CP-97-01.1 Aviator Power Unit.pmd

CP-97-01.1 Aviator Power Unit.pmd
SERVICE MANUAL
CP-97-01.1
(Replaces CP-97-01)
May - 2008
A
R
C
H
IV
E
AVIA
TORTM POWER UNIT
VIAT
Portable Power Generation T
echnology
Technology
MODEL:
75983-02 For Use Only With:
- 75979 (REATM-90)
- 75982 (REATM-90 Waterborne)
- 75980 (REATM-70)
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: €25.00
25.00 (Euro)
$30.00 (U.S.)
N O T E : This manual has been changed from revision CP-97-01 to revision CP-97-01.1
CP-97-01.1.
Reasons for this change are noted under “Manual Change Summary” inside the back
cover of this manual.
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CP-97-01.1
AVIATOR Power Unit - Contents
CONTENTS
PAGE
SAFETY:
1-6
SAFETY PRECAUTIONS............................................................................................................ 1
HAZARDS / SAFEGUARDS........................................................................................................ 2-5
ATEX:
7-8
EUROPEAN ATEX DIRECTIVE................................................................................................. 7
EUROPEAN ATEX LABELS....................................................................................................... 8
INTRODUCTION:
9-10
DESCRIPTION............................................................................................................................. 9
FUNCTIONS................................................................................................................................. 9
AIR REQUIREMENTS................................................................................................................. 10
SPECIFICATIONS....................................................................................................................... 10
INSTALLATION:
11-12
LOCATION / MOUNTING............................................................................................................ 11-12
EXTERNAL CONNECTIONS...................................................................................................... 12
OPERATION:
13-14
OPERATION................................................................................................................................ 13
MAINTENANCE:
15-20
REMOVAL OF GENERATING UNIT FROM ENCLOSURE...................................................... 15
INSTALLATION OF GENERATING UNIT INTO ENCLOSURE................................................ 15
GENERATING UNIT DISASSEMBLY......................................................................................... 15
GENERATOR REMOVAL........................................................................................................... 16
GENERATOR REPLACEMENT / INSTALLATION.................................................................... 16
AIR MOTOR REMOVAL.............................................................................................................. 16
AIR MOTOR REPLACEMENT / INSTALLATION....................................................................... 17
PC BOARD REMOVAL................................................................................................................ 17
PC BOARD REPLACEMENT...................................................................................................... 18
CABLE REMOVAL....................................................................................................................... 18
CABLE REPLACEMENT............................................................................................................. 18
THEORY OF OPERATION......................................................................................................... 19
TROUBLESHOOTING................................................................................................................. 19-20
PARTS IDENTIFICATION:
21-24
AVIATOR POWER UNIT EXPLODED VIEW / PARTS LIST..................................................... 21-24
AVIATOR / APPLICATOR MODEL IDENTIFICATION.............................................................. 24
ACCESSORIES........................................................................................................................... 24
WARRANTY POLICIES:
25
LIMITED WARRANTY.................................................................................................................. 25
CP-97-01.1
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AVIATOR Power Unit - Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
ITW Ransburg 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.
!
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.
!
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
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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CP-97-01.1
AVIATOR Power Unit - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Spray Area
Fire Hazard
The 76447 power supply MUST be installed in a
NON-hazardous location in accordance with NFPAImproper or inadequate operation 33.
and maintenance procedures will
Fire extinguishing equipment must be present in the
cause a fire hazard.
spray area and tested periodically.
Protection against inadvertent
arcing that is capable of causing Spray areas must be kept clean to prevent the
fire or explosion is lost if any safety accumulation of combustible residues.
interlocks are disabled during
operation. Frequent power supply Smoking must never be allowed in the spray area.
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 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 setup operations. Production should
never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne
installations to spray solvent based materials.
The paint process and equipment should be set up
and operated in accordance with NFPA 33, NEC, and
OSHA requirements.
CP-97-01.1
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2
AVIATOR Power Unit - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
Electrostatic Arcing
Ensure the Ground Wire Assembly is connected from
the power supply ground stud to a true earth ground.
may occur.
Spray Area
Ensure that the power supply is plugged into a
properly grounded outlet.
If shocks or sparks are noticed at any point in the
spray system, immediately turn off the power supply
and check the complete system for the cause. DO
NOT use the system again until the problem has
beenidentified and corrected.
Never operate the applicator without properly grounding
the following:
A. Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
leg straps may be used.
Operators must maintain contact with the handle
of the applicator. If work gloves are used, the
palm section should be cut out.
Operators must remove from themselves all
metal objects that are not grounded.
NOTE: REFER TO NFPA-33 REGARDING
OPERATOR GROUNDING.
B. Parts being sprayed. Resistance between the
part and a grounded conveyor must not exceed
1 megohm.
C. Every metal and conductive object in the spray
area. This includes the booth, parts hangers,
fire extinguishers, conductive flooring, etc.
Grounded conductive flooring must be provided in the
spray area.
Turn off voltage at the power supply before flushing
out, cleaning, or removing any parts from the
applicator.
Provide proper protection for waterborne supply
systems.
Never install a applicator into a fluid system using an
isolated solvent supply.
3
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CP-97-01.1
AVIATOR Power Unit - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
Electrostatic Arcing
Always discharge Waterborne system capacitance
prior to servicing.
may occur.
Spray Area
(Continued)
Do not touch applicator electrode while applicator is
energized.
General Use and Improper operation or maintenance Personnel must be given training in accordance with
may create a hazard.
the requirements of NFPA-33.
Maintenance
Personnel must be properly trained Instructions and safety precautions must be read and
in the use of this equipment.
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.
Always turn power to the power supply OFF, unplug
the electrical cord from its outlet, and remove the front
panel fuse, before opening the power supply door. If
necessary, lock the power supply out so that it cannot
be turned ON until the work is finished.
Whenever removing high voltage cables from
equipment, ground the contact end of the cable by
holding the cable such that the contact touches earth
ground for several seconds. Do not touch the contact
until it has been grounded. This will reduce the
possibility of residual charge causing electrical shock.
The High Voltage Multiplier Assembly contains energy
storage components that can cause serious shock
injury, and therefore is not field repairable. Warranty
will be voided if the High Voltage Multiplier seal is
broken. If the High Voltage Multiplier is defective
contact your authorized ITW Ransburg representative
for exchange or repair.
The High Voltage Multiplier and high voltage cable
contain significant capacitance that will store charge.
Allow approximately 10 seconds for this charge to
bleed off before opening the cabinet door or removing
the high voltage cable from the power supply or spray
applicator.
CP-97-01.1
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4
AVIATOR Power Unit - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards
Tells what the hazard is.
Tells how to avoid the hazard.
may occur.
Explosion Hazard/ Halogenated hydrocarbon Aluminum is widely used in other spray application
solvents for example: methylene equipment - such as material pumps, regulators,
Incompatible
chloride and 1,1,1,-Trichlor- triggering valves, etc. Halogenated hydrocarbon
Materials
oethane 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.
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.
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.
Personnel Safety Skin puncturing by sharp electrode. Take precautions to see that flesh is not punctured by
sharp electrode.
Personnel Safety Fluid Injection Hazard
(High Pressure
Equipment)
Never let any part of the body come in direct contact
with the fluid stream exiting from the nozzle. If fluid
leaks occur in the applicator or in the fluid delivery
components, depressurize fluid system before
servicing.
Never aim the applicator at any part of the body under
any circumstances.
If you are injured by High Pressure Fluid Injection than
immediate medical treatment MUST be sought.
5
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CP-97-01.1
AVIATOR Power Unit - Safety
NOTES
CP-97-01.1
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6
AVIATOR Power Unit - 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:
8. The certification of this equipment relies upon
the following materials used in its construction:
1. The equipment may be used with flammable
gases and vapors with apparatus groups II and
with temperature class T6.
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.
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 60079-14:1997.
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.
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: 77657, 79132, and 79318.
10. The characteristics of the equipment shall be
detailed e.g. electrical, pressure, and voltage
parameters.
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.
7
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
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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CP-97-01.1
AVIATOR Power Unit - Atex
Aviator Power Unit A
TEX ProdATEX
uct Marking Definitions
Label 77657
Ex Certificate Number: Sira 08ATEX5040X
Sira = Notified Body performing EC-type
examination
08 = Year of certification
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
040 = Document serial number
X = Special conditions for safe use apply
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 75983-XX Power Supply is
suitable for use in electrostatic spraying
installations complying with EN 50050 as they are
a Type A class with a discharge energy limit of
0.24mJ.
W
Label 79132
Label 79318
CP-97-01.1
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8
AVIATOR Power Unit - Introduction
INTRODUCTION
DESCRIPTION
The AVIATORTM Power Generator is an airpowered device that creates voltage to power
special REATM-70 or REATM-90 Applicator units.
With the ability to generate power from any air
source, the AVIATOR is a portable device,
designed to move from air drop to air drop. Both
AVIATOR models are approved for use in Class
1 Division 1 hazardous areas. The unit has been
designed to meet all explosion proof requirements
for hazardous areas. This makes the AVIATOR
highly suited for applications where the power unit
must be located inside the hazardous area.
The AVIATOR may be connected to special models
of the REA-70 or REA-90. There are two power
unit assemblies available, one for the REM (7598301) and one for the REA 70/90 (75983-02).
A regulated pressure fluid system delivers coating
material to the atomizer. At the atomizer, air is
applied which atomizes the coating material by
forming a spray mist which, under the influence of
the electrostatic field, becomes electrically
charged. 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 overspray
around and deposit it on the back surface of the
target. Therefore, a high percentage of the spray
is deposited on the target.
FUNCTIONS
High V
oltage Adjustment Knob
Voltage
The high voltage adjustment knob allows
adjustment of applicator output voltage from 0 to
100% full voltage of the specific applicator.
Cable
! WARNING
The cable transmits the voltage out to the applicator.
Do NOT use a 75981 REM applicator
assembly with a 75983-02 AVIATOR. The
AVIATOR requires a special cable assembly that is different from the standard cable
assemblies that are used with the 9030
control unit. Cable lengths are available in
36’, 50’, 75’, and 100’ for the AVIATOR.
For cable requirements over 100’, consult
your ITW Ransburg representative.
>
The ITW Ransburg REA Process
The REA process is an air atomized method for
applying coatings to objects electrostatically. The
REA 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.
9
Filter Regulator
The preset, nonadjustable filter regulator controls
pressure to the AVIATOR. The filter removes
particulates that may contaminate the air motor
and degrade overall performance.
Slide V
alve
Valve
The slide valve turns the unit on and off, and is
the air inlet for the unit.
Exhaust
The exhaust fitting allows exhaust air out of the
enclosure.
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CP-97-01.1
AVIATOR Power Unit - Introduction
AIR REQUIREMENTS
SPECIFICA
TIONS
SPECIFICATIONS
With installations that have instrument-quality air
feeding the AVIATOR, the life of the air motor may
be shortened. To extend the life of the motor, it is
recommended to coat the 5 micron air filter with a
non-silicone based SAE #10 oil. This coating will
extend the life of the air motor. A lubricator may be
used and, if so, should be set at one drop of oil
every 10 minutes.
Physical
For installations that do not have instrument-quality
air, the compressor oil in the line is adequate to
lubricate the motor.
Weight:
10 pounds (4.5 Kg)
Length:
15-inches (37.7 cm)
Width:
4-inches (10.4 cm)
Depth:
4-inches (10.4 cm)
Operating
Maximum Air Pressure:
100 psig (6.8 bar)
Minimum Air Pressure:
50 psig (4.1 bar)
Air Consumption:
@ 60 psig 8 SCFM
Maximum Output Voltage: 10 V RMS
(Same as the 9040)
Maximum Output Current: 1.2 Amps RMS
Sound Pressure Level:
75 dB(A)
Maximum Cable Length: 100 feet (32.7 m)
FM approved for electrostatic finishing
operations using Class 1, Group D spray
materials.
Figure 1: AVIATOR Power Unit
CP-97-01.1
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10
AVIATOR Power Unit - Installation
INST
ALLA
TION
INSTALLA
ALLATION
! WARNING
! WARNING
> The control unit MAY be located inside
the hazardous area. (See NFPA-33,
OSHA, and ITW Ransburg Bulletin: "Operating Your Electrostatic Coating System
Safely".)
The user MUST read and be familiar
with the "Safety" section and safety precautions in this manual.
>
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 requirements for operating and servicing safely are followed. The
user should be aware of and adhere to ALL
local building and fire codes and ordinances, as well as NFPA-33 and OSHA,
prior to installing, operating, and/or servicing this equipment.
>
The ground wire assembly MUST be
connected from the control unit ground stud
to a true earth ground.
>
LOCA
TION / MOUNTING
LOCATION
The AVIATOR may be located within the hazardous
location. It may be mounted on a booth wall, pump
cart, or other suitable place.
The AVIATOR features a flexible mounting system
that allows either hard mounting of the unit, or
semi-removable mounting.
To mount the unit, anchor suitably into the booth
wall. The bolt pattern is indicated in Figure 2.
(Mount the bracket to the wall with appropriately
sized fasteners.)
NOTE
> As each installation is unique, this information is intended to provide general installation information for the AVIATOR control
unit. Consult your authorized ITW Ransburg
distributor for specific directions pertaining to
the installation of your equipment.
It is recommended that the AVIATOR be installed in a vertical position to give best performance to the unit.
!
Figure 2: Mounting Bolt Pattern
CAUTION
Do Not use the AVIATOR in environments above 110o F.
>
11
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CP-97-01.1
AVIATOR Power Unit - Installation
Rigid Mounting
To rigidly mount the AVIATOR unit, first remove
the four (4) screws holding the unit to the enclosure,
and save to use later. Pull the handle to release
the unit from the enclosure. Using a 7/64" Allen
wrench, remove the two (2) screws that secure
the handle, then remove the handle. Install the
mounting bracket using the existing screws and
two (2) 8/32-inch nuts. Reinstall the enclosure
with the four (4) screws. Mount to the wall.
! WARNING
Interlocks: As outlined in NFPA-33
and OSHA, the inlet air line MUST be
series-interlocked with both the exhaust fan
and the conveyor.
>
Interlock the booth fan to a solenoid valve
that controls air flow to the AVIATOR unit.
! WARNING
Semi-Rigid Mounting
To mount the AVIATOR for easy removal, complete
the above procedure for mounting the bracket.
Then, lift the AVIATOR unit so that the bar can be
inserted into the bracket’s slot, as in Figure 3.
Then drop the bottom of the unit until the bar comes
forward in the slot.
Remove the AVIATOR unit by pushing it toward
the back of the bracket and lifting up.
The solenoid valve MUST be located
outside the hazardous location.
>
The AVIATOR requires its own air supply. This
air supply must be separate from the applicator
air for best performance of the unit.
! WARNING
Do NOT remove the filter and regulator
from the unit, as the AVIATOR is specifically designed to filter and control air
pressure.
>
Connect an air line to the unit’s slide valve.
Minimum pressure required to run the AVIATOR
is 50 psig at the filter/regulator unit.
The supply air should be clean, dry air.
Figure 3: Inserting Bar into Bracket Slot
EXTERNAL
CONNECTIONS
! WARNING
> Prior to starting up any equipment, read
! WARNING
> The ground wire assembly MUST be
connected from the control unit ground stud
to a true earth ground.
CP-97-01.1
Connect and secure the cable into the applicator
and the AVIATOR is ready to use.
and completely understand the manual for
the applicator being used. Be sure to
review all safety items associated with the
specific product.
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12
AVIATOR Power Unit - Operation
OPERA
TION
OPERATION
Once the AVIATOR has been connected to a
regulated air source, you are ready to begin
spraying. Apply 50 psig (3.4 bar) air pressure to
the inlet of the AVIATOR while the unit is running.
To start the AVIATOR, slide the sleeve of the on/
off valve upwards until the sleeve clicks into
position. At this point, the AVIATOR should begin
running.
NOTES
The AVIATOR will not produce voltage until the
applicator is actuated. The AVIATOR produces
voltage on demand. This means that there is very
little delay time from the time the applicator is
triggered until full electrostatic voltage at the tip of
the applicator is achieved. When the applicator is
actuated, the speed of the motor will decrease
slightly.
! WARNING
The inlet air of the AVIATOR MUST be
interlocked with the spray booth. Reference
NFPA-33 for more information.
>
! WARNING
> For REA applicators, never trigger paint
flow without atomization air on. Failure to
follow this warning could cause fire or
personal injury.
13
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CP-97-01.1
AVIATOR Power Unit - Operation
NOTES
CP-97-01.1
ARCHIVE
14
AVIATOR Power Unit - Maintenance
MAINTENANCE
! WARNING
> Prior to performing any maintenance on
the AVIATOR, all electrical circuits must be
de-energized. Be sure that the supply air is
completely disconnected from the unit and
the unit removed to a non-hazardous location for service.
INST
ALLA
TION OF
INSTALLA
ALLATION
GENERA
TING UNIT
GENERATING
INTO ENCLOSURE
1. Perform "Removal of Generating Unit From
Enclosure" steps 1 through 6 in reverse order.
Locate the handle bar with respect to the air inlet
as shown in the "Parts Identification" section.
REMOV
AL OF
REMOVAL
GENERA
TING UNIT
GENERATING
FROM ENCLOSURE
GENERA
TING UNIT
GENERATING
DISASSEMBL
Y
DISASSEMBLY
1. Remove eight (8) Allen head screws from the
enclosure using a 5/64-inch Allen wrench.
To Service PC Board, Generator
Generator,,
Air
Motor
and
Cable
Motor,,
Replacement
2. Remove the bottom plate by pulling it straight
out of the enclosure.
3. Remove the ground connection and ground
wiring harness connection to the bottom plate by
removing nuts, washers, and ground stud. Set all
parts aside in a secure area to prevent loosing any
of these parts.
4. From the bottom of the enclosure, locate the air
motor. With light side to side pressure towards the
front of the enclosure, push the generating unit
from the enclosure.
5. Disconnect the air line from the swivel fitting.
6. Remove the ground wiring harness connection
to the generating unit by removing the bolt. The
motor and generating unit should now be separated
from the enclosure.
1. Perform all steps described in the "Removal of
Generating Unit from Enclosure" section of this
manual.
2. Remove the air motor and generator assembly
from the generating assembly by using the special
spanner wrench supplied with the unit. Insert the
circular tooth of the spanner wrench into the
counter bored hole on the generator retaining ring.
Turn the ring counterclockwise for removal.
3. Pull the generating assembly straight out of the
cylinder until the generator connector and PC
board connector are visible. Disconnect the two
connectors by pressing down on the cantilever
arm of the generator connector and pulling the two
apart.
NOTE
> Each of the connectors is keyed in
such a way that there is only one way for
assembly. Also, each connector is designed only to fit together with the proper
mating connector.
15
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CP-97-01.1
AVIATOR Power Unit - Maintenance
GENERA
TOR REMOV
AL
GENERATOR
REMOVAL
1. Loosen the two coupling set screws using a
5/64" Allen wrench.
2. Remove two (2) set screws from the generator
mounting plate using a 1/8" Allen wrench and pull
the generator straight out of the generator mounting
plate.
GENERA
TOR
GENERATOR
REPLACEMENT/
INST
ALLA
TION
INSTALLA
ALLATION
!
CAUTION
> The set screws and the socket head
cap screws used in the AVIATOR all have
a nylon thread lock adhesive. They may be
assembled and disassembled up to 10
times. After 10 uses of the fasteners, it is
recommended that they be replaced. When
replacing these screws it is recommended
that only genuine ITW Ransburg replacement parts are used to prevent problems
with AVIATOR performance.
AIR MOT
OR REMOV
AL
MOTOR
REMOVAL
1. Apply a light coat of dielectric grease (5997200) to the mounting shoulder of the generator.
Locate the two (2) counter bores in the mounting
shoulder of the generator. Align these holes with
the two threaded holes in the generator mounting
plate. Push the generator straight into the mounting
plate until the generator bottoms out. Tighten the
two (2) set screws until they just contact the
generator.
1. Loosen the two (2) coupling set screws using
a 5/64" Allen wrench.
2. Remove set screw from the air motor mounting
plate using a 1/8" Allen wrench and pull the air
motor straight out of the air motor mounting plate.
NOTE
> For most maintenance applications, it
NOTE
Both screws must touch the generator. Pushing the generator into the mounting plate, tighten the two (2) screws.
>
!
CAUTION
> Failure to carefully assemble and
tighten the set screws will cause the shaft
to contact the ID of the upper plate and the
unit will not function properly.
2. Be sure the shaft of the generator inserts
directly into the coupling. Tighten the coupling set
screws using a 5/64" Allen wrench.
CP-97-01.1
will not be necessary to perform steps 3
and 4 of this section. These components
do not require removal for generator or air
motor removal.
3. To remove the air motor mounting plate from
the generator assembly, remove three (3) socket
head cap screws from the motor/generator
standoffs using a 1/8" Allen head wrench.
4. To remove the three (3) standoffs, using an
adjustable wrench turn each of the standoffs
counter-clockwise. These standoffs are secured
to the generator mounting plate by a light retention
adhesive. When reinstalled, be sure to secure
these standoffs with a suitable adhesive.
ARCHIVE
16
AVIATOR Power Unit - Maintenance
Locate spacer [4]
at this location on
opposite side of
PC board.
AIR MOTOR
REPLACEMENT/
INST
ALLA
TION
INSTALLA
ALLATION
The air motor used for this product has been
specifically designed for the application. Use of
any other part other than the ones purchased from
ITW Ransburg may not perform adequately or
may fail prematurely, and will also void all product
warranties.
1. Install the air motor air inlet fitting into the proper
port or the motor. The proper port is the port to the
right when the air motor shaft is pointing upward
and ports are facing forward.
!
Figure 4: PC Board View
PC BOARD REMOV
AL
REMOVAL
CAUTION
> To extend the life of the air motor, do not
use any Teflon tape past the inlet to the filter
regulator unit. It is recommended to use a
liquid thread sealant such as 7969-10.
2. Install the exhaust restrictor in the remaining
port.
3. Apply a light coat of dielectric grease (5997200) to the mounting shoulder of the air motor.
Locate one of the countersinks in the mounting
shoulder of the air motor. Align the countersink
with the threaded hole in the air motor mounting
plate. Push the air motor straight into the mounting
plate until the generator bottoms out. Tighten the
set screw.
4. Be sure the shaft of the air motor inserts directly
into the coupling. Tighten the coupling set screws
using a 5/64" Allen wrench.
17
Locate [41]
washer
here on
this side of
PC board.
1. Perform "Removal of Generating Unit from
Enclosure" procedure in the "Maintenance" section.
2. Perform "Generating Unit Disassembly"
procedure located in the "Maintenance" section.
3. Remove the explosion proof cylinder from the
upper plate by turning the cylinder counterclockwise.
4. Holding the upper plate assembly in your hand,
disconnect the PC board from the cable and at the
potentiometer connection. Both can be easily
removed by pressing the connector lever and
pulling straight apart.
5. Remove the PC board from the standoffs by
removing three (3) slotted screws. Be sure to
notice the position of the ground washer and the
standoff spacer.
ARCHIVE
CP-97-01.1
AVIATOR Power Unit - Maintenance
PC BOARD
REPLACEMENT
NOTE
1. Install new PC board into place. The PC board
can only be positioned on the standoffs one way.
Be sure to install the spacer under the PC board as
shown in Figure 4.
> Each of the connectors is keyed in
such a way that there is only one way for
assembly. Also, each connector is designed only to fit together with the proper
mating connector.
2. Perform steps 1 through 5 from "PC Board
Removal" in reverse order.
5. With an adjustable wrench, remove the cable
fitting from the upper plate assembly.
CABLE REMOV
AL
REMOVAL
6. Push the cable connector through the threaded
hole in the upper plate assembly. Some side to
side movement of the connector may be required.
NOTE
> Due to the explosion proof design of
the AVIATOR, the cable is not removable
by a connection outside the AVIATOR.
! WARNING
> Prior to performing any maintenance on
the AVIATOR, all electrical circuits must be
de-energized. Be sure that the supply air is
completely disconnected from the unit and
the unit removed to a non-hazardous location for service.
1. Perform "Removal of Generating Unit from
Enclosure" procedure in the "Maintenance" section.
CABLE REPLACEMENT
1. Perform steps 1 through 6 from "Cable
Removal" section in reverse order.
2. Connect the cable to the applicator. Reference
the appropriate applicator manual for further
information.
! WARNING
> Prior to performing any maintenance on
the AVIATOR, all electrical circuits must be
de-energized. Be sure that the supply air is
completely disconnected from the unit and
the unit removed to a non-hazardous location for service.
2. Perform "Generating Unit Disassembly"
procedure in the "Maintenance" section.
3. Remove the explosion proof cylinder from the
upper plate by turning the cylinder counterclockwise.
4. With the upper plate assembly separated from
the rest of the unit, disconnect the PC board
connector from the cable connector.
CP-97-01.1
ARCHIVE
18
AVIATOR Power Unit - Maintenance
THEOR
Y OF OPERA
TION
THEORY
OPERATION
The AVIATOR operates on standard clean, dry
air. The air is used to drive a rotating motor
(outside the gun) which is connected to a generator.
This generator puts out a voltage to the PC board
that converts the generator signal, conditions it,
and regulates it. This voltage is then transported
down the cable and halted at a reed switch at the
end of the cable. If the reed switch is open, the
applicator is off. If the reed switch is closed, the
applicator has been triggered and voltage is
produced by the applicator.
TROUBLESHOOTING
No kV at the Applicator
(Easy Checks)
• Ensure air is on to the AVIATOR.
• Ensure the AVIATOR is properly grounded.
• Filter is plugged, replace element.
• Ensure 60 psig (4.1 bar) air is present with
the unit running.
• Ensure voltage adjust potentiometer is adjusted to full voltage.
• Ensure air motor to generator coupling is
properly secured to the shaft of each.
No kV at the Applicator
(Complex Checks)
If the AVIATOR is not producing power but you
can audibly hear the unit running, perform the
tests listed below to determine the cause of the
problem. Reference the "Maintenance" section
for repair/removal information.
! WARNING
> Prior to performing any maintenance on
the AVIATOR, all electrical circuits must be
de-energized. Be sure that the supply air is
completely disconnected from the unit and
the unit removed to a non-hazardous location for service.
1. Remove the cable from the applicator by
loosening the cable set screw in the handle of the
applicator. Pull the sleeve back off the cable (see
Figure 5). Using a suitable jumper, jump around
the reed switch.
Using a suitable VOM meter and the AVIATOR
running, measure the voltage at the two (2) female
pin connections of the cable. If voltage exists, the
problem is either the air valve magnet (reference
appropriate applicator manual), the reed switch
itself, or the applicator. If the reed switch is bad, a
new plug assembly is required. Reference the
"Cable Removal" and "Cable Replacement"
sections of this manual.
• Ensure cable is installed into applicator properly.
• Ensure a compatibly designed applicator is
being used with the AVIATOR (AVIATOR
requires specific applicator models, see
"Aviator/Applicator Capability" in the "Parts
Identification" section).
• Switch applicators to determine if the applicator or the AVIATOR is the cause of the
problem.
Figure 5: Reed Switch Jump
• Ensure pressure gauge reads 40-45 psi.
19
ARCHIVE
CP-97-01.1
AVIATOR Power Unit - Maintenance
If there is still no voltage, the following procedure
must be followed:
2. Perform "Removal of Generating Unit from
Enclosure" procedure.
If the measured voltages are the same at these
three points, the PC board requires replacement.
To replace the PC board, reference "PC Board
Removal" and "PC Board Replacement" sections
of this manual.
3. Perform "Generating Unit Disassembly"
procedure.
4. Perform "Cable Removal" procedure.
5. With the reed switch still jumped around, (see
Figure 5) use an appropriate VOM meter to
determine if the problem is in the cable or the
AVIATOR. Using the VOM probes, check the
continuity of the cable. If the cable is broken,
replace with appropriate cable.
Figure 6: Three Prong Connector
If the cable is not the problem perform the following:
6. With the generating unit on the bench, apply
approximately 20 psi (1.4 bar) air pressure to the
air motor.
! WARNING
Do NOT place fingers near rotating
parts.
>
With a VOM set to measure AC voltage, connect
one of the VOM lines to the metal casing of the
generating unit. Insert the other probe into each of
the three available openings of the connector,
measuring and recording the voltage at each of the
pins of the three prong connector as shown in
Figure 6.
The measured voltage at positions 1, 2, and 3
should be approximately the same. If any of the
three voltages are considerably lower than one
another, the generator requires replacement.
Reference "Generator Removal" and "Generator
Replacement/Installation" sections of this manual.
CP-97-01.1
ARCHIVE
20
AVIATOR Power Unit - Parts Identification
PAR
TS IDENTIFICA
TION
ARTS
IDENTIFICATION
Figure 7a: Aviator Power Unit Exploded View
21
ARCHIVE
CP-97-01.1
AVIATOR Power Unit - Parts Identification
Figure 7b: Aviator Power Unit Exploded View
CP-97-01.1
ARCHIVE
22
AVIATOR Power Unit - Parts Identification
VIAT
PAR
ARTS
AVIA
TOR POWER UNIT - P
AR
TS LIST (Figures 7a and 7b)
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
23
Part Number Description
76069-00
7747-16C
76062-01
73487-02
20481-11
76118-00
76070-00
76084-00
70105-02
76088-00
76082-00
76083-00
9704-03
76073-00
76085-00
76091-00
76071-00
76072-00
76100-00
78085-XX
76142-00
-7596-01
76143-00
-76144-00
-76079-00
----41-FBR-1000
--76080-00
76179-00
-76192-00
--78086-00
70539-00
RPM-419
76249-00
Cylinder, Explosion Proof
Machine Screw, #6-32 X 1/2" (3 Required)
PC Board Assembly, for REA-70, REA-90, and M90
Insulating Grommet
Standoff (3 Required)
Potentiometer Assembly
Upper Plate
Socket Head Cap Screw (5 Required)
Knob, Knurled
Handle
Air Motor
Coupling, Rotational
Polyethylene Tubing (16" Long)
Mounting Flange, Air Motor
Set Screw (3 Required)
Retaining Ring, AVIATOR
Standoff (3 Required)
Generator Mounting Plate
Generator
Cable Assembly, Low Voltage
Slide Valve, AVIATOR
Street Elbow, 90o, Brass
Bushing, Brass
Filter/Regulator/Lubricator
Reducer, 1/4" NPT X 1/8" NPT
Bulkhead Fitting
Flat Socket Head Cap Screw, 6-32 X 1/4" (8 Required)
Bottom Plate
Screw, Hex Head, 1/4-20 X 1"
Washer, Split Lock, 1/4-20 (2 Required)
Nut, 1/4-20 (2 Required)
Flat Washer, 1/4" (2 Required)
Breather
Bulkhead, 1/4" NPT, Female
Tubing, 1/8" NPT X 1/4", 90o
Enclosure, AVIATOR
Ground Wire Assembly, AVIATOR
Hex Head Cap, 1/4-20 X 1/2"
Replacement Filter
Lock Washer, 1/4" Int.
Lock Washer
Mounting Bracket
Ground Clamp
Special Spanner
Exhaust Orifice
ARCHIVE
CP-97-01.1
AVIATOR Power Unit - Parts Identification
78085 Low V
oltage Cable Assembly
Voltage
Dash
No.
36
50
75
100
Description
36' Low Voltage Cable Assemby
50' Low Voltage Cable Assembly
75' Low Voltage Cable Assembly
100' Low Voltage Cable Assembly
AVIA
TOR / APPLICA
TOR
VIAT
APPLICAT
MODEL IDENTIFICA
TION
IDENTIFICATION
The AVIATOR can be used with various applicators and cable lengths as shown below:
Model No.
75983 - XX XX
02 - For 75979 REA-90
For 75982 REA-90 Waterborne
For 75980 REA-70
36 - 36 ft. Low Voltage Cable and Hoses
50 - 50 ft. Low Voltage Cable and Hoses
75 - 75 ft. Low Voltage Cable and Hoses
100 - 100 ft. Low Voltage Cable and Hoses
Note: If no digits are used, cable will not be
(Note:
included)
VIAT
AVIA
TOR POWER UNIT - ACCESSORIES
Description
Part Number
REA-70 (72074) / REA-90 (75785, 75786) Applicator Conversion Kit
76145-00
CP-97-01.1
ARCHIVE
24
AVIATOR Power Unit - 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, ASSOCIATED VALVES AND TUBING, AND
SUPPORTING HARDWARE IN PLASTIC,
SHRINK-WRAP, OR ANY OTHER NONAPPROVED COVERING, WILL VOID THIS
WARRANTY.
25
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
CP-97-01.1
MANUAL CHANGE SUMMAR
Y
SUMMARY
This manual was published to replace Service
Manual CP-97-01
CP-97-01, AVIATOR Power Unit
Portable Power Generation Technology, to
make the following changes:
1. Added "
" to "Front Cover".
2. Added "Service Manual Price: €15.00 (Euro)
$20.00 (U.S.)" to "Front and Back Covers".
3. Removed "Model 75983-01 for use only with
75981 (REM)" on the "Front Cover".
4. Revised "Safety" section.
5. Added "Atex" section.
6. Added "Troubleshooting - No kV at the
Applicator (Easy Checks) - Ensure pressure
gauge reads 40-45 psi.
7. Revised "Aviator Power Unit Parts List - Item
20 - Low Voltage Cable Assembly - Part #
78085-XX" in the "Parts Identification" section.
8. Added "78085 Low Voltage Cable Assembly"
in the "Parts Identification" section.
9. Removed "Paint and Solvent Viscosity
Chart and Viscosity Conversion Chart". See
literature IL-307 Technical Supplement for All
Products.
10. Added "Warranty Policies" section.
11. Revised "Contact Information" on "Back
Cover".
CP-97-01.1
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
IV
E
Telephone: 800/ 626-3565 Fax: 419/ 470-2040
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
Telephone: 800/ 233-3366 Fax: 419/ 470-2071
A
R
C
H
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. CP-97-01.1
Litho in U.S.A.
05/08
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