Ransburg RMA-303 User manual

SERVICE MANUAL
LN-9266-11.3
(REPLACES: LN-9266-11.2)
April — 2013
RMA-303 Robot Mounted Rotary
Atomizer Direct Charge
MODEL:A12867
IMPORTANT: 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.)
Service Manual Price: $50.00 (U.S.)Service Manual Price: $50.00 (U.S.)
Service Manual Price: $50.00 (U.S.)

LN-9266-11.3
CONTENTS
PAGE
SAFETY: 1-6
SAFETY PRECAUTIONS ......................................................................................................... 1
HAZARDS / SAFEGUARDS .................................................................................................. 2-6
INTRODUCTION: 8-33
FEATURES ............................................................................................................................... 8
GENERAL DESCRIPTION .................................................................................................. 9-10
SPECIFICATIONS ............................................................................................................. 11-12
IMPORTANT NUMBERS ........................................................................................................ 13
GRAPHS............................................................................................................................ 14-26
RMA-303 TOOL POINT DIMENSIONS .............................................................................. 27-30
CIRCUIT SCHEMATICS .................................................................................................... 31-32
VALVE SCHEMATICS ............................................................................................................ 33
INSTALLATION: 34-44
AIR FILTER INSTALLATION .................................................................................................. 34
TUBE SIZE / AIR PRESSURE REQUIREMENTS ................................................................... 35
EQUIPMENT GROUNDING / SAFETY RECOMMENDATIONS ............................................. 36
AIR HEATER REQUIREMENTS ........................................................................................ 37-38
AIR FILTRATION REQUIREMENTS ....................................................................................... 39
MOUNTING ............................................................................................................................ 40
ELECTRICAL AND FIBER OPTIC CONNECTIONS ............................................................... 40
FLUID CONNECTIONS .......................................................................................................... 40
TYPICAL INSTALLATION ....................................................................................................... 41
TUBING BUNDLE INSTALLATION ......................................................................................... 42
BUNDLE LUBRICATION ........................................................................................................ 42
RMA-303 WIRING INSTALLATION ........................................................................................ 43
INTERLOCKS ......................................................................................................................... 44
OPERATION: 46-56
FLUID FLOW RATE ................................................................................................................ 46
TURBINE SPEED ................................................................................................................... 47
BEARING AIR ADJUSTMENT ................................................................................................ 48
SHAPING AIR KITS #1, #2, #3, #4, #5 .............................................................................. 48-52
BRAKE AIR ............................................................................................................................. 52
ELECTROSTATIC VOLTAGE ................................................................................................. 52
TARGET DISTANCE .............................................................................................................. 53
GENERAL OPERATING SEQUENCE ............................................................................... 53-54
LOW VOLTAGE CABLE INSTALLATION AND REMOVAL .................................................... 55
LOW VOLTAGE ON ROBOT .................................................................................................. 56

RMA-303 Direct Charge - Contents
LN-9266-11.3
MAINTENANCE: 58-83
O-RINGS ................................................................................................................................ 58
CLEANING PROCEDURES .............................................................................................. 58-60
VIBRATION NOISE ................................................................................................................ 60
TURBINE MAINTENANCE ..................................................................................................... 60
GENERAL / PREVENTIVE MAINTENANCE ..................................................................... 60-62
BELL CUP PREVENTATIVE MAINTENANCE / CLEANING .............................................. 62-64
CLEANING SHAPING AIR HOLES ......................................................................................... 65
RMA-303 PREVENTATIVE MAINTENANCE SCHEUDLE ...................................................... 66
DISASSEMBLY PROCEDURES ....................................................................................... 67-79
TROUBLE SHOOTING GUIDE .......................................................................................... 80-83
PARTS IDENTIFICATION: 85-112
RMA-303 DIRECT CHARGE ROTARY ATOMIZER MODEL IDENTIFICATION ................ 85-88
RMA-303 ASSEMBLY / PARTS LIST ................................................................................ 89-96
A12000-XXXXXX, A12215-XXXXXX TUBING BUNDLE ASSEMBLY .............................. 97-103
RECOMMENDED SPARE PARTS ................................................................................ 104-109
ASSEMBLY TOOLS ............................................................................................................. 110
ACCESSORIES / SERVICE KITS / AIR FILTER REPLACEMENT ............................... 111-112
WARRANTY POLICIES: 114
LIMITED WARRANTY .......................................................................................................... 114

RMA-303 Direct Charge - Safety
1 LN-9266-11.3
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 infor-
mation relates to USER SAFETY and PRE-
VENTING EQUIPMENT PROBLEMS. To help
you recognize this information, we use the fol-
lowing symbols. Please pay particular attention
to these sections.
A WARNING! states information to alert you
to a situation that might cause serious inju-
ry 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 pro-
cedure in progress.
While this manual lists standard specifications
and service procedures, some minor devia-
tions may be found between this literature and
your equipment. Differences in local codes and
plant requirements, material delivery require-
ments, etc., make such variations inevitable.
Compare this manual with your system instal-
lation drawings and appropriate Ransburg
equipment manuals to reconcile such differ-
ences.
Careful study and continued use of this manual
will provide a better understanding of the
equipment and process, resulting in more effi-
cient 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.
SAFETY
The user MUSTread and be familiar
with the Safety Section in this manual and
the Ransburg safety literature therein
identified.
This manual MUSTbe read and thor-
oughly understood by ALLpersonnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGSand safety requirements
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to ALL local building and fire
codes and ordinances as well as NFPA-33
SAFETY STANDARD, LATEST EDITION,
prior to installing, operating, and/or servic-
ing this equipment.
! W A R N I N G
! W A R N I N G
The hazards shown on the following
pages may occur during the normal use
of this equipment. Please read the haz-
ard chart beginning on page 2.

RMA-303 Direct Charge - Safety
LN-9266-11.3 2
AREA
Tells where haz-
ards may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate opera-
tion and maintenance proce-
dures 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. Frequent Pow-
er Supply or Controller shut-
down 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 ac-
cumulation 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, flushing or mainte-
nance.
When using solvents for cleaning:
•
Those used for equipment flushing should
have flash points equal to or higher than those
of the coating material.
•
Those used for general cleaning must have
flash 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 main-
tained during cleaning operations using flammable
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 re-
quired 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 modifications may cause fire 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 water-
borne installations to spray solvent based materi-
als.
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.

RMA-303 Direct Charge - Safety
3 LN-9266-11.3
AREA
Tells where haz-
ards may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Explosion Hazard
Improper or inadequate opera-
tion and maintenance proce-
dures 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.
Frequent Power Supply or Con-
troller 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 re-
quired at all times.
Unless specifically approved for use in hazardous
locations, all electrical equipment must be located
outsideClass I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Test only in areas free of flammable or combus-
tible 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 fire or explosion is lost if the current over-
load 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
flushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no ob-
jects 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 fire extinguishing equipment readily available
and tested periodically.
General Use and
Maintenance
Improper operation or mainte-
nance may create a hazard.
Personnel must be properly
trained in the use of this equip-
ment.
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, fire protection, opera-
tion maintenance, and housekeeping. Reference
OSHA, NFPA-33, EN Norms and your insurance
company requirements.

RMA-303 Direct Charge - Safety
LN-9266-11.3 4
AREA
Tells where haz-
ards may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area / High
Voltage Equip-
ment
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting coat-
ing materials.
Inadequate grounding will cause
a spark hazard. A spark can
ignite many coating materials
and cause a fire or explosion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on convey-
ors 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 insu-
lating 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 applica-
tor 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 flooring must be provided in
the spray area.
Always turn off the power supply prior to flushing,
cleaning, or working on spray system equipment.
Unless specifically approved for use in hazardous
locations, all electrical equipment must be located
outsideClass I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.

RMA-303 Direct Charge - Safety
5 LN-9266-11.3
AREA
Tells where haz-
ards may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Electrical
Equipment
Electrical Discharge
High voltage equipment is uti-
lized in the process. Arcing in
the vicinity of flammable or
combustible materials may oc-
cur. Personnel are exposed to
high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a fire or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shut-
down indicates a problem in the
system which requires correc-
tion.
An electrical arc can ignite coat-
ing materials and cause a fire or
explosion.
Unless specifically 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 flammable or combus-
tible 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 Substanc-
es
Chemical Hazard
Certain materials may be harm-
ful if inhaled, or if there is con-
tact with the skin.
Follow the requirements of the Material Safety
Data Sheet supplied by coating material manufac-
turer.
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.

RMA-303 Direct Charge - Safety
LN-9266-11.3 6
AREA
Tells where haz-
ards may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Explosion Hazard—
Incompatible Materials
Halogenated hydrocarbon sol-
vents for example: methylene
chloride and 1,1,1,-
Trichloroethane are not chemi-
cally compatible with the alumi-
num that might be used in many
system components. The
chemical reaction caused by
these solvents reacting with alu-
minum can become violent and
lead to an equipment explosion.
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 equip-
ment during spraying, flushing, 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.

RMA-303 Direct Charge - Safety
7 LN-9266-11.3
N O T E S

RMA-303 Direct Charge - Introduction
LN-9266-11.3 8
INTRODUCTION
FEATURES
Features which make the RMA-303 advanta-
geous for use in electrostatic applications
include:
•
Assembly components made of durable
engineered resin material for optimum
mechanical strength and solvent re-
sistance.
•
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 70 krpm. (See
“Specifications” in the “Introduction”
section of this manual for bell cup speed
ratings.)
•
Serrated and non-serrated bell cups are
available for application flexibility and color
match. All bell cups are made using
Titanium material. The 55mm bell cup is
also available in aluminum.
•
Two independent shaping air supply tubes
for pattern control.
•
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
maneuverability in tight areas.
•
Negligible maintenance down time. With
the quick disconnect feature, an atomizer
can be exchanged in less than 2 minutes
for off-line maintenance.
•
The easily removable front and rear
shrouds, turbine assembly and the inter-
nally mounted fluid valves, make off-line
maintenance more efficient and economi-
cal.
•
Fast color changes are achieved using
center feed fluid delivery and the fluid
valves provide for simultaneous paint
push out while solvent washes the feed
tube and bell cup interior.
•
Internal and external bell wash is quick
and efficient. Solvent is controlled at the
feed tube with an internally mounted
solvent valve. Externally mounted
regulators control the flow.
•
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 configurations.
•
Direct charging of fluid (solvent borne
paint) promotes high transfer efficiency.
•
Large range of fluid tip sizes available.

RMA-303 Direct Charge - Introduction
9 LN-9266-11.3
GENERAL DESCRIPTION
Bell Cup Assembly
All bell cups are made of high strength Titani-
um. They are available in 65mm serrated,
non-serrated for base coat applications. A
30mm and 55mm aluminum bell cup is availa-
ble.
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 fluid feed tube and
fiber optic turbine speed emitter are threaded
into the front of the manifold. The turbine,
fluid, and air manifolds are separated from the
bell plate assembly by five support rods.
Nested between the manifolds and the bell
Figure 1: RMA-303 Robot Mounted Rotary Atomizer–
Direct Charge
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 as-
sembly. The air and fluid ports are compactly
oriented for use in robotic applications. The
interior air supplies are ported through the five
support rods and also directly to the air mani-
fold 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.
Robot Plate
The robot plate is a component of the tubing
bundle assembly and intended to be perma-
nently mounted to the robot. A wrist adapter
is also available, which matches the robot’s
mounting configuration. The incoming air
lines, fluid lines, low voltage cable, and fiber
optic cable are connected to the fittings pro-
vided on the back of the robot plate. The bell
plate of the atomizer assembly is secured to
the robot plate with a threaded retaining ring.
Break-Away Feature (Optional)
The RMA-303 can be converted to have a
break-away feature. By replacing the five (5)
stainless steel screws with five (5) special de-
signed plastic screws (77524-00). This fea-
ture minimizes the damage to the atomizer,
robot, etc. If a collision occurs, the five (5)
plastic break-away screws fail and the atomiz-
er will break free. This will leave the break-
away ring and the mounting ring attached to

RMA-303 Direct Charge - Introduction
LN-9266-11.3 10
the robot. (The applicator will fall to the booth
grate or floor).
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 Mi-
croPak is multiplied by the internal cascade to
the high voltage level required. This elimi-
nates the need for a high voltage cable. A low
voltage cable interconnects the cascade and
MicroPak control. The MicroPak format is de-
signed to fit in a conventional 19-inch or 10-
inch rack and requires a 24V power input at a
maximum 3 amps. The MicroPak and the in-
ternal cascade will produce voltages up to
100,000 VDC.
The MicroPak is designed to electronically lim-
it 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 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-303 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 fiber optic transmitter lo-
cated on the applicator. A Serial Digital Mod-
ule 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 com-
mon mother board.

RMA-303 Direct Charge - Introduction
11 LN-9266-11.3
SPECIFICATIONS - Electrical / Mechanical
Electrical
Power Supply Type: MicroPak
Charging Method: Direct
Output Voltage: 0-100 kV Variable
Output Current
:
125 µA
Turbine Speed Control: Atomizer Module
Part Spray ability: Determine spray ability of part to be coated using Test Equip
-
ment (76652) (Paint Conductivity Meter)
Mechanical
Length:
.
(See RMA-303 Tool Point, Center of Gravity, and Envelop
e
Dimen sions (Single and Dual Flex) figure in the “Introduction
”
section.)
Diameter
:
(See RMA-303 Tool Point, Center of Gravity, and Envelop
e
Dimen sions (Single and Dual Flex) figure in the “Introduction
”
section.)
Approximate Weight
Atomizer Only: 17.3 lbs. (7.83 Kg) max.
Total Payload with Robot
Plate & Adapter: 20.1 lbs. (9.12 Kg) max.
Turbine Type
:
Air Bearing Impulse Drive
Turbine Air Supply: Variable (See “Pressure Flow Data Charts” in th
e
“Introduction” section.)
Maximum/Minimum
Turbine Speed
:
Continuous 70K rpm max./20K rpm min.
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)
Shaping Air #1 (SAI) Supply: Variable (See “Pressure Flow Data Charts” in th
e
“Introduction” section.)

RMA-303 Direct Charge - Introduction
LN-9266-11.3 12
Mechanical (Continued)
Shaping Air #2 (SAO) Supply: Variable (See “Pressure Flow Data Charts” in th
e
“Introduction” section.)
Brake Air Supply (Nominal): 60-100 psig (414-689 kPa)
Maximum Fluid Pressure Supply
Paint
:
200 psi (1379 kPa)
Solvent
:
150 psi (1035 kPa)
Fluid Flow Rate
:
25-700 cc/min. (300 cc/min. maximum for 30mm Bell Cup)
Bell Cup Cleaning Time
(Internal/External)
:
2.7 sec. (approx.)
Color Change Time
:
Dependent on system configuration, fluid pressures, flui
d
viscosity, fluid line lengths, etc.
Speed Readout: Magnetic pick-up, unidirectional fiber 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 LECU5004-17 (V.3.84)
Atomizer Module A11925-00 (V.0.4)
I/O Module A11435-00 (V.1.4) (0.01V) (4-20 mA)
* Specifications and ratings based on testing at sea level standard conditions.

RMA-303 Direct Charge - Introduction
13 LN-9266-11.3
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.
Bell Cup Part Numbers/Serial Number
(cup only, not with splash plate)
Atomizer Serial Number
Turbine Serial Number

RMA-303 Direct Charge - Introduction
LN-9266-11.3 14
Graphical information provided for reference only for all charts. Unless otherwise specified,
all pressure data shown was measured 12-inches (305mm) behind the applicator.
GRAPHS

RMA-303 Direct Charge - Introduction
15 LN-9266-11.3

RMA-303 Direct Charge - Introduction
LN-9266-11.3 16

RMA-303 Direct Charge - Introduction
17 LN-9266-11.3