Carlisle RMA-670 Robot Atomizers User manual

EN

SERVICE MANUAL

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RMA-670 Robot Mounted Rotary

Atomizer Indirect Charge

XXXX XXXX II 2 G T6

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CONTENTS EN

CONTENTS

(Continued on next page)

SAFETY: 4-8

Safety Precautions .................................................................................................................................................... 4

Hazards / Safeguards ................................................................................................................................................ 5

ATEX/UKEX: 9

Requirements ............................................................................................................................................................ 9

INTRODUCTION: 13-31

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

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

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

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

 PartsIdentication .................................................................................................................................................... 17

Important Numbers ................................................................................................................................................... 21

Performance Graphs ................................................................................................................................................ 22

Tool Point Dimensions .............................................................................................................................................. 26

Circuit Schematics .................................................................................................................................................... 30

Valve Schematic ....................................................................................................................................................... 31

INSTALLATION: 32-41

Air Filter Installation .................................................................................................................................................. 32

Tube Size / Air Pressure Requirements .................................................................................................................. 33

Equipment Grounding / Safety Recommendations ................................................................................................. 33

Air Heater Requirements ......................................................................................................................................... 34

Air Heater and Filtration Options ............................................................................................................................. 35

A13230-XX Air Heater and Filter Combinations ...................................................................................................... 36

Mounting .................................................................................................................................................................. 37

Electrical and Fiber Optic Connections ................................................................................................................... 37

Fluid Connections .................................................................................................................................................... 38

Typical Installation ................................................................................................................................................... 38

Tubing Bundle Installation ........................................................................................................................................ 40

Bundle Lubricant ...................................................................................................................................................... 40

Interlocks .................................................................................................................................................................. 40

OPERATION: 42-45

Fluid Flow Rate Control ........................................................................................................................................... 42

Fluid Valve Control .................................................................................................................................................. 42

Turbine Speed ......................................................................................................................................................... 43

Bearing Air Adjustment ............................................................................................................................................ 43

Shaping Air Kits ....................................................................................................................................................... 44

MAINTENANCE: 46-80

O-Rings ................................................................................................................................................................... 46

Cleaning Procedures ............................................................................................................................................... 46

Brake Air .................................................................................................................................................................. 46

Electrostatic Voltage ................................................................................................................................................ 46

Target Distance ....................................................................................................................................................... 47

(Continued on next page)

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CONTENTS

EN

CONTENTS (Cont.)

MAINTENANCE (Cont.): 16-80

General Operating Sequence .................................................................................................................................. 47

Protective Covers .................................................................................................................................................... 48

Cleaning Procedures ............................................................................................................................................... 49

Vibration Noise ........................................................................................................................................................ 49

Turbine Maintenance ............................................................................................................................................... 50

General Maintenance .............................................................................................................................................. 50

Preventive Maintenance .......................................................................................................................................... 50

Bell Cup Preventive Maintenance ........................................................................................................................... 52

Bell Cup Cleaning .................................................................................................................................................... 52

Cleaning Shaping Air Holes ..................................................................................................................................... 53

Preventive Maintenance Schedule .......................................................................................................................... 54

Disassembly Procedures ......................................................................................................................................... 55

High Voltage Connections for Shielded/Non-Metallic Core Cable - A13685-XX ..................................................... 58

Checking Probes ..................................................................................................................................................... 72

Electrode Resistance Test ....................................................................................................................................... 73

Operator Maintenance Warnings ............................................................................................................................. 74

Tubing Bundle Assembly ......................................................................................................................................... 75

Troubleshooting Guide ............................................................................................................................................ 77

PARTS IDENTIFICATION: 81-104

 IndirectChargeRotaryAtomizerModelIdentication ............................................................................................. 81

Atomization Assembly .............................................................................................................................................. 83

High Voltage Ring Assembly .................................................................................................................................... 86

Atomization Assembly ............................................................................................................................................. 87

Atomizer Extension Assembly ................................................................................................................................. 88

Internal Tubing ......................................................................................................................................................... 89

Cup Wash Manifold Assembly ................................................................................................................................. 90

Rear Plate Assembly ............................................................................................................................................... 91

 TubingBundleModelIdentication ......................................................................................................................... 92

Tubing Bundle (TB670) ........................................................................................................................................... 94

Atomizer Recommended Spare Parts ...................................................................................................................... 96

Bell Cup Recommended Spare Parts ..................................................................................................................... 97

Tube Bundle Spare Parts List .................................................................................................................................. 98

Shape Air Kit Spare Parts List ............................................................................................................................... 100

High Voltage Ring Kit / Electrode Assembly .......................................................................................................... 101

Accessories / Tool Kits ........................................................................................................................................... 102

Service Kits ........................................................................................................................................................... 103

Filter and Heater Assembly / Air Heater and Filter Combinations .......................................................................... 104

APPENDIX A: 105-107

Tests of the Stationary Equipment .......................................................................................................................... 105

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. Differences 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 differences.

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ef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 off

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 (25mm) for

every 10KV 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 (25mm) for

every 10KV 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off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off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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ATEX/UKEX

Requirements

This product provides an indirect charge to water-based

materialsthatwillimprovethetransferefciencyovernon-

electrostatic products. Because it is In-direct charge, the

uid delivery system may be completely grounded from

the source all the way to the applicator. This applicator is

approved for use with non-ignitable water-based materials

as well as ignitable materials.

• Ignitablematerialsaredenedasmaterialsthatcould

be ignited by an effective ignition source and continue to

burn after the source is removed. (Ref. EN 50176, 3.7)

• Non-ignitable materials are dened as materials that

could not be ignited by a source with an energy of 2J

or above. (Ref. EN 50176, 3.9)

The safe distances listed for each bell cup size must be

maintained for this product to be compliant with EN 50176.

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 affected, 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 affect 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 di-electric oil.

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

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

numbers: 80108-15, A14847-00.

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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0518 II (2) G

2813

Power Supply Marking

RMA-670 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-670 Applicator shall only be used with associ-

ated A13613 Micropak 2e Power Supply according to

congurationdrawingA14846-00.

• 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-670 Electrostatic

Bell is 150mm minimum when using the 81mm bell cup,

and 100mm minimum when using the 65mm 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 probes when the applicator is energized or

operating.

• The RMA-670 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 insure that all voltage is completely

de-energized and the bell cup is not rotating. Minimum 2

minute wait after turbine air has been shut off.

•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 150mm safe distance when using

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

the 65mm 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-670 Electrostatic Bell and type Micropak

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

•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.

RMA-670 UKEX Product Marking Denitions

UKEXCerticateNumber:FM22UKEX0009X

 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

ATEX/UKEX EN

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80108-15

A14847-00

A11201-05

LABELS

74793-03 / 74793-04

INTRODUCTION

EN

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INTRODUCTION

FEATURES

Features which make the RMA-670 advantageous for use

in electrostatic applications include:

• 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, that is capable of speeds

up to 100 krpm. (See “Specications” in the “Introduc-

tion” section of this manual for bell cup speed ratings.)

• Serrated and non-serrated bell cups are available for ap-

plicationexibilityandcolormatch.Coatedbellcupsare

available for longer life expectancy. All bell cups are made

using Titanium.

• Aerodynamic design for ease of cleaning external surfaces.

• 60° angled body provides more maneuverability and facil-

itates robotic programming.

• Speedcontrolusesreliablemagneticpickupforberoptic

transmission of rotational speed data.

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

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

paint push out while solvent washes the feed tube and bell

cup interior and exterior.

•

Heated bell wash material is recommended to be recirculated

at the robot plate. Internal solvent and air valves provide for

afastsolvent/airchopmethodtoquicklyandefcientlyclean

the interior and exterior of the bell cup.

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

internally next to the feed tube.

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

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

and easier to repair damaged tubes.

• Front feed ber optic cable for quick change out of

cables without removing the plate from the robot.

APPLICATOR DESCRIPTION

The RMA-670 is an automatic, robot mountable rotary

atomizer capable of spraying waterborne coatings

electrostatically or non-electrostatically. It incorporates the

latest in high speed spindle technology, and 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 offer the maximum in wear and chemical

resistance. The applicator is capable of applying 70,000

VDC to the coating material.

This RMA-670 model is designed specically for indirect

charge water-based applications only. The design eliminates

the need for material isolation equipment normally needed

for use with electrostatic waterborne applications.

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GENERAL DESCRIPTION

Bell Cup Assembly

Bell cups are made of high strength Titanium. Serrated

and non-serrated cups are available in 65mm and 81mm.

Coated and non-coated bell cups are available for longer

life expectancy. See ordering matrix for exact size and

material combination availability.

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

the atomizer extension.

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 interior air supplies are

ported through the color-coded tubing 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, and ber

optic cable are connected at the robot plate. The bell plate

of the atomizer assembly is secured to the robot plate with a

threaded retaining ring.

Power Supply and Controls

The high voltage cascade (74793-03 or 74793-04) is located

outside the hazardous area and is controlled by the MicroPak

2e control unit. The low voltage output of the MicroPak 2e is

multiplied by the cascade to the high voltage level required.

The high voltage is supplied to the atomizer by a high voltage

cable (A13685-XX). A low voltage cable interconnects the

cascade and MicroPak 2e control.

The MicroPak 2e is designed to electronically limit current

to provide safe operation in a spray booth. The voltage and

current draw of the atomizer are continuously displayed on

the MicroPak 2e control panel. Voltage and over current limits

are adjustable on the front of the MicroPak 2e. MicroPak 2e

internal safety circuits will shut down the system on over-

current and cable faults.

The MicroPak 2e Single Bell Controller (A13613-XX), is a

free-standing unit which provides voltage to a remotely located

cascade and closed loop speed control for atomizer units.

The 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efciency,while

maintaining the maximum safety.

The MicroPak 2e Atomizer Controller builds upon previous

control technology and tightly integrates the MicroPak 2e

Atomizer Controller with the MicroPak 2e High Voltage

Controller.

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

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

Reference Manual LN-9265-00 (Latest Revision)

The RMA-670 is backwards compatible with the original

MicroPak Controller (LECU 5004) in exsisting installations.

INTRODUCTION

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Length: (SeeRMA-670ToolPoint,CenterofGravity,andEnvelopeDimensionsgureinthe

“Introduction” section)

Diameter: (SeeRMA-670ToolPoint,CenterofGravity,andEnvelopeDimensionsgureinthe

“Introduction” section)

Approximate Weight

Atomizer Only:

8.4 Kg (18.4 lbs.)

Total Payload: 9.6 Kg (21.1 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”)

81mm 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 at the Applicator:

(Nominal):

414-689 kPa (60-100 psig)

Maximum Fluid Pressure Supply:

Paint: 1035 kPa (150 psi)

Solvent: 1035 kPa (150 psi)

SPECIFICATIONS

Electrical:

Power Supply Type: MicroPak 2e

Charging Method: Indirect

Output Voltage: 30-70 kV Variable

Output Current: 1000 µA Maximum

Turbine Speed Control: Multi-function 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)

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Mechanical (Cont.):

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

Bell Cup Replacement Time:

Less than 2 min.

MicroPak 2e Software:

V 1.1.00 and higher

Air Filter Requirements:

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

 recommended.Seeair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canoperate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 mar-

kets.Operatingabovethisrangeisforhighlyspecializedapplicationsandmayreduceef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.

*

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

65 mm Bell Cup Max. Flow Rate: 1000 cc/min. at 60 krpm

Max. Flow Rate: 200 cc/min. at 100 krpm

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

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

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

INTRODUCTION

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PARTS IDENTIFICATION

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

RMA-670 INDIRECT CHARGE ROTARY ATOMIZER

Single Purge

When ordering, use RMA670-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.)

Shape Air Kit

Dual Air

Bell Cup Size Bell Cup Type

A

Splash Plate

B

Fluid Tip

CC

••

•

65 - 65mm Diameter

81 - 81mm 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 - S.S. With Titanium Base

07 - 0.7mm/.028in Opening

09 - 0.9mm/.035in Opening

10 - 1.0mm/.039in Opening

11 - 1.1mm/.045in Opening

13 - 1.3mm/.051in Opening

16 - 1.6mm/.062in Opening

07 - 0.7mm/.028in Opening

09 - 0.9mm/.035in Opening

10 - 1.0mm/.039in Opening

11 - 1.1mm/.045in Opening

13 - 1.3mm/.051in Opening

16 - 1.6mm/.062in Opening

•

Part Number Reference - CCDE Assembly Part Number

65mm 81mm

Bell Cup Size

Titanium Serrated

Splash Plate (Included in Assembly Part Number)

DLC Coated S.S. With Titanium Base

Bell Cup Type

TABLE A – BELL CUP

RMA670-1265ABCC

RMA670-1281ABCC

07 A14467-07 07 - 0.7 mm (.028”) Opening

09 A14467-09 09 - 0.9 mm (.035”) Opening

10 A14467-10 10 - 1.0 mm (.039”) Opening

11 A14467-11 11 - 1.1 mm (.045”) Opening

13 A14467-13 13 - 1.3 mm (.051”) Opening

16 A14467-16 16 - 1.6 mm (.062”) Opening

Part No. Reference - FF Part No. Description

TABLE B – FLUID NOZZLES

Titanium Non-Serrated

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TUBING BUNDLE MODEL IDENTIFICATION

When ordering, use TB670-AABBCDEEFF as indicated by the following tables.

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

TABLE AA – ROBOT ADAPTER

Conguration Number Description Robot Adapter Number

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

TABLE BB – TUBING BUNDLE LENGTH

Conguration Number Tubing Length TA Length

00 NO TUBING NO TUBING

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

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

TABLE C – FIBER OPTIC CABLE

Conguration Number Description Fiber Optic Cable Qty.

0 NONE 0

F INCLUDED 1

TABLE D – HIGH VOLTAGE AND GROUND CABLE

Conguration Number Description High Voltage and

Ground Cable Assemblies Qty.

0 NONE 0

V INCLUDED 1

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TABLE FF – SECONDARY FIBER OPTIC CABLE LENGTH

Conguration Number Conguration Number Fiber Optic Cable Extension Qty. Fiber Optic Extension Cable Number Fiber Optic / Low Voltage Connector

Assembly Qty.

00 N/A 0 N/A 0

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

12 12 m (40 FT.) 1 A14195-16 1

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

20 20 m (65 FT.) 1 A14195-18 1

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

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

40 40 m (125 FT.) 1 A14195-21 1

TABLE EE – PRIMARY

HIGH VOLTAGE CABLE LENGTH

Conguration Number Cable Length High Voltage Cable Number

00 N/A N/A

01 1.5 m (4 FT.) A13685-05

03 3 m (10 FT.) A13685-10

04 4.6 m (15 FT.) A13685-15

06 6 m (20 FT.) A13685-20

08 8 m (25 FT.) A13685-25

10 10.7 m (35 FT.) A13685-35

15 15 m (50 FT.) A13685-50

22 22.9 m (75 FT.) A13685-75

30 30 m (100 FT.) A13685-100

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SINGLE BELL CONTROLLER MODEL IDENTIFICATION

When ordering, use A13613-009916A9BC-D1740 as indicated by the following

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

TABLE A – AC INPUT CABLE

Conguration Number Description Cable Number

0 AC INPUT CABLE - NORTH AMERICA 76449-00

1 AC INPUT CABLE - EUROPE 76449-02

2 AC INPUT CABLE - CHINA 76449-03

TABLE B – UNILINK CONFIGURATION

Conguration Number Description

1 UNILINK MODE DISABLED

2 UNILINK MODE ENABLED

TABLE C - MULTI I O BOARD CONFIGURATION

Conguration Number Description Multi I-O Board Number

0 NO MULTI I-0 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

LOW VOLTAGE CABLE MODEL IDENTIFICATION

Part Number Description Length

A13745-01 LOW VOLTAGE CABLE ASSEMBLY, RP1000 TO MP2e SINGLE BELL CONTROLLER 23 m (75 FT.)

A13745-02 LOW VOLTAGE CABLE ASSEMBLY, RP1000 TO MP2e SINGLE BELL CONTROLLER 30 m (100 FT.)

A13745-03 LOW VOLTAGE CABLE ASSEMBLY, RP1000 TO MP2e SINGLE BELL CONTROLLER 9 m (30 FT.)

HIGH VOLTAGE CASCADE MODEL IDENTIFICATION

Part Number Description

74793-03 CASCADE ASSEMBLY, RANSPAK 1000, TOP CONNECTOR

74793-04 CASCADE ASSEMBLY, RANSPAK 1000, STRAIGHT CONNECTOR

74793-03 74793-04

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Carlisle RMA-670 Robot Atomizers User manual

Carlisle RMA-670 Robot Atomizers User manual

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