Home

AA-99-01.1 EFM & EMFD.pmd

Contents

1. IT SECTION A A Figure 24a 76368 Valve Manifold Assembly Dual 90 Sheet 1 of 2 65 AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification SECTION D D AH INY in 4 SCALE 2 1 LANES SOD X ES 8 Z Figure 24b 76368 Valve Manifold Assembly Dual 90 Sheet 2 of 2 AA 99 01 1 66 EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg 76368 VALVE MANIFOLD ASSEMBLY PARTS LIST Figures 24a 8 24b tem Pas Description Ql 1 7638000 Applicator Valve Body Dual 90DegreeHeads 1 2 EMF400 Valve Cover Assembly oZ 34 3 EMF20 AirFitmg TE 4 SSP 6076 TubeFiting Nylon 5 16 T_________ gt gt 2 Tube Fitting Barb 1 16 ID Tube 6 SSF 3128 Screw SHCS 6 32 x 1 00 Long Steel Black 5 3 O Spring Compression 8 7416000 _ Needleand SeatAssemby 2 9 7636900 Retainer Seat o 2 10 7637000 Suppor Lower Diaphragm 1 00X 1 1 12 7640400 Cap Regulator EMF 2 00 j 1 tg 76405 00 Diaphragm Support EME 200 4 Screw PHMS 44 40 x 25 Long Stainless Steel 2 OOOO AO 7554 09 O Ring Fluorocarbon Viton 76377 00 Diaphragm 1 00 7554 05 O Ring Fluorocarbon Viton 7554 33 O Ring Fluorocarbon
2. A WARNING rrv Ransburg gt Iftarget distance is less than 4 inches an arc could ATOMIZING AIR SHUTTLE VALVE occur ATOMIZING AIR SUPPLY FAN AIR SHUTTLE VALVE FAN AIR SUPPLY BLACK WHITE RED GREEN GUN TRIGGER FAN AND ATOMIZING AIR PILOT SOLENOID PILOT SOLENOID T I FLUID REGULATOR SOLENOID SUPPLY REGULATOR PILOT AIR FLUID INLET LINE DUMP VALVE DUMP VALVE eme PILOT AIR DUMP OUTLET LINE f Figure 4 Simplified Air and Fluid Flow Passage Layout AA 99 01 1 rrv Ransburg INTRINSIC SAFE WIRING Wiring Practices Instrinsically safe wiring must be separated from non intrinsically safe wiring in order to preventthe transfer of unsafe levels of energy to the hazardous area The following are a few recommended practices NOTE These sections are to be used as guidelines or recommendations only For rules and more detailed practices refer to National Electrical Code Hazardous Area In the hazardous area all intrinsically safe and non
3. AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Toxic Substances Certain material may be harmful if Follow the requirements of the Material Safety Data inhaled or if there is contact with Sheet supplied by coating material manufacturer the skin Adeguate exhaust must be provided to keep the air free of accumulations of toxic materials Use a maskor respirator wheneverthere isa 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 Spray Area There is a high voltage device that Parts being sprayed must be supported on conveyors High Voltage can induce an electrical charge on orhangersandbe grounded Theresistance between Equipment objects which is capable of igniting the part and ground must not exceed 1 megohm coating materials All electrically conductive objects in the spray area Inadequate grounding will cause a with the exception of those objects required by the spark hazard A spark can ignite process to be at high voltage must be grounded many coating materials and cause afire or explosion Any person working in the spray area must be grounded Unless specifically approved for use in hazardous locatio
4. 5 7653400 Fitting Paint EEN 2 6 EMF 103 AirAtomization Tube H Formed II Tubing 5 16 OD x 3 16 ID LL 8 EMF402 FanAirTube E Formed AM 9 EMF 6 X PaintCoil Tube F Formed so A1001401 Plug Threaded 10 32UNF Nylon___________ 1 11 7554060 O Ring Fluorocarbon Vitoo CT 4 12 755400 O Ring Fluorocarbon Viton CE 2 18 75442 O RingjFluorocarbon Viton____________ gt _ gt _ 1 14 755411 O Ring Fluorocarbon Vitoo II 15 LSORO00507 O Ring TeflonEncapsulated LL 16 SSG 8162 O Ring Solvent Resistant C 2 itting Modified 3 8 OD Tubing 2 Tube Fitting Barb 1 16 ID Tube 4 Screw Set 10 24 x 3 8 Long Nylon Tip Pin Roll 3 16 x 1 00 Long Steel 2 1 22 7060606 Ferrule Back 5 16 Stainless Steel 2 28 7060706 Ferrule Front 5 16 Stainless Steel 2 N N AA 99 01 1 38 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg 18 X L FT REQ D FAN AIR X 16 INCHES REQ D 18 x U FT READ X 13 INCHES REQ D ATOMIZATION AIR Figure 13a 76494 Manifold Assembly Sheet 1 of 2 39 BE rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification LID di di A AA n Pp E B B SECTION VIEW REF REF REF FT REQ D K 3 PIECES REQ D x Figure 13b 76494 Manifold Assembly Sheet 2 of 2 BE 40 EFM D Solventbor
5. I AA 99 01 1 26 EFM D Solventborne Robotic Atomizers Maintenance REMOVING APPLICATOR FROM THE ROBOT MANIFOLD ASSEMBLY See Figure 7 Any time service is reguired within the applicator shroud the applicator must be removed from the robot manifold assembly After the applicator is removed from the robot manifold always move to a clear clean work area to remove the applicator shroud and begin servicing 1 Purge all fluid from the system and blow lines dry with pushout air before the applicator is re moved rrv Ransburg 2 All pressures must be removed both air and fluid before removing the applicator Fluid pressure can be removed by actuating the applicator trigger with the paint regulator open 3 Remove the applicator from the robot manifold assembly by unscrewing six socket head cap screws 7 The screws are retained inthe mounting flange and only need to be unscrewed far enough to release the threads from the robot manifold AWARNING Eye protection should be worn while servic ing applicator n myRansburg Electrostatic Systems Bo Figure 7 Applicator Removal from Robot Manifold 76480 EFM APPLICATOR ASSEMBLY PARTS LIST Figure 7 Pata Description eo 76479 00 y Spray Head Assembly Resistive EFM 76481 00 Applicator Housing Assembly Single 60 Degree 3 EMFO0600 02 Shroud ITW Logo EFM 7554 08 SSF 3125 6 EMF
6. Manifold Plate Assembly EMF Bracket Tie Rod Mounting Tie Rod Short 1 8 O D Polyurethane Tube Screw SHCS 10 24 x 75 Long Nylon Screw SHCS 1 4 20 x 5 Long Nylon Screw SHCS 1 4 20 x 1 Long Steel O Ring Teflon Washer Flat 10 Nylon Stud Threaded 3 8 16 PARTS LIST BULLET DEFINITION TABLE Figure 16 1 59972 00 dielectric grease spread a small amount evenly in each groove of both parts TUBE FUNCTIONS Figure 16 Tube deen No Length Routing Instructions Description mue nz s CS Due Jame s emm CL Twee 2060 e _ RoutethuPartGot Pr Regt P ue hase G epuer DumpReodetorit ubere Jere RwemPanCo Iessen meern Ewes _ hstalvin Smal TapredEnd Towers NS AA 99 01 1 48 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg mvvRansburg Electrostatic Systems Figure 17 76482 EFM Applicator Assembly Single 90 49 N S ja II AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76482 EFM APPLICATOR
7. Replace any parts that show signs of wear or damage 8 Remove fluid nozzle 15 by unscrewing counterclockwise Inspect o ring 11 and all passagesfor build up or damage Clean orreplace as necessary Reinsert o ring into applicator barrel and reinstall fluid nozzle Torque fluid nozzle to 25 Ibs in gt If using needle nose pliers to unscrew the front needle be very careful Do notgriponthe tapered sealing surface If the pliers slip they could damage the tapered sealing surface of the needle NOTE There should be a small gap between the fluid nozzle and the applicator barrel aftertightening 9 After cleaning insert the electrode assembly back into the spray head assembly Apply Loctite 222 low strength purple thread locker to the threads of the electrode assembly 16 before reassembly 10 Screw fluid tip 18 back into place Hand tighten first then with a small wrench tighten an additional 30 degrees 11 Replace air cap clip 19 air cap 20 and air cap retainer 21 rrv Ransburg 12 Apply a thin film of petroleum jelly to piston spring 3 Install piston spring and spring retainer 2 back into the rear ofthe spray head assembly 13 Screw piston cap 1 back on Current Output Test 1 Turn the control unit power ON 2 Flush applicator with non conductive solvent 3 Activate high voltage and slowly approach the applicator electrode with ground hook or wire 4 Monitor the c
8. DIMENSION VERTICAL PLANE j CENTERLINE TO OPTIMUM SPRAY PATTERN z DIMENSION 3 D PLANE Figure 1 Applicator Tool Point Representation BE s EFM D Solventborne Robotic Atomizers Installation rrv Ransburg INSTALLATION EFM AND EFMD NOTES ROBOTIC ATOMIZER INSTALLATION This information is intended ONLY to indicate the general installation parameters of this product and where applicable its working relationship to other ITW Ransburg system components in typical use Each installation is unique and should be directed by an authorized ITW Ransburg representative or conducted from the ITW Ransburg installation drawings provided for your particular installation POWER SUPPLY ASSEMBLY Refer to the ITW Ransburg Service Manual MicroPak Control Unit tor complete information regarding power supply installation Twolow voltage control cables 76495 and 76496 connect from the Output terminal connection J3 located on the back of the power supply assembly These cables connectfromthe terminal block J3 to the robot manifold plate AWARNING gt The power supply MUST be located outside the HAZARDOUS area Reference OSHA and NFPA 33 gt User should be aware of and adhere to all local fire codes and ordinances gt The user MUST provide a properly fused disconnect betweenthe power source andthe power supply which complies with appropri ate codes AA 99 01 1 EFM D Solventborne Robotic Atomi
9. ing to start The robot must be locked out and tagged out per OSHA Solvents used for eguipment flushing must have flash point ratings equal to or greaterthan the flash point rating of the coating material Solvents used for general cleaning must have flash point ratings higher than 100 F 37 8 C ROUTINE MAINTENANCE SCHEDULE Follow these maintenance steps to extend the life of the applicator and ensure efficient operation Several Times Daily 1 Turn the LECU5004 MicroPak Control Unit OFF 2 Inspect the fluid nozzle and electrode wire for paint accumulation Clean as frequently as necessary See Procedures in the Mainte nance section AWARNING Take precautions to see that skin is not punctured by sharp electrode Daily Or at Shift Start 1 Turn the LECU5004 MicroPak Control Unit OFF and Check within 20 feet of the point of operation of the applicator and remove or ground ALL loose or ungrounded containers Inspect workholders foraccumulated coating materials remove such accumulations if present Check that the nozzle assembly is clean and undamaged Straighten the applicator electrode if necessary gt Do not bend the applicator electrode while wiping Never immerse the applicator in sol vents This will cause damageto the electrical components AA 99 01 1 AA 99 01 1 rrv Ransburg 2 Turn the LECU5004 MicroPak Control Unit ON Energize high voltage Shu
10. 0 035A 1 2W The MicroPak power supply control unit provides Paint Flow Rate Variable to 1500 cc min a low voltage signal through the robot manifold to I the EFM or EFMD spray applicator The high Operating Air Pressures voltage cascade located within the applicator Atomizing Air 100 psig max converts the low voltage DC signal to a high k voltage electrostatic output See MicroPak Fan Air 100 psig max Control Unit Service Manual tor details of the NEC LECU5004 MicroPak control unit ES Regulator Pilot 60 psig max SPECIFICATIONS Dump Pilot 60 psig max Robot Mounting Compatibility ABB Robotics Operating Fluid Fanuc P150 155 200 Pressure 300 psig max Motion Machine Gun Bar Robot Manifold Tubing Reguirements Applicator Control Atomizing Air 1 2 OD Nylon Unit LECU5004 MicroPak control unit Fan Air 1 2 OD Nylon Weight Trigger Air 3 16 OD Nylon Single Headed 76480 02 60 8 25 Ibs 76482 02 90 8 25 Ibs Regulator Pilot 3 16 OD Nylon Dual Headed 76485 02 60 9 50 lbs Dump Pilot 3 16 OD Nylon 76488 02 90 9 50 Ibs Fluid Manifold 76494 XX 2 00lbs Polyethylene 1 4 or 3 16 ID No tubing or Cable Teflon 1 4 or 3 16 ID Length Dump Single Headed 76480 02 60 15 5 8 Polyethylene 1 4 or 3 16 ID 76482 02 90 14 1 2 Teflon 1 4 or 3 16 ID Dual Headed See Manifold Selection Guide in the Introductin 76485 02 60 13 7 8 section for proper manifold tubing size material length
11. 76488 02 90 13 3 8 ordernumber Manifold 76494 16X 16 76494 25X 25 76494 50X 50 BEN EFM D Solventborne Robotic Atomizers Introduction rrv Ransburg MANIFOLD SELECTION GUIDE WITH 3 16 ID POLYETHYLENE PAINT AND DUMP TUBING ORDER 76494 16A for 16 length tubing 76494 25A for 25 length tubing 76494 50A for 50 length tubing 1 4 ID TEFLON PAINT AND DUMP TUBING ORDER 76494 16B for 16 length tubing 76494 25B for 25 length tubing 76494 50B for 50 length tubing 3 16 ID TEFLON PAINT AND DUMP TUBING ORDER 76494 16C for 16 length tubing 76494 25C for 25 length tubing 76494 50C for 50 length tubing 1 4 ID POLYETHYLENE PAINT AND DUMP TUBING ORDER 76494 16D for 16 length tubing 76494 25D for 25 length tubing 76494 50D for 50 length tubing 3 16 ID TEFLON PAINT AND 1 4 ID TEFLON DUMP TUBING ORDER 76494 16E for 16 length tubing 76494 25E for 25 length tubing 76494 50E for 50 length tubing 7 AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Introduction To allow for ease of configuration operation and modification of robot teach patterns the following spray point verticies are provided Refer to Figure 1 for explanation of coordinates X Y 76480 02 EFM 60 14 812 13 397 76482 02 EFM 90 12 894 14 313 76485 02 EFMD 60 13 252 14 738 76488 02 EFMD 90 11 240 15 078 m X DIMENSION HORIZONTAL PLANE WRIST TO TIP DISTANCE Y
12. ASSEMBLY PARTS LIST Figure 17 1 7647900 e 76483 00 6 SC F 3125 7 8 76554 00 AA 99 01 1 Description Spray Head Assembly Resistive EFM Applicator Housing Assembly Single 90 Degree Shroud ITW Logo EFM O Ring Fluorocarbon Viton crew SHCS 5 16 18 x 75 Long Nylon Screw Locating Pin Ring Socket Head Cap Screw Captive Flange Mounting Ring 50 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg q 2 9 NOILO3S lt x a 8 8 NOILO3S KA z NK S Sech a a NOI193S V AA 99 01 1 Figure 18 76484 Valve Manifold Assembly Single 90 51 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76484 VALVE MANIFOLD ASSEMBLY PARTS LIST Figure 18 tem pan Description Qty Applicator Valve Body Single 90 Degree Head Valve Cover Assembl Air Fitting Tube Fitting Nylon 5 16 T Tube Fitting Nylon Barb 1 16 ID Tube 6 J J SSF 3128 Screw SHCS 6 32 x 1 00 Long Steel Black Spring Compression 8 7416000 Needleand Seat Assembly 9 7636900 X Retainer Seat Support Lower Diaphragm 2 00 Support Upper Diaphragm 2 00 0 1 Cap Regulator 2 00 Spacer Diaphragm Support 2 00 Screw PHMS 44 40 x 25 Long Stainless Steel Diaphragm 2 00 Air Cartridge Valve Assembly 7
13. Figure 19 Tube DD Pan No Length Routing Instructions mew Hz s ane e OIL 5 bone Mime Fubec Hexe G RewetmuPantcol FudRegulator Plt et les 6 acteur space pere Jere ano iz Aria user ames Faite Tapored tra Tovardsthe Pearl Appa Panne AA 99 01 1 54 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg d d OI OI Electrostatic Systems myRansburg Z ES SS SS lt SS E ES ES D E SP E SS 2 gt g N Set A w O YA SE Figure 20 76485 EFM Applicator Assembly Dual 60 AA 99 01 1 55 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76485 EFM APPLICATOR ASSEMBLY PARTS LIST Figure 20 Pat Description 76479 00 Spray Head Assembly Resistive EFM 76486 00 Applicator Housing Assembly Dual 60 Degree EMF0600 02 Shroud ITW Logo EFM Q lt SSF 3125 Screw SHCS 5 16 18 x 75 Long Nylon EMF 97 Screw Locating Pin Ring EMF 204 Socket Head Cap Screw Captive 76554 00 Flange Mounting Ring 1 O Ring Fluorocarbon Viton 6 5 AA 99 01 1 56 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg SECTION C C iz Z IN
14. LAYOUT 17 INTRINSIGSAFEWIRIN E scumaissiai ri a 18 MAINTENANCE 19 34 ROUTINE MAINTENANCE SCHEDULE ooo ori 19 20 PROCEDURES ida A 20 21 2211 4m 21 SPRAY HEAD ASSEMBLY PARTS US Loi 22 24 FLUID REGULATOR OR DUMP VALVE PARTS LIST eee 25 26 REMOVING GUN FROM THE ROBOT MANIFOLD ASSEMBLY E KE 27 AIRGARTRIDGEVALVES ratas 28 29 SOLENOID TRIGGER VALVES PARTS LIT 29 30 LECU5004 MIGROPAK ee Che IN RE 31 76494 XXX ROBOT MANIFOLD ASSEMBLY idila cenis 31 eege 31 34 Continued On Next Page EFM D Solventborne Robotic Atomizers Contents PARTS IDENTIFICATION 76479 SPRAY HEAD ASSEMBLY PARTS LUST een 76490 APPLICATOR MANIFOLD PLATE ASSEMBLY PARTS LIST 76494 MANIFOLD ASSEMBLY PARTSLIST eee 76480 EFM APPLICATOR ASSEMBLY PARTS LIST eene 76366 VALVE MANIFOLD ASSEMBLY PARTS LIST eee 76481 APPLICATOR HOUSING ASSEMBLY PARTSTLIST 76482 EFM APPLICATOR ASSEMBLY PARTS LIST eene 76484 VALVE MANIFOLD ASSEMBLY PARTS LIST a 76483 APPLICATOR HOUSING ASSEMBLY PARTS LIST ees 76485 EFMD APPLICATOR ASSEMBLY PARTS LIST eene 76487 VALVE MANIFOLD ASSEMBLY PARTS LIST a 76486 APPLICATOR HOUSING ASSEMBLY PARTS LIST 76488 EFMD APPLICATOR ASS
15. Plug cator EMF 99 Rear Plug SSG 8161 O Ring These dump plugs are used to block the dump ports in the spray heads when the dump feature is not desired 76740 O RING KIT Figure 10 76740 01 76740 02 Description Single Head Dual Head Qty Qty 1 76690007 O RingSolvent esistant 2 2 2 ssast O Ring SolventResistant 2 f 3 ss6 stes OFig Sovent Resistant 6 EE EE 6 SSG 8136 O Ring SolventResistant scsi O Rina Sovent Resttant i 3 ssestes O Ring SolventResistant 2 f 2 T LE Lee kk 10 ssasiso O Ring SolventResistant 2 f 2 ssestso O Ring SolventResistant J 1 f r 12 SSG 8151 O RingSolvntResistan III 2 SSG 8155 SR Ring Solvent Resistant OT bi am eem _ Hi 33 AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Maintenance D E sO o Figure 10 Solvent Resistant O Ring Kit EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg PARTS IDENTIFICATION 9 SN SS RN ZEE EA STERN SN IS 20 18 y SESW X ib SSSNSSSSSNS eg NS Wy TU U ZN NZ dah INN v ES S y E 9 o SEEN Bi i d Dh 5 3 8 G lt Z lt Z Z Z RONA 22 76479 Spray Head Assembly AA 99 01 1 Figure 11 35 rrv Ransburg EFM D Solventborne Robotic At
16. Steps 1 through 3 under Removing Gun from the Robot Manifold Assembly in the Maintenance section 2 Removetwo wire connector 3 fromthe solenoid to be replaced Observe that a black wire and a red wire connect to the right hand valve fluid solenoid and a white wire and a green wire connect to the left hand valve air solenoid IT Ransburg NOTE While holding the EFM applicator with the spray head pointed down and away the fluid solenoid is on the right and the air solenoid is on the left 3 Usinga standard screwdriver gently pry offthe top plastic cap of the solenoid Slide the lower plastic shroud of the solenoid upward until the solenoid s positioning holes are revealed Using a small spanner wrench or Allen wrench loosen the solenoid from its mounting to the manifold plate 4 Toreassemble reverse the procedure of Step 3 gt Make sure the solenoid s wire terminal remains confined to the inside area of the manifold plate Some slight force may be reguired to properly seat the top plastic cap onto the solenoid Tapping with the handle end of a screwdriver or light use of a dead blow hammer is sufficient 5 Replace wire connectors 3 Plug short wire connector white amp green into air solenoid and plug long wire connector black 8 red into fluid solenoid 6 Refer to Figure 6b and reinstall shroud 3 and flange 8 Remount the applicator to the robot manifold Make sure that all o rin
17. intrinsically safe wiring must be separated by the same methods suggested for the safe area However the following requirements must also be followed 1 In enclosures containing multiple intrinsically safe circuits the terminals for connection must have a spacing of at least 6mm or a grounded or insulated partition between the circuits 2 Devices like limit switches or pressure switches must not contain a non intrinsically safe circuit in addition to an intrinsically safe circuit unless a Itis enclosed in a separate compartment or b Itis separated by 50mm spacing or contains a grounded metal or insulated partition 3 When conduit or raceway is utilized to enclose intrinsically safe wiring it must be sealed or vented so not to transfer the hazardous atmosphere to a safe area Safe Area In the non hazardous area intrinsically safe and non intrinsically safe wiring must be separated by one of the following methods 1 Raceway or conduit 2 Grounded metal or insulated partition between the intrinsically safe and non intrinsically safe wiring 3 Airspace of at least 50mm 2 inches between intrinsically safe and non intrinsically safe wiring and the wires must be tied down to prevent loosening and shorting together The same methods are used for intrinsically safe and non intrinsically safe terminals Requirements Intrinsically safe wiring must be identified prefer ably by color coding of light blue If light
18. of coating material and wrap back paint particles being deposited onthe applicatorbody orthe robot arm At close distances the voltage at the tip of the applicator will be reduced which decreases the charging effect of the applicator NOTE When using paints with metal par ticles a problem of alignment may oc cur When alignment is achieved appli cator current increases to maximum and applicator tip voltage decreases to near zero kV Alignment can normally be controlled by making sure thatthe power supply is turned on slightly after paint begins to flow and by turning the power supply off shortly before the paint stops flowing This timing function is controlled bythe LECU5004 MicroPak Control Unit and is adjustable by the user Refer to ITW Ransburg Service Manual MicroPak Control Unit for more de tails AA 99 01 1 rrv Ransburg NOTE gt H alignment occurs turning off the power supply will not usually break the aligned metal particles The paint located between the applicator and the point of first ground must be purged from the fluid passages before normal spray can re sume A WARNING gt Most paints and solvents including those listed in Polar and Non Polar Solvents Chart in the Maintenance section are toxic to a certain degree and flammable or combustible Usethemonly ina well ventilated atmosphere Use protective equipment as required in the Material Safety Data Sheet supplied with the subs
19. spring force trying to push it out Ifit does not come out on its own insert seat extraction tool 76385 00 into hole in seat retainer Tighten tool in hole and pull seat retainer out NOTE Regulatorcap and dump cap replace ment procedures are identical They dif fer only in size Maintenance rrv Ransburg 7 Inspect poppet seat assembly 2 for wear If wear or damage is evident replace Replace both poppet and seat at the same time because they are a matched set Inspect o ring for damage replace as necessary Part Number SSG 8172 8 Reassemble the fluid regulator by inserting the spring poppet and seat 1 and 2 back into the valve manifold housing Be sure to lube o ring before trying to insert back into manifold Secure the poppet seat assembly by screwing the seat retainer 4 into the valve manifold housing until a torque of 8 10 Ibs in is obtained NOTE gt When replacing the poppet seat or the regulator dump cap be cautious so that the plastic threads are not stripped by cross threading 9 When placing the diaphragm 6 or 13 remove the screw 16 that holds both halves together Inspect o ring for damage To reassemble make sure that the Teflon side is toward the lower support 5 or 10 Reinstall screw and tighten Be careful not to over tighten If the diaphragm is inserted wrong damage will occur Push the diaphragm assembly down in valve body 10 Place diaphragm support 8 or 14 back int
20. the assembly is firmly seated in the spray head 6 Place seal spring 12 over the rear needle in the front end of the spray head Hold the spray head upward as the spring will want to fall out 7 Still holding the spray head upward place o ring 11 into its seat and seal washer 13 and fluid seal 14 ontothe rear needle Thetapered end of the fluid seal should be pointed toward the front of the applicator 8 Reassemble fluid nozzle 15 by pushing the nozzle into the spray head until the threads engage Screw the nozzle into the spray head Torque to 23 25 Ibs in Plastic threads damage easily do notover tighten Notethe front flange of thefluid nozzle will not seatflush againstthe spray head 9 Apply Loctite 4222 Low Strength purple Threadlocker into the threads of plastic front needle 16 before assembling ontothe rear needle Be sure that the rear needle assembly is pushed all the way forward before threading on front needle 10 Reassemble fluid tip 18 Hand tighten first then with a small wrench turn an additional 30 degrees Place air cap clip 19 into groove in the fluid tip 11 Reassemble air cap 20 and air cap retainer 21 Do not let air cap rotate while loosening or tightening 12 Apply a thin film of petroleum jelly to piston spring 3 Install piston spring and spring retainer 2 Screw piston cap 1 back on 13 Lubricate all of the o rings on the underside of the spray head with petrol
21. 8 9 0 1 O Ring Fluorocarbon Viton Nut Nylon 3 8 T O Ring Solvent Resistant O Ring Fluorocarbon Viton O Ring Fluorocarbon Viton O Ring Teflon Encapsulated O Ring Solvent Resistant Spring High Voltage Contact Ferrule Front 3 8 T Nylon SSP 9012 Ferrule Back 3 8 T Nylon AA 99 01 1 52 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg I eege 209009117 O ON WY FZ EE SZZ RADM INS dem ae 2 9 Nous raza LH LT UU UL UDA U D G NU MI NOH HIN REO D N SU BEEN IA SIHL NI NMOHS LON TY NA S Figure 19 76483 Applicator Housing Assembly Single 90 AA 99 01 1 53 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76483 APPLICATOR HOUSING ASSEMBLY PARTS LIST Figure 19 Description Valve Manifold Assembly Single 90 Head Cascade Assembly HP404 Tie Rod Long Bracket Cascade Mounting Manifold Plate Assembly EFM Bracket Tie Rod Mounting Tie Rod Short 1 8 OD Polyurethane Tube Screw SHCS 10 24 x 75 Long Nylon Screw SHCS 1 4 20 x 5 Long Nylon Screw SHCS 1 4 20 x 1 Long Steel O Ring Teflon asher Flat 410 Nylon tud Threaded 3 8 16 lt PARTS LIST BULLET DEFINITION TABLE Figure 19 1 59972 00 dielectric grease spread a small amount evenly in each groove of both parts TUBE FUNCTIONS
22. 97 Locating Pin O Ring 42 011 Fluorocarbon Viton Screw SHCS 5 16 18 x 75 Long Nylon Locating Pin j EMF 204 Socket Head Cap Screw Captive 8 76554 00 Flange Mounting Ring 1 AA 99 01 1 AA 99 01 1 rrv Ransburg AIR CARTRIDGE VALVES See Figures 6b 7 12 15 and 16 1 Referring to Figure 6b remove flange 8 from the applicator shroud by loosening three slotted dog style set screws 6 2 To remove applicator shroud 3 pick up the applicator assembly place the two locating pins projecting from the applicator manifold plate onto a rigid surface Grasp the shroud in both hands and firmly push downward The shroud will slide off of the valve manifold assembly 3 Referring to Figure 16 remove three metal socket head cap screws 11 and o rings 12 holding applicator manifold plate assembly 5 to tie rods 3 and 7 gt Press against locating pins only Pressing against fluid fittings could cause damage 4 Remove nylon socket head cap screw 10 holding L shaped bracket 6 to the valve cover assembly and set aside Remove two screws 9 holding the bracket to short tie rod 7 and set aside 5 Referring to Figure 12 disconnect air atomization tube 6 and fan air tube 8 from air fittings 3 see Figure 15 on either edge of the valve cover assembly 6 Remove two air fittings 3 see Figure 15 7 Remove three small metal socket head cap screws 6 see Figure 15 T
23. CE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATE RIALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANS BURG ASSUMES NO LIABILITY FOR IN JURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PUR CHASER OR OTHERS EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume no responsibility for repair or replacement of the item or items The pur chaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable AA 99 01 1 rrv Ransburg MANUAL CHANGE SUMMARY This manual was published to supercede Service Manuals AA 96 01 1 REA 9000A and REA 9000LA Automatic Electrostatic Spray Guns Dual Atomization Technology and AA 97 01 1 REA 9000R and REA 9000RL Auto matic Electrostaic Robot Mount Spray Guns Dual Atomization Technology to make the following changes 1 To publish into Service Manual that list all present REA Automatic Electrostatic Spray Applicators including their updated information All Manual Sections 3 To include a Warranty Policies section to the Service Manual 4 Remove Appendix section See Literature IL 307 Technical Supp
24. ECU5004 MicroPak Control Unit Figure 4 in the Operation section generalizes the function of the airandfluid passages internalto the applicator POWER SUPPLY CONTROLS Refer to ITW Ransburg Service Manual MicroPak Control Unit tor complete information regarding power supply operation Voltage The LECU5004 MicroPak Control Unit provides a low voltage signal to the high voltage cascade within the spray applicator The unit may be configured for local mode operation The output voltage current levels are set by potentiometers on the front panel in this mode The unit may also be configured for remote analog control 0 10 VDO from a PLC controller Display Function The display board continually displays the kV and current output information 1rv Ransburg All of the display signals are buffered and continuously available for remote panels or PLC monitoring There is also an array of LEDs which display the status of the controller for operator convenience GENERAL INFORMATION AND ADJUSTMENTS Paint Conductivity The EFM EFMD spray applicators are capable of spraying typical automotive and industrial solvent base paints including metallic and mica paints Spray tests however should always be conducted before selecting an atomizer for use with highly conductive paints Target Distance The distance between the applicator tip and the article being painted should be between 10 and 14 inches Excessive distance causes a waste
25. EMBLY PARTS LIST eene 76368 VALVE MANIFOLD ASSEMBLY PARTS LIST a a 76489 APPLICATOR HOUSING ASSEMBLY PARTSTLIST WARRANTY POLICIES EIMITED WARRANTY f rrv Ransburg PAGE 35 70 AA 99 01 1 rrv Ransburg AA 99 01 1 EFM D Solventborne Robotic Atomizers Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any ITW Ransburg electrostatic coating system read and understand all of the technical and safety literature for your ITW Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EGUIPMENT PROBLEMS To help you recog nize this information we use the following sym bols 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 eguipment or how to avoid a situation that might cause minor injury A NOTE is information relevant to the pro cedure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your eguipment Differences in local codes and plant reguirements material delivery reguirements etc make such variations inevitable Com
26. Electrode and Air Cap Protectors 76381 XX Tool Kit Misc Shunts Misc Dump Plugs 9410 01 Plug Nut 76740 XX O Ring Kit rrv Ransburg INTRINSIC SAFE BARRIER AND HARDWARE Part 4 Description Eege 76741 00 75777 APPLICATOR COVERS Part 4 Description 75777 01 Single Head Applicator 75777 02 Dual Head Applicator 75777 03 Robot Wrist Flange EMF 430 1 Test Air Cap The EMF 430 1 Test Air Cap is designed for use with a Test Station or while the applicator is connected tothe robotor reciprocator The test air cap is comprised of two air pressure gauges pressure gauge stand special 76131 air cap and all required tubing and fittings The air cap has two tapped holes for small barbed tube fittings The fittings are located so that the gauges connected to them will measure the actual cap pressure of the atomization and pattern air Using this test cap will assure uniform atomization and pattern guality regardless of air supply tube lengths from one applicator to another EMF 176 Electrode and Air Cap Protector The EMF 176 is a plastic cylinder that fits over the air cap retainer The protector keeps the electrode and other spray head parts from being damaged during booth cleaning andat other times when the spray applicator is not in use AA 99 01 1 rrv Ransburg 76381 Tool Kit Provided with each applicator is a tool kitto aid in the disassembly and assembly of the applicator during servic
27. ID U N Mia PARTS LIST BULLET DEFINITION TABLE Figure 25 TUBE FUNCTIONS Figure 25 Tube ID Part No Length Routing Instructions Tuere ze G aper Sae uero ess G gepotert lU Pregla et es 6 enpuer a Regt ubere emos Rovetiupanico ore peti Ems nsalWwiSnaler Tapered na Tovaris re Pear goltor Paine AA 99 01 1 70 EFM D Solventborne Robotic Atomizers Warranty Policies 71 1rv Ransburg WARRANTY POLICIES LIMITED WARRANTY ITW Ransburg will replace or repair without charge any part and or eguipment that fails within the specified time see below because of faulty workmanship or material provided thatthe eguip ment has been used and maintained in accor dance with ITW Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANS BURG APPROVED PARTS VOIDS ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLAS TIC SHRINK WRAP ETC WILL VOID THIS WARRANTY ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLA
28. Needle Replacement See Figure 5 1 Removethe aircap fluidtip andthe fluid nozzle as described in Steps 1 through 8 of the Fluid Tip Nozzle and Front Needle Replacement in the Maintenance section 2 Remove metal rear needle 9 piston rod 8 piston seal 6 piston 5 and piston nut 4 as an assembly Pull the assembly out from the rear of the spray head 3 Piston 5 and piston seal 6 can be removed from the piston rod by unscrewing piston nut 4 H replacing piston seal 6 press flat side of seal down onto piston Apply a thin film of petroleum jelly to outside of seal Fluid seal 14 seal washer 13 and seal spring 12 will come free at this point Place hand over end as not to drop parts NOTE gt Damage will occur to the piston seal if removed If removed replace piston seal gt Do notremove the metal rear needle from the rod unless it is damaged and must be replaced 4 Inspect metal rear needle 9 for excessive wear If wear is observed longitudinal grooves or a noticeable reduction in diameter replace the needle Whenever replacing rear needle section you must also replace the seal 14 at the same time Upon reassembly apply Loctite Locquip Primer Grade T 4747 56 and Loctite 4290 Medium Strength green to the end of rear needle and ID of piston rod 8 before assembling into piston rod 5 Place the rear needle assembly back into the spray head Pushonthe piston until
29. S CONDITIONS AA 99 01 1 rrv Ransburg AA 99 01 1 EFM D Solventborne Robotic Atomizers Installation NOTES EFM D Solventborne Robotic Atomizers Installation rrv Ransburg Figure 3 Robot Manifold and Spray Applicator Installation 13 E rrv Ransburg EFM D Solventborne Robotic Atomizers Installation ROBOT MANIFOLD AND SPRAY APPLICATOR PARTS LIST Figure 3 Park Description 76488 02 EFM Spray Applicator TR SSF 024 5mm x 20mm Socket Head Cap Screws 76494 xx Robot Manifold Assembl 9 lt SSF 3125 5 16 18 x 1 Hex Socket Screws 76496 xx Low Voltage Power Cable 76495 xx Intrinsic Safe Solenoid Cable Manifold Plate 7 EH 14 EFM D Solventborne Robotic Atomizers Operation 15 OPERATION These instructions indicate the general operating parameters for this product in a normal working relationship with other ITW Ransburg system components in typical use Each user application is unigue and operation should be initiated under the guidance of an authorized ITW Ransburg representative and or be based on carefully conducted tests and on careful observation of the initial production characteristics SPRAY APPLCIATOR CONTROLS Fluid flow trigger dump atomization air pressure and fan air pressure are all remotely controlled from the robot PLC Atomization air fan air and fluid trigger timing are adjusted electronically from the L
30. Tells what the hazard is Tells how to avoid the hazard Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically Improper or inadeguate operation and maintenance procedures will Spray areas must be kept clean to prevent the cause a fire hazard accumulation of combustible residues Protection against inadvertent Smoking must never be allowed in the spray area arcing that is capable of causing fire or explosion is lost if any safety The high voltage supplied to the atomizer must be interlocks are disabled during turned off prior to cleaning flushing or maintenance operation Freguent power supply shutdown indicates a problem in When using solvents for cleaning the system reguiring correction Those used for eguipmentflushing should have flash points egual 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 and local codes In addition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high voltageto be on but only as instructed Non factory replacement parts or unauthorized equipment modifications may cause fire or injury If used the key switch bypass is intended fo
31. V SECTION E E 2X SIZE 7 2 Z A NUS yee SECTION B B SECTION A A ER Figure 21a 76487 Valve Manifold Assembly Dual 60 Sheet 1 of 2 57 AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 12 31 9 16 SCALE 2 1 SECTION D D 14 32 16 8 15 16 13 2 10 SCALE 2 1 18 17 Y N N Figure 21b 76487 Valve Manifold Assembly Dual 60 Sheet 2 of 2 AA 99 01 1 58 EFM D Solventborne Robotic Atomizers Parts Identification irw Ransburg 76487 VALVE MANIFOLD ASSEMBLY PARTS LIST Figures 21a amp 21b tem Pas Description ow 1 7654500 Applicator Valve Body Dual 60Heads gt 1 2 EME406 Valve Cover Assembly _ 1 3 EMF20 AirFitimg_ E Tube Fitting Nylon 5 16 T 2 Tube Fitting Barb 1 16 ID Tube 5 6 SSF32929 Screw SHCS 6 32 x 1 00 Long Steel Black ho 3 1j Spring Compression 8 7416000 Needleand SeatAssemby O 2 9 76369 00 Retainer Seat 1 1 2 O 10 7637000 Support Lower Diaphragm 1 00 1 Support Upper Diaphragm 1 00 1 12 7640400 CapRegueton2 00 II 13 76405 00 Spacer Diaphragm Support 2 00 ______ 1 Screw PHMS 44 40 x 25 Long Stainless Steel 2 15 763 800 _ Diapnragm2 00 1 Win 76376 00 Regulator Cap 1 00 76375 00 Spac
32. Viton LSORO0005 06 O Ring Teflon Encapsulated SSG 8128 O Ring Solvent Resistant SSG 8136 O Ring Solvent Resistant 1 i i d i i i i i a Spring High Voltage Contact 31 7640700 Support Lower Diaphragm 2 00 1 o 1 33 SSP 9011 Ferrule Front 3 8 T Nylon_______________ 2 Fere Back SIT Nyon bus NIN 67 AA 99 01 1 1rv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification NOTES AA 99 01 1 68 EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg IS ELI d L ALIVIO YO SMIA TIV NI NMOHS LON mr ae a A AXA O A q s SOSA PE Figure 25 76489 Applicator Housing Assembly Dual 90 AA 99 01 1 69 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76486 APPLICATOR HOUSING ASSEMBLY PARTS LIST Figure 25 tem Pata Description pp 1 7636800 Valve Manifold Assembly Dual 90 Degree Head 1 2 7593300 Cascade Assembly HP404 TE E gran 4 7652900 Bracket Cascade Mounting 1 5 76490 00 Manifold Plate Assembly EFM 1 EEN Ma E E 8 H2382 1 8 ODPolyurethaneTube____________ pe SS Screw SHCS 10 24 x 75 Long Nylon Screw SHCS 1 4 20 x 5 Long Nylon Screw SHCS 1 4 20 x 1 Long Steel 13 7570005 Washer Flat 10 Nylon SSP 6 6814 Tee T be 1 16
33. blue is used on non intrinsically safe wiring the intrinsi cally safe wiring may be marked by other means such as tagging This alternate means however must be visible after installation AA 99 01 1 EFM D Solventborne Robotic Atomizers Operation 18 EFM D Solventborne Robotic Atomizers Maintenance rrv Ransburg 19 MAINTENANCE Good maintenance is essential to safe and productive operation Schedules should be established by the user based on the following general information and observations of the initial production requirements The ITW Ransburg maintenance and safety information should be made available to each operator Normal fire protection measures are necessary including proper storage of paints and solvents and the proper disposal of waste Ready access to appropriate fire extinguishing equipment is required For details consult the appropriate NFPA safety information your local fire codes local painting equipment standards Reference OSHA NFPA 33 and your insurance carrier s information for additional information A WARNING gt An electrical discharge or spark may create an electrical and or fire hazard during maintenance Do not clean or service the spray applicator with the power supply on Verify that the power supply has been locked out and tagged out per OSHA gt Unexpected robot movement can be hazardous Do not adjust or repair the spray applicator when the robot is operating or wait
34. ca DurpReguacri nee jemo RwehuPamco JL eenseg Teer emre nsanWSmaerTepedEmiTowadsmeRearoiAgpioaor Pane AA 99 01 1 62 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg Z II A Wi O O b A myRansburg A Electrostatic Systems m section A A Figure 23a 76488 EFM Applicator Assembly Dual 90 Sheet 1 of 2 63 AA 99 01 1 EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg 5 SU RU 76488 EFM APPLICATOR ASSEMBLY PARTS LIST Figures 23a amp 23b Pat Description Spray Head Assembly Resistive EFM Applicator Housing Assembly Dual 90 Degree Shroud ITW Logo EFM O Ring Fluorocarbon Viton Screw SHCS 5 16 18 x 75 Long Nylon Screw Locating Pin Ring Socket Head Cap Screw Captive Flange Mounting Ring 7 8 76554 00 AA 99 01 1 EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg SECTION C C 2X SIZE SECTION E E ZZ V CR NN W Y
35. egree EME 406 Valve Cover Assembl Q lt Air Fitting Tube Fitting Nylon 5 16 T Tube Fitting Barb 1 16 ID Tube 6 J SSF 3128 Screw SHCS 6 32 x 1 00 Long Steel Black Spring Compression 8 7416000 Needleand Seat Assembly 9 7636900 X Retainer Seat Support Lower Diaphragm 2 00 Support Upper Diaphragm 2 00 Cap Regulator EMF 2 00 Diaphragm Support EMF 2 00 Screw PHMS 4 40 x 25 Long Stainless Steel Diaphragm 2 00 Air Cartridge Valve Assembly 7 9 0 7554 09 O Ring Fluorocarbon Viton 1 1 SSP 7816 Nut Nylon 3 8 T SSG 8172 O Ring Solvent Resistant 1 O Ring Fluorocarbon Viton O Ring Fluorocarbon Viton O Ring Teflon Encapsulated O Ring Solvent Resistant Spring High Voltage Contact Ferrule Front 3 8 T Nylon SSP 9012 Ferrule Back 3 8 T Nylon AA 99 01 1 46 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg D ws CS SS S 4 SS JA k 8 JANI Figure 16 76481 Applicator Housing Assembly Single 60 AA 99 01 1 47 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76481 APPLICATOR HOUSING ASSEMBLY PARTS LIST Figure 16 Description e lt Valve Manifold Assembly Single 60 Degree Head Cascade Assembly HP404 Tie Rod Long Bracket Cascade Mounting
36. embly Before performing any work on the spray applica tor always flush the fluid passages and blow dry with pushout air and wipe the spray applicator clean Referto Applicator Cleaning earlier inthe Maintenance section for instructions on how to properly clean the spray applicator Depressurize all fluid and air pressures before removing the applicator from its manifold Always work in a clear clean space to minimize parts loss and damage gt As the spray head is removed from the valve manifold assembly a certain amount of residual fluid may be present Care must be taken notto allow this fluid to drain into the high voltage terminal rings or air passages A WARNING Eye protection should be worn while servicing applicator AA 99 01 1 SPRAY HEAD ASSEMBLY Fluid Tip Nozzle and Front Needle Replacement NOTE y gt In any disassembly or reassembly procedure involving o rings care must be taken not to lose them O rings gray color are very expensive always reuse them unless they are damaged Disassemble spray head only enough to remove and replace defective parts For instance if only replacing the front needle it is not necessary to remove the fluid nozzle NOTE gt Atassembly apply a small amount of dielectric grease to grooves in spray head and valve manifold to reduce high voltage breakdown Excessive grease will not allow Spray Head 1 to seat fully against Applicator Housing A
37. ent selection 4 Remove piston cap 1 Removing the piston cap releases tension on all internal spray head components Remove spring retainer 2 and piston spring 3 which are loose after removing the piston cap 5 Remove the air cap retainer 21 and air cap 20 Soak in a non polar solvent if necessary lf paint remains in the air cap holes clean with a toothpick or similar soft wood object Air caps are best cleaned in an ultrasonic cleaner Never attempt to clean the air cap holes with a wire or other metal object Doing so may damage the air cap resulting in distor tion of the spray pattern POLAR AND NON POLAR SOLVENTS Nonconductive non polar Moderately Conductive Extremely Conductive polar Amyl Acetate Methyl Amyl Acetate Toluene Xylene High Flash Naptha Mineral Spirits Methyl Isobutyl Ketone Ethyl Acetate Methyl Ethyl Ketone Butyl Carbitol Methanol Carbitol Diacetone Butyl Alcohol Acetone Butyl Cellosolve EFM D Solventborne Robotic Atomizers Maintenance 21 6 Remove the air cap clip 19 and fluid tip 18 Clean using a non polar solvent 7 Tightly grip the plastic needle 16 and unscrew counter clockwise to remove the front needle assembly A short piece of H 2339 tubing 1 4 OD x 0 175 ID pressed over the front needle will assist in unscrewing the assembly If required use needle nose pliers with masking tape or duct tape Carefully clean with a non polar solvent
38. er Diaphragm Support 1 00 aa C E 7554 09 O Ring Fluorocarbon Viton 76377 00 Diaphragm 1 00 31 7640700 Support Lower Diaphragm 2 00 1 1 33 SSP 9011 Ferrule Front 3 8 T Nylon CT SSP 9012 Ferrule Back 3 8 T Nylon KE 1 19 i i 30 rp ata 59 AA 99 01 1 1rv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification NOTES AA 99 01 1 60 EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg LA EN SSS AA 99 01 1 Figure 22 76486 Applicator Housing Assembly Dual 60 61 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76486 APPLICATOR HOUSING ASSEMBLY PARTS LIST Figure 22 Pat Description 76487 00 Valve Manifold Assembly Dual 60 Degree Head lt co Cascade Assembly HP404 Tie Rod Long Bracket Cascade Mounting Manifold Plate Assembly EFM EMF 72 Bracket Tie Rod Mounting Tie Rod Short 1 8 OD Polyurethane Tube Screw SHCS 10 24 x 75 Long Nylon Screw SHCS 1 4 20 x 5 Long Nylon Screw SHCS 1 4 20 x 1 Long Steel O Ring Teflon Washer Flat 410 Nylon SSP 6814 Tee Tube 1 16 ID 7 12 13 14 TUBE FUNCTIONS Figure 22 Tube D Pan No Length Routing Instructions Description Tue pose s Rweturaca eet mese s Rehuranco regar nosov max G nouemnupan
39. eum jelly and apply a thin coat of dielectric grease EPS 4109 syringe to the grooves of the spray head and the valve manifold before reassembly 14 Refer to Figure 6b and replace spray head assembly 1 back onto applicator housing assembly 2 Screw four socket head cap screws 5 back into place Do not overtighten nylon screws as they can break EFM D Solventborne Robotic Atomizers Maintenance 24 EFM D Solventborne Robotic Atomizers 25 FLUID REGULATOR OR DUMP VALVE See Figure 6a 1 Remove all pressures both air and fluid from the line leading to the spray applicator 2 Purge all fluid from the applicator prior to performing any service 3 Remove dump cap 15 or regulator cap 9 Use EMF 445 Cap Tool for dump cap removal EMF 438 Cap Tool for regulator cap removal provided in the tool kit NOTE gt Once regulator cap 9 or dump cap 15 isremoved diaphragm support 8 or 14 will be loose and may fall out 4 Remove diaphragm support 8 or 14 and carefully remove elastomeric diaphragm 6 or 13 Use a small screwdriver blade and pry loose one edge and lift it out 5 Inspect the diaphragm for wear or damage Pay particular attention to the air side since this is a Buna N elastomer and can be damaged by solvent contact Replace if necessary 6 Use the poppet seat tool provided 76382 00 to unscrewthe poppet seat retainer Thetungsten carbide poppet seat may come out now because ofthe
40. gs are in place 29 AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Maintenance DS O SET Va NW FR Wool SN N co E N AA 99 01 1 EFM D Solventborne Robotic Atomizers Maintenance 31 LECU5004 MICROPAK CONTROL UNIT See MicroPak Control Unit Service Manual for service information 76494 XXX ROBOT MANIFOLD ASSEMBLY The 76494 XXX Robot Manifold Assembly is mounted to the robot wrist and includes two low voltage power cables andthe fluid pneumatic tubing required to operate the EFM applicator This manifold assembly utilizes swivel fitting fluid and dump lines that eliminate hose breakage due to twisting The fluid and dump lines can guickly be removed from the manifold by backing out the radially mounted spring loaded retaining pins This manifold assembly is designed to mount directly to a GMF P150 robot wrist When mounting to an ABB robot is desired an EMFD 54 adaptor plate is required This adaptor plate will move the face ofthe manifold plate out 1 250 inches fromthe robot wrist EMFD 54 1 2 250 thick and EMFD 54 2 3 250 thick adaptor plates are also available if required ACCESSORIES Accessories forthe EFM and EFMD Solventborne Spray Applicators include Misc Intrinsic Safe Barrier 75777 XX Applicator Covers EMF 430 1 Test Air Cap with Gauges EMF 176
41. he P 150 series robots which connects to a terminal strip If a terminal strip or connectors are used at the bulkhead plates you must run the exact same cable from the terminal strip back to the MicroPak controller Intrinsic safety rules must be followed when running these cables See Intrinisic Safe Wiring in the Operation section of this manual Leave 12 24 inches of extra length on all lines to prevent extreme tension being applied to these lines during robot movement rrv Ransburg EFM SPRAY APPLICATOR See Figure 3 Attach EFM spray applicator 1 to robot manifold plate 4 with six 6 5 16 18 x 1 inch hex socket screws 5 included with each applicator Nylon guide pins A10004 00 and nylon hex socket screws EMF 204 1 are offered as an option These nylon parts may be used in place of the metalhex socket screws and metal guide pins The plastic parts are designed to break quickly if aa applicator crash occurs Possible applicator or robot damage may be avoided if the spray applicator breaks away fromthe robot wrist during contact with the workpiece AWARNING Install and route the hoses and cable so that they are NOT exposed to temperatures in excess of 120 F Ensure that all hose and cable bends are NOT LESS THAN a 6 inch 15cm radius and are not subjected to more than 360 of torsional twist Failure to comply with these parameters could cause equipment malfunctions that might create HAZARDOU
42. hin film of petroleum jelly to o rings 20 and 21 before reassembling 14 Usethree small metal socket head cap screws 6 to attach valve cover assembly 2 back to valve manifold housing 1 15 Replace two air fittings 3 using care not to damage the plastic threads EFM D Solventborne Robotic Atomizers Maintenance 28 EFM D Solventborne Robotic Atomizers Maintenance 16 Reconnect two air supply tubes 6 and 8 Figure 12 making sure that both ferrules 25 and 26 Figure 15 are in place 17 Referring to Figure 16 replace L shaped bracket 6 and short tie rod 7 Replace two screws 9 through bracket into short tie rod 18 Attach manifold plate 5 back into three tie rods using metal socket head cap screws 11 and o rings 12 19 Referring to Figure 6b replace applicator shroud 3 and flange 8 Push shroud on asfar as possible by hand Align tab on shroud with notch in applicator body Use upside down applicator flange to assist in pushing shroud until shroud tab is fully engaged Replace flange 8 on bottom of applicator and retighten the three slotted dog style set screws 6 20 Vasoline all manifold o rings The applicator is now ready to be remounted to the robot manifold assembly NOTE gt Donotover tighten air fitting 3 Over tightening will cause the part to break in half SOLENOID TRIGGER VALVES Refer to Figure 12 1 To access the two solenoid trigger valves follow
43. his enables valve cover assembly 2 see Figure 15 to be removed 8 Referring to Figure 15 thread a 8 32 screw into the threaded hole at the center of valve piston Pull screw enabling the cartridge valve assembly 16 to come out 9 Referring to Figure 7 check valve piston 2 for free movement andthe four o rings for damage or wear One of the o rings 5 is located on the valve piston within the assembly Use two screwdrivers engaged into the slots on both ends of the assembly to disassemble Replace any damaged O rings NOTE gt When applying Loctite use very sparingly Apply one small drop to first thread of 2 then carefully assemble Do not get any Loctite on ID of 1 or OD of 2 Figure 7 Cartridge valve may malfunc tion 10 Apply Loctite Primer T 602 Locquip 747 56 and Loctite 222 Medium Strength purple to the threads of piston 2 before reassembly Allow assembly to set with piston end down for at least 3 hours prior to use Apply a thin film of petroleum jelly to all o rings 4 5 and 6 before reassembly Apply petroleum jelly to the inner surface of both ends of spool valve body 1 before reassembly 11 Referring to Figure 15 reassemble cartridge valve 16 Lubricate bore of valve manifold witha thin film of petroleum jelly Insert cartridge valve back into valve manifold housing 1 12 Examine valve cover o rings 20 and 21 for any damage Replace is necessary 13 Applyat
44. ing The contents ofthe tool kit differs depending on which applicator is to be serviced The following is a breakdown of the two tool kits offered 76381 01 TOOL KIT For Dual Head Applicators Description Tool Seat Retainer Tool Seat Extraction Tool 1 Cap Tool 2 Cap Tool 3 16 Hex Ball Driver Cover Robot Wrist Flange Cover Dual Head Applicator 76382 00 76385 00 EMF 445 EMF 438 SSH 9023 75777 03 75777 02 76382 EFM D Solventborne Robotic Atomizers Maintenance 76381 02 TOOL KIT For Single Head Applicators Tool 2 Cap 76382 00 76385 00 EMF 438 SSH 9023 75777 03 75777 01 SSH 9023 EMF 445 50 65 LBS IN kd EMF 438 120 135 LBS IN Figure 9 76381 Tool Kit AA 99 01 1 32 EFM D Solventborne Robotic Atomizers Maintenance rrv Ransburg Misc Shunts 9410 01 Plug Nut 77109 00 Regulator Shunt EFM The 9410 01 Plug Nut is used in conjunction with 77107 01 Regulator Shunt EFMD 90 the dump plugs to keep paint from going out the 77107 02 Regulator Shunt EFMD 60 dump lines This plugs the dump port on the valve manifold These shunts are used to bypass the regulators in the applicator 76740 O Ring Kit This kit is used to convert the EFM EFMD appli Misc Dump Plugs cators to a 100 solvent resistant o ring appli EMF 98 Front
45. ir Ransburg SERVICE MANUAL AA 99 01 1 Replaces AA 99 01 June 2007 EFM AND EFMD SOLVENTBORNE ROBOTIC ATOMIZERS MODEL 76480 76482 76485 76488 IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS APPROVED starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 40 00 Euro 50 00 U S rrv Ransburg NOTE This manual has been changed from revision AA 99 01 to revision AA 99 01 1 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual rrv Ransburg EFM D Solventborne Robotic Atomizers Contents CONTENTS PAGE SAFETY 1 4 SAFETY PRECAUTIONS api 1 HAZARDS SAFEGUA RD Sissi n 2 4 INTRODUCTION 5 8 THE ITW RANSBURG ELECTROSTATIC PROCESS 5 EFM AND EFMD SOLVENTBORNE GUNS eee emere 5 6 EE TON Si dais 6 MANIFOLD SELECTION GUIDE ciclo is 7 APPLICATOR TOOL POINT REPREGENTATION AAA 8 INSTALLATION EG EFM AND EFMD ROBOTIC ATOMIZER INSTALLATION eem 9 POWBERSUPPLYT ASSEMBLY x uu Luisa ciue linteis oreet Een Sasa chee aoe ead laude 9 LOW VOLTAGE CABLE CONNEGTIONS E 10 ROBOT MANIFOLD ASSEMBLY E 11 EFM SPRAY GUN ci aie Rinne 11 ROBOT MANIFOLD AND SPRAY GUN INSTALLATION PARTS Sd da 13 14 OPERATION 15 18 SPRAY APPLICATOR CONTROLS lt span 15 POWER SUPPLY lu 15 GENERAL INFORMATION AND ADJUSTMENTS AA 15 17 SIMPLIFIED AIR AND FLUID FLOW PASSAGE
46. lement for All Products 5 Added www itwransburg com to the Back Cover Service Manual Price 40 00 Euro 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 www itwransburg com Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts O 2007 Illinois Tool Works Inc All rights reserved Models and specifications subject to change without notice Form No AA 99 01 1 Litho in U S A 06 07
47. ne Robotic Atomizers Parts Identification rrvzRansburg 76494 MANIFOLD ASSEMBLY PARTS LIST Figures 13a 8 13b rett Description Qty soo 76560 01 Plate Manifold EMF Applicator P150 Robot Arm Fitting Cartridge Check Valve Fitting Air Pilot itting Modified 3 8 OD Tubing 1 4 NPT Screw Retaining Elec Connector 1 144 6 7658802 Screw Retaining Elec Connector 1 435 Tubing 3 8 OD x 040 Wall 250 PSI Paraflex 8 J SSP 7512 Union Reducing 1 2 x 3 8 Tubing 9 A1000800 Bearing Ball Miniature Flanged 2 10 A1000802 Bearing Ball Miniature Flanged 2 11 SSG8134 O Ring SolventResitant 12 7570601 Retaining Pin BodyShot TI 1 Retaining Pin Body Long Retaining Pin Assembly Spring Loaded 16 17 O Ring Solvent Resistant Tubing 1 2 OD x 3 8 ID Poly Flo White Tubing 3 16 OD x 025 Wall 250 PSI Paraflex C x D SeeChat DumpH ng O E SeeChat X PaintLineFludHose O G SeeChat Wiring Harness Intrinsic Solenoid Valves H j iri See Chart Wiring Harness Cascade See Parts List Reference Table PARTS LIST BULLET DEFINITION TABLE Figures 13a 8 13b 1 Apply 7969 05 Loctite thread locker blue to threads prior to assembly 13 14 15 m L 1 1 Apply 7969 10 Loctite thread sealer white to threads prior to assembly Apply thread lubricant i e tube lube to th
48. noid valvetimeris activated After the timer times out the fluid solenoid and the high voltage timer are activated This timer delays the start of the high voltage until after both the air and fluid are activated Timing can be set in nine different timing sequences from a minimum of zero to a maximum of 450 milliseconds When the electrical signal fromthe robot PLC is removed the timing operates in reverse High voltage is shut off fluid shuts off and finally the air solenoid valve shuts off See ITW Ransburg Service Manual MicroPak Control Unit for additional information on power supply operation and control features AA 99 01 1 EFM D Solventborne Robotic Atomizers Operation 16 EFM D Solventborne Robotic Atomizers Operation 17 Electrostatic Voltage Normally the voltage should be set to 90 kV atthe power supply Some conditions may dictate lower voltage settings If Faraday cage areas are predominant on the item being painted a lower voltage setting will aid in coating these areas Paints having high metallic flake content will sometimes align at high voltages Metallic flakes when aligned become a direct electrical path to ground and will reduce tip voltage This problem can be minimized by making sure that the paint is being sprayed from the applicator prior to turning the voltage on In some cases a reduction in applied voltage may be the only way to reduce alignment
49. ns the power supply and other electrical control equipment must not be used in Class 1 Division 1 or 2 locations Robot Work Area Improper use or maintenance can Applicator adjustments or maintenance should be General Use and lead to hazardous conditions done after the robot is taken out of service Do not Maintenance particularly from unexpected robot adjustor repairthe applicator ifthe robot is operating manipulator movement or standing ready to start Referto robotoperating instructions forthe procedures to take the robot out of service Personnel Safety Skinpuncturing by sharp electrode Take precautions to see that flesh is not punctured by sharp electrode AA 99 01 1 EFM D Solventborne Robotic Atomizers Introduction INTRODUCTION THE ITW RANSBURG ELECTROSTATIC PROCESS This process is a method for electrostatically applying coatings to objects A power supply produces a high voltage charge which is supplied to the applicator creating an electrostatic field between the applicator and the target object The target is electrostatically grounded through its support which may be either stationary or moving A regulated fluid system delivers coating material to the applicator where it is atomized forming a spray mist There under the influence of the electrostatic field the atomized coating becomes electrostatically charged The charged particles are attracted to and deposited on the grounded target
50. o the housing with the hump side up 11 Tighten the regulator cap 9 to 125 135 Ibs in usingthe EMF 438 Cap Tool Tightenthe regulator cap 9 by hand at first then use the cap tool Tighten the dump cap 15 to 50 65 Ibssin using the EMF 445 Cap Tool AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Maintenance Figure 6a 2 Regulator Assembly Figure 6b 1 Dump Assembly FLUID REGULATOR ASSEMBLY PARTS LIST Figures 6a 8 6b tem Pang Description Qy 1 7416100 Spring Compression IL 2 2 7416000 NeedleandSeatAssemby j 2 3 SSG817 J O Ring Solvent Resistant U 3 4 763690 Betaner Geat 1 1 1 2 5 76 0 Support Lower Diaphragm 200 6 76378 00 Diaphragm 2 00 1 7 764600 Support Upper Diaphragn 200 1 8 76405 00 SpacenDiaphragm Suppot 2 00 1 9 76404 00 _ RegulatorCap 2 00 j 1 19 76x00 Support Lower Diaphragm 100 1 11 SSG 8128 O Ring Solvent Resistant j 1 Support Upper Diaphragm 1 00 EE e 13 7637700 Diaphragm 1 00 1 y 14 768 500 Spacer Diaphragm Suppor 100 2 2 l nm ICOoIno no
51. object The forces between the charged particles and the target are sufficient to turn overspray around and deposit it on the back surface of the target Therefore a higher percentage of the spray is deposited EFM AND EFMD SOLVENTBORNE APPLICATORS The EFM Solventborne Applicator line consists of single and dual headed 100 kV automatic electrostatic spray applicators Developed for use on robots or reciprocators the EFM solventborne applicator incorporates a guick disconnect manifold and swivel tubing connections to minimize downtime Internal fluid and air solenoids andan internal high voltage power supply provide the user a compact efficient tool for the application of electrostatic coatings Because this is agrounded fluid system the EFM solventborne applicator is highly suitable for applying a wide range of solvent reduced coatings such as enamels lacquers two component and other such coatings 1rv Ransburg There are two single head models of the EFM Applicator Each model differs in the applicator to axis orientation of the spray head these models are 76480 02 EFM 60 Applicator 76482 02 EFM 90 Applicator Two dual head versions ofthe EFM Solventborne Applicator are also available designated EFMD The dual head version is identical to the EFM applicator with the exception of an additional spray head mounted to the applicator body EFMD Solventborne Applicators are primarily used where high volume fluid delive
52. omizers Parts Identification 76479 SPRAY HEAD ASSEMBLY PARTS LIST Figure 11 Mem 4 Pata Description Qty Piston Cap Retainer Spring Piston Spring Piston Nut Piston 6 SST 7714 Piston Seal 7 755405 O Ring Fluorocarbon Viton 8 76096 00 Piston Rod Assembly 9 76094 0 NeedleSection Rear Gun Barrel Assembly Resistive EFM 0 O Ring Solvent Resistant Seal Spring Seal Washer Seal Fluid Nozzle High Flow Black W Groove Electrode Assembl Air Cap Locator Fluid Tip EMF Gun 055 Dia Orifice Air Cap Clip Air Cap Air Cap Retainer O Ring Fluorocarbon Viton LSORO0005 08 O Ring Teflon Encapsulated 7554 06 O Ring Fluorocarbon Viton AA 99 01 1 36 EFM D Solventborne Robotic Atomizers Parts Identification rrvzRansburg SECTION A A Figure 14 76490 Applicator Manifold Plate Assembly 37 BE rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76490 APPLICATOR MANIFOLD PLATE ASSEMBLY PARTS LIST Figure 12 em 4 Pat4 L esegten JI on 1 7653200 Plate Manifold EFMApplicator 1 2 76491 00 Wiring Harness Cascade Adapter ECH 1 3 76492 00 Wiring Harness Intrinsic Solenoids Adapter 1 4 7653800 SolenoidValve Assembly LI 2
53. osion rrv Ransburg SAFEGUARDS Tells how to avoid the hazard Personnel must be given training in accordance with the reguirements of NFPA 33 Instructions and safety precautions must be read and understood prior to using this eguipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping Reference OSHA NFPA 33 and yourinsurance company requirements The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas Referto NFPA 33 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltageto 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 Aluminum is widely used in other spray application equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equip ment during spraying flushing or cleaning Readthe labelordata sheetforthe material you intendto spray If in doubt as to whether or not a coating or cleaning material is compatible contact your material sup plier Any other type of solvent may be used with aluminum equipment
54. pare this manual with your system installation drawings and appropriate ITW Ransburg eguipment manuals to reconcile such differences Careful study and continued use ofthis manual will provide a better understanding of the eguipment 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 ITW Ransburg representative or ITW Ransburg 1rv Ransburg AWARNING gt TheuserMUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literature therein iden tified This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD prior to install ing operating and or servicing this equip ment AWARNING gt The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 AA 99 01 1 rrv Ransburg AREA Tells where hazards may occur Spray Area Chi AA 99 01 1 EFM D Solventborne Robotic Atomizers Safety HAZARD SAFEGUARDS
55. r use only during setup operations Production should never be done with safety interlocks disabled Never use equipment intended for use in waterborne installations to spray solvent based materials The paint process and equipment should be set up andoperatedin accordance with NFPA 33 NEC and OSHA requirements EFM D Solventborne Robotic Atomizers Safety AREA Tells where hazards may occur General Use and Maintenance Electrical Eguipment Explosion Hazard Incompatible Materials HAZARD Tells what the hazard is Improper operation or maintenance may create a hazard Personnel mustbe properlytrained in the use of this equipment High voltage equipmentis utilized Arcing in areas of flammable or combustible materials may occur 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 correction An electrical arc can ignite coating materials and cause a fire or explosion Halogenated hydrocarbonsolvents for example methylene chloride and 1 1 1 Trichloroethane are not chemically compatible with the aluminum that might be used in many system components The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment expl
56. reads of fitting prior to assembly After connecting 3 8 OD lines to 1 2 OD lines with reducing union wrap unions with SS 9816 black electrical tape to prevent union tube nuts from coming loose Torque retaining screws to 1 50 4 0 Ibsein Align slot in plugs with slot in manifold plate 41 AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 1994 OS 1994 Sc 1994 91 19974 os 1994 Sc 1997 91 1994 OS 1997 Sc 19974 91 19974 0S 19974 Sc 1997 91 1994 OS 1994 Sc 1994 91 uibue 09 9692 0S S6t9Z LO 8Z 192 c0 8 LvZ LO S0 SZ Z0 S0ZSZ IL 91 309 7692 Sz 9679Z Sc S6v9 10 814 ESCH LO S0ZS4 ZO SOZSZ it au asc r6r92 0S 96v9 0S S6r9Z LO ELEZZ 10 1 24 Lo sovsz ene it at Q09 v6r97 91 969 94 9694 LO 8Z Lp 20 8414 LO S0ZGZ 20 8079 bit 9We 39L p6b9Z Sc 96v9 SZ S6r92 LO EL Z LO ELEZZ Lo sozsz ene v at aseveroz 91 96597 91 S6t97 LO EL ZZ LO LEZZ lo sozsz 109 27 pi at dq9r r6r92 0S 96r9Z 0S S6r9Z c0 8Z lt 2c0 8 LvZ 20 8028Z c0 S0ZSZ 91 91 O0S v6v9Z Sc 96r9Z Sc S6r9Z c0 8 Lt c0 8ZLtZ c0 SOZSZ c0 S0ZSZ 9k E 9k E OSc v6v9Z 91 9679Z 9 9694 c0 84 LZ 2c0 8 LvZ c0 S0ZSZ c0 S0ZSZ 91 iQ L E O9L v6v9Z ososvaz eso mam mam tosowsz tososz a at eos vevoz s994 eso mam oam 1090 92 tososz at at gsz r6r92 okoeroz aam mam wa Tse wOSO SL a La Joes O99692 eso oo ooew
57. ry is reguired These applicators supply twice the fluid delivery over Single Head EFM Solventborne Applicators The EFMD Solventborne Applicator is available intwo different configurations as follows 76485 02 EFMD 60 Applicator 76488 02 EFMD 90 Applicator Both EFM and EFMD Solventborne Applicators are comprised of five major sections 1 Spray head s 2 Valve manifold assembly 3 Ouick disconnect base manifold assembly 4 Robot mounted manifold assembly 5 High voltage cascade The spray head s and valve manifold contain the fluid air andhigh voltage passages Althoughthe guick disconnect base manifold and robot mounted manifold are fabricated from aluminum all fluid passages are contained within stainless steel and nylon fittings and are compatible with halogenated hydrocarbon solvents The robot manifold incorporates stainless steel swivel fluid connections The swivel connections reduce stress on the fluid lines minimizing breakage No aluminum parts are exposed to the fluid path on either manifold The high voltage cascade is entirely encapsulated with a solvent resistant epoxy AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Introduction The high voltage supply for the EFM and EFMD Output Voltage 30 100 kV applicators consists of two major components Output Range 0 125 pA The MicroPak Power Supply Control Unit LECU5004 and the HP404 Cascade 75933 Solenoid 00 Parameters 15 5 VDC
58. ssembly 2 See Figure 6b 22 EFM D Solventborne Robotic Atomizers Maintenance rrv Ransburg 20 21 Figure 5 Spray Head Removal 76479 SPRAY HEAD ASSEMBLY PARTS LIST Figure 5 Mem 4 Pat Description Qty 1 EMF13 PistnCap o 1 2 tMF22 4 RetneSpig n 3 mess PisonSpig Jj 4 RME6G6 PistonNu 1 5 RMEe9 Psn O O o 6 sst Pistonsa O 1 8 760600 Piston Rod Assembly 9 760400 NeedeSecionHea 1 i0 7649700 Applicator Barrel Assembly Resistive EFM 1 i 56814 O Ring SolventResistant C CC 1 12 mess j SeaSpng E j i3 MF7 SeaWaser o o o 14 AMES Se j 15 EMF 195 Fluid Nozzle High Flow BlackW Grove 16 7043000 EecmodeAsseemiy T 1 7 Mrig ArCaploatr j Fluid Tip EMF Gun 055 Dia Orifice EFX8 PH 23 AA 99 01 1 AA 99 01 1 rrv Ransburg Rear
59. t Down Or at Shift End 1 Turn the LECU5004 MicroPak Control Unit OFF 2 Flush the lines and allow the solvent to remain inthelines See Procedures inthe Maintenance section 1 Turn the LECU5004 MicroPak Control Unit OFF 2 Flush the lines and allow the solvent to remain inthe lines See Procedures in the Maintenance section 3 Wipe the applicator and robot wrist with a cloth and a suitable clean non polar solvent Weekly 1 Checkthe entire system for damage leaks and paint accumulation 2 Clean the atomizer assembly 3 Conduct a current output test See Proced ures in the Maintenance section PROCEDURES Gun Cleaning Service See Figure 5 1 Flush the paint supply line and the applicator paint passages using a solvent which is compat ible with the material being sprayed Continue to flush until all traces of paint are gone EFM D Solventborne Robotic Atomizers Maintenance 2 Turn off the solvent supply actuate paint pushout air at color changer and trigger the appli cator Allow all of the fluid to drain from the spray applicator fluid passages 3 Clean the exterior surfaces of the spray gun with a solvent soaked rag As long as the gun is intact a polar solvent may be used for all clean ing however after cleaning wipe off all surfaces with a nonpolar solvent to reduce conductive residue on the applicator s surface See Polar and Non Polar Solvents below regarding proper solv
60. tance Fluid Flow Rate Fluid flow is adjusted through the robot PLC by varying the pilot pressure to the fluid regulator within the EFM or EFMD spray applicator Fluid pressures from the circulating system may be as high as 300 psig Atomizing Air Adjustments are made through the robot PLC ora manually adjustable air regulator The lowest air pressure required to break up the paint should be used Lower atomizing air pressures resultin less overspray and increased transfer efficiency NOTE gt lthas been observed when spraying metallic paints that mottling marble ef fect can be reduced by increasing the fan air pressure slightly higher than the atomizing air Fan Air Adjusting the fan air increases or decreases the size of the spray pattern Increasing pressure decreases pattern size Pattern adjustment should be made to suit the size and shape of the object being painted This adjustment is made through the robot PLC or a manually adjustable air regula tor Trigger Control Air The EFM and EFMD applicators require a minimum of 70 psig trigger control air pressure to ensure proper operation of the applicator piston and air shuttle valves Trigger Timing The LECU5004 MicroPak Control Unit provides a means for the adjustment of the timing interval between air fluid and high voltage When the applicator receives a trigger on signal from the robot PLC the air solenoid valve actuates Atthe sametimethe fluid sole
61. urrent output on LECU 5004 Current should rise as ground approaches At approximately 80 microamperes the LECU5004 will begin limiting current If ground approaches the applicator guickly an overcurrent fault should occur The OVERCURRENT indicator should come on SERVICE Because we want to provide our users with the most up to date technology possible we are con stantly seeking to improve products If a change in product configuration occurs after it is on the market we willimplementthattechnology in future production and if practical make it available to current users Thefollowing service informationis based on standard specifications and procedures forthis product If you find some minor deviations between this information and your equipment be cause of design or manufacturing changes con tact your ITW Ransburg representative to resolve the difference AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Maintenance AWARNING Anelectrical discharge or spark may create an electrical and or fire hazard during mainte nance Do not service the spray applicator with the power supply on Verify that the power supply on off switch has been turned off Unexpected robot movement can be haz ardous Do not adjust or repair the spray applicator when the robot is operating or wait ing to start The robot must be locked out and tagged out per OSHA prior to removing the applicator from the robot manifold ass
62. z zosozsz zosozez ag Lag vosvevoz ssouJeH epeoseg He ssouJeH UHIM Gi esoH piniJ esoH piniJ Bus qI esoH dl 9SOH eur dung eur led IUISd dung IUISd qe pue eg sami 319VL 3ON3udd3u 1SI1 S1uvd 42 AA 99 01 1 EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg mw Ransburg m C Electrostatic Systems Figure 14 76480 EFM Applicator Assembly Single 60 43 AA 99 01 1 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76480 EFM APPLICATOR ASSEMBLY PARTS LIST Figure 14 tem Part Description JL ey 76479 00 Spray Head Assembly Resistive EFM 76481 00 Applicator Housing Assembly Single 60 Degree EMF0600 02 Shroud ITW Logo EFM D 76554 00 Flange Mounting Ring 1 AA 99 01 1 44 EFM D Solventborne Robotic Atomizers Parts Identification rrv Ransburg a a NOILO3S T sz po ANS VZ vw ccc v TITA VIZLLLLLLAALLL AA E EE EE ENO po Bee T te 73 7 le me iY UV V E H Figure 15 76366 Valve Manifold Assembly Single 60 AA 99 01 1 45 rrv Ransburg EFM D Solventborne Robotic Atomizers Parts Identification 76366 VALVE MANIFOLD ASSEMBLY PARTS LIST Figure 15 76367 00 Manifold Applicator Body Single 60 D
63. zers Installation rrv Ransburg j NNO 0N43 MN43 3HL OL TVNAJINI Q31V901 JYV SIN3NOdWOO 3S3HL SgION310S 34VS OISNISINI Lj D wolv Nva o m Ea 66L 3359131 N3349 39NvuO ame wem LSC A9 on NAOUS 308 ge GUS Modi 06 OJIVLOM JAV SIYM EICH ODZ 4Z LOJO a r u N 96v9 ama Ro V V ona N3389 a 39Nvu0 HA MOTA SNIVA AVID N35 m8 118 038 KMOMO xzZ LOJO a o r u S6V9IZ S NJIddva OISNI4LNI SERES W 416000231 Nd 89d 1080231 Nd ASSY 82d f AY ag UJHLON MOVAONJIN LT O iva Op vre 2 disnei SC z lt o T9 1 d b old P H E SINQSUEY AU 10 Low Voltage Cable Connections Figure 2 AA 99 01 1 EFM D Solventborne Robotic Atomizers Installation 11 ROBOT MANIFOLD ASSEMBLY See Figure 3 Bundle the seven lengths of tubing along with the two low voltage power cables 6 amp 7 and route them through the center of the robot face plate past the horizontal arm to the bulkhead bracket Use the six 5mm x 20mm socket head cap screws 2 included with the robot manifold assembly to attach the manifold assembly to the face plate of the robot Connectthe tubes to the appropriate fittings on the bulkhead bracket Connect low voltage power cables 6 amp 7 of the robot manifold assembly to the MicroPak Controller Shown is the version used with t

Download Pdf Manuals

Related Search

Related Contents

User Manual - X-Rite    KitchenAid KEMI300W User's Manual  User Manual PR8000 Series - prostar international electric co.,ltd.  Guía de Salud y seguridad, Uso y cuidado e Instalación  User Manual Single Phase Electronic Meter For Active Energy  SPEEDLINK Maia  XO_Manual (21R-4209) v04.cdr  Ilumiline Inground Tri-12 IP Optic 25 RGB Quick  COUVERTURE SOPROLIFE par langue:Mise en page 1.qxd  

Copyright © All rights reserved. Failed to retrieve file