AA-82-01.3 REA III 100 kV Auto Applicator.pmd

Transcription

SERVICE MANUAL
AA-82-01.3
(Replaces AA-82-01.2)
May - 2008
REA III 100KV
AUT
OMA
TIC APPLICA
TOR
AUTOMA
OMATIC
APPLICAT
MODEL: 70393
IMPOR
TANT
IMPORT
ANT:: Before using this equipment,
carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions in
this manual. Keep this Service Manual for
future reference.Service Manual Price: €25.00
25.00 (Euro)
$30.00 (U.S.)
N O T E : This manual has been changed from revision AA-82-01.2 to revision AA-82-01.3.
Reasons for this change are noted under “Manual Change Summary” inside the back cover of this
manual.
AA-82-01.3
REA III 100kV Automatic Applicator - Contents
CONTENTS
SAFETY:
PAGE
1-4
SAFETY PRECAUTIONS........................................................................................................... 1
HAZARDS/SAFEGUARDS......................................................................................................... 2-4
ATEX
5-8
EUROPEAN ATEX DIRECTIVE................................................................................................. 5
EUROPEAN ATEX LABELS....................................................................................................... 6-7
INTRODUCTION:
9-10
GENERAL DESCRIPTION......................................................................................................... 9
SPECIFICATIONS....................................................................................................................... 9
INSTALLATION:
11-14
INSTALLING................................................................................................................................ 11-12
TYPICAL REA AUTOMATIC APPLICATOR
INSTALLATION - WATERBORNE............................................................................................. 12-13
ATOMIZER ASSEMBLY SELECTION....................................................................................... 14
OPERATION:
15-18
SAFETY PROCEDURES............................................................................................................ 15-17
MAINTENANCE:
19-36
ROUTINE SCHEDULE...............................................................................................................
ATOMIZER ASSEMBLY CLEANING PROCEDURE................................................................
FLUSHING PROCEDURES.......................................................................................................
SERVICE.....................................................................................................................................
TROUBLESHOOTING GUIDE...................................................................................................
EVALUATING RESULTS OF SCI AND CURRENT
DEMAND TEST...........................................................................................................................
19-20
21-22
22
22--32
33-34
PARTS IDENTIFICATION:
37-44
35
70393 REA III 100KV AUTOMATIC APPLICATOR
EXPLODED VIEW....................................................................................................................... 37-38
70393 REA III AUTOMATIC APPLICATOR /
SOLVENTBORNE SYSTEMS PARTS LIST.............................................................................. 39-40
70393 REA III AUTOMATIC APPLICATOR /
WATERBORNE SYSTEMS PARTS LIST.................................................................................. 41-43
WARRANTY POLICIES:
45
LIMITED WARRANTY................................................................................................................. 45
AA-82-01.3
REA III 100kV Automatic Applicator - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
ITW Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your ITW Ransburg products. This
manual contains information that is important for
you to know and understand. This information
relates to USER SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help you
recognize this information, we use the following
symbols. Please pay particular attention to these
sections.
A W
ARNING! states information to alert you
WARNING!
to a situation that might cause serious injury
if instructions are not followed.
A CAUTION! states information that tells
how to prevent damage to equipment or how
to avoid a situation that might cause minor
injury
injury..
A NOTE is information relevant to the
procedure in progress.
While this manual lists standard specifications and
service procedures, some minor deviations may
be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this
manual with your system installation drawings and
appropriate ITW Ransburg equipment
manuals to reconcile such differences.
!
WARNING
> The user MUST read and be familiar with
the Safety Section in this manual and the
ITW Ransburg safety literature therein identified.
> This manual MUST be read and thoroughly
understood by ALL personnel who operate,
clean or maintain this equipment! Special
care should be taken to ensure that the
WARNINGS and safety requirements for
operating and servicing the equipment are
followed. The user should be aware of and
adhere to ALL local building and fire codes
and ordinances as well as NFPA-33
SAFETY STANDARD, prior to installing,
operating, and/or servicing this equipment.
!
WARNING
> The hazards shown on the following page
may occur during the normal use of this
equipment. Please read the hazard chart
beginning on page 2.
Careful study and continued use of this manual
will provide a better understanding of the
equipment and process, resulting in more efficient
operation, longer trouble-free service and faster,
easier troubleshooting. If you do not have the
manuals and safety literature for your Ransburg
system, contact your local ITW Ransburg
representative or ITW Ransburg.
1
AA-82-01.3
AREA
HAZARD
Tells where hazards Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
may occur.
Spray Area
Fire Hazard
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Improper or inadequate operation
and maintenance procedures will Spray areas must be kept clean to prevent the
accumulation of combustible residues.
cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation. Frequent power
supply shutdown indicates a
problem in the system requiring
correction.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.
Those used for general cleaning must have flash
points above 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, and local codes. In
addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.
Electrostatic arcing must be prevented.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipment modifications may cause fire or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne
installations to spray solvent based materials.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC, and
OSHA requirements.
AA-82-01.3
2
AREA
HAZARD
SAFEGUARDS
may occur.
General Use and
Maintenance
Improper operation or maintenance Personnel must be given training in accordance with
may create a hazard.
the requirements of NFPA-33.
Personnel must be properly trained Instructions and safety precautions must be read and
in the use of this equipment.
understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33, and your insurance company requirements.
Electrical
Equipment
High voltage equipment is utilized.
Arcing in areas of
flammable or combustible
materials may occur. Personnel
are ex-posed to high voltage during
operation and maintenance.
The power supply, optional remote control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas. Refer to NFPA-33.
Turn the power supply OFF before working on the
equipment.
Protection against inadvertent
arcing that may cause a fire or Test only in areas free of flammable or combustible
explosion is lost if safety circuits material.
are disabled during operation.
Testing may require high voltage to be on, but only
Frequent power supply shutdown as instructed.
indicates a problem in the system
Production should never be done with the safety
which requires correction.
circuits disabled.
An electrical arc can ignite coating materials and cause a fire or Before turning the high voltage on, make sure no
explosion.
objects are within the sparking distance.
3
AA-82-01.3
AREA
HAZARD
SAFEGUARDS
may occur.
Spray Area /
High Voltage
Equipment
This is a high voltage device that
can produce electrical arcs
capable of igniting coating
materials.
Parts being sprayed must be supported on conveyors
or hangers and be grounded. The resistance between
the part and ground must not exceed 1 megohm.
(Reference NFPA-33.)
A safe distance must be maintained between the parts
being coated and the atomizer bell. A distance of at
least 1 inch for each 10 KV of power supply output
voltage is required at all times.
Parts must be supported so that they will not swing
and reduce the clearance specified above.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
Unless specifically approved for use in hazardous
locations, the power supply and other electrical
equipment must not be used in Class I, Division 1 or
2 locations.
AA-82-01.3
4
REA III 100kV Automatic Applicator - Atex
EUROPEAN A
TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
ATEX
The following instructions apply to equipment
covered by certificate number Sira 08ATEX5040X:
8. The certification of this equipment relies upon
the following materials used in its construction:
1. The equipment may be used with flammable
gases and vapors with apparatus groups II and
with temperature class T6.
If the equipment is likely to come into contact with
aggressive substances, then it is the
responsibility of the user to take suitable
precautions that prevent it from being adversely
affected, thus ensuring that the type of protection
provided by the equipment is not compromised.
2. The equipment is only certified for use in
ambient temperatures in the range +12.8°C to
+40°C and should not be used outside this range.
3. Installation shall be carried out by suitably
trained personnel in accordance with the
applicable code of practice e.g. EN 6007914:1997.
4. Inspection and maintenance of this equipment
shall be carried out by suitably trained personnel
in accordance with the applicable code of practice
e.g. EN 60079-17.
5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and
adjustment of the equipment shall be fitted by
suitably trained personnel in accordance with the
manufacturer's documentation.
Refer to the "Table of Contents" of this service
manual:
a. Installation
b. Operation
c. Maintenance
d. Parts Identification
7. Components to be incorporated into or used as
replacement parts of the equipment shall be fitted
by suitably trained personnel in accordance with
the manufacturer's documentation.
5
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
Suitable precautions: e.g. regular checks as part
of routine inspections or establishing from the
material's data sheets that it is resistant to specific
chemicals.
Refer to "Specifications" in the "Introduction"
section:
a. All fluid passages contain stainless steel
or nylon fittings.
b. High voltage cascade is encapsulated with
a solvent resistant epoxy.
9. A recapitulation of the certification marking is
detailed in the "Atex" section, on the next page,
drawing numbers: 19688, 72562, 76454, 76854,
76896, 77059, 78886, 78894-04, and LEPS5016.
10. The characteristics of the equipment shall be
detailed e.g. electrical, pressure, and voltage
parameters.
The manufacturer should note that, on being
put into service, the equipment must be
accompanied by a translation of the
instructions in the language or languages
of the country in which the equipment is to
be used and by the instructions in the
original language.
AA-82-01.3
REA III 100kV Automatic
Applicator 70393 A
TEX Product
ATEX
Marking Definitions
Label 72562
Ex Certificate Number: Sira 08ATEX5040X
Sira = Notified Body performing EC-type
examination
08 = Year of certification
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
040 = Document serial number
X = Special conditions for safe use apply
Label 76454
Special conditions for safe use: The REA-III 70393
Automatic Applicator shall only be used with
associated 76447-XX, 76045-XX, LEPS5000-04,
LEPS-5002-00, and 78789-02 HV Control Units.
Product Marking
II 2 G
Ex = Specific marking of explosive protection
II = Equipment Group hazardous area characteristics
2 = Equipment Category
G = Type of explosive atmosphere (gases, vapors,
or mists)
EEx 0.24mJ = The REA-III 70393 Automatic
Applicator is suitable for use in automatic spraying
installations complying with EN 50050 as they are
a Type A class with a discharge energy limit of
0.24mJ.
Label 76854
Label 19688
Label 76896
AA-82-01.3
6
Label 77059
Label 78894-04
Label 78886
Label LEPS0016
7
AA-82-01.3
NOTES
AA-82-01.3
8
REA III 100kV Automatic Applicator - Introduction
INTRODUCTION
9
GENERAL DESCRIPTION
SPECIFICA
TIONS
SPECIFICATIONS
The REA III 100kV Automatic Applicator
applies a high voltage charge to the coating materials at the point of atomization using a 100kV
power supply. This electrostatic charge allows a
more efficient, uniform application of coating material to the front, edges, sides, and back of products, making it highly suitable for applying a wide
range of coatings to a variety of surface configurations: large targets, small parts, tubular wares,
concave and recessed parts, etc. It is available as
a grounded fluid system for solvent reduced coatings such as enamels, lacquers, epoxys, etc.
Environmental / Physical
One of the many safety features of the REA III 100
kV Automatic Applicator is the capability of limiting, to a desirable level, the electrical discharge
which is available from the charging electrode.
When organic solvent base paints are being
sprayed, this level must not exceed 0.25 mJ of
energy. In order to achieve this limitation, it is
necessary to prevent any flow of energy from the
paint supply through the paint line to the applicator
electrode. This is accomplished by grounding the
paint line at the applicator.
Short Circuit
Current:
Operating V
oltage: 100kV maximum
Voltage:
Operating Fluid
Pressure:
Operating Air
Pressure:
Flow Rate:
0-100 psi (0-6.9 bar)
0-100 psi (0-6.9 bar)
1000 cc/min. maximum
(viscosity dependent)
150 Microamperes
Air and Fluid Nozzles:
Any ITW Ransburg Air and Fluid Nozzle
combination. (See “Nozzle Selection” in the
“Operation” section.)
Optional Hose and
Cable Lengths:
25, 36, 50, 75, and 100 ft.
(8m, 11m, 15m, 23m, and
31m)
AA-82-01.3
REA III 100kV Automatic Applicator - Introduction
NOTES
AA-82-01.3
10
REA III 100kV Automatic Applicator - Installation
INST
ALLA
TION
INSTALLA
ALLATION
! WARNING
! WARNING
> Installation of the equipment MUST be in
> The power supply MUST be located
compliance with all Federal, State, Local and
National codes.
outside of the spray area. Install units in
accordance with the requirements of local
regulations.
The power supply MUST be located
OUTSIDE of the spray area.
>
Personnel MUST be GROUNDED to
prevent a shock or spark during electrostatic
operation.
>
> Install and route the hoses and cables so
they are NOT exposed to temperatures in
excess of 120°F (49°C) and so that all hose
and cable bends are NOT less than a 6-inch
(15 cm) radius. Failure to comply with these
parameters could cause equipment malfunctions that might create HAZARDOUS CONDITIONS!
INST
ALLING
INSTALLING
1. To connect the high voltage cable, remove the
cable retainer bracket and remove the protective
cap for the power supply high voltage cable
socket. Insert the high voltage cable (and plug)
into socket. Gently hand-tighten the cable
retaining nut. Reattach the bracket.
2. The control unit MA
MAY
Y be connected through
conduit with an explosion-proof terminal on or near
the spray booth where it will be convenient, or
may be connected with a line cord depending upon
application requirement.
3. Install Filters: Install the optional fluid filter on
output of fluid supply. Detail depends on whether
pressure tank, pump unit, recirculating system,
etc. is used. Filter must be installed vertically with
drain valve down and arrow pointing in direction
of flow (see Figure 1).
4. Install Line Hose (Air or Fluid):
NOTE
> ITW Ransburg supplies a standard
25 ft. (8m) hose. Optional hose lengths of
36 ft. (11m), 50 ft. (15m), 75 ft. (23m), and
100 ft. (31m) are available. To meet
various length requirements, the hose
fitting on one end has not been attached.
Determine the hose length that is needed
and cut the hose. Attach the other fitting
as follows:
a. Lubricate all fittings with petroleum jelly.
b. Screw ferrule counter-clockwise onto hose
until it bottoms. Then back it off about 1/8inch (3mm).
NOTE
NOTE
Refer to the Power Supply Service
Manual for the circuit diagram and instructions to connect the power supply.
>
11
> The union stem will not seat if the hose
is bottomed against the ferrule.
AA-82-01.3
c. Install nut over union stem and start the stem
into the hose.
d. Using the 1/8-inch Allen wrench, screw the
union stem into the hose until it bottoms
against the ferrule.
e. Connect one end of one hose to the appropriate fitting on the bottom of the applicator
body and the other end to the power supply
pressure switch for trigger air. Attach the
other hose to the atomizing air source.
! WARNING
NEVER use wooden boxes, pallets, or
boards as wood will absorb moisture and is a
poor insulator.
>
• Isolation stand MUST be at least 18-inches
from the grounded booth wall, chain link fence,
or other grounded objects.
• Air hoses to the pressure pot or pump on the
insulating stand should be nonconductive. Many
rubber hoses will have static grounding circuits
or carbon content and are NOT suitable.
• Air regulators for pots or pumps should be
mounted remotely outside the fence or cage
area to facilitate changes in pressure without
shutting the system down.
• Grounding hooks at the cage MUST be used
to ground portions of the system when
personnel are working close by.
• Fluid lines to the applicator MUST be protected
from scraping and abrasion on the floor or sharp
metal edges that could lead to voltage pinholing
and loss of kV on the charged system.
Figure 1: Installing Line Hose
• Cleanliness and maintenance are extremely
critical.
TYPICAL REA
AUT
OMA
TIC APPLICA
TOR
AUTOMA
OMATIC
APPLICAT
INST
ALLA
TION INSTALLA
ALLATION
WATERBORNE
• Fully discharge system capacitance prior to
service.
! WARNING
System capacitance must be fully discharged prior to any service or maintenance of
the applicator.
>
Using waterborne coating with electrostatic
equipment requires that the fluid source should
be isolated from ground and other precautions be
taken to ensure operator safety and system
efficiency. The following guidelines should be
followed:
> ALL charged (isolated) systems MUST be
• The fluid lines and source MUST be isolated
from ground. An isolating paint stand or similar
isolating (non-porous) material MUST be used.
inside a fence or cage to prevent contact by
personnel. An interlock system MUST be
provided that interrupts high voltage flow to the
applicator if the gate is opened.
AA-82-01.3
! WARNING
12
Paint Preparation
A proper paint mixture is essential to electrostatic
operation. Paint test equipment may be obtained
through your ITW Ransburg representative.
Consult ITW Ransburg literature “Paint Related
Information for REA and REM Applicators” manual
for paint formulation information. For further paint
formulation and testing procedures, consult your
ITW Ransburg representative and/or paint
supplier.
Atomizer Assembly Selection
!
CAUTION
> A counter-clockwise turn of the air cap
may loosen the fluid nozzle and cause air to
get into the paint or paint to cross over into
the air passages.
Applicator T
o T
arget Distance
To
Target
Mount the applicator 6-12-inches (152-305mm)
maximum from the target for best operation.
The “Atomizer Assembly Selection” charts are
provided to give you a comparison of the air caps
THE CHOICE OF
and fluid nozzles.
AT OMIZER
ASSEMBL
Y
SHOULD
ASSEMBLY
DEPEND ON QUALITIES DESIRED AND
MUST BE VERIFIED BY ACTUAL TRIAL.
See you authorized ITW Ransburg distributor for
atomizer demonstration.
Spray Pattern Adjustment
The spray pattern of fan atomizers is adjustable
from a small circle to an elongated oval,
approximately 10-12-inches (254-305mm) across
the useable long axis at 8-10-inches (203-254mm)
from the target. The swirl atomizer assemblies
produce a round pattern from 5-9-inches (127229mm) in diameter. To adjust pattern size,
increasing fan air pressure will expand the pattern,
a reduction will decrease it. To change the spray
pattern axis of fan atomizers from horizontal to
vertical, loosen retainer ring, rotate the air cap
clockwise to the desired position, and gently
tighten the ring.
13
AA-82-01.3
AT
OMIZER ASSEMBL
Y SELECTION
ATOMIZER
ASSEMBLY
REA NOZZLES
(Conventional Spray)
Air Cap
Part
Number
70899-00
LREA0002
4904-65R
4904-65R
4904-65R
4904-65R
4904-65R
4904-63
4904-63
4904-63
4904-63
4904-63
4904-98
4904-98
4904-98
4904-98
4904-98
Fluid Nozzle
Part Number
70898-00
LREA0003
4907-44
4907-45
4907-46
4907-47
4907-48
4907-44
4907-45
4907-46
4907-47
4907-48
4907-44
4907-45
4907-46
4907-47
4907-48
Orifice
ID
Swirl
Round
.055” (1.4mm)
.070” (1.8mm)
.042” (1.1mm)
.028” (0.7mm)
.047” (1.2mm)
.055” (1.4mm)
.070” (1.8mm)
.042” (1.1mm)
.028” (0.7mm)
.047” (1.2mm)
.055” (1.4mm)
.070” (1.8mm)
.042” (1.1mm)
.028” (0.7mm)
.047” (1.2mm)
Separate
Retaining
Ring
Pressure
Reducer
(Black)
4903-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
73569-00
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
74963-02
REA NOZZLES
(HVLP)
Air Cap
Part
Number
75601-00
75601-00
75601-00
AA-82-01.3
Fluid Nozzle
Part Number
75600-01
75600-02
75600-03
Orifice
ID
.055” (1.4mm)
.070” (1.8mm)
.086” (2.2mm)
Separate
Retaining
Ring
73569-00
73569-00
73569-00
Pressure
Reducer
(White)
74963-03
74963-03
74963-03
14
REA III 100kV Automatic Applicator - Operation
OPERA
TION
OPERATION
SAFETY PROCEDURES
! WARNING
> The simple safety measures outlined in the
“Safety” section are vital. Failure to observe
them could cause a spark capable of starting
a fire.
1. The articles being coated MUST be grounded
at all times.
2. All components of the applicator system MUST
be grounded at all times.
3. All contact points MUST be free of any
accumulation of non-conductive residue.
4. All electrically conductive objects, especially
solvent containers, within the spray area MUST
be either removed or grounded.
Any tool, if used improperly, can be dangerous.
Safety is ultimately the responsibility of those using
a tool. In like manner, safe operation of
electrostatic coating processes is the
responsibility of those who use such processes
and those who operate electrostatic coating
equipment. It is most important that equipment
operators and supervisory personnel understand
the requirements for safe operations.
Additional cards summarizing these safety
requirements are available from ITW Ransburg
on request. These cards should be posted in the
spraying area so that they can be readily referred
to and serve as a reminder to personnel that area
of responsibility. Additional copies of “Cleaning
Safety Requirements” are available upon request.
Each user should examine his own coating
operation, develop his own safety program and
ensure that his workers follow correct procedures.
ITW Ransburg hopes that the information it
provides is helpful to the user in establishing such
a program.
In addition to the available cards, labels, brochures,
and service manuals, the user should consult
other standards and recognized safety authorities.
Local codes and authorities also have standards
to be followed in the operation of your spray
equipment. Your insurance carrier will be helpful
in answering questions that arise in your
development of spray coating procedures.
All personnel MUST read and understand the
following ITW Ransburg literature, “T
“Technical
echnical
Supplement for All Products”.
! WARNING
> If ANY symptom of improper operation
occurs suspend use of the unit until the problem has been diagnosed and corrected. See
the appropriate “Troubleshooting Guide” or
contact your ITW Ransburg representative.
15
AA-82-01.3
! WARNING
> Verify that the applicator body assembly is
actually grounded before operating it! This is
done with a fully connected and operation
system, by placing one lead of an ohm meter
to the body assembly and the other to the
building electrical ground (cold water pipe,
building structure, etc.). The reading should
be essentially zero.
> If a reading much greater than zero is
obtained, check that the power supply is
grounded. Place one lead of the ohm meter on
the building electrical ground and the other on
the high voltage cable outlet bushing. If the
reading is much greater than zero, reconnect
the power supply ground. If the meter reads
zero, check the high voltage cable. Place one
lead on the high voltage cable retaining nut and
the other lead on the applicator body assembly. If the reading is much greater than zero,
the braided cable may be defective and should
be replaced.
1. Parts, Equipment and Supplies:
a. Ground the spray booth, the paint tank,
and the conveyor.
b. Ground ALL solvent containers.
c. Ground ALL work holders and hooks and
keep them free of paint.
2. Personel Procedures:
a. GROUND ALL PERSONS IN ALL
SPRA
Y AREAS by requiring that they
SPRAY
wear conductive soled shoes or personnel
grounding straps.
(See ITW Ransburg “Safety Literature
Handbook - Electrostatic Safety
Information from ITW Ransburg”.)
b. Turn the power supply OFF prior to
cleaning or working on the equipment.
c. NEVER immerse any part of, or all of a
spray applicator in any liquid, while
assembled.
d. Personnel MUST stay out of the spray
booth during operation.
3. Ventilation:
Electrostatic attraction greatly reduces paint
overspray, thereby reducing ventilation
requirements. An exhaust velocity of 100 to
150 FPM at the spray position is normally
adequate. Exhaust system (and conveyor)
MUST be interlocked with the triggering
function.
! WARNING
> Exhaust system and conveyor must be
interlocked with high voltage
d. See that no more than one gallon of solvent
per safety container per operator is inside
the work area.
e. See that the power supply is grounded and
located outside the spray area.
f.
See that conductive flooring is provided in
all spray areas.
g. See that the proper fire extinguishing
equipment is provided.
AA-82-01.3
16
4. Housekeeping:
NOTES
Good housekeeping is always necessary to
ensure quality finishes, eliminate rejects, and
reduce service requirements (see OSHA
standards).
a. Periodically strip all workholders to maintain proper grounding of parts.
b. Establish adequate cleaning and maintenance schedules based on observation of
initial production characteristics.
c. Employ fire protection measures, including proper storage of paints, solvents, and
waste, plus ready access to fire extinguishing equipment. Provide water
sprinklers, CO2, or chemical fire extinguishers within the spray area (check local
fire codes).
17
AA-82-01.3
NOTES
AA-82-01.3
18
REA III 100kV Automatic Applicator - Maintenance
MAINTENANCE
! WARNING
> The user MUST read and be familiar with
the SAFETY INSTRUCTIONS in this
manual.
> If compressed air is used in cleaning,
REMEMBER THAT HIGH PRESSURE
AIR CAN BE DANGEROUS AND
SHOULD NEVER BE USED AGAINST
THE BODY. It can blind, deafen, and may
even penetrate the skin. If used for cleaning
equipment, the users should wear safety glasses.
ALWAYS turn the control unit power
off prior to cleaning or servicing equipment.
>
Be SURE the power is OFF and the
system is grounded BEFORE using solvent
to clean ANY of the quipment.
>
DO NOT OPERATE A FAULTY
>
APPLICATOR!
> When using cleaning solvent, standard
health and safety precautions should apply.
!
CAUTION
NEVER remove the fluid nozzle assembly while paint is in the applicator or
paint may clog the air passages. Clogged
air passages will cause poor atomization
and electrical shorting. Air passages which
are clogged with conductive material may
lead to excessive current output levels and
consequent low operating voltage and long
range electrical damage. Before undertaking any atomizer assembly procedure, see
“Atomizer Assembly Cleaning Procedure”
in the “Maintenance” section.
>
> The applicator MUST be tilted front down
to remove the air cap and/or fluid nozzle.
Failure to do so may allow paint to enter the
air passages, thereby reducing air flow and
damaging the applicator barrel/cascade.
Applicators may be flushed in lieu of tilting.
However, they must be either flushed or
tilted down!
• Clean all insulating surfaces in the system.
Remove paint accumulation from the exterior
of the applicator and high voltage cable with a
solvent dampened cloth.
! WARNING
ROUTINE SCHEDULE
NEVER soak or submerge the electrical
components of the applicator (i.e. barrel, transformer, cable). Damage and failure may occur.
>
Follow these maintenance steps to extend the life
of the applicator and ensure efficient operation:
Times
Several T
imes Daily:
• Turn the control unit power to OFF!
Daily (at the start of each shift):
• Inspect the air cap for fluid/solvent accumulation. Clean as frequently as necessary with
a soft bristled brush and a suitable solvent.
• Verify that ALL solvent safety containers are
grounded!
• Check within 20 feet of the point of operation
(of the applicator) and remove or ground ALL
loose or ungrounded objects.
19
AA-82-01.3
• Inspect workholders for accumulated coating
materials, removing such accumulations.
2. Turn the fluid/solvent supply OFF.
3. Turn the atomizing air and fan air OFF.
• Check that atomizer assembly is clean and
undamaged.
• Straighten the applicator electrode if necessary.
!
CAUTION
> When straightening the electrode, be
careful not to distort the fluid nozzle orifice.
4. Turn piston air OFF.
5. Wipe the applicator, cable, and hoses with
a rag and a suitable cleaning solvent.
6. Flush the lines and allow the solvent to
remain in the lines unpressured. (See
“Flushing Procedures” in the “Maintenance”
section of this manual.)
NOTE
• Clean the fluid filter, if used.
• Turn the control unit power ON. The applicator’s red transformer light should light when
triggered.
• Run a current/voltage output test.
Electrical Current Output T
est
Test
2. Turn high voltage on at applicator.
3. Slowly approach the applicator electrode to
any grounded object and make contact.
4. Monitor the current output reading on the
power supply meter. As applicator approaches,
ground current should increase near 120 mA.
Overload current should “trip”, shutting off high
voltage. Overload indication should come on.
5. Release the trigger and turn the power supply
power OFF.
> If the shut-down time is to be short, the
lines may not require flushing, depending
on the type of coating material used. If the
solids in the material settle slowly, the
lines will not need to be flushed as soon
after shut-down as with fast settling solids. The fluid/solvent being used and the
length of time that the lines will be shutdown will determine the need for flushing.
Metallic paint and primer will require flushing sooner than some other types of coating materials.
!
CAUTION
> If the coating material is fast settling and
if the lines are not flushed soon enough, the
applicator’s fluid passages as well as the
lines may become clogged and cause excessive down-time and/or service and repair.
If the control unit does not trip, DO NOT use the
applicator until the problem has been corrected.
(See the “Troubleshooting Guide” in the
“Maintenance” section of this manual.)
Weekly
Shut-Down
(and at the end of each shift)
• Clean the atomizer assembly.
• Check the entire system for damage, leaks,
and paint accumulation.
1. Turn the power supply power OFF.
AA-82-01.3
20
REA III 100kV Automatic Applicator - Maintenace
ATOMIZER ASSEMBL
Y
ASSEMBLY
CLEANING
PROCEDURES
Routine Cleaning Equipment
Needed
For efficient operation, keep the applicator’s
exterior and the high voltage cable clean and free
of paint accumulation and dirt. This prevents the
loss of voltage to ground with a resulting reduction
in electrostatic effect. Solvent accumulation at
the air cap orifices reduces atomization quality
and increases the potential for paint “spits”. Clean
the air cap with a brush and cleaning solvent as
often as needed to ensure good atomization.
• An appropriate solvent
• Solvent safety container (grounded)
• Small soft bristled brush
• ITW Ransburg 19749-00 special multi-purpose
wrench from the installation kit.
!
CAUTION
> To avoid damage to the fluid nozzle,
needle/electrode, the fluid pressure MUST
be released by triggering the applicator prior
to removing the tip.
The applicator MUST be tilted front
down to remove the air cap and/or fluid
nozzle. Failure to do so may allow fluid/
solvent to enter the air passages, thereby
reducing air flow and damaging the applicator barrel/cascade. Applicators may be
flushed in lieu of removing nozzles. However, they MUST be either flushed prior to, or
tilted down during nozzle removal!
>
> The control unit power MUST always
be off when removing the nozzles or any
other service to the applicator.
> Using any tool other than the ITW Ransburg 19749-00 wrench to remove or reinstall the fluid nozzle may distort or damage
it.
21
! WARNING
> NEVER wrap the applicator in plastic to
keep it clean. A surface charge may build-up
on the plastic surface and discharge to the
nearest grounded object. Efficiency of the
applicator will also be reduced and damage or
failure of the applicator components may occur. WRAPPING THE APPLICATOR IN
PLASTIC WILL VOID THE WARRANTY.
Proceed as Follows:
1. Turn the power supply unit power OFF.
2. Release the trigger.
3. Turn the fluid/solvent flow OFF.
4. See “Service” section in the “Maintenance”
section of this manual for “Disassembly
Procedures”.
! WARNING
> Any damage to the applicator may
result in UNSAFE operating conditions.
5. Clean the removed parts with a soft bristled
brush and suitable solvent.
AA-82-01.3
!
CAUTION
> Metal tools and wire brushes must
NEVER be used. NEVER use a cleaning
tool that is harder than the plastic parts. If a
deposit cannot be removed with the solvent
and a rag or the soft brush, soak the part in
the solvent ONLY until the deposit can be
removed! NEVER SOAK THE APPLICATOR BODY, BARREL, OR TRANSFORMER!
SERVICE
All repairs should be made on a clean, flat surface.
If a vise is used to hold parts during service or
repair, DO NOT clamp onto plastic parts and
always pad the vise jaws! During assembly,
ALWAYS lubricate o-rings, chevron seals, and the
threads on part Items #45, 57, 58, 43, and 49, as
indicated, with a light coat of petroleum jelly. (Teflon
o-rings do not need lubrication.)
FLUSHING
PROCEDURES
!
CAUTION
> Do NOT USE any silicone lubrication
in this system!
1. Turn the control unit power OFF.
!
> ALWAYS remove the applicator from
3. Turn the atomizing air supply OFF.
4. Activate dump air and flush with a suitable
cleaning solvent until it is clear of fluids. Air purge
the dump line.
the work site for service or repair!
The following tools will be needed:
6. Disconnect the solvent supply.
•
•
•
•
7. Activate the trigger valve until it is clear of
solvent. After the preceding steps are complete,
the applicator is ready for color change, storage,
or service.
•
•
•
•
5. De-activate dump air and activate trigger air
until the applicator fluid passage is clear.
!
CAUTION
Special wrench 20049-00
Nozzle wrench 19749-00
3/32” Allen wrench
Open end wrenches: 15/16”, 7/8”, 11/16”,
9/16”, 7/16”, 3/4”, 3/8”, and 1/4”
Screwdriver (broad)
Paper clip (or similar rigid wire)
Lock-Tite, medium strength, P/N 7969-03
Plastic or wood dowel rod, 5/16-inch diameter
CAUTION
> Do NOT allow the fluid lines to stand
empty without flushing first! This will cause
dried solvent flaking into and clogging of the
fluid lines, applicator passages, and nozzles.
AA-82-01.3
22
R emove the Applicator from the
Work Site
1. Flush the applicator (see “Flush Procedure” in
the “Maintenance” section).
! WARNING
> 2. Turn ALL power, air, and fluid (coating
material and solvent) OFF at the source.
1. Air Nozzle:
a. Unscrew air nozzle [1] from barrel [8] and
clean or replace it.
b. Screw the cleaned or new nozzle assembly
onto barrel [8].
2. Fluid Nozzle:
a. Remove air nozzle [1] from barrel [8] and
clean or replace it.
b. With the nozzle wrench on the wrench flats,
remove fluid nozzle [2].
3. Detach fluid line from fitting [66].
4. Detach the air line fittings from applicator air
fittings [35] and [34].
5. Detach the high voltage cable [70] from the
applicator by unscrewing cable retaining nut [32]
and pulling the cable straight out of resistor
housing [37].
NOTE
> If the high voltage cable is to be replaced, see “High Voltage Cable Replacement” in the “Maintenance” section.
c. Clean or replace the fluid nozzle.
d. Screw the cleaned or new fluid nozzle [2]
into barrel [8]. Secure with the nozzle
wrench and release trigger air to applicator.
NOTE
> It may be necessary to loosen packing
nut [21] with the spanner wrench and retract the trigger to seat the nozzle completely.
e. Screw air nozzle [1] onto barrel [8].
6. Loosen set screws [28] and remove the
applicator from the work site.
Nozzle and Electrode Cleaning
or Replacement
!
NOTE
> If packing nut [21] has been loosened,
tighten it until needle shaft [7] moves in and
out with firm resistance.
CAUTION
> NEVER bend the electrode!
NOTE
> If the fluid nozzle is replaced, there is a
NOTE
> See “Nozzle Cleaning Procedures” in
the “Maintenance” section.
19
good chance that the needle tip assembly
[3] will need to be replaced too. A worn
neede tip assembly may not always seat
well in a new fluid nozzle.
AA-82-01.3
Needle T
ip Assembly
Tip
(Electrode)
2. Disengage nuts [58] and [57] from valve rod
extension [23].
1. See “Nozzle and Electrode Cleaning or
Replacment - Steps 1 and 2” to remove the air
cap and fluid nozzles.
3. Loosen barrel extension [11] with the spanner
wrench.
2. Insert the end of a paper clip (or similar rigid
wire) through the hole at the rear of the needle
shaft [7] to keep it from rotating.
4. Disengage fittings [10] and [9] and release fluid
tube [69].
5. Pull barrel [8] and body [26] STRAIGHT apart.
3. Hold barrel [8] in a vertical position, front end
up, and unscrew needle tip [3].
!
NOTE
> The vertical position is to keep adaptor
[4] from falling out.
CAUTION
> The barrel and body MUST be pulled
straight apart to avoid damage to the resistor housing [37].
NOTE
!
CAUTION
> Be SURE that adaptor [4] is in place and
> Gasket [13] should be kept with the
body assembly if it is not to be replaced.
facing the right direction when the applicator
is reassembled or the applicator will malfunction!
Barrel Removal
NOTE
> In normal operation and service, the
barrel extension need never be removed
from the barrel. It should be treated as a
permanent part of the barrel. If it should be
damaged and replacement becomes necessary, remove the barrel from it the same
as it is removed from the body assembly
AFTER the internal parts have been removed (see “Barrel Disassembly”).
NOTE
> There is no need to remove retaining
ring [12] or barrel nut [11] from barrel [8]
unless they are damaged. If they are to be
removed, lift one end of ring [12] out of its
groove and spiral it off of the end of the
barrel. Then nut [11] can be removed. To
replace them on the barrel, slide nut [11]
onto the barrel, place ring [12] against the
back of the barrel, lift one end of it onto the
barrel and spiral it on and into its groove.
!
CAUTION
> Spreading the retaining ring may break
it!
1. Remove piston housing [61], spring [60], and
spring [59].
AA-82-01.3
6. Part Items #57, 58, 59, and 60 may be stored
during barrel service by replacing them in the
piston housing and reattaching it to the body.
24
Barrel Disassembly
NOTE
1. Remove air nozzle [1] from barrel [8].
> If the needle valve assembly does not
2. Remove fluid nozzle [2] from the front barrel
with the nozzle wrench.
pull out of the chamber easily, hold the
barrel in a vertical position, front end up,
and press down against a hard surface
until parts [3] through [7] can be pulled from
the front of the chamber. Then, insert the
flat end of a smooth 5/16-inch plastic or
wood dowel rod into the front barrel chamber and press the packing tube [15] and
parts [17], [18], and [19] from the chamber.
3. Remove valve rod extension [23] and adjusting
nut [22] from needle valve rod [7].
4. Remove packing nut [21] from the barrel
chamber with the spanner wrench.
NOTE
> The six (6) spring washers [20] will come
out of the chamber at this point.
!
6. Slide parts [20], [18], [17], and [15] off of shaft
[7].
NOTE
CAUTION
> If parts [19] and [17] do not separate
> DO NOT lose any of the spring wash-
easily, wedge a knife blade between them
and pry them apart.
ers! The applicator MUST have six (6),
correctly positioned, spring washers in order to function properly.
5. With a firm pull, remove the needle valve
assembly [3] through [19] from the rear of the
barrel chamber.
7. Unscrew needle [3] from shaft [7] and slide
parts [4], [5], and [6] off of the shaft.
Barrel Assembly
• Clean all parts with a suitable, clean solvent.
!
CAUTION
•
If the electrode is bent, straighten it CAREY by hand.
FULLY
FULL
that the interior surface of the chamber is
NOT damaged (marred or scrateched).
•
This chamber is a seal area and the
barrel will have to be replaced if it is damaged.
Check all parts for damage or wear. Replace
those that are damaged or worn with new
parts.
•
Replace chevron seals [5], o-rings [16], and
u-cup [18] with new parts.
> During this operation, be CAREFUL
>
25
AA-82-01.3
CAUTION
5. Insert assembly [3] through [7] into the front
barrel chamber.
> To avoid damage to the chevron seals,
the needle shaft assembly MUST be installed from the front of the barrel.
6. Insert fluid nozzle [2] into the chamber and
secure it firmly with the nozzle wrench.
!
1. Place female chevron adaptor [6] onto the front
of shaft [7] with the concave side toward the front.
2. Place the four (4) new chevron seals on shaft
[7], concave sides forward, by carefully rotating
them.
!
7. Screw air nozzle [1] onto barrel [8] to protect
needle [3] during the balance of the assembly
procedures.
8. Place packing tube [25] over the end of shaft
[7] through the rear barrel chamber.
9. Place the new u-cup [18] into rear needle seat
retainer [17] with the open side out.
CAUTION
DO NOT push the chevron seals
straight onto the shaft. The shaft threads
may damage the chevron bore and cause
the applicator to malfunction.
NOTE
>
3. Place male chevron adaptor [4] onto shaft [7]
with the convex end rearward.
NOTE
> Part Items [4], [5], and [6] should seat
together to form an unbroken seal.
4. Screw needle tip [3] onto shaft [7] hand tight.
NOTE
> Apply a light coating of petroleum jelly to
the chevron seals.
> Seat the u-cup into the retainer very
carefully with the eraser end of a pencil or
a wood or plastic dowel rod.
10. Place the new o-ring [16] onto retainer [17].
11. Place retainer [17] over shaft [7] with the open
end toward the rear.
12. Place spacer [19] over shaft [7] flanged end
first. Seat parts [15], [17], and [19] into the
chamber carefully with the flat end of the tubular
spanner tool.
13. Place the six (6) spring washers [20] onto shaft
[7] with the first, third, and fifth ones cupped side
rearward and the second, fourth, and sixth ones
cupped side forward.
!
CAUTION
> There MUST be six (6) spring washers,
alternately faced, or the applicator will malfunction.
AA-82-01.3
26
14. Screw packing nut [21] into the chamber and
secure it with the spanner wrench.
NOTE
> The packing nut should be tight enough
that shaft [7] slides in and out with firm
resistance.
15. Screw trigger adjustment nut [33] onto shaft
[7] with the flanged end toward the rear.
16. Screw valve rod extension [23] onto shaft [7]
with the flanged end toward the front.
NOTE
> The hexagonal flanges of [22] and [23]
should face each other.
Figure 2: Barrel Assembly
17. To adjust [22] and [23]:
a. Push shaft [7] fully forward.
NOTE
> To prevent shaft [7] from rotating, secure
it with a wire through the hole at the rear.
NOTE
> Fluid nozzle [2] must be firmly in place
(see Step 6).
b. Measure 21/32-inch (16.6mm) from the
rear face of packing nut [21] to the rear
face of hexagonal flange of the valve rod
extension [23].
c. Secure the nut and rod extension together
at that dimension by rotating nut [22]
rearward until the two will not turn on the
shaft.
d. Tighten the two by holding rod extension
[23] with a 3/8-inch wrench and turning
nut [22] against it with another 3/8-inch
wrench.
27
AA-82-01.3
Barrel to Body Assembly
1. Remove piston housing [61] from body [26].
!
CAUTION
> DO NOT lose parts stored in piston
housing.
2. Place gasket [13] into the front body [26]
chamber.
NOTE
5. Secure the barrel assembly with nut [11] and
tighten.
!
> Nut [11] should be secured hand tight
only. NEVER apply more than 10 lbs•ft
(13.5 Nm) torque.
6. With the needle valve and piston shaft [52] fully
forward, secure lock nuts [57] and [58] onto
extension [23]. Allow 1/16-inch gap between nut
[57] and shaft [52].
> Secure the new gasket in place by
splitting it at the top and pressing it into the
chamber. The top is the broadest of the two
large hole margins.
CAUTION
NOTE
> Projection on nut [58] MUST face the
rear of the applicator.
3. Place new o-ring [38] on resistor housing [37].
4. Insert resistor housing [37] into the upper body
chamber and slide the barrel assembly straight
into the front body chamber over housing [37].
!
CAUTION
!
CAUTION
> The fluid valve shaft travel MUST be
adjusted so that the air valve is always
triggered FIRST
FIRST. If the air does not turn on
BEFORE the fluid, readjust nuts [57] and
[58] in relation to shaft [52].
> Be SURE that conductive sponge [36]
is in place. If it is not, the applicator will
eventually malfunction.
7. Engage fluid tube [69] to barrel [8] with fittings
[9] and [10].
NOTE
> The needle shaft [7] should engage
valve rod extension [23].
AA-82-01.3
28
Resistor Assembly Replacement
1. Remove the high voltage cable (see “High
Voltage Cable Replacement” in this section).
!
CAUTION
> If the conductive sponges are not in
place, the applicator will malfunction!
2. Remove the barrel assembly (see “Barrel
Removal” in this section).
3. Remove resistor housing tube [31].
11. Replace the barrel assembly (see “”Barrel to
Body Assembly” in this section).
4. Remove screw [29] and [30].
5. Remove mounting support [27] and resistor
housing [37] from the body chamber.
6. Place the new resistor assembly [37] into the
body chamber.
7. Place new o-rings [38] and [39] on the new
resistor assembly [37].
!
CAUTION
> Be SURE that conductive sponge [40] is
in place in the resistor housing chamber.
8. Place mounting support [27] in position on body
[26] and secure with screws [29] and [30].
9. Place resistor housing tube [31] over the end
of resistor housing [37] and screw it into the body
[8].
10. Install a new conductive sponge [36] in the
barrel chamber.
12.Install high voltage cable (see “High Voltage
Cable Replacement” in this section).
Valve Housing (Body) Service
When service is performed on any of the body
elements, it is best to remove the barrel assembly
and resistor assembly (see “Resistor Assembly
Replacement” in this section) in order to avoid
damage to the nozzle, electrode or any of the
plastic parts.
After disassembly of any body element:
• Clean all parts with a suitable, clean solvent.
• Check all parts for damage or wear. Replace
those that are damaged or worn with new
parts.
• Replace all seals and o-rings.
Fluid V
alve (T
rigger)
Valve
(Trigger)
1. Disassembly:
a. Rotate piston housing [61] to remove it from
the valve chamber.
b. Remove springs [59] and [60].
NOTE
> The old sponge MUST be removed! Use
a long wire with one end bent into a hook.
c. Turn nut [58] away from nut [57] using
appropriate wrenches.
d. Remove nuts [57] and [58] from shaft [23].
e. Remove the barrel assembly (see “Barrel
Removal” in this section).
f. Remove the resistor assembly (see
“Resistor Assembly Replacement” in this
section).
29
AA-82-01.3
g. Remove valve seal retaining nut [24] and
o-ring [25] from the front of the valve
chamber using a 3/8-inch nut driver.
NOTE
> Be SURE that o-ring [51] is in bushing
[50].
h. With a flat tipped wood or plastic dowel rod
inserted into the front of the valve chamber,
push piston assembly [52] through [56] out
of the rear of the valve chamber.
e. Replace the resistor assembly (see
“Resistor Assembly Replacement” in this
section).
i. Secure piston shaft [52] in a 3/8-inch
wrench (on the wrench flats) remove nut
[56] with a 9/16-inch socket.
f. Replace the barrel assembly (see “Barrel
to Body Assembly” in this section).
j. Slide piston assembly [53], [54], and [55],
from the shaft [52] and disassembly
components by hand.
g. Place nut [57] on shaft [23] 1/16-inch from
piston shaft [52].
k. Remove bushing assembly [50], [48], [49],
and [51] from the valve chamber with a
20049-00 wrench.
NOTE
> See “Barrel Assembly - Step 17” and
2. Assembly:
“Barrel to Body Assembly - Step 6” for
shaft [23] adjustment.
NOTE
h. Place nut [58] on shaft [23] and secure
against nut [57] using appropriate
wrenches.
> Replace all o-rings. Replace packing
cup [54] if it is worn.
i. Place springs [59] and [60] against piston
[55] and nut [58] and secure in place by
screwing piston housing [61] into the rear
of the valve housing.
a. Secure retaining nut [24] and o-ring [25] in
the front of the valve chamber using a 3/8inch nut driver.
b. Secure bushing assembly [50], [48], [49],
and [51],in the valve chamber using a
20049-00 wrench.
c. Secure shaft [52] in wrench (on 3/8-inch
wrench flats) and assembly washers [53],
cup [54], and piston [55] on the rear with
nut [56] using a 9/16-inch socket.
d. Place the piston assembly [52] through [56],
into the valve chamber through bushing [50]
and press into place.
AA-82-01.3
Fan Air Control V
alve
Valve
1.
Disassembly:
a. Turn control knob [42] to the open position
(fully extended) to accomodate Step b.
b. With a 9/16-inch wrench, unscrew retaining
nut [43] and remove the entire valve
assembly.
c. Return the control knob to the closed
position.
30
d. Secure control knob [42] in a bench vise
and, with a 1/4-inch wrench on the wrench
flats, break valve needle [47] free and
remove it from the assembly.
NOTE
> The valve needle is secured with LockTite.
f.
g. Unscrew control knob [42] to its “open”
position.
h. Screw retaining nut [43] into the valve
chamber with a 9/16-inch wrench.
NOTE
e. Remove spring [46].
f. Unscrew control knob [42] from retaining
nut [43].
g. With a 1/4-inch rod or other small diameter
tool, force washers [45] and o-ring [44] out
of the retaining nut.
2. Assembly:
a. Screw control knob [42] completely into
retaining nut [43].
NOTE
> Apply a light coating of petroleum jelly
With a 1/4-inch wrench on the wrench
flats, screw valve needle [47] onto the
control knob shaft. Remove the assembly
from the vise.
> Apply a light coating of petroleum jelly to
the retaining nut threads.
i.
Screw the control knob down to the
“closed” position.
To Return the Applicator to the
Work Site
1. Attach the air line fittings to applicator air fittings
[35] and [34].
2. Attach fluid hose to fluid tube fitting [66].
3. Attach and secure the high voltage cable.
to the control knob threads.
4. Turn the power, air, and fluid ON at the source
and return the applicator to service.
b. Place one (1) washer [45], o-ring [44], and
the other washer [45] onto the shaft of
control knob [42].
c. Use the flat end of the tubular spanner tool
to seat [45] and [44] in the bore of retaining
nut [43].
31
High V
oltage Cable
Voltage
Replacement
1. Disassembly:
a. Unscrew cable retaining nut [32].
b.
Pull the high voltage cable straight out of
the resistor housing.
d. Place spring [46] onto the shaft of control
knob [42].
c.
e. Secure control knob [42] in the bench vise
and put a small amount of medium
strength Lock-Tite on the shaft threads.
With a thin blade, lift one end of the cable
retaining ring out of its groove and spiral it
off of the end of the cable.
d.
Remove retainer [32] from the cable.
AA-82-01.3
2. Assembly:
a. Remove the cable retaining ring from the
new cable as in the “Disassembly
Procedure”.
b.
Place retainer [32] over the end of the new
cable.
c.
Place the cable retainer ring over the end
of the cable and with a blade, lift one end
of it into its groove and spiral it into place.
d.
Insert the high voltage cable into the
resistor housing and secure with retainer
[32].
AA-82-01.3
NOTES
32
TROUBLESHOOTING GUIDE
General Problem
Possible Causes
Corrective Action
DEFECTIVE SPRAY PATTERN:
Pattern Will Not
Shape
Pattern Heavy At
One End
1. Clogged or faulty fan valve
1. Clean, replace, or repair fan valve.
2. Air passages in applicator
or air feed lines clogged
2. Blow out air passages and air feed lines.
3. Worn, faulty, or clogged air
nozzle
3. Clean or replace air nozzle.
1. Clogged or faulty air nozzle
1. Clean or replace air nozzle.
2. Clogged or faulty fluid
nozzle
2. Clean or replace fluid nozzle.
DEFICIENT DELIVERY:
Air
1. Air passages in applicator
or air feed lines clogged
1. Blow out air passages and air feed lines.
2. Deficient factory air
2. Increase air.
1. Clogged or faulty fluid
nozzle
1. Flush or replace fluid nozzle.
2. Clogged fluid passages in
applicator or fluid feed lines
2. Flush fluid passages and fluid feed lines.
3. Insufficient fluid valve
needle travel
3. Adjust fluid valve needle.
Air
1. Defective valve or valve
spring
1. Replace valve or valve spring.
Fluid: Any at
Rear of Needle
Valve Shaft
1. Packing and/or seals faulty
1. Replace packing and/or seals.
Fluid: Slight at
Nozzle When
Trigger is
Released
1. Fluid nozzle not secure
1. Tighten fluid nozzle.
2. Air valve closing before
needle valve
2. Adjust needle valve travel.
Fluid
LEAKAGE:
33
AA-82-01.3
TROUBLESHOOTING GUIDE (Cont.)
General Problem
Possible Causes
Corrective Action
1. Worn or damaged needle
valve seat
1. Replace fluid nozzle.
2. Worn or damaged needle
valve
2. Replace needle valve.
3. Fluid nozzle not secure
3. Tighten fluid nozzle.
4. Fluid valve needle does not
close when trigger is released
4. Adjust fluid valve needle travel.
1. Improper grounding
1. Trace and correct.
2. Improper spray technique
2. Trace and correct. *
3. Improper booth exhaust
1. Dirty of faulty connections
1. Clean and check for proper contact at the conductive plugs and power supply.
2. Missing or faulty conductive
plugs at either end of the
resistor housing
2. Replace plugs.
3. Improper or no ground
4. Faulty resistor
4. Replace resistor.
5. Faulty high voltage cable
5. Replace high voltage cable.
6. Faulty power supply
6. See the Power Supply Service Manual.
7. Is the power turned ON?
7. Turn power ON.
LEAKAGE (C
ont.)
(Cont.)
ont.)::
Fluid: Constant
at Nozzle
ELECTRICAL:
Wrap-back
Improper or No
High Voltage Flow
* See REA Applicator Spray Techniques.
AA-82-01.3
34
35
SHORT
CIRCUIT
CURRENT
(SCI)
TEST
LOW
Under 130
microampere
NORMAL
130-150
microampere
HIGH
in excess of
150 microampere
SCI TEST
USING
TEST
RESISTOR
CURRENT
DEMAND
TEST
NORMAL
130-150 microampere
LOW
Under 130
microampere
HIGH
In excess of
100 microampere in
applicator
0-50 microampere
(no paint in applicator)
0-100 microampere
(paint in applicator)
NORMAL READING
0-50 microampere (no paint in applicator)
0-100 microampere (paint in applicator)
NORMAL READING
CURRENT
DEMAND
TEST
HIGH
in excess of
150 microampere
APPLICA
T OR IS
APPLICAT
DEFECTIVE:
BAD RESISTOR
POWER SUPPL
Y
SUPPLY
IS DEFECTIVE
FLUSH SYSTEM
ELECTRICAL
SYSTEM:
APPLICA
T OR &
APPLICAT
POWER SUPPL
Y
SUPPLY
IS “OK”
APPLICA
T OR OR
APPLICAT
POWER SUPPL
Y
SUPPLY
RESISTOR
DEFECTIVE
SHORT IN
APPLICA
TOR
AT
BEFORE
TOR
APPLICA
AT
RESISTOR: HV
CABLE SHORTED,
ETC.
HIGH
In excess of
50 microampere
(no paint in
applicator)
NORMAL
0-50 microampere
NORMAL
130-150
microampere
(no paint in
applicator)
APPLICA
TOR
AT
OR HV
CABLE
DEFECTIVE
RESIST
ANCE
RESISTANCE
OF P
AINT
PAINT
FORMULA
TION
FORMULATION
TOO LOW:
PAINT T
OO
TOO
CONDUCTIVE
APPLICA
TOR
AT
IS
DEFECTIVE
BAD
RESISTOR
POWER
Y IS
SUPPLY
SUPPL
DEFECTIVE
See the Power Supply Manual
for power supply test procedures.
REPEA
T
AT
CURRENT
DEMAND
TEST
SCI TEST
USING
TEST
RESISTOR
HIGH
In excess of
150 microampere
EV
ALUA
TING RESUL
TS OF SCI AND CURRENT DEMAND TESTS
EVALUA
ALUATING
RESULTS
AA-82-01.3
NOTES
AA-82-01.3
36
REA III 100kV Automatic Applicator - Parts Identification
PAR
TS IDENTIFICA
TION
ARTS
IDENTIFICATION
Figure 3a:
37
70393 REA III 100kV Automatic Applicator Exploded View
AA-82-01.3
Figure 3b:
AA-82-01.3
70393 REA III 100kV Automatic Applicator Exploded View
38
AUTOMA
OMATIC
APPLICAT
70393 REA III AUT
OMA
TIC APPLICA
T OR/
SOLVENTBORNE
PAR
ARTS
SOL
VENTBORNE SYSTEMS - P
AR
TS LIST (Figures 3a and 3b)
Item #
1
1A
2
3
4
5
6
7
8
8A
8B
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
39
Description
REA III Delta Automatic (Air Spray) Complete Assembly
(Solventborne Systems Only):
REA III Delta Automatic (HVLP) Complete Assembly
(Solventborne Systems Only):
Retaining Ring:
Swirl
HVLP, Air Spray, and Round
Air Cap:
Flat Pattern, HVLP
Flat Pattern, Air Spray
Round Pattern, Swirl
Round Pattern, Round
Fluid Nozzle:
Flat Pattern, HVLP
Electrode Assembly
---Seal Assembly, Cartridge, Non-Adjustable, REA
---Shaft Assembly, 2-Piece Needle, REA
Barrel, REA III
Reducer, Pressure, Air Spray, Black
Reducer, Pressure, HVLP, White
Ferrule
Connector, Fluid Tube
Nut, Retainer, Barrel (2 Required)
Ring, Retaining, Barrel (2 Required)
Gasket, Barrel (2 Required)
Extension, Barrel
Tube, Packing Adjustment
O-Ring, Solvent Resistant
Retainer, Needle Seal, Rear
Seal, Lip, Spring Loaded
Spacer, Seal
---Nut, Packing
Nut, Locking, Trigger Adjustment
Rod Extension, Valve, Fluid
Nut, Retaining, Valve Seal
O-Ring, Solvent Proof
Piston & Valve Body ("CC" Designation):
For -10 Bleed Applicators with Manual Fan Air Control
For -15 Bleed Applicators with Remote Fan Air Control
For -20 Non-Bleed Applicators with Manual Fan Air Control
For -25 Non-Bleed Applicators with Remote Fan Air Control
Support, Mounting
Screw, Set, Square Head (2 Required)
Screw, Cap, Socket Head (4 Required)
Screw, Cap, Socket Head
Support, Tube, Resistor Housing
Nut, Retaining, Cable
Part #
70393S-BBCC1
70393L-BBCC1
4903-00
73569-00
75601-00
4904-65R
70899-00
LREA0002-00
75600-01
4907-45
70898-00
LREA0003-00
70430-00
---78626-00
---78627-06
75037-00
74963-02
74963-03
18844-00
18843-00
LSMM0002
18835-00
18872-00
70431-00
18842-03
7554-08
78629-00
10051-05
78630-00
---78631-00
78632-00
78786-01
20053-00
13076-10
20947-02
20947-02
20947-01
20947-01
20062-00
8666-20C
8212-20C
8212-16C
20063-00
70439-00
AA-82-01.3
AUTOMA
OMATIC
APPLICAT
OR/SOLVENTBORNE
70393 REA III AUT
OMA
TIC APPLICA
T OR/SOL
VENTBORNE
PAR
ARTS
SYSTEMS - P
AR
TS LIST (Cont.) (Figures 3a and 3b)
Item #
33
34
35
36
37
38
39
40
41
42
43
43A
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
AA-82-01.3
Description
Part #
Bracket, Fluid Hose
Washer, Lock (2 Required)
Fitting, Elbow, 1/4” NPT x 3/8” Tube Atomization Air
Fitting, Elbow, 1/8” NPT x 1/4” Tube Trigger Air
Plug, Conductive Foam
Housing, Resistor
Valve Assembly, Fan Control: (Contains Items 42 thru 47)
Air Spray
HVLP
Knob, Control
Nut, Retaining, Fan Valve
Washer (2 Required)
Spring, Compression
Needle, Air Spray
Needle, HVLP
Bushing, Air Valve
Shaft, Piston & Valve
Washer, Piston
U-Cup, Packing, Teflon
Piston
Nut, Lock, Hexagon, Piston
Nut, Lock, Hexagon, Air Valve
Nut, Adjustment, Air Valve
Spring, Compression, Piston
Spring, Compression, Fluid Valve
Housing, Piston
Nut, Knurled Jam
Screw, Adjustment
Knob, Knurled
Set Screw
Fitting, Fluid Tube
Nut, Hexagon Jam
Nut and Ferrule
Tube, Fluid
Cable Assembly, High Voltage
Coiled Fluid Tube:
.093" ID
.250" ID
.125" ID
Remote Fan Air Valve: (Contains Items 72 thru 74) (Not Shown)
Fitting, Elbow, 3/8” NPT X 3/8” Tube
Body, Fitting
20938-00
8212-16F
7734-04
SSP-6440
SSP-6427
14061-05
70436-00
7554-11
7554-10
14061-08
18851-00
75133-00
77018-00
77019-00
72209-05
13076-08
18833-00
18829-00
18852-00
75132-00
13076-13
7554-33
20054-00
7554-28
20055-00
20057-00
7723-06
20056-00
7733-44
7733-07
20942-00
9334-00
17615-00
20943-00
20945-00
20944-00
20946-00
9697-08C
20993-00
10553-05
3587-02
20939-21
LREA4003-XX
75228-21
75228-22
75228-23
41-FTP-1007
74656-00
72375-02
40
REA III 100 kV Automatic Applicator - Parts Identification
AUTOMA
OMATIC
APPLICAT
OR/WA
70393 REA III AUT
OMA
TIC APPLICA
T OR/W
ATERBORNE
PAR
ARTS
SYSTEMS - P
AR
TS LIST (Figures 3a and 3b)
Item #
1
1A
2
3
4
5
6
7
8
8A
8B
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
41
Description
REA III Delta Automatic (Air Spray) Complete Assembly
(Waterborne Systems Only):
REA III Delta Automatic (HVLP) Complete Assembly
(Waterborne Systems Only):
Retaining Ring:
Swirl
HVLP, Air Spray, and Round
Air Cap:
Flat Pattern, HVLP
Fluid Nozzle:
Flat Pattern, HVLP
Electrode Assembly
---Seal Assembly, Cartridge, Non-Adjustable, REA
---Shaft Assembly, 2-Piece Needle, REA
Barrel, REA-III
Reducer, Pressure, Air Spray, Black
Reducer, Pressure, HVLP, White
------Nut, Retainer, Barrel (2 Required)
Ring, Retaining, Barrel (2 Required)
Gasket, Barrel (2 Required)
Extension, Barrel
Tube, Packing Adjustment
Retainer, Needle Seal, Rear
Seal, Lip, Spring Loaded
Spacer, Seal
---Nut, Packing
Nut, Locking, Trigger Adjustment
Rod Extension, Valve, Fluid
Nut, Retaining, Valve Seal
Piston & Valve Body ("CC" Designation):
For -10 Bleed Applicators with Manual Fan Air Control
For -15 Bleed Applicators with Remote Fan Air Control
For -20 Non-Bleed Applicators with Manual Fan Air Control
For -25 Non-Bleed Applicators with Remote Fan Air Control
Support, Mounting
Screw, Set, Square Head (2 Required)
Screw, Cap, Socket Head
Support, Tube, Resistor Housing
Nut, Retaining, Cable
Part #
70393S-BBCC2
70393L-BBCC2
4903-00
73569-00
75601-00
4904-65R
70899-00
LREA0002-00
75600-01
4907-45
70898-00
LREA0003-00
70430-00
---78626-00
---78627-06
75037-00
74963-02
74963-03
------LSMM0002
18835-00
18872-00
70431-00
18842-03
7554-08
78629-00
10051-05
78630-00
---78631-00
78632-00
78786-01
20053-00
13076-10
20947-02
20947-02
20947-01
20947-01
20062-00
8666-20C
8212-20C
8212-16C
20063-00
70439-00
AA-82-01.3
AUTOMA
OMATIC
APPLICAT
OR/WA
70393 REA III AUT
OMA
TIC APPLICA
T OR/W
ATERBORNE
PAR
ARTS
SYSTEMS - P
AR
Item #
33
34
35
36
37
38
39
40
41
42
43
43A
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
Description
Part #
Bracket, Fluid Hose
Washer, Lock (2 Required)
Fitting, Elbow, 1/4” NPT x 3/8” Tube Atomization Air
Fitting, Elbow, 1/8” NPT x 1/4” Tube Trigger Air
Housing, Resistor
Valve Assembly, Fan Control: (Contains Items 42 thru 47)
Air Spray
HVLP
Knob, Control
Nut, Retaining, Fan Valve
Washer (2 Required)
Spring, Compression
Needle, Air Spray
Needle, HVLP
Bushing, Air Valve
Shaft, Piston & Valve
Washer, Piston
U-Cup, Packing, Teflon
Piston
Nut, Lock, Hexagon, Piston
Nut, Lock, Hexagon, Air Valve
Nut, Adjustment, Air Valve
Spring, Compression, Piston
Spring, Compression, Fluid Valve
Housing, Piston
Nut, Knurled Jam
Screw, Adjustment
Knob, Knurled
Set Screw
------------Cable Assembly, High Voltage
---Remote Fan Air Valve: (Contains Items 72 thru 74) (Not Shown)
Fitting, Elbow, 3/8” NPT x 3/8” Tube
Body, Fitting
Waterborne Fluid Hose Assy: (Contains Items 85 thru 93) (Not Shown)
3/16" ID PE
1/4" ID PE
3/16" ID Teflon
1/4" ID Teflon
20938-00
8212-16F
7734-04
SSP-6440
SSP-6427
14061-05
70436-00
7554-11
7554-10
14061-08
18851-00
75133-00
77018-00
77019-00
72209-05
13076-08
18833-00
18829-00
18852-00
75132-00
13076-13
7554-33
20054-00
7554-28
20055-00
20057-00
7723-06
20056-00
7733-44
7733-07
20942-00
9334-00
17615-00
20943-00
20945-00
20944-00
20946-00
9697-08C
------------LREA4003-XX
---41-FTP-1007
74656-00
72375-02
72306-XX
74180-XX
77036-XX
77037-XX
(Continued on Next Page)
AA-82-01.3
42
AUTOMA
OMATIC
APPLICAT
OR/WA
70393 REA III AUT
OMA
TIC APPLICA
TOR/W
ATERBORNE SYSTEMS
PAR
ARTS
- P
AR
Item #
85
85A
86
87
88
89
90
91
92
93
Description
Part #
Ferrule, Nut, Waterborne
Spacer, Fluid
Connector, Fluid Tube
Nut, Fluid Line
Ferrule, Conductive
Nut, Fluid Line
Fitting, Fluid Line
Waterborne Fluid Hose:
3/16" ID PE
1/4" ID PE
3/16" ID Teflon
1/4" ID Teflon
Nut and Ferrule
Fitting, Swivel
72308-00
76993-00
72309-00
3587-02
72315-00
10553-05
72310-00
72307-XX
74179-XX
77038-XX
77039-XX
6241-06
7787-03
PISTON HOUSING CHART
70393-XXX1 = Applciator Assembly W/20947-01 Non-Bleed Body Assembly
70393-XXX2 = Applicator Assembly W/20947-02 Bleed Body Assembly
43
AA-82-01.3
NOTES
AA-82-01.3
44
REA III 100kV Automatic Applicator - Warranty Policies
WARRANTY POLICIES
LIMITED W
ARRANTY
WARRANTY
ITW Ransburg will replace or repair without charge
any part and/or equipment that falls within the
specified time (see below) because of faulty
workmanship or material, provided that the equipment has been used and maintained in accordance with ITW Ransburg's written safety and
operating instructions, and has been used under
normal operating conditions. Normal wear items
are excluded.
THE USE OF OTHER THAN ITW RANSBURG
APPROVED PARTS, VOID ALL WARRANTIES.
SPARE PARTS: One hundred and eighty (180)
days from date of purchase, except for rebuilt
parts (any part number ending in "R") for which
the warranty period is ninety (90) days.
EQUIPMENT: When purchased as a complete
unit, (i.e., guns, power supplies, control units,
etc.), is one (1) year from date of purchase.
WRAPPING THE APPLICATOR IN PLASTIC, ASSOCIATED VALVES AND TUBING, AND SUPPORTING HARDWARE IN
PLASTIC, SHRINK-WRAP, OR ANY
OTHER NON-APPROVED COVERING,
WILL VOIDE THIS WARRANTY.
45
ITW RANSBURG'S ONLY OBLIGATION
UNDER THIS WARRANTY IS TO REPLACE
PARTS THAT HAVE FAILED BECAUSE
OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
ITW RANSBURG ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FOR
CONSEQUENTIAL DAMAGES FOR LOSS
OF GOODWILL OR PRODUCTION OR
INCOME, WHICH RESULT FROM USE OR
MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS.
EXCLUSIONS:
If, in ITW Ransburg's opinion the warranty item in
question, or other items damaged by this part was
improperly installed, operated or maintained, ITW
Ransburg will assume no responsibility for repair
or replacement of the item or items. The purchaser, therefore will assume all responsibility for
any cost of repair or replacement and service
related costs if applicable.
AA-82-01.3
MANUAL CHANGE SUMMAR
Y
SUMMARY
This manual was published to replace Service
Manual AA-82-01.2 REA III 100kV Automatic
Applicator, to make the following changes:
1. Revised “
Label“ on the “Front Cover”.
2. Revised “Atex Labels 19688, 72562, 76454,
76854, 76896, 77059, 78886, 78894-04, and
LEPS0016” in the “Atex” section.
AA-82-01.3
Service Manual Price: €25.00
25.00 (Euro)
$30.00 (U.S.)
Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260/665-8800
Fax: 260/665-8516
Technical/Service Assistance
Automotive Assembly and Tier I
Industrial Systems
Ransburg Guns
www.itwransburg.com
Telephone: 800/ 626-3565 Fax: 419/ 470-2040
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
Technical Support Representative will direct you to the appropriate telephone
number for ordering Spare Parts.
© 2008 Illinois Tool Works Inc. All rights reserved.
Models and specifications subject to change without notice.
Form No. AA-82-01.3
Litho in U.S.A.
05/08

AA-82-01.3 REA III 100 kV Auto Applicator.pmd

Transcription

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