Man 41151 en 06

9MC Plasma Control Unit
9MCD Plasma Distribution Unit

Plasma Spraying
Product Manual
MAN 41151 EN 06
2008 Sulzer Metco
Supplier of this component:
Sulzer Metco (US) Inc.

1101 Prospect Avenue
Westbury, NY 11590
Phone +1 516 334 1300
Fax +1 516 338 2414
Find your Sulzer Metco sales office:
www.sulzermetco.com
Manual no.
Version
Reason for revision
Date
MAN 41151 EN 06
Revise to current documentation standards;

separate parts list (PL 41153).
06/2008
9MC Plasma Control Unit / 9MCD Plasma Distribution Unit
Intended Use
The 9MC Plasma Control Unit provides automatic operation, monitoring, and control of the Type 9MB Plasma Spray Gun, as well as other
Sulzer Metco two-hose plasma guns and extensions. It is intended for
use in an Atmosphere [Air] Plasma Spraying (APS) process. The 9MC
Plasma Control Unit cannot be used in a Vacuum Plasma Spray (VPS)
or High-Velocity Oxygenated Fuel (HVOF) process.
The 9MCD Plasma Distribution Unit is required with the 9MC Plasma
Control Unit. The 9MCD Plasma Distribution Unit delivers electrical
power from the system power supply and cooling water from the heat
exchanger, to the spray gun, via combination coaxial hose/cables.
For specific information, see Technical Data on page 27.
Designation
Characteristics
Automatic and semi-automatic plasma

control console.
Thermal Spray Processes
Atmosphere [Air] Plasma Spraying

(APS)
Compatible Spray Guns
3MB
9MB
11MB
iPro-901
F4
Compatible Powder Feeders
9MP
9MP-CL20
5MPE2
Twin 10-C
DANGER
Do not use the 9MC
Plasma Control Unit for
any application or purpose other than that
described in this manual. Improper use or
application can result in
equipment damage or
personal injury.
The 9MC Plasma Control Unit shall not be
used in any High-Velocity Oxygenated Fuel
(HVOF), Vacuum
Plasma Spray (VPS), or
Low Pressure Plasma
Spray (LPPS) process.
1. Requires modified 9MC Plasma Control Unit.

2. Requires 5MPA Feeder Interface.
Information About This Manual

The information in this manual is intended to ensure safe and reliable
operation of the 9MC Plasma Control Unit. A copy of this manual
should always be kept near your system.
Orientation Help
Table of Contents at the front of the manual
Index at the rear of the manual
MAN 41151 EN 06
Additional Documents
9MC Plasma Control Unit / 9MCD Plasma Distribution Unit Parts

List, PL 41153
Electrical Schematic and Gas Flow Diagrams, DIA 74602
Safety 9M Plasma Spray System, MAN 41154
Copyright Restrictions
The reproduction, duplication or distribution of this manual by any
means, in whole or in part, without prior written permission from Sulzer
Metco, is strictly prohibited.
Intended Audience
All personnel who work with the 9MC Plasma Control Unit should be
familiar with the material in this manual. The specific topics of interest
are outlined in the table below.
Read the relevant chapters, especially Chapter 1 Safety, before working with the 9MC Plasma Control Unit.
Chapter
1 Safety
Intended Audience
Everyone working with the 9MC
Plasma Control Unit.

2 Product Description
Everyone working with the 9MC
Plasma Control Unit.

3 Installation and Commissioning
Installation Engineers
4 Operation
Operators, Maintenance Engineers
5 Service
Maintenance Engineers
6 Maintenance
7 Troubleshooting
Sulzer Metco reserves the right to make improvements to the 9MC

Plasma Control Unit without prior notice.
MAN 41151 EN 06
Table of Contents
1
Safety
1.1
1.2
1.3
1.4
Safety Symbols..................................................................................................7
Authorized Use ..................................................................................................9
General Safety Regulations...............................................................................9
Specific Safety Regulations...............................................................................9
Product Description
2.1
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.3.9
2.4
Overview .........................................................................................................14
Principles of Operation ....................................................................................15
9MC Plasma Control Unit ................................................................................15
9MCD Plasma Distribution Unit .......................................................................15
Function of Components .................................................................................16
System Status Monitor ...................................................................................16
Gas Control Unit Front Panel ..........................................................................17
Gas Control Unit Rear Connections ...............................................................19
Electrical Control Unit Front Panel .................................................................20
Electrical Control Unit Rear Connections .......................................................22
Electrical Control Unit Internal Switches..........................................................23
Distribution Unit Front Panel ...........................................................................24
Distribution Unit Rear Connections ................................................................25
Remote Operator Pendant ..............................................................................26
Technical Data ................................................................................................27
Installation and Commissioning
3.1
3.2
3.2.1
3.2.2
3.2.3
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
Environmental / Site Requirements .................................................................28

Connection and Setup .....................................................................................28
Gas Connections .............................................................................................28
Electrical and Cooling Water Connections ......................................................30
Voltage Divider ................................................................................................32
Interfacing with External Equipment ...............................................................33
Remote Operation Interface ............................................................................34
Remote Operator Pendant ..............................................................................36
Robot Interface ................................................................................................37
Multiple System Interface ................................................................................38
Remote Emergency Stop (E-STOP) Interface.................................................39
Exhaust Interlock .............................................................................................40
Remote Alarms and Robot Faults ...................................................................40
Operation
4.1
4.2
4.3
4.3.1
4.3.2
4.4
Startup .............................................................................................................41
Shutdown ........................................................................................................42
Operating Procedures .....................................................................................43
Manual Test Functions ....................................................................................43
Automatic Operation........................................................................................44
Cooling Water Setpoint Adjustment.................................................................45
MAN 41151 EN 06
4.5
Status Messages .............................................................................................46
Service
Maintenance
6.1
6.2
6.3
Feedback Board ..............................................................................................49

Safety Interlocks / Maintenance Overrides......................................................50
Electrode Gap Adjustment...............................................................................51
Troubleshooting
7.1
7.2
Power-On Check .............................................................................................52

Power-On Troubleshooting .............................................................................53
Index .............................................................................................................. 55
MAN 41151 EN 06
Safety
This chapter contains important safety information. Please read it prior

to working with the spray process. Observe all safety regulations.
1.1
Safety Symbols
The following safety symbols may be found in Sulzer Metco documentation, such as technical manuals and product labeling, to alert the
user to the presence of important operating instructions, safety considerations and special instructions. Whenever these symbols are
encountered, the user should read, understand and proceed in accordance with the definition provided below.
General Information and Warnings
Presentation of general, but important information which

must be read and understood prior to proceeding.
INFO
General hazard warning which can result in minor personal injury or minor damage to machinery.
CAUTION
Warning of hazard which can result in severe personal
injury or severe damage to machinery.
WARNING
Danger! Failure to comply can result in severe personal
injuries or death.
DANGER
Mandatory Requirements
Mandatory requirement not covered by other symbols.
MAN 41151 EN 06
Additional Symbols
Personal Protection
Sound attenuating ear protection must
be worn.
Hand protection must be worn.
Respiratory protection must be worn.
Face protection (welding gear) must be

worn.
Protective clothing must be worn.
Eye protection must be worn.
Head protection must be worn.
Protective footgear must be worn.
Keep hands, hair, clothing and tools

away from moving parts.
Hazardous Materials and Conditions

Explosion hazard, explosive material
present.
Strong electromagnetic fields present.
Flammable material or presence of

high temperatures.
Poisonous substance present
High voltage or risk of electric shock

present.
High pressure warning.
Ultraviolet, infra-red or other damaging light radiation present.
Warning of laser present.
Noise hazard present.
Do not stack warning.
Heavy weight present above.
Electrical ground is not present.
Prohibitions
Personnel with pacemaker not permitted in area.
MAN 41151 EN 06
1.2
Authorized Use
This system is intended for the sole use of thermal coating of workpieces in atmosphere. The plasma spray system is designed and constructed in accordance with generally acknowledged safety regulations and codes. The plasma spray gun must be used only for
depositing thermal spray coatings following all guidelines specified
herein, other supporting equipment manuals, and all applicable regulations and codes. Failure to do so may result in hazardous or unsafe
conditions.
1.3
General Safety Regulations
Use of Sulzer Metco original spare parts is strongly recommended.

Use of non-OEM parts may void Sulzer Metco's warranty and result in
reduced performance of the equipment.
WARNING
Do not use the 9MC
Plasma Control Unit for
any application or purpose other than that
described in this manual. Improper use or
application can result in
equipment damage or
personal injury.
It is recommended that all personnel connected with thermal spraying

become familiar with the safety practices outlined in this document as
well as the established standards and regulations which have been set
by local, state and federal health officials (e.g., OSHA). All regulations
should be thoroughly read and understood to ensure proper compliance.
There are several basic precautions for thermal spraying which should
always be observed. These include: good housekeeping, proper material/gas storage and handling practices, use and maintenance of
equipment, operator training, sufficient exhausting of gases and fumes
and personal protective equipment (clothing, ear, eyes and breathing
(respirator) protection).
All personnel responsible for the safe use of this equipment must read
and understand this instruction manual.
In addition, the operator of this equipment must receive personal
instructions in its use. A thorough understanding of the operation,
maintenance, and safety requirements of this equipment is required.
1.4
Specific Safety Regulations
Eye Protection
The plasma spray gun generates electromagnetic radiation in the form
of visible light, infrared (radiant heat), and ultraviolet radiation. These
types of radiation are hazardous and can cause burns or blindness in
unprotected eyes.
MAN 41151 EN 06
DANGER
Ultraviolet radiation!
Never look directly at
the arc or spray stream
without protection.Wear
suitable protective goggles.
Ear Protection
WARNING
Noise emissions!
Wear ear protection!
The noise emission of greater than 85 dB caused by the spray gun

can damage hearing. Personal protective equipment in accordance
with a hearing conservation program is necessary. The plasma spray
process can produce noise levels as high as 130 dB.
Ventilation and Exhaust
DANGER
Respiratory protection
must be worn.
All thermal spray processes produce fumes and dust particles from the
materials being sprayed. To avoid the effects of dust and fumes generated by spraying, a suitable spray booth and sufficient exhaust system
are required. Proper installation, operation and maintenance are
important for system performance and maintaining a safe working
environment. For additional safety, dust collectors should be provided
with blow-out or relief panels in case of explosion. All local, state, and
national fire codes must be complied with when determining the location of the exhaust system. The exhaust duct of the ventilation system
should be vented to the outside of the building.
The plasma spray process generates ozone, NOx, dust, and fumes
that can damage the respiratory system. An adequate exhaust and
ventilation system is required. A minimum air velocity of 90 m/min (300
ft/min) is recommended in the areas adjacent to the spray gun and the
object being coated.
In addition to proper booth ventilation, appropriate personal respiratory
equipment must always be used when the operator is near the spray
process. An industrial hygienist should be consulted for recommendations on type and fit. Consult the Material Safety Data Sheet (MSDS)
for the products being sprayed for specific information regarding
chemical composition of the powder and Permissible Exposure Limits
(PEL).
Personal Protection
Protect exposed skin from the dust, fumes, heat, and UV radiation
generated by the plasma spray process.
WARNING
Hazards generated by
the spray process!
Wear personal protective clothing.
10
MAN 41151 EN 06
Hazardous Materials
OSHA and groups such as the American Conference of Government
Industrial Hygienists (ACGIH) and other government agencies have
developed extensive lists of hazardous materials and have set workplace exposure limits. Inasmuch as standards change and new information becomes available from time to time, it is strongly
recommended that the information contained in the Materials Safety
Data Sheet (MSDS) be consulted for the latest, up to date information.
There is also a considerable body of European standards that apply to
the spraying of powders.
Electrical Power
All electrical installations must be made in accordance with local and
national code requirements. All electrically powered equipment must
always be properly grounded. For additional information concerning
electrical installations refer to the National Electric Code (NFPA 70), or
EN 60204-1, or applicable local electrical code.
Plasma systems use an extremely high intensity arc to produce the
heat required for spraying. This high amount of electric power (amperage and voltage) can be extremely dangerous and should only be
handled by properly trained personnel. Always keep all covers and
guards in place on the equipment.
DANGER
High current and voltage!
Do not touch the power
cables while in operation.
Heat
The spray stream can heat up and ignite objects in the vicinity such as
the walls of the sound proof cabin, or cables and hoses. Never aim the
spray stream at people or objects other than the workpiece to be
coated.
DANGER
High temperatures!
Never aim the spray
gun at people or flammable objects!
MAN 41151 EN 06
11
Compressed Gases
Local, state and federal regulations relative to in-building use and storage of gas cylinders should always be observed. The improper storage, handling or use of gas cylinders can result in a serious safety
hazard. For additional information refer to NFPA 50, 50A, 51, 54, and
55 or other applicable local codes.
DANGER
Combustible gases
present under pressure.
The manifolding of more than two gas tanks may be required to permit
higher gas flows and longer spray times. Only approved pressure
adjusting regulators should be used with each gas, and should never
be over tightened or forced to make a connection. Gas regulator
adjusting screws should be fully released prior to opening cylinder
valves. Cylinder valves should be opened slowly to prevent surges
that can damage other related equipment. When opening a gas cylinder, stand to the side of the pressure-reducing regulator, never in front
of it.
The following guidelines should be followed when handling gas tanks:
12
Never drop tanks or knock tanks into one another. Some gases are
unstable (e.g., acetylene) even when in the tanks.
Gas tanks should always be secured to a wall or other supporting

fixture with chains or similar restraints even when the tanks are not
in use as they can easily tip over.
Only transport tanks in proper carriers. Gas carts are designed to

move tanks around, dollies are NOT. Do not attempt to carry or
drag tanks.
Never leave tanks in direct sunlight or extreme heat. Heat will

cause the tank pressure to increase dramatically resulting in an
unsafe situation.
Never smoke around tanks. Although no leak may be apparent,

some gas could be leaking and may ignite.
Tanks should always remain upright. They are designed to be

operated and transported in this position. If a tank is found lying on
its side, carefully return the tank to its upright position.
If a tank has been stored outside in a cold environment, allow the

tank to warm up at least one hour prior to use.
The caps on the gas tanks should be on at all times when the tank
is not in use. The cap is used to protect the weakest part of the
tank; that being the tank head.
Follow local guidelines and recommendations from the gas supplier for the allowable location of combustible gas tanks storage.
MAN 41151 EN 06
Gas Hoses and Piping

The gas supply installation must be carried out by qualified personnel
and must comply with the regulatory requirements applicable to the
location of the spray cell set-up.
Where large amounts of gas are required, the gas can be supplied
from a tank or several manifolded gas tanks and piped into the spray
booth. Gas piping should be constructed from stainless steel or other
similar solid metal material. It is recommended that pipe connections
should be welded or brazed. Gas piping should when possible, be laid
above ground and on the outside of the building. Piping should not be
laid in enclosed areas where gas leaks can accumulate, such as
above ceiling tiles or behind walls. The piping installation must be
checked for leaks and pressure tightness before putting it into service.
The piping installation should be routinely checked for leaks when in
service.
DANGER
Combustible gases
present under pressure.
Gas hose must be protected from mechanical damage. Gas hoses

should be routinely checked for loose connections, damage, and
leaks. Old gas hoses that are dry or cracked should never be used.
Hose connections should never be over tightened for this will cause
the hose stem to collapse and restrict gas flow.
Flame spray guns or torches or any other object should never be hung
on cylinder valves or regulators. This practice may result in a fire or
explosion.
When spray work has been completed or the equipment is shut down
(e.g., overnight, over a weekend), the gas supply should be turned off
and all gases should be drained from the hoses and regulator adjusting screws backed out.
MAN 41151 EN 06
13
Product Description
2.1
Overview
1
4
9mc_over
1
2
3
4
5
14

Status Monitor
Gas Control Unit
Electrical Control Unit
MAN 41151 EN 06
2.2
Principles of Operation
2.2.1 9MC Plasma Control Unit

During operation, plasma gases, compressed air, electricity and coating material are controlled and monitored through the 9MC Plasma
Control Unit (the Control Unit). At system startup, the Control Unit
checks if exhaust equipment is operating, purges all gas lines and initiates the flow of carrier gas through the spray gun. After verifying that
all parameter conditions are met, a high-frequency ignition signal is initiated to the gun for two seconds and stopped for one second. The
system will attempt four separate tries to light the gun. Process amperage is monitored during system startup to determine if plasma ignition
has occurred. If ignition has not occurred after four tries, the system
will automatically sequence to emergency stop status and indicate
IGNITION FAILURE on the Status Monitor message display.
Once ignition has been confirmed by the Control Unit, it will initiate the
arc current ramp and the secondary gas flow, both of which have been
preset by the operator prior to system startup. The Control Unit will
automatically start the feeding of powder to the spray gun.
Powder feeding can be remotely stopped or started at any time by the
operator or a robot to permit the coating to be checked or to allow the
part to cool.
At shutdown, the Control Unit automatically sequences the powder
feeder to stop feeding and the power supply to ramp down and terminate the arc current. Carrier gas, primary gas and water will continue
to flow for a short time to clear the powder hose and cool the gun electrode. After three minutes the fan in the power supply unit stops.
2.2.2 9MCD Plasma Distribution Unit

The 9MCD Plasma Distribution Unit (the Distribution Unit) provides
high-voltage and high current power from the system power supply
directly to the spray gun. The Distribution Unit also provides cooling
water from the heat exchanger. Cooling water and electrical power are
distributed to the spray gun via two water-cooled cables. Negative
power and cooling water return (blue cable) are connected to the
spray gun electrode. Positive power and the cooling water supply (red
cable) are connected to the spray gun nozzle.
The Distribution Unit contains a set of gapped electrodes that provide
a high-energy spark for ignition. The power consumed during operation is displayed on the Status Monitor. Voltage can be monitored at
the Distribution Unit or directly at the spray gun, when using the supplied voltage divider.
MAN 41151 EN 06
15
2.3
Function of Components
2.3.1 System Status Monitor
Front View
Rear View
4
9mc_statusmon
Item
No.
1
16
Description
Function
Amps digital display
Displays, in amperes, the power supply

current drawn by the spray gun.
Displays, in volts, the energy potential at
the spray gun or Distribution Unit. (See
DIST/GUN switch, item 4.)
20-character alpha-numeric display. Displays system status and error messages.
See Status Messages on page 46.
Used to select whether voltage is measured at the Distribution Unit or directly at
the spray gun. Monitoring voltage at the
spray gun requires use of the voltage
divider. See Voltage Divider on page 32.
Volts digital display
System Status display
DIST/GUN toggle
switch (5TGS)
MAN 41151 EN 06
2.3.2 Gas Control Unit Front Panel

2
14
13
12
11
10
9
9mc_gas_front
Item
No.
Description
Function
Primary Gas
Indicates the pressure of the primary
plasma gas supply. Pressure is controlled
by an external regulator.
2
Argon/Nitrogen flow
Indicates the flow rate of the primary
meter
plasma gas. Flow is controlled by the
Argon/Nitrogen flow control valve (3).
3
Flow control valve
Controls the flow rate of the primary
plasma gas.
Secondary Gas
4
Hydrogen flow meter Indicates the flow rate of the hydrogen
secondary plasma gas. Flow is controlled
by the Hydrogen flow control valve (5).
5
Hydrogen flow control Controls the flow rate of the hydrogen secvalve
ondary plasma gas.
6
Helium flow meter
Indicates the flow rate of the helium secondary plasma gas. Flow is controlled by
the Helium flow control valve (8).
(Continued on next page.)
1
Pressure gauge
MAN 41151 EN 06
17
(Continued from preceding page.)

Item
Description
Function
No.
7
Pressure gauge
Indicates the pressure of the secondary
plasma gas supply. Pressure is controlled
by an external regulator.
8
Helium flow control
Controls the flow rate of the helium secvalve
ondary plasma gas.
Vibrator Air
9
Feeder 2 pressure
Indicates the pressure of the vibrator air
gauge.
supplied to powder feeder number 2. Pressure is controlled by Vibrator Air Feeder
2 regulator control (10).
10
Feeder 2 regulator
Controls the pressure of the vibrator air
control
supplied to powder feeder number 2.
11
Feeder 1 pressure
gauge.
supplied to powder feeder number 1. Pressure is controlled by Vibrator Air Feeder
1 regulator control (12).
12
Feeder 1 regulator
Controls the pressure of the vibrator air
control
supplied to powder feeder number 1.
Cooling Air
13
Regulator control
Controls the pressure of the cooling air
supplied to the spray gun cooling apparatus.
14
Pressure gauge.
supplied to the spray gun cooling apparatus. Pressure is controlled by Cooling Air
regulator control (13).
18
MAN 41151 EN 06
2.3.3 Gas Control Unit Rear Connections
10
9mc_gas_rear
Item
No.
1
2
Description
Function
Plasma Gas fitting
Plasma gas output to spray gun (combined primary and secondary gas).
Input from argon supply for soft start.
Soft Start (Argon) fitting

Carrier #2 fitting
Carrier #1 fitting
Secondary Supply fitting
Primary Supply fitting
7
8
9
10
Vibrator Air #2 fitting

Vibrator Air #1 fitting
Cooling Air fitting
Air Supply fitting
3
4
5
MAN 41151 EN 06
Carrier gas output to powder feeder #2.

Carrier gas output to powder feeder #1.
Input from secondary plasma gas supply
(e.g., helium or hydrogen).
Input from primary plasma gas supply
(e.g., nitrogen or argon).
Vibrator air output to powder feeder #2.
Vibrator air output to powder feeder #1.
Cooling air output to spray gun air jets.
Input from facility air supply.
19
2.3.4 Electrical Control Unit Front Panel

4
10
11
3
Item
No.
1
Description
System 1 / System 2
selector switch
Alarm annunciator
Purge momentary
pushbutton (white)
Ignition momentary
pushbutton (yellow)
6
Feed On / Feed Off
selector switch
(Continued on next page.)
20
9mc_elec_front
Function
Multi-System Operation
Local / Remote selec- In single-system operation, Local selects
tor switch
operation from the Control Unit. Remote
selects operation from the Remote Operator Pendant or robot. (See Remote Operator Pendant on page 36.)
In multiple-system operation, all Control

Units in the chain are set to Remote.
In single-system operation, set to System
1.
In multiple-system operation, the master
Control Unit is set to System 1 and all others are set to System 2.
Audible alarm sounds when alarm is generated.
Test
Permits all gases and air supplies to flow
at the set flowmeter values. After two seconds, water begins to flow and the cooling
fan in the power supply unit turns on. Also
used to purge the gun and gas lines of
residual gases when shutting down the
system.
Used to check for high-voltage / arc at the
spray gun.
Turns powder feeding on or off at the powder feeder(s).
MAN 41151 EN 06
(Continued from preceding page.)

Item
Description
Function
No.
Automatic Gun Operation
7
Start momentary
Starts automatic spray cycle.
pushbutton (green)
8
Stop momentary
Stops automatic spray cycle.
pushbutton (red)
9
Preheat / Feed 1 /
Selects the powder feeder mode. Preheat
Feed 2 / Both selector suspends powder feeding, allowing the
switch
workpiece to be heated before coating.
Remaining switch positions select from
which powder feeders material is to be
delivered.
10
Arc Current potenti10-turn control for adjusting the arc current
ometer
at the spray gun. The range of values on
this control (0-999) has no correlation to
the actual arc current. Observe the Amps
digital display for actual current while
adjusting. (See System Status Monitor
on page 16.)
11
Emergency Stop
Push in to instantly disable operation of
the system, including the system power
pushbutton
supply and Distribution Unit. Also disables
output control signals and solenoid valves
of Control Unit. Input signals and the System Status display remain enabled, and
the purge fan in the Gas Control Unit
remains on.
Pull out to enable operation of the system.
MAN 41151 EN 06
CAUTION
Push in the Emergency
Stop pushbutton whenever the system is not
operating or is left unattended. Pull out the
Emergency Stop pushbutton only when you
are ready to begin system setup, ignition,
operation or testing.
21
2.3.5 Electrical Control Unit Rear Connections
2
3
6
4
5
9mc_elec_rear
Item
No.
1
2
INFO
Always install captive
cover on To Gun receptacle (5RECP) if handheld spray gun is not
connected.
Function
10MR connector
(6ARECP)
Distribution Unit connector (12RECP)
To Gun connector
(5RECP)
Connects to 10MR power supply via control cable (supplied).

Connects to 9MCD Plasma Distribution
Unit via control cable (supplied).
Connects to hand-held spray gun via gun
control cable (supplied with gun). Provides
powder feed control and emergency stop.
If a hand-held gun is not connected, the
captive connector cover must be installed.
This cover contains a jumper that closes
the emergency stop loop.
Connects to second powder feeder (if
used) via control cable supplied with powder feeder.
Connects to powder feeder via control
cable supplied with powder feeder.
Standard 3-prong AC plug connects to
facility power (115 VAC). If facility power is
200-240 VAC, use optional step-down
transformer.
Feeder 2 connector
(2RECP)
Feeder 1 connector
(1RECP)
Electrical cord (4PL)
22
Description
MAN 41151 EN 06
2.3.6 Electrical Control Unit Internal Switches

The Service Only switches are intended to be used by Sulzer Metco
Field Service or trained and qualified service technicians. During normal system operation, these switches should remain in the positions
specified below.
Do not override the door interlock switch or the safety interlock switch
without first reading Safety Interlocks / Maintenance Overrides on
page 50.
CAUTION
The Service Only
switches should only be
used by Sulzer Metco
Field Service or qualified service technicians.
3
4
DANGER
Do not override the door
interlock switch or the
safety interlock switch
without first reading
Safety Interlocks /
Maintenance Overrides on page 50.
5
6
9mc_elec_service
Item
No.
1
Description
Function
Service Only - Mode

toggle switch (1TGS)
Normal position is toward front of Control

Unit. Used only by service technicians to
select the service mode.
Normal position is toward front of Control
Unit. Used only by service technicians to
select the service mode.
Normal position is ON. OFF position disables soft start (argon) supply.
Normal position is #1. Position #2 is used
only for low water flow spray guns and gun
extensions. (See also, Cooling Water Setpoint Adjustment on page 45.)
Disables all power from Electrical Control
Unit, as safety measure when door is
open. See Safety Interlocks / Maintenance Overrides on page 50.
Facilitates override of ventilation fault
interlock, using attached key. See Safety
Interlocks / Maintenance Overrides on
page 50.
Service Only - Step

toggle switch (2TGS)
Soft Start toggle switch

(3TGS)
Water Flow toggle
switch (4TGS)
Door interlock switch

(1LS)
Safety interlock switch

(2LS)
MAN 41151 EN 06
23
2.3.7 Distribution Unit Front Panel
SULZER METCO
9MCD
Distribution Unit
Water Flow GPM

WATER FLOW TO GUN
UP
RUN
DN
SET
GPM
DC Electrode
ENTER
DC+
Nozzle
CAUTION
9mcd_front
Item
No.
1
Description
Function
Voltage sensor cable

(14PL)
Connects to voltage divider for measuring

voltage directly at the spray gun. See
Voltage Divider on page 32.
Displays, in gallons per minute (GPM),
the cooling water flow through the Distribution Unit to the spray gun.
Used to set the allowable limit(s) of cooling water flow to the spray gun (i.e., the
point below which the system will shutdown).
See Cooling Water Setpoint Adjustment
on page 45.
Select SET position to set or change the
current setpoint. Select RUN to accept the
current value and return to normal operation.
Used to increase (UP) or decrease (DN)
the setpoint value.
Press to enter the setpoint.
Positive electrical power and cooling water
supply to spray gun. Connects to spray
gun nozzle via red water-cooled cable.
Negative electrical power and cooling
water return from spray gun. Connects to
spray gun electrode via blue water-cooled
cable.
Setpoint control
RUN/SET momentary
switch
24
UP/DN momentary
switch
ENTER button
DC + Nozzle fitting
DC - Electrode fitting
MAN 41151 EN 06
2.3.8 Distribution Unit Rear Connections
Control Unit
Water In
Water Out
CAUTION
DC +
DC -
9mcd_rear
Item
No.
1
Description
Function
Control Unit connector (12RECP)

Water In fitting
Water Out fitting
DC - connectors
DC + connectors
Connects to 9MC Plasma Control Unit via

control cable.
Connects to cooling water supply hose
from heat exchanger.
Connects to cooling water return hose to
heat exchanger.
Three insulated connectors (black) connect to negative (-) output from system
power supply via three power cables.
Three insulated connectors (red) connect
to positive (+) output from system power
supply via three power cables.
MAN 41151 EN 06
25
2.3.9 Remote Operator Pendant
DANGER
The Remote E-STOP
input of the Remote
Operator Pendant is a
software-initiated emergency stop. It DOES
NOT satisfy the requirements of most national
or international safety
standards for safetyrelated emergency stop.
It is intended principally
for machine shutdown.
Do not rely solely on
this input for E-STOP
operation.
The Remote Operator Pendant is an optional accessory to the 9MC

Plasma Control Unit. When installed, it is hard-wired to the Control
Unit and duplicates the corresponding switches on the Electrical Control Unit front panel, including Emergency Stop. (See Electrical Control Unit Front Panel on page 20.) Once the settings and spraying
parameters have been set up at the Control Unit, the Remote Operator Pendant may be used to control the most common functions of the
automatic spray process up to 9 m (30) from the Control Unit. To operate from the Remote Operator Pendant, the Local / Remote switch on
the Control Unit is set to Remote.
EMERG
STOP
START
Always use the hardwired remote E-STOP

loop. (See Hardwired
Remote E-STOP on
page 39.)
STOP
FEED#1
ON/OFF
FEED#2
ON/OFF
PURGE
ON/OFF
For installation, refer to the accompanying instructions, AI 43563, supplied with the Remote Operator Pendant. See also, Remote Operation Interface on page 34.
26
MAN 41151 EN 06
2.4
Technical Data
1960 mm
(77)
500 mm
(20)
9mc_techdata
750 mm
(30)
610 mm
(24)
584 mm
(23)
750 mm
(30)

Characteristic
SI Units
US Units
208 kg
460 lb
161 kg
355 lb
Weight
Electrical Power Requirements

Voltage
(With optional 9MC420 step-down transformer)
Amperage
110 - 120 VAC, single phase, 50/60 Hz

200 / 220 / 240 VAC, single phase, 50/60 Hz
6.0 A @ 110 - 120 VAC
3.0 A @ 200 / 220 / 240 VAC
Plasma Power Control Capability
80 kw
Plasma Gas Requirements

Argon (Ar) (99.995% purity, Pre-purified grade)
98 NLPM @ 6.9 bar
224 SCFH @ 100 psig
Nitrogen (N2) (99.7% purity, Pre-purified grade)
91 NLPM @ 5.17 bar
207 SCFH @ 75 psig
Hydrogen (H) (99.95% purity, Pre-purified grade)
13 NLPM @ 5.17 bar
30 SCFH @ 75 psig
Helium (He) (99.995% purity, Pre-purified grade)
88 NLPM @ 5.17 bar
200 SCFH @ 75 psig
920 NLPM @ 5.9 bar
2100 SCFH @ 75 psig
Air Requirements
Clean, dry, oil-free
Compatibility
Spray Guns
3MB, 9MB, 11MB, iPro-901, F4
Powder Feeders
9MP, 9MP-CL20, 5MPE2, Twin 10-C
Power Supplies
10MR
1. Requires modified 9MC Plasma Control Unit.

2. Requires 5MPA Feeder Interface.
MAN 41151 EN 06
27
WARNING
All equipment shall be
installed and set up by
qualified personnel. In
addition to this manual,
refer also, to the documentation supplied with
the connecting equipment.
Installation and Commissioning
3.1
Environmental / Site Requirements
Relative location of the Control Unit, Distribution Unit, supporting

equipment (e.g., power supply, powder feeder(s), heat exchanger,
etc.) and the spray booth/area is limited only by the length of the interconnecting hoses and cables. Connections should never be stretched
and should remain slack enough to allow routine movement and use
of the equipment. The location should facilitate regular access to the
back of the units for connections and service. A smooth, hard floor is
necessary so that the units can be moved easily and safely. See
Technical Data on page 27 for specific electrical and gas supply
requirements.
3.2
DANGER
Ensure that facility
power is not connected
to any of the equipment.
Do not energize electrical equipment or apply
gas pressure during
connection and setup.
Failure to follow these
safety measures may
result in equipment
damage, personal injury
or death.
Connection and Setup
This section describes the typical gas, electrical and cooling water
connections of the Control Unit and Distribution Unit with other Sulzer
Metco equipment. Refer also, to the documentation supplied with the
connecting equipment. Do not energize electrical equipment or apply
gas pressure during connection and setup. See Operation on page
41.
3.2.1 Gas Connections

All gas connections are made to the fittings on the rear underside of
the Gas Control Unit. The illustration on page 29 shows the gas hose
connections of a typical 9M plasma system.
1. Connect carrier gas hose from Soft Start (Argon) fitting to argon
gas supply regulator (e.g., 7GNR).
2. Connect carrier gas hose from Secondary Supply fitting to secondary gas supply regulator (e.g., 7GNR, 7GNH).
3. Connect carrier gas hose from Primary Supply fitting to primary
gas supply regulator (e.g., 7GNR).
4. Connect air hose from Air Supply fitting to air supply regulator
(e.g., 6A).
5. Connect carrier gas hose from Carrier #1 fitting to Carrier Gas In
fitting of powder feeder no. 1.
6. Connect air hose from Vibrator Air #1 fitting to Vibrator Air In fitting of powder feeder no. 1.
7. Connect carrier gas hose from Carrier #2 fitting to Carrier Gas In
fitting of powder feeder no. 2.
8. Connect air hose from Vibrator Air #2 fitting to Vibrator Air In fitting of powder feeder no. 2.
(Continued on page 30.)
28
MAN 41151 EN 06
MAN 41151 EN 06
Air
N2 / Ar
He / H
Ar
Primary Gas In
Air In
6A Air Control Unit
7GNR
Secondary Gas In
7GNR / 7GNH
Soft Start (Argon) In
7GNR
Plasma
Gas
Out
9MBM Plasma Spray Gun
9MB
Plasma Gun
Cooling
Air
Out
Vibrator Air Out #2
Carrier Out #2
Vibrator Air Out #1
Carrier Out #1
9MP Powder Feeder (#2)
Gas Connections of 9M Plasma Spraying System (Typical)
9mc_gas_conn
29
(Continued from page 28.)

9. Connect carrier gas hose from Plasma Gas fitting to plasma gas
input fitting on spray gun.
10. Connect air hose from Cooling Air fitting (through wye connection) to air jet assembly on spray gun.
3.2.2 Electrical and Cooling Water Connections

The illustration on page 31 shows the electrical cable and cooling
water hose connections of a typical 9M plasma system.
DANGER
gas pressure during
safety measures may
result in equipment
or death.
1. On back of 9MC Plasma Control Unit Electrical Control Unit:

a. Connect control cable from 10MR power supply to 10MR connector.
b. Connect control cable from Control Unit connector on back of
Distribution Unit to Distribution Unit connector.
c. Connect control cable from CONTROL UNIT / POWER connector on back of powder feeder #1 (e.g., 9MP) to Feeder 1
connector.
d. Connect control cable from CONTROL UNIT / POWER connector on back of powder feeder #2 to Feeder 2 connector.
e. If handheld gun is used, connect gun control cable to To Gun
connector.
2. On back of 9MCD Plasma Distribution Unit:
a. Connect three DC (+) power cables from 10MR power supply
to three DC + connectors (red).
b. Connect three DC (-) power cables from 10MR power supply to
three DC - connectors (black).
c. Connect cooling water hose from heat exchanger supply (e.g.,
CLIMET-HE) to Water In fitting.
d. Connect cooling water hose from heat exchanger return to
Water Out fitting.
3. On front of 9MCD Plasma Distribution Unit:
a. Connect red water-cooled cable from DC + Nozzle fitting to
nozzle fitting on spray gun.
CAUTION
Do not plug in the electrical cord of the 9MC
Plasma Control Unit
until you are ready for
operation.
30
b. Connect blue water-cooled cable from DC - Electrode fitting to

electrode fitting on spray gun. (If using voltage divider, see
Voltage Divider on page 32.)
4. Do not plug in the electrical cord of the 9MC Plasma Control Unit
until you are ready for operation. (See Operation on page 41.)
MAN 41151 EN 06
MAN 41151 EN 06
To 10MR Power Supply
Control Cable
Control Cable
DC (-) Power Cables (3)
DC (+) Power Cables (3)
Control Cable
Control
Cable
Water In
DC +
Control Unit
DC Electrode
Distribution Unit
9MCD
CAUTION
GPM
ENTER
UP
DN
Water Out
(Rear)
CAUTION
(Front)
SET
RUN
WATER FLOW TO GUN
Water Flow GPM
DC -
DC+
Nozzle
SULZER METCO
9MCD Plasma
Distribution Unit
Manual Gun Control
Cooling Water In
Cooling Water Return
CLIMET-HE Heat
Exchanger
DC (-) To Electrode / Water Return

(Blue Water-Cooled Cable)
DC (+) To Nozzle / Water Supply

(Red Water-Cooled Cable)
Facility
Power
9MBH
Plasma
Spray
Gun
To
Chiller
Electrical and Cooling Water Connections of 9M Plasma Spraying System (Typical)
9mc_elec_h2o_conn
31
3.2.3 Voltage Divider

The voltage divider assembly is used to sense the voltage directly
across the electrode and nozzle, rather than measuring gun voltage at
the Distribution Unit. In either case, the voltage measured is the value
displayed on the Volts meter on the System Status Monitor. The difference between the voltage measured at the spray gun and that measured at the Distribution Unit is typically 3-4 volts. If the voltage
differential is greater than 5 volts, the red and blue water-cooled
cables should be inspected, serviced or replaced.
Extension Cable
Voltage
Divider
Body
Nozzle (+) Connection
9MB
Plasma Gun
Blue Water-Cooled Cable
Electrode (-) Fitting

9mcd600
The voltage divider body is installed on the electrode fitting of the

spray gun, in line with the blue water-cooled cable. The positive sensor wire is connected to the nozzle connection screw. The voltage
divider pigtail cable connects (via extension cable) to the cable on the
front of the Distribution Unit. The connection provides a scaled voltage
feedback signal to the feedback board in the Electrical Control Unit.
To display the voltage measured by the voltage divider on the Volts
meter, open the back of the System Status Monitor and set the GUN/
DIST switch to GUN. See System Status Monitor on page 16.
32
MAN 41151 EN 06
3.3
Interfacing with External Equipment
The 9MC Plasma Control Unit can interface with external equipment,
thus providing a fully integrated system. The Control Unit can be integrated with other 9MC Plasma Control Units, remote control and ESTOP pendants, robot / handling equipment, ventilation and exhaust
systems and external safety interlocks.
Interface signals and instructions for connecting each type of interface
are described in this section. All interface wiring connections are made
to terminal blocks 3TB and 4TB located in the Electrical Control Unit.
Wiring is routed through spare holes in back of the Electrical Control
Unit. For each interface, remove one spare hole plug and route the
wiring through the hole, along with a condulet connector, gasket seal
and locknut.
3TB
DANGER
gas pressure during
safety measures may
result in equipment
or death.
CAUTION
Wiring modifications
must be performed by
Sulzer Metco Field Service or a qualified maintenance technician.
4TB
5TB
Spare Hole Plugs

/ Condulet Connectors
(front view, door open)
9mc_TBs
INFO
Be sure to replace the
factory jumpers if interface wiring is disconnected in the future.
Some interfaces require factory jumper wires to be removed. Be sure

to replace the jumpers if the interface wiring is ever disconnected.
Refer also, to the 9MC Plasma Control Unit and 9MCD Plasma Distribution Unit Electrical Schematic and Gas Flow Diagrams, DIA 74602.
MAN 41151 EN 06
33
3.3.1 Remote Operation Interface

Input Commands
The Control Unit can be controlled from another 9MC Plasma Control
Unit, a remote device such as a robot controller or the Remote Operator Pendant. All input signals for the remote interface are -24 VDC,
supplied by the Programmable Logic Controller (PLC) input rack
power supply. The interface signals are specified in the following table.
Signal Name
Circuit #
(TB#-Term.#)
Description
Input Commands and Alarms

- Common
39
(3TB-1~7)
-24 VDC common (differential low) supplied by PLC input rack

power supply. Used for all PLC remote operation inputs.
Remote System Fault
101
(3TB-14)
Open contact activates input. Initiates E-STOP shutdown and displays REMOTE SYSTEM FAULT on System Status display until
fault is cleared. (Remove jumper to 3TB-1.)
Remote E-STOP
102
(3TB-13)
Open contact activates input. Initiates E-STOP shutdown and displays AUX E-STOP on System Status display until fault is
cleared. (Remove jumper to 3TB-2.)
Exhaust Fault
103
(3TB-12)
Open contact activates input. Initiates E-STOP shutdown and displays EXHAUST FAULT on System Status display until fault is
cleared. (Remove jumper to 3TB-3.)
Robot Fault 1
104
(3TB-11)
Closed contact activates input. Does not initiate E-STOP shutdown. Displays ROBOT FAULT 1 on System Status display
until fault is cleared.
Robot Fault 2
105
(3TB-10)
Open contact activates input. Does not initiate E-STOP shutdown.

Displays ROBOT FAULT 2 on System Status display until fault
is cleared. (Remove jumper to 3TB-5.)
Remote Alarm 1
106
(3TB-9)

Displays REMOTE ALARM 1 on System Status display until
alarm is cleared. (Remove jumper to 3TB-6.)
Remote Alarm 2
107
(3TB-8)

Displays REMOTE ALARM 2 on System Status display until
alarm is cleared. (Remove jumper to 3TB-7.)
Remote Cycle Start
112
(4TB-11)
Closed momentary contact (~0.5 s) activates input. Starts the

automatic spray cycle.
Remote Cycle Stop
113
(4TB-10)
Closed momentary contact (~0.5 s) activates input. Stops the automatic spray cycle.
Remote Feed No. 1
114
(4TB-9)
Closed contact activates input. As long as the input is active, the

control unit will be in the preheat mode. Preheat mode is defined
as no powder fed to the gun.
Remote Feed No. 2
115
(4TB-8)
Closed contact activates input. As long as the input is active, the

control unit will be in the preheat mode. Preheat mode is defined
as no powder fed to the gun.
Remote Purge
116
(4TB-12)
Closed momentary contact (~0.5 s) activates input. Starts the

purge sequence.
34
MAN 41151 EN 06
Output Commands
The Control Unit provides output commands and alarms for the other
Control Units or external equipment. All output signals for the remote
interface are +24 VDC, supplied by the PLC output rack power supply.
Generally, each signal is intended to energize a relay in the remote
equipment. The interface signals are specified in the following table.
Signal Name
Circuit #.
(TB#-Term.#)
Description
Output Commands and Alarms

+ Common
32
(4TB-1)
+24 VDC common (differential high) supplied by PLC output rack

power supply. Used for all remote command outputs.
Remote Start (Out)
044
(4TB-2)
Closed contact return for +24 VDC common activates output.

Starts the automatic spray cycle in all connected Control Units.
Remote Stop (Out)
045
(4TB-3)
Closed contact return for +24 VDC common activates output.

Stops the automatic spray cycle in all connected Control Units.
Remote Fault (Out)
046
(4TB-4)
Closed contact return for +24 VDC common activates output. Initiates emergency stop shutdown and provides fault indication of
the Control Unit.
Remote Feed No.1

(Out)
047
(4TB-5)
Closed contact return for +24 VDC common activates output. Controls the feed on/off signal for all no. 1 powder feeders.
Remote Feed No.2

(Out)
050
(4TB-6)
Closed contact return for +24 VDC common activates output. Controls the feed on/off signal for all no. 2 powder feeders.
MAN 41151 EN 06
35
3.3.2 Remote Operator Pendant
DANGER
The Remote E-STOP
input (circuit no. 102) of
the remote operation
interface is a softwareinitiated emergency
stop. It DOES NOT satisfy the requirements of
most national or international safety standards.
this signal for E-STOP
operation.
When using the Remote Operator Pendant, the Multi-System Operation switches on the Control Unit are set to Remote and System 2.
See Remote Operator Pendant on page 26. Refer also, to the
accompanying instructions, AI 43563, supplied with the Remote Operator Pendant.
Remote Operator
Pendant
9mc_rem_s2
4TB
EMERG STOP
Remote E - Stop
11
11A

loop. (See Hardwired
Remote E-STOP on
page 39.)
16
15
START
Remote Cycle Start
112
11
Remove
Jumper
STOP
Remote Cycle Stop
113
10
FEED # 1 ON/OFF
Remote Feed 1
9
114
FEED # 2 ON/OFF
Remote Feed 2
8
115
PURGE ON/OFF
Remote Purge
12
116
3TB
-24 VDC PLC Common
36
1-7
39
MAN 41151 EN 06
3.3.3 Robot Interface

When the system is operated from a robot controller, the Multi-System Operation switches on the Control Unit are set to Remote and
System 2. The Remote Fault signal is an output to the robot indicating
a fault in the Control Unit.
9mc_rem_s2
3TB
Robot Interface
-24 VDC PLC Common
39
Robot Dry Contact Outputs
Robot Fault 1
104
INFO
When using the remote
operation interface, do
not connect the Remote
E-STOP interface (circuit no. 102) to the robot
or workhandling equipment. The remote operation interface includes
its own remote fault,
which provides diagnostic benefits.
11
4TB
Remote Cycle Start
Remote Cycle Stop
Remote Feed 1
Remote Feed 2
11
112
10
113
9
114
8
115
Remote Purge
12
116
Remote Fault
46
+24 VDC PLC Common

To Robot Input
9MC Fault
1
32
From Robot Input Common
MAN 41151 EN 06
37
3.3.4 Multiple System Interface

When a 9M plasma system employs multiple interconnected Control
Units, the Multi-System Operation switches on the first Control Unit
are set to Remote and System 1. All subsequent Control Units in the
series are set to Remote and System 2. The remote operation outputs from each Control Unit are connected to the inputs of the next
Control Unit, and so on. The loop is closed by connecting the Remote
Fault output of the last Control Unit to the Remote Fault input of the
first.
Multi-System Operation
switch positions
9mc_rem_s2
9mc_rem_s2
9MC #1
112
113
9MC #2
4TB
4TB
11
10
44
45
114
47
8
115
50
Remote Cycle Start

Remote Cycle Stop
Remote Feed 1
Remote Feed 2
112
113
4TB
11
10
114
46
32
112
45
113
47
115
+24 VDC PLC

Common
50
4TB
11
10
115
50
4
46
1
32
32
3TB
Remote Fault
14
101
39
Remove
Jumper
45
47
46
32
44
114
3TB
39
44
4TB
101
9MC #3
4TB
9mc_rem_s2
3TB
14
101
39
Remove
Jumper
14
1
Remove
Jumper
Remote Fault (from last Control Unit only)
38
MAN 41151 EN 06
3.3.5 Remote Emergency Stop (E-STOP) Interface

Remote Operation Interface E-STOP
The remote emergency stop interface allows the Control Unit to be
connected to an emergency stop loop of a robot or workhandling
equipment. This interface is a software-initiated emergency stop. It
does not satisfy the requirements of most national or international
safety standards. It is intended principally for informational and diagnostic purposes and/or equipment related shutdown. Do not rely solely
on the this interface for E-STOP operation. Always use the hardwired
remote E-STOP loop.
(Energized
during
normal
operation.)
3TB
Remote E - Stop
Remove
Jumper
13
102
(N.O.)
DANGER
The Remote E-STOP
input (circuit no. 102) of
the remote operation
interface is a softwareinitiated emergency
stop. It DOES NOT satisfy the requirements of
most national or international safety standards.
this signal for E-STOP
operation.
2
39

loop.
Hardwired Remote E-STOP
The hardwired remote E-STOP is connected directly to the internal ESTOP loop of the Control Unit. This loop includes the Emergency
Stop pushbutton on the Electrical Control Unit front panel and the ESTOP on a hand-held spray gun, if connected. This interface is typically used to connect one or more emergency stop switches or remote
pendants. However many remote E-STOP switches are connected,
they are connected in a continuous loop. Remove the existing jumper
(4TB-15 to 4TB-16) prior to wiring in the external switch(es).
The Control Unit also contains an E-STOP output. It is a normallyopen set of contacts from the main contactor (MCR), which is energized whenever the E-STOP loop is closed. Either interface may be
used independently as needed.
Door
E-STOP
Remove Jumper
E-STOP
Pendant
4TB
16
11
15
MCR
11A
E-STOP
Loop
14
67
E-STOP Out
(N.O.)
13
MCR
68
MAN 41151 EN 06
39
3.3.6 Exhaust Interlock

This feature prevents the operation of the control unit until the exhaust
system is turned on. In the event of an exhaust failure, the unit will
shut down and the message EXHAUST FAULT will be displayed. The
exhaust interlock is connected to the customer supplied exhaust sensor for the spray booth. Remove the existing jumper (3TB-12 to 3TB3) prior to wiring in the sensor.
Exhaust Sensor
3TB
103
39
CAUTION
Make sure the exhaust
interlock switch and wiring are isolated from
any other source of
power (i.e., dry contacts only).
Normally-open
contacts (closed
when exhaust
system is on)
12
Remove Jumper
When wiring this interlock circuit, make sure that the exhaust interlock
switch and wiring are isolated from any other source of power, such as
the control wiring for the exhaust blower motor. This interlock circuit is
an isolated switch circuit only (i.e., dry contacts), and must not be
connected to any other source of power.
3.3.7 Remote Alarms and Robot Faults
INFO
Robot Fault 1 is a
closed circuit active
alarm. There is no factory installed jumper.
The remote alarms allow additional safety interlocks such as door

interlocks, multiple exhaust interlocks and additional customer supplied safeties to be wired to the control unit. These alarms do not
cause an E-STOP shutdown. There are two remote alarms and two
robot alarms. Generic messages are displayed on the System Status
display.
Typical application wiring of Remote Alarm 1 is shown below.
3TB
Door Interlock
Remote Alarm 1
106
39
Remove Jumper
40
MAN 41151 EN 06
Operation
Before operating the 9MC Plasma Control Unit:
Ensure that installation, connection and initial setup of all equipment is complete. See Connection and Setup on page 28.
Turn on, set up and allow powder feeder(s) to initialize.
Turn on exhaust system and wear protective clothing. Follow all

safety regulations. See Safety on page 7.
4.1
Startup
WARNING
Before operating the
thermal spray system,
turn on exhaust system
and wear protective
clothing.
1. On 9MC Plasma Control Unit, push in Emergency Stop button

and release (twist and pull out) all other E-STOP buttons.
2. Open each gas supply and adjust pressure as follows:
a. Open cylinder or supply valve slowly until full pressure is measured on high-pressure gauge of regulator. Then, open supply
valve all the way.
b. Turn regulator screw until pressure measured on the low-pressure gauge reads as listed below:
Argon (primary)
5.17 bar (75 psi)
Nitrogen (primary)
3.31 bar (48 psi)
Hydrogen (secondary)
3.45 bar (50 psi)
Helium (secondary)
5.17 bar (75 psi)
Air
5.17 bar (75 psi)
c. Check for leaks.

3. Plug in electrical cord of the 9MC Plasma Control Unit.
After a brief self-test, if all the proper gas and air pressures are
present, the System Status monitor displays E-STOP/FUEL
IS ON. This indicates that the emergency stop is activated and
fuel gases are present at the control unit.
If the System Status monitor displays EMERGENCY STOP, then
fuel gas has not been detected at the control unit. See Troubleshooting on page 52.
4. On Control Unit, release Emergency Stop button.
If all safeties, interlocks, and remote alarms are satisfied, the
System Status monitor displays 9MC SYSTEM READY. This
message is displayed anytime the Control Unit is in the spray
mode and ready to operate.
If the system status monitor displays an alarm message (e.g.,
CARRIER GAS PSI LOW), and the audible alarm is sounding,
MAN 41151 EN 06
41
one or more conditions exist that will prevent the system from
operating. Since the system status can only display one alarm at
a time, always service the alarms in the order they appear.
When the displayed alarm is cleared, the next alarm or SYSTEM
READY will appear.
5. Once all alarms are clear and system is ready to operate, push in
Emergency Stop button.
6. Turn on cooling water supply (e.g., booster pump, refrigerated
chiller, heat exchanger, etc.) and set cooling water flow rate, pressure and temperature to value specified for spray gun (minimum
11.36 lpm (3 gpm)).
7. Energize system power supply (i.e., 10MR).
8. When you are ready to begin spraying operations, proceed as
described under Operating Procedures on page 43.
4.2
Shutdown
When spraying operations are finished, shut down the 9MC Plasma
Control Unit as follows:
1. On Electrical Control Unit, press and hold Purge button for
approximately 5 to 10 seconds.
2. On Electrical Control Unit, push in Emergency Stop button. Push
in all E-STOP buttons in the loop.
3. Shut down 10MR power supply.
4. Shut down cooling water supply (chiller, heat exchanger, etc.).
5. Shut down powder feeders.
6. Close all gas supply valves and back out regulator screws all the
way.
7. Unplug electrical cord of 9MC Plasma Control Unit.
42
MAN 41151 EN 06
4.3
Operating Procedures
Before operating the 9MC Plasma Control Unit:
Ensure that installation, connection and initial setup of all equipment is complete. See Connection and Setup on page 28.
Turn on exhaust system and wear protective clothing. Follow all

safety regulations. See Safety on page 7.
Perform Startup on page 41.
4.3.1 Manual Test Functions
WARNING
Before operating the
thermal spray system,
turn on exhaust system
and wear protective
clothing.
The Control Unit provides three manual test functions which are operated by manual controls, located on the Test panel of the Electrical
Control Unit. (See Electrical Control Unit Front Panel on page
20.)These controls enable the operator to test the following functions
without having to operate the gun.
Purge
The main purpose of the purge function is to dry the nozzle bore after
changing gun hardware and clear the gas lines after closing the inlet
supply lines at the end of the day.
Pressing the Purge button will start the flow of primary and secondary
gas to the gun and carrier gas to the powder feeder (secondary gas
will not flow if the secondary flow tube is closed). Gas will continue to
flow for as long as the purge button is pressed. During this time, the
System Status monitor displays SYSTEM PURGING. Also, when the
Purge button is pressed and held for more than two seconds, the fan
in the power supply and the cooling water pump will turn on and
remain on for as long as the button is held.
Ignition
The Ignition test function enables the operator to test the high frequency ignition voltage circuit, which is used to light the gun. During
an ignition test, primary gas flows while the high frequency voltage is
turned on and off in a pulsing fashion. The high frequency voltage is
energized without arming the power supply, making it impossible to
accidentally start the gun. When checking the high frequency arc in
the gun, avoid looking directly down the nozzle bore and refrain from
prolonged viewing of the arc.
Ignition test is accomplished by pressing and holding in the Ignition
button. The System Status monitor displays IGNITION TEST. If the
high frequency arc is not observed or the gun does not light in the Auto
mode, adjustment of the ignition points may be required or the gun
hoses may be faulty. Refer to Troubleshooting on page 52.
MAN 41151 EN 06
43
Feed
Feed Test enables the operator to operate the powder feeder(s) without lighting the gun (e.g., to check the powder flow rate). When the
Feed On / Feed Off switch is set to Feed On, the selected powder
feeder and carrier gas are started, primary gas to the gun is turned on
and the selected vibrator air is turned on. The choice of feeders to be
tested is controlled by the Automatic Gun Operation powder feed
selector switch as follows:
INFO
Make sure secondary
gas flowmeters (Hydrogen and Helium) are
turned off.
Feed 1 - Powder feeder no.1 operates as described above and the

System Status monitor displays POWDER FEED TEST 1.
Feed 2 - Powder feeder no.2 operates as described above and the

System Status monitor displays POWDER FEED TEST 2.
Both - Powder feeders 1 and 2 operate as described above and

the System Status monitor displays POWDER FEED TEST 1&2.
Preheat - The powder feeder(s) will not start and the System Status monitor displays AUTO PREHEAT.
4.3.2 Automatic Operation

1. On Multi-System Operation panel, set switches to Local and
System 1.
2. Release Emergency Stop button. The System Status monitor
displays 9MC SYSTEM READY.
3. Set Arc Current control to 3. (Number is shown in window on top
of knob.)
INFO
If the control unit is not
warmed up (approx. 1/2
hour) prior to start-up,
arc current may drift
slightly, requiring minor
adjustment.
Natural erosion of the
gun hardware (nozzle
and electrode) from
continued use will
cause the arc current
and voltage to drift.
Minor adjustment of the
arc current control and
secondary gas flow (if
used) will be required.
44
4. Press and hold Purge button while setting primary flow. (Refer to
spray parameter tables for pressures and flows.) Check gun and
hoses for water leaks. (If any leaks are detected, they must be corrected before continuing.)
5. Press and release Start button. The auto cycle will begin. First, primary gas will flow from gun. Next, ignition will start and gun should
light. (If gun does not light after four ignition attempts, unit will shut
down and display IGNITION FAILURE.) Gun then ramps to initial
current setting.
6. Manually increase arc current while introducing secondary gas, if
required. (Arc Current control may be locked if desired.)
7. On Automatic Gun Operation panel, select desired function.
(Preheat, Feed 1, Feed 2, or Both.)
8. When operation has been completed, press the Stop button. The
control unit will automatically cycle off.
9. To rerun operation using the same parameters, press the Start
button again. The control unit will automatically light the gun and
ramp to the previous set points for primary gas, secondary gas and
arc current.
MAN 41151 EN 06
4.4
Cooling Water Setpoint Adjustment
The setpoint indicator on the 9MCD Plasma Distribution Unit:
Displays the current rate of cooling water flow to the spray gun.
Facilitates adjustment of up to two low-flow setpoints.
Issues a LOW WATER FLOW alarm to the Control Unit if the water
flow falls below the selected setpoint. This alarm causes a soft ESTOP shutdown of the system.
The setpoints are adjusted at the factory and should not be changed
for most spray gun applications. The default setpoints are 11.36 lpm (3
gpm) and 5.68 lpm (1.5 gpm).
The setpoints are selected by the Water Flow switch inside the Electrical Control Unit. The higher value corresponds to position #1 and is
suitable for most spray guns. The lower value corresponds to position
#2 and is generally used only for low-flow extension guns. Refer to the
cooling water requirements of the spray gun you are using.
To change a setpoint value, on the setpoint indicator:
1. Press and release the RUN/SET switch to SET. The display alternately displays SP1 and the current value.
2. Use the UP/DN switch to adjust the value.
3. Press ENTER to enter the setpoint. The display alternately displays SP2 and the current value.
4. To keep the current value, press and release the RUN/SET switch
to RUN.
MAN 41151 EN 06
45
4.5
Status Messages
The table below is the complete list of messages that can be displayed
on the System Status monitor. The Description column contains the
detailed interpretation of the message. Some of the status messages
are informational and can be expected during normal operation. Others are fault indications that may be accompanied by an audible
alarm, E-STOP shutdown or both. See Troubleshooting on page 52
for additional information.
No.
Message Text
Description
EMERGENCY STOP
Interruption in the main emergency stop (E-STOP) loop

(e.g., Control Unit, spray gun, remote pendant, purge fan,
etc.).
E-STOP/SEC GAS IS ON
E-STOP is activated and secondary gas (> 0.34 bar / 5 psi)

is present at the Control Unit. Pressure switch 1PS is
closed.
SECONDARY PSI LOW
Secondary plasma gas pressure is too low (< 2.76 bar / 40

psi). Pressure switch 3PS is open.
PRIMARY PSI LOW
Primary plasma gas pressure is too low (< 2.76 bar / 40 psi).
Pressure switch 4PS is open.
AIR PSI LOW
Air pressure is too low (< 3.79 bar / 55 psi) for operation of
vibrator(s) / cooling jets / purge air. Differential pressure
switch 5PS is open.
LOW WATER FLOW
Water flow through Distribution Unit is below setpoint.
VENTILATION FAULT
Purge air pressure drop in Electrical Control Unit (pressure

switch 7PS is open) or purge fan in Gas Control Unit is not
on (pressure switch 2PS is open).
CURRENT FAILURE
REMOTE SYSTEM FAULT
Fault alarm from external equipment (e.g., 9MC, robot, etc.).
10
AUX E-STOP
Remote (soft) E-STOP shutdown has been initiated.
11
EXHAUST FAULT
Exhaust system is off or remote exhaust sensor has tripped.
12
ROBOT FAULT 1
Generic (user defined) robot alarm.
13
ROBOT FAULT 2
Generic (user defined) robot alarm.
14
REMOTE ALARM 1
Generic (user defined) alarm.
15
REMOTE ALARM 2
Generic (user defined) alarm.
16
IGNITION FAILURE
Ignition sequence has failed - spray gun not lit.
17
CURRENT SENSOR FAULT
18
HIGH WATER TEMP
Water temperature sensor in Distribution Unit detects water

temperature above 49 C (120 F).
19
(Reserved)
20
LOW PRIMARY FLOW
Primary plasma gas flow to spray gun is too low (< 21.9
NLPM / 50 SCFH). Pressure switch 6PS is open.
21
9MC SYSTEM READY
No alarms present; Control Unit is in spray mode and ready

for operation.
22
IGNITION TEST
Control Unit is testing for ignition arc at the spray gun.
23
SYSTEM PURGING
Control Unit is purging the spray gun.
46
MAN 41151 EN 06
No.
Message Text
Description
24
(Reserved)
25
AUTO PREHEAT
Control Unit is in preheat mode (i.e., powder feeding suspended).
26
AUTO SPRAY FEED 1
Powder feeder no. 1 is feeding powder.
27
AUTO SPRAY FEED 2
Powder feeder no. 2 is feeding powder.
28
AUTO SPRAY FEED 1 & 2
Powder feeders 1 and 2 are feeding powder.
29
AUTO SYSTEM START
Automatic Gun Operation start sequence is initiated.
30
IGNITION SEQUENCE
Control Unit is in ignition sequence of automatic start cycle.
31
RAMP SEQUENCE
Control Unit is in ramp sequence of automatic start cycle.
32
SHUTDOWN SEQUENCE
Automatic Gun Operation stop sequence is initiated.
33
SERVICE MODE 1
(Service only)
34
SERVICE MODE 2
(Service only)
35
SERVICE MODE 3
(Service only)
36
POWDER FEED TEST 1
Manual test of powder feeder no. 1.
37
POWDER FEED TEST 2
Manual test of powder feeder no. 2.
38
POWDER FEED TEST 1&2
Manual test of powder feeders 1 and 2.
39
WATER FLOW OVERRIDE
(Service only)
40
SERVICE MODE 4
(Service only)
41
FEEDER 1 FAULT
Alarm received from powder feeder no.1.
42
FEEDER 2 FAULT
Alarm received from powder feeder no.2.
43
WATER TEMP OVERRIDE
(Service only)
44
CURRENT OVERRIDE
(Service only)
45
SERVICE MODE 5
(Service only)
46
47
48
49
50
MAN 41151 EN 06
47
Service
The 9MC Plasma Control Unit and 9MCD Plasma Distribution Unit
require only routine inspection and cleaning.
DANGER
Disconnect all electrical
power from equipment
prior to performing service or maintenance.
Service Interval
Daily
Weekly
Monthly
1
2
3
Legend:
Inspect
Clean
Replace
9mc_service
1. Visually inspect all equipment and connections each day before

commencing spraying operations.
2. Clean the exterior surfaces, panels and displays using cleaning
solvent and a lint-free cloth. Blow dust and debris from interiors of
enclosures using dried and filtered compressed air.
3. Periodically check the air filters in the Gas Control Unit. Inspect
them for moisture or contaminants and replace them as necessary.
(Frequency of filter replacement depends on the quality of compressed air supply.)
48
MAN 41151 EN 06
Maintenance
6.1
Feedback Board
The feedback board, located in the lower rear of the Electrical Control
Unit, measures scaled analog voltage and current feedback signals
from the spray gun and/or Distribution Unit. These signals are used to
control and regulate the power supply output and the actual power at
the spray gun.
Dip Switches
DANGER
9mc_feedback
The dip switches on the feedback board are set at the factory for a
starting current of 130 amps from the 10MR power supply. This setting
is appropriate for argon startup (i.e., soft-start). A higher starting current may be necessary for certain spray guns or for starting with nitrogen only. The following table lists all available starting current values
and corresponding dip switch settings.
Starting Current (Amps)
Dip
Switch
#
130
200
230
285
332
374
443
OFF
ON
OFF
ON
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
ON
ON
ON
OFF
ON
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
MAN 41151 EN 06
49
6.2
DANGER
Overriding the safety
interlocks can result in
serious injury or death.
Safety Interlocks / Maintenance Overrides
The Electrical Control Unit contains multiple safety and equipment

interlocks. When necessary to perform maintenance or troubleshooting with power applied to the Electrical Control Unit, these interlocks
can be overridden. Overriding the safety interlocks shall only be done
by Sulzer Metco Field Service or a trained and qualified maintenance
technician.
Door Interlock Switch (1LS)
WARNING
High voltage and current are present inside
the Electrical Control
Unit. Only Sulzer Metco
Field Service or qualified technicians shall
perform maintenance.
When overriding the
safety interlocks, begin
with the Emergency
Stop button pushed in.
Release the Emergency Stop button only
if and when necessary.
Key
Safety Interlock Switch (2LS)
9mc_interlocks
Always begin with the Emergency Stop button pushed in.

When the front door of the Electrical Control Unit is opened, the door
interlock switch opens, disabling all power to the 9MC Plasma Control
Unit. Power is only present at the line filter (1FL) at the bottom rear of
the enclosure.
To override the door interlock switch, pull out the switch actuator. This
applies power to the input PLC rack and purge fan in the Gas Control
Unit. The System Status monitor displays VENTILATION FAULT.
INFO
The override key, when
installed in the safety
interlock switch, prevents the door of the
from being closed.
50
The safety interlock switch is used to bypass the ventilation differential

pressure switch (7PS). Insert the key into the safety interlock switch.
Closing the safety interlock switch applies power to all other electrical
components in the Control Unit. The System Status monitor displays
EMERGENCY STOP.
The 9MC Plasma Control Unit is now fully powered and ready for
operation. Release the Emergency Stop button only if and when necessary to perform a specific task that requires all circuits to be energized. Use extreme caution when working inside the Electrical Control
Unit.
MAN 41151 EN 06
6.3
Electrode Gap Adjustment
If ignition problems cannot be resolved easily, check the condition of

the electrodes in the Distribution Unit. Using a thickness gauge, check
and adjust the electrode gaps to 0.030 - 0.036 mm (0.012 - 0.014).
DANGER
0.30-0.36 mm
(0.012-0.014)
9mcd_electrodes
MAN 41151 EN 06
51
Troubleshooting
This section is intended for trained and qualified maintenance technicians. Refer to the Electrical Schematic and Gas Flow Diagrams, DIA
74602, for the 9MC Plasma Control Unit and 9MCD Plasma Distribution Unit.
7.1
Power-On Check
When the control unit is plugged into a 120 VAC outlet, the following
sequence should occur:
1. The purge fan in the Gas Control Unit starts.
2. The message display lights up and shortly after, displays the message SELF TEST PAST for approximately 1-2 seconds.
3. If all proper gas and air pressures are present and the Emergency
Stop button is depressed, the message E-STOP/SEC GAS IS
ON will be displayed.
If the Emergency Stop button is not depressed, the message 9MC
SYSTEM READY will be displayed.
If one or more gas or air pressures are either low or turned off, one of
the following messages will be displayed:
- LOW CARRIER GAS PSI
- LOW PRIMARY GAS PSI
- LOW SECONDARY GAS PSI
- LOW AIR PSI
If the Emergency Stop button is not depressed, these messages will
be accompanied by an audible alarm. The alarm may be silenced by
depressing the Emergency Stop button. However, the message will
remain.
52
MAN 41151 EN 06
7.2
Power-On Troubleshooting
Problem
Probable Cause
Power On
Fan and message display does not come on.
No power incoming.
Door switch tripped or defective.
Fuse 1FU blown.
Defective Line Filter.
AC wiring problem.
Fan not on. VENTILA- Defective fan.

TION FAULT message. AC wiring problem.
Message display not on.
Defective display unit.

AC wiring problem.
No electrical cabinet purge air.

VENTILATION
FAULT message but fan Pressure differential switch 2PS or 7PS out of
is running.
adjustment.
Related wiring problem.
Check PLC input 023 and 1CR.
Message Unit on, but no

message.
Check message display connector (inside

message unit cabinet) and related wiring to
PLC.
Check CPU in PLC - power and run lights
should be on. If battery or CPU light is on, call
Sulzer Metco Field Service.
Manual Test Functions
Purge button inoperative.
E-STOP pressed.
Defective button (3PB) or related PLC input
circuitry (011) faulty.
Fuse 3FU blown.
Purge button operates

but gases not flowing.
Operating flow needle valve is closed.

Possible faulty solenoid or related wiring from
PLC output 033-037
Ignition button inoperative.
Purge button is being pressed.

E-STOP pressed.
Defective button (2PB) or related PLC input
circuitry (010) faulty.
Possible problem with 2CR (in Distribution
Unit) or related wiring from PLC output 030.
Fuse 2FU blown.
Powder feeder Ready

light not on.
Powder feeder Ready

light on but feeder does
not operate.
Defective control cable.

Possible problem with PLC output 073/074.
Defective powder feeder. (Refer to powder
feeder manual.)
MAN 41151 EN 06
E-STOP pressed.
Control cable disconnected
Fuse 4FU blown.
MCR relay or related wiring faulty.
53
Problem
Probable Cause
Automatic Spray Functions
Start button inoperative.
Master / Slave switch in Slave position.

E-STOP pressed.
Start button (4PB) or related circuitry (110)
faulty.
Stop button (5PB) or related circuitry (111)
shorted.
Start cycle runs but gun

does not light.
Check ignition circuitry.

See Ignition under Manual Test Functions
above.
Start cycle runs, gun

lights but powder feeder
does not start.
Check feeder circuitry.

See powder feeder under Manual Test Functions above.
Gun lights but goes out

under full operating flow.
Check lighting flow settings; adjust, if necessary.

Check gun hardware. (Refer to spray gun
manual.)
Gun does not shut down. Press E-STOP.

Check Stop button (5PB) or related circuitry
(111).
54
MAN 41151 EN 06
Index
A
additional documents ........................ 4
air requirements .............................. 27
alarms ..................................... 34, 40
authorized use .................................. 9
C
compatibility ................................... 27
components
Distribution Unit 24, 25
Electrical Control Unit 20, 22
function of 16
Gas Control Unit 17, 19
System Status Monitor 16
compressed gases .......................... 12
connection ..................................... 28
cooling water 30
electrical 30
exhaust interlock 40
external equipment 33
gas 28
multiple systems 38
remote alarms, robot faults 40
remote emergency stop (E-STOP) 39
remote operator pendant 36
robot 37
controls and displays ....................... 16
cooling water
connections 30
setpoints 45
copyright restrictions ......................... 4
D
dimensions ..................................... 27
Distribution Unit ........................ 24, 25
door interlock .................................. 50
E
ear protection ................................. 10
connections 22
functions 20
electrical power .............................. 11
electrodes ...................................... 51
emergency stop (E-STOP) ....36, 37, 39
exhaust interlock ............................. 40
external equipment interface ............ 33
eye protection ................................... 9
MAN 41151 EN 06
F
feedback board ............................... 49
feeding ........................................... 44
G
gas
connection 28
requirements 27
Gas Control Unit
connections 19
functions 17
gas hoses and piping ...................... 13
H
hazardous materials ........................ 11
hazardous materials and conditions .... 8
heat ............................................... 11
I
information about this manual ............ 3
input commands ............................. 34
installation ...................................... 28
intended audience ............................ 4
intended use .................................... 3
interlocks ....................................... 50
M
maintenance .................................. 49
multiple system interface ................. 38
O
operating procedures ...................... 43
operation ........................................ 41
automatic 44
output commands ........................... 35
overview ........................................ 14
P
personal protection ..................... 8, 10
power requirements ........................ 27
principles of operation ..................... 15
product description ......................... 14
purge ............................................. 43
R
remote commands .......................... 34
remote operation interface ............... 34
remote operator pendant ........... 26, 36
robot ........................................ 37, 40
S
safety ............................................... 7
compressed gases 12
55
ear protection 10
electrical power 11
eye protection 9
gas hoses and piping 13
general regulations 9
hazardous materials 11
heat 11
personal protection 10
specific regulations 9
symbols 7
ventilation and exhaust 10
safety interlocks .............................. 50
service ........................................... 48
setup .............................................. 28
shutdown ........................................ 42
site requirements ............................ 28
specifications .................................. 27
starting current ................................ 49
startup ............................................ 41
status messages ............................. 46
symbols
additional 8
hazardous materials and conditions 8
personal protection 8
safety 7
System Status Monitor
functions 16
T
technical data ................................. 27
test functions .................................. 43
troubleshooting ............................... 52
V
ventilation and exhaust .................... 10
voltage divider ................................ 32
W
weight ............................................ 27
56
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9MC Plasma Control Unit

9MCD Plasma Distribution Unit

2008 Sulzer Metco

Supplier of this component:

Sulzer Metco (US) Inc.

Find your Sulzer Metco sales office:

Reason for revision

Revise to current documentation standards;

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

9MC Plasma Control Unit

Automatic and semi-automatic plasma

Thermal Spray Processes

Atmosphere [Air] Plasma Spraying

Compatible Spray Guns

Compatible Powder Feeders

1. Requires modified 9MC Plasma Control Unit.

Information About This Manual

Table of Contents at the front of the manual

Index at the rear of the manual

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit Parts

Electrical Schematic and Gas Flow Diagrams, DIA 74602

Safety 9M Plasma Spray System, MAN 41154

Plasma Control Unit.

Everyone working with the 9MC

Plasma Control Unit.

Operators, Maintenance Engineers

Sulzer Metco reserves the right to make improvements to the 9MC

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

Installation and Commissioning

Environmental / Site Requirements .................................................................28

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

Status Messages .............................................................................................46

Feedback Board ..............................................................................................49

Power-On Check .............................................................................................52

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

This chapter contains important safety information. Please read it prior

Presentation of general, but important information which

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

Hand protection must be worn.

Respiratory protection must be worn.

Face protection (welding gear) must be

Protective clothing must be worn.

Eye protection must be worn.

Head protection must be worn.

Protective footgear must be worn.

Keep hands, hair, clothing and tools

Hazardous Materials and Conditions

Strong electromagnetic fields present.

Flammable material or presence of

Poisonous substance present

High voltage or risk of electric shock

High pressure warning.

Ultraviolet, infra-red or other damaging light radiation present.

Warning of laser present.

Noise hazard present.

Do not stack warning.

Heavy weight present above.

Electrical ground is not present.

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

General Safety Regulations

Use of Sulzer Metco original spare parts is strongly recommended.

It is recommended that all personnel connected with thermal spraying