REM Automatic Applicator (Serv. Man. AA-87-02.3

REM Automatic Applicator (Serv. Man. AA-87-02.3
SERVICE MANUAL
AA-87-02.3
(Replaces AA-87-02.2)
May - 2008
A
R
C
H
IV
E
REM™ AUT
OMA
TIC
AUTOMA
OMATIC
APPLICA
TOR
APPLICAT
MODEL: 73499
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: €15.00
15.00 (Euro)
$20.00 (U.S.)
N O T E : This manual has been changed from AA-87-02.2 to revision AA-87-02.3. Reasons for
this change are noted under “Manual Change Summary” inside the back cover of this
manual.
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AA-87-02.3
REM Automatic Applicator - Contents
CONTENTS
PAGE
SAFETY:
1 - 4
SAFETY PRECAUTIONS........................................................................................................... 1
HAZARDS/SAFEGUARDS......................................................................................................... 2-4
ATEX
5-6
EUROPEAN ATEX DIRECTIVE................................................................................................. 5
EUROPEAN ATEX LABELS....................................................................................................... 6
INTRODUCTION:
7-8
GENERAL DESCRIPTION......................................................................................................... 7
SPECIFICATIONS....................................................................................................................... 7
REM PROCESS.......................................................................................................................... 8
9-10
INSTALLATION:
REM AUTOMATIC APPLICATOR INSTALLATION.................................................................. 9
OPERATION:
11-14
SAFE OPERATION.....................................................................................................................
THE RIGHT TECHNIQUE..........................................................................................................
PREPARTION.............................................................................................................................
NOZZLE SELECTION GUIDE....................................................................................................
11
11-12
12-13
14
MAINTENANCE:
13-28
SAFE MAINTENANCE................................................................................................................ 13-14
ROUTINE MAINTENANCE SCHEDULE................................................................................... 14
PROCEDURES........................................................................................................................... 15-17
TROUBLESHOOTING GUIDE................................................................................................... 18-19
SERVICE..................................................................................................................................... 20
SERVICE PROCEDURES.......................................................................................................... 20-26
TUBE AND LINE INSTALLATION / REPLACEMENT............................................................... 27-28
PARTS IDENTIFICATION:
29-32
REM AUTOMATIC APPLICATOR EXPLODED VIEW /
PARTS LIST................................................................................................................................. 29-31
72453-00 REPAIR KIT................................................................................................................. 31
CABLE ASSEMBLIES................................................................................................................. 32
PLUG ASSEMBLIES................................................................................................................... 32
33
WARRANTY POLICIES:
LIMITED WARRANTY................................................................................................................. 33
AA-87-02.3
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TREM Automatic Applicator - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
ITW Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your ITW Ransburg products. This
manual contains information that is important for
you to know and understand. This information
relates to USER SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help you
recognize this information, we use the following
symbols. Please pay particular attention to these
sections.
A W
ARNING! states information to alert you
WARNING!
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
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 ITW 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, 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 Ransburg
system, contact your local ITW Ransburg
representative or ITW Ransburg.
1
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AA-87-02.3
REM Automatic Applicator - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Spray Area
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Fire Hazard
Improper or inadequate operation
and maintenance procedures will Spray areas must be kept clean to prevent the
accumulation of combustible residues.
cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation. Frequent power
supply shutdown indicates a
problem in the system requiring
correction.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.
Those used for general cleaning must have flash
points above 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, and local codes. In
addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.
Electrostatic arcing must be prevented.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipment modifications may cause fire or injury.
If used, the key switch bypass is intended for use
only during set-up operations. Production should
never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne
installations to spray solvent based materials.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC, and
OSHA requirements.
AA-87-02.3
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2
REM Automatic Applicator - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
General Use and
Maintenance
Improper operation or maintenance Personnel must be given training in accordance with
may create a hazard.
the requirements of NFPA-33.
Personnel must be properly trained Instructions and safety precautions must be read
in the use of this equipment.
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33, and your insurance company
requirements.
Electrical
Equipment
High voltage equipment is utilized.
Arcing in areas of
flammable or combustible
materials may occur. Personnel
are ex-posed to high voltage during
operation and maintenance.
The power supply, optional remote control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas. Refer to NFPA-33.
Turn the power supply OFF before working on the
equipment.
Protection against inadvertent
arcing that may cause a fire or Test only in areas free of flammable or combustible
explosion is lost if safety circuits material.
are disabled during operation.
Testing may require high voltage to be on, but only
Frequent power supply shutdown as instructed.
indicates a problem in the sys-tem
Production should never be done with the safety
which requires correction.
circuits disabled.
An electrical arc can ignite coating materials and cause a fire or Before turning the high voltage on, make sure no
explosion.
objects are within the sparking distance.
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.
3
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AA-87-02.3
REM Automatic Applicator - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Explosion
Hazard /
Incompatible
Materials
Spray Area /
High Voltage
Equipment
Halogenated
hydrocarbon
solvents for example: methylene
chloride and 1,1,1,-Trichloroethane
are not chemically compatible with
the aluminum that might be used
in many system components.
The chemical reaction caused by
these solvents reacting with
aluminum can become violent and
lead to an equipment explosion.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum
equipment during spraying, flushing, or cleaning.
Read the label or data sheet for the material you
intend to spray. If in doubt as to whether or not a
coating or cleaning material is compatible, contact
your material supplier. Any other type of solvent
may be used with aluminum equipment.
This is a high voltage device that
can produce electrical arcs
capable of igniting coating
materials.
Parts being sprayed must be supported on
conveyors or hangers and be grounded. The
resistance between the part and ground must not
exceed 1 megohm. (Reference NFPA-33.)
A safe distance must be maintained between the
parts being coated and the atomizer bell. A distance
of at least 1 inch for each 10 kV of power supply
output voltage is required at all times.
Parts must be supported so that they will not swing
and reduce the clearance specified above.
All electrically conductive objects in the spray area,
with the exception of those objects required by the
process to be at high voltage, must be grounded.
Unless specifically approved for use in hazardous
locations, the power supply and other electrical
equipment must not be used in Class I, Division 1
or 2 locations.
Personnel Safety Skin puncturing by sharp elec- Take precautions to see that flesh is not punctured
trode.
AA-87-02.3
by sharp electrode.
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4
REM Automatic Applicator - Atex
EUROPEAN A
TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
ATEX
The following instructions apply to equipment
covered by certificate number Sira
08ATEX5040X:
1. The equipment may be used with flammable
gases and vapors with apparatus groups II and
with temperature class T6.
2. The equipment is only certified for use in
ambient temperatures in the range +12.8°C to
+40°C and should not be used outside this range.
3. Installation shall be carried out by suitably
trained personnel in accordance with the
applicable code of practice e.g. EN 6007914:1997.
4. Inspection and maintenance of this equipment
shall be carried out by suitably trained personnel
in accordance with the applicable code of practice
e.g. EN 60079-17.
5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and
adjustment of the equipment shall be fitted by
suitably trained personnel in accordance with the
manufacturer's documentation.
Refer to the "Table of Contents" of this service
manual.
a.
b.
c.
d.
Installation
Operation
Maintenance
Parts Identification
7. Components to be incorporated into or used as
replacement parts of the equipment shall be fitted
by suitably trained personnel in accordance with
the manufacturer's documentation.
5
8. The certification of this equipment relies upon
the following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the
responsibility of the user to take suitable
precautions that prevent it from being adversely
affected, thus ensuring that the type of protection
provided by the equipment is not compromised.
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
Suitable precautions: e.g. regular checks as part
of routine inspections or establishing from the
material's data sheets that it is resistant to specific
chemicals.
Refer to "Specifications" in the "Introduction"
section:
a. All fluid passages contain stainless steel
or nylon fittings.
b. High voltage cascade is encapsulated with
a solvent resistant epoxy.
9. A recapitulation of the certification marking is
detailed in the "Atex" section, on the next page,
drawing numbers: 72354, 72562, and 76859.
10. The characteristics of the equipment shall be
detailed e.g. electrical, pressure, and voltage
parameters.
The manufacturer should note that, on being
put into service, the equipment must be
accompanied by a translation of the
instructions in the language or languages
of the country in which the equipment is to
be used and by the instructions in the
original language.
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AA-87-02.3
REM Automatic Applicator - Atex
REM Automatic Applicator
73499 A
TEX Product Marking
ATEX
Definitions
Label 72354
Ex Certificate Number: Sira 08 ATEX 5040X
Sira = Notified Body performing EC-type
examination
08 = Year of certification
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
040 = Document serial number
X = Special conditions for safe use apply
Label 72562
Special conditions for safe use: The REM
Automatic Atomizer 73499 shall only be used with
associated 76580-XX Control Unit.
Label 76859
Product Marking
II 2 G
Ex = Specific marking of explosive protection
II = Equipment Group hazardous area characteristics
2 = Equipment Category
G = Type of explosive atmosphere (gases, vapors,
or mists)
EEx 0.24mJ = The REM Automatic Applicator
73499 is suitable for use in automatic spraying
installations complying with EN 50050 as they are
a Type A class with a discharge energy limit of
0.24mJ.
AA-87-02.3
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6
REM Automatic Applicator - Introduction
INTRODUCTION
GENERAL DESCRIPTION
SPECIFICA
TIONS
SPECIFICATIONS
The REM™ Automatic Applicator applies an
85 kV DC charge to the coating materials at the
point of atomization. This electrostatic charge
allows a more efficient, uniform application of
coating material to the front, edges, sides, and
back of products, making it highly suitable for
applying coatings to a variety of surface configurations, large targets, small parts, tubular wares,
concave and recessed parts, etc. Because it is a
grounded fluid system, it is highly suitable for
applying a wide range of solvent reduced coatings
such as enamels, lacquers, epoxies, etc.
Environmental / Physical
One of the many features of the REM System is
that the electrical discharge which is available
from the resistive charging electrode is limited to
the optimum level of safety and efficiency.
Paint consumption savings of 25% to 50% over
conventional air spray are possible with the ITW
Ransburg REM Applicator. Curved and recessed
surfaces may be uniformly finished in fewer passes
because combined air and electrostatic forces
literally follow the shape of the work surface.
Bounce losses from work are reduced by the
proper use of electrostatic attraction.
The REM Automatic Applicator System includes
the automatic applicator (with various nozzle selections), low voltage cable, air and fluid hoses
and a control unit with an air and coating material
filter assemblies.
7
Hose and Cable
Lengths:
25 ft. (Optional: 36, 50,
75, and 100 ft.)
Assembly:
Multiple Fluid Nozzles
(See “Nozzle Selection
Guide” in the “Operation”
section.)
Weight:
3.2 lbs.
Length:
12-inches
Cable Length:
120 ft. maximum
Electrical Requirements
Output V
oltage:
Voltage:
85 kV (maximum)
Output Current:
120 Microamperes
(maximum)
Operating
Pressure:
Fluid:
Air:
Consumption:
1000 psi
0-100 psi
.5 CFM @ 30 psi
Fluid Flow Rate:
Variable to 1,000 cc/min.
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AA-87-02.3
REM Automatic Applicator - Introduction
NOTES
REM PROCESS
This is an air assisted method for electrostatically
applying coatings to objects. The REM system
applies a high voltage DC charge to the applicator
nozzle electrode, creating an electrostatic field
between the atomizer and the target object. The
target is electrically grounded through its support
which may be either stationary or moving.
A regulated pressure fluid system delivers coating
material to the atomizer. There the coating material
is atomized by passing through an orifice under
pressure, the resulting spray mist under the
influence of the electrostatic field, becomes
electrically charged. The air supply to the
applicator is adjustable at the rear of the applicator
and aids in shaping the coating material into a
desired pattern. The charged particles are
attracted to and deposited on the target object.
The forces between the charged particles and the
grounded target are sufficient to turn most normal
overspay around and deposit it on the back
surface of the target. Therefore, most of the spray
is deposited.
A control unit provides either manual or automatic
operation of the equipment. Controls normally
include, but are not limited to atomizing, triggering,
and shaping air, fan, and conveyor interlocks and
a protective current overload device.
AA-87-02.3
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8
REM Automatic Applicator - Installation
INST
ALLA
TION
INSTALLA
ALLATION
REM AUT
OMA
TIC
AUTOMA
OMATIC
APPLICA
TOR
APPLICAT
INST
ALLA
TION
INSTALLA
ALLATION
! WARNING
> Install and route the hoses and cable so they
are NOT exposed to temperature in excess of
120° F and so that all hose and cable bends
are NOT LESS than a 6-inch (15cm) radius.
Failure to comply with these parameters could
cause equipment malfunctions that might
create HAZARDOUS CONDITIONS!
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 ITW Ransburg representative or made from
the ITW Ransburg installion drawings provided
for your particular installation.
> The control unit MUST be located outside of
Safe Installation
the spray area. Install units in accordance with
the requirements of local regulations.
! WARNING
• Ground the spray booth, the paint supply, and
the conveyor or work support.
• Ground all solvent and waste safety containers.
• Ground all work holders and hooks and keep
them free of paint.
• Ground the target object to a structural ground
and not back to the applicator system. See that
all target objects have a resistance to ground of
one megohm or LESS.
• See that all elements of the coating system are
correctly grounded, connected, and located.
• Position all ancillary non-approved electrical
apparatus, including but not limited to: high
voltage power supplies, fluid pumps, air compressors, outside of the hazardous location.
(See the appropriate NFPA and/or OSHA
guidelines for your application and equipment.)
Low V
oltage Cable
Voltage
Connect the low voltage cable to the control unit
low voltage socket. Gently hand tighten the cable
retaining nut. The control unit MUST be
connected through conduit with an explosion-proof
switch on or near the spray booth where it will be
convenient to the operator.
NOTE
Refer to the current “Low Voltage
Control Unit” service manual for proper
installation.
>
• Provide appropriate fire extinguishing equipment.
• Provide conductive flooring in all spray areas.
9
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AA-87-02.3
REM Automatic Applicator - Installation
!
NOTES
CAUTION
> An air filter MUST be installed to prevent
contamination of the coating material by the
shaping air.
Filters
Install an air filter assembly on the factory air
regulator. Screw the fitting into the filter inlet. The
filter MUST be installed with the arrow pointing in
the direction of flow. (See the appropriate “Control
Unit” service manual for installation details.
Line Hose - Fluid
ITW Ransburg supplies a standard 36-foot hose.
Optional hose lengths of 50, 75, and 100-feet are
Y
available. ITW Ransburg offers this hose ONL
ONLY
as a complete assembly to ensure that the hose
is properly grounded at each end fitting.
AA-87-02.3
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10
REM Automatic Applicator - Operation
OPERA
TION
OPERATION
These Operating Instructions indicate the general
operating parameters for this product in a normal
working relationship with other ITW Ransburg
system components in typical use. Each user
application is unique and operation should be
initiated under the guidance of an ITW Ransburg
representative and/or be based on carefully
conducted tests and on careful observation of the
initial production characteristics.
SAFE OPERA
TION
OPERATION
• In NO event should any flammable solvent or
solvent reduced coating material be used in an
electrosatic, waterborne applicator system!
Such use will create an ignition hazard!
THE RIGHT TECHNIQUE
• Ground operators and all other persons in spray
areas by requiring that they wear conductive
soled shoes or grounding straps.
• Have exhaust fans operating while spraying.
• See that no more than 1-gallon of solvent per
safety container per operator is inside of the
hazard location.
• If ANY sumptom of improper operation occurs,
suspend use of the unit until the problem has
been diagnosed and corrected. See the appropriate “Troubleshooting Guide” or contact your
ITW Ransburg representative.
• Ground MUST be maintained during the addition
of fluid to any supply container! Whenever
transfering flammable fluid from one container
to another, both containers MUST be properly
connected to a proven ground first and then to
each other. Personnel executing such a transfer MUST also be grounded.
• A chemial reaction, resulting in the possibility of
a pressure EXPLOSION, may occur if 1.1,1Trichloroethane, Methylene Chloride other
Halogenated Hydrocarbon Solvents are used
in pressurizable fluid systems having aluminum
or galvanized wetted parts. Such an explosion
could cause death, serious bodily injury and/or
substantial property damage. Consult your fluid
supplier to determine the chemical content of
11
your solvents. (See ITW Ransburg Safety
Literature: HHC Explosion Hazard Danger Sign,
HHC Explosion Hazard Warning, and HHC
Explosion Hazard Bulletin.)
Following are some basic electrostatic spray
techniques. Depending on the spray target, it may
be necessary to adjust the technique.
Fan Width Determination
The size of the object being coated is the
determining factor in adjusting the fan pattern. The
larger the object, the larger the required fan pattern.
Fan width can range from approximately 6-inches
(minimum) to approximately 14-inches
(maximum). This is accomplished by nozzle
selection. Air control adjustment is used to
remove “tails” from the fan pattern.
NOTE
> The degree of atomization is dependent
on the viscosity of the paint formulation,
the applied fluid pressure, and nozzle
selection. Actual fan size may vary from
stated nozzle size depending on paint
pressure and paint atomizing characteristics.
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AA-87-02.3
REM Automatic Applicator - Operation
Assist Air Adjustment
Overlap
Assist air can be adjusted either locally (at the
applicator) or remotely (air regulator or analog
function).
For the best “hiding” and uniformity of film
thickness, the stroke overlap should be
approximately 50%. There should be some
Overlap at edges of the part to increase edge
coverage. overlap requirements may vary widely
with different paint formulations and different paint
formulations and different compositions of objects
being coated. Individual spray coating operational
experience should provide the guide lines for
efficiency in this instance.
NOTE
> Use only enough assist air to remove
the “tails”. Excessive assist air can decrease equipment efficiency.
T riggering
! WARNING
> Clockwise adjust will decrease assist air.
Locally
Assist air is adjusted by turning the control knob
[57] on right side of applicator (from rear of
applicator). A counter-clockwise adjustment will
increase assist air and reduce “tails” and generally
increase pattern.
Applicator triggering (ON-OFF) depends largely
on the desired results (the amount of wrap-around
required, edge coating, etc.). If the front and back
of the object are being coated, proper applicator
technique can edge coat in some instances without
making a specific pass for that purpose.
Triggering the applicator before the target is
directly in front of the applicator may cause heavy
edge build-up on the leading edge of the target
due to the electrostatic attraction.
PREP
ARA
TION
PREPARA
ARATION
Remote
Paint
NOTE
> With remote assist air the control knob
is replaced with a 1/4-inch NPT fitting.
Assist air is controlled remotely by the use of an
air regulator or a programmable controlled analog
function.
Applicator to T
arget Distance
Target
The distance between the applicator and the target
influences the appearance of the final finish coating
of the object. If the applicator is held too close
(under 4-inches), runs and sags with excessive
“bounce-back” may occur. If the applicator is held
too far from the object, the electrostatic attraction
is decreased. Normally, the best spacing between
applicator and target is in the 6 to 12-inch range.
AA-87-02.3
A selection of the proper paint mixture is essential
to electrostatic operation. Paint test equipment
may be obtained through your ITW Ransburg
representative. Consult the following ITW
Ransburg Literature: Technical Supplement for
All Products. For further paint formulation and
testing procedures, consult your ITW Ransburg
representative and/or paint supplier.
Fluid Nozzle
Because of the REM applicators, fluid nozzles
precision is paramount to prior functions. ITW
Ransburg makes every effort to assure that all
production of this part will meet the critical design
standards necessary for all applications.
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12
REM Automatic Applicator - Operation
The selection of the best nozzle to apply a give
coating to a specific article with maximum
efficiency is not an exact science. Testing is
usually necessary and wide experience with
many types of coating applications helps. Your
ITW Ransburg representative uses such
experience and actual laboratory testing when
recommending a nozzle for your application
needs.
Howevery, if parts, paints, or conveyor speeds
are changed, a different nozzle may be required
for best results. The following discussion and
guide will assist the user in making his own nozzle
selection whenever it becomes necessary.
Selection should always be verified by actual tests
to determine optimum efficiencies.
13
Refer to the “Nozzle Selection Guide” in this
section for the choice of fan width and spray
characteristics appropriate to the size and type
of target. The maximum nozzle flow capacity
depends on: the orrifice size, the fluid pressure,
the paint viscosity, and the spraying temperature.
Always remember, for maximum paint economy,
any nozzle selected should always be operated
at the lowest fluid pressure which will give good
atomization and the required flow rate.
!
CAUTION
> ITW Ransburg recommends the use of a
fluid filter to reduce nozzle clogging.
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AA-87-02.3
REM Automatic Applicator - Operation
NOZZLE SELECTION GUIDE
Production Requirements
Production Target
Size
Level
Low
Low
Low
Low
Medium
Medium
Medium
Medium
Medium
Medium
Medium
Medium
Medium
Medium
Medium
High
High
High
Small
Large
Large
Large
Small
Small
Small
Large
Large
Large
Large
Large
Large
Large
Large
Small
Large
Large
Coverage
In Sq. Ft.
Per Minute
705 to 9.5
9.5 to 15.5
9.5 to 15.5
9.5 to 15.5
11.5 to 16.5
11.5 to 16.5
11.5 to 16.5
11.5 to 16.5
11.5 to 16.5
14.5 to 20.5
14.5 to 20.5
14.5 to 20.5
14.5 to 20.5
14.5 to 20.5
14.5 to 20.5
15.5 to 21.5
15.5 to 21.5
19.5 to 21+
Operating Parameters
Pattern
Width
at 10-inch
6-inch
6-inch
8-inch
10-inch
6-inch
8-inch
10-inch
12-inch
14-inch
10-inch
14-inch
12-inch
10-inch
12-inch
14-inch
10-inch
14-inch
10-inch
Nozzle Identification
Nozzle
Orifice
Size
700 psi
In Inches
Paint Delivery In Fluid Ounces
Per Minute, Etc.
300 psi
500 psi
(21 bar)
(34.5 bar)
(48 bar)
3.9
5.2
5.2
5.2
7.8
7.8
7.8
7.8
7.8
N/R
N/R
N/R
N/R
N/R
N/R
N/R
N/R
N/R
5.0
6.8
6.8
6.8
10.1
10.1
10.1
10.1
10.1
13.5
13.5
13.5
16.9
16.9
16.9
20.3
20.3
27.0
6.0
8.1
8.1
8.1
13.0
13.0
13.0
13.0
13.0
17.3
17.3
17.3
21.7
21.7
21.7
26.0
26.0
35.0
0.009
0.011
0.011
0.011
0.013
0.013
0.013
0.013
0.013
0.015
0.015
0.015
0.017
0.017
0.017
0.018
0.018
0.021
REM Fluid
Nozzle
Part #
71260-1515
71260-1520
71260-2020
71260-2520
71260-1530
71260-2030
71260-2530
71260-3030
71260-3530
71260-2540
71260-3540
71260-3040
71260-2550
71260-3050
71260-3550
71260-2560
71260-3560
71260-2580
* The first two digits of the nozzle dash number indicate the spray pattern width in centimeters at a distance of
10-inches from the target. The second two digits indicate the flow rate in cc/min., divided by 10, at a pressure of
500 psi. For example: 41260-2540 has a 25cm fan pattern width and delivery of 400 cc/min.
N/R = Not Recommended
To convert fluid ounces to cc’s, multiply by 2959.
Lower viscosity (lower solids, higher temperature) paints will have higher flow rates. Higher viscosity paints will
have lower flow rates.
AA-87-02.3
ARCHIVE
14
REM Automatic Applicator - 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
maintenane and safety information should be made
available to each operator.
Normal fire protection measures are necessary,
including proper storage of paints and solvents
and the proper disposal of waste. Ready access
to appropriate fire extinguishing equipment is
required. For details, consult the appropriate ITW
Ransburg and NFPA safety information, your local
fire codes, local painting equipment standards,
and the OSHA Act of 1970, as well as your
insurance carrier’s recommendations.
You don’t have to maintain all of your equipment,
only those items that you want to continue to
operate.
SAFE MAINTENANCE
• The user MUST read and be familiar with the
Safety Section in this manual and the ITW
Ransburg safety literature therein identified.
• See that good housekeeping is maintained at
all times. Good housekeeping is always
necessary to ensure quality finishes, eliminate
rejects, and reduce service requirements.
• Turn the control unit power off prior to cleaning
or working on the equipment.
• Using applicators as solvent spray nozzles to
clean other equipment or products, even without
high voltage present, creates a fire or explosion
hazard if ground integrity is broken. NEVER
use an electrostatic applicator to spray solvent
for any reason except to flush the applicator and
ONL
Y WHEN THE HIGH VOL
TAGE IS
ONLY
VOLT
OFF!
13
Always use the minimum amount of solvent to
flush an applicator. Always flush into an
approved, grounded container and be sure that
both the applicator and the operator are securely
grounded.
• Never immerse any part of, or all of an
assembled applicator in any liquid.
• Periodically strip all workholders to maintain
proper grounding of parts.
• Establish adequate cleaning and maintenance
schedules based on observation of the initial
production characteristics.
• Employ fire protection measures, including
proper storage of paints, solvents, and waste.
• If compressed air is used in cleaning,
REMEMBER THA
T HIGH PRESSURE
THAT
AIR CAN BE DANGEROUS AND
SHOULD NEVER BE USED AGAINST
THE BODY
BODY.. It can blind, deafen, and may even
penetrate the skin. If used for cleaning equipment, the user should wear safety glasses.
• The integrity of the system ground MUST be
inspected regularly and maintained. (See ITW
Ransburg Literature Equipment Grounding.)
• There is an INJECTION HAZARD with ALL
hydraulically fed applicators, such as the REH
and REM applicators. They will cause serious
injury if the fluid penetrates the skin.
PAR
ART
DO NOT PLACE ANY P
AR
T OF THE
PA
SPRAY!
BODY IN THE P
ATH OF THE SPRA
Y!
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Maintenance
APPLICAT
AT
DO NOT POINT THE APPLICA
T OR A
T
ANY PERSON!
Shut-Down (or at shift end)
AT
APPLICAT
NEVER LOOK A
T THE APPLICA
T OR
FROM THE NOZZLE END!
2. Turn the assist air OFF.
1. Turn the control unit power OFF.
3. Turn the paint supply OFF.
TREA
T THIS APPLICA
T OR AS YOU
TREAT
APPLICAT
WOULD A LOADED WEAPON!
This system is capable of producing fluid
pressure up to 1000 psi. THIS IS ENOUGH
TO PRODUCE A LETHAL INJECTION!
ROUTINE MAINTENANCE
SCHEDULE
Follow these maintenance steps to extend the life
of the applicator and ensure efficient operation:
Times
Serveral T
imes Daily
1. Turn the control unit power OFF.
2. Inspect the fluid nozzle and electrode wire for
paint accumulation. Clean as frequently as
necessary. (See “Procedures” in this section.)
4. Wipe the applicator, cable, and hoses with a
rag and a suitable, clean solvent.
5. Flush the lines and allow the solvent to remain
in the lines. (See “Procedures” in this section.)
NOTE
> If the shut-down time is to be short, the
lines may not require flushing, depending
on the coating material being used. If the
solids in the material settle slowly, the
lines will not need to be flushed as soon
after shut-down as with fast setting solids. The paint being used and the length
of time that the lines will be shut-down will
determine the need for flushing. Metallic
paint and primer will require flushing sooner
than some other kinds.
Daily (or at shift start)
1. Turn the control unit power ON. Its green pilot
should light.
2. Run a current output test. (See “Procedures”
in this section.)
3. Turn the control unit power OFF and:
• Verify that ALL solvent safety containers are
grounded.
• Check within 20-feet of the point of operation
(of the applicator) and remove or ground ALL
loose or ungrounded objects.
• Inspect workholders for accumulated
coating materials (and remove such
accumulations if present).
• Check that nozzle assembly is clean and
undamaged.
• Straighten the applicator electrode if
necessary.
• Clean the fluid filter, if necessary.
AA-87-02.3
!
CAUTION
> If the coating material is fast settling and
if the lines are not flushed soon enough, the
applicator’s fluid passages as well as the
lines may become clogged and cause excessive down-time and/or service and repair.
Weekly
• Check the entire system for damage, leaks,
and paint accumulation.
• Clean the atomizer assembly.
ARCHIVE
14
REM Automatic Applicator - Maintenance
Transformer Output T
est
Test
PROCEDURES
Use Transformer Test Assembly 74195-00.
Current Output T
est
Test
1. Turn the paint supply OFF. Flush applicator
with non-conductive solvent.
NOTE
> This test should be performed before
the “Gun Output Test”.
2. Turn the control unit power ON.
3. Slowly approach the applicator electrode with
ground hook or wire.
4. Monitor current meter on control unit. Current
should rise as ground approaches. At
approximately 100 microamps overload circuit
should “trip” shutting “off” high voltge. Overload
indicator should come on.
1. Turn high voltage “OFF”. Turn power “OFF” to
control unit.
2. Remove the barrel assembly [18] from the body
[25] (see “Service - Barrel/Cascade Disassembly”
in this section).
3. Insert the Transformer Test Assembly into
chamber [100].
NOTE
High voltage overload “trip” point is
adjustable. (See current “Control Unit”
service manual.)
>
If the reading is outside of the acceptable range,
DO NOT use the applicator until the problem has
been corrected. (See “Troubleshooting Guide” in
the “Maintenance” section.)
4. Turn power “ON” to Control Unit, and trigger
high voltage to the applicator. Adjust kV output to
80.
5. Monitor the meter on the Transformer Test
Assembly. At 80 kV the meter should read .8
(±10%) milliamps.
6. Replace transformer if proper readings are not
obtained. (See “Transformer Assembly
Replacement” in this section.)
Gun Output T
est (Cascade)
Test
! WARNING
> DO NOT USE A FAULTY APPLICATOR!
Use High Voltage Output Test Assembly 7415002.
NOTE
Control Panel
See “Automatic Applicator Control Unit” service
manual” for proper testing and procedures.
Testing should be performed on the control unit to
ensure proper performance prior to testing the
cascade and/or transformer.
Test Transformer before performing
this test. Using Transformer Test Assembly 74195-00.
>
1. Turn high voltage “OFF”. Turn power “OFF” to
Control Unit.
2. Remove the nozzle nut [1], air nozzle [2], fluid
nozzle [3], and seal [4].
15
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Maintenance
3. Thread High Voltage Test Assembly to barrel
of the applicator.
4. Attach ground clip to a ground source.
! WARNING
NOTE
It may be necessary to soak some
parts in solvent and a soft bristle brush to
clean. Never use metal tools or wires or
metal bristle brushes to clean or unclog
nozzle assemblies.
>
> Injury to personnel and damage to equipment
is probable if the ground clip is NOT ATTACHED. Voltage is present at the clip. This step
MUST be accomplished before voltage is
applied.
5. Turn power “ON” at Control Unit and trigger
high voltage to the applicator. Adjust kV output of
80.
! WARNING
> If the nozzle is completely clogged, triggering
the applicator will not release the pressure.
Cover the end of the applicator with a heavy
rag and loosen the retaining cap slowly into a
catch container.
6. Monitor the meter on the High Voltage Output
Test assembly. At 80 kV the meter should read
35 (±10%) microamps.
> Do NOT soak or submerge the applicator.
7. Replace cascade/barrel if proper readings are
not obtained.
Soaking may cause permanent damage to the
applicator and result in unsafe operating conditions.
8. If proper readings are obtained, the problem is
not in the applicator. Check paint, solvent, ground,
etc.
Atomizer Assembly Cleaning
Equipment needed:
• Appropriate solvent
• Solvent safety container (grounded)
• Small soft-bristled brush
1. Unscrew nozzle nut [1] from barrel [18].
2. Remove air [2] and fluid [3] nozzles.
3. Clean all parts in a compatible solvent and
examine for wear and damage. To clear orifices,
blow compressed air through the fluid nozzle
assembly in the opposite direction from the fluid
flow. Soaking in solvent and/or brushing may also
be necessary to clean the orifice. Replace as
necessary.
! WARNING
4. Reassemble the parts in reverse order of
disassembly. When reassembling the seal, be
sure that the 45° chamfered portion is properly
seated in the nozzle assembly before reattaching
the nozzle.
Flushing Fluid Hose and
Applicator
The fluid system should be thoroughly cleaned
by flushing with a clean compatible solvent
whenever a color change is made, or when the
applicator will not be used for any extended period,
for example, a weekend or longer. Proceed as
follows:
1. Turn control unit OFF.
2. Turn off pump air supply. trigger applicator until
fluid flow ceases. Turn off shaping air supply.
3. Remove nozzle nut [1], air [2], and fluid nozzles
[3].
AA-87-02.3
ARCHIVE
16
REM Automatic Applicator - Maintenance
4. Remove pump inlet from paint supply. Set
pump air pressure at about 20 psi. Direct
applicator into grounded paint container until all
paint is forced from the applicator and hose.
NOTES
5. Place pump inlet in a container of suitable
solvent (1 gallon or enough to fill the system).
Pump solvent through the hose and applicator until
solvent runs clean from the applicator. Then
adjust air regulator to increase the pump speed.
Pump solvent at high speed for several minutes
into the grounded solvent container.
6. For a color change, remove pump inlet from
solvent container and pump system dry. If the
new paint uses a different, non-compatible
solvent, it is advisable to reflush with the new
solvent. Insert pump inlet in new paint. Start
pump. Replace air and fluid nozzles, seal, and
nut.
7. When the REM applicator is not to be reused
immediately, allow clean solvent to remain in the
fluid system. This will prevent any residual paint
from drying in the system. When the solvent is to
be left in the fluid system for some time, fill
applicator and lines with solvent as indicated
previously. Shut off pump petcock and trigger
applicator to release pressure in system.
! WARNING
> DO NOT SOAK APPLICATOR. This
may cause PERMANENT DAMAGE to
the applicator and result in UNSAFE
OPERATING CONDITIONS.
17
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Maintenance
TROUBLESHOOTING GUIDE
General Problem
Poor Atomization
and Distribution
Poor Wrap-Around
Paint Wraps Back
On Applicator and
Mounting
(Machine)
No Paint Delivery
AA-87-02.3
Possible Causes
Corrective Action
1. Partially clogged nozzle
1. Clean out.
2. Low fluid pressure
2. Increase pump air pressure.
3. Viscosity too high
3. Try nozzle with narrower fan or smaller orifice.
4. Improper nozzle
4. Try nozzle with narrower fan or smaller orifice.
5. Badly worn nozzle
5. Replace.
6. High voltage electrode bent
6. Straighten electrode or replace nozzle assembly.
7. Low shaping air pressure
7. Readjust shaping air pressure.
1. Poor atomization
1. See above.
2. Excessive exhaust velocity
2. Reduce (within code limits).
3. Excessive fluid pressure
3. Reduce air pressure to pump.
4. Applicator too close to target
4. Move applicator further back.
5. Paint too conductive
5. Consult ITW Ransburg for technical assistance.
6. Poor target ground
6. Check ground integrity from target through support to ground.
1. Poor ground on parts
1. Check that parts are fully grounded, strip
workholders.
2. Applicator too far from parts
2. Move applicator closer.
3. Booth exhaust insufficient or
improperly rounted
3. Increase or adjust direction. Change booth filter.
4. Improper spray technique
4. Keep applicator directed at work.
1. Clogged nozzle
1. Blow out nozzle.
2. Clogged hose or filters
2. Clean.
3. No pressure at paint pump
3. If pump air supply OK, consult pump manual.
ARCHIVE
18
REM Automatic Applicator - Maintenance
Troubleshooting Guide (Cont.)
General Problem
Possible Causes
Corrective Action
Excessive
Surging
1. Restriction in pump air line
1. Remove restriction.
2. Insufficient pump capacity
2. Secure larger pump or reduce output.
3. Clogged paint filter
3. Service or replace.
4. Low air volume capacity
4. Check factory air capacity.
5. Nozzle too large
5. Replace with correct nozzle.
6. Discharge lines too short to
dampen surging
6. Install surge suppressor.
1. Paint allowed to dry in
nozzle or line
1. Flush lines with solvent after each use.
2. Paint applicator filter too
coarse or damaged
2. Replace or change to finer screen paint filter.
3. Paint pigments too coarse
3. Pre-filter paint and/or use larger nozzle orifice.
1. Packing too tight
1. Back off on packing nut.
2. Improper trigger adjustment
2. Readjust.
3. Defective or dirty valve seat
3. Flush out or replace as necessary.
Paint leaks
Arount the Nozzle
Cap
1. Loose nut
1. Clean paint from needle shat and tighten nut.
2. Seals worn
2. Replace seals.
Paint Leaks at
Applicator Fluid
Inlet
1. Thread leaks at high pressure
1. Tighten nut.
Persistent Nozzle
Clogging
Paint Leaks
through Center of
Nozzle (Failure to
Shut Off)
Orange Peel or
Rough Finish
1. Evaporation rate too fast
2. Poor atomization
Paint Runs or has
Poor Hiding
Qualities
19
1. Use slower evaporating solvent.
2. See “Poor Atomization”.
3. Viscosity too high
3. Add solvent or heat.
1. Low solids paint
1. Use less solvent.
2. Low viscosity
2. Use less solvent.
3. Excessive delivery
3. Use smaller nozzle, wider fan angle, lower
pump pressure.
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Maintenance
!
SERVICE
CAUTION
> ALWAYS remove the applicator from
the work site for service or repair.
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 differences.
SERVICE PROCEDURES
!
CAUTION
> DO NOT USE any silicone lubrication
in this system.
Equipment Required:
• Gun Spanner (3 in 1 Nozzle Wrench) * for Barrel
Nut [19] and Packing Nut [16]
• Nozzle Tool * for Fluid Nozzle [3]
• 3/16” Allen Wrench for Hose Fittings
Al repairs should be made on a clean, flat surface.
If a vise is used to hold parts during service or
repair, DO NOT clamp onto plastic parts and
always pad the vise jaws!
Apply a heavy coat of 59972-00 Dielectric grease
to the following parts when assembling:
• Needle Shaft Assembly [7 - 15] External
• Tube, Packing Internal [12]
• Open End Wrenches: 9mm (2 Required),
15/16”, 7/8”, 11/16”, 9/16”, 7/16”, 3/4”, 3/8”
(2 Required), and 1/4”
• Screwdriver (broad)
• Dielectric Grease *
• Sealant *
• Plastic or Wood Dowel Rod, 5/16-inch diameter
• Transformer Assembly [44] connection to Body
Assembly [25]
• Externally to contact surface of Low Voltage
Cable and Transformer
Apply 7969-00 Sealant to the following parts when
assembling:
• External to contact surface of Piston/Valve and
Body Assembly [25]
• 3/8” Nut Driver
• Hook Tool (Dental Pick)
• T-Handle Tool (for Valve Body Service) [33]
• 3/32” Allen Wrench for Set Screws
* See “Parts Identification” section for part number.
• External to threads of Piston Housing [39]
• Set Screws [43]
AA-87-02.3
ARCHIVE
20
REM Automatic Applicator - Maintenance
To Remove the Applicator from
the Work Site
Nozzle / Electrode / Seal / Seat
Replacement
1. Turn the control unit power OFF.
2. Turn OFF pump air supply.
!
CAUTION
> NEVER BEND THE ELECTRODE!
3. Turn the assist air supply OFF.
4. Trigger the applicator until fluid flow ceases.
5. Connect the solvent supply.
!
6. Turn on air supply to pump. Adjust for low
pressure and slow cycling of pump.
7. Run solvent through the system until it runs
clear.
> Prior to disassembly of any portion of the
applicator, ensure the procedure for “Removing the Applicator from the Work Site”
has been completed.
1. Unscrew nozzle nut [1] from barrel [18].
8. Disconnect the solvent supply.
9. Trigger the applicator until it is clear of solvent.
10. Detach fluid line from fluid tube fitting [70].
11. Following removal of the fluid line, hold the
barrel up 45° from horizontal and trigger the
applicator to remove solvent remaining in the barrel
and nozzle passage ways.
12. Detach the air line assembly from applicator
air fittings [50] and [51].
13. Remove the plastic cable retaining screw [72]
on the back of the transformer [44] and pull the
cable out of the transformer.
NOTE
2. Remove the air [2] and fluid [3] nozzles from
the front of applicator by pulling straight out. Fluid
nozzle seal [4] can now be removed from the fluid
nozzle.
3. Remove valve body [5] with a blade type screw
driver wide enough to engage both slots of the
valve screw. Remove valve body seal [6] with
small hooked tool.
4. Clean the removed parts in a suitable solvent.
Examine the cleaned parts for excessive wear
and damage. Replace as necessary.
5. It may be necessary to soak some parts in
solvent and brush to clean. Blowing compressed
air through the nozzle in the opposite direction from
fluid flow may also be helpful.
> If the low voltage cord is to be replaced,
see “Low Voltage Cable Replacement” in
this section.
14. Loosen Socket Head Cap Screws [47] and
remove the applicator from the work site.
21
CAUTION
NOTE
> Never use metal tools or wires or metal
bristle brushes to clean or unclog nozzle
assemblies. Use only soft bristle brushes.
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Maintenance
6. Reassemble the cleaned or replaced parts in
reverse order of disassembly. Be sure the
applicator is triggered when the valve seat and
screw are assembled to the barrel. When
inserting the seal in the fluid nozzle, make sure
the 45° chamfered end is inserted first and points
in the direction of the front of the applicator.
7. Remove packing nut [16] from chamber [104]
with spanner wrench.
8. With a firm pull, remove needle shaft assembly
and seals from chamber [103].
NOTE
Barrel / Cascade Disassembly
> During this operation be careful that the
!
CAUTION
> Prior to disassembly of the applicator
ensure the procedure for “Removing the
Applicator from the Work Site” has been
completed.
interior surface of chamber [103] is not
damaged, marred, or scratched. The
bottom of this chamber is a seal area and
the barrel/cascade assembly will have to
be replaced if it is damaged.
9. Remove the trigger adjusting nut [17] from end
of needle shaft assembly [11].
1. Loosen barrel nut [19] with the spanner wrench.
2. Disengage fluid tube nut [67] from barrel [18].
3. Remove piston housing [39], springs [37] and
[38], adjusting nut [36], and jam nut [35].
4. Pull barrel [18] and body [25] straight apart.
10. To remove the front u-cup seal [9] from the
needle shaft assembly [11] place in paded vise,
gripping the center portion of the shaft with two
2.5mm wrenches. Unlock the ball valve needle
[7] from the jam nut {7A] using the flats on both.
The front u-cup seal [9], spreader seal [8], and
pusher seal [10] can now be removed.
11. The valve seal [6] and fluid tube seal [64] can
now be removed from the barrel.
NOTE
Barrel / Cascade Assembly
> There is no need to remove retaining
ring [20] or barrel nut [19] from barrel [18]
unless they are damaged. If they are to
be removed, lift one end of ring [20] over
the “captive ridge” and spiral it off of the
end of the barrel. Then nut [19] can be
removed. To replace them on the barrel,
slide nut [19] onto the barrel, place ring
[20] against the back of the barrel, lift one
end of it onto the barrel ad spiral it on and
into its groove.
5. Remove the air and fluid nozzles, seal, and
valve screw and seat as described in the previous
step.
6. Remove valve rod extension [22] from end of
shaft assembly [11] using two 9mm wrenches.
AA-87-02.3
• Clean all disassembled parts with a suitable
clean solvent.
• If the electrode is bent, straighten it carefully by
hand.
• Check all parts for damage or wear. Replace
those that are damaged or worn with new parts.
• Replace front u-cup seal [9] fluid line seal
[64] and valve seal [6] with new parts.
• Inspect the needle shaft [11] sealing surface
for wear. If it is rough or uneven, replace it as
follows:
1. Place pusher seal [10] onto the front of needle
shaft assembly [11] with the flat side toward the
front.
ARCHIVE
22
REM Automatic Applicator - Maintenance
2. Push front u-cup seal [9] on the needle shaft
[11] with the dished outside to the front of the needle
shaft [11].
3. Place spreader seal [8] on needle shaft [11]
with flatest side toward the front of the needle shaft
[11].
4. Place jam nut [7A] on the threads of the needle
shaft [11] and tighten until it reaches the bottom of
the threads. Place ball valve needle [7] on shaft
and finger tighten it until the threads bottom out.
then with the two 2.5mm wrenches, tighten the
jam nut [7A] against the ball valve neelde [7].
NOTE
Apply a heavy coating of dielectric
grease to the seals.
>
5. Insert the valve seal [6] and valve seat body
[5] into the front of the barrel [18], chamber [102]
and tighten snuggly.
6. Coat the plastic portion of the needle shaft [11]
with dielectric grease and slide the packing tube
[12] over the plastic portion of the needle shaft
[11].
NOTE
> The packing nut should be just tight
enough that shaft [11] slides in and out
with firm resistance.
12. Screw the trigger adjusting nut [17] and
extension valve rod [22] onto shaft [11] with the
hexagonal flange or nut facing each other.
13. To adjust nuts [17]:
a. Push needle shaft assembly [11] fully
forward until ball end [7] on shaft [11] seats
in valve seat [5].
b. Measure 11/18-inch from rear lip of barrel/
cascade chamber [103] to the rear face of
the hexagonal flange of the nut on the
extension rod [22].
NOTE
> The 11/16-inch dimension is a starting
point. Because of component stack-up,
wear and other variables, a slight increase or decrease in this setting may be
needed.
7. Slide the rear seal container [13], with the oring gland on the outside, toward the front of the
needle shaft [11].
8. Install the o-ring [13A] onto the outside of the
rear seal container [13].
9. Carefully put rear u-cup seal [14] with the oring to the rear of the needle shaft [11].
10. Put the rear seal retainer [15] onto the needle
shaft [11]. Grease the full assembly.
11. Place the packing nut [16] on the rear threads
of the needle shaft [11]. Insert the full assembly
into the barrel [103] and tighten Item 16 with the
spanner wrench.
Figure 1:
23
ARCHIVE
Nut Adjustment
AA-87-02.3
REM Automatic Applicator - Maintenance
c. Secure the two (2) nuts together at that
dimension by rotating the nut next to barrel
rearward until the two (2) nuts will not turn
on the shaft.
d. Tighten the two (2) nuts by holding each
with a 9mm wrench and rotating wrenches
in opposite directions.
14. Place gasket [21] into chamber [100] of body
assembly [25].
!
CAUTION
> The need shaft assembly travel must be
adjusted so that the air valve is always
triggered first. If the air does not turn on
before the fluid, readjust nut [17] and [22].
18. Place spring [38] on nut [36].
19. Place spring [37] into piston housing [39],
and secure housing onto body assembly [25].
NOTE
> Secure the new gasket in place with the
large hole at the bottom.
NOTE
> Ensure plug [40] is inserted into piston
housing.
15. Slide barrel assembly into the body chamber
[104] while aligning the transformer/barrel
electrical contacts.
16. Secure the barrel/cascade assembly [18]
to body assembly with nut [19] and tighten.
!
CAUTION
20. Insert fluid line seal [64] into barrel chamber
[101].
21. Insert connector [65] into barrel chamber [101]
and secure in place with retainer nut [67].
T ransformer Assembly
> Nut [19] should be secured hand tight
only with spanner wrench. Never apply
more than 10 lb•ft torque.
17. With the needle valve assembly and piston
shaft [30] fully forward, secure lock nuts [35] and
[36] onto extension [22]. Allow 1/8-inch gap
between nut [35] and shaft [30].
!
CAUTION
> The low voltage cable MUST be removed before removing the transformer/
hook assembly.
Replacement
1. Remove the low voltage cable. (See “Low
Voltage Cable Replacement” in this section.)
NOTE
> Projection on nut [36] must face the rear
of applicator.
!
CAUTION
> When removing or installing the low voltage cable. DO NOT rotate the assembly.
This can cause damage to the contact pins
or to the bottom of the tranformer/hook assembly.
AA-87-02.3
ARCHIVE
24
REM Automatic Applicator - Maintenance
Assist Air V
alve
Valve
NOTE
Disassembly:
Transformer assemblies manufactured in late 1986 or later have a screwed
in removable glass lense. The lense has
pin holes for an adjustable spanner wrench
with 18mm (.126-inch) pins. Earlier models have a glass lense epoxied in place
which can also be replaced.
>
1. Turn adjustment knob [58] to the open position
(fully extended), to accommodate Step 2.
2. With a 9/16” wrench, unscrew valve housing
[59] and remove the entire assembly from chamber
[107].
3. Return the control knob to the closed position.
2. Remove the barrel cascade assembly. (See
“Barrel/Cascade Assembly Replacement” in this
section.)
4. Secure adjustment knob [58] in a bench vise
and, with a 1/4” wrench on wrench flats [108], free
needle [63] and remove it from the assembly.
3. Remove gasket [21].
4. Slide transformer [44] toward and out of
channel [106].
5. Slide replacement transformer [44] into channel
[106].
NOTE
The needle/control knob is secured
with Lock-Tite.
>
6. Place gasket [21] in position.
5. Remove spring [62].
7. Install the barrel/cascade assembly. (See
“Barrel Assembly” in this section.)
6. Unscrew adjustment knob [59] from housing
[59].
8. Install low voltage cable. (See “Low Voltage
Cable Replacement” in this section.)
7. With a 1/4-inch rod or other small diameter tool,
force washers [61] and o-ring [60] out of the
housing [59].
Body Assembly Service
When service is performed on any of the handle
elements, it is best to remove the barrel/cascade
and hook/transformer assemblies, (see “Transformer/Assembly Replacement” in this section)
in order to avoid damage to the nozzle, needle/
electrode or any of the plastic parts. After
disassembly of any handle element:
Assist Air V
alve
Valve
Assembly:
1. Screw adjustment knob [58] completely into
housing [59].
NOTE
• Clean all parts with a suitable, clean solvent.
• Check all parts for damage or wear. Replace
those that are damaged or worn with new parts.
> Apply a light coating of dielectric grease
to the control knob threads [109].
• Replace and lubricate all seals and o-rings.
25
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Maintenance
2. Place one (1) washer [61], o-ring [60], and the
other washer [61] onto the shaft of adjustment
knob [58].
3. Use the flat end of the tubular spanner tool to
seat [61], [60], and [61] in the bore of the housing
[59].
Assembly:
1. Start low voltage cable [43] into chamber [118]
so the set screw indent is to the front of the
applicator.
2. Secure the low voltage cable [43] with front set
screw [72] using a 3/32” Allen wrench.
4. Place spring [62] onto the shaft of adjustment
knob [58].
5. Secure adjustment knob [58] in the bench vise
and put a small amount of 7969-00 medium
strength sealant on the shaft threads [114].
NOTE
> This step secures the grounding
bracket, air and fluid lines, and the cable
to the applicator handles.
6. With a 1/4” wrench on wrench flats [108], screw
needle [63] onto the control knob shaft. Remove
the assembly from the vise.
7. Unscrew adjustment knob [58] to its open
position.
8. Screw housing [59] into valve chamber [107]
with a 9/16” wrench.
!
CAUTION
> When removing or installing the low voltage cable, DO NOT rotate the assembly.
This can cause damage to the contact pins
or to the bottom of the transformer/hook
assembly.
NOTE
> Apply a light coating of dielectric
grease to the housing threads.
9. Screw the adjustment knob down to the closed
position.
Low V
oltage Cable Replacement
Voltage
Disassembly:
1. Follow the procedures in “To Remove the
Applicator from the Work Site” in this section.
2. Loosen (but do NOT remove) set screw [72]
with a 3/32” Allen wrench.
3. Pull low voltage cable [43] STRAIGHT OUT
OF CHAMBER [118].
AA-87-02.3
ARCHIVE
26
REM Automatic Applicator - Maintenance
3. Using two 3/8” wrenches, turn nut [36] away
from nut [35]. Remove both nuts from valve rod
extensions [22].
TUBE AND LINE
INST
ALLA
TION /
INSTALLA
ALLATION
REPLACEMENT
4. Remove barrel/cascade assembly (see
“Barrel/Cascade Assembly” in this section).
! WARNING
> Turn OFF all power, air, and fluid at the
source.
The fluid tube (from barrel to support bracket) is a
special machined and formed part which is
separated from the fluid line (from support bracket
to paint supply) by fitting [70] and locking nut [71]
which grounds the fluid at the handle through
support and bracket [52] and [55].
Valve Body Service
When service is performed on any of the body
elements, it is best to remove the barrel and
transformer assemblies to avoid damage to the
nozzle, electrode, or any of the plastic parts.
After disassembly of the body element:
• Clean all parts with a suitable clean solvent.
• Check all parts for damage or wear. Replace
those that are damaged or worn with new parts.
5. Remove transformer assembly
“Transformer Assembly” in this section).
6. Remove valve seal retaining nut [23] and oring [24] from front of valve body chamber [105]
using a 3/8” nut driver.
7. With a flat tipped wood or plastic dowel rod
inserted into the front of the valve body chamber
[105], push piston assembly [30] through [34] out
of the rear of the valve body [22], chamber [104].
8. Secure piston shaft [30] in a 3/8“ wrench (on
the wrench flats) and remove nut [34] with a 9/16”
socket wrench.
9. Slide piston assembly {31}, [32], and [33] from
shaft [30] and disassemble components by hand.
10. Remove bushing assembly [26], [27], [28],
and [29] from the valve chamber with a 20049
wrench.
Assembly:
NOTE
• Replace all seals and o-rings.
> Replace all o-rings. Replace packing
Disassembly
1. Rotate piston housing [39] to remove it from
the body [25].
!
> The piston housing is spring loaded. Use
2. Remove springs [37] and [38].
27
cup [32] if it is worn.
1. Secure retaining nut [23] and o-ring [24] in the
front of the valve chamber using a 3/8” nut driver.
CAUTION
care is disassembly.
(see
2. Secure bushing assembly, [26], [27], [28], and
[29] in the valve chamber using a 20049 wrench.
3. Secure shaft [30] in wrench (on 3/8” wrench
flats) and assemble washer [31], cup [32], and
piston [33] on the rear with nut [34] using a 9/16”
socket.
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Maintenance
4. Place the piston assembly [30] through [34] into
the valve chamber through bushing [28] and press
into place.
5. Remove bracket [55] and [70] from fluid tube
[69].
6. Remove fluid tube [89] from elbow connector
[88].
NOTE
> Be sure that o-ring [29] is in bushing
[28].
7. Using fluid fitting tool [75], place over fluid
connector [85] and remove from elbow connection
[66]. Nut [67] will come off when fluid connector
[65] is removed from elbow connection [68].
5. Replace the barrel/cascade assembly (see
“Barrel/Cascade Assembly” in this section).
6. Replace the transformer assembly (see
“Transformer Assembly” in this section).
NOTE
> This step may be eliminated if the Fluid
Connector [65] is NOT damaged.
7. Place nut [34] on rod extension [22] 1/16-inch
from piston shaft [30].
8. Place nut [36] on rod extension [22] and secure
against nut [35] using appropriate wrenches. Be
sure to maintain the 1/16-inch spacing between
nut [35] and piston shaft [30].
8. Replace o-rings [66], gasket [64] on any worn
or broken parts if required.
9. Place springs [37] and [38] against piston [33]
and nut [36] and secure in place by screwing
piston housing [39] into the rear of the valve
housing.
Fluid T
ube Removal
Tube
1. Remove fluid line and fluid filter [74] from fitting
[70].
2. Remove nut [71] from fitting [70].
3. Remove screw [56] from support bracket [52]
and [56] using 2.5mm Allen wrench.
4. Lossen nut [67] with an adjustable wrench. Grip
elbow connection [68] and pull straight down to
remove connector [67] from barrel [18] at [101].
!
CAUTION
> Removing the connector [67] other than
straight down from barrel [18] may damage
or breach the connector [67]
AA-87-02.3
ARCHIVE
28
REM Automatic Applicator - Parts Identification
PAR
TS IDENTIFICA
TION
ARTS
IDENTIFICATION
Figure 2:
29
REM Automatic Applicator Exploded View
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Parts Identification
AUTOMA
OMATIC
APPLICAT
PAR
ARTS
REM AUT
OMA
TIC APPLICA
TOR - P
AR
TS LIST (Figure 2)
Item #
1
2
3
4
5
6
7
7A
8
9
10
11
12
13
13A
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
Description
Part #
Assembly Complete
Nut, Nozzle
Nozzle, Air **
Nozzle, Fluid **
Barrel Cascade Assembly:
Seal, Fluid Nozzle *
Valve Seat Body Assembly *
Seal, Valve Seat Body *
Needle, Valve Ball *
Nut, Jam *
Spreader, Seal *
Seal, U-Cup Front *
Pusher Seal *
Needle/Shaft Assembly
Tube, Packing *
Container Ring Seal *
O-Ring *
U-Cup Sea l*
Retainer, Rear Seal *
Nut, Packing *
Nut, Trigger Adjusting
Barrel Assembly W/HighVoltage Cascade
Nut, Barrel Retainer
Retaining Ring, Barrel
Gasket *
Extension, Valve Rod *
Nut, Valve Seal Retainer
O-Ring *
Body Assembly Non-Bleed
O-Ring, Teflon *
O-Ring, Viton *
Bushing, Air Valve
O-Ring, Viton *
Shaft, Valve and Piston
Washer, Piston
U-Cup Piston, Teflon
Piston
Nut, Piston Lock
Nut, Air Valve Lock
Nut, Air Valve Adjustment
Spring, Piston Return
Spring, Fluid Valve Return
Housing Piston
Screw
Screw Set
---Low Voltage Cable Assembly
Transformer Assembly
Cap, Screw, Socket Head (4 Required)
Lense, Sight
Cap, Screw Socket Hd., M4 (2 Required)
Lock Washer, M4 (2 Required)
Nut, M4 (2 Required)
73499-XX
72353-00
72371-00
71260-XXXX
72327-00
73355-00
72375-03
73350-00
73351-00
73344-00
73345-00
73346-00
73352-00
72378-00
73347-00
72209-05
73349-00
73348-00
73354-00
72374-00
72362-00
72493-00
72494-00
72360-00
74192-00
20053-00
13076-10
74092-01
13076-13
7554-33
20054-00
7554-28
20055-00
20057-00
7723-06
20056-00
7733-44
7733-07
20942-00
9334-00
17615-00
20943-00
7730-08F
9937-12C
---78084-XXX
73488-00
8212-20C
72532-00
72543-01
72544-01
72544-01
(Continued On Next Page)
AA-87-02.3
ARCHIVE
30
REM Automatic Applicator - Parts Identification
AUTOMA
OMATIC
APPLICAT
PAR
ARTS
REM AUT
OMA
TIC APPLICA
TOR - P
AR
TS LIST (Figure 2)
Item #
50
51
52
53
54
55
56
57
58
59
60 *
61
62
63
64 *
65
66 *
67
68
69
70
71
72
73 *
74 ***
75
76
77
Part #
Description
Fitting, 1/4” Tube X 1/8” NPT, Trigger
Fitting, 3/8” Tube X 1/4” NPT, Assist Air
Bracket, Fluid Line
Screw, Socket Head (2 Required)
Lock Washer (2 Required)
Fluid Line Support
Screw Pan Head
Valve Assembly, Air Assist Complete (Includes Items 58 - 62)
Knob, Control
Nut Retaining
O-Ring
Washer (2 Required)
Spring
Needle
Gasket
Connector, Fluid
O-Ring
Nut, Union
Elbow Connection
Fluid Tube
Fitting, Fluid
Nut, Fitting Fluid
Screw, Pan Head
O-Ring
Fluid Filter
Fluid Connection Tool
T-Handle Tool
Nozzle Tool
7884-02
7884-03
74088-00
8212-16F
7734-04
72367-00
72406-04
18851-00
18840-00
18853-00
13076-08
18833-00
18829-00
18852-00
72375-02
74085-00
72209-02
72357-01
74086-00
74087-00
72381-01
72382-01
73490-01
7554-12
72400-00
74258-00l
20049-00
72468-00
** Dash number (-XX) reads in feet except 99 which = 100 feet (i.e. -36 = 36 feet). These items are
availble in standard lengths of 36, 50, 75, and 100 feet. When ordering High Voltage Cable, use footage
for -xx.
*** Dash number (-XXXX) indicates Fluid Nozzle configuration. See “Nozzle Selection Chart” in the
“Operation” section for Nozzle Specifications and Order Number Identification.
**** The configuration and number identification of this filter may change. When you order a 72400
Filter, your ITW Ransburg distributor will provide the current configuartion.
72453-00 REP
AIR KIT
REPAIR
Part #
Description
74150-02
High Voltage Test Assembly Applicator Output
74195-00
Tester Transformer Output
Note: Includes items indicated * on the “REM Automatic Applicator Exploded View Parts List”.
31
ARCHIVE
AA-87-02.3
REM Automatic Applicator - Parts Identification
CABLE ASSEMBLIES
Part #
Replaces
Description
78084-36, -50, -75, -100 76876-36, -50, -75, -100 New Low Voltage Cable Assembly with new connector. Used
on all hand, auto, solvent, and water applicators, except
AVIATOR.
PLUG ASSEMBLIES
Part #
Replaces
Description
76875-11
76875-01
REM/MGS applicator reed switch plug assembly with new receptacle.
76875-14
76875-04
REM/MGS applicator reed switch plug assembly with solvent proof
o-rings and new receptacle.
74191-01
AA-87-02.3
74191-00
Plug assembly for all automatic applicators, except REA9000R.
ARCHIVE
32
REM Automatic Applicator - Warranty Policies
WARRANTY POLICIES
LIMITED W
ARRANTY
WARRANTY
ITW Ransburg will replace or repair without charge
any part and/or equipment that falls 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, VOID 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, ASSOCIATED VALVES AND TUBING, AND SUPPORTING HARDWARE IN
PLASTIC, SHRINK-WRAP, OR ANY
OTHER NON-APPROVED COVERING,
WILL VOIDE THIS WARRANTY.
33
ITW RANSBURG'S ONLY OBLIGATION
UNDER THIS WARRANTY IS TO REPLACE
PARTS THAT HAVE FAILED BECAUSE
OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
ITW RANSBURG ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FOR
CONSEQUENTIAL DAMAGES FOR LOSS
OF GOODWILL OR PRODUCTION OR
INCOME, WHICH RESULT FROM USE OR
MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS.
EXCLUSIONS:
If, in ITW Ransburg's opinion the warranty item in
question, or other items damaged by this part was
improperly installed, operated or maintained, ITW
Ransburg will assume no responsibility for repair
or replacement of the item or items. The purchaser, therefore will assume all responsibility for
any cost of repair or replacement and service
related costs if applicable.
ARCHIVE
AA-87-02.3
MANUAL CHANGE SUMMAR
Y
SUMMARY
This manual was published to replace Service
Manual AA-87-02.2, REM TM Automatic
Applicator, to make the following changes:
1. Replaced “
Cover”.
Label“ on the “Front
2. Replaced “Labels 72354, 72562, and 76859”
in the “Atex” section.
AA-87-02.3
ARCHIVE
Service Manual Price: €15.00
15.00 (Euro)
$20.00(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.
© 2008 Illinois Tool Works Inc. All rights reserved.
Models and specifications subject to change without notice.
Form No. AA-87-02.3
Litho in U.S.A.
05/08
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