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Manual - Finishing Technologies

1. DOOR TO CABINET GROUND 1REC N NEUTRAL LINE CORD POWER CONNECTIONS As outlined in NFPA 33 and OSHA the AC power line must be series interlocked with both the exhaust fan and conveyor Figure ac Power Supply Sehamatic To install the power supply interlocks perform the following 1 Turn the power supply off disconnect it from its A r nd remove the f 2 Open the power supply cabinet door 25 06 02 11 ITovRansburg AWARNING ALWAYS double check that the power supply is unplugged from its AC outlet before working with any internal wiring 3 Using a small blade screwdriver remove the factory installed test jumper from TB1 L2 to TB1 L3 4 Using a shielded cable for the interlock wiring supplied by user route through the interlock connector on the rear of the power supply and terminate TB1 L2 and TB1 L3 as shown in Figure 9a The shielded cable must have a minimum rating of 300V and 105 C and its conductors should be 0 8mm 18 AWG minimum Secure the cable to the interlock connector as described in I O Connections inthe Installation section of this manual so that the shield of the cable is connected to the chassis of the enclosure NOTE Some codes may require the interlock wiring to be run in conduit In this case shielded cable is not necessary but the conductors used should still meet the rat ings specified above
2. o o o En Ver FDBK LOCKOUT JUMPER LOCATIONS Figure 16 Lockout Jumper Location Front Panel Lockout This feature locks out any changes to the kV setting from the front panel of the power supply 1 Setthe kV to the desired value using the front panel buttons This must be set prior to installing the jumper 2 Turn AC power off and access the interior of the power supply 3 Place the jumper across the two 2 pins at location 16 on the main PC board see Figure 17 4 Close the power supply and turn AC power back on Pressing the front panel or setpoint buttons will now have no affect on the kV setting ITovRansburg L JUMPER 16 INSTALLED FRONT PANEL CONTROL DE ACTIVATED Figure 17 Jumper Location Front Panel Lockout Overload Activation The overload circuit may be activated for applications that reguire overload indication or notification of high current draws of the applicator The overload value is set in the software to the maximum microamp rating minus 10 microamps 1 Turn AC power off and access the interior of the power supply 2 Plac
3. DESIGNATIONS E DESIGNATIONS A DESIGNATIONS Ex LE P CONFIGURATION DWG 79950 REV B AH 06 02 11 IT Ransburg OPTION A DESIGNATIONS CABLE LENGTH 0 FOR NO CABLE 1 FOR 10 METER CABLE PART NUMBER 79519 10 i 2 FOR 15 METER CABLE PART NUMBER 79519 15 3 FOR 20 METER CABLE PART NUMBER 79519 20 4 FOR 25 METER CABLE PART NUMBER 79519 25 5 FOR 30 METER CABLE PART NUMBER 79519 30 OPTION B DESIGNATIONS L TRIGGER 2 FOR TWO FINGER TRIGGER PART NUMBER 79325 02 4 FOR FOUR FINGER TRI GGER PART NUMBER 79325 04 OPTION C DESIGNATIONS FLUID HOSE LENGTH amp TYPE 0 FOR NO FLUID HOSE 1 FOR WATERBORNE FLUID HOSE 1 4 ID X 10m 30ft PART NUMBER 79525 10 2 FOR WATERBORNE FLUI D HOSE 3 16 ID X 10m 30ft PART NUMBER 79524 10 3 FOR WATERBORNE FLUID HOSE 1 4 ID X 15m 50ft PART NUMBER 79525 15 4 FOR WATERBORNE FLUID HOSE 3 16 ID X 15m 50ft PART NUMBER 79524 15 n 3 OPTION D DESIGNATIONS SPRAY TECHNOLOGY 0 FOR STANDARD SPRAY 65V CAP 44 NOZZLE PART NUMBER 79374 65 amp 79377 44 1 FOR STANDARD SPRAY 65V CAP 45 NOZZLE PART NUMBER 79374 65 79377 45 2 FOR TRANSTECH SPRAY 122V CAP 245 NOZZLE PART NUMBER 79374 122 am
4. 6 Use the special multi purpose wrench to loosen the retaining nut that secures the barrel to the AH 06 02 11 ITovRansburg applicator handle After unscrewing the nut slide itforward onto the barrel 7 Holdthe applicator handle and fluid tube so the barrel points downward With the other hand pull the barrel forward to separate it from the handle Once the barrel has cleared the handle remove the spring from the spring retainer and set it aside 8 Thereis no needtoremovethe retaining ring or nut from the barrel unless they are damaged If they areto be replaced liftone end of retaining ring overthe captive ridge and spiral it off the end ofthe barrel Then the retaining nut can be removed Usecare in removing the retaining ring If itis spread too much it could break DISASSEMBLY REASSEMBLY OF BARREL WITH THE 2K FLUID NEEDLE PACKINGS Disassembly 1 Remove the trigger adjustment nut and spring retainerfromthe needle shaft using two 3 8 open end wrenches 2 Position the barrel so the front is facing down Using the small spanner tool on the special multi purpose wrench unscrew the packing nut from the rear of the barrel by turning itcounter clockwise 2 Figure 28 Removal of Needle Shaft AH 06 02 11 3 Holdthe barrel in one hand and with a firm pull remove the needle shaft assembly from the packing chamber of the barrel The trigger adjustment nut can be reinstalled for additional grip
5. MI zb E Figure 25 Reinstalling Fluid Nozzle NOTE gt DO NOT over tighten the fluid nozzle into the barrel Doing so could damage or break the fluid nozzle or damage the thread of the barrel 4 Install the air cap and retaining ring onto the applicator refer to Air Cap Reinstall in the Maintenance section AH 06 02 11 NEEDLE ELECTRODE Removal 1 Remove the air cap and fluid nozzle from the applicator assembly 2 Secure the needle shaft at the rear of the barrel and unscrew the needle electrode from the needle shaft Cleaning and Inspection 1 Use a suitable solvent to clean the needle electrode 2 Examine the needle electrode for damage or wear Pay special attention to the area where the wire electrode extends from the main body This is a sealing surface that seats inside the fluid nozzle Ifthere are signs of wear inthis area both the needle electrode and fluid nozzle must be replaced 3 An electrical check of the needle electrode must be done prior to reinstalling it into the applicator assembly Referto Needle Electrode Resistance Testing inthe Maintenance section Reinstall 1 Securethe needle shaft atthe rear ofthe barrel and screw the needle electrode into place by hand 2 Reinstall the fluid nozzle and air cap onto the barrel Vector R Series Classic Applicators Maintenance 46 Vector R Series Classic Applicators Maintenance NEEDLE ELECTRODE RESISTAN
6. AH 06 02 11 rrv Ransburg VECTOR R70 CLASSIC SOLVENT BASED 79504 ABCDE BASE OPTION MODEL NO DESIGNATIONS ORDERING INFORMATION ONLY D DESIGNATIONS d C DESIGNATIONS BEEN S 9 E DESIGNATIONS A DESIGNATIONS i CONFIGURATION DWG 79949 REV B AH 06 02 11 rrv Ransburg OPTION A DESIGNATIONS CABLE LENGTH i 0 FOR NO CABLE mm 1 FOR 10 METER CABLE PART NUMBER 79518 10 Th 2 FOR 15 METER CABLE PART NUMBER 79518 15 ANA 3 FOR 20 METER CABLE PART NUMBER 79518 20 TAN 4 FOR 25 METER CABLE PART NUMBER 79518 25 5 FOR 30 METER CABLE PART NUMBER 79518 30 OPTION B DESIGNATIONS N lt TRIGGER TYPE LE Sy 2 FOR TWO FINGER TRIGGER PART NUMBER 79325 02 i 4 FOR FOUR FINGER TRIGGER PART NUMBER 79325 04 OPTION C DESIGNATIONS FLUID DELIVERY COMBI NATION 1 OFFSET WITH 093 ID FLUID TUBE PART NUMBER 79438 00 amp 9704 16 2 45 WITH 093 ID FLUID TUBE PART NUMBER 79439 00 amp 9704 16 3 OFFSET STAINLESS WITH 093 ID FLUID TUBE PART NUMBER 79438 01 amp 9704 16 4 OFFSET WITH 250 ID FLUID TUBE PART NUMBER 79438 00 amp 9704 11 5 45 WITH 250 ID FLUID TUBE PART NUMBER 79439 00 amp 9704 11 6 OFFSET STAINLESS WITH 250 ID FLUID TUBE PART NUMBER
7. 79438 01 amp 9704 11 7 OFFSET WITH 125 ID COILED FLUID TUBE PART NUMBER 79438 00 amp 79871 00 OPTION D DESIGNATIONS SPRAY TECHNOLOGY 0 FOR STANDARD SPRAY 65V CAP 44 NOZZLE PART NUMBER 79374 65 amp 79377 44 1 FOR STANDARD SPRAY 65V CAP 45 NOZZLE PART NUMBER 79374 65 79377 45 2 FOR TRANSTECH SPRAY 122V CAP 245 NOZZLE PART NUMBER 79374 122 amp 79552 245 3 FOR ROUND SPRAY PART NUMBER 79962 00 amp 79959 00 APPROVED SPARE FLUID NOZZLES LIST 79377 46 1 06mm ID STD WEAR 79377 47 71mm ID STD WEAR 79377 48 1 19mm ID STD WEAR 79377 144 1 40mm ID HIGH WEAR 79371 145 1 78mm ID HIGH WEAR 79377 146 1 06mm ID HIGH WEAR 79377 147 71mm ID HIGH WEAR 79552 244 1 40mm ID STD WEAR 79552 344 1 40mm ID HIGH WEAR 79552 345 1 78mm ID HIGH WEAR OPTION E DESIGNATIONS CONTROL UNIT Ub E EF 0 FOR NO CONTROL UNIT E Ph 1 FOR DOMESTIC SALES 110 120 V PART NUMBER 79344 111 HE 2 FOR EXPORT SALES 240V 50 60 Hz PART NUMBER 79344 112 me A CONFI GURATI ON DWG 79949 REV B AH 06 02 11 11 rrv Ransburg VECTOR R90 CLASSIC WATER BASED 79520 ABCDE BASE OPTION MODEL NO DESIGNATIONS ORDERING INFORMATION ONLY D DESIGNATIONS B DESIGNATIONS
8. an air flow switch is activated the kV setpointis displayed on the kV display the actual current draw on the pA display and the high voltage light illuminates Under the pA display is abar graph meter that illuminates according to the actual current draw uA BAR GRAPH METER FAULT YA RESET Figure 13 pA Bar Graph Meter Display The green and yellow regions of the bar graph meter indicate output current is in the optimum range for maximum transfer efficiency The red region ofthe bargraph indicates high output current causing decreased transfer efficiency Measuring High Voltage On Time The 9050 Power Supply records the amount of time the high voltage is triggered on up to 99 999 hours This value is displayed on the kV and pA displays of the unit There are two registers that retain this information one that may be reset the otherthatis permanently retained in memory The number of hours the unit s high voltage has been on may be displayed by depressing at the same time the preset 1 and reset buttons The display will show hours of use for 3 seconds This is the resettable register AH 06 02 11 DISPLAY OF HV ON TIME IN HOURS 16 TE lA Ransburg eg m3 PRESS AND HOLD BOTH FOR RESETTABLE ON TIME REGISTER Figure 14 Displa
9. 240 VAC Current 1A max RMS Frequency 50 60 Hz Wattage 40 watts max Output Voltage Current Physical Height Width Depth Weight Pneumatic Supply Air 20 65kV DC 79344 11X 20 90kV DC 79344 12X 140 microamps max 16 5cm 6 5 inches 37 8cm 14 9 inches 30 7cm 12 1 inches 10 2 kg 22 5 Ibs 6 9 bar 100 psig maximum Control Unit Inputs Outputs 9050 Part 79344 112 79344 121 Voltage Designation 110 120VAC 220 240 VAC 110 120VAC Maximum Output 65 kV DC 90 kV DC 79344 122 220 240 VAC 90 KV DC Control Unit Applicator Combinations 9050 Part For Use With 79344 12X 79520 XXXXX 70 Vector R Series Classic Applicators Waterborne IT Ransburg WATERDORNE COMPATIBLE WATERDORNE COMPATIBLE HK ES Cl Siva HJ HH R 1 MEG OHM Figure 48 R90 Classic Waterborne Typical Installation R90 CLASSIC WATERBORNE TYPICAL INSTALLATION No Description No Deseption AC Line Cord 110 220 9 FluidRegulator 9050 Power Suppl Air Line Vector Applicator High Voltage Cable Ball Valve 12 Fluid Valve Air Regulator W Pressure Gauge Isolated Fluid System Protect
10. 4 D 79555 244 79552 244 1 4mm 055 Acetal 79555 245 1 8mm 070 Acetal 79555 247 0 7mm 028 Acetal 79555 344 1 4mm 055 Peek 79555 345 1 8mm 070 Peek 79555 347 79552 347 0 7mm 028 Peek All Kits Include 79374 122 Air Cap 74963 06 Restrictor green and chosen Fluid Nozzle Kit 79555 replaces parts 74963 05 Restrictor 79377 45 Fluid Nozzle 79374 65 Air Cap NOTE For additional information on Solvent Viscosities and Conversion refer to Technical Manual IL 307 www itwransburg com ACCESSORIES FOR ECON FLUSH BOX COMPATIBILITY OPTIONAL Re 7 582 00 Nozzle Drain Flush Box 77581 00 REA90 to REA70 Adapter Flush Box ITovRansburg AH 06 02 11 ITovRansburg AH 06 02 11 Vector R Series Classic Applicators Parts Identification NOTES 82 Vector R Series Classic Applicators Parts Identification rrv Ransburg VECTOR CLASSIC APPLICATORS RECOMMENDED SPARE PARTS Description 10051 05 14061 05 14061 08 17130 00 18842 01 18842 02 19749 00 3587 02 3587 03 59972 00 70397 01 70397 02 70399 00 70430 01 75326 00 78626 00 78627 04 78627 05 78628 11 78628 12 78630 00 78631 00 78632 00 78633 00 78636 00 79001 06 79001 07 79001 08 79001 09 79001 16 79001 31 79310 00 79322 00 79325 02 up Seal Spring Loaded ponge Conductive Needle onge Conductive Handle pring Return acking Tube R90 acking Tube R70 pplicator Wrench utandFerru
11. 5 Secure the cabinet door replace the fuses and reconnect the AC source NOTE The interlock contacts supplied by user should be rated for at least 1 amp at 240VAC AH 06 02 11 HIGH VOLTAGE CABLE Position the spray applicator in the spray area and route the high voltage cable to the power supply The cable should be routed so that it is not damaged by foot and vehicle traffic and also so that it is not close to areas of high temperature 129 F The operator should have free movement of the applicator andall bendradii ofthe cable should not be less than 6 inches 15cm Connect the high voltage cable to the power supply and tighten the retaining nutand set screw If during the routing of the high voltage cable it is required to remove it from the spray applicator care should be taken when reinstalling so thatthe clip retaining the high voltage cable in the applicator is completely engaged and the high voltage cable retention screw is tightened to 5 7 Ibs in 6 8 Nm see Figure 10 HIGH VOLTAGE CABLE RETAINING CLIP Figure 10 High Voltage Cable Removal and Installation Vector R Series Classic Applicators Installation 26 Vector R Series Classic Applicators Installation 27 AWARNING The electrical discharge that is available from the charging electrode must not exceed 0 25 mJ of energy To achieve this limit any flow of energy from the paint supply through the paint line to the applica
12. R70 Power Supply 220 240 Vector R70 Power Supply 110 120 Vector R90 Power Supply 220 240 Vector R90 1 2 Main PC Board R70 Classic for 79344 11X Main PC Board R90 Classic for 79344 12X 3 AC Line Filter 4 Flow Switch 5 Nut Flow Switch High Voltage Connector Assembl 7 Washer Conduit 8 5307 04 Nut Condut 11 HV Multiplier Assembly Vector R70 65 kV for 79344 11X HV Multiplier Assembly Vector R90 90 kV for 79344 12X e Fuse 220 240 V 0 5 Amp Time Delay 5mm X 20mm Fuse 110 120 V 1 Amp Time Delay 5mm X 20mm 10 EMC Cable Gland Gland Nut 67 AH 06 02 11 I 12 1 1 rrv Ransburg Vector R Series Classic Applicators Waterborne COMPATIBLE COMPATIBLE WATERBORNE APPLICATOR MODEL 79520 XXXXX SECTION A WARNING Typical installations to spray non flammable conductive materials waterborne materials must not be used to handle flammable materials solvent based materials WATERDORNE WATERDORNE COMPATIBLE COMPATIBLE AH 06 02 11 68 Vector R Series Classic Applicators Waterborne IT Ransburg WATERDORNE WATERDORNE COMPATIBLE COMPATIBLE Figure 47 R90 Classic Waterborne Electrostatic Spray Applicator Features R90 CLASSIC WATERBORNE ELECTROSTATIC SPRAY APPLICATOR FEATURES Needle Electrode Description Adjusta
13. Screw Trigger Retention I 46 79521 00 Clip Retaining High Voltage Cable 47 Cable High Voltage for R90 Classic Cable High Voltage for R70 Classic 48 19749 00 Special Applicator Wrench TABLE A High Voltage Cable Lengths o nome TABLE B Trigger Type pass e Description 82 2 Finger Trigger 79325 02 4 Finger Trigger 79325 04 Fluid Delivery Combination 45 Bracket 093 ID Fluid Tube e _ 88 ar or een 7 Offset Bracket 125 ID Coiled Fluid Tube 79650 00 79438 00 10553 05 9871 00 0 63 AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Parts Identification TABLE D SPRAY SELECTION D Dena desernton coe oz os Standard Spray 65V Air Cap 1 4mm Fluid Nozzle 44 79374 65 79377 44 74963 05 Standard Spray 65V Air Cap 1 8mm Fluid Nozzle 445 79374 65 79377 45 74963 05 Trans Tech 122V Air Cap 1 8mm Fluid Nozzle 245 79374 122 79552 245 74963 06 2 Round Spray TABLE E Control Unit Control Description Unit Applicator with Cable Only No Power Supply Domestic Sales 110 120 V 79344 1X1 Export Sales 240 V 50 60 Hz 79344 1X2 VECTOR R90 R70 CLASSIC SOLVENTBORNE MODEL IDENTIFICATION 19503 79504 A B C D E 0 No Cable 0 Applicator Only 1 10m High Voltage Cable 1 Domestic Sales Complete W Power 2 15m High Voltage Cable Supply 110 120 3 20m High Volta
14. atomizer assembly is clean andundamaged NOTE Standard electrode is snap back spray wire electrode Straighten the applicator electrode if neces sary Cleanthe fluid filter if used Turn the power supply power ON Runa current voltage output test Electrical Current Output Test 1 Turn the paint and or solvent supply OFF AWARNING Paint and or solvent supply must be turned off during this test risk of fire or explosion 40 Vector R Series Classic Applicators Maintenance 2 Trigger the applicator high voltage ON 3 Slowly approach the applicator electrode to any grounded object and make contact 4 Monitor the current output reading on the voltage supply meter as the applicator ap proaches ground Upon ground contact the power supply should display atleast 140 pA and the green yellow and red LED s ofthe microamp bar graph meter should all be illuminated uA BAR GRAPH ME T Figure 22 Microamp Meter Current Output Test Reading If the reading is outside of the acceptable range 135 140 microamperes DO NOT use the applicator until the problem has been corrected see Troubleshooting Guide inthe Maintenance section 5 Releasethetrigger high voltage OFF andturn the power supply power OFF Shutdown or at end of each shift 1 Turn the power supply power OFF 2 Turn the paint supply OFF 3 Turn the atomizing a
15. from the rear surface of the barrel packing chamber refer to Figure 34 22 spring retainer in place and screw the fronttrigger adjustment nut rearward until contact is made Use two 3 8 open end wrenches to tighten and lock the adjustment nuts in place on the needle shaft DO NOT overtighten the hexagon adjustment nuts or damage may occur to the plastic threads or the needle shaft may break Finger tight is typically sufficient Maximum torque of 18 24 in oz AH 06 02 11 rrwvRansburg Attaching Barrel to Handle 1 If the barrel retaining nut has been removed it will have to be reinstalled before the barrel can be attached to the handle 2 Place the retaining nut over the rear of the barrel and slide it as far forward as possible 3 Spread the retaining ring and place it onto the barrel Starting at one end lift the retaining ring over the captive ridge and spiral into place 4 Place the large hole of the gasket over the needle shaft and onto the base of the barrel packing chamber 5 While holding the barrel with the air nozzle pointing downward install the needle shaft spring into the spring retainer Align the rear end of the barrel assembly with the matting area ofthe handle assembly and the needle shaft spring with the spring recess in the handle Slide the barrel into the handle cavity until it is seated against the gasket Ensure the needle shaft spring seats properly into the handle
16. in diameter The fan control knob provides control ofthe pattern shaping air Counter clockwise expands the pattern and clockwise reduces it The Vector has a distinct feature that allows counting of clicks The fan valve has 8 clicks per 1 full turn of the adjustment knob To change the spray pattern axis of fan atomizers from horizontal to vertical loosen the air nozzle retaining ring rotate the air cap clockwise to the desired indexed position and gently tighten the ring APPLICATOR TO TARGET DISTANCE Hold the applicator 6 12 inches maximum from the target for best operation higher transfer efficiency will be achieved at the closer target distance Trigger the applicator fully to operate NOTE gt See ITW Ransburg Bulletin Handgun Spray Techniques NOTES ITovRansburg AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Installation FLUID NOZZLE SELECTION STD SPRAY CHART Fluid Nozzle Part Nozzle Material Amm 055 inch 1 2mm 047 inch FLUID NOZZLE SELECTION TRANS TECH CHART Fluid Nozzle Part Nozzle Material AIR CAP FLUID NOZZLE SELECTION CHART Air Spray Trans Tech Spray Air Cap Fluid Nozzle Separate Pressure Part Part Retaining Ring Reducer 79374 122 79552 45 1 8mm 070 79379 00 74963 06 AH 06 02 11 30 Vector R Series Classic Applicators Installation rrv Ransburg AIR CAP FLUID NOZZLE PERFORMANCE CHART Air Pattern Delivery Spray Consumption P
17. separate easily wedge a knife blade be tween them and pry them apart Needle Shaft Insert Removal Figure 30 Chevron Seal Assembly 5 Unscrew needle electrode from shaft and slide the male chevron adapter the chevron seals and female chevron adapter off the shaft see Figure 30 6 Remove retaining ring and air cap from barrel 7 Loosenthe fluid nozzle using the special multi purpose wrench and unscrew itby handto remove rr Ransburg Cleaning and Inspection 1 Clean the packing chamber of the barrel witha suitable solvent anda soft bristle bottle brush DO NOT submerge or soak the barrel in solvent If the chamber has dry paint in it and cannot be cleaned out the barrel MUST BE REPLACED Soaking or submerging the barrel could allow solvents into the high voltage section of the barrel leading to applicator failure and or possible dangerous conditions that could result in property damage and personnel injury 2 Examine the plastic section of the needle shaft and the packing tube for signs of carbon tracking Also inspect the air passages and packing chamber of the barrel for signs of scratches additional carbon tracking or dried paint Shine a smallflashlight intothe front ofthe barrelto highlight any damage in these areas 3 From time to time it is desirable to test the electrical integrity of the 70430 01 resistive electrode see Needle Electrode Resi
18. to ensure that the warnings and requirements for operating and servicing safely are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 OSHA and all related country safety codes prior to installing operating and or servicing this equipment The fluid lines and fluid sources MUST be isolated from ground for waterborne applications Personnel MUST be GROUNDED to prevent a shock or spark during electro static operation Install and route the hoses and cable so they are NOT exposed to temperatures in excess of 120 F and so that all hose and cable bends are NO LESS than a 6 inch 15cm radius Failure to comply with these parameters could cause equipment malfunc tion that might create HAZARDOUS CONDITIONS ITovRansburg AWARNING NEVER wrap the applicator associated valves and tubing and supporting hardware in plastic to keep it clean A surface charge may build up on the plastic surface and discharge to the nearest grounded object Efficiency of the applicator will also be reduced and damage or failure of the appli cator components may occur WRAP PING THE APPLICATOR IN PLASTIC WILL VOID WARRANTY Only ap proved applicator covers should be used NOTE Aseachinstallation is unique this infor mation is intended to provide general instal lation information for the 9050 Power Sup ply Consult your authorized ITW Rans burg dis
19. 0 manner as described in the preceding paragraph Special fittings have been provided on the control panel for termination of these cables at that point The use of these fittings is described in the corresponding sections of this manual Usingthe methods previously described the 9050 Control Unit and Power Supply have been successfully tested to the stringent standards of the Electromagnetic Compatibility Directive of the European Union The results conclude thatthese units are neither a source of electrical noise nor affected by electrical noise when the above methods are utilized 360 Termination to ground good shielding Figure 5 Pigtailing Connection AH 06 02 11 I O CONNECTIONS For maximum noise immunity I O wiring should be run in conduit or cables having a foil shield with an overall braided shield The foil shield provides 100 shielding while the braid provides a means of making proper 360 shield terminations at the cable to cabinet connection points To make I O connections using shielded cable perform the following 1 Remove the cable grommet hardware from the desired I O connector housing see Figure 6 2 Route the desired length of I O cable through the connector housing and mark 1 span of cable that passes through connector housing to be stripped to braid see Figure 7 3 Remove cable and strip marked 1 section to cable braid 4 Slide the cable grommet hardware onto
20. 7862811 7862812 7863000 7863100 P 7863200 7868300 5 7863600 79001 06 7900107 79000108 700109 7900116 7900131 7031000 7932200 7 79325 02 7937300 79374 65 7937498 7037744 7937745 7937800 7937900 79350 79044530 7945000 7945400 7946565 7946585 Continued On Next 83 AH 06 02 1 1 rrv Ransburg Vector R Series Classic Applicators Parts Identification VECTOR CLASSIC APPLICATORS RECOMMENDED SPARE PARTS Cont Part Description 7900145 ApplicatorHookSea pp 7951840 High Voltage Cable R70 10m L 1 795190 High Voltage Cable R90 10m C 1 79529 00 15 79560 00 79599 01 79599 02 9704 16 EMF 202 05 EMF 203 05 LSOR0005 17 O Ring Teflon Encapsulated Power Supply Components 13742 01 Air Flow Switch 4 79390 02 Board R90 79390 01 PC Board R70 Classic 2 2 e 2 6 1 1 AH 06 02 11 84 Vector R Series Classic Applicators Warranty Policies ITovRansburg WARRANTY POLICIES LIMITED WARRANTY ITW Ransburg will replace or repair without charge any part and or equipment that fails within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with ITW Ransburg s written safety and ope
21. 863300 SpringRetainer NeedieShaft 7 SI 07 03 Service Instruction 65 AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Parts Identification Figure 45 R90 78628 11 and R70 78628 12 Classic Needle Shaft optional R90 78628 11 AND R70 78628 12 CLASSIC NEEDLE SHAFT OPTIONAL PARTS LIST Figure 45 rem rane Dee ty 1 7043001 Electrode High Flex 1 1 2 78626 00 SealCartidgeNon Adj Assembly 1 1 Shaft Assembly 2 Piece Needle R90 Shaft Assembly 2 Piece Needle R70 Tube Packing R90 Tube Packing R70 6 7900106 O Ring Solvent Proof f Z 8 1005105 CupSeal SpringLoaded 9 7863100 Nut Packing j Li AH 06 02 11 66 Vector R Series Classic Applicators Parts Identification rrv Ransburg d a Sai VIEW W DOOR REMOVED J 52 1 Ya S E n u i3 2 lo NES SIN I CER LIF AT es hee ot EE FET li Aa DE Je re J0 Figure 46 R90 70 Classic Power Supply R90 70 CLASSIC POWER SUPPLY PARTS LIST Figure 46 Pata Description Qty Power Supply 110 120 Vector
22. 90 CLASSIC WATERBORNE ELECTROSTATIC SPRAY APPLICATOR FEATURES o ooooooooooooooo oo oo 69 79520 R90 CLASSIC WATERBORNE SPECIFICATIONS oooooooooooooooooo 70 79344 1XX 9050 POWER SUPPLY ELECTRICAL SPECIFICATIONS 70 R90 CLASSIC WATERBORNE TYPICAL INSTALLATION enn 71 72 WATERBORNE ISOLATION SYSTEM INSTALLATION GUIDELINES 72 WATERBORNE HOSE FITTING INSTALLATION eene 72 73 WATERBORNE FLUID DELIVERY COMPONENTS PARTS 75 76 VECTOR R90 CLASSIC WATERBORNE MODEL IDENTIFICATION Y VECTOR AIR HOSE OPTIONS PARTS LIST o oooooooooooooooooooo m oo oom 78 VECTOR FLUID HOSE OPTIONS PARTS LIST o ooooooooooooooooooooooooooooo oo 78 VECTOR APPLICATOR COVER OPTIONS PARTS LIST enne 79 VECTOR SWIRL NOZZLE OPTIONS PARTS LIST oooooooooooooooooocooooooo oo 79 VECTOR FLUID TUBE OPTIONS PARTS LIST ooooooooooooooooo coco oom 79 TRANS TECH ATOMIZATION PARTS LIST a tette 80 79555 TRANS TECH CONVERSION KITS AVAILABLE nn 81 RECOMMENDED SPARE 5 83 84 WARRANTY POLICIES 85 TE NN 85 AH 06 02 11 ITovRansburg NOTES AH 06 02 11 Vector R Series Classic Applicators Safety SAFETY SAFETY PRECAUTIONS Before operating m
23. ASSIC SOLVENTBORNE ELECTROSTATIC SPRAY APPLICATOR FEATURES weni des anta man er dere vesc etie reet 16 79344 1XX 9050 POWER SUPPLY ELECTRICAL SPECIFICA TIONS mH 17 79344 1XX 9050 POWER SUPPLY 5 18 INSTALLATION 19 32 79503 R90 SOLVENTBORNE 79504 R70 SOLVENTBORNE INSTALLATION an 19 TYPICAL SOLVENTBORNE 19 21 ELECTRICAL NOISE oo eren an 21 22 VO CONNECTIONS on nina 22 23 AG INPUT CONNECTIONS sepini L oer reet t texte es tea eere Eee iia 23 24 INPUT VOLTAGE SELEG TION ori uae tbe vetu ta 24 25 INTEREOGCNKS esteri uy 25 26 HIGH VOLTAGE CABLE bic 5 26 27 RELAY CONTACT 27 PERS E 27 28 an 28 SPRAY PATTERN ADJUSTMENT iie eie ni ses il asian iot asa santai 29 APPLICATOR TO TARGET DISTANCE a ea 29 FLUID NOZZLE AIR CAP SELECTION CHARTS oo oo 30 31 OPERATION 33 38 STARTUP ema ea 33 SETTING AND ADJUSTING OUTPUT VOLTAGSE nenen 33 BASIC OPERATIONS oooooooo oo Women aan 34 er M 35 KV TES JUMPER circa ra ab eer eee ei eeu AA mani 36 FAULT DESC
24. CE TESTING The electrical resistance of the needle electrode should be tested periodically typically on a weekly basis or any time itis removed from the applicator Figure 26 Testing Resistive Electrode To Test 1 Installthe needle electrode ontothe front end of an available needle shaft Be surethatthe needle electrode is completely seated for proper contact between the metal shaft and the threaded insert of the needle electrode 2 Using a VOM meter that will read 15 megohms accurately connect the first meter lead to the metal needle shaft and the second lead to the needle electrode wire The needle electrode resistance should be 14 5to 19 megohms nominal 15 megohms at 9 volts or 12 to 17 megohms at 1000 volts Needle electrodes outside these ranges must be replaced 47 rr Ransburg BARREL ASSEMBLY Removal 1 While holding the barrel with one hand loosen the air cap retaining ring using the other hand 2 Unscrew the retaining ring completely and remove the air cap 3 Using a flat head screwdriver loosen the two 2 shoulder screws that retain the trigger to the applicator handle CCW Figure 27 Barrel Assembly Removal 4 Remove trigger from the applicator handle 5 Using an adjustable wrench unscrew the fluid tube connector from the barrel and slide it down the fluid tube The fluid tube must be removed before removing the barrel to prevent cascade damage
25. Ifthe needle shaft will not pull out ofthe barrel use the following procedure a Remove the needle electrode from the needle shaft b Pull the needle shaft from the rear of the barrel c Place the barrel on a work bench Holding the barrel in one hand with the front pointing upward push a 5 16 inch diameter wooden or plastic dowel rod downthroughthe center bore ofthe barrel This should push all ofthe packing chamber parts out the rear of the barrel NOTE gt The six 6 spring washers will come off the needle shaft assembly at this point During this operation be CAREFUL that the interior surface of packing chamber is NOT damaged marred or scratched This chamber is a seal area and the barrel applicator assembly will have to be replaced if it is damaged gt DO NOT lose any of the spring wash ers The gun MUST have all six 6 cor rectly positioned in order to function prop erly Vector R Series Classic Applicators Maintenance 48 Vector R Series Classic Applicators Maintenance 49 4 Remove the trigger adjustment nut if it was required when pulling the needle shaft from the barrel packing chamber Then removethe packing nut spacer rear seal retainer sub assembly and packingtube fromthe rear ofthe needle shaft The spring loaded u cup and o ring can now be re moved from the rear seal retainer E p tino 2 Figure 29 NOTE gt If the spacer and seal retainer do not
26. NLESS WITH 093 ID FLUID TUBE PART NUMBER 79438 01 amp 9704 16 4 OFFSET WITH 250 ID FLUID TUBE PART NUMBER 79438 00 amp 9704 11 5 45 WITH 250 ID FLUID TUBE PART NUMBER 79439 00 amp 9704 11 6 OFFSET STAINLESS WITH 250 ID FLUID TUBE PART NUMBER 79438 01 amp 9704 11 7 OFFSET WITH 125 ID COILED FLUID TUBE PART NUMBER 79438 00 amp 79871 00 OPTION D DESIGNATIONS SPRAY TECHNOLOGY 0 FOR STANDARD SPRAY 65V CAP 44 NOZZLE PART NUMBER 79374 65 amp 79377 44 1 FOR STANDARD SPRAY 65V CAP 45 NOZZLE PART NUMBER 79374 65 amp 79377 45 2 FOR TRANSTECH SPRAY 122V CAP 245 NOZZLE PART NUMBER 79374 122 amp 79552 245 3 FOR ROUND SPRAY PART NUMBER 79962 00 amp 79959 00 APPROVED SPARE FLUID NOZZLES LIST 79377 46 1 06mm ID STD WEAR 79377 47 71mm ID STD WEAR 79377 48 1 19mm ID STD WEAR 79377 144 1 40mm ID HIGH WEAR 79377 145 1 78mm ID HIGH WEAR 79377 146 1 06mm ID HIGH WEAR 79377 147 71mm ID HIGH WEAR 79552 244 1 40mm ID STD WEAR 79552 344 1 40mm ID HIGH WEAR 79552 345 1 78mm ID HIGH WEAR OPTION E DESIGNATIONS CONTROL UNIT Ur 0 FOR NO CONTROL UNIT 1 FOR DOMESTIC SALES 110 120 V PART NUMBER 79344 121 i 2 FOR EXPORT SALES 240V 50 60 Hz PART NUMBER 79344 122 LONE CONFIGURATION DWG 79948 REV B
27. P DISPLAY 90 kV Classic 65 kV Classic AWARNING DO NOT use a 65 kV Classic applica tor with the 90 kV power supply ITovRansburg SETTING AND ADJUSTING OUTPUT VOLTAGE The voltage on the 79344 1XX power supply is adjustable between 20 kV and full kV DC The factory preset voltages are Preset 1 full kV minus 20 kV Preset 2 full kV minus 10 kV and Preset 3 full kV The Vector spray applicator system has three voltage setpoints 1 2 and 3 Each of these setpoints can be individually adjusted between 20 and full kV using the and buttons on the front panel of the power supply When the or buttons are held in longerthan 1 second the kV display will begin incrementing or decrementing in units of 5 instead of 1 When the applicator trigger is off the present setpoint can be changed by pressing the 1 2 or3 buttons on the front panel SINGLE PUSHES INCREMENT VOLTAGE DOWN OR UP 4 IN SINGLE INCREMENTS HOLDING BUTTON INCREMENTIS VOLTAGE DOWN OR UP IN CREMENTS OF 5 kV SET POINT SELECT BUTTO Figure 12 kV Adjust Setpoint Buttons AH 06 02 11 rrwvRansburg BASIC OPERATIONS Triggering High voltage is actuated by pulling the trigger to start the flow of atomizing and fan control air through the applicator When the applicator is triggered
28. RIPTIONS niiina ite reato receta rte rea E peret ei has aan asn 36 37 Continued On Next Page AH 06 02 11 Vector R Series Classic Applicators Contents IT Ransburg PAGE MAINTENANCE 39 60 SUITABLE SOLVENTS FOR CLEANING VECTOR RIOTO APPLICATOR Seaia Ba bea 39 METER lia 40 41 APPLICATOR ASSEMBLY CLEANING PROCEDURE ettet 41 42 FLUSHING PROCEDURES rettet ttt tt ttt tt ttt tt ena 43 Au Nana 43 TO REMOVE THE APPLICATOR FROM THE WORK SITE ooooooooooooooooooomooo 44 l 44 SANA ora re U uuruuu uu A 45 46 NEDE ELEGTAODE na 46 NEEDLE ELECTRODE RESISTANCE TESTING ettet 47 BABRELASSEMBISY ras 47 48 DISASSEMBLY REASSEMBLY OF BARREL WITH THE 2K FLUID NEEDLE PACKING S crecian a tton 48 53 HANDLE RESISTOR TUBE oo ooooooooooooooooo oo Women 54 56 TROUBLESHOOTING GUIDE ara Uu S uuu Mn 57 59 PARTS IDENTIFICATION 61 84 R90 70 CLASSIC SOLVENTBORNE APPLICATOR BHEAEDONN PARTS na 61 64 VECTOR R90 70 CLASSIC SOLVENTBORNE MODELIDENTIEICATION tera certet rent e Rh Ie an AR 64 R90 79599 01 AND R70 79599 02 CLASSIC NEEDLE SHAFT 2K PACKINGS STANDARD PACKINGS PARTS LIST o o oooooooooooooooooooo 65 R90 78628 11 AND R70 78628 12 CLASSIC NEEDLE SHAFT OPTIONAL PARTS LIST 20 00 oerte p pre tori poeta ti petia An 66 R90 70 CLASSIC POWER SUPPLY PARTS LIST ettet 67 WATERBORNE APPLICATOR MODEL 79520 XXXXX SECTION R
29. Ransburg Vector R Series Classic Applicators Atex Vector R Series 79503 79504 Label 79496 and 79520 ATEX Product ETERS sh WS AE Marking Definitions ETTER 3 a Ex Certificate Number Sira O6ATEX5282X lem APPROVED 0518 2 6 IR BER 50050 PAINT FINISHING PPLICATIONS SIRA 06 5282 Sira Notified Body performing EC type examination 06 Year of certification ATEX Reference to ATEX Directive Label 79516 69 5 Protection Concept Code code 5 is titled Encapsulation 282 Document serial number X Special conditions for safe use apply For LE 1 N CONFIGURED PER DWG 79949 2 Special conditions for safe use The Vector 79503 79504 and 79520 R Series Classic Applicators shall only be used with associated 79344 1XX 9050 Power Supply Label 79516 89 Product Marking 126 Ex Specific marking of explosive protection Il Equipment Group hazardous area charac Label 79516 92 teristics si 2 Equipment Category G Type of explosive atmosphere gases vapors or mists LI TERIAL JNFIGURED PER DWG 79848 EEx 0 24mJ The Vector R Series 79503 79504 and 79520 Classic Applicators are suitable foruse in manual spraying installations complying with EN 50 050 as they are a Type A class with a discharge energy limit of 0 24mJ Labe
30. Techniques manual 3 Trace and correct 4 Reduce pressure 5 Decrease distance between applicator andtarget 1 Check power supply 2 Check air regulator 3 Check applicator trigger 4 Replace Fuse 5 Check and secure atthe applicator and atthe power supply 6 Check conductivity of paint 58 Vector R Series Classic Applicators Maintenance IT Ransburg Troubleshooting Guide Cont General Problem Possible Cause ELECTRICAL Continued Improper or No High Voltage Cont Isolation System Grounded Out 59 7 Faulty flow switch 9 Faulty high voltage cable 10 Faulty control PC board 11 Faulty high voltage multiplier assembly 12 Missing conductive sponge in resistortube 13 Faulty resistor tube assembly 1 Failed fluid hose 2 Insolation stand or charged equip ment too close to ground Solution 7 Replace flow switch 8 Improper or no ground at control unit 8 Trace and correct 9 Replace 10 Replace 11 Check and replace 12 Install 13 Replace 1 Replace fluid hose 2 Provide adequate ground distance AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Maintenance NOTES AH 06 02 11 60 Vector R Series Classic Applicators Parts Identification IT Ransburg PARTS IDENTIFICATION Figure 43 R90 70 Classic Solventborne Applicator Breakdown 61 AH 06 02 11 IT Ransburg Vector R Series Classic Applicators Part
31. Waterborne Allcharged isolated systems MUST be inside afence orcage to prevent contact by personnel An interlock system MUST be provided that interrupts high voltage flow to the applicator if the gate is opened Air regulators for pots or pumps should be mounted remotely outside the fence or cage area to facilitate changes in pressure without shutting the system down Grounding hooks at the cage MUST be used to ground the system when personnel are working close by Fluidlinestothe applicator MUST be protected from scraping and abrasion on the floor or sharp metal edges thatcould leadto voltage pin holing and loss of kV on the charged system Cleanliness and maintenance are extremely critical Referto Installation 79503 R90 Solventborne 79504 R70 Solventborne in the Installation section WATERBORNE HOSE FITTING INSTALLATION For 79520 R90 Classic Waterborne ITW Rans burg supplies the waterborne fluid hose factory pre assembled to the applicator unit Standard hose lengths are 10m 15m and 25m To modify the hose length use the following procedures All adjustments must be made atthe supply end ofthe system 1 Remove the male connector and swivel fitting from the end of the fluid hose by turning the nut of the male connector counter clockwise while holding its main body 2 Remove the male connector nut from the fluid hose 3 Determine the hose length that is needed and cut the hose off sq
32. age Cable removal e Fluid Air Hose removal 2 Remove the gasket from the handle if it was not removed with the barrel 3 Remove the fan air adjustment valve pull the rear cover straight off 1 Barrel Gasket 2 Fan Air Adjustment Valve 3 Rear Cover Figure 36 Gasket and Fan Air Adjustment Valve Removal 4 Remove the air valve retaining cap and o ring Remove the air valve return spring From the front of the applicator push the air valve out the rear of the applicator Remove the air valve retaining nut and seal from the base of the applicator AH 06 02 11 Vector R Series Classic Applicators Maintenance ue 6 fa JE 3 2 Na me 1 Air Valve Retaining Nut 2 Seal opening toward applicator rear 3 Air Valve 4 Air Valve Return Spring 5 Solvent Proof O Ring 6 Air Valve Retaining Cap Figure 37 Air Valve Retaining Cap and O Ring Removal 5 Remove the hook and hook gasket Pull the resister tube straight out of the applicator AN 1 227 1 Resistor Tube 2 Hook 3 Hook Gasket Figure 38 Hook and Hook Gasket Removal 54 Vector R Series Classic Applicators Maintenance rrv Ransburg 6 Remove the air inlet fitting and the fluid bracket 8 Remove the trigger stop by turning the knob of from the base of the applicator the stop counter clockwise until the thread of the stop is completely disengaged 1 Fluid Bracket 1 Trigger Stop Assembly 2 Air Inlet S
33. aintaining or servicing any ITWRansburg electrostatic coating system read and understand all of the technical and safety literature for your ITW Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS Tohelp yourecognize 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 avoid a situation that might cause minor injury A NOTE is information relevant to 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 continued use ofthis manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your ITW Ransbur
34. approved Spray applicators require thataluminum inlet fittings be replaced with stainless steel See accessories list Aluminum is widely used in other spray application equipment such as material pumps regulators valves etc Check all other equipment items before use and make sure they can also be used safely with these solvents Read the label or data sheet for the material you intend to spray If in doubt as to whether or not a coating or cleaning material is compatible contact your material supplier Any other type of solvent may be used with aluminum equipment The power supply optional remote control cabi net and all other electrical equipment must be located outside Class I or II Division 1 and 2 hazardous areas Exception AVIATOR series guns Referto applicable code for specific area or country Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combus tible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Spray Area Electrostatic Arcing Never operate the applicator without properly groundi
35. astic or Wood Dowel Rod 5 16 Diameter AH 06 02 11 ITovRansburg TO REMOVE THE APPLICATOR FROM THE WORK SITE ALWAYS remove the applicator from the work site for service or repair DO NOT use any silicone lubricants in order to avoid paint defects AWARNING Ensure the power supply power is OFF prior to any maintenance Solventborne Applicators 1 Flush the applicator refer to Flushing Procedures in the Maintenance section 2 With a wrench loosen and unscrew the fluid hose nut Remove the fluid hose assembly 3 With a wrench lock the air fitting in place and loosen the air hose nut using a second wrench Completely unscrew the nut and remove the air hose assembly 4 With a bladed screwdriver pry out the high voltage cable retaining clips 5 Using a 3 32 Allen wrench remove the cable retention screw Pullthe high voltage cable straight out 6 Remove the applicator from the work site AH 06 02 11 AIR CAP Removal 1 While holding the barrel with one hand loosen the air cap retaining nut using the other hand 2 Unscrew the retaining nut completely and remove the air cap Cleaning and Inspection 1 Use a suitable solvent to clean the air cap Refer to Suitable Solvents for Cleaning Vector R90 R70 Applicators in the Maintenance section 2 Examine the air cap for damage to the airhorns face and any air passages If any of these areas are damaged or worn the a
36. ble Trigger Shelf High Voltage Cable Connection Air Hose Connection Waterborne Source Connection Replaceable Hook Fan Air Adjust 2 Finger 4 Finger Trigger 69 AH 06 02 11 8 9 ITovRansburg 79520 R90 CLASSIC WATERBORNE E SPECIFICATIONS M Environmental Physical Gun Length 27cm 10 7 inches Weight 620 grams 21 9 oz Cable Lengths Std 10m 15m 20m 25m and 30m Atomizer Nozzle Assembly Std Electrical Operating Voltage 90 kV DC maximum 79374 65 79377 45 Current Output 140 microamperes maximum Part Sprayability Determine sprayability of part to be coated using 76652 Test Equipment See current Paint HV amp SCI Test Equipment service manual Mechanical Fluid Flow Capacity 1000 cc minute Operating Pressure Air Spray Fluid 0 6 9 bar 0 100 psi Air 0 6 9 bar 0 100 psi Air Inlet 1 4 18 NPSM M Fluid Inlet 3 8 18 NPSM M Ambient Temp 40 C to 12 8 C Consumption 510 18 0 SCFM 9 3 4 bar 50 psig inlet Sound Level 92dB A 50 psig inlet 1m from applicator This reflects the maximum fluid volume the appli cator can deliver The maximum spray volume that can be effectively atomized depends on fluid rheol ogy spray technology and finish quality required AH 06 02 11 Vector R Series Classic Applicators Waterborne 79344 1XX 9050 POWER SUPPLY ELECTRICAL SPECIFICATIONS Electrical Input Voltage 100
37. ce and discharge to the nearest grounded object Efficiency of the applica tor will also be reduced and damage or failure of the applicator components may occur WRAPPING THE APPLICA TOR IN PLASTIC WILL VOID WAR RANTY Only approved applicator covers should be used Proceed as follows 1 Turn OFF the power supply power 2 Release the trigger 3 Turn the paint flow OFF 4 See Applicator Repair in the Maintenance section for Disassembly Procedures AWARNING Any broken or damaged components must be replaced Any damage to the applicator may result in UNSAFE operat ing conditions 5 Clean the applicator and associated parts with a soft brush and suitable solvent Metal tools and wire brushes must NEVER be used NEVER use a cleaning tool that is harder than the plastic parts If a deposit cannot be removed with the solvent and a rag or the soft brush soak ONLY the part in the solvent until the deposit can be removed NEVER soak the applicator body or barrel 42 Vector R Series Classic Applicators Maintenance 43 FLUSHING PROCEDURES 1 Turn OFF the power supply power AWARNING Whenever solvent is flushed through the applicator the power supply power must be off 2 Turn the paint supply OFF 3 Turn the atomizing air supply OFF 4 Tilt the applicator down and trigger until it is clear of paint 5 Connect the solvent supply 6 Run solvent through the sys
38. connectto the filter as soon as it enters the cabinet with as short of leads as possible Additional noise protection can be provided by running the AC inputline to the control panel in grounded conduit SIDE VIEW For maximum noise protection any user supplied input output wiring should be made using shielded cable or conduit which is connected to earth ground in a continuous 360 fashion at both ends The best wayto dothis isto use a connector conduit fitting at each end of the cable conduit that makes contact to the shield conduit in a full 360 circle around the cable conduit and makes contact to the grounded enclosure in the same fashion Connecting the drain wire of a shield to a ground point on or in the cabinet usually referred to as pigtailing is not an effective method of shielding and actually makes things worse see Figure 5 Figure 4 Typical Power Supply Mounting 21 AH 06 02 11 ITovRansburg It is recommended that all AC I O interlocks be run in conduit If desired and codes permit cabling may be used for these signals but for maximum noise immunity the cabling must contain overall foil and braided shields and be terminated as described in the preceding paragraph Cable is recommended forthe DC I O high voltage output signal fault output signal Again for maximumnoise immunity the cabling must contain overall foil and braided shields and be terminated in a continuous 36
39. ctor R Series Classic Applicators Waterborne WATERBORNE FLUID DELIVERY COMPONENTS PARTS LIST Figure 49 item Pata Description ty 1 60a Bulk Tube Fluid 1 4 ID XXm Bulk Tube Fluid 3 16 ID XXm 61 Connector Bulk Head 63 79043800 Bracket Support Offset Std 1 1 Bracket Support Offset Stainless Steel Optional Conductive Ferrule Nut Connector Hose 67 68 EMF 202 05 Tube Ferrule Back 3 8 69 6241 06 Fitting Fluid 7787 03 Swivel Fitting Includes Items 60a 62 64 65 69 70 TABLE F Waterborne Fluid Hose Lengths and ID ICT 9 AH 06 02 11 76 Vector R Series Classic Applicators Waterborne rrv Ransburg WATERDORNE COMPATIBLE WATERDORNE COMPATIBLE VECTOR R90 CLASSIC WATERBORNE MODEL IDENTIFICATION 79520 A B C D E 0 No Cable 0 Applicator Only 1 10m High Voltage Cable 1 Domestic Sales Complete W Power 2 15m High Voltage Cable Supply 110 120 3 20m High Voltage Cable 2 Export Sales Complete W Power 4 25m High Voltage Cable Supply 240V 50 60Hz 5 30m High Voltage Cable _ 2 re 0 Standard Spray 65kV Air i cL Cap 1 4mm Fluid Nozzle 44 0 No Fluid Hose 1 Standard Spray 65kV Air Cap 1 8mm Fluid Nozzle 45 1 Waterborne Fluid Hose 1 4 ID x 10m 124 i 2 Trans Tech 122V Air 2 Waterborne Fluid Hose 3 16 ID x 10m Cap 1 8mm Fluid Nozzle 245 3 Waterborne Fluid H
40. e needle shaft the applicator s trigger should be actuated to pull the needle electrode away from the fluid nozzle Cleaning and Inspection 1 Use a suitable solvent to clean the fluid nozzle 2 Examine the fluid nozzle for damage to the air passages and the fluid nozzle tip Also examine the needle seat for damage or wear If any damaged or any worn areas are found the fluid nozzle must be replaced 1 Retaining Ring 2 O Ring Teflon Encapsulated 3 Air Cap 4 Fluid Nozzle 5 Electrode Assembly 6 Barrel Assembly Figure 24 Air Cap Fluid Nozzle and Nut NOTE gt Ifthe fluid nozzle is replaced there is a good chance that the needle electrode assembly will need to be replaced also A worn needle electrode assembly may not always seat well in a new fluid nozzle AH 06 02 1 1 ITovRansburg Reinstall 1 Check the needle electrode tightness on the needle shaft If it is loose tighten it refer to Needle Electrode in the Maintenance section 2 With the applicator trigger actuated place the fluid nozzle over the needle electrode and screw itinto the barrel by hand 3 Tighten it using the special multi purpose wrench with 3 8 square Torque to 35 40 Ibs in 3 9 4 5 Nm An alternate method if no torque wrench is available is to tighten then tighten an additional 1 16 turn in the clockwise direction CW 35 40 LBS IN 3 9 4 5 NM M BEN
41. e the jumper across the two 2 pins at location 17 on the main PC board see Figure 18 3 Close the power supply and turn AC power back on An overload fault will now occur if the microamp display comes within 10 microamps of the maximum output current PA GA Y Se JUMPER 17 INSTALLED OVERLOAD ACTIVATED Figure 18 Jumper Location Overload Activation AH 06 02 11 ITovRansburg KV TEST JUMPER To assist in testing and troubleshooting ajumper J8 has been added to the main PC board By covering shorting both terminals of this jumper the high voltage to the spray applicator can be activated Thus for testing and troubleshooting high voltage output can be obtained without the need to trigger air through the spray applicator After testing the jumper must be repositioned so that it covers only one terminal open or the high voltage will stay on all the time See Figure 16 for location of test jumper J8 gt If jumper J8 is left covering shorting both terminals high voltage will be on whenever AC power is turned on FAULT DESCRIPTIONS For in depth troubleshooting information on the 9050 refer to SI 09 05 If a fault occurs the Fault Indicator on the front of the power supply will light anda fault code
42. g C 2 Fm j 2 N 3022205 Si e ex AS X LA AN ve N CONDUIT ADAPTER PLATE SIDE VIEW Figure 9b Installation of Conduit Adapter Plate 24 Vector R Series Classic Applicators Installation rrv Ransburg INTERLOCKS Interlocks required by code are as follows AIRFLOW SWITCH Booth Fan Interlock When the booth fan is on a contact closure is made FAULT OUT OUT COM TRIGGER e Conveyor Interlock When the conveyor is moving a contact closure is made J2 1 ASSEMBLY Solvent Interlock When solvent supply to the applicator is off a contact closure is made MASTER PC BOARD AWARNING gt Failure to connect interlocks could result in fire or explosion A WARNING gt ALWAYS ensure that high voltage is OFF before flushing the spray applicator with solvent NEVER flush the spray applicator with high voltage ON as this is a severe fire hazard and risk to personnel safety It is recommended that the high voltage control be interlocked with the solvent flush signal so that high voltage is automatically locked out whenever flushing occurs Consult your authorized ITW Ransburg representative for information on interlocking the high voltage OFF signal with the solvent flush signal CURRENT FDBK 15VDC 3PL 3 P 55 sa 95 gt z
43. g normal operating conditions to cause ignition of specific hazardous materials in their most easily ignited concentrations in air The power supply provides voltage output to the applicator and contains controls for AC on off high voltage adjust one touch triple setpoint and displays kV and pA in real time As the applicator electrode approaches ground the power supply and applicator circuitry cause thehigh voltage to approach zero while the current approaches its maximum value AWARNING When more than one waterborne appli cator is fed from a common isolated fluid supply there is a potential for electrical energy discharge through any other applica tors when one applicator is triggered De pending upon the system capacity this discharge could be hazardous Install only one spray applicator per isolated fluid supply system AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Introduction NOTES AH 06 02 11 14 Vector R Series Classic Applicators Introduction 79503 R90 CLASSIC SOLVENTBRONE SPECIFICATIONS Environmental Physical Gun Length 27cm 10 7 inches Weight 620 grams 21 9 oz Cable Lengths Std 10m 15m 20m 25m and 30m Atomizer Nozzle Assembly Std Electrical Operating Voltage 90 kV DC maximum 79374 65 79377 45 Current Output 140 microamperes maximum Paint Resistance 1 MQ to co Use Model No 76652 Test Equipment Part Sprayability Determi
44. g system contact your local ITW Ransburg representative or ITW Ransburg irwRansburg A WARNING The user MUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literature therein identified This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this eguipment 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 or applicable country safety standard prior to install ing operating and or servicing this equip ment A WARNING The hazards shown on the following page may occur during the normal use of this eguipment Please read the hazard chart beginning on page 2 AH 06 02 11 Vector R Series Classic Applicators Safety ITovRansburg SAFEGUARDS Tells how to avoid the hazard AREA Tells where hazards HAZARD Tells what the hazard is may occur Spray Area AH 06 02 11 Fire Hazard Improper or inadequate opera tionand 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 shutdown indicates a problem in the system requiring cor
45. gainst the body It can blind deafen and may even penetrate the skin If used for cleaning equipment the user should wear safety glasses gt ALWAYS turn the power supply off prior to cleaning and servicing the equip ment Be SURE the power is OFF and the system is grounded before using solvent to clean ANY equipment DO NOT operate a faulty applicator gt When using cleaning solvent standard health and safety precautions should apply Any solvent used to clean the fluid passages must be discharged into a grounded container Use of ungrounded or plastic containers may cause fire or explosion Cleaning of the exterior surface of the applicator should be done with non polar solvents If cleaning requires the use of polar solvents the applicator should be wiped down with non polar solvent prior to going back into use Using polar solvents will leave a semi conductive film on the surface of the applicator that will effect efficiency of the applicator and cause damage to the components AH 06 02 11 rwvRansburg ROUTINE SCHEDULE Follow these maintenance steps to extend the life of the applicator and ensure efficient oper ation Several Times Daily Turn the power supply power to OFF Inspect the air cap for paint accumulation Clean as frequently as necessary with a soft bristled brush and a suitable solvent NEVER remove the fluid nozzle as sembly while paint is in the applicator or pa
46. ge Cable 2 Export Sales Complete W Power 4 25m High Voltage Cable Supply 240V 50 60Hz 5 30m High Voltage Cable 2 Two Finger Trigger 0 Standard Spray 65kV Air 4 Four Finger Trigger Cap 1 4mm Fluid Nozzle 44 1 Standard Spray 65kV Air 1 Offset Bracket 093 ID Fluid Tube Cap 1 8mm Fluid Nozzle 45 2 45 Bracket 093 ID Fluid Tube 2 Trans Tech 122V Air 3 Offset Bracket SS 093 ID Fluid Tube Cap 1 8mm Fluid Nozzle 245 4 Offset Bracket 250 ID Fluid Tube 3 Round Spray 5 45 Bracket 250 ID Fluid Tube 6 Offset Bracket SS 250 ID Fluid Tube 7 Offset Bracket 125 ID Coiled Fluid Tube AH 06 02 11 64 Vector R Series Classic Applicators Parts Identification rrv Ransburg WI 22 LF Figure 44 R90 79599 01 and R70 79599 02 Classic Needle Shaft 2k Packings Std Packings R90 79599 01 AND R70 79599 02 CLASSIC NEEDLE SHAFT 2K PACKINGS STD PACKINGS PARTS LIST Figure 44 item Part Description 78627 04 Shaft Assembly 2 Piece Needle R90 78627 05 Shaft Assembly 2 Piece Needle R70 a i TRI E 4 1432200 Seal Chevron 4 5 1882100 Adapter FemaieChevron f r Tube Packing R90 Tube Packing R70 1 K lt E Cup Seal Spring Loaded RE aa 173904 Washer Beville Spring 6 12 7863200 Nut Locking Trigger Adjustment 1 78631 00 NutPackng 21 14 7
47. gohm resistance If higher fluid flows are required the larger diameter tube either 125 inch or 250 inch may be used but depending on material conductivity the current draw during the spray operation may increase Figure 52 Applicator Cover Figure 53 Swirl Nozzle Figure 54 Fluid Tube rr Ransburg AH 06 02 1 1 rrv Ransburg Vector R Series Classic Applicators Parts Identification PARTS COMPARISON ARK L oe SAN QCA QV NS So 79374 65 Standard Air Spray Air Cap 79374 122 Trans Tech Air Spray Air Cap Standard Air Spray Nozzles have a number between 44 and 148 Trans Tech Air Spray Nozzles have a number between 244 and 348 3 Standard Air Spray Nozzles have a longer narrower tip Trans Tech Air Spray Nozzles have a shorter wider tip and have a shorter over all length 79377 XX Standard Air Spray Fluid Nozzle 79552 XXX Trans Tech Air Spray Fluid Nozzle TRANS TECH ATOMIZATION PARTS LIST home pane Deserpton Jo Standard Air Spray Cap Air Trans Tech Air Spray Cap Air Included in 79555 Kit Standard Air Spray Fluid Nozzle Trans Tech Air Spray Fluid Nozzle Included in 79555 Kit 5 Standard Air Spray Restrictor Black Vector 1 206505 Trans Tech Ar Spray Resttcior Green inouts T79555F AH 06 02 11 80 Vector R Series Classic Applicators Parts Identification 81 79555 TRANS TECH CONVERSION KITS AVAILABLE Fluid Nozzle Part
48. gun 5 Fill the inner diameter of the packing tube with dielectric grease 6 Insertthe needle shaft rear section first into the packingtube Rotate the needle shaft while moving back and forth inside the packing tube until fully inserted 7 With your finger wipe the excess grease from both ends of the packing tube Using the excess grease apply a thin film to the outer surface of the packing tube and to the external o ring on the cartridge seal NOTE Begenerous with the dielectric grease when applying it to the packing tube and needle shaft This helps to remove air voids from this chamber DO NOT apply so much grease that it creates an air lock during assembly of the gun 8 Apply a light film of dielectric grease to the seal retainer o ring and installitinto the external groove 9 Insertthe spring loaded u cup seal into the seal retainer with the concave side facing outward Use the short end of the spacer to seat the seal 10 While holding the rear seal retainer sub assembly and spacer together place these components with the spacer rearward onto the rear of the needle shaft and slide them over the sealing area 11 Place the six 6 spring washers onto shaft with the first third and fifth ones concave cupped side forward The second fourth and sixth ones should be cupped side rearward see Figure 32 Vector R Series Classic Applicators Maintenance 50 Vector R Series Classic Applicator
49. harge allows a more efficient uniform application of coating material to the front edges sides and back of products Itis highly suitable for applying coatings to a variety of surface configurations large targets small parts tubular wares concave and recessed parts etc Because it is a grounded fluid system for solvent based systems it is highly suitable for applying a wide range of solventreduced coatings such as enamels lacquers epoxies etc The 79520 model is available to accomodate waterborne materials Aregulated pressure fluid system delivers coating material to the atomizer At the time of triggering the applicator fan and atomization air is introduced which atomizes the coating material into a spray mist The atomized spray particles under the influence of the electrostatic field become electrically charged The charged particles are attracted to and deposited on the target object The forces between the charged particles and the grounded target are sufficient to turn most normal overspray around and deposit it on the back surface ofthetarget Therefore a high percentage of the coating is deposited on the target One of the many features of the Vector R90 70 applicator system is that the electrical energy which is available from the resistive charging electrode is limited to the optimum level of safety ITovRansburg and efficiency The systemisincapable of releasing sufficient electrical orthermal energy durin
50. iT Ransburg SERVICE MANUAL AH 06 02 11 Replaces AH 06 02 10 December 2011 VECTOR R SERIES CLASSIC APPLICATORS MODELS 79503 R90 Classic Solventborne 79504 R70 Classic Solventborne 79520 R90 Classic Waterborne KZ For Use With 79344 1XX 9050 Power Supply re EN IMPORTANT Before using this equipment LE Nx s carefully read SAFETY PRECAUTIONS APPROVED starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 40 00 Euro 50 00 U S ITovRansburg NOTE This manual has been changed from revision AH 06 02 10 to revision AH 06 02 11 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Contents CONTENTS PAGE SAFETY 1 4 SAFETY PREGAUTIONS cr ade bete e tee cetero edet vetere eet cete ere eed 1 HAZARDS SAFEGUARDS nennen ennemi enhn nnns sess aan 2 4 ATEX A EUROPEAN ATEX DIREC TIVE eto tenete tte aa nasa aa 5 EUROPEANAT EXLABELS atas anta 6 FM CONFIGURATION DRAWINGS L aaa iia 7 12 INTRODUCTION 13 18 GENERAL DESCRIPTION Comcel 13 79503 R90 CLASSIC SOLVENTBORNE 15 79504 R70 CLASSIC SOLVENTBORNE 15 R90 70 CL
51. ical noise refers to stray electrical signals in the atmosphere at various signal strengths and frequencies that can affect the operation of equipment One of the best ways to prevent this is to shield the equipment and cables within a The power supply may be free standing on any flat continuous ground envelope such that any surface or wall mounted wall mount brackets not incident noise will be conducted to earth ground supplied as shown in Figure 4 before it can affect the circuit conductors or adjacent to heat producing equipment such as ovens high wattage lamps etc For conductors inside the control unit or power supply the grounded enclosures provide this envelope Forthe cables that connectthe applicator to the control unit or power supply a shielded cable has been used The shield consists of an overall foil shield in combination with an overall braided shield This provides the most effective shielding as the foil covers the holes in the braid and the braid allows for practical 360 termination at both ends of the cable FRONT VIEW E The AC input cord is not shielded but instead is directed to an AC line filter as soon as it enters the cabinet This method filters out any noise that comes in on the AC line For maximum noise immunity the AC line should
52. int may enter into the air passages Clogged or restricted air passages will cause poor atomization and or electrical shorting Air passages that are clogged with conductive material can lead to exces sive current output levels and consequent low operating voltage or long term electrical damage Before undertaking any atomizer maintenance procedure see Applicator Assembly Cleaning Procedure in the Maintenance section The applicator barrel MUST be tilted front down to remove the fluid nozzle Failure to do so may allow paint to enter the air pas sages thereby reducing airflow and dam aging the applicator barrel cascade Appli cators may be flushed in lieu of tilting However they must be either flushed or tilted down during nozzle removal Clean all insulating surfaces in the system Remove paint accumulation from the exterior of the applicator and high voltage cable with a solvent dampened cloth AH 06 02 11 Vector R Series Classic Applicators Maintenance NEVER soak or submerge the electri cal components of the applicator i e barrel or cable Damage and failure may occur Daily or at start of each shift Verify that ALL solvent safety containers are grounded Check within 20 feet of the point of operation of the applicator and remove or ground ALL loose or ungrounded objects Inspect work holders for accumulated coat ing materials and remove such accumula tions Check that the
53. ion required Air Water Separator Main Air Supply Line Target Earth or Building Ground Fluid Supply Grounded 9050 Ground Separate Earth or Building Ground from human contact 71 AH 06 02 11 ITovRansburg AWARNING Typical installations to spray non flammable conductive materials water borne materials must not be used to handle flamable materials solvent based materials WATERBORNE ISOLATION SYSTEM INSTALLATION GUIDELINES Using waterborne coating with electrostatic equipment requires thatthe fluid source be isolated from ground Precautions should be taken to ensure operator safety and system efficiency The following guidelines should be followed The fluid lines and source MUST be isolated from ground An isolating paint stand or similar isolating non porous material MUST be used Never use wood products wooden boxes pallets or boards as an isolator Wood contains moisture and is a poor insulator Electrical current passing through these materials can ignite them causing a hazardous condition Isolation stands MUST be at least 18 inches from grounded booth walls chain link fences or other grounded objects Air hoses to the pressure pot or pump on the insulating stand should be non conductive plastic Many rubber hoses will have static grounding circuits or carbon content and are NOT suitable for this application AH 06 02 11 Vector R Series Classic Applicators
54. ir cap should be replaced Reinstall 1 Check the fluid nozzle to ensure that it is tightly screwed into the barrel 2 Place the air cap over the electrode wire of the needle electrode and set it onto the fluid nozzle 3 Place the retaining nut over the air cap and begin screwing it onto the barrel 4 Before securing the retaining nut to the barrel position the air cap for the desired spray pattern horizontal or vertical Vector R Series Classic Applicators Maintenance 44 Vector R Series Classic Applicators Maintenance 45 FLUID NOZZLE Refer to Figure 24 Removal 1 Remove the air cap from the applicator referto Air Cap Removal inthe Maintenance section 2 Tiltthe applicatorforward and pullthe triggerto make sure that all fluid in the applicator is drained out 19749 WRENCH FLUID NOZZLE Figure 23 Removal of Fluid Nozzle The applicator barrel MUST be tilted front down to remove the fluid nozzle Failure to do so may allow paint to enter the air passages thereby reducing airflow and damaging the applicator barrel Applicators may be flushed in lieu of tilting However they MUST be either flushed or tilted during nozzle removal 3 While holding the applicator assembly with the trigger pulled back remove the fluid nozzle with the open end ofthe special multi purpose wrench rr Ransburg NOTE gt To keep the needle electrode from unscrewing from th
55. l 79515 ITWRansburg VEG R 0518 Ex 26 EEx 0 24 mJ SIRA OGATEX5282X Made In USA FM Configuration These applicators are FM approved when configured to drawings 79948 79949 79950 shown on pages 7 thru 12 AH 06 02 11 6 rrv Ransburg VECTOR R90 CLASSIC SOLVENT BASED 79503 ABCDE BASE OPTION MODEL NO DESIGNATIONS ORDERING INFORMATION ONLY D DESIGNATIONS B DESIGNATIONS C DESIGNATIONS E DESIGNATIONS DESIGNATIONS CONFIGURATION DWG 79948 REV B AH 06 02 11 rrv Ransburg OPTION A DESIGNATIONS CABLE LENGTH 0 FOR NO CABLE nai 1 FOR 10 METER CABLE PART NUMBER 79519 10 TF 2 FOR 15 METER CABLE PART NUMBER 79519 15 3 FOR 20 METER CABLE PART NUMBER 79519 20 4 FOR 25 METER CABLE PART NUMBER 79519 25 5 FOR 30 METER CABLE PART NUMBER 79519 30 OPTION B DESIGNATIONS N lt TRIGGER TYPE Dj 2 FOR TWO FINGER TRIGGER PART NUMBER 79325 02 4 FOR FOUR FINGER TRIGGER PART NUMBER 79325 04 OPTION C DESIGNATIONS FLUID DELIVERY COMBINATION 1 OFFSET WITH 093 ID FLUID TUBE PART NUMBER 79438 00 amp 9704 16 2 45 WITH 093 ID FLUID TUBE PART NUMBER 79439 00 amp 9704 16 3 OFFSET STAI
56. le utand Ferrule ielectric Grease esistor Housing R70 esistor Housing R90 se Cable Support Bracket ectrode High Flex arrel Retaining Ring eal Cartridge haft Assembly 2 Piece Needle R90 haft Assembly 2 Piece Needle R70 eedle Shaft Assembly R90 Standard Packings eedle Shaft Assembly R70 Standard Packings pacer Seal acking Nut ut Locking Trigger Adjustment pring Retaining Needle Shaft pring Ring Solvent Proof Ring Solvent Proof Ring Solvent Proof Ring Solvent Proof Ring Solvent Proof O Ring Solvent Proof Air Valve Assembl Applicator Hook Trigger 2 Finger 79373 00 Barrel Retaining Nut 79374 65 Air Cap V65 79374 98 Air Cap V98 79377 44 Fluid Nozzle 1 4mm 055 79377 45 Fluid Nozzle 1 8mm 070 79378 00 asket Barrel 79379 00 Air Cap Retaining Ring 79385 00 Nut Connector Hose 79445 10 Fan Air Adjustment Assembl 79450 00 rigger Stop Assembl 79454 00 igger Retaining Screws 79465 65 arrel R70 Classic 79465 85 arrel R90 Classic 79471 11 ear Cover W No Switch ep gt o 2 o U gt A N IR IN IN Po Po m m m mm no 4 Joo 2 8 ro Ino o o 3 D 140105 1406108 1713000 1884201 1884202 1974900 358702 358703 5097200 70397 01 739702 7039900 70430 01 75326000 78626 00 7862704 7867 5
57. le to the power supply The fluid hose can be run with the high voltage cable and air hose or it can be separate and run to the fluid source Do not expose the hoses to high temperatures over 120 F and or conditions such as moving parts foot traffic vehicle traffic etc AWARNING When securing the air hose fluid hose and high voltage cable together take care not to use items such as wire or anything that might cut into the hoses or cable If wire ties are used they should only be tight enough to secure the cable and not so tight that they might restrict fluid and air flow Adjustthe length of the air hose to the high voltage power supply and install the fitting to the hose PAINT PREPARATION A proper paint mixture is essential to electrostatic operation Paint test equipment may be obtained through your ITW Ransburg distributor Reference Technical Manual Paint Related Information for REA REM Vector and M90 Guns for paint formulation information For further paint formulation and testing procedures consult your ITW Ransburg distributor and or your paint supplier 28 Vector R Series Classic Applicators Installation 29 SPRAY PATTERN ADJUSTMENT The spray pattern of fan atomizers is adjustable from a small circle to an elongated oval approximately 10 18 inches of useable pattern when sprayed from a target distance of 8 12 inches The swirl atomizer assemblies produce a round pattern from 4 6 inches
58. luid Inlet 3 8 18 NPSM M Ambient Temp 40 to 12 8 C Consumption 510 slpm 185 SCFM 9 3 4 bar 50 psig inlet Sound Level 92dB A 50 psig inlet 1m from applicator This reflects the maximum fluid volume the appli cator can deliver The maximum spray volume that can be effectively atomized depends on fluid rheol spray technology and finish quality required AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Introduction Figure 1 R90 70 Classic Solventborne Electrostatic Spray Applicator Features R90 70 CLASSIC SOLVENTBORNE ELECTROSTATIC SPRAY APPLICATOR FEATURES No Description no Description 1 Neede Elecrode 6 AdjstableTriggerSheif 2 Bai 7 FliidHoseComecion 3 BepicenbieHook HighVotage CableConnecion an C AH 06 02 11 16 Vector R Series Classic Applicators Introduction 17 79344 1XX 9050 POWER SUPPLY ELECTRICAL SPECIFICATIONS Electrical Input Voltage 100 240 VAC Current 1A max RMS Frequency 50 60 Hz Wattage 40 watts max Output Voltage Current Physical Height Width Depth Weight Pneumatic Supply Air 20 65 kV DC 79344 11X 20 90kV DC 79344 12X 140 microamps max 16 5cm 6 5 inches 37 8cm 14 9 inches 30 7cm 12 1 inches 10 2 kg 22 5 Ibs 6 9 bar 100 psig maximum ITovRansb
59. n the I O Connectors section of this manual NOTE Aninternal 24 VDC source voltage is available at TB2 1 Using a jumper wire this voltage may be connected to TB2 3 to be used as the source voltage for the relay contact outputs In this case the total cur rent sourced should not exceed 1 amp FILTERS NOTE Class 3 air quality is recommended Class 3 air quality has a maximum 5 micron particle size a dew point of 4 F 20 C and a relative humidity of 5 1 Install an air filter assembly on the air inlet of the power supply Connect applicator air hose to fitting marked out Connect regulated 100 psig 6 9 bar maximum factory airtothe filter inlet The filter MUST be installed with the arrow pointing in the direction of flow Refer to the appropriate Filter Assembly manual for Installation Instruc tions When the spray applicator is triggered the resulting air flow closes the contacts of the air flow switch thereby activating high voltage at the spray applicator AH 06 02 1 1 ITovRansburg gt An air filter MUST be installed to permit proper functioning of the air flow switch inside the power supply 2 ITW Ransburg recommends that fluid filter be installed atthe output of the fluid supply pressure pot pump circulating system etc It is the end user s responsibility to install the proper filter that meets their system s requirements Air Hose Recommendation ITW Ransburg recomme
60. nd an IEC 60320 C13 connector at the power supply end of the cord The cord should be rated for at least 60 C have 0 8mm 18 AWG minimum conductors and be less than 6m 20 feet in length NOTE gt In general conduit must be used for ap proved AC installation however if national and local codes permit the AC power may be supplied via the factory supplied line cord If conduit is utilized the power supply AC input wiring may be routed through an optional explosion proof switch mounted on or near the spray booth where it will be con venient to the operator For installations where it is required to run the AC input wiring in conduit perform the following 1 Ensure the AC line cord is unplugged and removethe AC inlet receptacle wiring from TB1 N TB1 L1 and TB1 EARTH GROUND see Figures 8 and 2 Remove the mounting hardware from the AC inlet receptacle and remove it from the rear of the control unit 3 Install the Conduit Adapter Plate supplied in the hole where the AC inlet receptacle was removed see Figure 9b AH 06 02 11 rrwvRansburg 4 Install the AC input wiring 0 8mm 18 AWG minimum through the Conduit Adapter Plate using conduit and wire to TB1 as follows Hot Line to TB1 L1 Neutral Common to TB1 N Ground to TB1 EARTH GROUND Safety Ground Crimp the appropriate connector onto the ground wire assembly and install from the power supply ground stud located on the side panel to a t
61. nd fan air OFF 4 Wipe the applicator cable and hoses with a rag and a suitable cleaning solvent 41 rr Ransburg NOTE If production downtime is to be short the fluid lines may not require flushing de pending on the coating material being used If the solids in the material settle slowly the lines will not need to be flushed as soon af ter shutdown as with fast settling solids The paint being used and the length of downtime will determine the need for flush ing Metallic paint and primer will require flushing sooner than other types of coating materials gt If the coating material is fast settling and the fluid lines are not flushed soon enough the internal passages may become clogged This can lead to excessive downtime for repair 5 Flush the lines and allow the solvent to re main in the lines unpressured see Flushing Procedures in the Maintenance section Weekly Check the entire system for damage leaks and paint accumulation Clean the atomizer assembly APPLICATOR ASSEMBLY CLEANING PROCEDURE Routine Cleaning Equipment Needed An appropriate solvent A solvent safety container grounded Asmall soft bristled brush The ITW Ransburg special multi purpose wrench 19749 00 AH 06 02 11 ITovRansburg To avoid damage to the fluid nozzle or needle electrode the paint pressure MUST be released by triggering the applicator prior to removing the tip The ap
62. nds using a 78547 XX air hose assembly that may be ordered through your authorized ITW Ransburg distributor This hose performs best with the Vector to reduce air hose stiffness along with weight reduction Available hose lengths are listed in Accessories in the Parts Identification section of this manual Any user supplied air hose must be rated at a minimum working pressure of 100 psig 6 9 bar Fluid Hose Recommendations ITW Ransburg recommends using a 78548 XX fluid hose assembly This assembly is made to specifically fit the fluid fitting size engineered into the applicator This hose is available from your authorized ITW Ransburg distributor Available hose lengths are listed in Accessories in the Parts Identification section of this manual Any user supplied fluid hose must be rated at a minimum working pressure of 100 psig 6 9 bar AH 06 02 11 Vector R Series Classic Applicators Installation Air and Fluid Hose Installation The fluid inlet fitting for the Vector applicator is 3 8 18 NPSM M When installing a fluid hose tighten the fitting adequately to prevent any fluid leaks The air inlet fitting is 1 4 18 NPSM M When installing the air hose use a wrench to hold the air inlet fitting on the Vector and tighten the air hose fitting enough to prevent any air leaks Routing of Air and Fluid Hoses Starting at the applicator route the air hose along the same path as the high voltage cab
63. ne sprayability of part to be coated using 76652 Test Equipment See current Paint HV amp SCI Test Equipment service manual Mechanical Fluid Flow Capacity 1000 cc minute Operating Pressure Air Spray Fluid 0 6 9 bar 0 100 psi Air 0 6 9 bar 0 100 psi Air Inlet 1 4 18 NPSM M Fluid Inlet 3 8 18 NPSM M Ambient Temp 40 C to 12 8 C Consumption 510 slpm 18 0 SCFM 9 3 4 bar 50 psig inlet Sound Level 92dB A 50 psig inlet 1m from applicator This reflects the maximum fluid volume the appli cator can deliver The maximum spray volume that can be effectively atomized depends on fluid rheol spray technology and finish quality required 15 ITovRansburg 79504 R70 CLASSIC SOLVENTBORNE SPECIFICATIONS Environmental Physical Gun Length 24cm 9 6 inches Weight 555 grams 19 6 oz Cable Lengths Std 10m 15m 20m 25m and 30m Atomizer Nozzle Assembly Std Electrical Operating Voltage 65 kV DC maximum 79374 65 79377 45 Current Output 140 microamperes maximum Paint Resistance 1 MQ to oo Use Model No 76652 Test Equipment Part Sprayability Determine sprayability of part to be coated using 76652 Test Equipment See current Paint HV amp SCI Test Equipment service manual Mechanical Fluid Flow Capacity 1000 cc minute Operating Pressure Air Spray Fluid 0 6 9 bar 0 100 psi Air 0 6 9 bar 0 100 psi Air Inlet 1 4 18 NPSM M F
64. ng the following A Operators Operators must be grounded Rubber soled insulating shoes should not be worn Grounding leg or wrist straps may be used Operators must maintain contact with the handle of the applicator If work gloves are used the palmsection must be cut out Operators must remove from themselves all metal objects that are not grounded NOTE REFER TO NFPA 33 REGARDING OPERATOR GROUNDING OR SPECIFIC COUN TRY SAFETY CODES B Parts being sprayed Resistance between the part anda grounded conveyor must not exceed 1 megohm Every metal and conductive object in the spray area This includes the booth parts hangers fire extinguishers conductive flooring etc Grounded conductive flooring must be provided in the spray area Turn off voltage at the power supply before flushing out cleaning or removing any parts from the applicator Never install a spray applicator into a fluid system using an isolated solvent supply Donottouch applicator electrode while applicator is energized Improper operation or main Personnel must be given training in accordance with tenance may create a hazard the requirements of NFPA 33 or country safety codes Personnel must be properly trained in the use of this Instructions and safety precautions must be read equipment and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection
65. olvent Proof O Ring 3 Air Inlet Fitting Figure 41 Trigger Stop Removal Figure 39 Air Inlet Fitting and Fluid Bracket Removal Reassembly Refer to Figures 7 Remove the trigger shelf by removing the set 36 37 38 39 40 41 and 42 screw with a 3 32 Allen wrench Push down on 1 Screw the trigger stop into the handle in a the shelf to remove clockwise direction 2 Push the finger shelf up on the dovetail pad on the handle to the desired height insert the set screw and tighten with a 3 32 Allen wrench 3 Insert the fluid bracket over the air fitting then install the o ring overthe airfitting Tighten the air fitting in a clockwise direction 1 Finger Shelf Set Screw 2 Finger Shelf pushed down Figure 40 Trigger Shelf Removal 55 AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Maintenance NOTES Figure 42 Hook Insertion Into Handle 4 Push the hook gasket into the groove of the hook Apply a light coat of dielectric grease LSCH0009 to the hook gasket exterior and slide the hook into position 5 Reinstalltheairvalve componentsinthe reverse order of disassembly 6 Pushthe rear cover onto the back ofthe handle Securethe cover by inserting the fan air adjustment valve into the handle and tighten in the clockwise direction 7 Insertthe barrel gasket back into the handle AH 06 02 11 56 Vector R Series Classic Applicators Maintenance TROUBLESHOOTING GUIDE General P
66. operation maintenance and housekeeping AH 06 02 1 1 4 Vector R Series Classic Applicators Atex ITovRansburg EUROPEAN ATEX DIRECTIVE 94 9 EC ANNEX II 1 0 6 The following instructions apply to equipment covered by certificate number Sira OGATEX5282X 1 The equipment may be used with flammable gases and vapors with apparatus groups II and with temperature class T6 2 The equipmentis only certified for use in ambient temperatures in the range 12 8 C to 40 C and should not be used outside this range 3 Installation shall be carried out by suitably trained personnel in accordance with the applicable code of practice e g EN 60079 14 1997 4 Inspection and maintenance of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice e g EN 60079 17 5 Repair of this equipment shall be carried out by suitable trained personnel in accordance with the applicable code of practice e g EN 60079 19 6 Putting into service use assembling and adjustment of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation Refer to the Table of Contents of this service manual a Installation b Operation c Maintenance d Parts Identification 7 Components to be incorporated into or used as replacement parts of the equipment shall be fitted by suitably trained personnel in accordance with the manufact
67. or replace AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Maintenance Troubleshooting Guide Cont General Problem LEAKAGE Air Fluid At rear of barrel Fluid Slight leak at nozzle when trigger is re leased Fluid Constant at nozzle Possible Cause 1 Defective valve seat or valve spring 1 Cartridge seal assembly and or needle electrode shaft defective 1 Nozzle not secure 2 Air valve closing before fluid valve 1 Worn or damaged fluid nozzle 2 Worn or damaged needle electrode 3 Loose fluid nozzle 4 Needle electrode does not seat when trigger is released Solution 1 Clean and lubricate or replace 1 See Barrel Assembly in the Mainte nance section 1 Tighten 2 Adjust needle shaft electrode travel 1 Replace fluid nozzle 2 Replace 3 Tighten 4 Adjust see Trigger Adjustment in the Maintenance section ELECTRICAL Wrap Back Improper or No High Voltage 1 Impropertarget ground Improperspray technique Improper booth exhaust Excessive atomizing air Excessive target distance Is the power turned Is the atomizing air turned on Isthe applicator triggered Blown fuse Faulty high voltage cable connec tions Is the paint too conductive Continued On Next Page AH 06 02 11 1 Trace and correct 1 megohm maxi mum ground to target resistance 2 See ITW Ransburg Handgun Spray
68. ose 1 4 ID x 15m 3 Round Spra 4 Waterborne Fluid Hose 3 16 ID x 15m y 77 AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Parts Identification Figure 50 Air Hose VECTOR AIR HOSE OPTIONS PARTS LIST Figure 50 j Air Hose Assembly 15m 49 Air Hose Assembly 20m 66 Air Hose Assembly 30m 99 Figure 51 Fluid Hose VECTOR FLUID HOSE OPTIONS PARTS LIST Figure 51 79548 10 Fluid Hose Assembly 10m 33 79548 15 Fluid Hose Assembly 15m 49 Fluid Hose Assembly 20m 66 Fluid Hose Assembly 30m 99 77031 XX Bulk Hose Fluid AH 06 02 11 78 Vector R Series Classic Applicators Parts Identification 79 VECTOR APPLICATOR COVER PARTS LIST 3 79529 00 ApplicatorCover 1 79529 00 K5 Applicator Cover Package of 5 VECTOR SWIRL NOZZLE OPTIONS PARTS LIST Pant Description a 79959 00 Fluid Nozzle Assembl 79962 00 AirCap Swirl VECTOR FLUID TUBE OPTIONS PARTS LIST Par Description Qty 9704 16 093 ID Tube See Item 36 Standard W Applicator 9704 15 125 ID Tube See Item 36 9704 11 250 ID Tube See Item 36 NOTE The standard fluid delivery tube is the smallest diameterto work best with highly conductive materials down to 1 me
69. ost of repair or replacement and service related costs if applicable AH 06 02 11 ITovRansburg MANUAL CHANGE SUMMARY This manual was published to replace Service Manual AH 06 02 10 Vector R Series Classic Applicators to make the following changes 1 Added air quality recommendation 2 Removed blank hook option from figures and parts list 3 Updated hook o ring part number 4 Updated restrictor for round spray AH 06 02 11 Service Manual Price 40 00 Euro 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier I Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 www itwransburg com Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts ISO 9001 HD Form No AH 06 02 11 2011 Illinois Tool Works Inc All rights reserved Quality Systems Litho in U S A Models and specifications subject to change without notice VEL 12 11
70. p 79552 245 3 FOR ROUND SPRAY PART NUMBER 79962 00 amp 79959 00 APPROVED SPARE FLUID NOZZLES LIST 79377 46 1 06mm ID STD WEAR 79377 47 71mm ID STD WEAR 79377 48 1 19mm ID STD WEAR 79377 144 1 40mm ID HIGH WEAR 79377 145 1 78mm ID HIGH WEAR 79377 146 1 06mm ID HIGH WEAR 79377 147 71mm ID HIGH WEAR 79552 244 1 40mm ID STD WEAR 79552 344 1 40mm ID HIGH WEAR 79552 345 1 78mm ID HIGH WEAR OPTION E DESIGNATIONS CONTROL UNIT 0 FOR NO CONTROL UNIT r CL p 1 FOR DOMESTIC SALES 110 120 V PART NUMBER 79344 121 2 FOR EXPORT SALES 240V 50 60 Hz PART NUMBER 79344 122 Lum CONFIGURATION DWG 79950 REV B AH 06 02 11 12 Vector R Series Classic Applicators Introduction INTRODUCTION GENERAL DESCRIPTION The Vector R90 70 Spray Applicator process is an air atomized method for electrosta tically applying product coatings The Vector R90 70 applicator system applies a high voltage DC charge to the applicator electrode creating an electrostatic field between the atomizer and the target object The Vector R90 Classic Spray Applicator see Figures 1 and 2 applies a 90 kV DC charge tothe coating materials atthe point of atomization The Vector R70 Classic Spray Applicator see Figure 1 applies a 65 kV charge This electrostatic c
71. plicator barrel MUST be tilted front down to remove the fluid nozzle Failure to do so may allow paint to enter the air passages thereby reducing airflow and damaging the applicator barrel cascade Applicators may be flushed in lieu of tilting However they must be either flushed or tilted down during nozzle removal The power supply power MUST be off when removing the nozzles and or during any applicator maintenance gt When installing or removing the fluid nozzle the applicator MUST be triggered Failure to do so may cause damage to the electrode or fluid nozzle Such damage can result in fluid leaks around the sealing area of these components Using any tool other than the ITW Ransburg multi purpose wrench 19749 00 to remove or install the fluid nozzle may cause damage For efficient electrostatic operation keep the applicator s exterior and high voltage cable free of paint accumulation This prevents the loss of voltage to ground with a resultant reduction in transfer efficiency Paint accumulation in and aroundthe air cap nozzles will reduce atomization quality Clean the air cap using clean solvent and a soft bristle brush as often as needed to ensure good atomization AH 06 02 11 Vector R Series Classic Applicators Maintenance AWARNING NEVER wrap the applicator associ ated valves and tubing and supporting hardware in plastic to keep it clean A surface charge may build up on the plastic surfa
72. rating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANS BURG APPROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR ASSO CIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY 85 ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATER IALS THERE ARE NO IMPLIED WARRAN TIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANS BURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume no responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any c
73. ration NOTES AH 06 02 11 38 Vector R Series Classic Applicators Maintenance MAINTENANCE SUITABLE SOLVENTS FOR CLEANING VECTOR R90 70 APPLICATORS When cleaning the Vector applicators a suitable solvent for cleaning depends on the part s of the applicator to be cleaned and the material that needs to be removed ITW Ransburg recommends that all exterior cleaning be done with non polar solvents to prevent a conductive residue on critical components We also understand that some of these solvents do not always meet the cleaning needs of some materials If conductive polar solvents are used to clean the applicator components all residue must be removed using a non conductive non polar solvent i e high flash Naphtha If there are any questions as to what solvents are best for cleaning contact your local ITW Ransburg distributor and or your paint supplier The Vector applicator air hoses fluid hose and high voltage cable assemblies should not be submerged or soaked in solvent However the outer surfaces of these items can be wiped with a suitable cleaning solvent The items that cannot be soaked are noted throughout this manual All electrical components cannot be soaked in any solvents ITovRansburg AWARNING The user MUST read and be familiar with the safety instructions in this manual gt If compressed air is used in cleaning REMEMBER that high pressure air can be dangerous and should NEVER be used a
74. recess 6 While holding the barrel in place screw the retaining nut onto the handle by hand and then tighten using the special multi purpose wrench NOTE gt Torque the retaining ring to 8 10 Ibs ft or after hand tightening torque an addi tional 1 6 to 1 8 turn using the special multi purpose wrench AH 06 02 11 Figure 35 Barrel to Handle Assembly 7 Check the spacing between the back of the spring retainer and the handle It should be about 1 8 inch If not check for one or more of the following Gasket has been left out Looseretaining nut Loose fluid nozzle e Improper adjustment of the trigger adjustment nut and spring retainer 8 Secure the trigger with the two 2 shoulder screws NOTE The needle shaft travel MUST be checked The air valve stem must be en gaged and moved back slightly before the trigger engages the trigger adjustment nut If this does not occur then the trigger ad justment nut and or the trigger set screw must be adjusted The 11 16 inch dimen sion is only a starting place for trigger ad justment and can be altered to obtain proper triggering sequence Vector R Series Classic Applicators Maintenance 52 Vector R Series Classic Applicators Maintenance IT Ransburg NOTES 53 AH 06 02 11 rwvRansburg HANDLE RESISTOR TUBE Removal 1 The following procedures must be performed prior to removing the hook and resistor tube Barrel removal High Volt
75. rection Fire extinguishing equipment must be presentin 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 used for general cleaning must have flash points above 100 F 37 8 C Spray booth ventilation must be kept at the rates required by local codes and country codes In addition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high voltage to 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 The paint process and equipment should be set up andoperatedin accordance with local and or country safety codes Vector R Series Classic Applicators Safety AREA Tells where hazards may occur HAZARD Tells what the hazard is Toxic Substances Certain mate
76. ressure Air Size Pressure ml min Type SCFM SLPM psi bar Cap inches Reducer Applicators 300 18 510 Vector Material Lacquer 18 Sec No 4 Ford Cup 72 F Results are material dependent Air Flow Air Pressure noted in next column Patterns at 8 inch target distance ROUND SPRAY PERFORMANCE Retaining Nozzle Air Cap Ring Spray Air Applicators Pressure Part Type SCFM SLPM psi bar Pattern Size Y Swivel 7 1 Fan Fan IPressure 79544 00 79542 00 79379 00 Round HornClosed202 25 1 7 Open Closed Reducer Applicators 8 1 2 0 3 5 Black Vector Horn Closed 230 50mm 89mm 31 AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Installation NOTES AH 06 02 11 32 Vector R Series Classic Applicators Operation 33 OPERATION START UP After all installation procedures are completed operation of the applicator may begin When the ON OFF switch is turned on the kV display will show the applicator type the 9050 Power Supply is configured for and the microamp display will show the current software revision level These items are displayed for about 2 3 seconds GUN TYPE NUMBER SOFTWARE REVISIC LEVEL I Hi Tee Spir ON OFF SWITCH Figure 11 Power Supply Start Up Display START U
77. rial may be harmful Explosion Hazard Incompatible Materials Electrical Equipment if inhaled or if there is contact with the skin 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 explosion High voltage equipment is utilized Arcing in areas of flammable or combustible mat erials may occur Personnelare 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 shutdown indicates a probleminthe system which requires correction An electrical arc can ignite coating materials and cause a fire or explosion Ransburg SAFEGUARDS Tells how to avoid the hazard 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
78. roblem DEFECTIVE SPRAY Pattern Will Not Shape Pattern Heavy At One End Extremely Heavy Spitting or Severely Deformed Pattern Possible Cause PATTERN 1 Clogged or faulty fan air valve 2 Air passages in applicator or air line clogged 3 Worn faulty or clogged air cap 4 Barrel restrictor missing 1 Clogged or faulty air cap 2 Clogged or faulty fluid nozzle 1 Wrong air cap fluid nozzle combina tion 2 Faulty air cap INADEQUATE DELIVERY Continued On Next 1 Air passages in applicator or air line clogged Inadequate air source Paint in air passage Clogged or faulty fluid nozzle Clogged passages in applicator fluid tube or fluid line Insufficient needle electrode travel Low fluid supply pressure Clogged fluid filter Clogged or obstructed valve or fluid regulator Page IT Ransburg Solution 1 Clean repair or replace 2 Blow out clean or replace 3 Clean orreplace 4 Replace barrel restrictor 1 Cleanorreplace 2 Clean or replace 1 Ensure proper fluid nozzle air nozzle pressure reducer combinations see Fluid Nozzle Tables in the Installa tion section 2 Replace 1 Blow out 2 Increase pressure flow capacity 3 Clean and blow out 1 Flush or replace 2 Flush 3 Adjust see Trigger Adjustment Nut Dimension Figure in the Mainte nance section 4 Increase 5 Cleanorreplace 6 Clean as required
79. rue earth ground The ground wire assembly MUST be connected from the power supply ground stud to a true earth ground INPUT VOLTAGE SELECTION The 9050 Power Supply accepts universal input voltage between 100 and 240 VAC There is no needto change any switch settings when changing inputfrom 115to 230 VAC orfrom 230to 115 VAC NOTE 9050 units 79344 1X1 shipped from the factory for 115 VAC input will have a 72771 06 1 amp front panel fuse installed While 9050 units 79344 1X2 shipped from the factory for 230 VAC input will have a 72771 01 0 5 amp front panel fuse in stalled If the other input is required it is recommended that the fuse be changed in order to keep the same level of protection AH 06 02 11 Vector R Series Classic Applicators Installation I Y N 0 LIU L3 126 612 FRONT OF CABINET Figure 8 Location of TB1 and TB2 In Power Supply USER SUPPLIED CONTACT CLOSURES BOOTH FAN INTERLOCK TT CONVEYOR INTERLOCK SOLVENT SUPPLY I INTERLOCK INTERLOCK AC IN COMMON NEUTRAL EARTH GROUND AC IN HOT LINE Figure 9a TB1 Interlock Wirin
80. s Maintenance AWARNING gt All six 6 spring washers MUST be replaced alternately as shown in Figure 32 or the applicator will malfunction Figure 32 eee Assembly 12 Place the packing nut large bore first on the rear needle shaft section 13 Screw the trigger adjustment nut onto the rear needle shaft section with the hexagon rearward and the spring retainer with the hexagon forward Do not lock the hexagon nuts in place 14 Install the needle shaft sub assembly into the packing chamber from the rear of the barrel with the needle electrode forward 15 Push the needle shaft sub assembly forward until the packing nut will engage its mating thread in the barrel and screw it into place by hand approximately 3 turns Hit Figure 33 Needle Shaft Assembly Into Barrel rr Ransburg 16 Pull the needle shaft rearward as far as it will go 17 Install the fluid nozzle air cap and retaining nut refer to Air Cap and Fluid Nozzle in the Maintenance section 18 Tighten the packing nut using the spanner tool onthe special multi purpose wrench until it bottoms 27 Figure 34 Trigger Adjustment Nut Dimensions 19 Push the needle shaft forward until the needle electrode seats into the fluid nozzle 20 Adjustthetrigger adjustment nutas far forward on the needle shaft as possible 21 Adjustthe needle shaft spring retaineruntil the rear of the hexagon is 11 16 inch
81. s Identification R90 70 CLASSIC SOLVENTBORNE APPLICATOR PARTS LIST Figure 43 om rang Deo ay 1 79465 85 Barrel MachinedRQ0 1 7946565 Barrel MachinedR70 _ o o 1 2 7987300 Nut Retaining Barrel 3 7532600 Ring Retaining j 41 4 Needle Shaft Assembly R90 2k Packings Std Needle Shaft Assembly R70 2k Packings Std Table 0 02 Nozzle Fluid Standard Air Spray Table D D1 Cap Air 65V Standard Air Spra LSOR0005 17 O Ring Teflon Encapsulated 79379 00 Nut Retaining Air Nozzle 79001 45 EN E Resistor Housing Machined R70 Resistor Housing Machined R90 eu Table B B2 Table B 1 1 JPY JD N Table C C5 Table C Table C Table C 1 ooo 8 9 Ring i 32 3 3 0 See Fluid Nozzle Selection Chart in the Installation section See Air Cap Fluid Nozzle Selection Chart in the Installation section Continued On Next Page AH 06 02 11 62 Vector R Series Classic Applicators Parts Identification rrv Ransburg R90 70 CLASSIC SOLVENTBORNE APPLICATOR PARTS LIST Cont Figure 43 Description Fitting Air Inlet 1 4 NPSM M a 1884700 Fitting Air Inlet 3 8 NPSM M optional
82. stance Testing in the Maintenance section Ressembly Refer to Figures 30 31 32 33 and 34 NEEDLE SHAFT SPRING RETAINER U CUP OPENING TOWARD HANDLE RETURN SPRING TRIGGER ADJUSTMENT NUT PACKING NUT BEVILLE SPRING WASHERS SOLVENT PROOF O RING SEAL RETAINER 2 PIECE NEEDLE PACKING TUBE CHEVRON SEAL ASS Y ELECTRODE ASSEMBLY Figure 31 Needle Shaft Assembly 2k Packings AH 06 02 11 ITovRansburg gt To avoid damage to the chevron seals they MUST be installed from the rear of the barrel 1 Place conductive female chevron adapter onto the front of shaft with the concave side toward the front 2 Screw the four 4 chevron seals onto shaft concave sides forward see Figure 32 DO NOT push the chevron seals straight onto the shaft The shaft threads may damage the chevron bore and cause the applicator to leak fluid gt Inspect needle electrode shaft sealing surface for wear If it is rough or uneven replace it 3 Place male nonconductive chevron adapter onto shaft with the convex end rearward NOTE The chevron adapters and chevron seals should seat together to form an un broken seal 4 Screw needle electrode onto shaft and hand tighten NOTE Apply a light coating of dielectric grease to the chevron seals and needle shaft AH 06 02 11 FAILURE to coat the needle shaft assembly MAY CAUSE lower electrical output of the
83. tem until it runs clear AWARNING Any solvent used to clean the fluid passages must be discharged into a grounded container Use of ungrounded or plastic containers may cause fire or explo sion 7 Disconnect the solvent supply 8 Trigger the applicator until itis clear of solvent After the preceding steps are complete the applicator is ready for color change storage or maintenance gt DO NOT allow the fluid lines to stand empty without flushing first This will cause dried paint flaking and clogging of the fluid lines applicator passages and or nozzles srRansburg APPLICATOR REPAIR All repairs should be made on aclean flat surface If a vise is used to hold parts during service or repair DO NOT clamp onto plastic parts and always pad the vise jaws The following parts should be thoroughly packed with dielectric grease LSCH0009 00 leaving NO air space or voids when assembling All O Rings Teflon o rings do not need lubrication Needle Shaft Assembly Packing Tube Cartridge Assembly Non Adjustable Air Valve Rod Assembly Apply sealant 7969 10 to the external threads of the following parts when assembling Nut Air Valve Retaining 78635 00 Cep Air Valve 79317 00 Equipment Required Special Multi Purpose Wrench 19749 00 3 32 Allen Wrench for Set Screws Screwdriver blade Dielectric Grease LSCH0009 00 Sealant Medium Strength 7969 10 Pl
84. the cable in the order shown in Figure 6 5 Route the cable back through the connector housing and connect its wires to the desired I O terminals inside the 9050 Control Unit or power supply 6 Tighten the cable grommet ensuring the grommet spring makes 360 contact with the exposed braid of the cable for maximum noise immunity 7 For maximum noise immunity connect the braid of the cable to earth ground at the end opposite the control unit or power supply Vector R Series Classic Applicators Installation 22 Vector R Series Classic Applicators Installation Cable Grommet Figure 6 Cable Grommet Analog 1 0 Neo Da 0 64cm v X 1 2 54cm Inside of Cobinet Connector Housing Figure 7 Cable Stripping AC INPUT CONNECTIONS For non conduit installations plug the detachable AC line cord into the receptacle on the side of the power supply Plug the other end of the line cord into a properly grounded 120 volt AC outlet 23 ITovRansburg NOTE gt Due to variations in source connec tions European units are shipped without an AC line cord When selecting a line cord for these units select one that has the ap propriate source connector at the plug end a
85. to the spray applicator with no trigger If this occurs reset the power supply Ifthis fault occurs repeatedly upon reset replace the main PC board SAFETY FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS SF Figure 21 Safety Fault Display Overload Fault OL This fault will occur ifthe overload feature is active see Overload Activation previously in the Operation section andthe output current comes within 10 uA or less of the maximum current Remove the condition causing excess microamps and reset the fault If microamps are typically in this range due to special circumstances turn the overload feature off Current Limit Fault CL This fault will occur if the output current exceeds the maximum current by more than 20 uA for 2 3 seconds Ifthis occurs reset the fault If this fault occurs repeatedly investigate the main PC board or applicator barrel for the cause Voltage Feedback Fault UF This fault will occur if the microprocessor detects a loss of the voltage feedback signal If this occurs reset the fault If this fault occurs repeatedly replace the main PC board Feedback Fault FF This fault will occur if the microprocessor detects a loss of the current feedback signal If this occurs reset the fault If this fault occurs repeatedly replace the main PC board AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Ope
86. tor electrode must be prevented by grounding the paint line at the applicator handle Verify that the applicator handle is actually grounded before operating it This is done with a fully connected and operational system by placing one lead of an ohm meter to the handle and the other to the building electrical ground cold water pipe building structure steel etc This reading should be essentially zero If a greater reading is obtained check that the power supply is grounded See the AC Input Connections Safety Ground in the Installation section AWARNING The power supply must be off when the applicator is removed or reinstalled RELAY CONTACT OUTPUTS A set of relay contacts for high voltage CR1 and fault CR2 conditions is provided at TB2 4 and TB2 2 see Figure 8 One end of these relay contacts are connected together and also connected to a source inputterminal at TB2 3 see Figure 9c When a source voltage is present at TB2 3 and either the high voltage is on or a fault condition occurs the source voltage will become available at the output end of the corresponding contact Maximum contact ratings are as follows smrRansburg MAXIMUM CONTACT RATINGS oe Description C W 62 5VA Max Switching Capacity Max Operating Voltage 125VAC Max Operating Current 2A When wiring to TB2 use a shielded cable and route the wiring through the standard I O connector as described i
87. tributor for specific directions per taining to the installation of your equipment TYPICAL SOLVENTBORNE INSTALLATION See Figure 3 Typical Solventborne Installation Features Location of the Power Supply Install the power supply in an area outside the hazardous location in accordance with federal state and local codes The area should protect the power supply from the possibility of environmentalintrusion such as dust or moisture have ambient temperatures that do not exceed 120 F andbeasclosetothe applicator as possible to minimize the length of high voltage cable AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Installation ai E R 1 MEG OHM Figure 3 Typical Solventborne Installation Features TYPICAL SOLVENTBORNE INSTALLATION FEATURES No Description no Description AC Line Cord 110 220 8 FluidSupply Grounded gt sosoPowerSippy 9 Fuoreguetr 6 AmwaterSeparator 19 Target EanhorBulcingGroun AH 06 02 11 20 Vector R Series Classic Applicators Installation IT Ransburg ELECTRICAL NOISE DO NOT locate the power supply near Electr
88. uarely 72 Vector R Series Classic Applicators Waterborne 73 AWARNING gt Special care must be taken when re moving the sheathing from the fluid hose Make sure all tools are very sharp and only score the surface of the sheath Inserting the knife too deep can score the surface of the core material and lead to pin holing and failure of the hose 4 Carefully score the outer jacket linearly and then radially approximately 18 inches back from the cut end Splitthe outer jacket along the linear score mark and peelitaway fromthe inner sheath Then remove the jacket completely by tearing along the radial score mark 5 Lightly scorethe inner sheath linearly and then radially 1 inch from the outer jacket Splitthe inner sheath along the linear score mark and peel it away from the core fluid hose Then remove the sheath completely by tearing along the radial score mark 6 Roll the inner sheath back over itself until it touches the outer jacket 7 Cutapproximately 1 4 inch of inner sheath off NOTES rrwvRansburg AH 06 02 11 ITovRansburg AH 06 02 11 Vector R Series Classic Applicators Waterborne NOTES 74 Vector R Series Classic Applicators Waterborne WATERDORNE COMPATIBLE ITovRansburg WATERDORNE COMPATIBLE Figure 49 Waterborne Fluid Delivery Components 75 refer to parts list for figure 49 e refer to parts list figure 43 AH 06 02 11 rrv Ransburg Ve
89. urer s documentation 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 thenitis the responsibility ofthe userto take suitable precautions that prevent it from being adversely affected thus ensuring thatthe 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 itis resistant to specific chemicals Refer to Specifications in the Introduction section a All fluid passages contain stainless steel or nylon fittings b High voltage cascade is encapsulated with a solvent resistant epoxy 9 A recapitulation of the certification marking is detailed in the ATEX section on the next page drawing numbers 79515 79496 79516 79537 79538 and 79540 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 accompanied by a translation of the instructions in the language or languages of the country in which the equipment is to be used and by the instructions in the original language AH 06 02 11 rrv
90. urg Control Unit Inputs Outputs 9050 Part 79344 111 79344 112 79344 121 79344 122 Voltage Designation 110 120VAC 220 240 VAC 110 120 220 240 VAC Output 90 kV DC 90 kV DC Control Unit Applicator Combinations 9050 Part 4 79344 11X 79344 12X 79504 XXXXX 79503 XXXXX 79520 XXXXX AH 06 02 11 rrv Ransburg Vector R Series Classic Applicators Introduction Q 20 Figure 2 79344 1XX 9050 Power Supply Features 79344 1XX 9050 POWER SUPPLY FEATURES No Description Desorption _ kV Meter 9 kV Setpoint Adjust Buttons High Voltage On Indicator Air Flow Switch Connections 6 On offSwitth Grundig O 08 One Touch kV Setpoint Button Interlock I O Connector AH 06 02 11 18 Vector R Series Classic Applicators Installation INSTALLATION 79503 R90 SOLVENTBORNE 79504 R70 SOLVENTBORNE INSTALLATION 19 AWARNING The 9050 Power Supply MUST be located outside the hazardous area The User MUST read and be familiar with the Safety section of this manual This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken
91. will be displayed on the microamp meter Faults can be reset by pressing the Reset button on the front of the power supply Cable Fault CF This fault will occur if high voltage is active and the microprocessor detects that no current is being supplied to the applicator Typical causes include a broken or improperly connected cable Other causes could include loose wiring in the control unit or a faulty cascade circuit in the applicator Whenthis fault occurs determine the cause ofthe problem then press the reset button AH 06 02 11 CABLE FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS CF BA Figure 19 Cable Fault Display cg Over Voltage Fault OU This fault will occur if the microprocessor detects the unit is trying to output voltage above that required for the specific applicator type If this occurs reset the power supply If this fault continues to occur replace the main PC board OVERVOLTAGE FAULT ILLUMINATES FAULT INDICATOR AND DISPLAYS OU nu UJ T FAULT AK Figure 20 Over Voltage Fault Display Vector R Series Classic Applicators Operation 36 Vector R Series Classic Applicators Operation IT Ransburg 37 Safety Fault SF This fault will occur if the microprocessor detects the unit is trying to output voltage
92. ying High Voltage On Time PRESS AND HOLD BOTH FOR NON RESETTABLE ON TIME REGISTER Toresetthis register press the reset button while the hours are displayed To view the non resettable register press and hold the preset 2 and reset buttons at the same time Local Remote Mode Button The 9050 Power Supply product line is designed currently for applicators only The mode should be set to local for all Vector applicator applications LOCAL REMOTE HV CONTROL Figure 15 Local Remote Mode Button gt If unit is in remote mode with no external signal the unit will not function The unit must be in local mode Vector R Series Classic Applicators Operation 34 Vector R Series Classic Applicators Operation 35 LOCKOUTS There are lockouts that may be done at the PC board see Figure 16 These lockouts may be used individually or in combination as required If the jumpers are disconnected the original functions are re enabled After changing any jumpers the AC power must be cycled for the new setting to take affect O D6 D De T o o 2865

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