Ransburg A12374-XXX User Manual
SERVICE MANUAL
AA-08-01.1
January - 2013
EVOLVER 303TM DUAL PURGE SOLVENTBORNE
ROBOTIC ATOMIZERS
MODEL: A12374-XXX
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.
With
Technology
Service Manual Price: $50.00 (U.S.)
CONTENTS
SAFETY:
Evolver 303 Dual Purge Robotic Atomizers - Contents
PAGE
1-4
SAFETY PRECAUTIONS.............................................................................................................
HAZARDS / SAFEGUARDS.........................................................................................................
INTRODUCTION:
RANSBURG ELECTROSTATIC PROCESS......................................................................
EVOLVER 303 DUAL PURGE SOLVENTBORNE
SPRAY APPLICATORS..............................................................................................................
SPECIFICATIONS.......................................................................................................................
EVOLVER 303 DUAL PURGE APPLICATOR ASSEMBLY.....................................................
EVOLVER 303 DUAL PURGE TUBING BUNDLE ASSEMBLY (METRIC)..............................
EVOLVER 303 DUAL PURGE SOLVENTBORNE
ROBOTIC APPLICATORS..........................................................................................................
FEATURES..................................................................................................................................
A12374-XXX EVOLVER DUAL PURGE SPRAY
APPLICATOR ASSEMBLY..........................................................................................................
TOOL CENTER-POINT COMPARISONS TABLE.....................................................................
INSTALLATION:
EVOLVER 303 DUAL PURGE ROBOTIC ATOMIZER
INSTALLATION............................................................................................................................
POWER SUPPLY ASSEMBLY...................................................................................................
MOUNTING..................................................................................................................................
ELECTRICAL AND FIBER OPTIC CONNECTIONS.................................................................
FLUID CONNECTIONS...............................................................................................................
TYPICAL INSTALLATION...........................................................................................................
LOW VOLTAGE CABLE CONNECTIONS.................................................................................
EVOLVER 303 DUAL PURGE SPRAY APPLICATOR
AIR AND FLUID LAYOUT...........................................................................................................
APPLICATOR AND MANIFOLD ASSEMBLY............................................................................
LOW VOLTAGE CABLE INSTALLATIONS................................................................................
LOW VOLTAGE CABLE ON ROBOT.........................................................................................
BULKHEAD CUT-OUT DIAGRAM..............................................................................................
ROBOT PLATE............................................................................................................................
QUICK-DISCONNECT CABLES................................................................................................
SIGNAL IDENTIFICATION TABLE BELLS (APPLICATORS)...................................................
APPLICATOR AND MANIFOLD ASSEMBLY / PARTS LIST....................................................
SPRAY / BELL APPLICATOR TRIGGERING............................................................................
CONVERSION SCHEMATIC.....................................................................................................
TUBING BUNDLE INSTALLATION............................................................................................
BUNDLE LUBRICATION.............................................................................................................
1
2-4
5-12
5
5-6
7
8
8
9
10
11
12
13-24
13
13
13
13
13
13
14
15
16-17
17-18
19
20
20
20
21
22
23
23
24
24
(Continued On Next Page)
Evolver 303 Dual Purge Robotic Atomizers- Contents
CONTENTS (Cont.)
PAGE
OPERATION:
SPRAY APPLICATOR CONTROLS...........................................................................................
HVLP SPRAY...............................................................................................................................
FLUID VALVE CONTROLS.........................................................................................................
DUAL PURGE SPRAYING.........................................................................................................
DUAL PURGE AIR AND FLUID PASSAGE SCHEMATIC........................................................
MAINTENANCE:
ROUTINE MAINTENANCE SCHEDULE....................................................................................
PROCEDURES............................................................................................................................
SPRAY HEAD REMOVAL / ASSEMBLY / PARTS LIST............................................................
SERVICE......................................................................................................................................
SPRAY HEAD ASSEMBLY..........................................................................................................
79138 EVOLVER 303 DUAL PURGE APPLICATOR HEAD
ASSEMBLY / PARTS LIST...........................................................................................................
REMOVING SPRAY APPLICATOR FROM THE
REAR MANIFOLD ASSEMBLY...................................................................................................
EVOLVER 303 DUAL PURGE 60° SINGLE HEAD
APPLICATOR ASSEMBLY / PARTS LIST..................................................................................
DISASSEMBLY OF A12373 SPRAY APPLICATOR
ASSEMBLY / PARTS LIST...........................................................................................................
CASCADE WIRE PLUG ASSEMBLY..........................................................................................
LOW VOLTAGE CABLE REMOVAL / PARTS LIST...................................................................
A12376-00 DUAL PURGE VALVE MANIFOLD
DISASSEMBLY / PARTS LIST.....................................................................................................
TROUBLESHOOTING GUIDE....................................................................................................
25-28
25
25-26
26
26-27
28
29-52
29-30
30-32
33-34
35
35-38
39-40
41
42
43-44
45
45-47
48
49-52
PARTS IDENTIFICATION:
A12374 SPRAY APPLICATOR ASSEMBLY W/A12283
TUBING BUNDLE ASSEMBLY/ PARTS LIST............................................................................
79138-01/-04 CONVENTIONAL AND 79138-02/-05 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...................................................................................
A12373 MANIFOLD ASSEMBLY / PARTS LIST.........................................................................
A12375-01 REAR PLATE ASSEMBLY (SINGLE PURGE) /
PARTS LIST..................................................................................................................................
A12283-XXXXXXX TUBING BUNDLE ASSEMBLY (METRIC) /
PARTS LIST..................................................................................................................................
SIGNAL IDENTIFICATION TABLE BELLS (APPLICATORS)....................................................
(Continued On Next Page)
53-78
53-54
55-57
58
58
59
59-60
61-62
63-64
65-66
67
Evolver 303 Dual Purge Robotic Atomizers - Contents
CONTENTS (Cont.)
PARTS IDENTIFICATION (Cont.):
A12283-XXXXXXX TUBING BUNDLE ASSEMBLY MODEL
IDENTIFICATION (METRIC).......................................................................................................
A10406 OR LECU5004 MICROPAK CONTROL UNIT...............................................................
ACCESSORIES AND SERVICE KITS........................................................................................
REPAIR KITS................................................................................................................................
SERVICE PARTS.........................................................................................................................
LUBRICANTS AND SEALERS....................................................................................................
EVOLVER 303 DUAL PURGE RECOMMENDED SPARE PARTS..........................................
PAGE
53-78
68-69
70
70-73
74
75
75
76-77
WARRANTY POLICIES:
LIMITED WARRANTY..................................................................................................................
79
79
Evolver 303 Dual Purge Robotic Atomizers - Safety
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 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 specications and
service procedures, some minor deviations may be
found between this literature and your equipment.
Dierences 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
dierences.
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 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 or applicable country safety
standards 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 ecient 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.
1
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - 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 shut-down indicates a problem in the system
requiring correc-tion.
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 local and/or country codes. In addition, ventilation
must be maintained during cleaning operations using
ammable or combustible solvents.
General Use and
Maintenance
1
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
modications may cause re or injury.
If used, the key switch bypass is intended for use only
during set-up operations. Production should never be
done with safety interlocks disabled.
The paint process and equipment should be set up and
operated in accordance with local and/or country safety
codes.
Personnel must be given training in accordance with the
requirements of NFPA-33.
Instructions and safety precautions must be read and
understood prior to using this equipment.
Comply with appropriate local, state, and national codes
governing ventilation, re protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, and
your insurance company requirements.
AA-08-01.1
2
Evolver 303 Dual Purge Robotic Atomizers - Safety
AREA
Tells where hazards
may occur.
Toxic Substances
Explosion Hazard/
Incompatible
Materials
HAZARD
Tells what the hazard is.
Certain material may be harmful if
inhaled, or if there is contact with
the skin.
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.
SAFEGUARDS
Tells how to avoid the hazard.
Follow the requirements of the Material Safety Data
Sheet supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the air
free of accumulations of toxic materials.
Use a mask or respirator whenever there is a chance of
inhaling sprayed materials. The mask must be compatible with the material being sprayed and its concentration. Equipment must be as prescribed by an industrial
hygienist or safety expert, and be NIOSH approved.
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.
Electrical
Equipment
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 shutdown
indicates a problem in the system
which requires correction.
An electrical arc can ignite coating
materials and cause a re or explosion.
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
applicable code for specic area and/or country.
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.
3
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - Safety
AREA
Tells where hazards
may occur.
Robot Work AreaGeneral Use and
Maintenance
Personnel Safety
HAZARD
Tells what the hazard is.
Improper use or maintenance can
lead to hazardous conditions, particularly from unexpected robot
manipulator movement.
Skin puncturing by sharp electrode.
SAFEGUARDS
Tells how to avoid the hazard.
Applicator adjustments or maintenance should be done
after the robot is taken out of service. Do not adjust or
repair the applicator if the robot is operating or standing ready to start.
Refer to robot operating instructions for the procedures
to take the robot out of service.
Take precautions to see that esh is not punctured by
sharp electrode.
AA-08-01.1
4
Evolver 303 Dual Purge Robotic Atomizers - Introduction
INTRODUCTION
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.
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 sucient to turn overspray around and deposit it
on the back surface of the target. Therefore, a higher
percentage of the spray is deposited.
EVOLVER™ 303 DUAL PURGE
SOLVENTBORNE SPRAY
APPLICATORS
The Evolver™ 303 Dual Purge Spray Appli-cators System
will allow for the use of spray applicators or bell applicators with minimal required down-time during
the switching process. This system can also operate
as a spray applicator system only that later can be
upgraded to allow for bell applicators having "Unilink
Technology"to be used. This system can allow a user
currently possessing an RMA-303 bell system to use
spray applicators as well, with minimal conversion
required. Lastly, this system is a true dual purge
system in that paint can be sprayed with full voltage
on, while simultaneously color changing the second
paint line. The Evolver 303 Dual Purge Solventborne
Applicator line consists of both 60° and 90° single
and dual-headed 100kV automatic electrostatic applicators. Developed for use on robot, the Evolver
303 Dual Purge spray applicator incorporates a
unique 1/3 turn quick-disconnect spray head and a
one piece slide over manifold cover, providing the
user an ecient tool for the electrostatic application
of coatings.
There are two single-head models of the Evolver 303
Dual Purge Applicators (see Figure 1). Each model
diers in the applicator to axis orientation of the spray
head. These models are:
A12374-0XX 60° Single-Head
A12374-1XX 90° Single-Head
Two dual-head versions of the Evolver 303 Dual Purge
Applicator are also available (see Figure 1). The dualheaded applicators are primarily used where high
volume uid delivery is required. The dual-headed
applicator is available in two dierent congurations
as follows:
A12374-2XX 60° Dual-Head
A12374-3XX 90° Dual-Head
5
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - Introduction
The Evolver 303 Dual Purge Spray Applicator System
consists of four major components:
1. Quick-Disconnect Spray Head
2. Applicator Head Mounting Block Assembly
3. Valve Manifold Assembly (Includes the High
Voltage Cascade with a Quick-Disconnect
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 encapsulated
with a solvent resistant epoxy. This cascade generates
voltages up to 100kV fed by a low voltage cable.
NOTES
There are three sources for the high voltage supply
to the Evolver 303 Dual Purge Applicators:
• MicroPak™ Control Unit (LECU5004)
• Stand-alone control/power supply unit
(A10406)
• MicroPakTM Control Unit (LECU5004-31)
The MicroPak Power Supply control unit provides a
low voltage signal through the robot manifold to the
spray applicator. The high voltage cascade located
within the applicator converts the low voltage DC
signal to a high voltage electrostatic output.
For applications that have the ability to control fan
and atomization air remotely, the bleed style head
is available.
AA-08-01.1
6
Evolver 303 Dual Purge Robotic Atomizers - Introduction
SPECIFICATIONS
Environmental/Physical Electrical Requirements
Robot/Mounting Compatibility:
All hollow wrist robots
Applicator Control Unit:
MicroPak Control Unit - LECU5004-31
Stand-Alone Control Unit - A10406
Operating Temperature
Range: 55°F (12.8°C) - 131°F (55°C)
Approximate Weight
Single-Headed:
60° 9.02 lb. (4.1 Kg)
90° 8.71 lb. (3.9 Kg)
Dual-Headed:
60° 10.91 lb. (4.9 Kg)
90° 10.76 lb. (4.9 Kg)
Manifold:
A12373-XX 6.82 lb. (3.1 Kg)
(No tubing or cable)
Length
Single-Headed:
60° 16.5-inch (41.9 cm)
90° 13.6-inch (34.5 cm)
Dual-Headed:
60° 15.8-inch (40.1 cm)
90° 12.4-inch (31.5 cm)
Tubing Manifolds (Metric):
A12283-0XXXXXX Air Tubing not
included
A12283-1XXXXXX 4 1/2m (15-ft.)
A12283-2XXXXXX 9m (30-ft.)
Output Voltage: 30-100kV
Output Range: 0-85 µA
Paint Flow Rate: Variable to 1500 cc/min.
(Depending on viscosity and conguration)
Trigger Response
Time: 134ms Open
318ms Closed
Operating Air Pressures
Atomizing Air: 100 psig (6.9 bar)
max.
Fan Air: 100 psig (6.9 bar)
max.
Trigger Pilot: 70 psig min./100
psig
(4.8 - 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
Atomizing Air
Fan Air
Trigger Air
Dump Pilot
Fluid:
Dump:
7
Tubing Bundle
Metric
8mm OD Nylon
8mm OD Nylon
6mm OD Nylon
4mm OD Nylon
8mm OD
(Non-Shielded)
7mm ID
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - Introduction
EVOLVER 303 DUAL PURGE APPLICATOR ASSEMBLY
A12374 - A B C
Head Conguration
0 = 60° Single-Head
1 = 90° Single-Head
2 = 60° Dual-Head
3 = 90° Dual-Head
Body Style
0 = For Highly Resistive Materials (Clear Coat)
1 = For Conductive Materials (Base / Clear)
2 = For Highly Conductive Materials (Base / Clear)
Atomization Technology
0 = Conventional Spray / Non-Bleed
1 = HVLP Spray / Non-Bleed
4 = Conventional Spray / Bleed
5 = HVLP Spray / Bleed
EVOLVER 303 DUAL PURGE TUBING BUNDLE ASSEMBLY METRIC
A12283 - A BB CC DD
Tubing Bundle Length
0 = Air Tubing (Not Included)
1 = 4.5m (15-ft.) Long Tubing Assembly
2 = 9m (30-ft.) Long Tubing Assembly
Low Voltage Cable Length
0 0 = Low Voltage Cable Not Included
01 = 15-ft. Low Voltage - Quick Connect to MicroPak
02 = 25-ft. Low Voltage - Quick Connect to MicroPak
03 = 40-ft. Low Voltage - Quick Connect to MicroPak
04 = 50-ft. Low Voltage - Quick Connect to MicroPak
05 = 75-ft. Low Voltage - Quick Connect to MicroPak
Robot Adapter
00 = Adapter Not Included
01 = Adapter (Fanuc P-155) 78983-00
02 = Adapter (ABB 5400, 5002) 79107-00
03 = Adapter (Fanuc-P200/P-250) 79131-00
04 = Adapter (KAWASAKI-KE610L) A10847-00
05 = Adapter (MOTOMAN-PX2850) A10848-00
06 = Adapter (MOTOMAN-PX2900) A10849-00
07 = Adapter (B & M LZ2000) A10851-00
08 = Adapter (ABB 5400 Enhanced Wrist) A12036-00
Fiber Optic Cable Length
00 = Fiber Optic Cable Not Included
01 = 15-ft. Long Fiber Optic Cable
02 = 25-ft. Long Fiber Optic Cable
03 = 40-ft. Long Fiber Optic Cable
04 = 50-ft. Long Fiber Optic Cable
05 = 75-ft. Long Fiber Optic Cable
06 = 100-ft. Long Fiber Optic Cable
AA-08-01.1
8
SPRAY HEAD
ASSY.
MOUNTING
BLOCK ASSY.
VALVE MANIFOLD
ASSY.
A12374-3XX
90° DUAL HEAD
SPRAY HEAD
ASSY.
MOUNTING
BLOCK ASSY.
VALVE MANIFOLD
ASSY.
A12374-2XX
60° DUAL HEAD
SPRAY HEAD
ASSY.
MOUNTING
BLOCK ASSY.
VALVE MANIFOLD
ASSY.
A12374-1XX
90° SINGLE HEAD
SPRAY HEAD
ASSY.
MOUNTING
BLOCK ASSY.
VALVE MANIFOLD
ASSY.
A12374-0XX
60° SINGLE HEAD
A12283-XXXXXXX REAR MANIFOLD TUBING ASSY. - METRIC
Evolver 303 Dual Purge Robotic Atomizers - Introduction
Figure 1: Evolver 303 Dual Purge Solventborne Robotic Applicators
9
AA-08-01.1
FEATURES
ROBOT MANIFOLD QUICK
DISCONNECT RING
ROBOT SPACER PLATE
A12374
-0XX
60° SINGLE HEAD
MOUNTED ON ROBOT
ROBOT MANIFOLD QUICK
DISCONNECT RING
ROBOT SPACER PLATE
A12374
-1XX
90° SINGLE HEAD
MOUNTED ON ROBOT
Evolver 303 Dual Purge Robotic Atomizers - Introduction
The features of the Evolver 303 Dual Purge Series
Applicators include:
! Quick-disconnect spray head
! High quality Ransburg air cap and uid
nozzle
! Various adapter plates available to match
most robotic mounting congurations
! No external high voltage cable. The intern ally mounted high voltage cascade requires
only low voltage control wiring
! Less waste to the spray booth with the dump
valve located internally next to the feed tube
! Assembly components made of durable
engineered resin material for optimum
mechanical strength and solvent resistance
! Heavy duty design ensures excellent service
life even when subjected to the quick motions
of robotic applicators
! Small, light weight package allows for better
maneuverability in tight areas
! Negligible maintenance down time with the
quick-disconnect feature. An atomizer can
be exchanged in less than two minutes for
o-line maintenance
! Field proven high voltage system
! Dual start, dual pitch air cap retaining ring
! Quick color change capability
! Clean interior design with slip-on shroud
! Internal fan and atomization air control valve,
with a mechanically timed trigger sequence
! Color coded air and trigger actuation lines
! Quick change to a RMA-303 bell applicator
! True dual purge technology, allowing the user
to spray one color at voltage, while simul-
taneously purging the second color
AA-08-01.1
Figure 2: Typical Robotic Applicator Mounting
10
Evolver 303 Dual Purge Robotic Atomizers - Introduction
A12374XXX EVOLVER DUAL
PURGE SPRAY APPLICATOR
ASSEMBLY
The spray applicator assembly is designed to connect
to hollow wrist robots. A low voltage control cable
is supplied with the tubing bundle to connect the
cascade to the MicroPak power supply.
Tool Center-Point
Figure 3 shows the tool center-point information for
the four applicators. For dual head applicators, the
tool center-point is based upon the convergence
point. For the single head applicators it is based
upon a 10" target distance. The "Tool Center-Point
Comparisons Table" compares the tool center-point
of several automatic spray applicators.
11
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - Introduction
6 [151.9]
DUAL HEAD 90°
SINGLE HEAD 90°
SINGLE HEAD 60°
DUAL HEAD 60°
CONVERGENCE POINT
CONVERGENCE POINT
ROBOT ADAPTER AND
MOUNTING PLATE
ROBOT ADAPTER AND
MOUNTING PLATE
ROBOT ADAPTER AND
MOUNTING PLATE
ROBOT ADAPTER AND
MOUNTING PLATE
23
1
8
[587.5]
15
1
4
[386.3]
15
1
2
[392.8]
22
3
4
[578.4]
11
3
4
[299.9]
6
3
8
[161.4]
11 [279.1]
15
3
8
[390.6]
10 [254.0]
TARGET DISTANCE
10 [254.0]
TARGET DISTANCE
12
1
4
[310.2]
20
1
8
[511.4]
12
3
8
[314.5]
9
5
8
[245.6]
19
3
4
[502.4]
AA-08-01.1
Figure 3: Tool Center-Point
12
Evolver 303 Dual Purge Robotic Atomizers - Installation
INSTALLATION
EVOLVER 303 DUAL PURGE
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.
• MicroPak Control Unit (LECU5004)
• Stand-alone control/power supply unit
(A10406)
ELECTRICAL AND FIBER OPTIC
CONNECTIONS
The ber optic cable is included in the Evolver 303
dual purge tubing bundle, but not used. It is there,
ready to use, in case a user is using or chooses to use
in the future, a bell applicator, which requires the
ber optic cable. The ber optic connection is made
on the back of the applicator's robot plate. The ber
optic cable comes preassembled with connectors that
are secured in place by set screws tightened from the
side of the robot plate. An adequate ground must be
provided to the mounting plate to ensure that uid
ttings, etc. are at ground potential.
FLUID CONNECTIONS
The paint, solvent, and dump uid tubing are connected on the back of the robot plate with stainless
steel compression ttings and PFA tubing. Fluid
tubing requirements are shown in the "Signal Identication Tables" in the "Installation" section.
• MicroPak Control Unit (LECU5004-31)
MOUNTING
The Evolver 303 dual purge is equipped with a quick
disconnect assembly. The quick disconnect feature
consists of a robot plate which is permanently attached to the robot through a wrist adapter plate
and a mating rear plate which is part of the Evolver
303 Dual Purge Spray Applicator assembly. The applicator is secured to the robot plate with a threaded
retaining ring.
13
TYPICAL INSTALLATION
Figure 4 shows a typical installation of the Evolver
303 dual purge and the wiring installation of the
applicator with the MicroPak.
AA-08-01.1
HV GND. BUS
3
2
J6
1
J10
J2
+24 VDC
24 VRET
1
2
FACT. GND
+24 VDC
24 VRET 3
2
1
MICROPAK
BARE (DRAIN)
BARE (DRAIN)
YELLOW
ORANGE
N/C
N/C
N/C
N/C
GRAY
BLACK
N/C
N/C
GREEN
BLUE
N/C
J3
WHITE
RED
3/4" BRAID CABLE EARTH GROUND
Evolver 303 Dual Purge Robotic Atomizers - 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.
Figure 4: Low Voltage Cable Connections
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14
Evolver 303 Dual Purge Robotic Atomizers - Installation
SHAPING AIR/ATOMIZATION AIR
SEAL AIR/FAN AIR
BEARING AIR/PAINT TRIGGER
SOLVENT VALVE TRIGGER SIGNAL
LEAVE TUBING SLACK IN THE WRIST AND ELBOW
AREA TO REDUCE ROTATION STRESS.
TRIGGER SOLENOID
(IF USED)
SUPPLIED BY OTHERS
(MAIN AIR IF EXTERNAL TRIGGER USED)
INSIDE ENCLOSURE
3/4" HV GND BRAID (DEARBORN #91234 OR EQUIVALANT)
ATTACH TO ISOLATED H.V. GND (FOR MICROPAK)
ATTACH TO PANEL
GROUND
AC NEUTRAL
120VAC
BUILDING STEEL/GROUND ROD
L.V. CABLE
CONTROL PANEL
CONTROLS BY OTHERS
ANALOG SIGNAL AND
TRANSDUCER REQUIRED
IF USING A CAP CLEANER THE
IF A CAP CLEANER IS USED IT MUST BE
VENTED TO ATMOSPHERE WITHOUT PRESSURE
DIRECTLY INTO THE AIR CAP.
SOLVENT/AIR SHOULD NOT BE SPRAYED
BUILD UP.
LUBRICATE THE TUBING BUNDLE
EXCESSIVELY TO EASE INSTALLATION
AND EXTEND TUBING LIFE.
(BLUE)
(GRAY)
(YELLOW)
(BLUE)
PAINT 1 TRIGGER VALVE SIGNAL
PAINT 1 DUMP VALVE TRIGGER SIGNAL
(GREEN)
(ORANGE)
SOLVENT SUPPLY
WITH THE ITW EQUIPMENT PURCHASE.
FOR REFERENCE ONLY AND IS NOT INCLUDED
THE ROBOT IS SHOWN
DUMP
SOLVENT INBOUND
DUMP LINE OUT
PAINT SUPPLY 1
PAINT 1 INBOUND
PAINT 2 TRIGGER/PEGULATOR PILOT
(USED FOR DUAL PURGE AND REGULATED APPLICATIONS)
(NATURAL)
15
Figure 5: Evolver 303 Dual Purge Spray Applicator Air and Fluid Layout
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - Installation
APPLICATOR 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 (76566-24C) included
with the rear manifold tubing assembly to attach
the rear manifold assembly ( A12283) to the robot
spacer plate (see Table 1).
Connect each signal line as required per "Signal
Identication Tables (Metric) Tubing Bundles" in the
"Installation" section.
Rear Plate Assembly
The rear plate assembly is designed to be at ground
potential when mounted to the robot plate component within the tubing bundle assembly. The air and
uid ports are compactly oriented for use in robotic
applications. The interior air supplies are ported
through the ve (5) support rods and also directly
tubed to the upper manifold assembly. On the exterior side of the rear plate, the ports are provided
with o-ring seals so that the applicator can be quickly
mated and secured to the robot plate
Robot Plate
The robot plate is a component of the tubing bundle
assembly and intended to be permanently mounted
to the robot. A wrist adapter is also available, which
matches the robot's mounting conguration. The
incoming air lines, uid lines, low voltage cable, and
ber optic cable are connected to the ttings provided
on the back of the robot plate. The rear plate of the
applicator assembly is secured to the robot plate with
a threaded retaining ring.
Break-Away Feature (Optional)
The Evolver 303 dual purge can be converted to
have a break-away feature, by replacing the ve (5)
stainless steel screws with ve (5) special designed
plastic screws (77524-00). This feature is meant to
reduce the damage to the applicator, robot, etc. If a
collision occurs, the ve (5) plastic break-away screws
fail and the applicator will break free. This will leave
the break-away ring and the mounting ring attached
to the robot.
Power Supply and Controls
The high voltage cascade located inside the Evolver
303 dual purge is controlled by the MicroPak control
unit. The low voltage ouput of the MicroPak is multiplied by the internal cascade to the high voltage level
required. This eliminates the need for a high voltage
cable. A low voltage cable interconnects the cascade
and the MicroPak control. The MicroPak Eurocard
format is designed to t in a conventional 19-inch
or 1-inch rack and requires a 24V power input at a
maximum 3 amps. The MicroPak and the internal
cascade will produce voltages up to 100,000VDC.
The MicroPak is designed to electronically limit current to provide safe operation in a spray booth. The
voltage and current draw of the applicator are continuously displayed on the MicroPak control panel.
Voltage and over-current limits are adjust-able on
the front of the MicroPak. MicroPak internal safety
circuits will shut down the system on over-current
and cable faults.
With additional control modules, all of the functions
of the Evolver 303 dual purge and MicroPak can be
controlled by a programmable controller. A Serial
Digital Module pneumatically controls the paint and
dump valves located on the applicator. An I/O module
provides communication between these modules
and the PLC.
The above modules are mounted in one 19-inch rack
and interconnected through a common motherboard.
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16
Evolver 303 Dual Purge Robotic Atomizers - 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. This provides the
nal position to top dead center of the robot.
Six (6) robot spacer plates shown in Table 1 are available for this product.
TABLE 1 - SPACER PLATES
Part # Description
79107-00 ABB 5400, 5002 Robots
78983-00 Fanuc P155, 145 Robots
79131-00 Fanuc P200/P-250 Robots
A10847-00 Adapter (Kawasaki-KE610L)
A10848-00 Adapter (Motoman-PX2850)
A10849-00 Adapter (Motoman-PX2900)
A10851-00 Adapter (B & M LZ2000)
A12036-00 Adapter (ABB 5400 Enhanced Wrist)
LOW VOLTAGE CABLE
It is important that the quick disconnect tting be
secured to a good ground source. The A12241-XX
cable is supplied with a ground cable which can be
secured to the bulkhead connector and the other
end to a known ground source. The cable can also
be grounded by attaching the bulkhead connector
to a grounded bulkhead plate. The bulkhead plate
can be no more than 1/8-inch (3.18mm) in thickness.
The bracket should be made as in Figure 7 to hold
the connector from turning. To mate the connectors, align the raised key section of the cable on the
applicator end with the key groove of the cable that
goes to the MicroPak. Push the male end into the
mating connector until an audible click is heard. Tug
on cable to ensure that it is locked in place. To remove
or disconnect the cable, pull back on the male connector shell and pull cable back at the same time. To
remove this section from the robot plate, remove the
applicator. Locate the set screw holding the anged
plastic 9 pin connector. Loosen with a 3/32" hex key
wrench. Pull the cable out from the robot plate end.
Install new cable in reverse direction, align the 9 pin
connector with the alignment mark on the robot
plate face and tighten set screw. Torque 5-10 lbs•in
(0.56-1.13 Nm).
W A R N I N G
!
> Cable connector shell must be electrically
grounded. Electrical noise or other interference
may result.
INSTALLATIONS
(See Figures 6, 7, and 8)
A low voltage cable is provided to send power to
the high voltage cascade in the applicator as well
as sending important information during operation
back to the MicroPak controls. One piece of the cable
is a permanent length of approximately
72-inches (1.8 meters) from the robot plate end. The
connecting cable can be ordered in various lengths
depending on the distance required to reach from
the robot arm to the MicroPak controller. The ends of
the cables have a male and female quick disconnect
end. This provides for a quick and easy removal of
the cable at the robot plate if servicing or replacement is required.
17
NOTE
> With the exception of uid, dump, and
bearing air/paint trigger, all other pilot and
air supply lines should be bulkheaded and
their diameters increased one nominal size.
For example: atomization air should be increased to an 1/2" ID (8mm) from bulkhead
plate to the volume booster.
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - Installation
NOTE
> If the length of the fan or atomization air
lines exceeds 30-ft. (10m), the lines must be
upsized to 1/2" ID (12mm for metric).
NOTE
> For the dipswitch settings for the
Evolver 303 dual purge, reference the current
microPak service manual
NOTE
> Leave 12-24-inches (.30-.61m) of
extra length on all lines to prevent extreme
tension being applied to these lines during
robot movement. This increases tubing
bundle life.
NOTES
AA-08-01.1
18
Evolver 303 Dual Purge Robotic Atomizers - Installation
ALIGN TIMING MARKS ON ROBOT PLATE
AND LOW VOLTAGE CABLE CONNECTOR AS SHOWN.
TIGHTEN SET SCREW TO 5-10 LBS./IN (0.56-1.13 Nm) TORQUE
ROBOT PLATE
(ATOMIZER SIDE)
FEMALE KEY SLOT
RAISED MALE KEY
PUSH TO RELEASE
BULKHEAD AND MICROPAK
CABLE END
MALE CONNECTOR AND
APPLICATOR CABLE END
CONNECT HERE TO BULKHEAD OR
ATTACH GROUND CABLE HERE
OPTIONAL GROUND CABLE
0.53"
(13.49mm)
0.59"
(15.00mm)
Figure 6: Bulkhead Cut-Out Diagram
1.00"
(25.40mm)
!
C A U T I O N
> Do not exceed 100-ft. combined length of
the low voltage cables.
W A R N I N G
!
> If a non-explosion proof junction box/termi-
nal strip is used, it must be located outside the
hazardous area.
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!
Figure 7: Robot Plate
Figure 8: Quick-Disconnect Cables
19
AA-08-01.1
Evolver 303 Dual Purge Robotic Atomizers - Installation
SIGNAL IDENTIFICATION TABLE BELLS APPLICATORS
Abbr.
B.A/P.T Bearing Air (Paint Trigger) Yellow Nylon 6mm OD X 4mm ID
B.A RTN Bearing Air Return Yellow Nylon 4mm OD X 2.7mm ID
BRK Brake Air Orange Nylon 6mm OD X 4mm ID
DL1/DL2 Dump Line Natural 10mm OD X 7mm ID
F.O Fiber Optic Cable Natural Polyethylene 1/4" OD (jacket)
LV Low Voltage Cable Black N/A N/A
P1.IN/P2.IN Paint In Natural 5/16" OD X 3/16" ID
P1T Paint 1 Trigger Green Nylon 4mm OD X 2.7mm ID
P2T Paint 2 Trigger Natural Nylon 4mm OD X 2.7mm ID
P1D Paint 1 Dump Trigger Silver Nylon 4mm OD X 2.7mm ID
P2D Paint 2 Dump Trigger Black Nylon 4mm OD X 2.7mm ID
SA.I/A.A Inner Shaping Air (Atom. Air) Blue Nylon 8mm OD X 6mm ID
SOL Solvent In Natural 6mm OD X 4mm ID
SA.O/F.A Outer Shape Air (Fan Air) Gray Nylon 8mm OD X 6mm ID
ST/RP Solvent Trigger Signal Blue Nylon 4mm OD X 2.7mm ID
T.A Turbine Air Natural Nylon 10mm OD X 7mm ID
Description Color
Tubing Material
Tubing Size
AA-08-01.1
20
Evolver 303 Dual Purge Robotic Atomizers - Installation
3
1
2
4
Figure 9: Applicator and Manifold Assembly
APPLICATOR AND MANIFOLD ASSEMBLY - PARTS LIST
(Figure 9)
Item #
1 A12283-XXXXXXX Tubing Bundle Assembly (Metric) 1
2 A12374-XXX Evolver 303 Dual Purge Spray Applicator Assembly 1
3 76566-24C Screw, 1/4-20 X 3/4" Lg., SHCS 6
4 See Table 1 Robot Adapter 1
Part # Description Qty
21
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