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1. Figure 11 Air Before Fluid Adaptor Piston Housing not shown for clarity 38 REA Automatic Applicators Maintenance 39 TRANSFORMER ASSEMBLY REPLACEMENT REA 9000R AND 900A A WARNING Turn OFF all power air and fluid at the source gt The low voltage cable MUST be removed before removing the transformer assembly 1 Remove the low voltage cable connector from the transformer by removing the scew and pull STRAIGHT out of the chamber 2 Remove the barrel cascade assembly See Barrel Assembly Removal in the Maintenance section 3 Remove the fiberglass screw 4 Slide transformer backward and upward out of body channel NOTE Generously lubricate transformer assembly base and body channel with LSCHO0009 00 dielectric grease 5 Slide replacement transformer into channel of automatic body 6 Place gasket in position 7 Replace the barrel cascade assembly See Barrel Assembly Removal in the Maintenance section Ransburg 8 Install low voltage cable connector by matching the hole on the connector and the transformer and pushing the connector straight into the chamber 9 Secure in place with screw LOW VOLTAGE CABLE REPLACEMENT REA 9000R 1 Remove applicator from robot 2 Remove rear mounting plate from fobot 3 Using awrench on connector flats disconnect low voltage cable from connector assembly 4 Rep
2. NEVER remove the fluid nozzle assembly while paint is in the gun or paint may clog the air passages Clogged air passages will cause poor atomization and electrical shorting Air passages which are clogged with conductive material may lead to excessive current output levels and consequent low operating voltage and long range electrical damage Before un dertaking any atomizer assembly procedure see AtomizerAssembly Cleaning Procedure The applicator MUST be tilted front down to remove the air cap and or fluid nozzle Failure to do so may allow paint to enter the air passages thereby reducing air flow and damaging the applicator barrel cascade Applicators may be flushed in lieu of tilting However they must be either flushed or tilted DO NOT OPERATE A FAULTY APPLI down CATOR When using cleaning solvent standard Clean all insulating surfaces in the system health and safety precautions should apply Remove paintaccumulation fromthe exteriorof the applicator low voltage cable and air lines with a solvent dampened cloth Use only non polar non conductive solvent ROUTINE SCHEDULE A WARNING Follow these maintenance steps to extend the life NEVER soak or submerge the electrical of the applicator and ensure efficient operation components of the applicator i e barrel trans former cable Damage and failure may occur Several Times Daily e Turn the control unit power to OFF
3. Cable 36 ft 78084 36 Cable 50 ft 78084 50 Cable 75 ft 78084 75 Cable 100 ft 78084 100 Applicator Body Assembly 76231 00 Fitting 3 16 T x 1 8 NPT LSF10025 09 Screw 5 16 18 x 1 50 LG 2 Required 16198 48C O Ring 426 ID x 070 CS Solvent Proof 13076 13 O Ring 614 ID x 070 CS Solvent Resistent 1554 42 Bushing Assembly 76216 00 Bushing Retainer 76200 00 O Ring 487 ID x 103 CS Solvent Resistent 7554 28 O Ring 299 ID x 103 CS Solvent Resistent 1554 111 Piston Shaft 76220 00 Piston Washer 20057 00 Packing Cup 1123 06 Piston Jam Nut 3 8 24 20056 00 Spring Hex Nut 10 32 Air Valve Adjust Nut Spring Piston Housing Fitting 1 8 NPT x 1 4 T LSF10025 12 Valve Assembly Includes items 60 70 7691 7 00 Valve Cap 76925 00 Clamping Nut 76926 00 Piston Cup VA 246 Piston Nut 76919 00 AA 99 02 5 Valve Spring 76928 00 54 REA Automatic Applicators Parts Identification Ransburg REA 900A SOLVENTBORNE PARTS LIST Model No 77359 Cont Figure 15 Mem amp Description Part Spring Washer 76927 00 Needle Seal Valve Body 76920 00 76918 00 O Ring 426 ID x 070 CS Solvent Proof SSG 8136 Needle Seat 75960 00 Valve Needl
4. Daily at the start of each shift Verify that ALL solvent safety containers are grounded e nspecttheaircapforpaintaccumulation Clean as frequently as necessary with a soft bristled brush and a suitable solvent and blow clean Check within 20 feet of the point of operation of the applicator and remove or ground ALL loose or ungrounded objects AA 99 02 5 20 REA Automatic Applicators Maintenance 21 Inspect workholders for accumulated coating materials removing such accumulations Check that atomizer assembly is clean and undamaged Straighten the applicator electrode if necessary A CAUTION When straightening the electrode be careful not to distort the fluid nozzle orifice e Clean the fluid filter if used Turn the control unit power ON The applicatorred transformer light should light when triggered Run a current voltage output test Electrical Current Output Test 1 Turn the paint supply OFF 2 Turn high voltage on at applicator 3 Slowly approach the applicator electrode to any grounded object and make contact 4 Monitor the current output reading on the voltage supply meter As applicator approaches ground current should increase near 100 mA overload current should trip shutting off high voltage Overload indication should come on 5 Release the trigger and turn the control unit power OFF If the control unit does not trip DO NOT use the applicat
5. FLOW SWITCH MAX AR FLOW CK AND INJURY SERVICE TRAINING REQUIRED APPROVED PRESS PRESS Ce 0518 2 G 100 Psi EN 50050 SIRA OBATEX5040X SUPPLY UNLESS VENTILATING FANS ARE IN OPERATION 4 SERVICE WARNING ENCLOSURE PROTECTS AGAINST HO 5 Kee POWER SUPPLY OUTSIDE THE HAZARDOUS 25 CFM 8 20 PSI 6 66 Nor ATTEMPT OPERATION OR REPAIR BEFORE READING SERVICE MANUAL 7 FOR ELECTROSTATIC PAINT FINISHING APPLICATIONS Label 76858 Ransburg APPROVED FOR ELECTRO FIN APPL CL 1 AIR ATOMIZING SYSTEM WHICH CONSISTS OF THE FOLLOWING REA 9000R 761 10S L 00 36 37 50 51 75 76 98 99 10 15 20 25 A B C D E F G H 1 APPLICATOR 76580 5 1 2 0 0 2 1 2 3 LOW VOLTAGE P 76222 36 36A 50 50A 75 75A 100 100A REAR MOUNTING PLATE OR REA 9000A 75795S L 36 50 75 100 151 APPLICATOR 76580 5 1 2 0 0 2 1 2 3 LOW VOLTAGE P FOR USE WITH ALL OF THE FOLLOWING 78084 36 50 75 100 LOW VOLTAGE CABLE SIRA GP D SPRAY MATL OWER SUPPLY OWER SUPPLY O8ATEX5040X APPROVED Label 78974 APPROVED FOR ELECTRO FIN APPL CL AIR ATOMIZING SYSTEM WHICH CONSISTS OF REA 900A AUTOMATIC SOLVEN 77359S L 36 50 75 101 1 78084 36 50 75 LOW VOLTAGE CABLE APPROVED FOR ELECTRO FIN APPL MA NOT SUSTAIN BURNING LONGER THAN SPECIFIED WITH ASTM D 4206 REA 900A AUTOMATIC WATERBORNE 77359S L 36 37 50 51 75 76 101 44 2 APP
6. AA 99 02 5 Ransburg Assembly 1 Connect low voltage cable to control unit hand tighten 2 Connect other end of low voltage cable to con nector assembly using a wrench on the connector flats to tighten DO NOT overtighten low voltage cable con nection to spray applicator as damage to plastic parts may occur VALVE BODY SERVICE REA 9000W When service is performed on any of the body elements it is best to remove the barrel and high voltage module transformer assembly to avoid damage to the nozzle electrode or any of the plastic parts After the disassembly of any body element Clean all parts with a suitable clean solvent Check all parts for damage or wear Replace those that are damaged or worn with new parts AIR VALVE BODY DISASSEMBLY REA 9000W 1 Remove barrel assembly see Barrel Re moval for the 9000W previously discussed in this section 2 Remove high voltage module transformer assembly see Transformer Assembly Re place ment for the 9000W previously discussed in this section 3 Remove two 2 back plate screws AA 99 02 5 REA Automatic Applicators Maintenance TO RETURN THE SPRAY APPLICATOR TO THE WORK SITE 1 Attach applicator to mounting bar and secure screws 2 Attach the air line to applicator air fittings 3 Attach fluid hose to fluid hose fitting 4 Attach and secure the low high voltage cable to the spray applicator 5 Turn the p
7. Service for 9000W previously discussed in the Maintenance section of this manual gt To avoid damage to the chevron seals they MUST be installed from the rear of the barrel BARREL REASSEMBLY REA 9000R and 900A 1 Place conductive female chevron adaptor onto the front of shaft with the concave side toward the front 2 Screw the four 4 new chevron seals onto shaft concave sides forward DO NOT push the chevron seals straight onto the shaft The shaft threads may damage the chevron bore and cause the applicator to leak fluid Inspect needle electrode shaft sealing surface for wear If it is rough or uneven replace it 3 Place male non conductive chevron adaptor onto shaft with the convex end rearward NOTE The chevron adaptors and chevron seals should seat together to form an unbroken seal 35 Ransburg 4 Screw needle electrode onto shaft hand tighten NOTE Apply a light coating of dielectric grease to the chevron seals The pack ing tube 18842 02 should be thoroughly packed with LSCH0009 00 dielectric grease leaving no air space or voids when assembling Failure to pack the needle electrode elec trode shaft assembly and packing tube may cause lower electrical output of the applicator 5 Place packing tube over the end of shaft 6 Place the new u cup into rear retainer with the open side out NOTE Seat the u cup into the rear retainer ve
8. gt PRIOR to performing a applicator removal be sure ALL power to the control unit is turned off Needle shaft LREA4005 00 Transformer assembly LREA4004 00 EQUIPMENT REQUIRED REA 9000R 9000W and 900A 19749 00 spanner nozzle wrench 3 in 1 for barrel nut fluid nozzle and needle shaft assembly Screwdriver broad Dielectric grease 59972 00 or LSCHO0009 00 e 1 2 inch 13mm nut driver e 9 16 inch socket and handle Adjustable wrenches AA 99 02 5 TO REMOVE THE APPLICATOR FROM THE WORK SITE 1 Turn the control unit power OFF 2 Detach voltage cable from applicator 3 Turn the paint supply OFF 4 Turn the atomizing air supply OFF 5 Properly flush the applicator 6 Remove air actuation fittings 7 Remove fluid in and out lines 8 Remove the applicator from the work site and voltage cable if necessary 26 REA Automatic Applicators Maintenance NOZZLE AND ELECTRODE CLEANING OR REPLACEMENT REA 9000W gt NEVER bend the electrode NOTE See Atomizer Assembly Cleaning Procedure previously discussed in this section A WARNING NEVER shorten the electrode wire Air Cap 1 Unscrew retaining ring remove air cap from barrel and clean using proper method or replace it 2 Replace air cap and tighten retaining ring back onto the barrel 27 Ransburg Fluid Nozzle To avoid damage to the fluid nozzle needle electrode the paint p
9. 9 Check and secure at the applicator and at the control unit Replace Trace and correct Replace Replace Replace See the Control Unit manual Replace 65 10 Clean passages with soft bristled brush High Current Draw 25 Paint in air passages Dirty dump line Paint in dump line Dirty applicator exterior Clean passages with soft bristled brush Clean or replace dump line always use lines Review air push cycle Clean with appropriate sol vent and install new applicator cover AA 99 02 5 Ransburg REA Automatic Applicators Maintenance SERVICE REA 9000W SERIES All repairs should be made on a clean flat sur face If a vise is used to hold parts during service or repair DO NOT clamp onto plastic parts and always pad the vise jaws The following parts should be thoroughly packed with LSCHOOO9 OO dielectric grease leaving NO air space or voids when assembling All o rings o rings do not need lubrication chevron seals and all internal and external threads Failure to pack the needle electrode electrode shaft assembly and packing tube MAY CAUSE lower electrical output of the applicator REPLACEMENT PROCEDURE REA 9000R 9000W and 900A gt ALWAYS remove the applicator from the work site for service or repair DO NOT USE any silicone lubricants in order to avoid paint defects A WARNING
10. 99 Low Voltage Plug 76873 01 Extension Assembly Screw M5 76871 00 Screw M5 73490 01 Low Voltage Cable Assembly Cable 36 Ft 78084 36 Cable 50 Ft 78084 50 Cable 75 Ft 78084 75 Cable 100 Ft 78084 100 O Ring Kit for Rear Plate 76527 00 Dielectric Grease 1 02 LSCH0009 00 Dielectric Grease 4 oz 59972 00 Special Multi Purpose Wrench 19749 00 Spanner Wrench 20049 00 AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification REA 9000R Spare Parts In Kit Form Model No 76110 Item Rebuild Kits Description For Dump Valve Only 76917 00 Includes the Following Part 76931 00 1 Needle Seat 75960 00 Valve Needle 76921 00 O Ring 426 ID x 070 CS Solvent Resistent 7554 10 76920 00 1 1 1 Needle Seal 1 Valve Spring 76928 00 1 Piston Seal VA 246 AA 99 02 5 Soft Parts for the Applicator Includes the Following 76526 00 1 Male Chevron Adapter 74653 00 Chevron Seal 14323 00 Female Chevron Adapter 18821 00 O Ring 301 ID x 070 CS Solvent Resistent 7554 08 U Cup 10051 05 O Ring 364 ID x 070 CS Solvent Resistent 7554 09 Gasket Barrel 72360 00 13076 10 O Ring 426 ID x 070 CS Solvent Proof 13076 13 614 ID x 070
11. CS Solvent Resistent 7554 42 O Ring 299 ID x 103 CS Solvent Resistent 7554 111 Packing Cup 7723 06 4 1 1 1 1 1 1 O Ring 239 ID x 070 CS Solvent Proof 1 1 1 1 1 Dielectic Grease 1 oz LSCH0009 00 1 O Ring 801 ID x 070 CS Solvent Resistent For DR1 Regulator Includes the Following 1 Diaphragm 7554 33 73913 00 74157 03 1 Diaphragm 74157 04 1 Diaphragm 3 O Ring 489 ID x 070 CS Solvent Resitent For DR1 Regulator Needle and Seat 74273 00 7554 11 74160 00 Needle Shaft Assembly Completely Assembled Needle Shaft Less Grease 1 Electorde Needle Shaft 75732 01 70130 00 16665 04 Male Chevron Adapter 74653 00 Chevron Seals 14323 00 Female Chevron Adapter 18821 00 Packing Tube 18842 00 Retainer 18836 00 7554 08 Spacer 18837 00 Packing Nut 18838 00 Nut 18859 00 U Cup Seal 10051 05 1 1 4 1 1 1 1 O Ring 301 ID x 070 CS Solvent Resistent 1 1 2 1 6 Belville Washer 17390 04 46 REA Automatic Applicators Parts Identification Ransburg REA 9000R Recommended Spare Parts Model No 76110 Description Part No of Applicators 1 2 3 4 5 6 7 8 Rebuild Kit Applicator Only 76526 00 Rebuild Kit Cartridge Valve Only 76931 00 Regulator Rebuild Kit 73913 00 A
12. Electrode 76816 03 4904 65R 4907 46 Atomization Kit Includes the following items 1 Air Cap 1 Fluid Nozzle 70430 00 1 Electrode 76816 04 Atomization Kit Includes the following items 4904 63 1 Air Cap 4907 44 1 Fluid Nozzle 70430 00 AA 99 02 5 1 Electrode 58 REA Automatic Applicators Parts Identification Ransburg Miscellaneous Kits for REA 90008 REA 9000W and REA 900A Part Description Part Description 73570 01 Conversion Kit Includes the following items 73570 09 Conversion Kit Includes the following items 4904 65R 1 Air Cap 4904 98 1 Air Cap 4907 44 1 Fluid Nozzle 4907 47 1 Fluid Nozzle 73569 00 73570 02 1 Retaining Ring Conversion Kit Includes the following items 1 Retaining Ring Conversion Kit Includes the following items 4904 65R 1 Air Cap 1 Air Cap 4907 45 1 Fluid Nozzle 1 Fluid Nozzle 73569 00 1 Retaining Ring 1 Retaining Ring 73570 03 Conversion Kit Includes the following items Conversion Kit Includes the following items 4904 65R 4907 46 1 Air Cap 1 Fluid Nozzle 1 Air Cap 1 Fluid Nozzle 73569 00 1 Retaining Ring 1 Retaining Ring 73570 04 Conversion Kit Includes the following items Conversion Kit Includes the following items 4904 65R 1 Air Cap 1 Ai
13. N gt Only if DR1 Fluid Regulator is used O Ring Mounting Plate Kit 76527 00 O Ring SSG 8163 O Ring SSG 8134 O Ring SSG 8162 O Ring SSG 8136 Electrode 70430 00 Needle Shaft 18865 04 Packing Tube 18842 01 Cartridge Valve 76917 00 Transformer LREA4004 00 Barrel Assembly 75038 06 Cable Assembly 76876 XX NIN 3 EE 00 00 PA oo sch gt 3 Od OO XX must be replaced with desired length of 36 50 75 or 100 Screw 73490 00 Wrench 19749 00 Fluid Nozzle 4907 XX NINNIN 3 Replace XX with 44 45 46 47 or 46 Air Cap 4904 XX Replace XX with 63 98 or 65R Cap Retaining Ring 73569 00 High Voltage Test Probe Kit 76652 01 For Troubleshooting Complete Assembly 47 AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification R _ Figure 14 REA 9000W Waterborne Assembly 60 AA 99 02 5 48 REA Automatic Applicators Parts Identification 49 Item REA 9000W Description Complete Assembly Ransburg REA 9000W WATERBORNE PARTS LIST Model No 77140 Figure 14 Part 77140 01 High Voltage Probe Assembly includes items 1 13 77156 03 High Volt
14. Body 76231 00 Screw 5 16 18 x 1 50 LG 2 Required 76198 48C Retaining Nut 20053 00 O Ring 239 ID x 070 CS Solvent Proof 13076 10 Elbow 3 8 T x 1 4 NPT 14157 03 Screw 10 LSFA0027 00 Transformer LREA4004 00 O Ring 551 ID x 070 CS Solvent Resistent Screws M5 7554 12 73490 01 O Ring 426 ID x 070 CS Solvent Proof 13076 13 O Ring 614 ID x 070 CS Solvent Resistent 7554 42 Bushing 76216 00 O Ring 801 ID x 070 CS Solvent Resistent Bushing Retainer 7554 33 76200 00 O Ring 487 ID x 103 CS Solvent Resistent 7554 28 O Ring 299 ID x 103 CS Solvent Resistent 7554 111 Piston Shaft 76220 00 Piston Washer 20057 00 Piston Cup 7723 06 Piston 20056 00 Nut 7733 44 Spring 9334 00 Nut 7733 07 Air Valve Adjustment Nut 76199 00 Spring 17615 00 Piston Housing 76217 00 AA 99 02 5 Spacer 2 Required 76219 00 44 REA Automatic Applicators Parts Identification 45 REA 9000R SOLVENTBORNE PARTS LIST Model No 76110 Cont Figures 12 and 13 Description P Extension Ransburg 60 76232 01 90 76232 02 Retaining Ring 76224 00 Fitting 3 16 T x 1 8 NPT LSF10025 09 Fitting 1 8 T x 1 8 NPT 2 Required 75951 02 Rear P
15. F 1 4 ODT Dump Actuation 1 8 NPT F 1 4 ODT Shroud Purge Air 1 8 NPT F 1 4 ODT Gun Mounting Stud Diameter 98 1 00 Mount Woodruf Key Size 1 4 Nominal Paint Resistance 1 MQ to eo Ransburg AA 99 02 5 Ransburg REA Automatic Applicators Installation INSTALLATION A WARNING gt Install and route the hoses and cables so they are NOT exposed to temperatures in ex The 9000W is is intended for use with waterborne coating formulations only cess of 120 F and so that all hose and cable bends are NOT less than a 6 inch 15 cm radius Failure to comply with these parame ters could cause equipment malfunctions that might create HAZARDOUS CONDITIONS TYPICAL REA AUTOMATIC APPLICATOR INSTALLATION Connectthe voltage cable to the control unit voltage socket Gently hand tighten the cable retaining nut Connect the other end of the voltage cable to the receptacle at the rear mounting plate of the applicator using a wrench to tighten gt DO NOT overtighten voltage cable con nection to applicator as damage to plastic parts may occur The control unit of cascade style applicators MAY be connected through conduit with an ex plosion proof terminal on or near the spray booth where it will be convenient or may be connected with a line cord depending upon application re quirement NOTE Refer to the Control Unit Service manual for the Circuit Diagram and I
16. Fluid Tube Electrode 70430 00 Male Chevron Adapter 74653 00 Chevron Seal 4 Required 14323 00 Female Chevron Adapter Conductive 18821 00 Tubing 1 8 ID x 3 16 OD Fitting 178 T x 178 NPT Barb Valve Assembly includes Items 19 297 Valve Cap Clamping Nut Piston Cup Piston Nut Valve Spring Spring Washer Needle Seal Valve Body O Ring 426 1D x 070 CS Solvent Proof Needle Seat Valve Needle Fitting 5 16 T x 5 16 AN AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification REA 9000R SOLVENTBORNE PARTS LIST Model No 76110 Cont Figures 12 and 13 Description Fitting 1 4 T x 1 4 AN LSFI0022 04 Manifold 76922 02 O Ring 364 ID x 070 CS Solvent Proof SSG 8137 Ferrule 18844 00 Nut 18843 00 Needle Shaft Assembly 18865 04 Packing Tube 18842 01 Rear Retainer 18836 00 O Ring 301 ID x 070 CS Solvent Resistent 7554 08 U Cup Seal 10051 05 Spacer 18837 00 Spring Washer 6 Required 17390 04 Packing Nut 18838 00 Gasket 72360 00 Nut Valve Rod Extension 18859 00 76215 00 Fitting 3 8 T x 1 4 NPT LSF10025 21 Tubing 3 8 OD H 2338 Tubing 3 16 OD SSP 5014 Fitting 3 16 T x 1 8 NPT LSF10025 09
17. adversely affected thus ensuring that the type of protection provided by the equipment is not compromised Aggressive substances e g acidic liquids or gases that may attack metals or solvents that may affect polymeric materials Suitable precautions e g regular checks as part of routine inspections or establishing from the material s data sheets that it is resistant to specific chemicals Refer to Specifications in the Introduction section a All fluid passages contain stainless steel or nylon fittings b High voltage cascade is encapsulated with a solvent resistant epoxy 9 A recapitulation of the certification marking is detailed in the Atex section on the next page drawing numbers 72562 76858 78974 and 79648 10 The characteristics of the equipment shall be detailed e g electrical pressure and voltage parameters The manufacturer should note that on being put into service the equipment must be ac companied by atranslation of the instructions in the language or languages of the country in which the equipment is to be used and by the instructions in the original language REA Automatic Applicators Atex REA 900 and 9000 Automatic Applicators 77539 and 76110 ATEX Product Marking Definitions Ex Certificate Number Gira OBATEX5040X Sira Notified Body performing EC type exam ination 08 Year of certification ATEX Reference to ATEX Directive 5 Protection Concept Code code 5 is titl
18. against your hand until the needle assembly falls loose Pull the needle assembly out of the probe body 4 By hand unscrew counter clockwise or where necessary gently use needle nose pliers on the needle electrode ridges to remove it from the needle shaft assembly Clean as necessary using appropriate cleaning procedure 5 Inspectneedle assembly components for signs of high voltage arcing Replace if necessary DO NOT use dielectric grease inside the probe assembly Air must be able to flow freely through this assembly 6 If LREA4001 Resistive Electrode is being replaced it must be trimmed to the proper length Reassemble the probe with the new electrode Trim the electrode wire 1 16 inch from the end of the probe body AA 99 02 5 REA Automatic Applicators Maintenance To Test REA 9000W 1 Install electrode on front end of an available 18865 04 needle shaft Be sure that electrode is completely seated for proper contact between metal shaft and conductive threaded insert in rear of resistor 2 Using a VOM meter that will read 15 meg ohms accurately connect one meter lead to the metal needle shaft and the other lead to the wire at front of electrode Electrode should be 14 5 to 19 megohms nominal 15 megohms at 9 volts or 11 to 17 megohms at 1000 volts Electrodes outside this range must be replaced see Figure 6 Figure 6 Testing Resistive Electrode 28 REA Automatic Applic
19. bulkhead plate for ease of maintenance All fluid connections in this applicator use AN style fittings to eliminate dead spots in the fluid path for superior flushing The REA 9000R is a robot mounted applicator for hollow wrist robots produced by either FANUC or ABB The advantage of the REA 9000R applicator is that it can be removed quickly and easily from the robot mounting plate with the use of a threaded retaining ring The REA9000R incorporates two important safety features The first being a break away design that will shear two 2 nylon mounting bolts if the applicator comes in contact with the object being sprayed The second is the discharge which is available from the resistive charging electrode is limited tothe optimum level of safety and efficiency The REA9000W Not FM Approved is an external charge probe applicator designed to spray water borne coatings in systems utilizing a grounded fluid supply Applicator features include Probe Shroud Air and Electrode Shroud Air Low pressure air exiting around the probe body and electrode wire aid in keeping these components clean during op eration These features help to maintain maximum efficiency of the applicators over a longer period of time The REA 9000W applicator also offers conventional classiC high voltage technology The REA 9000R and 900A Series of applicators apply 85kV DC charge to the coating materials at the point of atomization This series
20. 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 be main tained during cleaning operations using flam mable or combustible solvents 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 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 an
21. piston and hex nut STRAIGHT out of the body 5 Using the 20049 00 special wrench remove the bushing nut 6 Remove the extension rod from the needle shaft or use an extra extension rod Insert the hex end of the extension rod into a slot of the bushing and pull straight out 7 Using a 3 8 inch nut driver remove the valve seal retaining nut and o ring 37 Ransburg AIR BUSHING BODY ASSEMBLY REA 9000R and 900A 1 Insert a new o ring into the valve seal re taining nut 2 Usinga 3 8 nutdriver tighten the valve seal retaining nut into the body 3 Insert a new o ring into the groove on the front of the bushing 4 Place a new o ring onto the o ring groove on the outside of the bushing 5 Insert the bushing into the rear of the body and firmly press into position NOTE gt The bushing has a locator pin pressed into the front This pin must align with the receptacle hole in the body see Figure 9 LOCATE RECEPTACLE HOLE HERE Figure 9 View of Rear Body AA 99 02 5 Ransburg 6 Insert the bushing nut into the rear of the body Using the 20049 00 Spanner Wrench securely tighten the bushing nut into the body 7 Pull the needle shaft back into an actuated position Screw the trigger adjustment nut onto the needle shaft until there are no more threads 8 Screw the extension rod on the needle shaft until the hex of the extension rod is flush against the hex of the trigger ad
22. plicator s fan and atomization air is applied which atomizes the material forming a spray mist The mist under the influence of the electrostatic field becomes electrically charged The charged par ticles of material are attracted to and deposited on the target The forces between the charged particles and the grounded target are sufficient to turn most normal overspray around and deposit it on the back surface of the target Therefore a high percentage of the spray is deposited on the target One of the many features of the REA Applicator Automatic System is the electrical discharge which is available from the resistive charging electrode is limited to the optimum level of safety and efficiency As the applicator electrode approaches ground the control unit and applicator circuitry shut down the high voltage and current to the applicator The control unit must then be reset to continue to spray electrostatically The REAAutomatic Electrostatic Spray Applicators are transformable between air spray and HVLP spray technology By changing a select few parts the applicator may be transformed to be operated in either spray mode See Spray Technology Conversion Procedure in the Installation section for details AA 99 02 5 REA Automatic Applicators Introduction The REA 900A Applicator is designed with a mov ing trigger shaft so no forward mounted trigger valve is required The dump valve is mounted on the rear
23. provided refer to Figure 2 for explanation of coordinates Optimum spray pattern is achieved at a distance of 10 14 inches from tip DIMENSION Ransburg 76110 REA 90008 60 12 29 6 50 76110 REA 90008 90 10 00 7 50 Figure 2 Applicator Tool Point Representation REA 9000R Automatic IMENSION EO 3150 121 014 is for 100 wrist EO 3461 127 001 is for 140 wrist For use with Fanuc P 200 Robots the following adapter plates must be used 11 AA 99 02 5 Ransburg REA Automatic Applicators Introduction 1 RE HI 1 1 CH ER SH Beg LIB HE X m Figure 3a REA 9000W Waterborne Electrostatic Spray Applicator PROBE PURGE TRIG pumt ATOM FA FL 1 DUMI Figure 3b View of Back Plate AA 99 02 5 12 REA Automa
24. 0 psig input for 10 psig nozzle output 3 8 NPT F 1 4 NPT F 3 8 ODT 3 8 NPT F 1 4 NPT F 3 8 ODT 1 4 AN F 1 4 ODT 1 4 AN F 3 8 ODT 1 4 ODT 1 8 NPT F 1 4 ODT 1 8 NPT F 1 4 ODT 1 8 NPT F 1 4 ODT 1 8 NPT F 98 1 00 Mount Woodruf Key Size 1 4 Nominal 14 REA Automatic Applicators 15 Introduction SPECIFICATIONS NOTES SOLVENTBORNE REA 900A Electrical Physical Operating Voltage Current Output Weight Applicator Diameter Applicator Length 85kV DC max 120 microamperes max 84 oz 2 1009 5 50 inch 13 9cm 14 85 inch 37 6cm Center Distance from Mount to Nozzle End Center Line of Nozzle Cable Lengths Atomizer Assembly Fluid Flow Rate 13 00 inch 32 9cm 1 90 inch 4 8cm 36 ft std Optional 50 75 and 100ft 4904 65R 4907 45 HVLP 75600 01 HVLP 75601 00 Variable to 1 000 cc min Operating Pressure Air Spray Fluid 0 100 psig 6 8 bar Air 0 100 psig 6 8 bar Consumption 16 SCFM 50 psig Operating Pressure HVLP Spray Fluid 0 100 psi 6 8 bar Air 0 100 psi 6 8 bar Consumption 22 SCFM 50 psig input for 10 psig nozzle output Atomization Air Inlet Size 1 4 NPT F 1 2 ODT Fan Air Inlet Size 1 4 NPT F 1 2 ODT Fluid Inlet Size 1 4 AN F 1 4 ODT Dump Outlet Size 1 4 AN F 3 8 ODT Trigger Actuation 1 8 NPT
25. 0R Solventborne Assembly 41 AA 99 02 5 Ransburg AA 99 02 5 REA Automatic Applicators Parts Identification Figure 13 REA 9000R Rear Mounting Plate Assembly 42 REA Automatic Applicators Parts Identification 43 REA 9000R SOLVENTBORNE PARTS LIST Model No 76110 Figures 12 and 13 REA 9000 Robot Description Complete Assembly Air Spray Ransburg 76110S XXXX1 REA 9000 Robot Complete Assembly HVLP 76110L XXXX1 Retaining Ring 73569 00 Air Cap Ftat Pattern Air Spray Standard 4904 65R Flat Pattern HVLP Standard 75601 00 Fluid Nozzle Flat Pattern Air Spray Standard 4907 45 Flat Pattern HVLP Standard 75600 01 Standard Pressure Reducer 74963 02 HVLP Pressure Reducer 74963 03 Barrel Replacement Kit Includes the Following 75038 06 1 Barrel N A 1 HVLP Pressure Reducer 74963 03 1 Standard Pressure Reducer 74963 02 1 Male Chevron Adapter 74653 00 4 Chevron Seals 14323 00 1 Packing Tube 18842 01 1 Dielectic Grease LSCH0009 00 1 Spray Technology Instruction Sheet 75739 00 1 Delta Series Instruction Sheet 74956 00 Shroud 60 76363 00 90 76396 00 Screw 8 32 x 5 2 Required 8350 16C Retaining Pins 5 Required 76650 01 Coiled
26. 1 00 Retaining Ring 75326 00 Needle Electrode 70430 00 Male Chevron Adapter 74653 00 Chevron Seal 4 Required 14323 00 Female Chevron Adapter 18821 00 Fitting 1 4 T x 1 4 AN LSF1022 04 Adapter Fitting 77556 00 O Ring 364 ID x 070 CS Solvent Proof SSG 8137 Standard Pressure Reducer 14963 02 HVLP Pressure Reducer 74963 03 Needle Assembly 18865 04 Packing Tube 18842 01 Rear Needle Retainer 18836 00 O Ring 301 ID x 070 CS Solvent Resistent 7554 08 Spring Loaded U Cup Seal 10051 05 53 Seal and Spring Spacer 18837 00 AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification REA 900A SOLVENTBORNE PARTS LIST Model No 77359 Cont Figure 15 Description Spring Washer 6 Required 17390 04 Packing Nut 18838 00 Barrel Gasket 72360 00 Trigger Adjust Lock Nut 8859 00 Valve Rod Extension 6215 00 Valve Seal Retaining Nut 20053 00 O Ring 239 ID x 070 CS Solvent Proof 13076 10 Elbow 1 4 NPT x 3 8 T 2 Required 14157 03 Transformer Assembly LREA4004 01 Screw 10 32 x 1 5 LSFA0027 00 O Ring 551 ID x 070 CS Solvent Resistent 7554 12 Low Voltage Cable Plug Assembly Includes item 35 74191 01 Screw M5 73490 01 Low Voltage Cable Assembly
27. 36 Continued On Next Page AA 99 02 5 Ransburg REA Automatic Applicators Contents Contents Cont PAGE MAINTENANCE Cont 20 40 P EXTENSION REMOVAL REA 9000R Ort 36 P EXTENSION REPLACEMENT 90008 Only ee ee ee 36 AIR BUSHING BODY DISASSEMBLY ee ee ee ee ee nrn 37 AIR BUSHING BODY ASSEMBLY 37 38 TRANSFORMER ASSEMBLY REPLACEMENT REA 9000R AND 9004 39 LOW VOLTAGE CABLE REPLACEMENT 9000R Ont 39 LOW VOLTAGE CABLE CONNECTOR ASSEMBLY 9000R Ont 39 40 LOW VOLTAGE CABLE PLUG ASSEMBLY 90008 Ort 40 PARTS IDENTIFICATION 41 60 REA 9000R SOLVENTBORNE ASSEMBLY sten 41 REA 9000R REAR MOUNTING PLATE ASSEMBLY ee ee ee ee 42 REA 9000R SOLVENTBORNE PARTS LIST 43 45 REA 90008 SPARE PARTS IN KIT RECOMMENDED SPARE PARTS 46 47 REA 9000W WATERBORNE ASSEMBLY ee ee ee 48 REA 9000W WATERBORNE PARTS LIST 49 51 REA 9000W SPARE PARTS IN KIT RECOMMENDED SPARE PARTS 51 REA 900A SOLVENTBORNE ASSEMBLY 52 REA 900A SOLVENTBORNE PARTS LIST 53 55 REA 900A SPARE PARTS IN KIT RECOMMENDED SPARE PARTS 56 57 MISCELLANEOUS KIT es SEE ettet RES eg Ee ee DNE esc ep ed 58 59 WARRANTIY POLICIES 60 LIMITED WARRANT Y us utter audiui Ee 60 AA 99 02 5 REA Automatic Applicators Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety liter atu
28. 7 48 73569 00 74963 02 4904 63 4907 44 73569 00 74963 02 4904 63 4907 45 73569 00 74963 02 4904 63 4907 46 73569 00 74963 02 4904 63 4907 47 73569 00 74963 02 4904 63 4907 48 73569 00 74963 02 4904 98 4907 44 73569 00 74963 02 4904 98 4907 45 73569 00 74963 02 4904 98 4907 46 73569 00 74963 02 4904 98 4907 47 73569 00 74963 02 4904 98 4907 48 73569 00 74963 02 REA NOZZLES HVLP Air Cap Part Number 75601 00 Fluid Nozzle Part Number 75600 01 Oriface ID Separate Retaining Ring 73569 00 Pressure Reducer White 74963 03 75601 00 75600 02 73569 00 74963 03 75601 00 75600 03 73569 00 74963 03 AA 99 02 5 Ransburg MAINTENANCE A WARNING gt The user MUST read and be familiar with the SAFETY INSTRUCTIONS in this manual f compressed air is used in cleaning RE MEMBER THAT HIGH PRESSURE AIR CAN BE DANGEROUS AND SHOULD NEVER BE USED AGAINST THE BODY It can blind deafen and may even penetrate the skin If used for cleaning equipment the users should wear safety glasses ALWAYS turn the control unit power off prior to cleaning or servicing equipment Be SURE the power is OFF and the system is grounded BEFORE using solvent to clean ANY of the equipment REA Automatic Applicators Maintenance
29. After the preceding steps are complete the applicator is ready for color change storage or service Ransburg AA 99 02 5 Ransburg REA Automatic Applicators Maintenance TROUBLESHOOTING GUIDE eneral Problem DEFECTIVE SPRAY Pattern will not shape Possible Cause PATTERN Clogged or faulty fan valve remote fan air line Air passages in applicator or air feed lines clogged Worn faulty or clogged air cap Solution 1 Clean replace or repair 2 Blow out 3 Clean or replace Pattern heavy at one end Clogged or faulty air cap Clogged or faulty fluid nozzle 1 Clean or replace 2 Clean or replace Extremely heavy spitting or severely deformed pattern Wrong air cap fluid nozzle combination Timing of fluid on and air on is not adjusted DEFECTIVE DELIVERY Air passages in applicator or air feed lines clogged Deficient source air Paint in air passage 1 Ensure proper fluid nozzle air nozzle pressure reducer combinations see chart 2 Check programming se quence 1 Blow out 2 Increase 3 Clean and blow out Clogged or faulty fluid nozzle Clogged passages in applicator fluid tube or fluid feed lines Insufficient needle electrode travel Low source pressure Clogged fluid filter Clogged or obstructed ball valve or fluid regulator 1 Flush or replace 2 Flush 3 Adjust see Trigger Nut Adjustment 4 Incr
30. Automatic Applicators Parts Identification REA 900A SOLVENTBORNE PARTS LIST Model No 77359 Figure 15 REA 900A Automatic Description Air Spray Ransburg Assembly Complete without Dump Valve Assembly Complete with Dump Valve 77359S BB111 77359S BB221 Assembly Complete with Dump Valve 77359S BB331 REA 900A Automatic HVLP Assembly Complete without Dump Valve 77359L BB111 Assembly Complete with Dump Valve 7359L BB221 Assembly Complete with Dump Valve 77359L BB3311 Air Nozzle Retaining Ring 76936 00 Air Cap Flat Pattern Air Spray Standard 4904 65R Flat Pattern HVLP Standard 75601 00 Fluid Nozzle Flat Pattern Air Spray Standard 4907 45 Flat Pattern HVLP Standard 75600 01 Seal Nut 76935 00 O Ring 1 612 ID x 103 CS Solvent Resistent 1504 85 Shroud 77554 00 Coiled Fluid Tube route on right side LREA0023 00 Barrel Replacement Kit includes the following 75038 06 1 Barrel 1 HVLP Pressure Reducer N A 14963 03 1 Standard Pressure Reducer 74963 02 1 Male Chevron Adapter 74653 00 4 Chevron Seals 14324 00 1 Packing Tube 18842 01 1 Dielectic Grease 1 oz LSCH0009 00 1 Spray Technology Instruction Sheet 75739 00 1 Delta Series Instruction Sheet 74956 00 Barrel Nut LREA002
31. E PARTS IN KIT FORM Model No 77359 ltem Description Rebuild Kit for Trigger and Dump Valves Includes the following Part 76931 00 Piston Cup VA 246 Needle Seal 76920 00 O Ring 1554 10 Needle Seat 5960 00 76928 00 Needle 76921 00 Instruction Sheet 76924 00 1 1 1 1 1 Valve Spring 1 1 1 O Ring SSG 8136 Soft Parts for the Applicator ncludes the following 76526 00 Male Chevron Adapter 74653 00 Chevron Seal 14323 00 18821 00 1554 08 10051 05 7554 09 72360 00 13076 10 13076 13 7554 42 7554 111 1723 06 LSCHOOO9 00 7554 33 Noodle Shaf Assembly Completely Assembled Needle Shaft Less Grease 75732 01 AA 99 02 5 1 Electrode 70130 00 1 Needle Shaft 18865 04 1 Male Chevron Adapter 74653 00 4 Chevron Seals 14323 00 1 Female Chevron Adapter 18821 00 Packing Tube 18842 00 Retainer 18836 00 O Ring 7554 08 Spacer 18837 00 18838 00 Nut 18859 00 U Cup Seal 10051 05 1 1 1 1 1 Packing Nut 2 1 6 Belville Washer 17390 04 56 REA Automatic Applicators Parts Identification 57 Description Part Ransburg RECOMMENDED SPARE PARTS FOR REA 900 Model No 77359 No o
32. EA0018 00 Screw 5 1 18 x 1 50 5 Required LSFA0028 01 Screw 5 16 18 x 1 2 Required LSFA0028 02 Fitting 1 4 T x 1 4 AN LSF10022 04 Screw 1 4 20 x 1 5 2 Required LSFA0004 48C Fitting 1 4 T x 1 8 AN 4 Required LSF10025 12 Fitting 3 8 T x 1 4 AN 2 Required LSFI0022 06 AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification REA 9000W WATERBORNE PARTS LIST Model No 77140 Cont Figure 14 Description Rear Bulkhead Part 77171 00 Tubing 3 8 OD x 1 4 ID FEP 12 Required SSP 5020 Screw 8 32 x 5 2 Required LSFA0026 00 Gasket 18872 00 Fitting 1 4 T x 1 8 NPT LSF10025 12 Fitting 1 4 AN x 1 4 OD LSF10022 04 Tubing 1 4 OD 9704 02 Elbow 1 4 T x 1 8 NPT 14057 04 Female Chevron Adapter 18821 00 Chevron Seal 4 Required 14323 00 Fluid Spacer 76797 00 Electrode 70430 00 Retaining Ring 75325 00 Barrel Nut LREA0021 00 High Voltage Module Bracket 77159 00 Screw 10 32 x 5 4 Required 77302 16F Barrel Replacement Kit includes the following 75038 06 1 Barrel N A 1 HVLP Pressure Reducer 74963 03 Standard Pressure Reducer 74963 02 Male Chevron Adapter 74653 00 14323 00 Packing Tube 18842 01 Dielectic Greas
33. EGUARDS 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 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 REA Automatic Applicators Safety AREA Tells where hazards may occur Electrical Eduipment e Toxic S
34. L 76580 C 1 2 0 0 2 1 3 4 LOW VOLTAGE POWER SUPPLY 78084 36 50 75 100 LOW VOLTAGE CABLE 78597 36 50 75 FLUID HOSE 78602 36 50 75 100 FLUID HOSE SIRA 22 33 1 APPLICATOR 76580 B 1 2 0 0 2 1 3 4 LOW VOLTAGE POWER SUPPLY GP D SPRAY MATL THE FOLLOWING L WHICH DOES N ACCORDANCE CATOR OBATEX5040X APPROVED Label 79648 Ransburg Angola REA 900 amp 9000 MODELS 761 N USA 10 amp 77559 0518 26 d 9 S N EEx 0 24 mJ SIRA OBATEX5040X LS lt A gt SUBSTITUTION OF COMPONENTS APPROVED MAY IMPAIR SAFETY RATINGS 1 THE SERIAL NUMBER INCLUDES THE DATE OF MANUFACTURE THE SPRAY GUN CABLE ASSEMBLY IS ONLY FM amp SIRA APPROVED WHE USED WITH 6580 XX LOW VOLTAGE POW ER SUPPLY LABEL REMOVAL VOIDS WARRANTY MADE IN U S A AA 99 02 5 Ransburg INTRODUCTION DESCRIPTIONS The REAAutomatic processes are an air atomized method for electrostatically applying coatings to objects The REAAutomatics apply a high voltage DC charge to the applicator electrode creating an electrostatic field between the atomizer and the target object The target is electrically grounded through its support which may be either stationary or moving Aregulated pressure fluid system delivers material to the atomizer At the time of triggering the ap
35. Model No 77140 Item Description Part Rebuild Kit for Trigger and Dump Valves 76931 00 Kit includes 1 Piston Cup VA 246 1 Needle Seal 76920 00 1 O Ring 1554 10 1 Valve Spring 76928 00 1 Needle Seat 75960 00 1 Valve Spring 76928 00 1 Needle 76921 00 1 Instruction Sheet 76924 00 1 O Ring SSG 8136 RECOMMENDED SPARE PARTS FOR REA 9000W Model No 77140 1 2 3 4 5 6 7 8 Rebuild Kit Cartridge Valve Only 76931 00 1 2 3 4 High Voltage Probe Assy 75156 03 1 1 2 2 Electrode LREA4001 01 1 2 3 4 Trim at assembly Probe Holder O Ring LSORO0007 05 2 2 4 4 Fluid Manifold O Ring SSG 8137 2 2 4 4 Needle Shaft LREA4005 00 1 1 2 2 Fluid Cartridge Valve 76917 00 1 1 2 2 Cartridge Valve O Ring SSG 8136 2 2 4 4 High Voltage Module 77301 01 1 1 1 1 Applicator Barrel Kit 75038 01 1 1 2 2 High Voltage Cable SSW 1064 Order Per Foot Fluid Nozzle 4907 XX 2 2 4 4 Replace XX with 44 45 46 47 or 48 Air Cap 4904 XX 2 2 4 4 Replace XX with 63 98 or 65R Air Cap Retaining Ring 73569 00 1 1 2 2 Disposable Applicator Covers 77342 00 1 1 2 2 Package of 5 Multi Tool Applicator Wrench 19749 00 2 2 4 4 High Voltage Test Probe Kit 76652 01 1 1 1 1 For Troubleshooting complete assembly AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification AA 99 02 5 Figure 15 REA 900A Solventborne Assembly 52 REA
36. N 8 14 Ve Ne ED N N 8 13 SPECIFICATIONS 14 OOS MCN UNICI 14 oi AN AE Ne N AE ER NN 15 INSTALLATION 16 19 TYPICAL REA AUTOMATIC APPLICATOR INSTALLATION e 16 19 ATOMIZER ASSEMBLY SELECTION TABLES ee 19 MAINTENANCE 20 40 ROUTINES CHE DOLE 20 21 ATOMIZER ASSEMBLY CLEANING PROCEDURE nee 22 FLUSHING PROCEDURES rsen 23 TROUBLESHOOTING GU DE eier 24 25 SERVICE REA 9000W SERIES EQUIPMENT REQUIRED edocet itesp dte 26 REPLACEMENT PROCEDURE erret 26 TO REMOVE APPLICATOR FROM THE WORKSITE e 26 NOZZLE AND ELECTRODE CLEANING REPLACEMENT 27 28 BARREL ASSEMBLY REMONNL tentent 29 BARREL DSASSEMEIN ttti 29 BARREL REASSEMBLY oo roD M De DR qe 30 BARREL TO BODY ASSEMELN ettet 31 HIGH VOLTAGE MODULE ASSEMBLY REPLACEMENT 9000W Only 31 LOW VOLTAGE CABLE REPLACEMENT 900A On 31 32 VALVE BODY SERVICE ees tlie echten tiu Hecate 32 AIR VALVE BODY DISASSEMBLY ete 32 RETURN THE SPRAY APPLICATOR TO THE WORK 32 SERVICE REA 9000R AND 900A SERIES BARREL ASSEMBLY REMONNL tte 33 NOZZLE AND ELECTRODE CLEANING OR REPLACEMENT 33 34 BARREL DISASSEMBLY sie eis ere eie eb ee intel 34 35 BARREL REASSEMBLY eet 35
37. Ransburg will assume no responsibility for repair or replacement of the item or items The purchas er therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable REA Automatic Applicators Warranty Policies 60 REA Automatic Applicators Manual Change Summary Ransburg MANUAL CHANGE SUMMARY This manual was published to replace Service Manual AA 99 02 4 REA Automatic Applicators to make the following changes 1 Change logo AA 99 02 5 Service Manual Price 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 www ransburg com Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No AA 99 02 5 2013 Ransburg All rights reserved ge Models and specifications subject to change without notice ISO 9001 SE ZER
38. SERVICE MANUAL Ransburg 49 025 Replaces 89 02 4 April 2013 REA AUTOMATIC APPLICATORS 11 HET 1 Dan O En LL 9000M Y Not FM Approved MODELS 77359 and 76110 77140 Not FM Approved IMPORTANT Before using this equipment C carefully read SAFETY PRECAUTIONS starting APPROVED on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 50 00 U S Ransburg REA Automatic Applicators NOTE This manual has been changed from revision AA 99 02 4 to revision AA 99 02 5 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual AA 99 02 5 REA Automatic Applicators Contents Ransburg CONTENTS PAGE SAFETY 1 5 SAFETYPRECAUTIONS 8818 1 HAZARDS SAFEGUARDS ettet itti 2 5 ATEX 67 EUROPEAN ATEX DIRECTIVE sss ttt ttti 6 EUROPEAN ATEX LARELS ee ee esse 7 INTRODUCTIO
39. age Probe Body 77157 03 Air Knife 11112 00 Electrode LREA4001 01 High Voltage Probe Needle Shaft 11167 03 Tubing 1 4 OD x 3 16 ID 4 25 Poly 9704 02 Coupling 77175 00 Compression Spring 75840 00 Contact Plug A10123 00 CO CO OX O1 BY A Retaining Plug 75836 01 Compression Spring 15831 03 Retaining Ring External 75832 05 Contact Pin 75833 02 Retaining Cap 75835 00 Retaining Nut 75847 01 Screw 1 4 20 x 2 4 Required 9141 64C High Voltage Probe Holder Assembly includes items 16 21 7 171 00 Probe Holder Body 77158 00 Contact Rod 5830 02 Compression Spring 75831 03 Retaining Ring 75832 05 Contact Plunger 71163 00 Retaining Cap 75884 00 O Ring 551 ID x 070 CS Solvent Resistent LSOR0007 05 High Voltage Module Assembly includes items 22 24 28 71301 01 Module Shell 77155 01 Screw 10 32 x 2 0 Cable Adapter 77302 65F 77168 01 Contact Assembly 77173 00 Nut 77170 01 Connector Body 18687 00 Tube Fitting Nut 3 8 T 3587 03 Fitting 3 8 T x 1 4 NPT 2 Required LSF10025 21 Bushing 3 8 NPT x 1 4 NPT 2 Required LSF10069 00 Applicator Body LREA0015 00 Mounting Bracket Upper LREA0019 00 Mounting Bracket Lower LR
40. ators Maintenance 29 BARREL ASSEMBLY REMOVAL REA 9000W 1 Remove air cap retaining ring 2 Pull shroud or applicator cover straight off the applicator exposing the trigger dump and barrel assemblies 3 REA 9000W ONLY remove the high voltage module to barrel mounting bracket 4 Loosen barrel nut with spanner wrench 5 Pull barrel and automatic body STRAIGHT apart Take extra care in handling barrel assembly to prevent damage 6 Remove the color valve manifold assembly by turning the nut counter clockwise until loose then pull the manifold straight out of the barrel 7 Remove the trigger valve Remove the ferruled connector for the fluid tube Remove the coiled fluid tube by removing the ferruled connector at the trigger valve manifold NOTE There is no need to remove retaining ring or barrel nut from barrel unless they are damaged Ifthey are to be removed lift one end of ring out of its groove and spiral it off of the end of the barrel The nut can be removed To replace them on the barrel slide nut onto the barrel place ring against the back of the barrel lift one end of it onto the barrel and spiral it on and into its groove Firmly spreading the retaining ring may break it Ransburg BARREL DISASSEMBLY REA 9000W 1 Remove needle shaft assembly from rear of the barrel with the 19749 00 spanner wrench 2 Firmly pullthe needle electrode shaft assembly out of the packing cham
41. ber During this operation be CAREFUL that the interior surface of packing chamber is NOT damaged marred or scratched This chamber is a seal area and the barrel assembly will have to be replaced if it is damaged 3 Unscrew needle electrode from shaft and slide parts off of the shaft see Figure 7 4 Inspect and replace parts as necessary Since the needle shaft in the REA 9000W does not move the packing wear should be minimal Rear Front Conductive Retainer Figure 7 Chevron Seal Assembly AA 99 02 5 Ransburg BARREL REASSEMBLY REA 9000W e Clean all parts with a suitable non polar non conductive solvent e Ifthe electrode wire is bent straighten it CARE FULLY by hand or use needle nose pliers e Check all parts for damage or wear Replace those that are damaged or worn with new parts e Replace chevron seals with new parts e From time to time it is desirable to test the electrical integrity of the LREA4001 00 resis tive electrode see To Test in the Service for 9000W in the Maintenance section gt To avoid damage to the chevron seals they MUST be installed from the rear of the barrel 1 Place conductive female chevron adaptor onto the front of shaft with the concave side toward the front 2 Screw the four 4 new chevron seals onto shaft concave sides forward gt DO NOT push the chevron seals straight onto the shaft The shaftthreads may damage the chevron bo
42. d European Health and Safety Norms REA Automatic Applicators Safety AREA Tells where hazards may occur Spray Area General Use and Maintenance 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 use of this equip ment Ransburg 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 Il 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 cur
43. e 76921 00 SS Male Connector 3 8 Tube x 1 4 NPT 41 FTC 1002 Tubing 3 8 OD x 1 4 ID 6ft Required FEP SSP 5020 Label Grounded Fluid Supply 2 Required 71557 00 Fitting 1 4 AN x 3 8 T LSF10022 06 Screw for use with Assembly Without Dump Valve 2 Required LSFA0004 40C Assembly With Dump Manifold 4 Required LSFA0004 64C Fitting 1 4 AN x 3 8 T LSF10022 06 Manifold Assembly Without Dump Valve 71550 01 Manifold Assembly with Dump Manifold 77550 02 Manifold Assembly with Dump Manifold 77550 03 Rear Bulkhead Plate 77553 00 Fitting 1 4 AN x 1 4 T LSF10022 04 Screw 3 8 16 x 75 2 Required LSFA0021 24C LSF10025 21 Tubing 3 16 OD x 025 Wall 10 5 Required SSP 5014 Tube Fitting 1 8 NPT x 3 16 OD LSF10025 09 Tube Fitting 1 4 NPT x 1 2 OD 2 Required LSF10025 26 Tube Fitting 1 8 NPT x 1 4 OD 2 Required LSFI0025 12 Applicator Bar Bracket Upper 77161 02 Screw 5 16 18 x 1 50 LG 5 Required LSFA0028 01 Applicator Bar Bracket Lower LREA0018 00 Dielectric Grease 1 02 LSCHOOO9 00 Dielectric Grease 4 oz 59972 00 Special Multi Purpose Wrench Spanner Wrench 19749 00 Nut Tool 77558 00 AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification REA 900A SPAR
44. e 1 oz LSCHOOO9 00 1 1 4 1 1 1 Chevron Seals Spray Technology Instruction Sheet 75739 00 1 Delta Series Instruction Sheet 74956 00 Fluid Nozzle 4907 45 Air Cap 4904 65R Air Cap Retaining Ring 73569 00 Pressure Reducer Standard Ferrule 74963 02 Nut O Ring 364 D x 070 CS Solvent Proof SSG 8137 Trigger Dump Manifold 76929 00 Fitting 1 4 T x 1 4 AN LSF10022 04 Fitting 3 8 T x 1 4 AN LSF10022 06 Valve Assembly includes items 69 79 76917 00 Valve Needle 76921 00 Needle Seat 75960 00 O Ring 426 ID x 070 CS Solvent Proof SSG 8136 Valve Body 76918 00 Needle Seal 76920 00 Spring Washer 76927 00 Valve Spring 76928 00 Piston Nut 76919 00 AA 99 02 5 Piston Cup VA 246 50 REA Automatic Applicators Parts Identification 51 Ransburg REA 9000W WATERBORNE PARTS LIST Model No 77140 Cont 78 Clamping Nut 76926 00 79 Valve Cap 76925 00 80 Elbow 1 8 NPT x 3 16 T 14157 08 81 Fitting 1 8 NPT x 3 16 T 2 Required 15 10025 09 82 Tubing 3 16 O D 20 Required SSP 5014 Dielectric Grease 1 02 LSCH0009 00 Dielectric Grease 4 oz 59972 00 Special Multi Purpose Wrench 19749 00 Applicator Cover 77342 00 REA 9000W SPARE PARTS IN KIT FORM
45. e gases and vapors with apparatus groups II and with temperature class T6 2 The equipment is only certified for use in ambi ent temperatures in the range 12 8 C to 40 C and should not be used outside this range 3 Installation shall be carried out by suitably trained personnel in accordance with the applicable code of practice e g EN 60079 14 1997 4 Inspection and maintenance of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice e g EN 60079 17 5 Repair of this equipment shall be carried out by suitable trained personnel in accordance with the applicable code of practice e g EN 60079 19 6 Putting into service use assembling and adjustment of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation Refer to the Table of Contents of this service manual a Installation b Operation c Maintenance d Parts Identification 7 Components to be incorporated into or used as replacement parts of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation AA 99 02 5 8 The certification of this equipment relies upon the following materials used in its construction If the equipment is likely to come into contact with aggressive substances then itis the responsibility of the user to take suitable precautions that prevent itfrom being
46. e it To change the spray pattern axis of fan atomizers from horizontal to vertical loosen retainer ring rotate the air cap clockwise to the desired position and gently tighten the ring Acounter clockwise turn of the air cap may loosen the fluid nozzle and cause air to get into the paint or paint to cross over into the air passages Applicator To Target Distance Mount the applicator 6 to 12 inches maximum from the target for best operation A higher transfer efficiency will be achieved at the closer target distance 18 REA Automatic Applicators Installation 19 Wiring The Unit The REA 9000R comes with a complete cable from the mounting plate A WARNING gt Ifthe REA 9000R cable must be terminated at the robot it must be done within a suitable explosion proof enclosure ATOMIZER ASSEMBLY SELECTION Air Cap Part Number 70899 00 Fluid Nozzle Part Number 70898 00 Ransburg The cable from the control unit of the REA 9000R should be run through suitable conduit and con nected at the robot explosion proof enclosure if necessary Oriface ID Separate Retaining Ring 4903 00 Pressure Reducer Black 74963 02 LREA0002 LREA0003 73569 00 74963 02 4904 65R 4907 44 73569 00 74963 02 4904 65R 4907 45 73569 00 74963 02 4904 65R 4907 46 73569 00 74963 02 4904 65R 4907 47 73569 00 74963 02 4904 65R 490
47. ease 5 Clean or replace 6 Clean as required LEAKAGE Air Loose or defective fittings 1 Tighten or replace Fluid at rear of barrel Packing chevron seals and or needle electrode shaft defective 1 Tighten needle or replace Fluid sight at nozzle when trigger is released AA 99 02 5 Nozzle not secure Trigger valve closing before fluid nozzle valve 1 Tighten 2 Check programming sequence 24 REA Automatic Applicators Maintenance TROUBLESHOOTING GUIDE Cont General Problem LEAKAGE Cont Fluid constant at nozzle ELECTRICAL Wrap Back Possible Cause 1 Worn or damaged fluid nozzle seat 2 Worn or damaged needle electrode 3 Nozzle not secure 4 Trigger valve needle seat 1 Improper target ground 2 Improper booth exhaust 3 Excessive atomizing air Ransburg Solution 1 Replace fluid nozzle 2 Replace 3 Tighten 4 Rebuild valve Trace and correct Trace and correct Reduce fan and atomization pressure Improper or No HV Faulty cable connections Faulty transformer assembly Improper or no ground Faulty barrel cascade assembly Faulty low voltage cable Faulty high voltage cable Faulty control unit Check fuses IS THE POWER TURNED ON IS THE ATOMIZING AIR TURNED ON IS THE RED LIGHT TRANS FORMER ON IS THE PAINT TOO CONDUCTIVE 10 Paint in air passages 2 3 4 5 6 7 8
48. ectrode seats in the fluid nozzle b Screw nut clockwise until it runs out of thread on end of needle shaft c Screw the valve extension rod until the faces ofthe nuts are seated against each other P EXTENSION REMOVAL REA 9000R 1 Remove transformer connecting screw and remove plug from transformer 2 Remove two 2 P extension screws from bot tom mounting plate Pull P extension away 3 Remove two 2 nylon screws from body 4 Gently pull P extension from body locating the two 2 spacers P EXTENSION REPLACEMENT REA 9000R 1 Locate two 2 spacers in the counter bores of the body 2 Locate the two 2 spacers in counter bores of the P extension 3 Secure the two 2 nylon screws in the body 4 Locatethe P extension into the bottom plate and fasten using two 2 screws 5 Reinstall P extension plug in transformer using screw 36 REA Automatic Applicators Maintenance AIR BUSHING BODY DISASSEMBLY A CAUTION The piston housing is spring loaded Use care in disassembly REA 9000R and 900A 1 Remove piston housing from body 2 Remove adjustment hex nut and air valve adjustment nut from extension rod 3 Remove retaining ring from body and pull the gt Pull barrel STRAIGHT out from body or bending of extension vale rod may occur barrel STRAIGHT out 4 Using pliers grab the piston nut and pull the piston o ring shaft valve piston piston washer packing cup
49. ed Encapsulation 040 Document serial number X Special conditions for safe use apply Special conditions for safe use The REA 77359 and 76110 Automatic Applicators shall only be used with associated 76580 XX Control Unit Product Marking x 12 Ex Specific marking of explosive protection l EquipmentGrouphazardousareacharacteristics 2 Equipment Category G Type of explosive atmosphere gases vapors or mists EEx 0 24mJ The REA Automatic Applicators 77359 and 76110 are suitable for use in automatic spraying installations complying with EN 50 050 as they are a Type A class with a discharge energy limit of 0 24mJ Label 72562 Ransburg Angola IN USA CONTROL UNIT POWER SUPPLY PART No SERIAL No AN WARNING VOLTS 115 220 MOT AMPERES HERTZ 50 60 p WATTS FAILURE TO OBSERVE THE FOLLOWING HE OUTPUT gag gag OUTPUT MAY RESULT IN AN ELECTRICAL DISCHARGI VOLTAGE F E CURRENT RS THIS POWER SUPPLY TO BE USED ONLY WITH THE FOLLOWING ITW RANSBURG SPRAY GUNS MAX_ PAINT PRESS MAX AR PRESS L 1 LABEL REMOVAL VOIDS WARRANTY 1 THE ARTICLE BEING COATED MUST BE GROUNDED 2 ALL OTHER ELECTRICALLY CONDUCTING OBJECTS AR GET WITHIN ABOUT TEN FEET OF THE OPERATING SPRAY GUN MODEL A B GUN MUST BE GROUNDED MAX APPRD 100 FT 100 PSI 3 THIS CONTROL UNIT POWER SUPPLY MUST BE CBL LENGTH INTERLOCKED WITH THE SPRAY BOOTH VENTILATORS SO AS TO PREVENT OPERATION OF THE POWER
50. emoving the fluid nozzle With a bladed screwdriver remove pressure reducers by turning counter clockwise from bar rel Install the desired pressure reducer Apply suitable liquid pipe thread sealant to threads Install appropriate fluid nozzle gently tightening into place using the applicator wrench 19749 00 Reinstall appropriate air cap and retaining ring See Nozzle Selection Chart later in this section for proper combination of air caps fluid nozzles and pressure reducers For remote HVLP fan air applications fan control air pressure should not exceed 10 psi Fan con trol pressure should be adjusted depending upon pattern size desired AA 99 02 5 REA Automatic Applicators Installation Atomizer Assembly Selection The Atomizer Assembly Selection Chart is pro vided to give you a comparison of the air caps and fluid nozzles THE CHOICE OF ATOMIZER ASSEMBLY SHOULD DEPEND ON QUALITIES DESIREDAND MUST BE VERIFIED BY ACTUAL TRIAL See your authorized Ransburg electro static distributor for atomizer demonstration Spray Pattern Adjustment The spray pattern of fan atomizers is adjustable from a small circle to an elongated oval approx imately 10 to 18 inches across the usable long axis at 8 to 12 inches from the target The swirl atomizer assemblies produce a round pattern from 5 to 9 inches in diameter To adjust pattern size increasing fan air pressure will expand the pattern a reduction will decreas
51. f Applicators 1 2 3 4 5 6 7 8 Notes Rebuild Kit Applicator Only 75778 00 1 2 3 4 Rebuild Kit Cartridge Valve Only 76931 00 1 2 3 4 Electrode 70430 00 2 2 4 4 Needle Shaft 18865 04 1 1 2 2 Packing Tube 18842 01 1 12 2 Cartridge Valve 76917 00 1 1 2 2 Transformer LREA4004 00 1 1 1 1 Barrel Replacement Kit 75038 06 1 1 2 2 Cable Assembly 76876 XX 1 12 2 XX must be replaced with desired length of 36 50 or 75 Screw 13490 01 1 2 2 3 Wrench 19749 00 2 2 4 4 Fluid Nozzle 4907 XX 2 2 4 4 Replace XX with 44 45 46 47 or 48 Air Cap 4904 XX 2 2 4 4 Replace XX with 63 98 or 658 Cap Retaining Ring 73569 00 1 1 2 2 High Voltage Test Probe Kit 76652 01 1 1 1 1 For Troubleshooting Complete Assembly Nozzle Nut Tool 77558 00 2 2 4 4 AA 99 02 5 Ransburg REA Automatic Applicators Parts Identification MISCELLANEOUS KITS FOR REA 9000R REA 9000W AND REA 900A Part Description 74035 10 EMF 126 Air Cap Test Kit for 63 Air Cap Includes the following items 2 Gages Part 76816 05 4904 63 Description Atomization Kit Includes the following items 1 Air Cap EMF 127 1 Bracket 4907 45 1 Fluid Nozzle 7113 09 6 Tubing 1 8 OD SSP 8201 74061 10 Fittings 73569 00 1 2 1 63 Air Cap Modified 1 Retaining Ring 70430 00 1 Electrode 76816 06 Atomizati
52. iar with the Safety Section in this manual and the Ransburg safety literature therein identified gt This manual MUST be read and thoroughly understood by ALL personnel who operate clean or maintain this equipment Special care should 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 servicing this equipment A WARNING gt The hazards shown on the following pages may occur during the normal use of this equip ment Please read the hazard chart beginning on page 2 AA 99 02 5 Ransburg AREA Tells where hazards may occur Spray Area AA 99 02 5 HAZARD Tells what the hazard is Fire Hazard Improper or inadeduate 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 REA Automatic Applicators 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
53. ig max 6 8 bar Fluid 0 100 psig 6 8 bar Piston Air Inlet Size 3 16 ODT Atomization Air Inlet Size 3 8 ODT Fan Air Inlet Size 3 8 ODT Fluid Inlet Size 1 4 ODT Paint Resistance 1 MO to Ransburg Meter AA 99 02 5 REA Automatic Applicators Introduction SPECIFICATIONS WATERBORNE REA 9000W Variable to 1 000 cc min Electrical Physical Operating Voltage Current Output Weight Bulkhead Diameter 7OkV DC max 120 microamperes max Classic 82 oz 2 3259 6 69 inch 16 9cm Max Applicator Height 7 90 inch 20 0cm Applicator Length 16 51 inch 33 0cm Center Distance from Mount to Probe End Nozzle End Center Line of Nozzle Center Line of Probe Cable Lengths Classic Version Atomizer Assembly 15 23 inch 38 6cm 11 80 inch 29 9cm 1 90 inch 4 8cm 5 92 inch 15 0cm 100 ft max SSW 1064 HVCable 4904 65R 4907 45 HVLP 75600 01 HVLP 75601 00 Fluid Flow Rate Variable to 1 000 cc min Operating Pressure Air Spray Fluid Air Consumption 0 100 psi 6 8 bar 0 100 psi 6 8 bar 16 SCFM 50 psig Operating Pressure HVLP Spray Fluid Air Consumption Atomization Air Inlet Size Fan Air InletSize Fluid Inlet Size Dump Outlet Size Trigger Actuation Dump Actuation Probe Shroud Knife Air Shroud Applicator Cover Purge Air Applicator Mounting Stud Diameter 0 100 psig 6 8 bar 0 100 psig 6 8 bar 22 SCFM 5
54. in plastic to keep it clean Asurface charge may build up on the plastic surface and discharge to the nearest grounded object Efficiency of the applicator will also be reduced and damage or failure of the applicator components may occur WRAP PING THE APPLICATOR IN PLASTIC WILL VOID WARRANTY Proceed as follows 1 Turn the control unit power OFF 2 Release the trigger 3 Turn the paint flow OFF 4 See Disassmbly Procedure in the Mainte nance section A WARNING Any damage to the gun may result in UN SAFE operating 5 Clean the removed parts with a soft brush and suitable solvent Metal tools and wire brushes must NEVER be used NEVER use a cleaning tool that is harder than the plastic parts If a deposit cannot be removed with solvent and a rag or soft brush soak the part in the solvent ONLY until the deposit can be removed NEVER SOAKTHEAPPLICATOR BODY BARREL OR TRANSFORMER REA Automatic Applicators Maintenance 22 REA Automatic Applicators Maintenance 23 FLUSHING PROCEDURES NOTES 1 Turn the control unit power OFF 2 Turn the paint supply OFF 3 Turn the atomizing air supply OFF 4 Activate dump air and flush with solvent until it is clear of paint Air purge the dump line 5 De activate dump air and activate trigger air until the applicator fluid passage is clear 6 Disconnect the solvent supply 7 Activate the trigger valve until it is clear of solvent
55. justment screw Using T Shaped Gauge on 19749 00 adjust to the 11 16 inch maximum dimension shown in Figure 10 9 Using two 2 3 8 wrenches tighten the two 2 hexes against each other to prevent movement of the parts 10 Lubricate the piston assembly with LSCHO009 00 dielectric grease 11 Insert the piston assembly into the rear of the body through the bushing nut 12 Slide the gasket onto the barrel assembly 13 Place the barrel assembly onto the front of the body Making sure that the extension rod slides STRAIGHT through the body 14 Tighten the retaining ring to the body using the 19749 00 Spanner Wrench Dee Lt 16 MAXIMUM Figure 10 Rod and Trigger Adjustment Nuts Do not exceed the 11 16 maximum dimension shown in this figure AA 99 02 5 REA Automatic Applicators Maintenance 17 Push the extension rod fully forward to seat the electrode into the fluid nozzle 18 Screw onto the extension rod jam nut and the air valve adjusting nut 19 Position the jam nut 1 16 inch from the end of the piston assembly 20 Tighten the nuts against each other to prevent movement see Figure 11 21 If the extension rod rotates while you are tight ening the nuts hold it using an adjustable wrench on the flats NOTE The hex nut and air valve adjust nut control your air before fluid adjustment 22 Install the two 2 springs 23 Install the rear piston housing
56. lace cable in robot arm 5 Connect new cable to connector assembly using a wrench on the connector flats to tighten gt DO NOT overtighten low voltage cable connection to spray applicator as damage to plastic parts may occur LOW VOLTAGE CABLE CONNECTOR ASSEMBLY REA 9000R 1 Remove applicator from robot 2 Remove rear mounting plate from fobot 3 Using a wrench on connector flats disconnect low voltage cable from connector assembly 4 Remove screw from rear mounting plate 5 Pull connector assembly out of mounting plate AA 99 02 5 Ransburg REA Automatic Applicators Maintenance 6 Install new connector assembly in rear mounting NOTES plate and secure with screw 7 Reconnect low voltage cable to connector assembly using a wrench on connector flats to tighten 8 Reinstall mounting plate and applicator to robot LOW VOLTAGE CABLE PLUG ASSEMBLY REA 9000R 1 Remove applicator from robot 2 Thread screws into threaded hole in plug as sembly 3 Pull on screw to remove plug assembly from P extension 4 Insert female end of new plug assembly into P extensions Push plug assembly in until com pletely seated NOTE gt It does not matter which receptacle of the plug assembly is connected to which pin of the P extension 5 Reinstall applicator to robot AA 99 02 5 40 REA Automatic Applicators Parts Identification Ransburg PARTS IDENTIFICATION Figure 12 REA 900
57. late 76229 00 Screw 5 16 LSFA0028 01 O Ring 208 ID x 070 CS Solvent Proof 3 Required SSG 8163 O Ring 426 ID x 070 CS Solvent Proof 2 Required SSG 8134 O Ring 301 ID x 070 CS Solvent Proof 2 Required SSG 8134 Fitting 2 Required All Parts are Required to Make a Complete Fitting 1 EMF 201 1 EMF 202 1 EMF 203 1 76223 00 1 SSG 8162 Fitting 3 8 T x 1 4 NPT 2 Required LSF10025 21 Rear Mounting Plate Assembly Includes Items 89 100 36 Ft of Cable and Hoses Polyethylene Tube 76222 36 50 Ft of Cable and Hoses Polyethylene Tube 76222 50 75 Ft of Cable and Hoses Polyethylene Tube 76222 75 100 Ft of Cable and Hoses Polyethylene Tube 76222 100 36 Ft of Cable and Hoses Tube 50 Ft of Cable and Hoses Tube 76222 36A 76222 50A 75 Ft of Cable and Hoses Tube 76222 75A 100 Ft of Cable and Hoses Tube 76222 100A DR1 Regulator Rear Plate 76607 02 76197 00 Barbed Fitting 3 Required EMF 82 1 Fitting 1 4 T x 1 4 AN LSF10033 03 Fitting 3 8 T x 1 4 NPT 2 Required 77947 00 Tubing 3 16 OD Fitting 5 16 T x 5 16 AN Tubing 1 4 OD SSP 5014 LSF10033 02 SSP 5012 Tubing 5 16 OD SSP 5011 O Ring 551 ID x 070 CS Solvent Resistent 7554 12 Plut Connector Includes Items 97 amp
58. le 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 hygienist 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 AA 99 02 5 Ransburg REA Automatic Applicators Atex EUROPEAN ATEX DIRECTIVE 94 9 EC ANNEX Il 1 0 6 The following instructions apply to equipment covered by certificate number Sira OBATEX5040X 1 The equipment may be used with flammabl
59. le or the sealing taper of the electrode 3 With the nozzle wrench on wrench flats remove fluid nozzle from barrel 4 Clean or replace fluid nozzle using appropri ate cleaning method AA 99 02 5 REA Automatic Applicators Maintenance 5 Screwthe cleaned or new fluid nozzle into barrel and secure with the nozzle wrench 6 Screw retaining ring over the air cap onto barrel NOTE gt Ifthe fluid nozzle is replaced there is a good chance that the needle electrode assembly will need to be replaced too BARREL DISASSEMBLY REA 9000R and 900A 1 Remove packing nut from rear of the barrel with the 19749 00 spanner wrench 2 Firmly pull the needle electrode shaft as sembly using the extension valve rod out of the packing chamber Resistive Electrode Accessory Male Chevron Adapter Chevron Seals 4 required Female Chevron Adapter conductive Needle Electrode Shaft Packing Tube O Ring Rear Seal Retainer U Cup spring loaded Spacer and Belville Spring Washers 6 required 3 Remove extension valve rod and adjustin nut with two 2 3 8 wrenches e Checkallparts for damage or wear Replace those that are damaged or worn with new parts Replace chevron seals o ring and u cup with new parts 34 REA Automatic Applicators Maintenance From time to time it is desirable to test the electrical integrity of the 70430 00 resistive electrode see To Test in the
60. ll a fluid filter on the output of fluid supply as shown in Figure 5 2 Detail depends on whether pressure tank pump unit recirculating system etc is used The filter must be installed vertically with drain valve down and arrow pointing in direction of flow From Paint lt Supply Drain Valve Figure 5 Typical Fluid Filter Installation AA 99 02 5 Ransburg Paint Preparation A proper paint mixture is essential to electrostatic operation Paint test equipment may be obtained through your Ransburg representative Consult Ransburg Paint Related Information for REAand REM Applicators manual for paint formulation information For further paint formu lation and testing procedures consult your Ransburg rep resentative and or your paint supplier Spray Technology Conversion Procedure Remove existing retaining ring and air cap from end of applicator Remove fluid nozzle using applicator wrench 19749 00 To avoid damage to the fluid nozzle and electrode the paint pressure and trigger return spring tension MUST be released by triggering the applicator priorto removing the fluid nozzle gt The applicator MUST be tilted front down to remove the fluid nozzle Failure to do so may allow paint to enter the air passages thereby reducing air flow and damaging the applicator barrel or cause electrical shorting Applicators may be flushed in lieu of tilting but they MUST be either flushed or tilted BEFORE r
61. nstructions to Connectthe Control Unit AA 99 02 5 A WARNING The control unit MUST be located at least three feet outside of the spray area Install units in accordance with the code require ments see NFPA 33 OSHA andlocal codes A WARNING gt The electrical discharge which is available from the charging electrode must not exceed 0 25 mJ of energy To achieve this limit any flow of energy from the paint supply through the paint line to the applicator electrode MUST BE prevented by grounding the paint line at the inlet Verify that the paint inlet is actually ground ed BEFORE operating it This is done with a fully connected and operational system by placing one lead of an ohmmeter to the inlet fitting and the other to the building electrical ground cold water pipe building structure etc The reading should be essentially zero gt Ifa greater reading is obtained check that the control unit is grounded See the Control Unit manual for Grounding Procedure 16 REA Automatic Applicators Installation 17 To Install the REA 9000W or REA 900A 1 Mount the applicator to the reciprocator bar It is recommended to use a keyed bar with 1 4 Woodruff key The applicator may be mounted on bars from the size 98 inch diam 25 mm to 1 00 inch diam 27 mm Tighten the five 5 mounting screws securely 2 Run 1 4 inch ODT air line to the trigger line fitting NOTE gt All fitting
62. of applicators is intended for use with grounded solventborne coating systems The REA 9000W Series of applicators applies 70kV DC Charge This elec trostatic charge allows a more efficient uniform application of coating material to the front edges sides and back of products It is highly suitable REA Automatic Applicators Introduction Ransburg for applying coatings to a variety of surface con NOTES figurations large targets small parts tubular wares concave and recessed parts etc keeping these components clean during operation These features help to maintain maximum efficiency of the applicators over a longer period of time These series of applicators include the automatic applicator low or high voltage cable control unit fluid hose and air tubing The control unit provides voltage output to the applicator and contains controls for AC on off high voltage adjust kV microamp meter and triple setpooint or analog input control 9 AA 99 02 5 Ransburg REA Automatic Applicators Introduction H ue Ka Figure 1a REA 90008 Solventborne Electrostatic Spray Applicator L Figure 1b View of Mounting Plate Assembly AA 99 02 5 10 REA Automatic Applicators Introduction NOTE gt 0 allow for ease of configuration operation and modification of robot teach patterns the following X Y verti cles are
63. on Kit Includes the following items 74035 11 Air Cap Test Kit for 65R Air Cap Includes the following items EMF 126 2 Gages EMF 127 1 Bracket 7113 09 6 Tubing 1 8 OD 4904 63 1 Air Cap 4907 46 1 Fluid Nozzle 70430 00 1 Electrode 76816 07 Atomization Kit Includes the following items SSP 8201 Fittings 74061 12 73569 00 1 2 1 65R Air Cap Modified 1 Retaining Ring 74035 12 Air Cap Test Kit for 98 Air Cap Includes the following items EMF 126 2 Gages EMF 127 7113 09 1 Bracket 6 Tubing 1 8 OD SSP 8201 Fittings 74061 13 73569 00 1 2 1 1 98 Air Cap Modified Retaining Ring 76816 01 Atomization Kit Includes the following items 4904 98 1 Air Cap 4907 44 1 Fluid Nozzle 70430 00 1 Electrode 76816 08 4904 98 Atomization Kit Includes the following items 1 Air Cap 4907 45 1 Fluid Nozzle 70430 00 1 Electrode 76816 09 Atomization Kit Includes the following items 4904 98 1 Air Cap 4907 46 1 Fluid Nozzle 70430 00 1 Electrode 4904 65R 1 Air Cap 4907 44 1 Fluid Nozzle 70430 00 1 Electrode 76816 02 Atomization Kit Includes the following items 4904 65R 4907 45 1 Air Cap 1 Fluid Nozzle 70430 00 1
64. or until the problem has been corrected See the Troubleshooting Guide in the Mainte nance section of this manual Ransburg Shut Down and at the end of each shift 1 Turn the control unit power OFF 2 Turn the paint supply OFF 3 Turn the atomizing air and fan air OFF 4 Wipe the applicator cable and hoses with a rag anda suitable non polar non conductive solvent 5 Flush the lines and allow the solvent to remain in the lines unpressured See Flushing Proce dures inthe Maintenance section of this manual NOTE Ifthe shutdown is to be short the lines may not require flushing depending on the coating material being used If the solids in the material settle slowly the lines will not need to be flushed as soon after shut down as with fast settling solids The paint being used and the length of time that the lines will be shut down will determine the need for flush ing Metallic paint and primer will require flushing sooner than some other kinds of coating materials gt the coating material is fast settling and if the lines are not flushed soon enough the applicator s fluid passages as well as the lines may become clogged and cause excessive down time and or service and repair Weekly Check the entire system for damage leaks and paint accumulation Clean the atomizer assembly AA 99 02 5 Ransburg ATOMIZER ASSEMBLY CLEANING PROCEDURE Routine Cleaning Equipmen
65. ower air and fluid on at the source and return the applicator to service 32 REA Automatic Applicators Maintenance 33 Ransburg SERVICE REA 9000R AND REA 900A SERIES BARREL ASSEMBLY REMOVAL REA 9000R amp 900A gt Firmly spreading the retaining ring may break it 1 REA 900A ONLY Remove pneumatic and fluid lines from the front of the bulkhead plate Remove the bulkhead plate 2 Remove rear housing and two 2 springs 3 Using an adjustable wrench on the flats of the valve rod extension remove the air valve adjusting and air valve lock nut 4 Disconnect coiled fluid tube at the fluid inlet fitting 5 Loosen barrel nut with 19749 00 spanner wrench 6 Pullthe barreland automatic body STRAIGHT apart Take extra care in handling barrel assembly to prevent bending of the extension valve rod NOTE There is no need to remove retaining ring or barrel nut from barrel unless they are damaged If they are to be removed lift one end of ring out of its groove and spiral it off of the end of the barrel then barrel nut can be removed To replace them on the barrel slide nut onto the bar rel place ring against the back of the bar rel lift one end of it onto the barrel and spiral it on and into its groove NOZZLE AND ELECTRODE CLEANING OR REPLACEMENT REA 9000R amp 900A A CAUTION gt NEVER bend the electrode NOTE See Atomizer Assembly Cleaning Procedure previou
66. pecified time see below because of faulty workmanship or material provided thatthe equipment has been used and maintained in accordance with Rans burg s written safety and operating instructions and has been used under normal operating con ditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG AP PROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THEAPPLICATOR ASSOCIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY AA 99 02 5 RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP ORMATERIALS THEREARE NOIMPLIED WARRANTIES NORWARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEQUEN TIALDAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained
67. r Cap 4907 47 1 Fluid Nozzle 1 Fluid Nozzle 73569 00 1 Retaining Ring 1 Retaining Ring 73570 05 Conversion Kit Includes the following items Conversion Kit Includes the following items 4904 65R 1 Air Cap 4904 63 1 Air Cap 4907 48 1 Fluid Nozzle 4907 46 1 Fluid Nozzle 73569 00 1 Retaining Ring 73569 00 1 Retaining Ring 73570 06 Conversion Kit Includes the following items 73570 14 Conversion Kit Includes the following items 4904 98 1 Air Cap 4904 63 1 Air Cap 4907 44 1 Fluid Nozzle 4907 47 1 Fluid Nozzle 73569 00 1 Retaining Ring 73569 00 1 Retaining Ring 73570 07 Conversion Kit Includes the following items 73570 15 Conversion Kit Includes the following items 4904 98 Air Cap 4904 63 1 Air Cap 4907 45 1 Fluid Nozzle 73569 00 1 1 Fluid Nozzle 1 Retaining Ring 1 Retaining Ring 73570 08 Conversion Kit Includes the following items Conversion Kit HVLP Includes the following items 4904 98 1 Air Cap 1 Air Cap 4907 46 1 Fluid Nozzle 73569 00 59 1 Fluid Nozzle 1 Retaining Ring 1 Retaining Ring AA 99 02 5 Ransburg WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any partand or equipmentthatfalls within the s
68. re and cause the applicator to leak fluid Inspect needle electrode shaft sealing sur face for wear If itis rough or uneven replace it AA 99 02 5 REA Automatic Applicators Maintenance 3 Place male nonconductive chevron adaptor onto shaft with the convex end rearward NOTE The chevron adaptors and chevron seals should seat together to form an unbroken seal 4 Screw needle electrode onto shaft and hand tighten 5 When replacing the needle electrode on the needle shaft of the REA 9000W applicator ONLY the electrode wire MUST be trimmed OFF flush with the electrode body Failure to do so may allow the fluid supplylLine to become charged thus reducing available voltage at the external probe electrode NOTE Apply a coating of dielectric grease to the chevron seals and needle shaft FAILURE to coat the needle shaft assem bly MAY CAUSE lower electrical output of the applicator 6 Insert the assembled items through the rear barrel packing chamber of the barrel cascade assembly DO NOT over tighten Over tightening may result in stripped threads or cracked barrel 30 REA Automatic Applicators Maintenance BARREL TO BODY ASSEMBLY REA 9000W 1 Slide gasket over the rear end of the barrel assembly Lightly coat cascade high voltage con nections with LSCHO009 00 dielectric grease 2 Tighten retaining ring with 19749 00 spanner wrench Nut should be secured hand
69. re 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 lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation draw ings and appropriate Ransburg equipment man uals to reconcile such differences Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg Ransburg A WARNING gt The user MUST read and be famil
70. rent 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 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 AA 99 02 5 Ransburg AREA Tells where hazards may occur AA 99 02 5 Spray Area High Voltage Eduipment 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 REA Automatic Applicators Safety SAF
71. ressure MUST be released by triggering the applicator prior to removing the tip The applicator MUST be tilted front down to remove the air cap and or fluid nozzle Failure to do so may allow paint to enter the air passag es thereby reducing air flow and damaging the applicator barrel cascade Applicators may be flushed in lieu of removing nozzles However they MUST be either flushed or tilted down BEFORE removing the fluid nozzle The control unit power MUST always be off when removing the nozzles Using any tool other than the Ransburg 19749 00 wrench to remove or reinstall the fluid nozzle may distort or damage it Over tightening of plastic parts may cause breakage 1 Remove air cap and retaining ring from barrel and clean or replace it 2 With the nozzle wrench on wrench flats remove fluid nozzle from barrel 3 Cleanorreplacefluid nozzle using appropri ate cleaning method 4 Screw the cleaned or new fluid nozzle into barrel and secure with the nozzle wrench 5 Screw retaining ring over the air cap onto barrel AA 99 02 5 Ransburg NOTE gt Ifthe fluid nozzle is replaced there is a good chance thatthe needle electrode assembly will need to be replaced too Needle Electrode REA 9000W Only 1 Unscrew probe retaining nut and pull probe straight out of the probe holder body 2 Unscrew the rear plastic plunger nut of the probe assembly and remove 3 Gently tap the probe body
72. ry carefully with the eraser end of a pencil or a wood or plastic dowel rod 7 Place new o ring onto rear retainer 8 Place rear retainer over shaft with the open end toward the rear 9 Place the spacer over shaft flanged end first 10 Place the six 6 Belville spring washers onto shaft with the first third and fifth ones with the cupped side facing the electrode front of shaft and the second fourth and sixth ones with the cupped side facing the rear of shaft see Figure 8 AA 99 02 5 Ransburg There MUST be six 6 spring washer alternately faced orthe applicator will malfunction Figure 8 Spring Washer Assembly 11 Place packing nut onto shaft 12 Place adjustment nut onto shaft 13 Insertfluid nozzle into frontof barrel and secure itfirmly with the 19749 00 spanner nozzle wrench DONOT over tighten Over tightening may result in stripped threads or cracked barrel 14 Insert the assembled items through the rear packing chamber ofthe barrel cascade assembly 15 Screw packing nut into rear of barrel and secure it with the 19749 00 Spanner Wrench NOTE The packing nut should be tight enough that the needle shaft moves in and out with firm resistance AA 99 02 5 REA Automatic Applicators Maintenance 16 Place the extension valve rod onto shaft and align the nuts 17 To adjust 3 8 inch hex nut and extension valve rod a Push shaft fully forward until needle el
73. s may be replaced with alternate fittings depending on your installation See Specifications previously discussed in the Introduc tion section for female thread size A WARNING gt ALL fittings used must be noncon ductive The use of electrical conductive fitting may cause injury or fire 3 Run 3 8 inch ODT or 1 2 inch ODT fluid line to the applicator 4 Connect atomization air and fan air lines De pending upon atomization technology used size the line accordingly NOTE gt The atomization and fan airline should always lead the trigger signal when the applicator is on and lag the trigger signal when the applicator is off Failure to follow this procedure will cause applicator spits 5 Install 1 4 ODT air line to shroud or probe purge air Set pressure between 5 10 psig Ransburg A CAUTION Failure to connect the shroud purge air line on the REA 900A Gun can allow excessive corona to build up within the shroud and cause premature failure of the barrel and transformer assemblies 6 Install 1 4 inch ODT air line for dump actuation 7 Install 3 8 inch ODT fluid line to dump out ACAUTION Failure to use dump line will degrade col or change time and applicator performance A WARNING Whenever the applicator is in the dump or flush mode the electrostatics must be off Filters NOTE For optimum finish quality use clean dry filtered air 1 Insta
74. sly discussed in this section A WARNING NEVER shorten the electrode wire Air Cap 1 Unscrew retaining ring remove air cap from barrel and clean using proper method or replace it 2 Replace air cap and tighten retaining ring back onto the barrel AA 99 02 5 Ransburg Fluid Nozzle gt To avoid damage to the fluid nozzle needle electrode the paint pressure MUST be released by triggering the applicator prior to removing the tip The applicator MUST be tilted front down to remove the air cap and or fluid nozzle Failure to do so may allow paint to enter the air passag es thereby reducing air flow and damaging the applicator barrel cascade Applicators may be flushed in lieu of removing nozzles However they MUST be either flushed or tilted down BEFORE removing the fluid nozzle The control unit power MUST always be off when removing the nozzles Using any tool other than the Ransburg 19749 00 wrench to remove or reinstall the fluid nozzle may distort or damage it Over tightening of plastic parts may cause breakage 1 Remove air cap and retaining ring from barrel and clean or replace it 2 Prior to removing the fluid nozzle from the applicator barrel the trigger must be actuated by applying air pressure to the trigger port or by removing the rear piston housing and pulling back on the needle shaft assembly This will prevent damage to the inside sealing surface of the fluid nozz
75. t Needed An appropriate non polar non conductive solvent Asolvent safety container grounded Asmall soft bristled brush The Ransburg 19749 00 special Multi Purpose Wrench from the Installation Kit To avoid damage to the fluid nozzle nee dle electrode the paint pressure MUST be released by triggering the applicator prior to removing the tip The applicator MUST be tilted front down to remove the air cap and or fluid nozzle Failure to do so may allow paint to enter the air passages thereby reducing air flow and damaging the applicator barrel cascade Ap plicators may be flushed in lieu of removing nozzles However they must be either flushed prior to or tilted down during nozzle removal The control unit power MUST always be off when removing the nozzles or any other service to the applicator Using any tool other than the Ransburg 19749 00 wrench to remove or reinstall the fluid nozzle may distort or damage it For efficient operation keep the applicator s exte rior and the voltage cable clean and free of paint accumulation and dirt This prevents the loss of voltage to ground with a resulting reduction in electrostatic effect Paint accumulation at the air cap orifices reduces atomization quality and in creases the potential for paint spits Clean the air cap with a brush and solvent as often as needed to ensure good atomization AA 99 02 5 A WARNING NEVER wrap the applicator
76. tic Applicators Introduction Ransburg RR UIE LE L Figure da REA 900 Solventborne Electrostatic Spray Applicator PURGE d as P Ss TEI A N ATOM fo S d 20 FAN FLUI Figure 4b View of Back Plate 13 AA 99 02 5 Ransburg SPECIFICATIONS SOLVENTBORNE REA 9000R Electrical Physical Operating Voltage 85kV DC max Current Output 120 microamperes max Weight 41 oz 1 1629 Applicator Height Applicator Length Applicator Width 6 5 inch 33 66cm 13 25 inch 33 66cm 2 inch 5 08cm Cable Lengths 36 ft Optional 50 75 and 100 ft Atomizer Assembly 4904 65R 4907 45 HVLP 75600 01 HVLP 75601 00 Fluid Flow Rate Operating Pressure Air Spray Atomizing Air 0 100 psig 6 8 bar Fan Air 0 100 psig 6 8 bar Trigger Air 40 psig min 2 7 bar 100 psig max 6 8 bar Fluid 0 100 psig 6 8 bar Operating Pressure HVLP Spray Atomizing Air 0 100 psig 6 8 bar Fan Air 0 100 psig 6 8 bar Trigger Air 40 psig min 2 7 bar 100 ps
77. tight only NEVER apply more than 10 Ibeft torque HIGH VOLTAGE MODULE ASSEMBLY REPLACEMENT REA 9000W Only A WARNING Turn OFF all power air and fluid at the source A CAUTION The voltage cable MUST be removed before removing the high voltage module 1 Remove the voltage cable from the rear of the high voltage module assembly 2 Remove the high voltage module to barrel mounting bracket 3 Remove the four 4 1 4 20 flat head screws in the top of the probe holder body assembly Remove the probe AND body as ONE assembly Ransburg 4 Remove module retaining screw from the top of the module 5 Remove the two 2 1 4 20 screws that attach the rear bulkhead plate to the high voltage module These screws are accessed through holes in the sides of the bulkhead plate 6 Pull the high voltage module STRAIGHT out through the bulkhead plate 7 Install new high voltage module and assembly in reverse order NOTE Generously lubricate probe body metal plunger and high voltage module contact bore with LSCHO0009 00 dieletic grease LOW VOLTAGE CABLE REPLACEMENT REA 900A Only A WARNING Ensure control unit power is OFF before dis connecting cable from applicator or control unit Disassembly 1 Using wrench on connector flats disconnect low voltage cable from connector assembly 2 Disconnect other end of low voltage cable from control unit and remove cable from system
78. ubstances Spray Area 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 Certain material may be harmful if inhaled or if there is contact with the skin Explosion 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 Ransburg 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 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 flammab

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