Ransburg 70393 User Manual

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REA III 100KVREA III 100KV

REA III 100KV

REA III 100KVREA III 100KV

SERVICE MANUAL AA-82-01.3AA-82-01.3

AA-82-01.3

AA-82-01.3AA-82-01.3 (Replaces AA-82-01.2) May - 2008

AUTAUT

AUT

AUTAUT

OMAOMA

OMA

OMAOMA

TIC APPLICATIC APPLICA

TIC APPLICA

TIC APPLICATIC APPLICA

OROR

MODEL: 70393MODEL: 70393

MODEL: 70393

MODEL: 70393MODEL: 70393

IMPORIMPOR

IMPOR

IMPORIMPOR carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS, starting on page 1, and all instructions instarting on page 1, and all instructions in

starting on page 1, and all instructions in

starting on page 1, and all instructions instarting on page 1, and all instructions in this manual. Keep this Service Manual forthis manual. Keep this Service Manual for

this manual. Keep this Service Manual for

this manual. Keep this Service Manual forthis manual. Keep this Service Manual for future reference.future reference.

future reference.

future reference.future reference.

ANTANT

ANT

ANTANT

: Before using this equipment,: Before using this equipment,

: Before using this equipment,

: Before using this equipment,: Before using this equipment,

Service Manual Price:Service Manual Price:

Service Manual Price: €

Service Manual Price:Service Manual Price:

25.00 (Euro)25.00 (Euro)

25.00 (Euro)

25.00 (Euro)25.00 (Euro)

$30.00 (U.S.)$30.00 (U.S.)

$30.00 (U.S.)

$30.00 (U.S.)$30.00 (U.S.)

NOTE:NOTE:

NOTE: This manual has been changed from revision

NOTE:NOTE:

AA-82-01.2 AA-82-01.2

AA-82-01.2 to revision

AA-82-01.2 AA-82-01.2

AA-82-01.3. AA-82-01.3.

AA-82-01.3.

AA-82-01.3. AA-82-01.3. Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual.

AA-82-01.3

CONTENTSCONTENTS

SAFETY:SAFETY:

SAFETY:

SAFETY:SAFETY:

REA III 100kV Automatic Applicator - Contents

PAGEPAGE

PAGE

PAGEPAGE

1-41-4

1-4

1-41-4

SAFETY PRECAUTIONS...........................................................................................................

HAZARDS/SAFEGUARDS.........................................................................................................

ATEXATEX

ATEX

ATEXATEX

EUROPEAN ATEX DIRECTIVE.................................................................................................

EUROPEAN ATEX LABELS.......................................................................................................

INTRODUCTION:INTRODUCTION:

INTRODUCTION:

INTRODUCTION:INTRODUCTION:

GENERAL DESCRIPTION.........................................................................................................

SPECIFICATIONS.......................................................................................................................

INSTALLATION:INSTALLATION:

INSTALLATION:

INSTALLATION:INSTALLATION:

INSTALLING................................................................................................................................

TYPICAL REA AUTOMATIC APPLICATOR

INSTALLATION - WATERBORNE.............................................................................................

ATOMIZER ASSEMBLY SELECTION.......................................................................................

OPERATION:OPERATION:

OPERATION:

OPERATION:OPERATION:

SAFETY PROCEDURES............................................................................................................

1 2-4

5-85-8

5-8

5-85-8

5 6-7

9-109-10

9-10

9-109-10

9 9

11-1411-14

11-14

11-1411-14

11-12

12-13 14

15-1815-18

15-18

15-1815-18

15-17

MAINTENANCE:MAINTENANCE:

MAINTENANCE:

MAINTENANCE:MAINTENANCE:

ROUTINE SCHEDULE...............................................................................................................

ATOMIZER ASSEMBLY CLEANING PROCEDURE................................................................

FLUSHING PROCEDURES.......................................................................................................

SERVICE.....................................................................................................................................

TROUBLESHOOTING GUIDE...................................................................................................

EVALUATING RESULTS OF SCI AND CURRENT

DEMAND TEST...........................................................................................................................

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PARTS IDENTIFICATION:

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

70393 REA III 100KV AUTOMATIC APPLICATOR

EXPLODED VIEW.......................................................................................................................

70393 REA III AUTOMATIC APPLICATOR /

SOLVENTBORNE SYSTEMS PARTS LIST..............................................................................

70393 REA III AUTOMATIC APPLICATOR /

WATERBORNE SYSTEMS PARTS LIST..................................................................................

WARRANTY POLICIES:WARRANTY POLICIES:

WARRANTY POLICIES:

WARRANTY POLICIES:WARRANTY POLICIES:

LIMITED WARRANTY.................................................................................................................

19-3619-36

19-36

19-3619-36

19-20 21-22 22 22--32 33-34

37-4437-44

37-44

37-4437-44

37-38

39-40

41-43

4545

AA-82-01.3

REA III 100kV Automatic Applicator - Safety

SAFETYSAFETY

SAFETY

SAFETYSAFETY

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

Before operating, maintaining or servicing any ITW Ransburg electrostatic coating system, read and understand all of the technical and safety literature for your ITW Ransburg products. This manual contains information that is important for you to know and understand. This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the following symbols. Please pay particular attention to these sections.

W W

ARNING!ARNING!

ARNING!

W W

ARNING!ARNING!

to a situation that might cause serious injuryto a situation that might cause serious injury

to a situation that might cause serious injury

to a situation that might cause serious injuryto a situation that might cause serious injury if instructions are not followed.if instructions are not followed.

if instructions are not followed.

if instructions are not followed.if instructions are not followed.

A CAUTION!A CAUTION!

A CAUTION!

A CAUTION!A CAUTION! how to prevent damage to equipment or howhow to prevent damage to equipment or how

how to prevent damage to equipment or how

how to prevent damage to equipment or howhow to prevent damage to equipment or how to avoid a situation that might cause minorto avoid a situation that might cause minor

to avoid a situation that might cause minor

to avoid a situation that might cause minorto avoid a situation that might cause minor injuryinjury

injury

injuryinjury

A NOTE is information relevant to theA NOTE is information relevant to the

A NOTE is information relevant to the

A NOTE is information relevant to theA NOTE is information relevant to the procedure in progress.procedure in progress.

procedure in progress.

procedure in progress.procedure in progress.

While this manual lists standard specifications and service procedures, some minor deviations may be found between this literature and your equipment. Differences in local codes and plant requirements, material delivery requirements, etc., make such variations inevitable. Compare this manual with your system installation drawings and appropriate ITW Ransburg equipment manuals to reconcile such differences.

states information to alert youstates information to alert you

states information to alert you

states information to alert youstates information to alert you

states information that tellsstates information that tells

states information that tells

states information that tellsstates information that tells

> The user

the Safety Section in this manual and the ITW Ransburg safety literature therein identified.

> This manual

understood by clean or maintain this equipment! Special care should be taken to ensure that the WARNINGSWARNINGS

WARNINGS and safety requirements for

WARNINGSWARNINGS operating and servicing the equipment are followed. The user should be aware of and adhere to and ordinances as well as SAFETY STANDARD, SAFETY STANDARD,

SAFETY STANDARD, prior to installing,

SAFETY STANDARD, SAFETY STANDARD, operating, and/or servicing this equipment.

MUSTMUST

MUST read and be familiar with

MUSTMUST

MUST be read and thoroughly

MUSTMUST

ALLALL

ALL personnel who operate,

ALLALL

ALL local building and fire codes

ALLALL

NFPA-33NFPA-33

NFPA-33

NFPA-33NFPA-33

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> The hazards shown on the following page

may occur during the normal use of this equipment. Please read the hazard chart beginning on page 2.

Careful study and continued use of this manual will provide a better understanding of the equipment and process, resulting in more efficient operation, longer trouble-free service and faster easier troubleshooting. If you do not have the manuals and safety literature for your Ransburg system, contact your local ITW Ransburg representative or ITW Ransburg.

AA-82-01.3

AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

REA III 100kV Automatic Applicator - Safety

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Spray AreaSpray Area

Spray Area

Spray AreaSpray Area

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 shutdown indicates a problem in the system requiring correction.

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

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

Smoking must never be allowed in the spray area.

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

When using solvents for cleaning:

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

Those used for general cleaning must have flash points above 100oF (37.8oC).

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

Electrostatic arcing must be prevented.

Test only in areas free of combustible material.

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

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

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

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

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

AA-82-01.3

REA III 100kV Automatic Applicator - Safety

AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

General Use andGeneral Use and

General Use and

General Use andGeneral Use and MaintenanceMaintenance

Maintenance

MaintenanceMaintenance

ElectricalElectrical

Electrical

ElectricalElectrical EquipmentEquipment

Equipment

EquipmentEquipment

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

Improper operation or maintenance may create a hazard.

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

High voltage equipment is utilized. Arcing in areas of flammable or combustible materials may occur. Personnel are ex-posed to high voltage during operation and maintenance.

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

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

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

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Personnel must be given training in accordance with the requirements of NFPA-33.

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, and your insurance company requirements.

The power supply, optional remote control cabinet, and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas. Refer to NFPA-33.

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.

AA-82-01.3

REA III 100kV Automatic Applicator - Safety

AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

Spray Area /Spray Area /

Spray Area /

Spray Area /Spray Area /

High VoltageHigh Voltage

High Voltage

High VoltageHigh Voltage EquipmentEquipment

Equipment

EquipmentEquipment

HAZARDHAZARD

HAZARD

HAZARDHAZARD

Tells what the hazard is.

This is a high voltage device that can produce electrical arcs capable of igniting coating materials.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

Parts being sprayed must be supported on conveyors or hangers and be grounded. The resistance between the part and ground must not exceed 1 megohm. (Reference NFPA-33.)

A safe distance must be maintained between the parts being coated and the atomizer bell. A distance of at least 1 inch for each 10 KV of power supply output voltage is required at all times.

Parts must be supported so that they will not swing and reduce the clearance specified above.

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.

Unless specifically approved for use in hazardous locations, the power supply and other electrical equipment must not be used in Class I, Division 1 or 2 locations.

AA-82-01.3

REA III 100kV Automatic Applicator - Atex

EUROPEAN AEUROPEAN A

EUROPEAN A

EUROPEAN AEUROPEAN A

The following instructions apply to equipment covered by certificate number Sira 08ATEX5040X:

1. The equipment may be used with flammable gases and vapors with apparatus groups II and with temperature class T6.

2. The equipment is only certified for use in ambient temperatures in the range +12.8°C to +40°C and should not be used outside this range.

3. Installation shall be carried out by suitably trained personnel in accordance with the applicable code of practice e.g. EN 6007914:1997.

4. Inspection and maintenance of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice e.g. EN 60079-17.

5. Repair of this equipment shall be carried out by suitable trained personnel in accordance with the applicable code of practice e.g. EN 60079-19.

6. Putting into service, use, assembling, and adjustment of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer's documentation.

Refer to the "Table of Contents" of this service manual:

a. Installation b. Operation c. Maintenance d. Parts Identification

7. Components to be incorporated into or used as replacement parts of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer's documentation.

TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6

TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6

TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6TEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6

8. The certification of this equipment relies upon the following materials used in its construction:

If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection provided by the equipment is not compromised.

Aggressive substances: e.g. acidic liquids or gases that may attack metals, or solvents that may affect polymeric materials.

Suitable precautions: e.g. regular checks as part of routine inspections or establishing from the material's data sheets that it is resistant to specific chemicals.

Refer to "Specifications" in the "Introduction" section:

a. All fluid passages contain stainless steel

or nylon fittings.

b. High voltage cascade is encapsulated with

a solvent resistant epoxy.

9. A recapitulation of the certification marking is detailed in the "Atex" section, on the next page, drawing numbers: 19688, 72562, 76454, 76854, 76896, 77059, 78886, 78894-04, and LEPS5016.

10. The characteristics of the equipment shall be detailed e.g. electrical, pressure, and voltage parameters.

The manufacturer should note that, on beingThe manufacturer should note that, on being

The manufacturer should note that, on being

The manufacturer should note that, on beingThe manufacturer should note that, on being put into service, the equipment must beput into service, the equipment must be

put into service, the equipment must be

put into service, the equipment must beput into service, the equipment must be accompanied by a translation of theaccompanied by a translation of the

accompanied by a translation of the

accompanied by a translation of theaccompanied by a translation of the instructions in the language or languagesinstructions in the language or languages

instructions in the language or languages

instructions in the language or languagesinstructions in the language or languages of the country in which the equipment is toof the country in which the equipment is to

of the country in which the equipment is to

of the country in which the equipment is toof the country in which the equipment is to be used and by the instructions in thebe used and by the instructions in the

be used and by the instructions in the

be used and by the instructions in thebe used and by the instructions in the original language.original language.

original language.

original language.original language.

AA-82-01.3

REA III 100kV AutomaticREA III 100kV Automatic

REA III 100kV Automatic

REA III 100kV AutomaticREA III 100kV Automatic Applicator 70393 AApplicator 70393 A

Applicator 70393 A

Applicator 70393 AApplicator 70393 A Marking DefinitionsMarking Definitions

Marking Definitions

Marking DefinitionsMarking Definitions

Ex Certificate Number: Sira 08ATEX5040X

Sira = Notified Body performing EC-type examination 08 = Year of certification ATEX = Reference to ATEX Directive 5 = Protection Concept Code (code 5 is titled Encapsulation) 040 = Document serial number X = Special conditions for safe use apply

Special conditions for safe use: The REA-III 70393 Automatic Applicator shall only be used with associated 76447-XX, 76045-XX, LEPS5000-04, LEPS-5002-00, and 78789-02 HV Control Units.

TEX ProductTEX Product

TEX Product

TEX ProductTEX Product

REA III 100kV Automatic Applicator - Atex

Label 72562Label 72562

Label 72562

Label 72562Label 72562

Label 76454Label 76454

Label 76454

Label 76454Label 76454

Product MarkingProduct Marking

Product Marking

Product MarkingProduct Marking

II 2 GII 2 G

II 2 G

II 2 GII 2 G

Ex = Specific marking of explosive protection II = Equipment Group hazardous area characteristics 2 = Equipment Category G = Type of explosive atmosphere (gases, vapors, or mists)

EEx 0.24mJEEx 0.24mJ

EEx 0.24mJ = The REA-III 70393 Automatic

EEx 0.24mJEEx 0.24mJ Applicator is suitable for use in automatic spraying installations complying with EN 50050 as they are a Type A class with a discharge energy limit of

0.24mJ.

Label 19688Label 19688

Label 19688

Label 19688Label 19688

Label 76854Label 76854

Label 76854

Label 76854Label 76854

Label 76896Label 76896

Label 76896

Label 76896Label 76896

AA-82-01.3

REA III 100kV Automatic Applicator - Atex

Label 77059Label 77059

Label 77059

Label 77059Label 77059

Label 78886Label 78886

Label 78886

Label 78886Label 78886

Label 78894-04Label 78894-04

Label 78894-04

Label 78894-04Label 78894-04

Label LEPS0016Label LEPS0016

Label LEPS0016

Label LEPS0016Label LEPS0016

AA-82-01.3

REA III 100kV Automatic Applicator - Atex

NOTESNOTES

NOTES

NOTESNOTES

AA-82-01.3

REA III 100kV Automatic Applicator - Introduction

INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

GENERAL DESCRIPTIONGENERAL DESCRIPTION

GENERAL DESCRIPTION

GENERAL DESCRIPTIONGENERAL DESCRIPTION

REA III 100kV Automatic ApplicatorREA III 100kV Automatic Applicator

The

REA III 100kV Automatic Applicator

REA III 100kV Automatic ApplicatorREA III 100kV Automatic Applicator

applies a high voltage charge to the coating materials at the point of atomization using a 100kV power supply. This electrostatic charge allows a more efficient, uniform application of coating material to the front, edges, sides, and back of products, making it highly suitable for applying a wide range of coatings to a variety of surface configurations: large targets, small parts, tubular wares, concave and recessed parts, etc. It is available as a grounded fluid system for solvent reduced coatings such as enamels, lacquers, epoxys, etc.

SPECIFICASPECIFICA

SPECIFICA

SPECIFICASPECIFICA

Environmental / PhysicalEnvironmental / Physical

Environmental / Physical

Environmental / PhysicalEnvironmental / Physical

Operating VOperating V

Operating V

Operating VOperating V

Operating FluidOperating Fluid

Operating Fluid

Operating FluidOperating Fluid Pressure:Pressure:

Pressure: 0-100 psi (0-6.9 bar)

Pressure:Pressure:

Operating AirOperating Air

Operating Air

Operating AirOperating Air Pressure:Pressure:

Pressure: 0-100 psi (0-6.9 bar)

Pressure:Pressure:

Flow Rate:Flow Rate:

Flow Rate: 1000 cc/min. maximum

Flow Rate:Flow Rate:

TIONSTIONS

TIONS

TIONSTIONS

oltage:oltage:

oltage: 100kV maximum

oltage:oltage:

(viscosity dependent)

One of the many safety features of the REA III 100 kV Automatic Applicator is the capability of limiting, to a desirable level, the electrical discharge which is available from the charging electrode. When organic solvent base paints are being sprayed, this level must not exceed 0.25 mJ of energy. In order to achieve this limitation, it is necessary to prevent any flow of energy from the paint supply through the paint line to the applicator electrode. This is accomplished by grounding the paint line at the applicator.

Short CircuitShort Circuit

Short Circuit

Short CircuitShort Circuit Current:Current:

Current: 150 Microamperes

Current:Current:

Air and Fluid Nozzles:Air and Fluid Nozzles:

Air and Fluid Nozzles:

Air and Fluid Nozzles:Air and Fluid Nozzles:

Any ITW Ransburg Air and Fluid Nozzle combination. (See “Nozzle Selection” in the “Operation” section.)

Optional Hose andOptional Hose and

Optional Hose and

Optional Hose andOptional Hose and Cable Lengths: Cable Lengths:

Cable Lengths: 25, 36, 50, 75, and 100 ft.

Cable Lengths: Cable Lengths:

(8m, 11m, 15m, 23m, and

31m)

AA-82-01.3

REA III 100kV Automatic Applicator - Introduction

NOTESNOTES

NOTES

NOTESNOTES

AA-82-01.3

1010

REA III 100kV Automatic Applicator - Installation

INSTINST

INST

INSTINST

> Installation of the equipment

compliance with all Federal, State, Local and National codes.

> The power supply

OUTSIDEOUTSIDE

OUTSIDE of the spray area.

OUTSIDEOUTSIDE

> Personnel

prevent a shock or spark during electrostatic operation.

> Install and route the hoses and cables so

they are excess of 120°F (49°C) and so that all hose and cable bends are (15 cm) radius. Failure to comply with these parameters could cause equipment malfunctions that might create DITIONS!DITIONS!

DITIONS!

DITIONS!DITIONS!

INSTINST

INST

INSTINST

1. To connect the high voltage cable, remove the cable retainer bracket and remove the protective cap for the power supply high voltage cable socket. Insert the high voltage cable (and plug) into socket. Gently hand-tighten the cable retaining nut. Reattach the bracket.

2. The control unit conduit with an explosion-proof terminal on or near the spray booth where it will be convenient, or may be connected with a line cord depending upon application requirement.

ALLAALLA

ALLA

ALLAALLA

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

NOTNOT

NOT exposed to temperatures in

NOTNOT

ALLINGALLING

ALLING

ALLINGALLING

TIONTION

TION

TIONTION

MUSTMUST

MUST be in

MUSTMUST

MUST MUST

MUST be located

MUST MUST

MUSTMUST

MUST be

MUSTMUST

MAMA

GROUNDEDGROUNDED

GROUNDED to

GROUNDEDGROUNDED

NOTNOT

NOT less than a 6-inch

NOTNOT

HAZARDOUS CON-HAZARDOUS CON-

HAZARDOUS CON-

HAZARDOUS CON-HAZARDOUS CON-

Y be connected through

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> The power supply

outside of the spray area. Install units in accordance with the requirements of local regulations.

3. Install Filters: Install the optional fluid filter on output of fluid supply. Detail depends on whether pressure tank, pump unit, recirculating system, etc. is used. Filter must be installed vertically with drain valve down and arrow pointing in direction of flow (see Figure 1).

4. Install Line Hose (Air or Fluid):

> ITW Ransburg supplies a standard

25 ft. (8m) hose. Optional hose lengths of 36 ft. (11m), 50 ft. (15m), 75 ft. (23m), and 100 ft. (31m) are available. To meet various length requirements, the hose fitting on one end has not been attached. Determine the hose length that is needed and cut the hose. Attach the other fitting as follows:

a. Lubricate all fittings with petroleum jelly.

b. Screw ferrule counter-clockwise onto hose

until it bottoms. Then back it off about 1/8inch (3mm).

MUSTMUST

MUST be located

MUSTMUST

NOTENOTE

NOTE

NOTENOTE

NOTE

NOTENOTE

NOTE

NOTENOTE

> Refer to the Power Supply Service

Manual for the circuit diagram and instructions to connect the power supply.

> The union stem will not seat if the hose

is bottomed against the ferrule.

AA-82-01.3

REA III 100kV Automatic Applicator - Installation

c. Install nut over union stem and start the stem

into the hose.

d. Using the 1/8-inch Allen wrench, screw the

union stem into the hose until it bottoms against the ferrule.

e. Connect one end of one hose to the appro-

priate fitting on the bottom of the applicator body and the other end to the power supply pressure switch for trigger air. Attach the other hose to the atomizing air source.

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

NEVERNEVER

NEVER use wooden boxes, pallets, or

NEVERNEVER boards as wood will absorb moisture and is a poor insulator.

• Isolation stand from the grounded booth wall, chain link fence, or other grounded objects.

• Air hoses to the pressure pot or pump on the insulating stand should be nonconductive. Many rubber hoses will have static grounding circuits or carbon content and are

• Air regulators for pots or pumps should be mounted remotely outside the fence or cage area to facilitate changes in pressure without shutting the system down.

• Grounding hooks at the cage to ground portions of the system when personnel are working close by.

MUST MUST

MUST be at least 18-inches

MUST MUST

NOTNOT

NOT suitable.

NOTNOT

MUSTMUST

MUST be used

MUSTMUST

Figure 1: Installing Line HoseFigure 1: Installing Line Hose

Figure 1: Installing Line Hose

Figure 1: Installing Line HoseFigure 1: Installing Line Hose

TYPICAL REATYPICAL REA

TYPICAL REA

TYPICAL REATYPICAL REA AUTAUT

AUT

AUTAUT INSTINST

INST

INSTINST WW

Using waterborne coating with electrostatic equipment requires that the fluid source should be isolated from ground and other precautions be taken to ensure operator safety and system efficiency. The following guidelines should be followed:

• The fluid lines and source

OMAOMA

OMA

OMAOMA

ALLAALLA

ALLA

ALLAALLA

TERBORNETERBORNE

TERBORNE

TERBORNETERBORNE

from ground. An isolating paint stand or similar isolating (non-porous) material

TIC APPLICATIC APPLICA

TIC APPLICA

TIC APPLICATIC APPLICA

TION -TION -

TION -

TION -TION -

MUSTMUST

MUST be isolated

MUSTMUST

MUST be used.

MUSTMUST

OROR

• Fluid lines to the applicator from scraping and abrasion on the floor or sharp metal edges that could lead to voltage pinholing and loss of kV on the charged system.

• Cleanliness and maintenance are extremely critical.

• Fully discharge system capacitance prior to service.

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> System capacitance must be fully dis-

charged prior to any service or maintenance of the applicator.

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> ALL charged (isolated) systems

inside a fence or cage to prevent contact by personnel. An interlock system provided that interrupts high voltage flow to the applicator if the gate is opened.

MUSTMUST

MUST be protected

MUSTMUST

MUST be

MUSTMUST

MUST be

MUSTMUST

AA-82-01.3

1212

REA III 100kV Automatic Applicator - Installation

Paint PreparationPaint Preparation

Paint Preparation

Paint PreparationPaint Preparation

A proper paint mixture is essential to electrostatic operation. Paint test equipment may be obtained through your ITW Ransburg representative. Consult ITW Ransburg literature “Paint Related Information for REA and REM Applicators” manual for paint formulation information. For further paint formulation and testing procedures, consult your ITW Ransburg representative and/or paint supplier.

Atomizer Assembly SelectionAtomizer Assembly Selection

Atomizer Assembly Selection

Atomizer Assembly SelectionAtomizer Assembly Selection

The “Atomizer Assembly Selection” charts are provided to give you a comparison of the air caps and fluid nozzles. AA

OMIZER ASSEMBLOMIZER ASSEMBL

OMIZER ASSEMBL

OMIZER ASSEMBLOMIZER ASSEMBL

DEPEND ON QUALITIES DESIRED ANDDEPEND ON QUALITIES DESIRED AND

DEPEND ON QUALITIES DESIRED AND

DEPEND ON QUALITIES DESIRED ANDDEPEND ON QUALITIES DESIRED AND MUST BE VERIFIED BY ACTUAL TRIAL.MUST BE VERIFIED BY ACTUAL TRIAL.

MUST BE VERIFIED BY ACTUAL TRIAL.

MUST BE VERIFIED BY ACTUAL TRIAL.MUST BE VERIFIED BY ACTUAL TRIAL. See you authorized ITW Ransburg distributor for atomizer demonstration.

THE CHOICE OFTHE CHOICE OF

THE CHOICE OF

THE CHOICE OFTHE CHOICE OF

SHOULD SHOULD

SHOULD

SHOULD SHOULD

> A counter-clockwise turn of the air cap

may loosen the fluid nozzle and cause air to get into the paint or paint to cross over into the air passages.

Applicator TApplicator T

Applicator T

Applicator TApplicator T

Mount the applicator 6-12-inches (152-305mm) maximum from the target for best operation.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

o To T

arget Distancearget Distance

o T

arget Distance

o To T

arget Distancearget Distance

Spray Pattern AdjustmentSpray Pattern Adjustment

Spray Pattern Adjustment

Spray Pattern AdjustmentSpray Pattern Adjustment

The spray pattern of fan atomizers is adjustable from a small circle to an elongated oval, approximately 10-12-inches (254-305mm) across the useable long axis at 8-10-inches (203-254mm) from the target. The swirl atomizer assemblies produce a round pattern from 5-9-inches (127229mm) in diameter. To adjust pattern size, increasing fan air pressure will expand the pattern, a reduction will decrease it. To change the spray pattern axis of fan atomizers from horizontal to vertical, loosen retainer ring, rotate the air cap clockwise to the desired position, and gently tighten the ring.

1313

AA-82-01.3

ATAT

OMIZER ASSEMBLOMIZER ASSEMBL

OMIZER ASSEMBL

ATAT

OMIZER ASSEMBLOMIZER ASSEMBL

REA III 100kV Automatic Applicator - Installation

SELECTION SELECTION

SELECTION

SELECTION SELECTION

REA NOZZLESREA NOZZLES

REA NOZZLES

REA NOZZLESREA NOZZLES

(Conventional Spray)(Conventional Spray)

(Conventional Spray)

(Conventional Spray)(Conventional Spray)

Air CapAir Cap

Air Cap

Air CapAir Cap Part Part

Part

Part Part NumberNumber

Number

NumberNumber

70899-00 70898-00 Swirl 4903-00 74963-02 LREA0002 LREA0003 Round 73569-00 74963-02 4904-65R 4907-44 .055” (1.4mm) 73569-00 74963-02 4904-65R 4907-45 .070” (1.8mm) 73569-00 74963-02 4904-65R 4907-46 .042” (1.1mm) 73569-00 74963-02 4904-65R 4907-47 .028” (0.7mm) 73569-00 74963-02 4904-65R 4907-48 .047” (1.2mm) 73569-00 74963-02 4904-63 4907-44 .055” (1.4mm) 73569-00 74963-02 4904-63 4907-45 .070” (1.8mm) 73569-00 74963-02 4904-63 4907-46 .042” (1.1mm) 73569-00 74963-02 4904-63 4907-47 .028” (0.7mm) 73569-00 74963-02 4904-63 4907-48 .047” (1.2mm) 73569-00 74963-02 4904-98 4907-44 .055” (1.4mm) 73569-00 74963-02 4904-98 4907-45 .070” (1.8mm) 73569-00 74963-02 4904-98 4907-46 .042” (1.1mm) 73569-00 74963-02 4904-98 4907-47 .028” (0.7mm) 73569-00 74963-02 4904-98 4907-48 .047” (1.2mm) 73569-00 74963-02

Fluid Nozzle Fluid Nozzle

Fluid Nozzle

Fluid Nozzle Fluid Nozzle Part Number Part Number

Part Number

Part Number Part Number

Orifice Orifice

Orifice

Orifice Orifice

IDID

Separate Separate

Separate

Separate Separate Retaining Retaining

Retaining

Retaining Retaining Ring Ring

Ring

Ring Ring

PressurePressure

Pressure

PressurePressure

Reducer Reducer

Reducer

Reducer Reducer

(Black)(Black)

(Black)

(Black)(Black)

REA NOZZLESREA NOZZLES

REA NOZZLES

REA NOZZLESREA NOZZLES

(HVLP)(HVLP)

(HVLP)

(HVLP)(HVLP)

Air CapAir Cap

Air Cap

Air CapAir Cap Part Part

Part

Part Part NumberNumber

Number

NumberNumber

75601-00 75600-01 .055” (1.4mm) 73569-00 74963-03 75601-00 75600-02 .070” (1.8mm) 73569-00 74963-03 75601-00 75600-03 .086” (2.2mm) 73569-00 74963-03

AA-82-01.3

Fluid Nozzle Fluid Nozzle

Fluid Nozzle

Fluid Nozzle Fluid Nozzle Part Number Part Number

Part Number

Part Number Part Number

Orifice Orifice

Orifice

Orifice Orifice

ID ID

Separate Separate

Separate

Separate Separate Retaining Retaining

Retaining

Retaining Retaining Ring Ring

Ring

Ring Ring

Pressure Pressure

Pressure

Pressure Pressure Reducer Reducer

Reducer

Reducer Reducer

(White)(White)

(White)

(White)(White)

1414

REA III 100kV Automatic Applicator - Operation

OPERAOPERA

OPERA

OPERAOPERA

SAFETY PROCEDURESSAFETY PROCEDURES

SAFETY PROCEDURES

SAFETY PROCEDURESSAFETY PROCEDURES

> The simple safety measures outlined in the

“Safety” section are vital. Failure to observe them could cause a spark capable of starting a fire.

1. The articles being coated at all times.

2. All components of the applicator system be grounded at all times.

3. All contact points accumulation of non-conductive residue.

4. All electrically conductive objects, especially solvent containers, within the spray area be either removed or grounded.

TIONTION

TION

TIONTION

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

MUSTMUST

MUST be grounded

MUSTMUST

MUST be free of any

MUSTMUST

MUST

MUSTMUST

MUST

MUSTMUST

Additional cards summarizing these safety requirements are available from ITW Ransburg on request. These cards should be posted in the spraying area so that they can be readily referred to and serve as a reminder to personnel that area of responsibility. Additional copies of “Cleaning Safety Requirements” are available upon request.

Each user should examine his own coating operation, develop his own safety program and ensure that his workers follow correct procedures. ITW Ransburg hopes that the information it provides is helpful to the user in establishing such a program.

In addition to the available cards, labels, brochures, and service manuals, the user should consult other standards and recognized safety authorities.

Local codes and authorities also have standards to be followed in the operation of your spray equipment. Your insurance carrier will be helpful in answering questions that arise in your development of spray coating procedures.

Any tool, if used improperly, can be dangerous. Safety is ultimately the responsibility of those using a tool. In like manner, safe operation of electrostatic coating processes is the responsibility of those who use such processes and those who operate electrostatic coating equipment. It is most important that equipment operators and supervisory personnel understand the requirements for safe operations.

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

ANYANY

> If

ANY symptom of improper operation

ANYANY occurs suspend use of the unit until the problem has been diagnosed and corrected. See the appropriate “Troubleshooting Guide” or contact your ITW Ransburg representative.

All personnel MUST read and understand the

“T“T

following ITW Ransburg literature,

Supplement for All Products”.Supplement for All Products”.

Supplement for All Products”.

Supplement for All Products”.Supplement for All Products”.

echnicalechnical

“T

echnical

“T“T

echnicalechnical

1515

AA-82-01.3

REA III 100kV Automatic Applicator - Operation

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> Verify that the applicator body assembly is

actually grounded before operating it! This is done with a fully connected and operation system, by placing one lead of an ohm meter to the body assembly and the other to the building electrical ground (cold water pipe, building structure, etc.). The reading should be essentially zero.

> If a reading much greater than zero is

obtained, check that the power supply is grounded. Place one lead of the ohm meter on the building electrical ground and the other on the high voltage cable outlet bushing. If the reading is much greater than zero, reconnect the power supply ground. If the meter reads zero, check the high voltage cable. Place one lead on the high voltage cable retaining nut and the other lead on the applicator body assembly. If the reading is much greater than zero, the braided cable may be defective and should be replaced.

1. Parts, Equipment and Supplies:

a. Ground the spray booth, the paint tank,

and the conveyor.

2. Personel Procedures:

GROUND ALL PERSONS IN ALLGROUND ALL PERSONS IN ALL

GROUND ALL PERSONS IN ALL

GROUND ALL PERSONS IN ALLGROUND ALL PERSONS IN ALL SPRASPRA

SPRA

SPRASPRA wear conductive soled shoes or personnel grounding straps.

(See ITW Ransburg “Safety Literature Handbook - Electrostatic Safety Information from ITW Ransburg”.)

b. Turn the power supply

cleaning or working on the equipment.

NEVERNEVER

NEVER immerse any part of, or all of a

NEVERNEVER spray applicator in any liquid, while assembled.

d. Personnel

booth during operation.

3. Ventilation:

Electrostatic attraction greatly reduces paint overspray, thereby reducing ventilation requirements. An exhaust velocity of 100 to 150 FPM at the spray position is normally adequate. Exhaust system (and conveyor) MUSTMUST

MUST be interlocked with the triggering

MUSTMUST function.

AREAS AREAS

AREAS by requiring that they

AREAS AREAS

OFFOFF

OFF prior to

OFFOFF

MUSTMUST

MUST stay out of the spray

MUSTMUST

b. Ground

c. Ground

d. See that no more than one gallon of solvent

e. See that the power supply is grounded and

f. See that conductive flooring is provided in

g. See that the proper fire extinguishing

AA-82-01.3

ALLALL

ALL solvent containers.

ALLALL

ALL work holders and hooks and

ALLALL

keep them free of paint.

per safety container per operator is inside the work area.

located outside the spray area.

all spray areas.

equipment is provided.

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> Exhaust system and conveyor must be

interlocked with high voltage

1616

REA III 100kV Automatic Applicator - Operation

4. Housekeeping:

Good housekeeping is always necessary to ensure quality finishes, eliminate rejects, and reduce service requirements (see OSHA standards).

a. Periodically strip all workholders to main-

tain proper grounding of parts.

b. Establish adequate cleaning and mainte-

nance schedules based on observation of initial production characteristics.

c. Employ fire protection measures, includ-

ing proper storage of paints, solvents, and waste, plus ready access to fire extinguishing equipment. Provide water sprinklers, CO guishers within the spray area (check local fire codes).

, or chemical fire extin-

NOTESNOTES

NOTES

NOTESNOTES

1717

AA-82-01.3

REA III 100kV Automatic Applicator - Operation

NOTESNOTES

NOTES

NOTESNOTES

AA-82-01.3

1818

REA III 100kV Automatic Applicator - Maintenance

MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> The user

SAFETY INSTRUCTIONSSAFETY INSTRUCTIONS

the

SAFETY INSTRUCTIONS in this

SAFETY INSTRUCTIONSSAFETY INSTRUCTIONS

manual.

MUSTMUST

MUST read and be familiar with

MUSTMUST

> If compressed air is used in cleaning,

REMEMBER THAT HIGH PRESSUREREMEMBER THAT HIGH PRESSURE

REMEMBER THAT HIGH PRESSURE

REMEMBER THAT HIGH PRESSUREREMEMBER THAT HIGH PRESSURE AIR CAN BE DANGEROUS ANDAIR CAN BE DANGEROUS AND

AIR CAN BE DANGEROUS AND

AIR CAN BE DANGEROUS ANDAIR CAN BE DANGEROUS AND SHOULD NEVER BE USED AGAINSTSHOULD NEVER BE USED AGAINST

SHOULD NEVER BE USED AGAINST

SHOULD NEVER BE USED AGAINSTSHOULD NEVER BE USED AGAINST THE BODY. THE BODY.

THE BODY. It can blind, deafen, and may

THE BODY. THE BODY. even penetrate the skin. If used for cleaning equipment, the users should wear safety glasses.

ALWAYS ALWAYS

ALWAYS turn the control unit power

ALWAYS ALWAYS

off prior to cleaning or servicing equipment.

> Be

system is grounded to clean

APPLICATOR!APPLICATOR!

APPLICATOR!

APPLICATOR!APPLICATOR!

SURESURE

SURE the power is

SURESURE

ANYANY

ANY of the quipment.

ANYANY

DO NOT OPERATE A FAULTYDO NOT OPERATE A FAULTY

DO NOT OPERATE A FAULTY

DO NOT OPERATE A FAULTYDO NOT OPERATE A FAULTY

BEFORE BEFORE

BEFORE using solvent

BEFORE BEFORE

OFF OFF

OFF and the

OFF OFF

> When using cleaning solvent, standard

health and safety precautions should apply.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

NEVERNEVER

NEVER remove the fluid nozzle as-

NEVERNEVER

sembly while paint is in the applicator or paint may clog the air passages. Clogged air passages will cause poor atomization and electrical shorting. Air passages which are clogged with conductive material may lead to excessive current output levels and consequent low operating voltage and long range electrical damage. Before undertaking any atomizer assembly procedure, see “Atomizer Assembly Cleaning Procedure” in the “Maintenance” section.

> The applicator

to remove the air cap and/or fluid nozzle. Failure to do so may allow paint to enter the air passages, thereby reducing air flow and damaging the applicator barrel/cascade. Applicators may be flushed in lieu of tilting. However, they must be either flushed or tilted down!

• Clean all insulating surfaces in the system. Remove paint accumulation from the exterior of the applicator and high voltage cable with a solvent dampened cloth.

MUSTMUST

MUST be tilted front down

MUSTMUST

ROUTINE SCHEDULEROUTINE SCHEDULE

ROUTINE SCHEDULE

ROUTINE SCHEDULEROUTINE SCHEDULE

Follow these maintenance steps to extend the life of the applicator and ensure efficient operation:

Several TSeveral T

Several T

Several TSeveral T

• Turn the control unit power to OFF!

• Inspect the air cap for fluid/solvent accumulation. Clean as frequently as necessary with a soft bristled brush and a suitable solvent.

1919

imes Daily:imes Daily:

imes Daily:

imes Daily:imes Daily:

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

NEVERNEVER

NEVER soak or submerge the electrical

NEVERNEVER components of the applicator (i.e. barrel, transformer, cable). Damage and failure may occur.

Daily (at the start of each shift):Daily (at the start of each shift):

Daily (at the start of each shift):

Daily (at the start of each shift):Daily (at the start of each shift):

• Verify that ALL solvent safety containers are grounded!

• Check within 20 feet of the point of operation (of the applicator) and remove or ground loose or ungrounded objects.

ALLALL

ALL

ALLALL

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

• Inspect workholders for accumulated coating materials, removing such accumulations.

• Check that atomizer assembly is clean and undamaged.

• Straighten the applicator electrode if necessary.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> When straightening the electrode, be

careful not to distort the fluid nozzle orifice.

• Clean the fluid filter, if used.

• Turn the control unit power ON. The applicator’s red transformer light should light when triggered.

• Run a current/voltage output test.

Electrical Current Output TElectrical Current Output T

Electrical Current Output T

Electrical Current Output TElectrical Current Output T

1. Turn the fluid/solvent supply OFF.

2. Turn high voltage on at applicator.

3. Slowly approach the applicator electrode to

any grounded object and make contact.

estest

est

estest

2. Turn the fluid/solvent supply OFF.

3. Turn the atomizing air and fan air OFF.

4. Turn piston air OFF.

5. Wipe the applicator, cable, and hoses with a rag and a suitable cleaning solvent.

6. Flush the lines and allow the solvent to remain in the lines unpressured. (See “Flushing Procedures” in the “Maintenance” section of this manual.)

NOTENOTE

NOTE

NOTENOTE

> If the shut-down time is to be short, the

lines may not require flushing, depending on the type of coating material used. If the solids in the material settle slowly, the lines will not need to be flushed as soon after shut-down as with fast settling solids. The fluid/solvent being used and the length of time that the lines will be shutdown will determine the need for flushing. Metallic paint and primer will require flushing sooner than some other types of coating materials.

4. Monitor the current output reading on the

power supply meter. As applicator approaches, ground current should increase near 120 mA. Overload current should “trip”, shutting off high voltage. Overload indication should come on.

5. Release the trigger and turn the power supply

power OFF.

If the control unit does not trip, applicator until the problem has been corrected. (See the “Troubleshooting Guide” in the “Maintenance” section of this manual.)

Shut-DownShut-Down

Shut-Down

Shut-DownShut-Down (and at the end of each shift)(and at the end of each shift)

(and at the end of each shift)

(and at the end of each shift)(and at the end of each shift)

1. Turn the power supply power OFF.

AA-82-01.3

DO NOTDO NOT

DO NOT use the

DO NOTDO NOT

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> If the coating material is fast settling and

if the lines are not flushed soon enough, the applicator’s fluid passages as well as the lines may become clogged and cause excessive down-time and/or service and repair.

WeeklyWeekly

Weekly

WeeklyWeekly

• Check the entire system for damage, leaks, and paint accumulation.

• Clean the atomizer assembly.

2020

REA III 100kV Automatic Applicator - Maintenace

OMIZER ASSEMBLOMIZER ASSEMBL

OMIZER ASSEMBL

OMIZER ASSEMBLOMIZER ASSEMBL

CLEANINGCLEANING

CLEANING

CLEANINGCLEANING PROCEDURESPROCEDURES

PROCEDURES

PROCEDURESPROCEDURES

Routine Cleaning EquipmentRoutine Cleaning Equipment

Routine Cleaning Equipment

Routine Cleaning EquipmentRoutine Cleaning Equipment NeededNeeded

Needed

NeededNeeded

• An appropriate solvent

• Solvent safety container (grounded)

• Small soft bristled brush

• ITW Ransburg 19749-00 special multi-purpose wrench from the installation kit.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> To avoid damage to the fluid nozzle,

needle/electrode, the fluid pressure be released by triggering the applicator prior to removing the tip.

> The applicator

down to remove the air cap and/or fluid nozzle. Failure to do so may allow fluid/ solvent to enter the air passages, thereby reducing air flow and damaging the applicator barrel/cascade. Applicators may be flushed in lieu of removing nozzles. However, they tilted down during nozzle removal!

MUSTMUST

MUST be either flushed prior to, or

MUSTMUST

MUST MUST

MUST be tilted front

MUST MUST

MUST

MUST MUST

For efficient operation, keep the applicator’s exterior and the high voltage cable clean and free of paint accumulation and dirt. This prevents the loss of voltage to ground with a resulting reduction in electrostatic effect. Solvent accumulation at the air cap orifices reduces atomization quality and increases the potential for paint “spits”. Clean the air cap with a brush and cleaning solvent as often as needed to ensure good atomization.

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

NEVERNEVER

NEVER wrap the applicator in plastic to

NEVERNEVER keep it clean. A surface charge may build-up on the plastic surface and discharge to the nearest grounded object. Efficiency of the applicator will also be reduced and damage or failure of the applicator components may occur. PLASTIC WILL VOID THE WARRANTY.PLASTIC WILL VOID THE WARRANTY.

PLASTIC WILL VOID THE WARRANTY.

PLASTIC WILL VOID THE WARRANTY.PLASTIC WILL VOID THE WARRANTY.

Proceed as Follows:Proceed as Follows:

Proceed as Follows:

Proceed as Follows:Proceed as Follows:

1. Turn the power supply unit power OFF.

2. Release the trigger.

3. Turn the fluid/solvent flow OFF.

4. See “Service” section in the “Maintenance” section of this manual for “Disassembly Procedures”.

WRAPPING THE APPLICATOR INWRAPPING THE APPLICATOR IN

WRAPPING THE APPLICATOR IN

WRAPPING THE APPLICATOR INWRAPPING THE APPLICATOR IN

2121

> The control unit power

be off when removing the nozzles or any other service to the applicator.

> Using any tool other than the ITW Rans-

burg 19749-00 wrench to remove or reinstall the fluid nozzle may distort or damage it.

MUST MUST

MUST always

MUST MUST

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> Any damage to the applicator may

result in

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

UNSAFEUNSAFE

UNSAFE operating conditions.

UNSAFEUNSAFE

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> Metal tools and wire brushes must

NEVERNEVER

NEVER be used.

NEVERNEVER tool that is harder than the plastic parts. If a deposit cannot be removed with the solvent and a rag or the soft brush, soak the part in the solvent removed! CATOR BODY, BARREL, OR TRANS-CATOR BODY, BARREL, OR TRANS-

CATOR BODY, BARREL, OR TRANS-

CATOR BODY, BARREL, OR TRANS-CATOR BODY, BARREL, OR TRANSFORMER!FORMER!

FORMER!

FORMER!FORMER!

FLUSHINGFLUSHING

FLUSHING

FLUSHINGFLUSHING PROCEDURESPROCEDURES

PROCEDURES

PROCEDURESPROCEDURES

ONLYONLY

ONLY until the deposit can be

ONLYONLY

NEVER SOAK THE APPLI-NEVER SOAK THE APPLI-

NEVER SOAK THE APPLI-

NEVER SOAK THE APPLI-NEVER SOAK THE APPLI-

NEVERNEVER

NEVER use a cleaning

NEVERNEVER

SERVICESERVICE

SERVICE

SERVICESERVICE

All repairs should be made on a clean, flat surface. If a vise is used to hold parts during service or repair, always pad the vise jaws! During assembly, ALWAYS lubricate o-rings, chevron seals, and the threads on part Items #45, 57, 58, 43, and 49, as indicated, with a light coat of petroleum jelly. (Teflon o-rings do not need lubrication.)

DO NOTDO NOT

DO NOT clamp onto plastic parts and

DO NOTDO NOT

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

in this system!

NOT USE NOT USE

NOT USE any silicone lubrication

NOT USE NOT USE

1. Turn the control unit power OFF.

2. Turn the fluid/solvent supply OFF.

3. Turn the atomizing air supply OFF.

4. Activate dump air and flush with a suitable cleaning solvent until it is clear of fluids. Air purge the dump line.

5. De-activate dump air and activate trigger air until the applicator fluid passage is clear.

6. Disconnect the solvent supply.

7. Activate the trigger valve until it is clear of solvent. After the preceding steps are complete, the applicator is ready for color change, storage, or service.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

ALWAYS ALWAYS

ALWAYS remove the applicator from

ALWAYS ALWAYS

the work site for service or repair!

The following tools will be needed:

• Special wrench 20049-00

• Nozzle wrench 19749-00

• 3/32” Allen wrench

• Open end wrenches: 15/16”, 7/8”, 11/16”, 9/16”, 7/16”, 3/4”, 3/8”, and 1/4”

• Screwdriver (broad)

• Paper clip (or similar rigid wire)

• Lock-Tite, medium strength, P/N 7969-03

• Plastic or wood dowel rod, 5/16-inch diameter

empty without flushing first! This will cause dried solvent flaking into and clogging of the fluid lines, applicator passages, and nozzles.

AA-82-01.3

NOT NOT

NOT allow the fluid lines to stand

NOT NOT

2222

REA III 100kV Automatic Applicator - Maintenance

emove the Applicator from theemove the Applicator from the

emove the Applicator from the

emove the Applicator from theemove the Applicator from the

Work SiteWork Site

Work Site

Work SiteWork Site

1. Flush the applicator (see “Flush Procedure” in the “Maintenance” section).

W A R N I N GW A R N I N G

W A R N I N G

W A R N I N GW A R N I N G

> 2. Turn

material and solvent)

3. Detach fluid line from fitting [66].

4. Detach the air line fittings from applicator air fittings [35] and [34].

5. Detach the high voltage cable [70] from the applicator by unscrewing cable retaining nut [32] and pulling the cable straight out of resistor housing [37].

ALL ALL

ALL power, air, and fluid (coating

ALL ALL

OFFOFF

OFF at the source.

OFFOFF

1. Air Nozzle: a. Unscrew air nozzle [1] from barrel [8] and

clean or replace it.

b. Screw the cleaned or new nozzle assembly

onto barrel [8].

2. Fluid Nozzle: a. Remove air nozzle [1] from barrel [8] and

clean or replace it.

b. With the nozzle wrench on the wrench flats,

remove fluid nozzle [2].

c. Clean or replace the fluid nozzle.

d. Screw the cleaned or new fluid nozzle [2]

into barrel [8]. Secure with the nozzle wrench and release trigger air to applicator.

NOTENOTE

NOTE

NOTENOTE

NOTE

NOTENOTE

> If the high voltage cable is to be re-

placed, see “High Voltage Cable Replacement” in the “Maintenance” section.

6. Loosen set screws [28] and remove the applicator from the work site.

Nozzle and Electrode CleaningNozzle and Electrode Cleaning

Nozzle and Electrode Cleaning

Nozzle and Electrode CleaningNozzle and Electrode Cleaning or Replacementor Replacement

or Replacement

or Replacementor Replacement

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

NEVERNEVER

NEVER bend the electrode!

NEVERNEVER

NOTENOTE

NOTE

NOTENOTE

> See “Nozzle Cleaning Procedures” in

the “Maintenance” section.

> It may be necessary to loosen packing

nut [21] with the spanner wrench and retract the trigger to seat the nozzle completely.

e. Screw air nozzle [1] onto barrel [8].

NOTENOTE

NOTE

NOTENOTE

> If packing nut [21] has been loosened,

tighten it until needle shaft [7] moves in and out with firm resistance.

NOTENOTE

NOTE

NOTENOTE

> If the fluid nozzle is replaced, there is a

good chance that the needle tip assembly [3] will need to be replaced too. A worn neede tip assembly may not always seat well in a new fluid nozzle.

1919

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

Needle TNeedle T

Needle T

Needle TNeedle T (Electrode)(Electrode)

(Electrode)

(Electrode)(Electrode)

1. See “Nozzle and Electrode Cleaning or Replacment - Steps 1 and 2” to remove the air cap and fluid nozzles.

2. Insert the end of a paper clip (or similar rigid wire) through the hole at the rear of the needle shaft [7] to keep it from rotating.

3. Hold barrel [8] in a vertical position, front end up, and unscrew needle tip [3].

> The vertical position is to keep adaptor

[4] from falling out.

ip Assemblyip Assembly

ip Assembly

ip Assemblyip Assembly

NOTENOTE

NOTE

NOTENOTE

2. Disengage nuts [58] and [57] from valve rod extension [23].

3. Loosen barrel extension [11] with the spanner wrench.

4. Disengage fittings [10] and [9] and release fluid tube [69].

5. Pull barrel [8] and body [26]

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> The barrel and body

straight apart to avoid damage to the resistor housing [37].

NOTENOTE

NOTE

NOTENOTE

STRAIGHTSTRAIGHT

STRAIGHT apart.

STRAIGHTSTRAIGHT

MUSTMUST

MUST be pulled

MUSTMUST

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

SURESURE

> Be

facing the right direction when the applicator is reassembled or the applicator will malfunction!

Barrel RemovalBarrel Removal

Barrel Removal

Barrel RemovalBarrel Removal

SURE that adaptor [4] is in place and

SURESURE

NOTENOTE

NOTE

NOTENOTE

> In normal operation and service, the

barrel extension need never be removed from the barrel. It should be treated as a permanent part of the barrel. If it should be damaged and replacement becomes necessary, remove the barrel from it the same as it is removed from the body assembly AFTERAFTER

AFTER the internal parts have been re-

AFTERAFTER moved (see “Barrel Disassembly”).

> Gasket [13] should be kept with the

body assembly if it is not to be replaced.

NOTENOTE

NOTE

NOTENOTE

> There is no need to remove retaining

ring [12] or barrel nut [11] from barrel [8] unless they are damaged. If they are to be removed, lift one end of ring [12] out of its groove and spiral it off of the end of the barrel. Then nut [11] can be removed. To replace them on the barrel, slide nut [11] onto the barrel, place ring [12] against the back of the barrel, lift one end of it onto the barrel and spiral it on and into its groove.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> Spreading the retaining ring may break

it!

1. Remove piston housing [61], spring [60], and spring [59].

AA-82-01.3

6. Part Items #57, 58, 59, and 60 may be stored during barrel service by replacing them in the piston housing and reattaching it to the body.

2424

REA III 100kV Automatic Applicator - Maintenance

Barrel DisassemblyBarrel Disassembly

Barrel Disassembly

Barrel DisassemblyBarrel Disassembly

1. Remove air nozzle [1] from barrel [8].

NOTENOTE

NOTE

NOTENOTE

2. Remove fluid nozzle [2] from the front barrel with the nozzle wrench.

3. Remove valve rod extension [23] and adjusting nut [22] from needle valve rod [7].

4. Remove packing nut [21] from the barrel chamber with the spanner wrench.

NOTENOTE

NOTE

NOTENOTE

> The six (6) spring washers [20] will come

out of the chamber at this point.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

DODO

ers! The applicator MUST have six (6), correctly positioned, spring washers in order to function properly.

NOTNOT

NOT lose any of the spring wash-

DODO

NOTNOT

> If the needle valve assembly does not

pull out of the chamber easily, hold the barrel in a vertical position, front end up, and press down against a hard surface until parts [3] through [7] can be pulled from the front of the chamber. Then, insert the flat end of a smooth 5/16-inch plastic or wood dowel rod into the front barrel chamber and press the packing tube [15] and parts [17], [18], and [19] from the chamber.

6. Slide parts [20], [18], [17], and [15] off of shaft

[7].

NOTENOTE

NOTE

NOTENOTE

> If parts [19] and [17] do not separate

easily, wedge a knife blade between them and pry them apart.

5. With a firm pull, remove the needle valve assembly [3] through [19] from the rear of the barrel chamber.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> During this operation, be

that the interior surface of the chamber is NOTNOT

NOT damaged (marred or scrateched).

NOTNOT

CAREFULCAREFUL

CAREFUL

CAREFULCAREFUL

> This chamber is a seal area and the

barrel will have to be replaced if it is damaged.

7. Unscrew needle [3] from shaft [7] and slide

parts [4], [5], and [6] off of the shaft.

Barrel AssemblyBarrel Assembly

Barrel Assembly

Barrel AssemblyBarrel Assembly

• Clean all parts with a suitable, clean solvent.

• If the electrode is bent, straighten it FULLFULL

FULL

Y by hand.

FULLFULL

• Check all parts for damage or wear. Replace those that are damaged or worn with new parts.

• Replace chevron seals [5], o-rings [16], and u-cup [18] with new parts.

CARE-CARE-

CARE-

CARE-CARE-

2525

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> To avoid damage to the chevron seals,

the needle shaft assembly stalled from the front of the barrel.

1. Place female chevron adaptor [6] onto the front of shaft [7] with the concave side toward the front.

2. Place the four (4) new chevron seals on shaft [7], concave sides forward, by carefully rotating them.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

DODO

straight onto the shaft. The shaft threads may damage the chevron bore and cause the applicator to malfunction.

NOTNOT

NOT push the chevron seals

DODO

NOTNOT

MUSTMUST

MUST be in-

MUSTMUST

5. Insert assembly [3] through [7] into the front barrel chamber.

6. Insert fluid nozzle [2] into the chamber and secure it firmly with the nozzle wrench.

7. Screw air nozzle [1] onto barrel [8] to protect needle [3] during the balance of the assembly procedures.

8. Place packing tube [25] over the end of shaft [7] through the rear barrel chamber.

9. Place the new u-cup [18] into rear needle seat retainer [17] with the open side out.

NOTENOTE

NOTE

NOTENOTE

> Seat the u-cup into the retainer very

carefully with the eraser end of a pencil or a wood or plastic dowel rod.

3. Place male chevron adaptor [4] onto shaft [7] with the convex end rearward.

NOTENOTE

NOTE

NOTENOTE

> Part Items [4], [5], and [6] should seat

together to form an unbroken seal.

4. Screw needle tip [3] onto shaft [7] hand tight.

NOTENOTE

NOTE

NOTENOTE

> Apply a light coating of petroleum jelly to

the chevron seals.

10. Place the new o-ring [16] onto retainer [17].

11. Place retainer [17] over shaft [7] with the open end toward the rear.

12. Place spacer [19] over shaft [7] flanged end first. Seat parts [15], [17], and [19] into the chamber carefully with the flat end of the tubular spanner tool.

13. Place the six (6) spring washers [20] onto shaft [7] with the first, third, and fifth ones cupped side rearward and the second, fourth, and sixth ones cupped side forward.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> There

alternately faced, or the applicator will malfunction.

MUSTMUST

MUST be six (6) spring washers,

MUSTMUST

AA-82-01.3

2626

REA III 100kV Automatic Applicator - Maintenance

14. Screw packing nut [21] into the chamber and secure it with the spanner wrench.

NOTENOTE

NOTE

NOTENOTE

> The packing nut should be tight enough

that shaft [7] slides in and out with firm resistance.

15. Screw trigger adjustment nut [33] onto shaft [7] with the flanged end toward the rear.

16. Screw valve rod extension [23] onto shaft [7] with the flanged end toward the front.

NOTENOTE

NOTE

NOTENOTE

> The hexagonal flanges of [22] and [23]

should face each other.

17. To adjust [22] and [23]:

NOTENOTE

NOTE

NOTENOTE

> To prevent shaft [7] from rotating, secure

it with a wire through the hole at the rear.

Figure 2: Barrel AssemblyFigure 2: Barrel Assembly

Figure 2: Barrel Assembly

Figure 2: Barrel AssemblyFigure 2: Barrel Assembly

a. Push shaft [7] fully forward.

NOTENOTE

NOTE

NOTENOTE

> Fluid nozzle [2] must be firmly in place

(see Step 6).

b. Measure 21/32-inch (16.6mm) from the

rear face of packing nut [21] to the rear face of hexagonal flange of the valve rod extension [23].

2727

c. Secure the nut and rod extension together

at that dimension by rotating nut [22] rearward until the two will not turn on the shaft.

d. Tighten the two by holding rod extension

[23] with a 3/8-inch wrench and turning nut [22] against it with another 3/8-inch wrench.

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

Barrel to Body AssemblyBarrel to Body Assembly

Barrel to Body Assembly

Barrel to Body AssemblyBarrel to Body Assembly

1. Remove piston housing [61] from body [26].

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

DODO

housing.

2. Place gasket [13] into the front body [26] chamber.

> Secure the new gasket in place by

splitting it at the top and pressing it into the chamber. The top is the broadest of the two large hole margins.

NOTNOT

NOT lose parts stored in piston

DODO

NOTNOT

NOTENOTE

NOTE

NOTENOTE

5. Secure the barrel assembly with nut [11] and tighten.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> Nut [11] should be secured hand tight

only. (13.5 Nm) torque.

6. With the needle valve and piston shaft [52] fully forward, secure lock nuts [57] and [58] onto extension [23]. Allow 1/16-inch gap between nut [57] and shaft [52].

NEVERNEVER

NEVER apply more than 10 lbs•ft

NEVERNEVER

NOTENOTE

NOTE

NOTENOTE

> Projection on nut [58]

rear of the applicator.

MUSTMUST

MUST face the

MUSTMUST

3. Place new o-ring [38] on resistor housing [37].

4. Insert resistor housing [37] into the upper body chamber and slide the barrel assembly straight into the front body chamber over housing [37].

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> Be

is in place. If it is not, the applicator will eventually malfunction.

SURE SURE

SURE that conductive sponge [36]

SURE SURE

NOTENOTE

NOTE

NOTENOTE

> The needle shaft [7] should engage

valve rod extension [23].

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> The fluid valve shaft travel

adjusted so that the air valve is always triggered BEFOREBEFORE

BEFORE the fluid, readjust nuts [57] and

BEFOREBEFORE [58] in relation to shaft [52].

7. Engage fluid tube [69] to barrel [8] with fittings [9] and [10].

FIRSTFIRST

FIRST. If the air does not turn on

FIRSTFIRST

MUST MUST

MUST be

MUST MUST

AA-82-01.3

2828

REA III 100kV Automatic Applicator - Maintenance

Resistor Assembly ReplacementResistor Assembly Replacement

Resistor Assembly Replacement

Resistor Assembly ReplacementResistor Assembly Replacement

1. Remove the high voltage cable (see “High Voltage Cable Replacement” in this section).

2. Remove the barrel assembly (see “Barrel Removal” in this section).

3. Remove resistor housing tube [31].

4. Remove screw [29] and [30].

5. Remove mounting support [27] and resistor housing [37] from the body chamber.

6. Place the new resistor assembly [37] into the body chamber.

7. Place new o-rings [38] and [39] on the new resistor assembly [37].

place, the applicator will malfunction!

11. Replace the barrel assembly (see “”Barrel to

Body Assembly” in this section).

12.Install high voltage cable (see “High Voltage

Cable Replacement” in this section).

alve Housing (Body) Servicealve Housing (Body) Service

alve Housing (Body) Service

alve Housing (Body) Servicealve Housing (Body) Service

When service is performed on any of the body elements, it is best to remove the barrel assembly and resistor assembly (see “Resistor Assembly Replacement” in this section) in order to avoid damage to the nozzle, electrode or any of the plastic parts.

> If the conductive sponges are not in

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

SURESURE

> Be

SURE that conductive sponge [40] is

SURESURE

in place in the resistor housing chamber.

8. Place mounting support [27] in position on body [26] and secure with screws [29] and [30].

9. Place resistor housing tube [31] over the end of resistor housing [37] and screw it into the body [8].

10. Install a new conductive sponge [36] in the barrel chamber.

NOTENOTE

NOTE

NOTENOTE

> The old sponge MUST be removed! Use

a long wire with one end bent into a hook.

After disassembly of any body element:

• Clean all parts with a suitable, clean solvent.

• Check all parts for damage or wear. Replace

those that are damaged or worn with new parts.

• Replace all seals and o-rings.

Fluid VFluid V

Fluid V

Fluid VFluid V

1. Disassembly: a. Rotate piston housing [61] to remove it from

b. Remove springs [59] and [60].

c. Turn nut [58] away from nut [57] using

d. Remove nuts [57] and [58] from shaft [23].

alve (Talve (T

alve (T

alve (Talve (T

the valve chamber.

appropriate wrenches.

rigger)rigger)

rigger)

rigger)rigger)

2929

e. Remove the barrel assembly (see “Barrel

Removal” in this section).

f. Remove the resistor assembly (see

“Resistor Assembly Replacement” in this section).

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

g. Remove valve seal retaining nut [24] and

o-ring [25] from the front of the valve chamber using a 3/8-inch nut driver.

h. With a flat tipped wood or plastic dowel rod

inserted into the front of the valve chamber, push piston assembly [52] through [56] out of the rear of the valve chamber.

i. Secure piston shaft [52] in a 3/8-inch

wrench (on the wrench flats) remove nut [56] with a 9/16-inch socket.

j. Slide piston assembly [53], [54], and [55],

from the shaft [52] and disassembly components by hand.

k. Remove bushing assembly [50], [48], [49],

and [51] from the valve chamber with a 20049-00 wrench.

2. Assembly:

NOTENOTE

NOTE

NOTENOTE

> Be

[50].

e. Replace the resistor assembly (see

f. Replace the barrel assembly (see “Barrel

g. Place nut [57] on shaft [23] 1/16-inch from

SURESURE

SURE that o-ring [51] is in bushing

SURESURE

“Resistor Assembly Replacement” in this section).

to Body Assembly” in this section).

piston shaft [52].

NOTENOTE

NOTE

NOTENOTE

> See “Barrel Assembly - Step 17” and

“Barrel to Body Assembly - Step 6” for shaft [23] adjustment.

NOTENOTE

NOTE

NOTENOTE

> Replace all o-rings. Replace packing

cup [54] if it is worn.

a. Secure retaining nut [24] and o-ring [25] in

the front of the valve chamber using a 3/8inch nut driver.

b. Secure bushing assembly [50], [48], [49],

and [51],in the valve chamber using a 20049-00 wrench.

c. Secure shaft [52] in wrench (on 3/8-inch

wrench flats) and assembly washers [53], cup [54], and piston [55] on the rear with nut [56] using a 9/16-inch socket.

d. Place the piston assembly [52] through [56],

into the valve chamber through bushing [50] and press into place.

h. Place nut [58] on shaft [23] and secure

against nut [57] using appropriate wrenches.

i. Place springs [59] and [60] against piston

[55] and nut [58] and secure in place by screwing piston housing [61] into the rear of the valve housing.

Fan Air Control VFan Air Control V

Fan Air Control V

Fan Air Control VFan Air Control V

1. Disassembly:

a. Turn control knob [42] to the open position

(fully extended) to accomodate Step b.

b. With a 9/16-inch wrench, unscrew retaining

nut [43] and remove the entire valve assembly.

c. Return the control knob to the closed

position.

alvealve

alve

alvealve

AA-82-01.3

3030

REA III 100kV Automatic Applicator - Maintenance

d. Secure control knob [42] in a bench vise

and, with a 1/4-inch wrench on the wrench flats, break valve needle [47] free and remove it from the assembly.

NOTENOTE

NOTE

NOTENOTE

> The valve needle is secured with Lock-

Tite.

e. Remove spring [46].

f. Unscrew control knob [42] from retaining

nut [43].

g. With a 1/4-inch rod or other small diameter

tool, force washers [45] and o-ring [44] out of the retaining nut.

f. With a 1/4-inch wrench on the wrench

flats, screw valve needle [47] onto the control knob shaft. Remove the assembly from the vise.

g. Unscrew control knob [42] to its “open”

position.

h. Screw retaining nut [43] into the valve

chamber with a 9/16-inch wrench.

NOTENOTE

NOTE

NOTENOTE

> Apply a light coating of petroleum jelly to

the retaining nut threads.

i. Screw the control knob down to the

“closed” position.

2. Assembly: a. Screw control knob [42] completely into

retaining nut [43].

NOTENOTE

NOTE

NOTENOTE

> Apply a light coating of petroleum jelly

to the control knob threads.

b. Place one (1) washer [45], o-ring [44], and

the other washer [45] onto the shaft of control knob [42].

c. Use the flat end of the tubular spanner tool

to seat [45] and [44] in the bore of retaining nut [43].

d. Place spring [46] onto the shaft of control

knob [42].

e. Secure control knob [42] in the bench vise

and put a small amount of medium strength Lock-Tite on the shaft threads.

o Return the Applicator to theo Return the Applicator to the

o Return the Applicator to the

o Return the Applicator to theo Return the Applicator to the

Work SiteWork Site

Work Site

Work SiteWork Site

1. Attach the air line fittings to applicator air fittings [35] and [34].

2. Attach fluid hose to fluid tube fitting [66].

3. Attach and secure the high voltage cable.

4. Turn the power, air, and fluid ON at the source and return the applicator to service.

High VHigh V

High V

High VHigh V ReplacementReplacement

Replacement

ReplacementReplacement

1. Disassembly: a. Unscrew cable retaining nut [32].

b. Pull the high voltage cable straight out of

c. With a thin blade, lift one end of the cable

d. Remove retainer [32] from the cable.

oltage Cableoltage Cable

oltage Cable

oltage Cableoltage Cable

the resistor housing.

retaining ring out of its groove and spiral it off of the end of the cable.

3131

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

2. Assembly: a. Remove the cable retaining ring from the

new cable as in the “Disassembly Procedure”.

b. Place retainer [32] over the end of the new

cable.

c. Place the cable retainer ring over the end

of the cable and with a blade, lift one end of it into its groove and spiral it into place.

d. Insert the high voltage cable into the

resistor housing and secure with retainer [32].

NOTESNOTES

NOTES

NOTESNOTES

AA-82-01.3

3232

REA III 100kV Automatic Applicator - Maintenance

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE

Possible CausesPossible Causes

Possible Causes

General ProblemGeneral Problem

General Problem

General ProblemGeneral Problem

DEFECTIVE SPRAY PATTERN:DEFECTIVE SPRAY PATTERN:

DEFECTIVE SPRAY PATTERN:

DEFECTIVE SPRAY PATTERN:DEFECTIVE SPRAY PATTERN:

Pattern Will NotPattern Will Not

Pattern Will Not

Pattern Will NotPattern Will Not ShapeShape

Shape

ShapeShape

Possible CausesPossible Causes

1. Clogged or faulty fan valve

2. Air passages in applicator or air feed lines clogged

Corrective ActionCorrective Action

Corrective Action

Corrective ActionCorrective Action

1. Clean, replace, or repair fan valve.

2. Blow out air passages and air feed lines.

3. Worn, faulty, or clogged air nozzle

Pattern Heavy AtPattern Heavy At

Pattern Heavy At

Pattern Heavy AtPattern Heavy At One EndOne End

One End

One EndOne End

DEFICIENT DELIVERY:DEFICIENT DELIVERY:

DEFICIENT DELIVERY:

DEFICIENT DELIVERY:DEFICIENT DELIVERY:

AirAir

Air

AirAir

FluidFluid

Fluid

FluidFluid

LEAKAGE:LEAKAGE:

LEAKAGE:

LEAKAGE:LEAKAGE:

1. Clogged or faulty air nozzle

2. Clogged or faulty fluid nozzle

1. Air passages in applicator or air feed lines clogged

2. Deficient factory air

1. Clogged or faulty fluid nozzle

2. Clogged fluid passages in applicator or fluid feed lines

3. Insufficient fluid valve needle travel

3. Clean or replace air nozzle.

1. Clean or replace air nozzle.

2. Clean or replace fluid nozzle.

1. Blow out air passages and air feed lines.

2. Increase air.

1. Flush or replace fluid nozzle.

2. Flush fluid passages and fluid feed lines.

3. Adjust fluid valve needle.

AirAir

Air

AirAir

Fluid: Any atFluid: Any at

Fluid: Any at

Fluid: Any atFluid: Any at Rear of NeedleRear of Needle

Rear of Needle

Rear of NeedleRear of Needle Valve ShaftValve Shaft

Valve Shaft

Valve ShaftValve Shaft

Fluid: Slight atFluid: Slight at

Fluid: Slight at

Fluid: Slight atFluid: Slight at Nozzle WhenNozzle When

Nozzle When

Nozzle WhenNozzle When Trigger isTrigger is

Trigger is

Trigger isTrigger is ReleasedReleased

Released

ReleasedReleased

3333

1. Defective valve or valve spring

1. Packing and/or seals faulty

1. Fluid nozzle not secure

2. Air valve closing before needle valve

1. Replace valve or valve spring.

1. Replace packing and/or seals.

1. Tighten fluid nozzle.

2. Adjust needle valve travel.

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

TROUBLESHOOTING GUIDE (Cont.)TROUBLESHOOTING GUIDE (Cont.)

TROUBLESHOOTING GUIDE (Cont.)

TROUBLESHOOTING GUIDE (Cont.)TROUBLESHOOTING GUIDE (Cont.)

Possible CausesPossible Causes

General ProblemGeneral Problem

General Problem

General ProblemGeneral Problem

Possible Causes

Possible CausesPossible Causes

Corrective ActionCorrective Action

Corrective Action

Corrective ActionCorrective Action

LEAKAGE (CLEAKAGE (C

LEAKAGE (C

LEAKAGE (CLEAKAGE (C

Fluid: ConstantFluid: Constant

Fluid: Constant

Fluid: ConstantFluid: Constant at Nozzleat Nozzle

at Nozzle

at Nozzleat Nozzle

ELECTRICAL:ELECTRICAL:

ELECTRICAL:

ELECTRICAL:ELECTRICAL:

Wrap-backWrap-back

Wrap-back

Wrap-backWrap-back

Improper or NoImproper or No

Improper or No

Improper or NoImproper or No High Voltage FlowHigh Voltage Flow

High Voltage Flow

High Voltage FlowHigh Voltage Flow

ont.)ont.)

ont.)

ont.)ont.)

1. Worn or damaged needle valve seat

2. Worn or damaged needle valve

3. Fluid nozzle not secure

4. Fluid valve needle does not close when trigger is released

1. Improper grounding

2. Improper spray technique

3. Improper booth exhaust

1. Dirty of faulty connections

1. Replace fluid nozzle.

2. Replace needle valve.

3. Tighten fluid nozzle.

4. Adjust fluid valve needle travel.

1. Trace and correct.

2. Trace and correct. *

3. Trace and correct.

1. Clean and check for proper contact at the conductive plugs and power supply.

2. Missing or faulty conductive plugs at either end of the resistor housing

3. Improper or no ground

4. Faulty resistor

5. Faulty high voltage cable

6. Faulty power supply

7. Is the power turned ON?

* See REA Applicator Spray Techniques.

2. Replace plugs.

3. Trace and correct.

4. Replace resistor.

5. Replace high voltage cable.

6. See the Power Supply Service Manual.

7. Turn power ON.

AA-82-01.3

3434

REA III 100kV Automatic Applicator - Maintenance

OROR

IS IS

IS YY

POWERPOWER

POWER

SUPPLSUPPL

SUPPL

DEFECTIVEDEFECTIVE

DEFECTIVE

HIGHHIGH

HIGH

In excess ofIn excess of

In excess of

150 microampere150 microampere

150 microampere

DEMAND TESTS DEMAND TESTS

DEMAND TESTS

OR TT

APPLICAAPPLICA

APPLICA

130-150130-150

130-150

NORMALNORMAL

NORMAL

microamperemicroampere

microampere

TESTTEST

TEST

USINGUSING

USING

SCI TESTSCI TEST

SCI TEST

RESISTORRESISTOR

RESISTOR

ISIS

BADBAD

BAD

RESISTORRESISTOR

RESISTOR

DEFECTIVEDEFECTIVE

DEFECTIVE

applicator)applicator)

applicator)

(no paint in(no paint in

(no paint in

TIONTION

TION

OOOO

ANCEANCE

ANCE

RESISTRESIST

RESIST

NORMALNORMAL

NORMAL

OO T T

T T

AINTAINT

AINT

AINTAINT

AINT

OF POF P

OF P

TOO LOW:TOO LOW:

TOO LOW:

CONDUCTIVECONDUCTIVE

CONDUCTIVE

FORMULAFORMULA

FORMULA

applicator)applicator)

applicator)

(no paint in(no paint in

(no paint in

0-50 microampere0-50 microampere

0-50 microampere

REPEAREPEA

REPEA

DEMANDDEMAND

DEMAND

CURRENTCURRENT

CURRENT

OROR

OR TT

OR HVOR HV

OR HV

APPLICAAPPLICA

APPLICA

HIGHHIGH

HIGH

TESTTEST

TEST

CABLECABLE

CABLE

DEFECTIVEDEFECTIVE

DEFECTIVE

In excess ofIn excess of

In excess of

50 microampere50 microampere

50 microampere

See the Power Supply ManualSee the Power Supply Manual

for power supply test procedures.for power supply test procedures.

See the Power Supply Manual

for power supply test procedures.

OROR

BEFOREBEFORE

BEFORE

SHORT INSHORT IN

SHORT IN

APPLICAAPPLICA

APPLICA

RESISTOR: HVRESISTOR: HV

RESISTOR: HV

CABLE SHORTED,CABLE SHORTED,

CABLE SHORTED,

HIGHHIGH

HIGH

in excess ofin excess of

in excess of

150 microampere150 microampere

TS OF SCI AND CURRENTTS OF SCI AND CURRENT

TS OF SCI AND CURRENT

150 microampere

OR OROR OR

OR OR TT

ETC.ETC.

ETC.

APPLICAAPPLICA

APPLICA

TESTTEST

TEST

DEMANDDEMAND

DEMAND

CURRENTCURRENT

CURRENT

RESISTORRESISTOR

RESISTOR

DEFECTIVEDEFECTIVE

DEFECTIVE

POWER SUPPLPOWER SUPPL

POWER SUPPL

NORMAL READINGNORMAL READING

NORMAL READING

0-50 microampere (no paint in applicator)0-50 microampere (no paint in applicator)

0-100 microampere (paint in applicator)0-100 microampere (paint in applicator)

0-50 microampere (no paint in applicator)

0-100 microampere (paint in applicator)

OR &OR &

OR & TT

SYSTEM:SYSTEM:

SYSTEM:

ELECTRICALELECTRICAL

ELECTRICAL

APPLICAAPPLICA

APPLICA

POWER SUPPLPOWER SUPPL

POWER SUPPL

0-50 microampere0-50 microampere

0-50 microampere

(no paint in appli- (no paint in appli-

cator) cator)

(no paint in appli-

cator)

NORMAL READINGNORMAL READING

NORMAL READING

IS “OK”IS “OK”

IS “OK”

FLUSH SYSTEMFLUSH SYSTEM

FLUSH SYSTEM

HIGHHIGH

HIGH

applicatorapplicator

applicator

In excess ofIn excess of

In excess of

0-100 microampere 0-100 microampere

(paint in applicator) (paint in applicator)

0-100 microampere

(paint in applicator)

TESTTEST

TEST

DEMANDDEMAND

DEMAND

CURRENTCURRENT

CURRENT

100 microampere in100 microampere in

100 microampere in

IS DEFECTIVEIS DEFECTIVE

IS DEFECTIVE

POWER SUPPLPOWER SUPPL

POWER SUPPL

LOWLOW

LOW

Under 130 Under 130

Under 130

microampere microampere

microampere

TESTTEST

TEST

USINGUSING

USING

SCI TESTSCI TEST

SCI TEST

OR ISOR IS

OR IS TT

DEFECTIVE:DEFECTIVE:

DEFECTIVE:

BAD RESISTORBAD RESISTOR

BAD RESISTOR

APPLICAAPPLICA

APPLICA

NORMALNORMAL

NORMAL

RESISTORRESISTOR

RESISTOR

130-150 microampere130-150 microampere

130-150 microampere

3535

TING RESULTING RESUL

TING RESUL

ALUAALUA

ALUA EVEV

EVEV

HIGHHIGH

HIGH

in excess ofin excess of

in excess of

150 microampere150 microampere

150 microampere

130-150130-150

130-150

NORMALNORMAL

NORMAL

microamperemicroampere

microampere

SHORTSHORT

SHORT

CIRCUITCIRCUIT

CIRCUIT

CURRENTCURRENT

CURRENT

(SCI)(SCI)

(SCI)

TESTTEST

TEST

LOWLOW

LOW

Under 130Under 130

Under 130

microamperemicroampere

microampere

AA-82-01.3

REA III 100kV Automatic Applicator - Maintenance

NOTESNOTES

NOTES

NOTESNOTES

AA-82-01.3

3636

REA III 100kV Automatic Applicator - Parts Identification

ARAR

TS IDENTIFICATS IDENTIFICA

TS IDENTIFICA

TS IDENTIFICATS IDENTIFICA

TIONTION

TION

TIONTION

3737

Figure 3a: 70393 REA III 100kV Automatic Applicator Exploded ViewFigure 3a: 70393 REA III 100kV Automatic Applicator Exploded View

Figure 3a: 70393 REA III 100kV Automatic Applicator Exploded View

Figure 3a: 70393 REA III 100kV Automatic Applicator Exploded ViewFigure 3a: 70393 REA III 100kV Automatic Applicator Exploded View

AA-82-01.3

REA III 100kV Automatic Applicator - Parts Identification

AA-82-01.3

Figure 3b: 70393 REA III 100kV Automatic Applicator Exploded ViewFigure 3b: 70393 REA III 100kV Automatic Applicator Exploded View

Figure 3b: 70393 REA III 100kV Automatic Applicator Exploded View

Figure 3b: 70393 REA III 100kV Automatic Applicator Exploded ViewFigure 3b: 70393 REA III 100kV Automatic Applicator Exploded View

3838

REA III 100kV Automatic Applicator - Parts Identification

70393 REA70393 REA

70393 REA

70393 REA70393 REA SOLSOL

VENTBORNE SYSTEMS - PVENTBORNE SYSTEMS - P

SOL

VENTBORNE SYSTEMS - P

SOLSOL

VENTBORNE SYSTEMS - PVENTBORNE SYSTEMS - P

Item #Item #

Item #

Item #Item #

3 Electrode Assembly 70430-00 4 ---- --- 5 Seal Assembly, Cartridge, Non-Adjustable, REA 78626-00 6 ---- --- 7 Shaft Assembly, 2-Piece Needle, REA 78627-06 8 Barrel, REA III 75037-00 8A Reducer, Pressure, Air Spray, Black 74963-02 8B Reducer, Pressure, HVLP, White 74963-03 9 Ferrule 18844-00 10 Connector, Fluid Tube 18843-00 11 Nut, Retainer, Barrel (2 Required) LSMM0002 12 Ring, Retaining, Barrel (2 Required) 18835-00 13 Gasket, Barrel (2 Required) 18872-00 14 Extension, Barrel 70431-00 15 Tube, Packing Adjustment 18842-03 16 O-Ring, Solvent Resistant 7554-08 17 Retainer, Needle Seal, Rear 78629-00 18 Seal, Lip, Spring Loaded 10051-05 19 Spacer, Seal 78630-00 20 ---- ---21 Nut, Packing 78631-00 22 Nut, Locking, Trigger Adjustment 78632-00 23 Rod Extension, Valve, Fluid 78786-01 24 Nut, Retaining, Valve Seal 20053-00 25 O-Ring, Solvent Proof 13076-10 26

27 Support, Mounting 20062-00 28 Screw, Set, Square Head (2 Required) 8666-20C 29 Screw, Cap, Socket Head (4 Required) 8212-20C 30 Screw, Cap, Socket Head 8212-16C 31 Support, Tube, Resistor Housing 20063-00 32 Nut, Retaining, Cable 70439-00

III AUT III AUT

III AUT

III AUT III AUT

DescriptionDescription

Description

DescriptionDescription

REA III Delta Automatic (Air Spray) Complete AssemblyREA III Delta Automatic (Air Spray) Complete Assembly

REA III Delta Automatic (Air Spray) Complete Assembly

REA III Delta Automatic (Air Spray) Complete AssemblyREA III Delta Automatic (Air Spray) Complete Assembly (Solventborne Systems Only): 70393S-BBCC1 REA III Delta Automatic (HVLP) Complete AssemblyREA III Delta Automatic (HVLP) Complete Assembly

REA III Delta Automatic (HVLP) Complete Assembly

REA III Delta Automatic (HVLP) Complete AssemblyREA III Delta Automatic (HVLP) Complete Assembly (Solventborne Systems Only): 70393L-BBCC1 Retaining Ring:Retaining Ring:

Retaining Ring:

Retaining Ring:Retaining Ring: Swirl 4903-00 HVLP, Air Spray, and Round 73569-00 Air Cap:Air Cap:

Air Cap:

Air Cap:Air Cap: Flat Pattern, HVLP 75601-00 Flat Pattern, Air Spray 4904-65R Round Pattern, Swirl 70899-00 Round Pattern, Round LREA0002-00 Fluid Nozzle:Fluid Nozzle:

Fluid Nozzle:

Fluid Nozzle:Fluid Nozzle: Flat Pattern, HVLP 75600-01 Flat Pattern, Air Spray 4907-45 Round Pattern, Swirl 70898-00 Round Pattern, Round LREA0003-00

Piston & Valve Body ("CC" Designation):Piston & Valve Body ("CC" Designation):

Piston & Valve Body ("CC" Designation):

Piston & Valve Body ("CC" Designation):Piston & Valve Body ("CC" Designation): For -10 Bleed Applicators with Manual Fan Air Control 20947-02 For -15 Bleed Applicators with Remote Fan Air Control 20947-02 For -20 Non-Bleed Applicators with Manual Fan Air Control 20947-01 For -25 Non-Bleed Applicators with Remote Fan Air Control 20947-01

OMAOMA

OMA

OMAOMA

TIC APPLICATIC APPLICA

TIC APPLICA

TIC APPLICATIC APPLICA

ARAR

TS LISTTS LIST

TS LIST

ARAR

TS LISTTS LIST

OR/OR/

OR/

OR/OR/

(Figures 3a and 3b) (Figures 3a and 3b)

(Figures 3a and 3b)

(Figures 3a and 3b) (Figures 3a and 3b)

Part #Part #

Part #

Part #Part #

3939

AA-82-01.3

REA III 100kV Automatic Applicator - Parts Identification

70393 REA70393 REA

70393 REA

70393 REA70393 REA SYSTEMS - PSYSTEMS - P

SYSTEMS - P

SYSTEMS - PSYSTEMS - P

Item #Item #

Item #

Item #Item #

33 Bracket, Fluid Hose 20938-00

34 Fitting, Elbow, 1/4” NPT x 3/8” Tube Atomization Air SSP-6440 35 Fitting, Elbow, 1/8” NPT x 1/4” Tube Trigger Air SSP-6427 36 Plug, Conductive Foam 14061-05 37 Housing, Resistor 70436-00 38 O-Ring, Solvent Resistant 7554-11 39 O-Ring, Solvent Resistant 7554-10 40 Plug, Conductive Foam 14061-08 41

42 Knob, Control 77018-00 43 Nut, Retaining, Fan Valve 77019-00 43A O-Ring, Solvent Resistant 72209-05 44 O-Ring, Solvent Proof 13076-08 45 Washer (2 Required) 18833-00 46 Spring, Compression 18829-00 47 Needle, Air Spray 18852-00

48 O-Ring, Solvent Proof 13076-13 49 O-Ring, Solvent Resistant 7554-33 50 Bushing, Air Valve 20054-00 51 O-Ring, Solvent Resistant 7554-28 52 Shaft, Piston & Valve 20055-00 53 Washer, Piston 20057-00 54 U-Cup, Packing, Teflon 7723-06 55 Piston 20056-00 56 Nut, Lock, Hexagon, Piston 7733-44 57 Nut, Lock, Hexagon, Air Valve 7733-07 58 Nut, Adjustment, Air Valve 20942-00 59 Spring, Compression, Piston 9334-00 60 Spring, Compression, Fluid Valve 17615-00 61 Housing, Piston 20943-00 62 Nut, Knurled Jam 20945-00 63 Screw, Adjustment 20944-00 64 Knob, Knurled 20946-00 65 Set Screw 9697-08C 66 Fitting, Fluid Tube 20993-00 67 Nut, Hexagon Jam 10553-05 68 Nut and Ferrule 3587-02 69 Tube, Fluid 20939-21 70 Cable Assembly, High Voltage LREA4003-XX 71

72 Fitting, Elbow, 3/8” NPT X 3/8” Tube 41-FTP-1007 73 Body, Fitting 74656-00 74 O-Ring, Solvent Proof 72375-02

III AUT III AUT

III AUT

III AUT III AUT

ARAR

DescriptionDescription

Description

DescriptionDescription

Screw, Cap, Socket Head (2 Required) 8212-16F Washer, Lock (2 Required) 7734-04

Valve Assembly, Fan Control: Valve Assembly, Fan Control:

Valve Assembly, Fan Control: (Contains Items 42 thru 47)

Valve Assembly, Fan Control: Valve Assembly, Fan Control: Air Spray 18851-00 HVLP 75133-00

Needle, HVLP 75132-00

Coiled Fluid Tube:Coiled Fluid Tube:

Coiled Fluid Tube:

Coiled Fluid Tube:Coiled Fluid Tube: .093" ID 75228-21 .250" ID 75228-22 .125" ID 75228-23 Remote Fan Air Valve: Remote Fan Air Valve:

Remote Fan Air Valve: (Contains Items 72 thru 74) (Not Shown)

Remote Fan Air Valve: Remote Fan Air Valve:

OMAOMA

OMA

OMAOMA

TS LISTTS LIST

TS LIST

TS LISTTS LIST

TIC APPLICATIC APPLICA

TIC APPLICA

TIC APPLICATIC APPLICA

(Cont.) (Figures 3a and 3b) (Cont.) (Figures 3a and 3b)

(Cont.) (Figures 3a and 3b)

(Cont.) (Figures 3a and 3b) (Cont.) (Figures 3a and 3b)

OR/SOLOR/SOL

OR/SOL

OR/SOLOR/SOL

VENTBORNEVENTBORNE

VENTBORNE

VENTBORNEVENTBORNE

Part #Part #

Part #

Part #Part #

AA-82-01.3

4040

REA III 100 kV Automatic Applicator - Parts Identification

70393 REA70393 REA

70393 REA

70393 REA70393 REA SYSTEMS - PSYSTEMS - P

SYSTEMS - P

SYSTEMS - PSYSTEMS - P

Item #Item #

Item #

Item #Item #

3 Electrode Assembly 70430-00 4 ---- --- 5 Seal Assembly, Cartridge, Non-Adjustable, REA 78626-00 6 ---- --- 7 Shaft Assembly, 2-Piece Needle, REA 78627-06 8 Barrel, REA-III 75037-00 8A Reducer, Pressure, Air Spray, Black 74963-02 8B Reducer, Pressure, HVLP, White 74963-03 9 ---- ---10 ---- ---11 Nut, Retainer, Barrel (2 Required) LSMM0002 12 Ring, Retaining, Barrel (2 Required) 18835-00 13 Gasket, Barrel (2 Required) 18872-00 14 Extension, Barrel 70431-00 15 Tube, Packing Adjustment 18842-03 16 O-Ring, Solvent Resistant 7554-08 17 Retainer, Needle Seal, Rear 78629-00 18 Seal, Lip, Spring Loaded 10051-05 19 Spacer, Seal 78630-00 20 ---- ---21 Nut, Packing 78631-00 22 Nut, Locking, Trigger Adjustment 78632-00 23 Rod Extension, Valve, Fluid 78786-01 24 Nut, Retaining, Valve Seal 20053-00 25 O-Ring, Solvent Proof 13076-10 26

7 Support, Mounting 20062-00 28 Screw, Set, Square Head (2 Required) 8666-20C 29 Screw, Cap, Socket Head (4 Required) 8212-20C 30 Screw, Cap, Socket Head 8212-16C 31 Support, Tube, Resistor Housing 20063-00 32 Nut, Retaining, Cable 70439-00

III AUT III AUT

III AUT

III AUT III AUT

ARAR

DescriptionDescription

Description

DescriptionDescription

REA III Delta Automatic (Air Spray) Complete AssemblyREA III Delta Automatic (Air Spray) Complete Assembly

REA III Delta Automatic (Air Spray) Complete Assembly

REA III Delta Automatic (Air Spray) Complete AssemblyREA III Delta Automatic (Air Spray) Complete Assembly (Waterborne Systems Only): 70393S-BBCC2 REA III Delta Automatic (HVLP) Complete AssemblyREA III Delta Automatic (HVLP) Complete Assembly

REA III Delta Automatic (HVLP) Complete Assembly

REA III Delta Automatic (HVLP) Complete AssemblyREA III Delta Automatic (HVLP) Complete Assembly (Waterborne Systems Only): 70393L-BBCC2 Retaining Ring:Retaining Ring:

Retaining Ring:

Retaining Ring:Retaining Ring: Swirl 4903-00 HVLP, Air Spray, and Round 73569-00 Air Cap:Air Cap:

Air Cap:

Air Cap:Air Cap: Flat Pattern, HVLP 75601-00 Flat Pattern, Air Spray 4904-65R Round Pattern, Swirl 70899-00 Round Pattern, Round LREA0002-00 Fluid Nozzle:Fluid Nozzle:

Fluid Nozzle:

Fluid Nozzle:Fluid Nozzle: Flat Pattern, HVLP 75600-01 Flat Pattern, Air Spray 4907-45 Round Pattern, Swirl 70898-00 Round Pattern, Round LREA0003-00

Piston & Valve Body ("CC" Designation):Piston & Valve Body ("CC" Designation):

Piston & Valve Body ("CC" Designation):

OMAOMA

OMA

OMAOMA

TS LISTTS LIST

TS LIST

TS LISTTS LIST

TIC APPLICATIC APPLICA

TIC APPLICA

TIC APPLICATIC APPLICA

(Figures 3a and 3b) (Figures 3a and 3b)

(Figures 3a and 3b)

(Figures 3a and 3b) (Figures 3a and 3b)

OR/WOR/W

OR/W

OR/WOR/W

TERBORNETERBORNE

TERBORNE

TERBORNETERBORNE

Part #Part #

Part #

Part #Part #

4141

AA-82-01.3

REA III 100kV Automatic Applicator - Parts Identification

70393 REA70393 REA

70393 REA

70393 REA70393 REA SYSTEMS - PSYSTEMS - P

SYSTEMS - P

SYSTEMS - PSYSTEMS - P

Item #Item #

Item #

Item #Item #

33 Bracket, Fluid Hose 20938-00

48 O-Ring, Solvent Proof 13076-13 49 O-Ring, Solvent Resistant 7554-33 50 Bushing, Air Valve 20054-00 51 O-Ring, Solvent Resistant 7554-28 52 Shaft, Piston & Valve 20055-00 53 Washer, Piston 20057-00 54 U-Cup, Packing, Teflon 7723-06 55 Piston 20056-00 56 Nut, Lock, Hexagon, Piston 7733-44 57 Nut, Lock, Hexagon, Air Valve 7733-07 58 Nut, Adjustment, Air Valve 20942-00 59 Spring, Compression, Piston 9334-00 60 Spring, Compression, Fluid Valve 17615-00 61 Housing, Piston 20943-00 62 Nut, Knurled Jam 20945-00 63 Screw, Adjustment 20944-00 64 Knob, Knurled 20946-00 65 Set Screw 9697-08C 66 ---- ---67 ---- ---68 ---- ---69 ---- ---70 Cable Assembly, High Voltage LREA4003-XX 71 ---- ----

72 Fitting, Elbow, 3/8” NPT x 3/8” Tube 41-FTP-1007 73 Body, Fitting 74656-00 74 O-Ring, Solvent Proof 72375-02

III AUT III AUT

III AUT

III AUT III AUT

ARAR

DescriptionDescription

Description

DescriptionDescription

Screw, Cap, Socket Head (2 Required) 8212-16F Washer, Lock (2 Required) 7734-04

Valve Assembly, Fan Control: Valve Assembly, Fan Control:

Valve Assembly, Fan Control: (Contains Items 42 thru 47)

Valve Assembly, Fan Control: Valve Assembly, Fan Control: Air Spray 18851-00 HVLP 75133-00

Needle, HVLP 75132-00

Remote Fan Air Valve: Remote Fan Air Valve:

Remote Fan Air Valve: (Contains Items 72 thru 74) (Not Shown)

Remote Fan Air Valve: Remote Fan Air Valve:

Waterborne Fluid Hose Assy: Waterborne Fluid Hose Assy:

Waterborne Fluid Hose Assy: (Contains Items 85 thru 93) (Not Shown)

Waterborne Fluid Hose Assy: Waterborne Fluid Hose Assy: 3/16" ID PE 72306-XX 1/4" ID PE 74180-XX 3/16" ID Teflon 77036-XX 1/4" ID Teflon 77037-XX

OMAOMA

OMA

OMAOMA

TS LISTTS LIST

TS LIST

TS LISTTS LIST

TIC APPLICATIC APPLICA

TIC APPLICA

TIC APPLICATIC APPLICA

(Cont.) (Figures 3a and 3b) (Cont.) (Figures 3a and 3b)

(Cont.) (Figures 3a and 3b)

(Cont.) (Figures 3a and 3b) (Cont.) (Figures 3a and 3b)

OR/WOR/W

OR/W

OR/WOR/W

TERBORNETERBORNE

TERBORNE

TERBORNETERBORNE

Part #Part #

Part #

Part #Part #

(Continued on Next Page)(Continued on Next Page)

(Continued on Next Page)

(Continued on Next Page)(Continued on Next Page)

AA-82-01.3

4242

REA III 100kV Automatic Applicator - Parts Identification

70393 REA70393 REA

70393 REA

70393 REA70393 REA

- P- P

ARAR

- P

- P- P

PISTON HOUSING CHARTPISTON HOUSING CHART

PISTON HOUSING CHART

PISTON HOUSING CHARTPISTON HOUSING CHART

70393-XXX1 = Applciator Assembly W/20947-01 Non-Bleed Body Assembly 70393-XXX2 = Applicator Assembly W/20947-02 Bleed Body Assembly

TS LISTTS LIST

TS LIST

ARAR

TS LISTTS LIST

Item #Item #

Item #

Item #Item #

85 Ferrule, Nut, Waterborne 72308-00 85A Spacer, Fluid 76993-00 86 Connector, Fluid Tube 72309-00 87 Nut, Fluid Line 3587-02 88 Ferrule, Conductive 72315-00 89 Nut, Fluid Line 10553-05 90 Fitting, Fluid Line 72310-00 91

92 Nut and Ferrule 6241-06 93 Fitting, Swivel 7787-03

III AUT III AUT

III AUT

III AUT III AUT

(Cont.) (Figures 3a and 3b) (Cont.) (Figures 3a and 3b)

(Cont.) (Figures 3a and 3b)

(Cont.) (Figures 3a and 3b) (Cont.) (Figures 3a and 3b)

DescriptionDescription

Description

DescriptionDescription

Waterborne Fluid Hose:Waterborne Fluid Hose:

Waterborne Fluid Hose:

Waterborne Fluid Hose:Waterborne Fluid Hose: 3/16" ID PE 72307-XX 1/4" ID PE 74179-XX 3/16" ID Teflon 77038-XX 1/4" ID Teflon 77039-XX

OMAOMA

OMA

OMAOMA

TIC APPLICATIC APPLICA

TIC APPLICA

TIC APPLICATIC APPLICA

OR/WOR/W

OR/W

OR/WOR/W

TERBORNE SYSTEMSTERBORNE SYSTEMS

TERBORNE SYSTEMS

TERBORNE SYSTEMSTERBORNE SYSTEMS

Part #Part #

Part #

Part #Part #

4343

AA-82-01.3

REA III 100kV Automatic Applicator - Parts Identification

NOTESNOTES

NOTES

NOTESNOTES

AA-82-01.3

4444

REA III 100kV Automatic Applicator - Warranty Policies

ARRANTYARRANTY

ARRANTY

ARRANTYARRANTY

LIMITED WLIMITED W

LIMITED W

LIMITED WLIMITED W

ITW Ransburg will replace or repair without charge any part and/or equipment that falls within the specified time (see below) because of faulty workmanship or material, provided that the equipment has been used and maintained in accordance with ITW Ransburg's written safety and operating instructions, and has been used under normal operating conditions. Normal wear items are excluded.

THE USE OF OTHER THAN ITW RANSBURGTHE USE OF OTHER THAN ITW RANSBURG

THE USE OF OTHER THAN ITW RANSBURG

THE USE OF OTHER THAN ITW RANSBURGTHE USE OF OTHER THAN ITW RANSBURG APPROVED PARTS, VOID ALL WARRANTIES.APPROVED PARTS, VOID ALL WARRANTIES.

APPROVED PARTS, VOID ALL WARRANTIES.

APPROVED PARTS, VOID ALL WARRANTIES.APPROVED PARTS, VOID ALL WARRANTIES.

ARRANTYARRANTY

ARRANTY

ARRANTYARRANTY

POLICIES POLICIES

POLICIES

POLICIES POLICIES

ITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATION

ITW RANSBURG'S ONLY OBLIGATION

ITW RANSBURG'S ONLY OBLIGATIONITW RANSBURG'S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACE

UNDER THIS WARRANTY IS TO REPLACE

UNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSE

PARTS THAT HAVE FAILED BECAUSE

PARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-

OF FAULTY WORKMANSHIP OR MATE-

OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-

RIALS. THERE ARE NO IMPLIED WAR-

RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHERRANTIES NOR WARRANTIES OF EITHER

RANTIES NOR WARRANTIES OF EITHER

RANTIES NOR WARRANTIES OF EITHERRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR A

MERCHANTABILITY OR FITNESS FOR A

MERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-

PARTICULAR PURPOSE. ITW RANS-

PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANSBURG ASSUMES NO LIABILITY FOR IN-BURG ASSUMES NO LIABILITY FOR IN-

BURG ASSUMES NO LIABILITY FOR IN-

BURG ASSUMES NO LIABILITY FOR IN-BURG ASSUMES NO LIABILITY FOR INJURY, DAMAGE TO PROPERTY OR FORJURY, DAMAGE TO PROPERTY OR FOR

JURY, DAMAGE TO PROPERTY OR FOR

JURY, DAMAGE TO PROPERTY OR FORJURY, DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSSCONSEQUENTIAL DAMAGES FOR LOSS

CONSEQUENTIAL DAMAGES FOR LOSS

CONSEQUENTIAL DAMAGES FOR LOSSCONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OROF GOODWILL OR PRODUCTION OR

OF GOODWILL OR PRODUCTION OR

OF GOODWILL OR PRODUCTION OROF GOODWILL OR PRODUCTION OR INCOME, WHICH RESULT FROM USE ORINCOME, WHICH RESULT FROM USE OR

INCOME, WHICH RESULT FROM USE OR

INCOME, WHICH RESULT FROM USE ORINCOME, WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PUR-MISUSE OF THE EQUIPMENT BY PUR-

MISUSE OF THE EQUIPMENT BY PUR-

MISUSE OF THE EQUIPMENT BY PUR-MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS.CHASER OR OTHERS.

CHASER OR OTHERS.

CHASER OR OTHERS.CHASER 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 IN PLAS-WRAPPING THE APPLICATOR IN PLAS-

WRAPPING THE APPLICATOR IN PLAS-

WRAPPING THE APPLICATOR IN PLAS-WRAPPING THE APPLICATOR IN PLASTIC, ASSOCIATED VALVES AND TUB-TIC, ASSOCIATED VALVES AND TUB-

TIC, ASSOCIATED VALVES AND TUB-

TIC, ASSOCIATED VALVES AND TUB-TIC, ASSOCIATED VALVES AND TUBING, AND SUPPORTING HARDWARE INING, AND SUPPORTING HARDWARE IN

ING, AND SUPPORTING HARDWARE IN

ING, AND SUPPORTING HARDWARE INING, AND SUPPORTING HARDWARE IN PLASTIC, SHRINK-WRAP, OR ANYPLASTIC, SHRINK-WRAP, OR ANY

PLASTIC, SHRINK-WRAP, OR ANY

PLASTIC, SHRINK-WRAP, OR ANYPLASTIC, SHRINK-WRAP, OR ANY OTHER NON-APPROVED COVERING,OTHER NON-APPROVED COVERING,

OTHER NON-APPROVED COVERING,

OTHER NON-APPROVED COVERING,OTHER NON-APPROVED COVERING, WILL VOIDE THIS WARRANTY.WILL VOIDE THIS WARRANTY.

WILL VOIDE THIS WARRANTY.

WILL VOIDE THIS WARRANTY.WILL VOIDE THIS WARRANTY.

EXCLUSIONS:EXCLUSIONS:

EXCLUSIONS:

EXCLUSIONS:EXCLUSIONS:

If, in ITW Ransburg's opinion the warranty item in question, or other items damaged by this part was improperly installed, operated or maintained, ITW Ransburg will assume no responsibility for repair or replacement of the item or items. The purchaser, therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable.

4545

AA-82-01.3

MANUALMANUAL

MANUAL

MANUALMANUAL

This manual was published to replace Service Manual

Applicator

1. Revised “ Label“ on the “Front Cover”.

2. Revised “Atex Labels 19688, 72562, 76454, 76854, 76896, 77059, 78886, 78894-04, and LEPS0016” in the “Atex” section.

AA-82-01.2 AA-82-01.2

AA-82-01.2

AA-82-01.2 AA-82-01.2

, to make the following changes:

REA III 100kV Automatic

CHANGE SUMMAR CHANGE SUMMAR

CHANGE SUMMAR

CHANGE SUMMAR CHANGE SUMMAR

AA-82-01.3

Service Manual Price:Service Manual Price:

Service Manual Price: €

Service Manual Price:Service Manual Price:

ManufacturingManufacturing

Manufacturing

ManufacturingManufacturing

25.00 (Euro)25.00 (Euro)

25.00 (Euro)

25.00 (Euro)25.00 (Euro)

$30.00 (U.S.)$30.00 (U.S.)

$30.00 (U.S.)

$30.00 (U.S.)$30.00 (U.S.)

1910 North Wayne Street Angola, Indiana 46703-9100 Telephone: 260/665-8800 Fax: 260/665-8516

echnical/Service Assistanceechnical/Service Assistance

echnical/Service Assistance

echnical/Service Assistanceechnical/Service Assistance Automotive Assembly and Tier I Telephone: 800/ 626-3565 Fax: 419/ 470-2040 Industrial Systems Telephone: 800/ 233-3366 Fax: 419/ 470-2071 Ransburg Guns Telephone: 800/ 233-3366 Fax: 419/ 470-2071 www.itwransburg.com

echnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephone

echnical Support Representative will direct you to the appropriate telephone

echnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts.number for ordering Spare Parts.

number for ordering Spare Parts.

number for ordering Spare Parts.number for ordering Spare Parts.

Form No. AA-82-01.3 Litho in U.S.A. 05/08

Ransburg 70393 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

SAFETY

INTRODUCTION

MAINTENANCE