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LN-9521-00.2 Aerobell 33 Rotary Atomizer 3-05.pmd

1. 3 5 LN 9521 00 2 52 s7v7Ransburg Aerobell 33 Rotary Atomizer Appendix Electrostatic Systems ITW RANSBURG VISCOSITY CONVERSION CHART Continued Universal SSU Craftsman Cup Centipoise _ TUTTE 6 Saybolt Sears A a NIN PLO DM S als ojojo 45 0 alo alo oja i A o o NI a 2T2 2T2 a ajala O O KRIN alS a o 5 e 000 2 C f 199 peo Note All viscosity comparisons are as accurate as possible with existing information Comparisons are made with a material having a specific gravity of 1 0 05 2004 Illinois Tool Works Inc All rights reserved LN 9521 00 2 58 Aerobell 33 Rotary Atomizer Appendix sT Ransburg Electrostatic Systems VOLUMETRIC CONTENT OF HOSE OR TUBE English Units cc ft Section st em BEEBEdE 3E 3E EE 4 fl oz 81 OZ 12 fl OZ 204 02 4 fl OZ 91 02 18 fl OZ 281 02 461 02 9 2 fl
2. 7 Aerobell 33 w 30mm Bell AER4015 06 AERO0038 RPM 80 TABLE Figure 16 Description zs S S Fluid Tube 041 1 0 76416 04 S S Fluid Tube 093 1 0 76416 09 S S Fluid Tube 125 1 0 76416 12 S S Fluid Tube 061 1 0 76416 06 38 LN 9521 00 2 sT Ransburg Aerobell 33 Rotary Atomizer Parts Identification Electrostatic Systems TABLE C Figure 16 Dash Description t Fua oiea Duno 78 aterase Fua vanto TABLE D Figure 16 Dash Description 2 14 or 38 O D supply wo Fiuid Regulator o Supt wewa tow Fow 2 9 Regulator Fow 2 1 Sup wra Regulator 13 tow Few 2 o 1 Sustr wis Ta Low Fow 2 1 o Regulator Few 2 tn amp Gsres wrop Reouior 18 tow Fow 2 _ o 1 Sup wru 1 Low Fow 2 A 8800 wir Regula 11 tow Fow 1 8595 wir Regulate t2 tow Fow E 7 9800 Sippy wird Regard Low Row tneesoorss 7
3. 9800 Regulator Slow T wiv 1 Loon 1 1 Supt 3 1 TABLE E Figure 16 Resistor Block 650 Megohm AER4012 LN 9521 00 2 39 Aerobell 33 Rotary Atomizer Parts Identification sT Ransburg 40 Electrostatic Systems AEROBELL 33 PARTS LIST Inge 16 Description oes 1 ____ AER4004 001 Manifold Assembly Air 1 2 See J Table A Shaping Air Gap wiShroud 1 Table Fluid Tibe ___ _ 1 gt _ a eons onn Swn 5 LSFA0014 00 Screw Retaining O 6 AER4013 00 Tube Assembly High Voltage CT 1 7900105 O Ring Solvent Prot 7 See L Table C Manifold Assembly Fluid 11 Stews Sse 5 867 ead __9 LSFA0004 56C Screw 1 4 20 x 1 3 4 Long Fill Head 7554103 Turbine Assembly O Ring Solvent Resistant 1 7554 2104 Turbine Assembly O Ring Solvent Resistant 1 11 755403 1 O Ring Solvent Resistant 1 12 HPM2 J RhRetanenShapngAirCap 1 13 See Ring Shaping Air 14 55994 25 Tubing 3 8 O D Teflon 275 15 LSOR0005 01 O Ring Solvent
4. As with any spray finishing system operation of the Aerobell 33 involves properly setting the operating parameters to obtain the best finish quality for the coating material being sprayed while maintaining correct operation and reliability of the equipment used Adjustments to operating parameters which cover spraying cleaning and on off control include Coating Materials Fluid Flow Rate Control Fluid Valve Control Turbine Speed Bearing Air Adjustment Shaping Air Brake Air Electrostatic Voltage Target Distance COATING MATERIALS The Aerobell 33 can be used with a full range of coating material conductivities However with coatings having very high conductivities such as waterborne paints it may be necessary to isolate paint supply from ground sT Ransburg Electrostatic Systems A WARNING gt Electrical discharge of a high electrical capacitance fluid paint system can cause fire or explosion with some materials If arcing occurs when a specific coating materials is used turn the system off and verify that the fluid is non flammable In these conditions the system is capable of releasing sufficient electrical and thermal energy to cause ignition of specific haz ardous material in air FLUID FLOW RATE CONTROL Fluid flow is controlled by an internally mounted dual diaphragm fluid regulator Reference the LREG5001 DR 1 Plastic Fluid Regulator Manual latest version for d
5. See Parts List Bullet Definition Table below a PARTS LIST BULLET DEFINITION TABLE Figure 18 2 Install fitting hand tight then 1 4 turn with wrench Apply 59915 01 teflon tape to all male pipe threads LN 9521 00 2 45 Aerobell 33 Rotary Atomizer Parts Identification sT Ransburg Electrostatic Systems Figure 19 Waterborne Fluid Manifold Assembly 46 LN 9521 00 2 Ransburg Aerobell 33 Rotary Atomizer Parts Identification Electrostatic Systems WATERBORNE FLUID MANIFOLD ASSEMBLY PARTS LIST Figure 19 3 AER4023 00 AER4020 AER4021 00 ak 1 AERO068 00 Manifold Fluid Engraved _____ 1 1 _ 2 1960092 04 174 Tube x 14 AN Union z 2 0 0 Tube 3A LSMM0035 05 Plug Protective 2 68700 Valve FV 4A AER4018 00_ Plug Assembly Vave Pot 2 5 t5H106 5 93 Fig Tube See Parts List Bullet Definition Table below PARTS LIST BULLET DEFINITION TABLE Figure 19 2_ Install fitting hand tight then 1 4 turn with wrench 1 Apply 59915 01 teflon tape to all male pipe threads LN 9521 00 2 47 Aerobell 33 Rotary Atomizer Parts Identification RECOMMENDED SPARE PARTS Pane
6. Bearing damage and subsequent turbine failure caused by running the turbine without bearing air will not be covered under the ITW Ransburg warranty The Aerobell 33 is equipped with a bearing air return line to monitor bearing air pressure at the turbine manifold When connected to the re mote Atomizer speed controller operation of the turbine will automatically be shut down whenever the bearing air pressure falls below 60 psi SHAPING AIR Shaping air is used to shape the spray pattern Lower input pressure results in wider pattern size while higher input pressure reduces the pattern size Shaping air does not help atomize the material butwill assistin the penetration of atomized particles into cavity areas Ideally shaping air 18 should be keptat the minimum pressure which will provide a proper finish for the fluid being sprayed Excessive shaping air will cause some atomized particles to blow by the target reducing the wrap around effect at edges and corners Excessive shaping air may also cause some paint particles to bounce back onto the atomizer causing the atomizer surface to become contaminated BRAKE AIR Brake air is used to slow the turbine speed ina minimum length of time It is advantageous for short cycle times during color change or may be used to reduce speed or stop the turbine Never operate brake air with the turbine air on Approximate brake times to reduce the turbine speed are shown in Figure 13
7. The bell rotational speed determines the quality of atomization and can be var ied for various paint flow rates and paint formulations For optimum transfer effi ciency and spray pattern control the bell rotational speed should be set at the mini mum required to achieve proper atomiza tion Excessive speed reduces transfer efficiency AWARNING gt Do not exceed the maximum rated intermittent operating speed and turbine inlet pressure 55 000 rpm at approxi mately 60 psi for the 57mm bell or 55 000 rpm at approximately 45 psi for the 30mm bell Excessive speed may cause air turbine damage or damage to the bell Aerobell 33 Rotary Atomizer Operation sT Ransburg Electrostatic Systems BEARING AIR ADJUSTMENT The nominal bearing air pressure is 90 psi measured at the rear of the atomizer Minimum pressure is 70 psi and maximum pressure is 100 psi The turbine should never be operated with less than 70 psi bearing air pressure Bearing air must be present when turning the turbine on Bearing air must remain on when the turbine air is turned off until the turbine stops spinning Never turn off bearing air to cause the turbine to stop spinning If connected brake air can be used to slow the turbine gt Bearing air must be on whenever the turbine is operated If not severe bearing damage will occur It is recommended that bearing air be left turned on at all times except during maintenance or disassembly
8. These times are based on 60 psi air pressure at the brake air connector The use of brake air is optional and may not be required for many installations The Atomizer Module control system provides the circuitry for automatic use of the brake air Seconds Approx 50 000 to 40 000 S o Brake From RPM 7 5 10 0 4 0 Figure 13 Braking Time LN 9521 00 2 Ransburg Aerobell 33 Rotary Atomizer Operation Electrostatic Systems ELECTROSTATIC NOTES VOLTAGE The Aerobell 33 Rotary Atomizer receives its operating voltage through a high voltage cable that is connected to a remote power supply The power supply model and high voltage setting will depend upon various application requirements See the Specifications section of this manual for approved power supplies and refer to that manual for detailed operating instructions NOTE gt If paint defects occur such as fatty edges or picture framing reducing the voltage should be a last resort To correct the problem adjustments to paint resistivity or lead and lag trigger adjust ments should be made The electrostatic voltage applied to the Aerobell 33 will affect pattern size trans fer efficiency wrap and penetration into cavity areas Normally 100 kV setting is appropriate for most applications TARGET DISTANCE The distance between the Aerobell 33 atomizer and the target will affect the finish quality and efficiency Closer distances give a small
9. Unloaded Shaping Air Flow 10 15 Pressure PSI Figure 5 Shaping Air Flow LN 9521 00 2 57mm Bell Loaded vs Unloaded 600 Water 30 35 40 45 50 55 Thousands RPM Figure 4 57mm Bell Loaded vs Unloaded Bearing Air Flow 2 6 2 5 24 2 3 2 2 2 1 2 1 9 1 8 1 7 1 6 1 5 55 60 65 70 75 80 85 90 95 Pressure PSI Figure 6 Bearing Air Flow Aerobell 33 Rotary Atomizer Installation INSTALLATION AIR FILTER INSTALLA TION The following air filter installation guidelines are essential for optimum performance 1 Use only recommended pre filters and bearing air filters as shown in Figure 8 Additional system air filtration i e refrigerted air dryer may also be used if desired 2 Mount the bearing air filter as close as possible to the Aerobell 33 Do not mount further than 30 feet away 3 Do not use Teflon tape pipe dope or other thread sealant downstream ofthe bearing air filter Loose flakes of Teflon tape or other sealant can break loose and plug the very fine air holes in the turbine air bearings 4 Ifairheaters are usedinthe system to minimize the effect of excessively humid conditions and the heated air will exceed 120 F the heaters must be located after all filters to
10. between the rear of the turbine assembly and the front of the air manifold assembly Any irregularity in this seam between the two assemblies would indicate improper mounting Looking into the front of the motor shaft observe the concentricity of the paint feed tube to the inside of the motor shaft If the paint feed tube is off center by more than 020 028 inches radially the motor as sembly may not be seated properly Do not use the four mounting bolts to pull the turbine assembly into air manifold This can cause the thread to be damaged Torque the four mounting bolts to 15 AWARNING gt Using the RPM 419 wrench mini mum of 50 Ib in of torque must be applied when tightening the bell cup onto the motor shaft to deter the bell cup from spinning off the shaft if the motor seizes Operating the turbine motor when it is not properly fitted to the air manifold can cause severe damage to the motor bell assembly and or operating personnel 29 Aerobell 33 Rotary Atomizer Maintenance Rear Shroud Removal The rear shroud Figure 16a item 33 can be removed for cleaning or inspection of the components on the inside of the assembly Loosen the two captive screws Figure 16a item 28 by turning them inward clockwise Slide the shroud backward over the hoses and high voltage cable Note that it is not necessary to remove the shroud completely from the hoses Slide it backward over the hoses for easy a
11. thorough cleaning When installing the front shroud onto the turbine assembly be sure that it is fully tightened The shroud will appear tight after a few turns but will still be loose The shroud can then be tightened down fully until it bottoms against the air manifold assembly LN 9521 00 2 Ransburg Electrostatic Systems Atomizer Bell Cup Removal remove the atomizer bell cup Figure 16a item 16 place the wrench part number RPM 419 over the flats on the motor shaft to lock in place Unscrew the bell by turning CCW with the other hand facing the front of the atomizer If the bell cannot be removed by hand use a second RPM 419 wrench placed over the wrench flats of the bell cup Refer to Preventive Maintenance in the Maintenance section for important information about bell and shaft cleanliness Do not install paint contaminated or damaged bell onthe turbine shaft When installing the bell on the shaft the bell should be firmly secured by hand or use wrench RPM 419 and torque to 50 0 40 Ib in Turbine Removal The turbine assembly Figure 16a item 10 is removed from the Aerobell 33 atomizer after removing the front shroud assembly Four mounting bolts Figure 16a item 8 will then be exposed which hold the turbine assembly to the air manifold assembly These are the larger socket head screws located toward the outer edge of the motor housing Holding the turbine assembly caref
12. Figure 17 Do not use any lubricant O ring must remain dry Place rear shroud over assembly before securing rear plate Install rear cover fasteners below the surface of rear plate before installing the rear shroud To lock the shroud into position align the mounting holes with the fasteners and rotate each fastener counter clockwise until it fits snugly against the shroud Orient mounting stud with flat towards front as shown Apply 59915 01 teflon tape to all male pipe threads LN 9521 00 2 43 Aerobell 33 Rotary Atomizer Parts Identification 44 sT Ransburg Electrostatic Systems P IN V VISOL Figure 18 Fluid Manifold Assembly LN 9521 00 2 s7v7Ransburg Aerobell 33 Rotary Atomizer Parts Identification Electrostatic Systems FLUID MANIFOLD ASSEMBLY PARTS LIST a 18 3 AER4003 00 AER4000 AER4001 00 a LSFI0022 04 Fiting 1 4 0 Tube x 14AN 2 2A 5 0 Protective s isror Eara SE OD Tube x SERITUR L1 SA SMMO035 05 Plug Protective te 69100 valve Reset Cartage 4A AER4018 00 Piug Assembly Valve Pot 2 1 5 __ LSFI0013 03_ Fitting 4O D TubexV8NPT 31 2 2 3 1
13. If conductive polar solvents are used to clean the Aerobell 33 unit all residue must be removed using a non conductive non polar solvent ex high flash naphtha LN 9521 00 2 s7v7Ransburg Electrostatic Systems Do not spray the Aerobell 33 unit with sol vent gun used for cleaning The cleaning fluid under pressure may aid conductive ma terials to wick into hard to clean areas or may allow fluids to be forced into the turbine as sembly Do not reuse an atomizer bell that shows signs of damage such as nicks heavy scratches dents or excessive wear AWARNING gt 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 surface and discharge to the nearest grounded object Efficiency of the applicator will also be reduced and dam age or failure of the applicator compo nents may occur WRAPPING THESE COMPONENTS IN PLASTIC WILL VOID WARRANTY AWARNING gt To reduce the risk of fire or explosion OSHA and NFPA 33 require that solvents used for exterior cleaning including bell cleaning and soaking be nonflammable flash points higher than 100 F 37 8 C Since electrostatic equipment is involved these solvents should also be non polar Examples of non flammable non polar solvents for cleaning are Amyl acetate methyl amyl acetate high flash naphtha and mineral spirits gt Do use conductive
14. Proof a 16 See N Table A Assembly 17 X LSFI0022 04 Fitting 1 4 O D Tube x 1 4 AN Union 18 ___ See T Table D ___ Regulator Assembly Fluid aes 22__ AERO043 00 Cover Connector Machined 21 LSFA0007 12C Screw 10 24 x 3 8 Long Nyl W 22 See X Table Voltage 00000 1 22A ___ 76419 00 Strain Relief High Voltage Cable ___6__ Ref 24 lt AERO063 00 Cover Rear Plate Not Shown 25 LSFI0022 07 Fitting 3 8 O D Tube x 3 8 AN Union s et 27 55994 28 Tubing 1 4 O D Teflon 7 corresponding table and column on pages 38 amp 39 See Parts List Bullet Definition Table on page 40 PARTS LIST BULLET DEFINITION TABLE Figure 16 300 dia Ref of feed tube 76416 xx to be concentric to 500 1 0 Ref of shaft AER0032 Ref to within 020 028 radially Use 76 01 Ref center checking gauge to check feed tube location Rebuild air motor bearing using AER4019 kit not included with this assembly Warning Torque to 50 Ib in 40 0 Ibein Tighten screws alternately to a final torque of 15 Ibein AER4014 support assembly is shown for reference only is not included with this assembly and must be ordered separately Must be connected between P OUT on flui
15. See Table B Pg 34 Fluid Tube SSG 8128 O Ring Solvent Resistant sT Ransburg Electrostatic Systems See Table N 34 LSFA0004 56C Screw 1 4 20 x 1 75 Long Nyl Fill Head 73913 01 Regulator Repair Kit w Solvent Proof O Rings Figure 20 Recommended Spare Parts SERVICE KITS AER4019 00 73913 00 Regulator Repair Kit w Solvent Resistant O Rings 73913 01 Regulator Repair Kit w Solvent Proof O Rings Figure 21 Service Kits AVAILABLE TOOLS Pat Description RPM 419 Shroud Wrench AERO0076 01 Feed Tube Center Location Gauge Figure 22 Available Tools 48 LN 9521 00 2 Ransburg Aerobell 33 Rotary Atomizer Parts Identification Electrostatic Systems NOTES LN 9521 00 2 49 Aerobell 33 Rotary Atomizer Warranty Policies sr Ransburg Electrostatic Systems WARRANTY POLICIES LIMITED WARRANTY ITW Ransburg will replace or repair without charge any part and or equipment that falls within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with ITW Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANS BURG APPROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts a
16. actuate 3a Fluid valve air pilot pressure is too low Clogged fluid tube Fluid valve open Fluid valve seat damaged or wom Insufficient back pressure to fluid regulator Fluid regulator does not control flow Damaged o ring s on outer diameter of valve body Damaged or worn needle seals inside valve assembly Regulator cap is loose Ruptured diaphragm Pinched or cut o ring between lower support washer and diaphragm Figure 15 Troubleshooting Verify that air pilot signal is present Increase air pressure to 70 psig minimum Replace fluid valve Remove and inspect fluid tube Remove air pilot signal If still open replace fluid valve Replace fluid valve seat Replace fluid tube with the next smaller inner diameter size Disassemble fluid regulator and inspect for failed components Replace o ring s Replace valve assembly Disassemble clean and reassemble Tighten regulator cap hardware Replace diaphragm Replace o ring Guide Continued LN 9521 00 2 sr Ransburg Aerobell 33 Rotary Atomizer Maintenance Electrostatic Systems NOTES LN 9521 00 2 35 sT Ransburg 33 Rotary Atomizer Parts Identification Electrostatic Systems PARTS IDENTIFICATION p Me EZR pe cA Lary ain S o ZZ 722 FEE A Zo GU ZU ces ce X A
17. be allowed in the spray area The high voltage supplied to the atomizer must be turned off priorto 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 NFPA 33 OSHA and local codes In addition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high 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 set up operations Production should never be done with safety interlocks disabled Never use equipment intended for use in waterborne installations to spray solvent based materials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and OSHA requirements LN 9521 00 2 s7v7Ransburg Electrostatic Systems AREA Tells where hazards may occur General Use and Maintenance Electrical Equipment e lt Explosion Hazard Incompatible Materials LN 9521 00 2 HAZARD Tells what the ha
18. is 1 9 inches for mounting to a reciprocator stationary stand or other means of support The atomizer assembly is mounted to this horizontal rod by a 3 4 inch insulating post inserted into a swivel clamp and secured by four plastic bolts The arrangement allows positioning of the front of the turbine Normally the insulator support rod is positioned perpendicular to the conveyor path with the swivel providing for left or right adjustment of the atomizer assembly The swivel clamp plate can be inverted to provide a locking mechanism to hold the applicator in line with the insulator support rod FLUID CONNECTIONS The paint supply to the Aerobell 33 is connected at the rear ofthe atomizer assembly to the regulator Solvent and dump line connections enter the housing and are connected to the appropriate valves Ports are labeled with blue lettering sT Ransburg Electrostatic Systems ELECTRICAL CONNECTIONS Electrical connections to the Aerobell 33 atomizer assembly consist of only the high voltage cable This cable plugs into the resistor module fitting located at the rear of the assembly which protrudes through an opening inthe rear bulkhead After inserting the cable entirely into the tube and feeling the banana plug make contact on the inside tighten the cable compression fitting nut around the high voltage cable with an appropriate wrench Reinstall connector cover with plastic screw SPEED MONITOR CONNECTION
19. prevent damage to the filter media 10 sT Ransburg Electrostatic Systems AIR PRESSURE REQUIREMENTS Tube Size Air Pressure Requirements Bearing Air 1 4 O D 90 psi 10 Supply B A 621kPa x 69kPa Bearing Air 1 4 O D 80 psi 10 Return B A 551kPa 69kPa Turbine 1 2 O D Shaping Air S A 3 8 O D Brake Air BRK 3 8 60 psi 10 if used 413kPa x 69kPa 1 4 80 psi x10 551kPa 69kPa Trigger Valve 80 psi 10 Control TV Dump Valve 551kPa 69kPa Control DV Solvent Valve Control SV T O D 80 psi 10 551kPa 69kPa Paint Fluid Regulator Optional High Flow Signal Air High 1 4 O D Variable 70 psi max 482 kPa Variable 80 psi max 551 kPa Low Flow 1 4 O D Signal Air Low Figure 7 Air Tubing Connections LN 9521 00 2 sT Ransburg Aerobell 33 Rotary Atomizer Installation Electrostatic Systems AIR FILTRATION REQUIREMENTS ITW Ransburg Replacement Filter Model Description Specifications Element Part No HAF 503 Pre filter removes coarse amounts of oil moisture amp dirt Used upstream of RPM 417 pre filter used in systems with poor air quality RPM 417 Pre filter coalescing type 136 scfm 98 5 efficiency particulate removal 3 to 6 micron max aerosol passed 1 0 micron max solid passed 4 micron dependent upon scfm requirement per applicator one RPM 417 can be used with up to three Aerobell 33 ass
20. pun etae idend 12 cA 13 OPERATION 14 19 COATING MATERIALS Dad banc E EE aaae EA a a 14 FLUID FLOW RATE CONTROL cederet 14 16 FEUIDVALVE CONTRO c cut bud 17 TUBE zampe L 17 BEARING AIR ADJUSTMENT iid etel sai o ce DU Ru on eats Cute UO ese toad bd enin 18 AIR RN E TUE Tr rr 18 BRAKE AIR or direi ema nen eae 18 ELECTROSTATIC VOLTAGE 2 ue reiner pu eb edes 19 E qan cuv bla dr tise ____ ET 19 MAINTENANCE 20 34 CLEANING PROCEDURE S ee dea a E iue us 20 22 VIBRA TONNOIS uu o 22 TURBINE REPAIR 22 HIGH VOLTAGE CONMEGTICNS pora ___ nenene 22 AIR FILTEBS ELEMENT REPLACEMENT etin e Ie REIHE 22 po Ez P a 23 Ciz morer O 23 PREVENTIVE MAINT ENAN sitire t retra eda rk Fendi arie RAS 23 27 LOWVOLFPAGE TES Licorne ucibus 28 DISASSEMBLY PROCEDURES dde nts interd ret 28 31 TROUBLESHOOTING GUIDE 9 52 9598513 0h10 er ra Oum ee 3
21. solvents such as MEK to clean the external surfaces of the Aerobell 33 gt When using rag to hand wipe the Aerobell 33 the turbine air should be off but leave the shaping air and bearing air turned on Ensure the rotation has come to a complete stop Be careful not to drip solvent into the opening behind the bell LN 9521 00 2 Aerobell 33 Rotary Atomizer Maintenance Bell Cleaning Normally the internal cleaning instructions will suffice to clean the bell If the internal cleaning instructions does not sufficiently remove all paint and residue from the bell the bell may be removed for hand cleaning NOTE gt It be advantageous to develop a maintenance schedule for hand cleaning and inspection of the atomizer bell cup See Service Literature IL 304 in the Appendix section of this manual Inspection of the bell semiconductive coating is required to determine if wear or flaking has occurred Excessive loss of bell coating can cause poor transfer efficiency and paint wrap back onto the atomizer Clean the bell by soaking in an appropriate solvent to soften paint residue Do not soakfor more than a 24 hour period Use a soft cloth to remove the paint and a soft tool like a toothpick to clean the paint holes Be sure that all signs of paint are removed Rinse and dry the bell AWARNING gt attempt clean the bell edge while the bell is rotating When attempting to stop or slow down
22. the air bearing Normally pneumatic inter locks will not allow the paint to trigger on when the turbine air is off A WARNING gt The high voltage and or coating material must never be turned on unless the bell cup is mounted on the motor shaft and the turbine is rotating gt Pneumatic input to the turbine air inlet must be controlled to prevent the turbine from exceeding the maximum rated intermittent speed of 55 000 rpm See Specifications in the Introduction section 2 It should not be possible for the coating material to be sprayed unless the turbine is spinning LN 9521 00 2 3 Two interconnected bearing air ports are pro vided one for supply air and the other to be used as a return signal for measuring bearing air pressure at the atomizer If bearing air falls below 60 psi at the atomizer the turbine air should be automatically interlocked to shut off 4 High voltage must be interlocked with the sol vent valve pilot signal to prevent solvent flow while high voltage is energized 5 Turbine air and brake air must be interlocked to prevent both from being used simultaneously Aerobell 33 Rotary Atomizer Installation 13 Aerobell 33 Rotary Atomizer Operation 14 OPERATION A WARNING Operators must be fully trained in safe operation of electrostatic equipment Operators must read all instructions and safety precautions prior to using this equipment See NFPA 33 Chapter 16
23. the bell not only transfers the high voltage to the bell edge but also helps to control the discharge energy at the bell edge to achieve safe operation High Voltage Cables The SSW 1064 high voltage cable is used to connect the power supply to the resistor module inside the atomizer assembly Speed Monitor Control The Aerobell 33 rotary atomizer is designed to operate with the ITW Ransburg PulseTrack or Atomizer Module for speed monitoring and or speed control Aerobell 33 Rotary Atomizer Introduction SPECIFICATIONS Electrical Power Supply LECU5003 LEPS5001 Type Voltage Master 76045 LEPS5002 MicroPak Charging Method Direct Output Voltage 30 100 kV Variable Output Current 125 Short Circuit Turbine Speed Control PulseTrack or Eurocard Atomizer Module Paint Resistance 1 to Use Model No 76652 Test Equipment Part Sprayability Determine sprayability of part to be coated using 76652 Test Equipment See TE 98 01 Mechanical Length Diameter Approximate Weight Turbine Type Turbine Air Supply At 30 000 rpm Nominal Maximum Turbine Speed 30mm Bell Cup 57mm Bell Cup Bearing Air Supply Nominal Shaping Air Supply Nominal Brake Air Supply Nominal Maximum Fluid Pressure Supply Fluid Flow Rate sr Ransburg Electrostatic Systems 16 5 inches 419mm 5 6 inches 142mm 10 3 Ibs 4 7 kg Air Bearing Impulse Drive V
24. the minimum required to achieve proper atomization of the coating material Shaping air should be set at the minimum volume required to gently direct the spray pattern toward the part being coated Exces sive shaping air will cause some atomized particles to blow by the part or bounce back onto the atomizer The recommended target distance is between 8 and 12 inches see Target Distance in the Operation section of this manual Verify supply air pressure Verify bearing air return signal Increase bearing air supply pressure to 90 psig 10 psig Remove brake air signal turbine air and brake air must be interlocked to prevent both from used simultaneously Repair or replace fiber optic cable Re install fiber optic cable and tighten the com pression nut Replace fiber optic transmitter Verify rotation of turbine the paint valve air pilot must be interlocked with the turbine speed feed back signal to ensure that paint does not flow into the air bearing Verify fluid supply Verify that air pilot signal is present Figure 15 Troubleshooting Guide Continued 33 Aerobell 33 Rotary Atomizer Maintenance sT Ransburg Electrostatic Systems General Problem Possible Causes Corrective Action No Fluid Flow Continued Continuous Fluid Flow Uncontrollable Fluid Flow Fluid Leakage Around Fluid Valve Fluid Leakage Around the Fluid Regulator Cap 34 3 Fluid valve does not
25. 2 34 LN 9521 00 2 Aerobell 33 Rotary Atomizer Contents sT Ransburg Electrostatic Systems ee PRBE PARTS IDENTIFICATION 36 48 AEROBELE 33 CROSS SEC HON VIEW 36 37 AEROBELL 33 MODEL 1 nennen nnne 38 39 33 PARTS EIST iicet etta tete eee ect ia e Eee ns stoves dace let eu ce Eos ctae 40 MANIFOLD ASSEMBLY PARTS 51 42 43 FEUIDMANIFOED ASSEMBLY PARTS LIS ccce tet rer cote oi tete e eee es 44 45 WATERBORNE FLUID MANIFOLD ASSEMBLY PARTS es Feci e ve cet Va ccs tinc E Ripe PvE d RE dd 46 47 RECOMMENDED SPARE PARUS tet roit fas terror asin eR Ree 48 SERVICERIT mtem 48 AVAILABLE TOOLS eter cese 48 WARRANTY POLICIES 50 LIMITED WARRANTY i ccena dev reet cin aa ecc c 50 APPENDIX 51 54 PAINT AND SOLVENT nen nennen nnn nna 51 VISCOSITY CONVERSION 52 53 VOLUMETRIC CONTENT OF HOSE 54 LN 9521 00 2 s7v7Ransburg Electrostatic Systems SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any ITW Ransburg electrostatic coating system read and understand all of the technical and safety literature for your ITW Ransburg products This manual contains information that
26. 60 SEC TURBODISK 20 TO 60 SEC AEROBELL 11 AEROBELL AEROBELL 33 RMA 101 20 TO 60 SEC PAINT ELECTRICAL RESISTANCE AMQTOce 1TO1MQ RECOMMENDED DELIVERY UP 1000 cc min 1500 cc min 180 cc min 1000 cc min GUIDE TO USABLE SOLVENT SELECTION Chemical Common Category Flash CAS Evap Name Name TCC Number Ratet DICHLOROMETHANE Methylene Chloride Chlorinated Solvents 75 09 2 500 cc min HIGH VM amp P NAPHTHA Naptha Aliphatic Hydrocarbons 8030 30 6 HIGH ACETONE Ketones 67 64 1 LOW METHYL ACETATE Esters 79 20 9 LOW BENZENE Aromatic Hydrocarbons 71 43 2 HIGH ETHYL ACETATE Esters 141 78 6 MEDIUM 2 BUTANONE MEK Ketones 78 93 38 MEDIUM ISO PROPYL ACETATE Esters 108 21 4 LOW ISOPROPYL ALCOHOL IPA Alcohols 67 63 0 LOW 2 PENTANONE MPK Ketones 107 87 9 MEDIUM METHANOL Methyl Alcohol Alcohols 67 56 1 LOW PROPYL ACETATE n Propyl Acetate Esters 109 60 4 LOW TOLUOL Toluene Aromatic Hydrocarbons 108 88 3 HIGH METHYL ISOBUTYL KETONE MIBK Ketones 108 10 1 MEDIUM ISOBUTYLACETATE Esters 110 19 0 LOW ETHANOL Ethyl Alcohol Alcohols 64 17 5 LOW BUTYL ACE
27. No High Voltage Bell cup damaged Low voltage Bad fluid regulator Paint lodged in shaping air ring High current draw Solvent valve is actuated Loss of high voltage con nection at the power supply Loss of high voltage con nection at the resistor module Loss of high voltage con nection at the turbine assembly Power supply failure Improper limiting current and voltage settings Atomizer grounding out usually indicated by high current draw Damaged high voltage cable between atomizer and power supply Improper color change i e paint or solvent in Replace bell cup See low or no voltage below Repair or replace fluid regulator Disassemble and clean Paint resistivity to be 1 MQ to e Remove solvent valve air pilot signal high volt age must be interlocked with the solvent valve air pilot signal to prevent solvent flow while high voltage is energized Ensure proper high voltage connection at the power supply Refer to Low Voltage Test in the Weekly Maintenance section of this manual Verify high voltage connection into the resistor module Refer to Low Voltage Test in the Weekly Maintenance section of this manual Verify high voltage tube connection into the turbine housing and resistor module Refer to Low Voltage Test in the Weekly Mainte nance section of this manual Refer to the power supply manual for detailed troubleshooting guide To readju
28. Oz 1 6 fl oz 3 3 fl 4 9 fl oz 8 2 fl oz 16 3 fl oz 251 02 5 1 fl 07 761 OZ 12 7 fl OZ 25 5 fl 07 ae eee ee Aa 371 02 7 3 fl Oz 11 0 fl 07 184 fl OZ 36 7 fl OZ 8 6 051 gal 102 gal 153 gal 255 gal 510 gal 6 5 fl oz 13 1 fl 19 6 fl oz 32 6 fl oz 65 3 fl oz VOLUMETRIC CONTENT OF HOSE OR TUBE Metric Units LD Cross Length cc m Section mm X9 som 45m som 7em 05 2004 Illinois Tool Works Inc All rights reserved 54 LN 9521 00 2 s7v7Ransburg Aerobell 33 Rotary Atomizer Appendix Electrostatic Systems MANUAL CHANGE SUMMARY This manual was published to replace Service Manual LN 9521 00 1 Aerobell 33 Rotary Atomizer to make the following changes 1 Added Bell Cup Cleaning Bell Cup Testing and Bell Cup Handling in the Maintenance section 2 Added Operator Maintenance Warnings in the Maintenance section 3 Revised Aerobell 33 Parts List in the Parts Identification section Items 4 6A and 10 4 Replaced Paintand Solvent Specifications in the Appendix section 5 Removed 1 304 High Performance Thermoplastic Bell Cup Preventitive Maintenance in the Appendix section Information added in the Maintenance section 6 Revised Contact Information on the Back Cover LN 9521 00 2 Service Manual Price 50 00 U S Manufacturing 1910 North Wayne Stree
29. S A fiber optic cable assembly connects the speed signal output of the rotary atomizer assembly to the Pulsetrak Speed Monitor Control System or Fotronics V Atomizer Module Fixed Pressure Atomizer nominal max 156 170 or 188 1 0 100 psig P IN PFA Teflon 689 kPa 125 I D PFA Teflon 250 I D PFA Teflon Solvent Line SOL Dump Line Figure 9 The normal fluid flow range is 25 500 cc min The maximum flow rate must not exceed 500 cc min to avoid solvent or paint from flooding into the internal portion of the air bearing motor assembly or front shroud 30 60 psig 207 413 kPa Fluid Tubing Connection Requirements LN 9521 00 2 s7v7 Ransburg Electrostatic Systems INTERLOCKS The following system interlocks are required to prevent equipment damage 1 Bearing air should remain on at all times should be shut off only by turning off the main air to the pneumatic control cabinet gt When the turbine air is turned off the turbine will continue to operate or coast down for about two minutes Provisions should be made to assure that the opera tor waits at least three minutes after shutting off the turbine air before shutting off the main air supply The bell assembly must be removed when making flow checks If the paint is turned on when the bell is mounted on the motor shaft and not rotating paint will enter the shaft and possibly damage
30. Safety Section in this manual and the ITW Ransburg safety literature therein identified gt This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD prior to installing operating and or servicing this equipment A WARNING The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 Aerobell 33 Rotary Atomizer Safety AREA Tells where hazards may occur Spray Area HAZARD Tells what the hazard is Fire Hazard Improper or inadequate opera tion and maintenance procedures will cause a fire hazard Protection against inadvertent arcing that is capable of causing fire or explosionis lost if any safety interlocks are disabled during operation Frequent power supply shutdown indicates a problem in the system requiring correction sT Ransburg Electrostatic Systems SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accumulation of combustible residues Smoking must never
31. TATE Esters 123 86 4 LOW ETHYLBENZENE Aromatic Hydrocarbons 100 41 4 HIGH 1 PROPANOL n Propyl Alcohol Alcohols 71 23 8 LOW 2 BUTANOL sec Butyl Alcohol Alcohols LOW XYLOL Xylene Aromatic Hydrocarbons HIGH AMYL ACETATE Esters MEDIUM 2 METHYLPROPANOL iso Butyl Alcohol Alcohols LOW METHYL AMYL ACETATE Esters LOW 5 METHYL 2 HEXANONE MIAK Ketones 110 12 3 MEDIUM 1 BUTANOL n Butyl Alcohol Alcohols 71 36 3 LOW 2 ETHOXYETHANOL Glycol Ethers 110 80 5 LOW 2 HEPTANONE MAK Ketones 110 43 0 MEDIUM CYCLOHEXANONE Ketones 108 94 1 MEDIUM AROMATIC 100 SC 100 Aromatic Hydrocarbons HIGH DIISOBUTYL KETONE DIBK Ketones 108 83 8 MEDIUM 1 PENTANOL Alcohol Alcohols 71 41 0 LOW DIACETONE ALCOHOL Ketones 123 42 2 LOW 2 BUTOXYETHANOL Butyl Cellosolve Glycol Ethers 111 76 2 LOW CYCLOHEXANOL Alcohols 108 93 0 LOW AROMATIC 150 SC 150 Aromatic Hydrocarbons HIGH AROMATIC 200 Aromatic Hydrocarbons CAS Number Chemical Abstract Service Number Electrical Resistance using the ITW Ransburg Meter Solvent Base rom http The lowest temperature at which a volatile fluid will ignite Information Obtained ly Isolvdb ncms org 05 2004 Illinois Tool W
32. ariable See Figures 1 4 23 psig 158 kPa 7 7 scfm 220 slpm Continuous Intermittent 40 000 rpm 55 000 rpm 40 000 rpm 55 000 rpm See Figure 6 90 psig 10 psi 621 kPa 69 kPa 2 1 scfm 60 slpm Variable See Figure 5 5 15 psig 34 103 kPa 4 7 9 8 scfm 134 280 slpm 60 psig 414 kPa 100 psig 689 kPa 25 500 cc minute Usable Spray Pattern Diameter Bell Cup Cleaning Time Color Change Time Speed Readout 15 30 inches 381 762 mm Approximately 2 3 seconds Dependent on system configuration fluid pressure fluid viscosity fluid line lengths etc Magnetic pickup unidirectional fiber optic transmission Atomizer Replacement Time Less than 2 minutes Bell Cup Replacement Time Less than 2 minutes LN 9521 00 2 Ransburg Electrostatic Systems Aerobell 33 Rotary Atomizer Introduction Turbine Speed vs Pressure 57mm Bell ae 10 20 30 40 Thousands RPM Figure 1 Turbine Speed vs Pressure Turbine Speed vs Flow pem 10 20 30 40 50 60 70 Thousands RPM Figure 2 Turbine Speed vs Flow 57mm Bell Loaded vs Unloaded 60 50 Load 600 cc min 40 Water 30 20 10 0 15 20 25 30 35 40 45 50 55 Thousands RPM Figure 3 57mm Bell Loaded vs
33. c Systems AIR FILTERS ELEMENT PREVENTIVE REPLACEMENT MAINTENANCE Daily Maintenance ITW Qty Duri Used During Each Preventive Maintenance Per A laminated poster entitled Rotary Atomizer Checklist part number AEROO75 is included with the assembly to be posted near the station as a handy reference Figure 14 Replacement Elements Open solvent valves and flush out feed tubes and bell cups for 3 5 seconds trigger and VALVES dump valve closed No maintenance is normally required on the valve other than flushing solventthrough the valve daily If there is any question about the valve opening AWARNING when air is present slide back the rear shroud on Make sure high voltage is off before the Aerobell 33 and inspect for valve action Visual approaching applicator with solvent cloth inspection for leaks should be made on a weekly basis Should the valve fail to function properly or Do not use reclaim solvent containing leaks appear it can be easily replaced Refer to d Limonene This can cause damage to the fluid valves service manual for detailed certain plastic components instructions on preventive maintenance and inspections gt Do not stop bell rotation by using a rag or gloved hand against the bell cup edge This can damage the resistance coating GENERAL at the bell cup edge Verify daily that the operating parameters have not varied from the s
34. ccessibility to the components such as valves If space parameters require that the spacing between the rear bulkhead and the mounting bar be less than the recommended 10 to 12 inch the Aerobell 33 can be swiveled on the insulator support so the rear shroud can be slid back fully If the outside or inside surfaces of the shroud are dirty wipe clean with a solvent damp rag Resistor Module Removal To remove the high voltage cable from the resistor module first remove the retaining screw Figure 16a item 21 and slide the connector cover Figure 16a item 20 back overthe cable Thenloosen the strain relief nut and pull the cable straight out of the module To remove the resistor module Figure 16a item 22 follow the procedures for removal of the rear shroud Then slightly lift the rear of the module to clear the step in the rear bulkhead Figure 17 item 12 and slide it backward until completely separated from the forward high voltage tube Figure 16a item 6 gt When reinstalling the resistor module care should be taken to avoid damage to the high voltage tube Also make sure the rear of the resistor module is properly seated in the pocket before sliding the rear shroud forward If the resistor hous ing is not properly seated and the rear shroud is forced into place damage can occur to the rear shroud 30 sT Ransburg Electrostatic Systems Fluid Regulator Removal Toremove the fluid regulator F
35. d at the bell will normally range between 85 and 91 of the kV set point displayed at the control unit Bell Cup Handling Always verify that high voltage is turned OFF and the atomizer bell has stopped spinning before performing any type of handling maintenance OPERATOR MAINTENANCE WARNINGS Do not attempt to hold a rag ora gloved hand againstthe bell edge to stop or slow down a rotating bell Do not attempt to clean the bell edge while the bell is rotating Do not attempt to use sharp or abrasive materials to clean the bell which will scratch or damage the plastic bell Do not use sharp or abrasive materials to clean the bell which will scratch the semi conductive coating on the surface of the bell Do not attempt to place a high voltage probe on the bell edge unless rotation is full stopped LN 9521 00 2 Do not use ultrasonic devices to clean the atomizer bell cup Do not use ammonia solutions or reclaim solvent containing d Limonenetocleanthe cups Do not use the bell cup to spray coatings containing N methyl pyrrolidone Do not use N methyl pyrrolidone to clean the bell cup Do not reuse an atomizer bell that shows signs of damage such as nicks heavy scratches dents or excessive wear defined under Bell Cup Cleaning bullet number 3 I 27 Aerobell 33 Rotary Atomizer Maintenance LOW VOLTAGE TEST When replacing the resistive Components trouble
36. d regulator and P IN on fluid manifold assembly LN 9521 00 2 Ransburg Aerobell 33 Rotary Atomizer Parts Identification Electrostatic Systems NOTES LN 9521 00 2 41 Aerobell 33 Rotary Atomizer Parts Identification Figure 17 Manifold Assembly 42 sT Ransburg Electrostatic Systems LN 9521 00 2 s7v7Ransburg Aerobell 33 Rotary Atomizer Parts Identification Electrostatic Systems MANIFOLD ASSEMBLY PARTS LIST Figure 17 ty Manod Ar Engaved AERO02600 Stud Mounting 1 AERO022 00 Pin 4 LSFipi30i Fino 2O D Tubex3BNPT 3 5 LSFi0302 Fiting3 BOD Tubex 2 N 6 LSFI0013 04 Fitting 1 4 O D Tube x 1 4 NPT 2 gt 1510023 02 Plug 3 8 O D Tube Fitting 8 LSFI0024 03 Plug 1 2 20 a 3 X LSFI0025 22 Fitting 3 8 O D Tube x 3 8 NPT 1 0 15080005 02 O Ring Solvent Proof 1 __ 6 021 00 Rod Rear Plate Support 062 01 Plate Rear pie AERO027 00 Shroud Rear LSFA0001 16C Screw 1 4 20 x 1 2 Long Nyl Pan Head 3 4 AERO0023 00 Fastener Rear Cover 2 See Parts List Bullet Definition Table below DI Co A PARTS LIST BULLET DEFINITION TABLE
37. emblies RPM 418 Bearing air filter coalescing type 19 scfm 99 995 efficiency particulate removal 3 to 6 micron max aerosol passed 6 micron max solid passed 2 micron one per applicator Figure 8 Recommended Air Filtration gt Air must be properly filtered to ensure extended turbine life and to prevent contamination of the paint finish Air which is not adequately filtered will foul the turbine air bearings and cause turbine failure The correct type of filters must be used in an Aerobell 33 system The filter elements must be replaced on a regular schedule to assure clean air gt It is the user s responsibility to ensure clean air at all times Tur bine failure resulting from contami nated air will not be covered under warranty Figure 8 shows the pre filter and bearing air filter s which are recom mended for use in Aerobell 33 systems If other filters are incorporated in the sys tem the filters to be used must have filtering capacities equal or better than those shown in Figure 8 gt user must ensure the bearing air supply is not inadvertently turned off while the Aerobell 33 air motor is turning This will cause air bearing failure LN 9521 00 2 HAF 15 Element One RPM 32 Elements Carton of 4 RPM 33 Elements Carton of 8 11 Aerobell 33 Rotary Atomizer Installation 12 MOUNTING The Aerobell 33 incorporates its own insulator mounting rod The diameter at the rear
38. er pattern wetter finish and greater efficiency Greater distance will provide a larger pattern size and drier finish The high voltage circuitry will enable the applicator bell to be operated to within a few inches of the target without adjusting the voltage setting The recommended target distance is 8 to 12 inches LN 9521 00 2 19 Aerobell 33 Rotary Atomizer Maintenance Ransburg MAINTENANCE CLEANING PROCE DURES AWARNING Electrical shock and fire hazards can exist during maintenance High voltage supply must be turned off before entering the spray area and performing any main tenance procedures on the atomizer Spray booth fans should remain on while cleaning with solvents gt Never touch the atomizer bell while it is spinning The front edge of the bell can easily cut into human skin or cut through gloves and other materials Be sure the atomizer bell has stopped spinning before attempting to touch it Approximate time for the bell to stop spinning after turning off turbine drive air is three minutes In addition to the above Warning which relates to potential safety hazards the following information must be observed to prevent damage to the equipment gt Do not immerse the Aerobell 33 turbine in solvent or other liquids Turbine components will be damaged gt Bearing air must be on during all cleaning procedures to protect the air bearing components Internal Fluid Path Cleaning Cleani
39. erobell 33 Cross Section View Figure 16a LN 9521 00 2 36 s7v7Ransburg Aerobell 33 Rotary Atomizer Parts Identification Electrostatic Systems DUMPS UES y HO DO lt gt SECTION Figure 16b Aerobell 33 Cross Section View SECTION Figure 16 Aerobell 33 Cross Section View LN 9521 00 2 37 Aerobell 33 Rotary Atomizer Parts Identification sT Ransburg Electrostatic Systems AEROBELL 33 MODEL IDENTIFICATION When ordering use part number AER5001 ABCDE as indicated by Tables A through E Table A Designates the bell type Table B Designates the fluid tube Table C Designates the fluid manifold assembly Table D Designates the regulator assembly Table E Designates the resistor block Five characters must follow the the basic part number as shown in the example below Example AER500 R 1 1 2 4 B 1 Resistor Block Basic Part Number From Table E Bell Type Regulator Assy From Table A From Table D Fluid Tube Fluid Manifold Assy From Table B From Table C TABLE Figure 16 Dash Description ae CO Aerobell 33 Assembly w 57mm Bell AER4016 02 AERO020 RPM 5 Aerobell 33 Assembly w 30mm Bell AER4015 02 038 80 5 Aerobell 33 Assembly w 57mm AER4016 03 020 RPM 5 Aerobell 33 w 30mm Bell Cup AER4015 05 AER0038 RPM 80
40. escribed input pressure The solvent valve controls the flow of cleaning solvent to the bell When actuated solvent flows through the manifold and fluid tube and intothe rear ofthe bell cup This provides cleaning of the inside of the bell cup The solvent valve is not triggered at the same time as the paint trigger valve to prevent solvent from flowing backward into the paintline gt The normal fluid flow range is 25 500 cc minute During a color change or when flushing the system higher flow rates may be required However the maximum flow rate must not exceed 500 cc minute to avoid solvent or paint from flooding into the internal portion of the air bearing motor assembly or front shroud High voltage must be interlocked with the solvent valve to prevent solvent spraying while high voltage is on LN 9521 00 2 Aerobell 33 Rotary Atomizer Operation AWARNING gt When flushing the Aerobell 33 always flush through the dump valve rather than the trigger valve Only use solvent to flush the fluid tube in the bell A solvent air mixture or sequence will cause paint build up on the fluid tube TURBINE SPEED Turbine speed is determined by the input pressure at the rear of the atomizer Turbine speed is intended to be closed loop controlled using the fiber optic speed transmitter located on the turbine manifold A speed input to a remote speed controller such as the Atomizer Module is recommended NOTE
41. et up standard A drastic A CAUTION change in system current high voltage turbine air shaping air pressure or fluid pilot pres gt Maximum flow rate should sure can be an early indicator of a component exceed 500 cc minute or system problem A CAUTION Daily removal and soaking of the bell cup may not be required if the bell cup is properly flushed as indicated above However the frequency of the feed tube and internal motor shaft inspection indi cated below under weekly maintenance can be done daily and later adjusted to weekly or as required depending on the results of the inspection LN 9521 00 2 Aerobell 33 Rotary Atomizer Maintenance Wait for rotation to cease and then clean off bell cup edge and shaping air ring and any other non protected unwrapped outer sur faces Use a soft cloth dampened with sol vent The protective disposable wrapping should be a material such as the type used on electrostatic guns One such suitable material is manufactured by Safety Ware located in Fort Wayne IN telephone 219 456 3535 or fax 219 744 9231 Visually inspect the bell cup edge for signs of abrasion If the coating is excessively worn back 1 16 inch or more or badly chipped as the result of contact with a part replace the AWARNING gt Inthe event the bell cup comes in contact with a part that cup should be checked for damage and replaced if necessary before continui
42. etailed information The regulator features two independently controllable flow pressure ranges from the fluid output port The high flow range port accom modates higher fluid deliveries thereby providing increased film build capabilities and minimal color changetimes The low flow range provides precise fluid delivery control There are seven low range models available 1 1 1 2 1 3 1 4 1 6 1 8 and 1 10 which can be selected based on the required fluid flow rate Separate pilot signals modulate each of the regulator s two diaphragms to control the amount of paint being delivered from the regulator to the atomizer bell cup These pilot signals can be controlled manually or automatically with closed loop flow control system Because ofthe regulator s dual range capabilities it provides the user flexibility of selecting either the high flow range or the low flow range Different coating material viscosities and quick color change requirements may necessitate the use of both LN 9521 00 2 s7v7Ransburg Electrostatic Systems ranges color change time is not a factor or if material viscosity remains relatively constant either port may be used depending on flow rate requirements The high flow port characteristics are similar to those found in most commercially available air operated fluid regulators Fluid regulation from the high flow port is therefore comparable in total flow capacity although consistency of fl
43. f paint to either the feed tube or dump line and to supply aintermittent solvent bell wash for the feed tube and bell cup LN 9521 00 2 The feed tube is available in several sizes See Figure 11 The viscosity and volume of the coating material being sprayed determine the correct size of feed tube for each installation The feed tube diameter acts as a linear restrictor to create back pressure on the fluid regulator so that it can provide accurate and repeatable flow to air signal resolution Fluid Flow Rate Check In test mode the flow rate can be measured by removing the bell cup from the atomizer turning the fluid flow on and capturing the material in a graduated beaker or measuring cup for a fixed period of time shaping air high voltage and turbine air must be off A WARNING gt Danger of shock and or personal injury can occur Proper grounding procedures must be followed Personnel must never work around the turbine when the turbine is spinning or when high voltage is turned on Low Flow Fixed Atomizer Rates Regulator Part No Figure 10 Fluid Regulator Selections Aerobell 33 Rotary Atomizer Operation 15 Aerobell 33 Rotary Atomizer Operation sT Ransburg Electrostatic Systems 041 1 0 76416 04 061 I D 76416 06 093 I D 76416 09 125 I D 76416 12 Figure 11 Fluid Tube Selections DR 1 FLOW VS SIGNAL PRESSURE DR 1 FLOW VS SIGNAL PRESSURE Viscosity 40 sec Za
44. ft can damage the bell motor or shaping air housing and may come off the shaft while rotating Electrostatic Systems VIBRATION NOISE Ifthe Aerobell 33 is vibrating or making an unusually loud noise it may mean thatthere is an unbalanced situation The bell assembly may have dried paint on it the bell may be physically damaged or there may be paint trapped between the bell and shaft preventing the bell from properly seating If any of these conditions exist they must be corrected prior to further operation Do not continue to operate a noisy turbine Warranty does not cover failure caused by imbalanced loading conditions AWARNING gt Ifa bell cup comes off a rotating shaft because of motor seizing or any other reason the bell must be returned to ITW Ransburg for inspection and evaluation to determine if the bell can be used in opera tion TURBINE REPAIR amp REBUILD Turbine field repair or rebuild only after factory warranty expires Any attempt to disassemble turbine during warranty period will void warranty 3 years or 15 000 hours Contact your distributor or ITW Ransburg for turbine rebuilding instructions HIGH VOLTAGE CONNECTIONS Use a small amount of light dielectric grease part number 59972 00 onthe high voltage cable ends to prevent moisture damage and ensure the integrity of the electrostatic system LN 9521 00 2 sT Ransburg Aerobell 33 Rotary Atomizer Maintenance Electrostati
45. h NFPA 33 when used and maintained in a proper manner Equipment cleanli ness and proper routine maintenance are required to maintain safe operating condi tions LN 9521 00 2 s7v7Ransburg Electrostatic Systems Bell Assembly This plastic bell cup is coated with a proprietary resistance material for transfer of electrostatic charge to the atomized fluid Two different sized bell cups are available 30mm and 57mm Each bell cup size has a matching shroud and shaping air ring See Table A Figure 16 Air Turbine Assembly The air bearing turbine assembly with bell cup is mounted to the air manifold assembly with four socket head cap screws The front resistor tube is also attached to the air turbine assembly and provides the high voltage connection to the motor shaft and bell Air and Fluid Manifold Assembly This unit mounts onto the insulator support rod assembly with a swivel post The fluid valve manifold block is mounted directly onto the back side connecting with fluid passages internal to the manifold Tube connections for valve control lines protrude through the rear shroud plate The fluid feed tube is screwed into the rear of this manifold block and the air turbine assembly mounts to the front with four socket head screws Insulator Support Rod Assembly The air and fluid manifold assembly mount onto the insulator support rod assembly which in turn is attached to the reciprocator or support stand Rea
46. hn 2 15ft 1 4 1 0 tubing 093 orifice 900 Viscosity 25 sec Zahn 2 80 15ft 1 4 1 0 tubing 093 orifice 70 600 500 400 FLOW CC MIN 300 200 100 9 12 15 21 26 32 37 42 48 54 59 65 70 75 81 SIGNAL PRESSURE PSI SIGNAL PRESSURE PSI Figure 12a DR 1 Flow Vs Signal Pressure Figure 12b DR 1 Flow Vs Signal Pressure 16 LN 9521 00 2 s7v7Ransburg Electrostatic Systems FLUID VALVE CONTROL Trigger Dump amp Solvent The fluid valves in the Aerobell 33 are actuated by an air signal The air pressure must exceed 70 psi to assure proper actuation of the valve Applying air to the valve actuator turns on the fluid flow for that valve The trigger valve controls the paint flow to the bell When actuated paint flows through the valve to the fluid tube and into the rear of the bell cup The bell must be spinning at least 10 000 rom when fluid is turned on to enable the fluid to flow through the bell paint passage holes and be atomized The dump valve controls the paint flow through the dump line When actuated paint flow is directed to the dump return line This provides a method of rapidly removing paint from the incoming line for cleaning and or color change Normally the dump valve is not actuated at the same time as the paint trigger valve since the trigger valve is intended to cause the fluid to flow to the bell at the pr
47. igure 16a item 18 follow the procedures for removal of the rear shroud Then disconnect the air pilot lines at the regulator andthe output fluid line at 5 connection into the fluid manifold assembly Figure 16a item 7 Disconnect the fluid supply line at the regulator inlet port loosen the retaining screws and pull the regulator straight out of the bulkhead Fluid Manifold Valve Removal To remove the fluid manifold assembly Figure 16a item 7 follow the procedures for removal of the rear shroud Then disconnect the air pilotlines at the tube connection of each individual valve NOTE gt four screws holding in the regula tor are held captive They do not back out completely of the regulator AWARNING Fluid pressure must be shut off and pressure relieved by actuating the valves prior to removal Disconnect all fluid connections including the dump line paint and solvent supply lines from the fluid manifold Then using a medium flat head screwdriver remove the mounting screws Figure 16a item 9 and pullthe manifold straight back to separate it from the fluid tube remove each individual fluid valve from the manifold use a 7 8 open end wrench and turn the valve CCW to disengage the threads Then pullthe valve straight out of the manifold LN 9521 00 2 33 Rotary Atomizer Maintenance Electrostatic Systems Speed Transducer Removal NOTES To remove the s
48. ined under Cleaning Procedures prior to performing any mainte nance 28 sT Ransburg Electrostatic Systems The air to all supply and pilot lines is off Thehigh voltage power supply has been shut off The atomizer s valves feed tube bell cup and fluid supply lines have been cleaned with sol vent and purged dry with air NOTE gt For reassembly instructions use the reverse of the following disassembly pro cedures The bell cup has stopped rotating All external surfaces must be clean and free of paint or paint residue Front Shroud Removal Removethe front shroud Figure 16a item 2 from the atomizer using the RPM 419 or other properly fitting spanner wrench and turning CCW viewed as facing the front end Note that when the front shroud is removed the shaping air cap Figure 16a item 13 is removed with it The Aerobell 33 turbine Figure 16a item 10 andthe bell assembly Figure 16a item 16 will now be exposed Using the same wrench it is also possible to separate the shaping aircap from the front shroud This is much easier to do if the front shroud is mounted on the turbine assembly since it is difficult to grasp the shroud and the wrench simultaneously if the parts are removed from the mechanical support of the assembly Hold the front shroud stationary while turning the shaping air ring CCW Note that it is only necessary to separate these parts if replacing one of them or for
49. ing allow atleasttwo minutes for it to come to a complete stop before touching it 4 LN 9521 00 2 Ransburg Aerobell 33 Rotary Atomizer Safety Electrostatic Systems NOTES LN 9521 00 2 5 Aerobell 33 Rotary Atomizer Introduction Electrostatic Systems INTRODUCTION FEATURES Features which make the Aerobell 33 Rotary Atomizer advantageous for use in electrostatic applications include Factory Mutual listed Limited energy is avail able to prevent ignition of flammable air sol vent mixtures Assembly components and bell made of du rable plastic material for optimum mechanical strength and solvent resistance Proven long life turbine motor capable of speeds up to 55k rpm at minimal air con sumption See Specifications in the Intro duction section of this manual for bell cup speed ratings 57mm and 30mm diameter bell assemblies available for application flexibility Fast color changes are achieved using center feed fluid delivery integral brake air high flow regulator and the fluid valves which provide for simultaneous paint push out while solvent washes the feed tube and bell cup Bell wash is quick and efficient Solvent us age is controlled at the feed tube with an inter nally mounted solvent valve Less waste to the spray booth with the dump valve located internally next to the feed tube More precise fluid regulation with an
50. is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS Tohelp you recognize this information we use the following symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that might cause serious injury if instructions are not followed A CAUTION states information that tells how to prevent damage to equipment or how to 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 make such variations inevitable Compare this manual with your system installation drawings and appropriate ITW Ransburg equipment manuals to reconcile such differences Careful study andcontinued use of this manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local ITW Ransburg representative or ITW Ransburg LN 9521 00 2 Aerobell 33 Rotary Atomizer Safety A WARNING gt user MUST read and be familiar with the
51. l 7 After removing all paint build up or residue rinse the bell in clean solvent and blow dry 8 Before reinstalling the bell onto the shaft check the mating surfaces of the thread and taper for any paint build up or residue Also check the fluid tube outside diameter and the shaft bore for any further paint build up These surfaces should be cleaned before installing the bell 9 A ring of semi conductive coating should also bevisible just inside the bell taper which will contact the shaft when properly seated If a contact area is not found replace the cup Install and tighten the bell according to the atom izer service manual LN 9521 00 2 s7v7Ransburg Electrostatic Systems BELL CUP TESTING NON ROTATING Check bell cup voltage using ITW Ransburg test meter kit part number 76652 01 or 76652 04 Verify that the output voltages have not varied much from the set up standard A drastic change in voltage can be an early indicator of a component or system problem The data shown below was collected under ideal lab conditions using a clean atomizer and an unloaded fluid delivery system Aerobell 33 Hotary Atomizer Maintenance The following data is for use with the RMA 101 or Aerobell 33R atomizers The output voltage measuredatthe bell will normally range between 91 and 97 ofthe kV set point displayed atthe control unit Thefollowing data isforuse with the Aerobell 33 atomizer The output voltage measure
52. n production A bell flush cycle may also be required while spraying batch parts of the same color Verify that high voltage is OFF and that the atomizer bell is spinning before flushing through the bell 2 If there is any remaining paint build up on any areas of the bell after flushing the bell should be removed for hand cleaning reference Bell Cup Handling listed on the back side of this data sheet The bell s leading edge paint feed holes or slots and serration cuts are some examples of areas for special attention 26 sT Ransburg Electrostatic Systems 3 Visually inspect the bell cup edge for signs of abrasion If the coating is excessively worn back 1 16 inch or more or badly chipped as the result of a collision with a part replace the cup immediately 4 Soaking the bell in solvent will not aid in loosening or removing paint build up The bell should be dipped in an appropriate solvent or the solution may be allowed to flow over and into the bell while cleaning 5 Use a soft bristle brush dipped in solvent to remove paint build up from the serration cuts paint feed holes or slots external and internal surfaces of the bell With a light source shinning into the rear of the bell any contamination in the paint feed holes will be easily seen when viewed from the front face 6 A soft lint free rag dampened with solvent may be used to remove any paint residue from the external and internal surfaces of the bel
53. ng the incoming from paint supply source such as color manifold through the fluid valve block and bell assembly 20 Electrostatic Systems Turn off high voltage and turn on the trigger valve Withthe bell spinning flush cleaning solventthrough the incoming paint line and through the manifold passages throughthe fluid tube and onto the bell The spinning bell will atomize the solvent and clean out the bell passages If desired open the dump valve to flush through the dump line for a faster and contained system flush Internal Fluid Path Cleaning With out Cleaning the Incoming Paint Line Turn off the high voltage and trigger valve With the bell spinning turn on the solvent valve to allow cleaning solvent to flow through the manifold passages throughthe fluidtube and onto the bell The spinning bell will atomize the solvent and clean out the bell passages With the solvent valve open open the dump valve to cleanthe remaining manifold fluid passage and to flush the dump line if desired Themaximum flow rate of 500 cc minute must not be exceeded during a flush routine External Atomizer Surface Cleaning Verify that the high voltage is turned off All external surfaces may be cleaned using a mild solvent and lint free rags to hand wipe the Aerobell 33 Turbine drive air must be off but leave shaping air and bearing air on Be careful not to drip solvent into the opening be hind the bell
54. ng to spray Check bell cup voltage using high voltage probe Voltage should be approximately 85 kV when 100 kV is set on the power supply AWARNING gt Do not place high voltage probe bell edge unless rotation is fully stopped NOTE Refer to the Troubleshooting Guide Figure 15 for details on determining the causes of low or no high voltage at the bell cup Check the amount of paint build up on the outer protective wrap If excessive replace wrap as required 24 sT Ransburg Electrostatic Systems NOTE The protective disposable wrap is for one time use only Do not wash and re use the wrap NOTE Normally the wrap will not need re placement daily and could last about one week See Weekly Maintenance in the Maintenance section Weekly Maintenance Prior to Start or End of Production Week Monitor rotational speed of all bells at the speed control should be within approximately 5 of target speed Monitor high voltage output indicated on the display of the control unit or at the meter of the power supply should be within approximately 5 of target output Check paint flow on all bells at minimum and maximum specified settings by taking beakered readings Check solvent flow by opening solvent valve and taking a beakered reading should be within approximately 10 of target flow rate gt Maximum flow rate should not exceed 500 cc minute Remove p
55. ning solution and blow dry before re placing Make sure the o ring is not exposed If so push the tube in place Remove bell cup and soak in solvent MEK and Xylene blend for 1 to 2 hours Remove from cleaning solution and blow dry before re placing AWARNING gt Do not use reclaim solvent containing d Limonene to soak bell cups NOTE gt It may be necessary to remove the bell cups for cleaning more frequently than weekly See Caution under Daily Maintenance LN 9521 00 2 Aerobell 33 Rotary Atomizer Maintenance Inspect the feed tube tip and clean any paint build up that has occurred on the feed tube tip Using a pen light determine if there is build up of paint in the motor shaft and or around the paint feed tube If so remove the motor as sembly following the disassembly procedures and clean out the inside diameter of the motor shaft using a tube brush and solvent Clean the outer surfaces of the feed tube AWARNING Make sure that no solvent or other contamination is allowed to enter the motor assembly air bearing and outer shaft Release the rear cover fasteners and slide the shroud back to expose the fluid manifold and regulator Visually inspect for signs of fluid leaks around fluid connections and manifold Correct problem and clean paint from all com ponents including internal portion of shroud Reinstall rear shroud bell cup and front shroud Rewrap the outer housing and ins
56. ny part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit 1 guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLAS TIC SHRINK WRAP ETC WILL VOID THIS WARRANTY 50 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 orreplacementofthe item oritems The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9521 00 2 s7v7Ransburg Electrostatic Systems APPENDIX PAINT AND SOLVENT SPECIFICATIONS RECOMMENDED VISCOSITY USINGA ZAHN NO 2 REA EFM EVOLVER 18 30 SEC Aerobell 33 Rotary Atomizer Appendix REM M90 18 30 SEC NO 2 HAND GUN 20 TO
57. optional internal regulator Easy to install and maintain Hosing and con nections are easily accessible at either the rear of the assembly or by sliding back the protective rear cover Quick removal of the turbine assembly for off line repair Annular shaping air passage design providing excellent pattern control at minimal air con sumption Aerodynamic design for ease of cleaning ex ternal surfaces Assembly can be swiveled to provide oblique spray angles for better paint coverage in diffi cult areas of the product Turbine air exhausts behind bell keeping paint and solvent contamination out of atomizer inte rior and keeping back of bell clean Speed readout or control uses reliable mag netic pickup for fiber optic transmission of ro tational speed data GENERAL DESCRIPTION Aerobell 33 System The ITW Ransburg Aerobell 33 is a high speed rotary atomizer system designed to meet agency safety requirements for safer operation This systemis incapable of releasing sufficient electrical or thermal energy during normal operating conditions to cause ignition of specific hazardous materials in their most easily ignited concentrations in air See NFPA 33 Regulations The Aerobell 33 provides electrostatic application with excellent atomization and transfer efficiency for a wide variety of coating materials AWARNING The Aerobell 33 System is designed to provide safer operation in accordance wit
58. orks Inc Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1 0 HIGH All rights reserved NOTE Chart provides resistance and control information that we feel is necessary when using ITW Ransburg equipment LN 9521 00 2 51 sT Ransburg Aerobell 33 Rotary Atomizer Appendix Electrostatic Systems lt T 2 gt gt gt 2 gt Y lt c 10 c lole lola amp 4 4 5 5 8 9 5 883 NIN o 515 15 dno ual 2 8 S F dng T o lt ____ d RR cle 4 91419 9 9 219 8 5 S 3 5 88 io o DIOIDIOIN NSS yoqkes 4 juogng olo olo SIS ojo esiodijue 9 1414919 28 318 Bw NX 4 M lt 5 o olo T NI Cp ep ele Je NIN ATA lt lt lt N
59. other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas Refer to NFPA 33 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltageto be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance Aluminum is widely used in other spray application equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents mustneverbe used with aluminum equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray If in doubt as to whether or not a coating or cleaning material is compatible contact your material supplier Any othertype of solvent may be used with aluminum equipment Aerobell 33 Rotary Atomizer Safety sT Ransburg Electrostatic Systems AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is Tells how to avoid the hazard may occur Toxic Substances Certain material may be harmful if Follow the requirements of the Material Safety Data inhaled or if there is contact with Sheet supplied by coating material manufacturer the skin Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a maskor respi
60. ow is improved considerably when using a regulator All regulators regardless of ratio designation have the high flow port The low flow i e 1 2 1 4 etc port provides a lower more precise flow response curve Fluid output as a result is less likely to be affected by pilot signal errors An increase in the ratio i e from 1 2 to 1 4 provides a lower slope but more precise response curve This same increase in ratio however will reduce flow capacity and should be considered when selecting the proper regulator ratio The following factors must then be considered when selecting the regulator ratio required for proper fluid control Maximum fluid output requirements Guide 10 psi minimum 30 psi max Fluid tubing inside diameter ID and length Fluid feed tube inside diameter ID and length Fluid viscosity Fluid input pressures Guide 10 psi above max fluid output pressure Only proper testing will determine which regulator ratio should be used If conditions change after installation which require a different low flow ratio this regulator can be altered easily by replacing the existing ratio spacer ring and upper retainer with the desired ratio ratio designation is etched on the side of the spacer ring The output ofthe regulatoris externally connected to a fitting on the fluid manifold assembly The fluid manifold assembly is equipped with valves which are pneumatically operated to direct the flow o
61. peed transducer follow the procedures for removal of the rear shroud Then loosen the compression nut on the transducer body and pull the fiber optic cable out Using an 11 16 open end wrench turn the speed transducer CCW to disengage the threads completely and then pull the unit straight out of the air manifold Fluid Tube Removal To remove the fluid tube assembly Figure 16a item 3 follow the procedures for removing the rear shroud and fluid manifold assembly Once the fluid manifold is removed the fluid tube will be exposed at the rear of the air manifold Using a standard 3 4 inch socket engage the hexagon flats on the feed tube and turn CCW to loosen After disengaging the threads completely pull the feed tube straight out of the air manifold Care should be taken to not over tighten the fluid tube and strip the threads When installing a new or old feed tube once it is securely tightened check the position of the feed tube in the shaft at the front of the assembly If the feed tube is off center by more than 020 028 radially replace it with another feed tube If the feed tube protrudes out of the shaft a dis tance other than 207 015 030 replace the tube with another feed tube LN 9521 00 2 31 Aerobell 33 Rotary Atomizer Maintenance TROUBLESHOOTING GUIDE sT Ransburg Electrostatic Systems General Problem Possible Causes Corrective Action 32 Bad Spray Pattern Low or
62. r Shroud Assembly The rear shroud assembly consists of a rear bulkhead which provides a passageway for fluid and air tubes mounting rods to connect the rear bulkhead to the air and fluid manifold assembly a fluid regulator mounted onto the outside surface of the rear bulkhead and a resistor module nested between the rear bulkhead and air manifold assembly Resistor Module The module encapsulates the high voltage resistors necessary for control of the electrostatic charge being fed to the bell through the high voltage cable LN 9521 00 2 Aerobell 33 Rotary Atomizer Introduction Power Supply and Junction Tank The Aerobell 33 System operates with a variety of high voltage power supplies The power supplies operate at output voltages of up to 100 000 volts DC Also available is a junction tank which is used to distribute high voltage to multiple Aerobell 33 assemblies from a single power supply AWARNING gt high voltage equipment that is used in this application creates a hazard for personnel The high voltage power supply is not approved for use inside of the spray booth as defined in NFPA 33 This high voltage power supply can produce sparks which are capable of igniting coating material NOTE The Aerobell 33 atomizer assembly includes an internal resistor module and resistor tube in series which provides ap propriate current limiting at the atomizer The resistance coating on the outer sur face of
63. rator 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 anindustrial hygienist or safety expert andbe NIOSH approved Spray Area There is a high voltage device that Parts being sprayed must supported on conveyors High Voltage can induce an electrical charge orhangers and be grounded The resistance between Equipment ungrounded objects which is the part and ground must not exceed 1 megohm capable of igniting coating materials electrically conductive objects in the spray area with the exception of those objects required by the Inadequate grounding will causea process to be at high voltage must be grounded spark hazard A spark can ignite many coating materials and cause Any person working in the spray area must be a fire or explosion grounded Unless specifically approved for use in hazardous locations the powersupply and other electrical control equipment must not be used in Class 1 Division 1 or 2 locations Personnel Safety The bell atomizer can rotate at Personnel must stay clear of the bell whenever it is Mechanical Hazards speeds upto 55 000 rpm Atthese rotating speeds the edge of the applicator can easily into skin Before touching the bell the turbine air must be shut Loose articles of clothing can also off be caught by the rotating bell Ifthe bell has been rotat
64. rotective wrap from outer housing and discard Clean any paint on outer surface of front and rear housing with soft cloth damp ened with solvent See Warning under Daily Maintenance on avoiding the use of cleaning solvent containing d Limonene LN 9521 00 2 s7v7Ransburg Electrostatic Systems Check the high voltage connection by remov ing the cable assembly from the resistor block Examine the tip of the banana plug for any contaminants or corrosion Clean or re place the plug as required Prior to reinstalling the cable assembly start at the rear of the ba nana plug and cover about 6 inches of high voltage cable with a thin film of dielectric grease Insert the high voltage cable until the banana plug seats into the connector within the resistor block The blind depth inside the resistor block is approximately 7 5 8 inch Ensure that the high voltage cable is properly seated tighten the strain relief and reinstall the connector cover In an oscillation or recip rocator type application always ensure ad equate cable slack between the applicator and the power supply termination point Remove the front shroud and check for any signs of solvent or paint leakage Clean as required Check position of high voltage tube where it enters the motor housing Make sure the o ring is not exposed If so push the tube in place Remove bell cup and soak in solvent MEK and Xylene blend for 1 to 2 hours Remove from clea
65. sT Ransburg SERVICE MANUAL LN 9521 00 2 Electrostatic Systems Replaces LN 9521 00 1 AEROBELL 33 ROTARY ATOMIZER Y A n AUI QU YYW MODEL AER5000 AER5001 APPROVED IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 50 00 U S sT Ransburg Electrostatic Systems NOTE This manual has been changed from revision LN 9521 00 1 to revision LN 9521 00 2 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9521 00 2 Ransburg Aerobell 33 Rotary Atomizer Contents Electrostatic Systems CONTENTS PAGE SAFETY 1 4 SAFETY PRECAUTIONS T ee ee 1 HAZARDS SAFEGUARDS eee ee eee eee eee 2 4 INTRODUCTION 6 9 FEATURES M ae en ee 6 CE IEA BE CUP TION neis Sh seesaw deca eben 6 7 a Ni cH 8 9 INSTALLATION 10 13 AIR ST GUISE SN 10 AIR PRESSURE REQUIREMENT RE eR 10 AIR FILTRATION REQUIREMEN Ue darn ce ieu rie 11 MOUNTING e T 12 certum eta aS rere a ME 12 ELECTRICAL CONNECTIONS acp han aes m bbc Poo 12 SPEED MONITOR CONNECTIONS 2 cct
66. shooting reassembling or as periodic inspection procedure a low voltage test can be performed on the rotator assembly to ensure that there are good electrical contacts and that the resistors are not defective A high voltage resistor tester Megger must be used which has an output voltage of 500 to 1000 VDC 1 With the high voltage turned OFF discon nect the high voltage cable from the rear of the rotator assembly 2 Insert a test cable or the test meter probe into the rear of the rotator and connect to the voltage output of the test meter 3 Remove the front shroud and bell cup and clip the test meter ground to the rotator shaft 4 Set the test meter voltage output to a mini mum of 500 VDC and maximum of 1000 VDC 5 The meter should indicate between approxi mately 725 Megohm and 770 Megohm Ifthe test instrument is reading higher than 770 Me gohm then the electrical contacts between the resistor tube resistor block and motor assem bly need to be checked 6 Remove the motor assembly and resistor tube and verify that the resistor tube springs are at least 3 8 and are not distorted Also make sure that there is no visible contamination in the motor cavity where the resistor tube inserts Refer also to the Troubleshooting Guide Fig ure 15 DISASSEMBLY PROCEDURES Make sure the following conditions exists prior to disassembly Pay particular attention to the procedures and Warning information outl
67. st settings refer to the power supply manual Clean atomizer externally with non polar solvent Check the atomizer for internal fluid leaks Check for internal arcing usually indicated by internal sparking sounds Repair or replace high voltage cable Optimize color change Figure 15 Troubleshooting Guide LN 9521 00 2 s7v7Ransburg Electrostatic Systems General Problem Possible Causes Corrective Action Low Transfer 1 Efficiency or light coverage No Turbine Air Speed Feedback Fault No Fluid Flow LN 9521 00 2 Aerobell 33 Rotary Atomizer Maintenance Low or no high voltage Poor grounding of parts being coated Excessive turbine speed Excessive shaping air Excessive target distance Turbine drive air not present 1 Bearing air return signal not 2a present Brake air is activated Damaged fiber optic cable between atomizer and control panel Connection at the fiber optic 2 transmitter is loose Fiber optic transmitter failure 3 Turbine is not rotating Fluid regulator does not 2a actuate b Verify high voltage at bell cup edge Normally a high voltage setting of 100kV is appropriate for most applications Verify that parts being coated are properly grounded the electrical resistance between the part and ground must not exceed 1 megohm For optimum transfer efficiency and spray pattern control the bell rotational speed should be set at
68. t Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts PA QN Form No LN 9521 00 2 50 9001 A orm 2005 Illinois Tool Works Inc All rights reserved Quality Systems 5j Litho in U S A Models and specifications subject to change without notice 3 05 ED
69. the bell cup do not hold a rag or gloved hand against the bell edge This could damage the bell edge which would adversely affect transfer efficiency and coating quality 21 Aerobell 33 Rotary Atomizer Maintenance sT Ransburg 22 gt Do use abrasive materials which will scratch or damage the plastic bell or which will scratch the semiconductive coating on the surface of the bell gt Before reinstalling the bell onto the shaft check and clean the tapered mating surfaces of the turbine shaft and bell for any paint residue Using an atomizer bell with paint buildup may cause bell imbalance An imbal anced bell may cause bearing damage and turbine failure or may create me chanical stress on the plastic bell when operating at high speeds Excessive paint residue caught between the internal tapered surface which seats in the motor shaft can prevent the bell from seating properly and result in an unbalanced tur bine condition Care must be taken when mounting the bell assembly onto the motor shaft The bell should turn on freely for several turns or until it fully bottoms on the motor shaft If resistance is felt when the bell is first being turned onto the shaft do not proceed further the bell may be cross threaded on the shaft Remove the cup and carefully reinstall If it is still difficult to turn replace the bell AWARNING gt Abell assembly that is cross threaded on the sha
70. ula tor mounting rod refer to Disassembly Pro cedures for definite instructions NOTE gt outer protective wrap may have to be replaced more frequently than weekly Daily inspection of the amount of paint buildup on the wrap will determine the frequency of replacement 25 Aerobell 33 Rotary Atomizer Maintenance HIGH PERFORMANCE THERMOPLASTIC BELL CUP PREVENTIVE MAINTENANCE It is the users responsibility to ensure proper maintenance of the atomizer bell at all times Bell cupfailure due to inadequate cleaning or handling will not be covered under warranty The Do Not bullets listed are some examples of improper handling which could adversely affect performance or personnel safety and should not be attempted for any reason BELL CUP CLEANING Always verify that high voltage is turned OFF and thatthe atomizer bell is spinning before performing any type of color change or bell flush cleaning cycle To reduce the risk of fire or explosion the solvents used for exterior cleaning must have flash points above 100 F 37 8 C Since electrostatic equipmentis involved these solvents should also be non polar Solvents usedfor equipmentflushing should have flash points equal to or higher than those of the coating material being sprayed 1 The atomizer bell includes a self cleaning feature and will normally be fully cleaned during a bell flush cycle Flushing should be done before any down time or break i
71. ully so that it does not drop and using a 5 32 inch Allen wrench remove the four mounting screws which hold the turbine tothe air manifold Pullthe turbine assembly straight forward until itis beyond the end of the fluid tube Figure 16a item 3 andthe high voltage tube Figure 16a item 6 is out of the resistor block Figure 16a item 22 The turbine assembly can now be replaced or serviced as necessary Reassemble Note Prior to replacing the turbine assembly make sure the bearing air o ring Figure 16a item 11 isinplace on the air manifold assembly Figure 16a item 1 To replace the turbine assembly center the turbine shaft with the feed tube align the high voltage tube with the resistor block the shaping air tube with the air manifold and push the turbine assembly slowly in Holding the turbine securely in place screw the four mounting bolts Figure 16a item 8 through the rear of the LN 9521 00 2 Aerobell 33 Rotary Atomizer Maintenance turbine assembly into the air manifold assembly Tighten the four mounting bolts alternately to a final torque of 15 Ibin Reassemble Note When the resistor module is installed onto the high voltage tube an air pocket can form inside the resistor module passage This air pocket can force the resistor module out of its seat Take care thatthe resistor module is securely seated into the rear bulkhead slot Make sure the turbine assembly is properly seated by examining the fit
72. zard is Improper operation ormaintenance may create a hazard Personnel mustbe properly trained in the use of this equipment High voltage equipmentis utilized Arcing in areas of flammable or combustible materials may occur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explosion Halogenated hydrocarbonsolvents for example methylene chloride 1 1 1 Trichloro ethane 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 Aerobell 33 Rotary Atomizer Safety SAFEGUARDS Tells how to avoid the hazard Personnel must be given training in accordance with he requirements of NFPA 33 Instructions and safety precautions must be read and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping Reference OSHA NFPA 33 and yourinsurance company requirements The power supply optional remote control cabinet and all

LN-9521-00.2 Aerobell 33 Rotary Atomizer 3-05.pmd

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