Carlisle RMA-660 Robot Atomizer User manual

EN

SERVICE MANUAL

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RMA-660 Single/Dual Purge

Robot Mounted Rotary

Atomizer Direct Charge

Model: RMA660

II 2 G T6XXXXXXXX

MANUAL CHANGES EN

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NOTE: This manual has been changed from revision LN-9288-21-R0 to

revision LN-9288-21-R1. Reasons for this change are noted under

“Manual Change Summary” inside the back cover of this manual.

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CONTENTS

EN

CONTENTS

(Continued On Next Page)

SAFETY: 5-9

Safety Precautions ........................................................................................................................................................5

Hazards / Safeguards ....................................................................................................................................................6

ATEX/UKEX: 10-12

European ATEX Directive/UKEX Directive ................................................................................................................. 10

European ATEX Labels/UKEX Labels ......................................................................................................................... 12

INTRODUCTION: 13-35

Applicator Description .................................................................................................................................................13

Features ......................................................................................................................................................................13

General Description .....................................................................................................................................................14

 Specications ..............................................................................................................................................................15

 RMA-660DirectChargeRotaryAtomizerModelIdentication ....................................................................................17

 TubingBundleModelIdentication ..............................................................................................................................18

 SingleBellControllerModelIdentication ...................................................................................................................19

Important Numbers .......................................................................................................................................................20

Performance Graphs ....................................................................................................................................................21

RMA-660 Tool Center Point Dimensions ......................................................................................................................26

Circuit and Valve Schematics (Dual and Single Purge) ................................................................................................32

INSTALLATION: 36-46

Air Filter Installation (General Guidelines) ................................................................................................................... 36

Equipment Grounding/Safety Recommendations ...................................................................................................... 37

Air Heater Requirements ............................................................................................................................................ 38

Air Heater and Filtration Options ................................................................................................................................ 39

A13230-XX Air Heater and Filter Combination ............................................................................................................ 40

Mounting ...................................................................................................................................................................... 41

Electrical and Fiber Optic Connections ....................................................................................................................... 41

Fluid Connections ........................................................................................................................................................ 42

Dual Purge Manifold .................................................................................................................................................... 42

Single Purge Manifold ................................................................................................................................................. 42

Typical Installation ....................................................................................................................................................... 42

Typical Installation of RMA-660 ................................................................................................................................... 43

Tubing Bundle Installation ........................................................................................................................................... 44

Bundle Lubricant ......................................................................................................................................................... 44

Turbine Exhaust .......................................................................................................................................................... 44

RMA-660 Wiring Installation ........................................................................................................................................ 45

Interlocks ..................................................................................................................................................................... 46

OPERATION: 47-55

Fluid Flow Rate Control ...............................................................................................................................................47

Dual Purge Spraying ...................................................................................................................................................48

Turbine Speed .............................................................................................................................................................48

Bearing Air Adjustment ................................................................................................................................................48

Shaping Air Kits #1 and #2 ..........................................................................................................................................49

Shaping Air Kits #3 .......................................................................................................................................................50

Brake Air ......................................................................................................................................................................50

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CONTENTS EN

CONTENTS (Cont.)

OPERATION (Cont.): 47-55

Electrostatic Voltage ....................................................................................................................................................50

Target Distance ............................................................................................................................................................51

General Operating Sequence .......................................................................................................................................51

Low Voltage Cable Installation and Removal ..............................................................................................................52

Low Voltage Cable on Robot .......................................................................................................................................54

Fiber Optic Cable Installation and Removal ................................................................................................................55

Turbine Air - Note ........................................................................................................................................................55

MAINTENANCE: 56-83

O-Rings .......................................................................................................................................................................56

Cleaning Procedures ...................................................................................................................................................56

Vibration Noise ............................................................................................................................................................57

Turbine Maintenance ...................................................................................................................................................58

General/Preventive Maintenance ................................................................................................................................58

Preventive Maintenance ..............................................................................................................................................58

Bell Cup Preventive Maintenance ...............................................................................................................................59

Bell Cup Cleaning ........................................................................................................................................................60

Cleaning Shaping Air Holes .........................................................................................................................................61

Preventive Maintenance Schedule ..............................................................................................................................62

Disassembly Procedures .............................................................................................................................................63

Cup Wash Connections For Single Purge Manifold ....................................................................................................74

Cup Wash Connections for Dual Purge Manifold .........................................................................................................75

Turbine Bundle Assembly .............................................................................................................................................76

Barb Fitting and Receiver Installation ...........................................................................................................................78

Troubleshooting Guide .................................................................................................................................................80

PARTS IDENTIFICATION: 84-105

RMA-660 Direct Charge Rotary Atomizer ...................................................................................................................84

Atomization Assembly ..................................................................................................................................................86

Body Assembly ............................................................................................................................................................90

Fitting and Ferrule Replacement .................................................................................................................................94

 TubingBundleModelIdentication .............................................................................................................................95

Tubing Bundle TB66X-AABBCDEEFF ........................................................................................................................97

Tubing Bundle Nomenclature ......................................................................................................................................98

Atomizer Recommended Spare Parts .........................................................................................................................99

TB66X Tube Bundle Recommended Spare Parts .....................................................................................................102

Filter and Heater Assembly .......................................................................................................................................104

Air Heater and Filter Combination .............................................................................................................................104

Service Kits ...............................................................................................................................................................105

Lubricant and Sealers ...............................................................................................................................................105

Air Filter / Replacement .............................................................................................................................................105

Accessories ...............................................................................................................................................................105

Tool Kits ......................................................................................................................................................................105

APPENDIX A: 106-108

Test of the Stationary Equipment ...............................................................................................................................106

MANUAL CHANGE SUMMARY: 109

Manual Changes .......................................................................................................................................................109

SAFETY

EN

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CAUTION

!

WARNING

!

NOTE

SAFETY PRECAUTIONS

Before operating, maintaining, or servicing any

electrostatic

coating system

, read and understand all of the technical

and safety literature for your products. This manual contains

information that is important for you to know and understand.

This information relates to USER SAFETY and PREVENTING

EQUIPMENT PROBLEMS. Please pay particular attention

to these sections. To help you recognize this information, we

use the following symbols:

A WARNING! states information to alert you to

a situation that might cause serious injury if

instructions are not followed.

A CAUTION! states information that tells how to

prevent damage to equipment or how to avoid a

situation that might cause minor injury.

A NOTE is information relevant to the procedure

in progress.

Whilethismanualliststandardspecicationsandservice

procedures, some minor deviations may be found between

thisliteratureandyourequipment.Dierencesinlocalcodes

and plant requirements, material delivery requirements, etc.,

make such variations inevitable. Compare this manual with

your system installation drawings and associated equipment

manualstoreconcilesuchdierences.

WARNING

!

WARNING

!

The user MUST read and be familiar with the

Safety Section in this manual and the safety literature

thereinidentied.

This equipment is intended to be used by

trained personnel ONLY.

Usage PROHIBITED for operators with active

body aids, e.g. cardiac pacemaker, insulin pump.

This manual MUST be 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 AND EN 16985

SAFETY STANDARDS, LATEST EDITION, or

applicable country safety standards, prior to installing,

operating, and/or servicing this equipment.

The hazards shown on the following pages may

occur during the normal use of this equipment.

SAFETY

Repairs not listed in this manual may only be performed by

personnel authorized by Carlisle Fluid Technologies.

Careful study and continued use of this manual will provide a

better understanding of the equipment and process, resulting

inmoreecientoperation,longertrouble-freeserviceand

faster, easier troubleshooting. If you do not have the manuals

and safety literature for your equipment, contact your local

Carlisle Fluid Technologies representative or Carlisle Fluid

Technologies technical support.

SAFETY EN

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AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area Fire Hazard

Improper or inadequate operation

and maintenance procedures will

causearehazard.

Protection against inadvertent

arcing that is capable of causing

reorexplosionislostifany

safety interlocks are disabled

during operation. Frequent Power

Supply or Controller shutdown

indicates a problem in the system

requiring correction.

Fire extinguishing equipment must be present in the

spray area and tested periodically.

Spray areas must be kept clean to prevent the

accumulation of combustible residues.

Smoking must never be allowed in the spray area.

Thehighvoltagesuppliedtotheatomizermustbeturnedo

priortocleaning,ushing,ormaintenance.

Spray booth ventilation must be kept at the rates required

by NFPA 33, EN 16985, country, and local codes. In

addition, ventilation must be maintained during cleaning

operationsusingammableorcombustiblesolvents.

Electrostatic arcing must be prevented. Safe sparking

distance must be maintained between the parts being

coated and the applicator. A distance of 1 inch (25 mm)

for every 10 kV of output voltage is required at all times.

Test only in areas free of combustible material.

Testing may require high voltage to be on, but only as

instructed.

Non-factory replacement parts or unauthorized

equipment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.

The paint process and equipment should be set up and

operated in accordance with NFPA 33, NEC, OSHA,

local, country, and European Health and Safety Norms.

SAFETY

EN

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AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Improper or inadequate operation

and maintenance procedures will

cause a

rehazard.

Protection against inadvertent

arcing that is capable of causing

reorexplosionislostifany

safety interlocks are disabled

during operation.

Frequent Power Supply or

Controller shutdown indicates a

problem in the system requiring

correction.

Improper operation or

maintenance may create

a hazard.

Personnel must be properly

trained in the use of this

equipment.

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, operation mainte-

nance, and housekeeping. Reference OSHA, NFPA 33,

EN Norms and your insurance company requirements.

General Use and

Maintenance

Spray Area Explosion Hazard

Electrostatic arcing must be prevented. Safe sparking

distance must be maintained between the parts being

coated and the applicator. A distance of 1 inch (25 mm) for

every 10 kV of output voltage is required at all times.

Unlessspecicallyapprovedforuseinhazardouslocations,

all electrical equipment must be located outside or applicable

county code hazardous areas, in accordance with NFPA 33.

Testonlyinareasfreeofammableorcombustiblematerials.

The current overload sensitivity (if equipped) MUST be

set as described in the corresponding section of the

equipment manual. Protection against inadvertent arcing

that is capable of causingreor explosion is lostif the

current overload sensitivity is not properly set. Frequent

power supply shutdown indicates a problem in the system

which requires correction.

Alwaysturnthecontrolpanelpoweropriortoushing,

cleaning, or working on spray system equipment.

Before turning high voltage on, make sure no objects are

within the safe sparking distance.

Ensure that the control panel is interlocked with the

ventilation system and conveyor in accordance with NFPA-

33, EN 16985.

Have re extinguishing equipment readily available and

tested periodically.

SAFETY EN

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AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area /

High Voltage

Equipment

There is a high voltage device

that can induce an electrical

charge on ungrounded objects

which is capable of igniting

coating materials.

Inadequate grounding will

cause a spark hazard. A

spark can ignite many coating

materialsandcauseare

or explosion.

Electrical Discharge

Parts being sprayed and operators in the spray area must be

properly grounded.

Parts being sprayed must be supported on conveyors or

hangers that are properly grounded. The resistance between

the part and earth ground must not exceed 1 Meg Ohm. (Refer

to NFPA 33, EN 16985.)

Operators must be grounded. Grounding straps on wrists or

legs may be used to assure adequate ground contact.

Footware to be used by operator shall comply with EN ISO 20344,

resistance not to exceed 100 Meg Ohm. Protective clothing

including gloves should comply with EN 1149-5, resistance not to

exceed 100 Meg Ohm.

Operators must not be wearing or carrying any ungrounded

metal objects.

When using an electrostatic handgun, operators must

assure contact with the handle of the applicator via

conductive gloves or gloves with the palm section cut out.

NOTE: REFER TO NFPA 33, EN 16985 OR SPECIFIC COUN-

TRY SAFETY CODES REGARDING PROPER OPERATOR

GROUNDING.

All electrically conductive objects in the spray area, with the

exception of those objects required by the process to be at high

voltage,mustbegrounded.Groundedconductiveooringmust

be provided in the spray area.

Alwaysturnothepowersupplypriortoushing,cleaning,or

working on spray system equipment or applicable county code.

Unless specically approved for use in hazardous locations,

all electrical equipment must be located outside or applicable

country code, hazardous areas, in accordance with NFPA 33.

Avoidinstallinganapplicatorintoauidsystemwherethe

solvent supply is ungrounded.

Do not touch the applicator electrode while it is energized.

SAFETY

EN

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AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

High voltage equipment is

utilized in the process. Arcing

inthevicinityofammableor

combustible materials 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.

Electrical Discharge

Electrical

Equipment

Follow the requirements of the Safety Data Sheet supplied

by coating material manufacturer.

Adequate exhaust must be provided to keep the air free of

accumulations of toxic materials. Reference EN 12215 or

applicable code.

Use a mask or respirator whenever there is a chance of

inhaling sprayed materials. The mask must be compatible

with the material being sprayed and its concentration.

Equipment must be as prescribed by an industrial hygienist

or safety expert, and be NIOSH approved.

Chemical HazardToxic

Substances Certain materials may be

harmful if inhaled, or if there

is contact with the skin.

Unlessspecicallyapprovedforuseinhazardouslocations,

the power supply, control cabinet, and all other electrical

equipment must be located outside or applicable country

codes, hazardous areas in accordance with NFPA 33 and

EN 16985.

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.

Spray applicators require that aluminum inlet ttings be

replaced with stainless steel.

Aluminum is widely used in other spray application

equipment - such as material pumps, regulators, triggering

valves, etc. Halogenated hydrocarbon solvents must

never be used with aluminum equipment during spraying,

ushing,orcleaning.Readthelabelordatasheetforthe

material you intend to spray. If in doubt as to whether or not

a coating or cleaning material is compatible, contact your

coating supplier. Any other type of solvent may be used

with aluminum equipment.

Halogenated hydrocarbon

solvents 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.

Explosion Hazard —

Incompatible Materials

Spray Area

ATEX/UKEX EN

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EUROPEAN ATEX DIRECTIVE

2014/34/EU

The following instructions apply to equipment covered

bycerticatenumbersFM22ATEX0009Xand

FM22UKEX0009X:

1. Theequipmentmaybeusedwithammablegasesand

vapors with apparatus groups II and with temperature

class T6.

2. The equipment is only certied for use in ambient

temperatures in the range +10°C to +40°C and should

not be used outside this range.

3. Installation shall be carried out by suitably trained

personnel in accordance with the applicable code of

practice e.g. EN 60079-14.

4. Inspection and maintenance of this equipment shall be

carried out by suitably trained personnel in accordance

with the applicable code of practice e.g. EN 60079-17.

5. Repair of this equipment shall be carried out by suitable

trained personnel in accordance with the applicable code

of practice e.g. EN 60079-19.

6. Putting into service, use, assembling, and adjustment of

theequipmentshallbettedbysuitablytrainedpersonnel

in accordance with the manufacturer's documentation.

Refer to the "Table of Contents" of this service manual:

a. Installation

b. Operation

c. Maintenance

 d.PartsIdentication

7. Components to be incorporated into or used as

replacement parts of the equipment shall be tted

by suitably trained personnel in accordance with the

manufacturer's documentation.

8. Thecerticationofthisequipmentreliesuponthefollowing

materials used in its construction:

If the equipment is likely to come into contact with

aggressive substances, then it is the responsibility of

the user to take suitable precautions that prevent it from

beingadverselyaected,thusensuringthatthetypeof

protection provided by the equipment is not compromised.

Aggressive substances: e.g. acidic liquids or gases that

mayattackmetals,orsolventsthatmayaectpolymeric

materials.

Suitable precautions: e.g. regular checks as part of

routine inspections or establishing from the material's

datasheetsthatitisresistanttospecicchemicals.

 Referto"Specications"inthe"Introduction"section:

a.

Alluidpassagescontainstainlesssteel,nylonttings,

or chemically compatible resins.

b. High voltage cascade is encapsulated in dielectric oil.

9. Arecapitulationofthecerticationmarkingisdetailed

in the "ATEX/UKEX" section, on the next page, drawing

numbers: 80108-15, A14736-00.

10. The characteristics of the equipment shall be detailed

e.g. electrical, pressure, and voltage parameters.

The manufacturer should note that, on being put into

service, the equipment must be accompanied by

a translation of the instructions in the language or

languages of the country in which the equipment is to

be used and by the instructions in the original language.

ATEX/UKEX

EN

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RMA-660 ATEX Product Marking Denitions

ExCerticateNumber:FM22ATEX0009X

 FM= NotiedbodyperformingEU-typeexamination

 22= Yearofcertication

ATEX = Reference to ATEX Directive

 0009= Sequentialissuancecerticate

X = Special conditions for safe use apply

 Ex= Specicmarkingofexplosiveprotection

II = Equipment Group hazardous area characteristics

2 = Equipment Category

G = Type of explosive atmosphere (gases, vapors, or mists)

 T6= Temperatureclassication.

Special conditions for safe use:

• The RMA-660 Applicator shall only be used with associ-

ated A13613 MicroPak 2e Power Supply according to

congurationdrawingA14735.

• The MicroPak 2e is intended for “Safe Area Use” only.

• The maximum speed for the 81mm bell cup is 55 kRPM.

Other safety items for consideration:

• The Safe Distance of use for the Type RMA-660

Electrostatic Bell is 150 mm minimum when using the 81

mm bell cup, 100 mm minimum when using the 65 mm

bell cup, and 50 mm minimum when using the 30 mm bell

cup: from the electrode to earthed parts. The end user

must ensure this distance, as a minimum is maintained

and that grounded objects are prevented from contacting

the applicator bell cup when the applicator is energized

or operating.

• The RMA-660 Electrostatic Bell is a potential hazard - refer

to the manufacturers instructions.

• The end user must ensure that installation is in accordance

with all applicable requirements of EN 50176. This includes

the means of re protection and re detection being

installed with this system.

• Before servicing bell ensure that all voltage is completely

de-energized and the bell cup is not rotating. Minimum

2-minutewaitafterturbineairhasbeenshuto.

•Ifignitableuidsareusedforcleaningpurposes,allparts

must be completely discharged of high voltage.

•Theuidsupplysystemmustbeproperlygrounded.

• If an object is within the 150 mm safe distance when using

the 81 mm bell cup, 100 mm safe distance when using

the 65 mm bell cup, or 50 mm safe distance when using

the 30 mm bell cup, it must be cleared prior to restarting

and/or re-energizing the system.

• The materials used in the construction of this equipment

contain levels of Al, Mg, Ti, and Zi that are greater than

that allowed for EPL Ga and Gb by clause 8.3 of EN

60079-0, therefore in rare cases, ignition sources due to

impact and friction sparks could occur. The equipment

shall therefore be protected from such impact and friction

when installed.

• The type RMA-660 Electrostatic Bell and type Micropak

2e (A13613) power supply complies with EN 50176: 2009.

Clauses 4, 5.1, 5.2.1, 5.2.2, 5.2.3, 5.2.4, 5.3, 5.5.1, 5.5.3,

5.5.5, 5.6, 6.1, 6.4, 7.2, 7.3 and 7.4. All remaining clauses

of EN 50176: 2009 are to be addressed during installation.

•Theinstallershallxthewarningsignthatissupplied

with these products in a position close to the equipment;

in addition, it shall also be clearly visible to the operator.

II 2 G T6

2813

Product Marking

Discharge Energy (W) =

The RMA-660 Applicator is suitable for use in automatic

spraying installations complying with EN 50176 as

they are a type C-L system with a discharge energy

of 350 mJ<W<2J.

II (2) G

2813

Power Supply Marking

RMA-660 UKEX Product Marking Denitions

UKEXCerticateNumber:FMUKEX0009X

 FM= NotiedbodyperformingUKEX-typeexamination

 22= Yearofcertication

UKEX = Reference to UKEX Directive

 0009= Sequentialissuancecerticate

X = Special conditions for safe use apply

II 2 G T60518

Product Marking

0518

ATEX/UKEX EN

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80108-15

A14736-00

A11201-04

LABELS

INTRODUCTION

EN

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INTRODUCTION

FEATURES

Features which make the RMA-660 advantageous for use

in electrostatic applications include:

• True dual purge capability. Spray one color while cleaning

the other paint line with no loss of tip voltage.

• Assembly components made of durable engineered

resin material for optimum mechanical strength and

solvent resistance.

• Heavy duty design ensures excellent service life

even when subjected to the quick motions of robotic

applications.

• Improved long life turbine motor, utilizing highly resilient

graphite bearing technology, is capable of speeds up

to100krpm.(See“Specications”inthe“Introduction”

section of this manual for bell cup speed ratings.)

• Serrated and non-serrated, coated and non-coated bell

cupsare available forapplication exibility andcolor

match. All bell cups are made using Titanium.

• Aerodynamic design for ease of cleaning external

surfaces.

• 60° angled body provides more maneuverability and

facilitates robotic programming.

• An extended length robot adapter is available. This

optiongivesgreaterexibilityandextendedtubinglife.

• Small lightweight package allows better maneuverability

in tight areas.

• Fast change out. With the quick disconnect feature,

an atomizer can be changed in less than 2-minutes for

o-linemaintenance.

• The easily removable front and rear shrouds, turbine

assemblyandtheinternallymounteduidvalves,make

o-line maintenance more ecient and economical.

A split shroud is standard for easy access to internal

components while still mounted on the robot.

• Fast color changes are achieved using center feeduid

deliveryandtheuidvalvesprovideforsimultaneous

paint push while solvent washes the feed tube and bell

cup interior and exterior.

• Internal and external bell wash is quick and ecient.

Solvent is controlled at the feed tube with an internally

mounted solvent valve (single purge only, dual requires

externalushcontrol).Externallymountedregulators

controltheow.

• Less waste to the spray booth, with the dump valve

located internally next to the feed tube.

• No external high voltage cable. The internally mounted high

voltage cascade requires only low voltage control wiring.

• Various adapter plates available to match most robotic

mountingcongurations.

• Directchargingofuid(solventbornepaint)promotes

hightransfereciency.

• Largerangeofuidtipsizesavailable.

• Fittinglesstubingbundle;moreexibilityintherobot

wrist and easier to repair damaged tubes.

• Frontfeedlowvoltagecableandberopticcablefor

quick change out of cables without removing the plate

from the robot.

APPLICATOR DESCRIPTION

The RMA-660 is an automatic robot mounted rotary atomizer

capable of spraying solvent borne coatings electrostatically or

non-electrostatically. It incorporates the latest in high speed

spindle technology, bell cup and shape air design to provide

the best in atomization and pattern control. The bell cups are

designed for durability using the best materials available. All

wettedcomponentsaredesignedtooerthemaximumin

wear and chemical resistance. The atomizer incorporates

an integrated internal cascade capable of applying 100,000

VDC directly to the coating materials.

INTRODUCTION EN

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GENERAL DESCRIPTION

Bell Cup Assembly

Bell cups are made of high strength Titanium. Serrated and

non-serratedbellcupsareoeredin30mm,65mm,and81

mmsizes.Allcupsareoeredwithorwithoutacoatingfor

longer life expectancy. See ordering matrix for exact size

and material combination availability.

RMA-660 Robot Mounted Rotary Atomizer – Direct Charge.

The Ransburg MicroPak 2e High Voltage Controller uses a

combination of proven high voltage generation technology

including microprocessor-based control with diagnostic and

communication functions. A variable voltage output is used to

supplyacascadethatampliesthevoltagetoahighvalue.

It also uses both current and voltage feedback information

to maintain the desired set point. The processor circuitry

providesthemaximuminapplicatortransfereciency,while

maintaining the maximum safety.

The MicroPak 2e requires an AC input voltage of 90-264

VAC via a proper line cord that is supplied with the unit.

The RMA-660 is backwards compatible with the original

MicroPak Controller (LECU5004) in existing installations.

Air Bearing Turbine Assembly

The air bearing turbine assembly with bell cup is mounted

to the air manifold assembly with a turbine retaining ring.

Air Manifold Assembly

Theatomizerextensionisangledat60˚forrobotapplications.

Theuidfeedtubeandberopticturbinespeedemitterare

threadedintothefrontofthemanifold.Theturbine,uid,and

air manifolds are separated from the bell plate assembly by

vesupportrods.Nestedbetweenthemanifoldsandthe

bell plate is the high voltage cascade.

Bell Plate Assembly

The bell plate assembly is designed to be at ground potential

when mounted to the robot plate component within the tubing

bundle assembly.  The air and uid ports are compactly

oriented for use in robotic applications. The air supplies

areportedthroughthevesupportrodsdirectlytotheair

manifold assembly. On the exterior side of the bell plate, the

ports are provided with O-ring seals so that the atomizer can

be quickly mated and secured to the robot plate.

Robot Plate

The robot plate is a component of the tubing bundle assembly

and intended to be permanently mounted to the robot. A

wrist adapter is also available, which matches the robot’s

mountingconguration.Theincomingairlines,uidlines,

lowvoltagecable,andberopticcableareconnectedto

the ttings provided at the robot plate. The bell plate of

the atomizer assembly is secured to the robot plate with a

threaded retaining ring.

Valve Manifold

Thismanifoldcanbeconguredforeithersingleordual

purge application. The dual purge can allow two colors to

be loaded at one time.

INTRODUCTION

EN

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Electrical:

Power Supply Type: MicroPak 2e

Charging Method: Direct

Output Voltage: 30-100 kV Variable (100 kV Maximum)

Output Current: 125 µA Maximum

Turbine Speed Control:

Multi-function I/O board included in the MicroPak 2e Controller

Part Spray Ability: Determine spray ability of part to be coated using Test Equipment (76652)

(Paint Conductivity Meter)

Mechanical:

(Continued on next page)

SPECIFICATIONS

Length: (See RMA-660 Tool Point, Center of Gravity, and Envelope Dimension

 (DualShapeAir)gureinthe“Introduction”section.)

Diameter: (See RMA-660 Tool Point, Center of Gravity, and Envelope Dimensions

 (DualShapeAir)gureinthe“Introduction”section.)

Approximate Weight

(Dual Shape Air) Atomizer Only:

6.4 kg. (14.1 lbs.)

Total Payload with Robot Plate

(Dual Shape Air) & Adapter: 7.6 kg. (16.8 lbs.)

Turbine Type: Air Bearing Impulse Drive

Turbine Air Supply: Variable (See “Pressure Flow Data Charts” in the “Introduction” section.)

Maximum/Minimum Continuous 100* +0/-2 krpm max. /20 krpm min.

Turbine Speed: (See exception at “Fluid Flow Rate”)

81 mm Bell Cup 55 krpm max.

Maximum Angular Velocity

for Turbine (Robot Motion): 250°/sec.

Tubing Bundle Max.

Rotation: 450° in Either Direction

Bearing Air Supply 621 kPa ±69 kPa (90 psig ±10 psi)

at the Applicator: At 100 krpm: 621 kPa +69/-0 kPa (90 psig +10/-0 psi)

(Nominal): 82 slpm (2.9 scfm)

Shaping Air #1 (SAI) Supply:

Variable (See “Pressure Flow Data Charts” in the “Introduction” section)

Shaping Air #2 (SAO) Supply:

Variable (See “Pressure Flow Data Charts” in the “Introduction” section)

Brake Air Supply (Nominal):

414-689 kPa (60-100 psig)

Maximum Fluid Pressure Supply:

Paint: 1035 kPa (150 psi)

Solvent: 1035 kPa (150 psi)

INTRODUCTION EN

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Mechanical (Cont.):

Fluid Flow Rate: 25-1000 cc/min. (See exclusion below)

30 mm Bell Cup Max. Flow Rate: 300 cc/min. at 80 krpm. Max

65 mm Bell Cup Max. Flow Rate: 200 cc/min. at 100 krpm. Max

Max. Flow Rate: 500 cc/min. at 80 krpm. Max.

Max. Flow Rate: 800 cc/min. at 70 krpm. Max.

Max. Flow Rate: 1000 cc/min. at 60 krpm. Max.

81 mm Bell Cup Max. Flow Rate: 500 cc/min. at 55 krpm. Max

Bell Cup Cleaning Time

(Internal/External): 2.7 sec. (approx.)

Color Change Time: Dependent on system

conguration,uidpres

sures,uidviscosity,

 uidlinelengths,etc.

Speed Readout: Magnetic pick-up, unidirec

tionalberoptictransmission

Atomizer Replacement Time:

Less than 5 min.

Bell Cup Replacement Time:

Less than 2 min.

Minimum Control Equipment

Requirements:

(Versions listed or higher)

MicroPak 2e V1.1.18

Air Filter Requirements:

Eachapplicatormusthaveitsownlterforbearingair.RPM-418orequivalentis

 recommended.Seeallheaterandltrationrecommendationslaterinthismanual.

Air Heater Recommendation:

An Air Heater is recommended for the turbine air supply. See Air Heater

 andltrationrecommendationlaterinthismanual

Althoughthisturbineassemblyiscapableofoperatingatcontinuousspeedsupto100krpm,nearlyallhighqualitynishescanbe

achieved within our recommended operating range of 20 to 70 krpm, based on experience with a wide variety of materials and various

markets.Operatingabovethisrangeisforhighlyspecializedapplications,andmayreduceeciencyandequipmentlife.Contactyour

Carlisle Fluid Technologies representative for additional information as required.

Specicationsandratingsbasedontestingatsealevelstandardconditions.

*

**

SPECIFICATIONS

INTRODUCTION

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RMA-660 DIRECT CHARGE ROTARY ATOMIZER

MODEL IDENTIFICATION

When ordering, use RMA660-ABCCDEFF as indicated by the following table.

Eight (8) digits must follow the basic part number.

*Model number and serial number of the atomizer are located on the face of the

rear plate assembly. (See “Important Numbers” in the “Introduction” section.)

Purge

Single Dual

Shape Air Kit

Dual Air Single Air

Bell Cup Size Bell Cup Type

A

Splash Plate

B

Fluid Tip

CC

• •

•

30 - 30 mm Diameter

65 - 65 mm Diameter

81 - 81 mm Diameter

1. Titanium Serrated

2. Titanium Serrated DLC Coated

3. Titanium Non-Serrated

4. Titanium Non-Serrated

DLC Coated

1. Titanium Serrated

2. Titanium Serrated DLC Coated

3. Titanium Non-Serrated

4. Titanium Non-Serrated

DLC Coated

1. Titanium Serrated

2. Titanium Serrated DLC Coated

3. Titanium Non-Serrated

4. Titanium Non-Serrated

DLC Coated

1 - S.S. With Titanium

Base

1 - S.S. With Titanium

Base

1 - S.S. With Titanium

Base

07 - 0.7 mm/.028in Opening

09 - 0.9 mm/.035in Opening

10 - 1.0 mm/.039in Opening

11 - 1.1 mm/.045in Opening

13 - 1.3 mm/.051in Opening

16 - 1.6 mm/.062in Opening

07 - 0.7 mm/.028in Opening

09 - 0.9 mm/.035in Opening

10 - 1.0 mm/.039in Opening

11 - 1.1 mm/.045in Opening

13 - 1.3 mm/.051in Opening

16 - 1.6 mm/.062in Opening

07 - 0.7 mm/.028in Opening

09 - 0.9 mm/.035in Opening

10 - 1.0 mm/.039in Opening

11 - 1.1 mm/.045in Opening

13 - 1.3 mm/.051in Opening

16 - 1.6 mm/.062in Opening

•

RMA660-1230ABCC

RMA660-2230ABCC

RMA660-1265ABCC

RMA660-2265ABCC

RMA660-1281ABCC

RMA660-2281ABCC

Part Number Reference - CCDE Assembly Part Number

65 mm 81 mm

Bell Cup Size

Titanium Serrated

Splash Plate (Included in Assembly Part Number)

Titanium Non-Serrated DLC Coated S.S. With Titanium Base

Bell Cup Type

TABLE A - BELL CUP

30 mm

3012 A14731-00 • • A14710-00

3022 A14731-02 • • • A14710-00

3032 A14731-01 • • A14710-00

3042 A14731-03 • • • A14710-00

6511 A14665-00 • • A14651-00

6521 A14665-02 • • • A14651-00

6531 A14665-01 • • A14651-00

6541 A14665-03 • • • A14651-00

8111 A14732-00 • • A14711-00

8121 A14732-02 • • • A14711-00

8131 A14732-01 • • A14711-00

8141 A14732-03 • • • A14711-00

INTRODUCTION EN

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When ordering, use TB660-AABBCDEEFF as indicated by the following

table. Ten (10) digits must follow the basic part number.

TUBING BUNDLE MODEL IDENTIFICATION

A1 ABB 5400/5002 STANDARD LENGTH 79107-00

A2 ABB 5400/5002 EXTENDED LENGTH A13735-00

F1 FANUC P200/P250 STANDARD LENGTH 79131-00

F2 FANUC P200/P250 EXTENDED LENGTH A13733-00

Conguration Number Description

TABLE AA - ROBOT ADAPTER

00 NO TUBING NONE NONE

02 2 m (6.5 FT.) 2 m (6.5 FT.) 2 m (6.5 FT.)

13 13 m (42 FT.) 13 m (42 FT.) 2 m (6.5 FT.)

TA Length

TABLE BB - TUBING BUNDLE LENGTH

0 NONE 0

F INCLUDED 1

TABLE C - FIBER OPTIC CABLE

Robot Adapter Number

Tubing LengthDescriptionConguration Number

Fiber Optic Cable QtyDescriptionConguration Number

0 (ALWAYS IN TB661 APPLICATORS) NONE 0

V INCLUDED 1

Conguration Number

TABLE D - LOW VOLTAGE CABLE

L.V. Cable Qty

Description

00 (ONLY IF CD=00) 0 N/A N/A

01 1 m (3 FT.) A14496-01 A14659-01

02 2 m (6 FT.) A14496-02 A14659-02

03 3 m (10 FT.) A14496-03 A14659-03

05 5 m (16 FT.) A14496-05 A14659-05

08 8 m (25 FT.) A14496-08 A14659-08

15 15 m (50 FT.) A14496-15 A14659-15

23 23 m (75 FT.) A14496-23 A14659-23

30 30 m (100 FT.) A14496-30 A14659-30

Conguration Cable Length Fiber Optic Cable Part Number Low Voltage Cable Part Number

TABLE EE - PRIMARY CABLE LENGTH (APPLICATOR TO BULKHEAD)

00 (ONLY IF CD=00) N/A 0 N/A 0 N/A

08 8 m (25 FT.) 1 A14195-15 1 A12433-25

15 15 m (50 FT.) 1 A14195-17 1 A12433-50

23 23 m (75 FT.) 1 A14195-19 1 A12433-75

30 30 m (100 FT.) 1 A14195-20 1 A12433-100

Conguration Cable Length

TABLE FF - SECONDARY CABLE LENGTH (BULKHEAD TO CONTROLLER)

Fiber Optic Extension Cable

Qty Number

Fiber Optic Extension

Cable Number

L.V. Extension Cable

Qty Number

L.V. Extension Cable

Number

INTRODUCTION

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SINGLE BELL CONTROLLER MODEL IDENTIFICATION

When ordering, use A13613-001815A1BC as indicated by the following

tables. Ten (10) digits must follow the basic part number.

Conguration Number Description Cable Number

0 AC INPUT CABLE - NORTH AMERICA 76449-00

1AC INPUT CABLE - EUROPE 76449-02

2AC INPUT CABLE - CHINA 76449-03

Conguration Number Description

1 UNILINK MODE DISABLED

2 UNILINK MODE ENABLED

TABLE A - AC INPUT CABLE

TABLE B - UNILINK CONFIGURATION

Conguration Number Description Multi I-O Board Number

0 NO MULTI I-O BOARD N/A

1 (0) 4-20 mA BOARDS INCLUDED A13245-01

2 (1) 4-20 mA BOARDS INCLUDED A13245-11

3 (2) 4-20 mA BOARDS INCLUDED A13245-21

4 (3) 4-20 mA BOARDS INCLUDED A13245-31

5 (4) 4-20 mA BOARDS INCLUDED A13245-41

6 (5) 4-20 mA BOARDS INCLUDED A13245-51

7 (6) 4-20 mA BOARDS INCLUDED A13245-61

8 (7) 4-20 mA BOARDS INCLUDED A13245-71

9 (8) 4-20 mA BOARDS INCLUDED A13245-81

TABLE C - MULTI I-O BOARD CONFIGURATION

INTRODUCTION EN

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IMPORTANT NUMBERS

Record these numbers in a log book for future reference.

The last digits of the Atomizer serial number are also the

Turbine serial numbers.

Bell Cup Part Numbers/Serial Number (Cup only, not with splash plate)

Atomizer Serial NumberTurbine Serial Number

TURBINE SERVICE KIT NUMBER

TURBINE SERIAL

NUMBER

ATOMIZER SERIAL

NUMBER

“B” BALANCED

(“B” SIGNIFIES THE BELL CUP HAS BEEN BALANCED) SERIAL NUMBER

PARTS REVISION

STATUS

BELL CUP PART

NUMBER

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Carlisle RMA-660 Robot Atomizer User manual

Carlisle RMA-660 Robot Atomizer User manual

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