Ransburg Rea-90 User manual

SERVICE MANUAL

AH-94-04.5AH-94-04.5

AH-94-04.5

(Replaces AH-94-04.4)

IMPORIMPOR

IMPORTT

TT

TANTANT

ANTANT

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

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

: Before using this equipment,

carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,

starting on page 1, and all instructions in thisstarting on page 1, and all instructions in this

starting on page 1, and all instructions in this

manual. Keep this Service Manual for futuremanual. Keep this Service Manual for future

manual. Keep this Service Manual for future

reference.reference.

reference.

Service Manual Price: $30.00 (U.S.)Service Manual Price: $30.00 (U.S.)

Service Manual Price: $30.00 (U.S.)

REA-90 and REA-90LREA-90 and REA-90L

REA-90 and REA-90L

ELECTROSTELECTROST

ELECTROSTAA

AA

ATIC SPRATIC SPRA

TIC SPRATIC SPRA

TIC SPRAYY

YY

YGUNSGUNS

GUNSGUNS

GUNS

Dual Atomization TDual Atomization T

Dual Atomization Technologyechnology

echnologyechnology

echnology

MODELS:MODELS:

MODELS:

75785 - ST75785 - ST

75785 - STANDARD (SOLANDARD (SOL

ANDARD (SOLANDARD (SOL

ANDARD (SOLVENTVENT

VENTVENT

VENT BASE)BASE)

BASE)BASE)

BASE)

75786 - ST75786 - ST

75786 - STANDARD (WANDARD (W

ANDARD (WANDARD (W

ANDARD (WAA

AA

ATERBORNE)TERBORNE)

TERBORNE)TERBORNE)

TERBORNE)

75979 - A75979 - A

75979 - AVIAVIA

VIAVIA

VIATT

TT

TOR/MGS (SOLOR/MGS (SOL

OR/MGS (SOLOR/MGS (SOL

OR/MGS (SOLVENTVENT

VENTVENT

VENT BASE)BASE)

BASE)BASE)

BASE)

75982 - A75982 - A

75982 - AVIAVIA

VIAVIA

VIATT

TT

TOR (WOR (W

OR (WOR (W

OR (WAA

AA

ATERBORNE)TERBORNE)

TERBORNE)TERBORNE)

TERBORNE)

NOTE:NOTE:

NOTE: This manual has been changed from revision AH-94-04.4AH-94-04.4

AH-94-04.4AH-94-04.4

AH-94-04.4 to revision AH-94-04.5AH-94-04.5

AH-94-04.5AH-94-04.5

AH-94-04.5.

Reasons for this change are noted under “Manual Change Summary” inside the back

cover of this manual.

AH-94-04.5

SAFETY:SAFETY:

SAFETY:

SAFETY PRECAUTIONS...........................................................................................................

HAZARDS / SAFEGUARDS......................................................................................................

PAGEPAGE

PAGE

INTRODUCTION:INTRODUCTION:

INTRODUCTION:

CONTENTSCONTENTS

CONTENTS

GENERAL DESCRIPTION.........................................................................................................

REA-90 WITH AVIATOR.............................................................................................................

75785 SOLVENT BASE REA-90 STANDARD &

75979 SOLVENT BASE REA-90 AVIATOR / MGS...................................................................

75786 WATERBORNE REA-90 STANDARD &

75982 WATERBORNE REA-90 AVIATOR................................................................................

INSTALLATION:INSTALLATION:

INSTALLATION:

75785 STANDARD SOLVENT BASE & 75979

AVIATOR / MGS SOLVENT BASE INSTALLATION................................................................

FILTERS......................................................................................................................................

75786 STANDARD WATERBORNE & 75982

AVIATOR WATERBORNE INSTALLATION.............................................................................

ISOLATION SYSTEM INSTALLATION GUIDELINES..............................................................

WATERBORNE HOSE FITTING INSTALLATION...................................................................

FLUID HOSE FITTING INSTALLATION....................................................................................

AIR HOSE FITTING INSTALLATION........................................................................................

PAINT PREPARATION..............................................................................................................

SPRAY TECHNOLOGY CONVERSION PROCEDURE.........................................................

SPRAY PATTERN ADJUSTMENT............................................................................................

GUN TO TARGET DISTANCE..................................................................................................

AIR CAP / FLUID NOZZLE SELECTION CHART....................................................................

AIR CAP / FLUID NOZZLE PERFORMANCE CHART............................................................

MAINTENANCE:MAINTENANCE:

MAINTENANCE:

SUITABLE SOLVENTS FOR CLEANING REA-90

HANDGUNS................................................................................................................................

ROUTINE SCHEDULE...............................................................................................................

HANDGUN ASSEMBLY CLEANING PROCEDURE................................................................

FLUSHING PROCEDURES.......................................................................................................

GUN REPAIR..............................................................................................................................

EQUIPMENT REQUIRED..........................................................................................................

TO REMOVE THE GUN FROM THE WORK SITE..................................................................

AIR CAP.......................................................................................................................................

FLUID NOZZLE...........................................................................................................................

NEEDLE / ELECTRODE.............................................................................................................

NEEDLE / ELECTRODE RESISTANCE TESTING..................................................................

1-71-7

1-7

8-138-13

8-13

14-2314-23

14-23

24-5724-57

24-57

1

2

8

9

10

12

14

15

16

17

18

19

20

21

22

23

24

25

26

28

29

31

32

33

REA-90 and 90L Spray Guns - Contents

(Continued On Next Page)(Continued On Next Page)

(Continued On Next Page)

AH-94-04.5

PARTS IDENTIFICATION:PARTS IDENTIFICATION:

PARTS IDENTIFICATION:

75785 SOLVENT BASE (STANDARD) AND 75979

SOLVENT BASE (AVIATOR / MGS) / MODEL

IDENTIFICATION / PARTS LIST............................................................................................

75786 WATERBORNE (STANDARD) AND 75982

WATERBORNE (AVIATOR) / MODEL

IDENTIFICATION / PARTS LIST............................................................................................

RECOMMENDED SPARE PARTS........................................................................................

MISC. PARTS..........................................................................................................................

SERVICE KITS........................................................................................................................

58-7158-71

58-71

58

64

70

71

WARRANTY POLICIES:WARRANTY POLICIES:

WARRANTY POLICIES: 7272

7272

72

LIMITED WARRANTY............................................................................................................. 72

REA-90 and 90L Spray Guns - Contents

PAGEPAGE

PAGE

APPENDIX:APPENDIX:

APPENDIX: 73-7673-76

73-7673-76

73-76

PAINT AND SOLVENT SPECIFICATIONS...........................................................................

VISCOSITY CONVERSION CHART.....................................................................................

VOLUMETRIC CONTENT OF HOSE OR TUBE..................................................................

73

74

76

MAINTENANCE: (continued)MAINTENANCE: (continued)

MAINTENANCE: (continued)

BARREL ASSEMBLY..............................................................................................................

HOOK / TRANSFORMER ASSEMBLY.................................................................................

HOOK / TRANSFORMER ON/OFF SWITCH

REPLACEMENT......................................................................................................................

HANDLE..................................................................................................................................

FAN AIR VALVE......................................................................................................................

AIR VALVE..............................................................................................................................

TRIGGER................................................................................................................................

NEEDLE SHAFT RETURN SPRING REPLACEMENT........................................................

LOW VOLTAGE CABLE PLUG ASSEMBLY

REPLACEMENT......................................................................................................................

LOW VOLTAGE CABLE REPLACEMENT............................................................................

FLUID TUBE (SOLVENT BASE GUNS)................................................................................

FLUID HOSE (SOLVENT BASE GUNS)...............................................................................

FLUID HOSE (WATERBORNE GUNS).................................................................................

AIR LINE..................................................................................................................................

FLUID TUBE BRACKET.........................................................................................................

TRIGGER ADJUSTMENT......................................................................................................

FAN AIR ADJUSTMENT.........................................................................................................

FLUID DELIVERY ADJUSTMENT.........................................................................................

ATOMIZING AIR ADJUSTMENT...........................................................................................

TROUBLESHOOTING GUIDE...............................................................................................

24-5724-57

24-57

33

39

41

42

43

44

45

46

47

48

49

50

52

53

54

55

AH-94-04.5

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

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 prod-

ucts. This manual contains information that is

important for you to know and understand. This

information 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 youA WARNING! states information to alert you

A WARNING! states information to alert you

to a situation that might cause serious injuryto a situation that might cause serious injury

to a situation that might cause serious injury

if instructions are not followed.if instructions are not followed.

if instructions are not followed.

A CAUTION! states information that tellsA CAUTION! states information that tells

A CAUTION! states information that tells

how to prevent damage to equipment orhow to prevent damage to equipment or

how to prevent damage to equipment or

how to avoid a situation that might causehow to avoid a situation that might cause

how to avoid a situation that might cause

minor injury.minor injury.

minor injury.

A NOTE is information relevant to the proce-A NOTE is information relevant to the proce-

A NOTE is information relevant to the proce-

dure in progress.dure in progress.

dure in progress.

While this manual lists standard specifications

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 draw-

ings and appropriate ITW Ransburg equipment

manuals to reconcile such differences.

Careful study and continued use of this manual

will provide a better understanding of the equip-

ment and process, resulting in more efficient op-

eration, 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 ITW Ransburg rep-

resentative or ITW Ransburg.

SAFETYSAFETY

SAFETY

REA-90 and 90L Spray Guns - Safety

> The user MUSTMUST

MUSTMUST

MUST read and be familiar

with the Safety Section in this manual and

the ITW Ransburg safety literature therein

identified.

>This manual MUSTMUST

MUSTMUST

MUST be read and thor-

oughly understood by ALLALL

ALLALL

ALL personnel who

operate, clean or maintain this equipment!

Special care should be taken to ensure that

the WARNINGSWARNINGS

WARNINGSWARNINGS

WARNINGS and safety requirements

for operating and servicing the equipment

are followed. The user should be aware of

and adhere to ALLALL

ALLALL

ALL local building and fire

codes and ordinances as well as NFPANFPA

NFPANFPA

NFPA

33 SAFETY STANDARD33 SAFETY STANDARD

33 SAFETY STANDARD, prior to

installing, operating, and/or servicing this

equipment.

> The hazards shown on the following

page may occur during the normal use of

this equipment. Please read the hazard

chart beginning on page 2.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

W A R N I N GW A R N I N G

W A R N I N G

!!

!

11

1

AH-94-04.5

REA-90 and 90L Spray Guns - Safety

AREAAREA

AREA

Tells where

hazards may occur.

HAZARDHAZARD

HAZARD

Tells what the hazard is.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

Tells how to avoid the hazard.

Spray AreaSpray Area

Spray Area Fire Hazard

Improper or inadequate opera-

tion 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. Frequent

power supply shutdown indicates

a problem in the system requir-

ing 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 maintenance.

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 100oF (37.8oC).

Spray booth ventilation must be kept at the rates

required by NFPA 33, OSHA and local codes. In

addition, ventilation must be maintained during

cleaning operations using flammable or combus-

tible solvents.

Electrostatic arcing must be prevented.

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 waterborne

installations to spray solvent based materials.

The paint process and equipment should be set up

and operated in accordance with NFPA 33, NEC, and

OSHA requirements.

22

2

Toxic SubstancesToxic Substances

Toxic Substances Certain material may be harmful

if inhaled, or if there is contact

with the skin.

Follow the requirements of the Material 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 pre-

scribed by an industrial hygienist or safety expert,

and be NIOSH approved.

AH-94-04.5

REA-90 and 90L Spray Guns - Safety

AREAAREA

AREA

Tells where

hazards may occur.

HAZARDHAZARD

HAZARD

Tells what the hazard is.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

Tells how to avoid the hazard.

ElectricalElectrical

Electrical

EquipmentEquipment

Equipment

High voltage equipment is uti-

lized. Arcing in areas of flam-

mable or combustible materials

may occur. Personnel are ex-

posed to high voltage during op-

eration 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 shutdown

indicates a problem in the sys-

tem which requires correction.

An electrical arc can ignite coat-

ing materials and cause a fire or

explosion.

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. (Exception: AVIATOR series guns) Refer

to NFPA 33.

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.

33

3

ExplosionExplosion

Explosion

Hazard /Hazard /

Hazard /

IncompatibleIncompatible

Incompatible

MaterialsMaterials

Materials

Halogenatedhydrocarbonsolvents,

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.

The REA-90 and REA-90L require that aluminum

inlet fittings be replaced with stainless steel. [See

accessories list] Aluminum is widely used in other

spray application equipment - such as material

pumps, regulators, valves, etc. Check all other

equipment items before use and make sure they

can also be used safely with these solvents. 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

material supplier. Any other type of solvent may

be used with aluminum equipment.

Intended UseIntended Use

Intended Use

(Waterborne Only)

Using coating materials and/or

cleaning and flushing solvents

which have flash points below

100

°

F (37.8

°

C) may cause a fire

hazard.

This system is intended for use with waterborne

coating formulations only.

Waterborne, waterbase and water reducible coat-

ings are considered the same. Although they may

not be highly flammable, their residues are consid-

ered combustible.

AH-94-04.5

REA-90 and 90L Spray Guns - Safety

44

4

AREAAREA

AREA

Tells where

hazards may occur.

HAZARDHAZARD

HAZARD

Tells what the hazard is.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

Tells how to avoid the hazard.

Spray AreaSpray Area

Spray Area Electrostatic Arcing Never operate the spray gun without properly

grounding the following.

A. Operators

Operators must be grounded. Rubber soled

insulating shoes should not be worn. Grounding

leg straps may be used.

Operators must maintain contact with the

handle of the gun. If work gloves are used, the

palm section should be cut out.

Operators must remove from themselves all

metal objects that are not grounded.

NOTE:NOTE:

NOTE: REFER TO NFPA 33 REGARDING

OPERATOR GROUNDING.

B. Parts being sprayed. Resistance between the

part and a grounded conveyor must not exceed

1 megohm.

C. Every metal and conductive object in the spray

area. This includes the booth, parts hangers,

fire extinguishers, conductive flooring, etc.

Grounded conductive flooring must be provided in

the spray area.

Turn off voltage at the power supply before flushing

out, cleaning, or removing any parts from the gun.

Provide proper protection for waterborne supply

systems.

Never install a spray gun into a fluid system using

an isolated solvent supply.

Always discharge Waterborne system capacitance

prior to servicing.

Do not touch gun electrode while gun is energized.

AH-94-04.5

REA-90 and 90L Spray Guns - Safety

55

5

AREAAREA

AREA

Tells where

hazards may occur.

HAZARDHAZARD

HAZARD

Tells what the hazard is.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

Tells how to avoid the hazard.

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.

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, and your insurance company re-

quirements.

Always turn power to the power supply OFF, un-

plug the electrical cord from its outlet, and remove

the front panel fuse, before opening the power sup-

ply door. If necessary, lock the power supply out

so that it cannot be turned ON until the work is fin-

ished.

Whenever removing high voltage cables from

equipment, ground the contact end of the cable by

holding the cable such that the contact touches

earth ground for several seconds. Do not touch

the contact until it has been grounded. This will

reduce the possibility of residual charge causing

electrical shock.

The High Voltage Multiplier Assembly contains en-

ergy storage components that can cause serious

shock injury, and therefore is not field repairable.

Warranty will be voided if the High Voltage Multi-

plier seal is broken. If the High Voltage Multiplier

is defective contact your authorized ITW Ransburg

representative for exchange or repair.

The High Voltage Multiplier and high voltage cable

contain significant capacitance that will store

charge. Allow approximately 10 seconds for this

charge to bleed off before opening the cabinet door

or removing the high voltage cable from the power

supply or spray gun.

General Use andGeneral Use and

General Use and

MaintenanceMaintenance

Maintenance

AH-94-04.5

REA-90 and 90L Spray Guns - Safety

66

6

AREAAREA

AREA

Tells where

hazards may occur.

HAZARDHAZARD

HAZARD

Tells what the hazard is.

SAFEGUARDSSAFEGUARDS

SAFEGUARDS

Tells how to avoid the hazard.

Use of hand tools may cause

cumulative trauma disorders

(CTD's). CTD's or musculoskel-

etal disorders, involve damage to

the hands, wrists, elbows, shoul-

ders, neck and back. Carpal

tunnel syndrome and tendinitis

(such as tennis elbow or rotator

cuff syndrome) are examples of

CTD's.

CTD's when using hand tools,

tend to affect the upper extremi-

ties. Factors which may in-

crease the risk of developing a

CTD include:

1. High frequency of the activity.

2. Excessive force, such as

gripping, pinching or pressing

with the hands and fingers.

3. Extreme or awkward finger,

wrist or arm positions.

4. Excessive duration of the

activity.

5. Tool vibration.

6. Repeated pressure on a

body part.

7. Working in cold temperatures.

Risk is reduced by avoiding or lessening the listed

hazards.

CTD's can also be caused by such activities as

sewing, golf, tennis and bowling, to name a few.

Pain, tingling, or numbness in the shoulder, fore-

arm, wrists, hands, or fingers, especially during the

night, may be early symptoms of a CTD. Do not

ignore them. Should you experience any such

symptoms, see a physician immediately. Other

early symptoms may include vague discomfort in

the hand, loss of manual dexterity, and nonspecific

pain in the arm. Ignoring early symptoms and con-

tinued repetitive use of the arm, wrist and hand can

lead to serious disability.

General Use andGeneral Use and

General Use and

MaintenanceMaintenance

Maintenance

AH-94-04.5

REA-90 and 90L Spray Guns - Safety

77

7

NOTES:NOTES:

NOTES:

AH-94-04.5

GENERAL DESCRIPTIONGENERAL DESCRIPTION

GENERAL DESCRIPTION

The REA process is an air-atomized method for

electrostatically applying coatings to objects.

The REA handgun system (technology) applies

a high voltage DC charge to the applicator elec-

trode, creating an electrostatic field between the

atomizer and the target object.

The REA-90 or REA-90L Delta Electrostatic

Spray Guns (see Figures 1 and 2) applies a -85

kV DC charge to the coating materials at the

point of atomization. This electrostatic charge

allows a more efficient, uniform application of

coating material to the front, edges, sides, and

back of products. It is highly suitable for apply-

ing coatings to a variety of surface configura-

tions: large targets, small parts, tubular wares,

concave and recessed parts, etc. Because it is

a grounded fluid system (for solvent based sys-

tems), it is highly suitable for applying a wide

range of solvent reduced coatings such as

enamels, lacquers, epoxies, etc. The 75786

and 75982 models are available to accommo-

date waterborne materials.

The REA-90 and REA-90L electrostatic spray

guns are transformable between air spray and

HVLP spray technology. The REA-90 is de-

signed for use as a conventional air spray (high-

pressure) or high volume/low-pressure (HVLP)

air spray to atomize the coating material. By

changing a select few parts, the gun may be

transformed to be operated in either spray

mode. (See "Spray Technology Conversion

Procedure" for details.)

A regulated pressure fluid system delivers coat-

ing material to the atomizer. At the time of trig-

gering the applicator, fan and atomization air is

introduced, which atomizes the coating material

into a spray mist. The atomized spray particles

under the influence of the electrostatic field be-

come electrically charged. The charged par-

ticles are attracted to, and deposited on, the tar-

INTRODUCTIONINTRODUCTION

INTRODUCTION

REA-90 and 90L Spray Guns - Introduction

88

8

get object. The forces between the charged

particles and the grounded target are sufficient

to turn most normal overspray around and de-

posit it on the back surface of the target. There-

fore, a high percentage of the coating is depos-

ited on the target.

One of the many features of the REA handgun

system is that the electrical energy, which is

available from the resistive charging electrode,

is limited to the optimum level of safety and effi-

ciency.

This system is incapable of releasing sufficient

electrical or thermal energy during normal oper-

ating conditions to cause ignition of specific

hazardous materials in their most easily ignited

concentrations in air (See NFPA 33 Regula-

tions).

The control unit provides low voltage output to

the gun and contains controls for AC on/off, high

voltage adjust, kV and micro amp meter.

As the gun electrode approaches ground, the

control unit and gun circuitry cause the high

voltage and current to “fold back” and decrease

towards zero for models 75785, 75979, and

75982. For models 75786, the fold back cir-

cuitry in the control unit has been turned off to

provide maximum voltage for waterborne appli-

cations.

> Never use a standard solvent base

handgun system (75785 or 75979) on a

standard waterborne control unit. Failure

to comply may cause damage to equip-

ment and/or risk of fire and injury.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

> Never use a waterborne (75786 or

75982) REA-90 system to spray solvent

reduced coating materials. Failure to

comply may cause damage to equipment

and/or risk of fire and injury.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

AH-94-04.5

REA-90 and 90L Spray Guns - Introduction

99

9

> When more than one waterborne gun

is fed from a common isolated supply,

there is a potential for electrical energy

discharge through any other guns when

one gun is triggered. Depending upon the

system capacity, this discharge could be

hazardous.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

REA-90 WITH AREA-90 WITH A

REA-90 WITH AVIAVIA

VIAVIA

VIATT

TT

TOROR

OROR

ORTMTM

TMTM

TM

The REA-90 may be used with the AVIATOR

power generator in hazardous locations. This

equipment meets Class 1, Division 1, and

Group D hazardous location requirements. This

allows moving the REA-90 power source inside

most spray booths or areas where the standard

control unit may not be conveniently located.

Examples are airplane hangars, etc.

NOTES:NOTES:

NOTES:

AH-94-04.5

REA-90 and 90L Spray Guns - Introduction

1010

10

SPECIFICASPECIFICA

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

MechanicalMechanical

Mechanical

Fluid FlowFluid Flow

Fluid Flow

Capacity:Capacity:

Capacity: 1000 cc/minute**

Operating Pressure (Air Spray)Operating Pressure (Air Spray)

Operating Pressure (Air Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 16 CFM @ 50 psi

Operating Pressure (HVLP Spray)Operating Pressure (HVLP Spray)

Operating Pressure (HVLP Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 22 CFM @ 50 psi

(handle input) for 10 psi

nozzle output

** This reflects the maximum fluid volume the gun

can deliver. The maximum spray volume that can

be atomized depends on fluid rheology, spray tech-

nology, and finish quality required.

Environmental / PhysicalEnvironmental / Physical

Environmental / Physical

Gun Length:Gun Length:

Gun Length: 11 inches

Weight:Weight:

Weight: 28 ounces

Hose & CableHose & Cable

Hose & Cable

Lengths:Lengths:

Lengths: 36 ft (Optional: 50, 75,

and 100 ft)

AtomizerAtomizer

Atomizer

Assembly (Std):Assembly (Std):

Assembly (Std): 4907-45, 4904-65R Air Spray

75601-00, 75600-01 HVLP

ElectricalElectrical

Electrical

Operating Voltage:Operating Voltage:

Operating Voltage: 85 kV DC (-) maximum

Current Output:Current Output:

Current Output: 90microamperes maximum

(foldback)

Paint Resistance:*Paint Resistance:*

Paint Resistance:* .1 MΩto ∞

**

*(Use Model No. 76652, Test Equipment)

Part Sprayability:Part Sprayability:

Part Sprayability: Determine sprayability of

part to be coated using

76652, Test Equipment

(see TE-98-01).

75785 SOL75785 SOL

75785 SOLVENTVENT

VENTVENT

VENT BASEBASE

BASEBASE

BASE

REA-90 STREA-90 ST

REA-90 STANDARDANDARD

ANDARDANDARD

ANDARD

SPECIFICASPECIFICA

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

75979 SOL75979 SOL

75979 SOLVENTVENT

VENTVENT

VENT BASEBASE

BASEBASE

BASE

REA-90 AREA-90 A

REA-90 AVIAVIA

VIAVIA

VIATT

TT

TOR/MGSOR/MGS

OR/MGSOR/MGS

OR/MGSTMTM

TMTM

TM

MechanicalMechanical

Mechanical

Fluid FlowFluid Flow

Fluid Flow

Capacity:Capacity:

Capacity: 1000cc/minute**

Operating Pressure (Air Spray)Operating Pressure (Air Spray)

Operating Pressure (Air Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 16 CFM @ 50 psi

Operating Pressure (HVLP Spray)Operating Pressure (HVLP Spray)

Operating Pressure (HVLP Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 22 CFM @ 50 psi

(handle input) for 10 psi

nozzle output

** This reflects the maximum fluid volume the gun

can deliver. The maximum spray volume that can

be atomized depends on fluid rheology, spray tech-

nology, and finish quality required.

Environmental / PhysicalEnvironmental / Physical

Environmental / Physical

Gun Length:Gun Length:

Gun Length: 11 inches

Weight:Weight:

Weight: 28 ounces

Hose & CableHose & Cable

Hose & Cable

Lengths:Lengths:

Lengths: 36 ft (Optional: 50, 75,

and 100 ft)

AtomizerAtomizer

Atomizer

Assembly (Std):Assembly (Std):

Assembly (Std): 4907-45, 4904-65R Air Spray

75601-00, 75600-01 HVLP

ElectricalElectrical

Electrical

Operating Voltage:Operating Voltage:

Operating Voltage: 85 kV DC (-) maximum

Current Output:Current Output:

Current Output: 90microamperes maximum

(foldback)

Paint Resistance:*Paint Resistance:*

Paint Resistance:* .1 MΩto ∞

**

*(Use Model No. 76652, Test Equipment)

Part Sprayability:Part Sprayability:

Part Sprayability: Determine sprayability of

part to be coated using

76652, Test Equipment

(see TE-98-01).

AH-94-04.5

REA-90 and 90L Spray Guns - Introduction

1111

11

Figure 1: REA-90 and REA-90L Standard & AVIATOR/MGS SolventborneFigure 1: REA-90 and REA-90L Standard & AVIATOR/MGS Solventborne

Figure 1: REA-90 and REA-90L Standard & AVIATOR/MGS Solventborne

Electrostatic Spray Gun FeaturesElectrostatic Spray Gun Features

Electrostatic Spray Gun Features

GUN:GUN:

GUN:

REA-90 (75785S & 75979S)

REA90L (75785L & 75979L)

AH-94-04.5

REA-90 and 90L Spray Guns - Introduction

1212

12

MechanicalMechanical

Mechanical

Fluid FlowFluid Flow

Fluid Flow

Capacity:Capacity:

Capacity: 1000 cc/minute**

Operating Pressure (Air Spray)Operating Pressure (Air Spray)

Operating Pressure (Air Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 16 CFM @ 50 psi

Operating Pressure (HVLP Spray)Operating Pressure (HVLP Spray)

Operating Pressure (HVLP Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 22 CFM @ 50 psi

(handle input) for 10 psi

nozzle output

** This reflects the maximum fluid volume the gun

can deliver. The maximum spray volume that can

be atomized depends on fluid rheology, spray tech-

nology, and finish quality required.

Environmental / PhysicalEnvironmental / Physical

Environmental / Physical

Gun Length:Gun Length:

Gun Length: 11 inches

Weight:Weight:

Weight: 28 ounces

Hose & CableHose & Cable

Hose & Cable

Lengths:Lengths:

Lengths: 36 ft (Optional: 50 and 75 ft)

AtomizerAtomizer

Atomizer

Assembly (Std):Assembly (Std):

Assembly (Std): 4907-45, 4904-65R Air Spray

75601-00, 75600-01 HVLP

ElectricalElectrical

Electrical

Operating Voltage:Operating Voltage:

Operating Voltage: 85 kV DC (-) maximum

Current Output:Current Output:

Current Output: 150 microamperes maximum

(no foldback)

Part Sprayability:Part Sprayability:

Part Sprayability: Determine sprayability of

part to be coated using

76652, Test Equipment

(see TE-98-01).

SPECIFICASPECIFICA

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

75786 W75786 W

75786 WAA

AA

ATERBORNETERBORNE

TERBORNETERBORNE

TERBORNE

REA-90 STREA-90 ST

REA-90 STANDARDANDARD

ANDARDANDARD

ANDARD

SPECIFICASPECIFICA

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

75982 W75982 W

75982 WAA

AA

ATERBORNETERBORNE

TERBORNETERBORNE

TERBORNE

REA-90 AREA-90 A

REA-90 AVIAVIA

VIAVIA

VIATT

TT

TOROR

OROR

OR

MechanicalMechanical

Mechanical

Fluid FlowFluid Flow

Fluid Flow

Capacity:Capacity:

Capacity: 1000cc/minute**

Operating Pressure (Air Spray)Operating Pressure (Air Spray)

Operating Pressure (Air Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 16 CFM @ 50 psi

Operating Pressure (HVLP Spray)Operating Pressure (HVLP Spray)

Operating Pressure (HVLP Spray)

Fluid:Fluid:

Fluid: 0-100 psi

Air:Air:

Air: 0-100 psi

Consumption:Consumption:

Consumption: 22 CFM @ 50 psi

(handle input) for 10 psi

nozzle output

** This reflects the maximum fluid volume the gun

can deliver. The maximum spray volume that can

be atomized depends on fluid rheology, spray tech-

nology, and finish quality required.

Environmental / PhysicalEnvironmental / Physical

Environmental / Physical

Gun Length:Gun Length:

Gun Length: 11 inches

Weight:Weight:

Weight: 28 ounces

Hose & CableHose & Cable

Hose & Cable

Lengths:Lengths:

Lengths: 36 ft (Optional: 50 and 75 ft)

AtomizerAtomizer

Atomizer

Assembly (Std):Assembly (Std):

Assembly (Std): 4907-45, 4904-65R Air Spray

75601-00, 75600-01 HVLP

ElectricalElectrical

Electrical

Operating Voltage:Operating Voltage:

Operating Voltage: 85 kV DC (-) maximum

Current Output:Current Output:

Current Output: 90microamperes maximum

(foldback)

Part Sprayability:Part Sprayability:

Part Sprayability: Determine sprayability of

part to be coated using

76652, Test Equipment

(see TE-98-01).

AH-94-04.5

REA-90 and 90L Spray Guns - Introduction

1313

13

Figure 2: REA-90 and REA-90L Standard & AVIATOR WaterborneFigure 2: REA-90 and REA-90L Standard & AVIATOR Waterborne

Figure 2: REA-90 and REA-90L Standard & AVIATOR Waterborne

Electrostatic Spray Gun FeaturesElectrostatic Spray Gun Features

Electrostatic Spray Gun Features

GUN:GUN:

GUN:

REA-90 (75786S & 75982S)

REA90L (75786L & 75982L)

AH-94-04.5

REA-90 and 90L Spray Guns - Installation

INSTINST

INSTALLAALLA

ALLAALLA

ALLATIONTION

TIONTION

TION

75785 ST75785 ST

75785 STANDARDANDARD

ANDARDANDARD

ANDARD

SOLSOL

SOLVENTVENT

VENTVENT

VENT BASE &BASE &

BASE &BASE &

BASE &

75979 A75979 A

75979 AVIAVIA

VIAVIA

VIATT

TT

TOR/MGSOR/MGS

OR/MGSOR/MGS

OR/MGS

SOLSOL

SOLVENTVENT

VENTVENT

VENT BASEBASE

BASEBASE

BASE

INSTINST

INSTALLAALLA

ALLAALLA

ALLATIONTION

TIONTION

TION

1414

14

> Installation of the equipment MUST be in

compliance with all Federal, State, and Local

Codes. Prior to installation, all personnel

should read and understand the National

Fire Protection Association Bulletin No. 33,

the Occupational Safety and Health Act of

1970, and ITW Ransburg Bulletin IL-247

"Operating Your Electrostatic Coating

System Safely".

W A R N I N GW A R N I N G

W A R N I N G

!!

!

> Do NOT overtighten the low voltage

connection at the handgun. The plastic

parts could be damaged.

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

C A U T I O N

!!

!

Location of Control UnitLocation of Control Unit

Location of Control Unit

(Non-A(Non-A

(Non-AVIAVIA

VIAVIA

VIATT

TT

TOR Units)OR Units)

OR Units)OR Units)

OR Units)

Install the low voltage control unit at least 3 feet

(0.9m) outside the spray area and/or in accor-

dance with federal, state, and local codes. Re-

fer to the low voltage control unit manual for

mounting details. The control unit can be wired

through conduit or with a line cord depending

upon application requirements and codes.

The control unit MAY be connected through

conduit to an explosion-proof switch (to turn

high voltage on and off) and explosion-proof in-

dicator light (indicates status of control unit)

within the hazardous area for the convenience

of the operator.

Location of Control UnitLocation of Control Unit

Location of Control Unit

(A(A

(AVIAVIA

VIAVIA

VIATT

TT

TOR Units)OR Units)

OR Units)OR Units)

OR Units)

The AVIATOR may be located within the haz-

ardous area. It may be mounted on a booth

wall, pump cart, or other suitable places. Refer

to the AVIATOR Power Generator manual, CP-

97-01, for details on its installation.

The air supply to the AVIATOR Power Genera-

tor must be interlocked with the exhaust air for

the spray area. If a conveyor system is used,

then the air supply must be interlocked with it

also.

Routing of Low VRouting of Low V

Routing of Low Voltage Cableoltage Cable

oltage Cableoltage Cable

oltage Cable

Position the spray gun in the spray area and

route the low voltage cable to the control unit.

The cable should be routed so that it is not dam-

aged by foot and vehicle traffic and also so that

it is not close to areas of high temperature

(129oF+). The operator should have free move-

ment of the gun and all bend radius of the cable

should not be less than 6 inches (15 cm). Con-

nect the low voltage cable to the control unit and

hand tighten the retaining nut. If during the rout-

ing of the low voltage cable it is required to re-

move it from the spray gun, care should be

taken when reinstalling it back that the retaining

nut is wrench tight and the nut cannot be re-

moved by hand.

> NEVERNEVER

NEVERNEVER

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 applica-

tor components may occur. WRAPPINGWRAPPING

WRAPPINGWRAPPING

WRAPPING

THE APPLICATOR IN PLASTIC WILLTHE APPLICATOR IN PLASTIC WILL

THE APPLICATOR IN PLASTIC WILL

VOID WARRANTY.VOID WARRANTY.

VOID WARRANTY.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

AH-94-04.5

REA-90 and 90L Spray Guns - Installation

1515

15

> The electrical discharge that is available

from the charging electrode must not

exceed 0.25 mJ of energy. To achieve this

limit, any flow of energy from the paint

supply through the paint line to the gun

electrode must be prevented by grounding

the paint line at the gun handle.

Verify that the gun handle is actually

grounded before operating it! This is done

with a fully connected and operational sys-

tem, by placing one lead of an ohmmeter to

the handle and the other to the building

electrical ground (cold water pipe, building

structure, steel, etc.). This reading should

be essentially zero.

If a greater reading is obtained, check that

the control unit is grounded. See the con-

trol unit manual for grounding procedure.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

FILFIL

FILTERSTERS

TERSTERS

TERS

1. Install an air filter assembly on the air

inlet of the control unit. Screw the fitting

into the filter inlet. The filter MUST be

installed with the arrow pointing in the

direction of flow. Refer to the appropri-

ate filter assembly manual for installation

instructions.

> When installing the AVIATOR Power

Generator, the air supply to the generator

must be interlocked with the booth exhaust

air and the conveyor system.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

Figure 3: Typical REA Handgun InstallationFigure 3: Typical REA Handgun Installation

Figure 3: Typical REA Handgun Installation 2. ITW Ransburg recommends that a fluid

filter be installed at the output of the fluid

supply (pressure pot, pump, circulating

system, etc.). It is the end users re-

sponsibility to install a filter that meets

their system's requirements.

> An air filter MUST be installed to permit

proper functioning of the air flow switch

inside the control unit.

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

C A U T I O N

!!

!

AH-94-04.5

REA-90 and 90L Spray Guns - Installation

1616

16

75786 ST75786 ST

75786 STANDARDANDARD

ANDARDANDARD

ANDARD

WW

WAA

AA

ATERBORNE &TERBORNE &

TERBORNE &TERBORNE &

TERBORNE &

75982 A75982 A

75982 AVIAVIA

VIAVIA

VIATT

TT

TOROR

OROR

OR

WW

WAA

AA

ATERBORNETERBORNE

TERBORNETERBORNE

TERBORNE

INSTINST

INSTALLAALLA

ALLAALLA

ALLATIONTION

TIONTION

TION

> Installation of the equipment MUST be in

compliance with all Federal, State, and

Local Codes. Prior to installation, all per-

sonnel should read and understand the

National Fire Protection Association Bulletin

No. 33, the Occupational Safety and Health

Act of 1970, and ITW Ransburg Bulletin IL-

247 "Operating Your Electrostatic Coating

System Safely".

> The control unit MUST be located

outside of the spray area.

> The fluid lines and fluid sources MUST

be isolated from ground.

> Personnel MUST be GROUNDED to

prevent a shock or spark during electro-

static operation.

> Install and route the hoses and cable so

they are NOT exposed to temperatures in

excess of 120o F and so that all hose and

cable bends are NO LESS than a 6-inch

(15cm) radius. Failure to comply with these

parameters could cause equipment mal-

function that might create HAZARDOUS

CONDITIONS!

> Install only one spray gun per isolated

fluid supply system.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

Location of Control UnitLocation of Control Unit

Location of Control Unit

(Non-A(Non-A

(Non-AVIAVIA

VIAVIA

VIATT

TT

TOR Units)OR Units)

OR Units)OR Units)

OR Units)

Position the low voltage control unit at least 3

feet (0.9m) outside the spray area and in accor-

dance with federal, state, and local codes. Re-

fer to the low voltage control unit manual for

mounting details. The control unit can be wired

through conduit or with a line cord depending

upon application requirements and codes.

The control unit MAY be connected through

conduit to an explosion-proof switch (to turn

high voltage on and off) and explosion-proof in-

dicator light (indicates status of control unit)

within the hazardous area for the convenience

of the operator.

Location of Control UnitLocation of Control Unit

Location of Control Unit

(A(A

(AVIAVIA

VIAVIA

VIATT

TT

TOR Units)OR Units)

OR Units)OR Units)

OR Units)

The AVIATOR may be located within the haz-

ardous area. It may be mounted on a booth

wall, pump cart, or other suitable places. Refer

to the AVIATOR Power Generator manual, CP-

97-01, for details on its installation.

The air supply to the AVIATOR Power Genera-

tor must be interlocked with the exhaust air for

the spray area. If a conveyor system is used,

then the air supply must be interlocked with it

also.

Routing of Low VRouting of Low V

Routing of Low Voltage Cableoltage Cable

oltage Cableoltage Cable

oltage Cable

Position the spray gun in the spray area and

route the low voltage cable to the control unit.

The cable should be routed so that it is not dam-

aged by foot and vehicle traffic and also so that

it is not close to areas of high temperature

(129oF+). The operator should have free move-

ment of the gun and all bend radius of the cable

should not be less than 6 inches (15 cm). Con-

nect the low voltage cable to the control unit and

hand tighten the retaining nut. If during the rout-

ing of the low voltage cable it is required to re-

move it from the spray gun, care should be

taken when reinstalling it back that the retaining

nut is wrench tight and cannot be removed by

hand.

> NEVERNEVER

NEVERNEVER

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 applica-

tor components may occur. WRAPPINGWRAPPING

WRAPPINGWRAPPING

WRAPPING

THE APPLICATOR IN PLASTIC WILLTHE APPLICATOR IN PLASTIC WILL

THE APPLICATOR IN PLASTIC WILL

VOID WARRANTY.VOID WARRANTY.

VOID WARRANTY.

W A R N I N GW A R N I N G

W A R N I N G

!!

!

Ransburg REA-90 User manual

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