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Hybrid Model A13368 (Serv. Man. LN-9276-14.1)

1. 30 INTERLOCKS Lu EE 31 32 39 FLUID FLOW RATE CONTROL E 32 33 TURBIN EE 33 BEARING AD IUSTMENT ettet ttt ttt 34 SHAPINGAIR qnom 35 37 GE TE 37 ELECTROSTATIC VOLTAGE u AER dn aH 37 CUP WASH MR m 38 TARGET DISTANCE E 38 GENERAL ele e 38 39 MAINTENANCE 40 73 O RINGS C P 40 CLEANING PROCEDURES Eed 40 41 VIBRATION e 42 TURBINE p pz ec 42 GENERAL PREVENTIVE MAINTENANCE ront rino hh pirata ninh Reha nobii buius 42 44 LN 9276 14 1 Ransburg RMA 590 Contents CONTENTS PAGE MAINTENANCE Cont 40 73 BELL CUP PREVENTIVE MAINTENBINQE tassa g t dE RANGER 44 BELL CUP GLEANING EE 45 46 CLEANING SHAPING AIR HOLES 46 PREVENTIVE MAINTENANCE SCHEDULE eidele EE 47 48 TROUBLESHOOTINCG GUIDE T u u usa usan ususi aaa gaa aa i ak Ga 49 55 used Ee 57 ELECTRODE RESISTANCE TEST E 57 58 EE Ebert eeneg 58 73 PARTS IDENTIFICATION 74 91 RMA 590 ROTARY ATOMIZER MODEL 74 76 RMA 590 ASSEMBLY PARTS LIST ET 77 80 TYPICAL BELL CUP PARTS BREAKDOWN iE in Eph copa ern 81 A13196 01 MOUNTING MANIFOLD ASSEMBLY eene nnne 82 A13125 01 SOLVENT BLOCK ASSEMBLY
2. 83 A13672 00 HIGH VOLTAGE RING KIT PARTS 83 SHAPING AIR KIT ASSEMBLY PARTS 84 ATOMIZER RECOMMENDED SPARE PARTS taire sa arp YE Pn rna gek 86 88 ASSEMBLY TOOLS AT1090 02 89 FILTER amp HEATER ASSEMBLY ET 90 SERVICE E 91 LUBRICANTS AND SEALERS uu a Sun dtu ra ttes atra 91 EECH WEE 91 AGCESSORIE E 91 WARRANTY POLICIES 92 LIMITED WARRANTY 92 LN 9276 14 1 Ransburg SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety liter ature for your 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 informa tion we use the following symbols Please pay particular attention to these sections A WARNING states information to alert you 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 A NOTE is information relevant to the proce dure in progress While this manual lis
3. 5 44444444 TVNSIS 4399141 LN3ATOS HSVM df Bes 204 TWNOIS 9 dWNA 1NIVd ald WUNLWN 24 LNIVd 3 TWUNLWN 1 i pe dina v H1008 2140 SE FYNSSTad LNOHLIM OL 1 AVudS a g N o8 38 15 LI 935 SI 4 V JI CHRIS HE a ONG va dV ONIdVHS JHL OLNI DEEN 5 38 LON OCHS SIV IN3AT0S WI Zeg hes a SOND dY V ONISN dI S310N NRE MOTA NANAY aly N3395 NIY Lei S Si EA 4 Adans Y mam won AE SS Zd 4915 2 1NIVd I Y 170 Td AlddNS T 1NIVd NIW 22 004 Q332X3 LON LSNW 4 1138 IHL MOT TVT331VN 9 M3ZIWOLV OL 35012 105 30078 HSYM dfi OL IN3ATOS SNI8 U AIDA H UM 38 7 1334 SZ SNAH TY pi NOLLVTYVLSNI OL LNO NAAOT8 G3NV3105 LSNW 3did MIN S31T101NO2
4. OLNI l 3OVEIOA OL H Meo NOTAN Abit ce s NIV ER Yad 6 AINE AWG 20d ZE S MOVIE TVN IS 99 1NIVd a vad Ag 97 5 GEI z TWUNLYN TvN9IS u3959n4L os 14 NOTAN WWP 26 9 ai diis mE Vad Wiwg 91 S 1 LI EBE NOTAN 2676 WANTS TVNSIS 8399181 AND T4 1NIVd WW Td vad vie 91 5 INTI 114 NOTAN 2 6 339541 T 1NIVd 15 NOTAN It S BN TVN IS 8399181 1N3ATOS Tvs WWS 91 5 aM IV SdVHS WINNI 1109 arm HSVM a g a 2 MOT TYNRLNI 095 NOTAN Dag 91 S GUD IV 3dVHS UINO NOTAN v T BCE N3ZIWOLV OL 21815508 SV 35012 vL NOTAN WW8 91 5 va 28 9 MOTIBA rv SNINV3H va NOUN V T IVAN Alddns lv SNIIVIB Al ES J18V2 2140 HOT ONTGNL Wk ZE S SC 1N3AIOS Wie ze s ME 26 5 f v 514 NOTAN Wu S TWVNDIS YaDSTUL IN3ATOS MOD HSVM 786 NOI ANAATOS 03 Wut 28 5 v Uy TWUnLYN NI HSVM nD MB T luy EEN 5 TVNSIS 9355181 NIV HSVM V v 3O C IOJINVI NOD HSVM dno 1138 uv 12018 HSVA 3L
5. O Alarm O Low Air Flow O Power On 8888 8888 lt Ransburg A11065 05 AIR HEATER SUGGEST 1 2 0 0 OR 12MM O D TUBING NYLON 1 2 NPT F PORT 1 4 NPT F PORT 1 2 NPT F PORT FLOW DIRECTION 3 K 1 4 NPT F PORT A11111 00 VOLUME BOOSTER A11065 05 Air Heater LN 9276 14 1 26 Ransburg RMA 590 Installation A13230 XX AIR HEATER AND FILTER COMBINATION This combination includes filtration for turbine as well as bearing air FLOW DIRECTION APPLY THREAD SEALANTTO FITTING AT THIS LOCATION NOTHREAD SEALANT ON FITTINGS ALLOWED AFTER FILTERS APPLY THREAD SEALANT TO FIFTING AT THIS LOCATION FILTER amp HEATER ASSEMBLY A13230 XX Dew ne _ A13230 01 115 V 13A METRIC FITTINGS A13434 01 A13426 00 A13429 00 A13726 00 A13230 02 230 V 6 5A METRIC FITTINGS A13434 02 A13426 00 A13429 00 A13726 00 A13230 03 115 13 FRACTIONAL FITTINGS A13434 01 SSP 6439 A13428 00 A13727 00 A13230 04 230 V 6 5A FRACTIONAL FITTINGS A13434 02 SSP 6439 A13428 00 A13727 00 A13230 XX AIR HEATER AND FILTER COMBINATION Re Ee ll ARBEOCK NIPPLES amp AIRHEATER e 2 A13427 00 INLET FITTING 3 8 NPS M X 1 2 NPT M BEARING AIR FEED SWIVEL ELBOW 1 4 O D TUBE X 1 4 NPT M BEARING AIR FEED 6mm
6. j Sld Wb 2678 GRY NEI H3DS9TNI IN3ATOS HSVM 419 F 9 IINIVd Id e NOD TANIYA 4399141 114 HSWM NIG 1N3AIOS 105 NOI 1N3ATOS Deem IN3AOS INI 15 WIVSNIdVHS IYS AH 4 v Z gie OVS Hv WAYN NI HSVM and ayaga ua v uv E Sete YAZIWOLY TWNSIS NIV HSVM di 4 NIV AM d MI va 40 Q IOJINVIW tiva BEEN HSWM TAA QN3931 HSVA JLOWIY 21 LN 9276 14 1 TYM GNNOYS HLAVA OL 8 RMA 590 Introduction SNOdYEVZVH SNOGYVZVH NON 39HVHO LO3MIQ 06S VIW3 00S851T2C8 86v87 MAWASSV Viv 1VOO 22 123MIONI ON 3S9VHO 192419 NI TF SI dNI 4 r mer 8870 SuaH1O A8 e Eel Hie S 2 D m 20 00 25184 00 66 o A m SC 09501v t OLvOTddv OL H i T t0b OL I lt 00
7. IHL OL 13S 431114 JHL 13915 SS3INIVIS 38 LSNW AtddNS rv SS3130 2 oT 40 IN MAC V HEN SLNVOTHEITI JO 3344 38 OL SI WEY Y3SN ONS Ag O2HSINST WILI S310N3Q Yu EE YO ANY S3009 3314 7201 AB AvedS 30 SLINIT X AXONWOYONTJYJd 9NTSn L AIMH TY I e ONISNL SLLYWNSNd TIY m ONIANL 5310 ON YIZIWOLY OL 3181SSOd SV 35012 SV 4320039 LNNOW LN 9276 14 1 Ransburg INTERLOCKS The following system interlocks are required to prevent equipment damage Bearing air should remain on at all times and should be shut off by turning off the main air to the pneumatic control cabinet It should not be possible for the coating material to be sprayed unless the turbine is spinning Two inter connected bearing air ports are provided one for supply air and the other to be used as a return signal for measur ing bearing air pressure at the atomizer If bearing air falls below 80 psi 551 6 kPa at the atomizer the turbine air should be automatically interlocked to shut off This interlock is provided by the Serial Atomizer Module See current Serial Atomizer ser vice manual High voltage must be interlocked with the solvent valve pilot signal to preven
8. Grasp high voltage ring from the front and twist counter clockwise 10 15 Slide the ring and probe forward off the applicator LN 9276 14 1 e dielectric grease to groove Clean old grease from groove and high voltage input hole Clean old dielectric grease from high voltage connection in the center and in the groove Fill groove only with dielectric grease 1 1 2 38 1 mm e APPLY DIELECTRIC GREASE Clean old dielectric grease from the end of the high voltage cable Verify cable protrudes from high voltage tube to dimension shown Add a small amount of dielectric grease to the banana jack only RMA 590 Maintenance 60 Push the high voltage ring onto the atomizer as sembly Position the high voltage input slightly to the left of center Locate the high voltage ring on the locking pins and twist the high voltage ring 10 15 clockwise to lock into position The high voltage input must be on center of the unit with the robot adapter Use 2 76772 00 wrenches to remove the atomizer assembly from the mounting manifold Hold the mounting ring with one wrench while removing the quick disconnect ring in a clockwise direction Once loose remove the wrench from the mount ing manifold Hold the atomizer with one hand while turning the ring until the unit is completely disengaged LN 9276 14 1 RMA 590 Maintenance Alignment marks Alignment holes Alignment pins Tore
9. Improper limiting current and voltage settings high voltage parts To readjust settings refer to MicroPak operating manual Atomizer grounding out usually indicated by high currentdraw orby MicroPak over current fault light a Clean atomizer externally with non po lar solvent Check the atomizer externally with non polar solvent Check for fluid leaks at quick discon nect mounting between bell plate and robot plate Check for internal arcing usually indi cated by internal sparking sounds Make sure cascade low voltage con nection is properly shielded 52 Ransburg RMA 590 Maintenance TROUBLESHOOTING GUIDE DIRECT CHARGE Cont General Problem Low or No High Voltage Cont Low Transfer Efficiency or light coverage No Turbine Air LN 9276 14 1 Possible Cause Faulty low voltage connections Usually indicated by MicroPak feedback fault light Solution Make sure quick disconnect electrical connection is aligned and clean a Checklow voltage connection atcascade Faulty high voltage connection Remove cascade and check continuity between cascade connection and turbine shaft MicroPak or cascade failure Refer to MicroPak service manual for detailed Troubleshooting Guide Improper color change i e paint or solvent in dump line Low or no high voltage Optimize color change Verify high voltage at bell cup edge Nor
10. Inspection of Bell Cups 2 Ifthere is any remaining paint build up on any areas of the bell after flushing the bell cup should be removed for hand cleaning tion cuts and of cup some exam front and rear splash plate halves If worn ples of areas for special attention replace entire assembly Bell Cup Soaking 7 Check the center holes of the splash plate for wear Hold splash plate up to a light 3 Bell cups and splash plates can be soaked source and look straight into the holes If in a heated solution for up to 2 hours in an light is clearly seen the angled holes are ultrasonic cleaner 120 F 49 C maximum worn and the splash plate must be replaced Bell cups alone may be soaked for an ex tended amount of time 8 Splash plate assemblies may be soaked for a short time under 2 hours to loosen dried material Clean with a soft bristle brush Blow out center holes to dislodge material Never use any kind of pick instrument to clean these holes Manual Inspection 4 Visually inspect the bell cup edge for signs of abrasion If the edge is excessively worn or badly chipped as the result of a collision with a part replace the cup immediately 9 Soaking the bell in solvent may aid in loos ening or removing paint build up It is recommended that the splash plate be re R lash plate tf a EEN moved and cleaned separately the bell cup where the fluid leaves the large diameter of the splash pl
11. A12874 12 Direct Charge Dual Flex55mm A13116 01 A13229 01 A13228 01 A12066 01 A12874 13 Direct Charge Dual Flex A13116 01 A13229 02 SHAPING AIR KIT PARTS LIST neme Fais Outer Shroud A13228 02 A12066 02 Shaping Air Ring Inner Shaping Air Ring Turbine Retaining Ring O Ring Solvent Proof O Ring Solvent Proof LN 9276 14 1 84 Ransburg RMA 590 Parts Identification LSOR0005 14 REF O RING FEP ENCAPULATED INCLUDED WITH ITEM 1 ASSEMBLY A13672 00 HIGH VOLTAGE RING KIT PARTS LIST A13137 00 HIGH VOLTAGE RING ASSEMBLY 79001 45 O RING SOLVENT PROOF A11343 02 ELECTRODE ASSEMBLY A11318 00 HIGH VOLTAGE TUBE NUT 7844 1 00 FERRULE NUT 3 8 O D TUBE A13138 00 HIGH VOLTAGE TUBE LN 9276 14 1 85 Ransburg RMA 590 Parts Identification ATOMIZER RECOMMENDED SPARE PARTS A12895 XX Air Turbine Assembly A11318 00 High Voltage Tube Nut 13737 24 Screw 1 4 20 x 3 8 Nylon 78441 00 Ferrule Nut A13128 00 Slip Ring A13137 00 High Voltage Ring Assembly A13138 00 High Voltage Tube A13737 24C Screw 1 4 20 x 3 4 Nylon 4 6 77367 00 Valve Seat assembly 3 5 78949 00 Valve Assembly 3 5 78944 00 Check Valve Assembly 2 4 A12821 00 Cup Wash Fitting 3 5 A12822 00 Cup Wash Ferrule 3 5 0 1 A11245 00 Fluid Tube Assembly A13143 00 Screw
12. S 123410 gt TO E62b2 I E ID fs 3vdOSDII 0001 OL D pae 0001 du CS l _ T 90 Zb6bZ Sz 09s01V ew 38 LSNW SOJ1VOTIddV MOVE 9NIWOO 3 ANNOYS 3avosvo LY ONISN 38 LSNW 319 0 ADVLIOA HOIH Ransburg SALON LN 9276 14 1 Ransburg INSTALLATION AIR FILTER INSTALLATION GENERAL GUIDELINES The following air filter installation guidelines are essential for optimum performance 1 Use 25 OD 1 Inch OD minimum inbound main air line 2 Useonlyrecommended pre filters and bearing air filters as shown in Air filtration Require ments chart in the Installation section Ad ditional system air filtration i e refrigerated air dryer may also be used if desired 3 Mount all the air filters as close as possible to the RMA 590 applicator DO NOT mount further than 30 Feet 9 1 meters away 4 DO NOT use tape pipe dope or other thread sealant downstream of the bearing air filter Loose flakes tape or other sealant can break loose and plug the very fine air holes in the turbine air bearings 5 Airheaters are highly recommended for use in the system to minimize the effect of excessively humid conditions and maintain turbine load capabilities Ifthe heated air will exceed 120 F 48 9 C the heater must be located after all filters to prevent damage to the filter m
13. To remove Remove check valve plug with A13142 00 tool Align the pins of the tool with the holes in the plug Remove by turning counter clockwise When re installing inspect o ring for damage Lubricate o ring with petroleum jelly Tighten into place Make sure top of plug is flush with atomizer face Check valve O Ring Use the opposite end of the A13142 00 tool to remove the check valve assembly Align the end of the tool with the slot of the check valve Re move by turning counter clockwise Make sure that o ring at the bottom of the bore is removed Assemble in reverse order LN 9276 14 1 RMA 590 Maintenance Remove high voltage cable cover by removing the 6 screws using a flat blade screwdriver Re install screws and tighten to 5 10 Ibs in 0 56 1 13 Nm torque Remove side panels by removing holding screw with a flat blade screwdriver To re install panels place in groove and tighten screw to 5 10 Ibs in 0 56 1 13 Nm torque 69 Ransburg RMA 590 Maintenance Remove panel by sliding out from grooves of the robot adapter SE Robot mounting adapter must be fitted to the robot wrist before installing robot adapter or applicator Screws to fit the robot adapter to the robot wrist are supplied by the end users To remove Remove the robot mounting adapter from the robot adapter by removing the 6 socket head cap screws with a 5 16 8mm hex key wrench The center ring is remove
14. O RING SOLVENT PROOF 79001 41 O RING SOLVENT PROOF 79001 42 O RING SOLVENT PROOF A11226 00 RETAINER FLUID TUBE 79001 44 O RING SOLVENT PROOF E FLUID TIP 79001 22 O RING SOLVENT PROOF A13143 00 SCREW 10 32 X 3 8 SHCS NYLON A13738 32C SCREW 5 16 16 X 1 SHCS NYLON A11252 01 TUBING A11305 00 LOWER FERRULE SOLVENT 79 Ransburg RMA 590 Parts Identification RMA HYBRID PARTS LIST Cont vem ay pane sity 00 11276 00 SOLVENT 78450 00 SOLVENT LINE TUBING COIL RMA 101 A13196 00 MOUNTING MANIFOLD ASSEMBLY A13144 00 RUBBER COVER A13535 00 FLUID TUBE ASSEMBLY A13195 00 APPLICATOR BODY ASSEMBLY SHORT A13198 02 FIBER OPTIC ASSEMBLY SHORT A12090 02 TOOL KIT 77141 31 LITERATURE 1 1 1 1 1 1 1 13142 00 VVV V CHECK VALVE TOOL TORQUE FLUID TUBE ASSEMBLY INTO ATOMIZER BODY USING A11220 00 TOOL TO 65 75 LBS IN 7 28 8 4 Nm TORQUE FLUID USING A11229 00 TOOL TO 25 30 LBS IN 2 83 3 4 Nm TORQUE TO 15 20 LBS IN AFTER VALVE IS DOWN 1 7 2 3 Nm TORQUE TO 15 20 LBS IN 1 7 2 3 Nm 2 APPLY A11545 00 PETROLATUM JELL TO ALL O RINGS PRIOR TO INSTALLATION Fluid Coils Separate Sales Parts Only If purchasing spare parts they must be modified as explained
15. TURBINE SPEED k RPM 12 Ransburg 60 Air Pressure psi Air Pressure psi LN 9276 14 1 FLOW VS PRESSURE Air Flow scfm 7 1 8 8 10 6 12 4 RMA 590 Introduction MONO FLEX SHAPE AIR SINGLE SUPPLY SOURCE A12874 05 06 07 SHAPING AIR KIT 15 9 400 350 15ft 4 6 m of 8mm x 6 mm Tubing 300 15ft 4 6 m of 250 200 Tubing Pressure 150 Air Pressure kPa 100 Air Flow slpm FLOW VS PRESSURE Air Flow scfm 12 4 15 9 19 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 MONO FLEX SHAPE AIR DUAL SUPPLY SOURCE A12874 05 06 07 SHAPING AIR KIT 26 2 15 ft 4 6 m of 8mm x 6 mm Tubing 2 15 ft 4 6 m of 8mm x 6mm Tubing Air Pressure kPa 350 400 450 500 550 Air Flow slpm 700 750 13 Ransburg RMA 590 Introduction RMA 560 DUAL FLEX AIR A12874 08 09 10 11 SERIES SHAPE AIR FLOW VS PRESSURE Air Flow scfm 26 35 44 53 62 71 79 88 97 106 11 5 124 132 141 150 15 9 16 8 177 18 5 19 4 203 21 2 OUTER AIR CMM Do a Pressure psi Pressure kPa 100 10 50 0 T T Y T T Y T T T T T T Y T T Y o 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600 Air Flow slpm A12874 12 13 55mm Dual Flex lt Inner Shape Air Air Pressure vs Air Consumption Air Pres
16. Continuous Fluid Flow Uncontrollable Fluid Flow LN 9276 14 1 Possible Cause Damaged fiber optic cable between robot plate and control panel Solution a Repair or replace fiber optic cable b Bad splice connection ortoo many splices Maximum three 3 splices permitted Connection at robot or bell plate is loose Fiber optic transmitter failure Bad transceiver module Excessive vibration Turbine is not rotating Re install cable and tighten locking set screw Replace fiber optic transmitter Replace transceiver module a Check bell cup for damage b Check bell cup for excessive paint build up Insure bell cup is tightened properly d Check cup and shaft tapers for cleanliness Verify rotation of turbine the paint valve air pilot must be interlocked with the turbine speed feed back signal to ensure that paint does not flow into the air bearing Fluid valve does not actuate Clogged fluid tube fluid tip Bad transceiver module a Verify that air pilot signal is present b Fluid valve air pilot pressure is too low Increase air pressure to 70 psig minimum c Replace fluid valve Remove and inspect fluid tube or fluid tip Replace transceiver module Clogged restrictor orifice Fluid valve open Fluid valve seat damaged or worn Insufficient back pressure to fluid regulator Fluid regulator does not control flow system Remove appropriate microvalve and seat
17. PRESSURE NO LOAD 50 330 310 290 40 270 250 lt 230 6 30 x 210 iii 3 190 oi 170 2 AM 150 9 E 130 E lt 110 9 lt 10 70 50 30 0 10 0 10 20 30 40 50 60 70 80 TURBINE SPEED k RPM TURBINE SPEED VS AIR CONSUMPTION NOLOAD 450 400 350 es 300 OQ 250 3 L 200 2 2 150 100 mx lt lt 50 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 TURBINE SPEED k RPM LN 9276 14 1 11 Ransburg RMA 590 Introduction TURBINE SPEED vs AIR CONSUNPTION LOAD 800cc Water di 24 1 22 7 Ge 21 2 GE j l 1198 e a 183 9 550 16 9 S 90 154 6 E 450 140 E 400 125 E 8 300 I 9 6 O o o 250 82 m lt 200 67 lt 150 5 3 100 3 8 50 24 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 TURBINE SPEED k RPM TURBINE SPEED vs PRESSURE LOAD 800cc Water 100 690 650 90 610 80 570 530 7 4900 lt 450 Xx 50 410 oc 30 5 2 x aan 9 x 250 E 30 210 170 20 130 10 d 50 0 3 TT T TTT rrr PTT TTTTTTTTT TEE 10 LN 9276 14 1 0 10 45 20 25 30 35 40 45 50 55 60 65 70 75 80
18. See Circuit Diagram in the Introduction tion Thefluid valves inthe RMA 590 are actuated by an air signal The air pressure must be greater than 70 psi 482 6 kPa to assure proper actuation of the valve Applying air to the valve actuator turns on the fluid or air for that valve The paint trigger valve controls the paint flow to the bell When actuated paint flows through the valve to the fluid tube and into the rear of the bell cup The bell cup must be spinning at least 30 000 rpm when fluid is turned on to enable the fluid to flow through the bell paint passage and be atomized The dump valve controls the paintflow through the dump line When actuated paint flow is directed to the dump return line This provides a method of rapidly removing paint from the incoming line for cleaning and or color change Normally the dump valve is not actuated at the same time as the paint trigger valve since the trigger valve is intended to cause the fluid to flow to the bell at the prescribed input pressure During spraying a separate air line supplies con stant flow of air to the dump line to keep it dry The air supply line is protected by a check valve to prevent reverse flow The solvent valve controls the flow of cup wash solvent When actuated solvent flows through a separate fluid tube passage and into the bell cup This provides cleaning of the inside of the bell cup The outside of the cup is simultaneously cleaned by
19. mally a high voltage setting of 70 100 kV is appropriate for most applications Poorgrounding of parts being coated Verify that parts being coated are properly grounded the electrical resistance between the part and ground must not exceed 1 megohm Excessive turbine speed Excessive inner outer shaping air For optimum transfer efficiency and spray pattern control the bell rotational speed should be set at the minimum required to achieve proper atomization of the coating material Shaping air should be set at the minimum air volume required to gently direct the spray pattern toward the part being coated Excessive shaping air will cause some atomized particles to blow by the part or bounce back onto the atomizer Excessive target distance Turbine drive air not present The recommended target distance is be tween 6 12 inches 152 4 304 8 Nm see Target Distance in the Operation section of this manual Verify supply air pressure Bearing air return signal not present a Verify bearing air return signal b Increase bearing air supply pressure to 90 psig 10 psig 620 5 68 9 kPa Brake air is activated Remove brake air signal turbine air and brake air must be interlocked to prevent both from being used simultaneously 53 Ransburg RMA 590 Maintenance TROUBLESHOOTING GUIDE DIRECT CHARGE Cont General Problem Speed Feedback Fault No Fluid Flow
20. output voltage measured at the bell will normally range between 9190 and 9790 of the kV set point displayed at the control unit Typical setting for spraying is 70 kV LN 9276 14 1 RMA 590 Maintenance ELECTRODE RESISTANCE TEST To verify that all indirect charge electrodes are functioning place one lead of a Yokogama meg ohm meter or equivalent to the metal contact at the base of the electrode and the other end to the small metal wire at the tip of the electrode Refer to the Electrode Assembly Resistance Reading chart for the proper resistance reading for the electrode assembly MEGLIHM METER ELECTRODE ASSEMBLY RESISTANCE READING Resistance Reading Used At Locations Megohms 209 231 Sea Level 129 151 Above 5 000 ft If readings fall out of this range disassemble elec trode assembly and check reading of resistor only If reading is in the acceptable range discard the electrode body A11342 00 and replace with a new one Rebuild electrode assembly as follows apply a small amount of dielectric grease to each end of the resistor slide resistor into the electrode body A11342 00 Install the contact assembly after the resistor Finally apply a small amount of dielectric grease to contact area of plunger contact assembly Thread plunger contact assembly into electrode body by hand until it stops Hand tight is good enough Over tightening will damage the electrode body see Disassembly Assembly Elect
21. reducing the voltage should be a last resort To cor rect the problem lead and lag trigger adjustments should be optimized first gt The electrostatic voltage applied to the RMA 590 will affect pattern size transfer efficiency wrap and penetration into cavity areas CUP WASH It is recommended for water based material that heated solvent be recirculated at the rear input of the atomizer 140 F 60 C Typical wash solvent is di water and amine 8 10 solution TARGET DISTANCE The distance between the RMA 590 atomizer and the target will affect the finish quality and efficiency Closer distances give a smaller pat tern wetter finish and greater efficiency Greater distance will provide a large pattern size and drier finish The MicroPak control circuit will enable the applicator bell to be operated to within a few inches of the target without adjusting the voltage setting The recommended target distance is 6 to 12 inches 152 4 304 8mm In general allow 1 inch 25 4mm target distance for every 10kV GENERAL OPERATING SEQUENCE WARNING gt t is recommended to leave bearing air on unless the applicator is being serviced or removed for service LN 9276 14 1 590 Operation Normally for painting application the process sequence should always be Bearing air on Always On Turbine air on Turbine speed to application speed Shaping air on Start fluid flow off part Vol
22. with petroleum jelly Valve seat assembly Using valve seat removal tool a10756 00 insert the small hex end into the female hex of the seat assembly Using a 3 8 10mm socket end wrench or adjustable wrench remove the seat by turning counter clockwise NOTE gt Seat should not be replaced unless there are indications of valve leakage during operation LN 9276 14 1 RMA 590 Maintenance 67 Ransburg Carefully start the seat assembly by hand It may be easily cross threaded Tighten fully by hand Final torque to 15 20 Ibs in 1 7 2 3 Nm Tighten Hand tighten valve until seated tighten fully to 15 20 Ibs in 1 7 2 3Nm torque after valve is down LN 9276 14 1 RMA 590 Maintenance To remove To remove external cup wash tube insert the 2 pins of the tool into the holes of the fitting and remove by turning counter clockwise Pull the fitting out to expose the interior fitting and tubing O Ring Remove the interior fitting in a counter clockwise direction Note the direction of the ferrule for re assembly purposes To re install slide fitting and ferrule over tubing as shown Make sure o ring is in its seat in the atomizer body Tighten fitting into exterior fitting tightly until an audible clicking is heard Tighten exterior fitting into atomizer body until tight Exterior fitting must be flush with atomizer body face 68 Ransburg
23. 10 32 x 3 8 Nylon 2 4 A13738 32C Screw 5 16 18 x 1 Nylon 4 6 A11252 01 Tubing cup wash 50 ft 20 meters A11305 00 Lower Ferrule Solvent 3 5 A11276 00 Fitting Solvent 3 5 78450 00 Fluid Coil 1 2 A13144 00 Rubber Cover 1 2 78803 00 Fitting 0 1 77516 04 Collet 4mm or 5 32 O D Tube 77762 04 Collet 8mm or 5 16 O D Tube 1 2 77516 01 Collet 1 4 O D Tube SSF 2052 Set Screw LSFI0022 05 Fitting 8mm or 5 16 O D Tube 79001 01 O ring Solvent Proof 79001 03 O ring Solvent Proof 79001 04 O ring Solvent Proof 79001 05 O ring Solvent Proof 79001 06 O ring Solvent Proof 79001 08 O ring Solvent Proof 79001 13 O ring Solvent Proof 79001 15 O ring Solvent Proof 79001 22 O ring Solvent Proof 79001 23 O ring Solvent Proof 79001 30 O ring Solvent Proof 79001 34 O ring Solvent Proof 79001 38 O ring Solvent Proof 79001 40 O ring Solvent Proof 79001 41 O ring Solvent Proof 79001 42 O ring Solvent Proof 79001 44 O ring Solvent Proof 79001 45 O ring Solvent Proof LSORO0005 14 O ring Encapsulated Customer must verify correct part number when re ordering LN 9276 14 1 86 Ransburg RMA 590 Parts Identification ATOMIZER RECOMMENDED SPARE PARTS Cont Select Option Below Fluid Tip Size A11240 01 028 A11240 02 9mm 035 A11240 03 1
24. 1mm 043 A11240 04 1 2mm 047 A11240 06 1 mm 0399 0 1 Select Option Below Electrode Assembly A11343 02 Electrode Assembly 220 Megohm A11342 00 Electrode Body Assembly Resistor Select Option Below Bell Cup Assembly WISplash Plate A13114 00 55mm Serrated Titanium TISF A13114 01 55mm Non Serrated Titanium TIF A12900 00 65mm Titanium Serrated TISF A12900 01 65mm Titanium Non Serrated TIF A12900 02 65mm Titanium Serrated W Long Life Splash Plate TISF A12900 03 65mm Titanium Non Serrated W Long Life Splash Plate A12900 04 65mm Aluminum Serrated W Plastic Splash Plate A12900 05 65mm Aluminum Non Serrated WI ong Life Splash Plate A12900 06 65MM Aluminum Serrated Plastic Splash Plate Black Coated Bell Cup ALCSCF A12900 07 65MM Aluminum Non Serrated Plastic Splash Plate Black Coated Bell Cup ALCF Select Option Below Bell Cup Only A12886 00 65mm Titanium Serrated TISF A12886 01 65mm Titanium Non Serrated TIF A12886 02 65mm Aluminum Serrated ALS A12886 03 65mm Aluminum Non Serrated ALF A13541 00 65mm Aluminum Serrated Black Coated ALSCF A1541 00 65mm Aluminum Non Serrated Black Coated ALCF A13113 00 55mm Titanium Serrated TISF A13113 01 55mm Titanium Non Serrated TIF Select Option Below Splash Plate A11269 00 For 55mm Bell Cups White Color A12071 00 For 65mm Bell Cups Black Color For 65mm Bell Cups Long Life Titanium top Select Option Below Shaping Air Kit A12874 05 65mm Mono Flex St
25. 2 gt APPLY 59915 01 THREAD TAPE 2 WRAPS 1 USE A LIGHT COATING OF A11545 PETROLATUM JELL ON ALL O RINGS O NM o O LN 9276 14 1 82 Ransburg RMA 590 Parts Identification A13125 00 SOLVENT BLOCK ASSEMBLY 13133 00 SOLVENT BLOCK 2 77367 00 ASSEMBLY 2 78949 00 VALVE ASSEMBLY NON REPAIRABLE 6 77516 04 4 10 79001 30 O RING SOLVENT PROOF b TORQUE TO 15 20 LBS IN AFTER VALVE IS DOWN 1 7 2 3 Nm 2 TORQUE TO 15 20 5 1 7 2 3 Nm 1 USE A11545 00 PETROLATUM JELL ON ALL O RINGS LN 9276 14 1 83 Ransburg SHAPING AIR KIT ASSEMBLY PARTS BREAK DOWN A12874 05 Description Direct Charge Mono Flex A12068 01 A12083 01 RMA 590 Parts Identification A12078 01 A12874 06 Direct Charge with Repulsion Ring Mono Flex A12068 02 A12083 01 A12078 01 A11945 01 A12874 07 A12874 08 Indirect Charge Mono Flex Direct Charge Dual Flex A12068 03 A12074 01 A12083 02 A12084 01 A12871 01 A12078 02 A12066 01 A12874 09 Direct Charge with Repulsion Ring Dual Flex A12074 02 A12084 01 A12871 01 A12066 01 A11945 02 A12874 10 Indirect Charge Dual Flex A12074 03 A12084 02 A12872 02 A12066 02 A12874 11 Indirect Charge Dual Flex TFE A12932 00 A12084 02 A12871 02 A12066 02
26. Gravity and Envelope Dimensions 65mm Dual Flex figure in the Introduction section Approximate Weight Atomizer with Indirect Charge Ring and Probes attached Atomizer without Indirect Charge Ring and Probes attached 23 85 lbs 10 82 Kg max 16 6 Ibs 7 53 Kg Turbine Type Air Bearing Impulse Drive Turbine Air Supply Variable See Pressure Flow Data Charts in the Introduction section Maximum Minimum Turbine Speed Continuous 100K rpm max 20K rpm min See exception at Fluid Flow Rate Maximum Angular Velocity for Turbine Robot Motion 250 sec Tubing Bundle Max Rotation 450 in Either Direction Bearing Air Supply at Applicator Nominal 90 psig 10 psi 621 kPa 69 kPa 2 9 SCFM 82 slpm Shaping Air 1 SAI Supply Variable See Pressure Flow Data Charts in the Introduction section Shaping Air 2 SAO Supply Variable See Pressure Flow Data Charts in the Introduction section Brake Air Supply Nominal 60 100 psig 414 689 kPa Maximum Fluid Pressure Supply Paint 200 psi 1379 kPa Solvent 150 psi 1035 kPa Fluid Flow Rate 25 1000 cc min See exclusion below 55mm Bell Cup Max Flow Rate 500 cc min at 80 000 rpm Max Flow Rate 800 cc min at 70 000 rpm 65mm Bell Cup Max Flow Rate 200 cc min at 100 000 rpm Max Flow Rate 500 cc min at 80 000 rpm Max Flow Rate 800 cc min at 70 000 rpm M
27. O D TUBE X 1 4 NPT M STRAIGHT ADAPTER AIR FITTING SWIVEL ELBOW 5 32 O D TUBE X 1 4 NPT M OUTLET FITTING 1 2 O D TUBE X 1 2 NPT M STAINLESS STEEL OUTLET FITTING 12mm O D TUBE X 1 2 NPT M STAINLESS STEEL VOLUME BOOSTER AIR FILTER amp NIPPLE INCLUDED A13230 XX SERVICE LITERATURE PROVIDED BY OTHER ALL UNITS REPLACEMENT PARTS SERVICE NOTE HEATING ELEMENT USE A13432 01 FOR A13230 01 AND A13230 03 115V UNITS A13432 02 FOR A13230 02 AND A13230 04 230V UNITS AIR FILTER ELEMENT USE A13232 00 THERMOMETER USE A13431 00 LN 9276 14 1 27 79253 02 7 A13433 00 51 13 07 Ransburg RMA 590 Installation AIR FILTRATION REQUIREMENTS WHEN USED WITH A11065 05 AIR HEATER OR NO AIR HEATER AR Description Specifications ReplacementElementPartNo HAF 503 HAF 15 Element One Pre filter removes coarse amounts of oil mois ture and dirt Used upstream of HAF 508 pre filter used in systems with poor air quality HAF 508 Pre filter coalescing type 136 SCFM 98 5 ef ficiency particulate removal 3 to 6 micron max aerosol passed 1 0 micron max solid passed 4 micron dependent upon SCFM requirement per applicator one HAF 508 can be used with up to three applicators HAF 38 Elements Carton of 4 RPM 418 RPM 33 Elements Carton of 8 Bearing air filter coalescing type 19 SCFM 99 995 efficiency particulate removal 3 to 6 micron max passed 6 micron max solid pa
28. To ensure proper sealing and holding the fittings require that the ends of the fluid coils have a groove cut into them as shown Use groove cut ter A11567 00 by sliding the end of the tool over the tubing until it bottoms out Hold the tubing in one hand and the tool in the other Make three complete revolutions of the tool on the tubing in the direction of the arrow stamped on the tool To remove the tool hold the tube and the main body of the tool with one hand slide the rear portion of the tool back until it stops Pull out the tubing from the end of the tool By pulling back the rear LN 9276 14 1 portion of the tool it relleves the pressure of the cutting edge off of the tubing before sliding it out Trim off ends to dimensions shown End should be cut off square 1 8 E 1 8 GROOVE REAR GROOVE FLUID MANIFOLD END PLATE END 77517 00 AND 78450 00 80 Ransburg B BALANCED BELL CUP PART NUMBER OF CUP ONLY PART REVISION STATUS Bell Cup Part Number Serial Number TYPICAL BELL CUP PARTS BREAKDOWN Complete Cup Only Splash Plate A12900 00 65MM TITANIUM SERRATED TISF RMA 590 Parts Identification Bell Cup Parts Breakdown A12886 00 A12071 00 BLACK COLOR A12900 01 65MM TITANIUM NON SERRATED TIF A12886 01 A12071 00 BLACK COLOR A12900 02 65MM TITANIUM SERRATED LONG LIFE SPLASH PLATE TISF A12886 00 A13004 00 TITANIUM TOP A12900 03 65M
29. VISIBLE WEAR NEAR SPLASH PLATE OUTER EDGE SLIGHT SHALLOW GROOVES Photo 1 LATERAL LINES OR GROOVES Photo 2 44 Ransburg RMA 590 Maintenance BELL CUP CLEANING Rp DER Always verify that high voltage is OFF and that the atomizer bell is spinning before performing any type of color change or bell flush cleaning cycle To reduce the risk of fire or explosion the sol vents used for exterior cleaning must have flash points above 100 F 37 8 C Since electrostat ic equipment is involved these solvents should also be non polar i WORN OR BAD CONDITION N A Solvents used for equipment flushing should sss Cp S CAN E IEEE P SSS TO A LIGHT AND YOU CAN LOOK ACROSS have flash points equal to or higher than those Si WITHOUT INTERRUPTION SPLASH PLATE MUST of the coating material being sprayed AND REAR SURFACE ON TOP HALF OF ASSEMBLY 1 The atomizer bell will normally be fully cleaned during a bell flush cycle Flushing should be done before any down time or break in production A bell flush cycle may also be required while spraying batch parts of the same color Verify that high voltage is in off and that the atomizer bell is spinning before flushing through the bell NS NORMAL OR GOOD CONDITION SS K Ny A NORMAL TIP OR CUSP IF WHEN HELD UP TO A LIGHT AND YOU CAN NOT LOOK ACROSS WITHOUT INTERRUPTION SPLASH PLATE IS GOOD 2 sss
30. a nozzle mounted on the shaping air ring and shroud The solvent valve should never be triggered at the same time as the paint trigger valve to prevent solvent from flowing backward into the paint line To color change the applicator a solvent air chop must be provided through the main paint line see Typical Installation RMA 590 in the Installation section WARNING gt Never perform the interiorlexterior cup clean process with high voltage on LN 9276 14 1 RMA 590 Operation gt The normal fluid flow range is 25 1000 cc min During a color change or when flushing the system high flow rates may be required However the maximum flow rate through the bell cup must not exceed 1000 cc min to avoid solvent or paint from flooding into the internal portion of the air bearing motor assembly or front shroud High voltage must be interlocked with the solvent valve to prevent solvent spraying while high voltage is on TURBINE SPEED Turbine speed is determined by the input air pressure flow at the rear of the atomizer Turbine speed is intended to be closed loop controlled using the fiber optic speed transmitter located on the turbine manifold A speed input to a remote speed controller such as the Serial Atomizer Module is required See Speed and Pressure charts in the Introduction section NOTE gt The bell rotational speed determines the quality of atomization and can be varied for variou
31. atomizer s mounting manifold The fiber optic cable comes pre assembled with connectors that are secured in place by set screws tightened from the side of the robot plate Set screws should be tightened 15 20 Ibs in 1 7 2 2 Nm Maximum amount of splices for any length of cable is 3 including the mounting manifold and transceiver card The speed detection signal di may be affected if splices are exceeded Length in any combination for the fiber optic is 100 feet FIBER OPTIC CABLE A13393 00 FIBER OPTIC CABLE LOW VOLTAGE CABLE CONNECTION REF Description BRACKET FIBER OPTIC LOW VOLTAGE A13391 00 FIBER OPTIC BULKHEAD CONNECTOR A13537 00 HEX NUT M22 X 1 5 80073 00 LN 9276 14 1 STRAIN RELIEF CABLE GLAND 29 590 Installation TYPICAL INSTALLATION OF RMA 590 Ransburg YAUN 9NDiv38 09 LSAW IHL 154 08 JO WNWINIW v 38 me JHL YAZIWOLY O1 31815504 SV 35012 5 A ania L WIV 3dvHS sss A3UD C UIW 3dVHS wuno os 931712 30 WINS WHOIS INIVd N Y ag WNSIS 955791 INSATOS NIJD TWNDIS 9 18 LNIVd Se P 39ONVHO WNOIS 3551211 uly HSVA E HI NI IV HSVM
32. bell cup interior Internal and external bell wash is quick and efficient Solvent and air valves are located near the rear of the applicator on the robot adapter Less waste to the spray booth with the dump valve located internally next to the feed tube Compact high voltage control system The MicroPak Cascade control takes only 1 4 of the space in a 19 inch Euro rack leaving room for additional control modules Ransburg GENERAL DESCRIPTION Air Bearing Turbine Assembly The air bearing turbine assembly with bell cup is mounted to the atomizer body assembly with a turbine retaining ring Atomizer Body Assembly The atomizer body assembly houses the turbine fluid tube assembly fiber optic transmitter and the fluid valves The assembly incorporates 5 valves to control the fluid delivery to the bell cup to changes colors via dump valves and supply solvent to clean the fluid tube assembly and bell cup The assembly is attached to the mounting manifold with a threaded quick disconnect ring Mounting Manifold Assembly The mounting manifold assembly is attached to the robot adapter with 8 non metallic screws and is the connection point for all the various air and fluid supply tubing Robot Adapter The robot adapter is available in both 60 and 90 configurations These angles allow for more flexibility in robot painting processes The adapter houses the solvent and air valve block to clean the exterior of the
33. by pulling straight out LN 9276 14 1 70 Ransburg Alignment pin and hole To mountthe applicator to the robot adapter align the locating pin ofthe robot mounting adapter with the hole ofthe robot adapter Install the 6 screws and tighten to 15 Ibs in 1 7 Nm torque Using the valve removal tool A11922 00 engage the 4 pins an the tool with the 4 hole on the top ofthe valve body Using a 1 2 13mm socket end wrench or adjustable wrench remove by turning counter clockwise LN 9276 14 1 RMA 590 Maintenance To remove the valve seat assembly use the valve seat removal tool A10756 00 insert the small hex end into the female hex of the seat assem bly Using a 3 8 10mm socket end wrench or adjustable wrench remove the seat by turning counter clockwise NOTE gt Seat should not be replaced unless there are indications of valve leakage during operation See re assembly of the valve seat and valve as sembly in prior sections with the applicator body To remove the cup wash block from the robot adapter remove the 4 screws using a 5 32 4mm hex key wrench 71 Ransburg RMA 590 Maintenance Cup wash block removed Remove the o ring by using a non metallic pick 2 O rings 1 O ring Toreplace any collets use aflatblade screwdriver to pry collet from the pocket NOTE gt There are 2 o rings in the holes la beled air icw and sol In holes
34. has stopped spinning The bearing air and shaping air should remain ON 5 Clean all external surfaces of the applicator using a lint free rag dampened with solvent 6 After cleaning all conductive residue must be removed using a non conductive solvent Since electrostatic equipment is involved these solvents should also be non polar Naphtha 7 Inspect bell cup for nicks dents heavy scratches or excessive wear Replace if necessary 8 Check bell cup tightness Tighten to 50 70 Ibs in 5 65 7 91 Nm torque 9 Check the amount of paint build up on the outer protective cloth covers if used If excessive replace covers as required If cloths are wet find source and replace with dry cloth covers Ransburg WARNING gt The high voltage must be turned OFF be fore entering the spray area and performing any maintenance procedures Spray booth exhaust fan s should remain ON while cleaning the equipment with solvents gt Make sure high voltage is OFF before approaching applicator with solvent cloth gt DO NOT use reclaim solvent containing d Limonene This can cause damage to certain plastic components gt DO NOT stop bell rotation by using rag or gloved hand against the bell cup edge Maximum flow rate should not exceed 1000 cc min gt Daily removal and soaking of the bell cup may not be required if the bell cup is properly flushed However the frequency of the feed tube and internal
35. installed and maintained in accordance with Ransburg service manual instructions 4 Costofrepair replacement and return transportation from Ransburg of merchandise determined not to be defective 92 Ransburg RMA 590 Manual Changes MANUAL CHANGE SUMMARY This manual was published to supersede Service Manual LN 9276 14 RMA 590 to make the following changes gt F O N ZS LN 9276 14 1 Revise version number to 1 all pages Change krpm under features Page 6 Add new bullet point to features Page 6 Delete copy and add new copy Page 7 Update Output Voltage copy Page 8 Update the Turbine Speed rpm s Page 8 Add new lluid flow rates Page 8 Change part numbers in column E Page 26 Update Part numbers in table 2 items 6 and 7 Page 26 Add torque to copy Page 29 Correct rpm s in WARNING 9 Page 31 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Change cc min to 1000 in CAUTION Page 33 Change table name Page 35 Remove sample copy and table Page 36 Remove Sample Configurations copy and table Page 36 Change cc min to 1000 in CAUTION Page 41 Change cc min to 1000 in CAUTION Page 43 Update part numbers in Table C and D Page 75 Update some part numbers in PARTS LIST Page 79 Update some part numbers in PARTS LIST Page 80 Change table part number Page 82 Update part numbers in table head and item 1 Page 83 Upda
36. palm section cut out NOTE REFER TO NFPA 33 OR SPECIFIC COUNTRY SAFETY CODES REGARDING PROPER OPERATOR GROUNDING All electrically conductive objects in the spray area with the exception of those objects re quired by the process to be at high voltage must be grounded Grounded conductive flooring must be provided in the spray area Always turn off the power supply prior to flush ing cleaning or working on spray system equip ment Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class or Il Division 1 or 2 haz ardous areas in accordance with NFPA 33 Ransburg AREA Tells where hazards may occur Electrical Equipment Substances LN 9276 14 1 HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized in the process Arcing in the vicinity of flammable combustible materials may oc cur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correc tion An electrical arc can ignite coat ing materials and cause a fire or explosion Certain material may be harmful if inhaled or if there is contact with the skin Exp
37. this shaping air configuration is 75mm 300mm 3 12 inches LN 9276 14 1 590 Operation DUAL FLEX PATTERN SAMPLE Turbine Speed Inner Shape Outer Shape Fluid Flow Pattern Size krpm Air slpm Air slpm cc min mm inches Lm sso o 100 755 50 550 0 100 114 4 5 89 3 5 121 4 75 203 8 248 9 75 254 10 As per the chart above as the outer shape air is increased the pattern increases It should also be noted that when the turbine speed is increased the pattern size will decrease By varying com binations patterns between 75mm and 254mm can be achieved NOTE gt Use only plastic shape air compo nents for indirect charge spraying NOTE gt A minimum of 70 slpm 2 6 SCFM should always be kept flowing in the in ner shaping air passage to keep the face of the applicator clean during manual cleaning breaks 35 Ransburg RMA 590 Operation NOTE gt Use only plastic shape air compo nents for indirect charge spraying NOTE gt A minimum of 70 slpm 2 6 SCFM should always be kept flowing in the in ner shaping air passage to keep the face of the applicator clean during manual SHAPING AIR KIT 2 cleaning breaks A12874 12 Dual Flex Shaping Air Kits 55mm Bell Cups Direct Charge Only A12874 13 Direct Indirect Charge Asthe name implies both shaping air outlets sup ply airthatis counter to the rotation of the bell cup Both sets of shaping air
38. use of this equip ment 590 Safety SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class or 11 Division 1 or 2 hazardous areas in accordance with NFPA 33 Test only in areas free of flammable or combus tible materials The current overload sensitivity if equipped MUST be set as described in the correspond ing section of the equipment manual Protec tion against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power supply shutdown indicates a prob lem in the system which requires correction Always turn the control panel power off prior to flushing cleaning or working on spray system equipment Before turning high voltage on make sure no objects are within the safe sparking distance Ensure that the control panel is interlocked with the ventilation system and conveyor in accor dance with NFPA 33 EN 50176 Have fire extinguishing equipment readily avail able and tested periodically Personnel must be given training in accordance with the requirements of NFPA 33 EN 60079 0 Instructions
39. 001 54 O ring A12253 00 Set Screw Select Option Below Shaping Air Kit A12874 10 65mm Dual Flex Plastic A12074 03 Outer Shroud A12084 02 Shaping Air Ring A12871 02 Inner Shaping Air ring A12066 02 Turbine Retaining Ring 79001 11 O ring 79001 37 O ring 79001 54 O ring A12253 00 Set Screw Select Option Below Shaping Air Kit A12874 11 65mm Dual Flex Plastic TFE A12932 00 Outer Shroud A12084 02 Shaping Air Ring A12871 02 Inner Shaping Air ring A12066 02 Turbine Retaining Ring LN 9276 14 1 88 Ransburg RMA 590 Parts Identification Assembly Tools ASSEMBLY TOOLS A11090 02 INCLUDES ITEMS BELOW 76772 00 Wrench Spanner A12088 00 Wrench Turbine Retaining Ring A11373 00 Tool Tubing Removal A12061 00 Wrench Bell Cup A11229 00 Tool Fluid Tip Tube Removal A11388 00 Tool Splash Plate Removal A11922 00 Tool Valve Removal 78279 00 Tool Fiber Optic A10766 00 Microvalve Seat Removal LSCH 0009 00 Dielectric Grease 88 oz tube Not Shown jo N LN 9276 14 1 89 Ransburg RMA 590 Parts Identification FLOW DIRECTION EJ Li E E 85 f N O Alarm O Low Air Flow O Power On 8888 A
40. 1 Nm BELL CUP PREVENTIVE MAINTENANCE It is the user s responsibility to ensure proper maintenance of the atomizer bell at all times Bell cup failure due to inadequate cleaning or handling will not be covered under the War ranty The DO NOT bullets see Operator Maintenance Warnings in the Maintenance section listed are some examples of improper handling which could adversely affect perfor mance or personnel safety and should not be attempted for any reason LN 9276 14 1 RMA 590 Maintenance Bell Cup Handling Always verify that high voltage is turned off and the atomizer bell has stopped spinning before performing any type of handling maintenance Bell Cup Replacement Bell cup wear is dependent on many factors such as bell speed flow rate and type of coating being applied The bell cups shown in the photos below indicate if a bell cup has some usable life or should be re placed Photo 1 shows a bell cup that has some usable life The grooves worn around the splash plate pins are shallow The general appearance of the cup surface is smooth and uninterrupted Photo 2 shows a bell cup thatneeds to be replaced as well as the splash plate that was installed into the cup The grooves are deep a visible groove exists at the outer edge diameter of the splash plate and there are noticeable lateral grooves extending towards the outer edge of the cup SMOOTH CLEAN UNINTERRUPTED BELL CUP SURFACE LIGHT
41. C GREASE 8 OZ TUBE 76652 01 KIT FOR MEASURING HIGH VOLTAGE INCLUDES MULTI FUNCTION METER 76634 00 AND HIGH VOLTAGE PROBE ASSY 76667 00 76652 02 KIT FOR MEASURING SHORT CIRCUIT CURRENT SCI RESISTANCE AND SPRAY ABILITY INCLUDES MULTI FUNCTION METER 76634 00 AND TEST LEAD ASSY 76664 00 76652 03 76652 04 KIT FOR MEASURING PAINT RESISTIVITY INCLUDES MULTI FUNCTION METER 76634 00 AND PAINT PROBE ASSY 7922 00 DELUXE KIT PERFORMS ALL FUNCTIONS LISTED ABOVE INCLUDES MULTI FUNCTION METER 76634 00 PAINT PROBE ASSY 7922 00 TEST LEAD ASSY 76664 00 AND HIGH VOLTAGE PROBE ASSY 76667 00 A11567 00 LN 9276 14 1 GROOVE TOOL 74 OD TUBE 91 Ransburg RMA 590 Warranty Policy POLICIES LIMITED WARRANTY 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 Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THEUSEOF OTHERTHANRANSBURGAPPROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of pur chase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased a
42. Charts in the Introduction section Sample Mono Flex Shape Air Configurations Patterns sizes based on waterborne basecoat paint target distance 230mm 9 inches 70kV electrostatics applied Results will vary depending onfluid rate material viscosity target distance and with electrostatics applied Typical pattern size achievable with this shaping air configuration is 230mm 860mm 9 34 inches LN 9276 14 1 590 Operation MONO FLEX PATTERN SAMPLE krpm slpm cc min mm inches 60 120 200 660 26 737 29 864 34 279 11 381 15 482 19 228 9 NOTE gt Use only plastic shape air compo nents for indirect charge spraying NOTE gt A minimum of 70 slpm 2 6SCFM should always be kept flowing in the inner shaping air passage to keep the face of the applicator clean during manual clean ing breaks BRAKE AIR Brake air is used to slow the turbine speed in a minimum length of time It is advantageous for short cycle times during color change or may be used to reduce speed or stop the turbine Never operate brake air with the turbine air on ELECTROSTATIC VOLTAGE The RMA 590 Rotary Atomizer receives a low voltage control input from the MicroPak to control the operating electrostatic voltage refer to the current MicroPak manual for detailed for oper ating instructions 37 Ransburg NOTE gt If paint defects occur such as fatty edges or picture framing
43. ER POINT DIMENSIONS SHORT BODY 90 RMA 590 Introduction ADAPTER DIRECT CHARGE 65MM DUAL FLEX 04 50 114 31 8 46 214 8 3 34 8 31 211 0 COG 4 32 109 8 COG 84 8 17 26 438 5 L 4 83 122 8 RMA 590 SHORT BODY 90 ADAPTER DIRECT CHARGE 65MM DUAL FLEX TD Target Distance 6 Inches 152mm 23 26 Inches 590 8mm 122 8mm 8 Inches 203mm 25 26 Inches 641 6mm 4 83 Inches 122 8mm 10 Inches 254mm 4 83 Inches 122 8mm 12 Inches 305mm LN 9276 14 1 29 26 Inches 743 2mm 27 26 Inches 692 4mm 4 83 Inches 122 8mm 19 590 Introduction wolvordv lt HSYM aIv dna aIv AN3ATOS HSVM NIV HSVM d O 1X3 1NI 1359131 HSVM 1X3 1NI dwnd za 204 TINIWd CANIVd M399Tul Zld t3D5T4 L in Tid 705 15 Ws ONS ug WL Sid EI MOD MH f H T LNIVd TANIVd 3399041 N3AIOS W399rHL IN3AOS INI T CIRCUIT SCHEMATIC INDIRECT CHARGE C SNIdVHS MIV IV 3ADIG DNINV38 1 OLO 23814 QN3931 Od Ransburg Zad Tad ld va NLY va Sv 332n033 INNOW AGOA
44. M TITANIUM NON SERRATED LONG LIFE SPLASH PLATE TIF A12886 01 A13004 00 TITANIUM TOP A12900 04 65MMALUMINUM SERRATED PLASTIC SPLASH PLATE ALSF A12886 02 A12071 00 BLACK COLOR A12900 05 65MMALUMINUM NON SERRATED PLASTIC SPLASH PLATE ALF A12886 03 A12071 00 BLACK COLOR A12900 06 65MMALUMINUM SERRATED BLACK COATED PLASTIC SPLASH PLATE ALSCF A13541 00 A12071 00 BLACK COLOR A12900 07 65MMALUMINUM NON SERRATED BLACK COATED PLASTIC SPLASH PLATE ALCF A13541 01 A12071 00 BLACK COLOR A13114 00 55MM TITANIUM SERRATED TISF FOR 55MM DUAL FLEX SHAPE AIR KIT A13113 00 A11269 00 WHITE COLOR A13114 01 LN 9276 14 1 55MM TITANIUM NON SERRATED TIF FOR 55MM DUAL FLEX SHAPE AIR KIT A13113 01 A11269 00 WHITE COLOR 81 Ransburg RMA 590 Parts Identification A13196 00 MOUNTING MANIFOLD ASSEMBLY Dwm ay J Desr 2 1 A13102 01 MOUNTING MANIFOLD 12 1 78803 00 FITTING MODIFIED 33 3 79001 06 O RING SOLVENT PROOF 79001 30 O RING SOLVENT PROOF 77516 04 COLLET 4 MM 77762 04 8 77516 01 COLLET 79001 23 O RING SOLVENT PROOF 79001 13 O RING SOLVENT PROOF 79001 05 O RING SOLVENT PROOF 79001 04 O RING SOLVENT PROOF 49 e oni progr 51 79001 15 O RING SOLVENT PROOF 52 SSF 2052 SET SCREW 3 8 LG X 10 24 75 5 10022 05 FITTING 77 79001 34 O RING SOLVENT PROOF
45. OW3u 20 LN 9276 14 1 590 Introduction Ransburg CIRCUIT SCHEMATIC DIRECT CHARGE AGO8 OLNI DNI 39V L10A HOIH Oi GNS AH Zad z S CivanivN uly dna aim Ei O E C a SES 20 Wb ZE S JOVIS 8395131 dwn Z 1NIVd 24 WW 91 6 1NIVd Pane Zld NOTAN WW ZE S WUNLWN gt 1VN IS 2 1NIVd o JI ng dU MA E WOLVOTIddV WW 2 6 SATIS TVN IS 399191 AWN LNIVd VW iis ERN 011 ib HSVA dno L Toun M Tid z S TWNOIS DEI LINIYA 15 NOTAN ZE S 308 W359hLL LN3ATOS WW 91 5 ama 33VHS YANNI HSVM dnd 1103 NOI TWNUALNI ovs NOTAN Tei 91 S AY gie 3dVHS xag NOTAN tff DIU YIZIWOLY OL 3181SSOd SV 35019 suiaonaaw LNNOW vL WW 91 5 NLY V8 Mte CE S MOTA uly va WIV SNTiV38 0 wiv os 3718v2 2140 UIA I ri UAO9TUL die HSYM dN DG INI MOL ze s ee 1N3ATOS ONIGNL z S a i MH ONTANL WW ZE S Z INIVd zd v Z1NIVd ae
46. PPLY THREAD SEALANTTO NOTHREAD SEALANT ON 8888 FITTING AT THIS LOCATION FITTINGS ALLOWED AFTER Sous FILTERS OFF P 2 Ransburg APPLY THREAD SEALANT TO 27 FITTING AT THIS LOCATION A13230 XX Air Heater and Filter Combination A12247 00 Bell Cup Tool amp FILTER amp HEATER ASSEMBLY A13230 XX see 0 A13230 01 115 V 13A METRIC FITTINGS A13434 01 A13426 00 A13429 00 A13726 00 A13230 02 230 V 6 5A METRIC FITTINGS A13434 02 A13426 00 A13429 00 A13726 00 A13230 03 115 V 13A FRACTIONAL FITTINGS A13434 01 SSP 6439 A13428 00 A13727 00 A13230 04 230 V 6 5A FRACTIONAL FITTINGS A13434 02 SSP 6439 A13428 00 A13727 00 A13230 XX AIR HEATER AND FILTER COMBINATION EE E LL A ARBEOCK T Z f 2 13427 00 INLET FITTING 3 8 NPS M X 1 2 NPT M BEARING AIR FEED SWIVEL ELBOW 1 4 O D TUBE X 1 4 NPT M BEARING AIR FEED 6mm O D TUBE X 1 4 NPT M STRAIGHT ADAPTER AIR FITTING SWIVEL ELBOW 5 32 O D TUBE X 1 4 NPT M OUTLET FITTING 1 2 O D TUBE X 1 2 NPT M STAINLESS STEEL OUTLET FITTING 12mm O D TUBE X 1 2 NPT M STAINLESS STEEL E VOLUME BOOSTER A13433 00 AIR FILTER amp NIPPLE INCLUDED 51 13 07 A13230 XX SERVICE LITERATURE PROVIDED BY OTHER ALL UNITS REPLACEMENT PARTS SERVICE NOTE HEATING ELEMENT USE A13432 01 FOR A13230 01 AND A13230 03 115V UNIT
47. S A13432 02 FOR A13230 02 AND A13230 04 230V UNITS AIR FILTER ELEMENT USE A13232 00 THERMOMETER USE A13431 00 79253 02 LN 9276 14 1 90 Ransburg RMA 590 Parts Identification SERVICE KITS HAF 15 Pre Filter Replacement Element See below for qty amp where used HAF 38 Pre Filter Replacement Element See below for qty amp where used RPM 33 Bearing Air Filter Element See below for qty amp where used A12247 00 Bell Cup Removal Tool A11570 01 Reducing Straight Connector Push To Connect 6mm OD Tube To 4mm OD Tube A11570 02 Reducing Straight Connector Push To Connect 8mm OD Tube To 4mm OD Tube A11570 03 A11570 04 Reducing Straight Connector Push To Connect 8mm OD Tube To 6mm OD Tube Reducing Straight Connector Push To Connect 10mm OD Tube To 4mm OD Tube A11570 05 Reducing Straight Connector Push To Connect 10mm OD To 6mm OD Tube A11570 06 Reducing Straight Connector Push To Connect 10mm OD To 8mm OD Tube A11570 07 Reducing Straight Connector Push To Connect 12mm OD To 8mm OD Tube A11570 08 Reducing Straight Connector Push To Connect 12mm OD To 10mm OD Tube LUBRICANTS AND SEALERS A11545 00 PETROLATUM JELL LUBRICANT FOR ALL O RINGS AIR FILTER REPLACEMENT Ransburg Part Qty Elements Per Carton UsedOn 1 HAF 503 4 HAF 508 8 RPM 418 ACCESSORIES LSCH0009 00 DIELECTRI
48. S STEEL A12874 09 65MM DUAL FLEX DIRECT CHARGE STAINLESS STEEL REPULSION RING A12874 10 65MM DUAL FLEX INDIRECT CHARGE PLASTIC A12874 11 65MM DUAL FLEX INDIRECT CHARGE TFE SHROUD 08 A12874 12 55MM DUAL FLEX DIRECT CHARGE STAINLESS STEEL 09 A12874 13 55MM DUAL FLEX INDIRECT CHARGE PLASTIC TABLE C ROBOT ADAPTER 00 NONE NONE NONE 01 A13126 00 A13120 00 60 DEGREE ADAPTER 02 A13146 00 A13147 00 90 DEGREE ADAPTER TABLE D ROBOT ADAPTER PLATE 00 NONE NONE 13127 00 FANUC P200 SERIES TABLE E SPINDLE ASSEMBLY e n 12895 01 SPINDLE ASSEMBLY SILVER SHAFT 01 12895 04 SPINDLE ASSEMBLY BLACK LN 9276 14 1 75 Ransburg RMA 590 Parts Identification TABLE F FLUID TIPS se 01 A11240 01 028 7MM OPENING 035 9MM OPENING 03 A11240 03 043 1 1MM OPENING 04 A11240 04 047 1 2MM OPENING 05 A11240 05 062 1 6MM OPENING 06 A11240 06 039 1 0MM OPENING TIP ORIFICE SIZE Fluid Tip Selection TABLE G ELECTRODE ASSEMBLY me wem am prom pea arar arr 00 NONE NONE NONE NONE NONE NONE NONE NONE 01 A11343 02 220 OHMS FOR USE AT SEA LEVEL CONDITIONS 1 1 1 1 8 8 A11343 03 140 MEG OHMS FOR USE ABOVE 5000 FT SEA LEVEL CONDITIONS 1 1 1 1 TABLE H TOOL KIT 00 0 NONE 01 1 TOOL KIT AND CHECK VALVE TOOL LN 9276 14 1 76 Ransburg RMA 590 Parts Identific
49. SCFM while performing a cup flush Voltage On The voltage is turned on from a signal to the MicroPak The lag time to full voltage may be reduced if a setback voltage is used Recommended setback voltage is between 30 kV and 50 kV Trigger Fluid An air signal is sent through the PT line of the tubing bundle This should occur when the target is 6 12 inch es 152 4 304 8mm from the applicator centerline Not to be confused with target distance Voltage Off Setback Voltage Immediately precedes the trigger off Using a setback voltage shortens the cascade voltage ramp up time Fluid Trigger Off This should occur when the target is typically 0 6 inches 0 152 4mm past the applicator centerline Shaping Air to Setback The setback flow of air should never be below 70 slpm 2 6 SCFM for the shape air Color Change Sequence Used when col or is changed one to the other Typical se quence is shown in Typical Color Change Sequence figure in the Operation section NOTE gt During this sequence the applica tor should be moved to a position to collect the waste material The sequence shown is a starting point for processing but the final sequence will de pend on the material being sprayed and the solvent used to purge the applicator with 39 Ransburg MAINTENANCE O RINGS All O rings in this atomizer are solvent proof except those on the air bearing spindle These O rings must n
50. SERVICE MANUAL LN 9276 14 1 Ransburg JUNE 2014 590 ROBOT MOUNTED ROTARY ATOMIZER o p MODEL A13368 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 50 00 U S Ransburg RMA 590 NOTE This manual has been changed from revision LN 9276 14 to revision LN 9276 14 1 Reasons for this change are noted under Manual Change Summary on page 93 of this manual LN 9276 14 1 Ransburg RMA 590 Contents CONTENTS PAGE SAFETY 1 5 SAFE TY PRECAUTIONS eege 1 el RE ERT 2 5 APPLICATOR DESCRIPTION EE 6 e SUE 6 GENERAL DESCRIPTION E 7 SPEGIFICATIONS EE 8 9 IMPORTANT NUMBERS eer 10 EI SE e 11 15 TOOL CENTER POINT DIMENSIONS 5 tien 16 19 TC Ee ER EEN 20 22 AIR FILTER INSTALLATION ET ER EQUIPMENT GROUNDING SAFETY RECOMMENDATIONS eee 24 25 AIR le EE E 25 AIR HEATER AND FILTRATION OPTIONS cari atero 26 A13230 XX AIR HEATER AND FILTER COMBINATION eee 27 28 MOUNTING layanan 28 ELECTRICAL AND FIBER OPTIC CONNECTIONS 29 TYPICALINS
51. VOLTAGE RING ELECTRODES TABLE F FLUID TIPS TABLE E SPINDLE ASSEMBLY TABLE D ROBOT ADAPTER PLATE TABLE C ROBOT ADAPTER TABLE B SHAPING AIR KIT TABLE A BELL CUP ASSEMBLY BASIC PART NUMBER Model number and serial number of the atomizer is located on the face of the robot plate See Important Numbers in the Introduction section TABLE A BELL CUP ASSEMBLY pasna 00 12900 00 65MM TITANIUM TISF A12900 01 65MM TITANIUM NON SERRATED TIF 12900 02 65MM TITANIUM SERRATED LONG SPLASH PLATE TISF A12900 03 65MM TITANIUM NON SERRATED LONG LIFE SPLASH PLATE TIF A12900 04 65MM ALUMINUM SERRATED PLASTIC SPLASH PLATE ALSF A12900 05 65MM ALUMINUM NON SERRATED PLASTIC SPLASH PLATE ALF A12900 06 65MM ALUMINUM SERRATED PLASTIC SPLASH PLATE BLACK COATED BELL CUP ALCSCF A12900 07 65MM ALUMINUM NON SERRATED PLASTIC SPLASH PLATE BLACK COATED BELL CUP ALCF A13114 00 55MM TITANIUM SERRATED TISF 13114 01 55MM TITANIUM NON SERRATED TIF LN 9276 14 1 74 Ransburg RMA 590 Parts Identification TABLE B SHAPING AIR KIT gt se A12874 05 65MM MONO FLEX DIRECT CHARGE STAINLESS STEEL A12874 06 65MM MONO FLEX DIRECT CHARGE STAINLESS STEEL REPULSION RING A12874 07 65MM MONO FLEX INDIRECT CHARGE PLASTIC A12874 08 65MM DUAL FLEX DIRECT CHARGE STAINLES
52. a son the Atomizer and bell cup must be re turned to Ransburg for inspection and eval uation to determine if the bell can be used in operation TURBINE MAINTENANCE DO NOT attempt to rebuild the turbine Any endeavor to disassemble a turbine during the warranty period will void the warranty Contact your authorized distributor or Ransburg for instructions GENERAL PREVENTIVE MAINTENANCE Verify daily that the operating parameters have not varied significantly from the normal A drastic change in high voltage operating current turbine air or shaping air can be an early indicator of potential component failure LN 9276 14 1 RMA 590 Maintenance A laminated poster entitled Rotary Atomizer Checklist 75 02 is included with the assembly in the Literature Kit to be posted near the station as a handy reference Due to the close proximity of high voltage to ground potential a schedule must be developed for equipment maintenance cleanliness PREVENTIVE MAINTENANCE Daily Maintenance During Each Preventive Maintenance Break 1 Verify that high voltage is OFF and that shaping air bearing air and turbine drive air are ON 2 Open the dump valve flushing all paint from the supply lines and valve module 3 Open the solvent valve flushing all paint from the fluid tube and through the atomizer bell assembly 4 Re verify that high voltage is OFF turbine drive air is OFF and that the bell cup
53. aces it contacts This same expansion cooling can occur across the shaping air exit ports This cooling affect can cause surface temperatures to fall below the dew point of the booth which will result in condensa tion on the interior and exterior of the atomizer LN 9276 14 1 RMA 590 Installation machine and its components It is even possible that the temperature of the supply air may be be low the booth dew point even without additional expansion cooling Condensationis especially probable in waterborne applications when booth temperature and relative humidity levels are typically maintained very high This condensation will allow sufficient conductivity of the surfaces such that they act as an erratic ground source potential This can cause damage to the equipment It is therefore a requirement that turbine exhaust air temperature be maintained above the booth dew point to prevent condensation from forming on atomizer surfaces Doing so will eliminate moisture as a potential defect in painted surfaces as well as extending equipment life Thus it is recommended that air heaters be installed into the atomizer air supply lines i e turbine drive air shaping air and seal air The air heaters must be of sufficient capacity capable of raising the incoming air temperature at least 40 F 4 4 C at a flow rate of 60 SCFM per applicator The actual air heater process setting depends on applicator fluid flow rate load booth
54. agged out gt All fluid passages are cleaned purged out and depressurized gt Air turned off NOTE gt Direct Charge and Indirect Charge omizer removal instructions are the same with the exception of removing the high voltage ring LN 9276 14 1 Disassembly the turbine manifold assembly from the mounting manifold assembly by unscrewing the retaining ring counter clockwise Use ofthe span ner wrench to aid in removal may be necessary 58 Ransburg RMA 590 Maintenance 74MM X 4MM O RING 3MM X 1 5MM O RING BEARINGAIR 72MM X 3MM O RING 4MM X 1 5MM O RING BRAKE AIR 46MM X 3MM O RING TURBINE ALIGNMENT MARK TURBINE SERIAL NUMBER AND 6MM X 1 5MM O RING SERVICE KIT NUMBER LOCATION TURBINE AIR A11534 01 O RING KIT CONTAINS ALL 6 O RINGS FOR REPLACEMENT Turbine O Ring Replacement NOTE Remove air bearing turbine from the atomizer gt Turbine assemblies are field repairable Remove all exterior O rings after the initial one year warranty period Lightly lubricate all O rings with A11545 Petro Consult Ransburg representative for latum jell before reinstalling proper manuals and training before at tempting any repairs Any attempt to repair O Ring Kit A11534 00 contains all required the turbine before the one year warranty O rings for replacement period has expired will void the warranty LN 9276 14 1 59 Remove high voltage cable assembly from high voltage ring
55. ainless Steel A12068 01 Outer Shroud A12083 01 Shaping Air Ring A12078 01 Turbine Retaining ring 79001 11 O ring 79001 37 O ring A12253 00 Set Screw Select Option Below Shaping Air Kit A12874 06 65mm Mono Flex Repulsion Ring Stainless Steel A12068 02 Outer Shroud 0 1 A12083 01 Shaping Air ring 0 1 A12078 01 Turbine Retaining Ring 0 1 Customer must verify correct Part number when re ordering a 3 3 3 oo LN 9276 14 1 87 Ransburg RMA 590 Parts Identification BELL CUP RECOMMENDED SPARE PARTS A11945 01 Repulsion Ring L se 2 C C T 79001 11 O ring 79001 37 O ring A12253 00 Set Screw Select Option Below Shaping Air Kit A12874 07 65mm Mono Flex Plastic A12068 03 Shroud 0 1 A12078 02 Turbine Retaining ring 79001 11 O ring 79001 37 O ring A12253 00 Set Screw Select Option Below Shaping Air Kit A12874 08 65mm Dual Flex Stainless Steel A12074 01 Outer Shroud A12084 01 Shaping Air Ring A12871 01 Inner Shaping Air ring A12066 01 Turbine Retaining Ring 79001 11 O ring 79001 37 O ring 79001 54 O ring Select Option Below Shaping Air Kit A12874 09 65mm Dual Flex Repulsion Ring Stainless Steel A12074 02 Outer Shroud A12084 01 Shaping Air Ring A12066 01 Turbine Retaining Ring A12871 01 Inner Shaping Air ring A11945 02 Repulsion Ring 77580 08 Screw 79001 11 O ring 79001 37 O ring 79
56. air all defects IMMEDIATELY 2 Inspect the floor or grates for excessive accumulation of dried coating material or other residue If there is any remove it 24 Ransburg SAFE GROUNDING ISAMATTER OF PROPER EQUIPMENT MAINTENANCE AND INSTAL LATION CORRECT OPERATION AND GOOD HOUSEKEEPING Daily inspection of grounding apparatus and conditions however will help pre venthazards that are cause by normaloperations BE SURE THAT 1 All objects in the spray area are grounded 2 Personnel in the spray area are properly grounded Conductive safety shoes and coveralls 3 Thatthe target object is properly grounded less than 1 megohm resistance 4 Thatthe high voltage is off except during normal application 5 That the high voltage is off and applicators are grounded during maintenance opera tions 6 The spray area is kept free of accumulated coating deposits 7 All combustible liquids in the spray area outside of automatic delivery systems are kept to minimum and are kept in fire safe grounded containers See NFPA 30 and chapter 6 of NFPA 33 8 Proper ventilation is provided 9 Personnel must thoroughly understand the equipment its operation and maintenance and all safety precautions AIR HEATER REQUIREMENTS Turbine drive air expands as it moves through the turbine wheel cavity and as it exits the turbine from the exhaust port This expansion will cause cool ing of the exhaust air and the surf
57. ance The applicator is capable of applying 70 000 VDC for the Indirect charge and up to 100 000 VDC for the Direct charge FEATURES Features which make the RMA 590 advanta geous The ability to apply waterborne and solvent borne coatings with the same applicator without cleaning out the entire system Assembly components and bell made of du rable engineered resin material for optimum mechanical strength and solvent resistance Heavy duty design insures excellent service life even when subjected to the quick mo tions of robotic applications LN 9276 14 1 RMA 590 Introduction Proven long life turbine motor capable of speeds up to 100 krpm See Specifica tions in the Introduction section of this manual for bell cup speed ratings Serrated and non serrated bell cups are available for application flexibility and color match All bell cups are made using Tita nium Aluminum or Coated Aluminim The 55mm bell cup is Titanium only Aerodynamic design for ease of cleaning external surfaces 60 and 90 angled adapters provide more maneuverability and facilitates robotic pro gramming Negligible maintenance down time With the quick disconnect feature an atomizer can be exchanged in less than 2 minutes for off line maintenance Fast color changes are achieved using cen ter feed fluid delivery and the fluid valves provide for simultaneous paint push while solvent washes the feed tube and
58. and rear housing with a soft cloth damp ened with solvent See Warning on avoiding the use of cleaning solvent con taining d Limonene Remove the front shroud and check for any signs of solvent or paint leakage Clean as required as required Remove bell cup and soak in solvent for 1 2 hours Clean with a soft brush as required Remove from cleaning solution and blow dry before replacing With bearing air off carefully inspect the feed tube tip and clean any paint build up 43 Ransburg that has occurred on the feed tube tip Us ing a pen light determine if there is build up of paint in the motor shaft and or around the paint feed tube If so remove the motor assembly following the disassembly proce dures and clean out the inside diameter of the motor shaft using a tube brush and sol vent Clean the outer surfaces of the feed tube NOTE gt may be necessary to remove bell cups for cleaning more frequently than weekly See Note under Daily Mainte nance in the Maintenance section Visually inspect for signs of fluid leaks around fluid connections and manifold Correct problem and clean paint from all components including internal portion of shroud Reinstall bell cup and front shroud replace cover on the outer housing Refer to Dis assembly Procedures in the Maintenance section for definite instructions e Recheck bell cup tightness Torque to 50 70 Ibsein 5 65 7 9
59. and safety precautions must be read and understood prior to using this equip ment Comply with appropriate local state and na tional codes governing ventilation fire protec tion operation maintenance and housekeep ing Reference OSHA NFPA 33 EN Norms and your insurance company requirements Ransburg AREA Tells where hazards may occur Spray Area High Voltage Equipment LN 9276 14 1 HAZARD Tells what the hazard is Electrical Discharge There is a high voltage device that can induce an electrical charge on ungrounded objects which is capable of igniting coating materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion RMA 590 Safety SAFEGUARDS Tells how to avoid the hazard Parts being sprayed and operators in the spray area must be properly grounded Parts being sprayed must be supported on con veyors or hangers that are properly ground ed The resistance between the part and earth ground must not exceed 1 meg ohm Refer to NFPA 33 Operators must be grounded Rubber soled in sulating shoes should not be worn Grounding straps on wrists or legs may be used to assure adequate ground contact Operators must not be wearing or carrying any ungrounded metal objects When using an electrostatic handgun operators must assure contact with the handle of the ap plicator via conductive gloves or gloves with the
60. arranty period from installation date The warranty period for the air turbine does not begin again when a repair is completed under warranty Air turbines repaired by Ransburg after the warranty period will be warranted for 90 days from the date of shipment from the repair center The Warranty does not cover 1 An RMA 590 that has become inoperative because of a Misuse Particularly the flooding of the rotor area due to turning on the fluid before the turbine is up to speed b Negligence c Accidents Collisions with external objects fires or similar occurrences d Improper maintenance procedures e Attempted customer repair of an air turbine during warranty f Failure to insure clean air to air bearing and turbine g Operating turbine without bearing air h Operatingturbine with less than minimum specified air bearing pressure 80 psi 5 51 Bar i Operating with imbalanced loads heavy paint buildup on atomizer bell or shaft or damaged atomizer bell cup j Acts of God flood earthquake or similar occurrences k RMA 590 s being operated by control systems not designed by Ransburg or when others have 2 Labor or incidental costs occasioned by removal replacement or repair of rotary atomizer or air turbine other than by Ransburg unless we have given specific written or telegraphic authorization for repair by someone other than Ransburg 3 Rotary atomizers determined by Ransburg not to have been
61. assembly Remove orifice and clean a Remove air pilot signal b If still open replace fluid valve Replace fluid valve seat Replace fluid tip with the next smaller inner diameter size Disassemble fluid regulator and inspect for failed components system 54 Ransburg RMA 590 Maintenance TROUBLESHOOTING GUIDE DIRECT CHARGE Cont General Problem Fluid and or Air Leakage Between the Atomizer Body and Mounting Manifold Fluid Leakage In Robot Adapter Fluid Leakage Around Fluid Valve Turbine Cannot Attain Desired Speed Loss of Exterior Interior Cup Wash or Lack of Flow LN 9276 14 1 Possible Cause Atomizer mounting manifold ring is loose Solution Tighten mounting ring O ring is missing Install O ring O ring is damaged Fluid tubing not properly installed or tightened Damaged o ring s on outer diameter of valve body Visually inspect for damage and replace Inspect and retighten Replace o ring s Damaged or worn needle seals inside valve assembly Excessive vibration Replace valve assembly Check bell cup for damage Checkbell cupforexcessive paint buildup Bell cup loose tighten to proper torque Checkcupand shafttapers for cleanliness Have manufacturing check bell cup balance Low or no bearing air a Check bearing air pressure minimum 80 psi 352 kPa b Check filters for contamination c Check for bent or damaged beari
62. ate If any under cut in this area the cup should be replaced 10 Use a soft bristle brush dipped in solvent to remove paint build up from the serration cuts paint feed holes or slots and external and internal surfaces of the bell LN 9276 14 1 45 Ransburg RMA 590 Maintenance 11 A soft lint free rag dampened with solvent may be used to remove any paint residue from the external and internal surfaces of the bell 12 After removing all paint build up or residue rinse the bell in clean solvent and blow dry 13 Before reinstalling the bell on the shaft check the mating surfaces of the thread and taper for any paint build up or residue Also check the fluid tip fluid tube outside diameter and the shaft for any further paint build up These surfaces should be cleaned before installing 14 lt is recommended that extra bell cups be purchased The cups can then be cleaned off line in an automated cup cleaner 15 Reinstall cups to proper torque 50 70 Ibsein 5 65 7 91 Nm CLEANING SHAPING AIR HOLES In order to maintain uniform pattern control the shaping air holes ofthe inner ring and the shaping air cap must be clean and free of any blockage It is best to leave the shaping air supply ON during normal production break cleaning periods Shaping air can be reduced to 70 slpm during this time This will help stop material from entering the passage ways Periodically weekly the outer shaping air
63. ation DETAIL D SCALE 2 3 DETAIL A SCALE 1 1 DETAIL B SCALE 1 1 LN 9276 14 1 77 Ransburg RMA 590 Parts Identification OB p SS wore LX AVE IN um S288 LN 9276 14 1 78 Ransburg LN 9276 14 1 RMA 590 PARTS LIST Dwm ay Paz Deseto E RMA 590 Parts Identification MOUNTING RING A13129 00 ELECTRODE ASSEMBLY SPINDLE ASSEMBLY BELL CUP ASSEMBLY SHAPING AIR KIT ROBOT ADAPTER A11318 00 HIGH VOLTAGE TUBE NUT A13737 12C SCREW 1 4 20 X 3 8 LG NYLON FILLISTER HEAD A13125 00 SOLVENT BLOCK ASSEMBLY 78441 00 FERRULE NUT D PANEL A13128 00 SLIP RING ROBOT ADAPTER A11338 00 SCREW SOC HD CAP M8 X 25MM LG A13140 01 HIGH VOLTAGE COVER A13137 00 HIGH VOLTAGE RING ASSEMBLY A13138 00 HIGH VOLTAGE TUBE A13737 24C SCREW 1 4 20 X 3 8 LG NYLON FILLISTER HEAD 77367 00 VALVE SEAT ASSEMBLY 78949 00 VALVE ASSEMBLY 78944 00 ASSEMBLY CHECK VALVE 79001 06 O RING SOLVENT PROOF 79001 01 O RING SOLVENT PROOF A13132 00 CHECK VALVE PLUG 79001 08 O RING SOLVENT PROOF A13130 00 EXTERNAL CUP WASH FITTING HOLDER A12821 00 CUP WASH FITTING A12822 00 CUP WASH FERRULE 79001 45 O RING SOLVENT PROOF 78278 00 NUT FIBER OPTIC TENSIONING 79001 40
64. ax Flow Rate 1000 cc min at 60 000 rpm Continued on next page LN 9276 14 1 Ransburg RMA 590 Introduction Mechanical Cont Bell Cup Cleaning Time Internal External 2 7 sec approx Color Change Time Dependent on system configuration fluid pressures fluid viscosity fluid line lengths etc Speed Readout Magnetic pick up unidirectional fiber optic transmission Atomizer Replacement Time Less than 5 min Bell Cup Replacement Time Less than 2 min Minimum Control Equipment Requirements Versions listed or higher MicroPak LECU5004 17 V 3 84 Atomizer Module A11925 00 V 0 4 UO Module A11435 00 V 1 4 0 01V 4 20 mA Air Heater Recommendation An Air Heater is recommended for the turbine air supply See Air Heater and filtration recommendation later in this manual Although this turbine assembly is capable of operating at continuous speeds up to 100 000 rpm nearly all high quality finishes can be achieved within our recommended operating range of 20 000 to 70 000 rpm based on experience with a wide variety of materials and various markets Operating above this range is for highly specialized applications and may reduce efficiency and equipment life Contact your Finishing Brand representative for additional information as required The air turbine only is warranted for 15 000 operating hours or 3 years from date of first installation whichever occurs first If after inspection by Ransburg d
65. bell cup surface The rear plate lends itself to attaching various configurations for mounting on several manufacturers robots Robot Adapter Plate The adapter plate can be configured so that the applicator can be used with most manufacturers of robots The plate also incorporates a center non metallic bearing that it rotates as fluid air tubes and high voltage cables move and rotate during the robots motion Power Supply and Controls The high voltage cascade is located inside the applicator and is controlled by the MicroPak con trol unit The low voltage output of the MicroPak is multiplied by the internal cascade to the high voltage level required This eliminates the need for a high voltage cable Alow voltage cable inter LN 9276 14 1 RMA 590 Introduction connects the cascade and MicroPak control The MicroPak formatis designed to fit ina conventional 19 inch or 10 inch rack and requires a 24V power input at a maximum 3 amps The MicroPak and the internal cascade will produce voltages up to 100 000 VDC The MicroPak is designed to electronically limit current to provide safe operation in a spray booth The voltage and current draw of the atomizer are continuously displayed on the MicroPak control panel Voltage and over current limits are ad justable on the front of the MicroPak MicroPak internal safety circuits will shut down the system on over current and cable faults With additional control modules all of the fu
66. c arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times 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 unautho rized 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 dis abled Never use equipment intended for use in water borne installations to spray solvent based ma terials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC OSHA local country and European Health and Safety Norms Ransburg AREA Tells where hazards may occur Spray Area General Use and Maintenance LN 9276 14 1 HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate oper ation and maintenance proce dures will cause a fire hazard Protection against inadvertent arcing that is capable of caus ing fire or explosion is lost if any safety interlocks are dis abled during operation Frequent Power Supply or Controller shutdown indicates a problem in the system requir ing correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the
67. cap and the inner shaping air ring should be removed and thoroughly cleaned Use of an ultrasonic cleaner would make cleaning of hole diameters easier Inspect all holes for blockage Blow holes clear with compressed air after some time of soaking in solvent DO NOT use any type of pick to clear the holes Damage may result to parts and could affect performance of the equipment If holes are damaged oversized holes blockage and gauges it must be replaced LN 9276 14 1 46 Ransburg RMA 590 Maintenance RMA 590 PREVENTIVE MAINTENANCE SCHEDULE Mid Shift of Shift Weekly 2 Weeks Monthly 3 Months 6 Months Mid Shift Cleaning Wipe electrodes Wipe shroud Visually inspect cup End of Shift Cleaning Wipe electrodes Wipe shroud Wipe bell cup down Change cloth cover Shaping Air Shroud Clean inner shape air ring Clean outer shape air ring Remove and clean Bell cup removal inspection cleaning Fluid tip inspection cleaning Inspect Valve and Seat Assembly in valve module for leaking Replace Valves and Seats in valve module High Voltage Cable Inspections High Voltage Testing Regreasing of High Voltage Cables Check resistance of High Voltage Electrodes Regreasing Electrode Cavities of High Voltage Ring and High Voltage Input Inspect all screws Replace if broken Inspect for wear Tighten per specifications Inspection of Electrode Replace Electr
68. ch that the dump is closed as the paint reaches the trigger valve in the atomizer Paint in the dump line may cause high voltage issues The fluid coil and fluid tube can be cleaned in dependently by actuating the solvent valve in the atomizer High voltage must be turned off during this operation and the bell cup must be spinning typically 30 000 rpm for cup flushing sequences 40 Ransburg RMA 590 Maintenance Bell Cup Cleaning Cup Wash Without Clean For best operating conditions the atomizer ing the Incoming Paint Line surfaces must be dry Turn off the high voltage and trigger valve With Always final wipe all parts with a non polar sol the bell spinning at 30 000 rpm turn on the ex vent and wipe dry high flash Naphtha etc ternal solvent valve to allow cleaning solvent to flow through the manifold passages through the fluid tube and onto the bell The spinning bell will atomize the solvent clean out the bell passages WARNING both internally and externally Itis always required to blow the solvent line dry after the cleaning op gt NEVER wrap the applicator in plastic to eration Typical bell speed during the cup flush keep it clean A surface charge may build up sequence is 30 000 rpm Follow sequence as on the plastic surface and discharge to the outlined for cup wash in General Operating Se nearest grounded object Efficiency of the quence in the Operation section applicator will also be r
69. conditions turbine airflow settings and incoming airtempera ture The heater should be set as low as possi ble sufficient to maintain the applicator surface temperatures above the dew point in the booth Example With the incoming air temperature at 72 F 22 2 and RMA Hybrid with 65mm bell cup rotating unloaded at 60 krpm has a turbine outlet temperature drop of approximately 28 F 2 2 C 40 krpm unloaded A 14 F 10 Referring to the ASHRAE Psychrometric chart the saturation temperature range dew point of a spray booth maintained at 70 75 F 65 70 RH is 62 68 F 21 1 23 9 C 65 70 RH is 16 7 20 C Thus it is almost certain that the surface temperatures of the applicator will fall below the dew point of the booth and an air heater will be needed in this case To prevent condensation a Ransburg air heater assembly should be assembled after the air filters and volume booster See heater and filtration options later in this manual 25 Ransburg AIR HEATER AND FILTRATION OPTIONS NOTE gt Failure to use an air heater may cause damage to equipment or ruin the finished component being processed NOTE gt Connect air heater to turbine air tubing RMA 590 Installation NOTE gt If using the A11065 05 Air Heater air filters equivalent to HAF 503 HAF 508 and RPM 418 must be used See descrip tions in this manual 1 2 NPT M PORT SUGGEST 1 2 OD OR 12MM LJ O D TUBING NYLON
70. conductive material in the spray area If the conductive material does not provide a safe drain to electrical ground which will allow the charge to dissipate as fast as it accumulates it may store the charge When its electrical stor age limit is reached or when it is breached by external circumstances such as the approach of a grounded object or person or one at lower potential it may discharge its stored charge to the nearest ground If there is no safe path to ground such as a ground wire or braided cable it may discharge through the air as a spark Aspark may ignite the flammable atmosphere of a spray area The hazard area extends from the point of origin up to as much as a twenty foot radius See the NFPA 33 for definition and limitations of a hazard area Itis simple but vital matter to be sure that all con ductive objects withinthe spray area are grounded All cabinets housing bases supports and stands which are not by design insulated from ground be connected directly and_INDIVIDUALLY to earth ground Resting on a concrete floor or being attached to a building column may not always be sufficient ground In order to provide the best ground connection possible always attach a ground wire or insulated braided cable the terminal indicated by the ground LN 9276 14 1 RMA 590 Installation symbol and then to a proven ground Always check ground connections for integrity Some items such as rotators and paint s
71. d tighten locking set screw Fiber optic transmitter failure Replace fiber optic transmitter Bad transceiver module Replace transceiver module Excessive vibration a Check bell cup for damage b Check bell cup for excessive paint buildup c Insure bell cup is tightened properly d Check cup and shaft tapers for cleanliness 50 Ransburg RMA 590 Maintenance TROUBLESHOOTING GUIDE INDIRECT CHARGE Cont General Problem No Fluid Flow Continuous Fluid Flow Uncontrollable Fluid Flow LN 9276 14 1 Possible Cause Turbine is not rotating Solution Verify rotation of turbine the paint valve air pilot must be interlocked with the tur bine speed feed back signal to ensure that paint does not flow into the air bearing Fluid valve does not actuate a Verify that air pilot signal is present b Fluid valve air pilot pressure is too low Increase air pressure to 70 psig minimum c Replace fluid valve Clogged fluid tube fluid tip Bad transceiver module Remove and inspect fluid tube or fluid tip Replace transceiver module Clogged restrictor orifice Fluid valve open Remove appropriate microvalve and seat assembly Remove orifice and clean a Remove air pilot signal b If still open replace fluid valve Fluid valve seat damaged or worn Insufficient back pressure to fluid regulator Replace fluid valve seat Replace fluid tip with th
72. during manual clean ing breaks WARNING gt Never spray solvent when high voltage is on WARNING gt DO NOT use metal shape air compo nents when using the indirect charge ring 34 Ransburg A12874 08 09 METAL DIRECT CHARGE ONLY A12874 10 11 PLASTIC INDIRECT DIRECT CHARGE SHAPING AIR KIT 1 A12874 10 11 Dual Flex Shaping Air Kits for Use with 65mm Bell Cup A12874 08 09 Direct Charge Only As the name implies both shaping air outlets supply air that is counter to the rotation of the bell cup This combination will provide a pattern size from 3 inch to 10 inch 76mm 254mm depend ing on bell rotation speed fluid flow and air flow Both sets of shaping air holes are independently controlled The inner set of holes are supplied by connecting the tube labeled SAI to a regulated air source The outer set of shaping air holes are supplied by connecting the tube labeled SAO to a regulated source The air supplies work in combination with each other to provide desired results This combination of shaping air can be used with any 65mm bell cup Sample Dual Flex Shape Air Configurations Pattern sizes based on solvent borne metallic paint with a viscosity of 30 32 centipoise target distance 175mm 7 inches no electrostatics applied Results will vary depending on fluid flow rate material viscosity target distance and with electrostatics applied Typical pattern size achievable with
73. e next smaller inner diameter size Fluid regulator does not control flow system Disassemble fluid regulator and inspect for failed components system 51 Ransburg RMA 590 Maintenance TROUBLESHOOTING GUIDE DIRECT CHARGE General Problem Bad Spray Pattern Low or No High Voltage LN 9276 14 1 Possible Cause Bell cup damaged Solution Replace bell cup Low voltage See Low or No High Voltage below Paint lodged in shaping air ring High current draw Disassemble and clean See Maintenance section a Paint resistivity to be 1 MW to h b Replace coiled fluid line Solvent valve is actuated Remove solvent valve air pilot signal high voltage must be interlocked with the solvent valve air pilot signal to pre vent solvent flow while high voltage is energized Loss of low voltage cable connection between robot and bell plates a Remove atomizer and inspect low volt age connections on both plates Verify bell plates alignment marks between connectors and plates and verify that connector face is flush with plate Verify that set screws are secure but not too tight as this will prevent the spring loaded pins on the robot plate from extending and making contact b Faulty low voltage cable Improperly mounted air turbine Verify correct orientation of air turbine so that high voltage spring makes contact with metal pad on turbine assembly
74. edia RMA 590 Installation NOTE gt Each applicator must have its own filter for bearing air Recommended RPM 418 or equivalent With the exception of fluid dump and bearing air all other pilot and air supply lines should be bulk headed and their diameters increased one size Forexample Turbine air should be increased to 12mm OD from bulkhead plate to the volume booster or heater outlet Volume Booster Recommendation Turbine Air For use with A11065 05 Air Heater or Non Air Heater System Ransburg Part A11111 00 Pilot Operated Regulator Non Bleed Pilot SCFM 200 Supply 300 P S I Temperature Range 40 120 F TUBE SIZE AIR PRESSURE REQUIREMENTS x Tese Air Pressure Requirements Bearing Air Supply BA 1 4 OD 90 10 psi 621 69 kPa Pilot Dump 2 Air PD2 AIR 4mm OD 5 32 OD 30 psi 207 kPa Max Paint Valve 2 PT2 4mm OD 5 32 OD 80 10 psi 552 70 kPa Bearing Air Return BA RTN 4mm OD 5 32 OD 90 10 psi at atomizer card 552 70 kPa Brake Air BRK 1 4 OD 60 100 psi 414 689 kPa Pilot Dump 1 Air PD1 AIR 4mm OD 5 32 OD 30 psi 207 kPa Max Pilot Dump Valve 1 PD1 4mm OD 5 32 OD 80 10 psi 552 70 kPa Shape Air Outer SAO 8mm OD X 6mm 5 16 OD Variable see graphs in this manual Shape Air Inner SAI 8mm OD X 6mm 5 16 OD Variable see graphs in this manual Paint Valve 1 PT1 4
75. educed and damage or failure of the applicator components may A CAUTION occur WRAPPING THE APPLICATOR IN PLASTIC WILL VOID WARRANTY The maximum flow rate of 1000 cc min must not be exceeded during a flush rou tine Use of an in line fluid restrictor is rec ommended WARNING gt To reduce the risk of fire or explosion OSHA and NFPA 33 require that solvents used for exterior cleaning including bell cleaning and soaking be nonflammable flash Verify that the high voltage is turned off points higher than 100 F 37 8 C Since electrostatic equipment is involved these solvents should also be non polar Exam ples of non flammable non polar solvents for cleaning are Amyl acetate methyl amyl ac etate high flash naphtha and mineral spirits External Atomizer Surface Cleaning All external surfaces may be cleaned using a mild solvent and lint free rags to hand wipe the RMA 590 Turbine drive air must be off but leave bearing air on The in ner and outer shaping air if applicable should have approximately 70 slpm air flow through each to prevent the solvent from entering these passages gt Do not use conductive solvents such as MEK to clean the external surfaces of the RMA 590 without a second cleaning with a non polar solvent Do spray the RMA 590 unit with a solvent applicator used for cleaning The gt When using a rag to hand wipe RMA cleaning fluid und
76. efect is confirmed we will repair or replace the air turbine free of charge during the warranty period The repaired air turbine or replacement air turbine will continue to be warranted for the remainder of the initial warranty period from installation date The warranty period for the air turbine does not begin again when a repair is completed under warranty Air turbines repaired by Ransburg after the warranty period will be warranted for 90 days from the date of shipment from the repair center See Warranty section on last page for specific exclusions Specifications and ratings based on testing at sea level standard conditions LN 9276 14 1 9 Ransburg IMPORTANT NUMBERS Record these numbers in a log book for future reference The last digits of the Atomizer serial number are also the Turbine serial numbers SPINDLE PART NUMBER TURBINE SERIAL NUMBER AND SERVICE KIT NUMBER RMA 590 Introduction Turbine Serial Number ATOMIZER SERIAL NUMBER Atomizer Serial Number B BALANCED BELL CUP PART NUMBER PART SERIAL NUMBER REVISION STATUS Bell Cup Part Numbers Serial Number LN 9276 14 1 cup only not with splash plate 10 Ransburg RMA 590 Introduction GRAPHS Graphical information provided for reference only for all charts Unless otherwise specified all pressure data shown was measured 12 inches 305mm behind the applicator TURBINE SPEED VS
77. enist or safety expert and be NIOSH approved Aluminum is widely used in other spray appli cation equipment such as material pumps regulators triggering 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 If in doubt as to whether or not a coating or cleaning material is compatible contact your coating supplier Any other type of solvent may be used with aluminum equipment Ransburg INTRODUCTION APPLICATOR DESCRIPTION The RMA 590 Applicator is an automatic robot mounted rotary atomizer This device is capable of applying waterborne andsolventborne coatings electrostatically The waterborne coatings are applied using a method known as Indirect Charge This is where the coating material passes through an electrostatic field created between the charging probes the bell cup and the target to be coated The solvent borne coatings are applied using a method known as Direct Charge This is where the coating material has the electrostatic voltage applied directly to it This applicator incorporates the latest in high speed spindle technology bell cup and shape air design to provide the best in atomization and pattern control The bell cups are designed for durability using the best materials available All wetted components are designed to offer the maximum in wear and chemical resist
78. er pressure may aid con 590 the turbine air should be off but leave ductive materials to work into hard to clean areas or may allow fluids to be forced into the turbine assembly both the shaping air and bearing air turned on Ensure that rotation has come to a com plete stop Donotreuse an atomizer bell cup that shows any sign of damage such as nicks heavy scratches dents or excessive wear LN 9276 14 1 41 Ransburg VIBRATION NOISE Ifthe RMA 590 is vibrating or making an unusually loud noise it usually means there is an imbalance situation The atomizer bell cup may have dried paint on it or the bell may be physically damaged or there may be paint trapped between the bell cup and shaft preventingthe bell cup from properly seating If any ofthese conditions exist they MUST be corrected Excessive imbalance caused by one of these conditions may result in bearing damage and turbine failure Warranty DOES NOT cover failure caused by imbalanced loading conditions Todetermine ifthe bellis dirty or damaged remove the bell cup and turn the turbine ON If the noise is eliminated the bell cup is the problem If the noise continues the turbine may be damaged and should be inspected Excessive air required to achieve same speed may indicate a faulty or contaminated turbine DO NOT continue to op erate a noisy turbine WARNING gt f a bell cup comes off a rotating shaft because of motor seizing or any other re
79. es may occur during the normal use of this equipment Please read the hazard chart be ginning on page 2 Ransburg AREA Tells where hazards may occur Spray Area LN 9276 14 1 HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard Protection against inadver tent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during opera tion Frequent Power Supply or Controller shutdown indi cates a problem in the system requiring correction RMA 590 Safety SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accumulation of combustible residues 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 main tenance 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 100 F 37 8 C Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA country and local codes In addition ventilation must main tained during cleaning operations using flam mable or combustible solvents Electrostati
80. h Insure all o rings are in place on the rear side of the turbine before re assembly Lubricate all o tings with petroleum jelly Align the mark on the turbine body with the mark on the atomizer body Push and twist slightly until the locating pins align with the holes in the atomizer body and the turbine is fully seated Fluid Tube Centered Fluid tube must be centered If not remove turbine and look for the cause Re assemble and check again Install turbine retaining ring by hand Do not cross threads tighten 1 8 1 4 turn more with the A12088 00 spanner wrench To remove Use the opposite end of the A11229 00 fluid tube tool to remove the fluid tube retaining nut Remove the fluid tube by pulling straight out 65 Ransburg Install Check all o rings for damage Lubricate all o rings with petroleum jelly Push fluid tube into atomizer body until seated Tighten retaining nut clockwise to 45 50 Ibs in 7 34 8 47 Nm torque To remove Remove fiber optic retaining nut with 78279 00 tool in a counter clockwise direction LN 9276 14 1 RMA 590 Maintenance Pull fiber optic assembly straight out To remove Using the valve removal tool A11922 00 engage the 4 pins an the tool with the 4 hole on the top of the valve body Using a 1 2 13mm socket end wrench or adjustable wrench remove by turning counter clockwise 66 Ransburg To replace lubricate all o rings and valve bore
81. holes are independently controlled The inner set of holes are supplied by connecting the blue tube labeled SAI on the tubing bundle to a regulated air source The outer set of shaping air holes are supplied by connecting the gray tube labeled SAO on the tubing bundle to a regulated source The air supplies work in combination with each other to provide desired results This combination of shaping air can be used with any 55mm bell cup LN 9276 14 1 36 Ransburg A12074 05 METAL DIRECT CHARGE A12874 06 METAL DIRECT CHARGE WITH RING SHAPING AIR KIT 3 A12874 05 06 Shaping Air Kits Mono Flex Air Direct Charge 12874 07 Indirect Direct Charge for Use with All 65mm Bell Cups Only As the name implies shaping air outlet supply air that is counter to the rotation of the bell cup This combination will provide a pattern size from 10 inch to 24 inch 250mm 610mm depending on air flow fluid flow and cup rotation speed Connection is made using the blue 8mm tube labeled SAI onthe tubing bundle The other 8mm tube labeled SAO is gray in color and must be plugged However if additional air is required this tube can be connected to a secondary controlled air source Precautions must be taken that one does not have a significantly higher pressure than the other to avoid any back flow This shaping air combination can be used with any 65mm bell cup See Pressure and Flow Data
82. installthe atomizertothe mounting manifold align the 3 white pins with the appropriate holes Alignment marks at the top of each assembly are to be used as a guide Make sure all o rings are in position before re assembly While holding the applicator in position pull the quick disconnect ring forward and tighten in a counter clockwise direction until snug Further tighten the assembly together using the 2 76772 00 wrenches Use one wrench to hold the mounting manifold with tightening the quick disconnect ring in a counter clockwise direction until unit is tight Remove electrode in a counter clockwise direction Clean any old dielectric grease from the electrode body or the high voltage ring cavities Insure o ring is in place before re assembling Rubber gloves will help in removing the electrodes 61 Ransburg O Ring 8 Use non metallic pick to remove any o ring Inspect o rings for high voltage burning cuts etc Replace if required Add a small amount of dielec tric grease to these o rings before re assembly K The electrodes are field repairable Remove the endfitting spring contact and high voltage resistor Discard the electrode body if the metal tip is bent or eroded from high voltage Check resistance of the high voltage resistor to the specification listed in this manual Replace resistor only with a Ransburg part Add dielectric grease to areas shown in the picture Check resistance of the entire a
83. labeled pta and pts there is only 1 o ring in each hole LN 9276 14 1 72 Ransburg RMA 590 Maintenance Mounting Manifold Quick Connect Ring Robot Adapter The quick disconnectringis captured between the auek a Eer oprig mounting manifold and the robot adapter ring hole Alignment pin and hole d Fiber optic cable To install or remove the fiber optic cable align the notch in the quick connect ring with the hole for the fiber optic set screw Align the fiber optic ferrule flats with the set screw hole Fiber optic cable is to be flush with mounting manifold face Use a 3 32 hex key wrench to loosen or tighten Tighten to 10 Ibs in 1 13 Nm torque To re install slide the quick connect ring over the mounting manifold thread first Align the pin on the mounting manifold with the hole in the robot adepter Install the 8 screws with a 1 4 hex key wrench and tighten to 10 Ibs in 1 3 Nm torque To remove To remove the mounting manifold from the robot adapter remove the 8 screws using a 1 4 hex key wrench LN 9276 14 1 73 Ransburg RMA 590 Parts Identification PARTS IDENTIFICATION RMA 590 HYBRID ROTARY ATOMIZER MODEL IDENTIFICATION When ordering use A13368 ABCDEFGH as indicated by Tables A B C D E F G and H Fourteen 16 digits must follow the basic part number For Example A13368 XX XX XX XX XX XX XX XX L TABLE H TOOL KIT TABLE G HIGH
84. losion Hazard Incompatible Materials Halogenated hydrocarbon sol vents for example methylene chloride and 1 1 1 Trichlo roethane are not chemically compatible with the aluminum that might be used in many sys tem components The chemical reaction caused by these sol vents reacting with aluminum can become violent and lead to an equipment explosion 590 Safety SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazard ous locations the power supply control cabinet and all other electrical equipment must be locat ed outside Class or II Division 1 and 2 hazard ous areas in accordance with NFPA 33 and EN 50176 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combus tible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance Follow the requirements of the Material Safety Data Sheet supplied by coating material manu facturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equipment must be as prescribed by an industrial hygi
85. mm OD 5 32 OD 80 10 psi 552 70 kPa Turbine Air TA 8mm OD X 6mm 5 16 OD Variable see graphs in this manual Solvent Valve ST 4mm OD 5 32 OD 80 10 psi 552 70 kPa Pilot Dump Valve 2 PD2 4mm OD 5 32 OD 80 10 psi 552 70 kPa Paint 1 P1 8mm OD 5 16 OD PFA 200 psi Max 1379 kPa Paint 2 P2 8mm OD 5 16 OD PFA 200 psi Max 1379 kPa Dump 1 DL1 8mm OD 5 16 OD PFA 200 psi Max 1379 kPa Dump 2 DL2 8mm OD 5 16 OD PFA 200 psi Max 1379 kPa Solvent SOL 4mm OD 5 32 OD PFA LN 9276 14 1 100 psi Max 689 5 kPa Ransburg EQUIPMENT GROUNDING SAFETY RECOMMENDATIONS In electrostatic coating systems the flow of high voltage power from the power supply to the atomizer is insulated from ground and isolated from all other functions equipment When the voltage reaches the atomizer it is transferred to the coating material where by introducing a negative charge it causes the atomized fluid to seek the nearest positive ground In a properly constructed and operated system that ground will be the target object The directed conduction of the electric charge through its array of wires cables and equipment is accompanied by a variety of stray electrical charges passing through the air by various means such as air ionization charged particles in the air and radiated energy Such charges may be attracted to any
86. motor shaft inspection indicated below under weekly maintenance can be done daily and later adjusted to weekly or as required depend ing on the results of the inspection WARNING gt Inthe event the bell cup comes in con tact with a part that cup should be replaced before continuing to spray gt Do Not place high voltage test probe on bell edge unless rotation is fully stopped gt Make sure that no solvent or other contamination is allowed to enter the motor assembly air bearing and outer shaft LN 9276 14 1 RMA 590 Maintenance NOTE gt Refer to the Troubleshooting Guide in the Maintenance section for details on determining the causes of low or no high voltage at the bell cup Weekly Maintenance Prior to Start or End of Production Week Monitor rotational speed of all belts at the speed control Investigate cause if abnor mal Monitor high voltage and current output indi cated on the MicroPak display Investigate cause if abnormal e Check paint flow on all bells at minimum and maximum specified settings by taking beakered readings e Check solvent flow by opening solvent valve and taking a beakered reading should be within approx 10 of target flow rate residue found in the shaping air holes is not acceptable and must be removed pri or to applicator use see Cleaning Shaping Air Holes in the Maintenance section Clean any paint on outer surface of front
87. nc tions of the RMA and MicroPak can be controlled by a programmable controller A Serial Atomizer Module pneumatically controls the speed of the rotary atomizer with dynamic feedback through a fiber optic transmitter located on the applicator A Serial Digital Module pneumatically controls the paint solvent and dump valves located on the atomizer An I O module provides communication between these modules and the PLC The above modules are mounted in one 19 inch rack and interconnected through a common mother board Bell Cups are made of high strength Titanium or high wear Coated Aluminum Serrated cups are available in 30mm 55mm and 65mm sizes Non serreated cups are available in 55mm and 65mm sizes See ordering matrix for exact size and material combination availability Ransburg RMA 590 Introduction SPECIFICATIONS Electrical Power Supply Type MicroPak Charging Method Direct Indirect Output Voltage 30 70 kV Variable 70 kV Maximum indirect charge 30 100 kV Variable Direct Charge Output Current 1000 Indirect or Direct Charge Turbine Speed Control Atomizer Module Part Spray Ability Determine spray ability of part to be coated using Test Equipment 76652 Paint Conductivity Meter Mechanical Length See RMA Tool Point Center of Gravity and Envelope Dimension 65mm Dual Flex figure in the Introduction section Diameter See RMA Tool Point Center of
88. nections usually indicated by MicroPak feedback fault light Faulty high voltage connection a Make sure quick disconnection electri cal connection is aligned and clean b Check low voltage connection at cascade Verify that high voltage cable is fully seated in the cascade and the high voltage ring MicroPak or cascade failure MicroPak settings not correct Refer to current MicroPak manual for detailed Troubleshooting Guide Refer to current MicroPak manual for detailed Troubleshooting Guide Damaged high voltage cable Remove and inspect measure resis tance Dielectric breakdown of high volt age parts Check cascade high voltage ring and high voltage cable Replace defective parts Improper color change i e paint or solvent in dump line Low or no high voltage Optimize color change Verify high voltage at electrodes Nor mally a high voltage setting of 30 70 kV is appropriate for most applications Poor grounding of parts being coated Verify that parts being coated are prop erly grounded the electrical resistance between the part and ground must not exceed 1 megohm 49 Ransburg RMA 590 Maintenance TROUBLESHOOTING GUIDE INDIRECT CHARGE Cont General Problem Low Transfer Efficiency or light coverage Cont No Turbine Air Speed Feedback Fault LN 9276 14 1 Possible Cause Excessive turbine speed Solution F
89. ng air line d Poor turbine air pressure plant air e Damaged speed control cards Loss of fiber optic no feed back Bent of kinked supply tube Damaged fiber optic sensor bad cable too many splices Maximum three 3 slices permitted Replace No fluid flow Check microvalve check fluid supply source Blocked fluid tip or external nozzle Clean parts remove obstruction Ferrules holding tubing over tightened Replace tubing and ferrule assembly 55 Ransburg Splash Plate Removal All Bell Cups After removing the bell cup from the applicator put it on a plastic or wood surface to prevent damage to the edge of the cup Using the splash plate removal tool A11388 00 insert the small end of the tool into the end of the splash plate assembly Press the splash plate out It may be necessary to tap lightly with a hammer PRESS THIS DIRECTION 1 FLAT WOOD OR PLASTIC SURFACE Z BELL CUP REMOVAL TOOL SPLASH PLATE ASSEMBLY Splash Plate Removal A CAUTION gt Failure to replace a damaged bell cup will cause vibration of the applicator and or premature turbine failure LN 9276 14 1 RMA 590 Maintenance Splash Plate Insertion Cups Turn the splash plate removal tool over and use the large diameter end to press the splash plate back in place by hand It may be necessary on occasions to use an arb
90. odes Inspection of Tubing Bundle Regrease Tubing Bundle Replace Tubing Bundle Replace High Voltage Cable Inspect Turbine Spindle taper and threads LN 9276 14 1 47 Ransburg RMA 590 Maintenance RMA 590 PREVENTIVE MAINTENANCE SCHEDULE Cont Mid Shift End of Shift Weekly 2 Weeks Monthly 3 Months 6 Months Replace Bell Cups Replace Splash Plates Inspect and Clean Spindle Bore and Fluid Tube OD Check High Voltage Contact area for damage arcing Inspect for Fluid Leaks Check Exterior of High Voltage Ports for degradation Check External Cup Flush Carbide Tip for blockage LN 9276 14 1 48 Ransburg RMA 590 Maintenance TROUBLESHOOTING GUIDE INDIRECT CHARGE General Problem Bad Spray Pattern Low or No High Voltage Low Transfer Efficiency or light coverage LN 9276 14 1 Possible Cause Bell cup damaged Solution Replace bell cup Low voltage Paint lodged in shaping air ring High current draw See Low or No High Voltage below Disassemble and clean see Mainte nance section Check resistance of electrodes MicroPak controller cascade Inspect low voltage at the MicroPak and the cascade a Faulty low voltage cable Improperly mounted air turbine Verify ground connection of air turbine to earth ground at less than 1 megohm Faulty low voltage con
91. oduction RMA 590 TOOL CENTER POINT DIMENSIONS SHORT BODY 90 ADAPTER INDIRECT CHARGE 65MM DUAL FLEX 6 64 168 6 10 46 265 7 4 44 112 7 COG 3 34 84 8 7 63 193 9 COG 17 26 438 5 83 122 8 4 04 50 114 3 09 04 229 6 RMA 590 SHORT BODY 90 ADAPTER INDIRECT CHARGE 65MM DUAL FLEX TD Target Distance 6 Inches 152mm 23 26 Inches 590 8mm 8 Inches 203mm 25 26 Inches 641 6mm 4 83 Inches 122 8mm 4 83 Inches 122 8mm 4 83 Inches 122 8mm 4 83 Inches 122 8mm 10 Inches 254mm 27 26 Inches 692 4mm 12 Inches 305mm 29 26 Inches 743 2mm LN 9276 14 1 17 Ransburg RMA 590 Introduction RMA 590 TOOL CENTER POINT DIMENSIONS SHORT BODY 60 ADAPTER DIRECT CHARGE 65MM DUAL FLEX 4 48 EEN 3 90 199 01 6 29 159 7 COG 16 04 407 3 13 89 352 8 04 50 114 3 12 50 317 5 SA GE RMA 590 SHORT BODY 60 ADAPTER DIRECT CHARGE 65MM DUAL FLEX 6 Inches 152mm 15 50 Inches 393 7mm 19 09 Inches 484 9mm 8 Inches 203mm 16 50 Inches 419 1mm 20 82 Inches 528 8mm 10 Inches 254mm 17 50 Inches 444 5mm 22 55 Inches 572 8mm 12 Inches 305mm 18 50 Inches 469 9mm 24 28 Inches 616 7mm LN 9276 14 1 18 Ransburg RMA 590 TOOL CENT
92. or optimum transfer efficiency and spray pattern control the bell rotational speed should be set at the minimum required to achieve proper atomization of the coating material Excessive robot speed For optimum transfer efficiency spray pattern control bell speed and robot speed should be set at the minimum to achieve desired results of part to be coated Excessive inner outer shaping air Shaping air should be set at the mini mum volume required to gently direct the spray pattern toward the part being coated Excessive shaping air will cause some atomized particles to blow by the part or bounce back onto the atomizer Excessive target distance Turbine drive air not present Bearing air return signal not present The recommended target distance is be tween 6 and 12 inches 152 4 304 8mm see Target Distance in the Operation section of this manual Verify supply air pressure a Verify bearing air return signal b Increase bearing air supply pressure to 90 psig 10 psig 620 5 69 kPa Brake air is activated Damaged fiber optic cable between robot plate and control panel Connection at robot or bell plate is loose Remove brake air signal turbine air and brake air must be interlocked to prevent both from being used simultaneously a Repair or replace fiber optic cable b Bad splice connection or too many splices Maximum three 3 splices permitted Re install cable an
93. or press to install the splash plate Press splash plate to a hard stop see Splash Plate Insertion figure PRESS THIS DIRECTION FLAT WOOD OR PLASTIC SURFACE CUP SECTION VIEW ks OER A quu LA oi BELL CUP INNER SPLASH PLATE SURFACE BOTIOM Splash Plate Insertion 56 Ransburg NOTE gt There is a 3 inch center to center dis tance between the bell cup and the 3 8 inch socket square on the wrench This distance must be factored in when reading the proper torque on the wrench Example A desired true torque is desired using a 9 inch effective length torque wrench Wrench offset is 3 inches L 9 inches TT 50lbsein E 3 inches DR is dial reading DR 50 9 9 3 DR 37 5 Ibsein TRUE TORQUE FORMULAS DR DIAL READING n gre 060 E EXTENSION LENGTH L L EFFECTIVE WRENCH LENGTH p DRE L L E TRUE TORQUE TT INDICATED TORQUE ON DIAL READING DR Effective Length Torque Wrench CHECKING PROBES Check atomizer voltage using the Ransburg Test Meter Kit 76652 01 or 76652 04 Verify that the output voltages have not varied much from the setup standard A drastic change in voltage can be an early indicator of a component or system problem The data shown was collected under the ideal lab conditions using a clean atomizer and an unloaded fluid delivery system Thefollowing data isforuse with the RMA 590 The
94. ot be soaked in solvent if these are exposed or soaked in solvent they must be replaced These O rings are engineered to provide a fit between the air bearing spindle and it s mating parts to reduce or eliminate harmonic resonance vibration Some O rings are encapsulated These O rings have alimited amount of stretch and will not return to their original diameters if over stretched These O rings are subject to being distorted more easily than rubber O rings so it is important that they be sufficiently lubricated when mating parts are installed onto them They also will take a square set over time and should be replaced periodically if mating parts are removed repeatedly or if a new mating part is installed onto them Any O ring that is cracked nicked or distorted must be replaced A suitable lubricant is food grade petroleum jelly or A11545 00 Petrolatum Jell WARNING gt Electrical shock and fire hazards can exist during maintenance MicroPak supply must be turned off before entering the spray area and performing any maintenance procedures on the atomizer Spray booth fans should remain on while cleaning with solvents gt Never touch the atomizer bell while it is spinning The front edge of the bell can easily cut into human skin or cut through gloves and other materials Be sure the atomizer bell has stopped spinning before attempting to touch it Approximate time for the bell to stop spinning after turning off tu
95. pable of releasing suf ficient electrical and thermal energy to cause ignition of specific hazardous materials in the air LN 9276 14 1 RMA 590 Operation FLUID FLOW RATE CONTROL Externally mounted fluid regulators or gear pumps are typically used to control fluid flow Paint is supplied to the RMA 590 by way of the tubing bundle through the robot arm The atomizer assembly is equipped with micro valves which are pneumatically operated to di rect the flow of paint to either the feed tube or dump line and to supply an intermittent solvent to clean the interior and exterior of the bell cup The feed tube has several sized removable tips available from 7 1 6mm 027 inch 062 inch The viscosity and volume of the coating material being sprayed determine the correct size of feed tube tip for each installation Reference Fluid Tip Flow Rate chart in the Introduction section Fluid Flow Rate Check In the test mode the flow rate can be measured by removing the bell cup fromthe atomizer turning the fluid flow on and capturing the material in a graduated beaker or measuring cup for a fixed period of time shaping air high voltage and turbine air must be off WARNING gt Danger of shock and or personal injury can occur Proper grounding procedures must be followed Personnel must never work around the turbine when the turbine is spinning or when high voltage is turned on 32 Ransburg
96. rate or insert into bell cleaning station 4 Maintain solvent pressure of 100 150 689 1 034 kPa Maintain air push pressure at 80 100 psi 552 689 kPa 5 Use an alternating trigger sequence of sol vent air to create a chopping effect Always ensure that the last step in the sequence is an air push 6 Atypical sequence is 3 seconds solvent 1 7 seconds air push repeat 3 times This sequence may be modified for other paint and applications BELL SPEED INTERNAL SHAPING AIR ON r FLUID TRIGGER DN VOLTAGE ON OR UP FROM SETBACK SES Ee OFF OR SETBACK TO 40 50 KV r INTERNAL SHAPING A 10 SETBACK FLOW BELL TO SETBAC INTERLOCK V BF INT EXT CUP FLUS L COLOR CHANGE gg Typical Paint Sequence DUMP TRIGGER ACTUATED SOLVENT ON 1 SEC DURATION r AIR ON SEC DURATION SOLVENT ON amp SEC DURATION AIR ON SEC DURATION DUMP TRIGGER OFF PAINT TRIGGER SOLVENT ON amp SEC DURATION AIR ON 4 SEC DURATION SCH JON3n83S 1N3A3 Typical Color Change Sequence Sequence Event Explanation 1 Bell to Speed This is accomplished by a set point command from either the PLC robot or other input device through the I O module LN 9276 14 1 RMA 590 Operation Shaping Air Set to 350 450 12 4 15 9
97. rbine drive air is three minutes gt Ensure high voltage is off during any man ual cleaning procedure LN 9276 14 1 RMA 590 Maintenance WARNING gt Ensure that all energy sources are dis sipated electrical air paint solvent etc before removing the applicator or performing any maintenance In addition to the previous Warning which relates to potential safety hazards the following informa tion must be observed to prevent damage to the equipment gt DO NOT immerse the RMA Hybrid turbine in solvent or other liquids Turbine components will be damaged and warranty will be voided gt Bearing air must be on during all cleaning procedures to protect the air bearing compo nents CLEANING PROCEDURES Internal Fluid Path Purge Cleaning Cleaning the incoming paintline from paint supply source such as color manifold through the fluid manifold and bell assembly Turn off the high voltage and turn on the color stack trigger valve for solvent supply With the bell spinning open the dump valve and flush the incoming paint line with solventoran air solvent chop Make sure the last step of the sequence is air to purge the dump line of remaining solvent To speed the loading of the new paint leave the dump line open to allow the air in front of the paint push to escape The length of time the dump valve is open depends on several factors such as viscosity paint pres sure etc Timing should be su
98. rode Assembly figure Part No A11343 02 A11343 03 57 Ransburg If the tip is rounded or worn jagged it must be replaced Depending on use electrode tips will last 3 6 months The electrostatic field generated bythese electrodes are veryimportantto maintain paint transfer efficiency pattern uniformity and atomizer cleanliness SHOULD ROUNDED OR JAGGED TIP REPLACE ELECTRODE ASSEMBLY NOTE gt The outer protective cover may have to be replaced more frequently than week ly Daily inspection of the amount of paint build up on the cover will determine the frequency of replacement RMA 590 Maintenance DISASSEMBLY PROCEDURES NOTE gt Forreassembly instructions use the reverse of the following disassembly procedures gt To facilitate atomizer removal from hose manifold a robot program should be made that purges all paints and solvents from the RMA 590 Ideally it would then position the bell assembly in a bell remov al position where the bell cup is pointed downward at a 30 angle Any residual solvents would be contained in the J bend ofthe robot wrist gt All O rings described in the Mainte nance section of this manual should be lubricated with a food grade petroleum jel ly or with A11545 lubricant WARNING gt Prior to removing applicator from the ro bot the following tasks must be completed gt Robot put into E stop mode locked and t
99. s a complete unit i e guns pow er supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLASTIC SHRINK WRAP ETC WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF EITHER MER CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL ORPRODUCTION ORINCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIP MENT 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 as sume 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 Specific Air Turbine Warranty The air turbine only is warranted for 15 000 operating hours or 3 years from date offirst installation whichever comes first If after inspection by Ransburg defect is LN 9276 14 1 confirmed we will repair or replace the air turbine free of charge during the warranty period The repaired air turbine or replacement air turbine will continue to be warranted for the remainder of the initial w
100. s paint flow rates and paint formulations For optimum transfer efficiency and spray pattern control the bell rotational speed should be set at the minimum required to achieve proper at omization Excessive speed reduces transfer efficiency 33 Ransburg WARNING gt DO NOT exceed the maximum rated operating speed and turbine inlet pressure Excessive speed may cause air turbine damage or damage to the bell BEARING AIR ADJUSTMENT The nominal bearing air pressure is 90 psi 620 5 kPa measured at the rear of the atomizer Mini mum pressure is 80 psi 551 6 kPa and maximum pressure is 100 psi 689 5 kPa The turbine should never be operated with less than 80 psi 551 6 kPa bearing air pressure Bearing air must be present when turning the turbine on Bearing air must remain on when the turbine air is turned off until the turbine stops spinning Never turn off bearing air to cause the turbine to stop spinning If connected brake air can be used to slow the turbine The RMA 590 is equipped with a bearing air return line to monitor bearing air pressure at the turbine manifold When connected to the remote Serial Atomizer speed controller operation of the turbine will automatically be shut down whenever the bearing air pressure falls below the dip switch setting of 80 psi 551 6 kPa A WARNING gt Bearing air MUST be ON and supplied a minimum of 80 psig 551 6 kPa whenever the turbine is operated If no
101. ssed 2 micron one per applicator NOTE gt Air must be properly filtered to ensure extended turbine life and to prevent con tamination of the paint finish Air which is not adequately filtered will foul the turbine air bearings and cause turbine failure The correct type filters musts be used in an RMA 590 system The filter elements must be replaced regular schedule to assure clean air gt Itis the user s responsibility to ensure clean air at all times Turbine failure re sulting form contaminated air will not be covered under warranty If other filters are incorporated in the system the filters to be used must have filtering capacities equal or better than those shown in Air Filtration Requirements Charts gt The user must ensure the bearing air supply is not inadvertently turned off while the RMA 590 air motor is turning This will cause air bearing failure LN 9276 14 1 gt Each applicator must have its own fil ter for bearing air Recommended RPM 418 or equivalent MOUNTING The RMA 590 is equipped with a quick disconnect assembly The quick disconnectfeature consists of mounting manifold which is permanently mounted to the robot adapter and an atomizer body assem bly The atomizer body assembly is secured to the mounting manifold with a threaded ring 28 Ransburg RMA 590 Installation ELECTRICAL AND FIBER OPTIC CONNECTIONS The fiber optic connection is made on the back of the
102. ssembly to manufacturer s specification in this manual LN 9276 14 1 RMA 590 Maintenance Install bell cup wrench behind the bell cup and onto the hex flat of the shaft Grasp the bell cup by hand and hold steady Turn the bell cup wrench clockwise until the cup is loose Threads Taper Inspect the taper and threads on both the bell cup and air turbine Both components must be clean and free of paint or debris before re assembly 62 Ransburg 4 tighten Tighten To install the bell cup to the proper torque Install a 3 8 drive torque wrench into the space pro vided on the bell cup wrench Re assemble bell cup in reverse order of removal Hold the bell cup steady while turning the torque wrench in a counter clockwise direction Tighten to 50 70 Ibs In 5 69 7 91 Nm To tighten Insert the end of the A11229 00 tool over the fluid tip and align the 4 pins NOTE This is a left hand thread Turn clockwise to loosen and remove the fluid tip The paint orifice size is engraved on the body To install turn counter clockwise Tighten to 25 30 Ibs in 2 83 3 4 Nm Insure o ring is located on the back side of the larger diameter If omitted a leak of cup wash solvent will result LN 9276 14 1 RMA 590 Maintenance Orifice size engraved on this surface Fluid tip and cup wash o ring Removal Remove outer shroud by turning counter clock wise Lubricate o rings wi
103. sure kPa J00 34 5 69 103 5 138 1725 207 2415 276 3105 345 379 5 414 4485 483 SAO Outer Shape Air Air Consumption slpm Air Consumption scfm 5 10 15 20 25 30 35 40 45 50 55 60 65 70 Air Pressure psi LN 9276 14 1 14 Ransburg RMA 590 Introduction MAXIMUM FLOW RATE BY TIP SIZE HOSE LENGTH AND MATERIAL VISCOSITY 6mm 062 30 20 1 6mm 062 1380 15 20 39 630 9mm 035 520 0 mama e Gala m 062 705 30 30 1 6 062 910 KI 615 15 30 Ft of 8 x 6mm tubing Viscocity seconds in 4 Ford B50 0 200 400 600 800 1000 1200 1400 1600 cc min LN 9276 14 1 15 Ransburg RMA 590 Introduction RMA 590 TOOL CENTER POINT DIMENSIONS SHORT BODY 60 ADAPTER INDIRECT CHARGE 65MM DUAL FLEX 7 42 188 6 CO 4 48 113 8 5 20 138 6 _ 2 II 3 90 99 0 H ELLE ux 5 66 143 8 16 04 407 3 COG 13 89 352 8 lt EE E E 09 04 229 6 RMA 590 SHORT BODY 60 ADAPTER INDIRECT CHARGE 65MM DUAL FLEX 6 Inches 152mm 15 50 Inches 393 7mm 19 09 Inches 484 9mm 8 Inches 203mm 16 50 Inches 419 1mm 20 82 Inches 528 8mm 10 Inches 254mm 17 50 Inches 444 5mm 22 55 Inches 572 8mm 12 Inches 305mm 18 50 Inches 469 9mm 24 28 Inches 616 7mm LN 9276 14 1 16 Ransburg RMA 590 Intr
104. t severe bear ing damage will occur It is recommended that bearing air be left turned on at all times except during maintenance or disassembly gt Bearing damage and subsequent tur bine failure caused by running the turbine without bearing air WILL NOT be covered under the Ransburg warranty LN 9276 14 1 RMA 590 Operation Direct Charge Spraying When spraying solvent borne material you must provide voltage to the indirect charge ring and probes The voltage at the probes should be at a lower potential than that applied to the bell cup directly For example 70 is applied to the bell cup directly 65kv should be applied to the high voltage probes Having a higher potential on the probes may cause high voltage arching during spray operation This may cause fire or damage Use plastic or metal shape air component when spraying in direct charge mode Indirect Charge Spraying When spraying in this mode the bell cup is at earth ground potential High voltage is applied to the high voltage ring and probes 70kV maximum An electrostatic field develops between the high voltage probes the bell cup and the spray target An electrostatic charge is applied to the paint as it passes through this field Use only plastic shape air component when spraying in indirect charge mode NOTE gt A minimum of 70 slpm 2 6SCFM should always be kept flowing in the inner shaping air passage to keep the face of the applicator clean
105. t solvent flow while high voltage is energized direct charge only Turbine air and brake air must be inter locked to prevent both from being used si multaneously This interlock is provided by the Serial Atomizer Module See current Serial Atomizer service manual Any other interlocks required by local na tional code or international code The following system interlocks are required to prevent equipment damage LN 9276 14 1 RMA 590 Installation gt When the turbine air is turned off the turbine will continue to operate or coast down for about two minutes Provisions should be made to assure that the operator waits at least three minutes after shutting off the turbine air and before shutting off the main air supply gt The bell cup must be removed when making flow checks If the paint is turned on when the bell is mounted and the tur bine shaft is not rotating paint will enter the shaft and possibly damage the air bearing Material flow checks flow rate verification must be made with the bell cup off and the turbine not rotating Normally pneumatic interlocks will not allow the paint to trigger on when the turbine air is off WARNING gt The high voltage and or coating material must never be turned on unless the bell cup is mounted on the motor shaft and the turbine is rotating gt Pneumatic input to the turbine air inlet must be controlled to prevent the turbine from exceeding the maxim
106. tage on After spraying the object the sequence should be Voltage lowered to 30 50 kV Fluid off Shaping air to setback volume Turbine speed to set back speed 30 000 rpm recommended Recommended sample cup flush sequence is as follows voltage must be off internal and external cup wash 1 Turbine speed set to 25 000 30 000 rpm 2 Set shaping to 350 450 slpm 12 4 15 9 SCFM 3 Point atomizer at a grounded object such as a booth grate 4 Maintain solvent pressure of 100 150 psi 689 1 034 kPa Maintain air push pres sure at 80 100 psi 552 689 kPa 5 Use an alternating trigger sequence of sol vent air to create a chopping effect Always ensure that the last step in the sequence is an air push A typical sequence is 2 seconds solvent 1 0 second air push 1 7 seconds solvent and 2 0 seconds final air push This se quence may be modified for other paints and applications 6 It is recommended that an in line fluid filter be installed to ensure that no foreign debris enters the fluid tip or the external wash nozzle The RMA 590 is versatile in processing the fin ish of a component It can be setup as shown in Typical Paint Sequence figure 38 Ransburg Recommended sample cup purge sequence is as follows voltage must be off internal cup cleaning 1 Turbine speed set to 25 000 30 000 rpm 2 Increase shaping air to 350 450 slpm 12 4 15 9 SCFM 3 Paint atomizer at booth g
107. tands may be supported on an insulator but all components of the system up to the insulator MUST be grounded NOTE Ransburg recommends that ground connections to earth ground be 3 4 in sulated copper braided wire Grounds between assemblies within a machine should be run to a central point within the machine using 18 insulated stranded copper wire minimum All connections should be mechanically sound and have less than 5 ohms of resistance between assemblies and the common point The resistance between the central point and earth ground should be less than 5 ohms as well Where items are mounted directly on structur al components such as building columns the ground connection MUST still be made In many cases the structural component may be painted or coated with an insulated material and in all cases the equipment will provide the necessary connection at one end but the user must be sure that the other end is secured to an earth ground This may be achieved by the use of a standard ground clamp properly secured by brazing or by piercing the structural component enough to assure connection All ground connections should be made to the most conductive metallic structural ground available To be sure that everything is properly grounded the following steps should be undertaken at least daily 1 Inspect all ground wires Look for good firm joints at all points of connection Look for breaks in the ground wire Rep
108. te 3 Part numbers in Spare Parts list Page 86 Change part numbers in column E Page 90 Update Part numbers in table 2 items 6 and 7 Page 90 Change model numbers to 590 Page 92 93 Ransburg Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Phillips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts 2014 Finishing Brands Inc All rights reserved Form No LN 9276 14 1 Models and specifications subject to change without notice Litho in U S A 06 14
109. th petroleum jelly prior to re assembly Tighten until stop at the shoulder on the atomizer body 63 Ransburg To Remove Use a 3 16 end wrench to loosen and remove exterior cup wash fitting and tube before removing shaping air parts To Loosen Loosen but do not remove the set screw holding the inner shape air ring to the turbine body with a 2mm hex key Turn counter clockwise to remove inner and outer shape air assembly To re install tighten shape air assembly onto the turbine body threadsuntilstop Lubricate o rings with petroleum jelly prior to assembly tighten set screw after making contact with the turbine body to 5 Ibs in 0 56 Nm torque LN 9276 14 1 RMA 590 Maintenance Remove inner and outer shape airassembly from turbine body Separate the inner and our shape air components Do not use sharp or metal picks to clean shaping air holes Soak components and clean with a soft bristle brush flush with solvent and blow dry In spect all o rings prior to re assembly for damage Lubricate all o rings with petroleum jelly prior to re assembly 64 Ransburg Remove Remove the turbine retaining ring by engaging the pins on the A12088 00 spanner into the holes of the ring Turn counter clockwise to loosen and remove Pull turbine retaining ring forward to remove LN 9276 14 1 RMA 590 Maintenance Alignment marks Pull the turbine straight out while gently rocking back and fort
110. ts 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 draw ings and appropriate Ransburg equipment man uals to reconcile such differences Careful study and continued use ofthis 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 Ransburg representative or Ransburg LN 9276 14 1 590 Safety WARNING gt The user 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 thor oughly 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 SAFE TY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment WARNING gt The hazards shown on the following pag
111. um rated speed of 100 000 rpm See Specifications in the Introduction section gt High voltage must never be turned on while cleaning solvent is being sprayed either through the applicator supply or the cup wash line High voltage and both solvent triggers must be interlocked direct charge only Never Spray solvent with high voltage 31 Ransburg OPERATION WARNING gt Operators must be fully trained in safe operation of electrostatic equipment Op erators must read all instructions and safe ty precautions prior to using this equipment see NFPA 33 As with any spray finishing system operation of the RMA 590 involves properly setting the oper ating parameters to obtain the best finish quality for the coating material being sprayed while maintaining correct operation and reliability of the equipment used Adjustments to operating parameters which cover spraying cleaning and on off control include Coating materials Fluid flow rate control Fluid valve control Turbine speed Bearing air adjustment Shaping air Brake air Electrostatic voltage Target distance WARNING gt Electrical discharge of a high electrical capacitance fluid paint system can cause fire or explosion with some materials If arc ing occurs when a specific coating material is used turn the system off and verify that the fluid is non flammable In these condi tions the system is ca

Hybrid Model A13368 (Serv. Man. LN-9276-14.1)

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