL from power
supply 1SUP.
NOTE
> It is recommended that the three (3)
wires be tagged with their respective terminal connections to 1POT before
unsoldering.
CP-08-01
4. Remove the four (4) cover plate standoffs from
power supply 1SUP and remove the power supply
from the unit.
ARCHIVE
24
9040 Classic HV Power Supply - Maintenance
5. Install new 1SUP power supply (see "Parts
Identification" section of this manual for part
numbers) using the four (4) cover plate standoffs.
Ensure larger terminal strip (10PL) of power supply
1SUP faces left side of unit as shown in Figure 9.
NOTES
6. Connect connectors 8PL and 10PL to new
power supply and reinstall cover plate.
7. Secure cabinet door and plug power supply
back in.
25
ARCHIVE
CP-08-01
9040 Classic HV Power Supply - Maintenance
TROUBLESHOOTING GUIDE
General Problem Possible Cause
Solution
AC Power ON
1. Front panel fuse 1FU or PC board
Indicator (Green
fuse F2 defective
LED) Does Not
Light when ON/OFF 2. Connector 7PL or 9PL not properly
Switch is ON
plugged into main PC board
1. Replace defective fuse.
3. Improper input line voltage
4. Improper exhaust fan or conveyor
interlock connections
2. Properly attach connector.
3. Ensure voltage across terminals L1 and N of
terminal block 1TB is between 90 and 264
VAC.
4. Correct connection so that voltage across
terminals L2 and N of 1TB is between 90 and
264 VAC.
5. Defective ON/OFF switch 1SW
5. Voltage across terminals 1A and 2A of ON/
OFF switch 1SW should be between 90 and
264 VAC. If not, replace switch 1SW.
6. Defective power supply 1SUP
6. Voltage across terminals 2 and 3 of plug 7PL
on main PC board should be 18 VDC. If not,
replace power supply 1SUP.
7. Defective LED display board
7. If all other functions of power supply are
normal, replace LED display board.
No or Low kV
1. High voltage adjust knob not set to
Output at Spray
proper value
Applicator when HV
ON Indicator (Red
2. Connector 6PL or 1PL not properly
LED) is Lit
plugged into respective locations
1. Set high voltage adjust knob to proper value.
3. Defective spray applicator or high
voltage cable
3. Perform a kV output test on the power supply.
If proper readings are obtained, check cable or
spray applicator for cause (see spray applicator
service manual).
4. Loose or broken wire in power
supply
4. Check all wiring connections for integrity.
Repair wiring as needed.
5. Main PC board defective
5. Disconnect 1PL from high voltage multiplier
and plug into LTST5000 Tester. If improper
readings are obtained, replace main PC board.
6. Defective high voltage multiplier
6. Disconnect HV cable from power supply. If
problem is still present, connect LTST5000
Tester to 1PL and test. If results of test are
OK, replace high voltage multiplier.
2. Properly attach connector.
(Continued On Next Page)
CP-08-01
ARCHIVE
26
9040 Classic HV Power Supply - Maintenance
TROUBLESHOOTING GUIDE (Cont.)
General Problem Possible Cause
Solution
No kV Output at
Spray Applicator
and High Voltage
ON Indicator (Red
LED) is Not Lit
1. Connector 6PL not properly
plugged into PC board
1. Properly attach connector.
2. Improper air signal to high voltage
trigger device (air flow switch,
pressure switch, etc.)
2. Turn signal on and adjust to proper setting.
3. Defective high voltage trigger
device (flow switch, pressure
switch, etc.) or wiring
3. Short PC board jumper JP4. If high voltage
comes on, replace high voltage trigger device
or repair wiring from trigger device to PC board.
4. Main PC board defective
4. Replace main PC board.
1. Parts are too close to the spray
applicator
1. Ensure sufficient distance between spray
applicator and parts.
2. Overload set point set too sensitive
2. Adjust PC board potentiometer 1 turn counterclockwise to make less sensitive. Repeat if
necessary.
3. Disconnect high voltage cable from spray
applicator and test in open air, at least 1-foot
from surrounding objects. If overload goes
away, check spray applicator for cause.
(Warning: Contact end of cable will be at
high voltage; after testing, discharge
contact by contacting to ground before
touching!)
4. Test power supply with high voltage cable
removed. If overload goes away, replace the
high voltage cable.
5. Place PC board jumper JP5 over pins 1 and 2
(overload OFF) and test. If power supply
overloads, replace main PC board.
Power Supply
Overloads
Excessively
3. Defective spray applicator
4. Defective high voltage cable
5. Main PC board defective
Component Not
Working, but kV
Output OK
27
6. Defective high voltage multiplier
6. If 1 thru 5 above are OK, replace the high
voltage multiplier.
1. Wiring to/from component loose
or broken
1. Repair loose or broken wire.
2. Defective component
2. Replace component.
ARCHIVE
CP-08-01
9040 Classic HV Power Supply - Maintenance
Figure 7: Troubleshooting
CP-08-01
ARCHIVE
28
9040 Classic HV Power Supply - Maintenance
Figure 8: 77070-33 Classic High Voltage Power Supply Block Diagram
29
ARCHIVE
CP-08-01
9040 Classic HV Power Supply - Maintenance
NOTES
CP-08-01
ARCHIVE
30
9040 Classic HV Power Supply - Parts Identification
PAR
TS IDENTIFICA
TION
ARTS
IDENTIFICATION
Figure 9: 9040 Classic High Voltage Power Supply - Parts Diagram
31
ARCHIVE
CP-08-01
9040 Classic HV Power Supply - Parts Identification
VOLT
SUPPLY
9040 CLASSIC HIGH VOL
TAGE POWER SUPPL
Y ARTS
PAR
TS LIST (Figure 9)
Item #
Part #
1
77122-33
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CP-08-01
76304-04
LSME0087-00
LSME0081-00
70105-03
70556-03
76436-01
76436-02
25766-106
75337-05
LSME0082-04
76469-00
72771-06
72771-01
70539-00
LSME-0061-00
LSME0062-00
76441-00
76443-01
5627-00
LSME0060-00
LSME0062-00
76895-09
LSCH-0009
Description
PC Board and Heat Sink Assembly:
For 77070-33 Automatic Applicator
High Voltage Multiplier (Oil-Filled):
For 77070-33, 100kV
ON/OFF Switch and Cover
Bulb, 24V
Knob, High Voltage Adjust
High Voltage Adjust Potentiometer
Kilovolt (kV) Meter
Microamp (μA) Meter
Pressure Switch Assembly:
Pressure Switch
Power Supply, 18 VDC
Fuse, PC Board, Slow Blow, 4 Amp
Fuse, Front Panel:
Fuse Holder
Slow Blow, 1 Amp, 110-120 VAC Input
Slow Blow, 0.5 Amp, 220-240 VAC Input
Ground Wire Assembly
Overload Indicator and Reset Switch Assembly:
Overload Indicator
Bulb
Lens, Yellow
Bulb
Rubber Feet
High Voltage On Indicator
Bulb
Analog Input Board
Dielectric Lubricant (Not Shown)
ARCHIVE
Notation
1SW
1POT
1M
2M
1FS
1PS, 2PS
1SUP
F2
1FU, 2FU
1FU
1FU
32
9040 Classic HV Power Supply - Parts Identification
VOLT
SUPPLY
9040 CLASSIC HIGH VOL
TAGE POWER SUPPL
Y SPARE
PAR
ARTS
RECOMMENDED SP
ARE P
AR
TS
Description
Part #
Notes
Fuse, Front Panel
Deluxe Test Kit
72771-06
76652-04
1
1
1
1
2
1
2
1
Test Resistor
16688-01
1
1
1
1
Fuse, PC Board
PC Board Assembly
High Voltage Multiplier
Power Supply Tester
LSME0082-04
76892-33
76304-04
LTST5000-00
2
1
1
1
4
1
1
1
6
1
1
1
8
2
1
1
No. of Applicators
For Troubleshooting
Purposes Only
For Troubleshooting
Purposes Only
For Troubleshooting
Purposes Only
VOLT
SUPPLY
9040 CLASSIC HIGH VOL
TAGE POWER SUPPL
Y ACCESSORIES
33
Description
Part #
Control Unit/Power Supply Test Assembly
High Voltage Test Probe and Meter
Current/SCI Meter
Deluxe Meter Kit (Includes 76652-01, 76652-02, and Paint Meter)
Test Resistor
LTST5000-00
76652-01
76652-02
76652-04
16688-01
ARCHIVE
CP-08-01
9040 Classic HV Power Supply - Parts Identification
NOTES
CP-08-01
ARCHIVE
34
9040 Classic HV Power Supply - 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, ASSOCIATED VALVES AND TUBING, AND
SUPPORTING HARDWARE IN PLASTIC,
SHRINK-WRAP, OR ANY OTHER NONAPPROVED COVERING, WILL VOID THIS
WARRANTY.
35
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.
ARCHIVE
CP-08-01
CP-08-01
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
www.itwransburg.com
Technical/Service Assistance
E
Telephone: 800/ 626-3565 Fax: 419/ 470-2040
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
A
R
C
H
IV
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. CP-08-01
Litho in U.S.A.
11/08
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