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Aerobell 168 Atex MODEL:13350 (Serv. Man. LN

1. LN 9247 13 1 88 168 Parts Identification Ransburg DETAIL SCALE 2 1 NOTE DIRECTION OF TAPER ON FERRU 15 TOWARDS THE FITTING TYPICAL 4 PLACES y A 1 y i NW NV WS 18 LONG A13401 Machine Mount Kit with Valves 89 LN 9247 13 1 Ransburg Aerobell 168 Parts Identification MACHINE MOUNT KIT PARTS LIST A13401 Pate Description __ 1 2 2 36 8 9 0 SCREW SHCS M6 X 1 0 X 10MM SS 3 54 5 FERRULE BACK 1 4 56 0 72 3 4 5 76 77 1370600 MOUNTING YOKE ASSEMBLY FINGER TIGHT UNTIL CLICK 3 TORQUE TO 5 10 LBS IN 56 1 13 Nm Z TORQUE TO 15 20 LBS IN 1 69 2 26 Nm i gt TORQUE TO 15 20 LBS IN 1 69 2 26 Nm AFTER VALVE IS DOWN VVVV AIC 4 5 6 47 8 A V VVV V Pepe bates MM 0 LN 9247 13 1 90 Ransburg Aerobell 168 Parts Identification TABLE A MACHINE MOUNT KIT OPTIONS WITH FLUID TUBE Part C Receiver A13288 00 A13288 00 A13293 00 A13293 00 Part B Paint Fitting Part A Coil 13401 01 79879 00 13287 00 FOR 8 X 6 TUBING 13401 02 79879 01 13287 00 FOR 8 X 6 TUBING 13401 03 79879 00 13289 00 FOR 8 X 5 TUBING 13401 04 79879 01 13289 00 FOR 8 5 TUBING LN 9247 13 1 Description MACHINE MOUNT WITH TRIGGER DUMP CUP WAS
2. 38 1 1 4 JHL 315 INidld UJZINVAT O 0 KINO S M3L14 OL 9357 38 AVA SNIdld 3A08V NMOHS Q3O0N3WWOO3M FHL 133W LON 3500 AlddNS 3301SIOW UO HIM N3QYI SI AlddNS Ji Q30N3 WO233 Milli 3Md 05 4 IN3WdInO03 53402 TI380M3V JHL 40 NOILVTIVISNI OL 49144 431214409 38 IShMW ONidld AlddNAS Ni 354309439 NOILAYO MSL JHL Oi JHL 1009 Ol 0351 38 QINOHS Y43440 9319394134 V AMVSS323N 4 39vWvQ IN3Md no3 5 2 15 3SN3UNOO AVA Ss3LT4 Q3AOW3dH ION SMyOdvA YO 10 NIVINOO AVW 3uynivM3dWibl LNIANY 01 35010 38 LSNW 4311133334 JHL 3 flivudddWil t 9059 ly NMOHS LSNW Wdy 43Qv3H sv 013553 44009 WO3j 3130 3241 29 LN 9247 13 1 Ransburg AIR HEATER REQUIREMENTS Turbine drive air expands as it moves through the turbine wheel cavity and as itexits the turbine from the exhaust port This expansion will cause cool ing of the exhaust air and the surfaces it contacts This same expansion cooling can occur across the shaping air exit ports This cooling effect can cause surface temperatures to fall below the dew point of the booth which will result in conde
3. END A13386 XX CASCADE APPLICATOR END END 13348 TABLE J SPINDLE ASSEMBLY A12777 00 SILVER SHAFT STYLE 0 NONE 12777 02 BLACK STYLE Other Atex Requirements Foot wear worn by the operator shall comply with EN ISO 20344 the measured insulation resistance shall not exceed 100 Protective clothing including gloves shall comply with EN 1149 5 the measured insulation resistance shall not exceed 100 A13352 Configuration Drawing LN 9247 13 1 13 Ransburg INTRODUCTION GENERAL DESCRIPTION The Ransburg Aerobell 168 is a high speed bell type atomizer for electrostatic applications of conventional and high solids coating materials It is available in several configurations Contact your Ransburg representative for assistance in atomizer bell selection The Aerobell 168 turbine assembly incorporates precision airtype bearings for extended turbine life FEATURES Features which make the Aerobell 168 advan tageous for use in rotary atomizer electrostatic applications include Fast color change due to center feed fluid de livery and integral air brake Sleek configuration to facilitate cleaning of the exterior Braking air capability Field repairable turbine assembly after the warranty period Machine mountable Non hollow wrist robot mountable 30mm dual shape air configuration for opti mum pattern control e 65mm M
4. POLICIES LIMITED WARRANTY Ransburg willreplace orrepair without charge any partand or equipmentthatfails within the specified time see below because of faulty workmanship or material provided that the 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 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 WARRANT Y LN 9247 13 1 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 FORA PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEQUEN TIAL DAMAGES FORLOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ra
5. 16 Ransburg Aerobell 168 Introduction OPERATING CHARACTERISTICS AND SPECIFICATIONS Aerobell 168 Air Consumption vs Speed Loaded e 65mm 100 cc min Load f 65mm 200 cc min load 65mm 300 cc min Load e 65mm 400 cc min Load Air Consumption slpm Air Consumption scfm 65mm 500 cc min Load Note All Air Pressures and Air Consumption Data was taken 300mm behind applicator 30 000 40 000 50 000 60 000 Speed rpm Aerobell 168 Air Consumption vs Speed Loaded 3 65mm 100 Load f 65mm 200 cc min load 2 2 ire 65mm 300 Load 9 lt 65mm 400 Load 65mm 500 cc min Load Note All Air Pressures and Air Consumption Data was taken 300mm behind applicator 30 000 40 000 50 000 60 000 Speed rpm LN 9247 13 1 17 Ransburg Aerobell 168 Introduction OPERATING CHARACTERISTICS AND SPECIFICATIONS Aerobell 168 Air Consumption vs Speed Loaded 400 350 300 30mm 100 Load ll 30mm 200 cc min Load ig 30mm 300 cc min Load m e Air Consumption scfm Air Consumption slpm gt e 100 Note All Air Pressures and Air Consumption Data was taken 300mm behind applicator 50 Speed rpm Aerobell 168 Air Pressure vs Speed Loaded 50 45 40 35 P 30mm 100 cc min 2 5 Load A T m 30mm 200 cc min ao Load 25 2 2 5 2 30
6. 4 Ensure that no conductive sponges are used in any connector 5 A13386 XX or A13348 XX cables are not to be modified in the field To do so will void any and all warranties that may exist HIGH VOLTAGE CABLE CONFIGURATIONS There are two 2 high voltage cable assemblies available 13386 is shielded cable and is the most flexible It is available in several lengths per the Accessories chart in the Parts Identification section LN 9247 13 1 Aerobell 168 Installation A13348 XX is a resin core conductor cable with a polyethylene jacket and an exterior Nylon sleeve It comes pre assembled with banana jacks at each end AEROBELL 168 HIGH VOLTAGE CONNECT AT ATOMIZER END Installation of A13348 XX Cable Insert resistor Shipped seperately with Applicator A13382 00 into the applicator end of the cable APPLICATOR END CASCADE END Make sure the contact spring is outward as shown below Contact Spring N HV Connector Insertthe high voltage connector on the cable end into the applicator part marked with HV Tighten the connector in place A13382 A13348 Cms NS 33 Ransburg Aerobell 168 Installation Installation of A13386 XX Cable AEROBELL 168 Insertresistor Shipped seperately withApplicator CASCADE CONNECTION A13382 into the part of the applicator marked HV Insert the cable end of the A13386 XX cable into the external cascade as shown The spring shou
7. SHAPEARPLUG 000 0 96 Ransburg Aerobell 168 Parts Identification A15206 00 15mm Direct Charge A13206 00 15MM SHAPE AIR A12935 00 INNER SHAPE AIR RING A12933 00 SHROUD 15MM 79001 10 SOLVENT 79001 57 SOLVENT LN 9247 13 1 97 Ransburg Aerobell 168 Parts Identification FIBER OPTIC CABLE LENGTH Fiber Optic Cable Not Included A12409 01 3 Ft 0 9m Long Fiber Optic Cable A12409 02 6Ft 1 8m Long Fiber Optic Cable A12409 03 10 Ft 3 0m Long Fiber Optic Cable A12409 10 100 Ft 30 5m Long Fiber Optic Cable APPLICATOR END CASCADE END HIGH VOLTAGE CABLES SHIELDED A13386 15 15 Ft 4 6m High Voltage Cable Assy Shield Non Metallic Center Conductor 7 6m A13386 25 25 Ft 7 6m High Voltage Cable Assy Shield Non Metallic Center Conductor A13386 50 50 Ft 15 2m High Voltage Cable Assy Shield Non Metallic Center Conductor HEN II APPLICATOR END CASCADE END HIGH VOLTAGE CABLES NON SHIELDED A13348 15 15 Ft 4 6m High Voltage Cable Assembly 7 13348 25 25 Ft 7 6 Cable Assembly 13348 50 50 Ft 15 2 High Cable Assembly LN 9247 13 1 98 Ransburg Aerobell 168 Parts Identification HIGH VOLTAGE RESISTOR ASSEMBLY Description Assembly Resistor Consult Power Supply Manual CP 13 02 or CP 13 05 for available parts for the power s
8. 45 BELL CLEANING S uuu uu u E EU UE 46 CLEANING SHAPING AIR HOLES sss eene nhe nnne nnne 47 168 PREVENTIVE MAINTENANCE SCHEDULE 48 TOOLS REQUIRED DISASSEMBLE AEROBELL 1 eee 49 OPTIONAL TOOLS REQUIRED TO DISASSEMBLE AEROBELL 50 DISASSEMBLY PROCEDURES 15MM BELL 51 56 DISASSEMBLY PROCEDURES 30MM BELL 57 61 DISASSEMBLY PROCEDURES 65MM BELL 62 70 DISASSEMBLY PROCEDURES FOR ROBOT MACHINE MOUNT KITS 71 81 PARTS IDENTIFICATION 82 105 cde 82 85 APPLICATOR PARTS BREAKDOWN 86 87 5 E 88 MACHINE MOUNT PARTS LIST 89 91 ROBOT MOUNTKIT PARTS LIST 92 94 CONFIGURATOR 95 97 CABLE 98 HIGH VOLTAGE RESISTOR ASSEMBLY a a nhe nnne 99 EXTERNAL CASCADE COMPONENTS rr 99 ACCESSORIE M s 100 SE RUCE up u sua 101 RECOMMENDED SP
9. in addition it shall also be clearly visible to the operator Ransburg BRAND OF FINISHING BRANDS HOLDINGS INC TOLEDO OH WARNING FAILURE TO OBSERVE THE FOLLOWING PRECAUTIONS CONTROL UNIT POWER SUPPLY FOR ELECTROSTATIC PAINT FINISHING APPLICATIONS i CS DATE OF Mat aa SERIAL No CURRENT 1 RAENT 80108 APPROVED FOR USE IN FINISHING LOCATIONS WHEN CONFIGURED ACCORDING TO DRAWING 15551 00 AND ALL CONDITIONS FOR SAFE USE HAVE BEEN MET CONSULT MANUAL FOR FURTHER INFORMATION REFERENCE MANUAL 1 9247 15 SIRA 13ATEX5176X A13383 EN 50 176 COMPLIANT A13384 copo SIRA 1 5ATEX5176X A13349 Configurations These applicators are approved when configured to drawings shown on pages 8 thru 13 Ransburg Aerobell 168 Atex FM CONFIGURATION DRAWING A13351 ORDERING INSTRUCTIONS 13350 AS INDICATED IN TABLES A J TABLE J SPINDLE ASSEMBLY TABLE H HV CABLE LENGTH TABLE G POWER SUPPLY TABLE F ROBOT ADAPTER TABLE E TOOL KIT TABLE D MOUNTING AND VALVE OPTIONS TABLE C BELL CUP ASSEMBLY TABLE B FLUID TIP TABLE A SHAPE AIR KIT BASIC PART NUMBER TABLE SHAPE AIR KIT Description A13032 01 DUAL FLEX DUAL SHAPE AIR DIRECT CHARGE 13032 02 MONOFLEX SINGLE SHAPE AIR DIRECT CHARGE A13032 03 30MM DUAL SH
10. 13289 00 8mm x 5 fittings Step 26 Install the proper receiver over the tubing first Lightly lubricate the outside diameter of the barb fitting with petroleum jelly Step 27 Push tube fully onto barb un til it stops on the fitting back shoulder Aerobell 168 Maintenance 79 Ransburg LN 9247 13 1 Step 28 Lightly lubricate the outside diameter of the tubing with petroleum jelly Step 29 Using a flat plate or surface use an adjustable wrench to push the receiver fully over the tube and barb until it is flush with the back shoulder of the barb fitting Step 1 Removal Insert a flat blade screwdriver into the slot on the receiver body and twist to separate the components Screwdriver slot Aerobell 168 Maintenance 80 Ransburg LN 9247 13 1 Step 2 Repair Cut damaged tube away and repeat re assembly starting at step 26 Aerobell 168 Maintenance 81 Ransburg Aerobell 168 Parts Identification PARTS IDENTIFICATION WHEN ORDERING USE MODEL NUMBER A13350 XX XX XX XX XX X X X AS INDICATED TABLES A J TABLE J SPINDLE ASSEMBLY TABLE H HV CABLE AND LENGTH TABLE G POWER SUPPLY TABLE F ROBOT ADAPTER TABLE E TOOL KIT TABLE D MOUNTING AND VALVE OPTIONS TABLE C BELL CUP ASSEMBLY TABLE B FLUID TIP TABLE A SHAPE AIR KIT BASIC PART NUMBER TABLE A SHAPE AIR KIT A13032 01 DUAL FLEX DUAL SHAPE AIR DIRECT CHAR
11. 300 cc min 2 Load x 20 1 5 15 i Note Al Air Pressures 19 and Air Consumption Data was taken 300mm 0 5 behind applicator Speed rpm LN 9247 13 1 18 Ransburg Aerobell 168 Introduction DIMENSIONAL CHARACTERISTICS 20 00 508 1 13 21 335 5 lt 4 59 116 6 3 62 91 9 3 62 91 9 gt 33 8 4 CG 19 43 493 4 30 ROBOT MOUNT 60 DEGREES 15 FANUC ROBOT MOUNT 60 DEGREES 5 20 132 0 2 68 68 2 04 50 114 2 60 u _ 5 51 140 1 HM 0 75 19 0 1 00 25 4 18 157 0 3 72 94 4 30 MM POST MOUNT 15 MM POST MOUNT LN 9247 13 1 19 Ransburg Aerobell 168 Introduction DIMENSIONAL CHARACTERISTICS 5 20 132 0 18 50 469 7 12 03 305 6 e BY 5 72 145 4 pss Ke 0 gt 9 1 47 37 4 2 50 63 5 455 3 30 MM MACHINE MOUNT 60 DEGREES 15 MM MACHINE MOUNT 60 DEGREES 10 58 268 8 9 07 230 4 C 3 18 80 7 CG 6 82 173 2 296 5 17 98 456 7 30 MM MACHINE MOUNT STRAIGHT 15 MM MACHINE MOUNT STRAIGHT LN 9247 13 1 20 Ransburg Aerobell 168 Introduction DIMENSIONAL CHARACTERISTICS 20 47 519 9 13 30 337 7 CG 4 61 117 1 29 7 2 3 50 89 0 19 36 491 7 4 50 114 3 65
12. A13031 00 FANUC PAINT MATE 79798 00 SHCS M5 x 12MM LONG LN 9247 13 1 84 Ransburg Aerobell 168 Parts Identification TABLE G POWER SUPPLY NO POWER SUPPLY 53333336 2 TABLE H HIGH CABLE NO CABLE TABLE J SPINDLE ASSEMBLY NONE NONE 1 12777 00 SILVER SHAFT STYLE 2 12777 02 BLACK STYLE 2 NE NN o 5 LN 9247 13 1 85 168 Parts Identification Ransburg Applicator Parts Breakdown 86 LN 9247 13 1 Ransburg Aerobell 168 Parts Identification APPLICATOR PARTS BREAKDOWN Description Q ct lt LUID E A12796 00 SS Y FLUID TUBE 6 9 2 600 RUDTUBERETANR TRANSMITTER ASSEMBLY INDUCTOR TO FIBER OPTIC CONNECTOR LIQUID TIGHT COLLET 8 MM COLLET 4 MM MOUNTING MANIFOLD gt 58 X jsBeLLCUPASSEMBLY 60 TABLEE ITEMG TOOLKT 111 TABLEE 68 9422 ORNG 1424 69 TABLEF ROBOTADAPTER 40 RESISTOR ASSEMBLY NOT SHOWN A13698 00 PLUG FIBER OPTIC EXHAUST 2 ht These fluid tips can only be used with these bell cups See table B and C LN 9247 13 1 87 Ransburg Aerobell 168 Parts Identification 36 o o A13033 Stud Mount Assembly STUD MOUNT ASSEMBLY 12913 00 WASH 12822 00 WASH
13. Atex FM 13402 2 13401 TABLE TOOL KIT 02 13082 01 RPM 419 12899 00 11229 00 12088 00 POST MOUNT APPLICATOR WITH 30MM A11388 00 59972 00 OR 65MM BELL CUP 03 A13082 02 419 A12899 00 11229 00 A12088 00 APPLICATOR WITH 30MM OR 65MM BELL A11388 00 A11922 00 A10766 00 59972 00 CUP WITH VALVE PACKAGE 04 A13082 03 11229 00 A12088 00 A12939 00 POST MOUNT WITH15MM 59972 05 1 13082 04 RPM 419 A11229 00 A12088 00 A12939 00 APPLICATOR WITH 15MM BELL CUP A11922 00 A10766 00 59972 00 WITH VALVE PACKAGE TABLE F ROBOT ADAPTER NONE NONE A13031 00 FANUC PAINT MATE A13031 00 A13352 Configuration Drawing LN 9247 13 1 11 Ransburg TABLE G POWER SUPPLY Description NO POWER SUPPLY 0 DOMESTIC 10 RACK EUROPE 10 RACK CHINA 10 RACK DOMESTIC BOX STYLE 05 EUROPE BOX STYLE 6 CHINABOX STYLE 03 HEAD Fe C C 79338 15 LN 9247 13 1 80100 51X 80104 XX Aerobell 168 Atex FM A13352 Configuration Drawing 12 Ransburg Aerobell 168 Atex FM TABLE H HIGH VOLTAGE CABLE Dion Pans 0 NOCABLE HIGH VOLTAGE CABLE 15 4 5m HIGH VOLTAGE CABLE 25 7 6m HIGH VOLTAGE CABLE 50 15 2m HIGH VOLTAGE CABLE 15 4 5m HIGH VOLTAGE CABLE 25 7 6m 6 HIGH VOLTAGE CABLE 50 15 2m APPLICATOR CASCADE END
14. Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Yellow Dot Yellow Line Note the alignment marks on the Atomizer Body and Turbine Retaining Ring Step 18 Remove the Turbine no tool required Pull straight off NOTE gt The Turbine sealed with a O ring and may be difficult to remove Step 19 Note the alignment marks LN 9247 13 1 68 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Step 20 Note Two 2 locating pins are mount ed on the back of the Turbine to insure proper alignment When assembling these pins will easily insert when the alignment marks are properly matched Step 21 Locate the Fluid Tube and Fluid Tube Retainer Step 22 Remove the Fluid Tube Retainer us ing the opposite end of the Fluid Tip Tube Removal Tool A11229 00 When re installing tighten to 65 75 In Lbs 7 64 8 42 N m LN 9247 13 1 69 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Step 23 Using an Adjustable Wrench Note provided with Atomizer remove the Fiber Optic Holder When re installing tighten until unit is seated on back surface flush Step 24 Slide the Fiber Optic Holder from the Atomizer Step 25 Remove the Fiber Optic Transmitter Assembly from the Fiber Optic Holder LN 9247 13 1 70 Ransburg
15. 6 PAINT FITTING Dash ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 Ll FLUID COIL 12 COILS 1 4 X 1 8 1 0 8 X 6 PAINT FITTING 13401 03 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 8X5 PAINT FITTING 13401 04 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 FLUID COIL 12 COILS 1 4 X 1 8 1 0 8 X 5 PAINT FITTING A13402 03 ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 8X5 PAINT FITTING A13402 04 ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 FLUID COIL 12 COILS 1 4 O D X 1 8 1 0 8X5 PAINT FITTING TABLE E TOOL KIT _ TOOL 13082 01 RPM 419 12899 00 11229 00 A12088 00 POST MOUNT APPLICATOR WITH 11388 00 59972 00 65 BELL 03 1 13082 02 419 12899 00 A11229 00 A12088 00 APPLICATOR WITH 30MM OR 65MM A11388 00 A11922 00 A10766 00 59972 00 BELL CUP WITH VALVE PACKAGE 01 02 04 1 13082 03 RPM 419 A11229 00 A12088 00 A12939 00 POST MOUNT APPLICATOR WITH 59972 00 15 05 13082 04 419 11229 00 12088 00 12939 00 WITH 15 BELL 11922 00 10766 00 59972 00 WITH VALVE PACKAGE TABLE F ROBOT ADAPTER amp MTG SCREWS _ NONE NONE m
16. Aerobell 168 Maintenance DISASSEMBLY PROCEDURES Robot Machine Mount Kits Step 1 Using A11373 00 Tubing Removal Tool push downward on the outer ring of the push on fitting At the same time pull upward on the plastic tubing Remove all such plastic tubing from the Rear Manifold Step 2 Release the Fluid Coil as shown YYW 4 from the Rear Manifold using the Adjustable Wrench Step 3 Remove the Internal Cup Wash Fitting from the Rear Manifold When assembling the Internal Cup Wash Fitting tighten with fingers until an audible click is heard Note Be careful not to drop the Cup Wash Ferrule Make sure when assembling the Internal Cup Wash Fitting that the ferrule taper end is inserted into the Internal Cup Wash Fitting LN 9247 13 1 71 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES For Robot Machine Mount Kits Step 4 Remove the Cup Wash Fittings from the Y Fitting mounted on the Valve Manifold Note Please refer to pages 62 amp 63 for procedures on removal of the Cup Wash Fitting that is mounted on the Shape Air Ring with the 30 mm 65mm Bell Step 5 Remove the plastic SHCS from the Mounting Manifold using the 5 16 8mm Hex Key Wrench Step 6 This is how the Robot Machine Mount should look at this point LN 9247 13 1 72 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES Robot Machine Mount Kits Step 7 Remove
17. Be careful NOT to drop the Cup Wash Ferrule LN 9247 13 1 52 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES 15mm Bell Cup and Shape Air Ring Step 4a Remove Spacer A12934 00 BN Step 4b With a delicate pointed tool remove O Ring 79001 57 When installing new O Ring 79001 57 use caution and sharp tools to prevent damage Aerobell 168 Maintenance 53 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES 15mm Bell Cup and Shape Air Ring Step 5 Remove Shape Air Ring Pull straight off Note The Shape Air Ring is sealed with a O ring and may be difficult to remove Note When reassembling an audible Click should be heard Yellow Dot Blue Line H Note The Shape Air Ring has a blue alignment mark The blue alignment mark will line up with the yellow dot located on the Atomizer Body and the small yellow line located on the Tur bine All three 3 alignment marks will have to be in line when assembling Step 7 Note Two 2 locating pins are mounted on the back of the Shape Air Ring to insure proper alignment Aerobell 168 Maintenance 54 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES 15mm Bell Cup and Shape Air Ring Step 8 Insertthe Bell Cup Combo Wrench RPM 419 across the flats located Pn on the Turbine Re move the Bell Cup by hand 1 i i FE Bell Cup When reassembling the Bell Cup hand tighten i
18. Excessive speed will cause air turbine damage Do not exceed the maximum rated speed of 60 000 rpm 36 Ransburg BEARING AIR gt Air bearing air must be on whenever the turbine is operated If not severe bear ing damage will occur It is recommended to leave bearing air on at all times During maintenance or disassembly turbine air musts be off for a least 3 minutes before shutting off air or main line air gt Bearing damage and subsequent tur bine failure caused by running the turbine without bearing air will not be covered under Ransburg warranty When turning the turbine on bearing air must be present Likewise bearing air must remain on when the turbine air is turned off until the turbine stops spinning Never turn off bearing air to cause the turbine to stop spinning Brake air can be used to slow the turbine see Brake Air in this section Wait for the turbine to stop spinning before turning bearing air off gt Operating the turbine with bearing air pressure below 80 psi measured at turbine inlet may cause bearing damage gt The nominal bearing air pressure is 90 psi 6 bar 10 psi 7 bar 80 psi 5 5 bar minimum 100 psi 7 bar maximum Under no circumstances should the turbine be operated with less than 80 psi bearing air pressure LN 9247 13 1 Aerobell 168 Operation BRAKE AIR Brake air is used to slow the turbine speed It is advantageous for short color change c
19. Splash Plate that is pressed into the Bell Cup Step 11 Insert the narrow end of the Splash Plate Removal Tool A11388 00 into the hole on the back side of the Bell Cup Using a hard thrust from the palm of your hand remove the Splash Plate LN 9247 13 1 65 Ransburg Aerobell 168 Maintenance LN 9247 13 1 DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Step 12 11388 00 Splash Plate AE R Removal Tool Splash Plate gt 65mm Bell Cup Pc s 4 Step 13 To reassemble the Splash Plate place the Bell Cup with the back down on a flat surface and insert the Splash Plate into the Bell Cup hole Using the large end ofA11388 00 Splash Plate Removal Tool gently push into position Until an audible click is heard 553 542 14 05 13 76mm BELL CUP REAR FACE TO SPLASH PLATE INSERT FACE Step 13A Verify depth of insert to dimension shown 66 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Step 14 Remove the Fluid Tip using the A11229 00 Fluid Tip Tube Removal Tool NOTE gt The Threads on the Fluid Tips HANDED Step 15 Fluid should only tighten when assembled Step 16 Using the Turbine Retaining Ring 12088 00 remove the bine Retaining Ring LN 9247 13 1 67
20. air filter coalescing type 19 SCFM 99 995 efficiency particulate removal 3 to 6 micron max Aerobell 168 passed 6 micron max solid passed 2 micron one per Aerobell 168 adequately filtered will foul the turbine air bearings and cause turbine failure The cor rect type filters musts be used in an Aerobell 168 system The filter elements must be re placed regular schedule to assure clean air gt Itis the user s responsibility to ensure clean air at all times Turbine failure result ing form contaminated air will not be cov ered under warranty If other filters are incor porated in the system the filters to be used must have filtering capacities equal or better than those shown in Air Filtration Require ments Charts gt The user must ensure the bearing air supply is not inadvertently turned off while the Aerobell 168 air motor is turning This will cause air bearing failure LN 9247 13 1 Aerobell 168 Installation HAF 15 Element One HAF 38 Elements Carton of 4 RPM 33 Elements Carton of 8 NOTE gt Eachapplicator must have its own filter for bearing air Recommended RPM 418 or equivalent 27 Ransburg Aerobell 168 Installation om 8 Typical Multiple Applicator Configuration TYPICAL MULTIPLE APPLICATOR CONFIGURATION 80100 51X OR 80120 51X 9060 WITH 80104 01 EXTERNAL CASCADE 79338 15 LOW VOLTAGE CABLE A133
21. cleaner when the second set is in production 12 Reinstall cups to hand tighten torque Bell Cup Soaking Bell cups and splash plates can be soaked in a heated solution for up to 2 hours in an ultrasonic cleaner 120 F 49 C maximum 46 Ransburg Aerobell 168 Maintenance CLEANING SHAPING Resistor Assembly AIR HOLES Resistance Verification Using a yokogama megohm meter or equivalent Setthe meter to the 1000V scale Touch one lead In order to maintain uniform pattern control the to the flat exposed end of the resistor and the shaping air holes of the inner andthe shaping other lead to the contact spring the resistor air cap must be clean and free of any blockage The reading must be between 54 66 megohm Replace resistor assembly if required It is best to leave the shaping air supply ON during normal production break cleaning periods Shaping air can be reduced to 70 slpm during this time This will help material from entering the passage ways Periodically weekly or sooner the outer shaping air cap and the inner shaping air ring should be removed and thoroughly cleaned Use of an ultrasonic cleaner would make cleaning of hole diameters easier Inspect all holes for blockage Blow holes clear with compressed air after some time of soaking in solvent DO NOT use any type of pick to clear the holes Damage may result to parts and could affect performance of the equipment If holes are damaged oversiz
22. condition is met LN 9247 13 1 Every 12 months Continuously At every switch on Monthly Weekly Before each cleaning 106 Ransburg Aerobell 168 Appendix A SURVEY OF TESTS TABLE Cont Effectivity of measures doors and openings of the spraying area where Weekly for protection against the hazard of contact with parts under high voltage direct contact exists the presence of the high voltage shall be safeguarded in such a way that the high voltage is disconnected when entrance is gained The inter lock shall satisfy the performance level d of EN ISO Interlocks protection 13849 1 Otheropenings ofthe spraying area through against entrance which parts under high voltage could be contacted shall be locked in such a way to be only opened by keys or tools When using systems of types C L and D L an interlock of the high voltage with all doors and openings shall be installed to prevent an electric shock of persons Effectivity of grounding All conductive components of the equipment like Weekly measures floor walls ceilings fences conveyors workpiec es containers for coating material reciprocators or elements or elements of construction etc within the spraying area except for parts under high voltage for operational reasons shall be connected to the grounding system Parts ofthe booth shall be earthed in compliance with EN 12215 2004 If an appropriate grounding of the conductive parts accordi
23. or more often Atomizer Bell Assembly Inspectthe atomizer bell assembly for any damage wear or paint build up every day 45 Ransburg BELL CUP CLEANINGS Always verify that high voltage is off and that the atomizer bell is spinning before performing any type of bell flush cleaning cycle To reduce the risk of fire or explosion the solvents used for exterior surface cleaning must have flash points above 5 C 9 F greater than the ambient temperature Since electrostatic equipment is involved these solvents must also be non polar Solvents used for equipment flushing should have flash points equal to or higher than those of the coating material being sprayed 1 The atomizer bell will normally be fully cleaned during a bell flush cycle Flushing should be done before any downtime or break in production Abell flush cycle may also be required while spraying batch parts of the same color Verify that high voltage is off and that the atomizer bell is spinning before flushing through the bell 2 If there is any remaining paint build up on any areas of the bell after flushing the bell should be removed for hand cleaning The bell s leading edge splash plate and serration cuts are some examples of areas for special attention Manual Inspection 3 Visually inspect the bell cup edge for signs of abrasion If the edge is worn or chipped as the result of a collision with a part replace the cup immediately 4 Remove s
24. 00 A12942 02 13676 00 12833 01 12833 03 13207 00 TABLE D MOUNTING AND VALVE OPTIONS Part Description A13033 00 STUD MOUNT ONLY NO VALVES WITH REMOTE CUP WASH MANIFOLD A13401 01 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 8X6 PAINT FITTING A13401 02 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 FLUID COIL 12 COILS 1 4 X 1 8 1 0 8X6 PAINT FITTING FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 8X6 PAINT FITTING mn ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 m 13402 00 ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 12 COILS 1 4 O D X 1 8 1 0 8X6 PAINT FITTING A13401 03 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 8X5 PAINT FITTING A13401 04 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 FLUID COIL 12 COILS 1 4 X 1 8 1 0 8X 5 PAINT FITTING A 13402 03 ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 16 COILS 1 4 X 1 8 1 0 8X 5 PAINT FITTING 13402 04 ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 FLUID 12 COILS 1 4 O D X 1 8 1 0 8 X 5 PAINT FITTING A13033 00 A13352 Configuration Drawing LN 9247 13 1 10 Ransburg Aerobell 168
25. 4 Where possible the pre filter s and bearing er grounded objects The safe distance is air filter s should be mounted where they can be 204mm 8 easily seen so the user willsee when maintenance 15 required This must be installed with fire protection and fire detection per EN 50 176 5 Standard black iron or galvanized piping may be used prior to the HAF 503 or HAF 508 pre fil gt Power Unit must be interlocked with con ters only All piping after the pre filter should be veyor and booth fan brass stainless steel aluminum or hose poly nylon nyliner etc 6 Do not use PTFE tape pipe dope or other A CAUTION thread sealant downstream of the bearing air filter Loose flakes of PTFE tape or other sealant can gt Aerobell 168 shipping container in break loose and plug the very fine air holes in the cludes the basic atomizer assembly with turbine bearings bell and manifold Tool options for bell cup removal and dis assembly of other compo 7 Use clear see through air tubing between the nents can be purchased with the atomizers bearing air filter and bearing air fitting to clearly or ordered separately indicate to the user if oil or moisture contamination is getting past the filter gt Mountthe Aerobell 168 securely to a sta tionary or reciprocating fixture with the 3 4 8 If air heaters are used in the system to mini inch 19MM diameter stud provided mize the effect of excessively humid condit
26. 6 AIR FILTRATION 21 TYPICAL MULTIPLE APPLICATOR CONFIGURATION 28 29 AIR HEATER REQUIREMENTS c ene 30 31 ges 31 32 HIGH VOLTAGE CABLE 33 HIGH VOLTAGE CABLE 33 AEROBELL 168 HIGH VOLTAGE CONNECT AT ATOMIZER 33 34 AEROBELL 168 CASCADE CONNECTION eee mme 34 35 H5 mclbe OOOOO 36 F to eee ee 37 uu ee m er eee 37 ELECTROSTATIC VOLTAGE 37 RARING AIR 38 FEUID FEOW RATE 38 FLUID TIP STREAM AND STYLE 38 39 TAROE IO u y 39 MATERIAL CONDUC TIVI TY mmc 39 39 TURBINE AIR es M 40 IDCM 40 Continued on next page LN 9247 13 1 Ransburg Aerobell 168 Contents CONTE NTS Cont PAGE MAIN ENN U s ecc 42 43 PREVENTIVE MAINTENANCE nnne nne esten 43 45 AIR FILTERS ELEMENT REPLACEMENT
27. 79879 00 1 4 OD X 125 ID PFA High Conductive Paints 16 Coils 79879 01 1 4 OD X 170 ID PFA 12 Coils Select Option Below Shaping Air Kit A13032 01 Dual Flex 65mm A12909 00 12911 00 12910 00 79001 11 79001 35 79001 16 12898 00 12779 01 12896 00 79001 52 79001 10 79001 16 12898 00 12830 00 12831 00 79001 52 79001 10 79001 16 12898 00 LN 9247 13 1 104 Ransburg Aerobell 168 Parts Identification RECOMMENDED SPARE PARTS Cont Part Description Select Option Below Shaping Air Kit A13206 00 15mm 12933 00 Shroud 12935 00 Inner Shape Air Ring LN 9247 13 1 105 Ransburg Aerobell 168 Appendix A APPENDIX A TESTS OF THE STATIONARY EQUIPMENT The tests shall be carried out for each single spraying system The test shall be carried out by skilled persons and include the tests according to this table and the internal notes SURVEY OF TESTS TABLE Review amp Testing The stationary equipment In this context especially the disconnection threshold for electrostatic coating the overcurrent and the minimum voltage Uni shall with ignitable liquid coating be defined and documented with respectto operational materials shall be tested for and local conditions occupationally safe state Effectivity of forced e Ventilation must be properly interlocked with high ventilation exhaust voltage power supply air systems Forced ventilation mu
28. 86 XX OR A13348 XX HIGH VOLTAGE CABLE TRUE EARTH GROUND BOOTH WALL HAZARDOUS AREA SIDE BOOTH WALL SAFE AREA SIDE VERTICAL GUN BAR OR RECIPROCATOR OR STATIONARY STAND AB 168 APPLICATOR LN 9247 13 1 28 L 40 SADLY Vd 34V 51050439 30 66 71390437 168 Installation 113803 4 834 L M31714 8917 Ly M3ZINOIv 3HL OL 31815504 SV 35010 SV 5431115 8 347307 78151 5 WLLNFY44 dtd 331055349 JHL OS 5431115 3192001 uv Jive 1138033V 1 8 o A SNIgvHS SSVd Q IVHL SLVINOILYVYd ANY MOHS OL 5831113 MIV 9351 38 0110 5 ONIANL HYJI 9NIav3g Ransburg 434 81 OL NI J3LIVA 1 4 38 OL SINVNIWVINO 10 39 5511 Ol OL JaNLSIOW ONY sv QILVAOLNY NMOHS SY 40553444029 dva 30MIONI LSNW 37815509 SV 1944493 OL 35012 SV u3 14 38d 31 201 SW31SAS TIY NI 9351 3113 8O0S VH ISOH 2115 14 MO 11315 SS31NIVLS
29. A Tells where hazards may occur Spray Area High Voltage Equipment LN 9247 13 1 HAZARD Tells what the hazard is Electrical Discharge There is a high voltage device that can induce an electrical charge on ungrounded objects which is capable of igniting coating materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion Aerobell 168 Safety SAFEGUARDS Tells how to avoid the hazard Parts being sprayed and operators in the spray area must be properly grounded Parts being sprayed must be supported on conveyors or hangers that are properly grounded The resistance between the part and earth ground must not exceed 1 meg ohm Refer to NFPA 33 Operators must be grounded Rubber soled insulating 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 applicator 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 required by the process to be at high voltage must be grounded Grounded conductive flooring must be provided
30. APE AIR DIRECT CHARGE A13206 00 DUAL SHAPE AIR 15MM DIRECT CHARGE A13032 02 MONO FLEX DIRECT CHG A13032 01 DUAL FLEX DIRECT CHG A13352 Configuration Drawing LN 9247 13 1 8 urg A13032 03 30MM DIRECT CHG TABLE B FLUID TIP Aerobell 168 Atex FM 13206 00 15 LN 9247 13 1 Part 11240 01 11240 02 11240 03 11240 04 11240 05 11240 06 13601 00 13625 00 13625 01 13625 02 13625 03 13625 04 13625 05 02807MM 11240 13625 Qt Pte Description 13625 06 093 2 4 Straight 1 25 07 1283 2 Straight 1 1 25 08 070 0 25mm Straight 1 At3645 00 028 0 7MM Industria 1_ 1 5 01 035 0 9mm Industrial 1 5 02 039 1 0mm Industria 1 A13645 03 Industrial 1_ t3645 04 047 1 2 1 1 5 05 062 1 6mm Industria 1 A13645 06 09972 4mm Industrial 1 5 07 125 32mm Industrial At3645 08 070 0 25mm industrial _ A13645 A13352 Configuration Drawing Ransburg Aerobell 168 Atex FM TABLE C BELL CUP ASSEMBLY gt u 30MM ALUMINUM PLATED A13207 00 15MM TITANIUM A12936 00 A12833 03 30MM TITANIUM A13531 00 A13676 00 65MM TITANIUM A13675
31. ARE PARIS 102 105 APPENDIX 106 108 TESTS OF THE STATIONARY 106 108 WARRANTY POLICIES 109 u u 109 LN 9247 13 1 Ransburg SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety literature for your Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS Tohelp you recognize this information 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 avoida situation that might cause minor injury 15 information relevantto the procedure 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 drawings and appropriate Ransburg equipment manuals to reconcile such differences Careful study and cont
32. GE 13032 03 DUAL 5 AIR DIRECT 13206 00 DUAL SHAPE AIR 15MM DIRECT CHARGE A13032 02 MONO FLEX SINGLE SHAPE AIR DIRECT CHARGE LN 9247 13 1 82 Ransburg Aerobell 168 Parts Identification TABLE B FLUID TIP ht ht ht ht ht ht ht A13645 07 125 3 2MM INDUSTRIAL A13645 08 010 0 25 INDUSTRIAL TABLE BELL CUP ASSEMBLY A12942 02 65MM ALUMINUM PLATED A12782 00 A13644 00 A12833 01 30MM ALUMINUM PLATED 13832 00 13274 00 01 02 03 04 05 07 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 13207 00 15 TITANIUM 12936 00 bo 12833 03 30MM TITANIUM A13531 00 A13274 00 A13676 00 65MM TITANIUM A13675 00 A13644 00 These fluid tips can only be used with these bell cups See table B and C 01 02 03 04 05 LN 9247 13 1 83 Ransburg Aerobell 168 Parts Identification TABLE D MOUNTING AND VALVE OPTIONS EEA A13033 00 STUD MOUNT ONLY NO VALVES WITH REMOTE CUP WASH MANIFOLD A13401 01 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 8 X 6 PAINT FITTING A13401 02 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 01 FLUID COIL 12 COILS 1 4 O D X 1 8 1 0 8 X 6 PAINT FITTING A13402 00 ROBOT MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH 79879 00 FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 8 X
33. H SOLVENT VALVES amp FLUID 16 COILS 1 4 O D X 1 8 1 0 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES amp FLUID COIL 12 COILS 1 4 O D X 1 8 I D MACHINE MOUNT WITH RIGGER DUMP CUP WASH SOLVENT VALVES amp FLUID 16 COILS 1 4 O D X 1 8 1 0 MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES amp FLUID 12 COILS 1 4 O D X 1 8 I D 91 Ransburg Aerobell 168 Parts Identification 48 74 68 a T DETAIL B AD SCALE 2 1 526 47 76 15 LONG A13402 Robot Mount Kit With Valves LN 9247 13 1 92 Ransburg Aerobell 168 Parts Identification ROBOT MOUNT KIT A13402 2 E VVVV CUP WASH Y FITTING CUP WASH FERRULE VVV V PFA TUBING FINGER TIGHT UNTIL CLICK TORQUE TO 5 10 LBS IN 56 1 13 Nm TORQUE TO 15 20 LBS IN 1 69 2 26 Nm TORQUE TO 15 20 LBS IN 1 69 2 26 Nm AFTER VALVE IS DOWN V s te a 1 2 7 10 11 36 38 39 40 41 45 46 47 48 51 53 54 55 56 71 72 73 74 75 76 77 VVVV LN 9247 13 1 93 Ransburg Aerobell 168 Parts Identification TABE A MACHINE MOUNT KIT OPTIONS WITH FLUID TUBE Part A Fluid Coil 13402 00 79879 00 A I LN 9247 13 1 Part B Paint Fitting 13318 00 FOR 8 X 6 TUBING A13318 00 FOR 8 X 6 TUBING A13319 00 FOR 8 X 5 TUBING A13319 00 FOR 8 X 5 TUBING Part C Re
34. Microvalve Seat Removal Tool A10766 00 and the Adjustable Wrench loosen the Microvalve Seat Aerobell 168 Maintenance 75 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES For Robot Machine Mount Kits Step 16 Remove the Microvalve Seat When reassembling the Microvalve Seat tighten to 15 20 In 16 1 68 2 24 N m Step 17 Using the 5mm Hex Key Wrench re move the five 5 SHCS and detach the Top Valve Plate from the Valve Manifold Step 18 Tighten to 10 15 In Lbs 1 23 1 68 N m Valve Manifold Top Valve Plate LN 9247 13 1 76 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES For Robot Machine Mount Kits Step 19 Using the 5mm Hex Key Wrench remove the five 5 SHCS that secure the Mounting Block to the Valve Manifold Step 20 There are different Mounting Blocks for other applications Step 21 By hand remove the four 4 A13096 00 Tube Receivers 4mm 3 3 z E uS 168 Maintenance 77 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES For Robot Machine Mount Kits Step 22 By hand remove the four 4 A13118 00 Tube Fittings Step 23 A13096 00 Tube Receiver Step 24 By hand remove the four 4 A13288 00 receivers 8mm LN 9247 13 1 78 Ransburg LN 9247 13 1 Step 25 By hand remove the four 4 A13287 00 8mm x 6mm or
35. NT ELEMENTS Qty Elements Per Carton HAF 503 HAF 15 Pre Filter HAF 508 HAF 38 Pre Filter RPM 418 8 418 Bearing Air Filter Ransburg Aerobell systems should include pre filter s and final filters for all air to the Aerobell 168 unit The final filter is for bearing air only filters contain elements that must be replaced on a regular basis to assure clean air HAF 508 and RPM 418 filters also contain an automatic drain and pressure differential indicator The pressure differential indicator provides a visu al indicator that pops up becomes more visible as the filter element becomes plugged Replace the filter elements when the visual indicator be comes visible don t wait until it pops up fully As the elements become plugged their efficiency drops The frequency of filter element change will depend upon the quality of the plant air It is recommended that all elements be replaced at least every 4 to 6 months In plants where heavy amounts of oil and moisture vapor are present in the air lines a refrigerated air dryer may be necessary The Aerobell 168 is designed to give dependable service and extended life One of the most import antfactors in realizing long life is the quality of air It istherefore essentialforthe userto closely monitor the quality of their air and to properly maintain the air filters by replacing the filter elements as often as necessary Replace elements at least every 4 6 months
36. Note NOTE gt coating material used is heated check the maximum rated temperature for the fluid tubing used Polyethylene tubing H 2338 and H 2339 is rated for a maximum of 80 F 27 C Nylon tubing H 2340 and H 2341 is rated for 200 F 95 C maximum gt Any user supplied air hoses must be rat ed at a minimum working pressure of 100 psig 7 bar gt Any user supplied fluid hoses must be rated at a minimum working pressure of 150 psig 10 bar 31 Ransburg HIGH VOLTAGE See Typical Multiple Application Configurations in the Introduction section INTERLOCKS Thefollowing system interlocks are recommended to prevent equipment damage 1 Bearing air should remain on at all times and should be shut off only by turning off the main air to the pneumatic control cabinet 2 It should not be possible for the coating mate rial to be sprayed unless the turbine is spinning 3 wo 2 interconnected bearing air ports are provided one for supply air and the other to be used as a return signal for measuring bearing air pressure at the atomizer If bearing air falls below 80 psi 552 kPa at the atomizer the turbine air should be automatically interlocked to shut off 4 High voltage must be interlocked with the solvent valve pilot signal to prevent solvent flow while high voltage is energized 5 Turbine air and brake air must be interlocked to prevent both from being used simultaneousl
37. ROBOT MOUNT 5 20 132 0 2 79 c 0450 1143 Qo X 20 5 0 p CG 5 52 140 1 0 75 mE 1 00 25 4 6 05 153 7 3 72 94 4 65 MM POST MOUNT LN 9247 13 1 21 Ransburg Aerobell 168 Introduction DIMENSIONAL CHARACTERISTICS 18 97 481 8 12 09 307 2 5 71 145 0 sa O 1 40 35 6 CG 2 39 60 6 17 86 453 6 04 50 114 3 65 MM MACHINE MOUNT 60 DEGREES 17 85 453 3 10 82 274 9 5 72 145 4 3 26 82 9 CG 2 43 61 8 296 5 65 MM MACHINE MOUNT STRAIGHT LN 9247 13 1 22 Ransburg Aerobell 168 Introduction IMPORTANT NUMBERS Record these numbers in a log book for future reference The last digits ofthe Atomizer serial number are also the Turbine serial number Turbine Serial Number Located On the Spindle Barrel Serial Number Located On Back Face Of Cup Number Located On Back face Of Cup AXXXXX LN 9247 13 1 23 Ransburg Aerobell 168 Introduction HOSE SPECIFICATIONS 9 5 HOLDING 204MM 89784 OScery 12094 REAR MANIFOLD PORT CONNECTIONS HOSE SPECIFICATIONS IDENTIFICATION Description 8MM 5 16 O D TUBE 8MM 5 16 O D TUBE FIBER OPTIC CONNECTION OPTIONAL FOR LIGHT SOURCE REFLECTIVE TYPE MU T BY INTEGRATOR 4 MM SH6OD TUBE 5 HIGH VOLTAGE CABLE CONNECTION 6 FIBER OP
38. SERVICE MANUAL LN 9247 13 1 Ransburg May 2014 AEROBELL 168 MODEL 13350 IMPORTANT Before using this equipment C carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 50 00 U S Ransburg Aerobell 168 NOTE This manual has been changed from revision LN 9247 13 to revision LN 9247 13 1 Reasons for this change are noted under Manual Change Summary on page 110 of this manual LN 9247 13 1 Ransburg Aerobell 168 Contents CONTENTS PAGE SAFETY 1 5 SAFETY PRECAUTION 1 HAZARDS J SAFEGUARDS E ERAO 2 5 ATEX 6 13 EUROPEAN ATEX DIRECTIVE 6 7 CONFIGURATION 0 444 8 13 14 FEATURE 14 OPERATING CHARACTERISTICS AND SPECIFICATIONS 15 18 DIMENSIONAL 5 5 19 22 IMPORTANT NUMBER 23 2 24 GENEISAL INFORMA HON uuu 25 AIR FILTER INSTALLA HON 25 SPEGIPIC ATION 2
39. TIC CONNECTION RANSBURG MAGNETIC TYPE 7 EXTERNAL WASH CONNECTION SSS 8 4MW SG20D TUBE 79 71 s sC s s NIERNALCUPWASHCONNECTION 1 4 O D TUBE PAINT SUPPLY LN 9247 13 1 24 Ransburg Aerobell 168 Installation INSTALLATION GENERAL INFORMATION AIR FILTER INSTALLATION The following guidelines must be observed when installing air filters for the Aerobell 168 system see Air Filtration Requirements Chart for additional information This information is intended ONLY to indicate the general installation parameters of this product and where applicable its working relationship to other Ransburg system components in typical use 1 Use only recommended pre filters and bearing air filters as shown in Recommended Air Filtration Requirements in this section Additional system air filtration 1 refrigerated air dryer may also be used if desired Each installation is unique and should be direct ed by an authorized Ransburg representative or conducted using the Ransburg installation drawings provided for your particular installation 2 Use one bearing air filter per Aerobell Mount the bearing air filter as close as possible A WARNING to the Aerobell 168 do not mount further than 30 gt Risk of arcing fire hazard The Aerobell feet 9M away 168 must be located a safe distance from the object to be sprayed as well as all oth
40. TURBINE EXHAUST AIR Turbine air must be able to exhaust freely howev er too much exiting the rear of the manifold may cause a vacuum between the fluid tube and the turbine shaft In the event of low to medium flow rates and mid to high turbine speeds paint may be pulled back into the shaft and into the turbine motor To provide a balance in this flow plugs for unused ports have been installed into the Aerobell 168 Manifold assembly See drawing below for restriction on their use TURBINE EXHAUST PORT KEEP PLUG A13368 00 INSTALLED UNLESSAFITTINGAND TUBINGIS INSTALLED TO ROUTE EXHAUST AWAY FROM APPLICATOR M12 X 1 75 THD OPTIONAL FIBER OPTIC PORT PLUG A13368 00 MUST BE KEPT INSTALLED IF NOT IN USE M12 X 1 75 THD 204MM HOLDIN G Ing 8916 TURBINE EXHAUST PORT DO NOT BLOCK OR RESTRICT USE LARGE TUBING IF ROUTING EXHAUST AIR AWAY FROM APPLICATOR M14 X 2 THD LN 9247 13 1 Aerobell 168 Operation A WARNING gt Non ignitable cleaning fluids are pre ferred gt Ignitable cleaning liquids shall only be used if after disconnection of the high voltage supply all parts under high volt age are discharged to an energy of less than 0 24mJ before these parts may be serviced Appropriate measures shall ensure that the resistance to earth of the sus pending point of the work piece shall not exceed 1MQ measured at 500v 1000v gt Use only electrically conduct
41. aint trapped between the bell and shaft preventing the bell from properly seating If any of these conditions exist they must be corrected Excessive imbalance caused by one of these conditions may result in bearing damage and turbine failure Warranty DOES NOT cover failure caused by imbalanced loading conditions To determine if the bell is dirty or damaged re move the bell and turn the turbine on If the noise is eliminated the bell cup is the problem If the noise continues the turbine may be damaged and should be inspected Excessive air required to achieve same speed may indicate a faulty or contaminated turbine DO NOT continue to operate a noisy turbine LN 9247 13 1 Aerobell 168 Maintenance PREVENTIVE MAINTENANCE See Preventive Maintenance Schedule Daily Weekly Maintenance gt Due to the close proximity of high voltage to ground potential a schedule must be developed for equipment maintenance cleanliness gt Verify that high voltage is OFF and that shap ing air bearing air and turbine drive air are ON gt Open the dump valve if equipped flushing all paint from the supply lines and valve module gt Open the solvent valve if equipped flushing all paint from the fluid tube and through the at omizer bell assembly gt Verify that high voltage is OFF turbine drive air is OFF and that the bell cup has stopped spinning The bearing air and shaping air should remain ON gt Clean all
42. alve manifold tube fittings Ring Solvent Proof Ring Solvent Proof Ring Solvent Proof Screw M4 X 10mm SS SHCS Screw M6 X 10mm SS SHCS Resistor Assembly Tube Receiver 8mm Tube Fitting 8mm x 6mm Tube Fitting 8mm x 5mm Screw M6 X 12mm SS SHCS 78449 00 Fitting Fluid A13030 00 Set Screw M8 X 12mm Cup Pt SS A12824 00 Cup Wash Y Fitting A11252 01 Cup Wash Tubing 10 20 ft A12821 00 Cup Wash Fitting A12822 00 Cup Wash Ferrule 65 Customer must verify their spindle for o ring replacement LN 9247 13 1 102 Ransburg Aerobell 168 Parts Identification RECOMMENDED SPARE PARTS Cont Part Description Qty Select Option Below Fluid Tip Size Style A11240 02 11240 03 11240 04 11240 05 11240 06 12601 00 12625 00 12625 0 12625 02 A13625 03 A 13625 04 12625 05 13625 06 12625 07 12625 08 13645 00 A13645 0 A13645 02 A13645 03 13645 04 A13645 05 A 1364508 12645 07 13645 06 Select Option Below Cup Assembly W Splash Plate Select Option Below Bell Cup Only A12782 00 65MM Aluminum Plated A12832 00 30mm Aluminum Plated A12936 00 A13531 00 A13675 00 15mm Titanium 30mm Titanium 65mm Titanium LN 9247 13 1 103 Ransburg Aerobell 168 Parts Identification RECOMMENDED SPARE PARTS Cont Part Description Qty Select Option Below Splash Plate Only A13644 00 For 65mm Bell Cups 13274 00 30mm Cups Select Option Below Fluid
43. at a minimum consistent with coating requirements Excessive shaping air will cause some atomized particles to blow by the target not allowing full wrap or paint particles to bounce back onto the atomizer Note When Mono Flex shape air configuration is used one of the inputs on the atomizer body will be required to be plugged Either input can be used for Mono Flex SAI or SAO DualFlex Shaping Air Configuration Both inputs are required Pattern adjustment Increasing the inner air will make the pattern smaller Increasing the outer air will make the pattern larger FLUID FLOW RATE CONTROL Externallymounted fluidregulators orgear pumps are typically used to control fluid flow The atomizer assembly is equipped with valves which are pneumatically operated to direct the flow of paint to either the feed tube or dump line FLUID TIP STREAM AND TIP STYLE USE As the picture on the right shows the fluid stream should be straight and steady It is best to start out with the smallest tip to achieve the desired fluid flow rate Either the Straight or the Industrial tip can be used with any 30mm or 65mm bell cup LN 9247 13 1 Aerobell 168 Operation Determining which type of tip style to use is de pendent on the several factors such as viscosity flow rate type of equipment supplying the paint As couple of suggestions follow Straight Fluid tip With positive shutoff devices like a microvalve with all ranges of f
44. at installation is in ac cordance with all applicable requirements of EN 50 176 This includes the means of fire protection and fire detection being installed with this system Before servicing bell insure that all voltage is com pletely de energized and the bell cup is not rotating Minimum 1 minute waitafterturbine air has been shut off f ignitable fluids are used for cleaning purposes all parts must be completely discharged of high voltage The fluid supply system must be properly grounded LN 9247 13 1 Aerobell 168 Atex FM e f an object is within the 204mm safe distance it must be cleared prior to restarting and or re energizing the system materials used in the construction of this equip ment contain levels of Al Mg Ti and Zi that are greater than that allowed for EPL Ga and Gb by clause 8 3 of EN 60079 0 therefore in rare cases ignition sources due to impact and friction sparks could occur The equipment shall therefore be protected from such impact and friction when installed The type AB168 Electrostatic Bell and type 9060 80120 51X0r80100 51X power supply complies with EN 50 176 2009 Clauses 4 5 1 5 2 1 5 2 2 5 2 3 5 2 4 5 3 5 5 1 5 5 3 5 5 5 5 6 6 1 6 4 7 2 7 3 and 7 4 All remaining clauses of EN 50 176 2009 are to be addressed during installation installer shall fix the warning sign that is supplied with these products in a position close to the equipment
45. at the fluid is non flammable In these conditions the sys tem is capable of releasing sufficient electrical and thermal energy to cause ignition of specific hazardous materials in the air gt When turning the turbine on bearing air must be present Likewise bearing air must remain on when the turbine air is turned off until the turbine stops spinning Never turn off bearing air to cause the turbine to stop spinning Brake air can be used to slow the turbine see Brake Air in this section Wait for the turbine to stop spinning before turning bearing air off LN 9247 13 1 Aerobell 168 Operation As with any spray finishing system operation of the Aerobell 168 involves properly setting the operating parameters to obtain the best finish quality for the coating material being sprayed while maintaining correct operation and reliability of the equipment used Adjustments to operating parameters which cover spraying cleaning and ON OFF control include the following Coating Materials e Fluid Flow Rate Control e Fluid Valve Trigger Control Turbine Speed Shaping Air pattern control Electrostatic Voltage e Target Distance TURBINE SPEED The speed of the turbine is determined by the air inlet pressure See Turbine Air Pressure RPM SCFM in the Installation section for more infor mation The desired speed will depend upon the type of coating material and various application requirements
46. causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent Power Supply or Controller shutdown indicates a problem in the system requiring correction Aerobell 168 Safety SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accumulation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or maintenance 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 solvents used for cleaning must have a flash point at minimum of 5 C 9 F greater than the ambient temperature It is the end users responsibility to insure this condition is met Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA country and local codes In addition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A distance of 1 inch for every 10KV of output voltage is required at all times Test only in areas free of combustible material Testing may require high voltage t
47. ceiver A13288 00 A13288 00 A13293 00 A13293 00 Description ROBOT MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH FLUID COIL 16 COILS 1 4 O D X 1 8 1 0 ROBOT MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH FLUID COIL 12 COILS 1 4 O D X 1 8 I D ROBOT MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH FLUID COIL 16 COILS 1 4 O D X 1 8 I D ROBOT MACHINE MOUNT WITH TRIGGER DUMP CUP WASH SOLVENT VALVES WITH FLUID COIL 12 COILS 1 4 O D X 1 8 I D 94 Ransburg Aerobell 168 Parts Identification A13032 01 DUAL FLEX DIRECT CHG A13032 02 MONO FLEX DIRECT CHG Ransburg Aerobell 168 Parts Identification A13032 03 30mm Direct Charge MASTER CONFIGURATION TABLE PART A13032 03 65MM DUAL FLEX SHP AIR DIRECT CHG A12911 00 12910 00 12909 00 3 A13032 02 65MM MONO FLEX SHP AIR KIT DIRECT CHG 12896 00 12779 01 30MM DIRECT CHG a s le DESCRIPTION HP AIR RING SHAP AIR MANIFOLD A13032 03 30MM SHAPE AIR 7 10 LN 9247 13 1 6 LT 09 Description A HAPE AIR RING B SHAPEAIR MANIFOLD 6 79001 10 SOLVENT PROOF 79001 52 SOLVENT 12898 00 SHAPE AIR PLUG RING SOLVENT PROOF RING RING SOLVENT PROOF RING SOLVENT PROOF SHAPEAIRRING O SS O SHAPEAIRMANIFOLD S
48. e ones in the air bearing spindle These O rings must not be soaked in solvent if these are exposed or soaked in solvent they must be replaced These O rings are engineered to provide a fit between the air bearing spindle and mating parts to reduce or eliminate harmonic resonance vibration Some O rings are PTFE encapsulated These O rings have alimitedamountofstretch and will not return to their original diameters if over stretched These O rings are subjectto being distorted more easily than rubber O rings so it is important that they be sufficiently lubricated when mating parts are installed onto them They also willtake a square set over time and should be replaced periodically if mating parts are removed repeatedly or if a new mating part is installed onto them Any O ring that is cracked nicked or distorted must be replaced A suitable lubricant is food grade petroleum jelly or A11545 00 Petrolatum Jell Cleaning Procedures The precise sequence of flushing the system of paint will vary according to the type of color valve arrangement used and other automatic features built into the system But follow these basic pro cedures when cleaning 1 Verify high voltage is off 2 With the bearing air and turbine air on flush paint out of material lines with solvent Flushing should be done before any break in production If the Aerobell 168 is mounted vertical facing up rotate to horizontal plane before flushing or cl
49. eaning 3 Flushing should be done with the atomizer bell cup installed The bell cup will normally be fully cleaned with flushing However if there is any remaining paint build up on any areas of the bell after flushing the bell should be removed for hand cleaning LN 9247 13 1 Aerobell 168 Maintenance 4 Cleanthe bell cup by soaking in an appropriate solvent as long as necessary to loosen paint Use a soft bristle brush dipped in solvent to remove paint Make sure all signs of paint are removed See the following Warning Rinse and dry bell Using a non metallic item toothpick clean the center holes of the splash plate Using plenty of cleaning fluid flush these holes towards rear of bell cup Make sure these holes are clean 5 Beforereinstalling the bell onto the shaft check the tapered mating surfaces of the turbine shaft and bell for any paint residue Clean any residue See Warning below 6 Clean the exterior of the Aerobell 168 See Warning below 7 Donotreuse an atomizer bell that shows signs of damage such as nicks heavy scratches dents Or excessive wear 8 Periodic cleaning ofthe holes in the shaping air ring will prevent paint build up which does affect pattern control or cause defects in parts being coated Follow Cleaning Shaping Air Holes and Annulus the Maintenance section and clean the slots of the shaping air ring using a soft bristle brush To prevent paint build up in hol
50. ed holes blockage gouges it must be replaced Inspect Bell Cup Daily Check for signs of damage such as nicks heavy scratches dents or excessive wear Replace the cup assembly with any of these conditions LN 9247 13 1 47 Ransburg Aerobell 168 Maintenance AEROBELL 168 PREVENTIVE MAINTENANCE SCHEDULE Procedure Mid Shift Cleaning Wipe shroud Visually inspect cup End of Shift Cleaning Wipe shroud Wipe bell cup down Change cloth cover shaping Air Shroud and Cap Clean shroud Clean shape air cap Bell Cup Removal Inspection Cleaning Tightening Fluid tip inspection cleaning Inspect Valve and Seat Assembly for leaking Replace Valves and or Seats in valve module Verify Resistance of High Voltage Resistor High Voltage Cable Inspections High Voltage Testing Inspect all screws Replace if broken Inspect for wear Tighten per specifications Inspect Turbine Spindle Taper and Threads Replace Bell Cups Replace Splash Plates Inspect and Clean Spindle Bore e Fluid Tube OD Inspect for Fluid Leaks LN 9247 13 1 Frequency Maximum Yearly Daily 48 Ransburg Aerobell 168 Maintenance TOOLS REQUIRED TO DISASSEMBLE AEROBELL Use the following tools to disassemble the Aerobell 168 Tool Kit A13082 XX A11229 00 Fluid RPM 419 Bell Cup Adjustable Wrench A12899 00 59972 00 Tip Tube Combo Wrench Not Supplied in Bell Cup Dielectric G
51. en assembling the Cup Wash Fitting tighten with fingers until an audible click is heard Note Be careful not to drop the Cup Wash Ferrule Make sure when assembling the Cup Wash Fitting that the ferrule taper end is inserted into the Cup Wash Fitting Step 5 Insert the Bell Cup Removal Tool A12899 in the hole located on the Shape Air Ring and align with the hole in the Turbine Shaft Aerobell 168 Maintenance 63 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Step 6 The Bell Cup should turn easily by hand When reassembling the Bell Cup hand tighten is sufficient Step 7 Remove Shape Air Ring Pull straight off Note The Shape Air Ring is sealed with a O ring and may be difficult to remove Note When reassembling an audible Click should be heard Step 8 gt Yellow Line Blue Line Note The Shape Air Ring has a blue alignment mark The blue alignment mark will line up with the yellow dot located on the Atomizer Body and the small yellow line lo cated on the Turbine All three 3 alignment marks will have to be in line when assembling Aerobell 168 Maintenance 64 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Step 9 Note Two 2 locating pins are mounted on the back of the Shape Air Ring to insure proper alignment Step 10 Locate the
52. erior Rinsing Air Supply Valve Manifold omm 1 0 x 8mm O D 197 1 0 x 5 16 WARNING gt hazard exist if ungrounded gt supplied air hoses must metal connections air or fluid are used in ed at a minimum working pressure of 100 the spray area Use plastic non conductive psig 7 bar connections or ensure metal connections are at ground potential A CAUTION PFA hoses must never be replaced with Nylon hoses Only Polyamide Nylon hoses gt Any user supplied fluid hoses must be can be used for air connections Polyure rated at a minimum working pressure of 150 thane hoses are prohibited psig 10 bar Ultra Pure Polytetrafluoroethylene LN 9247 13 1 26 Ransburg AIR FILTRATION REQUIREMENTS Ransb Filt Replacement Description Specifications P Part No HAF 503 HAF 508 RPM 418 gt Air must be properly filtered to ensure extended turbine life and to prevent contam ination of the paint finish Air which is not Pre filter removes coarse amounts of oil moisture and dirt Used upstream of HAF 508 pre filter used in systems with poor air quality Pre filter coalescing type 136 SCFM 98 5 efficien cy particulate removal 3 to 6 micron max aerosol passed 1 0 micron max solid passed 4 micron dependent upon SCFM requirement per applicator one HAF 508 can be used with up to three Aerobell 168 assemblies Bearing
53. es of shaping air ring while installed clean shroud assembly with shaping air ON Clean with a damp rag or soft bristle brush Donotsoak or saturate area to force fluid or paint into the holes or annulus 70 100 SLPM of shaping air is recommended gt Using as atomizer bell with paint buildup will cause a bell imbalance An imbalance bell may cause bearing damage and turbine failure Also any paint residue caught be tween the tapered surfaces can prevent the bell from seating properly and result in an imbalance condition 42 Ransburg A WARNING Those solvents used for cleaning must have a flash point at minimum of 5 C 9 F greater than ambient temperature It is the end users responsibility to insure this condi tions is met Also since electrostatic equip ment is involved these solvents should be non polar Example of non flammable non polar solvents for wipe down are acetate methyl amyl acetate high flash naphtha and mineral spirits a If using rag to hand wipe the Aerobell turbine air should be off but leave shaping air on 70 100 SLPM for shaping air is rec ommended b Do not use conductive solvents such as MEK to clean the Aerobell 168 Vibration Noise If the Aerobell 168 is vibrating or making an un usually loud noise it usually means there is an imbalance situation The atomizer bell may have dried paint on it or the bell may be physically damaged or there may be p
54. est ground object Efficiency of the applicator will also be reduced and damage of failure of the applicator components may occur WRAP PING THE APPLICATOR IN PLASTIC WILL VOID WARRANTY 44 Ransburg A WARNING To reduce the risk of fire or explosion Solvents used for cleaning must have a flash point at minimum of 5 C 9 F greater than the ambient temperature It is the end users responsibility to insure this condi tion is met Since electrostatic equipment is involved these solvents should also be non polar Example of non flammable non polar solvents for cleaning are acetate methyl amyl acetate high flash naphtha and mineral spirits gt Use solvent compatible with the coat ing being applied to clean the exterior of the applicator Use VM 8 P Naptha as a final wipe to remove surface conductivity When using a rag to hand wipe the Aerobell the turbine air should be off but leave both the shaping air and bearing air turned on Ensure that rotation has come to a complete stop AIR FILTERS ELEMENT REPLACEMENT A WARNING gt Introducing air which contains oil mois ture and dirt may cause wear and damage to the bearings It is the user s responsibility to monitor the quality of air and to replace the filter elements as often as necessary Turbine failure caused by poor air quality will not be covered under warranty LN 9247 13 1 Aerobell 168 Maintenance REPLACEME
55. external surfaces of the applica tor using a lint free rag dampened with solvent External surfaces include the shroud and valve module gt After cleaning all conductive residue must be removed using a non conductive solvent since electrostatic equipment is involved these sol vent should also be non polar nspect bell cup for nicks dents heavy scratches or excessive wear Replace if nec essary 43 Ransburg A WARNING gt The high voltage must be turned OFF be fore entering the spray area and performing any maintenance procedures Spray booth exhaust fan s should remain ON while cleaning the equipment with solvents Internal Fluid Path Purge Cleaning and Load Cleaning the incoming paint line from paint supply source such as color manifold through the fluid manifold and bell assembly Open the dump valve and flush the incoming paint line with solvent or an air solvent chop Make sure the last step of the sequence 15 air to purge the dump line of remaining solvent To speed the loading of the new paint leave the dump line open to allow the air in front of the paint push to escape The length of time the dump valve is open depends on several factors such as viscosity paint pressure etc Timing should be such that the dump is closed as the paint reaches the trigger valve in the atomizer Paint in the dump line may cause high voltage issues External Atomizer Surface Cleaning Verify that the hig
56. h voltage is turned off All external surfaces may be cleaned using a mild solvent and lint free rags to hand wipe Turbine drive air must be off butleave bearing air on The shaping air should have approximately 70 SLPM air flow through each to prevent the solvent from entering these passages LN 9247 13 1 Aerobell 168 Maintenance gt Do not spray the unit with a solvent applica tor used for cleaning The cleaning fluid under pressure may aid conductive materials to work into hard to clean areas or may allow fluids to be forced into the turbine assembly Do not reuse an atomizer bell cup that shows any sign of damage such as nicks heavy scratches dents or excessive wear Always final wipe all parts with a non polar solvent and wipe dry high flash Naphtha etc Bell Cup Cleaning Cup Wash Without Cleaning the Incoming Paint Line Turn off the high voltage and trigger valve With the bell spinning at 30 000 rpm turn on the exter nal solvent valve to allow cleaning solvent to flow through the manifold passages through the fluid tube and into the bell cup The spinning bell will atomize the solvent clean out the bell passages Itis always recommended to blow the solvent line dry afterthe cleaning operation Typical bell speed during the cup flush sequence is 30 000 rpm A WARNING gt Never wrap the applicator in plastic to keep it clean A surface charge may build up on the plastic and discharge to the near
57. hich the equipment is to be used and by the instructions in the original language Ransburg AB168 A13350 ATEX PRODUCT MARKING DEFINITIONS Certificate Number Sira 13ATEX5176X Sira Notified Body performing EC type examination 13 Year of certification ATEX Reference to ATEX Directive 5 Protection Concept Code code 5 is titled Encapsulation 176 Document serial number X Special conditions for safe use apply Product Marking 0518 x 12676 Ex Specific marking of explosive protection Equipment Group hazardous area characteristics 2 Equipment Category Type of explosive atmosphere gases vapors or mists T6 Temperature classification Power Supply Marking 0518 II 2 Special conditions for use The 168 Applicator shall only be used with asso ciated 80120 51X or 80100 51X 9060 Power Supply according to configuration drawing A13351 The safe Distance of use for the AB168 Elec trostatic Bell is 204mm minimum from the electrode to earthed parts The end user must ensure this distance as a minimum is maintained and that grounded objects are prevented from contacting the applicator bell cup when the applicator is energized or operating The 9060 and external cascade is intended for Safe Area Use only he 168 Electrostatic Bell is a potential hazard refer to the manufacturers instructions The end user must insure th
58. in the spray area Always turn off the power supply prior to flushing cleaning or working on spray system equipment Unless specifically approved for use in hazardous locations all electrical equipment must be located outside Class or Division 1 or 2 hazardous areas in accordance with NFPA 33 Ransburg AREA Tells where hazards may occur Electrical Equipment e Toxic Substances Spray Area LN 9247 13 1 HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is utilized in the process Arcing in the vicinity 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 Certain material may be harmful if inhaled or if there is contact with the skin Explosion Hazard Incompatible Materials Halogenated hydrocarbon solvents 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
59. inued 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 nothave the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg LN 9247 13 1 Aerobell 168 Safety WARNING gt The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified gt This manual MUST read 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 WARNING gt 5 shown following pages occur during normal use of this equipment Please read the hazard chart beginning on page 2 Ransburg AREA Tells where hazards may occur Spray Area LN 9247 13 1 HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of
60. ions and the heated air will exceed 120 F the heaters must be located after all filters to prevent damage to the filter media LN 9247 13 1 25 Ransburg Aerobell 168 Installation HOSE SPECIFICATIONS Hose Characteristic Paint Supply Applicator 1 4 O D Tube Fitting Paint Supply Valve Manifold omm I D x 8mm O D 197 1 0 x 5 16 O D Option Paint Supply o Valve Manifold 6mm 1 0 x 8mm O D PFA 236 1 0 x 5 16 O D Option Turbine Supply Applicator 6mm 1 0 x 8mm O D Nylon 236 1 0 x 5 16 O D Turbine Braking Air Supply Applicator 6mm I D x 8mm O D Nylon 236 1 0 x 5 16 O D Bearing Air Supply Q Applicator 6mm 1 0 x 8mm O D Nylon 236 I D x 5 16 O D Bearing Air Return Q Applicator 2 mm 1 0 x 4mm Nylon 107 1 0 x 5 32 Shaping Air 1 Applicator 6mm 1 0 x 8mm Nylon 236 1 0 x 5 16 O D Sharping Air 2 Applicator 6mm 1 0 x 8mm Nylon 236 1 0 x 5 16 O D Interior and Bell Cup Exterior Rinsing Air Solvent 1 16 1 0 x 3 32 O D Dump Valve Manifold omm I D x 8mm O D 197 1 0 x 5 16 Option Dump Valve Manifold 6mm I D x 8mm 236 1 0 x 5 16 Option Pilot for all Microvalves 2 mm 1 0 x 4mm 1 0 Nylon 107 1 D x 5 32 O D Interior and Bell Cup Exterior Rinsing Solvent Supply Valve Manifold omm I D x 8mm O D 197 1 0 x 5 16 Interior and Bell Cup Ext
61. ive con tainer for cleaning liquids the containers must be earthed to ground 40 Ransburg MAINTENANCE Good maintenance is essentialto safe and produc tive operation Schedules should be established by the user based on the following general infor mation and observations of the initial production requirements The 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 ap propriate fire extinguishing equipmentis required For details consult the appropriate NFPA safety information your local fire codes local painting equipment standards OSHArequirements as well as your insurance carrier s information Refer to Appendix A for tests for stationary equip ment and test frequency per EN 50 176 A WARNING gt Unexpected robot movement can be haz ardous Do not adjust or repair the Aerobell 168 when the robot is operating or waiting to start The robot must be locked out and secured against restart gt Do not adjust or repair the Aerobell 168 when the power supply is ON Secure the supply against a restart Those solvents used for cleaning must have a flash point at minimum of 5 C 9 F greater than ambient temperature It is the end users responsibility to insure this condi tions is met gt Never remove Aerobell 168 while i
62. ld be inserted first into the part APPLICATOR END CASCADE END A13386 XX Using the applicator end of the cable loosen the strain relief and remove the cable from the High Voltage Connector Thread and tighten the High Voltage Connector into the Port marked HV on the back ofthe applicator Insert the cable through the strain relief until contact is made with the re sistor Tighten the strain relief to secure the cable Insert the cascade of the A13348 XX cable end into the external cascade as shown A13382 00 ys A13386 XX 22 _ Z LN 9247 13 1 34 168 Installation Ransburg 35 ALVIN LNIVd AlddNS 0906 GALNNOW ININS9 4399141 NNO aD 0350 103705 10804 HIOO8H LNIVd TIVA WAWA IddAS WOJ MOLVANDAN TAC v ES SETS W3dld SSV IDIX3 ld i J18vo AH mm Alddns M3MOd 0906 LN 9247 13 1 Ransburg OPERATION A WARNING gt Operators must be fully trained in safe operation of electrostatic equipment Oper ators must read all instructions and safety precautions prior to using this equipment see NFPA 33 EN 50 176 gt Electrical discharge on high electrical capacitance fluid paint system can cause fire or explosion with some materials If arcing occurs when a specific material is used turn the system OFF and verify th
63. licator is energized or op erating A WARNING gt Risk of arcing fire hazard The Aerobell 168 must be located a safe distance from the object to be sprayed as well as all other grounded objects The safe distance is 204mm 8 LN 9247 13 1 Aerobell 168 Operation MATERIAL CONDUCTIVITY The Aerobell 168 can be used with a full range of conductive coating materials With coatings having higher conductivity it may be necessary to isolate the material supply tank and hoses from ground If there is any question as to the suitability of spraying a material with the Aerobell 168 contact your Ransburg distributor or representative See the following Warning A WARNING gt Electrical discharge can cause fire or explosion If arcing occurs when a specific coating material is used turn the system off immediately and notify your coating supplier Do not restart system until proper adjust ments are made to your coating material BELL CUPS Do not use any tools or sharp objects to stop the rotation of any bell cup Doing so will result in damage to the plating material on the aluminum bell cups and may cause premature failure of the bell cup or turbine 39 Ransburg TURBINE AIR NOTE If the turbine air is heated check the maximum rated temperature for the air supply tubing to be used Polyethylene tubing is rated for a maximum of 80 F 27 C Nylon tubing is rated for 200 F 95 maximum
64. luid flow rates and viscosities Industrial Fluid tip With pilot operated fluid regulators with high vis cosities and low fluid flow rates Preferred Avoid 38 Ransburg Fluid Flow Rate Check In the test mode the flow rate can be measured by removing the bell cup from the atomizer turning the fluid flow on and capturing the material in a graduated beaker or measuring cup for a fixed period of time shaping air high voltage and turbine air must be off A WARNING gt Danger of shock and or personal injury can occur Proper ground procedures must be followed Personnel must never work around the turbine when the turbine is spin ning or when high voltage is turned on TARGET DISTANCE The distance from the Aerobell 168 atomizer to target affects the spray application For instance closer distances give a smaller spray pattern and greater efficiency Increasing the distance will give a larger pattern and possibly reduce efficiency If the distance is too great material may wrap back on the Aerobell 168 The safe distance for the Aerobell 168 is 204mm or 8 All ground ob jects must be prevented from entering this area A WARNING The safe distance of use for type AB168 Electrostatic Bell is 204mm from the bell cup to earthed parts The end user must ensure this distance as a minimum is main tained and that grounded objects are pre vented from contacting the applicator bell cup when the app
65. ment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation LN 9247 13 1 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 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 nylon fittings or chemically compatible resins b High voltage cascade is encapsulated in di electric oil 9 A recapitulation of the certification marking is detailed in the ATEX section on the next page drawing numbers 80108 A13349 13383 A13384 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 w
66. nector Push to Connect 10mm OD to 6mm OD Tube A11570 06 Reducing Straight Connector Push to Connect 10mm OD to 8mm OD Tube A11570 07 Reducing Straight Connector Push to Connect 12mm OD to 8mm OD Tube A11570 08 Reducing Straight Connector Push to Connect 12mm OD to 10mm OD Tube L f RN Alarm Low Flow Power e Ransburg s 2 A 196302 HEATER LN 9247 13 1 101 Ransburg Aerobell 168 Parts Identification RECOMMENDED SPARE PARTS Part Description Qty 12777 77762 04 12796 00 77591 00 77516 04 77367 00 LSFI0022 04 EMF 203 04 EMF 203 04 A12807 00 A12808 00 78949 00 12409 79001 34 79001 30 79001 41 7554 127 13096 00 13118 00 79001 22 12816 00 79001 04 79001 40 79001 42 79001 44 11119 10 10468 10 13382 00 13288 00 13287 00 13289 00 10468 12 Air Turbine Assembly Collect 8mm Fluid Tube Assembly Fiber Optic Transmitter Assembly Collect 4mm Valve Seat Assembly Fitting 1 4 O D X AN Front Ferrule 1 4 O D Tubing Back Ferrule 1 4 O D Tubing Screw M10 X 16mm Nylon SHCS Screw M12 X 25mm Nylon SHCS Fluid Valve Assembly Fiber Optic Cable Ring Solvent Proof Ring Solvent Proof Ring Solvent Proof Ring Solvent Resistant Tube Receiver 4mm Tube Fitting 4mm O Ring Solvent Proof Tube Fitting 8mm Ring Solvent Proof For all v
67. ng to 5 7 1 cannot be achieved the possible discharge energy shall not exceed 0 24mJ resistance to earth from the suspending point of each workpiece shall not exceed 1 MO The voltage during measurement shall be 500 V or 1000 V The construction of hangers shall ensure that the work pieces remain earthed during the coating process Note Since workpieces are often earthed by metallic hooks it is important to clean these hooks regularly or to design them in such a way that the built up of insulating layers of coating materials is prevented e appropriate grounding of the workpiece accord ing to 5 7 1 cannot be ensured the dissipation of electrical charges at the workpiece by other devices e g ionizers is permitted Such devices shall not ex ceed the permitted discharge energy of the spraying systems for which they are used Moreover these devices shall be submitted to the same test for ad missible discharge energy as the spraying systems they are used with The dissipation device shall be interlocked with the spraying system in such a way to disconnect the high voltage and to stop coating in case of failure of this dissipation device LN 9247 13 1 107 Ransburg Aerobell 168 Appendix A SURVEY OF TESTS TABLE Cont Review amp Testing Effectivity of locally acting n addition to a room protection system localy Evrey 6 fire extinguishing system acting fire extinguishing systems installed fixedl
68. nsa tion on the interior and exterior of the atomizer machine and its components It is even possible that the temperature of the supply air may be be low the booth dew point even without additional expansion cooling Condensationis especially probable in waterborne applications when booth temperature and relative humidity levels are typically maintained very high This condensation will allow sufficient conductivity of the surfaces such that they act as an erratic ground source potential This can cause damage to the equipment It is therefore a requirement that turbine exhaust air temperature be maintained above the booth dew point to prevent condensation from forming on atomizer surfaces Doing so will eliminate moisture as a potential defect in painted surfaces as well as extending equipment life Thus it is recommended thatair heaters be installed into the atomizer air supply lines i e Turbine air The air heaters must be of sufficient capacity capable of raising the incoming air temperature at least 40 F 4 4 C at a flow rate of 60 SCFM per applicator The actual air heater process setting depends on applicator fluid flow rate load booth conditions turbine airflow settings and incoming air tempera ture The heater should be set as low as possi ble sufficient to maintain the applicator surface temperatures above the dew point in the booth LN 9247 13 1 Aerobell 168 Installation Example With the incoming ai
69. nsburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg willassume responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable 109 Ransburg Aerobell 168 Manual Changes MANUAL CHANGE SUMMARY This manual was published to supersede Service Manual LN 9247 13 Aerobell 168 to make the following changes 1 Updated Atex product marking definitions with updated label 80108 Page 7 2 Updated fluid tips Page 9 3 Updated Tables C and D Page 10 4 Added Titanium Bell Cups to drawings Page 11 5 Update distance specifications Page 15 6 Update hose specifications Page 26 7 Added Fluid Tip Stream and Tip Style Use 38 8 Added Exhaust Air Page 40 9 Added Resistor Assembly Page 47 10 Updated Disassembly Procedures steps 18 25 with new pictures Page 76 11 Revised model ordering number added Table J Page 82 12 Updated Tables B and C Page 83 13 Updated Table D Page 84 14 Added Table J Page 85 15 Updated Applicator Parts Breakdown table Page 87 16 A13668 00 was changed from 12892 00 Page 88 17 New drawing of A13401 Machine Mount Kit with Valves Page 89 18 Revised Machine Mount Kit Parts List Page 90 19 Re
70. o 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 for 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 and operated in accordance with NFPA 33 NEC OSHA local country and European Health and Safety Norms Ransburg AREA Tells where hazards may occur Spray Area General Use and Maintenance LN 9247 13 1 HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent Power Supply or Controller shutdown indicates a problem in the system requiring correction Improper operation or maintenance may create a hazard Personnel must be properly trained in the use of this equipment Aerobell 168 Safety SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A distance of 1 inch for every 10KV of output voltage is required at all
71. ono Flex and Dual Flex shaping air configuration for optimum pattern control e 15mm Titanium bell cups are available 30 and 65mm Bell cups are electroless nickel coated Aluminum and Titanium LN 9247 13 1 Aerobell 168 Introduction Proven long life air bearing spindle opeed control This unit has flexibility in speed sensing capability Both magnetic and light sensing for speed reading and control can be utilized Internal and external bell cup wash capability Lightweight Atex approved when properly configured Power supply has di dt function to shut down if current of the system rises too quickly Power supply may be controlled either locally or remotely by PLC or other control feature Figure 1 Aerobell 168 14 Ransburg Aerobell 168 Introduction OPERATING CHARACTERISTICS AND SPECIFICATIONS Atomizer Robot Mount Valves 65mm Maximum Operating Current 80 uA Paint Resistivity 0 1 to 4 9 bar Min 10 bar Max 75 150 psi 5 5 bar Min 7 bar Max 80 100 psi Brake Air 4 bar Min bar Max 60 100 psi Bi See Chart When measured with Ransburg meter 76652 LN 9247 13 1 15 Ransburg Aerobell 168 Introduction OPERATING CHARACTERISTICS AND SPECIFICATIONS FIBER OPTIC SENSOR FLUID TUBE RETAINER ATOMIZER BODY FLUID TUBE SHAPING AIR MANIFOLD FLUID TIP TURBINE TURBINE RETAINING RING SHAPING AIR SHROUD BELL CUP LN 9247 13 1
72. osion Aerobell 168 Safety SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazardous locations the power supply control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas in accordance with NFPA 33 and EN 50176 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible 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 manufacturer 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 application 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 doub
73. ote Be careful not to drop the Cup Wash Ferrule Make sure when assembling the Cup Wash Fitting that the ferrule taper end is inserted into the Cup Wash Fitting Step 5 Remove Shape Air Ring Pull straight off Note The Shape Air Ring is sealed with a O ring and may be difficult to remove Note When reassembling an au dible Click should be heard Aerobell 168 Maintenance 58 Ransburg LN 9247 13 1 Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 30 Bell and Shape Air Ring Yellow Dot Yellow Line Blue Line Note The Shape Air Ring has a blue alignmentmark The blue alignment mark will line up with the yellow dot located on the Atomizer Body and the small yellow line located on the Turbine All three 3 alignment marks will have to be in line when assembling Note Two 2 locating pins are mounted on the back of the Shape Air Ring to insure proper alignment Step 8 Insert the Bell Cup Combo Wrench RPM 419 across the flats located on the Turbine Remove the Bell Cup by hand Bell Cup When reassembling the Bell Cup hand tighten is sufficient 59 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 30 Bell and Shape Air Ring Step 9 The Bell Cup should turn easily by hand Step 10 Locate the Splash Plate that is pressed into the Bell Cup Step 11 Insert the narrow end of the Splash Plate Removal Tool A11388 00 in
74. plash plate Inspect for wear on the bell cup where the fluid leaves the large diameter of the splash plate If any undercut in this area the cup should be replaced If worn replace entire splash plate assembly LN 9247 13 1 Aerobell 168 Maintenance 5 plates may be soaked to loosen dried material Clean with a soft bristle brush Blow out center holes to dislodge material Never use any kind of pick instrument to clean these holes as it will damage them 6 Soaking the bell in solvent may aid in loosening or removing paint build up It is recommended that the splash plate be removed and cleaned separately 7 Use a soft bristle brush dipped in solvent to remove paint build up from the serration cuts paint feed holes or slots and external and internal surfaces of the bell 8 A soft lint free rag dampened with solvent may be used to remove any paint residue from the external and internal surfaces of the atomizer 9 After removing all paint build up or residue rinse the bell in clean solvent and blow dry 10 Before reinstalling the bell on the shaft check the mating surfaces ofthe thread and taperfor any paint build up or residue Also check the fluid tip fluid tube outside diameter and the shaft for any further paint build up These surfaces should be cleaned before installing the bell 11 Itis recommended that extra bell cups be pur chased The cups can then be cleaned off line in an automated cup
75. r temperature at 72 F 22 2 C anAerobell 168 with 65mm bell cup rotating unloaded at 60 krpm has a turbine outlet temperature drop of approximately 28 F 2 2 40 krpm unloaded DT 14 F 10 C Referring to the ASHRAE Psychometric chart the saturation temperature range dew point of a spray booth maintained at 70 75 F 65 70 RH is 62 68 F 21 1 23 9 C 65 70 RH is 16 7 20 Thus it is almost certain that the surface temperatures of the applicator will fall below the dew point of the booth and an air heater will be needed in this case To prevent condensation Ransburg air heater assembly should be assembled after the air filters Reference the current Air Heater Assembly service manual for further information NOTE gt Failure to use air heater may cause damage to equipment or ruin the finished component being processed 30 Ransburg A WARNING gt Arcing fire hazard exist if ungrounded metal connections air or fluid are used in the spray area Use plastic non conductive connections or ensure metal connections are at ground potential gt Do not use PTFE tape or pipe dope on any air beyond the final air filter for BEARING AIR The tape or dope may break free and cause plugging of the turbine air bearings and result in turbine failure See pages 23 amp 24 for tubing connections and sizes Bearing Use tubing clear see through nylon natural to connecta p
76. rease Removal Tool Tool Kit Removal Tool Not Supplied in Tool Kit A12088 00 Turbine Retaining Ring Wrench LN 9247 13 1 49 Ransburg Aerobell 168 Maintenance OPTIONAL TOOLS REQUIRED TO DISASSEMBLE AEROBELL Use the following optional tools to disassemble the Aerobell 168 A11388 00 A11922 00 A10766 00 5mm Hex Key 5 16 amm Hex 3 8 Hex Key Splash Plate Microvalve Microvalve Seat Wrench Key Wrench Wrench Removal Tool Removal Tool Removal Tool NOT supplied NOT supplied with NOT supplied with the tool kit the tool kit with the tool kit A11373 00 Tubing Removal Tool A12939 Insert Tool NOT supplied in the tool kit LN 9247 13 1 50 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 15mm Bell Cup and Shape Air Ring NOTE gt Mean time to repair entire assembly Is 60 Minutes Step 1 Place the Aerobell 168 on a clean stable working surface or mount Step 2 Remove the Shaping Air Shroud by hand no tool required LN 9247 13 1 51 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 15mm Bell Cup and Shape Air Ring Step 3 Locate the Cup Wash Fitting that is mounted on the Shape Air Ring Step 4 Make sure when assembling the Cup Wash Fitting that the ferrule taper end is inserted into the Cup Wash Fitting Remove the Cup Wash Fitting from the Shape Air Ring When assembling the Cup Wash Fitting tighten with fingers until an audible click is heard Note
77. roperly filtered air source to the bearing air fitting on the manifold It is recommended to use tubing clear see through for bearing air so that any contamination that gets past the final bearing air filter will be apparent Also refer to the previous Caution Under the Operation section which follows there is a Caution regarding bearing damage if the turbine is run while bearing air is off Since the turbine must not be operated without first turning on bearing air it is required to provide some means of assuring the presence of bearing air before turning the turbine On One method is by interlocking the turbine drive air to the bearing air i e with an air piloted valve gt Provisions should also be made to as sure bearing air remains on during the coast down period when turbine air is turned off See Specifications in the Introduction section of this manual LN 9247 13 1 Aerobell 168 Installation Brake Air NOTE Brake air is used to slow the turbine when changing speed It is recommend ed that the brake air turbine drive air be interlocked Turbine Turbine drive air must be interlocked with paint flow Damage to spindle will occur if paint is triggered without the bell cup spinning It is recommended that the bell cup is spinning at least 10 000 rom before any fluid is turned on FLUID CONNECTIONS See pages 24 amp 26 for connections See the following
78. s sufficient Step 9 The Bell Cup should turn easily by hand Step 10 Locate the Bell Cup Insert A12938 00 that is screwed into the Bell Cup Note the two 2 holes located in the Bell Cup Insert Aerobell 168 Maintenance 55 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES 15mm Bell Cup and Shape Air Ring Step 11 Insertthe Insert Tool 12939 into the two 2 holes in the Bell Cup Insert located on the back side ofthe Bell Cup Remove the Bell Cup Insert Step 12 15mm Bell Cup Insert Tool A12939 00 Step 13 Use care when inserting the Bell Cup Insert to prevent stripping the threads Note To continue the process of disas sembly procedures of the Aerobell 168 go to Step 14 on page 67 Aerobell 168 Maintenance 56 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 30 Bell and Shape Air Ring NOTE gt Mean time to repair entire assembly Is 60 Minutes Step 1 Place the Aerobell 168 on a clean sta ble working surface or mount Step 2 Remove the Shaping Air Shroud by hand no tool required Step 3 Locate the Cup Wash Fitting that is mounted on the Shape Air Ring LN 9247 13 1 57 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES 30mm Bell Cup and Shape Air Ring Step 4 Remove the Cup Wash Fitting from the Shape Air Ring When assembling the Cup Wash Fitting tighten with fingers until an audible click is heard N
79. st be proved to be working effectively Safe disconnection of high The disconnection threshold shall be defined and voltage shall be tested for documented with respect to operational and local voltage controlled and con conditions stant voltage operation be tested if the high voltage is disconnected in case of inadmissible increase ofthe operational current h and if the disconnection threshold is reached n this context the disconnection threshold defined during the initial test shall be checked e A disconnection threshold giving rise to expect an occurrence of hazardous discharges or flashover between parts under high voltage and earthed parts of the plant in case the safety distance drops below the permissible limit is not permitted Safe disconnection of high e Validate safety circuits are performing as designed voltage shall be tested for voltage controlled and con stant voltage operation Protection against too Discharge energy must be less than 300 mJ prior to high discharge energy reaching the parts Protection against ignition of Use non flamable cleaning agents if possible cleaning agents Those used for equipment flushing should have flash points equal to or higher than those of the coating material hose solvents used for cleaning must have a flash point at minimum of 5 C 9 F greater than the am bient temperature It is the end users responsibility to insure this
80. t as to whether or not a coating or cleaning material is compatible contact your coating supplier Any other type of solvent may be used with aluminum equipment Ransburg Aerobell 168 Atex FM EUROPEAN ATEX DIRECTIVE 94 9 II 1 0 6 The following instructions apply to equipment covered by certificatenumber Sira 13ATEX5176X 1 The equipment may be used with flammable gases and vapors with apparatus groups and with temperature class T6 2 The equipment is only certified for use in am bient temperatures in the range 0 C to 40 C and should not be used outside this range 3 Installation shallbe carried outby 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 equip
81. t is under pressure gt If ignitable fluids are used for cleaning purposes all parts must completely dis charged of high voltage LN 9247 13 1 Aerobell 168 Maintenance A WARNING gt Electrical shock arcing and fire hazards can exist during maintenance The high volt age must be turned off before entering the spray area and performing any maintenance procedures Spray booth exhaust fan s should remain on while cleaning the equip ment with solvents gt Never touch the atomizer bell while it is spinning The front edge can easily cut into human skin Make sure the atomizer bell has stopped spinning before attempting to touch it Wait at least a minimum of 1 minute after turbine air is off before touching the bell gt Do not immerse the Aerobell 168 turbine in solvent or other liquids Turbine compo nents will be damaged gt Bearing air must be on during all clean ing procedures gt If the Aerobell 168 is sprayed off with a solvent applicator for cleaning the turbine should be turned on as well as shaping air high voltage off Air exhaust from the tur bine and shaping air form a curtain around the back edge of the bell and help prevent solvent from getting into the cavity behind the bell Do not direct at the opening behind the edge of the bell as this may allow sol vent to be forced into the turbine 41 Ransburg O RINGS All O rings in this atomizer are solvent proof ex cept th
82. the plastic SHCS from the Mounting Yoke using the 3 8 Hex Key Wrench Step 8 Remove the plastic SHCS from the Valve Manifold using 5 16 8mm Hex Key Wrench Step 9 Remove the plastic Wash Cup Y Fitting from the Valve Manifold by hand no wrench required Aerobell 168 Maintenance 73 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES For Robot Machine Mount Kits Step 10 Remove the plastic Fluid Tube Fitting and Fluid Tube Coil from the Valve Manifold using the Adjustable Wrench Step 11 To remove the Microvalve Assembly use the Microvalve Removal Tool A11922 00 Notice the small threaded shaft protruding from the tool and the four 4 locating pins Microvalve Assembly Threaded Shaft Locating Pin Microvalve Removal Tool A11922 00 Step 12 Align and insert the four 4 locating pins on the Microvalve Removal Tool into the Microvalve Assembly four 4 holes Secure the Microvalve Removal Tool by hand tightening the threaded shaft atthe knurled end of the tool Aerobell 168 Maintenance 74 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES Robot Machine Mount Kits Step 13 After securing the Microvalve Re moval tool to the Microvalve Assem bly loosen the Microvalve Assembly with the Adjustable Wrench Step 14 Remove the Microvalve Assembly When reassembling the Microvalve Assembly tighten to 15 20 1 Ibs 1 68 2 24 N m Step 15 Using the
83. times Unless specifically approved for use in hazardous 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 combustible materials The current overload sensitivity if equipped MUST be set as described in the corresponding section of the equipment manual Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which requires correction Always turn the control panel power off prior to flushing cleaning or working on spray system equipment Before turning high voltage on make sure no objects are within the safe sparking distance Ensure that the control panel is interlocked with the ventilation system and conveyor in accordance with NFPA 33 EN 50176 Have fire extinguishing equipment readily available and tested periodically Personnel must be given training in accordance with the requirements of NFPA 33 EN 60079 0 Instructions and safety precautions must be read and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance housekeeping Reference OSHA NFPA 33 EN Norms and your insurance company requirements Ransburg ARE
84. to the hole on the back side of the Bell Cup Using ahard thrustfrom the palm of your hand remove the Splash Plate LN 9247 13 1 60 Ransburg Aerobell 168 Maintenance LN 9247 13 1 DISASSEMBLY PROCEDURES 30 Bell and Shape Air Ring Step 12 30mm Bell Cup mmn Splash Plate Plate Removal Tool Step 13 Toreassemble the Splash Plate place the Bell Cup with the back down on a flat surface and insert the Splash Plate into the Bell Cup hole Using the large end of A11388 00 Splash Plate Removal Tool gently push into position Until an audible click is heard Note Tocontinue the process of disassembly procedures of the Aerobell 168 go to Step 14 on page 67 574 544 14 58 13 81mm BELL CUP REAR FACE TO SPLASH PLATE INSERT FACE Step 13A Verify depth of insert to dimension shown 61 Ransburg Aerobell 168 Maintenance DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring NOTE gt Mean time to repair entire assembly Is 60 Minutes Step 1 Place the Aerobell 168 on a clean stable working surface or mount Step 2 Remove the Shaping Air Shroud by hand no tool required Step 3 Locate the Cup Wash Fitting that is mounted on the Shape Air Ring LN 9247 13 1 62 Ransburg LN 9247 13 1 DISASSEMBLY PROCEDURES 65mm Bell Cup and Shape Air Ring Step 4 Remove the Cup Wash Fitting from the Shape Air Ring Wh
85. upplies 80104 01 EXTERNAL CASCADE COMPONENTS 80074 00 7296 00 8521 06 80104 01 79350 01 Not included with the 80104 01 Assembly but with the A13386 XX Assembly 6 LN 9247 13 1 99 Ransburg Aerobell 168 Parts Identification ACCESSORIES LUBRICANTS 59972 00 Dielectric Grease 76652 01 Kit for measuring high voltage Includes Multi Function Meter 76634 00 and High Voltage Probe Assy 76667 00 76652 02 Kit for measuring short circuit current SCI resistance and spray ability Includes Multi Function Meter 76634 00 and Test Lead Assy 76664 00 76652 03 Kit for measuring paint resistivity Includes Multi Function Meter 76634 00 and Paint Probe Assy 7922 00 76652 04 Deluxe Kit performs all functions listed above Includes Multi Function Meter 76634 00 Paint Probe Assy 7922 00 Test Lead Assy 76664 00 and High Voltage Probe Assy 76667 00 A11545 00 Petrolatum Jell Lubricant for all O Rings LN 9247 13 1 100 Ransburg Aerobell 168 Parts Identification SERVICE KITS RPM 32 Pre Filter Replacement Element RPM 33 Bearing Air Filter Element A11570 01 Reducing Straight Connector Push to Connect 6mm OD to 4mm OD Tube A11570 02 Reducing Straight Connector Push to Connect 8mm OD to 4mm OD Tube A11570 03 Reducing Straight Connector Push to Connect 8mm OD to 6mm OD Tube A11570 04 Reducing Straight Connector Push to Connect 10mm OD to 4mm OD Tube A11570 05 Reducing Straight Con
86. vised Table Page 91 20 New drawing for A13402 Robot Mount Kit with Valves Page 92 21 Revised Robot Mount Kit Parts List Page 93 22 Revised Table Page 94 23 Updated Recommended Spare Parts List Page 102 105 LN 9247 13 1 110 Ransburg Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Philips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No LN 9247 13 1 2014 Finishing Brands Inc All rights reserved Litho in U S A Models and specifications subject to change without notice 5 14
87. y 6 Any other interlocks required by local code national code or international code 7 High voltage must be interlocked with the booth entry door 8 High voltage must be interlocked through the power unit with conveyor and booth fan air Ref erence manual CP 13 02 for procedures LN 9247 13 1 Aerobell 168 Installation A WARNING gt When the turbine air is turned off the turbine will continue to operate or coast down for about two minutes Provisions should be made to assure that the operator waits at least three minutes after shutting off the turbine air and before shutting off the main air supply gt Under normal operation the high volt age and or coating material must never be turned on unless the bell cup is mounted on the motor shaft and the turbine is rotating gt Pneumatic input to the turbine air inlet must be controlled to prevent the turbine from exceeding the maximum rated speed of 60 000 rpm See Specifications in the Introduction section gt High voltage must never be turned on while cleaning solvent is being sprayed ther through the applicator supply or the cup wash line High voltage and solvent trig ger must be interlocked Never spray solvent with high voltage on gt The bell cup must be removed when making flow checks If the paint is turned on when the bell is mounted and the turbine shaft is not rotating paint will enter the shaft and possibl
88. y damage the air bearing Mate rial flow checks flow rate verification must be made with the bell cup and the turbine not rotating Normally pneumatic interlocks will not allow the paint to trigger on when the turbine air is off These interlocks may need to be by passed with proper safety proce dures as required gt Bell cup must be rotating at least 10 000 rpm when fluid is triggered Turning on fluid without the bell cup spinning may flood the turbine and cause damage to components 32 Ransburg HIGH VOLTAGE CABLE ASSEMBLIES General Instructions 1 When routing cable ensure that no chaffing binding or pulling cable will occur Maintain at least a 4 inch 100mm bend radius When possible sleeve cable with the appropriate sized tubingfor external cable protection Torsion stress should be minimized 2 Considerations should be taken when routing cables next to other cabling and fluid tubing Be cognizant of the placement of such cable near control wires and fluid lines Follow NEC or EN standard wiring standards where applicable Separation of AC control wiring and fluid tubing is advisable 3 ensure that all cable connections are clean and free of foreign materials wipe with Naphtha This also applies to the cascade splitter and applicator connectors gt Do not use any di electric grease or oil on any of the cable connections or on the ca bles themself Damage to cables will occur
89. y months and allocated to the object shall give effective protection for the hazard zone between the outlet of coating materials and the workpiece It shall be proved for each individual case if the aspects of the locally acting fire extinguishing systems and the room protection system could be satisfied by one fire extinguishing system Electrostatic spraying systems shall be equipped with locally acting automatic fire extinguishing sys tems which are actuated immediately in case of fire When the fire extinguishing system has been activated the high voltage supply the supply of coating materials and the pressurized air shall be cut off automatically EN 13478 shall be observed It shall be checked in each individual case whether a present room protection system is also able to fulfill the function of a locally acting automatic fire extin guishing system Conductive parts of the Where conductive parts are used for the coating spraying material supply material supply system these parts shall be either system bonded to earth or connected with the high voltage supply system so that the potential level is invari ably identical with that of the electrostatic spraying system Minimum clearance Insure all earthed items are outside the safe use air distance of 204mm Other tests compliance with EN 12215 2004 Tc pines WI EN 12215 2004 LN 9247 13 1 108 Ransburg Aerobell 168 Warranty Policy
90. ycle times and may be used for stopping the turbine Use of the brake involves 1 turning off turbine drive air and then 2 turning the brake air on for a short duration Brake air should be interlocked so that it is impos sible for air to be applied to the braking system while the turbine air is on A WARNING gt Electrical discharge of a high electrical capacitance fluid paint system can cause fire or explosion with some materials If arcing occurs when a specific coating ma terial is used turn the system off an verify that the fluid is non flammable In these conditions the system is capable of releas ing sufficient electrical and thermal energy to cause ignition of specific hazardous materials in the air ELECTROSTATIC VOLTAGE Depending upon the power supply model used the maximum output voltage of the power supply can vary The actual voltage setting will depend upon various coating application requirements The level of voltage applied to the Aerobell 168 plays an important role with regard to pattern size efficiency wrap penetration into cavity areas and target distance 37 Ransburg SHAPING AIRS Shaping air is used to shape the spray pattern Thelowerthe pressure the widerthe pattern and conversely higher pressures result in narrower patterns Shaping air does not help atomize the material but does assist in the penetration of atomized particles into cavity areas Shaping air should be kept

Aerobell 168 Atex MODEL:13350 (Serv. Man. LN

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