Ransburg 9060 User Manual
SERVICE MANUAL
CP-13-01.1
April — 2013
for 80104 External Cascade
9060 Power Supply Kit
MODEL: 80143-XXX for use with
Esta-Quick Applicator AEMD600
(Atex Approved)
MODEL: 80146-XXX for use with
Evolver SE (Non-Approved)
IMPORTANT: Before using this equipment, carefully read
SAFETY PRECAUTIONS, starting on page 1, and all instructions
in this manual. Keep this Service Manual for future reference.
Service Manual Price: $50.00 (U.S.)
Service Manual Price: $50.00 (U.S.)
Service Manual Price: $50.00 (U.S.)Service Manual Price: $50.00 (U.S.)
CP-13-01.1
9060 Power Supply Kit - Contents
CONTENTS
SAFETY: 1-6
SAFETY PRECAUTIONS ......................................................................................................... 1
HAZARDS / SAFEGUARDS................................................................................................... 2-6
INTRODUCTION: 8-15
GENERAL DESCRIPTION ........................................................................................................ 8
THE RANSBURG SPRAY PROCESS ...................................................................................... 8
9060 CASCADE LOW VOLTAGE CONTROL UNIT KIT ........................................................... 8
9060 CASCADE LOW VOLTAGE CONTROL UNIT KIT 80143 AND 80146 ............................. 8
9060 LOW VOLTAGE CONTROL UNIT KIT PART STRUCTURE ............................................ 9
SPECIFICATIONS .................................................................................................................. 10
CASCADE CONTROL UNIT FEATURES .......................................................................... 11-13
EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6 ................................................ 14-15
INSTALLATION: 16-18
TYPICAL INSTALLATION 80143-XXX .................................................................................... 17
HIGH VOLTAGE CABLE A10560-XXD ................................................................................... 18
LOW VOLTAGE CABLE 79338-XX ......................................................................................... 18
OPERATION: 19
OPERATING PROCEDURES ................................................................................................. 19
MAINTENANCE: 20
SPARE PARTS 21
WARRANTY POLICIES: 22
LIMITED WARRANTY............................................................................................................. 22
PAGE
CP-13-01.1
9060 Power Supply Kit - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your Ransburg products. This
manual contains information that is important
for you to know and understand. This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help
you recognize this information, we use the following symbols. Please pay particular attention
to these sections.
A WARNING! states information to alert you
to a situation that might cause serious injury if instructions are not followed.
A CAUTION! states information that tells
how to prevent damage to equipment or
how to avoid a situation that might cause
minor injury.
A NOTE is information relevant to the procedure in progress.
While this manual lists standard specifications
and service procedures, some minor deviations may be found between this literature and
your equipment. Differences in local codes and
plant requirements, material delivery requirements, etc., make such variations inevitable.
Compare this manual with your system installation drawings and appropriate Ransburg
equipment manuals to reconcile such differences.
The user MUST read and be familiar
with the Safety Section in this manual and
the Ransburg safety literature therein
identified.
This manual MUST be read and thor-
oughly understood by ALL personnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGS and safety requirements
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to ALL local building and fire
codes and ordinances as well as NFPA-33
SAFETY STANDARD, LATEST EDITION,
prior to installing, operating, and/or servicing this equipment.
The hazards shown on the following
pages may occur during the normal use
of this equipment. Please read the hazard chart beginning on page 2.
!
!
W A R N I N G
W A R N I N G
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
Ransburg representative or Ransburg.
1 CP-13-01.1
9060 Power Supply Kit - Safety
AREA
Tells where haz-
HAZARD
Tells what the hazard is.
ards may occur.
Spray Area 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 or Controller shutdown indicates a problem in the
system requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
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 solvents used for cleaning must have a
flash point at minimum of 5oC (9oF) greater
than the ambient temperature. It is the end
users responsibility to insure this condition is
met.).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained during cleaning operations using flammable
or combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance
of 1 inch for every 10KV of output voltage is required at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipment modifications may cause fire or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
OSHA, local, country, and European Health and
Safety Norms.
CP-13-01.1 2
9060 Power Supply Kit - Safety
AREA
Tells where haz-
HAZARD
Tells what the hazard is.
ards may occur.
Spray Area Explosion 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 or Controller shutdown indicates a
problem in the system requiring
correction.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance
of 1 inch for every 10KV of output voltage is required at all times.
Unless specifically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Test only in areas free of flammable or combustible materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding
section of the equipment manual. Protection
against inadvertent arcing that is capable of
causing fire or explosion is lost if the current overload sensitivity is not properly set. Frequent
power supply shutdown indicates a problem in the
system which requires correction.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
Always turn the control panel power off prior to
flushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no objects are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance
with NFPA-33, EN 50176.
Have fire extinguishing equipment readily available
and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
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, EN Norms and your insurance
company requirements.
3 CP-13-01.1
9060 Power Supply Kit - Safety
AREA
Tells where hazards may occur.
Spray Area / High
Voltage Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting coating materials.
Inadequate grounding will cause
a spark hazard. A spark can
ignite many coating materials
and cause a fire or explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The
resistance between the part and earth ground must
not exceed 1 meg ohm. (Refer to NFPA-33.)
Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding straps
on wrists or legs may be used to assure adequate
ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the palm
section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
Grounded conductive flooring must be provided in
the spray area.
Always turn off the power supply prior to flushing,
cleaning, or working on spray system equipment.
Unless specifically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
CP-13-01.1 4
9060 Power Supply Kit - Safety
AREA
Tells where hazards may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is utilized in the process. Arcing in
the vicinity of flammable or
combustible materials may occur. Personnel are exposed to
high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a fire or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shutdown indicates a problem in the
system which requires correction.
An electrical arc can ignite coating materials and cause a fire or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specifically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 50176.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of flammable or combustible material.
Testing may require high voltage to be on, but only
as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Toxic Substances
Chemical Hazard
Certain materials may be harmful if inhaled, or if there is contact with the skin.
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.
5 CP-13-01.1
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