Ransburg RMA-560 User Manual
SERVICE MANUAL
LN-9278-13
DECEMBER - 2013
RMA-560 SINGLE/DUAL PURGE
ROBOT MOUNTED ROTARY
ATOMIZER DIRECT CHARGE
Ransburg
MODEL: A13364
Service Manual Price: $50.00 (U.S.)
RMA-560 Single/Dual Purge Direct Charge - Contents
CONTENTS
SAFETY: 1-5
SAFETY PRECAUTIONS ......................................................................................................1
HAZARDS / SAFEGUARDS ..................................................................................................2-5
INTRODUCTION: 6-22
FEATURES .............................................................................................................................6
GENERAL DESCRIPTION ....................................................................................................7-8
SPECIFICATIONS .................................................................................................................9
IMPORTANT NUMBERS .......................................................................................................10
GRAPHS ...............................................................................................................................11-16
TOOL POINT DIMENSIONS ..................................................................................................17-20
CIRCUIT SCHEMATICS .........................................................................................................21
VALVE SCHEMATIC...............................................................................................................22
Ransburg
PAGE
INSTALLATION: 23-33
AIR FILTER INSTALLATION .................................................................................................23
EQUIPMENT GROUNDING / SAFETY RECOMMENDATIONS ............................................24-25
AIR HEATER REQUIREMENTS ............................................................................................25
AIR HEATER AND FILTRATION OPTIONS ...........................................................................26-28
MOUNTING ............................................................................................................................28
ELECTRICAL AND FIBER OPTIC CONNECTIONS ..............................................................28-29
FLUID CONNECTIONS ..........................................................................................................29
TYPICAL INSTALLATION .......................................................................................................29
TYPICAL INSTALLATION OF RMA-560 ................................................................................30
TUBING BUNDLE INSTALLATION ........................................................................................31
BUNDLE LUBRICANT ............................................................................................................31
RMA-560 WIRING INSTALLATION ........................................................................................32
INTERLOCKS.........................................................................................................................33
OPERATION: 34-42
FLUID FLOW RATE CONTROL ............................................................................................34-35
DUAL PURGE SPRAYING .....................................................................................................35
TURBINE SPEED...................................................................................................................35
BEARING AIR ADJUSTMENT ................................................................................................36
SHAPING AIR KITS 1-4 .........................................................................................................36-38
BRAKE AIR.............................................................................................................................38
ELECTROSTATIC VOLTAGE .................................................................................................38
TARGET DISTANCE ..............................................................................................................39-40
LOW VOLTAGE CABLE INSTALLATION AND REMOVAL ....................................................40-41
LOW VOLTAGE CABLE ON ROBOT .....................................................................................42
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Contents
CONTENTS (Cont.)
MAINTENANCE: 43-71
O-RINGS ...............................................................................................................................43
CLEANING PROCEDURES ...................................................................................................43-44
VIBRATION NOISE ................................................................................................................45
TURBINE MAINTENANCE .....................................................................................................45
GENERAL/PREVENTIVE MAINTENANCE ...........................................................................45
PREVENTIVE MAINTENANCE ..............................................................................................46-47
BELL CUP PREVENTIVE MAINTENANCE ...........................................................................47-48
BELL CUP CLEANING ...........................................................................................................48-49
CLEANING SHAPING AIR HOLES ........................................................................................49
RMA-580 PREVENTIVE MAINTENANCE SCHEDULE .........................................................50
DISASSEMBLY PROCEDURES ............................................................................................51-67
TROUBLESHOOTING GUIDE ...............................................................................................68-71
PARTS IDENTIFICATION: 72-99
Ransburg
PAGE
RMA-560 DIRECT CHARGE ROTARY ATOMIZER MODEL IDENTIFICATION ...................72
SHAPE AIR KITS - TABLE A ..................................................................................................72
BELL CUP ASSEMBLY - TABLE B .........................................................................................73
MOUNTING RING - TABLE C ................................................................................................73
VALVE MANIFOLD ASSEMBLY - TABLE D ...........................................................................73
SPINDLE ASSEMBLY - TABLE E ...........................................................................................74
FLUID COIL - TABLE F ..........................................................................................................74
FLUID TIP - TABLE G .............................................................................................................74
TOOL KIT - TABLE H..............................................................................................................75
REAR SHROUD - TABLE J ...................................................................................................75
TYPICAL BELL CUP PARTS BREAKDOWN .........................................................................76
RMA-560 ASSEMBLY ............................................................................................................77-80
RMA-560 SINGLE/DUAL PURGE DIRECT CHARGE ASSEMBLY .......................................81-82
A13430-00 REAR PLATE ASSEMBLY - PARTS LIST............................................................83
SHAPING AIR KIT ASSEMBLY PARTS BREAK-DOWN ........................................................84
SHAPING AIR KIT - PARTS LIST ...........................................................................................84
A12289-00 VALVE MANIFOLD ASSEMBLY - PARTS LIST ...................................................85
SHAPING AIR KITS................................................................................................................86
TUBING BUNDLE ASSEMBLY MODEL IDENTIFICATION ...................................................87-91
ATOMIZER RECOMMENDED SPARE PARTS ......................................................................92-95
TUBE BUNDLE RECOMMENDED SPARE PARTS ...............................................................95-96
ASSEMBLY TOOLS ...............................................................................................................97
FILTER & HEATER ASSEMBLY A13230-XX ..........................................................................98
A13230-XX AIR HEATER AND FILTER COMBINATION .......................................................98
SERVICE KITS / ACCESSORIES ..........................................................................................99
WARRANTY POLICIES: 100
LIMITED WARRANTY ...........................................................................................................100
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Safety
SAFETY
Ransburg
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.
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 SAFETY STANDARD, LATEST EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
!
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.
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.
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.
1
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - 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
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Safety
Ransburg
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.
3
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - 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
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Safety
Ransburg
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.
5
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
INTRODUCTION
Ransburg
APPLICATOR DESCRIPTION
The RMA-560 is an automatic robot mounted
rotary atomizer capable of spraying solvent borne
coatings electrostatically or non-electrostatically.
It incorporates the latest in high speed spindle
technology, bell cup and shape air design to provide the best in atomization and pattern control.
The bell cups are designed for durability using the
best materials available. All wetted components
are designed to offer the maximum in wear and
chemical resistance. The atomizer incorporates
an integrated internal cascade capable of applying
100,000 VDC directly to the coating materials.
FEATURES
Features which make the RMA-560 advantageous
for use in electrostatic applications include:
• True dual purge capability. Spray one color
while cleaning the other paint line with no loss
of tip voltage.
• Assembly components made of durable engi-
neered resin material for optimum mechanical
strength and solvent resistance.
• Heavy duty design insures excellent service
life even when subjected to the quick motions
of robotic applications.
• Proven long life turbine motor capable of
speeds up to 80 krpm. (See “Specications”
in the “Introduction” section of this manual for
bell cup speed ratings.)
• Serrated and non-serrated bell cups are
available for application exibility and color
match. All bell cups are made using Titanium,
Aluminum or Coated Aluminum. The 55mm
Bell Cup is Titanium only.
• Aerodynamic design for ease of cleaning
external surfaces.
• 60° angled body provides more maneuver-
ability and facilitates robotic programming.
• Small light weight package allows better ma-
neuverability in tight areas.
• Negligible maintenance down time. With the
quick disconnect feature, an atomizer can be
changed in less than 2 minutes for off-line
maintenance.
• The easily removable front and rear shrouds,
turbine assembly and the internally mounted
uid valves, make off-line maintenance more
efcient and economical. A split shroud is avail-
able for easy access to internal components
while still mounted on the robot.
• Fast color changes are achieved using center
feed uid delivery and the uid valves provide
for simultaneous paint push while solvent
washes the feed tube and bell cup interior.
• Internal and external bell wash is quick and
efcient. Solvent is controlled at the feed tube
with an internally mounted solvent valve. Externally mounted regulators control the ow.
• Less waste to the spray booth, with the dump
valve located internally next to the feed tube.
• No external high voltage cable. The internally
mounted high voltage cascade requires only
low voltage control wiring.
• Compact high voltage control system. The
MicroPak™ Cascade control takes only 1/4
of the space in a 19-inch Euro rack, leaving
room for additional control modules.
• Various adapter plates available to match most
robotic mounting congurations.
• Direct charging of uid (solvent borne paint)
promotes high transfer efciency.
• Large range of uid tip sizes available.
• Optional repulsion ring and shroud for tighter
pattern control and less overspray.
• Fitting less tubing bundle, more exibility in the
robot wrist and easier to repair damaged tubes.
• Valve manifold can be ordered as a single or
dual purge version.
6
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
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 at the robot plate. The bell plate of the
Figure 1: RMA-560 Dual Purge Robot Mounted Rotary Atomizer– Direct Charge. With and without Repulsion Ring.
atomizer assembly is secured to the robot plate
with a threaded retaining ring.
Valve Manifold
Ransburg
GENERAL DESCRIPTION
Bell Cup Assembly
Bell cups are made of high strength Titanium, Aluminum or High Wear Coated Aluminum. Serrated
cups are available in 30mm, 55mm and 65 mm.
Non-serrated are available in 55mm and 65mm.
See ordering matrix for exact size and material
combination availability.
Air Bearing Turbine Assembly
The air bearing turbine assembly with bell cup
is mounted to the air manifold assembly with a
turbine retaining ring.
Air Manifold Assembly
The atomizer extension is angled at 60˚ for robot
applications. The uid feed tube and ber optic
turbine speed emitter are threaded into the front of
the manifold. The turbine, uid, and air manifolds
are separated from the bell plate assembly by ve
support rods. Nested between the manifolds and
the bell plate is the high voltage cascade.
Bell Plate Assembly
The bell 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 air supplies are
ported through the ve support rods directly to
the air manifold assembly. On the exterior side of
the bell plate, the ports are provided with O-ring
seals so that the atomizer can be quickly mated
and secured to the robot plate.
This manifold can be congured for either single or
dual purge application. The dual purge can allow
two colors to be loaded at one time.
Break-Away Feature (Optional)
The RMA-560 is available with or without a break-
away feature. By replacing the ve (5) stainless
steel screws with ve (5) special designed plastic
screws (77524-00). This feature minimizes the
damage to the atomizer or robot, if a collision
occurs, the ve (5) plastic break-away screws fail
and the atomizer will break free. This will leave the
break-away ring and the mounting ring attached
to the robot. (The applicator will fall to the booth
grate or oor).
Power Supply and Controls
The high voltage cascade is located inside the
applicator and is controlled by the MicroPak control unit. The low voltage output 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 MicroPak control. The
MicroPak format is designed to t in a conventional
19-inch or 10-inch rack and requires a 24V power
input at a maximum 3 amps. The MicroPak and
the internal cascade will produce voltages up to
100,000 VDC.
The MicroPak is designed to electronically limit
current to provide safe operation in a spray booth.
The voltage and current draw of the atomizer are
continuously displayed on the MicroPak control
panel. Voltage and over-current limits are adjustable on the front of the MicroPak. MicroPak
7
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
internal safety circuits will shut down the system
on over-current and cable faults.
With additional control modules, all of the functions
of the RMA-560 and MicroPak can be controlled
by a programmable controller. A Serial Atomizer
Module pneumatically controls the speed of the
rotary atomizer with dynamic feedback through a
ber optic transmitter located on the applicator. A
Serial Digital Module pneumatically controls the
paint, solvent, and dump valves located on the
atomizer. 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
mother board.
Ransburg
8
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
SPECIFICATIONS
Ransburg
Electrical:
Power Supply Type: MicroPak
Charging Method: Direct
Output Voltage: 30-100 kV Variable
(100 kV Maximum)
Output Current: 125 µA
Turbine Speed
Control: Atomizer Module
Part Spray Ability: Determine spray ability of
part to be coated using
Test Equipment (76652)
(Paint Conductivity Meter)
Mechanical:
Length: (See RMA-560 Tool Point, Center of
Gravity, and Envelope Dimension
(Single and Dual Flex) gure in the
“Introduction” section.)
Diameter: (See RMA-560 Tool Point, Center of
Gravity, and Envelope Dimensions
(Single and Dual Flex) gure in the
“Introduction” section.)
Approximate Weight (Dual Flex)
Atomizer Only: 12.77 lbs. (5.8 Kg) max.
Total Payload with Robot Plate (Dual Flex)
& Adapter: 15.57 lbs. (7.1 Kg) max.
Turbine Type: Air Bearing Impulse Drive
Turbine Air Supply: Variable (See “Pressure
Flow Data Charts” in the
“Introduction” section.)
Maximum/Minimum
Turbine Speed:
/20K rpm min. See excep tion at “Fluid Flow Rate”
Maximum Angular
Velocity for Turbine
(Robot Motion): 250°/sec.
Tubing Bundle
Max. Rotation: 450° in Either Direction
Bearing Air Supply
at the Applicator: 90 psig (±10 psi)
(Nominal): (621 kPa ±69 kPa) 2.9
SCFM (82 slpm)
Continuous 80K rpm max.
Mechanical (Cont.):
Shaping Air #1 Variable (See “Pressure
(SAI) Supply: Flow Data Charts” in the
“Introduction” section)
Shaping Air #2 Variable (See “Pressure
(SAO) Supply: Flow Data Charts” in the
“Introduction” section)
Brake Air Supply
(Nominal):
Maximum Fluid Pressure Supply:
Paint: 200 psi (1379 kPa)
Solvent: 150 psi (1035 kPa)
Fluid Flow Rate: 25-800 cc/min.
(See exclusion below)
30mm Bell Cup Max. Flow Rate: 300 cc/
min. at 80,000 rpm
55mm Bell Cup Max Flow Rate: 500 cc/
min. at 80,000 rpm
Max. Flow Rate: 800 cc/
min at 70,000 rpm
65mm Bell Cup Max. Flow Rate: 500 cc/
min at 80,000 rpm
Max. Flow Rate: 800 cc/
min. at 70,000 rpm
Bell Cup Cleaning Time
(Internal/External): 2.7 sec. (approx.)
Color Change Time: Dependent on system
conguration, uid pres
uid viscosity,uid line
lengths, etc.
Speed Readout: Magnetic pick-up, unidirec-
tional ber optic transmission
Atomizer
Replacement Time: Less than 5 min.
Bell Cup
Replacement Time: Less than 2 min.
Minimum Control Equipment
Requirements: (Versions listed or higher)
MicroPak LECU5004-11 (V.3.84)
Atomizer Module A11925-00 (V.0.4)
I/O Module A11435-00 (V.1.4)
(0.01V) (4-20 mA)
* Specications and ratings based on testing at sea
level standard conditions.
Air Heater Recommendation:
An Air Heater is recommended for the turbine air
supply. See Air Heater and lteration recommendation later in this manual
60-100 psig (414-689 kPa)
sures,
9
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
IMPORTANT NUMBERS
Record these numbers in a log book for future reference. The last digits of the Atomizer serial number
are also the Turbine serial numbers.
Ransburg
Turbine Serial Number
Atomizer Serial Number
Bell Cup Part Numbers/Serial Number
(cup only, not with splash plate)
10
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
GRAPHS
Graphical information provided for reference only for all charts. Unless otherwise specied, all
pressure data shown was measured 12-inches (305mm) behind the applicator.
TURBINE SPEED VS. PRESSURE - NO LOAD
Ransburg
TURBINE SPEED VS. AIR CONSUMPTION - NO LOAD
11
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
Ransburg
12
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
BEARING AIR FLOW RATE VS. SUPPLY PRESSURE
Ransburg
13
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
FLOW VS. PRESSURE
MONO FLEX SHAPE AIR - SINGLE SUPPLY SOURCE
A12874-05/-06/-07 SHAPING AIR KIT
Ransburg
FLOW VS. PRESSURE
MONO FLEX SHAPE AIR - DUAL SUPPLY SOURCE
A12874-05/-06/-07 SHAPING AIR KIT
14
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
RMA-560 DUAL FLEX AIR
A12874-08/-09/-10 SERIES SHAPE AIR
FLOW VS. PRESSURE
Ransburg
SHAPING AIR FLOW VS. SUPPLY PRESSURE
30MM GHOST BUSTER SHROUD STYLE
A12874-03/04 SHAPING AIR KIT
15
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
MAXIMUM FLOW RATE BY TIP SIZE,
HOSE LENGTH, AND MATERIAL VISCOSITY
Ransburg
16
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
RMA-560 TOOL CENTER POINT DIMENSIONS (30mm)
Ransburg
17
30MM WITH AND WITHOUT REPULSION RING
TD X
6-Inches (152mm) 19.87-Inches (504.7mm) 10.67-Inches (271.3mm)
8-Inches (203mm) 20.87-Inches (530.1mm) 12.41-Inches (315.2mm)
10-Inches (254mm) 21.87-Inches (555.5mm) 14.14-Inches (359.2mm)
12-Inches (305mm) 22.87-Inches (580.9mm) 15.87-Inches (403.1 mm)
Weight:
With Repulsion Ring 13.99 lbs. (6.35 Kg)
Without Repulsion Ring 14.99 lbs. (6.44 Kg)
Y
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
RMA-560 TOOL CENTER POINT DIMENSIONS (55mm)
Ransburg
18
55MM DUAL FLEX WITH AND WITHOUT REPULSION RING
TD X
6-Inches (152mm) 19.79-Inches (502.7mm) 10.53-Inches (267.5mm)
8-Inches (203mm) 20.79-Inches (528.1mm) 12.26-Inches (311.4mm)
10-Inches (254mm) 21.79-Inches (553.5mm) 13.99-Inches (355.3mm)
12-Inches (305mm) 22.79-Inches (578.9mm) 15.72-Inches (399.3mm)
Weight:
13.88 lbs. (6.3 Kg)
Y
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
RMA-560 TOOL CENTER POINT DIMENSIONS (65mm Mono Flex)
Ransburg
19
65MM MONO FLEX WITH AND WITHOUT REPULSION RING
TD X
6-Inches (152mm) 19.83-Inches (503.6mm) 10.61-Inches (269.5mm)
8-Inches (203mm) 20.83-Inches (529mm) 12.34-Inches (313.4mm)
10-Inches (254mm) 21.83-Inches (554.4mm) 14.07-Inches (357.4mm)
12-Inches (305mm) 22.83-Inches (579.8mm) 15.80-Inches (401.3mm)
Weight:
With Repulsion Ring 14.3 lbs. (6.49 Kg)
Without Repulsion Ring 14.1 lbs. (6.40 Kg)
Y
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
RMA-560 TOOL CENTER POINT DIMENSIONS (65mm Dual Flex)
Ransburg
20
65MM DUAL FLEX WITH AND WITHOUT REPULSION RING
TD X
6-Inches (152mm) 19.83-Inches (503.6mm) 10.61-Inches (269.4mm)
8-Inches (203mm) 20.83-Inches (529mm) 12.34-Inches (313.4mm)
10-Inches (254mm) 21.83-Inches (554.4mm) 14.07-Inches (357.4mm)
12-Inches (305mm) 22.83-Inches (579.8mm) 15.80-Inches (401.4mm)
Weight:
With Repulsion Ring 15.57 lbs. (7.1 Kg)
Without Repulsion Ring 15.37 lbs. (6.97 Kg)
Y
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
CIRCUIT SCHEMATIC
Ransburg
21
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Introduction
VALVE SCHEMATIC
Ransburg
22
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Installation
INSTALLATION
Ransburg
AIR FILTER INSTALLATION
(GENERAL GUIDELINES)
The following air lter installation guidelines are
essential for optimum performance:
1. Use 25mm OD (1-Inch OD) minimum inbound
main air line.
2. Use only recommended pre-lters and bearing
air lters as shown in “Air ltration Requirements” chart in the ”Installation” section. Additional system air ltration (i.e., refrigerated
air dryer) may also be used if desired.
3. Mount all the air lters as close as possible
to the RMA-560 applicator. (DO NOT mount
further than 30-Feet (9.1 meters) away.)
4. DO NOT use tape, pipe dope, or other thread
sealant downstream of the bearing air lter.
Loose akes of tape or other sealant can break
loose and plug the very ne air holes in the
turbine air bearings.
5. Air heaters are highly recommended for use in
the system to minimize the effect of excessively
humid conditions and maintain turbine load
capabilities. If the heated air will exceed 120°F
(48.9°C), the heater must be located after all
lters to prevent damage to the lter media.
NOTE
Each applicator must have its own lter
for bearing air. Recommended: RPM-418
or equivalent.
With the exception of uid, dump, and bearing
air, all other pilot and air supply lines should be
bulk-headed and their diameters increased one
size. For example: Turbine air should be increased
to 12mm OD from bulkhead plate to the volume
booster or heater outlet.
Volume Booster Recommendation
(Turbine Air): (For use with A11065-05
Air Heater or Non-Air Heater System)
Ransburg Part # A11111-00
• Pilot Operated Regulator Non-Bleed Pilot
• SCFM-200
• Supply - 300 P.S.I.
• Temperature Range: 40˚ - 120° F
23
TUBE SIZE AIR PRESSURE REQUIREMENTS
Tube Size
Bearing Air Supply (BA/PT) 8 X 6 mm (Natural) (90 psi +/- 10 kPa) (621 +/- 69 kPa)
Bearing Air Return (BA RTN) 4mm (5/32”) (Yellow) 90 psi +/- 10 at atomizer card (552 +/- 138 kPa)
Turbine Air (T.A.) 10 X 8mm (Green) Variable
Outer Air (SAO/FA) 8 X 6mm (Gray Variable
Pattern Control Air #1 (SAI/AA) 8 X 6mm (Blue) Variable
Brake Air (BRK) (if used) 8 X 6 mm (Natural) 60-100 psi (414-689 kPa)
Paint Valve #1 (P1T) 4mm OD (5/32”) (Natural) 80 psi +/- 10 (552 +/- 70 kPa)
Dump Valve #1 Control (P1D) 4mm OD (5/32”) (Gray) 80 psi +/- 10 (352 +/- 70 kPa)
Solvent Valve Control (ST/RP) 4mm OD (5/32”) (Blue) 80-100 psi (552-873 kPa)
Paint Valve #2 (P2T) 4mm (5/32”) (Natural) (552 +/- 70 kPa)
Dump Valve #2 Control (P2D) 4mm (5/32”) (Black) 80 psi +/- 70 kPa)
Air Pressure Requirements
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Installation
Ransburg
EQUIPMENT GROUNDING / SAFETY RECOMMENDATIONS
In electrostatic coating systems, the ow of high
voltage power from the power supply to the
atomizer is insulated from ground and isolated
from all other functions equipment. When the
voltage reaches the atomizer, it is transferred
to the coating material where, by introducing a
negative charge, it causes the atomized uid to
seek the nearest positive ground. In a properly
constructed and operated system, that ground will
be the target object.
The directed conduction of the electric charge,
through its array of wires, cables, and equipment,
is accompanied by a variety of stray electrical
charges passing through the air by various means
such as: air ionization, charged particles in the
air and radiated energy. Such charges may be
attracted to any conductive material in the spray
area. If the conductive material does not provide
a safe drain to electrical ground, which will allow
the charge to dissipate as fast as it accumulates,
it may store the charge. When its electrical storage limit is reached, or when it is breached by
external circumstances (such as the approach
of a grounded object or person, or one at lower
potential), it may discharge its stored charge to
the nearest ground. If there is no safe path to
ground (such as a ground wire or braided cable) it
may discharge through the air as a spark. A spark
may ignite the ammable atmosphere of a spray
area. The hazard area extends from the point
of origin up to as much as a twenty-foot radius.
(See the NFPA-33 for denition and limitations of
a hazard area.)
symbol and then to a proven ground. Always
check ground connections for integrity. Some
items, such as rotators and paint stands, may be
supported on an insulator, but all components of
the system up to the insulator MUST be grounded.
NOTE
Ransburg recommends that ground
connections to earth ground be 3/4” insulated copper braided wire. Grounds
between assemblies within a machine
should be run to a central point within the
machine using #18 insulated stranded
copper wire minimum. All connections
should be mechanically sound and have
less than 5 ohms of resistance between
assemblies and the common point. The
resistance between the central point
and earth ground should be less than 5
ohms as well.
Where items are mounted directly on structural components such as building columns, the
ground connection MUST still be made. In many
cases the structural component may be painted
or coated with an insulated material and in all
cases, the equipment will provide the necessary
connection at one end, but the user must be sure
that the other end is secured to an earth ground.
This may be achieved by the use of a standard
ground clamp (properly secured), by brazing or
by piercing the structural component enough to
assure connection. All ground connections should
be made to the most conductive metallic structural
ground available.
It is simple, but vital matter to be sure that all conductive objects within the spray area are grounded.
All cabinets, housing, bases, supports, and stands,
which are not by design, insulated from ground, be
connected directly and INDIVIDUALLY to earth
ground. Resting on a concrete oor or being
attached to a building column may not always
be sufcient ground.
In order to provide the best ground connection
possible, always attach a ground wire or insulated
braided cable the terminal indicated by the ground
24
To be sure that everything is properly grounded,
the following steps should be undertaken at least
daily:
1. Inspect all ground wires. Look for good, rm
joints at all points of connection. Look for
breaks in the ground wire. Repair all defects
IMMEDIATELY!
2. Inspect the oor or grates for excessive
accumulation of dried coating material or
other residue. If there is any, remove it!
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Installation
Ransburg
SAFE GROUNDING IS A MATTER OF PROPER
EQUIPMENT MAINTENANCE AND INSTALLATION, CORRECT OPERATION AND GOOD
HOUSEKEEPING. Daily inspection of grounding
apparatus and conditions, however, will help prevent hazards that are cause by normal operations.
BE SURE THAT:
1. All objects in the spray area are grounded.
2. Personnel in the spray area are properly
grounded. (Conductive safety shoes and
coveralls.)
3. That the target object is properly grounded
(less than 1 megohm resistance).
4. That the high voltage is off except during
normal application.
5. That the high voltage is off and applicators
are grounded during maintenance operations.
6. The spray area is kept free of accumulated
coating deposits.
7. All combustible liquids in the spray area
(outside of automatic delivery systems) are
kept to minimum and are kept in re safe,
grounded containers. (See NFPA-30 and
chapter 6 of NFPA-33.)
and its components. It is even possible that the
temperature of the supply air may be below the
booth dew point, even without additional expansion cooling.
Condensation is especially probable in waterborne
applications when booth temperature and relative
humidity levels are typically maintained very high.
This condensation will allow sufcient conductivity
of the surfaces such that they act as an erratic
ground source potential. This can cause damage
to the equipment.
It is therefore, a requirement that turbine exhaust
air temperature be maintained above the booth
dew point to prevent condensation from forming
on atomizer surfaces. Doing so will eliminate
moisture as a potential defect in painted surfaces
as well as extending equipment life. Thus, it is
recommended that air heaters be installed into
the atomizer air supply lines, i.e. turbine drive air,
shaping air, and seal air. The air heaters must
be of sufcient capacity, capable of raising the
incoming air temperature at least 40°F (4.4°C) at
a ow rate of 60 SCFM per applicator.
The actual air heater process setting depends on
applicator uid ow rate load, booth conditions,
turbine airow settings, and incoming air tempera-
ture. The heater should be set as low as possi-
ble, sufcient to maintain the applicator surface
temperatures above the dew point in the booth.
8. Proper ventilation is provided.
9. Personnel must thoroughly understand the
equipment, its operation and maintenance,
and all safety precautions.
AIR HEATER REQUIREMENTS
Turbine drive air expands as it moves through the
turbine wheel cavity and as it exits the turbine from
the exhaust port. This expansion will cause cooling of the exhaust air and the surfaces it contacts.
This same expansion cooling can occur across the
shaping air exit ports. This cooling affect can cause
surface temperatures to fall below the dew point
of the booth, which will result in condensation on
the interior and exterior of the atomizer, machine,
25
Example: With the incoming air temperature at
72°F (22.2°C), and RMA-560 with 65mm bell cup
rotating unloaded at 60 krpm has a turbine outlet
temperature drop of approximately 28°F (-2.2°C)
@ 40 krpm unloaded, ∆~14°F (-10°C). Referring
to the ASHRAE Psychrometric chart, the saturation
temperature range (dew point) of a spray booth
maintained at 70-75°F/65-70% RH is 62-68°F
(21.1-23.9°C/65-70°RH is 16.7-20°C). Thus it is
almost certain that the surface temperatures of
the applicator will fall below the dew point of the
booth, and an air heater will be needed in this case.
To prevent condensation, a Ransburg air heater
assembly should be assembled after the air lters
and volume booster. (See heater and ltration
options later in this manual).
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Installation
AIR HEATER AND FILTRATION OPTIONS
Ransburg
NOTE
Failure to use an air heater may cause
damage to equipment or ruin the nished
component being processed.
NOTE
Connect air heater to turbine air tubing.
NOTE
If using the A11065-05 Air Heater, air
lters equivelant to HAF-503, HAF-508
and RPM-418 must be used. (See descrip
tions in this manual).
-
26
A11065-05 Air Heater
LN-9278-13
RMA-560 Single/Dual Purge Direct Charge - Installation
A13230-XX AIR HEATER AND FILTER COMBINATION
This combination includes
ltration for turbine as well as
bearing air.
Ransburg
FILTER & HEATER ASSEMBLY A13230-XX
Dash No. “A” “B” “C” “D”
A13230-01 115 V.@ 13A METRIC FITTINGS A13434-01 A13426-00 A13429-00 A13433-00
A13230-02 230 V.@ 6.5A METRIC FITTINGS A13434-02 A13426-00 A13429-00 A13433-00
A13230-03 115 V.@ 13A FRACTIONAL FITTINGS A13434-01 SSP-6439 A13428-00 A13433-00
A13230-04 230 V.@6.5A FRACTIONAL FITTINGS A13434-02 SSP-6439 A13428-00 A13433-00
Description
A13230-XX AIR HEATER AND FILTER COMBINATION
Item Qty.Part #
1 “A” AIR BLOCK, NIPPLES & AIR HEATER 1
2 A13427-00 INLET FITTING, 3/8 NPS(M) X 1/2 NPT(M) 1
BEARING AIR FEED, SWIVEL ELBOW 1/4 O.D.TUBE X 1/4 NPT(M)
3 “B”
BEARING AIR FEED, 6mm O.D. TUBE X 1/4 NPT(M) STRAIGHT ADAPTER
4 79253-02 AIR FITTING, SWIVEL ELBOW 5/32 O.D. TUBE X 1/4 NPT(M) 2
OUTLET FITTING, 1/2 O.D. TUBE X 1/2 NPT(M) STAINLESS STEEL
5 “C”
OUTLET FITTING, 12mm O.D. TUBE X 1/2 NPT(M) STAINLESS STEEL
6 A11111-00 VOLUME BOOSTER 1
7 “D” AIR FILTER & NIPPLE INCLUDED 1
8 SI-13-07 A13230-XX SERVICE LITERATURE (PROVIDED BY OTHER) REF.
Description
1
1
ALL UNITS: REPLACEMENT PARTS: (SERVICE NOTE)
HEATING ELEMENT USE: A13432-01 FOR A13230-01 AND A13230-03 (115V UNITS)
A13432-02 FOR A13230-02 AND A13230-04 (230V UNITS)
AIR FILTER ELEMENT USE A13232-00
THERMOMETER USE A13431-00
27
LN-9278-13
Loading...