Ransburg 75983-02 User Manual
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ARCHIVE
VIAVIA
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VIAVIA
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OROR
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POWER UNIT POWER UNIT
POWER UNIT
POWER UNIT POWER UNIT
SERVICE MANUAL
CP-97-01.1CP-97-01.1
CP-97-01.1
CP-97-01.1CP-97-01.1
(Replaces CP-97-01)
May - 2008
Portable Power Generation TPortable Power Generation T
Portable Power Generation T
Portable Power Generation TPortable Power Generation T
echnologyechnology
echnology
echnologyechnology
MODEL:MODEL:
MODEL:
MODEL:MODEL:
75983-02 For Use Only With:75983-02 For Use Only With:
75983-02 For Use Only With:
75983-02 For Use Only With:75983-02 For Use Only With:
- 75979 (REATM-90)
- 75982 (REATM-90 Waterborne)
- 75980 (REATM-70)
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.
TT
T
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ANTANT
: Before using this equipment,: Before using this equipment,
ANT
: Before using this equipment,
ANTANT
: 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:
ARCHIVE
NOTE: This manual has been changed from revision
NOTE:NOTE:
Reasons for this change are noted under “Manual Change Summary” inside the back
cover of this manual.
CP-97-01CP-97-01
CP-97-01 to revision
CP-97-01CP-97-01
CP-97-01.1 CP-97-01.1
CP-97-01.1.
CP-97-01.1 CP-97-01.1
CP-97-01.1
CONTENTSCONTENTS
ARCHIVE
CONTENTS
CONTENTSCONTENTS
SAFETY:SAFETY:
SAFETY:
SAFETY:SAFETY:
AVIATOR Power Unit - Contents
PAGEPAGE
PAGE
PAGEPAGE
1-61-6
1-6
1-61-6
SAFETY PRECAUTIONS............................................................................................................
HAZARDS / SAFEGUARDS........................................................................................................
ATEX:ATEX:
ATEX:
ATEX:ATEX:
EUROPEAN ATEX DIRECTIVE.................................................................................................
EUROPEAN ATEX LABELS.......................................................................................................
INTRODUCTION:INTRODUCTION:
INTRODUCTION:
INTRODUCTION:INTRODUCTION:
DESCRIPTION.............................................................................................................................
FUNCTIONS.................................................................................................................................
AIR REQUIREMENTS.................................................................................................................
SPECIFICATIONS.......................................................................................................................
INSTALLATION:INSTALLATION:
INSTALLATION:
INSTALLATION:INSTALLATION:
LOCATION / MOUNTING............................................................................................................
EXTERNAL CONNECTIONS......................................................................................................
OPERATION:OPERATION:
OPERATION:
OPERATION:OPERATION:
OPERATION................................................................................................................................
MAINTENANCE:MAINTENANCE:
MAINTENANCE:
MAINTENANCE:MAINTENANCE:
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7-87-8
7-8
7-87-8
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15-2015-20
15-20
15-2015-20
REMOVAL OF GENERATING UNIT FROM ENCLOSURE......................................................
INSTALLATION OF GENERATING UNIT INTO ENCLOSURE................................................
GENERATING UNIT DISASSEMBLY.........................................................................................
GENERATOR REMOVAL...........................................................................................................
GENERATOR REPLACEMENT / INSTALLATION....................................................................
AIR MOTOR REMOVAL..............................................................................................................
AIR MOTOR REPLACEMENT / INSTALLATION.......................................................................
PC BOARD REMOVAL................................................................................................................
PC BOARD REPLACEMENT......................................................................................................
CABLE REMOVAL.......................................................................................................................
CABLE REPLACEMENT.............................................................................................................
THEORY OF OPERATION.........................................................................................................
TROUBLESHOOTING.................................................................................................................
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS IDENTIFICATION:
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
AVIATOR POWER UNIT EXPLODED VIEW / PARTS LIST.....................................................
AVIATOR / APPLICATOR MODEL IDENTIFICATION..............................................................
ACCESSORIES...........................................................................................................................
WARRANTY POLICIES:WARRANTY POLICIES:
WARRANTY POLICIES:
WARRANTY POLICIES:WARRANTY POLICIES:
LIMITED WARRANTY..................................................................................................................
CP-97-01.1
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AVIATOR Power Unit - Safety
ARCHIVE
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 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.
A WARNING! states information to alert youA WARNING! states information to alert you
A WARNING! states information to alert you
A WARNING! states information to alert youA WARNING! states information to alert you
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! states information that tellsA CAUTION! states information that tells
A CAUTION! states information that tells
A CAUTION! states information that tellsA CAUTION! states information that tells
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
injury.injury.
injury.
injury.injury.
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.
> The user
with the Safety Section in this manual and
the ITW Ransburg safety literature therein
identified.
> This manual
oughly understood by
operate, clean or maintain this equipment!
Special care should be taken to ensure that
WARNINGSWARNINGS
the
WARNINGS and safety requirements
WARNINGSWARNINGS
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to
codes and ordinances as well as
SAFETY STANDARD, SAFETY STANDARD,
SAFETY STANDARD, prior to installing,
SAFETY STANDARD, SAFETY STANDARD,
operating, and/or servicing this equipment.
> 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.
MUSTMUST
MUST read and be familiar
MUSTMUST
MUSTMUST
MUST be read and thor-
MUSTMUST
ALLALL
ALL personnel who
ALLALL
ALLALL
ALL local building and fire
ALLALL
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
!!
!
!!
NFPA-33NFPA-33
NFPA-33
NFPA-33NFPA-33
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.
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CP-97-01.1
AVIATOR Power Unit - Safety
ARCHIVE
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
Spray AreaSpray Area
Spray Area
Spray AreaSpray Area
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate operation
and maintenance procedures will
cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any safety
interlocks are disabled during
operation. Frequent power supply
shutdown indicates a problem in
the system requiring correction.
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
The 76447 power supply MUST be installed in a
NON-hazardous location in accordance with NFPA-
33.
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, flushing, or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.
Those used for general cleaning must have flash
points above 100
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.
o
F (37.8oC).
CP-97-01.1
The paint process and equipment should be set up
and operated in accordance with NFPA 33, NEC, and
OSHA requirements.
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AVIATOR Power Unit - Safety
ARCHIVE
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
Spray AreaSpray Area
Spray Area
Spray AreaSpray Area
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
Electrostatic Arcing Ensure the Ground Wire Assembly is connected from
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
the power supply ground stud to a true earth ground.
Ensure that the power supply is plugged into a
properly grounded outlet.
If shocks or sparks are noticed at any point in the
spray system, immediately turn off the power supply
and check the complete system for the cause. DO
NOT use the system again until the problem has
beenidentified and corrected.
Never operate the applicator without properly grounding
the following:
OperatorsOperators
A.
Operators must be grounded. Rubber soled
OperatorsOperators
insulating shoes should not be worn. Grounding
leg straps may be used.
Operators must maintain contact with the handle
of the applicator. If work gloves are used, the
palm section should be cut out.
Operators must remove from themselves all
metal objects that are not grounded.
NOTE: REFER TO NFPA-33 REGARDINGNOTE: REFER TO NFPA-33 REGARDING
NOTE: REFER TO NFPA-33 REGARDING
NOTE: REFER TO NFPA-33 REGARDINGNOTE: REFER TO NFPA-33 REGARDING
OPERATOR GROUNDING.OPERATOR GROUNDING.
OPERATOR GROUNDING.
OPERATOR GROUNDING.OPERATOR GROUNDING.
B. Parts being sprayed. Resistance between the
part and a grounded conveyor must not exceed
1 megohm.
C. Every metal and conductive object in the spray
area. This includes the booth, parts hangers,
fire extinguishers, conductive flooring, etc.
Grounded conductive flooring must be provided in the
spray area.
Turn off voltage at the power supply before flushing
out, cleaning, or removing any parts from the
applicator.
Provide proper protection for waterborne supply
systems.
Never install a applicator into a fluid system using an
isolated solvent supply.
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CP-97-01.1
AVIATOR Power Unit - Safety
ARCHIVE
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
Spray AreaSpray Area
Spray Area
Spray AreaSpray Area
(Continued)(Continued)
(Continued)
(Continued)(Continued)
General Use andGeneral Use and
General Use and
General Use andGeneral Use and
MaintenanceMaintenance
Maintenance
MaintenanceMaintenance
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
Electrostatic Arcing
Improper operation or maintenance
may create a hazard.
Personnel must be properly trained
in the use of this equipment.
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
Always discharge Waterborne system capacitance
prior to servicing.
Do not touch applicator electrode while applicator is
energized.
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.
Always turn power to the power supply OFF, unplug
the electrical cord from its outlet, and remove the front
panel fuse, before opening the power supply door. If
necessary, lock the power supply out so that it cannot
be turned ON until the work is finished.
Whenever removing high voltage cables from
equipment, ground the contact end of the cable by
holding the cable such that the contact touches earth
ground for several seconds. Do not touch the contact
until it has been grounded. This will reduce the
possibility of residual charge causing electrical shock.
The High Voltage Multiplier Assembly contains energy
storage components that can cause serious shock
injury, and therefore is not field repairable. Warranty
will be voided if the High Voltage Multiplier seal is
broken. If the High Voltage Multiplier is defective
contact your authorized ITW Ransburg representative
for exchange or repair.
The High Voltage Multiplier and high voltage cable
contain significant capacitance that will store charge.
Allow approximately 10 seconds for this charge to
bleed off before opening the cabinet door or removing
the high voltage cable from the power supply or spray
applicator.
CP-97-01.1
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AVIATOR Power Unit - Safety
ARCHIVE
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
Explosion Hazard/Explosion Hazard/
Explosion Hazard/
Explosion Hazard/Explosion Hazard/
IncompatibleIncompatible
Incompatible
IncompatibleIncompatible
MaterialsMaterials
Materials
MaterialsMaterials
Toxic SubstancesToxic Substances
Toxic Substances
Toxic SubstancesToxic Substances
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
Halogenated hydrocarbon
solvents
chloride and 1,1,1,-Trichloroethane are not chemically
compatible with the aluminum that
might be used in many system
components. The chemical
reaction caused by these solvents
reacting with aluminum can
become violent and lead to an
equipment explosion.
Certain material may be harmful if
inhaled, or if there is contact with
the skin.
for example: methylene
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum equipment
during spraying, flushing, or cleaning. Read the label
or data sheet for the material you intend to spray. If
in doubt as to whether or not a coating or cleaning
material is compatible, contact your material supplier.
Any other type of solvent may be used with aluminum
equipment.
Follow the requirements of the Material Safety Data
Sheet supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the air
free of accumulations of toxic materials.
Use a mask or respirator whenever there is a chance
of inhaling sprayed materials. The mask must be
compatible with the material being sprayed and its
concentration. Equipment must be as prescribed by
an industrial hygienist or safety expert, and be NIOSH
approved.
Personnel SafetyPersonnel Safety
Personnel Safety
Personnel SafetyPersonnel Safety
Personnel SafetyPersonnel Safety
Personnel Safety
Personnel SafetyPersonnel Safety
(High Pressure(High Pressure
(High Pressure
(High Pressure(High Pressure
Equipment)Equipment)
Equipment)
Equipment)Equipment)
Skin puncturing by sharp electrode. Take precautions to see that flesh is not punctured by
sharp electrode.
Fluid Injection Hazard Never let any part of the body come in direct contact
with the fluid stream exiting from the nozzle. If fluid
leaks occur in the applicator or in the fluid delivery
components, depressurize fluid system before
servicing.
Never aim the applicator at any part of the body under
any circumstances.
If you are injured by High Pressure Fluid Injection than
immediate medical treatment MUST be sought.
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CP-97-01.1
NOTESNOTES
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NOTES
NOTESNOTES
AVIATOR Power Unit - Safety
CP-97-01.1
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