sm-00-01 safety literature handbook electrostatic safety.pdf · bell and disk atomizers ... safety...

IMPORIMPORIMPORIMPORIMPORTTTTTANTANTANTANTANT: Before using any ITW Ransburg equipment, carefully: Before using any ITW Ransburg equipment, carefully: Before using any ITW Ransburg equipment, carefully: Before using any ITW Ransburg equipment, carefully: Before using any ITW Ransburg equipment, carefully

read all instructions, precautions, hazards, warnings and sections ofread all instructions, precautions, hazards, warnings and sections ofread all instructions, precautions, hazards, warnings and sections ofread all instructions, precautions, hazards, warnings and sections ofread all instructions, precautions, hazards, warnings and sections of

this manual. Keep this Safety Manual for future reference.this manual. Keep this Safety Manual for future reference.this manual. Keep this Safety Manual for future reference.this manual. Keep this Safety Manual for future reference.this manual. Keep this Safety Manual for future reference.

SAFETY MANUAL

SM-00-01SM-00-01SM-00-01SM-00-01SM-00-01January - 2008

SAFETYSAFETYSAFETYSAFETYSAFETY LITERA LITERA LITERA LITERA LITERATURETURETURETURETURE

HANDBOOKHANDBOOKHANDBOOKHANDBOOKHANDBOOK

Safety Manual Price:Safety Manual Price:Safety Manual Price:Safety Manual Price:Safety Manual Price: €25.00 (Euro)25.00 (Euro)25.00 (Euro)25.00 (Euro)25.00 (Euro)

$30.00 (U.S.)$30.00 (U.S.)$30.00 (U.S.)$30.00 (U.S.)$30.00 (U.S.)

ELECTROSTELECTROSTELECTROSTELECTROSTELECTROSTAAAAATICTICTICTICTIC

SAFETYSAFETYSAFETYSAFETYSAFETY

INFORMAINFORMAINFORMAINFORMAINFORMATIONTIONTIONTIONTION

FROMFROMFROMFROMFROM

ITW RANSBURGITW RANSBURGITW RANSBURGITW RANSBURGITW RANSBURG

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NOTE:NOTE:NOTE:NOTE:NOTE: This manual was published to supercede the following list of Safety Bulletins:

SL-77-01.6, SL-79-01.1, SL-80-08, SL-80-09, SL-81-08.2, IL-247-A, and IL-304-B.Reasons for this change are noted under “Manual Change Summary” inside the back coverof this manual.

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1-141-141-141-141-14SAFETY OVERVIEW:SAFETY OVERVIEW:SAFETY OVERVIEW:SAFETY OVERVIEW:SAFETY OVERVIEW:

PAGEPAGEPAGEPAGEPAGE

SAFETY PRECAUTIONS..........................................................................................................HAZARDS / SAFEGUARDS......................................................................................................

12-14

CONTENTSCONTENTSCONTENTSCONTENTSCONTENTS

INTRODUCTION........................................................................................................................GENERAL SAFETY....................................................................................................................OPERATING SAFELY................................................................................................................PRECAUTIONS FOR SAFE CLEANING..................................................................................

15-1717-1818-2222-25

OPERATING ELECTROSTATIC COATING SYSTEMS SAFELY:OPERATING ELECTROSTATIC COATING SYSTEMS SAFELY:OPERATING ELECTROSTATIC COATING SYSTEMS SAFELY:OPERATING ELECTROSTATIC COATING SYSTEMS SAFELY:OPERATING ELECTROSTATIC COATING SYSTEMS SAFELY: 15-2615-2615-2615-2615-26

GENERAL...................................................................................................................................PERSONNEL GROUNDING.....................................................................................................ADDITIONAL TIPS.....................................................................................................................

2727-2828-29

PERSONNEL GROUNDING:PERSONNEL GROUNDING:PERSONNEL GROUNDING:PERSONNEL GROUNDING:PERSONNEL GROUNDING: 27-3027-3027-3027-3027-30

GENERAL...................................................................................................................................EQUIPMENT GROUNDING......................................................................................................ADDITIONAL STEPS.................................................................................................................NO. 2 HAND APPLICATOR ON-SITE PAINTING....................................................................

3131-3232-3334

EQUIPMENT GROUNDING:EQUIPMENT GROUNDING:EQUIPMENT GROUNDING:EQUIPMENT GROUNDING:EQUIPMENT GROUNDING: 31-3431-3431-3431-3431-34

ADDITIONAL STEPS................................................................................................................. 39

TARGET GROUNDING:TARGET GROUNDING:TARGET GROUNDING:TARGET GROUNDING:TARGET GROUNDING: 3939393939

GENERAL...................................................................................................................................NO. 2 PROCESS HAND APPLICATOR GROUNDING (On-Site)...........................................9966 FLUID PUMP HEAD GROUNDING PROCEDURE........................................................

3536-3737-38

APPLICATOR GROUNDING:APPLICATOR GROUNDING:APPLICATOR GROUNDING:APPLICATOR GROUNDING:APPLICATOR GROUNDING: 35-3835-3835-3835-3835-38

Safety Literature - Contents

(Continued On Next Page)(Continued On Next Page)(Continued On Next Page)(Continued On Next Page)(Continued On Next Page)

MAXIMUM SAFE OPERATING SPEEDS:MAXIMUM SAFE OPERATING SPEEDS:MAXIMUM SAFE OPERATING SPEEDS:MAXIMUM SAFE OPERATING SPEEDS:MAXIMUM SAFE OPERATING SPEEDS: 4040404040

BELL AND DISK ATOMIZERS................................................................................................... 40

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Safety Literature - Contents

GENERAL..................................................................................................................................FIRE PROTECTION..................................................................................................................PERSONNEL.............................................................................................................................TRANSFERRING FLAMMABLE FLUID...................................................................................HIGH PRESSURE AIR..............................................................................................................COMPONENT RUPTURE.........................................................................................................FLUIDS.......................................................................................................................................HYDRAULIC INJECTION HAZARD.........................................................................................INSULATED FLUID SUPPLY....................................................................................................SAFE INSTALLATION...............................................................................................................SAFE OPERATION...................................................................................................................SAFE MAINTENANCE AND SERVICE....................................................................................PROTECTIVE COVERINGS FOR NYLON FLUID LINES......................................................FLUID LINE ROUTING FOR AUTOMATIC INSTALLATIONS................................................

41414142424242-4343-4444444444-464646-48

GENERAL..................................................................................................................................HAZARD EXPLANATIONS.......................................................................................................HALOGENATED SOLVENTS DEFINED.................................................................................

4949-5051

SOLVENT HAZARDS:SOLVENT HAZARDS:SOLVENT HAZARDS:SOLVENT HAZARDS:SOLVENT HAZARDS: 49-5149-5149-5149-5149-51

FLUID DELIVERY EQUIPMENT AND SYSTEMS:FLUID DELIVERY EQUIPMENT AND SYSTEMS:FLUID DELIVERY EQUIPMENT AND SYSTEMS:FLUID DELIVERY EQUIPMENT AND SYSTEMS:FLUID DELIVERY EQUIPMENT AND SYSTEMS: 41-4841-4841-4841-4841-48

CHECK LISTS:CHECK LISTS:CHECK LISTS:CHECK LISTS:CHECK LISTS: 55-5655-5655-5655-5655-56

WARRANTY POLICIES:WARRANTY POLICIES:WARRANTY POLICIES:WARRANTY POLICIES:WARRANTY POLICIES: 6767676767

PAGEPAGEPAGEPAGEPAGE

SAFETY TRAINING CHECK LIST............................................................................................SAFETY ADVISORY CHECK LIST..........................................................................................

5556

LIMITED WARRANTY............................................................................................................... 67

CONTENTS (Cont.)CONTENTS (Cont.)CONTENTS (Cont.)CONTENTS (Cont.)CONTENTS (Cont.)

HIGH PERFORMANCE THERMOPLASTIC BELL CUPHIGH PERFORMANCE THERMOPLASTIC BELL CUPHIGH PERFORMANCE THERMOPLASTIC BELL CUPHIGH PERFORMANCE THERMOPLASTIC BELL CUPHIGH PERFORMANCE THERMOPLASTIC BELL CUP

PREVENTIVE MAINTENANCE:PREVENTIVE MAINTENANCE:PREVENTIVE MAINTENANCE:PREVENTIVE MAINTENANCE:PREVENTIVE MAINTENANCE: 52-5452-5452-5452-5452-54

SAFETY SIGNS / POSTERS / LABELS:SAFETY SIGNS / POSTERS / LABELS:SAFETY SIGNS / POSTERS / LABELS:SAFETY SIGNS / POSTERS / LABELS:SAFETY SIGNS / POSTERS / LABELS: 57-6657-6657-6657-6657-66

SAFETY SIGNS / POSTERS / LABELS................................................................................... 57-66

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Safety Literature - Safety Precautions

11111

SAFETYSAFETYSAFETYSAFETYSAFETY

SAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONSSAFETY PRECAUTIONS

Before operating, maintaining or servicing anyITW Ransburg electrostatic coating system, readand understand all of the technical and safetyliterature for your ITW Ransburg products. Thismanual contains information that is important foryou to know and understand. This informationrelates to USER SAFETY and PREVENTINGEQUIPMENT PROBLEMS. To help you recog-nize this information, we use the following sym-bols. Please pay particular attention to thesesections.

A WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert youA WARNING! states information to alert you

to a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injury

if instructions are not followed.if instructions are not followed.if instructions are not followed.if instructions are not followed.if instructions are not followed.

A CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellsA CAUTION! states information that tellshow to prevent damage to equipment or howhow to prevent damage to equipment or howhow to prevent damage to equipment or howhow to prevent damage to equipment or howhow to prevent damage to equipment or how

to avoid a situation that might cause minorto avoid a situation that might cause minorto avoid a situation that might cause minorto avoid a situation that might cause minorto avoid a situation that might cause minor

injury.injury.injury.injury.injury.

A NOTE is information relevant to the pro-A NOTE is information relevant to the pro-A NOTE is information relevant to the pro-A NOTE is information relevant to the pro-A NOTE is information relevant to the pro-

cedure in progress.cedure in progress.cedure in progress.cedure in progress.cedure in progress.

While this manual lists standard specificationsand service procedures, some minor deviationsmay be found between this literature and yourequipment. Differences in local codes and plantrequirements, material delivery requirements, etc.,make such variations inevitable. Compare thismanual with your system installation drawingsand appropriate ITW Ransburg service manualsto reconcile such differences.

Careful study and continued use of this manual willprovide a better understanding of the equipmentand process, resulting in more efficient operation,longer trouble-free service and faster, easier trou-bleshooting. If you do not have the manuals andsafety literature for your Ransburg system, con-tact your local ITW Ransburg representative orITW Ransburg.

> The user MUST MUST MUST MUST MUST read and be familiar with

the Safety Sections in this manual thereinidentified.

> This manual MUST MUST MUST MUST MUST be read and thor-oughly understood by ALL ALL ALL ALL ALL personnel whooperate, clean or maintain this equipment!Special care should be taken to ensure thatthe WARNINGSWARNINGSWARNINGSWARNINGSWARNINGS and safety requirementsfor operating and servicing the equipmentare followed. The user should be aware ofand adhere to ALLALLALLALLALL local building and firecodes and ordinances as well as NFPA-33NFPA-33NFPA-33NFPA-33NFPA-33

SAFETY STANDARD,SAFETY STANDARD,SAFETY STANDARD,SAFETY STANDARD,SAFETY STANDARD, prior to installing,operating, and/or servicing this equipment.

W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G!!!!!

> The hazards shown on the following

pages may occur during the normal use ofcorresponding ITW Ransburg equipment.Please read the hazard charts beginning onpage 2.


SM-00-01 22222

Safety Literature - Hazards/Safeguards

ITEM #1 - FOR ALL EQUIPMENTITEM #1 - FOR ALL EQUIPMENTITEM #1 - FOR ALL EQUIPMENTITEM #1 - FOR ALL EQUIPMENTITEM #1 - FOR ALL EQUIPMENT

Spray AreaSpray AreaSpray AreaSpray AreaSpray Area Fire Hazard

Improper or inadequate operationand maintenance procedures willcause a fire hazard.

Protection against inadvertentarcing that is capable of causingfire or explosion is lost if anysafety interlocks are disabledduring operation. Frequent powersupply shutdown indicates aproblem in the system requiringcorrection.

Fire extinguishing equipment must be present in thespray area and tested periodically.

Spray areas must be kept clean to prevent theaccumulation of combustible residues.

Smoking must never be allowed in the spray area.

The high voltage supplied to the atomizer must beturned off prior to cleaning, flushing or maintenance.

When using solvents for cleaning:

Those used for equipment flushing should have flashpoints equal to or higher than those of the coatingmaterial.

Those used for general cleaning must have flashpoints above 100°F (37.8°C).

Spray booth ventilation must be kept at the ratesrequired by NFPA-33, OSHA, and local codes. Inaddition, ventilation must be maintained duringcleaning operations using flammable or combustiblesolvents.

Electrostatic arcing must be prevented.

Test only in areas free of combustible material.

Testing may require high voltage to be on, but only asinstructed.

Non-factory replacement parts or unauthorizedequipment modifications may cause fire or injury.

If used, the key switch bypass is intended for useonly during set-up operations. Production shouldnever be done with safety interlocks disabled.

Never use equipment intended for use in waterborneinstallations to spray solvent based materials.

The paint process and equipment should be set upand operated in accordance with NFPA-33, NEC, andOSHA requirements.

AREAAREAAREAAREAAREATells where hazardsmay occur.

HAZARDHAZARDHAZARDHAZARDHAZARDTells what the hazard is.

SAFEGUARDSSAFEGUARDSSAFEGUARDSSAFEGUARDSSAFEGUARDSTells how to avoid the hazard.

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(Except applicators listed under section 5 of the FM test standard)(Except applicators listed under section 5 of the FM test standard)(Except applicators listed under section 5 of the FM test standard)(Except applicators listed under section 5 of the FM test standard)(Except applicators listed under section 5 of the FM test standard)



33333

Improper operation or maintenancemay create a hazard.

Personnel must be properly trainedin the use of this equipment.

Personnel must be given training in accordance withthe requirements of NFPA-33.

Instructions and safety precautions must be readand understood prior to using this equipment.

Comply with appropriate local, state, and nationalcodes governing ventilation, fire protection, operationmaintenance, and housekeeping. Reference OSHA,NFPA-33, and your insurance company requirements.

General Use andGeneral Use andGeneral Use andGeneral Use andGeneral Use and

MaintenanceMaintenanceMaintenanceMaintenanceMaintenance

ElectricalElectricalElectricalElectricalElectrical

EquipmentEquipmentEquipmentEquipmentEquipment

High voltage equipment is utilized.Arcing in areas of flammable orcombustible materials may occur.Personnel are exposed to highvoltage during operation andmaintenance.

Protection against inadvertentarcing that may cause a fire orexplosion is lost if safety circuitsare disabled during operation.

Frequent power supply shut-downindicates a problem in the systemwhich requires correction.

An electrical arc can ignite coatingmaterials and cause a fire orexplosion.

The power supply, optional remote control cabinet,and all other electrical equipment must be locatedoutside Class I or II, Division 1 and 2 hazardousareas. Refer to NFPA-33.

Turn the power supply OFF before working on theequipment.

Test only in areas free of flammable or combustiblematerial.

Testing may require high voltage to be on, but only asinstructed.

Production should never be done with the safetycircuits disabled.

Before turning the high voltage on, make sure noobjects are within the sparking distance.







SM-00-01 44444



ExplosionExplosionExplosionExplosionExplosion

Hazard/Hazard/Hazard/Hazard/Hazard/

IncompatibleIncompatibleIncompatibleIncompatibleIncompatible

MaterialsMaterialsMaterialsMaterialsMaterials

Halogenated hydrocarbonsolvents for example: methylenechloride and 1,1,1,- Trichlor-oethane are not chemicallycompatible with the aluminum thatmight be used in many systemcomponents. The chemicalreaction caused by these solventsreacting with aluminum canbecome violent and lead to anequipment explosion.

Aluminum is widely used in other spray applicationequipment - such as material pumps, regulators,triggering valves, etc. Halogenated hydrocarbonsolvents must never be used with aluminumequipment during spraying, flushing, or cleaning.Read the label or data sheet for the material youintend to spray. If in doubt as to whether or not acoating or cleaning material is compatible, contactyour material supplier. Any other type of solventmay be used with aluminum equipment.




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55555

ITEM #5 - FOR ALL MANUAL EQUIPMENTITEM #5 - FOR ALL MANUAL EQUIPMENTITEM #5 - FOR ALL MANUAL EQUIPMENTITEM #5 - FOR ALL MANUAL EQUIPMENTITEM #5 - FOR ALL MANUAL EQUIPMENT

Use of hand tools may causecumulative trauma disorders(CTD's). CTD's or musculoskeletaldisorders, involve damage to thehands, wrists, elbows, shoulders,neck and back. Carpal tunnelsyndrome and tendinitis (such astennis elbow or rotator cuffsyndrome) are examples of CTD's.

CTD's when using hand tools, tendto affect the upper extremities.Factors which may increase therisk of developing a CTD include:

1. High frequency of the activity

2. Excessive force, such asgripping, pinching or pressingwith the hands and fingers

3. Extreme or awkward finger,wrist or arm positions

4. Excessive duration of theactivity

5. Tool vibration

6. Repeated pressure on a bodypart

7. Working in cold temperatures

Risk is reduced by avoiding or lessening the listedhazards.

CTD's can also be caused by such activities assewing, golf, 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 ignorethem. Should you experience any such symptoms,see a physician immediately. Other early symptomsmay include vague discomfort in the hand, loss ofmanual dexterity, and non-specific pain in the arm.Ignoring early symptoms and continued repetitiveuse of the arm, wrist and hand can lead to seriousdisability.






SM-00-01 66666



ITEM #7 - FOR "STIFF" AUTITEM #7 - FOR "STIFF" AUTITEM #7 - FOR "STIFF" AUTITEM #7 - FOR "STIFF" AUTITEM #7 - FOR "STIFF" AUTOMAOMAOMAOMAOMATIC EQUIPMENTTIC EQUIPMENTTIC EQUIPMENTTIC EQUIPMENTTIC EQUIPMENT

Spray Area /Spray Area /Spray Area /Spray Area /Spray Area /

High VoltageHigh VoltageHigh VoltageHigh VoltageHigh Voltage


This is a high voltage device thatcan produce electrical arcscapable of igniting coatingmaterials.

Parts being sprayed must be supported on conveyorsor hangers and be grounded. The resistance betweenthe part and ground must not exceed 1 megohm.(Reference NFPA-33.)

At sea level, a safe distance must be maintainedbetween the parts being coated and the atomizerbell. A distance of at least 1 inch for each 10 kV ofpower supply output voltage is required at all times.

Parts must be supported so that they will not swingand reduce the clearance specified above.

All electrically conductive objects in the spray area,with the exception of those objects required by theprocess to be at high voltage, must be grounded.

Unless specifically approved for use in hazardouslocations, the power supply and other electricalequipment must not be used in Class I, Division 1 or2 locations.




ToxicToxicToxicToxicToxic

SubstancesSubstancesSubstancesSubstancesSubstances

Certain material may be harmful ifinhaled, or if there is contact withthe skin.

Follow the requirements of the Material Safety DataSheet supplied by coating material manufacturer.

Adequate exhaust must be provided to keep the airfree of accumulations of toxic materials.

Use a mask or respirator whenever there is a chanceof inhaling sprayed materials. The mask must becompatible with the material being sprayed and itsconcentration. Equipment must be as prescribed byan industrial hygienist or safety experts, and beNIOSH approved.




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77777

ITEM #8 - UNIQUE TO LEPS5001ITEM #8 - UNIQUE TO LEPS5001ITEM #8 - UNIQUE TO LEPS5001ITEM #8 - UNIQUE TO LEPS5001ITEM #8 - UNIQUE TO LEPS5001

POWER SUPPLPOWER SUPPLPOWER SUPPLPOWER SUPPLPOWER SUPPLYYYYY AND AND AND AND AND

Spray AreaSpray AreaSpray AreaSpray AreaSpray Area Fire and/or explosion. Electrostatic arcing MUST be prevented.

The LECU5003 control panel, LEPS5001 powersupply and all other electrical equipment must belocated outside Class I or II, Division or 2 hazardousareas, in accordance with NFPA-33.

Test only in areas free of flammable or combustiblematerials.

The current overload sensitivity MUST be set asdescribed in the SAFETY OVERLOAD ADJUST-MENT section of the LECU5003 Control Panelmanual. Protection against inadvertent arcing thatis capable of causing fire or explosion is lost if thecurrent overload sensitivity is not properly set.Frequent power supply shutdown indicates a problemin the system which requires correction.

Always turn the control panel off prior to flushing,cleaning, or working on spray system equipment.

Ensure that the control panel is interlocked with theventilation system and conveyor in accordance withNFPA-33.

Have fire extinguishing equipment readily availableand tested periodically.




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ITEM #9 - ALL BELL MANUALSITEM #9 - ALL BELL MANUALSITEM #9 - ALL BELL MANUALSITEM #9 - ALL BELL MANUALSITEM #9 - ALL BELL MANUALS

Personnel Safety/Personnel Safety/Personnel Safety/Personnel Safety/Personnel Safety/

MechanicalMechanicalMechanicalMechanicalMechanical

HazardsHazardsHazardsHazardsHazards

The bell atomizer can rotate atspeeds up to 55,000 rpm. Atthese speeds, the edge of theapplicator can easily cut into skin.Loose articles of clothing can alsobe caught by the rotating bell.

Personnel must stay clear of the bell whenever it isrotating.

Before touching the bell, the turbine air must be shutoff.

If the bell has been rotating, allow at least twominutes for it to come to a complete stop beforetouching it.




ITEM #10 - FOR FM LISTED AUTITEM #10 - FOR FM LISTED AUTITEM #10 - FOR FM LISTED AUTITEM #10 - FOR FM LISTED AUTITEM #10 - FOR FM LISTED AUTOMAOMAOMAOMAOMATIC EQUIPMENTTIC EQUIPMENTTIC EQUIPMENTTIC EQUIPMENTTIC EQUIPMENT

Spray Area /Spray Area /Spray Area /Spray Area /Spray Area /

High VoltageHigh VoltageHigh VoltageHigh VoltageHigh Voltage


There is a high voltage device thatcan induce an electrical charge onobjects which is capable of ignitingcoating materials.

Inadequate grounding will cause aspark hazard. A spark can ignitemany coating materials and causea fire or explosion.

Parts being sprayed must be supported on conveyorsor hangers and be grounded. The resistance betweenthe part and ground must not exceed 1 megohm.

All electrically conductive objects in the spray area,with the exception of those objects required by theprocess to be at high voltage, must be grounded.

Any person working in the spray area must begrounded.

Unless specifically approved for use in hazardouslocations, the power supply and other electricalcontrol equipment must not be used in Class 1,Division 1 or 2 locations.




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99999

ITEM #12 - AEROBELL 33 ROBOTITEM #12 - AEROBELL 33 ROBOTITEM #12 - AEROBELL 33 ROBOTITEM #12 - AEROBELL 33 ROBOTITEM #12 - AEROBELL 33 ROBOT

BELL MANUAL ANDBELL MANUAL ANDBELL MANUAL ANDBELL MANUAL ANDBELL MANUAL AND

ITEM #1ITEM #1ITEM #1ITEM #1ITEM #11 - AEROBELL1 - AEROBELL1 - AEROBELL1 - AEROBELL1 - AEROBELL 33 33 33 33 33

Personnel SafetyPersonnel SafetyPersonnel SafetyPersonnel SafetyPersonnel Safety

/ Electrical/ Electrical/ Electrical/ Electrical/ Electrical

HazardHazardHazardHazardHazard(Outside of SprayArea)

The high voltage power supplyand junction tank used in thisapplication creates a hazard forpersonnel. The high voltage cancause injury. A spark from theequipment is capable of ignitingflammable or combustiblematerials.

High voltage equipment must be isolated frompersonnel. The high voltage equipment must bedeenergized prior to allowing personnel to performmaintenance procedures.




Robot WorkRobot WorkRobot WorkRobot WorkRobot Work

Area - GeneralArea - GeneralArea - GeneralArea - GeneralArea - General

Use andUse andUse andUse andUse and


Improper use or maintenance canlead to hazardous conditions,particularly from unexpected robotmanipulator movement.

Applicator adjustments or maintenance should bedone after the robot is taken out of service. Do notadjust or repair the applicator if the robot is operatingor standing ready to start.

Refer to robot operating instructions for the proceduresto take the robot out of service.




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ITEM #13 - HAND APPLICAITEM #13 - HAND APPLICAITEM #13 - HAND APPLICAITEM #13 - HAND APPLICAITEM #13 - HAND APPLICATTTTTORS ONLORS ONLORS ONLORS ONLORS ONLYYYYY

Spray AreaSpray AreaSpray AreaSpray AreaSpray Area Electrostatic Arcing Never operate the spray applicator without properlygrounding the following.

A. Operators

Operators must be grounded. Rubber soledinsulating shoes should not be worn. Groundingleg straps may be used.

Operators must maintain contact with the handleof the applicator. If work gloves are used, the palmsection should be cut out.

Operators must remove from themselves allmetal objects that are not grounded.

NOTE:NOTE:NOTE:NOTE:NOTE: REFER TO NFPA-33 REGARDINGOPERATOR GROUNDING.

B. Parts being sprayed. Resistance between thepart and a grounded conveyor must not exceed 1megohm.

C. Every metal and conductive object in the sprayarea. This includes the booth, parts hangers, fireextinguishers, conductive flooring, etc.

Grounded conductive flooring must be provided in thespray area.

Turn off voltage at the power supply before flushingout, cleaning, or removing any parts from theapplicator.

Provide proper protection for waterborne supplysystems.

Never install a spray applicator into a fluid systemusing an isolated solvent supply.

Always discharge Waterborne system capacitanceprior to servicing.

Do not touch applicator electrode while applicator isenergized.




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1111111111

ITEM #14 - REA-90, REA-90L, AND VECTITEM #14 - REA-90, REA-90L, AND VECTITEM #14 - REA-90, REA-90L, AND VECTITEM #14 - REA-90, REA-90L, AND VECTITEM #14 - REA-90, REA-90L, AND VECTOR APPLICAOR APPLICAOR APPLICAOR APPLICAOR APPLICATTTTTORSORSORSORSORS

ITEM #15 - MANUALITEM #15 - MANUALITEM #15 - MANUALITEM #15 - MANUALITEM #15 - MANUAL AND AUT AND AUT AND AUT AND AUT AND AUTO APPLICAO APPLICAO APPLICAO APPLICAO APPLICATTTTTORS ANDORS ANDORS ANDORS ANDORS AND

AEROBELL COPESAEROBELL COPESAEROBELL COPESAEROBELL COPESAEROBELL COPES

ITEM #16 - EMF WITEM #16 - EMF WITEM #16 - EMF WITEM #16 - EMF WITEM #16 - EMF WAAAAATERBASETERBASETERBASETERBASETERBASE

APPLICAAPPLICAAPPLICAAPPLICAAPPLICATTTTTOR, AEROBELLOR, AEROBELLOR, AEROBELLOR, AEROBELLOR, AEROBELL AND AND AND AND ANDDISKDISKDISKDISKDISK SYSTEM MANUALSSYSTEM MANUALSSYSTEM MANUALSSYSTEM MANUALSSYSTEM MANUALS

Intended UseIntended UseIntended UseIntended UseIntended Use Using coating materials and/orcleaning and flushing solventswhich have flash points below100°F (37.8°C) may cause a firehazard.

This system is intended for use with waterbornecoating formulations only.




Personnel SafetyPersonnel SafetyPersonnel SafetyPersonnel SafetyPersonnel Safety Skin puncturing by sharp electrode. Take precautions to see that flesh is not puncturedby sharp electrode.




ExplosionExplosionExplosionExplosionExplosion

Hazard /Hazard /Hazard /Hazard /Hazard /

IncompatibleIncompatibleIncompatibleIncompatibleIncompatible

MaterialsMaterialsMaterialsMaterialsMaterials

Halogenated hydrocarbon sol-vents, for example: methylenechloride and 1,1,1,-Trichlor-oethane, are not chemicallycompatible with the aluminum thatmight be used in many systemcomponents. The chemicalreaction caused by these solventsreacting with aluminum canbecome violent and lead to anequipment explosion.

The REA-90, REA-90L, and Vector applicators requirethat aluminum inlet fittings be replaced with stainlesssteel. (See accessories list) Aluminum is widelyused in other spray application equipment - such asmaterial pumps, regulators, valves, etc. Check allother equipment items before use and make surethey can also be used safely with these solvents.Read the label or data sheet for the material youintend to spray. If in doubt as to whether or not acoating or cleaning material is compatible, contactyour material supplier. Any other type of solventmay be used with aluminum equipment.




SM-00-01 1212121212


ITEM #19 - FOR WITEM #19 - FOR WITEM #19 - FOR WITEM #19 - FOR WITEM #19 - FOR WAAAAATERBORNETERBORNETERBORNETERBORNETERBORNE

Intended UseIntended UseIntended UseIntended UseIntended Use(Waterborne Only)

Using coating materials and/orcleaning and flushing solventswhich have flash points below100°F (37.8°C) may cause a firehazard.

This system is intended for use with waterbornecoating formulations only.

Waterborne, waterbase and water reducible coatingsare considered the same. Although they may not behighly flammable, their residues are consideredcombustible.




ITEM #17 - ALL DISK MANUALSITEM #17 - ALL DISK MANUALSITEM #17 - ALL DISK MANUALSITEM #17 - ALL DISK MANUALSITEM #17 - ALL DISK MANUALS

ITEM #18 - FOR ALL HIGHITEM #18 - FOR ALL HIGHITEM #18 - FOR ALL HIGHITEM #18 - FOR ALL HIGHITEM #18 - FOR ALL HIGH

Personnel Safety/Personnel Safety/Personnel Safety/Personnel Safety/Personnel Safety/

MechanicalMechanicalMechanicalMechanicalMechanical

HazardsHazardsHazardsHazardsHazards

The disk atomizer can rotate atspeeds up to 40,000 rpm. Atthese speeds, the edge of thedisk can easily cut into skin. Loosearticles can also be caught by therotating disk.

Personnel must stay clear of the disk whenever it isrotating.

Before touching the disk, the turbine air must beshut off.

If the disk has been rotating, allow at least threeminutes for it to come to a complete stop beforetouching it.




Personnel SafetyPersonnel SafetyPersonnel SafetyPersonnel SafetyPersonnel Safety(High PressureEquipment)

Fluid Injection Injury Never let any part of the body come in direct contactwith the fluid stream exiting from the nozzle. If fluidleaks occur in the applicator or in the fluid deliverycomponents, depressurize fluid system beforeservicing.

Never aim the applicator at any part of the bodyunder any circumstances.

If you are injured by High Pressure Fluid injection,then immediate medical treatment MUST be sought.




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1313131313




Improper operation or maintenancemay create a hazard.

Personnel must be properly trainedin the use of this equipment.

Personnel must be given training in accordance withthe requirements of NFPA-33.

Instructions and safety precautions must be readand understood prior to using this equipment.

Comply with appropriate local, state, and nationalcodes governing ventilation, fire protection, operationmaintenance, and housekeeping. Reference OSHA,NFPA-33, and your insurance companyrequirements.

Always turn power to the power supply OFF, unplugthe electrical cord from its outlet, and remove thefront panel fuse, before opening the power supplydoor. If necessary, lock the power supply out so thatit cannot be turned ON until the work is finished.

Whenever removing high voltage cables fromequipment, ground the contact end of the cable byholding the cable such that the contact touchesearth ground for several seconds. Do not touch thecontact until it has been grounded. This will reducethe possibility of residual charge causing electricalshock.

The High Voltage Multiplier Assembly containsenergy storage components that can cause seriousshock injury, and therefore is not field repairable.Warranty will be voided if the High Voltage Multiplierseal is broken. If the High Voltage Multiplier isdefective, contact your authorized ITW Ransburgrepresentative for exchange or repair.

The High Voltage Multiplier and high voltage cablecontain significant capacitance that will store charge.Allow approximately 10 seconds for this charge tobleed off before



ITEM #20 - FOR ALL MANUAL EQUIPMENTITEM #20 - FOR ALL MANUAL EQUIPMENTITEM #20 - FOR ALL MANUAL EQUIPMENTITEM #20 - FOR ALL MANUAL EQUIPMENTITEM #20 - FOR ALL MANUAL EQUIPMENT

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ITEM #21 - #2 PROCESS HAND APPLICAITEM #21 - #2 PROCESS HAND APPLICAITEM #21 - #2 PROCESS HAND APPLICAITEM #21 - #2 PROCESS HAND APPLICAITEM #21 - #2 PROCESS HAND APPLICATTTTTOR ONLOR ONLOR ONLOR ONLOR ONLYYYYY




Spray AreaSpray AreaSpray AreaSpray AreaSpray Area Electrostatic Arcing Never operate the spray applicator without properlygrounding the following.

A. Operators:Operators must be grounded. Rubber soledinsulating shoes should not be worn.Grounding leg straps may be used.

Operators must maintain contact with thehandle of the applicator. If work gloves are used,the palm section should be cut out.

Operators must remove from themselves allmetal objects that are not grounded.

NOTE: REFER TO NFPA-33 REGARDINGNOTE: REFER TO NFPA-33 REGARDINGNOTE: REFER TO NFPA-33 REGARDINGNOTE: REFER TO NFPA-33 REGARDINGNOTE: REFER TO NFPA-33 REGARDING

OPERATOR GROUNDINGOPERATOR GROUNDINGOPERATOR GROUNDINGOPERATOR GROUNDINGOPERATOR GROUNDING.

B. Parts being sprayed: Resistance between thepart and a grounded conveyor must not exceed1 megohm.

C. Every metal and conductive object in the sprayarea: This includes the booth, parts hangers,fire extinguishers, conductive flooring, etc.

D. Unless specifically approved for use inhazardous locations, the power supply andother electrical equipment must not be used inClass I, Division 1 or 2 locations.

Grounded conductive flooring must be provided inthe spray area.

Turn off voltage at the power supply before flushingout, cleaning, or removing any parts from theapplicator.

Never install a spray applicator into a fluid systemusing an isolated solvent supply.

Do not touch applicator electrode while applicator isenergized.

Ensure the Ground Wire Assembly is connectedfrom the power supply ground stud to a true earthground.

Ensure that the power supply is plugged in to aproperly grounded outlet.

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OPERAOPERAOPERAOPERAOPERATING ELECTROSATING ELECTROSATING ELECTROSATING ELECTROSATING ELECTROSATIC COATIC COATIC COATIC COATIC COATINGTINGTINGTINGTING

SYSTEMS SAFELSYSTEMS SAFELSYSTEMS SAFELSYSTEMS SAFELSYSTEMS SAFELYYYYY

Safety Literature - Operating Safely

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INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

Principles of ElectrostaticPrinciples of ElectrostaticPrinciples of ElectrostaticPrinciples of ElectrostaticPrinciples of Electrostatic

FinishingFinishingFinishingFinishingFinishingElectrostatic spray finishing combines themechanical process of atomization with thedistributive effects of electrical attraction andrepulsion to achieve a highly efficient productfinishing operation.

Atomization is achieved in liquid systems by air,airless, air-assisted, and rotary apparatus. Inpowder systems, the powder is maintained in airsuspension in fluidized-bed hoppers and broughtto applicators via a suction venturi and conveyingair stream.

In either type of system, the coating material isbrought into contact with or through the immediatevicinity of highly charged electrodes. As thisoccurs, a considerable level of electrical charge istransferred either by direct contact or by passagethrough a highly ionized zone near the applicatortip (which can be used up to 150 kV), to theparticles or droplets of coating material. Since allthe particles or droplets are similarly charged andsince like charges repel one another, the spraypattern in an electrostatic spray process tends tobe larger and more evenly distributed than that ofa non-electrostatic process. This increases theease and efficiency of the operation.

When a metallic object which is electrically neutralor grounded is present, the electric field isestablished between the charging electrodes ofthe applicator and the grounded object which, inthis case, is the item we wish to coat. Theelectrically charged particles or droplets of coatingmaterial are attracted via the electric field towardthe grounded object in much the same way thatiron filings are attracted to a magnet. As theparticles or droplets come in contact with thegrounded object, they begin to dissipate theirelectrical charges with the metal of the object.

However, since the object is grounded through itshanger and conveyor back to electrically neutralearth, the charge does not accumulate in the metalof the object, allowing it to continue to accept morecharges from newly arriving particles or dropletsof coating material. Since the particles or dropletsdo not shed all of their charge immediately, andsince like charges repel each other, newly drivingcharged particles or droplets will tend to be repelledfrom spots that are already coated and attracted tothe remaining areas of bare metal. Similarly,particles and droplets that were propelled beyondthe grounded object will tend to curve in aroundbehind it, thus giving the “wrap-around” and recesspenetration effects associated with electrostaticspray finishing. The net results of these effectsare high quality, evenly distributed finishes, andincreased efficiency of coating material use.

If, however, a metallic or otherwise electricallyconductive object is in the vicinity which is NOTproperly electrically grounded, an entirely differentprocess can occur. Initially, because it is anelectrically neutral condition, it will attract thecharged particles or droplets of coating material.However, as more and more coating materialarrives and shares its charge with the object, theelectrical charge will build up in the object becausethere is no pathway to ground, turning the objectinto a static electricity “battery”. Eventually, and inmany cases, this can mean just a few seconds,enough electrical charge can accumulate in theobject that a spark can be generated between itand the nearest grounded surface. Or, similarly,an ungrounded metallic object can simply retain itselectrical charge for an indefinite time until agrounded surface is brought near enough for aspark to occur. This grounded surface can be aswinging conveyor hook or an operator reachingout to touch the charged object. Likewise, a sparkcan occur between the electrostatic device anditself and a grounded object if the electrodes orother high voltage portion of the device are placedor brought too close to ground.

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It is these sparks being generated in a wet paintand solvent vapors environment or within a possiblyexplosive concentration of powder dust thatrepresent the greatest, although by no meansonly, fire and explosion hazard in electrostaticspray finishing operations. It is for that reason thatit is absolutely necessary to establish and maintainproper electrical grounding to metallic objects inan electrostatic spray area.

Hazards in ElectrostaticHazards in ElectrostaticHazards in ElectrostaticHazards in ElectrostaticHazards in Electrostatic

FinishingFinishingFinishingFinishingFinishingThere are three main types of hazards to be foundin electrostatic spraying. These are the fire orexplosion hazards, mechanical hazards whichmay be directly harmful to operators, and toxichazards which may represent immediate or long-term harm to operators or others in the vicinity.

Fire or Explosion HazardsFire or Explosion HazardsFire or Explosion HazardsFire or Explosion HazardsFire or Explosion HazardsThree elements are necessary to initiate andsustain a fire or explosion:

• Oxygen

• Flammable or combustible materials

• A source of ignition

The presence of oxygen in finishing processes is,of course, unavoidable.

Flammable or Combustible MaterialsFlammable or Combustible MaterialsFlammable or Combustible MaterialsFlammable or Combustible MaterialsFlammable or Combustible MaterialsThe presence of flammable or combustiblematerials is inherent in the nature of the processes.Powder coating materials, if present above certainlevels, can support a fire and even allow dustexplosions similar to those that occasionally occur

When the MEC value is exceeded, an explosionmay occur. Explosions have occurred in powdersystems where the powder content in therecirculated air has not been reduced to anacceptable safety level. This can occur due to thebreakdown of the air filtration system and a failureby the filtration monitoring system to detect it.

Another potential source of explosiveconcentrations of powder dust in the air is thepractice of cleaning booths and/or spray areaswith compressed air applicators, which tend to putlarge amounts of dust into air suspension.Additionally, the powder contained in powdercollection and separation devices can represent ahazardous source of explosive material if a flameor spark reaches it through the ductwork.

With few exceptions, such as water-based paints,liquid coating materials are highly flammable. Theyinclude in their compositions methanol, acetone,mineral spirits, styrene, methyl ethyl ketone,turpentine, toluene, xylene, and chlorinatedhydrocarbons, among other materials. With theexception of a few chlorinated hydrocarbons, thesesubstances have low flash points and will burn orexplode within certain limits of concentrations byvolume in air. Additionally, the solvents used incleaning paint systems and equipment consist ofsome of the previously listed substances andothers, (refer to “Technical Supplement for AllProducts”), that represent similar fire andexplosion hazard levels.

in grain storage elevators. This hazard is enhancedsince the material, when applied, is dispersed inair as a “fluidized” material or is sprayed onto theitem being coated.

>>>>> Proper electrical grounding is definedas an electrical pathway to neutral earthwith a resistance of less than 1.0megaohm.

NOTENOTENOTENOTENOTE

>>>>> Measurements have shown that theminimum explosive concentration(MEC) of the powders generaly used isin the rang of 30 oz./1000 ft3 of air (or 30gm/m3).


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Another source of flammable or combustiblematerials to feed a fire or explosion is solvent(liquid and powder) buildup in the spray areas, inpaint hoods, on dry filters, and within the ventilationand recovery systems and the surrounding areas.This is due to overspray or spillage of materials.

In the event of a spark from electrostatic sprayoperations, or other sources of ignition, a fire canrapidly flash through these areas causing extensivedamage. Spontaneous ignition may occur in theseareas if the system is not kept free of solvents andclear of organic materials such as rags or clothing.Spontaneous ignition may also occur if residuesfrom two or more incompatible types of coatingsare permitted to accumulate one on top of the otherin the spray area, ventilation system or filters.

Additionally, flexible hosing can become frayedand leak, or be accidentally cut during the sprayoperations, releasing volatile and explosive vaporsor liquids. In contact with a source of ignition, theycan ignite and explode.

Further sources of flammable and combustiblematerials are the cleaning solvents and othermaintenance connected items brought into thespray area for cleaning or repair functions.

Ignition SourcesIgnition SourcesIgnition SourcesIgnition SourcesIgnition SourcesThe problem of eliminating or controlling sourcesof ignition in electrostatic finishing systems is in-creased over other types of systems because ofthe presence of high voltage within the spray area.The most common ignitions sources are:

GENERAL SAFETYGENERAL SAFETYGENERAL SAFETYGENERAL SAFETYGENERAL SAFETY

OverviewOverviewOverviewOverviewOverviewAny tool if used improperly can be dangerous.Safety is ultimately the responsibility of thoseusing a tool. In like manner, safe operation ofelectrostatic coating processes is the responsibilityof those who use such processes and those whooperate electrostatic coating equipment. ThisSafety Manual outlines procedures to be followedin conducting electrostatic coating operationssafely.

• Electrical discharge spark from an improperlygrounded target object

! Electrical discharge spark from failure tomaintain correct minimum sparking distancebetween non-resistive electrostatic applicatorand grounded surface

! Electrical discharge spark from ungrounded object in the vicinity of spray operation

! Electrical discharge spark from improperly grounded personnel

• Spark from faulty or improperly installed electrical equipment

• Spark caused by the use of improper cleaningprocedures or the wrong tools

• Flame or spark from some other manufacturingprocess in the vicinity

• The use of pre-heating or cure oven temper-atures which exceed the ignition temperatureof the coating material.

• Spontaneous combustion of organic materials.

• Smoking

>>>>> For non-resistive atomizers: Proper mini-mum distance between the applicator tip andthe object part is one inch for every 10,000volts of electrostatic charge at standard (sealevel) altitude. This distance may need to beincreased at altitudes higher than seal leveldue to reduced air density.

C A U T I O NC A U T I O NC A U T I O NC A U T I O NC A U T I O N!!!!!

>>>>> Always be certain that all electrostaticequipment is completely stopped and de-engerized BEFOREBEFOREBEFOREBEFOREBEFORE beginning any mainte-nance work.


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All personnel connected with coating operationsshould read and understand this Safety Manual. Itis most important that equipment operators andsupervisory personnel understand therequirements for safe operation.

This manual cannot answer every circumstance.Each user should examine their own coatingoperation, develop their own safety program, andinsure that their workers follow correct procedures.Most of the precautions listed are applicablewhether liquid or powdered coatings are used, andapply equally to non-electrostatic as well as,electrostatic spraying operations. ITW Ransburghopes that this Safety Manual is helpful to the userand recommends that the precautions in this beincluded in any such program.

In addition to this manual, the user should consultother standards and recognized safety authorities.NFPA-33, Spray Application, is a standard forspray finishing with flammable materials that isapplicable to all spray painting operations. Threechapters, Chapters 11, 12, and 15 (2007 Edition),are specifically applicable to electrostatic coating.

Copies of NFPA bulletins are available at a nominalcost from:

National Fire Protection AssociationBatterymarch ParkQuincy, MA 02269www:NFPA.org

The National Fire Protection Association alsopublishes standards other than NFPA-33 relatingto the control of fire hazards. NFPA-33 specificallyrefers to the following bulletins of the National FireProtection Association as applicable to coatingoperations:

NFPA-63, Dust Explosion - Industrial PlantsNFPA-70, National Electrical CodeNFPA-86A, Ovens and FurnacesNFPA-91, Blower and Exhaust SystemsNFPA-654, Dust Explosion - PlasticsIndustryNFPA-30, Flammable Liquids CodeNFPA-34, Dipping & CoatingNFPA-77, Static Electricity

OPERAOPERAOPERAOPERAOPERATING SAFELTING SAFELTING SAFELTING SAFELTING SAFELYYYYY

In operating electrostatic coating systems safely,users should make every effort to:

••••• Avoid sparks

••••• Avoid accumulations of combustible coatingmaterials

••••• Avoid accumulations of combustible vapors

••••• Avoid operating equipment which has givenany indication of malfunctioning

The extent to which the user is successful inaccomplishing these ends determines largely thesafety that is present in his coating operation.Recomended operating procedures follow. Theseprocedures are applicable in the “spraying area”and make frequent references to “grounding”.Understanding of these terms is important.

The Spraying Area DefinedThe Spraying Area DefinedThe Spraying Area DefinedThe Spraying Area DefinedThe Spraying Area DefinedThe spraying area is any area in which flammablevapors or coating material deposits are presentdue to the operation of spraying processes. Itincludes the interior of spray booths, the interior ofducts exhausting from spraying processes, andany area in the direct paths of spray or any areacontaining quantities of air-suspendedcombustible coating materials, or of vapor as aresult of spraying operations. Where the user isuncertain of its extent, he should consider thespraying area as that area within 20 feet fromevery point at which the spraying equipment canbe operated.

GroundingGroundingGroundingGroundingGrounding (Overview)(Overview)(Overview)(Overview)(Overview)Grounding an object means providing an adequatepath for the flow of electrical charge from the objectto ground. An adequate path is one that permitscharge to flow from the object fast enough that itwill not accumulate to the extent that a spark canbe formed. It is not possible to define exactly whatwill be an adequate path under all conditions sinceit depends on many variables.

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In any event, the grounding means should havethe lowest possible electrical resistance.Grounding straps should be installed on all looseobjects in the spraying area. ITW Ransburgrecommends that grounding straps be made ofAWG No. 18 bare, stranded wire as a minimumand that larger wire be used where possible.Using bare wire permits the user easily to detectany break in the wire visually. Stranded wire isless likely to break than solid wire.

Why is Grounding Necessary?Why is Grounding Necessary?Why is Grounding Necessary?Why is Grounding Necessary?Why is Grounding Necessary?Electrostatic coating processes depend upon theproduction of a spray of paint particles that carryan electric charge to obtain a reduction in coatingmaterial waste. The electric charge is applied tothe paint particles in the operation of the electrostaticcoating equipment. Because the paint particlesare charged, they are attracted to a groundedobject, much like small metal objects are attractedto a magnet. The attraction between chargedspray particles and the object being coated giveselectrostatic coating its characteristic wrap-aroundtendency - the deposition of spray that wouldotherwise be wasted.

Upon reaching an object, however, the electriccharge on the spray particles is transferred to theobject. Unless the object is grounded (providedwith an escape path for this electric charge), thecharge wil build up on the object. This can havebad results. The charge can build up to such alevel that it will jump through the air in the form ofan electric spark. Everyone who has felt the smallelectric shock upon reaching for a door knob orlight switch after walking on carpeting hasexperienced such sparks. An electric spark, if itcontains enough energy, can ignite coating material

All Operators and Other PersonnelAll Operators and Other PersonnelAll Operators and Other PersonnelAll Operators and Other PersonnelAll Operators and Other PersonnelWorking in the Spraying Area Must beWorking in the Spraying Area Must beWorking in the Spraying Area Must beWorking in the Spraying Area Must beWorking in the Spraying Area Must beGroundedGroundedGroundedGroundedGroundedA human being, if not grounded, can accumulate acharge, which can be released in the form of aspark having enough energy to ignite flammablematerials. The following precautions should betaken to ground personnel working in the sprayingarea.

• Grounded conductive flooring MUST be providedin the spraying area.

• Personnel working in the spraying area shouldhave conductive footwear.

• Grounding leg straps can also be used to groundthe operator to conductive flooring in the sprayingarea.

• Grounding wrist straps may be used to groundthe operator to the grounded, conductiveapplicator handle.

and solvent vapors. Obviously sparks must beprevented. This brings us to the first rule of safeoperation.

Ground All Objects in the Spraying AreaGround All Objects in the Spraying AreaGround All Objects in the Spraying AreaGround All Objects in the Spraying AreaGround All Objects in the Spraying AreaEvery object in the spraying area must be grounded.This includes the spray booth, conveyor,workholders, hooks, paint tanks, solvent safetycontainers, tools, the equipment operator andother personnel and any other object which maycome within the spraying area. If an object is leftungrounded in the spraying area, electricallycharged particles can strike the object and willtransfer their electrical charge to the object. If theobject is not grounded, the charge will remain on it.As more and more charged particles arrive at theobject, the charge on it may build up to such a pointthat a spark will be formed. Sparks from suchungrounded objects in the spraying area maycontain enough energy to ignite any flammablecoating material deposit or flammable vapor in thearea of the spark. All objects in the spraying areamust be grouned to avoid such sparks.

>>>>> NFPA-77 states that the electrical re-sistance of such a leakage path may beas low as 1 megohm (106 ohms) but thatresistances as high as 10,000 megohmswill provide an adequate leakage path insome cases.


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Where the operator is a spray person using anITW Ransburg electrostatic hand applicator, theywill be grounded by contact between their handand the applicator handle. We recommend thatinsulating gloves not be used by the spray person.If, however, the spray person must use gloves, ahole must be cut in the palm of both gloves toestablish contact between either of the sprayperson’s hands and the applicator handle. Wriststraps or conductive gloves may be used in placeof cutting gloves. Hand applicator operators, likeall other personel working in the spraying area, ofcourse, must be grounded by wearing conductivefootwear, otherwise they will be ungrounded whennot holding the applicator. (See “PersonnelGrounding” section of this manual for moreinformation).

Ungrounded metal objects, such as wrenches,knives, pens, cigarette packs, coins, etc., shouldbe removed from pockets to prevent them frombecoming charged.

Ground the Object Being Coated WhileGround the Object Being Coated WhileGround the Object Being Coated WhileGround the Object Being Coated WhileGround the Object Being Coated Whilein the Spraying Areain the Spraying Areain the Spraying Areain the Spraying Areain the Spraying AreaThe object (target) being coated must also begrounded while in the spraying area and while it isbeing coated. The charged coating materialparticles are directed at the object being coatedand will impair their charge to that object. If theobject being coated is not grounded, this chargewill build up to such a point that it will produce aspark. The spark produced may have sufficientenergy that it will ignite any flammable materials orvapors in the area of the spark.

Since the workholder and the conveyor hooks areadjacent to the objects being coated, coatingmaterial may accumulate on these objects. Theobject or target is normally grounded by contactwith the workholder and by contact between theworkholder and the conveyor hook. The conveyormust, of course, be grounded. These two pointsof contact must be inspected frequently foraccumulations of coating material which mayprevent sufficient contact to provide a ground forthe object being coated.

Such accumulations of coating material can preventthe electrostatic charge on the object being coatedfrom flowing to the ground. Accumulated coatingmaterial can thus result in sparks either betweenthe object being coated and the workholder, orbetween the workholder and the conveyor. Thesesparks can contain sufficient energy to igniteflammable vapors or coating material in the path ofthe spark. In addition, if the object being coatedaccumulates a charge because it is not grounded,the charged coating material spray will tend to berepelled from the target and the efficiency ofelectrostatic coating will be reduced.

Inspect Workholders and ConveyorInspect Workholders and ConveyorInspect Workholders and ConveyorInspect Workholders and ConveyorInspect Workholders and ConveyorHooks FrequentlyHooks FrequentlyHooks FrequentlyHooks FrequentlyHooks FrequentlyKeep workholders and hooks as free of paint aspossible. In an electrostatic coating operation thisrequires a regular workholder and hook cleaningprogram. Many users find it advantageous tomaintain two sets of workholders and hooks.While one set is in use, the other set is beingcleaned.

If sparking between the object being coated andthe workholder, or between the workholder andthe conveyor hook is evident, coating operationsshould cease immediately, and not be resumeduntil cause of sparking is detected and corrected.Such sparking may indicate an excessiveaccumulation of coating materials separating eitherthe object being coated and the workholder, or theworkholder and the conveyor hook at their pointsof contact. Coating materials should never bepermitted to accumulate on workholders orconveyor hooks to such a degree that thegrounding contact between the object being coatedand the workholder or between the workholderand the conveyor hook is lost.

Workholders and conveyor hooks should beinspected frequently to determine if they needcleaning. Workholders should be kept as free ofpaint as possible over their entire area, not just thepoints of contact.

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>>>>> Dried coating material that has accumulatedon the parts of the workholder other than thepoints of contact MAMAMAMAMAYYYYY CAUSE CAUSE CAUSE CAUSE CAUSE dangerousoperating conditions. Such coating materialmay cause UNEXPECTED SPUNEXPECTED SPUNEXPECTED SPUNEXPECTED SPUNEXPECTED SPARKINGARKINGARKINGARKINGARKINGconditions and may act as a source of fuel toan unexpected flame.


Insure Any Coating Material Insure Any Coating Material Insure Any Coating Material Insure Any Coating Material Insure Any Coating Material Container isContainer isContainer isContainer isContainer is

GroundedGroundedGroundedGroundedGrounded


>>>>> Waterbase applications require differentgrounding protocal. When using an isolationstand, cage protection with suitable interlocksare REQUIRED since the material is isolatedfrom ground. When using the AquaTank, insurethe ground stud of the tank is connected to true,earth ground to insure the tank voltage will beproperly bled off. When using an AquaBlock,insure ALL voltage has been bled to groundPRIOR to servicing.

All coating material containers should be treatedas if they can become charged. Metallic(electrically conductive) containers must be usedas coating material containers or solventcontainers, and all portions of such containersshould be grounded during use. (Plastic insulatingbuckets should not be used for flamables.)

A grounding wire should be fastened to the coatingmaterial container at all times. The containershould be examined daily to insure that it isgrounded.

Some coating materials in use are so conductivethat the coating material container must be put onan insulated stand and left ungrounded in order forthe system to operate. Users should attempt touse coating materials which are not so conductive,where possible.

A grounding device should be kept adjacent to thecontainer for such use. Care should be taken ingrounding such containers. No attempt to groundthe container should be made until sufficient timehas elapsed after the high voltage is turned off thatany electrical charge on the container hasdissipated. The grounding device should befastened to the container near its base away fromthe opening of the container. Fastening thegrounding device away from the opening will reducethe likelihood that it will be dislodged during workwith the coating material in the container, and willlocate any spark that may occur as the groundingdevice is fastened to the container away from theopening of the container where the solvent vaporsare most dense. In addition, the coating materialcontainer or any pump or coating material supplyequipment associated with the use of suchconductive coating materials should be located inan area that is well ventilated and where personnelcannot inadvertently approach them. The erectionof suitable physical barriers to prevent suchinadvertent approach is recommended and is theresponsibility of the user. Appropriate warningsigns should be posted in the vicinity of coatingmaterial containers and supply equipmentassociated with the use of such coating materials.

>>>>> Care should be taken in operating systemswith such insulated stands. The high voltageto the electrostatic spraying equipment MUSTMUSTMUSTMUSTMUSTbe turned OFF OFF OFF OFF OFF and the coating material con-tainer GROUNDED BEFOREGROUNDED BEFOREGROUNDED BEFOREGROUNDED BEFOREGROUNDED BEFORE any work isdone around the coating material container insuch operations.


>>>>> Be sure that ALL ALL ALL ALL ALL coating material contain-ers in the electrostatic spray system aregrounded (and therefore discharged) before anywork is done around them, such as: addingcoating material or solvent, removing coatingmaterial, or stirring the contents.


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Turn the Voltage Off Unless ElectrostaticTurn the Voltage Off Unless ElectrostaticTurn the Voltage Off Unless ElectrostaticTurn the Voltage Off Unless ElectrostaticTurn the Voltage Off Unless ElectrostaticCoating is Being PerformedCoating is Being PerformedCoating is Being PerformedCoating is Being PerformedCoating is Being PerformedThe voltage should be turned on only when actuallyperforming coating operations. When coating isdiscontinued for any period of time, such as onbreaks, lunch period, repair work, examinationand cleaning, the voltage should be turned off.This is particularly true if the electrostatic coatingequipment is to be left unattended for any length oftime.

Testing of electrostatic coating equipmentsometimes requires the use of high voltage. Suchtesting must be done carefully and by trainedpersonnel only, and only after ensuring that noflammable vapors or materials are present. Suchwarning signs should include instructions as theprocedures set forth above.

Rules Of Electrostatic SafetyRules Of Electrostatic SafetyRules Of Electrostatic SafetyRules Of Electrostatic SafetyRules Of Electrostatic SafetyFirst RuleFirst RuleFirst RuleFirst RuleFirst RuleGround all conductive objects within the near field(10 foot radius) of any charged electrode!

Second RuleSecond RuleSecond RuleSecond RuleSecond RuleExcepting those being properly utilized in theapplication system, KEEP ALL FLAMMABLE KEEP ALL FLAMMABLE KEEP ALL FLAMMABLE KEEP ALL FLAMMABLE KEEP ALL FLAMMABLE

MATERIAL OUTSIDEMATERIAL OUTSIDEMATERIAL OUTSIDEMATERIAL OUTSIDEMATERIAL OUTSIDE of the electrical field (20foot radius) of any charged electrode.

Good HousekeepingGood HousekeepingGood HousekeepingGood HousekeepingGood HousekeepingAll use of high voltage systems MUST MUST MUST MUST MUST be incompliance with the National Electrical Code.Additional precautions are contained in NFPA-33(Spray Applications) and NFPA-77 (StaticElectricity). Frequent inspections should be madeto determine if accumulations of combustiblematerials are occurring in any part of the sprayingarea. Whenever such accumulations are found,spraying should cease, the voltage should beturned off, and the accumulations should beremoved.

The frequency of such cleaning depends largelyupon the housekeeping habits of the equipmentoperators and upon the efficiency of the sprayingsystem. Spray operators should be careful not tospill combustible coating materials or to allowthem to be misdirected in spraying onto surfaces,

other than those of the object being coated. Coatingmaterial deposits that accumulate within thespraying area may permit the spread of a flamethat is otherwise controllable into an uncontrollablefire. Good housekeeping is mandatory if anycoating system is to be operated safely.

PRECAUTIONS FORPRECAUTIONS FORPRECAUTIONS FORPRECAUTIONS FORPRECAUTIONS FOR

SAFE CLEANINGSAFE CLEANINGSAFE CLEANINGSAFE CLEANINGSAFE CLEANING

Users should recognize that the cleaning itselfpresents a hazard. Tools used for cleaningpurposes must be of non-sparking material.Residures, scrapings and debris contaminatedwith residue should be immediately removed formthe premises and properly disposed of. Firesafewaste cans MUST be provided for rags or wastematerials impregnated with finishing materials.Such cans should have the approval of theappropriate competent authority, such as

Underwriters LaboratoryUnderwriters LaboratoryUnderwriters LaboratoryUnderwriters LaboratoryUnderwriters Laboratory or or or or or Factory MutualFactory MutualFactory MutualFactory MutualFactory MutualEngineering CorporationEngineering CorporationEngineering CorporationEngineering CorporationEngineering Corporation. All such rags andwaste should be deposited immediately after theiruse in these approved waste cans. The contentsof the waste cans should be properly disposed ofat least once daily at the end of each shift. Sprayfinishing employee’s clothing should not be left onthe premises overnight unless kept in metallockers. Rags, clothing, towels, paper and suchmaterials contaminated with flammable materialspresent a source of spontaneous combustion andshould be handled accordingly.

Solvents used for cleaning purposes should, wherepractical, be of a type that will not burn. Cleaningsolvents should not emit vapors which aredangerous if inhaled by the personnel performingthe cleaning operation. Ventilating equipmentmust be operated while the spraying area is beingcleaned.

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Keep Flammable or CombustibleKeep Flammable or CombustibleKeep Flammable or CombustibleKeep Flammable or CombustibleKeep Flammable or CombustibleLiquids out of the Spraying AreaLiquids out of the Spraying AreaLiquids out of the Spraying AreaLiquids out of the Spraying AreaLiquids out of the Spraying AreaThe quantity of flammable and combustible liquidskept in the vicinity of spraying operations must bethe minimum required for operation. As notedearlier, all containers for such materials must begrounded and MUST be of an approved type forflammable or combustible liquids (see theFlammable and Combustible Liquid Code, NFPA-30 and Chapter 6 of NFPA-33). Such containersshould be kept closed to prevent the spread offlamable vapors beyond the container.

Fire Extinguishing Equipment MadeFire Extinguishing Equipment MadeFire Extinguishing Equipment MadeFire Extinguishing Equipment MadeFire Extinguishing Equipment MadeAvailableAvailableAvailableAvailableAvailableCommon sense dictates that automatic or manualfire extinguishing equipment be kept available inany industrial operation involving flammablematerial. Painting and other coating operationsare no different. Since most coating materials areflammable, means to extinguish a flame must bequickly available. If good housekeeping isobserved, flames will not spread beyond control,and prompt action with fire extinguishing equipmentwill prevent significant damage.

Fire extinguishing equipment should be protectedto prevent collection of coating material frominterfering with its operation. Such equipmentshould be inspected frequently to insure that it is inproper working order.

Understanding How to OperateUnderstanding How to OperateUnderstanding How to OperateUnderstanding How to OperateUnderstanding How to OperateElectrostatic Coating Equipment SafelyElectrostatic Coating Equipment SafelyElectrostatic Coating Equipment SafelyElectrostatic Coating Equipment SafelyElectrostatic Coating Equipment SafelyPersonnel who operate electrostatic coatingequipment and their supervisors must be trainedin the procedures used in operating electrostaticcoating equipment safely. Such personnel shouldread and understand this manual, the service

manuals, NFPA-33, and the codes of localauthorities. Periodic retraining of such personnelis important to emphasize the importance thatthey not become careless in following theseprocedures. Special care should be taken to seethat the personnel newly assigned to work withinthe spraying area are trained in safe operatingprocedures. In addition to such training, safetyinstructions should be posted in the spraying areaso that personnel working there may refer to themeasily. Such instructions should be prominentlydisplayed so that they may serve as a constantreminder of the importance of not being careless.

Ventilate the Spraying AreaVentilate the Spraying AreaVentilate the Spraying AreaVentilate the Spraying AreaVentilate the Spraying AreaAll spraying areas must be provided withmechanical ventilation adequate to removeflammable vapors, mists or powders to a safelocation and to confine or control combustibleresidues. The spraying area should be ventilatedat all times while spraying operations are beingperformed and for a sufficient time after sprayinghas stopped to allow vapors from deposited coatingmaterials (in the process of drying) to be exhausted.The ventilation and exhaust systems shouldcomply with NFPA-91, Standard for Blower andExhaust Systems for Vapor Removal, and Chapter5 of NFPA-33. Local codes should be observed,however.

Maintenance and Cleaning - LiquidMaintenance and Cleaning - LiquidMaintenance and Cleaning - LiquidMaintenance and Cleaning - LiquidMaintenance and Cleaning - LiquidElectrostatic Coating EquipmentElectrostatic Coating EquipmentElectrostatic Coating EquipmentElectrostatic Coating EquipmentElectrostatic Coating EquipmentDO NOT attempt to clean any electrostatic coatingequipment UNLESS the voltage has been turnedOFF and electrically charged equipmentcomponents have been grounded. Electrostatichand applicators should be carefully cleaned. Noconductive residues should be permitted toaccumulate on an electrostatic hand applicator.Solvents used to clean such applicators shouldthemselves be clean and of a type which will notleave a conductive film. (See the appropriateService Manuals for the “Recommended CleaningSolvents and Procedures”.)

>>>>> Like all other objects in the sprayingarea, fire extinguishing equipment mustbe grounded. Also, refer to NFPA-33 formore extensive issues of fire protection.


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A soft brush and solvent can be used to cleanelectrostatic hand applicators.

Maintenance and Cleaning - PowderMaintenance and Cleaning - PowderMaintenance and Cleaning - PowderMaintenance and Cleaning - PowderMaintenance and Cleaning - PowderElectrostatic Coating EquipmentElectrostatic Coating EquipmentElectrostatic Coating EquipmentElectrostatic Coating EquipmentElectrostatic Coating EquipmentPowder coating application equipment should becarefully cleaned on a regular basis. Theelectrostatic voltage should be turned OFF whenany work is performed on the applicators, controls,or the booth.

Some parts of ITW Ransburg electrostatic handapplicators can be removed and soaked, such asthe airairairairair and and and and and paint nozzlespaint nozzlespaint nozzlespaint nozzlespaint nozzles of the of the of the of the of the air sprayair sprayair sprayair sprayair sprayapplicatorapplicatorapplicatorapplicatorapplicator and and and and and spray tip spray tip spray tip spray tip spray tip and and and and and forward nutforward nutforward nutforward nutforward nut ofthe hydraulic applicators.

> Metal tools and wire brushes must NEV-NEV-NEV-NEV-NEV-

ERERERERER be used. NEVERNEVERNEVERNEVERNEVER use a cleaning toolthat is harder than the plastic parts. If adeposit cannot be removed with solvent anda rag or soft brush, soak the part in the solvent

ONLYONLYONLYONLYONLY until the deposit can be removed!

NEVER SOAK THE APPLICATORNEVER SOAK THE APPLICATORNEVER SOAK THE APPLICATORNEVER SOAK THE APPLICATORNEVER SOAK THE APPLICATOR

BODY, BARREL, OR TRANSFORM-BODY, BARREL, OR TRANSFORM-BODY, BARREL, OR TRANSFORM-BODY, BARREL, OR TRANSFORM-BODY, BARREL, OR TRANSFORM-

ER!ER!ER!ER!ER!


> To avoid damage to the fluid nozzle, needle/electrode, the paint pressure MUSTMUSTMUSTMUSTMUST be re-leased by triggering the applicator prior to re-moving the tip.

> The applicator MUST MUST MUST MUST MUST be tilted front down toremove the air cap and/or fluid nozzle. Failureto do so may allow paint to enter the air passag-es, thereby reducing air flow and damaging theapplicator barrel/cascade. Applicators may beflushed in lieu of removing nozzles. However,they must be either flushed prior to, or tilteddown during nozzle removal!

> The control unit power MUST MUST MUST MUST MUST always be offwhen removing the nozzles or any other ser-vice to the applicator.

> Using any tool other than the ITW Rans-burg 19749-00 wrench to remove or reinstallthe fluid nozzle may distort or damage it.


> Any damage to the applicator may result

in UNSAFEUNSAFEUNSAFEUNSAFEUNSAFE operating.

W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G!!!!! W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G

> NEVER NEVER NEVER NEVER NEVER soak or submerge the electrical

components of ITW Ransburg hand applicators(i.e. barrel, transformer, cable) in any liquid for

ANYANYANYANYANY reason. Damage and failure may occur!


> NEVER NEVER NEVER NEVER NEVER soak or submerge the powder

applicator or muzzle in any liquid for ANYANYANYANYANYreason. Damage and failure may occur!


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A special brush is supplied for cleaning out theapplicator. Some parts of the applicator assemblymay be cleaned in a mild solvent, such as:

!!!!! the muzzle union nut

!!!!! deflector tips

!!!!! deflector rod

Use only a dry, lint free cloth, or compressed air toblow off the components.

Powder ContainmentPowder ContainmentPowder ContainmentPowder ContainmentPowder ContainmentA powder applicator MUST NEVERMUST NEVERMUST NEVERMUST NEVERMUST NEVER be dis-charged outside of the powder booth! Wheneverpowder is being sprayed, blown, wiped down, ortransferred, the booth recovery air should be on sothat the powder will be contained in the booth.

Do Not Permit HorseplayDo Not Permit HorseplayDo Not Permit HorseplayDo Not Permit HorseplayDo Not Permit HorseplayHorseplay is out of place in any industrial operationand this includes electrostatic spraying operations.Spraying personnel should NOT be permitted tocharge themselves or other objects up so thatthey may “spark” over to other people or objects.Such sparks may have sufficient energy to ignitecombustible vapors. They are a hazard.

> NEVERNEVERNEVERNEVERNEVER use Acetone.

> DO NOTDO NOTDO NOTDO NOTDO NOT allow parts to soak overnight!

> Guide pin integrity should be MAINTAINED

for proper electrostatic contact.

> NEVERNEVERNEVERNEVERNEVER use any fluids to clean the control

cabinets.


> NEVERNEVERNEVERNEVERNEVER wrap the equipment in plastic to

keep it clean. A surface charge may build-upon the plastic surface and discharge to thenearest grounded object. Efficiency of theapplicator will also be reduced and damage orfailure of the applicator components may oc-cur. WRAPPING THE EQUIPMENT IN WRAPPING THE EQUIPMENT IN WRAPPING THE EQUIPMENT IN WRAPPING THE EQUIPMENT IN WRAPPING THE EQUIPMENT IN

PLASTIC WILL VOID ALL WARRAN-PLASTIC WILL VOID ALL WARRAN-PLASTIC WILL VOID ALL WARRAN-PLASTIC WILL VOID ALL WARRAN-PLASTIC WILL VOID ALL WARRAN-

TIES!TIES!TIES!TIES!TIES!


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NOTESNOTESNOTESNOTESNOTES

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GENERALGENERALGENERALGENERALGENERAL

PERSONNEL GROUNDINGPERSONNEL GROUNDINGPERSONNEL GROUNDINGPERSONNEL GROUNDINGPERSONNEL GROUNDING

Safety Literature - Personnel Grounding

2727272727

It is simple, but vital matter to be sure that allobjects in an electrostatic coating area aregrounded (reference NFPA-33).

1. Inspect all ground wires daily. Look for good,firm joints at all points of connection (paint pots,flow regulators, booth wall, power supply, etc.).Look for breaks in the ground wire. Repair anydefect IMMEDIATELY!IMMEDIATELY!IMMEDIATELY!IMMEDIATELY!IMMEDIATELY!

2. Inspect all conveyor apparatus (hooks, hang-ers, etc.) daily. If there is any accumulation ofdried coating material on any of these objects,remove it before using them!

3. Inspect the floor daily for excessive accumu-lation of dried coating material (or other residue). Ifthere is any, remove it!

Safe grounding is a matter of proper equipmentmaintenance, proper spray technique, and goodhousekeeping.

There are hazards to good equipment maintenancein any industry (cleaning crews, shop trucks,etc.). Daily inspection of grounding apparatus andconditions, however, will help prevent hazardsthat are caused by normal, daily operations.

PERSONNELPERSONNELPERSONNELPERSONNELPERSONNEL

GROUNDINGGROUNDINGGROUNDINGGROUNDINGGROUNDING

Personnel grounding is the most difficult area ofelectrical hazard control. Most people do notrealize what excellent capacitors they are. In avery short time, without proper grounding, thehuman body can build enough static charge tocause dangerous spark discharge. Therefore,ALL persons in an electrostatic coating area MUSTMUSTMUSTMUSTMUSTbe grounded at ALLALLALLALLALL times!

Manual equipment operators will be groundedthrough the equipment as long as it is being held incontact with the bare skin. As soon as theequipment is released from direct (skin) contactwith the operator, other grounding methods becomenecessary.

The operator SHOULD NOT SHOULD NOT SHOULD NOT SHOULD NOT SHOULD NOT wear insulatinggloves! Special conductive gloves may be usedand are recommended.

All persons in the spray area must be grounded atALL times!

This may be accomplished safely by the use ofconductive soled shoes, disposable conductiveboots, or personnel grounding straps.

>>>>> The integrity of the system ground MUST MUST MUST MUST MUST beinspected regularly and maintained. (See“Equipment Grounding” section of this SafetyManual).


>>>>> If insulating (cloth or rubber) gloves are worn,both palms MUSTMUSTMUSTMUSTMUST be cut out to allow bare skincontact with the equipment! This allows theoperator to change the equipment from onehand to the other.

>>>>> If gloves are worn for chemical safety,grounding wrist straps may be connected fromthe operator’s wrist to the applicator assem-bly.


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Disposable BootsDisposable BootsDisposable BootsDisposable BootsDisposable BootsConductive boots are available that are worn overthe shoe and fastened by either rubber bands orstring ties, at the ankles.

Conductive Soled ShoesConductive Soled ShoesConductive Soled ShoesConductive Soled ShoesConductive Soled ShoesLeather-soled shoes are generally adequate toprovide proper personnel grounding. However, itcan be difficult with the wide variety of materialsavailable, to know whether or not the soles of a pairof shoes are actually leather. A cursoryexamination could lead to the belief that soles aremade of leather, when actually the material is of asubstance that may or may not be conductive.


2828282828

70289-0170289-0270289-0370269-0476633-00

Adjust-A-Stat Ground StrapsAnkle-Stat Ground StrapsLeg-Stat Ground StrapsWrist StrapsConductive Gloves

Grounding StrapsGrounding StrapsGrounding StrapsGrounding StrapsGrounding StrapsA wide variety of anti-static, personnel groundingdevices are available. These devices take manydifferent forms with as many different methods ofattaching them to the user. Obviously, selection ofa specific type would be purely a matter of choice.

Grouding straps and conductive gloves areavailable as follows from ITW Ransburg:

ADDITIONAL TIPSADDITIONAL TIPSADDITIONAL TIPSADDITIONAL TIPSADDITIONAL TIPS

HousekeepingHousekeepingHousekeepingHousekeepingHousekeepingGood housekeeping is essential if this equipmentis to be operated safely and efficiently. Forexample, workholders must provide electricalgrounding of the articles, thus, workholders requireperiodic stripping. Clean-up and maintenanceschedules for the applicators, booth, and generalarea should be established by the user, based onrecommendations of the ITW Ransburgrepresentative and observation of initial productionoperation.

Fire ProtectionFire ProtectionFire ProtectionFire ProtectionFire ProtectionNormal fire protection measures are required.These include proper storage of paints, solventsand waste, plus adequate fire extinguishingequipment. For details, consult NFPA-33 whichrecommends automatic sprinkler systems andportable fire extinguishers. Check with your localfire code, local facility equipment standards, andyour insurance provider’s recommendations. Alsosee “Operating Your Electrostatic Coating SystemSafely” section of this Safety Manual.

Be sure to display all of the appropriate ITWRansburg furnished DANGER and CAUTIONsignage in and around the spray area.

ENSURE THAENSURE THAENSURE THAENSURE THAENSURE THATTTTT:::::1. All objects in the spray area are grounded.

2. Operators and all other persons in the sprayarea are properly grounded.

3. The object being coated is properly grounded(less than 1 megohm resistance to ground).

>>>>> All users of electrostatic coating equip-ment must be familiar with the safety require-ments prescribed under the OSHA Act of1970 and in NFPA-33.


>>>>> ITW Ransburg recommends thatground straps be made of #18 bare (mini-mum), standard wire. Where possible,use larger wire.


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2929292929

4. Workholders and conveyor hooks are free ofcoating accumulation.

5. High voltage is OFFOFFOFFOFFOFF and coating materialcontainer is grounded BEFOREBEFOREBEFOREBEFOREBEFORE adding, removingor mixing coating materials.

>>>>> Ground MUSTMUSTMUSTMUSTMUST be maintained during theaddition or transfer of fluid to any supply con-tainer!

>>>>> Whenever transfering flammable fluid fromone container to another, both containers

MUST MUST MUST MUST MUST be properly connected to a proventrue earth ground first and then to each other.Personnel executing such a transfer MUSTMUSTMUSTMUSTMUSTalso be grounded to true earth ground.


6. High voltage is OFFOFFOFFOFFOFF at all times when notactually conducting coating operations.

7. The spray area is kept free of accumulatedcoating deposits.

8. Combustible liquids in the spraying area arekept to a minimum, the containers are of theapproved types (see NFPA-30 and 33) andproperly grounded.

9. Proper ventilation is provided.

10. The operator thoroughly understands theequipment, has read and fully understands theoperations manual.

>>>>> Proper fire protection equipment must bein place and operable before ANYANYANYANYANY finishingequipment is operated.

>>>>> The user MUSTMUSTMUSTMUSTMUST read and be familiar withthe appropriate ITW Ransburg equipmentmanuals and literature.


>>>>> VENTILLAVENTILLAVENTILLAVENTILLAVENTILLATING EQUIPMENTTING EQUIPMENTTING EQUIPMENTTING EQUIPMENTTING EQUIPMENT MUST MUST MUST MUST MUST

BE INTERLOCKED BE INTERLOCKED BE INTERLOCKED BE INTERLOCKED BE INTERLOCKED with the sprayingequipment to insure proper ventilation whenequpment is in operation (see NFPA-33).


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3030303030


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Safety Literature - Equipment Grounding

3131313131

EQUIPMENT GROUNDINGEQUIPMENT GROUNDINGEQUIPMENT GROUNDINGEQUIPMENT GROUNDINGEQUIPMENT GROUNDING


In electrostatic coating systems, the flow of highvoltage power from the power supply to theatomizing head of the applicator is insulated fromground and isolated from all other functions andequipment. When the voltage reaches the atomizer,it is transferred to the coating material where, byintroducing a (normally) negative charge, it causesthe atomized fluid to seek the nearest (normally)positive ground. In a properly constructed andoperated system, that ground will be the targetobject.

The directed conduction of the electric chargethrough its array of wires, cables, and equipmentis accompanied by a variety of stray electricalcharges passing through the air by various meanssuch as air ionization; charged particles in the airand radiated energy. Such stray charges may beattracted to any conductive material in the sprayarea. If the conductive material does not providea safe drain to electrical ground which will allow thecharge to dissipate as fast as it accumulates, itmay store the charge. When its electrical storagelimit is reached, or when it is breached by externalcircumstances (such as the approach of agrounded object or person, or one at lower potential),it may discharge its stored charge to the nearestground. If there is no safe path to ground (such asa ground wire) it may discharge through the air asa spark. A spark may ignite the flammableatmosphere of a spray area. The hazard areaextends from the point of origin up to as much asa twenty foot radius. See the NFPA-33 for definitionand limitations of “hazard area”.

EQUIPMENTEQUIPMENTEQUIPMENTEQUIPMENTEQUIPMENT


It is a simple, but vital matter to be sure that ALLALLALLALLALLconductive objects within the spray area aregrounded. This will include such items as, but arenot limited to:

• CabinetsCabinetsCabinetsCabinetsCabinets ••••• BenchesBenchesBenchesBenchesBenches ••••• HousingsHousingsHousingsHousingsHousings• LaddersLaddersLaddersLaddersLadders • BasesBasesBasesBasesBases • ContainersContainersContainersContainersContainers• StandsStandsStandsStandsStands • PeoplePeoplePeoplePeoplePeople ••••• ProductProductProductProductProduct

ALLALLALLALLALL of which are not by design, insulated fromground MUSTMUSTMUSTMUSTMUST be connected directly and

INDIVIDUALLYINDIVIDUALLYINDIVIDUALLYINDIVIDUALLYINDIVIDUALLY to true earth ground. Restingon a concrete floor or being attached to a buildingcolumn may not always be sufficient ground. Inorder to provide the best ground connectionpossible, always attach a ground wire to theterminal indicated by the ground symbol and thento a proven, true earth ground. Always checkground connections for integrity. Some items,such as rotators and paint stands, may besupported on insulators, but all components of thesystem up to the insulator MUST be grounded.

Where items are mounted directly on structuralcomponents such as building columns, the groundconnection MUSTMUSTMUSTMUSTMUST still be made. In many casesthe structural component may be painted or coatedwith an insulating material, and in all cases the ITWRansburg equipment will be painted. Thesecoatings are insulating. The ground connectionmust be as perfect as possible. The indicatedground terminal on the ITW Ransburg equipment

>>>>> ITW Ransburg recommends thatground wires be made of No.18, bare,stranded wire (minimum). Where pos-sible, use larger wire.


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3232323232

will provide the necessary connection at one end,but the user must be sure that the other end issecured to a structural, true earth ground. Thismay be achieved by the use of a standard groundclamp (properly secured), by frazing or by piercingthe structural component enough to assureconnection. All ground connections should bemade to the most conductive metallic structuralground available.

ADDITIONAL STEPSADDITIONAL STEPSADDITIONAL STEPSADDITIONAL STEPSADDITIONAL STEPS

Daily InspectionDaily InspectionDaily InspectionDaily InspectionDaily InspectionTo ensure that everything is properly grounded,the following steps should be undertaken at leastdaily:

1. Inspect all ground wires. Look for good firmjoints at all points of connection. Look for breaksin the ground wire. Repair any defects

IMMEDIATELY!IMMEDIATELY!IMMEDIATELY!IMMEDIATELY!IMMEDIATELY!

2. Inspect all conveyor apparatus (hooks, hangers,etc.). If there is any accumulation of dried coatingmaterial on any of these objects, remove it

BEFOREBEFOREBEFOREBEFOREBEFORE using them!

3. Inspect the floor for excessive accumulation ofdried coating material or other residue. If there areany, REMOVEREMOVEREMOVEREMOVEREMOVE it!

SAFE GROUNDING IS A MATTER OFSAFE GROUNDING IS A MATTER OFSAFE GROUNDING IS A MATTER OFSAFE GROUNDING IS A MATTER OFSAFE GROUNDING IS A MATTER OF

PROPER EQUIPMENT MAINTENANCEPROPER EQUIPMENT MAINTENANCEPROPER EQUIPMENT MAINTENANCEPROPER EQUIPMENT MAINTENANCEPROPER EQUIPMENT MAINTENANCE

AND INSTALLATION, CORRECT OPER-AND INSTALLATION, CORRECT OPER-AND INSTALLATION, CORRECT OPER-AND INSTALLATION, CORRECT OPER-AND INSTALLATION, CORRECT OPER-

ATION AND GOOD HOUSEKEEPING.ATION AND GOOD HOUSEKEEPING.ATION AND GOOD HOUSEKEEPING.ATION AND GOOD HOUSEKEEPING.ATION AND GOOD HOUSEKEEPING.

Hazard Precautions ChecklistHazard Precautions ChecklistHazard Precautions ChecklistHazard Precautions ChecklistHazard Precautions ChecklistThere are hazards to safe equipment maintenancein any industry (personnel, shop trucks, etc.).Daily inspection of grounding apparatus andconditions, however, will help prevent hazardsthat are caused by normal operations.

••••• ALLALLALLALLALL objects in the spray area ARE ARE ARE ARE ARE grounded.

••••• Personnel in the spray area are properlygrounded. (See “Personal Grounding” sectionof this Safety Manual).

••••• The target object is properly grounded and freeof solvent accumulation.

••••• Workholders and conveyor hooks are free ofsolvent accumulation.

••••• The high voltage is OFF OFF OFF OFF OFF except during normalapplication.

••••• The high voltage is OFFOFFOFFOFFOFF and applicators aregrounded during maintenance operations (see“Maintenance” section of this Safety Manual).

••••• The spray area is kept free of accumulated coat-ing deposits.

••••• ALL combustible liquids in the spray area (out-side of automatic delivery systems) are kept toa minimum and are kept in fire safe, grounded

containers.

> Plastic containers due to their insulatednature should NOT be used with any and allspray operations. A charge can build upresuting in a fire. (See NFPA-33).


>>>>> ALL users of electrostatic coating equip-ment MUSTMUSTMUSTMUSTMUST be familiar with the safetyrequiremnts prescribed under the OSHA Actof 1970!


••••• Proper ventilation is provided.

••••• Personnel thoroughly understand the equip-ment, its operation and maintenance, and allsafety precautions.

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Booth Floor CoveringBooth Floor CoveringBooth Floor CoveringBooth Floor CoveringBooth Floor Covering

(Spark Gard)(Spark Gard)(Spark Gard)(Spark Gard)(Spark Gard)


3333333333

Since the beginning of industrial spray paintingthere has been a question as to the proper coveringfor spray booth floors. Any of the answers to thisquestion have left much to be disired regardingsafety, cost and/or convenience.

One type of paper called Spark Gard (GradeBWA-100) is available and MAYMAYMAYMAYMAY be a good solutionto the problem. Ostensible, this paper WILL NOTWILL NOTWILL NOTWILL NOTWILL NOTsupport combustion, is highly absorbent and hashigh wet strength.

It is somewhat more expensive than Kraft paper,for example, but its advantages may very welljustify this difference.

Another type of product called Spark Arrest, whichmay be used in welding operations, is a moredense paper than Spark Gard.

This type of covering DOES NOTDOES NOTDOES NOTDOES NOTDOES NOT supportcombustion either.

A third product is simply called Masking Tape. Itactually is an exceptionally “tight” sheet paperwhich is manufactured exclusively for masking inelectrostatic applications.

Static ElectricityStatic ElectricityStatic ElectricityStatic ElectricityStatic ElectricityElectronic Component DamageElectronic Component DamageElectronic Component DamageElectronic Component DamageElectronic Component DamageStatic electricity can easily be formed, such as byshoes rubbing on carpeting, or synthetic clothingrubbing on the skin. Any static charge whichbuilds up can spell disaster to certain electroniccomponents, such as integrated circuits (I.C.’s).If printed circuit boards containing I.C.’s (such asPC boards used in some of ITW Ransburg’sElectrostatic Power Supplies) are subjected to astatic charge, it is possible that the I.C.’s will fail.

Therefore, it is very important that precautions betaken during repair of electrostatic equipment toprevent static electricity from forming in the areawhere the repair is being done.

Static guard kits are available on the market to useduring electronic repair. These kits include aconductive place mat that the equipment is placedon and ground wires which ground out the placemat and repair person. A typical static guard kit isthe “3M” Model 8012 Veolostat Portable FieldService Kit. If a static guard it is not available foruse during repair, other common sense safeguardsshould be observed:

• Connect a ground wire to the power supplyground lug.

• If the workbench can be grounded, ground italso.

• The repair person should roll-up their sleevesand avoid contacting electronic componentswith clothing.

• The repair person should be bodily groundedby:

1. NOTNOTNOTNOTNOT wearing rubber-soled shoes

2. MAINTAININGMAINTAININGMAINTAININGMAINTAININGMAINTAINING contact with ground (such as with wrist ground straps).

>>>>> Some Electronic Components can be dam-aged by static electricity. Components suchas integrated circuits (I.C.’s) are sensitive tostatic electricity and can fail if subjected to astatic charge.

>>>>> Proper handling procedures MUSTMUSTMUSTMUSTMUST be ob-served while repairing electronic equipment toavoid static damage.


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3434343434

NO. 2 HANDNO. 2 HANDNO. 2 HANDNO. 2 HANDNO. 2 HAND

APPLICAAPPLICAAPPLICAAPPLICAAPPLICATTTTTOROROROROR

ON-SITE PAINTINGON-SITE PAINTINGON-SITE PAINTINGON-SITE PAINTINGON-SITE PAINTING(Near Computers or Other(Near Computers or Other(Near Computers or Other(Near Computers or Other(Near Computers or Other

Electronic Devices)Electronic Devices)Electronic Devices)Electronic Devices)Electronic Devices)

For over 35 years the No. 2 Process handapplicator has been the most widely used tool bythe on-site painting industry for the refinishing ofoffice furniture, office panels, lockers, schoolfurniture, and dozens of other items.

Quite often we are asked about the dangers andpossible damage to computers, phone systems,word processors, or electronically keyed securitysystems when electrostatic painting is donenearby.

Concerning those types of applications, thefollowing facts should be noted:

1. The No. 2 Process hand applicator is notelectromagnetic. It is electrostatic (much like thestatic from carpets or wool and synthetic clothing),and works at an output of 100 kilovolts at 30-50microamperes current draw (100 microamperesmaximum short circuit current).

>>>>> Grounding of all conductive objectsnear an electrostatic spray applicator isof utmost importance.


2. Unlike x-rays, electrostatic does not go“through” objects.

3. Some computers, phone systems or wordprocessors are now shielded by the manufactureragainst outside static.

4. If the static shielding of the unit is unknown, thekeyboard, CPU (central processing unit) and itscable preferably should be removed from theimmediate painting area for protection of the device.

If this is not feasible they should be completelywrapped in aluminum foil that is grounded to anearth ground. This will create a “Faraday cage”around the computerized device.

5. Electrical sparks of all types create an R.F.energy (radio frequency) that may radiate throughthe air and enter into electronic circuits. Theresulting damage is unpredictable.

6. Computer software such as tapes, disks,diskettes, etc., should be removed from inside ofand the immediate surrounding area of anyenclosures that are to be painted.

7. Lightning or electrostatic voltage sparkinginto an A.C. circuit can create “spikes” orelectromagnetic pulse (EMP) that can causeunpredictable damage to electronic hardware.

8. Surge suppressors are available that may helpprotect appliances from “spikes” of current if thesuppressor is in the A.C. line supplying theappliance.

9. When painting any type of electrical controlpanel or console it is generally not known if allpushbuttons, switches, meters or pilot lights areproperly grounded. In view of this, it is desirable tocover all of these items with aluminum foil which isgrounded to the panel or another earth ground.

10. All on-site painting companies should haveadequate liability insurance to protect them in theevent of any real or perceived damage as a resultof their operations.

In view of the above unknown and possibleuncontrolled conditions, ITW Ransburg does notrecommend the electrostatic painting of computercabinets, consoles or painting in close proximity tothese devices.

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APPLICAAPPLICAAPPLICAAPPLICAAPPLICATTTTTOR GROUNDINGOR GROUNDINGOR GROUNDINGOR GROUNDINGOR GROUNDING

GENERALGENERALGENERALGENERALGENERAL DO NOT DO NOT DO NOT DO NOT DO NOT allow the hook or its cable to touch theworking edge of a disk or bell atomizer. Thisedge is critical to good atomization and should

ALALALALALWWWWWAAAAAYSYSYSYSYS be protected from any contact that mightcause even the slightest damage. For overheadapplicators it may be necessary to suspend thecable with a spring or other elastic material in or-der to prevent edge contact. ITW RansburgWaterborne Fluid Supply Enclosures include aninsulated paint stand plus a grounded chain linkenclosure, and a gate that is equipped with a limitswitch, switch trip, warning light and control box.The enclosure is also equipped with a standardITW Ransburg ground hook assembly to groundthe paint supply when personnel are inside of theenclosure.

Personnel entering an insulated fluid supplyenclosure MUST FIRSTMUST FIRSTMUST FIRSTMUST FIRSTMUST FIRST be sure that the systemis NOTNOTNOTNOTNOT operating and that the Warning Light is

OFF!OFF!OFF!OFF!OFF! After entering the enclosure, the groundhook must be attached to the paint supply

BEFOREBEFOREBEFOREBEFOREBEFORE any personal contact is made. Theground hook MUSTMUSTMUSTMUSTMUST be attached during all serviceand above all, during the addition of fluid to thesupply container! When leaving the enclosure,remove the ground hook and close and secure thegate. The warning light MUSTMUSTMUSTMUSTMUST be ONONONONON wheneverthe system is operating.

Ground MUSTMUSTMUSTMUSTMUST be maintained during the additionof fluid to any supply container! Whenevertransferring flammable fluid from one container toanother, both containers MUSTMUSTMUSTMUSTMUST be properlyconnected to a proven ground first and then toeach other. Personnel executing such a transfer

MUSTMUSTMUSTMUSTMUST also be grounded. ITW Ransburg includesan appropriate number of ground hook assemblieswith those systems that require them. If yourinstallation is no longer equipped with the device,replacements may be purchased (15946) orfabricated according to.

Safety Literature - Applicator Grounding

3535353535


>>>>> The high voltage MUSTMUSTMUSTMUSTMUST be OFFOFFOFFOFFOFF and

GROUNDEDGROUNDEDGROUNDEDGROUNDEDGROUNDED before any direct personalcontact is made with the equipment.

Procedures to be followed for safely conductingelectrostatic coating operations are outlined in“Operating Your Electrostatic Coating SystemSafely” section in this Service Manual.

ITW Ransburg Electrostatic Systems depend onhigh voltage to atomize coating material and depositit on the target object. During operation, thesystem is at high voltage. Personnel mustPersonnel mustPersonnel mustPersonnel mustPersonnel must

NEVERNEVERNEVERNEVERNEVER attempt any direct contact with theequipment UNTILUNTILUNTILUNTILUNTIL the high voltage is OFFOFFOFFOFFOFF, theatomizer has STOPPEDSTOPPEDSTOPPEDSTOPPEDSTOPPED rotating and the groundhook has been attached to the applicator or paintsupply as indicated. The ground hook cable

MUSTMUSTMUSTMUSTMUST be secured to a proven, true earth groundand readily accessible to the applicator or paintsupply.

The ITW Ransburg ground hook is designed to beused with disk or bell atomizers or with insulatedfluid supplies. In addition to the aluminum hook,the standard assembly has 15 feet of aircraft cableand a solderless connecter for mounting. Oneassembly should be conveniently located at eachstation. After the high voltage is off and theatomizer has stopped, the hook should be touchedto the atomizer hub or applicator housingmomentarily to dissipate any residual charge. Itshould then be hooked to the applicator housing.

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3636363636

>>>>> Failure to observe the following rules forgrounding may result in inferior finishes, equip-ment failures, static shocks to the operatorand FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!


NO. 2 PROCESS HANDNO. 2 PROCESS HANDNO. 2 PROCESS HANDNO. 2 PROCESS HANDNO. 2 PROCESS HAND

APPLICAAPPLICAAPPLICAAPPLICAAPPLICATTTTTOROROROROR

GROUNDING (ON-SITE)GROUNDING (ON-SITE)GROUNDING (ON-SITE)GROUNDING (ON-SITE)GROUNDING (ON-SITE)

Proper grounding between the work piece, thehigh voltage power supply and the surroundingbuilding is essential for correct operation of theITW Ransburg No. 2 Process Hand ApplicatorSystem.

1 .1 .1 .1 .1 . Connect the Power Supply to theConnect the Power Supply to theConnect the Power Supply to theConnect the Power Supply to theConnect the Power Supply to the

Building Electrical Ground.Building Electrical Ground.Building Electrical Ground.Building Electrical Ground.Building Electrical Ground.The 3-prong grounding plug supplied with thepower supply is acceptable if the wall receptaclehas a proper connection to the ground pin.

2 .2 .2 .2 .2 . Ground the Power Supply to a BuildingGround the Power Supply to a BuildingGround the Power Supply to a BuildingGround the Power Supply to a BuildingGround the Power Supply to a Building

(Structural) Ground.(Structural) Ground.(Structural) Ground.(Structural) Ground.(Structural) Ground.If a 3-prong to 2-prong adapter is used or if theground in the AC receptacle is not connected, thena separate ground wire must be run to a metalbuilding member (electrical conduit, water line,steel building support, etc.). The power supply isequipped with a grounding cable for this purpose.


>>>>> ITW Ransburg suggests that eachoperating crew be supplied with a three-wire circuit analyzer which may be usedto quickly check the ground continuity ofthe building electrical system. Theseanalyzers are available from many sup-pliers such as Sears, Hubbell, orWookhead, at a cost of no more than afew dollars.


>>>>> Because the building electrical systemmay not always be properly grounded,using the alternate building ground connec-tion is a good practice in all situations.

4 .4 .4 .4 .4 . Ground Any Supporting Conveyance forGround Any Supporting Conveyance forGround Any Supporting Conveyance forGround Any Supporting Conveyance forGround Any Supporting Conveyance for

thethethethethe Power Supply. Power Supply. Power Supply. Power Supply. Power Supply.If the power supply is on a cart for portability,ground the cart to the power supply and to buildingground. If using a generator, ensure generatorframe is also connected to true earth ground. If atrue earth ground is not available, one may beestablished by driving a ground rod (see electricalsupplier) into the earth, assuming the soil hasadequate moisture content.

3. Ground the Work Piece to a building3. Ground the Work Piece to a building3. Ground the Work Piece to a building3. Ground the Work Piece to a building3. Ground the Work Piece to a building

(Structural) Ground.(Structural) Ground.(Structural) Ground.(Structural) Ground.(Structural) Ground.Secure wire from the work piece to the buildingground with a spring clip or a grounding clamp. Ifa good earth ground is not available, a secondground wire on power supply is available to groundthe part.


>>>>> A magnet is acceptable if the magnet iskept free of paint accumulation. Remem-ber that most paints are insulators! A mag-net will hold fast over many layers of paintbut may not provide good ground and thuscause sparking.

>>>>> DO NOT ground the work piece directly tothe power supply. It must be grounded with aseparate grounding wire to earth ground.Grounding directly to the power supply coulddamage the equipment.


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6. Operation of any high voltage electrostaticsystem requires an awareness of the phenomenonof INDUCTIVE CHARGING. INDUCTIVE CHARGING. INDUCTIVE CHARGING. INDUCTIVE CHARGING. INDUCTIVE CHARGING. Specifically, thisphenomenon occurs whenever an ungroundedobject (i.e., a metal can on a plastic tile floor) iswithin the electrostatic field generated by anelectrode charged to a high voltage. Theungrounded object will try to acquire a chargeequal in voltage to that of the electrode.

Therefore, the first rule of electrostatic safetyfirst rule of electrostatic safetyfirst rule of electrostatic safetyfirst rule of electrostatic safetyfirst rule of electrostatic safetyis: Ground all conductive objects within the nearfield (10 ft. radius) of any charged electrode!

The second rulesecond rulesecond rulesecond rulesecond rule is: Except those being properlyutilized in the application system, KEEP ALLFLAMMABLE material outside of the far field (20 ft.radius) of any charged electrode.

All use of high voltage systems MUSTMUSTMUSTMUSTMUST be incompliance with the National Electrical Code.Additional precautions are contained in NFPA-33and NFPA-77. Also see ITW Ransburg literature“No. 2 Hand Applicator Spray Techniques andNo. 2 Hand Applicator” service manual. See“Operating Your Electrostatic Coating SystemSafely” in this service manual

W A R N I N GW A R N I N GW A R N I N GW A R N I N GW A R N I N G!!!!!> > > > > FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!

> If this cable is NOTNOTNOTNOTNOT connected during opera-tion, it must be assumed that the pump headwill be charged and therefore, able to producean IGNITION CAPIGNITION CAPIGNITION CAPIGNITION CAPIGNITION CAPABLE SPABLE SPABLE SPABLE SPABLE SPARK.ARK.ARK.ARK.ARK. If thegrounding cable is disconnected during opera-tion, the pump head MUST be equipped withappropriate barriers which will prevent anyspark producing contact.


9966 FLUID PUMP HEAD9966 FLUID PUMP HEAD9966 FLUID PUMP HEAD9966 FLUID PUMP HEAD9966 FLUID PUMP HEAD


PROCEDUREPROCEDUREPROCEDUREPROCEDUREPROCEDURE

>>>>> This cable should be inspected frequentlyfor voltage leaks and checked for electrical con-tinuity of both the conductive wire and thegrounding braid.


5 .5 .5 .5 .5 . Ground the Operator to the Power Supply.Ground the Operator to the Power Supply.Ground the Operator to the Power Supply.Ground the Operator to the Power Supply.Ground the Operator to the Power Supply.The operator will be grounded by grasping themetal handle of the No. 2 Process Hand Applicatorwith their bare hand. The hand applicator isgrounded to the power supply through the metalbraid in the high voltage cable.

a. Paint accumulation on the handle must notbe allowed.

b. Gloves cannot be worn unless an alternateoperator ground is used.

c. The applicator handle MUST NOT becovered. Tape is an insulator!

> ALL personnel who operate, clean, or main-tain this equipment MUST read and thoroughlyunderstand the appropriate service and safetyliterature! Special care should be taken to en-sure that the WARNINGS and requirements foroperating and servicing safety are followed.


Pump HeadPump HeadPump HeadPump HeadPump HeadThis unit is equipped with a grounding cable [70992]that connects the pump head to the groundedbase section and prevents the head from becomingcharged during operation. This cable SHOULDbe connected as shown, whenever the paintconductivity is low enough to permit satisfactoryoperation with the head grounded. Some paints,however, may be too conductive to use with agrounded pump head, so it will be necessary todisconnect the cable.

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Component ContactComponent ContactComponent ContactComponent ContactComponent ContactIn ALLALLALLALLALL cases, NO NO NO NO NO contact should be made with

ANYANYANYANYANY ungrounded component of the system(atomizer, pump head or paint supply) without

FIRSTFIRSTFIRSTFIRSTFIRST grounding the subject item. It is particularly

IMPORTANTIMPORTANTIMPORTANTIMPORTANTIMPORTANT that NONONONONO paint or solvent betransferred from one container to another withoutgrounding BOTHBOTHBOTHBOTHBOTH containers.

Conductivity AdjustmentsConductivity AdjustmentsConductivity AdjustmentsConductivity AdjustmentsConductivity Adjustments

Paint SupplyPaint SupplyPaint SupplyPaint SupplyPaint SupplyIf ungrounded operation is necessary to producesatisfactory results, the paint supply SHOULDSHOULDSHOULDSHOULDSHOULDalso be insulated. The ITW Ransburg 5875-00Paint Stand should be used. It incorporates acircuit which quickly bleeds any accumulatedcharge to ground when the high voltage isinterrupted. This stand must be treated the sameway as the pump head. A grounding cable

SHOULDSHOULDSHOULDSHOULDSHOULD be connected to it whenever the paintconductivity is low enough to permit satisfactoryoperation with the fluid system grounded. If agrounding cable is NOT NOT NOT NOT NOT connected duringoperation, it must be assumed that the paint supplywill be charged and therefore, able to produce anIGNITION CAPABLE SPARK.GNITION CAPABLE SPARK.GNITION CAPABLE SPARK.GNITION CAPABLE SPARK.GNITION CAPABLE SPARK. If the groundingcable is not connected during operation, the paintsupply MUSTMUSTMUSTMUSTMUST be equipped with appropriatebarriers which will prevent any spark producingcontact.

Conductivity ChangesConductivity ChangesConductivity ChangesConductivity ChangesConductivity ChangesWhenever fluid conductivity is changed, theoverload sensitivity setting MUSTMUSTMUSTMUSTMUST be adjustedaccording to the instructions in the appropriatehigh voltage power supply manual. If theadjustment is NOT NOT NOT NOT NOT made, the level of systemsafety will be reduced thereby increasing thepossibility of an ignition capable spark.

9966 PUMP HEAD9966 PUMP HEAD9966 PUMP HEAD9966 PUMP HEAD9966 PUMP HEAD

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TTTTTARGETARGETARGETARGETARGET GROUNDING GROUNDING GROUNDING GROUNDING GROUNDING

Safety Literature - Target Grounding


3939393939

ADDITIONAL STEPSADDITIONAL STEPSADDITIONAL STEPSADDITIONAL STEPSADDITIONAL STEPS

Inspections and PrecautionsInspections and PrecautionsInspections and PrecautionsInspections and PrecautionsInspections and Precautions

ChecklistChecklistChecklistChecklistChecklistIn order to coat products safely and effectively, thefollowing conditions MUSTMUSTMUSTMUSTMUST be maintained:

••••• The target object MUSTMUSTMUSTMUSTMUST be in electrical con-tact with its properly grounded support, conveyoretc.

••••• Hooks, racks, supports, etc., used to hold thetarget object MUSTMUSTMUSTMUSTMUST be maintained clean anddemonstrate a ground resistance of one megohmor less (see NFPA-33).

••••• Points of contact between the support deviceand the target object should be as small aspossible (knife edged or sharp pointed).

••••• Contact points between target objects andsupport devices MUST MUST MUST MUST MUST be as protected aspossible from random spray.

••••• The point of conveyor attachment MUST bekept free of accumulated solvents.

Ground Resistance TGround Resistance TGround Resistance TGround Resistance TGround Resistance TestingestingestingestingestingTo test for ground resistance, use a MegohmMeter (high resistance). This meter is commonlyreferred to as a MEGGER. MEGGER. MEGGER. MEGGER. MEGGER. (There are manymanufacturers of such meters and local sourcescan be easily found to purchase one.) It generatessufficient voltage to penetrate small insulatingaccumulations and obtain a proper reading. Thepenetrating voltage is generally 500V DC to 1000VDC.

Because of the low voltage applied by a volt ohmmeter (VOM), accurate readings may not bepossible and may lead to thinking parts are notgrounded sufficiently when they actually are.

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Safety Literature - Safe Operating Speeds

4040404040

MAXIMUM SAFE OPERAMAXIMUM SAFE OPERAMAXIMUM SAFE OPERAMAXIMUM SAFE OPERAMAXIMUM SAFE OPERATING SPEEDSTING SPEEDSTING SPEEDSTING SPEEDSTING SPEEDS

BELLBELLBELLBELLBELL AND DISK A AND DISK A AND DISK A AND DISK A AND DISK ATTTTTOMIZERSOMIZERSOMIZERSOMIZERSOMIZERS

* Measured at the turbine.** All speeds are with equipment operating at ITW Ransburg specified standards.

RotatingRotatingRotatingRotatingRotating

AtomizerAtomizerAtomizerAtomizerAtomizerPartPartPartPartPart

NumberNumberNumberNumberNumberMaximumMaximumMaximumMaximumMaximum

Speed**Speed**Speed**Speed**Speed**PressurePressurePressurePressurePressure

Limit PSI*Limit PSI*Limit PSI*Limit PSI*Limit PSI*For use withFor use withFor use withFor use withFor use with

Turbine No.Turbine No.Turbine No.Turbine No.Turbine No.

DISKS:DISKS:DISKS:DISKS:DISKS:

Deep Well (12 inch)

Uni-Disk (6 inch)

Uni-Disk (8 inch)

Uni-Disk (10 inch)

Uni-Disk (12 inch)

Conical (6 inch)

Conical (9 inch)

Conical (12 inch)

Conical (6 inch with flip)



BELLS:BELLS:BELLS:BELLS:BELLS:

Standard

Standard

Honda

Standard

Standard

Standard

Standard

Standard

Standard

16775-11

19830-06

19830-08

19830-10

19830-12

20485-6X

20485-9X

20485-12X

20880-6X

20880-9X

20880-12X

20074

20074

70003-00

70122-XX

70351-XX

70571-XX

70256-XX

70461-XX

70900-XX

9,000

27,000

23,000

15,000

15,000

40,000

20,000

20,000

20,000

15,000

8,000

40,000

40,000

60,000

60,000

60,000

60,000

60,000

60,000

60,000

100

50

100

100

100

100

100

100

80

80

85

80

28

52

52

52

52

52

52

45

19840-70880

19840-70880

19840-70880

19840-70880

19840-70880

19840-70880

19840-70880

19840-70880

19840-70880

19840-70880

19840-70880

20172

20865

20865

20865

70798-20865

70586-71985

70253-70386

70446

70798-20865

70253-70386

> DO NOTDO NOTDO NOTDO NOTDO NOT operate any ITW RansburgTurbine Atomizer (disk or Bell) in EXCESSEXCESSEXCESSEXCESSEXCESS ofits “K” number rpm limit!!

> All atomizers manufactured after April 6,1982 bear a “K” number. That number indicatesthe maximum safe rotation speed for that seriesin tens of thousands.For Example: 40K = 40,000 rpm maximumFor Example: 40K = 40,000 rpm maximumFor Example: 40K = 40,000 rpm maximumFor Example: 40K = 40,000 rpm maximumFor Example: 40K = 40,000 rpm maximumsafe speedsafe speedsafe speedsafe speedsafe speed

> If you have an atomizer that does not havea “K” number, contact your ITW Ransburgrepresentative for its maximum safe operatingspeed.


> A maximum limit of 52 psi, measured at theturbine, will produce the maximum safe operat-ing speed of 60,000 rpm (60K) when using the70256, 70461, or 70571 atomizers. Typically, ifthe turbine air is supplied through 30 feet of 3/8inch ID hose, a regulator pressure of 63 psi willresult in a pressure of 50 psi at the turbine


>>>>> Always be certain that ALL electrostaticequipment is completely STOPPEDSTOPPEDSTOPPEDSTOPPEDSTOPPED and de-engerized BEFOREBEFOREBEFOREBEFOREBEFORE beginning any mainte-nance work.


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Because any tool, if used improperly, can bedangerous, safety is ultimately the responsibilityof the user. Safe use of ITW Ransburg equipment,therefore, is the responsibility of those who use it.Each user should examine their own operation,develop an appropriate safety program and ensurethat the correct procedures are followed. ITWRansburg hopes that the information it provides ishelpful to the user in establishing such a program.

It is most important that operating, maintenance,and supervisory personnel understand the safetyrequirements. Appropriate ITW Ransburg safetyand technical literature and signage is availableupon request. Most ITW Ransburg safety signageis available in Spanish and French. In addition tothe available cards, labels, brochures, and servicemanuals, the user should consult other standardsand recognized safety authorities such as theNFPA, OSHA, and NIOSH.

Copies of NFPA bulletins are available at a nominalcost from:

National Fire Protection AssociationBatterymarch ParkQuincy, MA 02269

4141414141

Safety Literature - Fluid Delivery Equipment and Systems

FLUID DELIVERFLUID DELIVERFLUID DELIVERFLUID DELIVERFLUID DELIVERYYYYY EQUIPMENT EQUIPMENT EQUIPMENT EQUIPMENT EQUIPMENT AND SYSTEMS AND SYSTEMS AND SYSTEMS AND SYSTEMS AND SYSTEMS



>>>>> The simple safety measures outlined inthis and your other ITW Ransburg Systemand Component Manuals are vital. Failure toobserve them may cause or contribute to oneor more of the hazards outlined in this safetysection.

>>>>> ITW Ransburg fluid delivery equipmentand systems are pressurized. Read the in-structions before operating and observe allsafety advisories.

Copies of NIOSH publications are available fromyour regional NIOSH office or the U.S. GovernmentPrinting Office. NIOSH and OSHA regional officescan also provide information on theOCCUPATIONAL SAFETY AND HEALTH ACT,including questions on standards interpretations,voluntary compliance information, as well asprovide copies of the OSHA Standards, OSHAAct, Employee Rights Posting Notice andPublications.

The available materials will be helpful in arriving ata program for safe operation. Local codes andauthorities also have standards to be followed inthe installation and operation of your equipment.Also, your insurance provider will be helpful inanswering questions that arise in the developmentof your operating procedures.

FIRE PROTECTIONFIRE PROTECTIONFIRE PROTECTIONFIRE PROTECTIONFIRE PROTECTION

Where flammable or combustible materials arehandled, normal fire protection measures arerequired. These include proper storage offlammables and the proper disposal of waste, plusready access to appropriate fire extinguishingequipment. For details, consult the recommendedNFPA Bulletins, your local fire codes, localequipment standards and the OSHA Act of 1970as well as, your insurance provider’srecommendations.

Many application for ITW Ransburg products,such as airless spraying systems, may generatestatic voltage which can produce an ignitioncapable spark. In such applications, allcomponents of the fluid delivery system, as wellas the target object, bust be properly connected toa proven, true earth ground.

PERSONNELPERSONNELPERSONNELPERSONNELPERSONNEL

All personnel should read and understand localcodes, appropriate NFPA Bulletins, OSHA Act of1970, and this Safety Manual.

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TRANSFERINGTRANSFERINGTRANSFERINGTRANSFERINGTRANSFERING

FLAMMABLE FLUIDFLAMMABLE FLUIDFLAMMABLE FLUIDFLAMMABLE FLUIDFLAMMABLE FLUID

Ground MUSTMUSTMUSTMUSTMUST be maintained during the transferof flammable fluid from any source to any receiver!Whenever transferring flammable fluid, both sourceand receiving containers MUST MUST MUST MUST MUST be properlyconnected to a proven, true earth ground first andthen to each other.

Ground MUST be maintained when insertingequipment (such as a pump assembly) into orremoving it from a supply container of flammablefluid! Both container and equipment MUSTMUSTMUSTMUSTMUST beproperly connected to a proven, true earth groundfirst and then to each other. Personnel executingsuch transfers MUST also be grounded.

> Plastic containers due to their insulatednature should NOT be used with any and allspray operations. A charge can build upresuting in a fire (see NFPA-33, and NFPA-30).


HIGH PRESSURE AIRHIGH PRESSURE AIRHIGH PRESSURE AIRHIGH PRESSURE AIRHIGH PRESSURE AIR

High pressure air can be dangerous and should

NEVER NEVER NEVER NEVER NEVER be used against the body. It can blind,deafen and may even penetrate. If used forcleaning equipment, the user should wear safetyglasses and other appropriate protection.

COMPONENT RUPTURECOMPONENT RUPTURECOMPONENT RUPTURECOMPONENT RUPTURECOMPONENT RUPTURE

Pressurized systems require special concernbecause of the inherent explosion hazard. Tominimize such hazard:

••••• The user should be familiar with OSHA Standard1910.169, Air Receivers and Eye and FaceProtection 1910.133.

••••• Never apply pressure greater than that recom-mended for the weakest component of thesystem.

••••• Never exceed the recommended temperaturelimit. To do so may weaken temperature sen-sitive elements of the device or the systemand contribute to the hazard.

Each ITW Ransburg product is subject to themaximum pressure indicated in its productspecifications (see the appropriate Service Manualor product label). To avoid rupture and injury, allcomponents of the system, including but not limitedto spray applicators, hose, hose connections,heaters and pumps, must have a maximum workingpressure not less than the highest indicatedcomponent pressure limit.

FLUIDSFLUIDSFLUIDSFLUIDSFLUIDS

The fluids (coating materials, chemicals, sealants,lubricants and/or solvents) used in the operationof ITW Ransburg equipment and/or systemsemploying ITW Ransburg equipment are neithermanufactured nor marketed by ITW Ransburg, itsDivisions or affiliates, and therefore ITW Ransburg,its Divisions and affiiates are excluded from anyresponsibility and/or responsibility and/or liabilityfor any and all deleterious effects to persons and/or property that may result from the use of, orcontact (direct or indirect, immediate or delayed)with these fluids.

Users of ITW Ransburg equipment and/or systemsare, therefore most urgently recommended toextend every effort to obtain (from their fluidsupplier) all pertinent and useful data about allfluids used in their ITW Ransburg equipment and/or system. Such information as: hazards tohuman, animal and plant life from ingestion,absorption, or inhalation of toxins; fire or explosion;and levels of hazard, both immediate and delayed;should be obtained by the user and disseminatedto, and learned by all persons using such fluids.The user should be aware of all fluid characteristics,including compatibility with other fluids used andthe system component materials, as well as

SM-00-01

Occupational Safety and Health Act of 1970(OSHA) prior to installing, operating and/orservicing this equipment.

BEFOREBEFOREBEFOREBEFOREBEFORE applying pressure to the system,

ALWAYS:ALWAYS:ALWAYS:ALWAYS:ALWAYS:

••••• Follow the manufacturer’s operating instructionsand maximum pressure recommendations.

••••• Secure the trigger in the OFFOFFOFFOFFOFF position andcheck all pressure connections.

••••• Use grounded, high pressure fluid lines.

••••• Check that the pump is properly grounded.

BEFOREBEFOREBEFOREBEFOREBEFORE disassembly of ANYANYANYANYANY part of thepressure system (including the applicator or itsnozzle) ALWAYS:ALWAYS:ALWAYS:ALWAYS:ALWAYS:

••••• Shut the pump OFF.OFF.OFF.OFF.OFF.

••••• Discharge the residual fluid and pressure fromthe applicator.

••••• Secure the trigger in the OFFOFFOFFOFFOFF position.

Follow these same three procedures anytime thatoperation is discontinued.

DO NOT DO NOT DO NOT DO NOT DO NOT undertake any of the following UNTIL UNTIL UNTIL UNTIL UNTILpressure is relieved from the ENTIREENTIREENTIREENTIREENTIRE system:

••••• Loosen or remove the nozzle.

••••• Disassemble any part of the applicator.

••••• Loosen or disconnect any fluid line fittings.

••••• Disassemble any part of the pump.

Be sure that the power to the pump is OFFOFFOFFOFFOFF and thesystem is depressurized before undertaking ANYANYANYANYANYrepair, maintenance, or adjustment.

If it is necessary to adjust or clean the nozzle onsite, be sure that it is aimed away from all personnel

4343434343


containment and handling requirements and shouldcompile, reproduce and distribute such informationto all appropriate personnel. ITW Ransburg furtherrecommends that regular training sessions beconducted to acquaint personnel with the systemand its use and to keep them up-to-date on newfluid and equipment characteristics andprocedures.

HYDRAULIC INJECTIONHYDRAULIC INJECTIONHYDRAULIC INJECTIONHYDRAULIC INJECTIONHYDRAULIC INJECTION

HAZARDHAZARDHAZARDHAZARDHAZARD

> All hydraulically fed applicators will causeserious injury if the sprayed or leaking fluidpenetrates the skin! If you are injected, SEEKSEEKSEEKSEEKSEEK

EMERGENCY MEDICAL TREATMENT IM-EMERGENCY MEDICAL TREATMENT IM-EMERGENCY MEDICAL TREATMENT IM-EMERGENCY MEDICAL TREATMENT IM-EMERGENCY MEDICAL TREATMENT IM-

MEDIATELY MEDIATELY MEDIATELY MEDIATELY MEDIATELY and advise medical personnel of thenature of the injury!


••••• DO NOTDO NOTDO NOTDO NOTDO NOT place any part of the body in the path of the spray!

••••• DO NOTDO NOTDO NOTDO NOTDO NOT point the applicator at any person!

••••• NEVERNEVERNEVERNEVERNEVER look at the applicator from the nozzleend!

• Treat this applicator as you would aTreat this applicator as you would aTreat this applicator as you would aTreat this applicator as you would aTreat this applicator as you would a

loaded weapon!loaded weapon!loaded weapon!loaded weapon!loaded weapon!

••••• Hydraulic spray systems are capable of enoughfluid pressure TO PRODUCE A LETHALTO PRODUCE A LETHALTO PRODUCE A LETHALTO PRODUCE A LETHALTO PRODUCE A LETHAL

INJECTION!INJECTION!INJECTION!INJECTION!INJECTION!

Airless and Air AssistedAirless and Air AssistedAirless and Air AssistedAirless and Air AssistedAirless and Air Assisted

Airless Spray Equipment SafetyAirless Spray Equipment SafetyAirless Spray Equipment SafetyAirless Spray Equipment SafetyAirless Spray Equipment SafetyALLALLALLALLALL personnel who operate, clean or maintain thisequipment MUSTMUSTMUSTMUSTMUST read and thoroughly understandthe appropriate ITW Ransburg service and safetymanuals. Special care should be taken to insurethat the WARNINGSWARNINGSWARNINGSWARNINGSWARNINGS and requirements foroperating and servicing safely are followed. Theuser should be aware of and adhere to ALLALLALLALLALL localbuilding and fire codes and ordinances and the

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4444444444

so that it may discharge safely if there is residualpressure in the system.

DO NOTDO NOTDO NOTDO NOTDO NOT use any replacement part that does notmeet and is not authorized to manufacturer’sspecifications.

Correct packing or valve seal leaks IMMEDIAT-IMMEDIAT-IMMEDIAT-IMMEDIAT-IMMEDIAT-

ELY.ELY.ELY.ELY.ELY.

Frequently check the condition of all pressurizedcomponents, especially fluid lines. Replace wornhoses and parts before they fail.

If nozzle clogging occurs frequently, use a fluidfilter.

Contact your ITW Ransburg representative if youhave any questions about safety or procedures.

INSULAINSULAINSULAINSULAINSULATED FLUIDTED FLUIDTED FLUIDTED FLUIDTED FLUID

SUPPLSUPPLSUPPLSUPPLSUPPLYYYYY

Where the product is part of the fluid supplysystem for a waterborne electrostatic system,personnel entering an insulated fluid supplyenclosure MUST FIRSTMUST FIRSTMUST FIRSTMUST FIRSTMUST FIRST be sure that the systemis NOTNOTNOTNOTNOT operating and that the Warning Light is

OFF!OFF!OFF!OFF!OFF! After entering the enclosure, the groundinghood must be attached to the paint supply

BEFOREBEFOREBEFOREBEFOREBEFORE any personnel contact is made. Thegrounding hook MUSTMUSTMUSTMUSTMUST be attached during allservice and above all, during the addition of fluid tothe supply container! When leaving the enclosure,the gate must be closed and secured. The warninglight MUSTMUSTMUSTMUSTMUST be on whenever the system isoperating. The integrity of the system ground

MUSTMUSTMUSTMUSTMUST be inspected regularly and maintained.

SAFE INSTSAFE INSTSAFE INSTSAFE INSTSAFE INSTALLAALLAALLAALLAALLATIONTIONTIONTIONTION

See that all elements of the system are correctlylocated, connected, and grounded. Position allauxiliary non-approved electrical apparatus,including but not limited to: High voltage power

SAFE OPERASAFE OPERASAFE OPERASAFE OPERASAFE OPERATIONTIONTIONTIONTION

If ANY symptom of improper operation occurs,suspend use of the unit until the problem has beendiagnosed and corrected. See the appropriateTroubleshooting Guide of the product’s servicemanual, or contact your ITW Ransburgrepresentative.

Ground MUSTMUSTMUSTMUSTMUST be maintained when inserting apump assembly into or removing it from a supplycontainer of hazardous material! Both containerand pump MUST MUST MUST MUST MUST be properly connected to aproven ground first and then to each other.Personnel executing such a transfer MUSTMUSTMUSTMUSTMUST alsobe grounded.

SAFE MAINTENANCESAFE MAINTENANCESAFE MAINTENANCESAFE MAINTENANCESAFE MAINTENANCE

AND AND AND AND AND SERVICESERVICESERVICESERVICESERVICE

Good housekeeping is essential to safe operation,see that it is maintained at all times. Cleanup andmaintenance schedules should be established bythe user, based on observations of the initialproduction operations. Maintenance and safetycards should be posted in clear view of the operator.Good housekeeping is also necessary to ensurequality work, eliminate rejects, and reduce servicerequirements.

Employ fire protection measures, including properstorage of flammables, cleaning solvents, andwaste.

Never operate any equipment without the requiredor provided protective covers, screens, shields,or devices.

Never alter a system or its components withoutnoting such changes on the appropriatedocuments, labels, and tags.

supplies, fluid pumps, and air compressors, outsideof hazardous locations. See the appropriate NFPAand/or OSHA guidelines for your application andequipment.

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4545454545

Before cleaning or servicing the equipment, turnthe electrical power and the air and fluid pressures

OFF. OFF. OFF. OFF. OFF. See that air and fluid pressures areappropriately relieved BEFOREBEFOREBEFOREBEFOREBEFORE opening orremoving any part or component.

Flush the system on an appropriate scheduledetermined by the fluid being used. ALWAYSALWAYSALWAYSALWAYSALWAYSflush the system when changing from one fluidbrand or formula to another. ALWAYSALWAYSALWAYSALWAYSALWAYS use thelowest pressure possible to flush the system (nomore than 20 psi.).

Cleaning Safety RequirementsCleaning Safety RequirementsCleaning Safety RequirementsCleaning Safety RequirementsCleaning Safety RequirementsSpecial care MUSTMUSTMUSTMUSTMUST be taken in cleaningelectrostatic and coating installations. To cleanyour equipment and installation safely, you MUSTMUSTMUSTMUSTMUSTfollow these requirements:

1. BEFORE BEFORE BEFORE BEFORE BEFORE attempting to clean any equipment,ensure that the voltage to the electrostatic coatingequipment is turned OFF and CANNOT CANNOT CANNOT CANNOT CANNOT beturned ON. A sign should be posted at the push-button switches to warn against turning the poweron.

2. Make sure you know the location of fire ex-tinguishing equipment and how it is operated

PRIORPRIORPRIORPRIORPRIOR to commencing any cleaning operations.Such equipment should be inspected regularly toensure it is in proper working order.

3. Attach a grounding cable to any high voltageatomizer or electrode during cleaning to protectagainst inadvertent energization of the coatingequipment.

4. ALL ALL ALL ALL ALL personnel involved in cleaning the elec-trostatic installation MUST NOTMUST NOTMUST NOTMUST NOTMUST NOT wear shoes thatinsulate them from the grounded conductive floorof the spraying area. ALLALLALLALLALL personnel involved incleaning operations MUSTMUSTMUSTMUSTMUST be grounded at alltimes.

5. ALLALLALLALLALL containers carried into the spray booth foruse in cleaning the installation MUSTMUSTMUSTMUSTMUST be groundedat ALLALLALLALLALL times. Maintain solvents at the minimumamount required for the cleaning operation andonly in approved type safety containers (see Item11.).

6. Use only cleaning solvents that have a flashpoint above 100oF.

7. Use cleaning solvents that have no toxicity,whenever possible. Wear respiration deviceswhenever cleaning requires the use of toxicsolvents.

8. Adequate ventilation MUSTMUSTMUSTMUSTMUST be provided inarea where cleaning operations are being con-ducted. Spraying area ventilation equipment mustbe operated during cleaning operation to carryaway solvent vapors that may be generated incleaning.

9. Use only non-sparking tools for cleaningpurposes.

10. Remove residue (scrapings and debriscontaminated with the scrapings) from the pre-mises IMMEDIATELY.IMMEDIATELY.IMMEDIATELY.IMMEDIATELY.IMMEDIATELY.

11. Place ALLALLALLALLALL rags or waste material imprenatedwith coating materials or solvents in fire-safewaste cans IMMEDIATELY IMMEDIATELY IMMEDIATELY IMMEDIATELY IMMEDIATELY after use. Suchcans should have the approval of appropriatecompetent authorities, such as UnderwritersLaboratories or Factory Mutual EngineeringCorporation.

12. DO NOTDO NOTDO NOTDO NOTDO NOT immerse any portion of ITWRansburg hand applicators in ANYANYANYANYANY liquid for ANYANYANYANYANYreason. Clean electrostatic hand applicators witha soft bristled brush and solvent. SOMESOMESOMESOMESOME parts ofITW Ransburg electrostatic hand applicators, suchas air caps and paint nozzles, can be REMOVEDREMOVEDREMOVEDREMOVEDREMOVEDfrom the applicators and soaked.

13. Wipe up or dry with air, IMMEDIATELYIMMEDIATELYIMMEDIATELYIMMEDIATELYIMMEDIATELY, anysolvent that may be spilled during the course ofcleaning operations.

14. DO NOTDO NOTDO NOTDO NOTDO NOT reconnect electrostatic coatingequipment until after the cleaning operation hasbeen completed and vapors generated in cleaningthe spraying area have been removed byventilation.

SM-00-01 4646464646


PROTECTIVEPROTECTIVEPROTECTIVEPROTECTIVEPROTECTIVE

COVERINGS FOR NYLONCOVERINGS FOR NYLONCOVERINGS FOR NYLONCOVERINGS FOR NYLONCOVERINGS FOR NYLON

FLUID LINESFLUID LINESFLUID LINESFLUID LINESFLUID LINES

FLUID LINE ROUTINGFLUID LINE ROUTINGFLUID LINE ROUTINGFLUID LINE ROUTINGFLUID LINE ROUTING

FOR AUTFOR AUTFOR AUTFOR AUTFOR AUTOMAOMAOMAOMAOMATICTICTICTICTIC

INSTINSTINSTINSTINSTALLAALLAALLAALLAALLATIONSTIONSTIONSTIONSTIONS

>>>>> Pinholing in fluid tubing CREACREACREACREACREATES ATES ATES ATES ATES A

HAZARDOUS CONDITION.HAZARDOUS CONDITION.HAZARDOUS CONDITION.HAZARDOUS CONDITION.HAZARDOUS CONDITION.


When the coating materials are heated it isnecessary to use a fluid tubing such as nylonwhich has a higher melting point than thepolyethylene tubing which is normally providedwith TURBODISK®, TURBOBELL® and R-E-A®

Automatic Systems. Since the nylon tubing hasless electrical strength than a polyethylene tubingthe nylon tube may pinhole when conductivecoatings are used.

To prevent this problem from occurring it isrecommended that a polyethylene outer tubing beplaced over the nylon tubing to provide addedelectrical protection. Other safety precautionsregarding fluid tubing are outlined in the “Fluid LineRouting for Automatic Installations” section of thisSafety Manual.

If nylon tubing is being used for any of the fluid linesplease consult your local ITW Ransburg distributoror the ITW Ransburg Technical Support forinformation on the proper size of polyethylenetubing that must be placed over the nylon tubing toprovide additional electrical production.

The polyethylene fluid line tubing used in ITWRansburg installations is sample tested by ITWRansburg Manufacturing at 125 kV for five minutes.Laboratory tests have been run on samples of thispolyethylene tubing which have been abraded orkinked. They were tested at 140 kV for as long aseight hours without failure. However, damagedtubing used for fluid lines will eventually fail.

>>>>> Pinholing in fluid tubing CREACREACREACREACREATES ATES ATES ATES ATES A

HAZARDOUS CONDITION.HAZARDOUS CONDITION.HAZARDOUS CONDITION.HAZARDOUS CONDITION.HAZARDOUS CONDITION.


The hazard can be avoided, however by a fewsimple precautions. As damage may occur duringeither installation or use, the user should exercisecare that all fluid tubing, when installed, is held freefrom all sharp edges or rough surfaces. If stationarytubing is allowed to remain in contact with a sharpedge or a rough surface, the normal structuralvibration and movement will eventually damage it.If the edge or surface is grounded, the hazard iscompounded. If edges or rough surfaces areunavoidable, they should be padded or the tubingshould be sheathed with ITW Ransburg approved,non-coductive sheathing or an insulation stand-offdevice should be used.

The fluid tube lengths should be more than isneeded to allow for expansion and contraction, butshould not be long enough to allow kinking orlooping. Suspending from above is better thansupport from below as a method of routing.

When installing tubing, it should be laid in place. Itshould NEVER be pulled or dragged acrosssurfaces or edges which might cause damage.

15. If any defect in the equipment is noted incleaning operations, report the defect tosupervisory or maintenance personnel PRIOR PRIOR PRIOR PRIOR PRIOR tothe commencement of coating operations. DODODODODO

NOT NOT NOT NOT NOT operate equipment suspected of beingdefective UNTIL UNTIL UNTIL UNTIL UNTIL equipment has been checkedcompletely.

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4747474747

>>>>> Tubing must NEVERNEVERNEVERNEVERNEVER be kinked, folded,scratched, pierced, perforated, abraded,mashed, smashed, or otherwise abused!

>>>>> Should a tube fail or show signs of poten-tial failure, the ONLONLONLONLONLYYYYY ITW Ransburg approvedrepair is total replacement of that completelength of tubing. Slicing, taping, etc., is PRO-PRO-PRO-PRO-PRO-

HIBITEDHIBITEDHIBITEDHIBITEDHIBITED and NOT NOT NOT NOT NOT ITW Ransburg ap-proved.



>>>>> The following table is for maximum rated pressures at the given temperature regardingTeflon tubing:

TUBING SIZE TUBING SIZE TUBING SIZE TUBING SIZE TUBING SIZE RA RA RA RA RATED PRESSURE TEMPERATED PRESSURE TEMPERATED PRESSURE TEMPERATED PRESSURE TEMPERATED PRESSURE TEMPERATURETURETURETURETURE

1/2” OD X .375” ID PFA Teflon 165 psig 75o F (24o C) 150 psig 100o F (38o C) 115 psig 150o F (66o C) 85 psig 200o F (93o C)



Where the tubing is subject to constant movement,as at a reciprocating unit, the slack should be theminimum needed and should be properlysuspended from an insulating support. Reciprocat-ing tubing is, of course, at such greater risk thanstationary tubing.

>>>>> When attaching fittings to fluid lines, exer-cise great care that the nut is NOT OVER-TIGHTENED. Excessive torque on the nutwill cause the ferrule to cut into the tube caus-ing an electrical stress point which will causepremature failure of th tube. The nut shouldbe snug and secure, but not over tight.


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A regular schedule of inspection should beestablished by the user to check the condition,routing and connections of all tubing, with specialattention to pinholing at points where the tubing isin close proximity to an electrically groundedcomponent.

ALL ROUTING TECHNIQUES SHOULDALL ROUTING TECHNIQUES SHOULDALL ROUTING TECHNIQUES SHOULDALL ROUTING TECHNIQUES SHOULDALL ROUTING TECHNIQUES SHOULD

BE APPROVED BY AN ITW RANSBURGBE APPROVED BY AN ITW RANSBURGBE APPROVED BY AN ITW RANSBURGBE APPROVED BY AN ITW RANSBURGBE APPROVED BY AN ITW RANSBURG

REPRESENTATIVE!REPRESENTATIVE!REPRESENTATIVE!REPRESENTATIVE!REPRESENTATIVE!

4848484848



SM-00-014949494949

SOLSOLSOLSOLSOLVENTVENTVENTVENTVENT HAZARDS HAZARDS HAZARDS HAZARDS HAZARDS


HAZARD EXPLANAHAZARD EXPLANAHAZARD EXPLANAHAZARD EXPLANAHAZARD EXPLANATIONSTIONSTIONSTIONSTIONS

There are three elements of the HalogenatedHydrocarbon (HHC) solvent hazard. Theseelements are:

••••• The Presence of HHC Solvents:1-1-1 Trichloroethane and Methylene Chlorideare the most common of these solvents.However, other HHC solvents are suspect ifused; either as part of paint or adhesivesformulation, or for clean-up flushing.

••••• Aluminum or Galvanized Parts:Most handling equipment contains theseelements. In contact with these metals, HHCsolvents could generate a corrosive reactionof catalytic nature.

Safety Literature - Solvent Hazards


>>>>> EXPLOSION HAZARD EXPLOSION HAZARD EXPLOSION HAZARD EXPLOSION HAZARD EXPLOSION HAZARD

> A hazardous situation may be presentA hazardous situation may be presentA hazardous situation may be presentA hazardous situation may be presentA hazardous situation may be present

in your coating system!in your coating system!in your coating system!in your coating system!in your coating system! HalogenatedHydrocarbon solvents can cause an explo-sion when used with aluminum components inclosed (pressurized) fluid system (pump, heat-ers, filters, valves, spray applicators, tanks,etc.).

> THE EXPLOSION COULD CAUSETHE EXPLOSION COULD CAUSETHE EXPLOSION COULD CAUSETHE EXPLOSION COULD CAUSETHE EXPLOSION COULD CAUSE

SERIOUS INJURY, DEATH, AND/ORSERIOUS INJURY, DEATH, AND/ORSERIOUS INJURY, DEATH, AND/ORSERIOUS INJURY, DEATH, AND/ORSERIOUS INJURY, DEATH, AND/OR

SUBSTANTIAL PROPERTY DAMAGE.SUBSTANTIAL PROPERTY DAMAGE.SUBSTANTIAL PROPERTY DAMAGE.SUBSTANTIAL PROPERTY DAMAGE.SUBSTANTIAL PROPERTY DAMAGE.

> Cleaning agents, coatings, paints, etc., may

contain Halogenated Hydrocarbon solvents.Some ITW Ransburg equipment includes alu-minum components and will be affected byHalogenated Hydrocarbon solvents.

••••• Equipment Capable of Withstanding Pressure:When HHC solvents contact aluminum orgalvanized parts inside a closed container,such as a pump, spray applicator, or fluidhandling system, the chemical reaction can,over time, result in a build-up of heat andpressure, which can reach explosive proportion.

When all three elements are present, the resultcan be an extremely violent explosion. The reactioncan be sustained with very little aluminum orgalvanized metal; any amount of aluminum is toomuch.

The reaction is unpredictable. Prior use of anHHC solvent without incident (corrosion orexplosion) does not mean that such use is safe.These solvents can be dangerous along (as clean-up or flushing agents) or when used as acomponent of coating material.

There is no known inhibitor that is effective underall circumstances. Furthermore, the mixing ofHHC solvents with other materials or solvents,such as MEK, alcohol and toluene, may renderthe inhibitors ineffective.

The use of reclaimed solvents is particularlyhazardous. Reclaimers may not add any inhibitors,or may add incorrect amounts of inhibitors. Also,the possible presence of water in reclaimedsolvents could feed the reaction.

Anodized or other oxide coatings cannot be reliedupon to prevent the explosive reaction. Suchcoatings can be worn, cracked, scratched or toothin to prevent contact. There is no known way tomake oxide coatings, or to employ aluminumalloys, which will safely prevent the chemicalreaction under all circumstances.

SM-00-01


5050505050

>>>>> If you are now using a Halogenated Hy-drocarbon solvent in pressurized fluid sys-tem having aluminum or galvanized wettedparts, IMMEDIAIMMEDIAIMMEDIAIMMEDIAIMMEDIATELTELTELTELTELYYYYY T T T T TAKE THE FOL-AKE THE FOL-AKE THE FOL-AKE THE FOL-AKE THE FOL-

LOWING STEPS:LOWING STEPS:LOWING STEPS:LOWING STEPS:LOWING STEPS:

! Empty system, shut off, completely de-

pressurize in accordance with equipment

instructions.

! Remove equipment from service, disas-

semble in accordance with equipment ser-vicing instructions.

! Inspect all parts for corrosion and/or wear.

Replace any damaged parts.

! Thoroughly clean all parts of the equip-

ment with a non-halogenated solvent andreassemble in accordance with equip-ment servicing instructions.

! Flush equipment with non-halogenated

solvent.

! DO NOTDO NOTDO NOTDO NOTDO NOT reuse equipment with HHC

solvents or with materials containing suchsolvents.

! Material suppliers and/or container labels

should be consulted to ensure that thesolvents used are compatible with yourequipment.


Some solvent suppliers promote HHC solventsfor use in coating systems. The increasing use ofHHC solvents is increasing the risk. Because oftheir exemption from many State ImplementationPlans as Volatile Organic Compounds (VOC's)their low flammability hazard and their not beingclassified as a toxic or carcinogenic substances,HHC solvents are very desirable in many respects.

>>>>> TAKE IMMEDIATE ACTION! TAKE IMMEDIATE ACTION! TAKE IMMEDIATE ACTION! TAKE IMMEDIATE ACTION! TAKE IMMEDIATE ACTION! Haloge-nated Hydrocarbon solvents are dangerouswhen used with aluminum components in aclosed fluid system.


We are aware of no stabilizers available to preventHalogenate Hydrocarbon solvents from reactingunder all conditions with aluminum components ina closed fluid system.

PLEASE DIRECT THIS IMPORTANTPLEASE DIRECT THIS IMPORTANTPLEASE DIRECT THIS IMPORTANTPLEASE DIRECT THIS IMPORTANTPLEASE DIRECT THIS IMPORTANT

SAFETY INFORMATIONSAFETY INFORMATIONSAFETY INFORMATIONSAFETY INFORMATIONSAFETY INFORMATION to the appropriatepeople in your organization such as general andproduction managers, paint line supervisors, andoperators, as well as, purchasing agents,maintenance personnel, and others who may beconcerned.

SM-00-01


HALOGENAHALOGENAHALOGENAHALOGENAHALOGENATEDTEDTEDTEDTED

SOLSOLSOLSOLSOLVENTS DEFINEDVENTS DEFINEDVENTS DEFINEDVENTS DEFINEDVENTS DEFINED

Any hydrocarbon solvent containing any of thefollowing elements:

Flourine (f) "-flour-"Flourine (f) "-flour-"Flourine (f) "-flour-"Flourine (f) "-flour-"Flourine (f) "-flour-"

Bromine (Br) "-bromo-"Bromine (Br) "-bromo-"Bromine (Br) "-bromo-"Bromine (Br) "-bromo-"Bromine (Br) "-bromo-"

Chlorine (C1) "-chloro-"Chlorine (C1) "-chloro-"Chlorine (C1) "-chloro-"Chlorine (C1) "-chloro-"Chlorine (C1) "-chloro-"

Iodine (I) "-iodo-"Iodine (I) "-iodo-"Iodine (I) "-iodo-"Iodine (I) "-iodo-"Iodine (I) "-iodo-"

Examples (not all-inclusive):

CHLORINATED SOLVENTS:CHLORINATED SOLVENTS:CHLORINATED SOLVENTS:CHLORINATED SOLVENTS:CHLORINATED SOLVENTS:Carbon tetrachlorideOrthodichlorobenzeneChloroformPerchloroethyleneEthylene dichlorideTRICHLOROETHANEMETHYLENE CHLORIDE -or-TrichloroethyleneDICHLOROMETHANEMonochlorotolueneMonochlorobenzene

FLOUROCARBON SOLVENTS:FLOUROCARBON SOLVENTS:FLOUROCARBON SOLVENTS:FLOUROCARBON SOLVENTS:FLOUROCARBON SOLVENTS:DichloroflouromethaneTrichloroflouromethane

BROMINATED SOLVENTS:BROMINATED SOLVENTS:BROMINATED SOLVENTS:BROMINATED SOLVENTS:BROMINATED SOLVENTS:Ethylene dibromideMethyl bromineMethylene chlorobromide

IODINATED SOLVENTS:IODINATED SOLVENTS:IODINATED SOLVENTS:IODINATED SOLVENTS:IODINATED SOLVENTS:N-butyl IodideEthyl IodideMethyl IodidePropyl Iodide

5151515151

Consult your material supplier to determine whetheryour solvent or coating contains HalogenatedHydrocarbon Solvents.

Contact ITW Ransburg or your ITW Ransburgrepresentative for the following safety literature:

DANGER - Explosion Hazard (HHC) LA-DANGER - Explosion Hazard (HHC) LA-DANGER - Explosion Hazard (HHC) LA-DANGER - Explosion Hazard (HHC) LA-DANGER - Explosion Hazard (HHC) LA-BEL BEL BEL BEL BEL (for posting to warn of hazard.)

SM-00-01

Safety Literature - Bell Cup Preventive Maintenance

5252525252

HIGH PERFORMANCE THERMOPLASTICHIGH PERFORMANCE THERMOPLASTICHIGH PERFORMANCE THERMOPLASTICHIGH PERFORMANCE THERMOPLASTICHIGH PERFORMANCE THERMOPLASTIC

BELL CUP PREVENTIVE MAINTENANCEBELL CUP PREVENTIVE MAINTENANCEBELL CUP PREVENTIVE MAINTENANCEBELL CUP PREVENTIVE MAINTENANCEBELL CUP PREVENTIVE MAINTENANCE

It is the user’s responsibility to ensure propermaintenance of the atomizer bell at all times. Bellcup failure due to inadequate cleaning or handlingwill not be covered under warranty. The “Do Not”“Do Not”“Do Not”“Do Not”“Do Not”bullets listed are some examples of improperhandling which could adversely affect performanceor personnel safety and should not be attemptedfor any reason.

Bell Cup CleaningBell Cup CleaningBell Cup CleaningBell Cup CleaningBell Cup CleaningAlways verify that high voltage is turned OFF andthat the atomizer bell is spinning before performingany type of color change or bell flush cleaningcycle.

To reduce the risk of fire or explosion, the solventsused for exterior cleaning must have flash pointsabove 100°F (37.8°C). Since electrostaticequipment is involved, these solvents should alsobe non-polar.

Solvents used for equipment flushing should haveflash points equal to or higher than those of thecoating material being sprayed.

1. The atomizer bell will normally be fully cleanedduring a bell flush cycle. Flushing should be donebefore any down time or break in production. A bellflush cycle may also be required while sprayingbatch parts of the same color. Verify that highvoltage is OFF and that the atomizer bell is spinningbefore flushing through the bell.

2. If there are any remaining paint build up on anyareas of the bell after flushing, the bell should beremoved for hand cleaning (reference “Bell CupHandling” in this section). The bell’s leading edge,paint feed holes or slots, and serration cuts aresome examples of areas for special attention.

3. Visually inspect the bell cup edge for signs ofabrasion. If the edge is excessively worn or badlychipped as the result of a collision with a part,replace the cup immediately.

4. Soaking the bell cup in solvent will not aid inloosening or removing paint build up! The bellshould be dipped in an appropriate solvent or thesolution may be allowed to flow over and into thebell while cleaning.

5. Use a soft bristle brush dipped in solvent toremove paint build up from the serration cuts, paintfeed holes or slots, and external and internalsurfaces of the bell. With a light source shinninginto the rear of the bell, any contamination in thepaint feed holes will be easily seen when viewedfrom the front face.

6. A soft, lint free rag dampened with solvent maybe used to remove any paint residue from theexternal and internal surfaces of the bell.

7. After removing all paint build up or residue, rinsethe bell in clean solvent and blow dry.

8. Before reinstalling the bell onto the shaft, checkthe mating surfaces of the thread and taper for anypaint build up or residue. Also, check the shaftplug, fluid tube outside diameter, and the shaftbore for any further paint build up. These surfacesshould be cleaned before installing the bell.

9. Be sure to install the provided shaft plug, PartNumber: RPM-76-1 or 77790-00, into the shaftprior to installing the bell cup.

Install and tighten the bell according to the Atomizerservice manual.

SM-00-01

Bell Cup TBell Cup TBell Cup TBell Cup TBell Cup Testing (Non-Rotating)esting (Non-Rotating)esting (Non-Rotating)esting (Non-Rotating)esting (Non-Rotating)Check bell cup voltage using ITW Ransburg TestMeter Kit, Part Number: 76652-01 or 76652-04.Verify that the output voltages have not variedmuch from the setup standard. A drastic changein voltage can be an early indicator of a componentor system problem.

The following data was collected under ideal labconditions using a clean atomizer and an unloadedfluid delivery system.

The following data is for use with the RMA-101Aerobell 33R Atomizers:

The output voltage measured at the bell will normallyrange between 91% and 97% of the kV setpointdisplayed at the control unit.

The following data is for use with the Aerobell 33Atomizers:

The output voltage measured at the bell will normallyrange between 85% and 91% of the kV setpointdisplayed at the control unit.

Bell Cup HandlingBell Cup HandlingBell Cup HandlingBell Cup HandlingBell Cup HandlingAlways verify that high voltage is turned OFF andthe atomizer bell has stopped spinning beforeperforming any type of handling maintenance.


5353535353


SM-00-01


5454545454

Do notDo notDo notDo notDo not attempt to hold a rag ora gloved hand against the belledge to stop or slow down arotating bell.

Do not Do not Do not Do not Do not attempt to clean the belledge while the bell is rotating.

Do not Do not Do not Do not Do not use sharp or abrasivematerials to clean the bell, whichwill scratch or damage theplastic bell.

Do notDo notDo notDo notDo not use sharp or abrasivematerials to clean the bell, whichwill scratch the semi-conductivecoating on the surface of the bell.

Do notDo notDo notDo notDo not use ammonia solutionsor reclaim solvent containingd-Limonene to clean the bellcups.

Do notDo notDo notDo notDo not attempt to place a highvoltage probe on the bell edgeunless rotation is fully stopped.

Do notDo notDo notDo notDo not reuse an atomizer bellthat shows signs of damagesuch as nicks, heavy scratches,dents, or excessive wear(defined under "Bell CupCleaning").

Do not Do not Do not Do not Do not use ultrasonic devicesto clean the atomizer bell cup.

OPERAOPERAOPERAOPERAOPERATTTTTOR / MAINTENANCEOR / MAINTENANCEOR / MAINTENANCEOR / MAINTENANCEOR / MAINTENANCE

***W***W***W***W***WARNINGS***ARNINGS***ARNINGS***ARNINGS***ARNINGS***

Do notDo notDo notDo notDo not use the bell cup to spraycoatings containing N-methylpyrrolidone.

Do notDo notDo notDo notDo not use N-methylpyrrolidone to clean the bell cup.

SM-00-01

Safety Literature - Check List

5555555555

SAFETY TRAINING CHECK LISTSAFETY TRAINING CHECK LISTSAFETY TRAINING CHECK LISTSAFETY TRAINING CHECK LISTSAFETY TRAINING CHECK LIST

Customer:Customer:Customer:Customer:Customer:

Location:Location:Location:Location:Location:

Job#:Job#:Job#:Job#:Job#:

DATE COMPLETEDDATE COMPLETEDDATE COMPLETEDDATE COMPLETEDDATE COMPLETED

1. Safety Signs Posted1. Safety Signs Posted1. Safety Signs Posted1. Safety Signs Posted1. Safety Signs Posted

2. Safety Manual Given to Customer Operations and2. Safety Manual Given to Customer Operations and2. Safety Manual Given to Customer Operations and2. Safety Manual Given to Customer Operations and2. Safety Manual Given to Customer Operations and

Safety Personnel Safety Personnel Safety Personnel Safety Personnel Safety Personnel

3. System Safety3. System Safety3. System Safety3. System Safety3. System SafetyA. GroundingA. GroundingA. GroundingA. GroundingA. Grounding

1. Parts1. Parts1. Parts1. Parts1. Parts

2. Personnel2. Personnel2. Personnel2. Personnel2. Personnel

3. Objects in Spray Area3. Objects in Spray Area3. Objects in Spray Area3. Objects in Spray Area3. Objects in Spray Area

4. Coating Material / Powder Feed System4. Coating Material / Powder Feed System4. Coating Material / Powder Feed System4. Coating Material / Powder Feed System4. Coating Material / Powder Feed System

5. Grounding Hook5. Grounding Hook5. Grounding Hook5. Grounding Hook5. Grounding Hook

6. Isolated system (explain rquirements)6. Isolated system (explain rquirements)6. Isolated system (explain rquirements)6. Isolated system (explain rquirements)6. Isolated system (explain rquirements)

B. Fire Extinguishing / Fire Detection EquipmentB. Fire Extinguishing / Fire Detection EquipmentB. Fire Extinguishing / Fire Detection EquipmentB. Fire Extinguishing / Fire Detection EquipmentB. Fire Extinguishing / Fire Detection Equipment1. Manual1. Manual1. Manual1. Manual1. Manual2. Automatic2. Automatic2. Automatic2. Automatic2. Automatic3. UV Detection System3. UV Detection System3. UV Detection System3. UV Detection System3. UV Detection System

C. Mechanical HazardsC. Mechanical HazardsC. Mechanical HazardsC. Mechanical HazardsC. Mechanical Hazards1. Rotating Atomizers1. Rotating Atomizers1. Rotating Atomizers1. Rotating Atomizers1. Rotating Atomizers2. Pump Gears2. Pump Gears2. Pump Gears2. Pump Gears2. Pump Gears3. Reciprocators / Motion Machine3. Reciprocators / Motion Machine3. Reciprocators / Motion Machine3. Reciprocators / Motion Machine3. Reciprocators / Motion Machine

4. Rolling Booth (Powder ONLY)4. Rolling Booth (Powder ONLY)4. Rolling Booth (Powder ONLY)4. Rolling Booth (Powder ONLY)4. Rolling Booth (Powder ONLY)

D. HousekeepingD. HousekeepingD. HousekeepingD. HousekeepingD. Housekeeping1. Spray Area1. Spray Area1. Spray Area1. Spray Area1. Spray Area2. Equipment2. Equipment2. Equipment2. Equipment2. Equipment

Customer Personnel Trained:

Installation Supervisor:

Customer Safety Director:

SM-00-01

Safety Literature - Check List

5656565656

SAFETY SAFETY SAFETY SAFETY SAFETY ADVISORY ADVISORY ADVISORY ADVISORY ADVISORY CHECK LISTCHECK LISTCHECK LISTCHECK LISTCHECK LIST

Attention:Attention:Attention:Attention:Attention:

Company:Company:Company:Company:Company:

The following unsafe conditions were noticed during my visit to your facility and need to becorrected immediately.

Solvents stored in ungrounded containersSolvents stored in ungrounded containersSolvents stored in ungrounded containersSolvents stored in ungrounded containersSolvents stored in ungrounded containers

Solvents stored in non-safety containerSolvents stored in non-safety containerSolvents stored in non-safety containerSolvents stored in non-safety containerSolvents stored in non-safety container

Equipment being flushed with high voltage “ON”Equipment being flushed with high voltage “ON”Equipment being flushed with high voltage “ON”Equipment being flushed with high voltage “ON”Equipment being flushed with high voltage “ON”

Parts too close to atomizerParts too close to atomizerParts too close to atomizerParts too close to atomizerParts too close to atomizer

Parts sparking due to poor groundingParts sparking due to poor groundingParts sparking due to poor groundingParts sparking due to poor groundingParts sparking due to poor grounding

Personnel being shocked due to (please check):Personnel being shocked due to (please check):Personnel being shocked due to (please check):Personnel being shocked due to (please check):Personnel being shocked due to (please check):

a .a .a .a .a . Insulated shoesInsulated shoesInsulated shoesInsulated shoesInsulated shoes

b.b .b .b .b . Wearing glovesWearing glovesWearing glovesWearing glovesWearing gloves

c .c .c .c .c . Ungrounded ObjectsUngrounded ObjectsUngrounded ObjectsUngrounded ObjectsUngrounded Objects

Using dirty work holderUsing dirty work holderUsing dirty work holderUsing dirty work holderUsing dirty work holder

Personnel handling electrostatically charged (isolated) systemPersonnel handling electrostatically charged (isolated) systemPersonnel handling electrostatically charged (isolated) systemPersonnel handling electrostatically charged (isolated) systemPersonnel handling electrostatically charged (isolated) system

Improper interlocksImproper interlocksImproper interlocksImproper interlocksImproper interlocks

Spraying flammable paints in waterborne (isolated) systemSpraying flammable paints in waterborne (isolated) systemSpraying flammable paints in waterborne (isolated) systemSpraying flammable paints in waterborne (isolated) systemSpraying flammable paints in waterborne (isolated) system

Power supplies / control equipment located in hazardous areaPower supplies / control equipment located in hazardous areaPower supplies / control equipment located in hazardous areaPower supplies / control equipment located in hazardous areaPower supplies / control equipment located in hazardous area

Misusing electrostatic equipmentMisusing electrostatic equipmentMisusing electrostatic equipmentMisusing electrostatic equipmentMisusing electrostatic equipment

Insufficient fire protectionInsufficient fire protectionInsufficient fire protectionInsufficient fire protectionInsufficient fire protection

Other, explain:Other, explain:Other, explain:Other, explain:Other, explain:

ITW Automotive FinishingITW Automotive FinishingITW Automotive FinishingITW Automotive FinishingITW Automotive Finishing

Representative’s Name (Printed):Representative’s Name (Printed):Representative’s Name (Printed):Representative’s Name (Printed):Representative’s Name (Printed):

Representative’s Signature:Representative’s Signature:Representative’s Signature:Representative’s Signature:Representative’s Signature:

Date:Date:Date:Date:Date:

Street Address:Street Address:Street Address:Street Address:Street Address: City:City:City:City:City: State:State:State:State:State: Zip:Zip:Zip:Zip:Zip:

SM-00-01

SAFETY SIGNS/POSTERS/LABELSSAFETY SIGNS/POSTERS/LABELSSAFETY SIGNS/POSTERS/LABELSSAFETY SIGNS/POSTERS/LABELSSAFETY SIGNS/POSTERS/LABELS

Safety Literature - Signs, Posters, Labels

5757575757

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SL-00-03.2 Danger - Keep Objects AwaySL-00-03.2 Danger - Keep Objects AwaySL-00-03.2 Danger - Keep Objects AwaySL-00-03.2 Danger - Keep Objects AwaySL-00-03.2 Danger - Keep Objects Away

ITW

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5858585858

Form SL-00-04.1

SL-00-04.1 Danger - Fire HazardSL-00-04.1 Danger - Fire HazardSL-00-04.1 Danger - Fire HazardSL-00-04.1 Danger - Fire HazardSL-00-04.1 Danger - Fire Hazard

FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!FIRE HAZARD!

DANGERDANGERDANGERDANGERDANGER

NO SMOKINGNO SMOKINGNO SMOKINGNO SMOKINGNO SMOKING

NO MANO MANO MANO MANO MATCHESTCHESTCHESTCHESTCHES

NO OPEN LIGHTSNO OPEN LIGHTSNO OPEN LIGHTSNO OPEN LIGHTSNO OPEN LIGHTS

IIIIIN SPRAN SPRAN SPRAN SPRAN SPRAYING AREAYING AREAYING AREAYING AREAYING AREA

ITW Ransburg Industrial Technical Service: 800/ 233-3366ITW Automotive Technical Service: 800/ 626-3565© 2006 Illinois Tool Works Inc. All rights reserved.

!!!!!

Esta informatión es disponible en español del ITW Ransburg Corporation.

SM-00-01

SHOCK HAZARD! SHOCK HAZARD! SHOCK HAZARD! SHOCK HAZARD! SHOCK HAZARD!

DANGERDANGERDANGERDANGERDANGER!!!!!

ITW Ransburg Industrial Technical Service: 800/ 233-3366ITW Automotive Technical Service: 800/ 626-3565© 2006 Illinois Tool Works Inc. All rights reserved. Form SL-00-05

Esta informatión es disponible en español del ITW Ransburg Corporation.


5959595959

SL-00-05 Danger - Shock HazardSL-00-05 Danger - Shock HazardSL-00-05 Danger - Shock HazardSL-00-05 Danger - Shock HazardSL-00-05 Danger - Shock Hazard

HIGHHIGHHIGHHIGHHIGH

VOLVOLVOLVOLVOLTTTTTAGEAGEAGEAGEAGE

SM-00-01


6060606060

CLEANING SAFETY REQUIREMENTSCLEANING SAFETY REQUIREMENTSCLEANING SAFETY REQUIREMENTSCLEANING SAFETY REQUIREMENTSCLEANING SAFETY REQUIREMENTS

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION!!!!!

Special care must be taken in cleaning electrostatic equipment and coating installations. To clean yourSpecial care must be taken in cleaning electrostatic equipment and coating installations. To clean yourSpecial care must be taken in cleaning electrostatic equipment and coating installations. To clean yourSpecial care must be taken in cleaning electrostatic equipment and coating installations. To clean yourSpecial care must be taken in cleaning electrostatic equipment and coating installations. To clean your

equipment and installation safely, you must follow these requirements:equipment and installation safely, you must follow these requirements:equipment and installation safely, you must follow these requirements:equipment and installation safely, you must follow these requirements:equipment and installation safely, you must follow these requirements:

1. BEFOREBEFOREBEFOREBEFOREBEFORE attempting to clean any equipment, ensure that the voltage to the electrostatic coating equipment is turned “OFF” and

CANNOTCANNOTCANNOTCANNOTCANNOT be turned “ON”. A sign should be posted at the push-button switches to warn against turning the power on.

2. Make sure you know the location of fire extinguishing equipment and how it is operated prior to commencing any cleaningoperations. Such equipment should be inspected regularly to ensure it is in proper working order.

3. Attach a grounding cable to any high voltage atomizer or electrode during cleaning to protect against inadvertent energization ofthe coating equipment.

4. All personnel involved in cleaning the electrostatic installation must NOTNOTNOTNOTNOT wear shoes that insulate them from the groundedconductive floor of the spraying area. All personnel involved in cleaning operations must be grounded at all times.

5. All containers carried into the spray booth for use in cleaning the installation must be grounded at all times. Maintain solvents atthe minimum amount required for the cleaning operation and only in approved type safety containers (see Item 11 below).

6. Use only cleaning solvents that have a flash point above 100oF.

7. Use cleaning solvents that have no toxicity, whenever possible. Wear respiration devices whenever cleaning requires the use oftoxic solvents. Avoid skin to solvent contact.

8. Adequate ventilation must be provided in areas where cleaning operations are being conducted. Spraying area ventilationequipment must be operated during cleaning operations to carry away solvent vapors that may be generated in cleaning.

9. Use only non-sparking tools for cleaning purposes.

10. Remove residue (contaminated scrapings and debris) from the premises immediately.

11. Place all rags or waste materials impregnated with coating materials or solvents in fire-safe waste cans immediately after use.Such cans should have the approval of appropriate competent authorities, such as Underwriters Laboratories or Factory MutualEngineering Corporation.

12. DO NOTDO NOTDO NOTDO NOTDO NOT immerse any portion of ITW Ransburg applicators in any liquid for any reason. Clean electrostatic applicators with asoft bristled brush and solvent. Some parts of ITW Ransburg electrostatic applicators, such as air caps and paint nozzles, canbe removed from the applicators and soaked.

13. Wipe up or dry with air, immediately, any solvent that may be spilled during the course of cleaning operations.

14. DO NOTDO NOTDO NOTDO NOTDO NOT reconnect electrostatic coating equipment until after the cleaning operation has been completed and vapors generatedin cleaning the spraying area have been removed by ventilation.

15. If any defect in the equipment is noted in cleaning operations, report the defect to supervisory or maintenance personnel prior tothe commencement of coating operations. DO NOTDO NOTDO NOTDO NOTDO NOT operate equipment suspected of being defective until equipment has beenchecked completely.

ITW Ransburg Industrial Technical Service: 800/ 233-3366ITW Automotive Technical Service: 800/ 626-3565© 2007 Illinois Tool Works Inc. All rights reserved. Form SL-00-07.3

SL-00-07.3 Caution - Cleaning Safety RequirementsSL-00-07.3 Caution - Cleaning Safety RequirementsSL-00-07.3 Caution - Cleaning Safety RequirementsSL-00-07.3 Caution - Cleaning Safety RequirementsSL-00-07.3 Caution - Cleaning Safety Requirements

SM-00-01


6161616161SL-00-08.2 Caution - Handling Coating MaterialsSL-00-08.2 Caution - Handling Coating MaterialsSL-00-08.2 Caution - Handling Coating MaterialsSL-00-08.2 Caution - Handling Coating MaterialsSL-00-08.2 Caution - Handling Coating Materials

HANDLING COAHANDLING COAHANDLING COAHANDLING COAHANDLING COATING MATING MATING MATING MATING MATERIALS SAFELTERIALS SAFELTERIALS SAFELTERIALS SAFELTERIALS SAFELY!Y!Y!Y!Y!

Automatic SystemsAutomatic SystemsAutomatic SystemsAutomatic SystemsAutomatic Systems


1. All coating material containers should be treated as if they can become charged. Metallic (electricallyconductive) containers must be used as coating material containers, and all portions of such containersshould be grounded during use. A grounding wire should be examined daily to ensure that it isgrounded.

2. Some coating materials in use are so conductive that the coating material container must be put on aninsulated stand and left ungrounded in order for the system to operate. User should attempt to use coatingmaterials which are not so conductive, where possible.

ITW Ransburg Industrial Technical Service: 800/ 233-3366ITW Automotive Technical Service: 800/ 626-3565© 2007 Illinois Tool Works Inc. All rights reserved. Form SL-00-08.2

WWWWWARNING!ARNING!ARNING!ARNING!ARNING!Be sure that all coating material containers in the electrostatic spray system areBe sure that all coating material containers in the electrostatic spray system areBe sure that all coating material containers in the electrostatic spray system areBe sure that all coating material containers in the electrostatic spray system areBe sure that all coating material containers in the electrostatic spray system are

grounded (and therefore discharged) before any work is done around them, such as:grounded (and therefore discharged) before any work is done around them, such as:grounded (and therefore discharged) before any work is done around them, such as:grounded (and therefore discharged) before any work is done around them, such as:grounded (and therefore discharged) before any work is done around them, such as:

adding coating material or solvent, removing coating material, or stirring the contents.adding coating material or solvent, removing coating material, or stirring the contents.adding coating material or solvent, removing coating material, or stirring the contents.adding coating material or solvent, removing coating material, or stirring the contents.adding coating material or solvent, removing coating material, or stirring the contents.

WWWWWARNING!ARNING!ARNING!ARNING!ARNING!Special care should be taken in operating insulated systems. The high voltage to theSpecial care should be taken in operating insulated systems. The high voltage to theSpecial care should be taken in operating insulated systems. The high voltage to theSpecial care should be taken in operating insulated systems. The high voltage to theSpecial care should be taken in operating insulated systems. The high voltage to the

electrostatic equipment must be turned OFF and the coating material container groundedelectrostatic equipment must be turned OFF and the coating material container groundedelectrostatic equipment must be turned OFF and the coating material container groundedelectrostatic equipment must be turned OFF and the coating material container groundedelectrostatic equipment must be turned OFF and the coating material container grounded

before any work is done around the coating material container in such a system.before any work is done around the coating material container in such a system.before any work is done around the coating material container in such a system.before any work is done around the coating material container in such a system.before any work is done around the coating material container in such a system.

1. A grounding device should be kept adjacent the container for such use. Care should be made untilsufficient time has elapsed after the high voltage is turned off that any electrical charge on the containerhas dissipated. The grounding device should be fastened to the container near its base, away from theopening of the container. Fastening the grounding device away from the opening will reduce the likelihoodthat it will be dislodged during work with the coating material in the container, and will locate any spark thatmay occur as the grounding device is fastened to the container away from the opening of the containerwhere the solvent vapors are most dense. In addition, the coating material container or any pump orcoating material supply equipment associated with the use of such conductive coating materials shouldbe located in an area that is well ventilated and where personnel cannot inadvertently approach them.

2. The erection of suitable physical barriers to prevent such inadvertent approach is recommended and isthe responsibility of the user.

3. Warning signs (such as this Caution sign) should be posted in close proximity to the coating materialscontainer, the pump and coating material supply equipment.

SM-00-01


6262626262

SAFETY REQUIREMENTS!SAFETY REQUIREMENTS!SAFETY REQUIREMENTS!SAFETY REQUIREMENTS!SAFETY REQUIREMENTS!

On-The-Job Safety Requires that YOU Follow These Simple Requirements!On-The-Job Safety Requires that YOU Follow These Simple Requirements!On-The-Job Safety Requires that YOU Follow These Simple Requirements!On-The-Job Safety Requires that YOU Follow These Simple Requirements!On-The-Job Safety Requires that YOU Follow These Simple Requirements!


WWWWWARNING!ARNING!ARNING!ARNING!ARNING!

1. DO NOTDO NOTDO NOTDO NOTDO NOT cover the floor with ANY ANY ANY ANY ANY insulating material.2. DO NOTDO NOTDO NOTDO NOTDO NOT wear insulating gloves (UNLESSUNLESSUNLESSUNLESSUNLESS the palms have been cut out to allow bare skin contact with the equipment).

Gloves containing conductive fibers are acceptable. If gloves are worn for chemical safety, grounding wrist straps may beconnected from the operator’s wrist to the applicator assembly.

3. DO NOTDO NOTDO NOTDO NOTDO NOT wear insulating shoes.4. ALL containers MUSTMUSTMUSTMUSTMUST be properly grounded during the transfer of flammable material.5. Where operating conditions require the coating material container to be placed on an insulated stand, the high voltage

MUSTMUSTMUSTMUSTMUST be OFFOFFOFFOFFOFF and the container MUSTMUSTMUSTMUSTMUST be grounded while ANY person is near it. (Also see ITW Ransburg CautionSign, HANDLING COAHANDLING COAHANDLING COAHANDLING COAHANDLING COATING MATING MATING MATING MATING MATERIALS SAFELTERIALS SAFELTERIALS SAFELTERIALS SAFELTERIALS SAFELYYYYY.....)

FLAME, FLAMMABLES, AND SPFLAME, FLAMMABLES, AND SPFLAME, FLAMMABLES, AND SPFLAME, FLAMMABLES, AND SPFLAME, FLAMMABLES, AND SPARKS:ARKS:ARKS:ARKS:ARKS:

1. Flames and sparks must NEVERNEVERNEVERNEVERNEVER be allowed in the spray area.2. ONLYONLYONLYONLYONLY the MINIMUMMINIMUMMINIMUMMINIMUMMINIMUM necessary flammable liquid may be allowed in the spray area and ONLYONLYONLYONLYONLY in approved, grounded

containers. (A maximum of one gallon of solvent per container).3. Functioning, correctly maintained fire extinguishing equipment MUSTMUSTMUSTMUSTMUST be available in the spray area.4. The high voltage MUSTMUSTMUSTMUSTMUST be OFFOFFOFFOFFOFF during the transfer (or stirring) of flammable liquids.DISTDISTDISTDISTDISTANCE FROM GROUND:ANCE FROM GROUND:ANCE FROM GROUND:ANCE FROM GROUND:ANCE FROM GROUND:1. When using listed resistive solvent base atomizers, the applicator target distance may be as close as 0” to 12” to grounded objects.

When using non-resistive or waterborne atomizers, the applicator to ground distance MUSTMUSTMUSTMUSTMUST be no closer than the statedminimum safe distance for that atomizer. (See the applicator service manual.)

HOUSEKEEPING:HOUSEKEEPING:HOUSEKEEPING:HOUSEKEEPING:HOUSEKEEPING:1. Good housekeeping MUSTMUSTMUSTMUSTMUST be maintained at ALLALLALLALLALL times.2. Keep ALLALLALLALLALL hooks and work holders free of accumulated coating material. (Strip and clean them frequently.)3. As often as it is needed, clean ALLALLALLALLALL coating material accumulation OFFOFFOFFOFFOFF of the applicator barrel and/or insulator using a non-

polar solvent. (Refer to the literature, “Technical Supplement for All Products - Paint & Solvent Specifications and“Technical Supplement for All Products - Paint & Solvent Specifications and“Technical Supplement for All Products - Paint & Solvent Specifications and“Technical Supplement for All Products - Paint & Solvent Specifications and“Technical Supplement for All Products - Paint & Solvent Specifications and

Viscosity Conversion Charts” section.Viscosity Conversion Charts” section.Viscosity Conversion Charts” section.Viscosity Conversion Charts” section.Viscosity Conversion Charts” section.)4. Flush fluid lines into a grounded container or evacuation system, NOTNOTNOTNOTNOT onto the floor or walls.5. The spray area MUSTMUSTMUSTMUSTMUST be clean and free of accumulated coating material.

EQUIPMENTEQUIPMENTEQUIPMENTEQUIPMENTEQUIPMENT:::::1. ALLALLALLALLALL equipment should be checked regularly for defects or malfunctions which might effect efficiency or safety. Safety problems

MUSTMUSTMUSTMUSTMUST be corrected immediately.2. Short circuit output currents MUSTMUSTMUSTMUSTMUST be within the manufacturers specified limits.3. NEVERNEVERNEVERNEVERNEVER immerse assembled applicators in ANYANYANYANYANY liquid.4. ALWAYSALWAYSALWAYSALWAYSALWAYS use equivalent (to original specifications) part and hose replacements. (Refer to the literature “Technical“Technical“Technical“Technical“Technical

Supplement for All Products - Volumetric Content of Hose or Tube” chartSupplement for All Products - Volumetric Content of Hose or Tube” chartSupplement for All Products - Volumetric Content of Hose or Tube” chartSupplement for All Products - Volumetric Content of Hose or Tube” chartSupplement for All Products - Volumetric Content of Hose or Tube” chart.)

PERSONNEL:PERSONNEL:PERSONNEL:PERSONNEL:PERSONNEL:

1. Adequate ventilation MUSTMUSTMUSTMUSTMUST be provided during ALLALLALLALLALL coating, cleaning, maintenance, and/or service operations.2. ALLALLALLALLALL power to and through the equipment MUSTMUSTMUSTMUSTMUST be OFFOFFOFFOFFOFF prior to cleaning, maintaining, or servicing it (within the spray area).3. A functioning grounding cable and hook MUSTMUSTMUSTMUSTMUST be attached to the atomizing head of automatic applicators prior to touching,

cleaning, maintaining, or servicing them. NOTE: Automatic equipment booths MUST MUST MUST MUST MUST be equipped with a readily availablegrounding cable with hook.

4. Keep ALLALLALLALLALL untrained and/or unauthorized personnel out of the spray area.5. ALL operating (and associated) personnel MUST MUST MUST MUST MUST read and understand the appropriate operating, service, and safety

instructions and the Occupational Safety and Health (OSHA) Standard, Section 1910.107.6. The high voltage should be OFFOFFOFFOFFOFF except during actual coating operations.7. DO NOTDO NOTDO NOTDO NOTDO NOT permit horseplay.

ITW Ransburg Industrial Technical Service: 800/ 233-3366ITW Automotive Technical Service: 800/ 626-3565© 2007 Illinois Tool Works Inc. All rights reserved.

Form SL-00-09.5

GROUNDING:GROUNDING:GROUNDING:GROUNDING:GROUNDING:

ALL conductive objects in the spray area MUSTMUSTMUSTMUSTMUST be grounded, including (but not limited to) the following:

! spray booth ! booth floor ! conveyor! workholder(s)/hook(s) ! solvent containers ! workpieces! applicator handles / supports ! loose, conductive objects ! ALL personnel! power supply / control panel (these MUST be located OUTSIDE the spray area)

SL-00-09.5 Caution - Safety Requirements SL-00-09.5 Caution - Safety Requirements SL-00-09.5 Caution - Safety Requirements SL-00-09.5 Caution - Safety Requirements SL-00-09.5 Caution - Safety Requirements

SM-00-01


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SL-81-02.4 Danger - Explosion HazardSL-81-02.4 Danger - Explosion HazardSL-81-02.4 Danger - Explosion HazardSL-81-02.4 Danger - Explosion HazardSL-81-02.4 Danger - Explosion Hazard

SM-00-01


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!!!! !

SM-00-01SL-83-03.4 Caution - Airless and Air AssistedSL-83-03.4 Caution - Airless and Air AssistedSL-83-03.4 Caution - Airless and Air AssistedSL-83-03.4 Caution - Airless and Air AssistedSL-83-03.4 Caution - Airless and Air Assisted

Airless Spray Equipment SafetyAirless Spray Equipment SafetyAirless Spray Equipment SafetyAirless Spray Equipment SafetyAirless Spray Equipment Safety


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Form SL-83-03.4 09/07ITW Ransburg Industrial Technical Service: 800/ 233-3366ITW Automotive Technical Service: 800/ 626-3565© 2007 Illinois Tool Works Inc. All rights reserved.

AIRLESS AND AIR ASSISTED AIRLESS SPRAYAIRLESS AND AIR ASSISTED AIRLESS SPRAYAIRLESS AND AIR ASSISTED AIRLESS SPRAYAIRLESS AND AIR ASSISTED AIRLESS SPRAYAIRLESS AND AIR ASSISTED AIRLESS SPRAY

EQUIPMENT SAFETYEQUIPMENT SAFETYEQUIPMENT SAFETYEQUIPMENT SAFETYEQUIPMENT SAFETYALL personnel who operate, clean or maintain this equipment MUSTMUSTMUSTMUSTMUST read and thoroughly understand the appropriate ITWRansburg equipment manuals and safety literature. Special care should be taken to ensure that the WARNINGSWARNINGSWARNINGSWARNINGSWARNINGS and requirementsfor operating and servicing the equipment are followed. The user should be aware of and adhere to ALLALLALLALLALL local building and firecodes and ordinances and the Occupational Safety and Health Act of 1970 (OSHA) prior to installing, operating and/or servicingthis equipment. If the appropriate literature is not available it may be obtained by contacting ITW Ransburg Electrostatic Systems.

Before applying pressure to the system, ALWAYSALWAYSALWAYSALWAYSALWAYS:> Follow the manufacturer’s operating instructions and maximum pressure recommendations> Secure the trigger in the OFF OFF OFF OFF OFF position and check all pressure connections> Use grounded, high pressure fluid lines> Check that the pump is properly grounded

Anytime that operation is discontinued ALWAYSALWAYSALWAYSALWAYSALWAYS:> Shut the pump OFFOFFOFFOFFOFF> Discharge the residual fluid and pressure from the applicator> Secure the trigger in the OFFOFFOFFOFFOFF positionFollow these same three procedures before disassembly of ANY ANY ANY ANY ANY part of the pressure system (including the applicator or its nozzle).

DO NOTDO NOTDO NOTDO NOTDO NOT undertake any of the following until pressure is relieved from the entire system:> Loosen or remove the nozzle> Disassemble any part of the applicator> Loosen or disconnect any fluid line fittings> Disassemble any part of the pump

Be sure that the power to the pump is OFFOFFOFFOFFOFF and the system is depressurized before undertaking ANYANYANYANYANY repair, maintenance, oradjustment.

If it is necessary to adjust or clean the nozzle on site, be sure that it is aimed away from all personnel so that it may discharge safelyif there is residual pressure in the system.

Only use genuine ITW Ransburg replacement parts.

Correct packing or valve seal leaks IMMEDIATELY.IMMEDIATELY.IMMEDIATELY.IMMEDIATELY.IMMEDIATELY.

Frequently check the condition of all pressurized components, especially fluid lines. Replace worn hoses and parts before theyfail.

If nozzle clogging occurs frequently, use a fluid filter.

If you have any questions about safety or procedures, contact your ITW Ransburg Representative.

> BECAUSE OF THE INJECTION HAZARD INHERENT WITH ALL HIGH PRESSURE AIRLESS AND AIR ASSISTEDAIRLESS (hydraulically fed) APPLICATORS, SPECIAL ATTENTION MUST BE PAID TO THE SAFETY CARDS,WARNING SIGNS AND SERVICE MANUAL NOTICES REGARDING THIS SUBJECT!

> DO NOT POINT THE APPLICATOR AT ANY PERSON.

> NEVER LOOK INTO THE BARREL OF THE APPLICATOR FROM THE FRONT (NOZZLE END)!

> NEVER trigger an airless or air assisted airless gun while it is aimed at a person. The hydraulic pressure may injectfluid into the flesh causing injury or death. If the fluid penetrates the skin, it WILL WILL WILL WILL WILL cause serious injury. Clothing,such as gloves will NOT provide protection! The system is capable of fluid pressure high enough to cause a LETHALINJECTION! TREAT THE APPLICATOR AS YOU WOULD A LOADED WEAPON!

WARNING: INJECTION HAZARDWARNING: INJECTION HAZARDWARNING: INJECTION HAZARDWARNING: INJECTION HAZARDWARNING: INJECTION HAZARD!!!!!

!!!!! CAUTIONCAUTIONCAUTIONCAUTIONCAUTION

SM-00-01


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!!!!!Any injury caused by high pressure liquidcan be serious. If you are injured or evensuspect an injury:• Go to an emergency room now.• Tell the doctor you suspect an injection

injury.• Show him this card.• Tell him what kind of material you were

spraying.

Cualquiera herida causada con liquido a altapresión es peligrosa. Si Ud. es herido osospecha que está herido:• Veáse al doctor de emergencia

inmediatamente.• Digale que Ud. ha sido herido conliquido

inyectado.• Enséñele ésta tarjeta.• Digale que clase de liquido es con la

que estaba rociando.

WARNINGWARNINGWARNINGWARNINGWARNING

¡PELIGRO!¡PELIGRO!¡PELIGRO!¡PELIGRO!¡PELIGRO!

The seriousness of the wound depends on where the injury ison the body, whether the substance hit something on its way inand deflected causing more damage, and many other variablesincluding skin microflora residing in the paint or applicatorwhich are blasted into the wound. If the injected paint containsacrylic latex and titanium dioxide that damage the tissue’sresistance to infection, bacterial growth will flourish. Thetreatment that doctors recommend for an injection injury to thehand includes immediate decompression of the closedvascular compartments of the hand to release the underlyingtissue distended by the injected paint, judicious wounddebridement, and immediate antibiotic treatment.

NATIONAL SPRAY EQUIPMENT MANUFACTURERS ASSOCIATION

ITW Ransburg Form SL-83-01.1 09/07

SM-00-01

WWWWWARRANTYARRANTYARRANTYARRANTYARRANTY POLICIES POLICIES POLICIES POLICIES POLICIES

LIMITED WLIMITED WLIMITED WLIMITED WLIMITED WARRANTYARRANTYARRANTYARRANTYARRANTY

ITW RansburgITW RansburgITW RansburgITW RansburgITW Ransburg will replace or repair withoutcharge any part and/or equipment that fails withinthe specified time (see below) because of faultyworkmanship or material, provided that the equip-ment has been used and maintained in accor-dance with ITW Ransburg’s written safety andoperating instructions, and has been used undernormal operating conditions. Normal wear itemsare excluded.

THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-THE USE OF OTHER THAN ITW RANS-

BURG APPROVED PARTS VOIDS ALLBURG APPROVED PARTS VOIDS ALLBURG APPROVED PARTS VOIDS ALLBURG APPROVED PARTS VOIDS ALLBURG APPROVED PARTS VOIDS ALL

WARRANTIES.WARRANTIES.WARRANTIES.WARRANTIES.WARRANTIES.

SPARE PARTS: One hundred and eighty (180)days from date of purchase, except for rebuiltparts (any part number ending in “R”) for which thewarranty period is ninety (90) days.

EQUIPMENT: When purchased as a completeunit, (example: guns, power supplies, controlunits, etc.), is one (1) year from date of purchase.

WRAPPING THE EQUIPMENT IN PLAS-WRAPPING THE EQUIPMENT IN PLAS-WRAPPING THE EQUIPMENT IN PLAS-WRAPPING THE EQUIPMENT IN PLAS-WRAPPING THE EQUIPMENT IN PLAS-

TIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOIDTIC, SHRINK-WRAP, ETC., WILL VOID

THIS WARRANTY.THIS WARRANTY.THIS WARRANTY.THIS WARRANTY.THIS WARRANTY.

ITW RANSBURG’S ONLY OBLIGATIONITW RANSBURG’S ONLY OBLIGATIONITW RANSBURG’S ONLY OBLIGATIONITW RANSBURG’S ONLY OBLIGATIONITW RANSBURG’S ONLY OBLIGATION

UNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACEUNDER THIS WARRANTY IS TO REPLACE

PARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSEPARTS THAT HAVE FAILED BECAUSE

OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-OF FAULTY WORKMANSHIP OR MATE-

RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-RIALS. THERE ARE NO IMPLIED WAR-

RANTIES NOR WARRANTIES OF EITHERRANTIES NOR WARRANTIES OF EITHERRANTIES NOR WARRANTIES OF EITHERRANTIES NOR WARRANTIES OF EITHERRANTIES NOR WARRANTIES OF EITHER

MERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR AMERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-PARTICULAR PURPOSE. ITW RANS-

BURG ASSUMES NO LIABILITY FOR IN-BURG ASSUMES NO LIABILITY FOR IN-BURG ASSUMES NO LIABILITY FOR IN-BURG ASSUMES NO LIABILITY FOR IN-BURG ASSUMES NO LIABILITY FOR IN-

JURY, DAMAGE TO PROPERTY OR FORJURY, DAMAGE TO PROPERTY OR FORJURY, DAMAGE TO PROPERTY OR FORJURY, DAMAGE TO PROPERTY OR FORJURY, DAMAGE TO PROPERTY OR FOR

CONSEQUENTIAL DAMAGES FOR LOSSCONSEQUENTIAL DAMAGES FOR LOSSCONSEQUENTIAL DAMAGES FOR LOSSCONSEQUENTIAL DAMAGES FOR LOSSCONSEQUENTIAL DAMAGES FOR LOSS

OF GOODWILL OR PRODUCTION OROF GOODWILL OR PRODUCTION OROF GOODWILL OR PRODUCTION OROF GOODWILL OR PRODUCTION OROF GOODWILL OR PRODUCTION OR

INCOME, WHICH RESULT FROM USE ORINCOME, WHICH RESULT FROM USE ORINCOME, WHICH RESULT FROM USE ORINCOME, WHICH RESULT FROM USE ORINCOME, WHICH RESULT FROM USE OR

MISUSE OF THE EQUIPMENT BY PUR-MISUSE OF THE EQUIPMENT BY PUR-MISUSE OF THE EQUIPMENT BY PUR-MISUSE OF THE EQUIPMENT BY PUR-MISUSE OF THE EQUIPMENT BY PUR-

CHASER OR OTHERS.CHASER OR OTHERS.CHASER OR OTHERS.CHASER OR OTHERS.CHASER OR OTHERS.

EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:EXCLUSIONS:

If, in ITW Ransburg’s opinion the warranty item inquestion, or other items damaged by this part wasimproperly installed, operated or maintained, ITWRansburg will assume no responsibility for repairor replacement of the item or items. The pur-chaser, therefore will assume all responsibility forany cost of repair or replacement and servicerelated costs if applicable.

Safety Literature - Warranty Policies

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SM-00-01

MANUALMANUALMANUALMANUALMANUAL CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMAR CHANGE SUMMARYYYYYThis manual was published to supercede the following list of Safety Bulletins (making them obsolete):

SL-77-01.5, SL-79-01.1, SL-80-08.2, SL-81-08.2, SL-84-02, IL-247-A, and IL-304-B to make

the following changes/updates:

1. To publish into one Safety Manual, that list all present and updated safety information, safety signs,posters (All Manual Sections). This is to be used as a reference guideline of general safety and issuespertaining to this subject matter, used in conjunction with all ITW Ransburg products and theircorresponding Service Manuals.

Service Manual Price:Service Manual Price:Service Manual Price:Service Manual Price:Service Manual Price: €25.00 (Euro)25.00 (Euro)25.00 (Euro)25.00 (Euro)25.00 (Euro)

$30.00 (U.S.)$30.00 (U.S.)$30.00 (U.S.)$30.00 (U.S.)$30.00 (U.S.)

Form No. SM-00-01Litho in U.S.A.01/08

© 2008 Illinois Tool Works Inc. All rights reserved.Models and specifications subject to change without notice.

ManufacturingManufacturingManufacturingManufacturingManufacturing1910 North Wayne StreetAngola, Indiana 46703-9100Telephone: 260/665-8800Fax: 260/665-8516

TTTTTechnical/Service Assistanceechnical/Service Assistanceechnical/Service Assistanceechnical/Service Assistanceechnical/Service AssistanceAutomotive Assembly and Tier I Telephone: 800/ 626-3565 Fax: 419/ 470-2040Industrial Systems Telephone: 800/ 233-3366 Fax: 419/ 470-2071Ransburg Guns Telephone: 800/ 233-3366 Fax: 419/ 470-2071www.itwransburg.com

TTTTTechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephoneechnical Support Representative will direct you to the appropriate telephone

number for ordering Spare Parts.number for ordering Spare Parts.number for ordering Spare Parts.number for ordering Spare Parts.number for ordering Spare Parts.

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