Man 41151 en 06 PDF

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
Revise to current documentation standards;

MAN 41151 EN 06 6 06/2008
separate parts list (PL 41153).
9MC Plasma Control Unit / 9MCD Plasma Distribution Unit
Intended Use
The 9MC Plasma Control Unit provides automatic operation, monitor-
ing, 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.
DANGER
Do not use the 9MC
The 9MCD Plasma Distribution Unit is required with the 9MC Plasma Plasma Control Unit for
Control Unit. The 9MCD Plasma Distribution Unit delivers electrical any application or pur-
power from the system power supply and cooling water from the heat pose other than that
exchanger, to the spray gun, via combination coaxial hose/cables. described in this man-
ual. Improper use or
For specific information, see Technical Data on page 27. application can result in
equipment damage or
Designation Characteristics personal injury.
9MC Plasma Control Unit Automatic and semi-automatic plasma The 9MC Plasma Con-
control console.
trol Unit shall not be
Thermal Spray Processes Atmosphere [Air] Plasma Spraying used in any High-Veloc-
(APS) ity Oxygenated Fuel
(HVOF), Vacuum
Compatible Spray Guns 3MB
Plasma Spray (VPS), or
9MB
11MB
Low Pressure Plasma
Spray (LPPS) process.
iPro-901
F4
Compatible Powder Feeders 9MP

9MP-CL20
5MPE2
Twin 10-C
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 3
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 work-

ing with the 9MC Plasma Control Unit.
Chapter Intended Audience

1 Safety 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.
4 MAN 41151 EN 06
Table of Contents
1 Safety
1.1 Safety Symbols..................................................................................................7
1.2 Authorized Use ..................................................................................................9
1.3 General Safety Regulations...............................................................................9
1.4 Specific Safety Regulations...............................................................................9
2 Product Description
2.1 Overview .........................................................................................................14
2.2 Principles of Operation ....................................................................................15
2.2.1 9MC Plasma Control Unit ................................................................................15
2.2.2 9MCD Plasma Distribution Unit .......................................................................15
2.3 Function of Components .................................................................................16
2.3.1 System Status Monitor ...................................................................................16
2.3.2 Gas Control Unit Front Panel ..........................................................................17
2.3.3 Gas Control Unit Rear Connections ...............................................................19
2.3.4 Electrical Control Unit Front Panel .................................................................20
2.3.5 Electrical Control Unit Rear Connections .......................................................22
2.3.6 Electrical Control Unit Internal Switches..........................................................23
2.3.7 Distribution Unit Front Panel ...........................................................................24
2.3.8 Distribution Unit Rear Connections ................................................................25
2.3.9 Remote Operator Pendant ..............................................................................26
2.4 Technical Data ................................................................................................27
3 Installation and Commissioning

3.1 Environmental / Site Requirements .................................................................28
3.2 Connection and Setup .....................................................................................28
3.2.1 Gas Connections .............................................................................................28
3.2.2 Electrical and Cooling Water Connections ......................................................30
3.2.3 Voltage Divider ................................................................................................32
3.3 Interfacing with External Equipment ...............................................................33
3.3.1 Remote Operation Interface ............................................................................34
3.3.2 Remote Operator Pendant ..............................................................................36
3.3.3 Robot Interface ................................................................................................37
3.3.4 Multiple System Interface ................................................................................38
3.3.5 Remote Emergency Stop (E-STOP) Interface.................................................39
3.3.6 Exhaust Interlock .............................................................................................40
3.3.7 Remote Alarms and Robot Faults ...................................................................40
4 Operation
4.1 Startup .............................................................................................................41
4.2 Shutdown ........................................................................................................42
4.3 Operating Procedures .....................................................................................43
4.3.1 Manual Test Functions ....................................................................................43
4.3.2 Automatic Operation........................................................................................44
4.4 Cooling Water Setpoint Adjustment.................................................................45
MAN 41151 EN 06 5
4.5 Status Messages .............................................................................................46
5 Service
6 Maintenance
6.1 Feedback Board ..............................................................................................49
6.2 Safety Interlocks / Maintenance Overrides......................................................50
6.3 Electrode Gap Adjustment...............................................................................51
7 Troubleshooting
7.1 Power-On Check .............................................................................................52
7.2 Power-On Troubleshooting .............................................................................53
Index .............................................................................................................. 55
6 MAN 41151 EN 06
1 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 documen-
tation, such as technical manuals and product labeling, to alert the
user to the presence of important operating instructions, safety consid-
erations and special instructions. Whenever these symbols are
encountered, the user should read, understand and proceed in accor-
dance with the definition provided below.
General Information and Warnings
Presentation of general, but important information which
i must be read and understood prior to proceeding.
INFO
General hazard warning which can result in minor per-
sonal 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 7
Additional Symbols
Personal Protection
Sound attenuating ear protection must Hand protection must be worn.
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 Strong electromagnetic fields present.
present.
Flammable material or presence of Poisonous substance present

high temperatures.
High voltage or risk of electric shock High pressure warning.

present.
Ultraviolet, infra-red or other damag- Warning of laser present.

ing light radiation present.
Noise hazard present. Do not stack warning.
Heavy weight present above. Electrical ground is not present.
Prohibitions
Personnel with pacemaker not permit-
ted in area.
8 MAN 41151 EN 06
1.2 Authorized Use

This system is intended for the sole use of thermal coating of work-
pieces in atmosphere. The plasma spray system is designed and con-
structed in accordance with generally acknowledged safety regula-
tions and codes. The plasma spray gun must be used only for WARNING
depositing thermal spray coatings following all guidelines specified Do not use the 9MC
herein, other supporting equipment manuals, and all applicable regu- Plasma Control Unit for
lations and codes. Failure to do so may result in hazardous or unsafe any application or pur-
conditions. pose other than that
described in this man-
ual. Improper use or
application can result in
1.3 General Safety Regulations equipment damage or
Use of Sulzer Metco original spare parts is strongly recommended. personal injury.
Use of non-OEM parts may void Sulzer Metco's warranty and result in
reduced performance of the equipment.
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 compli-
ance.
There are several basic precautions for thermal spraying which should
always be observed. These include: good housekeeping, proper mate-
rial/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
DANGER
The plasma spray gun generates electromagnetic radiation in the form Ultraviolet radiation!
of visible light, infrared (radiant heat), and ultraviolet radiation. These Never look directly at
types of radiation are hazardous and can cause burns or blindness in the arc or spray stream
unprotected eyes. without protection.Wear
suitable protective gog-
gles.
MAN 41151 EN 06 9
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
WARNING process can produce noise levels as high as 130 dB.
Noise emissions!
Wear ear protection!
Ventilation and Exhaust

All thermal spray processes produce fumes and dust particles from the
materials being sprayed. To avoid the effects of dust and fumes gener-
ated by spraying, a suitable spray booth and sufficient exhaust system
DANGER are required. Proper installation, operation and maintenance are
Respiratory protection important for system performance and maintaining a safe working
must be worn. 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 loca-
tion 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 recommenda-
tions 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 protec-

tive clothing.
10 MAN 41151 EN 06
Hazardous Materials
OSHA and groups such as the American Conference of Government
Industrial Hygienists (ACGIH) and other government agencies have
developed extensive lists of hazardous materials and have set work-
place exposure limits. Inasmuch as standards change and new infor-
mation 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 DANGER
EN 60204-1, or applicable local electrical code. High current and volt-
age!
Plasma systems use an extremely high intensity arc to produce the
heat required for spraying. This high amount of electric power (amper- Do not touch the power
age and voltage) can be extremely dangerous and should only be cables while in opera-
handled by properly trained personnel. Always keep all covers and tion.
guards in place on the equipment.
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
DANGER
coated.
High temperatures!
Never aim the spray

gun at people or flam-
mable objects!
MAN 41151 EN 06 11
Compressed Gases
Local, state and federal regulations relative to in-building use and stor-
age of gas cylinders should always be observed. The improper stor-
age, 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 The manifolding of more than two gas tanks may be required to permit
Combustible gases higher gas flows and longer spray times. Only approved pressure
present under 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 cylin-
der, stand to the side of the pressure-reducing regulator, never in front
of it.
The following guidelines should be followed when handling gas tanks:
1 Never drop tanks or knock tanks into one another. Some gases are
unstable (e.g., acetylene) even when in the tanks.
2 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.
3 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.
4 Never leave tanks in direct sunlight or extreme heat. Heat will
cause the tank pressure to increase dramatically resulting in an
unsafe situation.
5 Never smoke around tanks. Although no leak may be apparent,
some gas could be leaking and may ignite.
6 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.
7 If a tank has been stored outside in a cold environment, allow the
tank to warm up at least one hour prior to use.
8 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.
9 Follow local guidelines and recommendations from the gas sup-
plier for the allowable location of combustible gas tanks storage.
12 MAN 41151 EN 06
Gas Hoses and Piping

The gas supply installation must be carried out by qualified personnel
and must comply with the regulatory requirements applicable to the
location of the spray cell set-up.
Where large amounts of gas are required, the gas can be supplied
from a tank or several manifolded gas tanks and piped into the spray
booth. Gas piping should be constructed from stainless steel or other DANGER
similar solid metal material. It is recommended that pipe connections Combustible gases
should be welded or brazed. Gas piping should when possible, be laid present under pressure.
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.
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 adjust-
ing screws backed out.
MAN 41151 EN 06 13
2 Product Description
2.1 Overview
1
4 5
9mc_over
1 9MC Plasma Control Unit

2 Status Monitor
3 Gas Control Unit
4 Electrical Control Unit
5 9MCD Plasma Distribution Unit
14 MAN 41151 EN 06
2.2 Principles of Operation
2.2.1 9MC Plasma Control Unit

During operation, plasma gases, compressed air, electricity and coat-
ing 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 ini-
tiates the flow of carrier gas through the spray gun. After verifying that
all parameter conditions are met, a high-frequency ignition signal is ini-
tiated to the gun for two seconds and stopped for one second. The
system will attempt four separate tries to light the gun. Process amper-
age 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 termi-
nate 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 elec-
trode. 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 opera-
tion is displayed on the Status Monitor. Voltage can be monitored at
the Distribution Unit or directly at the spray gun, when using the sup-
plied voltage divider.
MAN 41151 EN 06 15
2.3 Function of Components
2.3.1 System Status Monitor
1 2 3
Front View
Rear View
9mc_statusmon
Item
Description Function
No.
1 Amps digital display Displays, in amperes, the power supply
current drawn by the spray gun.
2 Volts digital display Displays, in volts, the energy potential at
the spray gun or Distribution Unit. (See
DIST/GUN switch, item 4.)
3 System Status display 20-character alpha-numeric display. Dis-
plays system status and error messages.
See Status Messages on page 46.
4 DIST/GUN toggle Used to select whether voltage is mea-
switch (5TGS) sured 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.
16 MAN 41151 EN 06
2.3.2 Gas Control Unit Front Panel
1 2 3 4 5 6 7
14 13 12 11 10 9
9mc_gas_front
Item
No.
Primary Gas
1 Pressure gauge 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 sec-
valve ondary plasma gas.
6 Helium flow meter Indicates the flow rate of the helium sec-
ondary plasma gas. Flow is controlled by
the Helium flow control valve (8).
(Continued on next page.)
MAN 41151 EN 06 17
(Continued from preceding page.)

Item
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 sec-
valve ondary plasma gas.
Vibrator Air
9 Feeder 2 pressure Indicates the pressure of the vibrator air
gauge. supplied to powder feeder number 2. Pres-
sure 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. Pres-
sure 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 appara-
tus.
14 Pressure gauge. Indicates the pressure of the vibrator air
supplied to the spray gun cooling appara-
tus. Pressure is controlled by Cooling Air
regulator control (13).
18 MAN 41151 EN 06
2.3.3 Gas Control Unit Rear Connections
1 2 3 4 5 6 7 8 9 10
9mc_gas_rear
Item
No.
1 Plasma Gas fitting Plasma gas output to spray gun (com-
bined primary and secondary gas).
2 Soft Start (Argon) fit- Input from argon supply for soft start.
ting
3 Carrier #2 fitting Carrier gas output to powder feeder #2.
4 Carrier #1 fitting Carrier gas output to powder feeder #1.
5 Secondary Supply fit- Input from secondary plasma gas supply
ting (e.g., helium or hydrogen).
6 Primary Supply fitting Input from primary plasma gas supply
(e.g., nitrogen or argon).
7 Vibrator Air #2 fitting Vibrator air output to powder feeder #2.
8 Vibrator Air #1 fitting Vibrator air output to powder feeder #1.
9 Cooling Air fitting Cooling air output to spray gun air jets.
10 Air Supply fitting Input from facility air supply.
MAN 41151 EN 06 19
2.3.4 Electrical Control Unit Front Panel
4 5 7
1 10
11
6 9 8
9mc_elec_front
Item
No.
Multi-System Operation
1 Local / Remote selec- In single-system operation, Local selects
tor switch operation from the Control Unit. Remote
selects operation from the Remote Opera-
tor Pendant or robot. (See Remote Oper-
ator Pendant on page 36.)
In multiple-system operation, all Control

Units in the chain are set to Remote.
2 System 1 / System 2 In single-system operation, set to System
selector switch 1.
In multiple-system operation, the master

Control Unit is set to System 1 and all oth-
ers are set to System 2.
3 Alarm annunciator Audible alarm sounds when alarm is gen-
erated.
Test
4 Purge momentary Permits all gases and air supplies to flow
pushbutton (white) at the set flowmeter values. After two sec-
onds, 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.
5 Ignition momentary Used to check for high-voltage / arc at the
pushbutton (yellow) spray gun.
6 Feed On / Feed Off Turns powder feeding on or off at the pow-
selector switch der feeder(s).
(Continued on next page.)
20 MAN 41151 EN 06
(Continued from preceding page.)

Item
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 potenti- 10-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
pushbutton the system, including the system power
supply and Distribution Unit. Also disables
output control signals and solenoid valves
of Control Unit. Input signals and the Sys- CAUTION
tem Status display remain enabled, and Push in the Emergency
the purge fan in the Gas Control Unit Stop pushbutton when-
remains on. ever the system is not
operating or is left unat-
Pull out to enable operation of the system. tended. Pull out the
Emergency Stop push-
button only when you
are ready to begin sys-
tem setup, ignition,
operation or testing.
MAN 41151 EN 06 21
2.3.5 Electrical Control Unit Rear Connections
3
6
9mc_elec_rear
Item
No.
1 10MR connector Connects to 10MR power supply via con-
(6ARECP) trol cable (supplied).
2 Distribution Unit con- Connects to 9MCD Plasma Distribution
nector (12RECP) Unit via control cable (supplied).
i
3 To Gun connector Connects to hand-held spray gun via gun
(5RECP) control cable (supplied with gun). Provides
powder feed control and emergency stop.
If a hand-held gun is not connected, the
INFO
captive connector cover must be installed.
Always install captive This cover contains a jumper that closes
cover on To Gun recep- the emergency stop loop.
tacle (5RECP) if hand- 4 Feeder 2 connector Connects to second powder feeder (if
held spray gun is not (2RECP) used) via control cable supplied with pow-
connected. der feeder.
5 Feeder 1 connector Connects to powder feeder via control
(1RECP) cable supplied with powder feeder.
6 Electrical cord (4PL) Standard 3-prong AC plug connects to
facility power (115 VAC). If facility power is
200-240 VAC, use optional step-down
transformer.
22 MAN 41151 EN 06
2.3.6 Electrical Control Unit Internal Switches

The Service Only switches are intended to be used by Sulzer Metco
Field Service or trained and qualified service technicians. During nor-
mal system operation, these switches should remain in the positions
specified below. CAUTION
The Service Only
Do not override the door interlock switch or the safety interlock switch switches should only be
without first reading Safety Interlocks / Maintenance Overrides on used by Sulzer Metco
page 50. Field Service or quali-
fied service technicians.
1 2
3
DANGER
4
Do not override the door
interlock switch or the
safety interlock switch
without first reading
Safety Interlocks /
Maintenance Over-
rides on page 50.
5
9mc_elec_service
Item
No.
1 Service Only - Mode Normal position is toward front of Control
toggle switch (1TGS) Unit. Used only by service technicians to
select the service mode.
2 Service Only - Step Normal position is toward front of Control
toggle switch (2TGS) Unit. Used only by service technicians to
select the service mode.
3 Soft Start toggle switch Normal position is ON. OFF position dis-
(3TGS) ables soft start (argon) supply.
4 Water Flow toggle Normal position is #1. Position #2 is used
switch (4TGS) only for low water flow spray guns and gun
extensions. (See also, Cooling Water Set-
point Adjustment on page 45.)
5 Door interlock switch Disables all power from Electrical Control
(1LS) Unit, as safety measure when door is
open. See Safety Interlocks / Mainte-
nance Overrides on page 50.
6 Safety interlock switch Facilitates override of ventilation fault
(2LS) interlock, using attached key. See Safety
Interlocks / Maintenance Overrides on
page 50.
MAN 41151 EN 06 23
2.3.7 Distribution Unit Front Panel
9MCD SULZER METCO

Distribution Unit
1 Water Flow GPM 2
WATER FLOW TO GUN
UP
RUN
DN
SET
GPM ENTER
DC - DC+
Electrode CAUTION Nozzle
9mcd_front
4 3
Item
No.
1 Voltage sensor cable Connects to voltage divider for measuring
(14PL) voltage directly at the spray gun. See
Voltage Divider on page 32.
2 Setpoint control Displays, in gallons per minute (GPM),
the cooling water flow through the Distri-
bution Unit to the spray gun.
Used to set the allowable limit(s) of cool-
ing water flow to the spray gun (i.e., the
point below which the system will shut-
down).
See Cooling Water Setpoint Adjustment
on page 45.
RUN/SET momentary Select SET position to set or change the
switch current setpoint. Select RUN to accept the
current value and return to normal opera-
tion.
UP/DN momentary Used to increase (UP) or decrease (DN)
switch the setpoint value.
ENTER button Press to enter the setpoint.
3 DC + Nozzle fitting Positive electrical power and cooling water
supply to spray gun. Connects to spray
gun nozzle via red water-cooled cable.
4 DC - Electrode fitting Negative electrical power and cooling
water return from spray gun. Connects to
spray gun electrode via blue water-cooled
cable.
24 MAN 41151 EN 06
2.3.8 Distribution Unit Rear Connections
1 2 3
Control Unit
Water In Water Out
CAUTION
DC + DC -
9mcd_rear
5 4
Item
No.
1 Control Unit connec- Connects to 9MC Plasma Control Unit via
tor (12RECP) control cable.
2 Water In fitting Connects to cooling water supply hose
from heat exchanger.
3 Water Out fitting Connects to cooling water return hose to
heat exchanger.
4 DC - connectors Three insulated connectors (black) con-
nect to negative (-) output from system
power supply via three power cables.
5 DC + connectors Three insulated connectors (red) connect
to positive (+) output from system power
supply via three power cables.
MAN 41151 EN 06 25
2.3.9 Remote Operator Pendant

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 Con-
DANGER trol Unit front panel, including Emergency Stop. (See Electrical Con-
The Remote E-STOP trol Unit Front Panel on page 20.) Once the settings and spraying
input of the Remote parameters have been set up at the Control Unit, the Remote Opera-
Operator Pendant is a tor Pendant may be used to control the most common functions of the
software-initiated emer- automatic spray process up to 9 m (30) from the Control Unit. To oper-
gency stop. It DOES ate from the Remote Operator Pendant, the Local / Remote switch on
NOT satisfy the require- the Control Unit is set to Remote.
ments of most national
or international safety
standards for safety-
related emergency stop.
It is intended principally
for machine shutdown.
Do not rely solely on
this input for E-STOP EMERG
operation. STOP
START
Always use the hard-

wired remote E-STOP STOP
loop. (See Hardwired

FEED#1
Remote E-STOP on ON/OFF
page 39.)
FEED#2
ON/OFF
PURGE
ON/OFF
For installation, refer to the accompanying instructions, AI 43563, sup-

plied with the Remote Operator Pendant. See also, Remote Opera-
tion Interface on page 34.
26 MAN 41151 EN 06
2.4 Technical Data
1960 mm
(77)
500 mm
(20)
9mc_techdata
750 mm 584 mm 610 mm 750 mm

(30) (23) (24) (30)
9MC Plasma Control Unit 9MCD Plasma Distribution Unit

Characteristic SI Units US Units
Weight
9MC Plasma Control Unit 208 kg 460 lb
9MCD Plasma Distribution Unit 161 kg 355 lb
Electrical Power Requirements
Voltage 110 - 120 VAC, single phase, 50/60 Hz
(With optional 9MC420 step-down transformer) 200 / 220 / 240 VAC, single phase, 50/60 Hz
Amperage 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
Air Requirements
Clean, dry, oil-free 920 NLPM @ 5.9 bar 2100 SCFH @ 75 psig
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
3 Installation and Commissioning
3.1 Environmental / Site Requirements

WARNING Relative location of the Control Unit, Distribution Unit, supporting
All equipment shall be equipment (e.g., power supply, powder feeder(s), heat exchanger,
installed and set up by etc.) and the spray booth/area is limited only by the length of the inter-
qualified personnel. In connecting hoses and cables. Connections should never be stretched
addition to this manual, and should remain slack enough to allow routine movement and use
refer also, to the docu- of the equipment. The location should facilitate regular access to the
mentation supplied with back of the units for connections and service. A smooth, hard floor is
the connecting equip- necessary so that the units can be moved easily and safely. See
ment. Technical Data on page 27 for specific electrical and gas supply
requirements.
3.2 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
DANGER
gas pressure during connection and setup. See Operation on page
Ensure that facility
41.
power is not connected
to any of the equipment.
Do not energize electri- 3.2.1 Gas Connections
cal equipment or apply All gas connections are made to the fittings on the rear underside of
gas pressure during the Gas Control Unit. The illustration on page 29 shows the gas hose
connection and setup. connections of a typical 9M plasma system.
Failure to follow these
safety measures may
1. Connect carrier gas hose from Soft Start (Argon) fitting to argon
result in equipment
gas supply regulator (e.g., 7GNR).
damage, personal injury
or death. 2. Connect carrier gas hose from Secondary Supply fitting to sec-
ondary 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 fit-
ting 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 fit-
ting of powder feeder no. 2.
(Continued on page 30.)
28 MAN 41151 EN 06
9MC Plasma Control Unit
MAN 41151 EN 06
7GNR
Soft Start (Argon) In Carrier Out #1

Ar
Vibrator Air Out #1
7GNR / 7GNH Plasma
Gas
Out
Cooling
Secondary Gas In Air
He / H Out
7GNR
Primary Gas In
9MP Powder Feeder (#1)
N2 / Ar
Carrier Out #2
Gas Connections of 9M Plasma Spraying System (Typical)
6A Air Control Unit

Air Vibrator Air Out #2
Air In
9MB
Plasma Gun
9MBM Plasma Spray Gun 9MP Powder Feeder (#2)
9mc_gas_conn
29
(Continued from page 28.)
9. Connect carrier gas hose from Plasma Gas fitting to plasma gas
input fitting on spray gun.
10. Connect air hose from Cooling Air fitting (through wye connec-
tion) 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 1. On back of 9MC Plasma Control Unit Electrical Control Unit:
power is not connected
to any of the equipment. a. Connect control cable from 10MR power supply to 10MR con-
Do not energize electri- nector.
cal equipment or apply b. Connect control cable from Control Unit connector on back of
gas pressure during Distribution Unit to Distribution Unit connector.
connection and setup.
Failure to follow these c. Connect control cable from CONTROL UNIT / POWER con-
safety measures may nector on back of powder feeder #1 (e.g., 9MP) to Feeder 1
result in equipment connector.
or death. d. Connect control cable from CONTROL UNIT / POWER con-
nector 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 b. Connect blue water-cooled cable from DC - Electrode fitting to
Do not plug in the elec- electrode fitting on spray gun. (If using voltage divider, see
trical cord of the 9MC
Voltage Divider on page 32.)
Plasma Control Unit
until you are ready for 4. Do not plug in the electrical cord of the 9MC Plasma Control Unit
operation. until you are ready for operation. (See Operation on page 41.)
30 MAN 41151 EN 06
9MBH
9MC Plasma Control Unit Plasma
Spray
9mc_elec_h2o_conn
Gun
MAN 41151 EN 06
Manual Gun Control
Control Cable
Facility
Power
9MP Powder Feeder (#2) 9MCD Plasma

Distribution Unit
9MCD SULZER METCO
Distribution Unit
Water Flow GPM
WATER FLOW TO GUN

UP
RUN
Control Cable DN
SET
GPM ENTER
DC (+) To Nozzle / Water Supply

DC - DC+
Electrode CAUTION Nozzle (Red Water-Cooled Cable)
(Front) DC (-) To Electrode / Water Return

(Blue Water-Cooled Cable)
Control CLIMET-HE Heat

Cable Control Unit
Exchanger
9MP Powder Feeder (#1)
Water In Water Out Cooling Water Return
CAUTION
DC + DC -
Control Cable
To
(Rear) Chiller
To 10MR Power Supply DC (+) Power Cables (3)
DC (-) Power Cables (3) Cooling Water In

Electrical and Cooling Water Connections of 9M Plasma Spraying System (Typical)
31
3.2.3 Voltage Divider

The voltage divider assembly is used to sense the voltage directly
across the electrode and nozzle, rather than measuring gun voltage at
the Distribution Unit. In either case, the voltage measured is the value
displayed on the Volts meter on the System Status Monitor. The differ-
ence between the voltage measured at the spray gun and that mea-
sured 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.
Voltage
Divider
Extension Cable 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 sen-
sor wire is connected to the nozzle connection screw. The voltage
divider pigtail cable connects (via extension cable) to the cable on the
front of the Distribution Unit. The connection provides a scaled voltage
feedback signal to the feedback board in the Electrical Control Unit.
To display the voltage measured by the voltage divider on the Volts

meter, open the back of the System Status Monitor and set the GUN/
DIST switch to GUN. See System Status Monitor on page 16.
32 MAN 41151 EN 06
3.3 Interfacing with External Equipment

The 9MC Plasma Control Unit can interface with external equipment,
thus providing a fully integrated system. The Control Unit can be inte-
grated with other 9MC Plasma Control Units, remote control and E- DANGER
STOP pendants, robot / handling equipment, ventilation and exhaust Ensure that facility
systems and external safety interlocks. power is not connected
to any of the equipment.
Interface signals and instructions for connecting each type of interface Do not energize electri-
are described in this section. All interface wiring connections are made cal equipment or apply
to terminal blocks 3TB and 4TB located in the Electrical Control Unit. gas pressure during
Wiring is routed through spare holes in back of the Electrical Control connection and setup.
Unit. For each interface, remove one spare hole plug and route the Failure to follow these
wiring through the hole, along with a condulet connector, gasket seal safety measures may
and locknut. result in equipment
or death.
3TB CAUTION
Wiring modifications
4TB must be performed by
Sulzer Metco Field Ser-
5TB vice or a qualified main-
tenance technician.
Spare Hole Plugs

/ Condulet Connectors
i
INFO
Electrical Control Unit Be sure to replace the
(front view, door open) factory jumpers if inter-
face wiring is discon-
9mc_TBs
nected 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 Distri-
bution Unit Electrical Schematic and Gas Flow Diagrams, DIA 74602.
MAN 41151 EN 06 33
3.3.1 Remote Operation Interface
Input Commands
The Control Unit can be controlled from another 9MC Plasma Control
Unit, a remote device such as a robot controller or the Remote Opera-
tor 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.
Circuit #
Signal Name Description
(TB#-Term.#)
Input Commands and Alarms
- Common 39 -24 VDC common (differential low) supplied by PLC input rack
(3TB-1~7) power supply. Used for all PLC remote operation inputs.
Remote System Fault 101 Open contact activates input. Initiates E-STOP shutdown and dis-
(3TB-14) plays REMOTE SYSTEM FAULT on System Status display until
fault is cleared. (Remove jumper to 3TB-1.)
Remote E-STOP 102 Open contact activates input. Initiates E-STOP shutdown and dis-
(3TB-13) plays AUX E-STOP on System Status display until fault is
cleared. (Remove jumper to 3TB-2.)
Exhaust Fault 103 Open contact activates input. Initiates E-STOP shutdown and dis-
(3TB-12) plays EXHAUST FAULT on System Status display until fault is
cleared. (Remove jumper to 3TB-3.)
Robot Fault 1 104 Closed contact activates input. Does not initiate E-STOP shut-
(3TB-11) down. Displays ROBOT FAULT 1 on System Status display
until fault is cleared.
Robot Fault 2 105 Open contact activates input. Does not initiate E-STOP shutdown.
(3TB-10) Displays ROBOT FAULT 2 on System Status display until fault
is cleared. (Remove jumper to 3TB-5.)
Remote Alarm 1 106 Open contact activates input. Does not initiate E-STOP shutdown.
(3TB-9) Displays REMOTE ALARM 1 on System Status display until
alarm is cleared. (Remove jumper to 3TB-6.)
Remote Alarm 2 107 Open contact activates input. Does not initiate E-STOP shutdown.
(3TB-8) Displays REMOTE ALARM 2 on System Status display until
alarm is cleared. (Remove jumper to 3TB-7.)
Remote Cycle Start 112 Closed momentary contact (~0.5 s) activates input. Starts the
(4TB-11) automatic spray cycle.
Remote Cycle Stop 113 Closed momentary contact (~0.5 s) activates input. Stops the auto-
(4TB-10) matic spray cycle.
Remote Feed No. 1 114 Closed contact activates input. As long as the input is active, the
(4TB-9) control unit will be in the preheat mode. Preheat mode is defined
as no powder fed to the gun.
Remote Feed No. 2 115 Closed contact activates input. As long as the input is active, the
(4TB-8) control unit will be in the preheat mode. Preheat mode is defined
as no powder fed to the gun.
Remote Purge 116 Closed momentary contact (~0.5 s) activates input. Starts the
(4TB-12) purge sequence.
34 MAN 41151 EN 06
Output Commands
The Control Unit provides output commands and alarms for the other
Control Units or external equipment. All output signals for the remote
interface are +24 VDC, supplied by the PLC output rack power supply.
Generally, each signal is intended to energize a relay in the remote
equipment. The interface signals are specified in the following table.
Circuit #.
Signal Name Description
(TB#-Term.#)
Output Commands and Alarms
+ Common 32 +24 VDC common (differential high) supplied by PLC output rack
(4TB-1) power supply. Used for all remote command outputs.
Remote Start (Out) 044 Closed contact return for +24 VDC common activates output.
(4TB-2) Starts the automatic spray cycle in all connected Control Units.
Remote Stop (Out) 045 Closed contact return for +24 VDC common activates output.
(4TB-3) Stops the automatic spray cycle in all connected Control Units.
Remote Fault (Out) 046 Closed contact return for +24 VDC common activates output. Ini-
(4TB-4) tiates emergency stop shutdown and provides fault indication of
the Control Unit.
Remote Feed No.1 047 Closed contact return for +24 VDC common activates output. Con-
(Out) (4TB-5) trols the feed on/off signal for all no. 1 powder feeders.
Remote Feed No.2 050 Closed contact return for +24 VDC common activates output. Con-
(Out) (4TB-6) trols the feed on/off signal for all no. 2 powder feeders.
MAN 41151 EN 06 35
3.3.2 Remote Operator Pendant

When using the Remote Operator Pendant, the Multi-System Opera-
tion switches on the Control Unit are set to Remote and System 2.
See Remote Operator Pendant on page 26. Refer also, to the
DANGER accompanying instructions, AI 43563, supplied with the Remote Oper-
The Remote E-STOP ator Pendant.
input (circuit no. 102) of
the remote operation
interface is a software-
initiated emergency
stop. It DOES NOT sat-
isfy the requirements of Remote Operator
most national or interna- Pendant
tional safety standards. 9mc_rem_s2
It is intended principally 4TB

for machine shutdown. EMERG STOP
Do not rely solely on Remote E - Stop 16
11
this signal for E-STOP
operation. 15
11A
Always use the hard- START

wired remote E-STOP Remove
Remote Cycle Start 11
loop. (See Hardwired 112 Jumper
Remote E-STOP on
STOP
page 39.)
Remote Cycle Stop 10
113
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 1-7
39
36 MAN 41151 EN 06
3.3.3 Robot Interface

When the system is operated from a robot controller, the Multi-Sys-
tem Operation switches on the Control Unit are set to Remote and
System 2. The Remote Fault signal is an output to the robot indicating
i
a fault in the Control Unit. INFO
When using the remote
operation interface, do
not connect the Remote
E-STOP interface (cir-
cuit no. 102) to the robot
or workhandling equip-
ment. The remote oper-
9mc_rem_s2
ation interface includes
Robot Interface 3TB its own remote fault,
-24 VDC PLC Common 39
2 which provides diagnos-
tic benefits.
Robot Dry Contact Outputs
Robot Fault 1 11
104
4TB
Remote Cycle Start 11
112
Remote Cycle Stop 10

113
Remote Feed 1 9
114
Remote Feed 2 8
115
Remote Purge 12
116
Remote Fault 4
46
R
+24 VDC PLC Common 1
32
To Robot Input
9MC Fault R
From Robot Input Common
MAN 41151 EN 06 37
3.3.4 Multiple System Interface

When a 9M plasma system employs multiple interconnected Control
Units, the Multi-System Operation switches on the first Control Unit
are set to Remote and System 1. All subsequent Control Units in the
series are set to Remote and System 2. The remote operation out-
puts 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_rem_s2
9MC #1 9MC #2 9MC #3
4TB 4TB 4TB 4TB 4TB 4TB
11 2 Remote Cycle Start 11 2 11 2

112 44 112 44 112 44
10 3 Remote Cycle Stop 10 3 10 3
113 45 113 45 113 45
9 5 9 5 9 5
114 47
Remote Feed 1 114 47 114 47
8 6 8 6 8 6
115 50
Remote Feed 2 115 50 115 50
4 4 4
46 46 46
+24 VDC PLC
1 Common 1 1
32 32 32 32
3TB 3TB 3TB

14 Remote Fault 14 14
101 101 101
1 1 1
39 39 39
Remove Remove Remove
Jumper Jumper Jumper
Remote Fault (from last Control Unit only)
38 MAN 41151 EN 06
3.3.5 Remote Emergency Stop (E-STOP) Interface
Remote Operation Interface E-STOP

The remote emergency stop interface allows the Control Unit to be DANGER
connected to an emergency stop loop of a robot or workhandling The Remote E-STOP
equipment. This interface is a software-initiated emergency stop. It input (circuit no. 102) of
does not satisfy the requirements of most national or international the remote operation
safety standards. It is intended principally for informational and diag- interface is a software-
nostic purposes and/or equipment related shutdown. Do not rely solely initiated emergency
on the this interface for E-STOP operation. Always use the hardwired stop. It DOES NOT sat-
remote E-STOP loop. isfy the requirements of
most national or interna-
(Energized
tional safety standards.
during
R Remove
It is intended principally
normal
operation.) Jumper for machine shutdown.
3TB
Do not rely solely on
Remote E - Stop 13
102 this signal for E-STOP
R (N.O.)
operation.
2
39
Always use the hard-
wired remote E-STOP
loop.
Hardwired Remote E-STOP
The hardwired remote E-STOP is connected directly to the internal E-
STOP loop of the Control Unit. This loop includes the Emergency
Stop pushbutton on the Electrical Control Unit front panel and the E-
STOP on a hand-held spray gun, if connected. This interface is typi-
cally 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 normally-

open set of contacts from the main contactor (MCR), which is ener-
gized whenever the E-STOP loop is closed. Either interface may be
used independently as needed.
Remove Jumper
Door E-STOP
E-STOP Pendant 4TB
16
11
E-STOP
15 Loop
11A MCR
14
67
E-STOP Out (N.O.) MCR

13
68
MAN 41151 EN 06 39
3.3.6 Exhaust Interlock

This feature prevents the operation of the control unit until the exhaust
system is turned on. In the event of an exhaust failure, the unit will
shut down and the message EXHAUST FAULT will be displayed. The
exhaust interlock is connected to the customer supplied exhaust sen-
sor for the spray booth. Remove the existing jumper (3TB-12 to 3TB-
3) prior to wiring in the sensor.
Exhaust Sensor 3TB

12
103
3
39
Normally-open
contacts (closed
when exhaust Remove Jumper
system is on)
CAUTION
Make sure the exhaust
interlock switch and wir-
ing are isolated from
any other source of When wiring this interlock circuit, make sure that the exhaust interlock
power (i.e., dry con- switch and wiring are isolated from any other source of power, such as
tacts only). 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

The remote alarms allow additional safety interlocks such as door
interlocks, multiple exhaust interlocks and additional customer sup-
plied safeties to be wired to the control unit. These alarms do not
cause an E-STOP shutdown. There are two remote alarms and two
i
robot alarms. Generic messages are displayed on the System Status
display.
INFO Typical application wiring of Remote Alarm 1 is shown below.

Robot Fault 1 is a
closed circuit active 3TB
alarm. There is no fac- Door Interlock
Remote Alarm 1 9
tory installed jumper. 106
6
39
Remove Jumper
40 MAN 41151 EN 06
4 Operation
Before operating the 9MC Plasma Control Unit:
Ensure that installation, connection and initial setup of all equip-

ment 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 WARNING
safety regulations. See Safety on page 7. Before operating the
thermal spray system,
turn on exhaust system
and wear protective
4.1 Startup 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 mea-
sured on high-pressure gauge of regulator. Then, open supply
valve all the way.
b. Turn regulator screw until pressure measured on the low-pres-
sure 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 Trouble-
shooting on page 52.
4. On Control Unit, release Emergency Stop button.
If all safeties, interlocks, and remote alarms are satisfied, the
System Status monitor displays 9MC SYSTEM READY. This
message is displayed anytime the Control Unit is in the spray
mode and ready to operate.
If the system status monitor displays an alarm message (e.g.,
CARRIER GAS PSI LOW), and the audible alarm is sounding,
MAN 41151 EN 06 41
one or more conditions exist that will prevent the system from
operating. Since the system status can only display one alarm at
a time, always service the alarms in the order they appear.
When the displayed alarm is cleared, the next alarm or SYSTEM
READY will appear.
5. Once all alarms are clear and system is ready to operate, push in
Emergency Stop button.
6. Turn on cooling water supply (e.g., booster pump, refrigerated
chiller, heat exchanger, etc.) and set cooling water flow rate, pres-
sure and temperature to value specified for spray gun (minimum
11.36 lpm (3 gpm)).
7. Energize system power supply (i.e., 10MR).
8. When you are ready to begin spraying operations, proceed as
described under Operating Procedures on page 43.
4.2 Shutdown
When spraying operations are finished, shut down the 9MC Plasma
Control Unit as follows:
1. On Electrical Control Unit, press and hold Purge button for

approximately 5 to 10 seconds.
2. On Electrical Control Unit, push in Emergency Stop button. Push
in all E-STOP buttons in the loop.
3. Shut down 10MR power supply.
4. Shut down cooling water supply (chiller, heat exchanger, etc.).
5. Shut down powder feeders.
6. Close all gas supply valves and back out regulator screws all the
way.
7. Unplug electrical cord of 9MC Plasma Control Unit.
42 MAN 41151 EN 06
4.3 Operating Procedures

Before operating the 9MC Plasma Control Unit:
Ensure that installation, connection and initial setup of all equip-

ment is complete. See Connection and Setup on page 28.
Turn on exhaust system and wear protective clothing. Follow all WARNING
safety regulations. See Safety on page 7. Before operating the
thermal spray system,
Perform Startup on page 41. turn on exhaust system
and wear protective
4.3.1 Manual Test Functions clothing.
The Control Unit provides three manual test functions which are oper-
ated 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 fre-
quency ignition voltage circuit, which is used to light the gun. During
an ignition test, primary gas flows while the high frequency voltage is
turned on and off in a pulsing fashion. The high frequency voltage is
energized without arming the power supply, making it impossible to
accidentally start the gun. When checking the high frequency arc in
the gun, avoid looking directly down the nozzle bore and refrain from
prolonged viewing of the arc.
Ignition test is accomplished by pressing and holding in the Ignition

button. The System Status monitor displays IGNITION TEST. If the
high frequency arc is not observed or the gun does not light in the Auto
mode, adjustment of the ignition points may be required or the gun
hoses may be faulty. Refer to Troubleshooting on page 52.
MAN 41151 EN 06 43
Feed
Feed Test enables the operator to operate the powder feeder(s) with-
out 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:
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 Sta-
i tus monitor displays AUTO PREHEAT.
4.3.2 Automatic Operation

INFO
Make sure secondary 1. On Multi-System Operation panel, set switches to Local and
gas flowmeters (Hydro- System 1.
gen and Helium) are
turned off. 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.)
i
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 cor-
INFO rected before continuing.)
If the control unit is not
warmed up (approx. 1/2 5. Press and release Start button. The auto cycle will begin. First, pri-
hour) prior to start-up, mary gas will flow from gun. Next, ignition will start and gun should
arc current may drift light. (If gun does not light after four ignition attempts, unit will shut
slightly, requiring minor down and display IGNITION FAILURE.) Gun then ramps to initial
adjustment. current setting.
6. Manually increase arc current while introducing secondary gas, if
Natural erosion of the required. (Arc Current control may be locked if desired.)
gun hardware (nozzle
and electrode) from 7. On Automatic Gun Operation panel, select desired function.
continued use will (Preheat, Feed 1, Feed 2, or Both.)
cause the arc current 8. When operation has been completed, press the Stop button. The
and voltage to drift. control unit will automatically cycle off.
Minor adjustment of the
arc current control and 9. To rerun operation using the same parameters, press the Start
secondary gas flow (if button again. The control unit will automatically light the gun and
used) will be required. ramp to the previous set points for primary gas, secondary gas and
arc current.
44 MAN 41151 EN 06
4.4 Cooling Water Setpoint Adjustment

The setpoint indicator on the 9MCD Plasma Distribution Unit:
Displays the current rate of cooling water flow to the spray gun.
Facilitates adjustment of up to two low-flow setpoints.
Issues a LOW WATER FLOW alarm to the Control Unit if the water
flow falls below the selected setpoint. This alarm causes a soft E-
STOP 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 Elec-
trical 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 alter-
nately 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 dis-
plays SP2 and the current value.
4. To keep the current value, press and release the RUN/SET switch
to RUN.
MAN 41151 EN 06 45
4.5 Status Messages

The table below is the complete list of messages that can be displayed
on the System Status monitor. The Description column contains the
detailed interpretation of the message. Some of the status messages
are informational and can be expected during normal operation. Oth-
ers 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

1 EMERGENCY STOP Interruption in the main emergency stop (E-STOP) loop
(e.g., Control Unit, spray gun, remote pendant, purge fan,
etc.).
2 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.
3 SECONDARY PSI LOW Secondary plasma gas pressure is too low (< 2.76 bar / 40
psi). Pressure switch 3PS is open.
4 PRIMARY PSI LOW Primary plasma gas pressure is too low (< 2.76 bar / 40 psi).
Pressure switch 4PS is open.
5 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.
6 LOW WATER FLOW Water flow through Distribution Unit is below setpoint.
7 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).
8 CURRENT FAILURE
9 REMOTE SYSTEM FAULT Fault alarm from external equipment (e.g., 9MC, robot, etc.).
10 AUX E-STOP Remote (soft) E-STOP shutdown has been initiated.
11 EXHAUST FAULT Exhaust system is off or remote exhaust sensor has tripped.
12 ROBOT FAULT 1 Generic (user defined) robot alarm.
13 ROBOT FAULT 2 Generic (user defined) robot alarm.
14 REMOTE ALARM 1 Generic (user defined) alarm.
15 REMOTE ALARM 2 Generic (user defined) alarm.
16 IGNITION FAILURE Ignition sequence has failed - spray gun not lit.
17 CURRENT SENSOR FAULT
18 HIGH WATER TEMP Water temperature sensor in Distribution Unit detects water
temperature above 49 C (120 F).
19 (Reserved)
20 LOW PRIMARY FLOW Primary plasma gas flow to spray gun is too low (< 21.9
NLPM / 50 SCFH). Pressure switch 6PS is open.
21 9MC SYSTEM READY No alarms present; Control Unit is in spray mode and ready
for operation.
22 IGNITION TEST Control Unit is testing for ignition arc at the spray gun.
23 SYSTEM PURGING Control Unit is purging the spray gun.
46 MAN 41151 EN 06
No. Message Text Description

24 (Reserved)
25 AUTO PREHEAT Control Unit is in preheat mode (i.e., powder feeding sus-
pended).
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)
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)
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)
46
47
48
49
50
MAN 41151 EN 06 47
5 Service
The 9MC Plasma Control Unit and 9MCD Plasma Distribution Unit
require only routine inspection and cleaning.
DANGER
Disconnect all electrical
power from equipment Service Interval
prior to performing ser-
1
vice or maintenance. Daily
2
Weekly
3
Monthly
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 com-
pressed air supply.)
48 MAN 41151 EN 06
6 Maintenance
6.1 Feedback Board

The feedback board, located in the lower rear of the Electrical Control
DANGER
Unit, measures scaled analog voltage and current feedback signals
from the spray gun and/or Distribution Unit. These signals are used to
power from equipment
control and regulate the power supply output and the actual power at
the spray gun.
vice or maintenance.
Dip Switches 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 cur-
rent may be necessary for certain spray guns or for starting with nitro-
gen 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
#
1 OFF ON OFF ON ON OFF ON
2 OFF OFF OFF ON OFF ON ON
3 ON ON OFF ON OFF OFF OFF
4 ON ON ON ON ON ON ON
5 OFF OFF OFF OFF OFF OFF OFF
6 OFF ON OFF ON ON ON ON
7 OFF OFF ON ON ON ON ON
8 OFF OFF OFF OFF OFF OFF OFF
MAN 41151 EN 06 49
6.2 Safety Interlocks / Maintenance Overrides

The Electrical Control Unit contains multiple safety and equipment
interlocks. When necessary to perform maintenance or troubleshoot-
ing with power applied to the Electrical Control Unit, these interlocks
DANGER
can be overridden. Overriding the safety interlocks shall only be done
Overriding the safety
by Sulzer Metco Field Service or a trained and qualified maintenance
interlocks can result in
technician.
serious injury or death.
Door Interlock Switch (1LS)
WARNING Key
High voltage and cur-
rent are present inside
the Electrical Control
Unit. Only Sulzer Metco
Field Service or quali-
fied technicians shall
perform maintenance.
When overriding the Safety Interlock Switch (2LS)

safety interlocks, begin
with the Emergency
Stop button pushed in. 9mc_interlocks
Release the Emer-

gency Stop button only
if and when necessary. 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.
i 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
INFO
The override key, when components in the Control Unit. The System Status monitor displays
installed in the safety EMERGENCY STOP.
interlock switch, pre-
vents the door of the The 9MC Plasma Control Unit is now fully powered and ready for
Electrical Control Unit operation. Release the Emergency Stop button only if and when nec-
from being closed. essary to perform a specific task that requires all circuits to be ener-
gized. Use extreme caution when working inside the Electrical Control
Unit.
50 MAN 41151 EN 06
6.3 Electrode Gap Adjustment

If ignition problems cannot be resolved easily, check the condition of
the electrodes in the Distribution Unit. Using a thickness gauge, check
and adjust the electrode gaps to 0.030 - 0.036 mm (0.012 - 0.014). DANGER
power from equipment
vice or maintenance.
0.30-0.36 mm
(0.012-0.014)
9mcd_electrodes
MAN 41151 EN 06 51
7 Troubleshooting
This section is intended for trained and qualified maintenance techni-
cians. Refer to the Electrical Schematic and Gas Flow Diagrams, DIA
74602, for the 9MC Plasma Control Unit and 9MCD Plasma Distribu-
tion 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 mes-
sage SELF TEST PAST for approximately 1-2 seconds.
3. If all proper gas and air pressures are present and the Emergency
Stop button is depressed, the message E-STOP/SEC GAS IS
ON will be displayed.
If the Emergency Stop button is not depressed, the message 9MC
SYSTEM READY will be displayed.
If one or more gas or air pressures are either low or turned off, one of
the following messages will be displayed:
- LOW CARRIER GAS PSI

- LOW PRIMARY GAS PSI
- LOW SECONDARY GAS PSI
- LOW AIR PSI
If the Emergency Stop button is not depressed, these messages will
be accompanied by an audible alarm. The alarm may be silenced by
depressing the Emergency Stop button. However, the message will
remain.
52 MAN 41151 EN 06
7.2 Power-On Troubleshooting

Problem Probable Cause
Power On
Fan and message dis- No power incoming.
play does not come on. 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.
VENTILATION No electrical cabinet purge air.
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 Check message display connector (inside
message. 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 inopera- E-STOP pressed.
tive. Defective button (3PB) or related PLC input
circuitry (011) faulty.
Fuse 3FU blown.
Purge button operates Operating flow needle valve is closed.
but gases not flowing. Possible faulty solenoid or related wiring from
PLC output 033-037
Ignition button inopera- Purge button is being pressed.
tive. 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 E-STOP pressed.
light not on. Control cable disconnected
Fuse 4FU blown.
MCR relay or related wiring faulty.
Powder feeder Ready Defective control cable.
light on but feeder does Possible problem with PLC output 073/074.
not operate. Defective powder feeder. (Refer to powder
feeder manual.)
MAN 41151 EN 06 53
Problem Probable Cause

Automatic Spray Functions
Start button inoperative. Master / Slave switch in Slave position.
E-STOP pressed.
Start button (4PB) or related circuitry (110)
faulty.
Stop button (5PB) or related circuitry (111)
shorted.
Start cycle runs but gun Check ignition circuitry.
does not light. See Ignition under Manual Test Functions
above.
Start cycle runs, gun Check feeder circuitry.
lights but powder feeder See powder feeder under Manual Test Func-
does not start. tions above.
Gun lights but goes out Check lighting flow settings; adjust, if neces-
under full operating flow. sary.
Check gun hardware. (Refer to spray gun
manual.)
Gun does not shut down. Press E-STOP.
Check Stop button (5PB) or related circuitry
(111).
54 MAN 41151 EN 06
Index F
feedback board ............................... 49
feeding ........................................... 44
A
additional documents ........................ 4 G
air requirements .............................. 27 gas
alarms ..................................... 34, 40 connection 28
authorized use .................................. 9 requirements 27
Gas Control Unit
C connections 19
compatibility ................................... 27 functions 17
components gas hoses and piping ...................... 13
Distribution Unit 24, 25
Electrical Control Unit 20, 22 H
function of 16 hazardous materials ........................ 11
Gas Control Unit 17, 19 hazardous materials and conditions .... 8
System Status Monitor 16 heat ............................................... 11
compressed gases .......................... 12
I
connection ..................................... 28
information about this manual ............ 3
cooling water 30
input commands ............................. 34
electrical 30
installation ...................................... 28
exhaust interlock 40
intended audience ............................ 4
external equipment 33
intended use .................................... 3
gas 28
interlocks ....................................... 50
multiple systems 38
remote alarms, robot faults 40 M
remote emergency stop (E-STOP) 39 maintenance .................................. 49
remote operator pendant 36 multiple system interface ................. 38
robot 37
controls and displays ....................... 16 O
cooling water operating procedures ...................... 43
connections 30 operation ........................................ 41
setpoints 45 automatic 44
copyright restrictions ......................... 4 output commands ........................... 35
overview ........................................ 14
D
dimensions ..................................... 27 P
Distribution Unit ........................ 24, 25 personal protection ..................... 8, 10
door interlock .................................. 50 power requirements ........................ 27
principles of operation ..................... 15
E product description ......................... 14
ear protection ................................. 10 purge ............................................. 43
Electrical Control Unit
connections 22 R
functions 20 remote commands .......................... 34
electrical power .............................. 11 remote operation interface ............... 34
electrodes ...................................... 51 remote operator pendant ........... 26, 36
emergency stop (E-STOP) ....36, 37, 39 robot ........................................ 37, 40
exhaust interlock ............................. 40
external equipment interface ............ 33 S
eye protection ................................... 9 safety ............................................... 7
compressed gases 12
MAN 41151 EN 06 55
ear protection 10
electrical power 11
eye protection 9
gas hoses and piping 13
general regulations 9
hazardous materials 11
heat 11
personal protection 10
specific regulations 9
symbols 7
ventilation and exhaust 10
safety interlocks .............................. 50
service ........................................... 48
setup .............................................. 28
shutdown ........................................ 42
site requirements ............................ 28
specifications .................................. 27
starting current ................................ 49
startup ............................................ 41
status messages ............................. 46
symbols
additional 8
hazardous materials and conditions 8
personal protection 8
safety 7
System Status Monitor
functions 16
T
technical data ................................. 27
test functions .................................. 43
troubleshooting ............................... 52
V
ventilation and exhaust .................... 10
voltage divider ................................ 32
W
weight ............................................ 27
56 MAN 41151 EN 06

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9MC Plasma Control Unit

9MCD Plasma Distribution Unit

2008 Sulzer Metco

Sulzer Metco (US) Inc.

Find your Sulzer Metco sales office:

Manual no. Version Reason for revision Date

Revise to current documentation standards;

Compatible Powder Feeders 9MP

1. Requires modified 9MC Plasma Control Unit.

Information About This Manual

Table of Contents at the front of the manual

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

Read the relevant chapters, especially Chapter 1 Safety, before work-

Chapter Intended Audience

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

3 Installation and Commissioning

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

1.1 Safety Symbols

General Information and Warnings

Presentation of general, but important information which

i must be read and understood prior to proceeding.

Mandatory requirement not covered by other symbols.

Respiratory protection must be worn. Face protection (welding gear) must be

Protective clothing must be worn. Eye protection must be worn.

Head protection must be worn. Protective footgear must be worn.

Keep hands, hair, clothing and tools

Hazardous Materials and Conditions

Flammable material or presence of Poisonous substance present

High voltage or risk of electric shock High pressure warning.

Ultraviolet, infra-red or other damag- Warning of laser present.

Noise hazard present. Do not stack warning.

Heavy weight present above. Electrical ground is not present.

1.2 Authorized Use

It is recommended that all personnel connected with thermal spraying

In addition, the operator of this equipment must receive personal

1.4 Specific Safety Regulations

Ventilation and Exhaust

In addition to proper booth ventilation, appropriate personal respiratory

Wear personal protec-

Never aim the spray

The following guidelines should be followed when handling gas tanks:

Gas Hoses and Piping

Gas hose must be protected from mechanical damage. Gas hoses

1 9MC Plasma Control Unit

2.2 Principles of Operation

2.2.1 9MC Plasma Control Unit

Powder feeding can be remotely stopped or started at any time by the

At shutdown, the Control Unit automatically sequences the powder

2.2.2 9MCD Plasma Distribution Unit

The Distribution Unit contains a set of gapped electrodes that provide

2.3 Function of Components

2.3.1 System Status Monitor

2.3.2 Gas Control Unit Front Panel

(Continued from preceding page.)

2.3.3 Gas Control Unit Rear Connections

2.3.4 Electrical Control Unit Front Panel

In multiple-system operation, all Control

In multiple-system operation, the master

(Continued from preceding page.)