9040 classic high voltttage power supplyyy · pdf filehow to prevent damage to equipment or...

SERVICE MANUALCP-97-03.6CP-97-03.6CP-97-03.6CP-97-03.6CP-97-03.6(Supercedes CP-97-03.5)

IMPORIMPORIMPORIMPORIMPORTTTTTANTANTANTANTANT: Before using this equipment,: Before using this equipment,: Before using this equipment,: Before using this equipment,: Before using this equipment,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,starting on page 1, and all instructions instarting on page 1, and all instructions instarting on page 1, and all instructions instarting on page 1, and all instructions instarting on page 1, and all instructions inthis manual. Keep this Service Manual forthis manual. Keep this Service Manual forthis manual. Keep this Service Manual forthis manual. Keep this Service Manual forthis manual. Keep this Service Manual forfuture reference.future reference.future reference.future reference.future reference.

9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOLTTTTTAGE POWER SUPPLAGE POWER SUPPLAGE POWER SUPPLAGE POWER SUPPLAGE POWER SUPPLYYYYYfor the No. 2 Processfor the No. 2 Processfor the No. 2 Processfor the No. 2 Processfor the No. 2 ProcessTMTMTMTMTM Handgun Handgun Handgun Handgun Handgun

Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)

MODELS:MODELS:MODELS:MODELS:MODELS:76657-1476657-1476657-1476657-1476657-14 NO.2 HANDGUN, ELECTRIC MOTOR, DOMESTIC VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, DOMESTIC VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, DOMESTIC VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, DOMESTIC VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, DOMESTIC VERSION76657-14276657-14276657-14276657-14276657-142 NO.2 HANDGUN, ELECTRIC MOTOR, EXPORT VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, EXPORT VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, EXPORT VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, EXPORT VERSIONNO.2 HANDGUN, ELECTRIC MOTOR, EXPORT VERSION

NOTE:NOTE:NOTE:NOTE:NOTE: This manual has been changed from revision CP-97-03.5CP-97-03.5CP-97-03.5CP-97-03.5CP-97-03.5 to revision CP-97-03.6 CP-97-03.6 CP-97-03.6 CP-97-03.6 CP-97-03.6.Reasons for this change are noted under “Manual Change Summary” inside theback cover of this manual.

CP-97-03.6

SAFETY:SAFETY:SAFETY:SAFETY:SAFETY:

SAFETY PRECAUTIONS.........................................................HAZARDS / SAFEGUARDS.....................................................

PAGEPAGEPAGEPAGEPAGE

INTRODUCTION:INTRODUCTION:INTRODUCTION:INTRODUCTION:INTRODUCTION:

CONTENTSCONTENTSCONTENTSCONTENTSCONTENTS

GENERAL DESCRIPTION.......................................................SPECIFICATIONS.....................................................................

OPERATION:OPERATION:OPERATION:OPERATION:OPERATION:

THEORY OF OPERATION.......................................................OPERATING PROCEDURES..................................................

MAINTENANCE:MAINTENANCE:MAINTENANCE:MAINTENANCE:MAINTENANCE:

ROUTINE PREVENTIVE MAINTENANCE..............................TROUBLESHOOTING..............................................................TROUBLESHOOTING GUIDE.................................................9040 CLASSIC NO.2 POWER SUPPLY BLOCK DIAGRAM..SERVICE LEVEL.......................................................................REPLACEMENT PROCEDURES............................................

1-51-51-51-51-5

6-76-76-76-76-7

11-1211-1211-1211-1211-12

13-2313-2313-2313-2313-23

12

67

1112

131317192020

9040 Classic for the No. 2 Process Handgun - Contents

PARTS IDENTIFICATION:PARTS IDENTIFICATION:PARTS IDENTIFICATION:PARTS IDENTIFICATION:PARTS IDENTIFICATION:

9040 CLASSIC NO.2 POWER SUPPLY / PARTS LIST..........RECOMMENDED SPARE PARTS LIST..................................ACCESSORY PARTS LIST......................................................

24-2724-2724-2724-2724-27

242626

WARRANTY POLICIES:WARRANTY POLICIES:WARRANTY POLICIES:WARRANTY POLICIES:WARRANTY POLICIES: 2828282828

LIMITED WARRANTY............................................................... 28

APPENDIX:APPENDIX:APPENDIX:APPENDIX:APPENDIX:

PAINT AND SOLVENT SPECIFICATIONS.............................VISCOSITY CONVERSION CHART........................................VOLUMETRIC CONTENT OF HOSE OR TUBE.....................KV OUTPUT TEST & GROUND TEST LOG...........................

29-3329-3329-3329-3329-33

29303233

INSTALLATION:INSTALLATION:INSTALLATION:INSTALLATION:INSTALLATION:

LOCATION.................................................................................INPUT VOLTAGE SELECTION................................................INPUT CONNECTIONS............................................................EXTERNAL CONNECTIONS...................................................

8-108-108-108-108-10

8899

CP-97-03.6

CP-97-03.6

SAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONS

Before operating, maintaining or servicing anyRansburg coating system, read and understandall of the technical and safety literature for yourRansburg products. This manual contains in-formation that is important for you to know andunderstand. This information relates to USERSAFETY and PREVENTING EQUIPMENTPROBLEMS. To help you recognize this infor-mation, we use the following symbols. Pleasepay particular attention to these sections.

A WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryif instructions are not followed.if instructions are not followed.if instructions are not followed.if instructions are not followed.if instructions are not followed.

A CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellshow to prevent damage to equipment orhow to prevent damage to equipment orhow to prevent damage to equipment orhow to prevent damage to equipment orhow to prevent damage to equipment orhow to avoid a situation that might causehow to avoid a situation that might causehow to avoid a situation that might causehow to avoid a situation that might causehow to avoid a situation that might causeminor injury.minor injury.minor injury.minor injury.minor injury.

A NOTE is information relevant to the proce-A NOTE is information relevant to the proce-A NOTE is information relevant to the proce-A NOTE is information relevant to the proce-A NOTE is information relevant to the proce-dure in progress.dure in progress.dure in progress.dure in progress.dure in progress.

While this manual lists standard specificationsand service procedures, some minor deviationsmay be found between this literature and yourequipment. Differences in local codes and plantrequirements, material delivery requirements,etc., make such variations inevitable. Comparethis manual with your system installation draw-ings and appropriate Ransburg equipmentmanuals to reconcile such differences.

Careful study and continued use of this manualwill provide a better understanding of the equip-ment and process, resulting in more efficient op-eration, longer trouble-free service and faster,easier troubleshooting. If you do not have themanuals and safety literature for your Ransburgsystem, contact your local Ransburg represen-tative or Ransburg.

SAFETYSAFETYSAFETYSAFETYSAFETY

9040 Classic for the No. 2 Process Handgun - Safety

The user MUSTMUSTMUSTMUSTMUST read and be familiarwith the Safety Section in this manual andthe Ransburg safety literature thereinidentified.

This manual MUSTMUSTMUSTMUSTMUST be read and thor-oughly understood by ALLALLALLALLALL personnel whooperate, clean or maintain this equipment!Special care should be taken to ensure thatthe WARNINGSWARNINGSWARNINGSWARNINGSWARNINGS and safety requirementsfor operating and servicing the equipmentare followed. The user should be aware ofand adhere to ALLALLALLALLALL local building and firecodes and ordinances as well as NFPA 33NFPA 33NFPA 33NFPA 33NFPA 33SAFETY STANDARD, 2000 EDITION,SAFETY STANDARD, 2000 EDITION,SAFETY STANDARD, 2000 EDITION,SAFETY STANDARD, 2000 EDITION,SAFETY STANDARD, 2000 EDITION,prior to installing, operating, and/or servic-ing this equipment.

The hazards shown on the followingpage may occur during the normal use ofthis equipment. Please read the hazardchart beginning on page 2.

W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G!!!!!


11111

CP-97-03.6

Explosion Hazard/Explosion Hazard/Explosion Hazard/Explosion Hazard/Explosion Hazard/IncompatibleIncompatibleIncompatibleIncompatibleIncompatibleMaterialsMaterialsMaterialsMaterialsMaterials

Halogenated hydrocarbon solventsfor example: methylene chlorideand 1,1,1,-Trichloroethane are notchemically compatible with thealuminum that might be used inmany system components. Thechemical reaction caused by thesesolvents reacting with aluminumcan become violent and lead to anequipment explosion.

Aluminum is widely used in other spray applicationequipment - such as material pumps, regulators,triggering valves, etc. Halogenated hydrocarbonsolvents must never be used with aluminum equipmentduring spraying, flushing, or cleaning. Read the labelor data sheet for the material you intend to spray. Ifin doubt as to whether or not a coating or cleaningmaterial is compatible, contact your material supplier.Any other type of solvent may be used with aluminumequipment.


AREAAREAAREAAREAAREA

Tells where

hazards may occur.

HAZARDHAZARDHAZARDHAZARDHAZARD

Tells what the hazard is.

SAFEGUARDSSAFEGUARDSSAFEGUARDSSAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Spray AreaSpray AreaSpray AreaSpray AreaSpray Area

22222

Fire Hazard

Improper or inadequate opera-tion and maintenance procedureswill cause a fire hazard.

Protection against inadvertentarcing that is capable of causingfire or explosion is lost if anysafety interlocks are disabledduring operation. Frequentpower supply shutdown indicatesa problem in the system requir-ing correction.

Fire extinguishing equipment must be present in thespray area and tested periodically.

Spray areas must be kept clean to prevent theaccumulation of combustible residues.

Smoking must never be allowed in the spray area.

The high voltage supplied to the atomizer must beturned off prior to cleaning, flushing or maintenance.

When using solvents for cleaning:

Those used for equipment flushing should have flashpoints equal to or higher than those of the coatingmaterial.

Those used for general cleaning must have flashpoints above 100oF (37.8oC).

Spray booth ventilation must be kept at the ratesrequired by NFPA 33, 2000 Edition, OSHA and localcodes. In addition, ventilation must be maintainedduring cleaning operations using flammable orcombustible solvents.

Electrostatic arcing must be prevented.

Test only in areas free of combustible material.

Testing may require high voltage to be on, but only asinstructed.

Non-factory replacement parts or unauthorizedequipment modifications may cause fire or injury.

The paint process and equipment should be set upand operated in accordance with NFPA 33, NEC, andOSHA requirements.

CP-97-03.6 33333



Tells where

hazards may occur.





Spray AreaSpray AreaSpray AreaSpray AreaSpray Area Electrostatic Arcing Never operate the spray gun without properlygrounding the following.

A. Operators:Operators must be grounded. Rubber soledinsulating shoes should not be worn. Groundingleg straps may be used.

Operators must maintain contact with thehandle of the gun. If work gloves are used, thepalm section should be cut out.

Operators must remove from themselves allmetal objects that are not grounded.

NOTE:NOTE:NOTE:NOTE:NOTE: REFER TO NFPA 33, CHAPTER 10, 2000EDITION REGARDING OPERATOR GROUNDING.

B. Parts being sprayed: Resistance between thepart and a grounded conveyor must not exceed1 megohm.

C. Every metal and conductive object in the sprayarea: This includes the booth, parts hangers,fire extinguishers, conductive flooring, etc.

D. Unless specifically approved for use inhazardous locations, the power supply andother electrical equipment must not be used inClass I, Division 1 or 2 locations.

Grounded conductive flooring must be provided inthe spray area.

Turn off voltage at the power supply before flushingout, cleaning, or removing any parts from the gun.

Never install a spray gun into a fluid system usingan isolated solvent supply.

Do not touch gun electrode while gun is energized.

Ensure the Ground Wire Assembly is connectedfrom the power supply ground stud to a true earthground.

Ensure that the power supply is plugged in to aproperly grounded outlet.

CP-97-03.6


44444


Tells where

hazards may occur.





Improper operation or mainte-nance may create a hazard.

Personnel must be properlytrained in the use of this equip-ment.

Personnel must be given training in accordancewith the requirements of NFPA 33, Chapter 16,2000 edition.

Instructions and safety precautions must be readand understood prior to using this equipment.

Comply with appropriate local, state, and nationalcodes governing ventilation, fire protection, opera-tion maintenance, and housekeeping. OSHA refer-ences are Sections 1910.94 and 1910.107. Alsorefer to NFPA 33, 2000 edition and your insurancecompany requirements.

Always turn power to the power supply OFF, un-plug the electrical cord from its outlet, and removethe front panel fuse, before opening the power sup-ply door. If necessary, lock the power supply outso that it cannot be turned ON until the work is fin-ished.

Whenever removing high voltage cables fromequipment, ground the contact end of the cable byholding the cable such that the contact touchesearth ground for several seconds. Do not touchthe contact until it has been grounded. This willreduce the possibility of residual charge causingelectrical shock.

The High Voltage Multiplier Assembly contains en-ergy storage components that can cause seriousshock injury, and therefore is not field repairable.Warranty will be voided if the High Voltage Multi-plier seal is broken. If the High Voltage Multiplieris defective contact your authorized Ransburg rep-resentative for exchange or repair.

The High Voltage Multiplier and high voltage cablecontain significant capacitance that will storecharge. Allow approximately 10 seconds for thischarge to bleed off before opening the cabinet dooror removing the high voltage cable from the powersupply or spray gun.

General Use andGeneral Use andGeneral Use andGeneral Use andGeneral Use andMaintenanceMaintenanceMaintenanceMaintenanceMaintenance

CP-97-03.6 55555


Toxic SubstancesToxic SubstancesToxic SubstancesToxic SubstancesToxic Substances Certain material may be harmfulif inhaled, or if there is contactwith the skin.

Follow the requirements of the Material Safety DataSheet supplied by coating material manufacturer.

Adequate exhaust must be provided to keep the airfree of accumulations of toxic materials.

Use a mask or respirator whenever there is achance of inhaling sprayed materials. The maskmust be compatible with the material being sprayedand its concentration. Equipment must be as pre-scribed by an industrial hygienist or safety expert,and be NIOSH approved.


Tells where

hazards may occur.





CP-97-03.6

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

9040 Classic for the No. 2 Process Handgun - Introduction

66666

GENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTION

The RansburgThe RansburgThe RansburgThe RansburgThe RansburgNo. 2 Handgun ProcessNo. 2 Handgun ProcessNo. 2 Handgun ProcessNo. 2 Handgun ProcessNo. 2 Handgun Process

The No. 2 ProcessTM is an electrical atomizationmethod for applying coatings to objects electro-statically. The No. 2 Process Handgun systemapplies a high voltage, negative, DC charge tothe applicator bell, creating an electrostatic fieldbetween the bell and the target object. The tar-get is electrically grounded through its supportwhich may be stationary or moving; or throughan electrical connection to a known true earthground.

A regulated pressure fluid system delivers coat-ing material to the bell when the gun is triggered.There, the fluid travels across the face of therotating bell and becomes charged. The fluid iselectrically atomized at the edge of the bell form-ing a fine mist which, under the influence of theelectrostatic field, is attracted to and depositedon the target object. The forces between thecharged particles and the grounded target aresufficient to turn almost all overspray aroundand deposit it on the side and back surfaces ofthe target. Thus, a high percentage of the sprayis deposited on the target and overspray is con-trolled.

The 9040 Classic High VThe 9040 Classic High VThe 9040 Classic High VThe 9040 Classic High VThe 9040 Classic High VoltageoltageoltageoltageoltagePower SupplyPower SupplyPower SupplyPower SupplyPower Supply

The 9040 Classic Power Supply converts stan-dard AC line voltage to a high frequency, lowvoltage signal ranging from 0 to 10 Vrms. Thissignal is supplied to the High Voltage Multiplierwhere it is converted to DC high voltage. Thehigh voltage DC is then transferred from the9040 Classic Power Supply to the No. 2 Pro-cess spray gun through a super flex high volt-age cable. The voltage/current characteristic isdesigned to optimize the charging process un-der varying load conditions and to limit the oper-ating current to a safe maximum value.

In addition to supplying high voltage output tothe spray gun, the 9040 Classic power supplyalso provides controls for AC power ON/OFF, ahigh voltage meter, a current meter, a POWERON indicator, a HIGH VOLTAGE ON indicator,and a CURRENT OVERLOAD indicator andreset switch. Additionally, output terminals areprovided for remote overload reset and interlockconnections for a conveyor, exhaust fan andhigh voltage control on all 9040 Classic PowerSupplies.

The 9040 Classic No. 2 Power Supplyis factory supplied with a cabinet latchthat can be opened using a slotted screw-driver. If desired, the standard latch canbe easily replaced with a latch that re-quires the use of a key to open. This keylock can be ordered from: Austin Hard-ware, Inc., 8001 Central Ave. N. E.,Minneapolis, MN 55432; 1-800-328-2423;Key Lock Part Number: C8052-14A.

NOTENOTENOTENOTENOTE

The 9040 Classic Power Supply is availableThe 9040 Classic Power Supply is availableThe 9040 Classic Power Supply is availableThe 9040 Classic Power Supply is availableThe 9040 Classic Power Supply is availableas follows:as follows:as follows:as follows:as follows:

Except where indicated, this manual isapplicable to all models of the 9040 Clas-sic No. 2 Process Handgun Power Sup-ply.


Figure 1: 9040 Classic Power SupplyFigure 1: 9040 Classic Power SupplyFigure 1: 9040 Classic Power SupplyFigure 1: 9040 Classic Power SupplyFigure 1: 9040 Classic Power SupplyAvailabil i tyAvailabil i tyAvailabil i tyAvailabil i tyAvailabil i ty

Electric Motor, Domestic

Electric Motor, Export

76657-14

76657-142

19372

19372

Used with No. 2Used with No. 2Used with No. 2Used with No. 2Used with No. 2Gun TypeGun TypeGun TypeGun TypeGun Type

GunGunGunGunGun

No.No.No.No.No.

90409040904090409040Part No.Part No.Part No.Part No.Part No.

CP-97-03.6

9040 Classic for the No. 2 Process Handgun - Introduction

77777

SPECIFICASPECIFICASPECIFICASPECIFICASPECIFICATIONSTIONSTIONSTIONSTIONS

ElectricalElectricalElectricalElectricalElectrical

Input:Input:Input:Input:Input:Voltage:Voltage:Voltage:Voltage:Voltage: 90-264 VACCurrent:Current:Current:Current:Current: 0.6/0.3 Amps ACFrequency:Frequency:Frequency:Frequency:Frequency: 50/60 HertzWattage:Wattage:Wattage:Wattage:Wattage: 60 Watts (Maximum)

Output:Output:Output:Output:Output:Voltage:Voltage:Voltage:Voltage:Voltage: 0-100 kV DCCurrent:Current:Current:Current:Current: 100 Microamps Max.

PhysicalPhysicalPhysicalPhysicalPhysical

Height:Height:Height:Height:Height: 14 inches (35.6 cm)Width:Width:Width:Width:Width: 12 inches (30.5 cm)Depth:Depth:Depth:Depth:Depth: 6 inches (15.2 cm)Weight:Weight:Weight:Weight:Weight: 24 pounds (10.9 kg)

Figure 2: 9040 Classic No. 2 Power Supply FeaturesFigure 2: 9040 Classic No. 2 Power Supply FeaturesFigure 2: 9040 Classic No. 2 Power Supply FeaturesFigure 2: 9040 Classic No. 2 Power Supply FeaturesFigure 2: 9040 Classic No. 2 Power Supply Features

CP-97-03.6

9040 Classic for the No. 2 Process Handgun - Installation

88888

INSTINSTINSTINSTINSTALLAALLAALLAALLAALLATIONTIONTIONTIONTION

DO NOTDO NOTDO NOTDO NOTDO NOT locate the power supply nearor adjacent to heat producing equipmentsuch as ovens, high wattage lamps, etc.

C A U T I O NC A U T I O NC A U T I O NC A U T I O NC A U T I O N!!!!!

The 9040 Classic Power Supply MUSTMUSTMUSTMUSTMUSTbe located outside the hazardous area.(See National Fire Protection AssociationBulletin No. 33; the Occupational Safetyand Health Act of 1970, sections 1910.106and 1910.107 and Ransburg Bulletin IL-247, Operating Your Electrostatic CoatingSystem Safely.)

The user MUSTMUSTMUSTMUSTMUST read and be familiarwith the SAFETY and SAFETY PRECAU-TIONS SECTIONS of this manual.

This manual MUSTMUSTMUSTMUSTMUST be read and thor-oughly understood by ALLALLALLALLALL personnel whooperate, clean or maintain this equipment!Special care should be taken to ensure thatthe warnings and requirements for operat-ing and servicing safely are followed. Theuser should be aware of and adhere to ALLALLALLALLALLlocal building and fire codes and ordinancesas well as NFPA Standard 33 and TheOccupational Safety and Health Act of1970 (OSHA) prior to installing, operatingand/or servicing this equipment.


As each installation is unique, this in-formation is intended to provide general in-stallation information for the 9040 ClassicPower Supply. Consult your authorizedRansburg distributor for specific directionspertaining to the installation of your equip-ment.


LOCALOCALOCALOCALOCATIONTIONTIONTIONTION

Install the 9040 Classic Power Supply in anarea outside the hazardous location, where itwill be protected from the possibility of environ-mental intrusion, such as dust or moisture, andambient temperatures do not exceed 120oF, butas close to the applicator as possible to mini-

mize the length of the high voltage cable. ThePower Supply may be free standing on any flatsurface or wall mounted by rotating the wallmount brackets (supplied) as shown in Figure 3.In either case, the power supply MUST bemounted in an upright position. DO NOT DO NOT DO NOT DO NOT DO NOT laythe power supply on its side or back.

INPUTINPUTINPUTINPUTINPUT VOL VOL VOL VOL VOLTTTTTAGEAGEAGEAGEAGESELECTIONSELECTIONSELECTIONSELECTIONSELECTION

The 9040 Classic Power Supply accepts uni-versal input voltage between 90 and 264 VAC.There is no need to change any switch settingswhen changing input from 115 to 230 VAC orfrom 230 to 115 VAC.

9040 units shipped from the factory for115 VAC input will have a 72771-06, 1 ampfront panel fuse installed. While 9040 unitsshipped from the factory for 230 VAC inputwill have a 72771-01, 0.5 amp front panelfuse installed. If the other input is required,it is recommended that the fuse bechanged in order to keep the same level ofprotection. Both fuses are shipped with9040 power supplies.


Figure 3: Wall Mount BracketsFigure 3: Wall Mount BracketsFigure 3: Wall Mount BracketsFigure 3: Wall Mount BracketsFigure 3: Wall Mount Brackets

CP-97-03.6


99999

INPUT CONNECTIONSINPUT CONNECTIONSINPUT CONNECTIONSINPUT CONNECTIONSINPUT CONNECTIONS

Plug the AC line cord into a properly groundedAC outlet. Any extension of the AC line cordMUST conform to the following:

• It must be properly connected to wire withground.

• It must be 14 gauge minimum.

• It must be less than 100 feet total length.

• It should be continuous (as few connectionsas possible).

For portable use, the 9040 ClassicNo. 2 Power Supply comes factory wiredwith an AC line cord. For permanent instal-lations, conduit is generally required. How-ever, if national and local codes permit, theAC power may be supplied via the factoryinstalled line cord for permanent installationsalso. If conduit is utilized, the power supplywiring MAY be routed through an optionalexplosion proof switch mounted on or nearthe spray booth where it will be convenientto the operator.


Input Circuit TInput Circuit TInput Circuit TInput Circuit TInput Circuit Testestestestest

Prior to applying AC power to the Power Sup-ply, the phase and ground of the AC receptacleand/or extension cord MUST be tested usingthe Circuit Tester, P/N 20868-00. If the circuit isfound to be faulty or out of phase, the circuitMUST be corrected before operating the powersupply.

Operation of the power supply on anungrounded or improper circuit can lead tocomponent failure or unsafe operation.


EXTERNALEXTERNALEXTERNALEXTERNALEXTERNALCONNECTIONSCONNECTIONSCONNECTIONSCONNECTIONSCONNECTIONS

When connecting external control wiresto the 9040 Classic Power Supply, route thewiring through the external wiring grommetlocated on the side panel.


High VHigh VHigh VHigh VHigh Voltage (HV)oltage (HV)oltage (HV)oltage (HV)oltage (HV)Cable ConnectionCable ConnectionCable ConnectionCable ConnectionCable Connection

Remove the plastic protective plug from the HVCable Connector and squirt enough of the sup-plied dielectric oil (70863-00) into the HV Tubeto cover the electrical contact point.

With a clean, dry cloth, wipe the end of the HVCable. Insert the HV Cable into the HV CableConnector and tighten the cable nut securely.

Safety GroundSafety GroundSafety GroundSafety GroundSafety Ground

Crimp the appropriate connector onto theGround Wire Assembly and install from thepower supply ground stud, located on the sidepanel, to a true earth ground.

Squirting dielectric oil (70863-00) downthe HV Tube significantly reduces coronadischarge that can cause deterioration of theHV connection components.


The Ground Wire Assembly MUSTMUSTMUSTMUSTMUST beconnected from the Power Supply groundstud to a true earth ground. DO NOTDO NOTDO NOTDO NOTDO NOTattach the ground wire from the PowerSupply to the part being coated. Damage tothe power supply will occur! Separateground wires MUSTMUSTMUSTMUSTMUST be used for groundingthe part and the Power Supply.


CP-97-03.6


1010101010

InterlocksInterlocksInterlocksInterlocksInterlocks

As outlined in NFPA 33 and OSHA standard1910, the AC power line must be series inter-locked with both the exhaust fan and conveyor.To interlock the 9040 Classic power supply withthe exhaust fan and conveyor perform the fol-lowing:

1. Ensure the front panel fuse is removed,the power supply is unplugged, and theON/OFF switch is in the OFF position.

2. Open the power supply cabinet door.

ALWAYSALWAYSALWAYSALWAYSALWAYS ensure that high voltage is

OFFOFFOFFOFFOFF before flushing the spray gun withsolvent. NEVER NEVER NEVER NEVER NEVER flush the spray gun withhigh voltage ONONONONON, as this is a severe firehazard and risk to personnel safety. It isrecommended that the high voltage controlbe interlocked with the solvent flush signalso that high voltage is automatically lockedout whenever flushing occurs. Consultyour authorized Ransburg representativefor information on interlocking the highvoltage OFF OFF OFF OFF OFF signal with the solvent flushsignal.


3. Using a small blade screw driver, re-move the factory installed jumper from 1TB-L1 to 1TB-L2.

4. Route exhaust fan and conveyor inter-lock (supplied by user) wiring throughthe external wiring grommet on the sideof the power supply and connect to 1TB-L1 and 1TB-L2 as shown in Figure 4.The Interlock contacts should beThe Interlock contacts should beThe Interlock contacts should beThe Interlock contacts should beThe Interlock contacts should berated for at least 1 Amp at 240rated for at least 1 Amp at 240rated for at least 1 Amp at 240rated for at least 1 Amp at 240rated for at least 1 Amp at 240volts AC.volts AC.volts AC.volts AC.volts AC.

5. Secure the cabinet door, replace thefuse, and plug the power supply in.

ALWAYSALWAYSALWAYSALWAYSALWAYS double check that the powersupply is unplugged from its AC Outletbefore working with any internal wiring.


External Relay ContactsExternal Relay ContactsExternal Relay ContactsExternal Relay ContactsExternal Relay Contacts

A set of external relay contacts for High Voltage(K1) and overload (K2) conditions is provided at6PL-5, -6, & -7. See Figure 10 in the "Mainte-nance" section of this manual for exact wiringlocations. These relay contacts are sometimesuseful in configuring the control of the spray gunsystem.

External High VExternal High VExternal High VExternal High VExternal High Voltage Controloltage Controloltage Controloltage Controloltage Control

If a method of high voltage triggering, other thanthe factory supplied method, is required, the 9040Classic Power Supply allows for external highvoltage control from a PLC, pressure switch, airflow switch, or other user supplied device. To turnthe high voltage on, the user supplied device mustcreate a contact closure between terminals 6 and7 of terminal block one (1TB). To connect the usersupplied, external high voltage control device,perform the following:

1. Ensure the front panel fuse is removed,the power supply is unplugged, and theON/OFF switch is in the OFF position.

2. Open the power supply cabinet door.

3. Route the contact wires of the controldevice through the external wiring grom-met and connect to the existing wiringfor 1TB-6 and 1TB-7. The control de-vice contacts must be rated for at least100 milliamps at 15 volts DC.

4. Secure the cabinet door, replace thefuse, and plug in the power supply.

Figure 4: Terminal Block One (1TB)Figure 4: Terminal Block One (1TB)Figure 4: Terminal Block One (1TB)Figure 4: Terminal Block One (1TB)Figure 4: Terminal Block One (1TB)

CP-97-03.6

9040 Classic for the No. 2 Process Handgun - Operation

1111111111

OPERAOPERAOPERAOPERAOPERATIONTIONTIONTIONTION

The electrical discharge which isavailable from the charging electrode of theapplicator must not exceed 0.25 mJ ofenergy. To achieve this limit, any flow ofenergy from the paint supply through thepaint line to the gun electrode MUSTMUSTMUSTMUSTMUST beprevented by grounding the paint line at thegun handle or body. Verify that the appli-cator is actually grounded BEFOREBEFOREBEFOREBEFOREBEFOREoperating it! (See the appropriate spraygun manual.) If improper readings areobtained, check that the power supply isgrounded (see "Ground Test Procedure" inthe "Maintenance" section of this manual).

W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G!!!!! The user MUST MUST MUST MUST MUST read and be familiar

with the "SAFETY" SECTION "SAFETY" SECTION "SAFETY" SECTION "SAFETY" SECTION "SAFETY" SECTION of thismanual and the Ransburg safety literaturetherein identified BEFORE OPERATING BEFORE OPERATING BEFORE OPERATING BEFORE OPERATING BEFORE OPERATINGthe 9040 Classic power supply.


THEORTHEORTHEORTHEORTHEORYYYYY OF OPERA OF OPERA OF OPERA OF OPERA OF OPERATIONTIONTIONTIONTION

-REFER TO FIGURE 10-REFER TO FIGURE 10-REFER TO FIGURE 10-REFER TO FIGURE 10-REFER TO FIGURE 10

Line Voltage (90-264 VAC) is applied to inputterminals 11PL-1 and 11PL-2 of 18 VDC PowerSupply 1SUP through the user supplied exhaustfan and conveyor interlocks, fuse 1FU and ON/OFF switch 1SW. Line voltage from ON/OFFswitch 1SW is also supplied to the input of the24 VDC power supply 2SUP. The 24 VDC out-put of the power supply is then supplied to

Figure 5: Operating ControlsFigure 5: Operating ControlsFigure 5: Operating ControlsFigure 5: Operating ControlsFigure 5: Operating Controls

CP-97-03.6

9040 Classic for the No. 2 Process Handgun - Operation

1212121212

OPERAOPERAOPERAOPERAOPERATING PROCEDURESTING PROCEDURESTING PROCEDURESTING PROCEDURESTING PROCEDURES

1. Ensure that the AC power and high volt-age cables are connected as describedin the "Installation" section of thismanual.

2. Turn the ON/OFF switch to the ON posi-tion. The green LED will light indicatingthat AC power is being supplied to thepower supply.

3. The voltage to the No. 2 hand gun is ac-tivated by turning the toggle switch onthe back of the gun to the ON position.

Kilovolt and Microamp MetersKilovolt and Microamp MetersKilovolt and Microamp MetersKilovolt and Microamp MetersKilovolt and Microamp Meters

The kilovolt meter indicates the voltage in thou-sands of volts (kV) present at the bell edge.The microamp meter indicates the current in mil-lionths of amps (µA) leaving the bell edge.

High VHigh VHigh VHigh VHigh Voltage Safety Circuitoltage Safety Circuitoltage Safety Circuitoltage Safety Circuitoltage Safety Circuit

The 9040 Printed Circuit Board (PCB) containsa safety circuit that prevents high voltage frombeing present at the gun if the high voltage trig-ger device (gun toggle switch, flow switch, pres-sure switch, PC contact, etc.) has not been trig-gered. If a failure mode should occur that wouldattempt to send high voltage to the gun, eventhough the high voltage trigger has not been ac-tivated, the PC Board will shut down and enteran overload condition. If repeated overloads oc-cur, every time the overload reset button ispushed, open the cabinet door and see if the redLED (LED1, see Figure 7 for location) on thePC Board lights for about 2 seconds after push-ing the reset button. If it does, the PC Boardhas failed and should be replaced.

High VHigh VHigh VHigh VHigh Voltage ON Indicatoroltage ON Indicatoroltage ON Indicatoroltage ON Indicatoroltage ON Indicator

The red high voltage on LED will light when highvoltage is present at the spray gun.

AC Power ON IndicatorAC Power ON IndicatorAC Power ON IndicatorAC Power ON IndicatorAC Power ON Indicator

The green AC power ON LED will light when theAC Power ON/OFF switch is in the ON posi-tion.

Check that the power supply is properlygrounded!

C A U T I O NC A U T I O NC A U T I O NC A U T I O NC A U T I O N!!!!!LED1, the (+) end of relay coil K3 (mounted onthe relay board), and one of its normally opencontacts.

The output of power supply 1SUP, through PCboard fuse F2, provides the DC voltage whichpowers the PC Board regulators and the ACpower ON LED. The DC input to the oscillatorcircuit is obtained from a board regulator. Theoscillator circuit outputs a low voltage, high fre-quency AC signal to the High Voltage MultiplierCircuit. The High Voltage Multiplier Circuit recti-fies the AC voltage to DC and steps it up to pro-vide rated kV to the spray gun via the high volt-age cable.

The DC input to the oscillator is interlocked with1TB terminals 6 and 7, such that the oscillatorwill not function unless terminals 6 and 7 areconnected together. In this manner, high volt-age to the spray gun is controlled as follows:

1. Turning the ON/OFF toggle switch at theback of the spray gun to the ON positiongrounds relay board coil K3, thereby ac-tivating the coil. Activation of the coilcloses its two normally open contacts.Closure of one set of contacts suppliesLED2 and 24 VDC to the motor. Clo-sure of the second set of contacts con-nects 1TB-6 and 7 together, thereby pro-viding high voltage to the handgun.

2. Contact closure of a programmable con-troller output, robot output, or some otheruser supplied device connected to termi-nals 1TB-6 and 7 will activate high volt-age at the spray gun.

3. For testing and troubleshooting, boardjumper JP4 connects 1TB-6 and 7 to-gether, thereby providing high voltageoutput. (See "PC Board Test Jumper" inthe "Maintenance" section of thismanual.)

CP-97-03.6

9040 Classic for the No. 2 Process Handgun - Maintenance

1313131313

MAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCE

ROUTINE PREVENTIVEROUTINE PREVENTIVEROUTINE PREVENTIVEROUTINE PREVENTIVEROUTINE PREVENTIVEMAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCE

In general, little maintenance is necessary toensure proper operation. It is important, how-ever, to keep the interior of the unit clean andfree from moisture or foreign material. For thisreason:

1. Keep the exterior of the unit free fromdust accumulation.

2. Always clean the exterior prior to open-ing the cabinet door.

3. Open the cabinet door only to performmaintenance or repair.

4. If the power supply end of the high volt-age cable becomes dirty, clean the endof the cable with a suitable, clean, non-polar solvent and apply a light coat ofdielectric grease. On a yearly basis,check to ensure that the dielectric oil(70863-00) is covering the electricalcontact point in the High Voltage Tube.If not, add oil as needed.

5. Perform a Current Output (SCI) Test ap-proximately every 50 hours of high volt-age operation.

Squirting dielectric oil (70863-00) downthe HV Tube significantly reduces coronadischarge that can cause deterioration ofthe HV connection components.


Never immerse any part of, or all of anassembled applicator in any liquid.


TROUBLESHOOTINGTROUBLESHOOTINGTROUBLESHOOTINGTROUBLESHOOTINGTROUBLESHOOTING

PC Board TPC Board TPC Board TPC Board TPC Board Test Jumperest Jumperest Jumperest Jumperest Jumper

To assist in testing and troubleshooting, ajumper (JP4) has been incorporated on the9040 PC Board. By covering (shorting) bothterminals the high voltage on relay is triggered.Thus, for testing and troubleshooting, high volt-age output can be obtained without the need totrigger the spray gun or user supplied controldevice. Just remember to reposition the jumperafter testing, so that it covers only one terminal(open) or the high voltage will stay on all thetime (see Figure 7 for location of test jumperJP4).

If JP4 is left covering (shorting) bothterminals, high voltage will be on wheneverAC power is turned on. This could behazardous in some applications.


Ground TGround TGround TGround TGround Test Procedureest Procedureest Procedureest Procedureest Procedure

Equipment Required:Equipment Required:Equipment Required:Equipment Required:Equipment Required:Ohmmeter - To Measure Resistance

If shocks or sparks are noticed at any point inthe spray system, immediately turn off thepower supply and check the complete systemfor proper grounding. Proper grounding of thespray gun system can be verified as follows:

1. Ensure that the clamp of the 14 AWGGround Wire Assembly is connected totrue earth ground. The resistance be-tween the clamp and a known earthground should read less than 25 ohms.

2. Place one end of the ohmmeter on theclamp of the Ground Wire Assembly andthe other end on the Power Supplyground stud. If the ohmeter readsgreater than 25 ohms, replace the 14AWG Ground Wire Assembly.

CP-97-03.6


1414141414

3. Connect one end of the ohmeter to thePower Supply ground stud and the otherto the metal gun handle. If the ohmeterreads greater than 25 ohms repair or re-place the high voltage cable.

Current Output (SCI) TCurrent Output (SCI) TCurrent Output (SCI) TCurrent Output (SCI) TCurrent Output (SCI) Testestestestest

When a lack of high voltage at the applicator in-dicates a problem, a Current Output (SCI) Testshould be performed to help determine if thepower supply is at fault (see Figure 6).

4. Insert the Test Resistor (16688-02) intothe High Voltage Tube of the power sup-ply.

5. Set the switch on the Test Assembly(76652-02) to the µA position (if using aVOM set the scale for 200 microamps).

6. Connect the AC source power and turnthe power supply ON/OFF switch to theON position.

7. Using the clip lead, short circuit the HighVoltage Cable Connector pin 1CON-3 toground (rim of High Voltage Cable Con-nector), as shown in the balloon of Fig-ure 6. When proper connection is made,the red high voltage ON Indicator willlight.

ALWAYS ALWAYS ALWAYS ALWAYS ALWAYS ensure step 3 has beencompleted before proceeding with step 4.


8. Read the current draw on the Test As-sembly (76652-02) (or VOM). The read-ing should be approximately 75 to 110microamps. Readings outside of theselimits are indications of a defectivepower supply. Refer to the "Trouble-shooting Guide" (Figure 9) to locate thespecific problem.

9. Turn all power OFF, wait 10 seconds toallow high voltage charge to drain off,remove the Test Assembly and Resis-tor, and restore the unit to operating con-dition.

PC Board Test Jumper JP4 may beused instead of the user supplied clip lead,to trigger the high voltage on. (See "PCBoard Test Jumper", discussed earlier inthis section, for further information.)


If the power supply SCI is normal andthe control circuit operates correctly whenjumpered, then any lack of high voltage orcontrol malfunction should be isolated tothe gun and/or high voltage cable.


Equipment Required:Equipment Required:Equipment Required:Equipment Required:Equipment Required:Test Assembly (76652-02)Test Resistor (16688-02)Clip Lead (User Supplied)

1. Turn high voltage OFF and disconnectAC power to the unit.

2. Remove the high voltage (HV) cablefrom the power supply.

Whenever removing high voltage cablesfrom equipment, ground the plug end of thecable(s) by contacting the plug to electricalground. DO NOTDO NOTDO NOTDO NOTDO NOT touch the plug until it hasbeen grounded. This will eliminate the possibil-ity of residual charge causing electrical shock.


3. Using the 76652-02 Test Assembly withgun test leads attached (or other suitableVOM), connect the negative lead (white)to the grooved, metal end of the TestResistor (16688-02) and the positivelead (black) to the rim of the High Volt-age Cable Connector.

CP-97-03.6


1515151515

KV Output TKV Output TKV Output TKV Output TKV Output Testestestestest

When a lack of high voltage at the spray gunindicates a problem, a kV Output Test of thePower Supply may be performed to help deter-mine whether it is at fault.

Figure 6: Current Output TestFigure 6: Current Output TestFigure 6: Current Output TestFigure 6: Current Output TestFigure 6: Current Output Test

Equipment Required:Equipment Required:Equipment Required:Equipment Required:Equipment Required:Calibrated Ransburg High Voltage Test Probeand Meter (76652-01)

KV Output TKV Output TKV Output TKV Output TKV Output Test Procedureest Procedureest Procedureest Procedureest Procedure

1. Turn AC power to the power supplyOFFOFFOFFOFFOFF.

2. Remove the high voltage (HV) cablefrom the power supply.

3. Open the cabinet door and positionjumper JP4 on the main PC Board sothat it covers (shorts) both terminals.

Whenever removing high voltage cablesfrom equipment, ground the plug end of thecable(s) by contacting the plug to electricalground. DO NOT DO NOT DO NOT DO NOT DO NOT touch the plug until it hasbeen grounded. This will eliminate thepossibility of residual charge causing electri-cal shock.


4. Attach the appropriate HV cable to theTest Probe (76652-01), properly groundthe probe to a true earth ground and turnthe Test Probe Meter on (see OperationManual of 76652-01 Tester).

5. Insert the Test Probe HV cable into thePower Supply HV Tube until it bottomsout.

6. Turn the power supply ONONONONON.

7. Read the output voltage displayed on themeter, then turn the power supply OFF.If the voltage DOES READDOES READDOES READDOES READDOES READ correctly(see "Specifications" in the "Introduction"section of this manual), the problem isnot in the Power Supply, therefore theHV Cable and spray gun should bechecked for the cause. If the voltageDOES NOT READDOES NOT READDOES NOT READDOES NOT READDOES NOT READ correctly, theproblem is with the power supply. Con-sult the "Troubleshooting Guide" (Figure9) to locate the specific problem.

8. Disconnect the Test Probe (76652-01)and reposition JP4 so that it covers onlyone terminal. When ready to resumespray operations, reconnect the spraygun HV cable and turn the power supplyon.

Ensure that the Test Probe HV cablemakes good contact both inside the TestProbe and inside the Power Supply HVTube.


Figure 7: Main PC BoardFigure 7: Main PC BoardFigure 7: Main PC BoardFigure 7: Main PC BoardFigure 7: Main PC Board

CP-97-03.6


1616161616

Bench TBench TBench TBench TBench Testingestingestingestingesting

Equipment Required:Equipment Required:Equipment Required:Equipment Required:Equipment Required:

Volt/ohmmeter

The "Troubleshooting Guide" (Figure 9) pro-vides information for troubleshooting the powersupply when improper operation is obtained andthe problem has been traced to the power sup-ply. Proper troubleshooting should ONLY beaccomplished with specific test equipment byqualified electronics technicians or authorizedRansburg representatives.

Before troubleshooting, ensure that the powersupply is plugged into a live outlet of the appro-priate voltage. All electrical measurements inthe "Troubleshooting Guide" (Figure 9) arenominal and may vary as much as ±10% de-pending on the test conditions and the testequipment used. Refer to Figures 7 and 8 forlocation of parts called out in the "Troubleshoot-ing Guide".

For bench testing, jumper JP4 should be usedto trigger the high voltage output (see "PCBoard Test Jumper" previously discussed inthis section).

Procedures outlined in the "Trouble-shooting Guide" (Figure 9) require measure-ment of voltage potentials that can causeSERIOUS BODILY INJURY SERIOUS BODILY INJURY SERIOUS BODILY INJURY SERIOUS BODILY INJURY SERIOUS BODILY INJURY if propermeasuring procedures are not followed. Forthis reason, proper troubleshooting shouldONLY ONLY ONLY ONLY ONLY be accomplished with specific testequipment by qualified electronics techni-cians or authorized Ransburg representa-tives.


The High Voltage Multiplier and highvoltage cable contain significant capaci-tance that will store charge. ALLOWALLOWALLOWALLOWALLOWapproximately 10 seconds for this chargeto bleed off BEFORE BEFORE BEFORE BEFORE BEFORE opening the cabinetdoor OR REMOVINGOR REMOVINGOR REMOVINGOR REMOVINGOR REMOVING the high voltagecable from the power supply or spray gun.


Diagnostic LED'sDiagnostic LED'sDiagnostic LED'sDiagnostic LED'sDiagnostic LED's

There are two diagnostic LED's located on therelay board inside the cabinet (see Figure 8).LED1 is a green LED that indicates 24 VDC in-put is being received from power supply 2SUP.LED1 should be lit whenever the power supplyON/OFF switch is ON. LED2 is a red LED thatindicates 24 VDC is being output to the gun mo-tor. LED2 should be lit whenever the toggleswitch at the back of the gun is turned ON.

Figure 8: Troubleshooting DiagramFigure 8: Troubleshooting DiagramFigure 8: Troubleshooting DiagramFigure 8: Troubleshooting DiagramFigure 8: Troubleshooting Diagram

CP-97-03.6

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDETROUBLESHOOTING GUIDETROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

Figure 9: Troubleshooting Guide (Continued on Next Page)Figure 9: Troubleshooting Guide (Continued on Next Page)Figure 9: Troubleshooting Guide (Continued on Next Page)Figure 9: Troubleshooting Guide (Continued on Next Page)Figure 9: Troubleshooting Guide (Continued on Next Page)

General ProblemGeneral ProblemGeneral ProblemGeneral ProblemGeneral Problem Possible CausePossible CausePossible CausePossible CausePossible Cause SolutionSolutionSolutionSolutionSolution

AC Power ON IndicatorAC Power ON IndicatorAC Power ON IndicatorAC Power ON IndicatorAC Power ON Indicator(Green LED) Does Not(Green LED) Does Not(Green LED) Does Not(Green LED) Does Not(Green LED) Does NotLight When ON/OFFLight When ON/OFFLight When ON/OFFLight When ON/OFFLight When ON/OFFSwitch Is OnSwitch Is OnSwitch Is OnSwitch Is OnSwitch Is On

Motor Rotating, But NoMotor Rotating, But NoMotor Rotating, But NoMotor Rotating, But NoMotor Rotating, But NoOr Low kV Output AtOr Low kV Output AtOr Low kV Output AtOr Low kV Output AtOr Low kV Output AtSpray GunSpray GunSpray GunSpray GunSpray Gun

1. Front panel fuse 1FU orPC Board fuse F2defective

2. Connector 7PL or 9PL notproperly plugged into mainPC board

3. Improper input line voltage

4. Improper exhaust fan orconveyor interlockconnections

5. Defective ON/OFF switch1SW

6. Defective power supply1SUP

7. Defective LED displayboard

1. Connector 6PL or 1PL notproperly plugged in torespective locations

2. Defective spray gun orhigh voltage cable

3. Loose or broken wire inpower supply

4. Main PC board defective

5. Defective high voltagemultiplier

1. Replace defective fuse.

2. Properly attach connector.

3. Ensure voltage across terminals L1 and N ofterminal block 1TB is between 90 and 264VAC.

4. Correct connection so that voltage acrossterminals L2 and N of 1TB is between 90 and264 VAC.

5. Voltage across terminals 1A and 2A of ON/OFFswitch 1SW should be between 90 and 264VAC. If not, replace switch 1SW.

6. Voltage across terminals 2 and 3 of plug 7PL onmain PC board should be 18 VDC. If not,replace power supply 1SUP.

7. If all other functions of power supply are normal,replace LED display board.

1. Properly attach connector.

2. Perform a Current Output Test on the powersupply. If proper readings are obtained, checkcable or spray gun for cause. (See Spray Gun’sService Manual.)

3. Check all wiring connections for integrity.Repair wiring as needed.

4. Disconnect 1PL from high voltage multiplierand plug in to LTST5000 Tester. If improperreadings are obtained, replace main PC board.

5. Disconnect HV cable from power supply. Ifproblem is still present, connect LTST5000Tester to 1PL and test. If results of test areokay, replace high voltage multiplier.


1717171717

CP-97-03.6


1818181818

Figure 9: Troubleshooting Guide (Continued)Figure 9: Troubleshooting Guide (Continued)Figure 9: Troubleshooting Guide (Continued)Figure 9: Troubleshooting Guide (Continued)Figure 9: Troubleshooting Guide (Continued)

General ProblemGeneral ProblemGeneral ProblemGeneral ProblemGeneral Problem Possible CausePossible CausePossible CausePossible CausePossible Cause SolutionSolutionSolutionSolutionSolution

Motor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingAnd No kV Output AtAnd No kV Output AtAnd No kV Output AtAnd No kV Output AtAnd No kV Output AtSpray Gun, LED1 OffSpray Gun, LED1 OffSpray Gun, LED1 OffSpray Gun, LED1 OffSpray Gun, LED1 Off

Motor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingAnd No kV Output AtAnd No kV Output AtAnd No kV Output AtAnd No kV Output AtAnd No kV Output AtSpray Gun, LED1 OnSpray Gun, LED1 OnSpray Gun, LED1 OnSpray Gun, LED1 OnSpray Gun, LED1 On

Motor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingBut kV Output Ok,But kV Output Ok,But kV Output Ok,But kV Output Ok,But kV Output Ok,LED2 OffLED2 OffLED2 OffLED2 OffLED2 Off

Motor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingMotor Not RotatingBut kV Output Ok,But kV Output Ok,But kV Output Ok,But kV Output Ok,But kV Output Ok,LED2 OnLED2 OnLED2 OnLED2 OnLED2 On

Intermittent MotorIntermittent MotorIntermittent MotorIntermittent MotorIntermittent MotorOperationOperationOperationOperationOperation

Motor Rotating TooMotor Rotating TooMotor Rotating TooMotor Rotating TooMotor Rotating TooFastFastFastFastFast

Excessive CurrentExcessive CurrentExcessive CurrentExcessive CurrentExcessive CurrentDrawDrawDrawDrawDraw

Excessive ShockingExcessive ShockingExcessive ShockingExcessive ShockingExcessive Shocking

1. Improper input line voltageto connector 8PL

2. Defective 24 VDC powersupply 2SUP

1. Defective control wires incable or switch in gun

2. Defective relay board

1. Defective relay board fuseF4

1. Defective control wires inhigh voltage cable


1. Defective power supply2SUP

1. Short in cable or gun

2. Defective main PC board


1. Discontinuity in groundcircuit

1. Ensure voltage across terminals 1 and 2 ofconnector 8PL is between 90 and 264 VAC.

2. Voltage across terminals 1 and 6 of plug10PL of power supply 2SUP should be24VDC. If not, replace power supply 2SUP.

1. Check for continuity from 2TB-3 of relayboard to gun handle when switch at gun isON. If no continuity, replace high voltagecable or gun ON/OFF switch.

2. If #1 above checks ok, replace relay board.

1. Replace defective fuse.

1. Replace high voltage cable.

1. Replace high voltage multiplier.

1. Voltage across terminals 1 and 6 of plug10PL of power supply 2SUP should be24VDC. If not, replace power supply 2SUP.

1. Remove cable from power supply. If problemgoes away, check gun or cable for cause.

2. Test PC board with LTST5000 Tester.Replace PC board if improper results areobtained.

3. If 1 and 2 above are okay, replace highvoltage multiplier.

1. Perform the Ground Test Procedure asdescribed in the "Maintenance" section ofthis manual.

CP-97-03.6

Figure 10: 9040 Classic No. 2 Power Supply Block DiagramFigure 10: 9040 Classic No. 2 Power Supply Block DiagramFigure 10: 9040 Classic No. 2 Power Supply Block DiagramFigure 10: 9040 Classic No. 2 Power Supply Block DiagramFigure 10: 9040 Classic No. 2 Power Supply Block Diagram


1919191919

CP-97-03.6


2020202020

SERVICE LEVELSERVICE LEVELSERVICE LEVELSERVICE LEVELSERVICE LEVEL

Personnel who service this unit must be quali-fied electronics technicians. Replacement partsare designed to be made at the assembly level.See "Parts Identification" section of this manualfor part numbers and ordering information.

ALWAYS ALWAYS ALWAYS ALWAYS ALWAYS turn power to the powersupply OFFOFFOFFOFFOFF, unplug the electrical cord fromits outlet, remove the front panel fuse, andlock the power supply out before makingrepairs or replacements.


DO NOTDO NOTDO NOTDO NOTDO NOT attempt to make repairs tothe printed circuit board!

DO NOTDO NOTDO NOTDO NOTDO NOT attempt to make repairsbeyond those described. All others shouldbe made ONLYONLYONLYONLYONLY by Ransburg servicepersonnel.


REPLACEMENTREPLACEMENTREPLACEMENTREPLACEMENTREPLACEMENTPROCEDURESPROCEDURESPROCEDURESPROCEDURESPROCEDURES

Before making replacements, check for defec-tive wiring or connections between the affectedcomponents. If there is a broken wire, defectiveinsulation, or dirty, loose or corroded connec-tions, repair or replace them before going to theexpense of replacing a component.

Front Panel Fuse 1FUFront Panel Fuse 1FUFront Panel Fuse 1FUFront Panel Fuse 1FUFront Panel Fuse 1FU

1. Insert screwdriver into slot in front panelfuse holder, push in, and rotate counter-clockwise.

2. Remove screwdriver and fuse holder willslide out.

3. Remove fuse from fuse holder and re-place with new fuse (see "Parts Identifi-cation" section of this manual for partnumbers).

4. Insert fuse holder back into front paneland with a slight inward pressure, rotatescrewdriver clockwise until it locks intoplace.

PC PC PC PC PC Board Fuse F2Board Fuse F2Board Fuse F2Board Fuse F2Board Fuse F2

----- REFER TO FIGURE 7 FOR FUSEREFER TO FIGURE 7 FOR FUSEREFER TO FIGURE 7 FOR FUSEREFER TO FIGURE 7 FOR FUSEREFER TO FIGURE 7 FOR FUSELOCATIONLOCATIONLOCATIONLOCATIONLOCATION

1. Ensure power supply is unplugged fromAC outlet and open cabinet door.

2. Replace defective fuse (see "Parts Iden-tification" section of this manual for partnumbers).

3. Secure cabinet door and plug powersupply back in.

ON/OFF Switch 1SWON/OFF Switch 1SWON/OFF Switch 1SWON/OFF Switch 1SWON/OFF Switch 1SW

1. Ensure power supply is unplugged fromAC outlet and open the cabinet door.

A spare F2 PC board fuse, includedfrom the factory, is located in the lowerright hand corner inside the cabinet door.


2. Remove the four quick connect termi-nals from the rear of ON/OFF switch1SW.

ALWAYSALWAYSALWAYSALWAYSALWAYS double check that the powersupply is unplugged from its AC outletbefore working with any internal wiring.


3. Press panel retaining clips on top andbottom of switch 1SW together and pushswitch out of panel from the inside.

It is recommended that the four ON/OFF switch wires be tagged with their re-spective terminal connections to 1SW be-fore removing.


CP-97-03.6

4. Press new switch (see "Parts Identifica-tion" section of this manual for part num-bers) into panel opening with terminals1A and 2A to the bottom of the cabinet.

5. Reconnect the four quick connect termi-nals to the new switch as follows:


AC Line CordAC Line CordAC Line CordAC Line CordAC Line Cord


1SW-1

1SW-2

1SW-1A

1SW-2A

1FU-2

1TB-N

1TB-S1

1TB-S2

ToToToToToFromFromFromFromFrom

2. Using a screwdriver, disconnect dam-aged line cord from 1TB-L1, 1TB-N, and1TB-GROUND.

3. Loosen the line cord grommet on sidepanel and pull damaged cord out.

4. Insert new line cord (see "Parts Identifi-cation" section of this manual for partnumbers) through grommet and connectto 1TB as follows:

ALWAYSALWAYSALWAYSALWAYSALWAYS double check that the powersupply is unplugged from its AC outletbefore working with any internal wiring.


5. Tighten side panel grommet.


Line Cord Ground

Line Cord Neutral/Common

Line Cord Hot/Line

1TB-GROUND

1TB-N

1TB-L1

High VHigh VHigh VHigh VHigh Voltage Multiplieroltage Multiplieroltage Multiplieroltage Multiplieroltage Multiplier

1. Remove HV cable from power supply.


3. Unplug connector 1PL from the top ofthe high voltage multiplier.

4. Remove the screws that mount the highvoltage multipliers’ aluminum housing tothe back panel.

5. Disconnect 8PL and 10PL from 24 VDCpower supply 2SUP and remove (4)mounting screws from the relay board.

6. Rotate the high voltage multiplier assem-bly out from the power supply.

7. Remove the (3) screws that secure thealuminum housing to the high voltagemultiplier.

8. Install the aluminum housing on the newhigh voltage multiplier (see "Parts Identi-fication" section of this manual for order-ing information). Ensure connector 1PLfaces the front of the housing before in-stalling.

9. Install the high voltage multiplier assem-bly in the power supply by securing the(6) mounting screws to the back panel.

10. Plug connector 1PL back into the highvoltage multiplier, reconnect 8PL and10PL to 24 VDC supply 2SUP and se-cure the relay board.

Because the high voltage multipliercontains energy storage components thatcan cause serious shock injury, it is notfield repairable. Warranty will be voided ifthe high voltage multiplier seal is broken. Ifthe high voltage multiplier is defective, con-tact your authorized Ransburg representa-tive for exchange or repair.



2121212121

CP-97-03.6


2222222222

11. Secure the cabinet door and plug thepower supply back in.

12. Reinstall the HV cable.

LED Display BoardLED Display BoardLED Display BoardLED Display BoardLED Display Board


2. Unplug display board connector from9PL on main PC board.

3. Remove (2) hex nuts that mount displayboard to inside of cabinet door and re-move display board from power supply.

4. Install new display board (see "PartsIdentification" section of this manual forpart numbers) in power supply.

5. Reconnect connector 9PL to main PCboard.


Kilovolt (kV) orKilovolt (kV) orKilovolt (kV) orKilovolt (kV) orKilovolt (kV) orMicroamp (µA) MeterMicroamp (µA) MeterMicroamp (µA) MeterMicroamp (µA) MeterMicroamp (µA) Meter


2. Remove (2) hex nuts from wiring termi-nals and remove wire lugs.

3. Remove (4) hex nuts that mount meterto door.

4. Remove old meter and install new one.(See "Parts Identification" section of thismanual for part numbers.)

5. Reconnect wire lugs to meter (purplewire goes to + terminal of meter).


Main PC BoardMain PC BoardMain PC BoardMain PC BoardMain PC Board


2. Disconnect plugs 6PL, 7PL, and 9PL(see Figure 7).

3. Remove (2) screws from heat sink baseand lift the PC board out.

4. Insert new PC Board (see "Parts Identifi-cation" section of this manual for partnumbers) and secure the (2) heat sinkscrews.

5. Reconnect plugs 6PL, 7PL, and 9PL.


Relay BoardRelay BoardRelay BoardRelay BoardRelay Board


2. Disconnect plug 2TB from the relayboard.

3. Remove the (4) mounting screws fromthe relay board.

4. Install new relay board (see "Parts Iden-tification" section of this manual for partnumbers) and secure mounting screws.

5. Reconnect plug 2TB to the relay board.


DO NOTDO NOTDO NOTDO NOTDO NOT remove the PC board fromthe heat sink, as it is an integrated assem-bly.


CP-97-03.6

ALWAYSALWAYSALWAYSALWAYSALWAYS double check that the powersupply is unplugged from its AC outletbefore removing the cover plate from powersupply 1SUP.


Power Supply 1SUPPower Supply 1SUPPower Supply 1SUPPower Supply 1SUPPower Supply 1SUP


2. Remove the (4) screws from the 1SUPpower supply cover plate and removethe plate.


2323232323

3. Remove connectors 11PL and 12PLfrom power supply 1SUP.

4. Remove the (4) cover plate standoffsfrom power supply 1SUP and removethe power supply from the unit.

5. Install new 1SUP power supply (see"Parts Identification" section of thismanual for part numbers) using the (4)cover plate standoffs. Ensure larger ter-minal strip (12PL) of power supply 1SUPfaces left side of unit as shown in Figure8.

6. Connect connectors 11PL and 12PL tonew power supply and reinstall coverplate.


24 VDC Power Supply 2SUP24 VDC Power Supply 2SUP24 VDC Power Supply 2SUP24 VDC Power Supply 2SUP24 VDC Power Supply 2SUP

1. Remove HV cable from power supply.


3. Unplug connector 1PL from the top ofthe high voltage multiplier.

4. Remove the screws that mount the highvoltage multipliers’ aluminum housing tothe back panel.

5. Disconnect plugs 8PL and 10PL from 24VDC power supply 2SUP and removethe (4) mounting screws from the relayboard.

6. Rotate the high voltage multiplier assem-bly out from the power supply.

7. Remove the (4) mounting screws fromthe 24 VDC supply.

8. Install the new 24 VDC supply (see"Parts Identification" section of thismanual for part numbers). Ensure twopin connector of 24 VDC supply is clos-est to bottom of unit when installing.

9. Reinstall high voltage multiplier assem-bly in power supply.

10. Plug connector 1PL back into the highvoltage multiplier. Reconnect plugs 8PLand 10PL to the 24 VDC supply andresecure the relay board.

11. Secure the cabinet door, plug the powersupply back in and reinstall the HVcable.

CP-97-03.6

Figure 11: 9040 Classic No. 2 Power Supply Parts DiagramFigure 11: 9040 Classic No. 2 Power Supply Parts DiagramFigure 11: 9040 Classic No. 2 Power Supply Parts DiagramFigure 11: 9040 Classic No. 2 Power Supply Parts DiagramFigure 11: 9040 Classic No. 2 Power Supply Parts Diagram

9040 Classic for the No. 2 Process Handgun -Parts Identification

PPPPPARARARARARTS IDENTIFICATS IDENTIFICATS IDENTIFICATS IDENTIFICATS IDENTIFICATIONTIONTIONTIONTION

2424242424

CP-97-03.6


2525252525

Item #Item #Item #Item #Item #

9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPLYYYYY - P - P - P - P - PARARARARARTS LISTTS LISTTS LISTTS LISTTS LIST (Figure 1 (Figure 1 (Figure 1 (Figure 1 (Figure 11)1)1)1)1)

DescriptionDescriptionDescriptionDescriptionDescription Part NumberPart NumberPart NumberPart NumberPart Number

1

2

34578

9

10111213

14151617

PC Board & Heat Sink Assembly:For 76657-14 and 76657-142High Voltage Multiplier:For 76657-14 and 76657-142ON/OFF SwitchKilovolt (kV) MeterMicroamp (µA) Meter18 VDC Power SupplyFuse, PC Board, Slow Blow, 4 Amp(See Figure 7 for Location)Fuse, Front Panel:Slow Blow, 1 Amp, 110-120 VAC InputSlow Blow, 0.5 Amp, 220-240 VAC InputAC Line CordGround Wire AssemblyLED Display BoardOverload Indicator & Reset Switch Assembly:Reset Switch, Normally ClosedLens, YellowBulbRubber Feet24 VDC Power SupplyRelay BoardFuse, Relay Board, Slow Blow, 1 Amp

76892-14

76304-0376434-0176436-9176436-9275337-05

LSME0082-04

72771-0672771-016262-0070539-0076455-02

76442-0176441-0076443-015627-0075337-0476649-0011689-03

NotationNotationNotationNotationNotation

1SW1M2M

1SUP

F2

1FU1FU

2SUP

F4

CP-97-03.6


2626262626

Item #Item #Item #Item #Item #

9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOLTTTTTAGE POWER SUPPLAGE POWER SUPPLAGE POWER SUPPLAGE POWER SUPPLAGE POWER SUPPLYYYYYACCESSORACCESSORACCESSORACCESSORACCESSORYYYYY P P P P PARARARARARTS LISTTS LISTTS LISTTS LISTTS LIST


123456

Control Unit/Power Supply Test AssemblyHigh Voltage Test Probe and MeterCircuit TesterTest Assembly, SCI & SprayabilityTest Resistor, 525 MegohmsDeluxe Test Kit (Includes Items 2 & 4 above andPaint Meter Test Probe)

LTST5000-0076652-0120868-0076652-0216688-0276652-04

NotationNotationNotationNotationNotation

Figure 13: 9040 Classic High Voltage Power Supply Accessory Parts ListFigure 13: 9040 Classic High Voltage Power Supply Accessory Parts ListFigure 13: 9040 Classic High Voltage Power Supply Accessory Parts ListFigure 13: 9040 Classic High Voltage Power Supply Accessory Parts ListFigure 13: 9040 Classic High Voltage Power Supply Accessory Parts List

Figure 12: 9040 Classic High Voltage Power Supply Recommended Spare Parts ListFigure 12: 9040 Classic High Voltage Power Supply Recommended Spare Parts ListFigure 12: 9040 Classic High Voltage Power Supply Recommended Spare Parts ListFigure 12: 9040 Classic High Voltage Power Supply Recommended Spare Parts ListFigure 12: 9040 Classic High Voltage Power Supply Recommended Spare Parts List

9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPL9040 CLASSIC NO. 2 POWER SUPPLYYYYYRECOMMENDED SPRECOMMENDED SPRECOMMENDED SPRECOMMENDED SPRECOMMENDED SPARE PARE PARE PARE PARE PARARARARARTS LISTTS LISTTS LISTTS LISTTS LIST


AmmeterFuse, Front PanelFuse, PC BoardDeluxe Test Kit

Tester

Test Resistor

High Voltage Multiplier24 VDC SupplyRelay BoardFuse, Relay BoardMain PC Board18 VDC Supply

76436-9272771-06LSME0082-0476652-04

LTST5000-00

16688-02

76304-0375337-0476649-0011689-0376892-1475337-05

NotesNotesNotesNotesNotes

Two Required

For TroubleshootingPurposes Only



No. of GunsNo. of GunsNo. of GunsNo. of GunsNo. of Guns

1211

1

1

111111

1211

1

1

111111

2421

1

1

111211

2421

1

1

111211

CP-97-03.6


2727272727

NOTES:NOTES:NOTES:NOTES:NOTES:

CP-97-03.6

9040 Classic for the No. 2 Process Handgun -Warranty Policies

WWWWWARRANTYARRANTYARRANTYARRANTYARRANTY POLICIES POLICIES POLICIES POLICIES POLICIES

2828282828

LIMITED WLIMITED WLIMITED WLIMITED WLIMITED WARRANTYARRANTYARRANTYARRANTYARRANTY

Ransburg will replace or repair without chargeany part and/or equipment that falls within thespecified time (see below) because of faultyworkmanship or material, provided that theequipment has been used and maintained in ac-cordance with Ransburg's written safety andoperating instructions, and has been used undernormal operating conditions. Normal wear itemsare excluded.

THE USE OF OTHER THAN RANSBURGTHE USE OF OTHER THAN RANSBURGTHE USE OF OTHER THAN RANSBURGTHE USE OF OTHER THAN RANSBURGTHE USE OF OTHER THAN RANSBURGAPPROVED PARTS, VOID ALL WAR-APPROVED PARTS, VOID ALL WAR-APPROVED PARTS, VOID ALL WAR-APPROVED PARTS, VOID ALL WAR-APPROVED PARTS, VOID ALL WAR-RANTIES.RANTIES.RANTIES.RANTIES.RANTIES.

SPARE PARTS: One hundred and eighty (180)days from date of purchase, except for rebuiltparts (any part number ending in "R") for whichthe warranty period is ninety (90) days.

EQUIPMENT: When purchased as a completeunit, (i.e., guns, power supplies, control units,etc.), is one (1) year from date of purchase.WRAPPING THE APPLICATOR, ASSO-WRAPPING THE APPLICATOR, ASSO-WRAPPING THE APPLICATOR, ASSO-WRAPPING THE APPLICATOR, ASSO-WRAPPING THE APPLICATOR, ASSO-CIATED VALVES AND TUBING, ANDCIATED VALVES AND TUBING, ANDCIATED VALVES AND TUBING, ANDCIATED VALVES AND TUBING, ANDCIATED VALVES AND TUBING, ANDSUPPORTING HARDWARE IN PLASTIC,SUPPORTING HARDWARE IN PLASTIC,SUPPORTING HARDWARE IN PLASTIC,SUPPORTING HARDWARE IN PLASTIC,SUPPORTING HARDWARE IN PLASTIC,SHRINK-WRAP, OR ANY OTHER NON-SHRINK-WRAP, OR ANY OTHER NON-SHRINK-WRAP, OR ANY OTHER NON-SHRINK-WRAP, OR ANY OTHER NON-SHRINK-WRAP, OR ANY OTHER NON-APPROVED COVERING, WILL VOIDAPPROVED COVERING, WILL VOIDAPPROVED COVERING, WILL VOIDAPPROVED COVERING, WILL VOIDAPPROVED COVERING, WILL VOIDTHIS WARRANTY.THIS WARRANTY.THIS WARRANTY.THIS WARRANTY.THIS WARRANTY.

FLUID HANDLING: One (1) year from date ofpurchase (i.e., Totalizer, CCV Valves, etc.).

AIR BEARING ROTATORS: Fifteen thousand(15,000) hours or three (3) years, whichever oc-curs first. Warranty period begins on the date ofpurchase.

RANSBURG'S ONLY OBLIGATION UN-RANSBURG'S ONLY OBLIGATION UN-RANSBURG'S ONLY OBLIGATION UN-RANSBURG'S ONLY OBLIGATION UN-RANSBURG'S ONLY OBLIGATION UN-DER THIS WARRANTY IS TO REPLACEDER THIS WARRANTY IS TO REPLACEDER THIS WARRANTY IS TO REPLACEDER THIS WARRANTY IS TO REPLACEDER THIS WARRANTY IS TO REPLACEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEOF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-RANTIES NOR WARRANTIES OF EI-RANTIES NOR WARRANTIES OF EI-RANTIES NOR WARRANTIES OF EI-RANTIES NOR WARRANTIES OF EI-RANTIES NOR WARRANTIES OF EI-THER MERCHANTABILITY OR FITNESSTHER MERCHANTABILITY OR FITNESSTHER MERCHANTABILITY OR FITNESSTHER MERCHANTABILITY OR FITNESSTHER MERCHANTABILITY OR FITNESSFOR A PARTICULAR PURPOSE.FOR A PARTICULAR PURPOSE.FOR A PARTICULAR PURPOSE.FOR A PARTICULAR PURPOSE.FOR A PARTICULAR PURPOSE.RANSBURG ASSUMES NO LIABILITYRANSBURG ASSUMES NO LIABILITYRANSBURG ASSUMES NO LIABILITYRANSBURG ASSUMES NO LIABILITYRANSBURG ASSUMES NO LIABILITYFOR INJURY, DAMAGE TO PROPERTYFOR INJURY, DAMAGE TO PROPERTYFOR INJURY, DAMAGE TO PROPERTYFOR INJURY, DAMAGE TO PROPERTYFOR INJURY, DAMAGE TO PROPERTYOR FOR CONSEQUENTIAL DAMAGESOR FOR CONSEQUENTIAL DAMAGESOR FOR CONSEQUENTIAL DAMAGESOR FOR CONSEQUENTIAL DAMAGESOR FOR CONSEQUENTIAL DAMAGESFOR LOSS OF GOODWILL OR PRO-FOR LOSS OF GOODWILL OR PRO-FOR LOSS OF GOODWILL OR PRO-FOR LOSS OF GOODWILL OR PRO-FOR LOSS OF GOODWILL OR PRO-DUCTION OR INCOME, WHICH RE-DUCTION OR INCOME, WHICH RE-DUCTION OR INCOME, WHICH RE-DUCTION OR INCOME, WHICH RE-DUCTION OR INCOME, WHICH RE-SULT FROM USE OR MISUSE OF THESULT FROM USE OR MISUSE OF THESULT FROM USE OR MISUSE OF THESULT FROM USE OR MISUSE OF THESULT FROM USE OR MISUSE OF THEEQUIPMENT BY PURCHASER OR OTH-EQUIPMENT BY PURCHASER OR OTH-EQUIPMENT BY PURCHASER OR OTH-EQUIPMENT BY PURCHASER OR OTH-EQUIPMENT BY PURCHASER OR OTH-ERS.ERS.ERS.ERS.ERS.

EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:

If, in Ransburg's opinion the warranty item inquestion, or other items damaged by this partwas improperly installed, operated or main-tained, Ransburg will assume no responsibilityfor repair or replacement of the item or items.The purchaser, therefore will assume all re-sponsibility for any cost of repair or replacementand service related costs if applicable.

CP-97-03.6

9040 Classic for the No. 2 Process Handgun - Appendix

2929292929

PPPPPAINTAINTAINTAINTAINT AND SOL AND SOL AND SOL AND SOL AND SOLVENTVENTVENTVENTVENT SPECIFICA SPECIFICA SPECIFICA SPECIFICA SPECIFICATIONSTIONSTIONSTIONSTIONSAEROBELLAEROBELLAEROBELLAEROBELLAEROBELL®®®®® II*** II*** II*** II*** II***

AEROBELLAEROBELLAEROBELLAEROBELLAEROBELL ®®®®®

AEROBELLAEROBELLAEROBELLAEROBELLAEROBELL®®®®® 33 33 33 33 33

RMA-101RMA-101RMA-101RMA-101RMA-101TMTMTMTMTM

18 TO 30 SEC

.1 MΩ TO ∞1000 cc/min

TURBODISKTURBODISKTURBODISKTURBODISKTURBODISKTMTMTMTMTMNO. 2 HAND GUNNO. 2 HAND GUNNO. 2 HAND GUNNO. 2 HAND GUNNO. 2 HAND GUNREMREMREMREMREMTMTMTMTMTM / M90 / M90 / M90 / M90 / M90TMTMTMTMTMREAREAREAREAREATMTMTMTMTM / EFM / EFM / EFM / EFM / EFMTMTMTMTMTM

RECOMMENDED VISCOSITY USING A ZAHN NO. 2

PAINT ELECTRICAL RESISTANCE**

RECOMMENDED DELIVERY (UP TO)

18 TO 30 SEC


20 TO 60 SEC

.1 TO 1 MΩ180 cc/min

20 TO 60 SEC


20 TO 60 SEC


APPENDIXAPPENDIXAPPENDIXAPPENDIXAPPENDIX

NOTE: NOTE: NOTE: NOTE: NOTE: Chart provides resistance and control information that we feel is necessary when using Ransburg equipment.

***** CAS Number: Chemical Abstract Service Number.********** Electrical Resistance using the Ransburg Meter.*************** Solvent Base Configuration Only.† † † † † Information Obtained From: http://solvdb.ncms.org†† †† †† †† †† The lowest temperature at which a volatile fluid will ignite.Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1.0Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1.0Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1.0Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1.0Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1.0

DICHLOROMETHANE

VM & P NAPHTHA

ACETONE

METHYL ACETATE

BENZENE

ETHYL ACETATE

2-BUTANONE

ISO-PROPYL ACETATE

ISOPROPYL ALCOHOL

2-PENTANONE

METHANOL

PROPYL ACETATE

TOLUOL

METHYL ISOBUTYL KETONE

ISOBUTYL ACETATE

ETHANOL

BUTYLBUTYLBUTYLBUTYLBUTYL ACET ACET ACET ACET ACETAAAAATETETETETE

ETHYLBENZENE

1-PROPANOL

2-BUTANOL

XYLOL

AMYL ACETATE

2-METHYLPROPANOL

METHYL AMYL ACETATE

5-METHYL-2-HEXANONE

1-BUTANOL

2-ETHOXYETHANOL

2-HEPTANONE

CYCLOHEXANONE

AROMATIC-100

DIISOBUTYL KETONE

1-PENTANOL

DIACETONE ALCOHOL

2-BUTOXYETHANOL

CYCLOHEXANOL

AROMATIC-150

AROMATIC-200

Methylene Chloride

Naptha

MEK

IPA

MPK

Methyl Alcohol

n-Propyl Acetate

Toluene

MIBK

Ethyl Alcohol

n-Propyl Alcohol

sec.-Butyl Alcohol

Xylene

iso-Butyl Alcohol

MIAK

n-Butyl Alcohol

MAK

SC#100

DIBK

Amyl Alcohol

Butyl Cellosolve

SC#150

Chlorinated Solvents

Aliphatic Hydrocarbons

Ketones

Esters

Aromatic Hydrocarbons

Esters

Ketones

Esters

Alcohols

Ketones

Alcohols

Esters


Ketones

Esters

Alcohols

EstersEstersEstersEstersEsters


Alcohols

Alcohols


Esters

Alcohols

Esters

Ketones

Alcohols

Glycol Ethers

Ketones

Ketones


Ketones

Alcohols

Ketones

Glycol Ethers

Alcohols



75-09-2

8030-30-6

67-64-1

79-20-9

71-43-2

141-78-6

78-93-3

108-21-4

67-63-0

107-87-9

67-56-1

109-60-4

108-88-3

108-10-1

110-19-0

64-17-5

123-86-4123-86-4123-86-4123-86-4123-86-4

100-41-4

71-23-8

78-92-2

1330-02-07

628-63-7

78-83-1

108-84-9

110-12-3

71-36-3

110-80-5

110-43-0

108-94-1

108-83-8

71-41-0

123-42-2

111-76-2

108-93-0

14.514.514.514.514.5

1010101010

5.65.65.65.65.6

5.35.35.35.35.3

5.15.15.15.15.1

3.93.93.93.93.9

3.83.83.83.83.8

3.43.43.43.43.4

2.52.52.52.52.5

2.52.52.52.52.5

2.12.12.12.12.1

2.12.12.12.12.1

1.91.91.91.91.9

1.61.61.61.61.6

1.51.51.51.51.5

1.41.41.41.41.4

1.01.01.01.01.0

.89.89.89.89.89

.86.86.86.86.86

.81.81.81.81.81

.80.80.80.80.80

.67.67.67.67.67

.62.62.62.62.62

.50.50.50.50.50

.50.50.50.50.50

.43.43.43.43.43

.38.38.38.38.38

.40.40.40.40.40

.29.29.29.29.29

.20.20.20.20.20

.19.19.19.19.19

.15.15.15.15.15

.12.12.12.12.12

.07.07.07.07.07

.05.05.05.05.05

.004.004.004.004.004

.003.003.003.003.003

HIGH

HIGH

LOW

LOW

HIGH

MEDIUM

MEDIUM

LOW

LOW

MEDIUM

LOW

LOW

HIGH

MEDIUM

LOW

LOW

LOWLOWLOWLOWLOW

HIGH

LOW

LOW

HIGH

MEDIUM

LOW

LOW

MEDIUM

LOW

LOW

MEDIUM

MEDIUM

HIGH

MEDIUM

LOW

LOW

LOW

LOW

HIGH

HIGH

FFFFFAAAAASSSSSTTTTTEEEEERRRRR

⇓⇓⇓⇓⇓

SSSSSLLLLLOOOOOWWWWWEEEEERRRRR

⇑⇑⇑⇑⇑Evap.Evap.Evap.Evap.Evap.Ra teRa teRa teRa teRa te †††††

ChemicalChemicalChemicalChemicalChemicalNameNameNameNameName

CommonCommonCommonCommonCommonNameNameNameNameName

CategoryCategoryCategoryCategoryCategory *CAS*CAS*CAS*CAS*CASNumberNumberNumberNumberNumber

Elec.Elec.Elec.Elec.Elec.Res.**Res.**Res.**Res.**Res.**

GUIDE TGUIDE TGUIDE TGUIDE TGUIDE TO USABLE SOLO USABLE SOLO USABLE SOLO USABLE SOLO USABLE SOLVENTVENTVENTVENTVENT SELECTION SELECTION SELECTION SELECTION SELECTION

65oF

-18oF

90oF

12oF

24oF

16oF

35oF

53oF

104oF

50oF

55oF

48oF

60oF

69oF

7878787878 oooooFFFFF

64oF

74oF

72oF

79oF

106oF

82oF

96oF

96oF

95oF

164oF

102oF

111oF

111oF

120oF

133oF

154oF

111oF

149oF

203oF

Flash PointFlash PointFlash PointFlash PointFlash Point††††††††††

(TCC)(TCC)(TCC)(TCC)(TCC)

© 04/2003 Illinois Tool Works Inc. All rights reserved.

CP-97-03.6


3030303030

VISCOSITY CONVERSION CHARTVISCOSITY CONVERSION CHARTVISCOSITY CONVERSION CHARTVISCOSITY CONVERSION CHARTVISCOSITY CONVERSION CHART

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.9

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1.2

1.4

1.6

1.8

2.0

2.2

2.4

2.6

2.8

3.0

3.2

3.4

3.6

3.8

4.0

4.2

4.4

4.6

4.8

5.0

5.5

6.0

7.0

8.0

9.0

10.0

11.0

12.0

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C

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C

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10

15

20

25

30

40

50

60

70

80

90

100

120

140

160

180

200

220

240

260

280

300

320

340

360

380

400

420

440

460

480

500

550

600

700

800

900

1000

1100

1200

27

30

32

37

43

50

57

64

11

12

13

14

15

16

17

18

20

22

23

25

30

32

37

41

45

20

25

30

35

39

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15

17

18

21

24

29

33

39

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62

12

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19

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29

33

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41

45

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58

66

5

8

10

12

14

18

22

25

28

31

32

34

41

45

50

54

58

62

65

68

70

74

A-4

A-3

A-2

A-1

A

B

C

D

E

F

G

H

I

J

K

L

M

N

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R

S

T

U

V

W

000

00

0

30

33

35

37

38

40

43

46

48

50

52

54

56

58

59

60

62

64

66

67

68

69

71

74

77

81

85

88

92

60

80

100

130

160

210

260

320

370

430

480

530

580

690

790

900

1000

1100

1200

1280

1380

1475

1530

1630

1730

1850

1950

2050

2160

2270

2380

2480

2660

2900

3375

3380

4300

4600

5200

5620

30

34

37

41

44

52

60

68

16

17

18

19

20

22

24

27

30

34

37

41

49

58

66

74

82

10

12

14

16

18

20

23

25

27

30

32

34

36

39

41

43

46

48

50

52

54

57

63

68

10

11

13

14

16

17

18

20

21

22

24

25

26

28

29

30

32

33

34

36

37

40

44

51

58

64

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

27

30

35

40

45

49

55

59

19

20

21

23

24

26

27

31

34

38

40

44

10

11

12

13

14

15

16

18

21

23

25

27

31

34

38

43

46

51

55

58

63

68

72

76

82

86

90

95

100

104

109

112

124

135

160

172

195

218

CP-97-03.6


3131313131

VISCOSITY CONVERSION CHART (Continued)VISCOSITY CONVERSION CHART (Continued)VISCOSITY CONVERSION CHART (Continued)VISCOSITY CONVERSION CHART (Continued)VISCOSITY CONVERSION CHART (Continued)P

ois

eP

ois

eP

ois

eP

ois

eP

ois

e

13.0

14.0

15.0

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

30.0

35.0

40.0

45.0

50.0

55.0

60.0

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

110.0

120.0

130.0

140.0

150.0

160.0

170.0

180.0

190.0

200.0

300.0

Ce

nti

po

ise

Ce

nti

po

ise

Ce

nti

po

ise

Ce

nti

po

ise

Ce

nti

po

ise

Du

Po

nt

Du

Po

nt

Du

Po

nt

Du

Po

nt

Du

Po

nt

Pa

rlin

7

Pa

rlin

7

Pa

rlin

7

Pa

rlin

7

Pa

rlin

7

Du

Po

nt

Du

Po

nt

Du

Po

nt

Du

Po

nt

Du

Po

nt

Pa

rlin

1

0P

arl

in

10

Pa

rlin

1

0P

arl

in

10

Pa

rlin

1

0

Fis

he

r 1

Fis

he

r 1

Fis

he

r 1

Fis

he

r 1

Fis

he

r 1

Fis

he

r 2

Fis

he

r 2

Fis

he

r 2

Fis

he

r 2

Fis

he

r 2

Fo

rd C

up

3

Fo

rd C

up

3

Fo

rd C

up

3

Fo

rd C

up

3

Fo

rd C

up

3

Fo

rd C

up

4

Fo

rd C

up

4

Fo

rd C

up

4

Fo

rd C

up

4

Fo

rd C

up

4

Ga

rdn

er

-G

ard

ne

r -

Ga

rdn

er

-G

ard

ne

r -

Ga

rdn

er

-H

old

t B

ub

ble

Ho

ldt

Bu

bb

leH

old

t B

ub

ble

Ho

ldt

Bu

bb

leH

old

t B

ub

ble

Ga

rdn

er

-G

ard

ne

r -

Ga

rdn

er

-G

ard

ne

r -

Ga

rdn

er

-L

ith

og

rap

hic

Lit

ho

gra

ph

icL

ith

og

rap

hic

Lit

ho

gra

ph

icL

ith

og

rap

hic

Kre

bs

Un

itK

reb

s

Un

itK

reb

s

Un

itK

reb

s

Un

itK

reb

s

Un

itK

UK

UK

UK

UK

U

Sa

yb

olt

Sa

yb

olt

Sa

yb

olt

Sa

yb

olt

Sa

yb

olt

Un

ive

rsa

l S

SU

Un

ive

rsa

l S

SU

Un

ive

rsa

l S

SU

Un

ive

rsa

l S

SU

Un

ive

rsa

l S

SU

Za

hn

1

Za

hn

1

Za

hn

1

Za

hn

1

Za

hn

1

Za

hn

2

Za

hn

2

Za

hn

2

Za

hn

2

Za

hn

2

Za

hn

3

Za

hn

3

Za

hn

3

Za

hn

3

Za

hn

3

Za

hn

4

Za

hn

4

Za

hn

4

Za

hn

4

Za

hn

4

Za

hn

5

Za

hn

5

Za

hn

5

Za

hn

5

Za

hn

5

Se

ars

Se

ars

Se

ars

Se

ars

Se

ars

Cra

ftsm

an

C

up

Cra

ftsm

an

C

up

Cra

ftsm

an

C

up

Cra

ftsm

an

C

up

Cra

ftsm

an

C

up

Din

C

up

4

Din

C

up

4

Din

C

up

4

Din

C

up

4

Din

C

up

4

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2300

2400

2500

3000

3500

4000

4500

5000

5500

6000

6500

7000

7500

8000

8500

9000

9500

10000

11000

12000

13000

14000

15000

16000

17000

18000

19000

20000

30000

X

Y

Z

Z-1

Z-2

Z-3

Z-4

Z-5

Z-6

1

2

3

4

5

95

96

98

100

101

103

105

109

114

121

129

133

136

6100

6480

7000

7500

8000

8500

9000

9400

9850

10300

10750

11200

11600

14500

16500

18500

21000

23500

26000

2800

30000

32500

35000

37000

39500

41000

43000

46500

51000

55005

60000

65000

67500

74000

83500

83500

88000

93000

140000

64

Note:Note:Note:Note:Note: All viscosity comparisons are as accurate as possible with existing information.Comparisons are made with a material having a specific gravity of 1.0.

CP-97-03.6

9040 Classic for the No. 2 Process Handgunf - Appendix

3232323232

LengthLengthLengthLengthLength

VOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBE(English Units)(English Units)(English Units)(English Units)(English Units)

I.D.I .D.I .D.I .D.I .D.

(inches)(inches)(inches)(inches)(inches) 5ft. (60")5ft. (60")5ft. (60")5ft. (60")5ft. (60")

1/8

3/16

1/4

5/16

3/8

1/2

2.4

5.4

9.7

15.1

21.7

38.6

.012

.028

.049

.077

.110

.196

cc/f t .cc/ f t .cc/ f t .cc/ f t .cc/ f t .

CrossCrossCrossCrossCross

SectionSectionSectionSectionSection

(in.( in.( in.( in.( in.22222))))) 10ft. (120")10ft. (120")10ft. (120")10ft. (120")10ft. (120") 15ft. (180")15ft. (180")15ft. (180")15ft. (180")15ft. (180") 25ft. (300")25ft. (300")25ft. (300")25ft. (300")25ft. (300") 50ft. (600")50ft. (600")50ft. (600")50ft. (600")50ft. (600")

.003 gal.

.4 fl. oz.

.007 gal.

.9 fl. oz.

.013 gal.

1.6 fl. oz.

.020 gal.

2.5 fl. oz.

.029 gal.

3.7 fl. oz.

.051 gal.

6.5 fl. oz.

.006 gal.

.8 fl. oz.

.014 gal.

1.8 fl. oz.

.025 gal.

3.3 fl. oz.

.040 gal.

5.1 fl. oz.

.057 gal.

7.3 fl. oz.

.102 gal.

13.1 fl. oz.

.010 gal.

1.2 fl. oz.

.022 gal.

2.8 fl. oz.

.038 gal.

4.9 fl. oz.

.060 gal.

7.6 fl. oz.

.086 gal.

11.0 fl. oz.

.153 gal.

19.6 fl. oz.

.016 gal.

2.0 fl. oz.

.036 gal.

4.6 fl. oz.

.064 gal.

8.2 fl. oz.

.100 gal.

12.7 fl. oz.

.143 gal.

18.4 fl. oz.

.255 gal.

32.6 fl. oz.

.032 gal.

4.1 fl. oz.

.072 gal.

9.2 fl. oz.

.127 gal.

16.3 fl. oz.

.199 gal.

25.5 fl. oz.

.287 gal.

36.7 fl. oz.

.510 gal.

65.3 fl. oz.

LengthLengthLengthLengthLength

VOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBEVOLUMETRIC CONTENT OF HOSE OR TUBE(Metric Units)(Metric Units)(Metric Units)(Metric Units)(Metric Units)

I.D.I .D.I .D.I .D.I .D.

(mm)(mm)(mm)(mm)(mm) 1.5m1.5m1.5m1.5m1.5m

3.6

5.6

6.8

8.8

10.2

24.6

36.3

60.8

10.2

24.6

36.3

60.8

cc/mcc/mcc/mcc/mcc/m

CrossCrossCrossCrossCross

SectionSectionSectionSectionSection

(mm(mm(mm(mm(mm22222))))) 3.0m3.0m3.0m3.0m3.0m 4.5m4.5m4.5m4.5m4.5m 6.0m6.0m6.0m6.0m6.0m 7.5m7.5m7.5m7.5m7.5m

15.3 cc

36.9 cc

54.5 cc

91.2 cc

30.5 cc

73.9 cc

109.0 cc

182.5 cc

45.8 cc

110.8 cc

163.4 cc

273.7 cc

61.1 cc

147.8 cc

217.9 cc

364.9 cc

76.3 cc

184.7 cc

272.4 cc

456.2 cc

CP-97-03.6


3333333333

DateDateDateDateDatekV Output TestkV Output TestkV Output TestkV Output TestkV Output Test

Pages 16 & 17 / YearlyPages 16 & 17 / YearlyPages 16 & 17 / YearlyPages 16 & 17 / YearlyPages 16 & 17 / YearlyGround TestGround TestGround TestGround TestGround Test

Pages 15 & 16 / YearlyPages 15 & 16 / YearlyPages 15 & 16 / YearlyPages 15 & 16 / YearlyPages 15 & 16 / Yearly

Figure 14: kV Output Test & Ground Test LogFigure 14: kV Output Test & Ground Test LogFigure 14: kV Output Test & Ground Test LogFigure 14: kV Output Test & Ground Test LogFigure 14: kV Output Test & Ground Test Log

CP-97-03.6

NOTES:NOTES:NOTES:NOTES:NOTES:

CP-97-03.6

MANUALMANUALMANUALMANUALMANUAL CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMARYYYYY

This manual was published to replace ServiceManual CP-97-03.5CP-97-03.5CP-97-03.5CP-97-03.5CP-97-03.5, 9040 Classic HighVoltage Power Supply for the No. 2 ProcessHandgun, to make the following changes:

1. Revised "Paint and Solvent Specifications"in the "Appendix" section.

Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)

Form No. CP-97-03.610/04

© 2004 Illinois Tool Works Inc. All rights reserved.Models and specifications subject to change without notice.

ManufacturingManufacturingManufacturingManufacturingManufacturing1910 North Wayne StreetAngola, Indiana 46703-9100Telephone: 260/665-8800Fax: 260/665-8516

Technical/Service AssistanceTechnical/Service AssistanceTechnical/Service AssistanceTechnical/Service AssistanceTechnical/Service AssistanceAutomotive Assembly and Tier I Telephone: 800/ 626-3565 Fax: 419/ 470-2040Industrial Systems Telephone: 800/ 233-3366 Fax: 419/ 470-2071Ransburg Guns Telephone: 800/ 233-3366 Fax: 419/ 470-2071

Technical Support Representative will direct you to the appropriate telephone numberTechnical Support Representative will direct you to the appropriate telephone numberTechnical Support Representative will direct you to the appropriate telephone numberTechnical Support Representative will direct you to the appropriate telephone numberTechnical Support Representative will direct you to the appropriate telephone numberfor ordering Spare Parts.for ordering Spare Parts.for ordering Spare Parts.for ordering Spare Parts.for ordering Spare Parts.

9040 classic high voltttage power supplyyy · pdf filehow to prevent damage to equipment or...

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