Ransburg 9040 User Manual

SERVICE MANUAL

ARCHIVE

CP-97-02.5CP-97-02.5

CP-97-02.5

CP-97-02.5CP-97-02.5
(Replaces CP-97-02.4)
May - 2008

9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL

9040 CLASSIC HIGH VOL

9040 CLASSIC HIGH VOL9040 CLASSIC HIGH VOL

(for the REA(for the REA

(for the REA

(for the REA(for the REA

TM TM

TM

TM TM

& M90& M90

& M90

& M90& M90

TMTM

TM

TMTM

Classic Coating Systems) Classic Coating Systems)

Classic Coating Systems)

Classic Coating Systems) Classic Coating Systems)

TT

AGE POWER SUPPLAGE POWER SUPPL

T

AGE POWER SUPPL

TT

AGE POWER SUPPLAGE POWER SUPPL

YY

Y

YY

MODEL:MODEL:

MODEL:

MODEL:MODEL:

76447-10X / REA-IV APPLICA76447-10X / REA-IV APPLICA

76447-10X / REA-IV APPLICA

76447-10X / REA-IV APPLICA76447-10X / REA-IV APPLICA
76447-12X / REA-III APPLICA76447-12X / REA-III APPLICA

76447-12X / REA-III APPLICA

76447-12X / REA-III APPLICA76447-12X / REA-III APPLICA
76447-13X / REA-III AUT76447-13X / REA-III AUT

76447-13X / REA-III AUT

76447-13X / REA-III AUT76447-13X / REA-III AUT
76447-14X / M90 CLASSIC APPLICA76447-14X / M90 CLASSIC APPLICA

76447-14X / M90 CLASSIC APPLICA

76447-14X / M90 CLASSIC APPLICA76447-14X / M90 CLASSIC APPLICA

OMAOMA

OMA

OMAOMA

IMPORIMPOR

IMPOR

IMPORIMPOR
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 in

starting on page 1, and all instructions in

starting on page 1, and all instructions instarting on page 1, and all instructions in
this manual. Keep this Service Manual forthis manual. Keep this Service Manual for

this manual. Keep this Service Manual for

this manual. Keep this Service Manual forthis manual. Keep this Service Manual for
future reference.future reference.

future reference.

future reference.future reference.

TT

OROR

T

OR

TT

OROR

TT

OROR

T

OR

TT

OROR

TICTIC

TIC

TICTIC

TT

ANTANT

T

ANT

TT

ANTANT

TT

OROR

T

OR

TT

OROR

: Before using this equipment,: Before using this equipment,

: Before using this equipment,

: Before using this equipment,: Before using this equipment,

Service Manual Price:Service Manual Price:

Service Manual Price: €

Service Manual Price:Service Manual Price:

25.00 (Euro)25.00 (Euro)

25.00 (Euro)

25.00 (Euro)25.00 (Euro)

$30.00 (U.S.)$30.00 (U.S.)

$30.00 (U.S.)

$30.00 (U.S.)$30.00 (U.S.)

NOTE:NOTE:

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NOTE: This manual has been changed from revision

NOTE:NOTE:

Reasons for this change are noted under “Manual Change Summary” inside the back
cover of this manual.

CP-97-02.4CP-97-02.4

CP-97-02.4 to revision

CP-97-02.4CP-97-02.4

CP-97-02.5 CP-97-02.5

CP-97-02.5.

CP-97-02.5 CP-97-02.5

CP-97-02.5

CONTENTSCONTENTS

ARCHIVE

CONTENTS

CONTENTSCONTENTS

SAFETY:SAFETY:

SAFETY:

SAFETY:SAFETY:

9040 Classic for REA & M90 Systems - Contents

PAGEPAGE

PAGE

PAGEPAGE

1-61-6

1-6

1-61-6

SAFETY PRECAUTIONS...........................................................................................................

HAZARDS / SAFEGUARDS.......................................................................................................

ATEXATEX

ATEX

ATEXATEX

EUROPEAN ATEX DIRECTIVE.................................................................................................

EUROPEAN ATEX LABELS.......................................................................................................

INTRODUCTION:INTRODUCTION:

INTRODUCTION:

INTRODUCTION:INTRODUCTION:

GENERAL DESCRIPTION.........................................................................................................

SPECIFICATIONS......................................................................................................................

9040 CLASSIC FOR REA / M90 FEATURES............................................................................

INSTALLATION:INSTALLATION:

INSTALLATION:

INSTALLATION:INSTALLATION:

LOCATION..................................................................................................................................

INPUT VOLTAGE SELECTION.................................................................................................

INPUT CONNECTIONS.............................................................................................................

EXTERNAL CONNECTIONS.....................................................................................................

TYPICAL REA AND M90 APPLICATOR INSTALLATIONS......................................................

OPERATION:OPERATION:

OPERATION:

OPERATION:OPERATION:

1
2-5

7-87-8

7-8

7-87-8

7
8

9-119-11

9-11

9-119-11

9-10
10
11

12-1612-16

12-16

12-1612-16

12
12
13
13-15
16

17-2017-20

17-20

17-2017-20

OPERATING CONTROLS.........................................................................................................

THEORY OF OPERATION........................................................................................................

OPERATING PROCEDURES....................................................................................................

MAINTENANCE:MAINTENANCE:

MAINTENANCE:

MAINTENANCE:MAINTENANCE:

ROUTINE PREVENTIVE MAINTENANCE................................................................................

TROUBLESHOOTING................................................................................................................

SERVICE LEVEL.........................................................................................................................

REPLACEMENT PROCEDURES..............................................................................................

TROUBLESHOOTING GUIDE...................................................................................................

TROUBLESHOOTING DIAGRAM.............................................................................................

9040 CLASSIC POWER SUPPLY BLOCK DIAGRAM.............................................................

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PARTS IDENTIFICATION:

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

9040 CLASSIC FOR REA AND M90 PARTS DIAGRAM / PARTS LIST.................................

RECOMMENDED SPARE PARTS............................................................................................

ACCESSORIES..........................................................................................................................

WARRANTY POLICIES:WARRANTY POLICIES:

WARRANTY POLICIES:

WARRANTY POLICIES:WARRANTY POLICIES:

LIMITED WARRANTY.................................................................................................................

17
18
18-19

21-3421-34

21-34

21-3421-34

21
21-24
24
25-29
30-31
32
33

35-3835-38

35-38

35-3835-38

35-36
37
37

3939

39

3939

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CP-97-02.5

9040 Classic for REA & M90 Systems - Safety

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SAFETYSAFETY

SAFETY

SAFETYSAFETY

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

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

W A R N I N G

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

!!

!

!!

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 youA WARNING! states information to alert you

A WARNING! states information to alert you

A WARNING! states information to alert youA WARNING! states information to alert you
to a situation that might cause serious injuryto a situation that might cause serious injury

to a situation that might cause serious injury

to a situation that might cause serious injuryto a situation that might cause serious injury
if 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 tells

A CAUTION! states information that tells

A CAUTION! states information that tellsA CAUTION! states information that tells
how to prevent damage to equipment or howhow to prevent damage to equipment or how

how to prevent damage to equipment or how

how to prevent damage to equipment or howhow to prevent damage to equipment or how
to avoid a situation that might cause minorto avoid a situation that might cause minor

to avoid a situation that might cause minor

to avoid a situation that might cause minorto avoid a situation that might cause minor
injury.injury.

injury.

injury.injury.

A NOTE is information relevant to theA NOTE is information relevant to the

A NOTE is information relevant to the

A NOTE is information relevant to theA NOTE is information relevant to the
procedure in progress.procedure in progress.

procedure in progress.

procedure in progress.procedure in progress.

While this manual lists standard specifications
and service procedures, some minor deviations
may be found between this literature and your
equipment. Differences in local codes and plant
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.

> The user

with the Safety Section in this manual and
the ITW Ransburg safety literature therein
identified.

> This manual

oughly understood by
operate, clean or maintain this equipment!
Special care should be taken to ensure that

WARNINGSWARNINGS

the

WARNINGS and safety requirements

WARNINGSWARNINGS
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to
codes and ordinances as well as
SAFETY STANDARD SAFETY STANDARD

SAFETY STANDARD prior to installing,

SAFETY STANDARD SAFETY STANDARD
operating, and/or servicing this equipment.

> 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.

MUSTMUST

MUST read and be familiar

MUSTMUST

MUSTMUST

MUST be read and thor-

MUSTMUST

ALLALL

ALL personnel who

ALLALL

ALLALL

ALL local building and fire

ALLALL

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

W A R N I N G

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

!!

!

!!

NFPA-33NFPA-33

NFPA-33

NFPA-33NFPA-33

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.

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CP-97-02.5

9040 Classic for REA & M90 Systems - Safety

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AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

Spray AreaSpray Area

Spray Area

Spray AreaSpray Area

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

Fire Hazard

Improper or inadequate operation
and maintenance procedures will
cause a fire hazard.

Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any safety
interlocks are disabled during
operation. Frequent power supply
shutdown indicates a problem in
the system requiring correction.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

The 76447 power supply MUST be installed in a
NON-hazardous location in accordance with NFPA-

33.

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

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

Smoking must never be allowed in the spray area.

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

When using solvents for cleaning:

Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.

Those used for general cleaning must have flash
points above 100

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.

o

F (37.8oC).

CP-97-02.5

The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
and OSHA requirements.

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9040 Classic for REA & M90 Systems - Safety

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AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

Spray AreaSpray Area

Spray Area

Spray AreaSpray Area

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

Electrostatic Arcing Ensure the Ground Wire Assembly is connected from the

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

power supply ground stud to a true earth ground.

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:

OperatorsOperators

A.

Operators must be grounded. Rubber soled

OperatorsOperators
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.

NOTE:NOTE:

NOTE: REFER TO NFPA-33, REGARDING OPERATOR

NOTE:NOTE:
GROUNDING.

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.

33

3

33

Do not touch applicator electrode while applicator is
energized.

CP-97-02.5

9040 Classic for REA & M90 Systems - Safety

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AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

General Use andGeneral Use and

General Use and

General Use andGeneral Use and
MaintenanceMaintenance

Maintenance

MaintenanceMaintenance

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

Improper operation or maintenance
may create a hazard.

Personnel must be properly trained
in the use of this equipment.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Personnel must be given training in accordance with
the requirements of NFPA-33.

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

Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33,and your insurance company requirements.

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.

Explosion Hazard/Explosion Hazard/

Explosion Hazard/

Explosion Hazard/Explosion Hazard/
IncompatibleIncompatible

Incompatible

IncompatibleIncompatible
MaterialsMaterials

Materials

MaterialsMaterials

Halogenated hydrocarbon
solvents
chloride and 1,1,1,-Trichloroethane
are not 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.

for example: methylene

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.

Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
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.

CP-97-02.5

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9040 Classic for REA & M90 Systems - Safety

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AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

Toxic SubstancesToxic Substances

Toxic Substances

Toxic SubstancesToxic Substances

Personnel SafetyPersonnel Safety

Personnel Safety

Personnel SafetyPersonnel Safety

Personnel SafetyPersonnel Safety

Personnel Safety

Personnel SafetyPersonnel Safety
(High Pressure
Equipment)

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

Certain material may be harmful if
inhaled, or if there is contact with
the skin.

Skin puncturing by sharp electrode. Take precautions to see that flesh is not punctured by

Fluid Injection Injury Never let any part of the body come in direct contact

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

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

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.

sharp electrode.

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.

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.

55

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CP-97-02.5

9040 Classic for REA & M90 Systems - Safety

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NOTESNOTES

NOTES

NOTESNOTES

CP-97-02.5

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9040 Classic for REA & M90 Systems - Atex

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EUROPEAN AEUROPEAN A

EUROPEAN A

EUROPEAN AEUROPEAN A

The following instructions apply to equipment
covered by certificate number Sira 08ATEX5040X:

1. The equipment may be used with flammable
gases and vapors with apparatus groups II and
with temperature class T6.

2. The equipment is only certified for use in
ambient temperatures in the range +12.8°C to
+40°C and should not be used outside this range.

3. Installation shall be carried out by suitably
trained personnel in accordance with the applicable
code of practice e.g. EN 60079-14:1997.

4. Inspection and maintenance of this equipment
shall be carried out by suitably trained personnel
in accordance with the applicable code of practice
e.g. EN 60079-17.

5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19.

6. Putting into service, use, assembling, and
adjustment of the equipment shall be fitted by
suitably trained personnel in accordance with the
manufacturer's documentation.

Refer to the "Table of Contents" of this service
manual:

a. Installation
b. Operation
c. Maintenance
d. Parts Identification

7. Components to be incorporated into or used as
replacement parts of the equipment shall be fitted
by suitably trained personnel in accordance with
the manufacturer's documentation.

TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6

TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6

TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6

8. The certification of this equipment relies upon
the following materials used in its construction:

If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility
of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring
that the type of protection provided by the equipment
is not compromised.

Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.

Suitable precautions: e.g. regular checks as part
of routine inspections or establishing from the
material's data sheets that it is resistant to specific
chemicals.

Refer to "Specifications" in the "Introduction"
section:

a. All fluid passages contain stainless steel

or nylon fittings.

b. High voltage cascade is encapsulated with

a solvent resistant epoxy.

9. A recapitulation of the certification marking is
detailed in the "Atex" section, on the next page,
drawing number: 76454-XX.

10. The characteristics of the equipment shall be
detailed e.g. electrical, pressure, and voltage
parameters.

The manufacturer should note that, on being put
into service, the equipment must be accompanied
by a translation of the instructions in the language
or languages of the country in which the equipment
is to be used and by the instructions in the original
language.

77

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CP-97-02.5

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76447-XXX 9040 Classic A76447-XXX 9040 Classic A

76447-XXX 9040 Classic A

76447-XXX 9040 Classic A76447-XXX 9040 Classic A

Product Marking DefinitionsProduct Marking Definitions

Product Marking Definitions

Product Marking DefinitionsProduct Marking Definitions

Ex Certificate Number: Sira 08ATEX5040X

Sira = Notified Body performing EC-type
examination
08 = Year of certification
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
040 = Document serial number
X = Special conditions for safe use apply

Product Marking

II 2 G

Ex = Specific marking of explosive protection
II = Equipment Group hazardous area charac­teristics
2 = Equipment Category
G = Type of explosive atmosphere (gases, vapors,
or mists)

TEXTEX

TEX

TEXTEX

Label 76454Label 76454

Label 76454

Label 76454Label 76454

EEx 0.24mJEEx 0.24mJ

EEx 0.24mJ = The 76447 9040 Classic Power

EEx 0.24mJEEx 0.24mJ
Supply is suitable for use in electrostatic spraying
installations complying with EN 50050 as they are
a Type A class with a discharge energy limit of

0.24mJ.

CP-97-02.5

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9040 Classic for REA & M90 Systems - Introduction

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INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

GENERAL DESCRIPTIONGENERAL DESCRIPTION

GENERAL DESCRIPTION

GENERAL DESCRIPTIONGENERAL DESCRIPTION

The ITW Ransburg REA ProcessThe ITW Ransburg REA Process

The ITW Ransburg REA Process

The ITW Ransburg REA ProcessThe ITW Ransburg REA Process

The REA Process is an air atomized method for
applying coatings to objects electrostatically. The
REA system applies a high voltage DC charge to
the applicator nozzle electrode, creating an
electrostatic field between the atomizer and the
target object. The target is electrically grounded
through its support which may be either stationary
or moving.

A regulated pressure fluid system delivers coating
material to the atomizer. At the atomizer, air is
applied which atomizes the coating material forming
a spray mist which, under the influence of the
electrostatic field, becomes electrically charged.
The charged particles are attracted to, and
deposited on, the target object. The forces between
the charged particles and the grounded target are
sufficient to turn most normal over-spray around
and deposit it on the side and back surfaces of the
target. Therefore, a high percentage of the spray
is deposited on the target.

The ITW Ransburg M90 ProcessThe ITW Ransburg M90 Process

The ITW Ransburg M90 Process

The ITW Ransburg M90 ProcessThe ITW Ransburg M90 Process

This is a combined air-airless atomization method
for electrostatically applying coatings to objects.
The M90 system applies a high voltage DC charge
to the applicator nozzle electrode, creating an
electrostatic field between the atomizer and the
target object. The target is electrically grounded
through its support, which may be either stationary
or moving.

the charged particles and the grounded target are
sufficient to turn most normal overspray around
and deposit it on the side and back surfaces of the
target. Thus, a high percentage of the spray is
deposited on the target.

The 9040 Classic High VThe 9040 Classic High V

The 9040 Classic High V

The 9040 Classic High VThe 9040 Classic High V
Power SupplyPower Supply

Power Supply

Power SupplyPower Supply

The 9040 Classic 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
Power Supply to the REA/M90 applicator through
a super flex 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 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 Power Supplies.

oltageoltage

oltage

oltageoltage

A regulated
coating material to the atomizer. There the coating
material is atomized by passing through an orifice
under pressure. The resulting spray mist then
becomes electrically charged under the influence
of the electrostatic field surrounding the atomizer.
The charged particles are attracted to and
deposited on the target object. The forces between

99

9

99

highhigh

high pressure fluid system delivers

highhigh

CP-97-02.5

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NOTENOTE

NOTE

NOTENOTE

> The 9040 Classic Power Supply is fac-

tory supplied with a cabinet latch that can
be opened using a slotted screwdriver. If
desired, the standard latch can be easily
replaced with a latch that requires the use
of a key to open. This key lock can be or­dered from: Austin Hardware, Inc., 8001
Central Ave. N. E., Minneapolis, MN
55432; 1-800-328-2423; Key Lock Part
Number: C8052-14A.

The 9040 Classic Power Supply is avail-The 9040 Classic Power Supply is avail-

The 9040 Classic Power Supply is avail-

The 9040 Classic Power Supply is avail-The 9040 Classic Power Supply is avail­able for hand and automatic REA andable for hand and automatic REA and

able for hand and automatic REA and

able for hand and automatic REA andable for hand and automatic REA and
M90 applicators as follows:M90 applicators as follows:

M90 applicators as follows:

M90 applicators as follows:M90 applicators as follows:

90409040

9040

90409040

Part #Part #

Part #

Part #Part #

76447-10X

76447-12X

76447-13X

76447-14X

Used WithUsed With

Used With

Used WithUsed With
Applicator TypeApplicator Type

Applicator Type

Applicator TypeApplicator Type

REA-IV Applicator

REA-III Solvent Applicator

REA-III Water Applicator

REA-III Automatic

M90 Classic Applicator

ApplicatorApplicator

Applicator

ApplicatorApplicator

##

#

##

70404

70929

72316

70393

77132

SPECIFICASPECIFICA

SPECIFICA

SPECIFICASPECIFICA

PhysicalPhysical

Physical

PhysicalPhysical

Height:Height:

Height: 14-inches

Height:Height:

Width:Width:

Width:

Width:Width:

Depth:Depth:

Depth: 6-inches

Depth:Depth:

Weight:Weight:

Weight: 24-lbs.

Weight:Weight:

ElectricalElectrical

Electrical

ElectricalElectrical

INPUTINPUT

INPUT

INPUTINPUT

Voltage:Voltage:

Voltage:

Voltage:Voltage:

Current:Current:

Current: 0.6/0.3 Amps AC

Current:Current:

Frequency:Frequency:

Frequency: 50/60 Hertz

Frequency:Frequency:

Wattage:Wattage:

Wattage: 60 Watts (maximum)

Wattage:Wattage:

OUTPUTOUTPUT

OUTPUT

OUTPUTOUTPUT

Voltage:Voltage:

Voltage:

Voltage:Voltage:

TIONSTIONS

TIONS

TIONSTIONS

12-inches

90-264 VAC

0-65kV DC (76447-10x)
0-85kV DC (76447-14x)
0-90kV DC (76447-12x)
0-100kV DC (76447-13x)

NOTENOTE

NOTE

NOTENOTE

> Except where indicated, this manual is

applicable to all models of the 9040 Classic
Power Supply for the REA/M90 Systems.

Current:Current:

Current: 200 Microamps (maximum)

Current:Current:

PneumaticPneumatic

Pneumatic

PneumaticPneumatic

Supply Air:Supply Air:

Supply Air: 100 psi maximum

Supply Air:Supply Air:

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Figure 1: 9040 Classic Power Supply Features for the REA/M90 SystemsFigure 1: 9040 Classic Power Supply Features for the REA/M90 Systems

Figure 1: 9040 Classic Power Supply Features for the REA/M90 Systems

Figure 1: 9040 Classic Power Supply Features for the REA/M90 SystemsFigure 1: 9040 Classic Power Supply Features for the REA/M90 Systems

1111

11

1111

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INSTINST

INST

INSTINST

> The 9040 Classic Power Supply

be located outside the hazardous area.
(See NFPA-33, OSHA, and ITW Ransburg
Bulletin - "Operating Your Electrostatic
Coating System Safely".)

> The user

with the "SAFETY" section of this manual.

> This manual

oughly understood by
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
local building and fire codes and ordinances
as well as NFPA-33 and OSHA prior to
installing, operating, and/or servicing this
equipment.

ALLAALLA

ALLA

ALLAALLA

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

W A R N I N G

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

!!

!

!!

MUSTMUST

MUST read and be familiar

MUSTMUST

TIONTION

TION

TIONTION

MUSTMUST

MUST be read and thor-

MUSTMUST

ALLALL

ALL personnel who

ALLALL

MUSTMUST

MUST

MUSTMUST

ALLALL

ALL

ALLALL

shown in Figure 2. In either case, the power
supply MUST be mounted in an upright position.
DO NOT DO NOT

DO NOT lay the power supply on its side or back.

DO NOT DO NOT

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

C A U T I O N

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

!!

!

!!

DO NOTDO NOT

>

DO NOT locate the power supply

DO NOTDO NOT
near or adjacent to heat producing equip­ment such as ovens, high wattage lamps,
etc.

Figure 2: Wall Mount BracketsFigure 2: Wall Mount Brackets

Figure 2: Wall Mount Brackets

Figure 2: Wall Mount BracketsFigure 2: Wall Mount Brackets

NOTENOTE

NOTE

NOTENOTE

> As each installation is unique, this infor-
mation is intended to provide general instal­lation information for the 9040 Classic Power
Supply. Consult your authorized ITW Rans­burg distributor for specific directions per­taining to the installation of your equipment.

LOCALOCA

LOCA

LOCALOCA

Install the 9040 Classic 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, but as close to
the applicator as possible to minimize the length of
high voltage cable. The power supply may be free
standing on any flat surface or wall mounted by
rotating the wall mount brackets (supplied) as

TIONTION

TION

TIONTION

INPUTINPUT

INPUT

INPUTINPUT
SELECTIONSELECTION

SELECTION

SELECTIONSELECTION

The 9040 Classic 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.

> 9040 units shipped from the factory for
115 VAC input will have a 72771-06, 1 amp
front panel fuse installed. While 9040 units
shipped from the factory for 230 VAC input
will have a 72771-01, 0.5 amp front panel
fuse installed. If the other input is required,
it is recommended that the fuse be changed
in order to keep the same level of protec­tion. Both fuses are shipped with 9040
Power Supplies.

VOL VOL

VOL

VOL VOL

NOTENOTE

NOTE

NOTENOTE

TT

AGEAGE

T

AGE

TT

AGEAGE

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Safety GroundSafety Ground

Safety Ground

INPUT CONNECTIONSINPUT CONNECTIONS

INPUT CONNECTIONS

INPUT CONNECTIONSINPUT CONNECTIONS

Plug the AC line cord into a properly grounded
AC outlet.

NOTENOTE

NOTE

NOTENOTE

> In general, conduit must be used for ap-
proved 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.

EXTERNALEXTERNAL

EXTERNAL

EXTERNALEXTERNAL
CONNECTIONSCONNECTIONS

CONNECTIONS

CONNECTIONSCONNECTIONS

NOTENOTE

NOTE

NOTENOTE

> When connecting external wires to the

9040 Classic Power Supply, route the wir­ing through the external wiring grommet
located on the side panel.

Safety GroundSafety 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.

!!

!

!!

> The Ground Wire Assembly

connected from the Power Supply Ground
Stud to a true earth ground.

InterlocksInterlocks

Interlocks

InterlocksInterlocks

!!

!

!!

ALWAYSALWAYS

>

ALWAYS ensure that high voltage is

ALWAYSALWAYS

OFFOFF

OFF before flushing the spray gun with

OFFOFF
solvent.
with high voltage
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
OFFOFF

OFF signal with the solvent flush signal.

OFFOFF

NEVER NEVER

NEVER flush the spray applicator

NEVER NEVER

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

C A U T I O N

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

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

W A R N I N G

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

ONON

ON, as this is a severe fire

ONON

MUSTMUST

MUST be

MUSTMUST

High VHigh V

High V

High VHigh V
Cable ConnectionCable Connection

Cable Connection

Cable ConnectionCable Connection

Remove the plastic protective plug from the High
Voltage Cable Connector and squirt enough
dielectric oil (70863-00 (supplied)) into the high
voltage tube to cover the electrical contact point.

> Squirting 70863-00 dielectric oil down

the high voltage tube significantly reduces
corona discharge that can cause deterio­ration of the high voltage connection com­ponents.

With a clean, dry cloth, wipe the end of the high
voltage cable. Insert the high voltage cable into
the high voltage cable connector and tighten the
cable nut securely.

1313

13

1313

oltage (High Voltage (High V

oltage (High V

oltage (High Voltage (High V

NOTENOTE

NOTE

NOTENOTE

oltage)oltage)

oltage)

oltage)oltage)

As outlined in NFPA-33 and OSHA, the AC power
line must be series interlocked with both the
exhaust fan and conveyor. To interlock the 9040
Classic 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.

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

W A R N I N G

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

!!

!

!!

ALWAYSALWAYS

>

ALWAYS

ALWAYSALWAYS
supply is unplugged from its AC outlet
before working with any internal wiring.

double check that the power

CP-97-02.5

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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 3.
rated for at least 1 Amp at 240 volts AC.rated for at least 1 Amp at 240 volts AC.

rated for at least 1 Amp at 240 volts AC.

rated for at least 1 Amp at 240 volts AC.rated for at least 1 Amp at 240 volts AC.

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

Figure 3: Terminal Block One (1TB)Figure 3: Terminal Block One (1TB)

Figure 3: Terminal Block One (1TB)

Figure 3: Terminal Block One (1TB)Figure 3: Terminal Block One (1TB)

The interlock contacts should beThe interlock contacts should be

The interlock contacts should be

The interlock contacts should beThe interlock contacts should be

When the applicator is triggered, the resulting air
flow closes the contacts of the air flow switch,
thereby activating high voltage at the applicator.

Pneumatic ConnectionsPneumatic Connections

Pneumatic Connections

Pneumatic ConnectionsPneumatic Connections

(76447-13x)(76447-13x)

(76447-13x)

(76447-13x)(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.

External High VExternal High V

External High V

External High VExternal High V

If a method of high voltage triggering, other than
the factory supplied method, is required, the 9040
Classic power supply allows for external high
voltage control from a PLC, pressure switch, air
flow 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:

oltage Controloltage Control

oltage Control

oltage Controloltage Control

External Relay ContactsExternal Relay Contacts

External Relay Contacts

External Relay ContactsExternal 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 ConnectionsPneumatic Connections

Pneumatic Connections

Pneumatic ConnectionsPneumatic Connections

(76447-10x, -12x, & -14x)(76447-10x, -12x, & -14x)

(76447-10x, -12x, & -14x)

(76447-10x, -12x, & -14x)(76447-10x, -12x, & -14x)

Connect the Air Filter Assembly (supplied) to the
IN port of the air flow switch on the side of the 9040
Classic power supply. Connect regulated (100
psi maximum) factory air to the other end of the Air
Filter Assembly. Be sure that the fittings remain
clean and are securely tightened. Attach the
applicator air line to the OUT port of the air flow
switch.

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.
control device contacts must be rated for atcontrol device contacts must be rated for at

control device contacts must be rated for at

control device contacts must be rated for atcontrol device contacts must be rated for at
least 100 millamps at 15 volts DC.least 100 millamps at 15 volts DC.

least 100 millamps at 15 volts DC.

least 100 millamps at 15 volts DC.least 100 millamps at 15 volts DC.

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

TheThe

The

TheThe

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9040 Classic for REA & M90 Systems - Installation

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External Overload ResetExternal Overload Reset

External Overload Reset

External Overload ResetExternal Overload Reset

The 9040 Classic 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.

3. Remove the factory installed jumper from 1TB­5 to 1TB-6 and replace with contact wires of the
external reset device.
contacts must be rated for at least 100contacts must be rated for at least 100

contacts must be rated for at least 100

contacts must be rated for at least 100contacts must be rated for at least 100
milliamps at 15 volts DC. The contacts ofmilliamps at 15 volts DC. The contacts of

milliamps at 15 volts DC. The contacts of

milliamps at 15 volts DC. The contacts ofmilliamps at 15 volts DC. The contacts of
the external reset device must be normallythe external reset device must be normally

the external reset device must be normally

the external reset device must be normallythe external reset device must be normally
closed.closed.

closed.

closed.closed.

The external reset deviceThe external reset device

The external reset device

The external reset deviceThe external reset device

NOTESNOTES

NOTES

NOTESNOTES

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

1515

15

1515

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Figure 4: Typical REA Applicator InstallationFigure 4: Typical REA Applicator Installation

Figure 4: Typical REA Applicator Installation

Figure 4: Typical REA Applicator InstallationFigure 4: Typical REA Applicator Installation

CP-97-02.5

Figure 5: Typical M90 Applicator InstallationFigure 5: Typical M90 Applicator Installation

Figure 5: Typical M90 Applicator Installation

Figure 5: Typical M90 Applicator InstallationFigure 5: Typical M90 Applicator Installation

1616

16

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9040 Classic for REA & M90 Systems - Operation

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OPERAOPERA

OPERA

OPERAOPERA

TIONTION

TION

TIONTION

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

W A R N I N G

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

!!

!

!!

> The user

with the
"Safety" Section "Safety" Section

"Safety" Section in this manual and the

"Safety" Section "Safety" Section
ITW Ransburg safety literature therein
identified
9040 Classic power supply.

1717

17

1717

MUST MUST

MUST read and be familiar

MUST MUST

Safety Precautions Safety Precautions

Safety Precautions and

Safety Precautions Safety Precautions

BEFORE OPERATING BEFORE OPERATING

BEFORE OPERATING the

BEFORE OPERATING BEFORE OPERATING

Figure 6: Operating ControlsFigure 6: Operating Controls

Figure 6: Operating Controls

Figure 6: Operating ControlsFigure 6: Operating Controls

!!

!

!!

> The electrical discharge, which is

available from the charging electrode of the
applicator, must not exceed 0.25 mJ of
energy. To achieve this limit, any flow of
energy from the paint supply through the
paint line to the applicator electrode
be prevented by grounding the paint line at
the applicator handle or body.
the applicator is actually grounded
FOREFORE

FORE operating it! (See the appropriate

FOREFORE
applicator manual.) If improper readings are
obtained, check that the power supply is
grounded. (See "Ground Test Procedure" in
the "Maintenance" section of this manual).

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

W A R N I N G

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

MUSTMUST

MUST

MUSTMUST

Verify that

BE-BE-

BE-

BE-BE-

CP-97-02.5

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THEORTHEOR

THEOR

THEORTHEOR

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.

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.

YY

OF OPERA OF OPERA

Y

OF OPERA

YY

OF OPERA OF OPERA

TIONTION

TION

TIONTION

4. 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).

OPERAOPERA

OPERA

OPERAOPERA
PROCEDURESPROCEDURES

PROCEDURES

PROCEDURESPROCEDURES

1. Ensure that the AC power, pneumatics and
high voltage cables are connected as described in
the "Installation" section of this manual.

> Check that the power supply is properly

grounded!

2. Be sure that the high voltage adjustment knob
is turned FULLY counter-clockwise.

TINGTING

TING

TINGTING

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

C A U T I O N

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

!!

!

!!

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:

1. When air flows through the flow switch, the
switch contacts close connecting 1TB-6 and 7
together, thereby providing voltage to the REA-III,
REA-IV, and M90 Classic applicators.

2. When pressure signals are supplied to the
pressure switches, the switch contacts close
connecting 1TB-6 and 7 together, thereby providing
voltage to the REA-III automatic applicator.

3. 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.

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 REA-III, REA-IV, and M90
Classic applicators is activated by supplying
adequate air to the flow switch when the applicator
is triggered. The voltage to the REA III Automatic
applicator is activated by supplying adequate
pressure signals to the power supply pressure
switches.

5. Turn the voltage adjustment knob to the desired
operating point as indicated by the kilovolt and
microamp meters.

Kilovolt and Microamp MetersKilovolt and Microamp Meters

Kilovolt and Microamp Meters

Kilovolt and Microamp MetersKilovolt 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 electrode.

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High VHigh V

High V

High VHigh V

The high voltage adjustment knob allows infinite
control of the spray applicator electrode voltage
between 0 and rated kV.

Overload Indicator/Reset ButtonOverload Indicator/Reset Button

Overload Indicator/Reset Button

Overload Indicator/Reset ButtonOverload 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 7, in the "Maintenance" section of this
manual, 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.

oltage Adjustment Knoboltage Adjustment Knob

oltage Adjustment Knob

oltage Adjustment Knoboltage Adjustment Knob

NOTENOTE

NOTE

NOTENOTE

> Power supplies for applicators are

shipped from the factory with the overload
circuit OFF, while those for automatic appli­cators are shipped with the overload circuit
ON. This is because during normal use,
manually operated applicators may come in
close proximity to the part, causing an over­load which requires the operator to cease
the painting operation while going to reset
the overload. In addition, the operator will
notice when a failed part may be causing
the spray applicator to operate at less than
optimum performance, thus the overload
circuit is not necessary for this purpose.
Automatic applicators, however, typically
have a fixed distance between electrode
and target and

thus it is not likely that the spray applicator
would come into close proximity with the
part during normal use. If it should, then it is
desired that an overload occur to alert main­tenance so that the condition 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.

When turning the overload circuit ON for applicator
units it may be necessary to adjust the setpoint at
which overload occurs. If so, contact your
authorized ITW Ransburg representative for
assistance.

High VHigh V

High V

High VHigh V

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 (flow switch, pressure switch, PC contact,
etc.) has not been triggered. If a failure mode
should occur that would attempt to send high
voltage to the applicator, even though the high
voltage trigger has not been activated, the PC
board will shut down and enter an overload
condition. If repeated overloads occur, every time
the overload reset button is pushed, open the
cabinet door and see if the red LED (LED1, see
Figure 7, in the "Maintenance" section of this
manual for location) 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 VHigh V

High V

High VHigh V

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

AC Power ON IndicatorAC Power ON Indicator

AC Power ON Indicator

AC Power ON IndicatorAC Power ON Indicator

The green AC power ON LED will light when the
AC Power ON/OFF switch is in the ON position.

oltage Safety Circuitoltage Safety Circuit

oltage Safety Circuit

oltage Safety Circuitoltage Safety Circuit

oltage ON Indicatoroltage ON Indicator

oltage ON Indicator

oltage ON Indicatoroltage ON Indicator

("Note" continued in next column)

1919

19

1919

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NOTESNOTES

NOTES

NOTESNOTES

CP-97-02.5

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9040 Classic for REA & M90 Systems - Operation

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MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

ROUTINE PREVENTIVEROUTINE PREVENTIVE

ROUTINE PREVENTIVE

ROUTINE PREVENTIVEROUTINE PREVENTIVE
MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

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 dielectric oil (70863-00) is
covering the electrical contact point in the high
voltage tube. If not, add oil as needed.

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 7 for location
of test jumper JP4.)

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

C A U T I O N

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

!!

!

!!

> 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.

> Squirting 70863-00 dielectric oil down

the HV tube significantly reduces corona
discharge that can cause deterioration of
the HV connection components.

TROUBLESHOOTINGTROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTINGTROUBLESHOOTING

PC Board TPC Board T

PC Board T

PC Board TPC Board T

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

2121

21

2121

NOTENOTE

NOTE

NOTENOTE

est Jumperest Jumper

est Jumper

est Jumperest Jumper

Figure 7: Main PC BoardFigure 7: Main PC Board

Figure 7: Main PC Board

Figure 7: Main PC BoardFigure 7: Main PC Board

Ground TGround T

Ground T

Ground TGround T

Equipment Required:Equipment Required:

Equipment Required:

Equipment Required: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.

est Procedureest Procedure

est Procedure

est Procedureest Procedure

CP-97-02.5

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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.

NOTENOTE

NOTE

NOTENOTE

> 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.

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 Tester).

6. Insert the Test Probe High Voltage cable into
the power supply high voltage tube until it bottoms
out.

NOTENOTE

NOTE

NOTENOTE

> Ensure that the Test Probe high volt-

age cable makes good contact both inside
the Test Probe and inside the Power Sup­ply High Voltage Tube.

kV Output TkV Output T

kV Output T

kV Output TkV Output T

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.

Equipment Required:Equipment Required:

Equipment Required:

Equipment Required:Equipment Required:

- Calibrated ITW Ransburg 20791 High Voltage
Test Probe & Meter

kV Output Test ProcedurekV Output Test Procedure

kV Output Test Procedure

kV Output Test ProcedurekV Output Test Procedure

1. Turn AC power to the power supply

2. Remove the high voltage cable from the power
supply.

!!

!

!!

estest

est

estest

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

W A R N I N G

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

OFFOFF

OFF.

OFFOFF

> Whenever removing high voltage cables

from equipment, ground the plug end of the
cable(s) by contacting the plug to electrical
ground.
been grounded. This will eliminate the
possibility of residual charge causing electri­cal shock.

DO NOT DO NOT

DO NOT touch the plug until it has

DO NOT DO NOT

7. Turn the power supply ON.

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" to locate the
specific problem.

9. Disconnect the 20791 Test Probe 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) TCurrent Output (SCI) T

Current Output (SCI) T

Current Output (SCI) TCurrent Output (SCI) T

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.

estest

est

estest

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Equipment Required:Equipment Required:

Equipment Required:

Equipment Required:Equipment Required:

- Test Resistor (16688-01)

- Current Meter (76652-02)

1. Turn AC power to the power supply

OFFOFF

OFF.

OFFOFF

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.

2. Remove the high voltage cable from the power
supply.

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

W A R N I N G

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

!!

!

!!

> Whenever removing high voltage cables

from equipment, ground the plug end of the
cable(s) by contacting the plug to electrical
ground.
been grounded. This will eliminate the
possibility of residual charge causing electri­cal shock.

3. Turn the high voltage adjust knob FULLY
counter-clockwise.

4. Connect one end of the test resistor (16688-

01) through the current meter (76652-02) to ground
as shown in Figure 8. Insert the other end of the
test resistor into the HV output tube of the
power supply.

DO NOT DO NOT

DO NOT touch the plug until it has

DO NOT DO NOT

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.

POWER SUPPLIES ANDPOWER SUPPLIES AND

POWER SUPPLIES AND

POWER SUPPLIES ANDPOWER SUPPLIES AND
SCI VALUESSCI VALUES

SCI VALUES

SCI VALUESSCI VALUES

SCI RangeSCI Range

SCI Range

SCI RangeSCI Range

Power SupplyPower Supply

Power Supply

Power SupplyPower Supply

76447-10x, REA-IV
76447-12x, REA-III Applicator
76447-13x, REA-III Automatic
76447-14x, M90 Classic Applicator

(in μA)(in μA)

(in μA)

(in μA)(in μA)

90 - 140 μA
120 - 170 μA
120 - 170 μA

70 - 115 μA

!!

!

!!

> 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 (76652-02)
should read within the ranges noted in Figure 7. 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

2323

23

2323

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

C A U T I O N

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

Figure 8: Current Output TestFigure 8: Current Output Test

Figure 8: Current Output Test

Figure 8: Current Output TestFigure 8: Current Output Test

CP-97-02.5

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Bench TBench T

Bench T

Bench TBench T

Equipment Required:Equipment Required:

Equipment Required:

Equipment Required: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.

> The troubleshooting procedure outlined

in the "Troubleshooting Guide" requires
measurement of voltage potentials that can
cause
proper measuring procedures are not
followed. For this reason, proper trouble­shooting should
with specific test equipment by qualified
electronics technicians or authorized ITW
Ransburg representatives.

estingesting

esting

estingesting

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

W A R N I N G

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

!!

!

!!

SERIOUS BODILY INJURY SERIOUS BODILY INJURY

SERIOUS BODILY INJURY if

SERIOUS BODILY INJURY SERIOUS BODILY INJURY

ONLY ONLY

ONLY be accomplished

ONLY ONLY

NOTENOTE

NOTE

NOTENOTE

> Before going through the trouble of a

complete bench test, jumper JP4 on the
main PC Board to trigger the high voltage
and see if the suspected problem goes
away. If it does, replace the high voltage
trigger device (flow switch, pressure
switch, PC contact, etc.) or repair the in­ternal wiring of the power supply con­nected to the trigger device, and test
again. If the problem does not go away,
then proceed with a bench test.

SERVICE LEVELSERVICE LEVEL

SERVICE LEVEL

SERVICE LEVELSERVICE 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.)

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
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.

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).

!!

!

!!

> The High Voltage Multiplier and high

voltage cable contain significant capaci­tance that will store charge.
approximately 10 seconds for this charge
to bleed off

OR REMOVINGOR REMOVING

door

OR REMOVING the high voltage

OR REMOVINGOR REMOVING
cable from the power supply or spray
applicator.

+

/- 10% depending on the test

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

C A U T I O N

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

ALLOWALLOW

ALLOW

ALLOWALLOW

BEFORE BEFORE

BEFORE opening the cabinet

BEFORE BEFORE

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

W A R N I N G

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

!!

!

!!

ALWAYSALWAYS

>

ALWAYS turn power to the power

ALWAYSALWAYS
supply
its outlet, remove the front panel fuse, and
lock the power supply out before making
repairs or replacements.

>

the printed circuit board! Do not attempt to
make repairs beyond those described. All
others should be made
Ransburg service personnel.

OFFOFF

OFF, unplug the electrical cord from

OFFOFF

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

C A U T I O N

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

!!

!

!!

DO NOT DO NOT

DO NOT attempt to make repairs to

DO NOT DO NOT

ONLYONLY

ONLY by ITW

ONLYONLY

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REPLACEMENTREPLACEMENT

REPLACEMENT

REPLACEMENTREPLACEMENT
PROCEDURESPROCEDURES

PROCEDURES

PROCEDURESPROCEDURES

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 1FUFront Panel Fuse 1FU

Front Panel Fuse 1FU

Front Panel Fuse 1FUFront Panel Fuse 1FU

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

2. Remove screwdriver and fuse holder will slide
out.

3. Remove fuse from fuse holder and replace with
new fuse (see "Parts Identification" in this manual
for 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 F2PC Board Fuse F2

PC Board Fuse F2

PC Board Fuse F2PC Board Fuse F2

(Refer to Figure 6 for Fuse Location)(Refer to Figure 6 for Fuse Location)

(Refer to Figure 6 for Fuse Location)

(Refer to Figure 6 for Fuse Location)(Refer to Figure 6 for Fuse Location)

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).

ON/OFF Switch 1SWON/OFF Switch 1SW

ON/OFF Switch 1SW

ON/OFF Switch 1SWON/OFF Switch 1SW

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

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

W A R N I N G

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

!!

!

!!

ALWAYSALWAYS

>

ALWAYS double check that the control

ALWAYSALWAYS
unit is unplugged from its AC outlet
FOREFORE

FORE working with any internal wiring.

FOREFORE

2. Remove the four (4) quick connect terminals
from the rear of ON/OFF switch 1SW.

NOTENOTE

NOTE

NOTENOTE

> 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:

BE-BE-

BE-

BE-BE-

> A spare F2 PC board fuse, included

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.

2525

25

2525

NOTENOTE

NOTE

NOTENOTE

FromFrom

From

FromFrom

1FU-2

1TB-N
1TB-S1
1TB-S2

6. Secure cabinet door and plug power supply
back in.

ToTo

To

ToTo

1SW-1

1SW-2
1SW-1A
1SW-2A

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AC Line CordAC Line Cord

AC Line Cord

AC Line CordAC Line Cord

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

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

W A R N I N G

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

!!

!

!!

ALWAYSALWAYS

ALWAYS double check that the control

>

ALWAYSALWAYS
unit is unplugged from its AC outlet
FOREFORE

FORE working with any internal wiring.

FOREFORE

2. Using a screwdriver, disconnect damaged line
cord from 1TB-L1, 1TB-N, and 1TB-GROUND.

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

4. Insert new line cord (see "Parts Identification"
section of this manual for part numbers) through
grommet and connect to 1TB as follows:

BE-BE-

BE-

BE-BE-

6. Attach two (2) wires to new flow switch (see
"Parts Identification" section of this manual for
ordering information) terminals (it does not matter
which one goes where).

7. With flow switch terminals pointing towards the
cabinet door, reach into cabinet and push new flow
switch threads through mounting holes.

8. Secure flow switch to side panel with two (2)
hex nuts.

9. Secure cabinet door and plug power supply
back in.

10. Reconnect air lines to flow switch.

Pressure SwitchPressure Switch

Pressure Switch

Pressure SwitchPressure Switch

(76447-13x)(76447-13x)

(76447-13x)

(76447-13x)(76447-13x)

1. Disconnect pressure signal input line from
pressure switch.

1TB-GROUND

1TB-N

1TB-L1

5. Tighten side panel grommet.

6. Secure cabinet door and plug power supply
back in.

Flow Switch 1FSFlow Switch 1FS

Flow Switch 1FS

Flow Switch 1FSFlow Switch 1FS
(76447-10x, -12x, & -14x)(76447-10x, -12x, & -14x)

(76447-10x, -12x, & -14x)

(76447-10x, -12x, & -14x)(76447-10x, -12x, & -14x)

1. Disconnect air lines from flow switch.

2. Ensure power supply is unplugged from AC
outlet and open cabinet door.

3. Remove two (2) wires from flow switch
terminals.

4. Remove two (2) hex nuts from flow switch
threads.

Line Cord Ground

Line Cord Neutral/Common

Line Cord Hot/Line

2. Ensure power supply is unplugged from AC
outlet and open 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.

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.

5. Pull out defective flow switch.

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8. Secure cabinet door and plug power supply
back in.

9. Reconnect pressure signal input line to
pressure switch.

High VHigh V

High V

High VHigh V

oltage Multiplieroltage Multiplier

oltage Multiplier

oltage Multiplieroltage Multiplier

NOTENOTE

NOTE

NOTENOTE

> 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.

9. Plug connector 1PL back into the High Voltage
Multiplier.

10. Secure the cabinet door and plug the power
supply back in.

11. Reinstall the high voltage cable.

LED Display BoardLED Display Board

LED Display Board

LED Display BoardLED Display Board

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.

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.

5. Reconnect connector 9PL to main PC Board.

6. Secure the cabinet door and plug the power
supply back in.

Kilovolt (kV) orKilovolt (kV) or

Kilovolt (kV) or

Kilovolt (kV) orKilovolt (kV) or
Microamp (μA) MeterMicroamp (μA) Meter

Microamp (μA) Meter

Microamp (μA) MeterMicroamp (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.

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Main PC BoardMain PC Board

Main PC Board

Main PC BoardMain 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.

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

C A U T I O N

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

!!

!

!!

DO NOTDO NOT

DO NOT remove the PC Board from

>

DO NOTDO NOT
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.

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:

FromFrom

From

FromFrom

7PL-1
7PL-4
7PL-5

7. Secure the cabinet door and plug the power
supply back in.

8. Reinstall adjust knob using 1/16" Allen wrench.

ToTo

To

ToTo

1POT-1
1POT-2
1POT-3

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

6. Secure cabinet door and plug power supply
back in.

High VHigh V

High V

High VHigh V
PotentiometerPotentiometer

Potentiometer

PotentiometerPotentiometer

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.

oltage Adjustoltage Adjust

oltage Adjust

oltage Adjustoltage Adjust

NOTENOTE

NOTE

NOTENOTE

> It is recommended that the three (3)

wires be tagged with their respective ter­minal connections to 1POT before
unsoldering.

Power Supply 1SUPPower Supply 1SUP

Power Supply 1SUP

Power Supply 1SUPPower Supply 1SUP

1. Ensure 9040 Classic Power Supply is
unplugged from AC outlet and open the cabinet
door.

2. Remove the four (4) screws from the 1SUP
power supply cover plate and remove the plate.

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

W A R N I N G

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

!!

!

!!

ALWAYSALWAYS

>

ALWAYS double check that the power

ALWAYSALWAYS
supply is unplugged from its AC outlet
BEFOREBEFORE

BEFORE removing the cover plate from

BEFOREBEFORE
power supply 1SUP.

3. Remove connectors 8PL and 10PL from power
supply 1SUP.

4. Remove the four (4) cover plate standoffs from
power supply 1SUP and remove the power supply
from the unit.

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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.

6. Connect connectors 8PL and 10PL to new
power supply and reinstall cover plate.

7. Secure cabinet door and plug power supply
back in.

NOTESNOTES

NOTES

NOTESNOTES

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TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

General ProblemGeneral Problem

General Problem

General ProblemGeneral Problem

AC Power ONAC Power ON

AC Power ON

AC Power ONAC Power ON
Indicator (GreenIndicator (Green

Indicator (Green

Indicator (GreenIndicator (Green
LED) Does NotLED) Does Not

LED) Does Not

LED) Does NotLED) Does Not
Light when ON/OFFLight when ON/OFF

Light when ON/OFF

Light when ON/OFFLight when ON/OFF
Switch is ONSwitch is ON

Switch is ON

Switch is ONSwitch is ON

Possible CausePossible Cause

Possible Cause

Possible CausePossible Cause

1. Front panel fuse 1FU or PC board
fuse F2 defective

2. Connector 7PL or 9PL not properly
plugged into main PC board

3. Improper input line voltage

4. Improper exhaust fan or conveyor
interlock connections

5. Defective ON/OFF switch 1SW

6. Defective power supply 1SUP

7. Defective LED display board

SolutionSolution

Solution

SolutionSolution

1. Replace defective fuse.

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

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

No or Low kVNo or Low kV

No or Low kV

No or Low kVNo or Low kV
Output at SprayOutput at Spray

Output at Spray

Output at SprayOutput at Spray
Applicator when HVApplicator when HV

Applicator when HV

Applicator when HVApplicator when HV
ON Indicator (RedON Indicator (Red

ON Indicator (Red

ON Indicator (RedON Indicator (Red
LED) is LitLED) is Lit

LED) is Lit

LED) is LitLED) is Lit

1. High voltage adjust knob not set to
proper value

2. Connector 6PL or 1PL not properly
plugged into respective locations

3. Defective spray applicator or high
voltage cable

4. Loose or broken wire in power
supply

5. Main PC board defective

6. Defective high voltage multiplier

1. Set high voltage adjust knob to proper value.

2. Properly attach connector.

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

5. Disconnect 1PL from high voltage multiplier
and plug into LTST5000 Tester. If improper
readings are obtained, replace main PC board.

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.

(Continued On Next Page)

CP-97-02.5

3030

30

3030

9040 Classic for REA & M90 Systems - Maintenance

ARCHIVE

TROUBLESHOOTING GUIDE (Cont.)TROUBLESHOOTING GUIDE (Cont.)

TROUBLESHOOTING GUIDE (Cont.)

TROUBLESHOOTING GUIDE (Cont.)TROUBLESHOOTING GUIDE (Cont.)

General ProblemGeneral Problem

General Problem

General ProblemGeneral Problem

No kV Output atNo kV Output at

No kV Output at

No kV Output atNo kV Output at
Spray ApplicatorSpray Applicator

Spray Applicator

Spray ApplicatorSpray Applicator
and High Voltageand High Voltage

and High Voltage

and High Voltageand High Voltage
ON Indicator (RedON Indicator (Red

ON Indicator (Red

ON Indicator (RedON Indicator (Red
LED) is Not LitLED) is Not Lit

LED) is Not Lit

LED) is Not LitLED) is Not Lit

Power SupplyPower Supply

Power Supply

Power SupplyPower Supply
OverloadsOverloads

Overloads

OverloadsOverloads
ExcessivelyExcessively

Excessively

ExcessivelyExcessively

Possible CausePossible Cause

Possible Cause

Possible CausePossible Cause

1. Connector 6PL not properly
plugged into PC board

2. Improper air signal to high voltage
trigger device (air flow switch,
pressure switch, etc.)

3. Defective high voltage trigger
device (flow switch, pressure
switch, etc.) or wiring

4. Main PC board defective

1. Parts are too close to the spray
applicator

2. Overload set point set too sensitive

3. Defective spray applicator

4. Defective high voltage cable

5. Main PC board defective

SolutionSolution

Solution

SolutionSolution

1. Properly attach connector.

2. Turn signal on and adjust to proper setting.

3. Short PC board jumper JP4. If high voltage
comes on, replace high voltage trigger device
or repair wiring from trigger device to PC board.

4. Replace main PC board.

1. Ensure sufficient distance between spray
applicator and parts.

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(Warning: Contact end of cable will be at

(Warning: Contact end of cable will be at

(Warning: Contact end of cable will be at(Warning: Contact end of cable will be at
high voltage; after testing, dischargehigh voltage; after testing, discharge

high voltage; after testing, discharge

high voltage; after testing, dischargehigh voltage; after testing, discharge
contact by contacting to ground beforecontact by contacting to ground before

contact by contacting to ground before

contact by contacting to ground beforecontact by contacting to ground before
touching!)touching!)

touching!)

touching!)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.

Component NotComponent Not

Component Not

Component NotComponent Not
Working, but kVWorking, but kV

Working, but kV

Working, but kVWorking, but kV
Output OKOutput OK

Output OK

Output OKOutput OK

3131

31

3131

6. Defective high voltage multiplier

1. Wiring to/from component loose
or broken

2. Defective component

6. If 1 thru 5 above are OK, replace the high
voltage Multiplier.

1. Repair loose or broken wire.

2. Replace component.

CP-97-02.5

9040 Classic for REA & M90 Systems - Maintenance

ARCHIVE

Figure 9: Troubleshooting DiagramFigure 9: Troubleshooting Diagram

Figure 9: Troubleshooting Diagram

Figure 9: Troubleshooting DiagramFigure 9: Troubleshooting Diagram

CP-97-02.5

3232

32

3232

9040 Classic for REA & M90 Systems - Maintenance

ARCHIVE

3333

33

3333

Figure 10: 9040 Classic Power Supply Block DiagramFigure 10: 9040 Classic Power Supply Block Diagram

Figure 10: 9040 Classic Power Supply Block Diagram

Figure 10: 9040 Classic Power Supply Block DiagramFigure 10: 9040 Classic Power Supply Block Diagram

CP-97-02.5

9040 Classic for REA & M90 Systems - Maintenance

ARCHIVE

NOTESNOTES

NOTES

NOTESNOTES

CP-97-02.5

3434

34

3434

9040 Classic for REA & M90 Systems - Parts Identification

ARCHIVE

PP

P

PP

ARAR

AR

ARAR

TS IDENTIFICATS IDENTIFICA

TS IDENTIFICA

TS IDENTIFICATS IDENTIFICA

TIONTION

TION

TIONTION

3535

35

3535

Figure 11: 9040 Classic for REA and M90 - Parts DiagramFigure 11: 9040 Classic for REA and M90 - Parts Diagram

Figure 11: 9040 Classic for REA and M90 - Parts Diagram

Figure 11: 9040 Classic for REA and M90 - Parts DiagramFigure 11: 9040 Classic for REA and M90 - Parts Diagram

CP-97-02.5

9040 Classic for REA & M90 Systems - Parts Identification

ARCHIVE

9040 CLASSIC for REA9040 CLASSIC for REA

9040 CLASSIC for REA

9040 CLASSIC for REA9040 CLASSIC for REA

Item #Item #

Item #

Item #Item #

1

2

3 76434-01 ON/OFF Switch 1SW
4 70556-03 High Voltage Adjust Potentiometer 1POT
5 76436-91 Kilovolt (kV) Meter 1M
6 76436-92 Microamp (μA) Meter 2M
7

8 75337-05 Power Supply, 18 VDC 1SUP
9 LSME0082-04 Fuse, PC Board, Slow Blow, 4 Amp F2
10

11 6262-00 AC Line Cord
12 70539-00 Ground Wire Assembly
13 76455-02 LED Display Board
14

15 5627-00 Rubber Feet

Part #Part #

Part #

Part #Part #

76892-10 For 76447-10X, REA-IV Applicator (70404)
76892-12 For 76447-12X, REA-III Applicator (70929, 72316)
76892-13 For 76447-13X, REA-III Automatic (70393)
76892-15 For 76447-14X, M90 Classic Applicator (77132)

76304-02 For 76447-10X, 65kV
76304-07 For 76447-14X, 85kV
76304-01 For 76447-12X and 76447-13X, 90kV

13742-01 For 76447-10X and 76447-12X
13742-02 For 76447-14X
25766-106 Pressure Switch for 76447-13X 1PS, 2PS

72771-06 Slow Blow, 1 Amp, 110-120 VAC Input 1FU
72771-01 Slow Blow, 0.5 Amp, 220-240 VAC Input 1FU

76442-01 Reset Switch, Normally Closed
76441-00 Lens, Yellow
76443-01 Bulb

& M90 - P & M90 - P

& M90 - P

& M90 - P & M90 - P

DescriptionDescription

Description

DescriptionDescription

PC Board and Heat Sink Assembly:PC Board and Heat Sink Assembly:

PC Board and Heat Sink Assembly:

PC Board and Heat Sink Assembly:PC Board and Heat Sink Assembly:

High Voltage Multiplier (Oil-Filled):High Voltage Multiplier (Oil-Filled):

High Voltage Multiplier (Oil-Filled):

High Voltage Multiplier (Oil-Filled):High Voltage Multiplier (Oil-Filled):

Air Flow Switch Assembly:Air Flow Switch Assembly:

Air Flow Switch Assembly: 1FS

Air Flow Switch Assembly:Air Flow Switch Assembly:

Fuse, Front Panel:Fuse, Front Panel:

Fuse, Front Panel:

Fuse, Front Panel:Fuse, Front Panel:

Overload Indicator and Reset Switch Assembly:Overload Indicator and Reset Switch Assembly:

Overload Indicator and Reset Switch Assembly:

Overload Indicator and Reset Switch Assembly:Overload Indicator and Reset Switch Assembly:

ARAR

TS LISTTS LIST

AR

TS LIST

ARAR

TS LISTTS LIST

(Figure 1 (Figure 1

(Figure 1

(Figure 1 (Figure 1

1)1)

1)

1)1)

NotationNotation

Notation

NotationNotation

CP-97-02.5

3636

36

3636

9040 Classic for REA & M90 Systems - Parts Identification

ARCHIVE

9040 CLASSIC for REA9040 CLASSIC for REA

9040 CLASSIC for REA

9040 CLASSIC for REA9040 CLASSIC for REA

DescriptionDescription

Description

DescriptionDescription

Fuse, Front Panel
Deluxe Test Kit

Test Resistor

Fuse, PC Board
PC Board Assembly,
REA-IV Hand
PC Board Assembly,
REA-III Hand
PC Board Assembly,
REA-III Auto
PC Board Assembly,
M90 Classic
High Voltage Multiplier
High Voltage Multiplier
High Voltage Multiplier
Power Supply Tester

Part #Part #

Part #

Part #Part #

72771-06
76652-04

16688-01

LSME0082-04
76892-10

76892-12

76892-13

76892-15

76304-01
76304-02
76304-07
LTST5000-00

& M90 - RECOMMENDED SP & M90 - RECOMMENDED SP

& M90 - RECOMMENDED SP

& M90 - RECOMMENDED SP & M90 - RECOMMENDED SP

No. of ApplicatorsNo. of Applicators

No. of Applicators

No. of ApplicatorsNo. of Applicators

1
1

1

2
1

1

1

1

1
1
1
1

1
1

1

4
1

1

1

1

1
1
1
1

2
1

1

6
1

1

1

1

1
1
1
1

2
1

For Troubleshooting

1

For Troubleshooting

8
2

2

2

2

1
1
1
1

For 76447-12 & -13

For Troubleshooting

ARE PARE P

ARE P

ARE PARE P

Purposes Only

Purposes Only

For 76447-10

For 76447-12

For 76447-13

For 76447-14

For 76447-10
For 76447-14

Purposes Only

ARAR

AR

ARAR

NotesNotes

Notes

NotesNotes

TSTS

TS

TSTS

9040 CLASSIC for REA & M90 - ACCESSORIES9040 CLASSIC for REA & M90 - ACCESSORIES

9040 CLASSIC for REA & M90 - ACCESSORIES

9040 CLASSIC for REA & M90 - ACCESSORIES9040 CLASSIC for REA & M90 - ACCESSORIES

DescriptionDescription

Description

DescriptionDescription

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

Part #Part #

Part #

Part #Part #

LTST5000-00
76652-01
76652-02
76652-04
16688-01

3737

37

3737

CP-97-02.5

9040 Classic for REA & M90 Systems - Parts Identification

ARCHIVE

NOTESNOTES

NOTES

NOTESNOTES

CP-97-02.5

3838

38

3838

9040 Classic for REA & M90 Systems - Warranty Policies

ARCHIVE

WW

ARRANTYARRANTY

W

ARRANTY

WW

ARRANTYARRANTY

LIMITED WLIMITED W

LIMITED W

LIMITED WLIMITED W

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 RANS-THE USE OF OTHER THAN ITW RANS-

THE USE OF OTHER THAN ITW RANS-

THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS­BURG APPROVED PARTS, VOID ALLBURG APPROVED PARTS, VOID ALL

BURG APPROVED PARTS, VOID ALL

BURG APPROVED PARTS, VOID ALLBURG APPROVED PARTS, VOID ALL
WARRANTIES.WARRANTIES.

WARRANTIES.

WARRANTIES.WARRANTIES.

ARRANTYARRANTY

ARRANTY

ARRANTYARRANTY

POLICIES POLICIES

POLICIES

POLICIES POLICIES

ITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATION

ITW RANSBURG'S ONLY OBLIGATION

ITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATION
UNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACE

UNDER THIS WARRANTY IS TO REPLACE

UNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACE
PARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSE

PARTS THAT HAVE FAILED BECAUSE

PARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSE
OF FAULTY WORKMANSHIP OR MATER-OF FAULTY WORKMANSHIP OR MATER-

OF FAULTY WORKMANSHIP OR MATER-

OF FAULTY WORKMANSHIP OR MATER-OF FAULTY WORKMANSHIP OR MATER­IALS. THERE ARE NO IMPLIED WARRAN-IALS. THERE ARE NO IMPLIED WARRAN-

IALS. THERE ARE NO IMPLIED WARRAN-

IALS. THERE ARE NO IMPLIED WARRAN-IALS. THERE ARE NO IMPLIED WARRAN­TIES NOR WARRANTIES OF EITHERTIES NOR WARRANTIES OF EITHER

TIES NOR WARRANTIES OF EITHER

TIES NOR WARRANTIES OF EITHERTIES NOR WARRANTIES OF EITHER
MERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR A

MERCHANTABILITY OR FITNESS FOR A

MERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-

PARTICULAR PURPOSE. ITW RANS-

PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS­BURG ASSUMES NO LIABILITY FORBURG ASSUMES NO LIABILITY FOR

BURG ASSUMES NO LIABILITY FOR

BURG ASSUMES NO LIABILITY FORBURG ASSUMES NO LIABILITY FOR
INJURY, DAMAGE TO PROPERTY ORINJURY, DAMAGE TO PROPERTY OR

INJURY, DAMAGE TO PROPERTY OR

INJURY, DAMAGE TO PROPERTY ORINJURY, DAMAGE TO PROPERTY OR
FOR CONSEQUENTIAL DAMAGES FORFOR CONSEQUENTIAL DAMAGES FOR

FOR CONSEQUENTIAL DAMAGES FOR

FOR CONSEQUENTIAL DAMAGES FORFOR CONSEQUENTIAL DAMAGES FOR
LOSS OF GOODWILL OR PRODUCTIONLOSS OF GOODWILL OR PRODUCTION

LOSS OF GOODWILL OR PRODUCTION

LOSS OF GOODWILL OR PRODUCTIONLOSS OF GOODWILL OR PRODUCTION
OR INCOME, WHICH RESULT FROM USEOR INCOME, WHICH RESULT FROM USE

OR INCOME, WHICH RESULT FROM USE

OR INCOME, WHICH RESULT FROM USEOR INCOME, WHICH RESULT FROM USE
OR MISUSE OF THE EQUIPMENT BYOR MISUSE OF THE EQUIPMENT BY

OR MISUSE OF THE EQUIPMENT BY

OR MISUSE OF THE EQUIPMENT BYOR MISUSE OF THE EQUIPMENT BY
PURCHASER OR OTHERS.PURCHASER OR OTHERS.

PURCHASER OR OTHERS.

PURCHASER OR OTHERS.PURCHASER OR OTHERS.

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, ASSO-WRAPPING THE APPLICATOR, ASSO-

WRAPPING THE APPLICATOR, ASSO-

WRAPPING THE APPLICATOR, ASSO-WRAPPING THE APPLICATOR, ASSO­CIATED VALVES AND TUBING, ANDCIATED VALVES AND TUBING, AND

CIATED VALVES AND TUBING, AND

CIATED VALVES AND TUBING, ANDCIATED VALVES AND TUBING, AND
SUPPORTING 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 NON­APPROVED COVERING, WILL VOID THISAPPROVED COVERING, WILL VOID THIS

APPROVED COVERING, WILL VOID THIS

APPROVED COVERING, WILL VOID THISAPPROVED COVERING, WILL VOID THIS
WARRANTY.WARRANTY.

WARRANTY.

WARRANTY.WARRANTY.

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

AIR BEARING ROTATORS: Fifteen thousand
(15,000) hours or three (3) years, whichever occurs
first. Warranty period begins on the date of
purchase.

EXCLUSIONS:EXCLUSIONS:

EXCLUSIONS:

EXCLUSIONS: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.

3939

39

3939

CP-97-02.5

MANUALMANUAL

ARCHIVE

MANUAL

MANUALMANUAL

This manual was published to replace Service
Manual
Power Supply for the REA/REM/M90 Classic
Coating Systems, to make the following changes:

1. Added " " to the "Front Cover".

2. Added "Atex" section.

CP-97-02.4,CP-97-02.4,

CP-97-02.4,

CP-97-02.4,CP-97-02.4,

9040 Classic High Voltage

CHANGE SUMMAR CHANGE SUMMAR

CHANGE SUMMAR

CHANGE SUMMAR CHANGE SUMMAR

YY

Y

YY

CP-97-02.5

Service Manual Price:Service Manual Price:

ARCHIVE

Service Manual Price: €

Service Manual Price:Service Manual Price:

ManufacturingManufacturing

Manufacturing

ManufacturingManufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: [phone]
Fax: [phone]

Technical/Service AssistanceTechnical/Service Assistance

Technical/Service Assistance

Technical/Service AssistanceTechnical/Service Assistance
Automotive Assembly and Tier I Telephone: [phone] Fax: [phone]
Industrial Systems Telephone: [phone] Fax: [phone]
Ransburg Guns Telephone: [phone] Fax: [phone]
www.itwransburg.com

25.00 (Euro)25.00 (Euro)

25.00 (Euro)

25.00 (Euro)25.00 (Euro)

$30.00 (U.S.)$30.00 (U.S.)

$30.00 (U.S.)

$30.00 (U.S.)$30.00 (U.S.)

Technical Support Representative will direct you to the appropriate telephone numberTechnical Support Representative will direct you to the appropriate telephone number

Technical Support Representative will direct you to the appropriate telephone number

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

for ordering Spare Parts.

for ordering Spare Parts.for ordering Spare Parts.

© 2008 Illinois Tool Works Inc. All rights reserved.
Models and specifications subject to change without notice.

Form No. CP-97-02.5
Litho in U.S.A.
05/08