RPA-2 Powder Applicator (Serv. Man. LN-9271-12.2)

RPA-2 Powder Applicator (Serv. Man. LN-9271-12.2)
SERVICE MANUAL
LN-9271-12.2
April 2013
Supersedes LN-9271-12.1
RPA-2
MODEL: A12950-XXX
IMPORTANT: Before using this equipment,
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
Service Manual Price: $50.00 (U.S.)
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Contents
CONTENTS
SAFETY:
PAGE
1-6
SAFETY PRECAUTIONS ......................................................................................................... 1
HAZARDS / SAFEGUARDS................................................................................................... 2-6
INTRODUCTION:
7-11
GENERAL DESCRIPTION........................................................................................................ 7
POWDER APPLICATOR MAIN COMPONENTS ...................................................................... 8
TOOLS REQUIRED .................................................................................................................. 9
HIGH VOLTAGE GENERATION/ROUND NOZZLE DESCRIPTION ....................................... 10
SPECIFICATIONS/CENTER OF GRAVITY ............................................................................ 11
INSTALLATION:
12-13
CONNECTION PROCEDURE ................................................................................................ 12
FUNCTION CHECK AND SCHEMATIC .................................................................................. 13
OPERATION:
14-15
GENERAL OPERATION/START-UP ................................................................................. 14-15
MAINTENANCE:
16-27
TROUBLESHOOTING GUIDE ........................................................................................... 16-17
INSPECTING AND CLEANING.......................................................................................... 17-18
APPLICATOR DIS-ASSEMBLY ......................................................................................... 18-24
HIGH VOLTAGE CONTACT WIRE REPAIR ........................................................................... 25
APPLICATOR ASSEMBLY ..................................................................................................... 26
DEFECTIVE PARTS RECOGNITION ..................................................................................... 27
PARTS:
28-42
APPLICATOR PARTS DRAWING ..................................................................................... 28-30
PARTS LIST AND DRAWINGS.......................................................................................... 31-37
SHAPE AIR ASSEMBLY AND PARTS LIST ...................................................................... 37-38
ELECTRODE ASSEMBLY AND PARTS LIST ................................................................... 39-40
SPARE PARTS .................................................................................................................. 41-42
WARRANTY POLICIES:
43
LIMITED WARRANTY............................................................................................................. 43
LN-9271-12.2
RPA-2 POWDER APPLICATOR– Safety
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read
and understand all of the technical and safety
literature for your Ransburg products. This
manual contains information that is important
for you to know and understand. This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help
you recognize this information, we use the following symbols. Please pay particular attention
to these sections.
A WARNING! states information to alert you
to a situation that might cause serious injury if instructions are not followed.
A CAUTION! states information that tells
how to prevent damage to equipment or
how to avoid a situation that might cause
minor injury.
A NOTE is information relevant to the procedure in progress.
While this manual lists standard specifications
and service procedures, some minor deviations may be found between this literature and
your equipment. Differences in local codes and
plant requirements, material delivery requirements, etc., make such variations inevitable.
Compare this manual with your system installation drawings and appropriate Ransburg
equipment manuals to reconcile such differences.
!
WARNING
The user MUST read and be familiar
with the Safety Section in this manual and
the Ransburg safety literature therein
identified.
This manual MUST be read and thor-
oughly 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, LATEST EDITION,
prior to installing, operating, and/or servicing this equipment.
!
WARNING
The hazards shown on the following
pages 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
Ransburg representative or Ransburg.
1
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards may occur.
Tells what the hazard is.
Tells how to avoid the hazard.
Spray Area
Fire Hazard
Fire extinguishing equipment must be present in
the spray area and tested periodically.
Improper or inadequate operation and maintenance proce- Spray areas must be kept clean to prevent the accumulation of combustible residues.
dures will cause a fire hazard.
Protection against inadvertent Smoking must never be allowed in the spray area.
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation. Frequent Power Supply or Controller shutdown indicates a problem in the
system requiring correction.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing or maintenance.
When using solvents for cleaning:
•
Those used for equipment flushing should
have flash points equal to or higher than those
of the coating material.
•
Those used for general cleaning must have
flash points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained during cleaning operations using flammable
or combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance
of 1 inch for every 10KV of output voltage is required at all times.
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,
OSHA, local, country, and European Health and
Safety Norms.
LN-9271-12.2
2
RPA-2 POWDER APPLICATOR– Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards may occur.
Tells what the hazard is.
Tells how to avoid the hazard.
Spray Area
Explosion Hazard
Electrostatic arcing must be prevented. Safe
Improper or inadequate opera- sparking distance must be maintained between the
tion and maintenance proce- parts being coated and the applicator. A distance
dures will cause a fire hazard.
of 1 inch for every 10KV of output voltage is reProtection against inadvertent quired at all times.
arcing that is capable of causing
fire or explosion is lost if any Unless specifically approved for use in hazardous
safety interlocks are disabled locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
during operation.
areas, in accordance with NFPA-33.
Frequent Power Supply or Controller shutdown indicates a Test only in areas free of flammable or combusproblem in the system requiring tible materials.
correction.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding
section of the equipment manual. Protection
against inadvertent arcing that is capable of
causing fire or explosion is lost if the current overload sensitivity is not properly set. Frequent
power supply shutdown indicates a problem in the
system which requires correction.
Always turn the control panel power off prior to
flushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no objects are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance
with NFPA-33, EN 50176.
Have fire extinguishing equipment readily available
and tested periodically.
General Use and
Maintenance
Improper operation or mainte- Personnel must be given training in accordance
nance may create a hazard.
with the requirements of NFPA-33, EN 60079-0.
Personnel must be properly Instructions and safety precautions must be read
trained in the use of this equip- and understood prior to using this equipment.
ment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation maintenance, and housekeeping. Reference
OSHA, NFPA-33, EN Norms and your insurance
company requirements.
3
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards may occur.
Tells what the hazard is.
Tells how to avoid the hazard.
Spray Area / High Electrical Discharge
Voltage Equipment
There is a high voltage device
Parts being sprayed and operators in the spray
area must be properly grounded.
that can induce an electrical
charge on ungrounded objects
Parts being sprayed must be supported on conveywhich is capable of igniting coat- ors or hangers that are properly grounded. The
ing materials.
resistance between the part and earth ground must
not exceed 1 meg ohm. (Refer to NFPA-33.)
Inadequate grounding will cause
a spark hazard. A spark can
Operators must be grounded. Rubber soled insuignite many coating materials
lating shoes should not be worn. Grounding straps
and cause a fire or explosion.
on wrists or legs may be used to assure adequate
ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the palm
section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
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.
Grounded conductive flooring must be provided in
the spray area.
Always turn off the power supply prior to flushing,
cleaning, or working on spray system equipment.
Unless specifically approved for use in hazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
LN-9271-12.2
4
RPA-2 POWDER APPLICATOR– Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards may occur.
Tells what the hazard is.
Tells how to avoid the hazard.
Electrical
Equipment
Electrical Discharge
High voltage equipment is utilized in the process. Arcing in
the vicinity of flammable or
combustible materials may occur. Personnel are exposed to
high voltage during operation
and maintenance.
Unless specifically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 50176.
Turn the power supply OFF before working on the
Protection against inadvertent equipment.
arcing that may cause a fire or
explosion is lost if safety circuits Test only in areas free of flammable or combustible material.
are disabled during operation.
Frequent power supply shut- Testing may require high voltage to be on, but only
down indicates a problem in the as instructed.
system which requires correcProduction should never be done with the safety
tion.
circuits disabled.
An electrical arc can ignite coating materials and cause a fire or Before turning the high voltage on, make sure no
objects are within the sparking distance.
explosion.
Toxic Substances
Chemical Hazard
Follow the requirements of the Material Safety
Certain materials may be harm- Data Sheet supplied by coating material manufacful if inhaled, or if there is con- turer.
tact with the skin.
Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
Use a mask or respirator whenever there is a
chance of inhaling sprayed materials. The mask
must be compatible with the material being
sprayed and its concentration. Equipment must be
as prescribed by an industrial hygienist or safety
expert, and be NIOSH approved.
5
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Safety
AREA
HAZARD
SAFEGUARDS
Tells where hazards may occur.
Tells what the hazard is.
Tells how to avoid the hazard.
Spray Area
Explosion Hazard—
Incompatible Materials
Halogenated hydrocarbon solvents for example: methylene
chloride and 1,1,1,Trichloroethane are not chemically compatible with the aluminum that might be used in many
system components. The
chemical reaction caused by
these solvents reacting with aluminum can become violent and
lead to an equipment explosion.
LN-9271-12.2
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum equipment during spraying, flushing, or cleaning. Read
the label or data sheet for the material you intend
to spray. If in doubt as to whether or not a coating
or cleaning material is compatible, contact your
coating supplier. Any other type of solvent may be
used with aluminum equipment.
6
RPA-2 Powder Applicator - Introduction
INTRODUCTION
GENERAL DESCRIPTION
This operating manual contains all important
information required for working with the RPA2 Powder Applicator. It will give you references and tips for the optimal use of your new
powder coating system.
The RPA-2 is intended exclusively for the
electrostatic coating with organic powders.
Any other use is considered as nonconforming. The manufacturer is not responsible for any damage resulting from this; the risk
for this is assumed by the user alone.
With an integrated high voltage generator
(cascade), the RPA-2 is particularly suitable
for the coating of car bodies and parts. The
applicator is designed for operation on a freely
programmable hollow wrist robot (up to 7
axes).
The RPA-2 is installed on the front side of a
follow-arm coating robot. An appropriate
adapter piece for the corresponding robot type
is used for fitting the applicator to the robot.
This adapter provides a locating pin for exact
positioning of the applicator, as well as the
fixture of the applicator cable and hoses.
The RPA-2 has a high and constant transfer
efficiency.
The applicator is quick detachable, therefore
fast and easy for maintenance and repair.
The wear parts can be easily changed, even
with the applicator attached to the robot.
7
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Introduction
7
1
3
2
5
6
4
1– Shaping Air
5- Applicator Ground Cable and Low Voltage Cable
2– Applicator Body
6– Powder Hose Connection
3– High Voltage Cascade (Internal)
7– Nozzle
4—Robot Adapter
Figure 1: RPA-2 Powder Applicator
LN-9271-12.2
8
RPA-2 Powder Applicator - Introduction
Tools Required for Assembly/Dis-Assembly
76772-00 Spanner Wrench
Hex Keys
Adjustable
Wrench
6mm
A13001-00
Tool– Powder
Inlet Fitting
(Included with
applicator)
9
3/16
3/32
Flat Blade
Screwdriver
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Introduction
High Voltage Generation
Round Jet Nozzle With Air
Cleaned Electrode
The applicator high voltage control unit supplies a high frequency low-voltage signal to
the cascade. This voltage is fed through the
applicator cable and the cascade connection.
The low-voltage signal is multiplied in the cascade to produce the necessary high voltage
(up to 100 kV).
The high voltage is fed through a conductive
path in the atomizer to the central electrode
(see figure 1)
The round nozzle shapes and distributes the
powder. The powder cloud obtains a bellsimilar spray pattern by the deflector plate and
by the dynamic powder/air flow.
The powder is charged by means of the central electrode. The high voltage, which is produced by the cascade in the applicator, is connected to the electrode through the black contact ring on the nozzle holder. The round nozzle front face is rinsed with compressed air in
order to prevent powder accumulations. The
electrode rinsing air is fed into the electrode
holder through the small hole in the black contact ring of the nozzle holder. The electrode
rinsing air volume is typically maintained at a
constant setting of 40-50 SLPM.
POWDER EXIT
BLACK CONTACT
RING
FRONT FACE
CENTRAL
ELECTRODE
Round Nozzle (Figure
LN-9271-12.2
10
RPA-2 Powder Applicator - Introduction
SPECIFICATIONS
Environmental
Electrical
Operating Temperature:
Storage and Shipping
Temperature:
Humidity:
0°C to +55°C
-40°C to +85°C
95% Non-Condensing
Output Voltage:
100 kV @ Ø µa
Maximum Output Current:
240 µa @ 0 kV
Polarity:
Negative
Physical
11
Height:
See Figure
Width:
See Figure
Depth:
See Figure
Weight:
4.2 kg (9.26 lbs.)
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Installation
INSTALLATION
!
WARNING
The relevant Safety Standards, as well as the
Safety Regulations of the robot manufacturer
must be adhered to for the operation of the
RPA-2 applicator
CONNECTING PROCEDURE
1. Attach the robot adapter to the end of the robot.
2. Lay out the applicator powder hose, electrode
rinsing air hose, cascade rinsing air hose, and
shaping air hose in such a way that neither
kinks or twist can likely form
3. Connect the shaping air (SA) to the proper
push-in fitting on the robot plate. Clean pneumatic tubing of any debris.
4. Connect the electrode rinsing air (EA) to the
robot plate. Clean pneumatic tubes of any debris.
5. Connect the cascade rinsing air (CA) to the
robot plate.
6. Connect the ground cable to “GND” fitting on
the robot plate. Do Not Over Tighten
7. Connect the other end of the ground cable to
a good known earth ground source after installing the cable thru the robot arm.
8. Connect the low voltage cable to the robot
plate Align marks and tighten set screw. (See
Picture)
9. Install tubing and cables thru the robot arm.
Attach robot plate to robot adapter with (4)
77566-24C screws. (3/16 hex key)
LN-9271-12.2
10. Connect the low voltage cable to the control
unit. (see the current MicroPak or Evolver
MicroPak controller service manuals for wire
termination.)
Suggested switch setting:
SW-3 (1&2 On)
SW-7 (1 On) ( 5&6 Off)
11. Powder supply can either be delivered
through the dilute phase pump (Venturi) or
dense phase pump.
A. Dilute phase powder supply hose is
connected to the applicator. (Items 51,
52, 53,and 54 are ordered separately for
a Venturi Feed application.) “Table A—
Upper Powder Tube” in the “Parts Identi
fication” section shows optional parts
required for the tube connection. Con
nect dilute phase powder supply hose
(only if available.)
B. Dense phase powder supply hose is
connected to the multi-color integrator
(MCI). The MCI will use dilution air to
dilute the dense phase powder. Dilution
air requirements are powder dependent.
Connect the MCI to the open threaded
connection next to the pneumatic tube
connections.
The multi-color integrator will also have
the required powder supply lines and
one more pneumatic link used for a
pinch valve. Refer to “Function and
Operation” information from MCI
manufacturer’s documentation.
12. Align the 2 pins on the applicator rear plate
with the mating holes of the robot plate.
Spin the mounting ring to tighten applicator
to the robot plate.
12
RPA-2 POWDER APPLICATOR - Installation
5. Verify the presence of the high voltage field by
means of a high voltage probe.
Function Check
1. Switch on the high voltage controls. A good setting to start is 20 kV for doing checks
2. Adjust the high voltage at the control unit.
3. Slowly increase the high voltage. The value of
the high voltage display should increase slowly.
4. The maximum nominal output current can be
monitored on the applicator control unit.
6. Shaping air, electrode rinsing air, cascade rinsing air and dilution air (if available) are adjusted
depending on the application (see “Start-Up” in
the “Operation” section).
7. If all tests have been completed positively, the
applicator is ready for operation. If malfunctions
happen, the error cause can be determined by
means of the list in the ‘Troubleshooting Guide”
in the maintenance section.
Alignment Marks
Alignment Marks
13
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Operation
OPERATION
GENERAL OPERATION
START—UP
There are several variables that need to be considered when using this applicator. Each one influences the operation. They are:
Adjusting the Powder Output /Powder Cloud
1. High voltage affects how much the powder is
charged. If the kV is set too high, defects will
appear. If the kV is set too low, then the powder will not charge and will not stick to the substrate.
The powder output depends on the powder
type, the powder hose length, the powder
hose diameter, and the powder pump. The
RPA-2 applicator can be used in connection
with Venturi pumps and dense phase pumps
like (i.e. powder pressure pump).
2. Shaping air is used to control pattern size.
With high amounts of shaping air, the air will
propel the powder particles quickly towards
the target. This may reduce transfer efficiency.
a. Round Spray– Electrode rinsing air provides a cushion of air in front of the deflector and assists in keeping its front face
clear. This s usually set at 45-50 SLPM.
b. Open Bore Nozzle- set electrode rinsing
air 8-10 SLPM. The air helps keep the
electrodes clean.
3. Cascade air is used to ventilate the inside of
the applicator. The normal setting is between
25 and 50 SLPM.
4. Target distance between the applicator and
substrate will influence how big the pattern is.
A good starting point is 8-inches.
5. Robot arm speed (TIP speed) is used to influence the rate at which powder is applied.
6. Powder flow rate is the primary influencer of
the rate at which powder can be applied.
!
WARNING
Make sure that all electrostatically conductive parts within 5 meter of the spray
booth are grounded!
LN-9271-12.2
The operating principle of the injector and the
different powder pumps is explained in their
corresponding operating manuals.
1. Switch on the power supply.
2. Adjust the powder output.
3. Adjust the shaping air, so that the form of
the powder cloud corresponds to the desired size. A good initial setting is 20
SLPM.
4. Adjust the dilution air ( if powder applicable) so that the form of the powder cloud is
uniform. A good initial setting is 90 SLPM.
Lowest dilution air setting will be above 40
SLPM.
5. Adjust the electrode rinsing air flow, so
that the desired form of powder cloud is
not impaired. A good initial setting is 50
SPLM.
6. Switch high voltage on the control unit.
(See applicable service manual for operation of high voltage controls.)
7. A good initial voltage setting is 60 kV set
point for voltage or current control.
8. Trigger kV and Powder OFF.
14
RPA-2 POWDER APPLICATOR - Operation
9. The adjustments for high voltage, electrode rinsing air, shaping air, dilution air (if
available), and powder output can be left
as they are now that powder is triggered
off.
10. If work is interrupted such as lunch time,
night, etc.. Switch off the high voltage control unit and disconnect the main compressed air supply.
15
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Maintenance
MAINTENANCE
TROUBLESHOOTING GUIDE
General Problem
Possible Cause
Solution
High voltage display shows no
value, although
the control unit is
switched on and
high voltage is
being called for.
In the applicator:
1. Replace applicator low voltage cable,
send in for repair. Check connections
for proper contact.
During coating,
air flows out of
the applicator
body.
1. O-Ring defective or missing 1.
on shaping ring
2.
2. Loose fitting hose
1. Applicator cable defect
2. High voltage cascade defect
3. Wrong MicroPak switch settings
1. Powder hose, applicator,
The applicator
injector, non-return valve,
does not spray
powder in spite
or throttle on the injector
calling for powder
clogged
flow.
2. Insert sleeve on the injector
is worn
2. Replace high voltage cascade, send in
for repair.
3. Check MicroPak settings (Refer to current MicroPak service manual.
Replace or insert O-ring
Check fitting— push in hose
1.
Carry out corresponding cleaning.
2.
Replace( see the corresponding Operating Manual of the injector).
3.
Replace
4.
See “Dense Phase Pump” manual.
3. No conveying air:
a. Solenoid valve defective
4. Dense phase pump not
working
Powder applicator 1. Applicator plug, applicator
1.
sprays powder,
cable, or connection defecbut the powder
tive
2.
does not adhere
2. High voltage cascade is deon the work
fective
3.
piece.
3. Plugged electrode
LN-9271-12.2
Replace defective part or send in for
repair.
Send in the applicator for repair or replace high voltage cascade.
Pneumatically blow backwards
through hollow tube.
16
RPA-2 POWDER APPLICATOR - Maintenance
MAINTENANCE
TROUBLESHOOTING GUIDE
General Problem
Possible Cause
Applicator sprays 1. High voltage too low
powder, high volt2. Work piece not properly
age available, but
grounded
the powder does
not adhere on the
work piece.
INSPECTING AND CLEANING THE APPLICATOR
1. Blow off the atomizer externally with compressed air.
2. If a solvent wipe is required, use VM&P
Naphtha for a final wipe to remove any conductive residue.
3. Clean the atomizer only with a damp rag.
Never immerse the components into solvents.
Solution
1. Increase high voltage on the control unit.
2. Check the grounding/measure
3. Look for loose connections
•
Plastic on conductive component
•
Loose fitting hinges
•
Non-conductive coating present on substrate before spraying.
!
WARNING
Before cleaning applicator. switch off the
control unit. The compressed air used for
cleaning must be free of oil, water and other
contaminates.
!
WARNING
Make sure the large diameter threaded
ring (applicator body to shaping ring) is always tightened well. If it is fitted loosely,
there is a danger that a discharge may occur
with the high voltage, which leads inevitably
to damaging the plastic components.
4. Remove any impact fusion on deflector
without scratching or scoring the soft plastic
surface of the deflector. Impact fusion can
be removed with a solvent soaked towel.
5. If impact fusion is not removed, it will shorten the life of the parts and cause defects
6. Blow out all powder hoses with high
volume/high velocity air purge during cleaning.
17
!
WARNING
Be careful with nozzle electrode during
cleaning and maintenance— danger of injury! Never bend or pull electrode
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Maintenance
Cleaning Powder Hose
(Venturi Feed)
The powder hose has to be cleaned from the
residual powder. The cleaning takes place in
the following steps:
•
The deflector plate is no longer round or is
worn
•
The wedge of the electrode holder wear
bar is worn down to the electrode holder
•
Check low voltage cable for cuts, abrasion, and wear.
1. Strip the powder hose from the connection
on the Venturi pump.
2. Blow through the hose manually with compressed air to blow loose powder through
to the applicator.
3. Fit the powder hose onto the hose connection on the injector.
!
WARNING
Regular and conscientious maintenance
increases the life span of the RPA-2 applicator and provides for a larger continuous coating quality with reduced defects.
Weekly Cleaning and Inspection
1. Remove the electrode holder by removing
the shaping air ring. Clean on the inside
with compressed air and remove possible
powder accumulations.
2. Check for wear or damage on parts that
contact powder.
3. Follow “Daily Cleaning” steps.
4. The powder supply is to be filled with powder just before resumption of the operation.
DISASSEMBLING THE
APPLICATOR
Before disassembling the applicator, turn off
the air supply to shaping air, atomizing air( if
available), and rinsing airs.
1. Remove Robot Adapter Covers
Monthly Cleaning and Inspection
Follow “Daily cleaning” steps.
The atomizer wear parts are to be inspected
and replaced if:
•
Uneven powder distribution on deflector as
compared to starting
•
The spray pattern no longer has a regular
form
LN-9271-12.2
18
RPA-2 POWDER APPLICATOR - Maintenance
2. Remove Robot Adapter by unthreading
large diameter retaining ring.
4a. Unscrew the Shaping Air Ring
Applicator with Round Nozzle and
Electrode Holder Assembly
4b. Remove the Shaping Air Ring
3. Unscrew Round Deflector
4c. Remove the Nozzle With Power Tube
19
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Maintenance
5. Remove rear plugs to view elbows only
6. View of Lower Powder Tube and Ring
Ass’y, and O-ring in Correct Orientation.
6a. Lift Lower Powder Tube and Ring Ass’y
5a. Lift Elbow Off Lower Powder Tube and
Ring Ass’y
6b. Lower Powder Tube and Ring Ass’y
Alignment Pin
5b. Pull Out
Alignment Pin (White)
LN-9271-12.2
20
RPA-2 POWDER APPLICATOR - Maintenance
7. Backside of Applicator W/Counter
electrode contact (if equipped)
6c. Slot Position
SLOT
Counter Electrode Contact
6d. Extract Out Top Port
8. Remove (4) Screws From Applicator
Plate (6mm Hex Key)
6e. View of Lower Powder Tube and Ring
Ass’y and Slot
9. Remove Applicator Plate
SLOT
21
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Maintenance
10. Remove Cascade
11b. Resistor
11. Counter Electrode Dis-Assembly (If
Equipped)
11c. Counter Electrode Parts in Order of
Installation
12. Counter electrode (Front of Applicator)
11a. Contact Spring Assembly
Mounng Screw (2)
LN-9271-12.2
22
RPA-2 POWDER APPLICATOR - Maintenance
12a. Contact Spring—Front (Shown With
Mounting Screws Loose)
Mounting Screw
13c. Parts Required For No Counter
Screws
Counter Electrode Blank
Contact Spring, part of Gun
Counter Electrode Contact Blank
13. No Counter Electrode Option
Counter Electrode Contact Blank
13a. Counter Electrode Blank (Shown With
Mounting Screws Loose)
Screw
Counter Electrode Blank
Body Option Without Spring Contact
23
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Maintenance
Nozzle Assembly (A11295-00)
Diffuser and Nozzle Holder (Tighten Until
Stop)
Wear Bar and Conductive Seal
Wear Bar Slot (Push Wear Bar Straight In)
Slot
LN-9271-12.2
24
RPA-2 POWDER APPLICATOR - Maintenance
High Voltage Contact Repair
Pull damaged spring and wire out from the front of applicator with pliers. Insert new contact assembly from front of application until spring
rests in the bottom of the hole. From inside the cascade labyrinth, use
a 3/16” diameter flat-end plastic rod and bend over flat.
High Voltage Contact Repair
25
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Maintenance
ASSEMBLY OF THE APPLICATOR
Assemble the applicator in reverse order of
the disassembly.
Note: The lower powder tube has an alignment
slot (see above) which must align with the alignment pin in the gun body for proper fit of components.
Assembly Notes:
1. The lower powder tube and ring ass’y elbow, and upper
powder tube must align
to create a seal. The best method is to
assemble all three parts loosely, then
tighten the thumb screws, and then tighten
the shaping air or shroud.
SLOT
2. The power hose connection should always
be rotated in until the lower powder tube and
ring ass’y seals in the powder elbow.
Alignment Pin (White color)
LN-9271-12.2
26
RPA-2 POWDER APPLICATOR - Maintenance
Normal Deflector
Normal Nozzle Holder
Normal Wear Bar
27
Replace Deflector
Replace Nozzle
Replace Wear Bar
LN-9271-12.2
39
52
13
LN-9271-12.2
7
53
16
DETAIL C
SCALE 1 : 1
16
25
18
54
15
51
26
C
20
7
52
8
53
20
11
20
16
10
22
21
20
21
40
22
OR 48
54
8
9
22
51
40
40
10
23
21
11
23
3
40
9
20
15
15
22
49
40
21
24
24
42
2
24
12
49
41
24
4
56
1
43
27
36
19
33
37
34
45
29
35
63
D
61
38
32
31
RPA-2 POWDER APPLICATOR - Parts
RPA-2 ASSEMBLY
28
35
38
31
36
32
37
61
29
36
45
34
33
19
1
4
41
12
42
D
RPA-2 POWDER APPLICATOR - Parts
RPA-2 ASSEMBLY (CONT’D.)
29
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Parts
RPA-2 with Open Bore Nozzle
RPA-2 with Replaceable Elbow, Upper Tube, and Electrode Holder
RPA-2 ASSEMBLY (CONT’D.)
LN-9271-12.2
30
RPA-2 POWDER APPLICATOR - Parts
PARTS LIST
31
ITEM
1
2
3
4
7
8
9
10
11
12
13
15
16
18
19
20
21
22
23
24
25
26
27
29
31
32
33
34
35
36
37
38
39
40
PART NUMBER
A12944-00
A12945-00
A12946-00
G
A10890-02
O
N
M
L
K
E
SSF-2052
A11129-00
C
A12948-00
76566-24C
A12952-00
7554-08
7554-12
7554-09
Z
AA
A
A11571-00
A11174-00
A11124-00
A11173-00
A11122-00
J
I
B
H
W
A11338-00
41
42
43
45
47
48
49
51
52
53
54
55
56
61
62
63
X
Y
V
A
B
P
79001-09
R
S
T
U
A13001-00
A13101-00
A11131-00
D
A11146-00
DESCRIPTION
INLET FITTING
REAR PLATE
ROBOT PLATE
ASS'Y. CASCADE HP404
FITTING, 8 MM ODT X 1/4 BSP
BODY, RETAINING CAP
PLUG, RETAINING, CONTACT PIN
SPRING, CLOSED AND GROUND
PIN CONTACT
PLUG CONTACT
LOW VOLTAGE CABLE (QUICK DISCONNECT)
SET SCREW 3/8 LG X 10-24
FITTING, 1/4 UNIVERSAL X METRIC ODT PNEUMATIC
ROBOT ADAPTER (FANUC P-200/P-250)
MOUNTING RING
SCREW, STAINLESS 1/4-20 X 3/4 LG. S.H.C.S.
AIR STUD, MEDIUM MACHINED
O-RING, VITON
O-RING, VITON
O-RING, VITON
COVER
SCREW (M5 X 0.8) NYLON
UPPER POWDER TUBE
LOWER POWDER TUBE AND RING ASSEMBLY
TOP PLUG
O-RING (SOLVENT RESISTANT)
REAR PLUG
O-RING (SOLVENT RESISTANT)
CHARGING RING, SECONDARY OR BLANK SPACER
SCREW (M3 X 0.5 X 10 FLT HD.)
#2 ELECTRODE HOLDER ASSEMBLY
SHAPING AIR RING ASSEMBLY
GROUND CABLE ASSEMBLY (RMA-303)
SCREW, SOC HD CAP M8 X 25MM LG
RESISTOR, HIGH MEGAOHM, .5 GIG
CONTACT SPRING
RPA GUN BODY ASSEMBLY
ELBOW
OPEN BORE FLAT JET NOZZLE ASSEMBLY
HOLE PLUG, COUNTER ELECTRODE (NOT SHOWN)
O-RING, SOLVENT PROOF
POWDER TUBE THREAD ADAPTER
POWDER TUBE FITTING
POWDER TUBE CLAMP
O-RING ( 12.0 X 1.50 VITON)
TOOL (NOT SHOWN)
LABEL
O-RING (SOLVENT RESISTANT)
LOW VOLTAGE CABLE EXTENSION
PLUG
QTY
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
4
3
3
1
3
2
8
1
1
1
1
1
1
1
2
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Parts
TABLE A Upper Tube and Elbow
DASH
No
A
A
DESCRIPTION
1
A11196-00 A11199-01 UPPER POWDER
TUBE- ELBOW
(DENSE PHASE)
2
A11196-00 A11199-01 UPPER POWDER
TUBE- ELBOW
(VENTURI PHASE)
LN-9271-12.2
R
S
T
U
—
—
—
—
A11133 -00 A11132-00 A11127-00 A11130-00
32
RPA-2 POWDER APPLICATOR - Parts
TABLE B Electrode Holder
DASH
B
1
A11295-11
2
A12052-00
B
DESCRIPTION
ELECTRODE HOLDER ASSEMBLY W/ REPLACEMENT
WEAR BAR
A11138-00
OPEN BORE FLAT JET NOZZLE ASSEMBLY
TABLE C ROBOT ADAPTER
DASH NO.
33
C
DESCRIPTION
0
---
NONE
1
A12947-00
FANUC ROBOT ADAPTER (P-200/P-250)
2
A12955-00
MOTOMAN ROBOT ADAPTER (PX-2850)
3
A12956-00
MOTOMAN ROBOT ADAPTER (PX-2900)
4
A12958-00
ABB ROBOT ADAPTER (5400 ENHANCED)
LN-9271-12.2
LN-9271-12.2
——
A12433-75 A12239-06
08
11
A12433-50 A12239-06
07
——
A12433-25 A12239-06
06
10
A12241-75 A12239-06
05
A12239-75
A12239-50
A12239-25
A12241-50 A12239-06
04
——
A12241-40 A12239-06
03
09
A12241-25 A12239-06
02
——
A12241-15 A12239-06
——
00
E
01
D
DASH
NO.
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK (QUICK CONNECT
VERSION END TO STANDALONE MICROPAK)
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK (QUICK CONNECT
VERSION END TO STANDALONE MICROPAK)
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK (QUICK CONNECT
VERSION END TO STANDALONE MICROPAK)
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK (QUICK CONNECT
VERSION END TO STANDALONE MICROPAK)
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK (QUICK CONNECT
VERSION END TO STANDALONE MICROPAK)
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK (QUICK CONNECT
VERSION END TO STANDALONE MICROPAK)
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK( HARD WIRE VER-
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK( HARD WIRE VER-
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK( HARD WIRE VER-
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK( HARD WIRE VER-
LOW VOLTAGE CABLE– QUICK CONNECT TO MICROPAK( HARD WIRE VER-
N/A
DESCRIPTION
TABLE D LOW VOLTAGE CABLE
75 FT.
50 FT.
25 FT.
75 FT.
50 FT.
25 FT.
75 FT.
50 FT.
40 FT.
25 FT.
15 FT.
—
LENGT
H
RPA-2 POWDER APPLICATOR - Parts
34
RPA-2 POWDER APPLICATOR - Parts
TABLE E
DASH NO.
0
—
DESCRIPTION
NO MICROPAK HP-505 CASCADE
G– CASCADE
A10565-00
1
A11789-01 1 MICROPAK & 1 DISCRETE WITH STANDALONE
ENCL. HP-505
A10565-00
2
A11789-02 2 MICROPAK & 2 DISCRETE WITH STANDALONE
ENCL. HP-505
A10565-00
3
A11789-05 1 MICROPAK & 1 DISCRETE WITH STANDALONE
ENCL. HP-404
79010-01
4
A11789-06 2 MICROPAK & 2 DISCRETE WITH STANDALONE
ENCL. HP-404
79010-01
5
35
F
STANDALONE POWER SUPPLY
—
NO MICROPAK HP-404 CASCADE
79010-01
LN-9271-12.2
LN-9271-12.2
A11151-00
A12056-00
A11151-00
A12056-00
2
3
4
----
H
1
0
NO.
DASH
A12862-00
A12894-00
A12894-00
SHROUD AIR
(OPEN BORE NOZA12643-00
ZLE) WITH COUNTER ELECTRODE
A13029-00
SHAPING AIR
RING (EXTERNAL)
WITHOUT COUNTER ELECTRODE
SHROUD AIR
(OPEN BORE NOZZLE) WITHOUT
A13029-00
COUNTER ELECTRODE
----
J
A12862-00
----
I
A12643-00
SHAPING AIR
RING (EXTERNAL)
WITH COUNTER
ELECTRODE
NONE
DESCRIPTION
----
----
A10123-00
A10123-00
----
K
----
----
78660-00
78660-00
----
L
----
----
75831-03
75831-03
----
M
----
----
75836-00
75836-00
----
N
O
----
----
75835-00
75835-00
----
TABLE F SHAPING AIR RING / COUNTER ELECTRODE
A12963-00
A12963-00
----
----
----
P
A12949-01
A12949-01
A12949-00
A12949-00
----
V
----
----
78365-00
78365-00
----
X
----
----
A12959-00
A12959-00
----
Y
RPA-2 POWDER APPLICATOR - Parts
36
RPA-2 POWDER APPLICATOR - Parts
TABLE G GROUND CABLE ASSEMBLY
DASH NO.
W
DESCRIPTION
1
A11680-10
CABLE, HIGH VOLTAGE GROUND (10 FT.)
2
A11680-25
CABLE, HIGH VOLTAGE GROUND (25 FT.)
3
A11680-50
CABLE, HIGH VOLTAGE GROUND (50 FT.)
4
A11680-75
CABLE, HIGH VOLTAGE GROUND (75 FT.)
5
A11680-100
CABLE, HIGH VOLTAGE GROUND (100 FT.)
7
4
8
5
6
2
6
1
3
RPA-2 Powder Applicator Shaping Air Cowl (A11151-00)
RPA-2 Powder Applicator Shaping Air Cowl (A11151-00)
- Parts List
37
Item #
Part #
Description
QTY
1
A11142-00
THREADED RING (SHAPING AIR
1
2
A11143-00
SHAPING AIR RING ORIFICE (0,7 MM)
32
3
A11134-00
SHAPING AIR RING
1
4
A11163-00
O-Ring
1
5
A11150-00
O-Ring
32
6
A11149-00
O-Ring
2
7
A11148-00
O-Ring
1
8
A11147-00
O-Ring
1
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Parts
Shroud air ( Open Bore Nozzle) (A12056-00)
SHROUD AIR (OPEN BORE NOZZLE) (A12056-00) PARTS LIST
Item #
Part #
1
A12053-00
SHAPING AIR SHROUD
1
2
A12054-00
SHAPING AIR RING
1
3
A11149-00
O-RING
2
4
A12055-00
M2 X 8 mm LONG FLAT HEAD SCREW
3
5
7554-126
O-RING
1
6
A11163-00
O-RING
1
LN-9271-12.2
DESCRIPTION
QTY
38
RPA-2 POWDER APPLICATOR - Parts
Electrode Holder (A11295-XX)
Electrode Holder (A11295-XX) - PARTS LIST
39
Item #
Description
Part Number
Qty.
1
Deflector
“A”
“E”
2
“C” Ring
A11599-00
1
3
Conductive Seal
A11138-00
1
4
Hollow Electrode Holder Assembly
A11301-00
1
5
Electrode Holder
“B”
1
6
#2 Sleeve
A11293-00
1
7
Wear Bar
“C”
“D”
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Parts
ELECTRODE HOLDER MODEL IDENTIFICATION
When ordering, use A11295-A or B as indicated Tables A and B. Two digits must follow the Basic
Part
Number. For Example:
A11295- A
B
Basic Part Number
Table B
Electrode Holder
with Bar
With or Without Deflector
TABLE A
TABLE A—# 2 ELECTRODE DEFLECTOR
Dash No.
Description
“A”
QTY
1
Deflector
A11292-01
1
2
No Deflector
——
——
TABLE B— # 2 ELECTRODE HOLDER
Dash No.
Description
“B” Holder
“C” Wear Bar
“D” QTY
1
UHMW Electrode Holder (Replaceable
Wear Bar)
A11290-01
A11304-00
1
2
UHMW Electrode Holder (Wear Bar
Not Replaceable)
A11302-01
——
——
LN-9271-12.2
40
RPA-2 POWDER APPLICATOR - Parts
Recommended Spare Parts
Part #
Description
Qty.
Open Bore Nozzle Application
A12052-00
Open Bore Nozzle
1
A11138-00
Conductive Seal
1
7554-126
O-ring
1
A11163-00
O-ring
1
A11149-00
O-ring
1
Electrode Holder /Shape Air Application
option
A11295-XX
Electrode Holder Assembly (See Page 42)
1
A11138-00
Conductive Seal
1
A11163-00
O-ring
1
A11150-00
O-ring
1
A11149-00
O-ring
1
A11148-00
O-ring
1
A11147-00
O-ring
1
A11304-00
Wear Bar
1
A11290-01
Electrode Holder (use with A11304-00 Wear Bar)
1
A11302-01
Electrode Holder with non-replaceable Wear Bar
1
Counter Electrode Application
78365-00
Resistor (5 gig ohm)
1
A12643-00
Screw (M3 x 10 Flt Hd. SS)
2
A12862-00
Charging Ring, Secondary
1
A10123-00
Plug, Contact
1
75831-00
Spring
1
No Counter Electrode Application
41
A12894-00
Charging Ring Blank
1
A13029-00
Screw ( M3 x 10 Flt Hd, Nylon)
2
Gun Body Assembly
3
A12949-00
Gun Body Assy. / Counter Electrode Application
1
A12949-01
Gun Body Assy. / Non Counter Electrode Application
1
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Parts
Recommended Spare Parts (CONT’D.)
Part #
Description
Qty
Parts Common To All Applicators
7554-08
O-ring
1
7554-09
O-ring
1
7554-12
O-ring
1
79001-09
O-ring
1
A11131-00
O-ring
1
A11130-00
O-ring
1
A11124-00
O-ring (for Top Plug)
1
A11122-00
O-ring (for Rear Plug)
1
A11174-00
Top Plug
1
A11173-00
Rear Plug
1
A12953-00
Cover
1
A12954-00
Screw, Nylon (for A12953-00 Cover)
4
A11129-00
Fitting, 8mm Tube
1
A11338-00
Screw (M8 x 25 SHCS Fiberglass) (for Rear Plate)
4
A11196-00
Upper Powder Tube (Dense Phase Application)
1
A11199-01
Top Elbow (Dense Phase or Venturi Application)
1
A11196-03
Upper Powder Tube (Venturi application)
1
A11571-00
Lower Powder Tube and Ring Ass’y
1
A11680-XX
Ground Cable Assembly (See page 41)
1
A12239-XX
Low Voltage Cable (See page 38)
1
A12241-XX
Low Voltage Cable extension (See page 38)
1
LN-9271-12.2
42
RPA-2 POWDER APPLICATOR - Warranty Policies
WARRANTY POLICIES
LIMITED WARRANTY
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 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 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.
RANSBURG'S ONLY OBLIGATION
UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED
BECAUSE OF FAULTY WORKMANSHIP
OR MATER-IALS. THERE ARE NO
IMPLIED WAR-RANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
RANS-BURG 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 Ransburg's opinion the warranty item in
question, or other items damaged by this
part was improperly installed, operated or
maintained, Ransburg will assume no
responsibility for repair or replacement of the
item or items. The purchaser, therefore will
assume all responsibility for any cost of
repair or replacement and service related
costs if applicable.
WRAPPING THE APPLICATOR, ASSOCIATED VALVES AND TUBING, AND
SUPPORTING HARDWARE IN PLASTIC,
SHRINK-WRAP, OR ANY OTHER NONAPPROVED COVERING, WILL VOID THIS
WARRANTY.
43
LN-9271-12.2
RPA-2 POWDER APPLICATOR
Changes made to LN-9271-12.2 Service Manual:
•
Page 20, and 21, —Lower Powder Tube and Ring Ass’y was two (2) parts; Lower Tube and
Ring.
•
Page 28 and 29—Revised drawing to show Lower Powder Tube and Ring Ass’y.
•
Page 31— Item #29 was A11171 Lower Tube and item #46 was A11178 Ring.
•
Page 42— A11571-00 was A11178-00
Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260-665-8800
Fax: 260-665-8516
Technical Service—Assistance
320 Philips Ave.
Toledo, Ohio 43612-1493
Telephone (toll free): 800-233-3366
Fax: 419-470-2233
Technical Support Representative will direct you to the appropriate telephone number for
ordering Spare Parts.
© 2013 Ransburg. All rights reserved.
Models and specifications subject to change without notice.
LN-9271-12.2
Form No. LN-9271-12.1
Litho in U.S.A.
03/13
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