ESTA-QUICK AEMD-500

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ESTA-QUICK AEMD-500 | Manualzz

S e r v i c e M a n u a l

E L E C T R O S T A T I C A U T O M A T I C A P P L I C A T O R

E S T A Q U I C K A E M D

– 6 0 0

0518 II 2 G

EEx 0.24 mJ

SIRA 11ATEX5240X

Before using this equipment, carefully read the Safety and Safety

Precautions sections and all instructions in this manual. Keep this

Service Manual for future reference.

1-2-AEMD-E-010-3 EstaQuick Applicator

Table of Contents

1 General ................................................................................................................... 4

1.1

About this Manual .............................................................................................. 4

1.2

Electrostatic Automatic Applicator EstaQuick AEMD-600 ................................. 5

1.3

Components ...................................................................................................... 5

1.4

Symbols ............................................................................................................ 6

2 Safety Precautions .................................................................................................. 6

2.1

Intended Use ..................................................................................................... 6

2.2

Training ............................................................................................................. 6

2.3

Use of Electrostatic Spray Systems in Potentially Explosive Atmospheres ....... 6

2.4

Work Areas........................................................................................................ 7

2.5

Inside Coating of Hollow Parts .......................................................................... 7

2.6

Cleaning ............................................................................................................ 7

2.7

Conditions for Using the Spray Booth ............................................................... 7

2.8

Personal Protective Equipment ......................................................................... 7

2.9

Operation with Ignition Hazard .......................................................................... 7

3 ATEX ....................................................................................................................... 8

3.1

European ATEX Directive ................................................................................. 8

3.2

EstaQuick AEMD-600 ATEX Product Marking Definitions................................. 9

3.3

Tests ............................................................................................................... 10

4 Specification .......................................................................................................... 11

5 Design ................................................................................................................... 11

5.1

Different Models .............................................................................................. 11

6 Installation ............................................................................................................. 12

6.1

Connection of EstaQuick AEMD-600 to Adapter AEMD-4500-6 ..................... 12

6.2

Screwed connection of EstaQuick AEMD-600-FIX to Adapter AEMD-

4500-6-FIX ................................................................................................................ 13

6.3

Spray Pattern Adjustment ............................................................................... 14

6.4

Distance of Gun to Work Piece ....................................................................... 14

7 Preventive Maintenance ........................................................................................ 15

7.1

Maintenance Schedule .................................................................................... 15

8 Cleaning Procedures ............................................................................................. 17

8.1

Cleaning the Atomizer ..................................................................................... 17

8.1.1

Cleaning the Air Cap ................................................................................. 17

8.2

Flushing Process ............................................................................................. 17

9 Failures ................................................................................................................. 18

9.1

Troubleshooting Chart ..................................................................................... 18

10 Service .................................................................................................................. 20

10.1

Disassembling the Gun from the Adapter .................................................... 20

10.1.1

Preparations ............................................................................................. 20

10.1.2

Removal of the EstaQuick AEMD-600 ...................................................... 21

10.1.3

Removal of the EstaQuick AEMD-600-FIX ............................................... 21

10.2

Disassembling the EstaQuick AEMD-600 .................................................... 22

10.2.1

Necessary Tools ....................................................................................... 22

10.2.2

Grease and Bonding Agent....................................................................... 22

10.3

Cleaning and Examination of Gun Parts ...................................................... 25

10.3.1

Cleaning of Parts ...................................................................................... 26

10.3.2

Examination of Parts ................................................................................. 26

10.4

Assembly of the EstaQuick AEMD-600 ........................................................ 27

10.4.1

Preparation of the Assembly „Head“ ......................................................... 27

10.4.2

Preparation of the Assembly „End Plate“ .................................................. 28

10.4.3

Preparation of the Assembly „Head Bracket“ ............................................ 29

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10.4.4

Final Assembly of the EstaQuick AEMD-600 ............................................ 30

11 Ordering of Spare Parts ........................................................................................ 32

11.1

Exploded View EstaQuick AEMD-600.......................................................... 32

11.2

Parts List ...................................................................................................... 33

11.3

Tip Selection Chart....................................................................................... 34

11.4

Air Cap Selection Chart ................................................................................ 34

11.5

O-Ring Selection Chart ................................................................................ 34

11.6

Selection Chart Automatic Applicator AEMD-600 ........................................ 35

12 Machine Mounted Adapter .................................................................................... 36

12.1

Machine Mounted Adapter AEMD-4500-6 ................................................... 36

12.2

Exploded View Machine Mounted Adapter AEMD-4500-6 ........................... 37

12.3

Parts List ...................................................................................................... 37

13 Robot Mounted Adapter ........................................................................................ 38

13.1

Bracket ......................................................................................................... 38

13.2

Parts List ...................................................................................................... 38

13.3

Adapter ........................................................................................................ 38

13.4

Parts List ...................................................................................................... 38

14 Installation Low Voltage Control Unit..................................................................... 39

14.1

9060 Low Voltage Control Unit .................................................................... 39

14.2

9060 Low Voltage Control Unit Kit ............................................................... 40

15

EC Manufacturer’s Declaration ............................................................................. 41

16 Product Liability and Warranty .............................................................................. 42

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1 General

1.1 About this Manual

This service manual applies exclusively to the electrostatic automatic applicator

EstaQuick AEMD-600 for the application of solvent-based paints.

The information in this document is intended only to indicate the components and their working relationship in typical use. These are not installation instructions. Each installation is unique and should be directed by a FINISHING BRANDS RANSBURG representative.

This manual provides information for the service and maintenance of this RANSBURG electrostatic equipment at a typical installation configuration. While this manual lists standard specifications and service procedures, some minor deviations may be found between this literature and your equipment.

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 trouble-shooting.

Please conduct the specified tests and checks before requesting service assistance, and have this manual in hand for ready reference when requesting such assistance. We recommend that maintenance and operating personnel who are familiar with the service problem be authorized to contact us when service is required.

Separate service manuals are available for different adapters and accessory equipment.

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1.2 Electrostatic Automatic Applicator EstaQuick AEMD-600

The electrostatic automatic applicator EstaQuick AEMD-600 (in the following called

EstaQuick) is an air atomizing electrostatic automatic spray gun.

The EstaQuick is equipped with a quick disconnect system. The gun disconnects for service quickly thanks to an easy ¼ turn mounting bracket which includes all fluid lines, air lines, and the high voltage line.

The EstaQuick is suitable for use on hollow-wrist or flex arm robots or with automatic machines (reciprocators), or supports. The EstaQuick applies a voltage of up to 90 kV to the atomizing point of the coating material. 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 side and back surfaces of the target. Therefore, a high percentage of the spray is deposited on the target. The guns of this series are suitable for coating materials on solvent or water base.

Note

This service manual applies exclusively to hazard situations when operating with solvent-based paints. For the application of water dilatable paints the relevant service manual is valid.

Note

Both the gun and the interconnection with the high voltage control unit and high voltage cable have to be regarded as installation components which do not represent an operative complete system. Therefore, a EC type examination (ATEX

Certificate) cannot be established. An operative installation will only be developed in combination with the spray booth (i.e. ventilation and drawing-off air).

Note

CE/ATEX approval with this power source is only for the

EstaQuick

1.3 Components

The EstaQuick installation consists of the gun, an adapter, the air and fluid line, and the high voltage control unit incl. Low- and High Voltage Cable.

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1.4 Symbols

Information

Information you should pay special attention to.

Note

Important text passage you should pay special attention to.

Caution

Important information that tells how to prevent damage to equipment or how to avoid a hazardous situation.

2 Safety Precautions

2.1 Intended Use

Caution

This installation can be dangerous if the instructions of this

service manual are not being followed!

The EstaQuick is designed and built for operation in stationary electrostatic spraying installations for flammable liquid spray materials.

The EstaQuick must only be operated in potentially explosive atmospheres which are created by the spraying cloud of the used coating material itself.

2.2 Training

2.4.1 It is extremely important that equipment operators and supervisory personnel understand the safe operation requirements. All personnel must be adequately trained prior to operating the electrostatic equipment and accessories. Operators must be given adequate training at least once a year.

2.3 Use of Electrostatic Spray Systems in Potentially Explosive Atmospheres

2.3.1 Electrostatic spraying systems (spray guns) must only be operated in potentially explosive atmospheres where the potential hazard is exclusively caused by electrostatic spraying of flammable liquid coating materials.

2.3.2 Electrostatic spraying systems must only be operated if protective measures against typical endangering have been taken into consideration. It must also be secured that protective measures have been taken to avoid dangerous body current by

 avoiding unnecessary work at live installation components

 closing current less

 appropriate work wear

 protection against unintended reclosing

 determination of stress freeness

 grounding and short-out

 release for operation (allowance to pass)

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2.4 Work Areas

2.4.1 Always ensure that there are no ignition sources. Smoking and open fire in potentially explosive atmospheres must be forbidden.

2.4.2 Paint must never be permitted to accumulate in spray booths, spray stands, and in the work area.

2.4.3 Coating of hollow parts in which hazardous situations may occur due to gas, mist, or dust of the coating material must be forbidden, unless protective measures are taken.

2.4.4 It must be pointed out and checked that entrance doors at the spray booths are kept close during the spraying process.

2.5 Inside Coating of Hollow Parts

2.5.1 Inside coating of hollow parts in which hazardous situations may occur due to gas, mist, or dust of the coating material must be forbidden, unless special safety measure are taken.

2.6 Cleaning

2.6.1 Paint deposit of coating material must be removed in regular periods. Special care must be taken to clean the spray booth including suction plant, spray mist collector, and the surrounding area.

2.8.2 The work piece holders must be cleaned regularly.

2.6.2 Ensure that the spray area is properly ventilated during cleaning procedures.

2.6.3 Ensure that only electrically conductive solvent containers are being used and that the containers are properly grounded.

2.6.4 Prior to start cleaning the high voltage conducting parts with flammable solvents ensure that the discharge energy must not exceed 0,24 mJ. For the practical use this means that the system must be grounded.

2.7 Conditions for Using the Spray Booth

2.7.1 Always ensure that the spray area is properly ventilated and that the solvent concentration in the breathing air is not damaging to health.

2.7.2 Ensure that the floor of the spray booth is electrostatic conductive.

2.7.3 Always ensure that no person remains in the spray booth during the spraying process.

2.7.4 Ensure that the discharge energy which will be drawn off the high voltage circuit is <0,24mJ, if flammable liquids are being used for cleaning procedures.

2.8 Personal Protective Equipment

2.10.1 Ensure that all persons working with electrostatic spraying systems and all persons in the area of the electrostatic conductive floor wear antistatic shoes.

2.10.2 If protective gloves are necessary these gloves must be antistatic or similarly effective.

2.9 Operation with Ignition Hazard

2.11.1 It is the responsibility of the user to ensure that no work with ignition hazard is done in rooms at risk of fire or in potentially explosive atmospheres. Exceptions will only be possible if special protective measurements were taken (for example: removal of liquid spraying material, solvent, and other flammable goods.

Cleaning of all systems and parts of the building. Proper ventilation etc.).

2.11.2 Always ensure that next to potentially explosive rooms and areas operation with ignition hazard must only be carried out, if ignition sources cannot enter these rooms and areas.

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3 ATEX

3.1 European ATEX Directive

II ATEX

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3.2 EstaQuick AEMD-600 ATEX Product Marking Definitions

Note

ATEX APPROVAL with the Power Source 9060 LOW

VOLTAGE CONTROL UNIT KIT is only use for the

Electrostatic Automatic Applicator AEMD-600 incl. Machine

Mounted Adapter AEMD-4500-6.

EstaQuick AEMD-600 ATEX

Product Marking Definitions

Ex Certificate Number: Sira 11ATEX5240X

Sira = Notified Body performing EC-type

Examination

11 = Year of certification

ATEX = Reference to ATEX Directive

5 = Protection Concept Code (code 5 is titled

Encapsulation)

240 = Document serial number

X = Special conditions for safe use apply

Special condtions for safe use:

The applicator AEMD-600

Shall only be used with

Air- & Fluid hoses that meet

Safety requirements

Ex = Specific marking of explosive protection

II = Equipment Group hazardous area characteristics

2 = Equipment Category

G = Type of explosive atmosphere (gases, vapors, or mists)

EEX0.24mJ = The EstaQuick AEMD-600 applicator is suitable for use in automatic spraying installations

Complying with EN 50 050 as they are a Type A class

With a discharge energy limit of 0.24mJ.

1-2-AEMD-E-011-1 EstaQuick Applicator

0518 II (2) G

EEx 0.24 mJ

SIRA 11ATEX5240X

9 / 43

3.3 Tests

3.3.1 An automatic (stationary) spray installation for electrostatic spraying of coating materials must be tested by an expert prior to initial start-up.

3.3.2 Method, scope, and frequency of tests have to be determined by the user based on the individual production requirements and local conditions. In the individual case the professional trade association may require a written proof in form of a test book, EDP report, or similar.

3.3.3 Ensure that electrostatic spraying systems and installations and accessory parts be checked by an expert for safe operation whenever necessary, but at least once a year. This examination must be documented in writing.

3.3.4 The following checks must be carried out by a qualified electrician

1

:

Test Cycle drawing-off air conveyance for efficiency

Proper functioning of protection against over-current

Protection against exceeded discharge energy

Protection against ignition of flammable cleaning materials

Efficiency of protection measurements against direct touch

Efficiency of grounding measurements X

X

X

X

X

X

Isolation of all live installation components above 1kV X

Locking device, passing protection X

Keep ready access to appropriate fire extinguishing equipment. Check fire extinguishing equipment regularly, at least every 2 years. All personnel must be adequately trained with fire extinguishing equipment.

Keep ready an actual warning schedule showing the type of alarm and the triggering function (manually / automatically).

1

A qualified electrician is a person who has specialist training, knowledge, and experience as well as knowledge of the

relevant rules and who can recognize and judge possible hazards of th e works involved. (See § 2 Par. 3 UVV VBG 4).

Furthermore a qualified electrician must have the following qualifications: Specialist training and knowledge of explosion pr otection, electrostatic process technology, knowledge of local conditions, knowledge of the electric installation, and knowledge of the load of electric installation.

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4 Specification

Atomization:

Fluid pressure:

Cylinder air pressure:

Tip voltage:

Current max.:

Voltage input:

Gun weight:

Dimensions

Material:

5 Design

Conventional air atomizing 0 to 9 bar

0 to 7 bar

7 bar max. 90 kV DC voltage

120 µA

220V at 50/60Hz

245 g

125 x 46 x 56 mm

PEEK / POM / Stainless Steel

5.1 Different Models

The EstaQuick is available in different versions. These differ from different tips respectively different fluid feed versions. Please see the Tip and Air Cap Selection Chart for selection of fluid tips and air caps. The selection of the correct atomizer depends on the desired finish quality, the geometry of parts, and the paint viscosity. For this reason a test should be carried out with different fluid tips and fluid feed versions.

Information

For more information please note page 35.

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6 Installation

6.1 Connection of EstaQuick AEMD-600 to Adapter AEMD-4500-6

Insert the EstaQuick AEMD-600 with the locking device into the designated place by a turn of 45° to its later position. Push the gun body onto the adapter whereby the resistance of the spring must be surmounted. Turn the gun clockwise by 45° in its position until it locks into the adapter.

Position the gun by 45° to the adapter Insert the locking device into the seat

Push the gun downward against the spring force until it bottoms on the adapter

Click the gun into the rear locking device until it sits straight

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6.2 Screwed connection of EstaQuick AEMD-600-FIX to Adapter

AEMD-4500-6-FIX

In case of screwed connection insert the gun with the locking device into the designated place by a turn of 45° to its later position. Push the gun body onto the adapter whereby the resistance of the spring must be surmounted. Turn the gun clockwise by 45° in its position and fix it with the two screws in the front and back.

Position the gun by 45° to the adapter Insert the locking device into the seat

Push the gun downward against the spring force until it bottoms on the adapter

Click the gun into the rear locking device until it sits straight

Fix the gun at the back with screw (POS.22) Fix the gun at the front with the screw

(POS.21)

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Note

Before installing the gun apply a light coat of grease to the

O-rings to prevent from shearing off.

6.3 Spray Pattern Adjustment

The spray pattern of the atomizer is adjustable from round pattern to flat pattern.

By increasing the air supply (atomizing air) the pattern becomes wider, by reducing the air supply (atomizing air) it becomes more narrow.

Carry out tests in order to find the desired values.

In order to change-over the atomizer spray pattern from horizontal to vertical, reposition the baffle in the spray head. There are two position bores in the spray head (see picture).

Position for vertical spray pattern

Position for horizontal spray pattern

Note

For optimum finish quality always operate with clean, dry, and filtered air.

6.4 Distance of Gun to Work Piece

To achieve optimum finish quality, position the gun approximately 15 to 30 cm from the work piece.

Caution

The distance from the gun to mass must be significantly larger than the distance from the gun to the object to be coated.

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7 Preventive Maintenance

Caution

Never use a faulty spray gun!

7.1 Maintenance Schedule

For longer service life of the gun and for safe use of the spray installation this maintenance schedule must be followed:

7.1.1 Several Times Daily

Turn off the high voltage.

Check the air cap, spray tip, and electrode for paint residues. Clean as often as necessary with a soft brush and a suitable solvent and blow dry.

Clean all insulated surfaces of the installation. Remove paint residues from the gun exterior, the high voltage cable, and the air- and fluid hoses with a solvent wetted cloth.

Make sure the solvent in non-polar

Make sure that solvent has a flash temperature below temperature in booth

7.1.2 Daily (At the Begin of Each Shift)

Either remove or ground all loose or non-grounded objects in the surroundings of 6 meters of the operating range of the gun.

Check whether the atomizer head and the gun electrode are clean and not damaged.

Information

Never remove the fluid tip if there is still fluid in the gun, otherwise fluid can enter the air passages. In order to remove the fluid tip / air cap hold the gun downward.

Clogged air passages will cause improper atomization and might lead to short-circuit. If the air passages are clogged with conductive fluid, this will lead to increased current output and low operating voltage, and might finally damage the electrical components.

For maintenance of the atomizer please refer to the chapter „Cleaning of the Atomizer“.

Note

In order to change the fluid tip, pressure must be applied to the needle.

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7.1.3 During Operating Interruption (and at the End of Each Shift)

1. Turn off the high voltage.

2. Turn off material supply.

3. Turn off atomizing air and cylinder air.

4. Clean gun, cable, and hoses with a solvent wetted cloth. Use suitable solvent only.

5. Empty the fluid lines and leave solvent in the non-pressurized lines. (See the chapter „Flushing Procedure“).

Caution

For a short operating interruption (shorter than the respective pot-life of the fluid) it might not be necessary to flush the lines, depending on the coating material being used. If the solid particles of the fluid deposit slowly, the lines must not be flushed so quickly after an operating interruption as it would be the case with quickly depositing solid particles.

The necessity for flushing depends on the coating material and on the time of the operating interruption.

Metallic paints and primer will need more frequent flushing than some other paints.

7.1.4 Weekly

Check the complete system for damage, leakage, and paint residues.

Clean the atomizer unit.

Information

If quickly depositing material is being sprayed and the lines are not flushed frequently enough, the fluid passages of the gun and the lines may get clogged, resulting in more time consuming maintenance and repair.

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8 Cleaning Procedures

8.1 Cleaning the Atomizer

For regular cleaning procedures the following tools are needed:

Suitable solvent

Grounded solvent supply

A brush with soft bristles

Some pipe-cleaners

For safe and trouble-free operation keep the exterior surface of the gun clean and free of paint residues and dirt. This is to prevent high voltage loss to ground and reduction of the electrostatic effect. Contamination at the opening of the air cap will cause a reduction of atomizing quality. Clean the air cap as often as necessary with a soft brush and solvent in order to obtain optimum atomization..

Caution

Never wrap the gun into plastic film. A surface charging can be built up at the plastic material and might discharge to the next grounded object. This reduces the capacity of the gun which might lead to damaging the component FINISHING BRANDS

GERMANY GmbH will not be liable for any damages caused by wrapping the gun into plastic film. To protect the gun use the gun protection (AGMD-400 ).

8.1.1 Cleaning the Air Cap

To clean the air cap the following steps have to be performed:

1. Turn off the high voltage.

2. Turn off the material supply.

3. Clean the removed parts with a soft brush and suitable solvent.

Caution

Never use metal tools or metal brushes. For cleaning purposes never use any object that is harder than the plastic parts. If it is impossible to remove paint residues with a cloth or with a brush, the parts may be soaked in solvent, but only as long until the residues can be removed! Never soak the gun body, hoses, or the high voltage cable in solvent!

8.2 Flushing Process

1. Turn off the high voltage.

2. Turn off the material supply.

3. Turn off atomizing and fan control air.

4. Connect solvent supply to the gun.

5. Flush the system with solvent until clean solvent escapes.

6. Remove the solvent supply.

7. Activate the gun until there is no solvent left. After finishing these steps the gun will be ready for color change, storage, or maintenance.

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9 Failures

9.1 Troubleshooting Chart

General Problem

Faulty Spray Pattern

Possible Cause Solution

Asymmetric Shape 1. Air hose of the remote air supply to air valve obstructed or damaged.

2. Air channel and/or air inlet

Clean, replace or repair.

Blow out or clean. obstructed.

Unclean left or right side pattern 1. Air cap damaged or obstructed. Replace or clean.

Very uneven or deformed spray pattern.

1. Wrong air cap / fluid tip combination.

2. Air and fluid not synchronized.

Select the correct combination.

Check the programming sequence.

Insufficient Supply

Atomizing Air

Fluid Output

1. Air channel in gun or in air line obstructed.

2. Pressure too low.

1. Fluid tip obstructed or damaged.

2. Fluid channels in gun or fluid line obstructed.

3. Not enough travel of fluid valve needle.

4. Fluid pressure too low.

5. Fluid filter obstructed.

6. Fluid valve or fluid regulator obstructed.

Blow out.

Increase air pressure.

Flush or replace.

Flush.

Lubricate piston and needle packing.

Increase fluid pressure.

Clean or replace.

Clean.

Leakages

Air escapes

Fluid leakage at rear part of the gun.

Fluid leakage between gun and adapter.

1. Air valve cap loose or damaged. Tighten.

1. Packing, piston, needle or electrode damaged.

Replace faulty components.

1. O-Rings AGMD-93 damaged or missing.

2. Locking device does not seal properly.

3. Insulating surface between head, head bracket, and end plate is not even.

Insert O-Rings

Tighten cap screw AEMD-

2130.

Loosen 6 screws, align parts and tighten screws.

Fluid leakage at fluid tip 1. Fluid tip too loose.

2. Needle and tips do not close properly.

3. Retaining ring loose.

Continuous leakage at fluid tip. 1. Seat of fluid tip worn or damaged.

2. Needle / electrode worn or damaged.

3. Fluid tip not engaged.

4. Needle does not close (cylinder air line not deventilated)

Engage fluid tip.

Replace damaged components.

Tighten retaining ring.

Replace fluid tip.

Replace faulty part.

Engage fluid tip.

Check valve.

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Electrical Problems

Wrap back 1. Insufficient grounding of the work piece.

2. Insufficient booth ventilation.

3. Too much atomizing air.

Insufficient or no high voltage. 1. Faulty high voltage connections.

2. Line passage between transformer and electrode interrupted.

High Make Impulse

3. Insufficient or no grounding.

4. Faulty pressure switch.

5. High voltage cable damaged.

6. High voltage transformer damaged.

7. Check fuse.

8. Is the voltage turned on? Is the atomizing air turned on? Is the gun activated? Is the paint too conductive?

1. Paint in the air channels.

2. Paint in the rear part of the gun.

Check and correct.

Check and correct.

Reduce pressure.

Check and connect to adapter and high voltage transformer.

Check and correct.

Check and correct.

Replace.

Replace.

Please see Service Manual for the high voltage transformer.

Check.

Check.

Clean air channels with soft brush.

See Leakages.

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10 Service

Information

Only use genuine spare parts when servicing the EstaQuick.

Note

All personnel should read and understand this Service Manual prior to starting maintenance and service.

10.1 Disassembling the Gun from the Adapter

Caution

When servicing the gun always turn off and ground the high voltage, turn off the material supply, and relieve pressure from the material supply.

10.1.1 Preparations

To take off the gun from the adapter the following steps have to be followed:

1. Turn off high voltage.

2. Turn off material supply.

3. Turn off atomizing air and cylinder air.

4. Clean gun, cable, and hoses with a solvent wetted cloth. Use suitable solvent only.

5. Empty the fluid lines and leave solvent in the non-pressurized lines.

Caution

Prior to cleaning or color change turn off the high voltage and the supply voltage to the high voltage transformer.

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10.1.2 Removal of the EstaQuick AEMD-600

Activate the spring pad at the adapter, at the same time the spring pad will be pushed into the gun and the gun body can now be turned out of the adapter. Turn the gun body by 45° counter-clockwise. The gun can now be pulled off upward and the spare gun can be connected.

Push in the spring pad at the adapter Turn gun by 45° counter-clockwise and pull off upward

10.1.3 Removal of the EstaQuick AEMD-600-FIX

Remove first the two screws who fix the gun on the adapter. The gun body can now be turned out of the adapter. Turn the gun body by 45° counter-clockwise. The gun can now be pulled off upward and the spare gun can be connected.

Remove the two screws in front and back Turn gun by 45° counter-

clockwise and pull off upward

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10.2 Disassembling the EstaQuick AEMD-600

For disassembly and assembly please refer to Parts Lists and Exploded View in this

Service Manual.

Information

Disassembly and assembly of parts must only be carried out by adequately trained personnel. Works must be carried out on a clean and flat supporting surface.

10.2.1 Necessary Tools

Test adapter

Screw driver

Tip wrench (AEMD-101)

Allen screw wrench (SW 6)

Ring spanner (SW 3)

Multimeter

Calliper gauge

10.2.2 Grease and Bonding Agent

AGMD-010: for needle, needle packing and piston.

Electrostatic Grease (Order No. 59972-00): for O-Rings, packing, and hollow spaces.

LOCTITE 243 (screw locking “middle strength“)

LOCTITE 222 (screw locking “light strength”)

Information

Needle, needle packing and piston must only be lubricated with grease AGMD-010. Any other grease can lead to gun failure

(needle packing and piston might swell if improper grease is being used).

Once the gun has been disconnected from the adapter and has been replaced by a spare gun, the spraying operation can be continued, and the disconnected gun can be serviced at a suitable place.

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For disassembly the following steps have to be followed:

1. Connect he gun to be serviced onto a test adapter. Apply cylinder air with 6 bar pressure to the needle, this pushes the needle toward the springs and relieves the tip.

Caution

In order to protect the gun head from damages it is important that pressure air (min. 6 bar) is applied to the needle during the disassembly of the air cap and tip.

2. Loosen the retaining ring (Pos.15) and remove the air cap (Pos.14).

3. Only exchange the tip (Pos.13) by hand or use the tip wrench AEMD-101. It can be loosened by a light pressure and a ¼-turn counter clockwise. (See

Pictures).

Apply pressure of 6 bar to the gun Disassembly with fingers

Disassembly with tip wrench AEMD-101 Wrong: Disassembly with pliers or other tool

1-2-AEMD-E-011-1 EstaQuick Applicator 23 / 43

Cut B - B insertion position

Cut B - B locked position

4. Remove the baffle (Pos.11) and the O-Rings (Pos.24 and 26).

5. Relieve pressure from the test adapter and remove the gun.

6. Loosen the electrode (17.2) from the needle (17.1).

7. Firmly hold gun head (Pos.1) and head bracket (Pos.2) and carefully and evenly loosen the 6 connecting screws (Pos.23). Remove the end plate (Pos.3) from the head bracket (Pos.2).

8. Remove the pressure springs (Pos.19 and 20), the spring bolt / fluid needle assy. (Pos.18/17.1) and the piston (Pos.16). Remove the washer for the end plate (Pos.5).

Information

The fluid needle (Pos. 17.1) is glued into the spring bolt (Pos.

18) with LOCTITE 243. The positions 17.1 and 18 are one unit.

9. Disconnect the gun head (Pos. 1) from the head bracket (Pos. 2). Remove the contact lock (Pos. 10).

Information

The contact wire (Pos. 9) will remain in the head.

1-2-AEMD-E-011-1 EstaQuick Applicator 24 / 43

10. Remove the washer (Pos. 4) and both R-Rings (Pos. 24)

11. The needle packing (Pos. 8) must be exchanged at each disassembly. It will be destroyed at disassembly (see picture).

Insert screw driver Force screw driver with light blows of the hammer into needle packing

Unscrew faulty needle packing

12. The locking device (Pos. 6) and the cap screw (Pos. 7) will remain in the head.

Information

An electrical contact must exist between cap screw (Pos. 7) and contact wire (Pos. 9). Check this contact with a multimeter.

10.3 Cleaning and Examination of Gun Parts

After disassembly clean the gun parts at first and then check for proper condition.

1-2-AEMD-E-011-1 EstaQuick Applicator 25 / 43

10.3.1 Cleaning of Parts

Information

The kind of contamination of the gun parts might give an indication for gun failure.

For regular cleaning procedures the following tools are needed:

Suitable solvent

Grounded solvent supply

A brush with soft bristles

Some pipe-cleaners

Clean the contaminated gun parts with a soft brush and suitable solvent and blow dry. Clean the air- and fluid bores with a solvent soaked pipe-cleaner.

.

Information

Do not “bath” the gun parts in solvent but wipe them clean with a brush or an soaked cloth.

For safe and trouble-free operation keep the exterior surface of the gun clean and free of paint residues and dirt. This is to prevent high voltage loss to ground and reduction of the electrostatic effect. Contamination at the opening of the air cap will cause a reduction of atomizing quality. Clean the air cap as often as necessary with a soft brush and solvent in order to obtain optimum atomization.

10.3.2 Examination of Parts

Prior to assembly of the gun all gun parts must be checked. Faulty components must be replaced.

Caution

Never install faulty components into the gun!

Caution

Only use genuine Ransburg spare parts!

1-2-AEMD-E-011-1 EstaQuick Applicator 26 / 43

10.4 Assembly of the EstaQuick AEMD-600

This describes the assembly of a gun with new parts. For the renewed assembly of a gun, some parts will remain and will not have to be assembled again.

10.4.1

Preparation of the Assembly „Head“

1. Screw the needle packing (Pos.8) into the head (Pos.1) by use of an Allen screw wrench (SW 6), take care not to close the fluid bore in the head.

Right: Needle packing sits below the fluid bore

Wrong: Needle packing closes the fluid bore

2. Insert the contact wire (Pos. 9) into the bores and secure with light blows of the hammer.

Insert contact wire Secure contact wire with light blows of the hammer

1-2-AEMD-E-011-1 EstaQuick Applicator 27 / 43

3. Insert the locking device (Pos.6) into its place in the head (Pos.1) and tighten with cap screw (Pos.7). Check the electrical contact between cap screw (Pos.7) and contact wire (Pos.9) with the multimeter.

Insert locking device Screw in cap screw

Tighten cap screw Check the electrical contact between wire and cap screw

10.4.2

Preparation of the Assembly „End Plate“

4. Screw the spring pas (Pos.22) into the end plate (Pos.3), so that the ball shows for 3mm.

3mm

5. Counter the adjusted spring pad with the set screw (Pos. 21)

1-2-AEMD-E-011-1 EstaQuick Applicator 28 / 43

10.4.3 Preparation of the Assembly

„Head Bracket“

6. Lubricate the running surface of the piston in the head bracket (Pos.2) and the two running surfaces of the piston (Pos.16) with grease AGMD-010.

7. Press the piston into the head bracket.

Grease running surface of the piston in the Head bracket

Grease running surfaces of the piston

Press in the piston

8. Lubricate the washers for head and endplate (Pos.4 and 5) with electrostatic grease.

9. Insert the greased washers into the respective groove in the head bracket

(Pos.2).

Lubricating the washers Inserting the washers Insert the O-Rings

(Pos.24)

10. The needle shaft (Pos.17) will be glued into the spring bolt (Pos.18) with LOCTITE

„middle strong“.

1-2-AEMD-E-011-1 EstaQuick Applicator 29 / 43

10.4.4 Final Assembly of the EstaQuick AEMD-600

11. Insert the contact lock (Pos.10) into the needle packing (Pos.8) of the head (Pos.1).

12. Place the head bracket (Pos.2) onto the head (Pos.1).

Caution

The head bracket has a pocket into which the contact lock has to be inserted.

13. Push the needle shaft / spring bolt unit (Pos.17/18) into the bore of the piston

(Pos.15) until you feel resistance.

14. Place the two pressure springs (Pos.19 and 20) onto the spring bolt (Pos.18).

15. Insert the 6 screws (Pos.23) into the designed bores in the end plate (Pos.3).

16. Position the end plate with the screws onto the head bracket.

17. Push the end plate downward, thereby strength must be surmounted in order to press the needle into the needle packing.

18. Lightly and evenly tighten the 6 screws (Pos.23) crosswise.

19. Check the levelness of the sealing surface of the head (Pos.1), of the head bracket (Pos.2), and of the end plate (Pos.3) with a calliper gauge or an angle.

Then firmly tighten screws (Pos.23).

Push end plate downward Check for levelness with the calliper gauge

20. Screw the electrode (16) with LOCTIT

E 222 (screw locking “light strong”) onto the needle shaft (17) and tighten by hand.

21. Click the gun onto the test adapter and apply cylinder air of 6 bar.

22. Insert the baffle (Pos.11) into the head (Pos.1). Hereby it has to be decided whether a horizontal or vertical spray pattern is wanted, see Chapter 6.2 (Spray Pattern

Adjustment).

23. Lubricate the disc washer (Pos.26) with electrostatic grease and install it onto the baffle (Pos.11).

24. Lubricate the O-Ring (24) with electrostatic grease and install it into its place in the tip.

1-2-AEMD-E-011-1 EstaQuick Applicator 30 / 43

Insert disc washer with tapered side into the groove of the baffle

Information

Insert tip with lubricated O-Ring into the gun.

For longer service life the O-Rings must always be lubricated.

Never use faulty O-Rings.

25. Insert the tip (Pos. 13) with the guide pin into the bayonet of the head (Pos. 1).

Push it downward with light strength and fix it to the head by a ¼ turn clockwise.

Information

The bayonet is only designed for fixing the tip and not for sealing. Only after the gun has been equipped with air cap and retaining ring, the tip is sealed to the head.

Caution

Prior to each assembly of the tip into the head, the seat of the electrode must be checked.

26. Install the air cap (Pos. 14) onto the gun, take care that the horns of the baffle engage into the slots of the air cap.

27. Screw on the retaining ring (Pos. 15). Check the position of the air cap, before tightening. Then tighten retaining ring by hand.

Insert the slots of the air cap into the horns of the baffle.

Check the position of the air cap while

Screwing the retaining ring on.

28. Put the protective cap (Pos. 27) on the retaining ring to protect air cap and electrode.

1-2-AEMD-E-011-1 EstaQuick Applicator 31 / 43

11 Ordering of Spare Parts

Please have the Parts Lists in hand for ready reference of part numbers when ordering parts.

11.1 Exploded View EstaQuick AEMD-600

1-2-AEMD-E-011-1 EstaQuick Applicator

Check parts at disassembly and replace if necessary

Replace parts after each disassembly

32 / 43

11.2 Parts List

Parts List Electrostatic Automatic Applicator EstaQuick AEMD-600

Pos. Description Qty. Part No.

1 Gun Head 1 AEMD-2196

9

10

11

12

13

14

15

16

17

18

5

6

7

8 or

2

3

4

Gun Head for Circulating

Head Bracket

End Plate

Washer For Head

Washer for End Plate

Locking Device

Cap Screw

Needle Packing

Contact Wire

Contact Lock

Baffle

Tip

Air Cap

Retaining Ring

Piston

Electrode and Resistor

Needle Shaft

Spring Bolt

1

1

1

1

1

1

1

1

1

1

1

1

1

1

(1)

1

1

1

AEMD-2196-U

AEMD-2220

AEMD-2242

AEMD-2216

AEMD-2218

AEMD-2244

AEMD-2130

AGMD-405-1

AEMD-2240

AEMD-2241

AEMD-2033

See Chart 11.3

See Chart 11.4

AEMD-2368

AGMD-243-1

70430-01

AEMD-2420

AEMD-2219

19

20

21

22

23

24

25

26

Pressure Spring

Pressure Spring

Set Screw

Spring Pad

Pan Head Screw

O-Ring

O-Ring

Disc Washer

6

3

5

1

1

1

1

1

AGMD-110

AGMD-111

AGMD-116

AGMD-115

AEMD-2131

See Chart 11.5

See Chart 11.5

AEMD-2065

27

28

29

30

Protective Cap (not shown)

OPTION: Screw

OPTION: End Plate

OPTION: Screw

1

1

1

1

7331-03

AEMD-2131

AEMD-2242-1

DIN84M5X16PAG

OPTION: Vent connection

31 1 ESTA-408-4

(connected only with End Plate AEMD-2242-1)

Note: Pos. 28

– 30: Option for Electrostatic Automatic Applicator AEMD-600…..-800-FIX.

Screw Coupling with Machine Mounted Adapter AEMD-4500-6-FIX.

1-2-AEMD-E-011-1 EstaQuick Applicator 33 / 43

11.3 Tip Selection Chart

Tip Selection Chart

Pos.

12

Description

Tip with bore 0.8mm

Tip with bore 1.1mm

Tip with bore 1.4mm

Tip with bore 1.6mm

Round Pattern Tip

Round Pattern Tip

Tip Size

[mm]

0,8

1,1

1,4

1,6

A=6,31 mm²

A=7,22 mm

Part No.

AEMD-2915-G

AEMD-2915-FX

AEMD-2915-FF

AEMD-2915-FW

AEMD-2941

AEMD-2951

11.4 Air Cap Selection Chart

Air Cap

AEMD-800C

AEMD-800C

AEMD-800C

AEMD-800C

AEMD-850

AEMD-850

Viscosity

[sDIN4]

18-35

18-40

18-50

18-50

-

-

Fluid Flow

[ml/min]

250

350

350 up to 700

-

-

Spray

Pattern

[mm]

355

355

355

355

-

-

Air Cap Selection Chart

Pos. Description

13

Air Cap for Tip AEMD-2915

Air Cap for Round Pattern Tip AEMD-2941 and AEMD-2951

11.5 O-Ring Selection Chart

O-Ring Selection Chart

Part No.

AEMD-800c

AEMD-850

Pos. Description

24

25

1-2-AEMD-E-011-1

Standard O-Ring (Viton EX)

Option O-Ring for aggressive Solvent components, with Aromat,

Esters and Keton

Standard O-Ring (Viton EX) (5 parts per pack)

Option O-Ring for aggressive Solvent components, with Aromat,

Esters and Keton

EstaQuick Applicator

Part No.

AGMD-121

AGMD-121-C

AGMD-93-K5

AGMD-095

34 / 43

11.6 Selection Chart Automatic Applicator AEMD-600

Automatic Applicator EstaQuick AEMD-600 Selection Chart

Description

Tip Size

[mm]

0,8 AEMD-600-G-800

AEMD-600-FX-800

AEMD-600-FF-800

AEMD-600-FW-800

AEMD-600-2941-850

AEMD-600-2951-850

AEMD-600UG-800

AEMD-600UFX-800

AEMD-600UFF-800

AEMD-600UFW-800

AEMD-600U2941-850

AEMD-600U2951-850

AEMD-600-G-800-FIX

AEMD-600-FX-800-FIX

AEMD-600-FF-800-FIX

AEMD-600-FW-800-FIX

AEMD-600-2941-850-FI

AEMD-600-2951-850-FI

AEMD-600UG-800-FIX

1,1

1,4

1,6

A=6,31 mm²

A=7,22 mm²

0,8

AEMD-600UFX-800-FIX

AEMD-600UFF-800-FIX

1,1

1,4

AEMD-600UFW-800-FIX 1,6

AEMD-600U2941-850-FI A=6,31 mm²

AEMD-600U2951-850-FI A=7,22 mm

1,1

1,4

1,6

A=6,31 mm²

A=7,22 mm²

0,8

1,1

1,4

1,6

A=6,31 mm²

A=7,22 mm

0,8

Tip Size

Part No.

AEMD-2915-G

AEMD-2915-FX

AEMD-2915-FF

AEMD-2915-FW

AEMD-2941

AEMD-2951

AEMD-2915-G

AEMD-2915-FX

AEMD-2915-FF

AEMD-2915-FW

AEMD-2941

AEMD-2951

AEMD-2915-G

AEMD-2915-FX

AEMD-2915-FF

AEMD-2915-FW

AEMD-2941

AEMD-2951

AEMD-2915-G

AEMD-2915-FX

AEMD-2915-FF

AEMD-2915-FW

AEMD-2941

AEMD-2951

Air Cap

Part-No.

AEMD-800C

AEMD-850

AEMD-800C

AEMD-850

AEMD-800C

AEMD-850

AEMD-800C

AEMD-850

Machine Mounted Adaptor

Part-No.

AEMD-4500-6

AEMD-4500-6

AEMD-4500-6-FIX

AEMD-4500-6-FIX

1-2-AEMD-E-011-1 EstaQuick Applicator 35 / 43

12 Machine Mounted Adapter

12.1 Machine Mounted Adapter AEMD-4500-6 for Electrostatic Automatic Gun AEMD-600

1-2-AEMD-E-011-1 EstaQuick Applicator 36 / 43

12.2 Exploded View Machine Mounted Adapter AEMD-4500-6

12.3 Parts List

Parts List Machine Mounted Adapter AEMD-4500-6

Pos. Description Qty. Part No.

5

6

7

8

1

2

3

4

Base plate

Plate

Pressure plate

Pressure plate

Holding plate

Screw

Guide piece

Contact piston

1

1

1

1

1

2

1

1

AEMD-4501-6

AEMD-4102

AEMD-4346

AEMD-4247

AEMD-4246

AEMD-4129

AEMD-4502-1

AEMD-4503

9

10

Pressure spring

Pressure spring

Resistor

(60MΩ)

1

1

AEMD-2108

AGMD-114

11

12

13

14

15

16

17

Cable gland

Strain relief

Hose fitting for 8mm (atom & fan)

Hose fitting for 6mm (needle pressure, paint in &out)

OPTION: Screw

OPTION: Plate

1

1

1

2

3

1

1

AEMD-4216

AEMD-4217

ST-M16x1,5

AEMD-4134

AEMD-4135

AEMD-2131

AEMD-4102-1

18 OPTION: Screw 1 DIN84M5X16PA

Note: Pos. 16

– 18: Option for Machine Mounted Adapter AEMD-4500-6-FIX.

Screw Coupling with Electrostatic Automatic Applicator AEMD-600

…..-800-FIX.

1-2-AEMD-E-011-1 EstaQuick Applicator 37 / 43

13 Robot Mounted Adapter

13.1 Bracket

13.2 Parts List

Bracket for Machine Mounted Adapter AEMD-4500-6

Hollow Wrist Robot

Pos.

1

Description

Bracket

(Applicator and Machine Mounted Adapter are not included)

Qty. Part No.

1 AEMD-4250

13.3 Adapter

13.4 Parts List

Robot Adapter

No.

5

7

8

9

1

2

3

4

Description

Adapter ABB 5400, 580

Adapter ABB 5400 Enhanced Wrist

Adapter B&M LZ2000

Adapter Fanuc P-145/155

Adapter Fanuc P-200/250

Adapter Kawasaki KF192

Adapter Motoman EPX2850

Adapter Motoman EPX2900

Qty.

1

1

1

1

1

1

1

1

Part No.

AEMD-4260

AEMD-4261

AEMD-4263

AEMD-4264

AEMD-4265

AEMD-4266

AEMD-4267

AEMD-4268

1-2-AEMD-E-011-1 EstaQuick Applicator 38 / 43

14 Installation Low Voltage Control Unit

Note

CE/ATEX APPROVAL WITH THIS POWER SOURCE IS ONLY

FOR THE ELECTROSTATIC AUTOMATIC APPLICATOR

AEMD-600 INCL. MACHINE MOUNTED ADAPTER AEMD-

4500-6

Note

Installation of Low Voltage Control Unit see

Service Manual CP-13-01.1

14.1 9060 Low Voltage Control Unit

Installation Low Voltage Control Unit

Pos. Description

5

6

7

8

9

1

2

3

4

1-2-AEMD-E-011-1

9060 Low Voltage Unit

AEMD-600 (ATEX approved) with Machine Adapter AEMD-4500-6

A10560-XXD High Voltage Cable

80104-01 External Cascade

79338-XX Low Voltage Cable

Booth Wall

Cascade Ground Connection

Cascade Separate True Earth Ground

Control Unit Separate True Earth Ground

EstaQuick Applicator 39 / 43

14.2 9060 Low Voltage Control Unit Kit

Parts List 80143-ABC

Qty.

1

1

1

1

Part-No.

Table A

Table B

Table C

80104-01

Description

9060 Low Voltage Control Unit

High Voltage Cable Assembly

Low Voltage Cable Assembly

External Cascade 100kV

Table A

– Unit Power Type

“A” Dash No.

-1

-2

-3

-4

-5

-6

Description

110 / 120 V

USA 10” Rack

220 / 240 V Europe 10” Rack

220 / 240 V China 10” Rack

110 / 120 V USA 19” Box

220 / 240 V Europe 19” Box

220 / 240 V China 19” Box

Table B

– High Voltage Cable

A

80120-311

80120-312

80120-313

80100-311

80100-312

80100-313

“B” Dash No.

-1

-2

-3

-4

Description

High Voltage Cable-15` (5m)

High Voltage Cable-25` (8m)

High Voltage Cable-50` (15m)

High Voltage Cable-75` (22,5m)

Table C

– Low Voltage Cable

B

A10560-15D

A10560-25D

A10560-50D

A10560-75D

“C” Dash No.

Description

-1

-2

Low Voltage Cable-10m

Low Voltage Cable-15m

For ordering use 80143-ABC as indicated by Tables

-A Designates the 9060 Cascade Control Unit

-B Designates the High Voltage Cable Length

-C Designates the Low Voltage Cables Length

C

79338-10

79338-15

1-2-AEMD-E-011-1 EstaQuick Applicator 40 / 43

Check parts at disassembly and replace if necessary

Replace parts after each disassembly

15

EC Manufacturer’s Declaration

We Finishing Brands Germany GmbH

Justus-von-Liebig Str.31

D 63128 Dietzenbach hereby declare under our sole responsibility that the product(s) listed below confirm with the relevant provisions of directive 94/9/EC of March 1994.

Product EstaQuick

Type

Notified Body:

AEMD-600 incl. AEMD-4500-6

Sira Certification Service (0518)

Rake Lane

Eccleston

Chester

CH4 9JN

United Kingdom

Conformity has been demonstrated with reference to the following documentation:

EC type examination certificate Sira 11ATEX5240X

Quality Assurance notification Sira 12ATEX M519

Compliance with the Essential Health & Safety Requirements has been assessed by reference to the following standards:

EN 50050:2006 Electrical apparatus for potentially explosive atmospheres

Electrostatic hand-held spraying equipment

According to Annex II B of the EC Machine-Rule 2006/42/EG (MaschRL)

Applied Harmonized European Standard:

EN ISO 12100-1:2010

EN ISO 12100-2:2010

Safety of machines

— basic concepts, general design principles

— Part 1: Basic terminology, methodology

Safety of machines

— basic concepts, general design principles

— Part 2: Technical principles

EN 1953:2011

Dietzenbach,

Atomizing and spraying equipment for coating materials - Safety requirements

27th of November 2012

^

Name and Position Dave Smith

General Manager

1-2-AEMD-E-011-1 EstaQuick Applicator 41 / 43

16 Product Liability and Warranty

Important Note for Product Liability

On the basis of a valid EC Rule dated January 1, 1990, the manufacturer is only then liable for his product if all parts are originally coming from the manufacturer or have been released by the manufacturer, respectively the equipment has been mounted and maintained properly. The use of other than the manufacturer’s accessories and spare parts will void all warranties completely or partly.

We assume no liability for damage caused by the following reasons:

Inappropriate or improper use of the equipment, the use of other than FINISHING BRANDS GMBH

GERMANY RANSBURG approved parts, incorrect assembly, respectively initial start-up by the purchaser or third parties, natural wear, as well as wear parts, incorrect operation or maintenance.

Check parts at disassembly and replace if necessary

Replace parts after each disassembly

1-2-AEMD-E-011-1 EstaQuick Applicator 42 / 43

Finishing Brands Germany GmbH

Justus-von-Liebig-Str. 31

63128 Dietzenbach / Germany

Fon +49 6074 / 403-1

Fax +49 6074 / 403-281

1-2-AEMD-E-011-1 EstaQuick Applicator 43 / 43

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