tune-up your system your system your system your system the
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1. should check and maintain all settings regularly and for each application variable in order to continue efficient and economical operation QUICK REFERENCE CHART Control Solids amp Temperature Pot Pressure Pump Pressure Atom Air Pressure REA Needle Adjustment Hydraulic Pressure Airless amp Air Assisted Applicator Tip Orifice Size Rotation amp Conductivity 2 Process Viscosity Delivery _ Atomization Film Build Speed of Application Quality of Apperance IL 204 D 8 Tune Up Your System the RansCrafted Way rrvRansburg 11 This manual should be read and thoroughly understood by ALL personnel who operate or maintain this equipment Special care should be taken to ensure that the requirements for operating and servicing safely are followed during these procedures See the appropriate ITW Ransburg safety literature for your system The user should also be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 and the Occupational Safety and Health Act of 1970 OSHA prior to operating and or servicing this equipment REMEMBER REGGIE SAYS If You Play the Game by the Rules You ll be a Winner IL 204 D ITovRansburg MANUAL CHANGE SUMMARY This manual was published to replace Technical Manual IL 204 C Tune Up Your System The Ranscrafted Way to make the following changes 1 Added Service Manual Price 15 00 Euro to the Front Cover 2 Document create2. viscosity to aid in this process The purpose of using high solids and waterborne materials is to reduce environmental pollution If reducing viscosity produces the opposite effect another means of reduction such as application of heat or another method of application must be employed With the advantage of High Speed Rotators which can spray low and high solids material it is less important to have low viscosity In order to minimize the amount of organic solvents viscosity should remain as high as possible while still adequately atomizing the coating material When applying high solids coatings viscosity reduction should be done very slowly with slow evaporating solvents that will keep the material wetter and aid the flow without drastically reducing the solids content of the material The Viscosity Adjustment Procedure and Solvent Selection For the RansCraft Tune Up viscosity adjustment and solvent selection depends on the type of application equipment used and the material to be applied There are two axioms that apply when using electrostatic application equipment For No 2 Process Disk or Bell The Wetter The Better Because of the surface area and the speed capabilities of the rotating atomizer it is important to keep the material wetter This does not necessarily mean lower viscosity but may mean the use of slower evaporating solvents For early generation electrostatic equipment such as Electric and low speed Air Rotator
3. M TU Ra nsburg TECHNICAL MANUAL IL 204 D Replaces IL 204 C January 2008 TUNE UP YOUR SYSTEM THE RANSCRAFTED WAY IMPORTANT Before using this equipment care fully read all instructions in this manual Keep this Technical Manual for future reference Service Manual Price 15 00 Euro 20 00 U S rr Ransburg NOTE This manual has been changed from revision IL 204 C to revision IL 204 D Reasons for this change are noted under Manual Change Summary inside the back cover of this manual IL 204 D rrvRansburg Tune Up Your System the RansCrafted Way CONTENTS PAGE THE RANSCRAFTED PROCEDURE 1 11 TUNE UP YOUR SYSTEM THE RANSCRAFTED WAY ececceesseeeseeeeeeeeeeseeeeeaeeenenenneneees 1 TUNE UP YOUR SYSTEM FOR THE MOST ECONOMICAL AND EFFICIENT PERFORMANG Eo csnionjaniidoaaica ri Mintek 2 THE RANSGRAFTED PROCEDURE ura 3 VISCOSITY arenira ii is te rece Mica eee 3 FEUID FLOW RATE iio c 7 ATOMIZA TIO ocios tii cli diria 8 THE CPERA TON asas eee cece ri a 9 SUMMAR sti a da 10 IL 204 D Tune Up Your System the RansCrafted Way rr Ransburg TUNE UP YOUR SYSTEM THE RANSCRAFTED WAY Reggie Ransburg says Before you get into the game find out what the rules are Before operating maintaining or servicing any ITW Ransburg electrostatic coating system read and understand all of the technical and safety literature provided with ITW Ransburg products If you do not have the manuals and safety literat
4. d in standard manual format Made available electronically 3 Added Quick Reference Chart in the Summary section 4 Added Service Manual Price 15 00 Euro to the Back Cover 5 Added www itwransburg com to the Back Cover IL 204 D Service Manual Price 15 00 Euro 20 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 Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 www itwransburg com Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No IL 204 D Litho in U S A 01 08 2008 Illinois Tool Works Inc All rights reserved ISO 9001 Models and specifications subject to change without notice
5. e been established by the Rans Crafted process every operator will be able to produce optimum results with a minimum of effort if the operating parameters are maintained and adhered to Many employers take the position that no two operators work alike If that is the case it may be only because they have never been asked to work alike Demonstrations and mileage runs by ITW Ransburg engineers and technicians as well as user experience has proven that there is one best way in electrostatic coating operations If the operators seem unconcerned with cost it is possible that they are unaware of the magnitude of the problem can not see the forest for the trees Such problems as excessive overspray and blowby increased cleaning and stripping time increased conveyor maintenance and excessive paint use that are common with conventional systems and self taught operators can be eliminated with a RansCraft tuned electrostatic system and operator training The savings will become dramatically apparent When your system is tuned and the operators are trained you can expecta uniform superior finish The operator can then concentrate on results instead of short cuts and stop gaps Any operator can run any system because the rules for that game have been clearly defined and there is no need to waste time juggling problems 7 IL 204 D rrv Ransburg Tune Up Your System the RansCrafted Way SUMMARY An analysis of the RansCrafted procedures f
6. ed by selecting the best combination of nozzle and fluid pressure The atomization for ITW Ransburg No 2 Process applicators may be controlled through atomizer diameter disk and handgun or through rotator speed disk bell and air motor handgun The larger the diameter of the atomizer and or the faster the rotation speed the finer the atomization NOTE Each diameter atomizer has a flow limit and that atomization is directly affected by the amount of high voltage applied The No 2 Process applicator is very dependent on the resistivity of the coating material and the condition of the sharp edge and conductive bell coating IL 204 D 6 Tune Up Your System the RansCrafted Way rrv Ransburg THE OPERATOR The operator for these purposes is any person who exercises control over the coating process It may be the person who turns an automatic system on at the start of the shift the applicator operator in the touch up booth or the on site finisher in the field First attempts to establish control of electrostatic application procedures may meet with opposition from operators Most spray painters are self taught and fiercely proud of their skills However most of those skills are techniques developed to compensate for inadequate equipment lack of maintenance or environmental control or impossible goals for conventional equipment However once an ITW Ransburg electrostatic application system is in use and operating parameters hav
7. icate the impossibility of establishing universal adjustments that would apply equally to all installations So ITW Ransburg has devised a procedure that will help the user to create a tune up sequence for each individual operation This RansCrafted process is the result of over 60 years of ITW Ransburg engineering experience in originating and perfecting electrostatic coating It is the product of extensive laboratory and field testing by the people who pioneered the industry The three electrostatic coating parameters that are most easily measured and controlled are fluid 1 VISCOSITY The Flow Resistance of coating materials 2 FLOW RATE The Applicator Output measured in ounces or cc s per minute 3 ATOMIZATION Spot Size Atomizing Air Pressure REA Systems Fluid Pressure at the nozzle REM and M90 Systems Atomizer Rotation Speed amp High Voltage No 2 Process Automatic Systems Paint Resistance No 2 Process Manual and Automatic Systems Control of these three parameters Viscosity Flow Rate and Atomization can be maintained with optimum settings and allowable tolerances for any specific electrostatic coating system regardless of the application requirements by following the RansCrafted procedure IL 204 D 2 Tune Up Your System the RansCrafted Way rrv Ransburg THE RANSCRAFTED PROCEDURE NOTE gt This procedure MUST be followed in the exact sequence described The adjustment procedure mus
8. m thickness adding to the paint cost or to reduce efficiency Economical and efficient spray coating requires properly adjusted paint flow rate The Flow Rate Adjustment Procedure For the RansCrafted Tune up the flow rate should be reduced to a point below minimum standard and increase ONLY to the point where the applicator can deliver enough paint to provide film thickness to standard within the time frame allowed Flow rate should never be adjusted so low that there is no time cushion between targets or so high that there is time lag Remember the flow rate should be as low as possible consistent with established application rates The physical procedure may vary from one kind of applicator to another The REA air spray applicator for example should be adjusted by varying the applied paint pressure Needle valve adjustment is ONLY for fine adjustment and if used for gross adjustment of flow will produce excessive needle wear In systems where applied paint pressure adjustment is not practical a fluid regulator should be used to provide appropriate pressure to the subject applicator 5 IL 204 D rrvRansburg Tune Up Your System the RansCrafted Way The most practical method of adjusting flow for REM and M90 airless systems is by proper nozzle orifice selection Varying applied paint pressure may be used to make adjustments in airless spray systems however efficiency decreases rapidly with increased paint pressure due to increased noz
9. nt High speed rotation is usually necessary to better atomize waterborne materials since they are more susceptible to air entrapment Serrated disks or bells may aid in eliminating air entrapment in waterborne materials as well as in other coating materials For REA REM amp M90 The Deader The Better Because of the nature of air and hydraulic atomization it is important to select a solvent that does not create an electrical conductivity problem Polar solvents ie MEK and Acetone although good IL 204 D 4 Tune Up Your System the RansCrafted Way rrv Ransburg dilutants may cause excessive current draw on the system When selecting a solvent for reduction of viscosity it is important to keep in mind the REA REM and M90 application process and adjust the viscosity accordingly This may dictate the use of a minimum amount of low polar solvents that do not produce excessive current draw A slower evaporating solvent may be necessary to compensate for atomizing air or fluid pressure needed High solids material can be used in the REA REM and M90 applicators Fluid nozzle and or air cap orifice size may need to be changed to compensate for higher viscosity and to allow adequate flow volume Waterborne material may be used with REA III or REA 90 applicators that have fluid supplies and lines that are insulated from both the applicator and ground Flammable solvents should NEVER be used ina Charged System of this type without appropriate c
10. onversion to a Grounded System With charged fluid systems personnel must be aware of the potential spark hazards involved Solvent coatings that are too conductive for normal operation in a grounded fluid supply may be sprayed acceptably using an ITW Ransburg coiled fluid tube or short stopper Viscosity adjustment and solvent selection depend on which application process is employed It is important to understand both your solvents and your coating material It is advisable that no drastic modification be made in your formulation without contacting your supplier To determine the best formulation systematic testing should be done and recorded so that all variables will be known Good record keeping is a must After the preferred formula has been arrived at keep a record of the information so that it can be repeated with the next batch This facilitates consistent quality production results FLUID FLOW RATE Flow rate is defined as the rate of fluid flow at the atomizer It is expressed as the volume output within a specified time frame ie Cubic centimeters per minute or fluid ounces per minute When the flow rate is adjusted other variables may also be affected such as the application rate Ifthe flow rate is too low the applicator may not be able to keep up with a fast moving conveyor or a short time standard Therefore the flow rate must be sufficient to allow proper coating within the time available but not enough to allow excessive fil
11. or optimizing spray coating efficiency will show that any specific coating system can be operated efficiently and economically and that electrostatic application is as much as 30 more efficient than conventional coating systems Using the RansCrafted system any specific coating operation can be assigned its own set of operating parameter numbers for each application variable viscosity flow rate and atomization Therefore while all systems will use the same tune up procedure each variable target configuration desired finish etc will have a different established number for each parameter setting NEVER attempt to adjust any parameter OUT OF SEQUENCE That will throw the entire system farther off If a change in coating requirements such as increased conveyor speed change of target configuration different finish etc requires different parameter figures it is necessary that the adjustment be made in proper sequence viscosity flow rate and atomization To optimize the tune up it should be done at least twice the first time for gross adjustment and subsequently for fine tuning The final setting should then be recorded and appropriately posted 1 The viscosity 2 The paint formula Base and solvent identification and ratio 3 The flow rate In appropriate increments as well as regulator or pressure setting nozzle requirements etc 4 Atomization requirements Pressure nozzle speed and high voltage The operator
12. s there is a need to reduce the viscosity of modern coating materials to aid in the atomization process Lower viscosity and slower evaporating solvents keep the paint wetter as it moves across the atomizer surface This aids the atomization process which occurs mainly through the application of high voltage Viscosity is adjusted ONLY to the point that the material atomizes well and produces the necessary coating thickness and appropriate results on the product When using the Turbodisk or Aerobell with the capability of faster rotation it is often more benefi cial from an environmental point of view to maintain higher viscosity although low viscosity material will work as well The faster rotation and greater surface area of disk atomizers and the nature of new paint technology makes the solvent selection process more important It is in these cases that the use of slower evaporating solvents rather than lower viscosity should be the general practice Faster rotation compliments the high voltage in efficiently atomizing high viscosity materials This also makes the use of high solids and waterborne materials more viable Since the purpose of high solids is to maintain a lower fluid content higher viscosity to reduce emissions heat may be ap plied as a means to lower viscosity Waterborne materials may also be used to limit emissions Their viscosity may also be high but reduction is a lesser problem because water is used rather than solve
13. t be performed for each application requirement variable finish required target configura tion etc gt For specific details of how to make ap propriate adjustments to your application equipment refer to your ITW Ransburg service manual or contact your ITW Ransburg representative VISCOSITY Viscosity by definition is the resistance to flow of a fluid For the purpose of this procedure think of it as the thickness or thinness of the coating formulation Formulations of very low viscosity may be too thin and result in runs or sags in the applied coating In spray coating operations there are really two viscosities to be considered the one at the atomizer and the one at the target Of the two the viscosity at the atomizer is the most critical and will differ in nominal value from that of the paint on the target The difference is caused by solvent evaporation during the travel time from the atomizer to the target and by the method of atomization To facilitate the best possible quality of atomization it is necessary to keep the viscosity of the coating material at a point that is consistent with the application process while keeping in mind the nature of the coating material and the desired end result The viscosity may be lowered by adding solvent to the formulation or by applying heat If too much solvent is added the viscosity may be increased again by adding paint solids Because viscosity must be lower at the atomizer than at
14. the target the evaporation rate of the solvent becomes a critical factor You want the viscosity at the atomizer to be low enough to produce good atomization and the viscosity at the target to be high enough to prevent runs and sags The controlling factor is the rate of solvent evaporation during the travel time Careful selection of the solvent will produce optimum viscosity at both points Solvents with relatively high evaporation rates cause an effective increase in paint viscosity during travel time and will therefore allow both good atomization and good coating quality A discussion on viscosity must also be presented in terms of the type of equipment and the type of coating material to be used Itis important to understand that different types of equipment may require different viscosity and or solvent selection The viscosity requirements for Electric Rotators and Low Speed Air Rotators is different than that needed for the Turbodisk Turbodisk 2 Aerobell and 3 IL 204 D rrv Ransburg Tune Up Your System the RansCrafted Way Aerobell 33 and that may be different from that required for REA REM and M90 applicators Required viscosity for Electric and Low Speed Air Rotators is normally much lower than that needed for High Speed Turbine Rotators The nature of the slower equipment is such that because rotating speeds are limited the atomization process occurs mainly by the use of high voltage It is neces sary therefore to maintain lower
15. ure for your ITW Ransburg system contact your ITW Ransburg representative Reggie says Why gamble If you know how to play the game you ll be a winner 1 IL 204 D rrv Ransburg Tune Up Your System the RansCrafted Way TUNE UP YOUR SYSTEM FOR THE MOST ECONOMICAL AND EFFICIENT PERFORMANCE ITW Ransburg electrostatic coating equipment is designed and built to produce the desired finish in the production time allocated and to do it with the greatest efficiency of any spray coating equipment available However to get the most benefit from the equipment it must be adjusted properly and control of the adjustments must be maintained Some of the many variables inherent to any spray finishing operation are 1 THE TARGET size configuration and composition It may be anything from golf balls to cars to musical instruments 2 THE COATING MATERIAL composition and characteristics It can be enamel lacquer metallic high solids waterborne or almost any fluid 3 THE DESIRED FINISH Is it to be baked enamel smooth texture or 4 THE WORKING ENVIRONMENT The primary environmental elements are cleanliness ambient temperature and humidity control 5 THE EQUIPMENT Is it ITW Ransburg No 2 Process disk or bell REA REM or M90 Is it hand or automatic These variables are of course only a few of those possible throughout the industry Every application is in some way unique Brief though itis the list does ind
16. zle wear and this method should not be used as a primary adjustment ITW Ransburg No 2 systems will be adjusted by use of a flow regulator or if a paint pump is used for delivery by adjusting its speed ATOMIZATION Atomization is the reduction of the coating fluid to its smallest particulate component without altering its chemical composition The degree of atomization is dictated by the kind of finish that is required Atomization quality is the primary control over the appearance of the finish Coarse atomization will cause an orange peel effect with marginal hiding or covering characteristics Fine atomization on the other hand will produce the kind of smooth even coating that is required by the automotive and appliance industries Coating iron casting for example may be done with very coarse atomization and still produce an acceptable finish The orange peel effect that might be acceptable on the iron castings however would not be acceptable on an appliance such as a refrigerator The Atomization Adjustment Procedure Begin testing with atomization that produces the desired finish appearance easily Then decrease slowly at reasonable regular increments until the appearance starts to deteriorate From that point increase atomization only until the appearance meets the appropriate standard When using REA applicators the atomization is adjusted by varying the atomizing air pressure REM and M90 applicator atomization is controll
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