Aerobell 168 MODEL: A12787 (Serv. Man. LN-9270

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Aerobell 168 MODEL: A12787 (Serv. Man. LN-9270 | Manualzz

SERVICE MANUAL

LN-9270-12.4

May - 2014

Ransburg

MODEL: A12787

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.

Ransburg

Aerobell 168

NOTE: This manual has been changed from revision LN-9270-12.3 to revision LN-9270-12.4.

Reasons for this change are noted under “Manual Change Summary” on page 96

of this manual.

LN-9270-12.4

Ransburg

Aerobell 168 - Contents

CONTENTS

SAFETY:

PAGE

1-5

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

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

INTRODUCTION: 6-16

GENERAL DESCRIPTION ....................................................................................................6

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

SPECIFICATIONS .................................................................................................................7

OPERATING CHARACTERISTICS AND SPECIFICATIONS ................................................8-10

DIMENSIONAL CHARACTERISTICS ....................................................................................11-14

IMPORTANT NUMBERS ........................................................................................................15

HOSE SPECIFICATIONS .......................................................................................................16

INSTALLATION: 17-25

GENERAL INFORMATION ....................................................................................................17

AIR FILTER INSTALLATION .................................................................................................17

AIR FILTRATION REQUIREMENTS ......................................................................................18

TYPICAL MULTIPLE APPLICATOR CONFIGURATION ........................................................19

AIR HEATER REQUIREMENTS ............................................................................................20-21

FLUID CONNECTIONS ..........................................................................................................21

HIGH VOLTAGE .....................................................................................................................22

INTERLOCKS.........................................................................................................................22

HIGH VOLTAGE CABLE ASSEMBLIES .................................................................................23

HIGH VOLTAGE CONFIGURATIONS ....................................................................................23

HIGH VOLTAGE CABLE ASSEMBLY INSTRUCTIONS ........................................................24-25

OPERATION: 26-30

TURBINE SPEED ..................................................................................................................26

BEARING AIR ........................................................................................................................27

BRAKE AIR.............................................................................................................................27

ELECTROSTATIC VOLTAGE .................................................................................................27

SHAPING AIRS ......................................................................................................................28

FLUID FLOW RATE CONTROL .............................................................................................28

FLUID TIP STREAM AND TIP STYLE USE ...........................................................................28-29

TARGET DISTANCE ..............................................................................................................29

MATERIAL CONDUCTIVITY ..................................................................................................29

TURBINE AIR - NOTE ............................................................................................................29

TURBINE EXHAUST AIR .......................................................................................................29

BELL CUPS ............................................................................................................................30

(Continued on next page)

LN-9270-12.4

Ransburg

Aerobell 168 - Contents

CONTENTS

(Cont.)

MAINTENANCE:

PAGE

31-71

O-RINGS ...............................................................................................................................32-33

PREVENTIVE MAINTENANCE .............................................................................................33-35

AIR FILTERS / ELEMENT REPLACEMENT .........................................................................35

BELL CUP CLEANINGS ........................................................................................................36

CLEANING SHAPING AIR HOLES .......................................................................................37

AEROBELL 168 PREVENTIVE MAINTENANCE SCHEDULE .............................................38

TOOLS REQUIRED TO DISASSEMBLE AEROBELL ..........................................................39

OPTIONAL TOOLS REQUIRED TO DISASSEMBLE AEROBELL .......................................40

DISASSEMBLY PROCEDURES (15MM BELL CUP) ............................................................41-46

DISASSEMBLY PROCEDURES (30MM BELL CUP) ............................................................47-51

DISASSEMBLY PROCEDURES (65MM BELL CUP) ............................................................52-60

DISASSEMBLY PROCEDURES (FOR ROBOT/MACHINE MOUNT KITS) ...........................61-71

PARTS IDENTIFICATION: 72-94

MODEL IDENTIFICATION .................................................................................................... 72-75

APPLICATOR PARTS BREAKDOWN / PARTS LIST ........................................................... 77

STUD MOUNT ASSEMBLY ................................................................................................... 78

MACHINE MOUNT KIT / PARTS LIST ................................................................................. 79-81

ROBOT MOUNT KIT / PARTS LIST ..................................................................................... 82-84

CONFIGURATIONS ............................................................................................................. 85-87

CABLES ............................................................................................................................... 88

ACCESSORIES .................................................................................................................... 89

SERVICE KITS ..................................................................................................................... 90

RECOMMENDED SPARE PARTS ....................................................................................... 91-94

WARRANTY POLICIES: 95

LIMITED WARRANTY ...........................................................................................................95

LN-9270-12.4

Aerobell 168 - 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.

!

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

SAFETY 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.

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.

LN-9270-12.4

1

Aerobell 168 - 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 solvents used for cleaning must have a flash point at minimum of 5°C (9°F) greater than the ambient temperature. It is the end users responsibility to insure this condition is met.

Spray booth ventilation must be kept at the rates required by NFPA-33, OSHA, country, and local codes. In addition, ventilation must be maintained during cleaning operations using flammable or combustible solvents.

Electrostatic arcing must be prevented. Safe sparking distance must be maintained between the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage is required at all times.

Test only in areas free of combustible material.

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

Non-factory replacement parts or unauthorized equipment modifications may cause fire or injury.

If used, the key switch bypass is intended for use only during setup operations. Production should never be done with safety interlocks disabled.

Never use equipment intended for use in waterborne installations to spray solvent based materials.

The paint process and equipment should be set up and operated in accordance with NFPA-33,

NEC, OSHA, local, country, and European Health and Safety Norms.

LN-9270-12.4

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Aerobell 168 - Safety

AREA

Tells where hazards may occur.

Spray Area

HAZARD

Tells what the hazard is.

Explosion 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.

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.

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.

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.

LN-9270-12.4

3

Aerobell 168 - Safety

AREA

Tells where hazards may occur.

HAZARD

Tells what the hazard is.

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

Tells how to avoid the hazard.

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.

LN-9270-12.4

4

Aerobell 168 - Safety

AREA

Tells where hazards may occur.

Electrical

Equipment

HAZARD

Tells what the hazard is.

Electrical Discharge

High voltage equipment is utilized in the process. Arcing in the vicinity of flammable or combustible materials may occur. Personnel are exposed to high voltage during operation and maintenance.

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

Frequent power supply shut-down indicates a problem in the system which requires correction.

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

SAFEGUARDS

Tells how to avoid the hazard.

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.

LN-9270-12.4

5

Aerobell 168 - Introduction

INTRODUCTION

GENERAL DESCRIPTION

The Ransburg Aerobell 168 is a high speed bell type atomizer for electrostatic applications of conventional and high solids coating materials.

It is available in several configurations. Contact your Ransburg representative for assistance in atomizer bell selection.

The Aerobell 168 turbine assembly incorporates precision air type bearings for extended turbine life.

FEATURES

30 and 65mm bell cups available in electroless nickel coated Aluminum and Titanium

Proven long life air bearing spindle

Speed control: This unit has flexibility in speed sensing capability. Both magnetic and light sensing for speed reading and control can be utilized

Internal and external bell cup wash capability

Lightweight

Features which make the Aerobell 168 applications include: advantageous for use in rotary atomizer electrostatic

Fast color change due to center feed fluid delivery and integral air brake

Sleek configuration to facilitate cleaning of the exterior

Braking air capability

Field repairable turbine assembly after the warranty period

Machine mountable

Non-hollow wrist robot mountable

30mm dual shape air configuration for optimum pattern control

65mm Mono Flex and Dual Flex shaping air configuration for optimum pattern control

15mm Bell Cup is Titanium

Figure 1: Aerobell 168

LN-9270-12.4

6

SPECIFICATIONS

Atomizer Weight

Post Mount 65mm:

Robot Mount /Valves/65mm:

2.7 kg (6 lbs.)

4.4 kg (9.7 lbs.)

Voltage

Maximum Operating Voltage:

Maximum Operating Current:

100 kV

200 uA

Turbine

Recommended Turbine Speed:

Turbine Type:

Speed Readout Pickup:

15 to 60 Krpm

Impulse – Rear Exhaust

Magnetic or Light Source (2 Pulse/Rev.)

Paint

Flow Rate:

Normal Supply Pressure:

Maximum Pressure:

Viscosity:

Viscosity:

Paint Resistivity:

50-500 cm

3

/min max. (Depending on paint)

6 - 8 bar (90 psi - 120 psi)

10 bar (150 psi)

20 to 40 Seconds – Ford Cup # 4

20 to 45 Seconds – AFNOR Cup #4

>1 MOhm.cm

Air Pressure

Microvalve Pilot:

Bearing Air:

Shaping Air:

Brake Air:

4.9 bar (Min.) – 10 bar (Max.) (75 – 150 psi)

5.5 bar (Min.) – 7 bar (Max.) (80 – 100 psi)

7 bar (Max.) – (100 psi Max.)

4 bar (Min.) – 7 bar (Max.) (60 – 100 psi)

Change Time

Rotary Atomizer:

Bell:

Target Distance:

Less than 5 minutes

Less than 5 minutes

152 – 305mm (6 – 12 inches)

Compressed Air Quality

(See Filter Section)

Air Consumption

Bearing Air:

Shaping Air 1:

Shaping Air 2:

Turbine:

57 – 85 slpm (2 – 3 scfm)

75 to 600 NI/min. (2.65 – 21.2 scfm)

75 to 600 NI/min. (2.65 – 21.2 scfm)

See Charts

Bell Cups

15mm:

30mm:

65mm:

100 cc/min. (Max.)

300 cc/min. (Max.)

500 cc/min. (Max.)

Aerobell 168 - Introduction

LN-9270-12.4

7

Aerobell 168 - Introduction

OPERATING CHARACTERISTICS AND SPECIFICATIONS

LN-9270-12.4

8

Aerobell 168 - Introduction

OPERATING CHARACTERISTICS AND SPECIFICATIONS

LN-9270-12.4

9

Aerobell 168 - Introduction

OPERATING CHARACTERISTICS AND SPECIFICATIONS

LN-9270-12.4

10

Aerobell 168 - Introduction

DIMENSIONAL CHARACTERISTICS

30MM FANUC ROBOT MOUNT — 60 DEGREES

15MM FANUC ROBOT MOUNT — 60 DEGREES

LN-9270-12.4

30 MM POST MOUNT

15 MM POST MOUNT

11

Aerobell 168 - Introduction

DIMENSIONAL CHARACTERISTICS

30 MM MACHINE MOUNT - 60 DEGREES

15 MM MACHINE MOUNT - 60 DEGREES

LN-9270-12.4

30 MM MACHINE MOUNT - STRAIGHT

15 MM MACHINE MOUNT - STRAIGHT

12

Aerobell 168 - Introduction

DIMENSIONAL CHARACTERISTICS

65MM ROBOT MOUNT FANUC PAINT MATE

LN-9270-12.4

65 MM POST MOUNT

13

Aerobell 168 - Introduction

DIMENSIONAL CHARACTERISTICS

65MM MACHINE MOUNT— 60 DEGREES

LN-9270-12.4

65MM MACHINE MOUNT—STRAIGHT

14

LN-9270-12.4

Aerobell 168 - Introduction

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 number.

Turbine Serial Number

Located On the

Spindle Barrel

Serial Number

Located On Back

Face Of Cup

Bell Cup Part Number

Located On Back face

Of Cup (AXXXXX)

15

Aerobell 168 - Introduction

HOSE SPECIFICATIONS

Function Hose Characteristic

Paint Supply @ Applicator

Paint Supply @Valve Manifold

Paint Supply @Valve Manifold

Turbine Supply @ Applicator

Turbine Braking Air Supply @ Applicator 6mm I.D. x 8mm O.D. Nylon (.236” I.D. x 5/16” O.D.)

Bearing Air Supply @ Applicator 6mm I.D. x 8mm O.D. Nylon (.236” I.D. x 5/16” O.D.)

Bearing Air Return @ Applicator

Shaping Air 1 @ Applicator

2.7mm I.D. x .4mm O.D. Nylon cv/...(.107“ I.D. x 5/32” O.D.)

6mm I.D. x 8mm O.D. Nylon (.236” I.D. x 5/16” O.D.)

Sharping Air 2 @ Applicator

Interior and Bell Cup Exterior

Rinsing Air/Solvent

Dump @ Valve Manifold

Dump @ Valve Manifold

Pilot for all Microvalves

Interior and Bell Cup Exterior Rinsing

Solvent Supply @ Valve Manifold

1/4” O.D. Tube Fitting

5mm I.D. x 8mm O.D. PFA (.197” I.D. x 5/16” O.D.) Option

6mm I.D. x 8mm O.D. PFA (.236” I.D. x 5/16” O.D.) Option

6mm I.D. x 8mm O.D. Nylon (.236” I.D. x 5/16” O.D.)

6mm I.D. x 8mm O.D. Nylon (.236” I.D. x 5/16” O.D.)

1/16” I.D. x 3/32” O.D. PFA

5mm I.D. x 8mm O.D. PFA (.197” I.D. x 5/16” O.D.) Option

6mm I.D. x 8mm O.D. PFA (.236” I.D. x 5/16” O.D.) Option

2.7mm I.D. x .4mm I.D. Nylon (.107“ I.D. x 5/32” O.D.)

5mm I.D. x 8mm O.D. PFA (.197” I.D. x 5/16” O.D.)

Interior and Bell Cup Exterior Rinsing

Air Supply @ Valve Manifold 5mm I.D. x 8mm O.D. PFA (.197” I.D. x 5/16” O.D.)

!

W A R N I N G

†

Arcing/fire hazard exist if ungrounded metal connections (air or fluid) are used in the spray area. Use plastic non-conductive connections, or ensure metal connections are at ground potential.

PFA* hoses must never be replaced with

Nylon hoses. Only Polyamide Nylon hoses can be used for air connections. Polyurethane hoses are prohibited.

* PFA = Ultra Pure Polytetrafluoroethylene

!

C A U T I O N

†

Any user supplied air hoses must be rated at a minimum working pressure of 100 psig (7 bar)

!

C A U T I O N

†

Any user supplied fluid hoses must be rated at a minimum working pressure of 150 psig (10 bar)

LN-9270-12.4

16

Aerobell 168 - Installation

INSTALLATION

GENERAL INFORMATION

This information is intended ONLY to indicate the general installation parameters of this product and, where applicable, its working relationship to other Ransburg system components in typical use.

Each installation is unique and should be directed by an authorized Ransburg representative or conducted using the Ransburg installation drawings provided for your particular installation.

!

W A R N I N G

†

Risk of arcing/fire hazard. The Aerobell

168 must be located a safe distance from the object to be sprayed, as well as all other grounded objects. The safe distance is at least 1– inch per 10kV of electrostatic voltage. Example: If the Aerobell 168 is used with

100kV applied voltage, it must be at least

10-inches from the object to prevent arcing.

†

The Aerobell 168 shipping container includes the basic atomizer assembly with bell and manifold. Also required with the system are 2 (or more) RPM-419 wrenches (ordered separately). The RPM-419 wrenches are used to remove the shaping air cap and air ring, and the bell cup (wrenches not required during installation as the cap, ring, and bell are mounted in place).

†

Mount the Aerobell 168 securely to a stationary or reciprocating fixture with the

3/4-inch (19MM) diameter stud provided.

AIR FILTER INSTALLATION

The following guidelines must be observed when installing air filters for the Aerobell 168 system (see

“Air Filtration Requirements Chart” for additional information).

1. Use only recommended pre-filters and bearing air filters as shown in “Recommended Air Filtration

Requirements” in this section. Additional system air filtration (i.e., refrigerated air dryer) may also be used if desired.

2. Use one bearing air filter per Aerobell.

3. Mount the bearing air filter as close as possible to the Aerobell 168 (do not mount further than 30 feet (9M) away).

4. Where possible, the pre-filter(s) and bearing air filter(s) should be mounted where they can be easily seen, so the user will see when maintenance is required.

5. Standard black iron or galvanized piping may be used prior to the HAF-503 or HAF-508 pre-filters only. All piping after the pre-filter should be brass, stainless steel, aluminum, or hose (poly, nylon, nyliner, etc.).

6.

Do not use PTFE tape, pipe dope, or other

thread sealant downstream of the bearing air filter.

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

7. Use clear see-through air tubing between the bearing air filter and bearing air fitting to clearly indicate to the user if oil or moisture contamination is getting past the filter.

8. If air heaters are used in the system (to minimize the effect of excessively humid conditions), and the heated air will exceed 120°F, the heaters must be located after all filters to prevent damage to the filter media.

LN-9270-12.4

17

Aerobell 168 - Installation

AIR FILTRATION REQUIREMENTS

Ransburg Filter

Model No.

HAF-503

Description / Specifications

Pre-filter, removes coarse amounts of oil, moisture and dirt. Used upstream of HAF-508 pre-filter (used in systems with poor air quality.

Replacement

Element Part No.

HAF-15 Element One

HAF-508

RPM-418

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.

Bearing air filter, coalescing type,19 SCFM, 99.995% efficiency particulate removal .3 to .6 micron, max.

Aerobell 168 passed .6 micron max. solid passed .2 micron (one per Applicator)

HAF-38 Elements, Carton of 4

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 Aerobell

168 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 Aerobell 168 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.

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18

Aerobell 168 - Installation

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19

Aerobell 168 - Installation

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 effect 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, 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 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), an Aerobell 168 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, DT ~ 14°F (-.10°C).

Referring to the ASHRAE Psychometric 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, Ransburg air heater assembly should be assembled after the air filters.

(Reference the current “Air Heater Assembly” service manual for further information.)

NOTE

†

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

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20

Aerobell 168 - Installation

!

W A R N I N G

†

Arcing/fire hazard exist if ungrounded metal connections (air or fluid) are used in the spray area. Use plastic non-conductive connections, or ensure metal connections are at ground potential.

†

Do not use PTFE tape or pipe dope on any air beyond the final air filter for BEARING

AIR. The tape or dope may break free and cause plugging of the turbine air bearings, and result in turbine failure. See page 17 for tubing connections and sizes.)

Brake Air

NOTE

†

Brake air is used to slow the turbine when changing speed. It is recommended that the brake air turbine drive air be interlocked.

Turbine Air

Turbine drive air must be interlocked with paint flow.

Damage to spindle will occur if paint is triggered without the bell cup spinning. It is recommended that the bell cup is spinning at least 10,000 rpm before any fluid is turned on.

Bearing Air

Use tubing (clear, see-through, nylon, natural) to connect a properly filtered air source to the bearing air fitting on the manifold. It is recommended to use tubing (clear, see-through) for bearing air so that any contamination that gets past the final bearing air filter will be apparent. Also refer to the previous “Caution”.

Under the “Operation” section which follows, there is a “Caution” regarding bearing damage if the turbine is run while bearing air is off. Since the turbine must not be operated without first turning on bearing air, it is required to provide some means of assuring the presence of bearing air before turning the turbine “On.” One method is by interlocking the turbine drive air to the bearing air (i.e., with an air piloted valve).

FLUID CONNECTIONS

See the following “Note”.

NOTE

†

If the coating material used is heated, check the maximum rated temperature for the fluid tubing used. Polyethylene tubing (H-2338 and H-2339) is rated for a maximum of 80°F (27°C). Nylon tubing

(H-2340 and H-2341) is rated for 200°F

(95°C) maximum.

!

C A U T I O N

†

Provisions should also be made to assure bearing air remains on during the coast down period when turbine air is turned off.

See “Specifications” in the “Introduction” section of this manual

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21

Aerobell 168 - Installation

HIGH VOLTAGE

See “Typical Multiple Application Configurations” in the “Introduction” section.

INTERLOCKS

The following system interlocks are recommended to prevent equipment damage:

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

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

3. Two (2) interconnected 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 (552 kPa) at the atomizer, the turbine air should be automatically interlocked to shut off.

4. High voltage must be interlocked with the solvent valve pilot signal to prevent solvent flow while high voltage is energized.

5. Turbine air and brake air must be interlocked to prevent both from being used simultaneously.

6. Any other interlocks required by local code, national code, or international code.

7. High voltage must be interlocked with the booth entry door.

!

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 and the turbine not rotating. Normally pneumatic interlocks will not allow the paint to trigger on when the turbine air is off. These interlocks may need to be by passed with proper safety procedures as required.

†

Bell cup must be rotating at least 10,000 rpm when fluid is triggered. Turning on fluid without the bell cup spinning may flood the turbine and cause damage to components.

†

Under normal operation, 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 60,000 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 solvent trigger must be interlocked.

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Aerobell 168 - Installation

HIGH VOLTAGE CABLE

ASSEMBLIES

General Instructions

1. When routing cable, ensure that no chaffing, binding, or pulling on the cable will occur.

Maintain at least a 4-inch (100mm) bend radius.

When possible, sleeve cable with the appropriate sized tubing for external cable protection.

Torsion stress should be minimized.

2. Considerations should be taken when routing cables next to other cabling and fluid tubing. Be cognizant of the placement of such cable near control wires and fluid lines. Follow NEC wiring standards where applicable. Separation of AC, control wiring, and fluid tubing is advisable.

3. To ensure that all cable connections are clean and free of foreign materials, wipe with Naphtha.

This also applies to the cascade, splitter, and applicator connectors.

4. Apply dielectric grease (LSCH0009-08) on all cable end connectors (cascade, splitter, and applicator) to displace any encapsulated air.

5. Each time a cable is replaced, the nut assembly

(78441-00) must also be replaced.

6. Ensure that no conductive sponges are used in any connector!

7. A10560-XX cables are not to be modified in the field. To do so will void any and all warranties that may exist.

HIGH VOLTAGE CABLE

CONFIGURATIONS

There are two (2) high voltage cable assemblies available:

A10560-XX is a shielded cable and is the most flexible. It is available in several lengths per the “Accessories” chart in the “Parts Identification” section.

79006-XX is a metallic core conductor cable with a polyethylene jacket and an exterior PFA/FEP sleeve. It comes pre-assembled with banana jacks at each end.

A third option is to build your own cable to a specific length not to exceed 100-ft. (30.5 meters) in length. A non-shielded metallic conductor cable

(SSW-1064) is used. the end user must install the

EPS-4245 banana jacks. It is highly recommended that an insulating jacket (79007-00) be installed over the assembly to protect it from damage.

Voltage Master 2 (78789) Cable

Installation

The Voltage Master 2 contains a control panel and a power supply (LEPS5001). To install the high voltage cable, loosen the nut on the top of the LEPS5001-02 power supply tank and insert the high voltage cable through the nut and rubber grommet and push into tank until the banana jack is fully seated. Tighten the nut firmly by hand to grip the cable.

To connect multiple applicators, you can connect a high voltage cable from LEPS5001-02 tank to the input of a LEPS5000-05 junction tank. Up to five

(5) applicators can be supplied from the junction tank. High voltage cable connection on this tank is the same as the Voltage Master 2 tank.

LN-9270-12.4

23

High Voltage Cable

Assembly Instructions

(Instructions for assembling components when using High Voltage Cable SSW-1064)

1. Measure and cut cable to desired length. Make sure ends are cut square.

2. Thread banana plug assembly (EPS-4245) into the cable (SSW-1064) by hand for two turns.

Make sure to start on center of cable.

3. Take a 5/16” (8mm) deep well nut driver and slip it over the banana plug and cable. The nut driver will act as a guide while tightening the banana plug in place. Tighten banana plug until the hex seats on the face of the cable.

Check periodically to ensure screw of banana plug is being driven into center of cable.

Do this procedure for both ends of cable.

4. After assembling, use an ohm meter to check for continuity from one end of the cable to the other. The reading should be 10 ohms or less.

Aerobell 168 High Voltage Connect at Atomizer End (All High Voltage

Cables)

Insert high voltage cable with banana plug assembly thru ferrule nut (78441-00) and into high voltage connection until it bottoms into hole and seats firmly. Tighten compression nut by hand, then tighten 1/2 more turn with a wrench. Pull on cable to ensure a secure fitting. If cable is loose and can be pulled free, then reinsert cable and re-tighten as discussed previously.

Aerobell 168 - Installation

LN-9270-12.4

24

Aerobell 168 - Installation

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25

Aerobell 168 - Operation

OPERATION

!

W A R N I N G

†

When turning the turbine on, bearing air must be present. Likewise, 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. Brake air can be used to slow the turbine (see “Brake Air” in this section. Wait for the turbine to stop spinning before turning bearing air off.

†

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, EN 50 176)

†

Electrical discharge on a high electrical capacitance fluid/paint system can cause fire or explosion with some materials. If arcing occurs when a specific 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.

As with any spray finishing system, operation of the Aerobell 168 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 the following:

• Coating Materials

• Fluid Flow Rate Control

• Fluid Valve / Trigger Control

• Turbine Speed

• Shaping Air (pattern control)

• Electrostatic Voltage

• Target Distance

TURBINE SPEED

The speed of the turbine is determined by the air inlet pressure. See “Turbine Air Pressure, RPM,

SCFM” in the “Installation” section for more information. The desired speed will depend upon the type of coating material and various application requirements.

!

C A U T I O N

†

Excessive speed will cause air turbine damage. Do not exceed the maximum rated speed of 60,000 rpm.

†

Turbine speed may be controlled by either the use of A11515-XXXX Pulse Track

2 or A11925-00 Serial Atomizer Module in an

Euro rack configuration or as part of A11000-

XX Control Pak system.

LN-9270-12.4

26

BEARING AIR

!

C A U T I O N

†

Air bearing air must be on whenever the turbine is operated. If not, severe bearing damage will occur. It is recommended to leave bearing air on at all times. During maintenance or disassembly, turbine air musts be off for a least 3 minutes before shutting off air or main line air.

†

Bearing damage (and subsequent turbine failure) caused by running the turbine without bearing air will not be covered under

Ransburg warranty.

†

When turning the turbine on, bearing air must be present. Likewise, 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. Brake air can be used to slow the turbine (see “Brake Air” in this section).

Wait for the turbine to stop spinning before turning bearing air off.

†

Operating the turbine with bearing air pressure below 80 psi (measured at turbine inlet ) may cause bearing damage.

†

The nominal bearing air pressure is 90 psi (6 bar) +/- 10 psi (.7 bar), 80 psi (5.5 bar) minimum, 100 psi (7 bar) maximum.

Under no circumstances should the turbine be operated with less than 80 psi bearing air pressure.

Aerobell 168 - Operation

BRAKE AIR

Brake air is used to slow the turbine speed. It is advantageous for short color change cycle times, and may be used for stopping the turbine. Use of the brake involves (1) turning off turbine drive air, and then (2) turning the brake air on for a short duration.

Brake air should be interlocked so that it is impossible for air to be applied to the braking system while the turbine air is on.

!

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 an 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.

ELECTROSTATIC

VOLTAGE

Depending upon the power supply model used, the maximum output voltage of the power supply can vary. The actual voltage setting will depend upon various coating application requirements.

The level of voltage applied to the Aerobell 168 plays an important role with regard to pattern size, efficiency (wrap), penetration into cavity areas, and target distance.

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27

Aerobell 168 - Operation

SHAPING AIRS

(Mono Flex & 30mm)

Shaping air is used to shape the spray pattern.

The lower the pressure, the wider the pattern, and conversely, higher pressures result in narrower patterns. Shaping air does not help atomize the material, but does assist in the penetration of atomized particles into cavity areas. Shaping air should be kept at a minimum consistent with coating requirements. Excessive shaping air will cause some atomized particles to blow by the target not allowing full “wrap,” or paint particles to bounce back onto the atomizer.

Note: When Mono Flex shape air configuration is used, one of the inputs on the atomizer body will be required to be plugged. Either input can be used for Mono Flex (SAI or SAO).

Determining which type of tip style to use is dependent on the several factors, such as viscosity, flow rate, type of equipment supplying the paint.

As couple of suggestions follow:

Straight Fluid tip:

With positive shutoff devices like a microvalve with all ranges of fluid flow rates and viscosities.

Industrial Fluid tip:

With pilot operated fluid regulators with high viscosities and low fluid flow rates.

Dual Flex Shaping Air Configuration

Both inputs are required. Pattern adjustment:

Increasing the inner air will make the pattern smaller. Increasing the outer air will make the pattern larger.

FLUID FLOW RATE

CONTROL

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

The atomizer assembly is equipped with valves which are pneumatically operated to direct the flow of paint to either the feed tube or dump line

Preferred

FLUID TIP STREAM AND

TIP STYLE USE

As the picture on the right shows, the fluid stream should be straight and steady. It is best to start out with the smallest tip to achieve the desired fluid flow rate. Either the Straight or the Industrial tip can be used with any 30mm or 65mm bell cup.

Avoid

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28

Aerobell 168 - Operation

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

†

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

MATERIAL CONDUCTIVITY

The Aerobell 168 can be used with a full range of conductive coating materials. With coatings having higher conductivity, it may be necessary to isolate the material supply tank and hoses from ground.

If there is any question as to the suitability of spraying a material with the Aerobell 168, contact your Ransburg distributor or representative. (See the following “Warning”.)

!

W A R N I N G

†

Electrical discharge can cause fire or explosion. If arcing occurs when a specific coating material is used, turn the system off immediately and notify your coating supplier.

Do not restart system until proper adjustments are made to your coating material.

TARGET DISTANCE

The distance from the Aerobell 168 atomizer to target affects the spray application. For instance, closer distances give a smaller spray pattern and greater efficiency. Increasing the distance will give a larger pattern and possibly reduce efficiency.

If the distance is too great, material may “wrap back” on the Aerobell 168. The safe distance for the Aerobell 168 is 204mm or 8”. All ground objects must be prevented from entering this area.

TURBINE AIR - NOTE

If the turbine air is heated, check the maximum rated temperature for the air supply tubing to be used. Polyethylene tubing is rated for a maximum of 80

(95

0

0

F (27

0

C). Nylon tubing is rated for 200

0

F

C) maximum.

!

W A R N I N G

†

Risk of arcing/fire hazard. The Aerobell

168 must be located a safe distance from the object to be sprayed, as well as all other grounded objects. The safe distance is at least 1-inch (25mm) per 10kV of electrostatic voltage. Example: If the Aerobell 168 is used with 100kV applied voltage, it must be at least 10–inches (250mm) from the object to prevent arcing.

TURBINE EXHAUST AIR

Turbine air must be able to exhaust freely, however too much exiting the rear of the manifold may cause a vacuum between the fluid tube and the turbine shaft. In the event of low to medium flow rates and mid to high turbine speeds, paint may be pulled back into the shaft and into the turbine motor. To provide a balance in this flow, plugs for unused ports have been installed into the Aerobell

168 Manifold assembly. See drawing Ppage 31 for restriction on their use.

LN-9270-12.4

29

TURBINE EXHAUST PORT. KEEP

PLUG (A13368-00) INSTALLED

UNLESS A FITTING AND TUBING IS

INSTALLED TO ROUTE EXHAUST

AIR AWAY FROM APPLICATOR.

(M12 X 1.75 THD.)

OPTIONAL FIBER

OPTIC PORT. PLUG

(A13368-00) MUST

BE KEPT INSTALLED

IF NOT IN USE.

(M12 X 1.75 THD.)

Aerobell 168 - Operation

TURBINE EXHAUST PORT. DO NOT BLOCK OR RESTRICT. USE LARGE

TUBING IF ROUTING EXHAUST AIR AWAY FROM APPLICATOR.

(M14 X 2 THD.)

BELL CUPS

Do not use any tools or sharp objects to stop the rotation of any bell cup. Doing so will result in damage to the plating material on the aluminum bell cups and may cause premature failure of the bell cup, or turbine.

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30

Aerobell 168 - Maintenance

MAINTENANCE

Good maintenance is essential to safe and productive operation. Schedules should be established by the user, based on the following general information and observations of the initial production requirements.

The Ransburg maintenance and safety information should be made available to each operator.

Normal fire protection measures are necessary, including proper storage of paints and solvents and the proper disposal of waste. Ready access to appropriate fire extinguishing equipment is required.

For details, consult the appropriate NFPA safety information, your local fire codes, local painting equipment standards, OSHA requirements, as well as your insurance carrier’s information.

!

W A R N I N G

†

Electrical shock/arcing and fire hazards can exist during maintenance. 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.

†

Never touch the atomizer bell while it is spinning. The front edge can easily cut into human skin. Make sure the atomizer bell has stopped spinning before attempting to touch it. Wait at least a minimum of 1 minute after turbine air is off before touching the bell.

!

W A R N I N G

†

Unexpected robot movement can be hazardous. Do not adjust or repair the

Aerobell 168 when the robot is operating or waiting to start. The robot must be locked out and tagged out per OSHA.

†

Do not adjust or repair the Aerobell 168 when the power supply is ON. Turn OFF the power supply and follow OSHA lockout / tag out procedures.

†

Solvents used for equipment flushing must have flash points equal to or greater than the flash point rating of the coating material. Solvents used for general cleaning must have flash point ratings higher than

100 °F (37.8 °C).

†

Never remove Aerobell 168 while it is under pressure.

!

C A U T I O N

†

Do

not immerse the Aerobell 168 turbine

in solvent or other liquids. Turbine components will be damaged.

†

Bearing air must be on during all cleaning procedures.

†

If the Aerobell 168 is sprayed off with a solvent applicator for cleaning, the turbine should be turned on, as well as shaping air

(high voltage off). Air exhaust from the turbine and shaping air form a curtain around the back edge of the bell, and help prevent solvent from getting into the cavity behind the bell. Do not direct at the opening behind the edge of the bell, as this may allow solvent to be forced into the turbine.

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31

Aerobell 168 - Maintenance

O-RINGS

All O-rings in this atomizer are solvent proof except the ones in 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 FEP 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.

4. Clean the bell cup by soaking in an appropriate solvent as long as necessary to loosen paint.

Use a soft bristle brush dipped in solvent to remove paint. Make sure all signs of paint are removed (See the following “Warning”).

Rinse and dry bell. Using a non-metallic item

(toothpick), clean the center holes of the splash plate. Using plenty of cleaning fluid, flush these holes towards rear of bell cup. Make sure these holes are clean.

5. Before reinstalling the bell onto the shaft, check the tapered mating surfaces of the turbine shaft and bell for any paint residue. Clean any residue. (See “Warning” below.)

6. Clean the exterior of the Aerobell 168. (See

“Warning” below.)

7. Do not reuse an atomizer bell that shows signs of damage such as nicks, heavy scratches, dents, or excessive wear.

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.

Cleaning Procedures

The precise sequence of flushing the system of paint will vary according to the type of color valve arrangement used, and other automatic features built into the system. But follow these basic procedures when cleaning:

1. Verify high voltage is off.

8. Periodic cleaning of the holes in the shaping air ring will prevent paint build-up which does affect pattern control or cause defects in parts being coated. Follow “Cleaning Shaping Air

Holes and Annulus” in the “Maintenance” section and clean the slots of the shaping air ring using a soft bristle brush.

To prevent paint build-up in holes of shaping air ring while installed, clean shroud assembly with shaping air ON. Clean with a damp rag or soft bristle brush. Do not soak or saturate area to force fluid or paint into the holes or annulus (70-100

SLPM of shaping air is recommended).

2. With the bearing air and turbine air on, flush paint out of material lines with solvent. Flushing should be done before any break in production.

If the Aerobell 168 is mounted vertical-facing up, rotate to horizontal plane before flushing or cleaning.

3. Flushing should be done with the atomizer bell cup installed. The bell cup will normally be fully cleaned with flushing. However, if there is any remaining paint build up on any areas of the bell after flushing, the bell should be removed for hand cleaning.

!

C A U T I O N

†

Using as atomizer bell with paint buildup will cause a bell imbalance. An imbalance bell may cause bearing damage and turbine failure. Also, any paint residue caught between the tapered surfaces can prevent the bell from seating properly and result in an imbalance condition.

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32

Aerobell 168 - Maintenance

!

W A R N I N G

†

Those solvents used for cleaning must have a flash point at minimum of 5°C (9°F) greater than ambient temperature. It is the end users responsibility to insure this conditions is met. Also, since electrostatic equipment is involved, these solvents should be non-polar. Example of non-flammable, non-polar solvents for wipe down are: amyl acetate, methyl amyl acetate, high flash naphtha, and mineral spirits. a. If using a rag to hand wipe the Aerobell, turbine air should be off, but leave shaping air on. 70-100 SLPM for shaping air is recommended. b. Do not use conductive solvents such as .

MEK to clean the Aerobell 168.

Vibration Noise

If the Aerobell 168 is vibrating or making an unusually loud noise, it usually means there is an imbalance situation. The atomizer bell may have dried paint on it, or the bell may be physically damaged, or there may be paint trapped between the bell and shaft preventing the bell 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 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.

PREVENTIVE

MAINTENANCE

(See “Preventive Maintenance Schedule”)

Daily/Weekly Maintenance

†

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

†

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

†

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

†

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

†

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.

†

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

External surfaces include the shroud and valve module.

†

After cleaning, all conductive residue must be removed using a non-conductive solvent. Since electrostatic equipment is involved, these solvent should also be non-polar.

†

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

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33

Aerobell 168 - Maintenance

!

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.

†

Do not spray the 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.

Internal Fluid Path Purge

Cleaning and Load

Cleaning the incoming paint line (from paint supply source such as color manifold through the fluid manifold and bell assembly:

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.

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

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 into the bell cup. The spinning bell will atomize the solvent, clean out the bell passages.

It is always recommended to blow the solvent line dry after the cleaning operation. Typical bell speed during the cup flush sequence is 30,000 rpm.

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. Turbine drive air must be off, but leave bearing air on. The shaping air should have approximately 70 SLPM air flow through each to prevent the solvent from entering these passages.

!

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 and discharge to the nearest ground object. Efficiency of the applicator will also be reduced and damage of failure of the applicator components may occur.

WRAP-

PING THE APPLICATOR IN PLASTIC WILL

VOID WARRANTY.

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34

Aerobell 168 - Maintenance

!

W A R N I N G

†

To reduce the risk of fire or explosion.

Solvents used for cleaning must have a flash point at minimum of 5° C (9°F) greater than the ambient temperature. It is the end users responsibility to insure this condition is met. Since electrostatic equipment is involved, these solvents should also be non-polar. Example of non-flammable, non-polar solvents for cleaning are: amyl acetate, methyl amyl acetate, high flash naphtha, and mineral spirits.

†

Use a solvent compatible with the coating being applied to clean the exterior of the applicator . Use VM & P Naptha as a final wipe to remove surface conductivity.

†

When using a rag to hand wipe the

Aerobell, 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.

AIR FILTERS / ELEMENT

REPLACEMENT

!

W A R N I N G

†

Introducing air which contains oil, moisture, and dirt may cause wear and damage to the bearings. It is the user’s responsibility to monitor the quality of air and to replace the filter elements as often as necessary.

Turbine failure caused by poor air quality will not be covered under warranty.

REPLACEMENT ELEMENTS

HAF-503

HAF-508

RPM-418

1

4

8

Used On

HAF-15, Pre-Filter

HAF-38, Pre-Filter

RPM-418, Bearing Air Filter

Ransburg Aerobell systems should include a pre-filter(s) and final filters for all air to the Aerobell

168 unit. The final filter is for bearing air only. All filters contain elements that must be replaced on a regular basis to assure clean air. HAF-508 and

RPM-418 filters also contain an automatic drain and pressure differential indicator.

The pressure differential indicator provides a visual indicator that pops up (becomes more visible) as the filter element becomes plugged. Replace the filter elements when the visual indicator becomes visible, don’t wait until it pops up fully. As the elements become plugged, their efficiency drops. The frequency of filter element change will depend upon the quality of the plant air. It is recommended that all elements be replaced at least every 4 to 6 months.

In plants where heavy amounts of oil and moisture vapor are present in the air lines, a refrigerated air dryer may be necessary.

The Aerobell 168 is designed to give dependable service and extended life. One of the most important factors in realizing long life is the quality of air. It is therefore essential for the user to closely monitor the quality of their air and to properly maintain the air filters by replacing the filter elements as often as necessary. (Replace elements at least every

4-6 months or more often.)

Atomizer Bell Assembly

Inspect the atomizer bell assembly for any damage, wear, or paint build-up every day.

LN-9270-12.4

35

Aerobell 168 - Maintenance

BELL CUP CLEANINGS

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

To reduce the risk of fire or explosion, the solvents used for exterior surface cleaning must have flash points above 5°C (9°F) greater than the ambient temperature. Since electrostatic equipment is involved, these solvents must 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 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 should be removed for hand cleaning. The bell’s leading edge, splash plate, and serration cuts are some examples of areas for special attention.

5. Splash plates may be soaked 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, as it will damage them.

6. 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.

7. 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.

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

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

10. 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.

Manual Inspection

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

11. It is recommended that extra bell cups be purchased. The cups can then be cleaned off-line in an automated cup cleaner when the second set is in production.

12. Reinstall cups to hand tighten torque .

4. 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. If worn, replace entire splash plate assembly.

Bell Cup Soaking

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).

LN-9270-12.4

36

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 material from entering the passage ways.

Periodically (weekly or sooner) 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, gouges) it must be replaced.

Inspect Bell Cup Daily

Check for signs of damage such as nicks, heavy scratches, dents, or excessive wear. Replace the cup assembly with any of these conditions.

Aerobell 168 - Maintenance

LN-9270-12.4

37

Aerobell 168 - Maintenance

AEROBELL 168 PREVENTIVE MAINTENANCE SCHEDULE

Frequency (Maximum)

Procedure

Mid Shift Cleaning

• Wipe shroud

• Visually inspect cup

End of Shift Cleaning

• Wipe shroud

• Wipe bell cup down

• Change cloth cover

Shaping Air Shroud and Cap

• Clean shroud

• Clean shape air cap

Bell Cup Removal/Inspection/

Cleaning/Tightening

Fluid tip inspection/cleaning

Inspect Valve and Seat

Assembly for leaking

Replace Valves and or Seats in valve module

High Voltage Cable

Inspections

High Voltage Testing

Inspect all screws

• Replace if broken

• Inspect for wear

• Tighten per specifications

Inspect Turbine Spindle

Taper and Threads

Replace Bell Cups

Replace Splash Plates

Inspect and Clean

• Spindle

• Bore

• Fluid Tube OD

Inspect for Fluid Leaks

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

• • •

Daily

• •

• •

LN-9270-12.4

38

Aerobell 168 - Maintenance

TOOLS REQUIRED TO DISASSEMBLE AEROBELL

Use the following tools to disassemble the Aerobell 168.

A11229-00 Fluid

Tip/Tube Removal

Tool - Supplied with

Tool Kit A13082

RPM-419 Bell Cup

Combo Wrench NOT

Supplied in Tool Kit

Adjustable Wrench

NOT Supplied in

Tool Kit

A111229-00 Bell Cup

Removal Tool -

Supplied with Tool

Kit A13082

LSCH0009-00

Dielectric Grease

NOT Supplied in

Tool Kit

LN-9270-12.4

A12088-00 Turbine Retaining Ring Wrench -

Supplied with Tool Kit A13082

39

Aerobell 168 - Maintenance

OPTIONAL TOOLS REQUIRED TO DISASSEMBLE AEROBELL

Use the following optional tools to disassemble the Aerobell 168.

A11388-00

Splash Plate

Removal Tool

- Supplied with

Tool Kit A13082

A11922-00

Microvalve

Removal Tool

- Supplied with

Tool Kit A13082

A10766-00

Microvalve Seat

Removal Tool

- Supplied with

Tool Kit A13082

5mm Hex Key

Wrench

NOT supplied with the tool kit

5/16” (8mm) Hex

Key Wrench

NOT supplied with the tool kit

3/8” Hex Key

Wrench

NOT supplied with the tool kit

LN-9270-12.4

A11373-00 Tubing Removal Tool

NOT supplied in the tool kit

A12939 Insert Tool - Supplied with Tool Kit A13082

40

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(15mm Bell Cup and Shape Air Ring)

NOTE

†

Mean time to repair entire assembly is 60 Minutes.

Step 1

Place the Aerobell 168 on a clean stable working surface or mount.

Step 2

Remove the Shaping Air Shroud by hand (no tool required).

41

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(15mm Bell Cup and Shape Air Ring)

Step 3

Locate the Cup Wash Fitting that is mounted on the Shape Air Ring.

Step 4

Make sure when assembling the Cup

Wash Fitting that the ferrule taper end is inserted into the Cup Wash Fitting.

Remove the Cup Wash Fitting from the

Shape Air Ring.

When assembling the Cup Wash Fitting, tighten with fingers until an audible “click” is heard.

Note: Be careful NOT to drop the Cup

Wash Ferrule.

42

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(15mm Bell Cup and Shape Air Ring)

Step 4a

Remove Spacer A12934-00

LN-9270-12.4

Step 4b

With a delicate pointed tool remove O-Ring 79001-57.

When installing new O-Ring

79001-57 use caution, and no sharp tools, to prevent damage.

43

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(15mm Bell Cup and Shape Air Ring)

Step 5

Remove Shape Air Ring. Pull straight off.

Note: The Shape Air Ring is sealed

with a O-ring and may be difficult to remove.

Note: When reassembling an audible

“Click” should be heard.

Step 6

Yellow Dot

Yellow Line

Blue Line

Note: The Shape Air Ring has a blue

alignment mark . The blue alignment mark will line up with the yellow dot located on the Atomizer Body and the small yellow line located on the Turbine. All three (3) alignment marks will have to be in line when assembling.

Step 7

Note: Two (2) locating pins are

mounted on the back of the Shape

Air Ring to insure proper alignment.

44

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(15mm Bell Cup and Shape Air Ring)

Step 8

Insert the Bell Cup/ Combo Wrench

(RPM-419) across the flats located on the Turbine. Re-move the Bell

Cup by hand

Bell Cup

When reassembling the Bell Cup hand tighten is sufficient.

Step 9

The Bell Cup should turn easily by hand.

LN-9270-12.4

Step 10

Locate the Bell Cup Insert

(A12938-00) that is screwed into the Bell Cup.

Note the two (2) holes located in the Bell Cup Insert.

45

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(15mm Bell Cup and Shape Air Ring)

Step 11

Insert the Insert Tool (12939) into the two (2) holes in the

Bell Cup Insert located on the back side of the Bell Cup.

Remove the Bell Cup Insert.

Step 12

15mm Bell Cup

Insert Tool A12939-00

Bell Cup Insert

Step 13

Use care when inserting the Bell

Cup Insert to prevent stripping the threads.

46

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(30mm Bell Cup and Shape Air Ring)

NOTE

†

Mean time to repair entire assembly is 60 Minutes.

Step 1

Place the Aerobell 168 on a clean stable working surface or mount.

Step 2

Remove the Shaping Air Shroud by hand (no tool required).

LN-9270-12.4

Step 3

Locate the Cup Wash Fitting that is mounted on the Shape Air Ring.

47

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(30mm Bell Cup and Shape Air Ring)

Step 4

Remove the Cup Wash Fitting from the Shape Air Ring.

When assembling the Cup Wash

Fitting, tighten with fingers until an audible “click” is heard.

Note: Be careful not to drop the

Cup Wash Ferrule.

Make sure when assembling the Cup Wash Fitting that the ferrule taper end is inserted into the Cup Wash Fitting.

Step 5

Remove Shape Air Ring.

Pull straight off.

Note: The Shape Air Ring is

sealed with a O-ring and may be difficult to remove.

Note: When reassembling an au-

dible “Click” should be heard.

48

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(30mm Bell Cup and Shape Air Ring)

Step 6

Yellow Dot

Yellow Line

Blue Line

Note: The Shape Air Ring has a blue

alignment mark . The blue alignment mark will line up with the yellow dot located on the Atomizer Body and the small yellow line located on the

Turbine. All three (3) alignment marks will have to be in line when assembling.

Step 7

Note: Two (2) locating pins are mounted on the back of the Shape

Air Ring to insure proper alignment.

LN-9270-12.4

Step 8

Insert the Bell Cup/ Combo Wrench

(RPM-419) across the flats located on the Turbine. Remove the Bell

Cup by hand.

Bell Cup

When reassembling the Bell Cup hand tighten is sufficient.

49

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(30mm Bell Cup and Shape Air Ring)

Step 9

The Bell Cup should turn easily by hand.

Step 10

Locate the Splash Plate that is pressed into the Bell Cup.

LN-9270-12.4

Step 11

Insert the narrow end of the Splash

Plate Removal Tool (A11388-00) into the hole on the back side of the Bell

Cup. Using a hard thrust from the palm of your hand, remove the Splash Plate.

50

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(30mm Bell Cup and Shape Air Ring)

Step 12

30mm Bell Cup

Splash Plate

A11388-00 Splash

Plate Removal Tool

Step 13

To reassemble the Splash Plate, place the Bell Cup with the back down on a flat surface and insert the Splash

Plate into the Bell Cup hole. Using the large end of A11388-00 Splash Plate

Removal Tool gently push into position.

Until an audible “click” is heard.

51

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

NOTE

†

Mean time to repair entire assembly is 60 Minutes.

Step 1

Place the Aerobell 168 on a clean stable working surface or mount.

Step 2

Remove the Shaping Air Shroud by hand (no tool required).

LN-9270-12.4

Step 3

Locate the Cup Wash Fitting that is mounted on the Shape

Air Ring.

52

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 4

Remove the Cup Wash Fitting from the Shape Air Ring.

When assembling the Cup Wash

Fitting, tighten with fingers until an audible “click” is heard.

Note: Be careful not to drop the

Cup Wash Ferrule.

Make sure when assembling the Cup Wash Fitting that the ferrule taper end is inserted into the Cup Wash Fitting.

Step 5

Insert the Bell Cup Removal

Tool(A12899) in the hole located on the Shape Air Ring and align with the hole in the Turbine Shaft.

53

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 6

The Bell Cup should turn easily by hand.

When reassembling the Bell Cup hand tighten is sufficient.

Step 7

Remove Shape Air Ring. Pull straight off.

Note: The Shape Air Ring is

sealed with a O-ring and may be difficult to remove.

Note: When reassembling an

audible “Click” should be heard.

LN-9270-12.4

Step 8

Yellow Dot

Yellow Line

Blue Line

Note: The Shape Air Ring has a

blue alignment mark . The blue alignment mark will line up with the yellow dot located on the Atomizer

Body and the small yellow line located on the Turbine. All three (3) alignment marks will have to be in line when assembling.

54

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 9

Note: Two (2) locating pins are mounted on the back of the Shape

Air Ring to insure proper alignment.

Step 10

Locate the Splash Plate that is pressed into the Bell Cup.

LN-9270-12.4

Step 11

Insert the narrow end of the Splash

Plate Removal Tool (A11388-00) into the hole on the back side of the

Bell Cup. Using a hard thrust from the palm of your hand, remove the

Splash Plate

55

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 12

65mm Bell Cup

A11388-00 Splash Plate

Removal Tool

Splash Plate

Step 13

To reassemble the Splash Plate, place the Bell Cup with the back down on a flat surface and insert the Splash Plate into the Bell Cup hole. Using the large end of A11388-00 Splash Plate Removal

Tool gently push into position. Until an audible “click” is heard.

56

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 14

Remove the Fluid Tip using the A11229-00 Fluid Tip/Tube

Removal Tool.

NOTE

†

The Threads on the Fluid Tips are LEFT HANDED.

Step 15

The Fluid Tip should only be hand tighten when assembled.

Note: There is an O-ring behind

the Fluid Tip. Take care not to lose.

LN-9270-12.4

Step 16

Using the Turbine Retaining Ring

Tool (A12088-00) remove the Turbine Retaining Ring.

57

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 17

Yellow Dot

Yellow Line

Note the alignment marks on

the Atomizer Body and Turbine

Retaining Ring.

Step 18

Remove the Turbine (no tool required).

Pull straight off.

NOTE

†

The Turbine sealed with a O-ring and may be difficult to remove

LN-9270-12.4

Step 19

Note the alignment marks.

58

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 20

Note: Two (2) locating pins are mount-

ed on the back of the Turbine to insure proper alignment.

When assembling these pins will easily insert when the alignment marks are properly matched.

Step 21

Locate the Fluid Tube and Fluid

Tube Retainer.

LN-9270-12.4

Step 22

Remove the Fluid Tube Retainer using the opposite end of the Fluid Tip/

Tube Removal Tool (A11229-00).

When re-installing, tighten to 65-

75 In.-Lbs. (7.64-8.42 N-m)

59

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(65mm Bell Cup and Shape Air Ring)

Step 23

Using an Adjustable Wrench,

Note provided with Atomizer, remove the Fiber Optic Holder.

When re-installing, tighten until unit is seated on back surface (flush).

Step 24

Slide the Fiber Optic Holder from the Atomizer Body

.

LN-9270-12.4

Step 25

Remove the Fiber Optic

Transmitter Assembly from the Fiber Optic Holder.

60

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 1

Using A11373-00 Tubing Removal

Tool push downward on the outer ring of the push-on fitting.

At the same time pull upward on the plastic tubing.

Remove all such plastic tubing from the Rear Manifold.

Step 2

Release the Fluid Coil (as shown) from the Rear Manifold using the

Adjustable Wrench.

LN-9270-12.4

Step 3

Remove the Internal Cup Wash Fitting from the Rear Manifold.

When assembling the Internal Cup

Wash Fitting, tighten with fingers until an audible “click” is heard.

Note: Be careful not to drop the Cup

Wash Ferrule.

Make sure when assembling the Internal

Cup Wash Fitting that the ferrule taper end is inserted into the Internal Cup

Wash Fitting.

61

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 4

Remove the Cup Wash Fittings from the “Y” Fitting mounted on the Valve Manifold.

Note: Please refer to pages 62 & 63 for

procedures on removal of the Cup Wash

Fitting that is mounted on the Shape Air

Ring with the 30 mm (65mm)Bell Cup.

Step 5

Remove the plastic SHCS from the Mounting Manifold using the

5/16” (8mm) Hex Key Wrench .

LN-9270-12.4

Step 6

This is how the Robot/Machine

Mount should look at this point.

62

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 7

Remove the plastic SHCS from the Mounting Yoke using the

3/8” Hex Key Wrench .

Step 8

Remove the plastic SHCS from the Valve Manifold using the 5/16”

(8mm) Hex Key Wrench .

LN-9270-12.4

Step 9

Remove the plastic Wash Cup Y

Fitting from the Valve Manifold by hand, no wrench required.

63

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 10

Remove the plastic Fluid Tube

Fitting and Fluid Tube Coil from the Valve Manifold using the

Adjustable Wrench.

LN-9270-12.4

Step 11

To remove the Microvalve Assembly, use the Microvalve Removal Tool

(A11922-00). Notice the small threaded shaft protruding from the tool and the four (4) locating pins.

Microvalve Assembly.

Threaded Shaft

Locating Pin

Microvalve Removal Tool A11922-00

Step 12

Align and insert the four (4) locating pins on the Microvalve Removal Tool into the Microvalve Assembly four (4) holes.

Secure the Microvalve Removal Tool by hand tightening the threaded shaft at the knurled end of the tool.

64

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 13

After securing the Microvalve Removal tool to the Microvalve Assembly loosen the Microvalve Assembly with the Adjustable Wrench.

Step 14

Remove the Microvalve Assembly.

When reassembling the Microvalve

Assembly tighten to 15-20 In.– lbs.

(1.68– 2.24 N-m)

LN-9270-12.4

Step 15

Using the Microvalve Seat Removal

Tool (A10766-00 ) and the Adjustable

Wrench loosen the Microvalve Seat.

65

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 16

Remove the Microvalve Seat.

When reassembling the Microvalve

Seat tighten to 15-20 In.- lbs.

(1.68– 2.24 N-m)

Step 17

Using the 5mm Hex Key Wrench remove the five (5) SHCS and detach the Top Valve Plate from the Valve

Manifold.

LN-9270-12.4

Step 18

Five (5) SHCS

Tighten to 10-15 In.-Lbs.

(1.23-1.68 N-m)

Valve Manifold

Top Valve Plate

66

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 19

Using the 5mm Hex Key Wrench remove the five (5) SHCS that secure the Mounting Block to the

Valve Manifold

Step 20

There are different Mounting

Blocks for other applications.

LN-9270-12.4

Step 21

By hand remove the four (4) A13096-00

Tube Receivers (4mm).

67

LN-9270-12.4

Aerobell 168 - Maintenance

DISASSEMBLY PROCEDURES

(For Robot/Machine Mount Kits)

Step 22

By hand remove the four (4)

A13118-00 Tube Fittings.

Step 23

A13096-00 Tube Receiver (4mm)

A13118-00 Tube Fitting (4mm)

Step 24

By hand remove the four (4)

A13288-00 receivers (8mm)

68

Step 25

By hand remove the four (4)

A13287-00 (8mm x 6mm) or

A13289-00 (8mm x 5mm) fittings

LN-9270-12.4

Step 26

Install the proper receiver over the tubing first

Lightly lubricate the outside diameter of the barb fitting with petroleum jelly

Step 27

Push tube fully onto barb until it stops on the fitting back shoulder

Aerobell 168 - Maintenance

69

Step 28

Lightly lubricate the outside diameter of the tubing with petroleum jelly.

Step 29

Using a flat plate or surface, use an adjustable wrench to push the receiver fully over the tube and barb until it is flush with the back shoulder of the barb fitting.

LN-9270-12.4

Step 1 (Removal)

Insert a flat blade screwdriver into the slot on the receiver body and twist to separate the components.

Screwdriver slot

Aerobell 168 - Maintenance

70

LN-9270-12.4

Step 2 (Repair)

Cut damaged tube away and repeat re-assembly starting at step 26

Aerobell 168 - Maintenance

71

Aerobell 168 - Parts Identification

PARTS IDENTIFICATION

WHEN ORDERING USE MODEL NUMBER

A12787 XX XX XX XX XX XX X AS INDICATED IN TABLES A-G

TABLE G - (SPINDLE ASSEMBLY)

TABLE F - (ROBOT ADAPTER)

TABLE E - (TOOL KIT)

TABLE D - (MOUNTING AND VALVE OPTIONS)

TABLE C - (BELL CUP ASSEMBLY)

TABLE B - (FLUID TIP)

TABLE A - (SHAPE AIR KIT)

BASIC PART NUMBER

TABLE A - (SHAPE AIR KIT)

Dash #

01

02

03

07

Part #

A13032-01

A13032-02

A13032-03

A13206-00

Description

DUAL FLEX (DUAL SHAPE AIR) - DIRECT CHARGE

MONO FLEX (SINGLE SHAPE AIR)-DIRECT CHARGE

30MM (DUAL SHAPE AIR) - DIRECT CHARGE

DUAL SHAPE AIR, 15MM, DIRECT CHARGE

LN-9270-12.4

72

Aerobell 168 - Parts Identification

11

11

11

11

11

11

11

TABLE B - (FLUID TIP)

Dash #

Part #

Description

21

22

23

24

25

17

18

19

20

13

14

15

16

09

10

11

12

01

02

03

04

A11240-01

A11240-02

A11240-03

A11240-04

.028 /0.7MM

.035/ 0.9MM

.043/ 1.1MM

.047/ 1.2MM

05

06

A11240-05

A11240-06

.062/ 1.6MM

.039/ 1.0MM

07 A13601-00 .010/.025MM

08 A13625-00 .028/0.7MM STRAIGHT

A13625-01

A13625-02

A13625-03

A13625-04

A13625-05

A13625-06

A13625-07

A13625-08

.035/0.9MM STRAIGHT

.039/1.0MM STRAIGHT

.043/1.1MM STRAIGHT

.047/1.2MM STRAIGHT

.062/1.6MM STRAIGHT

.093/2.4MM STRAIGHT

.125/3.2MM STRAIGHT

.010/0.25MM STRAIGHT

A13645-00

A13645-01

A13645-02

A13645-03

A13645-04

A13645-05

A13645-06

A13645-07

A13645-08

.028/0.7MM INDUSTRIAL

.035/0.9MM INDUSTRIAL

.039/1.0MM INDUSTRIAL

.043/1/1MM INDUSTRIAL

.047/1.2MM INDUSTRIAL

.062/1.6MM INDUSTRIAL

.093/2.4MM INDUSTRIAL

.125/3.2MM INDUSTRIAL

.010/0.25MM INDUSTRIAL

11

11

TABLE C - (BELL CUP ASSEMBLY)

Dash # Part "B" Description

01 A12942-02 65MM ALUMINUM, PLATED

02 A12833-01 30MM ALUMINUM, PLATED

03 A13207-00 15MM TITANIUM

Bell Cup Only (Ref.) Splash Plate Only (Ref.)

A12782-00

A13832-00

A13644-00

A13274-00

A12936-00 - - - - - - - -

A13531-00 A13274-00

A13675-00 A13644-00

These fluid tips can only be used with these bell cups. (See table "B" and "C")

LN-9270-12.4

73

Aerobell 168 - Parts Identification

TABLE D - (MOUNTING AND VALVE OPTIONS)

Dash # Part # Description

01

02

03

04

05

06

07

08

09

A13033-00

A13401-01

A13401-02

A13402-00

A13402-01

A13401-03

A13401-04

A13402-03

A13402-04

STUD MOUNT ONLY, NO VALVES, WITH REMOTE CUP WASH MANIFOLD

MACHINE MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-00

FLUID COIL (16 COILS 1/4 O.D. X 1/8 I.D.) 8 X 6 PAINT FITTING

MACHINE MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-01

FLUID COIL (12 COILS 1/4 O.D. X 1/8 I.D.) 8 X 6 PAINT FITTING

ROBOT MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-00

FLUID COIL (16 COILS 1/4 O.D. X 1/8 I.D.) 8 X 6 PAINT FITTING

ROBOT MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-01

FLUID COIL (12 COILS 1/4 O.D. X 1/8 I.D.) 8 X 6 PAINT FITTING

MACHINE MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-00

FLUID COIL (16 COILS 1/4 O.D. X 1/8 I.D.) 8 X 5 PAINT FITTING

MACHINE MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-01

FLUID COIL (12 COILS 1/4 O.D. X 1/8 I.D.) 8 X 5 PAINT FITTING

ROBOT MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-00

FLUID COIL (16 COILS 1/4 O.D. X 1/8 I.D.) 8 X 5 PAINT FITTING

ROBOT MOUNT WITH TRIGGER, DUMP, CUP WASH SOLVENT VALVES WITH 79879-01

FLUID COIL (12 COILS 1/4 O.D. X 1/8 I.D.) 8 X 5 PAINT FITTING

A12899-00

BELL CUP

REMOVAL TOOL

A11388-00

SPLASH PLATE

REMOVAL TOOL

A10766-00

VALVE SEAT

REMOVAL TOOL

RPM-419

WRENCH ASSEMBLY

(15MM AND 30MM BELL

CUP REMOVAL)

A11229-00

FLUID TIP/TUBE

REMOVAL TOOL

A11922-00

VALVE REMOVAL

TOOL

A12939-00

INSERT REMOVAL

TOOL(15MM BELL

CUP)

A12088-00

TURBINE

RETAINING RING

WRENCH

TABLE E - (TOOL KIT)

Dash #

Part #

Tool Kit Includes

01 - - -

02 A13082-01

03 A13082-02

04 A13082-03

05 A13082-04

- - -

RPM-419, A12899-00, A11229-00, A12088-00,

A11388-00,59972-00

RPM-419, A12899-00, A11229-00, A12088-00,

A11388-00, A11922-00, A10766-00, 59972-00

RPM-419, A11229-00, A12088-00, A12939-00,

59972-00

RPM-419, A11229-00, A12088-00, A12939-00,

A11922-00, A10766-00, 59972-00

Description

NO TOOL KIT

POST MOUNT APPLICATOR WITH

30MM OR 65MM BELL CUP

APPLICATOR WITH 30MM OR 65MM

BELL CUP WITH VALVE PACKAGE

POST MOUNT APPLICATOR WITH

15MM

APPLICATOR WITH 15MM BELL CUP

WITH VALVE PACKAGE

LN-9270-12.4

74

Aerobell 168 - Parts Identification

TABLE F - ROBOT ADAPTER & MTG. SCREWS

Dash #

01

02

Part #

NONE

A13031-00

Description

NONE

FANUC PAINT MATE

Part #

- - -

79798-00

Qty.

Description

- - - - - -

5 SHCS M5 x 12MM LONG

TABLE G - (SPINDLE ASSEMBLY)

Dash #

0

1

2

Part "H"

NONE

A12777-00

A12777-02

NONE

SILVER SHAFT STYLE

BLACK SHAFT STYLE

Description

LN-9270-12.4

75

Aerobell 168 - Parts Identification

LN-9270-12.4

Applicator Parts Breakdown

76

Aerobell 168 - Parts Identification

2

3

5

5

3

2

APPLICATOR PARTS BREAKDOWN

Item # Qty Part # Description

15

16

17

18

19

20

23

24

3

4

5

6

9

12

13

14

1

1

1

1

1

1

5

5

1

1

1

1

1

1

1

1

A12796-00 ASS'Y, FLUID TUBE

TABLE B FLUID TIP

A12781-00 TURBINE RETAINING RING

TABLE A SHAPE AIR KIT

A11226-00 FLUID TUBE RETAINER

77591-00 TRANSMITTER ASSEMBLY, INDUCTOR TO FIBER OPTIC

A12810-00 FIBER OPTIC HOLDER

20869-14 CONNECTOR, LIQUID TIGHT

78803-00 FITTING, MODIFIED

LSFI0022-04 FITTING, 1/4 ODT X AN

77762-04

79001-34

COLLET, 8 MM SAI, SAO. BRK, BA, TA

O-RING, SOLVENT PROOF SAI, SAO, BRK, BA, TA

77516-04

79001-30

COLLET, 4 MM BA. RTN

O-RING, SOLVENT PROOF BA. RTN.

A12941-00 MOUNTING MANIFOLD

7554-127 O-RING CW EXT

68

69

70

71

72

25

26

28

29

1

1

1

1

79001-40

79001-42

79001-41

79001-44

49

58

1

1

TABLE G

TABLE C

59 1 TABLE D

60 TABLE E TABLE E

1

1

1

2

1

O-RING, SOLVENT PROOF FLUID TUBE BASE

O-RING, SOLVENT PROOF FLUID TUBE RETAINER I.D.

O-RING, SOLVENT PROOF FLUID TUBE O.D.

O-RING, SOLVENT PROOF FLUID TIP

ITEM H SPINDLE ASSEMBLY

BELL CUP ASSEMBLY

MOUNTING STYLE OPTION

ITEM G TOOL KIT

79001-22

TABLE F

O-RING MOUNTING MANIFOLD O.D.

ROBOT ADAPTER

79001-11 O-RING TURBINE RETAINING RING

A13698-00 PLUG, FIBER OPTIC, EXHAUST

77141-24 LITERATURE KIT

APPLY THREAD TAPE, 2 TURNS. (59915-01)

4. ASSEMBLE PER MIP2914 AND TEST PER MIP2915,

DWG SPECIFICATIONS TAKE PRECEDENT OVER WORK

INSTRUCTIONS AND MIP'S.

TORQUE FLUID TIP INTO FLUID TUBE USING TOOL A11229-00

(REF.) TO 25-30 IN-LBS (2.82-3.4 Nm)

TORQUE FLUID TUBE INTO MOUNTING MANIFOLD USING

TOOL A11229-00 (REF.) TO 65-75 IN-LBS (7.34-8.47 Nm)

LN-9270-12.4

77

Aerobell 168 - Parts Identification

A13033 Stud Mount Assembly

STUD MOUNT ASSEMBLY

Item #

6

7

9

2

3

4

5

Part # Description

A12913-00

A12822-00

CUP WASH Y FITTING

CUP WASH FERRULE

A12821-00 CUP WASH FITTING

LSFI0022-04 FITTING, 1/4 ODT X AN

A11252-01

A12807-00

A13668-00

PFA (3/32 O.D. X 1/16 I.D.) (2 PIECES- 3 FT. EACH)

SCREW (M10 X 16MM LONG)

POST MOUNT ASSEMBLY

Qty

6’

4

1

4

1

1

4

LN-9270-12.4

78

Aerobell 168 - Parts Identification

LN-9270-12.4

A13034 Machine Mount Kit (with Valves)

79

Aerobell 168 - Parts Identification

3

3

2

1

4

3

3

3

3

2

1

4

3

Item #

53

54

55

56

70

72

73

74

75

76

77

39

40

41

45

46

47

48

51

1

2

7

8

10

11

36

38

MACHINE MOUNT KIT - PARTS LIST (A13401)

Qty

1

1

4

4

1

1

1

1

4

4

1

2

3

7

31"

1

4

4

8

4

4

1

1

2

2

8

4

Part #

A12789-01

A12793-00

A12807-00

A12808-00

77367-00

78949-00

A12912-00

A12825-00

A12824-00

A12822-00

A12821-00

79001-04

A11119-10

A10468-10

A10468-12

A11252-01

TABLE A PART A

78449-00

EMF-202-04

EMF-203-04

A13693-00

A13694-00

TABLE A PART B

TABLE A PART C

A13096-00

A13118-00

A13706-00

Description

BRACKET ARM

BRACKET PIVOT

SCREW (M10 X 16MM LONG)

SCREW (M12 X 25MM LONG)

VALVE SEAT ASSEMBLY

VALVE ASSEMBLY (NON-REPAIRABLE)

MOUNTING BLOCK

TUBING GUIDE

CUP WASH Y FITTING

CUP WASH FERRULE

CUP WASH FITTING

O-RING, SOLVENT PROOF

SCREW, SHCS M4 X 10MM LONG SS

SCREW, SHCS, M6 X 1.0 X 10MM, SS

SCREW, SHCS, M6 X 1.0 X 12MM, SS

PFA TUBING

COILED FLUID TUBE

FITTING, FLUID

FERRULE, BACK 1/4" TUBE

FERRULE, FRONT 1/4" TUBE

VALVE MANIFOLD (4 VALVES)

TOP VALVE PLATE

BARB FITTING

RECEIVER

TUBE RECEIVER (4 X 2.7)

FITTING (4MM X 2.7MM WITH FLANGE)

MOUNTING YOKE ASSEMBLY

FINGER TIGHT UNTIL CLICK

TORQUE TO 5-10 LBS. - IN. (.56-1.13 Nm)

TORQUE TO 15-20 LBS. - IN. (1.69 - 2.26 Nm)

TORQUE TO 15-20 LBS. - IN. (1.69 - 2.26 Nm) AFTER VALVE IS DOWN

LN-9270-12.4

80

Aerobell 168 - Parts Identification

TABLE A - MACHINE MOUNT KIT OPTIONS WITH FLUID TUBE

Part #

Part A

(Coil)

Part B

(Paint Fitting)

Part C

(Receiver)

Description

A13401-01 79879-00 A13287-00

(FOR 8 X 6 TUBING)

A13288-00 MACHINE MOUNT WITH TRIGGER, DUMP,

CUP WASH SOLVENT VALVES & FLUID

COIL (16 COILS) 1/4 O.D. X 1/8 I.D.

A13401-02 79879-01 A13287-00

(FOR 8 X 6 TUBING)

A13288-00 MACHINE MOUNT WITH TRIGGER, DUMP,

CUP WASH SOLVENT VALVES & FLUID

COIL (12 COILS) 1/4 O.D. X 1/8 I.D.

A13401-03 79879-00 A13289-00

(FOR 8 X 5 TUBING)

A13293-00 MACHINE MOUNT WITH RIGGER, DUMP,

CUP WASH SOLVENT VALVES & FLUID

COIL (16 COILS) 1/4 O.D. X 1/8 I.D.

A13401-04 79879-01 A13289-00

(FOR 8 X 5 TUBING)

A13293-00 MACHINE MOUNT WITH TRIGGER, DUMP,

CUP WASH SOLVENT VALVES & FLUID

COIL (12 COILS) 1/4 O.D. X 1/8 I.D.

LN-9270-12.4

81

Aerobell 168 - Parts Identification

LN-9270-12.4

A13035 Robot Mount Kit (With Valves)

82

Aerobell 168 - Parts Identification

3

3

2

1

4

3

3

3

3

4

3

2

1

Item #

68

69

71

72

53

54

55

56

73

74

75

76

77

46

47

48

51

39

40

41

45

10

11

36

38

1

2

7

8

ROBOT MOUNT KIT (A13402)

Qty Part #

Description

2

3

7

31"

1

4

4

8

4

4

1

1

2

2

8

4

A12789-01

A12793-00

A12807-00

A12808-00

77367-00

78949-00

A12912-00

A12825-00

A12824-00

A12822-00

A12821-00

79001-04

A11119-10

A10468-10

A10468-12

A11252-01

BRACKET ARM

BRACKET PIVOT

SCREW (M10 X 16MM LONG)

SCREW (M12 X 25MM LONG)

VALVE SEAT ASSEMBLY

VALVE ASSEMBLY (NON-REPAIRABLE)

MOUNTING BLOCK

TUBING GUIDE

CUP WASH Y FITTING

CUP WASH FERRULE

CUP WASH FITTING

O-RING, SOLVENT PROOF

SCREW, SHCS M4 X 10MM LONG SS

SCREW, SHCS, M6 X 1.0 X 10MM, SS

SCREW, SHCS, M6 X 1.0 X 12MM, SS

PFA TUBING

1

4

4

4

4

1

1

1

1

TABLE A PART A

78449-00

EMF-202-04

EMF-203-04

COILED FLUID TUBE

FITTING, FLUID

FERRULE, BACK 1/4" TUBE

FERRULE, FRONT 1/4" TUBE

REF REFERENCE PRINT A13350 ADAPTER, ROBOT

1 A12976-00 MOUNTING YOKE

REF REFERENCE PRINT A13350 SHCS M5 x 12MM LONG SS

1 A13693-00 VALVE MANIFOLD (4 VALVES)

A13694-00

A13118-00

A13096-00

TABLE A PART B

TABLE A PART C

TOP VALVE PLATE

FITTING (4MM X 2.7MM WITH FLANGE)

TUBE RECEIVER (4 X 2.7)

BARB FITTING

RECEIVER

FINGER TIGHT UNTIL CLICK

TORQUE TO 5-10 LBS. - IN. (.56-1.13 Nm)

TORQUE TO 15-20 LBS. - IN. (1.69 - 2.26 Nm)

TORQUE TO 15-20 LBS. - IN. (1.69 - 2.26 Nm) AFTER VALVE IS DOWN

LN-9270-12.4

83

Aerobell 168 - Parts Identification

TABLE A - MACHINE MOUNT KIT OPTIONS WITH FLUID TUBE

Part #

Part A

(Fluid Coil)

Part B

(Paint Fitting)

Part C

(Receiver)

Description

A13402-00 79879-00 A13318-00

(FOR 8 X 6 TUBING)

A13288-00 ROBOT MACHINE MOUNT WITH TRIGGER,

DUMP, CUP WASH SOLVENT VALVES WITH

FLUID COIL-16 COILS (1/4 O.D. X 1/8 I.D.)

A13402-01 79879-01 A13318-00

(FOR 8 X 6 TUBING)

A13288-00 ROBOT MACHINE MOUNT WITH TRIGGER,

DUMP, CUP WASH SOLVENT VALVES WITH

FLUID COIL- 12 COILS (1/4 O.D. X 1/8 I.D.)

A13402-03 79879-00 A13319-00

(FOR 8 X 5 TUBING)

A13293-00 ROBOT MACHINE MOUNT WITH TRIGGER,

DUMP, CUP WASH SOLVENT VALVES WITH

FLUID COIL- 16 COILS (1/4 O.D. X 1/8 I.D.)

A13402-04 79879-01 A13319-00

(FOR 8 X 5 TUBING)

A13293-00 ROBOT MACHINE MOUNT WITH TRIGGER,

DUMP, CUP WASH SOLVENT VALVES WITH

FLUID COIL- 12 COILS (1/4 O.D. X 1/8 I.D.)

LN-9270-12.4

84

Aerobell 168 - Parts Identification

LN-9270-12.4

A13032-02

MONO FLEX

DIRECT CHG

85

Aerobell 168 - Parts Identification

A13032-03 30mm Direct Charge

MASTER CONFIGURATION TABLE

PART # DESCRIPTION

A

SHP AIR RING

B

SHAPE AIR

MANIFOLD

C

SHROUD

D E F G

A13032-01 65MM DUAL FLEX SHP AIR KIT - DIRECT CHG. A12911-00 A12910-00 A12909-00 3 1 1

A13032-02 65MM MONO FLEX SHP AIR KIT - DIRECT CHG.

A13032-03 30MM - DIRECT CHG.

A12896-00 A12779-01 2

A12831-00 A12830-00 1 1

A13032-03 30MM SHAPE AIR

Item #

5

6

7

8

1

2

3

4

9

10

Part # Description

A

B

C

79001-10

SHAPE AIR RING

SHAPE AIR MANIFOLD

SHROUD

O-RING, SOLVENT PROOF

79001-52 O-RING, SOLVENT PROOF

A12898-00 SHAPE AIR PLUG

79001-16

7554-72

O-RING, SOLVENT PROOF

O-RING

79001-11

79001-35

O-RING, SOLVENT PROOF

O-RING, SOLVENT PROOF

Qty

1

1

E

1

F

G

1

D

1

1

LN-9270-12.4

86

Aerobell 168 - Parts Identification

A15206-00 15mm Direct Charge

A13206-00 15MM SHAPE AIR

Item #

1

2

3

4

5

Part #

A12935-00

A12934-00

A12933-00

79001-10

79001-57

Description

INNER SHAPE AIR RING

SPACER

SHROUD, 15MM

O-RING, SOLVENT PROOF

O-RING, SOLVENT PROOF

Qty

1

1

1

1

1

LN-9270-12.4

87

FIBER OPTIC CABLE LENGTH

Part # Description

N/A Fiber Optic Cable (Not Included)

A12409-01 3 Ft. (0.9m) Long Fiber Optic Cable

A12409-02 6 Ft. (1.8m) Long Fiber Optic Cable

A12409-03 10 Ft. (3.0m) Long Fiber Optic Cable

A12409-04 15 Ft. (4.6m) Long Fiber Optic Cable

A12409-05 25 Ft. (7.6m) Long Fiber Optic Cable

A12409-06 40 Ft. (12.2m) Long Fiber Optic Cable

A12409-07 50 Ft. (15.2m) Long Fiber Optic Cable

A12409-08 65 Ft. (19.8m) Long Fiber Optic Cable

A12409-08 75 Ft. (22.9m) Long Fiber Optic Cable

A12409-10 100 Ft. (30.5m) Long Fiber Optic Cable

Aerobell 168 - Parts Identification

HIGH VOLTAGE CABLES (SHIELDED)

Part # Description

N/A

A10560-16

A10560-20

A10560-25

Fiber Optic Cable (Not Included)

15 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

20 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

25 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

A10560-50

A10560-75

50 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

75 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

A10560-100 100 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

SSW-1064

COAX CABLE

79007-00

PFA TUBING

EPS-4245

BANANA PLUG ASSEMBLY

(2 REQ'D)

HIGH VOLTAGE CABLES (NON-SHIELDED)

Part #

79006-15

79006-20

79006-50

79006-75

79006-100

Description

15 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

20 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

50 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

75 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

100 Ft. High Voltage Cable Assy. Shield, Non-Metallic Center Conductor

LN-9270-12.4

88

Aerobell 168 - Parts Identification

ACCESSORIES, LUBRICANTS

Part #

59972-00

76652-01

76652-02

76652-03

76652-04

A11545-00

Description

Dielectric Grease

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).

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)

Petrolatum Jell Lubricant for all O-Rings

LN-9270-12.4

89

Aerobell 168 - Parts Identification

SERVICE KITS

Part #

RPM-32

RPM-33

A11570-01

A11570-02

A11570-03

A11570-04

A11570-05

A11570-06

A11570-07

A11570-08

Description

Pre-Filter Replacement Element

Bearing Air Filter Element

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

Reducing Straight Connector, Push to Connect, 8mm OD to 4mm OD Tube

Reducing Straight Connector, Push to Connect, 8mm OD to 6mm OD Tube

Reducing Straight Connector, Push to Connect, 10mm OD to 4mm OD Tube

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

Reducing Straight Connector, Push to Connect, 10mm OD to 8mm OD Tube

Reducing Straight Connector, Push to Connect, 12mm OD to 8mm OD Tube

Reducing Straight Connector, Push to Connect, 12mm OD to 10mm OD Tube

LN-9270-12.4

90

Aerobell 168 - Parts Identification

RECOMMENDED SPARE PARTS

Part # Description

79001-41

7554-127

A13096-00

A13118-00

79001-22

A12816-00

79001-04

79001-40

79001-42

79001-44

A11119-10

A10468-10

A13288-00

A13287-00

A13289-00

A10468-12

A12777-XX

77762-04

A12796-00

Air Turbine Assembly*

Collect, 8mm

Fluid Tube Assembly

77591-00

77516-04

Fiber Optic Transmitter Assembly

Collect, 4mm

77367-00 Valve Seat Assembly

LSFI0022-04 Fitting, 1/4” O.D. X AN

EMF-203-04

EMF-203-04

A12807-00

A12808-00

78949-00

A12409-XX

79001-34

79001-30

Front Ferrule, 1/4” O.D. Tubing

Back Ferrule, 1/4” O.D. Tubing

Screw M10 X 16mm Nylon SHCS

Screw M12 X 25mm Nylon SHCS

Fluid Valve Assembly

Fiber Optic Cable

O-Ring, Solvent Proof

O-Ring, Solvent Proof

78449-00

A13030-00

A12824-00

A11252-01

A12821-00

A12822-00

O-Ring, Solvent Proof

O-Ring, Solvent Resistant

Tube Receiver, 4mm

Tube Fitting, 4mm

O-Ring, Solvent Proof

Tube Fitting, 8mm

O-Ring, Solvent Proof - (For all valve manifold tube fittings)

O-Ring, Solvent Proof

O-Ring, Solvent Proof

O-Ring, Solvent Proof

Screw M4 X 10mm SS SHCS

Screw M6 X 10mm SS SHCS

Tube Receiver, 8mm

Tube Fitting, 8mm x 6mm

Tube Fitting, 8mm x 5mm

Screw M6 X 12mm SS SHCS

Fitting, Fluid

Set Screw M8 X 12mm Cup Pt. SS

Cup Wash “Y” Fitting

Cup Wash Tubing

Cup Wash Fitting

Cup Wash Ferrule

* Customer must verify their spindle part number when ordering.

Qty.

1

2

1

1

2

2

1

1

2

2

3-5

3

2

2

1

1

1

2

6

10-20 ft.

2

4

1

1

5

1

1

1

2

2

5

1

1

1

1

2

1

LN-9270-12.4

91

RECOMMENDED SPARE PARTS (Cont.)

Part # Description

Select Option Below - Fluid Tip Size/Style

A11240-01 .028/0.7mm

A11240-02 .035/0.9mm

A11240-03 .043/1.1mm

A11240-04 .047/1.2mm

A11240-05 .062/1.6mm

A11240-06 .039/1.0mm

A13601-00 .010/0.25mm

A13625-00 .028/0.7mm Straight

A13625-01

A13625-02

.035/0.9mm Straight

.039/1.0mm Straight

A13625-03

A13625-04

A13625-05

A13625-06

.043/1.1mm Straight

.047/1.2mm Straight

.062/1.6mm Straight

.093/2.4mm Straight

A13625-07

A13625-08

A13645-00

A13645-01

A13645-02

A13645-03

A13645-04

A13645-05

.125/3.2mm Straight

.010/0.25mm Straight

.028/0.7mm Industrial

.035/0.9mm Industrial

.039/1.0mm Industrial

.043/1.1mm Industrial

.047/1.2mm Industrial

.062/1.6mm Industrial

A13645-06

A13645-07

.093/2.4mm Industrial

.125/3.2mm Industrial

A13645-08 .010/0.25mm Industrial

Select Option Below - Bell Cup Assembly W/Splash Plate

A12942-02

A12833-01

65mm Aluminum, Plated

30mm Aluminum, Plated

A13207-00

A12833-03

15mm Titanium

30mm Titanium

A13676-00 65mm Titanium

Select Option Below - Bell Cup Only

A12782-00

A12832-00

65mm Aluminum, Plated

30mm Aluminum, Plated

A12936-00

A13531-00

A13675-00

15mm Titanium

30mm Titanium

65mm Titanium

LN-9270-12.4

Aerobell 168 - Parts Identification

92

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Aerobell 168 - Parts Identification

RECOMMENDED SPARE PARTS (Cont.)

Part # Description

Select Option Below - Splash Plate Only

A13644-00 For 65mm Bell Cups

A13274-00 For 30mm Bell Cups

Select Option Below Fluid Coil

79879-00 1/4” OD X .125” ID, PFA, High Conductive Paints (16 Coils)

79879-01 1/4” OD X .170” ID, PFA (12 Coils)

Select Option Below Shaping Air Kit A13032-01 Dual Flex (65mm)

A12909-00

A12911-00

Outer Shroud (65mm)

Shaping Air Ring (65mm)

A12910-00

79001-11

Shape Air Manifold (65mm)

O-Ring

79001-10 O-Ring

79001-35 O-Ring

7554-72

79001-16

O-Ring

O-Ring

A12898-00 Shape Air Plug

Select Option Below Shaping Air Kit A13032-02 Mono Flex (65mm)

A12779-01

A12896-00

Outer Shroud (65mm)

Shape Air Manifold (65mm)

79001-52

79001-10

7554-72

79001-16

O-Ring

O-Ring

O-Ring

O-Ring

A12898-00 Shape Air Plug

Select Option Below Shaping Air Kit A13032-03 (30mm)

A12830-00

A12831-00

Outer Shroud (30mm)

Shape Air Manifold (30mm)

79001-52

79001-10

7554-72

79001-16

A12898-00

O-Ring

O-Ring

O-Ring

O-Ring

Shape Air Plug

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

LN-9270-12.4

93

RECOMMENDED SPARE PARTS (Cont.)

Part # Description

Select Option Below Shaping Air Kit A13206-00 (15mm)

A12933-00 Outer Shroud

A12935-00

A12934-00

Inner Shape Air Ring

Spacer

79001-10

79001-57

O-Ring

O-Ring

Aerobell 168 - Parts Identification

Qty.

1

1

1

1

1

A12088-00 TURBINE

RETAINING RING

WRENCH

TOOLS INCLUDED

Kit #

A13082-00

A13082-01

A13082-02

A13082-03

A13082-04

Description

Applicator Version Used With

NONE - - -

RPM-419, A12899-00, A11229-00, A12088-00, A11388-00 POST MOUNT APPLICATOR WITH

30MM OR 65MM BELL CUP

RPM-419, A12899-00, A11229-00, A12088-00, A11388-00 APPLICATOR WITH 30MM OR 65MM

A11922-00, A10766-00 BELL CUP WITH VALVE PACKAGE

RPM-419, A11229-00, A12088-00, A12939-00 POST MOUNT APPLICATOR WITH

15MM BELL CUP

RPM-419, A11229-00, A12088-00, A11922-00, A10766-00 APPLICATOR WITH 15MM BELL CUP

AND VALVE PACKAGE

LN-9270-12.4

94

Aerobell 168 - Warranty Policy

WARRANTY POLICIES

LIMITED WARRANTY

Ransburg will replace or repair without charge any

part and/or equipment that fails 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 AP-

PROVED PARTS VOID ALL WARRANTIES.

RANSBURG’S ONLY OBLIGATION UNDER

THIS WARRANTY IS TO REPLACE PARTS

THAT HAVE FAILED BECAUSE OF FAULTY

WORKMANSHIP OR MATERIALS. THERE ARE

NO IMPLIED WARRANTIES NOR WARRANTIES

OF EITHER MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE. RANSBURG

ASSUMES NO LIABILITY FOR INJURY, DAM-

AGE TO PROPERTY OR FOR CONSEQUEN-

TIAL DAMAGES FOR LOSS OF GOODWILL OR

PRODUCTION OR INCOME, WHICH RESULT

FROM USE OR MISUSE OF THE EQUIPMENT

BY PURCHASER OR OTHERS.

SPARE PARTS: One hundred and eighty (180) days from date of purchase, except for rebuilt parts (any part number ending in “R”) for which the warranty period is ninety (90) days.

EQUIPMENT: When purchased as a complete unit, (i.e., guns, power supplies, control units, etc.), is one (1) year from date of purchase.

WRAPPING

THE APPLICATOR, ASSOCIATED VALVES AND

TUBING, AND SUPPORTING HARDWARE IN

PLASTIC, SHRINK-WRAP, OR ANY OTHER

NON-APPROVED COVERING, WILL VOID THIS

WARRANTY.

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.

LN-9270-12.4

95

Aerobell 168 - Manual Changes

MANUAL CHANGE SUMMARY

This manual was published to supersede Service Manual

LN-9270-12.3 Aerobell 168

to make the following changes:

1. Update features (Page 6).

2. Update "Specifications (Page 7).

3. New image (Page 12).

4. New image and hose specifications (Page 16).

5. Update "Air Filtration Requirements" (Page 18).

6. Add "Fluid Tip Stream And Tip Style Use" copy (Page 28).

7. New image (Page 30).

8. New photo's for steps 18-29 and 1-2 for "Disassembly Procedures for Robot/Machine

Mount Kits (Pages 66-71).

9. Update model identification number (Page 72).

10. New Tables B through F (Pages 73-75).

11. New image (Page 76).

12. Update Applicator Parts Breakdown (Page 77).

13. Update "Stud Mount Assembly" list (Page 78).

14. New image for "Machine Mount Kit" (Page 79).

15. Update Machine Mount Kit - Parts List (Page 80).

16. New Robot Mount Kit image (Page 82).

17. Update Robot Mount Kit parts list (Page 83).

18. Update cable image (Page 88).

19. Update Recommended Spare Parts List (Pages 91-94).

20. Update Tools Included (Page 94).

LN-9270-12.4

96

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.

© 2014 Finishing Brands, Inc. All rights reserved.

Models and specifications subject to change without notice.

Form No. LN-9270-12.4

Litho in U.S.A.

5/14

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