Ransburg REA, VECTOR Technical Manual

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ITW RANSBURGITW RANSBURG

ITW RANSBURG

ITW RANSBURGITW RANSBURG

TECHNICAL MANUAL IL-246-BIL-246-B

IL-246-B

IL-246-BIL-246-B (Replaces IL-246-A) January - 2008

REA™ AND VECTREA™ AND VECT

REA™ AND VECT

REA™ AND VECTREA™ AND VECT

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

ORSORS

ORS

ORSORS

ELECTROSTELECTROST

ELECTROST

ELECTROSTELECTROST

TECHNIQUESTECHNIQUES

TECHNIQUES

TECHNIQUESTECHNIQUES

OR™OR™

OR™

OR™OR™

SPRASPRA

SPRA

SPRASPRA

TICTIC

TIC

TICTIC

IMPORIMPOR

IMPOR

IMPORIMPOR carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS, starting on page 1, and all instructions instarting on page 1, and all instructions in

starting on page 1, and all instructions in

starting on page 1, and all instructions instarting on page 1, and all instructions in this manual. Keep this Tthis manual. Keep this T

this manual. Keep this T

this manual. Keep this Tthis manual. Keep this T for future reference.for future reference.

for future reference.

for future reference.for future reference.

ANTANT

ANT

ANTANT

: Before using this equipment,: Before using this equipment,

: Before using this equipment,

: Before using this equipment,: Before using this equipment,

echnical Manualechnical Manual

echnical Manual

echnical Manualechnical Manual

echnical Manual Price:echnical Manual Price:

echnical Manual Price: €

echnical Manual Price:echnical Manual Price:

15.00 Euro)15.00 Euro)

15.00 Euro)

15.00 Euro)15.00 Euro)

$20.00 (U.S.)$20.00 (U.S.)

$20.00 (U.S.)

$20.00 (U.S.)$20.00 (U.S.)

Page 2

NOTE:NOTE:

NOTE: This manual has been changed from

NOTE:NOTE:

change are noted under “Manual Change Summary” inside the back cover of this manual.

IL-246-AIL-246-A

IL-246-A to revision

IL-246-AIL-246-A

IL-246-B.IL-246-B.

IL-246-B. Reasons for this

IL-246-B.IL-246-B.

IL-246-B

Page 3

REA/Vector Applicators Spray Techniques

CONTENTSCONTENTS

REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:

REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:

REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:

PAGEPAGE

PAGE

PAGEPAGE 1-111-11

1-11

1-111-11

USE THE RIGHT TECHNIQUE.................................................................................................

FAN CONTROL..........................................................................................................................

PATTERN....................................................................................................................................

FLAT SURFACES.......................................................................................................................

HORIZONTAL PASSES.............................................................................................................

VERTICAL PASSES...................................................................................................................

APPLICATOR TO TARGET DISTANCE...................................................................................

OVERLAP....................................................................................................................................

TRIGGERING.............................................................................................................................

LARGE OBJECTS......................................................................................................................

TUBULAR WORK.......................................................................................................................

RECESSED AREAS...................................................................................................................

SUMMARY..................................................................................................................................

SAFETY REQUIREMENTS........................................................................................................

9-10

IL-246-B

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REA/Vector Applicators Spray Techniques

Before operating, maintaining, or servicing any ITW Ransburg electrostatic coating system, read and understand all of the technical and safety literature provided with ITW Ransburg products. If you do not have the manuals and safety literature for your ITW Ransburg system, contact your ITW Ransburg representative.

USE THE RIGHT TECHNIQUESUSE THE RIGHT TECHNIQUES

USE THE RIGHT TECHNIQUES

USE THE RIGHT TECHNIQUESUSE THE RIGHT TECHNIQUES

REA/VREA/V

REA/V

REA/VREA/V

Savings of 25% to 50% in paint is possible when you replace conventional air spray with ITW Ransburg Electrostatic Applicators. You finish curved and recessed surfaces uniformly in fewer passes, because combined air and electrostatic forces literally follow the shape of the work surface. Bounce losses from work are reduced by the electrostatic attraction, when proper techniques are used.

The following describes basic electrostatic spray techniques. Depending on the type of work being sprayed, it may be necessary to change the technique slightly.

ector (Electrostatic) Applicatorsector (Electrostatic) Applicators

ector (Electrostatic) Applicators

ector (Electrostatic) Applicatorsector (Electrostatic) Applicators

IL-246-B

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REA/Vector Applicators Spray Techniques

AN CONTROLAN CONTROL

AN CONTROL

AN CONTROLAN CONTROL

Minimum

Maximum

The size of the object being coated is the determining factor in adjusting the fan pattern; the larger the object, the larger the required fan pattern. Fan control of the ITW Ransburg REA/Vector applicators is accomplished by rotating the adjusting knob located at the rear of the applicator. Fan width can be set for approximately a 3-inch width (minimum) to approximately a 14-inch (maximum). Fan widths and overall pattern appearances are illustrated.

POOR PATTERNPOOR PATTERN

POOR PATTERN

POOR PATTERNPOOR PATTERN Dirty, worn, or damaged nozzle. Clean or replace.

> The degree of atomization is dependent

on the viscosity of the paint formulation, the applied air pressure, and nozzle selection.

NOTENOTE

NOTE

NOTENOTE

SPLIT PATTERNSPLIT PATTERN

SPLIT PATTERN

SPLIT PATTERNSPLIT PATTERN Fan too wide - narrow adjustment slightly.

TTERNTTERN

TTERN

TTERNTTERN

GOODGOOD

GOOD

GOODGOOD

PATTERNPATTERN

PATTERN

PATTERNPATTERN

IL-246-B

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REA/Vector Applicators Spray Techniques

FLAFLA

FLA

FLAFLA

One of the most prevalent of "bad" spray painting habits is the one where the operator holds his arm steady and swings his wrist back and forth. This is a hard habit to break, it gives the illusion of adding speed to the coating operation, when in reality, it is slower and much more inefficient. Spray painting in this fashion results in light films on both sides, excessive film at center, and increased overspray with excessive "bounceback."

SURF SURF

SURF

SURF SURF

ACESACES

ACES

ACESACES

HORIZONTHORIZONT

HORIZONT

HORIZONTHORIZONT

The spray applicator should be maintained in a position at right angles to the object and should be moved in a path parallel to the object.

ALAL

PASSES PASSES

PASSES

ALAL

PASSES PASSES

VERTICAL PASSESVERTICAL PASSES

VERTICAL PASSES

VERTICAL PASSESVERTICAL PASSES

There may be instances where it is more practical to coat an object using vertical passes rather than horizontal. First, rotate the nozzle to shift the fan pattern, then holding the applicator at right angles to the object, move the applicator in a straight vertical path as illustrated.

IL-246-B

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REA/Vector Applicators Spray Techniques

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA TT

ARGETARGET

ARGET

ARGETARGET

OR TOR T

OR T

OR TOR T

DIST DIST

DIST

DIST DIST

Under 2"Under 2"

Under 2"

Under 2"Under 2"

ANCEANCE

ANCE

ANCEANCE

4" to 6"4" to 6"

4" to 6"

4" to 6"4" to 6"

The distance between the applicator and the target influences the appearance of the final finish coating of the object. If the applicator is held too close (under 4-inches), runs and sags with the excessive bounce-back can occur. If the applicator is held too far from the object, the electrostatic attraction is decreased. Normally,

best spacing best spacing

the

best spacing between applicator and target

best spacing best spacing is in the distance can vary with extremely high delivery systems. Maximum target distance should not exceed 12-inches.

> The object being coated is maintained at

ground potential, the spray applicator operator is also grounded, therefore, the operator has as much attraction for the electrostatic paint as the object. To prevent "wrapback" always keep the applicator closer to the target than it is to you.

4 to 12-inch area.4 to 12-inch area.

4 to 12-inch area. However, this

4 to 12-inch area.4 to 12-inch area.

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

Too FarToo Far

Too Far

Too FarToo Far

IL-246-B

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REA/Vector Applicators Spray Techniques

OVERLAPOVERLAP

OVERLAP

OVERLAPOVERLAP

For best hiding and uniformity of film thickness, stroke overlap should be approximately 50%. There should be some overlap at the top and bottom of the part to increase edge coverage. Overlap requirements can vary widely with different paint formulations and different compositions of objects being coated. Individual spray coating operational experience should provide the guidelines for efficiency in this instance.

TRIGGERINGTRIGGERING

TRIGGERING

TRIGGERINGTRIGGERING

Applicator triggering (ON/OFF) depends largely on the desired results; the amount of wraparound required, edge coating, etc. If front and back of the object are being coated, proper applicator technique can effect edge coating (in some instances) without making a specific pass for this purpose. Examples of different trigger times and the results that can be expected are illustrated.

A. Little or no wrap - incomplete coverage

TOP VIEW

DD (Trigger Off)

NOTENOTE

NOTE

NOTENOTE

> If front and back are both sprayed, there

may be enough wrap using Technique B or C to coat a small edge or flange. If wide flanges are to be coated, this may require individual coating of edges before the flat surfaces are sprayed.

B. Fair - some wrap

C. Good wrap (Triggered 2" to 3" past edge)

D. Too much overstroke may produce heavy

edges and produce more overspray.

IL-246-B

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LARGE OBJECTSLARGE OBJECTS

LARGE OBJECTS

LARGE OBJECTSLARGE OBJECTS

BlendingBlending

Blending

BlendingBlending

If the size of the object is greater than the spray applicator operator can reach, it should be coated in segments, the size of each segment being the length the spray applicator operator can comfortably span. Each segment should be blended with the adjacent segment using "feathering" or "over-lapping" strokes. A slight angle of the applicator improves the results of the "blending" pass.

REA/Vector Applicators Spray Techniques

TOP VIEW

C A U T I O NC A U T I O N

C A U T I O N

C A U T I O NC A U T I O N

> Too much overlap can result in runs and

sags or excessive film, where segments blend together.

TOP VIEW

IL-246-B

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REA/Vector Applicators Spray Techniques

TUBULAR WORKTUBULAR WORK

TUBULAR WORK

TUBULAR WORKTUBULAR WORK

Tubular parts or objects up to approximately 2-1/2" diameter can be coated successfully from one side, utilizing wraparound characteristics and proper techniques.

NOTENOTE

NOTE

NOTENOTE

> Avoid applicator to targe distances of

over 12-inches, excessive applicator to target distances will result in wrapback.

Adjust the fan for a pattern width slightly wider than the object. This allows some coating material to start around the sides of the object.

↑↑

↑

↑↑

MOTION

↓↓

↓

↓↓

FAN POSITION

(Example 1"

Diameter Part)

Increase the applicator to target distance to approximately 1012-inches. This will decrease the speed of the paint particles in the vicinity of the target.

A. Wrong fan position - little wrap. Heavy film on front surface,

possible sags.

B. Correct fan position - better wrap. More accurately con-

trolled film. Normally fan pattern should be slightly wider than parts being sprayed.

C. Correct fan position but excessively wide fan may produce

more overspray if used in this position.

D. A wide fan tilted at an angle may also work well. (Wide fans

have slower forward velocity.)

Hold the applicator at an angle of 30o to 45o to the object. This will direct paint more to target area.

SUGGESTION:SUGGESTION:

SUGGESTION: Small tubes may be racked in groups to simulate larger targets. This allows the use

SUGGESTION:SUGGESTION: of wider fans and may help improve efficiency.

IL-246-B

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REA/Vector Applicators Spray Techniques

RECESSED AREASRECESSED AREAS

RECESSED AREAS

RECESSED AREASRECESSED AREAS

Do not depend on electrostatic attraction alone for coating recessed areas, remember, the more exposed areas of the object have a stronger attraction for charged paint formulations than the recessed areas, therefore, the electrostatically charged paint particles will take the path of least resistance, and tend to build excessively on the more exposed areas.

→←

DIFFICULT

The best and most efficient technique is to coat the recessed areas first, utilizing air pressure to drive the paint into difficult areas or by narrowing fan width to effectively increase delivery rate per inch of pattern width. Then paint the more readily accessible areas, the electrostatic process with its "wraparound" and "opposite attraction" characteristics will probably have already partly coated these areas.

EASY

A. Voltage by itself will not pull paint into deep

recesses, but instead, paint will be attracted to more exposed edges.

Solution:

vantages of air atomization to drive paint into recesses.

NOTE:NOTE:

NOTE: Narrower fan may also be helpful.

NOTE:NOTE:

Move in closer and use the ad-

C. Doing the outside of the part first puts little

paint on the inside. If we now coat the inside, we will be double coating the edges and possibly overload them.

D. In this example, we coat the difficult area

first. We may then find that there was enough wrap around from overspray to coat much of the remaining areas.

IL-246-B

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REA/Vector Applicators Spray Techniques

SUMMARYSUMMARY

SUMMARY

SUMMARYSUMMARY

Adjust fan pattern in accordance with size of object to be coated.

Never swing spray applicator in an arc, hold applicator steady in a position at right angles to the object and move applicator in a straight path parallel to object.

Be sure applicator is held closer to object being coated than to the operator.

Stroke overlap of approximately 50% normally produces adequate film thickness uniformity.

IL-246-B

Page 13

ON OFF

REA/Vector Applicators Spray Techniques

For most economical and efficient coating, trigger applicator "ON" just before leading edge of object, trigger applicator "OFF" just after trailing edge of target. For best wraparound technique, trigger applicator "ON" 3-inches before, and "OFF" 3-inches after edges of target.

When painting large objects a section at a time, use "feather" stroke for blending sections together. Avoid excessive overlap to prevent runs and sags with excessive film thickness.

Tubular component coating; adjust fan width for a pattern slightly wider than the object, hold applicator 10 to 12-inches from object at an angle of 30 to 45inches. Move applicator straight in a parallel path with the object.

Paint "hard to reach" areas first, let wraparound and electrostatic attraction get the "easy" areas for you.

IL-246-B

1010

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REA/Vector Applicators Spray Techniques

SAFETYSAFETY

SAFETY

SAFETYSAFETY REQUIREMENTSREQUIREMENTS

REQUIREMENTS

REQUIREMENTSREQUIREMENTS

PersonnelPersonnel

Personnel

PersonnelPersonnel

• Operators must insulate them from the applicator handle.

• ALL personnel in the spraying area wear non-insulating shoes or alternative grounding devices so they will be grounded through the conductive floor. (See ITW Ransburg "Personnel Grounding" Safety Bulletin.)

• Personnel entering a waterborne paint isolation enclosure the Warning Light are hook must be attached to the paint supply BEFOREBEFORE

BEFORE contact, especially during the

BEFOREBEFORE addition of fluid! The gate and the interlocks functioning during use. (See the appropriate ITW Ransburg equipment manual.)

• The operator OFFOFF

OFF before cleaning or servicing the

OFFOFF equipment.

NEVERNEVER

•

NEVER immerse an applicator in any liquid.

NEVERNEVER

NOTNOT

NOT wear gloves that

NOTNOT

MUSTMUST

MUST

MUSTMUST

MUST be sure that the system and

MUSTMUST

OFF!OFF!

OFF! The grounding

OFF!OFF!

MUSTMUST

MUST be closed

MUSTMUST

MUST turn the power supply

MUSTMUST

• All conductive objects in the spraying area MUSTMUST

MUST be removed or grounded.

MUSTMUST

• A pressure EXPLOSION may occur if HALOGENATED HYDROCARBON solvents are used in PRESSURIZABLE fluid systems having ALUMINUM or GALVANIZED parts. (See ITW Ransburg "Danger - Explosion Hazard" and "Halogenated Hydrocarbon" Safety bulletins.)

• The high voltage power supply grounded and located outside of the Hazard Area. (See the appropriate ITW Ransburg equipment manual.)

• Appropriate, functioning fire extinguishing equipment

• Good housekeeping is essential to safe operation. Cleanup and maintenance schedules should be established by the user. Maintenance and safety cards should be posted in clear view of the operator.

• All flammable liquids grounded safety containers. Not more than one gallon should be in any container and the total amount in the spray area should be no more than the minimum required for the operation.

MUST MUST

MUST be provided.

MUST MUST

MUSTMUST

MUST be in approved,

MUSTMUST

MUST MUST

MUST be

MUST MUST

• Exhaust fans

Environment and EquipmentEnvironment and Equipment

Environment and Equipment

Environment and EquipmentEnvironment and Equipment

• The spray booth (including its floor), paint reservoir (except waterborne), and conveyor MUSTMUST

MUST be grounded.

MUSTMUST

• An adequate, grounded, protective enclosure that will assure safe isolation from personnel must surround the supply of waterborne paints. (See OSHA Standard 1910.107 (h) (10).)

• The spray target and all supporting holders, hooks, and conveyors the supporting structure. All support devices MUST MUST

MUST be free of accumulated coating

MUST MUST material.

1111

MUSTMUST

MUST be

MUSTMUST

ONON

ON during spraying.

ONON

MUSTMUST

MUST be grounded to

MUSTMUST

• All applicators proper operating limits. (See the appropriate ITW Ransburg equipment manual for short circuit current tests.)

MUSTMUST

MUST be maintained within

MUSTMUST

IL-246-B

Page 15

REA/Vector Applicators Spray Techniques

NOTESNOTES

NOTES

NOTESNOTES

IL-246-B

1212

Page 16

REA/Vector Applicators Spray Techniques

NOTESNOTES

NOTES

NOTESNOTES

1313

IL-246-B

Page 17

MANUALMANUAL

MANUAL

MANUALMANUAL

This manual was published to supercede

IL-246-A, ITW RansburgIL-246-A, ITW Ransburg

Technical Manual

REA/Vector Applicators Electro-Air SprayREA/Vector Applicators Electro-Air Spray

REA/Vector Applicators Electro-Air Spray

REA/Vector Applicators Electro-Air SprayREA/Vector Applicators Electro-Air Spray TechniquesTechniques

Techniques

TechniquesTechniques

1. Service literature was reformatted. Made available electronically.

2. Added "Technical Manual Price: €15.00 (Euro)"

to the "Front and Back Covers".

3. Added "Vector Applicators" to the "Spray Techniques".

4. New "Applicator Figures" throughout the service literature.

5. Added "www.itwransburg.com" to "Contact Information" on the back cover.

, to make the following change:

IL-246-A, ITW Ransburg

IL-246-A, ITW RansburgIL-246-A, ITW Ransburg

CHANGE SUMMAR CHANGE SUMMAR

CHANGE SUMMAR

CHANGE SUMMAR CHANGE SUMMAR

IL-246-B

Page 18

echnical Manual Price:echnical Manual Price:

echnical Manual Price:

echnical Manual Price:echnical Manual Price:

ManufacturingManufacturing

Manufacturing

ManufacturingManufacturing

15.00 Euro)15.00 Euro)

€

15.00 Euro)

15.00 Euro)15.00 Euro)

$20.00 (U.S.)$20.00 (U.S.)

$20.00 (U.S.)

$20.00 (U.S.)$20.00 (U.S.)

1910 North Wayne Street Angola, Indiana 46703-9100 Telephone: 260/665-8800 Fax: 260/665-8516

echnical/Service Assistanceechnical/Service Assistance

echnical/Service Assistance

echnical/Service Assistanceechnical/Service Assistance Automotive Assembly and Tier I Telephone: 800/ 626-3565 Fax: 419/ 470-2040 Industrial Systems Telephone: 800/ 233-3366 Fax: 419/ 470-2071 Ransburg Guns Telephone: 800/ 233-3366 Fax: 419/ 470-2071 www.itwransburg.com

echnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephone

echnical Support Representative will direct you to the appropriate telephone

echnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts.number for ordering Spare Parts.

number for ordering Spare Parts.

number for ordering Spare Parts.number for ordering Spare Parts.

Form No. IL-246-B Litho in U.S.A. 01/08