Ransburg 79190-XXXXXXXX User Manual
Ransburg
EVOLVERTM SOLVENTBORNE
SERVICE MANUAL
AA-03-02.12
(Replaces AA-03-02.11)
March - 2013
ROBOTIC ATOMIZERS
MODEL: 79190-XXXXXXXX
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: $50.00 (U.S.)
Evolver Solventborne Robotic Atomizers
NOTE: This manual has been changed from revision AA-03-02.11 to revision AA-03-02.12. Reasons for this
change are noted under “Manual Change Summary” inside the back cover of this manual.
DRAFT
Ransburg
AA-03-02.12
Ransburg
CONTENTS
SAFETY:
Evolver Solventborne Robotic Atomizers - Contents
PAGE
1-5
SAFETY PRECAUTIONS.............................................................................................................
HAZARDS / SAFEGUARDS.........................................................................................................
ATEX
EUROPEAN ATEX DIRECTIVE...................................................................................................
EUROPEAN ATEX LABELS........................................................................................................
INTRODUCTION:
RANSBURG ELECTROSTATIC PROCESS........................................................................
EVOLVER SOLVENTBORNE GUNS.........................................................................................
SPECIFICATIONS.......................................................................................................................
EVOLVER GUN SELECTION GUIDE........................................................................................
EVOLVER SOLVENTBORNE ROBOTIC ATOMIZER GUNS ....................................................
FEATURES.................................................................................................................................
79190-XXXXXXXX EVOLVER GUN ASSEMBLY......................................................................
INSTALLATION:
EVOLVER ROBOTIC ATOMIZER INSTALLATION.....................................................................
POWER SUPPLY ASSEMBLY...................................................................................................
LOW VOLTAGE CABLE CONNECTIONS.................................................................................
GUN AND MANIFOLD ASSEMBLY / PARTS LIST...................................................................
1
2-5
6-7
6
7
8-14
8
8-9
9
10-11
12
13
14
15-20
15
15
16
17-20
OPERATION:
SPRAY GUN CONTROLS............................................................................................................
HVLP SPRAY...............................................................................................................................
BACK PRESSURE - 48-1 & 481-1...............................................................................................
FLUID VALVE CONTROLS..........................................................................................................
DUAL PURGE SPRAYING...........................................................................................................
SIMPLIFIED AIR AND FLUID FLOW PASSAGE LAYOUT.........................................................
MAINTENANCE:
ROUTINE MAINTENANCE SCHEDULE.....................................................................................
PROCEDURES.............................................................................................................................
SPRAY HEAD REMOVAL ASSEMBLY / PARTS LIST..............................................................
SERVICE......................................................................................................................................
SPRAY HEAD ASSEMBLY..........................................................................................................
79138 EVOLVER GUN HEAD ASSEMBLY / PARTS LIST.........................................................
REMOVING GUN FROM THE REAR MANIFOLD ASSEMBLY...............................................
(Continued On Next Page)
AA-03-02.12
21-24
21
21
21
22
22-23
24
25-50
25-26
26-27
28-29
30
30-32
33-34
35
Evolver Solventborne Robotic Atomizers - Contents
Ransburg
PAGE
MAINTENANCE (Cont.):
79190 EVOLVER GUN ASSEMBLY / PARTS LIST....................................................................
MOUNTING BLOCK, SHROUD HALVES & RETAINING
RING REMOVAL / PARTS LIST.................................................................................................
DISASSEMBLY OF INTERMEDIATE GUN
HOUSING / PARTS LIST.............................................................................................................
VALVE MANIFOLD DISASSEMBLY / PARTS LIST...................................................................
LOW VOLTAGE CABLE REMOVAL / PARTS LIST...................................................................
FLUID REGULATOR (When Equipped)......................................................................................
FLUID REGULATOR ASSEMBLY / PARTS LIST.......................................................................
A10406 OR LECU5004 MICROPAK CONTROL UNIT...............................................................
ACCESSORIES............................................................................................................................
TROUBLESHOOTING GUIDE....................................................................................................
PARTS IDENTIFICATION:
79190-XXXXXXXX GUN ASSEMBLY / PARTS LIST...................................................................
SPRAY HEAD ASSEMBLY...........................................................................................................
79138-01 CONVENTIONAL SPRAY HEAD
ASSEMBLY / PARTS LIST...........................................................................................................
79138-02 HVLP SPRAY HEAD ASSEMBLY
PARTS LIST..................................................................................................................................
79179-00 SINGLE HEAD 60° / PARTS LIST...............................................................................
79243-00 DUAL HEAD 60° / PARTS LIST...................................................................................
79180-00 SINGLE HEAD 90° / PARTS LIST...............................................................................
79224-00 DUAL HEAD 90° / PARTS LIST...................................................................................
79175-XX MANIFOLD ASSEMBLY..............................................................................................
79175-XX OPTIONAL REGULATED VERSION.........................................................................
79175-XX MANIFOLD ASSEMBLY PARTS LIST.......................................................................
79175-07 MANIFOLD ASSEMBLY (ONLY) / PARTS LIST.........................................................
79156 REAR TUBING MANIFOLD ASSEMBLY -
ENGLISH / PARTS LIST..............................................................................................................
A10853 REAR TUBING MANIFOLD ASSEMBLY -
METRIC / PARTS LIST ................................................................................................................
SIGNAL IDENTIFICATION TABLE - ENGLISH
AND METRIC................................................................................................................................
SERVICE PARTS.........................................................................................................................
REPAIR KITS................................................................................................................................
25-50
36
37-38
39-40
41-42
43-44
44-45
46
47
47-48
49-50
51-75
51-54
55
56
57
58
58
59
59
60
61
62-63
64-65
66-68
69-71
72
73
74-75
WARRANTY POLICIES:
LIMITED WARRANTY..................................................................................................................
76
76
AA-03-02.12
Ransburg
SAFETY
Evolver Solventborne Robotic Atomizers - Safety
SAFETY PRECAUTIONS
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 situation 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 specications
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 Ransburg equipment manuals to reconcile such differences.
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 identied.
This manual MUST be read and thor-
oughly 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 SAFE-
TY STANDARD, LATEST EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
!
The hazards shown on the following pag-
es 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 efcient 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-03-02.12
1
Evolver Solventborne Robotic Atomizers - Safety
Ransburg
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
or Controller 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 off 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, OSHA, country, and local
codes. In addition, ventilation must be maintained during cleaning operations using ammable or combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
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 unautho-
rized equipment modications may cause re 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 NFPA33, NEC, OSHA, local, country, and European
Health and Safety Norms.
2
AA-03-02.12
Ransburg
Evolver Solventborne Robotic Atomizers - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate operation and maintenance proce-
dures will cause a re hazard.
Protection against inadvertent
arcing that is capable of caus-
ing re or explosion is lost if
any safety interlocks are disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2
hazardous areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding section of the equipment manual. Protection against inadvertent arcing that is capable
of causing re or explosion is lost if the current
overload sensitivity is not properly set. Frequent power supply shutdown indicates a problem in the system which requires correction.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no
objects are within the safe sparking distance.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accordance with NFPA-33, EN 50176.
Have re extinguishing equipment readily available and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
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. Reference OSHA, NFPA-33, EN Norms
and your insurance company requirements.
AA-03-02.12
3
Evolver Solventborne Robotic Atomizers - Safety
Ransburg
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
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.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The resistance between the part and earth
ground must not exceed 1 meg ohm. (Refer to
NFPA-33.)
Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the
palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
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. Grounded conductive ooring
must be provided in the spray area.
Always turn off the power supply prior to ushing, cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
4
AA-03-02.12
Ransburg
Evolver Solventborne Robotic Atomizers - Safety
AREA
Tells where hazards
may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may oc-
cur. 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 shutdown indicates a problem in the
system which requires correction.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous locations, the power supply, control cabinet,
and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN
50176.
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.
Toxic Substances
Spray Area
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Explosion Hazard –
Incompatible Materials
Halogenated hydrocarbon sol-
vents 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.
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.
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 coating supplier. Any
other type of solvent may be used with aluminum
equipment.
AA-03-02.12
5
Evolver Solventborne Robotic Atomizers - Atex
EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
Ransburg
The following instructions apply to equipment
covered by certicate number Sira 05ATEX5127X:
1. The equipment may be used with ammable
gases and vapors with apparatus groups II and
with temperature class T6.
2. The equipment is only certied for use in ambient temperatures in the range +12.8°C to +55°C
and should not be used outside this range.
3. Installation shall be carried out by suitably trained
personnel in accordance with the applicable code
of practice e.g. EN 60079-14:1997.
4. Inspection and maintenance of this equipment
shall be carried out by suitably trained personnel
in accordance with the applicable code of practice
e.g. EN 60079-17.
5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and
adjustment of the equipment shall be tted by
suitably trained personnel in accordance with the
manufacturer's documentation.
Refer to the "Table of Contents" of this service
manual.
a. Installation
b. Operation
c. Maintenance
d. Parts Identication
7. Components to be incorporated into or used as
replacement parts of the equipment shall be tted
by suitably trained personnel in accordance with
the manufacturer's documentation.
of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring that
the type of protection provided by the equipment
is not compromised.
Aggressive substances: e.g. acidic liquids or
gases that may attack metals, or solvents that
may affect polymeric materials.
Suitable precautions: e.g. regular checks as part
of routine inspections or establishing from the
material's data sheets that it is resistant to specic
chemicals.
Refer to "Specications" in the "Introduction"
section:
a. All uid passages contain stainless steel
or nylon ttings.
b. High voltage cascade is encapsulated with
a solvent resistant epoxy.
9. A recapitulation of the certication marking is
detailed in the "ATEX" section, on the next page,
drawing numbers: A10752, A10754, A10755, and
A10915.
10. The characteristics of the equipment shall
be detailed e.g. electrical, pressure, and voltage
parameters.
The manufacturer should note that, on being
put into service, the equipment must be accompanied by a translation of the instructions
in the language or languages of the country in
which the equipment is to be used and by the
instructions in the original language.
8. The certication of this equipment relies upon
the following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility
6
AA-03-02.12
Ransburg
Evolver Solventborne Robotic Atomizers - Atex
Evolver 79190 ATEX Product Mark-
ing Denitions
Ex Certicate Number: Sira 05 ATEX 5 127 X
Sira = Notied Body performing EC-type exam-
ination
05 = Year of certication
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
127 = Document serial number
X = Special conditions for safe use apply
Special conditions for safe use: The Evolver 79190
Series Automatic Atomizers shall only be used with
associated Micropak A10406 or LECU5004-31
Power Supplies.
Product Marking
II 2 G
Ex = Specic marking of explosive protection
II = Equipment Group hazardous area charac-teristics
2 = Equipment Category
G = Type of explosive atmosphere (gases, vapors,
or mists)
Label A10754
Label A10755
Label A10915
EEx 0.24mJ = The Evolver 79190 Series of automatic atomizers are suitable for use in automatic
spraying installations complying with EN 50176 as
they are a Type A class with a discharge energy
limit of 0.24mJ.
Label A10752
AA-03-02.12
7
Evolver Solventborne Robotic Atomizers - Introduction
INTRODUCTION
79190-X0XXXXXX 60° Single Head
THE RANSBURG
ELECTROSTATIC
PROCESS
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 eld between
the applicator and the target object. The target
is electrostatically grounded through its support
which may be either stationary or moving.
79190-X1XXXXXX 90° Single Head
Two dual-head versions of the Evolver Gun are
also available (see Figure 1). The dual headed
guns are primarily used where high volume uid
delivery is required. The dual headed gun is
available in two different congurations as follows:
79190-X2XXXXXX 60° Dual Head
79190-X3XXXXXX 90° Dual Head
The Evolver Spray Gun System consists of four
major components:
Ransburg
A regulated uid system delivers coating material
to the applicator, where it is atomized forming
a spray mist. There, under the inuence of the
electrostatic eld, 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 sufcient to turn overspray around and deposit it on the back surface
of the target. Therefore, a higher percentage of
the spray is deposited.
EVOLVER
SOLVENTBORNE GUNS
The EvolverTM Solventborne Gun Line consists
of both 600° and 90° single and dual-headed 100
kV automatic electrostatic spray guns. Developed
for use on robots, the Evolver gun incorporates a
unique 1/3 turn quick-disconnect spray head and
a two piece snap together manifold cover, provid-
ing the user an efcient tool for the electrostatic
application of coatings.
The Evolver gun also has the ability to color change
while spraying with no voltage draw down, a true
dual purge function.
There are two single head models of the Evolver
Gun (see Figure 1). Each model differs in the
gun to axis orientation of the spray head. These
models are:
1. Quick-Disconnect Spray Head
2. Gun Head Mounting Block Assembly
3. Valve Manifold Assembly (Includes the
High Voltage Cascade with a Quick-Discon nect Ring)
4. Rear Tubing Manifold Assembly (Both
English and Metric)
The spray head(s) and valve manifold contain
the uid, air, and high voltage passages. All uid
passages contain stainless steel and/or nylon
ttings, compatible with halogenated hydrocarbon solvents. The robot manifold incorporates
stainless steel uid connections.
The high voltage cascade is entirely encapsulat-
ed with a solvent resistant epoxy. This cascade
generates voltages up to 100 kV fed by a low
voltage cable.
There are two sources for the high voltage supply
to the Evolver guns:
• Stand-alone control/power supply unit
(A10406)
• MicroPakTM control unit (LECU5004-31)
NOTE
> The Evolver Gun assemblies are NOT
FM approved when used with any other
power source.
8
AA-03-02.12
Ransburg
Evolver Solventborne Robotic Atomizers - Introduction
The MicroPak power supply control unit provides
a low voltage signal through the robot manifold
to the spray gun. The high voltage cascade located within the gun converts the low voltage DC
signal to a high voltage electrostatic output. (See
the most current "MicroPak" and "Stand-Alone
Evolver MicroPak Controller" Service Manuals for
details of the control unit.)
SPECIFICATIONS
Environmental/Physical
Robot/Mounting Compatibility:
All hollow wrist robots
Gun Control Unit:
MicroPak Control Unit - LECU5004-31
Stand-Alone Control Unit - A10406
Operating Temperature Range:
55°F (12.8°C) - 131°F (55°C)
Weight
Single-Headed:
60° 9.9 lbs. (4.5 Kg)
90° 9.6 lbs. (4.4 Kg)
Dual-Headed:
60° 10.4 lbs. (4.7 Kg)
90° 10.4 lbs. (4.7 Kg)
Manifold:
79175-XX 1.7 lbs. (.77 Kg)
(No tubing or cable)
Length
Single-Headed:
60° 17" (43.18cm)
90° 14 1/2" (36.83 cm)
Dual-Headed:
60° 16-1/4" (41.28cm)
90° 13" (33.02cm)
Tubing Manifolds (English):
79156-01 25 ft.
79156-02 50 ft.
79156-03 75 ft.
79156-04 100 ft.
Tubing Manifolds (Metric):
A10853-01 7.62m
A10853-02 15.24m
A10853-03 22.86m
A10853-04 30.48m
Electrical Requirements
Output Voltage: 30-100 kV
Output Range: 0-85 µA
Paint Flow Rate:
Variable to 1500 cc/min. (Depending on
viscosity & conguration)
Trigger Response Time: 150m sec. Open
220m sec. Closed
Operating Air Pressures
Atomizing Air: 100 psig (6.9 bar) max.
Fan Air: 100 psig (6.9 bar) max.
Trigger Air: 70 psig min./100 psig
(4.8 - 6.9 bar) max.
Regulator Pilot: 0 psig min./100 psig
(0 - 6.9 bar) max.
Dump Pilot: 70 psig min./
100 psig max.
(4.8 - 6.9 bar)
Operating Fluid
Pressure: 200 psig (13.8 bar) max.
100 psig (6.9 bar) max.
Regulated (with on-board
regulator)
Robot Manifold Tubing Requirements
English Metric
Atomizing Air
Fan Air
Trigger Air
Regulator Pilot
Dump Pilot
Fluid:
Polyethylene
Dump:
3/8"
3/8"
3/16"
3/16"
3/16"
1/4" or 3/16" ID
(Shielded &
Non-Shielded
1/4" or 3/16" ID
(Shielded & NonShielded)
3/16" ID
10mm OD Nylon
10mm OD Nylon
4mm OD Nylon
4mm OD Nylon
4mm OD Nylon
6mm
(Non-Shielded)
6mm
AA-03-02.12
9
Evolver Solventborne Robotic Atomizers - Introduction
EVOLVER GUN SELECTION GUIDE
79190 - A B C D E FF G
Table A = Atomization Technology
0 = Air Spray
1 = HVLP
Table B = Spray Head Conguration
0 = 60° Single Head
1 = 90° Single Head
2 = 60° Dual Head
3 = 90° Dual Head
Table C = Purge/Regulator Conguration
0 = Single Purge / No Regulator
1 = Dual Purge / No Regulator
2 = Single Purge / With Fluid Regulator
3 = Dual Purge / With Fluid Regulator
4 = Single Purge / No Regulator / Non-Electrostatic
5 = Dual Purge / No Regulator / Non-Electrostatic
6 = Single Supply / No Valves / Short Fluid Tube
Ransburg
Table D = Robot Adapter Plate
0 = No Adapter
1 = ABB
2 = Fanuc P-155
3 = Fanuc P-200
4 = Adapter (KAWASAKI-KE610L)
5 = Adapter (MOTOMAN-PX2850)
6 = Adapter (MOTOMAN-PX2900)
Table E = Fluid Hose Type
0 = No Fluid Hose
1 = 3/16" ID Non-Shielded
2 = 3/16" ID Shielded
3 = 1/4" ID Non-Shielded
4 = 1/4" ID Shielded
5 = 6 mm ID Non-Shielded
(Continued on next page)
10
AA-03-02.12
Ransburg
EVOLVER GUN SELECTION GUIDE (Cont.)
79190 - A B C D E FF G
Table FF = Cable & Tubing Manifold Conguration
00 = Gun Only (No cable or manifold)
23 = No Cable (English tubing manifold)
24 = No Cable (Metric tubing manifold)
For Use W/Power Supply Conguration 3 or 4:
English Metric
01 = 25' Cable (one-piece cable) 12 = 7.6m Cable (one-piece cable)
02 = 50' Cable (one-piece cable) 13 = 15.2m Cable (one-piece cable)
03 = 75' Cable (one-piece cable) 14 = 22.9m Cable (one-piece cable)
04 = 100' Cable (one-piece cable) 15 = 30.5m Cable (one-piece cable)
05 = 15' Cable to Junction Box; 15' Cable to Robot 16 = 4.6m Robot to Junction Box; 4.6m Cable to Robot
06 = 40' Cable to Junction Box; 15' Cable to Robot 17 = 12.2m Cable to Junction Box; 4.6m Cable to Robot
07 = 60' Cable to Junction Box; 15' Cable to Robot 18 = 18.3m Cable to Junction Box; 4.6m Cable to Robot
08 = 75' Cable to Junction Box; 15' Cable to Robot 19 = 22.9m Cable to Junction Box; 4.6m Cable to Robot
09 = 25' Cable to Junction Box; 25' Cable to Robot 20 = 7.6m Cable to Junction Box; 7.6m Cable to Robot
10 = 50' Cable to Junction Box; 25' Cable to Robot 21 = 15.2m Cable to Junction Box; 7.6m Cable to Robot
11 = 75' Cable to Junction Box; 25' Cable to Robot 22 = 22.9m Cable to Junction Box; 7.6m Cable to Robot
Evolver Solventborne Robotic Atomizers - Introduction
For Use W/Power Supply Conguration 1 or 2:
English Metric
31 = 25' Cable (one-piece cable) 51 = 7.6m Cable (one-piece cable)
32 = 50' Cable (one-piece cable) 52 = 15.2m Cable (one-piece cable)
33 = 75' Cable (one-piece cable) 53 = 22.9m Cable (one-piece cable)
34 = 100' Cable (one-piece cable) 54 = 30.5m Cable (one-piece cable)
35 = 15' Cable to Junction Box; 15' Cable to Robot 55 = 4.6m Cable to Junction Box; 4.6m Cable to Robot
36 = 40' Cable to Junction Box; 15' Cable to Robot 56= 12.2m Cable to Junction Box; 4.6m Cable to Robot
37 = 60' Cable to Junction Box; 15' Cable to Robot 57 = 18.3m Cable to Junction Box; 4.6m Cable to Robot
38 = 75' Cable to Junction Box; 15' Cable to Robot 58 = 22.9m Cable to Junction Box; 4.6m Cable to Robot
39 = 25' Cable to Junction Box; 25' Cable to Robot 59 = 7.6m Cable to Junction Box; 7.6m Cable to Robot
40 = 50' Cable to Junction Box; 25' Cable to Robot 60 = 15.2m Cable to Junction Box; 7.6m Cable to Robot
41 = 75' Cable to Junction Box; 25' Cable to Robot 61 = 22.9m Cable to Junction Box; 7.6m Cable to Robot
Table G = Power Supply Conguration
0 = No Power Supply
1 = A10406-01 Power Supply Enclosure with one MicroPak and one Discreet I/O Card
2 = A10406-01 Power Supply Enclosure with two MicroPaks and two Discreet I/O Cards
3 = One LECU5004-31 MicroPak (FM Approved)
4 = One LECU5004-11 MicroPak (Not FM Approved)
AA-03-02.12
11
Evolver Solventborne Robotic Atomizers - Introduction
Ransburg
12
Figure 1: Evolver Solventborne Robotic Atomizer Guns
AA-03-02.12
Ransburg
FEATURES
Evolver Solventborne Robotic Atomizers - Introduction
The features of the Evolver series guns include:
• Quick-disconnect spray head
• High quality Ransburg air cap and uid nozzle
• True "dual purge function"
• Dual uid supply passages
• Dual uid dump valves are located adjacent
to the uid passages
• Internal uid regulator
• Field proven high voltage system
• Dual start, dual pitch air cap retaining ring
• Quick-disconnect robot mount plate
• Quick color change capability with integrated
solvent valve
• Clean interior design with split shroud
• Internal fan and atomization air control valve,
with a mechanically timed trigger sequence
• Color coded air and trigger actuation lines
AA-03-02.12
Figure 2: Typical Robotic Applicator Mounting
13
Evolver Solventborne Robotic Atomizers - Introduction
79190-XXXXXXXX
EVOLVER GUN ASSEMBLY
Ransburg
The gun assembly is designed to connect to hollow wrist robots. A low voltage control cable is
supplied with the gun to connect the cascade to
the MicroPak power supply.
The "Paint In" lines come in both 3/16" ID and
1/4" ID shielded or non-shielded.
Tool Center-Point
Figure 3 shows the tool center-point information
for the four guns. They are all based upon a 10"
(245mm) target distance.
14
Figure 3: Tool Center-Point
AA-03-02.12
Ransburg
INSTALLATION
Evolver Solventborne Robotic Atomizers - Installation
EVOLVER ROBOTIC
ATOMIZER INSTALLATION
This information is intended ONLY to indicate the
general installation parameters of this product
and, where applicable, its working relationship
to other Ransburg system components in typical
use. Each installation is unique and should be
directed by an authorized Ransburg representative or conducted from the Ransburg installation
drawings provided for your particular installation.
POWER SUPPLY
ASSEMBLY
Refer to the most current Power Supply Unit
manuals for complete information regarding power
supply installation.
W A R N I N G
!
> The power supply MUST be located outside
the HAZARDOUS area (Reference OSHA,
NFPA-33, and your insurance company requirements.)
> User should be aware of, and adhere to,
all local re codes and ordinances.
> The user MUST provide a properly fused
disconnect between the power source and the
power supply which complies with appropriate
codes.
> Fluid supply must be grounded per NFPA-33.
AA-03-02.12
15
Evolver Solventborne Robotic Atomizers - Installation
Ransburg
16
Figure 4: Low Voltage Cable Connections
AA-03-02.12
Ransburg
Evolver Solventborne Robotic Atomizers - Installation
GUN AND MANIFOLD
ASSEMBLY
(See Figures 4 and 5)
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. Use
the six (6) socket head cap screws (7959-32C)
included with the rear manifold tubing assembly
to attach the rear manifold assembly ( 79156) to
the robot spacer plate (see Table 1).
Connect each signal line as required per signal
legend for both English and Metric tubing bundles,
table following.
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. This
provides the nal position to top dead center of
the robot.
For installations utilizing the LECU5004-XX MicroPak Power Supply, connect the low voltage cable
(79008-XX) from the robot manifold assembly to
the LECU5004-XX MicroPak Controller or junction
box. If connecting to a junction box, use a junction
cable (77062-XX) to make the connection from
the junction box to the LECU5004-XX MicroPak.
Make connections as shown in Figure 4.
For installations utilizing the A10406-XX Evolver
MicroPak Power Supply, connect the low voltage
cable (A11353-XX or A11356-XX) from the robot
manifold assembly or junction box to the receptacle
on the rear of the A10406-XX power supply. To
maintain FM Approval, this cable must be secured
to the stress relief bar on the rear of the power
supply. (See "A10406-XX Evolver
MicroPak Power Supply" manual for further information on connecting the low voltage cable.)
C A U T I O N
!
> Leave 12-24 inches of extra length on all
lines to prevent extreme tension being applied
to these lines during robot movement.
!
C A U T I O N
> Do not exceed 100' combined length of the
low voltage cables.
The six (6) robot spacer plates, Table 1, are available for this product.
TABLE 1 - SPACER PLATES
Part # Description
79107-00 ABB Robots
78983-00 Fanuc P155, 145 Robots
79131-00 Fanuc P200 Robot
A10847-00 Adapter (Kawasaki-KE610L)
A10848-00 Adapter (Motoman-PX2850)
A10849-00 Adapter (Motoman-PX2900)
AA-03-02.12
W A R N I N G
!
> Install and route the hoses and cable so
that they are NOT exposed to temperatures
in excess of 120° F. Ensure that all hose and
cable bends are NOT LESS THAN a 6 inch
(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 HAZARDOUS
CONDITIONS!
W A R N I N G
!
> If a non-explosion proof junction box/ter-
minal strip is used, it must be located outside
the hazardous area.
17
Evolver Solventborne Robotic Atomizers - Installation
SIGNAL IDENTIFICATION TABLE - ENGLISH
Ransburg
Abbr.
P1 Paint #1 Clear 5/16" OD X 3/16" ID 29
P2 Paint #2 Black Urethane/Poly 5/16" OD X 3/16" ID 29
P1 Paint #1 Clear 3/8" OD X 1/4" ID 29
P2 Paint #2 Black Urethane/Poly 3/8" OD X 1/4" ID 29
SOL Solvent Black Urethane/Poly 3/8" OD X .187" ID 28
P1T Paint #1 Trigger Green Nylon 3/16" OD X .050" Wall 24
P1D Paint #1 Dimp Gray Nylon 3/16" OD X .050 Wall 25
P2T Paint #2 Trigger Natural Nylon 3/16" OD X .050" Wall 17
P2D Paint #2 Dump Black Nylon 3/16" OD X .050" Wall 31
TP Trigger Pilot Black Nylon 3/16" OD X .050" Wall 27
DL Dump Line Natural .313" OD X .188" ID 19
RP Regulator Pilot Natural Nylon 3/16" OD X .050" Wall 17
ST Solvent Trigger Blue Nylon 3/16" OD. X .050" Wall 26
F Fan Air Black Nylon 3/8" OD X .250" ID 23
A Atomization Air Natural Nylon 3/8" OD X .250" ID 16
LV Low Voltage Cable Black N/A N/A 2
Description
Color
Tubing Material
Tubing Size
SIGNAL IDENTIFICATION TABLE - METRIC
Abbr. Description
Color
Tubing Material
Tubing Size
Item #
Item #
P1 Paint #1 Clear 8mm OD X 6mm ID 29
P2 Paint #2 Clear 8mm OD X 6mm ID 29
SOL Solvent Clear 8mm OD X 6mm ID 29
P1T Paint #1 Trigger Green Nylon 4mm OD X .106" ID 24
P1D Paint #1 Dimp Silver Nylon 4mm OD X .106" ID 25
P2T Paint #2 Trigger Natural Nylon 4mm OD X .106" ID 17
P2D Paint #2 Dump Black Nylon 4mm OD X .106" ID 31
TP Trigger Pilot Yellow Nylon 4mm OD X .106" ID 27
DL Dump Line Clear 8mm OD X 6mm ID 29
RP Regulator Pilot Natural Nylon 4mm OD X .106" ID 17
ST Solvent Trigger Blue Nylon 4mm OD X .106" ID 26
F Fan Air Black Nylon 10mm OD X 8mm ID 23
A Atomization Air Natural Nylon 10mm OD X 8mm ID 16
LV Low Voltage Cable Black N/A N/A 2
18
AA-03-02.12
Ransburg
Evolver Solventborne Robotic Atomizers - Installation
AA-03-02.12
Figure 5: Gun and Manifold Assembly
19
Evolver Solventborne Robotic Atomizers - Installation
GUN AND MANIFOLD ASSEMBLY - PARTS LIST (Figure 5)
Ransburg
Item #
1 79190-XXXXXXXX Evolver Spray Gun 1
2 76566-32C Socket Head Cap Screws, 1/4-20 X 1" Long, 6
Stainless Steel
3 79156-XXXX Rear Manifold Tubing Assembly (English) 1
4 See Table 1 Spacer Plates 1
5 A10853-XXXX Rear Manifold Tubing Assembly (Metric) 1
Part # Description Qty
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AA-03-02.12
Ransburg
OPERATION
Evolver Solventborne Robotic Atomizers - Operation
SPRAY GUN CONTROLS
Atom (A) / Fan Air (F)
The atomization and fan air are turned on by the
trigger line and are controlled by an internal air
valve located in the gun head. During normal
operation with gun triggered off, there is a slight
bleed of air through the atomization part.
Atomizing 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 efciency.
Fan Air
Adjusting the fan air increases or decreases the
size of the spray pattern. Increasing pressure
increases 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.
Air cap pressures should be set using air cap test
kit. This provides a consistent measurement, so
initial settings may be duplicated at any time. (See
"Parts Identication" section for "Air Cap Test Kit
part numbers".)
HVLP SPRAY
The Evolver HVLP models, when properly set-up,
are designed to provide maximum transfer efciency by limiting air cap pressures to 10 psi (0.7
bar) (in the U.S., this complies with rules issued
by SCAQMD and other air quality authorities).
Air cap pressures should be measured with an
optional air cap test kit. (See "Accessories" in
the "Maintenance" section.)
NOTE
> For HVLP operation (max. 10 psi, -0.7
bar cap pressure), DO NOT exceed the
air inlet pressure, which was read at the
gun base before the tubing manifolds,
given as follows:
PSI (Bar) CAP #
42 (2.9) 48-1
42 (2.9) 481-1
BACK PRESSURE 48-1 and 481-1
AA-03-02.12
NOTE
> Insure that the fan and atomization air
are on and owing prior to triggering the
uid. Failure to follow this sequence will
cause spits and defects on the part being
painted.
Due to the unique cone shape of the MP uid tips
(nozzle), a slight back pressure is created against
the uid column. This will reduce the amount of
uid output. To compensate, increase the uid
regualtor pressure slightly if necessary. With 10
psi (0.7 bar) cap pressure, back pressures are
approximately 3.5 psi (0.24 bar).
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