Ransburg RMA-303 User manual

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
LN-9259-07.1
Replaces LN-9259-07
April - 2013
RMA-303 INDIRECT / RMA-303 DIRECT
EVOLVER 303 / EVOLVER NE
TEST STATIONS
Service Manual Price: $30.00 (U.S.)
TURB I NE S.A.O./FAN
S.A.I./ATOM
DESC
MANUFACTURER
CAT
MANUFACTURER
CAT DESC
16 016 0
DESC
MANUFACTURER
CAT
100 100100 100 100
BEAR I N G AIR

LN-9259-07.1

LN-9259-07.1
1-4
SAFETY:
PAGE
SAFETYPRECAUTIONS............................................................................................................
HAZARDS / SAFEGUARDS.......................................................................................................
1-2
3-4
CONTENTS
MAINTENANCE: 21-22
INTRODUCTION:
GENERAL INFORMATION.........................................................................................................
SPECIFICATIONS.......................................................................................................................
FEATURES..................................................................................................................................
5-8
5
5
6-7
9-20
OPERATION:
RMA TEST PROCEDURE..........................................................................................................
INITIAL TEST SETTIN
GS............................................................................................................
TESTTRIGGERS........................................................................................................................
TURBINE TEST.........................................................................................................................
..
9
9-10
11-14
15-16
16-17
17-19
WARRANTY POLICIES: 23
Test Stations - Contents
LIMITED WARRANTY................................................................................................................. 23
MAINTENAN 21

LN-9259-07.1
SAFETY
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety litera-
ture for your Ransburg products. This manual
contains information that is important for you to
know and understand. This information relates to
USER SAFETY and PREVENTING EQUIPMENT
PROBLEMS. To help you recognize this informa-
tion, we use the following symbols. Please pay
particular attention to these sections.
A WARNING! states information to alert you to a
situation that might cause serious injury if instruc-
tions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard specications
and service procedures, some minor deviations
may be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements,
etc., make such variations inevitable. Compare
this manual with your system installation drawings
and appropriate 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 ef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 representa-
tive or Ransburg.
SAFETY PRECAUTIONS
> The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
> This manual MUSTbe read and thoroughly
understood by ALL personnel who operate,
clean or maintain this equipment! Special
care should be taken to ensure that the
WARNINGS and safety requirements for
operating and servicing the equipment are
followed. The user should be aware of and
adhere to ALL local building and re codes
and ordinances as well as NFPA-33 SAFETY
STANDARD, prior to installing, operating,
and/or servicing this equipment.
W A R N I N G
>The hazards shown on the following page
may occur during the normal use of this
equipment. Please read the hazard chart
beginning on page 3.
W A R N I N G
Test Stations - Safety
1

LN-9259-07.1
> The high voltage is interlocked electri-
cally with the uid trigger switches. When
a uid switch is triggered on, the HV will
automatically be turned off.
> Wear the proper safety protection such as
eye and ear protection.
> NEVER wear loose clothing while working
around the applicator.
> NEVER run the applicator with anyone near
the bell. Serious injury COULD OCCUR if
the bell is contacted while it is rotating.
> NEVER stop the rotation of the bell by
hand. Use the manual air brake supplied
on the test stand panel.
> Ensure ALL items in the test area are
grounded. Ensure there are NO open contain-
ers of ammable materials in the test area.
W A R N I N G
NOTES
N O T E
Test Stations - Safety
2

LN-9259-07.1
Test Stations - Safety
Fire Hazard
Improper or inadequate op-
eration and maintenance
procedures will cause a re
hazard.
Protection against inadver-
tent arcing that is capable
of causing re or explosion
is lost if any safey interlocks
are disabled during opera-
tion. Frequent power supply
shutdown indicates a problem
Fire extinguishing equipment must be present in
the spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray
area.
The high voltage supplied to the atomizer must
be turned off prior to cleaning, ushing, or main-
tenance.
When using solvents for cleaning:
Those used for equipment ushing should have
ash points equal to or higher than those of the
coating material.
Those used for general cleaning must have ash
points above 100 ° F (37.8 ° C).
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 ammable or com-
bustible 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 modications may cause re or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
Never use equipment intended for use in wa-
terborne 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.
Spray Area
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
3

LN-9259-07.1 4
Test Stations - Safety
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
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, re protection, opera-
tion maintenance, and housekeeping. Reference
OSHA, NFPA-33, and your insurance company
requirements.
General Use and
Maintenance
Electrical
Equipment
High voltage equipment is uti-
lized. Arcing in areas of am-
mable or combustible materi-
als may occur. Personnel are
exposed to high voltage during
operation and maintenance.
Protection against inadvertent
arcing that may cause a re
or explosion is lost if safety
circuits are disabled during
operation.
Frequent power supply shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause
a re or explosion.
The power supply, optional remote control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas (refer to NFPA-33).
Turn the power supply OFF before working on
the equipment.
Test only in areas free of ammable or combustible
material.
Testing may require high voltage to be on, but
only as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.

LN-9259-07.1
INTRODUCTION
SPECIFICATIONS
Electrical / Physical
GENERAL INFORMATION
The Ransburg Applicator Performance Test Stand
was developed to assist in determining the appli-
cator’s level of performance in an off-line condi-
tion. (Ensuring the applicator functions properly
after any maintenance has been performed to it
and reduces the costs associated with verifying
performance during production.) With line speeds
critical to the through-put of a facility, every uptime
minute counts to underwrite protability. This
Test Stand device helps to ensure the applicator
performs correctly when it is put into service.
This Test Stand will verify performance of single
or dual uid applicators, bearing air, shaping air,
brake air, turbine drive air, and ber optic func-
tionality. As well, it checks kV and µA electrical
performance of the applicator.
The Test Stand was developed with the user and
the safety of the user in mind. The user must
become familiar with the overall function and
operation of the unit.
Air Requirements: 1-inch NPT(F) Inlet
3/4-inch ID Air Line to Stand
100 psi (6.4 bar) minimum
30 SCFM
0.3 to 0.6 Micron Filtration
Dimensions
Height: 67-inch (1702cm)
Width: 30-inch (762cm)
Length: 48-inch (1219cm)
Fluids: Use distilled or deionized
water only for testing.
Maximum Fluid
Pressure: 80 psi (5.2 bar)
N O T E
> For all test station toggle switches, with the
switch lever in the “UP” position, the valve it
describes is “ON” or “actuated.”
Test Stations - Introduction
5

LN-9259-07.1
100 100 100
16 016 0
100 100
BEARI NGAIR
DESC
MANUFACTURER
CAT
MANUFACTURER
CAT DESC
TURB I NE S.A.O./FAN
S.A.I./ATOM
Figure 1a: Basic Station Features
Test Stations - Introduction
6
FEATURES
1 Main Control Panel
2 Air Flow Meters
3 Test Applicator
4 Table
5 Pressure Pot
6 Dump Bucket
7 High Voltage Cascade
8 Air Filter

LN-9259-07.1
Test Stations - Introduction
7
Figure 1b: Basic Station Features
1 Power Control - On/Off Button
2 Main Air Gauges - Leak Down, Supply Air
3 Fiber Optic Voltage Readout
4 Air Flow Meter - Atom Air
5 Air Flow Meter - Outer Shaping Air
6 Air Flow Meter - Bearing Air
7 Air Flow Meter - Inner Shaping Air
8 Fluid Enable - Paint In, Cup Wash Solvent
In, Cup Wash Air In
9 Atomizer Speed Select Card
10 Atomizer Card
11 MicroPak Power Supply
12 Applicator Enable, Paint Trigger, Cup Wash
Solvent, Cup Wash Air, Dump
13 Regulated Function Gauges - Bearing Air,
Outer Shaping Air, Inner Shaping Air
14 High Voltage - On/Off Switch
TUR B I NE S.A.O./FAN
S.A.I./ATOM
DESC
MANUFACTURE R
CAT
MANUFACTURE R
CAT DESC
16 016 0
DESC
MANUFACTURE R
CAT
10 0 10 010 0 10 0 10 0
BE A R I NG A I R

LN-9259-07.1
Test Stations - Introduction
8
NOTES

LN-9259-07.1
1. Ensure that ground connections, cart ground,
and applicator ground are made to a true earth
ground.
OPERATION
W A R N I N G
> If true earth ground is not made, injury
to personnel or serious damage may occur
to the equipment.
> Ensure ALL items in the test area are
grounded. Ensure there are NO open
containers of ammable materials in the
test area.
> NEVER use solvent as a test uid for this
device!
> Using any material OTHER than distilled
water or de-ionized water may cause re
during the test. Use only distilled water or
de-ionized to test the applicator.
W A R N I N G
N O T E
> When opening dump valve for any test,
hold tubing securely by hand or clamp to
prevent whipping.
RMA TEST PROCEDURE
Setup
2. Provide air ltration to the manifold that has
the capability of passing 30 SCFM with particulate
removal of .3 to .6 micron particle size (bearing
air ltration is provided with the stand).
3. Provide a minimum 3/4-inch ID air line to the
lter at the manifold inlet. A minimum of 100 psig
pressure is required at the manifold inlet.
4. Install water supply line and air pressure line
to the pressure pot.
5. Fill the pressure pot liner with approximately
one (1) gallon of either de-ionized or distilled
water.
6. Plug the unit into a suitable 110/120V outlet.
INITIAL TEST SETTINGS
1. High voltage is off unless instructed to turn on.
Main power off.
Test Stations - Operation
9
N O T E
> Refer to the applicator service manual
for all parts and part number identications.

LN-9259-07.1
2. Fluid enable off (toggle switch lever in the
down position).
3. Attach the applicator to the Test Stand bracket
with three (3) M10 screws (78268-00).
4. Connect tubing from the Test Stand to the ap-
plicator as labeled.
5. Supply 100 psig air pressure to the stand,
reference supply air gauge on panel. If required,
adjust air input regulator attached to stand.
6. Set speed select to 00.
7. Adjust bearing air regulator to 90 psig mini-
mum.
10 0
Test Stations - Operation
10

LN-9259-07.1
Test Stations - Operation
11
TEST TRIGGERS
1. Ensure uid supply is OFF.
2. Turn “uid” switch to AIR.
5. Toggle on the “Dump” switch; air should be
escaping from the “Dump Port” of the applicator.
Turn off the “Dump” switch.
3. Toggle the “Paint Fluid Enable” switch on (up)
to supply air pressure to the applicator.
4. Toggle on the “Paint Trigger” switch; air should
be escaping from the feed tube. Turn off the
“Paint Trigger”.
6. Toggle “Paint Fluid Enable” switch to the off
(down) position.
7. Turn on the “Cup Wash Air” switch, now turn on
the “Bell Solvent” trigger, air should be escaping
from the feed tube and cup wash spout. Turn off
the “Cup Wash Air” trigger and the “Cup Wash
Air In” switch.
8. Turn on the “Cup Wash Solvent” switch, air
should be escaping from the feed tube and cup
wash spout. Turn off the “Cup Wash Solvent” and
“Cup Wash Solvent In”.

LN-9259-07.1
Test Stations - Operation
12
Air Test
1. Turn the “Fluid” switch to “Air” then “Off” to
pressurize the system.
2. Observe the leak test gauge. The pressure
must not drop more than 2 psi in 10 seconds.
16 0
3. Open the “Dump” to de-pressurize the system
and turn off all of the trigger valves. Switch the
“Dump” to “Off”
4. Turn the “Fluid Air” regulator to 0 psig. Open
the manual relief valve on the pressure pot. Turn
all switches off. Ensure “Fluid Enable” switches
are all off.
10 0
Static Decay / Water
Pressure Test
The purpose of this test is to verify that each of the
valves in the applicator will pass uid. Also, this
test veries all seals along the uid passages have
been properly installed to prevent any leakage.
1. Ensure all toggle switches are set to the “off”
or “down” position.
2. Position the applicator where any water
sprayed out of the bell may be collected and
properly disposed of.
3. Verify there is no residual pressure in the
pressure pot included with the test stand. Turn
the regulator dial on the pressure pot counter-
clockwise until all pressure is released. Pull the
bleed-off valve to release any remaining pressure.

LN-9259-07.1
Test Stations - Operation
13
> Never use solvent as a test uid for
this device.
W A R N I N G
4. Loosen the pressure pot clamps until the lid
may be removed from the pot. Fill the pressure
pot with de-ionized or distilled water.
5. Close the lid, tighten the lid clamps so that the
lid is secure and no air pressure may escape.
6. Turn the “Fluid” switch to “Water” position.
7. Turn the “Fluid Air” regulator to the pressure
pot to 80 psi.
8. Make sure the dump line is secured in the buck-
et and the dump valve is in the “Open” position.
9. Turn on “Paint Fluid Enable” and cup wash
“Solvent Fluid Enable” in the Fluid Enable section.

LN-9259-07.1
Test Stations - Operation
14
10. Activate the “dump” trigger until the air is
completely purged from the manifold. You will see
water running from the dump output. Turn the
“Dump” switch off which will stop the water ow.
Turn “Fluid” switch to “off”. Leak gauge should
stay at pressure.
11. Observe the applicator for any possible water
leakage, wait 3 minutes. No seepage is allowed.
12. If leak is found, turn the “Fluid” switch to “Air”
and activate the dump until all water is evacu-
ated. Turn “Fluid” switch to “Off”. Repair leak
and repeat the test.
13. If no leak is found, turn the “Fluid” switch to
“Air”. Open the dump to purge out the water.
14. When all water has been evacuated, close
the dump, turn off all switches and turn the “Fluid”
switch to “Off”.
Shaping Air Consumption Test (Inner and
Outer)
1. Reduce the turbine speed from 70k to 30k rpm.
2. Turn on the “Shaping Air” dial and adjust the
outer shaping air to 60 psi. Reference the shaping
air gauge for the correct pressure reading. Ensure
no air leak is present between the shaping air cap
and shroud. If present, inspect the assembly.
3. Look at the shaping air ow meter. It should
be reading 10-13 CFM (outer) and 10-13 CFM
(inner). Make sure the ow meter regulator is
10 010 0 10 010 0
adjusted to 100 psi input pressure.
4. Readjust the shaping air dial to 25 psi. Refer-
ence shaping air gauge for the correct pressure
reading.
5. Look at the shaping air ow meter. It should
be reading 4-7 CFM (outer) and 4-7 CFM (inner).
Make sure the ow meter regulator is adjusted to
100 psi input pressure.
6. Turn off the “Shaping Air” dial.
T UR B I NE S . A. O. /FAN
S.A.I./ATOM
B E AR I NG AI R

LN-9259-07.1
Bearing Air / Drive Air Test
This test is to verify the applicator responds to
changes in setpoints in the speed selector.
1. Raise the safety spin guard and lock it in place
with the pin.
N O T E
> Bell cup and shroud must be attached
to end of turbine.
TURBINE TEST
The purpose of this test is to verify the applica-
tor rotates properly and sprays reasonably well.
With de-ionized or distilled water as the test uid
it is difcult to accurately assess the spray per-
formance characteristics. However, it can give a
relative indication of how well the bell will spray
in production.
Test Stations - Operation
15
2. Adjust the air regulator for bearing air to 90
psig minimum.
3. The turbine shaft must rotate freely with bear-
ing air supplied.
4. Set the atomizer speed select to 30,000 rpm.
5. Toggle “Enable 1” “On” or in the “Up” position
on the atomizer speed select card. Then press
the “Speed Enter” button. The turbine should now
begin spinning. This should be audible.
6. Adjust the speed select to 50,000 rpm. Press
the “Speed Enter” button to enter the new speed.
An audible difference in speed should be de-
tected. Adjust the speed again to 70,000 rpm
and press “Speed Enter” to enter the new speed.
7. Observe the atomizing air gauge. At 70,000
rpm the air consumption should not exceed 17.0
SCFM.
Brake Test
1. Re-adjust the turbine speed select card to
70k rpm.
2. Set the atomizer speed card to 1k rpm. (Do not
activate this speed until the next step.)
3. Using a stop watch to time the brake speed,
press the atomizer speed card button and watch
the time it takes for the applicator to reach 1k rpm.
4. Brake time should NOT exceed 14 seconds.

LN-9259-07.1
Test Stations - Operation
16
Fiber Optic Transceiver Test
1. While the turbine is spinning observe the “Fiber
Optic Transceiver Voltage” display. The voltage
must be greater than .75mV.
2. If the voltage is out of range, there are several
> During any part of the turbine tests
where the applicator bell is rotating, DO
NOT come near or in contact with the
spinning bell. Because of the bell rota-
tional speed, injury can easily occur.
Locate the bell in a posiiton where mini-
mal exposure to anyone passing by may
come in contact with the spinning bell.
> NEVER use any uid other than
distilled or de-ionized water to test the
applicator performance. Using any
other material will cause a risk of re or
severe personal injury.
W A R N I N G
!
HIGH VOLTAGE TEST
In-Direct Charge Test
(70kV Maximum)
1. Install the high voltage cable to the high voltage
ring and cascade as prescribed in the applica-
tor service manual. Ensure all components are
properly grounded.
2. Install the ground cable into the HV/GND port
of the mounting manifold.
3. Turn on the main power to the MicroPak.
possible causes. The most likely are:
a. Transmitter inside the bell is bad or is
positioned incorrectly. (Refer to the
RMA- 303 service manual
for instructions to cor- rect
the problem.)
b. Transmitter (75911) or cable (SMC-424-
XX) is not properly connected or may be
broken.
3. On the atomizer speed select card, toggle the
“Enable 1” switch “Off” or “Down”.
4. Stop the spinning turbine shaft by pressing
the manual brake button on the front panel of the
test station. Do not allow the turbine to spin in
the reverse direction or it may damage the unit.
N O T E
> If these are bad, the applicator most
likely will not rotate because the atomizer
card will shut the air to the turbine off.
> DO NOT use your hand or any object
to stop bell cup rotation.
W A R N I N G
!
> DO NOT hold manual brake button in
below 5k rpm.
C A U T I O N
!
N O T E
> Ensure all personnel near the eld are
grounded.
Display should be reading 00 on the kV and µA
display.
4. Turn on the “kV Enable” switch. kV should be
reading what has been set by adjusting the dial.
5. Using the High Voltage Test Probe (76634-00)
check the actual voltage from the high voltage ring

LN-9259-07.1
Test Stations - Operation
17
Bleed Air Test (Volume)
N O T E
> Ensure that the regulator at the ow
meter is set at 100 psi.
1. Verify “Bell/Applicator” switch is in the applica-
tor position.
EVOLVER NE TEST
PROCEDURE
Direct Charge Test
(90kV Maximum)
1. Install the high voltage cable to the applicator
and cascade as described in the applicator ser-
vice manual. Ensure all components are properly
grounded.
2. Turn on the main power to the MicroPak.
Display should be reading 00 on the kV and µA
display.
2. Turn up “Fan Air Control” knob on the panel
until there is 50 psi owing on the fan air/outer
shaping air gauge.
10 010 0
Air Operation
1. Connect the “Test Air Cap” to the spray head.
Toggle the “Applicator Trigger” switch on.
by placing the High Voltage Test Probe on the high
voltage ring probe tips. Test probe display should
match the MicroPak display.
6. Turn off the power supply to the MicroPak.
N O T E
> Ensure all personnel near the eld are
grounded.
3. Turn on the “kV Enable” switch. kV should be
reading what has been set by adjusting the dial.
4. Using the High Voltage Test Probe (76634-
00) check the actual voltage from the applicator
by placing the High Voltage Test Probe on the
bell cup. Test probe display should match the
MicroPak display.
5. Turn off the power supply to the MicroPak.