Evolver 202 Solvent (Serv. Man. AA-07-01

Evolver 202 Solvent (Serv. Man. AA-07-01
SERVICE MANUAL
AA-07-01
June - 2007
A
R
C
H
IV
E
EVOL
VER 202TM SOL
VENTBORNE
EVOLVER
SOLVENTBORNE
ROBOTIC A
TOMIZERS
AT
With
MODEL: A1
1918-XXX
A11918-XXX
Technology
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.)
DRAFT
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AA-07-01
Evolver 202 Robotic Atomizers - Contents
CONTENTS
PAGE
1-4
SAFETY:
SAFETY PRECAUTIONS............................................................................................................. 1
HAZARDS / SAFEGUARDS......................................................................................................... 2-4
INTRODUCTION:
5-14
ITW RANSBURG ELECTROSTATIC PROCESS...................................................................... 5
EVOLVER 202 SOLVENTBORNE SPRAY APPLICATORS.................................................... 5-6
SPECIFICATIONS....................................................................................................................... 7
EVOLVER 202 APPLICATOR ASSEMBLY................................................................................ 8
EVOLVER 202 TUBING BUNDLE ASSEMBLY (ENGLISH)..................................................... 9
EVOLVER 202 TUBING BUNDLE ASSEMBLY (METRIC)....................................................... 10
EVOLVER 202 SOLVENTBORNE ROBOTIC ATOMIZER APPLICATORS............................ 11
FEATURES.................................................................................................................................. 12
A11918-XXX EVOLVER SPRAY APPLICATOR ASSEMBLY.................................................. 13
TOOL CENTER-POINT COMPARISONS TABLE..................................................................... 14
INSTALLATION:
15-22
EVOLVER 202 ROBOTIC ATOMIZER INSTALLATION............................................................ 15
POWER SUPPLY ASSEMBLY................................................................................................... 15
LOW VOLTAGE CABLE CONNECTIONS................................................................................. 16
EVOLVER SPRAY APPLICATOR AIR AND FLUID LAYOUT.................................................. 17
APPLICATOR AND MANIFOLD ASSEMBLY............................................................................ 18
LOW VOLTAGE CABLE INSTALLATIONS................................................................................ 18-19
SIGNAL IDENTIFICATION TABLES (ENGLISH/METRIC)....................................................... 20
APPLICATOR AND MANIFOLD ASSEMBLY / PARTS LIST.................................................... 21
SPRAY / BELL APPLICATOR TRIGGERING............................................................................ 22
CONVERSION SCHEMATIC...................................................................................................... 22
OPERATION:
23-26
SPRAY APPLICATOR CONTROLS........................................................................................... 23
HVLP SPRAY............................................................................................................................... 23
FLUID VALVE CONTROLS......................................................................................................... 23
DUAL PURGE SPRAYING......................................................................................................... 24-26
MAINTENANCE:
27-52
ROUTINE MAINTENANCE SCHEDULE..................................................................................... 27-28
PROCEDURES............................................................................................................................. 28-29
SPRAY HEAD REMOVAL / ASSEMBLY / PARTS LIST.......................................................... 31-32
SERVICE...................................................................................................................................... 33
SPRAY HEAD ASSEMBLY.......................................................................................................... 33-35
79138 EVOLVER APPLICATOR HEAD ASSEMBLY / PARTS LIST........................................ 37-38
(Continued On Next Page)
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Evolver 202 Robotic Atomizers- Contents
PAGE
MAINTENANCE (Cont.):
27-52
REMOVING SPRAY APPLICATOR FROM THE
REAR MANIFOLD ASSEMBLY................................................................................................... 39
EVOLVER 202 60° SINGLE HEAD APPLICATOR
ASSEMBLY / PARTS LIST........................................................................................................... 40
MOUNTING BLOCK, SHROUD HALVES AND RETAINING
RING REMOVAL / PARTS LIST.................................................................................................. 41
DISASSEMBLY OF INTERMEDIATE APPLICATOR
HOUSING / PARTS LIST............................................................................................................. 43-44
LOW VOLTAGE CABLE REMOVAL / PARTS LIST................................................................... 45-46
79103-00 DUAL PURGE VALVE MANIFOLD
DISASSEMBLY / PARTS LIST..................................................................................................... 47
79103-01 SINGLE PURGE VALVE MANIFOLD
DISASSEMBLY / PARTS LIST..................................................................................................... 47
REGULATOR VALVE MANIFOLD ASSEMBLY......................................................................... 48
A10745 FLUID REGULATOR ASSEMBLY / PARTS LIST......................................................... 49
TROUBLESHOOTING GUIDE.................................................................................................... 50-52
PARTS IDENTIFICATION:
53-88
A11918 SPRAY APPLICATOR ASSEMBLY / PARTS LIST...................................................... 53-54
79138-01 SPRAY HEAD ASSEMBLY / PARTS LIST................................................................. 55-57
79179-00 SINGLE HEAD 60° / PARTS LIST............................................................................... 58
79243-00 DUAL HEAD 60° / PARTS LIST................................................................................... 58
79180-00 SINGLE HEAD 90° / PARTS LIST............................................................................... 59
79224-00 DUAL HEAD 90° / PARTS LIST................................................................................... 59
A11917 MANIFOLD ASSEMBLY / PARTS LIST......................................................................... 61-63
79105-01 REAR PLATE ASSEMBLY (UN-REGULATED VERSION) /
PARTS LIST.................................................................................................................................. 64
A10747-00 REAR PLATE ASSEMBLY (REGULATOR VERSION) /
PARTS LIST.................................................................................................................................. 65
REAR PLATE / BREAK-AWAY ASSEMBLY (SINGLE PAINT
WITH REGULATOR MANIFOLD ASSEMBLY ONLY) / PARTS LIST....................................... 66
79106-XXXXXXX TUBING BUNDLE ASSEMBLY (ENGLISH) / PARTS LIST.......................... 67-72
A10892-XXXXXXX TUBING BUNDLE ASSEMBLY (METRIC) / PARTS LIST......................... 73-78
A10406 OR LECU5004 MICROPAK CONTROL UNIT............................................................... 79
ACCESSORIES AND SERVICE KITS........................................................................................ 79-81
REPAIR KITS................................................................................................................................ 82-83
SERVICE PARTS......................................................................................................................... 84
LUBRICANTS AND SEALERS.................................................................................................... 84
RECOMMENDED SPARE PARTS............................................................................................. 85-87
WARRANTY POLICIES:
89
LIMITED WARRANTY.................................................................................................................. 89
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Evolver 202 Robotic Atomizers - Contents
AA-07-01
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Evolver 202 Robotic Atomizers - 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.
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 Ransburg equipment manuals to reconcile such differences.
!
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 or applicable
country safety standards prior to installing, operating, and/or servicing this equipment.
!
WARNING
> The hazards shown on the following page
may occur during the normal use of this
equipment. Please read the hazard chart
beginning on page 2.
Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efficient operation,
longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals
and safety literature for your ITW Ransburg system, contact your local ITW Ransburg representative or ITW Ransburg.
1
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AA-07-01
Evolver 202 Robotic Atomizers - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
Fire Hazard
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Improper or inadequate operation and maintenance procedures will cause a fire hazard.
Spray areas must be kept clean to prevent the accumulation of combustible residues.
may occur.
Spray Area
Smoking must never be allowed in the spray area.
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.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.
Those used for general cleaning must have flash
points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by local and/or country 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.
The paint process and equipment should be set up and
operated in accordance with local and/or country safety
codes.
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.
Personnel must be properly
trained in the use of this equipment.
Instructions and safety precautions must be read and
understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33, and your insurance company requirements.
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2
Evolver 202 Robotic Atomizers - 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 if Follow the requirements of the Material Safety Data
inhaled, or if there is contact with Sheet supplied by coating material manufacturer.
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.
Explosion Hazard/ Halogenated hydrocarbon solvents Aluminum is widely used in other spray application
for example: methylene chloride equipment - such as material pumps, regulators,
Incompatible
and 1,1,1,-Trichlor-oethane are not triggering valves, etc. Halogenated hydrocarbon
Materials
Electrical
Equipment
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.
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.
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 applicable code for specific area and/
or country.
Turn the power supply OFF before working on the
Protection against inadvertent arc- equipment.
ing that may cause a fire or explosion is lost if safety circuits are Test only in areas free of flammable or combustible
material.
disabled during operation.
Frequent power supply shutdown Testing may require high voltage to be on, but only as
indicates a problem in the system instructed.
which requires correction.
Production should never be done with the safety
An electrical arc can ignite coating circuits disabled.
materials and cause a fire or explosion.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
3
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AA-07-01
Evolver 202 Robotic Atomizers - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Robot Work Area Improper use or maintenance can Applicator adjustments or maintenance should be
-General Use and lead to hazardous conditions, par- done after the robot is taken out of service. Do not
ticularly from unexpected robot adjust or repair the applicator if the robot is operating
Maintenance
manipulator movement.
or standing ready to start.
Refer to robot operating instructions for the procedures to take the robot out of service.
Personnel Safety
AA-07-01
Skin puncturing by sharp electrode. Take precautions to see that flesh is not punctured
by sharp electrode.
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4
Evolver 202 Robotic Atomizers - Introduction
INTRODUCTION
THE ITW RANSBURG
ELECTROST
ATIC
ELECTROSTA
PROCESS
EVOL
VER 202™
EVOLVER
SOL
VENTBORNE SPRA
Y
SOLVENTBORNE
SPRAY
APPLICA
TORS
APPLICAT
This process is a method for electrostatically
applying coatings to objects. A power supply
produces a high voltage charge which is supplied
to the applicator, creating an electrostatic field
between the applicator and the target object. The
target is electrostatically grounded through its
support which may be either stationary or moving.
The Evolver 202 Spray Applicators System
will allow for the use of spray applicators or bell
applicators with minimal required down-time during
the switching process. This system can also
operate as a spray applicator system only that
later can be upgraded to allow for bell applicators
to be used. Lastly, this system can allow a user
currently possessing an RMA-202 bell system to
use spray applicators as well, with minimal conversion required. The Evolver 202 solventborne
applicator line consists of both 60° and 90° single
and dual-headed 100 kV automatic electrostatic
applicators. Developed for use on robots, the
Evolver 202 spray applicator incorporates a unique
1/3 turn quick-disconnect spray head and a two
piece bolt together manifold cover, providing the
user an efficient tool for the electrostatic application
of coatings.
A regulated fluid system delivers coating material
to the applicator, where it is atomized forming a
spray mist. There, under the influence of the
electrostatic field, the atomized coating becomes
electrostatically charged. The charged particles
are attracted to and deposited on the grounded
target object. The forces between the charged
particles and the target are sufficient to turn
overspray around and deposit it on the back surface
of the target. Therefore, a higher percentage of
the spray is deposited.
The Evolver 202 spray applicator also has the
ability to color change while spraying with no
voltage draw down, a true dual purge function
(depending on the unit purchased).
There are two single head models of the Evolver
202 applicator (see Figure 1). Each model differs
in the applicator to axis orientation of the spray
head. These models are:
A11918-0XX 60° Single Head
A11918-1XX 90° Single Head
Two dual-head versions of the Evolver 202 applicator are also available (see Figure 1). The dual
headed applicators are primarily used where high
volume fluid delivery is required. The dual headed
applicator is available in two different configurations as follows:
A11918-2XX 60° Dual Head
A11918-3XX 90° Dual Head
5
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AA-07-01
Evolver 202 Robotic Atomizers - Introduction
The Evolver 202 spray applicator system consists of four major components:
NOTES
1. Quick-Disconnect Spray Head
2. Gun Head Mounting Block Assembly
3. Valve Manifold Assembly (Includes the High
Voltage Cascade with a Quick-Disconnect
Ring)
4. Rear Tubing Manifold Assembly (both English
and Metric)
The spray head(s) and valve manifold contain the
fluid, air, and high voltage passages. All fluid
passages contain stainless steel and/or nylon
fittings, compatible with halogenated hydrocarbon
solvents. The robot manifold incorporates stainless steel fluid connections.
The high voltage cascade is entirely encapsulated
with a solvent resistant epoxy. This cascade
generates voltages up to 100 kV fed by a low
voltage cable.
There are three sources for the high voltage
supply to the Evolver 202 applicators:
• MicroPak™ Control Unit (LECU5004)
(for non-FM installations)
• Stand-alone control/power supply unit
(A10406) (for FM installations)
• MicroPakTM Control Unit (LECU5004-31)
(for FM installations)
The MicroPak Power Supply Control unit provides
a low voltage signal through the robot manifold to
the spray applicator. The high voltage cascade
located within the applicator converts the low
voltage DC signal to a high voltage electrostatic
output.
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6
Evolver 202 Robotic Atomizers - Introduction
SPECIFICA
TIONS
SPECIFICATIONS
Environmental/Physical
Electrical Requirements
Robot/Mounting Compatibility:
All hollow wrist robots
Output Voltage:
30-100 kV
Output Range:
0-85 μA
Applicator Control Unit:
MicroPak Control Unit - LECU5004-31
Stand-Alone Control Unit - A10406
Paint Flow Rate: Variable to 1500 cc/min.
(Depending on viscosity & configuration)
Operating Temperature Range:
55°F (12.8°C) - 131°F (55°C)
Trigger Response
Time:
Weight
Single-Headed:
60
60°
90
90°
Dual-Headed:
60
60°
90
90°
Manifold:
A11919-XX
Length
Single-Headed:
60
60°
90
90°
Dual-Headed:
60
60°
90
90°
10.87 lbs. (4.93 Kg)
10.56 lbs. (4.79 Kg)
12.76 lbs. (5.79 Kg)
12.61 lbs. (5.72 Kg)
8.67 lbs. (3.93 Kg)
(No tubing or cable)
Operating Air Pressures
Atomizing Air:
100 psig
(6.9 bar) max.
Fan Air:
Trigger Pilot:
Regulator Pilot:
Dump Pilot:
15.4 in. (39.1cm)
12.6 in. (32.0cm)
14.7 in. (37.3cm)
11.3 in. (28.7cm)
Tubing Manifolds (English):
79106-0XXXXXX
Air Tubing not
included
79106-1XXXXXX
15 ft.
79106-2XXXXXX
30 ft.
Tubing Manifolds (Metric):
A10892-0XXXXXX
Air Tubing not
included
A10892-1XXXXXX
4 1/2m (15 ft.)
A10892-2XXXXXX
9m (30 ft.)
Operating Fluid
Pressure:
100 psig
(6.9 bar) max.
70 psig min./100 psig
(4.8 - 6.9 bar) max.
0 psig min./100 psig
(0 - 6.9 bar) max.
70 psig min./
100 psig max.
(4.8 - 6.9 bar)
200 psig
(13.8 bar) max.
100 psig
(6.9 bar) max.
Regulated (with
on-board regulator)
Robot Manifold Tubing Requirements
Atomizing Air
Fan Air
Trigger Air
Regulator Pilot
Dump Pilot
Fluid:
Teflon
Dump:
Teflon
7
191ms Open
206ms Closed
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Tubing Bundle
Tubing Bundle
English
3/8" OD Nylon
3/8" OD Nylon
1/4" OD Nylon
5/32" OD Nylon
3/8" OD Nylon
Metric
10mm OD Nylon
8mm OD Nylon
4mm OD Nylon
5/32" OD Nylon
10mm OD Nylon
1/4", 3/8", or
5/16" OD
(Non-Shielded)
6mm, 8mm, or
10mm OD
(Non-Shielded)
1/4" ID
8mm ID
AA-07-01
Evolver 202 Robotic Atomizers - Introduction
EVOLVER
APPLICAT
ASSEMBLY
EVOL
VER 202 APPLICA
T OR ASSEMBL
Y
A11918 - A
B C
Head Configuration
0 = 60° Single Head
1 = 90° Single Head
2 = 60° Dual Head
3 = 90° Dual Head
Body Style
0 = Single Purge / No Regulator /
For Highly Conductive Materials (Base/Clear)
1 = Dual Purge / No Regulator /
For Highly Conductive Materials (Base/Clear)
2 = Single Purge / With Regulator
3 = Single Purge / No Regulator /
For Conductive Materials (Base/Clear)
4 = Dual Purge / No Regulator /
For Conductive Materials (Base/Clear)
5 = Single Purge / No Regulator /
For Highly Resistive Materials (Clear Coat)
6 = Dual Purge / No Regulator /
For Highly Resistive Material (Clear Coat)
Atomization Technology
0 = Conventional Spray
1 = HVLP Spray
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Evolver 202 Robotic Atomizers - Introduction
EVOLVER
ASSEMBLY
EVOL
VER 202 TUBING BUNDLE ASSEMBL
Y (ENGLISH)
79106 - A BB C D E F
Tubing Bundle Length
0 = Air Tubing (Not Included)
1 = 15 Ft. Long Tubing Assembly
2 = 30 Ft. Long Tubing Assembly
Low Voltage Cable Length
00 = No Cable
01 = 25 Ft. Low Voltage, Non-Junction
02 = 40 Ft. Low Voltage, Non-Junction
03 = 50 Ft. Low Voltage, Non-Junction
04 = 75 Ft. Low Voltage, Non-Junction
05 = 100 Ft. Low Voltage, Non-Junction
06 = 15 Ft. Robot to JB / 15 Ft. JB to MicroPak
07 = 15 Ft. Robot to JB / 40 Ft. JB to MicroPak
08 = 15 Ft. Robot to JB / 60 Ft. JB to MicroPak
09 = 15 Ft. Robot to JB / 75 Ft. JB to MicroPak
10 = 25 Ft. Robot to JB / 25 Ft. JB to MicroPak
11 = 25 Ft. Robot to JB / 50 Ft. JB to MicroPak
12 = 25 Ft. Robot to JB / 75 Ft. JB to MicroPak
13 = 40 Ft. Robot to JB / 15 Ft. JB to MicroPak
14 = 40 Ft. Robot to JB / 25 Ft. JB to MicroPak
15 = 40 Ft. Robot to JB / 40 Ft. JB to MicroPak
16 = 40 Ft. Robot to JB / 60 Ft. JB to MicroPak
31 = 25 Ft. Low Voltage, Non-Junction, Evolver
MicroPak
32 = 50 Ft. Low Voltage, Non-Junction,
Evolver MicroPak
33 = 75 Ft. Low Voltage, Non-Junction,
Evolver MicroPak
34 = 100 Ft. Low Voltage, Non-Junction,
Evolver MicroPak
35 = 15 Ft. Robot to JB / 15 Ft. JB to Evolver MicroPak
36 = 15 Ft. Robot to JB / 40 Ft. JB to Evolver MicroPak
37 = 15 Ft. Robot to JB / 60 Ft. JB to Evolver MicroPak
38 = 15 Ft. Robot to JB / 75 Ft. JB to Evolver MicroPak
39 = 25 Ft. Robot to JB / 25 Ft. JB to Evolver MicroPak
40 = 25 Ft. Robot to JB / 50 Ft. JB to Evolver MicroPak
41 = 25 Ft. Robot to JB / 75 Ft. JB to Evolver MicroPak
Part #2 Supply Line - Dump Line #2
0 = None
1 = Paint Line, 1/4" OD X .170" ID, PFA Teflon
- Dump Line, 3/8" OD X .250" ID, PFA
Teflon
2 = Paint Line, 3/8" OD X .250" ID, PFA Teflon
- Dump Line, 3/8" OD X .250" ID, PFA
Teflon
3 = Paint Line, 5/16" OD X .188" ID, PFA
Teflon - Dump Line, 3/8" OD X .250" ID,
PFA Teflon
Paint #1, Dump Line #1
1 = Paint Line, 1/4" OD X .170" ID, PFA Teflon
- Dump Line, 3/8" OD X .250" ID, PFA
Teflon
2 = Paint Line, 3/8" OD X .250" ID, PFA Teflon
- Dump Line, 3/8" OD X .250" ID, PFA
Teflon
3 = Paint Line, 5/16" OD X .188" ID, PFA
Teflon - Dump Line, 3/8" OD X .250" ID,
PFA Teflon
Robot Adapter
0 = Adapter (Not Included)
1 = Adapter (Fanuc)
2 = Adapter (ABB)
3 = Adapter (Fanuc-P200)
4 = Adapter (KAWASAKI-KE610L)
5 = Adapter (MOTOMAN-PX2850)
6 = Adapter (MOTOMAN-PX2900)
7 = Adapter (B & M LZ2000)
Fiber Optic Cable Length
0 = Fiber Optic Cable Not Included
1 = 15 Ft. Long Fiber Optic Cable
2 = 25 Ft. Long Fiber Optic Cable
3 = 50 Ft. Long Fiber Optic Cable
4 = 75 Ft. Long Fiber Optic Cable
5 = 100 Ft. Long Fiber Optic Cable
6 = 40 Ft. Long Fiber Optic Cable
9
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Evolver 202 Robotic Atomizers - Introduction
NOTES
EVOLVER
ASSEMBLY
EVOL
VER 202 TUBING BUNDLE ASSEMBL
Y (METRIC)
A10892 - A BB C D E F
Tubing Bundle Length
0 = Air Tubing (Not Included)
1 = 4 /12m (15 Ft.) Long Tubing Assembly
2 = 9m (30 Ft.) Long Tubing Assembly
Low Voltage Cable Length
0 0 = No Cable
01 = 25 Ft. Low Voltage, Non-Junction
02 = 40 Ft. Low Voltage, Non-Junction
03 = 50 Ft. Low Voltage, Non-Junction
04 = 75 Ft. Low Voltage, Non-Junction
05 = 100 Ft. Low Voltage, Non-Junction
06 = 15 Ft. Robot to JB / 15 Ft. JB to MicroPak
07 = 15 Ft. Robot to JB / 40 Ft. JB to MicroPak
08 = 15 Ft. Robot to JB / 60 Ft. JB to MicroPak
09 = 15 Ft. Robot to JB / 75 Ft. JB to MicroPak
10 = 25 Ft. Robot to JB / 25 Ft. JB to MicroPak
11 = 25 Ft. Robot to JB / 50 Ft. JB to MicroPak
12 = 25 Ft. Robot to JB / 75 Ft. JB to MicroPak
13 = 40 Ft. Robot to JB / 15 Ft. JB to MicroPak
14 = 40 Ft. Robot to JB / 25 Ft. JB to MicroPak
15 = 40 Ft. Robot to JB / 40 Ft. JB to MicroPak
16 = 40 Ft. Robot to JB / 60 Ft. JB to MicroPak
31 = 25 Ft. Low Voltage, Non-Junction,
Evolver MicroPak
32 = 50 Ft. Low Voltage, Non-Junction,
Evolver MicroPak
33 = 75 Ft. Low Voltage, Non-Junction,
Evolver MicroPak
34 = 100 Ft. Low Voltage, Non-Junction,
Evolver MicroPak
35 = 15 Ft. Robot to JB /
15 Ft. JB to Evolver MicroPak
36 = 15 Ft. Robot to JB /
40 Ft. JB to Evolver MicroPak
37 = 15 Ft. Robot to JB /
60 Ft. JB to Evolver MicroPak
38 = 15 Ft. Robot to JB /
75 Ft. JB to Evolver MicroPak
39 = 25 Ft. Robot to JB /
25 Ft. JB to Evolver MicroPak
40 = 25 Ft. Robot to JB /
50 Ft. JB to Evolver MicroPak
41 = 25 Ft. Robot to JB /
75 Ft. JB to Evolver MicroPak
AA-07-01
Part #2 Supply Line - Dump Line #2
0 = None
1 = Paint Line, 6mm OD X 4mm ID, PFA Teflon /
Dump Line, 10mm OD X 8mm ID, PFA Teflon
2 = Paint Line, 8mm OD X 6mm ID, PFA Teflon /
Dump Line, 10mm OD X 8mm ID, PFA Teflon
3 = Paint Line, 10mm OD X 8mm ID, PFA Teflon /
Dump Line, 10mm OD X 8mm ID, PFA Teflon
Paint #1, Dump Line #1
1 = Paint Line, 6mm OD X 4mm ID, PFA Teflon /
Dump Line, 10mm OD X .8mm ID, PFA
Teflon
2 = Paint Line, 8mm OD X 6mm ID, PFA Teflon /
Dump Line, 10mm OD X 8mm ID, PFA Teflon
3 = Paint Line, 10mm OD X 8mm ID, PFA Teflon /
Dump Line, 10mm OD X 8mm ID, PFA Teflon
Robot Adapter
0 = Adapter (Not Included)
1 = Adapter (Fanuc)
2 = Adapter (ABB)
3 = Adapter (Fanuc-P200)
4 = Adapter (KAWASAKI-KE610L)
5 = Adapter (MOTOMAN-PX2850)
6 = Adapter (MOTOMAN-PX2900)
7 = Adapter (B & M LZ2000)
Fiber Optic Cable Length
0 = Fiber Optic Cable Not Included
1 = 15 Ft. Long Fiber Optic Cable
2 = 25 Ft. Long Fiber Optic Cable
3 = 50 Ft. Long Fiber Optic Cable
4 = 75 Ft. Long Fiber Optic Cable
5 = 100 Ft. Long Fiber Optic Cable
6 = 40 Ft. Long Fiber Optic Cable
ARCHIVE
10
Evolver 202 Robotic Atomizers - Introduction
MOUNTING
BLOCK ASSY.
SPRAY HEAD
ASSY.
SPRAY HEAD
ASSY.
MOUNTING
BLOCK ASSY.
VALVE MANIFOLD
ASSY.
VALVE MANIFOLD
ASSY.
A11918-3XX
90° DUAL HEAD
A11918-2XX
60° DUAL HEAD
SPRAY HEAD
ASSY.
SPRAY HEAD
ASSY.
MOUNTING
BLOCK ASSY.
MOUNTING
BLOCK ASSY.
VALVE MANIFOLD
ASSY.
VALVE MANIFOLD
ASSY.
A11918-1XX
90° SINGLE HEAD
A11918-0XX
60° SINGLE HEAD
79106-XXXXXXX REAR MANIFOLD TUBING ASSY. - ENGLIGH
A10892-XXXXXXX REAR MANIFOLD TUBING ASSY. - METRIC
Figure 1:
11
Evolver 202 Solventborne Robotic Atomizer Applicators
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Introduction
! Field proven high voltage system
FEA
TURES
FEATURES
! Dual start, dual pitch air cap retaining ring
The features of the Evolver 202 Series Applicators
include:
! Quick disconnect spray head
! Quick disconnect robot mount plate
! Quick color change capability with
integrated solvent valve
! High quality ITW Ransburg air cap and fluid
nozzle
! Dual fluid supply passages
! Clean interior design with split shroud
! Internal fan and atomization air control valve,
with a mechanically timed trigger sequence
! Dual fluid dump valves are located adjacent
to the fluid passages
! Single purge with integrated fluid regulator
option
ROBOT SPACER PLATE
! Color coded air and trigger actuation lines
! Quick Change to a RMA-202 bell applicator
ROBOT MANIFOLD QUICK
DISCONNECT RING
A11918-0XX
60° SINGLE HEAD
MOUNTED ON ROBOT
Figure 2:
AA-07-01
ROBOT SPACER PLATE
ROBOT MANIFOLD QUICK
DISCONNECT RING
A11918-1XX
90° SINGLE HEAD
MOUNTED ON ROBOT
Typical Robotic Applicator Mounting
ARCHIVE
12
Evolver 202 Robotic Atomizers - Introduction
Tool Center-Point
A1
1918-XXX EVOL
VER
A11918-XXX
EVOLVER
SPRA
Y APPLICA
TOR
SPRAY
APPLICAT
ASSEMBL
Y
ASSEMBLY
The spray applicator assembly is designed to
connect to hollow wrist robots. A low voltage
control cable is supplied with the tubing bundle to
connect the cascade to the MicroPak power
supply.
Figure 3 shows the tool center-point information
for the four applicators. For dual head applicators,
the tool center-point is based upon the convergence
point. For the single head applicators it is based
upon a 10" target distance. The Tool Center-Point
Comparisons Table compares the tool centerpoints of several automatic spray applicators.
ROBOT ADAPTER AND
MOUNTING PLATE
ROBOT ADAPTER AND
MOUNTING PLATE
6 [152.4]
151
4 [386.5]
111
4 [285.6]
10 [254.0]
TARGET DISTANCE
1 [318.8]
122
111
4 [287.0]
151 [394.5]
2
141
4 [363.1]
DUAL HEAD 90°
CONVERGENCE POINT
SINGLE HEAD 90°
ROBOT ADAPTER AND
MOUNTING PLATE
ROBOT ADAPTER AND
MOUNTING PLATE
55 [143.3]
8
10 [254.0]
TARGET DISTANCE
111 [291.8]
2
203 [518.4]
8
95 [245.8]
8
201 [511.4]
8
233 [595.2]
8
231 [587.5]
8
CONVERGENCE POINT
SINGLE HEAD 60°
DUAL HEAD 60°
Figure 3:
13
Tool Center-Point
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Introduction
TOOL CENTER-POINT COMPARISONS TABLE
Single 90°
EFM
76482-02 - Single 90°
EMF
EMF-504 - Single 90°
EVOLVER 202
Single 90° Applicator Only
Single 90° Applicator, Robot
Plate, Robot Adapter
EVOLVER
Single 90°
Single 60°
X
Y
13.0
14.0
X
Y
13.0
14.0
X
Y
12.5
15.3
15.3
15.5
X
Y
13.3
15.4
EFM
X
Y
19.9
11.5
X
Y
17.4
11.6
X
Y
Single 60° Applicator Only
20.4
11.5
Single 60° Applicator, Robot
Plate, Robot Adapter
23.4
11.5
76480-02 - Single 60°
EMF
EMF-502 - Single 60°
EVOLVER 202
EVOLVER
Single 60°
Dual 90°
EFM
X
Y
21.2
11.8
X
Y
19.6
15.1
X
Y
19.6
15.1
X
Y
Dual 60°
X
Y
11.1
15.5
X
Y
11.3
15.4
X
Y
Dual 90° Applicator Only
11.3
17.3
Dual 60° Applicator Only
20.1
15.3
Dual 90° Applicator, Robot
Plate, Robot Adapter
14.3
17.3
Dual 60° Applicator, Robot
Plate, Robot Adapter
23.1
15.3
X
Y
X
Y
12.1
17.6
21.8
17.6
76482-02 - Dual 90°
EMF
EMFD-504 - Dual 90°
EVOLVER 202
EVOLVER
Dual 90°
AA-07-01
EFM
76482-02 - Dual 60°
EMF
EMFD-502 - Dual 60°
EVOLVER 202
EVOLVER
Dual 60°
ARCHIVE
14
Evolver 202 Robotic Atomizers - Installation
INST
ALLA
TION
INSTALLA
ALLATION
EVOL
VER 202 ROBOTIC
EVOLVER
ALLA
TION
ATOMIZER INST
INSTALLA
ALLATION
This information is intended ONLY to indicate the
general installation parameters of this product
and, where applicable, its working relationship to
other ITW Ransburg system components in typical use. Each installation is unique and should be
directed by an authorized ITW Ransburg representative or conducted from the ITW Ransburg
installation drawings provided for your particular
installation.
POWER SUPPL
Y
SUPPLY
ASSEMBL
Y
ASSEMBLY
!
WARNING
> The power supply MUST be located outside
the HAZARDOUS area (Reference OSHA,
NFPA-33, and your insurance company requirements.)
> User should be aware of, and adhere to, all
local fire codes and ordinances.
> The user MUST provide a properly fused
disconnect between the power source and the
power supply which complies with appropriate
codes.
> Fluid supply must be grounded per NFPA33.
Refer to the most current Power Supply Unit
manuals for complete information regarding power
supply installation.
• MicroPak Control Unit (LECU5004)
(for non-FM installations)
• Stand-alone control/power supply unit
(A10406) (for FM installations)
• MicroPak Control Unit (LECU5004-31)
(for FM installations)
15
ARCHIVE
AA-07-01
AA-07-01
2
3
+24 VDC
24 VRET
2
24 VRET
3
2
1
J6
1
+24 VDC
J10
1
FACT. GND
J2
MICROPAK
HV GND. BUS
J3
N/C
N/C
N/C
N/C
N/C
N/C
N/C
3/4" BRAID CABLE
BARE (DRAIN)
BARE (DRAIN)
ORANGE
GRAY
YELLOW
BLUE
GREEN
BLACK
RED
WHITE
EARTH GROUND
Evolver 202 Robotic Atomizers - Installation
Figure 4: Low Voltage Cable Connections
ARCHIVE
16
17
Figure 5:
ATTACH TO PANEL
GROUND
AC NEUTRAL
120VAC
BUILDING STEEL/GROUND ROD
ARCHIVE
CONTROLS BY OTHERS
CONTROL PANEL
ANALOG SIGNAL AND
TRANSDUCER REQUIRED
3/4" HV GND BRAID (DEARBORN #91234 OR EQUIVALANT)
ATTACH TO ISOLATED H.V. GND (FOR MICROPAK)
INSIDE ENCLOSURE
PAINT 1 INBOUND
(BLUE)
(BLUE)
SOLVENT VALVE TRIGGER SIGNAL
BEARING AIR/PAINT TRIGGER(YELLOW)
(MAIN AIR IF EXTERNAL TRIGGER USED)
(NATURAL)
PAINT 2 TRIGGER/PEGULATOR PILOT
(USED FOR DUAL PURGE AND REGULATED APPLICATIONS)
(ORANGE)
(GREEN)
(GRAY)
PAINT 1 DUMP VALVE TRIGGER SIGNAL
PAINT 1 TRIGGER VALVE SIGNAL
SEAL AIR/FAN AIR
SHAPING AIR/ATOMIZATION AIR
L.V. CABLE
SOLVENT INBOUND
LUBRICATE THE TUBING BUNDLE
EXCESSIVELY TO EASE INSTALLATION
AND EXTEND TUBING LIFE.
DUMP LINE OUT
THE ROBOT IS SHOWN
FOR REFERENCE ONLY AND IS NOT INCLUDED
WITH THE ITW EQUIPMENT PURCHASE.
DUMP
PAINT SUPPLY 1
SOLVENT SUPPLY
BUILD UP.
VENTED TO ATMOSPHERE WITHOUT PRESSURE
IF A CAP CLEANER IS USED IT MUST BE
DIRECTLY INTO THE AIR CAP.
SOLVENT/AIR SHOULD NOT BE SPRAYED
IF USING A CAP CLEANER THE
TRIGGER SOLENOID
(IF USED)
SUPPLIED BY OTHERS
LEAVE TUBING SLACK IN THE WRIST AND ELBOW
AREA TO REDUCE ROTATION STRESS.
Evolver 202 Robotic Atomizers - Installation
Evolver Spray Applicator Air and Fluid Layout
AA-07-01
Evolver 202 Robotic Atomizers - Installation
APPLICA
TOR AND
APPLICAT
MANIFOLD ASSEMBL
Y
ASSEMBLY
LOW VOL
TAGE CABLE
VOLT
INST
ALLA
TIONS
INSTALLA
ALLATIONS
(See Figures 4, 5, and 6)
The tubing, hose, and low voltage cable come
bundled from the factory. Pull the bundle through
the robot spacer plate and robot wrist carefully to
prevent any cuts on the cable or hoses. Use the
six (6) socket head cap screws (76566-24C)
included with the rear manifold tubing assembly to
attach the rear manifold assembly (79106 or
A10892) to the robot spacer plate (see Table 1).
Connect each signal line as required per "Signal
Identification Tables (English and Metric) Tubing
Bundles" in the "Installation" section.
Robot Spacer Plate
The robot spacer plate is included with the robot
manifold assembly to increase life of the tubing
bundle. The extra spacing it provides increases
the bend radius of the tubes and decreases the
hose or cable stress at the connector.
There is only one way the spacer plate may be
assembled to the mounting plate. The spacer
plate has an alignment pin that may only engage
in one hole position in the robot mount plate. This
provides the final position to top dead center of the
robot.
Six robot spacer plates shown in Table 1 are
available for this product.
SPACER
PLATES
TABLE 1 - SP
ACER PLA
TES
Part #
79107-00
78983-00
79131-00
A10847-00
A10848-00
A10849-00
A10851-00
AA-07-01
Description
ABB Robots
Fanuc P155, 145 Robots
Fanuc P200 Robot
Adapter (Kawasaki-KE610L)
Adapter (Motoman-PX2850)
Adapter (Motoman-PX2900)
Adapter (B & M-LZ2000)
For installations utilizing the LECU5004-XX
MicroPak power supply, connect the low voltage
cable (79008-XX) from the robot manifold assembly
to the LECU5004-XX MicroPak controller or
junction box. If connecting to a junction box, use
a junction cable (77062-XX) to make the connection
from the junction box to the LECU5004-XX
MicroPak. Make connections as shown in Figure
4.
For installations utilizing the A10406-XX Evolver
MicroPak power supply, connect the low voltage
cable (A11353-XX or A11356-XX) from the robot
manifold assembly or junction box to the receptacle
on the rear of the A10406-XX power supply. To
maintain FM Approval, this cable must be secured
to the stress relief bar on the rear of the power
supply. (See A10406-XX Evolver MicroPak
Power Supply manual for further information on
connecting the low voltage cable.)
NOTE
> If the length of the fan or atomization
air lines exceeds 30 ft. (10m), the lines
must be upsized to 1/2" ID (12mm for
metric).
NOTE
> For the dipswitch settings for the
Evolver 202, reference the current
MicroPak service manual.
NOTE
> Leave 12-24 inches (.30m-.61m) of
extra length on all lines to prevent extreme tension being applied to these lines
during robot movement. This increases
tubing bundle life.
ARCHIVE
18
Evolver 202 Robotic Atomizers - Installation
NOTES
CAUTION
!
> Do not exceed 100' combined length of the
low voltage cables.
!
WARNING
> Install and route the hoses and cable so that
they are NOT exposed to temperatures in
excess of 120° F. Ensure that all hose and
cable bends are NOT LESS THAN a 6 inch
(15cm) radius and are not subjected to more
than 360° of torsional twist. Failure to comply
with these parameters could cause equipment
malfunctions that might create HAZARDOUS
CONDITIONS!
!
WARNING
> If a non-explosion proof junction box/terminal strip is used, it must be located outside the
hazardous area.
19
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Installation
IDENTIFICATION
TABLE
SIGNAL IDENTIFICA
TION T
ABLE (ENGLISH)
Abbr.
B.A/P.T
B.A
BRK
DL1
DL2
F.O.
LV
P1.IN
P1T
P1D
P2.IN
P2T
P2D
S.A/A.A
S.IN
SL.A/F.A
ST
T.A
Description
Bearing Air (Paint Trigger)
Bearing Air Return
Brake Air
Dump Line #1
Dump Line #2
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 (Atomizer Air)
Solvent In
Seal Air (Fan 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
See Tubing Bundle Assy. Chart
5/32" OD X .106" ID
5/32" OD X .106" ID
See Tubing Bundle Assy. Chart
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
IDENTIFICATION
TABLE
SIGNAL IDENTIFICA
TION T
ABLE (METRIC)
Abbr.
B.A/P.T
B.A
BRK
DL1
F.O.
LV
P1.IN
P1T
P1D
P2.IN
P2T
P2D
S.A/A.A
S.IN
SL.A/F.A
ST
T.A
DL2
AA-07-01
Description
Bearing Air (Paint Trigger)
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 (Atomizer Air)
Solvent In
Seal Air (Fan Air)
Solvent Trigger Signal
Turbine Air
Dump Line #2
Color
Tubing Material
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
ARCHIVE
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
See Tubing Bundle Assy. Chart
5/32" OD X .106" ID
5/32" OD X .106" ID
See Tubing Bundle Assy. Chart
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
20
Evolver 202 Robotic Atomizers - Installation
Figure 6:
Applicator and Manifold Assembly
APPLICAT
ASSEMBLY
PAR
ARTS
APPLICA
TOR AND MANIFOLD ASSEMBL
Y - P
AR
TS LIST
Item #
1
2
3
4
21
Part #
Description
A11918-XXX
76566-32C
79106-XXXXXXX
A10892-XXXXXXX
See Table 1
Evolver 202 Spray Applicator Assembly
Socket Head Cap Screws, 1/4-20 X 1" Long
Rear Manifold Tubing Assembly (English)
Rear Manifold Tubing Assembly (Metric)
Spacer Plates
ARCHIVE
(Figure 6)
Qty
1
6
1
1
AA-07-01
Evolver 202 Robotic Atomizers - Installation
SPRA
Y / BELL
SPRAY
APPLICA
TOR
APPLICAT
TRIGGERING
If you are currently using an RMA-202 bell
applicator system and want to add the Evolver 202
spray applicator system to spray using the same
tubing bundle, a simple conversion must be made
in order to allow for switching between spray and
bell applicators. Figure 7 shows the recommended
system that should be placed in the bearing air line
between the main air input and the robot manifold
plate. It is suggested that this circuit be placed on
the robot arm. This system should also be used
when the user is implementing the Evolver 202
spray applicator system and plans to use RMA202 bell applicators as well.
In Figure 7, the trigger solenoid must be an
electronically activated, normally closed valve
with exhaust, or a 3-way valve, with 100 psi max.,
24VDC. Typically this solenoid already exists in
the robot arm and can be used in this circuit. The
spray applicator trigger/bearing air select valve
must be a pneumatically activated, normally open
solenoid. A suggested solenoid is ITW P/N 1167801. An additional solenoid must be used to activate
the P1T (Paint 1 Trigger) or P2T (Paint 2 Trigger)
valves. If any of these solenoids are located inside
a hazardous area, they must be explosion proof.
BEARING AIR LINE
SPRAY APPLICATOR TRIGGER/
BEARING AIR SELECT
SPRAY APPLICATOR SIDE
BELL APPLICATOR SIDE
TRIGGER
SOLENOID
MAIN AIR LINE
Figure 7:
AA-07-01
Conversion Schematic
ARCHIVE
22
Evolver 202 Robotic Atomizers - Operation
OPERA
TION
OPERATION
SPRA
Y APPLICA
TOR
SPRAY
APPLICAT
CONTROLS
> For HVLP operation (max. 10 psi, 0.7
Atomization Air (SA/AA) /
Fan Air (SL.A/F
.A)
(SL.A/F.A)
bar cap pressure), DO NOT exceed the
air inlet pressure, which was read at the
gun base before the tubing manifolds,
given as follows:
The atomization and fan air are turned on by the
trigger line and are controlled by an internal air
valve located in the applicator head. During normal operation with applicator triggered off, there is
a slight bleed of air through the atomization port.
NOTE
PSI
42
42
(Bar) CAP #
(2.9) 48-1
(2.9) 481-1
Atomizing Air
Adjustments are made through the robot PLC or a
manually adjustable air regulator. The lowest air
pressure required to break up the paint should be
used. Lower atomizing air pressures result in less
overspray and increased transfer efficiency.
Fan Air
Adjusting the fan air increases or decreases the
size of the spray pattern. Increasing pressure
increases pattern size. Pattern adjustment should
be made to suit the size and shape of the object
being painted. This adjustment is made through
the robot PLC or a manually adjustable air regulator.
Air cap atomization and fan pressures should be
set and recorded using an air cap test kit. This
provides a consistent measurement, so initial
settings may be duplicated at any time. (See
"Accessories" in the "Parts Identification" section.)
HVLP SPRA
Y
SPRAY
The Evolver 202 HVLP models, when properly
set-up, are designed to provide maximum transfer
efficiency by limiting air cap pressures to 10 psi
(0.7 bar) (in the U.S., this complies with rules
issued by SCAQMD and other air quality
authorities). Air cap pressures should be measured
with an optional air cap test kit. (See "Accessories"
in the "Parts Identification" section.)
23
FLUID V
AL
VE CONTROLS
VAL
ALVE
Trigger
rigger,, Dump, and Solvent
(S
ee Figure 8)
(See
The fluid valves in the Evolver 202 are actuated by
an air signal. The air pressure must exceed 70 psi
(4.8 bar) to assure proper actuation of the valve.
Applying air to the valve actuator turns on the fluid
flow for that valve.
The paint valve controls the paint flow to the
applicator. When actuated, paint flows through
the valve to the coiled fluid tube and into the spray
head.
The dump valve controls the paint flow through the
dump line. When actuated, paint flow is directed to
the dump return line. This provides a method of
rapidly removing paint from the incoming line for
cleaning and/or color change. Normally, the dump
valve is not actuated at the same time as the paint
valve since the paint valve is intended to cause the
fluid to flow to the applicator head at the prescribed
input pressure.
The solvent valve controls the flow of cleaning
solvent to the applicator. When actuated, solvent
flows through the fluid tube and into the spray
head. 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.
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Operation
DUAL PURGE SPRA
YING
SPRAYING
The Evolver 202 applicator system 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. The
solvent valve opens and cleans from the coiled
fluid tube and up through the head and out the
nozzle. A second color is then loaded through the
"B" side. Side "A" is then color changed through
the "A" side feed lines to the applicator and valve
ports, while the waste from side "A" is exited
through the dump lines. To operate in the dual
purge mode, two (2) separate color valve
systems or ITW MCV2 Dual Purge must be
installed.
When the target part is finished and a color change
is desired, ensure voltage is turned off.
!
WARNING
> Failure to turn voltage OFF during color
change sequence when solvent is flowing
through the fluid nozzle, could cause a fire
or explosion.
When the cleaning cycle with solvent is complete,
an air purge for several seconds is recommended
to clean and dry the ID of the dump line hose.
Fluid Flow Rate
Fluid flow is adjusted through the robot PLC by
varying the pilot pressure to either an exterior or
the on-board fluid regulator within the spray applicator. Fluid pressures from the circulating system
may exceed the maximum fluid pressure rating of
the Evolver 202 applicator. Because of these high
fluid pressures, a manual step-down fluid regulator must be used.
Applicator T
rigger Control Air
Trigger
The Evolver applicators require a minimum of 70
psig trigger control air pressure to ensure proper
operation of the applicator piston.
Electrostatic V
oltage
Voltage
Under no load conditions, the maximum voltage
limit for these spray applicators is 100 kV. Some
painting operations may require different voltage
settings to obtain optimum transfer efficiencies. If
Faraday cage areas are predominant on the item
being painted, a lower voltage setting would aid in
coating these areas.
When not spraying, it is recommended to set back
voltage to 30-40 kV or off between target parts.
NOTE
If a 0 kV command is sent to the
MicroPak, a feedback fault will occur.
>
Paint V
iscosity
Viscosity
The applicator is capable of atomizing paint of
most any desired viscosity. It is recommended to
keep the material viscosity as low as possible.
This allows spraying at lower fan and atomization
air pressures which result in less overspray and
higher transfer efficiency.
!
WARNING
Sometimes, depending upon target carrier spacing, higher setback voltages may be required. The
ramp-up time for the HP-404 cascade (0-100 kV)
is approximately 3 seconds.
The MicroPak voltage ramp-down works at a rate
of 33 kV/sec.
> Most paints and solvents, including those
listed in "Polar & Non-Polar Solvents Chart" in
the "Maintenance" section, are toxic to a certain degree and flammable or combustible.
Use them only in a well ventilated atmosphere.
Use protective equipment as required in the
Material Safety Data Sheet supplied with the
substance.
AA-07-01
ARCHIVE
24
Evolver 202 Robotic Atomizers - Operation
Target Distance
The distance between the applicator tip and the
article being painted should be 10-14 inches (.25m.36m) for a single head applicator and at or near
the convergence point for dual head applicator.
Excessive distance causes a waste of coating
material and wrap back (paint particles being
deposited on the applicator body or the robot arm).
At close distances the voltage at the tip of the
applicator will be reduced, which decreases the
charging effect of the applicator.
!
WARNING
WARNING
If a bell applicator is being used, and
needs to be switched to a spray applicator,
the bell applicator must have all voltage and
air turned off, and the bell cup completely
spun-down before the change-out can occur.
Dump Valve
PAINT 1
To Paint Waste Tank
SOLVENT VALVE
Paint 1 SUPPLY
SOLVENT IN
Paint Trigger 1
>
PAINT TRIGGER 2 (PLUGGED)
Fluid Tube
!
DUMP VALVE
PAINT 2 (PLUGGED)
> If target distance is less than 8 inches
(.20m), an arc could occur.
Figure 8a: Single Purge Air and Fluid
Passage Schematic
25
ARCHIVE
AA-07-01
Figure 8b:
AA-07-01
Dual Purge Air and Fluid Passage
Schematic
ARCHIVE
Paint 1 SUPPLY
EVOLVER STYLE HGS REGULATOR
Paint 2 SUPPLY
Paint 1 SUPPLY
SOLVENT IN
SOLVENT IN
SOLVENT VALVE
SOLVENT VALVE
Fluid Tube
Fluid Tube
Dump Valve
PAINT 1
To Paint Waste Tank
Paint Trigger 1
PAINT TRIGGER 2
To Paint Waste Tank
DUMP VALVE
PAINT 2
Dump Valve
PAINT 1
To Paint Waste Tank
Paint Trigger 1
Evolver 202 Robotic Atomizers - Operation
Figure 8c: Single Purge Regulator Air and
Fluid Passage Schematic
26
Evolver 202 Robotic Atomizers - Maintenance
MAINTENANCE
Good maintenance is essential to safe and productive operation. Schedules should be established by the user, based on the following general
information and observations of the initial production requirements. The ITW Ransburg maintenance and safety information should be made
available to each operator.
ROUTINE MAINTENANCE
SCHEDULE
Normal fire protection measures are necessary,
including proper storage of paints and solvents
and the proper disposal of waste. Ready access
to appropriate fire extinguishing equipment is required. For details, consult the appropriate NFPA
safety information and/or applicable country safety
standard.
Several Times Daily
!
WARNING
> An electrical discharge or spark may create
an electrical and/or fire hazard during maintenance. Do not clean or service the spray
applicator with the power supply on. Verify
that the power supply has been locked out and
tagged out per OSHA and/or your applicable
country safety codes.
> Unexpected robot movement can be hazardous. Do not adjust or repair the spray
applicator when the robot is operating or waiting to start. The robot must be locked out and
tagged out per OSHA and/or your applicable
country safety codes.
> Solvents used for equipment flushing must
have flash point ratings equal to or greater
than the flash point rating of the coating material. Solvents used for general cleaning must
have flash point ratings higher than 100°F
(37.8°C).
> Never remove spray applicator head from
assembly while under pressure.
Follow these maintenance steps to extend the life
of the spray applicator and ensure efficient operation:
1. Turn the MicroPak control unit OFF
OFF! Follow
"Lockout/Tagout Procedures".
2. Inspect the fluid nozzle, air cap, and electrode wire for paint accumulation. Clean as
frequently as necessary. See "Procedures" in
the "Maintenance" section.
!
WARNING
> Take precautions to see that skin is not
punctured by sharp electrode.
!
CAUTION
> Do not bend the applicator electrode while
wiping. Never immerse the applicator in solvents. This will cause damage to the electrical
components.
Daily (Or at Shift Start)
1. Turn the MicroPak control unit OFF and:
• Check within 20' (6.1 meters) of the point of
operation (of the applicator) and remove or
ground ALL loose or ungrounded containers.
• Inspect workholders for accumulated coating
materials (remove such accumulations if
present). Ensure resistance to ground from
work holder is less than 1 megohm.
• Check that the nozzle assembly is clean and
undamaged. Ensure air caps are clean and
undamaged.
27
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
2. Turn the MicroPak control unit ON
ON! Energize
high voltage.
!
CAUTION
> Failure to use a non-polar solvent may
Shut-Down (Or at Shift End)
1. Turn the MicroPak control unit OFF.
2. Flush the lines and allow the solvent to remain
in the lines. See "Procedures" in the "Maintenance" section.
3. Wipe the applicator (including the air cap) and
robot wrist with a cloth and a suitable, clean nonpolar solvent.
cause a decrease in voltage at the tip of the
applicator. This will significantly decrease
transfer efficiency.
4. Remove end cap [1]. Removing the end cap
releases tension on all internal spray head components. Remove needle spring [2] and valve spring
[3], which are loose after removing the end cap.
Weekly
1. Check the entire system for damage, leaks,
and paint accumulation.
!
CAUTION
> Never attempt to clean the air cap holes
2. Clean the atomizer assembly.
3. Conduct a current output test. See "Procedures" in the "Maintenance" section.
PROCEDURES
with a wire or other metal object. Doing so
may damage the air cap, resulting in distortion of the spray pattern.
Applicator Cleaning/Service
(See Figure 9a and 9b)
5. Remove the air cap retainer [36] and air cap
[35]. Soak in a non-polar solvent if necessary. If
paint remains in the air cap holes, clean with a
toothpick or similar soft wood object. Air caps are
best cleaned in an ultrasonic cleaner.
1. Flush the paint supply line and the applicator
paint passages using a solvent which is compatible with the material being sprayed. Continue to
flush until all traces of paint are gone.
6. Remove the air cap locator [33] and fluid tip [34].
Clean using a non-polar solvent.
2. Turn off the solvent supply, actuate paint pushout air at color changer, and trigger the applicator
and P1T or P2T. Allow all of the fluid to drain from
the spray applicator fluid passages.
3. Clean the exterior surfaces of the spray applicator with a solvent soaked rag. As long as the
applicator is intact, a polar solvent may be used
for all cleaning, however, after cleaning, wipe off all
surfaces with a non-polar solvent to reduce
conductive residue on the applicator's surface.
(See "Polar & Non-Polar Solvents Chart" in the
"Maintenance" section regarding proper solvent
selection.)
AA-07-01
7. Tightly grip the plastic needle [6] and unscrew
counter-clockwise to remove the front electrode
needle assembly. A short piece of H-2339 tubing
(1/4" OD x 0.175" ID) pressed over the front
needle will assist in unscrewing the assembly. If
required, use needle nose pliers with masking
tape or duct tape. Carefully clean with a non-polar
solvent. Replace any parts that show signs of
wear or damage.
!
CAUTION
> If using needle nose pliers to unscrew the
front needle, be very careful. Do not grip on the
tapered sealing surface. If the pliers slip, they
could damage the tapered sealing surface of
the needle.
ARCHIVE
28
Evolver 202 Robotic Atomizers - Maintenance
POLAR
SOLVENTS
AND NON-POLAR SOL
VENTS
Non-Conductive (Non-Polar)
Moderately Conductive
Extremely Conductive (Polar)
Amyl Acetate
Methyl Amyl Acetate
Toluene
Xylene
High Flash Naptha
Mineral Spirits
Methyl Isobutyl Ketone
Ethyl Acetate
Methyl Ethyl Ketone
Butyl Carbitol
Methanol
8. Remove fluid nozzle [32] by unscrewing
counter-clockwise. Inspect o-ring [30] and all
passages for build up or damage. Clean or replace as necessary. Lubricate and reinsert oring into applicator barrel and reinstall fluid nozzle.
Torque fluid nozzle to 25 lbs•in (2.82 Nm).
Carbitol
Diacetone
Butyl Alcohol
Acetone
Butyl Cellosolve
10. Screw fluid tip [34] back into place. Hand
tighten first, then with a small wrench, tighten an
additional 30 degrees.
11. Replace air cap locator [33], air cap [35], and
air cap retainer [36].
12. Apply a thin film of petroleum jelly to valve and
needle springs [2] and [3]. Install the springs back
into the end cap and the spray head assembly.
NOTE
> There should be a small gap between
the fluid nozzle and the applicator barrel
after tightening.
13. Screw end cap [1] back on.
Current Output T
est
Test
1. Clean and blow out all fluid passages with nonconductive solvent.
9. After cleaning, insert the electrode assembly
[31] back into the spray head assembly. Apply
Loctite #222, low strength (purple) thread-locker,
to the threads of the electrode assembly before
reassembly.
2. Remove from robot and perform bench test
using a spare tubing bundle.
3. Turn the control unit power ON
ON.
4. Activate high voltage and slowly approach the
applicator electrode with ground hook or wire.
NOTE
The fluid tip [34] should always be
installed and tightened before installing
the needle and valve springs.
5. Monitor the current output on MicroPak. Current should rise as ground approaches. At
approximately 85 microamperes, the MicroPak
will shut off. The OVERCURRENT indicator
should come on.
CAUTION
The spray head can be removed from assembly
as shown in Figure 9a for cleaning and service.
>
!
> After tightening the fluid tip, always check
to see if the proper gap (1/16") between the
needle nuts and air valve stem occur, before
installng the needle and valve springs back
into the head.
29
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
NOTES
AA-07-01
ARCHIVE
30
Evolver 202 Robotic Atomizers - Maintenance
ROTATE HEAD APPROX.
45° CCW TO REMOVE
3
INSERT A 16
" ALLEN WRENCH
THROUGH THE HOLE TO LOOSEN
THE LOCKING SCREW (3), TURN
THE SCREW CLOCKWISE, WHICH IN
TURN WILL DISENGAGE THE
LOCKING TAB (2), TURN UNTIL THE
TAB COMES IN CONTACT WITH THE
INSIDE WALL. AS ILLUSTRATED IN
FIGS. 19 THRU 22.
THEN ROTATE THE HEAD AS
SHOWN BY HAND AND PULL UP TO
REMOVE.
Figure 9a:
Spray Head Removal
1/16"
32
36
30
29
28
(1.59 MM)
27
1
33
3
35
2
31
34
5
6
Figure 9b:
31
4
Spray Head Assembly
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
SPRAY
REMOVAL
ASSEMBLY
PAR
ARTS
SPRA
Y HEAD REMOV
AL / ASSEMBL
Y - P
AR
TS LIST (Figure 9b)
Item #
1
2
3
4
5
6
27
28
29
30
31
32
33
34
35
36
Part #
Description
79148-00
17615-00
9334-00
7733-07
76199-00
79151-00
RME-38
EMF-7
RME-32
79001-01
70430-01
EMF-195
EMF-192
79140-02
79153-65R-1
79154-00
End Cap, Spray Head
Spring, Compression
Spring, Valve Return
Jam Nut
Rear Adjusting Nut
Assembly, Needle Shaft
Return Spring, Piston
Seal, Washer
Seal
O-Ring, Solvent Proof
Electrode, High Wear
Nozzle, Fluid Hole
Locator, Air Cap
Fluid Tip, .055" (1.4mm) Diameter
Air Cap, Pined
Retaining Ring, Tapered
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
NOTE
> Ensure that the fan and atomization air
are on and flowing prior to triggering the
fluid. Insure air before fluid adjustment is
correct. Failure to follow this sequence
will cause spits and defects on the part
being painted.
AA-07-01
ARCHIVE
32
Evolver 202 Robotic Atomizers - Maintenance
SER
VICE
SERVICE
!
CAUTION
> As the spray head is removed from the valve
Because we want to provide our users with the
most up-to-date technology possible, we are constantly seeking to improve products. If a change
in product configuration occurs after it is on the
market, we will implement that technology in future
production and, if practical, make it available to
current users. The following service information is
based on standard specifications and procedures
for this product. If you find some minor deviations
between this information and your equipment because of design or manufacturing changes, contact your ITW Ransburg representative to resolve
the difference.
!
manifold assembly, a certain amount of residual fluid may be present. Care must be
taken not to allow this fluid to drain into the high
voltage terminal rings or air passages.
!
WARNING
> Eye protection should be worn while servicing gun.
SPRA
Y HEAD ASSEMBL
Y
SPRAY
ASSEMBLY
WARNING
NOTE
> An electrical discharge or spark may create
an electrical and/or fire hazard during maintenance. Do not service the spray applicator
with the power supply on. Verify that the
power supply on/off switch has been turned
off.
Disassemble the spray head only
enough to remove and replace defective
parts. For instance, if only replacing the
front electrode it is not necessary to remove the fluid nozzle.
>
> Unexpected robot movement can be hazardous. Do not adjust or repair the spray
applicator when the robot is operating or waiting to start. The robot must be locked out and
tagged out per OSHA prior to removing the
applicator from the robot manifold assembly.
Before performing any work on the spray applicator, always flush the fluid passages, blow dry with
pushout air, and wipe the spray applicator clean.
Refer to "Applicator Cleaning" in the "Maintenance" section for instructions on how to properly
clean the spray applicator. Depressurize all fluid
and air passages before removing the applicator
from its manifold. Always work in a clear, clean
space to minimize part loss and damage.
33
NOTE
> At assembly, apply a small amount of
dielectric grease to grooves in spray head
and valve manifold to reduce high voltage
breakdown. Excessive grease will not
allow spray head [3] to seat fully against
mounting block assembly [8] (see Figure
11).
> To prevent damage, always lubricate
the o-rings located on the underside of the
spray head.
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
Rear Needle Replacement
(See Figure 9b)
1. Remove the air cap, fluid tip, and the fluid nozzle
as described in steps 1 through 8 of the "Fluid Tip,
Nozzle, and Front Needle Replacement" in the
"Maintenance" section.
2. Remove the rear needle [6] and lock nuts [4]
and [5] as an assembly. Pull the assembly out
from the rear of the spray head.
9. Apply Loctite #222 Low Strength (purple)
Threadlocker into the threads of plastic front
needle [31] before assembling onto the rear needle.
Be sure that the rear needle assembly is pushed
all the way forward before threading on front
needle.
10. Reassemble fluid tip [34]. Hand tighten first;
then with a small wrench turn an additional 30°.
CAUTION
11. Reinstall the two (2) lock nuts [4] and [5] in the
correct order on the back needle as shown making sure to maintain an 1/16" clearance (see
Figure 9b).
> Fluid seal [29], seal washer [28], and seal
spring [27] will come free at this point. Place
hand over front end to prevent dropping parts.
NOTE
!
> Ensure that the fan and atomization air
3. Inspect the metal portion of the rear needle [6]
for excessive wear. If wear is observed (longitudinal grooves or a noticeable reduction in diameter) replace the needle. Remove the two (2) lock
nuts from the rear needle and save. When ever
replacing rear needle section, you must also replace the seal [29] at the same time.
4. Place the rear needle assembly back into the
spray head.
5. Place seal spring [27] over the rear needle in
the front end of the spray head. Hold the spray
head upward as the spring will want to fall out.
6. Still holding the spray head upward, place the
seal washer [28] and thread the fluid seal [29] onto
the rear needle. The tapered end of the fluid seal
should be pointed toward the front of the applicator.
7. Insert the lubricated o-ring [30] into the applicator head. Gently push, with small flat object, down
upon its seating edge. Be careful not to push
o-rings into fluid groove (see Figure 9b).
8. Reassemble fluid nozzle [32] by pushing the
nozzle into the spray head and through the o-ring
until the threads engage. Screw the nozzle into
the spray head. Torque to 23-25 lbs•in (2.6-2.8
Nm). Plastic threads damage easily; do not overtighten. Note the front flange of the fluid nozzle will
not seat flush against the spray head.
AA-07-01
are on and flowing prior to triggering the
fluid. Ensure air before fluid adjustment is
correct. Failure to follow this sequence
will cause spits and defects on the part
being painted.
12. Reassemble air cap [35] and air cap retainer
[33]. The air cap rotate positioning pins must be
engaged with the air cap locator holes before final
tightning.
13. Apply a thin film of petroleum jelly to valve
spring [3] and needle spring [2], and insert back
into the end cap. Screw end cap [1] back on.
14. Lubricate all of the o-rings on the underside of
the spray head with petroleum jelly, and apply a
thin coat of dielectric grease to the grooves of the
spray head and the valve manifold before reassembly.
15. Reattach spray head to manifold block by
engaging the connection plug [24] into the mounting block cavity [3], and turn clockwise until head
contacts stop pin on the block.
16. Secure with locking tab by turning screw
counter-clockwise (see Figure 9a).
ARCHIVE
34
Evolver 202 Robotic Atomizers - Maintenance
Air V
alve Removal
Valve
(See Figure 10)
1. After removal of end cap and spring, the air
valve can be pulled straight out the back of the
head assembly.
2. Inspect and replace the u-cup [8], if necessary,
by holding the air valve shaft on it's flats and
loosening the piston nut [7] counter-clockwise.
3. Remove the seal carrier with seal removal tool
[B].
4. Use a bent hook to reach inside the air valve
bushing [14], grip slot and pull out. Use the same
procedure to pull out the rear seal carrier [17].
!
CAUTION
> Use Caution as NOT TO scratch or raise
burrs on inside diameters of the parts.
12. If the locking tab plug connection [24] needs
to be replaced, first remove the electrode spring
connector [23] by pulling straight out with a needle
nose pliers. If removed, the spring wire should be
replaced.
13. Remove socket head screw [22] and connection plug [24] from body.
14. Replace conductive compressable contact
[25] if necessary.
15. Reinstall the connection plug [24] into the
body, making sure the tabs on the bottom align
with the notches in the body [19].
16. Insert and tighten the screw [22], making sure
the tabs remain inside the notches [24] in the body.
17. Insert the spring electrode wire [23] through
the hole in the screw using a needle nose pliers on
the straight wire portion. Carefully rotate and
push the wire through the screw hole and into the
compressable contact until the spring contacts
the screw head.
5. Remove and replace all o-rings if necessary.
6. O-rings [12] and [18] must be installed inside
their mating parts (see Figure 10).
7. The Teflon o-ring [16] should be inserted into
the front of the bushing [14] and one of the o-rings
[15] installed onto the outside groove before the
bushing is installed.
8. Reassemble the remaining parts as shown in
Figure 9 making sure that the alignment tab on the
bushing [14] lines up with the align groove in the
body [19].
9. Torque the seal carriage [13] to 30-35 lbs•in
(4.0-4.5 Nm).
10. If the u-cup needs to be replaced, assemble
on piston plate [9] and push both onto shaft,
tighten securely with piston nut [7] and install in
body as one assembly.
11. Assemble the remainder of the applicator
head as stated earlier.
35
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
NOTES
AA-07-01
ARCHIVE
36
Figure 10:
37
B
7
8
10
ALIGN TAB ON AIR
VALVE BUSHING (14)
INTO GROOVE OF BODY
9
11
LOCATED
INSIDE 13
12
15
15
16
18
17
15
LOCATED
INSIDE 17
ARCHIVE
AIR VALVE SHAFT FLATS
13 TORQUE TO 30-35 IN/LBS
14
ALIGN TAB
19
22
23
24
25
ALIGNMENT TABS
Evolver 202 Robotic Atomizers - Maintenance
79138 Evolver Applicator Head Assembly
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
EVOLVER
APPLICAT
ASSEMBLY
PAR
ARTS
79138 EVOL
VER APPLICA
T OR HEAD ASSEMBL
Y - P
AR
TS LIST
(Figure 10)
Item #
7
8
9
10
11
12
13
14
15
16
17
18
19
22
23
24
25
B
AA-07-01
Part #
79147-00
7723-06
79145-00
79144-00
79001-28
79001-29
79146-00
79143-00
79001-01
13076-13
79172-00
79001-06
79137-00
79142-00
79171-00
79141-00
14061-09
A10400-00
Description
Nut, Piston
Piston, U-Cup
Plate, Piston
Shaft, Air Valve
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Seal Carrier, Rear Piston
Bushing, Air Valve
O-Ring, Solvent Proof
O-Ring, Teflon
Carrier, Rear Seal
O-Ring, Solvent Proof
Head, Machining
Screw, #8-32 X .75" Long, SHCS
Spring, Connector
Plug, Connection
Conductive Compressable Contact
Seal Carrier Tool
ARCHIVE
Qty
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
38
Evolver 202 Robotic Atomizers - Maintenance
REMOVING SPRA
Y
SPRAY
APPLICA
TOR FROM THE
APPLICAT
REAR MANIFOLD
ASSEMBL
Y
ASSEMBLY
(See Figure 1
1)
11)
Anytime service is required within the applicator
shroud, the applicator should be removed from the
robot mounting plate assembly. After the applicator
is removed from the robot, always move to a clear,
clean work area to remove the applicator shroud
and begin servicing.
1. Purge all fluid from the system and blow lines
dry with pushout air before the applicator is
removed.
2. All pressures must be removed, both air and
fluid, before removing the applicator. Fluid pressure
can be removed by actuating the applicator trigger
with the fluid regulator open.
3. Turn off the power supply to the applicator.
4. Remove applicator from robot by turning the
retaining ring counter-clockwise from the manifold
robot mounting plate.
5. Remove spray head [3] (see Figure 11) as
previously described in Figure 9a. (see Figure
11).
S pray Applicator Disassembly
(S
ee Figures 12, 13, and 14
(See
14))
6. Remove the four (4) screws [1] from mounting
block [10] and pull the block out of the upper
manifold [11] as shown in Figure 12.
7. Remove and inspect the o-rings [2, 8, and 9].
Replace if necessary (see Figure 12).
10. Loosen the two (2) screws [3] on the shroud
halves. Carefully pry the shroud halves [4 and 5]
apart by placing a thin blade screw driver in
between them.
11. Loosen one end of the coiled fluid tube [13] by
removing the nut [6] and ferrules [7 and 8] from the
valve manifold [5] (see Figure 13).
12. Loosen one end of the gray rigid tube [12] by
removing the nut [9] and ferreles [10 and 11] from
the valve manifold [5].
13. Remove the six (6) screws [17] and the four
(4) screws [14] from the bottom of the mounting
plate [4] (see Figure 13). Inspect the four (4)
o-rings [15] located within the screws [14] and
replace if necessary.
14. Carefully pull upward on the head manifold
block [22] which will disengage from the bottom
valve assembly block [5]. Inspect o-rings [2] on
the ends of the connecting rods [1]. Replace if
necessary (see Figure 13).
15. Remove the four (4) connecting rods [1] by
unscrewing counter-clockwise. Remove and
inspect the four (4) studs [3] and the o-rings [2] and
replace if necessary.
16. Remove and inspect the coiled fluid tube by
removing the tube nut [6] and ferrules [7 and 8]
from the upper head manifold [22].
17. Release the cascade cable from the valve
manifold by loosening the set screw [23]. Pull the
cable out of the mounting plate [4], and cascade
[19] out of the upper head manifold [22].
18. Reassemble in reverse order making sure to
align the cascade wire plug timing mark with the
timing mark on the mounting plate [4] as shown in
Figure 13. Tighten set screw [23].
8. Remove mounting ring cover [7] by pulling
straight up as shown in Figure 12.
9. Remove mounting ring [6] by pulling straight up
as shown in Figure 12.
39
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
3
8
7
1
6
4
5
Figure 11:
CCW TO REMOVE
2
Evolver 202 60
60°° Single Head Applicator Assembly
EVOLVER
60°° SINGLE HEAD APPLICA
APPLICAT
ASSEMBLY
EVOL
VER 202 60
TOR ASSEMBL
Y ARTS
11)
PAR
TS LIST (Figure 1
1)
Item #
1
2
3
4
5
6
7
8
AA-07-01
Part #
77523-00
77522-00
79138-01
79138-02
79106
A10892
A11916
77524-00
78976-00
79179-00
Description
Upper Shroud, Machined RMA-101
Lower Shroud, Machined RMA-101
Spray Head Assembly, Conventional Spray
Spray Head Assembly, HVLP Spray
Tubing Bundle, RMA-202 (English)
Tubing Bundle, RMA-202 (Metric)
Manifold, Evolver 202
Screw, Machined, RMA-101 Break-Away
Mounting Ring, RMA-202
Mounting Block Assembly
ARCHIVE
Qty
1
1
1
1
1
2
1
1
40
Evolver 202 Robotic Atomizers - Maintenance
1
10
9
2
2
4
11
8
7
5
3
6
12
Figure 12:
Mounting Block, Shroud Halves, and Retaining Ring Removal
HALVES,
RETAINING
MOUNTING BLOCK, SHROUD HAL
VES, AND RET
AINING
ARTS
REMOVAL
PAR
RING REMOV
AL - P
AR
TS LIST (Figure 12)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
41
Part #
LSFA0027-00
79001-06
77524-00
77523-00
77522-00
78976-00
78979-00
79001-14
79001-04
79184-00
A11916
79103-XX
Description
Screw, Retaining #10-32 x 1.50"
O-Ring, Solvent Proof
Screw, Machined, RMA-101 Break-Away
Upper Shroud, Machined, RMA-101
Lower Shroud, Machined, RMA-101
Mounting Ring, RMA-202
Mounting Ring Cover, RMA-202
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Plate, Retention
Upper Manifold, Evolver 202
Valve Manifold Assembly, RMA-202
ARCHIVE
Qty
4
2
2
1
1
1
1
1
1
1
1
1
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
NOTES
AA-07-01
ARCHIVE
42
Evolver 202 Robotic Atomizers - Maintenance
22
3
2
11
8
10
7
9
6
13
12
1
9
6
2
7
10
8
11
5
18
19
4
23
21
15
20
14
16
17
ALLIGN TIMING AS SHOWN
Figure 13:
43
Disassembly of Intermediate Applicator Housing
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
INTERMEDIATE
APPLICAT
INTERMEDIA
TE APPLICA
TOR HOUSING Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
AA-07-01
Part #
79134-00
79001-08
77509-00
79105-01
79103-00
78449-00
EMF-202-04
EMF-203-04
70591-01
EMF-202-05
EMF-203-05
77538-01
78450-00
77508-00
79001-07
78992-00
77524-00
79030-00
79010-01
79001-04
79001-06
A11916
SSF-2052
PAR
ARTS
P
AR
TS LIST (Figure 13)
Description
Connecting Rod, Machined
O-Ring, Solvent Proof
Threaded Stud, Machined
Bell Plate Assembly, RMA-202
Valve Manifold Assembly, RMA-202
Fitting,Fluid
Ferrule, Back, 1/4" Tube
Ferrule, Front, 1/4" Tube
Nut, Fluid Fitting, 1/4"
Ferrule, Back, 1/4" Tube
Ferrule, Front, 1/4" Tube
Tubing, 3/8" OD X .250" ID, Polyethylene
Tube, Coiled, 1/4" OD X 1/8" ID
Air Bolt, Machined
O-Ring, Solvent Proof
Ring, Break-Away, RWA-101
Screw, Machined, Break-Away, RMA-101
Cascade Stop Plate
Cascade Assembly, HP-404
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Upper Manifold, Evolver 202
Set Screw, 3/8" Lg. X #10-24
ARCHIVE
Qty
4
8
4
1
1
2
2
2
2
2
2
1
1
4
4
1
6
1
1
1
4
1
1
44
Evolver 202 Robotic Atomizers - Maintenance
10
2
3
Figure 14:
Low Voltage Cable Removal
VOLT
REMOVAL
PAR
ARTS
LOW VOL
TAGE CABLE REMOV
AL - P
AR
TS LIST (Figure 14)
Item #
2
2
2
3
3
10
45
Part #
79008-XX
A11353-XX
A11355-XX
79155-00
A10975-00
SSF-2052
Description
Low Voltage Cable, One-Piece, for LECU5004-XX Power Supply
Low Voltage Cable, One-Piece, for A10406-XX Power Supply
Low Voltage Cable, Junction, for A10406-XX Power Supply
Robot Mounting Plate, English Fittings
Robot Mounting Plate, Metric Fittings
Set Screw
ARCHIVE
Qty
1
1
1
1
1
1
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
Low V
oltage Cable Removal
Voltage
(Refer to Figure 14)
NOTES
1. Disconnect low voltage cable [2] from rear of
power supply. For A10406-XX power supply,
disconnect circular connector from receptacle on
rear of power supply. For LECU5004-XX power
supply, disconnect wires from connector J3 at
rear of MicroPak.
2. Loosen retaining ring [6] (see Figure 12) and
remove applicator from robot wrist.
3. Using 3/16" Allen wrench, remove set screw
[10].
4. Remove the low voltage cable [2] by pulling
through the robot arm and mounting plate.
5. To reinstall, insert power supply end of cable [2]
through mounting plate [3], pull through robot arm
and connect to junction box or power supply. For
connections to power supply, plug connector into
receptacle (A10406-XX power supply) or connect
wires as shown in Figure 4 (LECU5004-XX power
supply).
6. Align the timing mark of the plug on the applicator end of the cable [2] with the mark on the
mounting plate [3] and tighten set screw [10].
AA-07-01
ARCHIVE
46
Evolver 202 Robotic Atomizers - Maintenance
2
3
Figure 15a:
1
79103-00 Dual Purge Valve Manifold Disassembly
VAL
ALVE
PAR
ARTS
79103-00 DUAL PURGE V
AL
VE MANIFOLD - P
AR
TS LIST
(Figure 15a)
Item #
1
2
3
Part #
Description
79026-00
78949-00
77367-00
Qty
Valve Manifold
Fluid Valve Assembly
Valve Seat Assembly
1
5
5
1
2
2
3
1
4
Figure 15b:
79103-01 Single Purge Valve Manifold Disassembly
VAL
ALVE
PAR
ARTS
79103-01 SINGLE PURGE V
AL
VE MANIFOLD - P
AR
TS LIST
(Figure 15b)
Item #
1
2
3
4
Part #
79026-00
78949-00
77367-00
77620-00
Description
Valve Manifold
Fluid Valve Assembly
Valve Seat Assembly
Kit, Valve Plug
Qty
1
3
3
2
1
2
ARTS
TABLE
PAR
TS LIST BULLET DEFINITION T
ABLE - (Figures 15a and 15b)
1
2
47
Install assemblies as shown. Apply A11545-00 Petroleum jelly to o-rings. Torque to 15-20 lbs•in (1.702.3 Nm) after valve is down.
Install valve seat assemblies as shown. Apply A11545-00 Petroleum jelly to o-rings. Torque to 15-20
lbs•in (1.70-2.3 Nm)
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
REGULA
TOR VAL
VE
REGULAT
VALVE
MANIFOLD ASSEMBL
Y
ASSEMBLY
(Figure 16)
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 A10676-00, 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.
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 Petroleum jelly. 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 scews and tighten in an
alternating 180° method. Install regulator cap and
tighten to 125-135 lbs•in (14.1-15.3 Nm).
Regulator Diaphragm
Remove the screw 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.
AA-07-01
ARCHIVE
48
Evolver 202 Robotic Atomizers - Maintenance
14
15
16
17
1
4
7
9
6
2
12
3
5
11
8
10
13
Figure 16:
A10745 Fluid Regulator Assembly
REGULAT
ASSEMBLY
PAR
ARTS
A10745 FLUID REGULA
TOR ASSEMBL
Y - P
AR
TS LIST (Figure 16)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
49
Part #
74161-00
77354-00
77354-00
79001-08
79001-06
76374-08C
79220-00
79222-00
79221-00
A10741-00
A10740-00
A10746-00
79001-35
78949-00
77367-1
A10743-00
Description
Spring, Regulator
Assembly, Needle and Seat
Assembly, Needle and Seat
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Screw
Diaphragm
Upper Plate, Regulator
Lower Plate, Regulator
Bonnnet, Regulator
Cap, Regulator
Screw, Slotted Fillister Head, Staineless Steel
O-Ring, Solvent Proof
Fluid Valve Assembly
Valve Seat Assembly
Valve Manifold, Regulator, Evolver 202
ARCHIVE
Qty
1
1
1
1
1
1
1
1
1
1
1
6
1
3
3
1
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
TROUBLESHOOTING GUIDE
General Problem
Possible Causes
Corrective Action
Fluid Does Not
Turn On
1. Trigger pilot regulator has
not been set to a minimum
of 70 psig
2. The green air tube possibly
left disconnected during reassembly
3. Green tube leading from
the source to the applicator
mounting plate is pinched or
broken
4. Piston seal within the applicator spray head is not in
place or there is an extremely tight fit between the
seal and the cylinder wall
1. Increase to 70 psig minimum.
5. P1T or P2T not actuated
6. Paint trigger (BA/PT) not
actuated
No Fan or
Atomization Air
Pressure At the
Air Cap
Excessive
Current or Loss of
High Voltage
2. Reconnect tubing.
3. Check the tubing for kinks or damage. Replace if worn or damaged.
4a. Make sure that the seal is in the proper position and/or lubricate with a small amount of
petroleum jelly.
4b. O-rings left out of small Ø tie rods.
4c. O-ring missing between mounting block and
upper manifold.
4d. O-ring missing between mounting block and
replaceable head.
5. Make sure P1T or P2T (whichever paint line is
in use) is activated. Both P1T or P2T and BA/
PT (paint trigger) must be activated to trigger
the applicator on.
6. Make sure paint trigger (BA/PT) is actuated.
Both P1T or P2T and BA/PT must be actuated
to trigger the applicator on.
1. Low trigger pilot air pressure (70 psi min. required)
2. Air tubes 79134-00 are not
installed properly.
3. Blue or gray 3/8" OD
tube is cut or pinched
1. Increase pressure.
1. Metallic particle alignment
in coiled tube
2. Fluid leaks inside
1. Start fluid flow before turning voltage on.
3. Fluid coil pin-holed
4. Exterior of applicator
contaminated
2. Reinstall and tighten as required.
3. Examine, repair as required.
2. Repair/replace fittings and/or coiled fluid tube
as required.
3. Replace coil as required.
4. Clean with non-polar solvent.
Note: A test station to bench test the applicator off-line will speed the Troubleshooting process.
(Continued On Next Page)
AA-07-01
ARCHIVE
50
Evolver 202 Robotic Atomizers - Maintenance
TROUBLESHOOTING GUIDE (Cont.)
General Problem
Possible Causes
Corrective Action
No Electrostatics
1. Cascade not functioning
1. Check low voltage cable and harness timing
mark positions. Correct as required.
2. Cascade bad. Replace as required.
3. Low voltage cable connections wrong at
MicroPak.
4. Low voltage cable bad. Replace as required.
Low kV, High μA
Output
1. Exterior of applicator
contaminated with conductive material
1. Replace applicator cover.
Low kV, Low μA
Output
1. Cascade failure
1. Replace as required.
No Fluid Flow
1. Fluid valve does not actuate
2. Clogged fluid tube
1.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.
2. Remove and inspect fluid tube.
3. Bad transceiver module
3. Replace transceiver module.
4. Plugged inlet
4. Flush clean
5. Regulator (needle and seat)
stuck
6. No pilot air
5. Remove and clean or replace
7. Two component valve
contaminated
8. In-line mix tube clogged
7. Remove valve manifold and clean
1. Fluid valve open
1 a. Remove air pilot signal.
b. If still open, replace fluid valve.
2. Replace fluid valve seat.
Continuous Fluid
Flow
2. Fluid valve seat damaged or
worn
3. Regulator (needle and seat)
dirty
4. Regulator pilot air not shut
off
51
2. Clean exterior with a non-polar solvent.
6. Check air pilot
8. Replace
3. Remove and clean or replace.
4. Check air supply.
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
TROUBLESHOOTING GUIDE (Cont.)
General Problem
Possible Causes
Corrective Action
Uncontrollable
Fluid Flow
1. Insufficient back pressure
to fluid regulator
2. Fluid regulator does not
control flow (system)
3. Diaphragm stretched from
excessive air pressure
4. Ruptured diaphragm
1. Replace fluid tube with the next smaller inner
diameter size.
2. Disassemble fluid regulator and inspect for
failed components (system).
3. Rebuild regulator.
5. Inconsistent air pilot supply
5. Check air source.
Paint Sputtering
1. Ruptured Diaphragm
1. Replace regulator diaphragm.
Fluid Leakage
Around Fluid
Valve
1. Damaged o-ring(s) on outer
diameter of valve body
2. Damaged or worn needle
seals inside valve assembly
1. Replace o-ring.
Paint Leakage
(Regulator)
1. Diaphragm (screws) loose
1. Replace o-ring(s).
2. Ruptured diaphragm
2. Replace valve assembly.
4. Rebuild regulator.
2. Inspect tubing coil for scratches and replace if
damaged.
Note: To check for fluid leaks, it is easiest to first remove the applicator from the test station and remove the shroud
from the applicator. Then the applicator can be remounted to the test station. Leak detector may be used at all
appropriate sources. Be certain to wipe off all residual solution using a non-conductive solvent such as Naphtha.
AA-07-01
ARCHIVE
52
Evolver 202 Robotic Atomizers - Parts Identification
PAR
TS IDENTIFICA
TION
ARTS
IDENTIFICATION
4
1
3
2
5
Figure 17:
53
A11918 Spray Applicator Assembly
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
A11918
SPRAY
APPLICAT
ASSEMBLY
PAR
ARTS
A1
1918 SPRA
Y APPLICA
TOR ASSEMBL
Y - P
AR
TS LIST
(Figure 17)
Item #
Part #
1
2
3
4
5
Table
Table
Table
Table
Table
Qty
Description
A
B
A
C
D
-
"A"
"B"
"C"
"E"
"F"
Screw, #10-32, Thread
Manifold Assembly
Assembly, Mounting Block
Assembly, Head Robot Gun
Robot Adapters
4
1
1
Table A - "D"
1
TABLE A
CONFIGURATION
HEAD CONFIGURA
TION
Dash
No.
Description
"A"
"C"
"D"
0
1
2
3
60° Single Head
90° Single Head
60° Dual Head
90° Dual Head
LSFA0027-00
LSFA-0027-00
79206-00
79206-00
79179-00
79180-00
79234-00
79224-00
1
1
2
2
TABLE B
CONFIGURATION
MANIFOLD CONFIGURA
TION
Dash
No.
0
1
2
3
4
5
6
Description
"B"
Single Purge, No Regulator, for Highly Conductive Materials (Base/Clear)
Dual Purge , No Regulator, for Highly Conductive Materials (Base/Clear)
Single Purge W/Regulator
Single Purge, No Regulator, for Conductive Materials (Base/Clear)
Dual Purge, No Regulator, for Conductive Materials (Base/Clear)
Single Purge, No Regulator, for Highly Resistive Materials (Clear Coat)
Dual Purge, No Regulator, for Highly Resistive Materials (Clear Coat)
A11917-01
A11917-02
A11917-03
A11917-04
A11917-05
A11917-06
A11917-07
TABLE C
OMIZATION
AT OMIZA
TION TECHNOLOGY
TABLE D
ROBOT ADAPTERS
Dash
No. Description
Dash
No. Description
0
1
Conventional Spray
HVLP Spray
AA-07-01
"E"
79138-01
79138-02
0
1
2
3
4
5
6
7
No Adapter
"ABB" Robot Adapter
"Fanuc" P-155 Robot Adapter
"Fanuc" P-200 Robot Adapter
Adapter (Kawasaki-KE610L)
Adapter (Motoman-PX2850)
Adapter (Motoman-PX2900)
Adapter (B & M-LZ2000)
ARCHIVE
"F"
---79107-00
78983-00
79131-00
A10847-00
A10848-00
A10849-00
A10851-00
54
19
20
55
21
1
21
22
2
3
Figure 18:
ARCHIVE
23
24
25
5
26
4
27
6
28
7
29
8
10
30
9
31
11
LOCATED
INSIDE 13
12
32
13
15
16
18
17
15
LOCATED
INSIDE 17
33
34
35
TORQUE TO 30-35 LBS/IN
(3.4-4.0 NEWTON METER)
14
15
36
Evolver 202 Robotic Atomizers - Parts Identification
79138-01 Spray Head Assembly
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
SPRAY
ASSEMBLY
79138-01 CONVENTIONAL SPRA
Y HEAD ASSEMBL
Y ARTS
PAR
TS LIST (Figure 18)
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
AA-07-01
Part #
79148-00
17615-00
9334-00
7733-07
76199-00
79151-00
79147-00
7723-06
79145-00
79144-00
79001-28
79001-29
79146-00
79143-00
79001-01
13076-13
79172-00
79001-06
79137-00
79001-04
79001-06
79142-00
79171-00
79141-00
14061-09
79001-05
RME-38
EMF-7
RME-32
79001-01
70430-01
EMF-195
EMF-192
79140-01
79140-02
79140-03
79153-65R-1
79196-98-1
79197-63-1
79154-00
Description
End Cap, Spray Head
Spring, Compression
Spring, Valve Return
Nut, Jam
Nut, Adjustment Rear
Assembly, Needle Shaft
Nut, Piston
Piston, U-Cup
Plate, Piston
Shaft, Air Valve
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Seal Carrier, Rear Piston
Bushing, Air Valve
O-Ring, Solvent Proof
O-Ring, Teflon
Carrier, Rear Seal
O-Ring, Solvent Proof
Head, Machining
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Screw, SHCS
Spring, Connector
Plug, Connection
Conductive Compressable Contact
O-Ring, Solvent Proof
Return Spring, Piston
Seal, Washer
Seal
O-Ring, Solvent Proof
Electrode, High Wear
Nozzle, Fluid Hole (8)
Locator, Air Cap
Fluid Tip, .042" (1.07mm) Diameter
Fluid Tip, .055" (1.40mm) Diameter
Fluid Tip, .070" (1.78mm) Diameter
Air Cap, Certified 65R-1
Air Cap, Certified 98-1
Air Cap, Certified 63-1
Ring, Retaining
ARCHIVE
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
56
Evolver 202 Robotic Atomizers - Parts Identification
SPRAY
ASSEMBLY
PAR
ARTS
79138-02 HVLP SPRA
Y HEAD ASSEMBL
Y - P
AR
TS LIST
(Figure 18)
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
57
Part #
79148-00
17615-00
9334-00
7733-07
76199-00
79151-00
79147-00
7723-06
79145-00
79144-00
79001-28
79001-29
79146-00
79143-00
79001-01
13076-13
79172-00
79001-06
79137-00
79001-04
79001-06
79142-00
79171-00
79141-00
14061-09
79001-05
RME-38
EMF-7
RME-32
79001-01
70430-01
79183-00
EMF-192
79182-01
79182-02
79182-03
79182-04
79182-05
79185-48-1
79186-481-1
79154-00
Qty
Description
End Cap, Spray Head
Spring, Compression
Spring, Valve Return
Nut, Jam
Nut, Adjustment Rear
Assembly, Needle Shaft
Nut, Piston
Piston, U-Cup
Plate, Piston
Shaft, Air Valve
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Seal Carrier, Rear Piston
Bushing, Air Valve
O-Ring, Solvent Proof
O-Ring, Teflon
Carrier, Rear Seal
O-Ring, Solvent Proof
Head, Machining
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Screw, Shcs.
Spring, Connector
Plug, Connection
Conductive Compressable Contact
O-Ring, Solvent Proof
Return Spring, Piston
Seal, Washer
Seal
O-Ring, Solvent Proof
Electrode, High Wear
Nozzle, Fluid Hole (8) (HVLP)
Locator, Air Cap
Fluid Tip, .028" (.71mm) Diameter (Used with Air Cap 79186-48-1)
Fluid Tip, .042" (1.07mm) Diameter (Used with Air Cap 79186-48-1)
Fluid Tip, .055" (1.40mm) Diameter (Used with Air Cap 79186-48-1)
Fluid Tip, .070" (1.78mm) Diameter (Used with Air Cap 79186-481-1)
Fluid Tip, .086" (2.18mm) Diameter (Used with Air Cap 79186-481-1)
Air Cap, Certified 48-1 (Used with 79182-01, 02, 03 Tips)
Air Cap, Certified 481-1 (Used with 79182-04, 05 Tips)
Ring, Retaining
ARCHIVE
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
2
1
6
4
5
5
Figure 19:
3
79179-00 Single Head 60
60°°
60°° - P
PAR
ARTS
79179-00 SINGLE HEAD 60
AR
TS LIST (Figure 19)
Item #
1
2
3
4
5
6
Part #
Description
79188-00
79173-00
79174-00
79184-00
79149-00
A-10612
Qty
Assembly, Mounting Block 60° Single Head
Block, Locking
Screw, Nylon 1/4-20 x 1-1/4" Long
Plate, Retention
Screw, Retaining #10-32 x .50" Long NY
Square Cut Ring, Solvent Proof
1
1
1
1
2
1
1
6
3
5
2
4
Figure 20:
79243-00 Dual Head 60
60°
60°° - P
PAR
ARTS
79243-00 DUAL HEAD 60
AR
TS LIST (Figure 20)
Item #
1
2
3
4
5
6
AA-07-01
Part #
79242-00
79173-00
79174-00
79184-00
79149-00
A-10612
Description
Assembly, 60° Block Dual Head
Block, Locking
Screw, Nylon 1/4-20 X 1-1/4" Long
Plate, Retention
Screw, Retaining #10-32 X .50" Long NY
Square Cut Ring, Solvent Proof
ARCHIVE
Qty
1
2
2
2
4
2
58
Evolver 202 Robotic Atomizers - Parts Identification
1
7
2
3
4
5
6
5
Figure 21:
79180-00 Single Head 90
90°
90°° - P
PAR
ARTS
79180-00 SINGLE HEAD 90
AR
TS LIST (Figure 21)
Item #
1
2
3
4
5
6
7
Part #
Description
79189-00
79173-00
79174-00
79184-00
79149-00
79194-00
A10612
Qty
Assembly, Mounting Block 90° Single Head
Block, Locking
Screw, Nylon 1/4-20 X 1-1/4" Long
Plate, Retention
Screw, Retaining #10-32 X .50" Long NY
Plug, Fluid Flush
Square Cut Ring, Solvent Proof
1
1
1
1
2
1
1
1
3
5
6
2
4
Figure 22:
79224-00 Dual Head 90
90°
90°° - P
PAR
ARTS
79224-00 DUAL HEAD 90
AR
TS LIST (Figure 22)
Item #
1
2
3
4
5
6
59
Part #
79227-00
79173-00
79174-00
79184-00
79149-00
A-10612
Description
Assembly, Mounting Block 90° Dual Head
Block, Locking
Screw, Nylon 1/4-20 X 1-1/4" Long
Plate, Retention
Screw, Retaining #10-32 X .50" Long NY
Square Cut Ring, Solvent Proof
ARCHIVE
Qty
1
2
2
2
4
2
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
NOTES
AA-07-01
ARCHIVE
60
30
31
33
16
Figure 23:
61
26
25
26
24
27
3
20
2
1
17
2
19
11
8
10
7
9
6
23
12
13
9
10
6
11
8
7
21
28
28
31
18
29
4
30
28
5
32
14
26
15
17
22
Evolver 202 Robotic Atomizers - Parts Identification
A11917 Manifold Assembly
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
A11917
ASSEMBLY
PAR
ARTS
A1
1917 MANIFOLD 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
1
Part #
79134-00
79001-08
77509-00
79105-01
Table E - "G"
78449-00
EMF-202-04
EMF-203-04
70591-01
EMF-202-05
EMF-203-05
77538-01
78450-00
77508-00
79001-07
78992-00
77524-00
79030-00
77523-00
77522-00
78976-00
78979-00
79010-01
79001-14
79001-04
79001-06
A11916
78949-00
77367-00
Table E - "H"
Table E - "I"
79001-09
79001-03
Description
Connecting Rod, Machined
O-Ring, Solvent Proof
Threaded Stud, Machined
Bell Plate Assembly, RMA-202
Valve Manifold Assembly, RMA-202
Fitting,Fluid
Ferrule, Back, 1/4" Tube
Ferrule, Front, 1/4" Tube
Nut, Fluid Fitting, 1/4"
Ferrule, Back, 1/4" Tube
Ferrule, Front, 1/4" Tube
Tubing, 3/8" OD X .250" ID, Polyethylene
Tube, Coiled, 1/4" OD X 1/8" ID
Air Bolt, Machined
O-Ring, Solvent Proof
Ring, Break-Away, RWA-101
Screw, Machined, Break-Away, RMA-101
Cascade Stop Plate
Upper Shroud, Machined, RMA-101
Lower Shroud, Machined, RMA-101
Mounting Ring, RMA-202
Mounting Ring Cover, RMA-202
Assembly, Cascade, HP404
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Upper Manifold, Evolver 202
Valve Assembly
Seat Assembly
Valve Assembly, Plug, or Regulator Assembly
Seat Assembly, Plug, or Regulator Assembly
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Qty
4
8
4
1
1
2
2
2
2
2
2
1
1
4
4
1
8
1
1
1
1
1
1
1
1
6
1
3
3
2
2
1
1
1
1
1
1
Tighten to 15-25 lbs•in (1.7-2.8 Nm) torque.
AA-07-01
ARCHIVE
62
Evolver 202 Robotic Atomizers - Parts Identification
TABLE E
CONFIGURATION
MANIFOLD CONFIGURA
TION
Description
"G"
A11917-01 Single Purge, No Regulator
A11917-02 Dual Purge, No Regulator
A11917-03 Single Purge W/Regulator
79026-00
79026-00
A10742-00
Item #
"H"
"I"
Kit 77620-00
77367-00
78949-00
Table "F"
TABLE F
REGULAT
ASSEMBLY
REGULA
TOR ASSEMBL
Y - SINGLE PURGE
Item #
74161-00
77354-00
79001-08
79001-06
76374-08C
79220-00
79222-00
79221-00
A10741-00
A10740-00
A10746-00
79001-35
78949-00
77367-1
63
Description
Qty.
Spring, Regulator
Assembly, Needle and Seat
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Screw
Diaphragm
Upper Plate, Regulator
Lower Plate, Regulator
Bonnet, Regulator
Cap, Regulator
Screw, Slotted Fillister Head, Stainless Steel
O-Ring, Solvent Proof
Fluid Valve Assembly
Valve Seat Assembly
ARCHIVE
1
1
1
1
1
1
1
1
1
1
6
1
3
3
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
Figure 24:
79105-01 Rear Plate Assembly (Un-Regulated Version)
PLATE
ASSEMBLY
(UN-REGULATED
79105-01 REAR PLA
TE ASSEMBL
Y (UN-REGULA
TED VERSION)
ARTS
PAR
TS LIST (Figure 24)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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
79621-00
Description
Qty
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, #2-015
Large Air Stud, Machined
O-Ring, #2-013
Small Air Stud, Machined
O-Ring, #2-010
O-Ring, #2-011
O-Ring, #2-007
Medium Air Stud, Machined
Set Screw, #10-24 UNC X 3/8" Long SHCS
O-Ring, #2-008,Kalrez
Stainless Steel Cup, PT socket Set Screw, 3/8"-24
ARTS
TABLE
PAR
TS LIST BULLET DEFINITION T
ABLE
Apply thread sealer 7969-10 to threads prior to assembly.
2
Apply a thin film of SSL-11 Petroleum jelly to o-rings before assembly
3
Apply thread sealer 7969-03 to threads prior to assembly.
ARCHIVE
1
2
1
2
1
2
2
2
1
3
- (Figure 24)
1
AA-07-01
1
2
2
2
1
4
4
10
10
10
2
2
2
1
1
64
Evolver 202 Robotic Atomizers - Parts Identification
Figure 25:
A10747-00 Rear Plate Assembly (Regulator Version)
PLATE
ASSEMBLY
(REGULAT
A10747-00 REAR PLA
TE ASSEMBL
Y (REGULA
TOR VERSION) ARTS
PAR
TS LIST (Figure 25)
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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
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
ARTS
TABLE
PAR
TS LIST BULLET DEFINITION T
ABLE - (Figure 25)
65
1
Apply thread sealer 7969-10 to threads prior to assembly.
2
Apply A11545-00 Petroleum jelly to o-rings.
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
Figure 26: Rear Plate/Break-Away Assembly
(Single Paint With Regulator Manifold Assembly Only)
PLATE
BREAK-AW
ASSEMBLY
ARTS
REAR PLA
TE / BREAK-A
WAY ASSEMBL
Y - PAR
TS LIST (Single Paint
with Regulator Manifold Assembly Only) (Figure 26)
Item #
1
2
3
4
AA-07-01
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
Evolver 202 Robotic Atomizers - Maintenance
CAUTION
!
45
29
27
39
22
48
28
13
12
17
Figure 27:
67
Torque to
10 lbs-in
max.
33
5
1
42
3
2
13
8
20
16
38
36
34
5
16
30
51
Torque to
10 lbs-in
max.
14
37
24
41
52
11
49
35
7
23
31
18
43
50
47
15
25
>
Do not over-tighten the 77544-01 [13]
beyond the maximum 10 lbs•in force.
79106-XXXXXXX Tubing Bundle Assembly (English)
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Maintenance
ASSEMBLY
79106-XXXXXXX TUBING BUNDLE ASSEMBL
Y (ENGLISH) ARTS
PAR
TS LIST (Figure 27)
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
50
51
52
AA-07-01
Description
Part #
79025-00
76566-24C
SSF-2052
---77947-00
---A10608-03
See Table
------See Table
See Table
77544-01
77545-04
77536-05
SSP-6054
77545-07
A10609-02
---See Table
---See Table
See Table
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
See Table
See Table
---See Table
See Table
See Table
See Table
See Table
See Table
See Table
See Table
K - "N"
K - "P"
K- "Q"
K- "V"
K - "T"
K- "S"
H - "K"
J - "M"
I - "L"
H - "U"
L - "Z"
L - "AB"
L - "AA"
L - "X"
L - "W"
L - "Y"
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, Nylon
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
Low Voltage Cable, HP-404 Extension
Dump Line #2, 3/8" OD X .250" ID, PFA, Teflon
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
ARCHIVE
Qty
See
See
See
See
See
See
See
See
See
See
See
See
See
See
See
1
6
2
---3
---Table G - "H"
1
------Table G - "H"
1
5
1
Table G - "H"
3
2
Table G - "J"
---1
---1
Table G - "H"
1
Table G - "H"
1
Table G - "H"
1
Table G - H"
1
Table G - "H"
---1
1
Table G - "H"
1
Table G - "H"
1
Table G - "H"
---Table G - "H"
1
1
---1
1
Table G - "H"
1
1
Table G -"H"
1
1
Notes
3
3
3
6
4
3
3
3
4
6
3
4
6
7
3
3
68
Evolver 202 Robotic Atomizers - Parts Identification
ARTS
TABLE
PAR
TS LIST BULLET DEFINITION T
ABLE
- (Figure 27)
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.
SIGNAL IDENTIFICA
TION T
ABLE (ENGLISH)
IDENTIFICATION
TABLE
Abbr.
B.A/P.T
B.A
BRK
DL1
F.O
LV
P1.IN
P1T
P1D
P2.IN
P2T
P2D
S.A/A.A
S.IN
SL.A/F.A
ST
T.A
DL2
69
Description
Color
Bearing Air (Paint Trigger)
Bearing Air Return
Brake Air
Dump Line #1
Fiber Optic Cable
Low Voltage Cable
Paint #1 In
Paine #1 Trigger
Paint #1 Dump
Paint #2 In
Paint #2 Trigger
Paint #2 Dump
Shaping Air (Atomizer Air)
Solvent In
Seal Air (Fan Air)
Solvent Trigger Signal
Turbine Air
Dump Line #2
Yellow
Yellow
Orange
Natural
Natural
Black
Natural
Green
Orange
Natural
Natural
Black
Gray
Natural
Blue
Blue
Green
Natural
Tubing Material
Nylon
Nylon
Nylon
Teflon
Polyethylene
N/A
Teflon
Nylon
Nylon
Teflon
Nylon
Nylon
Nylon
Teflon
Nylon
Nylon
Nylon
Teflon
ARCHIVE
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
1/4" OD (jacket)
N/A
See Table K
5/32" OD X .106" ID
5/32" OD X .106" ID
See Table L
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
3/8" OD X 1/4" ID
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
79106XXXXXXX TUBING BUNDLE ASSEMBL
Y
79106-XXXXXXX
ASSEMBLY
MODEL IDENTIFICA
TION (ENGLISH)
IDENTIFICATION
When ordering, use 79106-ABBCDEF as indicated by Tables G thru L.
Seven digits must follow the basic part number, for example:
79106
-
1
00
2
1
0
1
Basic Part Number
Tubing Assy. Length
(Table G)
Low Voltage Cable Length
Fiber Optic Cable Length
(Table L) Paint #2 Supply
Line Size Dump Line #2 Size
(Table H)
(Table K)
(Table I)
(Table J)
Paint #1 Supply
Line Size Dump Line #1 Size
Robot Adapter
TABLE G
ASSEMBLY
TUBING ASSEMBL
Y LENGTH
Dash
No.
0
1
2
Description
(Not Included)
15' Tubing Assembly
30' Tubing Assembly
"H"
(Length)
---15 Ft.
30 Ft.
"J"
(Total Length)
---30 ft. (2-15 Ft. Lengths)
60 ft. (2-30 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.
AA-07-01
ARCHIVE
70
Evolver 202 Robotic Atomizers - Parts Identification
TABLE H
VOLT
LOW VOL
TAGE CABLE LENGTH
Dash
No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
31
32
33
34
35
36
37
38
39
40
41
71
"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
25' Low Voltage, Non-Junction, Evolver MicroPak
50' Low Voltage; Non-Junction, Evolver MicroPak
75' Low Voltage; Non-Junction; Evolver MicroPak
100' Low Voltage; Non-Junction; Evolver MicroPak
15' Robot to JB; 15' JB to Evolver MicroPak
15' Robot to JB; 40' JB to Evolver MicroPak
15' Robot to JB; 60' JB to Evolver MicroPak
15' Robot to JB; 75' JB to Evolver MicroPak
25' Robot to JB; 25' JB to Evolver MicroPak
25' Robot to JB; 50' JB to Evolver MicroPak
25' Robot to JB; 75 JB to Evolver 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
A11353-25
A11353-50
A11353-75
A11353-100
A11355-15
A11355-15
A11355-15
A11355-15
A11355-25
A11355-25
A11355-25
ARCHIVE
"U"
(Low Voltage
Cable Extension)
------------------77062-15
77062-40
77062-60
77062-75
77062-25
77062-50
77062-75
77062-15
77062-25
77062-40
77062-60
------------A11356-15
A11356-40
A11356-60
A11356-75
A11356-25
A11356-50
A11356-75
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
TABLE J
ROBOT ADAPTER
TABLE I
FIBER OPTIC LENGTH
Dash
No.
0
1
2
3
4
5
6
Description
Dash
No.
"L"
(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
----SMC-424-5
SMC-424-6
SMC-424-2
SMC-424-7
SMC-424-1
SMC-424-8
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)
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
PAINT
SUPPLY
TABLE K - P
AINT #1 SUPPL
Y LINE - DUMP LINE #1 SIZE
Dash
No
Description
"N"
Fitting
"P"
Tubing
"Q"
Insert
Description
"S"
Tubing
"T"
Insert
"V"
Fitting
------None
None
------------Paint Line, 1/4" OD x 77540-04 76698-01 77539-02 Dump Line, 3/8" OD X 76698-04 77539-04 77540-06
.170" ID, PFA Teflon
.250" ID, PFA Teflon
Paint Line, 3/8" OD x 77540-06 76698-04 77539-04 Dump Line, 3/8" OD X 76698-04 77539-04 77540-06
.250" ID, PFA Teflon
.250" ID, PFA Teflon
Paint Line, 5/16" OD x 77540-05 76698-02 77539-03 Dump Line, 3/8" OD x 76698-04 77539-04 77540-06
.188" ID, PFA Teflon
.250" ID, PFA Teflon
0
1
2
3
PAINT
SUPPLY
TABLE L - P
AINT #2 SUPPL
Y LINE - DUMP LINE #2 SIZE
Dash
No
0
1
2
3
Description
"W"
Fitting
"X"
Tubing
"Y"
Insert
Description
"Z"
Tubing
"AA"
Insert
"AB"
Fitting
------None
---None
---------Paint Line, 1/4" OD x 77540-04 76698-01 77539-02 Dump Line, 3/8" OD X 76698-04 77539-04 77540-06
.170" ID, PFA Teflon
.250" ID, PFA Teflon
Paint Line, 3/8" OD x 77540-06 76698-04 77539-04 Dump Line, 3/8" OD X 76698-04 77539-04 77540-06
.250" ID, PFA Teflon
.250" ID, PFA Teflon
Paint Line, 5/16" OD x 77540-05 76698-02 77539-03 Dump Line, 3/8" OD x 76698-04 77539-04 77540-06
.188" ID, PFA Teflon
.250" ID, PFA Teflon
AA-07-01
ARCHIVE
72
Evolver 202 Robotic Atomizers - Parts Identification
!
CAUTION
> Do not over-tighten the 77544-01 [10]
32
14
21
20
27
Figure 28:
73
Torque to
10 lbs-in
max.
23
6
1
29
3
10
2
7
17
44
15
43
12
24
4
41
12
9
38
18
10
Torque to
10 lbs-in
max.
35
26
40
8
42
28
39
25
36
19
5
22
16
30
13
37
34
11
beyond the maximum 10 lbs•in force.
A10892-XXXXXXX Tubing Bundle Assembly (Metric)
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
ASSEMBLY
A10892-XXXXXXX TUBING BUNDLE ASSEMBL
Y (METRIC) ARTS
PAR
TS LIST (Figure 28)
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
Description
Part #
79025-00
76566-24C
SSF-2052
A10891-03
A10893-07
A10891-04
See Table
See Table
See Table
77544-01
77536-05
A10891-02
A10840-08
A10840-09
A10891-01
A10894-01
See Table
See Table
See Table
77536-01
A10839-03
77536-08
A10890-01
A10895-03
A10841-03
77536-04
77536-03
A10839-06
See Table
See Table
---See Table
See Table
See Table
See Table
See Table
See Table
See Table
See Table
77545-04
77545-13
77545-02
77545-01
77545-03
Q - "N"
Q - "P"
Q - "Q"
Q - "V"
Q - "T"
Q - "S"
M - "K"
P - "M"
N
M
R
R
R
R
R
R
-
"L"
"U"
"Z"
"AB"
"AA"
"X"
"W"
"Y"
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
Male Connector, 1/4" NPT
Paint #1 Supply Tubing, PFA, Teflon
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)
Dump #2 Supply Tubing, PFA, Teflon
Male Connector, 10mm OD X 1/4" NPT
Insert, Stainless Steel Tube
Paint #2 Supply Tubing, PFA, Teflon
Male Connector, 1/4" NPT
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
See
See
See
See
See
See
See
See
See
See
See
See
See
See
See
See
1
6
2
1
Table
2
1
Table
1
5
Table
2
Table
Table
1
Table
1
1
Table
Table
Table
Table
1
1
Table
Table
Table
Table
1
1
---1
1
Table
1
1
Table
1
1
1
1
1
1
1
3
3
L - "H"
3
3
L - "H"
6
4
3
L - "H"
3
L - "H"
L - "H"
3
L - "H"
3
4
L
L
L
L
-
"H"
"H"
"H"
"H"
6
3
4
L
L
L
L
-
"H"
"H"
"H"
"H"
6
7
L - "H"
3
L - "H"
3
ARTS
TABLE
PAR
TS LIST BULLET DEFINITION T
ABLE - (Figure 28)
7
Apply thread sealer 7969-10 to threads prior to assembly.
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.
AA-07-01
ARCHIVE
74
Evolver 202 Robotic Atomizers - Parts Identification
IDENTIFICATION
TABLE
SIGNAL IDENTIFICA
TION T
ABLE (METRIC)
Abbr.
B.A/P.T
B.A
BRK
DL1
F.O
LV
P1.IN
P1T
P1D
P2.IN
P2T
P2D
S.A/A.A
S.IN
SL.A/F.A
ST
T.A
DL2
75
Description
Color
Tubing Material
Tubing Size
Bearing Air (Paint Trigger)
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 (Atomizer Air)
Solvent In
Seal Air (Fan Air)
Solvent Trigger Signal
Turbine Air
Dump Line #2
Yellow
Yellow
Orange
Natural
Natural
Black
Natural
Green
Orange
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
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
See Table R
5/32" OD X .106" ID
5/32" OD X .106" ID
See Table S
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
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
A10892-XXXXXXX TUBING BUNDLE ASSEMBL
Y
ASSEMBLY
MODEL IDENTIFICA
TION (METRIC)
IDENTIFICATION
When ordering, use A10892-ABBCDEF as indicated by Tables M through S. Seven digits must
follow the basic part number, for example:
A10892 - 1 00
2
1
1
(Table S)
Basic Part Number
Tubing
Assembly Length
(Table M)
Low Voltage
Cable Length
(Table N)
Fiber Optic
Cable Length
0
(Table R)
(Table Q)
Paint #2 Supply Line Dump Line #2
Paint #1 Dump Line #1
Robot Adapter
(Table P)
TABLE M
ASSEMBLY
TUBING ASSEMBL
Y LENGTH
Dash
No.
0
1
2
AA-07-01
Description
"H"
Air Tubing Not Included
4 1/2m Long Tubing Assembly
9m Long Tubing Assembly
---4.6m (15 Ft.)
9.2m (30 Ft.)
ARCHIVE
76
Evolver 202 Robotic Atomizers - Parts Identification
TABLE N
VOLT
LOW VOL
TAGE CABLE LENGTH
Dash
No.
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
31
32
33
34
35
36
37
38
39
40
41
77
"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
25' Low Voltage; Non-Junction, Evolver MicroPak
50' Low Voltage; Non-Junction, Evolver MicroPak
75' Low Voltage; Non-Junction; Evolver MicroPak
100' Low Voltage; Non-Junction; Evolver MicroPak
15' Robot to JB; 15' JB to Evolver MicroPak
15' Robot to JB; 40' JB to Evolver MicroPak
15' Robot to JB; 60' JB to Evolver MicroPak
15' Robot to JB; 75' JB to Evolver MicroPak
25' Robot to JB; 25' JB to Evolver MicroPak
25' Robot to JB; 50' JB to Evolver MicroPak
25' Robot to JB; 75' JB to Evolver 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
A11353-25
A11353-50
A11353-75
A11353-100
A11355-15
A11355-15
A11355-15
A11355-15
A11355-25
A11355-25
A11355-25
ARCHIVE
"U"
(Low Voltage
Cable Extension)
------------------77062-15
77062-40
77062-60
77062-75
77062-25
77062-50
77062-75
77062-15
77062-25
77062-40
77062-60
------------A11356-15
A11356-40
A11356-60
A11356-75
A11356-25
A11356-50
A11356-75
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
TABLE Q
ROBOT ADAPTER
TABLE P
FIBER OPTIC CABLE LENGTH
Dash
No.
Description
"L"
Dash
No.
"M"
(Robot
Adapter)
Description
0
(Not Included)
-----
0
Adapter (Not Included)
1
15' Fiber Optic Cable
SMC-424-5
1
Adapter (Fanuc P-155, P-145)
78983-00
2
25' Fiber Optic Cable
SMC-424-6
2
Adapter (ABB 5400, 5002)
79107-00
3
50' Fiber Optic Cable
SMC-424-2
4
SMC-424-7
3
Adapter (Fanuc P-200)
75' Fiber Optic Cable
5
100' Fiber Optic Cable
SMC-424-1
6
40' Fiber Optic Cable
SMC-424-8
7
120' Fiber Optic Cable
SMC-424-3
-----
79131-00
4
Adapter (Motoman - PX2900)
A10849-00
5
Adapter (Motoman - PX2850)
A10848-00
6
Adapter (Kawasaki - KE610L)
A10847-00
7
Adapter (B & M LZ2000)
A10851-00
PAINT
SUPPLY
TABLE R - P
AINT #1 SUPPL
Y LINE - DUMP LINE #1 SIZE
Dash
No
0
1
Description
None
Paint Line, 6mm OD X
"N"
Fitting
"P"
Tubing
"Q"
Insert
----
----
----
Paint Line, 8mm OD X
None
"S"
Tubing
"T"
Insert
"V"
Fitting
----
----
----
A10890-01 A10841-03 A10895-03 Dump Line, 10mm OD X A10841-01 A10895-01 A10890-03
.4mm ID, PFA Teflon
2
Description
8mm ID, PFA Teflon
A10890-02 A10841-02 A10895-02 Dump Line, 10mm OD X A10841-01 A10895-01 A10890-03
6mm ID, PFA Teflon
8mm ID, PFA Teflon
Paint Line, 10mm OD X A10890-03 A10841-01 A10895-01 Dump Line, 10mm OD X A10841-01 A10895-01 A10890-03
3
8mm ID, PFA Teflon
8mm ID, PFA Teflon
PAINT
SUPPLY
TABLE S - P
AINT #2 SUPPL
Y LINE - DUMP LINE #2 SIZE
Dash
No
0
1
Description
None
Paint Line, 6mm OD X
.4mm ID, PFA Teflon
2
Paint Line, 8mm OD X
6mm ID, PFA Teflon
3
"W"
Fitting
"X"
Tubing
"Y"
Insert
----
----
----
Description
None
"Z"
Tubing
"AA"
Insert
"AB"
Fitting
----
----
----
A10890-01 A10841-03 A10895-03 Dump Line, 10mm OD X A10841-01 A10895-01 A10890-03
8mm ID, PFA Teflon
A10890-02 A10841-02 A10895-02 Dump Line, 10mm OD X A10841-01 A10895-01 A10890-03
8mm ID, PFA Teflon
Paint Line, 10mm OD X A10890-03 A10841-01 A10895-01 Dump Line, 10mm OD X A10841-01 A10895-01 A10890-03
8mm ID, PFA Teflon
8mm ID, PFA Teflon
AA-07-01
ARCHIVE
78
Evolver 202 Robotic Atomizers - Parts Identification
A10406 OR LECU5004
MICROP
AK CONTROL
MICROPAK
UNIT
ACCESSORIES
Accessories for the Evolver 202 Solventborne
spray applicators include:
(See the current "MicroPak" Service Manual
supplied with the control unit for service
information.)
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 Assembly (76667-00).
76652-02
Kit for measuring short circuit current (SCI), resistance, and sprayability. Includes MultiFunction Meter (76634-00) and Test Lead Assembly. (76664-00).
76652-03
Kit for measuring paint resistivity. (Includes Multi-Function Meter (76634-00) and Paint
Probe Assembly (7922-00).
76652-04
Deluxe Kit (Performs all functions listed above.) Includes Multi-Function Meter
(76634-00), Paint Probe Assembly (7922-00). Test Lead Assembly (76664-00), and High
Voltage Probe Assembly (76667-00).
79
RPM-32
Pre-Filter Replacement Element
RPM-33
Bearing Air Filter Element
75777-XX
Spray Applicator Covers
74035-XX
Test Air Cap and Gauge Assembly
73896-01
Electrode and Air Cap Protector
79203-00
Tool Kit
77620-00
Valve Plug Kit
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
SPRAY
75777-XX SPRA
Y
APPLICAT
APPLICA
T OR COVERS
Part #
Description
75777-01
75777-02
75777-03
Single Head Spray Applicator
Dual Head Spray Applicator
Robot Wrist Flange
74035-XX TEST AIR CAPS &
ASSEMBLY
GAUGE ASSEMBL
Y
Part #
Description
74035-21
74035-22
74035-23
74035-24
74035-25
#65R-1 Test Cap
#98-1 Test Cap
#63-1 Test Cap
#48-1 Test Cap
#481-1 Test Cap
79203-00 T
ool Kit
Tool
Provided with each applicator is a tool kit to aid in
the disassembly and assembly of the applicator
during servicing.
79203-00
TOOL KIT
Part #
Description
A10756-00
A10766-00
76772-00
A10400-00
Valve Removal Tool
Valve Seat Removal Tool
Retaining Ring Spanner
Seal Carrier Tool
The 74035, Test Air Cap and Gauge Assembly, is
designed for use with a Test Station or while the
applicator is connected to the robot or reciprocator.
The test air cap is comprised of two air pressure
gauges, pressure gauge stand, special 74061-XX
air caps, and all required tubing and fittings.
The air cap has two tapped holes for small barbed
tube fittings. The fittings are located so that the
gauges connected to them will measure the actual
cap pressure of the atomization and pattern air.
Using this test cap will assure uniform atomization
and pattern quality, regardless of air supply tube
lengths from one applicator to another.
73896-01 Electrode and Air Cap
Protector
This is a plastic cylinder that fits over the air cap
retainer. The protector keeps the electrode and
other spray head parts from being damaged during
booth cleaning and at other times when the spray
applicator is not in use.
AA-07-01
Figure 29:
79203-00 Tool Kit
A10410-00 SPRA
Y HEAD
SPRAY
O-RING KIT
Available for purchase as a kit containing all of the
o-rings used for a single Evolver 202 spray head.
This kit can be purchased to replace o-rings.
SPRAY
A10410-00 SPRA
Y HEAD
O-RING KIT
Part #
Description
79001-04
79001-06
79001-05
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
ARCHIVE
Qty
1
1
1
80
Evolver 202 Robotic Atomizers - Parts Identification
A1041
1-00 Spray Head Repair Kit
A10411-00
Available for purchase as a kit for the common
spray head parts that require replacement. This
kit contains parts for one applicator head.
Fluid Coils (Separate Sales
Parts Only)
If purchasing spare parts, they must be modified
as explained.
77620-00 V
alve Plug Kit
Valve
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 31).
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 tool, 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.
Available for purchase is a Valve Plug Kit than can
be used in place of valves and seats to convert the
applicator to a single purge applicator.
Tighten nuts into manifolds by hand until it stops.
Using a 9/16" end-wrench, tighten 1/4-1/2 turn.
A10411
SPRAY
A1041
1 SPRA
Y HEAD
REPAIR
REP
AIR KIT
Part #
Description
79151-00
7723-06
79001-28
79001-29
13076-13
RME-38
RME-32
79001-01
79001-04
79001-06
79001-05
Needle Shaft
Piston, U-Cup
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Teflon
Spring
Seal
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Qty
1
1
1
1
1
1
1
4
1
3
1
VAL
ALVE
77620-00 V
AL
VE PLUG KIT
(Optional - Use In Place Of
Valve & Seat
Seat))
Part #
79244-00
77618-00
79001-19
79001-14
Description
Plug
Plug Seat
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Qty
1
1
1
1
Figure 31:
Figure 30:
81
Fluid Coils
77620-00 Valve Plug Assembly
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
REPAIR
REP
AIR KITS
Part #
Number of Applicators
1-2
3-4
5-6
7-8
Description
Notes
A10407
Robot Mounting Plate
O-Ring Kit
1
2
3
4
Includes:
9 ea. - 79001-05 O-Ring
(Solvent Proof)
2 ea. - 79001-06 O-Ring
(Solvent Proof)
2 ea. - 79001-07 O-Ring
(Solvent Proof)
1 ea. - 79001-01 O-Ring
(Solvent Proof)
A10408
Manifold Assembly O-Ring
Kit
1
2
3
4
Includes:
2 ea. - 7554-10 O-Ring
(Solvent Resistant)
4 ea. - 7554-11 O-Ring
(Solvent Resistant)
4 ea. - 79001-05 O-Ring
(Solvent Proof)
2 ea. - 79001-06 O-Ring
(Solvent Proof)
1 ea. - 79001-04 O-Ring
(Solvent Proof)
1 ea. - 79209-00 O-Ring
(Solvent Resistant)
4 ea. - 7554-07 O-Ring
(Solvent Resistant)
1 ea. - 79001-09 O-Ring
(Solvent Proof)
1 ea. - 79001-14 O-Ring
(Solvent Proof)
A10409
Regulator Repair Kit
1
2
2
3
If gun is equipped with 79208-00
Regulator and Includes:
1 ea. - 79220-00 Diaphragm
1 ea. - 74161-00 Spring
1 ea. - 77354-00 Needle & Seat
1 ea. - 79001-08 O-Ring
(Solvent Proof)
A10410
Spray Head Mounting Seal
O-Ring Kit
1
2
3
4
Includes:
1 ea. - 79001-04 O-Ring
(Solvent Proof)
2 ea. - 79001-06 O-Ring
(Solvent Proof)
1 ea. - 79001-05 O-Ring
(Solvent Proof)
(Continued On Next Page)
AA-07-01
ARCHIVE
82
Evolver 202 Robotic Atomizers - Parts Identification
REP
AIR KITS
REPAIR
Part #
A10411
83
(C
ont.)
(Cont.)
Description
Spray Head Repair Kit
Number of Applicators
1-2 3-4 5-6 7-8
1
2
3
4
ARCHIVE
Notes
Includes:
1 ea. - 79151-00 Needle Shaft
1 ea. - 7723-06 Piston, U-Cup
1 ea. - 79001-28 O-Ring
(Solvent Proof)
1 ea. - 79001-29 O-Ring
(Solvent Proof)
3 ea. - 79001-01 O-Ring
(Solvent Proof)
1 ea. - 13076-13 O-Ring (Teflon)
1 ea. - 79001-06 O-Ring
(Solvent Proof)
1 ea. - RME-38 Spring
1 ea. - RME-32 Seal
1 ea. - 79001-01 O-Ring
(Solvent Proof)
1 ea. - 79001-04 O-Ring
(Solvent Proof)
2 ea. - 79001-06 O-Ring
(Solvent Proof)
1 ea. - 79001-05 O-Ring
(Solvent Proof)
2 ea. - 14061-09 Conductive
Foam
1 ea. - 79171-00 Contact Spring
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
SERVICE
PAR
ARTS
SER
VICE P
AR
TS
Part #
Number of Applicators
1-2
3-4
5-6
7-8
Description
79138-00
79153-65R-1
Complete Head Assembly
Air Cap
1
1
2
2
2
3
3
4
79140-02
Fluid Tip
1
2
3
4
70430-01
79142-00
79171-00
79141-00
14061-09
79144-00
79143-00
79173-00
79174-00
77367-00
Electrode
Screw
Spring, Connector
Plug, Connection
Conductive Foam
Shaft, Air Valve
Bushing, Air Valve
Block, Locking
Screw
Seat Assembly
1
2
2
2
1
1
1
2
1
1
2
2
2
2
1
1
1
2
1
1
3
4
4
4
2
2
2
4
2
2
4
4
4
4
2
2
2
4
2
2
Notes
79196-98-1, 79197-63-1
(Optional Air Caps)
01=.042,03=.070
(Optional Fluid Tips)
LUBRICANTS AND SEALERS
Part #
Description
A11545-00
Petroleum Jelly 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
AA-07-01
ARCHIVE
84
Evolver 202 Robotic Atomizers - Parts Identification
EVOLVER
SPARE
PAR
ARTS
EVOL
VER 202 RECOMMENDED SP
ARE P
AR
TS (Per Applicator)
85
Part #
Description
Qty.
77539-01
77539-02
77539-03
77539-04
76698-01
76698-02
76698-03
76698-04
77536-01
77536-03
77536-04
77536-05
77538-01
SSP-6054
77540-06
77540-04
77540-05
78449-00
70591-01
77544-01
A10841-03
A10841-02
A10841-01
A10839-06
A10839-03
A10893-07
A10840-08
A10840-09
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
79008-XX
77062-XX
A11353-XX
A11356-XX
Tubing Bundle
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, 8/32" 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, 3/8" OD X .2506" ID, Gray, Pe
Male Connector, 1/4" OD X 1/8" NPT (3)
Male Connector, 3/8" OD X 1/4" NPT
Male Connector, 1/4" OD X 1/4" NPT
Male Connector, 5/16" OD X .188" NPT
Fitting
Fitting
Male Connector, 5/32" OD X #10-32, Threaded
Tubing, 6mm OD X 4mm ID, PFA, Teflon
Paint Tubing, 8mm OD X 6mm ID, PFA, Teflon
Tubing, 10mm OD X 8mm ID, PFA, Teflon
Tubing, 10mm OD X 8mm ID, Green, Nylon
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, 4mm OD X .106" ID, Natural, Nylon
Tubing, 4mm OD X .106" ID, Black, Nylon
Tubing, 4mm OD X .106" ID, Orange, Nylon
Tubing, 4mm OD X 2.7mm ID, Orange, 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
Low Voltage Cable
Low Voltage Cable, HP 404, Extension
Cable Assembly, Low Voltage, Evolver MicroPak
Low Voltage Cable, HP 404, Extension, Evolver MicroPak
1
1
1
1
---------0-2
0-1
0-1
0-1
0-1
0-1
8-10
--------------0-1
0-1
0-1
0-1
0-1
0-1
0-1
1
1
1
1
1
1
1
ARCHIVE
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
EVOLVER
SPARE
PAR
ARTS
EVOL
VER 202 RECOMMENDED SP
ARE P
AR
TS (Per Applicator)
(Cont.)
Part #
79010-01
77524-00
EMF-203-04
EMF-202-04
EMF-203-05
EMF-202-05
79001-03
79001-04
79001-05
79001-06
79001-07
79001-08
79001-09
79034-00
77541-00
77543-00
78372-00
76566-24C
SSF-2052
78367-00
77517-00
78450-00
77531-00
A11917-XX
79173-00
79142-00
A10612-00
LSFA0027-00
79206-00
79174-00
79141-00
A10756-00
A10766-00
A10400-00
76772-00
LSCH0009-00
78949-00
77367-00
A11214-00
77508-00
77507-00
77506-00
77505-00
9334-00
70430-01
79148-00
EMF-7
Description
Manifold
Cascade Assembly, HP 404
Break-Away Screw, Machined
Front Ferrule, 1/4" OD Tubing
Back Ferrule, 1/4" OD Tubing
Front Ferrule, 3/8" OD Tubing
Back Ferrule, 3/8" OD Tubing
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
Diaphragm, RMA-202
Flat Washer, .089" ID X .149" OD, Stainless Steel
Screw, #2-56 UNC X 1/4" Long, 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
Coiled Tube, 1/4" OD X .170 ID, PFA, Conductive Materials
Coiled Tube, 1/4" OD X .125ID, PFA, Highly Conductive Materials
Coiled Tube, 1/4" OD X .125 ID, PFA, High Resistive Materials
Complete Evolver 202
Block, Locking
Screw, #8-32 X .75 Lg. SHCS, Fiberglass
Ring, Square Cut
Screw, Fillister HD, #10-32, Fiberglass
Screw, Fillister HD, #10-32 X 2 1/4" Lg.
Screw, 1/4-20 X 1 1/4" Lg., Nylon
Connection Plug
Valve Removal Tool
Valve Seat Removal Tool
Seal Carrier Tool
Retaining Ring Spanner
Dielectric Grease
Fluid Valve Assembly
Valve Seat Assembly
Support Rod
Air Bolt
Air Stud, Small
Air Stud, Medium
Air Stud, Large
Applicator Head
Spring, Valve Return
Electrode, High Flex
End Cap, Spray Head
Seal, Washer
(Continued On Next Page)
AA-07-01
Qty.
ARCHIVE
1
6
2
2
2
2
2
2
10
11
8
10
2
2
2
2
2
4-6
2
1
0-1
0-1
0-1
1
2
3
2-4
0-4
0-4
2-4
1
Accessory
Accessory
Accessory
Accessory
1
3-5
3-5
1-2
2
2
2
2
2
4
3
4
86
Evolver 202 Robotic Atomizers - Parts Identification
EVOLVER
SPARE
PAR
ARTS
EVOL
VER 202 RECOMMENDED SP
ARE P
AR
TS (Per Applicator)
(Cont.)
Part #
RME-32
79151-00
79001-01
79001-04
79001-05
79001-06
79001-07
79001-08
79001-09
79001-14
79001-16
79001-28
79001-29
79001-31
79153-65R-1
79185-48-1
EMF-195
79183-00
79140-02
79182-03
79154-00
79137-00
75777-XX
13076-13
79146-00
7723-06
79138-XX
87
Description
Qty.
Applicator Head (Cont.)
Seal
Assembly, Needle Shaft
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 Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
O-Ring, Solvent Proof
Air Cap, Pinned
4
1
8
2
2
8
4
4
6
2
6
2
2
2
0-3
Nozzle, Fluid (8) Hole
0-3
Fluid Tip, 0.055" Diameter
0-3
Retaining Ring, Tapered
Head, Machined, Robot Applicator
Applicator Covers
O-Ring, .566" OD X .426" ID, Teflon
Seal, Rear Piston
Piston, U-Cup
Complete Spray Head
ARCHIVE
2
1
Accessory
2
1
1
1
AA-07-01
Evolver 202 Robotic Atomizers - Parts Identification
AA-07-01
ARCHIVE
88
Evolver 202 Robotic Atomizers - Warranty Policies
WARRANTY POLICIES
LIMITED W
ARRANTY
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, (i.e., guns, power supplies, control units,
etc.), is one (1) year from date of purchase.
WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THIS WARRANTY.
89
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,
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
AA-07-01
AA-07-01
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
Telephone: 800/ 626-3565 Fax: 419/ 470-2040
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
A
R
C
H
IV
E
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. AH-07-01
Litho in U.S.A.
06/07
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