PRODUCT MANUAL
AA-09-01
Evolver® SE
Robotic Atomizer
MODEL: A12455-XXXXXXXX
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.
Product Manual Price: $50.00
Evolver SE Robotic Atomizer - Notes
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Evolver SE Robotic Atomizer - Contents
CONTENTS
Section 1: SAFETY
Safety Precautions............................................................................................................. 1
Hazards / Safeguards........................................................................................................ 2-6
Section 2: INTRODUCTION
Evolver SE.........................................................................................................................
Specifications....................................................................................................................
Features............................................................................................................................
Evolver SE Applicator Selection Guide.............................................................................
7
7
8
9
Section 3: INSTALLATION
Overview............................................................................................................................
High Voltage Cable and Tubing (installation).....................................................................
High Voltage Cable and Tubing (removal).........................................................................
Paint Mate Robot...............................................................................................................
Changing Gun Head Angle................................................................................................
Non-Hollow Wrist / Hollow Wrist Conversion.....................................................................
ITW Ransburg REA-III / Evolver SE Conversion Bracket.................................................
Evolver SE to 9040 Power Supply Connections................................................................
Evolver SE to 9050 Power Supply Connections................................................................
Evolver SE to Voltage Master-2 Power Supply Connections.............................................
10
10-11
12
13
13
14
15
16
17
18
Section 4: OPERATION
Overview............................................................................................................................ 19
General Guidelines............................................................................................................ 20
Gun Controls..................................................................................................................... 21-22
Section 5: MAINTENANCE
Overview............................................................................................................................
Routine Maintenance Schedule.........................................................................................
Applicator Cleaning............................................................................................................
Service Overview...............................................................................................................
Proper Tools.......................................................................................................................
Spray Head Assembly (removal).......................................................................................
Spray Head Disassembly...................................................................................................
Spray Head Reassembly....................................................................................................
Spray Head Assembly (installation)...................................................................................
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23-24
25-29
30
31-32
33
34-46
47-61
62
Evolver SE Robotic Atomizer - Contents
Section 6: APPENDIX
Paint and Solvent Specifications........................................................................................
Viscosity Conversion Chart................................................................................................
Volumetric Content of Hose or Tube..................................................................................
Tool Center Point Drawings...............................................................................................
Evolver SE Complete Assembly Parts Identification..........................................................
Spray Head Assembly Parts Identification.........................................................................
Manifold Assembly Parts Identification..............................................................................
High Voltage Cable Selection Part Identification................................................................
Recommeded Spare Parts.................................................................................................
Repair Kits, Lubricants and Sealers...................................................................................
Troubleshooting Guide.......................................................................................................
Warranty Policies................................................................................................................
63
64
65
66-70
71
72-74
75
76
77-78
79
80-81
82
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Section 1: 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:
WARNING - states information to alert you to a situation that might cause serious
injury if instructions are not followed.
CAUTION - states information that tells how to prevent damage to equipment or
how to avoid a situation that might cause minor injury.
NOTE
- information relevant to the procedure in progress.
(please pay particular attention to these sections)
WARNING
• 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, 2009 EDITION, prior to installing, operating, and/or servicing
this equipment.
• The hazards shown on the following pages may occur during normal use of this equipment.
Please read the hazard chart begining on page 2.
While this manual lists standard specifications and service procedures, some minor deviations
may be found between the 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.
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.
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1
General Safety
SAFEGUARDS
AREA
HAZARD
Tells where
hazards may occur.
Tells where the hazard is. Tells how to avoid the hazard.
Spray Area
Fire Hazard
Fire extinguishing equipment must be present
in the spray area and test periodically.
Improper or inadequate
operation and
Spray areas must be kept clean to prevent the
maintenance procedures accumulation of combustable residues.
will cause a fire hazard.
Smoking must never be allowed in the spray
Protection against
area.
inadvertent arcing that is
capable of causing fire
The high voltage supplied to the atomizer
or explosion is lost if any must be turned off prior to cleaning, flushing
safety interlocks are
or maintenance.
disabled during
operation. Frequent
When using solvents for cleaning:
power supply shutdown • Those used for equipment flushing should
indicates a problem in
have flash points equal to or higher than
the system requiring
those of the coating material.
correction.
• Those used for general cleaning must have
flash points above 1000F (37.80C).
Spray booth ventilation must be kept at the
rates required by NFPA 33, 2009 Edition,
OSHA and local codes. Ventilation must be
maintained during cleaning operations using
flammable or combustable 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, a key switch bypass is intended for
use only during setup operations. Production
should never be done with safety interlocks
disabled.
Never use equipment for use in waterborne
installations to spray solvent based materials.
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General Safety
SAFEGUARDS
AREA
HAZARD
Tells where
hazards may occur.
Tells where the hazard is. Tells how to avoid the hazard.
Spray Area
Fire and/or explosion
Electrostatic arcing MUST be prevented.
All electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA 33, 2009
Edition.
Test only in areas free of flammable or
combustable materials.
The current overload sensitivity (if equipped)
MUST be set as described in 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 shutdown indicates a
problem with the system which requires
correction.
Always turn the control panel off prior to
flushing, cleaning, or working on spray system
equipment.
Ensure that the control panel is interlocked
with the ventilation system and conveyor in
accordance with NFPA 33, 2009 Edition.
Have fire extinguishing equipment readily
available and tested periodically.
General Use and Improper operation or
maintenance may
Maintenance
create a hazard.
Personnel must be
properly trained in the
use of this equipment.
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Personnel must be given training in
accordance with the requirements of NFPA
33, 2009 Edition.
Instructions and safety precautions must
understood prior to using this equipment.
Comply with appropriate codes governing
ventilation, fire protection, operation
maintenance, and housekeeping. OSHA
references are sections 1910.94 and
1910.107. Also refer to NFPA 33, 2009
Edition and your insurance company
requirements.
3
General Safety
SAFEGUARDS
AREA
HAZARD
Tells where
hazards may occur.
Tells where the hazard is. Tells how to avoid the hazard.
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.
Electrical
Equipment
High voltage equipment
is utilized. Arcing in
areas of flammable or
combustable materials
may occur. Personnel
are exposed to high
voltage during
operation and
maintenance.
All electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas. Refer to NFPA 33, 2009 Edition.
Protection against
inadvertent arcing that
may cause a fire or
explosion is lost if
safety circuits are
disabled during
operation.
Testing may require high voltage to be on, but
only as instructed.
Turn the power supply OFF before working on
the equipment.
Test only in areas free of flammable or
combustible material.
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.
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.
4
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General Safety
SAFEGUARDS
AREA
HAZARD
Tells where
hazards may occur.
Tells where the hazard is. Tells how to avoid the hazard.
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 the coating
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 /
High Voltage
Equipment
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.
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Parts being sprayed must be supported on
conveyors or hangers and be grounded. The
resistance between the part and ground must
not exceed 1 megaohm.
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.
Any person working in the spray area must be
grounded.
Unless specifically approved for use in
hazardous locations, the power supply and
other electrical control equipment must NOT
be used in Class I, Division 1 or 2 locations.
5
General Safety
SAFEGUARDS
AREA
HAZARD
Tells where
hazards may occur.
Tells where the hazard is. Tells how to avoid the hazard.
Robot Work
Area - General
Use and
Maintenance
Improper use or
maintenance can lead to
hazardous conditions,
particularly from
unexpected robot
manipulator movement.
Applicator adjustments or maintenance
should be done after the robot is taken out of
service. Do not adjust or repair the applicator
if the robot is operating or standing ready to
start.
Refer to robot operating instructions for the
procedures to take a robot out of service.
Personnel Safety Skin puncturing by
sharp electrode.
6
Take precautions to see that flesh is not
punctured by the sharp electrode.
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Section 2: INTRODUCTION
Evolver® SE
The Evolver SE is an automatic robot mounted spray applicator capable of spraying
solventborne or waterborne coatings electrostatically or non-electrostatically. It incorporates a
unique 1/3 turn quick disconnect spray head. The spray head and valve manifold contain fluid
and air passages. All fluid passages contain stainless steel and/or plastic fittings, compatible
with halogenated hydrocarbon solvents.
SPECIFICATIONS - Environmental / Physical
Robot / Mounting Compatibility: All non-hollow and hollow wrist robots, Paint Mate,
reciprocator and stationary stands.
Operating Voltage: 85 kV maximum with 9050, 9040 or Voltage Master power supply.
Operating Temperature Range: 55 0F (12.8 0C) to 131 0F (55 0C)
Weight: SE with gun, manifold and bracket = 3.35 lbs (1.52 kg) max.
SE with gun, manifold, dump block and bracket = 3.60 lbs (1.64 kg) max.
Length: Dependent on configuration (see configuration drawings)
Paint Flow Rate: Variable to 500 cc/min.
(depending on viscosity and configuration)
Trigger Response Time: 150 msec. OPEN
220 msec. CLOSED
Operating Air Pressures
Atomizing Air: 100 psig max. (6.9 bar)
Fan Air: 100 psig max. (6.9 bar)
Trigger Air: 70 psig min. - 100 psig max. (4.8 - 6.9 bar)
Dump Pilot: 70 psig min. - 100 psig max. (4.8 - 6.9 bar)
Operating Fluid Pressure: 100 psig max. (6.9 bar)
Tubing Requirements
Atomizing Air: 5/16" (8mm) OD Nylon
Fan Air: 5/16" (8mm) OD Nylon
Trigger Air: 5/32" (4mm) OD Nylon
Dump Pilot: 5/32" (4mm) OD Nylon
Fluid (Teflon): 5/16" (8mm) non-shielded
Fluid (optional): 3/8" OD shielded (for waterborne or highly conductive materials)
Dump (Teflon): 5/16" (8mm)
Robot Wrist Movement: Axis 6 limit to 4300
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7
Evolver SE - Introduction
FEATURES
The features of the Evolver SE applicator includes:
• Quick disconnect spray head.
• High quality ITW Ransburg air cap and fluid nozzle.
• Dual start, dual pitch air cap retaining ring.
• Bleed or non-bleed option.
• Internal fan and atomization air control valve, with a mechanically timed trigger
sequence.
• Adaptable to any robot mounting configuration.
• Adjustable angle spray head.
• Dump valve version available.
8
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Evolver SE - Introduction
Evolver SE - APPLICATOR SELECTION GUIDE
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9
Section 3: INSTALLATION
Evolver SE Installation
This information is intended ONLY to indicate the general installation parameters of this product
and, where applicable, its working relationship to other ITW Ransburg system components in
typical use.
Each installation is unique and should be directed by an authorized ITW Ransburg
representative or conducted using the ITW Ransburg installation drawings provided for your
particular installation.
High Voltage Cable and Tubing (installation)
• Connect the high voltage cable to the body assembly by first adding a small amount of
dielectric grease (NOT petroleum jelly) to the banana plug end. Fully insert cable until it
bottoms out in the plug receptacle. Once fully inserted, place the red collet lock behind the
collet to secure the cable in place. Gently pull the cable to ensure it is locked securely.
• Insert the 5/16" (8mm) or optional 3/8" Teflon paint line into the compression fitting and
tighten securely. Use two wrenches to prevent fitting from turning. Gently pull on the tubing
to ensure it is secure.
• Install the 5/16" (8mm) fan and atomization air tubing into the collet style fittings. Make sure
to push the tubing past the o-ring. Gently pull on the tubing to ensure it is secure.
• Install the 5/32" (4mm) trigger pilot tubing into the collet style fitting. Make sure
to push the tubing past the o-ring. Gently pull on the tubing to ensure it is secure.
• If equipped with dump valve: Install the 5/16" (8mm) dump line (Teflon) into the compression
fitting on the dump block body. Use two wrenches to prevent fitting from turning. Gently pull
on the tubing to ensure it is secure. Install the 5/32" (4mm) dump pilot tubing into the collet
style fitting. Make sure to push the tubing past the o-ring. Gently pull on the tubing to ensure
it is secure.
Non-recirculating Version
10
Recirculating Version
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Evolver SE - Installation
Evolver SE Installation (continued)
Manifold Block Configurations:
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11
Evolver SE - Installation
Evolver SE Installation (continued)
High Voltage Cable and Tubing (removal)
**Ensure high voltage is turned OFF and pressure in ALL air and fluid lines are at ZERO.
• High voltage cable: Remove red retaining clip. Push down on the collet and then pull cable
straight out.
• Air tubing (all): Push down on collet and pull straight out.
• Fluid tubing (all): Use two wrenches to prevent the fitting from turning. Loosen nut and
ferrule and remove by hand.
12
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Evolver SE - Installation
Evolver SE Installation (continued)
Paint Mate Robot
• Typical tubing bundle management consists of wrapping entire bundle with spiral wrap.
• Start at approximately 18 inches behind the applicator.
• Wrap every 2-3 ft.
• Route tubing through the center arm open area.
• Secure a strain relief (surgical tubing) from the main support arm and attach to the tubing.
• Allow at least 2-3 ft. of slack in tubing at the applicator.
• Tubing on wrist rotation should be held to a maximum rotation of 4300.
• Cycle program slowly to check for any pinch or catch points.
Changing Gun Head Angle
• To change the angle of the gun head, the shoulder screws need to be removed.
• Align the threaded holes to the gun head angle position desired.
• Install shoulder screws at tighten to a final torque of 15 lbs/in (1.69 Nm).
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13
Evolver SE - Installation
Evolver SE Installation (continued)
Non-Hollow Wrist / Hollow Wrist Conversion
Conversion from a non-hollow wrist robot configuration to a hollow wrist robot can be easily
done by removing the screws indicated in the above drawing and simply lifiting out the center
piece.
14
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Evolver SE - Installation
Evolver SE Installation (continued)
ITW Ransburg REA-III / Evolver SE Conversion Bracket
With the optional conversion bracket (see below), the Evolver SE can be a direct replacement
for the ITW Ransburg REA-III gun.
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15
Evolver SE - Installation
Evolver SE Installation (continued)
Evolver SE to 9040 Power Supply Connections
The below drawing shows the connections between the Evolver SE and the 9040 power supply.
16
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Evolver SE - Installation
Evolver SE Installation (continued)
Evolver SE to 9050 Power Supply Connections
The below drawing shows the connections between the Evolver SE and the 9050 power supply.
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17
Evolver SE - Installation
Evolver SE Installation (continued)
Evolver SE to Voltage Master-2 Power Supply Connections
The below drawing shows the connections between the Evolver SE and the Voltage Master-2
power supply.
18
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Section 4: OPERATION
Evolver SE Operation
WARNING
• Operators must be fully trained in safe operation of electrostatic equipment. Operators must
read all instructions and safety precautions prior to using this equipment (see NFPA-33).
WARNING
• Electrical discharge of a high electrical capacitance fluid/paint system can cause fire or
explosion with some materials. If arcing occurs when a specific coating material is used, turn
the system OFF and verify that the fluid in non-flammable. In these conditions, the system is
capable of releasing sufficient electrical and thermal energy to cause ignition of specific
hazardous materials in the air.
As with any spray finishing system, operation of the Evolver SE involves properly setting the
operating parameters to obtain the best finish quality for the coating material being sprayed
while maintaining correct operation and reliability of the equipment used. Adjustments to
operating parameters, which cover spraying, cleaning, and ON/OFF control, include the
following:
• Coating Materials
• Fluid Flow Rate Control
• Fluid Valve / Trigger Control
• Atomization Air (paint atomization control)
• Fan Air (pattern control)
• Electrostatic Voltage
• Target Distance
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19
Evolver SE - Operation
General Guidelines
Paint Viscosity: The applicator is capable of atomizing paint of most any desired viscosity,
however it is recommended to keep the material viscosity as low as possible. This allows
spraying at lower fan and atomization air pressures which result in less overspray and higher
transfer efficiency.
WARNING
• Most paints and solvents, including those listed in "Solvent Selection Guide" in the Appendix
section, are toxic to a certain degree and flammable or combustable. Use them only in a well
ventilated atmosphere. Use protective equipment as required in the Material Safety Data
Sheet (MSDS) supplied with the substance.
Fluid Flow Rate: Fluid flow is adjusted through the robot PLC by varying the pilot pressure to
an exterior fluid regulator. Fluid pressures from the circulating system may exceed the
maximum fluid pressure rating of the Evolver SE applicator. Because of these high fluid
pressures, a manual step-down fluid regulator must be used.
Target Distance: The distance between the applicator tip and the article being painted should
be 10-14 inches (0.25-0.36 meters) when using high voltage. Excessive distance will reduce
transfer efficiency and cause wrap back (paint particles being deposited on the applicator body
or the robot arm). At close distances the voltage at the tip of the applicator will be reduced,
which decreases the charging effect of the applicator.
WARNING
• If target distance is less than 8 inches (0.20 meters), an arc could occur.
Electrostatic Voltage: Under no load conditions, the maximum voltage limit for the Evolver SE
applicator is 85 kV. Some painting operations may require different voltage settings to obtain
optimum transfer efficiencies. If Faraday cage areas (narrow or recessed areas) are
predominant on the item being painted, a lower voltage setting would aid in coating these areas.
When not spraying, it is recommended to set back voltage 30-40 kV or OFF between target
parts. Sometimes, depending on the target carrier spacing, higher setback voltages may be
required.
20
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Evolver SE - Operation
Evolver SE Gun Controls (Fluid Valve / Trigger)
Trigger and Dump: The fluid valves in the Evolver SE are actuated by an air signal. The air
pressure must exceed 70 psi (4.8 bar) to assure proper actuation of the valve. Applying air to
the valve actuator turns on the fluid flow for the valve.
The paint trigger valve controls the paint flow to the applicator. When actuated, paint flows
through the valve to the fluid tube and into the spray head.
The dump valve controls the paint flow through the dump line. When actuated, paint flow is
directed to the dump return line. This provides a method of rapidly removing paint from the
incoming line for cleaning and/or color change. Normally the dump valve is not actuated at the
same time as the paint valve since the paint valve is intended to cause the fluid to flow to the
applicator head at the set input pressure.
Evolver SE Gun Controls (Air)
Atomization (A) / Fan Air (F): The atomization and fan air are turned on by the trigger line and
are controlled by an internal air valve located in the applicator head. During normal operation
with the applicator triggered off, there is a slight bleed of air through the atomization port. This
helps keep the passage clean.
Atomizing Air: Adjustments are made through the robot PLC or a manually adjustable air
regulator. The lowest air pressure required to break up the paint should be used. Lower
atomizing air pressures result in less overspray and increased transfer efficiency.
Fan Air: Adjusting the fan air increases or decreases the size of the spray pattern. Increasing
pressure increases pattern size. Pattern adjustment should be made to suit the size and shape
of the object being painted. This adjustment is made through the robot PLC or a manually
adjustable air regulator.
HVLP Spray: The Evolver SE HVLP models, when properly set-up, are designed to provide
maximum transfer efficiency by limiting air cap pressures to 10 psi (0.7 bar). In the U.S., this
complies with rules issued by SCAQMD and other air quality authorities.
NOTE
- For HVLP operation (max. 10psi, 0.7 bar cap pressure), DO NOT exceed the air
inlet pressure, which was read at the gun base before tubing manifolds, given as
follows:
PSI
42
42
(Bar)
(2.9)
(2.9)
CAP #
48-1
481-1
Air cap pressures (Atomization & Fan) should be set using an air cap test kit. This
provides a consistent measurement, so initial settings may be duplicated at any time.
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21
Evolver SE - Operation
Evolver SE Gun Controls (mechanically timed trigger)
The mechanically timed trigger of the Evolver SE ensures that the atomization and fan air are
ON before paint flows out of the applicator (see diagram below). The helps prevent the gun
from spitting paint from lack of atomization or fan air.
22
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Section 5: MAINTENANCE
Good maintenance is essential to safe and productive operation. Schedules should be
established by the user, based on the following general information and observations of the
initial production requirements.
The ITW Ransburg maintenance and safety information should be made available to each
operator.
Normal fire protection measures are necessary, including proper storage of paints and solvents
and the proper disposal of waste. Ready access to appropriate fire extinguishing equipment is
required. For details, consult the appropriate NFPA safety information, your local fire codes,
local painting equipment standards, OSHA requirements, as well as your insurance carrier's
information.
WARNING
• Unexpected robot movement can be hazardous. Do not adjust or repair the spray applicator
when the robot is operating or waiting to start. The robot must be locked out and tagged out
per OSHA.
• Do not adjust or repair the spray applicator when the power supply is ON. Turn OFF the
power supply and follow OSHA lockout / tagout procedures.
• Solvents used for equipment flushing must have flash points equal to or greater than the
flash point rating of the coating material. Solvents used for general cleaning must have flash
point ratings higher than 100 0F (37.8 0C). Refer to the "Solvent Selection Guide" in the
Appendix section.
• Never remove spray applicator head from assembly while it is under pressure.
Routine Maintenance Schedule
Follow these maintenance steps to extend the life of the applicator and ensure efficient
operation:
Several Times Daily
1. Inspect the fluid nozzle and electrode wire for paint accumulation. Clean as frequently
as necessary. (See "Procedures" in the "Maintenance" section.)
1
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2
23
Evolver SE - Maintenance
Daily (or at Shift Start)
1. Inspect workholders for accumulated coating materials (remove such accumulations if
present). Using a Megger, measure the resistance of the workholder to ground (should be
less than 1 Mega Ohm).
2. Check that the nozzle assembly is clean and undamaged.
Overhead Conveyor Workholder
Nozzle Assembly
1. Flush the lines and allow the solvent to remain in the lines. (See "Procedures" in the
"Maintenance" section.)
2. Wipe the applicator and robot wrist with a cloth and a suitable, clean non-polar solvent.
Weekly
1. Check the entire system for damage, leaks and paint accumulation.
2. Clean the atomizer assembly.
24
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Evolver SE - Maintenance
Applicator Cleaning
Cleaning
1. Flush the paint supply line and the applicator paint passages using a solvent which is
compatible with the material being sprayed. Continue to flush until all traces of paint are
gone.
2. Turn off the solvent supply, actuate paint push out air at the color changer and trigger
the applicator. Allow all of the fluid to drain from the spray applicator fluid passages.
3. Clean the exterior surfaces of the spray applicator with a solvent soaked rag.
4. Remove end cap. Removing the end cap releases tension on all internal spray head
components. Remove needle spring and valve spring, which are loose after removing the
piston cap.
2
1
1
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2
3
25
Evolver SE - Maintenance
Applicator Cleaning (continued)
CAUTION
• Never attempt to clean the air cap holes with a wire or other metal object. Doing so may
damage the air cap, resulting in distortion of the spray pattern.
5. Remove the air cap retainer and air cap. Soak in a solvent if necessary. If paint
remains in the air cap holes, clean with a toothpick or similar soft wood object. Air caps
are best cleaned in an ultrasonic cleaner.
6. Remove the air cap locator and fluid tip. Clean using a solvent.
2
1
3
4
26
5
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Evolver SE - Maintenance
Applicator Cleaning (continued)
7. Tightly grip the needle and unscrew counter-clockwise to remove the electrode. A
short piece of H-2339 tubing (1/4" OD x 0.175" ID) pressed over the electrode will assist in
unscrewing the assembly. If required, use needle nose pliers with masking or duct tape.
Carefully clean with a solvent. Replace any parts that show signs of wear or damage.
2
1
CAUTION
• If using needle nose pliers to unscrew the electrode, be very careful. Do not grip on the
tapered sealing surface. If the pliers slip, they could damage the tapered sealing surface of the
electrode.
8. Remove fluid nozzle by unscrewing counter-clockwise. Inspect o-ring and all passages
for build-up or damage. Clean or replace as necessary. Lubricate and reinsert o-ring into
applicator barrel and reinstall fluid nozzle. Torque fluid nozzle to 25 lbs-in (2.82 Nm).
NOTE - There should be a small gap between the fluid nozzle and the applicator barrel
after tightening.
1
AA-09-01
2
3
27
Evolver SE - Maintenance
Applicator Cleaning (continued)
9. After cleaning, insert the front needle back into the spray head assembly. Apply Loctite
#222, low strength (purple) thread locker, to the threads of the tip assembly before
reassembly.
Rear
10. Install the electrode.
Front
NOTE
- The electrode should always be installed and tightened before installing the
fluid tip and valve springs.
11. Screw fluid tip back into place. Hand tighten first, then with a small wrench, tighten an
additional 300.
1
28
2
AA-09-01
Evolver SE - Maintenance
Applicator Cleaning (continued)
CAUTION
• After tightening the fluid tip, always check to see if the proper gap of 1/16" (1.59mm) between
the needle nuts and air valve stem occur, before installing the needle and valve springs back
into the head.
12. Replace air cap locator, air cap, and air cap retainer .
13. Apply a thin film of petroleum jelly to valve and needle springs. Install the springs
back into the end cap and the spray head assembly.
14. Screw end cap back on.
1
1
1
AA-09-01
2
3
2
3
2
29
Evolver SE - Service
Service
WARNING
• Unexpected robot movement can be hazardous. Do not adjust or repair the spray applicator
when the robot is operating or waiting to start. The robot must be locked out and tagged out
per OSHA prior to removing the applicator from the robot manifold assembly.
Before performing any work on the spray applicator, always flush the fluid passages and blow
dry with push-out air, and wipe the spray applicator clean. Refer to "Gun Cleaning / Service" in
the "Maintenance" section, for instructions on how to properly clean the spray applicator.
Depressurize all fluid and air pressures before removing the applicator from its manifold.
Always work in a clear, clean space to minimize part loss and damage.
WARNING
• Eye protection should be worn while servicing gun.
Spray Head Assembly
NOTE
- Disassemble spray head only enough to remove and replace defective parts.
For instance, if only replacing the front electrode it is not necessary to remove the
fluid nozzle.
NOTE - To prevent damage, always lubricate the o-rings located on the underside of
the spray head.
30
AA-09-01
Evolver SE - Service
Proper Tools
When servicing the Evolver SE, be sure to use the proper tools.
Wrenches /
Special Tools
3/8" drive, in./lbs. torque
wrench
Standard hex key set
Combination wrenches
• 1/4"
• 9/16"
• 15/16" • 1-1/8"
• 11/32" • 2-3/8"
Seal carrier tool
Socket for seal carrier tool
Screwdrivers
Flat head screwdrivers
Torque screwdriver
AA-09-01
31
Evolver SE - Service
Proper Tools (continued)
When servicing the Evolver SE, be sure to use the proper tools.
Miscellaneous
Sealants
Lubricants
Insulators
32
AA-09-01
Evolver SE - Service
Spray Head Assembly (removal)
Step 1
Loosen the spray head
retainer:
• use a 3/16" hex
wrench
• turn clockwise to
loosen
Step 2
Turn the spray head clockwise
and remove.
1
2
3
AA-09-01
33
Evolver SE - Service
Spray Head Disassembly
• Spray Head End Cap:
79148-00
• Compression Spring:
17615-00
• Valve Return Spring:
9334-00
Step 1
Remove spring tension on the
electrode / fluid tip by
removing the piston cap.
1
2
Step 2
Remove the piston and needle
return springs.
1
2
3
34
AA-09-01
Evolver SE - Service
Spray Head Disassembly (continued)
• Air Cap: 791XX-XX
• Retaining Ring:
79154-00
Step 3
Loosen and remove the air
cap retaining ring.
1
2
Step 4
Remove and inspect the air
cap:
• wear
• material build-up
• cracks or damage
AA-09-01
35
Evolver SE - Service
Spray Head Disassembly (continued)
• Air Cap Locator:
EMF-192
• Fluid Tip: 791XX-XX
Step 5
Remove the air cap locator.
1
2
Step 6
Remove and inspect the fluid
tip.
1
2
36
AA-09-01
Evolver SE - Service
Spray Head Disassembly (continued)
• Solvent Proof O-Ring:
79001-01
• High Wear Electrode:
70430-01
• Fluid Hole Nozzle
Step 7
Remove the electrode:
1
• turn counter-clockwise
• use H-2339 tubing
(1/4" OD x 0.175 ID) if
necessary
Inspect tapered surface for
damage.
2
Wire should be straight and
roughly 1/2" long.
Step 8
Remove and inspect the fluid
nozzle.
1
2
AA-09-01
37
Evolver SE - Service
Spray Head Disassembly (continued)
Step 9
Remove the o-ring from the
spray head if it does not come
out with the nozzle.
Step 10
Remove the rear needle
assembly.
38
AA-09-01
Evolver SE - Service
Spray Head Disassembly (continued)
Step 11
The fluid seal, seal washer,
and seal spring can now be
removed from the front of the
gun.
Step 12
Use two 3/8" wrenches to
loosen the air valve
adjustment nut and jam nut.
1
2
3
AA-09-01
39
Evolver SE - Service
Spray Head Disassembly (continued)
Step 13
Slide the piston assembly out
of the body (use pliers if
necessary).
1
2
Step 14
Remove the piston nut.
1
2
40
AA-09-01
Evolver SE - Service
Spray Head Disassembly (continued)
Step 15
Remove the piston u-cup from
the piston plate.
1
2
Step 16
Remove the o-ring from the air
shaft.
1
2
AA-09-01
41
Evolver SE - Service
Spray Head Disassembly (continued)
Step 17
Using the seal carrier tool,
remove the seal retainer from
the spray head.
1
2
3
Step 18
Remove the o-ring from the
seal retainer.
1
2
42
AA-09-01
Evolver SE - Service
Spray Head Disassembly (continued)
Step 19
Slide the bushing out of the
spray head. It may require
hooking and pulling the
bushing out using an Allen
wrench or similar object.
1
2
Step 20
AA-09-01
Remove the two o-rings from
the bushing.
43
Evolver SE - Service
Spray Head Disassembly (continued)
Step 21
Slide the seal carrier out of
the spray head.
1
2
Step 22
Remove the o-ring from the
seal carrier.
1
2
44
AA-09-01
Evolver SE - Service
Spray Head Disassembly (continued)
Step 23
Remove the o-ring from the
spray head.
1
2
Step 24
Remove the high voltage
contact spring from the spray
head.
1
2
AA-09-01
45
Evolver SE - Service
Spray Head Disassembly (continued)
Step 25
Remove the socket head cap
screw holding the connection
plug.
Step 26
Remove the connection plug
from the spray head.
1
2
46
AA-09-01
Evolver SE - Service
Spray Head Reassembly
Step 1
Install the conductive sponge
(if removed) and the
connection plug into the spray
head.
Step 2
Install and tighten the socket
head cap screw:
• torque the screw to 5
lbs.-in. (0.56 Nm)
AA-09-01
47
Evolver SE - Service
Spray Head Reassembly (continued)
Step 3
Insert the high voltage contact
spring into the spray head.
1
2
Step 4
Install the o-ring into the spray
head:
1
• push all of the way to
the bottom
• apply a thin layer of
petroleum jelly to the
o-ring
48
2
AA-09-01
Evolver SE - Service
Spray Head Reassembly (continued)
Step 5
Install the o-ring into the seal
carrier.
1
• apply a thin layer of
petroleum jelly to the
o-ring
2
Step 6
Install the seal carrier into the
spray head:
1
• push all of the way to
the bottom
2
AA-09-01
49
Evolver SE - Service
Spray Head Reassembly (continued)
Step 7
Install the o-ring into the spray
head:
1
• push all of the way to
the bottom
• apply a thin layer of
petroleum jelly to the
o-ring
Step 8
2
Install the two o-rings onto the
bushing:
• white Teflon o-ring
(shuts OFF the fan air)
• Viton o-ring (keeps fan
and atomization air
separated)
• apply a thin layer of
petroleum jelly to the
Viton o-ring
50
AA-09-01
Evolver SE - Service
Spray Head Reassembly (continued)
Step 9
Install the bushing into the
spray head.
Step 10
Ensure that the alignment pin
is in the correct position.
AA-09-01
51
Evolver SE - Service
Spray Head Reassembly (continued)
Step 11
Install the o-ring into the seal
retainer. This o-ring
separates cylinder air and
atomization air.
• apply a thin layer of
petroleum jelly to the
o-ring
Step 12
Using the seal carrier tool,
install the seal retainer into the
spray head:
1
2
1
• torque to 30-35 lbs.-in.
(3.4-4.0 Nm)
If not properly torqued, the
atomization and fan air may
equalize resulting in lack of
fan control.
52
2
AA-09-01
Evolver SE - Service
Spray Head Reassembly (continued)
Step 13
Install the o-ring onto the air
valve shaft. This o-ring
separates fan and atomization
air.
• apply a thin layer of
petroleum jelly to the
o-ring
Step 14
Insert the piston plate into the
piston u-cup:
1
2
1
• will leak trigger air out
the vent hole in the
rear cap if bad
2
AA-09-01
53
Evolver SE - Service
Spray Head Reassembly (continued)
Step 15
Install the piston nut.
1
2
Step 16
54
Slide the piston assembly into
the spray head.
AA-09-01
Evolver SE - Service
Spray Head Reassembly (continued)
Step 17
Loosely install the air valve
adjustment nut and jam nut
onto the needle shaft:
• the air valve
adjustment nut should
be approximately
flush with the end of
the needle shaft
Step 18
AA-09-01
1
2
Install the rear needle
assembly into the spray head.
55
Evolver SE - Service
Spray Head Reassembly (continued)
Step 19
Install the spring, seal washer,
and fluid seal onto the needle
shaft.
Step 20
Install the o-ring into the spray
head. Push the o-ring all the
way to the shoulder.
56
AA-09-01
Evolver SE - Service
Spray Head Reassembly (continued)
• Solvent Proof O-Ring:
79001-01
• High Wear Electrode:
70430-01
• Fluid Hole Nozzle
Step 21
nstall the fluid nozzle:
1
• torque fluid nozzle to
23-25 ibs.-in.
(2.6-2.8 Nm)
Apply a thin layer of
petroleum jelly to the o-ring
and threads on the fluid
nozzle assembly.
2
Install the electrode:
• use low strength
thread lock (Loctite
#222)
AA-09-01
57
Evolver SE - Service
Spray Head Reassembly (continued)
• Air Cap Locator:
EMF-192
• Fluid Tip: 791XX-XX
Step 23
Install the fluid tip (hand tight
plus 300).
1
2
Step 24
Install the air cap locating ring.
1
2
58
AA-09-01
Evolver SE - Service
Spray Head Reassembly (continued)
• Air Cap: 791XX-XX
• Retaining Ring:
79154-00
Step 25
Install the air cap and the air
cap retaining ring.
1
2
AA-09-01
59
Evolver SE - Service
Spray Head Reassembly (continued)
Step 26
With the electrode seated in
the fluid tip, measure the
distance between the jam nut
and the piston assembly.
Step 27
Tighten the air valve
adjustment nut to the jam nut
when 1/16" is measured.
Re-check measurement.
This adjustment ensures that
atomization and fan air are ON
before the fluid needle is
engaged.
AA-09-01
Evolver SE - Service
Spray Head Reassembly (continued)
Step 28
Install the piston and needle
return springs.
1
2
3
Step 29
Apply a thin layer of petroleum
jelly to the piston cap threads.
1
Install the piston cap.
2
AA-09-01
61
Evolver SE - Service
Spray Head Assembly (installation)
Step 1
Apply dielectric grease into
the labyrinth of the spray head.
Apply a thin layer dielectric
grease onto the o-rings before
installing the spray head.
Step 2
Install the spray head onto the
mounting block and turn it
(counter-clockwise) into
position.
1
2
3
Step 3
Tighten the spray head
retainer:
• use a 3/16" hex
wrench
• turn counterclockwise to tighten
• Do not over-tighten
62
AA-09-01
Section 8: APPENDIX
AA-09-01
63
Appendix
64
AA-09-01
Appendix
AA-09-01
65
Appendix
Tool Center Point Drawings
66
AA-09-01
Appendix
Tool Center Point Drawings
AA-09-01
67
Appendix
Tool Center Point Drawings
68
AA-09-01
Appendix
Tool Center Point Drawings
AA-09-01
69
Appendix
Tool Center Point Drawings
70
AA-09-01
Appendix
Evolver SE Complete Assembly Parts Indentification
AA-09-01
71
Appendix - Complete Assembly Parts Identification
AA-09-01
Appendix
Spray Head Assembly Parts Indentification
Figure 23
AA-09-01
72
Appendix
Conventional Spray Head
73
AA-09-01
Appendix
HVLP Spray Head
AA-09-01
74
Appendix
Dump Manifold Assembly Parts Indentification
75
AA-09-01
Appendix
High Voltage Cable Selection Part Identification
Standard with Gun Assembly:
AA-09-01
76
Appendix
Recommended Spare Parts
77
AA-09-01
Appendix
Recommended Spare Parts
AA-09-01
78
Appendix
79
AA-09-01
Appendix
Troubleshooting Guide
General Problem
Possible Cause
Corrective Action
Fluid Does Not Turn
On
1. Insufficient trigger
pilot air.
1. Increase to 70 psig minimum.
2. Trigger air tube
possibly left
disconnected.
2. Reconnect tubing.
3. Trigger air tube is
pinched or broken.
3. Check tubing for kinks or damage.
Replace if worn or damaged.
4. Piston seal within
the applicator spray
head is not in place or
there is an extremely
tight fit between the
seal and the cylinder
wall.
4. Make sure that the seal is in the
proper position and/or lubricate with a
small amount of petroleum jelly.
5. Piston u-cup is bad.
5. Replace if damaged (trigger air will
leak out of rear cap).
1. Clogged fluid nozzle.
1. Remove, inspect and clean fluid
nozzle.
2. Plugged fluid inlet.
2. Flush clean.
3. No trigger pilot air.
3. Check trigger air pilot (70 psig
minimum required).
1. Trigger pilot air is not
shutting off.
1. Remove trigger pilot air.
2. Weak or damaged
needle spring.
2. Replace needle spring.
3. Fluid seal is worn or
damaged.
3. Replace fluid seal.
No Fluid Flow
Continuous Fluid
Flow
AA-09-01
80
Appendix
Troubleshooting Guide
General Problem
Possible Cause
Corrective Action
Lack of Fan Air
Control
1. Improperly torqued
seal retainer.
1. Ensure that seal retained is torqued
to 30-35 lbs.-in.
2. Teflon o-ring on
bushing is damaged.
2. Replace Teflon o-ring (this shuts off
the fan air).
3. Viton o-ring on
bushing is damaged.
3. Replace Viton o-ring (keeps fan and
atomization air separated).
1. High current draw.
1. Ensure that paint resistivity is greater
than 0.1 Mega Ohms.
2. Loss of high voltage
cable connection
between power supply
and manifold.
2. Check HV cable connection to
manifold. Apply dielectric grease to
cable end and reconnect.
3. Contact spring
damaged.
3. Replace contact spring.
4. Conductive sponge
damaged / removed.
4. Replace conductive sponge.
5. Applicator grounding
out.
5a. Clean atomizer externally with nonpolar solvent.
Low or No High
Voltage
5b. Check the atomizer for internal fluid
leaks.
5c. Check for internal arcing (usually
indicated by internal sparking sounds).
81
6. Power supply is
damaged.
6. Refer to specific power supply
manual for troubleshooting.
7. Dirty dump line.
7. Clean or replace dump line.
AA-09-01
Appendix
Warranty Policies
LIMITED WARRANTY
ITW Ransburg will replace of repair without charge any part/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 ITW Ransburg's written safety
and operating instructions, and has been used under normal operating conditions. Normal
wear items are excluded.
THE USE OF OTHER THAN ITW RANSBURG APPROVED PARTS 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, (i.e. guns, power supplies, control units,
etc.), is one (1) year from date of purchase.
WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THIS WARRANTY.
ITW RANSBURG'S ONLY OBLIGATION UNDER 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. ITW RANSBURG
ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FOR
CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR
INCOME, WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY
PURCHASER OR OTHERS.
EXCLUSIONS:
If, in ITW Ransburg's opinion the warranty item in question, or other items damaged by this
part was improperly installed, operated or maintained, ITW Ransburg will assume NO
responsibility for repair or replacement of the item or items. The purchaser, therefore will
assume all responsibility for any cost of repair or replacement and service related costs if
applicable.
AA-09-01
82
Product Manual Price: $50.00 (U.S.)
Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260-665-8800
Fax: 260-665-8516
Technical Service - Assistance
320 Phillips Ave.
Toledo, Ohio 43612-1493
Telephone (toll free): 800-233-3366
Telephone: 419-470-2021
Fax: 419-470-2040
Technical Support Representatives can direct you to the appropriate telephone
number for ordering spare parts.
© 2009 Illinois Tool Works, Inc. All rights reserved.
Models and specifications subject to change without notice.
Form No. AA-09-01
Litho in U.S.A.
06/09
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