Ransburg RMA-202 TEST STAND MODEL: FOR RMA-202

Transcription

1 ATOM AIR BEARING AIR SHAPING AIR SEAL AIR SERVICE MANUAL RMA-202 TEST STAND MODEL: FOR RMA-202 IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting on page 1, and all instructions in this manual. Keep this Service Manual for future reference. Service Manual Price: $30.00 (U.S.)

2 RMA-202 Test Stand - Safety CONTENTS PAGE SAFETY: 1-5 SAFETY PRECAUTIONS... 1 HAZARDS / SAFEGUARDS INTRODUCTION: 6-8 GENERAL INFORMATION... 6 SPECIFICATIONS... 7 FEATURES INSTALLATION: 9-17 SETUP PROCEDURE... 9 INITIAL TEST SETTINGS... 9 HIGH VOLTAGE TEST TROUBLESHOOTING HV TEST TEST TRIGGERS PRESSURIZED WATER TESTS TURBINE TESTS PREPARARATION OF APPLICATOR FOR PRODUCTION PLACEMENT MAINTENANCE: 19 MAINTENANCE...19 WARRANTY POLICIES: 20 LIMITED WARRANTY...20 APPENDIX: PAINT AND SOLVENT SPECIFICATIONS VISCOSITY CONVERSION CHART VOLUMETRIC CONTENT OF HOSE OR TUBE... 24

3 RMA-202 Test Stand - Safety SAFETY SAFETY PRECAUTIONS Before operating, maintaining or servicing any electrostatic coating system, read and understand all of the technical and safety literature for your 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 this information, we use the following symbols. Please pay particular attention to these sections. A WARNING! states information to alert you to a situation that might cause serious injury if instructions are not followed. A CAUTION! states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury. A NOTE is information relevant to the procedure in progress. While this manual lists standard specifications and service procedures, some minor deviations may be found between this literature and your equipment. Differences in local codes and plant requirements, material delivery requirements, etc., make such variations inevitable. Compare this manual with your system installation drawings and appropriate equipment manuals to reconcile such differences.!! W A R N I N G The user MUST read and be familiar with the Safety Section in this manual and the 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 SAFE- TY STANDARD, LATEST EDITION, prior to installing, operating, and/or servicing this equipment. W A R N I N G The hazards shown on the following pages may occur during the normal use of this equipment. Please read the hazard chart beginning on page 2. Careful study and continued use of this manual will provide a better understanding of the equipment and process, resulting in more efficient operation, longer trouble-free service and faster, easier troubleshooting. If you do not have the manuals and safety literature for your system, contact your local representative or. 1

4 RMA-202 Test Stand - Safety AREA Tells where hazards may occur. Spray Area HAZARD Tells what the hazard is. Fire Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard. Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation. Frequent Power Supply or Controller shutdown indicates a problem in the system requiring correction. 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 maintenance. When using solvents for cleaning: Those used for equipment flushing should have flash points equal to or higher than those of the coating material. Those used for general cleaning must have flash points above 100 F (37.8 C). Spray booth ventilation must be kept at the rates required by NFPA-33, OSHA, country, and local codes. In addition, ventilation must be maintained during cleaning operations using flammable or combustible solvents. Electrostatic arcing must be prevented. Safe sparking distance must be maintained between the parts being coated and the applicator. A distance 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 unauthorized equipment modifications may cause fire or injury. If used, the key switch bypass is intended for use only during setup operations. Production should never be done with safety interlocks disabled. Never use equipment intended for use in waterborne installations to spray solvent based materials. The paint process and equipment should be set up and operated in accordance with NFPA- 33, NEC, OSHA, local, country, and European Health and Safety Norms. 2

5 RMA-202 Test Stand - Safety AREA Tells where hazards may occur. Spray Area HAZARD Tells what the hazard is. Explosion Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard. Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation. Frequent Power Supply or Controller shutdown indicates a problem in the system requiring correction. 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 distance of 1 inch for every 10KV of output voltage is required at all times. Unless specifically approved for use in hazardous locations, all electrical equipment must be located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33. Test only in areas free of flammable or combustible materials. The current overload sensitivity (if equipped) MUST be set as described in the corresponding section of the equipment manual. Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set. Frequent power supply shutdown indicates a problem in the system which requires correction. Always turn the control panel power off prior to flushing, cleaning, 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 accordance with NFPA-33, EN Have fire extinguishing equipment readily available and tested periodically. General Use and Maintenance Improper operation or maintenance may create a hazard. Personnel must be properly trained in the use of this equipment. Personnel must be given training in accordance with the requirements of NFPA-33, EN Instructions and safety precautions must be read and understood prior to using this equipment. Comply with appropriate local, state, and national codes governing ventilation, fire protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms and your insurance company requirements. 3

6 RMA-202 Test Stand - Safety AREA Tells where hazards may occur. Spray Area / High Voltage Equipment 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. 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 conveyors or hangers that are properly grounded. The resistance between the part and earth ground must not exceed 1 meg ohm. (Refer to NFPA-33.) Operators must be grounded. Rubber soled insulating 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 applicator 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 required 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 flushing, cleaning, or working on spray system equipment. Unless specifically approved for use in hazardous locations, all electrical equipment must be located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33. 4

7 RMA-202 Test Stand - Safety AREA Tells where hazards may occur. Electrical Equipment HAZARD Tells what the hazard is. Electrical Discharge High voltage equipment is utilized in the process. Arcing in the vicinity 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 shutdown indicates a problem in the system which requires correction. An electrical arc can ignite coating materials and cause a fire or explosion. SAFEGUARDS Tells how to avoid the hazard. Unless specifically approved for use in hazardous locations, the power supply, control cabinet, and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN 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. Toxic Substances Certain material may be harmful if inhaled, or if there is contact with the skin. Follow the requirements of the Material Safety Data Sheet supplied by coating material manufacturer. Adequate exhaust must be provided to keep the air free of accumulations of toxic materials. Use a mask or respirator whenever there is a chance of inhaling sprayed materials. The mask must be compatible with the material being sprayed and its concentration. Equipment must be as prescribed by an industrial hygienist or safety expert, and be NIOSH approved. Spray Area Explosion Hazard Incompatible Materials 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. 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 coating supplier. Any other type of solvent may be used with aluminum equipment. 5

8 RMA-202 Test Stand - Introduction INTRODUCTION GENERAL INFORMATION The Applicator Performance Test Stand was developed to assist in determining the applicator level of performance in an off-line condition. Insuring the applicator functions properly after any maintenance has been performed to it off-line reduces the costs associated with verifying performance during production. With line speeds critical to the through-put of a facility, every uptime minute counts to underwrite profitability. This Test Stand device helps to insure the applicator performs correctly when it is put into service. The Test Stand will verify performance of single or dual fluid applicators, bearing air, seal air, shaping air, brake air and atomizing air. It also checks for kv and µa electrical performance of the applicator. SPECIFICATIONS Electrical / Physical Power Requirements: 110/120 v AC Air Requirements: Dimensions: Height: Width: Length: 1 NPT (F) Inlet 3/4 ID Air Line to Stand 100 psi (6.4 bar) (90 psig 20 SCFM) Min. 0.3 to 0.6 Micron Filtration 67 (1702 cm) 30 (762 cm) 48 (1219 cm) The Test Stand was developed with the user and the safety of the user in mind. The user must become familiar with the overall function and operation of the unit. Fluids: Maximum Fluid Pressure: Use distilled or de-ionized water only for testing 80 psi (5.2 bar) N O T E > For all test stand toggle switches, with the switch lever in the UP position, the valve it describes is ON or actuated. Test Specification Summary At Voltage: Fluid Leaks: Bearing Air Flow Rate: KV 20 µa Max. No pressure drop for 2 minutes 1.5 to 2.5 SCFM Turbine Air Flow At 50K rpm: Shaping Air Flow: Seal Air: 14 SCFM Max SCFM at 25 psig SCFM at 60 psig 9-11 SCFM at 30 psig Fiber Optic Voltage:.68V at 50K RPM Min. 6

9 ATOM AIR BEARING AIR SHAPING AIR SEAL AIR RMA-202 Test Stand - Introduction FEATURES Figure 1: Basic Stand Features BASIC STAND FEATURES Item # Description Main Control Panel Air Flow Meters Test Applicator Table Pressure Pot Dump Bucket Spin Guard Main Air Regulator 7

10 ATOM AIR BEARING AIR SHAPING AIR SEAL AIR RMA-202 Test Stand - Introduction Figure 2: Basic Stand Features BASIC STAND FEATURES Item # Description Power Control - On/Off Button Main Gauges - Leak Down, Supply Air Air Flow Meter - Turbine Air, Shape Air, Seal Air Air Flow Meter - Bearing Air Fiber Optic Voltage Readout Atomizer Speed Select Card Atomizer Card MicroPak Power Supply Paint, Dump, and Solvent Trigger Switches (Applicator Enable Switches) Fluid Enable Switches (Paint #1, Paint #2, Solvent) Regulated Function Gauges : Bearing Air, Seal Air, Fluid Air, Shaping Air, Brake Air, Atomizing Air Control Switches: Single/Dual, HV On/Off, Water/Air 8

11 RMA-202 Test Stand - Installation INSTALLATION SETUP PROCEDURE 1. Insure that ground connections, cart ground, and applicator ground are made to a true earth ground. W A R N I N G! > If true earth ground is not made, injury to personnel or serious damage may occur to the equipment. > Insure ALL items in the test area are grounded. Insure there are NO open containers of flammable materials in the test area. 2. Provide air filtration to the manifold that has the capability of passing 136 SCFM with particulate removal of.3 to.6 micron particle size. (Bearing air filtration is provided with the stand.) 3. Provide a minimum 1/2-inch I.D. air line to the filter at the manifold inlet. A minimum of 100 psig pressure is required at the manifold inlet. 4. Install water supply line and air pressure line to the pressure pot. W A R N I N G! > NEVER use solvent as a test fluid for this device! > Using any material OTHER than distilled water or de-ionized water may cause fire during the test. Use only distilled or deionized water to test the applicator. 5. Plug the unit into a suitable 110/120V outlet. INITIAL TEST SETTINGS 1. Set RMA-202 type switch to dual or single fluid depending upon applicator. (See Figure 8) 2. HV is off unless instructed to turn on. Main power off. 3. Fluid enable off (toggle switch lever in the down position). 4. Supply 100 psig air pressure to the stand, reference supply air gage on panel. If required, adjust air input regulator attached to stand. 5. All toggle switches in the off position (lever in down position). 6. Attach the applicator to the manifold plate using the proper spanner wrench. Tighten as required. (Note: Lubricate o-rings prior to assembly.) 7. Set speed select to Adjust bearing air regulator to 80 psig minimum. N O T E > Using tap water or city water MAY CAUSE problems with chemical incompatibilities with the production spray material. HIGH VOLTAGE TEST The purpose of the high voltage test is to insure all voltage-generating components are set or installed properly. If the applicator is not properly rebuilt, a voltage deficiency will be identified while the applicator is off-line and no downtime should occur. 9

12 RMA-202 Test Stand - Installation 1. Insure the main power switch is in the Off position. Remove the shroud from the applicator and install applicator on to the manifold mounting plate as shown in Figure Turn the main control power switch to the on position by pushing the green button. The green illuminated indicator should now be illuminated. Figure 5: Main Power Indicators Figure 3: Applicator (Shroud Removed) N O T E > For this part of the test, the spin guard should be in the down position. 4. Turn the MicroPak power supply On. Switch the unit to the Local setting. Adjust the voltage adjustment potentiometer to read kv on the display with no current draw (applicator end is still bagged, voltage is contained, minimal current draw to atmosphere). N O T E 2. With control panel power Off, cover the end of the applicator with a plastic bag to contain the electrostatic voltage and prevent current from being drawn off to the atmosphere. Insure that the bag fits tight around the applicator (See Figure 4). A non-metallic external elastic band may be used if required. > If voltage is set to a level that 10 µa of current or less is drawn, feedback faults will occur. 5. Insure the HV On switch on the test panel is in the ON position. (See Figure 6.) 6. Read the kv and µa current reading from the appropriate display of the MicroPak. The reading of voltage should be between 90 to 100 kv. Typical current draw of applicator when bagged is between 10 and 20 µamps. Figure 4: Applicator (With Plastic Bag) Figure 6: HV ON/OFF Switch 10

13 RMA-202 Test Stand - Installation TROUBLESHOOTING - HV TEST If the voltage display of the MicroPak reads less than 90 kv or the current draw is above 20 µa with the MicroPak kv and µa potentiometer adjusted fully clockwise, the fluid lines may need to be purged or the voltage test bag is leaking current and voltage to the air. If you have no voltage reading at all, proceed to HV Troubleshooting in this section. If you have voltage, check to make sure the voltage test bag is secured tight to the applicator. If it is, follow the procedure Blow The Fluid Lines Out. Blow The Fluid Lines Out 1. Turn the MicroPak voltage off at the switch on panel and also at MicroPak. 2. Remove the voltage containment bag from the end of the applicator. Figure 8: Fluid Supply Switch 5. Set RMA-202 types either single or dual fluid type. (See Figure 8) 6. Trigger Paint #1 toggle switch in the Fluid Enable section of the panel. Trigger Paint #2 toggle if so equipped with dual fluid. N O T E > The HV is interlocked electrically with the trigger switches. When a fluid switch is triggered on, the HV will automatically be turned off. 3. Remove the front shroud and bell cup from the end of the applicator (this prevents flooding of the turbine motor assembly). 4. Turn the fluid selector switch to the Air position. (See Figure 7) Figure 9: Fluid Enable Switches 7. Trigger the Paint #1 dump and the Paint #2 dump toggle switch to blow out any excess water. Figure 10: Paint #1 & Paint #2 Dump Toggle Switches 8. After (2) to (3) minutes of purging with air, inspect the fluid dump lines visually to determine if all the fluid has been pushed out of the lines. Turn Dump #1 and Dump #2 to Off position in the Application Enable section. Figure 7: Fluid Selector Switch Position 9. Trigger the (2) paint lines (Paint #1, Paint #2, and solvent) material in these areas and Paint #1, Paint #2, and solvent triggers in the Applicator Enable to purge all fluid from bell. Fluid coil should be free and clear of all fluids. 11

14 RMA-202 Test Stand - Installation TEST TRIGGERS (Checking Plumbing In The Bell) Figure 11: P#1 & P#2 Trigger Switches 10. Turn off all triggers. 11. Reinstall the front shroud, bell, and voltage containment bag. 12. Restart voltage test, sections 4 through 6. All current and voltage readings should meet the listed specifications for the applicator to deliver the performance that is expected from it. Hv Troubleshooting If there is zero kv reading at the MicroPak display with the voltage adjust potentiometer turned fully clockwise, there could be several different causes. Some of the most likely to cause the problem are: 1. The cascade connector is loose, was not properly connected at the wiring harness, or properly aligned. Remove applicator from mounting plate and verify alignment marks. 2. The connection spring ( ) inside the manifold may be missing. This small spring may have been forgotten during the rebuild of the applicator. For information on placement and location of this spring, consult the most current RMA-202 service manual for the applicator (turbine motor must be removed to inspect spring placement). 3. The cascade assembly ( ) may be bad. Install a known good cascade in the applicator and check for improved results. When reinstalling the cascade, use LSCH0009, dielectric lubricant around the circle labyrinth at the spring connection end of the cascade assembly ( ). The purpose of the trigger test section is to guarantee all the triggers on the applicator have been properly hooked up and when they receive an air signal, they properly cycle. Verify Trigger Functions With Air Air is used in the initial test to reduce the mess associated with water if the trigger valves or dump valves have not been properly plumbed or rebuilt. The following procedure describes the test of each of the following valves in the applicator: N O T E > For this part of the test, the spin guard should be in the down position. 1. Insure that the MicroPak main power control is in the Off position and High Voltage switch is in the Off position. 2. Remove the shaping air shroud from the end of the applicator using RPM-419 wrench. 3. Using (2) RPM-419 wrenches, remove the bell from the turbine shaft. 4. Install the test bell ( ) and seal ( ) using the RPM-419 wrench. Insure the test bell is installed on the turbine shaft properly, hand tighten only. 5. Turn the Fluid selector switch to the Air posi- Figure 12: Pressure Test Bell 12

15 RMA-202 Test Stand - Installation! tion (See Figure 7). C A U T I O N > With the test bell and seal installed, DO NOT attempt to rotate the turbine shaft. Any attempt to rotate the turbine shaft WILL CAUSE DAMAGE to the fluid feed tube. 6. Trigger the bell solvent switch (See figure 13). When this is triggered, you see the valve actuate via a flag through the opening in the valve cover. Each of the valve positions is engraved on the fluid manifold. Once actuation function is verified, turn switches to off position. 7. Each of the valve positions is engraved on the Figure 13: Bell Solvent Switch fluid manifold such as solvent, Paint #1, Paint #2, etc. By triggering each of these functions, verify visually each respective valve triggers when its toggle switch is turned on. The trigger functions that require verification are: Paint #1 Trigger Paint #1 Dump Paint #2 Trigger Paint #2 Dump Solvent 8. If the valves do not function as expected, recheck to insure micro valves or micro valve seats are properly installed and seated in Fluid Enable and Applicator Enable. N O T E PRESSURIZED WATER TESTS (Static) The purpose of this section of the test is to verify that each of the valves in the applicator will pass fluid. Also, this test verifies all seals along the fluid passages have been properly located to prevent any fluid leakage. To complete the pressurized water tests, complete the following: 1. Insure all toggle switches are set to the Off or Down position. 2. Position the applicator where any water sprayed out of the bell may be collected and properly disposed of. 3. Verify there is no residual pressure in the pressure pot included with the test stand. Turn the regulator adjustor on the pressure pot counterclockwise until all pressure is released. Pull the bleed-off valve to release the pressure if any. 4. Loosen the pressure pot clamps till the lid may be removed from the pot itself. Fill the pressure pot with de-ionized or distilled water.! W A R N I N G > Never use solvent as a test fluid for this device. 5. Close the lid, tighten the lid clamps so that the lid is secure and no air pressure may escape. 6. Turn the fluid actuation switch to water (See Figure 14). > For signal line verification consult the most current RMA-202 applicator service manual. Pull valves out of manifold. 13

16 RMA-202 Test Stand - Installation 14. Observe the test pressure gauge for 2 to 3 minutes. The leak pressure should stay constant over this period. If it does not, locate the source of the leak, repair it and retest the applicator. Figure 14: Fluid Selector Switch Position for Water Tests 7. Manually turn up the water pressure to 70 psig (read on the front panel) by adjusting the pressure regulator on the pressure pot. Verify by looking at the pressure gage for fluid pressure. 8. Verify the test station test bell cup is still on the applicator. 9. Turn Fluid Enable Paint #1, Paint #2, and solvent In to the On position. 10. Turn Applicator Enable switches Bell Solvent, Paint #1, and Paint #2 Trigger (if equipped) to the On position. 11. Visually inspect each of the coiled fluid tubes to verify there is fluid in them. 12. Visually inspect around the applicator to insure there are no visible water leakage. 13. Turn the fluid selector switch to the Off position. 15. If the system does not hold pressure, visually inspect for leaks. Potential areas are paint and dump valves and their seats. 16. Turn the fluid selector switch back to air. Depressurize the pressure pot. 17. Actuate the dump triggers and blow out the lines per the procedure outlined in the HV Troubleshooting in this section. 18. Remove the test bell from the end of the applicator. Adequately blow out all fluid in the coil and upper section of the applicator. Install the production bell cup and shroud per the instructions in the most current RMA-202 applicator service manual. 19. Dump contents of dump bucket. TURBINE TESTS The purpose of this test is to verify the applicator rotates properly and sprays reasonable well. With de-ionized or distilled water as the test fluid, it is difficult to accurately access the spray performance characteristics. However, it can give a relative indication of how the bell will spray in production. N O T E > Bell cup and shroud must be attached to end of turbine. Figure 15: Fluid Selector Switch OFF Position 14

17 RMA-202 Test Stand - Installation! W A R N I N G > During any part of the turbine tests where the applicator bell is rotating, DO NOT come near or in contact with the spinning bell. Because of the bell rotational speed, injury can easily occur. Locate the bell in a position where minimal exposure to anyone passing by may come in contact with the spinning bell. > NEVER use any fluid other than distilled or de-ionized water to test the applicator performance. Using any other material will cause a risk of fire or severe personal injury. 3. Set the atomizer speed select to 50,000 rpm. Turn on the #1 speed enable toggle switch. Press the speed enter button. The turbine should now begin spinning. This should be audible. At 50K rpm the air flow should be not exceed 14 SCFM. The reading is taken from the Atomizing air flow meter. 4. Adjust the speed select to 45,000 rpm. Press the speed enter button to enter the new speed. An audible difference in speed should be detected. 5. Re-adjust the speed to 50,000 rpm. Read the fiber optic transmiter voltage from the panel. It should read a minimum of 0.68V at 50,000 rpm. Bearing Air Test This test is to verify the applicator responds to changes in set points in the speed selector. The procedure to accomplish this is: 1. Push up the bell spin guard against the face of the bell. Adjust the air regulator for bearing air to 80 psig minimum. (See Figure 16) The bearing air flow meter should read between 1.5 SCFM to 2.5 SCFM airflow. If it is below or above this limit, consult the applicator manual for solutions Figure 17: Fiber Optic Transceiver Voltage Readout 6. If the voltage is out of range, there are several possible causes. The most likely are: a. Transmitter inside the bell is bad or is positioned wrong. Refer to most current RMA-202 applicator service manual for instructions to correct. b. Transmitter (75911) or cable (75921) is not properly connected or may be broken. Figure 16: Bearing Air Pressure Gauge & Adjustment Regulator N O T E > If these are bad, the applicator most likely will not rotate because the atomizer card will shut the air to the turbine off. 2. Use the manual brake button to make sure the applicator bell is not rotating. When this is verified, check by hand that the turbine shaft assembly rotates freely. 7. Set the atomizer speed select to 45,000 rpm. Press the speed enter button. Again, an audible change in speed should be detected. 15

18 RMA-202 Test Stand - Installation! W A R N I N G > DO NOT use your hand or any object to stop bell cup rotation. 8. On the atomizer speed select card, toggle the Enable #1 switch down. 9. Stop the spinning bell by pressing the manual brake button on the front panel of the test station. Do not allow the turbine to spin in the reverse direction or it will damage unit. C A U T I O N! > DO NOT hold manual brake button in below 5K rpm. 4. Increase the shaping air pressure to 60 psig at the gauge. Read the flow meter for airflow rate. The rate for this pressure should be between 17 to 21 SCFM (481 SLPM to 594 SLPM). (Note: This depends on length of shaping air hose.) 5. Set the shaping air pressure back down to 0 psig and return the switch to the off position. Turn off turbine. 6. Turn on seal air switch. 7. Increase the seal air pressure to 30 psig Shaping Air / Seal Air Test 1. Turn the shaping air switch to the On postion. Set the shaping air pressure gage to read 25 psig by adjusting the regulator. 2. Set the atomizer speed select to 50,000 rpm. Press the speed enter button. The turbine should now begin spinning. This should be audible. 3. Select the shaping air flow meter at the flow rate select button. The flow rate should read between 8 (226 SLPM) to 13 SCFM (368 SLPM) (Note: This depends on length of shaping air hose.) 10 0 Figure 19: Seal Air Controls 8. Select seal at flow rate select switch. Read flow rate at the meter. The range of flow should be between 8 SCFM to 12 SCFM (226 SLPM to 340 SLPM). 9. Turn seal air switch off. N O T E Figure 18: Shaping Air Controls > If the On/Off switches for the shaping and seal air are rapidly turned on and off, the air flow meter may de-couple and show a zero reading. To recouple, leave the air On/Off switch in the on position and adjust the regulated air pressure back to zero. 16

19 RMA-202 Test Stand - Installation 17 SPRAY PATTERNS The purpose of this section is to get a visual feel that the atomization and shaping air are controlling the spray pattern as desired. Since water does not physically behave the same as paints, pattern sizes will not be the same as when the applicator is used to spray paint. The procedure to spray water through the bell is: 1. Position the applicator such that any water sprayed from the bell may be captured and properly disposed of. W A R N I N G! > During any part of the turbine test where the applicator bell is rotating, DO NOT come near or in contact with the spinning bell. Because of the bell rotational speed, injury can easily occur. Locate the bell in a position where minimal exposure to anyone passing by may come in contact with the spinning bell. 2. Set the pressure pot fluid regulator pressure to 10 psig. C A U T I O N! > Setting the pressure pot regulator pressure above 10 psig can cause the applicator bell to flood. If this occurs, damage to the turbine assembly may occur. 3. Set the atomizer speed select to 40,000 rpm. Press the speed enter button. The turbine should now begin spinning. This should be audible. 4. Trigger Paint #1 switch. Turn shaping air on and set to 40 psig. Adjust the shaping air up and down by adjusting the pressure regulator on the front panel. The pattern should increase or decrease in size as air pressure for the shaping air is adjusted. 5. Turn the fluid select to fluid. Fluid enable Paint #1. Turn off the trigger for Paint #1. Trigger Paint #2 switch and repeat the adjustment process. The pattern should increase or decrease in size as air pressure for the shaping air is adjusted. 6. Turn off the trigger for Paint #2. Trigger the solvent line and repeat the adjustment process. The pattern should increase or decrease in size as air pressure for the shaping air is adjusted. 7. Trigger solvent in to the On position in the fluid enable section. Trigger the (2) paint lines (Paint #1, Paint #2, and solvent), to purge any residual material in these areas. This material will exit from the bell. All three may be triggered at one time. Allow air to blow through the lines for an additional 30 to 40 seconds. 8. Turn off all the triggers that are on. Use the manual brake to stop the turbine. PREPARATION OF APPLICATOR FOR PRODUCTION PLACEMENT Once all the tests have been completed, the applicator needs to be prepared for placement into the production environment. To accomplish this, all the water needs to be completely purged from the coils and valves in the applicator. C A U T I O N! > During this part of the test, the turbine must be running or the turbine motor may be flooded. To blow the fluid lines out, complete the following steps: 1. Set the atomizer speed select to 40,000 rpm. Press the speed enter button. N O T E > Shaping air must be on during the entire air purge cycle. 2. Turn on and adjust shaping air pressure to 25 psig.out of the coiled lines.

20 RMA-202 Test Stand - Installation 3. Turn the fluid selector switch to the Air position. (Refer back to Figure 7.) 4. Trigger the dump Paint #1 and Paint #2 toggle switch in the fluid enable section of the panel. (Refer back to Figure 9.) 5. Trigger the Paint #1 and the Paint #2 toggle switches to blow out any excess water. There are (2) dump solenoids on this dual paint assembly. Each paint line has its own dump line. (Refer back to Figure 10.) Turn off the dump switches. 6. After 3 to 4 minutes of purging with air, inspect visually to determine if all the fluid has been pushed out of the coiled lines The applicator is now ready for placement into the production environment once the last few steps have been completed. 1. Turn bearing air regulator to zero pressure. 2. Release all pressures from the system including the pressure in the pressure pot. 3. Press the control power off button on the front panel. 4. Remove the applicator from the mounting plate using the proper spanner wrench. 7. Trigger solvent in to the On position in the fluid enable section. Trigger the (2) paint lines (Paint #1, Paint #2, and solvent), to purge any residual material in these areas. This material will exit from the bell. All three may be triggered at one time. Allow air to blow through the lines for an additional 30 to 40 seconds. 8. Turn off all the triggers that are on. Use the manual brake to stop the turbine. C A U T I O N! > Do not depress the manual brake button if turbine speed is zero. This will cause the turbine shaft to rotate in reverse. This will cause damage to the turbine assembly. 18

21 RMA-202 Test Stand - Maintenance MAINTENANCE There should be no maintenance required. If any maintenance is required, consult factory for spare part availability. 19

22 RMA-202 Test Stand - Warranty Policies WARRANTY POLICIES LIMITED WARRANTY will replace or repair without charge any part and/or equipment that fails within the specified time (see below) because of faulty workmanship or material, provided that the equipment has been used and maintained in accordance with s written safety and operating instructions, and has been used under normal operating conditions. Normal wear items are excluded. THE USE OF OTHER THAN RANSBURG AP- PROVED PARTS VOIDS 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, (example: 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 WAR- RANTY. THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. RANS-BURG ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME, WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTH- ERS. EXCLUSIONS: If, in s opinion the warranty item in question, or other items damaged by this part was improperly installed, operated or maintained, 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. FLUID HANDLING: One (1) year from date of purchase (example: Totalizer, CCV Valves, etc.). AIR BEARING ROTATORS: Fifteen thousand (15,000) hours or three (3) years, whichever occurs first. Warranty period begins on the date of purchase. RANSBURG S ONLY OBLIGATION UNDER 20

23 RMA-202 Test Stand - Appendix APPENDIX PAINT AND SOLVENT SPECIFICATIONS REA TM / EFM TM EVOLVER RECOMMENDED VISCOSITY USING A ZAHN NO TO 30 SEC PAINT ELECTRICAL RESISTANCE**.1 MW TO RECOMMENDED DELIVERY (UP TO) 1000 cc/min REM TM / M90 TM 18 TO 30 SEC.1 MW TO 1500 cc/min NO. 2 HAND GUN 20 TO 60 SEC.1 TO 1 MW 180 cc/min TURBODISK TM 20 TO 60 SEC.1 MW TO 1000 cc/min AEROBELL II*** AEROBELL AEROBELL 33 RMA TM TO 60 SEC.1 MW TO 500 cc/min Chemical Name DICHLOROMETHANE VM & P NAPHTHA ACETONE METHYL ACETATE BENZENE ETHYL ACETATE 2-BUTANONE ISO-PROPYL ACETATE ISOPROPYL ALCOHOL 2-PENTANONE METHANOL PROPYL ACETATE TOLUOL METHYL ISOBUTYL KETONE ISOBUTYL ACETATE ETHANOL BUTYL ACETATE ETHYLBENZENE 1-PROPANOL 2-BUTANOL XYLOL AMYL ACETATE 2-METHYLPROPANOL METHYL AMYL 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 GUIDE TO USABLE SOLVENT SELECTION Common Name Methylene Chloride Naptha MEK IPA MPK Methyl Alcohol n-propyl Acetate Toluene MIBK Ethyl Alcohol n-propyl Alcohol sec.-butyl Alcohol Xylene iso-butyl Alcohol MIAK n-butyl Alcohol MAK SC#100 DIBK Amyl Alcohol Butyl Cellosolve SC#150 Category Chlorinated Solvents Aliphatic Hydrocarbons Ketones Esters Aromatic Hydrocarbons Esters Ketones Esters Alcohols Ketones Alcohols Esters Aromatic Hydrocarbons Ketones Esters Alcohols Esters Aromatic Hydrocarbons Alcohols Alcohols Aromatic Hydrocarbons Esters Alcohols Esters Ketones Alcohols Glycol Ethers Ketones Ketones Aromatic Hydrocarbons Ketones Alcohols Ketones Glycol Ethers Alcohols Aromatic Hydrocarbons Aromatic Hydrocarbons * CAS Number: Chemical Abstract Service Number. ** Electrical Resistance using the Meter. *** Solvent Base Configuration Only. Information Obtained From: The lowest temperature at which a volatile fluid will ignite. Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1.0 Flash Point (TCC) 65 o F -18 o F 90 o F 12 o F 24 o F 16 o F 35 o F 53 o F 104 o F 50 o F 55 o F 48 o F 60 o F 69 o F 78 o F 64 o F 74 o F 72 o F 79 o F 106 o F 82 o F 96 o F 96 o F 95 o F 164 o F 102 o F 111 o F 111 o F 120 o F 133 o F 154 o F 111 o F 149 o F 203 o F *CAS Number NOTE: Chart provides resistance and control information that we feel is necessary when using equipment Evap. Rate F A S T E R S L O W E R Elec. Res.** HIGH HIGH HIGH MEDIUM MEDIUM MEDIUM HIGH MEDIUM HIGH HIGH MEDIUM MEDIUM MEDIUM MEDIUM HIGH MEDIUM HIGH HIGH All rights reserved. 21

24 VISCOSITY CONVERSION CHART A-4 A-3 A-2 A-1 A B C D E F G H I J K L M N O P Q R S T U V W Poise Centipoise Parlin 7 Parlin 10 Fisher 1 Fisher 2 Ford Cup 3 Ford Cup 4 Gardner - Holdt Bubble Gardner - Lithographic Krebs Unit KU Saybolt Universal SSU Zahn 1 Zahn 2 Zahn 3 Zahn 4 Zahn 5 Sears Craftsman Cup Din Cup 4 RMA-202 Test Stand - Appendix 22

25 RMA-202 Test Stand - Appendix VISCOSITY CONVERSION CHART (Continued) Poise Centipoise Parlin 7 Parlin 10 Fisher 1 Fisher 2 Ford Cup 3 Ford Cup 4 Gardner - Holdt Bubble Gardner - Lithographic Krebs Unit KU Saybolt Universal SSU Zahn 1 Zahn 2 Zahn 3 Zahn 4 Zahn 5 Sears Craftsman Cup Din Cup X Y Z Z-1 Z-2 Z-3 Z-4 Z-5 Z Note: All viscosity comparisons are as accurate as possible with existing information. Comparisons are made with a material having a specific gravity of All rights reserved. 23

26 RMA-202 Test Stand - Appendix I.D. (inches) 1/8 3/16 1/4 5/16 3/8 1/2 cc/ft VOLUMETRIC CONTENT OF HOSE OR TUBE (English Units) Cross Section Length (in. 2 ) 5ft. (60 ) 10ft. (120 ) 15ft. (180 ) 25ft. (300 ) 50ft. (600 ) gal..4 fl. oz..007 gal..9 fl. oz..013 gal. 1.6 fl. oz..020 gal. 2.5 fl. oz..029 gal. 3.7 fl. oz..051 gal. 6.5 fl. oz..006 gal..8 fl. oz..014 gal. 1.8 fl. oz..025 gal. 3.3 fl. oz..040 gal. 5.1 fl. oz..057 gal. 7.3 fl. oz..102 gal fl. oz..010 gal. 1.2 fl. oz..022 gal. 2.8 fl. oz..038 gal. 4.9 fl. oz..060 gal. 7.6 fl. oz..086 gal fl. oz..153 gal fl. oz..016 gal. 2.0 fl. oz..036 gal. 4.6 fl. oz..064 gal. 8.2 fl. oz..100 gal fl. oz..143 gal fl. oz..255 gal fl. oz..032 gal. 4.1 fl. oz..072 gal. 9.2 fl. oz..127 gal fl. oz..199 gal fl. oz..287 gal fl. oz..510 gal fl. oz. I.D. (mm) cc/m VOLUMETRIC CONTENT OF HOSE OR TUBE (Metric Units) Cross Section Length (mm 2 ) 1.5m 3.0m 4.5m 6.0m 7.5m cc 30.5 cc 45.8 cc 61.1 cc 76.3 cc cc 73.9 cc cc cc cc cc cc cc cc cc cc cc cc cc cc 05/2004 Illinois Tool Works Inc. All rights reserved. 24

27 Service Manual Price: $30.00 (U.S.) Manufacturing 1910 North Wayne Street Angola, Indiana Telephone: 260/ Fax: 260/ Technical/Service Assistance Telephone: 800/ Fax: 419/ Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts All rights reserved. Models and specifications subject to change without notice. Form No. Litho in U.S.A. 03/13