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AH-07-01.8

Vector AA90 Applicators - Operation

5 4

APPLICA

APPLICAT

TOR REP

OR REP

OR REPAIR

AIR

All repairs should be made on a clean, flat surface.
If a vise is used to hold parts during service or
repair, DO NOT clamp onto plastic parts and
always pad the vise jaws!

Apply dielectric grease (LSCH0009-00) to the
following parts when assembling:

• All O-Rings (Teflon o-rings do not need lu-

brication)

• Needle Shaft Assembly
• Packing Tube
• Resistor Tube Assembly (Classic)
• Air Valve Rod Assembly 79310-00

Apply sealant (7969-10) to the external threads of
the following parts when assembling:

• Air Valve Retaining Nut

EQUIPMENT REQUIRED

• Special Multi-Purpose Applicator

Wrench 19749-00

• Air Cap Removal Tool 79642-00

• 2.5mm Wrenches 74133-00 (2)

• Nozzle Wrench 76428-00

• 3/32-inch Allen Wrench

• Open End Wrenches: 15/16, 7/8, 11/16,

9/16, 7/16, 3/4, 3/8, and 1/4-inch

• Screwdriver (blade)

• Dielectric Grease LSCH0009-00

• Medium Strength Sealant 7969-10

• Plastic or Wood Dowel Rod, 5/16-inch

diameter

Содержание Vector AA90 79580

Страница 1: ...nd all instructions in this manual Keep this Service Manual for future manual Keep this Service Manual for future manual Keep this Service Manual for future manual Keep this Service Manual for future...

Страница 2: ...s been changed from revision AH 07 01 7 AH 07 01 7 AH 07 01 7 AH 07 01 7 AH 07 01 7 to revision AH 07 01 8 AH 07 01 8 AH 07 01 8 AH 07 01 8 AH 07 01 8 Reasons for this change are noted under Manual Ch...

Страница 3: ...NSTALLATION CASCADE CASCADE CASCADE CASCADE CASCADE TYPICAL AA90 CASCADE APPLICATOR INSTALLATION FEATURES MOUNTING THE CONTROL UNIT 79527 00 9050 MOUNTING KIT PARTS LIST 79527 00 9050 CASCADE ENCLOSUR...

Страница 4: ...ON CASCADE UNITS CLASSIC CLASSIC CLASSIC CLASSIC CLASSIC START UP CLASSIC UNITS SETTING AND ADJUSTING OUTPUT VOLTAGE BASIC OPERATIONS CLASSIC UNITS TO REMOVE THE APPLICATOR FROM THE WORK SITE APPLICAT...

Страница 5: ...TS LIST 7994 XXFLUIDLINE 79575 00 AA90 NEEDLE SHAFT PARTS LIST FAN AIR VALVE PARTS LIST 79513 13X CONTROL UNIT PARTS LIST AA90 CLASSIC POWER SUPPLY PARTS LIST AA90 APPLICATORS RECOMMENDED SPARE PARTS...

Страница 6: ...ury A NOTE is information relevant to the A NOTE is information relevant to the A NOTE is information relevant to the A NOTE is information relevant to the A NOTE is information relevant to the proced...

Страница 7: ...to the atomizer must be turned off prior to cleaning flushing or maintenance When using solvents for cleaning Thoseusedforequipmentflushingshouldhaveflash points equal to or higher than those of the c...

Страница 8: ...Explosion Explosion Explosion Explosion Explosion Hazard Hazard Hazard Hazard Hazard Incompatible Incompatible Incompatible Incompatible Incompatible Materials Materials Materials Materials Materials...

Страница 9: ...the applicator If work gloves are used the palm section should be cut out Operators must remove from themselves all metal objects that are not grounded NOTE NOTE NOTE NOTE NOTE REFER TO APPLICABLE COU...

Страница 10: ...lockthepowersupplyoutsothatitcannot be turned ON until the work is finished Whenever removing high voltage cables from equipment ground the contact end of the cable by holdingthecablesuchthattheconta...

Страница 11: ...tennis and bowling to name a few Pain tingling or numbness in the shoulder forearm wrists hands or fingers especially during the night may be early symptoms of a CTD Do not ignore them Should you exp...

Страница 12: ...dedbytheequipment 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...

Страница 13: ...80AA90CascadeSeriesApplicator shall only be used with associated 79513 Series Control Unit Product Marking Product Marking Product Marking Product Marking Product Marking II 2 G II 2 G II 2 G II 2 G I...

Страница 14: ...AH 07 01 8 CONFIGURATION DWG 79952 REV A E DESIGNATIONS B DESIGNATIONS C DESIGNATIONS A DESIGNATIONS D DESIGNATIONS 9 9 9 9 9...

Страница 15: ...1009 1013 TIP 79691 1013 1018 TIP 79691 1018 1021 TIP 79691 1021 1311 TIP 79691 1311 1313 TIP 79691 1313 1315 TIP 79691 1315 1318 TIP 79691 1318 1511 TIP 79691 1511 1513 TIP 79691 1513 1515 TIP 79691...

Страница 16: ...AH 07 01 8 11 11 11 11 11 CONFIGURATION DWG 79953 REV A E DESIGNATIONS B DESIGNATIONS C DESIGNATIONS A DESIGNATIONS D DESIGNATIONS...

Страница 17: ...PART NUMBER 79691 1011 4 FOR 1015 TIP WITHOUT PREORIFICE PART NUMBER 79691 1015 OPTION D DESIGNATIONS FLUID HOSE LENGTH 0 FOR NO FLUID HOSE 1 FOR 11m 36FT FLUID HOSE PART NUMBER 7994 36 2 FOR 15m 50F...

Страница 18: ...around and deposit it on the back surfaceofthetarget Therefore ahighpercentage of the coating is deposited on the target One of the many features of the Vector AA90 applicator system is that the elec...

Страница 19: ...AH 07 01 8 Vector AA90 Applicators Introduction 14 14 14 14 14 NOTES NOTES NOTES NOTES NOTES...

Страница 20: ...Flow Rate Fluid Flow Rate Fluid Flow Rate Fluid Flow Rate Fluid Flow Rate Variable to 1 500 cc minute spraytipdependent Air Pressure Air Pressure Air Pressure Air Pressure Air Pressure 6 9 bar 0 100ps...

Страница 21: ...ption Description Description Description Cap Electrode Barrel HP ReplaceableHook Fan Air Adjust 2 FingerTrigger AA90 CASCADE SOL AA90 CASCADE SOL AA90 CASCADE SOL AA90 CASCADE SOL AA90 CASCADE SOLVEN...

Страница 22: ...Description Description Description Description Setpoint Adjust Buttons kV Setpoint Adjust Button kV Meter HV On Indicator A Meter Local RemoteModeIndicator 79513 13X CASCADE CONTROL 79513 13X CASCADE...

Страница 23: ...ysical Environmental Physical Electrical Electrical Electrical Electrical Electrical Mechanical Mechanical Mechanical Mechanical Mechanical Sound Level Sound Level Sound Level Sound Level Sound Level...

Страница 24: ...Description Description Description Description Description Cap Electrode Barrel HP ReplaceableHook Fan Air Adjust 2 FingerTrigger AA90 CLASSIC SOL AA90 CLASSIC SOL AA90 CLASSIC SOL AA90 CLASSIC SOL A...

Страница 25: ...igh Voltage On Indicator Reset Button A Meter Fault Indicator On Off Switch Local Remote Mode Indicator One Touch kV Setpoint Button 79344 14X 9050 POWER SUPPL 79344 14X 9050 POWER SUPPL 79344 14X 905...

Страница 26: ...YPICAL AA90 CASCADE APPLICA APPLICA APPLICA APPLICA APPLICAT T T T TOR OR OR OR OR INST INST INST INST INSTALLA ALLA ALLA ALLA ALLATION TION TION TION TION Connect the low voltage cable to the control...

Страница 27: ...LineCord 110 220 9050ControlUnit Vector Applicator Ball Valve AirRegulatorW PressureGauge Air WaterSeparator Main Air Supply TYPICAL TYPICAL TYPICAL TYPICAL TYPICAL AA90 CASCADE APPLICA AA90 CASCADE A...

Страница 28: ...ed to the wall or ceiling studs If secured to the wall or ceiling studs If secured to the wall or ceiling studs If mounting to a metal wall or ceiling mounting to a metal wall or ceiling mounting to a...

Страница 29: ...24 5 2 4 5 2 5 3 2 5 2 1 1 1 1 2 5 2 3 5 2 5 2 4 5 Figure 6 79527 00 9050 Cascade Enclosures Figure 6 79527 00 9050 Cascade Enclosures Figure 6 79527 00 9050 Cascade Enclosures Figure 6 79527 00 9050...

Страница 30: ...nduit For maximum noise protection any user supplied input output I O wiring should be made using shielded cable or conduit which is connected to earth ground in a continuous 360 fashion at both ends...

Страница 31: ...d mark 1 inch span of cable that passes through connector housing to be stripped to braid see Figure 9 3 Remove cable and strip marked 1 inch section to cable braid 4 Slide the cable grommet hardware...

Страница 32: ...cal codes permit the AC power may be supplied via the factory supplied line cord If conduit is utilized the control unit AC input wiring may be routed through an optional explosion proof switch mounte...

Страница 33: ...relay contacts for high voltage CR1 and fault CR2 conditions is provided at TB2 3 and TB2 1 see Figure 10a One end of these relay contacts are connected together and also connected to a source input t...

Страница 34: ...atic Figure 10b Interlock Schematic Figure 10b Interlock Schematic Figure 10b Interlock Schematic Figure 10b Interlock Schematic Figure 10c Installation of Conduit Adapter Figure 10c Installation of C...

Страница 35: ...mJ of energy To achieve this limit any flow of energy from the paint supply through the paint line to the applicator electrode must be prevented by grounding the paint line at the applicator handle V...

Страница 36: ...ACLineCord 110 220 9050ControlUnit Vector Applicator Ball Valve AirRegulatorW PressureGauge Air WaterSeparator Main Air Supply TYPICAL TYPICAL TYPICAL TYPICAL TYPICAL AA90 CLASSIC APPLICA AA90 CLASSIC...

Страница 37: ...ousing see Figure 14 2 Route the desired length of I O cable through the connector housing and mark 1 inch span of cable that passes through connector housing to be stripped to braid see Figure 15 3 R...

Страница 38: ...re the AC line cord is unplugged and removetheACinletreceptaclewiringfromTB1 N TB1 L1 and TB1 EARTH GROUND see Figures 16a and 16b 2 Remove the mounting hardware from the AC inlet receptacle and remov...

Страница 39: ...ion of TB1 and TB2 In Figure 16a Location of TB1 and TB2 In Power Supply Power Supply Power Supply Power Supply Power Supply Figure 16b TB1 Interlock Wiring Figure 16b TB1 Interlock Wiring Figure 16b...

Страница 40: ...mation on interlocking the high voltage OFF OFF OFF OFF OFF signal with the solvent flush signal W A R N I N G W A R N I N G W A R N I N G W A R N I N G W A R N I N G Figure 16d Power Supply Schematic...

Страница 41: ...itisnotdamagedby foot and vehicle traffic and also so that it is not close to areas of high temperature 129 F The operator should have free movement of the applicator andallbendradiiofthecableshouldno...

Страница 42: ...r assembly onto the factory air Max Switching Capacity Max Operating Voltage Max OperatingCurrent MAXIMUM CONT MAXIMUM CONT MAXIMUM CONT MAXIMUM CONT MAXIMUM CONTACT ACT ACT ACT ACT RA RA RA RA RATING...

Страница 43: ...AH 07 01 8 Vector AA90 Applicators Installation 38 38 38 38 38 NOTES NOTES NOTES NOTES NOTES...

Страница 44: ...dsuppliertodeterminethechemicalcontent ofyoursolvents See HHCExplosionHazard Danger Sign and Halogenated Hydrocarbon Safety Bulletin Never flush the applicator with solvent while electrostatics are on...

Страница 45: ...s necessary for all applications The selection of the best nozzle to apply a given coating to a specific article with maximum efficiency is not an exact science Testing is usuallynecessaryandwideexper...

Страница 46: ...le Nozzle Part Part Part Part Part Pattern Pattern Pattern Pattern Pattern Width at Width at Width at Width at Width at 10 in mm 10 in mm 10 in mm 10 in mm 10 in mm Nozzle Nozzle Nozzle Nozzle Nozzle...

Страница 47: ...ascade Units This fault will occur if high voltage is active and the microprocessor detects that no current is being supplied to the applicator This indicates a connection problem from the control uni...

Страница 48: ...overload jumper JP17 in the power supply to the open position Current Limit Fault CL Current Limit Fault CL Current Limit Fault CL Current Limit Fault CL Current Limit Fault CL This fault will occur...

Страница 49: ...he Fault Troubleshooting Section to determine if the problem is with the low voltage cable the cascade unit in the gun or the main PC board in the control unit Classic Units Classic Units Classic Unit...

Страница 50: ...he software revision level in the A display for 2 3 seconds Figure 23 Control Unit Start Up Display Figure 23 Control Unit Start Up Display Figure 23 Control Unit Start Up Display Figure 23 Control Un...

Страница 51: ...ontrol Unit Figure 24 Front View of Control Unit Figure 24 Front View of Control Unit Figure 24 Front View of Control Unit Figure 24 Front View of Control Unit Setpoints cannot be adjusted below 20 kV...

Страница 52: ...ont Panel Lockout Front Panel Lockout Front Panel Lockout Front Panel Lockout This feature locks out any changes to the kV setting from the front panel of the control unit 1 Set the kV to the desired...

Страница 53: ...for applications that require notification of high applicator output currents The overload value is set in the software and is maximum microamp rating minus 10 microamps 1 Turn AC power off and acces...

Страница 54: ...fficiency The display at the rear of the applicator also doublesasamicroampbargraphmeterwhenhigh voltageison seeFigure30 Its functionissimilar to that of the control unit bar graph display Figure 32 V...

Страница 55: ...he microamp display will show the current software revision level These items are displayed for about 2 3 seconds DO NOT DO NOT DO NOT DO NOT DO NOT use a 65 kV Classic applica tor with the 90 kV powe...

Страница 56: ...ge for maximum transfer efficiency The red regionofthebargraphindicateshighoutputcurrent causing decreased transfer efficiency SETTING AND SETTING AND SETTING AND SETTING AND SETTING AND ADJUSTING OUT...

Страница 57: ...T I O N C A U T I O N C A U T I O N Measuring High V Measuring High V Measuring High V Measuring High V Measuring High Voltage On oltage On oltage On oltage On oltage On T T T T Time ime ime ime ime T...

Страница 58: ...unscrew the nut by hand Remove the low voltage cable by pulling it from the plug assembly Classic Applicator Classic Applicator Classic Applicator Classic Applicator Classic Applicator Pull the clip o...

Страница 59: ...ion Needle Shaft Assembly Packing Tube Resistor Tube Assembly Classic Air Valve Rod Assembly 79310 00 Apply sealant 7969 10 to the external threads of the following parts when assembling Air Valve Ret...

Страница 60: ...hat cannot be soaked are noted throughout this manual All electrical components cannot be cleaned or soaked in any solvents ROUTINE SCHEDULE ROUTINE SCHEDULE ROUTINE SCHEDULE ROUTINE SCHEDULE ROUTINE...

Страница 61: ...ode Slide the test probe straight over the electrode wire of the applicator Injury to personnel and damage to equipment is probable if the ground clip is NOT ATTACHED NOT ATTACHED NOT ATTACHED NOT ATT...

Страница 62: ...pes of coating material NOTE NOTE NOTE NOTE NOTE If the coating material is fast settling and the fluid lines are not flushed soon enough the internal passages may be come clogged This can lead to exc...

Страница 63: ...e replaced Any damage to the applicator may result in UNSAFE UNSAFE UNSAFE UNSAFE UNSAFE operat ing conditions W A R N I N G W A R N I N G W A R N I N G W A R N I N G W A R N I N G A wire brush or met...

Страница 64: ...ip Removal Carbide Installation Installation Installation Installation Installation Barrel Removal Barrel Removal Barrel Removal Barrel Removal Barrel Removal 1 Remove air cap and retaining ring 2 Wit...

Страница 65: ...e 44b Barrel Disassembly Figure 44b Barrel Disassembly Figure 44b Barrel Disassembly Figure 44b Barrel Disassembly Needle Shaft Packing Needle Shaft Packing Needle Shaft Packing Needle Shaft Packing N...

Страница 66: ...al rear u cup rear spreader seal front u cup seal front spreader seal as shown Orient seals per Figure 52a 2 Installjamnutallthewayontheshaft Installthe carbide ball all the way down using two 74133 t...

Страница 67: ...ckingnutuntilresistanceontheshaft may be felt when the shaft is pushed in and out Figure 48c Rebuilding Barrel Figure 48c Rebuilding Barrel Figure 48c Rebuilding Barrel Figure 48c Rebuilding Barrel Fi...

Страница 68: ...move the barrel 2 Remove the fluid tube from the bracket 3 Remove the fan valve and rear cover Figure 49b Install Barrel on Handle Figure 49b Install Barrel on Handle Figure 49b Install Barrel on Hand...

Страница 69: ...dle Disassembly Figure 50g Handle Disassembly Figure 50g Handle Disassembly Figure 50g Handle Disassembly 9 For Classic Units remove resistor tube assembly Apply LSCH0009 00 dielectric grease to resis...

Страница 70: ...le 5 Badly worn nozzle 6 High voltage electrode bent 7 Low shaping air pressure 1 Pooratomization 2 Excessive exhaust veloc ity 3 Excessive fluid pressure 4 Applicator held too close to target 5 Paint...

Страница 71: ...uns or Has Paint Runs or Has Paint Runs or Has Poor Hiding Poor Hiding Poor Hiding Poor Hiding Poor Hiding Qualities Qualities Qualities Qualities Qualities 1 Restriction in pump air line 2 Insufficie...

Страница 72: ...connections 2 Improper or no ground at control unit 3 Faultybarrel cascadeassem bly 4 Faulty low voltage cable 5 Faulty control PC board 6 Dirtyaircapand orfluidnozzle 7 Blown fuse 8 Is the power turn...

Страница 73: ...AH 07 01 8 Vector AA90 Applicators Maintenance 68 68 68 68 68 NOTES NOTES NOTES NOTES NOTES...

Страница 74: ...de Solventborne Cable Cascade Solventborne Cable Lengths Metric Lengths Metric Lengths Metric Lengths Metric Lengths Metric 79338 10 79338 15 79338 10 2 79338 15 10 79338 15 2 A A A A A Cable Length C...

Страница 75: ...id Hose Length ABLE J Fluid Hose Length ABLE J Fluid Hose Length ABLE J Fluid Hose Length ABLE J Fluid Hose Length 0 1 2 3 4 7994 36 7994 50 7994 75 7994 100 Dash Dash Dash Dash Dash No No No No No J...

Страница 76: ...xploded View Figure 51 Vector AA90 Cascade Exploded View Figure 51 Vector AA90 Cascade Exploded View Figure 51 Vector AA90 Cascade Exploded View Figure 51 Vector AA90 Cascade Exploded View 41 42 44 2...

Страница 77: ...22 79454 00 Screw TriggerRetention 2 23 79638 00 Trigger Lock Assembly 1 24 25 26 8301 08C SHCS 1 27 79566 10 Assembly Valve Fan Click Adjust 1 28 79322 00 Hook Molded 1 29 79479 00 O Ring Cord 1 30...

Страница 78: ...ector AA90 Classic Exploded View Figure 52 Vector AA90 Classic Exploded View Figure 52 Vector AA90 Classic Exploded View Vector AA90 Applicators Parts Identification 73 73 73 73 73 45 47 2 9 38 4 14 2...

Страница 79: ...ve 1 23 79471 11 Assembly Rear Housing AA90 Classic 1 24 79453 00 Cap Retaining Air Valve 1 25 8301 08C SHCS 1 26 17130 00 Spring Return 1 27 79001 31 O Ring Solvent Proof 1 28 79378 00 Gasket Barrel...

Страница 80: ...1 79529 00 K5 Disposable Applicator Cover Lots of 5 7 74187 02 Air Hose Assembly 2m Whip 6 5 ft 1 8 77105 00 Adapter 3 8 AN Male to 1 4 NPSM M 1 9 79338 01 1 Meter Low Voltage Cable 79580 Vector Casca...

Страница 81: ...t Figure 55 79575 00 AA90 Needle Shaft Figure 55 79575 00 AA90 Needle Shaft 1 79618 00 Spreader Seal Front 1 2 73345 00 Seal Front U Cup 1 3 72378 01 Packing Tube 1 4 73347 00 Container RearSeal 1 5 7...

Страница 82: ...Qty Qty Qty Qty F F F F FAN AIR V AN AIR V AN AIR V AN AIR V AN AIR VAL AL AL AL ALVE P VE P VE P VE P VE PAR AR AR AR ARTS LIST TS LIST TS LIST TS LIST TS LIST Figure 56 Figure 56 Figure 56 Figure 56...

Страница 83: ...lips Pan Head Stainless Steel 8 5 79428 00 Power Supply 24 VDC 1 6 79491 00 Filter AC Line Assembly 1 7 72771 06 Fuse 110 120 V 1 Amp Time Delay 5mm X 20mm 2 8 76449 00 AC Line Cord 1 9 A11357 01 Cabl...

Страница 84: ...5307 04 Nut Conduit 1 9 79350 02 HV Multiplier Assembly 65 kV for 79344 11X 1 79350 01 HV Multiplier Assembly 90 kV for 79344 12X 1 72771 01 Fuse 220 240 V 0 5 Amp Time Delay 5mm X 20mm 2 72771 06 Fus...

Страница 85: ...Paint Filter 100 Mesh 1 1 7720 02 Paint Filter 60 Mesh 1 1 78824 00 Spring 1 1 79566 10 Fan Air Valve Assembly 1 1 79695 00 Air Cap 1 1 79691 XXXX Carbide Spray Tips 1 1 79616 00 RearU CupSeal 1 1 79...

Страница 86: ...USE OF FAULTY WORKMANSHIP OR MATER OF FAULTY WORKMANSHIP OR MATER OF FAULTY WORKMANSHIP OR MATER OF FAULTY WORKMANSHIP OR MATER OF FAULTY WORKMANSHIP OR MATER IALS THERE ARE NO IMPLIED WARRAN IALS THE...

Страница 87: ...7 AH 07 01 7 AH 07 01 7 AH 07 01 7 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...

Страница 88: ...hnical Support Representative will direct you to the appropriate telephone number Technical Support Representative will direct you to the appropriate telephone number Technical Support Representative...

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