Ransburg A12950-XXX User Manual
SERVICE MANUAL
LN-9271-12.2
April 2013
Supersedes LN-9271-12.1
RPA-2
MODEL: A12950-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.
Service Manual Price: $50.00 (U.S.)
LN-9271-12.2
RPA-2 POWDER APPLICATOR - Contents
CONTENTS
SAFETY: 1-6
SAFETY PRECAUTIONS ......................................................................................................... 1
HAZARDS / SAFEGUARDS................................................................................................... 2-6
INTRODUCTION: 7-11
GENERAL DESCRIPTION ........................................................................................................ 7
POWDER APPLICATOR MAIN COMPONENTS ...................................................................... 8
TOOLS REQUIRED .................................................................................................................. 9
HIGH VOLTAGE GENERATION/ROUND NOZZLE DESCRIPTION ....................................... 10
SPECIFICATIONS/CENTER OF GRAVITY ............................................................................ 11
INSTALLATION: 12-13
CONNECTION PROCEDURE ................................................................................................ 12
FUNCTION CHECK AND SCHEMATIC .................................................................................. 13
OPERATION: 14-15
GENERAL OPERATION/START-UP ................................................................................. 14-15
MAINTENANCE: 16-27
TROUBLESHOOTING GUIDE ........................................................................................... 16-17
INSPECTING AND CLEANING .......................................................................................... 17-18
APPLICATOR DIS-ASSEMBLY ......................................................................................... 18-24
HIGH VOLTAGE CONTACT WIRE REPAIR ........................................................................... 25
APPLICATOR ASSEMBLY ..................................................................................................... 26
DEFECTIVE PARTS RECOGNITION ..................................................................................... 27
PARTS: 28-42
APPLICATOR PARTS DRAWING ..................................................................................... 28-30
PARTS LIST AND DRAWINGS .......................................................................................... 31-37
SHAPE AIR ASSEMBLY AND PARTS LIST ...................................................................... 37-38
ELECTRODE ASSEMBLY AND PARTS LIST ................................................................... 39-40
SPARE PARTS .................................................................................................................. 41-42
WARRANTY POLICIES: 43
LIMITED WARRANTY............................................................................................................. 43
PAGE
LN-9271-12.2
RPA-2 POWDER APPLICATOR– 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 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 specifications
and service procedures, some minor deviations may be found between this literature and
your equipment. Differences in local codes and
plant requirements, material delivery requirements, etc., make such variations inevitable.
Compare this manual with your system installation drawings and appropriate Ransburg
equipment manuals to reconcile such differences.
The user MUST read and be familiar
with the Safety Section in this manual and
the Ransburg safety literature therein
identified.
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 fire
codes and ordinances as well as NFPA-33
SAFETY STANDARD, LATEST EDITION,
prior to installing, operating, and/or servicing this equipment.
pages may occur during the normal use
of this equipment. Please read the hazard chart beginning on page 2.
!
!
The hazards shown on the following
W A R N I N G
W A R N I N G
Careful study and continued use of this manual
will provide a better understanding of the
equipment and process, resulting in more efficient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not
have the manuals and safety literature for your
Ransburg system, contact your local
Ransburg representative or Ransburg.
1 LN-9271-12.2
RPA-2 POWDER APPLICATOR - Safety
AREA
Tells where haz-
HAZARD
Tells what the hazard is.
ards may occur.
Spray Area Fire Hazard
Improper or inadequate operation and maintenance procedures will cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation. Frequent Power Supply 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, flushing or maintenance.
When using solvents for cleaning:
• Those used for equipment flushing should
have flash points equal to or higher than those
of the coating material.
• Those used for general cleaning must have
flash points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained during cleaning operations using flammable
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 unauthorized
equipment modifications may cause fire or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
OSHA, local, country, and European Health and
Safety Norms.
LN-9271-12.2 2
RPA-2 POWDER APPLICATOR– Safety
AREA
Tells where haz-
HAZARD
Tells what the hazard is.
ards may occur.
Spray Area Explosion Hazard
Improper or inadequate operation and maintenance procedures will cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation.
Frequent Power Supply 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 specifically 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 flammable 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 fire 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
flushing, 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 fire 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, fire protection, operation maintenance, and housekeeping. Reference
OSHA, NFPA-33, EN Norms and your insurance
company requirements.
3 LN-9271-12.2
RPA-2 POWDER APPLICATOR - Safety
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 fire 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 flooring must be provided in
the spray area.
Always turn off the power supply prior to flushing,
cleaning, or working on spray system equipment.
Unless specifically 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.
LN-9271-12.2 4
RPA-2 POWDER APPLICATOR– 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 flammable or
combustible materials may occur. Personnel are exposed to
high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a fire or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shutdown indicates a problem in the
system which requires correction.
An electrical arc can ignite coating materials and cause a fire or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specifically 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 flammable or combustible material.
Testing may require high voltage to be on, but only
as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Toxic Substances
Chemical Hazard
Certain materials may be harmful if inhaled, or if there is contact with the skin.
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.
5 LN-9271-12.2
RPA-2 POWDER APPLICATOR - Safety
AREA
Tells where haz-
HAZARD
Tells what the hazard is.
ards may occur.
Spray Area Explosion Hazard—
Incompatible Materials
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.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum equipment during spraying, flushing, or cleaning. Read
the label or data sheet for the material you intend
to spray. If in doubt as to whether or not a coating
or cleaning material is compatible, contact your
coating supplier. Any other type of solvent may be
used with aluminum equipment.
LN-9271-12.2 6
RPA-2 Powder Applicator - Introduction
INTRODUCTION
GENERAL DESCRIPTION
This operating manual contains all important
information required for working with the RPA-
2 Powder Applicator. It will give you references and tips for the optimal use of your new
powder coating system.
The RPA-2 is intended exclusively for the
electrostatic coating with organic powders.
Any other use is considered as nonconforming. The manufacturer is not responsi-
ble for any damage resulting from this; the risk
for this is assumed by the user alone.
With an integrated high voltage generator
(cascade), the RPA-2 is particularly suitable
for the coating of car bodies and parts. The
applicator is designed for operation on a freely
programmable hollow wrist robot (up to 7
axes).
The RPA-2 is installed on the front side of a
follow-arm coating robot. An appropriate
adapter piece for the corresponding robot type
is used for fitting the applicator to the robot.
This adapter provides a locating pin for exact
positioning of the applicator, as well as the
fixture of the applicator cable and hoses.
The RPA-2 has a high and constant transfer
efficiency.
The applicator is quick detachable, therefore
fast and easy for maintenance and repair.
The wear parts can be easily changed, even
with the applicator attached to the robot.
7 LN-9271-12.2
RPA-2 POWDER APPLICATOR - Introduction
7
1
3
2
5
1– Shaping Air 5- Applicator Ground Cable and Low Voltage Cable
2– Applicator Body 6– Powder Hose Connection
3– High Voltage Cascade (Internal) 7– Nozzle
6
4
4—Robot Adapter
Figure 1: RPA-2 Powder Applicator
LN-9271-12.2 8
RPA-2 Powder Applicator - Introduction
Tools Required for Assembly/Dis-Assembly
76772-00 Spanner Wrench
A13001-00
Tool– Powder
Inlet Fitting
(Included with
applicator)
Adjustable
Wrench
Flat Blade
Screwdriver
Hex Keys
6mm
3/16
3/32
9 LN-9271-12.2
RPA-2 POWDER APPLICATOR - Introduction
High Voltage Generation
The applicator high voltage control unit supplies a high frequency low-voltage signal to
the cascade. This voltage is fed through the
applicator cable and the cascade connection.
The low-voltage signal is multiplied in the cascade to produce the necessary high voltage
(up to 100 kV).
The high voltage is fed through a conductive
path in the atomizer to the central electrode
(see figure 1)
Round Jet Nozzle With Air
Cleaned Electrode
The round nozzle shapes and distributes the
powder. The powder cloud obtains a bellsimilar spray pattern by the deflector plate and
by the dynamic powder/air flow.
The powder is charged by means of the central electrode. The high voltage, which is produced by the cascade in the applicator, is connected to the electrode through the black contact ring on the nozzle holder. The round nozzle front face is rinsed with compressed air in
order to prevent powder accumulations. The
electrode rinsing air is fed into the electrode
holder through the small hole in the black contact ring of the nozzle holder. The electrode
rinsing air volume is typically maintained at a
constant setting of 40-50 SLPM.
BLACK CONTACT
RING
Round Nozzle (Figure
POWDER EXIT
FRONT FACE
CENTRAL
ELECTRODE
LN-9271-12.2 10
RPA-2 Powder Applicator - Introduction
SPECIFICATIONS
Environmental
Operating Temperature: 0°C to +55°C
Storage and Shipping
Temperature: -40°C to +85°C
Humidity: 95% Non-Condensing
Physical
Height: See Figure
Width: See Figure
Depth: See Figure
Weight: 4.2 kg (9.26 lbs.)
Electrical
Output Voltage: 100 kV @ Ø µa
Maximum Output Current: 240 µa @ 0 kV
Polarity: Negative
11 LN-9271-12.2
Suggested switch setting:
B. Dense phase powder supply hose is
manufacturer’s documentation.
RPA-2 POWDER APPLICATOR - Installation
INSTALLATION
The relevant Safety Standards, as well as the
Safety Regulations of the robot manufacturer
must be adhered to for the operation of the
RPA-2 applicator
!
CONNECTING PROCEDURE
1. Attach the robot adapter to the end of the robot.
2. Lay out the applicator powder hose, electrode
rinsing air hose, cascade rinsing air hose, and
shaping air hose in such a way that neither
kinks or twist can likely form
3. Connect the shaping air (SA) to the proper
push-in fitting on the robot plate. Clean pneumatic tubing of any debris.
W A R N I N G
10. Connect the low voltage cable to the control
unit. (see the current MicroPak or Evolver
MicroPak controller service manuals for wire
termination.)
SW-3 (1&2 On)
SW-7 (1 On) ( 5&6 Off)
11. Powder supply can either be delivered
through the dilute phase pump (Venturi) or
dense phase pump.
A. Dilute phase powder supply hose is
connected to the applicator. (Items 51,
52, 53,and 54 are ordered separately for
a Venturi Feed application.) “Table A—
Upper Powder Tube” in the “Parts Identi
fication” section shows optional parts
required for the tube connection. Con
nect dilute phase powder supply hose
(only if available.)
4. Connect the electrode rinsing air (EA) to the
robot plate. Clean pneumatic tubes of any debris.
5. Connect the cascade rinsing air (CA) to the
robot plate.
6. Connect the ground cable to “GND” fitting on
the robot plate. Do Not Over Tighten
7. Connect the other end of the ground cable to
a good known earth ground source after installing the cable thru the robot arm.
8. Connect the low voltage cable to the robot
plate Align marks and tighten set screw. (See
Picture)
9. Install tubing and cables thru the robot arm.
Attach robot plate to robot adapter with (4)
77566-24C screws. (3/16 hex key)
connected to the multi-color integrator
(MCI). The MCI will use dilution air to
dilute the dense phase powder. Dilution
air requirements are powder dependent.
Connect the MCI to the open threaded
connection next to the pneumatic tube
connections.
The multi-color integrator will also have
the required powder supply lines and
one more pneumatic link used for a
pinch valve. Refer to “Function and
Operation” information from MCI
12. Align the 2 pins on the applicator rear plate
with the mating holes of the robot plate.
Spin the mounting ring to tighten applicator
to the robot plate.
LN-9271-12.2 12
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