Carlisle Vector R Series User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
Models: 79503 R90 Classic - Solventborne
79504 R70 Classic - Solventborne
79520 R90 Classic - Waterborne
For Use With 80130-XXX 9060 Power Supply
VectorTM R Series
Classic Applicators
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision AH-06-02-R15 to revision
AH-06-02-R16. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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MANUAL CHANGES
EN

CONTENTS
SAFETY: 5-9
Safety Precautions .................................................................................................................................................... 5
Hazards / Safeguards ................................................................................................................................................ 6
ATEX/FM: 10-17
European ATEX Directive ........................................................................................................................................ 10
European ATEX Labels ............................................................................................................................................11
 FMCongurationDrawings..................................................................................................................................... 12
INTRODUCTION: 18-23
General Description ................................................................................................................................................. 18
 79503R90ClassicSolventborneSpecications..................................................................................................... 19
 79504R70ClassicSolventborneSpecications..................................................................................................... 20
R70/90 Classic Solventborne Electrostatic Spray Applicator Features ................................................................... 21
 80130-XXX9060PowerSupplyElectricalSpecications ....................................................................................... 22
 80130-XXX9060PowerSupplyFeatures............................................................................................................... 23
INSTALLATION: 24-30
R90/70 Solventborne Installation ............................................................................................................................. 24
Typical Solventborne Installation ............................................................................................................................. 24
Typical Solventborne Installation Features .............................................................................................................. 25
High Voltage Cable .................................................................................................................................................. 26
Filters ....................................................................................................................................................................... 26
Paint Preparation...................................................................................................................................................... 27
Spray Pattern Adjustment ........................................................................................................................................ 28
Applicator to Target Distance ................................................................................................................................... 28
Fluid Nozzle Selection Charts ................................................................................................................................. 29
Round Spray Performance Chart ............................................................................................................................ 30
OPERATION: 31
Start-Up ................................................................................................................................................................... 31
MAINTENANCE: 32-50
Suitable Solvents for Cleaning Vector R90/70 Applicators ...................................................................................... 32
Routine Schedule .................................................................................................................................................... 33
Applicator Assembly Cleaning Procedure ............................................................................................................... 34
Flushing Procedures ............................................................................................................................................... 36
Applicator Repair ..................................................................................................................................................... 36
To Remove the Applicator from the Work Site ......................................................................................................... 37
Air Cap .................................................................................................................................................................... 37
Fluid Nozzle ............................................................................................................................................................. 38
Needle Electrode ..................................................................................................................................................... 39
Needle Electrode / Resistance Testing .................................................................................................................... 39
Barrel Assembly ...................................................................................................................................................... 40
 Disassembly/ReassemblyofBarrelwiththe2KFluidNeedlePackings ............................................................... 40
Handle / Resistor Tube ............................................................................................................................................ 45
Troubleshooting Guide ............................................................................................................................................ 48
(Continued On Next Page)
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CONTENTS
EN

CONTENTS (Cont.)
PARTS IDENTIFICATION: 51-73
 R90/70ClassicSolventborneApplicatorBreakdown-PartsList ............................................................................ 51
 VectorR90/70ClassicSolventborneModelIdentication........................................................................................ 54
R90 and R70 Classic Needle Shaft ......................................................................................................................... 56
R90 and R70 Classic Needle Shaft (Optional) - Parts List ...................................................................................... 57
Waterborne Applicator Model 79520-XXXXX Section ............................................................................................. 58
R90 Classic Waterborne Electrostatic Spray Applicator Features............................................................................ 59
 Specications-79520R90ClassicWaterborne ..................................................................................................... 60
 Specications-80130-51X9050PowerSupplyElectrical...................................................................................... 60
Control Unit ............................................................................................................................................................. 61
R90 Classic Waterborne Typical Installation ............................................................................................................ 62
Waterborne Isolation System Installation Guidelines .............................................................................................. 63
Waterborne Hose Fitting Installation ....................................................................................................................... 63
Waterborne Fluid Delivery Components .................................................................................................................. 64
 VectorR90ClassicWaterborneModelIdentication .............................................................................................. 66
Vector Hose Options ............................................................................................................................................... 67
Vector Applicator Cover Options ............................................................................................................................. 68
 VectorSwirlNozzleOptions .................................................................................................................................... 68
Vector Fluid Tube Options ....................................................................................................................................... 69
Parts Comparison .................................................................................................................................................... 70
Vector Classic Recommended Spare Parts ............................................................................................................ 72
MANUAL CHANGE SUMMARY: 74
Manual Changes ..................................................................................................................................................... 74
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system , read and understand all of the technical
and safety literature for your products. This manual
containsinformationthatisimportantforyoutoknowand
understand. This information relates to USER SAFETY
and PREVENTING EQUIPMENT PROBLEMS. To help you
recognizethisinformation,weusethefollowingsymbols.
Please pay particular attention to these sections.
A WARNING! states information to alert you to
a situation that might cause serious injury if
instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
Whilethismanuallistsstandardspecications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asscoiatedequipment
manuals to reconcile such differences.
WARNING
!
WARNING
!
The user MUSTreadandbefamiliarwiththe
Safety Section in this manual and the safety literature
thereinidentied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly
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 AND EN 50177
SAFETY STANDARDS, LATEST EDITION, or
applicable country safety standards, prior to installing,
operating, and/or servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment.
SAFETY
Repairs may only be performed by authorized personnel.
Carefulstudyandcontinueduseofthismanualwillprovidea
better understanding of the equipment and process, resulting
inmoreefcientoperation,longertrouble-freeserviceand
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your equipment, contact your local
Carlisle Fluid Technologies representative or Carlisle Fluid
Technologies technical support.
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SAFETY
EN

AREA
Tellswherehazards
may occur.
HAZARD
Tellswhatthehazardis.
SAFEGUARDS
Tellshowtoavoidthehazard.
Spray Area 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.
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.
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 unauthorized
equipmentmodications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.
The paint process and equipment should be set up
andoperatedinaccordancewithNFPA-33,NEC,
OSHA, local, country, and European Health and
Safety Norms.
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SAFETY
EN

AREA
Tellswherehazards
may occur.
HAZARD
Tellswhatthehazardis.
SAFEGUARDS
Tellshowtoavoidthe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.
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specically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.
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.
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
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.
General Use and
Maintenance
Spray Area Explosion Hazard
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SAFETY
EN

AREA
Tellswherehazards
may occur.
HAZARD
Tellswhatthehazardis.
SAFEGUARDS
Tellshowtoavoidthehazard.
Spray Area /
High Voltage
Equipment
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.
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megohm.(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specically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.
Avoidinstallinganapplicatorintoauidsystem
wherethesolventsupplyisungrounded.
Donottouchtheapplicatorelectrodewhileitis
energized.
Electrical Discharge
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SAFETY
EN

AREA
Tellswherehazards
may occur.
HAZARD
Tellswhatthehazardis.
SAFEGUARDS
Tellshowtoavoidthehazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. 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 shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
reorexplosion.
Unless specically 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.
Electrical Discharge
Electrical
Equipment
Certain materials may be
harmful if inhaled, or if there
iscontactwiththeskin.
Follow the requirements of the 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.
Chemical HazardToxic Substances
Sprayapplicatorsrequirethataluminuminletttings
bereplacedwithstainlesssteel.
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.
Halogenated hydrocarbon
solventsforexample:
methylene chloride and 1,1,1,
- Trichloroethane are not
chemicallycompatiblewiththe
aluminum that might be used
in many system components.
The chemical reaction
caused by these solvents
reactingwithaluminumcan
become violent and lead to an
equipmentexplosion.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

EUROPEAN ATEX DIRECTIVE 2014/34/EU
Thefollowinginstructionsapplytoequipmentcoveredby
certicatenumberSira06ATEX5282X:
1. Theequipmentmaybeusedwithammablegasesand
vaporswithapparatusgroupsIIandwithtemperature
class T6.
2. The equipment is only certied for use in ambient
temperatures in the range +0°C to +40°C and should
not be used outside this range.
3. Installation shall be carried out by suitably trained
personnelinaccordancewiththeapplicablecodeof
practice e.g. EN 60079-14.
4. Inspection and maintenance of this equipment shall be
carried out by suitably trained personnel in accordance
withtheapplicablecodeofpracticee.g.EN60079-17.
5. Repair of this equipment shall be carried out by suitable
trainedpersonnel inaccordancewiththeapplicable
code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and adjustment
of the equipment shall be tted by suitably trained
personnel in accordance with the manufacturer's
documentation.
Refer to the "Table of Contents" of this service manual:
a. Installation
b. Operation
c. Maintenance
  d.PartsIdentication
7. Components to be incorporated into or used as re-
placement parts of the equipment shall be tted by
suitably trained personnel in accordance with the
manufacturer'sdocumentation.
8. The certication of this equipment relies upon the
followingmaterialsusedinitsconstruction:
 If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility of
the user to take suitable precautions that prevent it
from being adversely affected, thus ensuring that the
type of protection provided by the equipment is not
compromised.
Aggressive substances: e.g. acidic liquids or gases
that may attack metals, or solvents that may affect
polymeric materials.
Suitable precautions: e.g. regular checks as part of
routineinspectionsorestablishingfromthematerial's
datasheetsthatitisresistanttospecicchemicals.
 Referto"Specications"inthe"Introduction"section:
a.Alluidpassagescontainstainlesssteelor
nylonttings.
b.Highvoltagecascadeisencapsulatedwith
asolventresistantepoxy.
9. Arecapitulationofthecerticationmarkingisdetailed
inthe"ATEX"section,onthenextpage,drawingnum-
bers: 80081, 80082, 80108, 79516, 79515.
10. The characteristics of the equipment shall be detailed
e.g. electrical, pressure, and voltage parameters.
The manufacturer should note that, on being put into
service, the equipment must be accompanied by
a translation of the instructions in the language or
languages of the country in which the equipment is to
be used and by the instructions in the original language.
AH-06-02-R16 (10/2019) 10 / 75 www.carlisleft.com
ATEX
EN