SERVICE MANUAL

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

9040 CLASSIC HIGH VOLTAGE POWER SUPPL

VOLT Y
SUPPLY
(for the REA TM & M90 TM Classic Coating Systems)

E
IV
H
C
R
A

MODEL:
76447-10X / REA-IV APPLICA
APPLICATT OR
76447-12X / REA-III APPLICA
APPLICATT OR
76447-13X / REA-III AUT OMA
AUTOMA TIC
OMATIC
76447-14X / M90 CLASSIC APPLICA T OR
APPLICAT

IMPOR
IMPORT TANT
ANT:: Before using this equipment,
carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions in
this manual. Keep this Service Manual for
future reference.
Service Manual Price: 25.00
25.00 (Euro)
$30.00 (U.S.)
N O T E : This manual has been changed from revision CP-97-02.4 to revision CP-97-02.5
CP-97-02.5.
Reasons for this change are noted under Manual Change Summary inside the back
cover of this manual.

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CP-97-02.5
 9040 Classic for REA & M90 Systems - Contents

CONTENTS
PAGE
SAFETY: 1-6
SAFETY PRECAUTIONS........................................................................................................... 1
HAZARDS / SAFEGUARDS....................................................................................................... 2-5

ATEX 7-8
EUROPEAN ATEX DIRECTIVE................................................................................................. 7
EUROPEAN ATEX LABELS....................................................................................................... 8

INTRODUCTION: 9-11
GENERAL DESCRIPTION......................................................................................................... 9-10
SPECIFICATIONS...................................................................................................................... 10
9040 CLASSIC FOR REA / M90 FEATURES............................................................................ 11

INSTALLATION: 12-16
LOCATION.................................................................................................................................. 12
INPUT VOLTAGE SELECTION................................................................................................. 12
INPUT CONNECTIONS............................................................................................................. 13
EXTERNAL CONNECTIONS..................................................................................................... 13-15
TYPICAL REA AND M90 APPLICATOR INSTALLATIONS...................................................... 16

OPERATION: 17-20
OPERATING CONTROLS......................................................................................................... 17
THEORY OF OPERATION........................................................................................................ 18
OPERATING PROCEDURES.................................................................................................... 18-19

MAINTENANCE: 21-34
ROUTINE PREVENTIVE MAINTENANCE................................................................................ 21
TROUBLESHOOTING................................................................................................................ 21-24
SERVICE LEVEL......................................................................................................................... 24
REPLACEMENT PROCEDURES.............................................................................................. 25-29
TROUBLESHOOTING GUIDE................................................................................................... 30-31
TROUBLESHOOTING DIAGRAM............................................................................................. 32
9040 CLASSIC POWER SUPPLY BLOCK DIAGRAM............................................................. 33

PARTS IDENTIFICATION: 35-38

9040 CLASSIC FOR REA AND M90 PARTS DIAGRAM / PARTS LIST................................. 35-36
RECOMMENDED SPARE PARTS............................................................................................ 37
ACCESSORIES.......................................................................................................................... 37

WARRANTY POLICIES: 39
LIMITED WARRANTY.................................................................................................................39

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CP-97-02.5
9040 Classic for REA & M90 Systems - Safety

SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
ITW Ransburg coating system, read and
understand all of the technical and safety literature
for your ITW Ransburg products. This manual
contains information that is important for you to
know and understand. This information relates to
USER SAFETY and PREVENTING EQUIPMENT
PROBLEMS. To help you recognize this
information, we use the following symbols. Please
pay particular attention to these sections.
A WARNING! states information to alert you
to a situation that might cause serious injury
if instructions are not followed.
A CAUTION! states information that tells
how to prevent damage to equipment or how
to avoid a situation that might cause minor
injury.
! WARNING
> The user MUST read and be familiar
with the Safety Section in this manual and
the ITW Ransburg safety literature therein
identified.
> This manual MUST be read and 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 prior to installing,
operating, and/or servicing this equipment.

A NOTE is information relevant to the ! WARNING

procedure in progress. > The hazards shown on the following
page may occur during the normal use of
While this manual lists standard specifications this equipment. Please read the hazard
and service procedures, some minor deviations chart beginning on page 2.
may be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this
manual with your system installation drawings
and appropriate ITW Ransburg equipment
manuals to reconcile such differences.

Careful study and continued use of this manual will

provide a better understanding of the equipment
and process, resulting in more efficient operation,
longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system,
contact your local ITW Ransburg representative
or ITW Ransburg.

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 9040 Classic for REA & M90 Systems - Safety

AREA HAZARD SAFEGUARDS

Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.

Spray Area Fire Hazard The 76447 power supply MUST be installed in a
NON-hazardous location in accordance with NFPA-
Improper or inadequate operation 33.
and maintenance procedures will
cause a fire hazard. Fire extinguishing equipment must be present in the
spray area and tested periodically.
Protection against inadvertent
arcing that is capable of causing Spray areas must be kept clean to prevent the
fire or explosion is lost if any safety accumulation of combustible residues.
interlocks are disabled during
operation. Frequent power supply Smoking must never be allowed in the spray area.
shutdown indicates a problem in
the system requiring correction. The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing, or maintenance.

When using solvents for cleaning:

Those used for equipment flushing should have flash

points equal to or higher than those of the coating
material.

Those used for general cleaning must have flash

points above 100oF (37.8oC).

Spray booth ventilation must be kept at the rates

required by NFPA-33, OSHA, and local codes. In
addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.

Electrostatic arcing must be prevented.

Test only in areas free of combustible material.

Testing may require high voltage to be on, but only

as instructed.

Non-factory replacement parts or unauthorized

equipment modifications may cause fire or injury.

If used, the key switch bypass is intended for use

only during setup operations. Production should
never be done with safety interlocks disabled.

Never use equipment intended for use in waterborne

installations to spray solvent based materials.

The paint process and equipment should be set up

and operated in accordance with NFPA-33, NEC,
and OSHA requirements.

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CP-97-02.5 2
9040 Classic for REA & M90 Systems - Safety

AREA HAZARD SAFEGUARDS

Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.
Spray Area Electrostatic Arcing Ensure the Ground Wire Assembly is connected from the
power supply ground stud to a true earth ground.

Ensure that the power supply is plugged into a properly

grounded outlet.

If shocks or sparks are noticed at any point in the spray

system, immediately turn off the power supply and check
the complete system for the cause. DO NOT use the
system again until the problem has been identified and
corrected.

Never operate the applicator without properly grounding the

following:

A. Operators must be grounded. Rubber soled

insulating shoes should not be worn. Grounding
leg straps may be used.

Operators must maintain contact with the handle of

the applicator. If work gloves are used, the palm
section should be cut out.

Operators must remove from themselves all metal

objects that are not grounded.

NOTE:REFER TONFPA-33,REGARDINGOPERATOR
GROUNDING.

B. Parts being sprayed. Resistance between the part and

a grounded conveyor must not exceed 1 megohm.

C. Every metal and conductive object in the spray

area. This includes the booth, parts hangers, fire
extinguishers, conductive flooring, etc.

Grounded conductive flooring must be provided in the

spray area.

Turn off voltage at the power supply before flushing out,

cleaning, or removing any parts from the applicator.

Provide proper protection for waterborne supply systems.

Never install an applicator into a fluid system using an

isolated solvent supply.

Always discharge Waterborne system capacitance prior to

servicing.

Do not touch applicator electrode while applicator is

energized.

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 9040 Classic for REA & M90 Systems - Safety

AREA HAZARD SAFEGUARDS

Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.
General Use and Improper operation or maintenance Personnel must be given training in accordance with
Maintenance may create a hazard. the requirements of NFPA-33.

Personnel must be properly trained Instructions and safety precautions must be read
in the use of this equipment. and understood prior to using this equipment.

Comply with appropriate local, state, and national

codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33,and your insurance company requirements.

Always turn power to the power supply OFF, unplug

the electrical cord from its outlet, and remove the
front panel fuse, before opening the power supply
door. If necessary, lock the power supply out so that
it cannot be turned ON until the work is finished.

Whenever removing high voltage cables from

equipment, ground the contact end of the cable by
holding the cable such that the contact touches
earth ground for several seconds. Do not touch the
contact until it has been grounded. This will reduce
the possibility of residual charge causing electrical
shock.

The High Voltage Multiplier Assembly contains energy

storage components that can cause serious shock
injury, and therefore is not field repairable. Warranty
will be voided if the High Voltage Multiplier seal is
broken. If the High Voltage Multiplier is defective
contact your authorized ITW Ransburg representative
for exchange or repair.

The High Voltage Multiplier and high voltage cable

contain significant capacitance that will store charge.
Allow approximately 10 seconds for this charge to
bleed off before opening the cabinet door or removing
the high voltage cable from the power supply or
spray applicator.

Explosion Hazard/ Halogenated hydrocarbon Aluminum is widely used in other spray application
Incompatible solvents for example: methylene equipment - such as material pumps, regulators,
Materials chloride and 1,1,1,-Trichloroethane triggering valves, etc. Halogenated hydrocarbon
are not chemically compatible with solvents must never be used with aluminum
the aluminum that might be used equipment during spraying, flushing, or cleaning.
in many system components. The Read the label or data sheet for the material you
chemical reaction caused by these intend to spray. If in doubt as to whether or not a
solvents reacting with aluminum coating or cleaning material is compatible, contact
can become violent and lead to an your material supplier. Any other type of solvent
equipment explosion. may be used with aluminum equipment.

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CP-97-02.5 4
9040 Classic for REA & M90 Systems - Safety

AREA HAZARD SAFEGUARDS

Tells where hazards Tells what the hazard is. Tells how to avoid the hazard.
may occur.
Toxic Substances Certain material may be harmful if Follow the requirements of the Material Safety Data
inhaled, or if there is contact with Sheet supplied by coating material manufacturer.
the skin.
Adequate exhaust must be provided to keep the air
free of accumulations of toxic materials.

Use a mask or respirator whenever there is a chance

of inhaling sprayed materials. The mask must be
compatible with the material being sprayed and its
concentration. Equipment must be as prescribed by
an industrial hygienist or safety expert, and be NIOSH
approved.

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

Personnel Safety Fluid Injection Injury Never let any part of the body come in direct contact
(High Pressure with the fluid stream exiting from the nozzle. If fluid
Equipment) leaks occur in the applicator or in the fluid delivery
components, depressurize fluid system before
servicing.

Never aim the applicator at any part of the body under

any circumstances.

If you are injured by high pressure fluid injection then

immediate medical treatment MUST be sought.

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 9040 Classic for REA & M90 Systems - Safety

NOTES

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CP-97-02.5 6
9040 Classic for REA & M90 Systems - Atex
EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
ATEX
The following instructions apply to equipment
covered by certificate number Sira 08ATEX5040X:
1. The equipment may be used with flammable
gases and vapors with apparatus groups II and
with temperature class T6.
2. The equipment is only certified for use in
ambient temperatures in the range +12.8C to
+40C and should not be used outside this range.
3. Installation shall be carried out by suitably
trained personnel in accordance with the applicable
code of practice e.g. EN 60079-14:1997.
4. Inspection and maintenance of this equipment
shall be carried out by suitably trained personnel
in accordance with the applicable code of practice
e.g. EN 60079-17.
5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and
adjustment of the equipment shall be fitted by
suitably trained personnel in accordance with the
manufacturer's documentation.
Refer to the "Table of Contents" of this service
manual:
a. Installation
b. Operation
c. Maintenance
d. Parts Identification
7. Components to be incorporated into or used as
replacement parts of the equipment shall be fitted
by suitably trained personnel in accordance with
the manufacturer's documentation.
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7 CP-97-02.5
8. The certification of this equipment relies upon
the following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility
of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring
that the type of protection provided by the equipment
is not compromised.
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
Suitable precautions: e.g. regular checks as part
of routine inspections or establishing from the
material's data sheets that it is resistant to specific
chemicals.
Refer to "Specifications" in the "Introduction"
section:
a. All fluid passages contain stainless steel
or nylon fittings.
b. High voltage cascade is encapsulated with
a solvent resistant epoxy.
9. A recapitulation of the certification marking is
detailed in the "Atex" section, on the next page,
drawing number: 76454-XX.
10. The characteristics of the equipment shall be
detailed e.g. electrical, pressure, and voltage
parameters.
The manufacturer should note that, on being put
into service, the equipment must be accompanied
by a translation of the instructions in the language
or languages of the country in which the equipment
is to be used and by the instructions in the original
language.
 9040 Classic for REA & M90 Systems - Atex

76447-XXX 9040 Classic A TEX

ATEX Label 76454

Product Marking Definitions

Ex Certificate Number: Sira 08ATEX5040X

Sira = Notified Body performing EC-type

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

Product Marking

II 2 G

Ex = Specific marking of explosive protection

II = Equipment Group hazardous area charac-
teristics
2 = Equipment Category
G = Type of explosive atmosphere (gases, vapors,
or mists)

EEx 0.24mJ = The 76447 9040 Classic Power

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

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CP-97-02.5 8
9040 Classic for REA & M90 Systems - Introduction
INTRODUCTION
GENERAL DESCRIPTION
The ITW Ransburg REA Process
The REA Process is an air atomized method for
applying coatings to objects electrostatically. The
REA system applies a high voltage DC charge to
the applicator nozzle electrode, creating an
electrostatic field between the atomizer and the
target object. The target is electrically grounded
through its support which may be either stationary
or moving.
A regulated pressure fluid system delivers coating
material to the atomizer. At the atomizer, air is
applied which atomizes the coating material forming
a spray mist which, under the influence of the
electrostatic field, becomes electrically charged.
The charged particles are attracted to, and
deposited on, the target object. The forces between
the charged particles and the grounded target are
sufficient to turn most normal over-spray around
and deposit it on the side and back surfaces of the
target. Therefore, a high percentage of the spray
is deposited on the target.
The ITW Ransburg M90 Process
This is a combined air-airless atomization method
for electrostatically applying coatings to objects.
The M90 system applies a high voltage DC charge
to the applicator nozzle electrode, creating an
electrostatic field between the atomizer and the
target object. The target is electrically grounded
through its support, which may be either stationary
or moving.
A regulated high pressure fluid system delivers
coating material to the atomizer. There the coating
material is atomized by passing through an orifice
under pressure. The resulting spray mist then
becomes electrically charged under the influence
of the electrostatic field surrounding the atomizer.
The charged particles are attracted to and
deposited on the target object. The forces between
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9 CP-97-02.5
the charged particles and the grounded target are
sufficient to turn most normal overspray around
and deposit it on the side and back surfaces of the
target. Thus, a high percentage of the spray is
deposited on the target.
The 9040 Classic High Voltage
Voltage
Power Supply
The 9040 Classic Power Supply converts standard
AC line voltage to a high frequency, low voltage
signal ranging from 0 to 10 Vrms. This signal is
supplied to the High Voltage Multiplier where it is
converted to DC high voltage. The high voltage
DC is then transferred from the 9040 Classic
Power Supply to the REA/M90 applicator through
a super flex high voltage cable. The voltage/
current characteristic is designed to optimize the
charging process under varying load conditions
and to limit the operating current to a safe maximum
value.
In addition to supplying high voltage output to the
applicator, the 9040 Classic Power Supply also
provides controls for AC power ON/OFF, infinite
high voltage adjustment, a high voltage meter, a
current meter, a POWER ON indicator, a HIGH
VOLTAGE ON indicator, and a CURRENT
OVERLOAD indicator and reset switch. Addition-
ally, output terminals are provided for remote
overload reset and interlock connections for a
conveyor, exhaust fan and high voltage control on
all 9040 Classic Power Supplies.
 9040 Classic for REA & M90 Systems - Introduction

NOTE SPECIFICATIONS
SPECIFICATIONS
> The 9040 Classic Power Supply is fac-
tory supplied with a cabinet latch that can Physical
be opened using a slotted screwdriver. If Height: 14-inches
desired, the standard latch can be easily
replaced with a latch that requires the use Width: 12-inches
of a key to open. This key lock can be or-
dered from: Austin Hardware, Inc., 8001 Depth: 6-inches
Central Ave. N. E., Minneapolis, MN
55432; 1-800-328-2423; Key Lock Part Weight: 24-lbs.
Number: C8052-14A. Electrical
INPUT

The 9040 Classic Power Supply is avail- Voltage: 90-264 VAC

able for hand and automatic REA and
M90 applicators as follows: Current: 0.6/0.3 Amps AC

9040 Used With Applicator Frequency: 50/60 Hertz

Part # Applicator Type #
Wattage: 60 Watts (maximum)
76447-10X REA-IV Applicator 70404
76447-12X REA-III Solvent Applicator 70929 OUTPUT
REA-III Water Applicator 72316
Voltage: 0-65kV DC (76447-10x)
76447-13X REA-III Automatic 70393 0-85kV DC (76447-14x)
76447-14X M90 Classic Applicator 77132 0-90kV DC (76447-12x)
0-100kV DC (76447-13x)

Current: 200 Microamps (maximum)

NOTE Pneumatic
> Except where indicated, this manual is Supply Air: 100 psi maximum
applicable to all models of the 9040 Classic
Power Supply for the REA/M90 Systems.

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CP-97-02.5 10
9040 Classic for REA & M90 Systems - Introduction

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

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11 CP-97-02.5
 9040 Classic for REA & M90 Systems - Installation

INSTALLA
INSTALLATION
ALLATION
shown in Figure 2. In either case, the power
! WARNING supply MUST be mounted in an upright position.
> The 9040 Classic Power Supply MUST DO NOT lay the power supply on its side or back.
be located outside the hazardous area.
(See NFPA-33, OSHA, and ITW Ransburg
Bulletin - "Operating Your Electrostatic ! CAUTION
Coating System Safely".)
> DO NOT locate the power supply
> The user MUST read and be familiar near or adjacent to heat producing equip-
with the "SAFETY" section of this manual. ment such as ovens, high wattage lamps,
etc.
> 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 requirements for operat-
ing and servicing safely are followed. The
user should be aware of and adhere to ALL
local building and fire codes and ordinances
as well as NFPA-33 and OSHA prior to
installing, operating, and/or servicing this
equipment.
Figure 2: Wall Mount Brackets

NOTE INPUT VOLTAGE

VOLT
> As each installation is unique, this infor- SELECTION
mation is intended to provide general instal-
lation information for the 9040 Classic Power
The 9040 Classic Power Supply accepts uni-
Supply. Consult your authorized ITW Rans-
versal input voltage between 90 and 264 VAC.
burg distributor for specific directions per-
There is no need to change any switch settings
taining to the installation of your equipment.
when changing input from 115 to 230 VAC or
from 230 to 115 VAC.

LOCATION
LOCATION
NOTE
> 9040 units shipped from the factory for
Install the 9040 Classic Power Supply in an area
115 VAC input will have a 72771-06, 1 amp
outside the hazardous location, where it will be
front panel fuse installed. While 9040 units
protected from the possibility of environmental
shipped from the factory for 230 VAC input
intrusion, such as dust or moisture, and ambient
will have a 72771-01, 0.5 amp front panel
temperatures do not exceed 120oF, but as close to
fuse installed. If the other input is required,
the applicator as possible to minimize the length of
it is recommended that the fuse be changed
high voltage cable. The power supply may be free
in order to keep the same level of protec-
standing on any flat surface or wall mounted by
tion. Both fuses are shipped with 9040
rotating the wall mount brackets (supplied) as
Power Supplies.

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CP-97-02.5 12
9040 Classic for REA & M90 Systems - Installation
INPUT CONNECTIONS
Plug the AC line cord into a properly grounded
AC outlet.
NOTE
> In general, conduit must be used for ap-
proved AC installation, however, if national
and local codes permit, the AC power may
be supplied via the factory installed line
cord. If conduit is utilized, the power supply
wiring MAY be routed through an optional
explosion proof switch mounted on or near
the spray booth where it will be convenient
to the operator.
EXTERNAL
CONNECTIONS
NOTE
> When connecting external wires to the
9040 Classic Power Supply, route the wir-
ing through the external wiring grommet
located on the side panel.
High Voltage (High V
Voltage oltage)
Voltage)
Cable Connection
Remove the plastic protective plug from the High
Voltage Cable Connector and squirt enough
dielectric oil (70863-00 (supplied)) into the high
voltage tube to cover the electrical contact point.
NOTE
> Squirting 70863-00 dielectric oil down
the high voltage tube significantly reduces
corona discharge that can cause deterio-
ration of the high voltage connection com-
ponents.
With a clean, dry cloth, wipe the end of the high
voltage cable. Insert the high voltage cable into
the high voltage cable connector and tighten the
cable nut securely.
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13
Safety Ground
Crimp the appropriate connector onto the ground
wire assembly and install from the power supply
ground stud, located on the side panel, to a true
earth ground.
! CAUTION
> The Ground Wire Assembly MUST be
connected from the Power Supply Ground
Stud to a true earth ground.
Interlocks
! WARNING
> ALWAYS ensure that high voltage is
OFF before flushing the spray gun with
solvent. NEVER flush the spray applicator
with high voltage ON
ON, as this is a severe fire
hazard and risk to personnel safety. It is
recommended that the high voltage control
be interlocked with the solvent flush signal
so that high voltage is automatically locked
out whenever flushing occurs. Consult your
authorized ITW Ransburg representative for
information on interlocking the high voltage
OFF signal with the solvent flush signal.
As outlined in NFPA-33 and OSHA, the AC power
line must be series interlocked with both the
exhaust fan and conveyor. To interlock the 9040
Classic Power Supply with the exhaust fan and
conveyor, perform the following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged, and the ON/OFF
switch is in the OFF position.
2. Open the power supply cabinet door.
! WARNING
> ALWAYS double check that the power
supply is unplugged from its AC outlet
before working with any internal wiring.
CP-97-02.5
 9040 Classic for REA & M90 Systems - Installation
3. Using a small blade screwdriver, remove the
factory installed test jumper from 1TB-L1to 1TB-
L2.
4. Route exhaust fan and conveyor interlock
(supplied by user) wiring through the external
wiring grommet on the side of the power supply
and connect to 1TB-L1 and 1TB-L2 as shown in
Figure 3. The interlock contacts should be
rated for at least 1 Amp at 240 volts AC.
5. Secure the cabinet door, replace the fuse and
plug the power supply in.
Figure 3: Terminal Block One (1TB)
External Relay Contacts
A set of external relay contacts for high voltage
(K1) and overload (K2) conditions is provided at
6PL-5, -6 & -7. See Figure 10 for exact wiring
locations. These relay contacts are sometimes
useful in configuring the control of the applicator
system.
Pneumatic Connections
(76447-10x, -12x, & -14x)
Connect the Air Filter Assembly (supplied) to the
IN port of the air flow switch on the side of the 9040
Classic power supply. Connect regulated (100
psi maximum) factory air to the other end of the Air
Filter Assembly. Be sure that the fittings remain
clean and are securely tightened. Attach the
applicator air line to the OUT port of the air flow
switch.
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CP-97-02.5
When the applicator is triggered, the resulting air
flow closes the contacts of the air flow switch,
thereby activating high voltage at the applicator.
Pneumatic Connections
(76447-13x)
Connect an atomization air pressure signal to one
pressure switch port and a trigger air pressure
signal to the other. When pressure signals (25 psi
minimum, 100 psi maximum) are applied to both
switches their contacts close, thereby activating
high voltage at the applicator. Both pressure
switches must be activated to receive high voltage.
External High Voltage Control
Voltage
If a method of high voltage triggering, other than
the factory supplied method, is required, the 9040
Classic power supply allows for external high
voltage control from a PLC, pressure switch, air
flow switch, or other user supplied device. To turn
the high voltage on, the user supplied device must
create a contact closure between terminals 6 and
7 of terminal block one (1TB). To connect the user
supplied, external high voltage control device,
perform the following:
1. Ensure the front panel fuse is removed, the
power supply is unplugged, and the ON/OFF
switch is in the OFF position.
2. Open the power supply cabinet door.
3. Route the contact wires of the control device
through the external wiring grommet and connect
to the existing wiring for 1TB-6 and 1TB-7. The
control device contacts must be rated for at
least 100 millamps at 15 volts DC.
4. Secure the cabinet door, replace the fuse, and
plug in the power supply.
14
9040 Classic for REA & M90 Systems - Installation

External Overload Reset NOTES

The 9040 Classic power supply allows for use of
an external (normally closed) overload reset button.
This is convenient when the power supply is
mounted in a hard to reach or inconvenient location
or when it is desired to control overload reset of
several power supplies from a single location.

To utilize the external overload reset perform the

following:

1. Ensure the front panel fuse is removed, the

power supply is unplugged and the ON/OFF switch
is in the OFF position.

2. Open the power supply cabinet door.

3. Remove the factory installed jumper from 1TB-

5 to 1TB-6 and replace with contact wires of the
external reset device. The external reset device
contacts must be rated for at least 100
milliamps at 15 volts DC. The contacts of
the external reset device must be normally
closed.

4. Secure the cabinet door, replace the fuse, and

plug in the power supply.

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15 CP-97-02.5
 9040 Classic for REA & M90 Systems - Installation

Figure 4: Typical REA Applicator Installation

Figure 5: Typical M90 Applicator Installation

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CP-97-02.5 16
9040 Classic for REA & M90 Systems - Operation
OPERATION
OPERATION
Figure 6: Operating Controls
! WARNING
> The user MUST read and be familiar
with the Safety Precautions and
"Safety" Section in this manual and the
ITW Ransburg safety literature therein
identified BEFORE OPERATING the
9040 Classic power supply.
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17
! WARNING
> The electrical discharge, which is
available from the charging electrode of the
applicator, must not exceed 0.25 mJ of
energy. To achieve this limit, any flow of
energy from the paint supply through the
paint line to the applicator electrode MUST
be prevented by grounding the paint line at
the applicator handle or body. Verify that
the applicator is actually grounded BE-
FORE operating it! (See the appropriate
applicator manual.) If improper readings are
obtained, check that the power supply is
grounded. (See "Ground Test Procedure" in
the "Maintenance" section of this manual).
CP-97-02.5
 9040 Classic for REA & M90 Systems - Operation
THEOR Y OF OPERATION
THEORY OPERATION
Line voltage (90-264 VAC) is applied to input
terminals 8PL-1 and 8PL-2 of power supply
1SUP through the user supplied exhaust fan and
conveyor interlocks, fuse 1FU and ON/OFF switch
1SW.
The output of power supply 1SUP, through PC
board fuse F2 provides the DC voltage which
powers the PC board regulators and the AC
Power ON LED. The DC input to the oscillator
circuit is obtained from a board regulator through
high voltage adjust knob 1POT. The oscillator
circuit outputs a low voltage, high frequency AC
signal to the High Voltage Multiplier circuit. The
high voltage multiplier circuit rectifies the AC voltage
to DC and steps it up to provide rated kV to the
spray applicator via the high voltage cable. The
high voltage adjust knob controls the level of
output voltage from the oscillator to the High
Voltage Multiplier. In this manner, complete
adjustability from 0 to maximum kV of the spray
applicator is achieved.
The DC input to the oscillator is interlocked with
1TB terminals 6 and 7, such that the oscillator
will not function unless terminals 6 and 7 are
connected together. In this manner, high voltage
to the spray applicator is controlled as follows:
1. When air flows through the flow switch, the
switch contacts close connecting 1TB-6 and 7
together, thereby providing voltage to the REA-III,
REA-IV, and M90 Classic applicators.
2. When pressure signals are supplied to the
pressure switches, the switch contacts close
connecting 1TB-6 and 7 together, thereby providing
voltage to the REA-III automatic applicator.
3. Contact closure of a programmable controller
output, robot output, or some other user supplied
device connected to terminals 1TB-6 and 7 will
activate high voltage at the spray applicator.
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CP-97-02.5
4. For testing and troubleshooting, board jumper
JP4 connects 1TB-6 and 7 together, thereby
providing high voltage output (see PC Board Test
Jumper in the "Maintenance" section of this
manual).
OPERATING
OPERATING
PROCEDURES
1. Ensure that the AC power, pneumatics and
high voltage cables are connected as described in
the "Installation" section of this manual.
! CAUTION
> Check that the power supply is properly
grounded!
2. Be sure that the high voltage adjustment knob
is turned FULLY counter-clockwise.
3. Turn the ON/OFF switch to the ON position.
The green LED will light indicating that AC power
is being supplied to the power supply.
4. The voltage to the REA-III, REA-IV, and M90
Classic applicators is activated by supplying
adequate air to the flow switch when the applicator
is triggered. The voltage to the REA III Automatic
applicator is activated by supplying adequate
pressure signals to the power supply pressure
switches.
5. Turn the voltage adjustment knob to the desired
operating point as indicated by the kilovolt and
microamp meters.
Kilovolt and Microamp Meters
The kilovolt meter indicates the voltage in thousands
of volts (kV) present at the spray applicator. The
microamp meter indicates the current in millionths
of amps (A) leaving the electrode.
18
9040 Classic for REA & M90 Systems - Operation
High Voltage Adjustment Knob
Voltage
The high voltage adjustment knob allows infinite
control of the spray applicator electrode voltage
between 0 and rated kV.
Overload Indicator/Reset Button
Lighting of the yellow overload/reset lamp indicates
that an overload condition has occurred. The
overload circuitry is integral to the power supply
and is factory calibrated and sealed. It allows
normal operation, testing, and maintenance. It will
only activate if the spray applicator current exceeds
the preset limit as a result of component (barrel,
transformer, cable) failure or improper applicator
to target distance. If the overload should trip,
locate and correct the problem. Then reset the
overload by pushing the reset switch in, or turning
the ON/OFF switch OFF and back ON again.
The overload feature can be turned ON or OFF by
moving jumper JP5 on the main PC Board (see
Figure 7, in the "Maintenance" section of this
manual, for location of JP5). To turn the overload
circuit OFF, position jumper JP5 so that it covers
(shorts) pins 1 and 2. To turn the overload circuit
ON, position jumper JP5 so that it covers (shorts)
pins 2 and 3.
NOTE
> Power supplies for applicators are
shipped from the factory with the overload
circuit OFF, while those for automatic appli-
cators are shipped with the overload circuit
ON. This is because during normal use,
manually operated applicators may come in
close proximity to the part, causing an over-
load which requires the operator to cease
the painting operation while going to reset
the overload. In addition, the operator will
notice when a failed part may be causing
the spray applicator to operate at less than
optimum performance, thus the overload
circuit is not necessary for this purpose.
Automatic applicators, however, typically
have a fixed distance between electrode
and target and
("Note" continued in next column)
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19
thus it is not likely that the spray applicator
would come into close proximity with the
part during normal use. If it should, then it is
desired that an overload occur to alert main-
tenance so that the condition can be cor-
rected. Additionally, since there is no opera-
tor with automatic applicators, the overload
circuit is required to alert maintenance when
failed parts may be causing the spray appli-
cator to operate at less than optimum perfor-
mance.
When turning the overload circuit ON for applicator
units it may be necessary to adjust the setpoint at
which overload occurs. If so, contact your
authorized ITW Ransburg representative for
assistance.
High Voltage Safety Circuit
Voltage
The 9040 Printed Circuit Board (PCB) contains a
safety circuit that prevents high voltage from being
present at the applicator if the high voltage trigger
device (flow switch, pressure switch, PC contact,
etc.) has not been triggered. If a failure mode
should occur that would attempt to send high
voltage to the applicator, even though the high
voltage trigger has not been activated, the PC
board will shut down and enter an overload
condition. If repeated overloads occur, every time
the overload reset button is pushed, open the
cabinet door and see if the red LED (LED1, see
Figure 7, in the "Maintenance" section of this
manual for location) on the PC Board lights for
about 2 seconds after pushing the reset button. If
it does, the PC Board has failed and should be
replaced.
High Voltage ON Indicator
Voltage
The red high voltage on LED will light when high
voltage is present at the spray applicator.
AC Power ON Indicator
The green AC power ON LED will light when the
AC Power ON/OFF switch is in the ON position.
CP-97-02.5
 9040 Classic for REA & M90 Systems - Maintenance

NOTES

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CP-97-02.5 20
9040 Classic for REA & M90 Systems - Operation

MAINTENANCE
ROUTINE PREVENTIVE
MAINTENANCE
In general, little maintenance is necessary to
ensure proper operation. However, it is important
to keep the interior of the unit clean and free from
moisture or foreign material. For this reason the
following must be done:
1. Keep the exterior of the unit free from dust
accumulation.
2. Always clean the exterior prior to opening the
cabinet door.
obtained without the need to trigger the spray
applicator or user supplied control device. Just
remember to reposition the jumper after testing, so
that it covers only one terminal or the high voltage
will stay on all the time. (See Figure 7 for location
of test jumper JP4.)
! CAUTION
> If JP4 is left covering (shorting) both
terminals, high voltage will be on whenever
AC power is turned on. This could be
hazardous in some applications.

3. Open the cabinet door only to perform

maintenance or repair.

4. If the power supply end of the high voltage

cable becomes dirty, clean the end of the cable
with a suitable, clean, non-polar solvent and apply
a light coat of dielectric grease. On a yearly basis,
check to ensure that the dielectric oil (70863-00) is
covering the electrical contact point in the high
voltage tube. If not, add oil as needed.

Figure 7: Main PC Board

NOTE
> Squirting 70863-00 dielectric oil down Ground Test Procedure
Test
the HV tube significantly reduces corona
discharge that can cause deterioration of Equipment Required:
the HV connection components. - Ohmmeter (to measure resistance)

If shocks or sparks are noticed at any point in the

TROUBLESHOOTING
PC Board Test Jumper
Test
To assist in testing and troubleshooting, a jumper
(JP4) has been incorporated on the 9040 PC
Board. By covering (shorting) both terminals, the
high voltage on relay is triggered. Thus, for testing
and troubleshooting, high voltage output can be
spray system, immediately turn off the power
supply and check the complete system for proper
grounding. Proper grounding of the spray applicator
system can be verified as follows:
1. Ensure that the clamp of the 14 AWG ground
wire assembly is connected to true earth ground.
The resistance between the clamp and a known
earth ground should read less than 25 ohms.

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21 CP-97-02.5
 9040 Classic for REA & M90 Systems - Maintenance
2. Place one end of the ohmmeter on the clamp of
the ground wire assembly and the other end on the
power supply ground stud. If the ohmmeter reads
greater than 25 ohms, replace the 14 AWG ground
wire assembly.
3. Connect one end of the ohmmeter to the Power
Supply Ground Stud and the other to the metal
applicator body (automatics) or handle bracket
(applicators). If the ohmmeter reads greater than
25 ohms, repair or replace the high voltage cable.
NOTE
> On applicators, ground is passed from
the high voltage cable to the handle by
way of the handle set screw. Ensure the
set screw is completely tightened and re-
peat step 3 before replacing the high volt-
age cable on applicator units.
kV Output Test
Test
When a lack of high voltage at the spray applicator
indicates a problem, perform a kV Output Test of
the power supply to determine whether it is at fault.
Equipment Required:
- Calibrated ITW Ransburg 20791 High Voltage
Test Probe & Meter
kV Output Test Procedure
1. Turn AC power to the power supply OFF
OFF.
2. Remove the high voltage cable from the power
supply.
! WARNING
> Whenever removing high voltage cables
from equipment, ground the plug end of the
cable(s) by contacting the plug to electrical
ground. DO NOT touch the plug until it has
been grounded. This will eliminate the
possibility of residual charge causing electri-
cal shock.
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CP-97-02.5
3. Turn the high voltage adjust knob FULLY
counter-clockwise.
4. Open the cabinet door and position jumper JP4
on the main PC Board so that it covers (shorts)
both terminals.
5. Attach the appropriate high voltage cable to the
20791 Test Probe, properly ground the probe to a
true earth ground, and turn the test probe meter on
(see the "Operation Manual" for the 20791 Tester).
6. Insert the Test Probe High Voltage cable into
the power supply high voltage tube until it bottoms
out.
NOTE
> Ensure that the Test Probe high volt-
age cable makes good contact both inside
the Test Probe and inside the Power Sup-
ply High Voltage Tube.
7. Turn the power supply ON.
8. Turn the high voltage adjust knob FULLY
clockwise and read the output voltage displayed
on the meter, then turn the power supply OFF. If
the voltage read correctly (see "Specifications" in
the "Introduction" section of this manual), the
problem is not in the power supply and the high
voltage cable and spray applicator should be
checked for the cause. If the voltage did not read
correctly, the problem is with the power supply.
Consult the "Troubleshooting Guide" to locate the
specific problem.
9. Disconnect the 20791 Test Probe and reposition
JP4 so that it covers only one terminal. When
ready to resume spray operations, reconnect the
spray applicator high voltage cable and turn the
power supply on.
Current Output (SCI) Test
Test
When a lack of high voltage at the applicator
indicates a problem a Current Output (SCI) Test
may be performed, in addition to the kV output test,
to help determine if the power supply is at fault.
22
9040 Classic for REA & M90 Systems - Maintenance

Equipment Required: reading is not within the specified range refer to

- Test Resistor (16688-01) "Bench Testing" in the "Maintenance" section of
- Current Meter (76652-02) this manual. If the external current meter reads
correctly, but the meter on the power supply does
1. Turn AC power to the power supply OFF
OFF. not, replace the power supply meter.

2. Remove the high voltage cable from the power 8. Turn the power supply OFF. Disconnect the
supply. current meter (76652-02) and remove the test
resistor (16688-01). Reposition JP4 so that it
covers only one terminal. When ready to resume
spray operations, reconnect the high voltage cable
! WARNING and turn the power supply ON.
> Whenever removing high voltage cables
from equipment, ground the plug end of the
cable(s) by contacting the plug to electrical
ground. DO NOT touch the plug until it has POWER SUPPLIES AND
been grounded. This will eliminate the SCI VALUES
possibility of residual charge causing electri- SCI Range
cal shock. Power Supply (in A)
76447-10x, REA-IV 90 - 140 A
76447-12x, REA-III Applicator 120 - 170 A
3. Turn the high voltage adjust knob FULLY 76447-13x, REA-III Automatic 120 - 170 A
counter-clockwise. 76447-14x, M90 Classic Applicator 70 - 115 A

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

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

! CAUTION
> Ensure the current meter (76652-02) is
set to the A scale.

5. Open the cabinet door and position jumper JP4

on the main PC Board so that it covers (shorts)
both terminals.

6. Turn the AC power to the power supply ON.

7. SLOWLY adjust the kV adjust knob fully

clockwise. The external current meter (76652-02)
should read within the ranges noted in Figure 7. If
Figure 8: Current Output Test
it reads correctly, the problem is not in the power
supply and the high voltage cable and spray
applicator should be checked for the cause. If the

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 9040 Classic for REA & M90 Systems - Maintenance

Bench Testing
Testing
Equipment Required:
- Volt/ohmmeter
The "Troubleshooting Guide" provides information
for troubleshooting the power supply when improper
operation is obtained and the problem has been
traced to the power supply. Proper troubleshooting
should ONLY be accomplished with specific test
equipment by qualified electronics technicians or
authorized ITW Ransburg representatives.
! WARNING
> The troubleshooting procedure outlined
in the "Troubleshooting Guide" requires
measurement of voltage potentials that can
cause SERIOUS BODILY INJURY if
proper measuring procedures are not
followed. For this reason, proper trouble-
shooting should ONLY be accomplished
with specific test equipment by qualified
electronics technicians or authorized ITW
Ransburg representatives.
NOTE
> Before going through the trouble of a
complete bench test, jumper JP4 on the
main PC Board to trigger the high voltage
and see if the suspected problem goes
away. If it does, replace the high voltage
trigger device (flow switch, pressure
switch, PC contact, etc.) or repair the in-
ternal wiring of the power supply con-
nected to the trigger device, and test
again. If the problem does not go away,
then proceed with a bench test.
SERVICE LEVEL
Personnel who service this unit must be qualified
electronics technicians. Replacement parts are
designed to be made at the assembly level. (See
the "Parts Identification" section of this manual for
replacement assemblies and part numbers.)

Before troubleshooting, ensure that the power ! WARNING

supply is plugged into a live outlet of the appropriate
voltage. All electrical measurements in the
"Troubleshooting Guide" are nominal and may
vary as much as +/- 10% depending on the test
conditions and the test equipment used. Refer to
Figures 6 and 9 for location of parts called out in the
"Troubleshooting Guide" in this section.
> ALWAYS turn power to the power
supply OFF
OFF, unplug the electrical cord from
its outlet, remove the front panel fuse, and
lock the power supply out before making
repairs or replacements.

For bench testing, jumper JP4 should be used to ! CAUTION

trigger the high voltage output (see "PC Board
> DO NOT attempt to make repairs to
Test Jumper" discussed at the beginning of the
the printed circuit board! Do not attempt to
"Maintenance" section).
make repairs beyond those described. All
others should be made ONLY by ITW
! CAUTION Ransburg service personnel.
> The High Voltage Multiplier and high
voltage cable contain significant capaci-
tance that will store charge. ALLOW
approximately 10 seconds for this charge
to bleed off BEFORE opening the cabinet
door OR REMOVING the high voltage
cable from the power supply or spray
applicator.

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9040 Classic for REA & M90 Systems - Maintenance

REPLACEMENT ON/OFF Switch 1SW

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

Before making replacements, check for defective

wiring or connections between the affected
components. If there is a broken wire, defective
insulation, or dirty, loose, or corroded connections,
repair or replace them before going to the expense
of replacing a component.
! WARNING
> ALWAYS double check that the control
unit is unplugged from its AC outlet BE-
FORE working with any internal wiring.

Front Panel Fuse 1FU

1. Insert screwdriver into slot in front panel fuse 2. Remove the four (4) quick connect terminals
holder, push in, and rotate counter-clockwise. from the rear of ON/OFF switch 1SW.

2. Remove screwdriver and fuse holder will slide

out.
3. Remove fuse from fuse holder and replace with
new fuse (see "Parts Identification" in this manual
for part numbers).
4. Insert fuse holder back into front panel and with
a slight inward pressure, rotate screwdriver
clockwise until it locks into place.
PC Board Fuse F2
(Refer to Figure 6 for Fuse Location)
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Replace defective fuse (see "Parts Iden-
tification" section of this manual for part numbers).
NOTE
> It is recommended that the four (4)
ON/OFF switch wires be tagged with
their respective terminal connections to
1SW before removing.
3. Press panel retaining clips on top and bottom of
switch 1SW together and push switch out of panel
from the inside.
4. Press new switch (see "Parts Identification"
section of this manual for part number) into panel
opening with terminals 1A and 2A to the bottom of
the cabinet.
5. Reconnect the four (4) quick connect terminals
to the new switch as follows:

NOTE From To
1FU-2 1SW-1
> A spare F2 PC board fuse, included 1TB-N 1SW-2
from the factory, is located in the lower 1TB-S1 1SW-1A
right hand corner inside the cabinet door.
1TB-S2 1SW-2A

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

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 9040 Classic for REA & M90 Systems - Maintenance
AC Line Cord
1. Ensure power supply is unplugged from AC
outlet and open the cabinet door.
! WARNING
> ALWAYS double check that the control
unit is unplugged from its AC outlet BE-
FORE working with any internal wiring.
2. Using a screwdriver, disconnect damaged line
cord from 1TB-L1, 1TB-N, and 1TB-GROUND.
3. Loosen the line cord grommet on side panel
and pull damaged cord out.
4. Insert new line cord (see "Parts Identification"
section of this manual for part numbers) through
grommet and connect to 1TB as follows:
1TB-GROUND Line Cord Ground
1TB-N Line Cord Neutral/Common
1TB-L1 Line Cord Hot/Line
5. Tighten side panel grommet.
6. Secure cabinet door and plug power supply
back in.
Flow Switch 1FS
(76447-10x, -12x, & -14x)
1. Disconnect air lines from flow switch.
2. Ensure power supply is unplugged from AC
outlet and open cabinet door.
3. Remove two (2) wires from flow switch
terminals.
4. Remove two (2) hex nuts from flow switch
threads.
5. Pull out defective flow switch.
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CP-97-02.5
6. Attach two (2) wires to new flow switch (see
"Parts Identification" section of this manual for
ordering information) terminals (it does not matter
which one goes where).
7. With flow switch terminals pointing towards the
cabinet door, reach into cabinet and push new flow
switch threads through mounting holes.
8. Secure flow switch to side panel with two (2)
hex nuts.
9. Secure cabinet door and plug power supply
back in.
10. Reconnect air lines to flow switch.
Pressure Switch
(76447-13x)
1. Disconnect pressure signal input line from
pressure switch.
2. Ensure power supply is unplugged from AC
outlet and open cabinet door.
3. Remove two (2) wires from pressure switch
terminals.
4. Loosen hex nut from fitting and remove pressure
switch and fitting from the power supply.
5. Remove fitting from defective pressure switch
and install on new pressure switch (see "Parts
Identification" section of this manual for part
numbers).
6. Install new pressure switch in power supply by
securing hex nut to fitting.
7. Attach two (2) wires to the NO (normally open)
and C (common) terminals of the pressure switch
(it does not matter which one goes where). DO
NOT attach any wires to the NC terminal of the
pressure switch.
26
9040 Classic for REA & M90 Systems - Maintenance
8. Secure cabinet door and plug power supply
back in.
9. Reconnect pressure signal input line to
pressure switch.
High Voltage Multiplier
Voltage
NOTE
> Because the High Voltage Multiplier
contains energy storage components that
can cause serious shock injury, it is not
field repairable. Warranty will be voided if
the High Voltage Multiplier seal is broken.
If the High Voltage Multiplier is defective
contact your authorized ITW Ransburg
representative for exchange or repair.
1. Remove high voltage cable from power supply.
2. Ensure power supply is unplugged from AC
outlet and open cabinet door.
3. Unplug connector 1PL from the top of the High
Voltage Multiplier.
4. Remove the six (6) screws that mount the High
Voltage Multipliers aluminum housing to the back
panel.
5. Remove the High Voltage Multiplier Assembly
from the power supply.
6. Remove the three (3) screws that secure the
aluminum housing to the High Voltage Multiplier.
7. Install the aluminum housing on the new High
Voltage Multiplier (see "Parts Identification" section
of this manual for part numbers and ordering
information). Ensure connector 1PL faces the
front of the housing before installing.
8. Install the High Voltage Multiplier Assembly in
the power supply by securing the six (6) mounting
screws to the back panel.
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27
9. Plug connector 1PL back into the High Voltage
Multiplier.
10. Secure the cabinet door and plug the power
supply back in.
11. Reinstall the high voltage cable.
LED Display Board
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Unplug display board connector from 9PL on
main PC Board.
3. Remove two (2) screws that mount display
board to inside of cabinet door and remove display
board from power supply.
4. Install new display board (see "Parts
Identification" section of this manual for part
numbers) in power supply.
5. Reconnect connector 9PL to main PC Board.
6. Secure the cabinet door and plug the power
supply back in.
Kilovolt (kV) or
Microamp (A) Meter
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Remove two (2) hex nuts from wiring terminals
and remove wire lugs.
3. Remove four (4) hex nuts that mount meter to
door.
4. Remove old meter and install new one. (See
"Parts Identification" section of this manual for
ordering information.)
5. Reconnect wire lugs to meter (purple wire goes
to + terminal of meter).
6. Secure cabinet door and plug power supply
back in.
CP-97-02.5
 9040 Classic for REA & M90 Systems - Maintenance
Main PC Board
1. Ensure power supply is unplugged from AC
outlet and open cabinet door.
2. Disconnect plugs 6PL, 7PL, and 9PL (see
Figure 7).
3. Remove two (2) screws from heat sink base
and lift the PC Board out.
! CAUTION
> DO NOT remove the PC Board from
the heat sink as it is an integrated assem-
bly.
4. Insert new PC Board (see "Parts Identification"
section of this manual for part numbers) and
secure the two (2) heat sink screws.
5. Reconnect plugs 6PL, 7PL, and 9PL.
6. Secure cabinet door and plug power supply
back in.
High Voltage Adjust
Voltage
Potentiometer
1. Remove knob from high voltage adjust
potentiometer by using a 1/16" Allen wrench to
remove the two (2) set screws.
2. Ensure power supply is unplugged from AC
outlet and open cabinet door.
3. Remove the heat shrink tubing and unsolder
the three (3) wires from high voltage adjust
potentiometer 1POT.
NOTE
> It is recommended that the three (3)
wires be tagged with their respective ter-
minal connections to 1POT before
unsoldering.
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CP-97-02.5
4. Remove the hex nut securing 1POT to the
cabinet door and remove 1POT.
5. Install the new potentiometer (see "Parts
Identification" section of this manual for part
numbers) in the cabinet door.
6. Using heat shrink tubing and appropriate solder
techniques, solder the three (3) wires to the new
potentiometer as follows:
From To
7PL-1 1POT-1
7PL-4 1POT-2
7PL-5 1POT-3
7. Secure the cabinet door and plug the power
supply back in.
8. Reinstall adjust knob using 1/16" Allen wrench.
Power Supply 1SUP
1. Ensure 9040 Classic Power Supply is
unplugged from AC outlet and open the cabinet
door.
2. Remove the four (4) screws from the 1SUP
power supply cover plate and remove the plate.
! WARNING
> ALWAYS double check that the power
supply is unplugged from its AC outlet
BEFORE removing the cover plate from
power supply 1SUP.
3. Remove connectors 8PL and 10PL from power
supply 1SUP.
4. Remove the four (4) cover plate standoffs from
power supply 1SUP and remove the power supply
from the unit.
28
9040 Classic for REA & M90 Systems - Maintenance

5. Install new 1SUP power supply (see "Parts NOTES

Identification" section of this manual for part
numbers) using the four (4) cover plate standoffs.
Ensure larger terminal strip (10PL) of power supply
1SUP faces left side of unit as shown in Figure 9.

6. Connect connectors 8PL and 10PL to new

power supply and reinstall cover plate.

7. Secure cabinet door and plug power supply

back in.

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29 CP-97-02.5
 9040 Classic for REA & M90 Systems - Maintenance
TROUBLESHOOTING GUIDE
General Problem Possible Cause
AC Power ON 1. Front panel fuse 1FU or PC board
Indicator (Green fuse F2 defective
LED) Does Not
Light when ON/OFF 2. Connector 7PL or 9PL not properly
Switch is ON plugged into main PC board
3. Improper input line voltage
4. Improper exhaust fan or conveyor
interlock connections
5. Defective ON/OFF switch 1SW
6. Defective power supply 1SUP
7. Defective LED display board
No or Low kV 1. High voltage adjust knob not set to
Output at Spray proper value
Applicator when HV
ON Indicator (Red 2. Connector 6PL or 1PL not properly
LED) is Lit plugged into respective locations
3. Defective spray applicator or high
voltage cable
4. Loose or broken wire in power
supply
5. Main PC board defective
6. Defective high voltage multiplier
(Continued On Next Page)
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CP-97-02.5
Solution
1. Replace defective fuse.
2. Properly attach connector.
3. Ensure voltage across terminals L1 and N of
terminal block 1TB is between 90 and 264
VAC.
4. Correct connection so that voltage across
terminals L2 and N of 1TB is between 90 and
264 VAC.
5. Voltage across terminals 1A and 2A of ON/
OFF switch 1SW should be between 90 and
264 VAC. If not, replace switch 1SW.
6. Voltage across terminals 2 and 3 of plug 7PL
on main PC board should be 18 VDC. If not,
replace power supply 1SUP.
7. If all other functions of power supply are
normal, replace LED display board.
1. Set high voltage adjust knob to proper value.
2. Properly attach connector.
3. Perform a kV Output Test on the power supply.
If proper readings are obtained, check cable or
spray applicator for cause (see spray applicator
service manual).
4. Check all wiring connections for integrity.
Repair wiring as needed.
5. Disconnect 1PL from high voltage multiplier
and plug into LTST5000 Tester. If improper
readings are obtained, replace main PC board.
6. Disconnect HV cable from power supply. If
problem is still present, connect LTST5000
Tester to 1PL and test. If results of test are
OK, replace High Voltage Multiplier.
30
9040 Classic for REA & M90 Systems - Maintenance
TROUBLESHOOTING GUIDE (Cont.)
General Problem Possible Cause
No kV Output at 1. Connector 6PL not properly
Spray Applicator plugged into PC board
and High Voltage
ON Indicator (Red 2. Improper air signal to high voltage
LED) is Not Lit trigger device (air flow switch,
pressure switch, etc.)
3. Defective high voltage trigger
device (flow switch, pressure
switch, etc.) or wiring
4. Main PC board defective
1. Parts are too close to the spray
Power Supply applicator
Overloads
Excessively 2. Overload set point set too sensitive
3. Defective spray applicator
4. Defective high voltage cable
5. Main PC board defective
6. Defective high voltage multiplier
Component Not 1. Wiring to/from component loose
Working, but kV or broken
Output OK
2. Defective component
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31
Solution
1. Properly attach connector.
2. Turn signal on and adjust to proper setting.
3. Short PC board jumper JP4. If high voltage
comes on, replace high voltage trigger device
or repair wiring from trigger device to PC board.
4. Replace main PC board.
1. Ensure sufficient distance between spray
applicator and parts.
2. Adjust PC board potentiometer 1 turn counter-
clockwise to make less sensitive. Repeat if
necessary.
3. Disconnect high voltage cable from spray
applicator and test in open air, at least 1-foot
from surrounding objects. If overload goes
away, check spray applicator for cause.
(Warning: Contact end of cable will be at
high voltage; after testing, discharge
contact by contacting to ground before
touching!)
4. Test power supply with high voltage cable
removed. If overload goes away, replace the
high voltage cable.
5. Place PC board jumper JP5 over pins 1 and 2
(overload OFF) and test. If power supply
overloads, replace main PC board.
6. If 1 thru 5 above are OK, replace the high
voltage Multiplier.
1. Repair loose or broken wire.
2. Replace component.
CP-97-02.5
 9040 Classic for REA & M90 Systems - Maintenance

Figure 9: Troubleshooting Diagram

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CP-97-02.5 32
9040 Classic for REA & M90 Systems - Maintenance

Figure 10: 9040 Classic Power Supply Block Diagram

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33 CP-97-02.5
 9040 Classic for REA & M90 Systems - Maintenance

NOTES

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CP-97-02.5 34
9040 Classic for REA & M90 Systems - Parts Identification

PARTS IDENTIFICA
ARTS TION
IDENTIFICATION

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

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35 CP-97-02.5
 9040 Classic for REA & M90 Systems - Parts Identification

PAR
9040 CLASSIC for REA & M90 - PARTS
ARTS LIST 11)
(Figure 11)
Item # Part # Description Notation
1 PC Board and Heat Sink Assembly:
76892-10 For 76447-10X, REA-IV Applicator (70404)
76892-12 For 76447-12X, REA-III Applicator (70929, 72316)
76892-13 For 76447-13X, REA-III Automatic (70393)
76892-15 For 76447-14X, M90 Classic Applicator (77132)
2 High Voltage Multiplier (Oil-Filled):
76304-02 For 76447-10X, 65kV
76304-07 For 76447-14X, 85kV
76304-01 For 76447-12X and 76447-13X, 90kV
3 76434-01 ON/OFF Switch 1SW
4 70556-03 High Voltage Adjust Potentiometer 1POT
5 76436-91 Kilovolt (kV) Meter 1M
6 76436-92 Microamp (A) Meter 2M
7 Air Flow Switch Assembly: 1FS
13742-01 For 76447-10X and 76447-12X
13742-02 For 76447-14X
25766-106 Pressure Switch for 76447-13X 1PS, 2PS
8 75337-05 Power Supply, 18 VDC 1SUP
9 LSME0082-04 Fuse, PC Board, Slow Blow, 4 Amp F2
10 Fuse, Front Panel:
72771-06 Slow Blow, 1 Amp, 110-120 VAC Input 1FU
72771-01 Slow Blow, 0.5 Amp, 220-240 VAC Input 1FU
11 6262-00 AC Line Cord
12 70539-00 Ground Wire Assembly
13 76455-02 LED Display Board
14 Overload Indicator and Reset Switch Assembly:
76442-01 Reset Switch, Normally Closed
76441-00 Lens, Yellow
76443-01 Bulb
15 5627-00 Rubber Feet

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CP-97-02.5 36
9040 Classic for REA & M90 Systems - Parts Identification

SPARE
9040 CLASSIC for REA & M90 - RECOMMENDED SP PAR
ARE PARTS
ARTS
Description Part # No. of Applicators Notes
Fuse, Front Panel 72771-06 1 1 2 2
Deluxe Test Kit 76652-04 1 1 1 1 For Troubleshooting
Purposes Only
Test Resistor 16688-01 1 1 1 1 For Troubleshooting
Purposes Only
Fuse, PC Board LSME0082-04 2 4 6 8
PC Board Assembly, 76892-10 1 1 1 2 For 76447-10
REA-IV Hand
PC Board Assembly, 76892-12 1 1 1 2 For 76447-12
REA-III Hand
PC Board Assembly, 76892-13 1 1 1 2 For 76447-13
REA-III Auto
PC Board Assembly, 76892-15 1 1 1 2 For 76447-14
M90 Classic
High Voltage Multiplier 76304-01 1 1 1 1 For 76447-12 & -13
High Voltage Multiplier 76304-02 1 1 1 1 For 76447-10
High Voltage Multiplier 76304-07 1 1 1 1 For 76447-14
Power Supply Tester LTST5000-00 1 1 1 1 For Troubleshooting
Purposes Only

9040 CLASSIC for REA & M90 - ACCESSORIES

Description Part #
Control Unit/Power Supply Test Assembly LTST5000-00
High Voltage Test Probe and Meter 76652-01
Current/SCI Meter 76652-02
Deluxe Meter Kit (Includes 76652-01, 76652-02, and Paint Meter) 76652-04
Test Resistor 16688-01

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37 CP-97-02.5
 9040 Classic for REA & M90 Systems - Parts Identification

NOTES

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CP-97-02.5 38
9040 Classic for REA & M90 Systems - Warranty Policies

WARRANTY POLICIES
LIMITED WARRANTY
WARRANTY
ITW Ransburg will replace or repair without charge
any part and/or equipment that falls within the
specified time (see below) because of faulty
workmanship or material, provided that the
equipment has been used and maintained in
accordance with ITW Ransburg's written safety
and operating instructions, and has been used
under normal operating conditions. Normal wear
items are excluded.
THE USE OF OTHER THAN ITW RANS-
BURG APPROVED PARTS, VOID ALL
WARRANTIES.
SPARE PARTS: One hundred and eighty (180)
days from date of purchase, except for rebuilt
parts (any part number ending in "R") for which the
warranty period is ninety (90) days.
EQUIPMENT: When purchased as a complete
unit, (i.e., guns, power supplies, control units,
etc.), is one (1) year from date of purchase.
WRAPPING THE APPLICATOR, ASSO-
CIATED VALVES AND TUBING, AND
SUPPORTING HARDWARE IN PLASTIC,
SHRINK-WRAP, OR ANY OTHER NON-
APPROVED COVERING, WILL VOID THIS
WARRANTY.
ITW RANSBURG'S ONLY OBLIGATION
UNDER THIS WARRANTY IS TO REPLACE
PARTS THAT HAVE FAILED BECAUSE
OF FAULTY WORKMANSHIP OR MATER-
IALS. THERE ARE NO IMPLIED WARRAN-
TIES NOR WARRANTIES OF EITHER
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. ITW RANS-
BURG ASSUMES NO LIABILITY FOR
INJURY, DAMAGE TO PROPERTY OR
FOR CONSEQUENTIAL DAMAGES FOR
LOSS OF GOODWILL OR PRODUCTION
OR INCOME, WHICH RESULT FROM USE
OR MISUSE OF THE EQUIPMENT BY
PURCHASER OR OTHERS.
EXCLUSIONS:
If, in ITW Ransburg's opinion the warranty item in
question, or other items damaged by this part was
improperly installed, operated or maintained, ITW
Ransburg will assume no responsibility for repair
or replacement of the item or items. The purchaser,
therefore will assume all responsibility for any cost
of repair or replacement and service related costs
if applicable.

FLUID HANDLING: One (1) year from date of

purchase (i.e., Totalizer, CCV Valves, etc.).

AIR BEARING ROTATORS: Fifteen thousand

(15,000) hours or three (3) years, whichever occurs
first. Warranty period begins on the date of
purchase.

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39 CP-97-02.5
 MANUAL CHANGE SUMMARY
SUMMARY
This manual was published to replace Service
Manual CP-97-02.4, 9040 Classic High Voltage
Power Supply for the REA/REM/M90 Classic
Coating Systems, to make the following changes:

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

2. Added "Atex" section.

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CP-97-02.5
Service Manual Price: 25.00
25.00 (Euro)
$30.00 (U.S.)

Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260/665-8800
Fax: 260/665-8516

Technical/Service Assistance
Automotive Assembly and Tier I Telephone: 800/ 626-3565 Fax: 419/ 470-2040
Industrial Systems Telephone: 800/ 233-3366 Fax: 419/ 470-2071
Ransburg Guns Telephone: 800/ 233-3366 Fax: 419/ 470-2071
www.itwransburg.com

E
Technical Support Representative will direct you to the appropriate telephone number
for ordering Spare Parts. IV
H
C
R
A

Form No. CP-97-02.5

2008 Illinois Tool Works Inc. All rights reserved. Litho in U.S.A.
Models and specifications subject to change without notice. 05/08