RPA-2 Powder Applicator (Serv. Man. LN-9271-12.2)
Contents
1. 27 PARTS 28 42 APPEICATOR PARTS DRAWING ee 28 30 PARTS ECISTAND DRAWINGS uu o bh 31 37 SHAPE AIR ASSEMBLY AND PARTS LIST uu uuu uuu kezeket tetszo oto qhu aha sa 37 38 ELECTRODE ASSEMBLY AND PARTS LIST seca diet a Ru te ose 39 40 SPAREPART OG ee 41 42 WARRANTY POLICIES 43 Wi RR E RECH EE 43 LN 9271 12 2 RPA 2 POWDER APPLICATOR Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety literature for your Ransburg products This manual contains information that is important for you to know and understand This infor mation relates to USER SAFETY and PRE VENTING EQUIPMENT PROBLEMS To help you recognize this information we use the fol lowing symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that might cause serious inju ry 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 pro cedure in progress While this manual lists standard specifications and service procedures some minor devia tions may be found between this literature and your equipme2. MICROPAK 505 CASCADE 10565 00 F A11789 01 1 MICROPAK amp 1 DISCRETE WITH STANDALONE A10565 00 ENCL HP 505 A11789 02 2 MICROPAK amp 2 DISCRETE WITH STANDALONE A10565 00 ENCL HP 505 A A11789 06 2 MICROPAK 2 DISCRETE WITH STANDALONE 79010 01 ENCL HP 404 2 NO MICROPAK HP 404 CASCADE 79010 01 3 11789 05 1 1 MICROPAK amp 1 DISCRETE WITH STANDALONE 79010 01 ENCL HP 404 LN 9271 12 2 36 0813 LNOHLIM 412 ZON 3404 N3dO CNOHHS 00 9606 LV B B B B MEN E 3408109313 831 NNOD LNOHLIM 3 DNIH HIV DNIdVHS 00 ISLLLV L0 6v6cIV SP 0 676 LV 00 6962 LY 00 99581 00 6v6cIV B 00 6962 LY 00 99682 00 6v6cIV B Ee 3408109313 831 977 ZON 3404 N3dO HIV CNOHHS 00 9902 Ly RPA 2 POWDER Parts 3 3 ONIX HIV SNIdVHS 3NON NOI LdlHOS3Q H HSVd 00 ISLLLV to 2 390412313 YALNNOD HIV 9NIdVHS 4 31971 LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Parts Ransburg 3 TABLE G GROUND CABLE ASSEMBLY DASH NO DESCRIPTION 1 1680 10 CABLE HIGH VOLTAGE GROUND 10 FT A11680 25 CABLE HIGH VOLTAGE GROUND 25 FT A11680 50 CABLE HIGH VOLTAGE GROUND 50 FT CABLE HIGH VOLTAG
3. 23 LN 9271 12 2 RPA 2 POWDER APPLICATOR Maintenance Ransburg Nozzle Assembly A11295 00 Diffuser and Nozzle Holder Tighten Until Stop Wear Bar and Conductive Seal LN 9271 12 2 24 RPA 2 POWDER APPLICATOR Maintenance Ransburg High Voltage Contact Repair Pull damaged spring and wire out from the front of applicator with pli ers Insert new contact assembly from front of application until spring rests in the bottom of the hole From inside the cascade labyrinth use a 3 16 diameter flat end plastic rod and bend over flat 78997 01 HIGH VOLTAGE CONTACT SPRING INSTALL FROM THIS END INSERT WIRE FROM FRONT OF APPLICATOR THRU TO HOLE IN CASCADE LABYRINTH BEND WIRE OVER AS SHOWN USING A FLAT END OF A 3 16 DIA PLASTIC ROD High Voltage Contact Repair 25 LN 9271 12 2 Ransburg ASSEMBLY OF THE APPLI CATOR Assemble the applicator in reverse order of the disassembly Assembly Notes 1 The lower powder tube and ring ass y el bow and upper powder tube must align to create a seal The best method is to assemble all three parts loosely then tighten the thumb screws and then tighten the shaping air or shroud 2 The power hose connection should always be rotated in until the lower powder tube and ring ass y seals in the powder elbow k d Du Alignment Pin White color LN 9271 12 2 RPA 2 POWDER APPLICATOR Maintenance Note The lower powder tube has a
4. 52 S POWDER TUBE FITTING 1 53 T POWDER TUBE CLAMP 1 54 U O RING 12 0 X 1 50 VITON 1 55 A13001 00 TOOL NOT SHOWN 1 56 A13101 00 LABEL 1 61 11131 00 O RING SOLVENT RESISTANT 1 62 D LOW VOLTAGE CABLE EXTENSION 1 63 11146 00 PLUG 1 31 Ransburg LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Parts WHEN ORDERING USE A12950 X X X XX X X X AS INDICATED BY TABLES A THROUGH EIGHT DIGITS MUST FOLLOW THE BASIC PART NUMBER FOR EXAMPLE A12950 X X X XX X X X BASIC PART NUMBER UPPER TUBE AND ELBOW TABLE A ELECTRODE HOLDER TABLE B ROBOT ADAPTER TABLE C GROUND CABLE ASSEMBLY TABLE G SHAPING AIR RING TABLE F STANDALONE POWER SUPPLY TABLE E LOW VOLTAGE CABLE TABLE D TABLE A Upper Tube and Elbow n 1 11196 00 A11199 01 UPPER POWDER TUBE ELBOW DENSE PHASE 2 A11196 00 A11199 01 UPPER POWDER A11133 00 1 1132 00 A11127 00 A11130 00 TUBE ELBOW VENTURI PHASE LN 9271 12 2 32 RPA 2 POWDER APPLICATOR Parts Ransburg TABLE B Electrode Holder GE DESCRIPTION 1 A11295 11 ELECTRODE HOLDER ASSEMBLY W REPLACEMENT WEAR BAR 2 A12052 00 A11138 00 OPEN BORE FLAT JET NOZZLE ASSEMBLY 33 LN 9271 12 2 14 SL 14 0S 13 Se 14 SZ 14 0S 13 Se 14 SZ RPA 2 POWDER APPLICATOR Parts 14 09 14 OV 14 Ge 14 91 19N31I Ransburg MVdOHO
5. 77566 24 screws 3 16 hex key LN 9271 12 2 RPA 2 POWDER APPLICATOR Installation 10 Connect the low voltage cable to the control unit see the current MicroPak or Evolver MicroPak controller service manuals for wire termination Suggested switch setting SW 3 1 amp 2 On SW 7 1 On 5 amp 6 Off 11 Powder supply can either be delivered through the dilute phase pump Venturi or dense phase pump A Dilute phase powder supply hose is connected to the applicator Items 51 52 53 and 54 are ordered separately for a Venturi Feed application Table A Upper Powder in the Parts Identi fication section shows optional parts required for the tube connection Con nect dilute phase powder supply hose only if available B Dense phase powder supply hose is connected to the multi color integrator The MCI will use dilution air to dilute the dense phase powder Dilution air requirements are powder dependent Connect the MCI to the open threaded connection next to the pneumatic tube connections The multi color integrator will also have the required powder supply lines and one more pneumatic link used for a pinch valve Refer to Function and Operation information from MCI manufacturer s documentation 12 Align the 2 pins on the applicator rear plate with the mating holes of the robot plate opin the mounting ring to tighten applicator to the robot plate 12 RPA 2 POWDER APPLICATO
6. See Figure Weight 4 2 kg 9 26 Ibs 10 02 254 4 COG 02 6 x LJ 04 91 124 8 09 T 5 6 1 COG ar OCG 6 57 166 9 05 31 135 0 18 45 468 5 11 2 2 Ransburg INSTALLATION The relevant Safety Standards as well as the Safety Regulations of the robot manufacturer must be adhered to for the operation of the RPA 2 applicator CONNECTING PROCEDURE 1 Attach the robot adapter to the end of the ro bot 2 Lay out the applicator powder hose electrode rinsing air hose cascade rinsing air hose and shaping air hose in such a way that neither kinks or twist can likely form 3 Connect the shaping air SA to the proper push in fitting on the robot plate Clean pneu matic tubing of any debris 4 Connect the electrode rinsing air EA to the robot plate Clean pneumatic tubes of any de bris 5 Connect the cascade rinsing air CA to the robot plate 6 Connect the ground cable to GND fitting on the robot plate Do Not Over Tighten 7 Connect the other end of the ground cable to a good known earth ground source after in stalling the cable thru the robot arm 8 Connect the low voltage cable to the robot plate Align marks and tighten set screw See Picture 9 Install tubing and cables thru the robot arm Attach robot plate to robot adapter with 4
7. e Page 31 Item 29 was A11171 Lower Tube and item 46 was A11178 Ring e Page 42 A11571 00 was A11178 00 Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Philips 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 2013 Ransburg All rights reserved Form No LN 9271 12 1 Models and specifications subject to change without notice Litho in U S A 03 13 LN 9271 12 2
8. 12944 00 INLET FITTING 1 2 A12945 00 REAR PLATE 1 3 A12946 00 PLATE 1 4 G ASS Y CASCADE HP404 1 7 A10890 02 FITTING 8 MM ODT X 1 4 BSP 1 8 O BODY RETAINING CAP 1 9 N PLUG RETAINING CONTACT PIN 1 10 M SPRING CLOSED AND GROUND 1 11 L PIN CONTACT 1 12 K PLUG CONTACT 1 13 E LOW VOLTAGE CABLE OUICK DISCONNECT 1 15 SSF 2052 SET SCREW 3 8 LG X 10 24 2 16 A11129 00 FITTING 1 4 UNIVERSAL X METRIC ODT PNEUMATIC 3 18 C ROBOT ADAPTER FANUC P 200 P 250 1 19 A12948 00 J MOUNTING RING 1 20 76566 24C SCREW STAINLESS 1 4 20 X 3 4 LG S H C S 4 21 A12952 00 AIR STUD MEDIUM MACHINED 3 22 7554 08 O RING VITON 3 23 7554 12 O RING VITON 1 24 7554 09 O RING VITON 3 25 Z COVER 2 26 AA SCREW M5 X 0 8 NYLON 8 27 A UPPER POWDER TUBE 1 29 11571 00 LOWER POWDER TUBE AND RING ASSEMBLY 1 31 A11174 00 TOP PLUG 1 32 11124 00 O RING SOLVENT RESISTANT 1 33 11173 00 REAR PLUG 1 34 11122 00 O RING SOLVENT RESISTANT 1 35 J CHARGING RING SECONDARY OR BLANK SPACER 1 36 I SCREW M3 X 0 5 X 10 FLT HD 2 37 B 2 ELECTRODE HOLDER ASSEMBLY 1 38 H SHAPING AIR RING ASSEMBLY 1 39 W GROUND CABLE ASSEMBLY RMA 303 1 40 11338 00 SCREW SOC HD CAP 8 X 25MM LG 4 41 X RESISTOR HIGH MEGAOHM 5 GIG 1 42 Y CONTACT SPRING 1 43 V RPA GUN BODY ASSEMBLY 1 45 A ELBOW 1 47 B OPEN BORE FLAT JET NOZZLE ASSEMBLY 1 48 P HOLE PLUG COUNTER ELECTRODE NOT SHOWN 1 49 79001 09 SOLVENT PROOF 1 51 R POWDER TUBE THREAD ADAPTER 1
9. E GROUND 75 FT CABLE HIGH VOLTAGE GROUND 100 FT RPA 2 Powder Applicator Shaping Air Cowl A11151 00 RPA 2 Powder Applicator Shaping Air Cowl A11151 00 Parts List THREADED RING SHAPING AIR SHAPING AIR RING ORIFICE 0 7 MM s e fone o gt Joen 1 LN 9271 12 2 RPA 2 POWDER APPLICATOR Parts Ransburg o di a Ls ss Shroud air Open Bore Nozzle A12056 00 SHROUD AIR OPEN BORE NOZZLE A12056 00 PARTS LIST A12053 00 lt AIR SHROUD me T LN 9271 12 2 38 RPA 2 POWDER APPLICATOR Parts Ransburg EM Electrode Holder A11295 XX Electrode Holder A11295 XX PARIS LIST s esas C emm Je T 39 LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Parts ELECTRODE HOLDER MODEL IDENTIFICATION When ordering use A11295 A or B as indicated Tables A and B Two digits must follow the Basic Part Number For Example Basic Part Number Table B Electrode Holder with Bar With or Without Deflector TABLE A TABLE A 2 ELECTRODE DEFLECTOR 3 TABLE B 2 ELECTRODE HOLDER 1 UHMW Electrode Holder Replaceable A11290 01 A11304 00 Wear Bar 2 UHMW Electrode Holder Wear Bar A11302 01 Not Replaceable LN 9271 12 2 40 RPA 2 POWDER APPLICATOR Parts Ransburg 22 Nozzle Application Electrode Holder Sha
10. IN 3NOTVOINV LS OL QN3 LOANNOO MOINO 4vdOUOIIN OL LO3NNOO 318VO 39V L 10A MOT MVdOHOIN ANOTVGNVLS AN3 NOISH3A LOANNOO M9If1O 3vdOUOIIN OL LO3NNOO 318VO 39V L 10A MOT MVdOHOIN 16 OL AN3 NOISH3A LOANNOO 491010 MvdOUOIIN OL LO3NNOO 318VO 39V L1OA MOT VdOUOIIN 16 OL AN3 LOANNOO MOINO 3vdOUOIIN OL LO3NNOO 318VO 39V L 10A MOT WVdOHOIN 16 AN3 NOISH3A LOANNOO MOINO 3vdOUOIIN OL LO3NNOO 318VO 39V L 10A MOT GL 6EZZ LY W 0S 682Z LY 01 90 LV 6 LV 90 6ecclIV OG EEVCLV ZO 90 66 lV wa 90 6 V SO 90 6EcclV v0 90 66 LV ws 50 90 6 LV cO 90 LV LO Wa ON LN 9271 12 2 LlvdOH OI ANOTVGNVLS AN3 NOISHJA LOANNOO MvdO4HJIAI OL LO3NNOO 318VO 39V L 10A MOT H3A 3UIM JXvV dOHJIAI OL LO3NNOO 318V9 39V LTOA MOT H3A 3UIM LO3NNOO 318V9 39V L1TOA MOT H3A 3UIM YVdOHOIN LO3NNOO 318V9 MOT H3A YVdOHOIN LO3NNOO 318V9 39V LTOA MOT H3A 3UIM YVdOHOIN LO3NNOO 318V9 ADVLIOA MOT V N NOI LdIlHOS3Qd 318V9 ADVLIOA MOT 318V L 34 RPA 2 POWDER APPLICATOR Parts Ransburg 35 TABLEE STANDALONE POWER SUPPLY DASH NO re DESCRIPTION G CASCADE
11. OI OQ N NI oi ci a a OI OD OINI OF CO OIOI NI OT Ot N NI oO TT a 9 elj e gt El Y O in gt gt xi OF ol ol O O olol ol SI SI SI S o S l S SO l S ol 3 5 Top Plug Rear Plug Cover Screw Nylon for A12953 00 Cover Fitting 8mm Tube Screw M8 x 25 SHCS Fiberglass for Rear Plate DA Upper Powder Tube Dense Phase Application Top Elbow Dense Phase or Venturi Application Upper Powder Tube Venturi application Lower Powder Tube and Ring Ass y Ground Cable Assembly See page 41 Low Voltage Cable See page 38 Low Voltage Cable extension See page 38 LN 9271 12 2 42 RPA 2 POWDER APPLICATOR Warranty Policies WARRANTY 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 THE USE OF OTHER THAN RANSBURG APPROVED PARTS VOID ALL WARRAN TIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period
12. R Installation Function Check 1 Switch on the high voltage controls A good ting to start is 20 kV for doing checks Adjust the high voltage at the control unit set Slowly increase the high voltage The value of the high voltage display should increase slowly f Ransburg 5 Verify the presence of the high voltage field by means of a high voltage probe Shaping air electrode rinsing air cascade rins ing air and dilution air if available are adjusted depending on the application see Start Up in the Operation section If all tests have been completed positively the applicator is ready for operation If malfunctions 4 The maximum nominal output current can be happen error cause can determined by monitored on the applicator control unit Weg wp means of the list in the Troubleshooting Guide in the maintenance section LEGEND SA SHAPING AIR EA ELECTRODE AI CA CASCADE AIR bmm URETHAN SA 6mm URETHANE BLUE SA SA FROM SHAPING AIR RING omm URETHANE EA 6mm URE ANE GREEN EFA FROM ELECTRODE AIR Em
13. SERVICE MANUAL Ra nsburg LN 9271 12 2 April 2013 Supersedes LN 9271 12 1 RPA 2 MODEL A12950 XXX 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 LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Contents CONTENTS PAGE SAFETY 1 6 SAFETY RER H LE 1 HAZARD SE ARE CUAR unu uuu eee 2 6 INIRODUCTION 7AT GENERALE DESCRIP TION vases ua ua o ead ets y POWDERAPPLEICATOR MAIN COMPONENTS u u uuu uu dU 8 TOOLS ceu peer 9 HIGH VOLTAGE GENERATION ROUND NOZZLE DESCRIPTION 10 SPECIFICATIONS CENTER OF GRAVITY Serum 11 INSTALLATION 12 13 GONNECTION BROCE DURE uu EEUU EZEN HE LOI MEN SEDE IH uU Shut 12 FUNG HON GHECK AND SGFIEMATICG L etica cte en iat eat D a oa ad 13 OPERATION 14 15 GENERAL OPEPATIONSIAPPPPUJP u ll esa bes nh pst il l it Pet 14 15 TROUBLESHOOTING GUIDE oe i E o een 16 17 INSPECTING AND GEEANINGE uuu uuu u REPRE PUR M d apa 17 18 APPLIGATORUDIS ASSEMBI Y u uu ett oe ern eden 18 24 HIGH VOLTAGE CONTACT WIRE REPAIR bue u 25 APPLICATOR E i5 iin VM Mtn 26 DEFECTIVE PARTS RECOGNITION
14. WDER APPLICATOR Operation 9 10 The adjustments for high voltage elec trode rinsing air shaping air dilution air if available and powder output can be left as they are now that powder is triggered off If work is interrupted such as lunch time night etc Switch off the high voltage con trol unit and disconnect the main com pressed air supply Ransburg LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Maintenance MAINTENANCE TROUBLESHOOTING GUIDE High voltage dis In the applicator 1 Replace applicator low voltage cable send in for repair Check connections for proper contact play shows no value although the control unitis 2 High voltage cascade defect 1 Applicator cable defect switched on and high voltage is being called for During coating air flows out of the applicator body The applicator does not spray powder in spite calling for powder flow Powder applicator sprays powder but the powder does not adhere on the work piece LN 9271 12 2 Wrong MicroPak switch set tings O Ring defective or missing on shaping ring Loose fitting hose Powder hose applicator injector non return valve or throttle on the injector clogged Insert sleeve on the injector is worn No conveying air a Solenoid valve defective Dense phase pump not working Applicator plug applicator cable or connection defec tive High voltage cascade is de fe
15. bon Trichloroethane are not chemi solvents must never be used with aluminum equip cally compatible with the alumi ment during spraying flushing or cleaning Read num that might be used in many the label or data sheet for the material you intend system components The to spray If in doubt as to whether or not a coating chemical reaction caused by or cleaning material is compatible contact your these solvents reacting with alu coating supplier Any other type of solvent may be lead to an equipment explosion LN 9271 12 2 6 RPA 2 Powder Applicator Introduction Ransburg INTRODUCTION GENERAL DESCRIPTION This operating manual contains all important Information required for working with the RPA 2 Powder Applicator It will give you refer ences and tips for the optimal use of your new powder coating system The RPA 2 is intended exclusively for the electrostatic coating with organic powders Any other use is considered as non conforming The manufacturer is not responsi ble for any damage resulting from this the risk for this is assumed by the user alone With an integrated high voltage generator cascade the RPA 2 is particularly suitable for the coating of car bodies and parts The applicator is designed for operation on a freely programmable hollow wrist robot up to 7 axes The RPA 2 is installed on the front side of a follow arm coating robot An appropriate adapter piece for the corresponding robot ty
16. cas cade to produce the necessary high voltage up to 100 kV The high voltage is fed through a conductive path in the atomizer to the central electrode see figure 1 RPA 2 POWDER APPLICATOR Introduction Round Jet Nozzle With Air Cleaned Electrode The round nozzle shapes and distributes the powder The powder cloud obtains a bell similar spray pattern by the deflector plate and by the dynamic powder air flow The powder is charged by means of the cen tral electrode The high voltage which is pro duced by the cascade in the applicator is con nected to the electrode through the black con tact ring on the nozzle holder The round noz zle front face is rinsed with compressed air in order to prevent powder accumulations The electrode rinsing air is fed into the electrode holder through the small hole in the black con tact ring of the nozzle holder The electrode rinsing air volume is typically maintained at a constant setting of 40 50 SLPM POWDER EXIT BLACK CONTACT RING N FRONT FACE CENTRAL ELECTRODE Round Nozzle Figure LN 9271 12 2 RPA 2 Powder Applicator Introduction Ransburg SPECIFICATIONS Environmental Electrical Operating Temperature 0 C to 55 C Output Voltage 100 kV Storage and Shipping Temperature 40 C to 85 C Maximum Output Current 240 0 kV Humidity 95 Non Condensing Polarity Negative Physical Height See Figure Width See Figure Depth
17. ctive Plugged electrode Replace high voltage cascade send in for repair Check MicroPak settings Refer to cur rent MicroPak service manual Replace or insert O ring Check fitting push in hose Carry out corresponding cleaning Replace see the corresponding Oper ating Manual of the injector Replace see Dense Phase Pump manual Replace defective part or send in for repair Send in the applicator for repair or re place high voltage cascade Pneumatically blow backwards through hollow tube 16 RPA 2 POWDER APPLICATOR Maintenance Ransburg 17 MAINTENANCE TROUBLESHOOTING GUIDE Applicator sprays 1 High voltage too low 1 Increase high voltage on the control unit powder high volt 2 Work piece not properly Check the grounding measure age available but grounded the powder does Look for loose connections not adhere on the Plastic on conductive component work piece ek Loose fitting hinges Non conductive coating present on sub strate before spraying INSPECTING AND CLEAN ING THE APPLICATOR Before cleaning applicator switch off the control unit The compressed air used for 1 Blow off the atomizer externally with com cleaning must be free of oil water and other pressed air contaminates 2 solvent wipe is required use VM amp P WARNING Naphtha for a final wipe to remove any con ductive residue Make sure the large diameter thread
18. distance must be maintained between the parts being coated and the applicator A distance of 1 inch for every 10KV of output voltage is re quired at all times Unless specifically approved for use in hazardous locations all electrical equipment must be located outside Class I or II 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 corresponding section of the equipment manual Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the current over load sensitivity is not properly set Frequent power supply shutdown indicates a problem 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 ob jects are within the safe sparking distance Ensure that the control panel is interlocked with the ventilation system and conveyor in accordance with NFPA 33 EN 50176 Have fire extinguishing equipment readily available and tested periodically Personnel must be given training in accordance with the requirements of NFPA 33 EN 60079 0 Instructions and safety precautions must be read and understood prior to using this equipment Comply with appropriate local state and national codes governing ventila
19. ed ring applicator body to shaping ring is al 3 Clean the atomizer only with a damp rag ways tightened well If it is fitted loosely Never immerse the components into sol there is a danger that a discharge may occur Jens with the high voltage which leads inevitably to damaging the plastic components 4 Remove any impact fusion on deflector without scratching or scoring the soft plastic surface of the deflector Impact fusion can be removed with a solvent soaked towel o If impact fusion is not removed it will short en the life of the parts and cause defects WARNING 6 Blow out all powder hoses with high ae gt careful with nozzle electrode during volume high velocity air purge during clean cleaning and maintenance danger of inju ing ry Never bend or pull electrode LN 9271 12 2 Ransburg Cleaning Powder Hose Venturi Feed The powder hose has to be cleaned from the residual powder The cleaning takes place in the following steps 1 Strip the powder hose from the connection on the Venturi pump 2 Blow through the hose manually with com pressed air to blow loose powder through to the applicator 3 Fit the powder hose onto the hose connec tion on the injector Weekly Cleaning and Inspection 1 Remove the electrode holder by removing the shaping air ring Clean on the inside with compressed air and remove possible powder accumulations 2 Check for wear or damage on parts tha
20. elbows only 6 View of Lower Powder Tube and Ring Ass y and O ring in Correct Orientation 6a Lift Lower Powder Tube and Ring Ass y Da Lift Elbow Off Lower Powder Tube and Ring Ass y 6b Lower Powder Tube and Ring Ass y Alignment Pin 5b Pull Out Alignment Pin White LN 9271 12 2 20 RPA 2 POWDER APPLICATOR Maintenance Ransburg 6c Slot Position 7 Backside of Applicator W Counter as electrode contact if equipped Counter Electrode Contact 6d Extract Out Top Port 8 Remove 4 Screws From Applicator Plate 6mm Hex Key 6e View of Lower Powder Tube and Ring Ass y and Slot 9 Remove Applicator Plate a 21 LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Maintenance 10 Remove Cascade 11b Resistor 11 Counter Electrode Dis Assembly If 11c Counter Electrode Parts in Order of Equipped Installation 12 Counter electrode Front of Applicator 11a Contact Spring Assembly Mounting Screw 2 LN 9271 12 2 22 RPA 2 POWDER APPLICATOR Maintenance Ransburg 12a Contact Spring Front Shown With 13c Parts Required For No Counter Mounting Screws Loose Mounting Screw Counter Electrode Blank Contact Spring part of Gun Counter Electrode Contact Blank 13 No Counter Electrode Option Counter Electrode Contact Blank 13a Counter Electrode Blank Shown With Mounting Screws Loose Body Option Without Spring Contact
21. is ninety 90 days EQUIPMENT When purchased as a complete unit 1 guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR ASSO CIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY 43 Ransburg RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO RE PLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATER IALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRAN TIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANS BURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUC TION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will assume no responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Changes made to LN 9271 12 2 Service Manual e Page 20 and 21 Lower Powder Tube and Ring Ass y was two 2 parts Lower Tube and Ring e Page 28 and 29 Revised drawing to show Lower Powder Tube and Ring Ass y
22. m URETHANE 6mm URETHANE GRAY CA CASCADE RINSE AIR FROM HOLLOW ELECTRODE CASCADE LV CABI DV TO SAME EARTH HIGH VOLTAGE GROUND AS MICROPAK GND NO OTHER COMPONENTS ON THIS GROUND PATH GROUND CONNECTION FOR SUPER CORONA RING AND AP ol ICATOR 13 LN 9271 12 2 Ransburg OPERATION GENERAL OPERATION There are several variables that need to be con sidered when using this applicator Each one influ ences the operation T hey are 1 High voltage affects how much the powder is charged If the kV is set too high defects will appear If the kV is set too low then the pow der will not charge and will not stick to the sub strate 2 Shaping air is used to control pattern size With high amounts of shaping air the air will propel the powder particles quickly towards the target This may reduce transfer efficiency a Round Spray Electrode rinsing air pro vides a cushion of air in front of the deflec tor and assists in keeping its front face clear This s usually set at 45 50 SLPM b Open Bore Nozzle set electrode rinsing air 8 10 SLPM The air helps keep the electrodes clean 3 Cascade air is used to ventilate the inside of the applicator The normal setting is between 25 and 50 SLPM 4 Target distance between the applicator and substrate will influence how big the pattern is A good starting point is 8 inches 5 Robot arm speed TIP speed is used to influ ence the rate at which powder is applied 6 P
23. n alignment slot see above which must align with the align ment pin in the gun body for proper fit of com ponents 26 RPA 2 POWDER APPLICATOR Maintenance Ransburg Normal Deflector Replace Deflector Normal Nozzle Holder Replace Nozzle Normal Wear Bar Replace Wear Bar 27 LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Parts DETAIL C SCALE 1 1 RPA 2 ASSEMBLY LN 9271 12 2 28 RPA 2 POWDER APPLICATOR Parts Ransburg SN RPA 2 ASSEMBLY CONT D 29 LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Parts ABLE A as M ABLE B 45 20 7 CH RPA 2 with Open Bore Nozzle ABLE A Inu IABLE 2 RPA 2 with Replaceable Elbow Upper Tube Electrode Holder RPA 2 ASSEMBLY CONT D LN 9271 12 2 30 RPA 2 POWDER APPLICATOR Parts PARTS LIST ITEM PART NUMBER DESCRIPTION QTY 1 A
24. nt Differences in local codes and plant requirements material delivery require ments etc make such variations inevitable Compare this manual with your system instal lation drawings and appropriate Ransburg equipment manuals to reconcile such differ ences Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more effi cient 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 Ransburg 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 opecial care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD LATEST EDITION prior to installing operating and or servic ing this equipment y he hazards shown on the following pages may occur during the normal use of this equipment Please read the haz ard chart beginning on page 2 LN 9271 12 2 Ransburg AREA Tells where haz ards may occur S
25. owder flow rate is the primary influencer of the rate at which powder can be applied Make sure that all electrostatically con ductive parts within 5 meter of the spray booth are grounded LN 9271 12 2 RPA 2 POWDER APPLICATOR Operation START UP Adjusting the Powder Out put Powder Cloud The powder output depends on the powder type the powder hose length the powder hose diameter and the powder pump The RPA 2 applicator can be used in connection with Venturi pumps and dense phase pumps like i e powder pressure pump The operating principle of the injector and the different powder pumps is explained in their corresponding operating manuals 1 Switch on the power supply 2 Adjust the powder output 3 Adjust the shaping air so that the form of the powder cloud corresponds to the de sired size A good initial setting is 20 SLPM 4 Adjust the dilution air if powder applica ble so that the form of the powder cloud is uniform A good initial setting is 90 SLPM Lowest dilution air setting will be above 40 SLPM 5 Adjust the electrode rinsing air flow so that the desired form of powder cloud is not impaired A good initial setting is 50 SPLM 6 Switch high voltage on the control unit See applicable service manual for opera tion of high voltage controls 7 good initial voltage setting is 60 kV set point for voltage or current control 8 Trigger kV and Powder OFF 14 RPA 2 PO
26. ower supply control cabinet and all other electrical equipment must be located outside Class or II Division 1 and 2 hazardous 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 manufac turer 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 hygienist or safety expert and be NIOSH approved LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Safety AREA HAZARD SAFEGUARDS Tells where haz Tells what the hazard IS Tells how to avoid the hazard ards may occur Spray Area Explosion Hazard Incompatible Materials Halogenated hydrocarbon sol Aluminum is widely used in other spray application vents for example methylene equipment such as material pumps regulators chloride and 1 1 1 triggering valves etc Halogenated hydrocar
27. pe is used for fitting the applicator to the robot This adapter provides a locating pin for exact positioning of the applicator as well as the fixture of the applicator cable and hoses The RPA 2 has a high and constant transfer efficiency The applicator is quick detachable therefore fast and easy for maintenance and repair The wear parts can be easily changed even with the applicator attached to the robot 7 LN 9271 12 2 RPA 2 POWDER APPLICATOR Introduction Ransburg POWDER INLET SHAPING AIR SA LOW VOLTAGE CABLE QUICK DISCONNECT O gt o o ELECTRODE AIR CASCADE AIR CA 1 Shaping Air 5 Applicator Ground Cable and Low Voltage Cable 2 Applicator Body 6 Powder Hose Connection 3 High Voltage Cascade Internal 7 Nozzle 4 Robot Adapter Figure 1 RPA 2 Powder Applicator LN 9271 12 2 RPA 2 Powder Applicator Introduction Ransburg Tools Required for Assembly Dis Assembly at UPS T ASW H 5 7246 P om Tu sis PES H Zo PIA E lt Sy gt l HA gt me Le d uh RSS 2577 Zi gd GH LN 9271 12 2 Ransburg High Voltage Generation The applicator high voltage control unit sup plies a high frequency low voltage signal to the cascade This voltage is fed through the applicator cable and the cascade connection The low voltage signal is multiplied in the
28. pe Air Application option x gt gt ola Co S Qi OH Dx Counter Electrode Application Screw M3 x 10 Flt Hd Nylon Gur Body Assy Non Counter Seen Applicaton 41 LN 9271 12 2 gt gt gt gt gt Gi GIG Gi gt gt gt gt gt gt gt gt bx co d on od ok J ok a no Po N a cO cO j oO DD 0 ro n2 wm o mn 9 Ol wo gt cO o 9 OIO Ololololo O OIO Oloio Ee O Ransburg RPA 2 POWDER APPLICATOR Parts Recommended Spare Parts CONT D Part Qt Description Parts Common To All Applicators O ring S Qi OH bu o S Qi OH s o O ring O ring O ring O ring O ring O ring for Top Plug O ring for Rear Plug gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt N nil zal eck nal szk k k lt al OI OQ NI eech NI NI zech a al
29. pray Area LN 9271 12 2 RPA 2 POWDER APPLICATOR Safety HAZARD Tells what the hazard IS Fire Hazard Improper or inadequate opera ton and maintenance proce dures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent Pow er Supply or Controller shut down indicates a problem in the system requiring correction 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 ac cumulation 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 mainte nance When using solvents for cleaning e 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 be main tained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A distance of 1 inch for eve
30. ry 10KV of output voltage is re quired 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 unauthorized eguipment modifications may cause fire or injury If used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks disabled Never use eguipment intended for use in water borne installations to spray solvent based materi als The paint process and eguipment should be set up and operated in accordance with NFPA 33 NEC OSHA local country and European Health and Safety Norms RPA 2 POWDER APPLICATOR Safety AREA Tells where haz ards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard IS Explosion Hazard Improper or inadequate opera ton and maintenance proce dures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent Power Supply or Con troller shutdown indicates a problem in the system requiring correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment Ransburg SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing must be prevented Safe sparking
31. t contact powder 3 Follow Daily Cleaning steps 4 The powder supply is to be filled with pow der just before resumption of the opera tion Monthly Cleaning and Inspection Follow Daily cleaning steps The atomizer wear parts are to be inspected and replaced if e Uneven powder distribution on deflector as compared to starting e he spray pattern no longer has a regular form LN 9271 12 2 RPA 2 POWDER APPLICATOR Maintenance e The deflector plate is no longer round or is worn e The wedge of the electrode holder wear bar is worn down to the electrode holder e Check low voltage cable for cuts abra sion and wear y Regular and conscientious maintenance increases the life soan of the RPA 2 applica tor and provides for a larger continuous coat ing quality with reduced defects DISASSEMBLING THE APPLICATOR Before disassembling the applicator turn off the air supply to shaping air atomizing air if available and rinsing airs 1 Remove Robot Adapter Covers 18 RPA 2 POWDER APPLICATOR Maintenance Ransburg 2 Remove Robot Adapter by unthreading 4a Unscrew the Shaping Air Ring large diameter retaining ring Applicator with Round Nozzle and 4b Remove the Shaping Air Ring Electrode Holder Assembly 3 Unscrew Round Deflector a e We 4 4c Remove the Nozzle With Power Tube 19 LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Maintenance 5 Remove rear plugs to view
32. tion fire protection opera tion maintenance and housekeeping Reference OSHA NFPA 33 EN Norms and your insurance company requirements LN 9271 12 2 Ransburg RPA 2 POWDER APPLICATOR Safety AREA HAZARD SAFEGUARDS Tells what the hazard is Tells how to avoid the hazard Tells where haz ards may occur Electrical Discharge Spray Area High Voltage Equip Parts being sprayed and operators in the spra ment g Spray p pray There is a high voltage device area must be properly grounded that can induce an electrical charge on ungrounded objects Parts being sprayed must be supported on convey which is capable of igniting coat ors or hangers that are properly grounded The ing materials resistance between the part and earth ground must not exceed 1 meg ohm Refer to NFPA 33 Inadequate grounding will cause a spark hazard A spark can Operators must be grounded Rubber soled insu ignite many coating materials lating shoes should not be worn Grounding straps and cause a fire or explosion 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 applica tor via conductive gloves or gloves with the palm section cut out NOTE REFER TO NFPA 33 OR SPECIFIC COUNTRY SAFETY CODES REGARDING PROPER OPERATOR GROUNDING All electricall
33. y conductive objects in the spray area with the exception of those objects required 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 flushing cleaning or working on spray system equipment Unless specifically approved for use in hazardous locations all electrical equipment must be located outside Class or II Division 1 or 2 hazardous areas in accordance with NFPA 33 LN 9271 12 2 4 RPA 2 POWDER APPLICATOR Safety AREA Tells where haz ards may occur Electrical Equipment a Toxic Substanc es HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized in the process Arcing in the vicinity of flammable or 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 Chemical Hazard Certain materials may be harm ful if inhaled or if there is con tact with the skin Ransburg SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazardous locations the p
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