Ransburg Rea User manual

TECHNICAL MANUAL

IL-246-BIL-246-B

IL-246-B

(Replaces IL-246-A)

January - 2008

IMPORIMPOR

IMPORTT

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 instarting on page 1, and all instructions in

starting on page 1, and all instructions in

this manual. Keep this Tthis manual. Keep this T

this manual. Keep this Technical Manualechnical Manual

echnical Manualechnical Manual

echnical Manual

for future reference.for future reference.

for future reference.

ITW RANSBURGITW RANSBURG

ITW RANSBURG

REA™ AND VECTREA™ AND VECT

REA™ AND VECTOR™OR™

OR™OR™

OR™

APPLICAAPPLICA

APPLICATT

TORSORS

ORSORS

ORS

ELECTROSTELECTROST

ELECTROSTAA

ATICTIC

TICTIC

TIC

SPRASPRA

SPRAYY

TECHNIQUESTECHNIQUES

TECHNIQUES

Technical Manual Price:echnical Manual Price:

echnical Manual Price:echnical Manual Price:

echnical Manual Price: €15.00 Euro)15.00 Euro)

15.00 Euro)15.00 Euro)

15.00 Euro)

$20.00 (U.S.)$20.00 (U.S.)

$20.00 (U.S.)

IL-246-B

NOTE:NOTE:

NOTE: This manual has been changed from IL-246-AIL-246-A

IL-246-AIL-246-A

IL-246-A to revision IL-246-B.IL-246-B.

IL-246-B.IL-246-B.

IL-246-B. Reasons for this

change are noted under “Manual Change Summary” inside the back cover of this manual.

IL-246-B

REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:

REA AND VECTOR APPLICATOR SPRAY TECHNIQUES:

USE THE RIGHT TECHNIQUE.................................................................................................

FAN CONTROL..........................................................................................................................

PATTERN....................................................................................................................................

FLAT SURFACES.......................................................................................................................

HORIZONTAL PASSES.............................................................................................................

VERTICAL PASSES...................................................................................................................

APPLICATOR TO TARGET DISTANCE...................................................................................

OVERLAP....................................................................................................................................

TRIGGERING.............................................................................................................................

LARGE OBJECTS......................................................................................................................

TUBULAR WORK.......................................................................................................................

RECESSED AREAS...................................................................................................................

SUMMARY..................................................................................................................................

SAFETY REQUIREMENTS........................................................................................................

PAGEPAGE

PAGE

CONTENTSCONTENTS

CONTENTS

1-111-11

1-11

9-10

REA/Vector Applicators Spray Techniques

IL-246-B

REA/Vector Applicators Spray Techniques

Before operating, maintaining, or servicing any ITW Ransburg electrostatic coating system, read and

understand all of the technical and safety literature provided with ITW Ransburg products. If you do not

have the manuals and safety literature for your ITW Ransburg system, contact your ITW Ransburg

representative.

USE THE RIGHT TECHNIQUESUSE THE RIGHT TECHNIQUES

USE THE RIGHT TECHNIQUES

REA/VREA/V

REA/Vector (Electrostatic) Applicatorsector (Electrostatic) Applicators

ector (Electrostatic) Applicatorsector (Electrostatic) Applicators

ector (Electrostatic) Applicators

Savings of 25% to 50% in paint is possible when you replace conventional air spray with ITW Ransburg

Electrostatic Applicators. You finish curved and recessed surfaces uniformly in fewer passes, because

combined air and electrostatic forces literally follow the shape of the work surface. Bounce losses from

work are reduced by the electrostatic attraction, when proper techniques are used.

The following describes basic electrostatic spray techniques. Depending on the type of work being

sprayed, it may be necessary to change the technique slightly.

IL-246-B

REA/Vector Applicators Spray Techniques

FAN CONTROLAN CONTROL

AN CONTROLAN CONTROL

AN CONTROL

The size of the object being coated is the determining factor in adjusting the fan pattern; the larger the

object, the larger the required fan pattern. Fan control of the ITW Ransburg REA/Vector applicators is

accomplished by rotating the adjusting knob located at the rear of the applicator. Fan width can be set

for approximately a 3-inch width (minimum) to approximately a 14-inch (maximum). Fan widths and

overall pattern appearances are illustrated.

Minimum

Maximum

PAA

ATTERNTTERN

TTERNTTERN

TTERN

POOR PATTERNPOOR PATTERN

POOR PATTERN

Dirty, worn, or

damaged nozzle.

Clean or replace.

SPLIT PATTERNSPLIT PATTERN

SPLIT PATTERN

Fan too wide - narrow

adjustment slightly.

GOODGOOD

GOOD

PATTERNPATTERN

PATTERN

ABB

BCC

> The degree of atomization is dependent

on the viscosity of the paint formulation, the

applied air pressure, and nozzle selection.

NOTENOTE

NOTE

IL-246-B

REA/Vector Applicators Spray Techniques

HORIZONTHORIZONT

HORIZONTALAL

ALAL

AL PASSESPASSES

PASSESPASSES

PASSES

The spray applicator should be maintained in a

position at right angles to the object and should be

moved in a path parallel to the object.

VERTICAL PASSESVERTICAL PASSES

VERTICAL PASSES

There may be instances where it is more practical

to coat an object using vertical passes rather than

horizontal. First, rotate the nozzle to shift the fan

pattern, then holding the applicator at right angles

to the object, move the applicator in a straight

vertical path as illustrated.

FLAFLA

FLATT

TSURFSURF

SURFSURF

SURFACESACES

ACESACES

ACES

One of the most prevalent of "bad" spray painting

habits is the one where the operator holds his arm

steady and swings his wrist back and forth. This

is a hard habit to break, it gives the illusion of

adding speed to the coating operation, when in

reality, it is slower and much more inefficient.

Spray painting in this fashion results in light films

on both sides, excessive film at center, and

increased overspray with excessive "bounce-

back."

IL-246-B

REA/Vector Applicators Spray Techniques

>The object being coated is maintained at

groundpotential,thesprayapplicator operator

is also grounded, therefore, the operator has

as much attraction for the electrostatic paint

as the object. To prevent "wrapback" always

keep the applicator closer to the target than it

is to you.

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

C A U T I O N

APPLICAAPPLICA

APPLICATT

TOR TOR T

OR TOR T

OR TOO

TARGETARGET

ARGETARGET

ARGET DISTDIST

DISTDIST

DISTANCEANCE

ANCEANCE

ANCE

The distance between the applicator and the target

influences the appearance of the final finish coating

of the object. If the applicator is held too close

(under 4-inches), runs and sags with the

excessive bounce-back can occur. If the

applicator is held too far from the object, the

electrostatic attraction is decreased. Normally,

the best spacingbest spacing

best spacingbest spacing

best spacing between applicator and target

is in the 4 to 12-inch area.4 to 12-inch area.

4 to 12-inch area.4 to 12-inch area.

4 to 12-inch area. However, this

distance can vary with extremely high delivery

systems. Maximum target distance should not

exceed 12-inches.

Too FarToo Far

Too Far

4" to 6"4" to 6"

4" to 6"

Under 2"Under 2"

Under 2"

IL-246-B

REA/Vector Applicators Spray Techniques

> If front and back are both sprayed, there

may be enough wrap using Technique B or

C to coat a small edge or flange. If wide

flanges are to be coated, this may require

individual coating of edges before the flat

surfaces are sprayed.

NOTENOTE

NOTE

OVERLAPOVERLAP

OVERLAP

For best hiding and uniformity of film thickness, stroke overlap should be approximately 50%. There

should be some overlap at the top and bottom of the part to increase edge coverage. Overlap

requirements can vary widely with different paint formulations and different compositions of objects

being coated. Individual spray coating operational experience should provide the guidelines for

efficiency in this instance.

TRIGGERINGTRIGGERING

TRIGGERING

Applicator triggering (ON/OFF) depends largely on the desired results; the amount of wraparound

required, edge coating, etc. If front and back of the object are being coated, proper applicator technique

can effect edge coating (in some instances) without making a specific pass for this purpose. Examples

of different trigger times and the results that can be expected are illustrated.

A. Little or no wrap - incomplete coverage

B. Fair - some wrap

C. Good wrap (Triggered 2" to 3" past edge)

D. Too much overstroke may produce heavy

edges and produce more overspray.

DCC

CBB

BAA

(Trigger Off)

TOP VIEW

IL-246-B

REA/Vector Applicators Spray Techniques

LARGE OBJECTSLARGE OBJECTS

LARGE OBJECTS

BlendingBlending

Blending

If the size of the object is greater than the spray

applicator operator can reach, it should be coated

in segments, the size of each segment being the

length the spray applicator operator can

comfortably span. Each segment should be

blended with the adjacent segment using

"feathering" or "over-lapping" strokes. A slight

angle of the applicator improves the results of the

"blending" pass.

TOP VIEW TOP VIEW

>Too much overlap can result in runs and

sags or excessive film, where segments

blend together.

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

C A U T I O N

IL-246-B

REA/Vector Applicators Spray Techniques

> Avoid applicator to targe distances of

over 12-inches, excessive applicator to tar-

get distances will result in wrapback.

NOTENOTE

NOTE

TUBULAR WORKTUBULAR WORK

TUBULAR WORK

Tubular parts or objects up to approximately 2-1/2" diameter can be coated successfully from one side,

utilizing wraparound characteristics and proper techniques.

A. Wrong fan position - little wrap. Heavy film on front surface,

possible sags.

B. Correct fan position - better wrap. More accurately con-

trolled film. Normally fan pattern should be slightly wider

than parts being sprayed.

C. Correct fan position but excessively wide fan may produce

more overspray if used in this position.

D. A wide fan tilted at an angle may also work well. (Wide fans

have slower forward velocity.)

SUGGESTION:SUGGESTION:

SUGGESTION: Small tubes may be racked in groups to simulate larger targets. This allows the use

of wider fans and may help improve efficiency.

↑↑

↑

↓↓

↓

FAN POSITION

(Example 1"

Diameter Part)

MOTION

Adjust the fan for a pattern

width slightly wider than the

object. This allows some

coating material to start

around the sides of the

object.

Increase the applicator to target

distance to approximately 10-

12-inches. This will decrease

the speed of the paint particles

in the vicinity of the target.

Hold the applicator at an angle

of 30o to 45oto the object. This

will direct paint more to target

area.

IL-246-B

REA/Vector Applicators Spray Techniques

RECESSED AREASRECESSED AREAS

RECESSED AREAS

Do not depend on electrostatic attraction alone for coating recessed areas, remember, the more

exposed areas of the object have a stronger attraction for charged paint formulations than the recessed

areas, therefore, the electrostatically charged paint particles will take the path of least resistance, and

tend to build excessively on the more exposed areas.

The best and most efficient technique is to coat the recessed areas first, utilizing air pressure to drive

the paint into difficult areas or by narrowing fan width to effectively increase delivery rate per inch of

pattern width. Then paint the more readily accessible areas, the electrostatic process with its

"wraparound" and "opposite attraction" characteristics will probably have already partly coated these

areas.

DIFFICULT

→←

EASY

A. Voltage by itself will not pull paint into deep

recesses, but instead, paint will be attracted

to more exposed edges.

Solution:

Move in closer and use the ad-

vantages of air atomization to drive paint

into recesses.

NOTE:NOTE:

NOTE: Narrower fan may also be helpful.

C. Doing the outside of the part first puts little

paint on the inside. If we now coat the inside,

we will be double coating the edges

and possibly overload them.

D. In this example, we coat the difficult area

first. We may then find that there was enough

wrap around from overspray to coat much of

the remaining areas.

IL-246-B

REA/Vector Applicators Spray Techniques

Adjust fan pattern in accordance with size of

object to be coated.

Never swing spray applicator in an arc, hold

applicator steady in a position at right angles to

the object and move applicator in a straight path

parallel to object.

Be sure applicator is held closer to object being

coated than to the operator.

Stroke overlap of approximately 50% normally

produces adequate film thickness uniformity.

SUMMARYSUMMARY

SUMMARY

IL-246-B

REA/Vector Applicators Spray Techniques

1010

For most economical and efficient coating, trigger

applicator "ON" just before leading edge of object,

trigger applicator "OFF" just after trailing edge of

target. For best wraparound technique, trigger

applicator "ON" 3-inches before, and "OFF" 3-inches

after edges of target.

When painting large objects a section at a time, use

"feather" stroke for blending sections together. Avoid

excessive overlap to prevent runs and sags with

excessive film thickness.

Tubular component coating; adjust fan width for a

pattern slightly wider than the object, hold applicator

10 to 12-inches from object at an angle of 30 to 45-

inches. Move applicator straight in a parallel path with

the object.

Paint "hard to reach" areas first, let wraparound and

electrostatic attraction get the "easy" areas for you.

ON OFF

IL-246-B

REA/Vector Applicators Spray Techniques

1111

SAFETYSAFETY

SAFETY

REQUIREMENTSREQUIREMENTS

REQUIREMENTS

PersonnelPersonnel

Personnel

• Operators must NOTNOT

NOTNOT

NOT wear gloves that

insulate them from the applicator handle.

• ALL personnel in the spraying area MUSTMUST

MUSTMUST

MUST

wear non-insulating shoes or alternative

grounding devices so they will be grounded

through the conductive floor. (See ITW

Ransburg "Personnel Grounding" Safety

Bulletin.)

• Personnelentering a waterborne paint isolation

enclosure MUSTMUST

MUSTMUST

MUST be sure that the system and

the Warning Light are OFF!OFF!

OFF!OFF!

OFF! The grounding

hook must be attached to the paint supply

BEFOREBEFORE

BEFORE contact, especially during the

addition of fluid! The gate MUSTMUST

MUSTMUST

MUST be closed

and the interlocks functioning during use. (See

the appropriate ITW Ransburg equipment

manual.)

• The operator MUSTMUST

MUSTMUST

MUST turn the power supply

OFFOFF

OFF before cleaning or servicing the

equipment.

•NEVERNEVER

NEVERNEVER

NEVER immerse an applicator in any liquid.

• Exhaust fans MUSTMUST

MUSTMUST

MUST be ONON

ONON

ON during spraying.

Environment and EquipmentEnvironment and Equipment

Environment and Equipment

• The spray booth (including its floor), paint

reservoir (except waterborne), and conveyor

MUSTMUST

MUST be grounded.

• An adequate, grounded, protective enclosure

that will assure safe isolation from personnel

must surround the supply of waterborne paints.

(See OSHA Standard 1910.107 (h) (10).)

• The spray target and all supporting holders,

hooks, and conveyors MUSTMUST

MUSTMUST

MUST be grounded to

the supporting structure. All support devices

MUSTMUST

MUST be free of accumulated coating

material.

• All conductive objects in the spraying area

MUSTMUST

MUST be removed or grounded.

• A pressure EXPLOSION may occur if

HALOGENATED HYDROCARBON solvents

are used in PRESSURIZABLE fluid systems

having ALUMINUM or GALVANIZED parts.

(See ITW Ransburg "Danger - Explosion

Hazard" and "Halogenated Hydrocarbon"

Safety bulletins.)

• The high voltage power supply MUSTMUST

MUSTMUST

MUST be

grounded and located outside of the Hazard

Area. (See the appropriate ITW Ransburg

equipment manual.)

• Appropriate, functioning fire extinguishing

equipment MUSTMUST

MUSTMUST

MUST be provided.

• Good housekeeping is essential to safe

operation. Cleanup and maintenance

schedules should be established by the user.

Maintenance and safety cards should be

posted in clear view of the operator.

• All flammable liquids MUSTMUST

MUSTMUST

MUST be in approved,

grounded safety containers. Not more than

one gallon should be in any container and the

total amount in the spray area should be no

more than the minimum required for the

operation.

• All applicators MUSTMUST

MUSTMUST

MUST be maintained within

proper operating limits. (See the appropriate

ITW Ransburg equipment manual for short

circuit current tests.)

IL-246-B

REA/Vector Applicators Spray Techniques

1212

NOTESNOTES

NOTES

IL-246-B

REA/Vector Applicators Spray Techniques

1313

NOTESNOTES

NOTES

IL-246-B

MANUALMANUAL

MANUAL CHANGE SUMMARCHANGE SUMMAR

CHANGE SUMMARCHANGE SUMMAR

CHANGE SUMMARYY

This manual was published to supercede

Technical Manual

IL-246-A, ITW RansburgIL-246-A, ITW Ransburg

IL-246-A, ITW Ransburg

REA/Vector Applicators Electro-Air SprayREA/Vector Applicators Electro-Air Spray

REA/Vector Applicators Electro-Air Spray

TechniquesTechniques

Techniques

, to make the following change:

1. Service literature was reformatted. Made

available electronically.

2. Added "Technical Manual Price: €15.00 (Euro)"

to the "Front and Back Covers".

3. Added "Vector Applicators" to the "Spray Tech-

niques".

4. New "Applicator Figures" throughout the service

literature.

5. Added "www.itwransburg.com" to "Contact

Information" on the back cover.

Form No. IL-246-B

Litho in U.S.A.

01/08

Models and specifications subject to change without notice.

ManufacturingManufacturing

Manufacturing

1910 North Wayne Street

Angola, Indiana 46703-9100

Telephone: 260/665-8800

Fax: 260/665-8516

Technical/Service Assistanceechnical/Service Assistance

echnical/Service Assistanceechnical/Service Assistance

echnical/Service Assistance

Automotive Assembly and Tier I Telephone: 800/ 626-3565 Fax: 419/ 470-2040

Industrial Systems Telephone: 800/ 233-3366 Fax: 419/ 470-2071

Ransburg Guns Telephone: 800/ 233-3366 Fax: 419/ 470-2071

www.itwransburg.com

Technical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephone

echnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephone

echnical Support Representative will direct you to the appropriate telephone

number for ordering Spare Parts.number for ordering Spare Parts.