REA III 100KV MODEL: IMPORTANT

Transcription

1 REA III 100KV AUTOMA OMATIC APPLICATOR SERVICE MANUAL (Replaces AA ) May MODEL: IMPORTANT ANT: : 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: (Euro) $30.00 (U.S.)

2 : This manual has been changed from revision AA to revision. Reasons for this change are noted under Manual Change Summary inside the back cover of this manual.

3 REA III 100kV Automatic Applicator - Contents CONTENTS SAFETY: SAFETY PRECAUTIONS... 1 HAZARDS/SAFEGUARDS ATEX EUROPEAN ATEX DIRECTIVE... 5 EUROPEAN ATEX LABELS INTRODUCTION: GENERAL DESCRIPTION... 9 SPECIFICATIONS... 9 INSTALLATION: INSTALLING... TYPICAL REA AUTOMATIC APPLICATOR INSTALLATION - WATERBORNE... ATOMIZER ASSEMBLY SELECTION... OPERATION: SAFETY PROCEDURES MAINTENANCE: ROUTINE SCHEDULE ATOMIZER ASSEMBLY CLEANING PROCEDURE FLUSHING PROCEDURES SERVICE TROUBLESHOOTING GUIDE EVALUATING RESULTS OF SCI AND CURRENT DEMAND TEST PARTS IDENTIFICATION: REA III 100KV AUTOMATIC APPLICATOR EXPLODED VIEW REA III AUTOMATIC APPLICATOR / SOLVENTBORNE SYSTEMS PARTS LIST REA III AUTOMATIC APPLICATOR / WATERBORNE SYSTEMS PARTS LIST... WARRANTY POLICIES: LIMITED WARRANTY PAGE

4 REA III 100kV Automatic Applicator - Safety SAFETY SAFETY PRECAUTIONS Before operating, maintaining or servicing any ITW Ransburg electrostatic coating system, read and understand all of the technical and safety literature for your ITW Ransburg products. This manual contains information that 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 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 ITW Ransburg 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 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, prior to installing, operating, and/or servicing this equipment. W A R N I N G > The hazards shown on the following page may occur during the normal use of this equipment. Please read the hazard chart beginning on page 2. 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 Ransburg system, contact your local ITW Ransburg representative or ITW Ransburg. 1

5 REA III 100kV Automatic Applicator - Safety AREA HAZARD Tells where hazards Tells what the hazard is. may occur. Spray Area 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 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 o F (37.8 o C). Spray booth ventilation must be kept at the rates required by NFPA-33, OSHA, and local codes. In addition, ventilation must be maintained during cleaning operations using flammable or combustible solvents. Electrostatic arcing must be prevented. Test only in areas free of combustible material. Testing may require high voltage to be on, but only as instructed. Non-factory replacement parts or unauthorized equipment modifications may cause fire or injury. If used, the key switch bypass is intended for use only during 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, and OSHA requirements. 2

6 REA III 100kV Automatic Applicator - Safety AREA Tells where hazards may occur. General Use and Maintenance HAZARD Tells what the hazard is. Improper operation or maintenance may create a hazard. Personnel must be properly trained in the use of this equipment. SAFEGUARDS Tells how to avoid the hazard. Personnel must be given training in accordance with the requirements of NFPA-33. Instructions and safety precautions must be read and understood prior to using this equipment. Comply with appropriate local, state, and national codes governing ventilation, fire protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, and your insurance company requirements. Electrical Equipment High voltage equipment is utilized. Arcing in areas of flammable or combustible materials may occur. Personnel are ex-posed 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. The power supply, optional remote control cabinet, and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas. Refer to NFPA-33. Turn the power supply OFF before working on the equipment. Test only in areas free of flammable or combustible material. Testing may require high 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. 3

7 REA III 100kV Automatic Applicator - Safety AREA Tells where hazards may occur. HAZARD Tells what the hazard is. SAFEGUARDS Tells how to avoid the hazard. Spray Area / High Voltage Equipment This is a high voltage device that can produce electrical arcs capable of igniting coating materials. Parts being sprayed must be supported on conveyors or hangers and be grounded. The resistance between the part and ground must not exceed 1 megohm. (Reference NFPA-33.) A safe distance must be maintained between the parts being coated and the atomizer bell. A distance of at least 1 inch for each 10 KV of power supply output voltage is required at all times. Parts must be supported so that they will not swing and reduce the clearance specified above. 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. Unless specifically approved for use in hazardous locations, the power supply and other electrical equipment must not be used in Class I, Division 1 or 2 locations. 4

8 REA III 100kV Automatic Applicator - Atex EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, The following instructions apply to equipment covered by certificate number Sira 08ATEX5040X: 1. The equipment may be used with flammable gases and vapors with apparatus groups II and with temperature class T6. 2. The equipment is only certified for use in ambient temperatures in the range C to +40 C and should not be used outside this range. 3. Installation shall be carried out by suitably trained personnel in accordance with the applicable code of practice e.g. EN : Inspection and maintenance of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice e.g. EN Repair of this equipment shall be carried out by suitable trained personnel in accordance with the applicable code of practice e.g. EN Putting into service, use, assembling, and adjustment of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer's documentation. Refer to the "Table of Contents" of this service manual: a. Installation b. Operation c. Maintenance d. Parts Identification 7. Components to be incorporated into or used as replacement parts of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer's documentation. 8. The certification of this equipment relies upon the following materials used in its construction: If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection provided by the equipment is not compromised. Aggressive substances: e.g. acidic liquids or gases that may attack metals, or solvents that may affect polymeric materials. Suitable precautions: e.g. regular checks as part of routine inspections or establishing from the material's data sheets that it is resistant to specific chemicals. Refer to "Specifications" in the "Introduction" section: a. All fluid passages contain stainless steel or nylon fittings. b. High voltage cascade is encapsulated with a solvent resistant epoxy. 9. A recapitulation of the certification marking is detailed in the "Atex" section, on the next page, drawing numbers: 19688, 72562, 76454, 76854, 76896, 77059, 78886, , and LEPS The characteristics of the equipment shall be detailed e.g. electrical, pressure, and voltage parameters. The manufacturer should note that, on being put into service, the equipment must be accompanied by a translation of the instructions in the language or languages of the country in which the equipment is to be used and by the instructions in the original language. 5

9 REA III 100kV Automatic Applicator - Atex REA III 100kV Automatic Applicator ATEX Product Marking Definitions Ex Certificate Number: Sira 08ATEX5040X Sira = Notified Body performing EC-type examination 08 = Year of certification ATEX = Reference to ATEX Directive 5 = Protection Concept Code (code 5 is titled Encapsulation) 040 = Document serial number X = Special conditions for safe use apply Label Label Special conditions for safe use: The REA-III Automatic Applicator shall only be used with associated XX, XX, LEPS , LEPS , and HV Control Units. Product Marking II 2 G Ex = Specific marking of explosive protection II = Equipment Group hazardous area characteristics 2 = Equipment Category G = Type of explosive atmosphere (gases, vapors, or mists) EEx 0.24mJ = The REA-III Automatic Applicator is suitable for use in automatic spraying installations complying with EN as they are a Type A class with a discharge energy limit of 0.24mJ. Label Label Label

10 REA III 100kV Automatic Applicator - Atex Label Label Label Label LEPS0016 7

11 REA III 100kV Automatic Applicator - Atex S 8

12 REA III 100kV Automatic Applicator - Introduction INTRODUCTION GENERAL DESCRIPTION The REA III 100kV Automatic Applicator applies a high voltage charge to the coating materials at the point of atomization using a 100kV power supply. This electrostatic charge allows a more efficient, uniform application of coating material to the front, edges, sides, and back of products, making it highly suitable for applying a wide range of coatings to a variety of surface configurations: large targets, small parts, tubular wares, concave and recessed parts, etc. It is available as a grounded fluid system for solvent reduced coatings such as enamels, lacquers, epoxys, etc. One of the many safety features of the REA III 100 kv Automatic Applicator is the capability of limiting, to a desirable level, the electrical discharge which is available from the charging electrode. When organic solvent base paints are being sprayed, this level must not exceed 0.25 mj of energy. In order to achieve this limitation, it is necessary to prevent any flow of energy from the paint supply through the paint line to the applicator electrode. This is accomplished by grounding the paint line at the applicator. SPECIFICATIONS Environmental / Physical Operating Voltage: 100kV maximum Operating Fluid Pressure: psi (0-6.9 bar) Operating Air Pressure: psi (0-6.9 bar) Flow Rate: Short Circuit Current: 1000 cc/min. maximum (viscosity dependent) 150 Microamperes Air and Fluid Nozzles: Any ITW Ransburg Air and Fluid Nozzle combination. (See Nozzle Selection in the Operation section.) Optional Hose and Cable Lengths: 25, 36, 50, 75, and 100 ft. (8m, 11m, 15m, 23m, and 31m) 9

13 REA III 100kV Automatic Applicator - Introduction S 10

14 REA III 100kV Automatic Applicator - Installation INSTALLA ALLATION > Installation of the equipment MUST be in compliance with all Federal, State, Local and National codes. > The power supply MUST be located OUTSIDE of the spray area. > Personnel MUST be GROUNDED to prevent a shock or spark during electrostatic operation. > Install and route the hoses and cables so they are NOT exposed to temperatures in excess of 120 F (49 C) and so that all hose and cable bends are NOT less than a 6-inch (15 cm) radius. Failure to comply with these parameters could cause equipment malfunctions that might create HAZARDOUS CON- DITIONS INSTALLING W A R N I N G 1. To connect the high voltage cable, remove the cable retainer bracket and remove the protective cap for the power supply high voltage cable socket. Insert the high voltage cable (and plug) into socket. Gently hand-tighten the cable retaining nut. Reattach the bracket. 2. The control unit MAY be connected through conduit with an explosion-proof terminal on or near the spray booth where it will be convenient, or may be connected with a line cord depending upon application requirement. > Refer to the Power Supply Service Manual for the circuit diagram and instructions to connect the power supply. W A R N I N G > The power supply MUST be located outside of the spray area. Install units in accordance with the requirements of local regulations. 3. Install Filters: Install the optional fluid filter on output of fluid supply. Detail depends on whether pressure tank, pump unit, recirculating system, etc. is used. Filter must be installed vertically with drain valve down and arrow pointing in direction of flow (see Figure 1). 4. Install Line Hose (Air or Fluid): > ITW Ransburg supplies a standard 25 ft. (8m) hose. Optional hose lengths of 36 ft. (11m), 50 ft. (15m), 75 ft. (23m), and 100 ft. (31m) are available. To meet various length requirements, the hose fitting on one end has not been attached. Determine the hose length that is needed and cut the hose. Attach the other fitting as follows: a. Lubricate all fittings with petroleum jelly. b. Screw ferrule counter-clockwise onto hose until it bottoms. Then back it off about 1/8- inch (3mm). > The union stem will not seat if the hose is bottomed against the ferrule. 11

15 REA III 100kV Automatic Applicator - Installation c. Install nut over union stem and start the stem into the hose. d. Using the 1/8-inch Allen wrench, screw the union stem into the hose until it bottoms against the ferrule. e. Connect one end of one hose to the appropriate fitting on the bottom of the applicator body and the other end to the power supply pressure switch for trigger air. Attach the other hose to the atomizing air source. W A R N I N G > NEVER use wooden boxes, pallets, or boards as wood will absorb moisture and is a poor insulator. Isolation stand MUST be at least 18-inches from the grounded booth wall, chain link fence, or other grounded objects. Air hoses to the pressure pot or pump on the insulating stand should be nonconductive. Many rubber hoses will have static grounding circuits or carbon content and are NOT suitable. Air regulators for pots or pumps should be mounted remotely outside the fence or cage area to facilitate changes in pressure without shutting the system down. Grounding hooks at the cage MUST be used to ground portions of the system when personnel are working close by. Figure 1: Installing Line Hose TYPICAL REA AUTOMA OMATIC APPLICATOR INSTALLA ALLATION - WATERBORNE Using waterborne coating with electrostatic equipment requires that the fluid source should be isolated from ground and other precautions be taken to ensure operator safety and system efficiency. The following guidelines should be followed: The fluid lines and source MUST be isolated from ground. An isolating paint stand or similar isolating (non-porous) material MUST be used. Fluid lines to the applicator MUST be protected from scraping and abrasion on the floor or sharp metal edges that could lead to voltage pinholing and loss of kv on the charged system. Cleanliness and maintenance are extremely critical. Fully discharge system capacitance prior to service. W A R N I N G > System capacitance must be fully discharged prior to any service or maintenance of the applicator. W A R N I N G > ALL charged (isolated) systems MUST be inside a fence or cage to prevent contact by personnel. An interlock system MUST be provided that interrupts high voltage flow to the applicator if the gate is opened. 12

16 REA III 100kV Automatic Applicator - Installation Paint Preparation A proper paint mixture is essential to electrostatic operation. Paint test equipment may be obtained through your ITW Ransburg representative. Consult ITW Ransburg literature Paint Related Information for REA and REM Applicators manual for paint formulation information. For further paint formulation and testing procedures, consult your ITW Ransburg representative and/or paint supplier. Atomizer Assembly Selection The Atomizer Assembly Selection charts are provided to give you a comparison of the air caps and fluid nozzles. THE CHOICE OF ATOMIZER ASSEMBLY SHOULD DEPEND ON QUALITIES DESIRED AND MUST BE VERIFIED BY ACTUAL TRIAL. See you authorized ITW Ransburg distributor for atomizer demonstration. C A U T I O N > A counter-clockwise turn of the air cap may loosen the fluid nozzle and cause air to get into the paint or paint to cross over into the air passages. Applicator To Target Distance Mount the applicator 6-12-inches ( mm) maximum from the target for best operation. Spray Pattern Adjustment The spray pattern of fan atomizers is adjustable from a small circle to an elongated oval, approximately inches ( mm) across the useable long axis at 8-10-inches ( mm) from the target. The swirl atomizer assemblies produce a round pattern from 5-9-inches ( mm) in diameter. To adjust pattern size, increasing fan air pressure will expand the pattern, a reduction will decrease it. To change the spray pattern axis of fan atomizers from horizontal to vertical, loosen retainer ring, rotate the air cap clockwise to the desired position, and gently tighten the ring. 13

17 REA III 100kV Automatic Applicator - Installation ATOMIZER ASSEMBLY SELECTION REA NOZZLES (Conventional Spray) Air Cap Separate Pressure Part Fluid Nozzle Orifice Retaining Reducer Number Part Number ID Ring (Black) Swirl LREA0002 LREA0003 Round R (1.4mm) R (1.8mm) R (1.1mm) R (0.7mm) R (1.2mm) (1.4mm) (1.8mm) (1.1mm) (0.7mm) (1.2mm) (1.4mm) (1.8mm) (1.1mm) (0.7mm) (1.2mm) REA NOZZLES (HVLP) Air Cap Separate Pressure Part Fluid Nozzle Orifice Retaining Reducer Number Part Number ID Ring (White) (1.4mm) (1.8mm) (2.2mm)

18 REA III 100kV Automatic Applicator - Operation OPERATION SAFETY PROCEDURES W A R N I N G > The simple safety measures outlined in the Safety section are vital. Failure to observe them could cause a spark capable of starting a fire. 1. The articles being coated MUST be grounded at all times. 2. All components of the applicator system MUST be grounded at all times. 3. All contact points MUST be free of any accumulation of non-conductive residue. 4. All electrically conductive objects, especially solvent containers, within the spray area MUST be either removed or grounded. Any tool, if used improperly, can be dangerous. Safety is ultimately the responsibility of those using a tool. In like manner, safe operation of electrostatic coating processes is the responsibility of those who use such processes and those who operate electrostatic coating equipment. It is most important that equipment operators and supervisory personnel understand the requirements for safe operations. Additional cards summarizing these safety requirements are available from ITW Ransburg on request. These cards should be posted in the spraying area so that they can be readily referred to and serve as a reminder to personnel that area of responsibility. Additional copies of Cleaning Safety Requirements are available upon request. Each user should examine his own coating operation, develop his own safety program and ensure that his workers follow correct procedures. ITW Ransburg hopes that the information it provides is helpful to the user in establishing such a program. In addition to the available cards, labels, brochures, and service manuals, the user should consult other standards and recognized safety authorities. Local codes and authorities also have standards to be followed in the operation of your spray equipment. Your insurance carrier will be helpful in answering questions that arise in your development of spray coating procedures. All personnel MUST read and understand the following ITW Ransburg literature, Technical Supplement for All Products. W A R N I N G > If ANY symptom of improper operation occurs suspend use of the unit until the problem has been diagnosed and corrected. See the appropriate Troubleshooting Guide or contact your ITW Ransburg representative. 15

19 REA III 100kV Automatic Applicator - Operation W A R N I N G > Verify that the applicator body assembly is actually grounded before operating it This is done with a fully connected and operation system, by placing one lead of an ohm meter to the body assembly and the other to the building electrical ground (cold water pipe, building structure, etc.). The reading should be essentially zero. > If a reading much greater than zero is obtained, check that the power supply is grounded. Place one lead of the ohm meter on the building electrical ground and the other on the high voltage cable outlet bushing. If the reading is much greater than zero, reconnect the power supply ground. If the meter reads zero, check the high voltage cable. Place one lead on the high voltage cable retaining nut and the other lead on the applicator body assembly. If the reading is much greater than zero, the braided cable may be defective and should be replaced. 1. Parts, Equipment and Supplies: a. Ground the spray booth, the paint tank, and the conveyor. b. Ground ALL solvent containers. c. Ground ALL work holders and hooks and keep them free of paint. d. See that no more than one gallon of solvent per safety container per operator is inside the work area. 2. Personel Procedures: a. GROUND ALL PERSONS IN ALL SPRAY AREAS by requiring that they wear conductive soled shoes or personnel grounding straps. (See ITW Ransburg Safety Literature Handbook - Electrostatic Safety Information from ITW Ransburg.) b. Turn the power supply OFF prior to cleaning or working on the equipment. c. NEVER immerse any part of, or all of a spray applicator in any liquid, while assembled. d. Personnel MUST stay out of the spray booth during operation. 3. Ventilation: Electrostatic attraction greatly reduces paint overspray, thereby reducing ventilation requirements. An exhaust velocity of 100 to 150 FPM at the spray position is normally adequate. Exhaust system (and conveyor) MUST be interlocked with the triggering function. W A R N I N G > Exhaust system and conveyor must be interlocked with high voltage e. See that the power supply is grounded and located outside the spray area. f. See that conductive flooring is provided in all spray areas. g. See that the proper fire extinguishing equipment is provided. 16

20 REA III 100kV Automatic Applicator - Operation 4. Housekeeping: S Good housekeeping is always necessary to ensure quality finishes, eliminate rejects, and reduce service requirements (see OSHA standards). a. Periodically strip all workholders to maintain proper grounding of parts. b. Establish adequate cleaning and maintenance schedules based on observation of initial production characteristics. c. Employ fire protection measures, including proper storage of paints, solvents, and waste, plus ready access to fire extinguishing equipment. Provide water sprinklers, CO 2, or chemical fire extinguishers within the spray area (check local fire codes). 17

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22 REA III 100kV Automatic Applicator - Maintenance MAINTENANCE W A R N I N G > The user MUST read and be familiar with the SAFETY INSTRUCTIONS in this manual. > If compressed air is used in cleaning, REMEMBER THAT HIGH PRESSURE AIR CAN BE DANGEROUS AND SHOULD NEVER BE USED AGAINST THE BODY. It can blind, deafen, and may even penetrate the skin. If used for cleaning equipment, the users should wear safety glasses. > ALWAYS turn the control unit power off prior to cleaning or servicing equipment. > Be SURE the power is OFF and the system is grounded BEFORE using solvent to clean ANY of the quipment. > DO NOT OPERATE A FAULTY APPLICATOR > When using cleaning solvent, standard health and safety precautions should apply. ROUTINE SCHEDULE Follow these maintenance steps to extend the life of the applicator and ensure efficient operation: Several Times Daily: Turn the control unit power to OFF Inspect the air cap for fluid/solvent accumulation. Clean as frequently as necessary with a soft bristled brush and a suitable solvent. > NEVER remove the fluid nozzle assembly while paint is in the applicator or paint may clog the air passages. Clogged air passages will cause poor atomization and electrical shorting. Air passages which are clogged with conductive material may lead to excessive current output levels and consequent low operating voltage and long range electrical damage. Before undertaking any atomizer assembly procedure, see Atomizer Assembly Cleaning Procedure in the Maintenance section. > The applicator MUST be tilted front down to remove the air cap and/or fluid nozzle. Failure to do so may allow paint to enter the air passages, thereby reducing air flow and damaging the applicator barrel/cascade. Applicators may be flushed in lieu of tilting. However, they must be either flushed or tilted down Clean all insulating surfaces in the system. Remove paint accumulation from the exterior of the applicator and high voltage cable with a solvent dampened cloth. C A U T I O N W A R N I N G > NEVER soak or submerge the electrical components of the applicator (i.e. barrel, transformer, cable). Damage and failure may occur. Daily (at the start of each shift): Verify that ALL solvent safety containers are grounded Check within 20 feet of the point of operation (of the applicator) and remove or ground ALL loose or ungrounded objects. 19

23 REA III 100kV Automatic Applicator - Maintenance Inspect workholders for accumulated coating materials, removing such accumulations. Check that atomizer assembly is clean and undamaged. Straighten the applicator electrode if necessary. C A U T I O N > When straightening the electrode, be careful not to distort the fluid nozzle orifice. 2. Turn the fluid/solvent supply OFF. 3. Turn the atomizing air and fan air OFF. 4. Turn piston air OFF. 5. Wipe the applicator, cable, and hoses with a rag and a suitable cleaning solvent. 6. Flush the lines and allow the solvent to remain in the lines unpressured. (See Flushing Procedures in the Maintenance section of this manual.) Clean the fluid filter, if used. Turn the control unit power ON. The applicator s red transformer light should light when triggered. Run a current/voltage output test. Electrical Current Output Test est 1. Turn the fluid/solvent supply OFF. 2. Turn high voltage on at applicator. 3. Slowly approach the applicator electrode to any grounded object and make contact. 4. Monitor the current output reading on the power supply meter. As applicator approaches, ground current should increase near 120 ma. Overload current should trip, shutting off high voltage. Overload indication should come on. 5. Release the trigger and turn the power supply power OFF. If the control unit does not trip, DO NOT use the applicator until the problem has been corrected. (See the Troubleshooting Guide in the Maintenance section of this manual.) Shut-Down (and at the end of each shift) 1. Turn the power supply power OFF. > If the shut-down time is to be short, the lines may not require flushing, depending on the type of coating material used. If the solids in the material settle slowly, the lines will not need to be flushed as soon after shut-down as with fast settling solids. The fluid/solvent being used and the length of time that the lines will be shutdown will determine the need for flushing. Metallic paint and primer will require flushing sooner than some other types of coating materials. C A U T I O N > If the coating material is fast settling and if the lines are not flushed soon enough, the applicator s fluid passages as well as the lines may become clogged and cause excessive down-time and/or service and repair. Weekly Check the entire system for damage, leaks, and paint accumulation. Clean the atomizer assembly. 20

24 REA III 100kV Automatic Applicator - Maintenace ATOMIZER ASSEMBLY CLEANING PROCEDURES Routine Cleaning Equipment Needed An appropriate solvent Solvent safety container (grounded) Small soft bristled brush ITW Ransburg special multi-purpose wrench from the installation kit. C A U T I O N > To avoid damage to the fluid nozzle, needle/electrode, the fluid pressure MUST be released by triggering the applicator prior to removing the tip. > The applicator MUST be tilted front down to remove the air cap and/or fluid nozzle. Failure to do so may allow fluid/ solvent to enter the air passages, thereby reducing air flow and damaging the applicator barrel/cascade. Applicators may be flushed in lieu of removing nozzles. However, they MUST be either flushed prior to, or tilted down during nozzle removal > The control unit power MUST always be off when removing the nozzles or any other service to the applicator. > Using any tool other than the ITW Ransburg wrench to remove or reinstall the fluid nozzle may distort or damage it. For efficient operation, keep the applicator s exterior and the high voltage cable clean and free of paint accumulation and dirt. This prevents the loss of voltage to ground with a resulting reduction in electrostatic effect. Solvent accumulation at the air cap orifices reduces atomization quality and increases the potential for paint spits. Clean the air cap with a brush and cleaning solvent as often as needed to ensure good atomization. > NEVER wrap the applicator in plastic to keep it clean. A surface charge may build-up on the plastic surface and discharge to the nearest grounded object. Efficiency of the applicator will also be reduced and damage or failure of the applicator components may occur. WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THE WARRANTY. W A R N I N G Proceed as Follows: 1. Turn the power supply unit power OFF. 2. Release the trigger. 3. Turn the fluid/solvent flow OFF. 4. See Service section in the Maintenance section of this manual for Disassembly Procedures. W A R N I N G > Any damage to the applicator may result in UNSAFE operating conditions. 5. Clean the removed parts with a soft bristled brush and suitable solvent. 21

25 REA III 100kV Automatic Applicator - Maintenance C A U T I O N > Metal tools and wire brushes must NEVER be used. NEVER use a cleaning tool that is harder than the plastic parts. If a deposit cannot be removed with the solvent and a rag or the soft brush, soak the part in the solvent ONLY until the deposit can be removed NEVER SOAK THE APPLI- CATOR BODY, BARREL, OR TRANS- FORMER SERVICE All repairs should be made on a clean, flat surface. If a vise is used to hold parts during service or repair, DO NOT clamp onto plastic parts and always pad the vise jaws During assembly, ALWAYS lubricate o-rings, chevron seals, and the threads on part Items #45, 57, 58, 43, and 49, as indicated, with a light coat of petroleum jelly. (Teflon o-rings do not need lubrication.) FLUSHING PROCEDURES 1. Turn the control unit power OFF. 2. Turn the fluid/solvent supply OFF. 3. Turn the atomizing air supply OFF. 4. Activate dump air and flush with a suitable cleaning solvent until it is clear of fluids. Air purge the dump line. 5. De-activate dump air and activate trigger air until the applicator fluid passage is clear. 6. Disconnect the solvent supply. 7. Activate the trigger valve until it is clear of solvent. After the preceding steps are complete, the applicator is ready for color change, storage, or service. C A U T I O N > Do NOT USE any silicone lubrication in this system C A U T I O N > ALWAYS remove the applicator from the work site for service or repair The following tools will be needed: Special wrench Nozzle wrench /32 Allen wrench Open end wrenches: 15/16, 7/8, 11/16, 9/16, 7/16, 3/4, 3/8, and 1/4 Screwdriver (broad) Paper clip (or similar rigid wire) Lock-Tite, medium strength, P/N Plastic or wood dowel rod, 5/16-inch diameter C A U T I O N > Do NOT allow the fluid lines to stand empty without flushing first This will cause dried solvent flaking into and clogging of the fluid lines, applicator passages, and nozzles. 22

26 REA III 100kV Automatic Applicator - Maintenance Remove the Applicator from the Work Site 1. Flush the applicator (see Flush Procedure in the Maintenance section). W A R N I N G > 2. Turn ALL power, air, and fluid (coating material and solvent) OFF at the source. 3. Detach fluid line from fitting [66]. 4. Detach the air line fittings from applicator air fittings [35] and [34]. 5. Detach the high voltage cable [70] from the applicator by unscrewing cable retaining nut [32] and pulling the cable straight out of resistor housing [37]. > If the high voltage cable is to be replaced, see High Voltage Cable Replacement in the Maintenance section. 6. Loosen set screws [28] and remove the applicator from the work site. Nozzle and Electrode Cleaning or Replacement C A U T I O N > NEVER bend the electrode > See Nozzle Cleaning Procedures in the Maintenance section. 1. Air Nozzle: a. Unscrew air nozzle [1] from barrel [8] and clean or replace it. b. Screw the cleaned or new nozzle assembly onto barrel [8]. 2. Fluid Nozzle: a. Remove air nozzle [1] from barrel [8] and clean or replace it. b. With the nozzle wrench on the wrench flats, remove fluid nozzle [2]. c. Clean or replace the fluid nozzle. d. Screw the cleaned or new fluid nozzle [2] into barrel [8]. Secure with the nozzle wrench and release trigger air to applicator. > It may be necessary to loosen packing nut [21] with the spanner wrench and retract the trigger to seat the nozzle completely. e. Screw air nozzle [1] onto barrel [8]. > If packing nut [21] has been loosened, tighten it until needle shaft [7] moves in and out with firm resistance. > If the fluid nozzle is replaced, there is a good chance that the needle tip assembly [3] will need to be replaced too. A worn neede tip assembly may not always seat well in a new fluid nozzle. 19

27 REA III 100kV Automatic Applicator - Maintenance Needle Tip Assembly (Electrode) 1. See Nozzle and Electrode Cleaning or Replacment - Steps 1 and 2 to remove the air cap and fluid nozzles. 2. Insert the end of a paper clip (or similar rigid wire) through the hole at the rear of the needle shaft [7] to keep it from rotating. 3. Hold barrel [8] in a vertical position, front end up, and unscrew needle tip [3]. > The vertical position is to keep adaptor [4] from falling out. 2. Disengage nuts [58] and [57] from valve rod extension [23]. 3. Loosen barrel extension [11] with the spanner wrench. 4. Disengage fittings [10] and [9] and release fluid tube [69]. 5. Pull barrel [8] and body [26] STRAIGHT apart. C A U T I O N > The barrel and body MUST be pulled straight apart to avoid damage to the resistor housing [37]. C A U T I O N > Be SURE that adaptor [4] is in place and facing the right direction when the applicator is reassembled or the applicator will malfunction Barrel Removal > In normal operation and service, the barrel extension need never be removed from the barrel. It should be treated as a permanent part of the barrel. If it should be damaged and replacement becomes necessary, remove the barrel from it the same as it is removed from the body assembly AFTER the internal parts have been removed (see Barrel Disassembly ). > Gasket [13] should be kept with the body assembly if it is not to be replaced. > There is no need to remove retaining ring [12] or barrel nut [11] from barrel [8] unless they are damaged. If they are to be removed, lift one end of ring [12] out of its groove and spiral it off of the end of the barrel. Then nut [11] can be removed. To replace them on the barrel, slide nut [11] onto the barrel, place ring [12] against the back of the barrel, lift one end of it onto the barrel and spiral it on and into its groove. C A U T I O N > Spreading the retaining ring may break it 1. Remove piston housing [61], spring [60], and spring [59]. 6. Part Items #57, 58, 59, and 60 may be stored during barrel service by replacing them in the piston housing and reattaching it to the body. 24

28 REA III 100kV Automatic Applicator - Maintenance Barrel Disassembly 1. Remove air nozzle [1] from barrel [8]. 2. Remove fluid nozzle [2] from the front barrel with the nozzle wrench. 3. Remove valve rod extension [23] and adjusting nut [22] from needle valve rod [7]. 4. Remove packing nut [21] from the barrel chamber with the spanner wrench. > If the needle valve assembly does not pull out of the chamber easily, hold the barrel in a vertical position, front end up, and press down against a hard surface until parts [3] through [7] can be pulled from the front of the chamber. Then, insert the flat end of a smooth 5/16-inch plastic or wood dowel rod into the front barrel chamber and press the packing tube [15] and parts [17], [18], and [19] from the chamber. > The six (6) spring washers [20] will come out of the chamber at this point. 6. Slide parts [20], [18], [17], and [15] off of shaft [7]. C A U T I O N > DO NOT lose any of the spring washers The applicator MUST have six (6), correctly positioned, spring washers in order to function properly. 5. With a firm pull, remove the needle valve assembly [3] through [19] from the rear of the barrel chamber. C A U T I O N > During this operation, be CAREFUL that the interior surface of the chamber is NOT damaged (marred or scrateched). > This chamber is a seal area and the barrel will have to be replaced if it is damaged. > If parts [19] and [17] do not separate easily, wedge a knife blade between them and pry them apart. 7. Unscrew needle [3] from shaft [7] and slide parts [4], [5], and [6] off of the shaft. Barrel Assembly Clean all parts with a suitable, clean solvent. If the electrode is bent, straighten it CARE- FULLY by hand. Check all parts for damage or wear. Replace those that are damaged or worn with new parts. Replace chevron seals [5], o-rings [16], and u-cup [18] with new parts. 25

29 REA III 100kV Automatic Applicator - Maintenance C A U T I O N > To avoid damage to the chevron seals, the needle shaft assembly MUST be installed from the front of the barrel. 1. Place female chevron adaptor [6] onto the front of shaft [7] with the concave side toward the front. 2. Place the four (4) new chevron seals on shaft [7], concave sides forward, by carefully rotating them. C A U T I O N > DO NOT push the chevron seals straight onto the shaft. The shaft threads may damage the chevron bore and cause the applicator to malfunction. 3. Place male chevron adaptor [4] onto shaft [7] with the convex end rearward. > Part Items [4], [5], and [6] should seat together to form an unbroken seal. 4. Screw needle tip [3] onto shaft [7] hand tight. > Apply a light coating of petroleum jelly to the chevron seals. 5. Insert assembly [3] through [7] into the front barrel chamber. 6. Insert fluid nozzle [2] into the chamber and secure it firmly with the nozzle wrench. 7. Screw air nozzle [1] onto barrel [8] to protect needle [3] during the balance of the assembly procedures. 8. Place packing tube [25] over the end of shaft [7] through the rear barrel chamber. 9. Place the new u-cup [18] into rear needle seat retainer [17] with the open side out. > Seat the u-cup into the retainer very carefully with the eraser end of a pencil or a wood or plastic dowel rod. 10. Place the new o-ring [16] onto retainer [17]. 11. Place retainer [17] over shaft [7] with the open end toward the rear. 12. Place spacer [19] over shaft [7] flanged end first. Seat parts [15], [17], and [19] into the chamber carefully with the flat end of the tubular spanner tool. 13. Place the six (6) spring washers [20] onto shaft [7] with the first, third, and fifth ones cupped side rearward and the second, fourth, and sixth ones cupped side forward. C A U T I O N > There MUST be six (6) spring washers, alternately faced, or the applicator will malfunction. 26

30 REA III 100kV Automatic Applicator - Maintenance 14. Screw packing nut [21] into the chamber and secure it with the spanner wrench. > The packing nut should be tight enough that shaft [7] slides in and out with firm resistance. 15. Screw trigger adjustment nut [33] onto shaft [7] with the flanged end toward the rear. 16. Screw valve rod extension [23] onto shaft [7] with the flanged end toward the front. > The hexagonal flanges of [22] and [23] should face each other. Figure 2: Barrel Assembly 17. To adjust [22] and [23]: a. Push shaft [7] fully forward. > To prevent shaft [7] from rotating, secure it with a wire through the hole at the rear. > Fluid nozzle [2] must be firmly in place (see Step 6). b. Measure 21/32-inch (16.6mm) from the rear face of packing nut [21] to the rear face of hexagonal flange of the valve rod extension [23]. c. Secure the nut and rod extension together at that dimension by rotating nut [22] rearward until the two will not turn on the shaft. 27 d. Tighten the two by holding rod extension [23] with a 3/8-inch wrench and turning nut [22] against it with another 3/8-inch wrench.

31 REA III 100kV Automatic Applicator - Maintenance Barrel to Body Assembly 1. Remove piston housing [61] from body [26]. 5. Secure the barrel assembly with nut [11] and tighten. C A U T I O N > DO NOT lose parts stored in piston housing. C A U T I O N > Nut [11] should be secured hand tight only. NEVER apply more than 10 lbs ft (13.5 Nm) torque. 2. Place gasket [13] into the front body [26] chamber. > Secure the new gasket in place by splitting it at the top and pressing it into the chamber. The top is the broadest of the two large hole margins. 6. With the needle valve and piston shaft [52] fully forward, secure lock nuts [57] and [58] onto extension [23]. Allow 1/16-inch gap between nut [57] and shaft [52]. > Projection on nut [58] MUST face the rear of the applicator. 3. Place new o-ring [38] on resistor housing [37]. 4. Insert resistor housing [37] into the upper body chamber and slide the barrel assembly straight into the front body chamber over housing [37]. C A U T I O N > Be SURE that conductive sponge [36] is in place. If it is not, the applicator will eventually malfunction. C A U T I O N > The fluid valve shaft travel MUST be adjusted so that the air valve is always triggered FIRST. If the air does not turn on BEFORE the fluid, readjust nuts [57] and [58] in relation to shaft [52]. 7. Engage fluid tube [69] to barrel [8] with fittings [9] and [10]. > The needle shaft [7] should engage valve rod extension [23]. 28

32 REA III 100kV Automatic Applicator - Maintenance Resistor Assembly Replacement 1. Remove the high voltage cable (see High Voltage Cable Replacement in this section). 2. Remove the barrel assembly (see Barrel Removal in this section). 3. Remove resistor housing tube [31]. 4. Remove screw [29] and [30]. 5. Remove mounting support [27] and resistor housing [37] from the body chamber. 6. Place the new resistor assembly [37] into the body chamber. 7. Place new o-rings [38] and [39] on the new resistor assembly [37]. C A U T I O N > Be SURE that conductive sponge [40] is in place in the resistor housing chamber. 8. Place mounting support [27] in position on body [26] and secure with screws [29] and [30]. 9. Place resistor housing tube [31] over the end of resistor housing [37] and screw it into the body [8]. 10. Install a new conductive sponge [36] in the barrel chamber. > The old sponge MUST be removed Use a long wire with one end bent into a hook. C A U T I O N > If the conductive sponges are not in place, the applicator will malfunction 11. Replace the barrel assembly (see Barrel to Body Assembly in this section). 12.Install high voltage cable (see High Voltage Cable Replacement in this section). Valve Housing (Body) Service When service is performed on any of the body elements, it is best to remove the barrel assembly and resistor assembly (see Resistor Assembly Replacement in this section) in order to avoid damage to the nozzle, electrode or any of the plastic parts. After disassembly of any body element: Clean all parts with a suitable, clean solvent. Check all parts for damage or wear. Replace those that are damaged or worn with new parts. Replace all seals and o-rings. Fluid Valve (Trigger) 1. Disassembly: a. Rotate piston housing [61] to remove it from the valve chamber. b. Remove springs [59] and [60]. c. Turn nut [58] away from nut [57] using appropriate wrenches. d. Remove nuts [57] and [58] from shaft [23]. e. Remove the barrel assembly (see Barrel Removal in this section). f. Remove the resistor assembly (see Resistor Assembly Replacement in this section). 29

33 REA III 100kV Automatic Applicator - Maintenance g. Remove valve seal retaining nut [24] and o-ring [25] from the front of the valve chamber using a 3/8-inch nut driver. h. With a flat tipped wood or plastic dowel rod inserted into the front of the valve chamber, push piston assembly [52] through [56] out of the rear of the valve chamber. i. Secure piston shaft [52] in a 3/8-inch wrench (on the wrench flats) remove nut [56] with a 9/16-inch socket. j. Slide piston assembly [53], [54], and [55], from the shaft [52] and disassembly components by hand. k. Remove bushing assembly [50], [48], [49], and [51] from the valve chamber with a wrench. 2. Assembly: > Replace all o-rings. Replace packing cup [54] if it is worn. a. Secure retaining nut [24] and o-ring [25] in the front of the valve chamber using a 3/8- inch nut driver. b. Secure bushing assembly [50], [48], [49], and [51],in the valve chamber using a wrench. c. Secure shaft [52] in wrench (on 3/8-inch wrench flats) and assembly washers [53], cup [54], and piston [55] on the rear with nut [56] using a 9/16-inch socket. d. Place the piston assembly [52] through [56], into the valve chamber through bushing [50] and press into place. > Be SURE that o-ring [51] is in bushing [50]. e. Replace the resistor assembly (see Resistor Assembly Replacement in this section). f. Replace the barrel assembly (see Barrel to Body Assembly in this section). g. Place nut [57] on shaft [23] 1/16-inch from piston shaft [52]. > See Barrel Assembly - Step 17 and Barrel to Body Assembly - Step 6 for shaft [23] adjustment. h. Place nut [58] on shaft [23] and secure against nut [57] using appropriate wrenches. i. Place springs [59] and [60] against piston [55] and nut [58] and secure in place by screwing piston housing [61] into the rear of the valve housing. Fan Air Control Valve 1. Disassembly: a. Turn control knob [42] to the open position (fully extended) to accomodate Step b. b. With a 9/16-inch wrench, unscrew retaining nut [43] and remove the entire valve assembly. c. Return the control knob to the closed position. 30