Ransburg 78863-90, 78863-60 User Manual

(Replaces AA-03-01)

ROBOT WATERBASE APPLICATOR

SERVICE MANUAL

AA-03-01.1

January - 2013

MODEL: 78863-90, 78863-60

IMPORTANT: Before using this equipment, carefully
read SAFETY PRECAUTIONS, starting on page 1, and all
instructions in this manual. Keep this Service Manual
for future reference.

Service Manual Price: $30.00

AA-03-01.1

CONTENTS

SAFETY:

Robot Waterbase Applicator - Contents

PAGE

1-4

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

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

INTRODUCTION:

DESCRIPTION.............................................................................................................................

RWA-EFM ELECTROSTATIC SPRAY GUNS FOR

HIGHLY CONDUCTIVE COATINGS..........................................................................................

EFM SERIES SPRAY GUNS & 78941-XXXXX ROBOT

MANIFOLD ASSEMBLY..............................................................................................................

FEATURES..................................................................................................................................

- 78941-XXXXX Robot Manifold Assembly.................................................................................

- Typical Robotic Applicator Mounting.........................................................................................

- Power Supply............................................................................................................................

- Tool Center Point.......................................................................................................................

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

INSTALLATION:

POWER SUPPLY........................................................................................................................

POWER SUPPLY, MANIFOLD AND GUN WIRING..................................................................

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

ROBOT SPACER PLATE............................................................................................................

ROBOT SPACER PLATE MOUNTING......................................................................................

1
2-4

6-10

6

6

7
8
8
8
9
9
10

11-15

11
12
13
14
14-15

OPERATION:

SPRAY GUN CONTROLS..........................................................................................................

MAINTENANCE:

PREVENTIVE MAINTENANCE..................................................................................................

- Internal Cleaning & Flushing......................................................................................................

- External Cleaning......................................................................................................................

POLAR AND NON-POLAR SOLVENTS....................................................................................

APPLICATOR DISASSEMBLY...................................................................................................

HEAD REMOVAL / REPAIR........................................................................................................

HEAD ASSEMBLY DIAGRAM....................................................................................................

HEAD REBUILD...........................................................................................................................

VALVE BODY REMOVAL / REPAIR..........................................................................................

FLANGE REMOVAL....................................................................................................................

REAR PLATE REMOVAL DIAGRAM.........................................................................................

HARNESS REMOVAL.................................................................................................................

(Maintenance Cont. Next Page)

AA-03-01.1

16-17

16-17

18-36

18
18
18
19
19
19-20
21
22
22
22
23-24
24

Robot Waterbase Applicator - Contents

MAINTENANCE (Cont.):

CASCADE / TIE ROD REMOVAL...............................................................................................

ISOLATION TUBE REMOVAL....................................................................................................

CHECK VALVE REMOVAL.........................................................................................................

DUMP VALVE REMOVAL...........................................................................................................

LOW VOLTAGE CABLE REMOVAL...........................................................................................

FLUID TUBE REPAIR / REPLACE.............................................................................................

FLUID TUBE REASSEMBLY......................................................................................................

FLUID HOSE CUTBACK DIAGRAM..........................................................................................

ASSEMBLED HOSE LENGTH DIAGRAM.................................................................................

BARBED FITTING DIAGRAM.....................................................................................................

COLOR CODE TABLE................................................................................................................

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

PARTS IDENTIFICATION:

78863-XX RWA-EFM APPLICATOR DIAGRAM /

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

76479-01 HEAD ASSEMBLY DIAGRAM /

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

REAR PLATE DIAGRAM / PARTS LIST.....................................................................................

AIR, VOLTAGE, MATERIAL, AND TIE ROD

COMPONENTS............................................................................................................................

RWA-EFM VALVE MANIFOLD ASSEMBLIES

DIAGRAM / PARTS LIST.............................................................................................................

ROBOT MANIFOLD ASSEMBLY DIAGRAM /

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

18-36

26
27-28
29
30
31-32
32
32
32
33
33
33
34-36

38-49

38-39

40-41
42-43

44-45

46-47

48-49

WARRANTY POLICIES:

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

APPENDIX:

PAINT AND SOLVENT SPECIFICATIONS................................................................................

VISCOSITY CONVERSION CHART...........................................................................................

VOLUMETRIC CONTENT OF HOSE OR TUBE........................................................................

50

50

51-54

51
52-53
54

AA-03-01.1

SAFETY

SAFETY PRECAUTIONS

Robot Waterbase Applicator - Safety

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

A WARNING! states information to alert you to a situ-
ation that might cause serious injury if instructions
are not followed.

A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.

A NOTE is information relevant to the procedure in
progress.

While this manual lists standard specications and
service procedures, some minor deviations may be
found between this literature and your equipment.
Dierences in local codes and plant requirements,
material delivery requirements, etc., make such
variations inevitable. Compare this manual with
your system installation drawings and appropriate
Ransburg equipment manuals to reconcile such
dierences.

W A R N I N G

!

> The user MUST read and be familiar with the

Safety Section in this manual and the Ransburg
safety literature therein identied.

> This manual MUST be read and thoroughly

understood by ALL personnel who operate, clean
or maintain this equipment! Special care should
be taken to ensure that the WARNINGS and safety
requirements for operating and servicing the
equipment are followed. The user should be
aware of and adhere to ALL local building and re
codes and ordinances as well as NFPA 33 SAFETY
STANDARD, 1995 EDITION, prior to installing,
operating, and/or servicing this equipment.

W A R N I N G

!

> The hazards shown on the following page

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

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

AA-03-01.1

1

Robot Waterbase Applicator - Safety

AREA

Tells where hazards

may occur.

Spray Area

HAZARD

Tells what the hazard is.

Fire Hazard

Improper or inadequate operation
and maintenance procedures will
cause a re hazard.

Protection against inadvertent arc­ing that is capable of causing re or
explosion is lost if any safety inter­locks are disabled during operation.
Frequent power supply shutdown
indicates a problem in the system
requiring correction.

SAFEGUARDS

Tells how to avoid the hazard.

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

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

Smoking must never be allowed in the spray area.

The high voltage supplied to the atomizer must be
turned o prior to cleaning, ushing or maintenance.

When using solvents for cleaning:

Those used for equipment ushing should have ash
points equal to or higher than those of the coating
material.

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

Spray booth ventilation must be kept at the rates re­quired by NFPA 33, 1995 Edition, OSHA and local codes.
In addition, ventilation must be maintained during
cleaning operations using ammable or combustible
solvents.

General Use and
Maintenance

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 modications may cause re or injury.

If used, the key switch by-pass is intended for use only
during set-up 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, 1995 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, re protection, operation main­tenance, and housekeeping. OSHA references are Sec­tions 1910.94 and 1910.107. Also refer to NFPA-33, 1995
edition and your insurance company requirements.

2

AA-03-01.1

Robot Waterbase Applicator - Safety

AREA

Tells where hazards

may occur.

Electrical
Equipment

HAZARD

Tells what the hazard is.

High voltage equipment is utilized.
Arcing in areas of ammable or
combustible materials may occur.
Personnel are exposed to high volt­age during
operation and maintenance.

Protection against inadvertent arc­ing that may cause a re 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 re or explo­sion.

SAFEGUARDS

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 No. 33, 1995 Edition.

Turn the power supply OFF before working on the
equipment.

Test only in areas free of ammable 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 /
Incompatible
Materials

Toxic 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, ushing, 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 spray-ed and its concentra­tion. Equipment must be as prescribed by an industrial
hygienist or safety expert, and be NIOSH approved.

AA-03-01.1

3

Robot Waterbase Applicator - Safety

AREA

Tells where hazards

may occur.

Spray Area / High
Voltage Equipment

Robot Work Area ­General Use and
Maintenance

HAZARD

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 re or explosion.

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

SAFEGUARDS

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 specically 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.

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.

Personnel Safety

Skin puncturing by sharp elec­trode.

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

Take precautions to see that esh is not punctured by
sharp electrode.

4

AA-03-01.1

Notes:

Robot Waterbase Applicator - Safety

AA-03-01.1

5

Robot Waterbase Applicator - Introduction

INTRODUCTION

DESCRIPTION

The Ransburg Robot Waterbase Applicator RWA-EFM
Series Spray Applicators for highly conductive coat­ings are air atomizing, fan pattern 100 kV automatic
electrostatic spray guns. The waterbase or solvent­base paint is charged by the resistive electrode in
the spray head of the gun. These guns have been
developed for use on today's robots. These guns
were designed to be used with a voltage block sys­tem such as the AquaBlock or isolated paint tanks.
A separate manifold assembly includes single low
voltage cable and the hosing required to operate
the spray gun. The guns are manufactured in either
60° or 90° head congurations.

RWA-EFM ELECTROSTATIC
SPRAY GUNS FOR HIGHLY
CONDUCTIVE COATINGS

There are two models of the RWA-EFM Spray Guns
for highly conductive coatings. (See Figure 1) All
internal gun componenets are basically the same;
the only apparent dierences is the head angle,
either 60° or 90°.

The spray gun has three major parts: the spray head
assembly, the valve manifold section, and the valve
housing section. (See Figure 1) The gun body is fab­ricated with the uid, air, and dump passages. There
is a removable check valve to allow air to blow down
the dump line while paint is spraying. This prevents
grounding out of the applicator when spraying highly
conductive materials.

EFM SPRAY GUN MODELS

Model # Description

78863-60 60° Single Spray Head Assembly

78863-90 90° Single Spray Head Assembly

6

AA-03-01.1

Robot Waterbase Applicator - Introduction

AA-03-01.1

Figure 1: RWA-EFM Series Spray Guns and 78941-XXXXX Robot Manifold Assembly

7

Robot Waterbase Applicator - Introduction

FEATURES

The features of the RWA-EFM series guns include:

• Standard Ransburg air cap (76131-01), tip
(76132- 00), and nozzle (EMF-195).

• Integral dump valve and dump air purge.

• Fluid dump valve is located adjacent to the uid
passages.

• HP-404 Internal Cascade

• Waterbase or solventbase compatible

• Screw on robot mount plate quick disconnect.

The EFM spray gun system consists of two major
components: the gun assembly (78863-XX) and
the robot manifold assembly (78941-XXXXX).

78941-XXXXX Robot Manifold Assembly

78941-XXXXX is designed to connect the 78863-60
or 78863-90 spray gun to the Fanuc or ABB robots. A
50 ft. low voltage control cable (76496-50) is supplied
with the robot manifold to connect the cascade to
the MicroPak power supply.

The uid hose and dump line hose is shielded to
prevent voltage from charging or bleeding voltage
to items the hose comes in contact with.

The "Paint In" line is 3/16" I.D. (standard) and is
1/4" I.D. for the dump line (standard).

Figure 2: Typical Robotic Applicator Mounting

8

AA-03-01.1

Robot Waterbase Applicator - Introduction

Power Supply

Figure 2 shows the optional isolated uid supply
system in line with the RWA-EFM applicators. This
supply is required to create a voltage block which is
necesary to keep the voltage from passing throughout
the entire uid supply system when highly conductive
materials are used. Voltage is supplied to the uid
through contact with the resistive electrode in the
gun. The resistive electrode in the gun passes back
to the voltage block where it is "blocked" or "isolated"
from traveling any further through the uid supply
system. The uid tube enters an opening in the end
of the robot arm. The uid tube passes through the
robot arm to the robot manifold where the spray gun
attaches to the robot.

The RWA-EFM series spray guns operate from any
MicroPak power supply.

Tool Center Point

Figure 3 shows the tool center-point information
on both guns. Both are based upon a 10" (254mm)
target distance.

AA-03-01.1

Figure 3: Gun Tool Center-Point Representation

9

Robot Waterbase Applicator - Introduction

SPECIFICATIONS

RWA-EFM Series Electrostatic Spray Guns for Highly Conductive Coatings

Weight

78863-60: 10.2 lbs. (4.6Kg)
78863-90: 10.1 lbs. (4.6Kg)

Length

78863-60: 14.93" (379mm)
(See Figure 3)

78863-90: 12.93" (328mm)
(See Figure 3)

Operating Air Pressures

Atomizing Air: 100 psig max. (6.9 bar)

Fan Air: 100 psig max. (6.9 bar)

Trigger Air: 150 psig max./70 psig min.
(10.3 bar / 4.8 bar)

Purge Air: 200 psig max. (13.8 bar)

Dump Pilot: 150 psig max./70 psig min.
(10.3 bar/4.8 bar)

Fluid Pressure

Max Fluid Pressure: 250 psig
(17.2 bar)

Air Flow Rates/Pressures
(Recommended start point for fan and
atomizing pressures.)
Note: Pressure taken at the cap

Robot Manifold Tubing Requirements

Atomizing Air: 3/8" O.D. Nylon
(Natural color)

Pattern Air: 3/8" O.D. Nylon
(Black color)

Paint In: 3/16" I.D. Shielded

Dump Out: 1/4" I.D. Shielded

Trigger Air: 3/16" O.D. Nylon
(Green color)

Dump Pilot: 3/16" O.D. Nylon
(Red color)

Air Purge: 3/16" O.D. Nylon
(Blue color)

Electrical

Operating Voltage: 0-100 kV
0-125 µA

Applicator Nomenclature/Hose Identication:

A Atomization Air (Natural)
F Fan Air (Black)
T Trigger (Green)
DP Dump Pilot (Red)
AP Purge Air (Blue)
TB Trigger Bleed
P Paint In
D Dump Out

Atomizer Air: 27 psig (1.8 bar)

Fan Air: 30 psig (2.1 bar)

Total Air Flow: 17.50 SCFM
(496 SLPM)
Air Purge: 35 psig

10

AA-03-01.1

INSTALLATION

Robot Waterbase Applicator - Installation

W A R N I N G

!

> If improperly located, certain electrical equip-

ment will become a source of ignition and may
cause re or explosion. Any power supply must
be located outside Class I or Class II, Division 1
and 2 hazardous areas. (Reference NFPA #33 or
National Electrical Code, article 516).

POWER SUPPLY

Refer to the Ransburg Service Instruction for the
power supply being used for complete information.
(Reference the current MicroPak Service Manual.)

A low voltage cable, 76496-XX (See Figure 4), con­nects from an output connection in the MicroPak
to the robot manifold plate. (Refer to Figure 4 for
connection diagram.)

AA-03-01.1

11

Robot Waterbase Applicator - Installation

EARTH GROUND3/4" BRAID CABLE

Figure 4: Power Supply, Manifold, and Gun Wiring

12

AA-03-01.1

Robot Waterbase Applicator - Installation

ROBOT MANIFOLD ASSEMBLY

The tubing, hose, and low voltage cable come
bundled from the factory. Pull the bundle through
the robot spacer plate and robot wrist carefully to
prevent any cuts on the cable or hoses. Connect
each signal line as required per signal legend:

AP Air Purge (Blue color)
DP Dump Pilot (Red color)
TP Trigger Pilot (Green color)
A Atomizer Air (Natural color)
F Fan Air (Black color)

Connect "Paint In" and "Dump Out" line (shielded
hose) to their proper respective connections. Im­proper connection of these lines could cause damage
to the applicator.

NOTE

NOTE

> Failure to strip back the shielded hose will

increase current draw and lower tip voltage
reducing eciency of the applicator.

> "Paint In" line is 3/16" I.D., "Dump Out"

line is 1/4" I.D.

Once all connections have been veried, install the
robot spacer plate to the robot wrist using 6 screws
(not provided).

Insure the shielded hose for the paint in line has
stripped back the outer jacket and conductive sheath
at least 12" from the exit of the voltage block devise.
(See Figure 5)

!

C A U T I O N

> Do Not nick or cut the inner paint line

hose. This will cause premature failure of the
hose.

Figure 5: Shielded Hose Stripbacks Diagram

NOTE

> Try to keep the shielded 3/16" I.D. "Paint

In" line and the 1/4" I.D. "Dump Out" line as
long as possible. If these hoses should pin­hole, this will allow a cut-o of the pinhole
section. Strip back and re-assemble rather
than replacing the entire hose.

AA-03-01.1

13

Robot Waterbase Applicator - Installation

Robot Spacer Plate

The robot spacer plate is included with the robot
manifold assembly to increase life of the tubing
bundle. The extra spacing it provides, increases the
bend radius of the tubes and decreases the hose or
cable stress at the connector.

There is only one way the spacer plate may be as­sembled to the mounting plate. The spacer plate
has an alignment pin that may only engage in one
hole position in the robot mount plate.

TABLE 2  SPACER PLATES

Part # Description

79107-00 ABB Robots
78983-00 Fanuc P155, 145 Robots
79131-00 Fanuc P200 Robot

Three spacer plates are available for this product, one
for ABB robots and two for Fanuc robots as shown
in Table 2.

Robot Spacer Plate Mounting

Mount the spacer plate to the tube bundle assembly
with scews [6] (7959-24C). Locate the spacer plate
with the robot locating pin away from the robot
mount plate. (See Figure 6)

14

AA-03-01.1