Ransburg 76480, 76482, 76485, 76488 User Manual

SERVICE MANUAL
AA-99-01.1AA-99-01.1

AA-99-01.1

AA-99-01.1AA-99-01.1
(Replaces AA-99-01)
June - 2007

SOLSOL

SOL

SOLSOL

TMTM

TM

EFMEFM

EFM

EFMEFM

VENTBORNE ROBOTIC AVENTBORNE ROBOTIC A

VENTBORNE ROBOTIC A

VENTBORNE ROBOTIC AVENTBORNE ROBOTIC A

TMTM

AND EFMD AND EFMD

AND EFMD

AND EFMD AND EFMD

TMTM

TM

TMTM

TT

OMIZERSOMIZERS

T

OMIZERS

TT

OMIZERSOMIZERS

MODEL: 76480, 76482, 76485, 76488MODEL: 76480, 76482, 76485, 76488

MODEL: 76480, 76482, 76485, 76488

MODEL: 76480, 76482, 76485, 76488MODEL: 76480, 76482, 76485, 76488

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

ANTANT

T

ANT

TT

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:

40.00 (Euro)40.00 (Euro)

40.00 (Euro)

40.00 (Euro)40.00 (Euro)

$50.00 (U.S.)$50.00 (U.S.)

$50.00 (U.S.)

$50.00 (U.S.)$50.00 (U.S.)

NOTE:NOTE:

NOTE: This manual has been changed from revision

NOTE:NOTE:

AA-99-01AA-99-01

AA-99-01 to revision

AA-99-01AA-99-01

AA-99-01.1AA-99-01.1

AA-99-01.1.

AA-99-01.1AA-99-01.1
Reasons for this change are noted under “Manual Change Summary” inside the back cover of this
manual.

AA-99-01.1

CONTENTSCONTENTS

CONTENTS

CONTENTSCONTENTS

SAFETY:SAFETY:

SAFETY:

SAFETY:SAFETY:

EFM(D) Solventborne Robotic Atomizers - Contents

PAGEPAGE

PAGE

PAGEPAGE

1-41-4

1-4

1-41-4

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

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

INTRODUCTION:INTRODUCTION:

INTRODUCTION:

INTRODUCTION:INTRODUCTION:

THE ITW RANSBURG ELECTROSTATIC PROCESS.............................................................

EFM AND EFMD SOLVENTBORNE GUNS..............................................................................

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

MANIFOLD SELECTION GUIDE................................................................................................

APPLICATOR TOOL-POINT REPRESENTATION...................................................................

INSTALLATION:INSTALLATION:

INSTALLATION:

INSTALLATION:INSTALLATION:

EFM AND EFMD ROBOTIC ATOMIZER INSTALLATION........................................................

POWER SUPPLY ASSEMBLY...................................................................................................

LOW VOLTAGE CABLE CONNECTIONS.................................................................................

ROBOT MANIFOLD ASSEMBLY................................................................................................

EFM SPRAY GUN.......................................................................................................................

ROBOT MANIFOLD AND SPRAY GUN INSTALLATION /

PARTS LIST.................................................................................................................................

OPERATION:OPERATION:

OPERATION:

OPERATION:OPERATION:

1
2-4

5-85-8

5-8

5-85-8

5
5-6
6
7
8

9-149-14

9-14

9-149-14

9
9
10
11
11

13-14

15-1815-18

15-18

15-1815-18

SPRAY APPLICATOR CONTROLS...........................................................................................

POWER SUPPLY CONTROLS..................................................................................................

GENERAL INFORMATION AND ADJUSTMENTS...................................................................

SIMPLIFIED AIR AND FLUID FLOW PASSAGE LAYOUT.......................................................

INTRINSIC SAFE WIRING..........................................................................................................

MAINTENANCE:MAINTENANCE:

MAINTENANCE:

MAINTENANCE:MAINTENANCE:

ROUTINE MAINTENANCE SCHEDULE....................................................................................

PROCEDURES............................................................................................................................

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

SPRAY HEAD ASSEMBLY / PARTS LIST.................................................................................

FLUID REGULATOR OR DUMP VALVE / PARTS LIST...........................................................

REMOVING GUN FROM THE ROBOT MANIFOLD

ASSEMBLY / PARTS LIST..........................................................................................................

AIR CARTRIDGE VALVES.........................................................................................................

SOLENOID TRIGGER VALVES / PARTS LIST.........................................................................

LECU5004 MICROPAK CONTROL UNIT..................................................................................

76494-XXX ROBOT MANIFOLD ASSEMBLY............................................................................

ACCESSORIES...........................................................................................................................

(Continued On Next Page)(Continued On Next Page)

(Continued On Next Page)

(Continued On Next Page)(Continued On Next Page)

15
15
15-17
17
18

19-3419-34

19-34

19-3419-34

19-20
20-21
21
22-24
25-26

27
28-29
29-30
31
31
31-34

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Contents

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PARTS IDENTIFICATION:

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PAGEPAGE

PAGE

PAGEPAGE

35-7035-70

35-70

35-7035-70

76479 SPRAY HEAD ASSEMBLY / PARTS LIST.......................................................................

76490 APPLICATOR MANIFOLD PLATE ASSEMBLY / PARTS LIST......................................

76494 MANIFOLD ASSEMBLY / PARTS LIST............................................................................

76480 EFM APPLICATOR ASSEMBLY / PARTS LIST..............................................................

76366 VALVE MANIFOLD ASSEMBLY / PARTS LIST...............................................................

76481 APPLICATOR HOUSING ASSEMBLY / PARTS LIST....................................................

76482 EFM APPLICATOR ASSEMBLY / PARTS LIST..............................................................

76484 VALVE MANIFOLD ASSEMBLY / PARTS LIST...............................................................

76483 APPLICATOR HOUSING ASSEMBLY / PARTS LIST....................................................

76485 EFMD APPLICATOR ASSEMBLY / PARTS LIST............................................................

76487 VALVE MANIFOLD ASSEMBLY / PARTS LIST...............................................................

76486 APPLICATOR HOUSING ASSEMBLY / PARTS LIST....................................................

76488 EFMD APPLICATOR ASSEMBLY / PARTS LIST............................................................

76368 VALVE MANIFOLD ASSEMBLY / PARTS LIST...............................................................

76489 APPLICATOR HOUSING ASSEMBLY / PARTS LIST....................................................

WARRANTY POLICIES:WARRANTY POLICIES:

WARRANTY POLICIES:

WARRANTY POLICIES:WARRANTY POLICIES:

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

35-36
37-38
39-42
43-44
45-46
47-48
49-50
51-52
53-54
55-56
57-59
61-62
63-64
65-67
69-70

7171

71

7171

71

AA-99-01.1

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Safety

SAFETYSAFETY

SAFETY

SAFETYSAFETY

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

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.

A WARNING!A WARNING!

A WARNING!

A WARNING!A WARNING!
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.

states information to alert youstates information to alert you

states information to alert you

states information to alert youstates information to alert you

> The user

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
33 SAFETY STANDARD, 33 SAFETY STANDARD,

33 SAFETY STANDARD, prior to install-

33 SAFETY STANDARD, 33 SAFETY STANDARD,
ing, operating, and/or servicing this equip­ment.

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 read and be familiar with

MUSTMUST

MUSTMUST

MUST be read and thor-

MUSTMUST

ALLALL

ALL personnel who

ALLALL

ALLALL

ALL local building and fire

ALLALL

NFPA-NFPA-

NFPA-

NFPA-NFPA-

A NOTE is information relevant to the pro-A NOTE is information relevant to the pro-

A NOTE is information relevant to the pro-

A NOTE is information relevant to the pro-A NOTE is information relevant to the pro­cedure in progress.cedure in progress.

cedure in progress.

cedure in progress.cedure 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.

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.

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.

11

1

11

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Safety

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.

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

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

Smoking must never be allowed in the spray area.

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

When using solvents for cleaning:

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

Those used for general cleaning must have flash
points above 100°F (37.8°C).

Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, 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-99-01.1

22

2

22

EFM(D) Solventborne Robotic Atomizers - Safety

AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

General UseGeneral Use

General Use

General UseGeneral Use
andand

and

andand
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 exposed to high
voltage during operation and
maintenance.

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

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

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

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.

Explosion Hazard /Explosion Hazard /

Explosion Hazard /

Explosion Hazard /Explosion Hazard /
IncompatibleIncompatible

Incompatible

IncompatibleIncompatible
MaterialsMaterials

Materials

MaterialsMaterials

33

3

33

Halogenated hydrocarbon solvents
for example: methylene chloride
and 1,1,1,-Trichloroethane are not
chemically compatible with the
aluminum that might be used in
many system components. The
chemical reaction caused by these
solvents reacting with aluminum
can become violent and lead to an
equipment explosion.

Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum equip­ment during spraying, flushing, or cleaning. Read the
label or data sheet for the material you intend to spray.
If in doubt as to whether or not a coating or cleaning
material is compatible, contact your material sup­plier. Any other type of solvent may be used with
aluminum equipment.

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Safety

AREAAREA

AREA

AREAAREA

Tells where hazards

may occur.

Toxic SubstancesToxic Substances

Toxic Substances

Toxic SubstancesToxic Substances

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.

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

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

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

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

SAFEGUARDSSAFEGUARDS

Tells how to avoid the hazard.

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.

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.

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.

Any person working in the spray area must be
grounded.

Robot Work Area -Robot Work Area -

Robot Work Area -

Robot Work Area -Robot Work Area ­General Use andGeneral Use and

General Use and

General Use andGeneral Use and
MaintenanceMaintenance

Maintenance

MaintenanceMaintenance

Personnel SafetyPersonnel Safety

Personnel Safety

Personnel SafetyPersonnel Safety

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

Improper use or maintenance can
lead to hazardous conditions,
particularly from unexpected robot
manipulator movement.

Skin puncturing by sharp electrode. Take precautions to see that flesh is not punctured

Applicator adjustments or maintenance should be
done after the robot is taken out of service. Do not
adjust or repair the applicator if the robot is operating
or standing ready to start.

Refer to robot operating instructions for the procedures
to take the robot out of service.

by sharp electrode.

AA-99-01.1

44

4

44

EFM(D) Solventborne Robotic Atomizers - Introduction

INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

THE ITW RANSBURGTHE ITW RANSBURG

THE ITW RANSBURG

THE ITW RANSBURGTHE ITW RANSBURG
ELECTROSTELECTROST

ELECTROST

ELECTROSTELECTROST
PROCESSPROCESS

PROCESS

PROCESSPROCESS

This process is a method for electrostatically
applying coatings to objects. A power supply
produces a high voltage charge which is supplied
to the applicator, creating an electrostatic field
between the applicator and the target object. The
target is electrostatically grounded through its
support which may be either stationary or moving.

A regulated fluid system delivers coating material
to the applicator, where it is atomized forming a
spray mist. There, under the influence of the
electrostatic field, the atomized coating becomes
electrostatically charged. The charged particles
are attracted to and deposited on the grounded
target object. The forces between the charged
particles and the target are sufficient to turn
overspray around and deposit it on the back
surface of the target. Therefore, a higher
percentage of the spray is deposited.

AA

TICTIC

A

TIC

AA

TICTIC

There are two single-head models of the EFM
Applicator. Each model differs in the applicator to
axis orientation of the spray head, these models
are:

76480-02 EFM 60° Applicator
76482-02 EFM 90° Applicator

Two dual-head versions of the EFM Solventborne
Applicator are also available, designated EFMDTM.
The dual-head version is identical to the EFM
applicator with the exception of an additional spray
head mounted to the applicator body. EFMD
Solventborne Applicators are primarily used where
high volume fluid delivery is required. These
applicators supply twice the fluid delivery over
Single-Head EFM Solventborne Applicators. The
EFMD Solventborne Applicator is available in two
different configurations as follows:

76485-02 EFMD 60° Applicator
76488-02 EFMD 90° Applicator

Both EFM and EFMD Solventborne Applicators
are comprised of five major sections:

EFM AND EFMDEFM AND EFMD

EFM AND EFMD

EFM AND EFMDEFM AND EFMD
SOLSOL

SOL

SOLSOL
APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

The EFMTM Solventborne Applicator line consists
of single and dual-headed 100 kV automatic
electrostatic spray applicators. Developed for
use on robots or reciprocators, the EFM
solventborne applicator incorporates a quick­disconnect manifold and swivel tubing connections
to minimize downtime. Internal fluid and air
solenoids and an internal high voltage power supply
provide the user a compact, efficient tool for the
application of electrostatic coatings. Because this
is a grounded fluid system, the EFM solventborne
applicator is highly suitable for applying a wide
range of solvent reduced coatings such as enamels,
lacquers, two-component and other such coatings.

55

5

55

VENTBORNEVENTBORNE

VENTBORNE

VENTBORNEVENTBORNE

TT

ORSORS

T

ORS

TT

ORSORS

1. Spray head(s)

2. Valve manifold assembly

3. Quick-disconnect base manifold
assembly

4. Robot-mounted manifold assembly

5. High voltage cascade.

The spray head(s) and valve manifold contain the
fluid, air, and high voltage passages. Although the
quick-disconnect base manifold and robot­mounted manifold are fabricated from aluminum,
all fluid passages are contained within stainless
steel and nylon fittings and are compatible with
halogenated hydrocarbon solvents. The robot
manifold incorporates stainless steel swivel fluid
connections. The swivel connections reduce
stress on the fluid lines minimizing breakage. No
aluminum parts are exposed to the fluid path on
either manifold. The high voltage cascade is
entirely encapsulated with a solvent resistant
epoxy.

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Introduction

The high voltage supply for the EFM and EFMD
applicators consists of two major components:

The MicroPakTM Power Supply Control Unit
(LECU5004), and the HP404 Cascade (75933-

00).

The MicroPak power supply control unit provides
a low voltage signal through the robot manifold to
the EFM or EFMD spray applicator. The high
voltage cascade located within the applicator
converts the low voltage DC signal to a high
voltage electrostatic output. See

Control Unit Service ManualControl Unit Service Manual

Control Unit Service Manual

Control Unit Service ManualControl Unit Service Manual

LECU5004, MicroPak control unit.

SPECIFICASPECIFICA

SPECIFICA

SPECIFICASPECIFICA

Robot/Mounting Compatibility:Robot/Mounting Compatibility:

Robot/Mounting Compatibility:

Robot/Mounting Compatibility:Robot/Mounting Compatibility:

Applicator ControlApplicator Control

Applicator Control

Applicator ControlApplicator Control
Unit:Unit:

Unit:

Unit:Unit:

TIONSTIONS

TIONS

TIONSTIONS

ABB Robotics
Fanuc P150/155/200
Motion Machine Gun Bar

LECU5004 MicroPak
control unit

for details of the

MicroPakMicroPak

MicroPak

MicroPakMicroPak

Output Voltage:Output Voltage:

Output Voltage: 30-100 kV

Output Voltage:Output Voltage:

Output Range:Output Range:

Output Range: 0-125 μA

Output Range:Output Range:

SolenoidSolenoid

Solenoid

SolenoidSolenoid
Parameters:Parameters:

Parameters:

Parameters:Parameters:

Paint Flow Rate:Paint Flow Rate:

Paint Flow Rate:

Paint Flow Rate:Paint Flow Rate:

Operating Air PressuresOperating Air Pressures

Operating Air Pressures

Operating Air PressuresOperating Air Pressures

Atomizing Air:Atomizing Air:

Atomizing Air: 100 psig max.

Atomizing Air:Atomizing Air:

Fan Air:Fan Air:

Fan Air:

Fan Air:Fan Air:

Trigger Air:Trigger Air:

Trigger Air: 70 psig min./100 psig max.

Trigger Air:Trigger Air:

Regulator Pilot:Regulator Pilot:

Regulator Pilot: 60 psig max.

Regulator Pilot:Regulator Pilot:

Dump Pilot:Dump Pilot:

Dump Pilot:

Dump Pilot:Dump Pilot:

Operating FluidOperating Fluid

Operating Fluid

Operating FluidOperating Fluid
Pressure: Pressure:

Pressure:

Pressure: Pressure:

Robot Manifold Tubing RequirementsRobot Manifold Tubing Requirements

Robot Manifold Tubing Requirements

Robot Manifold Tubing RequirementsRobot Manifold Tubing Requirements

Atomizing Air:Atomizing Air:

Atomizing Air:

Atomizing Air:Atomizing Air:

Fan Air:Fan Air:

Fan Air: 1/2" OD Nylon

Fan Air:Fan Air:

15.5 VDC@0.035A, 1/2W

Variable to 1500 cc/min.

100 psig max.

60 psig max.

300 psig max.

1/2" OD Nylon

WeightWeight

Weight

WeightWeight

Single-Headed:Single-Headed:

Single-Headed:

Single-Headed:Single-Headed:

Dual-Headed:Dual-Headed:

Dual-Headed: 76485-02 (60°) 9.50 lbs.

Dual-Headed:Dual-Headed:

Manifold:Manifold:

Manifold: 76494-XX 2.00lbs.

Manifold:Manifold:

LengthLength

Length

LengthLength

Single-Headed:Single-Headed:

Single-Headed: 76480-02 (60°) 15-5/8"

Single-Headed:Single-Headed:

Dual-Headed:Dual-Headed:

Dual-Headed:

Dual-Headed:Dual-Headed:

Manifold:Manifold:

Manifold:

Manifold:Manifold:

76480-02 (60°) 8.25 lbs.
76482-02 (90°) 8.25 lbs.

76488-02 (90°) 9.50 lbs.

(No tubing or Cable)

76482-02 (90°) 14-1/2"

76485-02 (60°) 13-7/8"
76488-02 (90°) 13-3/8"

76494-16X 16'
76494-25X 25'
76494-50X 50'

Trigger Air:Trigger Air:

Trigger Air: 3/16" OD Nylon

Trigger Air:Trigger Air:

Regulator Pilot:Regulator Pilot:

Regulator Pilot: 3/16" OD Nylon

Regulator Pilot:Regulator Pilot:

Dump Pilot:Dump Pilot:

Dump Pilot: 3/16" OD Nylon

Dump Pilot:Dump Pilot:

Fluid:Fluid:

Fluid:

Fluid:Fluid:

Polyethylene: 1/4" or 3/16" ID

Teflon: 1/4" or 3/16" ID

Dump:Dump:

Dump:

Dump:Dump:

Polyethylene: 1/4" or 3/16" ID

Teflon: 1/4" or 3/16" ID

* See "Manifold Selection Guide" in the "Introductin"
section for proper manifold tubing size, material length
order number.

AA-99-01.1

66

6

66

EFM(D) Solventborne Robotic Atomizers - Introduction

MANIFOLD SELECTION GUIDEMANIFOLD SELECTION GUIDE

MANIFOLD SELECTION GUIDE

MANIFOLD SELECTION GUIDEMANIFOLD SELECTION GUIDE

WITH 3/16" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:WITH 3/16" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:

WITH 3/16" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:

WITH 3/16" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:WITH 3/16" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:

76494-16A for 16' length tubing
76494-25A for 25' length tubing
76494-50A for 50' length tubing

WITH 1/4" ID TEFLON PAINT AND DUMP TUBING, ORDER:WITH 1/4" ID TEFLON PAINT AND DUMP TUBING, ORDER:

WITH 1/4" ID TEFLON PAINT AND DUMP TUBING, ORDER:

WITH 1/4" ID TEFLON PAINT AND DUMP TUBING, ORDER:WITH 1/4" ID TEFLON PAINT AND DUMP TUBING, ORDER:

76494-16B for 16' length tubing
76494-25B for 25' length tubing
76494-50B for 50' length tubing

WITH 3/16" ID TEFLON PAINT AND DUMP TUBING, ORDER:WITH 3/16" ID TEFLON PAINT AND DUMP TUBING, ORDER:

WITH 3/16" ID TEFLON PAINT AND DUMP TUBING, ORDER:

WITH 3/16" ID TEFLON PAINT AND DUMP TUBING, ORDER:WITH 3/16" ID TEFLON PAINT AND DUMP TUBING, ORDER:

76494-16C for 16' length tubing
76494-25C for 25' length tubing
76494-50C for 50' length tubing

WITH 1/4" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:WITH 1/4" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:

WITH 1/4" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:

WITH 1/4" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:WITH 1/4" ID POLYETHYLENE PAINT AND DUMP TUBING, ORDER:

76494-16D for 16' length tubing
76494-25D for 25' length tubing
76494-50D for 50' length tubing

WITH 3/16" ID TEFLON PAINT AND 1/4" ID TEFLON DUMP TUBING, ORDER:WITH 3/16" ID TEFLON PAINT AND 1/4" ID TEFLON DUMP TUBING, ORDER:

WITH 3/16" ID TEFLON PAINT AND 1/4" ID TEFLON DUMP TUBING, ORDER:

WITH 3/16" ID TEFLON PAINT AND 1/4" ID TEFLON DUMP TUBING, ORDER:WITH 3/16" ID TEFLON PAINT AND 1/4" ID TEFLON DUMP TUBING, ORDER:

76494-16E for 16' length tubing
76494-25E for 25' length tubing
76494-50E for 50' length tubing

77

7

77

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Introduction

To allow for ease of configuration, operation, and modification of robot teach patterns, the following
spray point verticies are provided. Refer to Figure 1 for explanation of coordinates.

XX

X

XX

76480-02 EFM-6076480-02 EFM-60

76480-02 EFM-60° 14.812 13.397

76480-02 EFM-6076480-02 EFM-60

76482-02 EFM-9076482-02 EFM-90

76482-02 EFM-90° 12.894 14.313

76482-02 EFM-9076482-02 EFM-90

76485-02 EFMD-6076485-02 EFMD-60

76485-02 EFMD-60° 13.252 14.738

76485-02 EFMD-6076485-02 EFMD-60

76488-02 EFMD-9076488-02 EFMD-90

76488-02 EFMD-90° 11.240 15.078

76488-02 EFMD-9076488-02 EFMD-90

Y Y

Y

Y Y

AA-99-01.1

Figure 1: Applicator Tool-Point RepresentationFigure 1: Applicator Tool-Point Representation

Figure 1: Applicator Tool-Point Representation

Figure 1: Applicator Tool-Point RepresentationFigure 1: Applicator Tool-Point Representation

88

8

88

EFM(D) Solventborne Robotic Atomizers - Installation

INSTINST

INST

INSTINST

EFM AND EFMDEFM AND EFMD

EFM AND EFMD

EFM AND EFMDEFM AND EFMD

ROBOTIC AROBOTIC A

ROBOTIC A

ROBOTIC AROBOTIC A
INSTINST

INST

INSTINST

This information is intended
general installation parameters of this product
and, where applicable, its working relationship to
other ITW Ransburg system components in typical
use. Each installation is unique and should be
directed by an authorized ITW Ransburg
representative or conducted from the ITW
Ransburg installation drawings provided for your
particular installation.

POWER SUPPLPOWER SUPPL

POWER SUPPL

POWER SUPPLPOWER SUPPL
ASSEMBLASSEMBL

ASSEMBL

ASSEMBLASSEMBL

ALLAALLA

ALLA

ALLAALLA

ALLAALLA

ALLA

ALLAALLA

TIONTION

TION

TIONTION

TT

OMIZEROMIZER

T

OMIZER

TT

OMIZEROMIZER

TIONTION

TION

TIONTION

YY

Y

YY

ONLYONLY

ONLY to indicate the

ONLYONLY

YY

Y

YY

NOTESNOTES

NOTES

NOTESNOTES

Refer to the ITW Ransburg Service Manual

MicroPak Control UnitMicroPak Control Unit

MicroPak Control Unit

MicroPak Control UnitMicroPak Control Unit

regarding power supply installation.

Two low voltage control cables, 76495 and 76496,
connect from the Output terminal connection
(J3), located on the back of the power supply
assembly. These cables connect from the terminal
block (J3) to the robot manifold plate.

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 the
OSHA and NFPA-33).

> User should be aware of, and adhere to,

all local fire codes and ordinances.

> The user

disconnect between the power source and the
power supply which complies with appropri­ate codes.

HAZARDOUSHAZARDOUS

HAZARDOUS area (Reference

HAZARDOUSHAZARDOUS

MUSTMUST

MUST provide a properly fused

MUSTMUST

, for complete information

MUSTMUST

MUST be located

MUSTMUST

99

9

99

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Installation

AA-99-01.1

Figure 2: Low Voltage Cable ConnectionsFigure 2: Low Voltage Cable Connections

Figure 2: Low Voltage Cable Connections

Figure 2: Low Voltage Cable ConnectionsFigure 2: Low Voltage Cable Connections

1010

10

1010

EFM(D) Solventborne Robotic Atomizers - Installation

ROBOT MANIFOLDROBOT MANIFOLD

ROBOT MANIFOLD

ROBOT MANIFOLDROBOT MANIFOLD
ASSEMBLASSEMBL

ASSEMBL

ASSEMBLASSEMBL

(See Figure 3)(See Figure 3)

(See Figure 3)

(See Figure 3)(See Figure 3)

Bundle the seven lengths of tubing along with the
two low voltage power cables [6 & 7] and route
them through the center of the robot face plate past
the horizontal arm to the bulkhead bracket. Use
the six 5mm x 20mm socket head cap screws [2]
included with the robot manifold assembly to attach
the manifold assembly to the face plate of the
robot.

Connect the tubes to the appropriate fittings on the
bulkhead bracket. Connect low voltage power
cables [6 & 7] of the robot manifold assembly to the
MicroPak Controller. Shown is the version used
with the P-150 series robots which connects to a
terminal strip.

If a terminal strip or connectors are used at the
bulkhead plates, you must run the exact same
cable from the terminal strip back to the MicroPak
controller. Intrinsic safety rules must be followed
when running these cables. See "Intrinisic Safe
Wiring" in the "Operation" section of this manual.

!!

!

!!

YY

Y

YY

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

EFM SPRAEFM SPRA

EFM SPRA

EFM SPRAEFM SPRA
APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

(See Figure 3)(See Figure 3)

(See Figure 3)

(See Figure 3)(See Figure 3)

Attach EFM spray applicator [1])to robot manifold
plate [4] with six (6) 5/16-18 x 1 inch hex socket
screws [5] included with each applicator.

Nylon guide pins (A10004-00) and nylon hex
socket screws (EMF-204-1) are offered as an
option. These nylon parts may be used in place of
the metal hex socket screws and metal guide pins.
The plastic parts are designed to break quickly if
aa applicator crash occurs. Possible applicator
or robot damage may be avoided if the spray
applicator breaks away from the robot wrist during
contact with the workpiece.

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

!!

!

!!

> Install and route the hoses and cable so

that they are
excess of 120
cable bends are
(15cm) radius and are not subjected to more
than 360° of torsional twist. Failure to comply
with these parameters could cause equipment
malfunctions that might create
CONDITIONS!CONDITIONS!

CONDITIONS!

CONDITIONS!CONDITIONS!

YY

Y

YY

TT

OROR

T

OR

TT

OROR

NOTNOT

NOT exposed to temperatures in

NOTNOT

° F. Ensure that all hose and

NOT LESS THANNOT LESS THAN

NOT LESS THAN a 6 inch

NOT LESS THANNOT LESS THAN

HAZARDOUSHAZARDOUS

HAZARDOUS

HAZARDOUSHAZARDOUS

> Leave 12-24 inches of extra length on all

lines to prevent extreme tension being applied
to these lines during robot movement.

1111

11

1111

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Installation

NOTES

AA-99-01.1

1212

12

1212

EFM(D) Solventborne Robotic Atomizers - Installation

1313

13

1313

Figure 3: Robot Manifold and Spray Applicator InstallationFigure 3: Robot Manifold and Spray Applicator Installation

Figure 3: Robot Manifold and Spray Applicator Installation

Figure 3: Robot Manifold and Spray Applicator InstallationFigure 3: Robot Manifold and Spray Applicator Installation

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Installation

ROBOTROBOT

ROBOT

ROBOTROBOT
(Figure 3)(Figure 3)

(Figure 3)

(Figure 3)(Figure 3)

Item #Item #

Item #

Item #Item #

1 76488-02 EFM Spray Applicator 1
2 TR-SSF-024 5mm x 20mm Socket Head Cap Screws 6
3 76494-xx Robot Manifold Assembly 1
4 76560-01 Manifold Plate 1
5 SSF-3125 5/16-18 x 1" Hex Socket Screws 6
6 76496-xx Low Voltage Power Cable 1
7 76495-xx Intrinsic Safe Solenoid Cable 1

MANIFOLD MANIFOLD

MANIFOLD

MANIFOLD MANIFOLD

Part #Part #

Part #

Part #Part #

AND SPRA AND SPRA

AND SPRA

AND SPRA AND SPRA

DescriptionDescription

Description

DescriptionDescription

YY

APPLICA APPLICA

Y

APPLICA

YY

APPLICA APPLICA

TT

OR OR

T

OR

TT

OR OR

- P- P

- P

- P- P

ARAR

TS LISTTS LIST

AR

TS LIST

ARAR

TS LISTTS LIST

QtyQty

Qty

QtyQty

AA-99-01.1

1414

14

1414

EFM(D) Solventborne Robotic Atomizers - Operation

OPERAOPERA

OPERA

OPERAOPERA

These instructions indicate the general operating
parameters for this product in a normal working
relationship with other ITW Ransburg system
components in typical use. Each user application
is unique and operation should be initiated under
the guidance of an authorized ITW Ransburg
representative and/or be based on carefully
conducted tests and on careful observation of the
initial production characteristics.

SPRASPRA

SPRA

SPRASPRA
CONTROLSCONTROLS

CONTROLS

CONTROLSCONTROLS

Fluid flow, trigger, dump, atomization air pressure,
and fan air pressure are all remotely controlled
from the robot PLC. Atomization air, fan air, and
fluid trigger timing are adjusted electronically from
the LECU5004 MicroPak Control Unit. Figure 4 in
the "Operation" section generalizes the function of
the air and fluid passages internal to the applicator.

POWER SUPPLPOWER SUPPL

POWER SUPPL

POWER SUPPLPOWER SUPPL
CONTROLSCONTROLS

CONTROLS

CONTROLSCONTROLS

Refer to ITW Ransburg Service Manual

Control UnitControl Unit

Control Unit

Control UnitControl Unit

power supply operation.

YY

Y

YY

TIONTION

TION

TIONTION

APPLCIA APPLCIA

APPLCIA

APPLCIA APPLCIA

, for complete information regarding

YY

Y

YY

TT

T

TT

OROR

OR

OROR

MicroPakMicroPak

MicroPak

MicroPakMicroPak

All of the display signals are buffered and
continuously available for remote panels or PLC
monitoring. There is also an array of LEDs, which
display the status of the controller for operator
convenience.

GENERALGENERAL

GENERAL

GENERALGENERAL
AND ADJUSTMENTSAND ADJUSTMENTS

AND ADJUSTMENTS

AND ADJUSTMENTSAND ADJUSTMENTS

Paint ConductivityPaint Conductivity

Paint Conductivity

Paint ConductivityPaint Conductivity

The EFM/EFMD spray applicators are capable of
spraying typical automotive and industrial solvent
base paints including metallic and mica paints.
Spray tests, however, should always be conducted
before selecting an atomizer for use with highly
conductive paints.

TT

arget Distancearget Distance

T

arget Distance

TT

arget Distancearget Distance

The distance between the applicator tip and the
article being painted should be between 10 and 14
inches. Excessive distance causes a waste of
coating material and wrap back (paint particles
being deposited on the applicator body or the robot
arm). At close distances the voltage at the tip of
the applicator will be reduced, which decreases
the charging effect of the applicator.

INFORMA INFORMA

INFORMA

INFORMA INFORMA

NOTENOTE

NOTE

NOTENOTE

TIONTION

TION

TIONTION

VV

oltageoltage

V

oltage

VV

oltageoltage

The LECU5004 MicroPak Control Unit provides a
low voltage signal to the high voltage cascade
within the spray applicator. The unit may be
configured for local mode operation. The output
voltage/current levels are set by potentiometers
on the front panel in this mode. The unit may also
be configured for remote analog control (0-10
VDC) from a PLC controller.

Display FunctionDisplay Function

Display Function

Display FunctionDisplay Function

The display board continually displays the kV and
current output information.

1515

15

1515

> When using paints with metal par-

ticles, a problem of alignment may oc­cur. When alignment is achieved, appli­cator current increases to maximum and
applicator tip voltage decreases to near
zero kV. Alignment can normally be
controlled by making sure that the power
supply is turned on slightly after paint
begins to flow and by turning the power
supply off shortly before the paint stops
flowing. This timing function is controlled
by the LECU5004 MicroPak Control Unit
and is adjustable by the user. Refer to
ITW Ransburg Service Manual

MicroPak Control UnitMicroPak Control Unit

MicroPak Control Unit

MicroPak Control UnitMicroPak Control Unit

tails.

, for more de-

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Operation

NOTENOTE

NOTE

NOTENOTE

> If alignment occurs, turning off the

power supply will not usually break the
aligned metal particles. The paint located
between the applicator and the point of
first ground must be purged from the fluid
passages before normal spray can re­sume.

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

!!

!

!!

> Most paints and solvents, including those

listed in "Polar and Non-Polar Solvents Chart"
in the "Maintenance" section, are toxic to a
certain degree and flammable or combustible.
Use them only in a well ventilated atmosphere.
Use protective equipment as required in the
Material Safety Data Sheet supplied with the
substance.

Fluid Flow RateFluid Flow Rate

Fluid Flow Rate

Fluid Flow RateFluid Flow Rate

Fluid flow is adjusted through the robot PLC by
varying the pilot pressure to the fluid regulator
within the EFM or EFMD spray applicator. Fluid
pressures from the circulating system may be as
high as 300 psig.

Atomizing AirAtomizing Air

Atomizing Air

Atomizing AirAtomizing Air

Adjustments are made through the robot PLC or a
manually adjustable air regulator. The lowest air
pressure required to break up the paint should be
used. Lower atomizing air pressures result in less
overspray and increased transfer efficiency.

Fan AirFan Air

Fan Air

Fan AirFan Air

Adjusting the fan air increases or decreases the
size of the spray pattern. Increasing pressure
decreases pattern size. Pattern adjustment should
be made to suit the size and shape of the object
being painted. This adjustment is made through
the robot PLC or a manually adjustable air regula­tor.

TT

rigger Control Airrigger Control Air

T

rigger Control Air

TT

rigger Control Airrigger Control Air

The EFM and EFMD applicators require a minimum
of 70 psig trigger control air pressure to ensure
proper operation of the applicator piston and air
shuttle valves.

TT

rigger Trigger T

T

rigger T

TT

rigger Trigger T

The LECU5004 MicroPak Control Unit provides a
means for the adjustment of the timing interval
between air, fluid, and high voltage. When the
applicator receives a trigger on signal from the
robot PLC, the air solenoid valve actuates. At the
same time the fluid solenoid valve timer is activated.
After the timer times out, the fluid solenoid and the
high voltage timer are activated. This timer delays
the start of the high voltage until after both the air
and fluid are activated.

Timing can be set in nine different timing
sequences, from a minimum of zero to a maximum
of 450 milliseconds. When the electrical signal
from the robot PLC is removed, the timing operates
in reverse. High voltage is shut off, fluid shuts off,
and, finally, the air solenoid valve shuts off. See
ITW Ransburg Service Manual

Control UnitControl Unit

Control Unit

Control UnitControl Unit

supply operation and control features.

imingiming

iming

imingiming

, MicroPak, MicroPak

, MicroPak

, MicroPak, MicroPak

, for additional information on power

> It has been observed when spraying

metallic paints that mottling (marble ef­fect) can be reduced by increasing the
fan air pressure slightly higher than the
atomizing air.

AA-99-01.1

NOTENOTE

NOTE

NOTENOTE

1616

16

1616

EFM(D) Solventborne Robotic Atomizers - Operation

Electrostatic VElectrostatic V

Electrostatic V

Electrostatic VElectrostatic V

Normally the voltage should be set to 90 kV at the
power supply. Some conditions may dictate lower
voltage settings. If Faraday cage areas are
predominant on the item being painted, a lower
voltage setting will aid in coating these areas.

Paints having high metallic flake content will
sometimes align at high voltages. Metallic flakes,
when aligned, become a direct electrical path to
ground and will reduce tip voltage. This problem
can be minimized by making sure that the paint is
being sprayed from the applicator prior to turning
the voltage on. In some cases, a reduction in
applied voltage may be the only way to reduce
alignment.

oltageoltage

oltage

oltageoltage

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

!!

!

!!

> If target distance is less than 4 inches, an

arc could occur.

1717

17

1717

Figure 4: Simplified Air and Fluid Flow Passage LayoutFigure 4: Simplified Air and Fluid Flow Passage Layout

Figure 4: Simplified Air and Fluid Flow Passage Layout

Figure 4: Simplified Air and Fluid Flow Passage LayoutFigure 4: Simplified Air and Fluid Flow Passage Layout

AA-99-01.1

EFM(D) Solventborne Robotic Atomizers - Operation

INTRINSIC SAFE WIRINGINTRINSIC SAFE WIRING

INTRINSIC SAFE WIRING

INTRINSIC SAFE WIRINGINTRINSIC SAFE WIRING

Wiring PracticesWiring Practices

Wiring Practices

Wiring PracticesWiring Practices

Instrinsically safe wiring must be separated from
non-intrinsically safe wiring in order to prevent the
transfer of unsafe levels of energy to the hazardous
area. The following are a few recommended
practices:

Safe AreaSafe Area

Safe Area

Safe AreaSafe Area

In the non-hazardous area, intrinsically safe and
non-intrinsically safe wiring must be separated by
one of the following methods:

1. Raceway or conduit

2. Grounded metal or insulated partition between
the intrinsically safe and non-intrinsically safe
wiring

NOTENOTE

NOTE

NOTENOTE

> These sections are to be used as

guidelines or recommendations only. For
rules and more detailed practices, refer
to National Electrical Code.

Hazardous AreaHazardous Area

Hazardous Area

Hazardous AreaHazardous Area

In the hazardous area, all intrinsically safe and
non-intrinsically safe wiring must be separated by
the same methods suggested for the safe area.
However, the following requirements must also be
followed:

1. In enclosures containing multiple intrinsically
safe circuits, the terminals for connection must
have a spacing of at least 6mm or a grounded or
insulated partition between the circuits.

2. Devices like limit switches or pressure switches
must not contain a non-intrinsically safe circuit in
addition to an intrinsically safe circuit unless:

3. Airspace of at least 50mm (2 inches) between
intrinsically safe and non-intrinsically safe wiring
and the wires must be tied down to prevent
loosening and shorting together.

The same methods are used for intrinsically safe
and non-intrinsically safe terminals.

RequirementsRequirements

Requirements

RequirementsRequirements

Intrinsically safe wiring must be identified, prefer­ably by color coding of light blue. If light blue is
used on non-intrinsically safe wiring, the intrinsi­cally safe wiring may be marked by other means
such as tagging. This alternate means, however,
must be visible after installation.

a. It is enclosed in a separate compartment, or

b. It is separated by 50mm spacing or contains

a grounded metal or insulated partition.

3. When conduit or raceway is utilized to enclose
intrinsically safe wiring, it must be sealed or vented
so not to transfer the hazardous atmosphere to a
safe area.

AA-99-01.1

1818

18

1818

EFM(D) Solventborne Robotic Atomizers - Maintenance

MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

Good maintenance is essential to safe and
productive operation. Schedules should be
established by the user, based on the following
general information and observations of the initial
production requirements. The ITW Ransburg
maintenance and safety information should be
made available to each operator.

Normal fire protection measures are necessary,
including proper storage of paints and solvents
and the proper disposal of waste. Ready access
to appropriate fire extinguishing equipment is
required. For details, consult the appropriate
NFPA safety information, your local fire codes,
local painting equipment standards. Reference
OSHA, NFPA-33, and your insurance carrier's
information for additional information.

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

!!

!

!!

> An electrical discharge or spark may

create an electrical and/or fire hazard during
maintenance. Do not clean or service the
spray applicator with the power supply on.
Verify that the power supply has been locked
out and tagged out per OSHA.

ROUTINE MAINTENANCEROUTINE MAINTENANCE

ROUTINE MAINTENANCE

ROUTINE MAINTENANCEROUTINE MAINTENANCE
SCHEDULESCHEDULE

SCHEDULE

SCHEDULESCHEDULE

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

Several Times DailySeveral Times Daily

Several Times Daily

Several Times DailySeveral Times Daily

1. Turn the LECU5004 MicroPak Control Unit
OFFOFF

OFF!

OFFOFF

2. Inspect the fluid nozzle and electrode wire for
paint accumulation. Clean as frequently as
necessary. (See "Procedures"
nance" 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

!!

!

!!

> Take precautions to see that skin is not

punctured by sharp electrode.

Daily (Or at Shift Start)Daily (Or at Shift Start)

Daily (Or at Shift Start)

Daily (Or at Shift Start)Daily (Or at Shift Start)

1. Turn the LECU5004 MicroPak Control Unit
OFFOFF

OFF and:

OFFOFF

in the "Mainte-

> Unexpected robot movement can be

hazardous. Do not adjust or repair the spray
applicator when the robot is operating or wait­ing to start. The robot must be locked out and
tagged out per OSHA.

> Solvents used for equipment flushing must

have flash point ratings equal to or greater than
the flash point rating of the coating material.
Solvents used for general cleaning must have
flash point ratings higher than 100

1919

19

1919

°F (37.8°C).

• Check within 20 feet of the point of operation
(of the applicator) and remove or ground
ALLALL

ALL loose or ungrounded containers.

ALLALL

• Inspect workholders for accumulated coating
materials (remove such accumulations if
present)

• Check that the nozzle 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

!!

!

!!

> Do not bend the applicator electrode while

wiping. Never immerse the applicator in sol­vents. This will cause damage to the electrical
components.

AA-99-01.1