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Aerobell 33 (AER5000/AER5001) (Serv. Manual LN

1. 7 2 0 0 o 5 lt 2 ae B scd Aa lt e ia e lt z Tm amp Sh Re Figure 16a Aerobell 33 Cross Section View 35 LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Parts Identification 9 22 2 e GOO gt DIN WS P 7 4 SECTION Figure 16b Aerobell 33 Cross Section View J ZNR OC EN FEN DUMR WSA 4 SOL A SECTION Figure 16c Aerobell 33 Cross Section View LN 9521 00 4 36 Aerbell 33 Rotary Atomizer Parts Identification Ransburg AEROBELL 33 MODEL IDENTIFICATION When ordering use part number AER5001 ABCDE as indicated by Tables A through E Table A
2. EA 5555 j 0 63 50 27 124 t OO v0 j 735 35 M _ Ivp pepe 1 5 79 70417 5 gt PS m 49 LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Appendix RANSBURG VISCOSITY CONVERSION CHART Continued E eso eoo _ 180 1600 ES 0 2000 EE EET rf Pt p pepe 30013000 T LL Ld a 55 0 5500 14 p T 25000 Ford Cup 4 Gardner Holdt Bubble Gardner Lithographic Saybolt Universal SSU Sears Craftsman gt Faso sso 950 9500 E L L e LLL L moomoo fao 130003000 L 600
3. peoopso 1776 7590470 j jeso j j d 190090 gt 20002000 af L L L L L L 11111 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 2013 Ransburg All rights reserved LN 9521 00 4 50 Aerbell 33 Rotary Atomizer Appendix Ransburg VOLUMETRIC CONTENT OF HOSE OR TUBE English Units Cross Length Section in 5 60 104 1207 158 180 25 300 50ft 600 003 gal 006 gal 010 gal 016 gal 032 gal 4 fl oz 8 fl oz 1 2 fl oz 2 0 fl oz 4 1 fl oz 012 028 007 gal 014 gal 022 gal 036 gal 072 gal 049 013 gal 025 gal 038 gal 064 gal 127 gal 077 020 040 gal 060 gal 100 gal 199 gal 110 029 gal 057 gal 086 gal 143 gal 287 gal 38 6 196 051 gal 102 gal 153 gal 255 gal 510 gal VOLUMETRIC CONTENT OF HOSE OR TUBE Metric Units Cross Length Section 2 110 8 147 8 184 7 cc 4 6 36 3 109 0 cc 163 4 cc 217 9 cc 272 4 cc 60 8 182 5 cc 273 7 cc 364 9 cc 456 2 cc 2013 Ransburg All rights reserved LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Manual Changes
4. IIIa 14 16 FLUID 17 TURBINE SPEED tte ttt ntt ttt ttt ttes 17 BEARING AIR ADJUSTMENT u breed eI SEE 18 SHAPING AIR MN ADORA IUD M EO UAM ANCONA IM 18 PIN SP 18 ELECTROSTATIC VOLTAGE eroii 19 e 19 MAINTENANCE 20 34 CLEANING PROCEDURES 20 22 VIBRATION NOISE socie nitet 22 TURBINE REPAIR amp REBUILD 22 HIGH VOLTAGE CONNECTIONS 22 AIR FILTER ELEMENT REPLACEMENT ocior asbestos 23 es 23 GENERAL 23 PREVENTIVE MAINTENANCE 23 25 HIGH PERFORMANCE THERMOPLASTIC BELL CUP PREVENTIVE MAINTENANCE 26 CUP CLEANING E 26 LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Contents CONTE NTS Cont PAGE MAINTENANCE Cont 20 34 BELL CUP TESTING NONSISO DATING 27 OPERATOR MAINTENANCE WARNINGS nasa 27 LOW VOLTAGE TES T ERU 28 DISASSEMBLY PROCEDURES 28 31 TROUBLESHOOTING GUIDE uuu uuu usa 32 34 AEROBELL 39 CROSS SECTION VIEW ae HIC RUM LEGE Ru an
5. 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 9 2 LN 9521 00 4 Ransburg LOW VOLTAGE TEST When replacing the resistive components trouble 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 resistortester Meg ger must be used which has an output voltage of 500 to 1000 VDC 1 With the high voltage turned OFF disconnect 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 Setthetest meter voltage output to a minimum 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 assembly 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 th
6. 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 ISOBUTYL ACETATE Esters 110 19 0 LOW ETHANOL Ethyl Alcohol Alcohols 64 17 5 LOW BUTYL ACETATE 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 MEDIUM 1 BUTANOL n Butyl Alcohol Alcohols 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 CYCLOHEXANOL Butyl Cellosolve Glycol Ethers 111 76 2 108 93 0 LOW Alcohols AROMATIC 150 SC 150 Aromatic Hydrocarbons AROMATIC 200 CAS Number Chemical Abstract Service Number Electrical Resistance using the Ransburg Meter Solve
7. 69kPa 80 psi 10 551kPa 69kPa 80 psi 10 3 8 O D 1 4 O D 1 4 O D Low Flow 1 4 O D Signal Air Low Figure 7 Air Tubing Connections 10 Aerbell 33 Rotary Atomizer Installation 11 AIR FILTRATION REQUIREMENTS Ransburg D E ificati Replacement Filter Model No escription 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 assemblies 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 Air must be properly filtered to ensure extended turbine life and to prevent contam ination of the paint finish Air which is not ad equately filtered will foul the turbine air bear ings 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 It is the user s responsibility to en sure clean air at all times Tur
8. MANUAL SUMMARY CHANGES This manual was published to replace Service Manual LN 9521 00 3 Aerobell 33 Rotary Atomizer to make the following changes 1 Change logo LN 9521 00 4 52 Service Manual Price 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No LN 9521 00 4 2013 Ransburg All rights reserved ISO 9001 Litho in U S A Models and specifications subject to change without notice Quality Systems 01 13
9. or working on spray system equipment Before turning high voltage on make sure no objects are within the safe sparking distance Ensure that the control panel is interlocked with the ventilation system and conveyor in accor dance with NFPA 33 EN 50176 Have fire extinguishing equipment readily avail able and tested periodically Personnel must be given training in accordance with the requirements of NFPA 33 EN 60079 0 Instructions and safety precautions must be read and understood prior to using this equip ment Comply with appropriate local state and na tional codes governing ventilation fire protec tion operation maintenance and housekeep ing Reference OSHA NFPA 33 EN Norms and your insurance company requirements LN 9521 00 4 Ransburg AREA Tells where hazards may occur Spray Area High Voltage Equipment LN 9521 00 4 HAZARD Tells what the hazard is Electrical Discharge There is a high voltage device that can induce an electrical charge on ungrounded objects which is capable of igniting coating materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion Aerbell 33 Rotary Atomizer Safety SAFEGUARDS Tells how to avoid the hazard Parts being sprayed and operators in the spray area must be properly grounded Parts being sprayed must be supported on con veyors or hangers that are properly groun
10. Aerbell 33 Rotary Atomizer Maintenance TROUBLESHOOTING GUIDE General Problem Bad Spray Pattern Low or No High Voltage LN 9521 00 4 Possible Cause Bell cup damaged Solution Replace bell cup Low voltage See low or no voltage below Bad fluid regulator Repair or replace fluid regulator Paint lodged in shaping air ring High current draw Disassemble and clean Paint resistivity to be 1 MQ to Solvent valve is actuated Remove solvent valve air pilot signal high voltage must be interlocked with the solvent valve air pilot signal to prevent solvent flow while high voltage is energized Loss of high voltage connection at the power supply Ensure proper high voltage connection at the power supply Refer to Low Voltage Test in the Weekly Maintenance section of this manual Loss of high voltage connection at the resistor module Verify high voltage connection into the re sistor module Refer to Low Voltage Test in the Weekly Maintenance section of this manual Loss of high voltage connection at the turbine assembly Verify high voltage tube connection into the turbine housing and resistor module Refer to Low Voltage Test in the Weekly Maintenance section of this manual Power supply failure Refer to the power supply manual for de tailed troubleshooting guide Improper limiting current and volt age settings To readjust settings ref
11. 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 5001 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 A Figure 16 Aerobell 33 Assembly w 57mm Bell AER4016 02 0020 RPM 5 Aerobell 33 Assembly w 30mm Bell AER4015 02 038 RPM 80 Aerobell 33 Assembly w 30mm Slotted Bell AER4015 04 AERO038 RPM 80 5 Aerobell 33 Assembly w 57mm Bell Cup AER4016 03 0020 RPM 5 BN Aerobell 33 w 30mm Bell Cup AER4015 05 AERO038 RPM 80 w Holes amp Secondary Charging Ring 7 Aerobell 33 w 30mm Bell Cup AER4015 06 0038 RPM 80 ABLE B Figure 16 S S Fluid Tube 041 76416 04 S S Fluid Tube 093 76416 09 S S Fluid Tube 125 I D 76416 12 S S Fluid Tube 061 76416 06 37 LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Parts Identification ABLE C Figure 16 Dash Description ABLE D Figure 16 8 5 1 4 O D Supply w Fluid Regulator 1 1 Low Flow LREG5001 01 ENESES 1 4 O D Supply w Fluid Regulator 1 2 Low Flow LREG5001 02 o
12. PARTS LIST BULLET DEFINITION TABLE Figure 19 2 Install fitting hand tight then 1 4 turn with wrench 1 Apply 59915 01 tape to all male pipe threads 45 LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Parts Identification RECOMMENDED SPARE PARTS See Table B K Pg 34 Description Fluid Tube lt 556 8128 O Ring Solvent Resistant LSFA0004 56C Screw 1 4 20 x 1 75 Long Nyl Fill Head 7554 03 O Ring Solvent Resistant RPM 2 Shaping Air Cap Retainer LSORO0005 01 O Ring Encapsulated See Table A N Pg 34 Bell Cup Assembly LSORO0005 02 O Ring Encapsulated 76917 00 Valve Plastic Fluid 73913 00 Regulator Repair Kit w Solvent Resistant O Rings 73913 01 SERVICE KITS Regulator Repair Kit w Solvent Proof O Rings 02 PO Figure 20 Recommended Spare Parts AER4019 00 Air Bearing Rebuild Kit 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 RPM 419 Shroud Wrench AER0076 01 Feed Tube Center Location Gauge Figure 22 Available Tools LN 9521 00 4 46 Aerbell 33 Rotary Atomizer Warranty Policies 47 Ransburg WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipment that fails within the spec
13. 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 components including internal portion of shroud Reinstall rear shroud bell cup and front shroud Rewrap the outer housing and insulator mount ing rod refer to Disassembly Procedures for definite instructions NOTE The outer protective wrap may have to be replaced more frequently than week ly Daily inspection of the amount of paint buildup on the wrap will determine the fre quency of replacement LN 9521 00 4 Ransburg HIGH PERFORMANCE THERMOPLASTIC BELL CUP PREVENTIVE MAINTENANCE It is the user s responsibility to ensure proper maintenance of the atomizer bell at all times Bell cup failure 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 that the 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 sol vents used for exterior cleaning must have flash points above 100 F 37 8 C Since electrostatic equipmentis involved these solvents should als
14. 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 Fixed Atomizer SOUR 97 SEM Regulator Part No 1 1 LREG5001 01 1 2 LREG5001 02 1 4 LREG5001 04 1 6 LREG5001 06 1 8 LREG5001 08 LREG5001 10 Figure 10 Fluid Regulator Selections LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Operation 041 76416 04 061 I D 76416 06 093 76416 09 Figure 11 Fluid Tube lecti 125 76416 12 Selections DR 1 FLOW VS SIGNAL PRESSURE 900 Viscosity 40 sec Zahn 2 15ft 1 4 1 0 tubing 01 093 orifice _ HIGH FLOW 8 4004 300 200 100 4 Figure 12a DR 1 Flow Vs 1 6 110 Signal Pressure 5 9 12 15 21 26 32 37 42 48 54 59 65 70 75 81 SIGNAL PRESSURE PSI DR 1 FLOW VS SIGNAL PRESSURE 1400 Viscosity 25 sec 1200 Zahn 2 158 1 4 I D tubing 1000 093 orifice 2 800 600 400 Figure 12b DR 1 Flow Vs Signal Pressure 9 12 15 21 26 32 37 42 48 54 59 65 70 75 81 SIGNAL PRESSURE PSI LN 9521 00 4 16 Aerbell 33 Rotary Atomizer Operation 17 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
15. to disengage the threads Then pull the valve straight out of the manifold 30 Aerbell 33 Rotary Atomizer Maintenance 31 Speed Transducer Removal To remove the speed transducer follow the pro cedures 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 itis 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 distance other than 207 7 015 030 replace the tube with another feed tube NOTES Ransburg LN 9521 00 4 Ransburg
16. valve With the bell spinning turn on the solvent valve to al low cleaning solvent to flow through the manifold passages through the fluid tube 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 clean the remaining manifold fluid passage and to flush the dump line if desired gt The maximum 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 theAerobell 33 Turbine drive air mustbe off but leave shaping air and bearing air on Be careful not to drip solvent into the opening behind the bell 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 20 Aerbell 33 Rotary Atomizer Maintenance 21 Do not spray the Aerobell 33 unit with a sol vent gun used for cleaning The cleaning fluid under pressure may aid conductive materials to wick into hard to clean areas or may allow fluids to be forced into the turbine asembly Do not reuse an atomizer bell that shows signs of damage such as nicks heavy scratches dents or excessive wear WARNING NEVER wrap the applicator associated valves and tubing and suppor
17. 1 C 1 4 O D Supply w Fluid Regulator 1 3 Low Flow LREG5001 03 KEE 1 4 O D Supply w Fluid Regulator 1 4 Low Flow LREG5001 04 EES 1 4 O D Supply w Fluid Regulator 1 6 Low Flow LREG5001 06 ETEN 1 4 O D Supply w Fluid Regulator 1 8 Low Flow LREG5001 08 EJES 1 4 O D Supply w Fluid Regulator 1 10 Low Flow LREG5001 10 oja 3 8 O D Supply w Fluid Regulator 1 1 Low Flo 1 1 LREG5001 11 1 a Rep E 3 8 O D Supply w Fluid Regulator 1 3 Low Flow L 1 3 8 O D Supply w Fluid Regulator 1 4 Low Flow L 3 8 O D Supply w Fluid Regulator 1 6 Low Flow 1 3 8 O D Supply w Fluid Regulator 1 8 Low Flow 3 8 O D Supply w Fluid Regulator 1 10 Low Flow oja Te o sus B e NM KE KE KE ES i KE KE EN i ABLE E Figure 16 x Resistor Block 650 Megohm AER4012 LN 9521 00 4 38 Aerbell 33 Rotary Atomizer Parts Identification Ransburg 39 AEROBELL 33 PARTS LIST Figure 16 bach AER4004 01 Manifold Assembly Air 1 See J Table A Shaping Air Cap w Shroud 1 O See K Table B Fluid Tube 7900105 SovenProt L r FLSFADUI4 00 SeewRelamng O PT 6 AER4013 00 Tube Assembly High Voltage L 6A 7900105 O Ring SovenProt Rej See L Table C Manifold Asse
18. 1760170 Assembly 7 2 2 3 4A AER4018 00 Plug Assembly Valve Pon 2 71 1 5 LSFI0013 03 Fitting 1 4 D Tubex NPT 3 2 2 1 3 See Parts List Bullet Definition Table below PARTS LIST BULLET DEFINITION TABLE Figure 18 2 Install fitting hand tight then 1 4 turn with wrench Apply 59915 01 tape to all male pipe threads 43 LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Parts Identification EA 0 0 SOL S LN 9521 00 4 Figure 19 Waterborne Fluid Manifold Assembly 44 Aerbell 33 Rotary Atomizer Parts Identification Ransburg WATERBORNE FLUID MANIFOLD ASSEMBLY PARTS LIST Figure 19 En e N ui lt Description 1 AEROO68 00 Manifold Fluid 1 1 2 15 0035 03 Plug Protective V4AN 2 2 _ s Fling 38 OD Tube x E AN Uis ET LSMMOO35 05 Plug Protective BAN 2 2 4 76917 00 Valve Assembly Cartridge 1 2 2 95 JAER4018 00 PlugAssembly Valve Port 2 1 1 5 _ LSFI0013 03_ Fitting 1 4 O D Tube x 1 8 NPT__ 1 2 2 5 p See Parts List Bullet Definition Table below AER4023 00 4021 00 AER4022 00 lt NI NI
19. 35 36 AEROBEEL 39 MODEL IDENTIFICATION et 37 38 AEROBELL 33 PARTS Aa Nat 39 MANIFOLD ASSEMBLY BEER cai 40 41 FLUID MANIFOLD ASSEMBLY Papa 42 43 WATERBORNE FLUID MANIFOLD ASSEMBLY tau nitus 44 45 RECOMMENDED SPARE PARTS a ENa CON 46 SERVICE m 46 e uM 46 WARRANTY POLICIES 47 LIMITED WARRANT Y er 47 APPEND C C C C Ca C s PAINT AND SOLVENT SPECIFICATIONS verrions inanasan 48 RANSBURG VISCOSITY CONVERSION CFIBER Laut ls bata etna c Rub crac Run 49 50 VOLUMETRIC CONTENT OF HOSE OR TUBE ENGLISH 51 LN 9521 00 4 Aerbell 33 Rotary Atomizer Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety liter ature for your Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize
20. 8 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 accessibility to the components such as valves If space parameters require that the spacing be tween 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 over the cable Then loosen 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 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 for ward If the resis
21. D 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 outputofthe 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 of paint to either the feed tube or dump line and to supply a intermittent solvent bell wash for the feed tube and bell cup Ransburg The feed tube is available in several sizes See Figure 11 The viscosity and volume of the coat ing 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 tur bine air must be off A WARNING Danger of
22. SERVICE MANUAL Ransburg LN 9521 00 4 Replaces LN 9521 00 3 March 2013 AEROBELL 33 ROTARY ATOMIZER ww AEROBELL 33 MODEL AER5000 AER5001 APPROVED IMPORTANT Before using this equipment care fully 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 Aerbell 33 Rotary Atomizer Ransburg NOTE This manual has been changed from revision LN 9521 00 3 to revision LN 9521 00 4 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Contents CONTENTS PAGE SAFETY 1 5 SA ELEM MEL 1 HAZARDS T SAFEGUAPIS nta diei 2 5 INTRODUCTION 6 9 FEATURES Lue EU EE 6 GENERAL DESCRIPTION 6 7 8 9 INSTALLATION 10 13 AIT PILTERINSTAELATION U e ERR 10 AIR PRESSURE REQUIREMENTS ttt 10 AIR FILTERATION REQUIREMENTS ctt 11 uuu ua naya nan anus masana MM MIN MM 12 FLUID ONIN IONS usu REPERI EE E EE 12 ELECTRICAL CONNECTIONS ttt 12 SPEED MONITOR tenete dete notre beta 12 2 tuer nt 13 OPERATION 14 19 COATING 14 FLUID FLOW RATECONTROL
23. TS LIST BULLET DEFINITION TABLE Figure 16 300 dia Ref of feed tube 76416 xx to be concentric to 500 1 0 Ref of shaft AERO032 Ref to within 020 028 radially Use 0076 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 Ibsin 40 0 Ibsin 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 fluid regulator and on fluid manifold assembly LN 9521 00 4 Ransburg p LN 9521 00 4 Aerbell 33 Rotary Atomizer Parts Identification AEROBELL 55 Figure 17 Manifold Assembly SECTION 40 Aerbell 33 Rotary Atomizer Parts Identification 41 Ransburg MANIFOLD ASSEMBLY PARTS LIST Figure 17 Part EI LSFIO013 04 Fitting 1 4 D Tube x 1 4 NPT 15 10023 02 Plug 3 8 O D Tube Fittin 9 9 8 15 10024 03 Plug 1 2 20 9 __ LSFI0025 22 Fitting 3 8 O D Tube x 3 8 NPT LSORO0005 02 O Ring Solvent Proof AERO0021 00 Rod Rear Plate Support 3 12 AERO0062 01 Plate Rear 7 12 13 AERO0027 00 Shroud Rear 13 LSFA0001 16C Screw 1 4 20 x 1 2 Long Nyl Pan Head 3 AERO023 00 Fastener Rear Cov
24. age 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 f paint defects occur such as fat ty edges or picture framing reducing the voltage should be a last resort To correct the problem adjustments to paint resis tivity or lead and lag trigger adjustments should be made The electrostatic voltage applied to the Aerobell 33 will affect pattern size transfer efficiency wrap and penetration into cavity areas Normally 100 kV setting is appro priate for most applications TARGET DISTANCE Thedistance between theAerobell 33 atomizer and the target will affectthe finish quality and efficiency Closer distances give a smaller pattern wetter finish and greater efficiency Greater distance will provide a larger pattern size and drier finish Thehigh 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 NOTES Ransburg LN 9521 00 4 Ransburg MAINTENANCE CLEANING PROCEDURES WARNING gt Electrical shock and fire hazards can ex ist during maintenance High voltage supply must be turned off before entering the spray area and performing any maintenance pro cedures on the atomizer Spray booth fans should remain on while cleanin
25. al 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 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 ex cept during maintenance or disassembly Bearing damage and subsequent turbine failure caused by running the turbine with out bearing air will not be covered under the 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 ma terial but will assist in the penetration of atomized particles into cavity areas Ideally shaping air shou
26. allation 13 INTERLOCKS The following system interlocks are required to prevent equipment damage 1 Bearing air should remain on at all times and should be shut off only by turning off the main air to the pneumatic control cabinet When the turbine air is turned off the tur bine will continue to operate or coast down for about two minutes Provisions should be made to assure that the operator waits at least three minutes after shutting off the turbine air 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 the air bear ing Normally pneumatic interlocks 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 tur bine is rotating gt Pneumatic input to the turbine air inlet must be controlled to prevent the turbine from exceeding the maximum rated intermit tent speed of 55 000 rpm See Specifica tions in the Introduction section Ransburg 2 Itshould not be possible for the coating material to be sprayed unless the turbine is spinning 3 Two interconnected bearing air ports are pro vided one for supply air and the other to be used as a return signal for
27. ator Solvent and dump line connections enter the housing and are connected to the appropriate valves Ports are labeled with blue lettering Fixed Pressure Atomizer nominal max 156 170 or 100 psig 188 1 0 PFA 689 kPa Solvent Line ge 30 60 psig SOL 207 413 kPa Dump Line pd Variable DUMP Figure 9 Fluid Tubing Connection Requirements Paint Line P IN gt The normal fluid flow range is 25 500 min The maximum flow rate must not ex ceed 500 cc min to avoid solvent or paint from flooding into the internal portion of the air bearing motor assembly or front shroud LN 9521 00 4 Aerbell 33 Rotary Atomizer Installation 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 atthe rear ofthe assembly which protrudes through an opening in the rear bulkhead After inserting the cable entirely into the tube and feel ing the banana plug make contact on the inside tighten the cable compression fitting nut around the high voltage cable with an appropriate wrench Reinstall the connector cover with plastic screw SPEED MONITOR CONNECTIONS A fiber optic cable assembly connects the speed signal output of the rotary atomizer assembly to the Pulsetrak Speed Monitor Control System or Fotronics Atomizer Module 12 Aerbell 33 Rotary Atomizer Inst
28. bearing motor assembly or front shroud gt High voltage must be interlocked with the solvent valve to prevent solvent spraying while high voltage is on Ransburg A WARNING 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 mix ture 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 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 min imum required to achieve proper atomiza tion Excessive speed reduces transfer efficiency A WARNING Do not exceed the maximum rated in termittent operating speed and turbine inlet pressure 55 000 rpm at approximately 60 psi for the 57mm bell or 55 000 rpm at ap proximately 45 psi for the 30mm bell Ex cessive speed may cause air turbine dam age or damage to the bell LN 9521 00 4 Ransburg BEARING AIR ADJUSTMENT The nomin
29. bine fail ure resulting from contaminated air will not be covered under warranty Figure 8 shows the pre filter and bearing air filter s which are recommended for use in Aerobell 33 systems If other filters are incorporat ed in the system the filters to be used must have filtering capacities equal or better than those shown in Figure 8 The 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 Ransburg HAF 15 Element One RPM 32 Elements Carton of 4 RPM 33 Elements Carton of 8 LN 9521 00 4 Ransburg MOUNTING The Aerobell 33 incorporates its own insulator mounting rod The diameter at the rear 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 po sitioned 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 of the atomizer assembly to the regu l
30. burg The following data is for use with the RMA 101 or Aerobell 33R atomizers The output voltage measured at the bell will normally range between 91 and 97 of the kV set point displayed at the control unit The following data is for use with the Aerobell 33 atomizer The output voltage measured 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 rag or a gloved hand against the bell edge to stop or slow downa 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 2 2 2 Do not use ultrasonic devices to clean the atomizer bell cup Donotuse ammoniasolutions or reclaim solventcontaining d Lim onene to clean the bell cups Do notuse the bell cup to spray coatings containing N methyl pyrrolidone Donotuse N methyl pyrrolidone to clean the bell cup
31. cur 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 correc tion An electrical arc can ignite coat ing materials and cause a fire or explosion Certain material may be harmful if inhaled or if there is contact with the skin Explosion Hazard Incompatible Materials Halogenated hydrocarbon sol vents for example methylene chloride 1 1 1 roethane are not chemically compatible with the aluminum that might be used in many sys tem components The chemical reaction caused by these sol vents reacting with aluminum can become violent and lead to an equipment explosion Ransburg SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazard ous locations the power supply control cabinet and all other electrical equipment must be locat ed outside Class or Division 1 and 2 hazard ous areas in accordance with NFPA 33 and EN 50176 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combus tible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high vo
32. d ed The resistance between the part and earth ground must not exceed 1 meg ohm Refer to NFPA 33 Operators must be grounded Rubber soled in sulating shoes should not be worn Grounding straps on wrists or legs may be used to assure adequate ground contact Operators must not be wearing or carrying any ungrounded metal objects When using an electrostatic handgun operators must assure contact with the handle of the ap plicator via conductive gloves or gloves with the palm section cut out NOTE REFER TO NFPA 33 OR SPECIFIC COUNTRY SAFETY CODES REGARDING PROPER OPERATOR GROUNDING All electrically conductive objects in the spray area with the exception of those objects re quired by the process to be at high voltage must be grounded Grounded conductive flooring must be provided in the spray area Always turn off the power supply prior to flush ing cleaning or working on spray system equip ment Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class or Il Division 1 or 2 haz ardous areas in accordance with NFPA 33 Aerbell 33 Rotary Atomizer Safety AREA Tells where hazards may occur Electrical Equipment hem e Toxic Substances Spray Area HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized the process Arcing in the vicinity of flammable or combustible materials may oc
33. d Exces sive shaping air will cause some atomized particles to blow by the part or bounce back onto the atomizer Excessive target distance Turbine drive air not present Therecommended target distance is between 8 and 12 inches see Target Distance in the Operation section of this manual Verify supply air pressure Bearing air return signal not present a Verify bearing air return signal b Increase bearing air supply pressure to 90 psig 10 psig Brake air is activated Damaged fiber optic cable between atomizer and control panel Remove brake air signal turbine air and brake air must be interlocked to prevent both from being used simultaneously Repair or replace fiber optic cable Connection at the fiber optic transmitter is loose Re install fiber optic cable and tighten the compression nut Fiber optic transmitter failure Turbine is not rotating Replace fiber optic transmitter Verify rotation of turbine the paint valve air pilot must be interlocked with the turbine speed feedback signal to ensure that paint does not flow into the air bearing Fluid regulator does not actuate a Verify fluid supply b Verify that air pilot signal is present Figure 15 Troubleshooting Guide Continued LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Maintenance TROUBLESHOOTING GUIDE cont General Problem No Fluid Flow Continued Continuous Flui
34. d Flow Uncontrollable Fluid Flow Fluid Leakage Around Fluid Valve Fluid Leakage Around the Fluid Regulator Cap LN 9521 00 4 Possible Cause Fluid valve does not actuate Solution a Verify that air pilot signal is present b Fluid valve air pilot pressure is too low Increase air pressure to 70 psig minimum c Replace fluid valve Clogged fluid tube Fluid valve open Remove and inspect fluid tube a Remove air pilot signal b If still open replace fluid valve Fluid valve seat damaged or worn Insufficient back pressure to fluid regulator Fluid regulator does not control flow Damaged o ring s on outer diameter of valve body 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 Damaged or worn needle seals inside valve assembly Regulator cap is loose Replace valve assembly Disassemble clean and reassemble Tighten regulator cap hardware Ruptured diaphragm Replace diaphragm Pinched or cut o ring between lower support washer and diaphragm Replace o ring Figure 15 Troubleshooting Guide Continued 34 Aerbell 33 Rotary Atomizer Parts Identification Ransburg PARTS IDENTIFICATION
35. e motor cavity where the resistor tube inserts Refer also to the Troubleshooting Guide Figure 15 DISASSEMBLY PROCEDURES Make sure the following conditions exists prior to disassembly Pay particular attention to the procedures and Warning information outlined under Cleaning Procedures prior to performing any mainte nance LN 9521 00 4 Aerbell 33 Rotary Atomizer Maintenance The air to all supply and pilot lines is off The high voltage power supply has been shut off The atomizer s valves feed tube bell cup and fluid supply lines have been cleaned with solvent and purged dry with air NOTE 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 Remove the 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 and the bell assembly Figure 16a item 16 will now be exposed Usingthe same wrench itis also possible to sepa rate the shaping air cap from the front shroud This is much easier to do if the front shroud is mounted onthe turbine assembly since itis diffic
36. e no responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9521 00 4 Ransburg APPENDIX Aerbell 33 Rotary Atomizer Appendix PAINT AND SOLVENT SPECIFICATIONS REA EFM EVOLVER RECOMMENDED VISCOSITY USING A ZAHN 2 18 30 SEC AEROBELL II AEROBELL AEROBELL 33 RMA 101 20 TO 60 SEC REM 907 18 TO 30 SEC NO 2 HAND GUN 20 TO 60 SEC TURBODISK 20 TO 60 SEC PAINT ELECTRICAL RESISTANCE 1 MQ TO 1 MO TO 1 TO 1 MO 1 MO TO 1 MO TO RECOMMENDED DELIVERY UP TO 1000 cc min 1500 cc min 180 cc min 1000 cc min 500 cc min GUIDE TO USABLE SOLVENT SELECTION Chemical Common Category Name Name Methylene Chloride Chlorinated Solvents DICHLOROMETHANE Elec Res HIGH Flash Point CAS Evap TCC Number Ratet 75 09 2 VM amp P NAPHTHA 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 3 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
37. ea son the bell must be returned to Ransburg for inspection and evaluation to determine if the bell can be used in operation 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 Ransburg for turbine rebuilding instructions HIGH VOLTAGE CONNECTIONS Use a small amount of light dielectric grease part number 59972 00 on the high voltage cable ends to prevent moisture damage and ensure the integrity of the electrostatic system 22 Aerbell 33 Rotary Atomizer Maintenance AIR FILTERS ELEMENT REPLACEMENT Qty Elements Pte 95 ane Usedon RPM 32 RPM 417 Pre Filter RPM 33 RPM 418 Bearing Air Filter Figure 14 Replacement Elements VALVES No maintenance is normally required on the valve other than flushing solventthrough the valve daily If there is any question about the valve opening when air is present slide back the rear shroud on the Aerobell 33 and inspectfor valve action Visual inspection for leaks should be made on a weekly basis Should the valve fail to function properly or leaks appear it can be easily replaced Refer to the fluid valves service manualfor detailed instruc tions on preventive maintenance and inspections GENERAL Verify daily that the operating parameters have not varied from the set up sta
38. er 2 See Parts List Bullet Definition Table below wo N PARTS LIST BULLET DEFINITION TABLE Figure 17 Do not use any lubricant O ring must remain dry Place rear shroud over assembly before securing rear plate B gt 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 count er clockwise until it fits snugly against the shroud 2 Orient mounting stud with flat towards front as shown Apply 59915 01 tape to all male pipe threads LN 9521 00 4 Ransburg Aerbell 33 Rotary Atomizer Parts Identification Figure 18 Fluid Manifold Assembly LN 9521 00 4 42 Aerbell 33 Rotary Atomizer Parts Identification Ransburg FLUID MANIFOLD ASSEMBLY PARTS LIST Figure 18 AER4000 00 AER4002 00 AER4003 00 AER4001 00 AERO017 00 Manifold Fluid Engraved 1 1 t 1 __ 2 LSFI0022 04 Fitting 1 4 Tube x 14AN Unon 4 1 2A 15 0035 05 Plug Protective __ 7 3 15 0022 07 _ Fitting 3 8 Tube x 38AN 1 1 3A LSMM0035 05 Protective 71 T 4
39. er to the power supply manual Atomizer grounding out usually indicated by high current draw a Clean atomizer externally with non polar solvent b Check the atomizer for internal fluid leaks c Check for internal arcing usually indicated by internal sparking sounds Damaged high voltage cable be tween atomizer and power supply Repair or replace high voltage cable Improper color change paint or solvent in dump line Optimize color change Figure 15 Troubleshooting Guide 32 Aerbell 33 Rotary Atomizer Maintenance 33 Ransburg TROUBLESHOOTING GUIDE cont General Problem Low Transfer Efficiency or light coverage No Turbine Air Speed Feedback Fault No Fluid Flow Possible Cause Low or no high voltage Solution Verify high voltage at bell cup edge Normally a high voltage setting of 100kV is appropriate for most applications Poor grounding of parts being coated Verify that parts being coated are properly grounded the electrical resistance between the part and ground must not exceed 1 megohm Excessive turbine speed Foroptimumtransfer efficiency and spray pat tern control the bell rotational speed should be set at the minimum required to achieve proper atomization of the coating material Excessive shaping air Shaping air should be set at the minimum volume required to gently direct the spray pattern toward the part being coate
40. 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 Spray booth ventilation must be kept at the rates required by NFPA 33 OSHA country and local codes In addition ventilation must be main tained during cleaning operations using flam mable or combustible solvents Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Test only in areas free of combustible material Testing may require high voltage to be on but only as instructed Non factory replacement parts or unautho rized equipment modifications may cause fire or injury If used the key switch bypass is intended for use only during setup operations Production should never be done with safety interlocks dis abled Never use equipment intended for use in water borne installations to spray solvent based ma terials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC OSHA local country and European Health and Safety Norms Aerbell 33 Rotary Atomizer Safety AREA Tells where hazards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Explosion Haza
41. g with solvents gt Never touch the atomizer bell while it is spinning The front edge of the bell can eas ily 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 infor mation must be observed to prevent damage to the equipment gt Do not immerse the Aerobell 33 turbine in solvent or other liquids Turbine compo nents will be damaged Bearing air must be on during all clean ing procedures to protect the air bearing components Internal Fluid Path Cleaning Cleaning the incoming paint from paint supply source such as color manifold through the fluid valve block and bell assembly LN 9521 00 4 Aerbell 33 Rotary Atomizer Maintenance Turn off high voltage and turn on the trigger valve With the bell spinning flush cleaning solvent through 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 Without Cleaning the Incoming Paint Line Turn off the high voltage and trigger
42. he applicator and the power supply termination point Remove the frontshroud 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 and Xylene blend for 1 to 2 hours Remove from cleaning solution and blow dry before replacing Make sure the o ring is not exposed If so push the tube in place Remove bell cup and soak in solvent and Xylene blend for 1 to 2 hours Remove from cleaning solution and blow dry before replacing A WARNING 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 Main tenance Ransburg 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 A WARNING Make sure that no solvent or other con tamination is allowed to enter the motor as sembly air bearing and outer shaft Release the rear
43. hort Circuit PulseTrack or Eurocard Atomizer Module 1 MO to Use Model No 76652 Test Equipment Part Sprayability Mechanical Length Diameter Approximate Weight Turbine Type Turbine Air Supply At 30 000 rpm Nominal Maximum Turbine Speed 30mm Bell Cup 57mm Bell Cup LN 9521 00 4 Determine sprayability of part to be coated using 76652 Test Equipment See 98 01 16 5 inches 419mm 5 6 inches 142mm 10 3 Ibs 4 7 kg Air Bearing Impulse Drive Variable 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 Aerbell 33 Rotary Atomizer Introduction Mechanical Cont Bearing Air Supply Nominal Shaping Air Supply Nominal Brake Air Supply Nominal Maximum Fluid Pressure Supply Fluid Flow Rate Usable Spray Pattern Diameter Bell Cup Cleaning Time Color Change Time Speed Readout Atomizer Replacement Time Bell Cup Replacement Time 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 15 30 inches 381 762 mm Approximately 2 3 sec Dependent on system configuration fluid pressure fluid viscosity fluid line lengths etc Magnetic pickup unidirectional fiber optic transmiss
44. ified time See below because of faulty work manship or material provided that the equipment has beenused and maintained in accordance with Ransburg s written safety and operating instruc tions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG AP PROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc isone 1 yearfrom date of purchase WRAPPING THEAPPLICATOR ASSOCIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THEREARE NOIMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAM AGE TO PROPERTY OR FOR CONSEQUEN TIAL DAMAGES FORLOSS OF GOODWILLOR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg willassum
45. ines 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 tape pipe dope or other thread sealant downstream of the bearing air filter Loose flakes of tape or other sealant can break loose and plug the very fine air holes in the turbine air bearings 4 f air heaters are used in the system to mini mize the effect of excessively humid conditions and the heated air will exceed 120 F the heaters must be located after all filters to prevent damage to the filter media LN 9521 00 4 Aerbell 33 Rotary Atomizer Installation AIR PRESSURE REQUIREMENTS Tube Size Bearing Air Supply 4 4 O D Air Pressure Requirements 90 psi 10 621kPa 69kPa 80 psi 10 551kPa 69kPa Variable Bearing Air Return 4 4 O D Turbine Air T A 1 2 Shaping Air S A 3 8 O D Variable Brake Air BRK if used Trigger Valve Control TV Dump Valve Control DV 551 69kPa Solvent Valve 1 4 80 psi 10 Control SV 551kPa 69kPa Paint Fluid Regulator Optional High Flow 1 4 Variable Signal Air High 70 psi max 482 kPa Variable 80 psi max 551 kPa 60 psi 10 413kPa
46. ing and inspection of the atomizer bell cup See Service Literature IL 304 in the Ap pendix section of this manual Inspection of the bell semiconductive coating is required to determine if wear or flaking has oc curred 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 soak for 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 A WARNING Do not attempt to clean the bell edge while the bell is rotating When attempting to stop or slow down 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 effi ciency and coating quality LN 9521 00 4 Ransburg Do not use abrasive materials which will scratch or damage the plastic bell or which will scratch the semiconductive coating on the surface of the bell Before reinstalling the bell onto the shaft check and clean the tapered mating surfac es of the turbine shaft and bell for any paint residue Using an atomizer bell with paint buildup may cause a bell imbalance An imbal anced bell may cause bearing damage and turbine fail ure or may create mechanical stress on the plastic bell when operat
47. ing 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 turbine 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 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 A WARNING A bell assembly that is cross threaded on the shaft can damage the bell motor or shaping air housing and may come off the shaft while rotating LN 9521 00 4 Aerbell 33 Rotary Atomizer Maintenance VIBRATION NOISE Ifthe Aerobell 33 is vibrating or making an unusually loud noise it may mean that there is an unbalanced situation The bell assembly may have dried paint onit 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 op erate a noisy turbine Warranty does not cover failure caused by imbalanced loading conditions A WARNING f a bell cup comes off a rotating shaft because of motor seizing or any other r
48. ing the front shroud assembly Four mounting bolts Figure 16a item 8 will then be exposed which hold the turbine assembly to the air mani fold assembly These are the larger socket head screws located toward the outer edge of the motor housing Holding the turbine assembly carefully so that it does not drop and using a 5 32 inch wrench remove the four mounting screws which hold the turbine to the air manifold Pull the turbine assembly straight forward until it is beyond the end of the fluid tube Figure 16a item 3 and the 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 isin place on the air manifold assem bly 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 Ransburg bolts Figure 16a item 8 through the rear of the turbine assembly into the air manifold assembly Tighten the four mounting bolts alternately to a final torque of 15 Reassemble Note When the resistor module is installed onto the high voltage tube an air pock et can form inside the resi
49. ion Less than 2 minutes Less than 2 minutes Aerbell 33 Rotary Atomizer Introduction Ransburg Turbine Speed vs Flow Figure 3 57mm Bell Loaded vs Unloaded Shaping Air Flow 20 18 16 14 30mm E Bell PE o 8 mm iid Bell 6 4 2 0 0 5 10 15 20 25 Pressure PSI Figure 5 Shaping Air Flow 20 Turbine Speed vs Pressure 15 57mm Bell 5 10 30mm 4 o D 30 Bell 20 10 0 0 0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 Thousands RPM Thousands RPM Figure 1 Turbine Speed vs Pressure Figure 2 Turbine Speed vs Flow 57m Bell Loaded vs Unloaded 57m Bell Loaded vs Unloaded 16 60 14 Load 600 cc min 50 Load 600 cd min 12 ater _ 40 Water 10 30 2 20 Unloaded 10 0 4 5 20 2 30 3 40 45 50 5 5 20 2 30 35 40 45 50 55 Thousands RPM Thousands RPM Figure 4 57mm Bell Loaded vs Unloaded SCFM Bearing Air Flow 55 60 65 70 75 8 85 90 Pressure PSI 95 Figure 6 Bearing Air Flow LN 9521 00 4 Ransburg INSTALLATION AIR FILTER INSTALLATION The following air filter installation guidel
50. ipment 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 SAFE TY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment A WARNING The hazards shown on the following pag es may occur during the normal use of this equipment Please read the hazard chart be ginning on page 2 LN 9521 00 4 Ransburg AREA Tells where hazards may occur Spray Area LN 9521 00 4 HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard Protection against inadver tent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during opera tion Frequent Power Supply or Controller shutdown indi cates a problem in the system requiring correction Aerbell 33 Rotary Atomizer Safety SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accumulation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or main tenance When using solvents
51. it 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 Remove protective 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 gt Maximum flow rate should not exceed 500 cc minute 24 Aerbell 33 Rotary Atomizer Maintenance 25 Checkthe high voltage connection by removing the cable assembly from the resistor block Examine the tip of the banana plug for any contaminants or corrosion Cleanorreplace the plug as required Prior to reinstalling the cable assembly start at the rear of the banana plug and cover about 6 inches of high voltage cable with athin film of dielectric grease Insertthe 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 reciprocator type application always ensure adequate cable slack between t
52. ld be kept at the minimum pressure which will LN 9521 00 4 Aerbell 33 Rotary Atomizer Operation 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 in a 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 Approx imate brake times to reduce the turbine speed are shown in Figure 13 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 500001940000 37 To Brake From RPM 50 000 to 0 400001920000 40 40 000 10 0 390 Figure 13 Braking Time 7 37 90 000 to 20 000 4 0 18 Aerbell 33 Rotary Atomizer Operation 19 ELECTROSTATIC 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 volt
53. ltage on make sure no objects are within the sparking distance Follow the requirements of the Material Safety Data Sheet supplied by coating material manu facturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equipment must be as prescribed by an industrial hygienist or safety expert and be NIOSH approved Aluminum is widely used in other spray appli cation equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray If in doubt as to whether or not a coating or cleaning material is compatible contact your coating supplier Any other type of solvent may be used with aluminum equipment LN 9521 00 4 Ransburg 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 solvent mixtures Assembly components and bell made of durable plastic material for optimum mechanical strength and solvent resistance Proven long life turbine motor capable of
54. mbly Fluid LSFA0006 16F Screw 10 32 x 1 2 Long SST Socket Head Cap 4 gt 9 LSFAO004 56C 7 Screw 1 4 20 x 1 3 4 Long Nyl Fill Head ____ 2 10 AER4006 00 Turbine Assembly AirBearing 1 77554105 Turbine Assembly O Ring Sovent Ressen 1 7554 104 Turbine Assembly O Ring Solvent Resistant T 7554 03 S ORo Sovent Resistant 1 12 2 JgRetanenShapngAirCap O 1 See M Table A Ring Shaping Air 14 55994 25 Tubing 38O D 275 5 LSOROO05 01 _____ O Ring Solvent Proof 1 See N Table AJ Bell Cup Assembly 1 f 17 LSF10022 04 Fitting 1 4 OD Tube x 1 AAN Union See T Table D Regulator Assembly Fluid S 19 20 AER0043 00 Cover Connector Machined 21 ____ LSFA0007 12C Screw 410 24x3 8LongNy PanHead w See X Table E Module Voltage 1 224 76419 00 si Strain Relief High Voltage Cable Ref 23 5599425 Tubing 38O D 36 Cover Rear Plate Not Shown Fitting 3 8 O D Tube x 3 8 AN Union RR 2 Elbow 1 4 O D Tube x 1 8 NPT Special 55994 28 Tubing 1 4 O D x d See corresponding table and column on pages 38 amp 39 See Parts List Bullet Definition Table on page 40 PAR
55. 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 solvent valve pilot signal to prevent solvent flow while high voltage is energized 5 Turbine air and brake air must be interlocked to prevent both from being used simultaneously LN 9521 00 4 Ransburg OPERATION A WARNING gt Operators must be fully trained in safe operation of electrostatic equipment Op erators must read all instructions and safe ty precautions prior to using this equipment See NFPA 33 Chapter 16 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 LN 9521 00 4 Aerbell 33 R
56. ndard A drastic change in system current high voltage turbine air shaping air pressure or fluid pilot air pres sure can be an early indicator of a component or system problem Ransburg PREVENTIVE MAINTENANCE Daily Maintenance During Each Preventive Maintenance Break 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 Open solvent valves and flush out feed tubes and bell cups for 3 5 seconds trigger and dump valve closed A WARNING Make sure high voltage is off before ap proaching applicator with solvent cloth Do not use reclaim solvent containing d Limonene This can cause damage to cer tain plastic components Do not stop bell rotation by using a rag or gloved hand against the bell cup edge This can damage the resistance coating at the bell cup edge Maximum flow rate should not exceed 500 cc minute Daily removal and soaking of the bell cup may not be required if the bell cup is prop erly flushed as indicated above However the frequency of the feed tube and internal motor shaft inspection indicated below un der weekly maintenance can be done daily and later adjusted to weekly or as required depending on the results of the inspection LN 9521 00 4 Ransburg Wait for rotation to cease and then clean off bell cup edge and shaping air ring and any other ou
57. nt Base Configuration Only T Information Obtained From http solvdb ncms org tt The lowest temperature at which a volatile fluid will ignite Aromatic Hydrocarbons 2013 Ransburg All rights reserved Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1 0 NOTE Chart provides resistance and control information that we feel is necessary when using Ransburg equipment LN 9521 00 4 48 Aerbell 33 Rotary Atomizer Appendix Ransburg RANSBURG VISCOSITY CONVERSION CHART Centipoise Gardner Holdt Bubble Gardner Lithographic Saybolt Universal SSU Sears Craftsman 2 3 0 12 Ford Cup 3 4 5 25 4 EEEEEE BN D SU e Sj tf 2 __ 27 s __ 2 12 120 NT B M s BEN Li 25 260 Je s i af t se L2 e T p peer p p T 3 Le 7 EI E m u E Lr Jer jj PE mp pow 48 4 0 2380 54 109
58. o be non polar Solvents used for equipment flushing should have flash points equal to or higher than those of the coating material being sprayed 1 The atomizer bell includes a self cleaning fea ture and will normally be fully cleaned during a bell flush cycle Flushing should be done before any down time or break in 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 LN 9521 00 4 Aerbell 33 Rotary Atomizer Maintenance 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 acollision with a part replace the cup immediately 4 Soaking the bell in solvent will not aid in loos ening 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 sl
59. o 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 A WARNING The high voltage equipment that is used in this application creates a hazard for person nel 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 gt 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 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 op erate with the Ransburg PulseTrack or Atomizer Module for speed monitoring and or speed control LN 9521 00 4 Ransburg SPECIFICATIONS Electrical Power Supply LECU5003 LEPS5001 Type Voltage Master Charging Method Output Voltage Output Current Turbine Speed Control Paint Resistance 76045 LEPS5002 MicroPak Direct 30 100 kV Variable 125 pA S
60. 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 rpm when fluid is turned on to enable the fluid to flow through the bell paint passage holes and be atomized Thedumpvalve 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 prescribed 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 into the rear of the 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 paint line 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 inter nal portion of the air
61. otary Atomizer Operation 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 igni tion of specific hazardous 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 Man ual latest version for detailed information The regulator features two independently control lable 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 change times 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 the required fluid flow rate Separate pilot signals modulate each of the reg ulator 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 of the regulator s dual range capabilities it pr
62. ots 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 Asoft lint free rag dampened with solvent may be used to remove any paint residue from the external and internal surfaces of the bell 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 Aring of semi conductive coating should also be visible 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 26 Aerbell 33 Rotary Atomizer Maintenance 27 BELL CUP TESTING NON ROTATING Check bell cup voltage using 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 Rans
63. ovides the user flexibility of selecting either the high flow range or the low flow range Different coating material viscosities and quick 14 Aerbell 33 Rotary Atomizer Operation 15 color change requirements may necessitate the use of both ranges If 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 flow is im proved 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 I
64. peed readout or control uses reliable magnet ic pickup for fiber optic transmission of rotational speed data GENERAL DESCRIPTION Aerobell 33 System The Ransburg Aerobell 33 is a high speed rotary atomizer system designed to meet agency safety requirements for safer operation This system is incapable of releasing sufficient electrical or ther mal 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 excellentatomization and transfer efficiency for a wide variety of coating materials 7 WARNING The Aerobell 33 System is designed to provide safer operation in accordance with NFPA 33 when used and maintained in a proper manner Equipment cleanliness and proper routine maintenance are required to maintain safe operating conditions Aerbell 33 Rotary Atomizer Introduction 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
65. rd Improper or inadequate oper ation and maintenance proce dures will cause a fire hazard Protection against inadvertent arcing that is capable of caus ing fire or explosion is lost if any safety interlocks are dis abled during operation Frequent Power Supply or Controller shutdown indicates a problem in the system requir ing correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment Ransburg SAFEGUARDS Tells how to avoid the hazard Electrostatic arcing must be prevented Safe sparking distance must be maintained between the parts being coated and the applicator A dis tance of 1 inch for every 10KV of output voltage is required at all times Unless specifically approved for use in hazard ous locations all electrical equipment must be located outside Class Division 1 or 2 hazardous areas in accordance with NFPA 33 Test only in areas free of flammable or combus tible materials The current overload sensitivity if equipped MUST be set as described in the correspond ing section of the equipment manual Protec tion against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set Fre quent power supply shutdown indicates a prob lem in the system which requires correction Always turn the control panel power off prior to flushing cleaning
66. speeds up to 55k rpm at minimal air consumption See Specifications in the Introduction 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 usage is controlled at the feed tube with an internally 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 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 LN 9521 00 4 Aerbell 33 Rotary Atomizer Introduction Annular shaping air passage design providing excellent pattern control at minimal air consump tion Aerodynamic design for ease of cleaning ex ternal surfaces Assembly can be swiveled to provide oblique spray anglesfor better paint coverage in difficult 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 S
67. stor module passage This air pocket can force the resistor module out of its seat Take care that the resistor module is securely seated into the rear bulkhead slot Make sure the turbine assembly is prop erly seated by examining the fit between the rear of the turbine assembly and the front of the air manifold assembly Any irregulari ty in this seam between the two assemblies would indicate improper mounting Looking into the front of the motor shaft ob serve 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 assembly 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 Ibein WARNING gt Using the RPM 419 wrench a minimum of 50 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 gt 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 LN 9521 00 4 Ransburg Rear Shroud Removal The rear shroud Figure 16a item 33 can be removed for cleaning or inspection of the com ponents on the inside of the assembly Loosen the two captive screws Figure 16a item 2
68. ter surfaces Use asoft cloth dampened with solvent 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 cup Check bell cup voltage using high voltage probe Voltage should be approximately 85 kV when 100 kV is set on the power supply Check the amount of paint build up on the outer protective wrap If excessive replace wrap as required A WARNING the event the bell cup comes in con tact with a part that cup should be checked for damage and replaced if necessary be fore continuing to spray A WARNING 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 Weekly Maintenance Prior to Start or End of Production Week e Monitor rotational speed of all bells at the speed control should be within approximately 5 of target speed LN 9521 00 4 Aerbell 33 Rotary Atomizer Maintenance NOTE The protective disposable wrap is for one time use only Do not wash and reuse the wrap NOTE Normally the wrap will not need placement daily and could last about one week See Weekly Maintenance in the Maintenance section Monitor high voltage output indicated on the display of the control un
69. 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 Rear 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 nest ed between the rear bulkhead and air manifold assembly Resistor Module The module encapsulates the high voltage re sistors necessary for control of the electrostatic charge being fed to the bell through the high voltage cable Ransburg 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 t
70. this informa tion 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 avoidasituation that might cause minor injury A NOTE is information relevant to the proce dure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment Differences in local codes and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation draw ings and appropriate Ransburg equipment man uals to reconcile such differences Careful study and continued use ofthis manual will provide a better understanding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg Ransburg A WARNING The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equ
71. ting hardware in plastic to keep it clean A surface charge may build up on the plastic surface and dis charge to the nearest grounded object Effi ciency of the applicator will also be reduced and damage or failure of the applicator com ponents may occur WRAPPING THESE COMPONENTS IN PLASTIC WILL VOID WARRANTY A WARNING 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 sol vents for cleaning are acetate methyl amyl acetate high flash naphtha and miner al spirits Do not use conductive solvents such as MEK to clean the external surfaces of the Aerobell 33 gt When using a rag to hand wipe the Aero bell 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 Ransburg 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 It may be advantageous to develop maintenance schedule for hand clean
72. tor housing is not proper ly seated and the rear shroud is forced into place damage can occur to the rear shroud LN 9521 00 4 Aerbell 33 Rotary Atomizer Maintenance Fluid Regulator Removal To remove the fluid regulator Figure 16a item 18 follow the procedures for removal of the rear shroud Then disconnect the air pilot lines at the regulator and the output fluid line at its connection into the fluid manifold assembly Figure 16a item 7 Disconnectthe 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 The four screws holding in the regula tor are held captive They do not back out completely of the regulator A WARNING gt Fluid pressure must be shut off and pres sure 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 pull the manifold straight back to separate it from the fluid tube To remove each individual fluid valve from the manifold use a 7 8 open end wrench and turn the valve CCW
73. ult 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 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 28 Aerbell 33 Rotary Atomizer Maintenance 29 Atomizer Bell Cup Removal To 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 Main tenance section for important information about bell and shaft cleanliness Do not install a paint contaminated or damaged bell onthe turbine shaft Wheninstalling the bell on the shaft the bell should be firmly secured by hand or use wrench RPM 419 and torque to 50 0 40 Ibein Turbine Removal The turbine assembly Figure 16a item 10 is removed from the Aerobell 33 atomizer after re mov

Aerobell 33 (AER5000/AER5001) (Serv. Manual LN

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