Service Manual - Finishing Brands EUROPE
Contents
1. o ef 2380 sa 2 109 50 500 SEI SEC T J LL J Iri ef 4 z 124 Leo ec P zy 2f s 30 15 _ 5 76 j o 35h s 4j 1 9o sof P j ej 45 17195 e 4 5 of eff seb 5200 59 Vill Viscosity Conversion Chart 12 10 2005 Page 36 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg ITW RANSBURG VISCOSITY CONVERSION CHART Continued iili Pt Potent 69 J 150 1500 SEE 1601160 59 sof uo 1700 sof 1801100 200 200 j 220 220 L pL f peo EE ESSI I psu 242 ttt i tt tt tee 35 0 3500 __ 400 40 _ poe 18500 Eee 500 5000 _ 20 55 0 5500 26000 EOE E _ 30000 _ 32500 35000 2 a co Lad uPont arlin 7 uPont arlin 10 Saybolt Universal SSU E Ford2. 14 ST MEME 5 TTE 14 22 CONNECCION T 14 5 6 Speed Monitor COMMGCIONS eesescdxaiquesadadosiqudaqadsspsquqaduestqedadaqetadadas2 quta pida Midas 14 gt E gt Ce 15 922 COATING MI Tm 16 oO 16 Ple 17 917 WAU UU m UTEM 17 912 AIP AGIUSUMOCNE E 18 18 18 ON MEI eism Voltage Tm 19 2219 cedit 19 SEMI iic acne 20 GIleanidg PIOSSduleS eran autem aptare met M DD MEE 20 6 2 Internal fluid path s serron aiino onnea 20 6 3 Internal fluid path cleaning without cleaning the incoming paint line 20 6 4 Bell 21 607 22 6 6 Turbine Repair And 23 6 7 Air Filter Element Replacement 23 __ __ _____ _ ________ 23 _ ___ ___ ___ __ _____________ 6 6 23 6 10 23 6 10 1 Daily Maintenance During Each Preventive Maintenance 23 6 10 2 Weekly Maintenance Prior to start or End of Production Week
3. 4 Lithographic 2 a z E o Gardner T E 5 N 70 0 7000 f 80 0 8000 ___ j EN ___ Lo lj mopo 1 1 2 2 _ J eo T spes _ 650 meoneo oojoo 11 83500 18001180000 88000 93000 140000 edem 1 Spo 11 111 12 10 2005 Page 37 of 40 IX Viscosity Conversion Chart Cont 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 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg VOLUMETRIC CONTENT OF HOSE OR TUBE English Units Cross Length Section 58 60 120 158 180 258 00 600 1 8 2 4 012 003 gal 006 gal 010 gal 016 gal 032 gal A fl oz 8 fl oz 1 2 fl oz 2 0 fl oz 4 1 fl oz 9 fl oz 8 fl oz 2 8 fl oz 4 6 fl oz 9 2 fl oz 1 6 fl oz 3 3 fl oz 4 9 fl oz 8 2 fl oz 16 3 fl oz 2 5 fl oz 5 1 fl oz 7 6 fl oz 12 7 fl oz 25 5 fl oz
4. 25 0 11 LOW VOllage VC SU dta diss aav 26 6 12 Disassembly FIOOGSQU IGS a usscogs _ ______ __________ 27 5 12 ROME GI 27 6 14 Atomizer Bell 27 FUNERO noe eee 2 12 10 2005 Page 3 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg Content Cont E aee CUG RETE ee 28 TT UEM 31 8 1 ENIO SON VION 31 8 2 Parts List Ice 32 MEER UJeE Ic 33 9 Warranty adole mmm 34 nce a ee 34 10 APPENA ee ten 35 10 1 ITW Ransburg Paint And Solvent Specifications 35 10 2 ITW Ransburg Viscosity Conversion 36 12 10 2005 Page 4 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 1 Safety 1 1 Safety Precautions Before operating maintaining or servicing any ITW Ransburg electrostatic coating system read and understand all of the technical and safety literature for your ITW Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING
5. Cleaning Procedures WARNING e Electrical shock and fire hazards can exist during maintenance High voltage supply must be turned off before entering the spray area and performing any maintenance procedures on the atomizer Spray booth fans should remain on while cleaning with solvents e Never touch the atomizer bell while it is spinning The front edge of the bell can easily cut into human skin or cut through gloves and other materials Be sure the atomizer bell has stopped spinning before attempting to touch it Approximate time for the bell to stop spinning after turning off turbine drive air is three minutes In addition to the above Warning which relates to potential safety hazards the following information must be observed to prevent damage to the equipment CAUTION e Do not immerse the ICE Bell turbine in solvent or other liquids Turbine components will be damaged e Bearing air must be on during all cleaning procedures to protect the air bearing components Internal fluid path cleaning Cleaning the incoming paint line from paint supply source such as color manifold through the fluid valve block and bell assembly 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 through the fluid tube and onto the bell The spinning bell will atomize the solvent and clean out the bell passages If desired o
6. _____ 406 4 L Connection R1 4 A 8mm 41 ____ 1 ________ ESTA 421 2 ____ Twin Push Nippel8 mm 1 0 NJ 5 Go 19 JESTA4372 jAngeConectr8mm 4 ___ 2 A J it Turbine 2 0 2 f ___ 2 4 RPM 401 1 Turbine 1 22 RPM 00 _ amp 31h 23 SSF 3137 Screw 1 B 24 __ RPM 439 25 79001 05 26 1102047 jJAdaperRng 1 ___ 27 5 96 3 2 8 SSF 3117 Screw 3 2 9 KK4460 _______ Latch Button RepairKit 1 210 9704 211 Shaping Air hose 1t7mm 3 1 31 10209 FrontEnd 1 AGMD 22 O Ring 4 AGMD 19 O Ring 14 0 DIN amp 4M4X10PA 5 11 AGMD 28 _______ 1____ NENNEN Do _ 39 JESTA4341 ____ AirCoolerhose 2 7 4 it Be 1 41 1 42 111065 lt 1 ___ 43 1754 6 5 7 39 2 54 Unit Shaping Air Screw Ring 51 __ ______ 102050 03 Shaping 141 ___ 52 1020510 ShapingAirRing 14 ___ 53 __ DINeAMAXIOPA Screwplastic A 6 1002 ShapingNut 14 7 102054 Shroud 1 02 8 DINe4MSXIOPA Screwplastic 3 ___ 9 1 ESTA422 X T Comedoa mm 4 10 IQSDRV4 One WayRestrictor J1 14 4602 j hosefX2mmn SMT 12 1 J ESTA4321 _
7. _____2 PROPYL ACETATE METHYL ISOBUTYL KETON ISOBUTYLACETATE VPROPANL BUTANOL _____ __ 2METHYLPROPANOL SMETHYL 2 HEXANONE ZETHOXYETHANOL AROMATICHO0 DIISOBUTYLKETONE TPENTANL DIACETONE ALCOHOL CYCLOHEXANOL 150 wT 9 in Vil Guide to Usable Solvent Selection CAS Number Chemical Abstract Service Number Using the Ransburg Meter Solvent borne Configuration Only Information Obtained From http solvdb ncms org Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1 0 NOTE This page resistivity determination and control information that we feel is necessary when using ITW Ransburg equipment 12 10 2005 Page 35 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Gema Ransburg 10 2 ITW Ransburg Viscosity Conversion Chart ITW RANSBURG VISCOSITY CONVERSION CHART 4p 10 Las sof fas of of af xp 17 15 aep sp val ar oo aa 2 t
8. The filter elements must be replaced on a regular schedule to assure clean air 15 the user s responsibility to ensure clean air at all times Turbine failure resulting from contaminated air will not be covered under warranty The above shows the pre filter and bearing air filter s which are recommended for use in AeroBell 33 systems If other filters are incorporated in the system the filters to be used must have filtering capacities equal or better than those shown above The user must ensure the bearing air supply is not inadvertently turned off while the ICE Bell air motor is turning This will cause air bearing failure 12 10 2005 Page 13 of 40 ICE BELL Service Manual ITW 5 3 Mounting The ICE bell incorporates its own insulator mounting rod The diameter at the rear is 49mm for mounting to a reciprocator stationary stand or other means of support The atomizer assembly is mounted to this horizontal rod by a 3 4 inch insulating post inserted into a swivel clamp and secured by four plastic bolts The arrangement allows positioning of the front of the turbine Normally the insulator support rod is positioned perpendicular to the conveyor path with the swivel providing for left or right adjustment of the atomizer assembly The swivel clamp plate can be inverted to provide a locking mechanism to hold the applicator in line with the insulator support rod 5 4 Fluid Connections The paint supply to th
9. The optional solvent valve controls the flow of cleaning solvent to the bell When actuated solvent flows through the manifold and fluid tube 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 CAUTION e he nominal fluid range is 25 500cc min During a color change or when flushing the system higher flow rates may be required However the maximum flow rate must not exceed 500cc min to avoid solvent or paint from flooding into the internal portion of the air bearing motor assembly or front shroud High voltage must be interlocked with the solvent valve to prevent solvent spraying while high voltage is on 5 11 Turbine Speed Turbine speed is determined by the input pressure at the rear of the atomizer The 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 determines the quality of atomization and can be varied for various paint flow rates and paint formulations For optimum transfer efficiency and spray pattern control the bell rotational speed should be set at the minimum required to achieve proper atomization Excessive speed reduces transfer
10. 1000 cc min 1500 cc min 180 cc min 1000 cc min 500 cc min GUIDE TO USABLE SOLVENT SELECTION CHEMICAL COMMON CATEGORY CAS EVAP ELECTRICAL NAME NUMBER RATE RESISTANCE DICHLOROMETHANE Methylene Chloride HIGH MYTHYL ACETATE VM amp NAPHTHA Naptha HIGH ACETONE O HIGH BENZENE ETHYL ACETATE MEDIUM Ketones MEDIUM 2 BUTANONE 2 r M ISO PROPYL ACETATE ISOPROPYL ALCOHOL IPA O 2 PENTANONE MEDIUM METHANOL Methyl Alcohol LOW mPropylAcetae Esters 109604 PROPYL ACETATE Toluene Aromatic Hydrocarbons HIGH r m E TOLUOL MIBK Y MEDIUM Ethyl Alcohol n Propyl Alcohol sec Butyl Alcohol Xylene 67 iso Butyl Alcohol 108 84 9 MIAK 3 n Butyl Alcohol SC 100 DIBK Amyl Alcohol Butyl Cellosolve SC 150 Aromatic Hydrocarbons ISOBUTYL ACETATE ETHANOL BUTYL ACETATE ETHYLBENZENE 1 PROPANOL 2 BUTANOL XYLOL AMYLACETATE 2 METHYLPROPANOL METHYLAMYL ACETATE 5 METHYL 2 HEXANONE 1 BUTANOL 2 ETHOXYETHANOL 2 HEPTANONE CYCLOHEXANONE AROMATIC 100 DIISOBUTYL KETONE 1 PENTANOL DIACETONE ALCOHOL 2 BUTOXYETHANOL CYCLOHEXANOL AROMATIC 150 AROMATIC 200 O LO HIGH LOW O HIGH MEDIUM O O MEDIUM O O MEDIUM MEDIUM HIGH MEDIUM O LOW O O HIGH HIGH rim r lt lt lt r lt lt MYTHYL ACETATE BENZENE ETHYL ACETATE 2BUTANONE ISOPROPYL ALCOHOL
11. 12 10 2005 Page 29 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg General Possible Cause Problem Fluid valve open a Remove air pilot signal b If still open replace fluid valve Continuous Fluid Flow Fluid valve seat damaged or Replace fluid valve seat worn Insufficient back pressure to Replace fluid tube with the next smaller inner Uncontrollabl fluid regulator diameter size e Fluid Flow Fluid regulator does not control 2 Disassemble fluid regulator and inspect for failed flow components Damaged o ring s on outer Replace o ring s Fluid leakage diameter of valve body Around Fluid Valve Damaged or worn needle seals 2 Replace valve assembly inside valve assembly 12 10 2005 Page 30 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Gema Ransburg 8 Parts Identification 8 1 Explosion View Figure 2 Parts Identification 12 10 2005 Page 31 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 82 PARTS LIST ICE BELL Pos Designation Number _ Unit Manifold 11 102048 Manifold 12 102053 Nippel 13 AGMD12 1 4 14 1 7 4024 Straight Connector R3 8 A 12mm 1 1 1 8 402 2 StraightConnectorR1 4 A 12mm __ 1 16 5 4021 Straight Connector R1 4 A 8mm __ 1 17
12. 3 7 fl oz 7 3 fl oz 11 0 fl oz 18 4 fl oz 36 7 fl oz 051 gal 102 gal 153 gal 255 gal 510 gal 6 5 fl oz 13 1 fl oz 19 6 fl oz 32 6 fl oz 65 3 fl oz X Volumetric Content of Hose or Tube English Units VOLUMETRIC CONTENT OF HOSE OR TUBE Metric Units cc m Section mas 15m 3 0m 45m 6 0m 75m INE WD NUR XI Volumetric Content of Hose or Tube Metric Units 12 10 2005 Page 38 of 40 EC Manufacturer s Attestation According to Annex II B of the EC Machine Rule 98 37 MaschRL ITW Oberflachentechnik Hereby declare that the Type Binks DeVilbiss Ransburg ITW Oberflachentechnik GmbH amp Co KG Justus von Liebig Str 31 D 63128 Dietzenbach Stationary Electrostatic Spraying Device ICE Bell Model RPM 6093 PSE for waterborne paints Is designed for the mounting into a machine assembly with other machines into one machine and that initial operation is not permitted unless it has been ascertained that the machine into which this machine shall be mounted complies with the requirement of EC Rule 98 37 EC Applied Harmonized Standard EN ISO 12100 1 2003 EN ISO 12100 2 2003 EN 13463 1 2001 EN 1953 1998 EN 50176 1996 Dietzenbach the day of Signature Name and Position 12 10 2005 Safety of machines basic concepts general design principles Part 1 Basic terminology methodology Safety of machines b
13. Fifteen thousand 15 000 hours or three 3 years whichever occurs first Warranty period begins on the date of purchase ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NEITHER IMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume no responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable 12 10 2005 Page 34 of 40 ICE BELL Service Manual ITW Automotive Finishing Binks DeVilbiss Ransburg 10 Appendix AEROBELL 1 AEROBELL 10 1 ITW Ransburg Paint And Solvent Specifications AEROBELL 33 REA EFM REM M90 MN TURBODISK 101 RECOMMENDED VISCOSITY USING A ZAHN NO 2 18 TO 30 SEC 18 TO 30 SEC 20 TO 60 SEC 20 TO 60 SEC 20 TO 60 SEC PAINTELECTRICAL RESISTANCE 1M2 TO x AMO TO 1 01 0 IMaTox IMaTox RECOMMENDED DELIVERY UP TO
14. bell cups NOTE It may be necessary to remove the bell cups for cleaning more frequently than weekly See Caution under Daily Maintenance Inspect the feed tube tip and clean any paint build up that has occurred on the feed tube tip Using a pen light determine if there is build up of paint in the motor shaft and or around the paint feed tube If so remove the motor assembly 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 Page 25 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg WARNING Make sure that no solvent or other contamination is allowed to enter the motor assembly air bearing and outer shaft e Release the rear cover fasteners and slide 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 e Reinstall rear shroud bell cup and front shroud Rewrap the outer housing and insulator mounting rod refer to Disassembly Procedures for definite instructions NOTE The outer protective wrap may have to be replaced more frequently than weekly Daily inspection of the amount of paint buildup on the wrap will determine the frequency of replacement 6 11 Low Voltag
15. noisy turbine Warranty does not cover failure caused by imbalanced loading conditions 12 10 2005 WARNING If a bell cup comes off a rotating shaft because of motor seizing or any other reason the bell must be returned to ITW Ransburg for inspection and evaluation to determine if the bell can still be used in operation Page 22 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 6 6 Turbine Repair And Rebuild Turbine field repair or rebuild after factory warranty expires Any attempt to disassemble turbine during warranty will void warranty 3 years or 15 000 hours Contact your distributor or Ransburg for turbine rebuilding instructions 6 7 AirFilter Element Replacement Replacement Elements ITW Part Qty Elements Used on per Carton RPM 32 RPM 417 Pre Filter RPM 33 RPM 418 Bearing Air Filter V Replacement Elements 6 8 Valves No maintenance normally is normally required on the valve other than flushing solvent through the valve daily If there is any question about the valve opening when air is present slide back the rear shroud on the ICE Bell and inspect for valve action Visually 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 manual for detailed instructions on preventive maintenance and inspection 6 9 General Verif
16. on at all times and should be shut off only by turning off the main air to the pneumatic control cabinet CAUTION e When the turbine air is turned off the turbine will continue to operate or coast down for about two minutes Provisions should be made to assure that the operator waits at least three minutes after shutting off the turbine air before shutting off the main air supply e he 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 bearing Normally pneumatic inter locks will not allow the paint to trigger on when the turbine air is off WARNING e he high voltage and or coating material must never be turned on unless the bell cup is mounted on the motor shaft and the turbine is rotating e Pneumatic input to the turbine air inlet must be controlled to prevent the turbine from exceeding the maximum rated intermittent speed of 55 000 rpm See Specifications 2 should not be possible for the coating material to be sprayed unless the turbine is spinning 3 Two interconnected bearing air ports are provided one for supply air and the other to be used as a return signal for measuring bearing air pressure at the atomizer If bearing air falls below 4 bars at the atomizer the turbine air should be automatically interlocked to shut off 4 High voltage must be interlo
17. 2005 Page 18 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 5 15 Electrostatic Voltage The ICE Bell Rotary Atomizer receives its operating voltage through a high voltage cable that is connected to a remote power supply The power supply model and high voltage set ting 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 The electrostatic voltage applied to the ICE Bell will affect pattern size transfer efficiency wrap and penetration into cavity areas Normally 80 100 kV setting is appropriate for most applications NOTE If paint defects occur such as fatty edges or picture framing reducing the voltage should be a last resort 5 16 Target Distance The distance between the ICE Bell atomizer and the target will affect the 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 The high voltage circuitry will enable the applicator bell to be operated to within a few inches of the target without adjusting the voltage setting The recommended target distance is 200 to 300 mm 12 10 2005 Page 19 of 40 ICE BELL Service Manual Automotive Finishing 6 6 1 6 2 6 3 Binks DeVilbiss Ransburg Maintenance
18. Bearing Air Supply Nominal o bar nominal 7 bar maxi 0 1 m min Shaping Air Supply Nominal 10 bar maxi 0 4 m min Brake Air Supply Nominal 4 bar maxi Maximum Fluid Pressure Supply 7 bar maxi Fluid Flow Rate 25 500 cc minute Usable Spray Pattern Diameter 381 762 mm Bell Cup Cleaning Time Approximately 2 3 seconds Color Change Time Dependent on system configuration fluid pressure fluid viscosity fluid line lengths etc Speed Readout Magnetic pickup unidirectional fiber optic transmission Atomizer Replacement Time Less than 2 minutes Bell Cup Replacement Time Less than 2 minutes 12 10 2005 Page 11 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 5 Installation 5 1 Air Filter Installation The following air filter installation guidelines are essential for optimum performance e Use only recommended pre filters and bearing air filters Additional system air filtration i e refrigerated air dryer may also be used if desired e Mount the bearing air filter as close as possible to the ICE Bell Do not mount further than 10 meters away Do not use Teflon tape pipe dope or other thread sealant downstream of the bearing air filter Loose flakes of Teflon tape or other sealant can break loose and plug the very fine air holes in the turbine air bearings Requirements Bearing Air 1 4 O D 6 bar maxi Supply B A Return B A Turbine Air 1 2 O Variable Shap
19. EQUIPMENT PROBLEMS To help you recognize this information we use the following symbols Please pay particular attention to these sections WARNING A WARNING states information to alert you to a situation that might cause serious injury if instructions are not followed CAUTION A CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that cause minor injury NOTE Important information relevant to the procedure in progress WARNING user MUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literature therein identified This manual MUST be read and thoroughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD 2000 EDITION prior to installing operating and or servicing this equipment e The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 5 12 10 2005 Page 5 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg Hazardous Areas and Precautions AREA HAZARD SAFEGUARDS does Dele Tells what the hazard
20. Service Manual ICE BELL ROTARY ATOMIZER Model RPM 6093 PSE For the Application of Waterborne Paints Before using this equipment carefully read the Safety and Safety Precautions sections and all instructions in this manual Keep this Service Manual for future reference 12 10 2005 Page 1 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg This page is intentionally left blank 12 10 2005 Page 2 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg Content gt ee ee 5 SONY PrO gt mM 5 2 I E enmt Me T Im UPON DNI NIE 9 2 1 TTE 9 gt 10 9d ICE Bell System s 10 32 High li 36 0 Em 10 oo CO 10 MH SDOCIICOOLS seecontriseeuntrsni 11 4 1 sonny 11 TRU AVID 11 2 ON TU 12 _ _ _ 12 5 2 Air filtration 13 onc n a E EEEREN
21. _ 5 13 ESTA4322 X Hose2 7XAmm IMT 14 RPM 419 Wrench Assembly 1 0 VI Parts List ICE Bell 06 11 2006 Page 32 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 8 3 Drawing Units 1 UNIT Manifold 3 UNIT Front End 2 UNIT Turbine 12 10 2005 Page 33 of 40 ICE BELL Service Manual Automotive Finishing 9 1 Binks DeVilbiss Ransburg Warranty Policies Limited Warranty ITW Ransburg will replace or repair without charge any part and or equipment that falls within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with ITW Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN ITW RANSBURG APPROVED PARTS VOID ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLASTIC SHRINK WRAP ETC WILL VOID THIS WARRANTY FLUID HANDLING One 1 year from date of purchase i e Totalizer CCV Valves etc AIR BEARING ROTATORS
22. ansburg 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 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 The bell cup has stopped rotating All external surfaces must be clean and free of paint or paint residue NOTE For reassembly instructions use the reverse of the following disassembly procedures Front Shroud Removal Remove the front shroud Parts Identification Page 8 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 Parts Identification Page 8 Item 13 is removed with it The ICE Bell turbine and the bell assembly will now be exposed Using the same wrench it is also possible to separate the shaping air cap from the front shroud This is much easier to do if the front shroud is mounted on the turbine assembly since it is difficult to grasp the shroud and the wrench simultaneously if the parts are removed from the mechanical support of the assembly Hold the front shroud stationary while turning the shaping air ring CCW N
23. ap xp mp 25 af A 4 sf sof svp 1 9 C sp ep s px S o 3 33 39 28 9 2312 2 a ca Lud arlin 10 Ford Cup 4 Saybolt Universal SSU ears a 3 E E 8 Lithographic Gardner DuPont Parlin 7 3 1 25 25 s s o so v 2127 9 4s 50 3 31 pw rp a rg qw s d p o se wf v se ase s wo m z w Lao zw sw 2212 sve sw v s EL 5 65 _ 20 e aj se 28 20 se gt 2 4 __ 0 9 1 1475 3 24 15 68 32 320 5 NJ 26 77 76 36 360 _ 38 380 gt 5 gt 40 ej 195 46 42 420 1 tof s 2 10 46 460
24. ary atomizer system designed to meet agency safety requirements for safer operation The ICE Bell provides electrostatic application with excellent atomization and transfer efficiency for a wide variety of coating materials WARNING The ICE Bell System is designed to provide safer operation in accordance with European regulations when used maintained in a proper manner Equipment cleanliness and proper routine maintenance are required to maintain safe operating conditions 3 2 X High Voltage Cables The SSW 1064 high voltage cable is used to connect the power supply to the resistor module inside the atomizer assembly 3 3 Speed Monitor Control The ICE Bell rotary atomizer is designed to operate with the ITW Ransburg PulseTrack or Atomizer Module for speed monitoring and or speed control 12 10 2005 Page 10 of 40 ICE BELL Service Manual i site Binks DeVilbiss sate 4 Specifications 4 1 Electrical Power Supply Type Voltage master 2 Charging Method Direct Output Voltage 30 100 kV Variable Output Current 1000 pA Short Circuit Turbine Speed Control PulseTrack or Eurocard Atomizer Module 42 Mechanical Length 419mm Diameter 142mm Approximate Weight 5 0 kg Turbine Type Air Bearing Impulse Drive Turbine Air Supply at 30 000 rpm 3 5 bar maxi Nominal 0 5 m min Maximum Turbine Speed Continuous Intermittent 30mm Bell Cup 40 000 rpm 55 000 rpm 5 mm Bell Cup 40 000 rpm 55 000 rpm
25. asic concepts general design principles Part 2 Technical principles Non electrical equipment for potentially explosive atmospheres Spraying equipment for liquid spraying material safety requirements Stationary electrostatic spraying installations for flammable liquid spraying material Seite 39 von 40 ITW Oberflachentechnik Gmbh amp Co KG Justus von Liebig Str 31 D 63128 Dietzenbach Tel 49 0 6074 403 1 Fax 49 0 6074 403 303 www itweuropeanfinishing com 12 10 2005 Ransburg ITW Industrial Finishing Ringwood Road Bournemouth Dorset BH11 9LH Phone 44 0 1202 571111 Fax 44 0 1202 590073 www itweuropeanfinishing com ITW Surfaces et Finitions 163 171 Avenue des Aur ats 1453 26014 Valence Cedex Tel 33 0 4 75 75 2700 Fax 33 0 4 75 75 2779 www itweuropeanfinishing com Seite 40 von 40
26. ch Allen wrench remove the four mounting screws which hold the turbine to the air manifold The turbine assembly can now be replaced or serviced as necessary 12 10 2005 Page 27 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 7 Troubleshooting Guide General Possible Cause Problem Bell cup damaged Replace bell cup Bad spray pattern Low voltage See low or no voltage below Paint lodged in shaping air Disassemble and clean High current draw Improve paint line isolation Solvent valve is actuated Remove solvent valve air pilot signal high volt age must be interlocked with the solvent valve air pilot signal to prevent solvent flow while high voltage is energized 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 Verify high voltage connection into the manifold connection Refer to Low Voltage Test in the Weekly Maintenance section of this manual Loss of high voltage Verify high voltage tube connection into the turbine connection at the turbine housing See Low Voltage Test in the Weekly Mow orno assembly Maintenance section of this manual High Voltage Power supply failure Refer to the power supply manual for detailed troubleshooting guide Improper limiting current a
27. cked 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 WARNING e Operators must be fully trained in safe operation of electrostatic equipment Operators must read all instructions and safety precautions prior to using this equipment 12 10 2005 Page 15 of 40 ICE BELL Service Manual Automotive Finishing 5 8 5 9 12 10 2005 Binks DeVilbiss Ransburg As with any spray finishing system operation of the ICE Bell 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 Adjustments to operating parameters which cover spraying cleaning and on off control include Coating Materials e Cool air control e Fluid Valve Control e Turbine Speed e Bearing Air Adjustment e Shaping Air e Brake Air e Electrostatic Voltage e Target Distance Coating Materials The ICE Bell can be used with a full range of waterborne coating material conductivities However with coatings having very high fast drying process such as dispersion paints the ICE Bell remain the unique choice Cool Air Control The cool air is provided by the 4 air coolers located around the turbine Those patented devices use an additional air inlet port whic
28. e ICE Bell is connected at the rear of the atomizer assembly to the regulator Solvent and dump line connections enter the housing and are connected to the appropriate valves Ports are labeled with blue lettering 5 5 Electrical Connections Electrical connections to the ICE Bell atomizer assembly consist of only the high voltage cable This cable plugs into the module fitting located at the rear of the assembly After inserting the cable tighten the cable compression fitting nut around the high voltage cable with an appropriate wrench 5 6 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 Fluid Tubing Connection Requirements Fixed Pressure Atomizer nominal max P IN I D PFA Teflon Solvent 125 1 0 PFA Line SOL Teflon Dump Line 250 1 0 PFA Teflon Variable Ill Fluid Tubing Connection Requirements CAUTION The normal fluid flow range is 25 500 cc min The maximum flow rate must not exceed 500cc min to avoid solvent or paint from flooding into the internal portion of the air bearing motor assembly or front shroud 12 10 2005 Page 14 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 5 7 interlocks The following system interlocks are required to prevent equipment damage 1 Bearing air should remain
29. e Test When replacing the resistive components troubleshooting reassembling or as periodic inspection procedure a low voltage test can be performed on the rotator assembly to ensure that there are good electrical contacts and that the resistors are not defective A high voltage resistor tester Megger must be used which has an output voltage of 500 to 1000 VDC e With the high voltage turned OFF disconnect the high voltage cable from the rear of the rotator assembly e Insert a test cable the test meter probe into the rear of the rotator and connect to the voltage output of the test meter e Remove the front shroud and bell cup and clip the test meter ground to the rotator shaft Set the test meter voltage output to a minimum of 500 V DC and maximum of 1000 VDC meter should indicate between approximately 725 Mega O and 770 Mega Q If the test instrument is reading higher than 770 Mega Q then the electrical contacts between the resistor tube resistor block and motor assembly need to be checked e Remove the motor assembly and resistor tube and verify that the resistor tube springs are at least 3 8 and are not distorted Also make sure that there is no visible contamination in the motor cavity where the resistor tube inserts Refer also to the Troubleshooting Guide 12 10 2005 Page 26 of 40 ICE BELL Service Manual Automotive Finishing 6 12 6 13 6 14 6 15 Binks DeVilbiss R
30. e protective disposable wrapping be a material such as the type used on electrostatic guns WARNING IN In the event the bell cup comes in contact with a part that cup should be checked for damage and replaced if necessary before continuing to spray gt Check bell cup voltage using high voltage probe Voltage should be approximately 85kV when 100kV is set on the power supply WARNING Do not place high voltage probe on bell edge unless rotation is fully stopped NOTE Refer to the Troubleshooting Guide for details on determining the causes of low or no voltage at the bell cup gt e Check the amount of paint build up on the outer protective wrap If excessive replace wrap as required 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 replacement daily and could last about one week See Weekly Maintenance in the Maintenance Section 12 10 2005 Page 24 of 40 ICE BELL Service Manual Automotive Finishing 6 10 2 12 10 2005 Binks DeVilbiss Ransburg Weekly Maintenance Prior to start or End of Production Week Monitor rotational speed of all bells at the speed control should be within approximately 5 of target output Monitor high voltage output indicated on the display of the control unit or at the meter of the power supply should be within approximately 596 of target ou
31. efficiency WARNING Do not exceed the maximum rated intermittent operating speed and turbine inlet pressure 55 000 rom for the 57mm bell or 55 000 rpm for the 30mm bell Excessive speed may cause air turbine damage or damage the bell 12 10 2005 Page 17 of 40 ICE BELL Service Manual Automotive Finishing 5 12 5 13 5 14 Binks DeVilbiss Ransburg Bearing Air Adjustment The nominal bearing air pressure is 6 bar measured at the rear of the atomizer Minimum pressure is 5 bar and maximum pressure is 7 bar The turbine should never operated with less than 5 bar 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 CAUTION e Bearing air must be on whenever the turbine is operated If not severe bearing damage will occur It is recommended that bearing air be left turned on at all times except during maintenance or disassembly e Bearing damage and subsequent turbine failure caused by running the turbine without bearing air will not be covered under the ITW Ransburg warranty The ICE Bell 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 controlle
32. es to blow by the part or bounce back onto the atomizer Excessive target distance Bell The recommended target distance is between 200 amp cup damaged 300 mm see Target Distance in the Operation section of this manual Turbine drive air not present Verify supply air pressure Bearing air return signal not a Verify bearing air return signal No Turbine present b Increase bearing air supply pressure to 6 bar Air Brake air is activated Remove brake air signal turbine air and brake air must be interlocked to prevent both from being used simultaneously Damaged fiber optic cable Repair or replace fiber optic cable between atomizer and control Speed panel Feedback Fault Connection at the fiber optic Re install fiber optic cable and tighten the transmitter is loose compression nut Fiber optic transmitter failure Replace fiber optic transmitter Turbine is not rotating Verify rotation of turbine the paint valve air pilot must be interlocked with the turbine speed feed back signal to ensure that paint does not flow into the air bearing Fluid regulator does not actuate 2 a Verify fluid supply b Verify that air pilot signal is present No fluid Flow 3 Fluid valve does not actuate 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 Remove and inspect fluid tube
33. h creates by vortec effect a reduction of temperature in front of the atomizer Each individual air cooler is equipped with adjustment s screws to allow the possibility of temperature adjustment and to keep the bell cup at 15 C constantly The air inlet connection located at the back of the manifold is designed to dispatch the proper air volume to each of the vortec turbines Page 16 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 5 10 Fluid Valve Control The fluid valve in the ICE Bell is actuated by an air signal The air pressure must exceed 5 bar to assure proper actuation of the valve Applying air to the valve actuator turns on the fluid flow for that valve The trigger valve controls the paint flow to the bell When actuated paint flows through the valve to the fluid tube and into the rear of the bell cup The bell must be spinning at least 10 000 rpm when fluid is turned on to enable the fluid flow through the bell paint passage holes and be atomized The optional dump valve controls the paint flow through the dump line When actuated paint flow is directed to the dump return line This provides a method of rapidly removing paint from the incoming line for cleaning and or color change Normally the dump valve is not actuated at the same time as the paint trigger valve since the trigger valve is intended to cause the fluid to flow to the bell at the prescribed input pressure
34. ing Air S A Variable Control TV Control DV Solvent Valve 1 4 O D 5 5 bar 1 Air Tubing Connections Brake Air BRK 3 8 O D if used 12 10 2005 Page 12 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 5 2 Air filtration Requirements Air Filtration Requirements ITW Ransburg Description Specifications Replacement Element Fiter mogel No aN Pre filter removes coarse amounts of oil moisture HAF 503 amp dirt Used upstream of RPM 417 pre filter used in systems with poor air quality Pre filter coalescing type 136 scfm 98 5 efficiency particulate removal 3 to 6 microns max aerosol passed RPM 417 1 0 micron max solid passed 4 micron RPM 32 Elements dependent upon scfm requirement per applicator Carton of 4 one RPM 417 can be used with up to three Aerobell 33 assemblies Bearing air filter coalescing type 19 scfm RPM 418 99 995 efficiency particulate removal 3 to 6 RPM 33 Elements microns max aerosol passed 6 micron max Carton of 8 solid passed 2 micron one per applicator Air Filtration Requirements CAUTION e Air must be properly filtered to ensure extended turbine life and to prevent contamination of the paint finish Air which is not adequately filtered will foul the turbine air bearings and cause turbine failure The correct type of filters must be used in an Ice Bell system
35. is Tells how to avoid the hazard hazards may occur Spray Area Fire Hazard Fire extinguishing equipment must be present in th d tested periodically Improper or inadequate operation and maintenance procedures will Spray areas must be kept clean to prevent the cause a fire hazard accumulation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or maintenance When using solvents for cleaning Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation Frequent power Those used for equipment flushing should have supply shutdown indicates a flash points equal to or higher than those of the problem in the system requiring coating material correction Those used for general cleaning must have flash points above 37 8 C Spray booth ventilation must be kept at the rates required by the European regulations In addition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented Test only in areas free of combustible material Testing may require high voltage to be on but only as instructed Non factory replacement parts or unauthorized equipment modifications may cause fire or injury If used the key switch by pass is intended for u
36. lectrical arc can ignite coating materials and cause a fire or explosion Halogenated hydrocarbon solvents for example methylene chloride and 1 1 1 Trichloroethane are not chemically compatible with the aluminum that might be used in many system components The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion Certain material may be harmful if inhaled or if there is contact with the skin SAFEGUARDS Tells how to avoid the hazard The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance Aluminum is widely used in other spray application equipment such as material pumps regulators triggering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray If in doubt as to whether or not a coating or cleaning material is compatible contact your material supp
37. lier Any other type of solvent may be used with aluminum equipment Follow the requirements of the Material Safety Data Sheet supplied by coating material manufacturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equipment must be as prescribed by an industrial hygienist or safety expert Page 7 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg Hazardous Areas and Precautions cont AREA HAZARD SAFEGUARDS bos Tells what the hazard is Tells how to avoid the hazard azards may occur Spray Area High There is a high voltage device Parts being sprayed must be supported on Voltage Equipment that can induce an electrical conveyors or hangers and be grounded The charge on ungrounded objects resistance between the part and ground must which is capable of igniting not exceed 1 megaQ coating materials All electrically conductive objects in the spray Inadequate grounding will cause area with the exception of those objects a spark hazard A spark can required by the process to be at high voltage ignite many coating materials and must be grounded cause a fire or explosion Any person working in the spray area must be grounded Unless specifically a
38. lity 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 Proven air coolers which brings the bell temperature below 15 C Easy to install and maintain Hosing and connections are easily accessible at either the rear of the assembly or by sliding back the protective rear cover Quick removal of the turbine assembly for off line repair Annular shaping air passage design providing excellent pattern control at minimal air consumption Aerodynamic design for ease of cleaning external surfaces Assembly can be swiveled to provide oblique spray angles for better paint coverage in difficult areas of the product Turbine air exhausts behind bell keeping paint and solvent contamination out of atomizer interior and keeping back of bell clean Speed readout or control uses reliable magnetic pickup for fiber optic transmission of rotational speed data 12 10 2005 Page 9 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg 3 General Description 3 1 ICE Bell System The Ransburg Ice Bell is a high speed rot
39. nd voltage settings To readjust settings refer to the power supply manual Atomizer grounding out a Clean atomizer externally with non polar usually indicated by high solvent current draw b Check the atomizer for internal fluid leaks Check for internal arcing usually indicated by internal sparking sounds Damaged high voltage cable Repairorreplace high voltage cable between atomizer and power supply 10 Improper color change __ 10 Optimize color change i e paint or solvent in dump line 12 10 2005 Page 28 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg General Possible Cause Problem 1 Low or no high voltage Verify high voltage at bell cup edge Normally a high voltage setting of 100kV is appropriate for most applications Poor grounding of parts being Verify that parts being coated are properly coated grounded the electrical resistance between the part and ground must not exceed 1 megQ Excessive turbine speed Foroptimum transfer efficiency and spray pattern Low Transfer control the bell rotational speed should be set at Efficiency or the minimum required to achieve proper light atomization of the coating material coverage Excessive shaping air Shaping air should be set at the minimum volume required to gently direct the spray pattern toward the part being coated Excessive shaping air will cause some atomized particl
40. ose solvents should also be non polar Examples of non flammable non polar solvents for cleaning are Amyl acetate methyl amyl acetate high flash naphtha and mineral spirits e Do NOT use conductive solvents such as MEK to clean the external surfaces of the ICE Bell e When using a rag to hand wipe the ICE Bell the turbine air should be off but leave the shaping air and the 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 Normally the internal cleaning instructions will suffice to clean the bell If the internal cleaning instruction does not sufficiently remove all paint and residue from the bell the bell may be removed for hand cleaning 12 10 2005 NOTE It may be advantageous to develop a maintenance schedule for hand cleaning and inspection of the atomizer bell cup 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 efficiency and coating quality Page 21 of 40 ICE BELL 6 5 Vibration Noise Service Manual Automotive Finishing Binks DeVilbiss Ransburg CAUTION Do not use abrasive materials which will scratch or damage the titanium bell Before reinstalling the bell onto the shaft check and clean
41. ote that it s 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 than be tightened down fully until it bottoms against the air manifold assembly Atomizer Bell Cup Removal To remove the atomizer bell cup place the wrench part number RPM 419 over tha flats on the motor shaft to lock in place Unscrew the bell by turning CCW with the other hand while facing to front of the atomizer If the bell cannot be removed by hand use a second RPM 419 wrench placed over the wrench flats of the bell cup Refer to Preventive Maintenance in the Maintenance section for important information about bell and shaft cleanliness Do not install a paint contaminated or damaged bell on the turbine shaft When installing the bell on the shaft the bell should be firmly secured by hand or use wrench RPM 419 and torque to 50 Ib in 0 40 Ib in Turbine Removal The turbine assembly is removed from the ICE Bell atomizer after removing the front shroud assembly Four mounting bolts will then be exposed which hold the turbine assembly to the air manifold assembly These are the larger socked 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 in
42. pen 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 valve With the bell spinning turn on the solvent valve to allow 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 pas sage and to flush the dump line if desired CAUTION The maximum flow rate of 500cc minute must not be exceeded during a flush routine 12 10 2005 Page 20 of 40 ICE BELL 6 4 Bell cleaning Service Manual Automotive Finishing Binks DeVilbiss Ransburg WARNING NEVER wrap the applicator associated valves and tubing and supporting hardware in plastic to keep it clean A surface charge may build up on the plastic surface and discharge on the nearest grounded object Efficiency of the applicator will also be reduced and damage or failure of the applicator components may occur WRAPPING THESE COMPONENTS IN PLASTIC WILL VOID WARRANT Y WARNING To reduce the risk of fire or explosion the regulations require that solvents used for exterior cleaning including bell cleaning and soaking be nonflammable flash points higher than 37 8 C e Since electrostatic equipment is involved th
43. pproved for use in hazardous locations the power supply and other electrical control equipment must not be used in Class 1 Division 1 or 2 locations Personnel safety The bell atomizer can rotate at Personnel must stay clear of the bell whenever it Mechanical speeds up to 55 000 rpm At is rotating 1558 E edge or the Before touching the bell the turbine air must be applicator can easily cut into skin Loose articles also be caught by the rotating bell If the bell has been rotating allow at least two minutes for it to come to a complete stop before touching it 12 10 2005 Page 8 of 40 ICE BELL Service Manual Automotive Finishing 2 2 1 Binks DeVilbiss Ransburg Introduction Features Features which make the ICE Bell Rotary Atomizer advantageous for use in electrostatic applications include CE listed Limited energy is available to prevent ignition of flammable air solvent mixtures Assembly components and bell made of durable Titanium material for optimum mechanical strength and Water resistance Proven long life turbine motor capable of speeds up to 55k rom at minimal air consumption See Specifications in the Introduction section of this manual for bell cup speed ratings Patented serrated edge bell provides excellent atomization quality at minimal rotational speeds 5 mm and 30mm diameter bell assemblies available for application flexibi
44. r operation of the turbine will automatically be shut down whenever the bearing air pressure falls below 4 bar Shaping Air Shaping air is used to shape the spray pattern Lower input pressure results in wider pattern size while higher input pressure reduces the pattern size Shaping air does not help atomize the material but will assist in the penetration of atomized particles into cavity areas Ideally shaping air should be kept at the minimum pres sure which will provide a proper finish for the fluid being sprayed Excessive shaping air will cause some atomized particles to blow by the target reducing the wrap around effect at edges and corners Excessive shaping air may also cause some paint particles to bounce back onto the atomizer causing the atomizer surface to become contaminated Brake Air Brake air is used to slow the turbine speed in a minimum length of time is advantageous for short cycle times during color change or may be used to reduce speed or stop the turbine Never operate brake air with the turbine air on Approximate brake times to reduce the turbine speed are shown in Table IV These times are based on 4 bar 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 Braking time To Brake from rpm Seconds approx 9 0 IV Braking Time 12 10
45. se only during set up operations Production should never be done with safety interlocks disabled Never use equipmentintended for use in waterborne installations to spray solvent based materials General Use and Improper operation or Personnel must be given training in accordance Maintenance maintenance may create a with the requirements of the European hazard regulations Instructions and safety precautions must be read and understood prior to using this equipment Personnel must be properly trained in the use of this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping 12 10 2005 Page 6 of 40 ICE BELL AREA Tells where hazards may occur Electrical Equipment gt Explosion Hazard incompatible Materials Toxic Substances 12 10 2005 Service Manual Automotive Finishing Binks DeVilbiss Gema Ransburg Hazardous Areas and Precautions cont HAZARD Tells what the hazard is High voltage equipment is utilized Arcing in areas of flammable or combustible materials may occur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correction An e
46. the tapered mating surfaces of the turbine shaft and bell for any paint residue Using an atomizer bell with paint buildup may cause a bell imbalance An imbalanced bell may cause bearing damage and turbine failure or may create mechanical stress on the plastic bell when operating at high speeds Excessive paint residue caught between the internal tapered surface which seats in the motor shaft can prevent the bell from seating properly and result in an unbalanced turbine condition CAUTION Care must be taken when mounting the bell assembly onto the motor shaft The bell should turn freely for several turns or until it fully bottoms on the motor shaft If resistance is felt when the bell is first being turned onto the shaft do not proceed further the bell may be cross threaded on the shaft Remove the cup and carefully reinstall If it is still difficult to turn replace the bell 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 If the ICE Bell is vibrating or making an unusually loud noise it may mean that there is an unbalanced situation The bell assembly may have dried paint on it the bell may be physically damaged or there may be paint trapped between the bell and the shaft preventing the bell from properly seating If any of these conditions exist they must be corrected prior to further operation Do not continue to operate a
47. tput 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 1096 of target flow rate CAUTION Maximum flow rate should not exceed 500cc min Remove protective wrap from outer housing and discard Clean any paint on outer surface of front and rear housing with soft cloth dampened with solvent See Warning under Daily Maintenance on avoiding the use of cleaning solvent containing d limonene Check the high voltage connection by removing the cable assembly from the manifold Examine the tip of the banana plug for any contaminants or corrosion Clean or replace the plug as required 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 the applicator and the power supply termination point Remove the front shroud and check for any signs of solvent or paint leakage Clean as required Check position of high voltage tube where it enters the motor housing Make sure the O Ring is not exposed If so push the tube in place Remove bell cup and soak in solvent MEK any Xylene blend for 1 to 2 hours Remove from cleaning solution and blow dry before replacing WARNING Do not use reclaim solvent containing d Limonene to soak
48. y daily that the operating parameters have not varied from the set up standard A drastic change in system current high voltage turbine air shaping air pressure or fluid pilot air pressure van be an early indicator of a component or system problem 6 10 Preventive Maintenance 6 10 1 Daily Maintenance During Each Preventive Maintenance Break e Open solvent valves and flush out fed tubes and bell cups for 3 5 seconds trigger and dump valve closed WARNING e Make sure high voltage is off before approaching applicator with solvent cloth e Do not use reclaim solvent containing d Limonene This can cause damage to certain plastic components e Do not stop bell rotation by using a rag ort gloved hand against the bell cup edge This can damage the resistance coating at the bell cup edge 12 10 2005 Page 23 of 40 ICE BELL Service Manual Automotive Finishing Binks DeVilbiss Ransburg CAUTION Daily removal and soaking of the bell cup may not be required it the bell cup is properly flushed as indicated above However the frequency of the feed tube and internal motor shaft inspection indicated below under weekly maintenance can be done daily and later adjusted to weekly or as required depending on the results of the inspection e Wait for rotation to cease and then clean off bell cup edge and shaping air ring and any other non protected unwrapped outer surfaces Use a soft cloth dampened with solvent Th
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