(Serv. Man. LN-9244-03.3) (LN9244033sm)

(Serv. Man. LN-9244-03.3) (LN9244033sm)
SERVICE MANUAL
LN-9244-03.3
(Replaces LN-9244-03.2)
October - 2007
AR
C
H
IV
E
RMATM-202 ROBOT MOUNTED
TOMIZER
ROT
AR
Y A
ROTAR
ARY
AT
MODEL: 79014
IMPOR
TANT
IMPORT
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: €40.00
40.00 (Euro)
$50.00 (U.S.)
NOTE: This manual has been changed from LN-9244-03.2 to revision LN-9244-03.3
LN-9244-03.3. Reasons for this
change are noted under “Manual Change Summary” inside the back cover of this manual.
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LN-9244-03.3
RMA-202 Rotary Atomizer - Contents
CONTENTS
PAGE
1-4
SAFETY:
SAFETY PRECAUTIONS........................................................................................................... 1
HAZARDS / SAFEGUARDS...................................................................................................... 2-4
INTRODUCTION:
5-20
FEATURES..................................................................................................................................5-6
GENERAL DESCRIPTION......................................................................................................... 6-7
SPECIFICATIONS...................................................................................................................... 8
GRAPHICAL INFORMATION (PRESSURE DATA)................................................................. 9-16
30MM RMA-202 TOOL POINT AND CENTER OF
GRAVITY DIMENSIONS............................................................................................................ 17
57MM AND 57MM "V" CUP RMA-202 TOOL POINT DIMENSIONS........................................18
MANIFOLD SCHEMATICS......................................................................................................... 19-20
INSTALLATION:
21-26
AIR FILTER INSTALLATION...................................................................................................... 21
AIR PRESSURE REQUIREMENTS.......................................................................................... 21
AIR FILTRATION REQUIREMENTS......................................................................................... 22
AIR HEATER REQUIREMENTS................................................................................................ 23
MOUNTING................................................................................................................................. 23
ELECTRICAL AND FIBER OPTIC CONNECTIONS................................................................ 24
FLUID TUBING CONNECTION REQUIREMENTS.................................................................. 24
FLUID CONNECTIONS.............................................................................................................. 25
INTERLOCKS.............................................................................................................................. 25-26
TUBING BUNDLE INSTALLATION........................................................................................... 26
BUNDLE LUBRICANT................................................................................................................ 26
OPERATION:
27-32
FLUID FLOW RATE CONTROL................................................................................................. 27
FLUID VALVE CONTROL.......................................................................................................... 28
DUAL PURGE SPRAYING......................................................................................................... 28
FLUID REGULATION MANIFOLD............................................................................................. 28
DUAL COMPONENT MANIFOLD.............................................................................................. 28-29
TURBINE SPEED....................................................................................................................... 29
BEARING AIR ADJUSTMENT................................................................................................... 29
SHAPING AIR............................................................................................................................. 30
SEAL AIR..................................................................................................................................... 30
BRAKE AIR.................................................................................................................................. 30
ELECTROSTATIC VOLTAGE.................................................................................................... 30
TARGET DISTANCE.................................................................................................................. 31
(Continued On Next Page)
LN-9244-03.3
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RMA-202 Rotary Atomizer - Contents
PAGE
33-54
MAINTENANCE:
O-RINGS..................................................................................................................................... 33
CLEANING PROCEDURES....................................................................................................... 33-35
VIBRATION NOISE..................................................................................................................... 35
TURBINE REPAIR AND REBUILD............................................................................................ 35
HIGH VOLTAGE CONNECTIONS............................................................................................ 35
GENERAL MAINTENANCE....................................................................................................... 36
PREVENTIVE MAINTENANCE.................................................................................................. 36-38
DISASSEMBLY PROCEDURE.................................................................................................. 38-49
TROUBLESHOOTING GUIDE.................................................................................................. 50-53
PARTS IDENTIFICATION:
55-86
RMA-202 ASSEMBLY / PARTS LIST......................................................................................... 55-56
RMA-202 MODEL IDENTIFICATION / PARTS LIST................................................................. 57-59
AIR MANIFOLD ASSEMBLY / PARTS LIST.............................................................................. 60
79103-00 VALVE MANIFOLD ASSEMBLY / PARTS LIST........................................................ 61
79103-01 VALVE MANIFOLD ASSEMBLY / PARTS LIST....................................................... 62
REAR PLATE / BREAK-AWAY ASSEMBLY / PARTS LIST..................................................... 63
A10676 VALVE MANIFOLD ASSEMBLY / PARTS LIST........................................................... 64
79105-00 REAR PLATE ASSEMBLY / PARTS LIST................................................................. 65
A10745 REGULATOR VALVE MANIFOLD ASSEMBLY /
PARTS LIST................................................................................................................................ 66
REAR PLATE / BREAK-AWAY ASSEMBLY / PARTS LIST..................................................... 67
A10747-00 REAR PLATE ASSEMBLY / PARTS LIST.............................................................. 68
79106-XX FRACTIONAL TUBING BUNDLE ASSEMBLY /
PARTS LIST................................................................................................................................ 69-71
79106-XXXXX TUBE BUNDLE ASSEMBLY MODEL
IDENTIFICATION (FRACTIONAL)............................................................................................. 72-74
A10892-XX METRIC TUBING BUNDLE ASSEMBLY / PARTS LIST....................................... 75-76
A10892-XX TUBING BUNDLE MODEL IDENTIFICATION (METRIC)..................................... 77-79
RMA-202 RECOMMENDED SPARE PARTS ........................................................................... 80-82
ACCESSORIES AND SERVICE KITS...................................................................................... 83
LUBRICANTS AND SEALERS................................................................................................... 83
AVAILABLE TOOLS.................................................................................................................... 84
TEACH BRACKET KIT............................................................................................................... 85
WARRANTY POLICIES:
87
LIMITED WARRANTY................................................................................................................. 87
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LN-9244-03.3
RMA-202 Rotary Atomizer - Contents
LN-9244-03.3
ARCHIVE
RMA-202 Rotary Atomizer - 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 NOTE is information relevant to the
procedure in progress.
! 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, prior to installing,
operating, and/or servicing this equipment.
! WARN
! ING
> 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.
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.
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
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LN-9244-03.3
RMA-202 Rotary Atomizer - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Spray Area
Fire Hazard
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Improper or inadequate operation and maintenance pro- Spray areas must be kept clean to prevent the
cedures will cause a fire hazard. accumulation of combustible residues.
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.
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 100oF (37.8oC).
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 set-up 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.
LN-9244-03.3
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2
RMA-202 Rotary Atomizer - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be given training in accordance with
the requirements of NFPA-33.
Instructions and safety precautions must be read
Personnel must be properly
trained in the use of this and understood prior to using this equipment.
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
exposed to high voltage during
operation and maintenance.
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.
Protection against inadvertent
arcing that may cause a fire or Test only in areas free of flammable or combustible
explosion is lost if safety circuits material.
are disabled during operation.
Testing may require high voltage to be on, but only
Frequent power supply shutdown as instructed.
indicates a problem in the system
Production should never be done with the safety
which requires correction.
circuits disabled.
An electrical arc can ignite coating
materials and cause a fire or Before turning the high voltage on, make sure no
objects are within the sparking distance.
explosion.
Explosion
Hazard/
Incompatible
Materials
3
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 material supplier. Any other type of solvent may be used
with aluminum equipment.
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LN-9244-03.3
RMA-202 Rotary Atomizer - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Toxic Substances Certain material may be harmful Follow the requirements of the Material Safety Data
if inhaled, or if there is contact Sheet supplied by coating material manufacturer.
with the skin.
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 objects which is
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.)
All electrically conductive objects in the spray area,
Inadequate grounding will cause with the exception of those objects required by the
a spark hazard. A spark can process to be at high voltage, must be grounded.
ignite many coating materials and
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 1, Division 1 or
2 locations.
Personnel
Safety/
Mechanical
Hazards
Robot Work
Area - General
Use and
Maintenance
The bell atomizer can rotate at
speeds up to 50,000 rpm. At
these speeds, the edge of the
applicator can easily cut into skin.
Loose articles of clothing can
also be caught by the rotating
bell.
Personnel must stay clear of the bell whenever it is
rotating.
Before touching the bell, the turbine air must be shut
off.
If the bell has been rotating, allow at least two minutes
for it to come to a complete stop before touching it.
Improper use or maintenance can Applicator adjustments or maintenance should be
lead to hazardous conditions, done after the robot is taken out of service. Do not
particularly from unexpected robot adjust or repair the applicator if the robot is operating
or standing ready to start.
manipulator movement.
Refer to robot operating instructions for the procedures
to take the robot out of service.
LN-9244-03.3
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4
RMA-202 Rotary Atomizer - Introduction
INTRODUCTION
FEA
TURES
FEATURES
regulator.
Features which make the RMATM-202 Robot
Mounted Rotary Atomizer advantageous for
use in electrostatic applications include:
! Assembly components made of durable plastic material for optimum mechanical strength
and solvent resistance.
! Proven long life turbine motor capable of
speeds up to 50k rpm at minimal air consumption. See "Specifications" in the
"Introduction" section of this manual for bell
cup speed ratings.
! 57mm, 30mm, and 57mm "V" cup diameter
bell assemblies available for application flexibility . "V" cup technology designed for base
coat color match in bell/bell applications. All
Titanium for extended wear life.
! Shaping air passage design provides excellent pattern control at minimal air
consumption.
! The addition of seal air used, in conjunction
with rear exhaust, allows for variable control
of the amount of air supplied behind the bell
cup (independent of turbine air exhaust).
! Aerodynamic design for ease of cleaning external surfaces.
! Speed readout (or control) uses reliable magnetic pickup for fiber optic transmission of
rotational speed data.
! Negligible maintenance down time. With the
quick disconnect feature, an atomizer can be
exchanged in less than 2 minute for off-line
maintenance.
! Two component manifold and in-line mix
feature.
! The easily removable front and rear shrouds,
turbine assembly and the internally mounted
fluid valves, make off-line maintenance more
efficient and economical.
! Fast color changes are achieved using
center feed fluid delivery, integral brake air,
and the fluid valves which provide for simultaneous paint push out while solvent washes
the feed tube and bell cup.
! Bell wash is quick and efficient. Solvent usage is controlled at the feed tube with an internally mounted solvent valve.
! Less waste to the spray booth, with the dump
valve located internally next to the feed
tube.
! No external high voltage cable. The internally mounted high voltage cascade requires
only low voltage control wiring. Removable
without disassembling entire unit.
! Compact high voltage control system. The
MicroPak cascade control takes only 1/4 of
the space in a 19-inch Euro rack, leaving
room for additional control modules.
! 60o angled body provides more maneuverability and facilitates robotic programming.
! Heavy duty design ensures excellent service
life even when subjected to the quick motions
of robotic applications.
! Various adapter plates available to match
most robotic mounting configurations.
! Direct charging of fluid (solventborne paint)
promotes high transfer efficiency.
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! Single purge manifold with intergrated fluid
5
! Three different cups allows versatility of
atomization and pattern size.
! Fractional and metric tubing connections
LN-9244-03.3
RMA-202 Rotary Atomizer - Introduction
Robot Plate
available.
! Teathered break-away features insures atomizer remains with robot in case of a
collision.
! Optional true dual purge capability. Spray
one color while cleaning the other paint line
with no loss of tip voltage.
The robot plate is a component of the tubing bundle
assembly and intended to be permanently mounted
to the robot. A wrist adapter is also provided,
which matches the robot's mounting configuration.
The incoming air lines, fluid lines, low voltage
cable, and fiber optic cable are connected to the
fittings provided on the back of the robot plate. The
bell plate of the atomizer assembly is secured to
the robot plate with a threaded retaining ring.
Valve Manifold
GENERAL DESCRIPTION
Bell Cup Assembly
All bell cups are made of high strength Titanium.
They are available in 30mm, 57mm, and 57mm "V"
cup diameters. Each bell cup size has its own
matching shroud and shaping air ring.
Air Bearing T
urbine Assembly
Turbine
The air bearing turbine assembly with bell cup is
mounted to the air manifold assembly with four
socket head cap screws.
Air Manifold Assembly
The air manifold assembly is angled at 60° for
robot applications. The fluid feed tube and fiber
optic turbine speed emitter are threaded into the
front of the manifold. The turbine, fluid, and air
manifold are separated from the bell plate assembly
by four support rods. Nested between the
manifolds and the bell plate is the high voltage
cascade.
Bell Plate Assembly
The bell plate assembly is designed to be at
ground potential when mounted to the robot plate
component within the tubing bundle assembly.
The air and fluid ports are compactly oriented for
use in robotic applications. The interior air supplies
are ported through the four (4) support rods and
also directly tubed to the air manifold assembly.
On the exterior side of the bell plate, the ports are
provided with o-ring seals so that the atomizer can
be quickly mated and secured to the robot plate.
LN-9244-03.3
The valve manifold houses valves required for
fluid triggering and color changing. The solvent
valve is used for flushing of the valve cavities, the
fluid tube, and the bell cup. All valves are easily
accessed.
Break-Away Feature
The RMA-202 assembly is equipped with a breakaway feature to minimize the damage to the
atomizer, robot, etc. If a collision occurs, the six
(6) plastic break-away screws fail and the atomizer
will break free. This will leave the break-away ring
and the mounting ring attached to the robot. A
tether will be activated which is connected to the
atomizer and the break-away ring, preventing the
atomizer from failing. This feature can be disabled
by replacing the six (6) break-away screws with
six (6), glass filled nylon, 1/4-20 X 1/2" long, fillister
head screws (LSFA0004-16C).
Power Supply and Controls
The high voltage cascade located inside the RMA202 is controlled by the MicroPakTM control unit.
The low voltage output of the MicroPak is multiplied
by the internal cascade to the high voltage level
required. This eliminates the need for a high
voltage cable. A low voltage cable interconnects
the cascade and MicroPak control. The MicroPak
Eurocard format is designed to fit in a conventional
19 inch or 10 inch rack and requires a 24 V power
input at a maximum 2.5 amps. The MicroPak and
the internal cascade will produce voltages up to
100,000 VDC.
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6
RMA-202 Rotary Atomizer - Introduction
The MicroPak is designed to electronically limit
current to provide safe operation in a spray booth.
The voltage and current draw of the atomizer are
continuously displayed on the MicroPak control
panel. Voltage and overcurrent limits are adjustable
on the front of the MicroPak. MicroPak internal
safety circuits will shut down the system on overcurrent and cable faults.
NOTES
With additional control modules, all of the functions
of RMA-202 and MicroPak can be controlled by a
programmable controller. An Atomizer module
pneumatically controls the speed of the rotary
atomizer with dynamic feedback through a fiber
optic transmitter located on the applicator. An
AirTronic module pneumatically controls the
atomizer’s shaping air. A Digital module pneumatically controls the paint, solvent, and dump
valves located on the atomizer. An I/O module
provides communication between these modules
and the PLC.
The above modules are mounted in one 19-inch
rack and interconnected through a common mother
board.
7
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LN-9244-03.3
RMA-202 Rotary Atomizer - Introduction
SPECIFICA
TIONS *
SPECIFICATIONS
Electrical
Mechanical (Cont.)
Power Supply
Type:
MicroPak
Charging Method:
Direct
Output Voltage:
30-100kV Variable
Output Current:
125 μA
Seal Air Supply:
Nominal):
(Nominal):
Variable
(See Page 9)
Eurocard Atomizer
Module
Brake Air Supply:
(Nominal):
60-90 psig
(414-621 kPa)
Turbine Speed
Control:
Shaping Air
Control:
Eurocard AirTronic Module
Part Sprayability: Determine sprayability of
part to be coated using Test Equipment (76652)
Mechanical
Length:
16.2-inches (412mm)
Diameter:
5.5-inches (140mm)
Approximate Weight:
15 lbs. (6.80 Kg)
Atomizer Only:
18 lbs. (8.16 Kg)
Total Payload:
Turbine Type:
Turbine Air Supply:
Maximum Turbine
Speed:
30mm Bell Cup
57mm Bell Cup
57mm TI Bell Cup
Air Bearing Impulse
Drive
Variable
(See Page 10)
Continuous
50,000 rpm
50,000 rpm
50,000 rpm
Bearing Air Supply: 90 psig (±10 psi)
(Nominal):
(621 kPa ±69 kPa)
2.1 SCFM (60 slpm)
Shaping Air Supply: Variable
(See Page 9)
Maximum Fluid Pressure Supply:
200 psi (1379 kPa)
Paint:
10-30 psi (69-207 kPa)
Solvent:
Fluid Flow Rate:
25-500 cc/minute
Bell Cup Cleaning
Time:
2-3 seconds (Approx.)
Color Change Time: Dependent on system
configuration, fluid pressures, fluid viscosity, fluid
line lengths, etc.
Speed Readout: Magnetic pick-up, unidirectional fiber optic transmission
Atomizer Replacement
Time:
Less than 2 minutes
Bell Cup Replacement
Time:
Less than 2 minutes
* Specifications and ratings based on
testing at sea level standard conditions.
LN-9244-03.3
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8
RMA-202 Rotary Atomizer - Introduction
NOTE
> Graphical information provided for
reference only. Performance will vary
depending on coating material viscosity
and flow rate, supply tubing lengths, etc.
(Pressure data shown was measured 12inches (304.8mm) behind the applicator.)
9
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LN-9244-03.3
RMA-202 Rotary Atomizer - Introduction
TURBINE AIR SUPPLY PRESSURE vs TURBINE SPEED
LOADED WITH 500 CC WATER AND UNLOADED
30MM BELL CUP
40.0
LOADED
30.0
20.0
UNLOADED
10.0
0.0
60.0
50.0
LOADED
40.0
UNLOADED
30.0
20.0
10.0
0.0
10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000
10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000
RPM
RPM
TURBINE AIR FLOW vs TURBINE SPEED
LOADED WITH 500 CC WATER AND UNLOADED
57MM BELL CUP
TURBINE AIR SUPPLY PRESSURE vs TURBINE SPEED
LOADED WITH 500 CC WATER AND UNLOADED
57MM "V" CUP BELL CUP
80.0
600
20
550
70.0
18
450
16
14
LOADED
350
12
300
10
UNLOADED
8
200
(SCFM)
VOLUME (SPLM)
400
60.0
PRESSURE (PSIG)
500
250
(kPA)
50.0
70.0
550
525
500
475
450
425
400
375
350
325
300
275
250
225
200
175
150
125
100
75
50
25
0
50.0
LOADED
40.0
UNLOADED
30.0
20.0
6
150
4
100
2
50
10.0
0.0
550
525
500
475
450
425
400
375
350
325
300
275
250
225
200
175
150
125
100
75
50
25
0
(kPA)
PRESSURE (PSIG)
60.0
80.0
PRESSURE (PSIG)
70.0
550
525
500
475
450
425
400
375
350
325
300
275
250
225
200
175
150
125
100
75
50
25
0
(kPA)
80.0
TURBINE AIR SUPPLY PRESSURE vs TURBINE SPEED
LOADED WITH 500 CC WATER AND UNLOADED
57MM "V" CUP BELL CUP
10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000
0
0
10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000
RPM
RPM
LN-9244-03.3
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10
RMA-202 Rotary Atomizer - Introduction
11
ARCHIVE
LN-9244-03.3
Y
10.83 Inches
(275.1mm)
12.56 Inches
(319mm)
14.29 Inches
(363.0mm)
16.03 Inches
(407.2mm)
17.76 Inches
(451.1mm)
X
18.16 Inches
(461.3mm)
19.16 Inches
(488.6mm)
20.16 Inches
(512.1mm)
21.16 Inches
(537.5mm)
22.16 Inches
(562.9mm)
T.D.
4 Inches
(102mm)
6 Inches
(152mm)
8 Inches
(203mm)
10 Inches
(254mm)
12 Inches
(305mm)
30mm RMA-202 TOOL
POINT DIMENSIONS
RMA-202 Rotary Atomizer - Introduction
Figure 1:
LN-9244-03.3
30mm RMA-202 Tool Point and Center of Gravity Dimensions
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12
13
Y
10.68 Inches
(271mm)
12.41 Inches
(315mm)
14.15 Inches
(359mm)
15.88 Inches
(403mm)
17.61 Inches
(447mm)
X
18.07 Inches
(459mm)
19.07 Inches
(484mm)
20.07 Inches
(510mm)
21.07 Inches
(535mm)
22.07 Inches
(561mm)
T.D.
4 Inches
(102mm)
6 Inches
(152mm)
8 Inches
(203mm)
10 Inches
(254mm)
12 Inches
(305mm)
57mm RMA-202 TOOL
POINT DIMENSIONS
RMA-202 Rotary Atomizer - Introduction
Figure 2:
57mm and 7mm "V" Cup RMA-202 Tool Point Dimensions
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LN-9244-03.3
Y
10.83 Inches
(275.1mm)
12.56 Inches
(319mm)
14.29 Inches
(363.0mm)
16.03 Inches
(407.2mm)
17.76 Inches
(451.1mm)
X
18.16 Inches
(461.3mm)
19.16 Inches
(488.6mm)
20.16 Inches
(512.1mm)
21.16 Inches
(537.5mm)
22.16 Inches
(562.9mm)
T.D.
4 Inches
(102mm)
6 Inches
(152mm)
8 Inches
(203mm)
10 Inches
(254mm)
12 Inches
(305mm)
30mm RMA-202 TOOL
POINT DIMENSIONS
RMA-202 Rotary Atomizer - Introduction
Figure 3:
LN-9244-03.3
30mm "Ghost Buster" RMA-202 Tool Point and Center of Gravity Dimensions
ARCHIVE
14
RMA-202 Rotary Atomizer - Introduction
Figure 4a:
Figure 4b:
15
Single Purge Manifold Schematic
Dual Purge Manifold Schematic
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Introduction
Figure 4c:
Figure 4d:
LN-9244-03.3
2 Component Manifold Schematic
Single Purge Regulator Manifold Schematic
ARCHIVE
16
RMA-202 Rotary Atomizer - Installation
INST
ALLA
TION
INSTALLA
ALLATION
AIR FIL
TER
FILTER
INST
ALLA
TION
INSTALLA
ALLATION
AIR PRESSURE
REQUIREMENTS
Tube
Size
The following air filter installation guidelines are
essential for optimum performance:
1. Use only recommended pre-filters and bearing
air filters as shown "Air Filtration Requirements"
chart. Additional system air filtration (i.e.,
refrigerated air dryer) may also be used if desired.
2. Mount the bearing air filter as close as possible
to the RMA-202. (DO NOT mount further than 30
feet (9.1 meters) away.)
3. DO NOT use Teflon tape, pipe dope, or other
thread sealant downstream of the bearing air filter.
Loose flakes of Teflon tape or other sealant can
break loose and plug the very fine air holes in the
turbine air bearings.
4. If air heaters are used in the system (to minimize the effect of excessively humid conditions),
and the heated air will exceed 120oF (48.9°C), the
heaters must be located after all filters to prevent
damage to the filter media.
Bearing Air
Supply (B.A)
Bearing Air
Return (B.A)
1/4" OD
(Yellow)
1/4" OD
(Yellow)
Turbine Air
(T.A)
Shaping Air
(S.A)
Seal Air
(SL.A)
Brake Air
(BRK) (if used)
3/8" OD
(Green)
3/8" OD
(Gray)
3/8" OD
(Blue)
1/4" OD
(Orange)
Trigger Valve
Control (P2T)
Dump Valve
Control (DL2)
Trigger Valve
Control (P1T)
Dump Valve
Control (DL1)
Solvent Valve
Control (ST)
5/32" OD
(Natural)
5/32" OD
(Black)
5/32" OD
(Green)
5/32" OD
(Orange)
5/32" OD
(Blue)
Air Pressure
Requirements
90 psi +/- 10
620 kpa ± 68.9
80psi +/- 20
551.6 kpa ± 68.9
(at atomizer card)
Variable
Variable
Variable
60-90 psi +/- 10
413.7-620.5 kpa ±
68.9
80 psi +/- 5
551.6 kpa ± 34.5
80 psi +/- 5
551.6 kpa ± 34.5
80 psi +/- 5
551.6 kpa ± 34.5
80 psi +/- 5
551.6 kpa ± 34.5
80 psi +/- 5
551.6 kpa ± 34.5
NOTE
> With the exception of fluid, dump, and
bearing air, all other pilot and air supply
lines should be bulkheaded at the booth
wall and their diameters increased one
size. For example: Turbine air should be
increased to a 1/2-inch OD from bulkhead
plate to the volume booster.
17
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Installation
AIR FIL
TRA
TION REQUIREMENTS
FILTRA
TRATION
ITW Filter
No.
Model No
Description / Specifications
Replacement
Element Part No.
HAF-503
Pre-filter, removes coarse amounts of oil, moisture & dirt. Used HAF-15 Element, One
upstream of RPM-417 pre-filter (used in systems with poor air
quality).
RPM-417
Pre-filter, coalescing type, 136 SCFM, 98.5% efficiency particulate RPM-32 Elements,
removal .3 to .6 micron, max. aerosol passed 1.0 micron, max. Carton of 4
solid passed .4 micron (dependent upon scfm requirement per
applicator, one RPM-417 can be used with up to three RMA-202
assemblies).
RPM-418
Bearing air filter, coalescing type, 19 SCFM, 99.995% efficiency RPM-33 Elements,
particulate removal .3 to .6 micron, max. aerosol passed .6 micron, Carton of 8
max. solid passed .2 micron (one per applicator).
!
CAUTION
> Air must be properly filtered to ensure
extended turbine life and to prevent
contamination of the paint finish. Air which is
not adequately filtered will foul the turbine air
bearings and cause turbine failure. The
correct type of filters must be used in an
RMA-202 system. The filter elements must
be replaced on a regular schedule to assure
clean air.
> It is the user’s responsibility to
ensure clean air at all times. Turbine
failure resulting from contaminated air
will not be covered under warranty.
"Air Filtration Requirements" chart shows
the pre-filter(s) and bearing air filter which are
recommended for use in RMA-202 systems.
If other filters are incorporated in the system,
the filters to be used must have filtering
capacities equal or better than those shown
in "Air Filtration Requirements" chart.
> The user must ensure the bearing air
supply is not inadvertently turned off while
the RMA-202 air motor is turning. This will
cause air bearing failure.
LN-9244-03.3
ARCHIVE
18
RMA-202 Rotary Atomizer - Installation
AIR HEA
TER
HEATER
REQUIREMENTS
Turbine drive air expands as it moves through the
turbine wheel cavity and as it exits the turbine from
the exhaust port. This expansion will cause
cooling of the exhaust air and the surfaces it
contacts. This same expansion cooling can occur
across the shaping air exit ports. This cooling
effect can cause surface temperatures to fall
below the dew point of the booth, which will result
in condensation on the interior and exterior of the
atomizer, machine, and its components. It is even
possible that the temperature of the supply air may
be below the booth dew point, even without additinal
expansion cooling.
Condensation is especially probable in waterborne
applications when booth temperature and relative
humidity levels are typically maintained very high.
This condensation will allow sufficient conductivity
of the surfaces such that they act as an erratic
ground source potential. This can cause damage
to the equipment.
It is therefore, a requirement that turbine exhaust
air temperature be maintained above the booth
dew point to prevent condensation from forming
on atomizer surfaces. Doing so will eliminate
moisture as a potential defect in painted surfaces
as well as extending equipment life. Thus, it is
recommended that air heaters be installed into the
atomizer air supply lines, i.e. turbine drive air,
shaping air, and seal air. The air heaters must be
of sufficient capacity, capable of raising the
incoming air temperature at least 40°F (4.4°C) at
a flow rate of 60 SCFM (1700 slpm) per applicator.
The actual air heater process setting depends on
applicator fluid flow rate load, booth conditions,
turbine airflow settings, and incoming air
temperature. The heater should be set as low as
possible, sufficient to maintain the applicator
surface temperatures above the dew point in the
booth.
19
Example: With the incoming air temperature at
72°F (22.2°C), and RMA-202 with 57mm bell cup
rotating unloaded at 50 krpm has a turbine outlet
temperature drop of approximately 28°F (-2.2°C)
(@ 40 krpm unloaded, at 50 krpm has a turbine
outlet temperature drop of approximately 28°F
(@ 40 krpm unloaded, ΔT ~ 14°F (-10°C)).
Referring to the ASHRAE Psychrometric chart,
the saturation temperature range (dew point) of a
spray booth maintained at 70-75°F / 65-70% RH is
62-68°F (21.1-23.9° / 65-70% RH is 16.7-20°C).
Thus it is almost certain that the surface
temperatures of the applicator will fall below the
dew point of the booth, and an air heater will be
needed in this case.
To prevent condensation, an ITW Air Heater
Assembly (A11065-02) should be assembled after
the air filters. (Reference the current "Air Heater
Assembly" Service Manual for further information.)
NOTE
> Failure to use an air heater may cause
damage to equipment or ruin the finished
component being processed.
MOUNTING
The RMA-202 is equipped with a quick disconnet
assembly. The quick disconnect feature consists
of a robot plate which is permanently attached to
the robot through a wrist adapter plate, and a
mating bell plate which is a part of the RMA-202's
atomizer assembly. The atomizer is secured to
the robot plate with a threaded retaining ring. A
plastic cover is placed over the threaded ring for
overspray protection.
NOTE
> An adjustable spanner wrench (76772)
is available to tighten the threaded ring to
the RMA-202's robot plate.
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Installation
ELECTRICAL AND FIBER
OPTIC CONNECTIONS
The low voltage electrical and fiber optic
connections are made on the back of the atomizer's
robot plate. The low voltage electrical and fiber
optic cables come preassembled with connectors
that are secured in place by set screws tightened
from the side of the robot plate. Before securing
the electrical cable, the slot in the connector must
be aligned with the slot in the robot plate. An
adequate ground must be provided to the mounting
plate to ensure that fluid fittings and tubing do not
electrically break down.
FLUID TUBING CONNECTION REQUIREMENTS
Fixed Atomizer
Paint Line
(P1.IN, P2.IN)
Solvent Line
(S.IN)
Dump Line
(DL)
LN-9244-03.3
Pressure (Nominal/Maximum)
.170", .188, or .250" ID / PFA, Teflon
200 psi max. (1379 kpa)
.125" ID / PFA, Teflon
10-30 psig (69-207 kpa)
3/8" OD X 1/4 ID / PFA, Teflon
Variable
ARCHIVE
20
RMA-202 Rotary Atomizer - Installation
FLUID CONNECTIONS
The paint, solvent, and dump fluid tubing are
connected on the back of the robot plate with
stainless steel compression fittings and PFA Teflon
tubing. Fluid tubing requirements are shown in
"Fluid Tubing Connections Requirements" chart.
For single, dual purge, and two component follow
labels for tubing connections and functions per
back of robot plate and diagrams in this manual.
Particular attention needs to be paid to the
connection of tubing for the regulator style version
of the RMA-202 (see the following diagrams).
Fluid and Pilot Connections for RMA-202 Dual
Purge and Two-Component Version
(All Other Air Connection Typical for All
Versions)
INTERLOCKS
The following system interlocks are required to
prevent equipment damage:
1. Bearing air should remain on at all times and
should be shut off only by turning off the main air
to the pneumatic control cabinet.
Fluid and Pilot Connections for RMA-202
Single Purge Version
(All Other Air Connection Typical for All Versions)
!
CAUTION
> When the turbine air is turned off, the
turbine will continue to operate or “coast
down” for about two minutes. Provisions
should be made to assure that the operator
waits at least three minutes, after shutting off
the turbine air and before shutting off the main
air supply.
> The bell cup must be removed when
making flow checks. If the paint is turned on
when the bell is mounted on the motor shaft
and not rotating, paint will enter the shaft and
possibly damage the air bearing. Normally
pneumatic interlocks will not allow the paint to
trigger on when the turbine air is off.
Fluid and Pilot Connections for RMA-202
Regulator Version
(All Other Air Connection Typical for All Versions)
21
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Installation
! WARNING
> The high voltage and/or coating material
must never be turned on unless the bell cup
is mounted on the motor shaft and the turbine
is rotating.
> Pneumatic input to the turbine air inlet must
be controlled to prevent the turbine from
exceeding the maximum rated speed of
50,000 rpm. (See "Specifications" in the
"Introduction" section.)
2. It should not be possible for the coating material
to be sprayed unless the turbine is spinning.
3. Two interconnected bearing air ports are provided, one for supply air and the other to be used
as a return signal for measuring bearing air
pressure at the atomizer. If bearing air falls below
60 psi at the atomizer, the turbine air should be
automatically interlocked to shut off.
4. High voltage must be interlocked with the
solvent valve pilot signal to prevent solvent flow
while high voltage is energized.
Fasten the cable bundle at the exit of the arm.
Push the robot spacer plate and applicator
mounting plate to the robot wrist plate aligning the
top dead center marks of the spacer plate and
robot wrist plate. Fasten using appropriate screws.
Installing the tubing bundle in this fashion will
increase tubing bundle life significantly.
BUNDLE LUBRICANT
When the tubing bundle is installed, it should be
lubricated with a generous amount of lubricant to
increase the service life of the tubes. A
recommended lubricant is Shell Alvania EP #02.
There are other lubricants that are available for
use. Prior to using a lubricant, insure it is silicone
free, resists heat breakdown, and is compatible
with the materials it will contact.
250 MM
(10")
APPROX.
TYPICAL
ROBOT
ARM
5. Turbine air and brake air must be interlocked to
prevent both from being used simultaneously.
ROBOT WRIST PLATE
TUBING BUNDLE
INST
ALLA
TION
INSTALLA
ALLATION
ROBOT
SPACER
PLATE
APPLICATOR
MOUNTING
PLATE
Typically, the tubing bundle is pulled through the
robot arm from the robot wrist side. Keep the
bundle taped except for the bundle that will be
inside the arm. Pull the tubing through the wrist
and arm, leaving about 250mm (10") of tubing
sticking out the front of the wrist plate (see Figure
5).
LN-9244-03.3
Figure 5:
ARCHIVE
Tubing Bundle Installation
22
RMA-202 Rotary Atomizer - Operation
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).
As with any spray finishing system, operation of
the RMA-202 involves properly setting the
operating parameters to obtain the best finish
quality for the coating material being sprayed,
while maintaining correct operation and reliability
of the equipment used. Adjustments to operating
parameters, which cover spraying, cleaning, and
on/off control, include:
!
!
!
!
!
!
!
!
!
!
Coating Materials
Fluid Flow Rate Control
Fluid Valve Control
Turbine Speed
Bearing Air Adjustment
Shaping Air
Seal Air
Brake Air
Electrostatic Voltage
Target Distance
! 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 is non-flammable. In
these conditions the system is capable of
releasing sufficient electrical and thermal
energy to cause ignition of specific hazardous
materials in air.
23
FLUID FLOW RA
TE
RATE
CONTROL
Externally mounted fluid regulators or gear pumps
are typically used to control fluid flow. Paint is
supplied to the RMA-202 by way of the tubing
bundle through the robot arm.
The atomizer assembly is equipped with micro
valves which are pneumatically operated to direct
the flow of paint to either the feed tube or dump line
and to supply an intermittent solvent to clean the
feed tube and bell cup.
The feed tube is available in several sizes: .035,
.045, .062, and .094. The viscosity and volume of
the coating material being sprayed determine the
correct size of feed tube for each installation. The
feed tube diameter acts as a linear restrictor to
create back pressure on the fluid regulator so that
it can provide accurate and repeatable flow to air
signal resolution.
Fluid Flow Rate Check
In the test mode, the flow rate can be measured by
removing the bell cup from the atomizer, turning
the fluid flow on, and capturing the material in a
graduated beaker or measuring cup for a fixed
period of time (shaping air, high voltage, and
turbine air must be off).
! WARNING
> Danger of shock and/or personal injury
can occur. Proper grounding procedures
must be followed. Personnel must never
work around the turbine when the turbine is
spinning or when high voltage is turned on.
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Operation
FLUID V
AL
VE CONTROL
VAL
ALVE
FLUID REGULA
TION
REGULATION
MANIFOLD
(T
rigger
(Trigger
rigger,, Dump & Solvent)
(See "Figures 4a and 4b for Schematics".) The
fluid valves in the RMA-202 are actuated by an air
signal. The air pressure must exceed 70 psi
(482.6 kPa) to assure proper actuation of the
valve. Applying air to the valve actuator turns on
the fluid flow for that valve.
The RMA-202 has an optional fluid regulator style
valve manifold. Fluid regulation can be easily
controlled at the applicator. This valve manifold
contains one trigger valve, one dump valve, and
one solvent valve. The regulator unit is located
upstream of the trigger valve.
The trigger valve controls the paint flow to the bell.
When actuated, paint flows through the valve to
the fluid tube, and into the rear of the bell cup. The
bell cup must be spinning at least 10,000 rpm
when fluid is turned on to enable the fluid to flow
through the bell paint passage holes and be
atomized.
DUAL COMPONENT
MANIFOLD
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
trigger valve since the trigger valve is intended to
cause the fluid to flow to the bell at the prescribed
input pressure.
The solvent valve controls the flow of cleaning
solvent to the bell. When actuated, solvent flows
through the fluid tube and into the rear of the bell
cup. This provides cleaning of the inside of the bell
cup. The solvent valve is not triggered at the same
time as the paint trigger valve to prevent solvent
from flowing backward into the paint line.
DUAL PURGE SPRA
YING
SPRAYING
The RMA-202 has optional dual purge capability.
This means the applicator can continue to spray
paint, at voltage, while side "B" or "Paint 2" is being
flushed or cleaned. To operate in the dual purge
mode, two (2) separate color valve systems
must be installed.
LN-9244-03.3
The RMA-202 has an optional dual component
manifold. This manifold allows two component
material to be supplied to the manifold by external
fluid proportioning devices. The components are
mixed within the applicator, in-line with the fluid
tube. Both valves have integrated check valves to
prevent reverse flow. The manifld incorporates
two trigger valves, two dump valves, and one
solvent valve.
!
CAUTION
> The normal fluid flow range is 25-500 cc/
min. During a color change or when flushing
the system, higher flow rates may be required.
However, the maximum flow rate through the
bell cup must not exceed 500 cc/min. to avoid
solvent or paint from flooding into the internal
portion of the air bearing motor assembly or
front shroud.
> High voltage must be interlocked with the
solvent valve to prevent solvent spraying
while high voltage is on.
ARCHIVE
24
RMA-202 Rotary Atomizer - Operation
! WARNING
> When flushing the RMA-202 ALWAYS
flush through the dump valve rather than the
trigger valve. Only use solvent to flush the
fluid tube in the bell. A solvent/air mixture or
sequence will cause paint build-up on the
fluid tube.
TURBINE SPEED
Turbine speed is determined by the input pressure
at the rear of the atomizer.
Turbine speed is intended to be closed loop
controlled using the fiber optic speed transmitter,
located on the turbine manifold. A speed input to
a remote speed controller, such as the atomizer
module, is recommended.
NOTE
> The bell rotational speed determines the
quality of atomization and can be varied for
various paint flow rates and paint formulations. For optimum transfer efficiency and
spray pattern control, the bell rotational
speed should be set at the minimum required to achieve proper atomization.
Excessive speed reduces transfer
efficiency!
! WARNING
> DO NOT exceed the maximum rated
operating speed and turbine inlet pressure.
Excessive speed may cause air turbine
damage or damage to the bell.
25
BEARING AIR
ADJUSTMENT
The nominal bearing air pressure is 90 psi, (620.5
kPa) measured at the rear of the atomizer. Minimum
pressure is 70 psi (482.6 kPa) and maximum
pressure is 100 psi (689.5 kPa). The turbine
should never be operated with less than 70 psi
(482.6 kPa) bearing air pressure.
Bearing air must be present when turning the
turbine on. Bearing air must remain on when the
turbine air is turned off until the turbine stops
spinning. Never turn off bearing air to cause the
turbine to stop spinning. If connected, brake air
can be used to slow the turbine.
!
CAUTION
> Bearing air MUST be ON whenever the
turbine is operated. If not, severe bearing
damage will occur. It is recommended that
bearing air be left turned on at all times,
except during maintenance or disassembly.
> Bearing damage (and subsequent turbine
failure) caused by running the turbine without
bearing air WILL NOT be covered under the
ITW Ransburg warranty.
The RMA-202 is equipped with a bearing air return
line to monitor bearing air pressure at the turbine
manifold. When connected to the remote Atomizer
speed controller, operation of the turbine will
automatically be shut down whenever the bearing
air pressure falls below the dip switch setting of
60, 70, or 75 psi (413.7, 482.6, or 517.1 kPa).
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Operation
SHAPING AIR #1
Shaping air is used to shape the spray pattern.
Lower input pressure results in wider pattern size,
while higher input pressure reduces the pattern
size. Higher shaping will assist in the penetration
of atomized particles into cavity areas. Ideally,
shaping air should be kept at the minimum pressure
which will provide a proper finish for the fluid being
sprayed. Excessive shaping air will cause some
atomized particles to blow by the target, reducing
the wrap around effect at edges and corners.
Excessive shaping air may also cause some paint
particles to bounce back onto the atomizer, causing
the atomizer surface to become contaminated.
SHAPING AIR #2
(Refered to as "Seal Air")
This secondary air is a controlled source of
supplemental air used in directing paint particles
away from the outside surface of the atomizer bell.
This air is typically supplied from a regulated
source and should be kept at the minimum
pressure, sufficient for keeping the bell surface
clean. These conditions are true for the 79004-00,
RPM-457, and RPM-452 bell cup options. With
these cups and shroud assemblies, excessive air
will influence the effects of the first shaping air.
With the A11957 bell cup option, this second
shaping air will provide better control of the pattern,
better pattern shape consistency, and provide a
good tool for penetration of deep cavity parts when
used in conjunction with the first shaping air.
BRAKE AIR
Brake air is used to slow the turbine speed in a
minimum length of time. It is advantageous for
short cycle times during color change, or may be
used to reduce speed or stop the turbine. Never
operate brake air with the turbine air on.
LN-9244-03.3
Approximate brake times to reduce the turbine
speed are shown in "Braking time" chart. These
times are based on 60 psi (413.7 kPa) air pressure
at the brake air connector.
The use of brake air is optional, and may not be
required for many installations. The Atomizer
Module Control system provides the circuitry for
automatic use of the brake air.
BRAKING TIME
To Brake From
(RPM)
Seconds
(Approx.)
3.7
7.5
10.0
4.0
9.0
50,000 to 40,000
50,000 to 20,000
50,000 to 0
40,000 to 20,000
40,000 to 0
ELECTROST
ATIC
ELECTROSTA
VOL
TAGE
VOLT
The RMA-202 Rotary Atomizer receives a low
voltage control input from the MicroPak to control
the operating electrostatic voltage. Refer to the
MicroPak manual for detailed operating instructions.
(See Figure 6 for power curve of HP-404 Cascade.)
NOTE
> If paint defects occur, such as fatty
edges or picture framing, reducing the
voltage should be a last resort. To correct
the problem, adjustments to paint resistivity or lead and lag trigger adjustments
should be made.
> The electorstatic voltage applied to the
RMA-202 will affect pattern size, transfer
efficiency, wrap and penetration into cavity areas. Normally a setting of 70-100 kV
is appropriate for most applications.
ARCHIVE
26
RMA-202 Rotary Atomizer - Operation
TARGET DIST
ANCE
DISTANCE
NOTES
The distance between the RMA-202 atomizer and
the target will affect the finish quality and efficiency.
Closer distances give a smaller pattern, wetter
finish, and greater efficiency. Greater distance
will provide a large pattern size and drier finish.
The MicroPak control circuit will enable the
applicator bell to be operated to within a few inches
of the target without adjusting the voltage setting.
The recommended target distance is 6 to 12inches (152.4-304.9mm). In general, allow 1-inch
target distance for every 10 kV.
Figure 6:
27
HP-404 Cascade Power Curve
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Operation
NOTES
LN-9244-03.3
ARCHIVE
28
RMA-202 Rotary Atomizer - Maintenance
MAINTENANCE
O-RINGS
All o-rings in this atomizer are solvent proof except
the ones on the air bearing spindle. These o-rings
must not be soaked in solvent; if these are exposed
or soaked in solvent, they must be replaced.
These o-rings are engineered to provide a fit
between the air bearing spindle and it's mating
parts to reduce or eliminate harmonic resonance
(vibration).
Some o-rings are Teflon encapsulated. These orings have a limited amount of stretch and will not
return to their original diameters if over stretched.
These o-rings are subject to being distorted more
easily than rubber o-rings, so it is important that
they be sufficiently lubricated when mating parts
are installed onto them. They also will take a
square set over time and should be replaced
periodically if mating parts are removed repeatedly
or if a new mating part is installed onto them.
Any o-ring that is cracked, nicked, or distorted
must be replaced.
CLEANING PROCEDURES
! WARNING
> Electrical shock and fire hazards
can exist during maintenance. MicroPak supply must be turned off before
entering the spray area and performing
any maintenance procedures on the
atomizer. Spray booth fans should remain on while cleaning with solvents.
> Never touch the atomizer bell while
it is spinning. The front edge of the bell
can easily cut into human skin or cut
through gloves and other materials. Be
sure the atomizer bell has stopped spinning before attempting to touch it.
Approximate time for the bell to stop
spinning after turning off turbine drive air
is three minutes.
29
In addition to the previous Warning, which relates to potential safety hazards, the following
information must be observed to prevent damage to the equipment.
!
CAUTION
> DO NOT immerse the RMA-202
turbine in solvent or other liquids. Turbine components will be damaged.
> Bearing air must be on during all
cleaning procedures to protect the air
bearing components.
Internal Fluid Path Purge
Cleaning
Cleaning the incoming paint line (from paint supply
source such as a color manifold, through the
atomizer valve manifold):
High voltage does not have to be turned off
if flushing through the dump valve but must
be turned off if flushing through the bell cup
or any bell cup flushing sequence.
Open the dump valve and flush the incoming paint
line with solvent or an air/solvent chop. Make sure
the last step of the sequence is air to purge the
dump line of remaining solvent. To speed the
loading of the new paint, leave the dump line open
to allow the air in front of the paint push to escape.
The length of time the dump valve is open depends
on several factors such as viscosity, paint
pressure, etc. Timing should be such that the
dump is closed as the paint reaches the trigger
valve in the atomizer. Paint in the dump line may
cause high voltage issues.
The fluid coil and fluid tube can be cleaned
independently by actuating the solvent valve in the
atomizer. High voltage must be turned off
during this operation and the bell cup must
be spinning (typically 30,000 rpm for cup
flushing sequences).
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RMA-202 Rotary Atomizer - Maintenance
If utilizing a dual purge manifold, one side of the
valve manifold in the atomizer can be cleaned and
loaded with new paint while the other side of the
manifold is in the spraying operation. When the
new color on the second side needs to be sprayed,
only the fluid coil and fluid tube needs to be purged,
making cycle time very fast and efficient.
The regulator manifold version is flushed the same
way as the other manifolds except the pilot air to
the regulator should be increased to fully open the
regulator for a faster cycle time.
The 2 component manifold version is operated in
the same way as the other manifolds except the
pilot air to the regulator should be increased to fully
open the regulator for a faster cycle time.
The 2 component manifold version is operated in
the same way as the previous manifolds; however
it is recommended that this manifold is purged
frequently to prevent damage as the result of the
dual component material being sprayed.
Bell Cup Cleaning
(Without Cleaning the Incoming
Paint Line)
Turn off the high voltage and trigger valve. With
the bell spinning, turn on the solvent valve to allow
cleaning solvent to flow through the manifold passages, through the fluid tube, and onto the bell.
The spinning bell will atomize the solvent, clean
out the bell passages. It is always preferable to
blow the solvent line dry after the cleaning operation. Typical bell speed during the cup flush
sequence is 30,000 rpm.
!
External Atomizer Surface Cleaning
• Verify that the high voltage is turned off.
• All external surfaces may be cleaned using a
mild solvent and lint free rags to hand wipe
the RMA-202 Turbine drive air must be off,
but leave shaping air, seal air, and bearing air
on. Be careful not to drip solvent into the
opening behind the bell.
• All residue must be removed using a nonconductive non-polar solvent (ex., high flash
naphtha).
• Do not spray the RMA-202 unit with a solvent
gun used for cleaning. The cleaning fluid under pressure may aid conductive materials to
wick into hard to clean areas or may allow
fluids to be forced into the turbine assembly.
• Do not reuse an atomizer bell cup that shows
signs of damage such as nicks, heavy
scratches, dents, or excessive wear.
! WARNING
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 WARRANTY.
>
CAUTION
> The maximum flow rate of 500 cc/min.
must not be exceeded during a flush routine. Use of an in-line fluid restricter is
recommended. (Example: Hosco P/N
RIL-6-AJ or similar)
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30
RMA-202 Rotary Atomizer - Maintenance
! WARNING
> To reduce the risk of fire or explosion,
OSHA and NFPA-33 require that solvents
used for exterior cleaning, including bell
cleaning and soaking, be nonflammable (flash
points higher than 100oF/37.8oC). Since
electrostatic equipment is involved, these
solvents should also be non-polar. Examples
of non-flammable, non-polar solvents for
cleaning are: Amyl acetate, methyl amyl
acetate, high flash naphtha, and mineral
spirits.
> Do not use conductive solvents such as
MEK to clean the external surfaces of the
RMA-202.
> When using a rag to hand wipe the RMA202, the turbine air should be off, but leave
the shaping air, seal air, and bearing air
turned on. Ensure that rotation has come to a
complete stop. Be careful not to drip solvent
into the opening behind the bell.
VIBRA
TION NOISE
VIBRATION
If the RMA-202 is vibrating or making an unusually
loud noise, it usually means there is an imbalance
situation. The atomizer bell cup may have dried
paint on it or the bell may be physically damaged,
or there may be paint trapped between the bell cup
and shaft preventing the bell cup from properly
seating. If any of these conditions exist, they
MUST be corrected. Excessive imbalance
caused by one of these conditions may result in
bearing damage and turbine failure. Warranty
DOES NOT cover failure caused by imbalanced
loading conditions.
To determine if the bell is dirty or damaged, remove
the bell cup and turn the turbine ON. If the noise
is eliminated, the bell cup is the problem. If the
noise continues, the turbine may be damaged and
should be inspected. Excessive air required to
achieve same speed may indicate a faulty or
contaminated turbine. DO NOT continue to
operate a noisy turbine.
31
! WARNING
> If a bell cup comes off a rotating
shaft because of motor seizing or any
other reason, the Atomizer and bell cup
must be returned to ITW Ransburg for
inspection and evaluation to determine if
the bell can be used in operation.
TURBINE REP
AIR AND
REPAIR
REBUILD
DO NOT attempt to rebuild the turbine until after
factory warranty expires. Any endeavor to
disassemble a turbine during the warranty period
will void the warranty. (3 years or 15,000 hours).
Contact your distributor or ITW Ransburg for
turbine rebuilding instructions.
HIGH VOL
TAGE
VOLT
CONNECTIONS
Use a small amount of light dielectric grease
(LSCH0009) on the end of the spring of the high
voltage cascade and the high voltage contact
plate ("T" shape piece) on the rear side of the
turbine housing assembly. This will prevent
moisture damage and ensure the integrity of the
electrostatic system.
AIR FIL
TERS/ELEMENT
FILTERS/ELEMENT
REPLACEMENT ELEMENTS
ITW
Part#
Qty. Elements
Per Carton
RPM-32
4
RPM-33
8
ARCHIVE
Used On
RPM-417,
Pre-Filter
RPM-418,
Bearing Air Filter
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RMA-202 Rotary Atomizer - Maintenance
GENERAL MAINTENANCE
Verify daily that the operating parameters have not
varied significantly from the normal. A drastic
change in high voltage, turbine air, or shaping air,
can be an early indicator of potential component
failure.
PREVENTIVE
MAINTENANCE
• After cleaning, all conductive residue must be
removed using a non-conductive solvent. Since
electrostatic equipment is involved, these
solvents should also be non-polar.
• Inspect bell cup for nicks, dents, heavy
scratches, or excessive wear. Replace if
necessary.
! WARNING
Daily Maintenance
(During Each Preventive Maintenance
Break)
• A laminated poster entitled “Rotary Atomizer
Checklist (AER0075)" is included with the
literature kit with the assembly to be posted
near the station as a handy reference.
• Due to the close proximity of high voltage to
ground potential, a schedule must be developed
for equipment maintenance (cleanliness).
• Verify that high voltage is OFF and that shaping
air, bearing air, and turbine drive air are ON.
• Open the dump valve, flushing all paint from the
supply lines and valve module.
• Open the solvent valve, flushing all paint from
the fluid tube and through the atomizer bell
assembly.
• Verify that high voltage is OFF, turbine drive air
is OFF, and that the bell cup has stopped
spinning. The bearing air and shaping air
should remain ON.
• Clean all external surfaces of the applicator
using a lint-free rag dampened with solvent.
> The high voltage must be turned
OFF before entering the spray area and
performing any maintenance procedures. Spray booth exhaust fan(s)
should remain ON while cleaning the
equipment with solvents.
Valve Seat and V
alve Assembly
Valve
Leakage Check
Remove the rear upper and lower shroud halves.
Inspect the valve weep ports on the valve manifold
body for leaks or contamination. These holes are
approx. 3/32-inches in diameter and are located
on the inside face of the valve manifold towards
the rear of the unit (see Figures 15a and 15b).
These weep holes are common to all valve manifold
styles. If any paint contamination is visible, continue
to the "Valve Removal / Replacement" section of
this manual. Replace valve and seat assembly
every 6 months, or as necessary.
! WARNING
> Make sure high voltage is OFF before approaching applicator with solvent
cloth.
> Do not use reclaim solvent containing d-Limonene. This can cause damage to certain plastic components.
> Do not stop bell rotation by using a
rag or gloved hand against the bell cup
edge.
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RMA-202 Rotary Atomizer - Maintenance
!
NOTE
CAUTION
Maximum flow rate should not
>
exceed 500 cc/min.
> Daily removal and soaking of the bell
cup may not be required if the bell cup is
properly flushed. However, the frequency of the feed tube and internal motor
shaft inspection indicated under "Weekly
Maintenance" can be done daily and
later adjusted to weekly or as required
depending on the results of the inspection.
! WARNING
> In the event the bell cup comes in
contact with a part, that cup should be
checked for damage and replaced if
necessary before continuing to spray.
> Normally the cover will not need replacement daily and could last about one
week. See "Weekly Schedule" in the
"Maintenance" section.
Weekly Maintenance
(Prior to Start or End of
Production Week)
• Monitor rotational speed of all bells at the speed
control.
• Monitor high voltage output indicated on the
MicroPak display.
• Check paint flow on all bells at minimum and
maximum specified settings by taking beakered
readings.
• Check solvent flow by opening solvent valve
and taking a beakered reading (should be within
approx. 10% of target flow rate).
! WARNING
> Do not place high voltage probe on
bell edge unless rotation is fully stopped.
!
CAUTION
> Maximum flow rate should not exceed 500 cc/min.
NOTE
> Refer to the "Troubleshooting Guide"
in the "Maintenance" section for details on
determining the causes of low or no high
voltage at the bell cup.
• Check the amount of paint build-up on the
outer protective cover, if used. If excessive,
replace cover as required.
• Paint residue found in the shaping air or exhaust holes is not acceptable and must be re
moved prior to assembly.
• Clean any paint on outer surface of front and
rear housing with soft cloth dampened with
solvent. (See "Warning" on previous page, on
avoiding the use of cleaning solvent containing d-Limonene.)
• Remove the front shroud and check for any
signs of solvent or paint leakage. Clean as
required.
• Remove bell cup and soak in solvent for 1-2
hours. Remove from cleaning solution and
blow dry before replacing.
33
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RMA-202 Rotary Atomizer - Maintenance
NOTE
> It may be necessary to remove the bell
DISASSEMBL
Y
DISASSEMBLY
PROCEDURES
cups for cleaning more frequently than
weekly. (See Note under "Daily Maintenance".)
NOTE
> Mean time to repair entire assembly is
• Inspect the feed tube tip and clean any paint
build-up that has occurred on the feed tube
tip. Using a pen light, determine if there is
build-up of paint in the motor shaft and/or
around the paint feed tube. If so, remove the
motor assembly following the disassembly
procedures and clean out the inside diameter
of the motor shaft using a tube brush and solvent. Clean the outer surfaces of the feed
tube.
60 minutes.
NOTE
> For reassembly instructions, use the
reverse of the following disassembly procedures.
NOTE
! WARNING
> Make sure that no solvent or other
contamination is allowed to enter the
motor assembly (air bearing and outer
shaft).
• Remove the rear shroud to expose the fluid
valve manifold assembly. Visually inspect for
signs of fluid leaks around fluid connections
and manifold. Correct problem and clean
paint from all components, including internal
portion of shroud.
• Reinstall rear shroud, bell cup, and front
shroud (refer to "Disassembly Procedures"
for definite instructions).
> To fascilitate Atomizer removal from
hose manifold, a robot program should be
made that purges all paints and solvents
from the RMA-202. Ideally it would then
position the bell assembly in a bell removal
position where the bell cup is pointed downward at a 30° angle. Any residual solvents
would be contained in the "J bend" of the
robot wrist.
Atomizer Removal/Reassembly
(Insure all lines are purged and pressures are
relieved before atomizer removal.) The atomizer
is secured to the plate with a threaded retaining
ring (Figure 13, Item 8). While steadying the
atomizer with one hand, unscrew the retaining ring
with the other. Then pull the atomiizer forward to
clear the air studs and fluid connections. Use of a
spanner tool (76772-00) may aid removal.
When reassemblying, slide the mounting ring back
far enough to view the two (2) guide pins on the
rear manifold assembly. Align these two (2) pins
with the corresponding holes of the robot plate.
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34
RMA-202 Rotary Atomizer - Maintenance
Engage rear manifold as tight as possible to the
robot plate. Slide the mounting ring toward the
robot plate and tighten in a clockwise direction.
Tighten the ring firmly. The use of the spanner tool
(76772-00) will insure the ring is tight.
Reassembly Note: Make sure the proper
o-ring seals on the face of the bell plate are in place
and clean. Apply a thin film of A11545-00
Petrolatum jell or pure food grade petroleum jelly
to all o-rings. (Refer to Figures 18 and 21 on the
placement of these o-rings prior to reassembly to
the robot plate.)
Rear Shroud Removal
Using a large flat head screwdriver, turn the slotted
plastic fastener counter-clockwise, while keeping
a downward force on the screw. The screw is
designed to act as a mechanical jack and will
separate the bottom shroud section from the top.
The bottom section is only to be lightly supported
during disassembly. Note: Rear shroud
removal is not required to remove the
atomizer from the robot mounting plate.
Front Shroud/Shaping Air Cap
Removal, Disassembly
Disassembly,, and
Reassembly
Remove the front shroud from the atomizer, using
the RPM-419, or other properly fitting spanner
wrench, and turning counter-clockwise (viewed
as facing the front end).
Note that when the front shroud is removed,
the shaping air cap is removed with it. The
RMA-202 turbine and the bell assembly will
now be exposed.
Using the same wrench, it is also possible to
separate the shaping air cap from the front shroud.
This is much easier to do if the front shroud is
mounted on the turbine assembly, since it is
difficult to grasp the shroud and the wrench
simultaneously if the parts are removed from the
mechanical support of the assembly. Hold the
front shroud stationary while turning the shaping
air cap counter-clockwise. Note that it is only
necessary to separate these parts if
replacing one of them, or for thorough
cleaning.
35
To ensure proper pattern control, remove the
shaping air cap from the shroud and inspect the
shaping air annulus of the 57mm shroud, the holes
of the 57mm "V" cup shroud and the extended
slots or holes of the 30mm shroud, for damage or
accumulation of paint deposits. Clean these areas
with a soft bristle brush or a toothpick and wipe
clean using non-polar solvent as a final wash.
Blow dry with clean low pressure air.
When reassembling the front shaping air cap onto
the shroud of the 30mm extended slot or the 57mm
annular style, tighten until the face of both parts
are flush ± .007 inches (.18mm). On the annular
57mm shroud examine the annulus, it should have
an even gap all the way around. An uneven
annulus will cause a distortion of the pattern and
the damaged parts must be replaced.
When installing the front shroud onto the turbine
assembly, be sure that it is fully tightened. The
shroud will appear tight after a few turns, but will
still be loose. The shroud must be tightened down
fully until it bottoms against the air manifold
assembly.
Cleaning Shaping Air Ring and
Cap While "On" the Applicator
! WARNING
> Turn OFF all air to the applicator
except the bearing air and a small
amount of shaping air. Turn Off all high
voltage to the applicator. Make sure
applicator bell cup is not spinning before
starting any cleaning procedure.
To clean the shaping air ring and cap/shroud while
on the applicator, it is preferable to leave a small
amount of shaping air "ON" so that paint and
solvents are not forced into the annulus, slots or
holes of the shaping air ring. Wipe the exterior of
the shroud and the area between the shaping air
ring and the bell cup using a solvent soaked rag.
Use a soft bristle brush to clean the face of the
shaping air ring and shroud with solvent. Be
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RMA-202 Rotary Atomizer - Maintenance
careful not to push wet or dried paint into the air
slots or annulus of the shaping air ring. When
finished, wipe all exterior surfaces with a nonpolar solvent such as VM & PNaphtha. Allow to
dry.
to full depth. Discard screws and replace with new
ones. Push the splash plate off its seat from
behind using a plastic bolt to prevent damage to
the plate. When reassembling, tighten screws to
2-4 lbs•in (.23-.45 Nm) torque.
Cleaning Shaping Air Ring and
Cap While "Off" the Applicator
Inspect the splash plate and bell cup for wear. Pay
special attention to the center four holes in the
splash plate. Look for erosion between the
holes. Replace any part if necessary.
To clean the shaping air ring and cap/shroud off
the applicator, remove the shaping air ring from the
cap/shroud. It is preferable that no plastic parts be
soaked in solvent for an extended period of time
(overnight). However, parts may be soaked for a
short time, long enough to loosen the dried material.
The soaking solution should be weak or mild, such
as Xylene, Naphtha, or Isopropyl Alochol.
Stainless steel material may be soaked overnight.
Use only soft bristle brushes to clean the air
passages and the shaping air slots/holes. All
stainless steel shaping air caps/shrouds may be
cleaned with a fine abrasive cloth such as
Scotchbrite pads (white colored type). Rinse all
componenets after cleaning with a non-polar
solvent such as VM & PNaphtha. Blow or wipe the
parts dry. Reassemble parts with the proper tools
and torque to specifications.
A1
1957-00 Bell Cup and Splash
A11957-00
Plate Disassembly
Splash Plate Removal
After removing the bell cup from the applicator, put
it on a plastic or wood surface to prevent damage
to the edge of the cup. Using the splash plate
removal tool (A11388-00), insert the small end of
the tool into the end of the splash plate assembly.
Press the splash plate out. It may be necessary
to tap lightly with a hammer.
Atomizer Bell Cup Removal,
Cleaning, Disassembly
Disassembly,, and
Reassembly
• Remove the front shroud by unscrewing
counter-clockwise.
• To remove atomizer bell cup, place RPM-419
(wrench) over flats of shaft to lock shaft. Unscrew
atomizer bell by hand turning counter-clockwise.
• If the atomizer bell cup is tight and cannot be
removed by hand, use the second RPM-419
(wrench) to place over the wrench flats of the
atomizer bell cup.
Figure 7:
Splash Plate Removal
If the splash plate of the atomizer bell cup needs to
be removed , RPM-457 (57mm), do not use a hex
key with a ball end. This will cause the head to strip
or "roundout" prematurely. Use a 1/16" hex key
with a squared-off end for best results. Before
removing the three (3) flat head screws, make
sure the sunken hex of each screw is cleaned out
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RMA-202 Rotary Atomizer - Maintenance
Splash Plate Insertion
Turn the splash plate removal tool over and use
the large diameter end to press the splash plate
back in place by hand. It may be necessary on
occasions to use an arbor press to install the
splash plate. Press splash plate to a hard stop.
Face of bell cup should line up with undercut as
shown on tool (see Figure 8).
• Bell cups normally are not required to be taken
apart to be cleaned, however, some instances
may require this operation.
• Before reinstalling the bell onto the shaft, check
the tapered matting surfaces of the turbine
shaft and bell cup for any paint residue. Clean
any residue. (See "Caution" on the following
page.)
• Before reassembling the atomizer bell, ensure
the tapers of the shaft and bell cup which mate
are totally clean, as well as the shaft and bell
threads.
• Place RPM-419 (wrench) over wrench flats of
shaft to lock the shaft.
• Screw atomizer bell onto shaft in CW direction.
Tighten to 50 lbs•in (5.65 Nm) torque.
• Reinstall shroud until it stops against the air
manifold.
! WARNING
Figure 8:
Splash Plate Insertion
• Clean the bell by soaking in an appropriate
solvent as long as necessary to loosen paint.
Use a soft bristle brush dipped in solvent to
remove paint. Using a soft bristle brush, clean
the serrations at the edge of the cup in a motion
parallel to the serrations.
> Do not attempt to clean the bell edge
while the bell is rotating. When attempting to stop or slow down the bell cup, do
not hold a rag or gloved hand against the
bell edge. This could damage the bell
edge which would adversely affect
transfer efficiency and coating quality.
• Using a non-metallic item (toothpick), clean the
center holes of the splash plate. Using plenty of
cleaning fluid, flush these holes towards rear of
bell cup. Make sure these holes are clean.
• Clean the outside of the bell cup with a solvent
soaked rag.
• Check mounting threads and shaft serrations in
the back of the bell cup. Clean with a soft bristle
brush. Flush with plenty of cleaning fluid. Make
sure all signs of paint are removed. (See "Caution"
on the next page.) Rinse and dry bell.
37
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LN-9244-03.3
RMA-202 Rotary Atomizer - Maintenance
CAUTION
! WARNING
> Do not use abrasive materials which
> A bell assembly that is crossthreaded on the shaft can damage the
bell, motor or shaping air housing and
may come off the shaft while rotating.
!
will scratch or damage the bell cup.
> Before reinstalling the bell onto the
shaft, check and clean the tapered
mating surfaces of the turbine shaft and
bell for any paint residue.
Using an atomizer bell with paint buildup may
cause a bell imbalance. An imbalanced bell
may cause bearing damage and turbine failure, or may create mechanical stress on the
bell when operating at high speeds. Excessive paint residue caught between the internal
tapered surface which seats in the motor shaft
can prevent the bell cup from seating properly
and result in an unbalanced turbine condition.
NOTE
> Bell cups must be inspected daily for
nicks or wear. A nick on the bell cup will
cause an unbalanced condition, leading to
premature turbine failure. Excessive cup
wear may cause poor atomization or low
appearance quality finish. Replace damaged bell cups.
!
CAUTION
> Make sure the turbine assembly is
properly seated by examining the fit between
the rear of the turbine assembly and the front
of the air manifold assembly. Any irregularity
in this seam between the two assemblies
would indicate improper mounting.
Looking into the front of the motor shaft,
observe the concentricity of the paint feed
tube if it is off center by more than .020-.028
in. (.51-.71mm) radially the motor assembly
may not be seated properly.
Do not use the four mounting bolts to pull the
turbine assembly into air manifold. This can
cause the thread(s) to be damaged. Torque
the four (4) mounting bolts to 15 lbs•in (1.70
Nm).
! WARNING
!
CAUTION
> Care must be taken when mounting
the bell assembly onto the motor shaft.
The bell should turn on freely for several
turns or until it fully bottoms on the motor
shaft. If resistance is felt when the bell
is first being turned onto the shaft, do not
proceed further, the bell may be crossthreaded on the shaft. Remove the cup
and carefully reinstall. If it is still difficult
to turn, replace the bell.
LN-9244-03.3
> Using wrench (RPM-419 ), a minimum of 50 lbs•in (5.65 Nm) of torque
must be applied when tightening the bell
cup onto the motor shaft to deter the bell
cup from spinning off the shaft if the
motor seizes.
> Operating the turbine motor when it
is not properly fitted to the air manifold
can cause severe damage to the motor,
bell assembly and/or operating personnel.
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RMA-202 Rotary Atomizer - Maintenance
Mounting Ring Cover Removal /
Installation
Remove mounting ring cover (Figure 13, Item 4)
by tapping with a soft face rubber hammer or with
the open palm of your hand on the back side of the
cover (edge towards robot arm) alternating at
different positions (i.e., 12 o'clock, 6 o'clock, 3
o'clock, 9 o'clock). Extra force may be needed to
get the four (4) buttons on the cover to start over
the edge of the mounting ring. Once the ring is
over the mounting ring, rock back and forth to fully
remove. Cover will now slide off over the atomizer
assembly.
Lubricate the o-ring on the turbine assembly to
insure it stays in place. To replace the turbine
assembly, center the turbine shaft over the feed
tube and push the turbine assembly slowly in.
Make sure the shaping air and bearing air ports are
aligned with their respective port on the air manifold.
Make sure the electrical spring on the turbine
manifold makes contact with the metal surface on
the "T" shaped flange of the turbine assembly.
Holding the turbine securely in place, screw the
four mounting bolts (Figure 9, Item 13) through the
rear of the turbine assembly into the air manifold
assembly. Tighten the four mounting bolts
alternately to a final torque of 15 lbs•in (1.70 Nm).
To reinstall use the same tapping method as
removing the cover. When cover is over (OD of
mounting ring) push until cover is completely over
mounting ring. When cover is fully installed, cover
may or may not be freely rotated. This condition is
OK, as the intended purpose is to protect the
mounting ring and robot adapter from paint
overspray.
Turbine Removal
The turbine assembly is removed from the RMA202 atomizer after removing the front shroud
assembly. Four (4) mounting bolts will then be
exposed, which hold the turbine assembly to the
air manifold assembly. These are the larger
socket head cap screws, located toward the
outer edge of the motor housing.
Holding the turbine assembly carefully so that it
does not drop and using a 5/32" Allen wrench,
remove the four mounting screws which hold the
turbine to the air manifold. Pull the turbine assembly
straight forward until it is beyond the end of the fluid
tube.
The turbine assembly can now be replaced or
serviced as necessary.
Reassembly Note: Prior to replacing the turbine assembly, make sure the bearing air and
shaping air o-rings are in place on the air manifold
assembly (Figure 14, Items 13 and 14). Also
make sure the electrical contact spring protrudes
beyond the face of the air manifold (Figure 14, Item
2). Use a small amount of dielectric grease
(LSCH0009) on the "T" shaped high voltage contact
on the rear of the turbine housing assembly.
39
Figure 9:
Turbine Assembly
Break-A
way Ring / T
ether
Break-Away
Tether
Removal / Replacement
In case of a collision, the break-away screws will
fail causing the tether system to engage. If this
ocurrs, the tether assembly must be replaced. If
possible, relieve all air and fluid pressures.
Remove the applicator from the robot. Using a
1/16" hex key wrench, remove the set screws
holding the tether to the rear manifold and the
break-away ring. Slide the cable from its slots and
discard. Inspect both the ring and manifold for
damage to the slots that hold the ball end of the
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RMA-202 Rotary Atomizer - Maintenance
cable. Replace if damaged. Remove any broken
pieces of the break-away screws that may be left
in the rear manifold.
Replace the tether as follows (see the following
pictures):
Push the ball end of the cable into the tapped hole
of the break-away ring. Slide the ball and cable
into the slot next to the tapped hole. Install the set
screw so that it is flush or just below the face on the
guide pin side of the ring. After the ball is attached,
push the cable into the radial groove of the ring. It
may be necessary to use a screwdriver or similar
tool to push the cable into the groove. Make sure
no part of the cable or plastic cable covering is left
sticking up out of the groove. This will cause
interference when the break-away ring is attached
to the rear manifold. Once it is fully inserted, take
the other ball end and insert it into the tapped hole
of the rear manifold. Slide the ball and cable into
the slot, then install the set screw so that it is flush
or just below the inside face of the rear manifold.
Reinstall break-away ring by aligning the four (4)
holes (2 at 9 o'clock and 2 at 3 o'clock position)
with the dowel pins on the recessed face of the
rear manifold. Reinstall the six (6) plastic breakaway screws. The break-away ring must lie flat
against the face of the rear manifold. Do not pinch
the cable between the two (2) plates. Torque
evenly to 5 lbs•in (.56 Nm).
Step #2
Step #3
Step #4
Step #1
LN-9244-03.3
ARCHIVE
40
RMA-202 Rotary Atomizer - Maintenance
Valve Manifold Removal and
Reassembly
• Remove the atomizer from the robot
• Remove the rear shroud halves
• Remove cascade stop plate and slide cascade out of air manifold and off to the side.
• Remove fluid coil and gray shape air supply
from the air manifold.
• Remove the fiber optic cable attached to
the rear manifold.
• Remove the four (4) air bolts from the rear
plate assembly.
• Separate the valve manifold and rear plate
assembly from the atomizer assembly.
• On the rear face of the rear manifold,
loosen the four socket head cap screws
with a 3/16" Allen wrench and remove.
• Separate the valve manifold from the rear
plate assembly.
• Clean all surfaces prior to reassembly. Do
not allow paint or foreign materials to enter
any of the pilot air holes.
• Install new o-rings. Lubricate o-rings lightly
with A11545-00 Petrolatum jell.
• Reassemble in reverse order.
41
Valve Removal/Replacement
Prior to removing the valves and the valve seats
from the valve manifold, flush the system with
solvent and purge with air. Relieve any fluid or air
pressure from the system.
Using the valve removal tool (78985-00) insert the
tool into the four (4) holes located on the cap of the
valve. Loosen by turning in a counter-clockwise
direction. When the valve is fully unthreaded,
remove by hand. If this can not be done, reverse
the tool and thread the tool stud into the center of
the valve cap a couple of turns and pull the valve
out.
Use the valve removal tool (78985-00) or a 5/16"
hex key wrench to remove the valve seat, loosen
in a counter-clockwise direction, grasp the valve
seat out of the air manifold with long nosed pliers.
Discard the old seat.
Clean any contamination or liquids from the valve
cavities if present.
Lightly lubricate the valve bores, the o-rings of the
new valves, and the o-ring of the new valve seat
with a thin film of A11545-00 Petrolatum jell.
Install the new valve seats into the valve ports.
DO NOT OVERTIGHTEN. Torque to 15-20
lbs•in (1.7-2.3 Nm). Use caution not to cross
threads.
Install the valve into the cavity until it bottoms out
in the cavity. Tighten to 15-20 lbs•in (1.7-2.3 Nm)
torque.
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Maintenance
Cascade Removal /
Replacement
This cascade may be removed without
disassembly of the entire atomizer.
• Remove the atomizer from the robot
• Remove the rear shroud halves
• Loosen the set screw holding the low volt
age contact housing in the rear manifold by
loosening the set screw with a 3/32" Allen
wrench. Access to this set screw is in the
groove of the rear manifold where the
shroud seats. Push the low voltage contact housing towards the cascade until it is
free of the rear manifold.
• Remove the cascade stop plate by inserting a screwdriver into one of the holes of
the stop plate. Using the screwdriver as a
lever, pry the plate upward until loose.
• Rock the cascade back and forth while
pulling towards the rear of the atomizer.
Note the orientation of the cascade
before removing.
• Clean all excess dielectric grease from the
grooves in the air manifold.
• Check that the brass colored wire is located in the centermost hole. (If not, call an
ITW Ransburg representative to replace
this item.)
• Apply new dielectric grease (LSCH0009) to
each of the grooves
• Install the new cascade by inserting the
groove end into the air manifold first.
• Make sure cascade is fully inserted into the
air manifold. The black side of the cascade
should face outward.
• Install the cascade stop plate by sliding it
into the groove of the valve manifold. A
slight tap with a plastic hammer may be required.
LN-9244-03.3
• Install the low voltage connector into the
rear manifold until it stops. The face of the
white plastic should be flush with the rear
face of the rear manifold.
• Align the timing mark on the low voltage
connector with the mark on the rear manifold and tighten the set screw to 10 lbs•in
(1.13 Nm) torque.
• Press brass pins with a piece of plastic to
make sure the pins actuate. If not, loosen
set screw holding the connector slightly.
Recheck pins. If pin still sticks, replace
cascade.
Speed T
ransducer
Transducer
ransducer,, Fiber Optic
Cable Removal / Replacement
Remove the applicator from the robot. Remove
the front shroud assembly. Remove the turbine
assembly. Remove the rear shroud halves.
Remove the break-away ring. Locate the set
screw holding the fiber optic cable into the rear
manifold assembly. Loosen with a 3/32" Hex key
and pull out towards the front of the unit. Loosen
the cap and ferrule holding the cable at the air
manifold side. Using tool (78279-00) slide it over
the fiber optic sensor at the front of the air manifold.
Unscrew the nut until it comes off completely.
Grasp the sensor and gently pull forward until the
rear of the sensor is clearly exposed and the nut
holding the cable can be held by two fingers. (You
must push the cable from the back side of the
manifold while pulling from the front.) Unscrew the
black nut holding the cable to the sensor and pull
the sensor free.
Install a new sensor by first removing the black nut
from the sensor and sliding over the cable until it is
approximately 1/2-inch over the black portion of
the cable. Insert the clear portion of the cable into
the sensor until it stops. Gently slide the nut
towards the sensor and tighten securely. Push
the sensor and cable back into the manifold until it
stops. (You must also pull from the back side, but
use caution, as more pulling than pushing may
cause cable to come out of the sensor.) Slide nut
over sensor and tighten securely with tool provided.
Retighten nut and ferrule of the fitting at the rear of
the air manifold. Install the cable end into the rear
ARCHIVE
42
RMA-202 Rotary Atomizer - Maintenance
manifold. Note the flat sections on the cable must
line up with the set screw. When properly installed,
the cable must be flush to face of raised boss on
the rear side of the rear manifold assembly. Tighten
set screw to 10 lbs•in (1.13 Nm) torque.
VALVE MANIFOLD
CHECK VALVE
O-RING
VALVE ASSEMBLY
MANIFOLD FITTING
Fluid T
ip / T
ube Removal /
Tip
Tube
Replacement (Front and Rear)
Remove the front shroud. Remove the bell cup.
Slide tool (78982-00) over the front of the fluid tip
and remove by loosening in a counter-clockwise
direction. Inspect through hole and o-ring. Clean
hole and replace o-ring if damaged. Replace by
tightening in a clockwise direction. Over-tightening
may cause rear fluid tube to loosen. Tighten fluid
tip to 7-9 lbs•in (.79-1.02 Nm) torque.
Rear Fluid Tube and One Piece Stainless
Fluid Tube
Remove the front shroud. Remove the bell cup.
Remove turbine. At the flats provided, use a 3/8"
open-end wrench, remove by turning in a clockwise
direction. This portion has a left hand thread.
Inspect through hole and o-ring. Clean hole and
replace o-ring if damaged. Replace by tightening
in a counter-clockwise direction until firmly seated.
Tighten to 15-25 lbs•in (1.70-2.83 Nm) torque.
Two Component Manifold Check
Valve Removal / Replacement
Remove the manifold fitting using a 3/16" Hex key
wrench. Remove the check valve by prying loose
with a dental pick and pulling straight out. If parts
are stuck in place because of two component
curing, the entire manifold will need to be
disassembled and soaked until material softens
enough for parts to be removed. After check valve
is removed, clean cavity thoroughly of any paint
buildup or debris. Do not use any sharp
instruments, such as picks, on these surfaces.
Stubborn materials will have to be soaked longer
until soft.
43
VALVE SEAT
Figure 10: Manifold Check Valve
Removal / Replacement
Replace the check valve, o-ring end into the hole
first, gently push into place with a plastic rod or the
eraser end of a pencil. Lightly lubricate the o-ring
on the manifold fitting with A11545-00 Petrolatum
jell before installing. Make sure to start threads
straight. Tighten to 8-10 lbs•in (.90-1.13 Nm)
torque. Parts are installed properly when face of
manifold and face of manifold fitting are flush.
Regulator V
alve Manifold
Valve
Assembly
Regulator Removal / Replacement
Prior to removing the regulator and related parts
from the manifold, flush the system with solvent
and purge with air.
Using tool A10742-00, remove the regulator cap.
Remove the six (6) stainless steel screws with a
flat head screwdriver. Carefully remove the
regulator bonnet. Then remove the diaphragm
assembly. Next remove the needle and seat
assembly using a 3/16" Hex key.
Clean entire regulator with solvent and blow dry.
Do not use any metal object to remove dried paint
from any surface. Damage to the diaphragm
sealing surface and the needle seat assembly will
result in leaks and may permanently damage
valve manifold. If regulator was disassembled
because of leakage (fluid downstream of regulator), discard entire needle, seat, o-ring, and
spring and replace with new.
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Maintenance
Regulator Diaphragm
Remove the scew holding the upper plate and
lower plate of the assembly with a Phillips
screwdriver. Pull parts apart and discard the
diaphragm. Inspect the lower plate for any damage,
replace if necessary. Replace the o-ring that was
between the lower plate and the diaphragm.
Diaphragm Assembly
Carefully place the o-ring on the lower plate center
a new diaphragm over the parts, and center the
upper plate over these parts. Install the screw with
a small amount of loctite (7969-05) on the threads.
Tighten together to a torque of 8-10 lbs•in (.90-1.13
Nm). Make sure that Teflon (white side of the
diaphragm faces towards the lower plate.
Seat Assembly Replacement
Install the spring into the center-most cavity of the
manifold. Place the pointed end of the needle onto
the center of the spring. Install the o-ring into the
cavity of the seat. Lightly lubricate the o-ring with
A11545-00 Petrolatum jell. Secure the needle/
seat assembly by screwing the seat retainer into
the regulator cavity until a torque of 8-10 lbs•in
(.90-1.13 Nm) is obtained. Use a 3/16" Hex key
driver.
Replacing Diaphragm Assembly
Install assembly with the black rubber face towards
the outside and align with the screw holes in the
cavity. Place the regulator bonnet over the
diaphragm assembly and align with screw holes of
the diaphragm assembly and cavity. Insert all six
(6) stainless steel screws and tighten in an
alternating 180° method. Install regulator cap and
tighten to 125-135 lbs•in (14.1-15.3 Nm).
LN-9244-03.3
!
CAUTION
> The fluid tube has left hand threads.
To remove the fluid tube, turn clockwise
and to install, turn counter clockwise.
> Care should be taken to not over
tighten the fluid tube and strip the
threads.
When installing a new or old feed tube,
once it is securely tightened, check the
position of the feed tube in the shaft at
the front of the assembly. If the feed
tube is off center by more than .020-.028
(.51-.71 Nm) radially, replace it with
another feed tube. If the feed tube
protrudes out of the shaft a distance
other than .225 (5.7 Nm) replace the
tube with another feed tube.
Low V
oltage Cable Removal
Voltage
(79106-XX T
ubing Bundle
Tubing
Assembly)
The low voltage cable installed in the robot plate/
tubing bundle assembly may be removed without
disassembling the entire unit from the robot.
Purge all fluid lines and blow through with dry air.
turn off all air supply to the atomizer. Turn off
atomizer electrical controls. Remove applicator
from robot. Disconnect low voltage wires from the
supply source (i.e., junction box, Euro rack, etc.)
and attach a rope or wire strong enough to pull the
new cable back through the robot arm. Loosen the
set screw holding the low voltage cable into the
robot plate using a 3/32" Hex key. The low voltage
cable should pop forward from the plate face, if not,
reach inside the robot adapter at the wrist and
push the cable forward. Remove old cable. When
installing a new cable, make sure electrical
connection ends are protected before pulling
through the robot. Align timing mark of low voltage
connector with timing mark on robot plate face.
tighten set screw. Tighten to 10 lbs•in (1.13 Nm)
torque.
ARCHIVE
44
RMA-202 Rotary Atomizer - Maintenance
Bell Cup Shaft Seal
Replacement (RPM-452-3 and
RPM-452-10 Bell Cups)
Remove old Teflon shaft seal from inside the bell
cup from the open end of the bell cup. Clean
interior of cup thoroughly.
Periodically, the shaft seal will remain on the shaft
when the bell cup is removed. Use a pliers to
gently remove the shaft plug from the turbine shaft
and discard it.
Place new shaft seal, small diameter end, into the
turbine spindle shaft until the larger diameter face
is flush with the turbine spindle face. Screw bell
cup onto shaft and tighten to 50 lbs•in (5.65 Nm)
torque. Seal is now properly sized for the bell cup
interior.
Shaping Air #1 Seal
Replacement (see Figure 1
1)
11)
This seal separates the two independently
controlled shaping airs. On occassion this seal
may need to be removed and replaced due to
damage. Inspect outer edges for nicks, dents, or
deformed. Damage to this seal will cause poor
pattern control. To replace the seal, grip the seal
with a pair of pliers and pull forward off the housing.
To reinstall, start by inserting the inside diameter
of the seal into the groove of the turbine housing.
Using your thumb and fingers, hold the seal in
place and walk the seal inside diameter around
until the entire inside diameter of the seal is in the
groove. Be careful not to distort the seal during
installation. After installation, check that the seal
is round. If necessary, cup fingers around the seal
to reform it.
Fluid Coils (Separate Sales
Parts Only)
If purchasing spare parts, they must be modified
as explained.
To ensure proper sealing and holding, the fittings
require that the ends of the Teflon fluid coils have
a groove cut into them as shown (see Figure 8).
Use groove cutter A11567-00, by sliding the end
of the tool over the Teflon tubing until it bottoms out.
Hold the tubing in one hand and the tool in the
other. Make three complete revolutions of the tool
on the tubing in the direction of the arrow stamped
on the tool. To remove the tool, hold the tube and
the main body of the tool with one hand, slide the
rear portion of the tool back until it stops. Pull out
the tubing from the end of the tool. By pulling back
the rear portion of the rool, it relieves the pressure
of the cutting edge off of the tubing before sliding it
out. Trim off ends to dimensions shown. End
should be cut off square. Slide the fitting and
ferrules onto the tube as shown. The tapered
ferrule must go past the newly cut groove to
properly lock into place when installed.
Tighten nuts into manifolds by hand until it stops.
Using a 9/16" end-wrench tighten 1/4 - 1/2 more
turn.
Figure 12:
Figure 11:
45
ARCHIVE
Fluid Coils
Shaping Air #1 Seal Replacement
LN-9244-03.3
RMA-202 Rotary Atomizer - Maintenance
TROUBLESHOOTING GUIDE
General Problem
Possible Causes
Corrective Action
No Turbine Air
1. Turbine drive air not
present
1. Verify supply air pressure.
2. Bearing air return signal
not present
2. a. Verify bearing air return signal.
b. Increase bearing air supply pressure to 90
psig (±10 psig) (620.5 ± 69 Nm).
3. Brake air is activated
3. Remove brake air signal (turbine air and brake
air must be interlocked to prevent both from
being used simultaneously).
1. Damaged fiber optic cable
between robot plate and
control panel
1. Repair or replace fiber optic cable.
2. Connection at robot or bell
plate is loose
2. Re-install cable and tighten locking set screw.
3. Fiber optic pick-up failure
3. Replace fiber optic pickup.
4. Bad transceiver module
4. Replace transceiver module.
1. Turbine is not rotating
1. Verify rotation of turbine (the paint valve air pilot must be interlocked with the turbine speed
feed back signal to ensure that paint does not
flow into the air bearing).
2. Fluid valve does not actuate
2. a. Verify that air pilot signal is present.
b. Fluid valve air pilot pressure is too low.
Increase air pressure to 70 psig minimum.
c. Replace fluid valve.
3. Clogged fluid tube
3. Remove and inspect fluid tube.
4. Bad transceiver module
4. Replace transceiver module.
5. Plugged inlet
5. Flush clean.
6. Regulator (needle and
seat) stuck
6. Remove and clean or replace
7. No pilot air
7. Check air pilot
8. Two component valve
contaminated
8. Remove valve manifold and clean
9. In-line mix tube clogged
9. Replace
Speed Feedback
Fault
No Fluid Flow
(Continued On Next Page.)
LN-9244-03.3
ARCHIVE
46
RMA-202 Rotary Atomizer - Maintenance
TROUBLESHOOTING GUIDE (Cont.)
General Problem
Continuous Fluid
Flow
Possible Causes
1. Fluid valve open
1. a. Remove air pilot signal.
b. If still open, replace fluid valve.
2. Fluid valve seat damaged or
worn
2. Replace fluid valve seat.
3. Regulator (needle and seat)
dirty
3. Remove and clean or replace.
4. Regulator pilot air not shut
off
4. Check air supply.
1. Insufficient back pressure
to fluid regulator
1. Replace fluid tube with the next smaller inner
diameter size.
2. Fluid regulator does not
control flow (system)
2. Disassemble fluid regulator and inspect for
failed components (system).
3. Diaphragm stretched from
excessive air pressure
3. Rebuild regulator.
4. Ruptured diaphragm
4. Rebuild regulator.
5. Inconsistent air pilot supply
5. Check air source.
Paint Sputtering
1. Ruptured diaphragm
1. Replace regulator diaphragm
Low or No High
Voltage
1. High current draw
1. a. Paint resistivity to be .1 MΩ to ∞
b. Replace coiled fluid line
c. Start fluid flow before turning voltage on
2. Solvent valve is actuated
2. Remove solvent valve air pilot signal (high
voltage must be interlocked with the solvent
valve air pilot signal to prevent solvent flow
while high voltage is energized).
3. Loss of low voltage cable
connection between robot
and bell plates
3. Remove atomizer and inspect low voltage connections on both plates. Verify alignment marks
between connectors and plates, andverify that
connector face is flush with plate. Verify that
set screws are secure, but not too tight, as this
will prevent the spring-loaded pins on the robot
plate from extending and making contact.
4. Improperly mounted air
turbine
4. Verify correct orientation of air turbine so that
high voltage spring makes contact with metal
pad on turbine assembly.
5. Improper limiting current
and voltage settings
5. To readjust settings, refer to the current
MicroPak operating manual.
Uncontrollable
Fluid Flow
.
47
Corrective Action
(Continued On Next Page.)
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Maintenance
General Problem
Low or No High
Voltage
(Continued)
Possible Causes
Corrective Action
6.
6. Atomizer grounding out
(usually indicated by high
current draw or by MicroPak
over current fault light)
a. Clean atomizer externally with non-polar
solvent.
b. Check the atomizer for internal fluid leaks.
c. Check for fluid leaks at quick disconnect
mounting (between bell plate and robot
plate).
d. Check for internal arcing (usually indicated
by internal sparking sounds).
e. Make sure cascade low voltage connection
is properly shielded.
7. Fluid coil pin-holed
7.
Replace fluid coil
8. Cascade not functioning
8.
a. Check low voltage cable and harness timing
b. Cascade bad; replace
c. Low voltage cable bad; replace
9. Faulty low voltage connections (usually indicated by
MicroPak feedback fault
light)
9.
a. Make sure quick disconnection electrical
connection is aligned and clean.
b. Check low voltage connection at cascade.
10. Faulty high voltage connec- 10. a. Remove cascade and check continuity
tion
between cascade connection and turbine
shaft.
b. Replace high voltage contact spring
(Figure 14, Item 2).
11. MicroPak or cascade failure 11. Refer to current "MicroPak" manual for detailed
troubleshooting guide
Low Transfer
Efficiency (or
light coverage)
12. Improper color change (i.e.,
paint or solvent in dump
line)
12. Optimize color change.
1. Low or no high voltage
1.
Verify high voltage at bell cup edge. Normally,
a high voltage setting of 70-100kV is appropriate for most applications.
2. Poor grounding of parts
being coated
2.
Verify that parts being coated are properly
grounded (the electrical resistance betweenthe
part and ground must not exceed 1 megohm).
3. Excessive turbine speed
3.
For optimum transfer efficiency and spray
pattern control, the bell rotational speed should
be set at the minimum required to achieve
proper atomization of the coating material.
ARCHIVE
(Continued On Next Page)
LN-9244-03.3
48
RMA-202 Rotary Atomizer - Maintenance
TROUBLESHOOTING GUIDE (Cont.)
General Problem
Possible Causes
Corrective Action
Low Transfer
Efficiency (or
light coverage)
(Continued)
4. Excessive shaping air
4. Shaping air should be set at the minimum
volume required to gently direct the spray
pattern toward the part being coated. Excessive shaping air will cause some atomized
particles to "blow-by" the part or bounce back
onto the atomizer.
5. Excessive seal air
5. See "Seal Air Description" in the "Operation"
section of this manual.
6. Excessive target distance
6. The recommended target distance is between 6
and 12-inches (152-305 Nm) (see "Target Distance" in the "Operation" section of this manual).
7. Robot speed excessive
7. Set fluid flow, turbine speed, shaping air, and
robot speed at minimum to achieve desired results of parts being coated.
1. Bell cup damaged
1. Replace bell cup
2. Low voltage
2. See "low voltage" below
3. Paint lodged in shaping air
ring.
3. Disassemble and clean
1. Atomizer mounting nut is
loose
1. Tighten mounting nut.
2. O-ring is missing
2. Install o-ring.
3. O-ring is damaged
3. Visually inspect for damage and replace.
Fluid Leakage In
Fluid Manifold or
Bell Plate
1. O-ring is damaged
1. Replace o-ring.
2. Outer diameter of tubing
coil is damaged
2. Inspect tubing coil for scratches and replace if
damaged.
Fluid Leakage
Around Fluid
Valve
1. Damaged o-ring(s) on outer
diameter of valve body
1. Replace o-ring(s).
2. Damaged or worn needle
seals inside valve assembly
2. Replace valve assembly.
1. Diaphragm (screws) loose
1. Tighten per "Assembly Procedure"
2. Ruptured diaphragm
2. Rebuild regulator
Bad Spray
Pattern
Fluid and/or Air
Leakage Between
the Robot and
Bell Manifold
Plates
Paint Leakage
(Regulator)
49
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Maintenance
General Problem
Possible Causes
Corrective Action
Frequent High
Voltage Faults
1. Di dt setting too sensitive
1. Adjust sensitivity at MicroPak
2. Atomizer to close to object
being sprayed.
2. a. Resset target distance
b. Lower voltage
1. Loose bell cup
1. Tighten bell cup to 50 lbs•in (5.65 Nm) torque
2. Damaged bell cup
2. Replace bell cup
3. Paint buildup in bell cup
3. Clean bell cup thoroughly
4. Little or no bearing air
4. Ensure proper bearing air pressure minimum
70 psi (482 kPa).
Excessive
Vibration
LN-9244-03.3
ARCHIVE
50
RMA-202 Rotary Atomizer - Parts Identification
PAR
TS IDENTIFICA
TION
ARTS
IDENTIFICATION
Figure 13:
51
RMA-202 Assembly
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
ASSEMBLY
PAR
ARTS
RMA-202 ASSEMBL
Y - P
AR
TS LIST (Figure 13)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Part #
79102-00
79010-00
77525-00
78979-00
79028-00
Table C, Item
77524-00
78976-00
79032-00
77522-00
Table A, Item
Table A, Item
LSFA0006-16F
RPM-2
Table B, Item
Table A, Item
Table A, Item
79001-03
Table B, Item
78449-00
EMF-203-04
EMF-202-04
Table D, Item
79029-00
EMF-203-05
EMF-202-05
77538-01
79030-00
------77509-00
79001-08
77508-00
79001-07
75911-00
78278-00
75921-02
76703-00
79106-XXXX
A10756-00
78372-00
78367-00
7959-24C
Table C, Item
Table A, Item
Table A, Item
78982-00
78279-00
A10766-00
"K"
"B"
"N"
"C"
"A"
"D"
"P"
"J"
"G"
"E"
"F"
Description
Qty
Air Manifold Assembly
Cascade Assembly
Upper Shroud Assembly
Mounting Ring Cover
Ring, Break-Away
Bell Plate Assembly
Break-Away Screw, Machined
Mounting Ring
Connecting Rod
Lower Shroud
Shroud
Air Turbine Assembly
Screw, #10-32 X 1/2" Long, Stainless Steel, SHCS
Shaping Air Seal
Fluid Tip
Bell Cup Assembly
Shaping Air Cap, RMA-202
O-Ring, Solvent Proof
Fluid Tube, Rear
Fitting
Front Ferrule, 1/4" OD Tubing
Back Ferrule, 1/4" OD Tubing
Tubing Coil
Fitting
Front Ferrule, 3/8" OD Tubing
Back Ferrule, 3/8" OD Tubing
Tubing, 3/8" OD X .250" ID, Gray, Polyethylene
Cascade Stop Plate
------Threaded Stud, Machined
O-Ring, Solvent Proof
Air Bolt, Machined
O-Ring, Solvent Proof
Fiber Optic Transmitter Assembly
Nut, Fiber Optic Transmitter
Fiber Optic Cable Assembly
Fiber Optic Fitting
Tubing Bundle Assembly
Tools, Valve Removal
Set Screw, #8-32 X 1/4", Cup Point
Steel Cable, W/Ball and Shank
Screw, 1/4-20 X 3/4" SHCS
Valve Manifold Assembly (RMA-202)
O-Ring, 2.864" ID X .070" C/S, Solvent Proof
O-Ring, 2.489" ID X .070" C/S, Solvent Proof
Fluid Tip Tool
Transmitter Removal Tool
Tool, Valve Seat Removal
1
1
1
1
1
1
6
1
4
1
1
1
4
1
1
1
1
2
1
2
2
2
1
2
2
2
1
1
------4
8
4
4
1
1
1
1
Ref.
1
2
1
4
1
1
1
1
1
1
Notes
7
10
8
2
1
18
14
15
(See Page 58 for Bullet Definition Table.)
(Continued On Next Page)
LN-9244-03.3
ARCHIVE
52
RMA-202 Rotary Atomizer - Parts Identification
ASSEMBLY
PAR
ARTS
RMA-202 ASSEMBL
Y - P
AR
TS LIST (Cont.) (Figure 13)
Item #
50
51
52
53
54
55
56
57
58
Part #
76772-00
---RPM-419
Table A,
Table A,
79001-03
Table A,
Table A,
Table A,
Description
Qty
Adjustable Spanner Wrench
---Bell Cup Wrench
Repulsion Ring Assembly
Screw, 8-32 X 1/4", BSHC
O-Ring, 2-007
O-Ring, 2-040
O-Ring, 2-038
Tool, Splash Plate Removal
Item "L"
Item "M"
Item "Q"
Item "R"
Item "S"
Notes
1
-1
1
3
1
1
1
1
30MM BELL CUP "GHOST BUSTER" - P
AR
TS LIST
PAR
ARTS
(Figure 13)
Item #
1
2
Part #
Description
A11949-00
A11954-00
Bell Cup
Splash Plate Assembly
PAR
ARTS
57MM BELL CUP - P
AR
TS LIST
Item #
Qty
1
1
(Figure 13)
Part #
Description
1
RPM-457-1
Atomizer Assembly, Bell Cup, 57mm
1
2
3
4
78594-16F
76610-01
RPM-104-1
Screw, Socket Flat Head Cap
Splash Plate
Atomizer Bell
3
1
1
Qty
1
(See Page 58 for Bullet Definition Table.)
53
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
RMA-202 MODEL IDENTIFICA
TION *
IDENTIFICATION
When ordering, use 79014-ABCD as indicated by Tables A, B, C, and D. Four digits must follow the
basic part number, for example:
79014
-
1
2
3
4
Basic Part Number
Bell Cup Style
(Table A)
(Table C) Valve Manifold Assembly
Fluid Tube Size
(Table B)
(Table D)
Fluid Coil Size
* Model number and serial number of the atomizer is located on the face of the rear plate
assembly.
TABLE A - Bell Cup Style
Dash
#
1
"B"
"D"
"E"
"F"
"L"
"M"
"N"
"Q"
"R"
"S"
RPM-452-3
78978-00
78977-00
--
--
--
--
75867-00
--
--
--
57mm Bell Cup Assy., RPM-457-1
75892-00
75893-00
--
--
--
--
75867-00
--
--
--
79002-00
79003-00 LSOR0005-01 79001-10
--
--
75867-00
--
--
--
78977-00
--
--
75867-00
--
--
--
A10901-00 20391-08C A10896-00
--
--
--
A11753-00 A11754-00 LSOR0005-01 79001-10 A10901-00 20391-08C A10896-00
--
--
--
57mm Bell Cup Assy., RPM-457-1 A11753-00 A11754-00 LSOR0005-01 79001-10 A10901-00 20391-08C A10896-00
--
--
--
Description
30mm Bell Cup,
"A"
Titanium W/Holes
2
17
3
17
Titanium
57mm Bell Cup Assy.,
79004-00
"V" Cup, Vortex
Shroud 57mm
4
17
5
17
6
17
30mm Bell Cup,
RPM-452-10 78978-00
--
--
--
--
Titanium W/Holes
57mm Bell Cup Assy., RPM-457-1 A10897-00 A10902-00
Titanium (Repul. Ring)
57mm Bell Cup Assy.,
79004-00
"V" Cup, Vortex
Shroud 57mm,
(Repul. Ring)
7
17
Vortex Shroud
(Repul. Ring)
8
30mm Cup/Button
26
Special Plate, SS
A11957-00 A11947-00 A11955-00
79001-52
79001-53
A11957-00 A11947-00 A11946-00
79001-52
79001-53 A11945-00 77580-08C A11948-00 79001-11 79001-54 A11388-00
--
--
A11948-00 79001-11 79001-54 A11388-00
Cap (No Repul. Ring)
9
26
30mm Cup/Button
Special Plate, SS
Cap (Repul. Ring)
ARCHIVE
LN-9244-03.3 (See Page 58 for Bullet Definition Table.)
54
RMA-202 Rotary Atomizer - Parts Identification
57MM TI
57MM
30MM
79004-00
For Use With 79118-XX and
A11508-XX Fluid Tip Style
RPM-457-1
For Use With 79118-XX and
A11508-XX Fluid Tip Style
RPM-452-3
With 77790-00 Shaft Plug
RPM-452-10
With A10706-00 Shaft Plug For
Use With 79118-XX and
A11508-XX Fluid Tip Styles
30MM
A10706-00 Bell Cup Shaft
For Use With 79118 Fluid Tip and
A11508-XX Fluid Tube Assy.
55
77790-00
Bell Cup Shaft Plug
For Use With 78981 Fluid Tip
ARCHIVE
A11957-00 With A11953-XX
Fluid Tubes
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
TABLE
B
Tube
- Fluid T
ube Size
"P"
"C"
Fluid Tube Rear /
"P" Assembly
" C " Tip (Front)
Comments
Fluid
Fluid Tube
Fluid Tip
Rear/Assy.
Comments
(Front)
Dash
#
Description
1
Ø.094
78981-01
78980-00
Stainless Tip / Plastic Rear
2
Ø.062
78981-02
78980-00
Stainless Tip / Plastic Rear
3
Ø.045
78981-03
78980-00
Stainless Tip / Plastic Rear
4
Ø.035
78981-04
78980-00
Stainless Tip / Plastic Rear
17
5
Ø.094
79118-01
78980-00
Stainless Tip / Plastic Rear
17
6
Ø.062
79118-02
78980-00
Stainless Tip / Plastic Rear
17
7
Ø.045
79118-03
78980-00
Stainless Tip / Plastic Rear
17
8
Ø.035
79118-04
78980-00
Stainless Tip / Plastic Rear
17
9
Ø.094
N/A
A11508-01
One Piece Stainless Assembly
17
10
Ø.062
N/A
A11508-02
One Piece Stainless Assembly
17
11
Ø.045
N/A
A11508-03
One Piece Stainless Assembly
17
12
Ø.035
N/A
A11508-04
One Piece Stainless Assembly
26
13
Ø.094
N/A
A11953-01
One Piece / SS / 30mm Button Spl. Plt. Cup
26
14
Ø.062
N/A
A11953-02
One Piece / SS / 30mm Button Spl. Plt. Cup
26
15
Ø.045
N/A
A11953-03
One Piece / SS / 30mm Button Spl. Plt. Cup
26
16
Ø.035
N/A
A11953-04
One Piece / SS / 30mm Button Spl. Plt. Cup
(See Page 58 or Bullet Definition Table.)
78981-XX
For Use With 78980-00 Rear Fluid Tube
For Use With RPM-452-3 Bell Cup
79118-XX
For Use With 78980-00 Rear Fluid Tube
For Use With 79004-00 and
RPM-457-1 Bell Cups
A11508-XX
One Piece Stainless Steel For Use
With 79004-00 and RPM-457-1 Bell Cups
A11953-XX
One Piece Stainless Steel
For Use With A11957-00 Bell Cup
LN-9244-03.3
ARCHIVE
56
RMA-202 Rotary Atomizer - Parts Identification
TABLE
Dash
#
C -
Description
"K"
Dual Paint Supply (No Regulator)
79103-00
79105-00
2
Single Paint Supply (No Regulator)
79103-01
79105-00
3
Valve Manifold Assy. (2k) (No Regulator)
A10676-00
79105-00
4
Single Paint Supply W/Regulator
A10745-00
A10747-00
Dash
#
20
"G"
1
TABLE
20
Valve
V
alve Manifold Assembly
D - Fluid Coil Size
"J"
Description
1
1/4" OD X .170" ID PFA
77517-00
2
1/4" OD X .125" ID PFA, High Conductive Paints
78450-00
3
Static Mix Tube Assembly
A10671-00
Can only be used with A10676-00 (Ref.) Manifold Assembly.
77517-00 Fluid Coil
1/4" OD X .160 ID
A10671-00
Static Mix Tube Assembly
78450-00 Fluid Coil
1/4" OD X .125" ID
57
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
PAR
ARTS
TABLE
** P
AR
TS LIST BULLET DEFINITION T
ABLE
18
Tighten to 15-25 lbs•in (1.70-2.83 Nm) torque.
17
When ordering these bell cups, these fluid tubes must be used.
14
Tighten the valve manifold mounting screws, alternately, to a final torque reading of 15 lbs•in
(1.70 Nm).
Remove front ferrule, replace with o-ring 7554-05.
11
Shaft plug 77790-00 is included in the RPM-452-3, bell cup assembly.
10
Tighten the break-away ring mounting screws, alternately, to a final torque reading of 5 lbs•in
(.56 Nm).
Tighten the bell cup assembly to a final torque reading of 50 lbs•in (5.65 Nm).
15
9
7
Tighten the air turbine mounting screws, alternately, to a final torque reading of 15 lbs•in (1.70
Nm).
Orient cascade assembly so that potting compound faces up.
1
Tighten fluid tip clockwise to 7-9 lbs•in (.79-1.02 Nm) torque.
8
LN-9244-03.3
ARCHIVE
58
RMA-202 Rotary Atomizer - Parts Identification
Figure 14:
Air Manifold Assembly
ASSEMBLY
PAR
ARTS
AIR MANIFOLD ASSEMBL
Y - P
AR
TS LIST
Item #
59
Part #
(Figure 14)
Description
Qty
1
79104-00
Air Manifold Assembly, RMA-202
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
78997-00
LSF10025-10
Table D, Item "J"
77538-01
76703-00
79029-00
EMF-203-05
EMF-202-05
78449-00
EMF-203-04
EMF-202-04
7554-07
7554-03
78278-00
75911-00
7554-05
78279-00
Contact Spring
Fitting, 3/16" Tube X 1/4 " NPT
Tubing Coil
Tubing, 3/8" OD X .250" ID, Gray, Polyethylene
Fiber Optic Fitting
Fitting
Front Ferrule, 3/8" OD Tubing
Back Ferrule, 1/4" OD Tubing
Fitting
Front Ferrule, 1/4" OD Tubing
Back Ferrule, 1/4" OD Tubing
O-Ring, .239" ID X .070" C/S, Solvent Resistant
O-Ring, .114" ID X .070" C/S, Solvent Resistant
Nut, Fiber Optic Transmitter
Fiber Optic Transmitter Assembly
O-Ring, Solvent Resistant
Fiber Optic Tool
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Remove front ferrule from fitting and replace with Item #17 o-ring (7754-05).
2
Apply A11545-00 Petrolatum jell to o-rings.
18
Tighten to 15-25 lbs•in (1.70-2.83 Nm).
ARCHIVE
1
2
2
18
2
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
Figure 15a:
79103-00 Valve Manifold Assembly (Dual Paint Supply)
VAL
ALVE
ASSEMBLY
PAR
ARTS
79103-00 V
AL
VE MANIFOLD ASSEMBL
Y - P
AR
TS LIST
(DUAL P
AINT SUPPL
Y) (Figure 15a)
PAINT
SUPPLY)
Item #
1
2
3
4
1
Part #
Description
79026-00
78949-00
77367-00
78985-00
Valve Manifold
Fluid Valve Assembly
Valve Seat Assembly
Valve Tool
Qty
1
5
5
1
1
2
Install valve assemblies as shown. Apply A11545-00 Petrolatum jell to o-rings.
Torque to 15-20 lbs•in (1.70-2.3 Nm) after valve is down.
2
Install valve seat assemblies as shown. Apply A11545-00 Petrolatum jell to o-rings.
Torque to 15-20 lbs•in (1.70-2.3 Nm).
LN-9244-03.3
ARCHIVE
60
RMA-202 Rotary Atomizer - Parts Identification
Figure 15b:
79103-01 Valve Manifold Assembly (Single Paint Supply)
VAL
ALVE
ASSEMBLY
PAR
ARTS
79103-01 V
AL
VE MANIFOLD ASSEMBL
Y - P
AR
TS LIST
PAINT
SUPPLY)
(SINGLE P
AINT SUPPL
Y) (Figure 15b)
Item #
1
2
3
4
5
61
Part #
Description
79026-00
78949-00
77367-00
77620-00
78985-00
Valve Manifold
Fluid Valve Assembly
Valve Seat Assembly
Kit, Valve Plug
Valve Tool (Not Shown)
Qty
1
Install valve assemblies as shown. Apply A11545-00 Petrolatum jell to o-rings.
Torque to 15-20 lbs•in (1.70-2.3 Nm) after valve is down.
2
Install valve seat assemblies as shown. Apply A11545-00 Petrolatum jell to o-rings.
Torque to 15-20 lbs•in (1.70-2.3 Nm).
ARCHIVE
1
3
3
2
1
1
2
2
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
Figure 16: Rear Plate / Break-Away Assembly
(Dual Paint, Single Paint, and 2k Manifold Assemblies Only)
PLATE
BREAK-AW
ASSEMBLY
PAR
ARTS
REAR PLA
TE / BREAK-A
WAY ASSEMBL
Y - P
AR
TS LIST
(For Dual Paint, Single Paint, and 2k Manifold Assemblies
Only) (Figure 16)
Item #
1
2
3
4
LN-9244-03.3
Part #
79028-00
79105-00
78372-00
78367-00
Description
Ring, Break-Away
Bell Plate Assembly
Set Screw, #8-32 X 1/4", Cup Point
Steel Cable, W/Ball and Shank
ARCHIVE
Qty
1
1
2
1
62
RMA-202 Rotary Atomizer - Parts Identification
6
5
3
1
4
2
Figure 17:
A10676 Valve Manifold Assembly (2k)
A10676 V
AL
VE MANIFOLD ASSEMBL
Y - P
AR
TS LIST
VAL
ALVE
ASSEMBLY
PAR
ARTS
(Figure 17)
Item #
1
2
3
4
5
6
63
Part #
78949-00
77367-00
A10675-00
A10674-00
79001-05
A10670-00
Description
Fluid Valve Assembly
Valve Seat Assembly
Check Valve, Modified
Manifold Fitting (2k)
O-Ring, Solvent Proof
Valve Manifold (2k)
4
Install o-ring end into hole first.
3
Install valve seat assemblies as shown. Apply A11545-00 Petrolatum jell onto o-rings.
Torque 15-20 lbs•in (1.70-2.3 Nm) after valve is down.
2
Install valve seat assemblies as shown. torque to 15-20 lbs•in (1.70-2.3 Nm).
1
Torque to 15-20 lbs•in (1.70-2.3 Nm).
ARCHIVE
Qty
3
3
2
2
2
1
3
2
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
Figure 18:
79105-00 Rear Plate Assembly
PLATE
ASSEMBLY
PAR
ARTS
79105-00 REAR PLA
TE ASSEMBL
Y - P
AR
TS LIST
(Figure 18)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part #
79027-00
79034-00
77541-00
77543-00
79001-09
77505-00
79001-07
77507-00
79001-05
79001-06
79001-03
77506-00
SSF-2052
79001-04
Description
Rear Mounting Plate, RMA-202
Diaphragm, RMA-202
Flat Washer, .089" ID X .149" OD, Stainless Steel
Screw, #2-56 UNC X 1/4" Long, SHCS
O-Ring, Solvent Proof
Large Air Stud, Machined
O-Ring, Solvent Proof
Small Air Stud, Machined
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Medium Air Stud, Machined
Set Screw, #10-24 UNC X 3/8" Long
O-Ring, Solvent Proof
1
Apply thread sealer (7969-10) to threads prior to assembly
2
Apply A11545-00 Petrolatum jell to o-rings
LN-9244-03.3
ARCHIVE
Qty
1
2
2
2
4
4
4
10
10
11
2
3
2
1
2
1
2
1
2
2
2
1
2
64
RMA-202 Rotary Atomizer - Parts Identification
13
12
14
7
4
5
16
2
1
15
11
10
3
9
6
8
4
Figure 19:
A10745 Regulator Valve Manifold Assembly
REGULAT
VAL
ALVE
ASSEMBLY
A10745 REGULA
TOR V
AL
VE MANIFOLD ASSEMBL
Y ARTS
PAR
TS LIST (Figure 19)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A10743-00
74161-00
77367-00
77354-00
79001-08
78949-00
79221-00
79001-05
79220-00
79222-00
76374-08C
A10741-00
A10746-00
A10740-00
79001-35
79001-13
Description
Valve Manifold, Regulator
Spring, Regulator
Valve Seat Assembly
Assembly, Needle and Seat
O-Ring, Solvent Proof
Fluid Valve Assembly
Lower Plate, Regulator
O-Ring, Solvent Proof
Diaphragm
Upper Plate, Regulator
Screw
Bonnet, Regulator
Screw, Slotted Fillister Head, Stainless Steel
Cap, Regulator
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Qty
1
1
3
1
1
3
1
1
1
1
1
1
6
1
1
1
2
1
3
4
5
6
Apply Loctite (7969-05) onto threads sparingly.
5
Tighten to 125-135 lbs•in (14.12-15.25 Nm) torque.
4
Tighten screws 6-8 lbs•in (.68-90 Nm) in an alternating 180° method.
3
Install valve assemblies as shown; apply A11545-00 Petrolatum jell onto o-rings; torque to 15-20 lbs•in
(1.70-2.3 Nm) after valve is down. Install valve seat assemblies as shown; torque to 15-20 lbs•in (1.702.3 Nm).
2
1
65
Part #
ARCHIVE
Secure needle/seat assembly to a torque of 8-10 lbs•in (.90-1.13 Nm).
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
Figure 20: Rear Plate / Break-Away Assembly
(Single Paint With Regulator Manifold Assembly Only)
PLATE
BREAK-AW
ASSEMBLY
PAR
ARTS
REAR PLA
TE / BREAK-A
WAY ASSEMBL
Y - P
AR
TS LIST
(Single Paint With Regulator Manifold Assembly Only)
(Figure 20)
Item #
1
2
3
4
LN-9244-03.3
Part #
79028-00
A10747-00
78372-00
78367-00
Description
Ring, Break-Away
Bell Plate Assembly
Set Screw, #8-32 X 1/4", Cup Point
Steel Cable, W/Ball and Shank
ARCHIVE
Qty
1
1
2
1
66
RMA-202 Rotary Atomizer - Parts Identification
Figure 21:
A10747-00 Rear Plate Assembly (Regulator Version)
PLATE
ASSEMBLY
(REGULAT
A10747-00 REAR PLA
TE ASSEMBL
Y (REGULA
T OR
PAR
ARTS
VERSION) - P
AR
TS LIST (Figure 21)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
67
Part #
79027-00
79034-00
77541-00
77543-00
79001-09
77505-00
79001-07
77507-00
79001-05
79001-06
79001-03
77506-00
SSF-2052
79001-04
A10744-00
Description
Rear Mounting Plate, RMA-202
Diaphragm, RMA-202
Flat Washer, .089" ID X .149" OD, Stainless Steel
Screw, #2-56 UNC X 1/4" Long, SHCS
O-Ring, Solvent Proof
Large Air Stud, Machined
O-Ring, Solvent Proof
Small Air Stud, Machined
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Medium Air Stud, Machined
Set Screw, #10-24 UNC X 3/8" Long SHCS
O-Ring, Solvent Proof
Fitting, Regulator Pilot
1
Apply thread sealer (7969-10) to threads prior to assembly
2
Apply A11545-00 Petrolatum jell to o-rings
ARCHIVE
Qty
1
2
2
2
1
4
4
7
7
9
2
3
2
1
1
1
2
1
2
1
2
2
2
1
2
1
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
NOTES
LN-9244-03.3
ARCHIVE
68
RMA-202 Rotary Atomizer - Parts Identification
CAUTION
!
32
14
21
Figure 22:
69
23
6
1
29
3
2
10
7
17
15
44
43
12
4
24
12
41
38
9
18
10
35
27
40
26
42
8
39
28
36
25
5
19
22
16
13
30
37
34
11
20
> Item #10 - Male Connector - 77544-01
DO NOT exceed 10 lbs•in torque (1.13 Nm).
79106-XX Fractional Tubing Bundle Assembly
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
79106-XX FRACTIONAL TUBING BUNDLE ASSEMBL
Y - P
AR
TS
ASSEMBLY
PAR
ARTS
LIST (Figure 22)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Description
Part #
79025-00
7959-24C
SSF-2052
---77947-00
---A10608-03
Table E, Item
------Table E, Item
Table E, Item
77544-01
77545-04
77536-05
SSP-6054
77545-07
A10609-02
---Table E, Item
---Table E, Item
Table E, Item
77545-02
77536-01
77545-09
A10608-02
77545-06
A10609-01
77545-13
77536-08
---77540-04
77539-01
76698-03
77545-01
77536-04
77545-03
77536-03
---A10608-01
Table B, Item
Table D, Item
---Table C, Item
"N"
"P"
"Q"
"V"
"T"
"S"
"K"
"M"
"L"
Robot Mounting Plate
Screw, 1/4-20 X 3/4" Long, SHCS.
Set Screw, #10-32 UNC X 3/8" Long, SHCS
---Fitting Modified, 3/8" OD X 1/4" NPT
---Tubing, 3/8" OD X .275" ID, Blue, Nylon
Male Connector, 1/4" NPT
------Paint #1 Supply Tubing, PFA Teflon
Insert, Stainless Steel Tube
Male Connector, 5/32" OD X 10-32 Thd.
Cap, 5/32" OD Tube, Natural Identification
Tubing, 5/32" OD X .106" ID, Natural Nylo
Male Connector, 1/4" OD X 1/8" NPT
Cap, 5/32" OD Tube, Yellow Identification
Tubing, 1/4" OD X .170" ID, Yellow, Nylon
---Male Connector, 3/8" OD X 1/4" NPT
---Insert, 3/8" OD X .250" ID Tube
Tubing, 3/8" OD X .250" ID, PFA Teflon
Cap, 5/32" OD Tube, Black Identification
Tubing, 5/32" OD X .106" ID, Black, Nylon
Cap, 3/8" OD Tube, Gray Identification
Tubing, 3/8" OD X .275" ID, Gray, Nylon
Cap, 1/4" OD Tube, Orange Identification
Tubing, 1/4" OD X .170" ID, Orange, Nylon
Cap, 5/32" OD Tube, Orange Identification
Tubing, 5/32" OD X .106" ID, Orange, Nylon
---Male Connector, 1/4" OD X 1/4" NPT
Insert, 1/4" OD X .125" ID Tube
Tubing, 1/4" OD X .125" ID, PFA Identification
Cap, 5/32" OD Tube, Blue Identification
Tubing, 5/32" OD X .106" ID, Blue, Nylon
Cap, 5/32" OD Tube, Green Identification
Tubing, 5/32" OD X .106", Green, Nylon
---Tubing, 3/8" OD X .275" ID, Green, Nylon
Low Voltage Cable
Adapter
---Fiber Optic Cable
Qty
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
1
6
2
---3
---A, Item
1
------A, Item
1
5
1
A, Item
3
2
A, Item
---1
---1
A, Item
1
A, Item
1
A, Item
1
A, Item
1
A, Item
---1
1
A, Item
1
A, Item
1
A, Item
---A, Item
1
1
---1
Notes
3
3
"H"
3
"H"
6
4
3
"H"
3
"J"
3
4
"H"
6
"H"
"H"
"H"
"H"
3
4
"H"
6
"H"
"H"
"H"
7
(See Page 71 for Bullet Definition Table.)
(Continued On Next Page)
LN-9244-03.3
ARCHIVE
70
RMA-202 Rotary Atomizer - Parts Identification
79106-XX FRACTIONAL TUBING BUNDLE ASSEMBL
Y - P
AR
TS
ASSEMBLY
PAR
ARTS
LIST (Cont.) (Figure 23)
Item #
46
47
48
49
50
51
52
Description
Part #
Table
Table
Table
Table
Table
Table
Table
B,
F,
F,
F,
F,
F,
F,
Item
Item
Item
Item
Item
Item
Item
"U"
"Z"
"AB"
"AA"
"X"
"W"
"Y"
Qty
Fiber Optic Cable
Dump Line #2, 3/8" OD X .250" ID, PFATeflon
Male Connector, 3/8" OD X 1/4" NPT
Insert, 3/8" OD X .250" ID Tube
Paint #2 Supply Tubing, PFA Teflon
Male Connector, 1/4" NPT
Insert, Stainless Steel Tube
Notes
1
Table A, Item "H"
1
1
Table A, Item "H"
1
1
3
3
PAR
ARTS
TABLE
** P
AR
TS LIST BULLET DEFINITION T
ABLE
7
Slot in low voltage cable assembly must be aligned with slot in robot plate, as shown.
6
Label loose ends of fluid tubing with signal abbreviation for identification.
4
Install tube inserts fully into Teflon tubing before installing tubing into fitting.
3
Apply thread sealer 7969-10 to threads prior to assembly. Do not exceed 10 lbs•in torque (1.13 Nm).
IDENTIFICATION
TABLE
SIGNAL IDENTIFICA
TION T
ABLE (FRACTIONAL)
Abbreviation
B.A
B.A
BRK
DL1
DL2
F.O.
LV
P1.IN
P1T
P1D
P2.IN
P2T
P2D
S.A
S.IN
SL.A
ST
T.A
71
Description
Bearing Air
Bearing Air Return
Brake Air
Dump Line
Dump Line
Fiber Optic Cable
Low Voltage Cable
Paint #1 In
Paint #1 Trigger
Paint #1 Dump
Paint #2 In
Paint #2 Trigger
Paint #2 Dump
Shaping Air
Solvent In
Seal Air
Solvent Trigger Signal
Turbine Air
Color
Tubing Material
Yellow
Yellow
Orange
Natural
Natural
Natural
Black
Natural
Green
Silver
Natural
Natural
Black
Gray
Natural
Blue
Blue
Green
Nylon
Nylon
Nylon
Teflon
Teflon
Polyethylene
N/A
Teflon
Nylon
Nylon
Teflon
Nylon
Nylon
Nylon
Teflon
Nylon
Nylon
Nylon
Tubing Size
1/4" OD X .170" ID
1/4" OD X .170" ID
1/4" OD X .170" ID
3/8" OD X 1/4" ID
3/8" OD X 1/4" ID
1/4" OD (jacket)
N/A
Table E, Item "P"
5/32" OD X .106" ID
5/32" OD X .106" ID
Table F, Item "X"
5/32" OD X .106" ID
5/32" OD X .106" ID
3/8" OD X .275" ID
1/4" OD X .125" ID
3/8" OD X .275" ID
5/32" OD X .106" ID
3/8" OD X .275" ID
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
79106XXXXX TUBING BUNDLE ASSEMBL
Y MODEL
79106-XXXXX
ASSEMBLY
IDENTIFICA
TION (FRACTIONAL)
IDENTIFICATION
When ordering, use 79106-ABCDEF as indicated by Tables A thru F.
Six digits must follow the basic part number, for example:
79106
-
3
00
2
1
0
Basic Part Number
1
Paint #2 Supply
Line Size (Table F) Dump Line #2 Size
(Table A)
Tubing Assy. Length
Low Voltage Cable Length
Fiber Optic Cable Length
(Table B)
(Table C)
(Table E)
(Table D)
Paint #1 Supply
Line Size Dump Line #1 Size
Robot Adapter
Tubing
TABLE A - T
ubing Assembly Length
Dash
No.
0
1
2
3
4
5
6
Description
(Not Included)
15' Tubing Assembly
25' Tubing Assembly
50' Tubing Assembly
75' Tubing Assembly
100' Tubing Assembly
40' Tubing Assembly
"H"
(Length)
---15 Ft.
25 Ft.
50 Fft.
75 Fft.
100 Ft.
40 Ft.
"J"
(Total Length)
---30 ft. (2-15 Ft. Lengths)
50 ft. (2-25 Ft. Lengths)
100 ft. (2-50 Ft. Lengths)
150 ft. (2-75 Ft. Lengths)
200 ft. (2-100 Ft. Lengths)
80 ft. (2-40 Ft. Lengths)
NOTE: To allow tubes to move freely in the robot wrist and
arm, remove all the black electrical tape holding tubing bundle
together. This tape is for shipping purposes only. Remove any
gummy residue left by tape by wiping with a mild solvent. Do
Not use any solvent to wipe outer sheathing of low voltage
cable.
LN-9244-03.3
ARCHIVE
72
RMA-202 Rotary Atomizer - Parts Identification
TABLE
Dash
No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
Voltage
B - Low V
oltage Cable Length
"K"
(Low Voltage
Cable)
Description
(Not Included)
25' Low Voltage Non-Junction Cable
40' Low Voltage Non-Junction Cable
50' Low Voltage Non-Junction Cable
75' Low Voltage Non-Junction Cable
100' Low Voltage Non-Junction Cable
15' Robot to JB; 15' JB to MicroPak
15' Robot to JB; 40' JB toMicroPak
15' Robot to JB; 60' JB to MicroPak
15' Robot to JB; 75' JB to MicroPak
25' Robot to JB; 25' JB to MicroPak
25' Robot to JB; 50' JB to MicroPak
25' Robot to JB; 75' JB to MicroPak
40' Robot to JB; 15' JB to MicroPak
40' Robot to JB; 25' JB to MicroPak
40' Robot to JB; 40' JB to MicroPak
40' Robot to JB; 60' JB to MicroPak
"U"
(Low Voltage
Cable Extension)
----79008-25
79008-40
79008-50
79008-75
79008-100
79008-15J
79008-15J
79008-15J
79008-15J
79008-25J
79008-25J
79008-25J
79008-40J
79008-40J
79008-40J
79008-40J
------------------------77062-15
77062-40
77062-60
77062-75
77062-25
77062-50
77062-75
77062-15
77062-25
77062-40
77062-60
TABLE C - Fiber Optic Cable Length
Dash
No.
0
1
2
3
4
5
6
73
Description
(Not Included)
15' Fiber Optic Cable
25' Fiber Optic Cable
50' Fiber Optic Cable
75' Fiber Optic Cable
100' Fiber Optic Cable
40' Fiber Optic Cable
"L"
----SMC-424-5
SMC-424-6
SMC-424-2
SMC-424-7
SMC-424-1
SMC-424-8
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
TABLE D - Robot Adapter
Dash
No.
0
1
2
3
4
5
6
7
"M"
Description
Adapter (Not Included)
Adapter (Fanuc P-155, P-145)
Adapter (ABB 5400, 5002)
Adapter (Fanuc P-200, 250)
Adapter (Kawasaki - KE610L)
Adapter (Motoman - PX2850)
Adapter (Motoman - PX2900)
Adapter (B & M LZ2000)
----78983-00
79107-00
79131-00
A10847-00
A10848-00
A10849-00
A10851-00
TABLE E - Paint #1 Supply Line - Dump Line #1 Size
Dash
No
1
Description
Paint Line, 1/4" OD x .170" ID,
"P"
"N"
Fitting Tubing
77540-04
76698-01
"Q"
Insert
Paint Line, 3/8" OD x .250" ID,
Paint Line, 5/16" OD x .188" ID,
"T"
Insert
"V"
Fitting
77539-04 77540-06
PFA Teflon
77540-06
76698-04
77539-04 Dump Line, 3/8" OD X .250" ID, 76698-04
77540-05
76698-02
77539-03 Dump Line, 3/8" OD x .250" ID,
PFA Teflon
3
"S"
Tubing
77539-02 Dump Line, 3/8" OD X .250" ID, 76698-04
PFA Teflon
2
Description
77539-04 77540-06
PFA Teflon
PFA Teflon
76698-04
77539-04 77540-06
"Z"
Tubing
"AA"
Insert
"AB"
Fitting
----
----
PFA Teflon
TABLE F - Paint #2 Supply Line - Dump Line #2 Size
Dash
No
Description
0
None
1
Paint Line, 1/4" OD x .170" ID,
"W"
Fitting
-77540-04
PFA Teflon
2
Paint Line, 3/8" OD x .250" ID,
Paint Line, 5/16" OD x .188"
ID, PFA Teflon
LN-9244-03.3
"Y"
Insert
--
--
Description
None
76698-01 77539-02 Dump Line, 3/8" OD X .250" ID,
---76698-04
77539-04 77540-06
76698-04
77539-04 77540-06
76698-04
77539-04 77540-06
PFA Teflon
77540-06
76698-04 77539-04 Dump Line, 3/8" OD X .250" ID,
77540-05
76698-02 77539-03 Dump Line, 3/8" OD x .250" ID,
PFA Teflon
3
"X"
Tubing
PFA Teflon
PFA Teflon
ARCHIVE
74
RMA-202 Rotary Atomizer - Parts Identification
!
CAUTION
32
14
Figure 23:
75
23
6
1
29
3
10
2
7
17
44
15
43
12
24
4
41
12
9
38
18
10
27
35
26
40
8
42
28
39
25
36
19
5
22
16
30
13
37
34
21
20
11
> Item #10 - Male Connector - 77544-01
DO NOT exceed 10 lbs•in torque (1.13 Nm).
A10892-XX Metric Tubing Bundle Assembly
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
ASSEMBLY
PAR
ARTS
A10892-XX METRIC TUBING BUNDLE ASSEMBL
Y - P
AR
TS LIST
(Figure 23)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Part #
79025-00
7959-24C
SSF-2052
A10891-03
A10893-07
A10891-04
Table D, Item
Table D, Item
Table D, Item
77544-01
77536-05
A10891-02
A10840-08
A10840-09
A10891-01
A10894-01
Table V
Table T
Table S
77536-01
A10839-03
77536-08
A10890-01
A10895-03
A10841-03
77536-04
77536-03
A10839-06
Table K
Table M
---Table L
Table U
Table E, Item
Table E, Item
Table E, Item
Table E, Item
Table E, Item
Table E, Item
77545-04
77545-13
77545-02
77545-01
77545-03
Description
Robot Mounting Plate
Screw, 1/4-20 X 3/4" Long, SHCS
Set Screw, #10-32 UNC X 3/8" Long
Fitting, 8mm X 1/4" NPT
Tubing, 8mm OD X 6mm ID,Blue, Nylon
Fitting, 10mm X 1/4" NPT
"N"
Male Connector, 1/4" NPT
"P"
Paint #1 Supply Tubing, PFA, Teflon
"Q"
Insert, Stainless Steel, Tube
Male Connector, 5/32" OD X 10-32 Thd.
Tubing, 5/32" OD X .106" ID, Natural, Nylon
Male Connector, 6mm OD X 1/8" NPT
Tubing, 6mm OD X 4mm ID, Yellow, Nylon
Tubing, 6mm OD X 4mm ID, Orange, Nylon
Male Connector, 4mm OD X 1/8" NPT
Tubing, 4mm OD X 2.7mm ID, Yellow, Nylon
Male Connector, 10mm OD X 1/4" NPT
Insert, Stainless Steel, Tube
Dump Line #1, 10mm OD X 8mm ID, PFA, Teflon
Tubing, 5/32" OD X .106" ID, Black, Nylon
Tubing, 10mm OD X 8mm ID, Silver, Nylon
Tubing, 5/32" OD X .106" ID, Orange, Nylon
Male Connector, 6mm OD X 1/4" NPT
Insert, 6mm OD X 4mm ID, Tube
Tubing, 6mm OD X 4mm ID, PFA, Teflon
Tubing, 5/32 OD X .106" ID, Blue, Nylon
Tubing, 5/32" OD X .106" ID, Green, Nylon
Tubing, 10mm OD X 8mm ID, Green, Nylon
Low Voltage Cable
Adapter
---Fiber Optic Cable
Low Voltage Cable, HP-404 Extension (Not Shown)
"Z"
Dump #2 Supply Tubing, PFA, Teflon
"AB" Male Connector, 10mm OD X 1/4" NPT
"AA" Insert, Stainless Steel, Tube
"X"
Paint #2 Supply Tubing, PFA, Teflon
"W" Male Connector, 1/4" NPT
"Y"
Insert, Stainless Steel, Tube
Cap, 5/32" OD Tube, Natural Identification
Cap, 5/32" OD Tube, Orange Identification
Cap, 5/32" OD Tube, Black Identification
Cap, 5/32" OD Tube, Blue Identification
Cap, 5/32" OD Tube, Green Identification
Qty
1
6
2
1
25 Ft.
2
1
25 Ft.
1
5
25 Ft.
2
25 Ft.
25 Ft.
1
25 Ft.
1
1
25 Ft.
25 Ft.
25 Ft.
25 Ft.
1
1
25 Ft.
25 Ft.
25 Ft.
25 Ft.
1
1
---1
1
25 Ft.
1
1
25 Ft.
1
1
1
1
1
1
1
Notes
3
3
3
3
4
3
3
3
4
3
4
3
Apply 7969-10 thread sealer to threads prior to assembly onto fittings DL1, DL2, P1IN, P2IN, and Solvent. Apply
7969-03 Loctite to BA, SA, BRK, TA, and SLA during assembly. Do not exceed 10 lbs•in torque (1.13 Nm).
4
Install tube inserts fully into Teflon tubing before installing tubing into fitting.
LN-9244-03.3
ARCHIVE
76
RMA-202 Rotary Atomizer - Parts Identification
A10892-XX TUBING BUNDLE
MODEL IDENTIFICA
TION (METRIC)
IDENTIFICATION
When ordering, use A10892-AABCDE as indicated by Tables A through E. Six digits must follow the
basic part number, for example:
A10892 -
00
2
1
0
1
(Table E)
Basic Part Number
Low Voltage
Cable Length
Fiber Optic
Cable Length
TABLE
Dash
No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
77
(Table A)
(Table B)
(Table D)
(Table C)
Paint #2 Supply Line Dump Line #2
Paint #1 Dump Line #1
Robot Adapter
Voltage
A - Low V
oltage Cable Length
"K"
"U"
(Low Voltage
(Low Voltage
Cable)
Cable Extension)
Description
(Not Included)
25' Low Voltage Non-Junction Cable
40' Low Voltage Non-Junction Cable
50' Low Voltage Non-Junction Cable
75' Low Voltage Non-Junction Cable
100' Low Voltage Non-Junction Cable
15' Robot to JB; 15' JB to MicroPak
15' Robot to JB; 40' JB toMicroPak
15' Robot to JB; 60' JB to MicroPak
15' Robot to JB; 75' JB to MicroPak
25' Robot to JB; 25' JB to MicroPak
25' Robot to JB; 50' JB to MicroPak
25' Robot to JB; 75' JB to MicroPak
40' Robot to JB; 15' JB to MicroPak
40' Robot to JB; 25' JB to MicroPak
40' Robot to JB; 40' JB to MicroPak
40' Robot to JB; 60' JB to MicroPak
----79008-25
79008-40
79008-50
79008-75
79008-100
79008-15J
79008-15J
79008-15J
79008-15J
79008-25J
79008-25J
79008-25J
79008-40J
79008-40J
79008-40J
79008-40J
ARCHIVE
------------------------77062-15
77062-40
77062-60
77062-75
77062-25
77062-50
77062-75
77062-15
77062-25
77062-40
77062-60
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
TABLE B - Fiber Optic Cable Length
Dash
No.
0
1
2
3
4
5
6
7
"L"
Description
(Not Included)
15' Fiber Optic Cable
25' Fiber Optic Cable
50' Fiber Optic Cable
75' Fiber Optic Cable
100' Fiber Optic Cable
40' Fiber Optic Cable
120' Fiber Optic Cable
----SMC-424-5
SMC-424-6
SMC-424-2
SMC-424-7
SMC-424-1
SMC-424-8
SMC-424-3
TABLE C - Robot Adapter
Dash
No.
0
1
2
3
4
5
6
7
LN-9244-03.3
"M"
(Robot
Adapter)
Description
Adapter (Not Included)
Adapter (Fanuc P-155, P-145)
Adapter (ABB 5400, 5002)
Adapter (Fanuc P-200, 250)
Adapter (Motoman - PX2900)
Adapter (Motoman - PX2850)
Adapter (Kawasaki - KE610L)
Adapter (B & M LZ2000)
----78983-00
79107-00
79131-00
A10849-00
A10848-00
A10847-00
A10851-00
ARCHIVE
78
RMA-202 Rotary Atomizer - Parts Identification
TABLE D - Paint #1 Supply Line - Dump Line #1
Dash
No
1
"N"
Fitting
Description
"P"
Tubing
"Q"
Insert
"V"
Fitting
PFA Teflon
Paint Line, 8mm OD x 6mm ID,
A10890-02 A10841-02 A10895-02 Dump Line, 10mm OD X 8mm ID, A10841-01 A10895-01 A10890-03
PFA Teflon
3
"T"
Insert
Paint Line, 6mm OD x .4mm ID, A10890-01 A10841-03 A10895-03 Dump Line, 10mm OD X 8mm ID, A10841-01 A10895-01 A10890-03
PFA Teflon
2
"S"
Tubing
Description
PFA Teflon
Paint Line, 10mm OD x 8mm ID, A10890-03 A10841-01 A10895-01 Dump Line, 10mm OD x 8mm ID, A10841-01 A10895-01 A10890-03
PFA Teflon
PFA Teflon
TABLE E - Paint #2 Supply Line - Dump Line #2
Dash
No
Description
"N"
Fitting
"P"
Tubing
"Q"
Insert
--
--
--
Description
"S"
Tubing
"T"
Insert
--
--
"V"
Fitting
--
0
----
1
Paint Line, 6mm OD x .4mm ID, A10890-01 A10841-03 A10895-03 Dump Line, 10mm OD X 8mm ID, A10841-01 A10895-01 A10890-03
PFA Teflon
2
PFA Teflon
Paint Line, 8mm OD x 6mm ID,
A10890-02 A10841-02 A10895-02 Dump Line, 10mm OD X 8mm ID, A10841-01 A10895-01 A10890-03
PFA Teflon
3
----
PFA Teflon
Paint Line, 10mm OD x 8mm ID, A10890-03 A10841-01 A10895-01 Dump Line, 10mm OD x 8mm ID, A10841-01 A10895-01 A10890-03
PFA Teflon
PFA Teflon
IDENTIFICATION
TABLE
SIGNAL IDENTIFICA
TION T
ABLE (METRIC)
Abbreviation
B.A
B.A
BRK
DL1
F.O.
LV
P1.IN
P1T
P1D
P2.IN
P2T
P2D
S.A
S.IN
SL.A
ST
T.A
DL2
79
Description
Color Tubing Material
Bearing Air
Bearing Air Return
Brake Air
Dump Line #1
Fiber Optic Cable
Low Voltage Cable
Paint #1 In
Paint #1 Trigger
Paint #1 Dump
Paint #2 In
Paint #2 Trigger
Paint #2 Dump
Shaping Air
Solvent In
Seal Air
Solvent Trigger Signal
Turbine Air
Dump Line #2
Yellow
Yellow
Orange
Natural
Natural
Black
Natural
Green
Silver
Natural
Natural
Black
Silver
Natural
Blue
Blue
Green
Natural
Nylon
Nylon
Nylon
Teflon
Polyethylene
N/A
Teflon
Nylon
Nylon
Teflon
Nylon
Nylon
Nylon
Teflon
Nylon
Nylon
Nylon
Teflon
Tubing Size
6mm OD X 4mm ID
4mm OD X 2mm ID
6mm OD X 4mm ID
10mm OD X 8mm ID
1/4" OD (Jacket)
N/A
Tables D & E
5/32" OD X .106" ID
5/32" OD X .106" ID
Tables D & E
5/32" OD X .106" ID
5/32" OD X .106" ID
10mm OD X 8mm ID
6mm OD X 4mm ID
8mm OD X 6mm ID
5/32" OD X .106" ID
10mm OD X 8mm ID
10mm OD X 8mm ID
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
SPARE
PAR
ARTS
RMA-202 RECOMMENDED SP
ARE P
AR
TS
Part #
79010-00
77524-00
75867-00
RPM-2
78980-00
EMF-203-04
EMF-202-04
EMF-203-05
EMF-202-05
79008-XX
SMC-424-X
79001-03
79001-04
79001-05
79001-06
79001-07
79001-08
79001-09
79001-04
7554-07
7554-03
79034-00
77541-00
77543-00
75911-00
78278-00
75921-02
LSFA0006-16F
78372-00
7959-24C
SSF-2052
78367-00
77539-01
77539-02
77539-03
77539-04
76698-01
76698-02
76698-03
76698-04
77536-01
77536-02
77536-03
77536-04
77536-05
77537-01
77537-02
77538-01
(Continued On Next Page)
LN-9244-03.3
Description
Cascade Assembly
Break-Away Screw, Machined
Air Turbine Assembly
Shaping Air Seal
Fluid Tube, Rear
Front Ferrule, 1/4" OD Tubing
Back Ferrule, 1/4" OD Tubing
Front Ferrule, 3/8" OD Tubing
Back Ferrule, 3/8" OD Tubing
Low Voltage Cable
Fiber Optic Cable
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Resistant
O-Ring, Solvent Resistant
Diaphragm, RMA-202
Flat Washer, .089" ID X .149" OD, Stainless
Screw, #2-56 UNC X 1/4" Long, SHCS
Fiber Optic Transmitter Assembly
Nut, Fiber Optic Transmitter
Fiber Optic Cable Assembly
Screw, #10-32 X 1/2" Long, Stainless Steel, SHCS
Set Screw, #8-32 X 1/4", Cup Point
Screw, 1/4-20 X 3/4" SHCS
Set Screw, #10-32 UNC X 3/8" Long, SHCS
Steel Cable, W/Ball and Shank
Insert, 1/4" OD X .125" ID Tube
Insert, 1/4" OD X .170" ID Tube
Insert, 5/16" OD X .188" ID Tube
Insert, 3/8" OD X .250" ID Tube
Paint Line, 1/4" OD X .170" ID, PFA, Teflon
Paint Line, 5/16" OD X .188" ID, PFA, Teflon
Tubing, 1/4" OD X .125" ID, PFA, Identification
Paint/Dump Line, 3/8" OD X .250" ID, PFA, Teflon
Tubing, 5/32" OD X .106" ID, Black, Nylon
Tubing, 5/32" OD X .106" ID, Red, Nylon
Tubing, 5/32" OD X .106" ID, Green, Nylon
Tubing, 5/32" OD X .106" ID, Blue, Nylon
Tubing, 5/32" OD X .106" ID, Natural, Nylon
Tubing, 1/4" OD X .170" ID, Yellow Pe
Tubing, 1/4" OD X .170" ID, Orange Pe
Tubing, 3/8" OD X .250" ID, Gray Pe
ARCHIVE
Qty
1
8
0-1
0-1
0-1
0-2
0-2
0-2
0-2
1
1
2
0-2
10
11
8
8-10
1
1
0-1
0-1
2
2
2
1
0-1
0-1
4
2
4-6
3
1
1
1
1
1
-------------------------------------
80
RMA-202 Rotary Atomizer - Parts Identification
SPARE
PAR
ARTS
RMA-202 RECOMMENDED SP
ARE P
AR
TS (Cont.)
Part #
77538-02
78449-00
77538-03
SSP-6054
77540-06
77540-04
79029-00
77544-01
78949-00
77367-00
A10706-00
A77790-00
A10841-03
A10841-02
A10841-01
A10839-06
A10841-01
A10839-03
A10893-07
A10840-08
A10840-09
A10841-03
77536-05
77536-01
77536-08
A10894-01
77536-04
77536-03
A10891-04
A10890-03
A10890-02
A10890-01
A10891-03
A10891-02
A10891-01
A10895-01
A10895-02
A10895-03
A10901-00
A10896-00
20391-08C
A11945-00
77580-08C
81
Description
Qty
Tubing, 3/8" OD X .250" ID, Green Pe
Fitting
Tubing, 3/8" OD X .250" ID, Blue Pe
Male Connector, 1/4" OD X 1/8" NPT
Male Connector, 3/8" OD X 1/4" NPT
Male Connector, 1/4" OD X 1/4" NPT
Fitting
Male Connector, 5/32" OD X 10-32 Threaded
Fluid Valve Assembly
Valve Seat Assembly
Shaft Plug for Fluid Tube / Tip A11508-XX and 79118-XX
Shaft Plug for Fluid Tip 78981-XX
Paint Tubing, 6mm OD X 4mm ID, PFA, Teflon
Paint Tubing, 8mm OD X 6mm ID, PFA, Teflon
Paint Tubing, 10mm OD X 8mm ID, PFA, Teflon
Tubing, 10mm OD X 8mm ID, Green, Nylon
Tubing, 10mm OD X 8mm ID, PFA, Teflon
Tubing, 10mm OD X 8mm ID, Silver, Nylon
Tubing, 8mm OD X 6mm ID, Blue, Nylon
Tubing, 6mm OD X 4mm ID, Yellow, Nylon
Tubing, 6mm OD X 4mm ID, Orange, Nylon
Tubing, 6mm OD X 4mm ID, PFA, Teflon
Tubing, 4mm OD X .106" ID, Natural, Nylon
Tubing, 4mm OD X .106" ID, Black, Nylon
Tubing, 4mm OD X .105" ID, Orange, Nylon
Tubing, 4mm OD X 2.7mm ID, Yellow, Nylon
Tubing, 4mm OD X .106" ID, Blue, Nylon
Tubing, 4mm OD X .106" ID, Green, Nylon
Fitting, 10mm OD X 1/4" NPT
Male Connector, 10mm OD X 1/4" NPT
Male Connector, 8mm OD X 1/4" NPT
Male Connector, 6mm OD X 1/4" NPT
Fitting, 8mm OD X 1/4" NPT
Male Connector, 6mm OD X 1/8" NPT
Male Connector, 4mm OD X 1/8" NPT
Insert, 10mm OD X 8mm ID, Tube
Insert, 8mm OD X 6mm ID, Tube
Insert, 6mm OD X 4mm ID, tube
Repulsion Ring
Air Turbine Assembly (Repulsion Unit)
Screw, #8-32 X 1/4" BSHCS
Repulsion Ring, 30mm Ghost Buster
Screw (For A11945-00 Repulsion Ring)
---0-1
---0-2
0-1
0-1
0-1
8-10
3-5
3-5
0-1
0-1
------------------------------------------------0-1
0-1
0-1
0-1
0-1
0-1
0-1
1
1
1
1
1
3-6
1
3-6
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
SPARE
PAR
ARTS
RMA-202 RECOMMENDED SP
ARE P
AR
TS (Cont.)
Description
Qty
Select Option Below
78981-01
78981-02
78981-03
78981-04
79118-01
79118-02
79118-03
79118-04
Fluid Tip Size
ø.094
ø.062
ø.045
ø.035
ø.094
ø.062
ø.045
ø.035
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
Select Option Below
A11957-00
A11949-00
A11954-00
Bell Cup
30mm Bell Cup Assembly, Ghost Buster
30mm Bell Cup, Ghost Buster, Cup Only
Splash Plate Assembly, Ghost buster
0-1
0-1
1
Select Option Below
A11508-01
A11508-02
A11508-03
A11508-04
A10706-00
A77790-00
Fluid Tube Assembly Size (Stainless Steel)
.094"
.062"
.045"
.035"
Shaft Plug for Fluid Tube / Tip A11508-XX and 79118-XX
Shaft Plug for Fluid Tip 78981-XX
0-1
0-1
0-1
0-1
0-1
0-1
Select Option Below
RPM-452-3
RPM-457-1
79004-00
Bell Cup
30mm Bell Cup, Titanium W/Holes
57mm Bell Cup Assembly, Titanium
57mm Bell Cup Assembly, 57 "V" Cup
0-1
0-1
0-1
Required for 79004-00
LSOR0005-01
79001-10
Bell Cup Option
O-Ring, Teflon, Encapsulated Viton
O-Ring, Solvent Proof
Select Option Below
77517-00
78450-00
A10671-00
Fluid Coil
1/4" OD X .170" ID PFA
1/4" OD X .125" ID PFA, High Conductive Paints
Static Mix Tube Assembly
Part #
LN-9244-03.3
ARCHIVE
1
1
0-1
0-1
1-2
82
RMA-202 Rotary Atomizer - Parts Identification
ACCESSORIES AND SERVICE KITS
Part #
Description
LSCH0009-00
Dielectric Grease (.88 oz. Tube)
76652-01
Kit for measuring high voltage. (Includes Multi-Function Meter (76634-00) and High
Voltage Probe Assy. (76667-00).
76652-02
Kit for measuring short circuit current (SCI), resistance, and sprayability. Includes
Multi-Function Meter (76634-00) and Test Lead Assy. (76664-00).
76652-03
Kit for measuring paint resistivity. (Includes Multi-Function Meter (76634-00) and
Paint Probe Assy. (7922-00).
76652-04
Deluxe Kit (Performs all functions listed above.) Includes Multi-Function Meter (76634-00),
Paint Probe Assy. (7922-00). Test Lead Assy. (76664-00), and High Voltage Probe
Assy. (76667-00).
1
RPM-32
Pre-Filter Replacement Element
RPM-33
Bearing Air Filter Element
AER4019
Air Bearing Rebuild Kit
LSFA-0004-166
Screw, 1/4-20 X 1/2" Long, Fillister Head, Glass Filled Nylon
A10568-XX
Teach Bracket Kit
1
Used as replacement screw option for 77524-00 break-away screws.
Tighten to 3-5 lbs•in (.34-.56 Nm).
LUBRICANTS AND SEALERS
Part #
83
Description
A11545-00
Petrolatum Jell Lubricant for all O-Rings
7969-03
Thread Sealant (Blue), Loctite 24077
7969-10
Thread Sealant (White), Loctite 59231, Teflon Paste
7969-05
Thread Sealant (Purple), Loctite 22221
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
AVAILABLE T
OOLS
TOOLS
RPM-419
Shroud / Bell Cup Wrench
(Optional)
78279-00
Fiber Optic Tool
(Supplied With Atomizer)
76772-00
Adjustable Spanner Wrench
(Optional)
78982-00
Fluid Tip Tool
(Supplied With Atomizer)
78985-00
Valve Tool
(Supplied With Atomizer)
A10742-00
Regulator Cap Tool
A11388-00
Splash Plate Removal Tool
LN-9244-03.3
ARCHIVE
84
RMA-202 Rotary Atomizer - Parts Identification
TEACH BRACKET KIT
Part #
Description
A10568-01
For Use With 30mm Bell Cup Atomizer
A10568-02
For Use With 57 and 57 "V" Bell Cup Atomizers
** Robot adapter not included with Kit.
Figure 24:
85
A11065-02 Air Heater
ARCHIVE
LN-9244-03.3
RMA-202 Rotary Atomizer - Parts Identification
NOTES
LN-9244-03.3
ARCHIVE
86
RMA-202 Rotary Atomizer - Warranty Policies
WARRANTY POLICIES
LIMITED WARRANTY
ITW Ransburg will replace or repair without
charge any part and/or equipment that fails within
the specified time (see below) because of faulty
workmanship or material, provided that the equipment has been used and maintained in accordance with 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, (example: guns, power supplies, control units,
etc.), is one (1) year from date of purchase.
WRAPPING THE APPLICATOR IN PLASTIC, SHRINK-WRAP, ETC., WILL VOID
THIS WARRANTY.
87
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.
ARCHIVE
LN-9244-03.3
MANUAL CHANGE SUMMAR
Y
SUMMARY
This manual was published to supercede Service
Manuals LN-9244-03.3, RMA-202 Robot
Mounted Rotary Atomizer to make the following
changes:
14. Added "RMA-202 Model Identification - 30mm
A11957-00 With A11953-XX Fluid Tubes Figure" in
the "Parts Identfication" section.
1. Added "Service Manual Price: €40.00 (Euro)"
to the "Front Cover".
15. Revised "RMA-202 Model Identification Table B - Fluid Tube Size - added Dash #13-16" in
the "Parts Identification" section.
2. Added "Shaping Air Flow vs Supply Pressure
30mm Ghost Buster Shroud Style graph" in the
"Introduction" section.
16. Added "A11953-XX Fluid Tube Figure" in the
"Parts Identification" section.
3. New "Figure 3 - 30mm "Ghost buster" RMA202 Tool Point and Center of Gravity Dimension" in
the "Introduction" section.
4. Added "Fluid Connections Diagram" in the
"Installation" section.
5. Added "Shaping Air #2" in the "Operation" section.
6. Added "A11957-00 Bell Cup and Splash Plate
Disassembly" in the "Maintenace" section.
7. New "Figure 7 - Splash Plate Removal" in the
"Maintenance" section.
8. Added "Figure 8 - Splash Plate Insertion" in the
"Maintenance" section.
9. Added "Disassembly Procedure - Shaping Air #1
Seal Replacement" in the "Maintenance" section.
10. Added "Figure 11 - Shaping Air #1 Seal
Replacement" in the "Maintenance" section.
11. New "Figure 13 - RMA-202 Assembly and Parts
List" in the "Parts Identification" section.
12. Revised "RMA-202 Assembly Parts List - Item
18 - 79001-03 - O-Ring, Solvent Proof, Qty. 1;
added Items 55 - 58" in the "Parts Identification"
section.
13. Revised "RMA-202 Model Identification - Bell
Cup Style - added Q, R, and S; added Dash #6-9"
in the "Parts Identification" section.
LN-9244-03.3
17. Added "Caution" to Figure 22 - 79106-XX
Tubing Bundle Assembly" in the "Parts Identification"
section.
18. Added "Caution" to Figure 23 - A10892-XX
Metric Tubing Bundle" in the "Parts Identification"
section.
19. Added "A10892-XX Metric Tubing Bundle Parts
List Bullet Definition - 3 - Do not exceed 10 lbs•in
torque (1.13 Nm)" in the "Parts Identification"
section.
20. Added "RMA-202 Recommended Spare Parts:
A11957-00 - 30mm Bell Cup Assembly Ghost Buster
A11949-00 - 30mm Bell Cup, Ghost Buster, Cup
Only
A11954-00 - Splash Plate Assembly, Ghost Buster
A11945-00 - Repulsion Ring, 30mm Ghost Buster
77580-08C - Screw (for A11945-00 Repulsion
Ring)" in the "Parts Identification" section.
21. Added "Avalable Tools - A11388-00 Splash
Plate Removal Tool" in the "Parts Identification"
section.
22. Revised "Available Tools - A10742-00 Regulator
Cap Tool" in the "Parts Identification" section.
23. Removed "Appendix" section. See literature
"IL-307 Technical Supplement for All Products".
24. Added "Service Manual Price: €40.00 (Euro)"
to the "Back Cover".
ARCHIVE
Service Manual Price: €40.00
40.00 (Euro)
$50.00 (U.S.)
Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260/665-8800
Fax: 260/665-8516
Technical/Service Assistance
Automotive Assembly and Tier I
Industrial Systems
Ransburg Guns
www.itwransburg.com
IV
E
Telephone: 800/ 626-3565 Fax: 419/ 470-2040
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
AR
C
H
Technical Support Representative will direct you to the appropriate telephone
number for ordering Spare Parts.
© 2007 Illinois Tool Works Inc. All rights reserved.
Models and specifications subject to change without notice.
Form No. LN-9244-03.3
Litho in U.S.A.
10/07
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