ESTA-QUICK AEMD-500
Contents
1. 22 10 2 1 INCCOSSAIYV 1 OOIS uu u sta ai cV hrs Vows a vv Pw sw Ru Eei 22 10 2 2 Grease and Bonding Agent 22 10 3 Cleaning and Examination of Gun Parts 25 AS ey GO UO T g ee eee ne eer E E E T 26 10 3 2 Examination PANS EE 26 10 4 Assembly of the EstaQuick AEMD GO00 en 27 10 4 1 Preparation of the Assembly Head 27 10 4 2 Preparation of the Assembly End Plate 28 10 4 3 Preparation of the Assembly Head Drackef 29 1 2 AEMD E 01 1 1 EstaQuick Applicator 2 43 lt Finishing grengen DW DOVHBISS Ransburg BGK SINKS Ransburg 10 4 4 Final Assembly of the EstaQuick AEMD 600 30 11 pde a me 32 11 1 Exploded View EstaQuick 600 32 uS D om 33 Jo li O c i CUO Mt ONAN TE ETT 34 114 AirCGapSeleGlioli CAM u u u uu uu u uu uuu uuu uuu asahan t aen iUe xxt nre 34 11 5 O RING Selection 34 11 6 Selection Chart Automatic Applicator AEMD 600 35 12 Machine Mounted u uu u2. V A EEN 10 4 Gpechceaton nennen nnne nnne rnnt rsen 11 3 PETO c I 11 Pi ud te TETTE R 11 mmm 12 6 1 Connection of EstaQuick AEMD 600 Adapter AEMD 4500 6 12 6 2 Screwed connection of EstaQuick AEMD 600 FIX to Adapter AEMD J 0 o F 13 63 Spray Pattern AdJuSUm e t uL uu u rov x mea xev exea ree 14 6 4 Distance of Gun to Work Piece a a 14 J Preventive NIaIlnienar Eeer ee 15 1 1 Maibiegsnceschedlilo EE EA EEA ES EE E 15 8 Cleaning PrOCOGQUEGS Geesen 17 Sal E 17 8 1 1 Cleaning the Air nennen nennen nnns nnns 17 9 2 Fl Shifig ee 17 J T E 18 9 1 Troubleshooting Chart 18 10 a 20 10 1 Disassembling the Gun from the 20 JUN ME LIO 20 10 1 2 Removal of the EstaQuick 600 21 10 1 3 Removal of the EstaQuick AEMD 600 FIX 21 10 2 Disassembling the EstaQuick 600
3. 17 18 cO 17 18 20 21 O Ring 26 27 OPTION Screw 28 OPTION Screw 29 30 31 1 2 AEMD E 01 1 1 EstaQuick Applicator 33 43 Finishing Brands Dr TC Ransburg BGK SINKS Ransburg 11 3 Tip Selection Chart 350 AEMD 800C 18 50 Round Pattern Tip A 6 31 mm AEMD 2941 0 850 gt gt Round Pattern Tip 7 22 AEMD 2951 AEMD 850 Tip with bore 0 8mm 08 AEMD 2915 G AEMD 800C 18 35 350 O 12 11 4 Air Cap Selection Chart Air Cap for Tip AEMD 2915 AEMD 800c Air Cap for Round Pattern Tip AEMD 2941 and AEMD 2951 AEMD 850 11 5 O Ring Selection Chart Standard O Ring Viton EX AGMD 121 Hir Option O Ring for aggressive Solvent components with Aromat Esters and Keton AGMD 121 C Hir Standard O Ring Viton EX 5 parts per pack AGMD 93 K5 Option O Ring for aggressive Solvent components with Aromat Esters and Keton AGMD 095 1 2 AEMD E 01 1 1 EstaQuick Applicator 34 43 e Finishing Brands N Ransbu rg Zu Ransburg BGK SINKS 11 6 Selection Chart Automatic Applicator AEMD 600 Automatic Applicator EstaQuick AEMD 600 Selection Chart Description Tip Size Tip Size Air Cap Machine Mounted Adaptor Part No Part No Part No AEMD 600 G 800 600 AEMD 600 G 800 800 AEMD 2915 G 2915 AEMD 2915 G AEMD 600 FX 800 AEMD 2915 FX AEMD 800C AEMD 600 FF 800 AEMD 2915 FF AEMD 4500 6 A
4. 9 Insert the greased washers into the respective groove in the head bracket Pos 2 Lubricating the washers Inserting the washers Insert the O Rings Pos 24 10 The needle shaft Pos 17 will be glued into the spring bolt Pos 18 with LOCTITE middle strong 1 2 AEMD E 01 1 1 EstaQuick Applicator 29 43 Hime 4 Ransburg DHNEISS Ransburg BGK SINKS 10 4 4 Final Assembly of the EstaQuick AEMD 600 9 11 Insert the contact lock Pos 10 into the needle packing Pos 8 of the head Pos 1 12 Place the head bracket Pos 2 onto the head Pos 1 Caution The head bracket has a pocket into which the contact lock has to be inserted 13 Push the needle shaft spring bolt unit Pos 17 18 into the bore of the piston Pos 15 until you feel resistance 14 Place the two pressure springs Pos 19 and 20 onto the spring bolt Pos 18 15 Insert the 6 screws Pos 23 into the designed bores in the end plate Pos 3 16 Position the end plate with the screws onto the head bracket 17 Push the end plate downward thereby strength must be surmounted in order to press the needle into the needle packing 18 Lightly and evenly tighten the 6 screws Pos 23 crosswise 19 Check the levelness of the sealing surface of the head Pos 1 of the head bracket Pos 2 and of the end plate Pos 3 with a calliper gauge or an angle Then firmly tighten screws Pos 23 Push end plate downward Check
5. To take off the gun from the adapter the following steps have to be followed Turn off high voltage Turn off material supply Turn off atomizing air and cylinder air Clean gun cable and hoses with a solvent wetted cloth Use suitable solvent only Empty the fluid lines and leave solvent in the non pressurized lines p D ES Caution Prior to cleaning or color change turn off the high voltage and the supply voltage to the high voltage transformer 1 2 AEMD E 01 1 1 EstaQuick Applicator 20 43 I Ransbu rg DHBISS Ransburg BGK SINKS 10 1 2 Removal of the EstaQuick AEMD 600 Activate the spring pad at the adapter at the same time the spring pad will be pushed into the gun and the gun body can now be turned out of the adapter Turn the gun body by 45 counter clockwise The gun can now be pulled off upward and the spare gun can be connected TH Turn gun by 45 counter clockwise and pull off upward 10 1 3 Removal of the EstaQuick AEMD 600 FIX Remove first the two screws who fix the gun on the adapter The gun body can now be turned out of the adapter Turn the gun body by 45 counter clockwise The gun can now be pulled off upward and the spare gun can be connected Remove the two screws in front and back Turn gun by 45 counter clockwise and pull off upward 1 2 AEMD E 01 1 1 EstaQuick Applicator 21 43 Dr Er Ransburg BGK SINKS Finishing Bran a B Ransburg 10 2 Disassembling th
6. Air channel in gun or in airline Blow out obstructed 2 Pressure too low Increase air pressure Fluid Output Fluid tip obstructed or damaged Flush or replace Fluid channels in gun or fluid line obstructed Not enough travel of fluid valve needle Fluid pressure too low Fluid filter obstructed Fluid valve or fluid regulator obstructed Clean 1 Air valve cap loose or damaged Tighten Fluid leakage at rear part of the 1 Packing piston needle or Replace faulty components gun electrode damaged Fluid leakage between gun and 1 O Rings AGMD 93 damaged or Insert O Rings adapter missing Locking device does not seal Tighten cap screw AEMD properly 2130 Insulating surface between Loosen 6 screws align parts head head bracket and end and tighten screws plate is not even Fluid leakage at fluid tip Fluid tip too loose Engage fluid tip Needle and tips do not close Replace damaged properly components Retaining ring loose Tighten retaining ring Continuous leakage at fluid tip Seat of fluid tip worn or Replace fluid tip damaged Needle electrode worn or Replace faulty part damaged Fluid tip not engaged Engage fluid tip Needle does not close cylinder Check valve air line not deventilated Flush Lubricate piston and needle packing Increase fluid pressure Clean or replace 1 2 AEMD E 01 1 1 EstaQuick Applicator 18 43 Finishing Bra DEVILBISS Ransbur
7. Push the gun downward against the spring Click the gun into the rear locking device until force until it bottoms on the adapter It sits straight Fix the gun at the back with screw POS 22 Fix the gun at the front with the screw POS 21 1 2 AEMD E 01 1 1 EstaQuick Applicator 13 43 a Finishing Brands N DNEISS Ransburg BGK SINKS Note Before installing the gun apply a light coat of grease to the Ja O rings to prevent from shearing off 6 3 Spray Pattern Adjustment The spray pattern of the atomizer is adjustable from round pattern to flat pattern By increasing the air supply atomizing air the pattern becomes wider by reducing the air supply atomizing air it becomes more narrow Carry out tests in order to find the desired values In order to change over the atomizer spray pattern from horizontal to vertical reposition the baffle in the spray head There are two position bores in the spray head see picture Ransburg Position for vertical spray pattern Position for horizontal spray pattern Note For optimum finish quality always operate with clean dry and Jp filtered air 6 4 Distance of Gun to Work Piece To achieve optimum finish quality position the gun approximately 15 to 30 cm from the Work piece Caution The distance from the gun to mass must be significantly larger than the distance from the gun to the object to be coated 1 2 AEMD E 01 1 1 EstaQuick Applicator 14 43 F
8. a solvent resistant epoxy 9 A recapitulation of the certification marking is detailed in the ATEX section on the next page 10 The characteristics of the equipment shall be detailed eg electrical pressure and voltage The manufacturer should note that on being put into service the equipment must be accompanied by a translation of the instructions in the language or languages of the country in which the equipment is to be used and by the instructions in the original language 8 43 gt UA Finishing Brands s 8 DOVIHBISS Ransburg BGK SINKS Ransburg 3 2 EstaQuick AEMD 600 ATEX Product Marking Definitions Note ATEX APPROVAL with the Power Source 9060 LOW VOLTAGE CONTROL UNIT KIT is only use for the Electrostatic Automatic Applicator AEMD 600 incl Machine Mounted Adapter AEMD 4500 6 EstaQuick AEMD 600 ATEX Product Marking Definitions Ex Gertificate Number Sira 11ATEX5240X oira Notified Body performing EC type Examination 11 Year of certification ATEX Reference to ATEX Directive 5 Protection Concept Code code 5 is titled Encapsulation 240 Document serial number X Special conditions for safe use apply C 0518 x I 2 G Special condtions for safe use EEx 0 24 mJ SIRA 11ATEX5240X The applicator AEMD 600 Shall only be used with Air amp Fluid hoses that meet oafety requirements Product Marking 9 Ex Specific marking of explosive protection II Equipm
9. against typical endangering have been taken into consideration It must also be secured that protective measures have been taken to avoid dangerous body current by avoiding unnecessary work at live installation components closing current less appropriate work wear protection against unintended reclosing determination of stress freeness grounding and short out release for operation allowance to pass 1 2 AEMD E 01 1 1 EstaQuick Applicator 6 43 2 4 2 5 2 6 2 7 2 8 2 9 Finishing BH A Dr BISS Ransburg BGK SINKS Ransburg Work Areas 2 4 1 Always ensure that there are no ignition sources Smoking and open fire in potentially explosive atmospheres must be forbidden 2 4 2 Paint must never be permitted to accumulate in spray booths spray stands and in the work area 2 4 3 Coating of hollow parts in which hazardous situations may occur due to gas mist or dust of the coating material must be forbidden unless protective measures are taken 2 4 4 t must be pointed out and checked that entrance doors at the spray booths are kept close during the spraying process Inside Coating of Hollow Parts 2 5 1 Inside coating of hollow parts in which hazardous situations may occur due to gas mist or dust of the coating material must be forbidden unless special safety measure are taken Cleaning 2 6 1 Paint deposit of coating material must be removed in regular periods Special care mus
10. eege has ha tr 36 12 1 Machine Mounted Adapter 4500 6 36 12 2 Exploded View Machine Mounted Adapter 4500 6 37 KSC EE 37 19 ele geet E ele ET EE 38 tol gt EE 38 J PS T mU 38 I AG Ee E EE 38 IT NER LT ee eee eee eee ee 38 14 Installation Low Voltage Control Unit 39 14 1 9060 Low Voltage Control Unit 39 14 2 9060 Low Voltage Control Unit kt 40 15 EC Manufacturer s Declaration 41 16 eelere e arg oid xpi 42 1 2 AEMD E 01 1 1 EstaQuick Applicator 3 43 gt UA Finishing Brands DHNEISS Ransburg BGK SINKS Ransburg 1 General 1 1 About this Manual e This service manual applies exclusively to the electrostatic automatic applicator EstaQuick AEMD 600 for the application of solvent based paints e The information in this document is intended only to indicate the components and their working relationship in typical use These are not installation instructions Each installation is unique and should be directed by a FINISHING BRANDS RANSBURG representative e This manual provides information for the service and maintenance of this RANSBURG electr
11. has been mounted and maintained properly The use of other than the manufacturer s accessories and spare parts will void all warranties completely or partly We assume no liability for damage caused by the following reasons Inappropriate or improper use of the equipment the use of other than FINISHING BRANDS GMBH GERMANY RANSBURG approved parts incorrect assembly respectively initial start up by the purchaser or third parties natural wear as well as wear parts incorrect operation or maintenance 1 2 AEMD E 01 1 1 EstaQuick Applicator 42 43 Finishing ln Ransbu rg DHNEISS Ransburg BGK SINKS Finishing Brands Germany GmbH Justus von Liebig Str 31 63128 Dietzenbach Germany Fon 49 6074 403 1 Fax 49 6074 403 281 1 2 AEMD E 01 1 1 EstaQuick Applicator 43 43
12. material is being sprayed and the lines are not flushed frequently enough the fluid passages of the gun and the lines may get clogged resulting in more time consuming maintenance and repair EstaQuick Applicator 16 43 Finishing Brands DeVILBISS Ransburg BGK SINKS Ransbu rg 8 Cleaning Procedures 8 1 Cleaning the Atomizer For regular cleaning procedures the following tools are needed e Suitable solvent e Grounded solvent supply e brush with soft bristles e Some pipe cleaners For safe and trouble free operation keep the exterior surface of the gun clean and free of paint residues and dirt This is to prevent high voltage loss to ground and reduction of the electrostatic effect Contamination at the opening of the air cap will cause a reduction of atomizing quality Clean the air cap as often as necessary with a soft brush and solvent in order to obtain optimum atomization Caution Never wrap the gun into plastic film A surface charging can be built up at the plastic material and might discharge to the next grounded object This reduces the capacity of the gun which might lead to damaging the component FINISHING BRANDS GERMANY GmbH will not be liable for any damages caused by wrapping the gun into plastic film To protect the gun use the gun protection AGMD 400 8 1 1 Cleaning the Air Cap To clean the air cap the following steps have to be performed 1 Turn off the high voltage 2 Turn off the mat
13. 3 Finishing Brands DeVILBISS Ransburg BGK SINKS Ransbu rg Symbols Information Information you should pay special attention to Note Important text passage you should pay special attention to Caution Important information that tells how to prevent damage to equipment or how to avoid a hazardous situation Safety Precautions Intended Use Caution Loi This installation can be dangerous if the instructions of this service manual are not being followed The EstaQuick is designed and built for operation in stationary electrostatic spraying installations for flammable liquid spray materials The EstaQuick must only be operated in potentially explosive atmospheres which are created by the spraying cloud of the used coating material itself Training 2 4 1 It is extremely important that equipment operators and supervisory personnel understand the safe operation requirements All personnel must be adequately trained prior to operating the electrostatic equipment and accessories Operators must be given adequate training at least once a year Use of Electrostatic Spray Systems in Potentially Explosive Atmospheres 2 3 1 Electrostatic spraying systems spray guns must only be operated in potentially explosive atmospheres where the potential hazard is exclusively caused by electrostatic spraying of flammable liquid coating materials 2 3 2 Electrostatic spraying systems must only be operated if protective measures
14. EMD 600 FW 800 AEMD 2915 FW AEMD 600 2941 850 A 6 31 mm AEMD 2941 AEMD 850 AEMD 600 2951 850 A 7 22 mm AEMD 2951 i el AEMD 600UG 800 O 3 AEMD 2915 G AEMD 600UFX 800 L3 3 AEMD 2915 FX AEMD 800C AEMD 600UFF 800 a AEMD 2915 FF AEMD 4500 6 AEMD 600UFW 800 ue AEMD 2915 FW AEMD 600U2941 850 A 6 31 mm AEMD 2941 AEMD 850 AEMD 850 7 22 mm WI AEMD 600 G 800 FIX eel AEMD 2915 G AEMD 600 FX 800 FIX ES AEMD 2915 FX AEMD 800C AEMD 600 FF 800 FIX 14 AEMD 2915 FF AEMD 4500 6 FIX AEMD 600 FW 800 FIX 006 AEMD 2915 FW EE Quick disconnection c o 2 c o x 2 bad Circulation U AEMD 600 2941 850 Fl A 6 31 mm AEMD 2941 AEMD 850 AEMD 600 2951 850 F I TM 7 22 mm M AEMD 600UG 800 FIX as ae AEMD 2915 G AEMD 600UFX 800 FIX AEMD 2915 FX AEMD 800C AEMD 600UFF 800 FIX 1 4 AEMD 2915 FF Nate ea AEMD 600UFW 800 FIX 046 AEMD 2915 FW AEMD 600U2941 850 Fl A 6 31 mm AEMD 2941 AEMD 850 AEMD 600U2951 850 Fl A 7 22 mm AEMD 2951 Circulation U Fixed 1 2 AEMD E 01 1 1 EstaQuick Applicator 35 43 Finishing Brands Ransburg DHVNLBISS Ransburg BGK SINKS 12 Machine Mounted Adapter 12 1 Machine Mounted Adapter AEMD 4500 6 for Electrostatic Automatic Gun AEMD 600 108 50 56 1 2 AEMD E 01 1 1 EstaQuick Applicator 36 43 7 Finishing weg DHNEISS Ransburg BGK SINKS Ransburg 12 2 Exploded View Machine M
15. Voltage Control Unit 9060 Low Voltage Unit AEMD 600 ATEX approved with Machine Adapter AEMD 4500 6 A10560 XXD High Voltage Cable Ce D H 80104 01 External Cascade 79338 XX Low Voltage Cable Booth Wall Cascade Ground Connection Cascade Separate True Earth Ground Control Unit Separate True Earth Ground 1 2 AEMD E 01 1 1 EstaQuick Applicator 39 43 Finishing Brands Ransburg WVILBISS Ransburg BGK SINKS 14 2 9060 Low Voltage Control Unit Kit Table A 80104 01 110 120 V USA 10 Rack 80120 311 220 240 V Europe 10 Rack 80120 312 220 240 V Europe 19 Box 80100 312 220 240 V China 19 Box 80100 313 220 240 V China 10 Rack 80120 313 8 110 120 V USA 19 Box 80100 31 1 Low Voltage Cable 10m 79338 10 Low Voltage Cable 15m 79338 15 For ordering use 80143 ABC as indicated by Tables Designates the 9060 Cascade Control Unit B Designates the High Voltage Cable Length Designates the Low Voltage Cables Length 1 2 AEMD E 01 1 1 EstaQuick Applicator 40 43 DHNEISS Ransburg BGK SINKS 15 EC Manufacturer s Declaration Finishing Bran E B Ransburg We Finishing Brands Germany GmbH Justus von Liebig Str 31 D 63128 Dietzenbach hereby declare under our sole responsibility that the product s listed below confirm with the relevant provisions of directive 94 9 EC of March 1994 Product EstaQuick Type AEMD 600 incl AEMD 4500 6 Notified Body Sira Cer
16. aners Clean the contaminated gun parts with a soft brush and suitable solvent and blow dry Clean the air and fluid bores with a solvent soaked pipe cleaner Information Do not bath the gun parts in solvent but wipe them clean with a brush or an soaked cloth For safe and trouble free operation keep the exterior surface of the gun clean and free of paint residues and dirt This is to prevent high voltage loss to ground and reduction of the electrostatic effect Contamination at the opening of the air cap will cause a reduction of atomizing quality Clean the air cap as often as necessary with a soft brush and solvent in order to obtain optimum atomization 10 3 2 Examination of Parts Prior to assembly of the gun all gun parts must be checked Faulty components must be replaced Caution Never install faulty components into the gun Caution Only use genuine Ransburg spare parts 1 2 AEMD E 01 1 1 EstaQuick Applicator 26 43 Finishing Brands DOH Er Ransburg BGK SINKS Ransburg 10 4 Assembly of the EstaQuick AEMD 600 This describes the assembly of a gun with new parts For the renewed assembly of a gun some parts will remain and will not have to be assembled again 10 4 1 Preparation of the Assembly Head 1 Screw the needle packing Pos 8 into the head Pos 1 by use of an Allen screw wrench SW 6 take care not to close the fluid bore in the head Right Needle packing sits below the fluid Wrong Nee
17. dle packing closes the fluid bore bore 2 Insert the contact wire Pos 9 into the bores and secure with light blows of the hammer Insert contact wire Secure contact wire with light blows of the hammer 1 2 AEMD E 01 1 1 EstaQuick Applicator 27 43 Nm Ransburg DHNEISS Ransburg BGK SINKS 3 Insert the locking device Pos 6 into its place in the head Pos 1 and tighten with cap screw Pos 7 Check the electrical contact between cap screw Pos 7 and contact wire Pos 9 with the multimeter Ke weg Insert locking device Screw in cap screw Tighten cap screw Check the electrical contact between wire and cap screw 10 4 2 Preparation of the Assembly End Plate 4 Screw the spring pas Pos 22 into the end plate Pos 3 so that the ball shows for 3mm DH HIGH GU ui gd ot 5 Counter the adjusted spring pad with the set screw Pos 21 1 2 AEMD E 01 1 1 EstaQuick Applicator 28 43 Gana Ransbu rg DHNLEISS Ransburg BGK SINKS 10 4 3 Preparation of the Assembly Head Bracket 6 Lubricate the running surface of the piston in the head bracket Pos 2 and the two running surfaces of the piston Pos 16 with grease AGMD 010 7 Press the piston into the head bracket x Grease running surface of the piston in Grease running surfaces of the piston the Head bracket le Press in the piston 8 Lubricate the washers for head and endplate Pos 4 and 5 with electrostatic grease
18. e EstaQuick AEMD 600 For disassembly and assembly please refer to Parts Lists and Exploded View in this Service Manual Information Disassembly and assembly of parts must only be carried out by adequately trained personnel Works must be carried out on a clean and flat supporting surface 10 2 1 Necessary Tools Test adapter Screw driver Tip wrench AEMD 101 Allen screw wrench SW 6 Ring spanner SW 3 Multimeter Calliper gauge 10 2 2 Grease and Bonding Agent AGMD 010 for needle needle packing and piston e Electrostatic Grease Order No 59972 00 for O Rings packing and hollow spaces e LOCTITE 243 screw locking middle strength e LOCTITE 222 screw locking light strength Information Needle needle packing and piston must only be lubricated with grease AGMD 010 Any other grease can lead to gun failure needle packing and piston might swell if improper grease is being used Once the gun has been disconnected from the adapter and has been replaced by a spare gun the spraying operation can be continued and the disconnected gun can be serviced at a suitable place 1 2 AEMD E 01 1 1 EstaQuick Applicator 22 43 Gana Ransbu rg DrVNBISS Ransburg BGK SINKS For disassembly the following steps have to be followed 1 Connect he gun to be serviced onto a test adapter Apply cylinder air with 6 bar pressure to the needle this pushes the needle toward the springs and relieves the tip Cau
19. ent Group hazardous area characteristics 2 Equipment Category Type of explosive atmosphere gases vapors or mists EEX0 24mJ The EstaQuick AEMD 600 applicator is suitable for use in automatic spraying installations Complying with EN 50 050 as they are a Type A class With a discharge energy limit of 0 24md 1 2 AEMD E 01 1 1 EstaQuick Applicator 9 43 Finishing Brande BHNBEISS Ransburg BGK SINKS 3 3 Tests Ransburg 3 3 1 automatic stationary spray installation for electrostatic spraying of coating materials must be tested by an expert prior to initial start up 3 3 2 Method scope and frequency of tests have to be determined by the user based on the individual production requirements and local conditions In the individual case the professional trade association may require a written proof in form of a test book EDP report or similar 3 3 3 Ensure that electrostatic soraying systems and installations and accessory parts be checked by an expert for safe operation whenever necessary but at least once a year This examination must be documented in writing 3 34 The following checks must be carried out by a qualified electrician e Keep ready access to appropriate fire extinguishing equipment Check fire extinguishing equipment regularly at least every 2 years All personnel must be adequately trained with fire extinguishing equipment e Keep ready an actual warning schedule sho
20. erial supply 3 Clean the removed parts with a soft brush and suitable solvent Caution AN Never use metal tools or metal brushes For cleaning purposes never use any object that is harder than the plastic parts If it is impossible to remove paint residues with a cloth or with a brush the parts may be soaked in solvent but only as long until the residues can be removed Never soak the gun body hoses or the high voltage cable in solvent 8 2 Flushing Process Turn off the high voltage Turn off the material supply Turn off atomizing and fan control air Connect solvent supply to the gun Flush the system with solvent until clean solvent escapes Remove the solvent supply Activate the gun until there is no solvent left After finishing these steps the gun will be ready for color change storage or maintenance Sg et 1 2 AEMD E 01 1 1 EstaQuick Applicator 17 43 Finishing BH A DHH rz Ransburg BGK SINKS Ransburg 9 Failures 9 1 Troubleshooting Chart General Problem PossibleCause 1 Solution Asymmetric Shape 1 Air hose of the remote air Clean replace or repair supply to air valve obstructed or damaged 2 Air channel and or air inlet Blow out or clean obstructed Very uneven or deformed spray 1 Wrong air cap fluid tip Select the correct pattern combination combination 2 Airand fluid not synchronized Check the programming sequence Insufficient Supply Atomizing Air 1
21. for levelness with the calliper gauge 20 Screw the electrode 16 with LOCTITE 222 screw locking light strong onto the needle shaft 17 and tighten by hand 21 Click the gun onto the test adapter and apply cylinder air of 6 bar 22 Insert the baffle Pos 11 into the head Pos 1 Hereby it has to be decided whether a horizontal or vertical spray pattern is wanted see Chapter 6 2 Spray Pattern Adjustment 23 Lubricate the disc washer Pos 26 with electrostatic grease and install it onto the baffle Pos 11 24 Lubricate the O Ring 24 with electrostatic grease and install it into its place in the tip 1 2 AEMD E 011 1 EstaQuick Applicator 30 43 Ke e eg Ransburg DEVILBISS Ransburg BGK Gre T Insert disc washer with tapered side into Insert tip with lubricated O Ring into the the groove of the baffle gun Information For longer service life the O Rings must always be lubricated Never use faulty O Rings 25 Insert the tip Pos 13 with the guide pin into the bayonet of the head Pos 1 Push it downward with light strength and fix it to the head by a turn clockwise Information The bayonet is only designed for fixing the tip and not for sealing Only after the gun has been equipped with air cap and retaining ring the tip is sealed to the head Caution Prior to each assembly of the tip into the head the seat of the electrode must be checked 26 Install the air cap P
22. g BGK SINKS Ransburg Electrical Problems Wrap back Insufficient grounding of the Check and correct work piece Insufficient booth ventilation Check and correct Too much atomizing air Heduce pressure Insufficient or no high voltage Faulty high voltage connections Check and connect to adapter and high voltage transformer Line passage between transformer and electrode Check and correct interrupted Insufficient or no grounding Check and correct Faulty pressure switch Replace High voltage cable damaged Replace High voltage transformer Please see Service Manual damaged for the high voltage transformer 7 Check fuse Check Is the voltage turned on Is the atomizing air turned on Is the Check gun activated Is the paint too conductive High Make Impulse 1 Paint in the air channels Clean air channels with soft brush 2 Paintin the rear part of the gun See Leakages 1 2 AEMD E 01 1 1 EstaQuick Applicator 19 43 Finishing q Ransbu rg Dr Er Ransburg BGK SINKS 10 Service Information Only use genuine spare parts when servicing the EstaQuick Note All personnel should read and understand this Service Manual prior to starting maintenance and service 10 1 Disassembling the Gun from the Adapter Caution When servicing the gun always turn off and ground the high voltage turn off the material supply and relieve pressure from the material supply 10 1 1 Preparations
23. ility of the user to ensure that no work with ignition hazard is done in rooms at risk of fire or in potentially explosive atmospheres Exceptions will only be possible if special protective measurements were taken for example removal of liquid spraying material solvent and other flammable goods Cleaning of all systems and parts of the building Proper ventilation etc 2 11 2 Always ensure that next to potentially explosive rooms and areas operation with ignition hazard must only be carried out if ignition sources cannot enter these rooms and areas 1 2 AEMD E 01 1 1 EstaQuick Applicator 7 43 Wasa DHNBISS Ransburg BGK SINKS 3 ATEX 3 1 European ATEX Directive EUROPEAN ATEX DIRECTIVE 94 9 EC ANNEX Il The following instructions apply to equipment covered by certificate number Sirall ATEX 1 The equipment may be used with flammable gases and vapors with apparatus groups ll and with temperature class T6 2 Theequipmentis only certified for use in ambient temperatures in the range OC to 40 C and should not be used outside this range Installation shall be carried out by suitably trained personnel in accordance with the applicable code of practice e g EN 60079 14 1997 4 Inspection and maintenance of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice e g EN 60079 17 5 Repair of this equipment shall be carried out by suitable trained perso
24. inishing Brande DEVILBISS Ransburg BGK SINKS Da Ransburg 7 Preventive Maintenance Caution Never use a faulty spray gun 7 1 Maintenance Schedule For longer service life of the gun and for safe use of the spray installation this maintenance schedule must be followed 7 1 1 Several Times Daily Turn off the high voltage Check the air cap spray tip and electrode for paint residues Clean as often as necessary with a soft brush and a suitable solvent and blow dry Clean all insulated surfaces of the installation Remove paint residues from the gun exterior the high voltage cable and the air and fluid hoses with a solvent wetted cloth Make sure the solvent in non polar Make sure that solvent has a flash temperature below temperature in booth 7 1 2 Daily At the Begin of Each Shift Either remove or ground all loose or non grounded objects in the surroundings of 6 meters of the operating range of the gun Check whether the atomizer head and the gun electrode are clean and not damaged Information e Never remove the fluid tip if there is still fluid in the gun otherwise fluid can enter the air passages In order to remove the fluid tip air cap hold the gun downward Clogged air passages will cause improper atomization and might lead to short circuit If the air passages are clogged with conductive fluid this will lead to increased current output and low operating voltage and might finally damage the elec
25. luid needle Pos 17 1 is glued into the spring bolt Pos 18 with LOCTITE 243 The positions 17 1 and 18 are one unit 9 Disconnect the gun head Pos 1 from the head bracket Pos 2 Remove the contact lock Pos 10 Information The contact wire Pos 9 will remain in the head 1 2 AEMD E 01 1 1 EstaQuick Applicator 24 43 Finishing Brands Ransbu rg Do 817 Ransburg BGK SINKS 10 Remove the washer Pos 4 and both R Rings Pos 24 11 The needle packing Pos 8 must be exchanged at each disassembly It will be destroyed at disassembly see picture Insert screw driver Force screw driver with light blows of the hammer into needle packing Unscrew faulty needle packing 12 The locking device Pos 6 and the cap screw Pos 7 will remain in the head Information An electrical contact must exist between cap screw Pos 7 and contact wire Pos 9 Check this contact with a multimeter 10 3 Cleaning and Examination of Gun Parts After disassembly clean the gun parts at first and then check for proper condition 1 2 AEMD E 01 1 1 EstaQuick Applicator 25 43 Finishing q Ransbu rg Dr Er Ransburg BGK SINKS 10 3 1 Cleaning of Parts Information he kind of contamination of the gun parts might give an indication for gun failure For regular cleaning procedures the following tools are needed ouitable solvent Grounded solvent supply A brush with soft bristles oome pipe cle
26. mu was Ransburg DOH 817 Ransburg BGK SINKS Service Manual ELECTROSTATIC AUTOMATIC APPLICATOR ESTAQUICK AEMD 600 0518 2 EEx 0 24 mJ SIRA 11ATEX5240X Before using this equipment carefully read the Safety and Safety Precautions sections and all instructions in this manual Keep this Service Manual for future reference 1 2 AEMD E 010 3 EstaQuick Applicator Finishing Brahe s R b DeViLOISS Ransburg BGK SINKS ans urg Table of Contents en E 4 ET ADOUSI EE 4 1 2 Electrostatic Automatic Applicator EstaQuick AEMD 600 5 1 9 SONIDOlIE EE 5 UNE ee NR 6 2 lev EH le EE 6 a ere En EE 6 6 23 Use of Electrostatic Spray Systems in Potentially Explosive Atmospheres 6 2 4 Work PCS uueseecncernendudssmuedieehaaqttantap aeta MaaMe UM HEFUNFPIIEMEEM EEUU E 7 2 5 Inside Coating of Hollow Parts 7 20 QOM ee Ebbe 2 Conditions for Using the Spray Booth 7 2 0 Personal Prolecive EOUIDITIe E 2 9 Operation with Ignition Hazard 7 2 ATEA 8 34 European ATEX DIFGCIIVG uus uuu u uuu uuu PA eh Ap eR IERTE 8 3 2 EstaQuick AEMD 600 ATEX Product Marking Detinitions 9 55 200 0 e
27. nes reciprocators or supports The EstaQuick applies a voltage of up to 90 kV to the atomizing point of the coating material The charged particles are attracted to and deposited on the target object The forces between the charged particles and the grounded target are sufficient to turn most normal overspray around and deposit it on the side and back surfaces of the target Therefore a high percentage of the spray is deposited on the target The guns of this series are suitable for coating materials on solvent or water base Note This service manual applies exclusively to hazard situations when operating with solvent based paints For the application of water dilatable paints the relevant service manual is valid Note Both the gun and the interconnection with the high voltage JU control unit and high voltage cable have to be regarded as installation components which do not represent an operative complete system Therefore a EC type examination ATEX Certificate cannot be established An operative installation will only be developed in combination with the spray booth i e ventilation and drawing off air Note CE ATEX approval with this power source is only for the EstaQuick 1 3 Components The EstaQuick installation consists of the gun an adapter the air and fluid line and the high voltage control unit incl Low and High Voltage Cable 1 2 AEMD E 01 1 1 EstaQuick Applicator 5 43 1 4 2 1 2 2 2
28. nnel in accordance with the applicable code of practice e g EN 60079 19 6 Putting into service use assembling and adjustment of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation Hefer to the Table of Contents of this service manual a Installation b Operation c Maintenance d Parts Identification 7 Components to be incorporated into or used as replacement parts ofthe equipment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation 1 2 AEMD E 01 1 1 EstaQuick Applicator Ransburg 1 0 6 8 The certification of this equipment relies upon the following materials used in its construction If the equipment is likely to come into contact with aggressive substances then itis the responsibility ofthe usertotake suitable precautions that prevent H from being adversely affected thus ensuring thatthetype of protection provided by the equipment is not compromised Aggressive substances eg acidic liquids or gases that may attack metals or solvents that may affect polymeric materials Suitable precautions eg regular checks as part of routine inspections or establishing from the material s sheets that itis resistant to specific chemicals Refer to Specifications in the Introduction section a Allfluid passages contain stainless steel or nylon fittings b High voltage cascade is encapsulated with
29. os 14 onto the gun take care that the horns of the baffle engage into the slots of the air cap 27 Screw on the retaining ring Pos 15 Check the position of the air cap before tightening Then tighten retaining ring by hand Insert the slots of the air cap into the Check the position of the air cap while horns of the baffle ocrewing the retaining ring on 28 Put the protective cap Pos 27 on the retaining ring to protect air cap and electrode 1 2 AEMD E 01 1 1 EstaQuick Applicator 31 43 Finishing ru BISS Ransburg BGK SINKS Ransburg 11 Ordering of Spare Parts Please have the Parts Lists in hand for ready reference of part numbers when ordering parts 11 1 Exploded View EstaQuick AEMD 600 e Check parts at disassembly and replace if necessary e Replace parts after each disassembly 1 2 AEMD E 01 1 1 EstaQuick Applicator 32 43 i Finishing Brands Ransburg UNLESS Ransburg BGK SINKS 11 2 Parts List Parts List Electrostatic Automatic Applicator EstaQuick AEMD 600 Description Qty Part No GunHeadforCirculaing LI AEMD2196 U OPTION Vent connection connected only with End Plate AEMD 2242 1 ESTA 408 4 Note Pos 28 30 Option for Electrostatic Automatic Applicator AEMD 600 800 FIX ocrew Coupling with Machine Mounted Adapter AEMD 4500 6 FIX 7 Cap Screw CapScew 0 0 0 0 0 0 Needle Packing 11 12 6 AN 8 9 11 12
30. ostatic equipment at a typical installation configuration While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment e Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier trouble shooting e Please conduct the specified tests and checks before requesting service assistance and have this manual in hand for ready reference when requesting such assistance We recommend that maintenance and operating personnel who are familiar with the service problem be authorized to contact us when service is required e Separate service manuals are available for different adapters and accessory equipment 1 2 AEMD E 01 1 1 EstaQuick Applicator 4 43 RN Finishing Brands DeVILBISS Ransburg BGK SINKS Ransbu rg 1 2 Electrostatic Automatic Applicator EstaQuick AEMD 600 The electrostatic automatic applicator EstaQuick AEMD 600 in the following called EstaQuick is an air atomizing electrostatic automatic spray gun The EstaQuick is equipped with a quick disconnect system The gun disconnects for service quickly thanks to an easy 1 4 turn mounting bracket which includes all fluid lines air lines and the high voltage line The EstaQuick is suitable for use on hollow wrist or flex arm robots or with automatic machi
31. ounted Adapter AEMD 4500 6 12 13 12 3 Parts List Parts List Machine Mounted Adapter AEMD 4500 6 Description Qty Part No 7 10 13 14 16 17 18 Note Pos 16 18 Option for Machine Mounted Adapter AEMD 4500 6 FIX Screw Coupling with Electrostatic Automatic Applicator AEMD 600 800 FIX 6 7 8 D 10 18 LU 16 17 18 1 2 AEMD E 011 1 EstaQuick Applicator 37 43 Finishing Brands Dr rz Ransburg BGK SINKS 13 Robot Mounted Adapter Ransburg 13 1 Bracket 13 2 Parts List Bracket Applicator and Machine Mounted Adapter are not included AEMD 4250 13 3 Adapter 13 4 Parts List AEMD 4260 AEMD 4261 AEMD 4263 Adapter ABB 5400 580 Adapter ABB 5400 Enhanced Wrist Adapter B amp M LZ2000 AEMD 4265 AEMD 4266 AEMD 4267 AEMD 4268 lt 1 2 AEMD E 011 1 EstaQuick Applicator 38 43 Dr Er Ransburg BGK SINKS Finishing Bran E B E Ransburg 14 Installation Low Voltage Control Unit Note CE ATEX APPROVAL WITH THIS POWER SOURCE IS ONLY FOR THE ELECTROSTATIC AUTOMATIC APPLICATOR AEMD 600 INCL MACHINE MOUNTED ADAPTER AEMD 4500 6 14 1 9060 Low Voltage Control Unit Note Installation of Low Voltage Control Unit see Service Manual CP 13 01 1 TY 10 VERSION 80120 X1X 19 VERSION 80100 X1X in SA A 5 k 1 x d m _ M 9 Lee L j li A f installation Low
32. t be taken to clean the spray booth including suction plant spray mist collector and the surrounding area 2 8 2 The work piece holders must be cleaned regularly 2 6 2 Ensure that the spray area is properly ventilated during cleaning procedures 2 6 3 Ensure that only electrically conductive solvent containers are being used and that the containers are properly grounded 2 6 4 Prior to start cleaning the high voltage conducting parts with flammable solvents ensure that the discharge energy must not exceed 0 24 mJ For the practical use this means that the system must be grounded Conditions for Using the Spray Booth 2 1 Always ensure that the spray area is properly ventilated and that the solvent concentration in the breathing air is not damaging to health 2 2 Ensure that the floor of the spray booth is electrostatic conductive 2 3 Always ensure that no person remains in the spray booth during the spraying process 2 4 Ensure that the discharge energy which will be drawn off the high voltage circuit is 0 24mJ if flammable liquids are being used for cleaning procedures Personal Protective Equipment 2 10 1 Ensure that all persons working with electrostatic spraying systems and all persons in the area of the electrostatic conductive floor wear antistatic shoes 2 10 2 If protective gloves are necessary these gloves must be antistatic or similarly effective Operation with Ignition Hazard 2 11 1 lt is the responsib
33. th different fluid tips and fluid feed versions Information For more information please note page 35 1 2 AEMD E 01 1 1 EstaQuick Applicator 11 43 Finishing Brands DrVNLBISS Ransburg BGK SINKS Ransburg 6 Installation 6 1 Connection of EstaQuick AEMD 600 to Adapter AEMD 4500 6 Insert the EstaQuick AEMD 600 with the locking device into the designated place by a turn of 45 to its later position Push the gun body onto the adapter whereby the resistance of the spring must be surmounted Turn the gun clockwise by 45 in its position until it locks into the adapter Position the gun by 45 to the adapter Push the gun downward against the spring Click the gun into the rear locking device force until it bottoms on the adapter until it sits straight 1 2 AEMD E 011 1 EstaQuick Applicator 12 43 Finishing Brands 8 8 8 DOH 2777 Ransburg BGK SINKS Ransburg 6 2 Screwed connection of EstaQuick AEMD 600 FIX to Adapter AEMD 4500 6 FIX In case of screwed connection insert the gun with the locking device into the designated place by a turn of 45 to its later position Push the gun body onto the adapter whereby the resistance of the spring must be surmounted Turn the gun clockwise by 45 in its position and fix it with the two screws in the front and back i Ex Lt ME ET 3 i MAR Position the gun by 45 to the adapter Insert the locking device into the seat
34. tification Service 0518 Rake Lane Eccleston Chester CH4 9JN United Kingdom Conformity has been demonstrated with reference to the following documentation EC type examination certificate Sira 11A TEX5240X Quality Assurance notification Sira 12ATEX M519 Compliance with the Essential Health amp Safety Requirements has been assessed by reference to the following standards EN 50050 2006 Electrical apparatus for potentially explosive atmospheres Electrostatic hand held spraying equipment According to Annex Il of the EC Machine Rule 2006 42 EG MaschRL Applied Harmonized European Standard EN ISO 12100 1 2010 Safety of machines basic concepts general design principles Part 1 Basic terminology methodology EN ISO 12100 2 2010 Safety of machines basic concepts general design principles Part 2 Technical principles EN 1953 2011 Atomizing and spraying equipment for coating materials Safety requirements Dietzenbach 27th of Nevember 2012 Name and Position Dave Smith General Manager 1 2 AEMD E 01 1 1 EstaQuick Applicator 41 43 Finishing Bra e DHNEISS Ransburg BGK SINKS 16 Product Liability and Warranty Ransburg Important Note for Product Liability On the basis of a valid EC Rule dated January 1 1990 the manufacturer is only then liable for his product if all parts are originally coming from the manufacturer or have been released by the manufacturer respectively the equipment
35. tion In order to protect the gun head from damages it is important that pressure air min 6 bar is applied to the needle during the disassembly of the air cap and tip 2 Loosen the retaining ring Pos 15 and remove the air cap Pos 14 Only exchange the tip Pos 13 by hand or use the tip wrench AEMD 101 It can be loosened by a light pressure and a 4 turn counter clockwise See Pictures Apply pressure of 6 bar to the gun Disassembly with fingers Disassembly with tip wrench AEMD 101 rong Disassembly with pliers or other tool 1 2 AEMD E 01 1 1 EstaQuick Applicator 23 43 Finishing q Ransbu rg DHNEISS Ransburg BGK SINKS ae SS Z e och E3 WSS Cut B B Cut B B insertion position locked position Remove the baffle Pos 11 and the O Rings Pos 24 and 26 Relieve pressure from the test adapter and remove the gun Loosen the electrode 17 2 from the needle 17 1 Firmly hold gun head Pos 1 and head bracket Pos 2 and carefully and evenly loosen the 6 connecting screws Pos 23 Remove the end plate Pos 3 from the head bracket Pos 2 8 Remove the pressure springs Pos 19 and 20 the spring bolt fluid needle assy Pos 18 17 1 and the piston Pos 16 Remove the washer for the end plate Pos 5 Information The f
36. trical components e For maintenance of the atomizer please refer to the chapter Cleaning of the Atomizer Note In order to change the fluid tip pressure must be applied to the Jp needle 1 2 AEMD E 01 1 1 EstaQuick Applicator 15 43 gt UA Finishing Brands DHNEISS Ransburg BGK SINKS Ransburg 7 1 3 During Operating Interruption and at the End of Each Shift 1 m Turn off the high voltage 2 Turn off material supply 3 4 Clean gun cable and hoses with a solvent wetted cloth Use suitable Turn off atomizing air and cylinder air solvent only Empty the fluid lines and leave solvent in the non pressurized lines See the chapter Flushing Procedure Caution e Fora short operating interruption shorter than the respective pot life of the fluid it might not be necessary to flush the lines depending on the coating material being used If the solid particles of the fluid deposit slowly the lines must not be flushed so quickly after an operating interruption as it would be the case with quickly depositing solid particles e he necessity for flushing depends on the coating material and on the time of the operating interruption e Metallic paints and primer will need more frequent flushing than some other paints 7 1 4 Weekly e Checkthe complete system for damage leakage and paint residues e Clean the atomizer unit 1 2 AEMD E 01 1 1 Information If quickly depositing
37. wing the type of alarm and the triggering function manually automatically A qualified electrician is a person who has specialist training knowledge and experience as well as knowledge of the relevant rules and who can recognize and judge possible hazards of the works involved See 2 Par 3 UVV VBG 4 Furthermore a qualified electrician must have the following qualifications Specialist training and knowledge of explosion protection electrostatic process technology knowledge of local conditions knowledge of the electric installation and knowledge of the load of electric installation 1 2 AEMD E 01 1 1 EstaQuick Applicator 10 43 in Finishing Bra DEVILBISS Ransburg BGK SINKS 4 Specification Atomization Fluid pressure Cylinder air pressure Tip voltage Current max Voltage input Gun weight Dimensions Material 5 Design 5 1 Different Models Ransburg Conventional air atomizing to 9 bar 0 to 7 bar 7 bar max 90 kV DC voltage 120 uA 220V at 50 60Hz 245 g 125 x 46 x 56 mm PEEK POM Stainless Steel The EstaQuick is available in different versions These differ from different tips respectively different fluid feed versions Please see the Tip and Air Cap Selection Chart for selection of fluid tips and air caps The selection of the correct atomizer depends on the desired finish quality the geometry of parts and the paint viscosity For this reason a test should be carried out wi
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