SAMES KREMLIN SRV 028-2-TWIN 60 User manual

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Sames
INSTRUCTION MANUAL
SRV 028-2-TWIN 60°- STD US
SPRAY GUN (Ang)
855 457
The information and characteristics given in this user manual are not binding and SAMES reserves the right to modify its models.
established by : checked by : checked by : approved by :
SAIA Sa. DI GIOIA M. GOISOT G. VEYRAT D.
Nature of the modification : Added plate CO2-1.
From February 1st, 2017 SAMES Technologies SAS becomes SAMES KREMLIN SAS
A partir du 1/02/17, SAMES Technologies SAS devient SAMES KREMLIN SAS

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TABLE OF CONTENTS Page
1. DESCRIPTION.............................................................................................................................4
2. INSTALLATION............................................................................................................................7
3. COMMISSIONING.......................................................................................................................9
4. MAINTENANCE..........................................................................................................................10
5. TROUBLESHOOTING................................................................................................................11
6. SPARE PARTS :
- BF1-3 - SRV 028-2 / UHT 151 RM / BSR 164-P / US.................................................................12
- BF1-4 - SRV 028-2 / UHT 151 RM / BSR 164-P / US.................................................................13
- BF2-3 - DISMANTLING AND RE-ASSEMBLY OF THE SRV 028-2-TWIN 60°SPRAY GUN....14
- BF2-4 - DISMANTLING AND RE-ASSEMBLY OF THE SRV 028-2-TWIN 60°SPRAY GUN....15
- BF3-1 - SRV 028 / BSR 164-PI / US SPRAY GUN - 855 459.................................................... 16
- BF4-1 - DISMANTLING AND RE-ASSEMBLY OF THE SRV 028-2 (US) SPRAY GUN............ 17
- BF5 - REPLACEMENT OF LOW VOLTAGE CABLE OR SOCKET........................................... 18
- BF6-1 - INTERNAL CONNECTIONS OF THE SRV 028-2 SPRAY GUN...................................19
- CO1-1 - HIGH VOLTAGE UNIT 151-RM - 757 474.................................................................... 20
- CO2-1 - CONNECTION DIAGRAM : SRV 028-2 SPRAY GUN / UHT 151- RM.........................21

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Fig. 1.
1.2 - TECHNICAL SPECIFICATIONS
1.2.1 - High Voltage Generator
• Max. supply voltage................................................................................. 22 V.
• Max. supply current................................................................................. 0.8 A.
• Max. output voltage................................................................................100 kV.
• Max. output current................................................................................ 200 µA.
• Polarity..................................................................................................negative.
1 - DESCRIPTION
1.1 - OVERVIEW
(Refer to Fig.1)
The SRV 028-2Twin 60°spray gun comprises the following elements:
• two SRV 028 guns [A],
• a high voltage generator [B],
• the linking cable [C] which links the GND 504-B unit (not described in the documentation) to the
high voltage generator,
• pneumatic pipes (diam. 5/6 mm) and powder feed pipes (diam.10/14).
Sames
A
B
C

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1.2.2 - SRV 028 Guns
• Max. recommended powder flow.......................................25 kg/h/gun (i.e. 50 kg/h/2 guns).
• Max. recommended output current...................................... 30 µA/gun (i.e. 60 µA/2 guns).
1.2.3 - Dimensions
(Refer to Fig.2)
• Length of powder spray gun..............................................................................375 mm.
• Distance between spraying point to spray gun axis ..........................................92 mm.
• SRV 028 gun orientation ...................................................................................60°.
Fig. 2.
60°
92
375

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1.3 - Operating Principle of Powder Spray Gun
(Refer to Fig.3)
The SRV 028-2-Twin 60°spray gun operates on the "corona" effect principle. An ionizing electrode [A]
located at the end of the spray gun and is connected to a high negative potential. Air is ionized by the
electrode which is surrounded by the intense electric field.
The emitted ions follow the magnetic field pattern and reach the part being painted. Powder is charged
when it passes through the ionized electric field.
In order to ensure that the powder sticks to the part being painted, the latter must be a good conductor
(or semi-conductor) and properly earthed (the electrical resistance of the part, in relation to the earth
must be less than 1 MΩ).
The high voltage generator is integral with the spray gun.
Fig. 3.
A

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2 - INSTALLATION
2.1 - SAFETY RULES
IMPORTANT NOTE..............This spray gun is only for use with
powder paints.
Use of the powder spray gun must comply with the safety precautions specified in this manual
(refer to articles R233-140 to R233-150 of the Code of Labour Law on paint booths and
powdering).
1 - The spray gun should only be used by trained personnel who are fully aware of the safety
rules specified in this section.
2 - Powder spraying must be conducted in a specially designed and correctly ventilated booth.
The logic control system must link the extractor fan system and the spraying equipment in
such a way as to ensure that spraying is only possible when the extractor fan system is
running.
3 - All conducting material located in the proximity of the spray gun (including, in particular, the
parts being painted) must be connected to the earth associated with the electrical power
supply.
4 - The electrical resistance of all parts for painting, in relation to the earth must be less than or
equal to 1 MΩ.
5 - The spraying equipment must be regularly maintained, in line with the instructions in the
manual. Any repair work must fully comply with the guidelines provided by the manufacturer
of the material.
6 - The high voltage current power supply must be turned off before starting to clean the spray
guns.
2.2 - INSTALLING THE EQUIPMENT
Care should be taken to ensure that the equipment is installed in compliance with the safety rules
specified in section 2.1.

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Fig. 4.
Sames
4
1
2
3

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3 - COMMISSIONING
3.1 - PREPARING THE SPRAY GUN
(Refer to Fig.4)
• Fasten the socket [1] of the electrical power supply cable onto the fixed flange [2]. Check
socket orientation (contact marks in front of plug contacts of plug [3] installed in the mobile
flange [4].
• Connect the pneumatic and powder feed pipes onto the fixed flange [2]. Fasten the fixed flange
onto the adapter flange [5].
3.2 - OPERATION AND SETTINGS
The SRV 028-2-Twin 60°powder spray gun should be installed 150 to 300 mm from the part to be
painted.
Voltage adjustments are described in the instructions manual of the GND 504-B control unit (see
RT 6017 manual).
CAUTION : Current consumption with the SRV 028-2-Twin 60°spray gun should never
exceed 30 µA per gun (i.e. 60 µA for two guns) during spraying. Higher current
consumption would result in fouling of the electrode and will cause loss of
efficiency of the spray gun.

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MAINTENANCE FREQUENCY
4 - MAINTENANCE
4.1 - PERIODICAL MAINTENANCE AND CHECK-UPS
IMPORTANT :All cleaning work should be carried out using compressed air, rags or if necessary
brushes.
Water should NEVER be used.
Spray gun soiling and wear, caused by powder flow, clearly depends on the type of powder used.
The guidelines as to cleaning and maintenance frequency provided in the table below can only be
taken as an indication of what is required.
Users of SAMES equipment should develop their own maintenance programmes.
As a first approach we recommend the following programme :
ACTION
• Before starting work.
• Every day.
• Between 150 and 300 hours (or more).
• Check rules 3, 4 and 6 of section 2.1.
• Remove the nozzles from the SRV 028 spray
gun and clean the electrode with a brush.
• Clean the nozzles with compressed air.
• Replace the nozzle if grooves are visible inside
nozzle.
4.2 - DISMANTLING AND RE-ASSEMBLY (GENERAL)
Dismantling and re-assembly of these complex assemblies are described in Chapter 6.
Easy and frequent component dismantling :
• SRV 028 spray gun (refer to plate BF4-1).

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5 - TROUBLESHOOTING
• Powder flow stopped.
• Powder flow impossible,
zero current even with the
trigger pulled.
• The quantity of powder is
insufficient.
• The powder does not adhere
to the parts.
• Incorrect assembly.
• Incorrect spray gun setting.
• Excess generator intensity.
• Incorrect spray gun setting.
• The parts being painted are not
properly connected to the earth.
• The ionizing electrode is covered
with powder.
• The voltage is too low.
• Check that installation and
connections comply with guide
lines in chapters 2 and 3.
• Follow instructions in section 3.2.
• Check rules 3, 4 and 6 in section
2.1.
• Cut power supply, then power up
again.
• Follow instructions in section 3.2.
• Check that the electrical resistance
of the parts, in relation to the earth
is less than 1 MΩ.
• Clean the electrode and check that
output current is < 30 µA for flat-jet
nozzles.
• Increase the voltage, and make
sure output current is < 30 µA/gun
(i.e. 60 µA for two guns).
SYMPTOMS PROBABLE CAUSES REMEDIES

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9
2
8
21
20
23
6
13
4
5
3
See view B
16
15
17
2
14
24
25
2
1
26
6. SPARE PARTS
SRV 028-2 / UHT 151 RM / BSR 164-P / US
45
48
49
50
47
19
23
16 20
21
50 47
46
13
26
6
View A : fitting the
UHT on its support
support
51

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SRV 028-2 / UHT 151 RM / BSR 164-P / US
Item SAMES Description Qty Sale
code unit
855 457 SRV 028-2 / UHT 151 RM / BSR 164-P / US 1
1• 546 440 Powder socket 2 1
2• 449 161 Short powder inlet piece 2 1
3• 855 459 SRV 028 spray gun with BSR 164-P nozzle 21
4• 855 461 Manifold with vortex 1 1
5•• F6R PUK 316 Ø 4 x 6 - 1/8" G union 2 1
6• 855 463 Mobile flange with vortex 1 1
7•• 546 442 Powder inlet end piece 2 1
8•• J3E TOR 020 O-ring Ø 10 x 2.5 2 2
9•• J3E TOR 004 O-ring Ø 4.2 x 1.9 3 1
12 •• F6R PUK 316 Ø 4 x 6 - 1/8" G union 2 1
13 • 855 465 Fixed flange with vortex 1 1
14 •• F6R AUR 083 Ø 2.7 x 4 - M 5 union 1 1
15 •• F6R PUK 316 Ø 4 x 6 - 1/8" G union 2 1
16 • 757 474 UHT 151 - RM (see plate CO1-1) 11
17 • 756 639 5 contacts female plug (with wires) 1 1
18 • 544 476 5 contacts male plug (without wires) 1 1
19 • 428 858 UHT bracket 1 1
20 • 428 881 Shell 1 1
21 • 416 792 Cover 1 1
23 • X9N VCB 221 Screw C M 6 x 10 nylon 2 1
24 • X9N VCB 226 Screw C M 6 x 20 nylon 2 1
25 • X9S VCB 183 Screw C M 5 x 15 glass fiber 2 1
26 • 744 633 Stainless steel Q/D nut 1 1
45 • X9N VFB 183 Screw FB M 5 x 16 - nylon 1 10
46 • X4F VSY 186 Screw CHc M 5 x 20 - Stainless steel 6 10
47 • X4F VSY 184 Screw CHc M 5 x 16 - Stainless steel 3 10
48 • X2B VKY 118 Screw SCR M 4 x 10 4 10
49 • J2C RAN 041 Sealing washer 4 4
50 • 438 704 Cover 1 1
51 • X4F VSY 184 Screw CHc M 5 x 16 - Stainless steel 2 10
7
VIEW B
12
6
18 19 26
51

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DISMANTLING AND RE-ASSEMBLY OF THE SRV 028-2-TWIN 60°SPRAY GUN
C
23
16
24
25
13
47
46
19
50
49
48
21
47
45
20
6
26
19
23
16 20
52
50 47
46
13
26
6
View A : fitting the
UHT on its support
support
51
44

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DISMANTLING AND RE-ASSEMBLY OF THE SRV 028-2-TWIN 60°SPRAY GUN
1 - DISMANTLING
- It is assumed that the spray gun has already been removed.
- Loosen the screws (25) and (45), and remove the cover (21).
- Loosen nut QD (26), and remove QD plate (13).
- Remove screws (24), (47) and remove shell (20). Remove nut QD (26).
- Disconnect powder feed pipes and compressed air hoses (see plate BF6-1).
- Remove screws (44) (see plate CO1-1), and remove gun assembly (C). Dismantle guns as needed (see
plate BF3-1).
- Remove the two screws (51) maintening the UHT 151-RM (16) on its support (19).
- Remove the four screws (48) and the four sealing washers (49) and remove the HV unit cover (50) in
order to access to the screws (23) maintening the UHT 151-RM (16) on its support (19) (see detail (A)).
- Disconnect the fastens (52) in the UHT 151-RM casing.
- Remove screws (23) and remove the UHT 151-RM (19) equiped with the male plug.
2 - RE-ASSEMBLY
- Check condition of sealing washers (49). Replace it if necessary.
- Place the UHT 151-RM (16) on its support (19), then fix it with the screws (23).
- Connecter the contacts (52).
Place the UHT cover (50), fix it with the screws (48) equiped with the sealing washers (49).
- Place nut QD (26) on the mobile flange (6).
- Align support (19), to HV unit (16), on the mobile flange (6), and secure with the screws (51).
Insert gun assembly (C) into HV unit and secure with two screws (44).
- Connect powder feed pipes and compressed air hoses to gun assembly (C) (see plate BF6-1).
- Align shell (20) to mobile flange and secure with screws (47) and (24).
- Align cover (21) to shell (20) and secure with screws (25) and (45).
- Align QD plate (13) to mobile flange (6) and secure by tightening nut QD (26).

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SRV 028 / BSR 164-PI / US SPRAY GUN - 855 459
Item SAMES Description Qty Sale
code unit
855 459 SRV 028 SPRAY GUN with BSR 164-PI nozzle (US) 1
28 736 222 90°powder inlet end piece 1 1
29 J2F TCF 178 O-ring 14 x 2 1 1
30 J3E TOR 031 O-ring 14 x 2.5 1 1
31 J2F TCF 051 O-ring 25 x 2.4 1 2
32 740 532 Resistor holder 1 1
33 1 500 885 BSR 164-PI nozzle 1 1
34 X9S VCB 232 Nylon screw M 6 x 50 glass fiber 2 1
35 X9S VCB 230 Nylon screw M 6 x 40 glass fiber 2 1
36 X7C VCB 064 Brass screw C M 3 x 6 1 1
37 J3T TOR 004 O-ring Ø 4.2 x 1.9 1 1
38 449 156 Contact washer 1 1
39 747 004 Nozzle nut 1 1
57 733 817 Back body of nozzle 1 1
58 755 118 Insulating axis of nozzle 1 1
59 747 037 Front body of nozzle 1 1
31
32
38
28
33
37
34 35
29
36
30
39
575859

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27
31
32
36
39
33
38 30
34
35 29 28
37
1 - DISMANTLING
- It is assumed that the spray gun has already been removed.
- Loosen the nozzle nut (39).
- Dismantle the nozzle (33).
- Loosen the screw (36) and remove the contact washer (38).
- Remove the O-ring (30).
- Dismantle the 90°powder feed pipe nozzle (28), then remove the O-ring (29).
2 - RE-ASSEMBLY
- Check condition of the O-rings (29), (30), (31) and (37) and of the brass screw (36). Replace if necessary.
- Install the O-ring (29). Install the 90°powder feed pipe nozzle (28).
- Install the O-ring (30).
- Install the brass screw (36) on the contact washer (38). Put the assy inside the gun body (27).
- Install the nozzle (33) in the nozzle nut (39). Tighten on the gun body (27).
- Install the gun assy on the HV unit connecting part.
Make sure the O-ring (31), the resistor holder (32) and the O-ring (37) are present.
- Fasten the gun using the screws (34) and (35).
DISMANTLING AND RE-ASSEMBLY OF THE SRV 028-2 (US) SPRAY GUN

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1 - DISMANTLING
- Remove the SRV 028-2-Twin 60°spray gun.
- Loosen the screws (40) and pull the receptacle connector assy (17).
- Disconnect the other end of low voltage cable and take off all parts.
- Loosen the packing box (42).
- Move apart the connector cover (41) and the receptacle connector (17).
- Identify the cable conductors (43) on the receptacle connector (17).
- Unsolder the contacts, remove the cable (43) and keep the packing box (42).
2 - RE-ASSEMBLY
- Install the packing box (42) and the connector cover (41) on the cable (43).
- Solder the cable conductors on the receptacle connector's contacts as per identification.
- Assemble the connector cover (41) and the receptacle connector (17).
- Install and tighten the packing box (42).
- Fasten the receptacle connector (17) onto the fixed flange (13) using the screws (40).
40
17
13
42
41
43
REPLACEMENT OF LOW VOLTAGE CABLE OR SOCKET

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INTERNAL CONNECTIONS OF THE SRV 028 SPRAY GUN
Vue de l'arrière du projecteur SRV 028
90°powder
inlet end
piece (28)
Union (5)
Powder feed pipe
Powder inlet end
piece (7)
90°powder
inlet end
piece (28)
Union (5)
Powder feed pipe
Powder inlet end
piece (7)
Air hose Air hose

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Item SAMES Description Qty Sales
code unit
16 757 474 High Voltage Unit 151-RM 1
44 X9N VCB 181 Screw C M 5 x 10 nylon 2 10
48 X2B VKY 118 Screw SCR M 4 x 10 4 10
49 J2C RAN 041 Sealing washer 4 4
50 438 704 Cover 1 1
53 J3E TOR 149 O-ring 76 / 3 1 1
54 J3E TOR 154 O-ring 81 / 2 1 1
55 448 768 Main isolator assy 1 1
56 J3E TOR 046 O-ring 22,5 x 2 1 2
HIGH VOLTAGE UNIT 151-RM - 757 474
16
54
53
49
48
50
55
56
44