Ransburg Evolver Solvent Robot Applicator 79190-XXXXXXXX User Manual

EVOLVERTM SOLVENTBORNE ROBOTIC ATOMIZERSSERVICE MANUALAA-03-02.12(Replaces AA-03-02.11)March - 2013MODEL: 79190-XXXXXXXXIMPORTANT: Before using this

EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6The following instructions apply to equipment covered by certicate number Sira 05ATEX5127X:1. The

Label A10755Label A10752Label A10915Evolver 79190 ATEX Product Mark-ing DenitionsEx Certicate Number: Sira 05 ATEX 5 127 X Sira = Notied Body perfo

THE RANSBURG ELECTROSTATICPROCESSThis process is a method for electrostatically apply-ing coatings to objects. A power supply produces a high voltage

Tubing Manifolds (Metric): A10853-01 7.62m A10853-02 15.24m A10853-03 22.86m A10853-04 30.48m

EVOLVER GUN SELECTION GUIDETable A = Atomization Technology0 = Air Spray1 = HVLPTable B = Spray Head Conguration0 = 60° Single Head1 = 90° Single Hea

EVOLVER GUN SELECTION GUIDE (Cont.)Table FF = Cable & Tubing Manifold Conguration00 = Gun Only (No cable or manifold)23 = No Cable (English tubin

Figure 1: Evolver Solventborne Robotic Atomizer GunsEvolver Solventborne Robotic Atomizers - Introduction12RansburgAA-03-02.12

Figure 2: Typical Robotic Applicator MountingFEATURESThe features of the Evolver series guns include:• Quick-disconnect spray head• High quality Rans

79190-XXXXXXXX EVOLVER GUN ASSEMBLYThe gun assembly is designed to connect to hol-low wrist robots. A low voltage control cable is supplied with th

INSTALLATIONEVOLVER ROBOTIC ATOMIZER INSTALLATIONThis information is intended ONLY to indicate the general installation parameters of this product and

NOTE: This manual has been changed from revision AA-03-02.11 to revision AA-03-02.12. Reasons for this change are noted under “Manual Change Summary

Figure 4: Low Voltage Cable ConnectionsEvolver Solventborne Robotic Atomizers - Installation16RansburgAA-03-02.12

GUN AND MANIFOLD ASSEMBLY(See Figures 4 and 5)The tubing, hose, and low voltage cable come bundled from the factory. Pull the bundle through the robo

Tubing MaterialTubing SizeItem #P1 Paint #1 Clear 5/16" OD X 3/16" ID 29P2 Paint #2 Black Urethane/Poly 5/16" OD X 3/16"

Figure 5: Gun and Manifold AssemblyEvolver Solventborne Robotic Atomizers - Installation19RansburgAA-03-02.12

1 79190-XXXXXXXX Evolver Spray Gun 1 2 76566-32C Socket Head Cap Screws, 1/4-20 X 1" Long, 6 Stainless Steel 3 79156-XXX

OPERATIONSPRAY GUN CONTROLSAtom (A) / Fan Air (F)The atomization and fan air are turned on by the trigger line and are controlled by an internal air v

When the cleaning cycle with solvent is complete, an air purge for several seconds is recommended to clean and dry the ID of the dump line hose.Paint

Electrostatic VoltageUnder no load conditions, the maximum volt-age limit for these spray guns is 100 kV. Some painting operations may require

Figure 6: Simplied Air and Fluid Flow Passage LayoutEvolver Solventborne Robotic Atomizers - Operation24RansburgAA-03-02.12

MAINTENANCEGood maintenance is essential to safe and produc-tive operation. Schedules should be established by the user, based on the following gener

SAFETY:SAFETY PRECAUTIONS...HAZARDS / SAFEGU

2. Turn the MicroPak Control Unit ON! Energize high voltage.Shut-Down (Or at Shift End)1. Turn the MicroPak Control Unit OFF.2. Flush the lines an

Figure 7: Polar and Non-Polar Solvents8. Remove uid nozzle [32] by unscrewing count-er-clockwise. Inspect o-ring [30] and all passages for build up

Figure 8: Spray Head Removal Assembly451/16" (1.59 MM)343135293633323028276231Evolver Solventborne Robotic Atomizers - Maintenance28RansburgAA-0

Item #SPRAY HEAD REMOVAL ASSEMBLY - PARTS LIST (Figure 8)Part # Description Qty1 79148-00 End Cap, Spray Head 1 2 17615-00 Spring, Compression

SERVICEBecause we want to provide our users with the most up-to-date technology possible, we are con-stantly seeking to improve products. If a change

Rear Needle Replacement(See Figure 8)1. Remove the air cap, uid tip, and the uid nozzle as described in steps 1 through 8 of the "Fluid Tip

their mating parts (see Figure 9).7. The o-ring [16] should be inserted into the front of the bushing [14] and one of the o-rings [15] installed on

Figure 9: 79138 Evolver Gun Head AssemblyLOCATED INSIDE 131018LOCATED INSIDE 17151412192224238792517151516TORQUE TO 30-35 LBS-IN1113AIR VALVE SHAFT F

7 79147-00 Nut, Piston 18 7723-06 Piston, U-Cup 19 79145-00 Plate, Piston 110 79144-00 Shaft, Air Valve 111 79001-28 O-Ring, Solvent Pro

REMOVING GUN FROM THE REAR MANIFOLD ASSEMBLY(See Figure 10)Anytime service is required within the gun shroud, the gun must be removed from the rea

PARTS IDENTIFICATION:79190-XXXXXXXX GUN ASSEMBLY / PARTS LIST...SPRAY HEAD ASSEMBLY...

3215467Figure 10: 79190 Evolver Gun Assembly8 1 79138-01 Spray Head Assembly, Conventional Spray 1 2 79175-02 Dual Purge, No Regulator 1 3

Figure 11: Mounting Block, Shroud Halves, and Retaining Ring Removal92302828223711213Evolver Solventborne Robotic Atomizers - Maintenance37RansburgAA

1 LSFA0027-00 Screw, for Both Single Head Mounting Blocks 4 79206-00 Screw, for Both Dual Head Mounting Blocks2 79179-00 60° Single Head Mounti

Figure 12: Disassembly of Intermediate Gun Housing263519211429233516158257271879171011651034ALLIGN TIMING AS SHOWN34Evolver Solventborne Robotic Atom

3 79169-00 Valve Manifold Assembly 14 79177-00 Fluid Fitting Assembly 15 7554-10 O-Ring 26 77508-00 Airbolt, Machined 27 7554-11 O-Ring 4

Figure 13: Valve Manifold Disassembly323131322412424202021132AGROUND PINBEvolver Solventborne Robotic Atomizers - Maintenance41RansburgAA-03-02.12

1 77367-00 Seat Assembly 32 78949-00 Valve Assembly 33 79169-00 Lower Manifold Assembly 14 79177-00 Fluid Fitting Assembly 120 79170-00

Figure 14: Low Voltage Cable Removal3210Evolver Solventborne Robotic Atomizers - Maintenance43RansburgAA-03-02.12

Low Voltage Cable Removal (Refer to Figure 14)1. Disconnect low voltage cable [2] from rear of power supply. For A10406-XX power supply, disconnect c

NOTESdamage will occur. Push the diaphragm assembly down in valve body aligning the screw holes.9. Tighten the regulator bonnet [10] to the block as

W A R N I N G!W A R N I N G!SAFETYSAFETY PRECAUTIONSBefore operating, maintaining or servicing any Ransburg electrostatic coating system, read and u

Figure 15: Fluid Regulator Assembly1 A11901-00 Regulator Block Assembly 12 79220 Diaphragm 13 74161 Spring, Regulator 14 77354-00 Assembly,

A10406 OR LECU5004 MICROPAK CONTROL UNIT(See the current "MicroPak" Service Manual sup-plied with the control unit for service information.

79151-00 Needle Shaft 17723-06 Piston, U-Cup 179001-28 O-Ring, Solvent Proof 179001-29 O-Ring, Solvent Proof 113076-13 O-Ring 1RME-38 Spring

TROUBLESHOOTING GUIDENote: A test station to bench test the applicator off-line will speed the Troubleshooting process.General ProblemPossible Causes

Note: To check for uid leaks, it is easiest to rst remove the gun from the test station and remove the shroud from the gun. Then the gun can be re

Figure 18: 79190-XXXXXXXX Gun AssemblyPARTS IDENTIFICATION1234567811109131215181716Evolver Solventborne Robotic Atomizers - Parts Identication51Rans

TABLE A ATOMIZATION TECHNOLOGY01DashNo.DescriptionConventional SprayHVLP Spray"Z"79138-0179138-02TABLE B HEAD CONFIGURATION0123DashNo.Des

(Continued On Next Page)TABLE FF - REAR MANIFOLD ASSEMBLY 002324010203040506070809101112131415161718192021223132333435363738394041DashNo.Description

TABLE FF - REAR MANIFOLD ASSEMBLY (Cont.) 5152535455565758596061DashNo.Description7.6m One-Piece Cable15.2m One-Piece Cable22.9m One-Piece Cable30.5m

Figure 19: Spray Head Assembly22212021232426293132333435369101278534612TORQUE TO 30-35 LBS/IN(3.4-4.0 NEWTON METER)131116151517LOCATED INSIDE 131415L

Spray AreaAREATells where hazards may occur.HAZARDTells what the hazard is.SAFEGUARDSTells how to avoid the hazard.Fire HazardImproper or inadequate o

1 79148-00 End Cap, Spray Head 12 17615-00 Spring, Compression 13 9334-00 Spring, Valve Return 14 7733-07 Nut, Jam 15 76199-00 Nut, Adj

1 79148-00 End Cap, Spray Head 12 17615-00 Spring, Compression 13 9334-00 Spring, Valve Return 14 7733-07 Nut, Jam 15 76199-00 Nut, Adj

Figure 20: 79179-00 Single Head 60° 1 79188-00 Assembly, Mounting Block 60° Single Head 12 79173-00 Block, Locking 13 79174-00 Screw, Nylon 1

Figure 23: 79224-00 Dual Head 90°1 79227-00 Assembly, Mounting Block 90° Dual Head 12 79173-00 Block, Locking 23 79174-00 Screw, Nylon 1/4-20

Figure 24: 79175-XX Manifold Assembly32651010101011115636173131223322174716151220303535242420191921352314291218872527262873783513934TORQUE TO 15-20

Figure 25: 79175-XX Optional Regulated VersionEvolver Solventborne Robotic Atomizers - Parts Identication61RansburgAA-03-02.12

1 77367-00 Seat Assembly 32 78949-00 Valve Assembly 33 79169-00 Assembly, Lower Manifold 14 79177-00 Assembly, Fluid Fitting 15 75

77367-0079175-XX MANIFOLD ASSEMBLY TABLE79175-0179175-0279175-0379175-0479175-0579175-06Part #DescriptionSingle Purge - No RegulatorDual Purge - No Re

Figure 26: 79175-07 Manifold Assembly (Only)1065561010101111174141342412235193524202420351930217416151429188725278237262837129134234742364443434443

1 ---- ---- --2 ---- ---- --3 79169-00 Assembly, Lower Manifold 14 79177-00 Assembly, Fluid Fitting 15 7554-10 O-Ring, Solvent

AREATells where hazards may occur.HAZARDTells what the hazard is.SAFEGUARDSTells how to avoid the hazard.Spray AreaImproper operation or mainte-nance

Figure 27a: 79156 Rear Tubing Manifold Assembly - English1144123292541321105455415141415121353191827 11288202226 181824 111161118256729301233029 6718

1 77947-00 Air Fitting, Modied 22 Table CD - "Q" Low Voltage Cable Assembly 13 79155-00 Mounting Plate, Robot Machined 14 7750

----76698-0274178-0276698-0474178-01A10841-02TABLE A - HOSE STYLE (ENGLISH)012345Dash No.DescriptionNo Fluid Hose3/16" ID X 5/16" OD, Non-Sh

Figure 27b: A10853 Rear Tubing Manifold Assembly - Metric> DO NOT over-tighten the 77544-01 (11) beyond the maximum 10 in•lbs force.C A U T I O

1 79579-00 Fitting, Male Connector, 1/4" X 10mm X 8mm Tube 22 Table CD - "Q" Low Voltage Cable Assembly 13 A10975-00 Mounti

----A10841-02TABLE A - HOSE STYLE (METRIC)01Dash No.DescriptionNo Fluid Hose6mm I.D. X 8mm OD Non-Shielded Hose"E"11220123DashNo.Descriptio

Tubing MaterialTubing SizeItem #P1 Paint #1 Clear 5/16" OD X 3/16" ID 29P2 Paint #2 Black Urethane/Poly 5/16" OD X 3/16"

79138-00 Complete Head Assembly 1 2 2 3 79153-65R-1 Air Cap 1 2 3 4 79196-98-1, 79197-63-1 (Optional Air Caps)79140-02 Fluid Tip 1 2 3 4 01=.

(Continued On Next Page)A10407 Robot Mounting Plate 1 2 3 4 Includes: O-Ring Kit 9 ea. - 79001-05 O-Ring (Solvent Pro

Part #REPAIR KITS (Cont.)Description Number of Guns 1-2 3-4 5-6 7-8NotesA10411 Spray Head Repair Kit 1 2 3 4 Includes:

AREATells where hazards may occur.HAZARDTells what the hazard is.SAFEGUARDSTells how to avoid the hazard.Spray Area / High Voltage EquipmentElectrical

WARRANTY POLICIESLIMITED WARRANTYRansburg will replace or repair without charge any part and/or equipment that fails within the specied time (see bel

MANUAL CHANGE SUMMARYThis manual was published to supercede Service Manual AA-03-02.11 Evolver Solventborne Robotic Atomizers to make the following c

Service Manual Price: $50.00 (U.S.)Form No. AA-03-02.12Litho in U.S.A.03/13Manufacturing1910 North Wayne StreetAngola, Indiana 46703-9100Telephone:

Toxic SubstancesCertain material may be harmful if inhaled, or if there is contact with the skin.Follow the requirements of the Material Safety Data S