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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

9MC Plasma Control Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

Maintenance Engineers

7 Troubleshooting

Maintenance Engineers

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


Plasma Control Unit without prior notice.

MAN 41151 EN 06

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

Product Description

2.1

Overview

1
4

9mc_over

1
2
3
4
5

14

9MC Plasma Control Unit


Status Monitor
Gas Control Unit
Electrical Control Unit
9MCD Plasma Distribution Unit

MAN 41151 EN 06

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

(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
Indicates the pressure of the vibrator air
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.
Indicates the pressure of the vibrator air
supplied to the spray gun cooling apparatus. Pressure is controlled by Cooling Air
regulator control (13).

18

MAN 41151 EN 06

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

(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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

2.4

Technical Data

1960 mm
(77)

500 mm
(20)
9mc_techdata

750 mm
(30)

610 mm
(24)

584 mm
(23)

9MC Plasma Control Unit

750 mm
(30)

9MCD Plasma Distribution Unit

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit


Characteristic

SI Units

US Units

9MC Plasma Control Unit

208 kg

460 lb

9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit

Vibrator Air Out #2

Carrier Out #2

Vibrator Air Out #1

Carrier Out #1

9MP Powder Feeder (#2)

9MP Powder Feeder (#1)

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

Gas Connections of 9M Plasma Spraying System (Typical)

9mc_gas_conn

29

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

(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
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.

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

9MP Powder Feeder (#1)

Control Cable

9MP Powder Feeder (#2)

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

9MC Plasma Control Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

Electrical and Cooling Water Connections of 9M Plasma Spraying System (Typical)

9mc_elec_h2o_conn

31

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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
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.

CAUTION
Wiring modifications
must be performed by
Sulzer Metco Field Service or a qualified maintenance technician.

4TB
5TB

Spare Hole Plugs


/ Condulet Connectors
Electrical Control Unit
(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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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)

Open contact activates input. Does not initiate E-STOP shutdown.


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

Remote Alarm 2

107
(3TB-8)

Open contact activates input. Does not initiate E-STOP shutdown.


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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.
It is intended principally
for machine shutdown.
Do not rely solely on
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

Always use the hardwired remote E-STOP


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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.
It is intended principally
for machine shutdown.
Do not rely solely on
this signal for E-STOP
operation.

2
39

Always use the hardwired remote E-STOP


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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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,

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9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.

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MAN 41151 EN 06

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.

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9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.

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9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.

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9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

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9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.)

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MAN 41151 EN 06

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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
Disconnect all electrical
power from equipment
prior to performing service or maintenance.

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

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9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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
Electrical Control Unit
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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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
Disconnect all electrical
power from equipment
prior to performing service or maintenance.

0.30-0.36 mm
(0.012-0.014)

9mcd_electrodes

MAN 41151 EN 06

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9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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.

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MAN 41151 EN 06

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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).

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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
Electrical Control Unit
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

9MC Plasma Control Unit / 9MCD Plasma Distribution Unit

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

MAN 41151 EN 06