robot waterbase applicator model: 78863-90
Contents
1. SPACER MANIFOLD PLATE QUIC DISCONNECT P RING 78863 90 90 SINGLE HEAD MOUNTED ON ROBOT ELD SHIELDED 4 1D HOSE SHIELDED DUMP OUT HOSE DUMP OUT is s SHEILDED 6 ID Diosc SHEILDED FLUID IN HOSE FLUID IN ISOLATED FLUID ISOLATED SUPPLY FLUID SUPPLY DUMP DUMP RESERVOIR RESERVOIR Figure 2 Typical Robotic Applicator Mounting OBOT MANIFOLD QUICK DISCONNECT RING 78863 60 60 SINGLE HEAD MOUNTED ON ROBOT AA 03 01 1 nsburg Robot Waterbase Applicator Introduction Power Supply Tool Center Point Figure 2 shows the optional isolated fluid supply Figure 3 shows the tool center point information system in line with the RWA EFM applicators This both guns Both are based upon a 10 254mm supply is required to create a voltage block whichis target distance necesaryto keepthe voltagefrom passing throughout theentirefluid supply system when highly conductive materials are used Voltage is supplied to the fluid through contact with the resistive electrode in the gun The resistive electrode in the gun passes back tothe voltage block whereit is blocked or isolated from traveling any further through the fluid supply system The fluid tube enters an opening in the end of the robot arm The fluid tube passes through the robot ar2. O L ojl ol l lt el ol ol ol el o 4 N a SO So 4 o o e el e asiodnuay 4 afin 6 sys n 95104 NP NE st 5 N VISCOSITY CONVERSION CHART 52 AA 03 01 1 Robot Waterbase Applicator Appendix Ransburg 5 3 2 lt JE U 2 n gt 2 U gt un gt of SI sls STS SIS sls S asiodnuay x SPR SISISISI sl 2 2 2 09 99 NT AT 4 oO al lo Ss
3. s 2 of ml lt ft un un S S ST S SG lt lt 95104 AININ N AI s 5 69 oj Sj 2 Note All viscosity comparisons as accurate as possible with existing information Comparisons are made with a material having a specific gravity of 1 0 53 AA 03 01 1 Robot Waterbase Applicator Appendix Ra nsburg VOLUMETRIC CONTENT OF HOSE OR TUBE English Units in cc ft Section in 1 108 120 120 1 15 1807 180 258 300 Soft 600 003 gal 005 009 015 gal 03 gal A fl oz 8 fl oz 1 2 fl oz 2 0 fl oz 4 0 fl oz on 02 181 02 271 02 4511 OZ 901 Oz ee 168 02 328 02 4811 OZ 801 02 1601 02 ENENENE SE eones nata zoro 238 02 4611 OZ 6 9 fl 02 1 54 02 2308 02 028 gal 056 gal 084 gal 140 gal 250 gal 6 5 1 13 0 fl oz 19 5 fl 325 fl oz 65 0 fl oz VOLUMETRIC CONTENT OF HOSE OR TUBE Metric Units Cross mm cc m Section mm ee s s ae E HE 54 AA 03 01 1 Service Manual Price 530 00 Automotive Systems Automotive Finishing Group 4
4. 3 om AA 03 01 1 41 Robot Waterbase Applicator Parts Identification Ransburg D D VAS VAIO Nou GNO ST e 8 o 5 Figure 24 Rear Plate 42 AA 03 01 1 nsburg Robot Waterbase Applicator Parts Identification REAR PLATE PARTS LIST Figure 23 1 2 3 4 5 7 10 11 34 O Ring Solvent Proof 926 ID X 07 CS 021 AA 03 01 1 O Ring Solvent Proof O Ring Solvent Proof O Ring Solvent Proof Plate Rear RWA EFM O Ring Encapsulated Set Screw 3 8 Lg X 10 24 Wiring Harness Fitting 3 16 OD Push To Lock SHCS 1 4 20 X 1 0 Long O Ring 43 Robot Waterbase Applicator Parts Identification Figure 25 Air Voltage Material and Tie Rod Components 44 Ransburg AA 03 01 1 nsburg Robot Waterbase Applicator Parts Identification AIR VOLTAGE MATERIAL AND TIE ROD COMPONENTS PARTS LIST Figure 25 LT 20 7751601 Fitting Barbed Blue Color Fitting 1 4 NPT X 3 8 ODT Nylon 7 15 006732 Threaded Insert 2 ___ 7 76530 00 Tie Rod Long T N N 1 n D 14 iS Ong 43910 2 3e emr i02 __________ 9 Tubing 5 32 OD X106 ID Blue Tubing 5 32 OD X 106 ID Red Tubing 5 32 OD X 106 ID Green Tubing 5 32 OD X 106 ID Natural K s
5. 1 1 1 ama STROTI 1 kasa mm Z xc BE 1 E II NED i DIS E XX 9649L BI MOTA Nuo ma duvap save XX 9 me vie 1 akl 20 udo EVE LL No e apen 1 kuk Ro 9 SERVE Par NOAH 4 224 EY kj sa 4 sun OA asa yo 2 gt IRA 2 Hr 2 H UN D par WAS lt g kj 8 or FH a ek 19A Fe mv mr zH am HA a IN Ar av 455 3182 AT 96 9 pa ar AA 03 01 1 Figure 4 Power Supply Manifold and Gun Wiring 12 nsburg Robot Waterbase Applicator Installation ROBOT MANIFOLD ASSEMBLY The tubing hose and low voltage cable come gt Failuretostripbackthe shielded hose will bundled from the factory Pull the bundle through increase current draw and lower tip voltage the robot spacer plate and robot wrist carefully to reducing efficiency of the applicator prevent any cuts on the cable or hoses Connect each signal line as required per signal legend AP Air Purge Blue color E amp APPLICATOR DP Dump Pilot Red color FLUID INLET TP Trigger Pilot Green color A Atomizer
6. METHYL ACETATE Esters 79 20 9 LOW BENZENE Aromatic Hydrocarbons 71 43 2 HIGH ETHYL ACETATE Esters 141 78 6 MEDIUM 2 BUTANONE MEK Ketones 78 93 3 MEDIUM ISO PROPYL ACETATE Esters 108 21 4 LOW ISOPROPYL ALCOHOL IPA Alcohols 67 63 0 LOW 2 PENTANONE MPK Ketones 107 87 9 MEDIUM METHANOL Methyl Alcohol Alcohols 67 56 1 LOW PROPYL ACETATE n Propyl Acetate Esters 109 60 4 LOW TOLUOL Toluene Aromatic Hydrocarbons 108 88 3 HIGH METHYL ISOBUTYL KETONE MIBK Ketones 108 10 1 MEDIUM ISOBUTYL ACETATE Esters 110 19 0 LOW ETHANOL Ethyl Alcohol Alcohols 64 17 5 LOW BUTYL ACETATE Esters 123 86 4 LOW ETHYLBENZENE Aromatic Hydrocarbons 100 41 4 HIGH 1 PROPANOL n Propyl Alcohol Alcohols 71 23 8 LOW 2 BUTANOL sec Butyl Alcohol Alcohols 78 92 2 LOW XYLOL Xylene Aromatic Hydrocarbons 1330 02 07 HIGH AMYL ACETATE Esters 628 63 7 MEDIUM 2 METHYLPROPANOL iso Butyl Alcohol Alcohols 78 83 1 LOW METHYL AMYL ACETATE Esters 108 84 9 LOW 5 METHYL 2 HEXANONE MIAK Ketones 110 12 3 MEDIUM 1 BUTANOL n Butyl Alcohol Alcohols 71 36 3 LOW 2 ETHOXYETHANOL Glycol Ethers 110 80 5 LOW 2 HEPTANONE MAK Ketones 11
7. 75933 00 Cascade HP 404 PT 45 AA 03 01 1 Robot Waterbase Applicator Parts Identification Ra nsburg Figure 26 RWA EFM Valve Manifold Assemblies 46 AA 03 01 1 nsburg Robot Waterbase Applicator Parts Identification RWA EFM VALVE MANIFOLD ASSEMBLIES PARTS LIST Figure 26 so Assembly Valve Body RWA EFM 90 Assembly Valve Body RWA EFM 60 78945 00 Plug Check Valve 78947 00 79001 06 O Ring Solvent Proof LSOR0005 06 O Ring Encapsulated Assembly Check Valve RWA EFM 5 47 03 01 1 Ransburg Robot Waterbase Applicator Parts Identification Figure 27 Robot Manifold Assembly 48 AA 03 01 1 nsburg Robot Waterbase Applicator Parts Identification ROBOT MANIFOLD ASSEMBLY PARTS LIST Figure 27 1 Fitting Air Modified 2 Hose Shielded 3 8 OD X 1 4 ID 3 6 7959 24C 1 Screw 1 4 20 x 3 4 Long Shcs 8 moso F igWatebxeWlt o EMFD 8 Conductive Feru 25igp O Clamp Retaining 12 Tubing 3 16 OD Red Color DP Tubing 3 16 OD Green Color T Tubing 3 16 OD Blue Color AP 13 Tubing 3 8 OD Natural Color ATOM Tubing 3 8 OD Black Color FAN ChekVaveCanndge Jf 3 Barb Fitting 3 16 ID MFD29 Barb Fitting 1 4 7 7 789906 O Ring Solvent Proof f 4 SSF 2052 Set Screw 3 8 Long x 10 24 1 A 03 01 1 49 Robot Wat
8. See Figure 7 A WARNING gt sure voltage is OFF all lines de pressur ized clean and dry Ransburg 2 Take applicator to a clean area outside the spray area preferably to a designated maintenance area 3 Remove the head of the gun See Figure 8 z 2 tocatinghin_ 3 Retaining Ring ESE Figure 10 Removal 4 Referring to Figure 10 remove 3 locating pins 2 Remove flange 1 from end of gun Remove the retaining ring 4 and shroud 3 AA 03 01 1 nsburg Robot Waterbase Applicator Maintenance Valve Manifold 10 Assembly Gun Manifold Plate RWAEFM 1 174 20X10Long ST 3 O Ring Solvent Proof 2 ORigSoentProo A 7 Cascade Harness Connector 1 O Ring Solvent Proof 2 Tube Formed 1 Tube Formed 1 10 11 Tubing 5 32 0DX 1 12 Tubing 5 320DX 106 D RediD 1 13 Tubing 5 32 OD X 106 ID Green T 1 1 14 Tubing 5 32 OD X 106 ID Natural TB Figure 11 Rear Plate Removal 23 AA 03 01 1 Robot Waterbase Applicator Maintenance 24 5 Referring to Figure 11 remove the 3 socket head cap screws 3 and o rings 4 from the rear of the gun 6 Remove the 3 6 OD tubes 11 12 13 and 14 from the barb fittings on the manifold or from the push to lock fittings on the plate assembly 2 7 Remo
9. Air Natural color Fan Air Black color 27 EN TO VOTAGE BLOCK OUTPUT TEFLON CORE Connect Paint In and Dump Out line shielded hose to their proper respective connections Im 1200 5048 VOLTAGE BLOCK STRIP BACK properconnection ofthese lines could cause damage DEVICE OUTER wacker AND v CONDUCTIVE SHEATH to the applicator NOTE gt Paint In line is 3 16 I D Dump Out line is 1 4 1 D Once all connections have been verified install the robot spacer plate to the robot wrist using 6 screws not provided Insure the shielded hose for the paint in line has NOTE stripped back the outer jacket and conductive sheath at least 12 from the exit of the voltage block devise gt Try to keep the shielded 3 16 I D Paint See Figure 5 In line and the 1 4 I D Dump Out line as long as possible If these hoses should pin hole this will allow a cut off of the pinhole A CAUTION section Strip back and re assemble rather than replacing the entire hose gt Do Not nick or cut the inner paint line Figure 5 Shielded Hose Stripbacks Diagram hose This will cause premature failure of the hose 13 AA 03 01 1 Robot Waterbase Applicator Installation Robot Spacer Plate The robot spacer plate is included with the robot manifold assembly to increase life of the tubing bundle The extra spacing it provides increases the bend radius of the tubes and decreases the hose or cab
10. b cu Rp eb pu 18 Internal Cl eaning amp Uil 18 rS p PL 18 POLAR AND NON POLAR 19 APPLICATOR DISASSEMBLY casi 19 HEAD REMOVAL REPA IR I I 1 u Su aS uqa as 19 20 HEAD ASSEMBIY DIAGRAM 21 HEAD REBUILD pane 22 VALVE BODY REMOVAL REPAIR spi ierit tici n od fac n on 22 FLANGE REMOVAL csi ERA RR 22 REAR PLATE REMOVAL DIAGRAM 23 24 HARNESS REMOVAL oksene a a 24 Maintenance Cont Next Page AA 03 01 1 Robot Waterbase Applicator Contents Ra nsburg MAINTENANCE Cont 18 36 CASCADE TIE ROD REMOVAL 26 ISOLATION TUBE REM UQCVAL VISA ka aves i eee even e eren eren 27 28 CHECK VALVE REMOVAL u eive eue tre eee AKAP S S veo o d 29 DUMP VALVE REMOVAL siete oni rore etuer eee eue enne veneta e 30 LOW VOLTAGE CABLE REMOVAL eerta tenti v eer e n vi ee 31 32 FLUID TUBE REPAIR REPLACE T et Ee iet obe rtu rer Q 32 FLUID TUBE REASSEMBLY itr rere p E eta eU EA E RNC 32 FLUID HOSE CUTBACK DIAGRAM vest tese I asken ia E Deae 32 ASSEMBLED HOSE LENGTH DIAGRAM J I 33 BARBED FITTING DIAGRAM U otn suni ren eaae asas sa 33 aoegaeni pid 33 TROUBLESHOOTING GUIDE icto 34 36 PARTS IDENTIFICATION
11. cause a spark hazard spark can ignite many coating materials and cause a fire or explosion Improper use or maintenance can lead to hazardous conditions par ticularly from unexpected robot manipulator movement Skin puncturing by sharp elec trode Ransburg SAFEGUARDS Tells how to avoid the hazard Parts being sprayed must be supported on conveyors or hangers and be grounded The resistance between the part and ground must not exceed I megohm Allelectrically conductive objects in the spray area with the exception of those objects required by the process to be at high voltage must be grounded Any person working in the spray area must be ground ed Unless specifically approved for use in hazardous loca tions the power supply and other electrical control equipment must not be used in Class 1 Division 1 or 2 locations Applicator adjustments or maintenance should be done after the robot is taken out of service Do not adjust or repair the applicator if the robot is operating or stand ing ready to start Refertorobot operatinginstructionsforthe procedures to take the robot out of service Take precautions to see that flesh is not punctured by sharp electrode AA 03 01 1 nsburg Robot Waterbase Applicator Safety Notes AA 03 01 1 Robot Waterbase Applicator Introduction INTRODUCTION DESCRIPTION The Ransburg Robot Waterbase Applicator RWA EFM Series Spray Applicators for highly
12. conductive coat ings are air atomizing fan pattern 100 kV automatic electrostatic spray guns The waterbase or solvent base paint is charged by the resistive electrode in the spray head of the gun These guns have been developed for use on today s robots These guns were designed to be used with a voltage block sys tem such as the AquaBlock or isolated paint tanks A separate manifold assembly includes single low voltage cable and the hosing required to operate the spray gun The guns are manufactured in either 60 or 90 head configurations Ransburg RWA EFM ELECTROSTATIC SPRAY GUNS FOR HIGHLY CONDUCTIVE COATINGS There are two models of the RWA EFM Spray Guns for highly conductive coatings See Figure 1 All internal gun componenets are basically the same the only apparent differences is the head angle either 60 or 90 The spray gun has three major parts the spray head assembly the valve manifold section and the valve housing section See Figure 1 The gun body is fab ricated with the fluid air and dump passages There is aremovable check valve to allow air to blow down the dump line while paint is spraying This prevents grounding out of the applicator when spraying highly conductive materials EFM SPRAY GUN MODELS Model 78863 60 60 Single Spray Head Assembly Description 78863 90 90 Single Spray Head Assembly AA 03 01 1 Ransburg 78863 90 90 SINGLE HEAD Robot Waterbase Applicato
13. manifold assembly manifold assembly Contaminated dump line Clean or replace Exterior of gun contaminat 2 Clean with non polar solvent Note To check for fluid leaks it is easiest to first remove the gun from the test station and remove the shroud from the gun The aluminum flange can be reattached to the gun manifold plate by using the three stainless steel screws Then the gun can be remounted to the test station Leak detector may be used at all appropriate sources Be certain to wipe off all residual solution using a non conductive solvent such as Naphtha 35 AA 03 01 1 Robot Waterbase Applicator Maintenance Ra nsburg Electrical General Problem Possible Causes Corrective Action No Electrostics 1 Cascade not functioning Check connection between cascade and harness 79200 00 Check low voltage cable and harness timing Correct as required Isolation tubes contaminated Clean and re install as required Fluid hose has pinholled Replace as required Cascade bad Replace as required Low voltage cable connections wrong at MicroPak Low voltage cable bad Replace as required Low High Output 1 Exterior of gun contaminated Replace gun cover with conductive material Clean exterior with a non polar solvent Low Kv Low Output 1 Cascade failure Replace as required 36 AA 03 01 1 Ransburg AA 03 01 1 Robot Waterbase Applicator Maintenance 37 Robot Waterb
14. safety cir cuits disabled Beforeturningthe high voltage on make sureno objects are within the sparking distance Aluminum is widely used in other spray application equipment such as material pumps regulators trig gering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray Ifin doubt as to whether or nota coating or cleaning material is com patible contact your material supplier Any other type of solvent may be used with aluminum equipment Follow the requirements of the Material Safety Data Sheet supplied by coating material manufacturer Adequate exhaust must be provided to keep the airfree of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compat ible with the material being spray ed and its concentra tion Equipment must be as prescribed by an industrial hygienist or safety expert and be NIOSH approved Robot Waterbase Applicator Safety AREA Tells where hazards may occur Spray Area High Voltage Equipment Robot Work Area General Use and Maintenance Personnel Safety HAZARD Tells what the hazard is There is a high voltage device that can induce an electrical charge on ungrounded objects which is capa ble of igniting coating materials Inadequate grounding will
15. 0 43 0 MEDIUM CYCLOHEXANONE Ketones 108 94 1 MEDIUM AROMATIC 100 SC 100 Aromatic Hydrocarbons HIGH DIISOBUTYL KETONE DIBK Ketones 108 83 8 MEDIUM 1 PENTANOL Alcohol Alcohols 71 41 0 LOW DIACETONE ALCOHOL Ketones 123 42 2 LOW 2 BUTOXYETHANOL Butyl Cellosolve Glycol Ethers 111 76 2 LOW CYCLOHEXANOL Alcohols 108 93 0 LOW AROMATIC 150 SC 150 Aromatic Hydrocarbons HIGH AROMATIC 200 CAS Number Chemical Abstract Service Number Electrical Resistance using the Ransburg Meter Solvent Base Configuration Only Information Obtained From http solvdb ncms or The lowest temperature at which a volatile fluid w ignite Aromatic Hydrocarbons Evaporation Rate is Based Upon Butyl Acetate Having Rate of 1 0 NOTE Chart provides resistance and control information that we feel is necessary when using Ransburg equipment AA 03 01 1 HIGH 04 2003 Illinois Tool Works Inc rights reserved Ransburg Robot Waterbase Applicator Appendix NSS JesioAtun MogKes o RIR y p104 e a a g 8 s s s 3 194514 l o ui of un NINI N N m OL uled lt N
16. 38 49 78863 XX RWA EFM APPLICATOR DIAGRAM PARTS UIST T 38 39 76479 01 HEAD ASSEMBLY DIAGRAM PARTS US 40 41 REAR PLATE DIAGRAM PARTS LIST esee 42 43 AIR VOLTAGE MATERIAL AND TIE ROD 5 2 riva Sa te SR WR EH ans RE E de d w v tO 44 45 RWA EFM VALVE MANIFOLD ASSEMBLIES DIAGRAM PARTS LIST aic iioc atento reto e ves ite ete div te e e e ERR 46 47 ROBOT MANIFOLD ASSEMBLY DIAGRAM PARTS UIST 48 49 WARRANTY POLICIES 50 LIMITED WARRANTY L a ua ns nashun nn 50 APPENDIX 51 54 PAINT AND SOLVENT SPECIFICATIQNS eire ette ea ri 5 VISCOSITY CONVERSION GHAR Ts terraa cti n v va eei era eene 52 53 VOLUMETRIC CONTENT OF HOSE OR TUBE toco ttov 54 AA 03 01 1 Ransburg SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Rans burg electrostatic coating system read and under stand all ofthe technical and safety literature for your Ransburg products This manual contains information thatisimportant foryouto 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 AWARNING states information to alert you to a situ ation that might cause s
17. 8152 West Road Wixom Michigan 48393 Telephone 248 668 8900 Fax 248 668 2160 E Mail marketing autofinish com Order Desk Telephone 800 726 8097 Fax 800 359 2341 Technical Service Assistance Telephone 800 626 3565 Fax 877 852 7796 Industrial Systems Ransburg Electrostatic Systems 320 Phillips Avenue Toledo Ohio 43612 Telephone 419 470 2000 Fax 419 470 2270 Website www ransburg com E Mail marketing ransburg com Order Desk Telephone 800 726 8097 Fax 800 359 2341 Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 ISO 9001 Form No AA 03 01 1 Ransburg Industrial Systems is an ISO 9001 compliant company registered with Factory Mutual Litho in U S A Models and specifications subject to change without notice 01 13 2013 Ransburg Electrostatic Systems USA
18. SERVICE MANUAL Ransburg Replaces 03 01 2013 ROBOT WATERBASE APPLICATOR MODEL 78863 90 78863 60 IMPORTANT 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 30 00 Ransburg AA 03 01 1 nsburg Robot Waterbase Applicator Contents CONTENTS PAGE SAFETY 1 4 SAFETY PRECAUTIONS pila 1 HAZARDS SAFEGUARDS lea 2 4 INTRODUCTION 6 10 DESCRIPTION vvs 6 RWA EFM ELECTROSTATIC SPRAY GUNS FOR HIGHLY CONDUCTIVE COATINGS cara 6 EFM SERIES SPRAY GUNS 4 78941 XXXXX ROBOT MANIFOLD ASSEMBLY aasan eid PRONUM DATEN y FEATURES C 8 78941 XXXXX Robot Manifold Assembly 8 Typical Robotic Applicator MOUNN 8 idees e T 9 Tool Center Point u haqa ai 9 SPECIFICATION ice 10 INSTALLATION MS POWER SUPPLY aene eian apt end dcum s 11 POWER SUPPLY MANIFOLD AND GUN WIRING a a a 12 ROBOT MANIFOLD ASSEMBLY asian 13 ROBOT SPACER PLATE cri 14 ROBOT SPACER PLATE M UNTING diera epit uuu u uuu u eH trt rv 14 15 OPERATION 1617 SPRACGUNCONIRO Lia 16 17 MAINTENANCE 18 36 PREVENTIVE MAINTENANCE pr bi abo D
19. URY 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 Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained 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 03 01 1 Ransburg Robot Waterbase Applicator Appendix APPENDIX PAINT AND SOLVENT SPECIFICATIONS AEROBELL I AEROBELL AEROBELL 33 RMA REA EFM REM M90 NO 2 HAND GUN TURBODISK NONA RECOMMENDED VISCOSITY USING A ZAHN NO 2 18 TO 30 SEC 18 TO 30 SEC 20 TO 60 SEC 20 TO 60 SEC 20 TO 60 SEC PAINT ELECTRICAL RESISTANCE 1 1 1 1 RECOMMENDED DELIVERY UP 1000 cc min 1500 cc min 180 cc min 1000 cc min 500 cc min GUIDE TO USABLE SOLVENT SELECTION Chemical Common Category Name Name DICHLOROMETHANE Methylene Chloride Chlorinated Solvents Elec Res HIGH Flash Point CAS Evap TCC Number Rate 75 09 2 amp P Aliphatic Hydrocarbons 8030 30 6 HIGH ACETONE Ketones 67 64 1 LOW
20. ase Applicator Parts Identification Ra nsburg PARTS IDENTIFICATION Figure 22 78863 XX RWA EFM Applicator 38 AA 03 01 1 Ransburg 78863 XX RWA EFM APPLICATOR PARTS LIST Figure 22 Robot Waterbase Applicator Parts Identification 1 79001 07 79001 06 6 7894600 97 EMF 97 8 fem 9 AA 03 01 1 Screw SHCS 5 16 18 Breakaway Flange RWA EFM Locating Pin Retaining Ring RWA EFM Solvent Proof Solvent Proof Solvent Proof Solvent Proof 39 Robot Waterbase Applicator Parts Identification Ransburg Figure 23 76479 01 Head Assembly 40 AA 03 01 1 nsburg Robot Waterbase Applicator Parts Identification 76479 01 HEAD ASSEMBLY PARTS LIST Figure 23 6 sma sSexPson 7 7500 04 O ing SoentPragf 2 8 mes sem TS Washer 11 EMF 195 Fluid Nozzle High Flow 8 Holes Std EMF 194 Nozzle Fluid Medium Flow 4 Holes EMF 43 1 Nozzle Fluid Low Flow 1 Hole 76132 00 Nozzle Fluid 055 Orifice Std Nozzle Fluid 043 Orifice 76132 03 Nozzle Fluid 070 Orifice 76497 00 Gun Barrel Assembly Resistive 22 Backup Piston ae RME 36 Spring Retun PG 79001 01 O Ring Solvent Proof 7613 00 rap L T EME 192 Air Cap Locator EE EPIO Clip Cap EP Ring Retaining 74035 16 Air Cap Test Kit K3
21. ces AA 03 01 1 HAZARD Tells what the hazard is High voltage equipment is utilized Arcing in areas of flammable or combustible materials may occur Personnel are exposed to high volt age during operation and maintenance Protection against inadvertent arc ingthatmay cause afire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explo sion Halogenated hydrocarbon solvents for example methylene chloride and 1 1 1 Trichloroethane are not chemically compatible with the aluminum that might be used in many system components The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion Certain material may be harmful if inhaled or if there is contact with the skin Robot Waterbase Applicator Safety SAFEGUARDS Tells how to avoid the hazard Thepower supply optional remote control cabinet and all other electrical equipment must be located outside Class I or Il Division 1 and 2 hazardous areas Refer to NFPA No 33 1995 Edition Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but only as instructed Production should never be done with the
22. d push in straight with the other hand 17 Install o rings on barbed fittings per Figure 21 J ARB O RINGS Figure 21 Barbed Fittings AA 03 01 1 Robot Waterbase Applicator Maintenance 18 Re connect all pilot lines to appropriate fit tings Color Code Table Pattern Fan Air Black 3 8 OD Nylon Atom Air Natural 3 8 OD Nylon Trigger Air Green 3 16 OD Nylon Dump Pilot Red 3 16 OD Nylon Air Purge Blue 3 16 OD Nylon 19 Re installtubing bundle and robot plate assembly back into the robot arm Re connect all fluid air and low voltage connections 20 Before re installing atomizer to the robot plate apply a film of LSCH0009 di electic lubricant over entire length of exposed paint and dump line 33 Robot Waterbase Applicator Maintenance TROUBLESHOOTING GUIDE Ransburg General Problem Possible Causes Corrective Action Fluid Does Not Turn On Trigger pilot regulator has not been set to a minimum of 70 psig Four nylon socket head cap screws holding the spray head are loose The green air tube possibly left disconnected during re assembly Green tube leading from the source to the gun mounting plate is pinched or broken Piston seal within the gun spray head is not in place or there is an extremely tight fit between the seal and the cylinder wall NoFanor Atomization Air Press
23. drain when spraying the target This voltage drain will cause lower voltage at the gun tip lowering transfer efficiency possibly causing paint defects Air Purge AP After the dump line has been properly cleaned and blown down turn the air purge AP line on This air flow should remain on during the spray cycle Re comended air pressure for air purge AP is 45 psig This may be adjusted up or down depending upon performance Paint Viscosity This applicator is capable of atomizing paint of most any desired viscosity It is recomended to keep the material viscosity as low as possible This allows spraying at lower fan and atomization air pressures which results in less overspray and higher transfer efficiency AA 03 01 1 nsburg Robot Waterbase Applicator Operation Sometimes depending upon target carrier spac WARNING ing higher setback voltages may be required The ramp up time for the HP 404 cascade 0 100 kV is approximately 3 seconds This may be slightly lon ger with waterbase applications due to the charge capacity of the fluid system gt Most paints and solvents are toxic to cer tain degree and flammable or combustible Use them only ina well ventilated atmosphere Use protectiveequipmentasrequiredin the material safety data sheet supplied with the paint coat ing or solvent The MicroPak voltage ramp down works at a rate of 33 kV sec However in waterbase applications this may be
24. erbase Applicator Warranty Policies 50 WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipment that fails within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with Ransburg s writ ten safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG APPROVED PARTS VOIDS 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 example guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLASTIC SHRINK WRAP ETC WILL VOID THIS WARRANT Y FLUID HANDLING One 1 yearfrom date of purchase example Totalizer CCV Valves etc AIR BEARING ROTATORS Fifteen thousand 15 000 hours or three 3 years whichever occurs first War ranty period begins on the date of purchase Ransburg RANSBURG S ONLY OBLIGATION UNDERTHIS WAR RANTYISTO REPLACE PARTSTHAT HAVE FAILED BE CAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NO IMPLIED WARRANTIES NOR WAR RANTIES OF EITHERMERCHANTABILITY ORFITNESS FORAPARTICULARPURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJ
25. erious 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 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 Ransburg equipment manuals to reconcile such differences Careful study and continued use of this manual will providea 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 Ransburg representative Ransburg AA 03 01 1 Robot Waterbase Applicator Safety A WARNING gt Theuser MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified gt This manual MUST be read and thoroughly understood by ALL personnel who operate clean or maintain this equipment Special care should betaken to ensure thatthe WARNINGS and safety requirements for operating and servicing the equipment are followed T
26. he user should be aware of andadhere to ALL local building and codes and ordinances as well as 33 SAFETY STANDARD 1995 EDITION prior to installing operating and or servicing this equipment A WARNING gt The hazards shown on the following page may occur during the normal use of this equip ment Please read the hazard chart beginning on page 2 Robot Waterbase Applicator Safety Ra nsburg AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur 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 cleanto preventthe accumula cause a fire hazard tion of combustible residues Protection against inadvertent arc Smoking must never be allowed in the spray area ing that is capable of causing fire or explosion is lost if any safety inter The high voltage supplied to the atomizer must be locks are disabled during operation turned off prior to cleaning flushing or maintenance Frequent power supply shutdown indicates problem in the system When using solvents for cleaning requiring correction 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 100 F 37 890 Spray booth ven
27. id 1 EE ET C Figure 9 Head Assembly 16 O Ring Solvent Proof 1 1 1 1 1 1 2 1 13 14 15 16 21 03 01 1 Robot Waterbase Applicator Maintenance 22 4 Remove end caps 3 by turning CCW by hand Remove backup piston 14 and spring return 15 5 Remove retaining ring 22 by turning CCW Remove air cap 19 air cap locator 20 and air cap clip 21 Remove fluid nozzle 12 using appropriate wrench by turning CCW 6 Remove electrode 2 by turning CCW A drift pin may be inserted into the provided hole in needle shaft 1 7 Pull needle shaft 1 straight out of the housing Remove fluid nozzle 11 by turning CCW Remove o ring 18 packing 8 and washer seal 9 from inside house bore 10 Piston Removal Replacement 8 Remove piston nut 4 from shaft 1 Unscrew CCW from the shaft piston 5 Carefully pry the piston seal 6 off the piston Replace the seal as required 9 To install the seal push the piston seal 6 onto the piston 5 with the spring side of the seal facing towards the smaller diameter of the piston 5 Head Rebuild 10 To rebuild follow steps 1 to 8 in reverse order NOTE gt Adropofpurpleloctite may be required on the needle shaft 1 end threads where electrode is assembled Valve Body Removal Repair 1 Remove the gun from the robot by turning the retaining ring counter clockwise from the robot mount plate
28. igure 7 AA 03 01 1 Methyl Isobutyl Ketone Ethyl Acetate Methyl Ethyl Ketone Butyl Carbitol Robot Waterbase Applicator Maintenance Methanol Carbitol Diacetone Butyl Alcohol Acetone Butyl Cellosolve ROBOT ANIFOLD QUICK DISCONNECT RING TO remove PN o 0 Figure 7 Removal of Applicator 2 Take applicator to a clean area outside the spray area preferably to a designated maintenance area 3 Remove head retaining screws 4 as shown in Figure 8 using a 1 4 wrench This removes the head from the manifold NOTE gt gt sure to contain all o rings between the head and manifold Robot Waterbase Applicator Maintenance 20 Ransburg Figure 8 Head Removal NOTE gt These headretention screws are designed and manufactured specifically for this prod uct so that if an impact occurs the screws break away Use of any other screws may cause damage to more expensive compo nents in the applicator Note Refer to Figure 9 for parts AA 03 01 1 nsburg Robot Waterbase Applicator Maintenance Needle Shaft Assembly Fe Gun Barrel Assembly Resistive i 14 Electrode High Wear 1 Backup Piston Cap End 135 Spring Return ti 1 2 NEN 7 SealWasher _______ 2 7 TO 1 22 Ring Retaining 1 T 23 O Ring Solvent Proof 4 12 Nozzle Flu
29. ization Air Natural Max Fluid Pressure 250 psig F Fan Air Black 17 2 bar T Trigger Green DP Dump Pilot Red Air Flow Rates Pressures AP Purge Air Blue Recommended start point for fan and TB Trigger Bleed atomizing pressures Paint In Note Pressure taken at the cap D Dump Out Atomizer Air 27 psig 1 8 bar Fan Air 30 psig 2 1 bar Total Air Flow 17 50 SCFM 496 SLPM Air Purge 35 psig 10 AA 03 01 1 Ransburg INSTALLATION WARNING gt Ifimproperly located certain electricalequip ment will become source of ignition and may cause fire or explosion Any power supply must be located outside Class I or Class II Division 1 and 2 hazardous areas Reference 33 or National Electrical Code article 516 AA 03 01 1 Robot Waterbase Applicator Installation POWER SUPPLY Refer to the Ransburg Service Instruction for the power supply being used for complete information Reference the current MicroPak Service Manual A low voltage cable 76496 XX See Figure 4 con nects from an output connection in the MicroPak to the robot manifold plate Refer to Figure 4 for connection diagram 11 Ransburg Installation Robot Waterbase Applicator 1 1 1 1 1 1 1 1 1 1 MOUNTING PLATE e ROBOT aat SSS 3GISNI vOY dH OL 1 1 1
30. le stress at the connector There is only one way the spacer plate may be as sembled to the mounting plate The spacer plate has an alignment pin that may only engage in one hole position in the robot mount plate TABLE 2 SPACER PLATES 79107 00 ABB Robots 78983 00 Fanuc P155 145 Robots 79131 00 Fanuc P200 Robot Three spacer plates are available for this product one for ABB robots and two for Fanuc robots as shown in Table 2 Robot Spacer Plate Mounting Mount the spacer plate to the tube bundle assembly with scews 6 7959 24C Locate the spacer plate with the robot locating pin away from the robot mount plate See Figure 6 14 Ransburg AA 03 01 1 nsburg Robot Waterbase Applicator Installation ROBO EAD ALIGNMENT MA ROBOT S ACE PLATE MOUNTING PLATE ALIGNMENT PI ROBOT MOUNT Figure 6 Mounting Spacer Plate Tube Bundle Assembly 15 AA 03 01 1 Robot Waterbase Applicator Operation 16 OPERATION SPRAY GUN CONTROLS Atom A Fan Air F The RWA EFM gun fluid On Off is controlled by trigger line where a signal comes from either the robot or a PLC This signal must be minimum of 70 psig The atomization and fan are always on and should be controlled by the solenoid valves either at the rob
31. longer Fluid Flow Rate Keep the fluid flow rate as low as possible consis tent with the conveyer or robot arm speed For an isolated paint system fluid flow is adjusted through the robot PLC by varying the pilot pressure to a fluid regulator within the paint equipment system Fluid pressures from the circulating system may be as high as 250 psig Target Distance The distance between the gun tip and the article being painted should be between 10 14 Excessive distance causesa waste of coating material and wrap back paint particles being deposited on the gun body or the robot arm At close distances the voltage at the tip of the gun will be reduced which decreases the charging effect of the gun Electrostatic Voltage The maximum voltage limit for these spray guns is 100 kV Some painting operations may require dif ferent voltage settings to obtain optimum transfer efficiencies If Faraday cage areas are predominant on the item being painted a lower voltage setting would aid in coating these areas When not spraying it is recomended to set back voltage to 30 40 kV or off NOTE gt IfaOkVcommandissenttothe MicroPak a feedback fault will occur 17 AA 03 01 1 Robot Waterbase Applicator Maintenance Ra nsburg MAINTENANCE PREVENTIVE MAINTENANCE DI water should only be used with waterbase ma terials WARNING NOTE gt Anelectrical discharge or spark may create gt Due to the design of this applica
32. lush the gun the fluid passages should then be flushed with heated Dl water 1309F to 140 F 54 C 60 0 and amine mixture AA 03 01 1 Ransburg POLAR AND NON POLAR SOLVENTS Non Conductive Non Polar Moderately Conductive Extremely Conductive Polar Amyl Acetate Methyl Amyl Acetate Toluene Xylene High Flash Naptha Mineral Spirits It is always best if the gun is covered with non con ductive gun cover This cover speeds upthe cleaning process of the exterior of the applicator The covers should be replaced as required As the gun covers fill with overspray material they must be replaced because they become path to ground lowering ouput and increasing current draw Applicator Disassembly WARNING gt Anelectrical discharge or spark may create an electrical and or fire hazard during maintenance Do not clean or service the spray gun with the power supply On Verify that the power supply has been turned OFF to ground gt Unexpected robot movement can be hazard ous Do not adjust or repair the spray gun when the robot is operating or waiting to start The robot must be taken out of service Follow all Lockout Tagout procedures prior to entering to service the applicator OSHA 29 CFR 1910 147 Head Removal Repair 1 Relieve all pressures flush out paint lines and blow all lines dry Remove gun from robot by turning the retaining ring counter clockwise from the robot mount plate See F
33. m to the robot manifold where the spray gun attaches to the robot The RWA EFM series spray guns operate from any MicroPak power supply 11 66 296 3 10 00 254 0 ____________19 95 506 8 wa 1 14 16 359 6 10 00 254 0 12 93 328 5 Figure 3 Gun Tool Center Point Representation AA 03 01 1 Robot Waterbase Applicator Introduction Ra nsburg SPECIFICATIONS RWA EFM Series Electrostatic Spray Guns for Highly Conductive Coatings Weight Robot Manifold Tubing Requirements 78863 60 10 2 165 4 6Kg Atomizing Air 3 8 Nylon 78863 90 10 1 Ibs 4 6Kg Natural color Length Pattern Air 3 8 O D Nylon Black color 78863 60 14 93 379mm See Figure 3 Paint In 3 16 1 0 Shielded 78863 90 12 93 328mm Dump Out 1 4 I D Shielded See Figure 3 Trigger Air 3 16 Nylon Operating Air Pressures Green color Atomizing Air 100 psig max 6 9 bar Dump Pilot 3 16 Nylon Red color Fan Air 100 psig max 6 9 bar Air Purge 3 16 Nylon 150 psig max 70 psig min Blue color 10 3 bar 4 8 bar Electrical Purge Air 200 psig max 13 8 bar Operating Voltage 0 100 kV Dump Pilot 150 psig max 70 psig min 0 125 uA 10 3 bar 4 8 bar Applicator Nomenclature Hose Identification Fluid Pressure A Atom
34. n the flats turn the tie rod 2 counter clockwise Pull the bracket 1 out of the slots in the tie rods Completely remove these parts Pull the cascade 3 completely out of the valve manifold 11 re install the cascade 3 apply generous amount of di electric grease to the labrynth end of the cascade Insert the cascade into the valve manifold Turn the tie rods 2 in by hand to within 1 2 of bottoming out in the valve manifold pocket Install the bracket 1 into the grooves Using the 3 8 open end wrench begin tightening the tie rods down sequencing from side to side until the tie rods have bottomed out against the valve body Ransburg AA 03 01 1 nsburg Robot Waterbase Applicator Maintenance 6 Tube Fluid Isolation 2 1 s 5 SHGW4 amp xoXSlog Figure 15 Isolation Tube Removal 27 AA 03 01 1 Robot Waterbase Applicator Maintenance 28 12 Refer to Figure 15 to remove the isolation tubes fittings and short tie rod Steps 12 13 14 15 and 16 Remove the isolation tube 6 by screwing the tube counter clockwise out of the valve maifold by hand Remove the 2 o rings from each end 12 and 13 NOTE gt This tube should be cleaned with the appropriate solvent to clean off the mate rial being sprayed Then this tube must be cleaned with a non polar solvent 13 Inspect the ID of the tubes for carbon tracking If any carbon t
35. ot arm or as close as possible to the gun Air cap pressures should be set using air cap test kit This provides a consistent measurement so initial settings may be duplicated at any time See Parts Identification section for air cap test kit part numbers NOTE gt Insure that the fan and atomization air are on and flowing prior to triggering the fluid Failure to follow this sequence will cause spits and defects on the part being painted Dump Pilot DP When the target part is finished and a color change is desired insure voltage is turned Off y WARNING gt Failure to turn voltage OFF during color change sequence could cause a fire or explo sion Actuatethe dump pilot DP signal and properly clean the line using an appropriate solvent for the material being sprayed When the cleaning cycle with solvent is complete an air purge for several seconds is recomended to clean and dry the I D of the dump line hose Ransburg WARNING gt gt Never apply voltage to robotic spray gun system when not in use When electrostatically spraying a waterborne material the entire paint column from the spray gun to the fluid tank or pump system is charged at high voltage In sure proper protection from voltage discharge Not providing protection may cause damage to equipment serious injury to personnel or death gt Failure to properly clean and blow down the walls ofthe dump line tube may cause a voltage
36. r Introduction SPRAY HEAD VALVE MANIFOLD 78863 60 60 SINGLE HEAD 78941 XXXXX ROBOT MANIFOLD PLATE ASSEMBLY Figure 1 RWA EFM Series Spray Guns and 78941 XXXXX Robot Manifold Assembly AA 03 01 1 Robot Waterbase Applicator Introduction FEATURES The features of the RWA EFM series guns include Standard Ransburg air cap 76131 01 tip 76132 00 and nozzle 195 e Integral dump valve and dump air purge Fluid dump valve is located adjacent to the fluid passages HP 404 Internal Cascade e Waterbase or solventbase compatible Screw on robot mount plate quick disconnect The EFM spray gun system consists of two major components the gun assembly 78863 XX and the robot manifold assembly 78941 XXXXX ROBOT Ransburg 78941 XXXXX Robot Manifold Assembly 78941 XXXXX is designed to connect the 78863 60 or 78863 90 spray gun to the Fanuc or ABB robots A 50ft low voltage control cable 76496 50 is supplied with the robot manifold to connect the cascade to the MicroPak power supply The fluid hose and dump line hose is shielded to prevent voltage from charging or bleeding voltage to items the hose comes in contact with The Paint In line is 3 16 I D standard and is 1 4 D for the dump line standard OBOT ROBOT SPACER PLATE
37. racking is seen the tube must be replaced If no tracks are seen install a generous amount of LSCH 0009 di electric grease on the ID of the tube 14 Remove the air fittings 5 and barbed fittings 1 2 3 and 4 When re installing these fittings use a non conductive pipe thread sealant on the threads 15 Remove short tie rod 7 by removing two screws 8 Remove tie rod bracket 10 by removing socket head cap screw 9 16 Remove shroud o ring 11 by prying out of groove Ransburg AA 03 01 1 nsburg Robot Waterbase Applicator Maintenance 6 ValveRemovalool Figure 16 Check Valve Removal 17 Refer to Figure 16 to remove the air purge check valve Remove the check valve plug 3 Remove the seal 4 Using check valve removal tool 79000 00 6 remove the check valve assembly 2 Remove the o ring 5 AA 03 01 1 29 Robot Waterbase Applicator Maintenance Ra nsburg Valve Assembly Valve Seat Assembly Valve Seat Removal Tool Valve Removal Tool Figure 17 Dump Valve Removal 18 Refer to Figure 17 to remove the dump valve Using the valveremoval tool 78985 00 4 re move the valve assembly 1 by turning counter clockwise Using the valve seat removal tool 77872 00 2 remove the seat Replace parts as required Torque seats 2 to 20 Ibs in torque Tighten valves down till they are tight in the valve body 30 AA 03 01 1 nsburg Robot Waterbase Applica
38. rg 9 Carefully slide the ferrules and nuts off the old fluid lines for re use 10 Cuttheexistingtubea minimum of 2 ft backfrom the end where the barbed fittings were located 11 Cut away the jacket and coductive sheath ac cording to Figure 19 COR OUTE CONDUCTIVE JACKE SHEATH Figure 19 Fluid Hose Cutback Diagram A WARNING gt If the inner of the fluid line is nicked in any way you must start over at Step 10 Any nicks will cause premature failure or high voltage pin holing after installation Fluid Tube Reassembly 12 Apply a thin film of SSL 11 petroleum jelly on the conductive sheath to aid installlation of ferrule 13 Slide nut over the tube Carefully slide the fer rule over the conductive sheath leaving no raised edges Insure the outer jacket of the tube bottoms out inside the ferrule 14 Apply anti sieze to the fitting threads Slide the tube inside the fitting until the ferrule shoulders against the back of the fitting Carefully slide the nut over the ferrule and tighten AA 03 01 1 Ransburg gt Dump line is 1 4 1 0 and paint line is 3 16 1 0 15 Insure the distance from the face of the robot plate to the end of the core is per Figure 20 Figure 20 Assembled Hose Length 16 Apply a thin film of SSL 11 petroleum jelly to barbed end of the fittings Press the appropriate fit ting into the end of the tube by holding the tube by hand an
39. tilation must be kept at the rates re quired by NFPA 33 1995 Edition 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 equip ment modifications may cause fire or injury If used the key switch by pass is intended for use only during set up operations Production should never be done with safety interlocks disabled Never use equipment intended for use in waterborne installations to spray solvent based materials General Use and Improperoperationormaintenance Personnel mustbegiventraining in accordance with the Maintenance may create a hazard requirements of NFPA 33 Chapter 16 1995 edition 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 main tenance and housekeeping OSHA references are Sec tions 1910 94and 1910 107 Alsorefer to NFPA 33 1995 edition and your insurance company requirements AA 03 01 1 Ransburg AREA Tells where hazards may occur Electrical Equipment 7 Explosion Hazard Toxic Substan
40. tor Maintenance Cable Removal Screw 1 4 20 X 3 4 Lg SHCS KA Set Screw 3 8 Lg X 10 24 Figure 18 Low Voltage Cable Removal AA 03 01 1 31 Robot Waterbase Applicator Maintenance 32 1 To remove and replace low voltage cable refer to Figure 18 Remove applicator from robot wrist See Figure 7 2 Remove screw 1 from position shown Insert 3 16 wrench to remove set screw 2 The cable may now be removed 3 To re install pull the cable through the robot arm Install in the low voltage cable hole Align the timing marks as shown in Figure 19 4 Tighten the set screw 2 until tight Re install the screw into position shown Fluid Tube Repair Replace 1 Remove the atomizer from the robot Refer to Figure 7 WARNING gt gt clean and blow all fluid lines dry gt Insure voltage is turned OFF gt Insure robot is locked out 2 Remove 6 screws that retain the tubing bundle to the robot wrist 3 Disconnect all cable and tubing connections 4 Clamptherobotplatein a softjawed viceto prevent any scratching or defacing of the plate 5 Remove all pilot lines around the fluid dump line 6 Remove the nut from the paint and dump line fittings 7 Cut off the end of the tube where the barbed fittings are located and discard the barbed fittings 8 Pull out the tube straight out of the fitting being carefull not to break the ferrules Ransbu
41. tor if electricaland or fire hazard during maintenance spraying with solvent based materials use Do not clean or service the spray gun with the the appropriate solvent recommended by power supply on Verify that the power supply the material supplier has been turned OFF to ground gt Unexpected robot movement can be hazard ous Do not adjust or repair the spray gun when the robot is operating or waiting to start The robot must be taken out of service gt Follow all Lockout Tagout procedures prior to entering to service the applicator OSHA 29 NOTE C CFR 1910 147 External Cleaning gt Solvents used for external cleaning should be non polar Non polar solvents leave the surface being cleaned non con ductive and will not cause voltage tracking to ground along cleaned surfaces A WARNING gt Solvents used for equipment flushing must have flash point ratings equal to or greater than the flash point rating of the coating material Solvents used for general cleaning must have flash point ratings higher than 100 F 37 8 C Internal Cleaning and Flushing Preventive maintenance on the RWA EMF spray guns is basically limited tothe cleaning andflushing ofthe guns Cleaning includes wiping the excess paint from the exterior of the gun and the spray head Flushing the gun will keep the fluid passages clear Flushing may be accomplished through the spray nozzles or dump valve In any method after using a solvent to f
42. ure At the Air Cap Low trigger pilot air pressure 70 psi min required Four nylon socket head screws holding the spray head are loose Air tubes EMF 102 103 are not installed properly Black or natural 3 8 OD tube is cut or pinched Increase to 70 psig minimum Tighten all screws Reconnect tubing Check the tubing for kinks or damage Replace if worn or damaged Make sure that the seal is in the proper position and or lubricate with a small amount of petroleum jelly Increase pressure Tighten all screws Re install and tighten as required Examine repair as required Note A test station to bench test the applicator off line will speed the Troubleshooting process 34 AA 03 01 1 nsburg Robot Waterbase Applicator Maintenenace Fluid System Fluid and Isolation Tube General Problem Possible Causes Corrective Action Excessive Current or Loss Fluid tube leak inside fluid 1 Replace any worn or damaged o rings on of High Voltage isolation tube charged paint EMFD 29 1 barbed fittings grounds out at robot arm manifold Replace any worn or damaged o rings on fluid isolation tube Fluid tube too short Check for correct length of fluid tube Refer to Figure 21 Robot Manifold Assembly Tubing or conductive Replace tubing or conductive sheath sheath nicked or cut Internal end of fluid tube not Ensurefluid tube is seated tightly into valve seated properly into valve
43. ve the formed tubes 9 and 10 by releas ing them from the push to lock fittings on the plate assembly 2 Disconnect the cascade harness 7 from the cascade The plate assembly 2 may now be removed by pulling the edges away from the valve manifold Ransburg 8 Refer to Figure 12 to remove the cascade harness 1 from the plate Using a 3 32 wrench remove the set screw 4 from the plate assembly 2 Pull the harness straight out Repair replace as necessary gt The cascade harness in the RWA EFM and the EFM applicators are not interchangeable Use only the harness with the tag 79200 00 for the RWA EFM applicators Reference Figure 12 79200 00 HARNESS IDENTIFICATION TAG USE FOR RWA EFM ONLY PE Wiring Harness Cascade EFM a Plate Read RWA EFM O Ring Encapsulated Set Screw 3 8 Long X 10 24 Fitting Push To Lock 3 16 OD Figure 12 Harness Removal AA 03 01 1 nsburg Robot Waterbase Applicator Maintenance ALIGN MARKS Figure 13 Mark Alignment AA 03 01 1 Robot Waterbase Applicator Maintenance 26 9 To re install the harness align the timing mark on plug with timing mark on plate and tighten set screw in place See Figure 13 Bracket Cascade Mounting Tie Rod Long Cascade Assembly HP 404 Figure 14 Cascade Tie Rod Removal 10 Refer to Figure 14 for cascade removal With a 3 8 open end wrench o
Download Pdf Manuals
Related Search