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Ransburg Vector AA90 Cascade Service Manual

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SERVICE MANUAL
AH-07-01.10
(Replaces AH-07-01.9)
MAY - 2015
VECTOR AA90 APPLICATORS
MODELS:
79580 Vector Cascade
79581 Vector Classic
IMPORTANT:
Before using this equipment,
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
Service Manual Price:
Ransburg
$50.00 (U.S.)

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Summary of Contents for Ransburg Vector AA90 Cascade

  • Page 1 SERVICE MANUAL Ransburg AH-07-01.10 (Replaces AH-07-01.9) MAY - 2015 VECTOR AA90 APPLICATORS MODELS: 79580 Vector Cascade 79581 Vector Classic IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting on page 1, and all instructions in this manual. Keep this Service Manual for future reference.
  • Page 2 Vector AA90 Applicators NOTE: This manual has been changed from revision AH-07-01.9 to revision AH-07-01.10. Reasons for this change are noted under “Manual Change Summary” on page 57 of this manual. AH-07-01.10...

  • Page 3: Table Of Contents

    EUROPEAN ATEX DIRECTIVE ....................5 EUROPEAN ATEX LABELS ....................6 FM CONFIGURATION DRAWINGS ..................7-10 INTRODUCTION: 11-17 THE RANSBURG ELECTROSTATIC VECTOR AA90 PROCESS ........11 CASCADE - SPECIFICATIONS SOLVENTBORNE (CASCADE) ............12 - 80131-41X CONTROL UNIT ELECTRICAL SPECIFICATIONS ........12 - AA90 CASCADE SOLVENTBORNE ELECTROSTATIC SPRAY APPLICATOR FEATURES - AIR ASSIST ................13...
  • Page 4 46-56 79580 VECTOR AA90 APPLICATOR MODEL IDENTIFICATION ........46 79581 VECTOR AA90 APPLICATOR MODEL IDENTIFICATION ........47 VECTOR AA90 CASCADE EXPLODED VIEW /PARTS LIST ..........48-49 VECTOR AA90 CLASSIC EXPLODED VIEW / PARTS LIST ..........50-51 ACCESSORIES ........................52 7994-XX FLUID LINE ......................53 79575-00 AA90 NEEDLE SHAFT ..................

  • Page 5: Safety

    Safety Section in this manual and understand all of the technical and safety litera- the Ransburg safety literature therein iden- ture for your Ransburg products. This manual tified. contains information that is important for you to know and understand. This information relates to †...

  • Page 6: Hazards / Safeguards

    Vector AA90 Applicators - Safety AREA HAZARD SAFEGUARDS Tells what the hazard is. Tells how to avoid the hazard. Tells where hazards may occur. Spray Area Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically. Improper or inadequate Spray areas must be kept clean to prevent the operation and maintenance...
  • Page 7 Vector AA90 Applicators - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. Certain material may be harmful Follow the requirements of the Material Safety Data Toxic if inhaled, or if there is contact Sheet supplied by coating material manufacturer.
  • Page 8 Vector AA90 Applicators - Safety AREA HAZARD SAFEGUARDS Tells where hazards Tells what the hazard is. Tells how to avoid the hazard. may occur. Spray Area Electrostatic Arcing Never operate the applicator without properly grounding the following. A. Operators Operators must be grounded. Rubber soled insulating shoes should not be worn.

  • Page 9: Atex/Fm

    Vector AA90 Applicators - Atex EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6 The following instructions apply to equipment 8. The certification of this equipment relies upon covered by certificate number Sira 06ATEX5282X: the following materials used in its construction: 1. The equipment may be used with flammable If the equipment is likely to come into contact with gases and vapors with apparatus groups II and aggressive substances, then it is the responsibility...

  • Page 10: European Atex Labels

    Vector AA90 Applicators - Atex Vector AA90 79580 and 79581 Label 79515 ATEX Product Marking Definitions Ex Certificate Number: Sira 06ATEX5282X Sira = Notified Body performing EC-type examination 06 = Year of certification ATEX = Reference to ATEX Directive 5 = Protection Concept Code (code 5 is titled Encapsulation) Label 79612-01 282 = Document serial number...

  • Page 11: Fm Configuration Drawings

    Vector AA90 Applicators - Atex "C" DESIGNATIONS "B" DESIGNATIONS "A" DESIGNATIONS "D" DESIGNATIONS "E" DESIGNATIONS CONFIGURATION DWG. 79952 REV A AH-07-01.10...
  • Page 12 Vector AA90 Applicators - Atex OPTION "A" DESIGNATIONS CABLE LENGTH 0 FOR NO CABLE 1 FOR 10 METER CABLE-PART NUMBER: 79338-10 2 FOR 15 METER CABLE-PART NUMBER: 79338-15 3 FOR 20 METER CABLE-PART NUMBER: 79338-10 (2) 4 FOR 25 METER CABLE-PART NUMBER: 79338-10 (1) & 793 38-15 (1) 5 FOR 30 METER CABLE-PART NUMBER: 79338-15 (2) OPTION "B"...
  • Page 13 Vector AA90 Applicators - Atex "C" DESIGNATIONS "B" DESIGNATIONS "A" DESIGNATIONS "E" DESIGNATIONS "D" DESIGNATIONS CONFIGURATION DWG. 79953 REV A AH-07-01.10...
  • Page 14 Vector AA90 Applicators - Atex OPTION "A" DESIGNATIONS CABLE LENGTH 0 FOR NO CABLE 1 FOR 10 METER CABLE-PART NUMBER: 79519-10 2 FOR 15 METER CABLE-PART NUMBER: 79519-15 3 FOR 20 METER CABLE-PART NUMBER: 79519-20 4 FOR 25 METER CABLE-PART NUMBER: 79519-25 5 FOR 30 METER CABLE-PART NUMBER: 79519-30 OPTION "B"...

  • Page 15: Introduction

    Vector AA90 Applicators - Introduction INTRODUCTION THE RANSBURG ELECTROSTATIC VECTOR AA90 PROCESS This is a combined air/airless method for electro- The power supply provides voltage output to the statically applying coatings to objects. The Vector applicator and contains controls for AC on/off, AA90 system applies a high voltage DC charge to high voltage adjust, "one touch"...

  • Page 16: Cascade

    Vector AA90 Applicators - Introduction SPECIFICATIONS 80131-41X CONTROL UNIT SOLVENTBORNE ELECTRICAL SPECIFICATIONS (CASCADE) Electrical Environmental/Physical Input Voltage: 100-240 VAC Applicator Length: 25.9cm (10.2-inches) Current: 1 A maximum RMS Weight: 760g (1.67 lbs.) Frequency: 50/60 Hz (Cascade) Wattage: 40 watts (maximum) Hose and Cable Lengths: 10m, 15m, 20m, 25m, and 30m...

  • Page 17: Aa90 Cascade Solventborne Electrostatic Spray Applicator Features - Air Assist

    Vector AA90 Applicators - Introduction Figure 1: AA90 Cascade Solventborne Electrostatic Spray Applicator Features - Air Assist AA90 CASCADE SOLVENTBORNE ELECTROSTATIC SPRAY APPLICATOR FEATURES - AIR ASSIST Description Description Cap/Electrode Trigger Lock Assembly Barrel, HP Fluid Hose Connection Replaceable Hook Air Inlet Connection Fan Air Adjust Low Voltage Cable Connection...

  • Page 18: 80131-13X Cascade Control Unit Features

    Vector AA90 Applicators - Introduction Figure 2: 80131-13X Cascade Control Unit Features 80131-41X 9060 CASCADE CONTROL UNIT FEATURES Description Description Setpoint Adjust Buttons Interlock Connector kV Setpoint Adjust Button AC Line Connector kV Meter Fuses HV On Indicator Ground Lug µA Meter Standard I/O Connector Local/Remote Mode Indicator...

  • Page 19: Classic

    Vector AA90 Applicators - Introduction SPECIFICATIONS 80130-41X 9060 POWER SOLVENTBORNE SUPPLY ELECTRICAL (CLASSIC) SPECIFICATIONS Environmental/Physical Electrical Applicator Length: 2.59cm Input Voltage: 100-240 VAC (10.2-inches) Current: 1 A maximum RMS Weight: 687.5g (1.52 lbs.) Frequency: 50/60 Hz (Classic) Hose and Cable Lengths: 10m, 15m, 20m, Wattage: 40 watts (maximum)

  • Page 20: Aa90 Classic Solventborne Electrostatic Spray Applicator Features - Air Assist

    Vector AA90 Applicators - Introduction Figure 3: AA90 Classic Solventborne Electrostatic Spray Applicator Features - Air Assist AA90 CLASSIC SOLVENTBORNE ELECTROSTATIC SPRAY APPLICATOR FEATURES - AIR ASSIST Description Description Cap/Electrode Trigger Lock Assembly Barrel, HP Fluid Hose Connection Replaceable Hook Air Inlet Connections Fan Air Adjust High Voltage Cable Connection...

  • Page 21: 80130-14X 9060 Power Supply Features

    Vector AA90 Applicators - Introduction Figure 4: 80130-14X 9060 Power Supply Features 80130-41X 9060 POWER SUPPLY FEATURES Description Description kV Setpoint/Adjust Buttons kV Meter Air Flow Switch Connections (Low Flow) High Voltage On Indicator High Voltage Cable Connector Reset Button Standard I/O Connector µA Meter Fuses...

  • Page 22: Installation

    • Provide conductive flooring in all spray areas. This information is intended ONLY to indicate general installation guidelines of this product and its working relationship to other Ransburg system components. Each installation is unique and TYPICAL AA90 CASCADE should be directed by an Ransburg representative.
  • Page 23 Vector AA90 Applicators - Installation R<1 Meg Ohm Figure 5: Typical AA90 Cascade Applicator Installation Features TYPICAL AA90 CASCADE APPLICATOR INSTALLATION FEATURES Description Description AC Line Cord (110/220) Fluid Supply (Grounded) 9060 Control Unit Fluid Regulator Vector Applicator Air Line Ball Valve Low Voltage Cable Air Regulator W/Pressure Gauge...

  • Page 24: Low Voltage Cable

    Vector AA90 Applicators - Installation LOW VOLTAGE CABLE W A R N I N G † The electrical discharge that is available Connect the low voltage cable from the control from the charging electrode must not exceed unit to the applicator using a wrench to tighten. 0.25 mJ of energy.
  • Page 25 Vector AA90 Applicators - Installation R<1 Meg Ohm Figure 12: Typical AA90 Classic Applicator Installation Features TYPICAL AA90 CLASSIC APPLICATOR INSTALLATION FEATURES Description Description AC Line Cord (110/220) Fluid Supply (Grounded) 9060 Control Unit Fluid Regulator Vector Applicator Air Line Ball Valve Low Voltage Cable Air Regulator W/Pressure Gauge...

  • Page 26: Classic Power Supply Installation

    Vector AA90 Applicators - Installation CLASSIC POWER HIGH VOLTAGE CABLE SUPPLY INSTALLATION Position the applicator in the spray area and route the high voltage cable to the power supply. The C A U T I O N cable should be routed so that it is not damaged by foot and vehicle traffic and also so that it is DO NOT locate the power supply near >...

  • Page 27: Filters

    (2800 psig) working pressure or above. LINE HOSE - AIR (CLASSIC AND CASCADE) Ransburg supplies a standard 2m whip hose with all applicator assemblies. Connect air hose of proper size and length based on application. W A R N I N G †...

  • Page 28: Operation

    See "Trou- bleshooting Guide" or contact your authorized NOTE Ransburg representative. † The degree of atomization is depen- • Ground MUST be maintained during the addition dent on the viscosity of the paint formula-...

  • Page 29: Preparation

    A selection of the proper paint mixture is essential to electrostatic operation. Paint test equipment may be obtained through your Ransburg repre- † Ransburg recommends the use of a fluid sentative. For further paint formulation and test filter in addition to the filter in the applicator procedures, consult your Ransburg representative fluid line to reduce nozzle clogging.
  • Page 30 Vector AA90 Applicators - Operation Table II shows the available pre-orifice sizes. The TABLE I pre-orifice selected should be sized approximately NOZZLE SELECTION GUIDE .025mm (.001-inch) larger than the tip size open- Nozzle Operating ing. The pre-orifice can significantly increase the Identification Parameters usefull spray life of the tip.

  • Page 31: Powering Up Control Unit

    Vector AA90 Applicators - Operation POWERING UP read zero, OFF will be displayed in the microamp meter, and all kV setpoint indicator lights will be CONTROL UNIT disabled. Pressing the kV button in for another 2-3 seconds turns the kV to the applicator back on. (CASCADE UNITS) When the AC power is turned on, the unit will W A R N I N G...
  • Page 32 Vector AA90 Applicators - Operation other that is permanently retained in memory. The number of hours the unit's high voltage has been on may be displayed by depressing at the same time the preset 1 and reset buttons. The display will show hours of use for 3 seconds.

  • Page 33: Start Up (Classic Units)

    Vector AA90 Applicators - Operation START-UP begin incrementing or decrementing in units of 5 instead of 1. (CLASSIC UNITS) When the applicator trigger is off, the present setpoint can be changed by pressing the 1, 2, or After all installation procedures are completed, 3 buttons on the front panel.
  • Page 34 Vector AA90 Applicators - Operation The green and yellow regions of the bar graph meter indicate output current is in the optimum range for maximum transfer efficiency. The red region of the bar graph indicates high output current causing decreased transfer efficiency. Local/Remote Mode Button The 9060 Power Supply product line is designed currently for applicators only.

  • Page 35: To Remove The Applicator From The Work Site

    Vector AA90 Applicators - Operation TO REMOVE THE APPLICATOR FROM THE WORK SITE 1. Flush the applicator. (Refer to "Flushing Pro- cedures" in the "Maintenance" section.) C A U T I O N † ALWAYS remove the applicator from the work site for service or repair! †...

  • Page 36: Applicator Repair

    Vector AA90 Applicators - Operation APPLICATOR REPAIR EQUIPMENT REQUIRED • Special Multi-Purpose Applicator All repairs should be made on a clean, flat sur- Wrench 19749-00 face. If a vise is used to hold parts during service or repair, DO NOT clamp onto plastic parts and •...

  • Page 37: Maintenance

    Ransburg recommends that all exterior cleaning be done with non-po- lar solvents to prevent a conductive residue on ROUTINE SCHEDULE critical components.
  • Page 38 Vector AA90 Applicators - Maintenance Daily (or at start of each shift) 4. Line up the hole in the test probe and the electrode. Slide the test probe straight over the • Verify that ALL solvent safety containers are electrode wire of the applicator. grounded! 5.

  • Page 39: Flushing Procedures

    Vector AA90 Applicators - Maintenance FLUSHING C A U T I O N PROCEDURES † If the coating material is fast settling and the fluid lines are not flushed soon enough, the internal passages may be- The fluid system should be thoroughly cleaned by come clogged.
  • Page 40 Vector AA90 Applicators - Maintenance W A R N I N G C A U T I O N Ensure supply pressures have been A wire brush or metal tools must NEV- > > bled to zero prior to servicing the applica- ER be used.
  • Page 41 Vector AA90 Applicators - Maintenance Spray Tip Removal/Carbide 4. Locate the female opening of the tip holder on the male portion of the 79642-00 tool as shown in Removal 42c. Locate the tip holder in the air cap lining up 1.
  • Page 42 Vector AA90 Applicators - Maintenance Figure 44b: Barrel Disassembly 3. Pull needle shaft assembly straight out. Needle Shaft Packing Replacement 1. Remove spring spray retainer and lock nut from Figure 43: Barrel Removal shaft. Pull all rear seal parts off shaft. Replace components as required.
  • Page 43 Vector AA90 Applicators - Maintenance Needle Shaft Pack Reassembly 2. Using two 74133 tools, remove carbide ball and jam nut. Remove packing components. 1. Install pusher seal, rear u-cup, rear spreader seal, front u-cup seal, front spreader seal as shown. Orient seals per Figure 52a.
  • Page 44 Vector AA90 Applicators - Maintenance Rebuild Barrel 1. Install tip and seals into barrel. Figure 48c: Rebuilding Barrel Figure 48a: Rebuilding Barrel Install Barrel on Handle 2. Install a generous amount of LSCH0009-00 1. Adjust spring retainer and locking nut to dimen- into needle shaft cavity.
  • Page 45 Vector AA90 Applicators - Maintenance Figure 49b: Install Barrel on Handle Figure 50b: Handle Disassembly Handle Disassembly 4. Remove trigger lock assembly. 1. Remove the barrel. 5. Remove air fitting and bracket. 2. Remove the fluid tube from the bracket. Figure 50a: Handle Disassembly Figure 50c: Handle Disassembly 3.
  • Page 46 Vector AA90 Applicators - Maintenance 9. For Classic Units - remove resistor tube as- sembly. Figure 50d: Handle Disassembly 7. Remove gasket, hook, and hook gasket. Figure 50g: Handle Disassembly Apply LSCH0009-00 dielectric grease to resistor tube prior to reassembly. Figure 50e: Handle Disassembly 8.

  • Page 47: Troubleshooting Guide

    3. Reduce air pressure to pump. 4. Applicator held too close 4. Hold applicator further back. to target 5. Paint too conductive 5. Consult Ransburg technical assistance. 6. Poor target ground 6. Check ground integrity from target through support to ground. Paint Wraps Back On 1.
  • Page 48 Vector AA90 Applicators - Maintenance TROUBLESHOOTING GUIDE (Cont.) General Problem Possible Cause Solution Excessive Surging 1. Restriction in pump air line 1. Remove restriction. 2. Insufficient pump capacity 2. Secure larger pump or reduce output. 3. Clogged paint filter 3. Service or replace. 4.
  • Page 49 Vector AA90 Applicators - Maintenance TROUBLESHOOTING GUIDE (Cont.) General Problem Possible Cause Solution Improper or No 1. Faulty low voltage cable 1. Check and secure at the applicator and at the High Voltage connections control unit. 2. Improper or no ground at 2.

  • Page 50: Parts Identification

    Vector AA90 Applicators - Parts Identification PARTS IDENTIFICATION 79580 VECTOR AA90 APPLICATOR MODEL IDENTIFICATION When ordering, use 79580-A, B, C, D, and E as indicated by Tables A, B, C, D, and E. Five digits must follow the basic part number, for example: 79580 - A B C D E (Table E)

  • Page 51: 79581 Vector Aa90 Applicator Model Identification

    Vector AA90 Applicators - Parts Identification 79581 VECTOR AA90 APPLICATOR MODEL IDENTIFICATION When ordering, use 79581-A, B, C, D, and E as indicated by Tables A, B, C, D, and E. Five digits must follow the basic part number, for example: 79581 - A B C D E (Table K)

  • Page 52: Vector Aa90 Cascade Exploded View /Parts List

    Vector AA90 Applicators - Parts Identification Figure 51: Vector AA90 Cascade Exploded View AH-07-01.10...
  • Page 53 Vector AA90 Applicators - Parts Identification VECTOR AA90 CASCADE - PARTS LIST (Figure 51) Item # Part # Description 79568-00 Ring, Retaining, Air Assist 19603-8F Set Screw, Cup Point 79460-04 Assembly, Plug, Low Voltage 79588-00 Assembly, Barrel AA90 With Needle, Retaining Ring...

  • Page 54: Vector Aa90 Classic Exploded View / Parts List

    Vector AA90 Applicators - Parts Identification 9 38 Figure 52: Vector AA90 Classic Exploded View AH-07-01.10...
  • Page 55 Vector AA90 Applicators - Parts Identification VECTOR AA90 CLASSIC - PARTS LIST (Figure 52) Description Item # Part # 79476-01 Handle Assembly 79568-00 Ring, Retaining, Air Assist 19603-8F Set Screw, Cup Point 77096-00 Fluid Tube Assembly, 76105-00 Swivel, High Pressure 79584-00 Assembly, Barrel, AA90 Classic With Needle, Retaining Ring and Resistor Tube...

  • Page 56: Accessories

    Vector AA90 Applicators - Parts Identification Figure 53: Accessories ACCESSORIES - PARTS LIST (Figure 53) * Item # Part # Description 79676-00 Wrench, Nozzle Removal 74133-00 Wrench, Needle 76104-00 High Pressure Whip Hose, 1m 19749-00 Wrench Assembly 71880-06 Nipple, Male Double 79529-00 Disposable Applicator Cover 79529-00-K5...

  • Page 57: 7994-Xx Fluid Line

    Vector AA90 Applicators - Parts Identification 7994-XX FLUID LINE (Figure 54) Length Part Number Feet Meters 7994-36 36' ± 9" 11 ± .23 7994-50 50' ± 12" 15 ± .30 7994-75 75' ± 18" 23 ± .46 7994-100 100' ± 24" 30 ± .61 Figure 54: 7994-XX Fluid Line Figure 55: 79575-00 AA90 Needle Shaft 79575-00 AA90 NEEDLE SHAFT - PARTS LIST...

  • Page 58: Fan Air Valve Components / Parts List

    Vector AA90 Applicators - Parts Identification Figure 56: Fan Air Valve Components FAN AIR VALVE - PARTS LIST (Figure 56) Description Item # Part # 79566-10 Assembly, Fan Air Adjust (Contains #2 and #3) 79001-16 O-Ring, Solvent Proof 79001-07 O-Ring AH-07-01.10...

  • Page 59: Aa90 Applicators Recommended Spare Parts

    Vector AA90 Applicators - Parts Identification AA90 APPLICATORS RECOMMENDED SPARE PARTS Part # Description Classic Cascade 10051-05 Cup Seal, Spring Loaded 17130-00 Return Spring 72209-05 O-Ring 72375-02 Seal, PTFE 72375-03 Seal, PTFE 72378-01 Packing Tube 73344-00 Seal, Spreader 73345-00 U-Cup Seal 73347-00 Container, Rear Seal, 73348-00...

  • Page 60: Warranty Policies

    (90) days. EXCLUSIONS: EQUIPMENT: When purchased as a complete If, in Ransburg’s opinion the warranty item in unit, (i.e., guns, power supplies, control units, etc.), question, or other items damaged by this part is one (1) year from date of purchase. WRAPPING...
  • Page 61 Vector AA90 Applicators - Manual Changes MANUAL CHANGE SUMMARY This manual was published to replace Service Manual AH-07-01.9 Vector AA90 Applicators, to make the following changes: 1. Corrected “Special conditions for safe use” information in “ATEX” section with appropriate gun model numbers and their corresponding control units and power supplies.
  • Page 62 Fax: 419-470-2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts. Form No. AH-07-01.10 Litho in U.S.A. 05/15 © 2015 Ransburg. All rights reserved. Models and specifications subject to change without notice. Finishing Brands COMPANY...

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