SERVICE MANUAL LN-9237-00.1 (Replaces LN-9237-00) AEROBELL® M TOMIZER ROT AR YA ROTAR ARY AT MODEL: 78101 IMPOR TANT IMPORT ANT:: 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.
NOTE: This manual has been changed from revision LN-9237-00 to revision LN-9237-00.1 LN-9237-00.1. Reasons for this change are noted under “Manual Change Summary” inside the back cover of this manual.
Aerobell M Rotary Atomizer - Contents CONTENTS SAFETY: PAGE 1-5 SAFETY PRECAUTIONS......................................................... 1 HAZARDS / SAFEGUARDS..................................................... 2 INTRODUCTION: 6-9 FEATURES................................................................................ 6 GENERAL DESCRIPTION....................................................... 6 SPECIFICATIONS.....................................................................
Aerobell M Rotary Atomizer - Contents PAGE PARTS IDENTIFICATION: 32-47 30mm AEROBELL M CROSS SECTION VIEW....................... 32 57mm AEROBELL M CROSS SECTION VIEW....................... 33 70mm AEROBELL M CROSS SECTION VIEW....................... 34 AEROBELL M CROSS SECTION VIEW.................................. 35 AEROBELL M MODEL IDENTIFICATION............................... 36 AEROBELL M PARTS LIST......................................................
Aerobell M Rotary Atomizer - Safety SAFETY SAFETY PRECAUTIONS Before operating, maintaining or servicing any ITW Ransburg electrostatic coating system, read and understand all of the technical and safety literature for your ITW 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.
Aerobell M Rotary Atomizer - Safety AREA HAZARD SAFEGUARDS Tells where Tells what the hazard is. Tells how to avoid the hazard. Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically. hazards may occur. Area Spray 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.
Aerobell M Rotary Atomizer - Safety AREA HAZARD SAFEGUARDS Tells where Tells what the hazard is. Tells how to avoid the hazard. High voltage equipment is utilized. Arcing in areas of flammable or combustible materials may occur. Personnel are exposed to high voltage during operation and maintenance. The power supply, optional remote control cabinet, and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas. Refer to NFPA 33, 2000 Edition.
Aerobell M Rotary Atomizer - Safety AREA HAZARD SAFEGUARDS Tells where Tells what the hazard is. Tells how to avoid the hazard. There is a high voltage device that can induce an electrical charge on ungrounded objects which is capable of igniting coating materials. Parts being sprayed must be supported on conveyors or hangers and be grounded. The resistance between the part and ground must not exceed 1 megohm. hazards may occur.
Aerobell M Rotary Atomizer - Safety NOTES: LN-9237-00.
Aerobell M Rotary Atomizer - Introduction INTRODUCTION FEA TURES FEATURES spray angles for better paint coverage in difficult areas of the product. Features which make the Aerobell® M Rotary Atomizer advantageous for use in electrostatic applications include: • Turbine air exhausts behind bell, keeping paint and solvent contamination out of atomizer interior and keeping back of bell clean. • Proven long life turbine motor capable of speeds up to 55k rpm at minimal air consumption.
Aerobell M Rotary Atomizer - Introduction Insulator Support Rod Assembly High V oltage Cables Voltage The air and fluid manifold assembly mount onto the insulator support rod assembly, which in turn is attached to the reciprocator or support stand. The SSW-1064, high voltage cable, is used to connect the power supply to the resistor module inside the atomizer assembly.
Aerobell M Rotary Atomizer - Introduction SPECIFICA TIONS SPECIFICATIONS Electrical Power Supply Type: LECU5003 / LEPS5001 (Voltage MasterTM) 76045 / LEPS5002 (MicroPakTM) Charging Method: Direct Output Voltage: 30-100 kV Variable Output Current: 125 μA (Short Circuit) Turbine Speed Control: PulseTrack or Eurocard Atomizer Module Paint Resistance:* .1 MΩ to ∞ *(Use Model No.
Aerobell M Rotary Atomizer - Introduction Turbine Speed vs. Flow 70 60 50 40 30 20 10 0 20 15 SCFM PSI Turbine Speed vs. Pressure 57mm Bell 30mm Bell 0 10 20 30 40 50 57mm Bell 10 30mm Bell 5 60 70 0 0 Thousands RPM 10 20 30 40 50 60 70 Thousands RPM Figure 1: Turbine Speed vs. Pressure Figure 2: Turbine Speed vs. Flow 57mm Bell/Loaded vs. Unloaded 16 60 50 40 30 20 10 0 14 Load 600 cc/min Water SCFM PSI 57mm Bell/Loaded vs.
Aerobell M Rotary Atomizer - Installation INST ALLA TION INSTALLA ALLATION AIR FIL TER INST ALLA TION FILTER INSTALLA ALLATION AIR PRESSURE REQUIREMENTS The following air filter installation guidelines are essential for optimum performance. 1. Use only recommended pre-filters and bearing air filters as shown in Figure 8. Additional system air filtration (i.e., refrigerated air dryer) may also be used if desired. 2. Mount the bearing air filter as close as possible to the Aerobell M.
Aerobell M Rotary Atomizer - Installation AIR FIL TRA TION FILTRA TRATION REQUIREMENTS ITW Ransburg Filter Model No. Description / Specifications Replacement Element Part No. HAF-503 Pre-filter, removes coarse amounts of oil, moisture & dirt. Used upstream of RPM-417 pre-filter (used in systems with poor air quality). HAF-15 Element, One RPM-417 Pre-filter, coalescing type, 136 scfm, 98.5% efficiency particulate removal .3 to .6 micron, max. aerosol passed 1.0 micron, max. solid passed .
Aerobell M Rotary Atomizer - Installation MOUNTING ELECTRICAL CONNECTIONS The Aerobell M incorporates its own insulator mounting rod. The diameter at the rear is 1.9 inches, for mounting to a reciprocator, stationary stand, or other means of support. The atomizer assembly is mounted to this horizontal rod by a 3/4 inch insulating post, inserted into a swivel clamp and secured by four plastic bolts. The arrangement allows positioning of the front of the turbine.
Aerobell M Rotary Atomizer - Installation INTERLOCKS 3. Two interconnected bearing air ports are provided, one for supply air and the other to be used as a return signal for measuring bearing air pressure at the atomizer. If bearing air falls below 60 psi at the atomizer, the turbine air should be automatically interlocked to shut off. 4. High voltage must be interlocked with the solvent valve pilot signal to prevent solvent flow while high voltage is energized. 5.
Aerobell M Rotary Atomizer - Operation OPERA TION OPERATION ! WARNING > Operators must be fully trained in safe operation of electrostatic equipment. Operators must read all instructions and safety precautions prior to using this equipment (See NFPA 33, Chapter 16).
Aerobell M Rotary Atomizer - Operation (i.e. from 1:2 to 1:4) provides a lower slope, but, more precise response curve. This same increase in ratio, however, will reduce flow capacity and should be considered when selecting the proper regulator ratio. The following factors must then be considered when selecting the regulator ratio required for proper fluid control: • Maximum fluid output requirements (Guide: 10 psi minimum, 30 psi max.
Aerobell M Rotary Atomizer - Operation DR-1 FLOW VS. SIGNAL PRESSURE 900 Viscosity=40 sec. Zahn #2 15ft 1/4 I.D. tubing .093 orifice 800 700 HIGH FLOW FLOW (CC/MIN) 600 500 400 1:2 300 200 1:1 1:4 1:3 1:8 100 1:6 1:10 0 9 12 15 21 26 32 37 42 48 54 59 65 70 75 81 SIGNAL PRESSURE (PSI) Figure 12a: DR-1 Flow Vs. Signal Pressure DR-1 FLOW VS. SIGNAL PRESSURE 1400 Viscosity=25 sec. Zahn #2 15ft 1/4 I.D. tubing .
Aerobell M Rotary Atomizer - Operation FLUID V AL VE CONTROL VAL ALVE (T rigger (Trigger rigger,, Dump & Solvent) The fluid valves in the Aerobell M are actuated by an air signal. The air pressure must exceed 70 psi to assure proper actuation of the valve. Applying air to the valve actuator turns on the fluid flow for that valve. The trigger valve controls the paint flow to the bell. When actuated, paint flows through the valve to the fluid tube, and into the rear of the bell cup.
Aerobell M Rotary Atomizer - Operation BEARING AIR ADJUSTMENT The nominal bearing air pressure is 90 psi, measured at the rear of the atomizer. Minimum pressure is 70 psi and maximum pressure is 100 psi. The turbine should never be operated with less than 70 psi bearing air pressure. Bearing air must be present when turning the turbine on. Bearing air must remain on when the turbine air is turned off until the turbine stops spinning. Never turn off bearing air to cause the turbine to stop spinning.
Aerobell M Rotary Atomizer - Operation ELECTROST ATIC ELECTROSTA VOL TAGE VOLT NOTES: The Aerobell M Rotary Atomizer receives its operating voltage through a high voltage cable that is connected to a remote power supply. The power supply model and high voltage setting will depend upon various application requirements. See the "Specifications" section of this manual for approved power supplies and refer to that manual for detailed operating instructions.
Aerobell M Rotary Atomizer - Maintenance MAINTENANCE CLEANING PROCEDURES ! WARNING > Electrical shock and fire hazards can exist during maintenance. High voltage supply must be turned off before entering the spray area and performing any maintenance procedures on the atomizer. Spray booth fans should remain on while cleaning with solvents. > Never touch the atomizer bell while it is spinning. The front edge of the bell can easily cut into human skin or cut through gloves and other materials.
Aerobell M Rotary Atomizer - Maintenance ! WARNING > NEVER wrap the applicator, associated valves and tubing, and supporting hardware in plastic to keep it clean. A surface charge may build up on the plastic surface and discharge to the nearest grounded object. Efficiency of the applicator will also be reduced and damage or failure of the applicator components may occur. WRAPPING THESE COMPONENTS IN PLASTIC WILL VOID WARRANTY.
Aerobell M Rotary Atomizer - Maintenance ! CAUTION > Care must be taken when mounting the bell assembly onto the motor shaft. The bell should turn on freely for several turns or until it fully bottoms on the motor shaft. If resistance is felt when the bell is first being turned onto the shaft, do not proceed further, the bell may be crossthreaded on the shaft. Remove the cup and carefully reinstall. If it is still difficult to turn, replace the bell.
Aerobell M Rotary Atomizer - Maintenance GENERAL Verify daily that the operating parameters have not varied from the set up standard. A drastic change in system current, high voltage, turbine air, shaping air pressure, or fluid pilot air pressure can be an early indicator of a component or system problem.
Aerobell M Rotary Atomizer - Maintenance • Check the amount of paint build up on the outer protective wrap. If excessive, replace wrap as required. NOTE > The protective disposable wrap is for one time use only. Do not wash and reuse the wrap. NOTE > Normally the wrap will not need replacement daily and could last about one week. See "Weekly Maintenance" in the "Maintenance" section.
Aerobell M Rotary Atomizer - Maintenance using a tube brush and solvent. Clean the outer surfaces of the feed tube. ! WARNING 4. Set the test meter voltage output to a minimum of 500 VDC and maximum of 1000 VDC. 5. The meter should indicate between approximately 725 Megohm and 770 Megohm. If the test instrument is reading higher than 770 Megohm, then the electrical contacts between the resistor tube, resistor block and motor assembly need to be checked. 6.
Aerobell M Rotary Atomizer - Maintenance Front Shroud Removal Turbine Removal Remove the front shroud (Figure 16, item 2) from the atomizer, using the RPM-419, or other properly fitting spanner wrench, and turning CCW (viewed as facing the front end). The turbine assembly (Figure 16, item 10) is removed from the Aerobell M atomizer after removing the front shroud assembly. Four mounting bolts (Figure 16, item 8) will then be exposed, which hold the turbine assembly to the air manifold assembly.
Aerobell M Rotary Atomizer - Maintenance ! CAUTION > Make sure the turbine assembly is properly seated by examining the fit between the rear of the turbine assembly and the front of the air manifold assembly. Any irregularity in this seam between the two assemblies would indicate improper mounting. Looking into the front of the motor shaft, observe the concentricity of the paint feed tube to the inside of the motor shaft. If the paint feed tube is off center by more than .020-.
Aerobell M Rotary Atomizer - Maintenance Fluid Regulator Removal Fluid T ube Removal Tube To remove the fluid regulator (Figure 16, item 18) follow the procedures for removal of the rear shroud. Then disconnect the air pilot lines at the regulator, and the output fluid line at its connection into the fluid manifold assembly (Figure 16, item 7). Disconnect the fluid supply line at the regulator inlet port, loosen the retaining screws, and pull the regulator straight out of the bulkhead.
Aerobell M Rotary Atomizer - Maintenance TROUBLESHOOTING GUIDE General Problem Possible Causes Corrective Action Bad Spray Pattern 1. Bell cup damaged 1. Replace bell cup. 2. Low voltage 2. See "low or no voltage" below. 3. Bad fluid regulator 3. Repair or replace fluid regulator. 4. Paint lodged in shaping air ring. 4. Disassemble and clean. 1. High current draw 1. Paint resistivity to be .1 MΩ to ∞. 2. Solvent valve is actuated 2.
Aerobell M Rotary Atomizer - Maintenance General Problem Possible Causes Corrective Action Low Transfer Efficiency (or light coverage) 1. Low or no high voltage 1. Verify high voltage at bell cup edge. Normally, a high voltage setting of 100kV is appropriate for most applications. 2. Poor grounding of parts being coated 2. Verify that parts being coated are properly grounded (the electrical resistance between the part and ground must not exceed 1 megohm). 3. Excessive turbine speed 3.
Aerobell M Rotary Atomizer - Maintenance General Problem Possible Causes Corrective Action No Fluid Flow (Continued) 3. Fluid valve does not actuate 3a. Verify that air pilot signal is present. b. Fluid valve air pilot pressure is too low. Increase air pressure to 70 psig minimum. c. Replace fluid valve. 4. Remove and inspect fluid tube. 4. Clogged fluid tube Continuous Fluid Flow 1. Fluid valve open 1a. Remove air pilot signal. b. If still open, replace fluid valve. 2. Replace fluid valve seat. 2.
Aerobell M Rotary Atomizer - Parts Identification PAR TS IDENTIFICA TION ARTS IDENTIFICATION Figure 16a: 30mm Aerobell M Cross Section View 32 LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification Figure 16b: 57mm Aerobell M Cross Section View LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification Figure 16c: 70mm Aerobell M Cross Section View 34 LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification Figure 16d: Aerobell M Cross Section View Figure 16e: Aerobell M Cross Section View LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification AEROBELL M MODEL IDENTIFICA TION IDENTIFICATION When ordering, use part number 78101-ABCDE as indicated by Tables A through E. Table A: Designates the bell type Table B: Designates the fluid tube Table C: Designates the fluid manifold assembly Table D: Designates the regulator assembly Table E: Designates the resistor block (Five characters must follow the basic part number as shown in the example below.
Aerobell M Rotary Atomizer - Parts Identification TABLE "C" (Figure 16) Dash # Description H 1 Fluid Manifold Assy, Trigger AER4000 2 Fluid Manifold Assy, Trigger/Dump AER4001 3 Fluid Manifold Assy, Trigger/Solvent AER4002 4 Fluid Manifold Assy, Trigger/Dump/Solvent AER4003 5 Waterbase Fluid Manifold Assy, Trigger AER4020 6 Waterbase Fluid Manifold Assy, Isolated Dump AER4021 7 Waterbase Fluid Manifold Assy, Isolated Solvent AER4022 8 Waterbase Fluid Manifold Assy, Isolated Dump/Sol
Aerobell M Rotary Atomizer - Parts Identification AEROBELL M - P AR TS LIST (Figure 16) PAR ARTS Item # 1 2 3 4 5 6 7 8 9 10 10A 10B 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Part # AER4004-02 See "F" (Table "A") See "G" (Table "B") SSG-8128 LSFA0014 AER4013 See "H" (Table "C") LSFA0006-16F LSFA0004-56C AER4006 7554-103 7554-104 7554-03 See "J" (Table "A") See "K" (Table "A") 55994-25 See "L" (Table "A") See "M" (Table "A") LSFI0022-04 See "Q" (Table "D") AER0043 LSFA0007-12C See "T"
Aerobell M Rotary Atomizer - Parts Identification NOTES: LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification Figure 17: AER4004-02 Air Manifold Assembly 40 LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification ASSEMBLY PAR ARTS AER4004-02 AIR MANIFOLD ASSEMBL Y-P AR TS LIST (Figure 17) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part # AER4005-00 AER0026-00 AER0022-00 LSFI0013-01 LSFI0013-02 LSFI0013-04 LSFI0023-02 LSFI0024-03 LSFI0025-22 LSOR0005-02 AER0021-00 AER0062-02 AER0027-01 LSFA0001-16C AER0023-00 Description Manifold, Air, Engraved Stud, Mounting Pin, Fiberglass Fitting, 1/2 O.D. Tube x 3/8 NPT Fitting, 3/8 O.D. Tube x 1/4 NPT Fitting, 1/4 O.D.
Aerobell M Rotary Atomizer - Parts Identification Figure 18: Fluid Manifold Assembly 42 LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification ASSEMBLY PAR ARTS FLUID MANIFOLD ASSEMBL Y-P AR TS LIST (Figure 18) Manifold, Fluid, Engraved Fitting, 1/4 O.D. Tube x 1/4 AN Union Plug, Protective, 1/4 AN Fitting, 3/8 O.D. Tube x 3/8 AN Union Plug, Protective, 3/8 AN Valve Assembly, Cartridge, HV Plug Assembly, Valve Port Fitting, 1/4 O.D.
Aerobell M Rotary Atomizer - Parts Identification Figure 19: Waterborne Fluid Manifold Assembly 44 LN-9237-00.
Aerobell M Rotary Atomizer - Parts Identification ASSEMBLY WATERBORNE FLUID MANIFOLD ASSEMBL YARTS PAR TS LIST (Figure 19) Manifold, Fluid, Engraved Fitting, 1/4 O.D. Tube x 1/4 AN Union Plug, Protective, 1/4 AN Fitting, 3/8 O.D. Tube x 3/8 AN Union Plug, Protective, 3/8 AN Valve Assembly, Cartridge, HV Plug Assembly, Valve Port Fitting, 1/4 O.D.
Aerobell M Rotary Atomizer - Parts Identification SPARE PAR ARTS RECOMMENDED SP ARE P AR TS Part # Description Qty See Table B, "G" (Pg. 36) SSG-8128 LSFA0004-56C 7554-03 See Table A, "J" (Pg. 36) See Table A, "L" (Pg. 36) See Table A, "M" (Pg. 36) LSOR0005-02 76917-00 73913-00 73913-01 Fluid Tube O-Ring, Solvent Resistant Screw, 1/4-20 x 1.75 Long, Nyl.
Aerobell M Rotary Atomizer - Parts Identification NOTES: LN-9237-00.
Aerobell M Rotary Atomizer - Warranty Policies WARRANTY POLICIES LIMITED W ARRANTY WARRANTY ITW Ransburg will replace or repair without charge any part and/or equipment that falls within the specified time (see below) because of faulty workmanship or material, provided that the equipment has been used and maintained in accordance with ITW Ransburg's written safety and operating instructions, and has been used under normal operating conditions. Normal wear items are excluded.
Aerobell M Rotary Atomizer - Appendix APPENDIX PAINT AND SOL VENT SPECIFICA TIONS SOLVENT SPECIFICATIONS RECOMMENDED VISCOSITY USING A ZAHN NO. 2 PAINT ELECTRICAL RESISTANCE** RECOMMENDED DELIVERY (UP TO) REATM / EFMTM 18 TO 30 SEC .1 MΩ TO ∞ 1000 cc/min REMTM / M90TM 18 TO 30 SEC .1 MΩ TO ∞ 1500 cc/min NO. 2 HAND GUN 20 TO 60 SEC .1 TO 1 MΩ 180 cc/min TURBODISKTM 20 TO 60 SEC .1 MΩ TO ∞ 1000 cc/min AEROBELL® II*** AEROBELL® AEROBELL® 33 RMA-101TM 20 TO 60 SEC .
Aerobell M Rotary Atomizer - Appendix 30 15 12 10 .25 25 37 14 35 17 15 12 A-2 .3 30 43 15 39 18 19 14 A-1 .4 40 50 16 50 21 25 18 .5 50 57 17 24 29 22 .6 60 64 18 29 33 25 .7 70 20 33 36 28 .8 80 22 39 41 31 .9 90 23 44 45 32 1.0 100 25 50 50 34 1.2 120 30 62 58 1.4 140 32 66 1.6 160 1.8 2.0 2.2 A Din Cup 4 13 Sears Craftsman Cup 32 Zahn 5 20 Zahn 4 .
Aerobell M Rotary Atomizer - Appendix X 14.0 1400 18.0 1800 1 Y 103 9850 22.0 2200 10300 Z 2 24.0 2400 Z-1 3 Din Cup 4 Sears Craftsman Cup 129 16500 133 18500 Z-3 136 21000 23500 55.0 5500 26000 Z-4 4 2800 65.0 6500 30000 70.0 7000 32500 75.0 7500 35000 80.0 8000 37000 85.0 8500 39500 90.0 9000 41000 95.0 9500 43000 Z-5 5 46500 110.0 11000 51000 120.0 12000 55005 130.0 13000 60000 140.0 14000 65000 150.0 15000 Zahn 5 121 14500 Z-2 50.0 5000 100.
Aerobell M Rotary Atomizer - Appendix VOLUMETRIC CONTENT OF HOSE OR TUBE (English Units) Cross Section (in.2) I.D. (inches) cc/ft. 1/8 2.4 .012 3/16 5.4 .028 1/4 9.7 .049 5/16 15.1 .077 3/8 21.7 .110 1/2 38.6 .196 Length 5ft. (60") .003 gal. .4 fl. oz. .007 gal. .9 fl. oz. .013 gal. 1.6 fl. oz. .020 gal. 2.5 fl. oz. .029 gal. 3.7 fl. oz. .051 gal. 6.5 fl. oz. 10ft. (120") 15ft. (180") 25ft. (300") 50ft. (600") .006 gal. .8 fl. oz. .014 gal. 1.8 fl. oz. .025 gal. 3.3 fl. oz. .040 gal.
NOTES: LN-9237-00.
NOTES: LN-9237-00.
MANUAL CHANGE SUMMAR Y SUMMARY This manual was published to replace Service Manual LN-9237-00 LN-9237-00, Aerobell M Rotary Atomizer, to make the following changes: 1. Revised Table A (Figure 16 - Model Identification) in the "Parts Identification" section. 2. Revised "Paints and Solvent Specifications" in the "Appendix" section. LN-9237-00.
Service Manual Price: $50.00 (U.S.) Industrial Systems ITW Industrial Finishing 320 Phillips Avenue Toledo, Ohio 43612-1493 Telephone: 419/ 470-2000 Fax: 419/ 470-2270 Website: www.itwransburg.com E-Mail: marketing@itwransburg.com Order Desk: Telephone: 866/ 489-4300 Fax: 877/ 790-6965 Technical/Service Assistance: Telephone: 800/ 233-3366 Fax: 419/ 470-2071 An Illinois Tool Works Company © 2003 Illinois Tool Works Inc. All rights reserved. Models and specifications subject to change without notice.
