Transcript
SERVICE INSTRUCTION SI– 14-07 June—2014
SERVICE INSTRUCTION A10560-XX and A13685-XX Ransburg offers 2 types of shielded high voltage cable assemblies: A10560-XX and A13685XX. Both assemblies can be used for applications requiring up to 100 kV. The shield in both cable assemblies provide the protection required to run them through areas where solvent and paint line or tubes are routed. This shield is connected to an earth ground. In the event that damage has occurred to the cable, HV will travel through this conductive shield causing it to dissipate and initiate a fault condition in the equipment supplying the voltage. Both cables can be run through “cat” track from the cascade to the applicator, including through the robot arm and wrist. It is highly recommended that, if possible, a jacket be placed over the cable when routing through “cat” track type areas to protect the outer sheathing of the cable. Suitable jacket material would be Nylon or FEP (fluorinated ethylene propylene) type tubing. There are however, applications where one type is more suitable than the other: A10560-XX: Although sometimes used in robotic applications, is most suitable for applications where the process motion does not require severe twisting, turning or bending. Reciprocators (vertical or horizontal) and stationary mounted applicators are typical examples. The cable bending radius should be maintained at 4.5 inches (114mm) or greater. Care should be taken on the exposed non-shielded ends of the cable that are affixed to the applicator or cascade by keeping any ground planes or grounded objects away by a minimum of 2 inches (50mm). Repetitive bending should be avoided at the transition locations near each end of this cable; where the shield is terminated and the unshielded portion begins. Repetitive bending at those locations can cause fatigue breakage. A13645-XX: This cable is more suited for processes subjected to rapid turning and bending motions, such as in a robot. The cable is flexible for easier bending in confined areas of overhead or side reciprocating machines. The cable bending radius should be limited to 4 inches (102mm) or greater. Care should be taken on the exposed non-shielded ends of the cable that are affixed to the applicator or cascade by keeping any ground planes or grounded objects away by a minimum of 2 inches (50mm). Caution: Unlike the A10560 shielded cable, it is recommended that no dielectric grease be used on the cable connections or the cable itself to prevent damage to the polymers used in the construction of this cable.
A10560-XX GENERAL INSTRUCTIONS 1. Only to be used with Ransburg RP-1000 Cascade, RP-404 Cascade, 80104-XX, Cascade, high voltage splitter, Voltage Master Power Supply, for direct and Indirect Charge applications. 2. When routing cable, ensure that no chaffing, binding, or pulling on the cables will occur. Maintain at least a 4.5 inch (114mm) bend radius. When possible, sleeve cable with the appropriate sized tubing for external cable protection. Torsion stress should be minimized. 3. Consideration should be taken when routing cables next to other cabling and fluid tubing. Be cognizant of the placement of such cables near control wires and fluid lines. Follow NEC wiring standards where applicable. Separation of AC, control wiring, and fluid tubing is advisable. 4. To ensure that all cable connections are clean and free of foreign materials, wipe with Naphtha. This also applies to the cascade, splitter, and applicator connectors. 5. Apply dielectric grease (59975200) on all cable connectors (cascade, splitter, and applicators) to displace and encapsulated air. 6. Each time a cable is replaced, the nut assembly (78441-00) must also be replaced 7. Ensure that no conductive sponges are used in any connector. 8. Cables are not to be modified in the field, to do so will void any and all warranties that may exist.
NOTE On all Indirect Charge high voltage rings, the labyrinth of the high voltage tube connector must be filled with dielectric grease. 959972-00) This will help to eliminate high voltage losses from the cable - applicator junction.
INSTALLATION PROCEDURE When using one of the high voltage cable assemblies (A10560) the following installation procedures must be adhered to: 1. To ensure that all cable connections are clean and free of foreign material, wipe with Naphtha or other non-polar solvent.
CASCADE RP-1000 INSTALLATION: 1.
Loosen connector nut assembly from the cascade.
Apply dielectric grease (59972-00) on the cascade end of the high voltage cable and inside the cascade tube.
Insert the cable though the back of the compression nut followed by the plastic gripper and sleeve (78841-00)
Insert the high voltage cable through the cascade high voltage tube, all the way through the nut assembly to the banana plug socket in the cascade tube assembly.
Slide the fitting and start threading onto the high voltage cascade tube threads. (Each piece of the fitting may have to be slid into place starting with the sleeve followed by the plastic gripper and then the nut.)
Turn the nut hand tight.
Wrench tighten the nut an additional 1/2 turn.
Pull on the cable to ensure a secure fitting. If the cable is loose and can be pulled free, then reinsert cable into cascade follow the above steps again with an additional 1/2 turn on the nut.
2. Attach ring-lug of the green ground wire to a known true earth ground (located on cascade end of the high voltage cable assembly).
NOTE On all Indirect Charge high voltage rings, the labyrinth of the high voltage tube connector must be filled with dielectric grease. This will help to eliminate high voltage losses from the cable - applicator junction.
HIGH VOLTAGE SPLITTER (78152-00) INSTALLATION: 1.
Loosen the connector nut from the high voltage splitter assembly.
Apply dielectric grease (59972-00) on the cascade end of the high voltage cable and the splitter assembly.
Insert the high voltage cable through the back of the nut all the way through the nut assembly to the banana plug socket in the splitter body.
Turn the nut hand tight.
Wrench tighten the nut an additional 1/2 turn.
Pull on the cable to ensure a secure fitting. If the cable is loose and can be pulled free, then reinsert cable into cascade follow the above steps again with an additional 1/2 turn on the nut.
2. Attach ring-lug of green ground wire to a known true earth ground (located on the cascade end of the high voltage cable assembly).
RMA/MMA SERIES APPLICATOR APPLICATIONS: 1. Verify that the high voltage standoff tube has been properly assembled to the high voltage ring . 2. Loosen and remove tube connector nut from high voltage stand-off tube. 3. The nut will be utilized for the remaining steps (78841-00):
Insert cable through the back of the compression nut followed by the plastic gripper and sleeve.
Apply dielectric grease (59972-00) on the applicator end of the high voltage cable and in the receiving end of the applicator (stand-off tube or directly into the applicator)
Insert the high voltage cable through the back of the nut all the way through the nut assembly to the banana plug socket in the high voltage ring assembly.
Slide the fitting and start threading on to the stand-off tube threads. (Each piece of the fitting may have to be slid into place starting with the sleeve followed by the plastic gripper and then the nut)
Turn hand tight.
Wrench tighten the nut an additional 1/2 turn.
Pull on the cable to ensure a secure fitting. If the cable is loose and can pull free, then reinsert the cable and follow the above steps again and tighten the nut an additional 1/2 turn.
Turn on high voltage to confirm terminations.
NOTE The above cable insertion procedures are to be followed when using the MMA applicator in the direct charge set up. The high voltage cable is inserted in the port on the back of the applicator mounting manifold labeled “HV/GND”
A10560-XX INFORMATION 1. Resistance—measured at low voltage
1. Up to 250k ohms per foot (0.3 meters) with 9v meter
2. Resistance—operating at high voltage
2a. Less than 20k ohms per foot at operating kV 2b. Note: Resistance varies at different kV levels
3. Maximum withstand voltage
3. 100 kV DC maximum voltage— continuous rating
4. Minimum bend radius
4. 4.5 inches (114mm)
5. Flexural testing
5. Over 1 million cycles in production
6. Recommended replacement frequency
6. Annually
Transition locations of shields
Cascade End
Applicator End
Ground wire
A10560-XX Shielded High Voltage Cable Assembly
A13685-XX GENERAL INSTRUCTIONS 1. Only to be used with Ransburg RP-1000 Cascade, RP-404 Cascade. 80104-XX Cascade, high voltage splitter, Voltage Master Power Supply, for Direct and Indirect Charge applications. 2. When routing cable, ensure that no chaffing, binding, or pulling on the cables will occur. Maintain at least a 4 inch (100mm) bend radius. When possible, sleeve cable with the appropriate sized tubing for external cable protection. Torsion stress should be minimized. 3. Consideration should be taken when routing cables next to other cabling and fluid tubing. Be cognizant of the placement of such cables near control wires and fluid lines. Follow NEC wiring standards where applicable. Separation of AC, control wiring, and fluid tubing is advisable. 4. To ensure that all cable connections are clean and free of foreign materials, wipe with Naphtha. This also applies to the cascade, splitter, and applicator connectors. 5. DO NOT apply dielectric grease on cable connectors (cascade, splitter, and applicators) 6. Each time a cable is replaced, the nut assembly (78441-00) must also be replaced 7. Ensure that no conductive sponges are used in any connector. 8. Cables are not to be modified in the field, to do so will void any and all warranties that may exist. INSTALLATION PROCEDURE When using one of the high voltage cable assemblies (A13685) the following installation procedures must be adhered to: 1. To ensure that all cable connections are clean and free of foreign material, wipe lightly with Naphtha. 2. DO NOT soak the any of the exposed ends of the cable with solvents. Damage will occur. CASCADE RP-1000 INSTALLATION: 1.
Loosen connector nut assembly from the cascade.
DO NOT apply dielectric grease on the cascade end of the high voltage cable or inside the cascade tube.
Insert the cable though the back of the compression nut followed by the plastic gripper and sleeve (78841)
Insert the high voltage cable through the cascade high voltage tube, all the way through the nut assembly to the banana plug socket in the cascade tube assembly.
Slide the fitting and start threading onto the high voltage cascade tube threads. (Each piece of the fitting may have to be slid into place starting with the sleeve followed by the plastic gripper and then the nut.)
Turn the nut hand tight.
Wrench tighten the nut an additional 1/2 turn.
Pull on the cable to ensure a secure fitting. If the cable is loose and can be pulled free, then reinsert cable into cascade follow the above steps again with an additional 1/2 turn on the nut.
2. Attach ring-lug of the green ground wire to a known true earth ground (located on cascade end of the high voltage cable assembly).
NOTE On all Indirect Charge high voltage rings, the labyrinth of the high voltage ring only must be filled with dielectric grease. (59972-00) This will help to eliminate high voltage losses from the cable - applicator junction. RMA/MMA SERIES APPLICATOR APPLICATIONS: 1. Verify that the high voltage standoff tube has been properly assembled to the high voltage ring . 2. Loosen and remove tube connector nut from high voltage stand-off tube. 3. The nut will be utilized for the remaining steps (78841):
Insert cable through the back of the compression nut followed by the plastic gripper and sleeve.
Do Not apply dielectric grease to the applicator end of the high voltage cable or in the receiving end of the applicator (stand-off tube or directly into the applicator)
Insert the high voltage cable through the back of the nut all the way through the nut assembly to the banana plug socket in the high voltage ring assembly.
Slide the fitting and start threading on to the stand-off tube threads. (Each piece of the fitting may have to be slid into place starting with the sleeve followed by the plastic gripper and then the nut)
Turn hand tight.
Wrench tighten the nut an additional 1/2 turn.
Pull on the cable to ensure a secure fitting. If the cable is loose and can pull free, then reinsert the cable and follow the above steps again and tighten the nut an additional 1/2 turn.
Turn on high voltage to confirm terminations.
NOTE The above cable insertion procedures are to be followed when using the MMA applicator in the direct charge set up. The high voltage cable is inserted in the port on the back of the applicator mounting manifold labeled “HV/GND”
A13685-XX INFORMATION 1. Resistance—measured at low voltage
1. Up to 45k ohms per meter (3.3 feet) with 9v meter
2. Maximum withstand voltage
2. 100 kV DC maximum voltage— continuous rating
3. Minimum bend radius
3. 4.0inches (100mm)
4. Flexural testing
4. Over I million cycles in production
5. Recommended replacement frequency
5. Annually
Applicator End
Cascade End
Transition locations of shields
Ground Wire
A13685-XX Shielded High Voltage Cable
