Ransburg 78101 User Manual
AEROBELLAEROBELL
AEROBELL
AEROBELLAEROBELL
®®
®
®®
M M
M
M M
SERVICE MANUAL
LN-9237-00.1LN-9237-00.1
LN-9237-00.1
LN-9237-00.1LN-9237-00.1
(Replaces LN-9237-00)
ROTROT
ROT
ROTROT
ARAR
AR
ARAR
YY
Y
YY
A A
A
A A
TT
OMIZEROMIZER
T
OMIZER
TT
OMIZEROMIZER
MODEL: 78101MODEL: 78101
MODEL: 78101
MODEL: 78101MODEL: 78101
IMPORIMPOR
IMPOR
IMPORIMPOR
fully read SAFETY PRECAUTIONS, starting onfully read SAFETY PRECAUTIONS, starting on
fully read SAFETY PRECAUTIONS, starting on
fully read SAFETY PRECAUTIONS, starting onfully read SAFETY PRECAUTIONS, starting on
page 1, and all instructions in this manual. Keeppage 1, and all instructions in this manual. Keep
page 1, and all instructions in this manual. Keep
page 1, and all instructions in this manual. Keeppage 1, and all instructions in this manual. Keep
this Service Manual for future reference.this Service Manual for future reference.
this Service Manual for future reference.
this Service Manual for future reference.this Service Manual for future reference.
TT
ANTANT
T
ANT
TT
ANTANT
: Before using this equipment, care-: Before using this equipment, care-
: Before using this equipment, care-
: Before using this equipment, care-: Before using this equipment, care-
Service Manual Price: $50.00 (U.S.)Service Manual Price: $50.00 (U.S.)
Service Manual Price: $50.00 (U.S.)
Service Manual Price: $50.00 (U.S.)Service Manual Price: $50.00 (U.S.)
NOTE:NOTE:
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.
LN-9237-00LN-9237-00
LN-9237-00 to revision
LN-9237-00LN-9237-00
LN-9237-00.1 LN-9237-00.1
LN-9237-00.1.
LN-9237-00.1 LN-9237-00.1
CONTENTSCONTENTS
CONTENTS
CONTENTSCONTENTS
SAFETY:SAFETY:
SAFETY:
SAFETY:SAFETY:
Aerobell M Rotary Atomizer - Contents
PAGEPAGE
PAGE
PAGEPAGE
1-51-5
1-5
1-51-5
SAFETY PRECAUTIONS.........................................................
HAZARDS / SAFEGUARDS.....................................................
INTRODUCTION:INTRODUCTION:
INTRODUCTION:
INTRODUCTION:INTRODUCTION:
FEATURES................................................................................
GENERAL DESCRIPTION.......................................................
SPECIFICATIONS.....................................................................
INSTALLATION:INSTALLATION:
INSTALLATION:
INSTALLATION:INSTALLATION:
AIR FILTER INSTALLATION.....................................................
AIR PRESSURE REQUIREMENTS.........................................
AIR FILTRATION REQUIREMENTS........................................
MOUNTING................................................................................
FLUID CONNECTIONS............................................................
ELECTRICAL CONNECTIONS................................................
SPEED MONITOR CONNECTIONS........................................
INTERLOCKS............................................................................
OPERATION:OPERATION:
OPERATION:
OPERATION:OPERATION:
COATING MATERIALS.............................................................
FLUID FLOW RATE CONTROL...............................................
FLUID VALVE CONTROL.........................................................
TURBINE SPEED......................................................................
BEARING AIR ADJUSTMENT..................................................
SHAPING AIR............................................................................
BRAKE AIR................................................................................
ELECTROSTATIC VOLTAGE..................................................
TARGET DISTANCE.................................................................
1
2
6-96-9
6-9
6-96-9
6
6
8
10-1310-13
10-13
10-1310-13
10
10
11
12
12
12
12
13
14-1914-19
14-19
14-1914-19
14
14
17
17
18
18
18
19
19
MAINTENANCE:MAINTENANCE:
MAINTENANCE:
MAINTENANCE:MAINTENANCE:
CLEANING PROCEDURES.....................................................
VIBRATION NOISE...................................................................
TURBINE REPAIR & REBUILD...............................................
HIGH VOLTAGE CONNECTIONS..........................................
AIR FILTERS / ELEMENT REPLACEMENT............................
VALVES.............................................................................................
GENERAL..................................................................................
PREVENTIVE MAINTENANCE................................................
LOW VOLTAGE TEST..............................................................
DISASSEMBLY PROCEDURES..............................................
TROUBLESHOOTING GUIDE.................................................
LN-9237-00.1
20-3120-31
20-31
20-3120-31
20
22
22
22
22
22
23
23
25
25
29
Aerobell M Rotary Atomizer - Contents
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS IDENTIFICATION:
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PAGEPAGE
PAGE
PAGEPAGE
32-4732-47
32-47
32-4732-47
30mm AEROBELL M CROSS SECTION VIEW.......................
57mm AEROBELL M CROSS SECTION VIEW.......................
70mm AEROBELL M CROSS SECTION VIEW.......................
AEROBELL M CROSS SECTION VIEW..................................
AEROBELL M MODEL IDENTIFICATION...............................
AEROBELL M PARTS LIST......................................................
AER4004-02 AIR MANIFOLD ASSEMBLY / PARTS LIST......
FLUID MANIFOLD ASSEMBLY / PARTS LIST........................
WATERBORNE FLUID MANIFOLD ASSEMBLY /
PARTS LIST...............................................................................
RECOMMENDED SPARE PARTS...........................................
SERVICE KITS..........................................................................
AVAILABLE TOOLS..................................................................
WARRANTY POLICIES:WARRANTY POLICIES:
WARRANTY POLICIES:
WARRANTY POLICIES:WARRANTY POLICIES:
LIMITED WARRANTY...............................................................
APPENDIX:APPENDIX:
APPENDIX:
APPENDIX:APPENDIX:
PAINT AND SOLVENT SPECIFICATIONS.............................
VISCOSITY CONVERSION CHART........................................
VOLUMETRIC CONTENT OF HOSE OR TUBE.....................
32
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49-5249-52
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LN-9237-00.1
SAFETYSAFETY
SAFETY
SAFETYSAFETY
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
SAFETY PRECAUTIONS
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
Aerobell M Rotary Atomizer - Safety
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.
A WARNING! states information to alert you toA WARNING! states information to alert you to
A WARNING! states information to alert you to
A WARNING! states information to alert you toA WARNING! states information to alert you to
a situation that might cause serious injury if in-a situation that might cause serious injury if in-
a situation that might cause serious injury if in-
a situation that might cause serious injury if in-a situation that might cause serious injury if instructions are not followed.structions are not followed.
structions are not followed.
structions are not followed.structions are not followed.
A CAUTION! states information that tells howA CAUTION! states information that tells how
A CAUTION! states information that tells how
A CAUTION! states information that tells howA CAUTION! states information that tells how
to prevent damage to equipment or how toto prevent damage to equipment or how to
to prevent damage to equipment or how to
to prevent damage to equipment or how toto prevent damage to equipment or how to
avoid a situation that might cause minor injury.avoid a situation that might cause minor injury.
avoid a situation that might cause minor injury.
avoid a situation that might cause minor injury.avoid a situation that might cause minor injury.
A NOTE is information relevant to the proce-A NOTE is information relevant to the proce-
A NOTE is information relevant to the proce-
A NOTE is information relevant to the proce-A NOTE is information relevant to the procedure in progress.dure in progress.
dure in progress.
dure in progress.dure 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, 2000 EDITION,SAFETY STANDARD, 2000 EDITION,
SAFETY STANDARD, 2000 EDITION,
SAFETY STANDARD, 2000 EDITION,SAFETY STANDARD, 2000 EDITION,
prior to installing, operating, and/or servicing this equipment.
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
> 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.
LN-9237-00.1
11
1
11
Aerobell M Rotary Atomizer - 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 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA 33, 2000 Edition, OSHA and
local codes. In addition, ventilation must be maintained during cleaning operations using flammable or combustible solvents.
General Use andGeneral Use and
General Use and
General Use andGeneral Use and
MaintenanceMaintenance
Maintenance
MaintenanceMaintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
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.
Personnel must be given training in accordance
with the requirements of NFPA 33, Chapter 16,
2000 edition.
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. OSHA references are Sections 1910.94 and 1910.107. Also
refer to NFPA 33, 2000 edition and your insurance
company requirements.
22
2
22
LN-9237-00.1
Aerobell M Rotary Atomizer - Safety
AREAAREA
AREA
AREAAREA
Tells where
hazards may
occur.
ElectricalElectrical
Electrical
ElectricalElectrical
EquipmentEquipment
Equipment
EquipmentEquipment
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
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 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.
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, 2000 Edition.
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 /
Incompatible MaterialsIncompatible Materials
Incompatible Materials
Incompatible MaterialsIncompatible Materials
Toxic SubstancesToxic Substances
Toxic Substances
Toxic SubstancesToxic Substances
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.
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
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.
LN-9237-00.1
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33
Aerobell M Rotary Atomizer - 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
Personnel Safety /Personnel Safety /
Personnel Safety /
Personnel Safety /Personnel Safety /
Mechanical HazardsMechanical Hazards
Mechanical Hazards
Mechanical HazardsMechanical Hazards
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting coating materials.
Inadequate grounding will cause
a spark hazard. A spark can
ignite many coating materials
and cause a fire or explosion.
The bell atomizer can rotate at
speeds up to 55,000 rpm. At
these speeds, the edge of the
applicator can easily cut into
skin. Loose articles can also be
caught by the rotating bell.
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.
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.
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.
Personnel must stay clear of the bell whenever it
is rotating.
Before touching the bell, the turbine air must be
shut off.
If the bell has been rotating, allow at least two
minutes for it to come to a complete stop before
touching it.
44
4
44
LN-9237-00.1
NOTES:NOTES:
NOTES:
NOTES:NOTES:
Aerobell M Rotary Atomizer - Safety
LN-9237-00.1
55
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55
Aerobell M Rotary Atomizer - Introduction
INTRODUCTIONINTRODUCTION
INTRODUCTION
INTRODUCTIONINTRODUCTION
FEAFEA
FEA
FEAFEA
Features which make the Aerobell® M Rotary
Atomizer advantageous for use in electrostatic
applications include:
• Proven long life turbine motor capable of
• 30mm, 57mm, and 70mm diameter bell as-
• Fast color changes are achieved using center
• Bell wash is quick and efficient. Solvent usage
TURESTURES
TURES
TURESTURES
speeds up to 55k rpm at minimal air consumption. See "Specifications" in the "Introduction" section of this manual for bell cup
speed ratings.
semblies available for application flexibility.
feed fluid delivery, integral brake air, high flow
regulator and the fluid valves which provide for
simultaneous paint push out while solvent
washes the feed tube and bell cup.
is controlled at the feed tube with an internally
mounted solvent valve.
spray angles for better paint coverage in difficult areas of the product.
• Turbine air exhausts behind bell, keeping paint
and solvent contamination out of atomizer interior and keeping back of bell clean.
• Speed readout (or control) uses reliable magnetic pickup for fiber-optic transmission of rotational speed data.
GENERAL DESCRIPTIONGENERAL DESCRIPTION
GENERAL DESCRIPTION
GENERAL DESCRIPTIONGENERAL DESCRIPTION
Bell AssemblyBell Assembly
Bell Assembly
Bell AssemblyBell Assembly
Metallic bell cups are available in both aluminum and titanium. Three different bell cup sizes
are available: 30mm, 57mm, and 70mm. Each
bell cup size has a matching front shroud and
shaping air ring.
• Less waste to the spray booth, with the dump
valve located internally next to the feed tube.
• More precise fluid regulation, with an (optional)
internal regulator.
• Easy to install and maintain. Hosing and connections are easily accessible at either the
rear of the assembly or by sliding back the
protective rear cover.
• Quick removal of the turbine assembly for offline repair.
• Annular shaping air passage design providing
excellent pattern control at minimal air consumption.
• Aerodynamic design for ease of cleaning external surfaces.
• Assembly can be swiveled to provide oblique
66
6
66
Air TAir T
urbine Assemblyurbine Assembly
Air T
urbine Assembly
Air TAir T
urbine Assemblyurbine Assembly
The air bearing turbine assembly with bell cup is
mounted to the air manifold assembly with four
socket head cap screws. The front resistor tube
is also attached to the air turbine assembly and
provides the high voltage connection to the motor shaft and bell.
Air and Fluid Manifold AssemblyAir and Fluid Manifold Assembly
Air and Fluid Manifold Assembly
Air and Fluid Manifold AssemblyAir and Fluid Manifold Assembly
This unit mounts onto the insulator support rod
assembly with a swivel post. The fluid valve
manifold block is mounted directly onto the back
side, connecting with fluid passages internal to
the manifold. Tube connections for valve control lines protrude through the rear shroud plate.
The fluid feed tube is screwed into the rear of
this manifold block and the air turbine assembly
mounts to the front with four socket head
screws.
LN-9237-00.1
Aerobell M Rotary Atomizer - Introduction
Insulator Support Rod AssemblyInsulator Support Rod Assembly
Insulator Support Rod Assembly
Insulator Support Rod AssemblyInsulator Support Rod Assembly
The air and fluid manifold assembly mount onto
the insulator support rod assembly, which in
turn is attached to the reciprocator or support
stand.
Rear Shroud AssemblyRear Shroud Assembly
Rear Shroud Assembly
Rear Shroud AssemblyRear Shroud Assembly
The rear shroud assembly consists of a rear
bulkhead which provides a passageway for fluid
and air tubes, mounting rods to connect the rear
bulkhead to the air and fluid manifold assembly,
a fluid regulator mounted onto the outside surface of the rear bulkhead, and a resistor module
nested between the rear bulkhead and air manifold assembly.
Resistor ModuleResistor Module
Resistor Module
Resistor ModuleResistor Module
The module encapsulates the high voltage resistors necessary for control of the electrostatic
charge being fed to the bell through the high
voltage cable.
High VHigh V
High V
High VHigh V
The SSW-1064, high voltage cable, is used to
connect the power supply to the resistor module
inside the atomizer assembly.
Speed Monitor/ControlSpeed Monitor/Control
Speed Monitor/Control
Speed Monitor/ControlSpeed Monitor/Control
The Aerobell M rotary atomizer is designed to
operate with the ITW Ransburg PulseTrackTM or
Atomizer Module for speed monitoring and/or
speed control.
oltage Cablesoltage Cables
oltage Cables
oltage Cablesoltage Cables
Power Supply andPower Supply and
Power Supply and
Power Supply andPower Supply and
Junction TJunction T
Junction T
Junction TJunction T
The Aerobell M System operates with a variety
of high voltage power supplies. The power supplies operate at output voltages of up to 100,000
volts DC. Also available is a junction tank which
is used to distribute high voltage to multiple
Aerobell M assemblies from a single power supply.
> The high voltage equipment that is
used in this application creates a hazard
for personnel. The high voltage power
supply is not approved for use inside of
the spray booth, as defined in NFPA 33.
This high voltage power supply can
produce sparks which are capable of
igniting coating material.
ankank
ank
ankank
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
!!
!
!!
LN-9237-00.1
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Aerobell M Rotary Atomizer - Introduction
SPECIFICASPECIFICA
SPECIFICA
SPECIFICASPECIFICA
ElectricalElectrical
Electrical
ElectricalElectrical
Power SupplyPower Supply
Power Supply LECU5003 / LEPS5001
Power SupplyPower Supply
Type:Type:
Type: (Voltage Master
Type:Type:
TIONSTIONS
TIONS
TIONSTIONS
TM
)
MechanicalMechanical
Mechanical
MechanicalMechanical
Length:Length:
Length:
Length:Length:
30mm Bell Cup:30mm Bell Cup:
30mm Bell Cup: 16.55 inches (420mm)
30mm Bell Cup:30mm Bell Cup:
57mm Bell Cup:57mm Bell Cup:
57mm Bell Cup: 16.37 inches (416mm)
57mm Bell Cup:57mm Bell Cup:
70mm Bell Cup:70mm Bell Cup:
70mm Bell Cup: 16.75 inches (425mm)
70mm Bell Cup:70mm Bell Cup:
Diameter:Diameter:
Diameter: 5.6 inches (142mm)
Diameter:Diameter:
76045 / LEPS5002
(MicroPakTM)
Charging Method:Charging Method:
Charging Method: Direct
Charging Method:Charging Method:
Output Voltage:Output Voltage:
Output Voltage: 30-100 kV Variable
Output Voltage:Output Voltage:
Output Current:Output Current:
Output Current: 125 μA (Short Circuit)
Output Current:Output Current:
Turbine SpeedTurbine Speed
Turbine Speed
Turbine SpeedTurbine Speed
Control:Control:
Control: PulseTrack or Eurocard
Control:Control:
Atomizer Module
Paint Resistance:*Paint Resistance:*
Paint Resistance:* .1 MΩ to
Paint Resistance:*Paint Resistance:*
**
*(Use Model No. 76652, Test Equipment)
**
Part Sprayability:Part Sprayability:
Part Sprayability: Determine sprayability of
Part Sprayability:Part Sprayability:
part to be coated using
76652, Test Equipment
(see TE-98-01).
∞
Approximate Weight:Approximate Weight:
Approximate Weight: 10.3 lbs. (4.7 kg)
Approximate Weight:Approximate Weight:
Turbine Type:Turbine Type:
Turbine Type: Air Bearing Impulse Drive
Turbine Type:Turbine Type:
Turbine Air Supply:Turbine Air Supply:
Turbine Air Supply: Variable (See Figures 1-4)
Turbine Air Supply:Turbine Air Supply:
At 30,000 rpmAt 30,000 rpm
At 30,000 rpm 23 psig (158 kPa)
At 30,000 rpmAt 30,000 rpm
(Nominal):(Nominal):
(Nominal): 7.7 scfm (220 slpm)
(Nominal):(Nominal):
Maximum TurbineMaximum Turbine
Maximum Turbine
Maximum TurbineMaximum Turbine
Speed:Speed:
Speed: Continuous (Intermittent)
Speed:Speed:
30mm Bell Cup:30mm Bell Cup:
30mm Bell Cup: 40,000 rpm (55,000 rpm)
30mm Bell Cup:30mm Bell Cup:
57mm Bell Cup:57mm Bell Cup:
57mm Bell Cup: 40,000 rpm (55,000 rpm)
57mm Bell Cup:57mm Bell Cup:
70mm Bell Cup:70mm Bell Cup:
70mm Bell Cup: 30,000 rpm (40,000 rpm)
70mm Bell Cup:70mm Bell Cup:
Bearing Air Supply:Bearing Air Supply:
Bearing Air Supply: (See Figure 6)
Bearing Air Supply:Bearing Air Supply:
(Nominal)(Nominal)
(Nominal) 90 psig (±10 psi)
(Nominal)(Nominal)
(621 kPa ±69 kPa)
2.1 scfm (60 slpm)
Shaping Air Supply:Shaping Air Supply:
Shaping Air Supply: Variable (See Figure 5)
Shaping Air Supply:Shaping Air Supply:
Nominal)Nominal)
(
Nominal) 5-15 psig (34-103 kPa)
Nominal)Nominal)
4.7-9.8 scfm (134-280 slpm)
Brake Air Supply:Brake Air Supply:
Brake Air Supply:
Brake Air Supply:Brake Air Supply:
(Nominal)(Nominal)
(Nominal)
(Nominal)(Nominal)
60 psig (414 kPa)
Maximum FluidMaximum Fluid
Maximum Fluid
Maximum FluidMaximum Fluid
Pressure Supply:Pressure Supply:
Pressure Supply: 100 psig (689 kPa)
Pressure Supply:Pressure Supply:
Fluid Flow Rate:Fluid Flow Rate:
Fluid Flow Rate: 25-500 cc/minute
Fluid Flow Rate:Fluid Flow Rate:
Usable Spray PatternUsable Spray Pattern
Usable Spray Pattern
Usable Spray PatternUsable Spray Pattern
Diameter:Diameter:
Diameter: 15-30 inches (381-762 mm)
Diameter:Diameter:
Bell Cup CleaningBell Cup Cleaning
Bell Cup Cleaning
Bell Cup CleaningBell Cup Cleaning
Time:Time:
Time: Approximately 2-3 seconds
Time:Time:
Color Change Time:Color Change Time:
Color Change Time: Dependent on system
Color Change Time:Color Change Time:
configuration, fluid
pressure, fluid viscosity,
fluid line lengths, etc.
Speed Readout:Speed Readout:
Speed Readout: Magnetic pickup,
Speed Readout:Speed Readout:
unidirectional fiber-optic
transmission
Atomizer ReplacementAtomizer Replacement
Atomizer Replacement
Atomizer ReplacementAtomizer Replacement
Time:Time:
Time: Less than 2 minutes
Time:Time:
Bell Cup ReplacementBell Cup Replacement
Bell Cup Replacement
Bell Cup ReplacementBell Cup Replacement
Time:Time:
Time: Less than 2 minutes
Time:Time:
88
8
88
LN-9237-00.1
Turbine Speed vs. Pr essur e
Aerobell M Rotary Atomizer - Introduction
Turbine Speed vs. Flow
20
70
60
PSI
50
40
30
20
10
57mm57mm
57mm
57mm57mm
BellBell
Bell
BellBell
30mm30mm
30mm
30mm30mm
BellBell
Bell
BellBell
0
0 10203040506070
Thousands RPM
Figure 1: Turbine Speed vs. PressureFigure 1: Turbine Speed vs. Pressure
Figure 1: Turbine Speed vs. Pressure
Figure 1: Turbine Speed vs. PressureFigure 1: Turbine Speed vs. Pressure
57mm Bell/Loaded vs. Unloaded
60
50
40
30
PSI
20
10
0
15 20 25 30 35 40 45 50 55
Load 600 cc/minLoad 600 cc/min
Load 600 cc/min
Load 600 cc/minLoad 600 cc/min
WaterWater
Water
WaterWater
Thousands RPM
UnloadedUnloaded
Unloaded
UnloadedUnloaded
15
57mm57mm
57mm
57mm57mm
BellBell
Bell
10
SCFM
5
0
0 10203040506070
Thousands RPM
Figure 2: Turbine Speed vs. FlowFigure 2: Turbine Speed vs. Flow
Figure 2: Turbine Speed vs. Flow
Figure 2: Turbine Speed vs. FlowFigure 2: Turbine Speed vs. Flow
BellBell
30mm30mm
30mm
30mm30mm
BellBell
Bell
BellBell
57mm Bell/Loaded vs. Unloaded
16
14
12
10
SCFM
8
6
4
15 20 25 30 35 40 45 50 55
Load 600 cc/minLoad 600 cc/min
Load 600 cc/min
Load 600 cc/minLoad 600 cc/min
WaterWater
Water
WaterWater
Thousands RPM
UnloadedUnloaded
Unloaded
UnloadedUnloaded
LN-9237-00.1
Figure 3: 57mm Bell / Loaded vs. UnloadedFigure 3: 57mm Bell / Loaded vs. Unloaded
Figure 3: 57mm Bell / Loaded vs. Unloaded
Figure 3: 57mm Bell / Loaded vs. UnloadedFigure 3: 57mm Bell / Loaded vs. Unloaded
Shaping Air Flow
20
18
16
14
12
10
SCFM
8
6
4
2
0
0 5 10 15 20 25
30mm30mm
30mm
30mm30mm
BellBell
Bell
BellBell
Figure 5: Shaping Air FlowFigure 5: Shaping Air Flow
Figure 5: Shaping Air Flow
Figure 5: Shaping Air FlowFigure 5: Shaping Air Flow
57mm57mm
57mm
57mm57mm
BellBell
Bell
BellBell
Pressure (PSI)
Figure 4: 57mm Bell / Loaded vs. UnloadedFigure 4: 57mm Bell / Loaded vs. Unloaded
Figure 4: 57mm Bell / Loaded vs. Unloaded
Figure 4: 57mm Bell / Loaded vs. UnloadedFigure 4: 57mm Bell / Loaded vs. Unloaded
Bearing Air Flow
2.6
2.5
2.4
2.3
2.2
2.1
2
SCFM
1.9
1.8
1.7
1.6
1.5
55 60 65 70 75 80 85 90 95
Pressure (PSI)
Figure 6: Bearing Air FlowFigure 6: Bearing Air Flow
Figure 6: Bearing Air Flow
Figure 6: Bearing Air FlowFigure 6: Bearing Air Flow
99
9
99
Aerobell M Rotary Atomizer - Installation
INSTINST
INST
INSTINST
AIR FILAIR FIL
AIR FIL
AIR FILAIR FIL
The following air filter installation guidelines are
essential for optimum performance.
1. Use only recommended pre-filters and
2. Mount the bearing air filter as close as
3. Do not use Teflon tape, pipe dope, or
4. If air heaters are used in the system (to
ALLAALLA
ALLA
ALLAALLA
TER INSTTER INST
TER INST
TER INSTTER INST
bearing air filters as shown in Figure 8.
Additional system air filtration (i.e., refrigerated air dryer) may also be used if desired.
possible to the Aerobell M. (Do not
mount further than 30 feet away.)
other thread sealant downstream of the
bearing air filter. Loose flakes of teflon
tape or other sealant can break loose
and plug the very fine air holes in the
turbine air bearings.
minimize the effect of excessively humid
conditions), and the heated air will exceed 120
after all filters to prevent damage to the
filter media.
o
TIONTION
TION
TIONTION
ALLAALLA
ALLA
ALLAALLA
F, the heaters must be located
TIONTION
TION
TIONTION
AIR PRESSUREAIR PRESSURE
AIR PRESSURE
AIR PRESSUREAIR PRESSURE
REQUIREMENTSREQUIREMENTS
REQUIREMENTS
REQUIREMENTSREQUIREMENTS
Tube SizeTube Size
Tube Size
Tube SizeTube Size
Bearing Air
Supply (B.A)
Bearing Air
Return (B.A)
Turbine Air (T.A)
Shaping Air (S.A)
Brake Air (BRK)
(if used)
Trigger Valve
Control (TV)
Dump Valve
Control (DV)
Solvent Valve
Control (SV)
Paint Fluid Regulator (Optional):Paint Fluid Regulator (Optional):
Paint Fluid Regulator (Optional):
Paint Fluid Regulator (Optional):Paint Fluid Regulator (Optional):
High Flow
Signal Air (High)
Low Flow
Signal Air (Low)
Figure 7: Air Tubing ConnectionsFigure 7: Air Tubing Connections
Figure 7: Air Tubing Connections
Figure 7: Air Tubing ConnectionsFigure 7: Air Tubing Connections
1/4" O.D.
1/4" O.D.
1/2" O.D.
3/8" O.D.
3/8" O.D.
1/4" O.D.
1/4" O.D.
1/4" O.D.
1/4" O.D.
1/4" O.D.
Air PressureAir Pressure
Air Pressure
Air PressureAir Pressure
RequirementsRequirements
Requirements
RequirementsRequirements
90 psi ±10
(621kPa ± 69kPa)
80 psi ±10
(551kPa ± 69kPa)
Variable
Variable
60 psi ±10
(413kPa ± 69kPa)
80 psi ±10
(551kPa ± 69kPa)
80 psi ±10
(551kPa ± 69kPa)
80 psi ±10
(551kPa ± 69kPa)
Variable
70 psi max.
(482 kPa)
Variable
80 psi max.
(551 kPa)
1010
10
1010
LN-9237-00.1
Aerobell M Rotary Atomizer - Installation
AIR FILAIR FIL
AIR FIL
AIR FILAIR FIL
REQUIREMENTSREQUIREMENTS
REQUIREMENTS
REQUIREMENTSREQUIREMENTS
ITW RansburgITW Ransburg
ITW Ransburg
ITW RansburgITW Ransburg
Filter Model No.Filter Model No.
Filter Model No.
Filter Model No.Filter Model No.
HAF-503
RPM-417
RPM-418
TRATRA
TRA
TRATRA
!!
!
!!
TIONTION
TION
TIONTION
Description / SpecificationsDescription / Specifications
Description / Specifications
Description / SpecificationsDescription / Specifications
Pre-filter, removes coarse amounts of oil, moisture &
dirt. Used upstream of RPM-417 pre-filter (used in
systems with poor air quality).
Pre-filter, coalescing type, 136 scfm, 98.5% efficiency
particulate removal .3 to .6 micron, max. aerosol passed
1.0 micron, max. solid passed .4 micron (dependent
upon scfm requirement per applicator, one RPM-417
can be used with up to three Aerobell M assemblies).
Bearing air filter, coalescing type, 19 scfm, 99.995%
efficiency particulate removal .3 to .6 micron, max.
aerosol passed .6 micron, max. solid passed .2 micron
(one per applicator).
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
Figure 8: Recommended Air FiltrationFigure 8: Recommended Air Filtration
Figure 8: Recommended Air Filtration
Figure 8: Recommended Air FiltrationFigure 8: Recommended Air Filtration
ReplacementReplacement
Replacement
ReplacementReplacement
Element Part No.Element Part No.
Element Part No.
Element Part No.Element Part No.
HAF-15 Element, One
RPM-32 Elements,
Carton of 4
RPM-33 Elements,
Carton of 8
> Air must be properly filtered to ensure
extended turbine life and to prevent
contamination of the paint finish. Air
which is not adequately filtered will foul
the turbine air bearings and cause turbine
failure. The correct type of filters must be
used in an Aerobell M system. The filter
elements must be replaced on a regular
schedule to assure clean air.
It is the user’s responsibility to en-It is the user’s responsibility to en-
>
It is the user’s responsibility to en-
It is the user’s responsibility to en-It is the user’s responsibility to en-
sure clean air at all times. Turbine failuresure clean air at all times. Turbine failure
sure clean air at all times. Turbine failure
sure clean air at all times. Turbine failuresure clean air at all times. Turbine failure
resulting from contaminated air will notresulting from contaminated air will not
resulting from contaminated air will not
resulting from contaminated air will notresulting from contaminated air will not
be covered under warranty.be covered under warranty.
be covered under warranty. Figure 8
be covered under warranty.be covered under warranty.
shows the pre-filter and bearing air filter(s)
which are recommended for use in
Aerobell M systems. If other filters are
incorporated in the system, the filters to
be used must have filtering capacities
equal or better than those shown in Figure
8.
LN-9237-00.1
> The user must ensure the bearing air
supply is not inadvertently turned off while
the Aerobell M air motor is turning. This
will cause air bearing failure.
1111
11
1111
Aerobell M Rotary Atomizer - Installation
MOUNTINGMOUNTING
MOUNTING
MOUNTINGMOUNTING
The Aerobell M incorporates its own insulator
mounting rod. The diameter at the rear is 1.9
inches, for mounting to a reciprocator, stationary
stand, or other means of support. The atomizer
assembly is mounted to this horizontal rod by a
3/4 inch insulating post, inserted into a swivel
clamp and secured by four plastic bolts. The
arrangement allows positioning of the front of
the turbine. Normally, the insulator support rod
is positioned perpendicular to the conveyor
path, with the swivel providing for left or right
adjustment of the atomizer assembly. The
swivel clamp plate can be inverted to provide a
locking mechanism to hold the applicator in line
with the insulator support rod.
FLUID CONNECTIONSFLUID CONNECTIONS
FLUID CONNECTIONS
FLUID CONNECTIONSFLUID CONNECTIONS
The paint supply to the Aerobell M is connected
at the rear of the atomizer assembly to the
regulator. Solvent and dump line connections
enter the housing and are connected to the
appropriate valves. Ports are labeled with blue
lettering.
ELECTRICALELECTRICAL
ELECTRICAL
ELECTRICALELECTRICAL
CONNECTIONSCONNECTIONS
CONNECTIONS
CONNECTIONSCONNECTIONS
Electrical connections to the Aerobell M atomizer assembly consist of only the high voltage
cable. This cable plugs into the resistor module
fitting, located at the rear of the assembly, which
protrudes through an opening in the rear bulkhead. After inserting the cable entirely into the
tube and feeling the banana plug make contact
on the inside, tighten the cable compression
fitting nut around the high voltage cable with an
appropriate wrench. Reinstall the connector
cover with plastic screw.
SPEED MONITSPEED MONIT
SPEED MONIT
SPEED MONITSPEED MONIT
CONNECTIONSCONNECTIONS
CONNECTIONS
CONNECTIONSCONNECTIONS
A fiber-optic cable assembly connects the
speed signal output of the rotary atomizer
assembly to the Pulsetrak Speed Monitor/
Control System or Fotronics Atomizer Module.
OROR
OR
OROR
FixedFixed
Fixed
FixedFixed
AtomizerAtomizer
Atomizer
AtomizerAtomizer
Paint Line
(P.IN)
Solvent Line
(SOL)
Dump Line
(DUMP)
Figure 9: Fluid Tubing Connection RequirementsFigure 9: Fluid Tubing Connection Requirements
Figure 9: Fluid Tubing Connection Requirements
Figure 9: Fluid Tubing Connection RequirementsFigure 9: Fluid Tubing Connection Requirements
> The normal fluid flow range is 25-500
cc/minute. The maximum flow rate must
not exceed 500 cc/minute to avoid solvent
or paint from flooding into the internal
portion of the air bearing motor assembly
or front shroud.
.156", .170", or .188" I.D.
PFA, Teflon
.125" I.D.
PFA, Teflon
.250" I.D.
PFA, Teflon
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
!!
!
!!
(nominal/max.)
(207-413 kPa)
PressurePressure
Pressure
PressurePressure
100 psig
(689 kPa)
30-60 psig
Variable
1212
12
1212
LN-9237-00.1
Aerobell M Rotary Atomizer - Installation
INTERLOCKSINTERLOCKS
INTERLOCKS
INTERLOCKSINTERLOCKS
The following system interlocks are required to
prevent equipment damage:
1. Bearing air should remain on at all times
and should be shut off only by turning off
the main air to the pneumatic control
cabinet.
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 the turbine air is turned off, the
turbine will continue to operate or “coast
down” for about two minutes. Provisions
should be made to assure that the operator waits at least three minutes, after
shutting off the turbine air, before shutting
off the main air supply.
> The bell assembly must be removed
when making flow checks. If the paint is
turned on when the bell is mounted on the
motor shaft and not rotating, paint will
enter the shaft and possibly damage the
air bearing. Normally pneumatic interlocks will not allow the paint to trigger on
when the turbine air is off.
3. Two interconnected bearing air ports are
provided, one for supply air and the
other to be used as a return signal for
measuring bearing air pressure at the
atomizer. If bearing air falls below 60 psi
at the atomizer, the turbine air should be
automatically interlocked to shut off.
4. High voltage must be interlocked with
the solvent valve pilot signal to prevent
solvent flow while high voltage is energized.
5. Turbine air and brake air must be interlocked to prevent both from being used
simultaneously.
2. It should not be possible for the coating
LN-9237-00.1
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 high voltage and/or coating
material must never be turned on unless
the bell cup is mounted on the motor shaft
and the turbine is rotating.
> Pneumatic input to the turbine air inlet
must be controlled to prevent the turbine
from exceeding the maximum rated
intermittent speed of 55,000 rpm for
30mm and 57mm bell cups and 40,000
rpm for 70mm bell cups. (See "Specifications" in the "Introduction" section.)
material to be sprayed unless the turbine
is spinning.
1313
13
1313
Aerobell M Rotary Atomizer - Operation
OPERAOPERA
OPERA
OPERAOPERA
!!
!
!!
> Operators must be fully trained in safe
operation of electrostatic equipment.
Operators must read all instructions and
safety precautions prior to using this
equipment (See NFPA 33, Chapter 16).
As with any spray finishing system, operation of
the Aerobell M involves properly setting the operating parameters to obtain the best finish
quality for the coating material being sprayed,
while maintaining correct operation and reliability of the equipment used. Adjustments to operating parameters, which cover spraying, cleaning and on/off control, include:
• Coating Materials
• Fluid Flow Rate Control
• Fluid Valve Control
• Turbine Speed
• Bearing Air Adjustment
• Shaping Air
• Brake Air
• Electrostatic Voltage
• Target Distance
COACOA
COA
COACOA
The Aerobell M can be used with a full range of
coating material conductivities. However, with
coatings having very high conductivities, such
as waterborne paints, it may be necessary to
isolate paint supply from ground.
TING MATING MA
TING MA
TING MATING MA
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
TERIALSTERIALS
TERIALS
TERIALSTERIALS
FLUID FLOW RAFLUID FLOW RA
FLUID FLOW RA
FLUID FLOW RAFLUID FLOW RA
CONTROLCONTROL
CONTROL
CONTROLCONTROL
Fluid flow is controlled by an internally mounted
dual diaphragm fluid regulator. Reference the
LREG5001, DR-1
Manual# LN-9221-00 (latest version) for
detailed information.
The regulator features two independently controllable flow pressure ranges from the fluid
output port. The high flow range port accommodates higher fluid deliveries thereby providing
increased film build capabilities and minimal
color change times. The low flow range provides precise fluid delivery control. There are
seven low range models available (1:1, 1:2, 1:3,
1:4, 1:6, 1:8, and 1:10) which can be selected
based on the required fluid flow rate.
Separate pilot signals modulate each of the
regulator’s two diaphragms to control the
amount of paint being delivered from the regulator to the atomizer bell cup. These pilot signals
can be controlled manually or automatically with
closed loop flow control system.
Because of the regulator’s dual range capabilities, it provides the user flexibility of selecting
either the high flow range or the low flow range.
Different coating material viscosities and quick
color change requirements may necessitate the
use of both ranges. If color change time is not a
factor or if material viscosity remains relatively
constant, either port may be used depending on
flow rate requirements.
TM
Plastic Fluid Regulator,
TETE
TE
TETE
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
!!
!
!!
> Electrical discharge of a high electrical
capacitance fluid/paint system can cause
fire or explosion with some materials. If
arcing occurs when a specific coating
materials is used, turn the system off and
verify that the fluid is nonflammable. In
these conditions the system is capable of
releasing sufficient electrical and thermal
energy to cause ignition of specific hazardous material in air.
1414
14
1414
The high flow port characteristics are similar to
those found in most commercially available, air
operated fluid regulators. Fluid regulation from
the high flow port is therefore comparable in total flow capacity, although consistency of flow is
improved considerably when using a regulator.
All regulators, regardless of ratio designation,
have the high flow port.
The low flow (i.e. 1:2, 1:4, etc.) port provides a
lower, more precise flow response curve. Fluid
output, as a result, is less likely to be affected
by pilot signal errors. An increase in the ratio
LN-9237-00.1
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