Ransburg RMA 590 A13368 Rotary Atomizer Service Manual

SERVICE MANUAL

LN-9276-14.1

JUNE - 2014

Ransburg

MODEL: A13368

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.)

Ransburg

NOTE: This manual has been changed from revision LN-9276-14 to revision LN-9276-14.1.

Reasons for this change are noted under “Manual Change Summary” on page 93

of this manual.

RMA-590

LN-9276-14.1

Ransburg

RMA-590 - Contents

CONTENTS

SAFETY:

PAGE

1-5

SAFETY PRECAUTIONS ......................................................................................................1

HAZARDS / SAFEGUARDS ..................................................................................................2-5

INTRODUCTION: 6-22

APPLICATOR DESCRIPTION ...............................................................................................6

FEATURES .............................................................................................................................6

GENERAL DESCRIPTION ....................................................................................................7

SPECIFICATIONS ..................................................................................................................8-9

IMPORTANT NUMBERS ........................................................................................................10

GRAPHS ................................................................................................................................11-15

TOOL CENTER POINT DIMENSIONS ..................................................................................16-19

CIRCUIT SCHEMATICS .........................................................................................................20-22

INSTALLATION: 23-31

AIR FILTER INSTALLATION .................................................................................................23

EQUIPMENT GROUNDING / SAFETY RECOMMENDATIONS ............................................24-25

AIR HEATER REQUIREMENTS ............................................................................................25

AIR HEATER AND FILTRATION OPTIONS ...........................................................................26

A13230-XX AIR HEATER AND FILTER COMBINATION .......................................................27-28

MOUNTING ............................................................................................................................28

ELECTRICAL AND FIBER OPTIC CONNECTIONS ..............................................................29

TYPICAL INSTALLATION .......................................................................................................30

INTERLOCKS.........................................................................................................................31

OPERATION: 32- 39

FLUID FLOW RATE CONTROL ............................................................................................32-33

TURBINE SPEED...................................................................................................................33

BEARING AIR ADJUSTMENT ................................................................................................34

SHAPING AIR KITS................................................................................................................35-37

BRAKE AIR.............................................................................................................................37

ELECTROSTATIC VOLTAGE .................................................................................................37

CUP WASH ............................................................................................................................38

TARGET DISTANCE ..............................................................................................................38

GENERAL OPERATING SEQUENCE ...................................................................................38-39

MAINTENANCE: 40-73

O-RINGS ...............................................................................................................................40

CLEANING PROCEDURES ...................................................................................................40-41

VIBRATION NOISE ................................................................................................................42

TURBINE MAINTENANCE .....................................................................................................42

GENERAL/PREVENTIVE MAINTENANCE ...........................................................................42-44

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RMA-590 - Contents

CONTENTS

(Cont.)

MAINTENANCE (Cont.) :

PAGE

40-73

BELL CUP PREVENTIVE MAINTENANCE ...........................................................................44

BELL CUP CLEANING ...........................................................................................................45-46

CLEANING SHAPING AIR HOLES ........................................................................................46

PREVENTIVE MAINTENANCE SCHEDULE .........................................................................47-48

TROUBLESHOOTING GUIDE ...............................................................................................49-55

CHECKING PROBES.............................................................................................................57

ELECTRODE RESISTANCE TEST ........................................................................................57-58

DISASSEMBLY PROCEDURES ............................................................................................58-73

PARTS IDENTIFICATION: 74-91

RMA-590 ROTARY ATOMIZER MODEL IDENTIFICATION ..................................................74-76

RMA-590 ASSEMBLY / PARTS LIST .....................................................................................77-80

TYPICAL BELL CUP PARTS BREAKDOWN .........................................................................81

A13196-01 MOUNTING MANIFOLD ASSEMBLY ..................................................................82

A13125-01 SOLVENT BLOCK ASSEMBLY ...........................................................................83

A13672-00 HIGH VOLTAGE RING KIT - PARTS LIST...........................................................83

SHAPING AIR KIT ASSEMBLY PARTS BREAK-DOWN ........................................................84

ATOMIZER RECOMMENDED SPARE PARTS ......................................................................86-88

ASSEMBLY TOOLS A11090-02 .............................................................................................89

FILTER & HEATER ASSEMBLY .............................................................................................90

SERVICE KITS .......................................................................................................................91

LUBRICANTS AND SEALERS ...............................................................................................91

AIR FILTER / REPLACEMENT ..............................................................................................91

ACCESSORIES......................................................................................................................91

WARRANTY POLICIES: 92

LIMITED WARRANTY ...........................................................................................................92

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RMA-590 - 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.

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.

!

W A R N I N G

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 thoroughly understood by ALL personnel who operate, clean or maintain this equipment!

Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed. The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA-33 SAFE-

TY STANDARD, LATEST EDITION, prior to installing, operating, and/or servicing this equipment.

!

W A R N I N G

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.

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RMA-590 - Safety

AREA

Tells where hazards may occur.

Spray Area

HAZARD

Tells what the hazard is.

Fire Hazard

Improper or inadequate operation and maintenance procedures will cause a fire hazard.

Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation. Frequent Power Supply or Controller shutdown indicates a problem in the system requiring correction.

SAFEGUARDS

Tells how to avoid the hazard.

Fire extinguishing equipment must be present in the spray area and tested periodically.

Spray areas must be kept clean to prevent the accumulation of combustible residues.

Smoking must never be allowed in the spray area.

The high voltage supplied to the atomizer must be turned off prior to cleaning, flushing or maintenance.

When using solvents for cleaning:

•

Those used for equipment flushing should have flash points equal to or higher than those of the coating material.

•

Those used for general cleaning must have flash points above 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.

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RMA-590 - Safety

AREA


Spray Area

HAZARD


SAFEGUARDS


Explosion Hazard

Improper or inadequate operation and maintenance procedures will cause a fire hazard.

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.

Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation.

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.

Frequent Power Supply or

Controller shutdown indicates a problem in the system requiring correction.

Test only in areas free of flammable or combustible materials.

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 maintenance may create a hazard.

Personnel must be properly trained in the use of this equipment.

Personnel must be given training in accordance with the requirements of NFPA-33, EN 60079-0.

Instructions and safety precautions must be read and understood prior to using this equipment.

Comply with appropriate local, state, and national codes governing ventilation, fire protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms and your insurance company requirements.

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RMA-590 - Safety

AREA


HAZARD


Spray Area /

High Voltage

Equipment

Electrical Discharge

There is a high voltage device that can induce an electrical charge on ungrounded objects which is capable of igniting coating materials.

Inadequate grounding will cause a spark hazard. A spark can ignite many coating materials and cause a fire or explosion.

SAFEGUARDS


Parts being sprayed and operators in the spray area must be properly grounded.

Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The resistance between the part and earth ground must not exceed 1 meg ohm. (Refer to

NFPA-33.)

Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding straps 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.

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RMA-590 - Safety

AREA


Electrical

Equipment

HAZARD


Electrical Discharge

SAFEGUARDS


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.

Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation.

Frequent power supply shutdown indicates a problem in the system which requires correction.

An electrical arc can ignite coating materials and cause a fire or explosion.

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 equipment.

Test only in areas free of flammable or combustible material.

Testing may require high voltage to be on, but only as instructed.

Production should never be done with the safety circuits disabled.

Before turning the high voltage on, make sure no objects are within the sparking distance.

Toxic Substances

Certain material may be harmful if inhaled, or if there is contact with the skin.

Follow the requirements of the Material Safety

Data Sheet supplied by coating material manufacturer.

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.

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.

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.

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RMA-590 - Introduction

INTRODUCTION

APPLICATOR

DESCRIPTION

The RMA-590 Applicator is an automatic robot mounted rotary atomizer. This device is capable of applying waterborne and solvent borne coatings electrostatically. The waterborne coatings are applied using a method known as Indirect Charge.

This is where the coating material passes through an electrostatic field created between the charging probes, the bell cup and the target to be coated.

The solvent borne coatings are applied using a method known as Direct Charge. This is where the coating material has the electrostatic voltage applied directly to it.

This applicator incorporates the latest in high speed spindle technology, bell cup and shape air design to provide the best in atomization and pattern control. The bell cups are designed for durability using the best materials available. All wetted components are designed to offer the maximum in wear and chemical resistance. The applicator is capable of applying 70,000 VDC for the Indirect charge and up to 100,000 VDC for the Direct charge.

FEATURES

Features which make the RMA-590 advantageous:

• The ability to apply waterborne and solvent borne coatings with the same applicator without cleaning out the entire system.

• Assembly components and bell made of durable engineered resin material for optimum mechanical strength and solvent resistance.

• Heavy duty design insures excellent service life even when subjected to the quick motions of robotic applications.

• Proven long life turbine motor capable of speeds up to 100 krpm. (See “Specifications” in the “Introduction” section of this manual for bell cup speed ratings.)

• Serrated and non-serrated bell cups are available for application flexibility and color match. All bell cups are made using Titanium, Aluminum, or Coated Aluminim. The

55mm bell cup is Titanium only.

• Aerodynamic design for ease of cleaning external surfaces.

• 60° and 90° angled adapters provide more maneuverability and facilitates robotic programming.

• Negligible maintenance down time. With the quick disconnect feature, an atomizer can be exchanged in less than 2 minutes for off-line maintenance.

• Fast color changes are achieved using center feed fluid delivery and the fluid valves provide for simultaneous paint push while solvent washes the feed tube and bell cup interior.

• Internal and external bell wash is quick and efficient. Solvent and air valves are located near the rear of the applicator on the robot adapter.

• Less waste to the spray booth, with the dump valve located internally next to the feed tube.

• Compact high voltage control system. The

MicroPak™ Cascade control takes only 1/4 of the space in a 19-inch Euro rack, leaving room for additional control modules.

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GENERAL DESCRIPTION

Air Bearing Turbine Assembly

The air bearing turbine assembly with bell cup is mounted to the atomizer body assembly with a turbine retaining ring.

Atomizer Body Assembly

The atomizer body assembly houses the turbine, fluid tube assembly, fiber optic transmitter and the fluid valves. The assembly incorporates 5 valves to control the fluid delivery to the bell cup, to changes colors via dump valves and supply solvent to clean the fluid tube assembly and bell cup. The assembly is attached to the mounting manifold with a threaded quick disconnect ring.

Mounting Manifold Assembly

The mounting manifold assembly is attached to the robot adapter with 8 non-metallic screws and is the connection point for all the various air and fluid supply tubing.

Robot Adapter

The robot adapter is available in both 60° and

90° configurations. These angles allow for more flexibility in robot painting processes. The adapter houses the solvent and air valve block to clean the exterior of the bell cup surface. The rear plate lends itself to attaching various configurations for mounting on several manufacturers robots.

Robot Adapter Plate

The adapter plate can be configured so that the applicator can be used with most manufacturers of robots. The plate also incorporates a center non-metallic bearing that it rotates as fluid/air tubes and high voltage cables move and rotate during the robots motion.

Power Supply and Controls

The high voltage cascade is located inside the applicator and is controlled by the MicroPak control unit. The low voltage output of the MicroPak is multiplied by the internal cascade to the high voltage level required. This eliminates the need for a high voltage cable. A low voltage cable interconnects the cascade and MicroPak control. The

MicroPak format is designed to fit in a conventional

19-inch or 10-inch rack and requires a 24V power input at a maximum 3 amps. The MicroPak and the internal cascade will produce voltages up to

100,000 VDC.

The MicroPak is designed to electronically limit current to provide safe operation in a spray booth.

The voltage and current draw of the atomizer are continuously displayed on the MicroPak control panel. Voltage and over-current limits are adjustable on the front of the MicroPak. MicroPak internal safety circuits will shut down the system on over-current and cable faults.

With additional control modules, all of the functions of the RMA and MicroPak can be controlled by a programmable controller. A Serial Atomizer

Module pneumatically controls the speed of the rotary atomizer with dynamic feedback through a fiber optic transmitter located on the applicator. A

Serial Digital Module pneumatically controls the paint, solvent, and dump valves located on the atomizer. An I/O module provides communication between these modules and the PLC.

The above modules are mounted in one 19-inch rack and interconnected through a common mother board.

Bell Cups are made of high strength Titanium, or high wear Coated Aluminum. Serrated cups are available in 30mm, 55mm, and 65mm sizes.

Non-serreated cups are available in 55mm and

65mm sizes. See ordering matrix for exact size and material combination availability.

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SPECIFICATIONS

Electrical:

Power Supply Type:

Charging Method:

Output Voltage:

Output Current:

Turbine Speed Control:

Part Spray Ability:

MicroPak

Direct / Indirect

30-70 kV Variable (70 kV Maximum indirect charge)

30-100 kV Variable - Direct Charge

1000 µa- Indirect or Direct Charge

Atomizer Module

Determine spray ability of part to be coated using Test Equipment (76652)

(Paint Conductivity Meter)

Mechanical

:

Length: (See RMA Tool Point, Center of Gravity, and Envelope Dimension (65mm

Dual Flex) figure in the “Introduction” section.)

Diameter:

Approximate Weight

Atomizer with Indirect Charge

Ring and Probes attached:

Atomizer without Indirect Charge

Ring and Probes attached:

(See RMA Tool Point, Center of Gravity, and Envelope Dimensions (65mm

Dual Flex) figure in the “Introduction” section.)

23.85 lbs. (10.82 Kg) max.

16.6 lbs (7.53 Kg)

Turbine Type:

Turbine Air Supply:

Air Bearing Impulse Drive

Variable (See “Pressure Flow Data Charts” in the “Introduction” section.)

Maximum/Minimum Turbine Speed: Continuous 100K* rpm max. /20K rpm min. (See exception at “Fluid Flow Rate”)

Maximum Angular Velocity

for Turbine (Robot Motion):

Tubing Bundle Max. Rotation:

250

450 °

° /sec.

in Either Direction

90 psig (±10 psi)

(621 kPa ±69 kPa) 2.9 SCFM (82 slpm)

Variable (See “Pressure Flow Data Charts” in the “Introduction” section)

Variable (See “Pressure Flow Data Charts” in the “Introduction” section)

Bearing Air Supply at Applicator:

(Nominal):

Shaping Air #1 (SAI) Supply:

Shaping Air #2 (SAO) Supply:

Brake Air Supply (Nominal):

Maximum Fluid Pressure Supply:

Paint:

Solvent:

Fluid Flow Rate:

55mm Bell Cup

65mm Bell Cup

60-100 psig (414-689 kPa)

200 psi (1379 kPa)

150 psi (1035 kPa)

25-1000 cc/min. (See exclusion below)

Max. Flow Rate: 500 cc/min. at 80,000 rpm






(Continued on next page)

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Mechanical (Cont.)

:

Bell Cup Cleaning Time

(Internal/External):

Color Change Time:

Speed Readout:

Atomizer Replacement Time:

2.7 sec. (approx.)

Dependent on system configuration, fluid pressures, fluid viscosity, fluid line lengths, etc.

Magnetic pick-up, unidirectional fiber optic transmission

Less than 5 min.

Bell Cup Replacement Time: Less than 2 min.

Minimum Control Equipment Requirements: (Versions listed or higher)

MicroPak

Atomizer Module

LECU5004-17 (V.3.84)

A11925-00 (V.0.4)

I/O Module A11435-00 (V.1.4) (0.01V) (4-20 mA)

Air Heater Recommendation: An Air Heater is recommended for the turbine air supply. See Air Heater and filtration recommendation later in this manual

* Although this turbine assembly is capable of operating at continuous speeds up to 100,000 rpm, nearly all high quality finishes can be achieved within our recommended operating range of 20,000 to 70,000 rpm, based on experience with a wide variety of materials and various markets. Operating above this range is for highly specialized applications, and may reduce efficiency and equipment life. Contact your Finishing Brand representative for additional information as required.

The air turbine only is warranted for 15,000 operating hours, or 3 years from date of first installation, whichever occurs first. If, after inspection by Ransburg, defect is confirmed, we will repair or replace the air turbine, free of charge, during the warranty period. The repaired air turbine (or replacement air turbine) will continue to be warranted for the remainder of the initial warranty period (from installation date). The warranty period for the air turbine does not begin again when a repair is completed under warranty. Air turbines repaired by Ransburg after the warranty period will be warranted for 90 days from the date of shipment from the repair center. (See Warranty section on last page for specific exclusions)

** Specifications and ratings based on testing at sea level standard conditions.

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IMPORTANT NUMBERS

Record these numbers in a log book for future reference. The last digits of the Atomizer serial number are also the Turbine serial numbers.

ATOMIZER SERIAL NUMBER

Turbine Serial Number Atomizer Serial Number

Bell Cup Part Numbers/Serial Number

(cup only, not with splash plate)

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GRAPHS

Graphical information provided for reference only for all charts. Unless otherwise specified, all pressure data shown was measured 12-inches (305mm) behind the applicator.

TURBINE SPEED VS. PRESSURE - NO LOAD

TURBINE SPEED VS. AIR CONSUMPTION - NO LOAD

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FLOW VS. PRESSURE

MONO FLEX SHAPE AIR - SINGLE SUPPLY SOURCE

A12874-05/-06/-07 SHAPING AIR KIT


MONO FLEX SHAPE AIR - DUAL SUPPLY SOURCE

A12874-05/-06/-07 SHAPING AIR KIT

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RMA-560 DUAL FLEX AIR

A12874-08/-09/-10/-11 SERIES SHAPE AIR



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MAXIMUM FLOW RATE BY TIP SIZE,

HOSE LENGTH, AND MATERIAL VISCOSITY

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RMA-590 TOOL CENTER POINT DIMENSIONS - SHORT BODY 60°

ADAPTER - INDIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 60° ADAPTER - INDIRECT CHARGE -

65MM - DUAL FLEX

Y TD (Target Distance)

6-Inches (152mm)

8-Inches (203mm)

10-Inches (254mm)

12-Inches (305mm)

X

15.50-Inches (393.7mm)

16.50-Inches (419.1mm)

17.50-Inches (444.5mm)

18.50-Inches (469.9mm)

19.09-Inches (484.9mm)

20.82-Inches (528.8mm)

22.55-Inches (572.8mm)

24.28-Inches (616.7mm)

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ADAPTER - INDIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 90° ADAPTER - INDIRECT CHARGE -


TD (Target Distance)

6-Inches (152mm)

8-Inches (203mm)

10-Inches (254mm)

12-Inches (305mm)

X

23.26-Inches (590.8mm)

25.26-Inches (641.6mm)

27.26-Inches (692.4mm)

29.26-Inches (743.2mm)

Y

4.83-Inches (122.8mm)

4.83-Inches (122.8mm)

4.83-Inches (122.8mm)

4.83-Inches (122.8mm)

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ADAPTER - DIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 60° ADAPTER - DIRECT CHARGE -



6-Inches (152mm)

8-Inches (203mm)

10-Inches (254mm)

12-Inches (305mm)

X

15.50-Inches (393.7mm)

16.50-Inches (419.1mm)

17.50-Inches (444.5mm)

18.50-Inches (469.9mm)

19.09-Inches (484.9mm)

20.82-Inches (528.8mm)

22.55-Inches (572.8mm)

24.28-Inches (616.7mm)

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ADAPTER - DIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 90° ADAPTER - DIRECT CHARGE -



6-Inches (152mm)

8-Inches (203mm)

10-Inches (254mm)

12-Inches (305mm)

X

23.26-Inches (590.8mm)

25.26-Inches (641.6mm)

27.26-Inches (692.4mm)

29.26-Inches (743.2mm)

4.83-Inches (122.8mm)

4.83-Inches (122.8mm)

4.83-Inches (122.8mm)

4.83-Inches (122.8mm)

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CIRCUIT SCHEMATIC - INDIRECT CHARGE

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CIRCUIT SCHEMATIC - DIRECT CHARGE

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HIGH VOLTAGE CIRCUIT SCHEMATIC


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RMA-590 - Installation

INSTALLATION

AIR FILTER INSTALLATION

(GENERAL GUIDELINES)

The following air filter installation guidelines are essential for optimum performance:

1. Use 25mm OD (1-Inch OD) minimum inbound main air line.

2. Use only recommended pre-filters and bearing air filters as shown in “Air filtration Requirements” chart in the ”Installation” section. Additional system air filtration (i.e., refrigerated air dryer) may also be used if desired.

3. Mount all the air filters as close as possible to the RMA-590 applicator. (DO NOT mount further than 30-Feet (9.1 meters) away.)

4. DO NOT use tape, pipe dope, or other thread sealant downstream of the bearing air filter.

Loose flakes of tape or other sealant can break loose and plug the very fine air holes in the turbine air bearings.

5. Air heaters are highly recommended for use in the system to minimize the effect of excessively humid conditions and maintain turbine load capabilities. If the heated air will exceed 120°F

(48.9°C), the heater must be located after all filters to prevent damage to the filter media.

NOTE

Each applicator must have its own filter for bearing air. Recommended: RPM-418 or equivalent.

With the exception of fluid, dump, and bearing air, all other pilot and air supply lines should be bulk-headed and their diameters increased one size. For example: Turbine air should be increased to 12mm OD from bulkhead plate to the volume booster or heater outlet.

Volume Booster Recommendation

(Turbine Air): (For use with A11065-05

Air Heater or Non-Air Heater System)

Ransburg Part # A11111-00

• Pilot Operated Regulator Non-Bleed Pilot

• SCFM-200

• Supply - 300 P.S.I.

• Temperature Range: 40˚ - 120° F

TUBE SIZE AIR PRESSURE REQUIREMENTS

Bearing Air Supply (BA)

Pilot Dump 2 Air (PD2 AIR)

Paint Valve 2 (PT2)

Bearing Air Return (BA RTN)

Brake Air (BRK)

Pilot Dump 1 Air (PD1 AIR)

Pilot Dump Valve 1 (PD1)

Shape Air Outer (SAO)

Shape Air Inner (SAI)

Paint Valve 1 (PT1)

Turbine Air (TA)

Solvent Valve (ST)

Pilot Dump Valve 2 (PD2)

Paint #1 (P1)

Paint #2 (P2)

Dump #1 (DL1)

Dump #2 (DL2)

Solvent (SOL)

Tube Size

1/4” OD

4mm OD (5/32” OD)

4mm OD (5/32” OD)

4mm OD (5/32” OD)

1/4” OD

4mm OD (5/32” OD)

4mm OD (5/32” OD)

8mm OD X 6mm (5/16” OD)

8mm OD X 6mm (5/16” OD)

4mm OD (5/32” OD)

8mm OD X 6mm (5/16” OD)

4mm OD (5/32” OD)

4mm OD (5/32” OD)

8mm OD (5/16” OD) PFA





Air Pressure Requirements

90 +/- 10 psi (621 +/- 69 kPa)

30 psi (207 kPa) Max.

80 +/- 10 psi (552 +/- 70 kPa)

90 +/- 10 psi at atomizer card (552 +/- 70 kPa)

60-100 psi (414-689 kPa)

30 psi (207 kPa) Max.

80 +/- 10 psi (552 +/- 70 kPa)

Variable (see graphs in this manual)


80 +/- 10 psi (552 +/- 70 kPa)


80 +/- 10 psi (552 +/- 70 kPa)

80 +/- 10 psi (552 +/- 70 kPa)

200 psi Max. (1379 kPa)

200 psi Max. (1379 kPa)

200 psi Max. (1379 kPa)

200 psi Max. (1379 kPa)

100 psi Max. (689.5 kPa)

LN-9276-14.1

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EQUIPMENT GROUNDING /

SAFETY RECOMMENDATIONS

In electrostatic coating systems, the flow of high voltage power from the power supply to the atomizer is insulated from ground and isolated from all other functions equipment. When the voltage reaches the atomizer, it is transferred to the coating material where, by introducing a negative charge, it causes the atomized fluid to seek the nearest positive ground. In a properly constructed and operated system, that ground will be the target object.

The directed conduction of the electric charge, through its array of wires, cables, and equipment, is accompanied by a variety of stray electrical charges passing through the air by various means such as: air ionization, charged particles in the air and radiated energy. Such charges may be attracted to any conductive material in the spray area. If the conductive material does not provide a safe drain to electrical ground, which will allow the charge to dissipate as fast as it accumulates, it may store the charge. When its electrical storage limit is reached, or when it is breached by external circumstances (such as the approach of a grounded object or person, or one at lower potential), it may discharge its stored charge to the nearest ground. If there is no safe path to ground (such as a ground wire or braided cable) it may discharge through the air as a spark. A spark may ignite the flammable atmosphere of a spray area. The hazard area extends from the point of origin up to as much as a twenty-foot radius.

(See the NFPA-33 for definition and limitations of a hazard area.)

It is simple, but vital matter to be sure that all conductive objects within the spray area are grounded.

All cabinets, housing, bases, supports, and stands, which are not by design, insulated from ground, be connected directly and INDIVIDUALLY to earth ground. Resting on a concrete floor or being attached to a building column may not always be sufficient ground.

In order to provide the best ground connection possible, always attach a ground wire or insulated braided cable the terminal indicated by the ground symbol and then to a proven ground. Always check ground connections for integrity. Some items, such as rotators and paint stands, may be supported on an insulator, but all components of the system up to the insulator MUST be grounded.

NOTE

Ransburg recommends that ground connections to earth ground be 3/4” insulated copper braided wire. Grounds between assemblies within a machine should be run to a central point within the machine using #18 insulated stranded copper wire minimum. All connections should be mechanically sound and have less than 5 ohms of resistance between assemblies and the common point. The resistance between the central point and earth ground should be less than 5 ohms as well.

Where items are mounted directly on structural components such as building columns, the ground connection MUST still be made. In many cases the structural component may be painted or coated with an insulated material and in all cases, the equipment will provide the necessary connection at one end, but the user must be sure that the other end is secured to an earth ground.

This may be achieved by the use of a standard ground clamp (properly secured), by brazing or by piercing the structural component enough to assure connection. All ground connections should be made to the most conductive metallic structural ground available.

To be sure that everything is properly grounded, the following steps should be undertaken at least daily:

1. Inspect all ground wires. Look for good, firm joints at all points of connection. Look for breaks in the ground wire. Repair all defects

IMMEDIATELY!

2. Inspect the floor or grates for excessive accumulation of dried coating material or other residue. If there is any, remove it!

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SAFE GROUNDING IS A MATTER OF PROPER

EQUIPMENT MAINTENANCE AND INSTAL-

LATION, CORRECT OPERATION AND GOOD

HOUSEKEEPING. Daily inspection of grounding apparatus and conditions, however, will help prevent hazards that are cause by normal operations.

BE SURE THAT:

1. All objects in the spray area are grounded.

2. Personnel in the spray area are properly grounded. (Conductive safety shoes and coveralls.)

3. That the target object is properly grounded

(less than 1 megohm resistance).

4. That the high voltage is off except during normal application.

5. That the high voltage is off and applicators are grounded during maintenance operations.

6. The spray area is kept free of accumulated coating deposits.

7. All combustible liquids in the spray area

(outside of automatic delivery systems) are kept to minimum and are kept in fire safe, grounded containers. (See NFPA-30 and chapter 6 of NFPA-33.)

8. Proper ventilation is provided.

9. Personnel must thoroughly understand the equipment, its operation and maintenance, and all safety precautions.

AIR HEATER

REQUIREMENTS

Turbine drive air expands as it moves through the turbine wheel cavity and as it exits the turbine from the exhaust port. This expansion will cause cooling of the exhaust air and the surfaces it contacts.

This same expansion cooling can occur across the shaping air exit ports. This cooling affect can cause surface temperatures to fall below the dew point of the booth, which will result in condensation on the interior and exterior of the atomizer,

LN-9276-14.1

machine, and its components. It is even possible that the temperature of the supply air may be below the booth dew point, even without additional expansion cooling.

Condensation is especially probable in waterborne applications when booth temperature and relative humidity levels are typically maintained very high.

This condensation will allow sufficient conductivity of the surfaces such that they act as an erratic ground source potential. This can cause damage to the equipment.

It is therefore, a requirement that turbine exhaust air temperature be maintained above the booth dew point to prevent condensation from forming on atomizer surfaces. Doing so will eliminate moisture as a potential defect in painted surfaces as well as extending equipment life. Thus, it is recommended that air heaters be installed into the atomizer air supply lines, i.e. turbine drive air, shaping air, and seal air. The air heaters must be of sufficient capacity, capable of raising the incoming air temperature at least 40°F (4.4°C) at a flow rate of 60 SCFM per applicator.

The actual air heater process setting depends on applicator fluid flow rate load, booth conditions, turbine airflow settings, and incoming air temperature. The heater should be set as low as possible, sufficient to maintain the applicator surface temperatures above the dew point in the booth.

Example: With the incoming air temperature at

72°F (22.2°C), and RMA Hybrid with 65mm bell cup rotating unloaded at 60 krpm has a turbine outlet temperature drop of approximately 28°F

(-2.2°C) @ 40 krpm unloaded, ∆~14°F (-10°C).

Referring to the ASHRAE Psychrometric chart, the saturation temperature range (dew point) of a spray booth maintained at 70-75°F/65-70%

RH is 62-68°F (21.1-23.9°C/65-70°RH is 16.7-

20°C). Thus it is almost certain that the surface temperatures of the applicator will fall below the dew point of the booth, and an air heater will be needed in this case.

To prevent condensation, a Ransburg air heater assembly should be assembled after the air filters and volume booster. (See heater and filtration options later in this manual).

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Ransburg

AIR HEATER AND

FILTRATION OPTIONS

NOTE

Failure to use an air heater may cause damage to equipment or ruin the finished component being processed.

NOTE

Connect air heater to turbine air tubing.


NOTE

If using the A11065-05 Air Heater, air filters equivalent to HAF-503, HAF-508 and RPM-418 must be used. (See descriptions in this manual).

LN-9276-14.1

A11065-05 Air Heater

26

Ransburg


A13230-XX AIR HEATER AND FILTER COMBINATION

This combination includes filtration for turbine as well as bearing air.

FILTER & HEATER ASSEMBLY A13230-XX

Dash No.

Description “A” “B” “C” “E”

A13230-01 115 V.@ 13A METRIC FITTINGS

A13230-02 230 V.@ 6.5A METRIC FITTINGS

A13434-01 A13426-00 A13429-00 A13726-00

A13434-02 A13426-00 A13429-00 A13726-00

A13230-03 115 V.@ 13A FRACTIONAL FITTINGS A13434-01 SSP-6439 A13428-00 A13727-00

A13230-04 230 [email protected] FRACTIONAL FITTINGS A13434-02 SSP-6439 A13428-00 A13727-00


Item Part # Description Qty.

1 “A” AIR BLOCK, NIPPLES & AIR HEATER

2 A13427-00 INLET FITTING, 3/8 NPS(M) X 1/2 NPT(M)

3 “B”

BEARING AIR FEED, SWIVEL ELBOW 1/4 O.D.TUBE X 1/4 NPT(M)

BEARING AIR FEED, 6mm O.D. TUBE X 1/4 NPT(M) STRAIGHT ADAPTER

4 79253-02 AIR FITTING, SWIVEL ELBOW 5/32 O.D. TUBE X 1/4 NPT(M)

5 “C”

OUTLET FITTING, 1/2 O.D. TUBE X 1/2 NPT(M) STAINLESS STEEL

OUTLET FITTING, 12mm O.D. TUBE X 1/2 NPT(M) STAINLESS STEEL

6 “E” VOLUME BOOSTER

7 A13433-00 AIR FILTER & NIPPLE INCLUDED

8 SI-13-07 A13230-XX SERVICE LITERATURE (PROVIDED BY OTHER)

ALL UNITS: REPLACEMENT PARTS: (SERVICE NOTE)

HEATING ELEMENT USE: A13432-01 FOR A13230-01 AND A13230-03 (115V UNITS)

A13432-02 FOR A13230-02 AND A13230-04 (230V UNITS)

AIR FILTER ELEMENT USE A13232-00

THERMOMETER USE A13431-00

LN-9276-14.1

2

1

1

1

REF.

1

1

1

27

Ransburg


AIR FILTRATION REQUIREMENTS WHEN USED WITH A11065-05

AIR HEATER OR NO AIR HEATER

Ransburg Filter

Model No.

Description / Specifications Replacement Element Part No.

HAF-503

HAF-508

Pre-filter, removes coarse amounts of oil, moisture and dirt. Used upstream of HAF-508 pre-filter

(used in systems with poor air quality.

Pre-filter, coalescing type, 136 SCFM, 98.5% efficiency particulate removal .3 to .6 micron, max. aerosol passed 1.0 micron, max. solid passed .4 micron (dependent upon SCFM requirement per applicator, one HAF-508 can be used with up to three applicators.

HAF-15 Element One

HAF-38 Elements,

Carton of 4

RPM-418 Bearing air filter, coalescing type,19 SCFM,

99.995% efficiency particulate removal .3 to .6 micron, max. passed .6 micron max. solid passed

.2 micron (one per applicator)

RPM-33 Elements,

Carton of 8

!

C A U T I O N

Air must be properly filtered to ensure extended turbine life and to prevent contamination of the paint finish. Air which is not adequately filtered will foul the turbine air bearings and cause turbine failure. The correct type filters musts be used in an

RMA-590 system. The filter elements must be replaced regular schedule to assure clean air.

It is the user’s responsibility to ensure clean air at all times. Turbine failure resulting form contaminated air will not be covered under warranty. If other filters are incorporated in the system, the filters to be used must have filtering capacities equal or better than those shown in “Air Filtration

Requirements Charts.”

The user must ensure the bearing air supply is not inadvertently turned off while the RMA-590 air motor is turning. This will cause air bearing failure.

NOTE

Each applicator must have its own filter for bearing air. Recommended: RPM-

418 or equivalent.

MOUNTING

The RMA-590 is equipped with a quick disconnect assembly. The quick disconnect feature consists of mounting manifold which is permanently mounted to the robot adapter and an atomizer body assembly. The atomizer body assembly is secured to the mounting manifold with a threaded ring.

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Ransburg

ELECTRICAL AND FIBER

OPTIC CONNECTIONS

The fiber optic connection is made on the back of the atomizer’s mounting manifold. The fiber optic cable comes pre-assembled with connectors that are secured in place by set screws tightened from the side of the robot plate. Set screws should be tightened 15-20 lbs•in (1.7-2.2 Nm).

Maximum amount of splices for any length of cable is 3, including the mounting manifold and transceiver card. The speed detection signal may be affected if splices are exceeded. Length in any combination for the fiber optic is 100-feet.


A13392-00 FIBER OPTIC/LOW VOLTAGE

CONNECTOR KIT - PARTS LIST

Item

1

2

3

4

Qty.

1

1

1

2

Part #

A13393-00

A13391-00

A13537-00

80073-00

Description

BRACKET, FIBER OPTIC/LOW VOLTAGE

FIBER OPTIC BULKHEAD CONNECTOR

HEX NUT, M22 X 1.5

STRAIN RELIEF, CABLE GLAND

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TYPICAL INSTALLATION OF RMA-590

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Ransburg

INTERLOCKS

The following system interlocks are required to prevent equipment damage.

• Bearing air should remain on at all times and should be shut-off by turning off the main air to the pneumatic control cabinet.

• It should not be possible for the coating material to be sprayed unless the turbine is spinning.

• Two inter-connected bearing air ports are provided, one for supply air and the other to be used as a return signal for measuring bearing air pressure at the atomizer. If bearing air falls below 80 psi (551.6 kPa) at the atomizer, the turbine air should be automatically interlocked to shut off. This interlock is provided by the Serial Atomizer

Module. (See current “Serial Atomizer” service manual.)

• High voltage must be interlocked with the solvent valve pilot signal to prevent solvent flow while high voltage is energized (direct charge only).

• Turbine air and brake air must be interlocked to prevent both from being used simultaneously. This interlock is provided by the Serial Atomizer Module. (See current

“Serial Atomizer” service manual.)

• Any other interlocks required by local national code or international code. The following system interlocks are required to prevent equipment damage:


!

C A U T I O N

When the turbine air is turned off, the turbine will continue to operate or “coast down” for about two minutes. Provisions should be made to assure that the operator waits at least three minutes, after shutting off the turbine air and before shutting off the main air supply.

The bell cup must be removed when making flow checks. If the paint is turned on when the bell is mounted and the turbine shaft is not rotating, paint will enter the shaft and possibly damage the air bearing.

Material flow checks (flow rate verification) must be made with the bell cup off and the turbine not rotating. Normally pneumatic interlocks will not allow the paint to trigger on when the turbine air is off.

!

W A R N I N G

The high voltage and/or coating material must never be turned on unless the bell cup is mounted on the motor shaft and the turbine is rotating.

Pneumatic input to the turbine air inlet must be controlled to prevent the turbine from exceeding the maximum rated speed of 100,000 rpm. (See “Specifications” in the

“Introduction” section.)

High voltage must never be turned on while cleaning solvent is being sprayed either through the applicator supply or the cup wash line. High voltage and both solvent triggers must be interlocked (direct charge only).

 Never Spray solvent with high voltage on.

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Ransburg

RMA-590 - Operation

OPERATION

!

W A R N I N G

Operators must be fully trained in safe operation of electrostatic equipment. Operators must read all instructions and safety precautions prior to using this equipment

(see NFPA-33).

As with any spray finishing system, operation of the RMA-590 involves properly setting the operating parameters to obtain the best finish quality for the coating material being sprayed, while maintaining correct operation and reliability of the equipment used. Adjustments to operating parameters, which cover spraying, cleaning, and on/off control, include:

• Coating materials

• Fluid flow rate control

• Fluid valve control

• Turbine speed

• Bearing air adjustment

• Shaping air

• Brake air

• Electrostatic voltage

• Target distance

FLUID FLOW RATE

CONTROL

Externally mounted fluid regulators or gear pumps are typically used to control fluid flow.

Paint is supplied to the RMA-590 by way of the tubing bundle through the robot arm.

The atomizer assembly is equipped with micro valves which are pneumatically operated to direct the flow of paint to either the feed tube or dump line and to supply an intermittent solvent to clean the interior and exterior of the bell cup.

The feed tube has several sized removable tips available from .7mm - 1.6mm (.027-inch - .062inch). The viscosity and volume of the coating material being sprayed determine the correct size of feed tube tip for each installation. (Reference

“Fluid Tip Flow Rate” chart in the “Introduction” section.)

Fluid Flow Rate Check

In the test mode, the flow rate can be measured by removing the bell cup from the atomizer, turning the fluid flow on, and capturing the material in a graduated beaker or measuring cup for a fixed period of time (shaping air, high voltage, and turbine air must be off).

!

W A R N I N G

Electrical discharge of a high electrical capacitance fluid/paint system can cause fire or explosion with some materials. If arcing occurs when a specific coating material is used, turn the system off and verify that the fluid is non-flammable. In these conditions the system is capable of releasing sufficient electrical and thermal energy to cause ignition of specific hazardous materials in the air.

LN-9276-14.1

!

W A R N I N G

Danger of shock and/or personal injury can occur. Proper grounding procedures must be followed. Personnel must never work around the turbine when the turbine is spinning or when high voltage is turned on.

32

Ransburg

RMA-590 - Operation

(See “Circuit Diagram” in the “Introduction” section.) The fluid valves in the RMA-590 are actuated by an air signal. The air pressure must be greater than 70 psi (482.6 kPa) to assure proper actuation of the valve. Applying air to the valve actuator turns on the fluid or air for that valve.

The paint trigger valve controls the paint flow to the bell. When actuated, paint flows through the valve to the fluid tube, and into the rear of the bell cup. The bell cup must be spinning at least

30,000 rpm when fluid is turned on to enable the fluid to flow through the bell paint passage and be atomized.

The dump valve controls the paint flow through the dump line. When actuated, paint flow is directed to the dump return line. This provides a method of rapidly removing paint from the incoming line for cleaning and/or color change. Normally, the dump valve is not actuated at the same time as the paint trigger valve since the trigger valve is intended to cause the fluid to flow to the bell at the prescribed input pressure.

During spraying, a separate air line supplies constant flow of air to the dump line to keep it dry.

The air supply line is protected by a check valve to prevent reverse flow.

The solvent valve controls the flow of cup wash solvent. When actuated, solvent flows through a separate fluid tube passage and into the bell cup. This provides cleaning of the inside of the bell cup. The outside of the cup is simultaneously cleaned by a nozzle mounted on the shaping air ring and shroud. The solvent valve should never be triggered at the same time as the paint trigger valve to prevent solvent from flowing backward into the paint line.

To color change the applicator, a solvent air chop must be provided through the main paint line (see

”Typical Installation RMA-590” in the Installation” section).

!

W A R N I N G

 Never perform the interior/exterior cup clean process with high voltage on.

!

C A U T I O N

The normal fluid flow range is 25-1000 cc/min. During a color change or when flushing the system, high flow rates may be required. However, the maximum flow rate through the bell cup must not exceed

1000 cc/min., to avoid solvent or paint from flooding into the internal portion of the air bearing motor assembly or front shroud.

 High voltage must be interlocked with the solvent valve to prevent solvent spraying while high voltage is on.

TURBINE SPEED

Turbine speed is determined by the input air pressure/flow at the rear of the atomizer.

Turbine speed is intended to be closed loop controlled using the fiber optic speed transmitter, located on the turbine manifold. A speed input to a remote speed controller, such as the Serial

Atomizer Module, is required. (See “Speed and

Pressure” charts in the “Introduction” section.)

NOTE

The bell rotational speed determines the quality of atomization and can be varied for various paint flow rates and paint formulations. For optimum transfer efficiency and spray pattern control, the bell rotational speed should be set at the minimum required to achieve proper atomization. Excessive speed reduces transfer efficiency!

LN-9276-14.1

33

Ransburg

!

W A R N I N G

DO NOT exceed the maximum rated operating speed and turbine inlet pressure.

Excessive speed may cause air turbine damage or damage to the bell.

BEARING AIR

ADJUSTMENT

The nominal bearing air pressure is 90 psi (620.5 kPa), measured at the rear of the atomizer. Minimum pressure is 80 psi (551.6 kPa) and maximum pressure is 100 psi (689.5 kPa). The turbine should never be operated with less than 80 psi

(551.6 kPa) bearing air pressure.

Bearing air must be present when turning the turbine on. Bearing air must remain on when the turbine air is turned off until the turbine stops spinning. Never turn off bearing air to cause the turbine to stop spinning. If connected, brake air can be used to slow the turbine.

The RMA-590 is equipped with a bearing air return line to monitor bearing air pressure at the turbine manifold. When connected to the remote

Serial Atomizer speed controller, operation of the turbine will automatically be shut down whenever the bearing air pressure falls below the dip switch setting of 80 psi (551.6 kPa).

Direct Charge Spraying

When spraying solvent borne material you must provide voltage to the indirect charge ring and probes. The voltage at the probes should be at a lower potential than that applied to the bell cup directly. For example 70kv is applied to the bell cup directly. 65kv should be applied to the high voltage probes. Having a higher potential on the probes may cause high voltage arching during spray operation. This may cause fire or damage.

Use plastic or metal shape air component when spraying in direct charge mode.

Indirect Charge Spraying

When spraying in this mode, the bell cup is at earth ground potential. High voltage is applied to the high voltage ring and probes (70kV maximum).

An electrostatic field develops between the high voltage probes, the bell cup and the spray target.

An electrostatic charge is applied to the paint as it passes through this field. Use only plastic shape air component when spraying in indirect charge mode.

NOTE

A minimum of 70 slpm (2.6SCFM) should always be kept flowing in the inner shaping air passage to keep the face of the applicator clean during manual cleaning breaks.

!

W A R N I N G

Bearing air MUST be ON and supplied at a minimum of 80 psig (551.6 kPa) whenever the turbine is operated. If not, severe bearing damage will occur. It is recommended that bearing air be left turned on at all times, except during maintenance or disassembly.

Bearing damage (and subsequent turbine failure) caused by running the turbine without bearing air WILL NOT be covered under the Ransburg warranty.

RMA-590 - Operation

!

W A R N I N G

Never spray solvent when high voltage is on.

!

W A R N I N G

DO NOT use metal shape air components when using the indirect charge ring.

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Ransburg

RMA-590 - Operation

DUAL FLEX PATTERN SAMPLE

A12874-08/09

(METAL DIRECT CHARGE ONLY)

A12874-10/11

(PLASTIC INDIRECT DIRECT CHARGE)

Turbine Speed

(krpm)

Inner Shape

Air (slpm)

Outer Shape

Air (slpm)

Fluid Flow

(cc/min)

Pattern Size

(mm/inches)

60 550 0 100 75/3

50 550 0 100 114/4.5

60 500 150 100 89/3.5

50 500 150 100 121/4.75

60 75 500 200 203/8

50 75 500 200 248/9.75

40 0 500 200 254/10

SHAPING AIR KIT #1

A12874-10/11 Dual Flex Shaping Air Kits for

Use with 65mm Bell Cup A12874-08/09 Direct

Charge Only

As the name implies, both shaping air outlets supply air that is counter to the rotation of the bell cup. This combination will provide a pattern size from 3-inch to 10-inch (76mm - 254mm) depending on bell rotation speed, fluid flow, and air flow.

Both sets of shaping air holes are independently controlled. The inner set of holes are supplied by connecting the tube labeled “SAI” to a regulated air source. The outer set of shaping air holes are supplied by connecting the tube labeled “SAO” to a regulated source. The air supplies work in combination with each other to provide desired results. This combination of shaping air can be used with any 65mm bell cup.

Sample Dual Flex Shape Air

Configurations:

Pattern sizes based on solvent borne metallic paint with a viscosity of 30-32 centipoise, target distance: 175mm (7 inches), no electrostatics applied (Results will vary depending on fluid flow rate, material viscosity, target distance and with electrostatics applied) Typical pattern size achievable with this shaping air configuration is

75mm-300mm (3-12 inches).

As per the chart above, as the outer shape air is increased, the pattern increases. It should also be noted that when the turbine speed is increased, the pattern size will decrease. By varying combinations, patterns between 75mm and 254mm can be achieved.

NOTE

Use only plastic shape air components for indirect charge spraying.

NOTE

A minimum of 70 slpm (2.6 SCFM) should always be kept flowing in the inner shaping air passage to keep the face of the applicator clean during manual cleaning breaks.

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Ransburg

RMA-590 - Operation

Y)

AL, DIRECT

NOTE



A12874-12 Dual Flex Shaping Air Kits 55mm

Bell Cups. Direct Charge Only. A12874-13

Direct/Indirect Charge

As the name implies, both shaping air outlets supply air that is counter to the rotation of the bell cup.

Both sets of shaping air holes are independently controlled. The inner set of holes are supplied by connecting the “blue” tube labeled “SAI” on the tubing bundle to a regulated air source. The outer set of shaping air holes are supplied by connecting the “gray” tube labeled “SAO” on the tubing bundle to a regulated source. The air supplies work in combination with each other to provide desired results. This combination of shaping air can be used with any 55mm bell cup.

NOTE

A minimum of 70 slpm (2.6 SCFM) should always be kept flowing in the inner shaping air passage to keep the face of the applicator clean during manual cleaning breaks.

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RMA-590 - Operation

MONO FLEX PATTERN SAMPLE


A12874-05/06 Shaping Air Kits (Mono Flex

Air - Direct Charge - A12874-07 Indirect/Direct

Charge for Use with All 65mm Bell Cups Only)

As the name implies, shaping air outlet supply air that is counter to the rotation of the bell cup.

This combination will provide a pattern size from

10-inch to 24-inch (250mm - 610mm) depending on air flow, fluid flow, and cup rotation speed.

Connection is made using the “blue” 8mm tube labeled “SAI” on the tubing bundle. The other 8mm tube labeled “SAO” is “gray” in color and must be plugged. However, if additional air is required, this tube can be connected to a secondary controlled air source. Precautions must be taken that one does not have a significantly higher pressure than the other to avoid any back flow. This shaping air combination can be used with any 65mm bell cup. (See “Pressure and Flow Data Charts” in the “Introduction” section.)

Turbine Speed

(krpm)

50

60

70

70

60

70

70

60

70

Inner Shape Air

(slpm)

Fluid Flow

(cc/min)

Pattern Size

(mm/inches)

120 100 457/18

120 200 660/26

120 300 737/29

120 400 864/34

350 200 279/11

350 300 381/15

350 400 482/19

525 300 228/9

525 400 10.5

NOTE


NOTE

A minimum of 70 slpm (2.6SCFM) should always be kept flowing in the inner shaping air passage to keep the face of the applicator clean during manual cleaning breaks.

BRAKE AIR

Brake air is used to slow the turbine speed in a minimum length of time. It is advantageous for short cycle times during color change, or may be used to reduce speed or stop the turbine. Never operate brake air with the turbine air on.

Sample Mono Flex Shape Air

Configurations:

Patterns sizes based on waterborne basecoat paint, target distance: 230mm (9 inches), 70kV electrostatics applied (Results will vary depending on fluid rate, material viscosity, target distance and with electrostatics applied) Typical pattern size achievable with this shaping air configuration is

230mm-860mm (9 - 34 inches).

ELECTROSTATIC

VOLTAGE

The RMA-590 Rotary Atomizer receives a low voltage control input from the MicroPak to control the operating electrostatic voltage. (refer to the current “MicroPak” manual for detailed for operating instructions.)

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Ransburg

RMA-590 - Operation

NOTE

If paint defects occur, such as fatty edges or picture framing, reducing the voltage should be a last resort. To correct the problem, lead and lag trigger adjustments should be optimized first.

The electrostatic voltage applied to the RMA-590 will affect pattern size, transfer efficiency, wrap and penetration into cavity areas.

CUP WASH

It is recommended for water based material that heated solvent be recirculated at the rear input of the atomizer (140° F, 60° C). Typical wash solvent is di-water and amine (8-10% solution).

TARGET DISTANCE

The distance between the RMA-590 atomizer and the target will affect the finish quality and efficiency. Closer distances give a smaller pattern, wetter finish, and greater efficiency. Greater distance will provide a large pattern size and drier finish. The MicroPak control circuit will enable the applicator bell to be operated to within a few inches of the target without adjusting the voltage setting. The recommended target distance is 6 to 12-inches (152.4-304.8mm). In general, allow

1-inch (25.4mm) target distance for every 10kV.

GENERAL OPERATING

SEQUENCE

!

W A R N I N G

It is recommended to leave bearing air on, unless the applicator is being serviced or removed for service.

Normally, for painting application, the process sequence should always be:

• Bearing air on (Always On)

• Turbine air on

• Turbine speed to application speed

• Shaping air on

• Start fluid flow off part

• Voltage on

After spraying the object, the sequence should be:

• Voltage lowered to 30-50 kV

• Fluid off

• Shaping air to setback volume

• Turbine speed to set back speed (30,000

rpm recommended)

Recommended sample cup flush sequence is as follows (voltage must be off) (internal and external cup wash):

1. Turbine speed set to 25,000-30,000 rpm.

2. Set shaping to 350-450 slpm (12.4-15.9

SCFM).

3. Point atomizer at a grounded object such as a booth grate.

4. Maintain solvent pressure of 100-150 psi

(689-1,034 kPa). Maintain air push pressure at 80-100 psi (552-689 kPa).

5. Use an alternating trigger sequence of solvent/air to create a chopping effect. Always ensure that the last step in the sequence is an air push.

A typical sequence is .2 seconds solvent,

1.0 second air push, 1.7 seconds solvent and 2.0 seconds final air push. This sequence may be modified for other paints and applications

6. It is recommended that an in-line fluid filter be installed to ensure that no foreign debris enters the fluid tip or the external wash nozzle.

The RMA-590 is versatile in processing the finish of a component. It can be setup as shown in “Typical Paint Sequence” figure.

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RMA-590 - Operation

Recommended sample cup purge sequence is as follows (voltage must be off) (internal cup cleaning):

1. Turbine speed set to 25,000-30,000 rpm.

2. Increase shaping air to 350-450 slpm (12.4-

15.9 SCFM).

3. Paint atomizer at booth grate or insert into bell cleaning station.

4. Maintain solvent pressure of 100-150 (689-

1,034 kPa). Maintain air push pressure at

80-100 psi (552-689 kPa).

5. Use an alternating trigger sequence of solvent/air to create a chopping effect. Always ensure that the last step in the sequence is an air push.

6. A typical sequence is .3 seconds solvent,

1.7 seconds air push, repeat 3 times. This sequence may be modified for other paint and applications.

Typical Paint Sequence

2. Shaping Air - Set to 350-450 (12.4-15.9

SCFM) while performing a cup flush.

3. Voltage On - The voltage is turned on from a signal to the MicroPak. The lag time to full voltage may be reduced if a setback voltage is used. Recommended setback voltage is between 30 kV and 50 kV.

4. Trigger Fluid - An air signal is sent through the PT line of the tubing bundle. This should occur when the target is 6-12-inches (152.4-304.8mm) from the applicator centerline. (Not to be confused with target distance.)

5. Voltage Off/Setback Voltage - Immediately precedes the trigger off. Using a setback voltage shortens the cascade voltage ramp up time.

6. Fluid Trigger Off - This should occur when the target is typically 0-6-inches (0-

152.4mm) past the applicator centerline.

7. Shaping Air to Setback - The setback flow of air should never be below 70 slpm (2.6

SCFM) for the shape air.

8. Color Change Sequence - Used when color is changed one to the other. Typical sequence is shown in “Typical Color Change

Sequence” figure in the “Operation” section.

NOTE

 During this sequence, the applicator should be moved to a position to collect the waste material.

Typical Color Change Sequence

Sequence Event Explanation:

1. Bell to Speed - This is accomplished by a set point command from either the PLC, robot, or other input device, through the I/O module.

The sequence shown is a starting point for processing, but the final sequence will depend on the material being sprayed and the solvent used to purge the applicator with.

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RMA-590 - Maintenance

MAINTENANCE

O-RINGS

All O-rings in this atomizer are solvent proof except those on the air bearing spindle. These

O-rings must not be soaked in solvent; if these are exposed or soaked in solvent, they must be replaced. These O-rings are engineered to provide a fit between the air bearing spindle and it’s mating parts to reduce or eliminate harmonic resonance (vibration).

Some O-rings are encapsulated. These O-rings have a limited amount of stretch and will not return to their original diameters if over stretched. These

O-rings are subject to being distorted more easily than rubber O-rings, so it is important that they be sufficiently lubricated when mating parts are installed onto them. They also will take a square set over time and should be replaced periodically if mating parts are removed repeatedly or if a new mating part is installed onto them.

Any O-ring that is cracked, nicked, or distorted must be replaced.

A suitable lubricant is food grade petroleum jelly or A11545-00 Petrolatum Jell.

!

W A R N I N G

Ensure that all energy sources are dissipated, (electrical, air, paint, solvent, etc.) before removing the applicator or performing any maintenance.

In addition to the previous Warning, which relates to potential safety hazards, the following information must be observed to prevent damage to the equipment.

!

C A U T I O N

DO NOT immerse the RMA Hybrid turbine in solvent or other liquids. Turbine components will be damaged and warranty will be voided.

Bearing air must be on during all cleaning procedures to protect the air bearing components.

!

W A R N I N G

Electrical shock and fire hazards can exist during maintenance. MicroPak supply must be turned off before entering the spray area and performing any maintenance procedures on the atomizer. Spray booth fans should remain on while cleaning with solvents.

Never touch the atomizer bell while it is spinning. The front edge of the bell can easily cut into human skin or cut through gloves and other materials. Be sure the atomizer bell has stopped spinning before attempting to touch it.

Approximate time for the bell to stop spinning after turning off turbine drive air is three minutes.

Ensure high voltage is off during any manual cleaning procedure.

LN-9276-14.1

CLEANING PROCEDURES

Internal Fluid Path Purge Cleaning

Cleaning the incoming paint line (from paint supply source such as color manifold through the fluid manifold and bell assembly): Turn off the high voltage and turn on the color stack trigger valve for solvent supply. With the bell spinning, open the dump valve and flush the incoming paint line with solvent or an air/solvent chop. Make sure the last step of the sequence is air to purge the dump line of remaining solvent. To speed the loading of the new paint, leave the dump line open to allow the air in front of the paint push to escape. The length of time the dump valve is open depends on several factors such as viscosity, paint pressure, etc. Timing should be such that the dump is closed as the paint reaches the trigger valve in the atomizer. Paint in the dump line may cause high voltage issues.

The fluid coil and fluid tube can be cleaned independently by actuating the solvent valve in the atomizer. High voltage must be turned off during this operation and the bell cup must be spinning (typically 30,000 rpm for cup flushing sequences).

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Bell Cup Cleaning (Cup Wash) Without Cleaning the Incoming Paint Line

Turn off the high voltage and trigger valve. With the bell spinning at 30,000 rpm, turn on the external solvent valve to allow cleaning solvent to flow through the manifold passages, through the fluid tube, and onto the bell. The spinning bell will atomize the solvent, clean out the bell passages both internally and externally. It is always required to blow the solvent line dry after the cleaning operation. Typical bell speed during the cup flush sequence is 30,000 rpm. Follow sequence as outlined for cup wash in “General Operating Sequence” in the “Operation” section.

• For best operating conditions, the atomizer surfaces must be dry.

• Always final wipe all parts with a non-polar solvent and wipe dry (high flash Naphtha, etc.).

!

W A R N I N G

NEVER wrap the applicator in plastic to keep it clean. A surface charge may build up on the plastic surface and discharge to the nearest grounded object. Efficiency of the applicator will also be reduced and damage or failure of the applicator components may occur. WRAPPING THE APPLICATOR IN

PLASTIC WILL VOID WARRANTY.

!

C A U T I O N

The maximum flow rate of 1000 cc/min. must not be exceeded during a flush routine. Use of an in-line fluid restrictor is recommended.

External Atomizer Surface Cleaning

• Verify that the high voltage is turned off.

• All external surfaces may be cleaned using a mild solvent and lint free rags to hand wipe the RMA-590. Turbine drive air must be off, but leave bearing air on. The inner and outer shaping air (if applicable) should have approximately 70 slpm air flow through each to prevent the solvent from entering these passages.

• Do not spray the RMA-590 unit with a solvent applicator used for cleaning. The cleaning fluid under pressure may aid conductive materials to work into hard to clean areas or may allow fluids to be forced into the turbine assembly.

• Do not reuse an atomizer bell cup that shows any sign of damage such as nicks, heavy scratches, dents, or excessive wear.

!

W A R N I N G

To reduce the risk of fire or explosion,

OSHA and NFPA-33 require that solvents used for exterior cleaning, including bell cleaning and soaking, be nonflammable (flash points higher than 100°F/ 37.8° C). Since electrostatic equipment is involved, these solvents should also be non-polar. Examples of non-flammable, non-polar solvents for cleaning are: Amyl acetate, methyl amyl acetate, high flash naphtha, and mineral spirits.

Do not use conductive solvents such as

MEK to clean the external surfaces of the

RMA-590 without a second cleaning with a non-polar solvent.

When using a rag to hand wipe the RMA-

590, the turbine air should be off, but leave both the shaping air and bearing air turned on. Ensure that rotation has come to a complete stop.

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VIBRATION NOISE

If the RMA-590 is vibrating or making an unusually loud noise, it usually means there is an imbalance situation. The atomizer bell cup may have dried paint on it or the bell may be physically damaged, or there may be paint trapped between the bell cup and shaft preventing the bell cup from properly seating. If any of these conditions exist, they MUST be corrected. Excessive imbalance caused by one of these conditions may result in bearing damage and turbine failure. Warranty DOES NOT cover failure caused by imbalanced loading conditions.

To determine if the bell is dirty or damaged, remove the bell cup and turn the turbine ON. If the noise is eliminated, the bell cup is the problem. If the noise continues, the turbine may be damaged and should be inspected. Excessive air required to achieve same speed may indicate a faulty or contaminated turbine. DO NOT continue to operate a noisy turbine.

!

W A R N I N G

If a bell cup comes off a rotating shaft because of motor seizing or any other reason, the Atomizer and bell cup must be returned to Ransburg for inspection and evaluation to determine if the bell can be used in operation.

TURBINE MAINTENANCE

DO NOT attempt to rebuild the turbine. Any endeavor to disassemble a turbine during the warranty period will void the warranty. Contact your authorized distributor or Ransburg for instructions.

GENERAL/PREVENTIVE

MAINTENANCE

Verify daily that the operating parameters have not varied significantly from the normal. A drastic change in high voltage, operating current, turbine air, or shaping air, can be an early indicator of potential component failure.

LN-9276-14.1

A laminated poster entitled “Rotary Atomizer

Checklist” (AER0075-02) is included with the assembly in the Literature Kit to be posted near the station as a handy reference.

Due to the close proximity of high voltage to ground potential, a schedule must be developed for equipment maintenance (cleanliness).

PREVENTIVE

MAINTENANCE

Daily Maintenance (During Each Preventive

Maintenance Break)

1. Verify that high voltage is OFF and that shaping air, bearing air, and turbine drive air are ON.

2. Open the dump valve, flushing all paint from the supply lines and valve module.

3. Open the solvent valve, flushing all paint from the fluid tube and through the atomizer bell assembly.

4. Re-verify that high voltage is OFF, turbine drive air is OFF, and that the bell cup has stopped spinning. The bearing air and shaping air should remain ON.

5. Clean all external surfaces of the applicator using a lint-free rag dampened with solvent.

6. After cleaning, all conductive residue must be removed using a non-conductive solvent.

Since electrostatic equipment is involved, these solvents should also be non-polar

(Naphtha).

7. Inspect bell cup for nicks, dents, heavy scratches, or excessive wear. Replace if necessary.

8. Check bell cup tightness. Tighten to 50-70 lbs•in (5.65-7.91 Nm) torque.

9. Check the amount of paint build-up on the outer protective cloth covers, if used. If excessive, replace covers as required. If cloths are wet, find source and replace with dry cloth covers.

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!

W A R N I N G

The high voltage must be turned OFF before entering the spray area and performing any maintenance procedures. Spray booth exhaust fan(s) should remain ON while cleaning the equipment with solvents.

Make sure high voltage is OFF before approaching applicator with solvent cloth.

DO NOT use reclaim solvent containing d-Limonene. This can cause damage to certain plastic components.

DO NOT stop bell rotation by using a rag or gloved hand against the bell cup edge.

!

C A U T I O N

Maximum flow rate should not exceed

1000 cc/min.

Daily removal and soaking of the bell cup may not be required if the bell cup is properly flushed. However, the frequency of the feed tube and internal motor shaft inspection indicated below under weekly maintenance can be done daily and later adjusted to weekly or as required depending on the results of the inspection.

!

W A R N I N G

In the event the bell cup comes in contact with a part, that cup should be replaced before continuing to spray.

Do Not place high voltage test probe on bell edge unless rotation is fully stopped.

Make sure that no solvent or other contamination is allowed to enter the motor assembly (air bearing and outer shaft).


NOTE

Refer to the “Troubleshooting Guide” in the “Maintenance” section for details on determining the causes of low or no high voltage at the bell cup.

Weekly Maintenance (Prior to Start or End of

Production Week)

• Monitor rotational speed of all belts at the speed control. Investigate cause if abnormal.

• Monitor high voltage and current output indicated on the MicroPak display. Investigate cause if abnormal.

• Check paint flow on all bells at minimum and maximum specified settings by taking beakered readings.

• Check solvent flow by opening solvent valve and taking a beakered reading (should be within approx. 10% of target flow rate).

• Paint residue found in the shaping air holes is not acceptable and must be removed prior to applicator use (see “Cleaning Shaping

Air Holes” in the “Maintenance” section).

• Clean any paint on outer surface of front and rear housing with a soft cloth dampened with solvent. (See “Warning” on avoiding the use of cleaning solvent containing d-Limonene.)

• Remove the front shroud and check for any signs of solvent or paint leakage. Clean as required as required.

• Remove bell cup and soak in solvent for 1-2 hours. Clean with a soft brush as required.

Remove from cleaning solution and blow dry before replacing.

• With bearing air off, carefully inspect the feed tube tip and clean any paint build-up

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RMA-590 - Maintenance that has occurred on the feed tube tip. Using a pen light, determine if there is build-up of paint in the motor shaft and/or around the paint feed tube. If so, remove the motor assembly following the disassembly procedures and clean out the inside diameter of the motor shaft using a tube brush and solvent. Clean the outer surfaces of the feed tube.

NOTE

It may be necessary to remove the bell cups for cleaning more frequently than weekly. (See Note under “Daily Maintenance” in the “Maintenance” section.)

• Visually inspect for signs of fluid leaks around fluid connections and manifold.

Correct problem and clean paint from all components, including internal portion of shroud.

• Reinstall bell cup and front shroud, replace cover on the outer housing. (Refer to “Disassembly Procedures” in the “Maintenance” section for definite instructions.)

• Recheck bell cup tightness. Torque to 50-

70 lbs•in (5.65-7.91 Nm).

Bell Cup Handling

Always verify that high voltage is turned off and the atomizer bell has stopped spinning before performing any type of handling maintenance.

Bell Cup Replacement

Bell cup wear is dependent on many factors such as bell speed, flow rate, and type of coating being applied.

The bell cups shown in the photos below indicate if a bell cup has some usable life or should be replaced. Photo 1 shows a bell cup that has some usable life. The grooves worn around the splash plate pins are shallow. The general appearance of the cup surface is smooth and uninterrupted.

Photo 2 shows a bell cup that needs to be replaced, as well as the splash plate that was installed into the cup. The grooves are deep, a visible groove exists at the outer edge diameter of the splash plate and there are noticeable lateral grooves extending towards the outer edge of the cup.

UNINTERRUPTED

SURFACE

BELL CUP PREVENTIVE

MAINTENANCE

It is the user’s responsibility to ensure proper maintenance of the atomizer bell at all times.

Bell cup failure due to inadequate cleaning or handling will not be covered under the Warranty. The “DO NOT” bullets (see “Operator/

Maintenance Warnings” in the “Maintenance” section) listed are some examples of improper handling which could adversely affect performance or personnel safety and should not be attempted for any reason.

LIGHT VISIBLE WEAR

OUTER EDGE

LATERAL LINES

OR GROOVES

Photo 1

SLIGHT, SHALLOW

GROOVES

DEEP

GROOVES

Photo 2

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BELL CUP CLEANING

Always verify that high voltage is OFF and that the atomizer bell is spinning before performing any type of color change or bell flush cleaning cycle.

To reduce the risk of fire or explosion, the solvents used for exterior cleaning must have flash points above 100°F (37.8°C). Since electrostatic equipment is involved, these solvents should also be non-polar.

Solvents used for equipment flushing should have flash points equal to or higher than those of the coating material being sprayed.

1. The atomizer bell will normally be fully cleaned during a bell flush cycle. Flushing should be done before any down time or break in production. A bell flush cycle may also be required while spraying batch parts of the same color. Verify that high voltage is in off and that the atomizer bell is spinning before flushing through the bell.

2. If there is any remaining paint build-up on any areas of the bell after flushing, the bell cup should be removed for hand cleaning.

The bell’s leading edge, splash plate, serration cuts, and rear of cup are some examples of areas for special attention.

Bell Cup Soaking

3. Bell cups and splash plates can be soaked in a heated solution for up to 2 hours in an ultrasonic cleaner (120°F. 49°C maximum).

Bell cups alone may be soaked for an extended amount of time.

Manual Inspection

4. Visually inspect the bell cup edge for signs of abrasion. If the edge is excessively worn or badly chipped as the result of a collision with a part, replace the cup immediately.

5. Remove splash plate. Inspect for wear on the bell cup where the fluid leaves the large diameter of the splash plate. If any undercut in this area, the cup should be replaced.

RMA-590 - Maintenance s

Inspection of Bell Cups

6. Also, check the three (3) pins between the front and rear splash plate halves. If worn, replace entire assembly.

7. Check the center holes of the splash plate for wear. Hold splash plate up to a light source and look straight into the holes. If light is clearly seen, the angled holes are worn and the splash plate must be replaced.

8. Splash plate assemblies may be soaked for a short time, under 2 hours, to loosen dried material. Clean with a soft bristle brush.

Blow out center holes to dislodge material.

Never use any kind of pick instrument to clean these holes.

9. Soaking the bell in solvent may aid in loosening or removing paint build-up. It is recommended that the splash plate be removed and cleaned separately.

10. Use a soft bristle brush dipped in solvent to remove paint build-up from the serration cuts, paint feed holes or slots, and external and internal surfaces of the bell.

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11. A soft, lint free rag dampened with solvent may be used to remove any paint residue from the external and internal surfaces of the bell.

12. After removing all paint build-up or residue, rinse the bell in clean solvent and blow dry.

13. Before reinstalling the bell on the shaft, check the mating surfaces of the thread and taper for any paint build-up or residue.

Also, check the fluid tip, fluid tube outside diameter, and the shaft for any further paint build-up. These surfaces should be cleaned before installing the bell.

14. It is recommended that extra bell cups be purchased. The cups can then be cleaned off line in an automated cup cleaner.

15. Reinstall cups to proper torque 50-70 lbs•in

(5.65-7.91 Nm).

CLEANING SHAPING

AIR HOLES

In order to maintain uniform pattern control, the shaping air holes of the inner ring and the shaping air cap must be clean and free of any blockage.

It is best to leave the shaping air supply ON during normal production break cleaning periods.

Shaping air can be reduced to 70 slpm during this time. This will help stop material from entering the passage ways.

Periodically (weekly) the outer shaping air cap and the inner shaping air ring should be removed and thoroughly cleaned. Use of an ultrasonic cleaner would make cleaning of hole diameters easier.

Inspect all holes for blockage. Blow holes clear with compressed air after some time of soaking in solvent. DO NOT use any type of pick to

clear the holes. Damage may result to parts and could affect performance of the equipment.

If holes are damaged (oversized holes, blockage, and gauges) it must be replaced.

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RMA-590 PREVENTIVE MAINTENANCE SCHEDULE

Frequency (Maximum)

Procedure

Mid Shift Cleaning

• Wipe electrodes

• Wipe shroud

• Visually inspect cup

End of Shift Cleaning

• Wipe electrodes

• Wipe shroud

• Wipe bell cup down

• Change cloth cover

Shaping Air Shroud

• Clean inner shape air ring

• Clean outer shape air ring

• Remove and clean

Bell cup removal/inspection/ cleaning

Fluid tip inspection/cleaning

Inspect Valve and Seat

Assembly in valve module for leaking

Replace Valves and Seats in valve module

High Voltage Cable

Inspections

High Voltage Testing

Regreasing of High Voltage

Cables

Check resistance of High

Voltage Electrodes

Regreasing Electrode

Cavities of High Voltage

Ring and High Voltage Input

Inspect all screws

• Replace if broken

• Inspect for wear

• Tighten per specifications

Inspection of Electrode

Replace Electrodes

Inspection of Tubing Bundle

Regrease Tubing Bundle

Replace Tubing Bundle

Replace High Voltage Cable

Inspect Turbine Spindle taper and threads

Mid-Shift End of Shift Weekly 2 Weeks Monthly 3 Months 6 Months Yearly

•

•

•

•

• •

•

• •

•

•

•

•

• •

•

•

•

•

•

•

•

•

•

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RMA-590 PREVENTIVE MAINTENANCE SCHEDULE (Cont.)

Frequency (Maximum)

Procedure

Replace Bell Cups

Replace Splash Plates

Inspect and Clean Spindle

Bore and Fluid Tube OD

Check High Voltage Contact area for damage/arcing

Inspect for Fluid Leaks

Check Exterior of High

Voltage Ports for degradation

Check External Cup Flush

Carbide Tip for blockage

Mid-Shift End of Shift Weekly 2 Weeks Monthly

•

3 Months

•

6 Months

• •

Yearly

• •

DAILY

•

• •

•

•

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TROUBLESHOOTING GUIDE - INDIRECT CHARGE

General Problem

Bad Spray Pattern

Possible Cause

Bell cup damaged

Low voltage

Paint lodged in shaping air ring

Low or No High

Voltage

High current draw

MicroPak controller cascade

Low Transfer

Efficiency (or light coverage)

Improperly mounted air turbine

Faulty low voltage connections

(usually indicated by MicroPak feedback fault light)

Faulty high voltage connection

MicroPak or cascade failure

MicroPak settings not correct

Damaged high voltage cable

Dielectric breakdown of high voltage parts

Improper color change (i.e., paint or solvent in dump line)

Low or no high voltage

Poor grounding of parts being coated

Solution

Replace bell cup.

See “Low or No High Voltage” below.

Disassemble and clean (see “Maintenance” section).

Check resistance of electrodes.

Inspect low voltage at the MicroPak and the cascade.

a. Faulty low voltage cable.

Verify ground connection of air turbine to earth ground at less than 1 megohm.

a. Make sure quick disconnection electrical connection is aligned and clean.

b. Check low voltage connection at cascade.

Verify that high voltage cable is fully seated in the cascade and the high voltage ring.

Refer to current MicroPak manual for detailed Troubleshooting Guide.

Refer to current “MicroPak” manual for detailed “Troubleshooting Guide.”

Remove and inspect/measure resistance.

Check cascade, high voltage ring, and high voltage cable. Replace defective parts.

Optimize color change.

Verify high voltage at electrodes. Normally, a high voltage setting of 30-70 kV is appropriate for most applications.

Verify that parts being coated are properly grounded (the electrical resistance between the part and ground must not exceed 1 megohm).

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(Cont.)

General Problem

Low Transfer

Efficiency (or light coverage) (Cont.)

No Turbine Air

Speed Feedback

Fault

Possible Cause

Excessive turbine speed

Excessive robot speed

Excessive inner/outer shaping air

Solution

For optimum transfer efficiency and spray pattern control, the bell rotational speed should be set at the minimum required to achieve proper atomization of the coating material.

For optimum transfer efficiency, spray pattern control, bell speed, and robot speed should be set at the minimum to achieve desired results of part to be coated.

Shaping air should be set at the minimum volume required to gently direct the spray pattern toward the part being coated. Excessive shaping air will cause some atomized particles to “blow-by” the part or bounce back onto the atomizer.

Excessive target distance

Turbine drive air not present

Bearing air return signal not present

Brake air is activated

The recommended target distance is between 6 and 12-inches (152.4-304.8mm)

(see “Target Distance” in the “Operation” section of this manual).

Verify supply air pressure.

a. Verify bearing air return signal.

b. Increase bearing air supply pressure to

90 psig (±10 psig) (620.5 +/- 69 kPa).

Remove brake air signal (turbine air and brake air must be interlocked to prevent both from being used simultaneously).

Damaged fiber optic cable between robot plate and control panel a. Repair or replace fiber optic cable.

Connection at robot or bell plate is loose b. Bad splice connection or too many splices.

Maximum three (3) splices permitted.

Re-install cable and tighten locking set screw.

Fiber optic transmitter failure

Bad transceiver module

Replace fiber optic transmitter.

Replace transceiver module.

Excessive vibration a. Check bell cup for damage b. Check bell cup for excessive paint buildup c. Insure bell cup is tightened properly d. Check cup and shaft tapers for cleanliness

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(Cont.)

General Problem

No Fluid Flow

Continuous Fluid

Flow

Uncontrollable

Fluid Flow

Possible Cause

Turbine is not rotating

Fluid valve does not actuate

Clogged fluid tube/fluid tip


Clogged restrictor orifice

Fluid valve open

Fluid valve seat damaged or worn

Insufficient back pressure to fluid regulator

Fluid regulator does not control flow (system)

Solution

Verify rotation of turbine (the paint valve air pilot must be interlocked with the turbine speed feed back signal to ensure that paint does not flow into the air bearing).

a. Verify that air pilot signal is present.

b. Fluid valve air pilot pressure is too low. Increase air pressure to 70 psig minimum.

c. Replace fluid valve.

Remove and inspect fluid tube or fluid tip.


Remove appropriate microvalve and seat assembly. Remove orifice and clean.

a. Remove air pilot signal.

b. If still open, replace fluid valve.

Replace fluid valve seat.

Replace fluid tip with the next smaller inner diameter size.

Disassemble fluid regulator and inspect for failed components (system).

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TROUBLESHOOTING GUIDE - DIRECT CHARGE

General Problem

Bad Spray Pattern

Low or No High

Voltage

Possible Cause

Bell cup damaged

Low voltage

Paint lodged in shaping air ring

High current draw

Solvent valve is actuated

Loss of low voltage cable connection between robot and bell plates

Improperly mounted air turbine

Improper limiting current and voltage settings high voltage parts

Atomizer grounding out (usually indicated by high current draw or by

MicroPak over-current fault light)

Solution

Replace bell cup.

See “Low or No High Voltage” below.

Disassemble and clean

(See “Maintenance” section).

a. Paint resistivity to be .1 MW to h.

b. Replace coiled fluid line.

Remove solvent valve air pilot signal

(high voltage must be interlocked with the solvent valve air pilot signal to prevent solvent flow while high voltage is energized).

a. Remove atomizer and inspect low voltage connections on both plates. Verify bell plates alignment marks between connectors and plates and verify that connector face is flush with plate.

Verify that set screws are secure, but not too tight, as this will prevent the spring-loaded pins on the robot plate from extending and making contact.

b. Faulty low voltage cable.

Verify correct orientation of air turbine so that high voltage spring makes contact with metal pad on turbine assembly.

To readjust settings, refer to “MicroPak” operating manual.

a. Clean atomizer externally with non-polar solvent.

b. Check the atomizer externally with non-polar solvent.

c. Check for fluid leaks at quick disconnect mounting (between bell plate and robot plate).

d. Check for internal arcing (usually indicated by internal sparking sounds).

e. Make sure cascade low voltage connection is properly shielded.

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(Cont.)

General Problem

Low or No High

Voltage (Cont.)

Low Transfer

Efficiency (or light coverage)

No Turbine Air

Possible Cause

Faulty low voltage connections

(Usually indicated by MicroPak. feedback fault light)

Faulty high voltage connection

Solution

Make sure quick disconnect electrical connection is aligned and clean.

a. Check low voltage connection at cascade.

Remove cascade and check continuity between cascade connection and turbine shaft.

MicroPak or cascade failure Refer to “MicroPak” service manual for detailed “Troubleshooting Guide”.

Optimize color change.

Improper color change (i.e., paint or solvent in dump line)

Low or no high voltage

Poor grounding of parts being coated

Excessive turbine speed

Excessive inner/outer shaping air

Excessive target distance

Turbine drive air not present

Bearing air return signal not present

Brake air is activated

Verify high voltage at bell cup edge. Normally a high voltage setting of 70-100 kV is appropriate for most applications.

Verify that parts being coated are properly grounded (the electrical resistance between the part and ground must not exceed 1 megohm).

For optimum transfer efficiency and spray pattern control, the bell rotational speed should be set at the minimum required to achieve proper atomization of the coating material.

Shaping air should be set at the minimum air volume required to gently direct the spray pattern toward the part being coated.

Excessive shaping air will cause some atomized particles to “blow-by” the part or bounce back onto the atomizer.

The recommended target distance is between 6-12 inches (152.4-304.8 Nm) (see

“Target Distance” in the “Operation” section of this manual).

Verify supply air pressure.

a. Verify bearing air return signal.

b. Increase bearing air supply pressure to

90 psig (± 10 psig) (620.5 ± 68.9 kPa).

Remove brake air signal (turbine air and brake air must be interlocked to prevent both from being used simultaneously).

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(Cont.)

General Problem

Speed Feedback

Fault

No Fluid Flow

Continuous Fluid

Flow

Uncontrollable

Fluid Flow

Possible Cause

Damaged fiber optic cable between robot plate and control panel

Solution

a. Repair or replace fiber optic cable.

b. Bad splice connection or too many splices.

Maximum three (3) splices permitted.

Connection at robot or bell plate is loose

Re-install cable and tighten locking set screw.

Fiber optic transmitter failure Replace fiber optic transmitter.

Bad transceiver module Replace transceiver module.

Excessive vibration a. Check bell cup for damage b. Check bell cup for excessive paint build up c. Insure bell cup is tightened properly d. Check cup and shaft tapers for cleanliness

Turbine is not rotating

Fluid valve does not actuate

Clogged fluid tube/fluid tip


Clogged restrictor orifice

Fluid valve open

Fluid valve seat damaged or worn

Insufficient back pressure to fluid regulator

Fluid regulator does not control flow

(system)

Verify rotation of turbine (the paint valve air pilot must be interlocked with the turbine speed feed back signal to ensure that paint does not flow into the air bearing).

a. Verify that air pilot signal is present.

b. Fluid valve air pilot pressure is too low.

Increase air pressure to 70 psig minimum.

c. Replace fluid valve.

Remove and inspect fluid tube or fluid tip.


Remove appropriate microvalve and seat assembly. Remove orifice and clean.

a. Remove air pilot signal.

b. If still open, replace fluid valve.

Replace fluid valve seat.

Replace fluid tip with the next smaller inner diameter size.

Disassemble fluid regulator and inspect for failed components (system).

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(Cont.)

General Problem

Fluid and/or Air

Leakage Between the Atomizer Body and Mounting

Manifold

Fluid Leakage In

Robot Adapter

Fluid Leakage

Around Fluid Valve

Turbine Cannot

Attain Desired

Speed

Loss of Exterior/

Interior Cup Wash or Lack of Flow

Possible Cause

Atomizer mounting manifold ring is loose

Solution

Tighten mounting ring.

O-ring is missing

O-ring is damaged

Install O-ring.

Visually inspect for damage and replace.

Fluid tubing not properly installed or tightened.

Inspect and retighten.

Replace o-ring(s).

Damaged o-ring(s) on outer diameter of valve body

Damaged or worn needle seals inside valve assembly

Excessive vibration

Replace valve assembly.

Low or no bearing air

Loss of fiber optic/no feed back a. Check bell cup for damage b. Check bell cup for excessive paint buildup c. Bell cup loose - tighten to proper torque d. Check cup and shaft tapers for cleanliness e. Have manufacturing check bell cup balance a. Check bearing air pressure (minimum 80 psi) (352 kPa) b. Check filters for contamination c. Check for bent or damaged bearing air line d. Poor turbine air pressure - plant air e. Damaged speed control cards

Damaged fiber optic sensor, bad cable, too many splices. Maximum three (3) slices permitted.

Bent of kinked supply tube

No fluid flow

Blocked fluid tip or external nozzle.

Ferrules holding tubing over

-tightened.

Replace.

Check microvalve, check fluid supply source.

Clean parts, remove obstruction.

Replace tubing and ferrule assembly.

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Splash Plate Removal (All Bell Cups)

After removing the bell cup from the applicator, put it on a plastic or wood surface to prevent damage to the edge of the cup. Using the splash plate removal tool (A11388-00), insert the small end of the tool into the end of the splash plate assembly.

Press the splash plate out. It may be necessary to tap lightly with a hammer.

Splash Plate Insertion (All Bell Cups)

Turn the splash plate removal tool over and use the large diameter end to press the splash plate back in place by hand. It may be necessary on occasions to use an arbor press to install the splash plate. Press splash plate to a hard stop

(see “Splash Plate Insertion” figure).

Splash Plate Removal

!

C A U T I O N

Failure to replace a damaged bell cup will cause vibration of the applicator and/or premature turbine failure.

Splash Plate Insertion

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NOTE

There is a 3-inch center-to-center distance between the bell cup and the 3/8inch socket square on the wrench. This distance must be factored in when reading the proper torque on the wrench.

Example: A desired true torque is desired using a 9-inch effective length torque wrench. Wrench offset is 3-inches.

L = 9-inches

TT = 50lbs•in

E = 3-inches

DR = is dial reading.

DR =50 (9)

(9+3)

DR =37.5 lbs•in

ELECTRODE RESISTANCE

TEST

To verify that all indirect charge electrodes are functioning, place one lead of a Yokogama megohm meter or equivalent to the metal contact at the base of the electrode and the other end to the small metal wire at the tip of the electrode.

Refer to the “Electrode Assembly Resistance

Reading” chart for the proper resistance reading for the electrode assembly.

ELECTRODE ASSEMBLY

RESISTANCE READING

Part No.

Reading

(Megohms)

Used At (Locations)

A11343-02 209-231 Sea Level

A11343-03 129-151 Above 5,000 ft.

Effective Length Torque Wrench

CHECKING PROBES

Check atomizer voltage using the Ransburg Test

Meter Kit (76652-01 or 76652-04). Verify that the output voltages have not varied much from the setup standard. A drastic change in voltage can be an early indicator of a component or system problem. The data shown was collected under the ideal lab conditions using a clean atomizer and an unloaded fluid delivery system.

The following data is for use with the RMA-590. The output voltage measured at the bell will normally range between 91% and 97% of the kV set-point displayed at the control unit. Typical setting for spraying is 70 kV.

LN-9276-14.1

If readings fall out of this range, disassemble electrode assembly and check reading of resistor only.

If reading is in the acceptable range, discard the electrode body (A11342-00) and replace with a new one. Rebuild electrode assembly as follows: apply a small amount of dielectric grease to each end of the resistor, slide resistor into the electrode body (A11342-00). Install the contact assembly after the resistor. Finally, apply a small amount of dielectric grease to contact area of plunger contact assembly. Thread plunger contact assembly into electrode body by hand until it stops. Hand-tight is good enough. Over-tightening will damage the electrode body (see “Disassembly/Assembly

Electrode Assembly” figure).

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If the tip is rounded or worn jagged, it must be replaced. Depending on use, electrode tips will last 3-6 months. The electrostatic field generated by these electrodes are very important to maintain paint transfer efficiency, pattern uniformity, and atomizer cleanliness.

DISASSEMBLY

PROCEDURES

NOTE

For reassembly instructions, use the reverse of the following disassembly procedures.

To facilitate atomizer removal from hose manifold, a robot program should be made that purges all paints and solvents from the RMA-590. Ideally it would then position the bell assembly in a bell removal position where the bell cup is pointed downward at a 30° angle. Any residual solvents would be contained in the “J bend

“ of the robot wrist.

All O-rings described in the “Maintenance” section of this manual should be lubricated with a food grade petroleum jelly or with A11545 lubricant.

NOTE

The outer protective cover may have to be replaced more frequently than weekly. Daily inspection of the amount of paint build-up on the cover will determine the frequency of replacement.

!

W A R N I N G

Prior to removing applicator from the robot, the following tasks must be completed.

Robot put into E-stop mode, locked and tagged out.

All fluid passages are cleaned, purged out, and depressurized.

Air turned off.

NOTE

Direct Charge and Indirect Charge Atomizer removal instructions are the same with the exception of removing the high voltage ring.

Disassembly the turbine manifold assembly from the mounting manifold assembly by unscrewing the retaining ring counter-clockwise. Use of the spanner wrench to aid in removal may be necessary.

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Turbine O-Ring Replacement

• Remove air bearing turbine from the atomizer.

• Remove all exterior O-rings.

• Lightly lubricate all O-rings with A11545 Petrolatum jell before reinstalling.

• O-Ring Kit (A11534-00) contains all required

O-rings for replacement

.

NOTE

Turbine assemblies are field repairable after the initial one year warranty period.

Consult a Ransburg representative for proper manuals and training before attempting any repairs. Any attempt to repair the turbine before the one year warranty period has expired will void the warranty.

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Remove high voltage cable assembly from high voltage ring.

Clean old grease from groove and high voltage input hole

Add dielectric grease to groove

Clean old dielectric grease from high voltage connection in the center and in the groove. Fill groove only with dielectric grease.

1-1/2”

(38.1 mm)

APPLY DIELECTRIC

GREASE

Grasp high voltage ring from the front and twist counter clockwise 10-15°. Slide the ring and probe forward off the applicator.

Clean old dielectric grease from the end of the high voltage cable. Verify cable protrudes from high voltage tube to dimension shown. Add a small amount of dielectric grease to the banana jack only.

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Alignment marks

Push the high voltage ring onto the atomizer assembly. Position the high voltage input slightly to the left of center. Locate the high voltage ring on the locking pins and twist the high voltage ring

10-15° clockwise to lock into position. The high voltage input must be on center of the unit with the robot adapter.

Alignment holes Alignment pins

To re-install the atomizer to the mounting manifold, align the (3)white pins with the appropriate holes.

Alignment marks at the top of each assembly are to be used as a guide. Make sure all o-rings are in position before re-assembly. While holding the applicator in position, pull the quick disconnect ring forward and tighten in a counter clockwise direction until snug. Further tighten the assembly together using the (2) 76772-00 wrenches. Use one wrench to hold the mounting manifold with tightening the quick disconnect ring in a counter clockwise direction until unit is tight.

Use (2) 76772-00 wrenches to remove the atomizer assembly from the mounting manifold. Hold the mounting ring with one wrench while removing the quick disconnect ring in a clockwise direction.

Once loose, remove the wrench from the mounting manifold. Hold the atomizer with one hand while turning the ring until the unit is completely disengaged.

Remove electrode in a counter clockwise direction.

Clean any old dielectric grease from the electrode body or the high voltage ring cavities. Insure o-ring is in place before re-assembling. Rubber gloves will help in removing the electrodes.

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O-Ring (8)

Use a non-metallic pick to remove any o-ring.

Inspect o-rings for high voltage burning, cuts, etc.

Replace if required. Add a small amount of dielectric grease to these o-rings before re-assembly.

Install bell cup wrench behind the bell cup and onto the hex flat of the shaft. Grasp the bell cup by hand and hold steady. Turn the bell cup wrench clockwise until the cup is loose.

Threads

CONTACT ASSEMBLY

SPRING CONTACT

HIGH VOLTAGE

RESISTOR

ELECTRODE

BODY

ASSEMBLY

ADD DIELECTRIC

GREASE AT THESE

LOCATIONS

METAL TIP

The electrodes are field repairable. Remove the end fitting, spring contact and high voltage resistor.

Discard the electrode body if the metal tip is bent or eroded from high voltage. Check resistance of the high voltage resistor to the specification listed in this manual. Replace resistor only with a Ransburg part. Add dielectric grease to areas shown in the picture. Check resistance of the entire assembly to manufacturer’s specification in this manual.

Taper

Inspect the taper and threads on both the bell cup and air turbine. Both components must be clean and free of paint or debris before re-assembly

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To tighten Tighten

To install the bell cup to the proper torque. Install a 3/8” drive torque wrench into the space provided on the bell cup wrench. Re-assemble bell cup in reverse order of removal. Hold the bell cup steady while turning the torque wrench in a counter clockwise direction. Tighten to 50-70 lbs.

In (5.69-7.91 Nm)

To tighten

Orifice size engraved on this surface

Fluid tip and cup wash o-ring.

O-Ring

Insert the end of the A11229-00 tool over the fluid tip and align the (4) pins.

NOTE

This is a left hand thread.

Turn clockwise to loosen and remove the fluid tip.

The paint orifice size is engraved on the body. To install turn counter clockwise. Tighten to 25-30 lbs/in (2.83-3.4 Nm). Insure o-ring is located on the back side of the larger diameter. If omitted, a leak of cup wash solvent will result.

Removal

Remove outer shroud by turning counter clockwise. Lubricate o-rings with petroleum jelly prior to re-assembly. Tighten until stop at the shoulder on the atomizer body.

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To Remove

Use a 3/16” end wrench to loosen and remove exterior cup wash fitting and tube before removing shaping air parts

Remove inner and outer shape air assembly from turbine body.

To Loosen

Loosen but do not remove the set screw holding the inner shape air ring to the turbine body with a

2mm hex key. Turn counter clockwise to remove inner and outer shape air assembly. To re-install, tighten shape air assembly onto the turbine body threads until stop. (Lubricate o-rings with petroleum jelly prior to assembly) tighten set screw after making contact with the turbine body to 5 lbs/in

(0.56 Nm) torque

Separate the inner and our shape air components.

Do not use sharp or metal picks to clean shaping air holes. Soak components and clean with a soft bristle brush, flush with solvent and blow dry. Inspect all o-rings prior to re-assembly for damage.

Lubricate all o-rings with petroleum jelly prior to re-assembly.

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Remove

Remove the turbine retaining ring by engaging the pins on the A12088-00 spanner into the holes of the ring. Turn counter clockwise to loosen and remove.

Alignment marks

Pull the turbine straight out while gently rocking back and forth. Insure all o-rings are in place on the rear side of the turbine before re-assembly.

Lubricate all o-tings with petroleum jelly. Align the mark on the turbine body with the mark on the atomizer body. Push and twist slightly until the locating pins align with the holes in the atomizer body and the turbine is fully seated.

Fluid Tube Centered

Fluid tube must be centered. If not, remove turbine and look for the cause. Re-assemble and check again. Install turbine retaining ring by hand. (Do not cross threads) tighten 1/8-1/4 turn more with the A12088-00 spanner wrench.

Pull turbine retaining ring forward to remove.

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To remove

Use the opposite end of the A11229-00 fluid tube tool to remove the fluid tube retaining nut. Remove the fluid tube by pulling straight out.

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Install

Check all o-rings for damage. Lubricate all o-rings with petroleum jelly. Push fluid tube into atomizer body until seated. Tighten retaining nut clockwise to 45-50 lbs/in (7.34/8.47 Nm) torque.

Pull fiber optic assembly straight out.

To remove

Remove fiber optic retaining nut with 78279-00 tool in a counter clockwise direction.

To remove

Using the valve removal tool, A11922-00, engage the (4) pins an the tool with the (4) hole on the top of the valve body. Using a 1/2” (13mm ) socket, end wrench or adjustable wrench, remove by turning counter clockwise.

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To replace, lubricate all o-rings and valve bore with petroleum jelly.

Valve seat assembly

Using valve seat removal tool, a10756-00, insert the small hex end into the female hex of the seat assembly. Using a 3/8” (10mm) socket, end wrench or adjustable wrench, remove the seat by turning counter clockwise.

NOTE

Seat should not be replaced unless there are indications of valve leakage during operation.

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Tighten

Carefully start the seat assembly by hand. It may be easily cross threaded. Tighten fully by hand.

Final torque to 15-20 lbs/in (1.7-2.3 Nm)

To remove

To remove external cup wash tube, insert the (2) pins of the tool into the holes of the fitting and remove by turning counter clockwise. Pull the fitting out to expose the interior fitting and tubing

O-Ring

Tighten

Hand tighten valve until seated, tighten fully to 15-

20 lbs/in (1.7-2.3Nm) torque after valve is down

To remove

Remove the interior fitting in a counter clockwise direction. Note the direction of the ferrule for re-assembly purposes. To re-install slide fitting and ferrule over tubing as shown. Make sure o-ring is in its seat in the atomizer body. Tighten fitting into exterior fitting tightly until an audible clicking is heard. Tighten exterior fitting into atomizer body until tight. Exterior fitting must be flush with atomizer body face.

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O-Ring


To remove

Remove check valve plug with A13142-00 tool.

Align the pins of the tool with the holes in the plug.

Remove by turning counter clockwise. When re-installing, inspect o-ring for damage. Lubricate o-ring with petroleum jelly. Tighten into place.

Make sure top of plug is flush with atomizer face.

Remove high voltage cable cover by removing the (6) screws using a flat blade screwdriver.

Re-install screws and tighten to 5-10 lbs/in (0.56

- 1.13 Nm) torque

Check valve

O-Ring

Use the opposite end of the A13142-00 tool to remove the check valve assembly. Align the end of the tool with the slot of the check valve. Remove by turning counter clockwise. Make sure that o-ring at the bottom of the bore is removed.

Assemble in reverse order.

Remove side panels by removing holding screw with a flat blade screwdriver. To re-install panels, place in groove and tighten screw to 5-10 lbs/in

(0.56 - 1.13 Nm) torque.

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Remove panel by sliding out from grooves of the robot adapter.

Robot mounting adapter must be fitted to the robot wrist before installing robot adapter or applicator.

Screws to fit the robot adapter to the robot wrist are supplied by the end users.

To remove

Remove the robot mounting adapter from the robot adapter by removing the (6) socket head cap screws with a 5/16” (8mm) hex key wrench.

The center ring is remove by pulling straight out.

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Alignment pin and hole


To remove the valve seat assembly use the valve seat removal tool, A10756-00, insert the small hex end into the female hex of the seat assembly. Using a 3/8” (10mm) socket, end wrench or adjustable wrench, remove the seat by turning counter clockwise.

NOTE

Seat should not be replaced unless there are indications of valve leakage during operation.

To mount the applicator to the robot adapter, align the locating pin of the robot mounting adapter with the hole of the robot adapter. Install the (6) screws and tighten to 15 lbs/in (1.7 Nm) torque

See re-assembly of the valve seat and valve assembly in prior sections with the applicator body.

Using the valve removal tool, A11922-00, engage the (4) pins an the tool with the (4) hole on the top of the valve body. Using a 1/2” (13mm ) socket, end wrench or adjustable wrench, remove by turning counter clockwise.

To remove the cup wash block from the robot adapter, remove the (4) screws using a 5/32”

(4mm) hex key wrench.

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Cup wash block removed

Remove the o-ring by using a non-metallic pick.

(2) O-rings (1) O-ring

To replace any collets, use a flat blade screwdriver to pry collet from the pocket.

NOTE

There are (2) o-rings in the holes labeled “air”, “ecw”, “icw” and “sol”. In holes labeled “pta” and “pts” there is only (1) o-ring in each hole.

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Mounting Manifold Quick Connect Ring Robot Adapter

Quick connect ring

Fiber optic set screw hole

Fiber optic cable flat

To install or remove the fiber optic cable, align the notch in the quick connect ring with the hole for the fiber optic set screw. Align the fiber optic ferrule flats with the set screw hole. Fiber optic cable is to be flush with mounting manifold face.

Use a 3/32” hex key wrench to loosen or tighten.

Tighten to 10 lbs/in (1.13 Nm) torque

The quick disconnect ring is captured between the mounting manifold and the robot adapter.

Alignment pin and hole

To remove

To remove the mounting manifold from the robot adapter, remove the (8) screws using a 1/4” hex key wrench.

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To re-install, slide the quick connect ring over the mounting manifold, thread first. Align the pin on the mounting manifold with the hole in the robot adepter. Install the (8) screws with a 1/4” hex key wrench and tighten to 10 lbs/in (1.3 Nm) torque

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PARTS IDENTIFICATION

RMA-590 - Parts Identification

RMA-590 HYBRID ROTARY

ATOMIZER MODEL IDENTIFICATION

When ordering, use A13368-ABCDEFGH as indicated by Tables A, B, C, D, E, F, G and H.

Fourteen (16) digits must follow the basic part number.

For Example:

A13368 - XX - XX - XX - XX - XX - XX - XX - XX

TABLE H - TOOL KIT

TABLE G - HIGH VOLTAGE RING/ELECTRODES

TABLE F - FLUID TIPS

TABLE E - SPINDLE ASSEMBLY

TABLE D - ROBOT ADAPTER PLATE

TABLE C - ROBOT ADAPTER

TABLE B - SHAPING AIR KIT

TABLE A - BELL CUP ASSEMBLY

BASIC PART NUMBER

* Model number and serial number of the atomizer is located on the face of the robot plate.

(See “Important Numbers” in the “Introduction” section.)

TABLE A - BELL CUP ASSEMBLY

Dash # “A” Description

00 NONE NONE

01 A12900-00 65MM TITANIUM, SERRATED (TISF)

02 A12900-01 65MM TITANIUM, NON-SERRATED (TIF)

03 A12900-02 65MM TITANIUM, SERRATED, LONG LIFE SPLASH PLATE (TISF)

04 A12900-03 65MM TITANIUM, NON-SERRATED, LONG LIFE SPLASH PLATE (TIF)

05 A12900-04 65MM ALUMINUM, SERRATED, PLASTIC SPLASH PLATE (ALSF)

06 A12900-05 65MM ALUMINUM, NON-SERRATED, PLASTIC SPLASH PLATE (ALF)

07 A12900-06 65MM ALUMINUM, SERRATED, PLASTIC SPLASH PLATE, BLACK COATED

BELL CUP (ALCSCF)

08 A12900-07 65MM ALUMINUM, NON-SERRATED, PLASTIC SPLASH PLATE, BLACK

COATED BELL CUP (ALCF)

09 A13114-00 55MM TITANIUM, SERRATED (TISF)

10 A13114-01 55MM TITANIUM, NON-SERRATED (TIF)

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TABLE B - SHAPING AIR KIT

Dash # “B” Description

01 A12874-05 65MM MONO FLEX, DIRECT CHARGE, STAINLESS STEEL

02 A12874-06 65MM MONO FLEX, DIRECT CHARGE, STAINLESS STEEL, REPULSION RING

03 A12874-07 65MM MONO FLEX, INDIRECT CHARGE, PLASTIC

04 A12874-08 65MM DUAL FLEX, DIRECT CHARGE STAINLESS STEEL

05 A12874-09 65MM DUAL FLEX, DIRECT CHARGE, STAINLESS STEEL, REPULSION RING

06 A12874-10 65MM DUAL FLEX, INDIRECT CHARGE, PLASTIC

07 A12874-11 65MM DUAL FLEX, INDIRECT CHARGE, TFE SHROUD

08 A12874-12 55MM DUAL FLEX, DIRECT CHARGE, STAINLESS STEEL

09 A12874-13 55MM DUAL FLEX, INDIRECT CHARGE, PLASTIC

TABLE C - ROBOT ADAPTER

Dash # “C” Robot Adapter

00

01

02

NONE

A13126-00

A13146-00

“D” Panel

NONE

A13120-00

A13147-00

Description

NONE

60 DEGREE ADAPTER

90 DEGREE ADAPTER

TABLE D - ROBOT ADAPTER PLATE

Dash #

00

01

“F”

NONE

A13127-00

NONE

FANUC P200 SERIES

Description

TABLE E - SPINDLE ASSEMBLY

Dash #

00

01

“G”

A12895-01

A12895-04

Description

SPINDLE ASSEMBLY, SILVER SHAFT

SPINDLE ASSEMBLY, BLACK SHAFT

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TABLE F - FLUID TIPS

Dash No.

01

02

03

04

05

06

“E”

A11240-01

A11240-02

A11240-03

A11240-04

A11240-05

A11240-06

.028/.7MM OPENING

.035/.9MM OPENING

.043/1.1MM OPENING

.047/1.2MM OPENING

.062/1.6MM OPENING

.039/1.0MM OPENING


Description

TIP ORIFICE SIZE

Fluid Tip Selection

TABLE G - ELECTRODE ASSEMBLY

“J” Description

00 NONE NONE

01 A11343-02 220 MEG OHMS- FOR USE AT SEA

LEVEL CONDITIONS

02 A11343-03 140 MEG OHMS- FOR USE ABOVE

5000 FT. SEA LEVEL CONDITIONS

“K” QTY “L” QTY “M” QTY “N” QTY “P” QTY “Q” QTY

NONE NONE NONE NONE NONE NONE

1 1 1 1 8 8

1 1 1 1 8 8

TABLE H - TOOL KIT

Dash #

00

01

“H”

0

1

Description

NONE

TOOL KIT AND CHECK VALVE TOOL

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3

4

5


RMA-590 - PARTS LIST

Item Qty Part #

1

3

4

5

6

1 A13129-00

“P” “J”

1

1

1

“G”

“A”

“B”

9

10

13

14

1 “C”

“K” A11318-00

2

1

A13737-12C

A13125-00

15 “N” 78441-00

17 2 “D”

18

19

1

1

A13128-00

“F”

29

30

31

32

20

23

6

1

A11338-00

A13140-01

27 “L” A13137-00

28 “M” A13138-00

6

5

5

2

A13737-24C

77367-00

78949-00

78944-00

33

34

35

36

2

2

2

1

79001-06

79001-01

A13132-00

79001-08

37

38

1

1

A13130-00

A12821-00

39 1 A12822-00

40 “Q” 79001-45

60

61

62

64

53

56

57

59

1

1

1

1

1

1

1

1

78278-00

79001-40

79001-41

79001-42

A11226-00

79001-44

“E”

79001-22

65

66

4

8

A13143-00

A13738-32C

67 12” A11252-01

68 1 A11305-00

Description

MOUNTING RING

ELECTRODE ASSEMBLY

SPINDLE ASSEMBLY

BELL CUP ASSEMBLY

SHAPING AIR KIT

ROBOT ADAPTER

HIGH VOLTAGE TUBE NUT

SCREW, 1/4-20 X 3/8 LG NYLON FILLISTER HEAD

SOLVENT BLOCK ASSEMBLY

FERRULE NUT

PANEL

SLIP RING

ROBOT ADAPTER PLATE

SCREW, SOC HD CAP M8 X 25MM LG

HIGH VOLTAGE COVER

HIGH VOLTAGE RING ASSEMBLY

HIGH VOLTAGE TUBE

SCREW, 1/4-20 X 3/8 LG NYLON FILLISTER HEAD

VALVE SEAT ASSEMBLY

VALVE ASSEMBLY

ASSEMBLY, CHECK VALVE

O-RING, SOLVENT PROOF


CHECK VALVE PLUG


EXTERNAL CUP WASH FITTING HOLDER

CUP WASH FITTING

CUP WASH FERRULE


NUT, FIBER OPTIC TENSIONING




RETAINER, FLUID TUBE


FLUID TIP


SCREW, #10-32 X 3/8 SHCS NYLON

SCREW, 5/16-16 X 1” SHCS, NYLON

TUBING

LOWER FERRULE, SOLVENT

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6

RMA HYBRID - PARTS LIST (Cont.)

Item Qty Part #

69

71

77

79

81

82

84

1

1

1

1

1

1

1

A11276-00

78450-00

A13196-00

A13144-00

A13535-00

A13195-00

A13198-02

85 “H” A12090-02

86 1 77141-31

87 “H” A13142-00

Description

FITTING, SOLVENT

SOLVENT LINE TUBING COIL, RMA-101

MOUNTING MANIFOLD ASSEMBLY

RUBBER COVER

FLUID TUBE ASSEMBLY

APPLICATOR BODY ASSEMBLY (SHORT)

FIBER OPTIC ASSEMBLY (SHORT)

TOOL KIT

LITERATURE KIT

CHECK VALVE TOOL

6

5

4

3

TORQUE FLUID TUBE ASSEMBLY INTO ATOMIZER BODY USING A11220-00

TOOL TO 65-75 LBS./IN. (7.28 - 8.4 Nm)

TORQUE FLUID TIP USING A11229-00 TOOL TO 25-30 LBS./IN. (2.83 - 3.4 Nm)

TORQUE TO 15-20 LBS./IN. AFTER VALVE IS DOWN. (1.7 - 2.3 Nm)

TORQUE TO 15-20 LBS./IN. (1.7 - 2.3 Nm)

2.) APPLY A11545-00 PETROLATUM JELL TO ALL O-RINGS PRIOR TO INSTALLATION.

Fluid Coils (Separate Sales Parts Only)

If purchasing spare parts, they must be modified as explained.

To ensure proper sealing and holding, the fittings require that the ends of the fluid coils have a groove cut into them as shown. Use groove cutter A11567-00, by sliding the end of the tool over the tubing until it bottoms out. Hold the tubing in one hand and the tool in the other. Make three complete revolutions of the tool on the tubing in the direction of the arrow stamped on the tool. To remove the tool, hold the tube and the main body of the tool with one hand, slide the rear portion of the tool back until it stops. Pull out the tubing from the end of the tool. By pulling back the rear portion of the tool, it relieves the pressure of the cutting edge off of the tubing before sliding it out.

Trim off ends to dimensions shown. End should be cut off square.

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Bell Cup Part Number / Serial Number Bell Cup Parts Breakdown

TYPICAL BELL CUP PARTS BREAKDOWN

Description

A12900-00 65MM TITANIUM, SERRATED (TISF)

A12900-01 65MM TITANIUM, NON-SERRATED (TIF)

A12900-02 65MM TITANIUM, SERRATED/LONG LIFE

SPLASH PLATE (TISF)

A12900-03 65MM TITANIUM, NON-SERRATED/LONG LIFE

SPLASH PLATE (TIF)

A12900-04 65MM ALUMINUM, SERRATED, PLASTIC

SPLASH PLATE (ALSF)

A12900-05 65MM ALUMINUM, NON-SERRATED, PLASTIC

SPLASH PLATE (ALF)

A12900-06 65MM ALUMINUM, SERRATED, BLACK

COATED, PLASTIC SPLASH PLATE (ALSCF)

A12900-07 65MM ALUMINUM, NON-SERRATED, BLACK

COATED, PLASTIC SPLASH PLATE (ALCF)

A13114-00 55MM TITANIUM, SERRATED (TISF) FOR

55MM DUAL FLEX SHAPE AIR KIT

A13114-01 55MM TITANIUM, NON-SERRATED (TIF) FOR

55MM DUAL FLEX SHAPE AIR KIT

A12886-00 A12071-00 (BLACK COLOR)

A12886-01 A12071-00 (BLACK COLOR)

A12886-00 A13004-00 (TITANIUM TOP)

A12886-01 A13004-00 (TITANIUM TOP)

A12886-02 A12071-00 (BLACK COLOR)

A12886-03 A12071-00 (BLACK COLOR)

A13541-00 A12071-00 (BLACK COLOR)

A13541-01 A12071-00 (BLACK COLOR)

A13113-00 A11269-00 (WHITE COLOR)

A13113-01 A11269-00 (WHITE COLOR)

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2

A13196-00 MOUNTING MANIFOLD ASSEMBLY

Item Qty

2 1

12 1

33 3

41 12

42 10

43 3

45 2

46 2

47 2

48 1

49 4

50 6

51 2

52 1

75 4

77 3

Part #

A13102-01

78803-00

79001-06

79001-30

77516-04

77762-04

77516-01

79001-23

79001-13

79001-05

79001-04

79001-03

79001-15

SSF-2052

LSFI0022-05

79001-34

Description

MOUNTING MANIFOLD

FITTING, MODIFIED



COLLET, 4 MM

COLLET, 8 MM

COLLET







SET SCREW 3/8 LG X 10-24

FITTING


2 APPLY 59915-01 THREAD TAPE (2 WRAPS)

1.) USE A LIGHT COATING OF A11545 PETROLATUM JELL ON ALL O-RINGS

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2

3

A13125-00 SOLVENT BLOCK ASSEMBLY

Item Qty

1

2

3

4

1

2

2

6

5 10

Part #

A13133-00

77367-00

78949-00

77516-04

79001-30

Description

SOLVENT BLOCK

VALVE SEAT ASSEMBLY

VALVE ASSEMBLY (NON-REPAIRABLE)

COLLET, 4 MM


3 TORQUE TO 15-20 LBS./IN. AFTER VALVE IS DOWN. (1.7 - 2.3 Nm)

2 TORQUE TO 15-20 LBS./IN. (1.7 - 2.3 Nm)

1. USE A11545-00 PETROLATUM JELL ON ALL O-RINGS.

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SHAPING AIR KIT ASSEMBLY PARTS BREAK-DOWN

Part #

A12874-05

A12874-06

A12874-07

A12874-08

A12874-09

A12874-10

A12874-11

A12874-12

A12874-13

Description

Direct Charge, Mono Flex

Direct Charge with Repulsion

Ring, Mono Flex

Indirect Charge, Mono Flex

Direct Charge, Dual Flex

Direct Charge with Repulsion

Ring, Dual Flex

Indirect Charge, Dual Flex

Indirect Charge, Dual Flex TFE

Direct Charge, Dual Flex 55mm

Direct Charge, Dual Flex

A

A12068-01

A12068-02

B C D

A12068-03

A12074-01

A12074-02

A12083-02 - A12078-02 - - - - -

A12084-01 A12871-01 A12066-01 - 1 - - -

A12084-01 A12871-01 A12066-01 A11945-02 1 - 1 3

A12074-03

A12932-00

A13116-01

A13116-01

A12084-02 A12872-02 A12066-02

A12084-02 A12871-02 A12066-02

A13229-01 A13228-01 A12066-01

A13229-02 A13228-02 A12066-02

E

A12083-01 - A12078-01 - - - - -

A12083-01 - A12078-01 A11945-01 - - 1 3

-

-

-

-

N P R S

1 - - -

1 - - -

1 - - -

1 - - -

SHAPING AIR KIT - PARTS LIST

Item # Part # Description

6

7

8

1

2

A

B

3 C

4 D

5 79001-11

Outer Shroud

Shaping Air Ring

Inner Shaping Air Ring

Turbine Retaining Ring

O-Ring, Solvent Proof

79001-52

E

O-Ring, Solvent Proof

Repulsion Ring

77580-08C Screw, 6-32X1/4” LG Button Cap Screw, SS

NOTE - Set screw for all shaping air configurations is A12253-00.

Qty

N

1

1

1

1

P

R

S

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A13672-00 HIGH VOLTAGE RING KIT - PARTS LIST

Item

1

2

3

4

5

6

Qty

1

8

8

1

1

1

Part #

A13137-00

79001-45

A11343-02

A11318-00

78441-00

A13138-00

Description

HIGH VOLTAGE RING ASSEMBLY

O-RING (SOLVENT PROOF)

ELECTRODE ASSEMBLY

HIGH VOLTAGE TUBE NUT

FERRULE NUT (3/8 O.D. TUBE)

HIGH VOLTAGE TUBE

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ATOMIZER RECOMMENDED SPARE PARTS

Part # Description

78450-00

A13144-00

78803-00

77516-04

77762-04

77516-01

SSF-2052

LSFI0022-05

79001-01

79001-03

79001-04

79001-05

79001-06

79001-08

79001-13

79001-15

A12895-XX

A11318-00

A13737-24C

78441-00

A13128-00

A13137-00

A13138-00

A13737-24C

77367-00

78949-00

78944-00

A12821-00

A12822-00

A11245-00

A13143-00

A13738-32C

A11252-01

A11305-00

A11276-00

79001-22

79001-23

79001-30

79001-34

79001-38

79001-40

79001-41

79001-42

79001-44

79001-45

LSOR0005-14

* Customer must verify correct part number when re-ordering.

Air Turbine Assembly*

High Voltage Tube Nut

Screw, 1/4-20 x 3/8, Nylon

Ferrule Nut

Slip Ring

High Voltage Ring Assembly

High Voltage Tube

Screw, 1/4-20 x 3/4, Nylon

Valve Seat assembly

Valve Assembly

Check Valve Assembly

Cup Wash Fitting

Cup Wash Ferrule

Fluid Tube Assembly

Screw, #10-32 x 3/8, Nylon

Screw, 5/16/-18 x 1”, Nylon

Tubing (cup wash)

Lower Ferrule, Solvent

Fitting, Solvent

Fluid Coil

Rubber Cover

Fitting

Collet, 4mm or 5/32 O.D. Tube

Collet, 8mm or 5/16 O.D. Tube

Collet, 1/4 O.D. Tube

Set Screw

Fitting, 8mm or 5/16 O.D. Tube

O-ring, Solvent Proof


















O-ring, Encapsulated

LN-9276-14.1


86

Qty

1-2

2-3

1-2

1-2

2-3

1-2

1-2

1-2

1-2

1-2

0-1

1-2

1-2

1-2

1-2

1-2

1-2

0-1

4-6

1-2

0-1

0-1

0-1

4-6

3-5

3-5

2-4

3-5

3-5

0-1

2-4

4-6

50 ft. (20 meters)

3-5

3-5

1-2

1-2

5-8

1-2

2-3

1-2

1-2

1-2

1-2

3-5

1-2

Ransburg


ATOMIZER RECOMMENDED SPARE PARTS (Cont.)

Part # Description Qty

Select Option Below- Fluid Tip Size

A11240-01 .7mm (.028”)

A11240-02

A11240-03

.9mm (.035”)

1.1mm (.043”)

A11240-04

A11240-05

1.2mm (.047”)

1.6mm (.062”)

A11240-06 1.0mm (.039”)

Select Option Below- Electrode Assembly

A11343-02

A11342-00

Electrode Assembly, 220 Megohm

Electrode Body Assembly

Resistor

Select Option Below- Bell Cup Assembly W/Splash Plate

A13114-00

A13114-01

55mm Serrated, Titanium (TISF)

55mm Non-Serrated, Titanium (TIF)

A12900-00

A12900-01

A12900-02

A12900-03

65mm Titanium Serrated (TISF)

65mm Titanium Non-Serrated (TIF)

65mm Titanium Serrated W/Long Life Splash Plate (TISF)

65mm Titanium Non-Serrated W/Long Life Splash Plate

A12900-04

A12900-05

A12900-06

A12900-07

65mm Aluminum Serrated W/Plastic Splash Plate

65mm Aluminum Non-Serrated W/Long Life Splash Plate

65MM Aluminum, Serrated, Plastic Splash Plate, Black Coated Bell Cup, (ALCSCF) 1

65MM Aluminum, Non-Serrated, Plastic Splash Plate, Black Coated Bell Cup, (ALCF) 1

Select Option Below- Bell Cup Only

A12886-00 65mm Titanium Serrated (TISF) 1

1

1

A12886-01

A12886-02

A12886-03

A13541-00

65mm Titanium Non-Serrated (TIF)

65mm Aluminum Serrated (ALS)

65mm Aluminum Non-Serrated (ALF)

65mm Aluminum, Serrated, Black Coated (ALSCF)

1

1

1

1

1

1

1

1

0-1

1

1

A1541-00

A13113-00

A11269-00

A12071-00

65mm Aluminum, Non-Serrated, Black Coated (ALCF)

55mm Titanium Serrated (TISF)

A13113-01 55mm Titanium Non-Serrated (TIF)

Select Option Below- Splash Plate

For 55mm Bell Cups (White Color)

For 65mm Bell Cups (Black Color)

A13004-00 For 65mm Bell Cups (Long Life- Titanium top)

Select Option Below- Shaping Air Kit A12874-05 (65mm Mono Flex) (Stainless Steel)

A12068-01

A12083-01

Outer Shroud

Shaping Air Ring

A12078-01 Turbine Retaining ring

79001-11 O-ring

79001-37 O-ring

A12253-00 Set Screw

0-1

1

1

1-2

Select Option Below- Shaping Air Kit A12874-06 (65mm Mono Flex) Repulsion Ring (Stainless Steel)

A12068-02 Outer Shroud 0-1

A12083-01

A12078-01

Shaping Air ring


0-1

0-1

1

1

1

0-1

0-1

1

1

1

0-1

0-1

0-1

1-2

1-2

0-1

0-1

0-1

* Customer must verify correct Part number when re-ordering.

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BELL CUP RECOMMENDED SPARE PARTS

Part # Description Qty

A11945-01 Repulsion Ring

77580-08C Screw

79001-11 O-ring

79001-37 O-ring

A12253-00 Set Screw

Select Option Below- Shaping Air Kit A12874-07 (65mm Mono Flex) (Plastic)

A12068-03 Outer Shroud

A12083-02

A12078-02

Shaping Air Ring

Turbine Retaining ring

79001-11 O-ring

79001-37 O-ring

A12253-00 Set Screw

Select Option Below- Shaping Air Kit A12874-08 (65mm Dual Flex) (Stainless Steel)

A12074-01

A12084-01

Outer Shroud

Shaping Air Ring

A12871-01

A12066-01

Inner Shaping Air ring


79001-11 O-ring

79001-37 O-ring

0-1

0-1

1

1-2

79001-54 O-ring

A12253-00 Set Screw

1

1-2

Select Option Below- Shaping Air Kit A12874-09 (65mm Dual Flex) Repulsion Ring (Stainless Steel)

A12074-02 Outer Shroud 0-1

A12084-01

A12066-01

A12871-01

A11945-02

Shaping Air Ring



Repulsion Ring

77580-08C Screw

79001-11 O-ring

79001-37 O-ring

79001-54 O-ring

A12253-00 Set Screw

Select Option Below- Shaping Air Kit A12874-10 (65mm Dual Flex) (Plastic)

A12074-03

A12084-02

Outer Shroud

Shaping Air Ring

3

1

1-2

1

1-2

0-1

0-1

0-1

0-1

0-1

0-1

0-1

0-1

1

1

1-2

0-1

0-1

0-1

3

1

1

1-2

0-1

A12871-02

A12066-02



79001-11 O-ring

79001-37 O-ring

79001-54 O-ring

A12253-00 Set Screw

Select Option Below- Shaping Air Kit A12874-11 (65mm Dual Flex) (Plastic TFE)

A12932-00 Outer Shroud

A12084-02

A12871-02

A12066-02

Shaping Air Ring



0-1

0-1

1

1-2

1

1-2

0-1

0-1

0-1

0-1

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Assembly Tools

ASSEMBLY TOOLS A11090-02 (INCLUDES ITEMS BELOW)

Item #

6

7

4

5

1

2

3

8

9

10

Part #

76772-00

A12088-00

A11373-00

A12061-00

A11229-00

A11388-00

A11922-00

78279-00

A10766-00

LSCH-0009-00

Description

Wrench, Spanner

Wrench, Turbine Retaining Ring

Tool, Tubing Removal

Wrench, Bell Cup

Tool, Fluid Tip/Tube Removal

Tool, Splash Plate Removal

Tool, Valve Removal

Tool, Fiber Optic

Microvalve Seat Removal

Dielectric Grease (.88 oz. tube) Not Shown

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A13230-XX Air Heater and Filter Combination

A11065-05 Air Heater

A12247-00 Bell Cup Tool

FILTER & HEATER ASSEMBLY A13230-XX

Dash No.

Description “A” “B” “C” “E”

A13230-01 115 V.@ 13A METRIC FITTINGS

A13230-02 230 V.@ 6.5A METRIC FITTINGS

A13434-01 A13426-00 A13429-00 A13726-00

A13434-02 A13426-00 A13429-00 A13726-00

A13230-03 115 V.@ 13A FRACTIONAL FITTINGS A13434-01 SSP-6439 A13428-00 A13727-00

A13230-04 230 [email protected] FRACTIONAL FITTINGS A13434-02 SSP-6439 A13428-00 A13727-00


Item Part # Description

1 “A” AIR BLOCK, NIPPLES & AIR HEATER

2 A13427-00 INLET FITTING, 3/8 NPS(M) X 1/2 NPT(M)

3 “B”

BEARING AIR FEED, SWIVEL ELBOW 1/4 O.D.TUBE X 1/4 NPT(M)

BEARING AIR FEED, 6mm O.D. TUBE X 1/4 NPT(M) STRAIGHT ADAPTER

4 79253-02 AIR FITTING, SWIVEL ELBOW 5/32 O.D. TUBE X 1/4 NPT(M)

5 “C”

OUTLET FITTING, 1/2 O.D. TUBE X 1/2 NPT(M) STAINLESS STEEL

OUTLET FITTING, 12mm O.D. TUBE X 1/2 NPT(M) STAINLESS STEEL

6 “E” VOLUME BOOSTER

7 A13433-00 AIR FILTER & NIPPLE INCLUDED

8 SI-13-07 A13230-XX SERVICE LITERATURE (PROVIDED BY OTHER)

ALL UNITS: REPLACEMENT PARTS: (SERVICE NOTE)

HEATING ELEMENT USE: A13432-01 FOR A13230-01 AND A13230-03 (115V UNITS)

LN-9276-14.1

A13432-02 FOR A13230-02 AND A13230-04 (230V UNITS)

AIR FILTER ELEMENT USE A13232-00

THERMOMETER USE A13431-00

Qty.

1

1

1

2

1

1

1

REF.

90

Ransburg


SERVICE KITS

Part #

HAF-15

HAF-38

RPM-33

A12247-00

A11570-01

A11570-02

A11570-03

A11570-04

A11570-05

A11570-06

A11570-07

A11570-08

Description

Pre-Filter Replacement Element (See below for qty. & where used)

Pre-Filter Replacement Element (See below for qty. & where used)

Bearing Air Filter Element (See below for qty. & where used)

Bell Cup Removal Tool

Reducing Straight Connector, Push To Connect, 6mm OD Tube To 4mm OD Tube




Reducing Straight Connector, Push To Connect, 10mm OD To 6mm OD Tube




LUBRICANTS AND SEALERS

Part #

A11545-00

Description

PETROLATUM JELL LUBRICANT FOR ALL O-RINGS

AIR FILTER / REPLACEMENT

Ransburg Part # Qty. Elements Per Carton Used On

HAF-15 1 HAF-503

HAF-38 4 HAF-508

RPM-33 8 RPM-418

ACCESSORIES

Part # Description

LSCH0009-00 DIELECTRIC GREASE (.8 OZ. TUBE)

76652-01

76652-02

KIT FOR MEASURING HIGH VOLTAGE. (INCLUDES MULTI-FUNCTION METER (76634-00)

AND HIGH VOLTAGE PROBE ASSY. (76667-00).

KIT FOR MEASURING SHORT CIRCUIT CURRENT (SCI), RESISTANCE, AND SPRAY ABILITY.

INCLUDES MULTI-FUNCTION METER (76634-00) AND TEST LEAD ASSY. (76664-00).

76652-03

76652-04

A11567-00

KIT FOR MEASURING PAINT RESISTIVITY. (INCLUDES MULTI-FUNCTION METER (76634-00)

AND PAINT PROBE ASSY. (7922-00).

DELUXE KIT (PERFORMS ALL FUNCTIONS LISTED ABOVE.) INCLUDES MULTI-FUNCTION

METER (76634-00), PAINT PROBE ASSY. (7922-00), TEST LEAD ASSY. (76664-00), AND HIGH

VOLTAGE PROBE ASSY. (76667-00).

GROOVE TOOL, ¼” OD TUBE

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RMA-590 - Warranty Policy

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. WRAPPING THE APPLICATOR IN

PLASTIC, SHRINK-WRAP, ETC., WILL VOID THIS

WARRANTY.

RANSBURG’S ONLY OBLIGATION UNDER THIS

WARRANTY IS TO REPLACE PARTS THAT HAVE

FAILED BECAUSE OF FAULTY WORKMANSHIP

OR MATERIALS. THERE ARE NO IMPLIED WAR-

RANTIES NOR WARRANTIES OF EITHER MER-

CHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE. RANSBURG ASSUMES NO LIABILITY

FOR INJURY, DAMAGE TO PROPERTY OR FOR

CONSEQUENTIAL DAMAGES FOR LOSS OF

GOODWILL OR PRODUCTION OR INCOME, WHICH

RESULT FROM USE OR MISUSE OF THE EQUIP-

MENT 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.

Specific Air Turbine Warranty

The air turbine only is warranted for 15,000 operating hours, or 3 years from date of first installation, whichever comes first. If, after inspection by Ransburg, defect is

LN-9276-14.1

confirmed, we will repair or replace the air turbine, free of charge, during the warranty period. The repaired air turbine (or replacement air turbine) will continue to be warranted for the remainder of the initial warranty period (from installation date). The warranty period for the air turbine does not begin again when a repair is completed under warranty. Air turbines repaired by

Ransburg after the warranty period will be warranted for 90 days from the date of shipment from the repair center.

The Warranty does not cover:

1. An RMA 590 that has become inoperative because of: a. Misuse - Particularly the flooding of the rotor area due to turning on the fluid before the turbine is

up to speed b. Negligence.

c. Accidents - Collisions with external objects, fires, or similar occurrences.

d. Improper maintenance procedures.

e. Attempted customer repair of an air turbine

during warranty.

f. Failure to insure clean air to air bearing

and turbine.

g. Operating turbine without bearing air.

h. Operating turbine with less than minimum specified air bearing pressure. (80 psi 5.51 Bar) i. Operating with imbalanced loads (heavy paint buildup on atomizer bell or shaft, or damaged atomizer bell cup).

j. Acts of God, flood, earthquake, or similar

occurrences. k. RMA-590’s being operated by control systems not designed by Ransburg, or when others have

2. Labor or incidental costs occasioned by removal, replacement or repair of rotary atomizer or air turbine (other than by Ransburg) unless we have given specific written or telegraphic authorization for repair by someone other than Ransburg.

3. Rotary atomizers determined by Ransburg not to have been installed and maintained in accordance with Ransburg service manual instructions.

4. Cost of repair/replacement and return transportation from Ransburg of merchandise determined not to be defective.

92

Ransburg

MANUAL CHANGE SUMMARY

RMA-590 - Manual Changes

This manual was published to supersede Service Manual LN-9276-14 RMA-590 to make the following changes:

1. Revise version number to .1 all pages

2. Change krpm under features (Page 6).

3. Add new bullet point to features (Page 6).

4. Delete copy and add new copy (Page 7).

5. Update Output Voltage copy (Page 8).

6. Update the Turbine Speed rpm’s (Page 8).

7. Add new fluid flow rates (Page 8).

8. Change part numbers in column E (Page 26)

9. Update Part numbers in table 2 items 6 and 7 (Page 26).

10. Add torque to copy (Page 29).

11. Correct rpm’s in WARNING 9 (Page 31).

12. Change cc/min. to 1000 in CAUTION (Page 33).

13. Change table name (Page 35).

14. Remove sample copy and table (Page 36).

15. Remove Sample Configurations copy and table (Page 36).



18. Update part numbers in Table C and D (Page 75).

19. Update some part numbers in PARTS LIST (Page 79).

20. Update some part numbers in PARTS LIST (Page 80).

21. Change table part number (Page 82).

22. Update part numbers in table head and item 1 (Page 83).

23. Update 3 Part numbers in Spare Parts list (Page 86).

24. Change part numbers in column E (Page 90)

25. Update Part numbers in table 2 items 6 and 7 (Page 90).

26. Change model numbers to 590 (Page 92).

LN-9276-14.1

93

Manufacturing

1910 North Wayne Street

Angola, Indiana 46703-9100

Telephone: 260-665-8800

Fax: 260-665-8516

Technical Service — Assistance

320 Phillips 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.

Ransburg

© 2014 Finishing Brands, Inc. All rights reserved.

Models and specifications subject to change without notice.

Form No. LN-9276-14.1

Litho in U.S.A.

06/14

Ransburg RMA 590 A13368 Rotary Atomizer Service Manual

Assistant Bot

SERVICE MANUAL

LN-9276-14.1

JUNE - 2014

Ransburg

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.

CONTENTS

SAFETY:

1-5

INTRODUCTION: 6-22

INSTALLATION: 23-31

OPERATION: 32- 39

MAINTENANCE: 40-73

CONTENTS

(Cont.)

MAINTENANCE (Cont.) :

40-73

PARTS IDENTIFICATION: 74-91

WARRANTY POLICIES: 92

SAFETY

SAFETY PRECAUTIONS

!

!

•

•

INTRODUCTION

APPLICATOR

DESCRIPTION

FEATURES

GENERAL DESCRIPTION

Air Bearing Turbine Assembly

Atomizer Body Assembly

Mounting Manifold Assembly

Robot Adapter

Robot Adapter Plate

Power Supply and Controls

SPECIFICATIONS

Electrical:

Mechanical

Mechanical (Cont.)

IMPORTANT NUMBERS

GRAPHS

TURBINE SPEED VS. PRESSURE - NO LOAD

TURBINE SPEED VS. AIR CONSUMPTION - NO LOAD

FLOW VS. PRESSURE

MONO FLEX SHAPE AIR - SINGLE SUPPLY SOURCE

A12874-05/-06/-07 SHAPING AIR KIT

FLOW VS. PRESSURE

MONO FLEX SHAPE AIR - DUAL SUPPLY SOURCE

A12874-05/-06/-07 SHAPING AIR KIT

RMA-560 DUAL FLEX AIR

A12874-08/-09/-10/-11 SERIES SHAPE AIR

FLOW VS. PRESSURE

MAXIMUM FLOW RATE BY TIP SIZE,

HOSE LENGTH, AND MATERIAL VISCOSITY

RMA-590 TOOL CENTER POINT DIMENSIONS - SHORT BODY 60°

ADAPTER - INDIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 60° ADAPTER - INDIRECT CHARGE -

65MM - DUAL FLEX

RMA-590 TOOL CENTER POINT DIMENSIONS - SHORT BODY 90°

ADAPTER - INDIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 90° ADAPTER - INDIRECT CHARGE -

65MM - DUAL FLEX

RMA-590 TOOL CENTER POINT DIMENSIONS - SHORT BODY 60°

ADAPTER - DIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 60° ADAPTER - DIRECT CHARGE -

65MM - DUAL FLEX

RMA-590 TOOL CENTER POINT DIMENSIONS - SHORT BODY 90°

ADAPTER - DIRECT CHARGE - 65MM - DUAL FLEX

RMA-590 SHORT BODY 90° ADAPTER - DIRECT CHARGE -

65MM - DUAL FLEX

CIRCUIT SCHEMATIC - INDIRECT CHARGE

CIRCUIT SCHEMATIC - DIRECT CHARGE

HIGH VOLTAGE CIRCUIT SCHEMATIC

INSTALLATION

AIR FILTER INSTALLATION

(GENERAL GUIDELINES)

NOTE